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ANNEXURE-II DETAILS OF MANUFACTURING PROCESS 1) (Step-I: Diclofenac Sodium) 2,6 DCP, sodium Methoxide, Ethyl Chloro Acetate, Aniline Caustic Are added to reactor in required proportion. The mass is allowed to react together at required temperature and pressure condition, once the reaction is over, the material is filtered and dried in drier and packed in drums and stored as DCDPA (Step-II: Diclofenac Sodium) DCDPA, Ethoxy Ethanol, Chloro Acetyl chloride are added to a reaction vessel, Hydrogen Chloride gas generated during the reaction is scrubbed off with the help of caustic solution in scrubber tower. The material filtered , washed and dried packed and store as CPDCA (Step-III: Diclofenac Sodium) CPDCA, Aluminium Chloride to allowed react in a reactor and controlled temperature condition. The mass is then quenched in water and filtered, Hydrogen chloride gas generated during reaction and quenching is taken to scrubber system. Neutralized material is filtered, washed, dried, Packed and store as Indolinone Diclofenac Sodium (DFS) (Step IV: Diclofenac Sodium) Indolinone, Caustic and solvent added reaction vessel, reaction is done under controlled condition the material after reaction is over, filtered, dried packed and stored as DFS 2) Nifedipine In order to prepare Nifedipine first Methanol Acetyl Chloride (MAC) is produced in MAC reaction vessel. The other raw material required for Nifedipine is Beneze Derivative (BD). The BD and MAC are reacted in a Nifedipine reaction vessel. Fitered in centrifuge after crystallization and subsequently these crystals are dried 3) Diclofenac Potassium (DFK) 2,6 DCP, sodium Methoxide, Ethyl Chloro Acetate, Aniline Caustic Are added to reactor in required proportion. The mass is allowed to react together at required temperature and pressure condition, once the reaction is over, the material is filtered and dried in dreir and packed in drums and stored as DCDPA DCDPA, Toluene, Chloro Acetyl chloride are added to a reaction vessel, Hydrogen Chloride gas generated during the reaction is scrubbed off with the help of caustic solution in scrubber tower. The material filtered , washed and dried packed and store as CPDCA CPDCA, Aluminium Chloride to allowed react in a reactor and controlled temperature condition. The mass is then quenched in water and filtered, Hydrogen chloride gas generated during reaction and quenching is taken to scrubber system. Neutralized material is filtered, washed, dried, Packed and store as Indolinone Indolinone, Caustic Potash and solvent added to reaction vessel, reaction is done under controlled condition and solvent recovered during the process, the material after reaction is over, filtered dried packed and stored as DFK 4) Product name: Fluconazole Epoxide compound intermediate & 1, 2,4 Triazole are treated in presence of Potassium Carbonate. Once reaction is over treated with Ethyl acetate , purified from IPA , filtered & dried to give Fluconazole.
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5) Product name: Ciprofloxacin Fluoro quonlinic acid & piperizine treated in presence of Dimethyl Sulphoxide. Caustic lye is added , to form a base. Treated with HCL.To give Ciprofloxacin. Purified using Methanol , filtered & dried to give Ciprofloxacin. 6).Product name:Ofloxacin Quonalinic acid & N- Methyl Piperizine reacted in Butanol. The reaction mass Acetic acid is added , mass is neutralized to give Ofloxacin. Purified , filtered & dried to give Ofloxacin. 7).Product name:Levetirecetam L- 2- amino butyric acid reacted with Thionyl Chloride. Neutralized with Ammonia. & treated with 4- Chloro Butyl Chloride. The mass is crystallized from water , filtered & dried to give Leveticetam 8).Product name:Lostaran Potassium 2-Butyl-4 chloro-5 hydroxy methyl imidazole reacted with 4-bromomethyl-2-cyanobiphenyl & Na Methoxide.Further treated with Sodium Azide & NH4CL in presence of DMF.. The mass is crystallized from Methanol to give Lostaran Potassim 9).Product name: Lisinopril N-[N2-Benzyloxycarbonyl-N6-tertiarybutoxycarbonyl-Lysyl]-L-Praline benylester Hydrogenated with Catalyst Hydrogenated & Water. The mass is further treated with 2-Oxo-4 Phenyl Butyric acid & Sodium Hydroxide. The resultant mass is crystallized from Methanol to yield Lisinopril. 10).Product name:Levocetrizine 1-[4-Chlorophenyl)phenylmethyl]piperizine is treated with L-Tartaric acid,(2-Chloroethoxy) & Acetonitrile. The mass is further treated with Sodium Carbonate, KI,.n-Butanol & Conc. HCl. The crude obtained is crystallized from Ethyl ACETATE, to give Levocetrizine. 11). Product name: Ropinrole 3-Chloro-4-[Carbonyl oxophenyl)ethyl]-1,3-dihydro-2-H-2-Indolinone hydrogenated using Palladium Hydrogen catalyst , neutralized with Caustic lye. The mass is treated with N,N dipropylamine in Methanol. The crude obtained is crystallized from IPA to give Ropinrole. 12). Product name:Atorvastatin Calcium (2R-trans)-5-(4-Fluorophenyl)-2-(1-Methyl)-N,4diphenyl-1-[2-Tetra hydroxy-4hydroxy-6-Oxo-2H-pyran-2-yl)ethyl]-1H-pyrrole-3-carboxamide treated with NAOH in IPA. The mass is treated with Calcium acetate solution. The crude obtained is crystallized from IPA to give Atorvastatin Calcium. 13).Product name: Clopidogril Sulphate
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Amino Ester (VIII) (+)-10-Camphorsulphonic acid reacted with Formic acid & Formaldehyde. The mass is treated with Sulphuric acid, IPA + Water. The crude obtained is crystallized using water + Methanol, filtered, and dried to give Clopidogril Sulphate. 14).Product name: Sertraline HCl 4-(3, 4-Dichlorophenyl)-3, 4-dihydro-1(2H)-naphthalene, Methyl amine Lewis acid & Hydrogen; D (-) Mandelic acid with Conc. HCl . The crystallized from Methanol + Water , filtered & dried to give Steraline HCL. 15).Product name:Oxcabazepine 5H-Dibenz[b,f]azepine-5- carbonitrile ; Sodium nitrite treated in presence of Acetic acid & Iron Boron Trifluoride is added . The mass is filtered to give crude product , crystallized from IPA, filtered & dried to give Oxcabazepine. 16).Product name:Midazolam & derivative 2-(2’-aminomethyl Carbonyl Methoxy)-7- Chloro-5-(2-Fluoro Phenyl)-1,3-dihydro-2H- 1,4-benzodiazepine & Triethyl orthoacetate treated , hydrolysed with NaOH. Further neutralized with Conc. HCl. The crude product obtained is crystallized from Methanol + Water. Filtered , dried to give MIDAZOLAM. 17). Product name: : Nebivolol Benzopyran-2-Carboxaldehyde Derivative treated with Trimethyl sulfoxonium iodide In presence of Potassium hydroxide & Water. The mass is further treated with Benzyl amine & Toluene, Ammonium formate using Pd/Catalyst. The mass is crystallized from Methanol, filtered & dried to give Nebivolol. 18).Product name: Bicalutamide 2-Cyano-4-amido benzo trifluoride is treated with Hydrogen peroxide & Water. The mass is treated with 4-Fluorobenzenethiol, Hydrogen peroxide & Acetic acid. The crude obtained is crystallized from IPA to give Biclutamide. 19). Gadopentatic acid: Gadonium Oxide is treated with DTPA , mass is dried to give Gadopentatic acid 20).Gadodiamide; Gadonium Oxide is treated with Diethanolamine. The mass is allow to reflux , cooled & filtered to give Gadodiamide 21). Product name: Pioglitazone HCL 5 Ethyl 2 Pyridyl ethanol; Toluene; 4-Hydroxy Benzaldehyde & Sodi. Boro hydroxide with K2CO3 & Thiozolidinone in presence Caustic lye. The crude is crystallized with IPA to give Pioglitazone. 22).Product name: FEXOFENADINE Sod. Borohydride; KI; Intermediate -8 treated in presence MIBK. The mass is further treated Azycyclonol & Denatured Spirit. The mass is treated with K2 CO3. The crude is crystallized from Methanol to give Fexofenadine.
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23).Product name: Citalopram 5-Bromophthalide, CUCN & 4-Fluorophenyl Mg-bromide in THF treated . The mass is further treated with dimethylaminopropyl magnesium chloride, NAOH, DMF .The resultant mass is further treated with Phosphoric acid & HCL, Crystallized from Water to give Citalopram 24). Iohexol/Iopamidol/iodixanol 2,4,6- Tri iodoisophthaloyl Chloride & 2-Amino-1,3-propanediol treated with Lactic acid , to give crude Iopamidol . Crystallized from IPA, FILTERED , dried to give Iopamidol. IOHEXOL: 5-amino – N,N(2,3 Dihydroxy propyl & isophthalamide TRIIODO DERIVATIVE treated with 3-Chloro ,2 –propanediol . The product is cryatallized from IPA , filtered & dried togive , Iohexol 25). Product: Pantoprazole & derivative 5-(diflouromethoxy)-1H-benziamidazole-2-thiol treated with 2-(chloromethyl)-3,4-dimethylpyridine, the resulatant mass is hydrolyzed with Sodium hydroxide & purified, filtered , washed & dried to give Pantoprazole Sodium deri. 26). Product name:Montelucast Ester compound , THF treated with NAOH. The reaction is further treated with Tartaric acid & Methanol , to form Montelucast. 27). Product name: IOXAGLIC ACID 3-amino 5-benzoyl 2, 4, 6-triiodo benzoic acid is treated with 2- amino ethanol , in presence of Toluene. The mass is further treated with Triethyl Amine to give IOXAGLIC ACID 28). )Product Name: Cilnidipine Brief Manufacturing Process: Charge Methanol heat and reflux distilled out IPA Add Methyl cellosolve., Cinramyl Aceto Acetate, 3 Nitro Benzaldihyde, Methanol cool & filters dry in RCVD to get CilinidipinE 29). Product name: Amlopidine Besylate:-
STEP 01: Phthalicanhydride & Ethanol Amine reacted to give step-I (Hep) STEP 02:- Step-I (Hep) is treated with ethyl chloro aceto acetate to give step-II (Pheema) STEP 03:- Step-II (Pheema) is treated with MAC to give Phthaloyl Amlodipine STEP04 Phthaloyal Amlodipine is reacted with NH3 to give Amlodipine Base STEP05:- Amlodipine Base is treated with to give Amlodipine Besylate
30). ). Cetrizine :Process flow diagram for Cetrizine: 1-[(4-Chlorophenyl)phenylmethyl] Piperizine reacted with L- Tartaric acid , 2 Chloro Ethoxy Acetonitrile in presence of Sodium Carbonate & KI , to form Base. Base is reacted with Conc. HCL to form Cetrizine HCL. 31). Product name: Carvidilol 2-(ethoxyphenoxy)ethylamine & 4-(2,3 epoxypropoxy)carbezole treated with mix of water & ethyl acetate, filtered & dried to give Carvidilol.
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32).Product name: ZOLPIDEM 3-bromo-N,N-dimethyl-4-oxo-4-p-tolyl-butyramide, MIBK are treated with 2-amino-5-methylpyridine. The reac mass treated with Sodium Carbonate. The stage -1 materail obtained is treated with Tartaric acid & crystallized from Acetone to give Zolpidem 33).Product name: Promedol HCL Trimeperidine is treated with HCL & crystallized from Acetone , filtered & dried to give Promedol HCL 34).Product name: Indolinone. 2,6 DCP, sodium Methoxide, Ethyl Chloro Acetate, Aniline Caustic Are added to reactor in required proportion. The mass is allowed to react together at required temperature and pressure condition, once the reaction is over, the material is filtered and dried in dreir and packed in drums and stored as DCDPA DCDPA, Toluene, Chloro Acetyl chloride are added to a reaction vessel, Hydrogen Chloride gas generated during the reaction is scrubbed off with the help of caustic solution in scrubber tower. The material filtered , washed and dried packed and store as CPDCA CPDCA, Aluminium Chloride to allowed react in a reactor and controlled temperature condition. The mass is then quenched in water and filtered, Hydrogen chloride gas generated during reaction and quenching is taken to scrubber system. Neutralized material is filtered, washed, dried, Packed and store as Indolinone 35).Product name: ATENALOL BRIEF MANUFACTURING PROCESS:- In the first stage, Para-Hydroxy Phenyl acetamide condensed with Epichlorohydrine in presence of Base to give epoxide compound. Which is condensed in second stage with Isopropylamine to give Atenolol crude compound. Atenolol crude converts in to Atenolol pure by purification. 36).Product name: 2 Methyl Imidazole Acetaldehyde is reacted with Glyoxal & than treated with Liq NH3. The mass is concentrated , treated with Toluene ,filtered through filtered & dried to get 2-MI 37). Name of product: Manu process for Maglumine: IPA is charged, add N –Octyl-D- Glucamine under stirring, slowly heat to 60-70 degree centigrade. Maintain for 5 hours. Cool the mass to room temp. Filter & dry the mass to give Maglumine. 38).Name of product: ). Lucanthone HydrochlorideCAS No. [584-57-2] Brief manufacturing process: Stage-1 Reaction of Dithiosalicylic acid and 4-Chlorotoluene with sulfuric acid gives intermediate Luca-I. Stage-II Lucanthone-I is reacted with N,N Diethyl ethylene Diamine & pyridine to give Lucanthone-II Stage-III Lucanthone –III is reacted with HCL to give Lucanthone Hydrochloride
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39). Name of product: Process of synthesis for METRONIDAZOLE: 2- Methyl 5 –Nitro Imidazole is reacted with Ethylene Oxide. The reacted mass is quenched in water, p H adjusted. Mixture of METRONIDAZOLE & 2 MNI is separated to yield Crude. Crude Metronidazole is crystallized, filtered, dried to give Metronidazole. Synthesis of Metronidazole Benzoate: Metronidazole is reacted with Benzoyl Chloride for 24 hours. Once reaction is over , solvent is distilled out. Methanol is added , chilled , filtered , dried to give Metronidazole Benzoate. 40).Name of product: ). Diatrizoic Acid (2, 4, 6-Triiodo-3, 5-diacetylaminobenzoic acid) Brief Manufacturing Process: Acetylation of 2, 4, 6 Triiodo-3, 5-diaminobenzoic acid by Acetic anhydride with sulfuric acid to give Diatrizoic acid derivative. 41). Name of product: ). Econazole Brief manufacturing process: Reaction of 1-(2, 4-dichlorophenyl)-2-imidazole-1yl- Ethanol with sodium hydride base in tetrahydrne to give its sodium salt followed by treatment of resulting sodium salt with p-chlorobenzyl chloride in dimethylformamide solvent at reflux temp to give Econazole. 42).Name of product: ). Meclizine CAS No. [596-65-3]Brief Manufacturing Process: Stage-1: Condensation of 1-(chloromethyl)-3-methylbenzene with piperazine and HCl gas to produce 1-[(3-methylphenyl) methyl] piperazine dihydrochloride (stage-1) Stage –II : Stage –I is reacted with 4 Chloro Benaz Hydryal Chloride to give step-II Meclizine crude Stage-III: Meclizine crude is purified to give Meclizine 43).Name of product: Chlorhexidine Digluconate: Process: Reaction of Hexamethylene bis-dicyandiamide with P-chloroaniline HCL with Ethoxy ethanol 130-140 for 2 hours to get Chlorhexidine Base. By addition of D-Gluconic acid to produce Chlorhexidine Digluconate. 44) Product Name: Indinavir Charge 3 Methyl pyridine, Piperazine, Ethyl Acetate, Caustic Flakes, D M Water IPA ethyl Acetate heat and reflux distilled out IPA Cool & filters dry in RCVD to get Indinavir 45).Name of product: Nevirapine Charge Dipyrido Diazepine, Ecyclopropyl chloride Caustic Flakes Toluene in reactor and add DM water IPA Ethyl acetate, IPA+HCl heat and reflux distilled out IPA Add DM water cool & filters dry in RCVD to get Nevirapine 46).. Product Name: Rizatriptan Charge Triazole Compound, Dimethyl amino Indole, Catalyst, Acetonitrile, Methanol, Water heat and reflux distilled out Methanolcool & filters dry in RCVD to get Rizatriptan
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47). Product Name: Gabapentine Charge 1, 2 Cyclohexaneutic Acid, Urea Toluene NaOH solution, water heat and reflux distilled out Toluene Add DM D M Water, Methanol and Con HCl cool & filters dry in RCVD to get Xabapentine 48). Product Name: Telmisartan Charge Benzaimidazole compound, N-methyl-O-phenylene diamine, toluene, Poly phosphoric Acid heat and reflux distilled out Toluene.Add Toluene and Bromoester cool & filters dry in RCVD to get Tewlmisartan 49). ) Product Name: Ondansetron Charge 1,2,3,9 Tetrahydro 9 methyl-4H-carbozole-4-One,N-(3-Chloro methyl)-2-Methyl-Indiazole, toluene, Phosphoric Acid PTS heat and reflux distilled out Toluene Add DM water, IPA, Conc Hcl cool & filters dry in RCVD to get Ondansetron 50) Product Name: Candesartan Charge Ethoxy benzimidazole compound, Biphenyl Tetrazole, toluene, KOH Flakes heat and reflux distilled out Toluene Add DM water, Ethyl acetate, Methanol, cool & filters dry in RCVD to get Candesartan 51). ) Product Name: Glipizide Charge 5-methyl pyrazine-carboxamide, Sulfenyl Compound, Toluene, NaOH flakes, PTS heat and reflux distilled out Toluene Add DM water, IPA, Ethyl acetate, Methanol, Toluene, Amino Cyclohexane cool & filters dry in RCVD to get Glipizide 52). ). Product Name: Glimepiride Charge Oxo pyroline compound, Methyl cyclohexyl sulfonyl compound, Toluene, NaOH flakes, PTS heat and reflux distilled out Toluene. Add DM water IPA Ethyl acetate, IPA+HCl cool & filters dry in RCVD to get Glimepiride 53). ) Product Name: Moxifioxacin Charge 1 cyclopropyl-6-fluro-4-oxo-chloro-quinoline carboxyliacid Octohydro pyrolo, Octohydro pyrolo pyridine compound, Toluene and NaOH flakes in reactor heat and reflux distilled out IPA.Add DM water IPA Ethyl acetate, IPA+HCl cool & filters dry in RCVD to get Moxifioxacin 54). ) Product Name: Meloxicam Charge Methyl benzothiazine amine, Hydroxy methyl thiazolyl T H F, K2CO3 heat and reflux distilled out IPA.Add Methanol , Acetonitrilel cool & filters dry in RCVD to get Meloxicam 55). Product Name: Lercandipine HCl Charge Di phenyl propylamino compound, Nitrophenyl pyridine di carboxalic acid, IPA, K2CO3, PTS heat and reflux distilled out IPA.Add Methanol, Ethyl Acetate, Con HCl cool & filters dry in RCVD to get Lercandipine HCl 56). ) Product Name: Anastrazole Charge Tetrazole compound1,3 Benzane, Dia acetronitrile-5-chloro methyl, Toluene, NaOH flakes heat and reflux distilled out Toluene.
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Add Cyclo Hexane, Ethyl Acetate cool & filters dry in RCVD to get Anastrazole 57). ) Product Name: Clomipramine HCl Charge Chloro Iminodibenzyl Dimethyl amino propyl chloride, Toluene, KOH heat and reflux distilled out Toluene.Add D M Water, Acetone, HCl cool & filters dry in RCVD to get Clomipramine HCl 58). ) Product Name: Letrozole Charge Triazol compound, Tanophenyl compound, I P A, NaOH Base heat and reflux distilled out IPA.Add DM water IPA Ethyl acetate, IPA+HCl cool & filters dry in RCVD to get Letrozole 59) Product Name: Isradipine Charge Benzofurazamyl compound, Methyl ethyl ester, Dichloro dimethyl pyridine dicarboxiacid, Na OH Base, Methanol heat and reflux distilled out MethanolAdd Hexane, IPA cool & filters dry in RCVD to get Isradipine 60). Product name: Product Name: Bisoprolol Charge Isopropyl amino propanol, Iso propyl ethoxy-p-tolyl compound, IPA, KOH flakes, D M Water heat and reflux distilled out IPA. Add DM water Acetone, Fumaric Acid cool & filters dry in RCVD to get Bisoprolol 61). Product Name: Olanzapine Charge Methyl piperazinyl Chloro-thieno benzodiazepine, N N DMA, catalyst heat and reflux distilled out .Add Acetonitrile cool & filters dry in RCVD to get Olanzapine 62). Product Name: Rosiglitazone Charge Methyl pyridinyl amino ethoxy phenyl in reactor and add 2,4 thiazo compound, IPA, Base heat and reflux distilled out IPA. Add methanol, Sodium Borohydride and 50% con HCl cool & filters dry in RCVD to get Rosiglitazone. 63) Product Name: Fentanyl Citrate Charge Phenyl piperidinyl compoundxy phenyl, Propinamide compound, THF, K3 CO3 and water heat and reflux distilled out THF.Add Acetone and citniacid cool & filters dry in RCVD to get Fentanyl Citrate 64). ) Product Name: Lacidipine Charge Ferbutoxy carboxyl compound, Mac, Aldehyde, Methanol, Base heat and reflux distilled out Methanol.Add Ethyl Acetate I P A cool & filters dry in RCVD to get Lacidipine 65).Product Name: Venlafaxine HCl Brief Manufacturing Process: Charge Formic Acid, VF2 Acetate, D M Water Formaldihyde Na OH K Flakes Ethyl Acetate heat and reflux distilled out IPA cool & filters dry in RCVD get Venlafaxine HCl 66)Product Name: Itopride Brief Manufacturing Process: Charge Benzamide, Toluene, Na OH Flakes D M Water and IPA heat and reflux distilled out IPA cool & filters dry in RCVD to get Itopride 67)Product Name: Calcium Fructo Borate Brief Manufacturing Process: Charge D-Frucose, Dist water, Boric Acid, Calcium Carbonate and Acetone heat and reflux distilled out Acetone cool & filters dry in RCVD to get Calcium Fructo Borat
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ANNEXURE - III WASTE WATER & TREATMENT The waste water generated from industrial activities is treated in an Effluent Treatment Plant Comprising of primary, secondary treatment & Tertiary treatment plant. The effluent generated from the plant is collected in a collection sump from where it is pumped to oil and grease trap to remove free oil from the raw effluent. After oil and grease removal the effluent goes to equalization cum Neutralization tank where Lime and Alum dosing is done. The effluent is pumped from equalization cum Neutralization tank & filtered through Filter press. The filtered clear effluent goes to Aeration tank for activated sludge biological treatment where non-settable suspended and colloidal organic matters are converted in settable biological mass which are settled in Clarifier. To maintain biomass concentration in Aeration tank active sludge from the Clarifier is partly recirculated in Aeration tank the over flow of the Clarifier. Treated effluent is again passed from Sand filter & Activated Carbon filter. Company has set up R-O Plant for treatment of waste water with evaporation system. The treated effluent finally is collected into treated water storage tank. R-O Plant & Evaporation systems are installed for water recovery. In existing Scenario treated effluent is analyzed & effluent passing in PCB norms is discharged through company’s own pipe line to Panoli GIDC sump. From Panoli GIDC sump carried through Narmada Clean Tech Ltd to Deep Sea through pipeline. Under proposed scenario the treated effluent from ETP plant will be pumped to Reverse Osmosis Plant for Waste water recovery. From R-O plant, R-O permeate water is collected & send to the Utility for reuse. R-O Rejection water is send to Evaporation plant , concentrated dried & solid waste collected are packed in bags & will be send to TSDF site BEIL – ANKLESHWAR. Unit will be ZERO LIQUID DISCHARGE for Industrial waste water. The solid waste is obtained from the effluent treatment facility, from the Filter press sludge transferred to the sludge collection & drying bed. The sludge collection/drying bed are two nos. The sludge a collection cum drying bed is provided with HDPE liner & from the bottom are connected to the Leatchet collection sump from leatchet collection sump what ever liquid effluent collected are transferred to Collection tank for treatment. The sludge after drying collected in to the HDPE bags & send to the common secured land fill facility at Ankleshwar Bharuch Enviro Infrastructure Ltd
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NAME AND SIZE OF EACH UNIT OF EFFLUENT TREATMENT PLANT
SN NAME OF UNIT SIZE CAPACITY 1 Oil & Grease Trap 1.25m X3.10mX1.75m SWD 7KL
2 Equalization/ NeutraliTank 6 m X6Mx3.5m SWDx4 NOS 400KL
3 Filter press 45 plate x 2 nos 1.2 M T 4 Collection sump 3.00mDiaX2.5m 20KL 5 Primary Aeration tank 10.00m Dia X8.00m 600KL 6 Primary Clarifier 4.00m DiaX 2.67m 30KL
7 Secondary Aeration tank 10.80m Dia X3.50m 310KL
8 Secondary Clarifier 1.5 meter X 2.67m x3 21KL 9 Final Clarifier 6.00m DiaX 2.67m 45KL
10 Chemical Solution Tank 2.00 X2.00X 1.5m SWDx2 nos 5KL 11 Chemical solution house 6.00mX6.00mX4.00m SWD 18 m3 space 12 Sludge drying bed 7.00m X5.00m X 1.8 m X 3 no 200KL 13 Sand filter --- 5KL 14 Carbon filter --- 5KL 15 Treated water tank --- 230KL 16 ONLINE flow meter --- 17 Reverse Osmosis Plant --- 350M3/day 18 Evaporation system --- 100M3/day
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FLOW DIAGRAM OF EFFLUENT TREATMENTPLANT (EXISTING SCENARIO)
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FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT (PROPOSED SCENARIO)
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APPENDIX-IV Hazardous waste: Unit generates hazardous waste from effluent treatment & process. The hazardous generated is collected, packed & stored in a place as per category of waste. The hazardous waste like drums, a liner etc. are decontaminated & than disposal is carried as per PCB permission. The hazardous waste is generated from effluent treatment & process is as under. The Hazardous waste is treated & disposal is carried out as per PCB permission.
v ETP Sludge: At effluent treatment plant during treatment ETP sludge is generated, which are filtered through filter press. Collected in Sludge bed , packed in bags & send to TSDF site BEIL- ANKLESHWAR
v Used drums & Plastic liners: The drums & Carboys which after use, returned to the party refilling of the same raw material. The drums which not returned to party for refilling are decontaminated & then sold to PCB approved drum dealer
v Used Carbon: The spent carbon after used in the final crystallization separated & collected into LDPE liner bags & packed in to spent carbon collection area spent carbon is being send to Ankleshwar at BEIL Ankleshwar OR for Co prcessing at Cement industry
v Expired drugs & Medicine/ Off specification material: Expired Drugs & Medicine / Off specification material is send for Incineration at common facility BEIL Ankleshwar OR for COPROCESSING at CEMENT industries.
v Distillation residue: Distillation residue material is send for Incineration at common facility BEIL Ankleshwar OR for COPROCESSING at CEMENT industries.
v Used Oil: Used Oil is send to CPCB approved Oil recycler OR is send for COPROCESSING at CEMENT industries.
The details of Hazardous waste is as per table TABLE_________________________________________________________
S N
Type of waste Category of Haz waste
Existing Generation
Proposed Generation
Total generation
Disposal
1. ETP sludge Category 34.3
75.0 MT/month
125.0 MT/month
200.0 MT/month
Sent to common TSDF site BEIL Ankleshwar
A Empty barrels & carboy from R .M
Category 33.3
600. No/month
100.0 No/month
700.0 No/month
After decontamination Sell to Dealer having PCB consent or send for refilling of same material
B Plastic liner Category 33.3
1.8 MT/Month
1.7 MT/Month
3.5 MT/Month
After decontamination Sell to Dealer having PCB consent.
2.
C Glass wool, thermocol
Category 33.3
25 kg/month 25 kg/month 25 kg/month Sent to BEIL Ankleshwar
3. Used oil from DG &Compre.
Category 5.1 72 liter/month
28 liter/month
100 liter/month
Sold to authorize Recycler having PCB & CPCB approval.
4. Distill. residue/ spent solvent
Category 25.2
5 MT/month 10 MT/month
15 MT/month
Incineration at common Inciner. facility BEIL Or Co processing at Cement plant
5. Expired Drugs Category 25.2
25 MT/month
10 MT/month
35 MT/month
Incineration at common Inciner. facility BEIL Or Co processing at Cement plant
6. Used Charcoal Category 28.2
2.5 MT/month
5 MT/month
7.5 MT/month
Incineration at common Inciner. facility BEIL Or Co processing at Cement plant
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ANNEXURE - V WATER BALANCE
WATER BALANCE DIAGRAM FOR EXISTING SCENARIO
2,00,000
5,000 45,000 35,000 20,000
PROCESS BOILER COOLING
DOMESTIC AGRICULTURE
84,000
65,000
WASHING
ETP
65,000 68,000
11,000
10,500 TO ETP 83,500 TO ETP
3,000 TO ETP
3,000 TO ETP
30,000 TO ETP
1, 30,000
Loss 500 Loss 2000 Loss 42000 Loss 5000
Loss 500
The treated effluents send to Panoli GIDC Sump. From GIDC sump pumped to NCTL (Collection & transfer facility). From NCTL treated effluent is pumped to deep sea by a pipeline
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WATER BALANCE DIAGRAM FOR PROPOSED SCENARIO
All quantity are in Liters/day
3, 90, 000
10,000 40000 50,000 8,000
PROCESS BOILER COOLING
DOMESTIC AGRICULTURE
2, 82,000
WASHING
ETP
85,000
Loss 210000
20,000 TO ETP
2, 50,000 TO ETP
15,000 TO ETP
10,000 TO ETP
30000 To Septic tank, Soak pit &
than to STP plant
30,000 Loss 30,000 Loss 20000
Loss 20,000
40,000
Reverse Osmosis Plant TREATMENT
R O reject to MEE PLANT
For Evaporation
R –O permeate for reuse
in Utility -195 KL
2, 95,000 TO RO PLANT
1 2 0 0 0 0
Solid wastes from MEE plant packed & send to TSDF site BEIL -ANKLESHWAR
From ETP plant treated Industrial waste water is send to R-O Plant. Recovered water send for use to Utility R-O Rejection will be evaporated in MEE. Thus unit will be Zero Industrial waste water discharge.
Loss 32,000
3 5 0 0 0
CARBON TOWER
6 0 0 0 0
CONDENASTE To reuse-60 KL
Loss 10,000
Loss 30,000
M/S. UNIQUE CHEMICALS (A div of J B CHEMICALS & PHARMACEUTICALS LTD) PANOLI
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ANNEXURE-VI DETAILS OF STACK/VENT
STACK EMISSION S N
Stack/Vent attached to
Height of stack
Dia of Stack
Type of Fuel
Fuel Consumption Parameter Permissible
limit
1. Boiler -6 MT/Hr
30 meter 60 cm Natural Gas
9600 SM3/Day
SPM SO2 NOX
150 mg/Nm3
100 ppm 50 ppm
2 Boiler -3 MT/Hr
30 meter 30 cm Natural Gas
3600 SM3/Day
SPM SO2 NOX
150 mg/Nm3
100 ppm 50 ppm
3.
Thermo Pac TP-04
(Existing-1 No &
Proposed -1 No )
30 meter 30 cm Natural Gas
2400 SM3/Day
SPM SO2 NOX
150 mg/Nm3
100 ppm 50 ppm
2.
D.G Set as stand by(Existing –
400 KVA -2no & 250 KVA -1No 1010 KVA – 2
no)
07 meter above
building height
15 cm HSD
70 Lit/ hrs/ 1010KVA & 45 Lit /hrs 400 KVA
SPM SO2 NOX
150 mg/Nm3
100 ppm 50 ppm
Process emissions
S N
Stack/Vent attached to
Height of stack
Dia of Stack
Pollution Control
equipment
Parameter Permissible limit
1.
Indolinone Reactor &
quencher – 6 Vent 3- Existing & 3-
Proposed
17 meter 30 cm Double packed Alkali Scrubber HCl 20 mg/Nm3
2
CPDCA Reactor-
3 Vent 2 Existing & 1
– proposed
17 meter 30 cm Double packed Alkali Scrubber HCl 20 mg/Nm3
M/S. UNIQUE CHEMICALS (A div of J B CHEMICALS & PHARMACEUTICALS LTD) PANOLI
20
ANNEXURE- VII
NOISE LEVEL MONITORED AT DIFFRENT SOURCES
SR NO LOCATION NOISE LEVEL MEASURED
(dBA) 1 Near Main Gate 61-63
2. Plant Area 71-73
3. Near Boiler House 79-80
4. ETP Area 64-66
5. Nr D G SET 72-75 NOISE GENERATING POINTS
1. BOILER 2 DGSET (DG SET will be with CANOPY)
M/S. UNIQUE CHEMICALS (A div of J B CHEMICALS & PHARMACEUTICALS LTD) PANOLI
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Appendix-VIII.
The unit is having on site & off site emergency plan. The rehearsal of onsite emergency plan
is performed at regular interval. Safety manual is in place. Safety booklet in local language
is given to each employee.
The brief description of safety measures implemented is as under.
1) At the storage tank of the acid & alkali provided with label capacity. Proper
material of construction, Level indicator, Dyke wall with acid proof brick lining for
Acid st. tank. All tanks are provided with pumps & transfer pumps with mechanical seal.
2) The statutory notice for acid & alkali danger is published in storage area.
3) Safety shower eye washers are provided in plant
4) Transfer of corrosive & toxic chemicals by close circuit only by pump & wearing
necessary personal protective equipments
5) At the hazardous chemicals marked with separate colour code
6) At the revolving & moving parts of the machineries are properly guarded.
