Project No: AESPL/IND-E/16-17/EIA/016

Environmental Impact Assessment Report

Proposed Expansion of Synthetic Organic

Chemicals Manufacturing Facility

Baseline Monitoring:
Winter 2017-18
By
M/s Centaur Pharmaceuticals Private Limited
Plot no. 74, 75, 76 & 76/1, Chikhloli MIDC,
Ambernath (west)
Dist: Thane, Maharashtra

October 2018

Environmental Consultant:
Aditya Environmental Services Pvt. Ltd., Mumbai
QCI- NABET Accredited EIA consultant
www.aespl.co.in
 Declaration by Experts contributing to the EIA “Proposed Expansion of Synthetic Organic
Chemicals Manufacturing Facility By M/s Centaur Pharmaceuticals Private Limited, Plot
no. 74, 75, 76 & 76/1, Chikhloli MIDC, Ambernath (west), Dist: Thane, Maharashtra”.
I, hereby, certify that I was a part of the EIA Team in the following capacity that
developed the above EIA.
EIA Coordinator:
Name: Mr. Rajiv V Aundhe

Signature & Date: 22nd October2018

Period of involvement: since December 2016
Contact information: Mob. 09821513367 E-mail: [email protected]
Functional Area Experts:

S.N. Functional Name of the Expert/s Involvement Signature & Date

Areas (Period &
Task**)
1 AP* Rajiv Aundhe (FAA since December
Swapnil Ubale) 2016
2 WP* Rajiv Aundhe (FAA since December
Swapnil Ubale) 2016
3 SHW* Rajiv Aundhe since December
2016
4 SE* Ms. Anju Chawhan Nov, Dec-2017,
Jan 2018
5 EB* N. K. Shendye Nov, Dec-2017,
Jan 2018
6 HG* -- -- --
7 GEO* -- -- --
8 SC* -- -- --
9 AQ* Sudhir Verma Nov, Dec-2017,
Jan 2018
10 NV* Rajiv Aundhe since December
2016
11 LU* Ms. Bela Pharate Nov, Dec-2017,
Jan 2018
12 RH* D. K. Joshi Nov, Dec-2017,
Jan 2018
NOTE: (*) Full forms of abbreviations given on Next Page
(**) Tasks for each Functional Area Expert given on Next Page
Environmental Baseline monitoring and analysis for this project was carried out by in-house,
environmental analytical laboratory, registered by MoEFCC, approved under Environment
Protection Act 1986, vide MoEFCC Notification S.O. no. 1190 (E), dated 1st May 2014. The
duration of recognition is from 1st May 2014 to 30th April 2019.
I, Rajiv V. Aundhe, hereby, confirm that the above mentioned experts prepared the EIA
“Proposed Expansion of Synthetic Organic Chemicals Manufacturing Facility By M/s Centaur
Pharmaceuticals Private Limited, Plot no. 74, 75, 76 & 76/1, Chikhloli MIDC, Ambernath (west),
Dist: Thane, Maharashtra’’.
I also confirm that Aditya Environmental Service Pvt. Ltd. shall be fully accountable for any mis-
leading information mentioned in this statement.

Name: Rajiv V. Aundhe

Designation: Director
Name of the EIA Consultant Organization: Aditya Environmental Service Pvt. Ltd.
NABET Certificate No.& Issue Date: NABET S.N. (5) as per QCI website.
S.N. Functional Complete Name of the Tasks
Area Code Functional Areas
1 AP Air Pollution Prevention, Assessing baseline ambient air quality, stack
Monitoring & Control emission, possible impacts and control
measures
2 WP Water Pollution Assessing baseline surface/ ground water
Prevention, Control & quality, possible impacts and control measures
Prediction of Impacts
3 SHW Solid Waste and Assessing solid/hazardous waste generation,
Hazardous Waste treatment and disposal
Management
4 SE Socio-Economics Assessing baseline Socioeconomic,
demographic situation, impacts and CSR plan/
measures for upliftment
5 EB Ecology and Biodiversity Assessing baseline biodiversity situation in
study area, impacts and Biodiversity
management plans
6 HG Hydrology, ground Water Assessing baseline hydrogeological situation
& Water Conservation in study area, impacts and management plans
7 GEO Geology Assessing baseline geological situation in
study area, impacts and management plans
8 SC Soil Conservation Assessing baseline soil quality, possible
impacts & control measures
9 AQ Meteorology, Air Quality Assessing nature and scale of impacts on
Modeling & Prediction ambient air quality through modeling and
management plans
10 NV Noise/ Vibration Assessing baseline ambient noise quality,
possible sources, impacts and control
measures
11 LU Land Use Assessing baseline Land use Land cover
possible impacts and control measures
12 RH Risk Assessment & Hazard Assessing safety measures taken up by
Management company modeling to assess scale of impacts,
disaster management and control measures
 ADITYA
ENVIRONMENTALSERVICES PVT. LTD.
Recognized by MOEF as “Environmental Laboratory” vide S.O.No. 983 valid up to 30.04.2019
ISO 9001:2008, OHSAS 18001:2007 Certified
Accredited by QCI-NABET as ‘A’ Category EIA Consultancy Organization

TO WHOMSOEVER IT MAY CONCERN

This is to confirm that the EIA/ EMP for the project “Proposed Expansion of Synthetic

Organic Chemicals Manufacturing Facility” located at Plot No. 74, 75, 76 & 76/1,

Chikhloli MIDC, Ambernath (west) Dist: Thane, Maharashtra by Centaur

Pharmaceuticals Private Limited has been prepared by me in the capacity of EIA

coordinator. The Standard ToRs prescribed by MoEFCC vide Notification dated 10th

April 2015 and the additional ToRs prescribed by SEAC -I committee during

142ndmeeting dated 14th September 2017 have been fully complied with in preparing

the EIA/ EMP. A point wise compliance to the ToRs prescribed as abvoe has been

presented in Chapter 1, Section No. 1.4.7.

We aslo confirm that the EIA prepared is based on factual data and all due diligence has

been followed in preparing the same.

For Aditya Environmental Services Pvt. Ltd.

Rajiv Aundhe
EIA cordinator

Date: 4th February 2019

Place: Mumbai

Reg. Office: 107, Hiren Light Indl. Estate, Mogul Lane, Mahim, Mumbai -400016Tel: 022 42127500 E-mail:
[email protected]
Central Lab :P-1, MIDC Mohopada, P.O. Rasayani, Dist. Raigad Pin 410207 Tel : 02192 252008 E-mail : [email protected]
Branches : Goa 08322652456 Ahmedabad :079 40063271 Pune : 915802585 Delhi : 01164595949 Baroda : 02652331790
CIN: U74999MH2001PTC132091
 LIST OF ABBREVIATIONS
Abbreviation Full form
AAQ Ambient Air Quality
ACGIH American Council for Governmental Industrial Hygienists
API Active Pharmaceutical Ingredient
BDL Below Detectable Limit
BOD Biological Oxygen Demand
CETP Common Effluent Treatment Plant
CGWA Central Ground Water Authority
CHWTSDF Common Hazardous Waste Treatment Storage and Disposal Facility
CMD Cubic Meter Per Day
COD Chemical Oxygen Demand
CPCB Central Pollution Control Board
CREP Corporate Responsibility for Environment Protection
DISH Directorate of Industrial Safety and Hygiene
EC Environment Clearance
EIA Environment Impact Assessment
EMP Environment Management Plan
ERPG Emergency Response Planning Guidelines
ISO International Organization for Standardization
GLC Ground Level Concentration
HW Hazardous Waste
LULC Land Use Land Cover
MIDC Maharashtra Industrial Development Corporation
MOEF Ministry of Environment and Forest
MOEFCC Ministry of Environment and Forest & Climate Change
MPCB Maharashtra Pollution Control Board
MSDS Material Safety Data Sheet
NAAQS National Ambient Air Quality Standard
NOC No Objection Certificate
OHSAS Occupational Hazard and Safety
O&M Operation and Maintenance
Abbreviation Full form
PM Particulate Matter
PM10 Particulate Matter < 10 µg/cum
PM2.5 Particulate Matter < 2.5 µg/cum
PPE Personal Protective Equipment
RWH Rain Water Harvesting
SOCMI Synthetic Organic Chemicals Manufacturing Industry
STEL Short Term Exposure Limit
SEAC State Expert Appraisal Committee (SEAC-I) for Maharashtra
SEIAA State Environmental Impact Assessment Authority
TPA Ton Per Annum
TLV Threshold Limiting Value
TOR Term of Reference
TPD Ton Per Day
TPH Ton Per Hour
TPM Ton Per Month
TWA Time Weighted Average
Table of Content
1 INTRODUCTION .................................................................................................................................................................1
1.1 PURPOSE OF ENVIRONMENTAL IMPACT ASSESSMENT (EIA) REPORT ........................................................................................ 1
1.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT.................................................................................................................... 1
1.3 BRIEF DESCRIPTION OF NATURE, SIZE, LOCATION OF THE PROJECT & ITS IMPORTANCE IN THE COUNTRY, REGION ........ 4
1.3.1 Nature& Size of Project ......................................................................................................................................................... 4
1.3.2 Location of the Project ........................................................................................................................................................... 5
1.3.3 Importance of the Project to the Country, Region ...................................................................................................... 6
1.4 REGULATORY FRAMEWORK OF THE PROPOSED EXPANSION........................................................................................................... 6
1.4.1 General clearances and other related permissions..................................................................................................... 6
1.4.2 Applicability of EIA Notification 2006 ............................................................................................................................. 7
1.4.3 Background to EIA Study Report: ...................................................................................................................................... 8
1.4.4 Process of EIA study ................................................................................................................................................................ 8
1.4.5 Methodology adopted for EIA study ................................................................................................................................. 9
1.4.6 Structure of EIA Report ....................................................................................................................................................... 12
1.4.7 Compliance to TOR ................................................................................................................................................................ 13
2 PROJECT DESCRIPTION ............................................................................................................................................... 23
2.1 TYPE OF PROJECT ................................................................................................................................................................................23
2.2 NEED OF THE PROJECT .......................................................................................................................................................................23
2.3 LOCATION OF THE PROJECT ...............................................................................................................................................................23
2.4 SIZE/ MAGNITUDE OF OPERATION ..................................................................................................................................................25
2.5 PROPOSED SCHEDULE FOR APPROVAL & IMPLEMENTATION ......................................................................................................27
2.6 TECHNOLOGY & PROCESS DESCRIPTION, ENVIRONMENTAL & SAFETY ASPECTS ...................................................................29
2.6.1 Category I (Hypnotic/Sedative/Tranquilizer/Anxiolytic/Antuconvulsant
/Anasthetic/Antidiabetic) ................................................................................................................................................................ 30
2.6.1.1 Reaction Chemistry – Group I Nitrazepam .................................................................................................................................. 30
2.6.1.2 Process Block diagram - Group I (Nitrazepam) ........................................................................................................................ 31
2.6.1.3 Process Description – Group I (Nitrazipam) .............................................................................................................................. 31
2.6.1.4 Material balance – Group I (Nitrazipam) ..................................................................................................................................... 32
2.6.1.5 Reaction Chemistry – Group II (Lorazepam) ............................................................................................................................. 32
2.6.1.6 Process Block diagram - Group II (Lorazepam)...................................................................................................................... 33
2.6.1.7 Process Description – Group II (Lorazepam) ............................................................................................................................. 34
2.6.1.8 Material balance – Group II (Lorazepam) .................................................................................................................................... 35
2.6.1.9 Reaction Chemistry – Group III (Zopiclone) ............................................................................................................................... 35
2.6.1.10 Process Block diagram - Group III (Zopiclone) ......................................................................................................................... 36
2.6.1.11 Process Description – Group III (Zopiclone) .............................................................................................................................. 36
2.6.1.12 Material balance – Group III (Zopiclone) ..................................................................................................................................... 37
2.6.1.13 Reaction Chemistry – Group IV (Zapeplon) ................................................................................................................................ 37
2.6.1.14 Process Block diagram - Group IV (Zaleplon) ............................................................................................................................ 37
2.6.1.15 Process Description – Group IV (Zaleplon) ................................................................................................................................. 38
2.6.1.16 Material balance – Group IV (Zaleplon) ........................................................................................................................................ 39
2.6.1.17 Reaction Chemistry – GroupV (Midazolam HCl) ...................................................................................................................... 39
2.6.1.18 Process Block diagram - Group V (Midazolam HCl) ................................................................................................................ 39
2.6.1.19 Process Description – Group V (Midazolam HCl) ..................................................................................................................... 40
2.6.1.20 Material balance – Group V (Midazolam HCl) ........................................................................................................................... 40
2.6.2 Category II (Antidepresant / CNS Stimulant) ............................................................................................................. 41
2.6.2.1 Reaction Chemistry – TRANYLCYPROMINE SULPHATE ...................................................................................................... 41
2.6.2.2 Process Block diagram - TRANYLCYPROMINE SULPHATE................................................................................................. 42
2.6.2.3 Process Description – TRANYLCYPROMINE SULPHATE...................................................................................................... 42
2.6.2.4 Material balance – TRANYLCYPROMINE SULPHATE ............................................................................................................. 43
2.6.3 Category III (ANTIGLUCOMA/ANTIHISTAMINIC) .................................................................................................... 43
2.6.3.1 Reaction Chemistry – Chloropyramine HCl ................................................................................................................................ 43
2.6.3.2 Process Block diagram – Chloropyramine HCl .......................................................................................................................... 44
2.6.3.3 Process Description – Chloropyramine HCl ................................................................................................................................ 45
2.6.3.4 Material balance – Chloropyramine HCl ....................................................................................................................................... 46
2.6.4 Category IV (ANTIPROTAZOAL) ...................................................................................................................................... 46
2.6.4.1 Reaction Chemistry – Nimorazole ................................................................................................................................................... 46
2.6.4.2 Process Block diagram – Nimorazole............................................................................................................................................. 47
2.6.4.3 Process Description – Nimorazole................................................................................................................................................... 48
 2.6.4.4 Material balance – Nimorazole ........................................................................................................................................................ 48
2.6.5 Category V (ANTIPSYCHOTIC/ANTIPYRETIC/ANTI-INFLAMATORY/ ANALGESIC/ANTI-ULCER) ..... 49
2.6.5.1 Reaction Chemistry – Acotiamide HCl Hydrate......................................................................................................................... 49
2.6.5.2 Process Block diagram – Acotiamide HCl Hydrate .................................................................................................................. 49
2.6.5.3 Process Description – Acotiamide HCl Hydrate ........................................................................................................................ 50
2.6.5.4 Material balance – Acotiamide HCl Hydrate .............................................................................................................................. 51
2.6.6 Category VI(ANTIEMETIC) ................................................................................................................................................ 51
2.6.6.1 Reaction Chemistry – Nabilone ......................................................................................................................................................... 51
2.6.6.2 Process Block diagram – Nabilone .................................................................................................................................................. 52
2.6.6.3 Process Description – Nabilone ........................................................................................................................................................ 52
2.6.6.4 Material balance – Nabilone ............................................................................................................................................................... 53
2.6.7 Category VII (ANTISPASMODIC/MUSCLE RELAXANT) .......................................................................................... 53
2.6.7.1 Reaction Chemistry – Pitofenone HCl ............................................................................................................................................ 53
2.6.7.2 Process Block diagram – Pitofenone HCl...................................................................................................................................... 54
2.6.7.3 Process Description – Pitofenone HCl ........................................................................................................................................... 54
2.6.7.4 Material balance – Pitofenone HCl ................................................................................................................................................. 55
2.6.8 Category VIII (ANTIDYSKINETIC/DIURETIC/SNR INHIBITOR/CHOLINERGIC/URINARY
INCONTINENCE .................................................................................................................................................................................... 55
2.6.8.1 Reaction Chemistry – Levomilnacipran HCl ............................................................................................................................... 55
2.6.8.2 Process Block diagram – Levomilnacipran HCl......................................................................................................................... 56
2.6.8.3 Process Description – Levomilnacipran HCl............................................................................................................................... 57
2.6.8.4 Material balance – Levomilnacipran HCl...................................................................................................................................... 58
2.6.9 Category IX (HYPERTENSION/ANTIHYPERTENSION (Pindolol) ....................................................................... 58
2.6.9.1 Reaction Chemistry – Pindolol .......................................................................................................................................................... 58
58
2.6.9.2 Process Block diagram – Pindolol.................................................................................................................................................... 59
2.6.9.3 Process Description – Pindolol.......................................................................................................................................................... 59
2.6.9.4 Material balance – Pindolol................................................................................................................................................................. 60
2.6.10 Category X (PLATELET INHIBITOR) .............................................................................................................................. 61
2.6.10.1 Reaction Chemistry – Prasugrel ....................................................................................................................................................... 61
2.6.10.2 Process Block diagram – Prasugrel ................................................................................................................................................. 62
2.6.10.3 Process Description – Prasugrel ....................................................................................................................................................... 62
2.6.10.4 Material balance – Prasugrel .............................................................................................................................................................. 63
2.6.11 Category R & D Activity and other .................................................................................................................................. 63
2.6.11.1 Reaction Chemistry – Silodosin ........................................................................................................................................................ 63
2.6.11.2 Process Block diagram – Silodosin .................................................................................................................................................. 64
2.6.11.3 Process Description – Silodosin ........................................................................................................................................................ 64
2.6.11.4 Material balance – Silodosin ............................................................................................................................................................... 65
2.6.12 Raw Material Consumption & Sourcing ........................................................................................................................ 65
2.6.13 Air emission, sources, quantities, concentration and control mechanism....................................................... 70
2.6.13.1 Fugitive emissions ................................................................................................................................................................................... 70
2.6.14 Details of Hazardous chemicals ....................................................................................................................................... 72
2.7 BULK STORAGE ....................................................................................................................................................................................74
2.8 FUEL REQUIREMENT ...........................................................................................................................................................................75
2.9 ENERGY REQUIREMENTS ...................................................................................................................................................................76
2.9.1 Electricity .................................................................................................................................................................................. 76
2.10 WATER BALANCE ................................................................................................................................................................................76
2.10.1 Existing water requirement and waste water generation .................................................................................... 76
2.10.2 Proposed water requirement and waste water generation .................................................................................. 77
2.10.3 Measures for VOC Control in Proposed expansion .................................................................................................... 79
2.10.4 Measures for Process Emissions Control in Proposed Facility ............................................................................. 79
2.10.5 Measures for Odor Control in Proposed Facility ........................................................................................................ 79
2.11 NON HAZARDOUS WASTE TREATMENT AND DISPOSAL ................................................................................................................80
2.12 HAZARDOUS WASTE TREATMENT AND DISPOSAL ........................................................................................................................80
2.13 SOLID AND HAZARDOUS WASTE MANAGEMENT ...........................................................................................................................81
2.14 ENVIRONMENTAL MONITORING & MANAGEMENT .......................................................................................................................81
2.14.1 Management System ............................................................................................................................................................. 82
2.15 RISK OF TECHNOLOGICAL FAILURE..................................................................................................................................................82
3 DESCRIPTION OF ENVIRONMENT ............................................................................................................................ 83
3.1 GENERAL SETTING OF SITE AND STUDY AREA............................................................................................................................83
3.1.1 Description of Study Area ................................................................................................................................................... 83
 3.1.2 Thane district climate .......................................................................................................................................................... 85
3.1.3 Salient Features of Site and Surroundings ................................................................................................................... 85
3.1.4 Defination of LULC Classes ................................................................................................................................................. 86
3.1.5 GIS Maps .................................................................................................................................................................................... 88
3.1.5.1 Contour Maps............................................................................................................................................................................................. 89
3.1.5.2 Digital Elevation Model (DEM) .......................................................................................................................................................... 89
3.1.5.3 Drainage maps........................................................................................................................................................................................... 89
3.1.5.4 Watershed Map ......................................................................................................................................................................................... 89
3.1.5.5 False Colour Composite Image .......................................................................................................................................................... 93
3.1.5.6 LULC Maps................................................................................................................................................................................................... 93
3.1.6 Statistics of LULC Classes .................................................................................................................................................... 95
3.2 SOIL QUALITY MONITORING .............................................................................................................................................................96
3.2.1 Methodology of Soil Monitoring ....................................................................................................................................... 97
3.2.2 Soil Characteristics in the study area............................................................................................................................. 97
3.2.3 Soil Monitoring Locations................................................................................................................................................... 97
3.3 SOLID/HAZARDOUS WASTE GENERATION, TREATMENT AND DISPOSAL .............................................................................. 100
3.4 CLIMATE AND METEOROLOGY ....................................................................................................................................................... 100
3.4.1 Wind ......................................................................................................................................................................................... 100
3.4.2 Temperature & Humidity ................................................................................................................................................. 101
3.5 AIR ENVIRONMENT .......................................................................................................................................................................... 102
3.5.1 Reconnaissance Survey ..................................................................................................................................................... 102
3.5.2 Onsite Air Environment .................................................................................................................................................... 103
3.5.3 Methodology for Selection of Monitoring Locations ............................................................................................. 105
3.5.4 Baseline Ambient Air Monitoring Studies ................................................................................................................. 105
3.6 NOISE ENVIRONMENT ..................................................................................................................................................................... 108
3.6.1 Noise Level Monitoring ..................................................................................................................................................... 108
3.7 WATER ENVIRONMENT ................................................................................................................................................................... 109
3.7.1 Onsite Water Environment.............................................................................................................................................. 109
3.7.1.1 Waste Water Generation, Treatment and Disposal .............................................................................................................. 109
3.7.1.2 Existing Trade Effluent Treatment scheme ............................................................................................................................. 110
3.7.2 Reconnaissance survey ..................................................................................................................................................... 111
3.7.3 Baseline water quality ...................................................................................................................................................... 111
3.7.3.1 Ground Water ......................................................................................................................................................................................... 111
3.7.3.2 Surface Water ......................................................................................................................................................................................... 115
3.8 BIOLOGICAL ENVIRONMENT ........................................................................................................................................................... 119
3.8.1 Bio geographical setting of Thane district ............................................................................................................... 119
3.8.2 Study Area .............................................................................................................................................................................. 120
3.8.3 Site Specific ............................................................................................................................................................................ 129
3.9 SOCIO ECONOMIC ENVIRONMENT ................................................................................................................................................. 131
3.9.1 Reconnaissance .................................................................................................................................................................... 131
3.9.2 Methodology ......................................................................................................................................................................... 132
3.9.3 Demographic Structure of the Study Area ................................................................................................................ 134
3.9.4 Infrastructural Facilities or Civic Amenities ............................................................................................................ 136
3.9.5 Occupational Pattern/ Economic Resource Base ................................................................................................... 138
3.9.6 CSR activities carried out by Centaur during 2016-17 ........................................................................................ 144
4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES ................................................. 145
4.1 INTRODUCTION ................................................................................................................................................................................. 145
4.2 IDENTIFICATION OF IMPACTS ......................................................................................................................................................... 145
4.3 PREDICTION OF IMPACTS DURING CONSTRUCTION PHASE AND MITIGATION MEASURES .................................................. 146
4.3.1 Land Environment .............................................................................................................................................................. 146
4.3.1.1 Anticipated Impacts ............................................................................................................................................................................. 146
4.3.1.2 Mitigation Measures ............................................................................................................................................................................ 147
4.3.1.3 Mitigation Measures ............................................................................................................................................................................ 148
4.3.2 Water Environment ........................................................................................................................................................... 148
4.3.2.1 Anticipated Impacts ............................................................................................................................................................................. 148
4.3.2.2 Mitigation Measures ............................................................................................................................................................................ 148
4.3.3 Air Environment .................................................................................................................................................................. 148
4.3.3.1 Anticipated Impacts ............................................................................................................................................................................. 148
4.3.3.2 Mitigation Measures ............................................................................................................................................................................ 148
 4.3.4 Ecological & Biological Environment ......................................................................................................................... 148
4.3.4.1 Anticipated Impacts ............................................................................................................................................................................. 148
4.3.4.2 Mitigation Measures ............................................................................................................................................................................ 149
4.3.5 Noise & Vibration Environment .................................................................................................................................... 149
4.3.5.1 Anticipated Impacts ............................................................................................................................................................................. 149
4.3.5.2 Mitigation Measures ............................................................................................................................................................................ 149
4.3.6 Occupational Health and Safety.................................................................................................................................... 149
4.3.6.1 Anticipated Impacts ............................................................................................................................................................................. 149
4.3.6.2 Mitigation Measures ............................................................................................................................................................................ 149
4.3.7 Socio-economic Environment ......................................................................................................................................... 149
4.3.7.1 Anticipated Impacts ............................................................................................................................................................................. 149
4.3.7.2 Mitigation Measures ............................................................................................................................................................................ 150
4.4 PREDICTION OF IMPACTS DURING COMMISSIONING PHASE AND MITIGATION MEASURES ................................................. 150
4.4.1 Anticipated Impacts ........................................................................................................................................................... 150
4.4.2 Mitigation Measures .......................................................................................................................................................... 150
4.5 PREDICTION OF IMPACTS DURING OPERATION PHASE AND MITIGATION MEASURES ......................................................... 151
4.5.1 Land Environment .............................................................................................................................................................. 151
4.5.1.1 Anticipated Impacts ............................................................................................................................................................................. 151
4.5.1.2 Mitigation Measures ............................................................................................................................................................................ 151
4.5.2 Water Environment ........................................................................................................................................................... 152
4.5.2.1 Anticipated Impacts: Additional Water use& Wastewater Generation ...................................................................... 152
4.5.2.2 Mitigation Measures Water Environment ................................................................................................................................ 153
4.5.3 Air Environment .................................................................................................................................................................. 154
4.5.3.1 Quantitative Assessment of Impacts due Fuel Burning ..................................................................................................... 155
4.5.3.2 Modeling Studies to Predict Magnitude of Impact on Air Quality from proposed activity ............................... 156
4.5.3.3 Modelling Impacts on SO2 ................................................................................................................................................................ 159
4.5.3.4 Modeling Impacts on NOx ................................................................................................................................................................. 160
4.5.3.5 Observations from dispersion modeling studies .................................................................................................................. 161
4.5.3.6 Other Air Pollution Impacts ............................................................................................................................................................. 161
4.5.3.7 Mitigation Measures ............................................................................................................................................................................ 161
4.5.3.8 Proposed Process and DG stacks ................................................................................................................................................... 162
4.5.4 Solvent Recovery ................................................................................................................................................................. 162
4.5.4.1 Solvent Management Plan ................................................................................................................................................................ 164
4.5.5 Flow Chemistry for new Products ................................................................................................................................. 166
4.5.6 Ecological & Biological Environment ......................................................................................................................... 167
4.5.6.1 Anticipated Impacts ............................................................................................................................................................................. 167
4.5.6.2 Mitigation Measures ............................................................................................................................................................................ 168
4.5.7 Noise & Vibration Environment .................................................................................................................................... 170
4.5.7.1 Anticipated Impacts ............................................................................................................................................................................. 170
4.5.7.2 Mitigation Measures ............................................................................................................................................................................ 170
4.5.8 Solid and Hazardous Waste ............................................................................................................................................ 171
4.5.8.1 Anticipated Impacts ............................................................................................................................................................................. 171
4.5.8.2 Mitigation Measures ............................................................................................................................................................................ 173
4.5.9 Occupational Health and Safety.................................................................................................................................... 173
4.5.9.1 Anticipated Impacts ............................................................................................................................................................................. 173
4.5.9.2 Mitigation Measures ............................................................................................................................................................................ 173
4.5.10 Socio-economic Environment ......................................................................................................................................... 174
4.5.10.1 Anticipated Impacts............................................................................................................................................................................. 174
4.5.10.2 Mitigation Measures ............................................................................................................................................................................ 176
4.5.10.3 Corporate Environmental Responsibility & Socio-Economic Welfare........................................................................ 177
4.6 PREDICTION OF IMPACTS DURING DE COMMISSIONING PHASE AND MITIGATION MEASURES........................................... 179
4.6.1 Anticipated Impacts ........................................................................................................................................................... 179
4.6.2 Mitigation Measures .......................................................................................................................................................... 179
4.7 ENVIRONMENTAL IMPACT MATRIX ............................................................................................................................................... 179
4.8 OBSERVATIONS AND CONCLUSIONS .............................................................................................................................................. 185
5 ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE) .................................................................................. 186
5.1 INTRODUCTION ................................................................................................................................................................................. 186
5.1.1 Analysis of Alternative Sites ............................................................................................................................................ 186
5.1.2 Analysis of Alternative Technologies........................................................................................................................... 186
6 ENVIRONMENTAL MONITORING PLAN ............................................................................................................... 187
 6.1 OBJECTIVE OF ENVIRONMENTAL MONITORING PROGRAM ....................................................................................................... 187
6.2 ENVIRONMENTAL MONITORING PROGRAM ................................................................................................................................. 187
6.2.1 Measurement Methodologies ......................................................................................................................................... 192
6.2.2 Reporting Schedules........................................................................................................................................................... 192
6.3 BUDGETARY PROVISIONS FOR EMP ............................................................................................................................................. 193
7 ADDITIONAL STUDIES (PUBLIC HEARING & RISK ASSESSMENT) ............................................................. 195
7.1 OBJECTIVES OF RISK ASSESSMENT ................................................................................................................................................ 195
7.2 HAZARD IDENTIFICATION AND RISK ASSESSMENT .................................................................................................................... 195
7.3 IDENTIFICATION OF HAZARDOUS AREAS ...................................................................................................................................... 197
7.4 QUALITATIVE RISK ASSESSMENT .................................................................................................................................................. 198
7.4.1 Hazardous chemical handling and storage protocol ............................................................................................ 207
7.5 HAZOP STUDY ................................................................................................................................................................................. 209
7.6 DOW FIRE AND EXPLOSION INDEX ................................................................................................................................................ 214
7.7 QUANTITATIVE RISK ASSESSMENT................................................................................................................................................. 221
7.7.1 Consequence Analysis based on ALOHA ..................................................................................................................... 221
7.7.2 Comments / Recommendations based on Consequence analysis ..................................................................... 225
7.7.2.1 Recommendations ................................................................................................................................................................................ 225
7.8 RECOMMENDATIONS BASED ON RISK ANALYSIS AND GOOD MANUFACTURING PRACTICES ................................................. 227
7.8.1 Control Measures Suggested for Methanol, Toluene, Ethyl acetate and Iso propyl tanks ..................... 227
7.9 DISASTER PREPAREDNESS AND EMERGENCY MANAGEMENT PLAN ....................................................................................... 228
7.9.1 Mutual Aid ............................................................................................................................................................................. 229
7.9.2 Disaster Management Plan ............................................................................................................................................. 229
7.9.3 Earthquake ............................................................................................................................................................................ 230
7.9.4 Hazard Control Measures ................................................................................................................................................ 231
7.9.4.1 Fire ............................................................................................................................................................................................................... 231
7.9.5 Natural Disasters ................................................................................................................................................................ 232
7.9.6 Electrical accidents ............................................................................................................................................................ 232
7.9.6.1 Prevention of Electrical accidents ................................................................................................................................................ 232
7.9.6.2 First aid and emergency procedures ........................................................................................................................................... 234
7.10 PUBLIC HEARING .............................................................................................................................................................................. 235
7.11 SOCIAL IMPACT ASSESSMENT, R & R (RELOCATION AND REHABILITATION) ACTION PLAN ............................................... 235
8 PROJECT BENEFITS .................................................................................................................................................... 236
8.1 IMPROVEMENT IN INFRASTRUCTURES .......................................................................................................................................... 236
8.2 EMPLOYMENT POTENTIAL.............................................................................................................................................................. 236
8.3 OTHER TANGIBLE & INTANGIBLE BENEFITS............................................................................................................................... 236
9 ENVIRONMENTAL COST BENEFIT ANALYSIS .................................................................................................... 237
10 ENVIRONMENTAL MANAGEMENT PLAN ............................................................................................................ 238
10.1 INTRODUCTION ................................................................................................................................................................................. 238
10.1.1 Objective & Scope of EMP................................................................................................................................................. 238
10.2 ENVIRONMENTAL MANAGEMENT SYSTEMS ................................................................................................................................. 239
10.3 ENVIRONMENT, HEALTH AND SAFETY (EHS) CELL .................................................................................................................. 240
10.4 EMP FOR WATER ENVIRONMENT MANAGEMENT ....................................................................................................................... 241
10.4.1 Water consumption ............................................................................................................................................................ 241
10.4.2 Water conservation measures ....................................................................................................................................... 241
10.4.3 Waste water generation, treatment and disposal ................................................................................................. 242
10.5 EMP FOR IMPACT ON NOISE LEVELS ............................................................................................................................................. 243
10.6 EMP FOR IMPACT ON LAND ENVIRONMENT .............................................................................................................................. 243
10.6.1 Hazardous/Non Hazardous Waste Management .................................................................................................. 243
10.6.2 EMP for impacts on Social Environment ................................................................................................................... 243
10.7 EMP FOR SOCIO ECONOMIC ENVIRONMENT ................................................................................................................................ 244
10.8 EMP FOR IMPACTS ON ECOLOGICAL ENVIRONMENT .................................................................................................................. 244
10.9 ENVIRONMENT MANAGEMENT THROUGH HOUSEKEEPING ........................................................................................................ 245
10.10 OCCUPATIONAL SAFETY AND HAZARD MANAGEMENT ...................................................................................................... 245
10.10.1 Occupational Health center (OHC) .................................................................................................................... 246
10.10.2 Onsite Medical treatment ...................................................................................................................................... 246
 10.10.3 Medical examination practice ............................................................................................................................. 246
10.10.4 Fund allocation for Occupational Health and Safety measures ............................................................. 247
10.11 ENVIRONMENT BUDGET ALLOCATION ................................................................................................................................ 249
10.12 ENERGY CONSERVATION MEASURES .................................................................................................................................... 249
10.12.1 Financial Provisions for EMP Implementation ............................................................................................. 249
Costs for pollution control, monitoring and management will be included in the account under separate
head in CAPEX as well as OPEX provisions. ............................................................................................................................. 249
10.12.2 Authorities Responsible for EMP Implementation ....................................................................................... 249
10.12.3 EMP Implementation Schedule............................................................................................................................ 250
10.13 REPORTING............................................................................................................................................................................... 250
11 SUMMARY AND CONCLUSION ................................................................................................................................. 251
11.1 INTRODUCTION ................................................................................................................................................................................. 251
11.2 COMPANY AND PROJECT PROPONENT ........................................................................................................................................... 251
11.3 PROJECT DESCRIPTION .................................................................................................................................................................... 251
11.3.1 Energy requirement and its management ................................................................................................................ 253
11.3.2 Electricity requirement..................................................................................................................................................... 254
11.1 DESCRIPTION OF THE ENVIRONMENT ........................................................................................................................................ 256
11.1.1 Study period and area ....................................................................................................................................................... 256
11.1.2 Land use and Land cover ................................................................................................................................................. 257
11.1.3 Meteorology .......................................................................................................................................................................... 257
11.1.4 Soil ............................................................................................................................................................................................ 257
11.1.5 Ambient Air Quality............................................................................................................................................................ 257
11.1.6 Noise ......................................................................................................................................................................................... 258
11.1.7 Ground Water Quality ....................................................................................................................................................... 258
11.1.8 Surface Water Quality ....................................................................................................................................................... 258
11.1.9 Biological Environment .................................................................................................................................................... 258
11.1.10 Socio economic environment ................................................................................................................................ 259
11.2 ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES .......................................................................... 260
11.2.1 Air environment ................................................................................................................................................................... 260
11.2.2 Noise ......................................................................................................................................................................................... 260
11.2.3 Water & wastewater .......................................................................................................................................................... 261
11.2.4 Land.......................................................................................................................................................................................... 261
11.2.5 Biological environment .................................................................................................................................................... 262
11.2.6 Socio economic environment .......................................................................................................................................... 263
11.2.7 Environmental monitoring program .......................................................................................................................... 264
11.3 ADDITIONAL STUDIES .................................................................................................................................................................... 268
11.3.1 Risk Assessment, Hazard identification and consequence analysis ................................................................ 268
11.4 PROJECT BENEFITS ......................................................................................................................................................................... 268
11.5 CONCLUSION ..................................................................................................................................................................................... 269
12 DISCLOSURE OF CONSULTANTS ENGAGED ........................................................................................................ 270
List of Tables
Table 1.1 Product / by product quantities ................................................................................................................................... 4
Table 1.2Statutory Clearances / Permissions required ......................................................................................................... 6
Table 1.3Compliance to Model ToR Prescribed by EAC (Model ToR for (activity 5(f))........................................ 13
Table 1.4Point wise Compliance to Additional TOR granted in 142ndSLEAC-I Meeting ....................................... 21
Table 2.1 Major IndustrieswithinChikhloli MIDC .................................................................................................................. 23
Table 2.2Existing and Proposed Products and Quantities ................................................................................................. 25
Table 2.3 Land Break-Up of site ..................................................................................................................................................... 27
Table 2.4 Raw Material consumption and sourcing ............................................................................................................. 66
Table 2.5 Fugitive dust, chemical vapor sources ................................................................................................................... 70
Table 2.6 Fugitive emission control measures ........................................................................................................................ 71
Table 2.7 Details of Major Hazardous Chemicals handled / to be handled at site ................................................. 72
Table 2.8 Details of Existing and proposed bulk storage ................................................................................................... 74
Table 2.9 Fuel requirement and Air pollution control system ......................................................................................... 75
Table 2.10 Fuel for DG sets .............................................................................................................................................................. 76
Table 2.11 Existing water requirement ..................................................................................................................................... 77
Table 2.12 Existing waste water generation ............................................................................................................................ 77
Table 2.13 Overall Water requirement for expansion ......................................................................................................... 77
Table 2.14 Total Water requirement (existing + proposed) ............................................................................................. 77
Table 2.15 Overall Waste water generation after expansion (Existing + Proposed) ............................................. 78
Table 2.16 Summary of overall water consumption, loss, effluent in CMD ................................................................ 79
Table 2.17 Nonhazardous waste generation and disposal ................................................................................................ 80
Table 2.18 Hazardous waste generation and disposal ........................................................................................................ 80
Table 3.1 Environmental sensitivity receptor ......................................................................................................................... 86
Table 3.2 Definition of LULC Classes ........................................................................................................................................... 86
Table 3.3Open series map showing study area around project site .............................................................................. 88
Table 3.4 Landuse/ Landcover Statistics of the 10 km radius Area .............................................................................. 95
Table 3.5 LULC Statistics of the 500m angular distance around project site ............................................................ 96
Table 3.6 Soil Analysis report ......................................................................................................................................................... 98
Table 3.7 Standard Soil Classification ......................................................................................................................................... 99
Table 3.8 Hazardous waste generation and disposal ......................................................................................................... 100
Table 3.9 Summarized Met Data Collected at Site ............................................................................................................... 101
Table 3.10 Air Pollution Control devices and stack details ............................................................................................. 103
Table 3.11 DG set stacks .................................................................................................................................................................. 103
Table 3.12 Source emission monitoring (Scrubber - old building)............................................................................. 103
Table 3.13 Boiler stack (600 kg/hr capacity) ........................................................................................................................ 103
Table 3.14 Work zone air quality monitoring results ........................................................................................................ 104
Table 3.15 Work zone air quality monitoring results ........................................................................................................ 104
Table 3.16 Ambient air quality monitoring results ............................................................................................................. 105
Table 3.17 Details of Ambient Air Monitoring Stations .................................................................................................... 106
Table 3.18 AAQM Results- winter 2017-18 ............................................................................................................................ 107
Table 3.19 National Ambient Air Quality Standards (CPCB, 2009) ............................................................................. 108
Table 3.20 Noise Monitoring Results (Winter 2017-18) .................................................................................................. 109
Table 3.21 Onsite noise monitoring results ........................................................................................................................... 109
Table 3.22 Domestic sewage analysis results....................................................................................................................... 111
Table 3.23ETP Plant outlet analysis .......................................................................................................................................... 111
Table 3.24Ground water analysis results ................................................................................................................................ 113
Table 3.25 Surface water sampling locations ........................................................................................................................ 115
Table 3.26Surface water analysis results ................................................................................................................................ 116
Table 3.27 Tolerance limits for Inland surface water ........................................................................................................ 118
Table 3.28 Area distribution of Forest cover ......................................................................................................................... 120
Table 3.29List of Flora observed within site.......................................................................................................................... 131
Table 3.30List of Sampling locations for SE Primary Survey ......................................................................................... 132
Table 3.31Administratively Coverage of Study Area Villages & Urban Areas ........................................................ 134
Table 3.32 Summarized Information on Demographic Structure of the Study Area ........................................... 134
Table 3.33Occupational Structure of the Study Area ......................................................................................................... 138
Table 3.34Economic Category wise Distribution of Workers ........................................................................................ 139
Table 3.35Details of M.I.D.C. Industrial Area – Thane & Palghar district (as on 31.03.2012) ......................... 139
Table 3.36Year-wise Trend of Units Registered at Thane and Palghar District ..................................................... 140
Table 3.37Local People Need & Expectation for Enhancement of their Quality of Life ...................................... 142
Table 3.38Vital Health Statistics of Thane District .............................................................................................................. 143
Table 4.1 Environmental Aspects and Impacts of the expansion Project ................................................................. 145
Table 4.2Expected waste water analysis ................................................................................................................................. 152
Table 4.3 Fuel Requirement (Proposed).................................................................................................................................. 154
Table 4.4 Air Pollution Sources: Proposed Operation ....................................................................................................... 155
Table 4.5 Top 10 incremental concentrations ...................................................................................................................... 158
Table 4.7 Prediction of GLC of SO2 (Stack cordinates 0,0) .............................................................................................. 159
Table 4.8 Prediction of GLC of NOx (Stack cordinates 0,0).............................................................................................. 160
Table 4.9 Proposed Process Stack and DG stack Details ................................................................................................... 162
Table 4.10 Solvent recovery .......................................................................................................................................................... 162
Table 4.11 Suggested Species for Green Belt – Outer pheriphery ................................................................................ 169
Table 4.12 Suggested Species for Green Belt – Inner pheriphery ................................................................................ 170
Table 4.13 Nonhazardous Waste Generation & Disposal ................................................................................................ 171
Table 4.14 Hazardous Waste Generation & Disposal ......................................................................................................... 172
Table 4.15 Yearwise Budget Allocation for Implementation of CER Activities) .................................................... 178
Table 4.16 Environmental Impact Matrix Evaluation without Mitigation Measures .......................................... 182
Table 4.17 Environmental Impact Matrix Evaluation with Mitigation Measures ................................................. 183
Table 6.1 Environment Monitoring Plan including Existing and Proposed Expansion ...................................... 188
Table 6.2 Reporting Schedule ....................................................................................................................................................... 192
Table 6.3 Budgetary Provisions for EMP ................................................................................................................................. 194
Table 7.1 Existing Onsite (OSBL) Storages ............................................................................................................................. 196
Table 7.2 Proposed Onsite (OSBL) Storages .......................................................................................................................... 197
Table 7.3Risk matrix for qualitative risk assessment ........................................................................................................ 198
Table 7.4Storage and handling of Toxic Chemicals(e.g. NaOH lye, HCl, Sulphuric acid etc) ............................. 199
Table 7.5Storage and handling of Flammable solvents / chemicals ........................................................................... 200
Table 7.6Storage and handling of solid Chemicals .............................................................................................................. 203
Table 7.7 Details of Major Hazardous Chemicals handled / to be handled at site ................................................ 204
Table 7.8 Compatibility chart ....................................................................................................................................................... 209
Table 7.9HAZOP Analysis ............................................................................................................................................................... 211
Table 7.10 Summerised HAZOP recommendations of ZOPICLONE process ........................................................... 211
Table 7.11 Hazard Identification & Risk Assessment at Different Project Stages ................................................. 212
Table 7.12 Hazard Category for Storage Tanks as per FETI study ............................................................................... 220
Table 7.13 Planned & Suggested Measure Based On Fire and Explosion Index..................................................... 220
Table 7.14 Consequence Analysis studies carried out ....................................................................................................... 221
Table 7.15 Failure Frequency Data ............................................................................................................................................ 222
Table 7.16 Findings of Consequence analysis studies ....................................................................................................... 223
Table 7.17First aid for burns ........................................................................................................................................................ 234
Table 10.1Proposed Medical Examination Plan ................................................................................................................... 246
Table 11.1 Total Products and its capacity ............................................................................................................................. 251
Table 11.2 Fuel burning sources details (Existing & Proposed) ................................................................................... 253
Table 11.3 Fuel for DG sets ............................................................................................................................................................ 254
Table 11.4 Total Water requirement (Existing & Proposed) .......................................................................................... 254
Table 11.5 Waste water generation and disposal (existing & Proposed) ................................................................. 255
Table 11.6 Non-hazardous waste generation and disposal pathway ......................................................................... 255
Table 11.7 Hazardous waste generation and disposal pathway ................................................................................... 255
List of Figures
Figure 1.1 Flow chart of EIA study .................................................................................................................................................. 9
Figure 2.1 Google Earth Image Showing 10 Km Surrounding .......................................................................................... 24
Figure 2.2 Google Earth Image Showing 1 Km Surroundings .......................................................................................... 24
Figure 2.3 Map of Chikhloli MIDC Indicating Location of Centaur ................................................................................. 25
Figure 2.4Plant Layout ....................................................................................................................................................................... 28
Figure 2.5 Overall water balance diagram after expansion .............................................................................................. 78
Figure 3.1 Google image of site with 10 km study area ...................................................................................................... 84
Figure 3.2 Google image of site with 1km study area .......................................................................................................... 84
Figure 3.3 Geographical Location of Project site .................................................................................................................... 86
Figure 3.4: Contour map of 10 km radius area around Project Site .............................................................................. 90
Figure 3.5: Contour map of 500 m angular distance around Project Site ................................................................... 90
Figure 3.6DEM of an area of 10 km angular distance around Project Site ................................................................. 91
Figure 3.7: Drainage map of 10 km radius area around Project Site ............................................................................ 91
Figure 3.8: Drainage map of 500 m angular distance around Project Site ................................................................. 92
Figure 3.9: Watershed Map of 10 km angular distance around Project Site ............................................................. 92
Figure 3.10: Geo-referenced False Colour Composite (FCC) Resourcesat-2 satellite image .............................. 93
Figure 3.11 Landuse/landcover map of 10 km radius area around Project Site ..................................................... 94
Figure 3.12Landuse/landcover map of 500m angular distance around Project Site ............................................ 94
Figure 3.13 Landuse/landcover statistics of 10 km radius area around Project Site............................................ 95
Figure 3.14 LULC statistics of 500 m angular distance around Project Site .............................................................. 96
Figure 3.15 Soil sampling locations in 10 km study area ................................................................................................... 97
Figure 3.16 Wind Rose for winter 2017-18 season ............................................................................................................ 101
Figure 3.17 Locations of AAQM stations .................................................................................................................................. 106
Figure 3.18 Existing water balance ............................................................................................................................................ 110
Figure 3.19 Existing ETP block diagram .................................................................................................................................. 111
Figure 3.20 Ground water monitoring locations .................................................................................................................. 112
Figure 3.21 Surface water sampling locations ...................................................................................................................... 115
Figure 3.22Map of Thane District Showing Study Area (Black Circle) ....................................................................... 119
Figure 3.23View of hilly Area in Reserve Forest .................................................................................................................. 121
Figure 3.24Biological richness in the study area, (Source: bis.iirs.gov.in/maps) ................................................. 122
Figure 3.25Graph showing tree species composition in Dense Vegetation ............................................................. 123
Figure 3.26Graph showing shrub & herb species composition in study area ......................................................... 123
Figure 3.27Graph showing climber & Grass species composition in study area ................................................... 124
Figure 3.28Graph showing overall composition in dense vegetation ........................................................................ 124
Figure 3.29 View of poultry & brick making in near by villages ................................................................................... 124
Figure 3.30Graph showing tree species composition in Human settlement ........................................................... 125
Figure 3.31Graph showing shrub & herb species composition in Human settlement ........................................ 125
Figure 3.32Graph showing overall composition in human settlement ...................................................................... 126
Figure 3.33 View of vegetable cultivation near project site ............................................................................................ 126
Figure 3.34 Graph showing tree species composition in agriculture ......................................................................... 127
Figure 3.35 Graph showing shrub, herb & climber species composition in agriculture .................................... 127
Figure 3.36 Graph showing overall floral composition in agriculture ....................................................................... 128
Figure 3.37 View of fauna associated with water bodies in study area ..................................................................... 129
Figure 3.38Graph showing overall floral composition in aquatic habitat ................................................................ 129
Figure 3.39View of flora in site premises ................................................................................................................................ 130
Figure 3.40 Existing plantation at site ...................................................................................................................................... 130
Figure 3.41 Ratio of Workers & Non Workers in the Study Area ................................................................................. 138
Figure 3.42Economic Category wise Distribution of Workers in the Study Area ................................................. 139
Figure 4.1 Wind rose for winter 2017-18 ............................................................................................................................... 158
Figure 4.3 Isopleths of SO2 (Stack Coordinates 0,0) ........................................................................................................... 159
Figure 4.4 Isopleths of NOx (Stack Coordinates 0, 0) ......................................................................................................... 160
Figure 4.5 Solvent storage and dispensing scheme ............................................................................................................ 166
Figure 7.1General dangerous good and combustible liquid storage compatibility chart .................................. 208
Figure 7.2 Dow Fire ad explosive index calculation for tanks ........................................................................................ 216
Figure 10.1 IMS certificate ............................................................................................................................................................. 239
Figure 10.2 HSE Policy ..................................................................................................................................................................... 239
Figure 10.3Environment, Health and Safety (EHS) Cell .................................................................................................... 241
Figure 10.4Solar panels installed at site .................................................................................................................................. 249
LIST OF ANNEXURES
Number Contents/Title
1.1 Existing Consent to Operate
1.2 Minutes of 142nd SEAC-I TOR meeting
1.3 Compliance status of Consent to Operate
1.4 Structural stability certificate of existing building
1.5 Plot amalgamation letter fromMIDC
2.1 Plot plan drawing
2.2 Water sanction / assurance letter from MIDC
3.1 Open Series map showing 10 km study area
3.2 Land Use Land cover report
3.3 Hazardous waste disposal membership
3.4 Datewise AAQM data
3.5 CETP membership letter
3.6 Biodiversity tables
3.7 Socio economic data
4.1 Proposed ETP Scheme and details
4.2 CER plan submitted to District collector
7.1 HAZOP study report and its recommendations
7.2 HAZOP study recommendations Confirmation letter from Centaur
7.3 ALOHA study and its results
7.4 Chemicals Handling protocol / Qualitative risk assessment, Onsite Safety
audit report
7.5 Fire detection and protection
7.6 Annual Health status report of workers
7.7 Onsite emergency plan
Environmental Impact Assessment Centaur Pharmaceuticals Private Limited
Chapter 1 – Introduction

1 INT RODUCT IO N

1.1 Purpose of Environmental Impact Assessment (EIA) Report

The purpose of this Environmental Impact Assessment report is to investigate and

assess the principal environmental concerns associated with the expansion of the
Synthetic Organic Chemical Manufacturing unit of Centaur Pharmaceuticals Private
Limited (Centaur) within its plots at Chickloli MIDC, Ambernath (west), District Thane,
Maharashtra.

1.2 Identification of project & project proponent

Centaur Pharmaceutical Private limited (Centaur) (Established in 1978) is India's

leading manufacturer and exporter of Psychotropic APIs with a footprint extending
across more than 95 countries worldwide, including regulated markets. Centaur caters
to the cream of the pharmaceutical industry in India and Multinational corporations
around the world.

Centaur, with a strong focus, has built strengths across their API, intermediates and
exports business. Centaur is now strategically poised to capitalize on the emerging
opportunities in the domestic and international markets and deliver enhanced long
term value.

Centaur’s core competence lies in the development of cost effective and value added
synthesis routes for bulk drugs and intermediates. Robust quality practices and
standard operating procedures translate into process and product consistency to
international standards and specifications.

Centaur is strengthening its infrastructure for developing innovative technologies,

creating intellectual capital and bolstering processes and systems to reinforce its
reputation as a supplier of international quality APIs and intermediates.

Centaur as a corporate,

• One of India’s few, fully integrated pharmaceutical players

• Proven proficiencies in new product development, custom synthesis, contract
research and contract manufacturing (CRAM)
• Leveraging competencies to build strategic alliances with global majors
• Foot print compasses 96 countries including regulated markets
• Global acceptance by the pharmaceutical industry and medical fraternity

API
• India’s largest manufacturer and exporter of Psychotropic API
• Introduced 24 API for the first time in India
• USFDA/EU/WHO inspected : ISO 9001:2015, ISO 14001:2015, ISO 45001: 2018
certified facility near Mumbai

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Environmental Impact Assessment Centaur Pharmaceuticals Private Limited
Chapter 1 – Introduction
• Core competencies – API conceptualization to commercialization
• Clientele – Big Pharma and generic majors

Contract manufacturing
• Strategically placed to deliver critical values
• Fully scalable 25,000 sq m oral solids formulation facility
• UK-MHRA/TGA/WHO approved facility at Pune neat Mumbai
• USFDA inspected
• Annual capacity – 3 billion tablets and 600 million capsules
• 1200 sq m R & D formulation and analytical development section

Formulations
• Strong presence in Asia, South America & Africa
• Pan India reach – Monthly coverage of 250,000 retailers and 25,000 doctors
• 50 million prescriptions generated annually by doctors of all specialities
• Sinarest – Brand leader an anticold segment, generates 1 prescription every
second
• Leadership in 6 therapy area across respiratory and ophthalmic categories

Contract Research
• International standard CRO, Lifescan, focused on clinical trials and BA-BE studies
• 10,000 sq ft with CPU and fully equipped ICU
• State of the Art bio analytical unit
• International standard R & D laboratories dedicated to API and formulations
development

Strategy
• Strategic global approach to widen geographical spread, enhance business
• Fully integrated setup to drive synergies across R & D, API, formulations, clinical
trials and contract manufacturing
• Vision – Global pharmaceutical providing end to end solutions
Centaur is the India’s largest manufacturer & exporter of psychotropic API and its
intermediate. Ambernath factory is built on total area of 9105 sq. m. It has hygienically
built washing and toilet facilities and proper drainage system. It has facilities like
treated water, steam, vacuum and compressed air.

This facility is having accreditations by USFDA, WHO, KFDA, ANVISA Brazil, EU GMP
France, COFEPRISS Mexico, ISO for Quality as well as HSE.

All departments are adequately staffed with qualified, trained and experienced
personnel for carrying out the job. Production scale reactions includes selective
reductions with complex metal hydride catalyst, Grignard reactions besides the
common reactions as oxidation, alkylation, amination, condensation, decarboxylation,
esterification, etherification, rearrangement, ring closure, resolutions etc. The APIs
(bulk Drugs) & Intermediates (chemicals) produced by Centaur are carefully controlled
using the latest precision analytical instruments and procedures.

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Environmental Impact Assessment Centaur Pharmaceuticals Private Limited
Chapter 1 – Introduction
The Whole manufacturing process is systematically documented on a Batch record,
which helps in tracing back any component anytime. Authorized SOPs at various levels,
right from receipt of raw materials to the dispatch of Finished Product are put in use.

All activities are performed taking into consideration the Good Manufacturing Practices,
Good Laboratory Practices, Safety aspect and applicable statutory & regulatory
requirements along with additional requirements specified by customer.

The company has a full-fledged Quality Control Laboratory with sophisticated

instruments like HPLC’s, HPTLC, LASER PARTICLES SIZE ANALYSER, GC, HSS, Digital
polarimeter, Autotitrator, Autokarl fisher, FT-IR & UV Spectrophotometer, Stability
Chambers etc. and microbiology related instruments. All the materials including packing
materials analyzed as per the specifications and results and properly documented.

The company has a full-fledged Microbiology Department with equipments like

Horizontal Laminar Flow unit, colony counter, BOD incubators, Vertical Autoclave etc.
for the determination of microbiological purity of APIs, potable water and purified
water.
All manufacturing activities carried out are authorized. Equipment cleaning and drying
operations are validated. Analytical methods & instruments are validated.

The Company provides training at all levels with respect of Good Manufacturing
practices, Equipment Handling, Unit operations, Safety and Good Laboratory Practices.
The Company has full-fledged effluent treatment plant for treatment of effluents
generated during the manufacturing processes.

Project Proponent brief profile:-

Name : Mr. Shivanand D. Sawant, Managing Director

Age : 77 years
Qualification: B. Sc. DIM LLB

Name :Dr. Shreekant D. Sawant, Joint Managing Director

Age: 65 years
Qualification: M.Sc. PhD.

Name :Dr. Anil M. Naik, Whole-time Director

Age: 54 years
Qualification: B.Sc. (Tech), PhD

Name: Dr. (Mrs.) Smita A. Phal, Whole-time Director

Age: 45 years
Qualification: MBBS, MD (Pharmacology), MSC (Biotechnology)

Name: Mrs. Rakhi S. Kadam, Director - Legal

Age: 42 years
Qualification: B.Com. L.L.B. & Diploma in Business Management

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Environmental Impact Assessment Centaur Pharmaceuticals Private Limited
Chapter 1 – Introduction
As a part of expansion, Centaur wishes to expand manufacturing facility at its plot no 74,
75, 76 & 76/1Chikhloli MIDC Ambernath.

1.3 Brief Description of Nature, Size, Location of the Project & Its
Importance in the Country, Region

1.3.1 Nature& Size of Project

Proposed project is an expansion of existing products plus new products as per market
demand as follows,
Table 1.1 Product / by product quantities
N Product / By product Existing Proposed Total
o Capacity (*) capacity kg/annu
kg/annum kg/annu m
m
1 HYPNOTIC/SEDATIVE/TRANQUILIZER/ANXIOLYTIC/
ANTICONVULSANT/ANASTHETIC/ANTIDIABETIC (BREAK UP OF IT AS BELOW)
Group I (Nitrazepam, Clonazepam, Bromazepam, 5773 13975 19748
Diazepam, Clotiazepam, Flurazepam Mono
hydrochloride, Tetrazepam, Delorazepam,
Clobazam, Phenazepam)
Group II (Alprazolam, Oxazepam, Lorazepam, 5751 13922 19673
Zolpidem Tartrate, Triazolam, Etizolam,
Temazepam)
Group III (Zopiclone (058) 5726 13862 19588
Group IV (Chloridazepoxide, Zaleplon, Sodium 4759 11520 16279
Oxybate, Stiriepentol, Brivaracetam, Empagliflozin,
Dapagliflozin, Saxagliptin, Sitagliptin, Teneligliptin,
Linagliptin, Vildagliptin, Chlorodiazepoxide
hydrochloride
Group V (Midazolam base, Midazolam HCl, 348 843 1191
Midazolam maleate, Clorazepate Di Potassium,
Brotizolam, Loprazolam Mesilate, Propiomazine
Maleate, Propiomazine HCl, Prazepam, Estazolam,
Fludiazepam, Flunitrazepam, Lormetazepam,
Pinazepam, Es-Zopiclone)
2 ANTIDEPRESSANT/CNS STIMULANT 3276 3969 7245
(Nortriptyline HCl, Melitracen HCl,
Tranylcypromine Sulphate, Amoxapine, Loxapine
Succinate, Loxapine HCl, Methylphenidate HCI,
Dixmethylphenidate HCl)
3 ANTIGLUCOMA/ANTIHISTAMINIC (Brimonidine 756 1213 1969
Tartrate, Timolol Maleate, Dorzoamide HCl,
Chloropyramine HCl, Olopatadine HCl)
4 ANTIPROTAZOAL (Nimorazole) 180 495 675
5 ANTIPSYCHOTIC/ANTIPYRETIC/ANTI- 1932 6355 8287
INFLAMATORY/ ANALGESIC /ANTI-ULCER
(Rebamipide, Acotiamide HCl Hydrate,
Fluphenazine HCl, Flupentixol, Dihydrochloride,
Aripiprazole, Flupentixol Decanoate, Fluphenazine
Decanoate, Asenapine Maleate, Benzydamine HCl

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Environmental Impact Assessment Centaur Pharmaceuticals Private Limited
Chapter 1 – Introduction
N Product / By product Existing Proposed Total
o Capacity (*) capacity kg/annu
kg/annum kg/annu m
m
USP, Zuclopentixol Acetate /HCl/Dacanoate,
Brexpiperazole Diperoxochloric Acid Concentrate,
Pimavanserin, Mexazolam Quinagolide)
6 ANTIEMETIC (Metopimazine, Nabilone) 60 507 567
7 ANTISPASMODIC/MUSCLE RELAXANT 3900 19109 23009
(Chlorzoxazone, Tiemonium Methyl sulphate,
Pitofenone HCl)
8 ANTIDYSKINETIC/DIURETIC/SNR 360 674 1034
INHIBITOR/CHOLINERGIC/URINARY
INCONTINENCE (Tetrabenazine, Metolazone(36),
Milnacipran HCl, Levomilnacipran HCl,
Fampyridine, Rivastigmine Hydrogen tartarate ,
Valebenazine, Deutetrabenazine , Propiverine HCl)
9 HYPERTENSION/ANTIHYPERTENSION (Pindolol) 24 111 135

10 PLATELET INHIBITOR (Prasugrel) 12 18 30

11 ANGINA 12 (-)12 0
12 ANTIVIRAL 12 (-)12 0
13 ANTI CARDIOVASCULAR 12 (-)12 0
14 CALCIMIMETIC 24 (-)24 0
15 ERECTILE DYSFUNCTION 12 (-)12 0
16 IRREVERSIBLE INHIBITOR OF MONOAMIDE 12
(-)12 0
OXDASE
17 R & D ACTIVITY & OTHERS (Tolterodine, 240 360 600
Silodosin, Voriconazole, Ezetimibe, Solifenacin,
Amitriptyline HCl, Pyridostigmine Bromide,
Indapamide, Acetazolamide, Clidinium bromide)
TOTAL 33180 86850 120030
18 Recovered solvent 120 MTPA 2880 3000
MTPA MTPA
The project will be executed within the existing plot of Centaur which is 9,105sq m in
area with capital investment of ~ Rs. 90.5 Cr.

1.3.2 Location of the Project

The existing plant facility is located at plot no. 74, 75, 76 & 76/1 of MIDC Industrial
Estate, Ambernath (west), Dist Thane Maharashtra.
Site is well connected by rail and road The Site is 4 km from Ambernath town and 4 km
from nearest Ambernath railway Station. The land and infrastructure is made available
by MIDC and the raw material is easily available through the easy transport via road
connectivity.
The plant expansion is to be located at existing adjacent plots owned by Centaur in well-
developed industrial estate.

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Major port is JNPT, about 45 Km to the south west of the plant site.

The Geographical Location of this Industry is 190 11’ 42” N Latitude and 730 12’ 31’’ E
Longitude with an elevation of 39 meter above sea level MSL.
Geographical plant site coordinates are as below:
Direction Latitude Longitude
North east corner 190 11’ 45.17” N 730 12’ 31.70”E
North west corner 190 11’ 42.38”N 730 12’ 28.30”E
South east corner 190 11’ 40.83”N 730 12’ 34.05”E
South west corner 19 11’ 42.54”N
0 730 12’ 31.80”E

1.3.3 Importance of the Project to the Country, Region

Centaur Pharmaceuticals Pvt. Ltd. API Division is mainly Export oriented unit. To cope
up with marketing demand we require the expansion of the facility. This helps us to
generate the foreign exchange by exporting our products, as well as increasing more
employment to the people.

Currently we are having number of export orders from the overseas customers but we
can’t meet the delivery schedule as per their timelines. Ultimately we have no other
option than to forgo the orders. To avoid this demand and supply gap of the export
orders, we need to go for expansion of the existing facility.

We are selling our 90% product in export market and 10% in the domestic market.

1.4 Regulatory framework of the proposed expansion

1.4.1 General clearances and other related permissions

Centaur shall obtain required statutory permission and clearances from concerned
authorities. Details of permits and clearance as applicable to this project expansion are
provided in table below.
Table 1.2Statutory Clearances / Permissions required
No Legal requirement
1 Environmental Impact Assessment Notification, 2006 as amended to date
2 Factory License
3 The Factories Act 1948 & Rules therein
4 The Water (Prevention and Control of Pollution) Act, 1974 and Rules, 1975, as
amended to date.
5 The Water (Prevention and Control of Pollution) Cess Act, 1977 and Rules, 1978,
as amended to date.
6 The Air (Prevention and Control of Pollution) Act, 1981 and Rules, 1982, as
amended to date.
7 The Manufacture, Storage and Import of Hazardous Chemical rules, 1989, as
amended to date.
8 The Hazardous Waste (Management, Handling and Trans boundary Movement)
Rules, 2016 as amended to date.
9 The Environment (Protection) Act, 1986 and Rules, 1986, as amended to date

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10 Chemical accidents (Emergency Planning, preparedness and response) Rules,
1996
11 The Motor Vehicles Act, 1988 & The Central Motor Vehicle rules, 1989
12 The Petroleum Act, 1934 & Rules, 2002.
13 The Explosive Act, 1884 and rules, 1983 as amended to date
14 The Gas Cylinders Rules, 2004
15 The Static and Mobile Pressure Vessels (Unfired) Rules, 1981
16 The Biomedical waste (Management and Handling) Rules, 2016 as amended to
date
17 The Batteries (Management and Handling) Rules, 2001, as amended to date
18 The Noise Pollution (Regulation and Control) Rules, 2000 as amended to date
19 Solid Waste Management Rules, 2016
20 The Biomedical waste (Management and Handling) Rules, 2016 as amended to
date
21 Plastic Waste Management Rules 2016
22 Construction and Demolition Waste Management Rules, 2016
23 E-waste (Management and Handling) Rules, 2011 as amended to date
24 Electricity Rule, 2005
25 Consents from MPCB
26 The Bureau of Indian Standards Act
27 Public Liability Insurance Act, 1991 and Rules, 1991 as amended to date
28 Chemical Accidents (Emergency planning, Preparedness and Response) Rules,
1996
29 The Central Motor Vehicle Rules, 1989
Note: Above list is indicative and not exhaustive.

Centaur Pharmaceuticals Private Limited has been granted Consent to Operate No. Format
1.0/BO/CAC Cell/ UAN No. 0000044143/R/5th CAC- 1812000081 dated 29.11.2018 valid
upto 30.04.2023 by Maharashtra Pollution Cotrol Board which is attached as Annexure
1.1.

1.4.2 Applicability of EIA Notification 2006

As a part of Environmental Clearance process, Centaur uploaded and submitted relevant

documents, namely Form – 1 (as per the EIA Notification, 2006, as amended), along with
a Pre-feasibility Report and Proposed Terms of Reference (ToRs) for carrying out EIA
Studies, to the MoEF&CC Online Environment Clearance portal on 26th December
2016(Proposal No.SIA/MH/IND2/18041/2016).
Proposal was accepted by State Expert Appraisal Committee (SEAC)-1 & presentation
has been made during the 142nd SEAC-I meeting held on 14th September 2017.
TOR has been finalized during the meeting to conduct the Environmental Impact
Assessment (EIA) & Environmental Management Plan (EMP) studies, vide MOM
attached as Annexure 1.2.
For conducting EIA as per the TORs, the Centaur has retained the services of M/s. Aditya
Environmental Services Private limited; Mumbai who are NABET accredited EIA
Consultant Organization for the 5(f) sector.

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Own Laboratory of Aditya Environmental Services Private limited (Recognized by
MOEF&CC as “Environmental Laboratory” vide SO no 983 valid till 30.04.2019) has
been utilized for various analytical activities of the EIA study.

1.4.3 Background to EIA Study Report:

Objectives& Scope

The objectives of EIA for the proposed establishment of project are listed below:

• Characterization and benchmarking of existing environmental status.

• To identify and quantify significant impact on the environmental parameters
during construction, commissioning and operation&closure phases of the
proposed project.
• To identify and quantify any environmental impacts associated with the project
and recommend appropriate mitigation measures to avoid/minimize pollution,
environmental disturbance and nuisance.
• Preparation of an environmental management plan to minimize adverse
impacts of proposed project.
• Recognize the scope and requirement of the ToR and comply with the same.

1.4.4 Process of EIA study

EIA is a management tool to identify, frame and prioritize the environmental issues in
such a way as to work out the mitigation measures to allow the negative impacts to be
minimized or to be avoided during the construction and operation phase of the
proposed establishment project.
EIA process passes through the following phases:

• Screening, Scoping and consideration of alternatives

• Study of the project details
• Application with environmental pre-feasibility study for approval of ToR.
• Collection of baseline data for study area
• Impact identification, prediction and evaluation
• Assessment of alternatives and delineation of Environment Management Plan
• Risk Assessment (RA) and Disaster Management Plan (DMP)
• Review and finalization of EIA report
• Final EIA report and EC Application.

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Flow chart of various activities to be carried out for EIA report preparation is depicted in
figure below.

Project initiation

Preliminary scan of Preliminary scan of

Existing environment Proposed environment

Select Environmental indicators

Describe Environmental Indicators Field survey /

Hazard sampling
and
Risk Select Environmental setting
Analysis

Impact evaluation (modeling)

Risk
assessm
ent and Rescanning of proposed
DMP
Environmental Impact Assessment Environment

Environmental Management Plan

EIA Report

Figure 1.1 Flow chart of EIA study

1.4.5 Methodology adopted for EIA study

The methodology adopted for conducting the EIA is mentioned below:

Screening and scoping: Screening is done to see whether a project requires clearance
as per the statutory notifications. Scales of investment, type and location of
development are the main criteria for screening the project activity. Screening of project
details w.r.t. EIA Notificationshows that Centaur Pharmaceutical Private Limited is
located in notified MIDC area (Chikhloli MIDC) and has Synthetic Organic Chemical
manufacturing and wish to expand the same in the proposed project which is covered
under nodes category 5(f) (B) of the EIA Notification 2006 & requires prior EC from
SLEAC-I.
Scoping is carried out in close association with the project proponent and guidance by
the Impact Assessment Agency. The MoEF&CC has published Model TOR’s for SOCMI
industries vide its notes dated April 2015, which outline the significant issues to be
addressed in the EIA studies.
In addition, details of the project were presented in the 142ndSLEAC-I meeting dated
14th September 2017 and the SEAC -I committee granted TOR for the project.

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Quantifiable impacts are assessed on the basis of magnitude, prevalence, frequency,
duration and significance of non-quantifiable impacts is commonly determined through
the socio-economic and other criteria. After the areas where the project can have
significant impact are identified, the baseline status of these are to be monitored and
then the likely changes in these on account of the construction and operation of the
proposed project are predicted.
• Desk top study: Desktop study has been conducted to establish an environmental
information database for the EIA. Reference materials such as textbooks, articles,
maps, internet, photographs and past EIA reports of similar industries have been
used for the preparation of EIA report.

• Field study: One season field study for the period of winter 2017-18 has been
carried out to verify and complement information gathered from desktop study.
Baseline data describes the existing environmental status of the identified study
area. The study covers all the relevant components of ambient air monitoring; noise,
water quality, soil monitoring, ecological, and socio-economic and health
components of the environment. The site-specific primary data has been monitored
for the identified parameters and supplemented by secondary data if available.

Air environment

Monitoring of the existing status of ambient air quality and analysis has been carried
out as per revised National Ambient Air Quality Standard. Total 8 locations (1 Onsite
& 7 sorrounding villages within study area) have been selected considering the pre-
dominant downward wind direction, population zone and sensitive receptor of the
region. Micro-meteorological data like hourly wind speed and direction,
temperature, relative humidity, rain fall, etc., have been collected by using wind
monitor. Stack/ Vent monitoring data from MoEFCC recognized laboratory
(Aavanira Biotech) has been accesed and presented. Air Modeling was done to
envisage the likely impact on ambient air quality due to proposed establishment of
the project.

Noise environment

Noise level monitoring has been carried out for day and night times by noise meter
to assess the present scenario of the noise environment at various AAQ station in the
study area.

Land Environment

Soil samples have been collected from 8 locations within the impact zone and
analyzed for relevant parameters. Studies on soil characteristics were carried out.
Existing land use and topography, landscape and drainage patterns within the study
area were analyzed.

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Water environment
Ground & Surface Water samples have been collected from various locations within
10 km radius from the project. Ground water samples of Dug well, Borewell &
Surface water samples of Ulhas River, Chikhloli dam, GIP railway dam, and lotus
pond has been collected & presented in EIA report. Analysis was carried out for
physio-chemical, heavy metal, microbiological and biological parameters. Results
have been compared to assess the water quality.

Ecology & Socio-Economic Environment

Secondary data of flora and fauna have been collected from various literatures
published by Forest Department. Data have also been verified by field visits &
questionnaire survey by Functional Area Experts Approved by QCI- NABET.
Collection of demographic and related socio-economic data,Projection of anticipated
changes in the socio-economic aspect due to the project related activities, were also
studied.

Laboratory Analysis

Samples collected during the field sampling were analyzed in the laboratory of
AESPL, which is recognized by MoEFCC under the Environment Protection Act,
1986, an established and NABL accredited laboratory.

Impact Prediction and Evaluation

Impact prediction is a way of ‘mapping’ the environmental consequences of the

significantaspects of the project and its alternatives Air Modeling was done to
envisage the likely impact on ambient air quality due to proposed establishment of
the project. Evaluation of all associated and potential impacts of the proposed
project were carried out using required models. Impact evaluation was carried out
using the matrix method.

Mitigation Measures and Environmental Management Plan

Environmental mitigation measures have been preperaed in the EIA for the selected
application and are supplemented with an Environmental Management Plan (EMP)
to guide the proponent towards environmental improvements. An EMP budget &
Monitroing plan has been drawnup & presented to ensure that action/plans
proposed are suitabily backed up. Significant risks and hazards and their mitigation
measures have been identified in the shall be incorporated in the risk report. Risk
report contains hazard identification by taking recourse to HAZOP, hazard indices,
consequence analysis of failures and accidents resulting in fire, explosion, hazardous
releases etc. Assessment of risk on the basis of the necessary evaluations and
preparation of an Onsite /Off site Emergency Plan and Disaster Management Plan
are also mentioned in the risk report.

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EIA Report

Based on the field survey visit primary & secondary data collection, compilation of
data and technical details were done by the project team and reviewed for EC. Draft
EIA report is prepared after incorporation of all the technical data, maps, drawings,
FAEs comments and inputs. Quality check was conducted by a QA/QC team and their
comments are incorporated in the report. After final confirmation from the project
proponent EIA report is submitted.

1.4.6 Structure of EIA Report

No Chapter Content
1 Introduction • Purpose of the report
• Identification of project & project proponent
• Brief description of nature, size, location of the project and
its importance to the country, region
• Scope of the study – details of regulatory scoping carried
out.
2 Project • Condensed description of those aspects of the project
Description (based on project feasibility study), likely to cause
environmental effects. Description contains the details of
the following:
• Type of project
• Need for the project
• Location details showing general location, specific location,
project boundary & project site layout
• Technology and process description including drawings
showing project layout, components of project etc.
• Description of mitigation measures incorporated into the
project to meet environmental standards.
3 Description of • Study area, period, components & methodology.
the Environment • Establishment of baseline for valued environmental
components, as identified in the scope.
• Study Period
• Base maps of all environmental components.
• Frequency of monitoring
4 Anticipated • Details of Investigated Environmental impacts due to
Environmental project location, possible accidents, project design, project
Impact and construction, regular operations.
mitigation • Measures for minimizing and / or offsetting adverse
measures impacts identified.
• Irreversible and Irretrievable commitments of
environmental components
• Assessment of significance of impacts (Criteria for
determining significance, Assigning significance)
• Mitigation measures.
5 Analysis of • Analysis of alternatives site considered for siting the
Alternatives (Site project.

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and Technology) • Analysis of alternatives technologies considered for the
project
6 Environmental • Technical aspects of environmental monitoring for the
monitoring effectiveness of mitigation measures (incl. Measurement
programme methodologies, frequency, location data analysis,
reporting schedules, emergency procedures, budget
&procurement schedules)
7 Additional • Hazard Identification
studies (Public • Risk Assessment & control/prevention Measures
hearing and Risk • Disaster Management
assessment) • Results of public hearing and recommendations
8 Project benefits • Details of the Socio-economic & other tangible / intangible
benefits of the project.
9 Environmental • Details of the environmental benefits of the project.
cost benefit
analysis
10 Environmental Description of the administrative aspects of ensuring that
management plan mitigation measures are implemented and their effectiveness
monitored, after approval of the Clearance. The Chapter
consist of:
• Mitigation measures for impacts
• Pollution Prevention Plan
• Greenbelt Development Plan
• Waste management plan
• Environment Management Cell
• Budgetary Provisions for EMS
11 Summary and • Brief description of EIA content, summary and conclusion
conclusions
12 Disclosure of • Details of EIA Consultant
consultant
engaged

1.4.7 Compliance to TOR

Compliance to Model ToR for Synthetic Organic Chemicals (activity 5(f)) and project
specific and additional TOR prescribed in 142nd SLEAC meeting dated 14th September
2017 are presented in below tables. (SEAC-I meeting minutes as given in Annexure1.2)
Table 1.3Compliance to Model ToR Prescribed by EAC (Model ToR for (activity
5(f))
Sr.
Particulars Compliance
No.
A STANDARD TERMS OF REFERENCE
1. Executive Summary Refer Chapter 11
2. Introduction
i Details of the EIA Consultant including NABET Refer Chapter 12
accreditation

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ii Information about the project proponent Refer Chapter 1
iii Importance and benefits of the project Refer Chapter 1 and
Chapter 8
3. Project Description
i Cost of project and time of completion Refer Chapter 2
ii Products with capacities for the proposed project. Refer Chapter 2
iii If establishment project, details of existing products Refer Chapter 2
with capacities and whether adequate land is available
for establishment, reference of earlier EC if any.
iv List of raw materials required and their source along Refer Chapter 2
with mode of transportation
v Other chemicals and materials required with quantities Refer Chapter 2
and storage capacities
vi Details of Emission, effluents, hazardous waste Refer Chapter 2
generation and their management
vii Requirement of water, power, with source of supply, Refer Chapter 2
status of approval, water balance diagram, man-power
requirement (regular and contract)
viii Process description along with major equipment and Refer Chapter 2
machineries, process flow sheet (quantitative) from raw
material to products to be provided
ix Hazard identification and details of proposed safety Refer Chapter 7
systems.
x Establishment/modernization proposals
a) Copy of all the Environmental Clearance(s) including Not applicable
Amendments thereto obtained for the project from
MOEF/SEIAA shall be attached as an Annexure. A
certified copy of the latest Monitoring Report of the
Regional Office of the Ministry of Environment and
Forests as per circular dated 30th May, 2012 on the
status of compliance of conditions stipulated in all the
existing environmental clearances including
Amendments shall be provided. In addition, status of
compliance of Consent to Operate for the ongoing /
existing operation of the project from SPCB shall be
attached with the EIA-EMP report.
b) In case the existing project has not obtained Existing Consent to
environmental clearance, reasons for not taking EC Operate is attached as
under the provisions of the EIA Notification 1994 Annexure 1.1.
and/or EIA Notification 2006 shall be provided. Compliance to CTO is
Copies of Consent to Establish/No Objection attached as Annexure
Certificate and Consent to Operate (in case of units 1.3
operating prior to EIA Notification 2006, CTE and
CTO of FY 2005-2006) obtained from the SPCB shall
be submitted. Further, compliance report to the
conditions of consents from the SPCB shall be
submitted.

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4 Site Details
i Location of the project site covering village, Taluka / Refer Chapter-2, &
Tehsil, District and State, Justification for selecting the Chapter- 5
site, whether other sites were considered.
ii A topo sheet of the study area of radius of 10 km and site Annexure 3.1
location on 1:50,000/1:25,000 scale on an A3/A2 sheet.
(including all eco-sensitive areas and environmentally
sensitive places)
iii Details w.r.t. option analysis for selection of site Refer Chapter 5
iv Co-ordinates (lat-long) of all four corners of the site. Refer Chapter 1
v Google map-Earth downloaded of the project site. Refer Chapter 2
vi Layout maps indicating existing unit as well as proposed Annexure 2.1
unit indicating storage area, plant area, greenbelt area,
utilities etc. If located within an Industrial area/ Estate/
Complex, layout of Industrial Area indicating location of
unit within the Industrial area/Estate
vii Photographs of the proposed and existing (if applicable) Refer Chapter 3
plant site. If existing, show photographs of
plantation/greenbelt, in particular
viii Land use break-up of total land of the project site Not applicable, Since
(identified and acquired), government/ private - the
agricultural, forest, wasteland, water bodies, project is within
settlements, etc shall be included. (not required for Chikhloli MIDC
industrial area)
ix A list of major industries with name and type within Refer Chapter- 2,
study area (10km radius) shall be incorporated. Land Table 2.1
use details of the study area Land use details are
given
at Chapter 3, Section
Land Environment
x Geological features and Geo-hydrological status of the Refer Chapter 3
study area shall be included
xi Details of Drainage of the project up to 5 km radius of Refer Chapter-3, Land
study area. If the site is within 1 km radius of any major Environment
river, peak and lean season river discharge as well as
flood occurrence frequency based on peak rainfall data
of the past 30 years. Details of Flood Level of the project
site and maximum Flood Level of the river shall also be
provided. (mega green field projects)
xii Status of acquisition of land. If acquisition is not Not applicable
complete, stage of the acquisition process and expected
time of complete possession of the land
Xiii R&R details in respect of land in line with state Not applicable
Government policy.
5. Forest and wildlife related issues (if applicable)

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I Permission and approval for the use of forest land Not applicable
(forestry clearance), if any, and recommendations of the
State Forest Department. (if applicable)

ii Land use map based on High resolution satellite imagery Not applicable
(GPS) of the proposed site delineating the forestland (in
case of projects involving forest land more than 40 ha)
iii Status of Application submitted for obtaining the stage I Not applicable
forestry clearance along with latest status shall be
submitted.
iv The projects to be located within 10 km of the National Not applicable
Parks, Sanctuaries, Biosphere Reserves, Migratory
Corridors of Wild Animals, the project proponent shall
submit the map duly authenticated by Chief Wildlife
Warden showing these features vis-à-vis the project
location and the recommendations or comments of the
Chief Wildlife Warden-thereon.
v Wildlife Conservation Plan duly authenticated by the Not applicable
Chief Wildlife Warden of the State Government for
conservation of Schedule I fauna, if any exists in the
study area.
vi Copy of application submitted for clearance under the Not applicable
Wildlife (Protection) Act, 1972, to the Standing
Committee of the National Board for Wildlife.
6 Environmental Status
i Determination of atmospheric inversion level at the Refer Chapter 3
project site and site-specific micrometeorological data
using temperature, relative humidity, hourly wind speed
and direction and rainfall.
ii AAQ data (except monsoon) at 8 locations for PM10, Refer Chapter 3
PM2.5, SO2, NOX, CO and other parameters relevant to the
project shall be collected. The monitoring stations shall
be based CPCB guidelines and take into account the pre-
dominant wind direction, population zone and sensitive
receptors including reserved forests.
iii Raw data of all AAQ measurement for 12 weeks of all ReferAnnexure 3.4
stations as per frequency given in the NAQQM
notification of Nov. 2009 along with - min., max., average
and 98% values for each of the AAQ parameters from
data of all AAQ stations should be provided as an
annexure to the EIA Report.
iv Surface water quality of nearby River (100m upstream Refer Chapter 3
and downstream of discharge point) and other surface
drains at eight locations as per CPCB/ MoEF&CC
guidelines.
v Whether the site falls near to polluted stretch of river There is no polluted

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identified by the CPCB/ MoEF& CC, if yes give details. stretchof river
identified by the
CPCB/MoEF&CC near
the site.
vi Ground water monitoring at minimum at 8 locations Refer Chapter 3
shall be included
vii Noise levels monitoring at 8 locations within the study Refer Chapter 3
area.
viii Soil Characteristic as per CPCB guidelines Refer Chapter 3
ix Traffic study of the area, type of vehicles, frequency of Not applicable as
vehicles for transportation of materials, additional proposed project will
traffic due to proposed project, parking arrangement not be generate
etc. additional traffic
x Detailed description of flora and fauna (terrestrial and Refer Chapter 3
aquatic) existing in the study area shall be given with
special reference to rare, endemic and endangered
species. If Schedule-I fauna are found within the study
area, a Wildlife Conservation Plan shall be prepared and
furnished.
xi Socio-economic status of the study area Refer Chapter 3
7 Impact and Environment Management Plan
i Assessment of ground level concentration of pollutants Refer Chapter 4
from the stack emission based on site-specific
meteorological features. In case the project is located on
a hilly terrain, the AQIP Modeling shall be done using
inputs of the specific terrain characteristics for
determining the potential impacts of the project on the
AAQ. Cumulative impact of all sources of emissions
(including transportation) on the AAQ of the area shall
be assessed. Details of the model used and the input data
used for modeling shall also be provided. The air quality
contours shall be plotted on a location map showing the
location of project site, habitation nearby, sensitive
receptors, if any.
ii Water Quality modeling - in case of discharge in water Notapplicable. Water
body discharge to CETP.
iii Impact of the transport of the raw materials and end Impacts are discussed
products on the surrounding environment shall be in
assessed and provided. In this regard, options for Impact activity
transport of raw materials and finished products and matrices at
wastes (large quantities) by rail or rail-cum road Chapter-4
transport or conveyor cum- rail transport shall be
examined.
iv A note on treatment of wastewater from different plant Refer Chapter-4
operations, extent recycled and reused for different
purposes shall be included. Complete scheme of effluent
treatment. Characteristics of untreated and treated

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effluent to meet the prescribed standards of discharge
under E(P) Rules.
v Details of stack emission and action plan for control of Refer Chapter-4
emissions to meet standards.
vi Measures for fugitive emission control Refer Chapter-4
vii Details of hazardous waste generation and their storage, Details at Chapter-4,
utilization and management. Copies of MOU regarding and EMP Chapter-10
utilization of solid and hazardous waste in cement plant
shall also be included. EMP shall include the concept of
waste-minimization, recycle/ reuse/ recover techniques,
Energy conservation, and natural resource conservation.
viii Proper utilization of fly ash shall be ensured as per Fly Not applicable.
Ash Notification, 2009. A detailed plan of action shall be
provided.
ix Action plan for the green belt development plan in 33 % Chapter- 4 and 10
area i.e. land with not less than 1,500 trees per ha.
Giving details of species, width of plantation, planning
schedule etc. shall be included. The green belt shall be
around the project boundary and a scheme for greening
of the roads used for the project shall also be
incorporated.
x Action plan for rainwater harvesting measures at plant Refer Chapter 4
site shall be submitted to harvest rainwater from the
roof tops and storm water drains to recharge the ground
water and also to use for the various activities at the
project site to conserve fresh water and reduce the
water requirement from other sources.
xi Total capital cost and recurring cost/ annum for Refer Chapter-10
environmental pollution control measures shall be
included.
xii Action plan for post-project environmental monitoring Refer Chapter 6
shall be submitted.
xiii Onsite and Offsite Disaster (natural and Man-made) Refer Chapter-7,
Preparedness and Emergency Management Plan Annexure 7.7
including Risk Assessment and damage control. Disaster
management plan should be linked with District
Disaster Management Plan.
8 Occupational Health
i Plan and fund allocation to ensure the occupational Refer Chapter 10
health &safety of all contract and casual Workers
ii Details of exposure specific health status evaluation of Refer Annexure 7.6
worker. If the workers' health is being evaluated by pre
designed format, chest x rays, Audiometry, Spirometry,
Vision testing (Far & Near vision, color vision and any
other ocular defect) ECG, during pre-placement and
periodical examinations give the details of the same.
Details regarding last month analyzed data of above

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Environmental Impact Assessment Centaur Pharmaceuticals Private Limited
Chapter 1 – Introduction
Sr.
Particulars Compliance
No.
mentioned parameters as per age, sex, duration of
exposure and department wise.
iii Details of existing Occupational & Safety Hazards. What Refer Chapter-10
are the exposure levels of hazards and whether they are
within Permissible Exposure level (PEL). If these are not
within PEL, what measures the company has adopted to
keep them within PEL so that health of the workers can
be preserved.
iv Annual report of health status of workers with special Annexuture 7.7
reference to Occupational Health and Safety.
9 Corporate Environment Policy
i Does the company have a well laid down Environment Yes. Company has HSE
Policy approved by its Board of Directors? If so, it may policy (Chapter 10)
be detailed in the EIA report.
ii Does the Environment Policy prescribe for standard Refer Chapter 10
operating process / procedures to bring into focus any
infringement / deviation / violation of the
environmental or forest norms / conditions? If so, it may
be detailed in the EIA.
iii What is the hierarchical system or Administrative order Refer Chapter 10
of the company to deal with the environmental issues
and for ensuring compliance with the environmental
clearance conditions? Details of this system may be
given.
iv Does the company have system of reporting of non- Refer Chapter 10
compliances / violations of environmental norms to the
Board of Directors of the company and / or shareholders
or stakeholders at large? This reporting mechanism
shall be detailed in the EIA report
10 Details regarding infrastructure facilities such as Sanitation, Restroom
sanitation, fuel, restroom etc. to be provided to the labor etc will be provided to
force during construction as well as to the casual the labors during
workers including truck drivers during operation phase. construction as well
as casual workers
including truck
drivers during
operation phase.
11 Enterprise Social Commitment (ESC)
Adequate funds (at least 2.5 % of the project cost) shall Refer Chapter 10
be earmarked towards the Enterprise Social
Commitment based on Public Hearing issues and item-
wise details along with time bound action plan shall be
included. Socio-economic development activities need to
be elaborated upon.
12 Any litigation pending against the project and/or any No such litigation
direction/order passed by any Court of Law against the pending against
project, if so, details thereof shall also be included. Has project

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Chapter 1 – Introduction
Sr.
Particulars Compliance
No.
the unit received any notice under the Section 5 of
Environment (Protection) Act, 1986 or relevant Sections
of Air and Water Acts? If so, details thereof and
compliance/ATR to the notice(s) and present status of
the case.
13 A tabular chart with index for point wise compliance of Complied
above TOR.
B SPECIFIC TERMS OF REFEREENCE
1 Details on solvents to be used, measures for solvent Solvents are being
recovery and for emissions control. used and solvent
recovery plan is
mentioned in Chapter
4
2 Details of process emissions from the proposed unit and Process emissions
its arrangement to control. from the proposed
unit
and its control
measures are
mentioned in Chapter
4
3 Ambient air quality data should include VOC, other Ambient air quality
process-specific pollutants* like NH3*, chlorine*, HCI*, data for the given
HBr*, H2S*, HF*, CS2* etc., (* as applicable) parameters is
incorporated in
Chapter 3
4 Work zone monitoring arrangements for hazardous Work zone
chemicals. monitoring
arrangements given in
Chaper 6.
5 Detailed effluent treatment scheme including Detailed ETP scheme
segregation of effluent streams for units adopting 'Zero' along with
liquid discharge. segregation of effluent
streams. Treated
effluent will be sent to
CETP. Refer Chapter 4.
6 Action plan for odor control to be submitted. Sufficient Ventilation
shall be provided in
all Plants as per
Maharashtra factory
Rules- 18 A.
7 A copy of the Memorandum of Understanding signed Not applicable
with cement manufacturers indicating clearly that they
co-process organic solid/hazardous waste generated.
8 Authorization/Membership for the disposal of liquid Authorization
effluent in CETP and solid/hazardous waste in TSDF, if hazardous waste in
any. TSDF- Annexure 3.3
Membership for the

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Sr.
Particulars Compliance
No.
disposal of liquid
effluent in CETP-
Annexure 3.5
9 Action plan for utilization of MEE/dryers salts MEE/dryers salts will
be sent to CHWTSDF.
10 Material Safety Data Sheet for all the Chemicals are MSDS for all the
being used/will be used. chemicals are being
used/will be used is
explained in
Annexure 7.4
11 Authorization/Membership for the disposal of solid/ Annexure 3.3
hazardous waste in TSDF are being used/will be used.
12 Authorization/Membership for disposal of solid/ Refer Annexure 3.3
hazardous waste in TSDF.
13 Risk assessment for storage and handling of hazardous A detailed Risk
chemicals/solvents. Action plan for handling & safety Assessment Study for
system to be incorporated. storage and handling
of hazardous
chemicals/solvents
has been incorporated
Chapter 7.
14 Arrangements for ensuring health and safety of workers Arrangements for
engaged in handling of toxic materials. ensuring health and
safety of workers
engaged in handling of
toxic materials are
mentioned in Chapter
7
Table 1.4Point wise Compliance to Additional TOR granted in 142ndSLEAC-I
Meeting
No Term of Reference Compliance/ Companies
Reply
1 PP to submit lay out plan showing internal roads, Refer Chapter 2,
location of pollution control equipment, parking areas, Annexure 2.1
33% green belt, rain water harvesting etc
2 PP to submit structural stability certificate of existing Refer Annexure 1.4 for
buildings. structural stability
certificate of existing
building
3 PP informed that the plot Nos. 74, 75 and 76 are not Refer Annexure 1.5 for
yet amalgamated and manufacturing processes are plot amalgamation letter
interlinked among these plots; PP asked to amalgamate from MIDC
the plots and submit copy of amalgamation.
4 PP to include detailed material balance charts for each Refer Chapter 2 for details
product showing consumption of raw material, sources
of pollution and mitigation measures to control the

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Chapter 1 – Introduction
No Term of Reference Compliance/ Companies
Reply
pollution and justified use of resources along with
quantities in the EIA report.
5 PP to carry out HAZOP and QRA and submit report Refer Chapter 7,
Annexure 7.1
6 PP to submit hazardous chemical handling protocol Refer Chapter 7
7 PP to submit on site and off site emergency plan. Refer Annexure 7.7
8 PP to submit details of high COD/TDS effluent, design Refer Chapter 4
details of ETP.
9 PP to submit design details of air pollution control Refer Chapter 4
systems.
10 PP to include details of solid waste generation and its Refer Chapter 2
quantity in the EIA report
11 PP to explore possibility of using flow chemistry for Refer section 4.5.5 (PP will
new products. explore possibility of flow
chemistry for new
products).

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Chapter 2 – Project Description

2 PROJ ECT DESC RIPT ION

2.1 Type of Project

The proposed project is an addition of manufacture of existing and new products at the
manufacturing site. As per EIA Notificationdated 14 September 2006, the proposed
expansion of manufacturing facility falls under 5(f)-B category i.e. Synthetic Organic
Chemical Manufacturing Industry (SOCMI) and being located in notified MIDC area,
needs prior environmental clearance from SLEAC and SEIAA.

2.2 Need of the Project

Centaur Pharmaceuticals Pvt. Ltd. API Division is mainly Export oriented unit. To cope
up with marketing demand we require the expansion of the facility. This helps us to
generate the foreign exchange by exporting our products, as well as increasing more
employment to the people.

2.3 Location of the Project

Plot No. 74, 75, 76 & 76/1are located towards the north east side of MIDC Chikhloli.
There is no large human settlement in immediate vicinity of the plant. MIDC Chikhloli is
located in notified Chemical Zone of Maharashtra Industrial Development Corporation
and has about 400 large/medium and small scale industries which occupy about 228.49
hectare area. Some major industries in MIDC are as below:
Table 2.1 Major IndustrieswithinChikhloli MIDC
No Name Type
1 Reliable spaces Infrastructure
2 Bombay Iron castings Steel
3 K T Steels Steel
4 Ion exchange (India) Limited Ion exchange resins
Bombay maulable iron casting and allied
5 Steel
industries ltd
The salient infrastructures of the MIDC are:
• Adequate water supply from MIDC (sourced from nearby Barvi dam by MIDC)
• Proximity of port facilities (JNPT port 50km SW)
• Easily accessible by rail and road
• Industrial area having CETP
Google earth image showing 10 km and 1 km area surrounding the plant is presented in
in below figures.

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Chapter 2 – Project Description

Figure 2.1 Google Earth Image Showing 10 Km Surrounding

Figure 2.2 Google Earth Image Showing 1 Km Surroundings

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Chapter 2 – Project Description

LOCATION OF PROPOSED PROJECT WITHIN MIDC

Bombay Iron
Indian K.T. STEEL casting
Schering MSEB
station
Piramal
Mill

Chikhloli Morivali
CETP

Centaur Garlic
Pharmaceutical Reliable India
spaces

Figure 2.3 Map of Chikhloli MIDC Indicating Location of Centaur

2.4 Size/ Magnitude of Operation

Centaur is proposing to manufacture following products at the site:

Table 2.2Existing and Proposed Products and Quantities
N Product / By product Existing Proposed Total
o Capacity (*) capacity kg/annu
kg/annum kg/annu m
m
1 HYPNOTIC/SEDATIVE/TRANQUILIZER/ANXIOLYTIC/ANTICONVULSANT/ANASTHETIC/A
NTIDIABETIC (BREAK UP OF IT AS BELOW)
Group I (Nitrazepam, Clonazepam, Bromazepam, 5773 13975 19748
Diazepam, Clotiazepam, Flurazepam Mono
hydrochloride, Tetrazepam, Delorazepam,
Clobazam, Phenazepam)
Group II (Alprazolam, Oxazepam, Lorazepam, 5751 13922 19673
Zolpidem Tartrate, Triazolam, Etizolam,
Temazepam)
Group III (Zopiclone (058) 5726 13862 19588
Group IV (Chloridazepoxide, Zaleplon, Sodium 4759 11520 16279
Oxybate, Stiriepentol, Brivaracetam, Empagliflozin,
Dapagliflozin, Saxagliptin, Sitagliptin, Teneligliptin,
Linagliptin, Vildagliptin, Chlorodiazepoxide

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N Product / By product Existing Proposed Total
o Capacity (*) capacity kg/annu
kg/annum kg/annu m
m
hydrochloride
Group V (Midazolam base, Midazolam HCl, 348 843 1191
Midazolam maleate, Clorazepate Di Potassium,
Brotizolam, Loprazolam Mesilate, Propiomazine
Maleate, Propiomazine HCl, Prazepam, Estazolam,
Fludiazepam, Flunitrazepam, Lormetazepam,
Pinazepam, Es-Zopiclone)
2 ANTIDEPRESSANT/CNS STIMULANT 3276 3969 7245
(Nortriptyline HCl, Melitracen HCl,
Tranylcypromine Sulphate, Amoxapine, Loxapine
Succinate, Loxapine HCl, Methylphenidate HCI,
Dixmethylphenidate HCl)
3 ANTIGLUCOMA/ANTIHISTAMINIC (Brimonidine 756 1213 1969
Tartrate, Timolol Maleate, Dorzoamide HCl,
Chloropyramine HCl, Olopatadine HCl)
4 ANTIPROTAZOAL (Nimorazole) 180 495 675
5 ANTIPSYCHOTIC/ANTIPYRETIC/ANTI- 1932 6355 8287
INFLAMATORY/ ANALGESIC /ANTI-ULCER
(Rebamipide, Acotiamide HCl Hydrate,
Fluphenazine HCl, Flupentixol, Dihydrochloride,
Aripiprazole, Flupentixol Decanoate, Fluphenazine
Decanoate, Asenapine Maleate, Benzydamine HCl
USP, Zuclopentixol Acetate /HCl/Dacanoate,
Brexpiperazole Diperoxochloric Acid Concentrate,
Pimavanserin, Mexazolam Quinagolide)
6 ANTIEMETIC (Metopimazine, Nabilone) 60 507 567
7 ANTISPASMODIC/MUSCLE RELAXANT 3900 19109 23009
(Chlorzoxazone, Tiemonium Methyl sulphate,
Pitofenone HCl)
8 ANTIDYSKINETIC/DIURETIC/SNR 360 674 1034
INHIBITOR/CHOLINERGIC/URINARY
INCONTINENCE (Tetrabenazine, Metolazone(36),
Milnacipran HCl, Levomilnacipran HCl,
Fampyridine, Rivastigmine Hydrogen tartarate ,
Valebenazine, Deutetrabenazine , Propiverine HCl)
9 HYPERTENSION/ANTIHYPERTENSION (Pindolol) 24 111 135

10 PLATELET INHIBITOR (Prasugrel) 12 18 30

11 ANGINA 12 (-)12 0
12 ANTIVIRAL 12 (-)12 0
13 ANTI CARDIOVASCULAR 12 (-)12 0
14 CALCIMIMETIC 24 (-)24 0
15 ERECTILE DYSFUNCTION 12 (-)12 0
16 IRREVERSIBLE INHIBITOR OF MONOAMIDE 12
(-)12 0
OXDASE
17 R & D ACTIVITY & OTHERS (Tolterodine, 240 360 600
Silodosin, Voriconazole, Ezetimibe, Solifenacin,

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Chapter 2 – Project Description
N Product / By product Existing Proposed Total
o Capacity (*) capacity kg/annu
kg/annum kg/annu m
m
Amitriptyline HCl, Pyridostigmine Bromide,
Indapamide, Acetazolamide, Clidinium
bromide)
TOTAL 33180 86850 120030
18 Recovered solvent 120 MTPA 2880 3000
MTPA MTPA
(*)Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023
Total plot area is 9,105m2. The land area utilization is as presented below:
Table 2.3 Land Break-Up of site
Total Area
Sr. No. Description of Activity Remarks
in m2
1 Total Plot area 9105 100%
2 Facility (Building area) 3098.17 34.03%
3 Green belt area 3019.69 33.16%
4 Roads 1885.65 20.71%
5 Parking area 919.4 10.09%
Minor areas left over around plants, tanks &
6 182.1 2%
open structure/ Set back area
7 Existing Built up area 6434.56
8 Proposed Built up Area 6211.65
9 Total Built up Area 12646.21 1.39% FSI
Details of plot area are attached as Annexure 2.1. Detailed plant layout showing
proposed plants, utilities, storage and other is presented overleaf.
Expected project cost is ~ Rs. 90.5 crore.

2.5 Proposed Schedule for Approval & Implementation

It is expected that the project will be executed within 12 – 18 month from date of
Environmental clearance.

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Chapter 2 – Project Description

Figure 2.4Plant Layout

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Chapter 2 – Project Description
2.6 Technology & Process Description, Environmental & Safety
Aspects

The bulk drugs and intermediates are divided in following major categories and groups,

No Description
Category 1 HYPNOTIC / SEDATIVE / TRANQUILIZER / ANXIOLYTIC /
ANTICONVULSANT /ANASTHETIC / ANTIDIABETIC
Group I Nitrazepam, Clonazepam, Bromazepam, Diazepam, Clotiazepam,
Flurazepam Mono hydrochloride, Tetrazepam, Delorazepam, Clobazam,
Phenazepam
Group II Alprazolam, Oxazepam, Lorazepam, Zolpidem Tartrate, Triazolam,
Etizolam, Temazepam
Group III Zopiclone (058)
Group IV Chloridazepoxide, Zaleplon, Sodium Oxybate, Stiriepentol,
Brivaracetam, Empagliflozin, Dapagliflozin, Saxagliptin, Sitagliptin,
Teneligliptin, Linagliptin, Vildagliptin, Chlorodiazepoxide hydrochloride
Group V Midazolam base, Midazolam HCl, Midazolam maleate, Clorazepate Di
Potassium, Brotizolam, Loprazolam Mesilate, Propiomazine Maleate,
Propiomazine HCl, Prazepam, Estazolam, Fludiazepam, Flunitrazepam,
Lormetazepam, Pinazepam, Es-Zopiclone
Category 2 ANTIDEPRESSANT/CNS STIMULANT (Nortriptyline HCl, Melitracen
HCl, Tranylcypromine Sulphate, Amoxapine, Loxapine Succinate,
Loxapine HCl, Methylphenidate HCI, Dixmethylphenidate HCl)
Category 3 ANTIGLUCOMA/ANTIHISTAMINIC (Brimonidine Tartrate, Timolol
Maleate, Dorzoamide HCl, Chloropyramine HCl, Olopatadine HCl)
Category 4 ANTIPROTAZOAL (Nimorazole)
Category 5 ANTIPSYCHOTIC/ANTIPYRETIC/ANTI-INFLAMATORY/ ANALGESIC
/ANTI-ULCER (Rebamipide, Acotiamide HCl Hydrate, Fluphenazine
HCl, Flupentixol, Dihydrochloride, Aripiprazole, Flupentixol Decanoate,
Fluphenazine Decanoate, Asenapine Maleate, Benzydamine HCl USP,
Zuclopentixol Acetate /HCl/Dacanoate, Brexpiperazole Diperoxochloric
Acid Concentrate, Pimavanserin, Mexazolam Quinagolide)
Category 6 ANTIEMETIC (Metopimazine, Nabilone)
Category 7 ANTISPASMODIC/MUSCLE RELAXANT (Chlorzoxazone, Tiemonium
Methyl sulphate, Pitofenone HCl)
Category 8 ANTIDYSKINETIC/DIURETIC/SNR
INHIBITOR/CHOLINERGIC/URINARY INCONTINENCE
(Tetrabenazine, Metolazone(36), Milnacipran HCl, Levomilnacipran
HCl, Fampyridine, Rivastigmine Hydrogen tartarate , Valebenazine,
Deutetrabenazine , Propiverine HCl)
Category 9 HYPERTENSION/ANTIHYPERTENSION (Pindolol)
Category 10 PLATELET INHIBITOR (Prasugrel)

Note: Among each group, single or more product will be manufactured at a time,
depending upon market condition, however total quantity produced shall not exceed
sanctioned quantity.

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Chapter 2 – Project Description
2.6.1 Category I (Hypnotic/Sedative/Tranquilizer/Anxiolytic/Antuconvulsant
/Anasthetic/Antidiabetic)
2.6.1.1 Reaction Chemistry – Group I Nitrazepam

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2.6.1.2 Process Block diagram - Group I (Nitrazepam)
Process flow diagram of Nitrazepam:

2-Amino-5-Nitrobenzophenone

1. Chloro acetyl chloride

Stage - 1 2. Toluene
3. Methanol
4. Potable water

2-Chloroacetamido-5-Nitrobenzophenone

1. Hexamine
Stage - 2 2. Ethanol
3. Potable water

Hexamine Complex of Nitrazepam

1. Ammonium Chloride
Stage - 3 2. Na-EDTA
3. Potable Water

Nitrazepam crude

Stage - 4 1. Methanol
2. Activated Carbon

Nitrazepam Final

2.6.1.3 Process Description – Group I (Nitrazipam)

Nitrazepam is manufactured in four stages.

Stage 1: Preparation of 2-Chloroacetamido, 5-Nitrobenzophenone.

2-Amino, 5-Nitrobenzophenone is treated with Chloro acetyl chloride (CAC) in toluene

& stirred for 30 – 40 min. The reaction mixture is then heated at 60-65 ºC & stirred for
3-4 hours. Completion of reaction is monitored by TLC. After completion of TLC, cooling
followed by chilling is applied to reactor and chilled reaction mixture at 0 to 5 ºC and
maintained for 2-3 hours. Crystallized product is isolated by filtration. Filtered wet
product is centrifuged using potable water and then dried.

Stage 2: Preparation of Hexaminium complex of Nitrazepam.

2-chloroacetamido, 5-nitrobenzophenone is treated with hexamine in alcoholic medium

at reflux temperature. The reaction completion is tested by TLC. The product is isolated
by filtration at lower temperature followed by potable water washing.

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Stage-3: Preparation of Nitrazepam crude.

Hexaminium complex of Nitrazepam is treated with ammonium chloride in Methanol at

reflux temperature for 10-12 hours. The completion of reaction is tested by TLC. After
completion of the reaction the product is isolated by filtration at lower temperature,
followed by potable water wash & then dried in Rotocone vacuum dryer.

Stage-4: Preparation of Nitrazepam Final.

Nitrazepam crude is dissolved in Methanol at reflux temperature & treated with

activated carbon. The solution is passed through sparkler filter & the filtrate is
concentrated & product isolated by filtration at lower temperature. The product is dried
in Rotocone vacuum dryer.
2.6.1.4 Material balance – Group I (Nitrazipam)
Input Ouput Losses
Proudct Effluent
Quantity Theoretica Spent Air Consumed Remark
Name Mol. Wt. Density Qty in kg Name 2nd Crop Residue Generatio
in kg l Yield Carbon Emission in reaction
n
(A) HYPNOTIC/SEDATIVE/TRANQUILIZER/ANXIOLYTIC/ANTICONVULSANT/ANASTHETIC (GROUP-I)
2-Amino,5-Nitrobenzophenone 242.23 1 200 2-Amino,5-Nitrobenzophenone Converted into Chloroacetamido-5-nitrobenzophenone
Chloroacetyl chloride 112.94 1 100 Chloroacetyl chloride 65.7 Consumed in reaction
2-Chloroacetamido, 5-Nitrobenzophenone 304.5 1 240 2-Chloroacetamido-5-nitrobenzophenone 240 263 0 23 Converted into Hexaminium Complex of Nitrazepam. Residue send for disposal to ETP
Hexamine 140.9 1 288 Hexamine 182 Dissolve in water & Send for disposal to ETP
N Hexaminium complex of Nitrazepam 393.27 1 195 Hexaminium complex of Nitrazepam 195 295 0 100 Converted to Nitrazepam Crude. Residue send for disposal to ETP
I Ammonium chloride 53.49 1 780 Ammonium chloride 780 Dissolve in water & Send for disposal to ETP
T Nitrazepam crude 281.27 1 120 Nitrazepam crude 120 168 0 48 Converted to Nitrazepam final. Residue send for disposal to ETP
R Toluene 92.14 0.86 877.2 Toluene 859.7 17.5 Solvent vapour scrub through scrubber
A
Methanol 32.04 0.79 8018.5 Methanol 7617.6 400.9 Solvent vapour scrub through scrubber
Z
E Potable water 18 1 11240 Potable water 11240 Send for disposal to ETP
P Ethanol 46 0.79 883.68 Ethanol 839.5 44.2 Solvent vapour scrub through scrubber
A Na-EDTA 372.24 1 0.18 Na-EDTA 0.18 Dissolve in water & Send for disposal to ETP
M Activated carbon 12 1 6 Activated carbon 6 Spent carbon send for disposal to TTCWMA
Byproducts 49.34 Send for disposal to ETP
Nitrazepam Final 105 120 15 Residue send for disposal to TTCWMA
TOTAL 9976.727 0 186 6 462.653 12251.52 65.7
TOTAL 22948.6 GRAND TOTAL 22948.6

2.6.1.5 Reaction Chemistry – Group II (Lorazepam)

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H H
O
N O
Acetic Acid/Acetic Anhy dride N
OCOCH 3
Cl N
O Cl N
Cl
Cl

7-Chloro-5-(2-chloropheny l)-1H,3H-benzo(f)-1,4 7-Chloro-5-(2-chloropheny l)-1,3-dihy dro-3-acetox y

-diazepine-2-one-4-ox ide -2H-1,4-Benzodiazepin-2-one.
(CBDO) (Acetyl Lorazepam)

Methanol/NaOH
Acetic acid

H Acetone H
O O
N
N Activ ated carbon
OH OH

N Cl N
Cl

Cl Cl

(+)-7-Chloro-5-(o-chloropheny l)-1,3-dihy dro-3 (+)-7-Chloro-5-(o-chloropheny l)-1,3-dihy dro-3

-hy drox y -2H-1,4-benzodiazepin-2-one -hy drox y -2H-1,4-benzodiazepin-2-one
(LORAZEPAM PURE) (LORAZEPAM CRUDE)

Cyclohexane

H
O
N

OH
Cl N

Cl

(+)-7-Chloro-5-(o-chloropheny l)-1,3-dihy dro-3

-hy drox y -2H-1,4-benzodiazepin-2-one
(LORAZEPAM FINAL)

2.6.1.6 Process Block diagram - Group II (Lorazepam)

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Process flow diagram of Lorazepam: Chapter 2 – Project Description

DICHLORO PHENYL BENZOXIDE (CBDO)

1. Acetic acid
STAGE-1 2. Acetic anhydride
3. Potable water

ACETYL LORAZEPAM

1. Methanol
2. Sodium Hydroxide
STAGE-2
3. Acetic acid
4. Potable Water
5. Na-EDTA

LORAZEPAM CRUDE

1. Acetone
STAGE-3
2. Activated Carbon
LORAZEPAM PURE

1. Cyclohexane
STAGE-4

LORAZEPAM FINAL

2.6.1.7 Process Description – Group II (Lorazepam)

Lorazepam is manufactured in four stages.

Stage-1: Preparation of Acetyl Lorazepam.

7-chloro-5- (2-chlorophenyl)-1h, 3h-benzo(f)- 1,4 -diazepine- 2-one - 4-oxide (CBDO) in
acetic acid is treated with acetic anhydride at elevated temperature. Reaction
completion is tested by TLC. After completion of reaction, product is isolated by
filtration at lower temperature & dried.

Stage-2: Preparation of Lorazepam Crude.

Acetyl Lorazepam is hydrolyzed with sodium hydroxide in alcoholic medium at lower
temperature gives Lorazepam crude. The reaction completion is tested by TLC. After
completion of reaction, pH is adjusted to neutral by acetic acid and then crystallized
product is isolated by filtration and dried.

Stage-3: Preparation of Lorazepam Pure.

Lorazepam crude is dissolved in refluxing acetone & treated with activated carbon. The
solution is passed through sparkler filter; the filtrate is concentrated & chilled to 0-5C.
The product is filtered, washed with chilled acetone & dried.

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Stage-4: Preparation of Lorazepam Final.
Lorazepam purified from acetone is refluxed in Cyclohexane with slow distillation of
solvent for 12-14 hrs. The suspension is cooled & product is filtered & Wet Lorazepam
final initially dried at 25-35 ºC for 1 ½ -2 hours under vacuum then at 40-50 ºC for 4-5
hours under vacuum. Semidried product is then unloaded and pulverized through 1 mm
mesh. Pulverized product is again charged to dryer and dried at 50-60 ºC for 4-5 hours
under vacuum.

2.6.1.8 Material balance – Group II (Lorazepam)

Input Ouput Losses
Proudct Theoreti Spent Air Effluent Consume Remark
Mol. Densit Qty in Quantit
Name Name cal 2nd Crop Residue Carbo Emissio Generatio d in
Wt. y kg y in kg
Yield n n n reaction
(A) HYPNOTIC/SEDATIVE/TRANQUILIZER/ANXIOLYTIC/ANTICONVULSANT/ANASTHETIC (GROUP-II)
Dichlorophenyl Benzoxide 321.2 1 100 Dichlorophenyl Benzoxide Converted to Acetyl Lorazepam
Sodium Hydroxide 40 1 17 Sodium Hydroxide 17 Dissolve in water & send to ETP
Sodium EDTA 372.24 1 0.05 Sodium EDTA 0.05 Dissolve in water & send to ETP
Converted to Lorazepam Crude & residue sent to
Acetyl Lorazepam 1 85 Acetyl Lorazepam 85 113 0 28
363 ETP for disposal
Lorazepam Crude 321.2 1 78 Lorazepam Crude 78 96.06 0 0 Converted to Lorazepam Pure
Lorazepam Pure 321.2 1 73 Lorazepam Pure 73 78 5 0 Converted to Lorazepam Final
L
Activated carbon 12 1 4 Activated carbon 4 Spent carbon send to TTCWMA for disposal
O
Acetic Acid (Also as
R Acetic Acid 1.045 586.56 605.36 Dissolve in water & send to ETP
60.09 byproduct)
A Acetic Anhydride 102.09 1.08 108 Acetic Anhydride 76.2 Consumed in reaction
Z Potable water 18 1 1894 Potable water 1894 Consumed in reaction
E Purified water 18 1 800 Purified water 800 Consumed in reaction
P Solvent recovery and Solvent vapour scrub through
Methanol 0.79 556.95 Methanol 529.10 27.85
A 32.04 scrubber
M Solvent recovery and Solvent vapour scrub through
Acetone 0.78 643.5 Acetone
58.08 611.33 32.18 scrubber
Solvent recovery and Solvent vapour scrub through
Cyclohexane 0.77 1181.95 Cyclohexane
84.16 1158.31 23.64 scrubber
Byproducts 7 Send to ETP for disposal
Lorazepam Final 67 73 0 6 Residue send to ETP for disposal
TOTAL 2601.74 5 41 4 83.66 3392.61 0
TOTAL 6128.01 GRAND TOTAL 6128.01

2.6.1.9 Reaction Chemistry – Group III (Zopiclone)

. HCl

N-methyl piperazinyl carbonyl chloride

Hydrochloride (ACID CHLORIDE)
6-(5-Chloropyrid-2-yl)-7-oxo-6,7-dihydro-5H-
Molecular Weight = 199.08
pyrrolo [3, 4-b] pyrazine-5-one.
Molecular Formula = C6H11ClN2O . HCl
(IMINO ALCOHOL)
Molecular Weight = 262.66 MDC
Molecular Formula = C11H7ClN4O2 Triethyl amine
Dimethylaminopyridine
Ammonia
purified w ater

(5RS)-6-(5-Chloropyridin-2-yl)-7-oxo-6,7-dihydro-5H-pyrrolo [3,4-
b]pyrazin-5-yl-4-methyl piperazine-1-carboxylate [Zopiclone
crude]
Molecular Weight = 388.82
Molecular Formula = C17H17ClN6O3

Ethyl acetate
Activated carbon

Isopropyl alcohol

ZOPICLONE FINAL

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2.6.1.10 Process Block diagram - Group III (Zopiclone)
PROCESS FLOW DIAGRAM OF ZOPICLONE:

IMIDOL
1. Methylene chloride OR DCM (Fresh / Distilled)
2. N-methyl piperazinyl carbonyl chloride HCl (Acid
chloride)
3. Triethylamine
Stage - 1
4. Dimethyl amino Pyridine
5. Ammonia
6. Activated carbon
7. IPA
8. Potable water

ZOPICLONE CRUDE

Stage - 2 1. Ethyl Acetate

2. Activated Charcoal

ZOPICLONE PURE
Stage - 3 1. Isopropyl Alcohol (IPA)

ZOPICLONE FINAL

2.6.1.11 Process Description – Group III (Zopiclone)

Zopiclone is manufactured in three stages:

Stage-1: Preparation of Zopiclone crude:

Imidol is treated with N-methyl piperazinyl carbonyl chloride HCl using triethylamine
as a base & Dimethylamino pyridine as a catalyst in methylene chloride. Resulting
reaction mixture is maintained at reflux temperature for 1 ½ -2 hours and completion
of reaction is monitored by TLC. Converted product is isolated by centrifugation & then
dried.

Stage-2: Preparation of Zopiclone pure:

Zopiclone crude is dissolved in refluxing ethyl acetate & treated with activated carbon.
The solution is passed through filter press. The solution is checked for clarity. The
filtrate is concentrated & chilled to lower temperature & isolated by filtration & then
dried in Rotocone vacuum dryer under vacuum.

Stage-3: Preparation of Zopiclone final:

Zopiclone pure is sludged in filtered Isopropanol at reflux temperature. The reaction
mixture is cooled to room temperature & isolated by filtration & then dried in Rotocone
vacuum dryer under vacuum.

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2.6.1.12 Material balance – Group III (Zopiclone)

Input Ouput Losses

Proudct Theoreti Spent Air Effluent Consume Remark
Mol. Densit Quantity 2nd Residu
Name Qty in kg Name cal Carbo Emissio Generatio d in
Wt. y in kg Crop e
Yield n n n reaction
(A) HYPNOTIC/SEDATIVE/TRANQUILIZER/ANXIOLYTIC/ANTICONVULSANT/ANASTHETIC (GROUP-III)
Imino Alcohol (Imidol) 262.65 1 125 Imino Alcohol (Imidol) Converted to Zopiclone Crude

N-Methyl piperazinyl carbonyl N-Methyl piperazinyl carbonyl

1 125 30 Consumed in reaction
chloride HCl (Acid Chloride) chloride HCl (Acid Chloride)
199.08
Dimethylamino pyridine (4-DMAP)122.17 1 4.4 Dimethylamino pyridine (4-DMAP) 4.4 Dissolve in water & send to ETP
Activated carbon 12 1 12 Activated carbon 12 Spent carbon send to TTCWMA for disposal
Z Converted to Zopiclone Pure & residue sent to ETP
Zopiclone Crude 1 175 Zopiclone Crude 175 185 0 10
388.82 for disposal
O
Converted to Zopiclone Final & residue sent to ETP
P Zopiclone Pure
388.82
1 120 Zopiclone Pure 120 175 0 55
for disposal
I Ammonia 17 0.91 56.42 Ammonia 56.42 Dissolve in water & send to ETP
C Isopropyl Alcohol (IPA) 60.09 0.79 444.6 Isopropyl Alcohol (IPA) 422.37 22.23 Dissolve in water & send to ETP
L Triethylamine 101.09 0.72 151.2 Triethylamine 151.2 Dissolve in water & send to ETP
O Solvent recovery and Solvent vapour scrub through
Methylene Chloride (MDC) 1.33 2292.25 Methylene Chloride (MDC) 2177.638 114.61
N 84.93 scrubber
E Ethyl Acetate 0.9 2281.5 Ethyl Acetate 2167.425 114.08
Solvent recovery and Solvent vapour scrub through
88.1 scrubber
Potable water 18 1 4335 Potable water 4335 Send to ETP
Byproducts 0 35 Send to ETP for disposal
Zopiclone Final 115 120 0 5 Residue sent to ETP for disposal
TOTAL 5177.43 0 70 12 250.92 4607.62 4.4
TOTAL 10122.37 GRAND TOTAL 10122.37

2.6.1.13 Reaction Chemistry – Group IV (Zapeplon)

2.6.1.14 Process Block diagram - Group IV (Zaleplon)

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Process flow diagram of Zaleplon:
Chapter 2 – Project Description

DOPEA

1. Methanol
STAGE-1 2. Para chloro aniline
3. Conc. HCl

PC-OPEA

1. Acetic Acid
2. Diazole (3-Amino pyrazole-4-
STAGE-2 carbonitrile)
3. Conc. HCl
4. Potable Water

ZALEPLON CRUDE

1. Methanol
STAGE-3
2. Activated Carbon
ZALEPLON PURE

1. Methanol
STAGE-4 2. Activated carbon

ZALEPLON FINAL

2.6.1.15 Process Description – Group IV (Zaleplon)

Zaleplon is manufactured in four stages.

Stage 1: Preparation of PC-OPEA

DOPEA is reacted with Parachloroaniline, in methanol in presence of Hydrochloric acid.
The reaction is monitored by TLC. After completion of reaction the product is isolated
by filtration and dried to obtain PC-OPEA.

Stage - 2: Preparation of Zaleplon Crude

PC-OPEA is reacted with 3-Aminopyrazole-4-carbonitrile in acetic acid water mixture.
The reaction is monitored by TLC. After completion of reaction the reaction mixture is
worked up and Zaleplon crude is filtered washed & dried to obtain Zaleplon crude.

Stage-3: Preparation of Zaleplon Pure.

Zaleplon crude is dissolved in refluxing methanol and treated with activated carbon.
The solution is filtered. The filtered solution is concentrated and product is isolated by
filtration. The moist product is taken for preparation of Zaleplon Final.

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Stage-4: Preparation of Zaleplon Final.
Zaleplon pure (Moist) is dissolved in refluxing methanol and treated with activated
carbon. The solution is filtered. The filtered solution is concentrated and product is
filtered, washed & dried. The product is passed through suitable mill.

2.6.1.16 Material balance – Group IV (Zaleplon)

Input Ouput Losses
Proudct Spent Air Effluent Consume Remark
Mol. Densit Quantit Theoreti
Residu 2nd
Name Qty in kg
Name Carbo Emissio Generati d in
Wt. y y in kg cal Yield
e Crop
n n on reaction
(A) HYPNOTIC/SEDATIVE/TRANQUILIZER/ANXIOLYTIC/ANTICONVULSANT/ANASTHETIC (GROUP-IV)
DOPEA 260 1 90 DOPEA Converted to PC-OPEA
Parachloroaniline 127.5 1 52.5 Parachloroaniline 8.3 Converted to PC-OPEA
Converted to Zaleplon Crude & residue sent to ETP for
1 109.5 PC-OPEA 109.5
PC-OPEA 342.5 118.55 0 9.05 disposal
Diazole Compound144.5 1 62 Diazole Compound 27 Consumed in reaction
Z Converted to Zaleplon Pure & residue sent to ETP for
Zaleplon Crude 1 75 Zaleplon Crude 75 97.61 0 22.61
A 305.34 disposal
L Converted to Zaleplon Final & residue sent to ETP for
Zaleplon Pure 1 67.5 Zaleplon Pure 67.5 75 0 7.5
305.34 disposal
E
Activated Carbon 12 1 7.5 Activated Carbon 7.5 Spent carbon sent to TTCWMA for disposal
P
Methanol 32.04 0.79 1994.75 Methanol 1895.01 99.74 Solvent recovery and Solvent vapour scrub through scrubber
L
Hydrochloric Acid 36.5 1.13 266.68 Hydrochloric Acid 266.68 Dissolve in water & send to ETP
O
Acetic Acid 60.05 1.045 534.56 Acetic Acid 534.56 Dissolve in water & send to ETP
N
Potable water 18 1 3404 Potable water 3404 Send to ETP for disposal
Byproducts 0 62.54 Send to ETP for disposal
Zaleplon Final 54 67.5 0 13.5 Residue sent to ETP for disposal
TOTAL 2201.01 0 52.66 7.5 99.74 4303.08 0
TOTAL 6663.99 GRAND TOTAL 6663.99

2.6.1.17 Reaction Chemistry – GroupV (Midazolam HCl)

2.6.1.18 Process Block diagram - Group V (Midazolam HCl)

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PROCESS FLOW DIAGRAM OF MIDAZOLAM HCl:

MIDAZOLAM BASE FINAL

Di isopropyl ether
1.
HCl
Stage - 1 2. Ethyl Acetate
3. Isopropyl Alcohol
4. Methanol
5. Acetone

MIDAZOLAM HCl FINAL

2.6.1.19 Process Description – Group V (Midazolam HCl)

Brief Manufacturing process

Preperation of Midazolam HCl

Midazolam Base final is dissolved in Ethyl acetate at 55-60 Deg C. The clear solution of
base in ethyl acetate solution is filtered through filter press at 55 – 60- deg C. Clear
filtrate obtained is treated with Di isopropyl ether (DIPE-HCl) below 30 deg C.
Precipitated product is isolated by filtration. Wet product is slurried in IPA followed by
isolation and under vacuum drying at elevated temperature in RVD. Dried product is
further dissolved in filtered methanol at 25-30 deg C. Clear solution is heated and
methanol removed completely by vacuum distillation. Degassed mas is further sludged
in acetone at reflux temperature and subsequently cooled to room temperatre, filtered
dried and milled to obtain final Midazolam HCl.
2.6.1.20 Material balance – Group V (Midazolam HCl)
Input Ouput Losses
Proudct Effluent Consume Remark
Quantity Theoreti Spent Air
Name Mol. Wt. Density Qty in kg Name 2nd Crop Residue Generatio d in
in kg cal Yield Carbon Emission
n reaction
(A) HYPNOTIC/SEDATIVE/TRANQUILIZER/ANXIOLYTIC/ANTICONVULSANT/ANASTHETIC (GROUP-V)

M Midazolam base 1 6 Midazolam base Converted to Midazolam HCl

325.78
I
D Ethyl Acetate 88.10 0.9 80.10 Ethyl Acetate 76.90 3.2 Solvent recovery and Solvent vapour scrub through scrubber
A Di-isopropyl
Di-isopropyl Ether
Z Ether HCl 36.5 1.09 10.46 9.78 Consumed in reaction
HCl (DIPE.HCl)
O (DIPE.HCl)
L Isopropyl
60.05 0.78 42.12 Isopropyl Alcohol (IPA) 40.01 2.11 Solvent recovery and Solvent vapour scrub through scrubber
A Alcohol (IPA)
M Methanol 32.04 0.79 31.6 Methanol 30.02 1.58 Solvent recovery and Solvent vapour scrub through scrubber
Acetone 58.08 0.78 28.08 Acetone 26.68 1.40 Solvent recovery and Solvent vapour scrub through scrubber
H
Midazolam HCl Final 5.5 6.68 0 1.18 Residue sent to ETP for disposal
C
TOTAL 179.11 0 1.18 0 8.29 0 9.78
l
TOTAL 198.36 GRAND TOTAL 198.36

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Chapter 2 – Project Description
2.6.2 Category II (Antidepresant / CNS Stimulant)
2.6.2.1 Reaction Chemistry – TRANYLCYPROMINE SULPHATE

ROS OF TRANYL CYPROMINE SULPHATE

Molecular Formula-C 8H 8O
Molecular Weight-120.15

Sty rene Oxide

Triethy lphosphonoacetate
N,N-Dimethy lf ormamide
Sodium hy dride
Methanol, Acetic acid

H
Hy drazine hy drate 80%
Toluene
Water NH 2
OEt

Stage-1
Trans-2-Pheny lcy clopropanecarbohy drazide

(RAN Hy drazide)
Trans-Ethy l-2-pheny lcy clopropanecarboxy late
Molecular Formula-C 10H 12N 2O
(insitu)
Molecular Weight- 176.22

Sodium nitrite
Stage-2
Hy drochloric acid

Toluene

Sodium hy droxide
Toluene

Stage-2
Tranylcypromine hydrochloride

Tranylcypromine Base (insitu)

(insitu)

Toluene
Stage-2
Methanol
Sulphuric Acid

Methanol
Potable Water . H 2SO4
. H 2SO4

Stage-3
2
2 Tranylcypromine sulfate Pure
Tranylcypromine sulfate crude Molecular Formula-(C 9H 11N)2 . H 2SO4
Molecular Formula-(C 9H 11N)2 . H 2SO4 Molecular Weight- 364.5
Molecular Weight- 364.5
Stage-4 Methanol

. H 2SO4

2
Tranylcypromine sulfate Final
Molecular Formula-(C 9H 11N)2 . H 2SO4
Molecular Weight- 364.5

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2.6.2.2 Process Block
PROCESSdiagram - TRANYLCYPROMINE
FLOW DIAGRAM SULPHATE
OF TRANYLCYPROMINE SULPHATE:

STYRENE OXIDE

1. Triethyl Phosphonoacetate
2. N,N-Dimethylformamide (DMF)
Stage - 1 3. Sodium Hydride
4. Methanol
5. Acetic Acid
6. Hydrazine Hydrate (80 %)
7. Toluene
8. Potable Water

RAN HYDRAZIDE

1. Sodium Nitrite
2. Hydrochloric Acid
3. Toluene
Stage- 2 4. Sodium Hydroxide
5. Methanol
6. Sulphuric Acid

TRANYLCYPROMINE SULPHATE CRUDE

1. Methanol
Stage- 3
2. Potable Water

TRANYLCYPROMINE SULPHATE PURE

Stage- 4 1. Methanol

TRANYLCYPROMINE SULPHATE FINAL

2.6.2.3 Process Description – TRANYLCYPROMINE SULPHATE

Tranylcypromine Sulphate is manufactured in four stages.

Stage 1: Preparation of RAN Hydrazide

Styrene oxide is reacted with tri ethyl phosphor acetate (APET) in presence of DMF at
higher temperature. After completion of maintaining, add methanol and adjust the pH to
neutral at lower temperature. Further reaction mixture is reacted with 80 % hydrazine
hydrate at higher temperature. Reaction progress is monitored by TLC. After
completion reaction, the product is isolated at lower temperature by adding water and
toluene followed by water slurry to get RAN Hydrazide. Use wet product for next stage.

Stage - 2: Preparation of Tranylcypromine Sulphate Crude

Raw hydrazide is diazotized using hydrochloric acid and sodium nitrite. After
completion of diazotization the mixture is reacted with hydrochloric acid and toluene.
Reaction is monitored by TLC. After completion of reation,the layer is separated. pH of
aquaeous layer is adjusted using sodium hydroxide solution, the layer is extracted with

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toluene. pH of toluene layer is then adjusted using sulphuric acid to give
Tranylcypromine Sulphate Crude. The product is isolated by filtration.

Stage-3: Preparation of Tranylcypromine Sulphate Pure

Tranylcypromine Sulphate Crude is purified using potable water and and methanol to
get Tranylcypromine Sulphate pure.

Stage-4: Preparation of Tranylcypromine Sulphate final

Tranylcypromine Sulphate pure is sludged in methanol to get Tranylcypromine
Sulphate final product.
2.6.2.4 Material balance – TRANYLCYPROMINE SULPHATE

Input Ouput Losses

Proudct Effluent Consume Remark
Quantity Theoreti Spent Air
Name Mol. Wt. Density Qty in kg Name 2nd Crop Residue Generatio d in
in kg cal Yield Carbon Emission
n reaction
(B) ANTIDEPRESSANT/CNS STIMULANT
Styrene Oxide 120.15 1 28 Styrene Oxide Converted to RAN Hydrazide
Sodium Hydride 24 1 10 Sodium Hydride 10 Consumed in reaction
Triethyl phosphono acetate
224.19 1.13 63.28 Triethyl phosphono acetate 63.28 Consumed in reaction
Converted to Tranylcypromine
T RAN Hydrazide 176.22 1 31 RAN Hydrazide 31 41 0 10 Sulfate Crude & residue sent to
ETP for disposal
R
Sodium Nitrite 69 1 13.5 Sodium Nitrite 13.5 Consumed in reaction
A
Disolve in water & send to ETP
N Sodium Hydroxide 40 1 24.8 Sodium Hydroxide 24.8
for disposal
Y Hyflow Supercell -- 1 3 Hyflow Supercell 3 Sent to TTCWMA for disposal
L Tranylcypromine Converted to Tranylcypromine
364.46 1 18 Tranylcypromine Sulfate Crude 18 64.11 0
C Sulfate Crude Sulfate Pure
Y Converted to Tranylcypromine
Tranylcypromine
P 364.46 1 16 Tranylcypromine Sulfate Pure 16 18 0 2 Sulfate Final & residue sent to
Sulfate Pure
ETP for disposal
R
Solvent recovery and Solvent
O Toluene 92.14 0.86 362.06 Toluene 354.82 7.24
vapour scrub through scrubber
M Dimethyl Formamide Disolve in water & send to ETP
73.09 1.1 123.2 Dimethyl Formamide (DMF) 123.20
I (DMF) for disposal
N 80 % Hydrazine
50.06 1.02 92.82 80 % Hydrazine Hydrate solution 73.58 Consumed in reaction
Hydrate solution
E
Solvent recovery and Solvent
Methanol 32.04 0.79 271.76 Methanol 258.17 13.59
vapour scrub through scrubber
S Disolve in water & send to ETP
Acetic Acid 60.04 1.045 2.91 Acetic Acid 2.91
U for disposal
L Disolve in water & send to ETP
Hydrochloric Acid 36.5 1.13 68.03 Hydrochloric Acid 68.03
F for disposal
Disolve in water & send to ETP
A Sulphuric Acid 98.08 1.84 4.42 Sulphuric Acid 4.42
for disposal
T Potable water 18 1 1070 Potable water 1070 Send to ETP for disposal
E Byproducts 19.24 Send to ETP for disposal

Tranylcypromine Sulfate Final 10.5 16 0 5.5 Residue send to ETP for disposal

TOTAL 688.49 0 17.5 3 20.83 1386.18 86.78

TOTAL 2202.78 GRAND TOTAL 2202.78

2.6.3 Category III (ANTIGLUCOMA/ANTIHISTAMINIC)

2.6.3.1 Reaction Chemistry – Chloropyramine HCl

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3
.
2 2 5
3

Chloropyridylethylm ine Dim ethylam inoethylchloride hydrochloride

Toluene
Potassium hydroxide (pow der)
Sodium hydroxide
DMSO
Potassium carbonate
Sodium carbonate
Acetic acid
Potable w ater

Chloropyram ine Base

IPA
Activated carbon
Isopropanolic HCl

IPA
Activated carbon
Acetone
. .

N-[(4-chlorophenyl)methyl]-N',N'-dimethyl-N-(2-pyridyl)
Chloropyram ine HCl crude ethane-1,2-diamine hydrochloride.
Chloropyram ine HCl final
Molecular Weight : 326.28(1)
Molecular Form ula : C16H20ClN3.ClH

2.6.3.2 Process Block diagram – Chloropyramine HCl

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PROCESS FLOW DIAGRAM OF CHLOROPYRAMINE HCl:

CHLOROPYRIDYL ETHYLAMINE

1. Diethyl amino ethyl chloride HCl

2. Toluene
3. Potassium Hydroxide powder
4. Dimethyl Sulphoxide (DMSO)
Stage - 1 5. Potassium carbonate
6. Sodium Hydroxide
7. Sodium carbonate
8. Acetic acid
9. Potable water

CHLOROPYRAMINE BASE
1. Isopropyl Alcohol (IPA)
Stage - 2 2. Isopropanolic HCl (IPA-HCl)

CHLOROPYRAMINE HCl CRUDE

Stage - 3 1. Isopropyl Alcohol (IPA)

2. Activated carbon
3. Acetone

CHLOROPYRAMINE HCl FINAL

2.6.3.3 Process Description – Chloropyramine HCl

Brief Manufacturing Process

Chloropyramine HCl is manufactured in three stages:

Stage - 1: Preparation of Chloropyramine base:

Chloropyridylethylamine is treated with Dimethylamino propyl chloride base in
presence of KOH powder in toluene / DMSO solvent to obtain Chloropyramine base.

Stage - 2: Preparation of Chloropyramine HCl crude:

Chloropyramine base dissolved in Isopropyl alcohol & treated with activated carbon.
The solution is filtered through sparkler filter press to obtain the clear filtrate. Filtrate
was checked for clarity and then treated with Isopropanolic HCl to get the
Chloropyramine Hydrochloride crude.

Stage-3: Preparation of Chloropyramine HCl Final:

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Chloropyramine hydrochloride crude is dissolved in IPA & treated with activated
carbon. The solution is filtered through sparkler filter. Filtrate is checked for clarity. IPA
is distilled off; filtered acetone is added, partially distilled. The product is isolated by
filtration & dried.

2.6.3.4 Material balance – Chloropyramine HCl

Input Ouput Losses
Proudct Theoreti Spent Air Effluent Consume Remark
Mol. Densit Qty in Quantit 2nd Residu
Name Name cal Carbo Emissio Generatio d in
Wt. y kg y in kg Crop e
Yield n n n reaction
(C) ANTIGLUCOMA/ANTIHISTAMINIC
Chloropyridyl
1 40 Chloropyridyl ethylamine Converted to Chloropyramine Base
ethylamine 218.5
Potassium Hydroxide Potassium Hydroxide
1 80 80 Disolve in water & send to ETP for disposal
(Powder) 56.11 (Powder)
Dimethylaminoethyl Dimethylaminoethyl chloride
1 80 61.6 Consumed in reaction
chloride HCl (DMC.HCl) HCl (DMC.HCl)
144.05
C
Sodium Hydroxide 40 1 28 Sodium Hydroxide 28 Disolve in water & send to ETP for disposal
H
Potassium carbonate 138.2 1 56 Potassium carbonate 56 Disolve in water & send to ETP for disposal
L
Sodium carbonate 105.99 1 4 Sodium carbonate 4 Disolve in water & send to ETP for disposal
O
Silica gel -- 1 8 Silica gel 8 Send to ETP for disposal
R
Activated carbon 12 1 7 Activated carbon 7 Sent to TTCWMA for disposal
O
Hyflow Supercell -- 1 4 Hyflow Supercell 4 Sent to TTCWMA for disposal
P
Converted to Chloropyramine HCl crude & residue
Y Chloropyramine base 1 44 Chloropyramine base 44.00 53 0 9
289.8 sent to ETP for disposal
R Chloropyramine HCl Converted to Chloropyramine HCl Final & residue
1 36 Chloropyramine HCl Crude 36.00 49.4 2.5 10.9
A Crude 326.3 sent to ETP for disposal
M Dimethyl Sulphoxide Dimethyl Sulphoxide
1.1 22 22.00 Disolve in water & send to ETP for disposal
(DMSO) 78.13 (DMSO)
I
Solvent recovery and Solvent vapour scrub through
N Toluene
92.14
0.86 597.7 Toluene 585.75 11.95
scrubber
E Acetic Acid 60.05 1.045 4.99 Acetic Acid 4.99 Disolve in water & send to ETP for disposal
Solvent recovery and Solvent vapour scrub through
H Isopropanol 0.78 358.8 Isopropanol 333.68 25.12
60.1 scrubber
C Isopropanolic HCl 36.5 0.9 26.1 Isopropanolic HCl 26.1 Consumed in reaction
l Solvent recovery and Solvent vapour scrub through
Acetone 0.78 171.6 Acetone 154.44 17.16
58.08 scrubber
Potable Water 18 1 1428 Potable Water 1428 Send to ETP

Chloropyramine HCl Final 30 36 5.88 0.12 Residue send to ETP for disposal

TOTAL 1183.87 8.38 20.02 19 54.23 1622.99 87.7

TOTAL 2996.19 GRAND TOTAL 2996.19

2.6.4 Category IV (ANTIPROTAZOAL)

2.6.4.1 Reaction Chemistry – Nimorazole

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Cl

. HCl
N

O
4-(2-Chloroethyl)morpholine Hydrochloride
Mol For: C 6H 12ClNO.HCl
Mol Wt: 186.08
NaOH
Water

Cl

N N
O
H
N

O
O

4(5)-Nitroimidazole 4-(2-Chloroethy l)morpholine

Mol For: C 3H 3N 3O2 Mol For: C 6H 12ClNO
Mol Wt: 113.07 Mol Wt: 149.6

T ol uene/ DM F
Potassium carbonate

Maleic acid / Methanol

Water/ Ammonia

Activ ated carbon

N
O
N

O
N

O
Nimorazole pure
Mol For: C 9H 14N 4O3

Mol Wt: 226.23

Isopropy l alcohol
Activ ated carbon

Nim or azole final

2.6.4.2 Process Block diagram – Nimorazole

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PROCESS FLOW DIAGRAM OF NIMORAZOLE: Chapter 2 – Project Description

4(5)-NITROIMIDAZOLE

4-(2-Chloroethyl)morpholine
1.
hydrochloride
2. Sodium Hydroxide
3. Potable Water
Stage - 1 4. Toluene
5. Dimethyl Formamide
6. Potassium carbonate
7. Maleic Acid
8. Methanol
9. Ammonia
10. Activated Carbon

NIMORAZOLE PURE

1. Isopropanol
Stage- 2 2. Activated carbon

NIMORAZOLE FINAL

2.6.4.3 Process Description – Nimorazole

Nimorazole is manufactured in two stages.

Stage 1: Preparation of Nimorazole pure
4(5) – Nitomidazole is reacted with 4-(2-chloroethyl)morpholine in presence of
potassium carbonate in toluene and N,NDimethyl formamide to give Nimorazole crude.
This is further treated insitu with maleic acid in methanol to form maleate salt. This is
puridied and treated with ammonia to give Nimorazole pure.

Stage - 2: Preparation of Nimorazole final

Nimorazole pure is crystallised from isopropyl alcohol to give Nimorazole final

2.6.4.4 Material balance – Nimorazole

Input Ouput Losses

Proudct Effluent Consume Remark
Mol. Densit Quantity Theoreti 2nd Spent Air
Name Qty in kg Name Residue Generatio d in
Wt. y in kg cal Yield Crop Carbon Emission
n reaction
(D) ANTIPROTAZOAL
4(5)-Nitroimidazole 113.07 1 50 4(5)-Nitroimidazole Converted to Nimorazole Pure
4-(2-chloroethyl) morpholine HCl
186.08 1 105 4-(2-chloroethyl) morpholine HCl 38 Consumed in reaction
Sodium Hydroxide 40 1 52.5 Sodium Hydroxide 52.5 Dissolve in water & sent to ETP for disposal
Potassium carbonate 138.2 1 61 Potassium carbonate 61 Dissolve in water & sent to ETP for disposal
Activated carbon 12 1 2.5 Activated carbon 2.5 Spent carbon sent to TTCWMA for disposal
Maleic Acid 116 1 60 Maleic Acid 60 Consumed in reaction
N Hyflow Supercell -- 1 2.5 Hyflow Supercell 2.5 Sent to TTCWMA for disposal
I Converted to Nimorazole Final & residue sent
Nimorazole Pure 1 45 Nimorazole Pure 45.00 100 0 55
M 226.23 to ETP for disposal
O Second Crop (From stage-2) 226.23 1 4 Second Crop (From stage-2) 4 Consumed in reaction
R Solvent recovery and Solvent vapour scrub
Toluene 92.14 0.86 537.5 Toluene 510.63 26.88
through scrubber
A
Dimethyl Formamide (DMF) 73.09 1.1 47 Dimethyl Formamide (DMF) 47 Dissolve in water & sent to ETP for disposal
Z
Solvent recovery and Solvent vapour scrub
O Methanol 32.04 0.79 588.55 Methanol 529.70 58.86
through scrubber
L Ammonia 17.03 0.91 39.13 Ammonia 39.13 Dissolve in water & sent to ETP for disposal
E Solvent recovery and Solvent vapour scrub
Isopropanol (IPA) 60.1 0.78 327.6 Isopropanol (IPA) 311.22 16.38
through scrubber
Potable water 18 1 1095 Potable water 1095 Sent to ETP for disposal
Byproduct 17 Send to ETP for disposal
Nimorazole Final 40 45 4 1 Residue sent to ETP for disposal
TOTAL 1436.54 4 56 5 102.11 1311.63 102
TOTAL 3017.28 GRAND TOTAL 3017.28

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2.6.5 Category V (ANTIPSYCHOTIC/ANTIPYRETIC/ANTI-INFLAMATORY/
ANALGESIC/ANTI-ULCER)
2.6.5.1 Reaction Chemistry – Acotiamide HCl Hydrate

2.6.5.2 Process Block diagram – Acotiamide HCl Hydrate

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2.6.5.3 Process Description – Acotiamide HCl Hydrate

BRIEF MANUFACTURING PROCESS:

Acotiamide HCl Hydrate is manufactured in four stages:
Stage-1: Preparation of IPVAT.
AVPI is reacted with T-Amine, 4-DAMP & Thionyl Chloride in organic solvent. The
progress of the reaction is monitored by TLC. After completion of reaction, product is
isolated by filtration and then dried.
Stage-2: Preparation of HVAT.
IPVAT is reacted with Aluminium chloride in organic solvent. The progress of the
reaction is monitored by TLC. After completion of reaction, Product is isolated by
filtration and then dried.
Stage-3: Preparation of Acotiamide Base.
HVAT is reacted with N,N-Diisopropylethylenediamine (DIPEDA) in organic solvent. The
progress of the reaction is monitored by TLC. After completion of reaction, Product is
isolated by filtrationand then dried.
Stage-4: Preparation of Acotiamide HCl Hydrate.
Acotiamide Base is converted to its hydrochloride salt by using HCl. The precipitated
Product is isolated by filtration and then dried.

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2.6.5.4 Material balance – Acotiamide HCl Hydrate
Input Ouput Losses
Proudct Spent Air Effluent Consum Remark
Quantity Theoreti 2nd Residu
Name Mol. Wt. Density Qty in kg Name Carbo Emissio Generatio ed in
in kg cal Yield Crop e
n n n reaction
(E) ANTIPSYCHOTIC/ANTIPYRETIC/TNTI-INFLAMATORY/ANALGESIC/ANTI-ULCER
AVPI 240.25 1 5.7 AVPI Converted to IPVAT
T-Amine 172.2 1 6.04 T-Amine 1.95 Consumed in reaction
4-DMAP 122.17 1 0.034 4-DMAP 0.034 Consumed in reaction
A
Sodium Bicarbonate 84.01 1 10.48 Sodium Bicarbonate 10.48 Disolve in water & sent to ETP for disposal
C
Thionyl Chloride 118.97 1.64 28.04 Thionyl Chloride 24.87 Consumed in reaction
O
IPVAT 394.44 1 8 IPVAT 8 9.35 0 1.35 Converted to HVAT & residue sent to ETP for disposal
T
Converted to Acotiamide Base & residue sent to ETP
I HVAT 1 4.8 HVAT 4.8 7.14 0 2.34
352.36 for disposal
A Converted to Acotiamide HCl Hydrate & residue sent
Acotiamide base 1 3.6 Acotiamide base 3.6 6.13 0 2.53
M 450.55 to ETP for disposal
I Aluminium Chloride 133.34 1 20.8 Aluminium Chloride 12.16 Disolve in water & sent to ETP for disposal
D DIPEDA (N,N-
DIPEDA (N,N-Diisopropyl
E Diisopropyl ethylene 172.2 0.79 4.12 4.12 Consumed in reaction
ethylene diamine
diamine
Conc. HCl 36.5 1.13 18.6 Conc. HCl 18.6 Disolve in water & sent to ETP for disposal
H
Methylene Chloride Solvent recovery and Solvent vapour scrub through
C 84.93 1.33 349.33 Methylene Chloride (MDC/DCM)314.397 34.933
(MDC/DCM) scrubber
l Solvent recovery and Solvent vapour scrub through
Methanol 32.04 0.79 272.55 Methanol 245.30 27.255
scrubber
H Dimethyl Formamide (DMF)73.09 1.1 8.8 Dimethyl Formamide (DMF) 8.8 Disolve in water & sent to ETP for disposal
Y Isopropanol (IPA) 60.1 0.78 5.62 Isopropanol (IPA) 5.62 Disolve in water & sent to ETP for disposal
D Solvent recovery and Solvent vapour scrub through
Toluene 92.14 0.86 57.62 Toluene
56.468 1.152 scrubber
R
Potable water 18 1 508 Potable water 508 Send to ETP for disposal
A
Purified water 18 1 48.2 Purified water 48.2 Send to ETP for disposal
T
Byproducts 11.08 Send to ETP for disposal
E
Acotiamide HCl Hydrate Final 3.78 4.3 0 0.52 Residue send to ETP for disposal
TOTAL 636.34 0 6.74 0 63.34 622.94 30.974
TOTAL 1360.33 GRAND TOTAL 1360.33

2.6.6 Category VI(ANTIEMETIC)

2.6.6.1 ReactionSYNTHETIC
ChemistryFLOW–SCHEME OF NABILONE:
Nabilone

O
OH

+
HO OH
H3C
CH3
BIL- Diphenol BIL-diene

SnCl4
MDC
H2O

O OH

OH AlCl3 O
MDC
H3C
Ethyl acetate
O CH3 HO

Nabilone crude Hemiketal Nabilone

Ethyl acetate

OH
H

H
O

Nabilone Final

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2.6.6.2 Process Block diagram – Nabilone
PROCESS FLOW DIAGRAM OF NABILONE:

BIL DIPHENOL

1. BIL diene
2. Sodium bicarbonate
Stage - 1 Sodium sulphate
3.
4. Potable water
5. MDC
6. Stannic chloride

HEMIKETAL NABILONE
1. Aluminum chloride
2. Sodium bicarbonate
Stage - 2 3. Sodium Sulphate
4. Potable water
5. MDC
6. Ethyl acetate

NABILONE CRUDE

Stage - 3 1. Ethyl Acetate

NABILONE FINAL

2.6.6.3 Process Description – Nabilone

Nabilone is manufactured in three stages.

Stage 1: Preparation of Hemiketal Nabilone
Bil diphenyl is reacted with Bil diene in presence of SnCL4 using MDC as solvent at lower
temperature to give Hemiketal Nabilone. Reaction between Bil diphenyl and Bil Diene is
monitored by TLC. After completion of the reaction, reaction mixture is quenched in
cold water. Product is extracted in MDC washed with aq. Sodium bi carbonate wash
followedby water. Solvent is distilled out partly Hemiketal is isolated by filtration,
further dried and used for next stage.

Stage - 2: Preparation of Nabilone crude

Hemiketal Nabilone is treated with AlCl3 in MDC at lower temperature to get crude
Nabilone. The reaction is monitored by TLC.After completion of the reaction, reaction
mixture is quenched in clod water. Product is extracted in MDC. The organic layer
washed with sodium bicarbonate followed by water. The solvent is distilled and product
is isolated by adding ethyl acetate. The product filtered, washed with ethyl acetate and
dried.

Stage - 3: Preparation of Nabiline Final

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Crude Nabilone is dissolved in ethyl acetate in hot condition and filtered. The filtrate is
cooled tolower temperature. The product crystallises out. It is filtered washed with
ethyl acetate and further dried.
2.6.6.4 Material balance – Nabilone
Input Ouput Losses
Proudct Effluent Consume Remark
Mol. Quantity Theoreti Spent Air
Name Density Qty in kg Name 2nd Crop Residue Generatio d in
Wt. in kg cal Yield Carbon Emission
n reaction
(F) ANTIEMETIC
BIL Diphenol 236.35 1 3 BIL Diphenol Converted to Hemiketal Nabilone
BIL Diene 168.23 1 4.8 BIL Diene 2.66 Consumed in reaction
Sodium Bicarbonate 84 1 0.5 Sodium Bicarbonate 0.5 Dissolve in water & sent to ETP for disposal
Sodium Sulphate 142.04 1 10 Sodium Sulphate 10 Dissolve in water & sent to ETP for disposal
Stannic Chloride 260.04 2.23 7.36 Stannic Chloride 7.36 Consumed in reaction
Hemiketal Converted to Nabilone Crude & residue sent to ETP for
N 1 2 Hemiketal Nabilone 2 4.7 0 1.7
Nabilone 372.54 disposal
A Aluminium
B 1 2 Aluminium Chloride 2 Sent to TTCWMA for disposal
Chloride 133.34
I Converted to Nabilone Final & residue sent to ETP for
Nabilone crude 1 1.5 Nabilone crude 1.50 2 0 0.5
L 372.54 disposal
O Methylene
Methylene Chloride
Chloride 84.93 1.33 526.03 499.73 26.30 Solvent recovery and Solvent vapour scrub through scrubber
N (MDC/DCM)
(MDC/DCM)
E Ethyl Acetate 88.10 0.9 14.94 Ethyl Acetate 14.19 0.75 Solvent recovery and Solvent vapour scrub through scrubber
Potable water 18 1 420.3 Potable water 420.3 Send to ETP for disposal
Byproduct 1.44 Send to ETP for disposal
Nabilone Final 1.3 1.5 0 0.2 Residue sent to ETP for disposal
TOTAL 518.72 0 2.4 0 27.05 432.24 12.02
TOTAL 992.43 GRAND TOTAL 992.43

2.6.7 Category VII (ANTISPASMODIC/MUSCLE RELAXANT)

2.6.7.1 Reaction Chemistry – Pitofenone HCl

SYNTHETIC FLOW SCHEME OF PITOFENONE HCl:

MeO O
O Dimethyl formamide, Sodium Iodide,
Activated carbon, Potable water, MeO O
Toluene, Acetic acid, Cyclohexane O

OH . HCl
N
Cl N
Methyl Hydroxy Benzoyl Benzoate N-(2-Chloroethyl) piperidine Hydrochloride O
Molecular Weight =256.26 Sodium hydroxide
Potassium carbonate
Pitofenone Base

Activated carbon,
Isopropyl alcohol,
Isopropanolic HCl

MeO O
O MeO O
O
Activated carbon,
. HCl Isopropyl alcohol
N . HCl
O N
O
PITOFENONE HCl
Molecular Formula = C22H25NO4 .HCl
Pitofenone HCl crude
Molecular Weight =403.9

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2.6.7.2 Process Block diagram – Pitofenone HCl
PROCESS FLOW DIAGRAM OF PITOFENONE HCl:

METHYL HYDROXY BENZOYL BENZOATE

1. N- (2-Chloroethyl piperidine HCl (Pipec HCl)

2. Water
Stage - 1 Toluene
3.
4. NaOH solution
5. Potassium Carbonate
6. Dimethyl Formamide
7. Sodium Iodide
8. Activated carbon
9. Acetic acid
10. Cyclohexane

PITOFENONE BASE

1. Isopropyl alcohol
Stage - 2
2. Isopropanolic HCl
3. Activated carbon

PITOFENONE HCl CRUDE

Stage - 3 1. Isopropyl alcohol

2. Activated carbon

PITOFENONE HCl FINAL

2.6.7.3 Process Description – Pitofenone HCl

Pitofenone HCl is manufactured in 3 stages.

Stage 1: Preparation of Pitofenone base

Methyl hydroxyl benzoyl benzoate is reacted with N-(2 Chloroethyl) piperidine(Pipec

base) in toluene and dimethyl formamide using potassium carbonateas base and
sodium iodide as catalyst. Reaction mixture is heated at 90 +/-2 deg C and maintained
for 3-4 hoursat same temperature. Completion of reaction is monitored by TLC. After
completion of reaction,water and toluene is added in reaction mixture followed by
extraction of products in toluene which is subsequently washed with dilute acetic acid
and then treated with activated carbon. Clear filtrate (toluene layer) is then heated to
completed degass out toluene from reaction mixture. Into the degassed mass
cyclohexane is then added and isolated the product by filtration. Filtered wet product is
again sludged in cyclohexane and isolated by filtration and then dried.

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Stage - 2: Preparation of Pitofenone HCl crude
Pitofenone base is dissolved in refluxing iso propyl alcohol and treatd with activated
carbon. The solution is passesd through filter press. The solution is then checked for
clarity. Clear filtrate is treated with isopropanolic HCl to adjust the pH of reaction
mixture to 3-4 below 35 deg C. Solid product precipitate out is isolated at lower
temperature.
Stage - 3: Preparation of Pitofenone HCl Final
Pitofenone HCl crude moist is dissolved in refluxing isopropyl alcohol and treated with
activated carbon. The solution is passed through filter press. The solution is checked for
clarity. The filtrate is cooled and then chilled to lower temperature and isolated by
filtration and dried.
2.6.7.4 Material balance – Pitofenone HCl
Input Ouput Losses
Proudct Effluent Consume Remark
Quantity Theoreti Spent Air
Name Mol. Wt. Density Qty in kg Name 2nd Crop Residue Generati d in
in kg cal Yield Carbon Emission
on reaction
(G) ANTISPASMODIC/MUSCLE RELAXANT
Methyl Hydroxy benzoyl Benzolate256.26 1 50 Methyl Hydroxy benzoyl Benzolate Converted to Pitofenone Base
Sodium Hydroxide 40 1 26 Sodium Hydroxide 26 Disolve in water & send to ETP for disposal
Potassium carbonate 138.21 1 65 Potassium carbonate 65 Disolve in water & send to ETP for disposal
P N-(2-Chloroethyl piperidine HCl N-(2-Chloroethyl piperidine HCl
184.11 1 57.50 21.56 Consumed in reaction
(Pipec HCl) (Pipec HCl)
I
Sodium Iodide 149.89 1 0.6 Sodium Iodide 0.6 Disolve in water & send to ETP for disposal
T
Converted to Pitofenone HCl Crude & residue sent to ETP for
O Pitofenone base 367.4 1 50 Pitofenone base 50 71.36 0 21.36
disposal
F Pitofenone HCl Crude 403.9 1 55 Pitofenone HCl Crude 55 55 0 0 Converted to Pitofenone HCl Final
E Activated carbon 12 1 15 Activated carbon 15 Spent Carbon to TTCWMA for disposal
N Toluene 92.14 0.86 860 Toluene 842.8 17.2 Solvent recovery and Solvent vapour scrub through scrubber
O Dimethyl Formamide (DMF) 73.09 1.1 110 Dimethyl Formamide (DMF) 110 Disolve in water & send to ETP for disposal
N Acetic Acid 60.05 1.045 2.34 Acetic Acid 2.34 Disolve in water & send to ETP for disposal
E Cyclohexane 84.16 0.77 385 Cyclohexane 365.75 19.25 Solvent recovery and Solvent vapour scrub through scrubber
Isopropanol 60.1 0.78 737.1 Isopropanol 700.25 31.86 Solvent recovery and Solvent vapour scrub through scrubber
H Isopropanolic HCl 36.5 0.9 31.50 Isopropanolic HCl 31.50 Consumed in reaction
C Potable water 18 1 1375.00 Potable water 1375.00 Send to ETP
l Byproduct 14.58 Send to ETP for disposal
Pitofenone HCl Final 50 55 0 5 Residue send to ETP for disposal
TOTAL 2063.80 0 26.36 15 68.31 1615.08 31.5
TOTAL 3820.04 GRAND TOTAL 3820.04

2.6.8 Category VIII (ANTIDYSKINETIC/DIURETIC/SNR

INHIBITOR/CHOLINERGIC/URINARY INCONTINENCE
2.6.8.1 Reaction Chemistry – Levomilnacipran HCl

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2.6.8.2 Process Block diagram – Levomilnacipran HCl

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PROCESS FLOW DIAGRAM OF LEVOMILNACIPRAN HCl: Chapter 2 – Project Description

LILN (1S, 5R) LACTONE

1. Aluminum Chloride (AlCl3)

2. Diethyl amine
3. MDC
4. Thionyl Chloride
Stage - 1
5. Toluene
6. Potassium Phthalimide
7. Triethylamine
8. Sodium Hydroxide
9. Conc. Hydrochloric acid
10. Methanol

LILN (1S, 2R) PHTHALIMIDE

1. Sodium chloride (NaCl)
2. Hyflow
3. Mono methyl amine 40 % solution
4. Toluene
5. Potable water
Stage - 2 6. Acetic acid
7. DIPE HCl
8. Ethyl acetate

LEVOMILNACIPRAN HCl CRUDE

1. IPA
Stage - 3 2. Acetone
3. Activated charcoal
4. Hyflow Supercell

LEVOMILNACIPRAN HCl FINAL

2.6.8.3 Process Description – Levomilnacipran HCl

Levomilnacipran HCl is manufactured in three stages.

Stage 1: Preparation of LI LN (1S, 2R) Phthalimide

Levolactone / LILN (1S, 5R) Lactone is reacted with Aluminium chloride & Diethyl amine in
presence of Methylene chloride. After completion of reaction, the reaction mixture is quenched
in HCl and extracted in MDC. Concentrated MDC layer is then reacted with thionyl chloride in
presence of toluene. Progress of reaction is monitored by TLC. After reaction completion, it is
further with potassium phthalimide and triethyl amine in toluene. Progress of reaction is
monitored by TLC. It is then extracted with toluene. It is the concentrated & isolated in aqueous
methanol to get LILN (1S,2R) phthalimide.

Stage - 2: Preparation of Levomilnacipran Hydrochloride crude

LILN (1S,2R) Phthalimide is reacted with Mono methyl amine in Toluene & potable
water. Progress of reaction is monitored by TLC. The extractions is done in Toluene &
concentrated. The crude product precipitated by DIPE. HCl in Ethyl acetate. The product is
isolated by filtration to get Levomilnacipran Hydrochloride crude.

Stage - 3: Preparation of Levomilnacipran HCl final

Levomilnacipran hydrochloride crude is dissolved & charcoalised in Isopropyl Alcohol

Concentrated & isolated in acetone by filtration and dried to get Levomilnacipran
Hydrochloride final.

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2.6.8.4 Material balance – Levomilnacipran HCl
Input Ouput Losses
Proudct Effluent Consume Remark
Quantity Theoreti Spent Air
Name Mol. Wt. Density Qty in kg Name 2nd Crop Residue Generatio d in
in kg cal Yield Carbon Emission
n reaction
(H) ANTIDYSKINETIC/DIURETIC/SNR INHIBITOR/CHOLINERGIC/URINARY INCONTINENCE
(1S,5R) Lactone 174.2 1 80 (1S,5R) Lactone Converted to LILN Phthalimide
Aluminium Chloride 133.34 1 83 Aluminium Chloride 83 Consumed in reaction
Potassium Phthalimide 185.22 1 162 Potassium Phthalimide 76.85 Consumed in reaction
Sodium Hydroxide 40 1 14 Sodium Hydroxide 14 Disolve in water & send to ETP for disposal
Hyflow supercell -- 1 10 Hyflow supercell 10 Sent to TTCWMA for disposal
Sodium Chloride 58.44 1 118 Sodium Chloride 118 Disolve in water & send to ETP for disposal
L Converted to Levomilnacipran HCl Crude & residue sent to
LILN Phthalimide 1 150 LILN Phthalimide 150 172 0 22
E 376.18 ETP for disposal
V Levomilnacipran HCl Converted to Levomilnacipran HCl Final & residue sent to
282.81 1 69.42 Levomilnacipran HCl Crude 69.42 112.77 4.2 39.15
O Crude ETP for disposal
Activated carbon 12 1 3.5 Activated carbon 3.5 Sent to TTCWMA for disposal
M
Diethyl amine 73.14 0.7 131.04 Diethyl amine 97.43 Disolve in water & send to ETP for disposal
I
Thionyl Chloride 118.97 1.64 68.88 Thionyl Chloride 68.88 Consumed in reaction
L
Triethyl amine 101.09 0.73 129.94 Triethyl amine 129.94 Disolve in water & send to ETP for disposal
N
Conc. HCl 36.5 1.13 237.3 Conc. HCl 237.3 Disolve in water & send to ETP for disposal
A
Methylene Chloride Methylene Chloride
C 84.93 1.33 887.75 843.36 44.39 Solvent recovery and Solvent vapour scrub through scrubber
(MDC/DCM) (MDC/DCM)
I Toluene 92.14 0.86 2632.46 Toluene Solvent recovery and Solvent vapour scrub through scrubber
2579.81 52.65
P Methanol 32.04 0.79 707.84 Methanol Solvent recovery and Solvent vapour scrub through scrubber
672.448 35.392
R 40 % Monomethyl 40 % Monomethyl amine
A 31 0.9 405 405 Disolve in water & send to ETP for disposal
amine solution solution
N Acetic Acid 60.05 1.045 0.98 Acetic Acid 0.98 Disolve in water & send to ETP for disposal
Diisopropyl ether HCl Diisopropyl ether HCl
36.5 0.9 97.2 97.2 Consumed in reaction
H (DIPE.HCl) (DIPE.HCl)
C Ethyl Acetate 88.11 0.9 1953 Ethyl Acetate 1855.35 97.65 Solvent recovery and Solvent vapour scrub through scrubber
l Isopropanol (IPA) 60.1 0.78 499.2 Isopropanol (IPA) 474.24 24.96 Solvent recovery and Solvent vapour scrub through scrubber
Acetone 58.08 0.78 386.1 Acetone 366.80 19.31 Solvent recovery and Solvent vapour scrub through scrubber
Potable water 18 1 4381.02 Potable water 4381.02 Send to ETP for disposal
Byproducts 63.99 Send to ETP for disposal
Levomilnacipran HCl Final 57.27 69.42 3.3 8.85 Residue send to ETP for disposal
TOTAL 7068.70 7.5 70 13.5 274.34 5447.66 325.93
TOTAL 13207.63 GRAND TOTAL 13207.63

2.6.9 Category IX (HYPERTENSION/ANTIHYPERTENSION (Pindolol)

2.6.9.1 Reaction Chemistry – Pindolol

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2.6.9.2 Process Block diagram – Pindolol
PROCESS FLOW DIAGRAM OF PINDOLOL:

BTTSI KETONE

1. Lithium chloride
2. Lithium Carbonate
3. Dimethyl Formamide
Stage - 1 4. Toluene
5. Conc.HCl
6. Sodium Hydroxide
7. Sodium Dithionite

TOSYLATE-4-HYDROXY INDOLE
1. Sodium Hydroxide
2. Ethyl Acetate
3. Acetic acid
4. Sodium Dithionite
5. Activated Charcoal
6. Epichlorohydrin
Stage - 2 7. Toluene
8. Isopropyl Amine
9. Methanol
10. Sodium Chloride
11. Sodium Sulphate

PINDOLOL CRUDE

Stage - 3 1. Methanol
2. Activated charcoal

PINDOLOL FINAL

2.6.9.3 Process Description – Pindolol

Pindolol is manufactured in three stages.

Stage 1: Preparation of Tosylate-4-hydroxy indole

BTTSI Ketone is reacted with Lithium chloride & Lithium carbonate in DMF. After
completion of reaction, reaction mixture is quenchd in water. Product is extracted in
toluene and then in sodium hydroxide solution. Product precipitates out bu conc HCl.
Product is then isolated by filtration and dried under vacuum to get Tosylate-4-hydroxy
indole.

Stage - 2: Preparation of Pindolol crude

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Tosylate-4-hydroxy indoleis reacted with sodium hydroxide solution. After completion
of reaction, acetic acid is added in the mixture. Product extracted in ethyl acetate and
distilled, degassed to get oily intermediate. Oily intermediate is reacted with sodium
hydroxide and epichlorohydrin in water. After completion of reaction product is
extracted in toluene. Toluene layer is then reacted with isopropyl amine. After
completion of reaction, product is filtered. Wet cake is sludged in mixture of toluene,
methanol and acetic acid. Then slurried liquor ammonia and water. Product isolated by
filtration and dried under vacuum to get Pindolol crude.

Stage - 3: Preparation of Pindolol Final

Pindolol crude is dissolved in methanol and treated with activated carbon. After carbon
treatment filtrate is dissolved out. Product is isolated by filtration at lower temperature
and dried under vacuum to get Pindololfinal product.
2.6.9.4 Material balance – Pindolol
Input Ouput Losses
Proudct Theoreti Spent Air Effluent Consume Remark
Mol. Densit Qty in Quantit 2nd Residu
Name Name cal Carbo Emissio Generatio d in
Wt. y kg y in kg Crop e
Yield n n n reaction
(I) HYPERTENSION/ANTIHYPERTENSION
BTTSI Ketone 368.24 1 24 BTTSI Ketone Converted to Tosylate-4-hydroxy Indole
Lithium Chloride 42.39 1 3.17 Lithium Chloride 3.17 Consumed in reaction
Lithium Carbonate 73.89 1 5.8 Lithium Carbonate 5.8 Consumed in reaction
Sodium Hydroxide 40 1 6 Sodium Hydroxide 6 Disolve in water & send to ETP for disposal
Sodium Dithionite 206.1 1 1.964 Sodium Dithionite 1.964 Disolve in water & send to ETP for disposal
Conc. HCl 36.5 1.13 20.34 Conc. HCl 20.34 Disolve in water & send to ETP for disposal
Sodium Chloride 58.44 1 10 Sodium Chloride 10 Disolve in water & send to ETP for disposal
Sodium Sulphate 142.04 1 12.5 Sodium Sulphate 12.5 Disolve in water & send to ETP for disposal
Tosylate-4-hydroxy Converted to Pindolol Crude & residue sent to ETP for
1 14 Tosylate-4-hydroxy Indole 14
Indole 287.33 18.72 0 4.72 disposal
P Converted to Pindolol Final & residue sent to ETP for
Pindolol Crude 1 3.75 Pindolol Crude 3.75 12 0 8.25
I 248.32 disposal
N Epichlorohydrin 92.53 1.18 20.65 Epichlorohydrin 20.65 Consumed in reaction
D Activated carbon 12 1 1.425 Activated carbon 1.425 Sent to TTCWMA for disposal
O Hyflow Supercell -- 1 3 Hyflow Supercell 3 Sent to TTCWMA for disposal
L Toluene 92.14 0.86 254.56 Toluene 249.47 5.09 Solvent recovery and Solvent vapour scrub through scrubber
O Acetic Acid 60.04 1.045 19.76 Acetic Acid 19.76 Disolve in water & send to ETP for disposal
L Ethyl Acetate 88.1 0.9 144.9 Ethyl Acetate 137.66 7.245 Solvent recovery and Solvent vapour scrub through scrubber
N,N-Dimethyl N,N-Dimethyl
73.09 1.1 79.2 79.2 Disolve in water & send to ETP for disposal
Formamide (DMF) Formamide (DMF)
Methanol 32.04 0.79 93.22 Methanol 88.559 4.661 Solvent recovery and Solvent vapour scrub through scrubber
Isopropyl Amine 59.11 0.72 12.6 Isopropyl Amine 12.6 Consumed in reaction
Liquor Ammonia 17 0.9 3.375 Liquor Ammonia 3.375 Disolve in water & send to ETP for disposal
Potable Water 18 1 586 Potable Water 586 Sent to ETP.
Byproducts 7.28 Send to ETP for disposal
Pindolol Final 3 3.75 0 0.75 Residue send to ETP for disposal
TOTAL 496.43 0 13.72 4.425 17.00 746.42 42.22
TOTAL 1320.21 GRAND TOTAL 1320.21

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2.6.10 Category X (PLATELET INHIBITOR)
2.6.10.1
SYNTHETIC Reaction Chemistry
FLOW SCHEME – Prasugrel
OF PRASUGREL:

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2.6.10.2 Process Block diagram – Prasugrel
PROCESS FLOW DIAGRAM OF PRASUGREL:

2-BROMO-2-(2-FLUOROPHENYL)-1-CYCLOPROPYL
ETHANONE

1. 5,6,7,7a-thieno[3,2-c]pyridine-2-one
2. Potassium carbonate
Stage - 1 3. Dimethyl formamide
4. Toluene
5. Potable water
6. Ethyl acetate

5-(ALPHA-CYCLOPROPYL CARBONYL-2-
FLUOROBENZYL)2-OXO-2,4,5,6,7A-
HEXAHYDROTHIENO[3,2-C]PYRIDINE
1. Dimethyl Formamide
2. Acetic anhydride
3. Sodium hydride
Stage - 2
4. Sodium sulphate
5. Toluene
6. Ethyl acetate
7. Potable water
8. Diispropyl ether

PRASUGREL FINAL

2.6.10.3 Process Description – Prasugrel

Prasugrel is manufactured in two stages.

Stage 1: Preparation of Prasugrel base

5-(Alpha cyclofropyl carboxyl-2-Flurobenzyl) 2-oxo-2,4.5.6.7a-hexahrothieno(3,2-

c)pyridine is prepared by condensing bromo compound with thieno-pyridine derivative
in presence of base in dimethyl formamide. After filtering off the insoluble the resulting
residue is purified using toluene and ethyl acetate.

Stage - 2: Preparation of Prsugrel final

Product from stage no 1 is treated with acetic anhydride in presence of sodium hydride
in dimethyl formamide. The product is extracted in ethyl acetate which is washed with

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brine solution and then drived over sodium sulphate. Final product is isolated by
evaporation and crystallization from isopropyl ether.

2.6.10.4 Material balance – Prasugrel

Input Ouput Losses
Proudct Effluent
Quantity Theoreti Spent Air Consumed Remark
Name Mol. Wt. Density Qty in kg Name 2nd Crop Residue Generatio
in kg cal Yield Carbon Emission in reaction
n
(J) PLATELET INHIBITOR
2-Bromo-2-(2-Fluorophenyl)- 2-Bromo-2-(2-Fluorophenyl)-
1 1.1 Converted to Intermediate
1-cyclopropyl ethanone 257.1 1-cyclopropyl ethanone
5,6,7,7a-thieno[3,2- 5,6,7,7a-thieno[3,2-
191.68 1 0.64 0.24 Consumed in reaction
c]pyridine-2-one c]pyridine-2-one
Potassium carbonate 138.21 1 1.12 Potassium carbonate 1.12 Dissolve in water & sent to ETP for disposal
P Sodium hydride 24 1 0.19 Sodium hydride 0.19 Consumed in reaction
R Sodium sulphate 142.04 1 2.75 Sodium sulphate 2.75 Dissolve in water & sent to ETP for disposal
A Intermediate 373.4 1 1.43 Intermediate 1.43 1.48 0.05 0 Converted to Prasugrel
S Dimethyl formamide (DMF) 73.09 1.1 14.98 Dimethyl formamide (DMF) 14.98 Dissolve in water & sent to ETP for disposal
U Toluene 92.14 0.86 65.62 Toluene 64.31 1.31 Solvent recovery and Solvent vapour scrub through scrubber
G Ethyl acetate 88.10 0.9 46.96 Ethyl acetate 44.61 2.35 Solvent recovery and Solvent vapour scrub through scrubber
R Acetic anhydride 102.09 1.08 3.21 Acetic anhydride 3.21 Consumed in reaction
E Diispropyl ether 102.18 0.73 4.37 Diispropyl ether 4.37 Solvent vapour scrub through scrubber
L Potable water 18 1 69 Potable water 69 Send to ETP
Byproduct 0.02 Send to ETP for disposal
Prasugrel Final 1 1.54 0.42 0.01 Residue sent to ETP for disposal
TOTAL 111.35 0.47 0.01 0 3.66 92.24 3.64
TOTAL 211.37 GRAND TOTAL 211.37

2.6.11 Category R & D Activity and other

2.6.11.1 Reaction Chemistry – Silodosin

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2.6.11.2 Process Block diagram – Silodosin

PROCESS FLOW DIAGRAM OF SILODOSIN:

5-[(2R)-2-aminopropyl]-1-[3-(benzoyloxy)propyl]-2,3-
dihydro-1H-indole-7-carbonitrile(2R,3R)-2,3-
dihydroxybutanedioate

Stage - 1

STAGE-1 COMPOUND

Stage - 2

SILODOSIN

2.6.11.3 Process Description – Silodosin

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Brief Manufacturing Process:

Silodosin is manufactured in two stages.

Stage 1: Preparation of Stage-1 Compound:
5-[(2R)-2-aminopropyl]-1-[3-(benzoyloxy)propyl]-2,3-dihydro-1H-indole-7-
carbonitrile(2R,3R)-2,3-dihydroxybutanedioate is reacted with 2-(2-(2,2,2-
trifluoroethoxy)phenoxy)ethyl methanesulfonate, potassium carbonate, dipotassium
hydrogen phosphate, Potassium Hydroxide, Tetrabutyl ammonium bromide. Progress of
reaction is monitored by TLC. After completion of reaction, the product is isolated by
filtration to get Stage-1 compound.

Stage - 2: Preparation of Silodosin:

Stage-1 compound is reacted with hydrogen peroxide, sodium sulfite, Potassium
Hydroxide, Sodium Chloride. Progress of reaction is monitored by TLC. After completion
of reaction, the product is isolated by filtration & dried to get Silodosin.

2.6.11.4 Material balance – Silodosin

Input Ouput Losses
Proudct Theoreti Spent Air Effluent Consume Remark
Mol. Densit Qty in Quantit 2nd Residu
Name Name cal Carbo Emissio Generatio d in
Wt. y kg y in kg Crop e
Yield n n n reaction
R & D ACTIVITIES
5-[(2R)-2-aminopropyl]-1-[3-
(benzoyloxy)propyl]-2,3- 5-[(2R)-2-aminopropyl]-1-[3-
(benzoyloxy)propyl]-2,3-dihydro-
dihydro-1H-indole-7- 513 1 23 Converted to Stage-1 Compound
1H-indole-7-carbonitrile(2R,3R)-
carbonitrile(2R,3R)-2,3- 2,3-dihydroxybutanedioate
dihydroxybutanedioate
2-(2-(2,2,2- 2-(2-(2,2,2-
trifluoroethoxy)phenoxy)eth 314 1 17.3 trifluoroethoxy)phenoxy)ethyl 17.3 Consumed in reaction
yl methanesulfonate methanesulfonate
Potassium carbonate 138.21 1 10 Potassium carbonate 10 Disolve in water & send to ETP for disposal
S
Dipotassium hydrogen phosphate174 1 7.00 Dipotassium hydrogen phosphate 7.00 Consumed in reaction
I
Potassium Hydroxide 56.11 1 10.8 Potassium Hydroxide 10.8 Disolve in water & send to ETP for disposal
L
Tetrabutyl ammonium bromide322.37 1 5 Tetrabutyl ammonium bromide 5 Disolve in water & send to ETP for disposal
O
Stage-1 Compound 477 1 14 Stage-1 Compound 14 21 0 7 Converted to Silodosin & residue sent to ETP for disposal
D
50 % hydrogen peroxide 34.01 1 5 50 % hydrogen peroxide 4 Consumed in reaction
O
Sodium sulfite 206.1 1 5 Sodium sulfite 5 Disolve in water & send to ETP for disposal
S
Sodium Chloride 59.96 1 3 Sodium Chloride 3.00 Disolve in water & send to ETP for disposal
I
Dimethyl sulphoxide 78.13 1.1 154 Dimethyl sulphoxide 154.00 Disolve in water & send to ETP for disposal
N
Cyclohexane 84.16 0.78 132.6 Cyclohexane 119.34 13.26 Solvent recovery and Solvent vapour scrub through scrubber
Acetic acid 60.04 1.045 5.20 Acetic acid 5.20 Disolve in water & send to ETP for disposal
Toluene 92.14 0.86 197.80 Toluene 178.02 19.78 Solvent recovery and Solvent vapour scrub through scrubber
Methanol 32.04 0.78 7.80 Methanol 7.80 Disolve in water & send to ETP for disposal
Potable water 18 1 625.00 Potable water 625.00 Send to ETP
Byproduct 2 Send to ETP for disposal
Silodosin 10 15 0 5 Residue send to ETP for disposal
TOTAL 321.36 0 12 0 33.04 827.80 28.3
TOTAL 1222.50 GRAND TOTAL 1222.50

2.6.12 Raw Material Consumption & Sourcing

Following table indicates expected raw material consumption and sourcing details.

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Table 2.4 Raw Material consumption and sourcing
Sr. Name of Existing & Proposed Raw Material Unit Existing Proposed add. Total Source of supply Transportation
No. quantity quantity quantity mode
1 2-AMINO-5-NITRO-2-CHLORO BENZOPHENONE MT/A 4 8 12 IMPORTED SEA/AIR
2 3-CHLORO- 4-MORPHOLINO-1,2,5 THAIDAIZOLE / TDZ MT/A 0.6 1.2 1.8 IMPORTED SEA/AIR
3 ACETIC ACID MT/A 151 302 453 LOCAL ROAD
4 ACETIC ANHYDRIDE MT/A 36 72 108 LOCAL ROAD
5 3-AMINO PYRAZOLE-4-CARBONITRILE (DIAZOLE) MT/A 0.37 0.75 1.12 LOCAL ROAD
6 2-AMINO PYRIDINE MT/A 0 12 12 LOCAL ROAD
7 ACETONE MT/A 68 134 202 IMPORTED FROM ROAD
MARKET
8 ACETYL HYDRAZONE MT/A 2 4 6 LOCAL ROAD
9 ACTIVATED CARBON MT/A 6.5 12.5 19 LOCAL ROAD
10 AMMONIUM CHLORIDE MT/A 28.2 56.3 84.5 IMPORTED FROM ROAD
MARKET
11 ALUMINIUM CHLORIDE MT/A 8 16 24 LOCAL ROAD
12 2-AMINO-5-CHLORO-PYRIDE MT/A 0 18 18 LOCAL ROAD
13 2-ACETYL THIOPHENE MT/A 0 24 24 LOCAL ROAD
14 BENZALDEHYDE MT/A 1.05 2.1 3.15 LOCAL ROAD
15 BENZYL CYANIDE MT/A 0 4.35 43.5 LOCAL ROAD
16 BENZYL TERTIARY ALCOHOL MT/A 1.43 2.86 4.29 LOCAL ROAD
17 POTASSIUM HYDROXIDE MT/A 2.06 4.12 6.18 LOCAL ROAD
18 SODIUM HYDROXIDE MT/A 158.57 317.14 475.71 LOCAL ROAD
19 CHLORO ACETOMIDO OF 2-AMINO-5-NITRO-2-CHLORO- MT/A 3.08 6.16 9.24 LOCAL ROAD
BENZOPHENONE / CHLORO ACTAMIDO OF CLONA
20 CHLORO ACETYL CHLORIDE MT/A 0.51 1.03 1.54 LOCAL ROAD
21 CHLORO PYRIDYL PIPERAZINYL IMIDOL / IMINO ALCOHOL MT/A 6.3 12.60 18.9 LOCAL ROAD
22 CHLOROFORM MT/A 50.31 100.61 150.92 LOCAL ROAD
23 CYCLO HEXANE MT/A 23.25 46.51 69.76 IMPORTED FROM ROAD
MARKET
24 CHLORO ACETOMIDO BROMO PYRIDYL BENZOPHENONE / MT/A 1.712 3.42 5.13 LOCAL ROAD
CABPB
25 DI METHYL AMINO PROPYL CHLORIDE HCL /DMAPC MT/A 3.5 7 10.5 LOCAL ROAD
26 DMAPCL-HCL MT/A 0 24 24 LOCAL ROAD
27 DI CHLORO PHENYL BENZOXIDE MT/A 0.9 1.6 2.5 LOCAL ROAD
28 1:4 DI BROMO BUTANE MT/A 1.2 2.4 3.6 LOCAL ROAD
29 DI METHYL SULPHATE / DMS MT/A 2.92 5.84 8.76 LOCAL ROAD
30 DI METHYL SULPHOXIDE / DMSO MT/A 1.5 3 4.5 IMPORTED FROM ROAD
MARKET

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Sr. Name of Existing & Proposed Raw Material Unit Existing Proposed add. Total Source of supply Transportation
No. quantity quantity quantity mode
31 DMF MT/A 0 90 90 IMPORTED FROM ROAD
MARKET/LOCAL
32 1,4-DIOXANE MT/A 15.1 30.2 45.3 IMPORTED FROM ROAD
MARKET/LOCAL
33 HYFLOW MT/A 5.1 10.15 15.25 IMPORTED FROM ROAD
MARKET/LOCAL
34 DI METHYL FORMAMIDE / DMF MT/A 34.62 69.24 103.86 IMPORTED FROM ROAD
MARKET/LOCAL
35 ETHYL ACETATE MT/A 91.82 183.63 275.45 LOCAL BY TANKER
36 ETHYLENE DI CHLORIDE / EDC MT/A 1 2 3 LOCAL ROAD
37 ETHYL CHLORO FORMATE MT/A 0 2.4 2.4 LOCAL ROAD
38 HANACARBAMATE / NRT-CARBAMATE MT/A 0.93 1.86 2.89 LOCAL ROAD
39 HEXAMINE MT/A 9.24 18.5 27.75 LOCAL ROAD
40 HYDROCHLORIC ACID CP MT/A 263.21 526.42 789.63 LOCAL ROAD
41 HYDROXY IMIDAZO AMIDE MT/A 1.51 3.02 4.55 LOCAL ROAD
42 HYDROGEN PEROXIDE MT/A 0 10.5 10.5 LOCAL ROAD
43 ISO PROPANOL / IPA MT/A 155.01 310.03 465.04 LOCAL/IMPORTED TANKER LOAD
44 ISO PROPANOLIC HCL / IPA HCL MT/A 1.71 3.42 5.13 LOCAL ROAD
45 LIQUOR AMMONIA MT/A 209.28 418.56 627.84 LOCAL ROAD
46 MALEIC ACID MT/A 0.37 0.75 1.13 LOCAL ROAD
47 MALONIC ACID AMINO KETONE / PHENYL CYCLIC AMIDE / DES MT/A 2.1978 4.39 6.59 LOCAL ROAD
CLOBA
48 METHANOL / MeOH MT/A 307.68 615.36 923.04 LOCAL/IMPORTED TANKER LOAD
49 MCB MT/A 0 300 300 LOCAL ROAD
50 METHYLENE DI CHLORIDE / MDC MT/A 91.03 182.06 273.09 LOCAL/IMPORTED ROAD
51 MORPHOLINE MT/A 0 24 24 LOCAL/IMPORTED ROAD
52 METHYL QUINOZOLINE PHENYL BENZOXIDE / METHYL CPBO MT/A 2 4 6 LOCAL ROAD
53 MONO CHLORO BENZENE / MCB MT/A 4.37 8.75 13.13 LOCAL ROAD
54 MAGANESE DIOXIDE / MNO2 MT/A 0.67 1.35 2.03 LOCAL ROAD
55 MONO METHYL AMINE / MMA MT/A 9.072 18.14 27.21 LOCAL ROAD
56 N-HEXANE MT/A 10.198 20.39 30.59 LOCAL/IMPORTED ROAD
FROM MARKET
57 N-METHYL PIPERAZINE CARBAMOYL CHLRIDE HCL / MT/A 5.84 11.70 17.53 LOCAL ROAD
NMPCCHCL
58 N2 HYDROXY ETHYL PIPERAZINYL MT/A 0.42 0.85 1.28 LOCAL/IMPORTED ROAD/SEA/AIR
59 POTASSIUM CARBONATE MT/A 3.80 7.61 11.41 LOCAL ROAD
60 PARAFORMALDEHYDE MT/A 0 8.4 8.4 LOCAL ROAD
61 POTASSIUM PERMANGANATE MT/A 0 384 384 LOCAL ROAD

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Sr. Name of Existing & Proposed Raw Material Unit Existing Proposed add. Total Source of supply Transportation
No. quantity quantity quantity mode
62 PHOSPHOROUS OXY CHLORIDE MT/A 0 18 18 LOCAL ROAD
63 POTASSIUM HYDROXIDE POWDER MT/A 1.81 3.63 5.45 LOCAL ROAD
64 QUINOZOLINE PHENYL BENZOXIDE MT/A 3 6 9 LOCAL ROAD
65 QUINOZOLINE CRUDE MT/A 1 2 3 LOCAL ROAD
66 SODIUM CARBONATE MT/A 17.42 34.84 52.26 LOCAL ROAD
67 SODIUM ACETATE MT/A 0 3.6 3.6 LOCAL ROAD
68 SODIUM BOROHYDRIDE MT/A 0 1.8 1.8 LOCAL/IMPORTED ROAD
FROM MARKET
69 SODIUM SULPHATE MT/A 0 9 9 LOCAL ROAD
70 SODIUM BICARBONATE MT/A 0 45 45 LOCAL ROAD
71 SODIUM HYDRIDE / NAH MT/A 2.66 5.33 7.99 LOCAL ROAD
72 SODIUM SULPHATE MT/A 0 1.5 1.5 LOCAL ROAD
73 SULPHURIC ACID MT/A 0 360 360 LOCAL ROAD
74 S-(-)-3-(TERT-BUTYLAMINO)-1,2 PROPANDIOL MT/A 0.4 0.8 1.12 IMPORTED SEA/AIR
75 THF MT/A 0 60 60 LOCAL/IMPORTED ROAD
FROM MARKET
76 TOLUENE MT/A 729.57 1459.14 2188.71 LOCAL/IMPORTED TANKER
FROM MARKET
77 TRIETHYL AMINE / TEA MT/A 10.20 20.40 30.60 LOCAL/IMPORTED ROAD
FROM MARKET
78 TERTIARY BUTANOL / TBA MT/A 4.38 8.76 13.14 IMPORTED FROM ROAD
MARKET
79 THIONYL CHLORIDE MT/A 2.50 5.00 7.51 LOCAL ROAD
80 ZINC CHLORIDE MT/A 0 4.8 4.8 LOCAL ROAD
81 ACETONITRILE / ACN MT/A 6.04 12.09 18.13 IMPORTED FROM ROAD
MARKET
82 THIO MORPHALINO PROPYL CHLORIDE MT/A 7.54 15.09 22.63 LOCAL ROAD
83 ZINC DUST MT/A 1.09 2.18 3.27 LOCAL ROAD
84 SULPHURIC ACID MT/A 1.15 2.31 3.46 LOCAL ROAD
85 1-(2,3 DI CHLORO PHENYL)PIPERAZINE HCL MT/A 0.48 0.96 1.44 LOCAL ROAD
86 SPECIAL DENATURED SPIRIT WITH 3% TOLUENE / SDS MT/A 6.41 12.83 19.24 LOCAL ROAD
87 N PROPANOL / NPA MT/A 0.6 1.2 1.8 IMPORTED FROM ROAD
MARKET
88 4,5-NITROIMIDAZOLE MT/A 0.4 0.8 1.2 LOCAL ROAD
89 N-CHLORO SUCCINIMIDE / NCS MT/A 0.5 0.1 1.5 LOCAL ROAD
90 POLYPHOSPHORIC ACID MT/A 0.39 0.78 1.18 LOCAL ROAD
91 NN DI METHYL FORMAMIDE DIMETHYL ACETYL / DMFDMA MT/A 1.10 2.21 3.31 IMPORTED FROM ROAD

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Sr. Name of Existing & Proposed Raw Material Unit Existing Proposed add. Total Source of supply Transportation
No. quantity quantity quantity mode
MARKET
92 2-CHLORO ACETAMIDO 5-CHLORO BENZOPHENONE OXIME MT/A 5.08 10.16 15.25 LOCAL ROAD
(CHLORO OXIME)
93 HYDRAZINE HYDRATE MT/A 1 2 3 LOCAL/IMPORTED ROAD
FROM MARKET
94 ACETYL HYDRAZIDE MT/A 0.5 0.1 1.5 LOCAL ROAD
95 ETHYL BROMIDE MT/A 0.69 1.39 2.09 LOCAL ROAD
96 3-ACETAMIDO ACETOPHENONE MT/A 0.80 1.60 2.40 LOCAL ROAD
97 2,5- DICHLORO BENZOIC ACID MT/A 0.5 1 1.5 IMPORTED SEA/AIR
98 PHENYL AMIDE / MALONIC ACID NITRO KETONE MT/A 0.60 1.21 1.82 LOCAL ROAD
99 QUINOZOLINE IN DICHLOROMETHENE MT/A 3.67 7.34 11.01 LOCAL ROAD
100 AMITRIPTYLINE HCL MT/A 1.17 2.35 3.52 ROAD ROAD
101 STYRENE OXIDE MT/A 0.6 1.2 1.8 LOCAL ROAD
102 METHYL FLUROPHENYL IMIDAZO BENZOXIDE MT/A 0.5 1.0 1.5 LOCAL ROAD
103 AMITRIPTYLINE HCL USP MT/A 0.5 1.0 1.5 LOCAL ROAD
104 2-METHYL AMINO-5-CHLORO BENZOPHENONE MT/A 0.51 1.02 1.53 LOCAL ROAD
105 MORFOLINE MT/A - 4.5 4.5 LOCAL/IMPORTED ROAD
FROM MARKET
106 NITRIC ACID MT/A - 3 3 LOCAL ROAD

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2.6.13 Air emission, sources, quantities, concentration and control mechanism

2.6.13.1 Fugitive emissions

Fugitive emissions can be defined as the emissions due:-

o to the evaporation of solvents and raw materials

o Due to spills, leaks, storage tanks, drums, improper handling and transfer
of chemicals.
o Poor housekeeping
o Lack of proper maintenance leads to fugitive emissions of
reactants/products/solvents.
o Dust during power handling

These emissions are generally from solvents with other associated raw
materials. These fugitive emissions usually spread in the process plant posing a
threat to the workmen and sometimes leading to formation of clouds and
explosions due to increased concentration of pollutants. Thus, proper collection,
conveyance, treatment and disposal become essential and necessary.

Table 2.5 Fugitive dust, chemical vapor sources

Area Type of activity Intermittent Fugitive Pollutant
/continuous dust type released to
air
Production area Chemical (solid) Intermittent Chemical Hazardous air
charging from bags dust pollutants
in form of
particulate
matter form
Solid product Bag filling of Intermittent Chemical -do-
bagging product powder dust
or lumps
Boiler area Ash handling Continuous Fine ash - do -
dust
Solvent storage Storage, loading Intermittent Chemical Hazardous air
/handling, and unloading, vapor pollutants
Production, drum Charging and having low
filling reaction vapor pressure

For control of fugitive dust, the concerned areas shall be enclosed/barricaded, covered
transfer systems shall be adopted, workers shall be provided with PPEs, machinery
shall be provided with dust extraction systems if found necessary by work place
monitoring., minimum manual operations, local exhausts and roof top ventilators shall
be provided.

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Table 2.6 Fugitive emission control measures
No Probable source Proposed control measure
1 Ash handling Area barricading for storage.
2 Pump glands and seals, All pumps handling HAP chemicals with low vapor
pressure shall have mechanical seals which are best for
preventing emissions.
3 Valves, Flanges, plugs Welded pipes to be used wherever feasible
and instrument Suitable gasket material to be used
connections Suitable gland packing to be used in valves
Periodic inspection and maintenance of pipes and pipe
fittings
4 Emissions from Bulk Breather valves, PSVs to be provided wherever
Storage Tanks during applicable. Tank Pressure equalization shall be applied
storage, loading and wherever required. Closed Transfer systems.
unloading
5 Chemical vapors during Covered transfer systems shall be adopted wherever
filtration and drying required, workers shall be provided PPEs
process
6 Drum filling operation Covered transfer systems shall be adopted, workers
shall be provided PPEs, fume extraction system shall be
provided wherever required. Minimum manual
operations, local exhausts and roof top ventilators
7 Warehouse storage of Spillages shall be strictly prevented by providing drip
drums and bags pans, proper handling equipment, Spill control
procedures and equipment shall be provided Hydraulic
drum lifting machine.
8 Release during sampling Close sampling system
9 Pressure relief valves For highly pressurized lines, pressure equalization.
Relief at suitable location / scrubber.
10 During reactions & All reactors shall be closed and provided with main
Solvent recovery condenser with cooling water circulation and vent
systems condensers with chilled water circulation for maximum
vapor recovery. Multi-purpose plant shall have
dedicated solvent recovery system with same
condensation system Temperature and pressure
conditions shall be stringently controlled as per the
process requirement and optimized with low
temperature and vacuum conditions wherever feasible.
11 Vents of storage tanks – Liquid raw materials will be charged by pumping &
during withdrawal to closed loops. Dedicated measuring tanks will be
day tanks provided for each reactor. Metering pumps shall also
be used wherever required. Suitable stoichiometric
calculations will be done and followed to regulate
thequantity of reactants to be charged to reaction
vessels in order to avoid use of excess chemicals.

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2.6.14 Details of Hazardous chemicals

The various hazardous chemicals as per the MSIHC rules 1989 & 2000 shall be stored
and handled by unit in terms of products, raw materials including solvents, fuels and
after the proposed expansion requirements of these chemicals will be increased with
the augmentation of new chemicals.

Details of such chemicals (major) are given in the table below,

Table 2.7 Details of Major Hazardous Chemicals handled / to be handled at site

Chem St colo Odor Sp Mel Boili Flas Explosive TLV Water NFPA Ha
ical at r Gr tin ng h limit pp solubi code zar
e g point poin m lity d
Poi Deg C t % % H F R
nt Deg LEL UEL
De C
gC
Acetic Li Colo Stron 1. - 139.9 49 2.7 10.3 5 Solu 3 2 0 Toxic,
anhy qu rless g 08 73. ble Flamm
dride id 1 able,
corros
ive
Acetic Li colo Pung 1. 16. 118 39 4 19.9 10 Solu 3 2 0 Toxic,
acid qu rless ent 05 6 ble Flamm
id able,
corros
ive
Caust Li colo Odorl 1. 318 1390 NA NA NA 2 Solu - - - Toxic,
ic lye qu rless ess 5 mg/ ble corros
id m3 ive
Meth Li colo Alcoh 0. - 64.5 12 6 36.5 200 Solu 1 3 0 Toxic,
anol qu rless ol 79 97. ble Flamm
id like 8 able
Tolue Li colo Benz 0. -95 111 4.4 1.1 7.1 50 Solu 2 3 0 Toxic,
ne qu rless ene 86 ble Flamm
id like able
Aceto Li colo Ether 0. -95 56 -20 2.6 12.8 750 Solu 1 3 0 Toxic,
ne qu rless like 79 ble Flamm
id able
Hydr Ga Colo No 0. - -253 Not 4 76 Not Not 0 4 0 Flamm
ogen s rless odor 07 259 avail avai solu able
gas (g able labl ble
as e
)
Sulph Li Colo Choc 1. -35 270 - - - 1 solu 3 0 2 Toxic
uric qu rless king 84 ble and
acid id odor corros
ive
IPA Li Colo Pleas 0. - 82.5 11.6 2 12.7 400 Solu 1 3 0 Toxic,
qu rless ant 78 88. ble Flamm
id 5 5 able
Ethyl Li Colo Ether 0. -83 77 -4.4 2.2 9.0 400 Solu 1 3 0 Toxic,
acetat qu rless eal, 90 ble Flamm
e id fruity 2 able
MDC Li Colo Not 1. - 39.75 Not 12 19 50 Part 2 1 0 Toxic,
qu rless availa 32 96. avail ially Flamm

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Chem St colo Odor Sp Mel Boili Flas Explosive TLV Water NFPA Ha
ical at r Gr tin ng h limit pp solubi code zar
e g point poin m lity d
Poi Deg C t % % H F R
nt Deg LEL UEL
De C
gC
id ble 7 able solu able
ble
Ethan Li Colo Pleas 0. - 78.5 12.7 3.3 19 100 Solu 2 3 0 Toxic,
ol qu rless ant 78 114 8 0 ble Flamm
id 9 .1 able
Cyclo Li Colo Chlor 0. 6.4 80.7 -18 1.3 8.4 300 Inso 1 3 0 Toxic,
hexan qu rless ofor 77 7 lubl Flamm
e id m 8 e in able
like cold
wat
er
DMF Li Colo Amin 0. -61 153 57.7 2.2 15.2 10 Solu 1 2 0 Toxic
qu urles e like 94 7 ble Flamm
id s 9 able
MTBE Li Colo Stron 0. - 55.2 - 28 2.5 15.1 Not Part 2 3 0 Toxic
qu rless g 74 109 avai ially Flamm
id labl in able
e cold
wat
er
THF Li Colo Ethre 0. - 65 - 2 11.8 590 Part 2 3 1 Toxic,
qu rless al, 88 108 14.5 ially Flamm
id fruity 9 .3 solu able,
ble reactiv
e
Di iso Li Colo Ether 0. -86 68.5 -28 1.4 7.9 250 Solu 1 3 1 Toxic,
propy qu rless al 72 ble Flamm
l id 5 able,
ether reactiv
e
Dimet Oil Colo Odorl 1. - Deco 83.3 Not Not 0.1 Part 4 2 0 Toxic
hyl y rless ess 33 31. mpos avail avail ially Flamm
sulph liq 8 es able able solu able
ate ui ble
d
Ethyl Li Colo Not 1. - 83.5 13 6.2 15.6 10 Slig 2 3 0 Toxic
ene di qu rless availa 23 35. htly Flamm
chlori id ble 5 3 solu able
de ble
Liquo Li Colo Amm 0. - Not Not Not Not 25 Solu 2 0 0 Toxic
r qu rless onoa 90 69. availa appl appl appl ble
amm id like 2 ble icabl icabl icabl
onia e e e
Mono Li Colo Amm 0. - 93 - 6.5 <- 4.9 20.7 5 Solu 3 4 0 Toxic
meth qu rless oniac 70 30 ble Flamm
yl id al able
amin
e
N Li Colo Gasol 0. - 95 68 - 1.15 7.5 50 Inso 1 3 0 Toxic
Hexa qu rless ine 66 22.5 lubl Flamm
ne id like e able

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Chem St colo Odor Sp Mel Boili Flas Explosive TLV Water NFPA Ha
ical at r Gr tin ng h limit pp solubi code zar
e g point poin m lity d
Poi Deg C t % % H F R
nt Deg LEL UEL
De C
gC
Tri Oil Colo Stron 0. - 89.7 -8.3 1.2 8.0 10 Solu 3 3 0 Toxic
ethyl y rless g 73 115 ble Flamm
amin liq able
e ui
d
Tert Li Colo Camp 0. 25. 82.41 11.1 2.4 8.0 300 Solu 1 3 0 Toxic
Butan qu rless hor 78 7 ble Flamm
ol id like able
Hydr Li Colo Not 1. - 113.5 72 4.7 - Not Solu 3 2 2 Toxic,
azine qu rless availa 0 51. avai ble Flamm
hydra id ble 7 labl able,
te e Reacti
ve
Note : Use of PPE’s shall be ensured while handling above chemicals such as safety helmet, splash proof goggles,
safety shoes, apron, rubber hand gloves as applicable.

2.7 Bulk storage

Following are the details of existing tanks and proposed bulk liquid storage tanks at site.
Table 2.8 Details of Existing and proposed bulk storage
No. Chemical Name No of Capacity,m3 Tank ID, m Tank
tanks length,m
Existing tanks
1 Methanol 1 1 15 2.0 5.0
2 Methanol 2 1 6 1.75 2.5
3 IPA 1 1 15 2.0 5.0
4 IPA 2 1 6 1.75 2.5
5 Toluene 1 1 15 2.0 5.0
6 Toluene 2 1 6 1.75 2.5
7 Ethyl Acetate 1 1 15 2.0 5.0
8 Ethyl Acetate 2 1 6 1.75 2.5
Proposed Tanks
1 Methanol 1 1 25 2.5 5.0
2 Methanol 2 1 15 2.0 5.0
3 Methanol 3 1 15 2.0 5.0
4 IPA 1 1 25 2.5 5.0
5 IPA 2 1 15 2.0 5.0
6 IPA 3 1 13 2.0 4.5
7 Toluene 1 1 25 2.5 5.0
8 Toluene 2 1 15 2.0 5.0
9 Toluene 3 1 15 2.0 5.0
10 Ethyl Acetate 1 1 25 2.5 5.0
11 Ethyl Acetate 2 1 13 2.0 4.5
12 Ethyl Acetate 3 1 10 2.0 3.0
13 Furnace oil 1 18 2.5 4.0

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Note:
1) All above tanks are and will be underground and horizontal. (except So No 13)
2) All above tanks are under CCOE/PESO. (except So No 13)
3) All tanks will be under nitrogen blanketing with 20 mbar pressure.( (except So
No 13)
4) In order to accommodate new tanks within site, some of existing tanks will be
replaced.

Other solid / liquid raw material and product shall be stored in ware house.

2.8 Fuel requirement

Existing and proposed Fuel requirement and air pollution control sources and controls
are as follows,
Table 2.9 Fuel requirement and Air pollution control system
Unit Status Fuel details Stack height Stack Exhaust
from ground & dia gas temp
APC system deg C
600 kg/hr Existing LSHS/LDO 300 20 m (common) 0.3 m 130 °C
steam boiler lit/day
600 kg/hr Existing
steam boiler
(stabdby)
Process Existing - Alkali scrubber 0.3 m 42°C
reactor (10 m)
Process Existing -
reactor
Boiler Proposed FO: 1.46 KL/day / 40 (APC : stack 0.5 m 150°C
(capacity NG - 1700 nm3/day height )
1000 kg/hr)

Boiler Proposed FO: 7.30 KL/day,

(capacity OR
5000 kg/hr) NG - 8000 Nm3/day
[To replace
existing 600
kg/hr boiler ]

Boiler Proposed
standby standby
(capacity
5000 kg/hr)
[To replace
existing 600
kg/hr boiler ]

Process Proposed Water Scrubber 0.3 42°C

reactor 10 m

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Process Proposed - Alkali scrubber 0.3 42°C

reactor 10 m
(Common)
Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023

2.9 Energy Requirements

2.9.1 Electricity

Existing power requirement of the site is 1000 KW which is sourced from MSEDCL.
Proposed additional power requirement shall be 3000 KW which also shall be sourced
from MSEDCL.

For emergency requirement there are two DG sets (380 and 40 KVA capacity).

For expansion need it is proposed to install 2 DG set of 1000 KVA and 750 KVA capacity.
Table 2.10 Fuel for DG sets
Unit Status Fuel details Stack height Stack dia Exhaust gas
from ground temp deg C
DG set 380 KVA Existing 260 12 m 0.1 m 115 °C
DG set 40 KVA Existing lit/month 12 m 0.1 m 104 °C
DG set 1000 Proposed HSD: 250 6.5 m above 0.2 m 115 °C
KVA Lit/hr roof
DG set 750 KVA Proposed HSD: 175 5.5 m above 0.2 m 104 °C
Lit/hr roof
Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023

2.10 Water Balance

Water requirement at site is mainly for

o Domestic purpose
o Industrial processing
o Boilers and cooling towers
o Gardening / Green belt maintenance
Fresh water requirements and waste water generation for existing and proposed
expansion are presented in the tables and figures below.
Fresh water is and will be sourced from MIDC’s water works.

2.10.1 Existing water requirement and waste water generation

Existing requirement as per Consent to operate granted by MPCB (Annexure 1.1) is as

follows,

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Table 2.11 Existing water requirement
No Water requirement for Cmd (M3/day)
1 Domestic 12
2 Industrial Process 25
3 Industrial cooling & Boiler feed 82
4 Gardening 10
Total 129
Ref: Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023
Existing waste water generation as per the consent is as follows,
Table 2.12 Existing waste water generation
No Source Total, cmd
1 Domestic effluent 9
2 Trade effluent 12
Total 21
Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023
As per the consent, soak pit is provided for sewage treatment. The treated sewage is
used for green belt within factory premises.
Existing effluent treatment plant capacity is for 20 cmd effluent as per the consent.
The treated effluent is sent to CETP.

2.10.2 Proposed water requirement and waste water generation

Proposed water requirement for the expansion is as follows,

Table 2.13 Overall Water requirement for expansion
No Water requirement Break Up Quantity (CMD)
1 Domestic 13
2 Industrial Process 60
3 Boiler feed & Cooling 185
4 Gardening 20
Total 278

Table 2.14 Total Water requirement (existing + proposed)

No Water requirement Break Up Existing Proposed Total
(cmd) (cmd) Quantity
(cmd)
1 Domestic 12 13 25
2 Industrial Process 25 60 85
3 Boiler feed & Cooling 82 185 267
4 Gardening 10 20 30
Total 129 278 407

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As can be seen from above, after expansion overall water requirement is 407 CMD
which shall be sourced from MIDC.
Centaur has applied to MIDC for the 407 cmd water requirement. Copy of letter from
MIDC is attached at annexure 2.2
Table 2.15 Overall Waste water generation after expansion (Existing + Proposed)
No Waste water from Quantity (CMD) Total
Existing Proposed
additional
1 Domestic 9 11 20
2 Trade effluent 12 62 74
Total 21 73 94

It is proposed to treat domestic sewage (20 CMD) in combined effluent treatment Plant
along with trade effluent.
Sewage and trade effluent treatment scheme is described in Chapter 4.
Overall water balance is represented below:

Figure 2.5 Overall water balance diagram after expansion

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Table 2.16 Summary of overall water consumption, loss, effluent in CMD

Particular Consumption (CMD) Loss (CMD) Effluent (CMD)
Water Existing Proposed Total Existing Proposed Total Existing Proposed Total
requirement
Domestic 12 13 25 3 2 5 9 11 20
Industrial
25 60 85 14 19 33 11 41 52
Processing
Cooling and
82 185 267 81 164 245 1 21 22
boiler feed
-Gardening
10 20 30 10 20 30 0 0 0
Total 129 278 407 108 205 313 21 73 94

2.10.3 Measures for VOC Control in Proposed expansion

Centaur is proposing to take following measures to control volatile organics in proposed

facility:
• Reactor vents to be connected to condensers to minimize escaping of VOC
emissions
• Reactor agitators and pumps to be provided with mechanical seal to eliminate
leakages
• Storage facilities to be provided with adequate measures to avoid losses by
exposure to ambient conditions
• Utility line sizes for condensers to be properly designed & adequate supply of
utility (flow & temperature) to be provided to all condensers
• Solvent traps to be provided in vent lines of reactors
• Proper earthing to be provided in all the electrical equipment wherever solvent
handling is to be carried out.

2.10.4 Measures for Process Emissions Control in Proposed Facility

Centaur is proposing to take following measures to control process emissions in its

proposed facility.
Overhead vapors from solvent distillation column shall be cooled / condensed by
cooling water. Uncondensed vapors shall be cooled / condensed by chilled water.

2.10.5 Measures for Odor Control in Proposed Facility

Centaur is proposing to control odor in its proposed facility through following ways:
• All solvent handling reactor vents to be connected to condensers to minimize
escaping of VOC emissions
• All solvent handling agitators and pumps to be provided with mechanical seal to
eliminate leakages
• Solvent handling agitator& pumps to be provided with mechanical seal to avoid
solvent losses to atmosphere

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• Storage facilities to be provided with adequate measures to avoid losses by
exposure to ambient condition
• Utility line sizes for condensers to be properly designed & adequate supply of
utility (flow & temperature) to be provided to all condensers
• Temperature indicators to be provided for condensers to avoid solvent losses
• Solvent traps to be provided in vent lines of reactors
• The charging of odorous raw materials if any to be done through closed systems
like Duct hoods, isolated cabins etc.

2.11 Non hazardous waste Treatment and Disposal

Waste generation and disposal for the proposed facility will be as follows:
Table 2.17 Nonhazardous waste generation and disposal
Existing
Proposed
No. Type of waste UOM Quantity Total Mode of Disposal
quantity
(*)
1 Empty drums Nos./Month 500 4,000 4,500 Sale to authorised recycler
2 Glass bottles Kg/Annum 3600 10,000 13,600 Sale to authorised recycler
3 Plastic bags Kg/Annum 1680 4,400 6,080 Sale to authorised recycler
4 Corrugated sheets Kg/Annum 1200 0 1200 Sale to authorised recycler
5 Metal scrap MT/Annum 8.5 11.5 20 Sale to authorised recycler
6 Paper waste MT/Annum 0 5 5 Sale to authorised recycler
7 Plastic waste MT/Annum 0 4 4 Sale to authorised recycler
8 Rubber waste MT/Annum 0 1 1 Sale to authorised recycler
Sale to authorised recycler/
9 Boiler Ash MT/Annum 0 15 15
CHWTSDF
10 Wooden waste MT/Annum 0 1 1 Sale to authorised recycler

* Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023

2.12 Hazardous Waste Treatment and Disposal

Hazardous waste generation and disposal in the proposed facility of Centaur will be as
follows:
Table 2.18 Hazardous waste generation and disposal
Category Existing
No Proposed
Description (as per HW UOM Quantity Total Mode of Disposal
quantity
rules 2016) (*)
Sludge and filters
1 contaminated with 3.3 TPA 0 2 2 CHWTSDF
oil
Sale to authorized Re
2 Used or spent oil 5.1 TPA 4.8 10 14.8
processor/CHWTSDF
Wastes or residues
3 5.2 TPA 0.1 0.2 0.3 CHWTSDF
containing oil
4 Discarded Asbestos 15.2 TPA 0 0.8 0.8 CHWTSDF
Process residue
5 28.1 TPA 2.4 660.6 663 CHWTSDF
andwastes
6 Spent carbon 28.3 TPA 6 248 254 CHWTSDF

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Category Existing
No Proposed
Description (as per HW UOM Quantity Total Mode of Disposal
rules 2016) quantity
(*)
Off specification
7 28.4 TPA 0 5 5 CHWTSDF
products
Date-expired
8 28.5 TPA 0 5 5 CHWTSDF
products
Sale to authorized
9 Spent solvent 28.6 TPM 5 395 400 Reprocessor/
CHWTSDF
Emptybarrels/
containers/ liners Sell to authorized
10 contaminated with 33.1 Kg/M 0 2000 2000 Reprocessor/
hazardous CHWTSDF
chemicals/ wastes
Contaminated
cottonrags or other
11 33.2 TPA 0 1 1 CHWTSDF
cleaning
materials
Exhaust air or gas
12 35.1 TPA 0 3 3 CHWTSDF
cleaning residue
Spent ion
exchangeresin
13 35.2 TPA 0 0.5 0.5 CHWTSDF
containing toxic
metals
Chemical sludge
14 fromwaste water 35.3 TPA 0.96 149.04 150 CHWTSDF
treatment
15 Filter medium 36.2 TPA 0 2 2 CHWTSDF
Sale to authorized
16 E waste - Kg/M 75 425 500 Reprocessor/
CHWTSDF
17 Biomedical waste - Kg/year 0 100 100 CHWTSDF
Sale to authorized
18 Used batteries - Nos/year 0 100 100 reprocessor / Buy
back

* Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023

2.13 Solid and Hazardous Waste Management

• Storage in separate storage area, duly segregated from each other

• Impervious flooring/ weather shed with lock & key.
• PPE’s for handling.
• Centaur to dispose the waste as per conditions specified in environmental
clearance/consent to operate

2.14 Environmental Monitoring & Management

Company will undertake monitoring of stacks & ambient air quality and neutralized
effluents through third party laboratory recognized by MOEF. The facility will
improve/develop its own Quality Control Lab for liquid effluent analysis.

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2.14.1 Management System

The facility will maintain ISO 9001:2015, ISO 14001:2015 & ISO 45001: 2018 so that the
environment/ health/ safety aspects are properly identified.

2.15 Risk of Technological Failure

Company is proposing to expand capacity of existing product range. The technology and
processes are specially developed by Centaur through its rigourous R & D efforts.

Centaur has vast experience in developing and optimizing process/technologies in the

field of the API’s proposed to be manufactured. In addition to this the facility is being
backed up by the R & D centre there would be continuous efforts for optimization of the
process to take care of the any technological failures.
Hence risk of technological failure is minimal for proposed expansion.

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3 D ESC RIPTIO N O F ENVIRO NMENT

The baseline data on the pre-installation status of the terrestrial environment

covering land environment, biological environment (flora & fauna) & socio-
economic environment in the study area was collected by undertaking Primary
surveys through field visits, monitoring and laboratory analysis. Secondary data was
collected from relevant agencies, such as Thane district town Planning, Forest
Department and Directorate of Census Operations. The baseline data collected and
generated, together with the relevant project activities will be considered for
predicting the likely impacts of the project on the environment. Subsequently, an
appropriate environmental management plan (EMP) will be presented to enable the
project proponent to run the project within acceptable level of environmental
impact and meet the compliance of the regulatory criteria (MOEF&CC Guidelines).
An Environmental Impact Statement (EIS) will be ultimately made to summarize the
post project status of the terrestrial environment, with the project proponent
incorporating the suggested EMP measures.
For the purpose of assessing the impacts, study area of 10 km radius around project
site was identified for the EIA as per MOEF&CC guidelines.

3.1 General Setting of Site and Study Area

3.1.1 Description of Study Area

The Geographical Location of this Industry is 190 11’ 42” N Latitude and 730 12’ 31’’
E Longitude.
The proposed expansion is on the existing location at plot no. 74, 75, 76 & 76/1 of
MIDC Industrial Estate, Ambernath (west), Dist Thane Maharashtra. This site is in
premises of Chikhloli MIDC area which is meant for these types of Industries.
Land ownership is with project proponents (Centaur Pharmaceuticals Private
limited) and is reserved for industrial use & presently project expansion site is at
the same plot. Infrastructure like water, electricity, telephone facility, roads already
available as this is an existing Industrial area
MIDC Ambernath provides basic facilities like uninterrupted water supply, power
and Road Network. When various alternatives sites were examined, this site
appeared to be environmentally best as also from the business angle and therefore
this option was finally adopted. This site is inside the campus of the MIDC and
means safe transportation, less need of Utilities, less constructing buildings and
roads, less fuel, less water with optimization of infrastructure.

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Figure 3.1 Google image of site with 10 km study area

Figure 3.2 Google image of site with 1km study area

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3.1.2 Thane district climate

The climate of the district is distinctly different on the coastal plains and on the
eastern slopes. Being fully tropical, the climate on the coast, the coastal strip
including Thane, Vasai, Palghar and Dahanu tahsils is very humid and warm. On the
other hand, the climate on the eastern slopes and in the plains at the foot of the
slopes is comparatively less humid. However, variation in temperature in the
eastern region is more than that on the coastal strip. The maximum temperature lies
between 28.0 to 35.2 centigrade and the minimum temperature lies between 16.3 to
26.5 centigrade.
Rainfall is by far the most important factor influencing the agricultural economy of
the district as it determines the pattern of crops. The spacing of rainfall perhaps
explains the culturable practices currently in vogue in the district.
In Thane district rainfall commences in the month of June and continues till the end
of the September. The rainfall is not uniform throughout the district. It is
considerably more inland than on the coast. Also it is less towards the north and
towards the south. The district, however, receives heavy and assured rainfall. The
annual rainfall in Dahanu, Palghar, Bhiwandi, Thane, Talasari, Mokhada, Kalyan and
Murbad talukas was less than 2,000 mm. during 1974, while in the rest of the
talukas it was between 2,000 mm. and 3,000 mm. during the same year. It was the
highest in Wada taluka and the lowest in Dahanu taluka. The average of rainy days
in a year was 99. The rainfall is entirely due to the south-west monsoon with the
highest intensity in July.

3.1.3 Salient Features of Site and Surroundings

Centaur Pharmaceuticals Pvt. Ltd. API Division is mainly Export oriented unit. To
cope up with marketing demand we require the expansion of the facility. This helps
us to generate the foreign exchange by exporting our products, as well as increasing
more employment to the people.
Currently they have a number of export orders from the overseas customers but
cannot meet the delivery schedule as per their timelines. To avoid this demand and
supply gap of the export orders, the company is going for expansion of the existing
facility.
The expansion will come up in existing complex of the company situated on
Maharashtra Industrial Development Corporation’s land (MIDC) in Chikhloli MIDC,
Maharashtra.

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Figure 3.3 Geographical Location of Project site

Table 3.1 Environmental sensitivity receptor
Receptot Approx. Distance & Direction
Buvapada 0.5 km to North
Ulhas river 3.5 km to North- East
Chikhloli Dam 1.8 km to South
Morivali village 1.1 km to North- West

3.1.4 Defination of LULC Classes

Definition of LULC Classes as per the Ministry of Statistics and Programme

Implementation (MOSPI) is given in the following table.
Table 3.2 Definition of LULC Classes
No Class Class Definition
It is an area (within the notified forest boundary) bearing an
Dense
1. association predominantly of trees and other vegetation types
Vegetation
capable of producing timber and other forest produce.
Semi- It is described as a forest, which comprises of thick and dense
evergreen / canopy of tall trees, which predominantly remain green
2. Moderate throughout the year. It includes both coniferous and tropical
Dense broad-leaved evergreen trees. Semi-evergreen forest is a
vegetation mixture of both deciduous and evergreen trees but the latter

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No Class Class Definition
predominate

Degraded It is described as a forest where the vegetative (crown)

3.
Vegetation density is less than 30% of the canopy cover.
It is described as openings amidst forests without any tree
Secondary
4. cover. It includes openings of assorted size and shapes as seen
Vegetation
on the imagery.
5. Scrub Land Scrub is a stunted tree or bush/shrub.
It is defined as the land primarily used for farming and for
production of food, fiber, and other commercial and
6. Agriculture
horticultural crops. It includes land under crops (irrigated and
un-irrigated), fallow, plantation, etc.
It is described as agricultural land which is taken up for
cultivation but is temporarily allowed to rest un-cropped for
7. Fallow Land one or more seasons, but not less than one year. These lands
are particularly those which are seen devoid of crops at the
time when the imagery is taken of both seasons.
It is described as an area under agricultural tree crops,
planted adopting certain agricultural management techniques.
8 Plantation
It includes tea, coffee, rubber, coconut, areca nut, citrus,
orchards and other horticultural nurseries.
Mine / quarry areas subject to removal of different earth
9. Quarry material (both surface and sub-surface) by manual and
mechanized operations.
It is described as openings amidst forests without any tree
10. Open land cover. It includes openings of assorted size and shapes as seen
on the imagery.
It is defined as an area of human habitation developed due to
Residential
non-agricultural use and that which has a cover of buildings,
11. Area
transport, communication utilities in association with water
(Urban/Rural)
vegetation and vacant lands.
Industrial
12. It is defined as an area of industrial activities.
Area
It is described as a dense thicker or woody aquatic vegetation
13. Mangrove or forest cover occurring in tidal waters near estuaries and
along the confluence of delta in coastal areas.
It is a course of flowing water on the land along definite
Water body/
14. channels. It includes from a small stream to a big river and its
River
branches. It may be perennial or non-perennial.
It is a natural or man-made enclosed water body with a
regulated flow of water. Reservoirs are larger than
15. Reservoir
tanks/lakes and are used for generating electricity, irrigation
and for flood control.

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A Survey of India (SOI) Open series map with 1:50,000 scale was used to identify
topographic features within 10 km radius around project site is shown as below.
Refer Annexure 3.1 for Open series map.

Table 3.3Open series map showing study area around project site
A detailed study area map for the study area is prepared that indicates roads,
railways, major settlements, rivers and tehsil boundaries. The project site is located
at plot no. 74, 75, 76 & 76/1 of MIDC Industrial Estate, Ambernath (west), Dist
Thane Maharashtra. This site is in premises of Chikhloli MIDC area which is meant
for these types of Industries.
Site is also accessible from the State Highway SH80. The nearest town is Ambernath
and nearest railway station is also Ambernath Railway Station. The site is well
connected.
The Geographical Location of this Industry is 190 11’ 42” N Latitude and 730 12’ 31’’
E Longitude with an elevation of 39 meter above sea level MSL.

3.1.5 GIS Maps

GIS maps consist of contour and drainage maps prepared using Digital Elevation
Model (DEM) whereas LULC maps are prepared with the help of RESOURCESAT-2
LISS- IV cloud free data.

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3.1.5.1 Contour Maps

Thematic manuscript for contour layer was generated from Survey of India
toposheet at 1:50,000 scale. After scanning, coverage was generated. Coverage was
edited to remove all errors of dangle. Attribute value was given to each contour in
the coverage.
A 20 m interval contour map was prepared for the area covering 10 km radius
around the centre of the project site. A prominent hilly region can be seen in the
southern side of the site with highest elevation of 720m MSL. The lowest contour
within the study area is 80m MSL.
Detailed map of 10 m interval contour covering 500 m angular distance is shown in
figure 7. The map shows comparatively flat terrain with no slope.
3.1.5.2 Digital Elevation Model (DEM)

Fig. 8 below represents the Digital Elevation Model (DEM) of an area of 10 km

surrounding the site. It can be seen from the same that there is a slight elevation to
the North east of the site. A hillock of maximum elevation 726m exists to the South
of the site.
3.1.5.3 Drainage maps

Drainage layer is generated after scanning the thematic manuscripts which is

further edited for line errors. Two different layers were made separately for line
drainage. Drainage order was given to all the drain lines in the layer.
Strahler’s method of ordering is used for giving order to drainage, wherein the
smallest permanent streams are designated as the first order and the confluences of
two first order streams give rise to second order stream and so on. The order of
trunk stream is not altered by the addition of lower order. The order of the stream
will increase only by the addition of streams of same order.
It can be seen from the Drainage Map of 10km surrounding the site (Fig. 9). that
first, second and third order streams and small rivulets run from the west of the site
to the North. Further they join the Ulhas River flowing from North to West.
3.1.5.4 Watershed Map

Fig. 11 below represents the Watershed Map of an area of 10 km surrounding the

site. It can be seen from the same that the site lies to the south of the catchment area
or watershed surrounding it. The site and surrounding area slopes gently to the
west, North west where small streams flow towards the west and join a riveulet
further north. These further join the Ulhas River flowing from North to West.

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Figure 3.4: Contour map of 10 km radius area around Project Site

Figure 3.5: Contour map of 500 m angular distance around Project Site

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Figure 3.6DEM of an area of 10 km angular distance around Project Site

Figure 3.7: Drainage map of 10 km radius area around Project Site

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Figure 3.8: Drainage map of 500 m angular distance around Project Site

Figure 3.9: Watershed Map of 10 km angular distance around Project Site

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The study area covering 500 m radius around project site exhibits third order
drainage pattern as shown in figure 10.
3.1.5.5 False Colour Composite Image

A false-colour image sacrifices natural colour rendition in order to ease the

detection of features that are not readily discernible otherwise – for example the use
of near infrared for the detection of vegetation in satellite images. The choice of
spectral bands is governed by the physical properties of the object under
investigation. The simplest false-colour encoding is to take an RGB image in the
visible spectrum, but map it differently, e.g. "GBR→RGB". For traditional false-colour
satellite images of Earth a "NRG→RGB" mapping is used, with "N" being the near-
infrared spectral band (and the blue spectral band being unused) – this yields the
typical "vegetation in red" false-colour images.
3.1.5.6 LULC Maps

The digital classification technique is used for the extraction of the landuse/
landcover information from the imagery (Fig 12). A landuse land cover map of 10
km radius around the project site is prepared and the same is shown as figure 13.
Eleven different landuse/ landcover classes have been identified in the area under

study.
Figure 3.10: Geo-referenced False Colour Composite (FCC) Resourcesat-2
satellite image

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Figure 3.11 Landuse/landcover map of 10 km radius area around Project Site

Figure 3.12Landuse/landcover map of 500m angular distance around Project

Site

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3.1.6 Statistics of LULC Classes

The area distributions along with percentage distribution of the different LULC classes
within the study area are shown in table 5 and figure 15 respectively.
Scrub land (24.7%) and Built up land (23.80%) dominates the land use pattern within
the 10 km angular distance around project site.
It is followed by Fallow Land contributing 16.10%. Barren/Query/sandy area is 10.0%,
Land with shrub 9.1%, Agricultural Crop Land is 7.5% whereas part of land is Open
Forest (5.8%) and open land (5.8%) and part is Dense Forest (2.4%). Plantation and
water bodies occupy about 2.1% and 1.9 % land respectively.
Table 3.4 Landuse/ Landcover Statistics of the 10 km radius Area
Sr. No. LULC Class Area (Sq. Km) Distribution (%)
1 Scrub Land 77.60 24.70
2 Builtup Land 74.80 23.80
3 Fallow Land 50.50 16.10
4 Barren/ Quarry/ Sandy Area 30.00 10.00
5 Land without Scrub 28.40 9.10
6 Agriculture Crop Land 23.40 7.50
7 Open Land 18.30 5.80
8 Open Forest 18.30 5.80
9 Dense Forest 7.60 2.40
10 Plantation 6.50 2.10
11 Waterbody 5.90 1.90
Total 314.30 100.00

Figure 3.13 Landuse/landcover statistics of 10 km radius area around Project Site

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A landuse landcover map covering 500 m angular distance around project site is shown
in Figure 16. The map shows 3 different landuse classes.
Most of the area around the site is Built Up land which is about 54.9% and dominates
the landuse pattern around 500 m angular distance from the project site. Scrub land is
about 40.4% whereas area under Tree Plantation is about 4.7%.
Table 3.5 LULC Statistics of the 500m angular distance around project site
Sr. No. LULC Class Area (Sq. Km) Distribution (%)
1 Builtup Land 0.431 54.9
2 Scrub Land 0.313 40.4
3 Tree Plantation 0.037 4.7
Total 0.785 100.00

Figure 3.14 LULC statistics of 500 m angular distance around Project Site
Detailed LULC report is attached at Annexure 3.2

3.2 Soil Quality Monitoring

Soil quality reflects how well a soil performs the functions of maintaining biodiversity
and Productivity, partitioning water and solute flow, filtering and buffering, nutrient
cycling, and providing support for plants and other structures. Soil management has a
major impact on soil quality.

Representative soil samples were collected from the study area to assess the quality of
soil. For studying the soil types and the soil characteristics, different sampling locations
were selected to assess the existing soil condition representing various land use
condition and geological features.

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3.2.1 Methodology of Soil Monitoring

A number of parameters were determined, which are indicative of physical, chemical

and fertility characteristics. Sampling and analysis was conducted as per established
standard methods and procedures prescribed in IS 2720 and ASTM.

Soil samples were collected by ramming a hand auger into the soil upto a depth of 90
cm. At each of the sampling location, soil samples were collected from three different
depth viz. 30 cm, 60 cm and 90 cm below the surface and homogenized. The
homogenized samples were then packed in a polythene plastic bag and sealed and the
sealed samples were sent to the Laboratory for analysis.

3.2.2 Soil Characteristics in the study area

The project is located within MIDC land and most of the land is back filled & leveled.
Soil quality studies were carried out in nearby villages in different land use areas as part
of baseline assessment. The parameters selected give basic information on type of soil,
particle size distribution and water retention and chemical characteristics.

3.2.3 Soil Monitoring Locations

The Soil Monitoring was conducted for studying the various parameters at eight different
locations within the study area. The summary of monitoring locations for the Soil Quality is
given in Table below. The sampling locations were chosen based on their proximity to the
project site. Figure below shows the soil sampling locations in the impact area map.

Figure 3.15 Soil sampling locations in 10 km study area

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Table 3.6 Soil Analysis report
Sr.N Project Matoshri Vadvali Thakurp Chikhlol Vasat Vasat Kailash
Parameter Unit Method of analysis
o. Onsite nagar village ada i village Phata village nagar
1 pH -- 6.78 6.62 6.73 6.76 6.42 6.59 6.64 6.73 IS-2720 (part 26) 1987
2 Moisture % 4.8 5.2 4.7 4.2 4.5 4.3 5.2 4.7 IS-9235-2005
Clay % 58.8 48.6 48.6 48.6 62.4 59.6 62.4 58.9
Silt % 7.2 4.8 4.8 4.8 5.1 8.2 7.8 9.9
Particle
3 Fine sand % 24.8 38.6 38.6 38.6 25.6 28.3 25.6 24.6 IS-2720 (part 4) 1985
Size
Coarse Sand
10.2 8.0 8.0 8.0 7.9 4.9 5.1 6.6
%
4 Texture -- Clay Clay Clay Clay Clay Clay Clay Clay IS-2720 (part 4) 1985
5 Water % 3.2 4.6 4 3.6 4.1 3.8 4.8 4.5 IS-14765-2000
6 holding
Bulk g/cm3 1 1.1 1 1 1.1 1.2 1.1 1.2 Clod method
7 capacity
Density
Chloride Kg/hector 326 334 421 286 304 386 326 326 IS-3025 (Part 32) 1988
8 Sulphate Kg/hector 125 126 120 96 112 98 123 123 IS-2720 (part 27) 1977
9 Ca Kg/hector 142 98 112 82 134 142 96 96 IS-3025 (Part 40) 1991
10 Mg Kg/hector 96 52 33.4 11.2 24.6 53 34 34 IS-3025 (Part 46) 1994
11 Na Kg/hector 113 120 128 104 98 101 82 82 IS-3025 (Part 45) 1993
12 K Kg/hector 64 51 64 72 46 67 24 24 IS-3025 (Part 45) 1993
13 TKN % ND ND ND ND ND ND ND ND IS-14684-2008
14 Phosphorus kg/hector ND ND ND ND ND ND ND ND IS-3025(Part 31)2009
15 TOC % 0.11 0.12 0.08 0.10 0.11 0.08 0.08 0.08 IS-2720(part 22)2010
16 TOM % 0.14 0.21 0.14 0.17 0.18 0.14 0.14 0.14 IS-2720(part 22)2010
Conductivit
17 µS/cm 352.32 459.7 324.6 448.96 615.6 689.3 558.3 558.3 IS-14767-2000
y
18 CEC Centimole/kg 18.4 16 18 18 15.6 17 16 19 --
Sodium
19 Absorption % 10 11.5 10.2 12 9 10.2 11 11.3 --
ratio (SAR)
ND - Not detected.

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Standard soil classification as per Handbook of Agriculture, Indian Council of
Agricultural Research is as follows,
Table 3.7 Standard Soil Classification
No Soil Test Classification
1 pH Less than 4.5 : Extremely acidic
4.51 – 5.50 : Very strongly acidic
5.51 – 6.50 : Moderately acidic
6.51 – 7.30 : Neutral
7.31 – 7.80 : Slightly alkaline
7.81 – 8.50 : Moderately alkaline
8.51 – 9.00 : Strongly alkaline
9.01 and above : Very strongly alkaline
2 Salinity Electrical Up to 1.00 : Average
conductivity (µmhos/cm) 1.01 to 2.00 : Harmful to germination
(1 ppm = 640 µmhos/cm) 2.01 to 3.00 : Harmful to crops (sensitive to
salts)
3 Organic Carbon (%) Up to 0.2 : Very less
0.21 to 0.40 : Less
0.41 to 0.50 : Medium
0.51 to 0.80 : On an average sufficient
0.81 to 1.00 : Sufficient
> 1.0 : More than sufficient
4 Nitrogen (Kg/Ha) Up to 50 : Very less
51 – 100 : Less
101 – 150 : Good
151 – 300 : Better
More than 300 : Sufficient
5 Phosporous (Kg/Ha) Up to 15 : Very less
16 – 30 : Less
31 – 50 : Medium
51 – 65 : On an average sufficient
66 – 80 : Sufficient
More than 80 : More than sufficient
6 Potash (Kg/ha) 0 – 120 : Very less
121 – 180 : Less
181 - 240 : Medium
241 - 300 : Average
301 – 360 : Better
More than 360 : More than sufficient
Source: Handbook of Agriculture, Indian Council of Agricultural Research
Observation and interpretation from results:
• Soil in the area is mainly clay in texture hence low water holding capacity.
• pH of soil varies from 6.42 to 6.78 which is as per above reference table is from
“Moderetly acidic” to “Neutral”.
• Conductivity of soil is observed within range of “Average” i.e. from 324.6 µS/cm
to 689.2 µS/cm.

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• Potassium content in the soil samples varies from 34 kg/Ha to 72 kg/Ha which is
“very less”
• % TOC is observed in range of 0.08 % to 0.12 % which is very less.
• Phosphate content in the soil is Not detected
• From above observation, it is observed that the soil is having low content of
macro nutrient.

3.3 Solid/Hazardous Waste Generation, Treatment and Disposal

Existing hazardous waste generation/ disposal as per consent and actual is presented
below,
Table 3.8 Hazardous waste generation and disposal
Quantity
Quantity as Treatment and
No Waste type Category for
per CTO disposal
2017-18
0.215 Sale to aurhorised
1 Used/Spent oil 5.1 4.8 TPA
Ton reprocessor/CHWTSDF
2 Cotton waste 5.2 0.1 TPA - CHWTSDF
Residue and 2.226
3 28.1 2.4 TPA CHWTSDF
waste Ton
4 Spent carbon 28.2 6.0 TPA 5.18 Ton CHWTSDF
5 ETP Sludge 34.3 0.96 TPA 0.88 Ton CHWTSDF
Spent / waste 5000 36.14 Sale to aurhorised
6 28.6
solvent Lit/Month Ton reprocessor/CHWTSDF
75 Sale to aurhorised
7 E waste - -
kg/Month reprocessor/Recyclers
Membership of CHWTSDF is enclosed in Annexure 3.3
Ref: Consent to Operate No. Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023

3.4 Climate and Meteorology

3.4.1 Wind

Winds are generally moderate except in the latter half of the summer and the south-
west monsoon season when they are stronger. Winds during May and the monsoon
months are mainly from directions between the north-west and south-west.
The prevailing micrometeorology at project site plays a vital role in transport and
dispersion of air pollutants released into atmosphere. The persistence of the
predominant wind direction and wind speed class during a particular time period at the
project site will decide the direction and extent of the worst impact zone at that time.
The prominent wind direction at project site during the study period (winter 2017-18)
is from south west with 64.5 % calm conditions. Wind rose diagram for project site is
presented in Figure below, (which shows predominant wind direction at site)

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Figure 3.16 Wind Rose for winter 2017-18 season

3.4.2 Temperature & Humidity

The air is generally dry during the months from February to May and particularly so in
the afternoons when the humidity is about 20 per cent on the average. The relative
humidity during south-west monsoon period is between 60 and 80 per cent. Thereafter
they decrease rapidly.
Temperature and humidity data collected at site during sampling period (November
2017 to January 2018) is presented below.
Table 3.9 Summarized Met Data Collected at Site
Month Factor Minimum Average Maximum
Temperature (0C) 18.7 30.9 36.3
November 2017
Humidity (%) 13.0 52.0 86.6
Temperature (0C) 17.2 25.5 35.2
December 2017
Humidity (%) 16.7 62.2 94.7
Temperature (0C) 16.5 26.2 36.1
January 2018
Humidity (%) 13.9 52.9 90.2

Rainfall

The average annual rainfall in the district is 2,294 mm. The rainfall in the district
increases from the coast towards the interior. The rainfall varies from 1,730 mm at
Mahim on the coast to 2588 at Shahapur in the interior. The rainfall during the south-
west monsoon season, June to September, constitutes about 94 per cent of the annual
rainfall. July is the rainiest month with a rainfall of about 40 per cent of the annual total.

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The variation in the annual rainfall from year to year in the district is not large. In the
fifty-year period, 1901 to 1950, the highest annual rainfall in the district amounting to
142 per cent of the normal occurred in 1931, while 1905 was the year with the lowest
annual rainfall which was only 56 per cent of the normal. In the same fifty-year period
the annual rainfall in the district was less than 80 per cent of the normal in seven years,
two being consecutive. Considering the rainfall at the individual stations, two or three
consecutive years of such low rainfall occurred once at eight out of the ten stations
during this fifty-year period. It will be seen from table No. 3 that the annual rainfall in
the district was between 1,800 and 2,800 mm in thirty-eight years out of fifty.

On an average there are 83 rainy days (i.e., days with rainfall of 2-5 mm or more) in a
year in the district. This number varies from 67 at Mahim on the coast to 92 at Thane.

The heaviest rainfall recorded in 24 hours at any station in the district was 481 mm at
Dahanu on 1st September 1958.

Rainfall data for the year 2015 is presented below and shows the following:

3.5 Air Environment

3.5.1 Reconnaissance Survey

The prime objective of this AAQ study is to establish the existing regional background
levels within study zone of proposed project. Major sources of air pollution are
identified as medium and small-scale units spread over surrounding 10 km area (parts
of Industrial Area) & traffic on nearby Roads and highway (Kalyan Badlapur road,
Ambernath Badlapur road).Other miscellaneous sources are identified as burning of
minor fuels and dust from movement of traffic along rural roads.

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Minor sources are identified as low quality fuels burnt in rural area and dust emanated
from unpaved roads, brick kilns and quarrying.
MIDC Chikhloli is a notified chemical zone and has about 100- 150 large/medium and
small scale industries.

3.5.2 Onsite Air Environment

Following are the air pollution sources, air pollution control devices provided and stack
details at Centaur site (as per Consent to operate).
Table 3.10 Air Pollution Control devices and stack details
S. Stack APC Height Type of Quantity % SO2
N. Attached to Provided (Mtrs.) Fuel Sulphur (Kg/day)
1 Boiler Stack 20 LSHS/ 300 lit/day 1.0/ 6.0/
2 Boiler (standby) Stack LDO 1.8 10.8
3 Process reactor Water 10 - - - -
scrubber
4 Process Reactor Alkali 10 - - - -
scrubber
5 DG set Stack 12 HSD 260 - -
6 DG set Stack lit/Month - -
Ref: Consent to Operate No. Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023
Stack monitoring is routinely carried out by Centaur. It is done by M/s. Aavanira biotech
(ISO 9001:2015 and OHSAS 18001:2007 certified company). Recent results of stack
monitoring are presented below.
Table 3.11 DG set stacks
Parameter Unit DG 40 KVA DG 380 KVA Limit as per MPCB consent
TPM mg/Nm3 41.02 54.12 <150
SO2 mg/Nm3 48.63 65.65 -
SO2 Kg/day 1.68 2.16 <10.8
Nox mg/Nm3 BDL BDL -
Ref: Sampling date 08.08.2018 Report no. AB/CPPL/08/2018-19/ 266, 265
Table 3.12 Source emission monitoring (Scrubber - old building)
Parameter Unit Result MPCB Limit
TPM mg/Nm3 4.13 < 150
Acid mist ppm 2.31 < 35
Ref: Sampling date 08.08.2018 Report no. AB/CPPL/08/2018-19/ 267
Table 3.13 Boiler stack (600 kg/hr capacity)
Parameter Unit Result Limit as per MPCB consent
TPM mg/Nm3 74.32 <150
SO2 mg/Nm3 57.11 -
SO2 Kg/day 2.16 <10.8
Nox mg/Nm3 3.31 -
Ref: Sampling date 08.08.2018 Report no. AB/CPPL/08/2018-19/ 264

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Above stack results indicates the monitored parameters are well within prescribed
limits.
In addition to the above, workzone environment and ambient air quality monitoring
results at site are summarized below,
Table 3.14 Work zone air quality monitoring results
Prod. Prod.
Prod. Dept
Dept 4th Dept 2nd Factory act
Location : 3rd floor
Parameter Unit floor floor 1948
R. M. Store (new
(new (new standard
bldg.)
bldg.) bldg.)
Not
SPM µg/m3 10.3 02.04 03.01 BDL
specified
Methylene
ppm BDL 03.19 03.65 04.12 -
dichloride
Acetic Acid ppm BDL 03.87 04.19 02.30 10
Methanol ppm 0.10 02.74 06.15 BDL 200
Acetone ppm 0.14 BDL BDL BDL 750
Ethyl acetate ppm BDL BDL BDL 02.13 400
Iso propanol
ppm BDL BDL BDL BDL 100
Alcohol
Toulene ppm BDL BDL BDL 01.09 100
Ref: Sampling date 11.08.2018, 10.08.2018, 08.08.2018 Report no. AB/CPPL/08/2018-19/ 262,
260, 259, 258
Table 3.15 Work zone air quality monitoring results
Prod.
Pharma
Dept 2nd Prod. Dept Factory act
area Solvent
Parameter Unit floor 1st floor 1948
(Ground area
(old (old bldg.) standard
floor)
bldg.)
BDL Not
SPM µg/m3 04.12 BDL BDL
specified
Methylene di BDL
ppm BDL BDL 02.47 -
chloride
Acetic Acid ppm BDL BDL BDL BDL 10
Methanol ppm 01.43 03.21 01.87 02.13 200
Acetone ppm BDL BDL BDL BDL 750
Ethyl acetate ppm BDL BDL BDL BDL 400
Iso propanol BDL
ppm 04.69 BDL 01.07 100
Alcohol
Toulene ppm BDL 01.69 BDL BDL 100
Ref: Sampling date 11.08.2018, 10.08.2018, 08.08.2018, 09.08.2018 Report no. AB/CPPL/08/2018-
19/ 261,257,256,263

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Table 3.16 Ambient air quality monitoring results
Near RM Near ETP Near Main NAAQ
Parameter Unit
store area gate standard
PM10 µg/m3 48.66 61.02 54.28 < 100
PM2.5 µg/m3 14.27 30.49 19.35 < 60
SO2 µg/m3 11.32 18.76 10.62 < 80
NOx µg/m3 07.89 10.29 09.31 < 80
Ozone (O3) µg/m3 BDL BDL BDL > 180 ( I hr)
Lead (pb) µg/m3 BDL BDL BDL <1
Carbon monoxide (CO) mg/m3 BDL BDL BDL < 4 (1 hr)
Ammonia (NH3) µg/m3 BDL BDL BDL < 400
Benzene (C6H6) µg/m3 0.10 BDL BDL <5
Benzo(a)pyrene (BaP) ng/m3 BDL BDL BDL <1
Arsenic (As) ng/m3 BDL BDL BDL <6
Nickel (Ni) ng/m3 BDL BDL BDL < 20
Ref: Sampling date08.08.2018, Report no. AB/CPPL/08/2018-19/254, 255, 253
It can be clearly seen from the above table that existing onsite air environment is
within the prescribed limits.

3.5.3 Methodology for Selection of Monitoring Locations

Ambient air quality status within the study area forms the baseline information over
which the predicted impacts due to the proposed activities are to be superimposed the
ambient air quality is assessed through a scientifically designed ambient air quality
monitoring network based on the following considerations:
• Meteorological conditions on synoptic scale.
• Topography of the study area.
• Representations of regional background levels.
• Representations of plant site.
• Representations of predominant and cross-sectional distribution in the
downward direction.
• Influence of the existing sources if any.
• Inclusion of population zone and sensitive receptors including reserve forests to
collect baseline.
Ambient Air Quality Monitoring (AAQM) stations were set up at 8 locations with due
consideration of above mentioned points. Table below and Figure overleaf give details
of AAQM stations selected.

3.5.4 Baseline Ambient Air Monitoring Studies

The baseline air quality was established by monitoring PM10, PM2.5, SO2, NOx, CO, nMHC
at Eight locations (1 Onsite & 7 surrounding area/villages) in winter 17-18 (November,
December & January) PM10& PM2.5 was monitored on 24 hourly bases whereas all
gaseous parameters were monitored on 8 hourly basis using respirable High Volume
Sampler and standard methods prescribed by APHA/IS.

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CO was monitored using hand held electronic meter (electro-chemical sensor).
Table and Figure below give locations of air monitoring stations, and bearing w.r.t. the
sites.
Table 3.17 Details of Ambient Air Monitoring Stations
Distance (km)
Sr. X UTM co Y UTM co Reason for
Location & Direction
No. ordinate orfdinate selection
w.r.t site
1 MIDC location 311664 2123397 - -
2 Matoshree Nagar 310366 2124962 2 to NW Downwind
3 Kailash Nagar 309837 2123640 1.8 to W Upwind
4 Thakur pada 311798 2121812 1.6 to S Upwind
5 Chikhloli village 313072 2121495 2.3 to SE Upwind
6 Vadavali village 441604 8126954 2.3 to E Downwind
7 Vasat phata 314391 2123772 2.7 to NE Downwind
8 Vasat village 314595 2124894 3.3 to NE Downwind

Figure 3.17 Locations of AAQM stations

The statistical data for each location is given in Table below. Date wise results of AAQ
data are presented in Annexure 3.4.

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Table 3.18 AAQM Results- winter 2017-18

PM10 PM2.5 SO2 NOX CO nMHC

Location
(μg/m3) (μg/m3) (μg/m3) (μg/m3) (mg/m3) (μg/m3)
Minimum 57.2 19.8 9.7 15.9 0.10 0.01
Maximum 69.2 24.2 14.5 23.8 0.40 0.06
MIDC
Average 62.8 22.0 12.3 20.0 0.24 0.03
location
98th
68.7 24.1 14.5 23.7 0.40 0.06
Percentile
Minimum 53.4 17.6 8.9 15.2 0.10 0.01
Maximum 64.2 21.3 13.7 22.2 0.30 0.03
Matoshree
Average 59.3 19.6 11.6 18.7 0.21 0.02
nagar
98th
64.2 21.3 13.7 21.8 0.30 0.03
Percentile
Minimum 52.1 16.8 9.0 14.6 0.10 0.01
Maximum 68.6 21.8 13.6 22.4 0.30 0.03
Kailash
Average 61.7 19.6 10.8 18.0 0.17 0.02
nagar
98th
68.0 21.7 13.6 22.3 0.30 0.03
Percentile
Minimum 51.9 16.6 8.9 14.4 0.10 0.01
Maximum 65.8 21.1 13.5 22.1 0.30 0.05
Thakur
Average 58.4 18.7 11.3 18.5 0.19 0.03
pada
98th
64.8 20.8 13.3 21.8 0.30 0.05
Percentile
Minimum 51.8 16.5 8.5 14.2 0.10 0.01
Maximum 66.0 21.1 14.2 23.1 0.40 0.05
Chikhloli
Average 60.0 19.2 11.0 18.2 0.24 0.02
village
98th
65.2 20.8 13.5 22.2 0.40 0.05
Percentile
Minimum 50.8 16.1 8.5 14.6 0.10 0.01
Maximum 66.3 21.2 13.2 21.7 0.40 0.03
Vadavali
Average 58.9 18.7 10.9 17.9 0.25 0.02
village
98th
65.8 21.0 13.2 21.6 0.38 0.03
Percentile
Minimum 51.1 16.2 8.4 13.5 0.10 0.01
Maximum 63.9 20.3 13.4 22.1 0.30 0.04
Vasat
Average 58.7 18.6 11.0 18.1 0.18 0.02
phata
98th
63.6 20.3 13.4 21.8 0.30 0.04
Percentile
Minimum 51.3 15.9 8.5 14.6 0.10 0.01
Maximum 65.5 20.3 13.5 22.2 0.30 0.04
Vasat
Average 58.5 18.1 10.9 18.0 0.17 0.02
village
98th
64.8 20.1 13.4 21.8 0.28 0.04
Percentile
NAAQ norms 100 60 80 80 2 ---
Observation from AAQM results:
• Concentration of PM10 is varying from 50.8 μg/m3 to 69.2 μg/m3. The maximum
concentration is mainly due to transportation / industrial activities within study
area.

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• Concentration of PM2.5 is varying from 15.9 μg/m3 to 24.2 μg/m3. The maximum
concentration is mainly due to transportation along MIDC road within study
area.
• Concentration of SO2 is varying from 8.4 μg/m3 to 14.5 μg/m3. The maximum
concentration is mainly due to industrial activities in study area.
• Concentration of NOx is varying from 13.5 μg/m3 to 23.8 μg/m3. NOx levels are
higher due to industrial activity/ fairly high traffic along MIDC road.
• Concentration of CO is varying from BDL to 0.4 mg/m3. The maximum
concentration is mainly due to transportation & high traffic.
• nMHC values varying from BDL to 0.06 ppm.
Results are compared with National Ambient Air Quality Standards (NAAQ) in respect of
monitored parameters. As can be seen the results, ambient air is well within the NAAQS
standards for Industrial and Residential areas.
Table 3.19 National Ambient Air Quality Standards (CPCB, 2009)

Pollutant Time Concentration in ambient air Method of measurement

weighted Industrial, Ecologically
Average Residential, sensitive Area
Rural and (Notified by Central
other area Government
Particulate Annual * 60 60 ▪ Gravimetric
Matter <10m ▪ TEOM
or PM10, µg/m3 24 hours** 100 100 ▪ Beta attenuation
Particulate Annual * 40 40 ▪ Gravimetric
Matter <2.5m ▪ TEOM
or PM2.5, µg/m3 24 hours** 60 60 ▪ Beta attenuation
Annual * 50 20 ▪ Improved West and Gaeke
Sulphur Di oxide
Method
(SO2), µg/m3
24 hours** 80 80 ▪ UV - fluorescence
Nitrogen di Annual * 40 30 ▪ Jacob & Hochheiser
oxide (NO2), modified Method
µg/m3 24 hours** 80 80 ▪ Chemiluminescenc
Carbon 8 hours ** 02 02 ▪ Non-dispersive infrared
Monoxide (CO) spectroscopy
(mg/m3) 1 hour** 04 04
Non-methane 1 hour Not specified Not specified ▪ Gas Chromatography
Hydrocarbon

3.6 Noise Environment

3.6.1 Noise Level Monitoring

Noise levels were monitored at nearby villages / on access routes to judge impact of
industrialization and transportation on ambient noise levels. The reports are as below:

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Table 3.20 Noise Monitoring Results (Winter 2017-18)

Noise Level Leq dB(A)

Sr. No. Location/Date of survey
Day Time Norms* Night Time Norms*
Land Use: Industrial

1 MIDC (22/12/17) 51.2 75 42.7 70

Land Use: Residential

2 Matoshri nagar (22/12/17) 52.4 44.6
3 Kailash nagar (22/12/17) 54.6 43.8
4 Thakur pada (23/12/17) 53.4 42.1
5 Chikhloli village (23/12/17) 52.8 55 40.6 45
6 Vadavali village (23/12/17) 53.1 41.5
7 Vasat Phata (16/12/17) 52.0 45.8
8 Vasat village (16/12/17) 50.4 48.9
(*) Standard as prescribed in Schedule II of the Environment Protection Act, 1986.
Note: Day Time: 06.00 am to 10.00 pm, Night Time: 10.00 pm to 06.00 am
Noise levels were found to be within prescribed standard.
Onsite noise monitoring is also carried out by Centaur periodically. Recent noise
monitoring results is tabulated below,
Table 3.21 Onsite noise monitoring results
Limit dB(A) Limit dB(A)
Day Limit dB(A)
Location Unit Night time Leq Night Factories Act
time Leq Daytime
time 1948*
Near main gate dB(A) 65.3 60.8
Near ETP area* dB(A) 79.6 77.8
Near RM store dB(A) 70.3 67.9 < 75 < 70 <90
Near DG sets dB(A) 72.6 67.0
Near utility area* dB(A) 81.3 79.8
Note: Limit as per Factories Act 1948 is 90 dB(A) Leq.
Ref: Sampling date 08.08.2018 Report no. AB/CPPL/08/2018-19/268

3.7 Water Environment

3.7.1 Onsite Water Environment

Existing facility of Centaur has permission for 129 cmd (12 cmd for domestic use, 82
cmd for industrial cooling/Boilers, 25 cmd for processing and 10 cmd for gardening).
Fresh water from MIDC water works which receives it from Barvi Dam.

3.7.1.1 Waste Water Generation, Treatment and Disposal

Waste water generation in existing facility is 21 cmd (Trade Effluent: 12 cmd and
Domestic sewage 9 cmd).

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Domestic sewage 9 cmd is treated in soak pit.
Trade effluent is treated in effluent treatment plant facility at site having primary,
secondary and tertiary treatment. Treated waste water is sent to CETP facility by
tanker. Refer Annexure 3.5 for CETP membership.
Water Balance at Centaur, as per CTO is presented in Figures below,
Existing Water Balance
ALL FIGURES IN CMD
Total water requirement
129
107 10 12
Industrial Domestic
Gardening

82 25
Consumption Consumption Consumption
Utility / Loss Processing / Loss
/ Loss
(Boilers/CT) 15 3
80
2 10
12 9
Effluent Treatment Plant

21

To CETP

Figure 3.18 Existing water balance

3.7.1.2 Existing Trade Effluent Treatment scheme

The existing trade effluent scheme is depicted below in following block diagram,
~

PROCESS ACTIVITY and

EFFLUENT GENERATION
VACUUM
COOLING TOWER SUMP BD BOILER BLOW SCRUBBER
BLOWDOWN DOWN EFFLUENT

DOMESTIC EFFLUENT

12 CMD
COMBINED PROCESS
EFFLUENT

By Gravity

BACK WASH WATER EXISTING COLLECTION &

HCl OR Caustic
NEUTRALISATION TANK

By Pump

PRIMARY SLUDGE
COAGULATION & FLOCULATION FeSO 4 & Polyelectrolyte

Gravity Flow

SLUDGE RECYCLE
ANOXIC BIODEGRADATION

By Pump
EXCESS SLUDGE

ANOXIC CLARIFIER
FILTRATE
Gravity Flow
9 CMD
SLUDGE SLUDGE RECYCLE
FILTER PRESS AEROBIC BIODEGRADATION
THICKNEER

Gravity Flow
DEWATERED
SLUDGE EXCESS SLUDGE
SECONDARY CLARIFIER

Gravity Flow
DISPOSAL TO
SECURED LANDFILL INTERMEDIATE COLLECTION
TANK

By Pump

SODIUM
DISINFECTION
HYPOCHLORITE

By pump

BACK WASH WATER PRESURE SAND FILTER AND

ACTIVATED CARBON ADSORBER

TREATED EFFLUENT STORAGE

21 CMD
CETP FOR FINAL DISPOSAL

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Figure 3.19 Existing ETP block diagram
The quality of various waste water streams is as follows,
Table 3.22 Domestic sewage analysis results
No Parameter Unit Result
1 pH - 6.79
2 BOD mg/lit 81
3 TSS mg/lit 42
Ref: Sampling date 11.08.2018 Report no. AB/CPPL/08/2018-19/252
Table 3.23ETP Plant outlet analysis
Unit ETP outlet Limits as per MOCB
No Parameter (treated consent (for outlet
effluent) parameters)
1 pH - 7.1 6.0 - 8.5
2 BOD mg/lit 64 < 100
3 COD mg/lit 176 < 250
4 Oil & Grease mg/lit BDL < 10
5 TSS mg/lit 57 < 100
6 TDS mg/lit 1014 <2100
7 Chlorides (Cl) mg/lit 32 < 600
8 Sulphates (SO4) mg/lit 16 < 1000
9 Sulphide (S) mg/lit BDL <2
10 Phenol mg/lit BDL <1
11 Hexa Chromium mg/lit BDL < 0.10
12 Bio Assay test % 93 -
Ref: Sampling date 11.08.2018 Report no. AB/CPPL/08/2018-19/251

3.7.2 Reconnaissance survey

The expansion will be located in notified chemical zone of MIDC Chikhloli Ambernath.
The fresh water for industrial and domestic uses in the industrial area is sourced by
MIDC through Barvi Dam. Majority of the study area (10 km around site) has an
agriculture land use. Agriculture in the area is rain fed. Majority of villages in the study
area get fresh water from dug/ bore wells.

3.7.3 Baseline water quality

Selected physico-chemical characteristic along with biological indicators of pollution

are used to describe the baseline status of water environment and assessing impacts
due to proposed project activities.
3.7.3.1 Ground Water

Baseline water samples were collected at 8 locations in study area (3 from MIDC tap
water and 5 from open wells). The location of water monitoring & results are presented
below:

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Figure 3.20 Ground water monitoring locations

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Table 3.24Ground water analysis results
Matoshri Vadvali Thakur Chikhloli Vasat Vasat Kailash Limits (IS 10500-2012) Method of Analysis
Sr Onsite
Parameter nagar village pada village Phate village nagar
No Desirable Permissible
MIDC water well water
1 Colour, Hazen <5 <5 <5 <5 <5 <5 <5 <5 5 15 APHA-2017(2120-B)
2 Conductivity,µS/cm 148.2 120.4 122.6 222.1 170.5 270.8 271.9 164.7 -- -- APHA-2017(2510-B)
3 TDS, mg/l 90 70 80 140 110 130 180 110 500 2000 APHA-2017(2540-C)
4 Odour Agreeable Agreeable Agreeable APHA-2017(2150-B)
5 pH 7.24 7.24 6.68 6.72 7.14 7.14 6.92 6.92 6.5 - 8.5 No Relaxation APHA-2017(4500H+-B)
6 Taste Agreeable Agreeable Agreeable APHA-2017(2160-B)
7 Turbidity, NTU ND ND ND ND ND ND ND ND 1 5 APHA-2017(2130-B)
8 Aluminium, mg/l ND ND ND ND ND ND ND ND 0.03 0.2 APHA-2017(3111-E)
9 NH3(as N), mg/l ND ND ND ND ND ND ND ND 0.5 No Relaxation APHA-2017(4500NH3-C)
10 Detergents, mg/l ND ND ND ND ND ND ND ND 0.2 1 APHA-2017(5540-C)
11 Barium, mg/l ND ND ND ND ND ND ND ND 0.7 No Relaxation APHA-2017(3111-D)
12 Boron, mg/l ND ND ND ND ND ND ND ND 0.5 1 APHA-2017(4500B-B)
13 Calcium, mg/l 16.8 14.4 11.2 38.4 30.4 58.4 34.4 20.8 75 200 APHA-2017(2340-C)
14 Chloramines, mg/l ND ND ND ND ND ND ND ND 4 No Relaxation US EPA 330.5
15 Chlorides, mg/l 24 18 18 48 36 57 69 42 250 1000 APHA-2017(4500Cl--B)
16 Copper, mg/l ND ND ND ND ND ND ND ND 0.05 1.5 APHA-2017(3111-B)
17 Fluoride, mg/l ND ND ND ND ND ND ND ND 1 1.5 APHA-2017(4500F--D)
18 Free Res Cl2, mg/l ND ND ND ND ND ND ND ND 0.2 1 APHA-2017(4500Cl-B)
19 Iron, mg/l 0.02 0.02 0.01 0.03 0.01 0.04 0.04 0.03 1 No Relaxation APHA-2017(3500Fe-B)
20 COD mg/l 10 10 10 50 40 60 60 20 -- -- APHA-2017(5220-B)
21 Magnesium, mg/l 8.64 5.76 6.72 7.2 5.28 8.64 21.1 11.04 30 100 APHA-2017(2340-C)
22 Manganese, mg/l ND ND ND ND ND ND ND ND 0.1 0.3 APHA-2017(3111-B)
23 Mineral oil, mg/l ND ND ND ND ND ND ND ND 0.5 No Relaxation APHA-2017(5520-B)
24 Nitrate, mg/l ND ND ND ND ND ND ND ND 45 No Relaxation APHA-2017(4500NO3-E)
25 Phenolic com, mg/l ND ND ND ND ND ND ND ND 0.001 0.002 APHA-2017(5530-C)
26 Selenium, mg/l ND ND ND ND ND ND ND ND 0.01 No Relaxation APHA-2017(3114-C)

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Sr Matoshri Vadvali Thakur Chikhloli Vasat Vasat Kailash Limits (IS 10500-2012) Method of Analysis
Parameter Onsite
No nagar village pada village Phate village nagar Desirable Permissible
27 Silver, mg/l ND ND ND ND ND ND ND ND 0.1 No Relaxation APHA-2017(3111-B)
28 Sulphate, mg/l 28 28 22 63 45 41 58 35 200 400 APHA-2017(4500SO4-E)
29 Sulphide, mg/l ND ND ND ND ND ND ND ND 0.05 No Relaxation APHA-2017(4500S2--F)
30 Alkalinity, mg/l 64 52 52 102 82 146 78 52 200 600 APHA-2017(2320-B)
31 Hardness, mg/l 78 60 56 126 98 182 174 98 200 600 APHA-2017(2340-C)
32 Zinc, mg/l ND ND ND ND ND ND ND ND 5 15 APHA-2017(3111-B)
33 Cadmium, mg/l ND ND ND ND ND ND ND ND 0.003 No Relaxation APHA-2017(3111-B)
34 Cyanide, mg/l ND ND ND ND ND ND ND ND 0.05 No Relaxation APHA-2017(4500-E)
35 Lead, mg/l ND ND ND ND ND ND ND ND 0.01 No Relaxation APHA-2017(3111-B)
36 Mercury, mg/l ND ND ND ND ND ND ND ND 0.001 No Relaxation APHA-2017(3112-B)
37 Molybdenum, mg/l ND ND ND ND ND ND ND ND 0.07 No Relaxation APHA-2017(3111-D)
38 Nickel, mg/l ND ND ND ND ND ND ND ND 0.02 No Relaxation APHA-2017(3111-B)
39 Arsenic, mg/l ND ND ND ND ND ND ND ND 0.01 0.05 APHA-2017(3114-C)
40 Coliforms Absent Absent Absent Present Present Present Present Present Absent Absent APHA-2012 (9222-B)
41 E Coli Absent Absent Absent Absent Absent Absent Absent Absent Absent Absent APHA-2012 (9222-H)
Note: All parameters in mg/L except where specifically indicated (pH has no units) (NS: Not specified)

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It is observed that all parameters of samples meet Drinking water standards except
coliform at well water. Out of 8 samples, 5 wellwater samples show presence of
coliform. Presence of coliform is mainly due to sewage contamination from nearby
areas.
3.7.3.2 Surface Water

Surface water sampling and analysis is carried out within study area at following 12
locations.
Frequency of Surface water sampling: Grab samples for above locations were
collected once in season.
Table 3.25 Surface water sampling locations
Water body Location
Gao devi lake- Near Kharwai MIDC
Lake/ pond
Lotus pond
Dam water GIP railway dam
Waldhuni nalla- Near Ulhasnagar station
Nalla sample
Waldhuni nalla- Near Govind pool Ambarnath
Ulhas river-Chamtoli village
Ulhas river-Kharvai village
Ulhas river-Jambhul village
River Ulhas river-Vasat village
Ulhas river-Rayate village
Ulhas river-Manivali village
Ulhas river-Ambivali village

Figure 3.21 Surface water sampling locations

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Table 3.26Surface water analysis results
Locations
Gao
devi Waldhuni nalla Pond Ulhas river Dam
lake
Sr.
Parameter
No.

Ulhasnaga

Ambarnat

Ambivali
Chamtoli

Manivali
Kharwai

r station

Jambhul
Kharvai

railway
Govind

Rayate
village

village

village

village

village

village

village
Vasat
Lotus
MIDC

pond
Near
Near

Near

pool

dam
GIP
h
1 pH 7.21 6.73 6.98 6.19 7.48 8.05 7.52 7.28 8.12 7.42 7.28 7.58
2 Dissolved Oxygen, mg/l, 4.8 4 3.2 2.1 6.5 6.4 6.6 6.7 6.1 6.3 6.3 6.2
3 BOD @20°C 5days 2 12 58 140 8 2 12 8 4 4 12 6
4 Colour, Hazen units <5 5 15 <5 <5 <5 <5 <5 <5 <5 <5 <5
5 Odour Unobjectionable
6 Taste Agreeable
7 TDS, mg/l 1210 1820 2110 110 60 70 80 80 80 80 110 90
8 Hardness (as CaCO3) mg/l 366 202 172 82 62 64 68 72 60 64 86 72
9 Ca (as CaCO3), mg/l 99.2 48.8 50.4 22.4 18.4 9.6 16.8 20 11.2 9.6 24.8 22.4
10 Mg (as CaCO3), mg/l 28.3 19.2 11 6.24 3.84 9.6 5.76 5.28 7.68 9.6 5.76 3.84
11 Copper (as Cu), mg/l ND ND ND ND ND ND ND ND ND ND ND ND
12 Iron (as Fe), mg/l, 0.04 0.06 0.12 0.04 0.02 0.04 0.06 0.05 0.06 0.03 0.09 0.07
13 Manganese (as Mn), mg/l ND ND ND ND ND ND ND ND ND ND ND ND
14 Chlorides (as Cl), mg/l 33 206 13 13 9 11 10 10 11 13 21 25
15 Sulphate (as SO4), mg/l 199 202 116 68 16 16 18 20 24 28 14 24
16 Nitrates (as NO3), mg/1 ND ND ND 4.8 5.8 3.4 5 6 3 12 12 ND
17 Fluorides (as F,) mg/l ND ND ND ND ND ND ND ND ND ND ND ND
Phenolic comp (as C6H5OH),
18 ND ND ND ND ND ND ND ND ND ND ND ND
mg/l
19 Mercury (as Hg), mg/l ND ND ND ND ND ND ND ND ND ND ND ND
20 Cadmium (as Cd), mg/ ND ND ND ND ND ND ND ND ND ND ND ND
21 Selenium (as Se), mg/l ND ND ND ND ND ND ND ND ND ND ND ND
22 Arsenic (as As), mg/l ND ND ND ND ND ND ND ND ND ND ND ND
23 Cyanides (as CN), mg/l ND ND ND ND ND ND ND ND ND ND ND ND
24 Lead (as Pb), mg/l ND ND ND ND ND ND ND ND ND ND ND ND
25 Zinc (as Zn), mg/l, ND ND ND ND ND ND ND ND ND ND ND ND

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26 Chromium (asCr6+), mg/l, ND ND ND ND ND ND ND ND ND ND ND ND
27 Anionic detergents, mg/l ND ND ND ND ND ND ND ND ND ND ND ND
28 PAH, mg/l ND ND ND ND ND ND ND ND ND ND ND ND
29 Mineral oil, mg/l ND ND ND ND ND ND ND ND ND ND ND ND
30 Barium (as Ba), mg/l ND ND ND ND ND ND ND ND ND ND ND ND
31 Silver (as Ag), mg/l ND ND ND ND ND ND ND ND ND ND ND ND
32 Pesticides Absent
33 Free Ammonia (as N), mg/l ND ND ND ND ND ND ND ND ND ND ND ND
Electrical Conductance at 25
34 1824 2645 3224 247.3 1683 1690 212.7 129.3 227 423.8 1044 165.2
°C, μS
35 Oils and Grease, mg/l ND ND ND ND ND ND ND ND ND ND ND ND
36 Sodium Adsorption Ratio,% 10 10 16.2 23.8 17.4 15.8 20 20 16.2 12.9 15.4 13.8
37 Boron (as B), mg/l ND ND ND ND ND ND ND ND ND ND ND ND
38 Sodium Percentage 0.8 0.8 9 9 0.6 06 07 07 5 4 06 05
39 Insecticide ND ND ND ND ND ND ND ND ND ND ND ND
40 Total Dissolved Solids, mg/l 1210 1210 2110 110 60 70 80 80 80 80 110 90
41 Coliforms >1600 >1600 >1600 >1600 >1600 >1600 >1600 >1600 >1600 >1600 >1600 >1600

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Table 3.27 Tolerance limits for Inland surface water

Tolerance Limits For Inland Surface Waters Method of Analysis
Sr.
Parameter Class Class – Class Class
No. Class – A
–B C –D –E
6.5 to 6.5 to 6.5 to 6.0 to
1 pH 6.5 to 8.5 APHA-2012(4500H+-B)
8.5 8.5 8.5 8.5
2 Dissolved Oxygen, mg/l, 6 5 4 4 -- APHA-2012(4500O--C)
3 BOD @20°C 5days 2 3 3 -- -- IS-3025(Part 44)1993
4 Colour, Hazen units 10 1.5 300 -- -- APHA-2012(2120-B)
Un
5 Odour -- -- -- -- APHA-2012(2150-B)
objectionable
6 Taste Agreeable -- -- -- -- APHA-2012(2160-B)
7 TDS, mg/l 500 -- -- -- -- APHA-2012(2540-C)
8 Hardness (as CaCO3) mg/l 300 -- -- -- -- APHA-2012(2340-C)
9 Ca (as CaCO3), mg/l 200 -- -- -- -- APHA-2012(2340-C)
10 Mg (as CaCO3), mg/l 100 -- -- -- -- APHA-2012(2340-C)
11 Copper (as Cu), mg/l 1.5 -- 1.5 -- -- APHA-2012(3111-B)
12 Iron (as Fe), mg/l, 0.3 -- 50 -- -- APHA-2012(3500Fe-B)
13 Manganese (as Mn), mg/l 0.5 -- -- -- APHA-2012(3111-B)
14 Chlorides (as Cl), mg/l 250 -- 600 -- 600 APHA-2012(4500Cl--B)
15 Sulphate (as SO4), mg/l 400 -- 400 -- 1000 APHA-2012(4500SO4-E)
16 Nitrates (as NO3), mg/1 20 -- 50 -- -- APHA-2012(4500NO3-E)
17 Fluorides (as F,) mg/l 1.5 -- 1.5 -- -- APHA-2012(4500F--D)
Phenolic comp (as
18 0.002 0.005 0.005 -- -- APHA-2012(5530-C)
C6H5OH), mg/l
19 Mercury (as Hg), mg/l 0.001 -- -- -- APHA-2012(3111-D)
20 Cadmium (as Cd), mg/ 0.01 -- 0.01 -- -- APHA-2012(3111-B)
21 Selenium (as Se), mg/l 0.01 -- 0.05 -- -- APHA-2012(3111-B)
22 Arsenic (as As), mg/l 0.05 0.2 -- -- -- APHA-2012(3111-C)
23 Cyanides (as CN), mg/l 0.05 0.05 0.05 -- -- APHA-2012(4500-E)
24 Lead (as Pb), mg/l 0.1 -- 0.1 -- -- APHA-2012(3111-B)
25 Zinc (as Zn), mg/l, 15 -- 15 -- -- APHA-2012(3111-B)
26 Chromium (asCr6+), mg/l, 0.05 1.0 0.05 -- -- APHA-2012(3500Cr-B)
27 Anionic detergents, mg/l 0.2 1.0 0.2 -- -- APHA-2012(5540-C)
28 PAH, mg/l 0.2 -- -- -- -- APHA 6440
29 Mineral oil, mg/l 0.01 -- -- -- -- APHA-2012(5520-B)
30 Barium (as Ba), mg/l 1.0 -- -- -- -- APHA-2012(3111-D)
31 Silver (as Ag), mg/l 0.05 -- -- -- -- APHA-2012(3111-B)
32 Pesticides Absent -- -- -- -- US EPA
33 Free Ammonia (as N), mg/l -- -- -- 1.2 -- APHA-2012(4500NH3-C)
Electrical Conductance at
34 -- -- -- 1000 2250 APHA-2012(2510-B)
25 °C, μS
35 Oils and Grease, mg/l -- -- 0.1 0.1 -- APHA-2012(5520-B)
Sodium Adsorption
36 -- -- -- -- 26 --
Ratio,%
37 Boron (as B), mg/l -- -- -- -- 2.0 APHA-2012(4500B-B)
38 Sodium Percentage -- -- -- -- 60 APHA-2012(3111-B)
39 Insecticide -- -- Absent -- -- US EPA
Total Dissolved Solids,
40 -- -- 1500 -- 2100 APHA-2012(2540-C)
mg/l
41 Coliforms 50 500 5000 -- -- APHA-2012(9222-B)

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Class of Water as per IS 2296 - 1982
CLASSIFICATION TYPE OF USE
CLASS A Drinking water source without conventional treatment but after disinfection
CLASS B Outdoor bathing
CLASS C Drinking water source with conventional treatment followed by disinfection
CLASS D Fish culture and wild life propogation
CLASS E Irrigation, industrial cooling or controlled waste disposal
Based on analysis, surface water analysis mostly falls under classification C& E.

3.8 Biological Environment

3.8.1 Bio geographical setting of Thane district

Thane is one of the coastal districts of Konkan. Geographically it contributes to hills, mid
lands and lowlands
comprising the wide
amphitheatre like basin
of the Ulhas and the
hilly Kalu river basin
together with plateaus
forming the Sahyadrian
scarp. The most rugged
terrain of the district is
a belt about 15-25 km
broad that runs parallel
to the coast at a
distance of 15-20 km
from the shore.
Towards eastern side
of the district, soil is
red and brown. It is not
very deep but is
suitable for rice.
Further east on the hill-
slopes, the soil is poor
and is used only for
growing grass and
coarse grains, viz., Nagli
and Vari. In the valleys
there are patches of
black soil in Bhiwandi,
Kalyan, Mokhada and
Shahapur talukas
where rice is grown in
ample quantity. In
coastal plains soils are
deep either pure sand
which supports
vegetation like

Figure 3.22Map of Thane District Showing Study Area (Black Circle)

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Casuarina or coastal Alluvium, supports vegetation like Babul. The climate in the district
is generally hot and humid. The temperature varies between 17 °C to 35 °C. The rainfall
in the district increases from the coast towards the interior. The average annual rainfall
in the district is 2,470 mm, mostly contributed by south-westerly monsoon.
These climatic and edaphic conditions support natural forests which are scattered all
over the district. As per Champion and Seth’s classification, more than 90 % of the
forests of Thane District fall under the type “Tropical moist (mixed) deciduous forests".
Though occurrence of Tectona granadis is only 25 to 30 per cent, it is associated with
other species like Terminalia elliptica, Acacia catechu, Pterocarpus marsupium,
Dalbergia latifolia, Bobax malbaricum etc. In coastal stretches, littoral swamp forests are
seen especially along bank of creeks, where they get shelter and suitable substratum.

According to ‘India State of Forest Report, 2015 & 2017’, Forest Survey of India;
forest cover in Thane district is changed from 30.4 to 31% of geographical area. Area
(km2) distribution of forest cover in Thane District is presented below:
Table 3.28 Area distribution of Forest cover
Year Geographical Very Moderately Open Total Scrub
Area Dense Dense Forest Forest
Forest Forest Area (%)
2015 9,558 0 1,281 1,627 2,908 (30.4) 222
2017 9,558 0 1,299 1,664 2,963 (31.0) 228

There is no National park/ Wildlife Sanctuary in study area.

3.8.2 Study Area

Study area under consideration encompasses part of Kalyan, Ulhasnagar talukas of

Thane district and Panvel and Karjat talukas of Raigad district. According to bio-
geographical zone classification of India, study area falls under ‘Western Ghats –
Malabar Palins’. One village (Pashane in Karjat Taluka) in study area is listed as
Ecological Sensitive Area, in directions under section 5 of Environment Protection Act
1986, dated 13th November 2013, issued by MoEF&CC. Matheran Eco-sensitive Zone
boundary (another notified eco-sensitive area) is located about 2 Km towards South
from plot. Ecology & Biodiversity study pertaining to Environmental Impact Assessment
report for the establishment organic chemical manufacturing facility at plot in
additional Ambernath MIDC by Centaur Pharma Industries pvt. ltd. was carried out in
winter 2017-18. There is no wildlife sanctuary/national park within study area. The
study was carried out by visiting locations at dusk, day and dawn, taking care that all
habitats were covered. Geographical coordinates were marked at important locations
and geo-tagged photographic evidences were collected using Global Positioning System.
Listing of flora and fauna was done based on actual sighting, interviewing locals,
indirect evidences, Literature survey, data collected from forest officials and internet
references. Occurrences of species in respective habitats are presented in tables below.

Field visits to site and surrounding reveals that, study area is dominated by urban and
hilly area. Some of hilly areas are classified as Reserve Forests (especially towards south
and eastern part of study area) and possesses mix of deciduous and evergreen
vegetation, forming prevailing forest type in the region.

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Figure 3.23View of hilly Area in Reserve Forest

Besides reserve forest, different habitats observed in study area like, agricultural fields/
plantations, water bodies, human settlements etc. These habitats possess different
characteristic which supports typical composition of flora and fauna within them.

A Reserve Forests
Reserve forests in study area are distributed in patches leaving open space/ agriculture
fields intermittently. Dominant species here is Tectona grndis and Terminalia
tomentosa. Most of the places, hill tops and slopes seems barren in satellite imagery due
to poor vegetation over and low tree density.

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Figure 3.24Biological richness in the study area, (Source: bis.iirs.gov.in/maps)

Locations of reserve forests in study area are as seen in study area Survey of India map.
5 number of Reserve Forests were observed in the Study area; Mohilipada-Vaholi in
north, Ambivali Tarf, Ambeshiv Kh-Poi-Barvi River in East, Kanhor in South east &
Bohonoli in South.

Species composition was observed to be similar at most of the places. Species

composition as Terminalia elliptica, Acacia catechu, Tectona grandis, Terminalia
paniculata Madhuka indica, Calycopteris floribunda, Carrissa carandas, Bombax
malbaricum, Holarrhena pubescens, Mangifera indica etc. These species create mix
microclimate supporting faunal life. Avifauna actually sighted such as orange headed
thrush, Crow Pheasant. Some bird calls were heard like Common Iora, Brown headed
barbet.

White throated Kingfisher Black Naped Monarch Magpie Robin

Ashy Prinia Red Avadavat Black Winged CuckooShrike

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Data obtained from forest department is compared with observations made during
survey within study area and found similarity in species composition.

Phyto-sociological study in this habitat was carried out to know Species composition of
trees, shrubs, herbs and climbers at each location which are presented below.

Trema orientalis Thespesia populnea

Terminalia paniculata Terminalia chebula,
100% Terminalia catappa Terminalia belerica
Terminalia arjuna Termenalia elliptica
90%
Tectona grandis Tamarindus indica
80% Syzygium cumini Semecarpus anacardium
Pongamia pinnata Phyllanthus emblica
70% Oroxylum indicum Neolamarckia cadamba
% Composition

Mymeceylon umbellatum Moringa oliefera

60% Mitragyna parviflora Mimusops elengi
Michelia champaka Mangifera indica
50% Macaranga peltata Lanea coromandelica
Lagerstroemia speciosa Holptelea integrifolia
40% Grewia tiliifolia Gmelina arborea
Gliricidia sepium Garcinia indica
30%
Ficus religiosa Ficus glomerata
20% Ficus bengalensis Eucalyptus sp.
Erythrina indica Cordia dichotoma
10% Caryota urens Careya arborea
Butea monosperma Bridelia retusa
0% Bombax malbaricum Bauhinia veriegata
1 2Quadrant3 4 Barringtonia acutangula Anacardium occidentale
Acacia nilotica Acacia catechu

Figure 3.25Graph showing tree species composition in Dense Vegetation

Achyranthus aspera
Hibiscus rosa sinensis
100% 100% Physalis minima
Bougainvillea spectabilis
90% 90% Alternanthera sessilis
Ziziphus rugosa
80% 80% Leea microphylla
Ziziphus oenoplia
70% 70% Urena sinuata
Vitex negundo
% Composition

60% Tricodesma indica

% Composition

60%
Woodfordia floribunda
50% 50% Ocimum basilicum
Sida rhomboidea
40% 40% Mimosa pudica
Lawsonia inermis
30% 30% Lantana camara
Holarrhena antidysenterica
20% 20% Ipomoea carnea
Helicteres isora
10% Jussiaea suffruiticosa
10%
0% Flueggea leucopyrus Canscora diffusa
0%
1 2 3 4 Carissa carandus 1 2 3 4 Boerhavia diffusa
Quadrant Calotropis gigentea Quadrant Ageratum conyzoides
Bauhinia recemosa Argemone mexicana

Figure 3.26Graph showing shrub & herb species composition in study area

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Ipomoea pes-tigridis Panicum miliare

100% Dioscorea bulbifera 100% Oryza sativa
90% Vitis repanda 90% Eragrostis unioloides
80% Tinospora cordifolia 80%
Cynodon dactylon
% Composition

% Composition
70% Marsdenia volubilis 70%
Coix lachryma-jobi
60% Ipomoea pes-tigridis 60%
Bambusa arundinacea
50% Hemidesmus indicus 50%
40% 40%
30% 30%
20% 20%
10% 10%
0% 0%
1 2 3 4 1 2 3 4
Quadrant Quadrant

Figure 3.27Graph showing climber & Grass species composition in study area

5%
37%
43%

15%

Trees Shrubs Herbs Climbers

Figure 3.28Graph showing overall composition in dense vegetation

Floral composition is found to be dominated by herbs followed by trees and shrubs.
This may be because of low soil cover, low rate of germination of woody species. Species
Richness and Shannon-Weiner diversity index for each habit is calculated separately
from all sampling locations. It reveals poor health of ecosystem. Phyto-sociological
results are presented graphically below:

Figure 3.29 View of poultry & brick making in near by villages

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B Human Settlement
Study area has mix of rural, semi-urban to urban setting. Villages are scattered all over
the study area along with agriculture fields. Typical plant species were found in
habituated areas which are intentionally planted for the purpose of beautification,
shade, protection from stray/grazing animals and for food value. Similarly, faunal
species of interest such as cattle etc. were noticed. In open spaces/ waste areas,
naturally grown plats support respective fauna and constitutes part of biodiversity. For
the purpose of listing the species; open/waste area adjacent to human settlement, road
side plantation etc. are also considered in this habitat.
Phyto-sociological analysis in human settelement was carried out at 4 locations. Species
composition of trees, shrubs and herbs at each location are presented below.
Acacia catechu Acacia nilotica
100% Anacardium occidentale Barringtonia acutangula
Bauhinia veriegata Bombax malbaricum
% Composition

80% Bridelia retusa Butea monosperma

Careya arborea Caryota urens
60% Cordia dichotoma Erythrina indica
40% Eucalyptus sp. Ficus bengalensis
Ficus glomerata Ficus religiosa
20% Garcinia indica Gliricidia sepium
Gmelina arborea Grewia tiliifolia
0% Holptelea integrifolia Lagerstroemia speciosa
1 2 3 4 Lanea coromandelica Macaranga peltata
Quadrant

Figure 3.30Graph showing tree species composition in Human settlement

Hibiscus rosa sinensis

100% 100% Physalis minima
Bougainvillea spectabilis 90% Alternanthera sessilis
90%
Lantana camara
80% 80%
Vitex negundo
% Composition

Ocimum basilicum
70%
% Composition

70% Mimosa pudica

60% Lawsonia inermis 60% Lantana camara
50% 50% Asparagus racemosus
Carissa carandus
40% 40%
30% Bauhinia recemosa 30%
20% 20%
Amorphophallus
10% 10%
campanulatus
0% Adhatoda vasica 0%
1 2 3 4 1 2 3 4
Quadrant Quadrant

Figure 3.31Graph showing shrub & herb species composition in Human

settlement

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Figure 3.32Graph showing overall composition in human settlement

Floral composition is found to be dominated by grass & herbs followed by trees. This
may be due to plantation of species intentionally for the purpose of beautification,
shade, protection from stray/grazing animals and for food value (e.g. public garden,
green belt in additional MIDC). Similarly, faunal species of interest such as cattle,
domestic animals/ birds were inhabited. Non-indiginous species plantation leads to
cause interference to local/ indigenous biodiversity.

C Agriculture Fields

In addition to species of interest in human settlements, some species are cultivated on

commercial basis as a crop in agricultural fields and forms part of flora. This flora
supports corresponding members of fauna in study area. Agricultural fields in study
area are seen scattered along with human settlement. Major crop in entire district is
Rice. Besides Rice, pulses are grown in shallow/sea water ingresses areas. In addition to
agriculture; vegetable plantation and animal husbandry was noticed. For the purpose of
listing of species; areas adjacent to fields, orchards, plantations and vegetation on fallow
lands are also included.

Figure 3.33 View of vegetable cultivation near project site

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Phyto-sociological study reveals shrubs are dominated followed by trees. This is mainly
because of dry season (no standing crop/fields were prepared for cultivation). Diversity
index depicts the same (poor health). Species composition of trees & shrubs at each
location are presented below
Thespesia populnea
Terminalia catappa
100%
Terminalia belerica
Tectona grandis
80%
Tamarindus indica
% Composition

60% Syzygium cumini

Semecarpus anacardium
40% Phyllanthus emblica
Moringa oliefera
20% Mangifera indica
Garcinia indica
0% Eucalyptus sp.
1 2 3 4 Artocarpus heterophyllus
Quadrant Anacardium occidentale

Figure 3.34 Graph showing tree species composition in agriculture

Figure 3.35 Graph showing shrub, herb & climber species composition in
agriculture

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As, species count of herbs & climbers is low to compute diversity index thus, they are
considered to represent overall flora.

Figure 3.36 Graph showing overall floral composition in agriculture

D Water Bodies
Natural drainage in study area is Kondeshwar Lake
mainly through River Ulhas and
Kalu (both meets each other near
Kalyan) and other small rivulate/
creeklets towards westward. For
the purpose of this study and
enlisting the species, areas
adjacent to these has also been
covered. Bridge Over Ulhas River in
Common aquatic floral species like
construction
Ipomoea aquatica, Cyperus were
observed throughout the study
area and so the fauna species e.g.
Cormorant, Egrets, Kingfisher.
Though, each above identified
habitat experiences similar
climatic conditions, they differ in
Dam near Ambernath MIDC & Kakol
edaphic conditions, location,
goan
use/interference of human and
shows variation in floral
composition. These members of
flora support different kinds of
fauna associated with it. Many
species are present in more than one habitat. List of flora observed within study area
during survey is presented in table below with respect to different habitats described
earlier. Floral data reported by forest department and data collected by primary survey
were compared and found similar species composition except at artificial plantation
especially in human habitation. None of the floral species mentioned above is recorded
in Red Data Book published by Botanical Survey of India. Climatic, edaphic and
topographic conditions along with various plant species together inhabits faunal
members at respective habitats described above. List of fauna includes captive
birds/animals also due to presence of human settlements in study area are also

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presented below.Faunal data reported by forest department and data collected by
primary survey were compared and found similar species composition except wildlife
such as higher carnivores. Schedule (as per Indian Wildlife Protection Act 1972) of each
species is given against respective name in tables.

Spot billed Duck Black winged Stilt

Cormorant Purple swamphen Turtle

Figure 3.37 View of fauna associated with water bodies in study area
Phyto-sociological study reveals herbs
contribute flora majourly, followed by
trees. This may be due to weeds and shore
vegetation. Shrubs and climbers are not
captured in Phyto-sociological study.
Diversity index scores low indicating poor
health.

Figure 3.38Graph showing overall

floral composition in aquatic habitat
Though, each above identified habitat experiences similar climatic conditions, they
differ in edaphic conditions, location, use/interference of human and shows variation in
floral composition. These members of flora support different kinds of fauna associated
with it. Some species are present in more than one habitat. List of flora & fauna
observed during survey, within study area is presented in Annexure 3.6, with respect
to different habitats described earlier.

3.8.3 Site Specific

Centaur Pharma in additional Ambernath MIDC is expansion in existing structures.

Where no tree cutting is involved for proposed project.

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The Site premise has very less number of trees standing on name of green belt. It’s
suggested to plant natural species in series forming green belt surrounding the plot.

Figure 3.39View of flora in site premises

Figure 3.40 Existing plantation at site

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Table 3.29List of Flora observed within site
Sr. Habitat
Scientific Name Common/ Local Name Family
No.
1 Ficus religiosa scared fig/Pimpal Moraceace t
2 Mangifera indica Mango, aam Anacardiaceae t
3 Cocus nucifera coconut Arecaceae t
4 Polyalthia longifolia Annonaceae t
5 Terminalia catappa indian badam combretaceae t
6 Annona squamosa sitaphal Annonaceae t
7 Musa paradisiaca Banana Mucaceae t
Crossandra
8 infundibuliformis Aboli acanthaceae h
9 Hibiscus rosa sinensis China Rose, Jaswand Malvaceae s
10 Ixora indica Rubiaceae s
11 Citrus limetta sweet lime rutaceae s

3.9 Socio Economic Environment

As a part of EIA the socio-economic study includes demographic structure, population

dynamics, infrastructure resources, status of human health and economic attributes like
employment, per-capita income, agriculture, trade, industrial development, tourist
attraction, historic and cultural monuments etc. in the study area. The study of these
parameters helps in identification, prediction and evaluation of likely impacts on
socioeconomics and parameters of human interest due to proposed project.
The socio economic data was collected & generated through both sources i.e. primarily
by field survey in sampling locations & it has been substantiated with relevant socio
economic data from secondary sources i.e. concerned office’s documented records. The
latest available primary & secondary data have been complied & amalgamated to
delineate the existing baseline scenario of socio economic environment in study area.

3.9.1 Reconnaissance

Centaur Pharmaceuticals Private Limited will be proposes to expand manufacturing

base of its Synthetic Organic Chemicals & manufacturing unit at its existing plot at
Chikhloli MIDC Ambernath west, Ambernath Tehsil, Dist Thane, Maharashtra State.
Ambarnath is part of Mumbai Metropolitan Region (MMR). Ambarnath lies
on Mumbai to Pune railway route. Most people rely on the railway link to commute to
Mumbai for work. Like all Mumbai suburbs Ambarnath is divided into Ambarnath East
and Ambarnath West by the railway. Ambarnath west is in an industrial zone and is
home to hundreds of small and large chemical factories. An Ordnance Factory of
the Ordnance Factories Board has been established by the Government of India. A large
manufacturing facility of WIMCO, India's largest manufacturer of safety matchsticks, is
also located in Ambarnath on the Kalyan - Badlapur Road. Ambarnath is also famous for
its Shiva temple, which is located in Ambarnath East.

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3.9.2 Methodology

Primary Data: Primary socio economic data collection through intensive field survey in
selected sampling locations i.e. villages & town/ wards in study area as well as the
observations by the survey team.
Primary socio economic survey is very essential in order to assess and evaluate likely
impacts arising out of any developmental projects on socio economic environment, it is
necessary to gauge the apprehensions of the people in the project area.
20% - 30% percent sampling location i.e. areas it may be village or urban areas were
selected located in all distance & directions of total areas falls within the study area of
10 km. Judgemental & purposive sampling method applied for selection of respondents
(representatives of local Gram Panchayat i.e. Sarpanch, members etc. & adult male &
female groups, senior citizen, cultivators, fishermen, business men etc.) Data collection
processing includes field survey and observations are made at each sampling areas and
the socioeconomic status of that region is studied. At each sampling locations group
discussions or group interviews were carried out with different sections of community
which representing the study area. Structured interviews involve the use of a set of
predetermined questions that includes fixed and alternative questions. The
questionnaire mainly highlights the parameters such as income and employment,
housing, water supply, sanitation, health, energy, transportation and communication,
education, environment and pollution etc. to assess the standard of living of that
particular region and general awareness, opinion and expectation of the respondents
about the proposed project or industrial development activity
Socio-economic survey was conducted in 17 areas i.e. 14 villages & 3 urban areas of the
study area located in all directions & distances with reference to the proposed project
site.
Table 3.30List of Sampling locations for SE Primary Survey
Distance from project Direction from site
Sr. No. Surveyed Village / Urban Areas
site (km)(approximate) (approximate)
1 Badlapur urban area 4.30 SE
2 Ambarnath urban area 2.20 SW
3 Gorpe 4.95 SW
4 Bonoholi 5.10 S
5 Sai 3.30 E
6 Vasant Shelvali 2.80 NE
7 Bhisol 5.20 NE
8 Nevali 6.55 W
9 Kharad 7.20 SW
10 Kushivali 7.80 SW
11 Posari 8.80 SW
12 Bhandhanwadi 10 SW
13 Bendshil 9.50 SE
14 Dahivali 8.10 SE
15 Jambale 8.60 SE
16 Rahatoli 7.85 SE
17 Ulhasnagar Urban Area 5.50 NW

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Snapshots showing the socio economic sampling team members are filling the
questionnaire scheduled by interviewing a local resident & Gram Panchayat official
members at selected sampling locations are illustrated below:

Village: Kharad

Village: Bhisol

Village: Gorpe

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Village: Dahivali
Administratively Coverage of Study Area Villages & Urban Areas (10 km from propose project
site) is shown below:

Table 3.31Administratively Coverage of Study Area Villages & Urban Areas

District Taluka No. of No. of Total No. of Wards in Towns

Villages Towns
50 wards (Ambarnath (M Cl))
Ambarnath 42 2
34 wards (Badlapur (M Cl))
107 wards (Kalyan-Dombivli (M
Thane Corp.))
Kalyan 32 3
1 ward (Kambe (CT))
1 ward (Mahral Bk (CT))
Ulhasnagar ----- 1 76 (Ulhasnagar (M Corp.))
Total 74 6 193
Source: Census CD 2011 Maharashtra State

Study area comprised under Ambarnath, Kalyan &Ulhasnagar tehsil of Thane district. Total
study area split into 74 villages from rural portion and 6 towns as a part of urban area. 55%
study areas covered under Ambarnath tehsil followed by 44% in Kalyan tehsil.

3.9.3 Demographic Structure of the Study Area

Demographic structure of the study area was studied in terms of selected parameters such as
households, population, sex ratio, scheduled caste, scheduled tribes, literacy etc. Summarized
information of demographic details of study area is shown below:

Table 3.32 Summarized Information on Demographic Structure of the Study Area

Demographic Parameters Details
Population: Total 2412630
Male 1266059

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Female 1146571
No. of Household 567471
Child Population 0 - 6 years (%) 250448 (10.4)
Sex Ratio (No. of females per 1000 males) 906
Family Size (person per household) 4.3
Scheduled Castes (%) 297196 (12.3)
Scheduled Tribes (%) 76285 (3.2)
Literate Population (%) 1932492 (80.1)

Source: Census CD 2011 Maharashtra State

SC & ST Population: Study Area

Scheduled Castes Schedule
12% d Tribes
3%

Other Castes
85%

The significant features of the demographic structure are given below:

❖ Total population of the study area is 2412630out of which 1266059 (52 per cent) are males
and 1146571 (48 per cent) are females.

❖ There are 567471households in the study area with average family size is 4.3 persons per
household as per 2011 census.

❖ Sex ratio (No. of females per 1000 males) is 906 which indicates that females are less in
number than their male counterpart in the study area. Proposed project site is located at

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Chikhloli MIDC, Ambernath west which itself is a part of urban area – Ambernath town & its
surrounded area i.e. Badlapur, Kalyan & Dombivali & Ulhasnagar all are towns and fully
urbanized & commercially & industrially developed areas as well as closed proximity to
Mumbai international trade Centre so high migrant population of male workers may be the
one factor that leading to low sex ratio in the study area. But during 2001 – 2011 sex ratio
of study area has been improved by recorded an increase of 20 points from 886 to 906.

❖ The child population 0 - 6 years account for about 10.4% of the total population

❖ 91.9% population of the study area lives in urban area

❖ Hindu predominantly inhabited both urban & rural region of the study area. Ranging from
Ambarnath town 78.7%, Badlapur town 81.0%, Ulhasnagar town 82.5%, Kalyan - Dombivli
town 80.8%, Ambernath tehsil 81.6%, Kalyan tehsil 82.3% & Thane district 78.8%. So if the
Hindu population is high other religion population is adhere small proportion such as
Muslim (Ambarnath town- 10.3, Badlapur town - 3.8, Ulhasnagar town- 6.3, Kalyan -
Dombivli - 6.8, Ambarnath & Kalyan Tehsil around 6% & Thane district 12.3% followed by
Buddhism & then Christian and Sikh & Jain religion population is mostly below 1% - 2%.

❖ Study area literacy rate (80.1%) is higher as compared with Thane district (74.4%) &
Maharashtra state (72.6%) average literacy rate.

3.9.4 Infrastructural Facilities or Civic Amenities

The infrastructure resources base of the villages and the urban area coming within the study
area with reference to education, medical facility, water supply, post and telegraph,
transportation and communication facility and power supply etc.have been abstracted from
District Census Handbook CD 2011 of Maharashtra State & from field visit at sampling location
which is enclosed in Annexure 3.7. Availability & satisfaction of population within the study
area regarding civic amenities is described below:
❖ The towns falls within the study area namely Ambarnath, Ulhasnagar, Badlapur & Kalyan-
Dombivali are well connected through the state highway 35 & 43 as well as all the towns
are connected with railway station facilities on the central line of the Mumbai Suburban
Railway Networks. All the junctions Ambarnath, Badlapur, Ulhasnagar, Kalyan& Dombivli
are the busiest & important terminals for local commuters. While rural region is also
connected with both Pucca (Paved) & Kacchha (Gravel) roads with Govt. bus facility is
available in eighty-five percent villages in the study area. The nearest airport is the
Chhatrapati Shivaji Maharaj International Airport.
❖ The Ulhas River is one of the important river in the Thane district. The Ulhas River & its
main tributaries Bhatsai & Barvi traverses through the study area and near Badlapur, the

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river is dammed and used for a drinking water reservoir. It supplies drinking water to
nearby towns such as Badlapur, Ambarnath and Kalyan etc. As per 2011 census treated tap
water facilities is available in all the towns & the system of storage is Pressure Tank,
Overhead Tank & Service Reservoir with water storing capacity in kilo liters is in
Ambarnath Town 3500 & 3800 and in Badlapur Town 5350 & 4550 & Ulhasnagar Town
2420 & Kalyan-Dombivali Town 24000. Tap water facility is also available in villages but
treated tap water facility is not available in all the villages and other sources of water
available in rural region includes Well, Hand Pump, Tube Wells/Borehole, River/Canal,
Tank/Pond/Lake & Spring.
❖ Educational sector in towns such as Ambarnath, Badlapur, Ulhasnagar, Kalyan& Dombivli is
well – developed with many famous and well – known schools and institutes. But in rural
region primary educational facilities are available in all villages followed by middle schools
in 61% villages but it is lacking in the area of higher educational facilities so there is also a
need for the development of higher level of educational institutes in rural region of the
study area.
❖ Primary health care is provided by city and district hospitals and rural primary health
centres (PHCs). These hospitals provide treatment free of cost. Primary health care is
focused on immunization, prevention of malnutrition, care during pregnancy, child birth,
postnatal care, and treatment of common illnesses. There are govt. hospitals were running
in Ambarnath, Badlapur, Ulhasnagar&Kalyan-Dombivali towns in urban region along with
large number of different health care institution such as Dispensary/Health Centre - 29,
Maternity Home & Nursing Home, Maternity and Child Welfare Centre in total - 12, Non-
Government Out-Patient - 1091, Non-Government In and Out Patient – 354 and Medicine
Shop – 1106 etc. In villages health facilities are mainly available in the form of primary
health sub centre – 21 & primary health centre exist in only 2 villages as part of Govt. health
facilities & Non-Government Medical facilities such as Out Patient – 57, In And Out Patient –
17 & Medicine Shop – 34. Health care facilities are inadequate in rural region of study area
since 42% villages are not having any kind of health facilities in their respective villages.
Therefore, medical facilities need to be developed in villages of the study area.
❖ Both open & closed drains reported in all the towns while in rural region open drainage
system is observed in 65% villages & in balanced villages there is no drains as per 2011
census data. As reported in both rural & urban region there are open drains which may lead
to serious health & environmental problems. So it can be recommended to closed the open
drains for transporting/disposing sewage & construct the drains in villages where it is not
available.

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❖ Electricity facility is available in all towns & all inhabited villages which is usable for all
purposes i.e. domestic, commercial & industrial etc. in the study area.
❖ Excluding census town Fire Fighting Service is available in all towns (Ambarnath, Badlapur,
Ulhasnagar, Kalyan& Dombivli).

3.9.5 Occupational Pattern/ Economic Resource Base

Summarized Information on Occupational Structure i.e. numbers of workers & non workers
details & economic category wise distribution of workers in the study area is shown in Tables
while its percentage is presented in Figures.

Table 3.33Occupational Structure of the Study Area

Persons Workers Non
Main Workers Marginal Workers Total Workers Worker
Total 834958 74971 909929 1502701
Male 668603 46472 715075 550984
Female 166355 28499 194854 951717
Source: Census CD 2011 Maharashtra State

Figure 3.41 Ratio of Workers & Non Workers in the Study Area
Workers & Non Workers: As per 2011 census total working population in the study area is
909929 both including main and marginal workers which works out to be 37.7% (main – 34.6+
marginal – 3.1) of the total population. It shows highest number of population is shared by non-
workers 62.3%.

Contribution of females in the total working population is significantly less i.e. 194854 about
females forming only 17.0% of the total working population (female main worker – 14.5 &
female marginal worker – 2.5).

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Table 3.34Economic Category wise Distribution of Workers
Workers Cultivators Agricultural Household Industry Other
Labourer Workers Workers
Main Worker 10303 8265 23354 793036
Marginal Worker 3300 3978 4936 62757
Source: Census CD 2011 Maharashtra State

Figure 3.42Economic Category wise Distribution of Workers in the Study Area

Existing Industrial Structures and Facilities: Thane district is industrially advanced district of
the State at Maharashtra. As it is very near to International market city like Mumbai, all
infrastructural facilities like Water, Electricity, State & National Highway, Railways are available
in the district. For the development of SSI, Medium and Large Scale Industries, MIDC has built
up Industrial Estates in the district. Existing Status of Industrial Areas & Year wise trend of
units registered in Thane and Palghar District are shown in below Tables

Table 3.35Details of M.I.D.C. Industrial Area – Thane & Palghar district (as on
31.03.2012)
Name of Land Land No. of No. of No. of No. of
Industrial Areas Acquired developed Plots allotte vacant units
(in (in d plots plots in
hectare) hectare) produc
tion
Thane 252.36 252.36 827 737 90 633
Tarapur 1028.54 1028.54 71588 70109 1479 1760
Dombivali 357.27 357.27 21468 19915 1553 1514
Mira 7.82 7.82 4647 4647 0 37
*Ambernath (Ambernath 228.49 228.49 291 290 1 250
Badlapur Rd
*Addl. Ambernath Anand 507.47 504.47 846 823 23 717
nagar)
*Addl. Ambernath Village 506.64 503.22 3 3 0 0
Pale
& Bohonoli)

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*Badlapur 101.10 99.80 374 331 43 274
Kalyan Bhiwandi 48.16 48.16 33 33 0 20
(Bhiwandi)
Addl. Kalyan Bhiwandi 4.27 44.27 2 2 0 0
(Bhiwandi)
Murbad 130.71 130.71 217 202 15 172
Addl. Murbad (Khudavali) 138.85 134.86 303 300 3 260
T.T.C. (Belapur Road) 2333.27 2333.27 3693 3664 29 2812
Total 5,644.95 5,673.24 1042 10105 3236 8449
92 6
Source: Brief Industrial Profile of Thane & Palghar District, MSME –DI Govt. of India, Mumbai

*MIDC Areas covered under Study Area

Table 3.36Year-wise Trend of Units Registered at Thane and Palghar District

(As on 31.03.2012)
YEAR Number of Employment Investment (Lakh
Registered Units Rs.)
2000 – 01 355 4152 923182
2001 – 02 315 3746 1050181
2002 – 03 324 3693 914115
2003 – 04 311 3594 697361
2004 – 05 318 3510 711050
2005 – 06 383 4384 910677
2006 – 07 734 7735 868056
2007 – 08 1038 20120 846656
2008 – 09 992 16532 623464
2009 – 10 1160 20287 781138
2010 – 11 2139 31148 1271124
Source: Brief Industrial Profile of Thane & Palghar District, MSME –DI Govt. of India, Mumbai

Major large scale units are situated at Thane, Kalwa, Belapur, Dombivli, Kalyan, Shahad and
Ambernath. The Department of Industries provide incentives for industries in backward areas
of Wada, Jawhar, Mokhada, Talasari etc. The major industries in the district are Chemical,
Automobiles, Pharmaceutical, Artificial fibre, Plastic and Plastic goods, Fertilizers, Insecticides,
Paints, Edible items etc. As the district is very near to Mumbai, the indigenous and International
market facility is also available for products.

Therefore well connectivity via road & rail network augments the growth of towns in study area
due to proximity to Mumbai, which is an international trade centre and port. Most people rely
on the railway link to commute to Mumbai for work. Like all Mumbai suburbs Ambernath is
divided into Ambernath East and Ambernath West by the railway. The City of Ambernath has
four Industrial Areas (4 MIDC’S). Ambernath west is in an industrial zone and is home to
hundreds of small and large chemical factories like Ceat, Godrej and Mahindra and Mahindra,
ASB International etc. Apart from this there are three central government (Min. of Defence)

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establishments falling under Ordnance Factory Board and DRDO. A large manufacturing facility
of WIMCO, India’s largest manufacturer of safety matchsticks, is also located in Ambernath on
the Kalyan - Badlapur Road.

So people are remarkably engaged in other activities namely jobs, business, trade & commerce,
working in industries located in West Ambernath & other adjacent urban areas like working in
Mumbai etc. Out of total main & marginal workers 95% & 83.7% respectively reported under
other workers category as per 2011 census.

Perception Regarding Industrial Development: People show their positive response regarding
industrial development but don’t want any such type of development which is hazardous for
health & living environment. As almost expect local unemployed youth should be recruit&
enhance the skill sets by the companies but at the same time corporate should implement time
to time all precautionary measures for control of all types of pollution without any loopholes.
Sampling Locations wise native needs & expectations from corporate for overall development
i.e. personal & Infrastructural & Area are shown in below table.

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 Sai
area
Areas

Gorpe

Posari
Nevali
Bhisod

Kharad

Jambale
Dahivali

Rahatoli
Khusvali

Bendshil
Bonoholi
Surveyed

urban area
Ambarnath

Ulhasnagar
Urban Area
Bhandhanwadi
Village / Urban

Vasant Shelvali
Badlapur urban
Local Employment

✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
Internal Roads / Road Facility

✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
Drinking Water Facility (HH Tap

✓
✓
✓
✓
✓
✓
✓
Connection)

Environmental Consultant
Environmental Impact Assessment

Health / Medical Facility

✓
✓
✓
✓
✓
✓
✓
Dr. required in PHS

Page 142
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓ Drainage Line

Periodically Garbage Collection

✓
✓
✓

Toilets

✓
✓
✓

Irrigation Facility

✓
✓
✓
✓
✓

Tree Plantation

✓
✓

Pvt. Ltd.
Repairing of Lake

✓ Strict Implementation of Water

✓

Pollution Control Measures so

Source: Information collected & tabulated by the AESPL Socio economic Team Members
Ulhas River cannot be polluted

Aditya Environmental Services

Educational Facility and School
✓
✓

Infrastructure development.
Centaur Pharmaceuticals Private Limited

Solar Light
✓
✓
✓

Water Filter Plant

✓

Local manpower Recruit on

✓
Table 3.37Local People Need & Expectation for Enhancement of their Quality of Life

Permanent Basis

Bus Facility
✓
✓

Vocational Training Programs for

needy youth & women & assistance
✓
✓

for Development of Small Scale

business

Assistance to BPL families for their

✓

economic growth
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Environmental Impact Assessment Centaur Pharmaceuticals Private Limited
Chapter 3 –Description of Environment
As concluded from the above table employment is the most important need of the population in
the study area & local manpower should be recruit first & emphasis should be given for
developing & enhancing the skills required at different level of jobs, trade & business etc. Along
with local recruitment people feel their standard of living may be improve if line of action taken
for improving the required needs or problems such as

❖ Fulfill the drinking water requirement through household tap water connection, RO / filter
plant& repairing of local water sources such as lakes etc.

❖ Sanitation facilities in the form of constructions of drains, closed the open drains & connect
the drains into sewer lines and periodically garbage collection facility, constructions of
toilets etc.

❖ Health facilities & educational facilities and related infrastructure development such as
construction of new building, classroom, toilets & compound boundary wall etc. at local
schools & Doctors should be available at local health institutes such as Primary Health Sub
Centre etc.

❖ Constructions of pucca roads as reported in most of the surveyed villages internal roads
within the villages are mostly kaccha roads

❖ Irrigation facility, tree plantation around the vicinity of their areas, strict & compulsory
implementation of water pollution control measures so Ulhas river cannot be polluted

❖ Assistance to BPL families for their economic growth, vocational training programs,
assistance for development of small scale business etc.

Health Status: Vital health statistics of Thane district is presented in below Table.

Table 3.38Vital Health Statistics of Thane District

Fertility & Mortality Rate Year – 2015
C.B.R. (Crude Birth Rate) 15.96
C.D.R.(Crude Death Rate) 4.89
I.M.R.(Infant Mortality Rate) 11.23
Morbidity Pattern (Diseases – Causes of Death of all Age
Year – 2014
Group)
Asthama 90
Cardiac Arrest 85
Liver cirrhosis, Alcoholic liver 60
Hemiplegia 39
Accidental injuries 25
Other forms of heart diseases 0
Pneumonia & Bronchitis 0
Diabetes Mellitus 14
Suicide 30
Conditions related to premature & L.B.W. baby 18

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Acute rheumatic fever & chronic heart disease 17
Congestive Cardiac failure 17
Cancer of Digestive Organs 0
Total 395
Data regarding health status has been collected from Deputy Director of Health Services State
bureau of Health intelligence Pune, Maharashtra. Birth rate, death rate and infant mortality rate
of Thane District were 15.96, 4.89 and 11.23 respectively in 2015. Highest number of people
suffered & causes of death happened due to asthama, cardiac arrest & Liver cirrhosis, Alcoholic
liver diseases in the year 2014 at Thane district.

3.9.6 CSR activities carried out by Centaur during 2016-17

Following activities as corporate social responsibility are carried out during 2016-17.

No CSR Project / activity Project sector Project Expenditure

identified area incurred, Rs
Lacs
1 Lala Sher Singh Memorial Promotion of education New Delhi 51.0
Jeevan Vigyan Trust Society
2 BGVS Medical centre Promotion of education Sadashivgad, 2.0
Karwar
Total 53.0
Ref : Annual report 2016-17

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Chapter 4 –Anticipated Environmental Impacts & Mitigation measures

4 A NT ICIPATED ENV IRONM ENTA L

IMPACTS & MIT IGAT IO N MEASURES

4.1 Introduction

Any Synthetic Organic Chemical manufacturing has various impacts during construction
commissioning, operation phase and at end of project life on environmental parameters
like land environment, water quality, air quality of surrounding area and due to
generation of solid and hazardous wastes.

4.2 Identification of Impacts

Environmental impact identification is based on stage of project and the type, scale and
location of proposed project activity. Environmental components that may be affected
negatively and positively due to proposed activity are identified for construction and
operation phase and presented below:
Table 4.1 Environmental Aspects and Impacts of the expansion Project
Sr. Step/Activity Environmental Impact
No. Aspect Type Severity
1.0 Construction of Emission to air (dust) Air Pollution Temporary
buildings and Use of water, energy Natural resources, Temporary
Erection of Plant and materials conservation
Use of manpower Employment Temporary
Hazardous and Land pollution Permanent
nonhazardous Waste
Disposal on land
Cutting of Trees Biodiversity loss Temporary
2.0 Commissioning Use of water, energy Air Pollution Temporary
and materials
Use & storage of Safety, Temporary
hazardous chemicals Occupational
Hazards
Waste Water Water Pollution Temporary
discharge
Hazardous and Land Pollution Temporary
nonhazardous Waste
Disposal on land
3.0 Operation Use of Water Natural Permanent
resources/
conservation
Wastewater discharge Water Pollution Permanent
Hazardous and Land Pollution Permanent

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Sr. Step/Activity Environmental Impact
No. Aspect Type Severity
nonhazardous waste
for disposal
Use of manpower Employment Permanent
Use of material, Air Pollution Permanent
energy and resources
Use & storage of Safety, Permanent
materials Occupational
Hazards
Production of goods Revenue Permanent
Generation
Operation of Plant and Noise Pollution Permanent
machinery
4.0 Closure and Stoppage of New Revenue & Permanent
Decommissioning product employment loss
Decommissioning Land pollution Permanent

4.3 Prediction of Impacts during Construction Phase and Mitigation

Measures

4.3.1 Land Environment

4.3.1.1 Anticipated Impacts

The proposed expansion is on the existing location at plot no. 74, 75, 76 & 76/1 of MIDC
Industrial Estate, Ambernath (west), Dist Thane Maharashtra. Since the expansion is
planned at plant site in a developed industrial area, no special/specific development is
anticipated. The proponent will have to do site related developmental activities.
The unit is located on an industrial plot is allotted by MIDC. The land shall be used as
“Industrial” land thus there shall be no change in land use. MIDC has provided all basic
infrastructures like electrical power, water supply, internal road network, external
approach road etc.
Land Form: Land is on plain contour, it is flat terrain.
Land Ownership: Land ownership is with project proponents (Centaur Pharmaceuticals
private limited).
Existing Land use Pattern: The Land is reserved for Industrial use & presently project
expansion site is at the same plot. Part of project area need to be demolished &
developed suitably for proposed expansion.
Existing Infrastructure: Presently there is an existing Infrastructure at the site.
Infrastructure like water, electricity, telephone facility, roads already available as this is
an existing Industrial area.
Considering the few site related developmental activities, the following are identified as
the probable impacts on the landuse/ landcover in the surrounding 500m and 10 km
study area during the construction phase of the project:
1. Dust and construction debris during demolition, excavation for foundation,
clearing, leveling the plot area and vehicular movements

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2. Transportation and handling of construction raw material and construction
equipment.
3. Disposal of sewage & garbage generated during the construction works from site.
4.3.1.2 Mitigation Measures

Measures suggested for mitigation of the probable impacts during the construction
phase are as follows:
• Spray water on the unpaved areas during summer season. Cover the waste layer
with fresh soil and compact it. Proper sprinkling system is to be adopted to
reduce the amount of flying dust. Excavated earth shall be stored in stockpiles
and covered with plastic/ tarpaulin sheets and reused for landscape
development.
• Transportation of hazardous waste to be done as per CPCB Guidelines. The
dumpers should be covered to prevent spillage or dusting. The drivers should be
imparted with proper training.
• Provide proper sanitation facilities for the construction workers. The sewage
should be disposed off through the septic tank & soak pit arrangement or
connected to existing sewage pipe/ STP.
• Separate area will be earmarked for storage of solid wastes generated while
hazardous wastes will be stored in existing covered area earmarked for the
purpose
• Substratum removed during demolition, foundation, broken pieces of concrete,
bricks will be given for leveling of nearby plots for other industries as directed
by MIDC.
• wastes like broken glass, plastic drum/ bags / iron scrap etc will be sold to scrap
dealers for recycle
• Waste paint cans, brushes and filters, glass wool material and asbestos packing
will be stored separately and disposed off to CHWTSDF facility.
• Separate space shall be earmarked for parking of construction trucks so that they
do not clog MIDC road. Heavy material will be brought in during night time only.
Plant erection involves leveling of land and excavation. Solid waste generated will
include demolition rubble, substratum removed during foundation, broken concrete,
glass, bricks etc and scrap iron pieces, insulation, packaging materials, plastic drums etc.
Hazardous waste generated includes paint drums, glass wool insulation, asbestos pieces
etc. Improper waste disposal can lead to unhygienic conditions and hazards to nearby
populace.
Construction material (concrete, iron sheets, plant and machinery etc) transport will
lead to increase in number of vehicles plying on MIDC roads by about 3 – 4 nos / day.
However existing service road is tarred by MIDC and hence no traffic congestion is
expected.

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4.3.1.3 Mitigation Measures

4.3.2 Water Environment

4.3.2.1 Anticipated Impacts

Additional water (20 - 30 cmd) required will be supplied from existing plant facility.
About 50-100 workers from nearby villages/area will be employed. Additional Sewage
generation (3 cmd) will be treated in existing combined ETPprovided at site.
4.3.2.2 Mitigation Measures

• Temporary arrangement of clean drinking water will be provided for workers.

• Toilets will be provided and connected to existing combined ETP at site

4.3.3 Air Environment

4.3.3.1 Anticipated Impacts

Impact on air environment will be due to dust generation and will be highly localized
and confined to plant boundaries. Also, there are no residential area upto 0.5 km from
site, hence impact will be localized and temporary in nature. Particulate emissions may
cause occupational health like respiratory problems i.e. allergic asthma and watering of
eyes etc.
4.3.3.2 Mitigation Measures

• Provision of PPE (dust masks, goggles) for onsite workers.

• Screening of construction area at boundary with tin sheets/suitable barrier.
• Periodic water sprinkling in the construction area.

4.3.4 Ecological & Biological Environment

4.3.4.1 Anticipated Impacts

There is no wild life sanctuary/national park located within study area. There is
considerable agricultural area in study area. The proposed industry is part of notified
industrial area of MIDC. Construction phase of expansion unit involves demolition of
existing old structure, removal of herbaceous vegetation within plot, assembling of
different components of plant etc.
Species of existing herbs within plot that need to be cleared are found commonly in the
region and does not have conservation concern. Clearing herbs does not pose significant
impact on flora. No mass nesting was observed within site during site visit, owing
construction activity there will be insignificant adverse impact on fauna also.
Particulate emissions during construction will have some impact on trees located near
construction site. However, since the particulate are non-toxic in nature and emission is
temporary thus no serious impacts are considered.

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4.3.4.2 Mitigation Measures

• Provide barriers around site with water sprinkling to reduce particulate dust
generation
• Planting trees around new plant boundary and on road sides adjoining plot.

4.3.5 Noise & Vibration Environment

4.3.5.1 Anticipated Impacts

Noise and vibrations will be generated in construction phase. The project site is part of
MIDC and there is no human settlement in 0.3 km vicinity of the site, thus the noise
generated will not have any major impact in the study area. As the phase of construction
and plant erection will be of temporary nature, noise pollution will be confined to plant
boundaries only.

4.3.5.2 Mitigation Measures

• Adequate PPE (ear muffs, ear plugs) for construction workers.

• Adequate barrier will be provided to prevent noise propagation.
• Use construction machinery meeting in EP Act norms for noise

4.3.6 Occupational Health and Safety

4.3.6.1 Anticipated Impacts

Health of workers may be affected due to dust and noise and possibility of accidents.
4.3.6.2 Mitigation Measures

• Adequate provision of PPE (helmets, safety shoes, harness, ear plugs, muffs, dust
masks) for construction workers.
• Insurance for construction workers and extending existing medical facilities to
them.
• Periodic health checkup shall be carried out.

4.3.7 Socio-economic Environment

Impacts on socio-economic environment due to proposed project during construction

phase are envisaged due to direct and indirect employment which will be beneficial.
4.3.7.1 Anticipated Impacts

There will be temporary employment for about 100 – 150 persons over about 8 - 12
months. It will create business opportunities to suppliers of construction material,
fabricators, manpower suppliers, civil contractors etc Local labors will be employed
during construction phase.

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4.3.7.2 Mitigation Measures

• Engage local contractors for non-specialized work

• Provide adequate water supply and sanitation for onsite workers.
• Employ local labors and youth for construction work

4.4 Prediction of Impacts during Commissioning Phase and Mitigation

Measures

4.4.1 Anticipated Impacts

Impacts during commissioning phase will be due to:
Use of water: Total additionalwater requirement for plant operation will be ~ 278 cmd
and will be sourced from existing source i.e. MIDC.
Similarly, electricity required will be sourced from MSEDCL. During commissioning
stage the water and energy demands will be fluctuating as commissioning activities are
carried out sequentially step by step.
Use of materials: Industry will be using Toluene, Methanol, Ethanol, IPA, Ethyl acetate,
acetic acid, acetic anhydride etc and many other chemicals required for the operation.
Incorrect procedures followed during initial stages can lead to accidental exposure to
employees, leakage of chemicals thereby polluting land and water bodies.
Waste water generation during plant operation will result in estimated additional ~
99 cmd of effluent. However, during commissioning phase risks of water pollution are
enhanced since in plant pollution control facility such as effluent treatment plant will
also be also under commissioning and there might be shock load to effluent treatment
plant.
Care has to be taken to store the untreated / treated effluent. In fact, Effluent treatment
system has to be commissioned in advance.
Waste generation as the plant operation is yet not stabilized, there is possibility of
failed batches which will need to be stored and disposed safely so as not to cause land
pollution.

4.4.2 Mitigation Measures

• Proper training to employees in handling of Toluene, Methanol, Ethanol, Ethyl

acetate, etc and other chemicals by hiring trained personnel well versed in handling
such chemicals.
• Personal supervision by Unit head and HSE staff to ensure that there is no shock
load to Effluent treatment plant. Active support from R & D and Quality control
staff to ensure that the plant process is stabilized as soon as possible to ensure that
loads to ETP remain at the predicted levels.
• Have a designated procedure to ensure waste generated during commissioning is
collected separately and sent to CHWTSDF.

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4.5 Prediction of Impacts during Operation Phase and Mitigation
Measures

4.5.1 Land Environment

4.5.1.1 Anticipated Impacts

Major concern in land environment during operation phase is contamination of land by:
• Spill and leak during transport, handling, storage activity of chemicals
• Spill of oil and greases during maintenance of equipment, machineries and
vehicles
• Improper storage/dumping of hazardous wastes, resulting in leachate
contaminating the soil
• Contaminated runoff from site and contaminated drain from storage areas,
hazardous wastes and chemical storages, tanker loading/unloading areas
draining to land
• Transportation in tanker or drums through highways, which may have
considerable impacts on environment of the area falling in the route of the
transportation. During the incidence of major accident, the hazardous materials
being transported can have serious impacts on land where on it spilled or leaked.
4.5.1.2 Mitigation Measures

• Production, maintenance area and warehouses for storage of raw materials,

finished products and hazardous wastes will be provided with impervious
flooring.
• All bulk storage tanks will be provided with adequate dyke walls to prevent
spreading of spill or leaked chemicals causing contamination of soil.
• Necessary cleanup procedures (SOPs) for the specific area will be designed and
implemented.
• Used oil from machineries/equipment etc. will be collected in drums & stored in
designated storage area. The used oil shall be sold to authorized refiners.
• ETP facilities for management of effluents will be provided as planned during
erection and commissioning phase and untreated effluents will not be disposed
off on land.
• The chemicals used will be transferred through closed pipelines by DCS control
system to avoid/prevent spill/leak of the materials.
• Hazardous waste management will be done as per statutory guidelines &
requirements.
• Sludge from effluent treatment systems will be dried in mechanical dewatering
system and stored on sludge drying beds or kept in sacks in covered godowns,
with impervious flooring sloping so that any leachate will be collected and taken
back for treatment.

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• Spent catalyst, Residues will be stored in existing / proposed covered area meant
for hazardous waste storage and sent back to supplier or sent to CHWTSDF
facility.
• Empty Chemical drums will be decontaminated and reused/recycled or sent
back to supplier or sold to MPCB authorized party.
• All transportation of hazardous wastes will be done in closed truck/tanker by
MPCB approved agencies
• HAZMAT guidelines will be followed for transport of all hazardous materials. All
required safety & emergency equipment & materials will be provided on the
transport vehicles.
• Proponent will maintain a good spill or leak control action plan to cope up with
such incidents.
• Monitoring of soil samples in areas near hazardous waste storage will be done as
per Environmental monitoring plan.
• No waste will be stored on open barren land under any condition

4.5.2 Water Environment

4.5.2.1 Anticipated Impacts: Additional Water use& Wastewater Generation

The total water requirement (existing + proposed) after expansion shall be 407 CMD.
Additional water requirement for proposed expansion project will be fulfilled from
MIDC.
Centaur has applied to MIDC for water assurance. The copy of assurance letter is
attached as Annexure 2.2.
The additional effluent generate from proposed expansion project will be Domestic ~
11 cmd and from utilities, process, plant washing ~ 62 CMD. (Totalling to 73 cmd
additional)
After expansion project, total domestic sewage generate will be 20 cmd and trade
effluent will be 74 cmd (Totalling to 94 cmd).
Centaur is proposing to treat both effluents in combined effluent treatment plant,
having primary, secondary and tertiary treatment (having RO & MEE for
maximumrecycle).
Expected analysis of the generated waste water is as follows,
Table 4.2Expected waste water analysis
No Source Quantity COD BOD TSS TDS TKN
, CMD (mg/lit) (mg/lit) (mg/lit) (mg/lit) (mg/lit)

1 Sewage effluent 20 400 120 100 600 20

2 CT Blow down 14 100 30 50 600 0
3 Boiler blow down 8 100 30 0 600 0
4 Process (Low 16 5625 2250 625 1250 2500
COD, Low TDS)

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5 Vacuum sump 5 7500 4500 0 2500 500
blow down
6 Scrubber effluent 1 400 120 100 600 29
7 Process (high 30 150000 45000 1000 50000 2000
COD, High TDS)
Total 94 - - - -

4.5.2.2 Mitigation Measures Water Environment

Effuent Treatment Scheme

The effluent generated from manufacturing process will be segregated into Low COD,
Low TDS stream and High COD, High TDS streams and will be collected into separate
collections tanks.
The Low COD, Low TDS stream will be imparted Primary Treatment with chemicals to
precipitate insolubles. The primary treated effluent will undergo Anoxic followed by
Aerobic Secondary Treatment to biodegrade organic compounds and finally will be
given Tertiary Treatment of Filtration and Activated Carbon adsorption to reduce
organic contents in the treated effluent.
The tertiary treated effluent will then be subjected to Reverse Osmosis Treatment to
separate dissolved solids such that the permeate from the Reverse Osmosis process is
suitable for recycle and reuse in plant for Cooling Tower makeup, floor washing etc.
The reject generated from the Reverse Osmosis process will be mixed with the High
COD, High TDS stream and will be treated in a well-designed Multiple Effect Evaporator.
The High COD, High TDS effluent stream segregated from the process plant will be
collected separately and will be subjected to Stripping followed by Evaporation and the
concentrated effluent will be dried through a suitable dryer to separate the Salts from
the effluent. The dried Salt will be sent to CHWTSDF for landfill. The stripped liquid
from the stripper will be either reused in the plant to recover organics or sent to
external authorised recycling facility to recover solvents. The condensate from the
Evaporator will be transferred to Equalisation tank of ETP for treating through the
Secondary and Tertiary Treatment of the ETP.
Details of the scheme is attached at Annexure 4.1
o Rain Water Harvesting Scheme
Areas considered for rainwater harvesting is as under
Area 1380 sq m
Average rain fall 2294 mm (2.294 m)
Water run off coefficient 0.8
Potential rainwater harvesting 1380 m2 x 2.294 m x 0.8= 2533 m3

Assuming days rain fall for 90 days, average rainwater harvesting potential= 2533 / 90 = 28 cmd

Centaur will provide 100 m3 undergroundwater tank for rain water storage/ harvesting.

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Following additional mitigation measures will be adopted to reduce impacts on water
environment:
• Implementation of scheme of in plant pollution control system for process
effluents generated comprising of segregation of process effluents
• Implementation of measures for management of hazardous chemicals/wastes as
given under land environment
• Regular monitoring of effluents for statutory purpose and to gauge the
functioning of treatment system be carried out as given in Chapter 6
• Proper preventive and breakdown maintenance of ETP units from civil,
mechanical, electrical and instrumental angle will be undertaken
• Adequate standby / spare unit / spare capacity shall be provided
• Regular log book of ETP and in plant effluent treatment system will be
maintained to indicate chemical consumption and operational status of
equipment
• Regular records of energy consumption for ETP units will be maintained
• Close monitoring of effluents will be undertaken to ensure proper functioning of
ETP to meet MPCB norms and recycle quality requirement.
• In plant online monitoring instruments shall be provided such as pH,
conductivity meters including flow measurement for accurate control.

4.5.3 Air Environment

Impact on air environment is anticipated due to proposed addition of Furnace oil fired
Boilers at site.(with installation of new boilers at site existing 2 No of boiles of 600
kg/hr each will be phased out).
Impact on air emission is also expected due to additional process stacks. These process
stacks will be provided with water scrubber and alkali scrubber. Height of stack for
these will be provided as per statutory norms.
Impact on air emission is also expected due to additional HSD operated DG sets. DG sets
be will be operated in case of emergency only. Height of stack for these will be provided
as per statutory norms.
Fuel Requirement- Proposed
Fuel requirement for proposed boilers is as follows:
Table 4.3 Fuel Requirement (Proposed)
No Fuel for Fuel type
1 1 TPH Boiler Furnace Oil: 1.46 TPD or Natural Gas: 1700 Nm3/day
2 5 TPH Boiler Furnace Oil: 7.30 TPD or Natural Gas: 8000 Nm3/day
3 5 TPH Boiler standby
(standby)
Total Furnace Oil: 8.76 TPD or Natural Gas: 9700 Nm3/day

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4.5.3.1 Quantitative Assessment of Impacts due Fuel Burning

Impact on air environment is anticipated due to emissions from fuel burning Furnace oil
leading to emission of sulfur dioxide, NOx and particulate matter.
The proponent is proposing to provide suitable stack height to the proposed boilers.
These emissions may cause occupational health impact on site and study area like
respiratory problems i.e. allergic asthma and watering of eyes, damage of respiratory
organs, necrosis of plant tissues, fruits due to acid rain and finally reduced yield etc.
Impacts of these emissions can be reduced by providing adequate stack height as APC
and by use of PPE.
Details of proposed stack are given in table below:
Table 4.4 Air Pollution Sources: Proposed Operation
Attached to Boiler Boiler Boiler
(standby)
Capacity - 1 TPH steam 5 TPH steam 5 TPH steam
Fuel type (worst - Furnace oil Furnace oil Furnace oil
case)
Sulphur content % 4.5 4.5 4.5
(Furnace oil)
Fuel quantity kg/hr 61 304 304
Sulphur kg/hr 2.7 13.7 13.7
SO2 emission kg/hr 5.5 27.4 27.4
Fuel quantity MT/day 1.46 7.30 7.30
Material of - CS
construction
Shape - Round
(round/rectangular)
Min Height, m meter 40
(above ground
level)
stack Diameter/size, meter 0.5 (combined stack)
in meters at top
Cross section area of m2 0.20
stack at top
Flue Gas quantity Nm3/hr 4861
Flue Gas quantity m3/hr 7532
Flue Gas Deg C 150
temperature at
stack
Flue gas exit meter/sec 10.65
velocity
SO2 (Furnace oil) grams/sec 7.289
NOx grams/sec 0.5607
Proposed APC - Stack height

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Note:
1) Above is for 2 boiler operation (1 TPH & 5 TPH). Third 5 TPH boiler will be
standby.
2) PM emission indicated is as per US EPA 42 (Section 1.3 Fuel oil combustion)
3) For NOx generation Low NOx burner will be provided.
4) NG will be used, if available.

Stack height calculation for Boiler (as per CPCB guidelines)

1) Based on Furnace oil (SO2 emission)
Fuel consumption (Furnace oil) = 365 kg/hr
Sulphur content = 4.5 % max (worst case scenario)
Sulphur di oxide generation= (365) x (4.5/100) x (2) = 32.85 kg/hr
Minimum stack height = 14 x (32.85)^0.3 =40 meters.
Based on SO2 emission 40 m stack height will be provided.
4.5.3.2 Modeling Studies to Predict Magnitude of Impact on Air Quality from proposed
activity

In order to compute air quality impacts due to proposed additional sources, dispersion
modeling studies are carried out using AERMOD model, assumptions of which are as
given below:
• Steady state conditions & uniform emission rates
• No removal/ transformation of pollutants
• Pollutant material
• Averaging time 24 hours
The AERMOD is steady state advanced Gaussian plume model that simulates air quality
and deposition fields up to 50 km radius. It is an advanced version of Industrial Source
Complex (ISCST3) model, utilizes similar input and output structure to ISCST3 sharing
many of the same features, as well as offering additional features. The model is
applicable to rural and urban areas, flat and complex terrain, surface and elevated
releases and multiple sources including point, area, flare, line and volume sources.
AERMOD is approved by USEPA and is widely used software for air dispersion
modelling studies. For prediction of maximum Ground Level Concentrations (GLC’s), the
air dispersion modelling software, AERMOD have been used.

Model overview
The AERMOD model features include:

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• The ability to model dispersion of primary pollutants, toxic and hazardous waste
pollutants;
• The ability to handle multiple sources in an industrial complex (point, area,
volume and pit types) with no buildings or single or multiple buildings with
building downwash;
• Constant or time-varying emissions;
• Gas and particle depositions;
• Concentration estimates for all terrain locations, except in lee areas;
• Predictions at distances up to 50 km from the source;
• Specification of receptors locations as gridded and/or discrete receptors in
Cartesian or polar coordinates; and
• Use of real-time meteorological data to account for the atmospheric conditions
that affect the dispersion of air pollutants.
Dispersion modelling using AERMOD requires hourly site specific meteorological data
which include wind direction, wind speed, temperature etc. AERMET is integral
software of AERMOD. AERMET provides a general purpose meteorological pre-
processor for organizing available meteorological data into a format suitable for use by
the AERMOD air quality dispersion model. Site specific data is used for executing
current modelling studies. The site specific meteorological data is processed using
AERMET processor and resultant output (pfl file) is used for air pollutant modelling
study.
Model Set up
The model set-up details are presented in Table-1.1 below.
# Parameter Details
1 Model Name AERMOD
2 Model Type Steady state Gaussian Plume Air Dispersion model
3 Topography Flat
4 Averaging Time 24 hours
5 Source Type Point Source
6 Boundary Limits 10 km X 10 km
7 Co-ordinate System Uniform Polar Grid
8 Receptor Height 2m
9 Surface meteorological data Pre-processed from Site Data
10 Upper air Data Pre-processed from Site Data
11 Anemometer Height 10 m
Site specific meteorological data for a period of three months (November 2017 to
January 2018) has been processed using AERMET. Site specific wind rose generated is

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shown in Figure below. As per the wind rose, it can be observed that the predominant
wind direction is from south west side.

Figure 4.1 Wind rose for winter 2017-18

Emission rates considered for modeling of SO2, NOx and PM10 are given in table above.
Results
The model simulations have been carried out to evaluate the pollutant emissions from
the project that are likely to contribute to the ambient air environment. For the short-
term simulations, the concentrations were estimated and evaluated to obtain an
optimum description of variations in concentrations over the site within 10 km radius
covering all the directions. The predicted results for pollutants are presented in table
below and isopleths showing the incremental concentrations are presented in Figures
below.
Based on the modeling results, the highest incremental increase in concentration of
Pollutants are summarized in the table below:
Table 4.5 Top 10 incremental concentrations
X Coordinate Y Coordinate SO2, NOx,
Highest (UTM) (UTM) Concentration in Concentration in
Values µg/m3 µg/m3
mts mts
1st 314422 2121083 2.1 0.2
2nd 314345 2121147 2.1 0.2
3rd 314498 2121019 2.1 0.2
4th 314575 2120954 2.1 0.2
5th 314268 2121211 2.1 0.2

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6th 314651 2120890 2.1 0.2
7th 314728 2120826 2.1 0.2
8th 314805 2120761 2.1 0.2
9th 314881 2120697 2.1 0.2
10th 314192 2121276 2.1 0.2

The concentration of incremental GLC is added to the baseline concentration at

locations in the study area to indicate predicted the ground level concentrations.
4.5.3.3 Modelling Impacts on SO2

Based on the modeling results, isopleths for incremental increase in concentrations for
SO2 are drawn and are shown below:

Figure 4.2 Isopleths of SO2 (Stack Coordinates 0,0)

Based on the modeling results, the highest incremental increase in concentration of SO2
occurs at coordinates in the south east direction at a distance of 3600 m and the
incremental increase is 2.1µg/m3.
The highest value concentration of GLC is added to the baseline concentration at
locations in villages in the study area with considering worst case scenario.
Table 4.6 Prediction of GLC of SO2 (Stack cordinates 0,0)
AAQM location Back Ground Predicted GLC Net Impact Norms*
value (µg/cum) (µg/cum) (µg/cum) (µg/cum)
MIDC location 12.3 2.1 14.4 80
Matoshree Nagar 11.6 2.1 13.7 80
Kailash Nagar 10.8 2.1 12.9 80

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Thakur pada 11.3 2.1 13.4 80
Chikhloli village 11.0 2.1 13.1 80
Vadavali village 10.9 2.1 13.0 80
Vasat phata 11.0 2.1 13.1 80
Vasat village 10.9 2.1 13.0 80
(*) Norms specified by Central Pollution Control Board, New Delhi vide Gazette
Notification dated 16th November 2009.
4.5.3.4 Modeling Impacts on NOx

Based on the modeling results, isopleths for incremental increase in concentrations for
NOx are drawn and are shown below:

Figure 4.3 Isopleths of NOx (Stack Coordinates 0, 0)

Based on the modeling results, the highest incremental increase in concentration of NOx
occurs at coordinates in the south east direction at distance of 3600 m and the
incremental increase is 0.20 µg/m3.
The highest value concentration of GLC is added to the baseline concentration at
locations in villages in the study area with considering worst case scenario.
Table 4.7 Prediction of GLC of NOx (Stack cordinates 0,0)
AAQM location Back Ground Predicted GLC Net Impact Norms*
value (µg/cum) (µg/cum) (µg/cum) (µg/cum)
MIDC location 20.0 0.2 20.2 80
Matoshree Nagar 18.7 0.2 18.9 80
Kailash Nagar 18.0 0.2 18.2 80

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Thakur pada 18.5 0.2 18.7 80
Chikhloli village 18.2 0.2 18.4 80
Vadavali village 17.9 0.2 18.1 80
Vasat phata 18.1 0.2 18.3 80
Vasat village 18.0 0.2 18.2 80
4.5.3.5 Observations from dispersion modeling studies

From the dispersion modeling studies conducted, it was observed that the maximum
ground level concentration occurs in the south east direction at about distance od3600
meters.
The incremental increase will have negligible impact on the air environment.
4.5.3.6 Other Air Pollution Impacts

1. VOC Emissions from Process:

The chemicals being proposed for manufacture are organic chemicals and will
lead to increased emissions of volatile organic chemicals during handling,
storage and from process and emergency vents.
VOCs are harmful to human health and cause secondary air pollutants on
emission into atmosphere. This may include formation of ozone on ground level.
Also, this will lead to increased odor nuisance for neighboring populace.
4.5.3.7 Mitigation Measures

Following mitigation measures are planned and suggested in view of air environment
during operation phase:
1. Boilers:
Stack of sufficient height for Boilers.
Process scrubbers
Regular monitoring for fuel burning stacks through MOEF approved laboratory
2. Controlling VOC emissions:
• Transportation must be done in closed approved vehicles only. All safety &
control measures shall be provided to prevent spill, leak and accident during
transportation.
• All transport vehicles must comply with HAZMAT guidelines & statutory
requirements.
• It is essential that best practicable control measures and practices are
introduced to control VOC emissions from plant such as
- Having a preventive maintenance program
- Providing mechanical seals on agitators, pumps, etc
- Training for staff in fitting out seals, packings etc so as to ensure that they are
properly fitted and do not “leak”

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3. General:
Provide green belt all around the factory to ensure that site is screened from
surroundings and air impacts are reduced.

4.5.3.8 Proposed Process and DG stacks

Following process stacks are proposed to be added in the expansion.

(The gaseous emission from process shall be scrubbed before letting it to atmosphere at
height, wherever applicable)
Table 4.8 Proposed Process Stack and DG stack Details
No Description APC System Stack ht. in Pollutant
meter
1 Process reactor Alkali Scrubber (Acidic 10 Acidic
mist/fumes scrubbing by 10 mist/fumes
NaOH solution)
2 Process Reactor Water Scrubber (Solvent 10 Solvent
traces scrubbing bywater) traces
3 DG set (1000 KVA) stack 6.5 m above SO2, NOx, PM
roof
4 DG set (750 KVA) stack 5.5 m above SO2, NOx, PM
roof

4.5.4 Solvent Recovery

Various solvents such as Toluene, Methanol, IPA, Ethanol, Ethyl acetate, Methylene di
chloride, DMF, Cyclohexane, Acetone, etc are used in the process.
Its quantity used and recovery planned in process is as follows,
Table 4.9 Solvent recovery
No Product Solvent Quanti Expecte Total % %
used ty of d Loss Reco Loss
solven quantity quantity very
t of (by
input, solven.4 differenc
kg t e)
recover
ed, kg
1 Nitrazepam Toluene 877.2 859.7 17.5 98.0 2.0
Methanol 8018.5 7617.6 400.9 95.0 5.0
Ethanol 883.7 839.5 44.2 95.0 5.0
2 Lorazepam Methanol 556.95 529.10 27.8 95.0 5.0
Acetone 643.5 611.33 32.2 95.0 5.0
Cyclohexa 1181.9 1158.31 23.6 98.0 2.0
ne 5
3 Zopiclone Isopropyl 444.6 422.37 22.2 95.0 5.0
Alcohol
Methylene 2292 2178 114.6 95.0 5.0

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Chloride
Ethyl 2282 2167 114.1 95.0 5.0
Acetate
4 Zapeplon Methanol 1995 1895 99.7 95.0 5.0
5 Tranylranylcypro Toluene 362.06 354.82 7.2 98.0 2.0
mine Sulphate
Methanol 271.76 258.17 13.6 95.0 5.0
6 Chloropyramine Toluene 597.7 585.75 12.0 98.0 2.0
HCl
IPA 358.8 333.68 25.1 93.0 7.0
Acetone 171.6 154.44 17.2 90.0 10.0
7 Nimorazole Toluene 537.5 510.63 26.9 95.0 5.0
Methanol 588.55 529.70 58.9 90.0 10.0
Isopropan 327.6 311.22 16.4 95.0 5.0
ol
8 Acotiamide Methylene 349.33 314.397 34.9 90.0 10.0
Chloride
Methanol 272.55 245.295 27.3 90.0 10.0
Toluene 57.62 56.4676 1.2 98.0 2.0
9 Nabilone Methylene 526.03 499.73 26.3 95.0 5.0
Chloride
Ethyl 14.94 14.19 0.7 95.0 5.0
Acetate
10 Petophenone Toluene 860 842.8 17.2 98.0 2.0
Cyclohexa 385 365.75 19.3 95.0 5.0
ne
Isopropan 737.1 700.245 36.9 95.0 5.0
ol
11 LEVOMILNACIPR 2632.4 2579.81 52.6 98.0 2.0
Toluene
AN HCl 6
Methanol 707.84 672.45 35.4 95.0 5.0
Ethyl 1953 1855.35 97.7 95.0 5.0
Acetate
Isopropan 499.2 474.24 25.0 95.0 5.0
ol
Acetone 386.1 366.80 19.3 95.0 5.0
12 Pindalol Toluene 144.9 137.655 7.2 95.0 5.0
Ethyl 93.22 88.559 4.7 95.0 5.0
Acetate
Methanol 93.22 88.559 4.7 95.0 5.0
13 Prasugrel Toluene 65.62 64.3076 1.3 98.0 2.0
Ethyl 46.96 44.612 2.3 95.0 5.0
acetate
14 Silodosin Cyclohexa 132.6 119.34 13.3 90.0 10.0
ne
Toluene 197.8 178.02 19.8 90.0 10.0

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Note :
1) Solvent DMF in product Tranylranylcypromine Sulphate, Nimorazole,
Acotiamide, Petophenone, Pindalol, Prasugrel.
2) Solvent Isoporpanol in Acotiamide and
3) Solvent diisopropyl ether in Prasugrel and methanol in Silodosin
Can not be recovered from product streams and are dissolved in water and are
treated in effluent treatment plant.
Note: The solvent lost during the process of solvent distillation is mainly due to organic
thermal disintegration and in form of residue left behind from the bottom un-distilled
product. Evaporation loss is minimized by the passage of chilled water through the
condenser.
4.5.4.1 Solvent Management Plan

o After the reaction is complete the solvents are recovered in a distillation unit.
o The distillation unit has two condensers in series (shell and tube type).
o The first condenser is passed with cooling tower water, while the second
condenser with chilled brine solution.
o After the vapors are condensed, the condensate along with un-condensed vapors
is passed through a trap which is cooled externally with chilled water.
o The vents of condenser and receiver are connected to scrubber system.
o All the reaction vessels and centrifuges are connected to a common line. These
fumes and exhausts are sucked by ID fan and scrubbed by alkali solution.

o All the solvents shall be directly distilled from product mixes and it shall be
purified in packed column with the help of reflux. The product solvent shall be
extracted, and the residue shall remain in distillation still.
o Pure solvent, crude solvent and distilled (recovered) solvent shall be stored only
in
Storage tanks and we shall not be using drums at any stage in the Solvent
Management System.
o Wherever required, the solvents shall be directly pumped into day tanks from
the
Storage tanks and shall be charged into the reactors without involving any
manual handling.
o All the solvent handing pumps shall be mechanical seal type to avoid any leakage
of solvent.
o All necessary firefighting systems shall be provided with alarm system. Flame
proof
Fitting/wiring and flame proof electrical accessories shall be provided to avoid
any mishap.
o All the storage tank and day tank shall be connected to a vent system through
cooling water and chilled brine condensers to prevent loss of solvents in the
atmosphere.
o All the distillation column vents will be connected to cooling water/chilled water
condensers for maximum possible recovery of the solvents.

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o Residue generated from the distillation will be sent to CHWTSDF site for
appropriate disposal.

Close solvent dispensing scheme at Centaur ensures minimum vapor loss and
personal exposure.

Typical solvent dispensing system at Centaur is as follows,

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Figure 4.4 Solvent storage and dispensing scheme

4.5.5 Flow Chemistry for new Products

In last few years it has been found that continuous flow chemistry as a real revolution of
the present and future in the way to perform chemical synthesis in machine-assisted
processes. This encompass reaction conditions that are far from conventional
laboratory practices such as the use of high pressures, high temperatures, high
concentrations or even solvent-free, and reactions that occur on an explosive regime,
which make possible the attainment of new chemical transformations.

Continuous-flow technology involves the continuous introduction of a stream of

chemical reactants into a flow or micro reactor to yield a desired reaction product on a
continuous basis. Continuous-flow technology offers potential advantages compared
with traditional batch manufacturing of pharmaceuticals, such as greater optimization
and control of the process, improved safety and environmental profiles for a given
process.

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A synthetic organic chemist works with round bottomed flasks (RBFs) where the scale
up of the optimized process is always a challenge due to the need for many additional
adjustments of the reaction parameters. To overcome these and other experimental
difficulties, continuous flow reactors can be used as apparatuses for optimization and
process development in organic synthesis. Continuous flow reactors are devices in
which synthetic transformations take place in a continuously flowing stream within
structures with general lateral internal dimensions from 1/16 to 1/8 inches. Several
different types of flow reactors are commercially available, and customization to a
desired process is generally needed depending on the reaction characteristics. This
allows researchers to explore reaction conditions not possible in the batch set-up, such
as heating organic solvents at much higher temperatures then their boiling point. In-line
reaction analysis is also possible by the use of FTIR, HPLC, NMR, MS and/or UV-Vis, as
well as quenching and purifications, allowing a researcher to begin with the crude
starting material and arrive at the purified product in a telescoped protocol.

Furthermore, some batch processes pose operational hazards, particularly with the use
of highly reactive reagents. These hazards can be diminished under continuous flow
conditions due to increased temperature control and short residence times. Most
importantly, since the size of the reactors is very small, the amount of hazardous
reagent or intermediates in an operation is minimal, increasing further the safety of the
process.

Enabling technologies allow the execution of many “impracticable” reactions, mainly on

the industrial scale by processes intensification (PI). In this context, PI has become a
concept of great relevance, since it aims to develop more sustainable and
environmentally friendly processes. This leads not only to smaller plants but also to
significant reduction of energy consumption and waste, resulting in cheaper and
greener processes.

Having known the benefits of flow reactors, Centaur has now started evaluation of the
existing and new projects in terms of its feasibility in transformation from conventional
batch manufacturing to continuous production by using continuous flow reactors.
Centaur has already started discussion on this matter with the experts of the flow
chemistry in the industry as well as academics and is willing to adopt the technology
which is more environmental friendly.

4.5.6 Ecological & Biological Environment

The impacts during operation phase of expansion are mentioned below:

4.5.6.1 Anticipated Impacts

Operation phase of expansion involves transportation of raw material and work force to
the site. This leads to increase in noise levels at site; however existing surrounding
activities have other noise sources, which overall establishes background noise level for
the area. Thus propose project activity envisage insignificant adverse impact on fauna
due to noise generation.

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Gaseous and particulate matter emission from stacks and other process related sources
are predicted to increase levels of particulate matters, SO2 & NOx.
As per guidelines for Green Belt development published by CPCB, Threshold limit of SO2
for sensitive plant species is 1820 µg/m3 for 1 hour exposure. Visible injury caused in
the form of development of interveinal necrotic blotches. Similarly, threshold limit of
NOx for sensitive plant species is 38000 µg/m3 for 1 hour exposure. Visible injury is
seen same as in case of SO2.
Considering baseline environmental conditions and pollution load calculation indicates,
concentrations of gaseous pollutants together with existing baseline concentrations are
lower than threshold limit specified in CPCB publication, March 2000 for Green belt
Development.
Operation phase of expansion unit envisage insignificant adverse impact on flora and
fauna, provided efficient working of suitable pollution control equipment and
development and proper maintenance of suitable green belt.
4.5.6.2 Mitigation Measures

Impacts of proposed expansion of synthetic organic chemicals at CENTAUR are

discussed in earlier chapter; these impacts can be minimized by adopting following
mitigation measures.
For particulate and noise abatement, two rows of trees will be planted all around the
boundary of site.
Green belt will be developed in two levels i.e. tall, native and evergreen broad leaved
species towards outer periphery whereas dwarf and native species towards inner side
of it. This arrangement provides better screening effect. Objectives and principles of
green belt development are listed below. In practice, green belt will be developed in
consultation with horticulture expert, as per available species nearby. Indicative species
list for green belt is given in Tables below.
Objectives of Green belt development
• Partial check on air pollution
• Partial check on noise level
• Increase in esthetic value of surrounding
• Indirect partial help to maintain biodiversity
Principles of Green belt development
- Green belt will be composed of native species
- Species will be suitable for agro-climatic zone
- Species will be selected according to soil type, climate, rain fall etc.
- Taller plants will be planted towards outer periphery
- Shorter plants will be planted towards inner periphery
- Evergreen species will be selected as far as possible to have least litter fall

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- Plant will be tolerant to air pollution
- Green belt will have indicator species with respect to air pollution
- Species may have quick growing ability
Area proposed under green belt is about 3019.69m2 (33.16%) Green belt lay out is
presented in Annexure 2.1.
There will be separate monitory provision made for green belt development. Plantation
will be started prior to commencement of site development for expansion unit.
In operation phase, yearly monitoring will be conducted to assess any sort of impact
due to project activity on flora and fauna, for first three years. Frequency of monitoring
may be reduce to once in three years from forth year. Reports prepared based on
monitoring, primary surveys will be conserved as record and made available on
demand. Monitoring will be conducted by QCI-NABET approved Functional Area Expert
for Ecology & Biodiversity or department of Botany/Zoology, Mumbai University or
officials of forest department.
There will be separate monitory provision made for maintenance of green belt and for
yearly monitoring to check any impact on ecology & biodiversity). A gardener will be
appointed for maintenance of green belt. Maintenance will include watering and
manuring plats at appropriate time, weeding out unwanted plants, cleaning, replacing
wilted/died plants etc.
Table 4.10 Suggested Species for Green Belt – Outer pheriphery
Sr. Scientific Height Growth Evergreen/ Crown
Common name
No. name (m) rate Deciduous Shape
Anona Fast
1. Custard apple 10 Evergreen Round
squamosa Growing
Mimusops Fast Oblong/
2. Bakuli 10 Evergreen
elengi Growing Round
Lagerstroemia Queen Crape Fast
3. 10 Evergreen Oblong
speciosa Myrtle Growing
Polyalthia Fast Conical/
4. Ashok 10 Evergreen
longifolia Growing Rounded
Fast
5. Careya arborea Kumbhi 8 Evergreen Spreading
Growing
Mangifera Fast Round/
6. Mango 15 Evergreen
indica Growing oblong
Ficus Fast
7. Umber 15 Evergreen Spreading
glomerata Growing
Hardwickia Fast
8. Anjan 8 Evergreen Spreading
binata Growing
Fast Round/
9. Aegle marmelos Bel 10 Evergreen
Growing oblong
Feronia Fast Round/
10. Kawath 12 Evergreen
elephantum Growing oblong
Azadirachta Fast
11. Neem 8 Evergreen Spreading
indica Growing

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Cochlospermum Fast
12. Ganeri 10 Evergreen Spreading
religiosum Growing
Holoptelea Ainsadada/ Fast
13. 10 Evergreen Spreading
integrifolia Vavla Growing
Balaniles Fast
14. Hinganbet/Hingu 10 Evergreen Spreading
roxburghii Growing
Table 4.11 Suggested Species for Green Belt – Inner pheriphery
Sr. Scientific Common Height Growth Evergreen/ Crown
No. name name (m) rate Deciduous Shape
Helicteris Murad Fast Round/
1. 5 Evergreen
isora sheng Growing oblong
Gymnosporia Fast
2. Henkal 3 Evergreen Spreading
montana Growing
Holarrhena Pandhra- Fast
3. 3 Evergreen Oblong
puboscens Kuda Growing
Bauhinia Butterfly Fast
4. 7 Deciduous Oblong
purpurea Tree Growing
Bauhinia Fast
5. Astha 5 Deciduous Oblong
racemosa Growing
Gardenia Fast
6. Anant 5 Evergreen Oblong
jasminoides Growing
Hibiscus rosa- Chinese Fast Round/
7. 3 Evergreen
sinensis Hibiscus Growing oblong
Nyctanthus Fast Oblong/
8. Parijatak 5 Deciduous
arbor-tristis Growing Round
Psidium Fast
9. Guava tree 5 Evergreen Oblong
guava Growing
Calycopteris Fast
10. Ukshi 3 Evergreen Spreading
floribunda Growing

4.5.7 Noise & Vibration Environment

4.5.7.1 Anticipated Impacts

Noise & vibrations generated from the equipment & machineries including pumps,
motors, blowers etc. will add to occupational noise level, exposing on site workers to
hearing loss The expansion project is part of MIDC and away from nearest habitat. Thus,
impacts of the noise sources of the proposed project will be restricted within the
premises only and will be within the prescribed norms of industrial area as well as
occupational exposure.
4.5.7.2 Mitigation Measures

• Low noise generating equipment and working methods for production unit shall be
selected to reduce noise generation in plant areas.
• Proper mounting of equipment & machinery on strong non-vibrating foundation &
fitted by proper shunting & rubber padding to avoid vibration and thereby noise.

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• Provision of ear protection equipment (ear plug/ ear muff) for activities that are
likely to create noise in excess of 75 dB (A) to protect worker’s health and safety.
• Undertake in plant audit to identify high noise level generating equipment
• Preventive maintenance including regular lubrication of machineries and
equipment to reduce noise level
• Static & dynamic balancing of all rotating equipment & machineries shall be done
on regular basis starting from the installation time to reduce the vibration & noise.
• Regular noise monitoring shall be done as per environment monitoring plan
chapter 6
• The impacts of noise on occupational health would be mitigated by proper shift
timing & annual audiological checkup of concern employees. Workers showing
hearing loss, if any, will be shifted to other less noisy areas.
• Dense Greenbelt development around the boundary of premises shall be done.

4.5.8 Solid and Hazardous Waste

4.5.8.1 Anticipated Impacts

During operation phase, following nonhazardous and hazardous wastes generation are
expected. Waste if not stored properly may cause short term, temporary impact on the
environment, particularly during monsoon season due leachate formation.
Non hazardous and Hazardous waste generation quantities from existing and proposed
operation are as follows:
Table 4.12 Nonhazardous Waste Generation & Disposal
Existing
Proposed add.
No. Type of waste UOM Quantity Total Mode of Disposal
quantity
(*)
Sale to authorised
1 Empty drums Nos./Month 500 4,000 4,500
recycler
Sale to authorised
2 Glass bottles Kg/Annum 3600 10,000 13,600
recycler
Sale to authorised
3 Plastic bags Kg/Annum 1680 4,400 6,080
recycler
Corrugated Sale to authorised
4 Kg/Annum 1200 0 1200
sheets recycler
Sale to authorised
5 Metal scrap MT/Annum 8.5 11.5 20
recycler
Sale to authorised
6 Paper waste MT/Annum 0 5 5
recycler
Sale to authorised
7 Plastic waste MT/Annum 0 4 4
recycler
Sale to authorised
8 Rubber waste MT/Annum 0 1 1
recycler
Sale to authorised
9 Boiler Ash MT/Annum 0 15 15
recycler/ CHWTSDF
Sale to authorised
10 Wooden waste MT/Annum 0 1 1
recycler

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* Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC- 1812000081 dated
29.11.2018 valid upto 30.04.2023

Table 4.13 Hazardous Waste Generation & Disposal

No Description Category UOM Existing Proposed Total Mode of Disposal
(as per HW Quantity add.
rules 2016)
(*) quantity
1 Sludge and filters
contaminated 3.3 TPA 0 2 2 CHWTSDF
with oil
2 Used or spent oil Sale to authorized Re
5.1 TPA 4.8 10 14.8
processor/CHWTSDF
3 Wastes or
residues 5.2 TPA 0.1 0.2 0.3 CHWTSDF
containing oil
4 Discarded
15.2 TPA 0 0.8 0.8 CHWTSDF
Asbestos
5 Process residue
28.1 TPA 2.4 660.6 663 CHWTSDF
and wastes
6 Spent carbon 28.3 TPA 6 248 254 CHWTSDF
7 Off specification
28.4 TPA 0 5 5 CHWTSDF
products
8 Date-expired
28.5 TPA 0 5 5 CHWTSDF
products
9 Spent solvent Sale to
28.6 TPM 5 395 400
authorizedReprocessor/CHWTSDF
10 Empty barrels
/containers/liners
Sell to authorized
contaminated 33.1 Kg/M 0 2000 2000
Reprocessor/CHWTSDF
with hazardous
chemicals /wastes
11 Contaminated
cotton rags or
33.2 TPA 0 1 1 CHWTSDF
other cleaning
materials
12 Exhaust air or gas
35.1 TPA 0 3 3 CHWTSDF
cleaning residue
13 Spent ion
exchange resin
35.2 TPA 0 0.5 0.5 CHWTSDF
containing toxic
metals
14 Chemical sludge
from waste water 35.3 TPA 0.96 149.04 150 CHWTSDF
treatment
15 Filter medium 36.2 TPA 0 2 2 CHWTSDF
16 E waste Sale to authorized
- Kg/M 75 425 500
Reprocessor/CHWTSDF
17 Biomedical waste - Kg/year 0 100 100 CHWTSDF
18 Used batteries Sale to authorized reprocessor /
- Nos/year 0 100 100
Buy back

* Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC- 1812000081dated
29.11.2018 valid upto 30.04.2023

Hazardous Wastes will be stored in impervious lining/flooring in covered shed. During

dry season ETP sludge will be stored on drying beds and then disposed off to Common
Hazardous Waste Treatment, Storage and Disposal Facility (CHWTSDF) periodically

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through trucks owned by MPCB authorized contractors or sold to MPCB authorized
recyclers.
No impacts are envisaged on the 10 km surrounding study area in case above disposal
methodologies are adhered to. However, close monitoring and control over waste
disposal contractors/transporters by use of manifest system is essential to ensure that
the waste reaches the designated waste disposal site and is not dumped in undesignated
areas impacting agricultural areas, soil and ground water adversely.
4.5.8.2 Mitigation Measures

• Adequate use of PPE for onsite workers.

• Disposal through authorized recycler/ re-processor or to designated CHWTSDF site
• Follow of Manifest system scrupulously to ensure waste reaches designated site
• Disposal through MPCB authorized transport contractor
• Waste storage in designated covered area having impervious flooring and epoxy
lining wherever necessary
• Maintenance of records as required under HW Rules 2016

4.5.9 Occupational Health and Safety

4.5.9.1 Anticipated Impacts

The proposed expansion project involves use of hazardous raw materials as per MSIHC
Rules, 2000 having fire and toxic hazards. Methanol, Toluene, Acetone, ethanol,
cyclohexane, MDC, Ethyl acetate, DMF, IPA etc are of major concern for impacts on
occupational health.
Continuous exposure of employee to the chemical beyond permissible limit (TWA/TLV)
may result in acute or chronic toxic or lethal effects. A detailed Quantitative Risk
Assessment (QRA) for the proposed project is conducted and it is noticed that the
hazardous condition causing serious effects on occupational health may occur only
during the catastrophic incident as described in Chapter 7 Additional Studies. However,
minor continuous exposure to toxic chemicals may lead to health issue in long term.
Hence, it is necessary to monitor the health status of all employees on regular basis.
Further, impacts on occupational health may also occur due to works like manual lifting
of heavy good, continuous working in single position, working in improper ergonomic
conditions etc. Such condition or operations may lead to health problems like back ache
etc. Considering these, proponent plans for closed automated transfer system for major
raw materials as well as forklift & trolley for other handlings.
4.5.9.2 Mitigation Measures

Following mitigation measures are planned and suggested in view of health and safe
environment during construction phase:
• Provide all necessary implements & tools, PPEs etc for ensuring safe work
condition.

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• Company will follow all statutory guidelines related with occupational health &
safety.
• Health check-up programs will be carried out regularly and all records &
documents related with employee health check-up program will be maintained.
• All risk control & prevention measures will be implemented in proposed unit.
• Management will provided necessary PPEs, safety equipment/ materials as
mentioned in Risk Assessment Report for risk reduction to ensure healthy & safe
work conditions.
• Regular inspection of the safety procedures and use of PPEs & Safety
equipment/material will be done by the management/safety cell.
• Pre-employment medical examination and periodical examination will be carried
out once in a six month and record will be maintained in Form No-32 & 33 as per
Factories Act.
• PFT & LFT test will be carried out during pre-placement and periodical
examination especially considering the toxic effects of chemicals.
• Training programs & safety audit shall be done on regular basis to prevent
impacts of the operational activities on occupational health as well as to improve
workplace condition & safe work system.
• Safety committee will be formed to ensure worker participation.
• Checkup and Periodic medical examination (once in a six month) and will
maintain records.
• PFT & LFT test will be carried out during pre-placement and periodical
examination considering the toxic effects of Methanol, Toluene, ethanol, DMF and
other solvents.
• Company follows all statutory guidelines related with occupational health &
safety which will be extended to the proposed expansion also.

4.5.10 Socio-economic Environment

Impacts on socio-economic environment due to proposed project during operation

phase are envisaged due to direct and indirect employment which will be beneficial.
4.5.10.1 Anticipated Impacts

• Employment generating capability of study area will be increase because it is

expected to generate about 200 No. of direct employment during operational
phase. As well as there will also be indirect employment in downstream
industries.
• Non workers population is high in the region so proposed expansion will be
beneficial for local workers to get employment.

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• Due to increased industrial activity pollution level is likely to increase in the
study area in the form of air, water and soil pollution etc. if proper pollutions
abatement measures are not adopted & executed from time to time.
• The required facilities such as power, water, roads & transportation &
communications facilities are available in the MIDC area so there is no pressure
on infrastructure facilities is envisaged due to proposed expansion activity. Infact
expected the proposed expansion along with industrial development will also
facilitate the development of infrastructure of the surroundings.
• No changes in land use pattern & no issues of land acquisition, rehabilitation &
resettlement is envisaged as the propose project activity is an expansion at
existing plot under the possession of Centaur in a well-developed area for
industrial development by MIDC at Chikhloli MIDC, Ambernath (West), Thane
district.
• Unplanned development may be responsible for generating number of problems
such as accommodations & related shortage of amenities as per the growing
need of the population. Ambernath is one of the growing industrial city in the
study area having large numbers of industrial units so there may be growth of
industrial workers population which demand for more residential
accommodations & basic amenities. If not carefully suffice the needs of growing
population then this may lead to the development of slums & Zopadpatties in the
town.
• Increase in the availability of Psychotropic APIs (bulk Drugs) & Intermediates
(chemicals) in the area which can fill gaps between demand and supply at
national & international level markets. As per the demand PP proposed
expansion activity & sale 90% product in export market & 10% in domestic
market. So there would be a growth in revenue generation at regional, national &
international level is very much anticipated.
• The proposed project will not affect any sensitive areas and cultural heritage
• Pollution level is likely to increase in the study area in the form of air, water and
soil pollution. But project proponent is committed to implement adequate
precautionary measures from design stage onwards to mitigate/control the
environmental pollution from proposed project to comply all
emissions/discharges as well as plans of waste management standards/norms
prescribed by MoEF/ CPCB with the MPCB objective of environment protection.
• The land use pattern in the study area will not be changed as proposed
expansion will be done with in existing plant located in MIDC area.
• There is likely to be growth in the revenue generation and economy at local,
regional and state levels. There will certainly be improvement in standard of
living due to required facilities provided or upgraded by management under
CSR/CER.

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4.5.10.2 Mitigation Measures

Following mitigation measures are planned and suggested in view of socio-economic

environment during operation phase:

• As much as possible Centaur should recruit local population, by considering their

skill & suitability as per the job requirements at 200 numbers of jobs in proposed
expansion activity.
• Adequate pollution control measures must be taken to keep the environment
pollution free as much as possible from design stage onwards to mitigate/control
the environmental pollution from proposed project to comply all
emissions/discharges as well as plans of waste management standards/norms
prescribed by MoEF/ CPCB/ MPCB with the objective of environment protection.
• Proper waste disposal should be done to mitigate the Ulhas River water pollution
in the project region
• Precautions should be taken along with industrial waste generated sewage waste
without treated should not be dispose through nallas to the Ulhas River
• Periodically organized health check-up camps (3 times in a year) including free
distribution of medicines and health and hygiene awareness camps.
• As per today demand of water increase the height of existing dams &
constructions of new dams. Maintain the potability by providing RO / filter plant
& repairing of Lakes etc. & household tap water connection facility in rural
region
• Awareness programmes must be taken to make people aware about the need for
water conservation & rainwater harvesting
• Collect as much as possible sewage by provide assistance to concerned
department for constructions of sewerage pipeline & connect it to sewage
treatment plant
• Assistance in ongoing Govt. schemes for the progress of the community such as
slum eradication program & poverty elevation programs, water & sanitation
programs & health Programs etc.
• Social surveys of unemployed youth should be carryout at neighbouring villages
& urban areas around the Ambernath MIDC area and collaboration may be
sought with at local employment exchange office so tentative unemployed local
needy youth figure may be obtain & recruit capable youth at respective vacancies
& should be extended training facilities which will develop the skills of locals &
help them to get jobs in & around MIDC area.
• Livelihood Development Activities includes Job oriented skill training courses
may be organized through industrial / Technical Training Institutions for
Educated Youth (both for male and female), like O & M of electrical, home need
appliances, tailoring, plumbing, typewriting and shorthand, computer, light

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&heavy Vehicle Driving. Four wheeler repairs, welding and fabrication and other
project related trades.
• Increase the industrial training centre for increasing skill labours in the region
• Undertake social forestry and roadside plantation program in consultation with
local Municipal Corporations / Gram Panchayat/Forest Department to create a
healthy environment
• Construction of village roads into gravel to paved (puccka) roads &Widening &
improvement of roads in urban region for good connectivity.

4.5.10.3 Corporate Environmental Responsibility & Socio-Economic Welfare

In order to mitigate adverse impact likely to arise in environmental, social and

economic aspects in the surrounding region the proposed project is expected to
contribute towards upliftment of local people quality of life. The proposed project will
help in improving socio – economic status of surrounding area as there will be direct
employment generation for about 200 people. Preference will be given to local people at
the time of man power recruitment. Preventive measures will be taken to control
pollution, which may arise from the proposed project. Communication with local
community will be institutionalized & done on regular basis by the project authorities.
As per OM F.No.22 -65/2017 issued by MOEF&CC dated 1st May 2018 on Corporate
Environment Responsibility (CER) the fund allocation for the CER is based on criteria
such as percent of capital investment for green field & brown field projects.

For Brown field project it is 1% of project capital investment. For Centaur

Pharmaceutical Private limited Project it will be Rs. 90.5 Lacs (1% of of Rs. 9050 Lacs).

Centaur Pharmaceuticals Private Limited has proposed following social development

activities under CER such as:

Sr. No. Social Welfare Activities Proposed Under CER

Water(assistance to water supply project such as)
1 Household Tap Water connection Facility at Rural region
2 Provision of RO / filter Plant
3 Rainwater Harvesting Awareness Programs
4 Developing & protecting a local water sources lakes, ponds, tanks & spring etc.
5 Replacement of Old water pipelines
6 Increase the height of existing dams & constructions of new dams
Sanitation
1 Construction of Drainage Line or Provision of pipelines to connect the
generated sewage to sewer lines
2 Closed the open drains
3 Sewage Treatment Plant / CETP
4 Reuse of treated Urban Sewage
5 Periodically garbage collection facility at towns
Health & Education
1 Periodically Organize Health Check-up Camps with free distribution of
medicines

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2 Assistance for development of Educational & Medical Facilities
3 Mobile medical dispensaries should be provided for medical check-up and
also for providing essential medicines to the villagers & slum population in
urban region or BPL families in the region
4 Infrastructural development activities in local educational & medical
institutions (construction of new building, classrooms, toilets etc. scholarship
to needy students, inter schools competitions etc.)
Roads or Connectivity
1 Construction of Pucca (Paved) roads
2 Widening & improvement of roads
Others
3 Provision of Solar Street light
4 Assistance in slum eradication programs
5 Assistance in poverty elevation programs
6 Provision of testing instruments to CETP
Afforestation Programs
1 Tree Plantation
Livelihood Development Programs
1 Organize Vocational Training Programs
2 Assistance to local Vocational training Institutes
3 Assistance to women self-help groups for small business
4 Assistance to needy / BPL families
Budgetary Provision for CER Activities: On the basis of total estimated capital
investments for proposed expansion of SOCMI, Centaur Pharmaceuticals Private
Limited earmarks INR 90 lakhs 50 thousand for the above CER/social developmental
activities. The allocated amount may vary time to time on the need based CER in the
surrounding areas of the proposed project. Refer Annexure 4.2 for copy of CER plan
submitted to District authority.
Table 4.14 Yearwise Budget Allocation for Implementation of CER Activities)
Proposed Year (April – March) wise allocation of Fund (lNR In Lakh)
activity Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Total
Water, Roads 5.0 5.4 4.0 4.0 4.0 4.0 3.6 30.0
& Sanitation
Education & 2.8 2.8 2.7 2.8 1.2 1.2 1.5 15.0
Health
Livelihood 0.9 0.8 0.9 0.7 1.1 0.5 0.6 5.5
Development
Tree 1.5 1.5 1.8 1.3 1.2 1.2 1.5 10.0
Plantation
Others 8.0 8.0 10.0 4.0 0 0 0 30.0
Total 18.2 18.5 19.4 12.8 7.5 6.9 7.2 90.5
Total budget for 7 years - Rupees Ninety Lakhs & Fifty Thousand (90.50 Lakhs)

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Chapter 4 –Anticipated Environmental Impacts & Mitigation measures
4.6 Prediction of Impacts during De Commissioning Phase and Mitigation
Measures

This section examines impacts during decommissioning of project, should the need
arise.

4.6.1 Anticipated Impacts

Impacts during de commissioning phase will be due to:

Stoppage of new production facilities the stoppage of production facilities will lead to
having a stockpile of chemicals at the site, which will need to be safely disposed of.
Decommissioning if not undertaken in a safe way may lead to catastrophic incidents
which may have effects within/outside the factory. In addition, decommissioning will
cause revenue loss to company and loss of employment to workers.
Waste generation there is possibility that failed batches will need to be stored and
disposed safely so as not to cause land pollution

4.6.2 Mitigation Measures

• Proper procedure for safe decommissioning shall be established as part of

project development with training to employees
• Wastes generated will have to be identified and disposed of safely and site will
not be considered shut down unless all wastes are safely disposed
• Have a designated procedure to ensure that workers do not suffer in this
eventuality

4.7 Environmental Impact matrix

The possible impacts of various constructional and operational activities as identified

above have been denoted in a matrix form. A quantitative matrix rating has been
devised to give severity of impacts in the following manner:
• Highly Negative Overall Impacts: Total Score= above -353
• Moderately Negative Overall Impacts: Total Score= -176 to - 352
• Slightly Negative Overall Impacts: Total Score= -1 to -176
• Neutral overall Impacts: Total Score = 0
• Slightly Positive Overall Impacts: Total Score= 1 to 176
• Moderately Positive Overall Impacts: Total Score= 176 to 352
• Highly Positive Overall Impacts: Total Score = above 353
The matrix system assumes the environmental indices into the following:
➢ Physical Parameters: Surface water quality
• Ground water quality
• Air quality & Climate

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Chapter 4 –Anticipated Environmental Impacts & Mitigation measures
• Soil Quality
• Land use pattern & Topography
➢ Ecological Parameters:
• Forests/ Parks/ Sanctuary
• Flora & Fauna
• Aquatic ecosystem
➢ Social Parameters: Aesthetics
• Local Housing structure
• Services
• Health & Safety
➢ Economic Parameters: Agriculture
• Fisheries
• Industries
• Employment
The assessment of the impact of the general impacting activities on the above
parameters of environmental indices can be done by establishing a co-relation by
“Cause and effect relationship” with the help of impact matrices. The matrices for
construction as well as operation phase are presented below for two conditions:
• Without mitigation/control measures.
• With proposed mitigation measures for adverse / beneficial effects.
The criteria for evaluation of qualitative matrix are presented herewith:
1. No Impact (0): This indicates that the project activity is unlikely to have any
impact on an environmental attribute.
2. Negligible Adverse Impact (-1) / Negligible Beneficial Impact (+1): It
signifies that the actions have minor effect, adverse or beneficial, on the
environmental parameters concerned.
3. Significant Adverse Impact (-2) / Significant Beneficial Impact (+2): The
activities and their environmental Impacts are judged to be significant if they
create, or have the potential to create concern in the public or professional
community.
4. High Adverse Impact (-3) / High Beneficial Impact (+3): The action that can
create or have a potential to create controversy in the public or professional
community due to its long-term effect. They may be at times irreversible.
The environmental Impact matrix without mitigation / control measures during the
construction phase and operation phase is given as Table 4.16 below, which shows the
slightly negative impact of the project is (-) 123 i.e no significant impact. The matrix
with proposed mitigation measures during the operation phase is given in Table

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Chapter 4 –Anticipated Environmental Impacts & Mitigation measures
4.17below, which shows the overall impact with environmental controls is reduced to
(-) 30 i.e. slightly negative.

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Chapter 4 –Anticipated Environmental Impacts & Mitigation measures
Table 4.15 Environmental Impact Matrix Evaluation without Mitigation Measures
Impact Source Construction Phase Operation Phase

Hazards associated with & construction

Hazards associated with chemicals &

Material transportation, storage &

Material transportation, storage &

Breakdown of control equipment

Breakdown of control equipment
Water requirement, wastewater

Water requirement, wastewater

Stationary, process & fugitive

Stationary, process & fugitive

Waste generation & disposal

Waste generation & disposal

Plant operation & process
End use of project site
generation & disposal

generation & disposal

End use of product

Plant construction

operation of plant
emissions

emissions
handling

handling
of plant

Total

Total
Noise

Noise
Parameters
Physico-chemical parameters:
Surface water quality 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Ground water quality 0 -1 0 0 -1 0 0 0 0 -2 0 -3 0 0 -3 -2 -3 -3 -2 -16
Air quality & climate -1 0 -1 0 0 -1 -1 0 0 -4 -3 0 -3 0 0 -2 -2 -3 -2 -14
Soil quality 0 -1 0 0 -1 0 0 0 0 -2 -1 -3 0 0 -3 -2 -2 -2 -1 -14
Land use pattern 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Ecological parameters:
Forest/ park/ sanctuary 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Flora & fauna 0 -1 -1 0 0 0 0 0 +1 -1 -2 -2 -2 -1 -2 -1 -2 -2 +3 -11
Aquatic ecosystem 0 0 0 0 0 0 0 0 0 0 -2 -2 -2 0 -2 -1 -2 -2 +2 -11
Social parameters:
Aesthetics -2 0 -2 0 -1 -1 -2 -1 0 -9 -2 -2 -2 -1 -2 -2 -2 -2 +1 -14
Local housing structure 0 -1 -1 -1 -1 -1 -1 -1 0 -7 0 -1 -1 0 -1 -1 -1 -1 0 -6
Service 0 -1 -1 0 0 -1 -1 -1 0 -5 0 -1 -1 0 0 -1 -2 -2 0 -7
Health & safety -2 -1 -1 -1 -1 -1 -1 -1 0 -9 -2 -1 -3 0 -2 -2 -1 -1 +2 -10
Economic parameters:
Agriculture 0 -1 0 0 -1 -1 0 0 0 -3 -2 -3 -3 0 -2 -1 -2 -1 -2 -16
Fisheries 0 -1 0 0 -1 -1 0 0 0 -3 0 -2 0 0 -2 0 0 -1 -1 -6
Industries 0 0 0 0 0 0 0 0 +1 +1 0 0 0 0 0 0 0 0 +2 +2
Employment +1 0 0 0 0 0 0 0 +2 +3 +2 0 0 0 0 0 0 0 -1 +1

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 Total
Parameters

Parameters
Impact Source

Impact Source

Surface water quality

Ground water quality 0
0
Plant construction

-4
Plant construction

Physico-chemical parameters:
Water requirement, wastewater Water requirement, wastewater

0
0
Environmental Impact Assessment

-8
generation & disposal generation & disposal
Stationary, process & fugitive Stationary, process & fugitive

0
0
-7
emissions emissions

Environmental Consultant
0
0
-2

Noise Noise
-7

0
0
Waste generation & disposal Waste generation & disposal

Material transportation, storage &

-7

Material transportation, storage &

0
0
handling handling
Hazards associated with & construction
-6

Hazards associated with &

0
0
of plant
construction of plant
-4

Breakdown of control equipment

0
0
Construction Phase

Breakdown of control equipment

Construction Phase
+4

End use of project site

0
0
End use of project site

Page 183
-41

Total

0
0
Total
-12

Plant operation & process

0
0 Plant operation & process
Water requirement, wastewater
-20

Water requirement, wastewater

0
0

generation & disposal

generation & disposal
Stationary, process & fugitive
-17

Stationary, process & fugitive

0
0

emissions
emissions
-2

Noise
0
0

Noise
-19

Waste generation & disposal

0
0

Waste generation & disposal

Table 4.16 Environmental Impact Matrix Evaluation with Mitigation Measures

Material transportation, storage &

Pvt. Ltd.
-15

Material transportation, storage & handling

0
0
Operation Phase

handling
Operation Phase

Hazards associated with chemicals &

-19

Hazards associated with chemicals

0
0

operation of plant
& operation of plant
Aditya Environmental Services
0
-20

Breakdown of control equipment

-1

Breakdown of control equipment

+1

End use of product

-1

End use of product

-2

Total
-123

Total
Centaur Pharmaceuticals Private Limited
Chapter 4 –Anticipated Environmental Impacts & Mitigation measures
Environmental Impact Assessment Centaur Pharmaceuticals Private Limited
Chapter 4 –Anticipated Environmental Impacts & Mitigation measures
Impact Source Construction Phase Operation Phase

Hazards associated with chemicals

Material transportation, storage &

Material transportation, storage &

Breakdown of control equipment

Breakdown of control equipment

Water requirement, wastewater

Water requirement, wastewater

Stationary, process & fugitive

Stationary, process & fugitive

Waste generation & disposal

Waste generation & disposal

Hazards associated with &

Plant operation & process

End use of project site
generation & disposal

generation & disposal

construction of plant

& operation of plant

End use of product

Plant construction

emissions

emissions
handling

handling
Noise

Noise
Total

Total
Parameters

Air quality & climate 0 0 0 0 0 0 0 0 0 0 -1 0 -1 0 0 -1 -1 -2 -1 -7

Soil quality 0 0 0 0 0 0 0 0 0 0 -1 -3 0 0 -3 -2 -2 -2 -1
Land use pattern 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Ecological parameters:
Forest/ park/ 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
sanctuary
Flora & fauna 0 0 0 0 0 0 0 0 +1 +1 -1 0 -1 0 0 -1 -1 -1 +2 -3
Aquatic ecosystem 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Social parameters:
Aesthetics 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1 -1 -1 0 -3
Local housing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
structure
Service 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Health & safety 0 0 0 0 0 0 0 -1 0 -1 -1 0 -1 0 0 -1 -1 -1 +2 -3
Economic parameters:
Agriculture 0 0 0 0 0 0 0 0 0 0 -1 0 -1 0 0 0 0 0 0 -2
Fisheries 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Industries 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 +2 +2
Employment +1 0 0 0 0 0 0 0 +2 +3 +2 0 0 0 0 0 0 0 0 +2
Total +1 0 0 0 0 0 0 -1 +3 +3 -3 -3 -4 0 -3 -6 -6 -8 +3 -30

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Chapter 4 –Anticipated Environmental Impacts & Mitigation measures

4.8 Observations and Conclusions

The study for the proposed expansion project of CENTAUR has revealed that the
upcoming activities of manufacturing will have negligible impacts which would mainly
occur only upon Improper discharge of effluent/ Release of untreated gaseous pollutant
to air/ Improper disposal of solid waste/ accidental spill/ leak of volatile/ gaseous
chemicals/materials. Risk assessment study has been conducted for the proposed
project and the suggestions made in the report shall be implemented strictly to prevent
any chances of environmental contamination and employee health & safety. By the
efficient implementation of Hazard/Risk control/Prevention measures the negative
impacts would be avoided.
Besides, the hazardous waste generated from the production process & utility operation
will be managed as per MoEF/CPCB/MPCB Guidelines. Hence issues of air & land
contamination are not envisaged. The water requirement will be met by MIDC &
through recycle of treated effluent hence no impact on ground water availability is
envisaged.
The proponent has planted varieties of trees & shrubs in and around the premises. The
Greenbelt will be maintained in excellent condition giving visual of dense vegetation.
The proponent will manage the greenbelt with all possible care & attention to improve
environmental condition. Thus the beneficial impacts due to the dense greenbelt are
envisaged.
It is also found that the high noise generation sources are not part of proposed
expansion project. Hence noise levels are not expected to go up. The noise level out of
the premises is envisaged to be <65-70 dB(A) in day and 55-60 dB(A) in night as
maximum. Thus looking to the source, potential noise level generation & planned
mitigation measures; impacts due to noise are not envisaged.
Company will regularly conduct the CSR activities for social welfare & upliftment.
Necessary documents & records of all activities shall be maintained. All aspects of safety
will be adequately managed and required safety material, equipment and facilities will
be provided to all employees, contractor & visitors. Thus issue of impacts due to
probable hazards/risk/disaster would be minimal.
Thus looking all the management procedures/actions, environmental management
activities and other allied functions of management system, it is concluded that there
will not be any major considerable impacts on environment.

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Chapter 5 –Analysis of Alternatives

5 A NA LYS IS O F ALT ERNAT IV ES

(T ECH NO LO GY & S ITE)

5.1 Introduction

5.1.1 Analysis of Alternative Sites

The proposed activity will be done at premises comprising of 9,105 Square meter of
land at MIDC Chikhloli, Ambernath, District Thane, Maharashtra. Following facts are
considered during the site selection
• Located in Chemicals Zone of MIDC Chikhloli.
• Availability of adequate land.
• Proximity to end users.
• Integration with existing manufacturing operation
• Land is part of MIDC, doesn’t involve R&R issues.
• No water body i.e. river or Nallah within the project site.
• No sensitive area (i.e. Tiger reserve, National Park, Wildlife Sanctuary, Protected
area) with in 5 km.
• State National highway (No 80, katai Ambernath badlapur road) is just 200 m
away from site.
• No human habitation in the project boundary.
• Availability of skilled and non-skilled workers in the area.
• Availability of firefighting facility, medical facility, educational facility,
transportation and infrastructure facility in the area.
• Economy of the project.

5.1.2 Analysis of Alternative Technologies

The technology for manufacture of products is well established by Centaur hence

analysis of alternative technologies does not arise.
Best available technologies for domestic and trade effluent treatment is proposed to be
implemented in the project.

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Chapter 6 –Environmental Monitoring plan

6 ENV IRONMENTAL MONITO RING PL A N

Based on the predicted & assessed impacts as well as the baseline environmental status
of the project area, present environmental monitoring plan is designed, suggested &
planned for implementation as post project environmental monitoring program.

6.1 Objective of Environmental Monitoring Program

For tracking of the effectiveness of mitigation measures & EMP at specific interval,
regular monitoring of the necessary environmental parameters is required. With this
vision, an environment monitoring program is prepared with due consideration of the
baseline status of the expansion project area, various components of project &
environmental attributes likely to be affected.
Major objectives of the Environmental Monitoring Program are as under:
• To comply with the statutory requirements of monitoring for compliance with
conditions of EC, Consent to operate and provisions under Factory Act &
Environmental Protection Act provisions
• Assessment of the changes in environmental conditions, if any, during the project
operation/activities.
• Monitoring & tracking the effectiveness of Environment Management Plan &
implementation of mitigation measures planned.
• Identification of any significant adverse transformation in environmental
condition to plan additional mitigation measures; if & as required.
Centaur shall implement the environment monitoring programs in line with the planned
schedule. The company shall ensure that the necessary requisite facilities are made
available and budgetary provision is made as & when required to ensure regular
efficient environmental monitoring activities.

6.2 Environmental Monitoring Program

Environmental monitoring parameters and frequencies of monitoring are given below

in Table. In case of accidental spill & leak of hazardous chemicals, monitoring of the
environment for detection of the spilled/leaked chemical shall be done in the affected
area. In such case, soil & groundwater sample of the affected area shall be collected and
analyzed for detection of the spilled / leaked chemicals at regular interval for the period
as required to ensure safe level of contamination.

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Chapter 6 –Environmental Monitoring plan
Table 6.1 Environment Monitoring Plan including Existing and Proposed Expansion
Sr. Project Phase Environmental Parameters Frequency Locations Conducted
No. Component by
1 Construction Air Environment
Ambient air PM10 / PM2.5/SO2/ NOx / CO Once/Month Adjacent to new MoEF
construction site approved
Ambient Noise Leq day and night time or over one work Once/Month At new Laboratory
Level shift construction site
Water Quality
Drinking Water Microbiological parameters as per IS Once/month Construction site- MoEF
Quality 10500 : 2012 each drinking approved
water locations. Laboratory
2 Commissioning Air Environment
Stage Ambient air PM10 / PM2.5/SO2/ NOx/CO/NMHC/ Once/Month Adjacent to new MoEF
construction site approved
Laboratory
Ambient Noise Leq day and night time or over one work Once/Month Adjacent to new MOEF
Level shift construction site approved
lab
Water Quality
Drinking Water Microbiological (as per IS 10500: 2012) Once/month at each drinking MOEF
Quality water locations. approved
lab
In plant ETP pH, TSS, TDS, COD, BOD and Oil and Grease Once/shift Plant/sectionwise In house lab
effluent and
periodically
through
MOEF
approved
lab

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Chapter 6 –Environmental Monitoring plan
Sr. Project Phase Environmental Parameters Frequency Locations Conducted
No. Component by
Waste
Generated
Spent As per Schedule II of HW Rules, 2016 and Once Spent catalyst CHWTSDF
carbon/Chemical parameters for identifying disposal sample or MOEF
sludge from pathway as per CPCB approved
waste water lab for
treatment/ identifying
demolished disposal
deburries pathway
Process residue As per Schedule II of HW Rules, 2016 and Once From process CHWTSDF
and waste parameters for identifying disposal plant or MOEF
pathway as per CPCB approved
lab for
identifying
disposal
pathway
3 Operation Phase Air Environment
Existing and new TPM/ SO2/ NOx Once/ month Plant MoEF
Stacks - Boiler approved
Existing / new Ammonia / Particulate matter/acid mist Once/ month Plant Laboratory
Process scrubber
Stacks
Ambient Air PM10 / PM2.5/SO2/ NOx/ CO/ NMHC/ once/month At 3 locations, MoEF
Workroom SPM/MDC/Acetonitrie/IPA/Methanol/ Once/ 3 Plant / Storage/ approved
environment Cyclohexane/Ethyl acetate/Acetone months handling Area: Laboratory
Oxygen Content/LEL As per Before vessel / Own
requirement confined space laboratory
entry

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Chapter 6 –Environmental Monitoring plan
Sr. Project Phase Environmental Parameters Frequency Locations Conducted
No. Component by
Water Environment
ETP Operational parameters like pH, TSS, COD, Daily Plant Own QC lab
BOD, TDS etc
All parameters as per MPCB Consent. Once/month At inlet and outlet MoEF
of ETP recognized
laboratory
Drinking water Microbiological parameters as per IS Once / 6 at each drinking MoEF
10500 : 2012 month water locations. recognized
laboratory
Noise Environment
Ambient Noise Leq (day & night) Once/ 3 at fence level and
month at nearest habitats.
Workroom noise Leq (8 hours) Once/ 6 near noise MoEF
month producing sources approved
like DG set, Boiler Laboratory
house etc.
Biological Environment
Ecological survey Study growth of trees at site as per plan Once every 3 At site QCI NABET
and identify new species for plantation years approved
Biological
expert
Land Contamination
Soil / Ground For specific contaminants of spilled Regularly At/near site of MOEF
water Quality chemicals until no spillage approved
traces laboratory
noticed
4 Decommissioning Ambient air PM10 / SO2/ NOx / CO / NMHC Once/Month Adjacent to project MoEF
Stage site approved
Laboratory

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Chapter 6 –Environmental Monitoring plan
Sr. Project Phase Environmental Parameters Frequency Locations Conducted
No. Component by
Ambient Noise Leq day and night time or over one work Once/Month Adjacent to project MOEF
Level shift site approved
lab
Soil /Ground For specific contaminants of spilled Regularly At/near site of MOEF
water Quality chemicals until no spillage approved
traces laboratory
noticed
ETP pH, TSS, TDS, COD, BOD, Oil and Grease Daily until At various stages
effluent stops of in plant effluent
completely treatment system
as in 2 above

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Chapter 6– Environmental Monitoring plan
6.2.1 Measurement Methodologies

Monitoring of environmental samples shall be done as per the methods/guidelines provided

by MoEF/ CPCB and /or relevant Indian Standards or methods as specified by Standard
Methods for Water and Wastewater Treatment by American Public Health Association
(APHA). Methodology of monitoring (sampling & analysis) shall be documented as SOP
(standard Operating Procedure) for parameters analyzed through in house laboratory and
shall be subjected to internal audit and review.
For monitoring of workplace area, methods suggested / published by National Institute of
Occupational Safety and Health (NIOSH), USA or as specified in Standard Methods for Air
Analysis published by APHA shall be adopted.

6.2.2 Reporting Schedules

The records of the monitoring program viz water, wastewater, solid waste, air, emission, soil
shall be prepared and preserved properly. The records showing results/outcome of the
monitoring programs will be submitted as per the schedule below.
Monitoring reports will be reviewed regularly by Factory Management along with
Environmental Consultant for necessary improvement of the monitoring plan/mitigation
measures/environmental technologies as well as for necessary actions of environmental
management cell.
Table 6.2 Reporting Schedule
Sr. Monitoring Reporting Applicable Compliance Reporting
No. During Schedule Statute To

1 Construction 1st June and 1st EIA Notification a) SEIAA, Maharashtra

Phase December of Clause 10 b) MPCB – Regional
each year till Office
end of c) MOEF- Western Zone
construction office and Monitoring
Cell
2 Commissioning 1st June and 1st EIA Notification a) SEIAA, Maharashtra
Phase December of Clause 10 b) MPCB – Regional
each year till Office
end of c) MOEF- Western Zone
construction office and Monitoring
Cell
3 Operation Phase 1 June and 1 EIA Notification a) SEIAA, Maharashtra
st st

December of Clause 10 b) MOEF- Western Zone

each year office & Monitoring
Cell
c) MPCB- Regional Office
Before 10th of Combined MPCB – Regional Office
next Month in Consent &
respect of Authorization
stack/ vents, (CC & A)
AAQ, ETP

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Chapter 6– Environmental Monitoring plan
Sr. Monitoring Reporting Applicable Compliance Reporting
No. During Schedule Statute To
inlet/outlet,
Noise levels
4 Decommissioning 1st June and 1st EIA Notification a) SEIAA, Maharashtra
Phase December of Clause 10 b) MPCB – Regional
each year Office
c) MOEF- Western Zone
office and Monitoring
Cell
Company will also file returns under HW Rules (yearly) and annual Environmental
statements &/or performance report/compliance report/audit report as per conditions of EC
and CC&A and submit to MPCB within the stipulated timeframe. CC&A and other statutory
permission/consents must be obtained & renewed timely as per legal provision & guidelines.
Similarly, all necessary report & forms will be prepared and submitted to the concern
authority as per the statutory requirement of Environmental Acts/rules, Factory Act & MSIHC
rules. Reporting of accident & other requirements will be made in prescribed format well
within stipulated time frame as per statutory requirements & guidelines.

6.3 Budgetary Provisions for EMP

On regular basis, environment management cell shall inspect the necessity & availability of
the materials, technologies, services & maintenance works. The cell shall make appropriate
budget for the purpose. Regular record review for change in financial requirement of
environment management shall be done and appropriate budgetary provisions shall be made.
Budget for environmental management shall be prepared and revised regularly. The budget
shall include provisions for:
• Environmental Monitoring Program
• Operation & Maintenance of environmental Technologies/Equipment
• Laboratory works for Environmental management activities
• Emergency Purchase of necessary material, equipment, tools, services
• Greenbelt development
• Social & Environmental Welfare & Awareness programs/training
• Annual Environmental Audit.

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Chapter 6– Environmental Monitoring plan
The company has made budgetary provision for the proposed expansion project along with
existing plant facilities & proposed demolition activity as a part of their initial planning. The
same is presented below.
Table 6.3 Budgetary Provisions for EMP
Recurring
Capital
cost (Rs
No Particular Cost in Rs Basis of cost estimation Basis of cost estimation
Lakhs) per
Lakhs
year
Air pollution Installation of scrubber system Maintenance of APC
1 25 3
control for process emissions, etc systems
Construction of ETP, RO, MEE, Treatment cost including
Water pollution
2 600 construction of storm water 180 chemicals, manpower,
control
network etc power consumption
Environment Installation of online Third party monitoring,
3 Monitoring & 50 monitoring, in house 1 EMS activities, Env audits,
Management monitoring, analytical facilities, statutory compliances etc
Construction of OHC and its OHC and safety expenses
Occupational facilities, PPE’s like helmet,
4 22 10
Health & Safety goggles, safety shoes, respirator
mask etc.
Green Belt Hiring agency for
Plantation, irrigation, fertilisers,
5 enhancement & 15 5 maintenance, irrigation,
pesticides
maintenance fertilizers, pesticides
Construction of storage area for Disposal cost, manpower
different types of wastes in cost, transportation cost
Solid waste compliance with HW rules, etc
6 35 5
management necessary infrastructure,
equipment’s for collection and
transport (supper decanter)
Routine wear and tear
7 LED 40 Installation of LED 10
and maintenance
Installation solar lights along Maintenance, Repairing
8 Solar 100 2
road, Solar bulbs work
Development of paved area, Maintenance, Repairing
Channeling of storm water work
Rain water drain, Construction of ground
9 20 1
harvesting water recharge pit, Channeling
of rain water to RWH tanks,
Construction of RWH tanks
Total 907 217

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Chapter 7– Additional studies (Public hearing & Risk Assessment)

7 A D D I T I O NA L ST U D I E S ( P U B L I C H E A R I N G &
RISK ASSESSMENT)

7.1 Objectives of Risk Assessment

Risk analysis follows an extensive hazard analysis. It involves the identification and
assessment of risks the neighbouring populations are exposed to as a result of hazards
present. This requires a thorough knowledge of failure probability, credible accident scenario,
vulnerability of population etc. (Much of this information is difficult to get or generate.
Consequently, the risk analysis is often confined to maximum credible accident studies).
It provides basis for
• The type and nature of its On-Site and Off-Site Emergency Plan and,
• The types of safety measures required.
Risk assessment is carried out for following objectives
• To identify hazard and risk resulting from the hazards
• To study and foresee the effects of such risks on the workers, public, property and
• Environment and to find out necessary control measures to prevent or minimize risk.
• To comply the legal requirement by various safety and environment laws of the
country like…
• The Factories Act, 1948
• The Maharashtra Act, 1963
• The Environment Protection Act and Rules, 1986
• Hazardous waste (Management & Handling) Rules, 2016
• Public Liability Insurance Act & Rules,1991
• Chemical Accident, (Emergency, planning, preparedness and response)
Rules,1996

7.2 Hazard Identification and Risk Assessment

Hazard analysis involves the identification and quantification of the various hazards (unsafe
conditions) associated with Synthetic Organic Chemicals Manufacturing Facility which is to be
located at Plot No. 74, 75, 76 & 76/1 Chikhloli MIDC, Ambernath Dist: Thane, Maharashtra.
The risk analysis deals with the quantification of risk to the plant equipment, personnel and
neighboring population, due to accidents resulting from hazards present in the plant.
Centaur handles various chemicals, majority of which are hazardous in nature by virtue of
their intrinsic chemical properties or their operating temperatures or pressures or a
combination of them. Fire, explosion, toxic release or combinations of them are the hazards

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associated with industrial plants using hazardous chemicals. More comprehensive, systematic
and sophisticated methods of Safety Engineering, such as, Hazard Analysis and
Qualitative/Quantitative Risk Assessment have been developed to improve upon the
integrity, reliability and safety of industrial plants, the same has been discussed in detail
under their respective headings.
Hazards identified during different stages of the project cycle are given in Table below
identifying cases where quantification of hazards might be necessary. This requires an
assessment of failure probability, credible accident scenario, vulnerability of population etc.
Much of this information is difficult to get or generate. Consequently, the risk analysis is often
confined to maximum credible accident studies.
A detailed study of the manufacturing processes involved in the production of various
chemicals mentioned in chapter 2 is carried out.
The bulk storages proposed as part of proposed expansion are as below (For information
existing tank details are also mentioned).
Table 7.1 Existing Onsite (OSBL) Storages
N Chemi No Type of Abov Tank Ta Ta Sp Gr Type of MO Fla Boili Pre N2
o cal of Storag e/ Dia.( nk nk of Chemic C sh ng ss Blanket
stored tan e Unde m) L/ Vol chemi al Of Poi Poin ing
ks r H (Kl cal Ta nt t °C
grou (m) ) stored nk °C
nd
1 UG Toxic, MS
Metha Horizo
1 2 5 15 0.7915 Flamma 12 64 Atm N
nol 1 ntal
ble
2 UG Toxic, SS
Metha Horizo
1 1.75 2.5 6 0.7915 Flamma 12 64 Atm N
nol 2 ntal
ble
3 Isopro UG
Toxic, MS
pyl Horizo 11.
1 2 5 15 0.785 Flamma 82.5 Atm N
alcohol ntal 6
ble
1
4 Isopro UG
Toxic, SS
pyl Horizo 11.
1 1.75 2.5 6 0.785 Flamma 82.5 Atm N
alcohol ntal 6
ble
2
5 UG Toxic, MS
Toluen Horizo
1 2 5 15 0.8636 Flamma 4.4 110.6 Atm N
e1 ntal
ble
6 UG Toxic, SS
Toluen Horizo
1 1.75 2.5 6 0.8636 Flamma 4.4 110.6 Atm N
e2 ntal
ble
7 Ethyl UG Toxic, MS
Horizo
acetate 1 2 5 15 0.902 Flamma -4.4 77 Atm N
ntal
1 ble
8 Ethyl UG Toxic, SS
Horizo
acetate 1 1.75 2.5 6 0.902 Flamma -4.4 77 Atm N
ntal
2 ble

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Table 7.2 Proposed Onsite (OSBL) Storages
N Chemi No Type Abov Tank Ta Ta Sp Gr Type of MO Fla Boili Pre N2
o cal of of e/ Dia.( nk nk of Chemic C sh ng ss Blanket
stored tan Storag Unde m) L/ Vol chemi al Of Poi Poin ing
ks e r H (Kl cal Ta nt t °C
grou (m) ) stored nk °C
nd
1 Metha Horizo UG 2.5 5.0 25 0.791 Toxic, 20
nol 1 1 ntal 5 Flamma SS 12 64 mba Y
ble r
2 Metha Horizo UG 2.0 5.0 15 0.791 Toxic, SS 20 Y
nol 2 1 ntal 5 Flamma 12 64 mba
ble r
3 Metha Horizo UG 2.0 5.0 15 0.791 Toxic, SS 20 Y
nol 3 1 ntal 5 Flamma 12 64 mba
ble r
4 IPA 1 Horizo UG 2.5 5.0 25 0.785 Toxic, SS 20 Y
11.
1 ntal Flamma 82.5 mba
6
ble r
5 IPA 2 Horizo UG 2.0 5.0 15 0.785 Toxic, SS 20 Y
11.
1 ntal Flamma 82.5 mba
6
ble r
6 IPA 3 Horizo UG 2.0 4.5 13 0.785 Toxic, SS 20 Y
11.
1 ntal Flamma 82.5 mba
6
ble r
7 Toluen Horizo UG 2.5 5.0 25 0.863 Toxic, 20 Y
e1 1 ntal 6 Flamma SS 4.4 110.6 mba
ble r
8 Toluen Horizo UG 2.0 5.0 15 0.863 Toxic, SS 20 Y
e2 1 ntal 6 Flamma 4.4 110.6 mba
ble r
9 Toluen Horizo UG 2.0 5.0 15 0.863 Toxic, SS 20 Y
e3 1 ntal 6 Flamma 4.4 110.6 mba
ble r
1 Ethyl Horizo UG 2.5 5.0 25 0.902 Toxic, SS 20 Y
0 Acetat 1 ntal Flamma -4.4 77 mba
e1 ble r
1 Ethyl Horizo UG 2.0 4.5 13 0.902 Toxic, SS 20 Y
1 Acetat 1 ntal Flamma -4.4 77 mba
e2 ble r
1 Ethyl Horizo UG 2.0 3.0 10 0.902 Toxic, 20 Y
2 Acetat 1 ntal Flamma SS -4.4 77 mba
e3 ble r
1 Vertical AG Toxic,
Furnac 150-
3 1 2.5 8 18 0.98 Flamma CS >40 Atm N
e oil 371
ble

7.3 Identification of Hazardous areas

At Centaur major risks have been identified for following areas

• Liquid and solid raw material and solvent storage and handling
• Hydrogen cylinder for laboratory/ testing
• LDO/FO storage and handling
• Toxic chemicals storage and handling

As an approach, Analysis of the risk qualitatively and quantitatively both has been carried out
in this study.

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Storage & Handling of Methanol, IPA, Toluene, Ethyl acetate etc have been considered for
Consequence Analysis. Hazardous properties of these chemicals have been summarized in
Table above.

7.4 Qualitative Risk Assessment

At times Risk involved in various processes / process equipment’s cannot be addressed

completely by Consequence Analysis. As a conservative approach, these risks have been
considered separately herein. The approach is to identify hazards associated in operation of
equipment’s as well as in processes, assessing its impacts, ranking the risk posed by it and
finally to propose remedial actions/mitigation measures such that the risk is minimized to
tolerable level.

The Risk Matrix presented below should be referred in evaluating this assessment.

In Qualitative Risk Assessment, risk has been analysed using methodology called HIRA-
Hazards Identification & Risk Assessment. In HIRA, major manual activities carried out by
plant personnel as well as contract labours have been considered.

Qualitative Risk Assessment has been carried out for the following areas:
1) Storage and Handling of Toxic Liquid Chemicals
2) Storage and Handling of Flammable Chemicals
3) Storage & Handling of Solid Chemicals
Table 7.3Risk matrix for qualitative risk assessment
Severity
Catastrophic Major/ Moderate Minor/Margi Insignificant
Likelihood / (Death/System Critical (Less nal /Negligible
Probability Loss) (Serious Serious
Injury/Illness)
(Minor (No
injury/Illness) Injury/Illness) injury/illness)
1 2 3 4 5
Almost E H H H M M
certain
Likely D H H M M L
Possible C H M M M L
Unlikely B M M M L L
Impossible A M M L L L

Risk range Criteria for risk Remark

Acceptability

H Unacceptable/ Management’s Decision/Action Plan Required.

High Potential offsite Impact.
M Medium Generally Minor Impact. Acceptable with
Management’s Review. Specific monitoring or SOP to
be followed.
L Low Acceptable without Review. Manage through Routine
Procedure.

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Table 7.4Storage and handling of Toxic Chemicals(e.g. NaOH lye, HCl, Sulphuric acid
etc)
N Activity / Hazard Safety and Initial risk Existing Residual Additional
o Process associat health control risk recommendati
ed impact risk measures ons

Likelihood

Likelihood
Severity

Severity
Risk

Risk
1 Tanker Toxic - Toxic 2 C M PPEs are 4 B L SOPs to be
unloadin chemica Vapour used. prepared and
g l release Inhalation followed.
-Skin/Eye Storage
Irritation/b tank area Spill
urn is and will containment
be in kit To be
open made
space. available

Flange/Ferrul
e joints etc. to
be checked
Periodically.
2 Transferri Spillage Inhalation of 2 C M Storage 4 B L As above
ng of / Toxic tank area
solvent Leakage. Vapours. is in open
from space.
storage
Spill
area to
containm
Process
plant. ent kit is
available.
PPEs are
used.
Only
trained
operators
are
allowed
to work in
this area.
Inspectio
n (for
pumps,
flange
joints
etc.) is
carried
out on
Regular

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N Activity / Hazard Safety and Initial risk Existing Residual Additional
o Process associat health control risk recommendati
ed impact risk measures ons

Likelihood

Likelihood
Severity

Severity
Risk

Risk
basis.

Table 7.5Storage and handling of Flammable solvents / chemicals

N Activity Hazard Safety Initial Existing Residual Additional
o / associate and risk control risk recommend
Process d health measures ations

Likelihoo

Likelihoo
Severity

Severity
impact

Risk

Risk
risk

d
1 Unloadi Spillage/ Burn 2 D H Spill 4 C M SOPs to be
ng from Leakage. injury. containment prepared
Tanker. kit And
Generatio Fatality. is available to followed.
n contain
of static Damage the leakage. Foam type
Charge. to fire
Equipm Earthing extinguisher
Fire/Expl ent’s mechanism is to be
osion and provided for provided in
facilities tankers. nearby
. Location.
Appropriate
PPEs like Fire monitor
Safety Goggles, with
Butyl or Nitrile provision of
rubber gloves, connection of
gumboot, foam
plastic apron To be
etc. are used. provided.

Only trained AFFF foam

operators are trolley
allowed to to be made
work in this available.
area.
Proper
fencing to be
provided for
underground
solvent
tanks.

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N Activity Hazard Safety Initial Existing Residual Additional
o / associate and risk control risk recommend
Process d health measures ations

Likelihoo

Likelihoo
Severity

Severity
impact

Risk

Risk
risk

d
2 Transfer Spillage/ Burn 2 D H Earthing is 4 C M As above
ring of Leakage. injury. done for
solvent transfer pump,
from Generatio Fatality. transfer lines
storage n etc.
area to of static Damage Flange-to-
process charge. to flange
plant. Fire / equipm bonding is
Explosion ents and done for
facilities transfer lines.
.
Storage Area is
marked as “No
Smoking”,
Hazardous
Area”, “Hot
work
Restricted” etc.

Only trained
operators are
allowed to
work in this
area.

Operators are
trained
for the
chemical
hazards,
preventive/mi
tigative
measures for
chemicals,
handling
emergency
situation
Inspection (for
pumps, flange
joints etc) is
carried out on
regular basis.

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N Activity Hazard Safety Initial Existing Residual Additional
o / associate and risk control risk recommend
Process d health measures ations

Likelihoo

Likelihoo
Severity

Severity
impact

Risk

Risk
risk

d
Spill
containment
kit
is available.
Firefighting
facilities
is available as
mentioned
above.
PPEs are used.
3 Storage Leakage Burn 2 D H Storage area 4 C M As above
Area injury. has
Fire Fatality. provision of Flame
Explosion natural/forced detectors,
Damage ventilation. Temperature
to Routine actuated heat
equipm inspection of detectors
ents and the area is with
facilities carried out alarms and
. by field automatic
operator.Stora sprinkler
ge Area is systems to
marked as “No be
Smoking”, installed in
“Hazardous storage
Area”, area, if
“Hot work possible or
Restricted” required.
etc.

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Table 7.6Storage and handling of solid Chemicals

N Activity Hazard Safety and Initial risk Existing Residual Additional
o / associate health control risk recommendatio
Process d impact risk measure ns

Likelihood

Likelihood
s

Severity

Severity
Risk

Risk
1 Handlin Exposure Skin / Eye 4 C M - 4 B L Operators/Work
g to the Irritation. Chemicals ers to be trained
Chemica chemical are stored for Safe Work
l bags in Practices.
isolated
storage Chemical
rooms handling bags to
having be labelled
provision properly.
for
natural & Chemicals
forced compatibility to
ventilatio be studied while
n. storing solid and
liquid in
Certified warehouse
Dust
respirator
is used.

Suitable
protective
clothing
and other
PPEs are
used.
2 Cleanin Fumes Severe 2 C M -Certified 4 B L Operators/Work
g of Inhalatio irritation Dust ers to be trained
Chemic n. to eyes, Respirato for Safe Work
al Dust skin. r is used. Practices.
Exposure. Inhalatio
Spillage
n. Suitable Chemical
.
protective handling bags to
clothing, be labelled
gloves, properly.
safety
shoes are Chemicals
used. compatibility to
be studied while
- Spillage storing solid and
is cleaned liquid in

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N Activity Hazard Safety and Initial risk Existing Residual Additional
o / associate health control risk recommendatio
Process d impact risk measure ns

Likelihood

Likelihood
Severity

Severity
s

Risk

Risk
or warehouse
neutralize
d with
suitable
media.

Chemica
ls are
stored in
isolated
storage
rooms
having
provision
for
natural &
forced

Table 7.7 Details of Major Hazardous Chemicals handled / to be handled at site

Chem Sta color Odor Sp Mel Boilin Flas Explosive TLV Wate NFPA Haza
ical te Gr ting g h limit pp r code rd
Poi point poin m solubi
nt Deg C t lity
Deg Deg % % H F R
C C LEL UEL
Acetic Liq Color Strong 1. - 139.9 49 2.7 10.3 5 Solu 3 2 0 Toxic,
anhyd uid less 08 73.1 ble Flamm
ride able,
corrosi
ve
Acetic Liq color Punge 1. 16.6 118 39 4 19.9 10 Solu 3 2 0 Toxic,
acid uid less nt 05 ble Flamm
able,
corrosi
ve
Causti Liq color Odorl 1. 318 1390 NA NA NA 2 Solu - - - Toxic,
c lye uid less ess 5 mg/ ble corrosi
m3 ve
Metha Liq color Alcoh 0. - 64.5 12 6 36.5 200 Solu 1 3 0 Toxic,
nol uid less ol 79 97.8 ble Flamm
like able
Tolue Liq color Benze 0. -95 111 4.4 1.1 7.1 50 Solu 2 3 0 Toxic,
ne uid less ne like 86 ble Flamm
able
Aceto Liq color Ether 0. -95 56 -20 2.6 12.8 750 Solu 1 3 0 Toxic,
ne uid less like 79 ble Flamm

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Chem Sta color Odor Sp Mel Boilin Flas Explosive TLV Wate NFPA Haza
ical te Gr ting g h limit pp r code rd
Poi point poin m solubi
nt Deg C t lity
Deg Deg % % H F R
C C LEL UEL
able
Hydro Ga Color No 0. - -253 Not 4 76 Not Not 0 4 0 Flamm
gen s less odor 07 259 avail avail solu able
gas (g able able ble
as)
Sulph Liq Color Chock 1. -35 270 - - - 1 solu 3 0 2 Toxic
uric uid less ing 84 ble and
acid odor corrosi
ve
IPA Liq Color Pleasa 0. - 82.5 11.6 2 12.7 400 Solu 1 3 0 Toxic,
uid less nt 78 88.5 ble Flamm
5 able
Ethyl Liq Color Ethere 0. -83 77 -4.4 2.2 9.0 400 Solu 1 3 0 Toxic,
acetat uid less al, 90 ble Flamm
e fruity 2 able
MDC Liq Color Not 1. - 39.75 Not 12 19 50 Parti 2 1 0 Toxic,
uid less availa 32 96.7 avail ally Flamm
ble able solu able
ble
Ethan Liq Color Pleasa 0. - 78.5 12.7 3.3 19 100 Solu 2 3 0 Toxic,
ol uid less nt 78 114. 8 0 ble Flamm
9 1 able
Cycloh Liq Color Chloro 0. 6.47 80.7 -18 1.3 8.4 300 Insol 1 3 0 Toxic,
exane uid less form 77 uble Flamm
like 8 in able
cold
wate
r
DMF Liq Colo Amine 0. -61 153 57.7 2.2 15.2 10 Solu 1 2 0 Toxic
uid urles like 94 7 ble Flamm
s 9 able
MTBE Liq Color Strong 0. - 55.2 - 28 2.5 15.1 Not Parti 2 3 0 Toxic
uid less 74 109 avail ally Flamm
able in able
cold
wate
r
THF Liq Color Ethrea 0. - 65 -14.5 2 11.8 590 Parti 2 3 1 Toxic,
uid less l, 88 108. ally Flamm
fruity 9 3 solu able,
ble reactiv
e
Di iso Liq Color Ethera 0. -86 68.5 -28 1.4 7.9 250 Solu 1 3 1 Toxic,
propyl uid less l 72 ble Flamm
ether 5 able,
reactiv
e
Xylen Liq Color Sweeti 0. - 138.5 24 1 7 434 Insol 2 3 0 Toxic
es uid less sh 86 47.4 uble Flamm
4 able
Benzy Liq Light Unple 1. 24 233 102 Not Not Not Solu - - - -
l uid yello asant 01 avail avail avail ble

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Chem Sta color Odor Sp Mel Boilin Flas Explosive TLV Wate NFPA Haza
ical te Gr ting g h limit pp r code rd
Poi point poin m solubi
nt Deg C t lity
Deg Deg % % H F R
C C LEL UEL
cyanid w 5 able able able
e
Chloro Liq Color Pleasa 1. - 61 Not Not Not 10 Sligh 2 0 0 Toxic
form uid less nt 48 63.5 appli appli appli tly
cable cable cable solu
ble
Dimet Oil Color Odorl 1. - Deco 83.3 Not Not 0.1 Parti 4 2 0 Toxic
hyl y less ess 33 31.8 mpose avail avail ally Flamm
sulpha liq s able able solu able
te uid ble
Ethyle Liq Color Not 1. - 83.5 13 6.2 15.6 10 Sligh 2 3 0 Toxic
ne di uid less availa 23 35.3 tly Flamm
chlori ble 5 solu able
de ble
Hydro Liq Color Odorl 1. -33 108 Not Not Not 1 Solu 2 0 1 Toxic,
gen uid less ess 1 appli appli appli ble reactiv
peroxi cable cable cable e
de
Liquor Liq Color Ammo 0. - Not Not Not Not 25 Solu 2 0 0 Toxic
ammo uid less noa 90 69.2 availa appli appli appli ble
nia like ble cable cable cable
Morph Liq Clear Amine 0. -4.9 128.2 35 1.8 11.2 20 Solu 3 3 0 Toxic
oline uid like 91 ble Flamm
able
Mono Liq Color Ammo 0. - 93 - 6.5 <- 4.9 20.7 5 Solu 3 4 0 Toxic
methy uid less niacal 70 30 ble Flamm
l able
amine
N Liq Color Gasoli 0. - 95 68 - 1.15 7.5 50 Insol 1 3 0 Toxic
Hexan uid less ne like 66 22.5 uble Flamm
e able
Tri Oil Color Strong 0. - 89.7 -8.3 1.2 8.0 10 Solu 3 3 0 Toxic
ethyl y less 73 115 ble Flamm
amine liq able
uid
Tert Liq Color Camp 0. 25.7 82.41 11.1 2.4 8.0 300 Solu 1 3 0 Toxic
Butan uid less hor 78 ble Flamm
ol like able
Hydra Liq Color Not 1. - 113.5 72 4.7 - Not Solu 3 2 2 Toxic,
zine uid less availa 0 51.7 avail ble Flamm
hydrat ble able able,
e Reactiv
e
Note : Use of PPE’s shall be ensured while handling above chemicals such as safety helmet, splash proof goggles, safety
shoes, apron, rubber hand gloves as applicable.

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7.4.1 Hazardous chemical handling and storage protocol

The site shall be handling various hazardous chemicals at site e.g. Methanol, Ethyl
acetate, Toluene, Sulphuric acid, Caustic flakes/Lye, Hydrogen, HCl, Ammonia, DMF,
Methylene di chloride, Iso propyl alcohol, Toluene, Ethanol, Acetone, Cyclohexane,
MTBE, THF, Acetic acid,acetic anhydride, Xylene, Benzyl cyanide, Benzaldehyde,
Chloroform, EDC, Hydrogen peroxide, Liquor ammonia, Monomethyl amine, Trethyl
amine, Hydrazine hydrate and many more.
Major bulk chemicals such as Methanol, Toluene, Ethyl acetate, IPA shall be stored in
underground tanks and will be stored/handled as per PESO protocol, requirement and
approval.
For other chemicals which are mainly stored in warehouse/tanks appropriate chemical
storage plans shall be designed to control physical and health hazards associated with
chemical storage.
There are several chemical compatibility schemes or methods available. Each one is
somewhat different but they have many similarities. No one system can address every
possible undesired chemical combination. The guidelines discussed below may be used
so that chemicals of different hazard classifications can be safely stored together.
The (material) safety data sheet from the manufacturer should be consulted as a
primary reference for storage guidance for that material.
General Guidelines for Safe Chemical Storage
o Designate a safe storage location for each chemical. Storage location should be
marked on each chemical container.
o When determining how to store the chemical, always check the chemical label
and MSDS/SDS first for the manufacturer’s recommended compatible storage.
o Keep chemicals away from ignition sources.
o Store flammable and combustible chemicals in an approved flammable chemicals
storage area.
o Avoid storing chemicals in direct sunlight or near a localized heat source.
o Store flammable and potentially explosive chemicals according to the
manufacturer’s directions or according to MSDS instructions.
o Use secondary containers to physically segregate incompatible chemicals when
they are stored in the same physical location.
o Label and date chemical containers when received and opened. Label working
solutions or chemicals removed from their original container so that all
individuals know what is in a given container.
o Maintain chemical identification labels, containers, and lids in good condition.
o Keep chemical containers closed with properly fitted caps when not in use.
o Hazardous chemicals must not be stored above shoulder height.
o Flammable chemicals should not be stored in a fume hood.
o Chemicals should never be stored on the floor.
o Chemical shelving should have containment lips or trays to contain small
leaks/spills.

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o Shelving should be strong enough to hold the weight of chemicals being stored
on them. Do not overload shelves. Always secure shelving to a permanent
structure. Shelves should be coated with a chemical-resistant material such as
chemical-resistant paint or another coating such as epoxy.
o Do not store chemicals in a domestic refrigerator or walk-in cooler. These
refrigeration devices contain ignition sources such as unsealed electrical
contacts. Flammable-safe refrigerators should be used whenever flammable
chemicals need to be refrigerated. Additionally, walk-in coolers are not vented,
creating the potential for accumulation of chemical vapors.
Secondary Containment Guidelines
Secondary containment is recommended to segregate chemicals from other
incompatible chemicals within the same storage area/cabinet. Segregating incompatible
chemicals using secondary containment is helpful when chemical storage space is
limited. Secondary containment is also recommended when storing highly toxic
materials to minimize exposure should the primary container become damaged. For
example, store liquid mercury inside a labeled unbreakable secondary container. Small
containers of compatible chemicals may be stored in a desiccator or other secure device.
Secondary containers should be compatible with the chemicals stored in them. They
should not corrode or degrade easily.
A Typical dangerous good and combustible liquid storage compatibility chart is given
below for reference,

Figure 7.1General dangerous good and combustible liquid storage compatibility

chart

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Table 7.8 Compatibility chart

Chemical Compactibility Chart

Name of Non Non

Compactible Reactant Compactible Reactant Compactible Non Comapctible Reactant
Chemicals Comapctible Comapctible

Acid HCL Caustic Triethlamine Methanol

Base Caustic Triethlamine Methanol Acetaldehyde

Amine Triethlamine Methanol Acetone Acetaldehyde

Ketone Acetone HCL Caustic Triethlamine

Aldehyde Acetaldehyde HCL Caustic Triethlamine

Saturated
Cyclohexane HCL Caustic Triethlamine
Hydrocarbon

Nitrile Acetonitrile HCL Caustic Triethlamine

Non
Comapctible

Compactible

Reactant

Qualitative risk assessment in handling various Chemicals and its MSDS are discussed at
Annexure 7.4.Onsite safety audit has been carried out during November 2017. The
observation & recommendations of safety audit is attached in Annexure 7.4.

7.5 HAZOP study

Hazard and Operability Study (HAZOP) is a structured and detailed technique,

developed primarily for application to chemical process systems.

HAZOP can generate a comprehensive understanding of the possible ‘deviations from

design intent’ that may occur. However, HAZOP is less suitable for identification of
hazards not related to process operations, such as mechanical integrity failures,
procedural errors, or external events.

HAZOP also tends to identify hazards specific to the section being assessed, while
hazards related to the interactions between different sections may not be identified.

This technique helps to identify hazards in a process plant and the operability problems.
It is performed once the engineering line diagrams of the plant are made available. It is
carried out during or immediately after the design stage. The purpose of the study is to

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identify all possible deviations from the way the design/operation is expected to work
and all the hazards associated with these deviations.

A multidisciplinary team was constituted with chemical, engineering (Mechanical and

instrumentation) engineers, HSE, R&D chemist and production supervisor. It is
important to keep the team smallenough to be efficient, while retaining a sufficient
spread of skills and disciplines for all aspects of the study to be covered
comprehensively.

The group discussion is facilitated by a Chairman and the results of the discussion are
recorded by a Secretary. Every investigation must be led by Chairman who is familiar
with the HAZOP study technique, which is primarily concerned with applying,
controlling the discussions and stimulating team thinking. The preparative work for
HAZOP studies consisted offour stages i.e., obtaining the data, converting into usable
form, planning the sequence of the study and arranging the necessary meetings. The
documents referred to for the study include process description, process flow diagrams,
P&I diagrams plant layout, operating manuals including startup & shutdown, safety
instructions etc., The parameters such as temperature, pressure, flow, level were
investigated for deviation and hazard situations are identified.

Some basic definitions of terms frequently used in HAZOP studies are deviation, causes,
consequences and guide words etc., Deviations are departures from the design intent
which are discovered by systematically applying the guide words. Causes are the
reasons why deviations might occur. Consequences are the reasons why deviations
should they occur. Guide words are simple words used to understand a particular plant
section in operating condition in order to guide and simulate the creative thinking
process and so discover deviations. NO, less, more, as well as, part of, reverse, other
than are guide words used.

Potential problems as represented by the consequences of the deviation should be

evaluated as they arise and a decision reached on whether they merit further
consideration or action. Except for major risk areas where a fully quantitative
assessment is required this decision is made semi-quantitatively on the consequence
(usually scaled as trivial, important or very probable).

Detailed step-wise hazop analysis studies describing process, operation, possible hazard
failure and remedial actions for each of the product manufactured is given in the table
below,

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Table 7.9HAZOP Analysis
No Product
1 Nitrazepam
2 Lorazepam
3 Zopiclone
4 Zapeplon
5 MIDAZOLAM
6 Tranylranylcypromine Sulphate
7 Chloropyramine HCl
8 Nimorazole
9 Acotiamide
10 Nabilone
11 Petophenone
12 LEVOMILNACIPRAN HCl
13 Pindalol
14 Prasugrel
15 Silodosin
One sample HAZOP study report of ZOPICLONE and its recommendations are is
enclosed at Annexure 7.1
Summerised recommendations of the HAZOP study report are consolidated and
reproduced below,
Table 7.10 Summerised HAZOP recommendations of ZOPICLONE process
No HAZOP study recommendation (Additional suggested control measures)
1 PTS (Powder transfer system) to be provided for solid charging.
2 It is suggested to provide PRV for jacket and reactor..
3 Record pressure of cooling water supply to the condenser in BMR.
4 Provide cooling water flow failure alarm in the field.
5 BMR to include instruction that as soon as vacuum falls below 300 mm / Hg, the
dryer must be closed immediately.
6 BMR to include the instructions that unless material is adequately cooled, the
same must not be discharged from dryer.
7 BMR to include instruction that as soon as vacuum falls below 300 mm / Hg, the
dryer must be closed immediately. Further, it is suggested to monitor vacuum in
the RVD during drying and is recorded in the BMR suitably.
8 Automation to be installed for solvent transfer.
9 It is recommended to vent the SRV in Reactors.
10 It is suggested to provide the vacuum trap to prevent vacuum pump water
entering filter.
Centaur iscommitted to comply with HAZOP recommendation. (Refer Annexure 7.2).

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Table 7.11 Hazard Identification & Risk Assessment at Different Project Stages
Sr Step/Activit Hazard Typical Possible Safety Risks
. y identificati Areas causes Measures
N on /activitie Required
o. s
1. Construction Physical
0 of buildings Hazards
and Erection - Fall from - Working - Untrained Fall Accidenta
of Plant height at ht > workers protection l injury
2m - Wearing - guardrail (personal
- Formwo loose - safety )
rk clothes net/PPEs
- Ramps - No safety - harness
- Unprote gear - warning
cted lines
sides - appropriate
and clothes
edges - supervision
- Roofing to identify
- Overhea hazards
d brick
laying
- Motor Ramps, - Untrained Vehicles with Accidental
vehicle excavatio reckless - service, injury
crash n sites, drivers emergency (personal
roads and parking )
brake
- hooter
system
- windows,
wipers,
lights, rear
window
mirrors,
reflectors
- Excavatio foundatio - Unidentifi Notify prior Accidenta
n n ed cables to starting l injury
accidents & utilities excavation (personal
Check oxygen )
levels Design
safe access
- Electrocu Entire site - Temporar Supervision Accidenta
tion y to identify l injury
connectio hazards (personal
ns )
- Cables
running
across

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Sr Step/Activit Hazard Typical Possible Safety Risks
. y identificati Areas causes Measures
N on /activitie Required
o. s
site
- Struck by Entire site walking Supervision Accidenta
falling below Warning l injury
objects loading or ribbons and (personal
working signs )
equipment
- Dust Entire site excavation Dust mask Injury
Generatio personal
n
Noise Entire Constructio Ear Personal
exposure plant n &erection Muffs/plugs injury
activities oiling and (noise
greasing induced
Vibration hearing
dampening loss)
2. Commissioni Electrocutio Use of Temporary Tagging & Electrocut
0 ng n Energy connection Lock out ion
s Warning (personal
signs injury)
Chemical Use & Improper Safety Personal
exposure storage of handling Gear/PPEs injury
chemicals Training (Chemical
burn,
organ
damage)
Instrument Complying On/offsite
al failure HAZOP Accident
recommendat injuries
ions
Noise Entire Commissio Ear Personal
exposure plant ning Muffs/plugs injury
activities Oiling and (noise
greasing induced
Vibration hearing
dampening loss)
3. Operation Electrocutio Use of Temporary Tagging & Electrocut
0 n Energy connection Lock out ion
s Warning (personal
signs injury)
Chemical Use & Improper Safety Personal
exposure storage of handling Gear/PPE’s injury
chemicals Training (Chemical
& burn,
hazardou organ
s wastes damage)

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Sr Step/Activit Hazard Typical Possible Safety Risks
. y identificati Areas causes Measures
N on /activitie Required
o. s
Instrument
Regular On/offsite
al failure
HAZOP Accident
&audits & injuries
complying
recommendat
ions
Noise Entire Improper Ear Personal
generation plant maintenanc Muffs/plugs injury
e Preventive (noise
maintenance, induced
oiling and hearing
greasing loss)
4. Closure and Chemical Use & Improper Safety Personal
0 Decommissio exposure storage of handling Gear/PPE’s injury
ning chemicals Training (Chemical
& burn,
hazardou organ
s wastes damage)

7.6 Dow Fire and Explosion Index

Dow Fire & Explosion Index for the Storage Tanks method is used as a rapid ranking
system to classify separate elements of the plants. The method is based on the Fire &
Explosion Index Hazard Classification Guide developed by M/s. Dow Chemical Company
(DOW INDEX) and the National Fire Protection Association (NFPA) indices for health
hazard.
The Fire and Explosion Index (F & E I) indicates the fire and/or explosion hazard of the
particular unit. Though the concept was developed basically for determining the "Risk
Insurance", it also provides guidance on the degree of preventive methods to be
provided. It also identifies the areas of priority for taking up the proactive control
measures.
The calculations of F & E I and Recommendations is done for the principle tanks of
Methanol, Toluene, Ethyl Acetate and Isopropyl Alcohol. Highest storage capacity of
each is considered for F & E Index. The degree of hazard is tabulated below based on F &
EI, Mond index.
The Mond index covers a wider range of process and storage installations, the
processing of chemicals with explosive properties and the evaluation of a toxicity
hazards index. It also allow for the off-setting effects of good design, and of control and
safety instrumentation. The Dow and Mond indexes are useful techniques, which can be
used in the early stages of a project design to evaluate the hazards and risks of the
proposed process. Calculation of the indexes for the various sections of the process will

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highlight any particularly hazardous sections and indicate where a detailed study is
needed to reduce the hazards.

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Figure 7.2 Dow Fire ad explosive index calculation for tanks
DOW FIRE & EXPLOSION INDEX CALCULATION FOR METHANOL TANK
Tank No - Equipment name Methanol Tank
Basic material for material factor Methanol Density 0.79 Kg/Litre
Properties of Material
Nh 1 Nf 3 Nr 0 M.F. 16
B.P. 147 Deg F Flash Point 52 Deg F Heat of Combusion 9,838 Btu/Lb
Quantity of material 20,000 Litre 15,800 Kg 34,760 Lb
Storage condition Temp 25 Deg C Pressure Atm bar
Penalty factor range Penalty factor used
1. General Process conditions Base Factor 1.00 1.00
A. Exothermic chemical reactions 0.30 to 1.25
B. Endothermic processes 0.20 to 0.40
C. Material handling and transfer 0.25 to 1.05 0.75
D Enclosed or Indoor Process Units 0.25 to 0.90 0.3
E Access 0.20 to 0.35 0.35
F Drainage and Spill Control 0.25 to 0.50 0.25
General Process Hazard Factor ( F1 ) Total 2.65

2. Special Process Hazards Base Factor 1.00 1.00

A Toxic material(s) 0.20
B Sub atmospheric pressure (< 500 mm Hg) 0.00
C Operation in or near flammable range --- ---
_____inerted ______noninerted
1. Tank farm storage flammable liquids 0.5 0.5
2. Process upset or purge failure 0.3 0.3
3. Combustible solids in storage. Dust in 0.8 0
process
D Dust Explosion 0.25 to 2.00 0
E Pressure Operating pressure ___ psig 0.3
Relief setting ________ psig
F Low temperature 0.20 to 0.30 0
G Quantity of flammable / unstable material --- ---
1. Liquids or gases in process 0
0.34 x 10^9 BTU 2. Liquids or gases in storage 1.1
3. Combustible Solids in Storage, Dust in Process 0
H Corrosion & Erosion 0.10 to 0.75 0.1
I Leakage - Joints & Packing 0.10 to 1.50 0.1
J Use of Fired Equipment 0.2
K Hot oil heat exchange system 0.15 to 1.15 0.15
L Rotating Equipment 0.5 0

Special Process Hazard Factor ( F2 ) Total 3.95

Process Unit Hazard Factor ( F3 = F1 x F2) 10.5

Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 167

Degree Hazard Based on F & E I Index Severe

MOND INDEX (Classification in Hazard category)
Mac value for Methanol 200
Th 50
Ts 50
GPHt 2.65
SPHt 3.95
T 7.6
Since T < 10 and F & EI index is 167 It falls under Hazard Category III

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DOW FIRE & EXPLOSION INDEX CALCULATION FOR TOLUENE TANK

Tank No - Equipment name Toluene Tank
Basic material for material factor Toluene Density 0.86 Kg/Litre
Properties of Material
Nh 2 Nf 3 Nr 0 M.F. 16
B.P. 232 Deg F Flash Point 40 Deg F Heat of Combusion 17,430 Btu/Lb
Quantity of material 20,000 Litre 17,200 Kg 37,840 Lb
Storage condition Temp 25 Deg C Pressure Atm bar
Penalty factor range Penalty factor used
1. General Process conditions Base Factor 1.00 1.00
A. Exothermic chemical reactions 0.30 to 1.25
B. Endothermic processes 0.20 to 0.40
C. Material handling and transfer 0.25 to 1.05 0.75
D Enclosed or Indoor Process Units 0.25 to 0.90 0.5
E Access 0.20 to 0.35 0.35
F Drainage and Spill Control 0.25 to 0.50 0.25
General Process Hazard Factor ( F1 ) Total 2.85

2. Special Process Hazards Base Factor 1.00 1.00

A Toxic material(s) 0.40
B Sub atmospheric pressure (< 500 mm Hg) 0.00
C Operation in or near flammable range --- ---
_____inerted ______noninerted
1. Tank farm storage flammable liquids 0.5 0.5
2. Process upset or purge failure 0.3 0.3
3. Combustible solids in storage. Dust in 0.8 0
process
D Dust Explosion 0.25 to 2.00 0
E Pressure Operating pressure ___ psig 0.3
Relief setting ________ psig
F Low temperature 0.20 to 0.30
G Quantity of flammable / unstable material --- ---
1. Liquids or gases in process 0
0.66 x 10^9 BTU 2. Liquids or gases in storage 1.1
3. Combustible Solids in Storage, Dust in Process 0
H Corrosion & Erosion 0.10 to 0.75 0.1
I Leakage - Joints & Packing 0.10 to 1.50 0.1
J Use of Fired Equipment 0.2
K Hot oil heat exchange system 0.15 to 1.15 0.15
L Rotating Equipment 0.5 0

Special Process Hazard Factor ( F2 ) Total 4.15

Process Unit Hazard Factor ( F3 = F1 x F2) 11.8

Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 189

Degree Hazard Based on F & E I Index Severe

MOND INDEX (Classification in Hazard category)
Mac value for Toluene 50
Th 125
Ts 75
GPHt 2.85
SPHt 4.15
T 16
Since T > 10 and F & EI index is 189 It falls under Hazard Category III

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DOW FIRE & EXPLOSION INDEX CALCULATION FOR ETHYL ACETATE TANK
Tank No - Equipment name Ethyl Acetate Tank
Basic material for material factor Ethyl Acetate Density 0.902 Kg/Litre
Properties of Material
Nh 1 Nf 3 Nr 0 M.F. 16
B.P. 171 Deg F Flash Point 24 Deg F Heat of Combusion 10,110 Btu/Lb
Quantity of material 20,000 Litre 18,040 Kg 39,688 Lb
Storage condition Temp 25 Deg C Pressure Atm bar
Penalty factor range Penalty factor used
1. General Process conditions Base Factor 1.00 1.00
A. Exothermic chemical reactions 0.30 to 1.25
B. Endothermic processes 0.20 to 0.40
C. Material handling and transfer 0.25 to 1.05 0.75
D Enclosed or Indoor Process Units 0.25 to 0.90 0.25
E Access 0.20 to 0.35 0.35
F Drainage and Spill Control 0.25 to 0.50 0.25
General Process Hazard Factor ( F1 ) Total 2.60

2. Special Process Hazards Base Factor 1.00 1.00

A Toxic material(s) 0.20
B Sub atmospheric pressure (< 500 mm Hg) 0.00
C Operation in or near flammable range --- ---
_____inerted ______noninerted
1. Tank farm storage flammable liquids 0.5 0.5
2. Process upset or purge failure 0.3 0.3
3. Combustible solids in storage. Dust in 0.8 0
process
D Dust Explosion 0.25 to 2.00 0
E Pressure Operating pressure ___ psig 0.3
Relief setting ________ psig
F Low temperature 0.20 to 0.30
G Quantity of flammable / unstable material --- ---
1. Liquids or gases in process 0
0.40 x 10^9 BTU 2. Liquids or gases in storage 1.05
3. Combustible Solids in Storage, Dust in Process 0
H Corrosion & Erosion 0.10 to 0.75 0.1
I Leakage - Joints & Packing 0.10 to 1.50 0.1
J Use of Fired Equipment 0.2
K Hot oil heat exchange system 0.15 to 1.15 0.15
L Rotating Equipment 0.5 0

Special Process Hazard Factor ( F2 ) Total 3.90

Process Unit Hazard Factor ( F3 = F1 x F2) 10.1

Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 162

Degree Hazard Based on F & E I Index Severe

MOND INDEX (Classification in Hazard category)
Mac value for Ethyl Acetate 400
Th 50
Ts 50
GPHt 2.60
SPHt 3.90
T 7.5
Since T > 10 and F & EI index is 162 It falls under Hazard Category III

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DOW FIRE & EXPLOSION INDEX CALCULATION FOR IPA TANK

Tank No - Equipment name IPA Tank
Basic material for material factor IPA Density 0.785 Kg/Litre
Properties of Material
Nh 1 Nf 3 Nr 0 M.F. 16
B.P. 207 Deg F Flash Point 74 Deg F Heat of Combusion 12,400 Btu/Lb
Quantity of material 20,000 Litre 15,700 Kg 34,540 Lb
Storage condition Temp 25 Deg C Pressure Atm bar
Penalty factor range Penalty factor used
1. General Process conditions Base Factor 1.00 1.00
A. Exothermic chemical reactions 0.30 to 1.25
B. Endothermic processes 0.20 to 0.40
C. Material handling and transfer 0.25 to 1.05 0.75
D Enclosed or Indoor Process Units 0.25 to 0.90 0.25
E Access 0.20 to 0.35 0.35
F Drainage and Spill Control 0.25 to 0.50 0.25
General Process Hazard Factor ( F1 ) Total 2.60

2. Special Process Hazards Base Factor 1.00 1.00

A Toxic material(s) 0.20
B Sub atmospheric pressure (< 500 mm Hg) 0.00
C Operation in or near flammable range --- ---
_____inerted ______noninerted
1. Tank farm storage flammable liquids 0.5 0.5
2. Process upset or purge failure 0.3 0.3
3. Combustible solids in storage. Dust in 0.8 0
process
D Dust Explosion 0.25 to 2.00 0
E Pressure Operating pressure ___ psig 0.3
Relief setting ________ psig
F Low temperature 0.20 to 0.30
G Quantity of flammable / unstable material --- ---
1. Liquids or gases in process 0
0.43 x 10^9 BTU 2. Liquids or gases in storage 1.05
3. Combustible Solids in Storage, Dust in Process 0
H Corrosion & Erosion 0.10 to 0.75 0.1
I Leakage - Joints & Packing 0.10 to 1.50 0.2
J Use of Fired Equipment 0.2
K Hot oil heat exchange system 0.15 to 1.15 0.15
L Rotating Equipment 0.5 0

Special Process Hazard Factor ( F2 ) Total 4.00

Process Unit Hazard Factor ( F3 = F1 x F2) 10.4

Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 166

Degree Hazard Based on F & E I Index Severe

MOND INDEX (Classification in Hazard category)
Mac value for IPA 200
Th 50
Ts 50
GPHt 2.60
SPHt 4.00
T 7.6
Since T > 10 and F & EI index is 166 It falls under Hazard Category III

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Table 7.12 Hazard Category for Storage Tanks as per FETI study
Chemical Name Fire & Degree of MOND Index Hazard
explosion Hazard Category
Index
Methanol 167 Severe 7.6 III
Toluene 189 Severe 16 III
Ethyl Acetate 162 Severe 7.5 III
Iso propyl 166 Severe 7.6 III
alcohol
Based on the study on the index, recommendations planned / suggested measures for
risk mitigation are given in Table below. Company has committed to provide the
Minimum Protective & Protective Features as per FEI Index (Confirmation Letter is
attached in Annexure 7.2).
Table 7.13 Planned & Suggested Measure Based On Fire and Explosion Index
Planned / Suggested Measure based on Fire and Explosion Index
Sr No Preventive & Protective Methanol, Toluene, Ethyl acetate, Iso
Features propyl alcohol (F & E Index > 90)

Recommendation* Remarks
Range of F & EI >90
1 Fireproofing 4 Required
2 Water Spray
2a Directional 4 Required
2b Area 4 Required
2c Curtain 4 Required
3 Special Instrumentation
3a Temperature 4 Required
3b Pressure 4 Required
3c Flow control 4 Required
4 Dust, blow down, spill control 4 Required
5 Internal examination 4 Required
6 Combustible gas Monitors
6a Signal alarm 4 Required
6b actuate equipment 4 Required
7 Remote operation 4
8 Diking 4 Required
NOTE: 1) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature
required.
All the tanks will be installed as per PESO guidelines.

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Qualitative risk assessment in handling various chemicals (its MSDS, properties of
material, fire and explosion data, threshold limits, hazards involved, first aid measures,
spill and its control measures), safety and precautions to be taken are discussed at
Annexure 7.4

7.7 Quantitative risk assessment

Quantitative Risk Assessment (QRA) is a structured approach of identifying and

understanding the risks associated with hazardous activities such as the
operation of a plant. The assessment starts by taking an inventory of potential
hazards, their likelihood and consequences. It involves the steps of identifying
the hazards associated with the operations/storage/unloading activity and
selecting the worst case scenario for consequence estimation. Finally, suggesting
the measures to minimize or mitigate risks to meet appropriate acceptability
criteria. The planning for emergency evacuation shall be borne in mind whilst
interpreting the results.
7.7.1 Consequence Analysis based on ALOHA

ALOHA (Arial Locations of Hazards Atmosphere) is an atmospheric dispersion model

used for evaluating releases of hazardous chemical vapors. ALOHA is a part of software
called CAMEO (Computer Aided Management of Emergency Operation). CAMEO is one
of the tools developed by EPA’s Chemical Emergency Preparedness and Prevention
Office (CEPPO) and the National Oceanic and Atmospheric Administration Office of
Response and Restoration (NOAA), to assist front-line chemical emergency planners
and responders.
CAMEO consists of three parts viz. CAMEO (which is basically a data base), ALOHA and
MARPLOT (Mapping Applications for Response, Planning, and Local Operational Tasks).
ALOHA allows the user to estimate the downwind dispersion of a chemical cloud based
on the toxicological/physical characteristics of the released chemical, atmospheric
conditions, and specific circumstances of the release. Graphical outputs include a "cloud
footprint" that can be plotted on maps with MARPLOT to display the location of other
facilities storing hazardous materials and vulnerable locations, such as hospitals and
schools. Specific information about these locations can be extracted from CAMEO
information modules to help make decisions about the degree of hazard posed.
Systematic study based on ALOHA has been carried out for Methanol, Toluene, Ethyl
acetate and Iso propyl alcohol storages. The detail study of ALOHA is attached in
Annexure 7.3. The details of consequence analysis studies carried out are presented
belowfor various accident and consequence scenarios like:
Table 7.14 Consequence Analysis studies carried out
Failure Scenarios Accident Scenario Effects
Catastrophic failure of vapor cloud formation and Toxic area of vapor cloud
tank dispersion
Flammable area of vapor cloud
Vapor cloud catching fire Radiation Effects from pool fire

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Explosion of vapor cloud Overpressure effects of VCE
Leakage from pump vapor cloud formation and Toxic area of vapor cloud
discharge valve dispersion
Flammable area of vapor cloud
Vapor cloud catching fire Radiation Effects from pool fire
Explosion of vapor cloud Overpressure effects of VCE
Failure frequency data as given in Loss Prevention in Process Industries by Frank P Lees
is presented below for information.
Table 7.15 Failure Frequency Data
SR. NO. ITEM FAILURE FREQUENCY
(No. per 106 years)
1 Shell
2 Process / Pressure Vessel 1.0
3 Atmospheric Pressure Storage 0.1
4 Full Bore Vessel Connection
25 30.0
40 10.0
50 7.5
100 4.0
150 3.0
5 Full Bore Process Pipeline (Diameter in mm)
Less Than 50 0.30*
>50, <150 0.09*
More than 150 0.03*
(*Failure frequency expressed in No. per met length per 106 years)

The Maximum Credible Accident scenario likely identified is leakage of pump discharge
line.
The above table indicates that probability of occurrence of this scenario is very low
(<0.5 X 106 years), which is within the acceptable limits. However, various preventive
and protective measures are required to ensure that the above accident scenarios do
not occur.

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Table 7.16 Findings of Consequence analysis studies
Calculations of affected distances considering various scenarios have been done and summarized results are as below:
Sr Substance Failure Scenerio Scenerio No Effects considered Level of concern (LOC) Distance
No , meters

1 Methanol The contents of the tanker leaking Methanol 1/1 Gas not burning – Toxicity AEGL-3 7200 < 10
and forming a pool effect ppm
AEGL-2 2100 < 10
ppm
AEGL-1 530 ppm < 10
Methanol 1/2 Flammable area of vapor cloud 60 % LEL 43080 <10
ppm
10 % LEL 7180 < 10
ppm
Methanol 1/3 Overpressure effect of vapor Bldg. 8.5 psi -
cloud explosion destruction (no
part above LEL)
Serious injury 3.5 psi -
Glass shatter 1 psi -
Methanol 1/4 Radiation effect from pool fire Potentially 10 < 10
lethal kw/m2
2 nd degree 5 kw/m2 < 10
burn
severe pain 2 kw/m2 < 10
Methanol 1/5 Radiation effect from th fireball Potentially 10 180
lethal kw/m2
2 nd degree 5 kw/m2 260
burn
severe pain 2 kw/m2 411
1 Methanol Failure of the transfer pump(full Methanol 2/1 Gas not burning – Toxicity AEGL-3 7200 49
bore leakage) effect ppm
AEGL-2 2100 102
ppm
AEGL-1 530 ppm 214
Methanol 2/2 Flammable area of vapor cloud 60 % LEL 43080 14
ppm
10 % LEL 7180 49
ppm
Methanol 2/3 Overpressure effect of vapor Bldg. 8.5 psi LOC not
cloud explosion destruction exceeded
Serious injury 3.5 psi LOC not
exceeded
Glass shatter 1 psi 14

Calculations of affected distances considering various scenarios have been done and summarized results are as below:
Sr Substance Failure Scenerio Scenerio No Effects considered Level of concern (LOC) Distance
No , meters

2 Toluene The contents of the tanker leaking Toluene 1/1 Gas not burning – Toxicity AEGL-3 3700 < 10
and forming a pool effect ppm
AEGL-2 560 ppm < 10
AEGL-1 67 ppm 40
Toluene 1/2 Flammable area of vapor cloud 60 % LEL 6600 < 10
ppm
10 % LEL 1100 <10
ppm
Toluene 1/3 Overpressure effect of vapor Bldg. 8.5 psi -
cloud explosion destruction (no
part above LEL)
Serious injury 3.5 psi -
Glass shatter 1 psi -
Toluene 1/4 Radiation effect from pool fire Potentially 10 < 10
lethal kw/m2
2 nd degree 5 kw/m2 < 10
burn
severe pain 2 kw/m2 < 10
Toluene 1/5 Radiation effect from th fireball Potentially 10 270
lethal kw/m2
2 nd degree 5 kw/m2 382
burn
severe pain 2 kw/m2 596
2 Toluene Failure of the transfer pump(full Toluene 2/1 Gas not burning – Toxicity AEGL-3 3700 34
bore leakage) effect ppm
AEGL-2 560 ppm 105
AEGL-1 67 ppm 376
Toluene 2/2 Flammable area of vapor cloud 60 % LEL 6600 25
ppm
10 % LEL 1100 70
ppm
Toluene 2/3 Overpressure effect of vapor Bldg. 8.5 psi LOC not
cloud explosion destruction exceede
Serious injury 3.5 psi d
18
Glass shatter 1 psi 38

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Calculations of affected distances considering various scenarios have been done and summarized results are as below:
Sr Substance Failure Scenerio Scenerio No Effects considered Level of concern (LOC) Distance
No , meters

3 Iso propyl The contents of the tanker leaking Iso propyl 1/1 Gas not burning – Toxicity PAC-3 12000 < 10
alcohol and forming a pool alcohol effect ppm
PAC-2 2000 < 10
ppm
PAC-1 200 ppm 15
Iso propyl 1/2 Flammable area of vapor cloud 60 % LEL 12000 < 10
alcohol ppm
10 % LEL 2000 < 10
ppm
Iso propyl 1/3 Overpressure effect of vapor Bldg. 8.5 psi -
alcohol cloud explosion destruction (no
Serious injury 3.5 psi -
Glass shatter 1 psi -
Iso propyl 1/4 Radiation effect from pool fire Potentially 10 <10
alcohol lethal kw/m2
2 nd degree 5 kw/m2 < 10
burn
severe pain 2 kw/m2 < 10
Iso propyl 1/5 Radiation effect from th fireball Potentially 10 227
alcohol lethal kw/m2
2 nd degree 5 kw/m2 323
burn
severe pain 2 kw/m2 507
3 Iso propyl Failure of the transfer pump(full Iso propyl 2/1 Gas not burning – Toxicity PAC-3 12000 21
alcohol bore leakage) alcohol effect ppm

PAC-2 2000 62
ppm
PAC-1 200 ppm 105
Iso propyl 2/2 Flammable area of vapor cloud 60 % LEL 12000 21
alcohol ppm

10 % LEL 2000 62
ppm
Iso propyl 2/3 Overpressure effect of vapor Bldg. 8.5 psi -
alcohol cloud explosion destruction
Serious injury 3.5 psi 15
Glass shatter 1 psi 33

Calculations of affected distances considering various scenarios have been done and summarized results are as below:
Sr Substance Failure Scenerio Scenerio No Effects considered Level of concern (LOC) Distanc
No e,
meters
4 Ethyl The contents of the tanker leaking Ethyl 1/1 Gas not burning – Toxicity PAC-3 10000 < 10
Acetate and forming a pool Acetate effect ppm
PAC-2 1700 14
PAC-1 ppm
1200 19
Ethyl 1/2 Flammable area of vapor cloud 60 % LEL ppm
13080 < 10
Acetate ppm
10 % LEL 2180 11
Ethyl 1/3 Overpressure effect of vapor Bldg. ppm
8.5 psi -
Acetate cloud explosion destruction (no
Serious injury 3.5 psi < 10
Glass shatter 1 psi < 10
Ethyl 1/4 Radiation effect from pool fire Potentially 10 < 10
Acetate lethal kw/m2
2 nd degree 5 kw/m2 < 10
burn
severe pain 2 kw/m2 < 10
Ethyl 1/5 Radiation effect from th fireball Potentially 10 202
Acetate lethal kw/m2
2 nd degree 5 kw/m2 290
burn
severe pain 2 kw/m2 457
4 Ethyl Failure of the transfer pump(full Ethyl 2/1 Gas not burning – Toxicity PAC-3 10000 21
Acetate bore leakage) Acetate effect ppm
PAC-2 1700 57
ppm
PAC-1 1200 69
ppm
Ethyl 2/2 Flammable area of vapor cloud 60 % LEL 13080 19
Acetate ppm
10 % LEL 2180 49
ppm
Ethyl 2/3 Overpressure effect of vapor Bldg. 8.5 psi -
Acetate cloud explosion destruction
Serious injury 3.5 psi 13
Glass shatter 1 psi 31

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• Observations based on above consquence analysis
The damage distances worked out for this scenario indicates that for most of the effects
the damage will be confined to the plant boundary except in case of Boiling liquid vapor
cloud explosion (BLEVE).

7.7.2 Comments / Recommendations based on Consequence analysis

7.7.2.1 Recommendations

1. Evacuation routes shall be planned such that alternate route is available from
any corner in more than one direction.
2. Extra precautions to be taken in unloading of flammable solvents. The details of
precautions during storage handling and transportation of solvents has been
mentioned separately.
3. Elaborate Firefighting arrangements shall be provided as per the statutory
guidelines.
4. Storage tanks: Statutory guidelines and good engineering practices shall be
followed in design, installation and maintenance of storage tanks.
5. General Fire detection and protection system is suggested at Annxure 7.4

Other recommendations to reduce risk of fire, explosion and toxic release

(Precautions to be considered during transportation, unloading and solvent
handling)
No Activity Safety Precautions
1 Transportation of o Training will be provided to driver and cleaner
Solvents like Methanol, regarding the safe driving, hazards of Flammable
Toluene, Ethyl Acetate, chemicals, emergency handling, and use of SCBA
Iso propyl alcohol sets.
o TREM card will be kept with Truck/tankers
o SCBA set will be kept with Tanker.
o Fire extinguishers will be kept with Tankers.
o Flame arrestor will be provided to Tanker exhaust.
o Instructions will be given not to stop road tanker in
populated area.
o Hazard Identification symbol and emergency
telephone
number will be displayed as per HAZCHEM CODE.
o Appropriate PPEs will be kept with Tanker.
Transportation of In case of leak or spill:
Solvents like Methanol,
Toluene, Ethyl Acetate, o Area will be isolated.
Iso propyl alcohol o Container / tanker shall be isolated.
o Source of leakage will be checked.
o Damaged containers or spilled material shall not be
attended without wearing appropriate protective
clothing.
o Leak will be stopped, if possible to do so without
risk.
o Water spray shall be used to reduce vapours (but do

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not put water directly on leak, spill area or inside
container).
o Combustibles (wood, paper, oil, etc.) shall be kept
away from spilled material.
2 Unloading of Solvents o Priority will be given to Tanker to immediately enter
from tanker. the storage premises at site and will not be kept
waiting near the gate or the main road.
o Security person will check License, TREM CARD,
Fireextinguisher condition; SCBA set condition,
Antidote Kit, required PPEs as per SOP laid down.
o Store officer will take sample as per sampling SOP
fromsampling point. After approval of QC
department unloading procedure will be allowed be
started.

Following precautions will be taken during unloading:

o Wheel stopper will be provided to tanker at

unloading platform.
o Static earthing will be provided to road tanker.
o Tanker unloading procedure will be followed
according to Check list.
o Only day time unloading will be permitted.
3 Solvent storage safety o Pipes and equipment shall be inspected at regular
intervals.
o All storage areas shall be isolated from all sources of
open flame and well posted with' NO SMOKING'
signs and will provided with adequate firefighting/
extinguishing system.
o Spark-resistant tools will be used.
o Water spray shall be used to reduce vapours (but do
not put water directly on leak, spill area or inside
container).
o Combustibles (wood, paper, oil, etc.) shall be kept
awayfrom spilled material.
o Dyke wall will be provided to storage tank.
o Level transmitter will be provided with low
level/high level.
o Provision of flame arrestor.
o Fire hydrant monitor with foam attachment facility
will be provided.
o Dumping /Drain vessel/alternate vessel will be
provided to collect the spillage material inside the
dyke wall.
o FLP type pump will be provided.
o Double static earthing will be provided to storage
tank, as per the requirement.
o Double Jumper clip shall be provided to all solvent
handling pipeline flanges.

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4 Solvents transfer from o Double mechanical seal type pump shall be
storage tank to Process provided.
Plant. o Double on / off switch shall be provided at tank farm
andprocess area near day tank. Pump auto cut off
with day tank high level shall be provided.
o Flame arrestor shall be provided on day tank vent.
o NRV shall be provided on pump discharge line.
o Double Jumper clip shall be provided to all solvent
handling pipelines.
o Double static earthing shall be provided to day tank.

7.8 Recommendations based on Risk Analysis and good manufacturing

practices

The recommendations/suggested control measures for the tanks are summarized

below

7.8.1 Control Measures Suggested for Methanol, Toluene, Ethyl acetate and Iso
propyl tanks

• Comprehensive SOP to be made to address unloading operation along with valve

sequence
• SOP to address communication with transporter
• Ensure that the tankers are regularly checked by the transporter, To be made as
part of SOP
• All tools used in connection with unloading of shall be kept free from oil, dirt,
and grit. During use they shall be kept wet with water to avoid sparking.
• The storage tank shall be constructed with compatible material
• Certificate of Analysis checked with internal standards
• QC check to be ensured before receipt / unloading
• Fire mock drill to be carried out to ensure emergency preparedness.
• Ensure preventive maintenance of PRV / FA (flame arrester)
• The periodic inspection and maintenance program of tanks, pumps and piping
would be ensured.
• Ensure that the tank is earthed and static electricity discharge system is full
proof.
• SOP to be formulated for emptying out the tank & making it hydrocarbon free.
• The pipelines will be supported adequately so as to avoid sagging of the same
during operation.
• Visual inspection of the pipelines will be done periodically to ascertain external
pitting and corrosion.

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• Use of protective equipment such as gloves, lab coat, vapor respirator, splash
goggles shall be ensured while handling the substance.
• Pipelines, tanks and pumps shall be inspected regularly for any leak.
• Prominent signage of hazards (such as “Danger”, No smoking”) of the substances
shall be provided on the tank and surroundings in addition to the cautionary
notice as required under provisions of Schedule XII of MFR 114.
• Precautionary measures against static charge shall be taken.
• Sprinkler system shall be provided as per standard storage rules

7.9 Disaster Preparedness and Emergency Management Plan

CENTAUR has prepared the onsite Disaster Management Plan which is in force for the
existing facility.

The purpose of this plan is to provide CENTAUR with the means to effectively utilize all
the resources at its disposal for the protection of life, environment and property.

CENTAUR will update existing emergency management system (Onsite DMP) to tackle
any emergency situation for proposed plants expansion.

Onsite emergency plan is attached at Annexure 7.7

The disaster management plan (DMP) provides for a framework of actions to handle
various emergency situations at the CENTAUR. It also provides for on-site resources and
appropriate outside assistance in case of any incident at the facility. The ERP will be in
place before the commencement of operations at site, and all personnel will have
undergone a comprehensive training in emergency response.
The primary objective of the plan is

• Minimization of the risks to lives and safety of proposed plant personnel and of
the neighboring community.

• Containing and minimizing environmental damage, to surroundings, and to site

property, and equipment, this could occur from emergency or accidental
situations beyond the normal operations of the plant.

• Coordinating appropriate and effective actions with outside regulatory agencies

during and after their involvement in on-site emergencies.

• Maintaining effective trained personnel capable of performing the established

emergency response procedures when it is required.

An on-site emergency is caused by an accident that takes place in plant itself and the
effects are confined to the factory premises involving only the people working in the
factory. On-site emergency plan to deal with such eventualities is the responsibility of
the occupier and is mandatory. An on-site emergency plan should contain the following
key elements:

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• Basis of the plan: Hazard analysis

• Accident prevention procedure/measures;
• Accident/emergency response procedure/measures and
• Recovery procedure.

7.9.1 Mutual Aid

It is essential to have mutual aid arrangements as it is useful in cases of major fire and
other emergencies. Mutual aid arrangements are to be worked out in the plan to
facilitate additional help in say, fire-fighting or medical attention which might be
beyond the capacity of an individual factory/unit. To make the mutual aid plan a
success, the following are considered essential:
• Written procedure which spells out how call for help will be made and how it
will be responded.
• The type of equipment which would be used and procedure for making
replacement.
• A quick hot-line method of communication.
• A brief mention of the type of hazard in each plant and fire-fighting measures.
• Orientation and joint training program for staff.
• Joint inspections and drills.

Centaur has mutual aid arrangement with nearby additional Ambernath MIDC
industries.

7.9.2 Disaster Management Plan

Emergency prevention through good design, operation, maintenance and inspection are
essential to reduce the probability of occurrence and consequential effect of such
eventualities. The overall objective of the DMP/Emergency Response Plan (ERP) is to
make use of the combined resources at the site and outside services to achieve the
following.

• Localize the emergency on property and people

• Minimize effects on property and people
• Effective rescue and medical treatment
• Evacuation.

A disastrous event strikes suddenly, violently and without warning. Identifying the
potential hazards ahead of time and advance planning can reduce the dangers of serious
injury, loss of life and damage to environment in the event of an incident occurrence.

The first response to a disaster is the job of the local government’s emergency services
with the help from the nearby municipalities and the volunteer service agencies. In a
catastrophic disaster only the govt. can provide the rescue search on the disaster site,
resumption of electric power, food, water, medicines, cloths, shelter and other basic
human needs. It is the long term recovery phase of disaster which places the most
severe financial strain to govt. in-addition to damage to public facilities and
infrastructure. It takes longer time to get aid from the govt. for rescue work when there

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is a natural calamity because of various constraints such as reaching the site, priority of
personnel involved, availability of material, equipment and rescue team personnel etc. It
is always advisable to develop teams within the organization for taking immediate
rescue action if possible. Industry has to prepare a detailed disaster control measures
and give information such as the quantity of hazardous material stored, the location of
storage, the approximate population living in the vicinity and the detail of the hazardous
characteristic of the material to the Employees, District Collector, Police, Fire service
department, Director of Factories, State Pollution control Board and the Public living in
the vicinity regularly to enable the government to prepare the disaster management
plan. Educate employees and the public living in the vicinity the safety measures
required to be taken in the event of an accident taking place.

7.9.3 Earthquake

During site selection stage based on the past seismic metrological data / reports earth
quake prone areas have to be avoided. Cover the site with public liability insurance as
per the advice of government. Design building to withstand minor shocks of earth quake
without damage to structures. Maintain inventory of material and the location of stock
on day today basis and submit the report to disaster management authority (district
collector) and the state pollution control board weekly / monthly also maintain parallel
record at H.O. Maintain MSDS of stored materials toxicity of gases that can emanate due
to reactions of stored materials. Provide communication facilities internal and with
people living in the vicinity. Educate the employees and the surrounding peoples about
the possible dangers in case of an earthquake and the safety measures required to be
taken.

Take preventive action of stopping work activities, informing and evacuating employees
and the public living in the vicinity to safe location as per the advice of government
agency if there is an advance earth quake warning from the agencies.

After an earth quake (if the site is affected), Inform disaster management authorities
and state pollution control board authorities over phone, e-mail or through messenger.
Display Phone Numbers of: District Collector, Police S.P, Fire Service Department,
Factories Inspectorate and nearby Hospitals. Inform company authorities through
phone: Phone numbers: Project Head, EHS Head, HR Head. Inform the insurance
authorities about the incident. Phone Numbers: Local Insurance officer and Divisional
Manager Test the nearby water sources and soil for contamination and the extent of
damage and compare data with the base data. If found contaminated, Inform public of
the affected area not to use water from the wells or bore wells through mobile public
announcement system and by using media like radio and TV. Arrange supply of drinking
water from outside till the condition is normalized. Use the services of the lab and
expertise of pollution board and find solutions to arrest the leakage of material and
leachate and start remedial measures. Divert material required for lining and transfer
skilled employees for new pit construction from other site along with additional
number of equipment. Construct new pit and start transfer landfill material / leachate in
to the new pit. Test the soil contamination level and find out the level of damage and
treat the soil if required or remove the contaminated soil and safely transfer it in the
new land fill. Check the water contamination level and advise authorities and public
about the usability of water. Asses the expenditure required for implementation of
required remedial measures. Prepare cost estimate of the total loss including the

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transport and remediation cost. Make insurance claim and pay compensation if any
advised by the govt. authorities to the affected victims.

7.9.4 Hazard Control Measures

7.9.4.1 Fire

To increase the level of safety in project, installation of smoke alarms or automatic fire
detection /alarm systems will be installed at strategic locations as an early warning of
fire to the occupants.

To prevent fire mishaps and to manage the emergency situation during fire in the
project the following activities and precautions are proposed.

• Emergency evacuation plan is important for all projects, and the same will be
prepared as per Fire & Safety rules.
• Regular mock drills will be carried out to create awareness on procedures to be
followed in times of emergency situation/evacuation
• It will be advised to keep oxygen cylinders, medical kits and masks to prevent
smoke inhalation especially for those with respiratory disorders for whom
smoke inhalation can be very dangerous.
• Plant manager will be advised to ensure that the firefighting equipment are in
good working conditions.
• The plant will be provided with sufficient firefighting gadgets (water, soil,
cylinders, etc).

Simple steps to be followed during emergency are as follows.

Call the fire rescue department: During fire in plant, leave the premises by nearest
available exit. Call fire department and do not assume anyone else has called the fire
department. If your cloth catches fire, do not get panic or run, stop, drop and roll.

Cover your nose and mouth with a wet clean cloth: Stay calm cover your nose and
mouth with a wet, clean cloth to prevent smoke inhalation injury and choking. Never
jump off or attempt to climb down the side of a tall structure as it will mean certain
death.

Do not run: During a fire, smoke containing poisonous gases such as CO tends to rise
up.
When you run in a smoke filled room, you tend to inhale the smoke faster. CO dulls the
senses and prevents clear thinking, leading to panic. To prevent being asphyxiated, dip
tissues or cloth in water and cover your noise with it.

Head-count of the occupants: During an emergency, make good use of the evacuation
procedure and help each other to reach out of plant/building safely. Ensure nobody is
left behind by doing a head-count of occupants. Visitors should read and understand the
evacuation plan before going into the plant/building area and ensure their safety.

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7.9.5 Natural Disasters

Disasters occur without notice. Most disasters are natural such as earthquake, floods,
hurricanes, sandstorms, landslides, tsunamis and volcanoes. We have no way of
stopping them, but we can learn to deal with the difficult situations that arise due to
them. During disasters like floods, fire, earth quake, landslides, rescue beings at site.
Even before external help arrives, people affected by the disasters help each other.

The government and many voluntary organizations send teams of workers trained in
rescue operations to disaster-affected areas. These teams join hands with the local
community helpers such as doctors, nurses, social workers and policemen.

Temporary shelters are built for displaced people. Doctors and nurses provide medical
aid. They treat the wounded and work to control epidemics. Social workers collect food
and cloth from all over the country for the disaster-affected people. The police maintain
law and order. Media –persons help in spreading news about the victims and their
conditions. They also post advertisements that urge people to donate for victims.

In extreme conditions, the army and Air force organize rescue operations. They clear
roads, send medical teams and help to move people to safer places. The air force drops
food, water and clothes in the affected areas. Organization like UN helps in providing aid
during massive disasters.

Individually, people from all over the world also come forward to help during a disaster.
They donate blood while many donate money. Some even reach the disaster affected
places to give an extra hand in the rescue operation. Families adopt children who have
lost their parents and thus give them a new home.

7.9.6 Electrical accidents

Electrical hazards can cause burns, shocks, and electrocution which can lead to serious
injury and even death. When dealing with potentially serious electrical hazards stop and
think! Instead of taking a chance and risking your personal safety, call trained
professionals to handle problems.

Many times people prefer to take electrical matters into their own hands. Other small
aspects of electrical repair in a business setting may be taken care of without needing
professional service technicians. If you do decide to take matters into your own hands,
safety precautions can avoid injuries and other losses.
7.9.6.1 Prevention of Electrical accidents

Flexible cords connected to appliance should be wired to confirm to the international

color code. Color of insulation wire is

• Brown represents live wire,

• Blue represents neutral wire and
• Green/yellow stripes represent earth wire.

What you should look for when selecting an electrical appliance are given below

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• The appliance should be suitable for operation on local electrical supply of 240
volts AC and frequency of 50 Hz.
• The appliance should preferably be tested and certified by a national or reputed
standards testing authority
• Look for certified plugs on the flexible cords connected to the appliances. If the
appliance is double insulated and has a 2-pin plug, then it should be fitted with a
suitable certified plug.
• An essential formality when buying any appliances is a duly completed
guarantee card with the dealers/retailer's official stamp and details of the
appliance (serial number, etc.).

Safety precautions to be taken when using electrical appliances

a. Avoid using handheld appliances when your hand and/or body is wet.

b. Do not use or leave appliances where liquid can splash onto them.

c. Flexible cords connecting the appliance and the plug should be in good condition,
if the cord is frayed, chaffed, cut or melted, have the entire cord replaced by a
competent person.

d. Check accessories such as plugs attached to appliances for cracks and burnt
marks and have them replaced. If undue overheating occurs or burnt marks
appear in any electrical appliance, have it checked.

Some common causes of electrical accidents in the house

a. Faulty wiring: This usually occurs when unauthorized extension or rewiring is

done by unqualified persons. Some of the usual faults are the omission of earth
wires and the Reversing of the live and neutral wires. Without an earth wire, the
exposed metal parts of appliances may deliver a lethal shock to the user when a
fault develops.

b. Improper flexible cords: This can be caused by connecting the flexible cord
wrongly to the plug. In the case of appliances which have exposed metallic parts,
a 2-core instead of a 3-core flexible cord is used. When the appliance is faulty, the
exposed metal parts may become live and a fatal accident could result.

c. Faulty appliance: Attempts to repair faults in electrical appliances by people not

trained to do so can result in accidental shock.

To prevent Electrical accidents, the following points should be kept in mind:

• All electrical wiring, rewiring or extension work must be carried out by licensed
electrical contractors. On completion, the contractors should test before
electricity supply is connected
• Repair of appliances and replacement of flexible cords should be carried out only
by competent persons.

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• To ensure electrical safety in the facility, a current-operated Earth Leakage
Circuit Breaker (ELCB) or Residual Current Circuit Breaker (RCCB) set to operate
at a very small leakage current is recommended. (This is usually marked 100mA
or 0.1A on the label). In case of dangerous electrical leakage to earth, it should
automatically cur off the supply of electricity.
• DO NOT use multi-way adaptors. Over loading can cause fire. One socket outlet is
for one appliance only.
• DO NOT carry out wiring extension, Engage a licensed wiring contractor for the
work.
• DO NOT use a two-way lighting adaptor for any extension.
• DO NOT connect any electrical appliance to lighting outlets. A lighting outlet does
not have an earth wire to prevent danger.

• DO NOT make joints to lengthen the lead of the electrical appliances. If the lead
wire is worn out or too short, replace it with a new wire.
• USE individual socket outlet for every electrical appliance.
• KEEP AWAY from danger areas such as a substation for whatsoever reasons.
• CHECK before carrying out excavation work to prevent damaging any
underground cable. The operator may receive severe electric shock or even be
electrocuted.
• TAKE PRECAUTION when working in the vicinity of overhead lines to avoid any
unforeseen incident. DO NOT meddle with any broken overhead wire. Report the
matter immediately to the nearest electric office.
• DO NOT climb any electric pole. You may receive an electric shock or get
electrocuted.
• NOT throw anything onto the overhead lines.
• NEVER attempt to retrieve anything stuck to overhead lines by whatever means.
• NOT climb transmission line towers. No one is safe from its high voltage shock.
• DO NOT erect any structure close to transmission lines.
• TAKE PRECAUTION when working in the vicinity of overhead lines to avoid any
unforeseen incident.
• NEVER stand on a damp or wet surface when using electrical equipment.
• USE a portable electrical tool, which is properly earthed.
• DO NOT tap electrical power without a proper plug.
• DO NOT use any electrical tool which has a damaged casing, cap, switch, lead or
plug.

7.9.6.2 First aid and emergency procedures

Burns can cause due acid spillage and leakage of electricity. Curative measures for any
issues of burns and First Aid procedures are given below:
Table 7.17First aid for burns
Burns covering small area Burns covering extensive area
Allow cold tap water to run gently over the Allow person to lie down.
area or immerse in cold water.
It may be necessary to cover with gauze or Cover burned areas with sterile dressing
a clean handkerchief, and bandage. or clean cloth and lightly bandage.

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If clothing is adhering, do not disturb;
leave the clothing alone.
Keep person warm. If person is not
nauseated, he may have sips of water.
Arrange for immediate medical care.

7.10 Public Hearing

“Public Hearing” refers to the process by which the concerns of local affected persons
and
others who have plausible stake in the environmental impacts of the project or activity
are
ascertained with a view to taking into account all the material concerns in the project or
activity design as appropriate. Since the proposed project of expansion is an synthetic
Organic chemical manufacturing unit falling under Category 5 (f)- B which is to be
located in well-developed Industrial estate i.e. Chikhloli MIDC, Hence, public
hearing is not required (Refer MOEF OM No. J-11013/36/2014-IA-I dated 10th
December 2014).
(http://www.moef.nic.in/sites/default/files/O.M%20Dated%2010.12.2014.pdf).

7.11 Social Impact Assessment, R & R (Relocation and rehabilitation)

action plan

Not Applicable (The proposed expansion is within existing plot of the company which is
located in notified industrial estate).

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Chapter 8– Project Benefits

8 PRO J ECT BENEF ITS

8.1 Improvement in Infrastructures

The proposed activity is to be carried out in MIDC industrial area and does not require any
additional infrastructure and the site is well connected so no major benefits in terms of direct
improvement in infrastructure is anticipated.
However, indirect improvement in public infrastructure may occur due to the CSR activities
by the company.

8.2 Employment Potential

The proposed peak manpower requirement during construction and commissioning will be
100 - 150 Persons and the operations & activities will require manpower of ~ 200 nos.
Recruitments will be done from local area which will be the considerable benefit to the local
area considering the demography of the region/project area. Further, the indirect
employment via increased transportation, ancillary units & local economic activities will also
add in the employment potential of the proposed project. Thus, the potential of employment
will be greatly beneficial to the local people.

8.3 Other Tangible & Intangible Benefits

Demand of chemicals proposed to be manufactured i.e. various API’s and intermediates are
increasing in India as well as in foreign countries day by day. Thus, the proposed project will
help the increase of export to many foreign countries. Successful exports by company, will
result in benefit to the country in form of foreign revenue, duties etc.
With this project, business for ancillary units like equipment manufacturers, machining
works, motor rewinding for regular maintenance, shut down annual and mechanical
consumable vendors, periodical painting works etc. thereby giving the indirect maintenance
people like equipment suppliers and various consumable vendors’ employment
opportunities.

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Chapter 9– Environmental Cost Benefit Analysis

9 ENV IRONMENTAL COST B ENEF IT

A NA LYS IS
This analysis is not carried out in this study as it is not recommended at scoping stage and not
specified in additional TOR. Also it is not considered as necessary as all the environmental
costs of the project are committed by the Project Proponent for implementation since they
are necessary measures for the environmental management of the project.

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10 ENV IRONMENTAL MANAG E MENT PLA N

10.1 Introduction

Description of the administrative aspects of ensuring the mitigative measures is implemented

and their effectiveness monitored, after approval of EIA are presented in this chapter.
Once mitigative measures are identified, an EMP is drafted as a joint activity by project
proponent and EIA consultant organization to detail out each activity required to accomplish
the proposed mitigation delineated in Impact Assessment section of this report.

o An EMP assures that the desired environmental management is communicated by the

management to the executing teams and members of the EHS cell in a systematic
manner without missing any vital / critical information.
o It helps the EHS cell in streamlining the role and responsibilities of the members and
their respective departments.
o The EMP also helps in formulating preventive measures in terms of inspections,
preventive maintenance, monitoring, etc. so that the performance of equipment and
manpower are verified periodically.

10.1.1 Objective & Scope of EMP

The Environmental Management Plan is prepared with the main objective of enlisting all the
requirements to ensure effective mitigation of adverse impacts for all the components of the
proposed project. The objectives taken into account in preparation of EMP are summarized
here as follows:
a. The prevention, control and abatement of pollution, i.e. air pollution, water pollution,
hazardous/ non-hazardous wastes and noise pollution,
b. To comply with the stipulated Enviro-legal requirements and standards,
c. To direct the steps to be followed, for effective maintenance and regulation of
environmental management system.
d. To ensure the better and safe work environment through pre-meditated planning of
prevention and control of hazards,
e. To direct the investments towards sustainable development by considering the cost of
effluent treatment, emission control, waste disposal, social development, green belt
development and health & safety in the planning stage only,
f. To account for recycling and reusing measures, proposed or required to be adopted
for minimization of consumption of resources and generation of pollutants.
As the proposed project is an expansion at the existing unit, the present EMP has been
prepared to meet the requirements of pollution control from existing & proposed project as
an integrated environment management plan. The present EMP may not be suitable &
feasible for any other upcoming activities other than those of the proposed project. The EMP

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does not cover scope of management of hazardous substance as it forms the key part of RA
study (Additional Studies).

10.2 Environmental Management systems

CENTAUR has established integrated HSE & Q management system at its manufacturing site,
IMS certificate and policy of the company is given below,

Figure 10.1 IMS certificate

Figure 10.2 HSE Policy

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10.3 Environment, Health and Safety (EHS) Cell

All the project activities will be monitored to ensure the appropriate implementation of all
Environmental mitigation activities and to identify areas where environmental management
plan compliance is not satisfied.

For effective implementation of the monitoring program, it is also necessary to have a

permanent organizational set-up. The unit has permanent environmental management cell
(EMC) for the effective implementation and monitoring of environmental management
system.

The unit will assign responsibility to officer from various disciplines and cadres to perform
and co-ordinate the activities concerned with management and implementation of
Environmental control measures.

In compliance with the requirement of EP Act and Factories Act, the unit has EHS cell to keep
a close watch on the performance of the pollution control equipment, emissions from the
sources and the quality of surrounding environment in accordance with the monitoring
program. The cell includes the safety cell for observing, inspecting and regulating the safety
measures inside the plant campus.
The EHS cell report directly to site head for environmental issues including non-compliances
and the board of directors are appraised through emails and other communication means.

Responsibilities of EHS cell are :-

o Collect information from regular monitoring and create database
o Analyze the data and decide thrust area.
o Carry out “project” in each thrust area to arrive at practical solutions to environmental
problems.
o Discuss the reports of study on environment and disseminate the information.
o Work out action plan for implementation of the recommendations made in the report.
o Prepare Management Information System (MIS) reports and budget for Environment
management program.
o To deal with the environmental issues and for ensuring compliance with the
Conditions prescribed by State pollution control board.
o Effluent Treatment plant operation, APCD’s, hazardous waste management, green belt
development, housekeeping, ambient air management, work area monitoring, safety
department and OHC / facilities etc. The activities are managed by systematic
assignment of responsibilities to each member.
o Monitor Health, Safety and Environment standards and practices
o Maintaining records of all the data, documents and information in line with the
statutory requirements and regularly furnish the same to the State regulatory
authorities.
o General prevention and maintenance of pollution control system as proposed to be
done by the maintenance department, to achieve optimum efficiency of the control
equipment and to maintain the quality of the environment.

Director

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Works Manager

Dy.Manager HSE

Assistant
Executive EHS
Manager (Safety)

HSE Officer Senior HSE Officer

Jr.HSE Officer HSE Officer

Jr.HSE Officer

Worker

Figure 10.3Environment, Health and Safety (EHS) Cell

EHS cell shall also act as safety department in compliance with the requirements of section 41
G & 41 H of Factories Act and 68 F & 68 J as per Factories Act with defined role and
responsibilities and defined framework covering all aspects of plant and personnel safety.

10.4 EMP for water environment management

10.4.1 Water consumption

The additional fresh water requirement for proposed expansion project is anticipated to be ~
278 CMD. It shall be fully supplied from MIDC and hence ground water levels shall not be
affected.

10.4.2 Water conservation measures

The process water consumption shall be optimized by the Centaur team by applying reuse
and recycling techniques, wherever possible.

Following are suggested measurs to further reduce fresh water consumption

• Water meters should be provided at main areas of consumption to maintain records
and to conduct water audit from time to time
• Drip irrigation for watering of green belt within plant premises
• Dry sweeping of passages and building floors in place of washing with water
• Water saving faucets in toilets and washrooms
• Centaur proposes to construct 1 nos. of Rain water storage tank ofcapacity 100 m3. It
is proposed to utilize rain water during monsoon season so as to reduce fresh water
consumption from MIDC.

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10.4.3 Waste water generation, treatment and disposal

Adequate waste water treatment provided with Primary, secondary and tertiary treatment.

• There shall be sufficient holding capacity for storage of treated and untreated effluent
(At least for 3 days)
• Proper housekeeping practices shall be followed in the unit to maintain clean and clear
environment and prevent contamination of surface runoffs and storm waters.
• The plant shall be provided with well-structured storm water drainage network for
preventing surface run-offs from mixing into sewers during monsoon.
• During monsoon, periodic monitoring of storm water shall be carried out to ensure
that it is not contaminated.
Proponent is committed for the following:
• To install online pH meters, flow and conductivity meters at strategic locations in the
treatment scheme in order to monitor performance of the treatment system.
• For performance monitoring of treatment systems, proponent shall provide and
maintain separate electric meter, operational logbook for effluent treatment systems.
• In house analytical laboratory for analysis of basic parameters of raw effluents as well
as effluent quality at various treatment stages shall be developed. Third party
sampling and analysis shall also be carried out.
• To take utmost care to prevent leakages from pipe fittings, valves etc., drains shall be
provided at all plants and tank farms to route such occasional effluents to effluent
treatment plant.
• Spill control procedures shall be practiced.
• To provide contingency storage capacity for at least 3 days of effluent generation.

Further to above following measures are suggested,

Consider EMP for unforeseen waste stream generation due to equipment breakdown or
emergency control

Causes or source of generation of wastewater stream can be -

- Spillage from drums, bags etc.
- Leakage from drums, bags, reactors, tanks, vessels, pipelines, valves, etc.
- Vessel washing, container washing

For such effluent generation, following measures should be taken,

All plant buildings handling chemicals shall be provided with drains which shall be connected
to separate collection tank for storage of such unexpected effluents. This effluent shall be
analyzed in laboratory for giving suitable treatment in controlled manner in the ETP.

Monsoon preparedness shall be implemented for following compliances

o Gate valves with shall be installed at all storm water outlets

o Maintenance of adequate freeboard in all open tanks / containers to prevent overflow
during monsoon

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o General Housekeeping in chemical storage areas to ensure that there is no spillage on
the ground which can mix with rain water and flow out of the industry

10.5 EMP for impact on noise levels

For noise abatement, following measures shall be taken –

▪ Use of acoustic enclosures for boiler and DG installations

▪ For minimizing and controlling noise levels, following measures are proposed

o Ear muffs and ear plugs to operating personnel / contract workmen

o Maintenance of pumps and machinery and all rotating equipment
o Maintaining the greenbelt since it also helps in reducing noise

10.6 EMP For Impact on Land Environment

o Storm water shall be collected and adequately drained.

o Pre-monsoon maintenance schedule for clearing storm water drain shall be carried
out.
o Appropriate precautionary measures to prevent contaminated run-offs from mixing in
storm water by regular analysis and necessary cordoning of process, ETP and storage
areas.
o All such areas which pose contamination of storm water should be provided with
drains going to ETP.
o Fugitive emissions and fugitive dusts shall be controlled.

10.6.1 Hazardous/Non Hazardous Waste Management

Storage

CENTAUR is committed to provide adequate facilities for collection, storage and disposal of
Hazardous and solid wastes in line with the requirements of Hazardous and Other Wastes
(Management and Transboundary Movement) Rules, 2016 and authorization granted by
MPCB.

o Wastes shall be segregated and stored in separate areas having covered roof and
concrete flooring.
o Appropriate leachate collection system shall also be provided. Leachate shall be sent
to ETP for treatment and recycle.
o It is also planned to explore possibilities for reducing manual handling of hazardous
wastes wherever possible – by packing the waste at place of generation, minimum
transport distances, transport in closed containers, minimum inventory of wastes.
o CENTAUR shall keep a vigilant check on the characteristics of each waste and review
storage and disposal methods periodically.

10.6.2 EMP for impacts on Social Environment

o Air emissions shall be controlled and monitored.

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o Effluent shall be treated and recycled within plant site.
o Ground water shall not be used.
o The plant sections shall be built with proper safety features and safety
equipment and devices at all required locations as per good engineering
practice and code.
o Fire hydrant system shall be provided to cover all plant facilities.
o Fire extinguishers shall be placed at all required locations of plant facilities.
o Safety and health of workers and all contract workmen shall be ensured
through proper SOPs, safety devices, fail-safe instrumentation, interlocks,
sound equipment, emergency control systems and procedures.
o Automation shall be used wherever possible and feasible
o Noise shall be controlled by –
▪ Placing of noise barriers along noise emitting area
▪ Ear muffs and ear plugs to workers
o Transporters shall be instructed to follow road safety and use well maintained
trucks and tankers
o Restrooms shall be provided for truck drivers and assistants
o Night time maintenance activities shall be avoided as far as possible

10.7 EMP for socio economic environment

o Proposed Man power: 200 Nos during operation phase

o Technical as well as non-technical recruitment shall be generated for skilled and
unskilled manpower
o CENTAUR is committed to give employment to locals according to skill and academic
qualification.
o Project specific training shall be imparted to enhance skills and increase employment
of local people.
o It shall also provide opportunities for trade and commerce and development of
ancillary businesses for the local people during construction phase and operational
phase, such as
▪ mechanical supplies,
▪ machinery services and repair work
▪ spare parts and accessories supplies
▪ canteen services and supplies,
▪ housekeeping,
▪ security,
▪ green belt maintenance,
▪ Contractual labor for packaging and other activities.

10.8 EMP for impacts on ecological environment

The management of air, water and land environment as proposed in the previous sections
shall ensure that there is no adverse impact on the terrestrial and aquatic ecology of the area.
CENTAUR proposes to develop green belt area within & outside plot. Green belt will be
developed in scientific manner to give screening effect to surrounding environment from
proposed facility.

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10.9 Environment management through housekeeping

Following are suggested good housekeeping practices,

▪ Prepare a check-list for maintaining good housekeeping in the plant premises.

▪ To regularly inspect the housekeeping in various sections of the plant
▪ The passages, floors and stairways should be kept in good condition
▪ Internal roads and major walkways as well as work areas should be carpeted either by
asphalt or paver blocks to minimize dusting as well as provide ease of transportation
and movement.
▪ Walkways should be free from obstructions, as well as marked
▪ All equipment and auxiliaries, piping should be labeled appropriately
▪ Piping Color code to be followed
▪ Wastes to be collected in separate containers with labels and marking in each
department and sent to common waste collection area in the factory for disposal.
▪ Spill Control procedures to be developed and given to shift in charge and all
concerned.
▪ Sweeping to be done in all departments on daily basis.
▪ Electrical wirings should be properly housed/ dressed
▪ Localized extraction and scrubbing facilities for dust and fumes should be provided
wherever required.

10.10 Occupational safety and hazard management

The chemicals involved in manufacturing processes are of toxic and flammable nature.

The major hazardous materials, their inventories and their hazardous properties are
tabulated in Chapter 2 and 7.

The unit is an MAH installation in accordance to the schedule 3 of MSIHC rules, 2000. The
probable hazards related to the various operations and processes have been assessed and
suitable control measures have been proposed. Details are provided in chapter 7 of this
report, which is summarized below,

Preventive Measures

Chilled water circulation, Flame proof fittings, Tank level control on DCS. CCOE License
premises,Earthing and Bonding, Tank insulated with suitable insulation, SOP for tanker
unloading, Flame arrester provided on tank Top, Lightning arrester provided near to tank,
Gas Leak Detectors.

Control Measures Provided :- Fire hydrant system, Portable Fire Extinguishers, Foam
Trolley,Water Hydrant and Monitor, Self-Contained Breathing Apparatus, Flame proof
electricals, Dyke wall for containment, Shower & Eye Washer near Tank Farm Area.

Following sections discuss on measures which shall be taken for fulfilling the requirements of
applicable statutory rules and regulations related to health aspects:

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First aid boxes:

In all plants / depts., First aid boxes (min. one no. in each plant or building) shall be installed
and all the necessary items shall be maintained. They shall be inspected on regular interval of
one month.

10.10.1 Occupational Health center (OHC)

Occupational Health Centre is nearmain gate. The OHC has necessary equipment and
arrangements for first-aid treatments in compliance with the requirements of Factories Act
and Maharashtra Factories Rules.

List of trained first aider which is trained approved organization shall be kept at all ECC as
well as in OHC and safety notice board to get help in organizing for medical help major
problem.

Antidotes for major chemicals handled by the unit are identified and listed and list is
maintained at OHC.

10.10.2 Onsite Medical treatment

Doctor shall be appointed as Factory Medical Officer (FMO) who shall visit the unit to attend
routine medical illness of workers and employees.

FMO shall also be responsible for carrying out pre as well as periodical medical examination.

There shall be ready to act preparedness for treating exposure to hazardous chemicals as
quickly as possible including oxygen administration at OHC.

10.10.3 Medical examination practice

o Pre-employment medical check-up of all employees and contract labor shall be carried
out by FMO and records shall be maintained.
o Full medical checkup of all employees as well as contract workers shall be carried out
half yearly and records shall be maintained.
o Health Register in Form No. 07 (prescribed under Rule 68 T and 102) shall be
maintained.
o Certificate of fitness shall be issued to workers by factory medical officer in Form No.
33.
Table 10.1Proposed Medical Examination Plan
Pre medical employment examination
Type of Test to be conducted By
employment (examining
agency)
For company - Physical Examination. External
employees as - Present complaints / illnesses Hospital
as well as - Family History

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contract - Past History
workmen - Hematology Profile - Complete Blood Count with
Differential Count, E S R & Blood Group & Rh factor.
- Urine Analysis
- Liver Profile - S G P T
- Kidney Profile - Blood, Urea, Uric Acid & Creatinine.
- Lipid Profile - Cholesterol, Trigycerides, HDL - Cholesterol
– VLDL Cholesterol,
- LDL Cholesterol, Cholesterol - HDL Cholesterol Ratio
(Risk Factor).
- X - Ray Chest - P A View
- E C G Signed by Cardiologist
- Blood Sugar

Six monthly medical examinations

Type of Test to be conducted By
employment (examining
agency)
For company - Physical Examination. Factory
employees as - Present complaints / illnesses medical
as well as - Family History Sergion
contract - Past History
workmen - Hematology Profile - Complete Blood Count with
Differential Count, E S R
& Blood Group & Rh factor.
- Urine Analysis
- Liver Profile - S G P T
- Kidney Profile - Blood, Urea, Uric Acid & Creatinine.
- Lipid Profile - Cholesterol, Trigycerides, HDL - Cholesterol
– VLDL Cholesterol,
- LDL Cholesterol, Cholesterol - HDL Cholesterol Ratio
(Risk Factor).
- X - Ray Chest - P A View
- Pulmonary Function Test
- E C G Signed by Cardiologist
- Blood Sugar
- USG – for chemicals which are toxic on liver (once in a
year frequency)
- Phenol in urine

10.10.4 Fund allocation for Occupational Health and Safety measures

Appropriate fund allocation shall be done for implementing Occupational Health and Safety
measures as delineated in Safety Manual of the company and standard procedures and
directions.

Towards management of occupational health and safety in the unit, provisions to be made for
maintaining an efficient system are described hereunder:

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o Safe and ergonomic design and layout of plant, machinery, tools and control
equipments keeping in view the safety and pollution prevention in mind.
o In-house Training programs as well as programs with help of outside agencies on
Health hazards and safety for the workers and staff. Trainings shall cover topics on fire
fighting, awareness training for hazards, first aid etc.
o Proper handling of all spillages by introducing spill control procedures for various
chemicals.
o Sufficient lighting, ventilation, drinking water facility, sanitary blocks, firefighting and
first aid arrangements.
o SOPs for all operations and critical equipment
o Work permit system for specific task
o PPE as per operations shall be provided and it shall be ensured that workers make
proper use of PPE
o Regular workplace monitoring as per Maharashtra Factories rule to be carried out and
records maintained in prescribed form 37.
o Material safety data sheet for all the concerned materials to be available at the site.
o Adequate firefighting equipment’s provided at relevant areas.
o Fire alarms and LEL detectors to be installed in process plants and storage areas.
o Emergency telephone numbers displayed at required places.
o Planned schedule for inspections of safety devices shall be followed and records shall
be maintained.
o On-site emergency plan to be prepared practiced and upgraded periodically.
o Regular emergency mock drills to be carried out
Following suggestions shall be considered by CENTAUR,

All aspects of Industrial hygiene and occupational health such as

▪ Noise minimization,
▪ Proper illumination at all floors,
▪ Minimum exposure to fugitive emission while charging,
▪ Proper plant layout and equipment design to provide correct working postures and
body postures,
▪ Suitable platforms and ladders to minimize accidents due to movements, etc

shall be considered at the time of detail engineering of the project.

o Since there are more than one main raw material for many of the products, it is
suggested to implement stringent three level permit system for raw material issue
from warehouse and tank farms before indenting in process plants so as to minimize
misoperation and batch failures due to miscommunication or operator flaws and
errors. A good record keeping practice should be maintained. Store activities need to
be given due importance and handled by qualified personnel.
o Ensure that the transporters of hazardous chemicals are provided with PPE and carry
TREM cards during transportation

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10.11 Environment Budget Allocation
Refer Table 6.3 for the details break up of Environmental management bydget.

10.12 Energy Conservation measures

o Steam condensate shall be returned back as far as possible

o Boiler blowdown shall be controlled by automatic system to save heat up losses
o Batch processes shall be monitored stringently for heating and cooling operations so
that there is minimum loss of energy and material by way of temperature, pressure
and flow controls.
o Level sensors and alarms shall be provided on day vessels to prevent unnecessary
pumping energy losses
o Insulations shall be maintained and damaged insulations shall be attended
immediately to prevent heat losses
o LED lights shall be provided to conserve electrical energy
o Solar panel of 20 KW is already installed at site and there is proposal to intall solar
panel of 200 KW.

Figure 10.4Solar panels installed at site

10.12.1 Financial Provisions for EMP Implementation

Costs for pollution control, monitoring and management will be included in the account
under separate head in CAPEX as well as OPEX provisions.

10.12.2 Authorities Responsible for EMP Implementation

• Structural measures (such as installation of MEE/ATFD, RO, ETP up gradation,

Tanks, preventive and protective equipment etc): Directors, Project manager,
accounting head/manager, Site Officer & engineers, Contractors.
• Non-Structural (SOP’s, studies, implementing systems etc): Directors, Production
manager, accounting head/manager, Plant in-charge, safety & environment Officer &
engineers, Contractors & operators.

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10.12.3 EMP Implementation Schedule

• Structural measures identified will be provided in construction phase prior to

commissioning of plant operation.
• Maintenance will be done throughout the extent of operation phase.
• Proper installation of pumps, motors will be done well before commissioning to
prevent wastage & efficient use of water
• The non-structural actions will be initiated with inception of commissioning stage and
will be implemented & practiced as routine throughout the project life.

10.13 Reporting

The proponent shall prepare & submit quarterly/half yearly reports regarding
implementation of the environmental management program as described in conditions of
various licenses/certificate of clearance like EC, CTO, CC etc. which will be submitted to
concerned authorities is as listed below:
• Board of Director through MD & General/Production manager.
• Maharashtra Pollution Control Boards & other authority as required by regulatory
provisions.
Other organizations/firms as directed timely by Board of Directors or General/production
Manager or Govt. authority like MoEF, MPCB, and CPCB etc.

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Chapter 11– Summary & Conclusion

11 S UMMA RY A ND CO NCLU S I O N

11.1 Introduction

As per EIA Notification S.O. No 1533 dated 14th Sep 2006 the proposed expansion
project falls under Project / Activity 5 (f) (Synthetic organic chemicals industry (dyes &
dye intermediates; bulk drugs and intermediates excluding drug formulations; synthetic
rubbers; basic organic chemicals, other synthetic organic chemicals and chemical
intermediates), Category “B” and requires environmental clearance from SEAC-I,
Environment Department, Maharashtra.

The proposal was considered by the State Level Expert Appraisal Committee in its 142nd
SEAC – I meeting dated 14th September 2017 for determination of the Terms of Reference
(TOR) for undertaking detailed EIA Study in accordance with the provisions of the EIA
notification dated September 14, 2006 (Item no 12 of the Agenda).

11.2 Company and Project proponent

Centaur Pharmaceutical Private Limited has its existing facility for manufacturing of API
and intermediates at Plot No. 74, 75, 76 & 76/1 at MIDC Chikhloli Dist. Thane. Centaur
wish to expand its manufacturing base at this plant site.

11.3 Project Description

Existing and proposed product and capacities are as follows,

Table 11.1 Total Products and its capacity
N Product / By product Existing Proposed Total
o Capacity (*) capacity kg/annu
kg/annum kg/annu m
m
1 HYPNOTIC/SEDATIVE/TRANQUILIZER/ANXIOLYTIC/
ANTICONVULSANT/ANASTHETIC/ANTIDIABETIC (BREAK UP OF IT AS BELOW)
Group I (Nitrazepam, Clonazepam, Bromazepam, 5773 13975 19748
Diazepam, Clotiazepam, Flurazepam Mono
hydrochloride, Tetrazepam, Delorazepam,
Clobazam, Phenazepam)
Group II (Alprazolam, Oxazepam, Lorazepam, 5751 13922 19673
Zolpidem Tartrate, Triazolam, Etizolam,
Temazepam)
Group III (Zopiclone (058) 5726 13862 19588
Group IV (Chloridazepoxide, Zaleplon, Sodium 4759 11520 16279
Oxybate, Stiriepentol, Brivaracetam, Empagliflozin,
Dapagliflozin, Saxagliptin, Sitagliptin, Teneligliptin,
Linagliptin, Vildagliptin, Chlorodiazepoxide
hydrochloride
Group V (Midazolam base, Midazolam HCl, 348 843 1191
Midazolam maleate, Clorazepate Di Potassium,

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Chapter 11– Summary & Conclusion
N Product / By product Existing Proposed Total
o Capacity (*) capacity kg/annu
kg/annum kg/annu m
m
Brotizolam, Loprazolam Mesilate, Propiomazine
Maleate, Propiomazine HCl, Prazepam, Estazolam,
Fludiazepam, Flunitrazepam, Lormetazepam,
Pinazepam, Es-Zopiclone)
2 ANTIDEPRESSANT/CNS STIMULANT 3276 3969 7245
(Nortriptyline HCl, Melitracen HCl,
Tranylcypromine Sulphate, Amoxapine, Loxapine
Succinate, Loxapine HCl, Methylphenidate HCI,
Dixmethylphenidate HCl)
3 ANTIGLUCOMA/ANTIHISTAMINIC (Brimonidine 756 1213 1969
Tartrate, Timolol Maleate, Dorzoamide HCl,
Chloropyramine HCl, Olopatadine HCl)
4 ANTIPROTAZOAL (Nimorazole) 180 495 675
5 ANTIPSYCHOTIC/ANTIPYRETIC/ANTI- 1932 6355 8287
INFLAMATORY/ ANALGESIC /ANTI-ULCER
(Rebamipide, Acotiamide HCl Hydrate,
Fluphenazine HCl, Flupentixol, Dihydrochloride,
Aripiprazole, Flupentixol Decanoate, Fluphenazine
Decanoate, Asenapine Maleate, Benzydamine HCl
USP, Zuclopentixol Acetate /HCl/Dacanoate,
Brexpiperazole Diperoxochloric Acid Concentrate,
Pimavanserin, Mexazolam Quinagolide)
6 ANTIEMETIC (Metopimazine, Nabilone) 60 507 567
7 ANTISPASMODIC/MUSCLE RELAXANT 3900 19109 23009
(Chlorzoxazone, Tiemonium Methyl sulphate,
Pitofenone HCl)
8 ANTIDYSKINETIC/DIURETIC/SNR 360 674 1034
INHIBITOR/CHOLINERGIC/URINARY
INCONTINENCE (Tetrabenazine, Metolazone(36),
Milnacipran HCl, Levomilnacipran HCl,
Fampyridine, Rivastigmine Hydrogen tartarate ,
Valebenazine, Deutetrabenazine , Propiverine HCl)
9 HYPERTENSION/ANTIHYPERTENSION (Pindolol) 24 111 135

10 PLATELET INHIBITOR (Prasugrel) 12 18 30

11 ANGINA 12 (-)12 0
12 ANTIVIRAL 12 (-)12 0
13 ANTI CARDIOVASCULAR 12 (-)12 0
14 CALCIMIMETIC 24 (-)24 0
15 ERECTILE DYSFUNCTION 12 (-)12 0
16 IRREVERSIBLE INHIBITOR OF MONOAMIDE 12
(-)12 0
OXDASE
17 R & D ACTIVITY & OTHERS (Tolterodine, 240 360 600
Silodosin, Voriconazole, Ezetimibe, Solifenacin,
Amitriptyline HCl, Pyridostigmine Bromide,
Indapamide, Acetazolamide, Clidinium
bromide)

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Chapter 11– Summary & Conclusion
N Product / By product Existing Proposed Total
o Capacity (*) capacity kg/annu
kg/annum kg/annu m
m
TOTAL 33180 86850 120030
18 Recovered solvent 120 MTPA 2880 3000
MTPA MTPA
(*)Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023
Total plot area is 9,105 sq.m and proposed project cost is ~ Rs. 90.50 Crores.

11.3.1 Energy requirement and its management

The existing & proposed stacks and fuel burning sources are / will be as below,
Table 11.2 Fuel burning sources details (Existing & Proposed)
Unit Status Fuel details Stack height Stack Exhaust
from ground & dia gas temp
APC system deg C
600 kg/hr Existing LSHS/LDO 300 20 m (common) 0.3 m 130
steam boiler lit/day
600 kg/hr Existing
steam boiler
(stabdby)
Process Existing - Alkali scrubber 0.3 m 42
reactor (10 m)
Process Existing -
reactor
Boiler Proposed FO: 1.46 KL/day or 40 (APC : stack 0.5 m 150
(capacity NG - 1700 nm3/day height)
1000 kg/hr)

Boiler Proposed FO: 7.30 KL/day

(capacity ORNatural Gas:
5000 kg/hr) 8000 Nm3/day
[To replace
existing 600
kg/hr boiler]

Boiler Proposed
standby standby
(capacity
5000 kg/hr)
[To replace
existing 600
kg/hr boiler]

Process Proposed - Water scrubber 0.3mreq 42

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reactor uireme
mt
Process Proposed - Alkali scrubber As per 42
reactor require
memt
(*)Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023

11.3.2 Electricity requirement

Electricity requirement of 3000 Kw for the proposed expansion shall be met from
MSEDCL.

For emergency requirement there are two DG sets (380 and 40 KVA capacity).

For expansion need it is proposed to install 2 DG set of 1000 KVA and 750 KVA capacity.
Table 11.3 Fuel for DG sets
Unit Status Fuel details Stack height Stack dia Exhaust gas
from ground temp deg C
DG set 380 KVA Existing 260 12 m 0.1 m 115
DG set 40 KVA Existing lit/month 12 m 0.1 m 104
DG set 1000 Proposed HSD: 250 6.5 m above 0.2 m 115
KVA Lit/hr roof
DG set 750 KVA Proposed HSD: 175 5.5 m above 0.2 m 104
Lit/hr roof

Water requirement
The total water requirement will about 407 cmd (Existing 129 cmd & Proposed 278
cmd) for domestic, process, cooling tower, and boiler and for green belt maintenance
purpose. Fresh water will be sourced from MIDC.
Table 11.4 Total Water requirement (Existing & Proposed)
No Water requirement Break Up Existing Proposed Total
(cmd)(*) (cmd) Quantity
(cmd)
1 Domestic 12 13 25
2 Industrial Process 25 60 85
3 Boiler feed & Cooling 82 185 267
4 Gardening 10 20 30
Total 129 278 407
(*)Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023
Effluent generation, treatment and disposal
Effluent generation from the proposed project shall be from domestic, process, cooling
tower blow down, boiler blow down, equipment washing, floor wash etc.

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Total effluent generation post expansion project is 94 cmd (20 cmd domestic and 74
cmd trade effluent).
Treated effluent will be sent to CETP facility.
Table 11.5 Waste water generation and disposal (existing & Proposed)
No Waste water Quantity (CMD) Total Disposal
from Existing(*) Proposed
additional
1 Domestic 9 11 20 Treated waste water
2 Trade effluent 12 62 74 will be sent to CETP.
Total 21 73 94
(*)Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023
Waste generation and its management
Nonhazardous and Hazardous waste generation from the proposed activity is given
below:
Table 11.6 Non-hazardous waste generation and disposal pathway
Existing Proposed
No. Type of waste UOM Quantity add. Total Mode of Disposal
(*) quantity
1 Empty drums Nos./Month 500 4,000 4,500 Sale to authorised recycler
2 Glass bottles Kg/Annum 3600 10,000 13,600 Sale to authorised recycler
3 Plastic bags Kg/Annum 1680 4,400 6,080 Sale to authorised recycler
Corrugated
4
sheets
Kg/Annum 1200 0 1200 Sale to authorised recycler
5 Metal scrap MT/Annum 8.5 11.5 20 Sale to authorised recycler
6 Paper waste MT/Annum 0 5 5 Sale to authorised recycler
7 Plastic waste MT/Annum 0 4 4 Sale to authorised recycler
8 Rubber waste MT/Annum 0 1 1 Sale to authorised recycler
Sale to authorised
9 Boiler Ash MT/Annum 0 15 15
recycler/ CHWTSDF
10 Wooden waste MT/Annum 0 1 1 Sale to authorised recycler
(*)Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023
Table 11.7 Hazardous waste generation and disposal pathway
No Description Category UOM Existing Proposed Total Mode of Disposal
(as per HW Quantity add.
rules 2016)
(*) quantity
1 Sludge and filters 3.3 TPA 0 2 2 CHWTSDF
contaminated
with oil
2 Used or spent oil 5.1 TPA 4.8 10 14.8 Sale to authorized Re
processor/CHWTSDF
3 Wastes or 5.2 TPA 0.1 0.2 0.3 CHWTSDF
residues
containing oil
4 Discarded 15.2 TPA 0 0.8 0.8 CHWTSDF
Asbestos

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No Description Category UOM Existing Proposed Total Mode of Disposal
(as per HW Quantity add.
rules 2016)
(*) quantity
5 Process residue 28.1 TPA 2.4 660.6 663 CHWTSDF
and wastes
6 Spent carbon 28.3 TPA 6 248 254 CHWTSDF
7 Off specification 28.4 TPA 0 5 5 CHWTSDF
products
8 Date-expired 28.5 TPA 0 5 5 CHWTSDF
products
9 Spent solvent 28.6 TPM 5 395 400 Sale to authorized
Reprocessor/CHWTSDF
10 Empty barrels 33.1 Kg/M 0 2000 2000 Sell to authorized
/containers/liners Reprocessor/CHWTSDF
s contaminated
with hazardous
chemicals /wastes
11 Contaminated 33.2 TPA 0 1 1 CHWTSDF
cotton rags or
other cleaning
materials
12 Exhaust air or gas 35.1 TPA 0 3 3 CHWTSDF
cleaning residue
13 Spent ion 35.2 TPA 0 0.5 0.5 CHWTSDF
exchange resin
containing toxic
metals
14 Chemical sludge 35.3 TPA 0.96 149.04 150 CHWTSDF
from waste water
treatment
15 Filter medium 36.2 TPA 0 2 2 CHWTSDF
16 E waste - Kg/M 75 425 500 Sale to authorized
Reprocessor/CHWTSDF
17 Biomedical waste - Kg/year 0 100 100 CHWTSDF
18 Used batteries - Nos/year 0 100 100 Sale to authorized
reprocessor / Buy back

(*)Consent to Operate No Format 1.0/ BO/ CAC Cell/ UAN No. 0000044143/R/5th CAC-
1812000081 dated 29.11.2018 valid upto 30.04.2023

11.1 Description of the Environment

11.1.1 Study period and area

Baseline environmental study/ monitoring is carried out during Winter 2017-18

(November, December, January) within 10 km radius of the proposed site to understand
ambient air quality, water quality, soil quality, noise level, biological study and socio-
economic status of study area.
Soil monitoring was carried out at 8 locations. AAQM monitoring was carried out at 8
locations. Noise monitoring was carried out at same locations of AAQM. Ground water
samples were collected from 8 locations & surface water locations were collected from
12 locations.

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11.1.2 Land use and Land cover

Scrub land (24.7%) and Built up land (23.80%) dominates the land use pattern within
the 10 km angular distance around project site.
It is followed by Fallow Land contributing 16.10%. Barren/Query/sandy area is 10.0%,
Land with shrub 9.1%, Agricultural Crop Land is 7.5% whereas part of land is Open
Forest (5.8%) and open land (5.8%) and part is Dense Forest (2.4%). Plantation and
water bodies occupy about 2.1% and 1.9 % land respectively.

11.1.3 Meteorology

MIDC Chikhloli falls in Raigad district which has warm & humid weather throughout the
year.
The area receives rainfall for more than four months of the year, which provides main
climatic variations. Out of total rainfall 90% is experienced during Monsoon season of
months June to August.

11.1.4 Soil
Based on the soil analysis for its physical and chemical properties, It is observed that
• Soil in the area is mainly clay in texture hence low water holding capacity.
• pH of soil varies from 6.42 to 6.78 which is as per above reference table is from
“Moderetly acidic” to “Neutral”.
• Conductivity of soil is observed within range of “Average” i.e. from 324.6 µS/cm
to 689.2 µS/cm.
• Potassium content in the soil samples varies from 34 kg/Ha to 72 kg/Ha which is
“very less”
• % TOC is observed in range of 0.08 % to 0.12 % which is very less.
• Phosphate content in the soil is Not detected
From above observation, it is observed that the soil is having low content of
macro nutrient.
11.1.5 Ambient Air Quality

The broad findings of the ambient air quality monitoring are as follows:
• Average Concentration of PM10 is varying from 58.4 μg/m3 to 62.8 μg/m3. The
maximum concentration is mainly due to transportation / industrial activities
within study area.
• Average Concentration of PM2.5 is varying from 18.1 μg/m3 to 22.0 μg/m3. The
maximum concentration is mainly due to transportation along MIDC road within
study area.
• Average Concentration of SO2 is varying from 10.8 μg/m3 to 12.3 μg/m3. The
maximum concentration is mainly due to industrial activities in study area.
• Average Concentration of NOx is varying from 17.9 μg/m3 to 20.0 μg/m3. NOx
levels are higher due to industrial activity/ fairly high traffic along MIDC road.

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• Average Concentration of CO is varying from 0.17 mg/m3 to 0.25 mg/m3. The
maximum concentration is mainly due to transportation & high traffic.
• nMHC values varying from 0.02 to 0.03 ppm.
Results are compared with National Ambient Air Quality Standards (NAAQ) in respect of
monitored parameters. As can be seen the results, ambient air is well within the NAAQS
standards for Industrial and Residential areas.

11.1.6 Noise

Industrial area: From results it was observed that noise levels in MIDC location is within
standards.
Residential area: Noise levels were found to be exceeding the standard at Vasat Phata
and Vasat village marginally during night time.

11.1.7 Ground Water Quality

Baseline water samples were collected at 8 locations in study area (3 from MIDC tap
water and 5 from open wells). It is observed that all parameters of samples meet
Drinking water standards except coliform at well water. Out of 8 samples, 5 well water
samples show presence of coliform. Presence of coliform is mainly due to sewage
contamination from nearby areas.

11.1.8 Surface Water Quality

Surface water grab samples were collected from following 12 locations.

Based on analysis, surface water analysis mostly falls under classification C& E as per
class of water standard IS 2296-1982.

11.1.9 Biological Environment

Thane is one of the coastal districts of Konkan. Geographically it contributes to hills, mid
lands and lowlands comprising the wide amphitheatre like basin of the Ulhas and the
hilly Kalu river basin together with plateaus forming the Sahyadrian scarp. The most
rugged terrain of the district is a belt about 15-25 km broad that runs parallel to the
coast at a distance of 15-20 km from the shore.

Study area under consideration encompasses part of Kalyan, Ulhasnagar talukas of

Thane district and Panvel and Karjat talukas of Raigad district. According to bio-
geographical zone classification of India, study area falls under ‘Western Ghats –
Malabar Palins’. One village (Pashane in Karjat Taluka) in study area is listed as
Ecological Sensitive Area, in directions under section 5 of Environment Protection Act
1986, dated 13th November 2013, issued by MoEF&CC. Matheran Eco-sensitive Zone
boundary (another notified eco-sensitive area) is located about 2 Km towards South
from plot. Ecology & Biodiversity study pertaining to Environmental Impact Assessment
report for the establishment organic chemical manufacturing facility at plot in

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additional Ambernath MIDC by Centaur Pharma Industries pvt. ltd. was carried out in
winter 2017-18. There is no wildlife sanctuary/national park within study area.

11.1.10 Socio economic environment

The Socio economic study spans a radius of 10 kms around the proposed project site
and covers parts of Ulhasnagar, Ambernath and Kalyan tehsil of Thane District.
Study area comprised under Ambarnath, Kalyan & Ulhasnagar tehsil of Thane district.
Total study area split into 74 villages from rural portion and 6 towns as a part of urban
area. 55% study areas covered under Ambarnath tehsil followed by 44% in Kalyan
tehsil.
Socio-economic survey was conducted in 17 villages of the study area located in all
directions & distances with reference to the proposed project site.
The significant features of the demographic structure are given below:
• Total population of the study area is 2412630 out of which 1266059 (52 per
cent) are males and 1146571 (48 per cent) are females.
• There are 567471 households in the study area with average family size is 4.3
persons per household as per 2011 census.
• Sex ratio (No. of females per 1000 males) is 906 which indicates that females are
less in number than their male counterpart in the study area. Proposed project
site is located at Chikhloli MIDC, Ambernath west which itself is a part of urban
area – Ambernath town & its surrounded area i.e. Badlapur, Kalyan & Dombivali
& Ulhasnagar all are towns and fully urbanized & commercially & industrially
developed areas as well as closed proximity to Mumbai international trade
Centre so high migrant population of male workers may be the one factor that
leading to low sex ratio in the study area. But during 2001 – 2011 sex ratio of
study area has been improved by recorded an increase of 20 points from 886 to
906.
• The child population 0 - 6 years account for about 10.4% of the total population
• 91.9% population of the study area lives in urban area.

Infrastructure facilities / Civic Amenities

• Educational sector in towns such as Ambarnath, Badlapur, Ulhasnagar, Kalyan&

Dombivli is well – developed with many famous and well – known schools and
institutes. But in rural region primary educational facilities are available in all
villages followed by middle schools in 61% villages.
• Primary health care is provided by city and district hospitals and rural primary
health centres (PHCs). These hospitals provide treatment free of cost. Primary
health care is focused on immunization, prevention of malnutrition, care during
pregnancy, child birth, postnatal care, and treatment of common illnesses.

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• Both open & closed drains reported in all the towns while in rural region open
drainage system is observed in 65% villages & in balanced villages there are no
drains as per 2011 census data.
• Electricity facility is available in all towns & all inhabited villages which is
usable for all purposes i.e. domestic, commercial & industrial etc. in the study
area.
• Fire Fighting Service is available in all towns (Ambarnath, Badlapur,
Ulhasnagar, Kalyan& Dombivli).

11.2 Anticipated Environmental Impacts and mitigation measures

11.2.1 Air environment

Impact on air environment is anticipated due to proposed addition of 1 TPH and 5 TPH
FO/ NG fired boilers. The increase in fuel requirement will have increase in SO2, PM and
NOx contents of the region.
Mitigation Measures for Air Quality Impacts
Following mitigation measures are planned and suggested in view of air environment
during operation phase:
1. Boilers:
Installation of cyclone separator followed by bag filter
Stack of sufficient height for Boilers.
Regular monitoring for fuel burning stacks through MoEFCC approved laboratory

11.2.2 Noise

Noise & vibrations generated from the equipment & machineries including pumps,
motors, blowers etc. will add to occupational noise level, exposing on site to high noise
which can lead to hearing loss.
The expansion project is within Chikhloli MIDC. The impacts of the noise sources will be
restricted within the premises only and will be within the prescribed norms of
industrial area as well as occupational exposure.
Mitigation Measures
• Low noise generating equipment and working methods for production unit shall be
selected to reduce noise generation in plant areas.
• Proper mounting of equipment & machinery on strong non-vibrating foundation &
fitted by proper shunting & rubber padding to avoid vibration and thereby noise.
• Provision of ear protection equipment (ear plug/ ear muff) for activities that are
likely to create noise in excess of 75 dB (A) to protect worker’s health and safety.

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• Undertake in plant audit to identify high noise level generating equipment.
• Preventive maintenance including regular lubrication of machineries and
equipment to reduce noise level.
• Static & dynamic balancing of all rotating equipment & machineries shall be done
on regular basis starting from the installation time to reduce the vibration & noise.
• Regular noise monitoring shall be done as per environment monitoring plan
chapter 6.
• The impacts of noise on occupational health would be mitigated by proper shift
timing & annual audiological checkup of concern employees. Workers showing
hearing loss, if any, will be shifted to other less noisy areas.
• Dense Greenbelt development around the noise source area and along the boundary
of premises shall be done.

11.2.3 Water & wastewater

As seen in chapter 2, total water requirement during operation phase will be ~ 407
cmd, which will be from MIDC.
Post expansion project, effluent generation will be 94 cmd (domestic ~ 20 cmd and
trade effluent ~ 74 cmd). Treated waste water will be sent to CETP.
Impacts on water resources may also occur as secondary impacts of soil contamination
as well as runoff of contaminated water from premises resulted due to the spill/ leak of
hazardous chemicals or from leachates from hazardous waste storage areas.
Centaur is proposing full-fledged combined ETP facility for treatment of waste water.
Detailed ETP scheme is described in Chapter 4.

11.2.4 Land

Major concern in land environment during operation phase is contamination of land by:
• ETP sludge
• Spill and leak during transport, handling, storage activity of chemicals
• Spill of oil and greases during maintenance of equipment, machineries and
vehicles
• Improper storage/dumping of hazardous wastes, resulting in leachate
contaminating the soil
• Contaminated runoff from site and contaminated drain from storage areas of
hazardous wastes and chemical storages, tanker loading/unloading areas
draining to land
• Transportation in tanker or drums through national highway, which may have
considerable impacts on environment of the area falling in the route of the
transportation. During the incidence of major accident, the hazardous materials
being transported can have serious impacts on land where on it spilled or leaked.

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• Mitigation measures
• ETP sludge shall be disposed to CHWTSDF facility
• Production, maintenance area and warehouses for storage of raw materials,
finished products and hazardous wastes will be provided with impervious
flooring.
• All bulk storage tanks will be provided with adequate dyke walls to prevent
spreading of spill or leaked chemicals causing contamination of soil.
• Necessary cleanup procedures (SOPs) for the specific area will be designed and
implemented.
• Used oil from machineries/equipment etc. will be collected in drums & disposed
off a per norms.
• ETP facilities for management of effluents will be provided as planned during
erection and commissioning phase and untreated effluents will not be disposed
off on land.
• The chemicals used will be transferred through closed pipelines by DCS control
system to avoid/prevent spill/leak of the materials.
• Hazardous waste management will be done as per statutory guidelines &
requirements. ETP sludge generated is dried in mechanical dewatering system
and stored on sludge drying beds or kept in sacks in covered godowns, with
impervious flooring sloping so that any leachate will be collected and taken back
for treatment.
• Discarded containers will be decontaminated and sale to MPCB authorized party.
• All transportation of hazardous wastes will be done in closed truck/tanker by
MPCB approved agencies
• HAZMAT guidelines will be followed for transport of all hazardous materials. All
required safety & emergency equipment & materials will be provided on the
transport vehicles.
• Proponent will maintain a good spill or leak control action plan to cope up with
such incidents.
• Monitoring of soil samples in areas near hazardous waste storage will be done as
per Environmental monitoring plan.
• No waste will be stored on open barren land under any condition

11.2.5 Biological environment

Operation phase involves transportation of raw material, work force and finished
goods; operation of machineries etc. this leads to increase in noise levels at site;
however industrial area has several other noise sources, which overall establishes
background noise level for MIDC area.
Considering baseline environmental conditions, air dispersion modeling has been done,
which indicates, incremental concentrations of gaseous pollutants together with

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existing baseline concentrations are lower than threshold limit specified in CPCB
publication, March 2000 for Green belt Development.
Greenbelt will be developed includes periphery plantation, road side plantation and
plantation around various buildings.
For particulate and noise abatement, two rows of trees will be planted around the
boundary of site wherever possible. Green belt will be developed in two levels i.e. tall,
native and evergreen broad leaved species towards outer periphery whereas dwarf and
native species towards inner side of it. This arrangement provides better screening
effect.

11.2.6 Socio economic environment

Impacts on socio-economic environment due to proposed project during operation

phase are envisaged due to direct and indirect employment which will be beneficial.
The proposed project will have positive effect on socio – economic environment as
there will be growth in employment for direct / indirect workers. During employment,
local populace will be given preference considering their skills & suitability.
Centaur proposes Rs. 90.5 Lakhs for its CER activities spread over 7 years.

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11.2.7 Environmental monitoring program

Sr. Project Phase Environmental Parameters Frequency Locations Conducted

No. Component by
1 Construction Air Environment
Ambient air PM10 / PM2.5/SO2/ NOx / CO Once/Month Adjacent to new MoEF
construction site approved
Ambient Noise Leq day and night time or over one work Once/Month At new Laboratory
Level shift construction site
Water Quality
Drinking Water Microbiological parameters as per IS Once/month Construction site - MoEF
Quality 10500 : 2012 each drinking approved
water locations. Laboratory
2 Commissioning Air Environment
Stage Ambient air PM10 / PM2.5/SO2/ NOx/CO/NMHC/ Once/Month Adjacent to new MoEF
construction site approved
Laboratory
Ambient Noise Leq day and night time or over one work Once/Month Adjacent to new MOEF
Level shift construction site approved
lab
Water Quality
Drinking Water Microbiological (as per IS 10500: 2012) Once/month at each drinking MOEF
Quality water locations. approved
lab
In plant ETP pH, TSS, TDS, COD, BOD and Oil and Grease Once/shift Plant/sectionwise In house lab
effluent and
periodically
through
MOEF
approved
lab

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Sr. Project Phase Environmental Parameters Frequency Locations Conducted
No. Component by
Waste
Generated
Spent As per Schedule II of HW Rules, 2016 and Once Spent catalyst CHWTSDF
carbon/Chemical parameters for identifying disposal sample or MOEF
sludge from pathway as per CPCB approved
waste water lab for
treatment identifying
disposal
pathway
Process residue As per Schedule II of HW Rules, 2016 and Once From process plant CHWTSDF
and waste parameters for identifying disposal or MOEF
pathway as per CPCB approved
lab for
identifying
disposal
pathway
3 Operation Phase Air Environment
Existing and new TPM/ SO2/ NOx Once/ month Plant MoEF
Stacks - Boiler approved
Existing / new Ammonia / Particulate matter/acid mist Once/ month Plant Laboratory
Process scrubber
Stacks
Ambient Air PM10 / PM2.5/SO2/ NOx/ CO/ NMHC/ once/month At 3 locations, MoEF
Workroom SPM/MDC/Acetonitrie/IPA/Methanol/ Once/ 3 Plant / Storage/ approved
environment Cyclohexane/Ethyl acetate/Acetone months handling Area: Laboratory
Oxygen Content/LEL As per Before vessel / Own
requirement confined space laboratory
entry
Water Environment

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Sr. Project Phase Environmental Parameters Frequency Locations Conducted
No. Component by
ETP Operational parameters like pH, TSS, COD, Daily Plant Own QC lab
BOD, TDS etc
All parameters as per MPCB Consent. Once/month At inlet and outlet MoEF
of ETP recognized
laboratory
Drinking water Microbiological parameters as per IS Once / 6 at each drinking MoEF
10500 : 2012 month water locations. recognized
laboratory
Noise Environment
Ambient Noise Leq (day & night) Once/ 3 at fence level and
month at nearest habitats.
Workroom noise Leq (8 hours) Once/ 6 near noise MoEF
month producing sources approved
like DG set, Boiler Laboratory
house etc.
Biological Environment
Ecological survey Study growth of trees at site as per plan Once every 3 At site QCI NABET
and identify new species for plantation years approved
Biological
expert
Land Contamination
Soil / Ground For specific contaminants of spilled Regularly At/near site of MOEF
water Quality chemicals until no spillage approved
traces laboratory
noticed
4 Decommissioning Ambient air PM10 / SO2/ NOx / CO / NMHC Once/Month Adjacent to project MoEF
Stage site approved
Laboratory

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Sr. Project Phase Environmental Parameters Frequency Locations Conducted
No. Component by
Ambient Noise Leq day and night time or over one work Once/Month Adjacent to project MOEF
Level shift site approved
lab
Soil /Ground For specific contaminants of spilled Regularly At/near site of MOEF
water Quality chemicals until no spillage approved
traces laboratory
noticed
ETP pH, TSS, TDS, COD, BOD, Oil and Grease Daily until At various stages of
effluent stops in plant effluent
completely treatment system
as in 2 above

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Chapter 11– Summary & Conclusion

11.3 Additional Studies

Public hearing is exempted as per para 7(i) III Stage (3)(i)(b) of EIA Notification, 2006 for
preparation of EIA/ EMP Report, being site is located in the Notified industrial area (MIDC).

11.3.1 Risk Assessment, Hazard identification and consequence analysis

The principal objective of the risk assessment study is to identify and quantify the major
hazards and the risk associated with various operations of the proposed project, which may
lead to emergency consequences (disasters) affecting the public safety and health.

All necessary measures to minimize the risk due to the proposed project will be taken during
design stage and also during operation period viz, Fire & safety control measures, Emergency
preparedness plan, Disaster Management plan, etc.

Risk assessment, Hazard identification is carried out for the proposed expansion for during
various project phases, Quantitative risk assessment/ consequence analysis based on ALOHA,
during storage and transportation of chemicals, loading and unloading of chemicals, HAZOP
study for storages, Safety aspects and main risks of process, Dow fire and explosion indexes
and suggested control measures.
Action plan has been drawn for all above aspects.

11.4 Project benefits

The proposed activity is to be carried out in MIDC industrial area and does not require any
additional infrastructure and the site is well connected so no major benefits in terms of direct
improvement in infrastructure is anticipated. However, indirect improvement in public
infrastructure may occur due to the CER/CSR activities by the company.
Employment Potential
The proposed peak manpower requirement during construction and commissioning will be
100 - 150 Persons and the operations & activities will require manpower of ~ 200 nos.
Recruitments will be done from local area which will be the considerable benefit to the local
area considering the demography of the region/project area. Further, the indirect
employment via increased transportation, ancillary units & local economic activities will also
add in the employment potential of the proposed project. Thus, the potential of employment
will be greatly beneficial to the local people.
Other Tangible & Intangible Benefits
Demand of chemicals proposed to be manufactured i.e. various API’s and intermediates are
increasing in India as well as in foreign countries day by day. Thus, the proposed project will
help the increase of export to many foreign countries. Successful exports by company, will
result in benefit to the country in form of foreign revenue, duties etc.
With this project, business for ancillary units like equipment manufacturers, machining
works, motor rewinding for regular maintenance, shut down annual and mechanical
consumable vendors, periodical painting works etc. thereby giving the indirect maintenance

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Chapter 11– Summary & Conclusion
people like equipment suppliers and various consumable vendors’ employment
opportunities.

11.5 Conclusion

The study for the proposed expansion project of Centaur Pharmaceuticals Private Limited at
MIDC Chikhloli has revealed that the upcoming expansion & associated activities will not have
much impacts in operation phase due to various measures proposed.
Proposed Project will result in benefit to the country in form of foreign exchange revenues,
duties etc. Enhanced production will also result in increased taxes to local gram panchayat
and State Exchequer.
The major impacts will be brought under acceptable limits by implementing the required
hazard prevention & control measures as suggested in the report. Centaur Pharmaceuticals
Private Limited will follow stipulated norms laid by MoEFCC, CPCB & MPCB.
As a part of social upliftment Centaur Pharmaceuticals Private Limited will provide local
employment. Further, the indirect employment via increased transportation, ancillary units &
local economic activities with enhances spending power will also add in the employment
potential.
Indirect improvement in public infrastructure through CER activities carried by Centaur
Pharmaceuticals Private Limited with enhances spending power will help to improve the
overall quality of life in study area.
Thus, it has been concluded that there would not be any major impacts due to the proposed
project except the impacts of major accident scenarios which may extend out of the plant area
for which adequate safety measures will be implemented.
The EIA study has concluded that the project would be environmentally acceptable, in
compliance with environmental legislation and standards, Hence the proposed project may
be considered for getting Environmental Clearance.

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Chapter 12– Disclosure of Conslutants engaged

12 D ISC LOSU RE OF C O NSU LTA NTS ENGAG ED

Name : ADITYA ENVIRONMENTAL SERVICES PVT. LTD.

Reg. Office : 107, Hiren Light Indl. Estate, Mogul Lane, Mahim, Mumbai – 400016
Phone No. : 022 42127500 Email id : [email protected]
Central Lab : P-1, MIDC Mohopada, P.O. Rasayani, Dist. Raigad Pin 410207
Phone No. : 02192 252008 Email id : [email protected]
Goa : 08322652456 Ahmedabad : 079 40063271
Branches : Pune : 915802585 Delhi : 011 64595949
Baroda : 02652331790
Accreditation : 1. ‘A’ Category EIA Consultancy Organization by QCI-NABET
Obtained 2. Recognized by MoEFCC as “Environmental Laboratory” vide S.O.No. 1190 (E)
dt. 01.05.2014 valid up to 30.04.2019
3. ISO 9001:2008 Certified
4. OHSAS 18001:2007 Certified
Services :  Environmental planning studies
Offered by  Policy planning studies for CPCB, MPCB and other agencies like World Bank.
AESPL  Environmental Impact Assessment (EIA) & Environment Management Plan
(EMP)
 Risk Analysis Studies & On Site/Off Site Emergency Management Plan.
 Environment Health & Safety audits & Due Diligence audits
 Effluent Characterization & Treatability Studies
 Project Management Consultancy for Effluent Treatment Plants
 Ventilation, work room air quality surveys
 Air pollution control system design
 Analytical Services covering entire spectrum of environmental analysis
➢ Ambient air monitoring
➢ Ambient noise level monitoring
➢ Ground & Surface water analysis
➢ Soil analysis
➢ Marine water & sediment analysis
➢ Ecological & Biodiversity surveys
➢ Socio-economic surveys
➢ Hydro-geological surveys
 Coastal engineering & coastal process studies & management plans
Website : www.aespl.co.in

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