1. introductionenvironmentclearance.nic.in/writereaddata/online/tor/0_0... · 2014. 12. 22. ·...

Pre-Feasibility Report Vijaya sri chemicals.

1

1. Introduction

M/s. Vijayasri Chemicals is located at Plot NO.42, in SVCIE, Jeedimetla,

Rangareddy District in Telangana. The unit was established in March

1998. Copy of sale deed is enclosed as Annexure I. The unit obtained

CFE of the Board and CFO vide letter no:

APPCB/10076/HYD/JDM/52/HO/CFO/2013-2274 dated 06.07.2013 to

manufacture Intermediates called Trimethyl Orthovalerate, Trimethyl

Orthobutyrate, Trimethyl Orthoproplonate & 2-Butyl 4-Chloro 5-

Formylimidazole with a capacity of 4.74 TPM. Copy of CFO of the Board is

enclosed at Annexure II. The unit obtained CFE for Change of product

mix in 2014. Copy of the same is enclosed as Annexure III.

As the unit is drug intermediate category and not covered under 1994 EIA

notification, EC requirement was not there and hence not taken.

In order to meet the market demand it is proposed to expand the

production Capacity from 4.74 TPM to 53.0 TPM


2

2. Introduction of the Project

The salient features of the project are described in table below

TABLE 1.0

Salient Features of the Project

Location Plot NO.42, SVCIE,

Jeedimetla, Rangareddy (D) Telangana.

Longitude and latitude

17031’12.3” N Latitude and 78027’33.9” E Longitude

Year of establishment 1998 Product category 5(f), Drug Intermediates Project category as per EIA

notification

A”( As the unit is located in 10 Km

radius of Bollaram & patancheru cluster which is notified under CEPI)

Proposed Activity Capacity expansion from 4.74 TPM to 53.0 TPM

Total investment on the plant Current - Rs. 10.7 Crores & Proposed – Rs.3.0

Total Investment on Environmental Infrastructure

Rs. 0.10 Crores (Current) Rs.1.5 Crore ( Proposed) – Total 1.6 Crores

Total area of the plant 4939.8 Sq meters

Total area of green belt 926.0 sq meters

Water requirement Total water requirement after expansion 69.9 KLD

Freshwater Requirement 30.6 KLD Recycled water is 39.3 KLD

Source of water

Purchased from outside tankers

Nearest habitation and distance from the site

Shapur nagar (V) at a distance of 1.0 Km from the site

Nearest surface water bodies Fox sagar-0.67 Km (NE) Nearest reserve forest Dulapalli reserve forest at a distance

of 1.31 Kms in North direction Environmentally sensitive areas within 10 km radius

None

Any national parks, wild life sanctuaries within 10 km radius

None

Nearest air port and distance Rajiv Gandhi International Airport, Shamshabad is nearly 31.18 Kms

from the plant site

Nearest railway station and

distance

Bharat nagar at distance of 10 Kms

from the site


3

i) About the Group & Promoters

M/s. Vijayasri Chemicals., is located Plot NO.42, in SVCIE, Jeedimetla,

Rangareddy District in Telangana to manufacture drug intermediate

The project proponent Mr. K.V.Ramarao, is a science graduate from

Andhra university and Has rich experience in the field of the fine

chemicals; intermediates and API’s. He is looking after the day to day

functioning’s in procurement of raw materials & creditors & debtor

Management. Vijayasri chemicals have highly profiled technical team

processing of post graduation and Doctorates level.

Our team is well Development of New molecules, polymorphic forms and

Stereo Isomers. Vijayasri has much experience in Catering of API’s

intermediates.


4

3. Project Description

3.1 Production Capacity

The Unit is currently manufacturing API & Drug Intermediates as detailed

below

TABLE 2.0

LIST OF EXISTING PRODUCTS

S.No Name of the Product Quantities in TPM

1. Trimethyl Orthovalerate 1.44

2. Trimethyl Orthobutyrate 1.20

3. Trimethyl Orthoproplonate 2.00

4. 2-Butyl 4-Chloro 5-Formylimidazole 0.1

Total 4.74

3.1.1 Proposed expansion:

It is now proposed to expand the production capacity by including 6 new

products along with 1 existing product. Below Table provides list of

products and proposed capacities.

TABLE 3.0

PROPOSED PRODUCTS & CAPACITY

S.No Name of the Product Qty. in TPM

Product Description

API/Intermediate/ Multipurpose chemicals

1 Valsartan 5.00 API

2 Ambroxol Hydrochloride 5.00 API

3 Pentaoperazol Sodium

5.00 API

4 Sertaline Hydrochloride 5.00 API

5 Losartan Potassium 20.00 API

6 Rabeprazol 5.00 API

7 2-Butyl-4-chloro-5-

formyl imidazol 8.00 Intermediate

Total 53.0


5

3.2 Manufacturing Process

Brief process description and process flow charts are given at Annexure

V

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 private suppliers through

tankers. The requirement for water in this unit is for process and domestic

purposes. The water balance for daily consumption is presented below.

TABLE 4.0

Water Balance– Current & Proposed

S. No

Stream

Water requirement in

KLD

Waste Water discharge in

KLD

Proposed method of treatment &

disposal

Current After Expan

sion

Current After Expan

sion

1 Process

4.664

35.9

4.664

39.9

MEE followed by

ATFD. (Condensate to ETP & RO)

2 Washings 3.0 3.0

MEE followed by

ATFD. (Condensate to ETP & RO)

3 Cooling Towers 9.7

16.0 -- 1.5 ETP & RO (RO Reject to MEE)

4 Boiler 8.0 0.4 1.0 ETP & RO (RO

Reject to MEE)

5 DM/Softene

r

-- 2.0 -- 2.0 ETP & RO (RO

Reject to MEE)

6 Domestic 2.5 4.0 1.5 3.2 ETP & RO (RO

Reject to MEE)

7 Gardening -- 1.0 -- --

Total 16.864 69.9 6.564 50.6


6

3.5 Wastes generation and control systems

3.5.1 Liquid Effluents

As detailed in table 4.0 waste water generation after expansion would be

50.6 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


7

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

Stripper Aq. Distillate to

recovery/ Cement

industries/ TSDF


8

Fig 1.2 Low TDS Effluent Treatment System

Domestic

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


9

3.5.2 Solid wastes management

Hazardous and non - hazardous wastes generated from the proposed

expansion project are detailed below. Mode of disposal are also identified

and listed. Adequate storage of hazardous waste is ensured at the site

TABLE 5.0

Solid Wastes and Disposal

S.No

Description

Quantity TPM Remarks

Current

After

Expansion

1 Spent Carbon 0.014 5.48 Sent to TSDF/ Cement plant

2 ETP sludge 13.50 25.0 Sent to TSDF Dundigal

3 MEE salts/ -- 74.0 Sent to TSDF Dundigal

4 Inorganic salt

from process

-- 77.69 Sent to TSDF Dundigal

5 Organic

residue

-- 25.17

6 Distillation bottom

residue

0.150 0.5 Sent to TSDF/ Cement plant

7 Process sludge

2.002 -- Sent to TSDF Dundigal

TOTAL 15.66 207.84

Non Hazardous Wastes

8 Ash from boilers

-- 4.75 TPD Sold to brick manufacturers

Wastes with recyclable options

9 Waste /Used

Oil

5 LPM 10 LPM Authorized Recyclers

10 De-toxified

container &

container liners

-- 100

Nos/month After detoxification, disposed

to outside agencies


10

TSDF facility is about 30 Kms from the site in RangaReddy District which

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. Vijayasri Chemicals is located at Plot NO.42, in SVCIE, Jeedimetla,

Rangareddy District in Telangana. The site is situated at 17031’12.3” N

Latitude and 78027’33.9” E Longitude. The land area of the plant is

4939.8 Sqmtrs. The nearest habitation from the site is Shapurnagar (V)

at a distance of 1.0 km. The nearest railway station is located at

Bharatnagar at a distance of 10 Kms from the site. There are no

ecologically sensitive areas like national parks, sanctuaries within 10 km

radius of the site.

The site is surrounded by other industries of IDA Jeedinetla. Following are

the surroundings of the site

North – Gampalabasti

South – Prince LaboratoresLtd.

East – Open plot followed by Gampalabasti

West – Approach Road followed by SteelGodown.

Following 7 reserve Forests are there within 10 KM radius of the site

Table 6.0

Reserve Forests in the study area

S.No Reserve Forest Direction from the

site

Distance from the

site

1 Dulapalli N 1.31

2 GajulaRamaram NW 4.07

3 Pochampalli N 5.41

4 Goudavalli N 7.21

5 Dundigal NW 9.94

6 Kajipalli NW 9.96

7 Kandalakoyya NE 9.44


11

Topo graphic features of the site and 10 KM study area is given at Fig 1.3

Plant Photographs are given at Fig. 1.4

Site lay out map is given at Fig 1.5


12

Fig 1.3

Topomap of the 10 KM study area


13

Base Map of the Study Area


14

Fig 1.4.

Plant Photographs


15

Fig 1.5

Site lay out plan


16

5.0 Planning in Brief

The project is envisaged to be completed by September 2015 and the

production shall be initiated thereon. Consultants are identified for

preparing the detailed project report.

6.0 Resource requirements 6.1 Power Requirement and Supply/Source

The total power requirement is 500 KVA. It shall be sourced from

TSCPDCL and D.G sets as alternative to Power failure.

6.2 Production facilities , Utilities and effluent handling facilities

There will not be any additions to production facilities for expansion as

existing infrastructure is sufficient. Utilities and ZLD facilities for proposed

expansion is given in the table below

TABLE 7.0

Utilities/ETP – Existing & Proposed

S.NO Details

Capacity/

No Current

Additions

After

expansion

Production facilities

1 Production Blocks- Nos 1 - 1

2 Clean rooms Nos 1 - 1

Utilities

3 Boiler ( coal Fired) TPH 2 TPH 5 TPH 5 TPH

4 DG sets KVA 1 X 125, 1X 250

1 X 500 500

5 Cooling tower TR 2X200, 1X125 -- 525

6 Softner/DM plant M3/hour 1 -- 1

Effluent handling & treatment facilities

7 collection tanks-

Storage

KL 8X 25 2X 25 250

8 Neutralisation tanks KL 1X 30, 1X 20 2X 30 110

9 Stripper, MEE, ATFD KLD 25 50 50

10 RO & Biological treatment

KLD -- 50 50


17

6.3 Land Requirement

The unit currently has 4939.8 Sq.mtrs of land and out of which 926

sq.mtrs of green belt is developed. Below table provides the land

statement. Detailed site lay out plan is given at Figure 1.5

Table 8.0

Land Statement

S.NO Purpose Units Extent

1 Built up area Sq.M 4013.8

2 Green belt Sq.M 926.0

Total Sq.M 4939.8

7.0 Air Pollution

The Sources of air emissions from the plant are 1x 5.0 TPH coal fired

boiler.

The process emissions from the second phase contain SO2, HCl, HBr and

CO2. HCl, SO2 & HBr emissions are scrubbed with caustic lye and

scrubbed waste is send to MEE. The other gases expected in the process

are carbon dioxide, which are let out into the atmosphere.

Below Table gives current & proposed emission sources from the plant.


18

Table 9.0

Emission Source – Current & Proposed

S.NO Source Capacity

Fuel Anticipated

emissions

Control

system

Current

1 Boiler 2 TPH Coal SPM, SO2

& NOx

Dust

collector

2 DG sets 1 X125,

1 X 250 KVA

Diesel SPM, SO2,

NOx

Acoustic

enclosure

3 Process emissions -- -- HCl Scrubber

Proposed additions

4 Boiler 5 TPH Coal SPM, SO2 & NOx

Multiclone,

bagfilter

5 DG sets 1X500 Diesel SPM, SO2, NOx

Acoustic enclosure

6 Process emissions -- -- HBr, HCl,SO2

Scrubber

8.0 Bulk Chemicals Storage

Following bulk chemical storage facilities are proposed for expansion

activity

Table No 10.0

Storage facilities of bulk chemicals

Sr

No

Capacity

(KL) Name of the solvent MOC

1 25 Acetone SS316

2 20 H2SO4 MS

3 20 Methanol SS316

4 20 Toluene SS316

5 20 Ethylacetate SS316

6 20 HCl PP/FRP


19

9.0 Project Financial

The estimated cost of the expansion project is approximately 3.0 Crores.

Out of this Rs. 1.5 Crores will be for effluents treatment facilities and rest

for other utilities

Project cost

Rs. In lakhs

Plant & machinery 100

Civil & structural 50

Roads/Drains/Dykes etc 10

Pipe lines & insulation

10% on plant &

machinery 25

Electricals & instrumentation 10% on plant & machinery 25

Erection & commissioning & painting

5% on plant &

machinery and structures 50

Safety & Environment 10

Furniture, fixtures, computers,

lighting etc 15

Contingencies & pre-operative

expenses 10

Project cost 295

Say Rs. 3.0 Crores

1. introductionenvironmentclearance.nic.in/writereaddata/online/tor/0_0... · 2014. 12. 22. ·...

Documents