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Pre-Feasibility Report Eco Services India Pvt. Ltd., Chennai – PRE “Natco Pharma L Pr Active Pharma Ing a Vaikkad Tiruv 600032 E FEASIBILITY REPORT for Limited, Chemical Division roposed Expansion of gredients (API) manufactur and Product Quantity At du Village, Ambattur Taluk vallur District, Tamil Nadu November 2016 Natco Pharma Limited Page _ 19 – Chennai” ring facility k,

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Page 1: Natco Pharma Limited - Welcome to Environmentenvironmentclearance.nic.in/writereaddata/FormB/TOR/Proposed_TOR... · Pre-Feasibility Report Eco Services India Pvt. Ltd., Chennai –

Pre-Feasibility Report

Eco Services India Pvt. Ltd., Chennai –

PRE FEASIBILITY REPORT

“Natco Pharma Limited, Chemical Division

Proposed

Active Pharma Ingredients

and Product Quantity

Vaikkadu Village, Ambattur Taluk,

Tiruvallur District, Tamil Nadu

600032

PRE FEASIBILITY REPORT

for

Pharma Limited, Chemical Division

Proposed Expansion of

Ingredients (API) manufacturing

and Product Quantity

At

Vaikkadu Village, Ambattur Taluk,

Tiruvallur District, Tamil Nadu

November 2016

Natco Pharma Limited

Page _ 19

Pharma Limited, Chemical Division – Chennai”

(API) manufacturing facility

Vaikkadu Village, Ambattur Taluk,

Page 2: Natco Pharma Limited - Welcome to Environmentenvironmentclearance.nic.in/writereaddata/FormB/TOR/Proposed_TOR... · Pre-Feasibility Report Eco Services India Pvt. Ltd., Chennai –

Pre-Feasibility Report Natco Pharma Limited

Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 20

CHAPTER–1

EXECUTIVE SUMMARY

S.No. Executive

Summary Description

1. Identification of

Project

NATCO PHARMA LIMITED (NATCO) head quartered at

Banjara Hills-Hyderabad in Telangana State is a vertically integrated

and R&D focused pharmaceutical company engaged in

developing, manufacturing and marketing of finished dosage

formulations (“FDF”) and active pharmaceutical ingredients

(“APIs”). Our focus is primarily on niche therapeutic areas and

complex products.

Natco has established an API manufacturing unit as Natco Pharma

Limited, Chemical Division – Chennai (earlier known as “Natco

organics Limited”) at S.No. 74/7B, Vaikkadu Village, Ambattur

Taluk, Tiruvallur District in the year 2007 to manufacture Active

Pharmaceutical Ingredients (APIs).

Natco Pharma Limited proposed to expand its manufacturing facility

and product quantity located at S.No. 74/7B, Vaikkadu TPP Salai,

Manali, Chennai

The proposed project is categorized as ‘B’ of 5(f) (as per the Gazette

Notificationdated 14th

September, 2006.

2. Project

Proponent

M/s. Natco Pharma Limited, Chemical Division – Chennai.

3. Brief Description

of Project

The current report deals with increase in expansion of product

quantity from 46.26 TPA to 66.24 TPA also there will be increase in

built-up area from 18,130 Sq.m to 22,946 Sq.m at Vaikkadu Village,

Ambattur Taluk, Tiruvallur district in the state of Tamil Nadu.

In the increased threat of the human life in our country with the

suffering of Cancer and the affordability of the medicine cost and

the easily availability of the medicine, it is planned to increase the

product portfolio. In order to satisfy this need, variety of products is

the need of our country. The expansion of the industry will be

beneficial to the region. The company will bring new job

opportunities for the local people.

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Pre-Feasibility Report Natco Pharma Limited

Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 21

Salient features

4. Total plot area 26.12 Acres (1,05,704Sqm)

5. Product Quantity 66.24 TPA

6. Location Particulars Details

Latitude 12°39'19.509" N

Longitude 80°09’14.992" E

Total Plot Area 26.12 Acres

Land Use Category Special and Hazardous Use Zone

Nearest Highway SH 114 – Ennore High Road

Nearest Railway Station Thiruvottiyur Railway Station (6 km)

Nearest Airport Chennai International Airport (30

km)

Nearest Harbour Chennai Port (19 km)

7. Project Cost 186.82 Crores (Existing: 86.82 Crores + Proposed : 100 Crores)

8. Water

Requirement

Total Fresh water requirement : 419KLD

For Industrial use : 271 KLD

For Domestic use : 25 KLD

For Green Belt Requirement : 123 KLD

Effluent Generation:

Effluent generated from the plant : 184 KLD

Details of Recycled & Recovered water:

Recycled water from ZLD : 163 KLD (Used for

cooling tower make up)

Recovered pure steam condensate : 52 KLD (Used for boiler

feed)

9. Source From CMWSSB and Private Tankers supply

10. Power Supply The power requirement for the proposed project is 2,350 kVA and it

is sourced from the nearby TNEB grid which is distributed through

the substation within project premises. It is proposed to install 1 nos.

of 1,010 kVA capacity and 1 no. of 100 kVA capacity DG set in

addition to 2 no. of 1010 kVA DG set installed at the plant as back-

up power supply source for the plant.

11. Alternative Site No alternative site has been considered and the existing plant is

situated inside the Manali Industrial Estate.

12. Quantity of

waste

Domestic waste : 90 Kg/day

Nonhazardous waste (Packing materials, Used Insulation waste,

Metal scrap) : 410 Kg/day

Fly ash from boiler : 2150 Kg/day

Industrial hazardous waste : 16.12 Tons/day

13. Total waste

water generation

The waste water generated from the plant would be 184 KLD.

The effluent generated from the plant will be segregated as HTDS,

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Pre-Feasibility Report Natco Pharma Limited

Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 22

LTDS and utility streams and treated in the “Waste water recycling

plant (ZLD)” consists of ETP (Primary & Secondary treatment),

Primary RO, High Pressure RO (HPRO), Secondary RO, Stripper,

Multi Effect Evaporator (MEE), Agitated Thin Film Dryer (ATFD),

Sludge Decanter & Sludge Paddle Dryer. Treated water is recycled

for cooling tower make up.

14. Land use & land

Ownership

The proposed site is located within the Manali Industrial Estate and

land use is Special and Hazardous Use Zone as per Chennai

Metropolitan Development Authority (CMDA).

Natco Pharma Limited has the ownership over the total land area of

26.12 Acres (1,05,704 Sqm) for Pharma development.

15. Conclusion Natco Pharma Limited, Chemical Division – Chennai, proposes to

expand its Active Pharmaceutical Ingredients (API) manufacturing

facility inorder to provide affordable medicines to all. API

manufacturing facility not only increases the market availability of

therapeutic drugs but also reduces the import burden on the country

and also support the government by paying the taxes will contribute

the growth of Indian economy and strengthen the socio-economic

values in the area.

The proposed expansion project will adopt the state of the art

technologies and a dedicated team of environmental professionals

for treatment and recycling of effluents, operation and monitoring of

all pollution control equipment. Natco has a defined EHS policy and

a robust Environmental Management system supported by a well-

defined organizational structure to ensure the prevention of pollution

and to protect the environment.

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Pre-Feasibility Report Natco Pharma Limited

Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 23

CHAPTER - 2

INTRODUCTION OF THE PROJECT

2.0 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

Natco Pharma Limited – Chemical Division is a Pharmaceutical company situated in the

Manali Industrial Estate situated approximately 30 kms north of Chennai in the State of

Tamil Nadu.Natco Pharma Limited proposed to expand its Active Pharmaceutical

Ingredients (API) manufacturing facility and product quantity in order to meet the demand

of off patent drugs. Natco Pharma Limited has obtained Environmental Clearance (EC) from

Ministry of Environmental and Forest (MOEF), New Delhi in 2007 for production quantity

of 46.26 TPA. The industry is having valid CTO from state pollution control Board. The

present study is the proposed expansion of API with the production quantity of 66.24 TPA

in the land extent of 26.12 Acres at S.No.74/7B, Vaikkadu TPP Salai, Manali, Chennai.

NATCO Pharma Limited (Public Limited Company) is one of the leading Pharmaceutical

companies in India, engaged in the development, manufacturing and distribution of Active

Pharmaceutical Ingredients (APIs) and API Intermediates.

NATCO Pharma Limited was incorporated in Hyderabad in the year 1981 with an initial

investment of INR.3.3 million, with a modest beginning of operation as a single unit with 20

employees, NATCO today has five manufacturing facilities spread across India which

dedicated modern research laboratories, capabilities in New Drug Development, etc.

NATCO currently consist of more than 3500 employees, consistently ranked among fastest

growing pharmaceutical companies in India.

Project Proponent

Shri V.C. Nannapaneni, Chairman and Managing Director, has over 42 years of experience

in the Pharmaceutical Industry. He has worked in the USA for more than a decade in various

Pharmaceutical companies. He holds Bachelors and Master’s Degree in Pharmacy from

Andhra University, Visakhapatnam (A.P), in addition to this he also holds a Master’s degree

in Pharmaceutical Administration from the Brooklyn College of Pharmacy, USA. Currently,

along with general management he also oversees the New Drug Discovery programme of the

company.

Mr. P.S.R.K. Prasad, Director and Executive Vice President - Corporate Engineering

Services, presently look after the General Administration, Engineering, regulatory, training,

environmental matters, safety, health, production and maintenance activities of the

Company. He has done BE Mechanical Engineering from Andhra University. Previously he

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Pre-Feasibility Report Natco Pharma Limited

Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 24

was associated with Ahmedabad Textile Industries Research Association, Coromandel

Fertilizers Ltd., Stiles India Ltd., Tirupati, Saudi Ceramic Co., Riyadh, K.S.A. Mr. Prasad

has got vast and good knowledge in procuring right equipment(s) and machinery for

production processes and to provide all utility services and to utilize the resources like

manpower, material in an optimum way and to ensure safety of life and property.

2.1 BRIEF DESCRIPTION OF THE NATURE OF PROJECT

Natco Pharma Limited has its head quartered at Banjara Hills-Hyderabad is a vertically

integrated and R&D focused pharmaceutical company engaged in developing, manufacturing

and marketing of finished dosage formulations (“FDF”) and active pharmaceutical

ingredients (“APIs”). Our focus is primarily on niche therapeutic areas and complex products.

NATCO had established an API unit Natco Pharma Limited, Chemical Division-Chennai

(earlier known as “Natco organics Limited”) at S.No:74/7B, Vaikkadu, TPP Salai, Manali,

Chennai, Tamil Nadu state in the year 2007 to make Active Pharmaceutical Ingredients

(APIs).

The company proposes to expand its Active Pharmaceutical Ingredients (APIs)

manufacturing capacity in the existing premises with a total investment of Rs.186.82 crores

includingthe existing investment of Rs 86.82 Crores (GFA certificate Attached as Annexure-

IV). The project site lies between 13°11'19.5" North latitude and 80°15’59.0" East longitude.

The project site is well connected by the National and State High Ways.

2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND

REGION

In the increased threat of the Human life in our country with the suffering of Cancer and the

affordability of the medicine cost and the easily availability of the medicine, it is planned to

increase the product portfolio. In order to satisfy this need, variety of Products is the need of

our country. The expansion of the industry will be beneficial to the region. The company will

bring new job opportunities for the local people. They will, therefore, become economically

stronger.

Natco Pharma Limited, Chemical Division-Chennai is a manufacturer of API (Active

Pharmaceutical Ingredients) / bulk drug, located in chennai.

Our commitment lies in providing the required quality API's and Intermediates to our existing

customers to our Country on prime and also to the other countries. We cater to a cross section

of clients in Asia, Canada, Brazil, Australia and USA

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Pre-Feasibility Report Natco Pharma Limited

Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 25

• Our Company’s strength in research and people has been the cornerstone of its success,

sustaining large investments in research initiatives of Rs.172 crores during the five years

leading to 2014-15.

• Our Company is integrated across the value chain – APIs to formulations - in the

manufacture of select products leading to corresponding advantages in terms of cost,

quality and logistics.

• Our Company addresses opportunities across the oncology, CNS, gastrointestinal,

migraine and anti-depressant segments, each of which is growing in size and scope.

• Our company established its brand as a strong global oncology player, respected for its

ability to develop world class generic products at one of the lowest costs.

• Our company has selected to grow its presence in value added niches where it addresses

the needs of specialists with a corresponding throughout per medical representative that is

considerably higher than the Indian pharmaceutical industry average.

• Our company is one of few in India to manufacture cytotoxic drugs across two plants, an

index of its commitment to invest in infrastructure and process sophistication in size and

scope.

2.3 DEMAND SUPPLY GAP

The demand for APIs and API intermediates is a derived demand. It gets derived from the

demand for various medicinal formulations (final administrable drugs) for the formulation

industry.

The APIs and API intermediates being manufactured by basic drug manufacturers are

exported as such or used by domestic formulators in their production processes. The

formulation firms further produce final medicines and export these as well as sell these in the

domestic market.

There is a wide gap in the demand and availability of cheap and quality medicines in India

and the world over.

Generic medicines and off patent drugs have significant potential to increase access to cheap

and effective medicines to poor people and in general to bridge the demand supply gap.

Indian basic drug manufacturers are playing a significant role in increasing access to

affordable off patent drugs.

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Pre-Feasibility Report Natco Pharma Limited

Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 26

2.4 EMPLOYMENT GENERATION

At present the company has over 190 employees. We have a strong team of R&D

(Hyderabad), Manufacturing, Maintenance, Quality Control and Quality Assurance chemists

with very pertinent skills in process development, manufacture and testing of our product

range. The team comprises of Engineers, Post Graduates, Graduates and Diploma holders

from some of the premier institutes in India.

The Details of employment during operational phase in this unit has given below:

The expansion facility will generate direct and indirect employment. About 450 employees

(including existing 190 employees) will be benefitted due to the proposed project, in that

180 nos. direct employment and 80 nos. of indirect employment.

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Pre-Feasibility Report Natco Pharma Limited

Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 27

CHAPTER - 3

PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

The proposed project is an expansion of Active and as per the Environment Impact

Assessment (EIA) Notification dated 14th

September 2006 and amendments in 2009 & 2011,

the proposed project falls under 'Category B2' with project or activity type number '5(f)',

which requires preparation of EIA Report to get Environmental Clearance from the State

Environmental Impact assessment Authority (SEIAA).

3.2 LOCATION

Natco Pharma Limitedproposes to expand the Active Pharmaceutical Ingredients/bulk drug

unit at R.S.No. 73/1A, 74/7B, 78/1B, 79/1, 79/2B, 79/3, 79/4B, 79/6A, 79/6B, 79/7, 80/1,

80/2, 80/3, 84/2, 84/3A, 84/5A, 84/6, 84/7A, 85/2B, 86/2B, 86/2C, 86/2D2, 86/3B, 86/4,

86/5, 86/6, 86/7, 86/8, 86/9 of Vaikkadu Village, Ambattur Taluk, Tiruvallur District. Also,

having its address as No.74/7B, Vaikkadu TPP Salai, Manali, Chennai.

3.3 DETAILS OF ALTERNATE SITE

No alternative site was examined, because this is an expansion of product quantity in the

existing plant at Vaikkadu Village, Ambattur Taluk, Tiruvallur district of Tamil Nadu. The

plant has the following advantages which is favorable for the expansion of product quantity:

� Land availability

� Existing setup support for maintenance, utilities and administrative controls (cost benefit).

� Feasible power requirement is available

� Sufficient water availability

� Connectivity of the site

3.4 PRODUCTS AND PRODUCTIONS QUANTITY

The existing products and their production quantity are as follows:

S.No Name of the product Quantity(Kgs/Annum)

1 Allylestrenol 4

2 Drospirenone 50

3 Nandrolone Decanoate 2

4 Testosterone Decanoate 2

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Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 28

5 Temozolomide 15

6 Daunomycin Hydrochloride 12

7 Altretamine 5

8 Epirubicin Hydrochloride 2

9 Idarubicin Hydrochloride 0.5

10 Chlorambucil 1

11 Doxorubicin Hydrochloride 2

12 Fulvestrant 1

13 Geftinib 500

14 Imatinib Methane Sulfonate 1000

15 GB-5 intermediate 3670

16 Melphalan 1

17 Sumatriptan 36000

18 Setraline Hydrochloride 5000

Total Production Quantity 46267.5

(46.267 TPA)

List of The proposed products and their quantity are as follows:

S.No. List of Products Quantity

(Kgs/Annum)

1. Chlorambucil 5

2. Doxorubicin Hydrochloride 40

3. Fulvestrant 40

4 Melphalan 5

5 Bendamustine Hydrochloride 250

6 Bortezomib 5

7 Sirolimus 120

8 Everolimus 20

9 Temsirolimus 5

10 Trabectedine 1

11 Decitabine 100

12 Azacitidine 250

13 Lenalidomide 360

14 Pomolidomide 250

15 Nelarabine 5

16 Thiotepa 5

17 Busulfan 50

18 Epothiline B 50

19 Carmustine 50

20 Gefitinib 4200

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Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 29

21 Imatinib Mesylate 8400

22 Cabozantinib- (S) -Malate 1000

23 Dasatinib Monohydrate 1200

24 Erlotinib Hydrochloride 4200

25 Lapatinib Ditosylate

Monohydrate

2040

26 Nilotinib Hydrochloride Hydrate 1800

27 Palbociclib 1800

28 Sorafenib Tosylate 4800

29 Sunitinib Malate 1800

30 Pazopanib Hydrochloride 1800

31 Dabigatran Etexilate 4500

32 Deferasirox 1000

33 Lansoprazole 4500

34 Lanthanum Carbonate Dihydrate 6000

35 Ledipasvir 3000

36 Ondansetron Hydrochloride

Dihydrate

3600

37 Pirfenidone 2000

38 Rizatriptan Benzoate 1000

39 Sertraline Hydrochloride 6000

40 Sumatriptan Succinate 3000

41 Ticagrelor 3000

42 Sacubitril 5000

43 Developmental Products (D) 200

Gross Total (Kgs/Annum) 77451

Total Production Quantity (At

any point of time totally 16

products will be manufactured

out of 42 products proposed and

the Developmental products)

66.24 TPA

3.5 RAW MATERIALS REQUIRED AND QUANTITIES

The raw materials required for the manufacture of proposed products are the chemicals/

solvents and the fuel. Thechemicals required for the process are mostly sourced from the

local (indigenous) markets. Some of these raw materials will be imported from various

countries. Mode of transportation of all raw materials and finished products from the project

site is by road to local markets and by road / rail / air / sea if exported.

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Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 30

3.6 MANUFACTURING PROCESS

The manufacturing process of bulk drugs consists of chemical synthesis extending to stages

of processing involving different type of chemical reactions. The generalized flow chart for

bulk drug manufacturing is shown in following figure:

The reactants / chemicals are fed into the reaction vessel for specific time. After completion

of the reaction the obtained product is sent to the separation section, the separation is done by

extraction / decanting / centrifugation / filtration techniques. After separation it is sent to

crystallization chamber followed by purification process. After that it is completely dried and

the final product is obtained. The waste water / effluents generated are sent to the Effluent

Treatment Plant (ETP) installed in the site. The hazardous waste generated is collected and

handed over to Tamil Nadu Waste Management Limited (TNMWL). The emissions are

controlled by scrubbers installed in the plant.

3.7 EQUIPMENT DETAILS

The existing equipment in the plant for the production of Active Pharmaceutical Ingredients

(API) is as follows:

S.No Equipment No Equipment

Name

MOC Capacity Quantity

(Nos.)

1. SSR-101 Reactor SS 300 L 1

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Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 31

2. SSR-102 Reactor SS 3000 L 1

3. SSR-103 Reactor SS 3000 L 1

4. SSR-104 Reactor SS 4000 L 1

5. SSR-105 Reactor SS 4000 L 1

6. SSR-106 Reactor SS 1500 L 1

7. SSR-107 Reactor SS 2000 L 1

8. SSR-108 Reactor SS 2000 L 1

9. SSR-109 Reactor SS 1500 L 1

10. MPR-101 SS Reactor SS 300 L 1

11. SFR-103 Fermenter SS 260 L 1

12. SFR-104 Fermenter SS 260 L 1

13. MFR-101 Fermenter SS 2160 L 1

14. MFR-102 Fermenter SS 2160 L 1

15. FSR-105 Feed Supply

Fermenter

SS 156 L

1

16. FSR-106 Feed Supply

Fermenter

SS 156 L

1

17. BSR-107 Feed Supply

Fermenter

SS 107 L

1

18. AGR-101 to AGR-104 All Glass

Reactor

Glass

Reactor

50 L 4

19. AGR-105 to AGR-108 All Glass

Reactor

All Glass

Reactor

20 L 4

20. AGR-109 to AGR-112 All Glass

Reactor

All Glass

Reactor

10 L 4

The equipment required for the expansion of Active Pharmaceutical Ingredients (API)

product quantity are as follows:

S.No Equipment Name MOC Capacity Quantity (Nos.)

1 Glass Lined Reactor MS 250 L 1

2 Glass Lined Reactor MS 600 L 2

3 Glass Lined Reactor MS 1000 L 2

4 Glass Lined Reactor MS 2000 L 1

5 Glass Lined Reactor MS 3000 L 4

6 Glass Lined Reactor MS 6000 L 12

7 Stainless Steel Reactor SS 2500 L 2

8 Stainless Steel Reactor SS 3000 L 2

9 Stainless Steel Reactor SS 5000 L 8

10 Stainless Steel Reactor SS 6000 L 7

11 Storage Tank SS 15000 L 9

12 Leaf Filter SS 6 Sq.m 4

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Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 32

13 Multi Mill SS 50-200 kg/hr 2

14 Rotary Paddle Blender SS 500 L 2

15 Rotary Vacuum Drier SS 750 L 2

16 Sifter SS 900 dia 2

17 SS Centrifuge SS 48” 18

18 SS Tray Drier SS 48 Trays 2

19 SS Tray Drier SS 96 Trays 10

20 Agitated Nutsche Filter Drier

(ANFD) SS 1000 L 4

3.8 WATER REQUIREMENT AND WASTE WATER GENERATION

Existing water requirement waste water requirement:

Water requirement of the project for the domestic and industrial activity during operation of

the plant is 216.5 KLD. The water required is met from CMWSSB and through the private

tankers which satisfy the water quality. The existing water requirement is given below:

The effluent generated from the plant is 113.7 KLD which is treated in the ETP installed in

the site. The Zero Liquid Discharge (ZLD) is achieved through the Multi Effect Evaporator

(MEE) system followed by Advanced Thin Film Drier (ATFD). The treated water is recycled

in the cooling tower top-up. The waste water generated from the plant is given below:

Parameter Fresh water Input (KLD)

Process 36.5

Utilities & Kettle washings 30

Boiler Feed 70

Cooling tower make up 25

Wet Scrubber make up 10

Domestic 20

Gardening 25

Total water requirement 216.5

Parameter Waste water

Generated (KLD)

Process 43.4

Utilities & Kettle washings 30

Boiler Feed 6

Cooling tower make up 3

Wet Scrubber make up 11.3

Domestic 20

Total waste water generated 113.7

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Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 33

The overall water balance is given below:

Proposed water requirement:

The Gross total water requirement for the plant after the expansion will be 634 KLD of which

total fresh water requirement will be 419 KLD. Treated water from waste water recycling

plant (ZLD) of about 163 KLD will be reused for cooling towers make up and pure steam

condensate of 52 KLD will be reused for boiler make up. Fresh water requirement will be

met from CMWSSB and through private tanker supply. The quality of water will satisfy the

bore well quality and the same is sufficient for the process activities.

The proposed Fresh water requirement is given below:

Parameter Fresh water Input (KLD)

Process 31

Process washings 20

QC Laboratory washings 5

Kilo Lab washings 5

Scrubbers 10

Domestic (@ 55 LPCD for 450 persons 25

Boiler feed 78

Cooling tower make up (3000 TR) 102

Utility rejects 15

Fire Hydrant system Make up 5

Gardening (@ 3.5 Lts / Sq.m for 35,151

Sq.m) 123

Total proposed Fresh water requirement 419 KLD

The proposed effluent generated from the plant will be 184 KLD. The effluent generated

from the plant will be segregated as HTDS, LTDS and utility streams and treated in the

“Waste water recycling plant (ZLD)” consists of ETP (Primary & Secondary treatment),

Primary RO, High Pressure RO (HPRO), Secondary RO, Stripper, Multi Effect Evaporator

Parameter Fresh water Input

(KLD)

Waste water

Generated (KLD)

Losses

(KLD)

Process 36.5 43.4 -6.9

Utilities & Kettle washings 30 30 -

Boiler Feed 70 6 64

Cooling tower make up 25 3 22

Wet Scrubber make up 10 11.3 -1.3

Domestic 20 20 -

Gardening 25 - 25

Total 216.5 113.7 102.8

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Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 34

(MEE), Agitated Thin Film Dryer (ATFD), Sludge Decanter & Sludge Paddle Dryer. Treated

water is recycled for cooling tower make up.

The waste water generated from the plant is given below:

Parameter Effluent Generation

(KLD)

From Process 35

From Process washings 20

From QC Laboratory washings 5

From Kilo Lab washings (Developmental products) 5

From Scrubbers 10

Domestic 21

From Boiler ( Blow down & Dirty condensate) 47

Cooling tower make up (3000 TR) 26

Utility rejects 15

Total Effluent Generation (KLD) 184

The overall proposed water balance is given below:

S.No. Purpose

Fresh

water

(KLD)

Recovered

water(KLD)

(Pure steam

condensate)

Recycled

water

(KLD)

Gross Water

Requirement

(KLD)

Loss

(KLD)

Effluent

(KLD)

1 Process 31 0 0 31

+3.75

KLD

added

from

reactions

35

2 Process Washes 20 0 0 20 0 20

3 QC Laboratory

washings 5 0 0 5 0 5

4

Kilo Lab

Washings

(Developmental

products)

5 0 0 5 0 5

5 Scrubbers 10 0 0 10 0 10

6 Domestic 25 0 0 25 4 21

7 Boiler feed 78 52 0 130 31 47

8 Cooling Tower

make up 102 0 163 265 239 26

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Pre-Feasibility Report Natco Pharma Limited

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9

Utility rejects

(MGF,ACF

Back wash,

Softener

/DMplant

regenerations,

etc)

15 0 0 15 0 15

10 Fire Hydrant

make up 5 0 0 5 5 0

11 Green belt 123 0 0 123 123 0

Total 419 52 163 634 402 184

The effluent generated for the proposed product expansion from the plant will be 184 KLD.

The effluent generated from the plant will be segregated as HTDS, LTDS and utility streams

for effective treatment and treated in the “Waste water recycling plant (ZLD)” consists of

ETP (Primary & Secondary treatment), Primary RO, High Pressure RO (HPRO), Secondary

RO, Stripper, Multi Effect Evaporator (MEE), Agitated Thin Film Dryer (ATFD), Sludge

Decanter & Sludge Paddle Dryer. Treated water is recycled for cooling tower make up.

Domestic effluents also send to waste water recycling plant and treated along with LTDS

process effluent. Waste water recycling plant process flow sheet is attached. The effluent

treatment scheme is devised on segregation approach (based on Total Dissolved Solids -

TDS) which is as follows:

• High Inorganic TDS (HTDS) effluent with TDS more than 25,000 mg/L

• Low Inorganic TDS (LTDS) effluent with TDS less than 25,000 mg/L

• Utility Low TDS Effluent

Treatment method for the HTDS/HCOD effluent (Stream – 1):

High TDS and High COD effluent which is generated from the process is passed through

stripper for removal of solvents and then the HTDS effluent is collected in the MEE Feed

tank. Reject water from High Pressure RO (HPRO) will also be collected in the MEE feed

tank. The combined HTDS effluent sent to Multiple Effect Evaporator (MEE) to enrich the

concentration level. The enriched concentration stream is sent to Agitated Thin Film Drier

(ATFD) to obtain salts and the recovered salts from ATFD will be collected and disposed to

Tamil Nadu Waste Management Limited (TNWML).The vapour condensate from MEE and

ATFD are sent to secondary RO plant for further treatment. Pure steam condensate returns

back to boiler.

Treatment method for the LTDS/LCOD effluent (Stream - 2):

Low TDS waste water from process, process washings, QC/ Kilo lab washings, scrubber

blow downs and domestic streams are considered as LTDS stream. All these streams are

treated in ETP consisting primary treatment followed by advanced electrochemical oxidation

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process, two stage secondary treatment system and sludge treatment (sludge decanter

followed by sludge paddle dryer).

LTDS effluents are collected in equalization tank of 300KL volume. For homogenization

mixing arrangement is available in equalization tank. From equalization tank effluent is

passed through automatic pH adjustment system followed by flash mixer and clariflocculator.

Acid/Alkali/ Coagulants/Polyelectrolyte dosing systems are installed. Clarified effluent is

passed through an Advanced Electrochemical Oxidation unit followed by aeration tank – 1

(alternatively Aeration tank - 1 will be operated as activated sludge process system) followed

by a clarifier and then send to Aeration tank – 2 followed by a clarifier. Treated effluent will

be collected in Primary RO Feed tank (Existing Equalization tank – 2) for further treatment.

Sludge generated from clariflocculator and clarifiers will be passed through sludge decanter.

Wet sludge cake is further sent to paddle sludge dryer system for removal of moisture. The

dried sludge (powder form) is packed in HDPE bags and stored in covered shed till one truck

load and then sent to TNWML for safe disposal.

Utility Low TDS Effluent (Stream -3):

Waste water generated from boiler blow down, dirty condensate, cooling tower blow downs

and utility rejects are considered as stream – 3. All these streams are collected in a collection

tank at ETP. Effluent pH is adjusted (If required) in the collection tank and sends to flash

mixer followed by lamella clarifier for removal of TSS. Clarified effluent is collected in

primary RO feed tank along with treated LTDS effluent.

Tertiary Treatment:

Tertiary treatment system consists of primary RO plant, High Pressure RO plant and

secondary RO plant. Treated low TDS effluents from ETP, Treated utility effluents and

secondary RO reject is collected in primary RO fed tank and passed through Primary RO

Plant (existing Primary RO plant will be upgraded) at a recovery rate of 80%. Permeate water

is collected in Secondary RO feed tank. Reject is collected in HP RO feed tank and then pass

through HPRO unit (new system will be installed) at a recovery rate of 40%. Permeate is

collected in Secondary RO feed tank and reject is collected in MEE feed tank.

Permeate water from primary RO, permeate from HP RO and vapor condensate from MEE &

ATFD will be passed through secondary RO (existing Secondary RO plant will be upgraded)

at a recovery rate of 80%. Permeate water is collected in a storage tank and will send to

cooling towers for makeup. Reject water send to primary RO feed tank for further recovery.

Every drop of waste water is collected, treated and recycled back.

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Pre-Feasibility Report Natco Pharma Limited

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Wastewater generation and Treatment Method for proposed expansion

S. No. Purpose Effluent

Stream

Stream

segregation

Quantity

(KLD) Disposal Method

1 From Process

Stream – 1

HTDS 20

Stream-1: HTDS/HCOD:

Qty:20KLD

Stripper → MEE → ATFD.

Stripped solvent send for

Incineration. Salt send to

TNWML. Vapour condensate

send to send to Secondary

RO.

2 From Process Stream -2 LTDS 15 Stream -2: LTDS/HCOD:

Qty:76KLD

ETP → Primary RO → HP

RO → Secondary RO.

Treated in ETP consists of

primary treatment, electro

chemical oxidation, two stage

secondary treatment & sludge

treatment. Tertiary treatment

consists of Primary RO, HP

RO, and Secondary RO.

Secondary RO permeate

recycled to cooling towers,

HP Ro reject send to MEE &

ATFD along with HTDS.

3 From Process

washings Stream -2 LTDS 20

4

From QC

Laboratory

washings

Stream -2 LTDS 5

5

From Kilo Lab

washings

(Development

prducts)

Stream -2 LTDS 5

6 From Scrubbers Stream -2 LTDS 10

7 Domestic Stream -2 LTDS 21

8 From Boiler Stream – 3 LTDS 47 Stream – 3: Utility (LTDS):

Qty.: 88KLD

Treated in lamella clarified

and send to primary RO along

with ETP treated LTDS

effluent for treatment in

Tertiary treatment system

9 From Cooling

towers Stream – 3 LTDS 26

10 From Utility

rejects Stream – 3 LTDS 15

Total Effluent Generation (KLD) 184

3.9 POWER AND FUEL REQUIREMENT

The power requirement for the plant is about 2,350 kVA and it is sourced from the TNEB.

Also, for the back-up power source 1 nos. of 1,010 kVA capacity & 1 no. of 100 kVA

capacity DG set will be installed in addition to 2 no. of 1,010 kVA DG sets to meet the

emergency power requirement of the plant.

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Pre-Feasibility Report Natco Pharma Limited

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The plant is already installed with 1 no of Oil Fired Boiler with capacity 3TPH (Tons per

Hour) and it is proposed to install additional 1 no. of Oil Fired Boiler / Briquette boiler with

6TPH (Tons per Hour). The existing 3TPH oil fired boiler will be used as stand by and the

proposed 6TPH boiler will be in operational after the expansion. Furnace oil / Briquette and

Low Sulphur HSD will be sourced from the local market.

The total fuel required inoperation of boilers and DG set is given below:

S.No. Boiler / DG set Fuel consumption Fuel type

1 3 TPH - Oil fired

boiler(Stand by)

4.128 T/day Furnace oil

2 6 TPH (Operational)

(Oil fired / Briquette fired)

8.256 T/day

21.50 T/day

Furnace oil

Briquette

4 DG Sets 11 kL/day (Assumed as 24 hrs

operation)

HSD

Emissions:

Boilers, DG sets and Incinerator are the main sources contribute to emissions from the plant.

Stack height of 11mts for existing DG sets is installed and for the proposed DG set same

height of stack will be installed. A stack height of 40mts is installed for the existing boiler.

The same stack will be used for the proposed boiler. Dust collector followed by Bag filters

will be installed if Briquette fired boiler is installed. Existing incinerator will be used for

incineration of hazardous wastes. A stack height of 40mts is installed with Venturi scrubber

followed by packed column to control the emissions.

All hazardous chemicals and volatile organic solvents are carefully handled in a closed

system, thereby preventing any discharge of these chemicals in to air. Gaseous emissions

from process will be scrubbed in two stages with water and caustic solution based the

characteristics of gases.

In order to control the emissions from process the scrubber system is installed in the site. The

existing scrubbers are as follows:

S. No Number Equipment Capacity Connected Area

1 SCR-301 Scrubber System 2000 CFM Fermentation Process area

2 SCR-302 Scrubber System 1000 CFM Extraction Process area

3 SCR-303 Scrubber System 1000 CFM Extraction Process area

4 SCR-304 Scrubber System 2000 CFM Synthetic Process area

5 SCR-305 Scrubber System

(2-Stage) 6000 CFM Synthetic Process area

6 SCR-306 Scrubber System 1000 CFM Connected to RM Store area

7 SCR-307 Scrubber system

(2-Stage) 3000 CFM Synthetic Process area

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Pre-Feasibility Report Natco Pharma Limited

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In the course of expansion, the following scrubbers will be installed in order to control the

emissions from the process area and utility area.

S. No Equipment Capacity Required No’s

1. Scrubber System

(2-Stage) 6000 CFM 3

3.10 SOLID WASTE GENERATION

Existing solid waste generation

The existing solid waste generation consists of non- hazardous waste 30 Kg/day and the

hazardous waste 1172.74 Kg/day. The non-hazardous waste (domestic waste) is handed over

to the local waste collection system and the hazardous waste is sent to Tamil Nadu Waste

Management Limited (TNWML). The existing solid waste generation and the disposal

methods are given below:

S. No Name of the Solid

Waste

Quantity

(Kg/Day) Disposal method

1 Non-hazardous waste

(Domestic) 30

Handed over to local waste

collection system

2 Inorganic solid waste

(Process Residues & Wastes) 183.21 Send to TNWML

3 Organic Waste (Process

Residues & Wastes) 101.60 Send to TNWML

4 Spent Catalyst/ carbon 2.77 Send to TNWML

5 Chemical Sludge from Waste

water Treatment 200 Send to TNWML

6 Salt from Evaporator 684.14 Send to TNWML

7

Ash from incineration of

hazardous waste, flue gas

cleaning residues

1.02 Send to TNWML

Total solid waste generation 1202.74

Proposed solid waste generation

The proposed solid waste generation after the expansion will consist of domestic solid waste

90 Kg/day, non- hazardous waste 410 Kg/day, fly ash from boiler 2150 Kg/day and the

hazardous waste 16.12 Tons/day. The domestic waste will hand over to the local waste

collection system, nonhazardous waste will be sent to recyclers and the hazardous waste will

be sent to Tamil Nadu Waste Management Limited (TNWML)/ send to cement industries for

co-processing/ In-house incineration.

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The proposed solid waste generation (Hazardous solid waste) and the disposal methods are

given below:

S.

No

Description of

Hazardous

Waste

Quantity Storage

Method Disposal method (Tons /

Day)

Tons /

Month

1 Spent carbon 0.082 2.46

Packed in

HDPE Bags

and stored in

covered shed

Send to TNWML /Cement

Industries for co-

processing

2 Organic Residue 1.28 38.4

Packed in

HDPE drums

and stored in

covered shed

Send to TNWML /Cement

Industries for co-

processing

3

Distillation

Bottom

Residues

0.586 17.58

Packed in

HDPE drums

and stored in

covered shed

Send to TNWML /Cement

Industries for co-

processing/Onsite

Incineration

4

Spent Mixed

Solvents from

Process &ETP

stripper:

3.47631 104.29 Stored in

tanks/drums

Send to TNWML /Cement

Industries for co-

processing/ Authorized

recyclers

5 Spent Solvents

(From Process) 1.12298 33.69

Stored in

Drums

After detoxification Send

to TNWML for

incineration /Cement

Industries for co-

processing/Onsite

Incineration (existing

Incinerator)

6

Date expired,

discarded and

Off specification

products/chemic

als

0.005 0.15

Packed in

HDPE Bags

and stored in

covered shed

Send to TNWML /Cement

Industries for

processing/Onsite

Incineration (existing

Incinerator)

7

Spill control

Wastes/Residues

containing Oil

0.001 0.03 Stored in

Drums Send to TNWML

8

Oil &Grease

skimming

residues

0.001 0.03 Stored in

Drums Send to TNWML

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Pre-Feasibility Report Natco Pharma Limited

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9 Inorganic Salts

(Process) 0.945 28.35

Packed in

HDPE Bags

and stored in

covered shed

Send to TNWML

10

Evaporation

Salts

(Process & Non

process effluent

- LTDS& Utility

streams)

7.996 239.88

Packed in

HDPE Bags

and stored in

covered shed

Send to TNWML

11 ETP Sludge 0.499 14.97

Packed in

HDPE Bags

and stored in

covered shed

Send to TNWML

12 Incinerator Ash 0.100 3.00

Packed in

HDPE Bags

and stored in

covered shed

Send to TNWML

13 Spent Catalysts 0.0184 0.55

Packed in

HDPE Bags

and stored in

covered shed

Sold to authorized

recyclers/send to TNWML

14 Used Oil 0.006 0.18 Stored in

Drums

Sent to authorized re-

processors / TNWML

15

Detoxified

containers /

Barrels / Liners

(Nos.)

40 Nos. 1200 Nos. Stored in Scrap

yard

After Detoxification send

to outside

agencies/recyclers

16

Decontaminated

media from

Microbiology

Lab

0.01 0.3

Packed in

HDPE bags and

stored in

covered shed

Autoclaved and send to

authorized biomedical

waste incinerator

17

Soiled waste

from OHC

(Cotton,

Dressings,

Soiled plaster

casts ,other

material)

0.0001 0.003

Packed in

yellow

coloured

biomedical

waste HDPE

bags and stored

in covered shed

Send to authorized

biomedical waste

incinerator/Dispose to near

by hospital with mutual

agreement.

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Pre-Feasibility Report Natco Pharma Limited

Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 42

18 E- Waste 0.001 0.03 Stored in

Covered shed

Send to authorized e-waste

collection

centres/registered

dismantlers/ authorized

recyclers/return back to

manufacturers

19 Used Lead Acid

batteries (Nos.) - 2 Nos.

Stored in

Covered shed

Send to manufacturers on

buy back basis

The proposed solid waste generation (Hazardous solid waste) and the disposal methods are

given below:

1

Non-hazardous

waste (Domestic

– canteen waste,

discarded

papers)

0.09 2.7

Packed in

drums /HDPE

bags

Handed over to local waste

collection system

2

Non-hazardous

waste (Paper

/cartons

/packing

materials, glass,

plastic/Used

PPE, etc.)

0.06 1.8 Stored in Scrap

yard

Sent to outside agencies /

recyclers

3 Used Insulation

waste 0.05 1.5

Stored in Scrap

yard

4

Metal scrap

(MS/SS/Alumini

um)

0.3 9 Stored in Scrap

yard

5 Fly Ash from

Boiler 2.15 64.5 Stored in silo

Send to Brick

Manufacturers

3.11PURPOSE OF EIA

As per the EIA notification dated 14th

September, 2006, it is mandatory for the proposed

activity to get Environmental clearance before setting up or expansion / modernization. The

detailed chart delineating the process is given in Figure 3.1.

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Pre-Feasibility Report Natco Pharma Limited

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Fig 3.1 Process of Environmental Clearance Procedure

Environmental Impact Assessment (EIA) is a well-planned process to predict the

environmental consequences of any kind of development, which is a result of human

activities and to suggest appropriate measures in order to reduce adverse effects and also to

augment positive effects. The EIA procures a rational and ethical approach for sustainable

development. However, it is more scientific process because it not only tells the past, present

and the future consequences of going on development, but also predicts the future events

which likely to change due to some reasons, In terms of the EIA notification, MoEF dated

14th

September 2006, the generic structure of EIA documents shall be as under:

� Introduction

� Project Description

� Description of the Environment

� Analysis of Alternatives (Technology & Site)

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� Anticipated Environmental Impact & mitigation Measures

� Environmental Monitoring Program

� Additional studies

� Project benefits

� Environmental Cost benefits Analysis

� EMP

� Summary & Conclusion

� Disclosure of Consultant Engaged

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CHAPTER - 4

SITE ANALYSIS

4.1 CONNECTIVITY

The nearest city is Chennai at about 18 Km from the plant. It is well connected with the road

and rail networks which is feasible for the proposed expansion viability.

Major roads Thiruvottiyur Highway- 5 Km

NH 5 (Chennai to Kolkatta)- 12 Km

Nearest Sea Port Chennai Sea Port - 19 Km

Ennore Sea Port - 17 Km

Nearest Railway Station Thiruvottiyur – 6 Km

Minjur – 8 Km

Central – 15 km

Nearest City Bus Stop Andarkuppam

Nearest Airport Chennai International Airport- 30 Km

4.2 LAND FORM, LANDUSE AND LAND OWNERSHIP

The proposed expansion in the plant in the land area of about 26.12 Acres (1,05,704 Sq.m)of

Vaikkadu Village, Ambattur Taluk, Tiruvallur District. The land use is categorized as Special

and Hazardous Zone by Chennai Metropolitan Development Authority (CMDA).

The Proposed land use details are given in the below table.

Table 4.1 Land use Breakup

S.No. Description Area in (Sqm) Percentage (%)

1. Total Land Area 1,05,704 100

2. Ground Coverage 22,946 22

3. Roads and Pavements 19,870 19

4. Green belt area 35,167 33

5. OSR area 10,562 10

6. Vacant area for future expansion 17,159 16

4.3 EXISTING INFRASTRUCTURE

The plant has the existing ground cover of 18130 Sq.m which is to be increased by 4,816

Sq.m to support the expansion. A well laid road internal roads are in place also it has easy

connectivity with the nearby Chennai city. There is an existing internal water connection

pipeline for the entire project site and the storm water drain is also well established along the

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road network. Power cable lines and the telecommunication lines are available for the

existing buildings around the project site.

4.4 SOIL CLASSIFICATION

Broadly, the soils can be put in four major groups, based on the basic fabric of soils i.e. Soil

texture which governs its many other properties. They are:

1) Clayey soil,

2) Red sandy or red loamy soil

3) Red sandy brown clayey soil and

4) Alluvial soil.

Of the above soils the district is mainly covered by three types of soils namely:

1) Silty loam soil

2) Clay loam soil

3) Silty Clay loam soil.

4.5 CLIMATIC DATA

The climatic conditions of the plant are given below:

Summer Max. Temp –37.6º C

Min. Temp - 24.5º C

Winter Max. Temp– 21.4º C

Min. Temp - 17.0º C

Rainfall Intensity 20 mm/Hr

Average Humidity Morning - 71%

Evening – 34%

4.6 SOCIAL INFRASTRUCTURE AVAILABLE

The plant is situated within the Manali Industrial Estate. There are number of industries in the

area like Ennore Thermal Power Station, Toshiba JSW power systems Pvt Ltd, Chennai

Petroleum Corporation Limited, Manali Petro chemicals Ltd, Kothari Industrial Corporation

Ltd, Carborundum universal Ltd and Madras Fertilizers Ltd. The present site is surrounded

by Raj Lubricants, Toshiba JSW power systems Pvt Ltd and Indian Oil Tanking.

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Pre-Feasibility Report Natco Pharma Limited

Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 47

CHAPTER - 5

PLANNING BRIEF

5.1 PLANNING CONCEPT

Natco Pharma Limited proposes to expand the Active Pharmaceutical Ingredients product

quantity. In India the threat of cancerhas been increased and the number of hospitals and the

patients are increasing now a days. But the generic drugs which are the medicine for the

cancer patients are of higher prices. The off patent drugs which can be manufactured in

Indian pharmaceutical industries are of low production quantity which cannot meet the actual

demand. Inorder to meet this demand and to provide healthier environment to the local

people we are proposed to expand the product quantity.

5.2 LAND USE PLANNING

The existing land use breakup is given in table below:

S.No. Description Area in (Sqm) Percentage (%)

1. Total Land Area 1,05,704 100

2. Ground Coverage 18,130 17

3. Roads and Pavements 19,870 19

4. Green belt area 35,167 33

5. OSR area 10,562 10

6. Vacant area for future expansion 21,975 21

The proposed land use breakup is given in below table:

S.No. Description Area in (Sqm) Percentage (%)

1. Total Land Area 1,05,704 100

2. Ground Coverage 22,946 22

3. Roads and Pavements 19,870 19

4. Green belt area 35,167 33

5. OSR area 10,562 10

6. Vacant area for future expansion 17,159 16

The proposed land use comes under Special and Hazardous Use Zone as per CMDA and

there is no change in land use.

5.3 EXISTING INFRASTRUCTURE

The Site has the required Infrastructure to meet the current and proposed requirements such

as

• Canteen

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• Potable drinking water

• Training block

• Laying of Black top / Concrete internal roads

• Fire hydrant facility

• Rain Water Harvesting Pond

• Eye/body wash showers

• First Aid kits at all prominent places.

• Occupational Health Centre.

• Rest Room for employees

• Pre-employment and routine medical examinations and the necessary follow up

actions

• Communication systems like Phone, Internet with safety measures, etc.

• Security system at the entrance etc.

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CHAPTER - 6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA

The area has well established internal road networks and also it is well connected to the

Chennai city and also to the nearby rail network. The plant is self-sufficient to cater the

expansion of the project. Hence, no new infrastructure is proposed.

6.2 NON PROCESSING AREA (RESIDENTIAL AREA)

All the manpower for the proposed project will be sourced from the neighboring villages,

hence no colony/ residential area is proposed in the project.

6.3 GREENBELT AREA

Nearly 33% area of total land area is proposed for greenbelt development plan. Indigenous

tree plantation is preferred in greenbelt development with the native species.

6.4 SOCIAL INFRASTRUCTURE

The project site is surrounded by schools, community health center and other adequate

infrastructures.

The impacts by the proposed expansion will be assessed and an appropriate plan of Corporate

Social Responsibility (CSR) activity will be planned. Some activities which were noted and

will contribute in the social activities are as follows:

• Infrastructure development in the nearby village schools

• Conducting Medical camp

6.5 CONNECTIVITY

The nearest city is Chennai at about 18 Km from the plant. It is well connected with the road

and rail networks which is feasible for the proposed expansion viability.

Major roads Thiruvottiyur Highway- 5 Km

NH 5 (Chennai to Kolkatta)- 12 Km

Nearest Sea Port Chennai Sea Port - 19 Km

Ennore Sea Port - 17 Km

Nearest Railway Station Thiruvottiyur – 6 Km

Minjur – 8 Km

Central – 15 km

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Nearest City Bus Stop Andarkuppam

Nearest Airport Chennai International Airport- 30 Km

6.6 DRINKING WATER MANAGEMENT

Water requirement for domestic will be availed from the private water supplies which met the

drinking water quality. Water required for the process will be met through the private tankers

and from CMWSSB supplies.

6.7 INDUSTRIAL WASTE (SEWAGE AND EFFLUENT) MANAGEMENT SYSTEM

The domestic wastewater and the process effluent generated from the plant will be treated in

Effluent Treatment Plant (ETP) installed in the site. The ETP installed will give rise to Zero

Liquid Discharge (ZLD) through Multi Effect Evaporator (MEE) System and the Advanced

Thin Film Drier (ATFD) installed at the site, so that the treated effluent will be reused for the

processes so that there is no discharge of the treated effluent. The effluent stream is divided

in to High Level Total Dissolved Solids (HTDS) stream and Low Level Total Dissolved

Solids (LTDS) stream and they are treated correspondingly in the ETP.

6.8 SOLID WASTE MANAGEMENT

The solid waste generated from the plant is mainly of hazardous waste (process waste) and

non-hazardous waste (domestic waste). The domestic waste will be collected, segregated as

biodegradable and non-biodegradable solid waste. The biodegradable solid waste will be

handed to over to the local waste collection facility and non-biodegradable waste will be

disposed through the recyclers. The hazardous waste mainly consists of organic residue,

inorganic solid waste, spent carbon, spent oil and fly ash from boiler will be collected and

sent to Tamil Nadu Waste Management Limited (TNWML) / authorized recyclers.

6.9 POWER REQUIREMENT

The power requirement for the plant is about 2,350 kVA and it is sourced from the TNEB.

Also, for the back-up power source 1 nos. of 1,010 kVA capacity& 1 no. of 100 kVA

capacity DG sets will be installed in addition to 2 no. of 1,010 kVA DG sets to meet the

emergency power requirement of the plant.

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CHAPTER - 7

R & R PLAN

6.0 REHABILITATION & RESETTLEMENT (R & R) PLAN

The plant is located within the Manali Industrial Estate which has group of industries. Also,

the proposal is expansion of Active Pharmaceutical Ingredients in the existing plant. There is

no residential settlement in the project site. Hence, the Rehabilitation and Resettlement

(R&R) Plan is not applicable in this proposed expansion.

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Pre-Feasibility Report Natco Pharma Limited

Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 52

CHAPTER - 8

PROJECT SCHEDULE & COST ESTIMATES

8.0 PROJECT SCHEDULE & COST ESTIMATES

The time schedule for the expansion will be 24 months after getting statuary approval from

related authorities. The total cost of proposed project expansion is Rs. 100.00 Crores

(excluding the existing). The copy of the GFA certificate is enclosed as Annexure – IV.

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CHAPTER - 9

ANALYSIS OF PROPOSAL

9.0 ANALYSIS OF PROPOSAL

The proposed expansion will help in benefitting the local people financially & socially. The

expected benefits to the local people are in areas like employment, communication,

educational activities and etc. The proposed expansion project will create direct employment

opportunities during the construction phase and in the operational phase both semi-skilled

and unskilled laborers. There will be social benefits from this proposed project.

The benefits through this proposed project are as follows:

• Local people will get direct financial benefit by way of employment.

• Local people will get some contracts of supply and services to get indirect income.

• Company will contribute in improving education and health facilities in nearby area.

Under the Corporate Social Responsibility the Industry will continue to develop a policy of

developing the villages in the vicinity by identifying the requirements. The industry will

define environmental monitoring program to monitor the Ambient Air Quality as well as

Stack Emissions from the Utilities and scrubbers. Industry will strengthen the existing

Environment, Health &Safety Department and also continue to engage recognized

laboratories to carry out all necessary monitoring parameters for its activities.

The segregated (HTDS/LTDS) wastewater will be regularly analyzed before and after

treatment in ETP-ZLD. Qualified staff will be appointed for the purpose of Operation and

Maintenance of the pollution control facilities. Stand-by facilities will be provided to all the

pumps so as to ensure fail proof treatment, handling and disposal. The hazardous waste will

be collected, segregated and disposed to Tamil Nadu Waste Management Limited

(TNWML). In order to mitigate the emissions from the DG sets adequate stack and to control

emission from process scrubber system will be provided.

Further activities will be analyzed, after the analysis of the baseline data generation and

socio- economic survey and the appropriate sustainable development will be contributed by

the proposed project. The appropriate amount of Corporate Social Responsibility is proposed

to be utilized for these beneficial activities.