PRE FEASIBILITY REPORT

Transcription

1 PIRAMAL ENTERPRISES LIMITED SY. NO. 71, 77, 78, 79A to 80A, 81A & 82A, DIGWAL VILLAGE, KOHIR MANDAL, MEDAK DISTRICT, ANDHRA PRADESH PRE FEASIBILITY REPORT Piramal Enterprises Limited Digwal (V), Kohir (M), Medak (Dist.) Phone: / Fax: E mail ID: ashok.podishetty@piramal.com alok.mishra@piramal.com SUBMITTED TO MINISTRY OF ENVIRONMENT AND FORESTS, GOVERNMENT OF INDIA PARYAVARAN BHAVAN, LODHI ROAD, NEW DELHI

2 Pre Feasibility Report Piramal Enterprises Limited at Sy. No. 71, 77, 78, 79A to 80A, 81A & 82A, Digwal Village, Kohir Mandal, Medak District, Andhra Pradesh DISCLAIMER The purpose and scope of this information memorandum is to introduce the subject matter and provide a general idea and information on the said area. All the material included in this document is based on data/information gathered from various sources and is based on certain assumptions. Although, due care and diligence has been taken to compile this document, the contained information may vary due to any change in any of the concerned factors, and the actual results may differ substantially from the presented information. M/s. Piramal Enterprises Limited, does not assume any liability for any financial or other loss resulting from this memorandum in consequence of undertaking this activity. Therefore, the content of this memorandum should not be relied upon for making any decision, investment or otherwise. The prospective user of this memorandum is encouraged to carry out his/her own due diligence and gather any information he/she considers necessary for making an informed decision. 1. Executive Summary M/s. Piramal Enterprises Limited, proposed to expand its Synthetic Organic Chemicals and intermediates manufacturing unit and Formulations in existing plant premises of an area 79 acres at Sy. No. 71, 77, 78, 79A to 80A, 81A & 82A, Digwal Village, Kohir Mandal, Medak District, Andhra Pradesh. The site is having a longitude (E) and latitude (N). The plant is surrounded by open land in north and east, National Highway No. 9 in south and road connecting Digwal village to Chillkeaplly village in west direction. The nearest human settlement from the site is Digwal from the site in southwest direction. There are no ecologically sensitive areas like national parks, sanctuaries within 10 km radius of the site. 1 P age

3 2. Introduction of the Project / Background Information: 2.1 Identification of Project and Project Proponent: The objective of this pre-feasibility study is to provide information for the expansion of Synthetic Organic Chemicals unit including formulations capacity from TPM to TPM at Sy. No. 71, 77, 78, 79A to 80A, 81A & 82A, Digwal Village, Kohir Mandal, Medak District, Andhra Pradesh, in an existing area of 79 acres. 2.2 Brief Description of Nature of the Project: The synthetic organic chemicals manufacturing will involve series of chemical reactions to get the final Product. The products of reaction are purified, filtered and dried before packing the final product. The Chemical reactions require various supporting services like Heating, Cooling and Agitation etc. 2.3 Need for the project and its importance to the country and or region: World population is growing at an alarming rate. In the Indian sub continent population growth is more than that of developed countries. To meet the needs and comforts of ever-growing population industrialization became inevitable. For the growing population the needs of health care substitutes are also increasing. 2.4 Demands-Supply Gap: The project is envisaged to meet the demand supply gap in both domestic market and export market, as API demand is increasing day by day. 2.5 Imports Vs. Indigenous Production: The project shall meet the reduce imports in some of the intermediate products and also enhance the foreign exchange reserves in view of the proposed exports of few products. 2.6 Domestic/export Markets: The products shall cater to both domestic and export markets. 2.7 Employment Generation (Direct and Indirect) due to the project: The present project for manufacturing of Synthetic Organic Chemicals requires substantial handling of raw materials, goods in process and finished goods. It is expected that no.s of employment will be generated by the proposed expansion project: 2 P age

4 3. Project Description 3.1 Type of Project including interlinked and interdependent projects, if any: M/s. Piramal Enterprises Limited, proposed to expand its Synthetic Organic Chemicals and intermediates manufacturing unit and Formulations in existing plant premises of an area 79 acres at Sy. No. 71, 77, 78, 79A to 80A, 81A & 82A, Digwal Village, Kohir Mandal, Medak District, Andhra Pradesh. 3.2 Size or magnitude of operation: List of products and manufacturing capacity Manufacturing Capacity After Expansion S.No Name of the Product Capacity (TPM) 1 Abacavir Sulfate 2 2 Diltiazem Hydrochloride 25 3 Cis Hydroxy Lactam 10 4 Ketoconazole Verapamil Hydrochloride Halothane Desflurane 25 8 Isoflurane Sevoflurane (Bottling ) Levobunolol Hydrochloride Brimonidine Tartrate Trazodone Hydrochloride FA (2,5-Bis (2,2,2-trifluoroethoxy)-2,2,2-trichloro acetophenone) Mebeverine Hydrochloride FC-4010 (hydroxsulphane) Paroxetine Oxybutynin Hydrochloride Iodoaniline Methyltriazole Immiquimod Flecainide Acetate Vitamin A Palmitate Vitamin E Alcohol Vitamin A Alcohol Dry Vitamin A Acetate Chloropurine Sevoflurane Amiodarone Hydrochloride Sertraline Hydrochloride 1 29 Quetiapine Hemifumarate Tolcapone P age

5 31 Methyl-2-(2-methyl-1H-pyrrolo [2,3-b] Pyridin-3yl) acetate (FCI-1641 ) Sodium Carboxymethyl Cellulose SSPP (4aS, 7aS)-Octahydro-1H-Pyrrolo[3,4-b] Pyridine Droxidopa Tramadol Hydrochloride Acyclovir Tafenoquine Succinate Spirapril Hydrochloride Dihydrate Clozapine Halofuginone Hydrobromide Donepezil Hydrochloride Irbesartan Telmisartan Sulindac Ziprasidone Hydrochloride Valacyclovir Hydro chloride 2 47 Metaxalone Lisnopril Dihydrate Loratadine Netaglinide Hydrochloride Imipramine Hydro chloride Opipramol Dihydrochloride Clomipramie Hydrochloride Memantine Hydrochloride Itra Itra Aprepitant Candesartan Cilexetil 3 59 Perindopril Erbumine Bittermelon Tinefcon Allopurinal 0.01 Total Process Description with process details (a schematic diagram/flow chart) 3.4 Raw material required along with estimated quantity likely source, marketing area of final product/s, mode of transport of raw material and finished product. All the raw materials required for manufacturing mostly available in India or from abroad. There are no banned chemicals or products which are proposed to be used. It is proposed to enter into long term arrangements with some of the raw material suppliers both in India and overseas to avoid shortages at any time. 4 P age

6 3.5 Availability of water its source, energy/power requirement and source should be given The total water requirement shall increased from KLD to KLD after expansion out of which 1295 KLD shall be drawn from ground water and balance shall be recycled water. The total water balance is presented table below. Total Water requirement After Expansion (Tentative) Purpose INPUT (KLD) OUTPUT (KLD) Fresh Water Recycled Water Loss Effluent Process Washings Scrubber Boiler Feed Cooling Tower RO/DM Plant Domestic Gardening Gross Total Total Electricity: The requirement of power will be 5685 KVA. Further, due to the nature of the reactions and requirement of continuous power. Therefore no delay or difficulty is foreseen on the power front. 5 P age

7 3.6 Quantity of wastes to be generated (liquid and solid) and Scheme for their Management/disposal Quantity of Effluent Generated and Mode of Treatment After Expansion (Tentative) Description of Effluent Quantity (KLD) Mode of Final Disposal Permitted After Expansion HTDS Effluents Process Treated in effluent treatment plant consist DM Rejects Boiler Blow Down Scrubbers 2 of Stripper, MEE, ATFD and Biological treatment followed by RO. RO Permeate reused for cooling tower makeup and RO rejects sent to MEE. Total HTDS - I LTDS Effluents Process Biological treatment followed by RO. RO Washings & Scrubber Lab Washings 29 Cooling Tower Blow Down Softner Rejetcs 15 DM Rejects 25 MEE Condensate Domestic Effluent Total LTDS - II Grand Total (I+II) Permeate reused for cooling tower makeup and RO rejects sent to MEE. 6 P age

8 Solid Wastes and Disposal After Expansion (Tentative) S.No Description Units Quantity Mode of Permitted After Expansion Treatment/Disposal 1 Organic residue (Process + Solvent residue) TPD Sent to TDSF/Cement Plants for Coincineration 2 Stripper Distillate KLD Sent to Cement Industries for Coincineration/ Authorized reprocessors/recyclers 3 Spent Carbon & Hyflow Kg/day Sent to TDSF/Cement Plants for Coincineration 4 Spent HCl KLD Sent to Authorized reprocessors/recyclers 5 Chromic Acid KLD Sent to Authorized reprocessors/recyclers 6 Spent Mixed Solvents KLD 8 10 Sent to authorized recovery units/cement plants for coincineration 7 Inorganic residue TPD 0.6 Sent to TSDF 8 Catalyst Kg/day Sent to Authorized Recyclers 9 Spent Silica TPD Sent to TSDF 10 Raney Nickel Kg/day Sent to TSDF 11 Evaporation salts TPD Sent to TSDF 12 ETP Sludge TPD Sent to TSDF 13 Ash from Boiler TPD 27 Sold to Brick manufactures 14 Detoxified containers & liners No.s/month Sold to authorized vendors 15 Off-Seperation & Kg/day Sent to TSDF discarded product 16 Discarded waste Kg/day Sent to TSDF mineral from dust collector, Vacuum system & floor sweeping 17 Iron Powder Kg/day Sent to TSDF 18 Waste oil KLD Sent to Authorized Recyclers 20 Used batteries No.s/Yr Sent to Authorized Recyclers 7 P age

9 4. Site Analysis 4.1 Plant Location M/s. Piramal Enterprises Limited, proposed to expand its Synthetic Organic Chemicals and intermediates manufacturing unit and formulations in existing plant premises of an area 79 acres at Sy. No. 71, 77, 78, 79A to 80A, 81A & 82A, Digwal Village, Kohir Mandal, Medak District, Andhra Pradesh. The site is having a longitude (E) and latitude (N). The plant is surrounded by open land in north and east, National Highway No. 9 in south and road connecting Digwal village to Chillkeaplly village in west direction. The nearest human settlement from the site is Digwal from the site in southwest direction. There are no ecologically sensitive areas like national parks, sanctuaries within 10 km radius of the site. 5. Planning Brief: The project is envisages to be completed by December 2015, and the production shall be initiated thereon. Consultants are identified for preparing the detailed project report. 6. Proposed Infrastructure: 6.1 Power Requirement and Supply/Source The total power requirement is 5685 KVA. 6.2 Utilities List of Utilities S.No Utility Permitted Proposed Total after expansion 1 Coal Fired Boiler 2x 4TPH* 3x6TPH * 16TPH 16TPH 4TPH 2x6TPH 2 Oil Fired Boilers 1x6TPH 1x6TPH 2x6TPH 3 DG Set* 2x1000KVA 3x500KVA 2x380KVA 2x250KVA 1x225KVA *One 4TPH 6TPH boiler will be removed 2x750 KVA 1x725KVA 2x1000KVA 3x500KVA 2x380KVA 2x250KVA 1x225KVA 2x750 KVA 1x725KVA 8 P age

10 Equipments The basic technology involved in the manufacturing of Bulk drugs is the process Kettles, Heat Exchangers, Centrifuges, and Storage Tanks. To support the process equipment Boilers, Chilling plants, Cooling Towers Etc. are required. All the above equipment can be sourced indigenously and the lead time to supply the equipment will not exceed 20 weeks. 6.3 Waste management Liquid Effluents The main sources of effluent generation from the plant are process, washings, Scrubber, blow downs from utilities like cooling tower, boiler & domestic effluents. These effluents are segregated on the basis on TDS and COD loads and treated in Effluent treatment system and treated effluent reused for cooling towers, boilers, scrubbers and washings. Air Pollution The sources of air pollution from the plant are from Coal fired boilers of 6TPH Oil fired existing, proposed 16 TPH coal fired boilers which will be in operation and 4TPH coal fired, 2x6TPH coal fired and 6TPH Oil fired (changed from existing coal to oil) will be standby mode and Backup DG sets of 2x1000, 3x500, 2x380KVA, 2x250 and 1x225 existing and 2x750KVA, 1x725KVA proposed. The proposed air pollution control equipment for coal fired boiler is bag filter and multi-cone cyclone separators. DG sets shall be provided with stack heights based on the CPCB formula for effective stack height. Solid waste Solid wastes are generated from the process, solvent distillation, distillate from stripper, salts from ATFD, sledges from ETP (primary & secondary), waste oil from DG sets, used batteries from DG sets. The stripper distillate, process residue and solvent residue are sent to TSDF/cement plants for co-incineration. The evaporation salts are sent to TSDF. Filter media like spent carbon, catalyst and hyflow are sent to TSDF/authorized recyclers. Waste oil and used batteries from the DG sets are sent to authorized recyclers. The sludge from effluent treatment plant is considered hazardous and the same is sent to TSDF. The ash from boiler is sold to brick manufacturers. The other solid wastes expected from the unit are containers, empty drums which are returned to the product seller or sold to authorize buyers after detoxification. 9 P age

11 7. Rehabilitation and Resettlement (R&R) Plan Not applicable as the land area is only 79 acres already acquired. 8. Project Schedule & Cost Estimates 8.1 Likely date of start of construction and likely date of completion (Time schedule for the project to be given) December Estimated project cost along with analysis in terms of economic viability of the project The estimated cost of the project is approximately Rs. 250 Crores. Project Cost Breakup Rs. In Crores Plant& machinery 120 Civil buildings 20 Structures 20 Total - I 160 Pipe lines & insulation 10% on plant & machinery 16 Electricals & instrumentation 10% on plant & machinery 16 Erection & commissioning & painting 8% on plant & machinery and structures 13 Pollution treatment Structural & equipment 20 Pollution treatment civil 10 Land & development 5 Material handling equipment charges 5 Laboratory equipment 2 Safety Equipment 2 Furniture, fixtures, computers, lighting etc 1 Total - II 90 Contingencies & pre-operative 5% on the above 4.5 expenses Project Cost (Total I+II) P age