5.4.1 Water supply and sewerage infrastructure 181
5.5 Amenities/facilities 181
6 CHAPTER – 6 PROPOSED INFRASTRUCTURE
182-185
6.1 Industrial area (processing area) 182
6.2 Green belt 182
6.3 Social infrastructure 182
6.4 Connectivity 182
6.5 Sewerage system 182
6.6 Industrial waste management 183
6.7 Solid waste management 183
6.8 Power requirement and supply source 183
6.9
7 CHAPTER – 7 REHABILITATION & RESETTLEMENT PLAN
184
8 CHAPTER – 8 PROJECT SCHEDULE & COST ESTIMATES
185
8.1 Time schedule 185
8.2 Estimate project cost 185
9 CHAPTER – 9 ANALYSIS OF PROPOSAL
186
iv
List of Tables Table
no. Description Pg. no
1.1 Present chemicals being manufactured 2
1.2 Proposed chemicals to be manufactured 2
1.3 Water consumption and discharge 9
1.4 Sewage/wastewater treatment and discharge 10
1.5 Raw Materials Requirement 10
1.6 Solvent Recovery 30
1.7 Sources of air pollution, type of fuel used, APC details 34
1.8 Solid Waste Generation during the Operation Phase 36
1.9 Hazardous raw materials 37
1.10 Quantity of spent Carbon waste generated from manufacturing process
37
1.11 Quantity of catalyst sent to reactivation 38
1.12 Quantity of catalyst generation from process 39
1.13 Types of hazardous waste generated 40
1.14 Environmental Management Plan during Operation Phase 42
3.1 Present & proposed Products to be manufactured 52
3.2 Raw Materials Requirement for production of specialty chemicals 130
3.3 Details of Storage Facilities 149
3.4 List of Machinery 150
3.4a List of Equipments 151
3.4b List of Utilities 151
3.5 Hazardous raw materials 152
3.6 Quantity of spent Carbon waste generated from manufacturing process
154
3.7 Hazardous Waste Quantity and Disposal Details 154
3.8 Water consumption and discharge 156
3.9 Sewage/ effluent treatment and discharge 158
3.10 Product wise water consumption, discharge 158
3.11 Product-wise effluent generation for process 160
3.12 Wastewater characteristics 163
3.13 Air pollution sources, fuel consumption and chimney height details
164
3.14 Solid waste generation 167
4.1 Connectivity from the project site 169
4.2 Existing land use pattern 172
4.3 Meteorological data of Kolar for the year 2015 173
5.1 Land use pattern 180
8.1 Time Schedule 185
8.2 Proposed Expansion Cost 185
v
List of figures
Fig. No. Description Pg. no
3.1 Google map showing project site 49
3.2 Maps showing and project site location on district map 50
3.3 Water balance chart 157
3.4 Water Jet Scrubber 166
3.6 Feasibility & environmental assessment process 168
4.1 Google map showing connectivity to project site 170
4.2 Topo Map of the project site 171
4.3 Windrose diagrams 176
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 1
1.1 INTRODUCTION
1.1.1 Preamble
Amendment of the Environmental Impact Notification No. S.O. 60(E) dated 27.01.1994,
issued by the MoEF, Govt. of India has made mandatory under Schedule-I of EIA
notification for 30 different activities to obtain CFE from the State Pollution Control Board
and Environmental Clearance from the Ministry of Environment & Forests, Govt. of India.
This amendment to the EIA Notification is effective from 14.09.2006.
As per the amended EIA notification dated 14th September, 2006 the Processing of Fine and
specialty chemicals industry will fall under category B schedule 5(f). The proposed project is
an Expansion project.
M/s. Somu Organo-Chem Pvt. Ltd. at No.20, 29th Main, II Stage, I Phase, BTM Layout, Bangalore-560 076 proposes to expand its process specialty fine chemicals, bulk drugs & cosmetic and pharma ingredients industry at Shed No.C-29, C-30 & adjacent plots, KSSIDC Industrial Estate, Malur- 563 130, Kolar District. The proposed expansion envisages addition of (29) new products along with the Existing (7)
products which will be manufactured within the existing manufacturing facilities.
The present fine & specialty chemicals manufactured are provided under Table 1.1& 1.2
CHAPTER 1
EXECUTIVE SUMMARY
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 2
Table 1.1 Present fine & specialty chemicals being manufactured Reference No. SEIAA letter No. SEIAA :5: IND 2010, dated 09/06/2010
SI. No. Fine &
Specialty Chemicals
Production capacity (Kg/month)
Production Capacity (Kg/annum)
1 Benzalkonium chloride 1,00,000 12,00,000
2 1,3 Cyclohexanedione 75,000 9,00,000
3 Ore flotation reagent 2,00,000 24,00,000
4 4-Hydroxy carbazole 2,000 24,000
5 2/4 Methylcyclohexanol 5,000 60,000
6 2,4 Thiazolidinedione 10,000 1,20,000
7 3,3,5 Trimethylcyclohexanol 20,000 2,40,000
Total(A) 4,12,000 49,44,000
Table 1.2 Proposed fine & specialty chemicals to be manufactured
SI.NO. Specialty fine Chemicals, bulk drugs, cosmetic and pharma
ingredients
Production capacity (Kg/month)
Production capacity (Kg/annum)
1 4-n Hexylresorcinol 250 3000
2 4-n Butylresorcinol 150 1800
3 EthylhexylTriazone 1000 12000
4 Iscotrizinol 50 600
5 PiroctoneOlamine 1500 18000
6 Tetrahydrocurcumin 125 1500
7 Tetrahydropiperine 125 1500
8 1,4-Cyclohexanedione and
acetal
1000 12000
9 1,4-Cyclohexanediol 500 6000
10 (S)-1-Phenyl-1,2,3,4-
Tetrahydroisoquinoline
1000 12000
11 3-Quinuclidinone hydrochloride 100 1200
12 R-(-)-3-Quinuclidinol 50 600
13 Ethyl isonipecotate 2,500 30000
14 1,2,3,9-Tetrahydro-9-methyl-
4(H)-carbazol-4-one
500 6000
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 3
The total production capacity is A+B= 49,44,000+3,70,860 = 5,314,860 Kg/annum EC to be obtained for total production capacity of 5,314,860 Kg/annum
15 4-(2,3-epoxypropoxy)carbazole 500 6000
16 4-Methoxyethylphenol and
Metoprolol
1,000 12000
17 Mebeverine Amine 1,000 12000
18 2-(2-
Ethoxyphenoxy)ethylbromide
10 120
19 R-1-(-Methoxyphenyl-N-(R)-1-
phenylethyl)propan-2-amine
hydrochloride
15 180
20 R,R-2-methoxy-5-[2-(1-
phenylethylamino)-propyl]
benzenesulfonamide
15 180
21 R-(-)-5-(2-Aminopropyl)-2-
methoxy-benzenesulfonamide
and Tamsulosin
15 180
22 4-Methylcyclohexanone 2,000 24000
23 Trans-4-Methylcyclohexyl amine 500 6000
24 Tris(Hydroxymethyl)aminometh
ane
500 6000
25 Trans-4-aminocyclohexanol 5,000 60000
26 Tranexamic acid 500 600
27 Benzethonium chloride 1,000 12000
28 Cinnamyl alcohol 5,000 60000
29 (R)-(-)-3-Carbamoylmethyl-5-
Methylhexanoic Acid and
Pregablin
5,000 60000
TOTAL(B) 30905 3,70,860
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 4
1.1.2 Project at Glance
Sl.No.
Details
1 Project Expansion process of hydrogenation, formulations and processing of fine and specialty chemicals industry– “M/s. SOMU Organo Chem Pvt. Ltd.,” at Shed No.C-29, C-30 & adjacent plots, KSSIDC Industrial Estate, Malur- 563 130, Kolar District.
2 Project developers M/s. Somu Organo-Chem Pvt. Ltd. at No.20, 29th Main, II Stage, I Phase, BTM Layout, Bangalore-560 076.
3 Location of the site Shed No. C-29, C-30 & adjacent plots, KSSIDC Industrial Estate, Malur- 563 130, Kolar District
4 Constitution of the Organization
Private Limited Company
5 Raw materials Details of the raw materials required by the industry is appended in Section 3.6. Chapter 3 of this report.
6 Product/s proposed to be manufactured with production capacities?
The following are proposed to be manufactured Existing 7 products and proposed 29 products
SI. No.
Fine & Specialty Chemicals Production capacity
(Kg/month)
1 Benzalkonium chloride 1,00,000
2 1,3 Cyclohexanedione 75,000
3 Ore flotation reagent 2,00,000
4 4-Hydroxy carbazole 2,000
5 2/4 Methylcyclohexanol 5,000
6 2,4 Thiazolidinedione 10,000
7 3,3,5 Trimethylcyclohexanol 20,000
Total(A) 4,12,000
1 4-n Hexylresorcinol 250
2 4-n Butylresorcinol 150
3 EthylhexylTriazone 1000
4 Iscotrizinol 50
5 PiroctoneOlamine 1500
6 Tetrahydrocurcumin 125
7 Tetrahydropiperine 125
8 1,4-Cyclohexanedione and acetal 1000
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 5
9 1,4-Cyclohexanediol 500
10 (S)-1-Phenyl-1,2,3,4-
Tetrahydroisoquinoline
1000
11 3-Quinuclidinone hydrochloride 100
12 R-(-)-3-Quinuclidinol 50
13 Ethyl isonipecotate 2,500
14 1,2,3,9-Tetrahydro-9-methyl-4(H)-
carbazol-4-one
500
15 4-(2,3-epoxypropoxy)carbazole 500
16 4-Methoxyethylphenol and
Metoprolol
1,000
17 Mebeverine Amine 1,000
18 2-(2-Ethoxyphenoxy)ethylbromide 10
19 R-1-(-Methoxyphenyl-N-(R)-1-
phenylethyl)propan-2-amine
hydrochloride
15
20 R,R-2-methoxy-5-[2-(1-
phenylethylamino)-propyl]
benzenesulfonamide
15
21 R-(-)-5-(2-Aminopropyl)-2-methoxy-
benzenesulfonamide and Tamsulosin
15
22 4-Methylcyclohexanone 2,000
23 Trans-4-Methylcyclohexyl amine 500
24 Tris(Hydroxymethyl)aminomethane 500
25 Trans-4-aminocyclohexanol 5,000
26 Tranexamic acid 500
27 Benzethonium chloride 1,000
28 Cinnamyl alcohol 5,000
29 (R)-(-)-3-Carbamoylmethyl-5-
Methylhexanoic Acid and Pregablin
5,000
TOTAL(B) 30905
The total production capacity is A+B= 4, 12,000 + 30,905=4, 42,905 Kg/month. Or say
5,314,860 Kg/annum
7 Project cost? The estimated project expansion cost would be Rs. 4.34 Crores
8 Total man power Construction phase: Since the proposed project is an existing
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 6
requirement during construction
phase occupancy
phase
industry there is no construction activity envisaged. Operational phase: Existing: 60 employees Proposed: 75employees
9 Proposed trees to be planted?
Trees planted – 52nos Trees proposed to be planted-20 nos
10 Species of trees to be planted?
Silver Wood, Teak wood, Coconut, Asoka Trees, Mango trees, neem, and several native species are found within the project site.
11 Rain water harvesting tank details?
30 KLD Capacity
12 Groundwater recharging pits details?
Storm water recharge pits are provided. The recharge pits are interconnected in such a way that the rain led to the first recharge pit is also led to the next pit.
13 Elevation of the project site with respect to MSL
Latitude 12° 58' 55.88” N Longitude 77° 55' 03.71” E and at 897 m above MSL.
14 Total area of the project
5,532.91SQM (about 1.36 Acres)
15 Ground water quality
Potability of water is tested and can be used for drinking.
16 Noise levels Noise levels are within the standard limits.
17 Facilities provided for the workers during construction phase at site?
As the proposed project is an existing industry, no construction activity is envisaged.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 7
1.1.3 Summary of Water, Wastewater, air and solid waste details
Sl. No. Particulars Details
A Water, wastewater details
1 Water supply sources Water tankers supply
2 Total water requirement 111KLD(proposed)+17,496LPD(Existing-16KLD industrial+ 1.5 KLD domestic) Total =130KLD
4 Treatment/Disposal details Industrial effluent generated is stored in two collection tanks of about 40,000 L capacity each and sent to Common Effluent Treatment Plant (CETP) of M/s. Eco Engineering for treatment and disposal.
B Air pollution details
1 Sources of air pollution Process sections, Boiler, DG set
2 Air pollution control units provided
*Flash drier cyclone separator with water jet scrubber is the existing air pollution control equipment and Steam jet ejector & Water ring vacuum pump is proposed for the process section. * A 250 kVA DG set of stack height 5mARL is under operation * Thermic Fluid Heater (TFH) of stack 3m ARL is provided and under operation * Scrubber attached to neutralization tank is under operation * Scrubber & packed fume extraction system attached to laboratory area is under operation. * A 2T/hr Boiler of stack height 30.5m AGL is proposed * Scrubber attached to reactor is proposed * Scrubber & packed fume extraction system attached to R&D lab area is under operation.
C Solid/Hazardous wastes
1 Source of solid waste Domestic sources and Manufacturing process.
The domestic wastes are segregated at source and collected in bins and handed over to KSSIDC for scientific disposal. The hazardous wastes shall be collected in leak proof containers and disposed only to KSPCB authorized reprocessors with valid authorization for processing and scientific disposal
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 9
1.1.4 Water Requirement and Wastewater Treatment and Discharge Details I) Quantity of
Water Required and Wastewater Generated
The total quantity of water requirement for the industry is about 111KLD. The break-up of the consumption of water is as presented in Table 1.3.
Table 1.3 Water consumption and discharge Water consumed for
Consumption
LPD
Recirculation
/RecycleLPD
Loss/Consumption/Evaporation /Daily Make Up Water Etc. LPD
Discharge
LPD
(a) Domestic 3750 3,750 3,375
(b) Landscape development 5,000 5,000 -
(c) Industrial purpose 1,02,000 74,000 30,450
Softener 43,000 15,000 14,750
a. Process water from Softener
b. Boiler water from Softener
7,631 or say 8,000
35,000
Recirculation water = 35,000-7000 (5250 Evaporation loss +1750 Blow down=28000
7,631 or say 8,000
Evaporation loss + blowdown loss(5250 +1750)=7000
11,000
1,750
(blow down)
Softener rejects 2000
1 Washings 14,000 14,000 14,000
2 Cooling tower 35,000
Evaporation loss + bleed off =(34,300+700)=35,000
700(bleed off)
3 Scrubber(1+1new) 1,000 1,000 1,000
4 Water for steam jet ejector
9,000 9,000 -
Total 1,10,750 28,000 82,750 33,825
LPD = L/day; KLD = kilo liter/day.
Startup water requirement for industrial purpose is110750 LPD or say 111KLD. Daily
requirement after recycling from boiler Condensate: 110750-28000=82750 LPD or say
82KLD
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 10
ii) WASTEWATER TREATMENT AND DISPOSAL DETAILS
The treatment methods and the final disposal of wastewater generated is appended in the
table 1.4
Table 1.4 Sewage/wastewater treatment and discharge
Sewage/effluent generated from
Treatment provided Final disposal point
(a) Domestic Sewage is treated in septic tank Disposed in Soak pit
(b) Industrial - Effluent generated from the industry is sent to Common Effluent Treatment Plant (CETP) of M/s. Eco Engineering for treatment and disposal.
1.1.5 Raw Materials The raw materials required for the production are appended in the table 1.5 below. Raw materials as listed will be procured as per the production requirement.
Table -1.5 Raw Materials Requirement
Sl.No. Product Raw materials Quantity Required Solvents
Various solvents are used during the manufacturing process. The solvents proposed to be recovered and recycled during the process of recovering the solvent of such products are detailed in table 1.6 below.
The major air pollution sources from the industry are DG set and process sections. These sources are provided with stacks of adequate height so as to disperse the emanating flue gases containing SPM, oxides of sulfur and nitrogen without affecting the ground level concentrations and packed column scrubbers are provided to the process sections with adequate stack height as per the regulatory requirements.
The sources of air pollution, type of fuel used, fuel consumption and chimney heights for each of the air pollution sources of the proposed project are indicated in the following table 1.7.
Table 1.7 Sources of air pollution, type of fuel used, APC details
SI. no.
Stack attached to
Fuel used Fuel consumption
Number of
stacks
Stack/s height
Air pollution control unit
Predicted emissions
1. Process (attached to reactors)
- - 1 5 m ARL
Scrubber Acid mist / VOCs
2. Attached to R&D lab
- - 1 5 m ARL
Scrubber & packed
fume extraction
system
Acid mist
3. Boiler 2T/hr. (proposed)
Wood/Agro waste
300Kg/hr 1 30.5m AGL
Stack SOx, NOx,SPM
Air Pollution Sources and Control (EXISTING) Chim
No.
Chimney
attached to
Minimum
chimney height
to be provided
above ground
level
Rate of
emission
Nm3/Hr.
Constituents
to be
controlled
in the
emission
Tolerance
Limits
mg/Nm3
Air pollution
Control equipment
to be installed, in
addition to
chimney height as
per Col.(3)
1. HSD fired
Thermic Fluid
Heater 2lakh
K.Cal/Hr.
13m AGL - SO2 - -
2. Process/Flash
drier 5m ARL - Acid mist
VOCs
35 Cyclone separator
with water jet
scrubber
3. 250KVA DG
set 5m ARL - SO2 - Acoustic
enclosures
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 35
4. Attached to
Laboratory
Area
3m ARL - Acid Mist 50 Scrubber & packed
fume extraction
system
5. Attached to
Neutralizing
Tanks (8Nos.)
3m ARL - Acid Mist 50 Scrubber
6. HSD fired
Thermic Fluid
Heater 2lakh
K.Cal/Hr.
13m AGL - SO2 - -
7. Process/Flash
drier 5m ARL - Acid mist
VOCs
- Cyclone separator
with water jet
scrubber
The exhaust temperature will be nearly ambient and adequate port holes with access platform will be provided as per KSPCB guidelines as under
1. Location of port holes and approach platform
The sampling porthole will be provided at a distance equal to at least eight times the stack diameters downstream and two diameters upstream from source of low disturbance such as bend, expansion, and construction valve fitting or visible flame for rectangular stacks. The equivalent diameter is calculated from the following equation
Equivalent diameter = 2 (Length x Width) (Length x Width)
2. The diameter of the sampling port will be minimum 3”. Arrangement will be made to close the port hole firmly during the period when it is not used for sampling.
3. An easily accessible platform will be provided to accommodate 3 to 4 persons to conveniently sample stack emissions from the portholes.
Ambient air quality and stack emission monitoring
Ambient air quality monitoring will be conducted once in a month as per the guidelines for SPM, SO2, NOx and CO and the record of monitoring reports will be maintained and made available to authorities. Similarly stack monitoring will also be conducted for SPM, SO2, NOx and CO.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 36
1.1.8 Noise pollution details
The major sources of noise pollution in the industry are the DG set, thermic fluid heater, flash drier cyclone separator with water jet scrubber for which acoustic enclosures are proposed. Also ambient noise levels will be maintained by developing vegetation along the periphery and at various locations within the industry premises. 1.1.9 Solid waste details The quantity of solid waste generated from the proposed industry is detailed in the following table 1.8.
Table: 1.8 Solid Waste Generation during the Operation Phase
Details Existing Proposed
Total no. of employees 60 75
Assuming per capita solid waste generation rate as 0.25 kg/capita/day
Quantity of solid waste generated 15kg/day 19 Kg/day
Organic solid waste : 60 % of the total waste 9kg/day 12 kg/day
Inorganic solid waste : 40 % of the total waste 6kg/day 7 kg/day
The domestic wastes are segregated at source and collected in bins and handed over to KSSIDC for scientific disposal.
1.1.10 Hazardous Raw Materials Used in the Manufacturing Process
The following raw materials used during the process of hydrogenation, formulations and processing of fine and specialty chemicals are hazardous in nature according to Hazardous Wastes (Management & Handling) Rules, 1989, (as amended on 24-9-2008), Schedule-1
Table: 1.9 Hazardous raw materials Hazardous raw material Sl. No. as per Manufacture, Storage and Import of Hazardous
Chemical (Amendment) Rules, 19th January, 2000, Schedule I,
Part II
Acetic acid 2
Acetone 4
Aluminium chloride 23
Ammonia solution 31
Benzoyl chloride 65
Benzyl chloride 67
Chlorosulfonic acid 136
Epichlorohydrin 239
Ethyl hexanol-2 254
Ethylene dibromide 263
Hexane 306
Hydrogen 314
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 37
Hydroquinone 319
Isopropyl alcohol 334
Methanol 377
Methyl isobutylketone 388
Nitrogen 429
Perchloroethylene 479
Phenol 481
Phosphorous oxychloride 504
Phosphorous pentaoxide 505
Potassium hydroxide 522
Sodium hydroxide 571
Sulphuric acid 591
Thionyl chloride 620
Triethylamine 652
1.1.11 Hazardous Waste Generation and Its Management during the Manufacturing Process
The hazardous wastes generated during the process of hydrogenation, formulations and
processing of fine and specialty chemicals are stored at hazardous waste storage area and sent
to authorize processers. The quantities of hazardous waste generated from various processes
are shown in the following tables 1.10.
1. Spent Carbon
Table: 1.10 Quantity of spent Carbon waste generated from manufacturing process
Si.No. Product Spent Carbon generated Kg/Batch
1 Ethyl hexyltriazone 10
2 Isocotrizinol 10
4 Tetrahydrocurcuminoids 13
5 Tetrahydropiperine 13
6 1,4-Cyclohexanedione and acetal 11
7 Tris(Hydroxymethyl)aminomethane 10
8 Trans-4-Aminocyclohexanol 10
9 Tranexamic acid 8
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 38
2. Catalyst Details – sent to Reactivation / Returned to supplier Table: 1.11 Quantity of catalyst sent to reactivation
Overall Quantity taken from above table. TABLE: 1.12 QUANTITY OF CATALYST GENERATION FROM MANUFACTURING PROCESS
Sl.No. Catalyst Quantity generated – sent for reactivation / Returned back to supplier
Kg/month Kg/Annum
1 Zinc catalyst 80 960
2 Raney Nickel catalyst 1046 12552
3 10% Palladium on carbon catalyst 266.5 3198
4 5% Ruthenium on carbon 54 648
Activated Carbon Sl.No. Product Quantity Required
Kg/Batch Kg/month Kg/Annum
1 Ethyl hexyltriazone 5 33.5 402
2 Isocotrizinol 5 2.5 30
4 Tetrahydrocurcuminoids 8 17 204
5 Tetrahydropiperine 8 17 204
6 1,4-Cyclohexanedione and acetal 6 60 720
7 Tris(Hydroxymethyl)aminomethane 5 25 300
8 Trans-4-Aminocyclohexanol 5 250 3000
9 Tranexamic acid 4 40 480
Total 445 5370
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 40
3). OTHERS: THE VARIOUS HAZARDOUS WASTE GENERATED FROM THE INDUSTRY IS PRESENTED IN TABLE 1.7
TABLE: 1.13 MISCELLANEOUS TYPES OF HAZARDOUS WASTE GENERATED (PROPOSED) Si. No. Source Category Quantity of
hazardous waste generated Kg/month
Disposal Options
1. Spent Carbon 28.2 867 Disposed through Cement industries for co incinerations
2. Waste oil from DG 5.1 30 liters Disposed through authorized recyclers
3. Spent Solvent 28.1 1,44,858 Disposed through KSPCB authorized
dealers
4. HDPE/Discarded containers 33.3 1,965Nos. Disposed through authorized recyclers
5. Chemical contaminated paper & plastic bags
33.3 1,340kg/month Disposed through authorized recyclers
6. Distillation residue sludge 34.3 500kg/month Stored in a secure manner and handed over to TSDF
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 41
MISCELLANEOUS TYPES OF HAZARDOUS WASTE GENERATED (EXISTING)
Waste category
Hazardous waste generated
Quantity Method of Handling
5.1
a)Used oil b)Vacuum oil
0.15KL/A 0.35KL/A
Shall be collected in leak-proof containers and disposed only to KSPCB registered authorized re-processors provided the oil meets the standards as per Schedule-5 Part-A of the Rules
5.2 a)Oil soaked cotton waste b)Oil filters
0.2MT/A 5Nos./A
Shall be stored in a secured manner and handed over to KSPCB authorized incinerator/co-processing in cement kiln.
33.3 Discarded containers Chemical contaminated paper & plastic bags
3600Nos./A 21MT/A
Stored in a secured manner and handed over to KSPCB authorized recycler after wash only
34.3 ETP sludge 0.4MT/A Stored in secure manner and handed over to KSPCB authorized to TDSF
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 42
Table 1.14 Environmental Management Plan during Operation Phase
Sl. no.
Environmental components
Predicted impacts Probable source of impact Mitigation measures Remarks
1 Ambient air quality
Minor negative impact.
Process of manufacture of APIs
Particulate and gaseous emissions from DG set and boiler
Vehicular Movement
Manufacturing process involves closed operations in various controlled reactors.
The process area is provided with abundant natural light and ventilation and high roofs to disperse the fumes/gases to the outside atmosphere; preventing the increase of ground level concentrations (GLC’S) as it gets dispersed.
Flash drier cyclone separator with water jet scrubber) for the process areas are installed to neutralize and control dust and fumes from the process section.
The treated waste gases and fumes will be let out through adequate stack height.
The emissions from DG will be let out through adequate stacks height
Orderly Movement of Vehicles will done in the premises.
The roads are made of tar and regularly water sprinkling will be done to control fugitive emissions.
DG sets will be used only during power failure.
2 Noise Minor negative impact near noise generation sources inside the premises.
Operation of machineries during the manufacturing process.
Handling and conveying of raw
The conveying system shall be maintained by following routine and periodic maintenance to reduce noise generation in material handling.
DG set with prebuilt acoustic enclosure as per CPCB norms is installed in
-
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 43
materials and semi-finished components to different areas of operations
Operation of DG set.
dedicated utility area, where the access will be restricted. Also the use of PPE (ear plugs) will be mandatory in this area.
Green belt at the project boundary will act as noise barrier and help in attenuation of noise.
3 Water quality No significant adverse impact
Discharge of and industrial effluent
Domestic sewage treated in septic tank and soak pit.
The effluent generated from the manufacturing process will be sent to Common Effluent Treatment Plant (CETP) of M/s. Eco Engineering for treatment and disposal.
Water conservation measures will be encouraged.
4 Land No negative impact
Discharge of wastewater.
Storage and disposal of solid wastes.
Domestic sewage will be treated in septic and sent to soak pit. The effluent generated from the
manufacturing process will be sent to Common Effluent Treatment Plant (CETP) of M/s. Eco Engineering for treatment and disposal.
-
5 Socio-economic Overall positive impact
Employment opportunities Locally available man power will be utilized to the maximum possible extent.
-
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 44
CHAPTER 2
INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
2.1 INTRODUCTION OF PROJECT PROPONENT
Somu group of companies are Manufacturers and Exporters of specialty fine chemicals,
specialty solvents, Pharma Intermediates, Agro Intermediates, Cosmetic ingredients and
nutraceutical ingredients. Also Importers, stockists and Distributors for solvents, Industrial
Chemicals and packaging products.
Headquartered in Bangalore, India, Somu & Co the parent company of Somu Group was
started in the year 1973 under the Stewardship of Mr.C.Somashekar, Chairman & Managing
Director of the group.
Currently leaders in manufacturing specialty fine chemicals, specialty solvents, Pharma
Intermediates, Agro intermediates, Cosmetic ingredients and Nutraceutical ingredients with
the "state of the art manufacturing" units, specialized in Hydrogenation under high
pressure, Esterification and Extraction processes. Also, Importers and Distributors for
petrochemical solvents, Industrial chemicals and packaging products and represent leading
industrial houses and Multinational companies for various products with marketing offices
at Chennai, Hosur, Hyderabad and Cochin.
Somu Organo-Chem Pvt. Ltd., was established in the year 1995 with a manufacturing unit
at Malur near Bangalore to manufacture Specialty Fine Chemicals, Bulk drugs, Cosmetic and
Pharma Ingredients, Perfumery and flavor Intermediates, Agro Chemical Intermediates,
Mining Chemicals and Flotation Reagents.
Specialized in the Hydrogenation under high pressure processes, Hydrogenation, Oxidation,
Condensation, Distillation, Esterifica
tion & Crystallization are some of the chemical operations based on which chemicals are
processed and formulated in the industry. The company is certified with ISO 14001:2004 –
EMS, b. ISO 9001:2008 – QMS & c. ISO 18001:2007 – OSHAS
M/s. Somu Organo-Chem Pvt. Ltd. now envisages expansion of its existing industry with
addition of new products to its process line.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 45
2.2 A Brief note on Fine and Specialty Chemicals
Fine chemicals are complex, single, pure chemical substances, produced in limited quantities in
multipurpose plants by multistep batch chemical processes.
They are used as starting materials for specialty chemicals, particularly in pharmaceuticals.
However, a significant portion of the fine chemicals total production volume is manufactured in
house by large users. The industry is fragmented and extends from small, privately owned
companies to divisions of big, diversified chemical enterprises. The term "fine chemicals" is
used in distinction to "heavy chemicals", which are produced and handled in large lots and are
often in a crude state.
Speciality chemicals are usually manufactured in batch chemical plants using batch processing techniques. Batch process is one in which a defined quantity of product is made from a fixed input of raw materials during a measured period of time. The batch process most often consists of introducing accurately measured amounts of starting materials into a vessel followed by a series of processes involving mixing, heating & cooling, making more chemical reactions, distillation, crystallization, separation, drying, packaging etc., taking place at predetermined and scheduled intervals. The manufacturing processes are supported by activities such as the quality testing, storage& warehousing, and management by recycling, treatment and disposal of by-products, and waste streams. For the next “batch” the equipment may be cleaned and the above processes repeated.
Most speciality chemicals are organic chemicals that are used in a wide range of every day products used by consumers and industry. It is a consumer driven sector and as such the specialty chemical industry has to be innovative, entrepreneurial and consumer-driven. In contrast to the production of commodity chemicals that are usually made on large scale single product manufacturing units to achieve economies of scale, specialty manufacturing units are required to be flexible because the products, raw materials, processes &, operating conditions and equipment mix may change on a regular basis to respond to the needs of customers.
Fine & specialty chemicals cover the manufacture of specialty products used in everything from adhesives, sealants and coatings to pharmaceuticals, detergents and electronic goods.
Highly complex with a huge portfolio of patented technologies, this sector is under growing pressure to meet increasingly stringent safety and environmental regulations and hone competitiveness, particularly as more and more fine chemicals are evolving into commodities.
Manufacturers are challenged to constantly innovate in the search for environmentally cleaner reactions and smart solutions to highly specialised problems.
The process of hydrogenation involves the use of hydrogen molecules to saturate organic compounds, in the presence of a catalyst. Catalysts are species that are used to speed up the rate of a reaction without being consumed during the process. Keep in mind that catalysts are essential to running this reaction. Common catalysts used during hydrogenation are metals such as nickel and platinum.
An important requirement in the hydrogenation process, besides a catalyst, is the presence of a hydrogen atom. The purpose of the hydrogen atom is to come in and remove the double or triple bond between atoms. In other words, hydrogen atoms turn an unsaturated hydrocarbon into a saturated one.
Saturated Versus Unsaturated Hydrocarbons
Saturated hydrocarbons are compounds that only contain single bonds in their structure. The perfect example of a saturated hydrocarbon is the alkane functional group. Alkanes are organic compounds that contain single bonds between its carbon and hydrogen atoms.
Unsaturated hydrocarbons are compounds that contain double bonds in their structure. The alkene functional group is a great example of an unsaturated hydrocarbon. Alkenes contain at least one double bond between the carbon atoms in its structure. Examples of both saturated and unsaturated hydrocarbons are shown here.
Formulation: Is the process in which different chemical substances, including the active drug, are combined to produce a final medicinal product.
2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/REGION Bulk drugs have become a part of our life for sustaining many of our day-to-day activities, preventing and controlling diseases. Bulk drugs manufacturing sector in India is well established and has recorded a steady growth in the overall Indian industrial scenario. The bulk drugs and allied industries have been amongst the fastest growing segments of the Indian industry.
The Indian Pharmaceutical Industry today is in the front rank of India’s science-based industries with wide ranging capabilities in the complex field of drug manufacture and technology. It is expected to reach a level of Rs 3200 billion by 2012. It ranks very high in the third world, in terms of technology, quality and range of medicines manufactured. From simple headache pills to sophisticated antibiotics and complex cardiac compounds, almost every type of medicine is now made indigenously.
Playing a key role in promoting and sustaining development in the vital field of medicines, Indian Pharma Industry boasts of quality producers and many units approved by regulatory authorities in USA and UK. International companies associated with this sector have stimulated, assisted and spearheaded this dynamic development in the past years and helped to put India on the pharmaceutical map of the world.
India's pharmaceutical industry is the third largest in the world in terms of volume. Its rank is 14th in terms of value. India is also one of the top five active pharmaceutical ingredients (API) producers (with a share of about 6.5 per cent).
The pharmaceutical industry in India meets around 70% of the country's demand for bulk drugs, drug intermediates, chemicals, tablets, capsules, orals and injectibles. Between September 2008 and September 2009, the total turnover of India's pharmaceuticals industry was US $21.04 billion. The domestic market was worth US $12.26 billion. This was reported by the Department of Pharmaceuticals, Ministry of Chemicals and Fertilizers. As per a report by IMS Health India, the Indian pharmaceutical market reached US $10.04 billion in size in July 2010. A highly organized sector, the Indian Pharma Industry is estimated to be worth $4.5 billion, growing at about 8 to 9 percent annually.
The pharmaceutical industry in Karnataka contributes Rs. 350 crore in revenue to the State exchequer and provides employment for 12,000 people. Its growth rate is between 10-12 percent as against the national pharma growth of 12-14 percent. Pharma products worth Rs. 2,000 crore are produced annually, which is 10 percent of the national production. The exports sales are Rs.850 crore which is 8 percent of Indian exports. International pharma majors have preferred many companies from the State. When large companies offer their services on contractual basis to global MNCs, they want to outsource drug production for the domestic market from quality small-medium manufacturers in State. Here the small-medium units ideally fit into slot as third party manufacturers and serve as a major hubs for pharmaceutical outsourcing. In fact, two of Indian pharma sectors top five brands, are already outsourced from Karnataka. The units have been recognized for stringent regulatory enforcement and known to manufacture quality products. Another added advantage favoring the State is that it is emerging as an investment destination. Hence the proponents have proposed the expansion of their specialty chemicals, bulk drugs, cosmetic and pharma ingredients manufacturing industry - M/s. Somu Organo-Chem Pvt. Ltd.,Shed No. C-29, C-30 & adjacent plots, KSSIDC Industrial Estate,Malur- 563 130, Kolar District 2.4 DEMAND SUPPLY GAP, IMPORTS vs INDIGENOUS PRODUCTION Indian pharmaceutical companies supply almost all the country's demand for API and nearly 70 per cent of demand for bulk drugs. The imports of pharmaceuticals are estimated at 10 to 12 percent of the total market. The major suppliers are Switzerland, China, USA, Germany, Italy, Denmark, France, and UK. Imports include raw materials and finished products. Some major pharmaceuticals which are imported include Provitamins and Vitamins, Cortisones, Hydrocortisone, Insulin, Penicillin, Osetrogen, Progesterone and other hormones, Erythromycin and other ANTIBIOTICS, Antisera & other blood fraction, and Glycosides.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 48
The imports are from Switzerland, US and Germany primarily consist of finished medicament in dosage forms for retail sales. 2.5 EXPORT POSSIBILITY: The size of the domestic pharmaceutical market is larger than export market. However, owing to the growth of global generics market, stringent price controls in the domestic market, and better margins, the export market is growing much faster than the domestic market. India exports pharmaceuticals to numerous countries around the world, including to the U.S., Germany, France, Russia and UK. The Indian pharmaceutical industry ranks 17th with respect to exports value of bulk actives and dosage. Exports constitute nearly 40 per cent of the production, with bulk drugs 45 per cent. According to the Pharmaceutical Export Promotion Council (Pharmexcil), the pharmaceutical exports in 2007-08 stood at US $6.68 billion against US $5.73 billion in 2006-07, recording a growth rate of 16 per cent. The industry has been clocking export growth rate, recording 18 per cent, 23 per cent and 17 per cent growth rates during 2006-07, 2005-06, and 2004-05, respectively. The overall pharmaceutical exports are estimated to increase at a CAGR of 30-32 percent and reach US $ 18.3 billion in 2010 - 11. 2.6 EMPLOYMENT GENERATION DUE TO THE PROJECT The total direct employment potential of the proposed industry is about 75 people. The existing number of workers being 60, the industry proposes to increase it to 75. However, there are indirect employment generation due to the project during the transportations, marketing & distribution etc.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 49
CHAPTER 3
PROJECT DESCRIPTION
3.1 TYPE OF PROJECT The proposed project is expansion of hydrogenation, formulations and processing of fine and specialty chemicals. The existing total production capacity of the industry is 49,44,000Kg/annum for which EC is obtained. Reference No. SEIAA letter No. SEIAA :5: IND 2010, dated 09/06/2010.
The industry now proposes the expansion of the production capacity from 49,44,000 Kg/annum
to 5,314,860Kg/annum by the addition of 3,70,860 Kg/annum.
3.2 LOCATION OF THE INDUSTRY
Fig 3.1 Google Map Showing Project Site
897 m above MSL; Latitude: 12°58’'56.71"N; Longitude: 77°55'04.70"E Note: The project site layout plan is appended in Annexure B
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 50
Fig 3.2 Map showing the Project Site Location on District map.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 51
3.3 BASIS OF SELECTING THE SITE
The efficient functioning of any industry mainly depends on the availability of its basic requirements viz. raw materials, fuel, power, water, manpower etc. The industry is established in Malur Industrial Area, Kolar and Bangalore. The choice of the land confers several advantages, which are summarized below.
1. The site is well connected by roadways. 2. Water will be supplied from water tankers. 3. Power will be supplied from BESCOM. 4. No incidence of cyclones, earthquake, floods or landslides in the region.
3.4 SIZE/MAGNITUDE OF OPERATION The industry “M/s Somu Organo-Chem Pvt. Ltd.,” is a small scale industrial unit with a total
capital investment of the Expansion project is Rs. 4.34 Crores. The total production capacity
proposed is 4, 42,905 kg/month
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 52
3.5 PRODUCTS MANUFACTURED M/s. Somu Organo-Chem Pvt. Ltd. now envisages expansion of its existing industry with
addition of new products to its process line.
The products (specialty chemicals) that are proposed to be manufactured in the expansion project are given in Table no-3.1
Table 3.1 shows present & proposed Products to be manufactured
SI. No. Fine & Specialty chemicals
Production capacity (Kg/month)
Production Capacity (Kg/annum)
1 Benzalkonium chloride 1,00,000 12,00,000
2 1,3 Cyclohexanedione 75,000 9,00,000
3 Ore flotation reagent 2,00,000 24,00,000
4 4-Hydroxy carbazole 2,000 24,000
5 2/4 Methylcyclohexanol 5,000 60,000
6 2,4 Thiazolidinedione 10,000 1,20,000
7 3,3,5 Trimethylcyclohexanol 20,000 2,40,000
Total(A) 4,12,000 49,44,000
Sl. No. Specialty fine Chemicals, bulk drugs, cosmetic and pharma ingredients
No. Of batches
Production capacity (kg/month)
1 4-n Hexylresorcinol 5 250
2 4-n Butylresorcinol 3 150
3 EthylhexylTriazone 7 1000
4 Iscotrizinol 0.5 50
5 PiroctoneOlamine 15 1500
6 Tetrahydrocurcumin 2 125
7 Tetrahydropiperine 2 125
8 1,4-Cyclohexanedione and acetal 10 1000
9 1,4-Cyclohexanediol 5 500
10 (S)-1-Phenyl-1,2,3,4-
Tetrahydroisoquinoline
20 1000
11 3-Quinuclidinone hydrochloride 1 100
12 R-(-)-3-Quinuclidinol 1 50
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 53
13 Ethyl isonipecotate 25 2,500
14 1,2,3,9-Tetrahydro-9-methyl-4(H)-
carbazol-4-one
5 500
15 4-(2,3-epoxypropoxy)carbazole 3 500
16 4-Methoxyethylphenol and Metoprolol 16 1,000
17 Mebeverine Amine 5 1,000
18 2-(2-Ethoxyphenoxy)ethylbromide 0.1 10
19 R-1-(-Methoxyphenyl-N-(R)-1-
phenylethyl)propan-2-amine
hydrochloride
0.3 15
20 R,R-2-methoxy-5-[2-(1-phenylethylamino)-
propyl] benzenesulfonamide
0.38 15
21 R-(-)-5-(2-Aminopropyl)-2-methoxy-
benzenesulfonamide and Tamsulosin
0.75 15
22 4-Methylcyclohexanone 25 2,000
23 Trans-4-Methylcyclohexyl amine 10 500
24 Tris(Hydroxymethyl)aminomethane 5 500
25 Trans-4-aminocyclohexanol 50 5,000
26 Tranexamic acid 10 500
27 Benzethonium chloride 4 1,000
28 Cinnamyl alcohol 50 5,000
29 (R)-(-)-3-Carbamoylmethyl-5-
Methylhexanoic Acid and Pregablin
50 5,000
TOTAL 30,905
The total production capacity is A+B= 4, 12,000 + 30,905=4, 42,905 Kg/month. Or 5,314,860 Kg/annum
21 R-(-)-5-(2-Aminopropyl)-2-methoxy-benzenesulfonamide and Tamsulosin
0.75 20 10 15
22 4-Methylcyclohexanone 25 80 1 2,000
23 Trans-4-Methylcyclohexyl amine 10 50 3 500
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 55
24 Tris(Hydroxymethyl)aminomethane
5 100 3 500
25 Trans-4-aminocyclohexanol 50 100 2 5,000
26 Tranexamic acid 10 50 4 500
27 Benzethonium chloride 4 250 5 1,000
28 Cinnamyl alcohol 50 100 1 5,000
29 (R)-(-)-3-(Carbamoylmethyl)-5-
methylhexanoic Acid and Pregablin
50 100 4 5,000
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 56
3.5.1 Manufacturing Process Description
3.5.2 Manufacturing process Details of each product
1. PRODUCT NAME : 4-n-HEXYL RESORCINOL : CAS NO : 136-77-6
Mol. Formula : C12H18O2
Mol. Wt. : 194.27
IUPAC Name : 4-Hexyl-1,3-benzene diol,1,3-dihydroxy phenyl hexane.
Structure :
Brief Process:
Resorcinol condensed with Caproic acid in the presence of zinc catalyst gives to 4-hexanoyl
resorcinol . Hydrogenation of hexanoyl resorcinol in the presence of Raney Nickel gives to 4-N
Hexyl Resorcinol.
Route of Synthesis:
Stage-I
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 57
Stage-II
Brief Process:
Resorcinol condensed with Caproic acid in the presence of zinc catalyst gives to 4-hexanoyl
resorcinol . Hydrogenation of hexanoyl resorcinol in the presence of Raney Nickel gives to 4-N
Hexyl Resorcinol.
Application :
Used as a skin whitening agent in cosmetics and also as a anti-dandruff agent in shampoo.
Process Flow Chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 58
2. PRODUCT: 4-n-BUTYL RESORCINOL CAS NO : 18979-61-8 Mol. Formula : C10H14O2
Mol. Wt : 166.22
IUPAC Name : 4-Butyl-1,3-benzene diol,3,4-dihydroxy-N-Butyl benzene Structure :
Brief Process:
Resorcinol condensed with butyric acid in the presence of zinc catalyst gives to 4-butyroyl
resorcinol . Hydrogenation of butyroyl resorcinol in the presence of Raney Nickel gives to 4-N
Butyl Resorcinol.
Route of Synthesis:
Stage-I
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 59
Stage-II
Application :
Used as a skin whitening agent in cosmetics and also as a anti-dandruff agent in shampoo .
Process Flow Chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 60
3. Ethyl Hexyl Triazone
CAS NO : 88122-99-0 Mol. Formula : C48H66N6O6
Mol. Wt : 823.07
IUPAC Name : 2-ethylhexyl 4-[[4,6-bis[[4-(2-ethylhexoxycarbonyl)phenyl]amino]-1,3,5-triazin-2- yl]amino]benzoate Structure : BRIEF PROCESS : Stage-I PNBA (P-Nitrobenzoic acid) is esterified with 2-Ethylhexanol in presence of catalytic quantity of Sulfuric acid to get PN2EHB (Para nitro 2-ethyl hexyl benzoate). The Sulfuric acid is neutralized with Soda ash and the Unreacted PNBA is extracted with aqueous Soda ash solution which on neutralization gives recovery PNBA. Stage-II
PN2HB is reduced to PA2EHB (Para amino 2-ethyl hexyl benzoate) in presence of Pd/C-H2 in methanol. Pd/C is filtered and reused. Methanol distilled and sent for column distillation. To the residue Hexane is added to expel the product and centrifuged. Stage-III
PA2EHB is reacted with Cyanuric chloride in Xylene to get Etone. To the reaction mass water is added and PH is adjusted with ammonia. Aqueous layer seperated and sent for
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 61
evaporation. The Xylene layer taken for Xylene distillation (recovery). To residue Acetonitrile is added and charcolised – cooled and filtered. Route of Synthesis:
Stage – I
Stage – II
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 62
Stage – III
Application It is used as an UV-B absorbing agent in sunscreen creams, lotions and sun oils.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 63
Process flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 64
4. ISOCOTRIZINOL CAS NO : 154702-15-5 Mol. Formula : C44H59N7O5
Mol. Wt : 765.98
IUPAC Name : Benzoicacid,4,4'-[[6-[[4-[[(1,1dimethylethyl)amino]carbonyl]phenyl]amino]- 1,3,5-triazine-2,4-diyl]diimino]bis-,1,1'-bis(2-ethylhexyl) ester STRUCTURE : BRIEF PROCESS : Stage-I : p -Nitrobenzoic acid is reacted with Thionyl Chloride in the presence of Dimethylformamide and Toluene solvent media to get Stage-1 Compound. Stage-II : Stage-1 Compound on treatment with tert-Butylamine in presence of Triethylamine using Toluene as solvent medium to form Stage-2 Intermediate. Stage-III : Stage-2 Intermediate on hydrogenation with Hydrogen in presence of Palladium Carbon catalyst in Methanol and Toluene solvent media gives Stage-3 Compound. Stage-IV : Stage-3 Compound on reaction with Cyanuric Chloride in presence of Potassium Carbonate using Acetonitrile as solvent medium to get Stage-4 Intermediate.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 65
Stage-V : Stage-4 Intermediate reacts with 2-Ethylhexyl 4-Aminobenzoate in presence of Ammonia in Toluene and Hexane solvent media to obtain the title compound. Route of Synthesis:
Stage – I
Stage – II
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 66
Stage – III
Stage –IV
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 67
Stage – V
Application Iscotrizinol is a superior active providing UVB and UVA photoprotection of skin with proven synergies with many sunscreen activities.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 68
Process flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 69
5. PIROCTONE OLAMINE: PRODUCT : PiroctoneOlamine CAS NO. : 68890-66-4 MOl.Formula : C14H23NO2 · C2H7NO Mol.Wt. 298.42 g/mol IUPAC Name : 1-Hydroxy-4-methyl-6-(2, 4, 4-trimethylpentyl) pyridin-2(1H)-one compound with 2-aminoethanol (1:1) Structure: BRIEF PROCESS : Stage-I: Esterification of 3, 3’DMAA with Methanol in the presence of con Sulphuric acid gives to Methyl ester of 3, 3’DMAA Stage-II: Further condensation of methyl ester of 3.3’DMAA with Isononanoyl chloride catalysed by Anhydrous Aluminium Chloride gives to Isononayl derivatives of 3,3’ DMAA. Stage-III: Isononanyl derivative of 3,3’ DMAA undergoes cyclisation in the presence of Sodium methoxide in methanol at 5 – 10 Deg C followed by neutralization with acetic acid gives to Crude 4-Methyl-6-(2,4,4-trimetylpentyl)-2-Pyrone. Further 4-Methyl-6-(2,4,4-trimetylpentyl)-2-Pyrone is purified by High Vacuum distillation. Stage-IV: The above purified 4-Methyl-6-(2,4,4-trimethylpentyl)-2-pyrone condensed with hydroxylamine hydrochloride in the presence of sodium Carbonate at 60 – 65 ˚C gives to 1-Hydroxy-4-Methyl-6-(2,4,4-trimethylpentyl)-2-pyridone further treated with monoethanolamineUnder chilled condition 8 – 10 ˚C results in formation of Crude Piroctoneolamine.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 70
The above obtained crude product is recrystallised from ethyl acetate ROUTE OF SYNTHESIS
Stage – I
Stage – II
Stage – III
Stage – IV
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 71
Application:
PiroctoneOlamine is a broad-spectrum microbiocide/microbiostat, may be used in
formulating antidabdruff shampoo, hair keep and hair care, soap, etc.
Process flow chart
.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 72
6. PRODUCT : TETRAHYDROCURCUMINOIDS CAS NO : 36062-04-1 Mol.Formula : C21H26O6
Brief Process: Curcuminoids obtained from Turmeric is hydrogenated by using Palladium on Carbon as a Catalyst gives to TetrahydroCurcuminoids. Filtered the Product and dried under Vacuum at 45-50 deg C till LOD reaches Less than 0.5% then packed in Clean Polythene Bag. Route of Synthesis
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 73
Application: Used as a skin conditioning and skin whitening agent. Process flow chart
Piperine obtained from Pepper is hydrogenated by using Palladium on Carbon as a Catalyst
gives to Tetrahydropiperine.
Filtered the Product and dried under Vacuum at 45-50 deg C till LOD reaches Less than 0.5%
then packed in Clean Polythene Bag.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 75
Route of Synthesis
Application:
Used as an enhancers of nutrient and bio availability enhancer for medicines.
Process flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 76
8. PRODUCT : 1,4-CYCLOHEXANEDIONE AND ACETAL CAS NO. : 637-88-7 MOl.Formula : C6H8O2 Mol.Wt. : 112.12 IUPAC Name : 1,4-Cyclohexanedione, Cyclohexane-1,4-dione Structure :
BRIEF PROCESS : Condensation of DMS in presence of Sodium methoxide followed by neutralization with Aquoussulphuric acid gives to Dicarbmethoxycarboxy -1,4-CHD . Decarboxylation of Dicarbmethoxycarboxy -1,4-CHD results in Cyclohexane-1,4-dione. Route of Synthesis
Stage - I
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 77
Stage – II
Application:
Intermediate for FROVATRPAN and used as a building block in the synthesis of more complex
BRIEF PROCESS : Hydroquinone in IPA undergoes hydrogenation in presence of Raney Nickel catalyst to give 1,4-Cyclohexanediol. Route of Synthesis
Application It is used in the production of polyester fibers and organic intermediates etc.Acts as an anti-inflammatory agent. It is a diol monomer. Used in skin care products.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 79
Process flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 80
10. (S)-1-PHENYL-1,2,3,4-TETRAHYDROISOQUINOLINE CAS NO. : 118864-75-8 MOl.Formula : C15H15N Mol.Wt. : 209.29 IUPAC Name : (1S)-1-Phenyl-1,2,3,4-tetrahydroisoquinoline Structure :
Brief Process: Stage-I: N-(2-Phenylethyl)benzamide: 2-Phenylethylamine condensed with benzoyl chloride in methylene dichloride as a solvent to give N-(2-Phenylethyl)benzamide. Stage-II: 1-Phenyl-1,2-dihydroisoquinoline: N-(2-Phenylethyl)benzamide reacts with phospphrous pentoxide and phosphorous oxychloride in the presence of sodium hydroxide by using toluene as a solvent to give 1-Phenyl-1,2-dihydroisoquinoline. Stage-III: 1-Phenyl-1,2,3,4-Tetrahydroisoquinoline: 1-Phenyl-1,2-dihydroisoquinoline undergoes reduction with sodium borohydride in methanol as a solvent to give 1-Phenyl-1,2,3,4-tetrahydroisoquinoline. Stage-IV (S)-1-Phenyl-1,2,3,4-Tetrahydroisoquinoline tartarate: 1-Phenyl-1,2,3,4-tetrahydroisoquinoline undergoes resolution with D-(-)-tartaric acid in IPA as a solvent to give (S)-1-Phenyl-1,2,3,4-Tetrahydrohydroisoquinoline tartarate salt. Stage-V (S)-1-Phenyl-1,2,3,4-Tetrahydroisoquinoline: 1-Phenyl-1,2,3,4-tetrahydroisoquinoline tartarate undergoes base hydrolysis in MDC as a solvent to give (S)-1-Phenyl-1,2,3,4-Tetrahydrohydroisoquinoline.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 81
Route of Synthesis
Stage – I
Stage – II
Stage – III
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 82
Stage-IV
Stage-V
Application
A Key Intermediate for the Anti muscarinic Agent Solifenacin
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 83
Process flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 84
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 85
11. 3-QUINUCLIDINONE HYDROCHLORIDE CAS NO. : 1193-65-3 MOl.Formula : C7H12ClNO Mol.Wt. : 161.63 IUPAC Name : 1-Azabicyclo[2.2.2]octan-3-one hydrochloride Structure :
Brief Process: Stage-I: Ethyl 1-(2-methoxy-2- oxoethyl)piperidine-4-carboxylate:Ehtyl piperidine-4-carboxylate is condensed with methyl chloroacetate in presence of sodium carbonate followed by hydrogenation to give ethyl 1-(2-methoxy-2- oxoethyl)piperidine-4-carboxylate. Stage-II: 3-Quinuclidinone Hydrochloride:Ethyl 1-(2-methoxy-2- oxoethyl)piperidine-4-carboxylate undergoes Dieckmann reaction in presence of potassium tertbutoxide followed by hydrolysis and decarboxylation gave title compound 3-quinuclidinone hydrochloride.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 86
Route of synthesis Stage - I
Stage – II
Application used in the synthesis of cevimeline, a thiolating agent.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 87
Process flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 88
12. R-(-)-3-QUINUCLIDINOL CAS NO. : 25333-42-0 MOl.Formula : C7H13NO Mol.Wt. : 127.18 IUPAC Name : (3R)-1-Azabicyclo[2.2.2]octan-3-ol Structure :
Brief Process: 3-Quinuclidinone in isopropyl alcohol undergoes hydrogenation in presence of 5% Ruthenium on carbon to give R-(-)-3-Quinuclidinol. Route of Synthesis
Application Hypotensive. Synthon for preparation of cholinergic receptor ligands and anesthetics.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 89
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 90
13. ETHYL ISONIPECOTATE CAS NO. : 1126-09-6 MOl.Formula : C8H15NO2 Mol.Wt. : 157.21 IUPAC Name : Ethyl 4-piperidinecarboxylate Structure :
Brief Process: Ethyl isonicotinate undergoes hydrogenation in the presence of 10% palladium on carbon gives ethyl isonipecotate Route of Synthesis
Application Reactant for synthesis of:
• SMN protein modulators • β-aryl and β-amino-substituted aliphatic esters by rhodium catalyzed tandem double bond migration/conjugate addition • Nitroethylenediamines by nucleophilic ring opening of nitroimidazolidinone
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 91
• RhoA inhibitors for cardiovascular disease therapy • Saccharin derived Mannich bases as antimicrobials and antioxidants
Process flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 92
14. 1,2,3,9-TETRAHYDRO-9-METHYL-4(H)-CARBAZOL-4-ONE CAS NO. : 27387-31-1 MOl.Formula : C13H13NO Mol.Wt. : 199.25 IUPAC Name : 1,2,3,9-Tetrahydro-9-methyl-4H-carbazol-4-one Structure :
Brief Process: 1,2,3,9-Tetrahydro-9-methyl-4(H)-carbazol-4-one: 1,2,3,9-Tetrahydro-4(H)-carbazol-4-one in methylene dichloride reacts with dimethylformamide in presence of tetrabutyl ammonium bromide to give 1,2,3,9-Tetrahydro-9-methyl-4(H)-carbazol-4-one. Route of synthesis
Application Intermediate of Ondansetron
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 93
Process flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 94
15. 4-(2,3-EPOXYPROPOXY)-9H-CARBAZOLE CAS NO. : 51997-51-4 MOl.Formula : C15H13NO2 Mol.Wt. : 239.27 IUPAC Name : 4-(2-Oxiranylmethoxy)-9H-carbazole; 4-Glycidyloxycarbazole Structure :
Brief Process: 4-(2,3-Epoxypropoxy)-9H-carbazole: 4-Hydroxycarbazole will be reacted with Epichlorohydrin& sodium hydroxide in presence of DMSO & D M Water. Further addition of DM water to Reacttion Mass will give the desired product. The crude product will be washed with water. Crude product will be purified by using activated charcoal, ethyl acetate and methanol to give pure product. Route of Synthesis
Application Intermediate for Carvedilol
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 95
Process flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 96
16. 4-(2-METHOXYETHYL)PHENOL AND METOPROLOL CAS NO. : 56718-71-9 MOl.Formula : C9H12O2 Mol.Wt. : 152.19 IUPAC Name : 4-(2-Methoxyethyl)phenol Structure :
Brief Process: Stage-I: 2-Chloro-1-(4-hydroxyphenyl)ethanone:Aluminium chloride was added to phenol in ethylene dichloride and heated to reflux. Then chlroacetyl chloride is added, heated and then cooled. Then the material is separated out and the material is purified methanol. Stage-II: 2-Methoxy-1-(4-hydroxyphenyl)ethanone: A solution of sodium methoxide and 2-chloro-1-(4-hydroxyphenyl)ethanone was stirred and concentrated. The material was treated with hydrochloric acid and and extracted with chloroform. The chloroform layer was washed with water and chloroform was distilled out to give 2-Methoxy-1-(4-hydroxyphenyl)ethanone. Stage-III: 4-(2-Methoxyethyl)phenol: 2-Methoxy-1-(4-hydroxyphenyl)ethanone was hydrogenated in methanol in the presence of 10% palladium on carbon. The material was filtered and the filtered solution was distilled out to give 4-(2-Methoxyethyl)phenol.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 97
Route of Synthesis Stage – I
Stage – II
Stage – III
Application used to manufacture Metoprolol
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 98
Process Flow Chart
(Reused / Regeneration)
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 99
17. MEBEVERINE AMINE CAS NO : 3625-06-7
Mol. Formula : C25H35NO5
Mol. Wt. : 492.55
IUPAC Name : (RS)-4-(ethyl[1-(4-methoxyphenyl)propan-2-yl]amino)butyl 3,4-dimethoxybenzoate Structure :
Brief Process: Stage-I: 3,4-Dimethoxybenzoic acid -4-bromobutyl ester: 3,4-Dimethoxybenzoic acid reacts with sodium methoxide in Methanol as a solvent to give sodium 3,4-dimethoxybenzoate. Sodium 3,4-dimethoxybenzoate undergoes esterification with 1,chloro-4-bromobutane to give 3,4-dimethoxybezoic acid-4-bromobutyl ester. Stage-II Ethyl-[2-(4-methoxyphenyl)-1-methylethyl]amine: 1-(4-methoxyphenyl)-propan-2-one undergoes reductive amino ethylation with hydrogen gas in presence of 10%Pd/C in Methanol as a solvent to give Ethyl-1-[2[(4-methoxyphenyl)-1-methylethyl]amine. Stage-III Mebeverine Amine: 3,4-Dimethoxybezoic acid-4-bromobutyl ester and Ethyl-1-[2[(4-methoxyphenyl)-1-methylethyl]amine reacts with sodium carbonate in presence of MIBK as a solvent to give Mebeverine amine.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 100
Route of Synthesis Stage – I
Stage – II
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 101
Stage – III
Application
Antispasmodic.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 102
Process Flow Chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 103
18. 2-(2-ETHOXYPHENOXY)ETHYL BROMIDE CAS NO. : 3259-03-8 MOl.Formula : C10H13BrO2 Mol.Wt. : 245.11 IUPAC Name : 1-(2-Bromoethoxy)-2-ethoxy-benzene Structure :
Brief Process: 2-Ethoxyphenol is reacted with Ethylene dibromide under phase transfer catalyst in toluene, 2-(2-Ethoxyphenoxy)ethyl bromide which on recrystalistion in IPA, pure product is formed. Route of Synthesis
Application It is used as an intermediate in Tamsulosin
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 104
Process Flow Chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 105
19. (R)-1-(4-METHOXYPHENYL)-N-(R)-1-PHENYLETHYL)PROPAN-2-AMINE HYDROCHLORIDE CAS NO : 50505-66-3
Mol. Formula : C18H24ClNO
Mol. Wt. : 305.84
IUPAC Name : (αR)-4-Methoxy-α-methyl-N-[(1R)-1-phenylethyl]benzeneethanamine Hydrochloride [R-(R*,R*)]-4-Methoxy-α-methyl-N-(1-phenylethyl)benzeneethanamine Hydrochloride Structure :
.HCl Brief Process: The reductocondensation of 4-Methoxyphenylacetone with R-(+)-phenylethylamine gives regioselectively the secondary amine as the HCl salt. Route of Synthesis
Application Used as an intermediate in Tamsulosin
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 106
Process Flow Chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 107
20. (R,R)-2-METHOXY-5-[2-(1-PHENYLETHYLAMINO)PROPYL]BENZENESULFONAMIDE Mol. Formula : C18H24N2O3S
Mol. Wt. : 348.46
Structure :
Brief Process: Stage-I The reductocondensation of 4-Methoxyphenylacetone with R-(+)-phenylethylamine gives regioselectively the secondary amine as the HCl salt. Stage-II The secondary amine.HCl undergoes sulfonation with chlorosulfonic acid and treatment with NH4OH yields (R,R)-2-methoxy-5-[2-(1-phenylethylamino)propyl]benzenesulfonamide . Route of Synthesis STAGE-I
.HClChlorosulfonic acid, Thionyl chloride 5-(2R-aminopropyl)-N-methylbenzyl Ammonia, Chloroform, 2-methoxybenzene.hydrochloride Application Used as an intermediate in Tamsulosin Process Flow Chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 108
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 109
21. R(-)-5-(2-AMINOPROPYL)-2-METHOXY-BENZENESULFONAMIDE AND TAMSULOSIN CAS NO : 112101-81-2
Mol. Formula : C10H16O3N2S
Mol. Wt. : 244.31
IUPAC Name : 5-[(2R)-2-Aminopropyl]-2-methoxy-benzenesulfonamide, (R)-5-(2-Aminopropyl)-2-methoxy-benzenesulfonamide, Structure :
Brief Process: Stage-I The reductocondensation of 4-Methoxyphenylacetone with R-(+)-phenylethylamine gives regioselectively the secondary amine as the HCl salt. Stage-II The secondary amine.HCl undergoes sulfonation with chlorosulfonic acid and treatment with NH4OH yields (R,R)-2-methoxy-5-[2-(1-phenylethylamino)propyl]benzenesulfonamide . Stage-III (R,R)-2-methoxy-5-[2-(1-phenylethylamino)propyl]benzenesulfonamide in methanol undergoes dehydrogenation with hydrogen gas in presence of 10% palladium on carbon to give R(-)-5-(2-Aminopropyl)-2-methoxy-benzenesulfonamide. Route of Synthesis STAGE-I
Phenyl acetone ethylamine 2-methoxybenzene.hydrochloride STAGE-II & III
.HClChlorosulfonic acid, Thionyl chloride 5-(2R-aminopropyl)-N-methylbenzyl Ammonia, Chloroform, Methanol R(-)5-(2-aminopropyl)2-methoxy- 2-methoxybenzene.hydrochloride Hydrogen gas, 10% Pd/C benzenesulfonamide Application Used as an intermediate in Tamsulosin Process Flow Chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 111
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 112
22. 4-METHYLCYCLOHEXANONE
CAS NO : 589-92-4
Mol. Formula : C7H12O
Mol. Wt. : 112.17
IUPAC Name : 4-Methylcyclohexanone
Structure :
Brief Process: 4-Methylcyclohexanone: 4-Methylcyclohexanol reacted with sodium hypochlorite and acetic acid followed by distillation to give 4-Methylcyclohexanone. Route of Synthesis
Application
Used a spermidine synthase inhibitor Process flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 113
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 114
23. TRANS-4-METHYLCYCLOHEXYL AMINE
CAS NO : 2523-55-9
Mol. Formula : C7H15N
Mol. Wt. : 113.20
IUPAC Name : trans-4-Methylcyclohexan-1-amine
Structure :
Brief Process: Stage-I: 4-Methylcyclohexanone: 4-Methylcyclohexanol reacted with sodium hypochlorite and acetic acid to give 4-Methylcyclohexanone. Stage-II: 4-Methylcyclohexanone oxime :4-Methylcyclohexanone reacted with hydroxylamine hydrochloride in presence of caustic soda lye to give 4-Methylcyclohexanone oxime. Stage-III: 4-Methylcyclohexyl amine: 4-Methylcyclohexanone oxime in methanol undergoes hydrogenation with hydrogen gas in presence of Raney Nickel catalyst. The reaction mass is filtered and methanol is completely distilled out under vacuum to give 4-Methyl amine. Stage-IV Trans-4-Methylcyclohexylamine hydrochloride: To a solution of4-Methylcyclohexylamine, methanolic hydrochloric acid is added to give 4-Methylcyclohexylamine hydrochloride, which is then purified in acetone to give trans-4-Methylcyclohexylamine hydrochloride. Stage-V Trans-4-Methylcyclohexylamine:
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 115
To a solution oftrans-4-Methylcyclohexylamine hydrochloride, methanolic sodium hydroxide is added to give trans-4-Methylcyclohexylamine, which is then purified to give trans-4-Methylcyclohexylamine. Route of Synthesis
Stage – I
Stage – II
Stage – III
Stage – IV
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 116
Stage – V
Application Used a spermidine synthase inhibitor Process Flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 117
24. TRIS(HYDROXYMETHYL)AMINOMETHANE
CAS NO : 77-86-1
Mol. Formula : C4H11NO3
Mol. Wt. : 121.14
IUPAC Name : 2-Amino-2-hydroxymethyl-propane-1,3-diol Structure :
Brief Process
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 118
Tris(hydroxymethyl)aminomethane may best be prepared by the exhaustive hydroxymethylation of nitromethane with the subsequent reduction of the nitro group. Route of Synthesis
Stage – I
Stage – II
Application
It is a zwitterionic biological buffer with a useful buffering range of 7.2-9.0, often used as a buffering agent in biological and biochemical research. Also known applied in bio-pharma manufacturing process. Process Flow Chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 119
25. TRANS-4-AMINOCYCLOHEXANOL
CAS NO : 27489-62-9
Mol. Formula : C6H13NO
Mol. Wt. : 115.18
IUPAC Name : Trans-4-Hydroxycyclohexylamine
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 120
Structure :
Brief Process: Stage-I Paracetamol undergoes hydrogenation in presence of Raney Nickel catalyst in IPA to give 4-Acetamidocyclohexanol. Stage-II 4-Acetamidocyclohexanol undergoes hydrolysis with sodium hydroxide to give 4-aminocyclohexanol. 4-aminocyclohexanol is refluxed in toluene and cooled to get trans-4-aminocyclohexanol. Route of Synthesis
Stage – I
Stage – II
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 121
Application It is used as raw material in organic synthesis and is an important intermediate in the synthesis
of drugs such as Ambroxol hydrochloride.
Process Flow Chart
26. TRANEXAMIC ACID
CAS NO : 1197-18-8
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 122
Mol. Formula : C8H15NO2
Mol. Wt. : 157.21
IUPAC Name : Trans-4-(Aminomethyl)cyclohexanecarboxylic acid Structure :
Route of Synthesis
Stage – I
Stage – II
Stage – III
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 123
Process flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 124
27. BENZETHONIUM CHLORIDE
CAS NO : 121-54-0
Mol. Formula : C27H42ClNO2
Mol. Wt. : 448.08
IUPAC Name : Benzyldimethyl(2-{2-[4-(2,4,4-trimethylpentan-2-yl)phenoxy]ethoxy}ethyl) azanium chloride Structure :
Brief Process: Stage-I p-octylphenol is reacted 2-chloroethanol in the presence of sodium hydroxide in toluene to get p-ter-octylphenoxyethanol. Stage-II p-octylphenoxyethanol is reacted 2-dimethylaminoethylchloride in the presence of sodium hydroxide in toluene to get p-tert-octylphenoxyethoxyethyldimethylamine. Stage-III p-tert-octylphenoxyethoxyethyldimethylamine is refluxed with benzylchloride in toluene to get benzethonium chloride.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 125
Route of Synthesis Stage -I
Stage –II
Stage – III
Application Used as a topical anti-infective agent. Benzethonium chloride is an ingredient in medicaments,
deodorants, mouthwashes, etc., and is used to disinfect apparatus, etc., in the food processing
and pharmaceutical industries, in surgery, and also as a preservative.
Process flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 126
28. CINNAMYL ALCOHOL
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 127
CAS NO : 104-54-1
Mol. Formula : C9H10O
Mol. Wt. : 134.18
IUPAC Name : 3-Phenyl-2-propen-1ol
Structure :
Brief Process: Cinnamaldehyde in methanol is reacted with sodium borohydridetogivecinnamyl alcohol. After distilling methanol, cinnamyl alcohol is also distilled out. Route of Synthesis
Application Used as a fragrance ingredient and as a flavoring agent Process flow chart
29. (R)-(-)-3-CARBAMOYMETHYL-5-METHYLHEXANOIC ACID AND PREGABLIN
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 128
CAS NO : 181289-33-8
Mol. Formula : C9H17NO3
Mol. Wt. : 187.24
IUPAC Name : (R)-3-(2-AMINO-2-OXOETHYL)-5-METHYLHEXANOIC ACID
Structure :
Brief Process: Stage-I Route of Synthesis Application Used as a fragrance ingredient and as a flavoring agent
Process flow chart
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 129
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 130
3.6 RAW MATERIALS The raw materials required and proposed for the production of specialty chemicals are appended in the table 3.2 below. Raw materials as listed will be procured as per the production requirement.
Table -3.2 Raw Materials Requirement for production of specialty chemicals S.No
Note: The Material Safety Data Sheet of Raw Materials (MSDS) is appended in Annexure C 3.6.1 STORAGE FACILITY FOR RAW MATERIALS AND PRODUCTS Adequate storage facilities with the required area is earmarked for the raw materials, specialty chemicals and packing material. Racking system/stackers, etc. are provided as per requirement. Corrosive chemicals are proposed to be kept in separate area with ventilation system. Closed storage rooms are provided for finished products as well as raw materials, as applicable. They are stored in polyethylene bags & drums, HMHDPE drums and metal coated drums (all in sealed condition) as per requirement.
Table 3.3:- Details of Storage Facilities
Sl. No. Storage Facility for Facility
1 Raw Materials Warehouse
2 Products Bonded finished goods store
3 Industrial Effluent The industrial effluents are stored in two collection tank of about 80,000 L capacity and sent to Common Effluent Treatment Plant (CETP) of M/s. Eco Engineering for treatment and disposal
4 Hazardous Waste In organic Process residue and organic waste from process is collected in HDPE Bags and sent to PCB authorized Processers for land filling
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 150
Spent carbon is collected in HDPE Bags and sent to PCB authorized Processers for land filling Used Containers after detoxification will be sold to authorized agents.
3.6.2 MACHINERY & EQUIPMENT DETAILS The detailed list of machinery& equipments in the industry are appended in the tables 3.4 below Table 3.4a List of Equipments
3.7 RESOURCE OPTIMIZATION/RECYCLING AND RE-USE ENVISAGED IN THE PROJECT 3.7.1 Solvent Recovery & Re-Use Various solvents are proposed to be used during the manufacturing process. The solvents
proposed to be recovered and recycled during the process of recovering the solvent of such
product are detailed in table 3.5 below.
Sl. no.
Utilities Nos.
1. Steam Boiler 2ton/hr. (Chimney height – 30.5m)
1
2. Brine Chiller 20TR/minus 20deg. 1
3. Cooling tower 250TR 1
4. Cooling Tower 1
5. Softener Water Plant 1
6. Water ring vacuum pump 2
7. Steam ejector 1
8. Water pump 10
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 152
3.7.2 SOLVENT RECOVERY SYSTEM 1. Solvent to be recovered is transferred in to a closed, Jacketed, Vertical, cylindrical and
agitated reactor.
2. Control measure for reactor, are Temperature, Pressure and speed of agitator.
3. Reactor Jacket has all the utility connections.
4. Vapor line connected to primary condenser, where in the cooling water is circulated.
(Cooling water has the multi pass facility to achieve better heat transfer and counter flow).
5. The system has an additional facility of reflux system.
6. The condensed liquid from primary condenser will flow to secondary condenser by gravity,
where in chilled water is circulated for further sub cooling of recovered solvent.
7. The vent of primary condenser is connected again to the same secondary condenser with
necessary control valve system. In total secondary condenser acts like sub cooler and as
well as vent cooler.
8. The measure control for both condenser and sub cooler are pressure and temperature both
on tube side and on shell side.
9. The sub cooled solvent then flows and collects in 2 receivers, where in further cooling is
made by circulating the chilled brine. The measure control for both receiver is the
temperature and pressure in shell as well as in Jacket.
10. The vent is always from the receiver to the wet scrubber or the vacuum pump.
3.8 HAZARDOUS RAW MATERIALS USED IN THE MANUFACTURING PROCESS The following raw materials used during the process of production of specialty chemicals are hazardous in nature according to Manufacture, Storage and Import of Hazardous Chemical (Amendment) Rules, 19th January 2000, Schedule I, Part II in the table 3.6
Table: 3.5 Hazardous raw materials
Hazardous raw material Sl. No. as per Manufacture, Storage and Import of Hazardous
Chemical (Amendment) Rules, 19th January, 2000, Schedule I,
Part II
Acetic acid 2
Acetone 4
Aluminium chloride 23
Ammonia solution 31
Benzoyl chloride 65
Benzyl chloride 67
Chlorosulfonic acid 136
Epichlorohydrin 239
Ethyl hexanol-2 254
Ethylene dibromide 263
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 153
Hexane 306
Hydrogen 314
Hydroquinone 319
Isopropyl alcohol 334
Methanol 377
Methyl isobutylketone 388
Nitrogen 429
Perchloroethylene 479
Phenol 481
Phosphorous oxychloride 504
Phosphorous pentaoxide 505
Potassium hydroxide 522
Sodium hydroxide 571
Sulphuric acid 591
Thionyl chloride 620
Triethylamine 652
3.8.1 Hazardous waste generation and its management during the manufacturing process
The hazardous wastes generated during the production of specialty fine chemicals, bulk drugs,
cosmetic and pharma ingredients are stored at hazardous waste storage area and sent to
authorized reprocessers. The quantities of hazardous waste generated from various processes
are shown in the Table- 3.7.
Note: The Product Hazop Study is appended in Annexure D
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 154
1. Spent Carbon
Table: 3.6 Quantity of spent Carbon waste generated from manufacturing process
Si .No. Product Spent Carbon generated Kg/Batch
1 Ethyl hexyltriazone 10
2 Isocotrizinol 10
4 Tetrahydrocurcuminoids 13
5 Tetrahydropiperine 13
6 1,4-Cyclohexanedione and acetal 11
7 Tris(Hydroxymethyl)aminomethane 10
8 Trans-4-Aminocyclohexanol 10
9 Tranexamic acid 8
3.8.2 Hazardous Waste Quantity and Disposal Details
Table 3.7a) Hazardous Waste Quantity and Disposal Details (EXISTING)
Sl.No Hazardous waste generated
Quantity Method of Handling
1 a)Used oil b)Vacuum oil
0.15KL/A 0.35KL/A
Shall be collected in leak-proof containers and disposed only to KSPCB registered authorized re-processors provided the oil meets the standards as per Schedule-5 Part-A of the Rules
2 a)Oil soaked cotton waste b)Oil filters
0.2MT/A 5Nos./A
Shall be stored in a secured manner and handed over to KSPCB authorized incinerator/co-processing in cement kiln.
3 Discarded containers Chemical contaminated paper & plastic bags
3600Nos./A 21MT/A
Store in a secured manner and handed over to KSPCB authorized recycler after wash only
4 ETP sludge 0.4MT/A Stored in secure manner and handed over to KSPCB authorized to TDSF
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 155
Table 3.7b) Hazardous Waste Quantity and Disposal Details (PROPOSED)
Sl. No. Source Quantity of hazardous waste
generated Kg/month
Disposal Options
1. Spent Carbon 867 Disposed through Cement industries for co incinerations
2. Waste oil from DG 30 liters Disposed through authorized recyclers
3. Spent Solvent 1,44,858 Disposed through KSPCB authorized dealers
4. HDPE/Discarded containers 1,965Nos. Disposed through authorized recyclers
5. Chemical contaminated paper & plastic bags
1,340kg/month Disposed through authorized recyclers
6. Distillation residue sludge 500kg/month Stored in a secure manner and handed over to TSDF
3.9 DOMESTIC SOLID WASTE RE-USE
The total quantity of domestic wastes generated for 75 workers is about19 kg/day of which 60% (12Kg/day) is organic and 40% (7Kg/day) is inorganic waste, which will be segregated at source, collected in bins and composted. The composted waste will be used as manure for landscape development.
3.10 WATER, ENERGY/POWER REQUIREMENT & SOURCE
3.10.1 Water
The water demand is met from water tanker supply. The requirement of water for the unit is appended in section 3.11.1 later in the report.
3.10.2 Power
The total power requirement of the industry is 459hp or 342 kVA. Further diesel generator of 250 kVA capacity is installed to serve as an alternative source of power supply to this unit.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 156
3.11 WASTES GENERATED & SCHEME FOR WASTE MANAGEMENT/DISPOSAL
3.11.1 Water demand and wastewater/effluent discharge for the proposed expansion
Source of water supply: Water Tanker Supply Total number of employees: 75 people
The total quantity of water required for the industry is about 111KLD. The break-up of the consumption of water is as presented below.
Table 3.8 Water consumption and discharge Water consumed for
Consumption
LPD
Recirculation
/RecycleLPD
Loss/Consumption/Evaporation /Daily Make Up Water Etc. LPD
Discharge
LPD
(a) Domestic 3750 3,750 3,375
(b) Landscape development 5,000 5,000 -
(c) Industrial purpose 1,02,000 74,000 30,450
Softener 43,000 15,000 14,750
c. Process water from Softener
d. Boiler water from Softener
7,631 or say 8,000
35,000
Recirculation water = 35,000-7000 (5250 Evaporation loss +1750 Blow down=28000
7,631 or say 8,000
Evaporation loss + blowdown loss(5250 +1750)=7000
11,000
1,750
(blow down)
Softener rejects 2000
5 Washings 14,000 14,000 14,000
6 Cooling tower 35,000
Evaporation loss + bleed off =(34,300+700)=35,000
700(bleed off)
7 Scrubber(1+1new) 1,000 1,000 1,000
8 Water for steam jet ejector
9,000 9,000 -
Total 1,10,750 28,000 82,750 33,825
LPD = L/day; KLD = kilo liter/day. Startup water requirement for industrial purpose is 110750 LPD or say 111KLD. Daily
requirement after recycling from boiler Condensate: 110750-28000 = 82750 LPD or say 82KLD
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 157
Proposed Water Balance Chart
Domestic wastewater
3375LPD
* Process effluent =11,000 LPD, DM rejects=2,000 LPD
30,450LPD or 31KLD will be sent to CETP
Septic tank Soak pit
Scrubber 10000LPD
500 LPD
Boiler makeup water 7,000LPD = (35,000 -28,000=7,000(1,750+5,250)
Cooling tower 35000LPD
Washing =14000
LPD
DM water Plant 20000 LPD
Process consumption
8000LPD
LANDSCAPING 5000 LPD
WATER TANKERS SUPPLY
Cooling Tower bleed off 700LPD
INITIAL WATER CONSUMPTION- 111KLD
DOMESTIC WATER DEMAND 3750 LPD
Scrubber effluent
10000 LPD
INDUSTRIAL WATER DEMAND- 111KLD Start up requirement Daily requirement after recycling from boiler Condensate: 110750-28000 = 82000 LPD or say82KLD
Boiler blow down1750LPD
Condensate
28000LPD
DAILY WATER CONSUMPTION =82KLD
Evaporation Loss= 5,250 LPD
Washing effluent
14000LPD
Evaporation Loss
34,300LPD
Steam jet ejector 9000
Lost 9000LPD
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 158
3.11.2 Total water requirement and waste water discharge details after expansion
The total water requirement for the industry after the proposed expansion is about 130KLD and
The total waste water discharge is about 50KLD.
Table 3.9: Sewage/effluent treatment and discharge
Sewage/effluent generated from
Treatment units provided Final disposal point
(a) Domestic Treated in Septic tank Disposed to Soak pit
(b) Industrial Two Collection tanks of 40,000 KL capacity each are provided.
Industrial effluent is sent to Common Effluent Treatment Plant (CETP) of M/s. Eco Engineering for treatment and disposal.
Description Existing (EC obtained) Proposed Total water
requirement after
expansion
(KLD)
Water requirement
(KLD)
Industrial 16 Industrial 102 118
Domestic 1.5 Domestic 3.7 5.2
Landscaping 1.0 Landscaping 5.0 6.0
Total 18.5 Total 110.5 Total=129
Waste water
Generation
(KLD)
Industrial 15 Industrial 31 46
Domestic 1.2 Domestic 3.0 3.2
Total 16.2 Total 34 Total=49.20
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 159
3.12 Product wise water consumption and discharge
Table 3.10: Product-wise water consumption for process and effluent discharge
29 R-()Carbamoylmethyl-5-methylhexanoic acid and Pregablin
Inorganic waste 35 1750 21000 50
Organic waste 539 26950 323400
Water 620 31000 372000
Total 1194 59700 716400
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 164
3.14 Waste Water Characteristics
Table 3.12 Waste Water Characteristics
Sl. No
Parameters Results Protocol
1 pH 6.22 IS:3025 (P 11)
2 Oil & grease, mg/L <1.0 IS:3025 (P 39)
3 Total suspended solids, mg/L 180 IS:3025 (P 17)
4 Bio-chemical Oxygen Demand (at 270C for
3 days), mg/L
27,000 IS:3025 (P 44)
5 Total Dissolved Solids, mg/L 2,46,620 IS:3025 (P 16)
6 Total hardness as CaCO3, mg/L 43.5 IS:3025 (P 21)
7 Conductivity, µ omh/cm 3,72,000 APHA
8 Magnesium, as Mg, mg/L 2.4 IS:3025 (P 46)
9 Total chlorides, as Cl, mg/L 91,266 IS:3025 (P 32)
10 Total sulfates, as SO4, mg/L 1.3 IS:3025 (P 24)
11 Silica, as SiO2, mg/L <0.2 IS:3025 (P 35)
12 Iron, as Fe, mg/L 13.7 IS:3025 (P 53)
13 Phenolpthalein alkalinity, as CaCO3, mg/L Nil IS:3025 (P 23)
14 Methylorange alkalinity, as CaCO3, mg/L 16,320 IS:3025 (P23)
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 165
3.15 Air Pollution Sources The major air pollution sources from the industry are DG set and process sections. These sources are provided with stacks of adequate height so as to disperse the emanating flue gases containing SPM, oxides of sulfur and nitrogen without affecting the ground level concentrations and packed column scrubbers are provided to the process sections with adequate stack height as per the regulatory requirements.
The sources of air pollution, type of fuel used, fuel consumption and chimney heights for each of the air pollution sources of the project are indicated in the following table 3.13.
Air Pollution Sources and Control (EXISTING)
Sl No.
Chimney attached to
Minimum chimney height to be provided above ground level
Rate of emiision Nm3/Hr.
Constituents to be controlled in the emission
Tolerance Limits mg/Nm3
Air pollution Control equipment to be installed, in addition to chimney height as per Col.(3)
Table-3.13 Air Pollution Sources and Control (PROPOSED)
SI. no.
Stack attached to
Fuel used Fuel consumption
Number of
stacks
Stack/s height
Air pollution control unit
Predicted emissions
1. Process (attached to reactors)
- - 1 5 m ARL Scrubber Acid mist / VOCs
2. Attached to R&D lab
- - 1 5 m ARL Scrubber & packed fume
extraction system
Acid mist
3. Boiler 2T/hr. (proposed)
Wood/Agro waste
300Kg/hr 1 30.5m AGL
Stack SOx, NOx,SPM
The exhaust temperature is nearly ambient and adequate port holes with access platform will be provided as per KSPCB guidelines as under
3.13.1 Scrubbing System Details
Scrubber systems are a diverse group of air pollution control devices that can be used to remove particulates and/or gases from industrial exhaust streams. Traditionally, the term "scrubber" has reference to pollution control devices that used liquid to "scrub" unwanted pollutants from a gas stream.The term is also used to describe systems that inject a dry reagent or slurry into a dirty exhaust stream to "scrub out" acid gases. Scrubbers are one of the primary devices that control gaseous emissions, especially acid gases.
Wet scrubber is a form of pollution control technology in which the polluted gas stream is brought into contact with the scrubbing liquid by spraying it with the liquid, by forcing it through a pool of liquid, or by some other contact method, so as to remove the pollutants.
The design of wet scrubbers or any air pollution control device depends on the industrial process conditions and the nature of the air pollutants involved. Inlet gas characteristics and dust properties (if particles are present) are of primary importance. Scrubbers can be designed to collect particulate matter and/or gaseous pollutants. Wet scrubbers remove dust particles by capturing them in liquid droplets; remove pollutant gases by dissolving or absorbing them into the liquid.
Any droplets that are in the scrubber inlet gas must be separated from the outlet gas stream by means of another device referred to as a mist eliminator or entrainment separator (these terms are interchangeable). Also, the resultant scrubbing liquid must be treated prior to any ultimate discharge or before being reused in the plant.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 167
There are numerous configurations of scrubbers and scrubbing systems, all designed to provide good contact between the liquid and polluted gas stream.
The process section and vapor adsorption unit are provided with scrubber to scrub the fumes and vapors generated in order to remove such emissions before it is let out into the atmosphere.
A PP with FRP scrubber of size 600 mm dia x 1000 mm overall height with 400 mm packing height and inbuilt sump tank fabricated with 3 mm polypropylene armored externally with 8 mm thick FRP using isophthalic resin and E-glass reinforcement complete with various nozzles, demister pad, spray pipe complete etc.
The scrubber is connected to PP with FRP blower (1 W + 1 SB) of capacity 1500 CMH against 200 mm water column with 2 HP 1440 RPM FLP motor and MS base frame. The scrubber is connected to a PP recirculation pump of capacity 12 CMH against 12 m head.
Flash drier cyclone separator with water jet scrubber unit set-up
Fig 3.4 Water jet scrubber
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 168
3.16 Noise pollution details The major source of noise pollution in the industry is the DG set for which acoustic enclosure is provided. Also ambient noise levels are ensured to be within the ambient standards by inbuilt design of mechanical equipment and building apart from vegetation (tree plantations) along the periphery and at various locations within the industry premises.
3.17 Solid waste details The quantity of solid waste generated from the proposed industry is detailed in the following table 3.14.
Table: 3.14 Solid Waste Generation during the Operation Phase
Details Existing proposed
Total no. of employees 60 75
Assuming per capita solid waste generation rate as 0.25 kg/capita/day
Quantity of solid waste generated 15kg/day 19Kg/day
Organic solid waste : 60 % of the total waste 9kg/day 12kg/day
Inorganic solid waste : 40 % of the total waste 6kg/day 7kg/day
The domestic wastes are segregated at source, collected in bins and handed over to KSSIDC for scientific disposal.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 169
3.18 SCHEMATIC REPRESENTATIONS OF THE OVERALL FEASIBILITY AND ENVIRONMENTAL ASSESSMENT PROCESS
Fig 3.6: Feasibility & environmental Assessment Process
Significant
Not
Economic
Feasibility study conducted for Newly proposed industry
Statement of intent by proponent
Guidelines for EIA by SEAC/MoEF
Abandon project
Determine the coverage of the EIA - scoping
Describe the environment – baseline study
Describe the project
Identify the impacts
Evaluate the impacts
Mitigation
Preventive measures
Prepare draft EIS
FINAL EIA REPORT
CONSIDER ALL PHASES OF PROJECT –
CONSTRUCTION, DEVELOPMENT, INSTALLATION &
FINAL OPERATION/ PRODUCTION
SO
CIO
-ECO
NO
MIC
ISSU
ES
MO
NIT
OR R
EVIE
W
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 170
4.1 SITE CONNECTIVITY Table-4.1 Connectivity from Project Site
The details of the industries and site bearings with other facilities available in the vicinity of the industry are as follows
Sl. No.
Industry/Facility Direction from the project site
1. KIADB area North
2. 15 m wide road East
3. Private land West
4. 15 m wide road South
5. Group Pharmaceutical 0.25 km, east
6. Malur Tubes Pvt. Ltd. (MS pipes) 0.25 km, south
7. Cauvery Petrochemical 0.5 km, north
8. Medo Pharma 0.5 km, east
The project site is well connected with roadways. The Bangalore- Malur road is at a distance of
around 2Km east of the project site. The McNally road is at a distance of 1Km North-east of the
project site.
CHAPTER 4 SITE ANALYSIS
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 171
Fig- 4.1 Google Map Showing Connectivity to Project Site Note: All distances mentioned are aerial.
Project site
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 172
4.2 LAND FORM, LAND USE & OWNERSHIP
M/s. Somu Organo-Chem Pvt. Ltd. at No.20, 29th Main, II Stage, I Phase, BTM Layout, Bangalore-560 076 is a proposes to expand its process of hydrogenation, formulations and processing of fine and specialty chemicals industry at Shed No.C-29, C-30 & adjacent plots, KSSIDC Industrial Estate, Malur- 563 130, Kolar District.
4.3 TOPOGRAPHY M/s. Somu Organo-Chem Pvt.Ltd., is located at latitude of 125856.71"N &
longitude 7, 75,504.70"E at an elevation of 897 m above MSL. The topo map showing the
location of the project site is appended as fig 4.2.
Fig-4.2 Topo Map
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 173
4.4 EXISTING LAND USE PATTERN
Table 4.2 Existing Land Use Pattern
Sl. No. Particulars Area (m2)
1 Total plot area 5,532.91 (100%)
2 Ground coverage area 2,693.04 (48.68%)
3 Hard paved area 1419.94 (25.66%)
4 Landscaped area 1419.94 (25.66%)
5 Built-up area 2,693.04
Note: Land Records are appended in Annexure A
4.5 EXISTING INFRASTRUCTURE
The list of existing infrastructure at the project site is 1. Water supply from Bore well 2. Power supply is from BESCOM 3. Storm water drainage system is provided
4.6 SOIL CLASSIFICATION
The soils of Bangalore Rural districts are broadly classified in to four categories viz (i). Loamy soil (ii) Lateritic soil (iii) Lateritic gravelly soil and (IV) Red sandy soil. Red loamy soils generally occur on hilly to undulating land slope on granite and granite gneisses. Lateritic soil occurs in undulating terrain forming plain to gently sloping topography of peninsular gneiss region. Lateritic gravelly soils occur in upland regions of lateritic soils, Red sandy soil occurs in undulating land slopes. These soils are derived from acidic rocks granites and granitic gneiss.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 174
4.7 CLIMATIC DATA FROM SECONDARY SOURCES
Table 4.3: Meteorological Data of Kolar for the Year 2015 Mont
h Temperature
0C Relative
humidity % Precipitation
rate (mm/hr)
Atmospheric pressure (mb)
Wind speed (m/s)
Inversion / mixing height
(m)
Cloud cover
(tenths) Min Max Max Min Min Max Min Max Min Max Day Night Min Max
4.7.1 Temperature The mean maximum temperature is observed at (32°C) in the month of May and the mean
minimum temperature at (11.8°C) is observed in the month of December. In the summer
season the mean minimum temperature is observed during the month of March (16.4°C).
During the monsoon the mean maximum temperature is observed to be 30.9°C in the month of
June with the mean minimum temperature at 17°C during August. By the end of September
with the onset of post monsoon season (October - November), day temperatures drop slightly
with the mean maximum temperature at 28.8°C in October and mean minimum temperature is
observed at 16.8°C for both October & November. The values are presented in table 4.3.
4.7.2 Relative Humidity
Minimum and maximum values of relative humidity have been recorded. The minimum
humidity is observed to be at 38.8% in the month of March and the maximum is 91.4% in the
month of September. The mean minimum values of humidity during summer, monsoon, post-
monsoon and rainy seasons are 38.8%, 71.7%, 73.5% & 44.8% during the months of March,
June, October and February respectively. Similarly the maximum values are 82.7%, 91.4%,
93.5%, 87.6% in the months of May, September, November & December during the summer,
monsoon and post monsoon & winter seasons. The values are presented in table 4.3.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 175
4.7.3 Rainfall
The monsoon in this region usually occurs twice in a year i.e. from June to September and from
October to November. The maximum annual rate of precipitation over this region ranges
between 1.02 to 4.83 mm/hr.
4.7.4 Atmospheric Pressure
The maximum and the minimum atmospheric pressures are recorded during all seasons. In the
summer season, the mean maximum and minimum pressure values are observed to be 917 mb
in the month of March and 905 mb in the month of May respectively. During monsoon season,
the maximum pressure is 913 mb and minimum 904 mb. The maximum pressure during the
post-monsoon season is observed to be 915 mb in November and minimum pressure is 904 mb
in the month of October. During the winter season the minimum atmospheric pressure is 906
mb in December and the maximum is 919 mb in the month of January. The values are
presented in table 4.3.
4.7.5 Inversion Height
The maximum inversion heights at the project site during the day time & night time for all the
months of the year is as given in the table 3.1. The maximum mixing height of 4000 m is
observed during the month of June during the night time and 3319 m during the month of May
during the day time. The minimum inversion heights are 1756 m in the month of December
during the day and 1786 m during the night in the month of February.
4.7.6 Cloud cover
The minimum cover measured in the unit of tenths is 2 and the maximum observed cloud cover
is 10.
4.7.7 Wind
The data on wind patterns are pictorially represented by means of wind rose diagrams for the entire year as figure 4.3 (for different seasons).
Predominant wind directions
Season Period Wind direction Summer March to May North West
Monsoon June to September East
Post monsoon October to November South West
Winter December to February North West
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 176
4.8 SOCIAL INFRASTRUCTURE
Infrastructure is the basic physical and organizational structures needed for the operation of a
society or enterprise or the services and facilities necessary for an economy to function.
The term typically refers to the technical structures that support a society, such as roads, water
supply, sewers, electrical grids, telecommunications and so forth and can be defined as "the
physical components of interrelated systems providing commodities and services essential to
enable, sustain or enhance societal living conditions”.
Viewed functionally, infrastructure facilitates the production of goods and services and also the
distribution of finished products to markets, as well as basic social services such as schools and
hospitals; for example, roads enable the transport of raw materials to a factory.
Infrastructure facilities The infrastructure and amenities available in the area reflects the economic wellbeing of the region
Educational facilities: The educational facilities available in and around the study area include good number of primary, middle, high school and junior colleges with good facilities apart from Anganwadies in rural sectors.
Communication facilities: The study area and its surroundings have sufficient post and telegraph offices, public telephone booths.
In addition to the above the study area and the villages surrounding it have been provided with good electrical power supply for domestic, industrial, agricultural and public lighting purposes. An electrical substation has been provided by the KSSIDC to ensure the power supply to the industries for most part of the day.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 177
Fig 4.3: Wind Rose Diagrams
1. March to May (summer season)
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 178
2. June to September (monsoon season)
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 179
3. October to November (post monsoon season)
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 180
4. December to February (winter season)
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 181
CHAPTER 5
PLANNING BRIEF
5.1 PLANNING CONCEPT
M/s. Somu Organo-Chem Pvt. Ltd,. proposes to expand its process of hydrogenation, formulations and processing of fine and specialty chemicals industry within the existing facility at Shed No.C-29, C-30 & adjacent plots, KSSIDC Industrial Estate, Malur- 563 130, Kolar District.
5.2 POPULATION PROJECTION The expansion and modification will be done in existing facility and no construction activity is envisaged.
Total no. of people employed during operation phase:
Existing: 60 workers
Proposed: 75 workers
5.3 LAND-USE PLANNING The land use planning is given in Table 5.1
Table 5.1: Land-Use Pattern
Sl. No. Particulars Area (m2) In %
1 Total plot area 5532.91 100%
2 Ground coverage area 2,693.04 48.68%
3 Hard paved area 1419.94 25.66%
4 Landscaped area 1419.94 25.66%
5 Built-up area 2,693.04 -
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 182
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND 1. Malur-Hosur road is at 1.11 Km from the project site towards east
2. National highway 207 is at 10.37Km from project site towards south east
3. National highway 4 is at a distance of 14km from project site towards south west
4. Hoskote-Malur road is at a distance of about 4Km west of the project site
5. The project is in designated industrial area with internal roads in the industrial area and
project site is already available.
5.4.1 Water supply & sewerage infrastructure Water demand for the industry is from tankers and existing Bore well.
The domestic sewage generated is treated in septic tank and sent to soak pit.
The industrial effluents are stored in two collection tank of each about 40,000 L capacity and sent to Common Effluent Treatment Plant (CETP) of M/s. Eco Engineering for treatment and disposal.
5.5 AMENITIES/FACILITIES Proper site services such as with Drinking water, safety equipments & first Aid is provided to
the workers.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 183
CHAPTER 6
PROPOSED INFRASTRUCTURE
6.1 INDUSTRIAL AREA (PROCESSING AREA) M/s. Somu Organo-Chem Pvt. Ltd. proposes to expand its process of hydrogenation, formulations and processing of fine and specialty chemicals industry within the existing facility at Shed No.C-29, C-30 & adjacent plots, KSSIDC Industrial Estate, Malur- 563 130, Kolar District.
6.2 GREEN-BELT An area of 696.36 Sq.m of total plot area is green-belt/landscape development. About 52 trees of various native/indigenous variety are already planted. Another 20 trees are proposed in the expansion project, 6.3 SOCIAL INFRASTRUCTURE Details Given in Chapter- 4, section 4.8 6.4 CONNECTIVITY The site is well connected with roadways. NH-207 & NH-4, Hosur-Malur road and Hoskote-
Malur road, Bangalore- Malur road which are at close proximity from the project site enabling
easy transportation of materials to and from the industry.
6.5 SEWERAGE SYSTEM Sewage pipes are laid in entire company for the removal and disposal of mainly non harmful
liquid wastes from the offices and domestic waste, these liquid wastes are sent to septic tank &
soak pit.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 184
6.6 INDUSTRIAL WASTE MANAGEMENT
The industrial effluents are stored in two collection tank of each about 40,000 L capacity and
sent to Common Effluent Treatment Plant (CETP) of M/s. Eco Engineering for treatment and
disposal.
6.7 SOLID WASTE MANAGEMENT The domestic wastes are segregated at source, collected in bins and handed over to KSSIDC for scientific disposal. Hazardous solid waste will be stored in HDPE bags and sent to authorize reprocessors.
6.8 POWER REQUIREMENT & SUPPLY SOURCE The total power requirement of the industry is 459hp or 342kVA which is sourced from
BESCOM. Further, a diesel generator of 250 kVA capacity is installed to serve as an alternative
source of power supply to this unit.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 185
CHAPTER 7
REHABILITATION & RESETTLEMENT PLAN M/s Somu Organo-Chem Pvt. Ltd. is in a designated industrial area. The expansion will be within
the existing facility. No home outstees/land outstees are expected & hence no rehabilitation
plan is envisaged.
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 186
CHAPTER 8
PROJECT SCHEDULE & COST ESTIMATES 8.1 TIME SCHEDULE M/s Somu Organo-Chem Pvt. Ltd. is in a designated industrial area. The expansion happening within the existing facility, the industry proposes the addition of new products to its process line. The industry does not particularly emphasize on the time schedule since it is already under operation and only planning to include the production of certain new products to its process line. Table 8.1 Time Schedule
Particulars Time schedule
Start of construction activity Existing plant
Completion Existing facility
8.2 ESTIMATED PROJECT COST The proposed project expansion cost would be Rupees 4.34crores.
Table 8.2 Proposed Expansion Cost
Sl.No. Description Value in Lac.
1 Civil & Structure 60
2 Plant Equipments 80
3 Utility Equipment 45
4 Process & Utility pipelines 25
5 Scrubbing system 9
6 Environment & Effluent Equipments 10
7 R& D and QC Lab instruments 90
8 Electrical 15
9 Insulation and paint 10
10 GMP Powder processing Plant 90
Total Rs 434
M/S Somu Organo-Chem Pvt. Ltd.,
Pre-Feasibility Report 187
CHAPTER – 9
ANALYSIS OF PROPOSAL
Observing the demographic pattern of the study area it can be inferred that occupational pattern is a mixture more of agriculture rather industrial. The proposed project will increase the employment potential by creating direct and in-direct employment opportunities and thus be beneficial for the local and nearby populace The management of the industry gives preference to local people with both direct and indirect employment.
