BALAJI AMINES LIMITED

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1 FOR EXPANSION OF EXISTING SYNTHETIC ORGANIC CHEMICALS MANUFACTURING UNIT BALAJI AMINES LIMITED At Plot No: 4 & 5, Beside Sub-Station-II, I.D.A, Bollaram, Jinnaram (M), Medak District, Telangana State

2 Contents S. No. Description Page no. 1.0 Executive Summary Introduction of The Project Project Proponent Brief description of nature of the project Need for the project and its importance to the country and or region Employment Generation(Direct and Indirect) due to the project Project description Product and Production Capacity Raw materials required and Quantities Manufacturing Process Resource Utilize and Recycling Water Power Requirement Fuel Requirement Quantity of wastes to be generated Waste Water Generation and utilization Solid waste generation and Disposal Schematic representations of the feasibility drawing which give information of EIA purpose Site Analysis Connectivity Land Form, Land use and Land ownership Existing Infrastructure Soil classification Climatic data from secondary sources Social Infrastructure available Planning brief Proposed infrastructure Industrial Area Residential Area Green Belt: Social Infrastructure Water management Sewerage System 13

3 6.7 Industrial Waste Management Rehabilitation and Resettlement (R&R) Plan Project Schedule and Cost estimates Analysis of project 14 LIST OF TABLES Table No Description Page no. 2.1 Total Employment Proposed Products and Quantities Water Requirement Details Wastewater generation and Treatment Method Solid and hazardous waste generation and Disposal Project Cost 13 LIST OF FIGURES Figure No Description Page no. 1.1 Location Map Google Earth Map Showing Balaji Amines Ltd 6 LIST OF FLOW CHART Flow Chart No Description Page no. 3.1 Generalized Flow Chart for Synthetic organic chemicals Manufacturing 8

4 1.0 EXECUTIVE SUMMARY M/s. BALAJI AMINES LTD.(BAL) is a limited company (the plant was originally in the name of Bhagyanagar Chemicals Ltd., which is a WOS of BAL having lease agreement) and commenced its commercial operations in 1994, Focusing its attention on developing technology for import substitute products without any kind of pollution, introduced quality products DMAHCL, TMAHCL other HCLs and natural products such as Solonesol, 10 DAB etc. S. No Parameter 1 Project Location 2 Category of Project as per EIA Notification & 5 F(A) Amendments 3 Project cost 3.0 Crores 4 Plot area 4.2 Acres Description Plot No: 4 & 5, Beside Sub-Station-II, I.D.A, Bollaram, Jinnaram (M), Medak District, Telangana State Proposed Products List of products are Enclosed 6 Resources (I)Electricity Requirement Source of electricity 600 HP TSSPDCL D. G. Sets Existing : 375 KVA Proposed : 360 KVA (II)Water consumption 135 KLD Source of water Waste water generation 7 Solid waste generation TSIIC Supply KLD 8 Nearest Highway NH KMs Organic Residue 901 Kg/Day Inorganic solid waste 38 Kg/Day MEE salts Kg/Day Spent carbon 16 Kg/Day Coal ash from Boiler 7050 Kg/Day ETP Sludge 30 Kg/Day Solvent Distillation bottom Residue 43 Kg/Day 9 Nearest Railway Station Lingampally Railway Station Km 10 Nearest Air Port Rajiv Gandhi International Airport KM M/s. Balaji Amines Ltd. Page 1

5 2.0 INTRODUCTION OF THE PROJECT The objective of this pre- feasibility study is to provide information for the expansion of unit of M/s. Balaji Amines Ltd. Plot No: 4 & 5, Beside Sub-Station-II, I.D.A Bollaram, Jinnaram (M),Medak District, Telangana State Project Proponent Mr. B. Jogeshwar Rao is the Plant Manager and is Graduate ( B.Sc ) in Chemistry from Nobel College, Machilipatnam (Andhra University). He has over 35 years of experience in Plant Management, Including process optimization and Process Scale up. He has handled projects dealing with organic and inorganic compounds. He has worked with companies like Pure Drugs Pvt.Ltd. and Vanilin and Fine Chemicals Ltd. and MCA Chemicals Ltd., and well acquainted with Operations of chemicals plants, safety and environment culture and other legal requirements. 2.2 Brief description of nature of the project. M/s. Balaji Amines Ltd. commenced its commercial operations in 1994 and manufactures DMAHCL and Natural Products such as Solonesol and 10 DAB etc. at Plot No: 4 & 5, Beside Sub-Station-II, I.D.A, Bollaram, Jinnaram (M), Medak District, Telangana State Need for the project and its importance to the country and or region We are the safest and largest manufacturer of DMAHCL products in India. The market for DMAHCL and other products is increasing at the rate of 30% year on year on volume basis. At present we only cater to Pharma sector. We are coming up with highly efficient products that can cater to Healthcare industries. Hence a need is felt to increase the present capacity of the plant and diversify to some of the new generation products. The plant employs people from the local community. With increase in plant capacity, the employment opportunity increases for the local people. We are the only manufacturer of DMAHCL and other products in South India and in future we intend to export this product to Global pharmaceutical industries. With increase in volume the tax outgo to the govt will increase substantially. M/s. Balaji Amines Ltd. Page 2

6 2.4 Employment Generation (Direct and Indirect) due to the project The unit has 20 permanent and 40 contractual employees. Apart from this there will be significant indirect employment generation at the supplier firms and service industry providing services to the company. Company shall be giving preference to people from economically weaker sections for employment in various semiskilled/unskilled jobs thereby contributing to their upliftment. The details of total employment in this unit shown in below Table 2.1. TABLE 2.1: TOTAL EMPLOYMENT AFTER EXPANSION Particulars No. of employees Key managerial staff 10 Administration 5 Office work Skilled and semi skilled 80 Total 95 Functional Area Finance, Marketing, Production, Quality control, R&D, Logistics etc. Manufacturing, Maintenance, Stores & Un skilled workers and contractors M/s. Balaji Amines Ltd. Page 3

7 3.0 Project Description M/s. Balaji Amines Limited was started in IDA, Bollaram of Telangana State in the year 1994 to produce DMAHCL and other products and now proposing for expansion of Existing Capacities with inclusion of new products apart from expanding DMAHCL capacities as this product is mainly used in treating diabetes. As the incidence of Diabetes has been growing rapidly, the capacity expansion is to meet the growing demand. The process does not generate any effluent. The Location map is shown at Figure -3.1 and Google earth map showing Balaji Amines Ltd. plant is shown at Figure The site central coordinates are Latitude : 17 32'54.20"N Longitude : 78 20'41.86"E There are no archaeological, historical sites located nearby. Therefore, the project site does not offer any negative impact on the local area, but rather has a positive impact on socio economic conditions of the habitants around it. The Balaji Amines Ltd. is 3 Km away from Nehru ORR and 6 Kms. from Lingampally Railway Station. M/s. Balaji Amines Ltd. Page 4

8 FIGURE 3.1: LOCATION MAP Balaji Amines Ltd. Plot No: 4 & 5, Beside Sub-Station-II, I.D.A, Bollaram, Jinnaram (M), Medak District, Telangana State M/s. Balaji Amines Ltd. Page 5

9 FIGURE 3.2: GOOGLE EARTH MAP SHOWING BALAJI AMINES LTD M/s. Balaji Amines Ltd. Page 6

10 3.1 Product and Production Capacity M/s. Balaji Amines Ltd. is proposes to produce below mentioned products with Manufacturing Capacity 1510 MT/Month and the list of product is shown in Table3.1. Table3.1: Proposed Products and Quantity S. No Product Name CAS No s Quantity Kg/Month 1 16-Alpha hydroxyprednisolone Beclomethasone Dipropionate Betamethasone 17-valerate Betamethasone Acetate Betamethasone dipropionate Betamethasone Sodium Phosphate Budesonide Ciclesonide Dimethylamine Hydrochloride , Emtricitabine Flumetasone Pivalate Fluticasone Furoate Lamivudine Mometasone Furoate Nadolol Povidone Iodine PVP-A Copolymer Series VP/DMAEMA Quaternized(PQ-11) Total 1,507, Raw materials required and Quantities All the raw materials required for manufacturing of above products will be sourced from local/non local market. The required raw materials and quantities are enclosed as Annexure. M/s. Balaji Amines Ltd. Page 7

11 3.3 Manufacturing Process: The manufacturing process of bulk drugs consists of chemical synthesis extending to stages of processing involving different type of chemical reactions. The generalized Flow chart for synthetic organic chemicals manufacturing is shown in Flow chart 3.1. FLOW CHART 3.1: GENERALIZED FLOW CHART FOR SYNTHETIC ORGANIC CHEMICALS MANUFACTURING 3.4 Resource Utilize & Recycling Water Water requirement of the project for domestic and industrial activity during operation phase will be KLD. The water requirement will be met through TSIIC supply. The detailed water requirement shown in below Table 3.2. M/s. Balaji Amines Ltd. Page 8

12 Table 3.2: WATER REQUIREMENT DETAILS PRE FEASIBILITY REPORT S. No Purpose Water Requirement In KLD 1 Process Washings Boiler Make up Cooling towers Make up Scrubbing system DM Plant Domestic Gardening 4.00 Total Power Requirement Power requirement of proposed project will be made available through TSPCPDCL. The total power requirement for the unit after expansion is 850 Hp respectively. Proposing to Install 360 KVA DG set In addition to existing 375 KVA DG to meet the emergency power requirement of the plant for the proposed Expansion. 3.5 Quantity of wastes to be generated Waste Water Generation and utilization Total effluent generated in the project is KLD. The process waste water from Process, floor Washes, scrubbers, QC and R&D are evaporated in MEE with stripper and ATFD after neutralization. The condensate from MEE and ATFD will be collected and treated in effluents treatment plant along with effluents from utilities followed by RO. RO rejects will be send back to MEE and RO Permeate will be reused back. To treat the sewage generated due to domestic activities will be disposed through septic tank following by soak pit. S. No Unit Table3.3: WASTEWATER GENERATION HTDS In KLD LTDS In KLD Effluent Generation In KLD Method of Disposal Process Washings Boiler Make up HTDS Sent to stripper followed by MEE and ATFD. Condensate will be send to ETP followed by RO. 4 Cooling towers Make up LTDS Effluents sent to ETP followed by M/s. Balaji Amines Ltd. Page 9

13 S. Unit HTDS In LTDS In Effluent Generation Method of Disposal No KLD KLD In KLD 5 Scrubbing system RO system.ro Rejects sent to MEE 6 DM Plant system and RO Permeate to Reuse. 7 Domestic Septic tank followed by soak pit Total Solid waste generation and Disposal The following solid waste will be generated like Used drums & Tins, and Used Oil etc. The types of Hazardous and non Hazardous wastes generated from the project, method of disposal is shown in below table-3.4. Table 3.4: Solid & Hazardous waste generation and Disposal S. Quantity Name of the Solid Waste No. In Kg/Day Disposal Method 1 Organic Residue Sent to Cement Industries 2 Inorganic solid waste Sent to TSDF 3 MEE salts Sent to TSDF 3 Spent carbon Sent to Cement Industries 4 Coal ash from Boiler Sent to Brick manufacturers 5 ETP Sludge Sent to TSDF 6 Solvent Distillation bottom Sent to Cement Industries Residue 7 Used Oils & Grease 8 Detoxified Containers, Liners Etc 500 Ltrs/Annum 1000 No s/month 9 Used Lead Acid Batteries 2 No s/annum SPCB Authorized Agencies for Reprocessing/Recycling After Detoxification sent back to suppliers/spcb Authorized Parties Send back to suppliers for buyback of New Batteries 3.6 Schematic representations of the feasibility drawing which give information of EIA purpose. The applicability of the S.O 1533 for the proposed project was explored by considering different possibilities & provision made in the said notification. Considering the products & project location of the proposed project it is noticed that the proposed project falls under Category 5 (f) A of the Schedule-I of EIA M/s. Balaji Amines Ltd. Page 10

14 Notification SO As per the provision of the SO 1533, it is necessary to get Environmental Clearance by applying to MoEF along with the Environmental Impacts Assessment Study Report for the proposed project prior to commissioning of the project activities. Therefore the EIA is required to conduct to comply with provisions of SO 1533 made for Category 5(f) A of schedule I of the notification. 4.0 Site Analysis 4.1 Connectivity Balaji Amines Ltd. is located at Plot No: 4 & 5, Beside Sub-Station-II, I.D.A, Bollaram, Jinnaram (M), Medak District, Telangana State The nearest habitation from the site is Bollaram at a distance of 0.5 Km (N). The nearest railway station is Lingampally Railway Station at a distance of 7.7 KMs from the site (SSW). The nearest airport is Rajiv Gandhi International Airport at a distance of KM. The Nearest road ways NH Km. 4.2 Land Form, Land use and Land ownership. Balaji Amines Ltd is an existing unit. There would be no any change in Land Use, Land Cover or Topography of plot. Green belt is already developed in the plant premises. 4.3 Existing Infrastructure. Project is a located very nearer to Nehru ORR Highway ( NH-2 KM) and the city is located (i.e Hyderabad Kms) and the basic infrastructure is already there. The plant is well connected with Road and Railway facilities 4.4 Soil classification The district is mainly covered by two types of soils i.e black and chalka (Sandy looms) covering 55% and 45% respectively of the total area. M/s. Balaji Amines Ltd. Page 11

15 4.5 Climatic data from secondary sources. Temperature Maximum: o C Minimum: 10.0 o C Normal annual rainfall 811.9mm 4.6 Social Infrastructure available. Well developed social infrastructure facilities are available at nearby Habitations. 5.0 Planning Brief Proposed expansion activities will be started after getting statutory clearance form related authorities. The project will be completed within two years. Further project activities will take care of all the rules and regulation of statutory authority and provide the control measure and devices to achieve the standard norms. 6.0 Proposed Infrastructure 6.1 Industrial Area The infrastructure and other facilities are already well developed in nearby Mandal head quarter and other villages. 6.2 Residential Area The employees who will work in the industry will be living in nearby Bollaram or Hyderabad & there no proposal for creating residential area for employees. 6.3 Green Belt: 33 % of Green Belt will be developed and it will be maintained. 6.4 Social Infrastructure: Facilities like road and communication are good; Banks, ATM's and medical facilities are also adequate in the area. Amenities: Education- schools including middle, secondary and higher secondary schools, social welfare hostels are available and technical education colleges are plenty in the nearby areas. M/s. Balaji Amines Ltd. Page 12

16 Medical and Health- Community Health Centre, & Primary Health center Are available near village and also there is a ESI dispensary in Bollaram Village. Power and water- All the villages are electrified and drinking water facilities are extended to all villages. Rail and Road- The project site is very well connected by road through Nehru ORR, South Central railways etc. 6.5 Water management Water requirement will be met through IDA Supply. 6.6 Sewerage System: Domestic waste water will be disposed off through soak pit system. 6.7 Industrial Waste Management: The Hazardous waste sent to TSDF. 7.0 Rehabilitation and Resettlement (R & R) Plan Rehabilitation & Resettlement (R&R) plan is not applicable to proposed project. 8.0 Project Schedule & Cost Estimates Expansion activities will be started after getting statutory clearance from concerned authorities. The project will be completed within two years. This Expansion will provide benefits to the local people in terms of sustainable development in terms of economical and social welfare. The project cost for proposed Project is 3.00 Crores will be used for constructing additional building, Equipments, Machinery, ZLD System and Air pollution control Equipments. TABLE 8.1: PROJECT COST S. No Particulars Rs. Crores 1 Land 0 3 Plant & Machinery Working Capital Margin 0.50 Total 2.50 M/s. Balaji Amines Ltd. Page 13

17 9.0 Analysis of proposal (Final Recommendations) Local people will get direct employment. which will in turn develop all the stakeholders. Local people will get some contracts of supply and services to get indirect income. Company will contribute in improving education and health facilities in nearby areas under CSR activities. M/s. Balaji Amines Ltd. Page 14