The unit obtained NOC (CFE) of A.P. Pollution control Board in the year 1988 and started operations.

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1 1. Introduction M/s. Sri Krishna Pharmaceuticals Limited, Unit-III (Formerly Sri Krishna Drugs Limited) was established in the year It is located at Sy. No. 57, Golkonda kalan, Raikunta (V), shamshabad (M), Rangareddy (D), Telangana state. The unit obtained NOC (CFE) of A.P. Pollution control Board in the year 1988 and started operations. The Ministry of Environment and Forests accorded Environmental Clearance to the industry vide Environmental Clearance File No: J /147/2005-IA.II(I) Dt: August 11,2005 to manufacture folic acid with a capacity of 96.0 TPA. Copy of Environmental clearance is enclosed as Annexure I. The unit obtained CFE for Change of Product mix vide order No. APPCB/HYD/KTN/311/CFE/HO/2009 dated and also vide order No. 311/TSPCB/CFE/RO-RR-I/HO/ dated Copy of latest CFE is enclosed as Annexure II. Subsequently obtained CFO of the Board vide letter No. APPCB/10017/ZO-HYD/ HO/CFO/ dated with a total capacity of 8.0 TPM. Current CFO Copy is enclosed as Annexure III In order to meet the market demand it is now proposed to expand the production capacity from 96.0 TPA to TPA. Applied for Certified Copy of Compliance Report from MoEF & CC, Government of India, Chennai Regional Office is enclosed at Annexure- IV 1

2 2. Introduction of the Project The salient features of the project are described in the table given below TABLE 1.0 Salient Features of the Project Location Sy. No. 57, Golkonda kalan, Raikunta (V), shamshabad (M), Rangareddy (D), Telangana Longitude and Latitude 17 o N & 17 o N Latitude 78 o E & 78 o E Longitude Year of Establishment 1988 Product Category 5(F) Bulk Drugs & Intermediates Project Category as per EIA A ( Not in notified Industrial Estate) notification Proposed Activity Capacity expansion from 96.0 TPA to TPA Total investment on the plant Current - Rs Crores & Proposed Total Investment on Environmental Infrastructure Total area of the plant Total area of green belt Water requirement Rs.40.0 Crores Rs. 5.0 Crores (Current) Rs Crores ( Proposed) 12.0 Acres 5.0 Acres Total water requirement after expansion KLD Fresh water requirement KLD Recycled water KLD Source of water Borewell Nearest habitation and distance Bahadurguda Km from the site Nearest surface water bodies Rainfed water tank at a distance of 0.78 Km from site Nearest reserve forest Nearest Reserve forest is at a distance of 1.4 km. Environmentally sensitive areas within 10 km radius Any national parks, wild life sanctuaries within 10 km radius Nearest air port and distance Nearest railway station and distance None None Shamshabad, RGI-3 Km Umdanagar-7.43 Km 2

3 i) Introduction of the company and proponent Sri Krishna Pharmaceuticals Limited, unit-iii (Formerly Sri Krishna Drugs Limited) was incorporated as a public limited company under the Companies Act, 1956 at Hyderabad in the state of Andhra Pradesh, India during the year The company is engaged in the manufacturing of Active Pharmaceutical Ingredients (APIs) and API Intermediates for catering to the domestic as well as international market. The company recognized the vital role of R & D for becoming successful in the generic market. About Proponent The management at Sri Krishna Pharmaceuticals Limited, Unit-III (Formerly Sri Krishna Drugs Limited) consists of highly qualified and richly experienced persons who have given the company the edge in terms of quality, consistency, timely delivery and ability. The company is headed by Mr. V. V Krishna Reddy, Managing Director, having vast experience in various businesses. About the Unit Sri Krishna Pharmaceuticals Limited established this manufacturing unit in the year 1988 and obtained Environmental Clearance from Ministry of Environment with a capacity to manufacture Bulk Drugs with a capacity of 96.0 TPA. Quality Management: Strict quality control measures, Good Manufacturing Practices (GMP) are integrated throughout the manufacturing process to ensure strict adherence to the quality parameters for both in-process and finished products. 3

4 3. Project Description 3.1 Production Capacity Currently the unit is permitted to manufacture 11 drugs out of which 4 are regular products and 7 are campaign products (any 3 products can be manufactured at a given point of time) with a total capacity of 8.0 TPM as detailed below TABLE 2.0 LIST OF EXISTING PRODUCTS S.No Name of the Products Quantity in TPM Regular Products 1 Folic acid pharma Metadoxine Fenoverine Tiemonium methyl sulphate 1.20 Campaign Products( Group B) an three products at a time 5 Doxylamine succinate Enalapril Maleate Iso Metheptene Mucate Phenylephrine Hydrochloride Meclazine Hydrochloride Sodium Phenyl Butyrate Butrorphanol Tartrate 0.02 Total ( Worst combination) Proposed expansion: It is now proposed to expand the production capacity of the existing 1 product and to manufacture all the existing products. Below Table provides list of products and proposed capacities. 4

5 TABLE 3.0 PROPOSED PRODUCTS & CAPACITY S.No Name of the Products Quantity in TPM 1 Folic acid pharma Metadoxine Fenoverine Tiemonium methyl sulphate Doxylamine succinate Enalapril Maleate Iso Metheptene Mucate Phenylephrine Hydrochloride Meclazine Hydrochloride Sodium Phenyl Butyrate Butrorphanol Tartrate 0.02 Total Manufacturing Process Brief process description and process flow charts are given at Annexure VI 3.3 Raw Materials List of raw material product wise is given at Annexure V 3.4 Water Requirement The water requirement will be met Ground water. The requirement for water in this unit is for process and domestic purposes. The water balance for daily consumption is presented below. 5

6 TABLE 4.0 Water Balance Current & Proposed S. No Stream 1 Process 2 Washings Water requirement in KLD Current 52.5 After Expansion Waste Water discharge in KLD Current After Expansion Scrubbers Boiler DM/Softener Cooling & Regeneration Domestic Gardening Proposed Method of Treatment and Disposal Stripper, MEE and ATFD (Condensate to RO) Stripper, MEE and ATFD (Condensate to RO) Stripper, MEE and ATFD (Condensate to RO) ETP followed by RO ( RO Reject to MEE) ETP followed by RO ( RO Reject to MEE) ETP followed by RO ( Ro Reject to MEE) ETP followed by RO ( Ro Reject to MEE) Total Wastes generation and control systems Liquid Effluents As detailed in Table 4.0 waste water generation after expansion would be KLD. It is proposed to segregate effluents into high COD and High TDS stream and Low COD and Low TDS streams. 6

7 High TDS and High COD stream would be treated in stripper followed by MEE and ATFD. The resultant sludge would be disposed to TSDF, Hyderabad. The Low TDS stream would be treated along with MEE/ATFD condensates in biological ETP followed by RO. The RO rejects would be fed back to MEE. The Permeate from RO would be used for cooling tower make up. Thus the treatment system proposed is based on Zero Liquid Discharge (ZLD) Concept The schematic diagrams of ETP proposed are given in Figure 1.1 and Figure 1.2 below 7

8 Fig 1.1 Schematic Treatment Scheme of High TDS Effluents Effluent from Process and Washings, Scrubber Equalization Tank Neutralization Tank Settling Tank Stripper Cement RO Reject Aq. Distillate to Plant/TSDF Recovery To TSDF MEE Condensate to Biological Treatment ATFD Condensate to Biological Treatment Sludge to TSDF 8

9 Fig 1.2 Low TDS Effluent Treatment System Domestic effluent Effluents from utilities & MEE condensate Screen Chamber Screen Chamber Equalization Tank Neutralization Tank Clarifier 1 Aeration Tank1 Aeration Tank2 Clarifier 2 Holding Tank Sludge Holding Tank Sand filter Sludge to TSDF Sludge Cake Filter Press Carbon Filter Permeate for re-use RO Ultra filtration Rejects to MEE 9

10 3.5.2 Solid wastes management Hazardous and non - hazardous wastes generated from the proposed expansion project are detailed below. Mode of disposal are also identified and listed. Adequate storage of hazardous waste is ensured at the site TABLE 5.0 Solid Wastes and Disposal Quantity S.N o Description Current TPM After Expansion TPM Remarks 1 MEE salts/ Gypsum/ Calcium Chloride equivalent salts * Sent to TSDF, Dundigal 2 Inorganic salts Sent to TSDF, Dundigal 3 Distillation bottom Residue/In soluble organic residue Authorized cement plants for coprocessing/ TSDF, Dundigal 4 Spent carbon ETP sludge Sent to TSDF, Dundigal 6 Iron sludge Spent Nickel 0.08 Total Authorized cement Industries For re-processing 8 Boiler Ash Sold to brick manufacturers 9 Waste oil 70.0 LPM Authorized recyclers/ reprocessors 10 Detoxified Container and container liners 50 No s/month After complete detoxification it shall be disposed to the outside agencies 10

11 Of hazardous waste chemicals 11 Used lead acid batteries 10 Nos/Year Authorized recyclers on buy back basis 12 Spent solvents 10 KL/ month 20.00kl/month To authorized recyclers/cement industries for co-processing *Includes salts from MEE and Neutralization salts. TSDF facility is about 70 KM from the site in Rangareddy District which is created for catering the industries in this area. Transport of Hazardous wastes to TSDF is done by the Ramky. In case other hazardous wastes, authorized recyclers will transport the wastes 4. Site Analysis 4.1 Plant Location M/S Sri Krishna Pharmaceuticals Limited, unit-iii Sy. No. 57, Golkonda kalan, Raikunta (V), shamshabad (M), Rangareddy (D), Telangana state. The site is situated at 17 o N and 17 o N Latitude and 78 o E and 78 o E Longitude. The land area of the plant is 11.3 acres. The nearest habitation from the site is bahadurguda (V) at a distance of 1.71 km. The nearest railway station located at Umdanagarat 7.43 KM from the Plant. There are no ecologically sensitive areas like national parks, sanctuaries within 10 km radius of the site. Following are the surroundings of the site North Private lands South Approach road followed by industry s own land with guest house East Private lands West - Outer ring road 11

12 Following 9 reserve Forests are there within 10 KM radius of the site Table 6.0 Reserve Forests in the study area S.No Reserve Forest Direction Distance from the from the site site (KM) 1 RF E RF S Maisaram SE Lemur SE Kongarkala SE Jallapalli NE Domnair NW RF W RF NE 3.7 Topo graphic features of the site and 10 KM study area and base map are given at Fig 1.3 & 1.4. Plant & Green Belt Photographs are given at Fig. 1.5 Site lay out map is given at Fig

13 Fig 1.3 Topo Sheet of the 10 KM study area 13

14 Fig 1.4 Base map of the study area 14

15 Fig 1.5 Plant & Green Belt Photographs 15

16 Fig 1.6 Site Lay Out Plan 16

17 5.0 Planning in Brief The project is envisaged to be completed by December 2016, and the production shall be initiated thereon. Consultants are identified for preparing the detailed project report. 6. Resource requirements 6.1 Power Requirement and Supply/Source The total power requirement is 6000 KVA. TSCPDCL and D.G sets as alternative to Power failure. It shall be sourced from 6.2 Production facilities, Utilities and effluent handling facilities Apart from the existing facilities it is proposed to add additional production facilities, utilities and effluents treatment infrastructure with an additional investment of Rs.40.0 Crores. The details are outlined in the below table TABLE 7.0 Production facilities/utilities/etp Existing & Proposed S.NO Details Production facilities Capacity/ No Current Additions After expansion 1 Production Blocks No s Clean Rooms No s Utilities 3 Boilers (Coal Fired) TPH DG sets KVA 1 X500, X Cooling Towers TR Softener/DM plant M 3 /hour Effluent handling & treatment facilities 7 collection tanks- KL Storage 8 Neutralisation tanks KL Stripper, MEE, ATFD KLD RO & Biological treatment KLD

18 6.3 Land Requirement The unit currently has 12.0 acres of land and out of which 5.0 acres of green belt is developed. The land requirement for proposed expansion activities will be 2.0 Acres which can be met from existing open area. Below table provides the land statement. Detailed site lay out plan outlining current and proposed expansion activities is given at Figure 1.6 Table 8.0 Land Statement S.No Purpose Units Extent 1 Built up area Acres Green belt Acres Open area Acres 5.0 Total Acres Area required for Proposed expansion Acres Air Pollution The Sources of air emissions from the plant are 6 TPH coal fired Boiler and proposed TPH coal fired boiler and additional DG sets The process emissions from the second phase containing SO 2, CH 4, NH 3 & HCl are scrubbed with caustic and scrubbed waste send to MEE. Below Table gives current proposed emission sources from the plant Table 9.0 Emission Source Current & Proposed S.N o Parameter Capacity Fuel Anticipated emissions Existing 1 Process HCl, SO 2, NH3, Cl2 2 Boiler Stack 6 TPH Coal SPM, SO 2, Control system Scrubber NO x meters, bag Stack Ht 30 filter & cyclone dust collector 3 DG sets 1x 500 KVA Diesel SPM,SO 2 Stack Height 18

19 and 1 X 380 KVA &NO x 4.5 & 3.9 Mts, Acoustic enclosures Proposed (additions) 1 Boiler 15 TPH Coal SPM,SO 2 &NO x Stack Height 30 meters 2 DG set 1000 KVA Diesel SPM, SO 2, NO x 8.0 Bulk Chemical Storages: Stack height of 6.3 meters & acoustic enclosure Following bulk chemical storage facilities are proposed for expansion activity Table No 10.0 Storage facilities of bulk chemicals Sr Capacity Name of the No (KL) solvent/chemical MOC Existing 1 15 Methanol MS Tank 2 30 Acetone MS Tank 3 15 Tolune MS Tank 4 15 IPA MS Tank Chloroform Drums Other Major chemicals 6 30 tons chlorine MS cylinder 7 10 HCl HDPE 8 40 H2SO4 MS Proposed Toluene MS Tank 19

20 9. Project Financial The estimated cost of the expansion project is approximately 40.0 Crores. Out of this Rs Crores will be for effluents treatment facilities and rest for other process equipment and safety equipment Project cost Rs. In Crores Plant& machinery Civil & Structural 5.00 Pipe lines & insulation Electricals & instrumentation Erection & commissioning & painting Total % on plant & machinery % on plant & machinery % on plant & machinery and structures 1.60 Safety & Environment Furniture, fixtures, computers, lighting etc 0.50 Contingencies & pre-operative expenses Project cost say Crores Total

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