prefeasibility of bsg -...
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Pre-Feasibility Report BSG Chemicals and Pharmaceuticals Pvt. Ltd.
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1. Introduction
M/s. BSG Chemicals and Pharmaceuticals private limited is located in Sy.
Nos. 3, 4, 5, 9 to 14 Donivanilakshmipuram (V), Nakkapalli (M),
Visakhapatnam District in Andhra pradesh. The unit acquired 70.4 Acres
of land in the following survey numbers.
S.No Survey No. Area in acres
1 Survey no.5 6.06
2 Survey no.4 2.90
3 Survey no.4 7.00
4 Survey no.5 3.00
5 Survey no.11/2 1.55
6 Survey no.12 3.48
7 Survey no.3/1 3.93
8 Survey no.3/2 1.24
9 Survey no.11/1 4.07
10 Survey no.3/1 0.71
11 Survey no.3/2 0.28
12 Survey no.3/4 1.37
13 Survey no.3/5 1.76
14 Survey no.9/2 1.04
15 Survey no.10/1 0.71
16 Survey no.10/2 0.33
17 Survey no.10/3 0.41
18 Survey no.11/1 0.73
19 Survey no.11/2 0.41
20 Survey no.12 0.64
21 Survey no.13/1 0.38
22 Survey no.13/2 0.55
23 Survey no.14/2 0.71
24 Survey no.9/2 5.00
25 Survey no.9/2 2.30
26 Survey no.10/1 2.70
27 Survey no.13/1 1.96
28 Survey no.13/2 2.63
29 Survey no.14/2 3.95
30 Survey no.5 3.0
31 Survey no.11/2 0.57
32 Survey no.10/2 1.63
33 Survey no.10/1 1.25
33 Survey no.10/3 2.15
Total 70.4
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It is proposed to establish a medium scale unit with an investment of Rs.
15.6 Crores. It is proposed to establish Zeroliquid Discharge plant with
adequate facilities for solvent handling and hazardous waste storage
facilities.
Copy of sale deed is enclosed at Annexure I.
Copy of land conversion documents are enclosed as Annexure II
As the site is situated outside the industrial area, this comes under
category A project under EIA notification 2006
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2. About the Project
The salient features of the project are described in table below
TABLE 1.0
Salient Features of the Project
Location Sy. No. 3,4,5,9 to 14
Donivanilakshmipuram (V), Nakkapalli (M), Visakhapatnam (D) Andhra pradesh
Longitude and latitude
17o 20’43.2’’ N & 82o 39’22.9’’ E 17o 20’42.4’’ N & 82o 39’31.6’’ E 17o 20’52.0’’ N & 82o 39’35.0’’ E 17o 20’52.6’’ N & 82o 39’29.4’’ E 17o 20’56.2’’ N & 82o 39’29.8’’ E 17o 20’59.3’’ N & 82o 39’11.0’’ E 17o 20’48.6’’ N & 82o 39’06.8’’ E
17o 20’42.4’’ N & 82o 39’22.7’’ E
Product category 5(f), Drugs & Drug Intermediates
Project category as per EIA notification
Category A
Proposed Activity Drugs , Drug intermediates and Chemicals-50.0TPM
Total investment on the plant Rs. 15.6 Crores
Total Investment on Environmental Infrastructure
Rs.2.5 Crores
Total area of the plant 70.4 Acres
Total area of green belt 28.16 Acres
Water requirement Total water requirement- 121.5 KLD Freshwater Requirement-81.5 KLD Recycled water is 40.0 KLD
Source of water
Borewell
Nearest habitation and
distance from the site
Donivani lakshmipuram (V) 0.9 Km(SE)
Nearest surface water bodies Rain fed water tank at a distance of 0.5 Km in SE direction from the site
Nearest reserve forest Vempadu reserve forest is at a distance of 0.4 Km(W)
Environmentally sensitive
areas within 10 km radius
None
Any national parks, wild life
sanctuaries within 10 km radius
None
Nearest air port and distance Visakhapatnam Airport-73 Km
Nearest railway station and distance
Tuni at a distance of 12.1 Km from the plant
Distance from National
highway
NH5 is at a distance of 5.16 Km
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i) About the Group & Promoters
The management at BSG Chemicals and pharmaceuticals private limited
consists of highly qualified and richly experienced persons. The company
is headed by B. Sarath Gopal Managing Director.
3. Project Description
3.1 Proposed Products & Production Capacity
M/S BSG Chemicals and pharmaceuticals private limited proposed to
establish manufacturing unit to manufacture Bulk Drugs, Drug
Intermediates and Organic chemicals. Also it is proposed to establish R&D
and Pilot Plant to manufacture customer synthesis products and R&D
Products to a tune of 1.2 TPA. Below Table provides list of proposed
products & capacity.
TABLE 2.0
LIST OF PROPOSED PRODUCTS
S.No Product Name
Production
Capacity TPM
Product Description
Drug/Intermediate/
Multipurpose chemicals
Bulk Drugs
1 Losatran potassium 2.4 Drug
3 Fluconozole 3.0 Drug
4 Ketorolactromethamine 3.0 Drug
5 Ondansetron Hydrochloride dihydrate
3.0 Drug
6 Atrovastatin Calcium 4.5 Drug
7 Olanzapine 2.4 Drug
8 Linezolide 1.5 Drug
9 Sumatriptan 0.6 Drug
10 QuetiapineFumarate 3.0 Drug
11 DronedroneHCL 3.0 Drug
Total Bulk Drugs 26.4 TPM
Drug Intermediates
1 CIS (+) Hydroxylactum 10.0 Drug Intermediate
2 Pramipexole Hydro chloride Intermediate
4.5 Drug Intermediate
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Total Drug
Intermediates 14.5 TPM
Multipurpose Chemicals
1 Sodium Methoxide 9.0 Chemical
Total Multi-Purpose
Chemicals 9.0 TPM
Custom Synthesis products & R&D products
1 Drugs and Intermediates in pilot scale
0.1 TPM
Total 50.0 TPM
3.2 Manufacturing Process
Brief process description and process flow charts are given at Annexure
III
3.3 Raw Materials
List of raw material product wise is given at Annexure IV
3.4 Water Requirement
The water requirement will be met from Borewell. The requirement for
water in this unit is for process and domestic purposes. The water balance
for daily consumption is presented below.
TABLE 3.0
Water Balance–Proposed
S.No Stream Water
requirement KLD
Wastewater Generation
KLD
Method of Treatment and
Disposal
1 Process 33.5 36.6
MEE followed by
ATFD. (Condensate to ETP & RO)
2 Washings 5.0 5.0
MEE followed by
ATFD. (Condensate
to ETP & RO)
3 Scrubbers 5.0 5.0
MEE followed by
ATFD. (Condensate
to ETP & RO)
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4 QC, R&D and Pilot
Plant
2.0 2.0 MEE followed by ATFD. (Condensate
to ETP & RO)
5 Boiler
make up 25.0 2.5
ETP & RO (RO Reject
to MEE)
6 Cooling Towers
make up 10.0 1.0
ETP & RO (RO Reject
to MEE)
7
RO back
washes and rejects
10.0 10.0 ETP & RO (RO Reject to MEE)
8 DM/Softner Plant back
washes
1.0 1.0 ETP & RO (RO Reject to MEE)
9 Domestic 10.0 8.0 ETP & RO (RO Reject to MEE)
10 Gardening 20.0 --
Total 121.5 71.1
3.5 Wastes generation and control systems
3.5.1 Liquid Effluents
As detailed in table 4.0 waste water generation would be 71.1 KLD. It is
proposed to segregate effluents into high COD and High TDS stream and
Low COD and Low TDS streams
High TDS and High COD stream would be treated in stripper followed by
MEE and ATFD. The resultant sludge would be disposed to TSDF,
Hyderabad. The Low TDS stream would be treated along with MEE/ATFD
condensates in biological ETP followed by RO. The RO rejects would be fed
back to MEE. The Permeate from RO would be used for cooling tower
make up. Thus the treatment system proposed is based on “Zero Liquid
Discharge” (ZLD) Concept
The schematic diagrams of ETP proposed are given in Figure 1.1 and
Figure 1.2 below
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Fig 1.1 Schematic treatment scheme of high TDS effluents
Effluent from
Process and
Reactor and RO rejects
Floor washings
Sludge to TSDF
Condensate to
Biological
Treatment
Condensate to Biological Treatment
Sludge to TSDF
Equalization
Tank
MEE
ATFD
Neutralization
Tank
Setting
Tank
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Fig 1.2 Low TDS Effluent Treatment System
Domestic effluent
Effluents from utilities MEE condensate
Sludge to TSDF
Permeate for re-use
Rejects to MEE
Screen
Chamber
Sludge Holding
Tank
Equalization
Tank
Neutralization
Tank
Clarifier
2
Holding
Tank
Filter Press
Sludge Cake
Aeration
Tank1
Clarifier
1
Sand
filter
Carbon
Filter
Ultra
filtration RO
Screen
Chamber
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3.6.2 Solid wastes management
Hazardous and non - hazardous wastes generated from the proposed
project are detailed below. Mode of disposal are also identified and listed.
Adequate storage of hazardous waste is ensured at the site
TABLE 4.0
Solid Wastes and Disposal
S.No
Description Quantity in TPM
Remarks
Hazardous waste
1 MEE salts 43.2 Sent to TSDF Dundigal
2 ETP Sludge 6.0
3 Process/ organic
Residue
69.6 Sent to TSDF/ Cement
plant for Co-
incineration in rotary kilns
4 Inorganic salt from process
0.39 Sent to TSDF Dundigal
5 Spent Carbon 3.63 Sent to TSDF Dundigal
TOTAL 122.82
Non- Hazardous waste with recycling option
6 Ash from boilers 171.0 Sold to brick
manufacturers
7 Waste /Used Oil 100 LPM Authorized Recyclers/
Re-processors
8 Mixed spent solvents 15.0 TPD Authorized Recyclers
9 Used batteries 5 Nos/
Annum
Sent to Authorized
Recyclers
10 container & container liners of hazardous
waste & chemicals
1000 Nos/month
After detoxification, disposed to outside
agencies
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TSDF Parawada facility in Visakhapatnam District is created for catering
the industries in this area. Transport of Hazardous wastes to TSDF is done
by Ramky. In case other hazardous wastes, authorized recyclers will
transport the wastes
4. Site Analysis
4.1 Plant Location
M/S BSG Chemicals and Pharmaceuticals is located at Sy. No. 3,4,5,9 to
14 Donivanilakshmipuram (V), Nakkapalli (M), Visakhapatnam District in
Andhra pradesh. The land area of the plant is 70.4 acres. The nearest
habitation from the site is Donivanilakshmipuram(V) at a distance of 0.9
Km. The nearest railway station is located at Tuni at a distance of 12.1
Km from the site.
There are few rainfed irrigation tanks within 10 KM radius of the site.
There are no ecologically sensitive areas like national parks, sanctuaries
within 10 km radius of the site. Following are the surroundings of the site
North – Road
South – Road & Mango plantations
East – Mango Plantations
West – Government land
There is only 1 reserve forest in the study area.
Table 5.0
Reserve Forests in the study area
S.No Reserve Forest Distance from the site
Direction from the site
1 Vempadu R.F 0.4 West
Topo graphic features of the site and 10 KM study area & Base map is
given at Fig 1.3.
Photographs of Current condition of the site is given at Fig. 1.4
Site lay out map is given at Fig 1.5.
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Fig 1.3
Topo map of the 10 KM study area
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Fig 1.4
Photographs of current condition of the site
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5.0 Planning in Brief
The project is envisaged to be completed by December 2017 and the
production shall be initiated thereon. Consultants are identified for
preparing the detailed project report.
6. Resource requirements
6.1 Power Requirement and Supply/Source
The total power requirement is 1250 KW. It shall be sourced from
APCPDCL
It is proposed to establish D.G sets as alternative to Power failure.
6.2 Production facilities, Utilities and effluent handling facilities
TABLE 6.0
Utilities/ETP –Proposed
S.NO Details Capacity/
No Proposed
Production facilities
1 Production Blocks Nos 2
2 Pharma Blocks Nos 1
3 Clean rooms Nos 1
4 Boiler (coal Fired) TPH 1 x6 & 1x4*
6 Thermic fluid heater Lakh/ Kcal 2.0
7 DG sets KVA 1 x 750 & 1 x
380
8 Cooling tower TR 2000
9 Nitrogen plant M3/Hr 5
10 Chilling plants TR 200 & 60
11 Softner/DM plant M3/hour 10
12 Fresh water RO Plant M3/hour 10
Effluent handling & treatment facilities
13 collection tanks-Storage KL 100
14 Neutralisation tanks KL 100
15 Stripper, MEE, ATFD KLD 50
16 RO & Biological treatment
KLD 100
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* 4 TPH boiler shall be kept as standby
* DG Sets are used only during load shutdown by APCPDCL
6.3 Land Requirement
The unit currently has 70.4 acres of land and out of which 28.16 acres of
green belt is developed. The land requirement for proposed activities will
be met from existing open area. Below table provides the land statement.
Detailed site lay out plan outlining proposed activities is given at Figure
1.5
Table 7.0
Land Statement
S.NO Purpose Units Extent
1 Built up area Sq.M 33878.61
2 Roads Sq.M 28497.72
3 Green belt Sq.M 113990.08
4 Open area Sq.M 108610.80
Total Sq.M 284977.20
7.0 Air Pollution
The Sources of air emissions from the plant are 6.0 TPH coal fired boiler &
4.0 TPH coal fired Boiler.
The process emissions contain HBr, CO2, O2, N2 and SO2. HBr emissions
are4 scrubbed in two stage scrubber, SO2 emissions are scrubbed with
caustic lye and scrubbed waste is send to MEE. The other gases expected
in the process are N2, O2 and CO2 which are let out into the atmosphere.
Below Table gives proposed emission sources from the plant.
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Table 8.0
Emission Source –Proposed
S.NO Source Capacity
Fuel Anticipated emissions
Control system
1 Boiler 6 & 4 TPH
Coal SPM, SO2, NOx
Bag Filters
2 DG sets 1 X 750 & 1 X
380 KVA
Diesel -- Acoustic enclosure
3 Thermic fluid heaters 2x105 k.cal/hr
Diesel -- Adequate stack
4 Process emissions -- -- HBr, SO2, Scrubber
8. Bulk Chemicals Storage
Following bulk chemical storage facilities are proposed.
Table No 9.0
Storage facilities of bulk chemicals
Sr
No
Capacity
(KL) Name of the solvent MOC
1 20 Acetone SS
2 20 IPA SS
3 20 Toluene SS
4 20 Ethylacetate SS
5 20 Toluene SS
6 20 Diesel SS
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9.0 Project Financial
The estimated cost of the project is approximately 15.6 Crores. Out of
this Rs. 2.5 Crores will be for effluents treatment facilities and rest for
other utilities
Project cost
Rs. In
lakhs
Land 180
Plant & machinery 800
Civil & structural
Roads/Drains/Dykes etc 200
Total 1180
Pipe lines & insulation 20% on plant & machinery 160
Electricals & instrumentation 10% on plant & machinery 80
Erection & commissioning & painting
10% on plant &
machinery and structures 80
Safety & Environment 25
Furniture, fixtures, computers,
lighting etc 15
Contingencies & pre-operative expenses 20
Project cost 1560
Say Rs. 15.6 Crores