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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,
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.
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,
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.
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
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
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.
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.
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
Pre-Feasibility Report Natco Pharma Limited
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
Pre-Feasibility Report Natco Pharma Limited
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.
Pre-Feasibility Report Natco Pharma Limited
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
Pre-Feasibility Report Natco Pharma Limited
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
Pre-Feasibility Report Natco Pharma Limited
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
Pre-Feasibility Report Natco Pharma Limited
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
Pre-Feasibility Report Natco Pharma Limited
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
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 35
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
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 36
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.
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 37
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.
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 38
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
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 39
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.
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 40
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
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 41
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.
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.
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 43
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)
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 44
� Anticipated Environmental Impact & mitigation Measures
� Environmental Monitoring Program
� Additional studies
� Project benefits
� Environmental Cost benefits Analysis
� EMP
� Summary & Conclusion
� Disclosure of Consultant Engaged
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 45
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
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 46
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.
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
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 48
• 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.
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 49
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
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 50
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.
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 51
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.
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.
Pre-Feasibility Report Natco Pharma Limited
Eco Services India Pvt. Ltd., Chennai – 600032 Page _ 53
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.