M/s. ZCL CHEMICALS LTD., ANKLESHWARenvironmentclearance.nic.in/writereaddata/Online/TOR/10_May_2017... · ZCL CHEMICALS LTD., ANKLESHWAR M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT.

M/s. ZCL CHEMICALS LTD., ANKLESHWAR

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

Page 1

1.0 EXECUTIVE SUMMARY

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

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

393002, Gujarat. Existing Product capacity is 304.9 MT/Year and the proposed capacity after

expansion will be 790 MT/Year.

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

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

Pharmaceutical Ingredients.

The details of products are given below table.

TABLE: 1

LIST OF PRODUCTS AS PER EXISTING CCA: AWH-72765

Sr.

No.

Name of Products Existing as per

CCA No.

AWH-72765

(MT/Year)

Group 1 204.3

1 Thrio Pypridil Amide 204.03

Either/ or

product will be

made

2 Ritalinic acid

3 4 - benzyloxy -3- nitrophenylace bromide

4 Zonisamide

5 Modafinil - EP/USP

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

phenyl butyl ] – n – (2 Methyl propyl) benzene

sulfonamide

7 Darunavir

8 Fluvoxamine Maleate

9 Trifluoperazine

10 Methylphenidate

11 R & D Products

12 Dex Methyl Phenidate



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Sr.

No.


CCA No.

AWH-72765

(MT/Year)

13 Chlordiazepoxide

14 Cillastazol

15 7 Hydroxy 1,2,3,4 tetra hydro quenoline

16 Chloro Methyl cyclo propane

17 1-(2,3 dichloro phenyl) - piperazine

hydrochloride (DCPP)

18 BBQ (7-(4-Bromobutoxy)-3, 4-

dihydroquinolin-2(1H)-one)

19 T2551 - Etravirin Inter

20 Canagliflozicin Inter (n-2): 2-(4-fluorophenyl)-

5-(5-iodo-2-methylbenzyl)thiophene

21 Aripiprazole

22 BET (1-(2-Bromoethyl)-4-ethyl-1,4-dihydro-

5H-tetrazol-5-one)

23 1-Amino Indane

GROUP – 2 42.03

24 Trimethyl pyruvic Acid AND/OR 42.03

25 4,4’-Diflurobenzhydryl Piperazine

26 2 Tri Pheno trimethyl phenothiazine

27 Levomepromazine

28 Betahistine IP / EP / USP

29 Betahistine Mesylate JP/EP

GROUP – 3 23.1

30 Phenyl 2 Piperidyl Acetamide 23.1

Either/ or

product will be

made

31 N- (1 Benzyl 4 Piperidinyl) N Phenyl

Propanamide HCL / NN Phenyl N 4 Piperidinyl

Propanamide HCl

32 N Acetyl Hydroxy Phenyl Piperazine

33 Amino Ethyl Phosphoric Acid

34 (1-Isopropyl-4-(hydroxyl Phenyl) (piperazine)

35 Memantine HCl

36 Quetiapine Fumerate

GROUP –4 23.266

37 Phenyl 2Pyridyl Acetamide 23.266



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Sr.

No.


CCA No.

AWH-72765

(MT/Year)

38 Zaltoprofen Either/ or

product will be

made

39 Alprazolam

40 Mono chloro acetonitrile

GROUP –5 : Individual Product 12.48

41 BOC Nitro 0

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

Piperdinyl]-N-Phenyl Propanamaide-

Ethanedioate.

0.06

43 Dex Ritalinic Acid 0.1

44 Remi N Benzyl Propeonamide eater Oxalate 0.02

45 Nebivolol 0.1

46 Flurbiprofen 0.4

47 Olanzapine 0.4

48 Levodropropizine 0.5

49 Atomoxetine 0.5

50 Felbiprofen 3

51 Clozapine 1.8

52 Diazepam 0.4

53 Oxazepam 0.4

54 Flupirtine maleate 0.4

55 Bromazepam 0.4

56 Benzhydrl Piprazine 4

Total 304.906



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TABLE: 2

LIST OF PRODUCT AFTER EXPANSION

Sr.

No Product Name

CAS No. Proposed

quantity

CNS Active API/Intermediates: 225 TPA

225 TPA

Either/ or

product will

be made

1 Thrio Pypril Amide 50288-62- 5

2 Ritalinic acid 19395-41- 6

3 Zonisamide - USP 68291-97- 4

4 Modafinil - EP/USP 68693-11- 8

5 Fluvoxamine Maleate- EP/BP/USP/JP - FLX/MDD 61718-82- 9

6 Trifluoperazine - USP/EP/BP 440-17- 5

7 Methylphenidate - USP/EP 298-59- 9

8 Dex Methyl Phenidate 19262-68- 1

9 Chlordiazepoxide 58-25-3

10 7 Hydroxy Quinoline 22246-18-0

11 1-Chloromethyl cyclopropane 5911-08-0

12 1-(2,3 dichloro phenyl) - piperazine hydrochloride (DCPP) 119532-26- 2

13 7-(4-Bromobutoxy)-3, 4-dihydroquinolin-2(1H)-one (BBQ) 129722-34-5

14 Aripiprazole 129722-12- 9

15 1-(2-bromoethyl)-4-ethyl-1,4-dihydro-5h-tetrazol-5-one

(BET)

84501-67-7

16 1-Amino Indane 34698-41-4

17 4,4’-Diflurobenzhydryl Piperazine 27469-60- 9

18 2 Tri Pheno trimethyl phenothiazine 92-30- 8

19 Levomepromazine 7104-38- 3

20 Betahistine 5579-84- 0

21 Betahistine Mesylate JP/EP - 54856-23-4

22 Phenyl 2 Piperidyl acetamide 19395-39- 2

23 N- (1 Benzyl 4 Piperidinyl) N Phenyl Propanamide HCL /

NN Phenyl N 4 Piperidinyl Propanamide HCl - (FC

1002/1003)

5156-58- 1

24 Memantine HCl 41100-52- 1

25 Quetiapine Fumerate 111974-72- 2

26 Phenyl 2Pyridyl Acetamide 7251-52- 7

27 Alprazolam 28981-97- 7

28 Mono chloro acetonitrile 107-14-2

29 Remi N Benzyl Propeonamide eater Oxalate 61085-73- 2

30 Olanzapine 132539-06- 1

31 Benzhydrl Piprazine 841-77-0



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Sr.

No Product Name

CAS No. Proposed

quantity

32 Alpha-phenylpiperidine-2-acetic acid (KMP) 19395-41-6

33 Fluvoxamine Oxalate (OXA) NA

34 5-methoxy-p-trifluoromethylvalerophenone-oxime (XIA) 61747-22-6

35 1,2,4-Triazolo[4,3,a]pyridine-3(2H)-one (TZP)

36 4-amino-2-methyl-10H-thieno[2,3b] [1,5]-benzodiazepine

hydrochloride (AMB)

138564-60-0

37 Lurasidone Hydrochloride 367514-88-3

38 2-bromo-3-(2,3-dimethylphenyl)butanal (MPB) 1421259-21-3

39 Brexpiprazole 913611-97-9

40 Nicorandil 65141-46-0

41 Quinfamide 62265-68-3

Group 2- Psychodynamic Substances

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

Phenyl Propanamaide,- Ethanedioate. (SUE / SU 10)

61086-13- 3

25 TPA Either/ or

product will

be made

43 Dex Ritalinic Acid 1382859-13-3

44 Atomoxetine 82248-59- 7

45 Diazepam 439-14-5

46 Oxazepam 604-75-1

47 Flupirtine maleate 75507-68-5

48 Bromazepam 1812-30-2

49 Nebivolol 152520-56-4

50 Levodropropizine - EP 99291-25-5

51 Clozapine 5786-21- 0

52 Eslicarbazepine Acetate 236395-14-5

Anti Asthmatic Intermediates: 40 TPA

53 4 - benzyloxy -3- nitrophenacyl bromide 43229-01- 2 40 TPA Either/ or

product will

be made

54 4-benzyloxy-3-nitrostyreneoxide (NSO) 51582-41-3

55 2-(2[3-(3-[2-(7-chloroquinoline-2-yl)ethenyl)phenyl)-3-

hydroxy-n-propyl]phenyl)-2-propan-1-ol (SMKT)

142569-70-8

Anti Viral API/ Intermediates: 200 TPA

56 Di Amino (BOC 1/ DRV II) 169280-56-2 200 TPA Either/ or

product will

be made

57 Darunavir 635728-49-3

58 T2551 - Etravirin Intermediate 269055-15-4

59 BOC Nitro 191226-98- 9

Antidiabetic API: 100 TPA

60 Canagliflozin Inter (n-2): 2-(4-fluorophenyl)-5-(5-iodo-2-

methylbenzyl)thiophene

842133-18-0 100 TPA Either/ or

product will

be made

61 Dapagliflozin 461432-26-8

62 Empagliflozin 864070-44-0



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Sr.

No Product Name

CAS No. Proposed

quantity

Antiinflammatory API

63 Zaltoprofen 74711-43- 6

75 TPA Either/ or

product will

be made

64 Flurbiprofen 5104-49-4

65 Felbinac - JP/BP 5728-52- 9

66 Loxoprofen Sodium 80382-23-6

67 Naproxen Sodium 26159-34-2

Miscelleneous groups: 125 TPA

68 Mirabegron 223673-61-8

125 TPA Either/ or

product will

be made

69 Deferasirox 201530-41-8

70 Colesevelam 182815-44-7

71 Tricyclo [3.3.1 13, 7] decan-1- aminium, N, N, N-Trimethyl

hydroxide (TMA)

NA

72 N, N-Dimethyl- 3, 5-dimethyl piperidinium hydroxide (TMP) NA

73 Pirfenidone 53179-13-8

74 Apalutamide (CAP/CBF) 956104-40-8

75 5-chloro-N-({(5S)-2-oxo-3-[4-(3-oxomorpholin-4-yl)phenyl]-

1,3-oxazolidin-5-yl}methyl)thiophene-2-carboxamide

(BAN/Rivaroxaban)

366789-02-8

76 Trimethyl pyruvic Acid 815-17-8

77 N Acetyl Hydroxy Phenyl Piperazine 67914-60-7

78 Amino Ethyl Phosphoric Acid 071-23-4

79 (1-Isopropyl-4-(hydroxyl Phenyl) (piperazine) 67914-97-0

80 Cilastazol 73963-72- 1

81 R & D Products

Total 790 TPA

COST OF PROJECT

Total cost for proposed project is approx. 40 crore. The plot has been purchased by M/s. ZCL

Chemicals Ltd. from GIDC. The total plot area of the unit is 35595 Square meter. The green belt

area is apprx 6200 square meters.



Page 7

FUEL CONSUMPTION

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

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

Thermic fluid heater, Diesel consumption for DG set.

ELECTRICITY CONSUMPTION

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

consumption is 1900 KVA. There will be no changes in Electricity consumption.

WATER CONSUMPTION

The source of water is from GIDC water supply scheme.

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

domestic & gardening purpose is 21.2 KL/day fresh water.

After Expansion, the water consumption for industrial purpose will be 344.8 KL/day (284.8

KL/day Fresh + 60 KL/day Recycle). The water consumption for the domestic & gardening

purpose will be 21.2 KL/day fresh water.

WASTE WATER GENERATION

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

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

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

treatment and its ultimate disposal to deep sea (facility operated by NCT).

After expansion, total waste water generation will be 140 KL/day. 85 KL/day will be recycled in

RO plant and remaining 55 KL/day will be discharged to FETP. Out of 55 kl/day discharged qty,

The industrial waste water is 45 KL/day and domestic waste water is 10 KL/day. Treated effluent

is discharged in to GIDC Pumping station – B through above ground fixed pipeline leading to the

inlet of FETP for further treatment and its ultimate disposal to deep sea (facility operated by

NCT).



Page 8

GASEOUS EMISSION

There is one stack of Boiler (capacity: 3.5 TPH) (one stand-by boiler 5TPH capacity is also

connected with same stack), one stack of Thermic fluid heater (capacity: 4 lac Kcal/Hr.) and

three stacks of three Diesel Engine Generators (capacity: 250,750 & 1010 KVA respectively).

The three D.G. sets will be used in case of emergency only.

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

in Plant-4, one stack attached to Reaction vessel in Plant-2. These stacks are connected with

scrubbers (Water + Caustic). There will be no change in process gas emission due to Proposed

Expansion.

HAZARDOUS WASTE MANAGEMENT

There is generation of ETP sludge (339 MT/Year), Carbon Waste (18.25 MT/Year), Distillation

residue (36.5 MT/Year), Discarded containers (43800 Nos/Year or 350.04 MT/Year), Distillation

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

Contaminated solvents not fit for originally intended use (2000 MT/Year), Spent solvent (73 MT

/ Year).

After Expansion, There is generation of ETP sludge (550 MT/Year), Carbon Waste (50

MT/Year), Distillation residue (105 MT/Year), Discarded containers (43800 Nos/Year or 350.04

MT/Year), Distillation residue from contaminated organic solvents (7 MT/Year), Used/Waste

Oil (10 MT/Year), Contaminated solvents not fit for originally intended use (2000 MT/Year),

Spent solvent (613 MT / Year), Wastes or residues containing oil (0.5 MT/Year), Off

specification products (5 MT/Year) and Date-expired products (5 MT/Year).

Mode of Disposal is given in Annexure-XI of Form 1.



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2.0 INTRODUCTION

2.1 THE PROJECT

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

manufacturing of Chemical Pharmaceuticals Intermediates and Active Pharmaceutical

Ingredients. Unit is proposed for expansion at same unit. The list of Existing & Proposed

products is provided in Table -1& 2.

2.2 PROJECT PROPONENT

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

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

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

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

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

Quality, Environment, Health and Safety

Policy:

The policy of the company is as under:

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

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

Pharmaceutical Ingredients and Safety Chemical in having Guidline principles that Comminted

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

Health and Safety must satisfy our Esteem Customers.

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

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

Environment impacts are Prevented.

Prevent Injuries and Occupational Illness at the Workplace.

Enhance quality, environment, health and safety awareness.

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

Health and Safety



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

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

Occupation Health and Safety risks.

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

Health And Safety.

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

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

18001 : 2007 Norms.

The name and address of Directors are given in Table 3.

TABLE: 3

CONTACT DETAILS OF THE DIRECTORS

Sr. No. Name & Address of Directors Designation Contact detail

1 Mr. Ajay Krishnakant Parikh

Managing Director 20/301, Gurukrupa,

Vithal Nagar, CHS Ltd.,

11th Road, JVPD

Scheme, Vile Parle (W),

Mumbai – 400 049

Phone No. - 022—

61539900

2 Mr. Nihar Ajay Parikh

Executive Director 20/301, Gurukrupa,

Vithal Nagar, CHS Ltd.,

11th Road, JVPD


Mumbai – 400 049

Phone No. - 022--

61539906

3 Mr Dhiren Shevantilal Shah

Non-Executive

Director,

Independent

Director

Cumbala Hill post Office,

Gamdevi P.Stn, Mumbai

– 400026.

Phone No. - 022—

61539999



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4 Mr. Piyush Maganlal Nathwani

Executive Director F 14, Shashwat Complex,

Dahej By Pass Road,

Bharuch-392001, Gujarat

Phone No. - 02646--

619405

5

Ms. Anuja Ajay Parikh

Non-Executive

Director

20/301, Gurukrupa,

Vithal Nagar Society,

11th Road, JVPD


Mumbai-400049.

Phone No. - 022—

61539999

6

Mr. Hargovind Rathore

Non-Executive

Director,

Independent

Director

7 Mr. Ling Wei Ong Non-Executive

Director

2.3 NATURE OF PROJECT

It is Expansion Project.

2.4 MARKET FEASIBILITY

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

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

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

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

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

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

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



Page 12

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

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

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

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

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

Our quality system is based on ICH Q7 GMP requirements.

Our quality consciousness shall be recognized through achieving excellent implementation level

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

2.5 EMPLOYMENT GENERATION DUE TO THE PROJECT

The details are given below

TABLE: 4

DETAILS OF MANPOWER

Sr.

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

1 During construction Contractual 150

2 During

commissioning Contractual

NA (existing

manpower shall be

used)

3 During operations

Managerial 210

Skilled 50

Un-skilled 140

Total: 400

3.0 PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

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

3.2 PROJECT LOCATION

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

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

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



Page 13

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

location map shown in Figure -2.

The salient features of the location of the project site are presented in below Table.5.

TABLE: 5

SALIENT FEATURES OFTHE PROJECT SITE

Particulars Details

Village Ankleshwar

Taluka/ Tehsil Ankleshwar

District Bharuch

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

Longitude: 73o 01’ 58” E

Nearest City Bharuch about 20 KM

Nearest Town Ankleshwar

Nearest Highway National Highway No. 8

Nearest State highway National Highway No. 8

Nearest Railway line/ Railway

station

Ankleshwar Railway Station

Nearest Airport/ Airbase Vadodara about 94 KM



Page 14

FIGURE: 1

LOCATION OF THE PROJECT SITE

Ankleshwar Industrial area

Panoli Industrial area

Jhagadia industrial area

Priaman CETP

Canal

Piraman to Katiyajal Effluent

Pipe

Jhagadia to Piraman CETP

Panoli to Piraman CETP

PROJECT SITE



Page 15

FIGURE: 2

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



Page 16

3.3 SITE SELECTION

The expansion will be done at existing unit. Unit has not consider any alternative site.

3.4 NEIGHBOURING INDUSTRIES

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

of the proposed project are given in the table 5:

TABLE: 5

NEARBY INDUSTRIES IN THE VICINITY

Name of Industry Direction with respect

to project site

Address

United Phosphorus

Limited (Unit- 2)

East side of company Plot No. 3405/3406, GIDC Industrial

Estate,Ankleshwar-393002

Glenmark

Pharmaceutical

Ltd.

North side of company Plot No. 3109/C, GIDC Industrial Estate,

Ankleshwar-393002

RPG Life Sciences

Limited.

South side of company Plot No. 3102/A, GIDC Industrial Estate,

Ankleshwar-393002

United Phosphorus

Limited (Unit- 3)

West side of company Plot No. 3101/2, Ankleshwar GIDC,

Ankleshwar - 393002

3.5 SIZE OF PROJECT

The expected cost of proposed project is Rs. 40 Crore.

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



Page 17

TABLE:6

CAPITAL COST OF PROJECT

Sr.

No.

Activities Capital cost in

Rs. Crore (Approx)

1. Land Existing land

2. Building 12

3. Plant and Machinery 21.69

4. Q.A. Lab set up ---

5. Env. Protection & Safety

a) Effluent treatment Plant

5.0 b) Air pollution control & Hazardous waste

management

c) Safety Equipment (PPE, fire extinguishers,

Ventilation, etc.)

1.0

d) Green belt development 0.31

Total 40

3.6 PROCESS TECHNOLOGY

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

Annexure-VI of Form-I.

3.7 RAW-MATERIALS

The required raw materials will be purchased from the local/ Indian market& foreign market.

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

3.8 RESOURCE OPTIMIZATION/RECYCLING AND REUSE

3.8.1 SOLVENT RECOVERY

Unit will follow solvent guideline & will recover more than 96% solvent.



Page 18

3.9 RESOURCE REQUIREMENTS

3.9.1 LAND

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

the unit is 35595 sq. m.

3.9.2 BUILDING

The new building will be constructed. The approximate requirement or construction materials are

given below table. Details are provided in plant lay out.

TABLE 6

APPROXIMATE REQUIREMENT OF CONSTRUCTION MATERIALS

Material Qty. Source

Bricks 2.09 Lacs no. From local

supply

Cement 12372 Bags

Sand 307 Brass.

TMT Steel 145 MT

Kapchi 383 Brass.

3.9.3 POWER AND FUEL

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

fuel consumption.

TABLE: 7

POWER AND FUEL REQUIREMENT

Sr.

No.

Particulars Existing as per

Consent Quantity

Proposed

Quantity

Total Quantity Source

1.

Natural Gas for

Boiler & Thermic

Fluid Heater

290 M3/Hrs NO CHANGE 290 M3/Hrs. Gujarat Gas

2. Diesel For DG

Sets 117 Lit./Day NO CHANGE 117 Lit./Day

Local

Supplier

3. Energy-Electricity 1900 KVA NO CHANGE 1900 KVA DGVCL



Page 19

3.9.4 WATER

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

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

consumption.

TABLE:8

DETAILS OF WATER CONSUMPTION

Particulars

Existing water

consumption

(KL/Day)

Proposed

consumption

(KL/Day)

After expansion

consumption

(KL/Day)

i) Domestic +

Others (gardening

etc)

21.2 0 21.2

Process 25 15 40

Boiler 12 40.5 52.5

Cooling 64.8 119.5 184.3

Washing 42 26 68

Total 165 201 366

3.9.5 MANPOWER

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

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

3.10 MITIGATION MEASURES & EMP

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

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

3.10.1 WASTEWATER MANAGEMENT

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



Page 20

TABLE:9

DETAILS OF WASTEWATER GENERATION

Particulars Existing Wastewater

generation (KL/Day)

Proposed

Wastewater

generation (KL /Day)

After Expansion

Wastewater generation

(KL /Day)

i) Domestic+

Others

(gardening etc)

10 0 10

i) Industrial

Process 14 16 30

Boiler 4 0 3

Cooling 3 0 4

Washing 24 44 68

RO reject 0 25 25

Total 55 85 140

3.10.1.2 WASTEWATER CHARACTERISTICS

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

characteristics of industrial wastewater are provided in Table 10.

TABLE: 10

WASTE WATER CHARACTERISTICS

Sr.

No. Parameters Units

Standards

prescribed

by GPCB

Standards

prescribed

by NCTL

Before

Treatment

After

Treatment

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

2 Colour Pt Co 100 -- 400-1000 50-70

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

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

35000 1000-2300

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

detected

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

detected

7 Cyanides mg/l 0.2 -- Not

detected

Not

detected

8 Ammonical Nitrogen mg/l 50 100 600-800 30-75

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

10 B.O.D.(3 days at 27°C) mg/l 30 -- 5000-

10000 55-70



Page 21

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

35000 50- 350

3.10.1.3 WASTEWATER TREATMENT & DISPOSAL

EFFLUENT TREATMENT SCHEME

HIGH STRENGTH EFFLUENT STREAM:

Following measures shall be adopted to reduce the strength of waste water —

� PRE-TREATMENT

The effluents from various plants will be collected in individual sumps/tanks and will be

equalized in Collection Tank. They will be neutralized in Neutralization tank by using acid or

alkali as per requirement till required pH range obtained. This neutralized effluent will be filtered

through Filter Press. This will be passed through clarifier after pH increase by alkali and

Settleable solids will be separated out. The supernatant will be neutralized using acid and fed to

stripper.

� TREATMENT

The filtered effluent will be fed to Solvent Stripper for Recovery of solvents. This stream

afterwards shall be subjected to Multiple Effect Evaporator (MEE) (Under Vacuum

Evaporation). Condensate shall be transferred in O & G Chamber for further treatment at ETP.

The concentrated stream (recycle) will be transferred to Agitated Thin Film Dryer (ATFD) for

drying salts and bagging. This will be stored in hazardous Waste Storage Yard and disposed of

for landfilling to TSDF’s as per requirement.

LEAN STRENGTH STREAM EFFLUENT:

The lean effluents will comprise of utility blowdown, MEE condensate, Reject water, etc. They

shall be mixed with other streams and the combined effluent shall be subjected to following

treatment cycle.

� PRIMARY TREATMENT

1. Screen, Oil and solvent trap: - This will ensure removal of free and floating material, oily

material and solvents. These are to be removed manually. The oil and solvent trap unit operation

shall work on gravity separation principle.

2. Equalization cum Neutralization tank: - The effluent after removal of screenings, oily matter /

solvents shall be collected in equalization cum neutralization tank. Suitable mixing device (flash



Page 22

mixer) shall be used to mix the contents of the tank. Acid and alkali shall be used as per the

incoming effluent pH. A pH of 7 to 8 shall be maintained here.

3. Tube Settler: - This will be used to remove the Settleable solids from the effluent by

sedimentation process and the effluent will be further transferred to Anoxic tank.

� SECONDARY TREATMENT

Biological Treatment: The biological treatment consist of an Anoxic tank to remove excess

Ammonical nitrogen from effluents. It will be followed by Aerobic process. There are two

aeration tanks with diffused aeration system. The oxygen supply shall be done by use of air

blower and air bubble diffusers. Suitable levels of mixed liquor suspended solids (MLSS) shall

be maintained in the aeration system as per detailed biological process design. The excess

biological sludge shall be discharged over to the sludge handling system via two clarifiers

connected with each aeration tank.

� TERTIARY TREATMENT

Partial Quantity of treated effluent after biological treatment shall be collected and transferred to

Treated Effluent Collection Tank for disposal to FETP. This will be pumped in overground

pressurized pipelines to GIDC pumping stations. Rest of the treated effluent shall pass through

Activated carbon filter, Multi Grade Sand filter. This effluent will be fed to UF and RO plants.

The reject will be added to MEE feed and permeate will be recycled back to Cooling Towers,

Scrubbers, water ejectors, etc. for further reuse.

� SALT/SLUDGE TREATMENT

Salt/Sludge handling system: The system shall consist of VTFD, filter press and decanter

centrifuge. The salt/sludge shall be dewatered/dried and salts/sludge cake shall be bagged. They

shall be stored in Hazardous Waste Storage Yard and disposed of to TSDF’s as per requirement.

� HAZARDOUS WASTE TREATMENT

The Hazardous waste generated from various plant processes will be collected, segregated and

stored at Hazardous Waste Storage Yard. They will be disposed to TSDF’s, Registered

Recyclers, Refiners, Co-processing Units, etc. complying all legal requirements.

MEE OPERATION PROCEDURE

Effluent Feeding:

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

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



Page 23

Pre Heaters

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

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

pumping under vacuum.

Main Steam application

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

4.0 Kg/Cm2.

Solvent stripper Unit

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

side glass) through adjustment of valve of Reboiler & recycle valve. Open Low pressure steam

valve gradually for solvent stripper column/re-boiler and maintain Temp around 85 oC. When

desired temp. attained in stripper column/Reboiler start condensate pump and transfer low boiler

vapor condensate via surface condensers to Stripper condensate collection tanks. The residual

high boiler effluent will be transferred to Calendria 1.

Calendria’s

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

necessary level is maintained in calendria’s. During level maintenance apply steam gradually and

maintain upto 8.0 Kg/cm2.

Condensate Pump

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

via MEE surface condensor (primary and secondary) is recirculated back in balance tank till

colour of the condensate is clear, colourless & free from any suspended solids. Then transfer this

condensate water in MEE O/L collection tank via MEE condensate pump.



Page 24

Recycle Pump

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

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

VTFD Unit

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

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

VTFD feed pump. Simultaneously open high pressure steam valve for VTFD and Maintain

steam pressure 8.0 – 8.5 Kg/cm2 gradually.

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

bottom end. Start Condensate pump and transfer condensate received from VTFD surface

condensor to E.T.P.

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

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



Page 25

TABLE: 11

DEMENTIONAL DETAILS OF ETP UNITS

DIMENSIONAL DETAILS OF ETP UNITS

Sr.

No. Name of Equipment Capacity

Retention

time in Hrs. MOC

1 Collection Tank 66 KL 26.4 RCC

2 Neutralization Tank 41 KL 16.4 RCC

3 Filter Press 10 M3/hr - MS

4 Filter Press Tank 05 KL

RCC

5 MEE Plant - Old 40 M3/Day - SS

6 MEE Plant - New 80 M3/Day SS

7 Stripper I/L Clarifier 26 KL RCC

8 O & G Chamber 1.70 KL RCC

9 Neutralization Tank 3 KL RCC

10 MEE O/L Collection Tank (New Eq.

Tank)

61 KL 14.4 RCC

11 Tube Settler 27 KL 0.17 RCC

12 Anoxic Tank 19 KL RCC

13 Aeration tank-1 463 KL 84 RCC

14 Primary Clarifier 26 KL RCC

15 Aeration Tank-2 409 KL RCC

16 Secondary Clarifier 26 KL RCC

17 New Final Treated Effluent Tank 10 KL RCC

18 Activated Carbon Filter (ACF) FRP *** *** FRP

19 Multi Grade Filter (MGF) FRP *** *** FRP

20 Ultrafiltration Plant (UF) (PVDF) 100 M3/Day SS

21 UF Permeate Tank 5 KL HDPE

22 Reverse Osmosis Plant (RO) 100 M3/Day SS

23 RO Permeate Tank 5 KL HDPE

24 Secondary O/L Collection tank 40 KL RCC

25 Holding Tank 12 KL 2.4 MS

26 Treated Effluent Tank 165 KL 72 RCC

27 MEE Cooling Tower - Old 70 TR RCC

28 MEE Cooling Tower - New 400 TR RCC

29 VTFD – Old 160 Kg/Hr. SS

30 VTFD - New 215 Kg/Hr. SS

31 Decanter Centrifuge 2 M3/Hr. SS

32 Decanter Feed tank 2 KL RCC



Page 26

FIGURE:3

FLOW DIAGRAM OF ETP

Dosing System

Stripper Condensate to Incineration / MEE C.T

MEE Condensate to New Eq. Tank (L.COD)

MEE Concentrate to VTFD / Storage Tanks

VTFD Salt to TSDF after bagaging

EFFLUENT TREATMENT SCHEME - ZCL CHEMICALS LIMITED

By gravity from

QC and R & D

and from U-3 & U-

1 sump via

pumping

LCOD effluent

from U-4

U-4 H.COD &

L.COD Sumps via

pumping

Sewage Effluent

From U-3 & U-1

sump via

pumping

REJECT

EFFLUENT

TO MEE

PERMEATE TO

REUSE IN C.T.'S,

UTILITIES

U-2 (NPC) sumps

via pumping

Low COD

Effluent from

Utilities

To Final

Discharge

Tank

(165 KL)

U-2 (NPC)

Sumps via

pumping

Sludge to

TSDF

To NCT (FETP)To Deep Sea

Decanter Feed

Tank

Sludge after

bagaging to

TSDF

Decanter

Centrate to

Low or High

COD Eq. Tank

To GIDC

Pumping

Station-B

Collection Tank(66 kl)

U-3 + U-1 effluent

tank T-03(10 kl)

Unit-2 effluent

tank T-02(10 kl)

Unit-2 effluent

tank T-01(10 kl)

Neutralization Tank(41 kl)

MEE PLANT with solvent stripper &

ATFD(80 KL/Day)

MEE PLANT with solvent stripper &

VTFD

Low COD Equalisation Tank

Neutralization Tank

with flash mixer

O & G Chamber

Aeration tank-1 (463 KL)

Anoxic Tank

(19 KL)

Settler(27 KL)

Primary Clarifier(26 KL)

Aeration tank-2 (409 KL)

Secondary Clarifier

Treated Effluent

Collection Tank

M

G

F

A

C

F

UF & RO Unit

Decanter

Centrifuge

QC + Unit-1 +

R & D + effluent

tank T-07(10 kl)



Page 27

FIGURE :4

FLOW DIAGRAM OF MEE



Page 28

3.10.2 GASEOUS EMISSIONS & CONTROL

3.10.2.1 FLUE GAS EMISSION

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

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

measures are covered in below table 12.

TABLE:12

DETAILS OF FLUE GAS EMISSIONS

Sr.

No.

Stack

Attached

To

Stack

Heigh

t

Stack

Diameter

Fuel

Consumption

Air

Pollution

Control

System

Type

of

Emission

Permissible

Limit

Existing Flue gas Emission As per CCA

1. Boiler

3TPH 30 m

0.45m

(Top) Natural gas --

PM

SO2

NOx

150

mg/NM3

100 PPM

50 PPM

2. Thermic

fluid heater 22 m

0.5m


3. DG Set-1

(250 KVA) 7 0.15m Diesel --

4. DG Set-2

(750 KVA) 8 0.2m Diesel --

After Expansion Flue gas Emission

1.

Boiler*

5TPH

(Stand By) 30 m

0.45m

(Top)

Natural gas --

PM

SO2

NOx

150

mg/NM3

100 PPM

50 PPM

2. Boiler

3TPH Natural gas --

3. Thermic

fluid heater 22 m

0.5m


4. DG Set-1

(250 KVA) 7 0.15m Diesel --

5. DG Set-2

(750 KVA) 8 0.2m Diesel --

6. DG Set-3*

(1010 KVA) 30 M 0.2 m Diesel --

* Boiler (5TPH)(Stand By) and DG Set-3 (1010 KVA) applied for CTE. The application

No. is 118851 in XGN



Page 29

3.10.2.2 PROCESS EMISSIONS

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

TABLE:13

DETAILS OF PROCESS EMISSIONS

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

3.10.3 HAZARDOUSWASTE MANAGEMENT

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

waste will be stored separately in a designated storage area.

Sr.

No.

Stack

Attached

To

Stack

Height

(m)

Stack

Diameter

(m)

Air Pollution

Control System

Type of

Emission

Permissible

Limit

As per Existing

1. Reactor Vessel

Plant - 4

25 0.15 Water Scrubber +

Caustic Scrubber

HCl

SO2

CL2

20 mg/Nm3

40 mg/Nm3

9 mg/Nm3

2. Reactor

Vessel Plant -

2

21 0.15 Water Scrubber +

Caustic Scrubber

HCl

CL2

NH3

20 mg/Nm3

9 mg/Nm3

175 mg/Nm3



Page 30

TABLE:14

DETAILS OF HAZARDOUS WASTE GENERATION

Sr.

No.

Processes as per

Schedule-1

Name of Waste

as per

Schedule-1

Type of waste Cat.

Quantity for Financial

Year

Method of disposal Existing

quantity

in

MT/Year

After

Expansion

Quantity in

MT/Year

1 Purification and

treatment of exhaust

air/gases, water and

waste water from the

processes in this

schedule and

common industrial

effluent treatment

plants (CETP’s)

Chemical sludge

from waste water

treatment

ETP Sludge 35.3 339 550 Collection, storage within

factory premises, transportation

and final disposal at TSDF

M/s.BEIL, RSPL,SEPPL

2 Purification process

for organic

compounds /solvents

Spent carbon or

filter medium

Carbon Waste 36.2 18.25 50 Collection, storage within


and incineration /Co-

processing at TSDF M/s.

BEIL, RSPL & Ambuja

Cements/ other cement plants

3 Production and/or

industrial use of

solvents

Distillation

residues

Distillation

residue

20.3 36.5 105 Collection, storage within


and landfill/incineration/co-


BEIL, RSPL & Ambuja

Cements/other cement plants



Page 31

Sr.

No.

Processes as per

Schedule-1

Name of Waste

as per

Schedule-1

Type of waste Cat.


Year


quantity

in

MT/Year

After

Expansion

Quantity in

MT/Year

4 Handling of

hazardous chemicals

and wastes

Empty barrels/

containers/liners

contaminated

with hazardous

chemicals/wastes

Discarded

containers/liners

33.1 350.04 350.04 Collection, storage with in


and sell to authorize agencies.

5 Hazardous waste

treatment processes,

e.g. pre-processing,

incineration and

concentration

Concentration or

evaporation

residues

Distillation

residue from

contaminated

organic solvents

37.3 0.73 7 Collection, storage within


and landfill/incineration/co-


BEIL, RSPL & Ambuja

Cements/other cement plants

for Co -processing.

6 Industrial operations

using mineral or

synthetic oil as

lubricant in

hydraulic systems or

other applications

Used or spent oil Used / Waste Oil 5.1 1.83 10 Collection, storage, treatment

within factory premises,

transportation and sell to

registered refiners

7 Production and/or

industrial use of

solvents

Contaminated

aromatic,

aliphatic or

napthenic

solvents may or

may not be fit

for reuse.

Contaminated

solvents not fit

for originally

intended use

20.1 2000 2000 Collection, storage, recovery

and reuse within premise at

site. Disposal at TSDF/

Incinerator.



Page 32

Sr.

No.

Processes as per

Schedule-1

Name of Waste

as per

Schedule-1

Type of waste Cat.


Year


quantity

in

MT/Year

After

Expansion

Quantity in

MT/Year

8

Spent solvents Spent solvent 20.2 73 73 Collection, storage, recovery

and reuse within premise at

site. Disposal at TSDF/ Co-

processing / Incinerator.

9 Spent solvents Spent solvents 20.2 540 540 Collection of High COD waste

from MEE Stripper Column,

storage, recovery, reuse within

premise at site and disposal at

TSDF/ Incinerator./ co-

processing

10 Industrial operations

using mineral or

synthetic oil as

lubricant in

hydraulic systems or

other applications

Wastes or

residues

containing oil

Wastes or

residues

containing oil

5.2 NA 0.5 Collection, storage,

transportation and sell to

registered refiners &/or

incineration at TSDF M/s.

BEIL, RSPL

11 Production /

formulation of drugs/

pharmaceutical and

health care product

Off specification

products

Off specification

products

28.4 NA 5 Collection, storage within


and incineration at TSDF M/s.

BEIL, RSPL & Ambuja

Cements for Co -processing.



Page 33

Sr.

No.

Processes as per

Schedule-1

Name of Waste

as per

Schedule-1

Type of waste Cat.


Year


quantity

in

MT/Year

After

Expansion

Quantity in

MT/Year

12 Date-expired

products

Date-expired

products

28.5 NA 5 Collection, storage within


and incineration at TSDF M/s.

BEIL, RSPL & Ambuja

Cements for Co -processing.



Page 34

3.10.4 NOISE CONTROL & ODOUR

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

acoustic enclosure will be provided around it.

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

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

pollution.

The following steps will be taken for odor control.

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

• All reactions will be taken in closed reactor system.

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

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

3.10.5 STORAGE, HANDLING AND TRANSPORT OF HAZARDOUS

CHEMICALS

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

hazards guide for the hazardous chemicals.

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

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

3.10.6 HEALTH AND SAFETY MEASURES

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

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

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

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

MSIHC Rules.

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

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

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

controlling the emergency.



Page 35

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

and environments.

• Hazards in storage area :

Following are possible storage hazards

� Fire

� Explosion

� Spillage / leakage

� Failure of storage tanks

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

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

with toxic materials.

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

according to their compatibility with other chemicals. The various places

where chemicals, solvents are stored are :

- Licensed tank farm area

- Raw material store

- Cold Room

- WIP room

- Bonded store

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

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

Controller of Explosives after due inspection.

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

1.1 times higher than biggest tank.

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

electricity due to flowing of solvent in the pipeline by accumulating

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

adequate number of static jumpers on each flange joints with proper

earthing.

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



Page 36

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

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

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

Company has implemented “No Smoking Policy” and at appropriate

places, boards are displayed.

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

is provided with adequate firefighting equipment also.

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

the tankers at the time of unloading.

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

liquid.

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

entering inside the factory premises.

� The raw water tanks with capacity 250 M3.

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

tank farm area.

� The employees are trained in first aid fire fighting.

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

employees are trained for the same.

� Spillage kit is provided to contain spillage / leakage.

• Fire and explosion

� The fire and explosion risk are associated with

- Solvents like Methanol, Toluene, Acetone, etc.

- Chemicals like phosphorous pentoxide, etc.

- certain chemical reaction like hydrogenation, Grignard, distillation,

� Electrical short circuit

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

to factory area.



Page 37

� The gas dispersion is Nil.

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

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

farm.

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

several places in plant and factory premises.

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

reduced fire risk.

� Vapor detector system are installed in the warehouse

• Spillage control

� SOP for prevention and control of spillage

- Eliminate all sources of ignition immediately.

- Ventilate the area but isolate the material.

- Absorb the chemical into sand.

- Allow atmospheric evaporation.

- Flush the spilled area with water and detergent.

� Spillage kit for spill control.

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

being checked regularly.

� Training for spillage control and handling to all employees.

� Fumes and cylinder leakage kit are available.

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

protective equipments.

� The duties of responsible persons are as follows :

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

- To ensure good housekeeping.

• Technological and civil

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

the use of hazardous chemicals, following steps are taken.



Page 38

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

specification laid down in appropriate specification of international and

national bodies in the subject.

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

indicators, safety valves, etc.

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

are provided.

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

health of plant, equipment and machinery.

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

Form 11 as per Factories Act.

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

tested for its quality and suitability under guidance of experts approved

under Government notification.

� The structure is being inspected by Government approved competent

person periodically and stability certificate is maintained.

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

regularly.

• Toxic release risk

The potential risk involved is leakage from tanks and pipelines.

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

leakage control kit is available.

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

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

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

Evacuation table is displayed at gate.

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

employees.



Page 39

4.0 SITE ANALYSIS

4.1 CONNECTIVITY

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

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

transport via road connectivity.

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

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

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

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

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

in this industrial estate.

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

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

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

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

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

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

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

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

other bridge on the highway is now ready to use.

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

section).

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

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

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

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

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

Ankleshwar GIDC.



Page 40

Healthcare

Hospitals include are the

• Jayaben Modi Hospital,

• Sarvajanik Hospital,

• Sanjivani Hospital

• Sardar Patel Hospital.

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

Construction.

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

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

Shopping and Recreation:

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

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

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

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

Bhandari, Garib nawaz, etc.

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

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

Classes.

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

Water Reservoir, and sports center.

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

recreation centers in the GIDC area.

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

Ankleshwar.

4.2 LAND USE AND LAND OWNERSHIP

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

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

geographical location is 21o 37’ 36” N latitude and longitude 73o1’ 58” E.



Page 41

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

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

4.3 LAND USE

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

notified by GIDC for industrial purpose.

4.4 EXISTING INFRASTRUCTURE

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

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

power to industries, effluent disposal facilities etc.

4.5 SOIL CLASSIFICATION

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

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

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

4.6 CLIMATE DATA

Based on the meteorological data, wind rose have been prepared for the summer season period

between the Oct-2016 to Dec-2016. The wind rose diagram prepared from same data is shown

at Figure 6.

TABLE: 14

METEOROLOGICAL DATA

Month -- Temp. (°C) Relative

Humidity (%)

Rain Fall

mm

October-16 Min. 23 28 0

Max. 35 94 13

Average 29 61 6.5

November-16 Min. 20 24 0

Max. 34 51 10

Average 27 37.5 5

December-16 Min. 17 23 0

Max. 32 52 11

Average 24.5 37.5 5.5



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FIGURE:6

WIND ROSE DIAGRAM FOR PERIOD OF OCTOBER-2016 to DECEMBER-2016

Observation: It was observed that wind is blowing mainly towards the SW direction from NE.

average wind speed was 2.38 m/s with calm winds recorded to be 10.6%.

4.7 SOCIAL INFRASTRUCTURE

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

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

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

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

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

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

5.0 PLANNING BRIEF



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5.1 PLANNING CONCEPT

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

plants& Pharmaceutical plants.

Unit is planning for expansion at existing plot.

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

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

water supply, power and road network.

5.2 POPULATION PROJECTION

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

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

city is 920 females per 1000 males.

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

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

5.3 LAND USE PLANNING

The proposed project is on a GIDC land.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND

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

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

water resources available in the nearby area.

5.5 AMENITIES/FACILITIES

The available basic amenities are as under:

(A) Education Facilities:

All the villages have a minimum of one primary school.

(B) Medical Facilities:

All the surrounding villages have medical facilities.

(C) Drinking water Facilities & Power Supply:



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

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

in the study region.

(D) Post, Telegraph & Telephone facilities

The information collected clearly indicates that the infrastructural facilities are provided

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

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

(E) Transport Facilities:

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

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

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

covered with 108 emergency facilities.

6.0 PROPOSED INFRASTRUCTURE

6.1 PROCESSING AREA

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

covered by the unit at ground level will be 9510.00 square meter.

6.2 NON PROCESSING AREA

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

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

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

open area near H2 plant, BHP Gully and all roads and passages, contractor sheds, Parking area

etc. The non process area covered by unit at ground level will be around 26085 square meter.

6.3 GREEN BELT

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

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

6.4 SOCIAL INFRASTRUCTURE



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The availability of basic amenities is covered as under:

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

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

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

activities.

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

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

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

purified water for drinking purpose.

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

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

(F) Power supply: There will be total connected load of 1900 KVA from DGVCL.

6.5 CONNECTIVITY

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

6.6 DRINKING WATER MANAGEMENT

Average daily water consumption of unit will be 10 KL/Day for domestic purpose. The entire

water requirement will be meeting through GIDC water supply system.

6.7 SEWAGE SYSTEM

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

6.8 INDUSTRIAL WASTE MANAGEMENT

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

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

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

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



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

Annexure-XI in Form-I.

6.9 SOLID WASTE MANAGEMENT

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

Equipments, etc

6.10 POWER REQUIREMENT & SUPPLY

The unit will use total 1900 KVA electricity connected load from DGVCL.

7.0 REHABILITATION AND RESETTLEMENT(R &R) PLAN

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

Gujarat-393002. There will be no any human settlement affected by proposed project.

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 PROJECT IMPLEMENTATION SCHEDULE

TABLE: 16

PROJECT IMPLEMENTATION SCHEDULE

Project implementation schedule

Sr.

No.

Activity Required Period

1. Civil work 10 months

2. Procurement of machinery

3. Erection & installation of machinery after 4 months of completion of building

4. Trial of machinery & equipment within 1 month of above activity

5. Commercial activity within 1 month of above activity

8.2 ESTIMATED PROJECT COST

The proposed project cost will be 40 Crore. Cost bifurcation is given in table 6.

9.0 ANALYSIS OF PROPOSAL

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

provide indirect employment opportunities by availing local contract services during

transportation during operational phase.

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

M/s. ZCL CHEMICALS LTD., ANKLESHWARenvironmentclearance.nic.in/writereaddata/Online/TOR/10_May_2017... · ZCL CHEMICALS LTD., ANKLESHWAR M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT.

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