List of Enclosures S. No Content...

List of Enclosures

S. No Content Annexure

1 APIIC Land Allotment Letter Enclosure-1

Additional info M/s. Srikar Chem & Pharma India Pvt. Ltd

Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 1

S. No Content Annexure

1 List of Products Annexure-I

2 Site Plan Annexure-II

3 Manufaturing Process Description Annexure-III

4 Water Consumption Details Annexure-IV

5 Hazardous waste

Annexure-V

6 Industrial Process waste

7 Sewage sludge

8 Solid waste

9 Stack Emission Details Annexure-VI

10 Process Emission Details Annexure-VII

11 List of Raw Materials Annexure- VIII

12 Waste water Details Annexure-IX



Annexure - I

LIST OF PROPOSED PRODUCTS

S. No Product Name CAS No Therapeutic Category

Production Capacities

Kgs/Month Kgs/Day Group-A

1 Benzyl Magnesium chloride 6921-34-2 Reagent 5000.00 166.67

2 Lithium Tertiary Butoxide 1907-33-1 Reagent 5000.00 166.67

3 Lithium HMDS 4039-32-1 Reagent 10000.00 333.33

4 Magnesium Tertiary Butoxide 32149-57-8 Reagent 5000.00 166.67

5 n-Butyl Magnesium Chloride 693-04-9 Reagent 5000.00 166.67

6 Potassium Tertiary Butoxide 865-47-4 Reagent 5000.00 166.67

7 Sodium amide 7782-92-5 Reagent 5000.00 166.67 8 Sodium HMDS 1070-89-9 Reagent 10000.00 333.33

9 Sodium Tertiary Butoxide 865-48-5 Reagent 5000.00 166.67

Total 55000.00 1833.33 Group-B

1 Domperidone 57808-66-9 Antiemetic 3500.00 116.67

2 Esomeprazole Magnesium Trihydrate

217087-09-7 Antiulcer agent 4000.00 133.33

3 Lopinavir 192725-17-0 Antiretroviral Agent. 3000.00 100.00

4 Omeprazole 73590-58-6 Anti ulcer Agent. 5000.00 166.67

5 Pantoprazole sodium 138786-67-1 Anti ulcer Agent. 4500.00 150.00

Total 20000.00 666.67 Total

(Worst combination of either Group-A or Group-B)

55000.00 1833.33



Annexure - II

SITE LAYOUT


Prepared By Rightsource Industrial Solutions Pvt. Ltd Page 4

Annexure - III

Manufaturing Process Description

1. BENZYL MAGNESIUM CHLORIDE

Process Description:

Stage-1

Magnesium metal is charged into a clean and dry reactor under nitrogen purging.

Charge DEE & THF and start stirring. Raise the reactor temperature up to required

temperature. Start and continue the addition of benzyl chloride up to completion of the

reaction. Distill off DEE and maintain for few hours and then cool to room temperature.

Check the sample and unload the material into the containers under nitrogen

atmosphere. Check the Product and unload the material into the containers under

Nitrogen atmosphere.

BENZYL MAGNESIUM CHLORIDE

Route of synthesis:

Stage-1:

Mg

Magnesium

24.31

+

Benzyl chloride

Cl

C7H7Cl

126.58

MgCl

Benzylmagnesium chloride

C7H7ClMg

150.89

THF




Flow Chart:

MagnesiumBenzyl chlorideDiethyl etherTetrahydrofuran

Diethyl ether RecTHF Rec

Stage-1



Material Balance:

Material Balance of Benzyl Magnesium Chloride Stage-1

Batch Size: 1000.0Kgs Name of the input Quantity

in Kg Name of the out put Quantity

in Kg

Magnesium 160.00 Benzyl magnesium chloride in THF Solution

2056.00

Benzyl chloride 840.00 Diethyl ether Recovery 732.00 Diethyl ether 770.00 Diethyl ether Loss 38.00 Tetrahydrofuran 1100.00 Tetrahydrofuran Loss 44.00 Total 2870.00 Total 2870.00



2. LITHIUM TERTIARY- BUTOXIDE

Process Description

Stage-1

Lithium metal is added with excess tert-butanol contained rotary dryer cum reactor

under argon atmosphere. Excess tert-butanol is recovered by thermic fluid heating

through a condenser and used again in the next batches. A small quantity of hydrogen

is let out through a liquid paraffin trap.

LITHIUM TERTIARY- BUTOXIDE

Route of Synthesis

Stage-1

+

Tert-Butanol

CH3

H3C

CH3

OH

CH3

H3C

CH3

OLi

C4H10O

74.12

Lithium tert-butoxide

+ 1/2 H2

Hydrogen gas

1/2X2=1.00

Li

Lithium

6.94 C4H9LiO

80.05




Flow Chart

Stage-1

LITHIUM TERT-BUTOXIDE

LithiumTert-Butanol

Hydrogen gasTert-Butanol Rec


Material Balance:

Material Balance of Lithium Tert-Butoxide Stage-1



in Kg Lithium 28.00 Lithium Tert-Butoxide 250.00 Tert-Butanol 325.00 Tert-butanol Loss 98.62 Process Emissions 4.38 (Hydrogen-4.38) Total 353.00 Total 353.00



3. LITHIUM HEXAMETHYLDISILAZANE

Process Description

Stage-1

Required quantity of lithium metal is charged into a clean and dry reactor under argon

purging. Charge THF and start stirring. Raise the reactor temparature upto reflux, start

and continue the addition of HMDS under reflux. Maintain the reflux for few hours and

cool to room temparature. Check the Product and unload the material into the

containers under argon/nitrogen atmosphere.

LITHIUM HEXAMETHYLDISILAZANE

Li

Lithium

6.94Hexamethyldisilazane

HN SiSi

CH3

CH3

CH3

H3C

H3C

H3C+

C6H19NSi2

161.39

Lithium HMDA

LiN SiSi

CH3

CH3

CH3

H3C

H3C

H3C

C6H18LiNSi2167.33

+ 1/2 H2

Hydrogen gas

1/2X2=1.00

THF




Stage-1Hydrogen gasTHF Rec


Lithium metalHexamethyldisilazaneTHF


Material Balance of Lithium Hexamethyldisilazane Stage-1

Batch Size: 500.0 Kgs Name of the input Quantity


in Kg

Lithium metal 19.00 Lithium Hexamethyldisilazane in THF Solution

976.00

HMDS 483.00 THF Loss 25.00 THF 500.00 Process Emissions 1.00 (Hydrogen-1) Total 1002.00 Total 1002.00



4. MAGNESIUM TERTIARY BUTOXIDE

Process Description

Stage-1

2 moles of Methyl Magnesium Chloride in THF are reacted under certain conditions to

form Di methyl Magnesium and Magnesium Chloride.

Stage-2

Di methyl Magnesium in THF is reacted with Tertiary Butanol to get Magnesium

Tertiary Butoxide. The Magnesium Tertiary Butoxide solution in THF is taken into a

dryer and THF is recovered and used in next batches. The dried product is packed in

polythene bags and kept in MS drums.

MAGNESIUM TERTIARY BUTOXIDE

Route of Synthesis

Stage-1

2 CH3MgCl

Methl magnesium chloride

2X74.79=149.58

THF(CH3)2Mg

Di MethylMagnesium

54.37

+ MgCl2

Magnesium Chloride

95.21

Stage-2



THF(CH3)2Mg

Dimethyl Magnesium

54.37

+

Tert Butanol

CH3

H3C

CH3

OH2

2X74.12=148.24

C4H9OH

Magnesium Tertiary Butoxide

(C4H9O)2Mg

C8H18MgO2

170.53

+ 2 CH4

Methane gas

2X16.04=32.08


Flow Chart

Stage-1

Stage-2

Methyl magnesium ChlorideTHF

THF RecMgCl2(Byproduct)

Stage-1Tert-Butanol

Methane gasTert-Butanol Rec



Material Balance:

Material Balance of Magnesium Tertiary Butoxide Stage-1

Batch Size:200.0Kgs Name of the input Quantity


in Kg



Methyl Magnsium Chloride 214.00 Stage-1+ THF 1400.00 THF 1400.00 THF Loss 70.00 By-product 144.00 (Magnesium chloride-144) Total 1614.00 Total 1614.00

Material Balance of Magnesium Tertiary Butoxide Stage-2



in Kg

Stage-1 + THF 1369.30 Magnesium Tertiary Butoxide in THF Solution

1528.00

Tert-Butanol 200.00 Process Emission 41.30 (Methane gas-41.30) Total 1569.30 Total 1569.30



5. n- BUTYL MAGNESIUM CHLORIDE

Process Description

Stage-1

Magnesium metal is charged into a clean and dry reactor under nitrogen purging.

Charge THF and start stirring. Raise the reactor temperature up to required

temperature. Start and continue the addition of butyl chloride up to completion of the

reaction. Maintain for few hours and cool to room temperature. Check the Products and

unload the material into the containers under Nitrogen atmosphere.

n- BUTYL MAGNESIUM CHLORIDE

Route of Synthesis

Stage-1

Mg

Magnesium

24.31

+

Butyl chloride

Nitrogen

Butyl Magnesium ChlorideTHF

CH3ClMg

ClCH3

116.87

C4H9MgClC4H9Cl

92.57




Flow Chart

Stage-1 THF RecMagnesium MetalButyl ChlorideTHF

BUTYL MAGNESIUM CHLORIDE


Material Balance:

Material Balance of n- Butyl Magnesium Chloride Stage-1

Batch Size: 1000.0 Kgs Name of the input Quantity


in Kg

Magnesium Metal 210.00 Butyl Magnesium Chloride in THF Solution

1768.00

Butyl Chloride 790.00 THF Loss 40.00 THF 805.00



Total 1808.00 Total 1808.00

6. POTASSIUM TERTIARY BUTOXIDE


Stage-1

Potassium is added into excess tert-Butanol in a rotatory drier cum reactor. Excess t-Butanol is used to ensure the complete reaction of the corresponding metals. Then the excess t-Butanol is recovered by thermic fluid heating through a condensor and used again in the next batches. A small quantity of hydrogen is let out through a liquid paraffin trap.

Route of synthesis:

Stage-1:

K +

Tertiary butanol

CH3

H3C

CH3

OH

39.10

PotassiumC4H10O

74.12

CH3

H3C

CH3

OK

C4H9KO

112.21

Potassium tertiary butoxide

+1/2 H2

Hydrogen1/2 X 2=1.00



POTASSIUM TERT BUTOXIDE

Flowchart:

Stage-1Tert Butanol RecH2

POTASSIUM TERTIARY BUTOXIDE

PotassiumTert butanol

POTASSIUM TERT BUTOXIDE

Material Balance:

Material Balance of Potassium tert butoxide Stage-1



in Kg Potassium 185.20 Potassium tert-butoxide 500.00 Tert butanol 641.42 Tert butanol Recovery 301.98 Tert butanol Loss 15.90 Process Emission 8.74 (Hydrogen-8.74) Total 826.62 Total 826.62



7. SODIUM AMIDE

Process Description

Stage-1

Sodium metal is charged into a reactor and the temperature is maintained at 300OC -

350oC.Then ammonia gas is passed into the reactor. During the reaction, Hydrogen is

liberated. This liberated hydrogen can be used in sodium hydride product. When the

reaction is completed, the mass is unloaded into a ball mill and powdered. The powder

is packed in polythene bags under Nitrogen atmosphere as per the requirement of the

customers and kept in drums.

SODIUM AMIDE

Route of Synthesis

Stage-1

Na

Sodium

23.00

+ NH3

Ammonia17.03

NaNH2

Sodium Amide

39.01

+ 1/2 H2

Hydrogen gas

1/2X2=1.00



SODIUM AMIDE

Flow Chart

Stage-1

SODIUM AMIDE

Sodium Amonia Hydrogen gas

SODIUM AMIDE

Material Balance:

Material Balance of Sodium Amide Stage-1



in Kg Sodium 310.00 Sodium Amide 500.00 Ammonia 203.38 Process Emissions 13.38 (Hydrogen-13.38) Total 513.38 Total 513.38



8. SODIUM HEXAMETHYL DISILAZANE


Stage-1

Required quantity of sodium amide powder is charged into a clean and dry reactor

under nitrogen purging. Charge THF and start stirring. Raise the reactor temparature

upto reflux, start and continue the addition of HMDS under reflux. Maintain the reflux

up to completion of the reaction, the liberated ammonia gas is recycled for hydrogen

genarating plant. Cool to room temparature and check the sample. Unload the material

into the containers under nitrogen atmosphere.

SODIUM HEXAMETHYL DISILAZANE

Route of Synthesis:

Stage-1:

NaNH2

Soda amide

39.01

Hexamethyldisilazane

HN SiSi

CH3

CH3

CH3

H3C

H3C

H3C+

C6H19NSi2

161.39

SodiumHMDA

NaN SiSi

CH3

CH3

CH3

H3C

H3C

H3C

C6H18NNaSi2183.37

+

Ammonia17.03

THFNH3




Flow Chart:

THF RecAmmoniaStage-1

Sodium amideHMDSTHF

SODIUM HMDA


Material Balance:

Material Balance of Sodium HMDA Stage-1



in Kg Sodium amide 421.00 Sodium HMDA in THF Solution 3154.00 HMDS 1765.00 THF Loss 61.00 THF 1215.00 Process Emission 186.00 (Ammonia-186) Total 3401.00 Total 3401.00



9. SODIUM TERTIARY BUTOXIDE

Process Description

Stage-1

Sodium is added into excess tert-butanol in a rotary drier cum reactor. Excess Tert-

Butanol is used to ensure the complete reaction of the corresponding metals. Then the

excess Tert-Butanol is recovered by thermic fluid heating through a condensor and

used again in the next batches. A small quantity of hydrogen is let out through a liquid

paraffin trap.

SODIUM TERTIARY BUTOXIDE

Route of Synthesis

Stage-1:

Na

22.99

+

Tert-Butanol

CH3

H3C

CH3

OH

CH3

H3C

CH3

ONa

Sodium metalC4H10O

74.12

Sodium tert-butoxide

96.10

+ 1/2 H2

Hydrogen gas

1/2X2=1.00C4H9ONa




Flow Chart:

Stage-1SodiummetalTert-Butanol

Hydrogen gasTert-Butanol Rec

SODIUM TERT- BUTOXIDE


Material Balance:

Material Balance of Sodium tert-Butoxide Stage-1

Batch Size:500.0 Kgs Name of the input Quantity


in Kg Sodium 141.18 Sodium tert-Butoxide 500.00 Tert-Butanol 650.00 t-Butanol Recovery 271.25 t-Butanol Loss 15.48 Process Emission 4.45



(Hydrogen-4.45) Total 791.18 Total 791.18

Group - B

1. DOMPERIDONE

Process Description: Stage-1:

N-carbethoxy-4-piperidone is reacted with Hydrogen and Ammonia in the presence of

Raney nickel as catalyst and Methanol as solvent media to give stage-1 as product.

Stage-2:

Stage-1 reacts with 2, 5-Dichloro nitrobenzene & Sodium Carbonate in presence of

Methanol as a solvent media to give Stage-2 as product.

Stage-3:

Stage-2 reacts with Hydrogen in presence of Raney Nickel as catalyst and Toluene

as solvent media to give Stage-3 as product.

Stage-4:

Stage-3 reacts with Urea in the presence of Sodium Hydroxide as a solvent media to

give Stage-4 as product.

Stage-5:

Stage-4 undergoes hydrolysis with Sodium Hydroxide to give Stage-5 as product.

Stage-6:



Stage-5 reacts with 1-(3-chloropropyl)-1, 3-dihydro-2H-benzimedazole-2-one and

Sodium Carbonate in the presence of Methyl Isobutyl Ketone as solvent media to give

Domperidone as product.

DOMPERIDONE

Route of synthesis:

Stage-1:

N-Carbethoxy-4-piperidone

N

O

O O CH3

C8H13NO3

171.19

+ H2

Hydrogen

2.00

+ NH3

Ammonia

17.03

+ H2O

4-Amino-piperidine-1-carboxylic acid ethyl ester

N

NH2

O O CH3

18.00

C8H16N2O2

172.22

Raney Nickel

Stage-2:



4-Amino-piperidine-1-carboxylic acid ethyl ester

N

NH2

O O CH3

C8H16N2O2

172.22

+

2,5-Dichloro Nitrobenzene

Cl

Cl

NO2

C6H3Cl2NO2

192.00

+ 1/2 Na2CO3

Sodium carbonate

1/2X105.98=52.99

N

HN

O O CH3

NO2

Cl

4-(4-Chloro-2-nitro-phenylamino)-piperidine-1-carboxylic acid ethyl ester

+

C14H18ClN3O4

327.76

NaCl

Sodium chloride

58.44

+ 1/2 H2O1/2 CO2

Carbon dioxide1/2X44=22.00

+

1/2X18=9.00

Methanol



Stage-3:

N

HN

O O CH3

NO2

Cl

4-(4-Chloro-2-nitro-phenylamino)-piperidine-1-carboxylic acid ethyl ester

C14H18ClN3O4

327.76

+ 3 H2

3X2=6.00

Hydrogen

N

HN

O O CH3

NH2

Cl

4-(2-Amino-4-chloro-phenylamino)-piperidine-1-carboxylic acid ethyl ester

C14H20ClN3O2

297.78

+ 2H2O

2X18=36.00

Raney Nickel

Toluene

Stage-4:

N

HN

O O CH3

NH2

Cl

4-(2-Amino-4-chloro-phenylamino)-piperidine-1-carboxylic acid ethyl ester

C14H20ClN3O2

297.78

+

Urea

H2N

O

NH2

CH4N2O

60.05

N

O O CH3

N

HNCl

O

4-(5-Chloro-2-oxo-2,3-dihydro-enzoimidazol-1-yl)-piperidine-1-

carboxylic acid ethyl ester

C15H18ClN3O3

323.77

+ 2NH3

2X17.03=34.06

Ammonia

NaOH



Stage-5:

N

O O CH3

N

HNCl

O

C15H18ClN3O3

323.77

+

Sodium hydroxide

NaOH

40.00

4-(5-Chloro-2-oxo-2,3-dihydro-benzoimidazol-1-yl)-piperidine-1-carboxylic acid ethyl ester

NH

N

HNCl

O

5-Chloro-1-piperidin-4-yl-1,3-dihydro-benzoimidazol-2-one

+ C2H5ONa

Sodium ethoxide

68.05

+ CO2

Carbon dioxide

44.00

C12H14ClN3O

251.71

Stage-6:

NH

N

HNCl

O

5-Chloro-1-piperidin-4-yl-1,3-dihydro-benzoimidazol-2-one

C12H14ClN3O

251.71

+

1-(3-chloropropyl)-1,3-dihydro -2H-(Benzimidazole-2-one)

N

HN

O

Cl

C10H11ClN2O

210.66

+ 1/2Na2CO3

Sodium carbonate

NH

N

ON

NH

N

O Cl

425.91

Domperidone

C22H24ClN5O2

+ NaCl

Sodium chloride

58.44

+ 1/2 H2O +1/2 CO2

Carbon dioxideWater

1/2X44=22.001/2X18=9.00

1/2X105.98=52.99

MIBK

DOMPERIDONE



Flow Chart:

Stage-1

Stage-2

Stage-3

Stage- 4

Stage-5

Stage-6

N-Carbethoxy-4-piperidoneAmmonia gasMethanolRaney NickelHydrogen

Methanol RecGenerated water

Stage-12,5-Dichloro NitrobenzeneSodium CarbonateMethanol

Methanol RecGenerated water

Stage-2HydrogenRaney NickelToluene

Toluene RecEffluent water

Stage-3UreaSodium Hydroxide (48%)

Effluent water

Stage-4Sodium Hydroxide Effluent water

Stage-51-(3-Chloropropyl)-1,3-dihydro2H-benzimedazole-2-oneSodium CarbonateMethyl Isobutyl Ketone

MIBK RecCarbon dioxide

DOMPERIDONE

DOMPERIDONE



Material Balance:

Material Balance of Domperidone Stage-1

Batch Size:50Kg Name of the input Quantity


in Kg N-Carbethoxy-4-piperidone 80.00 Stage-1 70.00 Ammonia gas 28.00 Methanol Recovery 283.00 Methanol 300.00 Methanol Loss 15.00 Raney Nickel 20.00 Raney Nickel Reuse 20.00 Hydrogen 5.00 Generated water 8.40 Organic Residue 12.60 (Organic Impurities-10.6,Methanol-

2)

Process Emission 24.00 (Ammonia-20,Hydrogen-4) Total 433.00 Total 433.00




in Kg Stage-1 70.00 Stage-2 95.00 2,5-Dichloro Nitrobenzene 78.00 Methanol Recovery 470.00 Sodium Carbonate 30.00 Methanol Loss 25.00 Methanol 500.00 Effluent Water 238.85 Water 200.00 (Water-200,generated water-

3.65,Sodium chloride-23.7,Sodium carbonate-8.5,Methanol-3)

Process Emission 8.93 (Carbon dioxide) Organic Residue 40.22 (Organic Impurities-38.22,Methanol-

2)

Total 878.00 Total 878.00






in Kg Stage-2 95.00 Stage-3 75.00 Hydrogen 5.00 Toluene Recovery 330.00 Raney Nickel 10.00 Toluene Loss 17.00 Toluene 350.00 Raney Nickel Reuse 10.00 Water 200.00 Effluent Water 211.43 (Water-200,generated water-10.43,

Toluene-1)

Process Emission 3.27 (Hydrogen) Organic Residue 13.30 (Organic Impurities-11.3,Toluene-2) Total 660.00 Total 660.00




in Kg Stage-3 75.00 Stage-4 67.00 Urea 20.00 Effluent Water 364.90 Sodium Hydroxide (48%) 60.00 (Water-300,Urea-4.9,Sodium

hydroxide-28.8,water from sodium hydroxide-31.2)

Water 300.00 Process Emission 8.57 (Ammonia) Organic Residue 14.53 Total 455.00 Total 455.00






in Kg Stage-4 67.00 Stage-5 45.00 Sodium Hydroxide 15.00 Effluent Water 170.70 Water 150.00 (Water-150,Sodium hydroxide-6.7,

Sodium ethoxide-14)

Process Emission 9.10 (Carbon dioxide) Organic Residue 7.20 Total 232.00 Total 232.00




in Kg Stage-5 45.00 Domperidone 50.00 1-(3-Chloropropyl)-1,3-dihydro-2H-benzimedazole-2-one

40.00 Methyl Isobutyl Ketone Recovery 1135.00

Sodium Carbonate 20.00 Methyl Isobutyl Ketone Loss 60.00 Methyl Isobutyl Ketone 1200.00 Effluent Water 224.50 Water 200.00 (Water-200,generated water-

1.6,Sodium chloride-10.4,Sodium carbonate-10.5,MIBK-2)

Process Emission 3.93 (Carbon Dioxide) Organic Residue 31.57 (Organic Impurities-28.57,MIBK-3) Total 1505.00 Total 1505.00



2. ESOMEPRAZOLE MAGNESIUM TRIHYDRATE Process

Description:

Stage-1

5-Methoxy-2-[(4-Methoxy-3,5-Dimethyl-2-pyridinyl) Methyl Thio]-1H-

Benzimidazole reacts with Cumin hydroperoxide and Potassium hydroxide in the

presence of Toluene as a solvent media to give stage-1 as product. Stage-2 Stage-1 undergoes hydrolysis with Magnesium sulfate in the presence of Toluene

as a solvent media to give Esomeprazole Magnesium Trihydrate as product.



ESOMEPRAZOLE MAGNESIUM TRIHYDRATE Route of synthesis:

Stage-1:

OCH3

H3C CH3

N OCH3

CH3 OH

H3C O

Toluene

N C S +

H2 N

H

+ KOH

5-Methoxy-2-[(4-methoxy-3,5-dimethyl-pyridin -2-ylmethyl Thio]-1H -Benzoimidazole

C17H19N3O2S

329.41

OCH3

H3C CH3

Cumin hydroperoxide

C9H12O2

152.19

H3C

Potassium hydroxide

56.10

CH3

OH

O N

N C S H2

N

K+

OCH3

H2O +

Esomeprazole potassium salt.Monohydrate Cumin hydroxide

C17H20KN3O4S C9H12O 136.19

401.52



Stage-2:

OCH3

H3C CH3

O

2

N OCH3

N C S H2

N

K+

H2O + MgSO4 + H2O

Esomeprazole potassium salt.Monohydrate

C17H20KN3O4S

2X401.52=803.04

Magnesium sulfate

120.36

18.00

OCH3

H3C CH3

O

N OCH3

Mg 3H2O + K2SO4

N C S H2

N 2

Esomeprazole Magnesium Tri Hydrate

C17H18N3O3S.Mg3H2O

767.15

Potassium sulfate

174.25



ESOMEPRAZOLE MAGNESIUM TRIHYDRATE Flow Chart:

Omeprazole sulfide Cumin hydroperoxide Potassium hydroxide Methanol

Stage-1

Methanol Rec

Stage-1 Magnesium sulfate Water

Stage-2

Effluent Water

ESOMEPRAZOLE MAGNESIUM



ESOMEPRAZOLE MAGNESIUM TRIHYDRATE Material Balance:

Material Balance of Esomeprazole Magnesium trihydrate Stage-1

Batch Size: 100 Kgs Name of the input Quantity in

Kg Name of the out put Quantity in

Kg Name of the input Quantity


In Kg Omeprazole sulfide 88.00 Stage-1 107.00 Cumin hydro peroxide 41.00 Toluene Recovery 305.00 Potassium hydroxide 15.20 Toluene loss 15.00 DET 11.30 Methanol Recovery 95.00 Titanium isopropoxide 2.50 Methanol Loss 5.00 NEDIPA 4.50 NEDIPA Loss 4.50 Toluene 320.00 Organic Residue 51.00 Methanol 100.00 (DET11.3,Titanium

isopropoxide-2.5,Cumin hydroxide-37.2,)

Total 582.50 Total 582.50

Material Balance of Esomeprazole Magnesium trihydrate Stage-2

Batch Size: 100 Kgs Name of the input Quantity in

Kg Name of the out put Quantity in

Kg Name of the input Quantity in

Kg Name of the out put Quantity

In Kg Stage-1 107.00 Esomeprazole Magnesium

trihydrate 100.00

Magnesium sulfate 16.00 Effluent water 980.80 Water 960.00 (Water-957.6,Potassium

sulfate-23.2)

Organic Residue 2.20 Total 1083.00 Total 1083.00



3. LOPINAVIR

Process Description

Stage-1 Step-A

(R)-2-amino-3-phenyl propanoic acid reacts with benzyl chloride ,Potassium carbonate

in presence of Ethanol as solvent media to give Stage-A as product.

Step-B Stage-A Product reacts with Acetonitrile, Sodium amide and citric acid monohydrate in presence of MTBE as solvent media to give Stage-1 product. Stage-2 Satge-1 reacts with Benzyl magnesium chloride in presence of THF, MTBE as solvent media to give Stage-2 as product. Stage-3 Step-A Stage-2 product reacts with sodium borohydride in presence of Methane sulphonic acid, TEA and 1, 2-DME to give step-A as product. Step-B Valina reacts with Methyl chloro formate and Acrylonitrile to give Stage-3B as product. Step-C Stage-3C Product undergoes Hydrogenation by using Raney nickel as catalyst and methanol as solvent media to give Stage-3C as product. Step-D (2S)- (1-Tetra hydro pyramid-2-one)-3-methyl butanoic acid reacts with Imidazole in presence of THF as solvent media to give Step-D as product. Step-E Step-A reacts with Step-D in presence of Ethyl acetate as solvent media to give Step-E as product.



Step-F Step-E reacts with Ammonium formate in presence of Palladium carbon and Methanol as solvent media to give Step-F as product. Step-G Step-F product reacts with L-Pyro glutamic acid in presence of DMF, Ethyl acetate as solvent media to give (2S, 3S, 5S)-2-Amino-3-hydroxy-5-(1-tetra hydro pyrmid-2-onyl)-3-methyl butanoyl) amino-1, 6-diphenyl hexane-S-pyro glutamate (THP). Stage-4 N-(4-Amino-1-benzyl-3-hydroxy-5-phenyl-pentyl)-3-methyl-2-(2-oxo-tetrahydropyrimidin-1-yl)-butyramide (S)-5-oxo-pyrrolidine-2-carboxylate reacts with 2,6-Dimethyl phenoxy acetyl chloride and sodium bicarbonate in the presence of Ethyl acetate as a solvent media to give stage-4 as product. Stage-5 Stage-4 undergoes purification with ethanol to give Lopinavir (pure) as product.



LOPINAVIR

Route of Synthesis:

Stage-1

Step-A

(R)-2-amino-3-phenyl propanoic acid

O

OH

H2N+

Benzyl Chloride

Cl

(R) -benzyl 2-(dibenzyl amino)-3-phenyl propanoate

OO

N

3 + 3 K2CO3

Potassium Carbonate

C9H11NO2

165.19

C7H7Cl3X126.58=379.74

3X138.21=414.63

+ 3 KCl + 3 KOH + 3 CO2

C30H29NO2

435.56

3X74.55=223.61 3X56.11=168.32 3X44=132

Ethanol



Step-B

Monosodium citrate

(R) -benzyl 2-(dibenzyl amino)-3-phenyl propanoate

C30H29NO2

435.56

+ CH3CN + NaNH2 +

C6H10O8

Acetonitrile Sodium Amide Citric Acid Monohydrate

41.05 39.01 210.14

MTBE

OH

1-Imino-4-(N,N-dibenzylamino)5-phenyl-3-oxo-pent-1-ene

C25H24N2O

368.47

+ + + NH4OH

Benzyl Alcohol Ammonium Hydroxide

C7H8O

108.14 35.05214.11

C6H7O7Na

OO

N

C

ON

NH

HO

OOH

O OH

O

HOH2O

Na+

HO

OO-

O OH

O

HO



Stage-2

1-Imino-4-(N,N dibenzylamino)-5-phenyl-3-oxo-pent-1-ene

C

O

N

NH

C25H24N2O

368.47

Benzyl Magnesium Chloride

MgCl+

Citric Acid monohydrate

(R,Z)-5-amino-2-(dibenzyl amino)-1,6-diphenyl hex-4-en-3-one

O

N

NH2

Magnesium Chloride

+ + NaClC6H8O7 H2O

58.5

C7H7MgCl

150.89

210.14

C32H32N2O

460.61

+ MgCl2

95.21

+ C6H7O7Na

Monosodium Citrate

+ H2O

214.11

Water

18.0

THF/MTBE



Stage-3

Step-A

(R,Z)-5-amino-2-(dibenzyl amino)-1,6-diphenyl hex-4-en-3-one

ON

NH2

C32H32N2O

460.61

(2R)-5-amino-2-(dibenzyl amino)-1,6-diphenyl hexane-3-ol

OHN

NH2

+ NaBH4 + 4H2O

37.8 72.0C32H36N2O

464.64

+ H3BO3 + NaOH + 2 H2

61.83 40.0 4.0

MSA

TEA/1,2 DME



Step-B

HO

O

NH2

CH3H3C

valina

C5H11NO2

117.15

+

Methylchloroformate

O

OClCH3

C2H3ClO2

94.50

+

Acrylonitrile

CH2

N

C3H3N

53.06

N-(2-Cyanoethyl)-N-(methoxycarbonyl)-L-valine

CN

N OCH3

OH3C CH3

HO

O

C10H16N2O4

228.25

+ HCl

Hydrochloric acid

36.5

Step-C

N-(2-Cyanoethyl)-N-(methoxycarbonyl)-L-valine

CN

N OCH3

OH3C CH3

HO

O

C10H16N2O4

228.25

Raney Ni

Methanol,NaOH

N NH

OH3C CH3

HO

O

3-Methyl-2-(2-oxo-tetrahydro-pyrimidin-1-yl)-butyric acid

C9H16N2O3

200.23

+ 2H2

4.00

+ CH3OH

32.04



Step-D

N

N

(2S)-(1-Tetrahydropyramid-2-one)-3-methylbutanoic acid

N

NH

O

OH

O

Imidazole

+

N

NH

O

O

C9H16N2O3 C3H4N2 C12H18N4O2

200.23 68.07 250.30

+ H2O

18.0

N

HN

1-[1-(Imidazole-1-carbonyl)-2-methyl-propyl]-tetrahydro-pyrimidin-2-one

THF



Step-E

N NN NH

O

O

1-[1-(4,5-Dihydro-imidazole-1-carbonyl)-2-methyl-propyl]-tetrahydro-pyrimidin-2-one

OHN

NH

N NH

N NH

O

O

Imidazole

OHN

NH2

5-Amino-2-dibenzylamino-1,6-diphenyl-hexan-3-ol

+

N-(1-Benzyl-4-dibenzylamino-3-hydroxy-5-phenyl-pentyl)-3-methyl-2-(2-oxo-tetrahydro

-pyrimidin-1-yl)-butyramideC41H50N4O3

+

646.86

C3H4N2

68.08

464.64

Ethyl acetate

Water

C12H18N4O2

250.30

C32H36N2O



Step-F

OHN

NH

N NH

O

O

N-(1-Benzyl-4-dibenzylamino-3-hydroxy-5-phenyl-pentyl)-3-methyl-2-(2-oxo-tetrahydro

-pyrimidin-1-yl)-butyramideC41H50N4O3

646.86

+ 2CH5NO2

Pd/C

OHH2N

NH

N NH

O

O

N-(4-Amino-1-benzyl-3-hydroxy-5-phenyl-pentyl)-3-methyl-2-(2-oxo-tetrahydro-

pyrimidin-1-yl)-butyramide

+

Ammonium formate

CH5NO2

2X63.06=126.12

2 C7H8

C27H38N4O3

466.62

TolueneC7H8

2X92.14=184.28

+ 2 NH3

Ammonia2x17=34

+ 2CO2

Carbondioxide2x44=88

MeoH



Step-G

OHH2N

NH

N NH

O

O

N-(4-Amino-1-benzyl-3-hydroxy-5-phenyl-pentyl)-3-methyl-2-(2-oxo-tetrahydro-

pyrimidin-1-yl)-butyramideC27H38N4O3

466.62

+

L-Pyroglutamic acid

HN

O

O

OH

C5H7NO3

129.11

DMF

Ethyl acetate

OHH2N

NH

N NH

O

O

HN

O

O

OH

(2S, 3S, 5S)-2-Amino-3-hydroxy-5-(1-tetra hydro pyrmid-2-onyl)-3-methyl butanoyl) amino-1, 6-

diphenyl hexane-S-pyro glutamate (THP)

C32H45N5O6

595.73



Stage-4

H2N

OH

NH

N

O

NH

O

NH

O

H

COOH

C32H45N5O6

595.72

+

CH3

CH3

O

HN

O

NH

OH

N

H3C CH3

O

NH

O

2,6-Dimethyl phenoxy acetyl chloride

O

CH3

CH3

O

Cl

C10H11ClO2

198.64

+

Sodium bicarbonate

NaHCO3

84.00

C37H48N4O5

628.80

+NH

H

COOHO

5-Oxo-pyrrolidine-2-carboxylic acid

C5H7NO3

129.11

+ NaCl

+ H2O+ CO2

Sodium chloride

58.44

18.0044.00

Ethyl acetate

N-{1-Benzyl-4-[2-(2,6-dimethyl-phenoxy)-acetylamino]-3-hydroxy-5-phenyl-pentyl}-3-methyl-2-(2-oxo-tetrahydro-

pyrimidin-1-yl)-butyramide (Lopinavir Crude)

N-(4-Amino-1-benzyl-3-hydroxy-5-phenyl-pentyl)-3-methyl-2-(2-oxo-tetrahydro-pyrimidin-1-yl)-butyramide;

compound with 5-oxo-pyrrolidine-2-carboxylic acid



Stage-5

CH3

CH3

O

HN

ONH

OHN

H3C CH3

ONH

O

Lopinavir Crude

C37H48N4O5

628.80

C37H48N4O5

628.80

Lopinavir (pure)

CH3

CH3

O

HN

ONH

OHN

H3C CH3

ONH

O

Ethanol



LOPINAVIR

Flow Chart:

L-Phenyl alaninePotassium carbonateBenzyl chlorideEthanol

Stage-1 Ethanol Rec

Stage-2 THF Rec

Stage-1Benzyl magnesium chlorideCitric acid monohydrateTHF

Stage-3 MTBE Rec

Stage-2Sodium Boro hydrideMethane sulphonic acidTriethyl amine1,2-Dimethoxy ethaneMTBEValinaRaney Nickel

Stage-4 Ethyl acetate RecTHP(Lopinavir Intermediate)2,6-Dimethyl phenoxy acetyl chloride (DPC)Ethyl acetate

Stage-5 Ethanol RecStage-4EthanolActivated carbon

LOPINAVIR



LOPINAVIR

Material Balance:

Material Balance of Lopinavir Stage-1

Batch Size: 100Kg Name of the input Quantity


in Kg L-Phenyl alanine 75.00 Stage-1 114.00 Potassium carbonate 190.00 n-Heptane Recovery 266.00 Benzyl chloride 172.00 n-Heptane Loss 14.00 Ethanol 865.00 MTBE Recovery 873.00 n-Heptane 280.00 MTBE Loss 45.00 Methanol 434.00 Methanol Recovery 408.00 Sodium amide 12.00 Methanol Loss 21.00 Acetonitrile 18.75 Ethanol Recovery 822.00 Citric acid monohydrate 50.00 Ethanol Loss 43.00 MTBE 918.00 Effluent water 720.70 Water 500.00 (Water-500,Ammonium hydroxide-

38.7, Benzyl Alcohol-49.1,Methanol-5, Monosodium citrate-50.9, Potassium Hydroxide-77)

Inorganic solid waste 101.00 (Potassium chloride-101) Process Emissions 60.00 (Carbon dioxide) Organic Residue 27.05 Total 3514.75 Total 3514.75






in Kg Stage-1 114.00 Stage-2 114.00 Benzyl magnesium chloride 46.00 Ethanol Recovery 770.00 Citric acid monohydrate 60.00 Ethanol Loss 40.00 THF 537.00 MTBE Recovery 689.00 Sodium chloride 29.00 MTBE Loss 36.00 Ethanol 810.00 THF Recovery 506.00 MTBE 725.00 THF Loss 26.00 Water 200.00 Effluent water 304.20 (Water-200, Magnesium chloride-

29.4, Generated water-8.8, THF-5, Monosodium citrate-61)

Organic Residue 35.80 Total 2521.00 Total 2521.00






in Kg Stage-2 78.00 (2S, 3S, 5S)-2-Amino-3-hydroxy-

5-(1-tetra hydro pyrmid-2-onyl)-3-methyl butanoyl) amino-1,6-diphenyl hexane-S-pyro glutamate (THP)

100.00

Sodium Boro hydride 10.00 1,2-Dimethoxy ethane Recovery 760.00 1,2-Dimethoxy ethane 800.00 1,2-Dimethoxy ethane Loss 40.00 Ammonium chloride 10.00 THF Recovery 280.00 Imidazole 12.00 THF Loss 15.00 THF 300.00 IPA Recovery 180.00 Ammonium formate 22.00 IPA Loss 10.00 Methanol 800.00 Methanol Recovery 750.00 Palladium carbon 10.00 Methanol Loss 40.00 L-Pyro glutamic acid 22.00 DMF Recovery 285.00 DMF 300.00 DMF Loss 15.00 IPA 200.00 Effluent water 533.30 Valina 20.00 (Water-487.80,Boric acid-10.37,

Sodium Chloride-19.92, Generated water-9.02, ,THF-5, Methanol-5,)

Methyl chloro formate 17.00 Spent Catalysts 12.00 Acrylonitrile 10.00 (Palladium carbon Recovered-10,

Raney Nickel Recovered-2.00)

Hydrogen gas 1.00 Toluene Recovery 30.90 Raney Nickel 2.00 Process Emissions 21.12 Water 500.00 (Hydrogen-0.67,Carbondioxide-

14.75,Ammonia-5.7 )

Inorganic Solid Waste 10.00 (Ammonium Chloride) Organic Residue 31.68 (Imidazole-11.42, organic

impurities-5.26,IPA-10, Methanol-5)

Total 3114.00 Total 3114.00




Batch Size: 100.0 Kg Name of the input Quantity


in Kg THP(Lopinavir Intermediate) 100.00 Stage-4 103.00 2,6-Dimethyl phenoxy acetyl chloride (DPC)

35.00 Ethyl acetate Recovery 760.00

Ethyl acetate 800.00 Ethyl acetate Loss 40.00 Sodium bicarbonate 17.00 Acetone Recovery 473.00 Sodium sulphate 5.00 Acetone Loss 25.00 Acetone 500.00 Effluent Water 537.46

Activated carbon 10.00 (Water-500,generated water-

3.64,Sodium chloride-11.82, Pyroglutamic acid-22)

Water 500.00 Spent Carbon 10.00 Inorganic Solid Waste 5.00 (Sodium Sulfate) Organic Residue 4.64

(Organic Impurities-2.64, Acetone-2)

Process Emissions 8.90 (Carbon dioxide) Total 1967.00 Total 1967.00


Batch Size: 100.0 Kg Name of the input Quantity


in Kg Stage-4 103.00 Lopinavir(pure) 100.00 Ethanol 920.00 Ethanol Recovery 865.00 Activated carbon 10.00 Ethanol Loss 45.00 Hyflow 5.00 Spent carbon & Hyflow 15.00 Water 500.00 Effluent Water 505.00 (Water-500,Ethanol-5) Organic Residue 3.00 (Organic impurities-3,Ethanol-5) Total 1538.00 Total 1538.00



4. OMEPRAZOLE

Process Description

Stage-1

5-Methoxy-2-(5-methoxy-3, 5-dimethyl-pyridin-2-ylmethylsulfanyl)-1-H-Benzimidazole

compound on reaction with Hydrogen Peroxide produces Omeprazole pharma.

Methanol and Acetone are used in the process.

OMEPRAZOLE

Route of Synthesis:

Stage-1

N

NH

OH3C

S

NCH3

H3C OCH3

5-Methoxy-2-(4-methoxy-3,5-dimethyl-pyridin-2-ylmethylsulfanyl)-

1H-benzoimidazoleC17H19N3O2S

329.42

+ H2O2

Hydrogen peroxide

34.01

Methanol

HN

NS

ON

O

O

OmeprazoleC17H19N3O3S

345.42

+ H2O

18.0



OMEPRAZOLE

Flow Chart:

Stage-1

5-Methoxy-2-(4-methoxy-3,5-dimethyl-pyridin-2ylmethylsulfanyl)-1H-BenzimidazoleHydrogen peroxideMethanolAcetone

Methanol RecAcetone Rec

OMEPRAZOLE

OMEPRAZOLE

Material Balance:

Material balance of Omeprazole Stage-1

Batch Size:100 Kg Name of the input Quantity


in Kg 5-Methoxy-2-(5-methoxy-3,5-dimethyl-pyridin-2-ylmethylsulfanyl)-1-H-Benzimidazole

94.00 Omeprazole 100.00

Hydrogen peroxide 12.00 Methanol Recovery 237.50 Methanol 250.00 Methanol Loss 12.50 Acetone 250.00 Acetone Recovery 237.50 Acetone Loss 12.50 Effluent water 6.00 (Generated Water) Total 606.00 Total 606.00



5. PANTOPRAZOLE SODIUM

Process Description

Stage-1

(3, 4-Dimethoxy-pyridin-2-yl)-methanolThionyl chloride compound when reacts with

Thionyl chloride an intermediate is formed.MDC is used as solvent. Product is

crystallized in Methanol. Finally product is purified with Acetone.

Stage-2

When 2-Chloromethyl-3, 4-dimethoxy-pyridine Hydrochloride reacts with 5-diFluoro

methoxy-2-mercapto-benzimidazole, in presence of Sodium hydroxide, product is

formed. Mythylene dichloride is the solvent.

Stage-3

Stage-9 is treated with Sodium hypochlorite in presence of Sodium hydroxide, to

produce the Pantoprazole sodium .This is purified in Acetone. Methylene dichloride is

used as solvent.



PANTOPRAZOLE SODIUM

Route of Synthesis:

Stage-1:

N

OCH3

OCH3

CH2OH

C8H11NO3

169.18

+ SOCl2

Thionyl chloride

118.97

MDC,MeOH

N

OCH3

OCH3

CH2Cl

HCl

224.12

+ SO2

Sulphur dioxide

64.02-Chloromethyl-3,4-dimethoxy-

pyridine Hydrochloride

C8H11Cl2NO2

(3,4-Dimethoxy-pyridin-2-yl)-methanol



Stage-2:

N

OCH3

OCH3

CH2ClHCl

C8H10ClNO2.HCl

224.12

+

NHN

OF

F

SH

5-Difluoromethoxy-2-mercaptobenzimidazole

C8H6F2N2OS

216.21

+ 2 NaOH MDC

2X40.0=80

N

OCH3

OCH3

CH2 SN

HN

OF

F

C16H15F2N3O3S

367.37

+ 2 NaCl + 2 H2O

Sodium chloride2x58.5=117

2x18.0=365-Difluoromethoxy-2-(3,4-dimethoxy-pyridin-2-ylmethylsulfanyl)-

1H-benzoimidazole

2-Chloromethyl-3,4-dimethoxy-pyridine Hydrochloride



Stage-3:

N

OCH3

OCH3

CH2 SN

HN

OF

F

C16H15F2N3O3S

367.37

+ NaOCl + NaOHMDC

Acetone

N

OCH3

OCH3

CH2 SN

N

OF

F

O

+ NaCl +Na

H2O

Pantoprazole sodium

C16H14F2N3NaO4S

405.35

Sodium chloride

58.5

18.0

Sodium hypochlorite

74.44

Sodium hydroxide

40.0

5-Difluoromethoxy-2-(3,4-dimethoxy-pyridin-2-ylmethylsulfanyl)-

1H-benzoimidazole



PANTOPRAZOLE SODIUM

Flow Chart:

(3,4-Dimethoxy-pyridin-2-yl)-methanolThionyl chloridechloroform Stage-1 Chloroform Rec

Stage-15-diFluoromethoxy-2-mercapto-benzimidazole Sodium chlorideStage-2

Stage-2Sodium hypochloriteSodium Hydroxide

Sodium chlorideEffluent water

Stage-3

PANTOPRAZOLE SODIUM



PANTOPRAZOLE SODIUM

Material Balance:

Material Balance of Pantoprazole Sodium Stage-1


in Kg Name of the output Quantity

in Kg (3,4-Dimethoxy-pyridin-2-yl)- methanolThionyl chloride

85.00 Stage-8 (Chloro compound)

112.00

Thionyl chloride 60.00 Chloroform Recovery 810.00 Chloroform 850.00 Chloroform Loss 40.00 Methanol 125.00 Methanol Recovery 99.00 Acetone 200.00 Methanol Loss 25.00 Acetone Recovery 189.00 Acetone Loss 10.00 Process Emission 32.00 (Sulphur Dioxide) Organic Residue 3.00 (Organic Impurities-1,

Methanol-1,Acetone-1)

Total 1320.00 Total 1320.00

Material Balance of Pantoprazole Sodium Stage-2



in Kg Stage-1 112.00 Stage-2 183.00 5-diFluoromethoxy-2-mercapto- benzimidazole

108.00 Toluene Recovery 472.00

Sodium Hydroxide flakes 40.00 Toluene Loss 25.00 Toluene 500.00 Effluent Water 778.00 Water 700.00 (Water-700,Sodium

Chloride-58.5,gen.Water-18, Toluene-1.5)

Organic Residue 2.00 (Organic Impurities-0.5,

Toluene-1.5)

Total 1460.00 Total 1460.00



Material Balance of Pantoprazole Sodium Stage-3 Pharma



in Kg Stage-8 183.00 Pantoprazole Sodium 200.00 Sodium hypochlorite (7%) 500.00 MDC Recovery 950.00 Sodium Hydroxide flakes 20.00 MDC Loss 50.00 Ammonium Chloride 25.00 Acetone Recovery 378.00 Methylene dichloride 1000.00 Acetone Loss 20.00 Activated Carbon 10.00 Effluent Water 1730.00 Acetone 400.00 (Water-1200,gen.water-9,

Sodium chloride-29,water from sodium hypochlorite-465, Aluminum chloride-25, Acetone-2)

Water 1200.00 Spent carbon 10.00 Total 3338.00 Total 3338.00



Annexure - IV

WATER CONSUMPTION DETAILS

S. No Purpose Water Input In KLD

1 Process 8.00 2 Washings 2.00 3 Boiler Daily Make up 18.00 4 Cooling Daily Towers Make up 36.00 5 DM Plant 1.00 6 Scrubbing system 2.00 7 Domestic Usage 3.00 8 Gardening 3.00 Total 73.00



Annexure - V

SOLID WASTE DETAILS

S. No Description Quantity In

Kg/Day

Method Of Disposal

1 Organic Solid Waste 420.00 Sent to Cement Industries 2 Inorganic solid waste 120.00 Sent to TSDF 3 Spent Carbon 20.00 Recycle till M. B. value is less

than 100 & send to cement industries

4 ETP Sludge 50.00 Sent to TSDF 5 MEE salts 900.00 Sent to TSDF 6 Solvent distillation Residue 35.00 Sent to Cement Industries 7 Coal Ash from Boiler 3500.00 Sent to Brick manufacturers

HAZARDOUS WASTE DETAILS

S. No Description Quantity Mode of Disposal 1 Waste Oils & Grease 500 Litres /

Annum SPCB Authorized Agencies for Reprocessing/Recycling

2 Detoxified Containers 300 No’s/Month After Detoxification sent back to suppliers/SPCB Authorized Parties

3 Used Lead Acid Batteries

2 No’s/Year Send back to suppliers for buyback of New Batteries



Annexure - VI

STACK EMISSION DETAILS FOR BOILERS

Particulars Units 2.0 TPH Coal fired Boiler

1.0 TPH Coal fired Boiler

Type of Fuel -- Indian Coal Indian Coal

Coal Consumption TPD 5.0 2.5

Ash Content % 47 47

Sulphur Content % 0.8 0.8

Nitrogen Content % 1.07 1.07

No. of Stacks No 1 1

Height of stack M 30 30

Diameter of Stack M 0.60 0.60

Temperature of Flue Gas oC 95 95

Velocity of Flue Gas m/s 7.5 7.5

Particulate Matter at outlet of Bag

filter (Based on 115 mg/Nm3 at

outlet)

gm/sec 0.24 0.24

Sulphur dioxide emission gm/sec 0.46 0.23

Oxides of Nitrogen emission gm/sec 0.62 0.31



STACK EMISSIONS FOR THERMOPACK BOILER

S. No Stack Connected to

Stack Ht(m)

Dia of stack

at top(m)

Temp. of exhaust gases (0C)

Exit velocity (m/sec)

Pollutant Emission Rate(mg/Nm3)

PM SO2 NOX 1 2lakh K.Cal

Thermic fluid Heater

30.0 0.30 120 10.9 67 20 29

STACK EMISSION DETAILS FOR D.G.SET

Capacity In KVA

Emission of SPM in Mg/Nm3

Emission Of SO2

in Mg/Nm3

Emission of NOx

in Mg/Nm3

Stack dia. In m

Flue Gas Temp. in

OC

Stack Height in (m)

Flue gas Velocity In m/sec.

200 KVA 65.0 110.0 135.0 0.30 220 10 18.50



Annexure - VII

PROCESS EMISSION DETAILS

POLLUTING PROCESS EMISSIONS

S. No Name of the Gas Quantity In Kg/Day

Treatment Method

1 Ammonia 71.00 Scrubbed by using Chilled water media 2 Sulfur dioxide 24.00 Scrubbed by using C. S. Lye solution

NON-POLLUTING PROCESS EMISSIONS

S. No Name of the Gas Quantity In Kg/Day

Treatment Method

1 Carbon dioxide 114.00 Dispersed into Atmosphere 2 Hydrogen

17.00 Diffused with Nitrogen through Flame

arrestor. 3 Methane

34.00 Diffused with Nitrogen through Flame

arrestor



Annexure - VIII

LIST OF RAW MATERIALS

GROUP-A

1. BENZYL MAGNESIUM CHLORIDE

S. No Raw Material Consumption/ Batch in Kgs

Consumption/ Day in Kgs Source

1 Magnesium 160.00 26.67 Indigenous 2 Benzyl chloride 840.00 140.00 Indigenous

2. LITHIUM TERT-BUTOXIDE



1 Lithium 28.00 18.67 Indigenous 2 Tert-Butanol 325.00 216.67 Indigenous

3. LITHIUM HEXAMETHYLDISILAZANE



1 Lithium metal 19.00 12.67 Indigenous 2 HMDS 483.00 322.00 Indigenous 3 THF 500.00 333.33 Indigenous



4. MAGNESIUM TERTIARY BUTOXIDE



1 Methyl Magnsium Chloride 214.00 178.33 Indigenous

2 THF 1400.00 1166.67 Indigenous 3 Tert-Butanol 200.00 166.67 Indigenous

5. BUTYL MAGNESIUM CHLORIDE


Consumption/ Day in Kgs

Source

1 Magnesium Metal 210.00 35.00 Indigenous 2 Butyl Chloride 790.00 131.67 Indigenous

6. POTASSIUM TERT BUTOXIDE



1 Potassium 185.20 61.73 Indigenous 2 Tert butanol 641.42 213.81 Indigenous



7. SODIUM AMIDE



1 Sodium 310.00 103.33 Indigenous 2 Ammonia 203.38 67.79 Indigenous

8. SODIUM HEXAMETHYLDISILAZINE



Source

1 Sodium amide 421.00 70.17 Indigenous 2 HMDS 1765.00 294.17 Indigenous

9. SODIUM TERT BUTOXIDE

S.No Raw Material Consumption/ Batch in Kgs


Source

1 Sodium 141.18 47.06 Indigenous 2 Tert-Butanol 650.00 216.67 Indigenous



GROUP-B

1. DOMPERIDONE



1 N-Carbethoxy-4-piperidone 80.00 186.67 Indigenous 2 Ammonia gas 28.00 65.33 Indigenous 3 Methanol 800.00 1866.67 Indigenous 4 Raney Nickel 30.00 70.00 Indigenous 5 Hydrogen 10.00 23.33 Indigenous 6 2,5-Dichloro Nitrobenzene 78.00 182.00 Indigenous 7 Sodium Carbonate 30.00 70.00 Indigenous 8 Toluene 350.00 816.67 Indigenous 9 Urea 20.00 46.67 Indigenous

10 Sodium Hydroxide (48%) 75.00 175.00 Indigenous 11 1-(3-Chloropropyl)-1,3-

dihydro-2H-benzimedazole-2-one

40.00 93.33 Indigenous

12 Sodium Carbonate 20.00 46.67 Indigenous 13 Methyl Isobutyl Ketone 1200.00 2800.00 Indigenous

2. ESOMEPRAZOLE MAGNESIUM TRIHYDRATE



1 Omeprazole sulfide 88.00 117.33 Indigenous 2 Cumin hydro peroxide 41.00 54.67 Indigenous 3 Potassium hydroxide 15.20 20.27 Indigenous 4 DET 11.30 15.07 Indigenous 5 Titanium isopropoxide 2.50 3.33 Indigenous 6 NEDIPA 4.50 6.00 Indigenous 7 Toluene 320.00 426.67 Indigenous 8 Methanol 100.00 133.33 Indigenous 9 Magnesium sulfate 16.00 21.33 Indigenous



3. LOPINAVIR



1 L-Phenyl alanine 75.00 75.00 Indigenous 2 1,2-Dimethoxy ethane 800.00 800.00 Indigenous 3 2,6-Dimethyl phenoxy acetyl

chloride (DPC) 35.00 35.00 Indigenous

4 Acetone 500.00 500.00 Indigenous 5 Acetonitrile 18.75 18.75 Indigenous 6 Acrylonitrile 10.00 10.00 Indigenous 7 Activated carbon 20.00 20.00 Indigenous 8 Ammonium chloride 10.00 10.00 Indigenous 9 Ammonium formate 22.00 22.00 Indigenous

10 Benzyl chloride 172.00 172.00 Indigenous 11 Benzyl magnesium chloride 46.00 46.00 Indigenous 12 Citric acid monohydrate 110.00 110.00 Indigenous 13 DMF 300.00 300.00 Indigenous 14 Ethanol 2595.00 2595.00 Indigenous 15 Ethyl acetate 800.00 800.00 Indigenous 16 Hydrogen gas 1.00 1.00 Indigenous 17 Hyflow 5.00 5.00 Indigenous 18 Imidazole 12.00 12.00 Indigenous 19 IPA 200.00 200.00 Indigenous 20 L-Pyro glutamic acid 22.00 22.00 Indigenous 21 Methanol 1234.00 1234.00 Indigenous 22 Methyl chloro formate 17.00 17.00 Indigenous 23 MTBE 1643.00 1643.00 Indigenous 24 n-Heptane 280.00 280.00 Indigenous 25 Palladium carbon 10.00 10.00 Indigenous 26 Potassium carbonate 190.00 190.00 Indigenous 27 Raney Nickel 2.00 2.00 Indigenous 28 Sodium amide 12.00 12.00 Indigenous 29 Sodium bicarbonate 17.00 17.00 Indigenous 30 Sodium Boro hydride 10.00 10.00 Indigenous 31 Sodium chloride 29.00 29.00 Indigenous 32 Sodium sulphate 5.00 5.00 Indigenous 33 THF 837.00 837.00 Indigenous 34 Valina 20.00 20.00 Indigenous



4. OMEPRAZOLE



1 5-Methoxy-2-(5-methoxy-3,5-dimethyl-pyridin-2-yl methyl sulfanyl)-1-H-Benzimidazole


2 Hydrogen peroxide 12.00 20.00 Indigenous 3 Methanol 250.00 416.67 Indigenous 4 Acetone 250.00 416.67 Indigenous

5. PANTOPRAZOLE SODIUM



1 (3,4-Dimethoxy-pyridin-2-yl)- methanolThionyl chloride 85.00 63.75 Indigenous

2 Thionyl chloride 60.00 45.00 Indigenous 3 Chloroform 850.00 637.50 Indigenous 4 Methanol 125.00 93.75 Indigenous 5 Acetone 600.00 450.00 Indigenous 6 5-diFluoromethoxy-2-

mercapto- benzimidazole


7 Sodium Hydroxide flakes 60.00 45.00 Indigenous 8 Toluene 500.00 375.00 Indigenous 9 Sodium hypochlorite (7%) 500.00 375.00 Indigenous

10 Ammonium Chloride 25.00 18.75 Indigenous 11 Methylene dichloride 1000.00 750.00 Indigenous 12 Activated Carbon 10.00 7.50 Indigenous



Annexure - IX

WASTE WATER DETAILS

S. No Purpose Effluent In KLD

1 Process 9.00 2 Washings 2.00 3 Boiler blow down 3.00 4 Cooling towers blow down 6.00 5 DM Plant Regeneration 1.00 6 Scrubbing system 2.00 7 Domestic 2.50 8 Gardening 0.00 Total 25.50

HTDS & LTDS DETAILS

S. No Purpose HTDS In KLD

LTDS In KLD

Effluent In KLD Disposal Method

1 Process 8.00 1.00 9.00 HTDS Effluent sent to ETP with MEE system. LTDS effluents treated in ETP-RO Rejects to MEE system and RO permeate to reuse, Condensate from MEE to reuse and MEE residue to ATFD.

2 Washings 2.00 0.00 2.00 3 Boiler blow down 3.00 0.00 3.00

4 Cooling towers blow down 0.00 6.00 6.00

5 DM Plant Regeneration 1.00 0.00 1.00

6 Scrubbing system 2.00 0.00 2.00

7 Domestic 0.00 2.50 2.50 Septic tank followed by Soak pit

Total 16.00 9.50 25.50

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