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PRE-FEASIBILITY REPORT ON ENVIRONMENTAL ASPECTS

PROPOSED EXPANSION

GLOBAL CALCIUM PRIVATE LIMITED

# 125, 126 SIPCOT Industrial Complex, Phase – 1, Hosur – 635 126.

MAY 2014

Pre-Feasibility Report GCPL

i

CONTENTS

1.0 INTRODUCTION .............................................................................................................. 1

2.0 PROPOSED PROJECT ...................................................................................................... 1

3.0 PROJECT LOCATION ...................................................................................................... 2

4.0 RAW MATERIALS CONSUMPTION ............................................................................. 4

5.0 MANUFACTURING PROCESS ....................................................................................... 7

6.0 RAW WATER REQUIREMENT .................................................................................... 12

7.0 ENERGY CONSUMPTION ............................................................................................ 14

8.0 WORK FORCE ................................................................................................................ 14

9.0 EXISTING ENVIRONMENTAL SCENARIO ............................................................... 14

9.1 Air Environment ................................................................................................................. 14

9.3 Water Environment ............................................................................................................. 17

9.4 Soil & Land Environment ................................................................................................... 20

10.0 WASTE & WASTE MANAGEMENT ............................................................................ 23

10.1 Air Pollution...................................................................................................................... 23

10.2 Wastewater Generation .................................................................................................... 25

10.3 Solid Wastes...................................................................................................................... 26

11.0 CONCLUSION ................................................................................................................. 26

Pre-Feasibility Report 1 GCPL

1.0 INTRODUCTION

As an EU-GMP certified global company and an established hallmark for pharmaceutical

standards, Global Calcium has stood the test of time since its inception in 1979 as Calcium

India. Today, Global Calcium represents the true hallmark of quality when it comes to

pharmaceutical products.

Global Calcium is backed by an excellent management team comprising of industry

specialists, technocrats, entrepreneurs and business specialists bringing in strong domain

expertise in the pharmaceutical industry.

Global Calcium prioritizes Research and Development over everything else; companies

today are well aware that only with superior R & D can they continue to innovate and

deliver international-quality products. The focused R&D effort and initiatives are behind the

cost advantages that the end customers enjoy.

Global Calcium's goal is to develop genuine business partnership with clients to result in a

win-win strategy. By combining its resources and expertise with its strategy pattern Global

Calcium achieves product development objectives and successful completion of quality

health formulations and products.

Global Calcium is one of the major producers of Nutrition Supplements/Additives in the

Domestic Market as also in the Global Market. These Nutrition Supplements are widely

used for human consumption as also for veterinary care.

2.0 PROPOSED PROJECT

Global Calcium Private Limited (GCPL) has proposed to expand its facility by installing

an additional unit to produce Active Pharmaceutical Ingredient in addition to existing

facility producing mineral salts of Gluconates, Lactates, Lactobionate etc.

The proposed expansion will be carried out within the existing premises of the existing

plant site itself.


The production details at present are as follows.

Pharmaceutical bulk drugs and chemicals such as Mineral salts of Gluconates, Citrates, Lactates, Lactobionates, Fumarates, Orotates etc by Conventional Process

1641 TPA

Pharmaceutical bulk drugs and chemicals such as Mineral salts of Gluconates, Citrates, Lactates, Lactobionates, Fumarates, Orotates etc by Conversion

1400 TPA

Calcium Glubionate , Calcium Borogluconate, Calcium lacto Gluconate, and other Mineral Salts by spray drier process

2615 TPA

Calcium Glubionate , Calcium Borogluconate, Calcium lacto Gluconate, and other Mineral Salts by Conversion using spray drier process.

1215 TPA

It is now proposed to expand by additionally installing a unit to produce Active Pharma Ingredients (API) Products, such as

Iron sucrose, Calcium dobesylate, Tiemonium methyl sulphate, Ethamsylate Tolperisone hcl, Calcium glycerophosphate, Magnesium glycerophosphate, Carbasalate calcium, Calcium d-saccharate, Alendronate sodium, Benfotiamine, Calcium folinate, Sodium beta glycerphosphate, Phenrocoumon etc

60 TPA

3.0 PROJECT LOCATION

The proposed expansion is within the premises of the existing plant site located at # 125,

126 SIPCOT Industrial Complex, Phase – 1, Hosur – 635 126, Tamil Nadu, which is a

notified industrial estate in Tamil Nadu.

State Industries Promotion Corporation of Tamil Nadu (SIPCOT) Limited, a fully

government owned premier institution, established in the year 1972, has been a catalyst in

development of small, medium and large scale industries in Tamil Nadu.

Total Area of the SIPCOT Complex Phase-1 at Hosur is 1235.86 Acres, which is well

connected by National Highway (NH-7) ie Chennai - Bangalore Highway. SIPCOT has also

established all requisite infrastructure to supply water to all the industries, and have also

established an exclusive substation to ensure uninterrupted power supply.

The Location Map is as shown in Fig.1.0.


Fig 1.0 LOCATION MAP


4.0 RAW MATERIALS CONSUMPTION

Existing List of Raw Materials including chemicals, Catalysts & Additives

List of Raw Material to be used at all stages

of Manufacturer

Quantity ( Ton Per Month)

for the full production

Capacity

Quantity per

Annum

Dextrose mono hydrate 174.667 2096.004

Sodium bromide / potassium bromide 10.291 123.492

Gluconic acid (Alternate to 1 & 2) 338.330 4059.96

Potassium Carbonate / Potassium Bicarbonate 2.083 24.996

Calcium carbonate 47.122 565.464

Sodium Carbonate / Sodium bicarbonate 0.593 7.116

Zinc carbonate / Zinc Oxide 1.250 15.000

Magnesium Carbonate / Magnesium oxide 1.083 12.996

Manganese Carbonate / Manganese Oxide 0.833 9.996

Lactic acid 104.170 1250.040

Calcium Gluconate 83.330 999.960

Calcium Lactobionate 5.417 65.004

Calcium Lactate 125.000 1500.000

Denatured Spirit (KL) 46.533 558.396

Lactose 26.250 315.000

Boric Acid 0.250 3.000

Glucona Delta Lactone 145.830 1749.960

Ferrous Sulphate / Iron Dust 3.000 36.000


Proposed List of Raw Material – Non Hazardous Sl. No

Name of the Products Name of the raw material

Quantity of Major RM in Tons

Qty of solvent Input in KL

1 IRON SUCROSE Ferric chloride Sucrose

22.4 70

3 TIEMONIUM METHYL SULPHATE

2-acetylthiophene 10.98 38.25

5 TOLPERISONE HCl 4-Methyl Propiophenone, 1,3-dioxalone

9.3 3

6 CALCIUM GLYCEROPHOSPHATE

Epichlorohydrin

Trisodium

Phosphate,

Calcium

Carbonate

108 10

7 MAGNESIUM GLYCEROPHOSPHATE

Magnesium Carbonate

59.25 5

8 CARBASALATE CALCIUM Aspirin Urea Calcium chloride

12 2

9 CALCIUM D-SACCHARATE Dextrose Monohydrate

13 1

10 ALENDRONATE SODIUM 4-aminobutyric acid

12.8 2

11 BENFOTIAMINE Thiamine hcl, Orthophosphoric acid,

37.5 6

12 CALCIUM FOLINATE Folic acid, sodium borohydride,

0.3 3.9

13 SODIUM BETA GLYCERPHOSPHATE

Glycerol,

Phosphorous

Oxy chloride

17.2 17.2

14 PHENROCOUMON 4-hydroxy coumarin

8.5 5.7

Total 329.83 178.89


Proposed List of Raw Material – Hazardous

Sl. No.

as per

MSIHC

Name of the raw material Quantity of Major RM in Tons

319

591

Hydroquinone

Sulphuric acid

13.8

408 Morpholine 10.98

319

591

196

Hydroquinone,

Sulphuric acid,

Diethyl amine

4.8

514 Piperidine, 9.3

506 Phosphorous trichloride 12.8

505

67

Phosphorous pentoxide,

Benzoyl chloride

37.5

652 Triethyl amine 0.3


5.0 MANUFACTURING PROCESS

EXISTING MANUFACTURING PROCESS

The process to produce Calcium Gluconate, Sodium Gluconate, Potassium Gluconate,

Magnesium Gluoconate, Zinc Glouconate, Manganese Gluconate involves the

following process

Calculated Quantity of Dextrose Mono Hydrate and Sodium Bromide are

dissolved in DM Water and Electrolysed to obtain Gluconic Acid.

Gluconic Acid thus obtained is Neutralized based on the Salt of Gluconate

required by either Calcium Carbonate, Sodium Carbonate, Potassium

Carbonate, Magnesium Carbonate, Zinc Carobonate, Manganese Carbonate.

The Neutralized Salt is then Filtered, Crystallized, Centrifuged, Dried, Milled and

Packed.

In the Alternate Process Gluconic Acid is Neutralized with respective Salts to obtain respective Gluconates which is then Filtered, Crystallized, Centrifuged, Dried, Milled & Packed.

In the Alternate Process using Spray Dried, Salts of Gluconates are Filtered, Dried & Packed.

ELECTROLYSIS NEUTRALISATION

CRYSTALLISATION

PACKING MILLING DRYING CENTRIFUGING

FILTERATION


CALCIUM LACTATE

Calcium Carbonate is Neutralized with Lactic Acid and then Filtered, Crystalised, Centrifuged, Dried & Packed.

CALCIUM GLUBIONATE

Calculated quantities of Calcium Gluconate & Calcium Lactobionate are Blended, Sieved and Packed.

In the Alternate Process calculated quantities of Calcium Gluconate and Calcium Lactobinate are dissolved in DM Water and then Filtered, Dried Sieved & Packed.

CALCIUM LACTO GLUCONATE

Calculated quantities of Calcium Lactate & Calcium Gluconate are Blended, Sieved and Packed.

In the Alternate Spray Drier Process Calcium Lactate & Calcium Gluconate are dissolved in DM Water and then Filtered, Dried Sieved & Packed.

In another Process either Gluconic Acid or Glucono Delta Lactone are Neutralized with Lactic Acid and Calcium Carbonate, the product thus obtained is Filtered, Dried, Sieved and Packed.

CALCIUM LACTOBIONATE

Calculated quantities of Lactose, Sodium Bromide, Calcium Carbonate are mixed in Water and electrolyzed.

The product is Filtered, Vaccum Concentrated, Crystallized with Alcohol, Centrifuged, Milled, Dried and Packed.

FERROUS GLUCONATE

Calcium Gluconate & Ferrous Sulphate are mixed with DM Water.

The Product is then Filtered, Concentrated, Dried, Milled and Packed.


PROPOSED MANUFACTURING PROCESS

IRON SUCROSE Ferric Chloride is dissolved in water and sodium bicarbonate solution is added to

precipitate ferric hydroxide which is filtered.

Above ferric hydroxide is mixed with sucrose and heated to get iron sucrose in solution.

Which is concentrated to get thick mass which is added with vigorous stirring to DNS and

then methanol to precipitate iron sucrose solid. This is centrifuged and slurried with DNS

and acetone again to remove the impurities. The wet material is dried under vacuum,

pulverized, redried, milled, blended as needed and packed.

TIEMMONIUM METHYL SULPFATE (TMS) Morpholine is reacted with 2-acetyl thiophene and p-formaldehyde in the presence of

hydrochloric acid in denatured spirit (DNS) to get the corresponding mannich base as HCl

salt. The above HCl salt is basified in toluene to get the corresponding mannich ketone

base. This is reacted with phenyl magnesium bromide in tetrahydrofuran to get

tiemmonium hydrochloride which is purified using methanol slurry. The pure hydrochloride

is converted to base and treated with dimethyl sulfate in acetone to get the tiemmonium

methyl sulfate. This is dried in a vacuum oven, milled, blended and packed.

PERAZINE DIMALEATE Stage – I: N-methyl piperazine is reacted with Bromochloro propane in presence of sodium

hydroxide.

Stage – II: condensation of phenothiazine with stage – I product in DMF (Dimethyl

formamide) to form Perazine base.

Stage – III: Perazine base reacted with Maleic acid in acetone to form Perazine Dimaleate.

CALCIUM D-SACHARIDE (CADS) Nitric acid reacted with Dextrose monohydrate (DMH) at hot condition. The reacted mass is

basified with Potassium hydroxide. Again the mass is acidified to get mono potassium salt

of D-sacharic acid. This salt is reacted with Sodium hydroxide. The mass is reacted with

Calcium chloride to form Calcium D-sacharide.


ALENDRONATE SODIUM 4-aminobutyric acid is treated with a mixture of phosphorous trichloride in presence of

methane sulphonic acid at 70°C Then hydrolysed by refluxing with water and then treated

with sodium hydroxide to get the required product.

PHENPROCOUMON Mixture of 1-phenyl-1-propanol and 4-hydroxy coumarin heated to reflux in ethylene

chloride. The reaction mass is extracted with sodium hydroxide. Then acidified with HCl to

get the product. The crude product is purified with DNS.

STRONTIUM RANELATE Stage - I: ethyl acetone dicarboxilate is made by reacting citric acid with chlorosulfonic

acid in methylene chloride.

Stage – II: ethyl acetone dicarboxilate is condensed with, Malano nitrile and Sulphur in

presence of triethylamine to get Stage – II.

Stage –III: Stage – II is reacted with Methyl bromoacetate and Potassium carbonate in

Acetone, and to get alkylated Stage – II.

Stage –IV: Stage – III reacted with strontium hydroxide in water under reflux condition

to get the final product which is washed with water, dried, milled and

packed.

CALCIUM GLYCEROPHOSPHATE Stage – I: Epichlorohydrin is hydrolised with dilute acid, and reacted with Tri sodium

phosphate, to get Crude sodium Glycerophosphate. Stage – II : To the Above crude Sodium Glycerophosphate solution, Calcium chloride is

added to get Crude Calcium Glycerophosphate Stage – III: Crude Calcium Glycerophosphate is washed with DNS: Water mixture to get

Pure Calcium Glycerophosphate, which is centrifuged and dried


MAGNESIUM GLYCEROPHOSPHATE Stage – I : Epichlorohydrin is hydrolised with dilute acid, and reacted with Tri sodium

phosphate, to get Crude sodium Glycerophosphate. Stage –II : To the Above crude Sodium Glycerophosphate solution ,Magnesium

chloride is added to get Crude Magnesium Glycerophosphate Stage – III : Crude Magnesium Glycerophosphate is washed with DNS: Water mixture to

get Pure Magnesium Glycerophosphate, which is centrifuged and dried SODIUM GLYCEROPHOSPHATE Stage – I: Epichlorohydrin is hydrolised with dilute acid, and reacted with Tri sodium

phosphate, to get Crude sodium Glycerophosphate solution which is concentrated and filtered to get Crude sodium Glycerophosphate

Stage–II: Crude Sodium Glycerophosphate is washed with DNS: Water mixture to get

Pure Sodium Glycerophosphate, which is entrifuged and dried . SODIUM BETA GLYCEROPHOSPHATE Stage – I : Glycerol is reacted reaction with pivaloyl chloride in presence pyridine in

Methyl tertiary butyl ether to get dipivaloyl glycerol, which is reacted with phosphorous oxychloride in presence of Triethylamine.

Stage – II : Stage I is quenched with water. And extracted with hexane and methanol:

water Stage – III: Methanol –water mixture is basified with sodium hydroxide to the beta

sodium salt which is Centrifuged and dried. CARBASALATE CALCIUM Aspirin is dissolved in water using sodium bicarbonate. This clear solution is reacted with urea and calcium chloride solution to get carbasalate calcium precipitated which is Centrifuged, washed with DNS and dried. ETHAMSYLATE Stage-I: Sulphuric acid is added to a suspention of hydroquinone in ethylene di

chloride. After the sulfonation, water is added and aqueous layer separated. Stage-II: Aqueous layer is neutralized with diethylamine, concentrated, chilled, the

product filtered and washed with isopropanol and dried.


CALCIUM DOBESYLATE Stage-I: Sulphuric acid is added to a suspension of hydroquinone in ethylene di

chloride. After the sulfonation, water is added and aqueous layer separated. Stage-II: Aqueous layer is neutralized with a slurry of calcium carbonate in water,

centrifuged to separate calcium sulfate. Liquid from centrifuge is concentrated, chilled, the product filtered and washed with isopropanol and dried.

6.0 RAW WATER REQUIREMENT

A full-fledged ETP with 2 stage RO/Evaporator provided to recycle the treated waste water

in process and make-up water met through SIPCOT supply.

The Plant operates at present, and will operate on expansion on Zero Discharge basis. The

entire waste water is treated & reused. There will be no discharge of waste water from the

Plant.

The additional make-up water requirement is met through SIPCOT sources. There is no

drawal of ground or surface water from the plant.


Water Balance Diagram All Values are in KL Existing [ ] Proposed ( )

Evaporation [27] + (5.54) = 32.54

Waste water [38] + (7.8) = 45.8

Evaporation [27] + (4) = 31

Waste water [18] + (2.6) = 20.6

Evaporation [1.4] + (0.2) = 1.6

Waste water [5.6] + (0.8) = 6.4

Permeate Recycled water [59.75] + (10.86) = 70.61

[142] + (20.94) =

162.94

Cooling water /

Floor wash

[45] + (6.6) = 51.6

Process/Boiler/

Equipment Cleaning [65]

+ (13.34) = 78.34

Domestic

[7] + (1) = 8

Garden [25] KL

ETP

[61.6] + (11.2) =

72.8

RO

SIPCOT / Outsourced

[82.25] + (10.08) = 92.33 ME

[59

.75

] +

(10

.86

) =

70

.61

Evaporation

Residue 0.65 kg


14

7.0 ENERGY CONSUMPTION

The details of existing and upon expansion power consumption and its source are as follows:

Power Consumption

Source Existing Proposed Upon Expansion

TNEB 0.9 MW 0.3 MW 1.2 MW

Global Calcium has its own windmill, and the entire power required is met through this windmill.

The plant runs entirely on this green energy.

D.G. Sets of 125 KVA x 3, 180 KVA x 2, 380 KVA, 450 KVA capacity will be used only during

emergency or grid failure.

8.0 WORK FORCE

The existing work force of 140 Nos. will continue to remain the same even upon expansion.

9.0 EXISTING ENVIRONMENTAL SCENARIO

9.1 Air Environment

Ambient air quality monitoring was carried out for 4-locations, one in the plant site and 3 in

different directions outside the plant site, the location of sampling station is given in the following

Table and as shown in Fig 2.0.


15

Fig 2.0 Location of Ambient Air Quality Monitoring Stations

SA1

SA2

SA3

SA4


16

Locations of Air Monitoring Stations

S. No. Code Sampling Station Direction to

proposed project

site

Distance from

proposed project

site (km)

1 SA1 Existing Plant - -

2 SA2 Bedarappalli N 1.5

3 SA3 Madam SSW 2.0

4 SA4 Jibi SE 2.5

Summary of air quality data

Location Station Concentration g/Nm

3

Code SO2 NO

X PM

10 PM

2.5

Existing Plant SA1 10-14 10-16 36-45 16-24

SA2 8-13 9-16 37-48 16-22

SA3 10-14 10-18 37-53 17-26

SA4 10-16 12-19 41-56 19-29

Overall 8-16 9-19 36-56 16-29

The Concentration of Ozone (O3), Lead (Pb), Carbon Monoxide (CO), Ammonia (NH3),

Arsenic (As), Nickel (Ni) Benzene (C6H6) and Benzo(a)Pyrene were Below Deductable Level

(BDL) in all locations.


17

9.2 Noise Environment

Noise level measurements, with 5 minutes interval, in four corner of plant site were carried out.

The observed ambient instantaneous noise levels at the plant site varied in the range of

42.5dB(A) – 63.9 dB(A) with most of the observed values less than 59 dB(A).

9.3 Water Environment

The ground/surface water quality in the study area, normally meets the desirable/essential

limits. The locations of water sampling stations marked in Fig 3.0 and the results are given in

the following Table.

Locations of Water Sampling Stations


proposed project

site

Distance from

proposed project

site (km)

1 SW1 Existing Plant - -

2 SW2 Bedarappalli (Borewell) N 1.5

3 SW3 Madam (Borewell) SSW 2.0

4 SW4 Attebele (Lake) NW 3.5


18

Fig 3.0 Location of Water Sampling Stations

SW1

SW2

SW3

SW4


19

Water Quality Data

S.No Parameters SW1 SW2 SW3 SW4

1 Colour (Hazen units) <1 <1 <1 <1

2 Odour Agreeable Agreeable Agreeable Agreeable 3 Total Suspended Solids, mg/l 15 15 16 18

4 Dissolved Solids mg/l 520 630 432 1200

5 PH Value 7.0 7.48 7.6 7.12

6 Temperature in oC 32 32 32 32

7 Oil & Grease, mg/l BDL BDL BDL BDL

8 Total Residual Chlorine, mg/l BDL BDL BDL BDL

9 Nitrate as No3, mg/l 14.12 16.14 0.05 22.21

10 B.O.D (3 days 27oC), mg/l 15 17 2 10

11 Arsenic (as As), mg/l BDL BDL BDL BDL

12 Mercury (as Hg), mg/l BDL BDL BDL BDL

13 Lead (as Pb), mg/l BDL BDL BDL BDL

14 Cadmium (as Cd), mg/l BDL BDL BDL BDL

15 Hexavalent Chromium (as Cr+6), mg/l

BDL BDL BDL BDL

16 Total Chromium (as Cr), mg/l BDL BDL BDL BDL

17 Copper (as Cu), mg/l BDL BDL BDL BDL

18 Zinc (as Zn), mg/l 0.02 0.02 <0.01 0.05

19 Selenium (as Se), mg/l BDL BDL BDL BDL

20 Nickel (as Ni), mg/l BDL BDL BDL BDL

21 Boron (as B), mg/l BDL BDL BDL BDL

22 Percent Sodium 28 31 20 29

23 Cyanide (as CN), mg/l BDL BDL BDL BDL

24 Chloride (as Cl), mg/l 296 290 102 460

25 Fluoride (as F), mg/l 0.3 1.2 Nil 1.2

26 Sulphate (as SO4), mg/l 138 156.06 3 158.9

27 Pesticides Nil Nil Nil Nil

28 Total Coliform Organisms, (MPN/100ml)

5 7 4 17

29 Phenolic Compounds (as C6 H5 OH), mg/l

Nil Nil Nil Nil


20

9.4 Soil Environment

A total of 4-samples was collected in and around the plant site. Samples were collected using

augers at depths upto 30, 60 and 100 cms. The Soil Samples were analysed for pH, electrical

conductivity, nitrogen, phosphorus, potassium, available magnesium, natural moisture

content, grain size distribution (gravel, sand, clay/silt) textural class, bulk density, plastic

limit, liquid limit etc. The undisturbed sample at 60 cm depth was analysed for field capacity,

wilting coefficient, and available water storage capacity. The results are given in the

following Table.

Locations of Soil Sampling Stations


proposed project

site

Distance from

proposed project

site (km)

1 SS1 Existing Plant - -

2 SS2 Bedarappalli N 1.5

3 SS3 Madam SSW 2.0

4 SS4 Jibi SE 2.5

Location of the sampling stations are marked in Fig 4.0.


21

Fig 4.0 Location of Soil Sampling Station

SS1

SS2

SS3

SS4


22

Soil Quality Data

S.No Location SS1 SS2 SS3 SS4

1. Depth, cm 0-30 30-60 60-100 0-30 30-60 60-100 0-30 30-60 60-100 0-30 30-60 60-100

2. PH 6.5 6.05 6.4 6.7 6.65 6.7 6.8 6.65 6.7 6.8 6.75 6.6

3. Electrical Conductivity ( mho/cm) 10.4 11.0 11.1 12.8 13.0 12.6 13.4 13.5 13.0 11.0 13.2 12.5

4. Moisture Content (%) 5.0 4.5 6.0 4.5 5.1 6.05 3.0 7.5 8.0 10.0 11.5 10.0

5. Organic matter (%) 1.85 1.98 1.5 1.1 1.4 1.25 1.13 1.24 1.2 1.98 2.46 2.38

6. Alkalinity 0.005 0.005 0.005 0.0051 0.0052 0.0051 0.0052 0.0055 0.0051 0.0052 0.0052 0.0053

7. Acidity Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil 8. Sodium Absorption Ratio 0.11 0.1 0.1 0.1 0.09 0.1 0.13 0.11 0.11 0.08 0.090 0.08

9. Nitrogen (as N, %) 0.004 0.004 0.005 0.001 0.001 0.001 0.003 0.004 0.004 0.005 0.003 0.003

10. Phosphorus (as P, %) 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001

11. Potassium (as K, %) 0.01 0.008 0.01 0.007 0.006 0.006 0.009 0.01 0.001 0.009 0.01 0.008

12. Iron (as Fe, %) 0.8 0.84 0.75 0.55 0.6 0.55 0.51 0.55 0.5 1.07 1.0 1.05

13. Copper (as Cu, %) 0.003 0.003 0.002 0.001 0.001 0.001 0.002 0.002 0.002 0.003 0.003 0.003

14. Zinc (as Zn, %) 0.01 0.01 0.01 0.004 0.003 0.001 0.005 0.005 0.005 0.010 0.005 0.005

15. Manganese (as Mn, %) 0.02 0.02 0.02 0.009 0.009 0.01 0.02 0.02 0.02 0.020 0.02 0.02

16. Boron (as B, ppm) 0.2 0.2 0.22 0.2 0.24 0.21 0.25 0.2 0.21 0.22 0.24 0.21

17. Sodium chloride (as Nacl, %) 0.013 0.016 0.013 0.009 0.008 0.008 0.01 0.01 0.01 0.060 0.04 0.05

18. Sodium Carbonate (as Na2CO3, %) 0.006 0.004 0.004 0.01 0.01 0.009 0.009 0.01 0.01 0.01 0.01 0.01

19. Texture Sandy Sandy Sandy Sandy Sandy Sandy Sandy Sand Sandy Sandy Sandy Sandy

20. Sand, % 89.45 89.05 89.2 90.4 90.15 90.05 84.4 84.95 84.25 88.55 88.1 87.9

21. Silt & Clay, % 10.5 10.85 10.75 9.55 9.8 9.95 15.6 15.05 15.7 11.45 11.8 12.05

22. Spedific gravity, g/cc 2.37 2.38 2.39 2.55 2.5 2.48 2.45 2.5 2.52 2.5 2.53 2.48

23. Bulk Density, g/cc 1.09 1.0 1.03 1.16 1.14 1.1 1.09 1.15 1.14 1.09 1.09 1.13

24. Infiltration Capacity (in cm/hr) 5.0 3.1 2.5 5.5 1.9 1.2 5.8 2.05 1.7 5.4 1.8 1.05

25. Arsenic as As (mg/kg) BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL

26. Cadmium as Cd (mg/kg) BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL

27. Chromium as Cr (mg/kg) BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL

28. Lead as Pb (mg/kg) BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL

29. Mercury as Hg (mg/kg) BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL


23

10.0 WASTE & WASTE MANAGEMENT

10.1 Air Pollution

The major sources of air emissions are from fuel burning in the Boiler and Thermopac,

apart from small quantity of emission of Bromine from production processes. However,

adequate measures are incorporated and the details are as follows:

Emissions from combustion of fuels

The emissions are from Diesel Generator, Wood fired boiler and Thermopac.

The Diesel Generator is used only when there is an electrical supply breakdown.

The Wood fired boiler capacity is of 4 T. The stack is to a height of 20 m as per the norms.

It will be ensured that the fuel used will have low sulphur, optimum air fuel ratio to limit NOx

emission. Moreover, the fuel used is wood, which is most environment friendly.

Thermopac used for hot air generator also has stack of adequate height as per norms

based on sulphur in the diesel.

Emissions from production process

The emissions from production process are mainly from the electrolytic cells. The reactions

are carried out in closed condition and the vent is connected to an alkali scrubber. The

emissions are absorbed in alkali media. The alkali strength is monitored and maintained

and changed, if required. Thus resulting in insignificant Bromine emissions.

Emissions from storage or transport

The material is stored in closed container and hence no possible emission on storage and

transport. The material are transported to the reactor tanks using residual vacuum, hence

very minimal emission is possible while transporting the emissions through the drum bunk

openings are very minimal.

Stack Emission Characteristics are given in the following Table.


24

Stack Emission Characteristics

Stack No 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Material of Construction PVC PVC M.S M.S M.S M.S M.S M.S M.S M.S M.S M.S S.S S.S

Stack attached to Electroly

tic Cells

Electroly

tic Cells

Milling/

Drying

Unit

D.G.Set

125 KVA

D.G.Set

180 KVA

D.G.Set

125 KVA

D.G.Set

180 KVA

D.G.Set

125 KVA

D.G.Set

380 KVA

D.G.Set

450 KVA

4 T

wood

Fired

BOILER

Thermo

pac

Spray

Drier

250

kg/hr

Spray

Drier

150

kg/hr

Stack height Above the ground

level in m

12.0 12.0 12.0 8.0 9.0 8.0 9.0 8.0 10.0 10.0 20.0 20.0 22.0 18.0

Stack

top

Circular/

Rectangular /

Square

Circular Circular Rectang

ular

Circular Circular Circular Circular Circular Circular Circular Circular Circular Circular Circular

Inside dimensions of the stack

at top, mm

500 500 400 x

250

200 200 200 200 200 300 350 600 350 400 400

Gas quantity – m3/hr 20000 20000 3600 1690 1900 1690 1900 1690 3200 4100 16000 6000 14000 7000

Flue gas temperature, oC 35 35 78 250 250 250 250 250 300 300 140 240 110 80

Exit velocity of the gas, m/s 28.0 28.0 10.0 15.0 16.8 15.0 16.8 15.0 12.6 12.0 16.0 18.5 20.0 16.0

Emission concentration , mg/m3

SO2 - - - 16.69 24.04 16.69 24.04 16.69 50.8 60.1 687 2340 - -

NOx - - - 164.22 236.48 164.22 236.48 164.22 499.2 591.2 189 569 - -

SPM - - 75.0 4.72 6.8 4.72 6.8 4.72 14.4 17.0 100 100 - -

Br 7.53 7.53 - - - - - - - - - - - -

Emission rate, g/s

SO2 - - - 0.0078 0.0127 0.0078 0.0127 0.0078 0.045 0.068 3.05 3.9 - -

NOx - - - 0.077 0.125 0.077 0.125 0.077 0.444 0.673 0.84 0.95 - -

SPM - - 0.075 0.0022 0.0060 0.0022 0.0060 0.0022 0.0128 0.0194 0.44 0.167 - -

Br 0.04 0.04 - - - - - - - - - - - -


25

10.2 Wastewater Generation

Description Quantity (m³/day)

Existing Proposed Additional

Upon Expansion

Process / Boiler / Equipment Cleaning 38.0 7.8 45.8

Cooling Water / Floor Washing 18.0 2.6 20.6

Domestic 5.6 0.8 6.4

TOTAL 61.6 11.2 72.8

10.2.1 Wastewater Management

At GCPL, trade effluent is generated from the floor washings and equipment cleaning.

The total quantity of this trade effluent generated upon expansion will be 72.8 Cu.m/d.

The trade effluent generated from floor washings/equipment cleanings is collected in a

collection tank.

At the inlet of the tank, hydrated lime slurry is added to effect neutralisation.

The neutralised waste is then pumped to flow control tank, from where the waste is

allowed to discharge into a settling tank.

The overflow from the settling tank is allowed to pass through a three stage anaerobic

contact filter.

After anaerobic treatment, the waste is aerobically treated in an aerated lagoon.

The treated wastewater from the lagoon is allowed to settle in a settling tank and is

pumped to aerated lagoon II, wherein polyelectrolyte is added for better flock formation

to enable easy settling of suspended particles.

The aerated water is then taken to settling tank II, from where the clear supernatant is

pumped into the collection tank.


26

The treated water is then passed through the RO plant. Treated water from RO is reused

and the RO rejects are subject to Mechanical evaporation. Condensed water from

Mechanical evaporator is also reused.

10.3 Solid Wastes

Sl. No. Type of Solid

Waste

Quantity TPA

Existing Proposed

Hazardous Non-

Hazardous

Hazardous Non-

Hazardous

1. Process Waste -- 3.0 18.875 113.5

2. ETP Sludge -- 1.5

Hazardous wastes from the production process are collected and stored in closed containers.

The containers containing the Hazardous waste is stored in a closed shed. The Hazardous

waste is disposed to common waste collection yard of Tamil Nadu Waste Management Limited

at Gummidipoondi, Tiruvallur District.

Sewage sludge / sludge from effluent treatment

The sewage is connected to SIPCOT sewage system and hence no sewage sludge is collected

within the premises.

The sludge from the effluent treatment is dried in Filter Press. The dried sludge is packed in

polythene woven / polythene bags and the sludge bags are stored in a closed shed. The

hazardous sludge will be disposed to common waste collection yard of Tamil Nadu Waste

Management Limited at Gummidipoondi, Tiruvallur District.

11.0 CONCLUSION

The proposed expansion is planned within the existing premises of GCPL located at # 125, 126

SIPCOT Industrial Complex, Phase – 1, Hosur – 635 126, Tamil Nadu, which is a notified

industrial estate in Tamil Nadu. More-over the plant with modern process and techniques

including efficient environment management plan viz., air pollution control system to limit air

emissions, treatment of effluent in a full-fledged ETP / 2 stage RO and disposal of solid waste in

common landfill as authorized will all result in insignificant impact on the ambient environment.

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