M/S. UNIQ UE C HEMICALS (A di v of J B CH EM IC ALS & PH ARMACEUTICALS LTD) PANO LI Page no. 1 PROJECT PRE-FEASIBILITY REPORT ON PROPOSED PROJECT FOR EXISTING & EXPANSION PROJECT FOR BULK DRUGS & INTERMEDIATES MANUFACTURING FACILITY OF M/S. UNIQUE CHEMICALS (A Div of J B CHEMICALS & PHARMA LTD) PLOT NO 5, PHASE-IV, GIDC, PANOLI -394116, DISTRICT – BHARUCH, GUJARAT
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M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 1
PROJECT PRE-FEASIBILITY REPORT
ON
PROPOSED PROJECT
FOR
EXISTING & EXPANSION PROJECT
FOR BULK DRUGS & INTERMEDIATES MANUFACTURING FACILITY
OF
M/S. UNIQUE CHEMICALS (A Div of J B CHEMICALS & PHARMA LTD)
PLOT NO 5, PHASE-IV, GIDC, PANOLI -394116, DISTRICT – BHARUCH,
GUJARAT
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 2
CONTENTS
Sr. No.
Particulars Page No.
1 SUMMARY 5 2 INTRODUC TIO N 5 2.1 The Project 9 2.2 Project Proponent 14 2.3 Nature of project 14 2.4 Market Feasibility 15 2.5 Demand Supp ly Gap 15 2.6 Employment Generation Due To The Project 15 3 PROJEC T DESCRIPTION 15 3.1 Type of Project 16 3.2 Project Location 16 3.3 Site selection 16 3.4 Size of project 17 3.5 Process Technology 17 3.6 Rawm aterial 17 3.7 Resource optimization/recycling reuse 17 3.7.1 Solvent recovery 18 3.8 Resource requirment 18 3.8.1 Land 18 3.8.2 Building 18 3.8.3 Power & Fuel 18 3.8.4 Water 19 3.8.5 Man power 19 3.9 Mitigation measures & EMP 19 3.9.1 Waste water Management 20 3.9.1.1 Wastewater Management 21 3.9.1.2 Wastewater Characteristics 24 3.9.1.3 Wastewater Treatment & Disposal 25 3.9.2 Gaseous emission & Control 29 3.9.2.1 Flue Gas Emissions 29 3.9.2.2 Process Emissions 30 3.9.3 Hazardous /non hazardous waste managment 30 3.9.4 Noise control& odour 32 3.9.5 Storage ,handling and transport of Hazardous
chemical 32
3.9.6 Health & Safety measures 33 3.10 Statutory permits 35 4 SITE ANALYSIS 35 4.1 Connectivity 35 4.2 Land use and land ownership 35 4.3 Topography 35 4.4 Existing landuse 36
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 3
Sr. No.
Particulars Page No.
4.5 Existing infrastructure 36 4.6 Climate data 36 5 PLANNING BRIEF 38 5.1 Planning concept 38 5.2 Land use planning 38 5.3 Assessment of infrastructure Demand 39 5.4 Ammentities 39 6 PROPOSED INFRASTRUC TURE 39 6.1 Processing area 39 6.2 Non processing area 39 6.3 Green belt area 39 6.4 Social Infrastructure 39 6.5 Connectivity 40 6.6 Drinking water management 40 6.7 Sewerage system 40 6.8 Industrial waste management 40 6.9 Solid waste management 40 6.10 Power requirment & Supply 41 7 REHABILITATION & RESETTLEMENT (R &
R) PLAN 41
8 PROJEC T SCHEDULE & CO ST ES TIMATES 41 8.1 Project Implementation Schedule 41 8.2 Estimated project cost 42 9 ANALYSIS OF PROPOSAL 42
LIS T O F TAB LES
Table No.
Topic Page No.
1.1 List of probable Products ( Existing + proposed) 6 1.2 List of Hazardous Waste Generation & Disposal 8 2.1 List of Directors 12-13 2.2 Manpower Requirement 15 3.1 Salient Features of The Project Site 16 3.2 Water Requirement 19 3.3 Waste Water Generation 21 3.4 Waste Water Charctristics (Existing Scenario) 24 3.5 Waste Water Charctristics (Total Proposed
Scenario) 24
3.6 Name & Size of Each Unit of Effluent Treatment Plant
26
3.7 Details of Flue Gas Emissions 29 3.8 Details of Process Emissions 30 3.9 Detail of Hazardous Waste 31 3.10 Noise Level Measurment 32 3.11 Details of Storage of Hazardous Chemical 33 3.12 Details of area break up 38
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 4
LIST OF APPENDIX
Appendix No.
Topic Page No.
I Brief manufacturing process & Material balance for the product
43-198
II Raw material consumption 199-209 III Safety health & environment policy 210 IV Consolidated Consent & Authorization & amendment 211-224 V C C A compliance report 225-228 VI Factory License & Factory layout 229-230
LIST OF FIGURES
Sr. No.
Description Page No.
1. Location Of Project Site 9
2. Satelite Lmaginary Of Location 10
3. Site Plant 11
4. Water Balance Diagram For Existing Scenario 22
5. Water Balance Diagram For Proposed Scenario 23 6. Flow Diagram Of Effluent Treatmentplant (Existing Scenario) 25
7. Flow Diagram Of Effluent Treatment Plant (Total Proposed Scenario)
26
8. Wind Rose Diagram 35 9. Enviromental Management Cell 222
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 5
M/s. Unique Chemicals (A div of J B CHEMICALS & P HARM ACEUTICALS LTD.) at
products These are some of the by-product for the probable products as given in process descr iption. *This can change based on product manufact ured Investment:
v There is investment of Rs 45 Crore for the project.
Fuel: Unit uses natural gas as a fuel for bo iler & thermopac. Nat ural gas consumption will be 25000 SCM/Day. DG Sets are provided but stand by facility utilized in case of power failur Em ission:
v The stack emissions are from Boiler, Thermopac & DG Set.
v The process emissions are HCl gas generated from process reactors. HCL gas are carried
by HDPE p ipelines to alkali water double packed Tower, where HCl gas neutralize.
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 7
Power:
v The present connected electrical load is 2500 KVA. This will be sufficient for capacity
Enhancement. However if require additional power available from DGVCL.
Water:
v The existing fresh water consumption is 200 KL/Day. It is proposed for additional
Fresh Water Consumption will be 325 KL/Day. Total fresh water consumption
will be- 525 KL/Day. For existing scenario Fresh water consumption for industrial
v In the existing practice, the Industrial waste water generated is 99KL/Day.
Waste water is treated in primary, secondary & tertiary treatment plant. The waste
Water is further treated in R-O plant. The permeate water from R-O plant used in
Utility. The R-O rejection evaporated in evaporation system. Salt generated from
Evaporation system is packed & sends to TSDF -site. The Unit is ZERO LIQUID
DISCHARGE for Industrial waste water.
v Under total proposed scenario (existing + expansion) the Industrial waste water
Generation for the unit will be 400 KL/Day. Under total proposed scenario the
Total industrial waste water will be treated in waste water treatment plant.
The waste water will be further treated in reverse osmosis plant, where waste water
recovery will be performed. The permeate water from R-O p lant will be used in utility &
R-O rejection will be send for evaporation & So lid waste collected will be send to TSDF
site. The unit will continue to maintain ZERO LIQUID DISCHARGE for Industrial
waste water.
Ø Thus there is no change in Pollution load for Industrial Waste water as there is no
discharge of waste water from the unit.
Domestic waste water:
v Under present scenar io Domestic waste water generated is collected & treated
Through Soak p it & Septic tank.
v Under total proposed scenario ( Existing + Proposed) Domestic waste water
Generated will be connected & treated through Septic tank & Soak p it. The
Overflow from the Soak pit will be collected & treated by Soil Bio Technology
Plant(SBT). SBT technology is patented environment friendly green technology.
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 8
Hazardous waste: v Hazardous waste generation under existing & proposed scenario
TABLE-1.2
LIS T O F HAZARDO US WASTE GENERATION & DISPO SAL
S N
Type of Waste
Category of
Haz Waste
Existing Generation
Proposed Generation
Total Generation
Disposal
1. ETP sludge Category 34.3
120 MT/ Month
80 MT/ Month
200MT/ Month
Sent to common TSDF site BEIL Ankleshwar
A empty barrels & carboy
(R M)
Category 33.3
600 No/ Month
100No/ Month
700No/ Month
After decontamination Sell to Dealer hav ing PCB consent or send for refilling of same material
B Plastic liner
Category 33.3
1.8 MT/ Month
1.7 MT/ Month
3.5 MT/ Month
After decontamination Sell to Dealer hav ing PCB consent.
2.
C Glasswool, Thermocol
Category 33.3
25 kg/ Month
25 kg/ Month
50 kg/ Month
Sent to BEIL Ankleshwar
3. Used oil from DG set & compressor
Category 5.1
72 liter/ Month
28 liter/ Month
100 liter/ Month
Sold to authorize Recycler having PCB &
CPCB approval.
4. Distillation residue/ spent solvent
Category 25.2
5 MT/ Month
30 MT/ Month
35 MT/ Month
Incineration at common Incineration facility BEIL Or Co processing at Cement plant
5. Expired Drugs
Category 25.2
25 MT/ Month
10 MT/ Month
35 MT/ Month
Incineration at common Incineration facility BEIL Or Co processing at Cement plant
6. Used Charcoal
Category 28.2
2.5 MT/ Month
12.5 MT/ Month
15 MT/ Month
Incineration at common Incineration facility BEIL Or Co processing at Cement plant
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 9
2.1. INTRODUC TION OF TH E PRO JEC T M/s. Unique Chemicals (A div of J B CHEMICALS & P HARM ACEUTICALS LTD.) at
plot no.5, Phase IV, GIDC, Pano li-394116, District- Bharuch (Gujarat) India is engaged in
manufacturing of Bulk drugs and intermediates. It is proposed for Industrial pro ject (Bulk
drugs & Intermediates) for
v Existing project capacity -78.02 MT/month as well as
v Enhancement of existing product capacity & addition of new product s. Total
capacity (Existing + proposed) -290 MT/Month. v The unit is ZERO LIQUID DISCHARGE (ZLD) & will continue to reamian ZERO
LQUID DISCHARGE.
v Pollution load for Waste water discharge is ZERO & continue to maintain Pollution
load ZERO waste water discharge.
v The sole cr iteria of ZLD adopated by the Unit has been achieved by setting up
Reverse osmosis p lant & evaporation system.
v The plot area of the unit is 64233 sq. meter. Location map is attached as f igure 1 & 2.
FIGURE: 1
LOCATIO N OF PROJEC T SITE
Proje ct Site
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 10
FIGURE: 2
SATELITE IMAGINARY O F LOCATIO N
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 11
FIGURE: 3
SITE PLAN
UNIQUE C HEMICALS
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 12
TABLE 2.1
LIS T O F DIREC TORS
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 13
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 14
2.2 INTRO DUCTION O F PRO JEC T PROPO NENT v Unique chemicals is a Bulk drugs & intermediate manufact uring div ision of
J. B.CHEMICALS & PHARMACEUTICALS LTD., located in t wo states Gujarat
& Maharashtra as well as Union tertiary Silvasa.
v Core business of the group company is manufacturing pharmaceutical formulation,
Bulk drugs & intermediates & marketing across the globe.
v Unique chemicals, is the flagsh ip company, for manufacturing of bulk drugs &
Intermediates. Operations of unit commenced in 1995 at Panoli.
v Unique chemical is having various certification & accreditations from USFDA &
EDQM Certificate of suitability as well as WHO GMP.
v The plants & system are built in accordance with Local & International regulatory
Compliance.
v The focus of the company is towards regulated markets like USA, EUROPE, and
JAP AN etc. 95% of the products manufactured is exported & balances 5% for
Captive consumption, thus earn export revenue.
v The company’s manufacturing un it in GIDC Panoli known to be quite attentive
towards their environmental and social obligation to the society. The unit is also
known for its excellent track record in environmental performance, safety & health.
UNIQUE QUALITY PO LIC Y Quality establishes the faith in the brands of the company therefore it cannot be
compromised at any cost. Quality is the prime focus, as we inculcate the spirit of quality in
every employee at all levels. Our quality standards meet all international norms, as they are
supported by well-written SOP s, which are continuously updated.
It is our commitment to design and manufacture products that respect the people and
environment.
2.3 NATURE OF PROJEC T
The proposed pro ject is for existing capacity as well as products & capacity enhancement
for existing Bulk drugs, intermediates & new products. The various categories of the drugs
like, anti inflammatory, anti hypertension, radio diagnostic, anti bacterial, antifungal, anti
histaminic, antidiabatic, sedative, anti parkinson, anti depressant, anesthetic etc. are
manufactured.
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 15
2.4 NEED FO R THE PROJEC T The proposed expansion project is for ex isting anti inflammatory (NSID),radio diagnostic,
anti hypertension & cardiac, anti bacterial, antifungal, anti h istaminic, antidiabatic, sedative,
anti parkinson, anti depressant, anesthetic etc product requirement increases & introduction
of next generation new bulk drugs where efficacy is higher. Huge demand for generic drugs
from US & European market. During the year 2014, API industry growth is expected to
remain 21% & in terms of value to reach US $ 17 Billion. Average export of API remains
more than 50%.
2.5 DEMAND SUPPLY GAP Demand & supply gap is huge for the export market. Since existing products are generic in
nature. Inventors of generic products stop manufact uring & they prefer to import from
Indian market.
Demand for the anti inflammatory (NSID), radio diagnostic, anti hypertension & cardiac,
anti bacterial, antifungal & antidiabatic is increasing at the rate of almost 28-30 % during
last three years.
2.6 EMPLOYMENT G ENERATION DUE TO THE PROJEC T Due enhancement of existing product capacity & addition of new product, there will be increase in employment, for the technically qualified workforce.
Major employment force will be from in & around Local areas.
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 16
3.0 PROJEC T DESCRIPTION
Existing operating industrial project for Bulk drugs & intermediates, proposed for
v Existing project capacity -78.02 MT/month as well as
v Enhancement of existing product capacity & addition of new products.
Total capacity (Existing + proposed) -290 MT/Month.
The project falls under 5 (f) category of EIA notification 2006
3.2 PROJEC T LOC ATION The project is already located at block: p lot no 5, Phase-IV, Gujarat Industrial Development
Corporation, (GIDC) Panoli-394116, District –Bharuch, Gujarat. For proposed capacity
enhancement & addition of new product of the unit, no new land will be purchased. It will
be on Block: Plot no 5, Phase-IV, Gujarat Industrial Development Corporation, (GIDC)
Panoli-394116, District –Bharuch, Gujarat Notified Industrial area. Developed by Gujarat
Industrial Development Corporation.
The geograph ical positioning of the existing operational project site is at Latitude: 210 55’
North, Longitude: 730 00’ East.
TABLE: 3.1 SALIENT FEATURES OF THE PRO JEC T SITE Particulars Details Tehsil Panoli District Bharuch Approx. Geographical positioning
Latitude: 210 554446’ North Longitude: 730 000277’ East
Nearest city Panoli – 5.5 Km Nearest Highway National Highway No. -08 at a distance of 1 Km Nearest railway station Panoli at a distance 5 Km Nearest Air port Vadodara at a distance 75 Km Protected Areas/ Sanctuaries Nil within 25 Km radius The unit is in existance since year 1995-1996 3.3 CRITERIA FOR SITE SELEC TION
The proposed capacity enhancement & new product addition will be carried out in the
existing running site & plot only. Major infrastructure is already available on the site.
Located in a chemical industrial estate developed by GIDC and Government of Gujarat to
promote industrial activities in the region having all the necessary infrastructure facilities.
3.1 TYPE OF PROJECT
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 17
For the project site was selected as major common facilities required for industrial activity
like, landfill T SDF site, incineration facility, CETP, treated eff luent conveyance pipe line to
deep sea etc. are already developed in the surrounding cluster. (Unit is Zero Liquid
Discharge , treated effluent conveyance to deep sea will not be utilized).
Notified Industrial area is developed by Gujarat Industrial Development Corporation.
3.4 SIZE & MAGNITUDE OF OPERATION Medium scale of industrial operation. The existing production capacity is 78.02 MT/Month,
after enhancement, total capacity (Existing + proposed) will be 290 MT/Month
3.5 PROC ESS TECHNOLOGY Process & technology for all bulk drugs & intermediate manufact uring has been developed
indigenously by companies R & D Centre. The material balance & chemical formulas for
the probable products are attached as Appendix- I.
3.6 RAW-MATERIALS Raw materials are available locally. The list of raw material for the probable product is as
per attached Appendix-II
3.7 RESO URC E OPTIMIZATION/REC YC LING AND REUS E The major resources required for the project is land, plant equipments, raw materials, power,
fuel, water etc.
As a part of resource optimization & recovery of products /byproducts it is proposed for
several byproducts. Some of the By-products are already recovered & so ld to GP CB
approved vendor.The Bye-products recovered will be either recycled or so ld to end users.
As a part of resource optimization it is proposed to carry out waste water treatment &
recovery of water. To reuse recovered water in utility with reverse osmosis plant. Thus
Project is “Zero Liquid discharge” for Industrial waste water & No pollution load for
Industrial waste water discharge.
New equipments will be purchase like for
Utility: Ch illing plant, Cooling tower, electrical PCC; Air compressor, DG Set, Bo iler &
Thermopac etc.
Process: Reactors (MS Glasslined,S S 316, M S Rubberlined),RCVD/VTD( SS 316 ,MS
Glasslined); Driers , filters, Centrifuges, ANFD , Storage tank (S S & HDPE) , heat
exchangers ( S S 316 , Graph ite), receivers ( S S316; MS lined) etc..
Environment protection: Scrubbers, MEE plant, Decanters, Filter press, Direct coal/baggase
fired hot gas spray drier, Aerators etc.
Laboratory: Lab. equipments like HPLC & GC etc.
& other equipment for material transfer, loading & unloading etc. as per needs.
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 18
3.7.1 SOLVENT RECO VERY Recovery of so lvents is performed under closed system with maximum condensation &
traps, thus normal % recovery of the solvents ranges to more than 95%.
Some of the recovered solvents are reuse in the process for manufacturing at intermediates
stage. The so lvent recovered from finished product manu. are sold to end users. This is
because for the finished product impur ities levels are checked in PPB level & impurity
present in recovered solvents can affect the product quality.
3.8 RESO URC E REQUIREMENTS
The total water requirement for the existing and proposed scenar io will be met from local
authority GIDC notified area. The net fresh water requirement for total scanerio (ex isting +
proposed) after implementation of the proposal will be around 525 KL/Day, which is with
additional requirement of fresh 325 KL/Day. Power supply is from DGVCL. DGVCL is a corporation developed by government of
Gujarat for power supply & distribution management.
Being a developed area, facility like transport, road, rail & other infrastruct ure (hospital; fire
brigade etc) are easily available.
3.8.1 LAND The total plot area of the unit is 64233 sq. meter on which manufacturing activities is carried
out. The land is fairly plain terrain land and well-developed industrial estate. The proposed
project enhancement on same land. The altitude of area is about 19.2 meter above mean sea
level.
3.8.2 BUILDING New construction activities will be done for the proposed capacity enhancement & addition of new products. Construction activity will be done for the equipment for environment
protection measures.
3.8.3 POWER AND FUEL Power: Power supply is from DGVCL, developed by Government of Gujarat for power
supply & distribution management in the region. Electrical load is 2500 KVA, which will
take care of expansion of project. If require additional power will be available from
DGVCL. For emergency a standby power supply arrangement is provided through low noise
power generating sets.
Fuel: As a fuel environment friendly & clean fuel Natural Gas is used by unit. Nat ural gas is
supplied by Gujarat Gas Co. Ltd through network of pipeline & no storage is required to
keep at the unit. Natural gas consumption will be 25000 SCM/Day.
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 19
3.8.4 WATER
The total water requirement for the existing and proposed capacity enhancement of the unit
is met from local authority GIDC notified area. The net fresh water requirement for total
scanerio (existing + proposed) after implementation of the proposal will be around 525
KL/Day, which is with additional requirement of fresh 325 KL/Day.
TABLE: 3.2 WATER REQ UIREMENT
Proposed Water
Consum ption
Total scenario (existing+
proposed)Water
C onsum ption
Water
consum ption (All quantity
in KL/Day)
Existing
Water
Consumption
Total Fresh Recovered Total Fresh Recovered
Process 84 298 298 0 382 382 0
Washing *11 19 0 19 30 0 30
Garden ing 20 18 18 0 38 38 0
Cooling
Tower
45 + (Rec. 80) 135 0 135 260 45 215
Boiler 5 20 5 15 25 10 15
Domestic 35 15 15 0 50 50 0
Total Water
consum ption
200 +
(Rec. 80)
505 336 164 785 525 260
*Under total scenario for washing on ly rec. water will be used.
3.8.5 MANPOW ER The total manpower requirement skilled & unskilled is fulfilled locally from the vicinity.
Bharuch being district centre & no. of technical & management institutions are established;
technically qualified manpower is easily available.
3.9 MITIGATIO N MEASURES & EMP As a part of environment management system EMP plans are defined & mitigation measures
are under taken with compliance of statutory provision. The detail of mitigating action &
EMP plan is as under for waste water, Air emission control & hazardous waste, noise
pollution. Environment management cell as per figure- 6
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 20
3.9.1 WASTEW ATER MANAGEMENT Industrial waste water generated from manufact uring bulk drugs & intermediates is treated
in primary, secondary & tertiary treatment plant. Treated waste water further treated in R-O
Plant & evaporation system.
The existing scenario fresh water consumption is 200 KL/Day & Industrial waste water
generation is 99KL/Day. Domestic waste water will be -30 KL/day.
With total proposed scenario (Existing + proposed) the unit will be consuming additional
fresh water 325 KL/Day. The additional Industrial waste water generation will be 301
KL/Day. Domestic waste water generation will be – 35 KL/day. The break up of waste
water generation is given in Table 3.7. The water balance diagram for ex isting scenario is
given in Figure-4 & for total proposed scenario (Existing + proposed) is given in Figure-5.
In the existing scenar io, the Industrial waste water is treated in primary, secondary & tertiary
treatment plant. Treated effluent is than passed from Sand filter & Activated Carbon filter.
Company has set up R-O Plant for treatment of waste water with evaporation system.
The tertiary treated eff luent send to R-O Plant where waste water recovery is carried out.
The R-O Permeate is used back in the plant. The R-O rejection is evaporated in Evaporation
systems. The salt generated from the Evaporation system is send to TSDF site BEIL-
ANKLESHWAR. Thus unit is “ZERO LIQUID DISCHARGE” for Industrial waste water.
Domestic waste water is passed from Septic tank & Soak p it.
With total proposed scenario (Ex isting + proposed) unit will treat total Industrial waste
water 400 KL/Day in Waste water treatment plant, followed by treatment in R-O Plant.
Recovery of Waste water will be performed. Recovered water sends for use to Utility. R-O
Rejection will be evaporated in evaporation system. The salt generated from the evaporation
system will be packed & send to T SDF –site. Thus unit Pollution Load for waste water
discharge will be ZERO. Unit will continue to maintain “ZERO LIQUID DISCHARGE”
status for Industrial waste water. Pollution load for Industrial waste water discharge will be
continued to maintain ZERO.
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 21
Domestic waste will be passed from Septic tank & Soak pit. The overflow from the Soak pit
will be send to Soil Bio Technology (SBT) technology. SBT technology is a patented
technology from IIT – Mumbai & Green techno logy.
3.9.1.1 WASTEW ATER G ENERATION
TABLE: 3.3
WASTE W ATER GENERATION
Waste Water
Generation
Existing Waste
Water Generation
Proposed W aste
Water Generation
Total
(Existing + Proposed)
Waste W ater Generation
Industrial waste water
Process 82.5 277.5 360
Washing 10.5 9.5 20
Cooling Tower 3 2 5
Boiler 3 12 15
Total Industrial
waste water
99 301 400
Dom estic waste water : Domestic 30 5 35
Total Dom estic
waste water
30 5 35
All quantities are in KL/Day
M/S. UNIQUE C HEMICALS (A di v of J B CHEMIC ALS & PHARMACEUTICALS LTD) PANOLI
Page no. 22
FIGURE: 4 WATER BALANCE DIAGRAM FOR EXISTING SCENARIO
2, 00,000
5,000 45,000 35,000 20,000
PROCESS BOILER COOLING DOMESTIC AGRICULTURE
84,000
65,000
WASHING
ETP Plant
65,000 68,000
11,000
10,500 TO ETP 82,500
TO ETP 3,000
TO ETP 3,000
TO ETP 30,000
Loss 1500 Loss 2000 Loss 122000 Loss 5000
Loss 500
SOAK PIT & SEPTIC TANK Loss 6000
93,000
Reverse Osmosis Plant 33,000 R-O rejectio ns to Evaporation system R-O Permeate to utility
CON DEN ASTE
80,000
60000
20000
Solid was te (Salts) to TSDF site
Loss 6000
The I ndustria l waste wa ter trea te d in ETP pla nt. Treated waste wa ter is se nd to R-O Plant. R-O permeate water utilize in Utility. R-O Reje ction evaporate d in M EE syste m. Unit is ZERO LIQUID DISCHARGE for Industrial waste water. Domestic wa ste water is treated in Septic ta nk followed by Soa k pit. All quantity in Liters.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 23
FIGURE: 5
WATER BALANCE D IAGRAM FOR TO TAL PRO POSED SCENARIO (EXISTING + PRO POSED)
All quantity is in Liters/Day
5, 25, 000
10,000 45000 50,000 38,000
PROCESS BOI LER COOLI NG
DOM ESTIC AGRI CULTURE
3, 82 ,000
WASHI NG
ETP
85,000
Loss 255000
20,000 TO ETP
3, 70 ,000 TO ETP
5,000 TO ETP
5,000 TO ETP
35000 To Sep tic tank, Soa k pit & than to SBT p lant
Loss 20,000 Loss
15000
Loss 10,000
Loss 5 ,000
90,000
Reverse Osmosis Pla nt TREATMENT
R O reject to Evap oration PLANT For Evaporation
R –O permea te f or re use
in Utility -260 KL
3, 95 ,000 TO RO PLANT
30,000
2 1 5 0 0 0
Solid wastes from MEE pla nt packe d & se nd to TSDF site BEI L -ANKLESHWAR
The I ndustria l waste wa ter treate d in ETP pla nt. Treated waste wa ter send to R-O Pla nt. R-O Per mea te wa ter send for utilization f or Utility. R-O Reje ction will be e vap orate d in Evaporation syste m. Unit will continue to maintain ZERO LIQUID DISCHARGE for Industrial waste water. Thus unit Wa ste water Loa d for disposal will be ZERO. Domestic wa ste water t reated in Septic tank & Soak pit, followed by SBT plant. Th e SBT treated water reused.
Loss 12,000
1 5 0 0 0
Loss 5 ,000
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 24
3.9.1.2 WASTEW ATER CHARAC TERIS TIC S
The characteristics of waste water before & after treatment is given in Table3.3
TAB LE: 3.4
WASTE WATER CHARCTRIS TIC S (EXISTING SCENARIO )
Sr. No.
Parameters Before Treatm ent
After Treatment
1 Ph 4- 6 6.8-7.5 2 Colour in Hazen 1000-1200 10-15 3 T.S.S in mg/L 1000- 1300 50-60 4 T.D.S. in mg/L 4000-6000 100- 150 5 B.O.D. in mg/L 2000- 3000 10-15 6 C.O.D. in mg/L 5000- 7000 30-50 7 Oil & Grease in mg/L 300-400 BDL 8 Phenolic Compound in mg/L 15-25 BDL 9 Ammonical Nitrogen in mg/L 5-10 Less than 1 10 Chlor ides in mg/L 3000-4500 30-40 11 Sulphate in mg/L 300-500 Absent 12 Sulphide in mg/L Absent Absent
TAB LE: 3.5
WASTE WATER CHARCTRISTICS (TOTAL EXISTING+ PROPOSED SCENARIO)
Sr. No.
Parameters Before Treatm ent
After Treatment
1 . p H 4- 6 6.8-7.5 2 Colour in Hazen 1000-1200 7-10 3 T.S.S in mg/L 1000- 1500 10-15 4 T.D.S. in mg/L 5000-8000 100- 150 5 B.O.D. in mg/L 2000- 3500 10-15 6 C.O.D. in mg/L 6000- 8000 30-50 7 Oil & Grease in mg/L 300-450 BDL 8 Phenolic Compound in mg/L 15-25 BDL 9 Ammonical Nitrogen in mg/L 10-15 Less than 1 10 Chlorides in mg/L 3000-5000 40-60 11 Sulphate in mg/L 300-500 10-15 12 Sulphide in mg/L Absent Absent
Unit is ZERO LIQUID DISCHARGE for Industrial waste water with R-O plant & Evaporation system. There is ZERO pollution load for waste water dischrge
Unit will continue to maintain ZERO LIQUID DISCHARGE for Industrial waste water with R-O plant & Evaporation system. There is ZERO Pollution load for the Industrial waste water discharge.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 25
3.9.1.3 WASTEW ATER TREA TMEN T & DISPOSAL DETAILS OF EFFLU ENT TREATMENT PLANT The waste water generated from industrial activities is treated in an Effluent Treatment Plant Comprising of pr imary, secondary treatment & Tertiary treatment plant. The effluent generated from the plant is collected in a collection sump from where it is pumped to oil and grease trap to remove free oil from the raw effluent. After oil and grease removal the effluent goes to equalization cum Neutralization tank where Lime and Alum dosing is done. The effluent is pumped from equalization cum Neutralization tank & filtered through Filter press. The filtered clear effluent goes to Aeration tank for activated sludge biological treatment where non-settable suspended and colloidal organic matters are converted in settable biological mass which are settled in Clarifier. To maintain biomass concentration in Aeration tank active sludge from the Clarifier is partly recirculated in Aeration tank the over flow of the Clarifier. Treated eff luent is again passed from Sand filter & Activated Carbon filter. Company has set up R-O Plant for treatment of waste water with evaporation system. In R-O Plant waste water recovery is carried out. The R-O Permeate is used back in the p lant the R-O rejection is evaporated in Evaporation systems. The salt generated from the Evaporation system is send to TSDF site BEIL- ANKLESHWAR. In existing Scenario: Under present scenario Industrial waste water is treated in Waste water treatment plant followed by R-O plant. Recovered water is reused. Thus there is no discharge of the waste water from the unit. The R-O rejection is evaporated in evaporation system. The unit is “ZERO LIQUID DISCHARGE” for In dustrial waste water. Domestic waste water treated in Septic tank followed by Soak p it. Under total proposed scenario (Existing + proposed) Under total proposed scenario Industrial waste water generated will be continued to be treated in Waste water treatmnet plant followed by Reverse Osmosis Plant for Waste water recovery. R-O permeate water is collected & send to the Utility for reuse. R-O Rejection water to Evaporation plant, concentrated dried & salt collected are packed in bags & send to TSDF site BEIL – ANKLESHWAR. The unit is “ZERO LIQUID DISCHARGE” for In dustrial waste water. The Pollution load for Industrial waste water discharge will be ZERO. Pollution load for Industrial waste water discharge with total proposed scenario(Ex isting + proposed) will remain ZERO. Domestic waste water treated in Septic tank, Soak p it. The overflow from Soak pit will be treated in SBT (Soil Bio Technology) plant. SBT is pateneted green technology. v The solid waste generated from the effluent treatment facility, from the Filter
press.The solid sludge is transferred to the sludge collection & drying bed. The sludge collection/drying bed are two nos. The sludge a collection cum drying bed is provided with HDPE liner & from the bottom are connected to the Leatchet collection sump from leatchet collection sump what ever liquid eff luent collected are transferred to Collection tank for treatment.
v The sludge after drying collected in to the HDPE bags & send to the common secured land fill facility at Ankleshwar Bharuch Enviro Infrastructure Ltd
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 26
TAB LE: 3.6
NAME & SIZE O F EAC H UNIT O F EFFLUENT TR EATM ENT PLANT
1) To ETP waste water DCP recovery Sodium Chloride 2) To recovery 3) Moisture loss
6.293 Total 1.00 Total 6.293 Total
Receiver
Reactor – 101
Filter
Collection
pit
Moisture removal
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 56
Product: DFK Step-II Material flow sheet
Qty Kgs
Input Reaction & Equipm ent Qty Kgs
Output
0.8 0.42 1.18 1.5
D.C.D.P.A Chloro Acetyl Chloride
Toulene Water
0.15 1.17 1.38 0.2
HCl gas to Scrubber Toluene recovery Waste water for treatment Drying loss
Kgs Starting Material
Kgs Product Kgs W aste
0.8 0.42 1.8 1.15
DCDP A Chloro Acetyl Chloride Toluene Water
1
C.P.D.C.A 0.15 1. 17 0.2 1.38
1) HCl gas 2) To recovery 3) Drying loss 4). Waste water for treatment
3.9 Total 1 Total 2.9 Total
Reactor – 201
Filter
Collection Tank
Drying
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 57
Product: DFK (Step-III) Material flow sheet
Qty Kgs
Input Reaction & Equipm ent Qty Kgs
Output
1.12 0.656 3.7
C.P.D.C.A Aluminium Chloride
Water
0.149 3.977 0.35
HCl Gas PAC solution for sell Drying loss
Kgs Starting Material
Kgs Product Kgs W aste
1.12 0.656 3.7
C.P.D.C.A Aluminium Chloride Water
1.00
Indolinone 3.977 0.149 0.35
1) PAC solution for sell 2)HCl 3) Moisture loss
5.476 Total 1.00 Total 4.476 Total
Reactor – 301
Filter
Collection pit
Moisture removal
Quencher
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 58
Diclofenac Potassium Material flow sheet:
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
1.09 0.38 0.009 2.4
Indolinone Potassium Hydroxide Charcoal
Water
2.57 0.009 0.3
Aqu. Effiuent Charcoal for Incineration Moisture drying loss
Kgs Starting Material
Kgs Product Kgs Waste
1.09 0.38 0.009 2.4
Indolinone Potassium Hydroxide Charcoal Water
1
Diclofenac Potassium
2.57 0.009 0.3
1) To ETP waste water 2) Charcoal 3) Moisture loss
3.879 Total 1 Total 2.879 Total
Reactor – 801
Filter
Collection pit
Moisture removel
Crystallizer
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 59
4) Product nam e: Fluconazole Epoxide compounds intermediate & 1, 2, 4 Triazole are treated in presence of potassium carbonate. Once reaction is over treated with ethyl acetate, purif ied from IPA, filtered & dried to give Fluconazole.
N
N NH+
N
NN
O
F
F
N
NN
F
F
OHN
NN
MW: 306.27
Fluconazole
1H-1,2,4-triazole
MW: 69MW: 237
Epoxide intermediate
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 60
PRO DUCT: FLUCONAZOLE Qty Kgs
Input Reaction & Equipm ent Qty Kgs
Output
1.20 1.43 0.175 2.0 2.00 2.4 1.50
Epoxide Intermediate 1,2,4-Triazole Pottasium Carbonate Dimethyl Formide Water Ethyl Acetate Isopropyl Alcoho l
1.92 5.785 1.2 0.3
DMF recovery Aqua Eff luent IPA recovery Drying loss
Kgs Starting Material Kgs Product Kgs W aste 1.20 1.43 0.175 2.0 2.00 2.4 1.50
Epoxide Intermediate 1,2,4-Triazole Pottasium Carbonate Dimethyl Formide Water Ethyl Acetate Isopropyl Alcoho l
1.0 FLUCONAZOLE
1.92 6.285 1.2 0.3
DMF recovery Aqua Eff luent IPA recovery Drying loss
10.705 Total 1 Total 9.705 Total
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 61
5) Product nam e: Ciprofloxacin Fluoro quonlinic acid & piper izine treated in presence of dimethyl sulphox ide.
Caustic lye is added, to form a base. Treated with HCl to give ciprof loxacin. Pur ified
using Methanol filtered & dried to give ciprof loxacin.
+NH
NH
Piperazine
Cl
F
N
OH
OO
Fluoro Chloro Quinolonic acid ( Q-Acid) (Intermediate for Ciprofloxacin)
MW: 281.5
N
F
N
OH
OO
NH
Ciprofloxacin MW: 331.34
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 62
Product: C iprofloxacin Stage-01 (Base) Material Flow Sheet:
Kgs Starting Material Kgs Product Kgs Waste 150 Q-Acid 1) To ETP waste:
102 Piperazine 4458 2) Waste Water
121.5 n-Butanol 175 Caustic lye so lution
90 3) Recovery of n-Butanol
100 Conc. HCl 30 4) Recovery loss 130 Acetic acid
4050 Water
150 Ciprof loxacin stage-01 (Base)
100 5) Drying Loss 4828.5 150 Total 4678 Total
Reactor
Filter
Drying
Receiver
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 63
Product: C iprofloxacin Stage-02 (Ciprofloxacin HCl) Material Flow Sheet:
Quantity Kgs
Inputs Reaction & Equipment Quantity Kgs
Out put
150 Ciprof loxacin Base stage-01
90 Conc. HCl
1020 Methanol 375 Water
1190 Recovery of methanol + water
Waste water
275 Evopration loss
20 Moisture drying lost
Kgs Starting Material Kgs Product Kgs Waste
150 Ciprof loxacin Base stage-01
1) To ETP waste:
90 Conc. HCl 2) Waste Water
1020 Methanol 375 Water
1190 3) Recovery
275 4) Recovery loss
150 Ciprof loxacin stage-02 (Ciprof loxacin HCl)
20 5) Drying Loss
1635 Total 150 Total 1485 Total
Reactor
Filter
Drying
Receiver
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 64
6).Product nam e- Ofloxacin: Quonalinic acid & N- methyl piperizine reacted in
butanol. The reaction mass acetic acid is added mass is neutralized to give of loxacin.
Purified, filtered & dried to give of loxacin.
Q-Acid
FO H
O O
N
OC H 3
F+
N H
NCH 3
N-Methyl Piperazine
FO H
O O
N
OC H 3
N
N
CH 3
Ofloxacin
MeOH105-110°C 105-110°C105-110°C105-110°C
MW: 361.37
MW: 280.20
9 , 1 0 -D if lu o ro - 3 - M e th y l- 7 -O x o - 2 , 3 -D ih y d r o 7 -H - P y ri d o - 1 , 2 , 3 - D E ] - 1 , 4 -B e n zo xy a z in e -6 - C a rb o x y lic A c i d
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 67
8).Product nam e: Lostaran Potassium 2-Butyl-4 chloro-5 hydroxy methyl imidazole reacted with 4-bromomethyl-2-cyanobiphenyl & Na Methoxide. Further treated with sodium azide & NH4 Cl in presence of DMF. The mass is crystallized from methanol to give lostaran potassium Reaction schem e:
N
NH
CH3
Cl
OH
2-Butyl-4 chloro-5 hydroxy methyl imidazole
+
MW: 188.65
4-bromomethyl-2-cyanobiphenyl
Br
N
MW: 272.14
NaN3
CH3ONa
NN
NH
N
N
N
CH3
ClKO
Losartan Potassium
MW: 461.01
KOH
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 69
9).Product nam e: Lisinopril N-[N2-Benzyloxycarbonyl-N6-tertiarybutoxycarbonyl-Lysyl]-L-Praline benylester Hydrogenated with Catalyst Hydrogenated & Water. The mass is further treated with 2-Oxo-4 Phenyl Butyric acid & Sodium Hydroxide. The resultant mass is crystallized from Methanol to yield Lisinopril.
Aqueous effluent for catalyst recovery Aqu. Effluent for Fe. Acetate recovered Mother liquor (methanol recovery) Drying loss
7.81 Total 1.00 Total 6.81 Total
Drying, Milling, Sifting
Purification
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 71
10).Product name: Levocetrizine 1-[4-Chlorophenyl) pheny lmethyl] piperizine is treated with L-Tartaric acid, (2-Chloroethoxy) & Acetonitrile. The mass is further treated with Sodium Carbonate, KI, .n-Butanol & Conc. HCl. The crude obtained is crystallized from ethyl acetate to give levocetrizine.
Solvent lo ss N-Butanol reco. Aqu.Effluent for Kl & Tartaric acid recovery E. Acetate recovery Drying loss
9.91 Total 1.00 Total 8.91 Total
Purification
Crude Levocetirizine
Drying, Milling, Sifting
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 73
11). Product name: Ropinrole 3-Chloro-4-[Carbonyl oxophenyl) ethyl]-1, 3-dihydro-2-H-2-Indolinone hydrogenated using Palladium Hydrogen catalyst, neutralized with Caustic lye. The mass is treated with N, N dipropylamine in Methanol. The crude obtained is crystallized from IPA to give Ropinrole.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Aqu. Effluent For Palladium recovery To effluent Methanol recovery IPA recovery Drying loss
8.07 Total 1.0 Total 7.07 Total 12). Product name: Atorvastatin Calcium (2R-trans)-5-(4-Fluorophenyl)-2-(1-Methyl)-N,4diphenyl-1-[2-Tetra hydroxy-4hydroxy-6-Oxo-2H-pyran-2-yl)ethyl]-1H-pyrrole-3-carboxamide treated with NaOH in IPA. The mass is treated with calcium acetate solution. The crude obtained is crystallized from IPA to give atorvastatin calcium.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Aqueous effluent for IPA recovery Aqu. Liquid for Ca acetate recovered Mother liquor (IPA recovery) Drying loss
7.6 Total 1.00 Total 6.6 Total 13).Product name: Clopidogril Sulphate Amino Ester (VIII) (+)-10-Camphorsulphonic acid reacted with Formic acid & Formaldehyde. The mass is treated with Sulphuric acid, IPA + Water. The crude obtained is crystallized using water + Methanol, filtered, and dried to give Clopidogril Sulphate.
Drying, Milling, Sifting
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 79
1.85 0.33 1.17 1.5 0.25 + 1.2
(VIII) (+)-10-Camphorsulphonic acid Formic acid Formaldehyde Sulphuric acid IPA + Water Water + Methanol
0.12 2.48 4.05 1.36 0.11
Solvent lo ss IPA reco. Aqu. Effluent Methanol + water recovery Drying loss
Kgs Starting Material Kgs Product Kgs W aste 2.82 1.85 0.33 1.17 1.5 0.25 + 1.2
Amino ester (VIII) (+)-10-Camphorsulpho ic acid Formic acid Formaldehyde Sulphuric acid IPA + Water Water + Methanol
1.0 Clop idogril Bisulphate
0.12 2.48 4.05 1.36 0.11
Solvent lo ss IPA Reco. Aqu. Effluent Methanol + Water recovery Drying loss
9.12 Total 1.0 Total 8.12 Total 14).Product name: Sertraline HCl 4-(3, 4-Dich lorophenyl)-3, 4-dihydro-1(2H)-naphthalene, Methyl amine Lewis acid & Hydrogen; D (-) Mandelic acid with Conc. HCl. The crystallized from Methanol + Water, filtered & dr ied to give Steraline HCL.
Purification
Crude Clopidogril Bisulphate
Drying, Milling, Sifting
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Aqueous effluent for Sod. Ace. Recovery Aqu. Effluent for Fe. Acetate recovered Mother liquor (IPA recovery) Drying loss
7.6 Total 1.00 Total 6.6 Total 16).Product name: Midazolam & derivative 2-(2’-aminomethyl Carbonyl Methoxy)-7- Ch loro-5-(2-Fluoro Phenyl)-1, 3-dihydro-2H- 1, 4-benzodiazepine & Triethyl orthoacetate treated, hydrolysed with NaOH. Further neutralized with Conc. HCl. The crude product obtained is crystallized from Methanol + Water. Filtered, dr ied to give MIDAZOLAM.
Drying, Milling, Sifting
Purification
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
MW: 325.77 Product: Midazolam. HCl Material flow sheet: Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 85
1.89 1.12 0.27 1.09 3.2
2-(2’-aminomethyl Carbony l Methoxy)-7- Chloro-5-(2-Fluoro Phenyl)-1,3-dihydro-2H- 1,4-benzodiazepine Triethyl orthoacetate NaOH Conc. HCl Methanol + Water
2.21 1.3 2.95 0.11
M/L for Recovery of T.E.O Aqu. Effluent Mother liquor (Methanol recovery) Drying loss
Kgs Starting Material Kgs Product Kgs W aste 1.89 1.12 0.27 1.09 3.2
2-(2’-aminomethyl Carbony l Methoxy)-7- Chloro-5-(2-Fluoro Phenyl)-1,3-dihydro-2H- 1,4-benzodiazepine Triethyl orthoacetate NaOH Conc. HCl Methanol + Water
1.00 Midazolem. HCl 2.21 1.3 2.95 0.11
M/L for Recovery of T.E.O Aqu. Effluent Mother liquor (Methanol recovery) Drying loss
7.57 Total 1.00 Total 6.57 Total
17). Product name : Nebivolo l Benzopyran-2-Carboxaldehyde Derivative treated with Trimethyl sulfoxon ium iodide In presence of Potassium hydroxide & Water. The mass is further treated with Benzyl
Drying, Milling, Sifting
Purification
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 86
amine & Toluene, Ammonium formate using Pd/Catalyst. The mass is crystallized from Methanol, filtered & dried to give Nebivolol.
O
F
OO
F
O
T rimethyl sulphoxonium iodide
KOH
NH2
O
F
NHOH
Benzyl amine
6-f luoro-3,4-dihydro-2H-chromene-2-carbaldehyde
O
F
O
O
F
N
OH
O
F
OH
HCOONH2 Toluene
O
F
NH
OH
O
F
OH
Benzyl nebivolol Nebivolol
MW: 405.43 Product: Nebivolol Material flow sheet: Qty Input Reaction & Equipm ent Qty Output
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Benzopyran-2- Carboxaldehyde Deri Trimethyl sulfoxonium Iodide Potassium hydrox ide Water Benzyl amine Toluene Ammonium formate (Hydrogen source)Pd/C Methanol
1.00 Nebivo lol 5.3 4.6 0.7 3.0 0.3 0.4
Aqueous effluent for KI (1.1 Kg) recovery Methanol Solvent lo ss Toluene Recovery Drying loss Carbon dioxide
15.32 Total 1.0 Total 14.32 Total 18).Product name: Bicalutamide 2-Cyano-4-amido benzo trifluoride is treated with Hydrogen peroxide & Water. The mass is treated with 4-Fluorobenzenethiol, Hydrogen peroxide & Acetic acid. The crude obtained is crystallized from IPA to give Biclutamide.
Protected Nebivo lol
Nebivo lol
Purification
Drying, Milling, Sifting
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
waste water Water Recov IPA recovery Solvent lo ss Insolubleso lid Drying loss
6.645 Total 1.00 Total 5.645 Total 20).Gadodiamide; Gadonium Oxide is treated with Diethanolamine. The mass is allow to reflux, cooled & filtered to give Gadodiamide Product: Gadodiamide
Chelation & water evaporation
Purification
Drying, Milling, Sifting
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 91
NH 2CF3
NC + CH 3
O H
CH 3O
S+
O
O
F
NaOH
CF3
NC
NH
CH 3
O H
O
S+
O
O
F
2 -C y a n o -4 -a m i d o b e n z o tr if l u o r i de 4-Fluorobenzenethiol
Bicalutamide
MW: 430
H2O2
Acetic acid
MW: 186MW: 280.5
Material flow sheet: Qty Kgs
Input Reaction & Equipm ent Qty Kgs
Output
1.47 0.68 4.0 0.5
DTPA anhydride Gadolinium oxide Water IPA
1.25 0.025 3.37 0.45 0.45
Aqueous Effluent Insoluble so lid water recovered Mother liquor (IPA recovered) Drying loss
Kgs Starting Material Kgs Product Kgs W aste 1.47 0.68 4.0 0.5
DTPA anhydride Gadolinium oxide Water IPA
1.00 Gadodiamide
1.25 3.37 0.45 0.1 0.025 0.45
Waste water Water Reco. IPA recovery Solvent lo ss Insoluble so lid Drying loss
6.65 Total 1.00 Total 5.65 Total 21). Product name: Pioglitazone HCL 5 Ethyl 2 Pyridyl ethanol; Toluene; 4-Hydroxy Benzaldehyde & Sodi. Boro hydroxide with K2CO3 & Thiozolidinone in presence Caustic lye. The crude is crystallized with IPA to give Pioglitazone.
Chelation & water
evaporation
Purification
Drying, Milling, Sifting
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Aqueous effluent Toluene recovery IPA recovery Drying loss
9.1 Total 1.00 Total 8.1 Total 22).Product name: FEXOFENADINE Sod. Borohydride; KI; Intermediate -8 treated in presence MIBK. The mass is further treated Azycyclonol & Denatured Spir it. The mass is treated with K2 CO3. The crude is crystallized from Methanol to give Fexofenadine.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 94
OOH
O
O
CH3 CH3CH3
+
NH
OH
N
OH
OH
O
O
CH3CH3CH3
K2CO3
N
OH
OH
OH
O
CH3CH3
Sodium Borohydride
NaBH4
Fexofenadine
MW: 501.65 Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 95
1..2 0.28 1.11 2..85 0.60 1. 0 4.2 3.50
Sod. Borohydride KI Intermediate -8 MIBK Azycyclonol Denat ured Spirit Water +K2CO3 Methanol
9.74 3.70 0..3
Aqu. Effluent Mother liquor Drying loss
Kgs Starting Material
Kgs Product Kgs Waste
1..2 0.28 1.11 2..85 0.60 1.0 4.2 3.50
Sod. Borohydride KI Intermediate -8 MIBK Azycyclonol Denat ured Spirit Water Methanol
1.00 Fexofenadine 9. 74 3. 70 0.3
Aqu. Effluent Mother liquor Drying loss
14.74 Total 1.00 Total 13.74 Total 23).Product name: Citalopram
Drying, Milling, Sifting
Purif icat ion
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 96
5-Bromophthalide, CuCN & 4-Fluorophenyl Mg-bromide in THF treated. The mass is further treated with dimethylaminopropyl magnesium chloride, NaOH, DMF .The resultant mass is further treated with Phosphoric acid & HCl, Crystallized from water to give Citalopram
6.0 toluene 1.68 HCl solution 30% 0.30 Drying loss 2.0 water
3.69 NaOH 0.42 Cu CN 3.36 Phosphoric acid 1.34 DMF
27.15 Total 1.0 Total 26.15 Total
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 98
24). Iohexol/Iopam idol/iodixanol BRIEF MANUFAC TURING PROC ESS O F IOPAMIDO L AND INTERMEIDATES: IOPAMIDOL: STAGE-01 (ATP): 5-Amino isophthalic acid is reacted with previously prepared KICl2 (prepared from iodine monochloride and potassium chloride) to yield 2, 4, 6-Triiodo-5-amino isophthalic acid (Iopamidol stage-01). STAGE-02 (ATD): 2, 4, 6-Triiodo-5-amino isophthalic acid (stage-01) is converted to acid dichlor ide by reaction with thionyl chloride in dichloromethane. After reaction workup using ethyl acetate so lvent to extract product and finally after ethylacetate distillation product isolated in toluene. STAGE-03 (ATA): 2, 4, 6-Triiodo-5-amino isophthalic acid dichloride ( stage-02) is reacted with Acetoxy propionyl chloride in dimethyl acetamide to yield L-5-(2-acetoxypropionylamino)-2, 4, 6-triiodo isophthalic acid dich loride ( stage-03) which is extract in ethylacetate and finally after ethyl acetate distillation product isolated in toluene. STAGE-04 (ATS): L-5-(2-acetoxypropionylamino)-2, 4, 6-triiodoisophthalic acid dichloride ( stage-03) is reacted with Ser inol in presence of dimethyl acetamide to yield L-5-(2-acetoxypropionylamino)-2, 4, 6-triiodo isophthalic acid bis-(1, 3-dihydroxypropy lamide) stage-04 which is finally iso lated in Methanol + IPA mixture. STAGE-05 (IOPAMIDOL FINAL): L-5-(2-acetoxypropionylamino)-2, 4, 6-triiodoisophthalic acid bis-(1, 3-dihydroxypropy lamide) (stage-04) is hydrolyzed in aq. Ammonium hydrox ide to yield Iopamido l. IOHEXOL: 5-amino – N, N (2, 3 Dihydroxy propyl & isophthalamide TRIIODO DERIVATIVE treated with 3-Chloro, 2 –propanediol. The product is cryatallized from IPA, filtered & dried togive, Iohexol
IOPAMIDOL:-
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
MDC +thionyl Recovery Ethyl acetate Recovery Toluene Recovery from ml
1665 Waste water
560 Recovery loss
10 drying lost
Kgs Starting Material Kgs Product Kgs Waste 200 Iopamidol stage-01
(ATP) 1) To ETP waste:
70 Triethylamine 1665 Waste Water
665 Methylene Dich loride
3043 2) To Recovery
247 Thionyl chloride 10 3) Drying Loss 2153 Ethyl acetate 380 4) Recovery loss
75 Sodium bicarbonate
180 Iopamidol stage-02 (ATD)
110 Sodium chloride 348 Toluene
1410 Purified water
5278 Total 180 Total 5278 Total
Reactor
Filter
Drying
Receiver
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 103
Product: Iopamidol Stage-03 (ATA) Material Flow Sheet:
Quantity Kgs
Inputs Reaction & Equipment Quantity Kgs
Out put
200 Iopamidol stage-03 (ATD)
126 L -2- Acetoxy propionyl chlor ide
188 N, N’-Dimethyl acetamide
1794 Ethyl acetate 80 Sodium bicarbonate
165 Sodium chloride 174 Toluene
4300 Purified water
1615 157
Ethyl acetate Recovery Toluene Recovery from ml
4733 Waste water
186 Recovery loss
10 drying lost
Kgs Starting Material Kgs Product Kgs Waste
200 Iopamidol stage-01 (ATP)
1) To ETP waste:
126 L -2- Acetoxy propionyl chlor ide
44859 Waste Water
188 N, N’-Dimethyl acetamide
1772 2) To Recovery
1794 Ethyl acetate 10 3) Drying Loss 80 Sodium bicarbonate 186 4) Recovery loss
165 Sodium chloride
200 Iopamidol stage-03 (ATA)
174 Toluene
4300 Purified water 7027
Total 200 Total 7027 Total
Reactor
Filter
Drying
Receiver
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 104
Product: Iopamidol Stage-03 (ATA) Material Flow Sheet:
Quantity Kgs
Inputs Reaction & Equipment Quantity Kgs
Out put
200 Iopamidol stage-02 (ATD)
126 L -2- Acetoxy propionyl chlor ide
188 N, N’-Dimethyl acetamide
1794 Ethyl acetate 80 Sodium bicarbonate
165 Sodium chloride 174 Toluene
4300 Purified water
1615 157
Ethyl acetate Recovery Toluene Recovery from ml
4859 Waste water
186 Recovery loss
10 drying lost
Kgs Starting Material Kgs Product Kgs Waste
200 Iopamidol stage-02(ATD)
1) To ETP waste:
126 L -2- Acetoxy propionyl chlor ide
4859 Waste Water
188 N, N’-Dimethyl acetamide
1772 2) To Recovery
1794 Ethyl acetate 10 3) Drying Loss 80 Sodium bicarbonate 186 4) Recovery loss
165 Sodium chloride
200 Iopamidol stage-03 (ATA)
174 Toluene
4300 Purified water 7027
Total 200 Total 7027 Total
Reactor
Filter
Drying
Receiver
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 105
Product: Iopamidol Stage-04 (ATS) Material Flow Sheet:
Quantity Kgs
Inputs Reaction & Equipment Quantity Kgs
Out put
200 Iopamidol stage-03 (ATA)
65 Serino l
104 Triethylamine
1505 N, N’-Dimethyl acetamide
1027 Methanol 1896 IPA
20 Purified water
1355 2631
N, N’-Dimethyl acetamide Recovery Methanol + IPA Recovery from ml
100 Waste solid
511 75
Recovery loss TEA.HCl salt
10 drying lost
Kgs Starting Material Kgs Product Kgs Waste
200 Iopamidol stage-03 (ATA)
1) To ETP waste:
65 Serino l 100 Waste solid
104 Triethylamine 3986 2) To Recovery
1505 N, N’-Dimethyl acetamide
10 3) Drying Loss
1027 Methanol 511 4) Recovery loss 1896 IPA
210 Iopamidol stage-04 (ATS)
20 Purified water
4817 Total 210 Total 4817 Total
Reactor
Filter
Drying
Receiver
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 106
Product: Iopamidol Stage-05 (Final) Material Flow Sheet:
Quantity Kgs
Inputs Reaction & Equipment Quantity Kgs
Out put
200 Iopamidol stage-04 (ATS)
300 Ammonia solution 25%
395 Methanol 553 IPA
2220 Purified water
854 2268
Methanol + IPA Recovery from ml Water recovery
0 Waste solid
346
Recovery loss
10 40
drying lost Residue
Kgs Starting Material Kgs Product Kgs Waste
200 Iopamidol stage-04 (ATS)
1) To ETP waste:
300 Ammonia solution 25%
2268 Waste recovery
395 Methanol 854 2) To Recovery 553 IPA 10 3) Drying Loss
2220 Purified water 346 4) Recovery loss
150 Iopamidol stage-05 (Final)
40 5) Residue
3668 Total 150 Total 3668 Total
Reactor
Filter
Drying
Receiver
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 107
25). Product: Pantoprazole & derivative 5-(dif louromethoxy)-1H-benziamidazole-2-thiol treated with 2-(chloromethyl)-3,4-dimethylpyridine, the resulatant mass is hydro lyzed with Sodium hydroxide & purif ied, filtered , washed & dried to give Pantoprazole Sodium deri.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 109
26). Product name: Montelucast Ester compound, THF treated with NAOH. The reaction is further treated with Tartaric acid & Methanol, to form Montelucast.
NCl
CH3 CH3
OH
SOH
O
NaOH
Ester compound
NCl
CH3CH3
OH
SO
O
Na
Montelucast Sodium salt
MW: 608.18
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 110
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 111
27). Product name: IO XAGLIC ACID 3-amino 5-benzoyl 2, 4, 6-triiodo benzoic acid is treated with 2- amino ethanol, in presence of Toluene. The mass is further treated with Triethyl Amine to give IOXAGLIC ACID
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 114
Product: C ilnidipine Stage-01 (CBD)Material Flow Sheet: Quantity Kgs
Inputs Reaction & Equipment Quantity Kgs
Out put
200 2-Methoxy Ethyl Acetoacetate (2-MEAA)
530
Isopropyl alcohol
17.5 Piperidine
208 3-Nitrobenzaldehyde
20 Glacial acetic acid
475 195
Recovery of Isopropyl alcohol To ETP waste
Waste water
45 Evopration loss
10 drying loss
Kgs Starting Material Kgs Product Kgs Waste
200 2-Methoxy Ethyl Acetoacetate (2-MEAA)
195 1) To ETP waste:
530 Isopropyl alcohol 0 2) Waste Water
17.5 Piperidine
208 3-Nitrobenzaldehyde
475 3) Recovery of Isopropyl alcohol
20 Glacial acetic acid 45 4) Recovery loss 10
250 Cilnidip ine stage-01 (CBD)
5) Drying Loss 975.5 Total 250 Total 725 Total
Reactor
Filter
Drying
Receiver
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 115
Product: C ilnidipine Final Material Flow Sheet:
Quantity Kgs
Inputs Reaction & Equipment Quantity Kgs
Out put
150 Cinnamyl Acetoacetate
50
Ammonium anhydrous Gas
198 CBD (Stage-01) 1363 Isopropyl Alcohol
0.370
2-Morpholinoethanesulfonic acid (Monohydrate)
3673.5 Methanol
3130 1160
Recovery of Methanol Recovery of IPA
138 Waste
746 Evopration loss of
40 drying loss
Kgs Starting Material Kgs Product Kgs Waste
150 Cinnamyl Acetoacetate
1) To ETP waste:
50 Ammonium anhydrous Gas
198 CBD (Stage-01)
3130 1160
2) Recovery of Methanol Recovery of IPA
1363 Isopropyl Alcohol 746 3) Recovery loss
0.370
2-Morpholinoethanesulfonic acid (Monohydrate)
138 4) waste
3673.5 Methanol
220 Cilnidip ine (Final)
40 5) Drying Loss 5434.87 Total 220 Total 5214 Total
Reactor
Filter
Drying
Receiver
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 116
29). Product name: Amlopidine Besylate:- STEP 01: Phthalicanhydride & Ethanol Aminereacted to give step-I (Hep) STEP 02:- Step-I (Hep) is treated with ethyl chloro aceto acetate to give step-II (Pheema) STEP 03:- St ep-II (Pheema) is treated with MAC to give Phthaloyl Amlodipine STEP0 4: Phthaloyal Amlodipine is reacted with NH3 to give Amlodipine Base STEP05:- Amlodipine Base is treated with to give Amlodip ine Besylate
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 120
30) Cetrizine: Process flow diagram for Cetrizine: 1-[(4-Chlorophenyl)pheny lmethyl] Piperizine reacted with L- Tartaric acid , 2 Chloro Ethoxy Acetonitrile in presence of Sodium Carbonate & KI , to form Base. Base is reacted with Conc. HCL to form Cetrizine HCL.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 121
Product: C etirizine Stage-01 (CMP) Material Flow Sheet:
Qty.Kg Inputs Reaction & Equipment Qty. Kgs Out put 70 4CHLOROBENZOPHE
NONE
1.8 CAUSTIC SODA FLAKES
6.3 SODIUM BOROHYDRIDE
15 GL ACIAL ACET IC ACID
545 HYDROCHLORIC ACID
85 CAL CIUM CHL ORIDE
670 TOL UE NE
100 PIPERAZINE ANHYDROUS
80 CAUSTIC SODA LYE 4540 PURIFIE D W ATER
600 Recovery of toluene
5720 Waste water 88 n-HEXANE
276 Meth anol 65 Evopration
Loss
Moisture
drying lost
Kgs Starting Material Kgs Product Kgs Waste 70 4-
CHLOROBENZOPHENONE 1) To ETP waste:
1.8 CAUSTIC SODA FLAKES 5720 2) Waste Water
6.3 SODIUM BOROHYD RIDE
15 GLACIAL ACETIC ACID 600 3) Recovery of
toluene 545 HYDROCHLORIC ACID 65 4) Recovery loss 85 CALCIUM CHLORIDE 20 5) Drying Loss
670 TOLUENE 100 PIPERAZINE ANHYDROUS 80 CAUSTIC SODA LYE
4540 PURIFIED WATER 88 n-HEXANE
276 Meth anol
70 Cetirizine stage-01 (CMP)
6477.1 70 Total 6405 Total
Reactor
Filter
Drying
Receiver
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 122
Product: C etirizine Stage-02 (Cetirizine HCl) Material Flow Sheet: Qty Kgs Inputs Reaction & Equipment Qty.Kgs Out put
70
1-[(4-chlorophenyl (phenyl) methyl] pi perazine
48.5 Triethyla mine (TE A)
30.5 2- Chloroetha nol
200 Dimethyl For mamide (DMF)
40 Potassi um Hydroxide Flakes (KOH)
42.6 Sodi um Monochloro Aceta te
50 Hydrochloric Acid (CP Grade)
612 Methyl ene Di chloride (MDC)
822 Acetone
560 430
Recovery of toluene Recovery of MDC
3070 Waste water 631 Toluene
1830 Water
240 15
Evopration loss Drying loss
Kgs Starting Material Kgs Product Kgs Waste 70
1-[(4-chlorophenyl (phenyl) methyl] piperazine
1) To ETP waste:
48.5 Triethyla mine (TE A) 3070 2) Waste Water 30.5 2- Chloroetha nol 990 3) Recovery 200 Dimethyl For mamide
(DMF) 240 4) Recovery loss
40 Potassi um Hydroxide Flakes (KOH)
42.6 Sodi um Monochloro Aceta te
15 5) Drying Loss
50 Hydrochloric Acid (CP Grade)
612 Methyl ene Di chloride (MDC)
822 Acetone 631 Toluene
1830 Water
60 Cetirizine stage-02 (Cetirizine HCl)
4376.6 60 Total 4315 Total
Reactor
Filter
Drying
Receiver
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 123
31). Product name: C arvidilol 2-(ethoxy phenoxy) ethylamine & 4-(2, 3 epoxy propoxy) carbezo le treated with mix of water & ethyl acetate, filtered & dr ied to give Carv idilol.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 124
32).Product name: ZO LPIDEM 3-bromo-N, N-dimethyl-4-oxo-4-p-tolyl-butyramide, MIBK are treated with 2-amino-5-methylpyridine. The reac mass treated with Sodium Carbonate. The stage -1 materail obtained is treated with Tartaric acid & crystallized from Acetone to give Zolpidem
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 127
34).Product name: Indolinone. 2, 6 DCP, sodium Methoxide, Ethyl Chloro Acetate, An iline Caustic Are added to reactor in required proportion. The mass is allowed to react together at required temperature and pressure condition, once the reaction is over, the material is f iltered and dried in dreir and packed in drums and stored as DCDPA DCDPA, Toluene, Chloro Acetyl chloride are added to a reaction vessel, Hydrogen Chlor ide gas generated during the reaction is scrubbed off with the help of caustic solution in scrubber tower. The material filtered, washed and dried packed and store as CPDCA CPDCA, Aluminium Chloride to allow react in a reactor and controlled temperature condition. The mass is then quenched in water and filtered, Hydrogen chlor ide gas generated during reaction and quenching is taken to scrubber system. Neutralized material is f iltered, washed, dried, Packed and store as Indolinone
OH
Cl
Cl
+ ClCH2COOC2H5
NH2
NH
Cl
Cl
2, 6-Dichloro phenol
Ethy l chloroacetate
2, 6-Dichlorodipheny l amine (DCDPA)MW: 163
MW: 122.5
MW: 238
Aniline
N
ClO
ClCH2COCl
Chloroacety l chloride
CPDCA
MW: 314.5
AlCl3N
O
Indolinone
MW: 278.1
Cl
Cl
Cl
Cl
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
1) To ETP waste Waste water DCP recovery Sodium Chloride 2) To recovery 3) Moisture loss
6.245 Total 1.00 Total 5.245 Total
Receiver
Reactor – 101
Filter
Collection pit
Moisture removal
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 129
Product: INDO LINO NE Step-II Material flow sheet
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
0.8 0.58 2.22
D.C.D.P.A Chloro Acetyl Chlor ide
Ethoxy ethanol
0.15 2.37 0.08
HCl gas to Scrubber Ethoxy ethanol recovery Drying loss
Kgs W aste Kgs Waste Kgs Waste 0.8 0.58 2.2
DCDP A Chloro Acetyl Chlor ide Ethoxy Ethanol
1
C.P.D.C.A 0.15 2. 37 0.08
1) HCl gas 2) To recovery 3) Drying loss
3.6 Total 1 Total 2.6 Total
Reactor – 201
Filter
Collection Tank
Drying
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 130
Product: INDOLINONE Material flow sheet
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
1.12 0.656 3.7
C.P.D.C.A Aluminium Chlor ide
Water
0.149 3.977 0.35
HCl Gas PAC solution for sell Drying loss
Kgs W aste Kgs W aste Kgs Waste 1.12 0.656 3.7
C.P.D.C.A Aluminium Chlor ide Water
1.00
Indolinone 3.977 0.149 0.35
1) PAC solution for sell 2)HCl 3) Moisture loss
5.476 Total 1.00 Total 4.476 Total
Reactor – 301
Filter
Collection pit
Moisture removal
Quencher
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 131
35).Product name: ATENALOL BRIEF MANUFACTURING P ROCESS:- In the first stage, Para-Hydroxy Phenyl acetamide condensed with Epichlorohydrine in presence of Base to give epox ide compound. This is condensed in second stage with Isopropylamine to give Atenolo l crude compound. Atenolol crude converts in to Atenolol pure by purification.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 132
Product: Atenolol Stage-01 (Crude) Material Flow Sheet:
Quantity Kgs
Inputs Reaction & Equipment Quantity Kgs
Out put
100 Para Hydroxy phenyl acetamide (PHPA)
57.5 Caustic Flakes
123 Epichlorohydrin
552 Mono isopropyl amine
50 Conc. HCl 2637.5 Water
420 Recovery of Mono isopropyl amine
Waste water
80 Evopration loss of Mono isopropyl amine
40 Moisture drying lost
Kgs Starting Material Kgs Product Kgs Waste
100 Para Hydroxy phenyl acetamide (PHPA)
1) To ETP waste:
57.5 Caustic Flakes 2850 2) Waste Water
123 Epichlorohydrin
552 Mono isopropyl amine
420 3) Recovery of Mono isopropyl amine
50 Conc. HCl 80 4) Recovery loss 2637.5 water
130 Atenolol stage-01 (Crude)
40 5) Drying Loss
3520 Total 130 Total 3520 Total
Reactor
Filter
Drying
Receiver
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 133
Product: Atenolol Stage-02 (Pure) Material Flow Sheet:
Quantity Kgs
Inputs Reaction & Equipment Quantity Kgs
Out put
130 Atenolol Crude stage-01
1027 Acetone
39 Acetic acid 32.5 Caustic flakes
942.5 Water
820 Recovery of Acetone
Waste water
200 Evopration loss of Acetone
30 Moisture drying lost
Kgs Starting Material Kgs Product Kgs Waste
130 Atenolol Crude stage-01
1) To ETP waste:
1027 Acetone 1020 2) Waste Water
39 Acetic acid 32.5 Caustic flakes
820 3) Recovery of Acetone
942.5 Water 200 4) Recovery loss
100 Atenolol stage-01 (Crude)
30 5) Drying Loss
2171 Total 100 Total 2070 Total
Reactor
Filter
Drying
Receiver
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 134
36).Product name: 2 Methyl Imidazole Acetaldehyde is reacted with Glyoxal & than treated with Liq NH3. The mass is concentrated, treated with Toluene, filtered through filtered & dried to get 2-MI
CH3 O
H
+H
H
O
O
+ NH3
NH N
CH3
2-methyl-1H-imidazole
acetaldehyde Glyoxal
Toluene
MW: 82.1
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 135
Qty Kgs
Input Reaction & Equipm ent Qty Kgs
Output
2.1 2.2 2.3 7
Glyoxal Ammonia Acetaldehyde Butanol
6.7 5.6 0.30
Butanol recovery Waste water Drying loss
Kgs Waste Kgs Waste Kgs W aste 2.1 2.2 2.3 7
Glyoxal Ammonia Acetaldehyde Butanol
1.00
Atenalol 6.7 5.6 0.3
Reco. Butanol Waste water Moisture loss
13.6 Total 1.00 Total 12.6 Total
Reactor
Filter
Collection pit
Moisture removal
Concentration
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 136
37). Name of product: Manu process for Maglumine: IPA is charged, add N –Octyl-D- Glucamine under stirring, slowly heat to 60-70 degree centigrade. Maintain for 5 hours. Cool the mass to room temp. Filter & dry the mass to give Maglumine.
+
Methylamine
OHOH
OH
OH
OH
OH
Sorbitol
(2R,3R,4R,5S)-hexane-1,2,3,4,5,6-hexol
OHNH
CH3
OH
OH
OH
OH- H2O
Meglumine (N - Methyl Glucamine)
+ IPA Purification
OHNH
CH3
OH
OH
OH
OH
Meglumine (N - Methyl Glucamine)
C6H14O6 MOL. WT: 182.17
CH3 NH2
CH5N MOL. WT: 31.06
C7H17NO5 MOL. WT: 195.21
C7H17NO5 MOL. WT: 195.21
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
1.0 Sorbitol
0.75 Methyl amine
3 IPA 3.75 Filtrate ML IPA recovery 0.85 Meglumine 0.15 Drying loss
Kgs Starting Material Kgs Product Kgs Waste
1.0 Sorbitol 0.85 Meglumine 3.75 1) Filtrate for IPA recovery
0.75 Methylamine 3.0 IPA 0.15 2) Drying loss
4.75 Total 0.85 Total 3.90 Total
Filteration FiltrationFiltr
Wet Solid
Moist ure
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 137
38).Nam e of product : Lucanthone Hydrochloride Stage-1 Reaction of Dithiosalicylic acid and 4-Chlorotoluene with sulfuric acid gives Intermediate Luca-I. Stage-II Lucanthone-I is reacted with N,N Diethyl ethylene Diamine & pyridine to give Lucanthone-II Stage-III Lucanthone –III is reacted with HCL to give Lucanthone Hydrochlor ide
To ETP Waste Waste Water Sodium Acetate Sodium Chlor ide 2) To Recovery 3) Moisture Loss
611 Total 70.00 Total 541 Total
Reciever
Reactor
Filter
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 139
39). Name of product: Process of synthesis for METRONIDAZO LE: 2- Methyl 5 –Nitro Imidazole is reacted with Ethylene Oxide. The reacted mass is quenched in water, p H adjusted. Mixt ure of METRONIDAZOLE & 2 MNI is separated to yield Crude. Crude Metronidazole is crystallized, filtered, dried to give Metronidazole. Reaction scheme:
Synthesis of Metronidazole Benzoate: Metronidazo le is reacted with Benzoyl Chlor ide for 24 hours. Once reaction is over, solvent is distilled out. Methanol is added , chilled , filtered , dried to give Metronidazo le Benzoate. Reaction Scheme:
N
N
CH3O2N
OH
Metronidazole
MW: 171.15
+
ClO OO
N
NO2N
CH3
Benzoy l chloride Metronidazole Benzoate
MW: 275.3MW: 140.56
Methanol
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 140
Name of product: Metronidazole Material Balance Qty Kgs
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 141
40).Nam e of product: Diatrizoic Acid (2, 4, 6-Triiodo-3, 5-diacetylaminobenzoic acid): Acetylation of 2, 4, 6 Triiodo-3, 5-diaminobenzoic acid by Acetic anhydride with sulfur ic acid to give Diatrizo ic acid derivative.
3.0 Acetic Anhydride 0.5 Sulfuric Acid 0.15 2) Drying loss
1.41 Purified Water 5.91 Total 0.86 Total 5.05 Total
Filteration
Reactor
Wet Solid
Moist ure
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 142
41). Name of product: Econazole Brief m anufacturing process: Reaction of 1-(2, 4-dichlorophenyl)-2-imidazole-1y l- Ethanol with sodium hydride base in tetrahydrne to give its sodium salt followed by treatment of resulting sodium salt with p-chlorobenzyl chloride in dimethylformamide solvent at reflux temp to give Econazo le.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 143
Nam e of product: Econazole Material balance Qty Kgs
Input Reaction & Equipm ent Qty Kgs
Output
1.0 1-(2,4 dichloropheny l)-2-
imidazole-1-y l-ethanol
0.22 Sodium Hydride
5.0 Tetrahydrofuran
11.2 Recovery & reuse
0.6 4-Chlrobenzyl chloride
0.22 Drying loss
6 Dimethylformamide
Kgs Starting Material Kgs Product Kgs Waste
1.0
1-(2,4 dichloropheny l)-2-imidazole-1yl ethanol 1.40 Econazo le 11.20
Recovery & reuse
0.22 Sodium Hydride
5.0 Tetrahydrofuran 0.22 Drying loss
0.6 4-Chlrobenzyl chloride
6 Dimethylformamide 12.84 Total 1.40 Total 11.42 Total
Filteration
Reactor
Wet Solid
Moist ure
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 144
42).Nam e of product: Meclizine CAS No. [596-65-3]Brief Manufacturing Process: Stage-1: Condensation of 1-(ch loromethyl)-3-methylbenzene with piperazine and HCl gas to produce 1-[(3-methylphenyl) methyl] piperazine dihydrochloride(stage-1) Stage –II: Stage –I is reacted with 4 Chloro Benaz Hydryal Chloride to give step-II Meclizine crude Stage-III : Meclizine crude is pur ified to give Meclizine
Stage-1:
Cl + NH NHN NH
3-Methyl benzyl ch loride Piieraz ine 1-[(3-methylphenyl)methyl]p iperazine dihydrochloride
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 145
Name of product: Meclizine Material balance Stage:1 1-[(3-methylphenyl)methyl]piperazine dihydrochloride Qty Kgs Input Reaction & Equipm ent Qty Kgs Output
1.0 1-(chloro methyl)-3 methyl benzen e
1.6 Piperazine
3.0 Methanol
3.0 Solvent Recycle
2.5 HCl(gas)
3.95 Waste for treatment
0.10 Drying loss
Kgs Starting Material Kgs Product Kgs Waste
1.0 1-(chloro methyl)- 3 methyl benzene 1.05
Stage-1 3.0
Solvent Recycle reuse
1.6 Piperazine 3.95 Waste for treat 3.0 Methanol 2.5 HCl (gas) 0.10 Drying loss 8.1 Total 1.05 Total 7.05 Total
Kgs Starting Material Kgs Product Kgs W aste 1.0 1-[(3-methylphenyl)-methyl 1.45 Meclizine 3.0 piperazine dihydrochloride
Solvent Recycle
1.25 (4chlorophenyl)phenylmethyl
Chlor ide 0.7 Waste for treatment
0.05 Potassium Carbonate 3.0 Toluene 0.15 Dry loss
5.30 Total 1.45 Total 3.85 Total
Filteration
Reactor
Wet Solid
Moist ure
Reactor
GENERAL
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 146
43).Nam e of product: Chlorhexidine Digluconate: Process: Reaction of Hexamethylene bis-dicyandiamide with P-chloroan iline HCL with Ethoxy ethanol 130-140 for 2 hours to get Chlorhexidine Base. By addition of D-Glucon ic acid to produce Chlorhexidine Digluconate.
NC NH C NH (CH 2)6 NH C N H C N
N HN H
+ .H Cl
C l
N H2
H ex am ethylene 1 ,6 Dic y and i amide
2
P -C hloroan iline Hy droch loride
E thox y ethano l
A cet ic ac id
D-G l ucon ic A c id
130-140 0C
H N C NH C N H (C H2)6 N H C NH C N H
NHNH
ClC l
NH N H
HO
O H
O H
O H
O H O
O H
H O
O H
O H
O H
O H O
O H
C hl orhexid i ne D ig luconate
D-G luc on ic ac id c om pound with N,N'' b is (4-ch loropheny l)-3 ,12-d i imi no-2 ,4 ,11,13-
te t raazate tradec ane d ii midam ide (2 :1)
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 147
(VII) Nam e of product: Chlorohexidine Gluconate Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
1.0 Hexamethylene bis-di cynamide
1.3 P-chloroaniline hydroch loride
7.1 Ethoxyethanol
7.1 Solvent Recovery
1.0 Acetic acid
2.0 Purified water
6.2 Waste water for
2.0 D-glucon ic acid 0.1 Drying loss
Kgs Starting Material
Kgs Product Kgs Waste
1.0 Hexamethylene bis dicyandiamide 1.0
Chlorhexidine Glucon 7.1
Solvent Recovery
1.3 P-chloroaniline hydroch loride 6.2
Waste water for
7.1 Ethoxyethanol treatment 1.0 Acetic acid 0.1 Drying loss 2.0 Purified water 2.0 D-glucon ic acid
14.4 Total 1.0 Total 13.4 Total
Reactor
Wet Solid
Add of D-
Moist ure
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 148
44) Product Name: Indinavir Charge 3 Methyl pyridine, Piperazine, Ethyl Acetate, Caustic Flakes, D M Water IPA ethyl Acetate heat and ref lux distilled out IPA. Cool & filters dry in RCVD to get
1) To ETP waste: Waste Water Sodium Acetate Sodium Chloride 2) To Recovery 3) Moisture Loss
2600 Total 70.00 Total 2530 Total
Reciever
Filter
Reactor
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 150
45).Nam e of product: Ne virapine Charge Dipyrido Diazepine, Ecyclopropyl chloride Caustic Flakes Toluene in reactor and add DM water IPA Ethyl acetate, IPA+HCl heat and reflux distilled out IPA Add DM water cool & filters dry in RCVD to get Nev irapine
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 151
Qty Kgs
Input Reaction & Equipm ent Qty Kgs
Output
100 60 40 700 1000
Dipyrido Diazep ine Eyclopropyl chloride Caustic Flakes Toluene Water
565 kg 1100 35
To recovery Waste water Moisture drying lost
Kgs Starting Material Kgs Product Kgs W aste 100 60 40 700 1000
Dipyrido Diazep ine Eyclopropyl chloride Caustic Flakes Toluene water
70 Kg Nevirapine 1100 40 90 565 35
To ETP waste: Waste Water Sodium Acetate Sodium Chlor ide 2) To Recovery 3) Moisture Loss
1900.00 Total 70.00 Total 1830.00 Total
Reciever
Reactor
Filter
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 152
46). Product Name: Rizatriptan Charge Triazole Compound, Dimethyl amino Indo le, Catalyst, Acetonitrile, Methanol, Water heat and reflux distilled out Methanolcool & filters dry in RCVD to get Rizatriptan
NHN
N
+ Cl
NH
N
CH3
CH3
1H-1,2,4-triazole Dimethy l amino indole
MW: 69 MW: 236.50
KOH
NH
N
CH3
CH3
NN
N
Rizatriptan
MW: 269.14
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 153
Qty Kgs
Input Reaction & Equipm ent Qty Kgs
Output
50 Triazole Compound
490 To recovery 80 Dimethyl amino
Indole 5 Catalyst
200 Acetinitrile 250 Methanol 500 Water
530 Waste water
25 Moisture drying lost
Kgs Starting Material Kgs Product Kgs Waste 50 Triazole Compound 1) To ETP waste:
80 Dimethyl amino Indole
530 Waste Water
5 Catalyst 200 Acetinitrile
Sodium Acetate
250 Methanol Sodium Chloride 500 Water 490 2) To Recovery
40 Kg Rizatriptan
25 3) Moisture Loss
1085 Total 40.00 Total 1045 Total
Reciever
Reactor
Filter
Moisture removal
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 154
47). Product Name: Gabapentine Charge 1, 2 Cyclohexaneutic Acid, Urea Toluene NaOH solution, water heat and reflux distilled out Toluene Add DM D M Water, Methanol and Con HCl cool & filters dry in RCVD to get Gabapentine
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 161
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
100 Ethoxy benzimidazo le comp
885 To recovery 80 Biphenyl Tetrazole
500 Toluene 35 KOH Flakes
600 D M Water
500 Ethyl Acetate 860 Waste water 400 Methanol
30 Moisture drying lost
Kgs Starting Material Kgs Product Kgs W aste 100 Ethoxy
benzimidazo le comp 80 Biphenyl Tetrazole
500 Toluene 35 KOH Flakes
700 D M Water 300 I P A
40 Con HCl
70 Kg Candesartan 505 115 150 885 30
To ETP Waste Waste Water Sodium Acetate Sodium Chlor ide 2) To Recovery 3) Moisture Loss
1755 Total 70.00 Total 1685 Total
Reciever
Reactor
Filter
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 162
51). Product Name: Glipizide Charge 5-methyl pyrazine-carboxamide, Sulfenyl Compound, Toluene, NaOH flakes, PTS heat and ref lux distilled out Toluene Add DM water, IPA, Ethyl acetate, Methanol, Toluene, Amino Cyclohexane cool & filters dry in RCVD to get Glipizide
N
N
H3C
NH-CH2-CH2 SO2NH2CO + Cl3-CO-HN
DMSO
SMO
Acetic Acid
N
N NH-CH2 -CH2 SO2NHCO
H3C
CO-HN
Glipizide
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 163
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
100 5-Methyl pyrazine-carboxamide
1330 To recovery 80 Sulfenyl Compound
600 Toluene 30 NaOH Flakes 15 PTS
700 D M Water
500 Ethyl Acetate 1030 Waste water 250 Methanol 400 Toluene
70 Amino Cyclohexane
35 Moisture drying lost
Kgs Starting Material Kgs Product Kgs W aste 100 5-Methyl pyrazine-
carboxamide 80 Sulfenyl Compound
600 Toluene 30 NaOH Flakes 15 PTS
700 D M Water 500 Ethyl Acetate 250 Methanol 400 Toluene
70 Amino Cyclohexane
70 Kg Glipizide 1030 130 150 1330 35
To ETP Waste Waste Water Sodium Acetate Sodium Chlor ide 2) To Recovery 3) Moisture Loss
2745 Total 70.00 Total 2675 Total
Reciever
Reactor
Filter
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 164
52). Product Name: Glim epiride Charge Oxo pyroline compound, Methyl cyclohexyl sulfony l compound, Toluene, NaOH f lakes, PTS heat and ref lux distilled out Toluene Add DM water IPA Ethyl acetate, IPA+HCl cool & filters dry in RCVD to get Glimepir ide
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 165
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
100 Oxo pyroline compound
715 To recovery 55 Methyl cyclohexyl
sulfonyl compound 600 Toluene
25 NaOH Flakes 15 PTS
500 D M Water
400 Ethyl Acetate 1030 Waste water 350 Methanol
30 Moisture drying lost
Kgs Starting Material Kgs Product Kgs W aste 100 Oxo pyroline
compound
55 Methyl cyclohexyl sulfonyl compound
600 Toluene 25 NaOH Flakes 15 PTS
500 D M Water 400 Ethyl Acetate 350 Methanol
70 Kg Glimepiride 1030 200 715 30
To ETP Waste Waste Water Sodium Acetate Sodium Chlor ide 2) To Recovery 3) Moisture Loss
2045.00 Total 70.00 Total 1975 Total
Reciever
Collection Pit
Reactor
Filter
Moisture removel
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 166
53). Product Name: Moxifioxacin Charge 1 cyclopropyl-6-fluro-4-oxo-chloro-quino line carboxyliacid Octohydro pyrolo, Octohydro pyrolo pyridine compound, Toluene and NaOH flakes in reactor heat and reflux distilled out IPA. Add DM water IPA Ethyl acetate, IPA+HCl cool & filters dry in RCVD to get Moxifioxacin
To ETP Waste Waste Water Sodium Acetate Sodium Chlor ide 2) To Recovery 3) Moisture Loss
2752 Total 75.00 Total 2677 Total
Reciever
Reactor
Filter
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 168
54).Product Name: Meloxicam Charge Methyl benzothiazine amine, Hydroxy methyl thiazolyl T H F, K2CO3 heat and reflux distilled out IPA Add Methanol, Acetonitrilel cool & filters dry in RCVD to get Meloxicam
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 175
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
100 Chloro Iminodibenzyl
440 To recovery 85 Dimethyl amino propyl chloride
600 Toluene 40 KOH
1000 DM Water 250 Acetone
ACETONE-250
30 HCl 1230 Waste water
25 Moisture drying lost
Kgs Starting Material Kgs Product Kgs W aste 100 Chloro Iminodibenzyl
85 Dimethyl amino propyl chloride
600 Toluene 40 KOH
1000 DM Water 250 Acetone
30 HCl
75Kg Clomipramine HCl 1230 135 200 440 25
To ETP Waste Waste Water Potassium salt Potassium Chlor ide 2) To Recovery 3) Moisture Loss
2105 Total 75 Total 2030 Total
Reciever
Reactor
Filter
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 176
58) Product Name: Letrozole Charge Triazol compound, Tanophenyl compound, I P A, NaOH Base heat and reflux distilled out IPA. Add DM water IPA Ethyl acetate, IPA+HCl cool & filters dry in RCVD to get Letrozole
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 179
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
40 Benzofurazamyl Comp
900 To recovery 40 Methyl ethyl ester
100 Dich loro dimethyl pyridine dicarboxicacid
25 NaOH (Base) 400 Methanol
500 Hexane 300 IPA
Hexane-478
30 Moisture drying lost
Kgs Starting Material Kgs Product Kgs W aste 40 Benzofurazamyl Comp 40 Methyl ethyl ester
100 Dich loro dimethyl pyridine dicarboxicacid
25 NaOH (Base) 400 Methanol 500 Hexane 300 IPA
75 Isradipine 400 900 30
To ETP Waste Waste Water Sodium Chlor ide 2) To Recovery 3) Moisture Loss
1405 Total 75.00 Total 1330 Total
Reciever
Reactor
Filter
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 180
60). Product name: Product Nam e: Bisoprolol Charge Isopropy l amino propanol, Iso propyl ethoxy-p-tolyl compound, IPA, KOH flakes, D M Water heat and reflux distilled out IPA. Add DM water Acetone, Fumaric Acid cool & filters dry in RCVD to get Bisoprolo l
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 181
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
60 Isopropyl amino propanol
520 To recovery 100 Iso propyl ethoxy-p-
tolyl compound 450 IPA
30 KOH Flakes 15 DM Water
500 D M Water 300 Acetone
40 Fumaric Acid 725 Waste water
40 Moisture drying lost
Kgs Starting Material Kgs Product Kgs W aste 60 Isopropyl amino
propanol
100 Iso propyl ethoxy-p-tolyl compound
450 IPA 30 KOH Flakes 15 DM Water
500 D M Water 300 Acetone
40 Fumaric Acid
80 Bisoprolo l Fumarate 725 130 520 40
To ETP Waste Waste Water Potassium Chlor ide 2) To Recovery 3) Moisture Loss
1495 Total 80.00 Total 1415 Total
Reciever
Reactor
Filter
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 182
61). Product Name: Olanzapine Charge Methyl piperazinyl Ch loro-thieno benzodiazepine, N N DMA, catalyst heat and reflux distilled out .Add Acetonitrile coo l & filters dry in RCVD to get Olanzapine
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 183
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
80 Methyl piperaziny l
510 To recovery 100 Chloro-thieno
benzodiazepine
400 N N DMA 10 Catalyst
300 Acetonitrile
25 Moisture drying lost
Kgs Starting Material Kgs Product Kgs W aste 80 Methyl piperaziny l
100 Chloro-thieno benzodiazepine
400 N N DMA 10 Catalyst
300 Acetonitrile
75 Olanzapine 280 510 25
To ETP Waste Waste Water 2) To Recovery 3) Moisture Loss
890 Total 75.00 Total 815 Total
Reciever
Reactor
Filter
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 184
62). Product Name: Rosiglitazone Charge Methyl pyridinyl amino ethoxy phenyl in reactor and add 2,4 thiazo compound, IPA, Base heat and reflux distilled out IPA. Add methanol, Sodium Borohydride and 50% con HCl cool & filters dry in RCVD to get Rosiglitazone.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 185
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
100 Methyl pyridinyl amino ethoxy phenyl
435 To recovery 70 2,4 Thiazo Compound
450 IPA 20 Base
100 Methanol
15 Sodium Borohydr ide 16 50% HCl
31 Moisture drying lost
Kgs Starting Material Kgs Product Kgs W aste 100 Methyl pyridinyl amino
ethoxy phenyl 70 2,4 Thiazo Compound
450 IPA 20 Base
100 Methanol 15 Sodium Borohydr ide 16 50% HCl
75 Rosiglitazone 230 435 31
To ETP Waste Waste Water Sodium Chlor ide 2) To Recovery 3) Moisture Loss
771 Total 75.00 Total 696 Total
Reciever
Reactor
Filter
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 186
63) Product Name: Fentanyl Citrate Charge Phenyl piperidinyl compoundxy phenyl, Propinamide compound, THF, K3 CO3 and water heat and ref lux distilled out THF Add Acetone and citniacid cool & filters dry in RCVD to get Fentanyl Citrate
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 187
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
60 Phenyl piperidinyl compoundxy phenyl
650 To recovery 100 Propianamide
compound 500 THF
30 K3 CO3
10 Water
300 Acetone
THF- 495
25 Citniacid
25 Moisture drying lost
Kgs Starting Material Kgs Product Kgs W aste 60 Phenyl piperidinyl
compoundxy phenyl
100 Propianamide compound
500 THF 30 K3 CO3 10 Water
300 Acetone 25 Citniacid
70 Fentanyl Citrate 130 150 650 25
To ETP Waste Waste Water Potassium Salt Potassium 2) To Recovery 3) Moisture Loss
1025 Total 70.00 Total 955 Total
Reciever Reactor
Filter
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 188
64). Product Name: Lacidipine Charge Ferbutoxy carboxyl compound, Mac, Aldehyde, Methanol, Base heat and reflux distilled out Methanol.Add Ethyl Acetate I P A cool & filters dry in RCVD to get Lacidip ine
CHO
CHO Ph3P=CH-COOtBuCHO
COOtBu
NH2 CH3
COOCH2CH3
CH3COOH
COOtBu
NH
O CH3OCH3
OO
CH3 CH3
MW: 455.54
Lacidipine
benzene-1,2-dicarbaldehyde
ethyl (2E)-3-aminobut-2-enoate
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
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Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
45 Ferbutoxy carboxyl compound
920 To recovery 60 Mac
50 Aldehyde 500 Methanol
20 Base
600 Ethyl Acetate
450 IPA
25 Moisture drying lost
Kgs Starting Material Kgs Product Kgs W aste 45 Ferbutoxy carboxyl
compound 60 Mac 50 Aldehyde
500 Methanol 20 Base
600 Ethyl Acetate 450 IPA
70 Lacidipine
410 300 920 25
To ETP Waste Waste Water Acetate 2) To Recovery 3) Moisture Loss
1725 Total 70.00 Total 1655 Total
Reciever
Reactor
Filter
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 190
65). Product Name: Venlafaxine HCl: Charge Formic Acid, VF2 Acetate, D M Water Formaldihyde Na OH K Flakes Ethyl Acetate heat and ref lux distilled out IPA cool & filters dry in RCVD get Venlafaxine HCl
NH2
OCH3
OH
HCOOHHCHO
N
OCH3
OH
CH3
CH3
O
N
OCH3
CH3
HCOONa
1-[2-amino-1-(4-methoxyphenyl)ethyl]cyclohexanol
MF: C15H23NO2
MW: 249
Venlafexine
MF: C17H27NO2MW: 277.40
MF: C15H23NO2
MW: 249
HCHO HCOOH
MW: 30 MW: 44
+ + MF: C17H27NO2
MW: 277.40
+ 3 H2O
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 191
(66).Product: Venlafaxine Material Flow Sheet:
Qty Kgs
Input Reaction & Equipment Qty Kgs
Output
100 Formic Acid
110 VF2 Acetate
1000 D M Water 200 Formaldihyde
32 NaOH Flasks
150 Ethyl Acetate 800 Waste Water
31 Moisture drying lost
Kgs Starting Material Kgs Product Kgs W aste 100 Formic Acid 110 VF2 Acetate
1000 D M Water 200 Formaldihyde
32 NaOH Flasks
70 Venlafaxine
800 200 341 31
To ETP Waste Waste Water Sodium Acetate Sodium Chlor ide 2) To Recovery 3) Moisture Loss
1442 Total 70.00 Total 1372 Total
Reciever
Reactor
Filter
Moisture removel
Collection Pit
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 192
67)Product Name: Itopride:Charge Benzamide, Toluene, Na OH Flakes D M Water and IPA heat and ref lux distilled out IPA coo l & filters dry in RCVD to get Itopride
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
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APPENDIX-III
SAFETY, HEALTH AND ENVIRONMENT PO LICY It is the policy of the company to manufacture, handle and dispose of all substances and products without making unacceptable risks to human health or the environment.
We believe that all identified health hazards are containable and all accidents are preventable. Our policy is to maintain safety beyond compromise. We will comply with all applicable laws and regulations and endeavor to improve such minimum legal requirements. We have a responsibility to know potential hazards and to make known to all others as needed. Even if we discover a hazard after its known. Line organization shall assume responsibility for health and safety for its people and product at all times. Periodic audits will be done to get a feedback, a verification of all that is intended to be done to meet the objectives. We are committed to have continual improvement in SHE Management and performance. If it is noticed that the Product/s produced by us is unsafe with respect to Safety, Health & Environment; then management will immediately stop the respective production. Executive Director (Technical & Production) Rev iewed on 31st December 2013 Next review date: December 2015
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
Page no 211
APPENDIX-IV CONSO LIDATED CO NS ENT & AUTHORIZATION
CC A – Amendm ent for ZLD
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
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CCA valid till 25/07/2018
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
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GPCB- “INC RESE IN PO LLUTION LO AD CERTIFICATE”
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
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FIGURE : 9 ENVIROMENTAL MANAG EMENT C ELL
GENERAL MANAGER PROD. & TECHNICAL
ENVIRONMENT & SAFETY OFFICER
Q.C. /QA MANAGER
CHEMIST EXECUTIVE/OFFICER /CHEMIST
CHEMIST
OPERATOR OPERATOR
EXECUTIVE DIRECTOR
SE.PRODUCTIONMANAGER
GENERAL MANAGER ENVIRONMENT
HEALTH & SAFETY
ENVIRONMENT EXECUTIVE
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
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APPENDIX-V
Compliance report for CCA am endment order no: AWH-79944
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
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M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
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C onsent order no: AWH-57529 dated 06/10/2013 compliance report Consolidated consent & authorization noAWH-57529 dated 06/10/2013 issued to M/ S.
Unique Chemicals (A div o f J B CHE MICALS & PHA RMACEUTICAL S L TD) v alid up to 25/07/2018.
Complian ce report for th e Consent o rder no: AWH-57529 is as under. 1. Consent o rder validity up to 25/07/2018. Co mpliance: Unit will apply fo r CCA renewal application three months befo re Validity over. 2. Consent o rder is issued for (43 no) Produ cts & total cap acity -78.02 MT/ month. Co mpliance: Unit h as manu factured products as p er Consent ord er & as per Consented Capacity. Unit will continue to manufacture product & capacity as per Consent order issued . 3. 3.1. The water consu mption quantity per day shall not exceeds 200 KL/day Compliance: Water consu mption by the unit is l ess than 200Kl/day & same will be Maintained . 3.2. The total quantity o f w aste water gen erated p er day sh all not exceeds 130.0KL/d ay (Do mestic-30 KL/day & Industrial -100 KL/day) Compliance: Unit will continue to maintain waste wat er g eneration quantityas per Consents o rder. 3.3. Sew age water sh all be disposed off through septic tank/ so ak pit syste, Compliance: Sewage w ater is disposed o ff th rough s eptic tank/ soak pit. 3.4. Unit shall affi x water met er as p er Section 4(1) o f Water Cess act-1977 for the purpose o f measuring & recording water consu med at such places. Compliance: Unit has fi xed water meter as p er requi rement. 3.5. 3.5.2 The effluent con fo rming to the standard shall be discharg ed in to GIDC underground d rainag e system and convey ed to FE TP which ulti mately leads to d eep sea fo r fin al disposal through BEAIL pipeline. Compliance: The unit is discharging treated waste wat er as p er pres cribed norms of FETP to GIDC collection su mp leads to FETP (NCTL ) fro m wh ere it is finally carried to d eep sea by pip eline. 3.5.3 The applicant sh all have to mak e storage facility for 48 hou rs. Compliance: Unit hav e already mad e arrangement for storag e of effluent for more than 48 hours . 3.5.4 The applicant sh all have to keep records of qu ality & quantity o f effluent discharge to FE TP. Compliance: Unit has fi xed a Magnetic flow meter & pH meter on discharge line. Treated effluent is tested & than discharg e to FE TP. 4. . 4.1. The following fuels should be us ed in the Boiler /DG set Compliance: In Boiler – Natu ral g as -7200 M3/day & DG s et – HSD 60Lit/hour for each DG s et is used . 4.2. Flue gas emission through stacks shall conform st andard. Compliance: Flue gas emissions fro m the stacks are confirming with prescribed standard 4.3. Process emissions through various stack /vents shall conform to the standard. Compliance: Process emissions fro m vents o f th e scrubber are con fi rming to the standard. 4.4. The con centration of parameter in ambient air within premises o f the industry sh all not exceed limits prescribed. Compliance: Con centration of v arious p arameters in ambient air remaining well within li mit prescribed 4.5. Compliance: The ai r pollution control equip ments are maintained efficiently &g aseous emissions always con forms to the standard speci fied . 4.6. Compliance: Necess ary port holes , ladd er & plat forms are provided for sampling & inspection o f air emissions. 4.7. Compliance: Ad equate measu res are tak en for Noise pollution like canopy . 5. 5.1. Compliance: Co mplied 5.2. Compliance: Co mplied 6. 6.1. Compliance: Hazardous waste gen erated fro m the unit, its collection, storag e , transportation & disposal are carried out as p er authorization issued by the board . Th e recovered material is send to actual end us ers as prescribed in the Consent order. 6.2. Compliance: Other conditions co mplied . 7. Compliance: Conditions 7.1 to 7.10 are complied.
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.
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Factory License
M/s. Unique C hemicals. (A Div. of J B CHEMICALS & PHARMACEUTICALS LTD.), PANO LI.