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M/s. ZCL CHEMICALS LTD., ANKLESHWAR

M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.

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1.0 EXECUTIVE SUMMARY

M/s. ZCL Chemicals Ltd. is engaged in manufacturing of Pharmaceuticals Intermediates and

Active Pharmaceutical Ingredients at Plot No. 3102/B, GIDC Industrial Estate, Ankleshwar -

393002, Gujarat.

As per EIA notification 2006 and its amendment, the proposed project is falling under category

5(f). The unit is having CCA for manufacturing of Pharma Intermediates and Active

Pharmaceutical Ingredients.

One of our manufacturing plant (Unit 1A) at this site is more than 15 years old and it does not

match with current standards of Emergency preparedness and safety of building. Building was

constructed in 1999 based on consideration of safety standards prevailing at that time.

As per remarks of Deputy Director (Industrial Safety and Health), Bharuch (Factory Inspector),

during his visit regarding inspection of said building, suggested that operation in Unit 1A plant to

be gradually stopped for manufacturing activities. Safety reasons are cited by Factory Inspector

in his remarks.

We have been informed by the competent chartered engineer that this building is now getting

older and as per his recommendations building will not be suitable for manufacturing in next 2-3

years.

To meet above requirements, related to quality and safety standards, we propose to relocate the

existing plant building in the open land available with us at same site. This building will be a

relocation of the Unit 1A building.

It is assured that, by this change, unit will neither increase production capacity nor pollution load

in any form.



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The details of products are given below table.

TABLE: 1

LIST OF PRODUCTS

Sr.

No.

Name of Products Existing as per

CCA No. AWH-

72765 (MT/Year)

1 Thrio Pypridil AmideAND/OR 204.03

2 Ritalinic acidAND/OR

3 4 - benzyloxy -3- nitrophenylace bromideAND/OR

4 Zonisamide – USPAND/OR

5 Modafinil - EP/USPAND/OR

6 4-Amino-N-[(2 R, 3S)- 3 Amino, 2 hydroxy, 4- phenyl

butyl ] – n – (2 Methyl propyl) benzene

sulfonamideAND/OR

7 Darunavir AND/OR

8 BOC Nitro

9 Fluvoxamine Maleate- EP/BP/USP/JP AND/OR

10 Trifluoperazine - USP/EP/BP AND/OR

11 Methylphenidate - USP/EP AND/OR

12 R & D Products AND/OR

13 Dex Methyl Phenidate AND/OR

14 Chlordiazepoxide AND/OR

15 Cillastazol AND/OR

16 7 Hydroxy 1,2,3,4 tetra hydro quenoline AND/OR

17 Chloro Methyl cyclo propane AND/OR

18 1-(2,3 dichloro phenyl) - piperazine hydrochloride

(DCPP) AND/OR

19 BBQ (7-(4-Bromobutoxy)-3, 4-dihydroquinolin-2(1H)-

one) AND/OR

20 T2551 - Etravirin Inter AND/OR

21 Canagliflozicin Inter (n-2): 2-(4-fluorophenyl)-5-(5-

iodo-2-methylbenzyl)thiophene AND/OR

22 Aripiprazole AND/OR

23 BET (1-(2-Bromoethyl)-4-ethyl-1,4-dihydro-5H-

tetrazol-5-one) AND/OR

24 1-Amino Indane AND/OR

GROUP – 1 (Total) 204.03



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Sr.

No.


CCA No. AWH-

72765 (MT/Year)

25 Trimethyl pyruvic AcidAND/OR 42.03

26 4,4’-Diflurobenzhydryl Piperazine AND/OR

27 2 Tri Pheno trimethyl phenothiazine AND/OR

28 Levomepromazine AND/OR

29 Betahistine IP / EP / USP AND/OR

30 Betahistine Mesylate JP/EP AND/OR


31 Phenyl 2 Piperidyl Acetamide AND/OR 23.1

32 N- (1 Benzyl 4 Piperidinyl) N Phenyl Propanamide

HCL / NN Phenyl N 4 Piperidinyl Propanamide HCl

AND/OR

33 N Acetyl Hydroxy Phenyl Piperazine AND/OR

34 Amino Ethyl Phosphoric Acid AND/OR

35 (1-Isopropyl-4-(hydroxyl Phenyl) (piperazine)

AND/OR

36 Memantine HCl AND/OR

37 Quetiapine Fumerate AND/OR


38 Phenyl 2Pyridyl Acetamide AND/OR 23.27

39 Zaltoprofen AND/OR

40 Alprazolam AND/OR

41 Mono chloro acetonitrile AND/OR


42 (N-[4-Methoxymethyl)-1-(phenyl methyl)-4-

Piperdinyl]-N-Phenyl Propanamaide- Ethanedioate.

0.06

43 Dex Ritalinic Acid 0.1

44 Remi N Benzyl Propeonamide eater Oxalate 0.02

45 Nebivolol 0.1

46 Flurbiprofen 0.4

47 Olanzapine 0.4

48 Levodropropizine 0.5

49 Atomoxetine 0.5

50 Felbinac 3



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Sr.

No.


CCA No. AWH-

72765 (MT/Year)

51 Clozapine 1.8

52 Diazepam 0.4

53 Oxazepam 0.4

54 Flupirtine maleate 0.4

55 Bromazepam 0.4

56 Benzhydrl Piprazine 4

Individual (Total) 12.48

Total 304.906

COST OF PROJECT

Total cost for proposed project is approx. 4635 lacs. The plot has been purchased by M/s. ZCL

Chemicals Ltd. from GIDC. The total plot area of relocated building is 1808 Square meter and

the total plot area of the unit is 35595 Square meter. The green belt area is 6215.04 square

meters.

FUEL CONSUMPTION

The existing unit uses Natural gas as fuel for Boiler & Thermic fluid heater and diesel used for

DG Set. There will be no changes in proposed project for Natural gas Consumption for Boiler&

Thermic fluid heater, Diesel consumption for DG set.

ELECTRICITY CONSUMPTION

The unit have electricity from Daxin Gujarat Vij Company Ltd. The existing electricity

consumption is 950 KVA. There will be no changes in Electricity consumption.

WATER CONSUMPTION

The source of water is from GIDC water supply scheme.

The water consumption for industrial purpose is 143.8 KL/day. The water consumption for the

domestic & gardening purpose is 21.2 KL/day fresh water. There will be no change in water

consumption.



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Note: Water shall be taken from the existing set up of water for construction work.

WASTE WATER GENERATION

The existing industrial waste water generation is 45 KL/day and domestic waste water is 10

KL/day. 55 KL/day of effluent is treated in ETP. Treated effluent is discharged in to GIDC

Pumping station – B through above ground fixed pipeline leading to the inlet of FETP for further

treatment and its ultimate disposal to deep sea (facility operated by NCTL). Since the proposed

building is a relocation of existing building, there will be no change in the waste water

generation, treatment and disposal.

GASEOUS EMISSION

There is one stack of one boiler (capacity: 3.5 Ton/Hr), one stack of Thermic fluid heater

(capacity: 4 lac Kcal) and two stack of two Diesel generators (capacity: 250 & 750 KVA

respectively). The two D.G. sets will be used in case of emergency only.

Process emission is from two numbers of stacks. There is one stack attached to Reaction vessel

in Plant-1, one stack attached to Reaction vessel in Plant-2. These stacks are connected with

scrubbers (Water +Caustic).

There is process emission from two vents of the Water scrubber & Caustic scrubber. Since the

proposed building construction is relocation of existing building, there will be no change in the

gaseous emissions.

HAZARDOUS WASTE MANAGEMENT

There will be generation of ETP sludge (339 MT/Year), Carbon Waste (18.25 MT/Year),

Distillation residue (36.5 MT/Year), Discarded containers (43800 Nos/Year), Distillation residue

from contaminated organic solvents (0.73 MT/Year), Used/Waste Oil (1.83 MT/Year),



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Contaminated solvents not fit for originally intended use (73 MT/Year), Spent solvent (73 MT /

Year).

ETP sludge will be disposed at TSDF M/s. BEIL. Carbon Waste, Distillation residue and

Distillation residue from contaminated organic solvents will be send to incineration at TSDF

M/s. BEIL/RSPL & Ambuja Cements for Co -processing. Discarded containers will be sold to

authorized vendors. Used / Waste Oil will be sold to registered refiners. Contaminated solvents

not fit for originally intended use, spent solvent will be reused within premise or dispose of at

TSDF for incineration.

Since the proposed building construction is a relocation of existing building, there will be no

change in the hazardous waste generation.

2.0 INTRODUCTION

2.1 THE PROJECT

M/s.ZCL Chemicals Limited has acquired plot no. 3102/B, GIDC Estate, Ankleshwar for

manufacturing of Chemical Pharmaceuticals Intermediates and Active Pharmaceutical

Ingredients. The list of products is provided in Table -1.

2.2 PROJECT PROPONENT

M/s.ZCL Chemicals Limited was incorporated in the year 1991. They have manufacturing unit

in Ankleshwar. The Company delivers a broad range of advance fine chemical Pharmaceuticals

intermediates and Active Pharmaceuticals Ingredients for pharmaceutical end use and services to

customers around the world. ZCL has been concentrating on Research and Development. The

project proponents are already in market and doing manufacturing and trading of these products.

Quality, Environment, Health and Safety

Policy:



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The policy of the company is as under:

Reflecting its Commitment to Global leadeaship and Excellence in Quality, Environment, Health

and Safety , ZCL Chemicals Ltd. Ankleshwar, Manufacturing Advance Intermediates, Active

Pharmaceutical Ingradient and Safety Chemical in having Guidline principles that Comminted

toward Compatancy in Quality, Lead Time , Overall Economic Feasibility through Environment

Health and Safety must satisfy our Esteem Customers.

It is Policy of ZCL Chemicals Ltd. , Ankleshwar, That

All Incident are Preventable, All identified Health Risk are Containable and identified

Environment impacts are Prevented.

Prevent Injuries and Occupational Illness at the Workplace.

Enhance quality, environment, health and safety awareness.

Comply with all Statutary and Regulatory Laws and Regulation for Quality, Environment,

Health and Safety

Continual improvement towards Quality, Technology, after Sale Service Aspect and Upgration

of Environment, Health and Safety Management system to Prevent/Minimize Pollution,

Occupation Health and Safety risks.

Enhance Visibility of Top Management towards Conservation Resource Quality, Environment,

Health And Safety.

Our Quality, Environment, Health and Safety Consciousness shall be Recognised through

acheiving excellence implementation level of ISO 9001 : 2008, ISO 14001: 2004 and Oshas

18001 : 2007 Norms.

The name and address of Directors are given in Table 2.



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TABLE: 2

CONTACT DETAILS OF THE DIRECTORS

List of Directors as on 01.03.16

Sr.

No. Name & Address of Directors

Date of

Appointment

Date of

Ceasing

Date of

Birth PAN No.

Contact

No.

1 Mr. Ajay Krishnakant Parikh 13.03.1991 Nil 24.06.1957 AACPP4774A

022--

61539900

20/301, Gurukrupa, Vithal Nagar,

CHS Ltd., 11th

Road, JVPD

Scheme,

Vile Parle (W), Mumbai – 400

049

2 Mr. Nihar Ajay Parikh 01.09.2010 Nil 13.11.1985 AKNPP4298E

022--

61539906

20/301, Gurukrupa, Vithal Nagar,

CHS Ltd., 11th Road, JVPD

Scheme,

Vile Parle (W), Mumbai – 400

049

3 Mr Dhiren Shevantilal Shah 05.09.2011 Nil 29.04.1956 AAEPS0922M

022--

61539999

Cumbala Hill post Office

Gamdevi P.Stn

Mumbai - 400026

4 Mr.Piyush Maganlal Nathwani 30.01.2015 Nil 24.04.1961 AAZPN7154P

02646-

619405

F 14,Shashwat Complex

Dahej By Pass Road

Bharuch-392001,Gujarat

5 Ms. Anuja Ajay Parikh 31.07.2015 Nil 26.07.1989 ASAPP0424F

022-

61539999

20/301,Guru Krupa,Vital Nagar

Society,

11th Road,JVPD Scheme,Vile

Parle(west)

Mumbai-400049,Maharastra



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2.3 NATURE OF PROJECT

The existing Unit1A plant is very old so considering about safety point of view M/s. ZCL

Chemicals Ltd. decided to relocate it.

2.4 MARKET FEASIBILITY

Established in 1991, ZCL Chemicals Ltd (ZCL) is head quartered in Mumbai. The cGMP

manufacturing facility and state-of-the art R&D Center are located in the Industrial park of

Ankleshwar in Gujarat State. ZCL combines the power of Science & Technology and has been

into manufacturing of Active Pharmaceutical Ingredients (APIs) and Advance Intermediates for

Innovator and Generic companies around the world. Has earned the preferred partner status from

some of the Global Pharmaceutical companies.ZCL production site has been successfully audited

and approved by the US FDA, KFDA, WHO-GMP and Japanese customers.

It is a policy of ZCL CHEMICALS LTD, That Commitment towards competency in Quality,

lead time and overall economic feasibility must satisfy our esteemed customers.

Continual improvement towards technical and after sales service aspects of all products shall be

our motto. Renovation towards the best shall be equally participated from all our employees to

drive the organization towards achieving further success & growth in business.

Our quality system is based on ICH Q7 GMP requirements.

Our quality consciousness shall be recognized through achieving excellent implementation level

of ISO 9001:2000; ISO 14001:2004, OHSAS 18001:2007 Norms.

2.5 EMPLOYMENT GENERATION DUE TO THE PROJECT

The details are given below

TABLE: 3

DETAILS OF MANPOWER

Sr.

No. Phase of Project Type of Labor No. of Worker

1 During construction Contractual 150

2 During

commissioning Contractual

NA (existing

manpower shall be

used)



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3.0 PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

The proposed project is not including any interlinked and interdependent projects.

3.2 PROJECT LOCATION

The proposed project site is located at Plot No. 3102/B, GIDC Industrial Estate, Ankleshwar,

Dist.Bharuch in the state of Gujarat. It is approximately 20 km distance from district head

quarter Bharuch. The approximate geographical positioning of the project site is at Latitude: 21o

37’ 36” N, Longitude: 73o01’ 58” E. The location of the project site can be identified from the

location map shown in Figure -2.

The salient features of the location of the project site are presented in below Table.4.

TABLE: 4

SALIENT FEATURES OFTHE PROJECT SITE

Particulars Details

Village Ankleshwar

Taluka/ Tehsil Ankleshwar

District Bharuch

Approx. Geographical positioning Latitude: 21o 37’ 36” N

Longitude: 73o

01’ 58” E

Nearest City Bharuch about 20 KM

Nearest Town Ankleshwar

Nearest Highway National Highway No. 8

Nearest State highway National Highway No. 8

Nearest Railway line/ Railway

station

Ankleshwar Railway Station

Nearest Airport/ Airbase Vadodara about 94 KM



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FIGURE: 1

LOCATION OF THE PROJECT SITE

Ankleshwar Industrial area

Panoli Industrial area

Jhagadia industrial area

Priaman CETP

Canal

Piraman to Katiyajal Effluent

Pipe

Jhagadia to Piraman CETP

Panoli to Piraman CETP

PROJECT SITE



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FIGURE: 2

AERIAL VIEW OF THE 5 KM RADIAL PERIPHERY FROM THE PROJECT SITE

3.3 SITE SELECTION

The existing plant is very old so considering about safety point of view M/s. ZCL Chemicals

Ltd. want to relocate Unit1A in the same premises .



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3.4 NEIGHBOURING INDUSTRIES

The industry is located in an area, which is already industrialized. The industries in the vicinity

of the proposed project are given in the table 5:

TABLE: 5

NEARBY INDUSTRIES IN THE VICINITY

Name of Industry Direction with

respect to project

site

Address

United Phosphorus

Limited (Unit- 2)

East side of

company Plot No. 3405/3406, GIDC Industrial

Estate,Ankleshwar-393001

Glenmark

Pharmaceutical

Ltd.

North side of

company

Plot No. 3109/C, GIDC Industrial Estate,

Ankleshwar-393001

RPG Life Sciences

Limited.

South side of

company

Plot No. 3102/A, GIDC Industrial Estate,

Ankleshwar-393001

United Phosphorus

Limited (Unit- 3)

West side of

company

Plot No. 3101/2, Ankleshwar GIDC,

Ankleshwar - 393001

3.5 SIZE OF PROJECT

The expected cost of proposed project is Rs. 4635 lacs.

The following table shows the break-up of the project cost.

TABLE:6

CAPITAL COST OF PROJECT

Sr.

No.

Activities Capital cost in

Rs. lacs/Annum

(Approx)

1. Land Existing land

2. Building 1035 lacs

3. Plant and Machinery 3368 lacs

4. Q.A. Lab set up NA (existing set up will be

used)

5. Env. Protection & Safety

a) Effluent treatment Plant NA(existing set up will be



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used, no additional effluent

load)

b) Air pollution control & Hazardous waste

management

120

c) Safety Equipment (PPE, fire extinguishers,

Ventilation, etc.)

110

d) Green belt development 2

Total 4635 lacs

3.6 PROCESS TECHNOLOGY

Process details like process description for each grade of products are covered separately in

Annexure-VI of Form-I.

3.7 RAW-MATERIALS

The required raw materials will be purchased from the local/ Indian market& China. Details of

raw-material consumption are covered in Annexure-V of Form-I.

3.8 RESOURCE OPTIMIZATION/RECYCLING AND REUSE

3.8.1 SOLVENT RECOVERY

Methanol (81% recovery), MDC (85% recovery), Toluene (93% recovery), Chloroform (85%

recovery), Xylene (85% recovery), Acetic Acid (88% recovery) and Hexane (88% recovery) are

the solvent to be used in the existing process. There are provisions of recovery of solvent.

3.9 RESOURCE REQUIREMENTS

3.9.1 LAND

The plot had been purchased by M/s.ZCL Chemicals Limited from GIDC. The total plot area of

the unit is 35595 sq. m.

3.9.2 BUILDING

The existing plant is very old so considering about safety point of view M/s. ZCL Chemicals

Ltd. decided to relocate the existing plant building Unit1A. Investment proof has been given by

Chartered Accountant.



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3.9.3 POWER AND FUEL

The unit’s power and fuel requirement is provided in Table 7. There will not be any increase in

fuel consumption.

TABLE:7

POWER AND FUEL REQUIREMENT

3.9.4 WATER

The category wise bifurcation of the water requirement is given in Table no 8. The source of

water will be from GIDC water supply scheme. There will be no change in Proposed Water

consumption.

TABLE:8

DETAILS OF WATER CONSUMPTION

3.9.5 MANPOWER

Sr.

No.

Particulars Existing as per

Consent Quantity

Proposed

Quantity

Total

Quantity

Source

1. Natural Gas

for Boiler &

Thermic Fluid

Heater

290 SCM/Hrs -- 290 SCM/Hrs Gujarat

Gas

2. Diesel For DG

Sets

117 Lit/Day -- 117 Lit/Day Local

Supplier

3. Energy-

Electricity

950 KVA -- 950 KVA DGVCL

Particulars Existing water

consumption (KL/Day)

Proposed water

consumption (KL /Day)

i) Domestic+Others

(gardening etc) 21.2 21.2

ii) Industrial

Process 25 25

Boiler 12 12

Cooling 64.8 64.8

Washing 42 42

Total 165 165



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The manpower required for the project as well as during the construction/commissioning

activities will be employed from the local area. The details are provided in Table 3.

Sr.

No. Phase of Project Type of Labor No. of Worker

1 During construction Contractual 150

2 During

commissioning Contractual

NA (existing

manpower shall be

used)

3 During operations

Managerial 130

Skilled 40

Un-skilled 120

Total: 290

3.10 MITIGATION MEASURES & EMP

Based on overall manufacturing & operation activities, the mitigation measures have been

proposed by the company for the control of the anticipated pollution load.

3.10.1 WASTEWATER MANAGEMENT

The category-wise bifurcation of the anticipated wastewater generation details is given in Table 9.

There will be no change in Proposed Wastewater generation due to Proposed construction work.

TABLE:9

DETAILS OF WASTEWATER GENERATION

Particulars Existing Wastewater

generation(KL/Day)

Proposed Wastewater

generation(KL /Day)

i) Domestic+

Others

(gardening etc)

10 10

ii) Industrial

Process 14 14

Boiler 4 4

Cooling 3 3

Washing 24 24

Total 55 55



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3.10.1.2 WASTEWATER CHARACTERISTICS

Industrial wastewater will be generated from process, cooling tower and boiler. The expected

characteristics of industrial wastewater are provided in Table 10.

TABLE: 10

WASTE WATER CHARACTERISTICS

Sr.

No. Parameters

Unit

s

Standards

prescribed

by GPCB

Standards

prescribed

by NCTL

Before

Treatmen

t

After

Treatmen

t

1 pH -- 5.5 to 8.5 5.5 to 8.5 6- 9 6.5-8.5

2 Colour Pt

Co 100 -- 400-1000 50-70

3 Total Suspended Solids mg/l 100 -- 4500-5500 30-60

4 Total Dissolved Solids mg/l 2100 -- 30000-

35000 2000-2300

5 Oil & grease mg/l 10 -- 8-11 Not

detected

6 Phenolic compounds mg/l 1 -- 1-3 Not

detected

7 Cyanides mg/l 0.2 -- Not

detected

Not

detected

8 Ammonical Nitrogen mg/l 50 100 600-800 30-50

9 Sulphate mg/l 1000 -- 5000-6000 200-300

10 B.O.D.(3 days at 27°C) mg/l 30 -- 10000-

12000 55-70

11 C.O.D. mg/l 100 1000 30000-

35000 170-200

3.10.1.3 WASTEWATER TREATMENT & DISPOSAL



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MEE OPERATION PROCEDURE

Effluent Feeding:

Neutralized effluent (High COD) from neutralization tank after passing through filter press shall be

brought for treatment through pipeline in balance tank at MEE plant.

Pre Heaters

This effluent will be pumped to Pre-heater 3, 2, 1 in series and finally to stripper column via MEE feed

pump with a flow of 1900-1950 Lit/Hr. and finally to solvent stripper column through pumping under

vacuum.

Main Steam application

After starting feed pump gradually open TVR Valve and maintain high steam pressure around 4.0

Kg/Cm2.

Solvent stripper Unit

Start Solvent stripper column pump and maintain solvent stripper column level (Half level of side glass)

through adjustment of valve of Reboiler & recycle valve. Open Low pressure steam valve gradually for

solvent stripper column/re-boiler and maintain Temp around 85 oC. When desired temp. attained in

stripper column/Reboiler start condensate pump and transfer low boiler vapor condensate via surface

condensers to Stripper condensate collection tanks. The residual high boiler effluent will be transferred to

Calendria 1.

Calendria’s

After receiving high boiler effluent start Calendria pump No. 01, 2, and 3 in successions after necessary

level is maintained in calendria’s. During level maintenance apply steam gradually and maintain upto 8.0

Kg/cm2.

Condensate Pump

After full steam is applied in MEE, MEE condensate pump is started and the condensate received via

MEE surface condensor (primary and secondary) is recirculated back in balance tank till colour of the



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condensate is clear, colourless & free from any suspended solids. Then transfer this condensate water in

MEE O/L collection tank via MEE condensate pump.

Recycle Pump

The remaining concentrated mass will be transferred after checking Baume (specific gravity) in VTFD

Balance Tank via recycle pump for further drying process in VTFD.

VTFD Unit

Start VTFD vacuum pump ensuring cooling circulation via vacuum Syntax pump.

The concentrated mass is kept agitated in VTFD Balance tank and is fed in VTFD agitator via VTFD feed

pump. Simultaneously open high pressure steam valve for VTFD and Maintain steam pressure 8.0 – 8.5

Kg/cm2 gradually.

Start main VTFD Agitator and set the valve opening such that dry powder/salt is received at the bottom

end. Start Condensate pump and transfer condensate received from VTFD surface condensor to E.T.P.

Collect dry powder/salt in drum from VTFD bottom hopper. Fill this powder/salt in empty bags and shift

to Haz Waste storage yard and dispose to TSDF time to time.



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TABLE: 11

DEMENTIONAL DETAILS OF ETP UNITS

Sr.

No. Name of Equipment Capacity

Retention time

in Hrs. MOC

1 Collection Tank 66 KL 26.4 RCC

2 Neutralization Tank 41 KL 16.4 RCC

3 Filter Press - - -

4 Filter Press Tank 05 KL 2 RCC

5 MEE Plant 40 M3/Day - MS

6 MEE O/L Collection Tank 36 KL 14.4 RCC

7 Primary Clarifier 20 KL 8 RCC

8 Aeration tank 150 KL 60 RCC

9 Secondary Clarifier 20 KL 8 RCC

10 Sludge Drying Bed 10 M2 - RCC

11 Secondary O/L Collection Tank 40 KL 16 RCC

12 Old Holding Tank 12 KL 4.8 MS

13 New Holding Tank (Final

Discharge Tank) 75 KL 30 RCC



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FIGURE:3

FLOW DIAGRAM OF ETP



Page 27

FIGURE :4

FLOW DIAGRAM OF MEE



Page 28

3.10.2 GASEOUS EMISSIONS & CONTROL

There will be flue gas emission from one Boiler, Thermic fluid heater and Two DG sets. Natural

gas is fuel and diesel will be used as fuel in DG set. The air pollution control measures are

covered in below table 12.

TABLE:12

DETAILS OF FLUE GAS EMISSIONS

Sr.

No.

Stack

Attached

To

Stack

Height

Stack

Diameter

Fuel

Consumption

Air

Pollution

Control

System

Type

of

Emission

Permissib

le Limit

As per Existing

1. Boiler

G1207A 30 m

0.45m

(Top) Natural gas -- PM

SO2

NOx

150

mg/NM3

100 PPM

50 PPM 2. Thermic

fluid heater 22 m

0.5m

(Top) Natural gas --

Note: There will be no change in proposed flue gas emissions due to Proposed Project

include only construction of new plant after demolishing existing Unit 1A.

3.10.2.2 PROCESS EMISSIONS

The process emissions from the proposed manufacturing activities are given in Table 13.

TABLE:13

DETAILS OF PROCESS EMISSIONS

Sr.

No.

Stack

Attached

To

Stack

Height

(m)

Stack

Diameter

(m)

Air Pollution

Control System

Type of

Emission

Permissible

Limit

As per Existing

1. Reactor Vessel

Plant - 1

25 0.15 Water

Scrubber+Caustic

Scrubber

HCl

SO2

CL2

20 mg/Nm3

40 mg/Nm3

9 mg/Nm3

2. Reactor

Vessel Plant -

15 0.15 Water

Scrubber+Caustic

HCl

CL2

20 mg/Nm3

9 mg/Nm3



Page 29

Note: There will be no change in proposed process emissions due to Proposed Project

include only construction of plant as relocation of existing Unit 1A.

3.10.3 HAZARDOUSWASTE MANAGEMENT

The following type of hazardous waste will be generated from the operational activities. All the

waste will be stored separately in a designated storage area.

TABLE:14

DETAILS OF HAZARDOUS WASTE GENERATION

Sr.

No.

Name of waste Cat.

No.

Quantity Method of disposal

Existing Total

1. ETP Sludge 34.3 339 MT / year 339 MT / year Collection, storage within

factory premises,

transportation and final

disposal at TSDF

M/s.BEIL.

2. Carbon Waste 35.3 18.25 MT /

year

18.25 MT /

year

Collection, storage within

factory premises,

transportation and

incineration at TSDF

M/s. BEIL/RSPL &

Ambuja Cements for Co -

processing.

3. Distillation

residue

20.3 36.5 MT /

year

36.5 MT / year Collection, storage within

factory premises,

transportation and


M/s. BEIL/ RSPL &


processing.

4. Discarded

containers

33.3 43800 Nos /

year

43800 Nos /

year

Collection, storage with

in factory premises,

transportation and sell to

authorized vendors.

2 Scrubber NH3 175 mg/Nm3



Page 30

5. Distillation

residue from

contaminated

organic solvents

36.4 0.73 MT /

year

0.73 MT / year Collection, storage within

factory premises,

transportation and


M/s. BEIL/RSPL &


processing.

6. Used / Waste Oil 5.1 1.83 MT /

year

1.83 MT / year Collection, storage,

treatment within factory

premises, transportation

and sell to registered

refiners.

7. Contaminated

solvents not fit

for originally

intended use

20.1 73 MT / year 73 MT /year Collection, storage,

recovery and reuse within

premise at site.

8. Spent solvent 20.2 73 MT / year 73 MT / year Collection, storage,

recovery and reuse within

premise at site.

9. High COD waste

from MEE

stripper

20.2 540 MT/year Max 540

MT/year

Collection, storage within

premises. Disposal at

TSDF/Incinerator.

Note: There will be no change in Hazardous waste generation .

3.10.4 NOISE CONTROL & ODOUR

The major noise generating installation will be the D.G. Set. It will be installed in a closed room,

acoustic enclosure will be provided around it.

Ear plugs will be provided to the operating personnel in boiler room. Low noise generating

equipments will be selected. Adequate engineering controls will be implemented to avoid noise

pollution.

The following steps will be taken for odor control.

• Raw-material feeding will be carried out by pumps and in close loop system.



Page 31

• All reactions will be taken in closed reactor system.

• Roof top ventilation will be provided in the entire plant area.

• Regular monitoring will be done of piping and fittings for checking of any leakages.

3.10.5 STORAGE, HANDLING AND TRANSPORT OF HAZARDOUS

CHEMICALS

The storage and mode of transport of chemicals will be done as per detailed MSDS and chemical

hazards guide for the hazardous chemicals.

Few chemical to be used in the proposed activities are listed as ‘Hazardous Chemicals’ as per the

Schedule-1 of the MSIHC Rules, as amended in 2000.

3.10.6 HEALTH AND SAFETY MEASURES

Few chemical to be used in the activities are listed as ‘Hazardous Chemicals’ as per the

Schedule-1 of the MSIHC Rules, as amended in 2000.

Physical hazards may manifest as fires, explosions, excessive temperatures, or the release of

large volumes of gas or toxic or flammable gases or vapors. According to Schedule 2 & 3 of

MSIHC Rules.

Below mentioned is the safety measure to be taken at site for control of anticipated hazards.

Identification, analysis, assessment of hazards and risk provides vital information to risk

management. Objective of this plan is to assess the risk and to provide guidelines for facing and

controlling the emergency.

This contains the information of possible hazards and their effects on the workers, general public

and environments.

• Hazards in storage area :

Following are possible storage hazards

� Fire

� Explosion

� Spillage / leakage

� Failure of storage tanks

Most of the chemicals are toxic in nature other than some exception. Toxic substances affect in



Page 32

three ways by ingestion, absorption and inhalation. Adequate provision of safety is done to work

with toxic materials.

� All raw materials, solvents, intermediates and finished goods are stored

according to their compatibility with other chemicals. The various places

where chemicals, solvents are stored are :

- Licensed tank farm area

- Raw material store

- Cold Room

- WIP room

- Bonded store

� All the flammable liquid materials are stored in storage tanks. The tank

farm for Petroleum Class A, B & C liquids is approved by Chief

Controller of Explosives after due inspection.

� The storage tanks are mounted above grounds with bund. Bund capacity is

1.1 times higher than biggest tank.

� The other chances of fire hazard may be due to generation of static

electricity due to flowing of solvent in the pipeline by accumulating

electrical charge & resulting spark. For this, company has provided

adequate number of static jumpers on each flange joints with proper

earthing.

� For vehicles like tanker, which carry flammable solvents, an additional

facility is provided at gate house for dissipation of static charge generated

by the tanker while coming to company from its supplier’s location.

� Rule of no smoking is observed strictly in the company premises.

Company has implemented “No Smoking Policy” and at appropriate

places, boards are displayed.

� All the safety standards & parameters are observed strictly. The total area

is provided with adequate firefighting equipment also.

� Earthing facility is provided at the unloading point to provide earthing to

the tankers at the time of unloading.



Page 33

� Flame arrestor is provided on the vents of tanks containing flammable

liquid.

� The tankers are provided with the flame arrestors (mufflers) while

entering inside the factory premises.

� The raw water tanks with capacity 250 M3.

� Water sprinkler provided on the tanks containing the flammable liquid in

tank farm area.

� The employees are trained in first aid fire fighting.

� Adequate SOPs are in place for safe handling of chemicals and concerned

employees are trained for the same.

� Spillage kit is provided to contain spillage / leakage.

• Fire and explosion

� The fire and explosion risk are associated with

- Solvents like Methanol, Toluene, Acetone, etc.

- Chemicals like phosphorous pentoxide, etc.

- certain chemical reaction like hydrogenation, grignard, distillation,

� Electrical short circuit

� The fire risk is not affecting outside factory. And hence the risk is limited

to factory area.

� The gas dispersion is Nil.

� To control the fire, fire extinguishers like DCP, CO2 and Foam are

provided. Also, factory has installed the DCP modular in the solvent tank

farm.

� Adequate water tanks having 750 M3 capacities. Facility for water at

several places in plant and factory premises.

� Sprinkler system in tank farm area to control vapour emission and thereby

reduced fire risk.

� Vapor detector system are installed in the warehouse



Page 34

• Spillage control

� SOP for prevention and control of spillage

- Eliminate all sources of ignition immediately.

- Ventilate the area but isolate the material.

- Absorb the chemical into sand.

- Allow atmospheric evaporation.

- Flush the spilled area with water and detergent.

� Spillage kit for spill control.

� In tank farm area, checking of bund and bund valve is introduced and

being checked regularly.

� Training for spillage control and handling to all employees.

� Fumes and cylinder leakage kit are available.

� All employees are trained for first aid fire fighting and use of personal

protective equipments.

� The duties of responsible persons are as follows :

- To guide the people to stop the leakage and spillage.

- To ensure good housekeeping.

• Technological and civil

Our main products are bulk drug and their advanced intermediates. Considering

the use of hazardous chemicals, following steps are taken.

� All structure and other equipments are fabricated as per the engineering

specification laid down in appropriate specification of international and

national bodies in the subject.

� Vessels are equipped with temperature indicators, pressure gauges, level

indicators, safety valves, etc.

� Vessels are pressure tested as per Factories Act, 1948. Flame proof fittings

are provided.



Page 35

� Regular inspection is carried out by external agency to maintain proper

health of plant, equipment and machinery.

� Thickness of tanks is carried out periodically and record maintained in

Form 11 as per Factories Act.

� Building structure is constructed as per standard practice. Material used is

tested for its quality and suitability under guidance of experts approved

under Government notification.

� The structure is being inspected by Government approved competent

person periodically and stability certificate is maintained.

� Inspection, maintenance, painting of plant / machinery etc, is carried out

regularly.

• Toxic release risk

The potential risk involved is leakage from tanks and pipelines.

To attain the toxic release of gases (DMS and Ammonia) from cylinder, cylinder

leakage control kit is available.

Fumex are available for the dilution of atmosphere inside the plant or used as an

exhaust or in case of tank cleaning it also used as a exhaust fan for fast dilute

Material Safety Data Sheet is kept as ready reference at all critical areas.

Evacuation table is displayed at gate.

Training is given related to Emergency Preparedness to both old and new

employees.

4.0 SITE ANALYSIS

4.1 CONNECTIVITY

The site is located at Plot no. 3102/B, GIDC Estate, Ankleshwar, Gujarat. The land and

Infrastructure is already available and the raw materials are easily available through the easy

transport via road connectivity.



Page 36

Ankleshwar Industrial Estate was set up by Gujarat Industrial Development Corporation in early

70s. This industrial estate is spread over an area of 1600 hectares in close proximity to National

Highway No.8 and Delhi-Mumbai Railway Line. Being an ideal location for industrialization, as

on date, more than 1500 industries, consisting of chemicals, pesticides, pharmaceuticals, bulk

drugs, petroleum products, engineering, textiles, plastics, rubber and packaging etc. are located

in this industrial estate.

The town is known for its industrial township called GIDC (Gujarat Industrial Development

Corporation). Ankleshwar has an office of the ONGC (Oil and Natural Gas Corporation

Limited). GIDC is organizing Trade fare and Industrial expo occasionally to attract large number

of industries all over from India. It also helps to get customer on large basis.

Ankleshwar is connected by Indian National Highway 8 (Mumbai to New Delhi) and by the

Western Railway Division of Indian Railways. The railway division also runs the broad

gauge train services to Rajpipla. The 133 year-old Golden Bridge connects Ankleshwar to

Bharuch across the Narmada on the station front while a new bridge connects the highway, the

other bridge on the highway is now ready to use.

Ankleshwar City Bus stand is located on Station Road (i.e. located in the City, the western

section).

Development project of Ankleshwar Airport & City Bus are in pipe line in last stage.

Ankleshwar is an educated city. It has an average literacy rate of 79%, higher than the national

average of 59.5%; with 56% of the males and 44% of females literate.

Ankleshwar JN Rail Way Station, Sanjali Rail Way Station are the very nearby railway station to

Ankleshwar GIDC. However Surat Rail Way Station is major railway station 56 KM near to

Ankleshwar GIDC.

Healthcare

Hospitals include are the

• Jayaben Modi Hospital,

• Sarvajanik Hospital,

• Sanjivani Hospital

• Sardar Patel Hospital.



Page 37

• And now ESIC's (Employee State Insurance Corporation) New Hospital is under

Construction.

• In April 2014, the "New Life" private hospital was constructed in Jasaat Plaza (Station

Road). It is conveniently served by Ankleshwar's main bus & railway stations.

Shopping and Recreation:

• There is a lake in GIDC & City area. Situated in front of GIDC Lake, Lakeview Plaza

Mall is city's first truly integrated mall for restaurants, entertainment and hotel stay.

• Nav Graha Jain Mandir (G.I.D.C), Manav Mandir, Sai & Swaminarayan Temple are big

temples in Ankleshwar. Ankleshwar City is also having big Mosques Halimsha Datar

Bhandari, Garib nawaz, etc.

• Centers of Brahma Kumaris World Spiritual University is located in both GIDC and City

area which helps you to know your true self with the help of Free Rajyoga Meditation

Classes.

• There are parks such as The Millennium Park and old parks in Ankleshwar city, the GIDC

Water Reservoir, and sports center.

• There are swimming pools, Joggers park, children's park, Rotary library and other

recreation centers in the GIDC area.

• There is an Open Air Theater in GIDC Area. Chauta Bazar is the biggest shopping area in

Ankleshwar.

4.2 LAND USE AND LAND OWNERSHIP

The existing project site is located at plot no 3102/B, GIDC Estate, Ankleshwar, Gujarat. The

total plot area of the unit is 35595 Sq. M. Land ownership is with project proponents. The

geographical location is 21o 37’ 36” N latitude and longitude 73

o1’ 58” E.

They have valid consent from Gujarat Pollution Control Board, Gandhinagar. And the consent

no. is AWH:72765 and it is attached as an Annexure-XIII.

4.3 LAND USE

The existing project site is located at plot no 3102/B, GIDC Estate, Ankleshwar, The plot is

notified by GIDC for industrial purpose.



Page 38

4.4 EXISTING INFRASTRUCTURE

The project is currently located in a well-developed zone, which have all essential facilities such

as well-connected road network with ease of transportation, arrangement for supply of water and

power to industries, effluent disposal facilities etc.

4.5 SOIL CLASSIFICATION

The soils of the district are derived from the Deccan trap which is main rock formation of the

district. The soil of the district can be classified as light, medium and heavy according to depth,

texture and location. There is sandy loam to loamy in texture, brownish black in color.

4.6 CLIMATE DATA

As per gathered meteorological data, the maximum temperature is 42.4°C, where as the

minimum temperature is 14.8°C. The relative humidity levels varied from 13% to 86%. The

maximum and minimum as well as relative humidity for a period of March, 2014 to May, 2014

are presented in Table 15.

TABLE:15

DETAILS OF MICRO METEOROLOGICAL DATA

(Data from Indian Meteorological Department, Ahmadabad)

Based on the above metrological data, wind rose has been prepared for the summer season

period from March 2014 to May 2014. As per the metrological data, it shows that the average

wind speed in March, April, and May 2014 is 2.76 m/s with wind direction blowing to NE.

The wind rose prepared from same data is shown at Figure 6.

Month Temperature(oc) Humidity (%) Rain fall (mm)

Maximum Minimum Maximum Minimum Maximum Minimum

MARCH 2014 38.2 14.8 84 13 00 00

APRIL 2014 41.8 20.6 86 14 00 00

MAY 2014 42.4 27.2 83 17 0.8 00



Page 39

FIGURE:5

WIND ROSE DIAGARM FOR PERIOD (MARCH TO MAY, 2014)

4.7 SOCIAL INFRASTRUCTURE

Population density and sex ratio of Bharuch District was reported 238 persons/sq.km. and 920

females per 1000 males respectively in 2011 census report. Total literacy of Bharuch District

was found 81.51 %.The basic amenities like primary and secondary education schools,

community health workers, primary health sub centre, private practitioners, primary health

centre, maternity and child welfare, dispensaries, T.B clinic, family welfare centre, hospital,

drinking water, transportation facilities, electricity , telephone etc. are available.

5.0 PLANNING BRIEF

5.1 PLANNING CONCEPT

Ankleshwar is largely an industrial area dominated by large scale industries, especially chemical

plants& Pharmaceutical plants.



Page 40

Now the unit has planning to construct new plant after demolishing the existing Unit 1A. The

production capacity remain same.

Ankleshwar in Gujarat has an industrial area with common effluent treatment plant, common

incinerator and land fill site. Govt. agencies provide many basic facilities like uninterrupted

water supply, power and road network.

5.2 POPULATION PROJECTION

As per provisional reports of Census India, Population of Bharuch District in 2011 is 1,551,019.

Population of male and female are 805,707 and 713,676 respectively. The sex ratio of Bharuch

city is 920 females per 1000 males.

In education section, total literates in Vadodara District are 2,893,080 of which 1,614,087 are

males while 1,278,993 are females. Average literacy rate of Vadodara district is 78.92%.

5.3 LAND USE PLANNING

The proposed project is on a GIDC land.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND

The M/s. ZCL Chemicals Ltd. shall get water from GIDC water supply scheme. So there will be

no additional stress on ground water resources and there will be no adverse effect on the ground

water resources available in the nearby area.

5.5 AMENITIES/FACILITIES

The available basic amenities are as under:

(A) Education Facilities:

All the villages have a minimum of one primary school.

(B) Medical Facilities:

All the surrounding villages have medical facilities.

(C) Drinking water Facilities & Power Supply:



Page 41

All the villages have potable water supply and in 100% area the drinking water is

supplied through taps, wells and tube wells. All the villages have power supply facilities

in the study region.

(D) Post, Telegraph & Telephone facilities

The information collected clearly indicates that the infrastructural facilities are provided

by respective government agencies for the development of this area. For communication

purpose, post office and phones are available in most of the villages.

(E) Transport Facilities:

Bus services are available in all the villages of the study region within 5 km area and are

the most preferable mode of transport in the region. Auto-rickshaw is also used as

transport facility. Villages are connected with paved roads. All the surrounding area is

covered with 108 emergency facilities.

6.0 PROPOSED INFRASTRUCTURE

6.1 PROCESSING AREA

The process area will cover plant area like Plant-1A, 1B, 2, 3, 4, ETP and utilities. The process

area for Unit 1A after relocation will be covered by 1808 square meters.

6.2 NON PROCESSING AREA

The non process area will cover Electrical panel room, CCOE area, Warehouse-solid & liquid,

TOC Room, 22KV Breaker Room, canteen, U/ground water tanks-all, Cold Room, Security

cabin & OHC Room, HT Yard and surrounding area-utility & main, Admin Block, Scrap yard,

and all roads and passages, contractor sheds, Parking area etc. The non process area covered by

unit will be around 1016 square meters and total non process area covered by unit at ground level

will be around 24860.37 square meters.

6.3 GREEN BELT

Out of the total land area of 35595 square meters approximately 18% will be utilized for green

belt development. The proposed greenbelt area is 6215.04 square meters.



Page 42

6.4 SOCIAL INFRASTRUCTURE

The availability of basic amenities is covered as under:

(A) Training & Education: All the employees will be trained and educated periodically about

the hazardous nature of chemicals used in the process. Also, training for firefighting, work

permit system, first aid, safe handling of hazardous chemicals and integrating safety, in all

activities.

(B) Medical facility: Pre-employment medical checkup at the time of employment. In order to

safe guard the health of the employees, all the employees undergo periodic health checkup.

(C) Drinking water: There will be provision of Aqua Guard/R.O. at different places to provide

purified water for drinking purpose.

(D) Transportation: The unit will provide basic transportation facility for workers.

(E) Telegraph & Post: There will be provision of telephone, fax & internet facility.

(F) Power supply: There will be total connected load of 950 KVA from DGVCL.

6.5 CONNECTIVITY

Ankleshwar estate is well connected by rail and road to rest of country.

6.6 DRINKING WATER MANAGEMENT

Average daily water consumption of unit will be 9.7 KL/Day for domestic purpose. The entire

water requirement will be meeting through GIDC water supply system.

6.7 SEWAGE SYSTEM

The sewage will be diverted in soak pit. The overflow of soak pit is treated in ETP.

6.8 INDUSTRIAL WASTE MANAGEMENT

The hazardous waste like ETP sludge, Carbon Waste, Distillation residue, Discarded containers,

Distillation residue from contaminated organic solvents, Used/Waste Oil, Contaminated solvents

not fit for originally intended use ,Spent solvent, High COD waste from MEE stripper will be

generated from the proposed activity. There will be no change in Hazardous waste generation



Page 43

due to proposed construction work. The hazardous waste management and disposal is shown in

Annexure-XI in Form-I.

6.9 SOLID WASTE MANAGEMENT

The record of hazardous and non Hazardous waste solid waste like Personal Protective

Equipments, etc

6.10 POWER REQUIREMENT & SUPPLY

The unit will use total 950 KVA electricity connected load from DGVCL.

7.0 REHABILITATION AND RESETTLEMENT(R &R) PLAN

The proposed project is located in Plot No: 3102/B, GIDC Estate, Ankleshwar, Dist-Bharuch,

Gujarat-392002. There will be no any human settlement affected by proposed project.

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 PROJECT IMPLEMENTATION SCHEDULE

TABLE: 16

PROJECT IMPLEMENTATION SCHEDULE

Project implementation schedule

Sr.

No.

Activity Required Period

1. Civil work 15 months

2. Procurement of

machinery

within 8 months after civil work start

3. Erection & installation

of machinery

after 4 months of completion of building

4. Trial of machinery &

equipment

within 1 month of above activity

5. Commercial activity within 1 month of above activity



Page 44

8.2 ESTIMATED PROJECT COST

Rs 46.35 Crore will be invested in relocation of existing Unit 1A.

9.0 ANALYSIS OF PROPOSAL

All the manpower is utilized from local region around Ankleshwar. Company shall also try to

provide indirect employment opportunities by availing local contract services during

transportation during operational phase.

CSR activities – Company shall comply with statutory provisions related with CSR activities .

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