Alathur
This site is located at Alathur village of Chengalpattu Taluk in Kancheepuram District. The plant is located about 3 km from the Bay of Bengal and about 12 kilometers away from Mamallapuram town on the East Coast Road. The site is part of the Small Industries Development Corporation (SIDCO) of the Government of Tamil Nadu.
As part of the project, OCPL will diversify the current operations on the existing site. It will also install a solvents recovery unit and the new sterile and non-sterile operations will have their own air emission recovery systems. All operations at this site will be in full compliance with the applicable World Bank guidelines.
There are two, seven and six-ton/h boiler systems, which burn, fuel oil. System 1 consists of six ton/h boilers and System 2 consists of three ton/h and four ton/ h boilers. Each of the boiler systems emits combustion gases through an independent stack. There is also a diesel back-up generator. As part of the project, OCPL will replace the boiler burners and will install particulate matter controls to ensure their compliance with the applicable World Bank guidelines.
The dust generated in the powder processing area is controlled with baghouses, the solvent vapors generated during the operation are recovered with a gas condensation system, and the acid fumes are controlled with packed column scrubbers. The sponsor will conduct stack emissions at each of the powder processing, solvents and acid vapor control devices, submit to IFC the results and corrective measures, as appropriate, along with the implementation deadlines and associated costs prior the first disbursement.
Water for process and drinking use is obtained from the municipal system and it is also purchased as surplus from agricultural wells in tankers. The process and domestics wastewaters generated are treated in an on-site wastewater treatment plant which will be upgraded to also treat the wastewaters generated by the proposed project and reuse them in the cooling towers, chilling plants, boiler steam production, etc. This will be a zero effluent discharge operation.
The residues from the evaporator bottoms and the waste solvents are incinerated in a dedicated incinerator which air emissions are controlled with a scrubber. The scrubber water is concentrated, further crystallized, and the salts generated are properly stored. The local authorities are in the process of setting up a secure landfill where these salts will be finally disposed. In the interim, OCPL will properly stored these wastes, ensuring that no soil or groundwater contamination will occur. The clear water is reused.
The non-incinerated solid residues are segregated and adequately stored in a warehouse. The sponsor is constantly identifying alternatives to reuse these residues. IFC will be kept informed of the new initiatives related to recycling and reuse of OCPL residues.
OCPL used vapor absorption systems and/or ammonia based systems for cooling and refrigeration operations. The freon-based room air conditioners will be phased out, as replacements are needed. Ambient noise levels will continue to be maintained in compliance with the applicable World Bank guidelines.
OCPL will ensure that the workplace noise levels as well as workplace dust and vapors concentrations comply with the applicable World Bank guidelines. OCPL will conduct periodic monitoring and report the results to IFC.
OCPL has a department in charge of environmental, health and safety issues, which implements rigorous health and safety programs. The employees undergo pre-medical as well as periodic medical examinations. Periodic safety as well as housekeeping audits are conducted. OCPL has installed a complete fire prevention system, maintains a trained fire brigade available at all times and conducts fire drills and fire safety training sessions. In addition, it has developed procedures for handling of hazardous materials, risky jobs (cold work, hot work, excavation, etc.) and has conducted a Hazard Operations (HAZOP) assessment and implemented the needed recommendations to reduce the likelihood of accidents.
Aurangabad
As part of the project, OCPL has acquired a bulk drug facility, located in the Industrial Estate zone at Maharashtra Industrial Development Corporation, at approximately 25 kilometers from the city of Aurangabad, to be upgraded.
OCPL anticipates installing all needed air pollution control systems to ensure compliance with the applicable World Bank guidelines. A detailed control program indicating sources, pollutant concentrations and control measures will be submitted to IFC before the first disbursement. The project site ambient air concentrations will be also provided prior the first disbursement.
The process as well as the domestic wastewaters generated will be treated in an on-site wastewater treatment plant to the Wold Bank guideline applicable concentrations. The sludges will be properly disposed in a secured landfill to prevent soil contamination.
OCPL has conducted a HAZOP analysis at the Aurangabad plant. All recommendations will be implemented by project completion. In addition, this plant will have the same health and safety measures already established at the Alathur plant and will establish procedures for proper handling and storage of hazardous materials and residues.
Sholinganallur
The OCPL Research and Development (R&D) laboratory, located in Sholinganallur, in the Chennai District, at approximately 30 km from the Chennai Sea Port and 5 kilometers from the sea Bay of Bengal, will be also upgraded as part of the project.
As part of the upgrade, OCPL anticipates installing an animal house to conduct testing. The wastes generated from this operation including animal carcasses and supporting materials (i.e., bedding husk, discarded animal feed, etc.) will be destroyed in a dedicated and properly controlled medical waste incinerator. The incinerator emissions will be in compliance with the applicable World Bank guidelines.
All wastewater generated at the R&D site will be transported by tankers to the Alathur wastewater treatment plant for treatment. The laboratory solvent residues will be also transported to the Alathur facility to be treated. Only dedicated tankers will be used for this purpose. The distance between the sites is approximately 25 kilometers.
OCPL will implement at the R&D laboratory the same health and safety measures already established at the Alathur plant and will develop procedures for proper handling and storage of hazardous materials and residues.
Irungattukottai
The new OCPL formulation and manufacturing plant will be located in Irungattukottai in the Industrial Estate complex of Tamil Nadu at approximately 42 km from Chennai. This site, which is surrounded by large-scale industries, was obtained through willing buyer/willing owner transaction in May 2000 and has utilities supported by the industrial estate.
OCPL is currently conducting an environmental impact assessment for this site and expect to have it complete by the end of March 2001. Copy of the EIA acceptable to IFC will be submitted as soon as it is ready but not later than the first disbursement.
OCPL will implement the same health and safety measures already established at the Alathur plant. No CFC containing equipment will be installed.
OCPL will develop procedures for proper handling and storage of hazardous materials and residues, will conduct a HAZOP, and ensure that it has developed standard operating procedures (SOPs) for all its operations. Outlines of the health and safety measures; the SOPs relevant to environmental, health and safety aspects; as well as copy of the HAZOP recommendations will be submitted to IFC as soon as they are completed but not later than project completion.
The preventive maintenance, accident prevention, and contingency and emergency response programs will be completed before the new plant begins operation and will be submitted to IFC before project completion.
At project completion and after implementation of the corrected actions, OCPL will commission an independent environmental audit and will submit the results to IFC to demonstrate compliance of the Project with the applicable World Bank guidelines and the Indian environmental regulations.
OCPL will establish a corporate environmental, health and safety department in charge of overseeing the environmental performance of all its operations and ensuring compliance of the Project with the applicable environmental requirements. OCPL will develop and implement an environmental management system integrating thereby the environmental, health and safety activities of their operations to ensure the sound environmental performance of all its operations. OCPL has already established a system at the Alathur plant since this plant is already ISO 14000 certified.
