Alcon Biosciences Plans Expansion Of its API Bulk Drug Unit
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Alcon Biosciences Plans Expansion
Of its API Bulk Drug Unit
From 5 TPM to 76 TPM
Alcon Biosciences Pvt. Ltd. plans for expansion of the production capacity of its API Bulk Drug Unit from 5 Ton/Month to 76 Ton/Month at GIDC Vapi in Valsad District, Gujarat.
Capacity Expansion :
API Bulk Drug
From 5 Ton/Month to 76 Ton/Month
The plant will have a production capacity of:
1. Phenytoin Sodium
Existing : 5 TPM
Proposed : 20 TPM
Total after Expansion : 25 Ton/Month
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2. Lidocaine Hydrochloride
Existing : Nil
Proposed : 40 TPM
Total (New) : 40 Ton/Month
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3. Trimetazidine Di Hydrochloride
Existing : Nil
Proposed : 1 TPM
Total (New) : 1 Ton/Month
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4. Alendronate Sodium Trihydrate
Existing : Nil
Proposed : 10 TPM
Total (New) : 10 Ton/Month
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Existing: 5 Ton/Month
Total (after expansion) : 76 Ton/Month
Location : GIDC Vapi,Valsad District
Gujarat.
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As on May 16, 2013 : The Project is under Planning Stage .
Total existing site area is 2702 Sq. Meter.
The expansion project would come up in the existing plant premises.
The unit has already developed 150 Sq. Meter of area as a green belt out of total 2702 Sq. Meter of plot area.
The company will also develop green belt on periphery of the factory.
In addition to this, majority of the vacantland shall be planted with trees and grasses.
IMPORTANT: As per the the discussion we had
on 09.05.2013 with Alcon Biosciences Pvt. Ltd.
the Project is under Panning Stage.
The company is waiting for Environmental Clearance.
The Project is Scheduled to be Completed by
in 7-8 Months from the date of the commencement
of the project work.
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So, this is the RIGHT TIME to contact and Follow Up at following address obtain the detailed Enquiry of each product in time and to
submit your quotation subsequently.
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The Main Scope of Supply includes:
1. Boiler
Capacity : 1 TPH - 1 No.
Fuel : Natural Gas (900 SCM/Day)
Stack : Height- 11 Meters
Heat Exchangers, Air Pre-heater
Existing Status of Heating Equipment:
Presently the company is operating One No. of Boiler
1. Boiler
Capacity : 800 Kgs./Hr - 1 No.
Fuel : Natural Gas (870 SCM/Day)
Stack : Height- 11 Meters
Air Polution Control:
The source of air pollution due to the proposed expansion project will be Flue gas emission
& process gas emission.
The source of flue gas emission will be from the stack attach to boiler & D G set.
There will be one number of 250 KVA DG Set for emergency backup.
Adequate height of chimney provided along with SMF. Process gas emission from reaction
vessel.
Adequate capacity of Water Scrubber followed by Alkali Scrubber along with 11 meters height of vent & SMF provided.
************************
Manufacturing process:
Phenytoin Sodium:
Benzyl (Pure) is treated with urea, caustic soda and methanol to obtain Phenytoin Base. This Phenytoin base is reacted with caustic soda gives final product Phenytoin sodium,which is dried & packed.
Lidocaine Hydrochloride:
Chloro Acetylxylidide is condensed with dimethylamine to get crude Lidocaine. This is purified through vaccum distillation to get Lidocaine Base pure.
This Pure Lidocaine is reacted with hydro chloric acid to get Lidocaine hydro chloride.
Trimetazidine Di Hydrochloride
2,3,4 tri methoxy benzaldehyde is dropped into Reactor which is found anhydrous piperazine and formic acid. Excess formic acid is recovered by neutralization with sodium hydroxide.
At higher pH, extraction with a solventremoves excess piperazine. Tri metazidine base isthen treated with IPA HCl to get Trimetazidine di hydro chloride.
Excess of hydrochloric acid isremoved by washing with methanol.
The Tri metazidine di hydro chloride is purified by means of activated carbon and after active carbon is separated the tri metazidine di hydro chloride is cooled. The precipitate is crystallized and then it is swirled, washed with water and
methanol. The swirled & dried productis packed.
Alendronate Sodium Trihydrate
First to prepare 45 % of Caustic Soda Flakes Solution in a S.S. Reactor than to charge Alendronic Acid under Stirring. Than to reflux the Mixture for two Hrs. than to add Activated Carbon stir for ½ hrs. than to filter the
reaction mass and to collect the clear filtrate & cool to 5 degree Centigrade for two
hrs. and centrifugre finally to wash the wet cake by Methanol & dry to pack...
Other Equipments:
SS Jacketed Reactor
---------------------------------------------
Vapour Absorption Machine : 100TR/hr.
Fuel : Natural Gas (300 SCM/Day)
Stack : Height- 11 Meters
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Chilling Water plant
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Filter Drier
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Cooling Tower
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Scrubber
A. Size of 1st scrubber
1. 300 mm Dia x 1500 mm
2. MOC of scrubber PP/FRP
3. Circulating liquid Water
4. Size of Tank 500 liters, HDPE
5. Capacity of the pump m3/hr : 3 HP
B. Size of 2nd Scrubber
1. 300 mm Dia x 1500 mm
2. MOC of packed column PP/FRP
3 Circulating liquid Alkali
4. Capacity of the blower : 1500 Nm3/hr
5. Vent diameter in mm 200
6. Height of the vent from ground 11 meter
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DM/R.O. plant
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Water Softener
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Air Compressor
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Effluent Treatment Plant
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Pumps
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Centrifuge
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SS & HDPE Storage Tanks
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Compressor
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DG sets :
250 KVA- 1 No.
For back up in the common areas as well as for essential services
above D.G.sets will be installed..
( Presently No DG Set is installed in the plant )
********************************************
SOLVENT MANAGEMENT PLAN
• The Reactors shall be connected to an efficient condenser system with cooling/chilling water circulation.
• Reactor and solvent handling pumps shall have mechanical seals to prevent leakages. Also provide with breather valve to prevent losses.
• Solvent will be taken from underground storage tank to reactors through closed pipe line. Storage tank shall be vented through trap receiver & condenser operated on cooling water.
• The condensers to be provided with sufficient HTA and residence time so as to prevent any loss of solvent.
• Proper earthing to be provided were eversolvent handling is done.
• Entire plant to be flameproof.
• Solvents to be stored as per statutory requirement.
Solventshall be kept at a separate specified area with all the safety measures.
********************************************
Water Treatment Plant:
Pumps, Valves, Custom Pipeline Work, Plumbing Work
The total water requirement after expansion (after MEE Condensate /ATFD recycle)
will be 35.34 m3/Day,
Present consumption is 9.5 m3/Day.
The Water requirement will be sourced from GIDC Vapi.
Details of Water Consumption (After Expansion )
1.Domestic : 3.0 M3/Day
2.Process Water : 12.74 M3/Day
3.Boiler : 12 M3/Day
4. Cooling : 15 M3/Day
5. Washing 2 M3/Day
7. Scrubber 0.50 M3/Day
6. Gardening : 1 M3/Day
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Grand Total: 46.24 M3/ Day
Total Industrial : 42.24 M3/ Day
*Recycled water : 10.9 M3/ Day
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Total Fresh Water : 35.34 M3/Day
* (Condensate from MEE Recycled)
Details of Waste Water Generation (After Expansion )
1.Domestic : 3.0 M3/Day
2.Process Water : 12.5 M3/Day
3.Boiler : 4 M3/Day
4. Cooling : 1 M3/Day
5. Washing 2 M3/Day
7. Scrubber 0.50 M3/Day
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Grand Total: 23 M3/ Day
Total Industrial : 20 M3/ Day
**Concentrated effluent: 12.5 M3/ Day
---------------------------------------------------------------------------------
Normal Effluent: 7.5 M3/Day
** To MEE
Effluent Treatment Plant:
Total industrial effluent generation shall 20 m3/day.
Out of which 12.5 m3/day of concentrated effluent shall be collected separately, neutralized, filtered & evaporated in proposed Multi Effect Evaporation System.
About 10.9 m3/day of condensate from evaporation system & Agitated Thin Film Dryer (ATFD) shall be recycled in the process & balance 1.28 MT/day of solid organic waste sent to common incineration system .
Average 7.5 m3/day of normal effluent from boiler blow down, cooling tower, floor washing & scrubber shall be treated in primary followed by Tertiary Effluent Treatment plant & discharge into underground effluent drainage linei for further treatment.
3.0 m3/day of domestic effluent shall be passed through septic tank/soak pit of adequate capacity.
Other Equipments:
Dosing Systems, Heat Exchangers, Ball Mills, Drum Mixers, Agitators, Pulverizes, Dryers, Solvent Calibration Tank, S S Reaction Vessel with Stirrer, Gear & Elec. Motor, Holding Vessel, Automatic Filling, Pluging & Capping Machine, Patent Automatic Liquid Filling / Weighing Machine, AIR Scrubber with hoodes, Hot Water Bath, Semi Automatic Box Strapping Machine, Heat Shrink Wrapping Machine, Induction Sealing Machine, Water Pumps, Chemical Pumps, Storage Tanks, Water & Acid line Valves, Control Vales, Cooling Towers, Custom Pipeline Work.
Ventilation & Exhaust System
Complete Laboratory Equipments
Fire fighting System as per TAC norms,
Green Belt Development plan in 150 Sq.m Area and a scheme for Rainwater Harvesting have to be put in place.
Scope Of Entire Civil & Construction Work:
Construction of Office Building, Factory Shed- Boiler House, Substation-Control Panel- Electrical Work, Plumbing Work, Structural Steel fabrication and Erection Work, Fabrication Storage Tank, Vessels etc. etc.
Companies/ General Industries/ Manufacturers / Contractors/ Sub Contractors/ Manufacturers of Chemical Plant & Machineries, Water & Effluent Treatment Plant , Fire Fighting Equipments, Air-conditioning, Boilers, Air Pollution Control Equipment, Pumps, Motors Valves For Acid line, Pipeline Jobs for the above project may Contact for etc.etc. may Contact for Specified Enquiry at :
Alcon Biosciences Pvt. Ltd.
Plot No. A-1/ 2104,III Phase Area, Industrial estate
GIDC Vapi, Ta: Pardi, Valsad- 396 195, Gujarat, India
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Tel : + 91-260- 2401565
Fax : + 91-260- 2433964
Email : pl...@alconpharma.com
Website : www.alconpharma.com
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