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M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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1.0 EXECUTIVE SUMMARY
M/s. ZCL Chemicals Ltd. is engaged in manufacturing of Pharmaceuticals Intermediates and
Active Pharmaceutical Ingredients at Plot No. 3102/B, GIDC Industrial Estate, Ankleshwar -
393002, Gujarat.
As per EIA notification 2006 and its amendment, the proposed project is falling under category
5(f). The unit is having CCA for manufacturing of Pharma Intermediates and Active
Pharmaceutical Ingredients.
One of our manufacturing plant (Unit 1A) at this site is more than 15 years old and it does not
match with current standards of Emergency preparedness and safety of building. Building was
constructed in 1999 based on consideration of safety standards prevailing at that time.
As per remarks of Deputy Director (Industrial Safety and Health), Bharuch (Factory Inspector),
during his visit regarding inspection of said building, suggested that operation in Unit 1A plant to
be gradually stopped for manufacturing activities. Safety reasons are cited by Factory Inspector
in his remarks.
We have been informed by the competent chartered engineer that this building is now getting
older and as per his recommendations building will not be suitable for manufacturing in next 2-3
years.
To meet above requirements, related to quality and safety standards, we propose to relocate the
existing plant building in the open land available with us at same site. This building will be a
relocation of the Unit 1A building.
It is assured that, by this change, unit will neither increase production capacity nor pollution load
in any form.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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The details of products are given below table.
TABLE: 1
LIST OF PRODUCTS
Sr.
No.
Name of Products Existing as per
CCA No. AWH-
72765 (MT/Year)
1 Thrio Pypridil AmideAND/OR 204.03
2 Ritalinic acidAND/OR
3 4 - benzyloxy -3- nitrophenylace bromideAND/OR
4 Zonisamide – USPAND/OR
5 Modafinil - EP/USPAND/OR
6 4-Amino-N-[(2 R, 3S)- 3 Amino, 2 hydroxy, 4- phenyl
butyl ] – n – (2 Methyl propyl) benzene
sulfonamideAND/OR
7 Darunavir AND/OR
8 BOC Nitro
9 Fluvoxamine Maleate- EP/BP/USP/JP AND/OR
10 Trifluoperazine - USP/EP/BP AND/OR
11 Methylphenidate - USP/EP AND/OR
12 R & D Products AND/OR
13 Dex Methyl Phenidate AND/OR
14 Chlordiazepoxide AND/OR
15 Cillastazol AND/OR
16 7 Hydroxy 1,2,3,4 tetra hydro quenoline AND/OR
17 Chloro Methyl cyclo propane AND/OR
18 1-(2,3 dichloro phenyl) - piperazine hydrochloride
(DCPP) AND/OR
19 BBQ (7-(4-Bromobutoxy)-3, 4-dihydroquinolin-2(1H)-
one) AND/OR
20 T2551 - Etravirin Inter AND/OR
21 Canagliflozicin Inter (n-2): 2-(4-fluorophenyl)-5-(5-
iodo-2-methylbenzyl)thiophene AND/OR
22 Aripiprazole AND/OR
23 BET (1-(2-Bromoethyl)-4-ethyl-1,4-dihydro-5H-
tetrazol-5-one) AND/OR
24 1-Amino Indane AND/OR
GROUP – 1 (Total) 204.03
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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Sr.
No.
Name of Products Existing as per
CCA No. AWH-
72765 (MT/Year)
25 Trimethyl pyruvic AcidAND/OR 42.03
26 4,4’-Diflurobenzhydryl Piperazine AND/OR
27 2 Tri Pheno trimethyl phenothiazine AND/OR
28 Levomepromazine AND/OR
29 Betahistine IP / EP / USP AND/OR
30 Betahistine Mesylate JP/EP AND/OR
GROUP – 2 (Total) 42.03
31 Phenyl 2 Piperidyl Acetamide AND/OR 23.1
32 N- (1 Benzyl 4 Piperidinyl) N Phenyl Propanamide
HCL / NN Phenyl N 4 Piperidinyl Propanamide HCl
AND/OR
33 N Acetyl Hydroxy Phenyl Piperazine AND/OR
34 Amino Ethyl Phosphoric Acid AND/OR
35 (1-Isopropyl-4-(hydroxyl Phenyl) (piperazine)
AND/OR
36 Memantine HCl AND/OR
37 Quetiapine Fumerate AND/OR
GROUP – 3 (Total) 23.1
38 Phenyl 2Pyridyl Acetamide AND/OR 23.27
39 Zaltoprofen AND/OR
40 Alprazolam AND/OR
41 Mono chloro acetonitrile AND/OR
GROUP – 4 (Total) 23.27
42 (N-[4-Methoxymethyl)-1-(phenyl methyl)-4-
Piperdinyl]-N-Phenyl Propanamaide- Ethanedioate.
0.06
43 Dex Ritalinic Acid 0.1
44 Remi N Benzyl Propeonamide eater Oxalate 0.02
45 Nebivolol 0.1
46 Flurbiprofen 0.4
47 Olanzapine 0.4
48 Levodropropizine 0.5
49 Atomoxetine 0.5
50 Felbinac 3
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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Sr.
No.
Name of Products Existing as per
CCA No. AWH-
72765 (MT/Year)
51 Clozapine 1.8
52 Diazepam 0.4
53 Oxazepam 0.4
54 Flupirtine maleate 0.4
55 Bromazepam 0.4
56 Benzhydrl Piprazine 4
Individual (Total) 12.48
Total 304.906
COST OF PROJECT
Total cost for proposed project is approx. 4635 lacs. The plot has been purchased by M/s. ZCL
Chemicals Ltd. from GIDC. The total plot area of relocated building is 1808 Square meter and
the total plot area of the unit is 35595 Square meter. The green belt area is 6215.04 square
meters.
FUEL CONSUMPTION
The existing unit uses Natural gas as fuel for Boiler & Thermic fluid heater and diesel used for
DG Set. There will be no changes in proposed project for Natural gas Consumption for Boiler&
Thermic fluid heater, Diesel consumption for DG set.
ELECTRICITY CONSUMPTION
The unit have electricity from Daxin Gujarat Vij Company Ltd. The existing electricity
consumption is 950 KVA. There will be no changes in Electricity consumption.
WATER CONSUMPTION
The source of water is from GIDC water supply scheme.
The water consumption for industrial purpose is 143.8 KL/day. The water consumption for the
domestic & gardening purpose is 21.2 KL/day fresh water. There will be no change in water
consumption.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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Note: Water shall be taken from the existing set up of water for construction work.
WASTE WATER GENERATION
The existing industrial waste water generation is 45 KL/day and domestic waste water is 10
KL/day. 55 KL/day of effluent is treated in ETP. Treated effluent is discharged in to GIDC
Pumping station – B through above ground fixed pipeline leading to the inlet of FETP for further
treatment and its ultimate disposal to deep sea (facility operated by NCTL). Since the proposed
building is a relocation of existing building, there will be no change in the waste water
generation, treatment and disposal.
GASEOUS EMISSION
There is one stack of one boiler (capacity: 3.5 Ton/Hr), one stack of Thermic fluid heater
(capacity: 4 lac Kcal) and two stack of two Diesel generators (capacity: 250 & 750 KVA
respectively). The two D.G. sets will be used in case of emergency only.
Process emission is from two numbers of stacks. There is one stack attached to Reaction vessel
in Plant-1, one stack attached to Reaction vessel in Plant-2. These stacks are connected with
scrubbers (Water +Caustic).
There is process emission from two vents of the Water scrubber & Caustic scrubber. Since the
proposed building construction is relocation of existing building, there will be no change in the
gaseous emissions.
HAZARDOUS WASTE MANAGEMENT
There will be generation of ETP sludge (339 MT/Year), Carbon Waste (18.25 MT/Year),
Distillation residue (36.5 MT/Year), Discarded containers (43800 Nos/Year), Distillation residue
from contaminated organic solvents (0.73 MT/Year), Used/Waste Oil (1.83 MT/Year),
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Contaminated solvents not fit for originally intended use (73 MT/Year), Spent solvent (73 MT /
Year).
ETP sludge will be disposed at TSDF M/s. BEIL. Carbon Waste, Distillation residue and
Distillation residue from contaminated organic solvents will be send to incineration at TSDF
M/s. BEIL/RSPL & Ambuja Cements for Co -processing. Discarded containers will be sold to
authorized vendors. Used / Waste Oil will be sold to registered refiners. Contaminated solvents
not fit for originally intended use, spent solvent will be reused within premise or dispose of at
TSDF for incineration.
Since the proposed building construction is a relocation of existing building, there will be no
change in the hazardous waste generation.
2.0 INTRODUCTION
2.1 THE PROJECT
M/s.ZCL Chemicals Limited has acquired plot no. 3102/B, GIDC Estate, Ankleshwar for
manufacturing of Chemical Pharmaceuticals Intermediates and Active Pharmaceutical
Ingredients. The list of products is provided in Table -1.
2.2 PROJECT PROPONENT
M/s.ZCL Chemicals Limited was incorporated in the year 1991. They have manufacturing unit
in Ankleshwar. The Company delivers a broad range of advance fine chemical Pharmaceuticals
intermediates and Active Pharmaceuticals Ingredients for pharmaceutical end use and services to
customers around the world. ZCL has been concentrating on Research and Development. The
project proponents are already in market and doing manufacturing and trading of these products.
Quality, Environment, Health and Safety
Policy:
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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The policy of the company is as under:
Reflecting its Commitment to Global leadeaship and Excellence in Quality, Environment, Health
and Safety , ZCL Chemicals Ltd. Ankleshwar, Manufacturing Advance Intermediates, Active
Pharmaceutical Ingradient and Safety Chemical in having Guidline principles that Comminted
toward Compatancy in Quality, Lead Time , Overall Economic Feasibility through Environment
Health and Safety must satisfy our Esteem Customers.
It is Policy of ZCL Chemicals Ltd. , Ankleshwar, That
All Incident are Preventable, All identified Health Risk are Containable and identified
Environment impacts are Prevented.
Prevent Injuries and Occupational Illness at the Workplace.
Enhance quality, environment, health and safety awareness.
Comply with all Statutary and Regulatory Laws and Regulation for Quality, Environment,
Health and Safety
Continual improvement towards Quality, Technology, after Sale Service Aspect and Upgration
of Environment, Health and Safety Management system to Prevent/Minimize Pollution,
Occupation Health and Safety risks.
Enhance Visibility of Top Management towards Conservation Resource Quality, Environment,
Health And Safety.
Our Quality, Environment, Health and Safety Consciousness shall be Recognised through
acheiving excellence implementation level of ISO 9001 : 2008, ISO 14001: 2004 and Oshas
18001 : 2007 Norms.
The name and address of Directors are given in Table 2.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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TABLE: 2
CONTACT DETAILS OF THE DIRECTORS
List of Directors as on 01.03.16
Sr.
No. Name & Address of Directors
Date of
Appointment
Date of
Ceasing
Date of
Birth PAN No.
Contact
No.
1 Mr. Ajay Krishnakant Parikh 13.03.1991 Nil 24.06.1957 AACPP4774A
022--
61539900
20/301, Gurukrupa, Vithal Nagar,
CHS Ltd., 11th
Road, JVPD
Scheme,
Vile Parle (W), Mumbai – 400
049
2 Mr. Nihar Ajay Parikh 01.09.2010 Nil 13.11.1985 AKNPP4298E
022--
61539906
20/301, Gurukrupa, Vithal Nagar,
CHS Ltd., 11th Road, JVPD
Scheme,
Vile Parle (W), Mumbai – 400
049
3 Mr Dhiren Shevantilal Shah 05.09.2011 Nil 29.04.1956 AAEPS0922M
022--
61539999
Cumbala Hill post Office
Gamdevi P.Stn
Mumbai - 400026
4 Mr.Piyush Maganlal Nathwani 30.01.2015 Nil 24.04.1961 AAZPN7154P
02646-
619405
F 14,Shashwat Complex
Dahej By Pass Road
Bharuch-392001,Gujarat
5 Ms. Anuja Ajay Parikh 31.07.2015 Nil 26.07.1989 ASAPP0424F
022-
61539999
20/301,Guru Krupa,Vital Nagar
Society,
11th Road,JVPD Scheme,Vile
Parle(west)
Mumbai-400049,Maharastra
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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2.3 NATURE OF PROJECT
The existing Unit1A plant is very old so considering about safety point of view M/s. ZCL
Chemicals Ltd. decided to relocate it.
2.4 MARKET FEASIBILITY
Established in 1991, ZCL Chemicals Ltd (ZCL) is head quartered in Mumbai. The cGMP
manufacturing facility and state-of-the art R&D Center are located in the Industrial park of
Ankleshwar in Gujarat State. ZCL combines the power of Science & Technology and has been
into manufacturing of Active Pharmaceutical Ingredients (APIs) and Advance Intermediates for
Innovator and Generic companies around the world. Has earned the preferred partner status from
some of the Global Pharmaceutical companies.ZCL production site has been successfully audited
and approved by the US FDA, KFDA, WHO-GMP and Japanese customers.
It is a policy of ZCL CHEMICALS LTD, That Commitment towards competency in Quality,
lead time and overall economic feasibility must satisfy our esteemed customers.
Continual improvement towards technical and after sales service aspects of all products shall be
our motto. Renovation towards the best shall be equally participated from all our employees to
drive the organization towards achieving further success & growth in business.
Our quality system is based on ICH Q7 GMP requirements.
Our quality consciousness shall be recognized through achieving excellent implementation level
of ISO 9001:2000; ISO 14001:2004, OHSAS 18001:2007 Norms.
2.5 EMPLOYMENT GENERATION DUE TO THE PROJECT
The details are given below
TABLE: 3
DETAILS OF MANPOWER
Sr.
No. Phase of Project Type of Labor No. of Worker
1 During construction Contractual 150
2 During
commissioning Contractual
NA (existing
manpower shall be
used)
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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3.0 PROJECT DESCRIPTION
3.1 TYPE OF PROJECT
The proposed project is not including any interlinked and interdependent projects.
3.2 PROJECT LOCATION
The proposed project site is located at Plot No. 3102/B, GIDC Industrial Estate, Ankleshwar,
Dist.Bharuch in the state of Gujarat. It is approximately 20 km distance from district head
quarter Bharuch. The approximate geographical positioning of the project site is at Latitude: 21o
37’ 36” N, Longitude: 73o01’ 58” E. The location of the project site can be identified from the
location map shown in Figure -2.
The salient features of the location of the project site are presented in below Table.4.
TABLE: 4
SALIENT FEATURES OFTHE PROJECT SITE
Particulars Details
Village Ankleshwar
Taluka/ Tehsil Ankleshwar
District Bharuch
Approx. Geographical positioning Latitude: 21o 37’ 36” N
Longitude: 73o
01’ 58” E
Nearest City Bharuch about 20 KM
Nearest Town Ankleshwar
Nearest Highway National Highway No. 8
Nearest State highway National Highway No. 8
Nearest Railway line/ Railway
station
Ankleshwar Railway Station
Nearest Airport/ Airbase Vadodara about 94 KM
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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FIGURE: 1
LOCATION OF THE PROJECT SITE
Ankleshwar Industrial area
Panoli Industrial area
Jhagadia industrial area
Priaman CETP
Canal
Piraman to Katiyajal Effluent
Pipe
Jhagadia to Piraman CETP
Panoli to Piraman CETP
PROJECT SITE
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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FIGURE: 2
AERIAL VIEW OF THE 5 KM RADIAL PERIPHERY FROM THE PROJECT SITE
3.3 SITE SELECTION
The existing plant is very old so considering about safety point of view M/s. ZCL Chemicals
Ltd. want to relocate Unit1A in the same premises .
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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3.4 NEIGHBOURING INDUSTRIES
The industry is located in an area, which is already industrialized. The industries in the vicinity
of the proposed project are given in the table 5:
TABLE: 5
NEARBY INDUSTRIES IN THE VICINITY
Name of Industry Direction with
respect to project
site
Address
United Phosphorus
Limited (Unit- 2)
East side of
company Plot No. 3405/3406, GIDC Industrial
Estate,Ankleshwar-393001
Glenmark
Pharmaceutical
Ltd.
North side of
company
Plot No. 3109/C, GIDC Industrial Estate,
Ankleshwar-393001
RPG Life Sciences
Limited.
South side of
company
Plot No. 3102/A, GIDC Industrial Estate,
Ankleshwar-393001
United Phosphorus
Limited (Unit- 3)
West side of
company
Plot No. 3101/2, Ankleshwar GIDC,
Ankleshwar - 393001
3.5 SIZE OF PROJECT
The expected cost of proposed project is Rs. 4635 lacs.
The following table shows the break-up of the project cost.
TABLE:6
CAPITAL COST OF PROJECT
Sr.
No.
Activities Capital cost in
Rs. lacs/Annum
(Approx)
1. Land Existing land
2. Building 1035 lacs
3. Plant and Machinery 3368 lacs
4. Q.A. Lab set up NA (existing set up will be
used)
5. Env. Protection & Safety
a) Effluent treatment Plant NA(existing set up will be
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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used, no additional effluent
load)
b) Air pollution control & Hazardous waste
management
120
c) Safety Equipment (PPE, fire extinguishers,
Ventilation, etc.)
110
d) Green belt development 2
Total 4635 lacs
3.6 PROCESS TECHNOLOGY
Process details like process description for each grade of products are covered separately in
Annexure-VI of Form-I.
3.7 RAW-MATERIALS
The required raw materials will be purchased from the local/ Indian market& China. Details of
raw-material consumption are covered in Annexure-V of Form-I.
3.8 RESOURCE OPTIMIZATION/RECYCLING AND REUSE
3.8.1 SOLVENT RECOVERY
Methanol (81% recovery), MDC (85% recovery), Toluene (93% recovery), Chloroform (85%
recovery), Xylene (85% recovery), Acetic Acid (88% recovery) and Hexane (88% recovery) are
the solvent to be used in the existing process. There are provisions of recovery of solvent.
3.9 RESOURCE REQUIREMENTS
3.9.1 LAND
The plot had been purchased by M/s.ZCL Chemicals Limited from GIDC. The total plot area of
the unit is 35595 sq. m.
3.9.2 BUILDING
The existing plant is very old so considering about safety point of view M/s. ZCL Chemicals
Ltd. decided to relocate the existing plant building Unit1A. Investment proof has been given by
Chartered Accountant.
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M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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3.9.3 POWER AND FUEL
The unit’s power and fuel requirement is provided in Table 7. There will not be any increase in
fuel consumption.
TABLE:7
POWER AND FUEL REQUIREMENT
3.9.4 WATER
The category wise bifurcation of the water requirement is given in Table no 8. The source of
water will be from GIDC water supply scheme. There will be no change in Proposed Water
consumption.
TABLE:8
DETAILS OF WATER CONSUMPTION
3.9.5 MANPOWER
Sr.
No.
Particulars Existing as per
Consent Quantity
Proposed
Quantity
Total
Quantity
Source
1. Natural Gas
for Boiler &
Thermic Fluid
Heater
290 SCM/Hrs -- 290 SCM/Hrs Gujarat
Gas
2. Diesel For DG
Sets
117 Lit/Day -- 117 Lit/Day Local
Supplier
3. Energy-
Electricity
950 KVA -- 950 KVA DGVCL
Particulars Existing water
consumption (KL/Day)
Proposed water
consumption (KL /Day)
i) Domestic+Others
(gardening etc) 21.2 21.2
ii) Industrial
Process 25 25
Boiler 12 12
Cooling 64.8 64.8
Washing 42 42
Total 165 165
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The manpower required for the project as well as during the construction/commissioning
activities will be employed from the local area. The details are provided in Table 3.
Sr.
No. Phase of Project Type of Labor No. of Worker
1 During construction Contractual 150
2 During
commissioning Contractual
NA (existing
manpower shall be
used)
3 During operations
Managerial 130
Skilled 40
Un-skilled 120
Total: 290
3.10 MITIGATION MEASURES & EMP
Based on overall manufacturing & operation activities, the mitigation measures have been
proposed by the company for the control of the anticipated pollution load.
3.10.1 WASTEWATER MANAGEMENT
The category-wise bifurcation of the anticipated wastewater generation details is given in Table 9.
There will be no change in Proposed Wastewater generation due to Proposed construction work.
TABLE:9
DETAILS OF WASTEWATER GENERATION
Particulars Existing Wastewater
generation(KL/Day)
Proposed Wastewater
generation(KL /Day)
i) Domestic+
Others
(gardening etc)
10 10
ii) Industrial
Process 14 14
Boiler 4 4
Cooling 3 3
Washing 24 24
Total 55 55
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3.10.1.2 WASTEWATER CHARACTERISTICS
Industrial wastewater will be generated from process, cooling tower and boiler. The expected
characteristics of industrial wastewater are provided in Table 10.
TABLE: 10
WASTE WATER CHARACTERISTICS
Sr.
No. Parameters
Unit
s
Standards
prescribed
by GPCB
Standards
prescribed
by NCTL
Before
Treatmen
t
After
Treatmen
t
1 pH -- 5.5 to 8.5 5.5 to 8.5 6- 9 6.5-8.5
2 Colour Pt
Co 100 -- 400-1000 50-70
3 Total Suspended Solids mg/l 100 -- 4500-5500 30-60
4 Total Dissolved Solids mg/l 2100 -- 30000-
35000 2000-2300
5 Oil & grease mg/l 10 -- 8-11 Not
detected
6 Phenolic compounds mg/l 1 -- 1-3 Not
detected
7 Cyanides mg/l 0.2 -- Not
detected
Not
detected
8 Ammonical Nitrogen mg/l 50 100 600-800 30-50
9 Sulphate mg/l 1000 -- 5000-6000 200-300
10 B.O.D.(3 days at 27°C) mg/l 30 -- 10000-
12000 55-70
11 C.O.D. mg/l 100 1000 30000-
35000 170-200
3.10.1.3 WASTEWATER TREATMENT & DISPOSAL
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MEE OPERATION PROCEDURE
Effluent Feeding:
Neutralized effluent (High COD) from neutralization tank after passing through filter press shall be
brought for treatment through pipeline in balance tank at MEE plant.
Pre Heaters
This effluent will be pumped to Pre-heater 3, 2, 1 in series and finally to stripper column via MEE feed
pump with a flow of 1900-1950 Lit/Hr. and finally to solvent stripper column through pumping under
vacuum.
Main Steam application
After starting feed pump gradually open TVR Valve and maintain high steam pressure around 4.0
Kg/Cm2.
Solvent stripper Unit
Start Solvent stripper column pump and maintain solvent stripper column level (Half level of side glass)
through adjustment of valve of Reboiler & recycle valve. Open Low pressure steam valve gradually for
solvent stripper column/re-boiler and maintain Temp around 85 oC. When desired temp. attained in
stripper column/Reboiler start condensate pump and transfer low boiler vapor condensate via surface
condensers to Stripper condensate collection tanks. The residual high boiler effluent will be transferred to
Calendria 1.
Calendria’s
After receiving high boiler effluent start Calendria pump No. 01, 2, and 3 in successions after necessary
level is maintained in calendria’s. During level maintenance apply steam gradually and maintain upto 8.0
Kg/cm2.
Condensate Pump
After full steam is applied in MEE, MEE condensate pump is started and the condensate received via
MEE surface condensor (primary and secondary) is recirculated back in balance tank till colour of the
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M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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condensate is clear, colourless & free from any suspended solids. Then transfer this condensate water in
MEE O/L collection tank via MEE condensate pump.
Recycle Pump
The remaining concentrated mass will be transferred after checking Baume (specific gravity) in VTFD
Balance Tank via recycle pump for further drying process in VTFD.
VTFD Unit
Start VTFD vacuum pump ensuring cooling circulation via vacuum Syntax pump.
The concentrated mass is kept agitated in VTFD Balance tank and is fed in VTFD agitator via VTFD feed
pump. Simultaneously open high pressure steam valve for VTFD and Maintain steam pressure 8.0 – 8.5
Kg/cm2 gradually.
Start main VTFD Agitator and set the valve opening such that dry powder/salt is received at the bottom
end. Start Condensate pump and transfer condensate received from VTFD surface condensor to E.T.P.
Collect dry powder/salt in drum from VTFD bottom hopper. Fill this powder/salt in empty bags and shift
to Haz Waste storage yard and dispose to TSDF time to time.
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TABLE: 11
DEMENTIONAL DETAILS OF ETP UNITS
Sr.
No. Name of Equipment Capacity
Retention time
in Hrs. MOC
1 Collection Tank 66 KL 26.4 RCC
2 Neutralization Tank 41 KL 16.4 RCC
3 Filter Press - - -
4 Filter Press Tank 05 KL 2 RCC
5 MEE Plant 40 M3/Day - MS
6 MEE O/L Collection Tank 36 KL 14.4 RCC
7 Primary Clarifier 20 KL 8 RCC
8 Aeration tank 150 KL 60 RCC
9 Secondary Clarifier 20 KL 8 RCC
10 Sludge Drying Bed 10 M2 - RCC
11 Secondary O/L Collection Tank 40 KL 16 RCC
12 Old Holding Tank 12 KL 4.8 MS
13 New Holding Tank (Final
Discharge Tank) 75 KL 30 RCC
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FIGURE:3
FLOW DIAGRAM OF ETP
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FIGURE :4
FLOW DIAGRAM OF MEE
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3.10.2 GASEOUS EMISSIONS & CONTROL
There will be flue gas emission from one Boiler, Thermic fluid heater and Two DG sets. Natural
gas is fuel and diesel will be used as fuel in DG set. The air pollution control measures are
covered in below table 12.
TABLE:12
DETAILS OF FLUE GAS EMISSIONS
Sr.
No.
Stack
Attached
To
Stack
Height
Stack
Diameter
Fuel
Consumption
Air
Pollution
Control
System
Type
of
Emission
Permissib
le Limit
As per Existing
1. Boiler
G1207A 30 m
0.45m
(Top) Natural gas -- PM
SO2
NOx
150
mg/NM3
100 PPM
50 PPM 2. Thermic
fluid heater 22 m
0.5m
(Top) Natural gas --
Note: There will be no change in proposed flue gas emissions due to Proposed Project
include only construction of new plant after demolishing existing Unit 1A.
3.10.2.2 PROCESS EMISSIONS
The process emissions from the proposed manufacturing activities are given in Table 13.
TABLE:13
DETAILS OF PROCESS EMISSIONS
Sr.
No.
Stack
Attached
To
Stack
Height
(m)
Stack
Diameter
(m)
Air Pollution
Control System
Type of
Emission
Permissible
Limit
As per Existing
1. Reactor Vessel
Plant - 1
25 0.15 Water
Scrubber+Caustic
Scrubber
HCl
SO2
CL2
20 mg/Nm3
40 mg/Nm3
9 mg/Nm3
2. Reactor
Vessel Plant -
15 0.15 Water
Scrubber+Caustic
HCl
CL2
20 mg/Nm3
9 mg/Nm3
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Note: There will be no change in proposed process emissions due to Proposed Project
include only construction of plant as relocation of existing Unit 1A.
3.10.3 HAZARDOUSWASTE MANAGEMENT
The following type of hazardous waste will be generated from the operational activities. All the
waste will be stored separately in a designated storage area.
TABLE:14
DETAILS OF HAZARDOUS WASTE GENERATION
Sr.
No.
Name of waste Cat.
No.
Quantity Method of disposal
Existing Total
1. ETP Sludge 34.3 339 MT / year 339 MT / year Collection, storage within
factory premises,
transportation and final
disposal at TSDF
M/s.BEIL.
2. Carbon Waste 35.3 18.25 MT /
year
18.25 MT /
year
Collection, storage within
factory premises,
transportation and
incineration at TSDF
M/s. BEIL/RSPL &
Ambuja Cements for Co -
processing.
3. Distillation
residue
20.3 36.5 MT /
year
36.5 MT / year Collection, storage within
factory premises,
transportation and
incineration at TSDF
M/s. BEIL/ RSPL &
Ambuja Cements for Co -
processing.
4. Discarded
containers
33.3 43800 Nos /
year
43800 Nos /
year
Collection, storage with
in factory premises,
transportation and sell to
authorized vendors.
2 Scrubber NH3 175 mg/Nm3
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5. Distillation
residue from
contaminated
organic solvents
36.4 0.73 MT /
year
0.73 MT / year Collection, storage within
factory premises,
transportation and
incineration at TSDF
M/s. BEIL/RSPL &
Ambuja Cements for Co -
processing.
6. Used / Waste Oil 5.1 1.83 MT /
year
1.83 MT / year Collection, storage,
treatment within factory
premises, transportation
and sell to registered
refiners.
7. Contaminated
solvents not fit
for originally
intended use
20.1 73 MT / year 73 MT /year Collection, storage,
recovery and reuse within
premise at site.
8. Spent solvent 20.2 73 MT / year 73 MT / year Collection, storage,
recovery and reuse within
premise at site.
9. High COD waste
from MEE
stripper
20.2 540 MT/year Max 540
MT/year
Collection, storage within
premises. Disposal at
TSDF/Incinerator.
Note: There will be no change in Hazardous waste generation .
3.10.4 NOISE CONTROL & ODOUR
The major noise generating installation will be the D.G. Set. It will be installed in a closed room,
acoustic enclosure will be provided around it.
Ear plugs will be provided to the operating personnel in boiler room. Low noise generating
equipments will be selected. Adequate engineering controls will be implemented to avoid noise
pollution.
The following steps will be taken for odor control.
• Raw-material feeding will be carried out by pumps and in close loop system.
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• All reactions will be taken in closed reactor system.
• Roof top ventilation will be provided in the entire plant area.
• Regular monitoring will be done of piping and fittings for checking of any leakages.
3.10.5 STORAGE, HANDLING AND TRANSPORT OF HAZARDOUS
CHEMICALS
The storage and mode of transport of chemicals will be done as per detailed MSDS and chemical
hazards guide for the hazardous chemicals.
Few chemical to be used in the proposed activities are listed as ‘Hazardous Chemicals’ as per the
Schedule-1 of the MSIHC Rules, as amended in 2000.
3.10.6 HEALTH AND SAFETY MEASURES
Few chemical to be used in the activities are listed as ‘Hazardous Chemicals’ as per the
Schedule-1 of the MSIHC Rules, as amended in 2000.
Physical hazards may manifest as fires, explosions, excessive temperatures, or the release of
large volumes of gas or toxic or flammable gases or vapors. According to Schedule 2 & 3 of
MSIHC Rules.
Below mentioned is the safety measure to be taken at site for control of anticipated hazards.
Identification, analysis, assessment of hazards and risk provides vital information to risk
management. Objective of this plan is to assess the risk and to provide guidelines for facing and
controlling the emergency.
This contains the information of possible hazards and their effects on the workers, general public
and environments.
• Hazards in storage area :
Following are possible storage hazards
� Fire
� Explosion
� Spillage / leakage
� Failure of storage tanks
Most of the chemicals are toxic in nature other than some exception. Toxic substances affect in
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three ways by ingestion, absorption and inhalation. Adequate provision of safety is done to work
with toxic materials.
� All raw materials, solvents, intermediates and finished goods are stored
according to their compatibility with other chemicals. The various places
where chemicals, solvents are stored are :
- Licensed tank farm area
- Raw material store
- Cold Room
- WIP room
- Bonded store
� All the flammable liquid materials are stored in storage tanks. The tank
farm for Petroleum Class A, B & C liquids is approved by Chief
Controller of Explosives after due inspection.
� The storage tanks are mounted above grounds with bund. Bund capacity is
1.1 times higher than biggest tank.
� The other chances of fire hazard may be due to generation of static
electricity due to flowing of solvent in the pipeline by accumulating
electrical charge & resulting spark. For this, company has provided
adequate number of static jumpers on each flange joints with proper
earthing.
� For vehicles like tanker, which carry flammable solvents, an additional
facility is provided at gate house for dissipation of static charge generated
by the tanker while coming to company from its supplier’s location.
� Rule of no smoking is observed strictly in the company premises.
Company has implemented “No Smoking Policy” and at appropriate
places, boards are displayed.
� All the safety standards & parameters are observed strictly. The total area
is provided with adequate firefighting equipment also.
� Earthing facility is provided at the unloading point to provide earthing to
the tankers at the time of unloading.
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� Flame arrestor is provided on the vents of tanks containing flammable
liquid.
� The tankers are provided with the flame arrestors (mufflers) while
entering inside the factory premises.
� The raw water tanks with capacity 250 M3.
� Water sprinkler provided on the tanks containing the flammable liquid in
tank farm area.
� The employees are trained in first aid fire fighting.
� Adequate SOPs are in place for safe handling of chemicals and concerned
employees are trained for the same.
� Spillage kit is provided to contain spillage / leakage.
• Fire and explosion
� The fire and explosion risk are associated with
- Solvents like Methanol, Toluene, Acetone, etc.
- Chemicals like phosphorous pentoxide, etc.
- certain chemical reaction like hydrogenation, grignard, distillation,
� Electrical short circuit
� The fire risk is not affecting outside factory. And hence the risk is limited
to factory area.
� The gas dispersion is Nil.
� To control the fire, fire extinguishers like DCP, CO2 and Foam are
provided. Also, factory has installed the DCP modular in the solvent tank
farm.
� Adequate water tanks having 750 M3 capacities. Facility for water at
several places in plant and factory premises.
� Sprinkler system in tank farm area to control vapour emission and thereby
reduced fire risk.
� Vapor detector system are installed in the warehouse
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• Spillage control
� SOP for prevention and control of spillage
- Eliminate all sources of ignition immediately.
- Ventilate the area but isolate the material.
- Absorb the chemical into sand.
- Allow atmospheric evaporation.
- Flush the spilled area with water and detergent.
� Spillage kit for spill control.
� In tank farm area, checking of bund and bund valve is introduced and
being checked regularly.
� Training for spillage control and handling to all employees.
� Fumes and cylinder leakage kit are available.
� All employees are trained for first aid fire fighting and use of personal
protective equipments.
� The duties of responsible persons are as follows :
- To guide the people to stop the leakage and spillage.
- To ensure good housekeeping.
• Technological and civil
Our main products are bulk drug and their advanced intermediates. Considering
the use of hazardous chemicals, following steps are taken.
� All structure and other equipments are fabricated as per the engineering
specification laid down in appropriate specification of international and
national bodies in the subject.
� Vessels are equipped with temperature indicators, pressure gauges, level
indicators, safety valves, etc.
� Vessels are pressure tested as per Factories Act, 1948. Flame proof fittings
are provided.
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� Regular inspection is carried out by external agency to maintain proper
health of plant, equipment and machinery.
� Thickness of tanks is carried out periodically and record maintained in
Form 11 as per Factories Act.
� Building structure is constructed as per standard practice. Material used is
tested for its quality and suitability under guidance of experts approved
under Government notification.
� The structure is being inspected by Government approved competent
person periodically and stability certificate is maintained.
� Inspection, maintenance, painting of plant / machinery etc, is carried out
regularly.
• Toxic release risk
The potential risk involved is leakage from tanks and pipelines.
To attain the toxic release of gases (DMS and Ammonia) from cylinder, cylinder
leakage control kit is available.
Fumex are available for the dilution of atmosphere inside the plant or used as an
exhaust or in case of tank cleaning it also used as a exhaust fan for fast dilute
Material Safety Data Sheet is kept as ready reference at all critical areas.
Evacuation table is displayed at gate.
Training is given related to Emergency Preparedness to both old and new
employees.
4.0 SITE ANALYSIS
4.1 CONNECTIVITY
The site is located at Plot no. 3102/B, GIDC Estate, Ankleshwar, Gujarat. The land and
Infrastructure is already available and the raw materials are easily available through the easy
transport via road connectivity.
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Ankleshwar Industrial Estate was set up by Gujarat Industrial Development Corporation in early
70s. This industrial estate is spread over an area of 1600 hectares in close proximity to National
Highway No.8 and Delhi-Mumbai Railway Line. Being an ideal location for industrialization, as
on date, more than 1500 industries, consisting of chemicals, pesticides, pharmaceuticals, bulk
drugs, petroleum products, engineering, textiles, plastics, rubber and packaging etc. are located
in this industrial estate.
The town is known for its industrial township called GIDC (Gujarat Industrial Development
Corporation). Ankleshwar has an office of the ONGC (Oil and Natural Gas Corporation
Limited). GIDC is organizing Trade fare and Industrial expo occasionally to attract large number
of industries all over from India. It also helps to get customer on large basis.
Ankleshwar is connected by Indian National Highway 8 (Mumbai to New Delhi) and by the
Western Railway Division of Indian Railways. The railway division also runs the broad
gauge train services to Rajpipla. The 133 year-old Golden Bridge connects Ankleshwar to
Bharuch across the Narmada on the station front while a new bridge connects the highway, the
other bridge on the highway is now ready to use.
Ankleshwar City Bus stand is located on Station Road (i.e. located in the City, the western
section).
Development project of Ankleshwar Airport & City Bus are in pipe line in last stage.
Ankleshwar is an educated city. It has an average literacy rate of 79%, higher than the national
average of 59.5%; with 56% of the males and 44% of females literate.
Ankleshwar JN Rail Way Station, Sanjali Rail Way Station are the very nearby railway station to
Ankleshwar GIDC. However Surat Rail Way Station is major railway station 56 KM near to
Ankleshwar GIDC.
Healthcare
Hospitals include are the
• Jayaben Modi Hospital,
• Sarvajanik Hospital,
• Sanjivani Hospital
• Sardar Patel Hospital.
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• And now ESIC's (Employee State Insurance Corporation) New Hospital is under
Construction.
• In April 2014, the "New Life" private hospital was constructed in Jasaat Plaza (Station
Road). It is conveniently served by Ankleshwar's main bus & railway stations.
Shopping and Recreation:
• There is a lake in GIDC & City area. Situated in front of GIDC Lake, Lakeview Plaza
Mall is city's first truly integrated mall for restaurants, entertainment and hotel stay.
• Nav Graha Jain Mandir (G.I.D.C), Manav Mandir, Sai & Swaminarayan Temple are big
temples in Ankleshwar. Ankleshwar City is also having big Mosques Halimsha Datar
Bhandari, Garib nawaz, etc.
• Centers of Brahma Kumaris World Spiritual University is located in both GIDC and City
area which helps you to know your true self with the help of Free Rajyoga Meditation
Classes.
• There are parks such as The Millennium Park and old parks in Ankleshwar city, the GIDC
Water Reservoir, and sports center.
• There are swimming pools, Joggers park, children's park, Rotary library and other
recreation centers in the GIDC area.
• There is an Open Air Theater in GIDC Area. Chauta Bazar is the biggest shopping area in
Ankleshwar.
4.2 LAND USE AND LAND OWNERSHIP
The existing project site is located at plot no 3102/B, GIDC Estate, Ankleshwar, Gujarat. The
total plot area of the unit is 35595 Sq. M. Land ownership is with project proponents. The
geographical location is 21o 37’ 36” N latitude and longitude 73
o1’ 58” E.
They have valid consent from Gujarat Pollution Control Board, Gandhinagar. And the consent
no. is AWH:72765 and it is attached as an Annexure-XIII.
4.3 LAND USE
The existing project site is located at plot no 3102/B, GIDC Estate, Ankleshwar, The plot is
notified by GIDC for industrial purpose.
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4.4 EXISTING INFRASTRUCTURE
The project is currently located in a well-developed zone, which have all essential facilities such
as well-connected road network with ease of transportation, arrangement for supply of water and
power to industries, effluent disposal facilities etc.
4.5 SOIL CLASSIFICATION
The soils of the district are derived from the Deccan trap which is main rock formation of the
district. The soil of the district can be classified as light, medium and heavy according to depth,
texture and location. There is sandy loam to loamy in texture, brownish black in color.
4.6 CLIMATE DATA
As per gathered meteorological data, the maximum temperature is 42.4°C, where as the
minimum temperature is 14.8°C. The relative humidity levels varied from 13% to 86%. The
maximum and minimum as well as relative humidity for a period of March, 2014 to May, 2014
are presented in Table 15.
TABLE:15
DETAILS OF MICRO METEOROLOGICAL DATA
(Data from Indian Meteorological Department, Ahmadabad)
Based on the above metrological data, wind rose has been prepared for the summer season
period from March 2014 to May 2014. As per the metrological data, it shows that the average
wind speed in March, April, and May 2014 is 2.76 m/s with wind direction blowing to NE.
The wind rose prepared from same data is shown at Figure 6.
Month Temperature(oc) Humidity (%) Rain fall (mm)
Maximum Minimum Maximum Minimum Maximum Minimum
MARCH 2014 38.2 14.8 84 13 00 00
APRIL 2014 41.8 20.6 86 14 00 00
MAY 2014 42.4 27.2 83 17 0.8 00
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FIGURE:5
WIND ROSE DIAGARM FOR PERIOD (MARCH TO MAY, 2014)
4.7 SOCIAL INFRASTRUCTURE
Population density and sex ratio of Bharuch District was reported 238 persons/sq.km. and 920
females per 1000 males respectively in 2011 census report. Total literacy of Bharuch District
was found 81.51 %.The basic amenities like primary and secondary education schools,
community health workers, primary health sub centre, private practitioners, primary health
centre, maternity and child welfare, dispensaries, T.B clinic, family welfare centre, hospital,
drinking water, transportation facilities, electricity , telephone etc. are available.
5.0 PLANNING BRIEF
5.1 PLANNING CONCEPT
Ankleshwar is largely an industrial area dominated by large scale industries, especially chemical
plants& Pharmaceutical plants.
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Now the unit has planning to construct new plant after demolishing the existing Unit 1A. The
production capacity remain same.
Ankleshwar in Gujarat has an industrial area with common effluent treatment plant, common
incinerator and land fill site. Govt. agencies provide many basic facilities like uninterrupted
water supply, power and road network.
5.2 POPULATION PROJECTION
As per provisional reports of Census India, Population of Bharuch District in 2011 is 1,551,019.
Population of male and female are 805,707 and 713,676 respectively. The sex ratio of Bharuch
city is 920 females per 1000 males.
In education section, total literates in Vadodara District are 2,893,080 of which 1,614,087 are
males while 1,278,993 are females. Average literacy rate of Vadodara district is 78.92%.
5.3 LAND USE PLANNING
The proposed project is on a GIDC land.
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND
The M/s. ZCL Chemicals Ltd. shall get water from GIDC water supply scheme. So there will be
no additional stress on ground water resources and there will be no adverse effect on the ground
water resources available in the nearby area.
5.5 AMENITIES/FACILITIES
The available basic amenities are as under:
(A) Education Facilities:
All the villages have a minimum of one primary school.
(B) Medical Facilities:
All the surrounding villages have medical facilities.
(C) Drinking water Facilities & Power Supply:
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All the villages have potable water supply and in 100% area the drinking water is
supplied through taps, wells and tube wells. All the villages have power supply facilities
in the study region.
(D) Post, Telegraph & Telephone facilities
The information collected clearly indicates that the infrastructural facilities are provided
by respective government agencies for the development of this area. For communication
purpose, post office and phones are available in most of the villages.
(E) Transport Facilities:
Bus services are available in all the villages of the study region within 5 km area and are
the most preferable mode of transport in the region. Auto-rickshaw is also used as
transport facility. Villages are connected with paved roads. All the surrounding area is
covered with 108 emergency facilities.
6.0 PROPOSED INFRASTRUCTURE
6.1 PROCESSING AREA
The process area will cover plant area like Plant-1A, 1B, 2, 3, 4, ETP and utilities. The process
area for Unit 1A after relocation will be covered by 1808 square meters.
6.2 NON PROCESSING AREA
The non process area will cover Electrical panel room, CCOE area, Warehouse-solid & liquid,
TOC Room, 22KV Breaker Room, canteen, U/ground water tanks-all, Cold Room, Security
cabin & OHC Room, HT Yard and surrounding area-utility & main, Admin Block, Scrap yard,
and all roads and passages, contractor sheds, Parking area etc. The non process area covered by
unit will be around 1016 square meters and total non process area covered by unit at ground level
will be around 24860.37 square meters.
6.3 GREEN BELT
Out of the total land area of 35595 square meters approximately 18% will be utilized for green
belt development. The proposed greenbelt area is 6215.04 square meters.
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6.4 SOCIAL INFRASTRUCTURE
The availability of basic amenities is covered as under:
(A) Training & Education: All the employees will be trained and educated periodically about
the hazardous nature of chemicals used in the process. Also, training for firefighting, work
permit system, first aid, safe handling of hazardous chemicals and integrating safety, in all
activities.
(B) Medical facility: Pre-employment medical checkup at the time of employment. In order to
safe guard the health of the employees, all the employees undergo periodic health checkup.
(C) Drinking water: There will be provision of Aqua Guard/R.O. at different places to provide
purified water for drinking purpose.
(D) Transportation: The unit will provide basic transportation facility for workers.
(E) Telegraph & Post: There will be provision of telephone, fax & internet facility.
(F) Power supply: There will be total connected load of 950 KVA from DGVCL.
6.5 CONNECTIVITY
Ankleshwar estate is well connected by rail and road to rest of country.
6.6 DRINKING WATER MANAGEMENT
Average daily water consumption of unit will be 9.7 KL/Day for domestic purpose. The entire
water requirement will be meeting through GIDC water supply system.
6.7 SEWAGE SYSTEM
The sewage will be diverted in soak pit. The overflow of soak pit is treated in ETP.
6.8 INDUSTRIAL WASTE MANAGEMENT
The hazardous waste like ETP sludge, Carbon Waste, Distillation residue, Discarded containers,
Distillation residue from contaminated organic solvents, Used/Waste Oil, Contaminated solvents
not fit for originally intended use ,Spent solvent, High COD waste from MEE stripper will be
generated from the proposed activity. There will be no change in Hazardous waste generation
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due to proposed construction work. The hazardous waste management and disposal is shown in
Annexure-XI in Form-I.
6.9 SOLID WASTE MANAGEMENT
The record of hazardous and non Hazardous waste solid waste like Personal Protective
Equipments, etc
6.10 POWER REQUIREMENT & SUPPLY
The unit will use total 950 KVA electricity connected load from DGVCL.
7.0 REHABILITATION AND RESETTLEMENT(R &R) PLAN
The proposed project is located in Plot No: 3102/B, GIDC Estate, Ankleshwar, Dist-Bharuch,
Gujarat-392002. There will be no any human settlement affected by proposed project.
8.0 PROJECT SCHEDULE & COST ESTIMATES
8.1 PROJECT IMPLEMENTATION SCHEDULE
TABLE: 16
PROJECT IMPLEMENTATION SCHEDULE
Project implementation schedule
Sr.
No.
Activity Required Period
1. Civil work 15 months
2. Procurement of
machinery
within 8 months after civil work start
3. Erection & installation
of machinery
after 4 months of completion of building
4. Trial of machinery &
equipment
within 1 month of above activity
5. Commercial activity within 1 month of above activity
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8.2 ESTIMATED PROJECT COST
Rs 46.35 Crore will be invested in relocation of existing Unit 1A.
9.0 ANALYSIS OF PROPOSAL
All the manpower is utilized from local region around Ankleshwar. Company shall also try to
provide indirect employment opportunities by availing local contract services during
transportation during operational phase.
CSR activities – Company shall comply with statutory provisions related with CSR activities .