VIRCHOW PETROCHEMICAL PVT. LTD.environmentclearance.nic.in/writereaddata/modification/...Virchow...

VIRCHOW PETROCHEMICAL PVT. LTD. SY.NO. 636 to 642, PEDDAPALLY VILLAGE,

JADCHERLA MANDAL, MAHABUBNAGAR DISTRICT, TELANGANA

FORM I

Project No. 1214‐21‐02December 2014

Virchow Petrochemical Pvt. Ltd. Sy. No. 17A, Phase – I , IDA, Patancheru, Medak District, Andhra Pradesh. Phone: 040‐30147102 Fax: 040‐30147126 E‐mail ID: [email protected]; [email protected]

STUDIES AND DOCUMENTATION BY TEAM Labs and Consultants B‐115‐117 & 509, Annapurna Block, Aditya Enclave, Ameerpet, Hyderabad‐500 038. Phone: 040‐23748 555/23748616, Telefax: 040‐23748666

SUBMITTED TO MINISTRY OF ENVIRONMENT AND FORESTS,

GOVERNMENT OF INDIA INDIRA PARYAVARAN BHAWAN, JOR BAGH ROAD, NEW DELHI

Virchow Petrochemical Pvt. Ltd.,

Form I Page 1

APPENDIX – I (See Paragraph – 6)

FORM I

I) Basic Information S.No. Item Details 1 Name of the Project/s Virchow Petrochemical Pvt. Ltd., 2 S. No in the Schedule 5 f – A category 3 Proposed capacity/area/length/tonnage to

be handled/command area/lease area/number of wells to be drilled

API’s (Synthetic Organic Chemicals). Capacity: Phase I 500TPM Phase II 450TPM Total after Phase II 950TPM

Co‐generation Plant (Phase – II) 4MW Cost of the project: 150 Crores

4 New/Expansion/Modernization New 5 Existing Capacity/Area etc. Not Applicable 6 Category of Project i.e. 'A' or 'B' “A” 7 Does it attract the general condition? If yes,

please specify No

8 Does it attract the Specific condition? If yes, please specify.

No

9 Location Plot/Survey/Khasra No. Sy.No. 636 to 642 Village Pedda pally(V), Pole Pally(Post) Tehsil Jadcherla Mandal District Mahabubnagar District State Andhra Pradesh‐509302

10 Nearest railway station/airport along with distance in kms.

Jadcherla(S.C Railways) 9 Km Rajivgandhi International Airport(Shamshabad)– 75 Km.

11 Nearest Town, City, District Headquarters along with distance in kms.

Jadcherla– 6 Km

12 Village Panchayats, Zilla Parishad, Municipal Corporation, Local body (complete postal address with telephone nos. to be given)

Pedda Pally‐ 1.5 KM

13 Name of the Applicant Mr. M. Narayana Reddy 14 Registered Address M/s. Virchow Petrochemical Pvt. Ltd.,

Plot No. 10, S.V.Co‐operative Industrial Estate, I.D.A Jeedimetla, Hyderabad‐500055.


Form I Page 2

15 Address for Correspondence: Name Mr. K. Nagendra Varma Designation(Owner/Partner/CEO) General Manager Address Sy. No. 17A, Phase‐I, IDA,

Patancheru, Medak District. Pin Code 502 319 E‐mail [email protected]

[email protected] Telephone Number 040‐30147102 Fax No. 040‐30147126

16 Details of alternative Sites examined, if any. Location of these sites should be shown on a topo sheet.

‐NA‐

17 Interlinked Projects ‐NA‐ 18 Whether separate application of interlinked

project has been submitted? No

19 If yes, date of submission 20 If no, reason 21 Whether the proposal involves

approval/clearance under: if yes, details of the same and their status to be given. (a) The Forest (Conservation) Act, 1980? (b) The Wildlife (Protection) Act, 1972? (c) The C.R.Z Notification, 1991?

‐NA‐

22 Whether there is any Government Order/Policy relevant/relating to the site?

No

23 Forest land involved (hectares) No 24 Whether there is any location pending

against the project and /or land in which the project is propose to be set up? (a) Name of the Court (b) Case No (c) Orders/directions of the Court, if any and its relevance with the proposed project.

No


Form I Page 3

(II) Activity

1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.) S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate quantities

/rates, wherever possible) with source of information data

1.1 Permanent or temporary change in land use, land cover or topography including increase in intensity of land use (with respect to local land use plan)

NO The proposal is for a green field project. The land area used for the proposed plant is 100.375acres. The land is plain and does not involve much of leveling/excavation.

1.2 Clearance of existing land, vegetation and buildings?

NO The land area is plain and is not used for any agricultural activity

1.3 Creation of new land uses? NO 1.4 Pre‐construction investigations e.g.

bore houses, soil testing? YES Soil test done and soil load bearing capacity

established. 1.5 Construction works?

NO Construction activity involves plant

construction, erection only. 1.6 Demolition works? NO

1.7 Temporary sites used for construction works or housing of construction workers?

NO Construction labor from local villages shall be employed.

1.8 Above ground buildings, structures orearthworks including linear structures, cut and fill or excavations

YES Office buildings, Production blocks, Storage facilities for raw material and final products shall be constructed. No major cut and fill or excavation is anticipated.

1.9 Underground works including mining or tunneling?

NO

1.10 Reclamation works? NO 1.11 Dredging? NO 1.12 Offshore structures? NO 1.13 Production and manufacturing

processes? YES Enclosed in Annexure – I

1.14 Facilities for storage of goods or materials?

NO Raw materials and solvents shall be stored with safety precautions.

1.15 Facilities for treatment or disposal of solid waste or liquid effluents?

YES Solid waste shall be disposed to end users/recyclers or sent to incineration. Effluent generated from the plant are treated and reused. Details presented in Annexure II

1.16 Facilities for long term housing of operational workers?

NO Local people shall be employed.

1.17 New road, rail or sea traffic during YES Construction materials shall be transported to


Form I Page 4

construction or operation? the site. The traffic density of the existing connecting road is negligible.

1.18 New road, rail, air waterborne or other transport infrastructure including new or altered routes and stations, ports, airports etc?

NO

1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements?

NO

1.20 New or diverted transmission lines or pipelines?

NO

1.21 Impoundment, damming, culverting, realignment or other changes to the hydrology of watercourses or aquifers?

NO

1.22 Stream crossings? NO 1.23 Abstraction or transfers of water

form ground or surface waters? YES Total water required shall be 706.9 KLD out of

which 493.9 KLD shall be drawn from bore well and the balance shall be recycled water.

1.24 Changes in water bodies or the land surface affecting drainage or run‐off?

NO

1.25 Transport of personnel or materials for construction, operation or decommissioning?

YES The construction material shall be drawn from local sources within 10 – 15 km. There is no transport of personnel, as the construction workers shall be drawn from local villages.

1.26 Long‐term dismantling or decommissioning or restoration works?

NO

1.27 Ongoing activity during decommissioning which could have an impact on the environment?

NO

1.28 Influx of people to an area in either temporarily or permanently?

YES The proposed project shall increase the employment potential and hence may lead to migration to surrounding villages.

1.29 Introduction of alien species? NO 1.30 Loss of native species or genetic

diversity? NO There are no major losses of tree/shrub

species. 1.31 Any other actions? NO


Form I Page 5

2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non‐renewable or in short supply): S.No. Information/checklist confirmation Yes/No Details thereof (with approximate quantities

/rates, wherever possible) with source of information data

2.1 Land especially undeveloped or agricultural land (ha)

YES 100.375acres. Located Sy.No. 636 to 642, Pedda pally Village, Pole Pally(Post), Jadcherla Mandal, Mahabubnagar District, Andhra Pradesh.

2.2 Water (expected source & competing users) unit: KLD

YES Total water required shall be 706.9 KLD out of which 493.9 KLD shall be drawn from bore well and the balance shall be recycled water. (Water Balance Enclosed in Annexure III)

2.3 Minerals (MT) NA 2.4 Construction material – stone,

aggregates, sand / soil (expected source – MT)

YES Shall be sourced from the local villages.

2.5 Forests and timber (source – MT) NO 2.6 Energy including electricity and fuels

(source, competing users) Unit: fuel (MT), energy (MW)

YES The required energy shall be drawn from APTRANSCO. The power shall be drawn from existing DG sets during load shut downs. Backup DG sets of 2 x 1000 & 2 x 725 KVA after phase II shall be provided to cater to energy requirement during power shut downs period.

2.7 Any other natural resources (use appropriate standard units)

NA


Form I Page 6

3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health. S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate

quantities/rates, wherever possible) with source of information data

3.1 Use of substances or materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies)

YES Solvents shall be used as reaction media. MSIHC rules shall be followed during storage, transportation and handling of raw materials and hazardous chemicals.

3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases).

NO

3.3 Affect the welfare of people e.g. by changing living conditions?

YES Shall increase the employment potential for locals and affect the living conditions for betterment.

3.4 Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderly etc.,

NO No sensitive receptors are present in the immediate vicinity of the site. The project shall not have any significant impact on vulnerable groups of people.

3.5 Any other causes NO

4. Production of solid wastes during construction or operation or decommissioning (MT/month) S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate


4.1 Spoil, overburden or mine wastes NO 4.2 Municipal waste (domestic and or

commercial wastes) NO Wastes from canteen, other commercial

wastes like paper, empty containers etc. The canteen wastes and commercial wastes shall be in the range of 30 kg/day

4.3 Hazardous wastes (as per Hazardous Waste Management Rules)

YES The quantity of hazardous wastes generated during construction contains waste oils and batteries from DG set.

The quantity of hazardous waste generated during operation contain salts from evaporators, stripper distillate, process residue, and solvent residues, ETP sludge and filtration media etc. enclosed in Annexure – IV


Form I Page 7

4.4 Other industrial process wastes YES Enclosed at Annexure IV 4.5 Surplus product NO 4.6 Sewage sludge or other sludge from

effluent treatment YES Sludge from Effluent treatment plant and

Salts from MEE & ATFD shall be sent to TSDF.

4.7 Construction or demolition wastes NO

4.8 Redundant machinery or equipment NO

4.9 Contaminated soils or other materials NO

4.10 Agricultural wastes NO

4.11 Other solid wastes NO Enclosed at Annexure IV

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr) S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate


5.1 Emissions from combustion of fossil fuels from stationary or mobile sources

YES Coal Shall be used as fuel. Quantity of fuel and emissions details are enclosed in Annexure V

5.2 Emissions from production processes YES Enclosed in Annexure ‐ VI 5.3 Emissions from materials handling

including storage or transport NO Material transfer takes place in closed

pipeline systems. 5.4 Emissions from construction activities

including plant and equipment YES Dust may rise during transport of material and

construction activity. The dust emissions shall be mitigated by water spraying on the roads within the premises.

5.5 Dust or odors from handling of materials including construction materials, sewage and waste

NO

5.6 Emissions from incineration of waste NO 5.7 Emissions from burning of waste in

open air (e.g. slash materials, construction debris)

NO

5.8 Emissions from any other sources NO


Form I Page 8

6. Generation of Noise and Vibration, and Emissions of Light and Heat: S.No. Information/Checklist

confirmation Yes/No Details thereof (with approximate

quantities/rates, wherever possible) with source of information data with source of information data

6.1 From operation of equipment e.g. engines, ventilation plant, crushers

YES Material transport and construction equipment shall be source of noise, while transfer pumps, vacuum systems, DG sets are the sources of noise during operation.

6.2 From industrial or similar processes

YES From DG sets, and controlled by providing Acoustic Enclosures.

6.3 From construction or demolition YES Noise during construction shall be due to construction equipment and emergency DG sets.

6.4 From blasting or piling NO

6.5 From construction or operational traffic

NO The increased traffic shall not have any significant impact.

6.6 From lighting or cooling systems NO

6.7 From any other sources NO

7.Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal waters or the sea: S.No. Information/Checklist

confirmation Yes/No Details thereof (with approximate


7.1 From handling, storage, use or spillage of hazardous materials

NO All the hazardous materials will be stored in Tanks/MS drums, in a covered shed and no contamination of soil is expected

7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of discharge)

NO All the wastes from domestic operations are sent to septic tank followed by soak pit.

7.3 By deposition of pollutants emitted to air into the land or into water

NO Air Pollutants generated are let out into atmosphere after meeting the prescribed standards.

7.4 From any other sources NO 7.5 Is there a risk of long term build

up of pollutants in environment from these sources?

NO


Form I Page 9

8.Risk of accidents during construction or operation of the Project, which could affect human health or the environment S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate


8.1 From explosions, spillages, fires etc from storage, handling, use or production of hazardous substances

YES All Inbuilt Safety precautions will be adopted and there will not be any damage to environment or human health

8.2 From any other causes NA 8.3 Could the project be affected by natural

disasters causing environmental damage (e.g? Floods, earthquakes, landslides, cloudburst etc)?

NO

9.Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality S. No. Information/Checklist confirmation Yes/No Details thereof (with approximate


9.1 Lead to development of supporting. facilities, ancillary development or development stimulated by the project which could have impact on the environment e.g.: • Supporting infrastructure (roads, power supply, waste or waste water treatment, etc.)• housing development • extractive industries • supply industries • other

YES The project shall enhance the socio economic status of the area by increasing the demand for housing, improving the employment. There are no major support industries required for this plant.

9.2 Lead to after‐use of the site, which could haven impact on the environment

NO

9.3 Set a precedent for later developments NO 9.4 Have cumulative effects due to proximity to

other existing or planned projects with similar effects

NO The baseline environmental status of the surrounding areas is within the prescribed limits as observed from the Secondary data.


Form I Page 10

(III) Environmental Sensitivity S.No. Areas Name/

IdentityAerial distance (within 15 km.) Proposed project location boundary

1 Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other related value

NA

2 Areas which are important or sensitive for ecological reasons ‐ Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests

YES Tigalapalli RF – 9Km – West Appannapalli RF – 9Km ‐ Southwest

3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration

NA

4 Inland, coastal, marine or underground waters NO 5 State, National boundaries NO 6 Routes or facilities used by the public for access

to recreation or other tourist, pilgrim areas NO

7 Defense installations NO 8 Densely populated or built‐up area YES Kaurapet is at a distance of 7.4KM

in north‐eest with population of 8000.

9 Areas occupied by sensitive man‐made land uses (hospitals, schools, places of worship, community facilities)

NA

10 Areas containing important, high quality or scarce resources (ground water resources, surface resources, forestry, agriculture, fisheries, tourism, minerals)

NO

11 Areas already subjected to pollution or environmental damage. (those where existing legal environmental standards are exceeded)

NO

12 Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)

NO


Form I Page 11

(IV) Proposed Terms of Reference for EIA studies Scope of Work of EIA “...The EIA shall cover the following: Description of the proposed project: The first task:” Description of the proposed project” forms a vital component of the Environmental Impact Assessment (EIA) as it provides the basis for evaluating the likely causes of Environmental Impacts.

Existing Environment and Baseline Conditions: The baseline assessment will be carried out to identify potentially sensitive and critical areas that may be affected by the project in an area of 10 km surrounding the project location. The critical and sensitive targets shall be plotted on land use map of project impact area. The existing environment and baseline conditions should be established from:‐ Analysis of existing information published and secondary data. ‐Consultation with relevant statutory authorities, and Field visits for supplementation of missing gaps.

The key subject areas which the EIA shall address include Ecology and Nature conservation, Air quality, surface and water quality in project impact area, soil quality, cultural heritage, landscape, land use, noise quality, etc. Natural habitats like national parks, wildlife reserves, sanctuaries, sacred grove, protected areas, forests, wetlands, major rivers and waterways if any, shall also be identified and marked.

Assessment of Environmental Impacts: Based upon the results from the review of existing information, field visits, site data collection and consultation, for each component of environment (physical, biological and socio economic) the positive, negative, direct and indirect, temporary and permanent impacts will be evaluated along with an indication of the degree of impact, i.e., whether the impact is significant, moderate, minor or negligible. The degree of impact shall also be quantified by using state of the art air quality impact prediction models based on ISCST3 algorithms.

Environment Management Plan And Mitigation Plan: For each significant negative impact identified, specialist shall work closely with the engineering team/technical consultants to suggest practicable measures to avoid or mitigate the impact. The mitigation of environmental impacts will be by three mechanisms. =>Introduction of mitigation features through the engineering practices. =>Implementation of environmental controls during construction and operation. =>Legislative control involving compliance with Indian environmental laws. The Environmental management plan shall include an estimate of capital and recurring costs of mitigation measures and will identify the institutional framework for implementation.

Monitoring Plan: Having identified the significant environmental impact that is likely to arise as a result of the project, the project team shall specify what monitoring is required during the various phases of the project cycle. The monitoring plan will identify parameters and frequency of monitoring and responsible organization.


Form I Page 12

I hereby give the undertaking that data and information given in the application and enclosures are true to the best of my knowledge and belief and I am aware that if any part of the data and information submitted is found to be false or misleading at any stage, the project will be rejected and clearance given, if any to the project will be revoked at our risk and cost.

Date:

Place:

Signature of the applicant With Name and Full Address

(Project Proponent/Authorized Signatory)

Mr. K. Nagendra Varma General Maager

M/s. Virchow Petrochemical Pvt. Ltd., Sy. No. 17A, Phase‐I, IDA,

Patancheru, Medak District.



ANNEXURES

SUBMITTED TO MINISTRY OF ENVIRONMENT AND FORESTS,

GOVERNMENT OF INDIA INDIRA PARYAVARAN BHAWAN, JOR BAGH ROAD, NEW DELHI

Virchow Petrochemical Pvt. Ltd., Form I Annexures

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Page 2

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Page 3

ANNEXURE - I

M/s. Virchow Petrochemical Pvt. Ltd., proposes to establish an Active pharma

ingredient/synthetic organic chemical manufacturing unit at Sy. No 636-642, Peddapally Village,

Jadcherla Mandal, Mahabubnagar District, Andhra Pradesh. The project shall be established in

two phases. The first phase shall have manufacturing facility for four products, while the second

phase shall has facility for five products along with 4 MW co-generation plant. The land area

acquired for the proposed project is 100.375 acres. The capital cost of the project is Rs. 150 crores.

The proposed list of products and manufacturing capacity is presented in Table A-1 and list of by-

products is presented in Table A-2.

Table A-1 List of Products and Manufacturing Capacity

S.No Name of the Product CAS No. Capacity TPM Kg/day

PHASE - I 1 7-Phenylacetamido-3-Chloromethyl-Cephalosporanic

acid para-methoxybenzylester (GCLE) 104146-10-3 200 6666.67

2 Meta-Chloro Anisol 845-89-8 150 5000 3 Cefdinir 91832-40-5 50 1666.67 4 Cefixime 79350-37-1 100 3333.33 Total 500 16666.7 PHASE - II

1 Aciclovir 59277-89-3 50 1666.67 2 Amoxicillin 26787-78-0 100 3333.33 3 Cephalexin 15686-71-2 100 3333.33 4 Ibuprofen 15687-27-1 100 3333.33 5 Tremadol Hydrogen Chloride 36282-47-0 100 3333.33 Total 450 15000

Total after Phase - II 950 31666.7 Co-generation Plant 4MW


Page 4

Table A-2 List of By-Products

S.No Name of the Product Stage Name of the By-Product Capacity Kg/day TPM

PHASE - I 1 7-Phenylacetamido-3-

Chloromethyl-Cephalosporanic acid para-methoxy benzylester (GCLE)

I Potassium Chloride 1547 46.4 Spent HCl 5702 171

2 Meta-Chloro Anisol I Sodium Hydroxide (48%) 2924 87.7 3 Cefdinir I 2-mercapto benzothiazole 705 21.1 4 Cefixime I Tri phenyl phosphine oxide 2260 67.8

II Phenyl Acetic Acid 937 28.1 III 2-mercapto benzothiazole 1228.8 36.9

PHASE - II 1 Aciclovir I Acetic Acid 998.3 29.9

III Di-methyl ammonium acetate

3112.1 93.4

2 Amoxicillin III Trimethylsilanol 821 24.6 Methyl acetoacetate 1059.1 31.8 Pivalic acid 930.5 27.9

3 Cefalexine III Pivalic acid 984.6 29.5 Ethyl aceto acetate 1123.9 33.7

4 Ibuprofen III Chromic sulfate 2114.3 63.4


Page 5

Process Description of GCLE

Stage I:

1 3 8 ( P e n G K )

( W a t e r ) ( S - O x i d e )

( H y d r o g e n p e r o x i d e ) ( P - A n i s i c A l c o h o l ) ( H y d r o c h l o r i c a c i d )

( P o t a s s i u m c h l o r i d e )

3 6 . 6

4 7 0 7 4 . 6 1 8

3 7 2 3 4

M e t h a n o lW a t e r

C 1 6 H 1 7 K N 2 O 4 S C 8 H 1 0 O 2 H C l H 2 O 2

C 2 4 H 2 6 N 2 O 6 S K C l 2 H 2 O

+ + +

+ +

Stage II:

( S - O x i d e )

( W a t e r )

( M B T ) ( B e n z e n e s u l f i n i c a c i d )

( S u l f o n e ) ( M B T )

C a t a l y s t N B A

D ST o l u e n eW a t e r4 7 0 1 6 7 1 4 2

5 9 4 1 6 7 1 8

H 2 O C 7 H 5 N S 2 C 3 0 H 3 0 N 2 O 7 S 2

C 7 H 5 N S 2 C 6 H 6 O 2 SC 2 4 H 2 6 N 2 O 6 S + +

++

Stage III:

(Sulfone) (Sodium bicarbonate)

(Chlorine) WaterMethanol

(Sodium methoxide)

84594 71 54

(GCLE) (Sodium Benzene sulfinate)

(Sodium chloride)

(Methanol)

32164 58.5486.5

C30H30N2O7S2 NaHCO3 Cl2 NaOCH3

C24H23N2O5SCl C6H5O2SNa NaCl CH3OH

+ ++

+ + + +

(Sodium ash)

106

Na2CO3 +

(Sodium bicarbonate)

84

NaHCO3

Process Description for Posaconazole:

Stage I: Penicillin G Potassium is reacted with p-Anisic alcohol, Hydrochloric Acid and Hydrogen

peroxide in presence of Acetone, Methylene dichloride and methanol to give p-methoxy benzyl 6-

phenacetamido penicillanate -1-oxide.

Stage II: P-methoxy benzyl 6-phenacetamido penicillanate -1-oxide is reacted with 2-mercapto

benzothiazole and Benzene Sulphinic Acid in presence of NBA and DS to form p-methoxy 2-

(benzene Sulphonyl thio)-α-(1-Methyl ethyl-4-Oxo-3-phenacetamido-1-azetidine Acetate. The MLs

are further distilled to remove complete DS and water is added. The mass is cooled and filtered to

get 2- mercapto benzothiazole for re-use.

Stage III: P-methoxy 2-(benzene Sulphonyl thio)-α-(1-Methyl ethyl-4-Oxo-3-phenacetamido-1-

azetidine Acetate is reacted with sodium bicarbonate and chlorine in presence of NBA and then

reacted with Sodium Methoxide to get p-methoxy benzyl-7-phenacetamido-3-chloromethyl-3-

cephem-4-caroxylate(GCLE). The process flow diagram for GCLE is presented in Fig A-1 and

material balance is presented in Table A-3.


Page 6

Potassium chloride

Reaction & Distillation

(Stage‐I)

Penicillin G‐Potassium

P‐Anisic Alcohol

Hydrochloric acid (35%)

Acetone

M.D.C

Hydrogen peroxide

Acetone

Water

M.D.C

Methanol

Residue

S‐Oxide

Sodium Bisulfite

Water

Sodium bisulfite

Methanol

Stage I


(Stage‐II)Toluene

MBT

NBA

Catalyst

Water

Toluene

MBT

NBA

DS

SULFONE

Water

Residue

B.S.A (87%)

DS


(Stage‐III)

S.M.O

Sodium bicarbonate

Soda ash

Water

Methanol

Carbon dioxide

Sodium Benzene sulfinate

GCLE

Water

Residue

Chlorine

NBA

NBA

Sodium chloride

Methanol

S‐OxideStage II

Stage III

Fig A-1 Process Flow Diagram of GCLE


Page 7

Table A-3 Material Balance for GCLE Stage I Input Quantity

(Kg/day) Output Quantity

(Kg/day) Remarks

Penicillin G-Potassium 9446.5 S-Oxide 11075.8 Stage I Product P-Anisic Alcohol 3684.2 Potassium Chloride 1547 By-Product Hydrochloric acid (35%) 6140.3 Potassium Chloride 211 To Wastewater Hydrogen peroxide(50%) 1889 Water formed during

reaction 424.2 To Wastewater

Acetone 23616 Water formed during reaction

424.2 To By-Product (Spent HCl)

Methylene Dichloride (MDC)

37786 Acetone Recovery 23333 Recovered & reused

Water 23616 Acetone Loss 47 Fugitive Loss Sodium Bisulfite 151.14 Acetone to Residue 118 Solvent in Residue Methanol 28340 Acetone to

Wastewater 118 To Wastewater

MDC Recovery 36180 Recovered & reused MDC Loss 94 Fugitive Loss MDC to Residue 378 Solvent in Residue MDC to Wastewater 1134 To Wastewater Methanol Recovery 27022 Recovered & reused Methanol Loss 43 Fugitive Loss Methanol to Residue 1275 Solvent in Residue Penicillin G-

Potassium 680.2 Organic Residue

P-Anisic Alcohol 432.1 Organic Residue Hydrochloric acid

(35%) 5277.8 By-Product (Spent

HCl) Hydrogen peroxide 143.4 To Wastewater Water 12280.5 Recovered & reused 12280.5 To Wastewater Sodium Bisulfite 151.1 To Wastewater Total Input 134670.1 Total Output 134669.8


Page 8

Stage II Input Quantity


(Kg/day) Remarks

S-Oxide 11075.81 Sulfone 11187.2 Stage II Product 2-mercapto benzothiazole 3876.5 2-mercapto

benzothiazole 2907.4 Recovered & reused

Benzene Sulfinic Acid (87%)

5537.9 2-mercapto benzothiazole

237.8 Organic Residue

N-Butyl Acetate (NBA) 44303 Water formed during reaction

339 To Wastewater

Catalyst 166.1 NBA Recovery 42531 Recovered & reused Denatured Spirit (DS) 44303 NBA Loss 222 Fugitive Loss Water 5538 NBA to Residue 1329 Solvent in Residue Toluene 11076 NBA to Wastewater 222 To Wastewater DS Recovery 42088 Recovered & reused DS Loss 222 Fugitive Loss DS to Residue 1551 Solvent in Residue DS to Wastewater 443 To Wastewater Toluene Recovery 10744 Recovered & reused Toluene Loss 33 Fugitive Loss Toluene to Residue 244 Solvent in Residue Toluene to


S-Oxide 2224 Organic Residue 2-mercapto

benzothiazole 731.3 Organic Residue

Benzene Sulfinic Acid (87%)

2143.6 Organic Residue

Water 3129 Recovered & reused 3129 To Wastewater Catalyst 166.1 Residue Total Input 125876.61 Total Output 125876.62


Page 9

Stage III Input Quantity


(Kg/day) Remarks

Sulfone 11187.2 GCLE 6666.7 Final Product Sodium Bicarbonate 3468.0 Sodium Benzene

Sulfinate 2247.3 Organic Residue

Sodium Carbonate 2237.4 Sodium Bicarbonate 2302.2 Recovered & reused Chlorine 1566.2 Sodium Methoxide(30%) 3468.0 Sodium Chloride 801.6 To Wastewater N-Butyl Acetate (NBA) 44749 Methanol 438.5 Recovered & reused Methanol 33561 NBA Recovery 42959 Recovered & reused Water 10068 NBA Loss 224 Fugitive Loss NBA to Residue 1298 Solvent in Residue NBA to Wastewater 268 To Wastewater Methanol Recovery 32084 Recovered & reused Methanol Loss 50 Fugitive Loss Methanol to Residue 1091 Solvent in Residue Methanol to


Methanol from Sodium Methoxide

2427.6 Recovered & reused

Sulfone 3047.4 Organic Residue Sodium Methoxide 300.4 Organic Residue Chlorine in Sulfone

Complex 593.3 Organic Residue

Sodium Bicarbonate 2317 To Wastewater Sodium Carbonate 785 To Wastewater Water 10068 To Wastewater Total Input 110305.34 Total Output 110305.67


Page 10

ANNEXURE – II: Wastewater Treatment Facilities

The effluent generated from the proposed M/s. Virchow Petrochemical Pvt. Ltd., is mainly from

process, washings, scrubbers, cooling towers & boiler blow downs and domestic effluent. Effluent

from process, washings and scrubbers are sent to Stripper, Multiple Effect Evaporator followed by

ATFD and Biological treatment system and RO. Cooling towers & boiler blow downs shall be

Biological treatment system followed by RO. RO permeate reused for cooling towers and rejects

shall be sent to MEE. Domestic effluent shall be sent to sewage treatment plant and treated effluent

shall be reused for gardening. Total Effluent generated after Phase II and mode of treatment is

presented in Table A-4 and quantity and quality of effluent generated from process is presented in

Table A-5.

Table A-4 Quantity of Effluent Generated

Description Quantity (KLD) Mode of Treatment Phase I Phase II

HTDS Effluents Process 84.3 45 Treated in effluent treatment plant consist

of Stripper, MEE, ATFD, Biological treatment and RO. RO permeate reused for cooling tower makeup. RO rejects sent to MEE.

Washings 15 10 Scrubber Effluent 6 10

Total – I (HTDS) 105.3 65 LTDS Effluents

Boiler Blow downs 3 6.5 Sent to Biological Treatment System followed by RO. RO permeate reused for cooling tower makeup. RO rejects sent to MEE.

Cooling Tower Blow downs

12.5 31

Total - II (LTDS) 15.5 37.5 Domestic 8 8 Sent to Sewage Treatment Plant and

treated effluent reused for gardening. Grand Total 128.8 110.5


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Table A-5. Quantity and Quality of Effluent Generated from Process S.No Name of the Product Kg/Day mg/l

Water Input

TDS COD Total Effluent

COD TDS

PHASE - I 1 GCLE 39222.7 4409 2810.4 33170.3 84737 132918 2 Meta-Chloro Anisol 11000 101.9 1.5 9583.9 158 10628 3 Cefdinir 5580 883.9 86.1 9203.7 9352 96037 4 Cefixime 26500 2406.1 813.3 32380.5 25117 74308 Total 82302.7 7800.9 3712 84338.8 44009 92494

PHASE - II 1 Aciclovir 5464.7 0 137.2 7405.8 18521 0 2 Amoxicillin 5199.9 625.8 19.8 6373.4 3112 98185 3 Cefalexine 186.1 56 3.9 773.8 4975 72362 4 Ibuprofen 14453 1390 150.5 16301.6 9229 85268 5 Tremadol Hydrogen

Chloride 10270 1121.6 294.7 14177.9 20786 79106

Total 35573.6 3193.3 606 45032.5 13457 70912 Total after Phase - II 117876.3 10994.2 4317.7 129371.3 33374 84982


Page 12

ANNEXURE – III: Water Balance

Water is required for process, scrubbers, washing, cooling tower makeup, steam generation and

domestic purposes. The required water shall be drawn from ground water sources in addition to

reuse of treated wastewater. It is proposed to provide storm water storage tank of 15000 KL

capacity, which shall meet the plant water requirement for at least 100 days. The total water

requirement after phase II is in the order of 706.9 KLD consisting of 493.9 KLD fresh water and 213

KLD of recycled water. The fresh water requirement for Phase I is 213.3 KLD and 280.6 KLD for

Phase II and treated wastewater reuse for Phase I is 115 KLD and 98 KLD for Phase II. The water

balance for daily consumption after Phase II is presented in Table A-6.

Table A-6 Total Water Balance

Purpose INPUT (KLD) OUTPUT (KLD) Fresh Water Recycled Water Loss Effluent

Phase I

Phase II

Phase I

Phase II

Phase I

Phase II

Phase I

Phase II

Process 82.3 35.6 84.3* 45* Washings 5 5 10 5 15 10 Scrubber 6 10 6 10 Boiler Feed 30 130 10 37 123.5 3 6.5 Cooling Tower 20 90 87 85 94.5 144 12.5 31 Domestic 10 10 2 2 8 8 Gardening 60 8 8 68 8 Gross Total 213.3 280.6 115 98 201.5 277.5 128.8 110.5 Total 493.9 213 479 239.4


Page 13

ANNEXURE – IV: Solid Waste

Solid wastes are generated from the process shall be sent to TSDF/ Cement Industries for Co-

incineration. The inorganic residue, evaporation salts from MEE and ATFD and ETP Sludge shall

be sent to TSDF. The list of solid wastes generated from the process is presented in Table A-7 and

total solid waste generated and mode of disposal is presented in Table A-8.

Table A-7 Solid Waste Generated from Process

S.No Name of the Product

Quantity (Kg/Day) Process Organic Residue

Process Inorganic Residue

Solvent Residue

Spent Carbon

Catalyst Total

PHASE - I 1 GCLE 12637.4 0 7283.1 166.1 20086.6 2 Meta-Chloro

Anisol 286.6 2982.5 122 3391

3 Cefdinir 1126.3 0 79 1205.3 4 Cefixime 3634 429.9 667.3 4731.2 Total 17684.4 3412.4 8111.3 0 166.1 29374.2

PHASE - II 1 Aciclovir 856.1 0.0 269.3 12.0 3.0 1140.4 2 Amoxicillin 1290.2 769.3 242.2 2301.8 3 Cefalexine 2319.4 1334.4 504.4 4158.2 4 Ibuprofen 2420.5 1747.1 529.3 103.2 4800.1 5 Tremadol HCl 640.9 1057.3 254.4 1952.6 Total 7527.2 4908.1 1799.5 12.0 106.2 14353

Total after Phase - II 25211.5 8320.5 9910.8 12.0 272.3 43272.2


Page 14

Table A-8 Total Solid Waste Generated and Mode of Disposal

S.No Description Units Phase I

Phase II

Mode of Disposal

1 Ash from Boiler TPD 13 32.6 Sold to Brick manufactures 2 Process Organic

residue TPD 17.68 7.5 Sent to TSDF/Cement Industries

3 Solvent Residue TPD 8.1 1.8 Sent to TSDF/Cement Industries 4 Spent Carbon Kg/day --- 12 Sent to TSDF/Cement Industries 5 Process Inorganic

Residue TPD 3.4 4.9 Sent to TSDF

6 Mixed Solvents KLD 90.5 24.2 Sent to authorized recovery units/Cement plants for co-incineration

7 Spent Solvents KLD 211.2 56.5 Recovered within the plant premises.

8 Evaporation Salts TPD 7.8 6.9 Sent to TSDF 9 Stripper Distillate KLD 4.97 2.75 Sent to Cement Industries for

Co-incineration. 10 Catalyst TPD 0.2 0.1 Returned to manufacturer 11 ETP Sludge TPD 2.2 0.5 Sent to TSDF 12 STP Sludge Kg/day 0.4 0.4 Sent to TSDF 13 Detoxified containers No.s/year 400 600 After detoxification sent to

Authorized agencies 14 Waste oil Kl/Month 2 2 Sent to Authorized Recyclers 15 Used batteries No.s/year 10 10 Sent to Authorized Recyclers


Page 15

ANNEXURE – V: Stack Emissions Details

The sources of air pollution from the plant are 12TPH and 30TPH coal fired Boilers and DG set of

1000 & 725 KVA capacity each in Phase I and Phase II respectively. The proposed air pollution

control equipment for coal fired boilers is bag filter and ESP for 12 and 30 TPH boilers

respectively. DG sets shall be provided with stack heights based on the CPCB formula for effective

stack height. The emission rates of SPM, SO2, NOx and SPM from each stack are presented in

Table A-9.

Table A-9 Stack Emission Details

S. No

Stack Connected to Stack Ht (m)

Dia of stack

at top(m)

Temp. of

exhaust gases (OC)

Exit Velocity (m/sec)

Pollutant Emission Rate (g/sec)

SPM SO2 NOx

Phase - I 1 12TPH Coal fired Boilers 32 1 180 10 0.36 0.5 1.0 2 1000KVA DG Set 10 0.15 151 10 0.01 0.02 0.03 3 725KVA DG Set 6 0.8 140 8 0.010 0.015 0.020

Phase - II 1 30TPH Coal fired Boilers 42 2 200 15 2.5 4.5 5.1 2 1000KVA DG Set 10 0.15 151 10 0.01 0.02 0.03 3 725KVA DG Set 6 0.8 140 8 0.010 0.015 0.020

*DG sets will be used during load shut down by APTRANSCO.

Table A-10 Process Emission

S.No

Name of the Product

Stage Name of the Gas

Quantity (Kg/day)

Mode of Disposal

PHASE - I 1 Cefdinir I Carbon dioxide 185.5 Let out into atmosphere safely 2 Cefixime I Carbon dioxide 336.8 Let out into atmosphere safely

PHASE - II 1 Amoxicillin II Ammonia 175.5 To Scrubber 2 Cefalexine II Ammonia 175.6 To Scrubber 3 Ibuprofen I Hydrogen

Chloride 817.1 To Scrubber

II Carbon dioxide 787.6 Let out into atmosphere safely II Hydrogen 17.9 Let into atmosphere safely

through water column



STUDIES AND DOCUMENTATION BY TEAM Labs and Consultants QCI: MoE&F OM, List A-1, S.No. 150. (An ISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007 Certified Organization) B-115, Annapurna Block, Aditya Enclave Ameerpet, Hyderabad-500 038. Phone: 040-23748 555/616, Telefax: 040-23748666 Email: [email protected]

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