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M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
SMT Organic Chemicals Pvt. Ltd A-204, Amargian Complex, Lal Bahadur Shastri Marg, Khopat,
Thane (W) Mumbai 400601
Tel-022-41128000 Fax-022-21720036
Mobile: - 7678018473
Email ID: smtorganics@gmail.com
Proposed Organic Manufacturing Plant at
Additional Patalganga MIDC, Plot No. E-
127, Taluka Khalapur, Dist. Raigad,
Maharashtra
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
i
Contents 1. Executive Summary .............................................................................................................. 1
1.1 General .............................................................................................................................. 1
1.2 Salient Features of the plant site ................................................................................... 1
1.3 Proposed Products .......................................................................................................... 2
2. Introduction of the Project/Background Information....................................................... 6
2.1 About Project & Proponent ............................................................................................ 6
2.2 Brief description and Nature of the project ................................................................. 6
2.3 Need for the Project & Project Benefits........................................................................ 7
2.4 Demand and Supply Gap .............................................................................................. 10
2.5 Imports Vs Indigenous Production .............................................................................. 14
2.6 Export Possibility .......................................................................................................... 14
2.7 Domestic /Export Markets ........................................................................................... 14
2.8 Employment Generation (Direct & Indirect) .............................................................. 15
2.9 Manpower ..................................................................................................................... 15
2.10 Project Cost: ............................................................................................................... 15
3. Project Description ............................................................................................................. 16
3.1 Project Site ..................................................................................................................... 16
3.2 Details of Alternative Sites and Justification of Site Selection ................................. 23
3.3 Details of Manufacturing Process ............................................................................... 23
3.4 Raw Material Requirements ........................................................................................ 54
3.5Resource Optimization / recycling and reuse envisaged in the project, if any, should
be given. .............................................................................................................................. 62
3.6 Recovery System ........................................................................................................... 62
3.7 Utility Requirements & its Source ............................................................................... 63
3.8 Hazardous Waste Generation and Management (Liquid and Solid) ........................ 66
4. Site Analysis ........................................................................................................................ 67
4.1 Connectivity ................................................................................................................... 67
4.2 Land Form, Land use and Land ownership ................................................................. 67
4.3 Existing Infrastructure ................................................................................................. 67
4.4 Topography ................................................................................................................... 68
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
ii
5. Planning Brief ..................................................................................................................... 69
5.1 Planning Concept (type of industries, facilities, transportation etc. ) Town and
Country Planning/Development authority Classification ................................................ 69
5.2 Population Projection ................................................................................................... 69
5.3 Land Use Planning (breakup along with green belt etc.) .......................................... 69
5.4 Amenities/Facilities ....................................................................................................... 70
5.5 Risk Assessment, HAZOP Study & Disaster Management Plan ................................. 70
6. Proposed Infrastructure .................................................................................................... 71
6.1 Industrial Area (Processing Area) ................................................................................ 71
6.2 Residential Area (Non Processing Area) ..................................................................... 71
6.3 Green Belt ...................................................................................................................... 72
6.4 Social Infrastructure ..................................................................................................... 72
6.5 Connectivity (Traffic and Transportation Road/Rail/Metro/Water ways etc) ......... 72
6.6 Drinking Water Management (Source & Supply of water) ...................................... 72
6.7 Industrial Pollution Details ........................................................................................... 72
6.7.1 Sewerage System/ ETP Details .................................................................................. 72
6.7.2 Noise & Vibration Control ......................................................................................... 79
8. Rehabilitation and Resettlement (R and R) Plan ............................................................. 81
9. Project Schedule & Cost Estimate ..................................................................................... 82
9.1 Schedule of Approval and Implementation ................................................................ 82
9.2 Capital Investment ........................................................................................................ 82
10. Analysis of proposal (Final Recommendations) ............................................................. 83
Table
Table No. 1.1 Proposed Products and Production Capacity ............................................................. 2
Table No. 1.2 Details of the proposed products with their uses .................................................... 3
Table No. 3.1 Salient features of the project site and study area ................................................ 18
Table No. 3.2 Breakup of Land ................................................................................................................. 19
Table No. 3.3 Material Balance & Chemical Composition (Chemical Reaction) –Hexamine
............................................................................................................................................................................. 30
Table No. 3.4 Material Balance & Chemical Composition –UF Resin Liquid & Melanine
Formaldehyde (MF) Liquid Resin ............................................................................................................ 33
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
iii
Table No. 3.5 Material Balance & Chemical Composition (Chemical Reaction) –Phenol
Formaldehyde (PF) (Liquid resin) AND/OR Phenol Formaldehyde (PF) (Powder resin) .... 38
Table No. 3.6 Material Balance & Chemical Composition (Chemical Reaction) – Methyla 48
Table No. 3.7 Product wise unit process and Operations .............................................................. 48
Table No. 3.8 Major Equipment’s and Machineries Details ........................................................... 48
Table No. 3.9 Major Equipment & Machinery Details of Formaldehyde Plant .................... 50
Table No. 3.10 Details of Raw Material (product wise) Requirements ..................................... 54
Table No. 3.11 Inventory of the storage material ............................................................................. 56
Table No. 3.12 Estimated Quantities of Solid waste and proposed disposal methods ........ 66
Table No. 6.1 Product-wise Water Requirement & Wastewater Generation .......................... 73
Table No. 6.2 Details of Gaseous Emissions from Process ............................................................. 77
Table No. 6.3 Air Pollution Control Units ............................................................................................. 77
Table No. 6.4 Details of Flue Gas Stacks ............................................................................................... 78
Table No. 9.1 Capital Cost ........................................................................................................................... 82
Figure
Figure No. 1.1 Glimpses of the Project Site ............................................................................................ 5
Figure No. 3.1 Location of the project site ........................................................................................... 16
Figure No. 3.2 MIDC MAP showing project site ................................................................................ 17
Figure No. 3.3 Plant Layout ....................................................................................................................... 20
Figure No. 3.4 Google Image showing 10 km radius from project site ...................................... 21
Figure No. 3.5 Toposheet map showing 10 km radius from project site ................................ 22
Figure No. 3.6 Process flow sheet .......................................................................................................... 27
Figure No.3. 7 Process flow sheet of Hexamine ................................................................................ 29
Figure No. 3.8 Process flow sheet of Urea Formaldehyde (UF) & Melamine Formaldehyde
(MF) (Liquid Resin) AND/OR Urea Formaldehyde (UF) & Melamine Formaldehyde (MF)
(Powder Resin) .............................................................................................................................................. 36
Figure No. 3.9 Process flow sheet of Phenol Formaldehyde (PF) (Liquid resin) AND/OR
Phenol Formaldehyde (PF) (Powder resin) ......................................................................................... 40
Figure No. 3.10 Process flow sheet of Sliver Refining ..................................................................... 41
Figure No.3. 11 Process flow sheet of Urea Formaldehyde Concentrate (UFC-85) ............... 46
Figure No. 3.12 ETP Layout ........................................................................................................................ 75
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
1
1. Executive Summary
1.1 General
SMT ORGANIC CHEMICALS PRIVATE LIMITED is proposing to set up Organic
Manufacturing unit at Plot No.E-127 Additional Patalganga MIDC, Khalapur, Dist. Raigad
Maharashtra. The said unit is designed to manufacture various chemicals like
Formaldehyde (37%), Hexamine, Urea Formaldehyde (UF) & Melamine Formaldehyde
(MF) (Liquid Resin) / (Powder Resin), Phenol Formaldehyde (PF) (Liquid resin) / (Powder
resin), Silver refining, Urea Formaldehyde Concentrate (UFC), Methylal (99.5%) etc.
The proposed project has been planned for the manufacturing of synthetic organic
chemicals. The entire development will take about 1 year for the completion of proposed
project. The construction activities and installation of plant & machineries will start after
obtaining Environmental Clearance from Ministry of Environment, Forests and Climate
Change (MoEF & CC) and Consent to Establish from Maharashtra Pollution Control Board
(MPCB).
1.2 Salient Features of the plant site
The project site is located at Plot No. E-127, Additional Patalganga MIDC, Khalapur,
in the Raigad District Maharashtra our Plot Area – 3997 Square Meter, having all
basic infrastructure facilities like availability of water, electricity, fuel, transport,
telecommunication systems etc. as the site is located in notified industrial area.
Availability of trained and skilled manpower in nearby areas.
Patches of reserve forest and Karnala Bird Wild Life Sanctuary exist within 10 km
radius from project site
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
2
1.3 Proposed Products
The unit proposes to manufacture following synthetic organic chemicals with total
maximum production capacity is given below for 300 days production
Table No. 1.1 Proposed Products and Production Capacity
Sr. No.
Product Name Production
Capacity (MTA)
1 Formaldehyde (37% to 55% Concentration) AND 36,000
2 Hexamine OR 3000
3A Urea Formaldehyde (UF) & Melamine Formaldehyde (MF) (Liquid Resin)AND/OR
31,304
3B
Urea Formaldehyde (UF) & Melamine Formaldehyde (MF) (Powder Resin) – 3A converted to 3B OR
15,652
4A Phenol Formaldehyde (PF) (Liquid resin) AND/OR 86,747
4B Phenol Formaldehyde (PF) (Powder resin) – 4A converted to 4B
43, 374
5 Silver refining OR 5
6 Urea Formaldehyde Concentrate OR 20,000
7 Methylal (99.5%) 33,333
Notes:
Production capacity of 36,000 MT/year for Formaldehyde Plant is derived
considering 37% concentration of Formaldehyde.
The Plants mentioned at Sr. Nos. 3A and 4A shall have the dual flexibility to
manufacture both liquid and powder products in varied proportions. The
production capacities for products in powder form are taken on the basis of100%
conversion of liquid product into powder form.
After production of 36,000 MT/year Formaldehyde, the products of 2, 3A, 4A, 6, 7
are derivative products of formaldehyde.
Silver used as silver catalyst in formaldehyde production will be refined as
mentioned in product 5 – one/two times a year.
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
3
After production of 36,000 Formaldehyde, it will be used to make 100 % of product
3A or 4A or 6 or 7 based on market conditions.
The proposed products are widely used for direct applications and also as raw materials
for various types of industries. Details of the proposed products with their uses are
described in following Table No. 1.2
Table No. 1.2 Details of the proposed products with their uses
Sr. No.
Products CAS No. & Synonyms
Purity % (wt) Use of Product
1 Aqueous Formaldehyde (37%
Mixture, Formalin 37% to 55% Formaldehyde
In Lamination industry, intermediate chemical for Oil field formulations, raw material for Insulation/Fiberglass industry, Fumigant for Poultry Farms, basic chemical for Synthetic Resins, Moulding Compounds, Powdered & liquid Resins, dye stuff, soil ,disinfection ,Organic chemicals, Pharmaceuticals, Inorganic Synthesis, Leather and Fur, industries, Metal working industries, Paper processing Rubber industry, Textile industry, Water Treatment industry, Sugar industry, Photographic Chemicals, Foundry moulds embalming fluids & Preservatives
2 Urea Formaldehyde Concentrate (UFC-85)
Mixture 60% Formaldehyde and 25% Urea
Used as Conditioning/anti caking agent for Urea Fertilizer raw material for Amino Resins, Spray Coating Agent for Urea Fertilizer, Slow Release Fertilizer, Urea Formaldehyde liquid resins, UF powdered resins, UF moulding Compounds, UF glues & adhesives
3 Hexamine 100-97-0, Hexa Methylene Tetra Amine
98.20% Used in Rubber Industry, Explosives Industry, Fuel Industry, Synthetic Resin Industry, Pharmaceuticals industry Photographic industry, Metal industry, Organic Synthesis industry.
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
4
Sr. No.
Products CAS No. & Synonyms
Purity % (wt) Use of Product
Leather Industry. Paper/ Cellulose industry. Lubricants Industry & Fertilizer Industry
4 Urea Formaldehyde (UF) (Liquid & Powder Resins)
9011-05- 6 Liquid: 40-50% Powder: 94-98%
UF Resin: Wood working Glues for MDF / Block / Ply /Chip boards moulding; Materials, Surface Coatings, textile and paper varnishes Adhesives,
5 Melamine Formaldehyde(MF) (Liquid & Powder Resins)
9003-08- 1 Liquid: 40-50% Powder: 94-98%
MF Resin: Decorative Laminates, Laminates for special electrical applications Textiles and paper Varnishes, Surface coatings, Moulding Materials
6 Phenol Formaldehyde (PF) Resins
Mixture Liquid: 45% Powder: 94-98%
Plywood/Chipboard/Flush Door manufacturing, Production of circuit boards, moulded Products like Pool, Balls, Laboratory counter tops coatings and Adhesives etc.
7 Methylal (99.5%) 109-87-5, Dimethoxymethane
99.50% Solvents, Perfumes, Resins, Adhesives, Paint strippers and protective coatings
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
5
Figure No. 1.1 Glimpses of the Project Site
Internal Road towards Factory Adjuscent area
Plot Showing Project site
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
6
2. Introduction of the Project/Background Information
2.1 About Project & Proponent
SMT Organic Chemicals Pvt. Ltd is proposed to setup organic manufacturing unit at plot
No E-127, Additional Patalganga MIDC, Khalapur, Dist. Raigad, Maharashtra. The
proposed unit shall have manufacturing facilities of various chemicals such as
Formaldehyde (37%), Hexamine, Urea Formaldehyde (UF) & Melamine Formaldehyde
(MF) (Liquid Resin) / (Powder Resin), Phenol Formaldehyde (PF) (Liquid resin) / (Powder
resin), Silver refining, Urea Formaldehyde Concentrate (UFC), Methylal (99.5%) etc.
The promoters of the project are already into sales & distribution of Formaldehyde,
Methanol, Melamine & Urea for the last 20 years. The Promoters represent known
chemicals manufacturers such as Hindustan Organic Chemicals Ltd. (HOCL), Gujarat State
Fertilizers Corporation (GSFC), Gujarat Narmada Fertilizers Corporation (GNFC), Atul Ltd.
etc. The Promoters are already into Methanol trading for over 20 years, which is the key
Raw Material for the manufacturing of Formaldehyde.
Now looking at the manufacturing opportunity, the promoter plans to set up its own
manufacturing factory for Formaldehyde (37%), Hexamine, Urea Formaldehyde (UF) &
Melamine Formaldehyde (MF) (Liquid Resin) / (Powder Resin), Phenol Formaldehyde (PF)
(Liquid resin) / (Powder resin), Silver refining, Urea Formaldehyde Concentrate (UFC),
Methylal (99.5%) etc. for which the market and customers are already established.
2.2 Brief description and Nature of the project
The proposed products are Synthetic Organic Chemicals and covered under Category 5
(f) as per new EIA notification of Ministry of Environment, Forest & Climate Change
(MoEF&CC) dated 14/09/06. The said project is being located in notified MIDC area will be
considered as category B project and public hearing (consultation) is waived off. The
proposed project for the manufacturing of various Synthetic Organic Chemicals will be
carried out at plot No. E-127, Additional Patalganga MIDC, Raigad district. Maharashtra.
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
7
The unit believes in sustainable development and equally concern about environment
preservation and pollution control. The unit will provide an adequate Environmental
Management System to ETP desired norms of effluent discharge (Water + Air + Solid) as
per the statutory recruitments for their proposed project and also will continue its
endeavour for the pollution prevention and betterment of environment.
2.3 Need for the Project & Project Benefits
The proposed products have wide applications in different types of industries. They are
usages for direct applications and also as raw materials. Looking to the increasing need
of the proposed products in domestic and national market & International and we have
large number of customers we have planned to manufacture these chemicals.
The unit is being set up also to achieve the critical mass of production and gain fair
market share in the domestic market for its range of products and to utilize the
increasing demand of the products in the domestic as well as international market. The
new project is expected to have 90% domestic sales and 10% export sales which will also
generate foreign revenues. Additional government revenue expected from royalty,
taxes, duties and other fees.
SMT Organic Chemicals Pvt. Ltd will be employee friendly organization and it has
discharged its social commitments to the fullest ever since its inception. SMT Organic
Chemicals Pvt. Ltd will encourage the employees to educate their children and will evolve
several schemes to promote education amongst the children of the employees.
The present project for manufacturing of Synthetic Organic Chemicals requires
substantial handling of raw materials, goods in process and finished goods. It is expected
that the proposed project will require about 20 personnel. So, the project will provide
direct employment to skilled workforce and indirect employment (transport, services
deliveries etc.) to semi-skilled and unskilled workers. Thus, the project will have
numerous induced impacts on society by generating employment opportunity and will
lead to improvement in the social infrastructure in the region.
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
8
Formaldehyde (CH2O) is the simplest and most commercially important aldehyde. It is a
colorless gas at room temperature and is soluble in water, alcohols and other polar
solvents. Urea-, phenol- and melamine-formaldehyde resins (UF, PF and MF resins)
accounted for about 63% of world demand in 2011; other large applications include
polyacetalresins, pentaerythritol, methylenebis (4-phenyl iso-cyanate) (MDI), 1,4-
butanediol and hexamethylenetetramine. Most formaldehyde producers are concerned
primarily with satisfying captive requirements for derivatives and/or supplying local
merchant sales. Formaldehyde is usually produced close to the point of consumption
since it is fairly easy to make, is costly to transport and can develop problems associated
with stability during transport. As a result, world trade in formaldehyde is minimal.
Construction/remodeling activity, vehicle and furniture production, and original
equipment manufacturer (OEM) account for most world consumption of formaldehyde.
Demand for these markets is greatly influenced by general economic conditions. As a
result, demand for formaldehyde largely follows the patterns of the leading world
economies. Formaldehyde resins are used predominantly in the wood products industry
as adhesives. Growth of these resins is strongly correlated to construction/remodeling
activity (which accounts for over 50% of consumption), and to a lesser degree, to the
automotive industry.
China is the largest single market for formaldehyde, accounting for about 34% of world
demand in 2011; other large markets include the United States, Canada, Brazil, Germany,
the Netherlands, Spain, Italy, Belgium, Poland, Russia, Japan and the Republic of Korea.
China is forecast to experience fast growth rates (around 7% per year) and significant
volume increases in demand for 37% formaldehyde during 2011–2016.
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
9
The above graphs show the difference in Demand & Supply of formaldehyde in Asia &
world. Asia experiences 5% gap in its demand and supply. Moreover World consumption
is forecasted to grow at an average annual rate of almost 5% during 2011–2016.
Continuing significant-to-rapid demand growth in Asia (mainly China) for most
applications will balance out moderate growth in North America, Western Europe, Africa
and Oceania.
The proposed products like Resins (Melamine Formaldehyde, Urea Formaldehyde and
Phenol Formaldehyde) mainly used to produce Electrical Insulation Board and H.P.
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
10
Decorative Laminated Sheets. These sheets have good market demand to develop the
home and office for furniture.
The other product of this unit like Adhesive is very useful compound. The use of
adhesives offers many advantages over binding techniques such as sewing, mechanical
fastening, thermal bonding, etc. These include the ability to bind different materials
together, to distribute stress more efficiently across the joint, the cost effectiveness of
an easily mechanized process, an improvement in aesthetic design, and increased design
flexibility.
The other product of this unit like Formaldehyde has many applications too. The products
generated from Formaldehyde include Urea Formaldehyde Resin, Melamine
Formaldehyde Resin, Phenol Formaldehyde Resin, Polyoxymethylene plastics, 1,4-
Butanediol, and Methylene Diphenyl Diisocyanate, etc. The textile industry uses
formaldehyde-based resins as finishers to make fabrics crease-resistant. Also theses
resins are used to produce decorative laminate sheets as mentioned above.
Formaldehyde-based materials are very important & essential to manufacture of
automobiles, and they are also used to make components for the transmission, electrical
system, engine block, door panels, axles and brake shoes. In India to meet the current
and future market demand, the project proponent intends to start a new unit.
2.4 Demand and Supply Gap
Currently Maharashtra State has total demand of FDH of 8000 MTs / Month. Supply is
being met from units in Maharashtra totaling to 3000MT/Month and balance of 5000 MTs
/ Month is met from factories in other States like Gujarat. Setting up unit in Maharashtra
shall have advantage of savings in transportation of finished products and also being
closer to the Customer and Raw Material Source. FDH and other products are not feasible
for imports as FDH has 2/3rd water and are not economically viable. Entire demand is
being met from indigenous source.
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
11
For India, the total demand for FDH is 16.8 Lakhs MT for the year 2015-16 and likely to
grow at 10%. The projections are given below in a graph.
Projected Demand
FDH demand forecast based upon the demand of its downstream products like
thermosetting resins (UF/PF/MF resins), derivatives (Hexamine, Pentaerythrytol, pyridine
derivatives), intermediate chemicals (Leather chemicals, constructions chemicals, agro
chemicals), miscellaneous.
Pricing and Distribution
Formaldehyde Price Trend (Rs.) per MT for past 3 years (No transport, excise and sales
tax cost added).
18.520.35
22.424.6
26.8
0
5
10
15
20
25
30
2016-17 2017-18 2018-19 2019-20 2020-21
FDH India Demand Forecast in Lakhs MT
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
12
Formaldehyde (F) and Methanol (M) Price Trend (Rs.) per MT for past 3 years (No
transport, excise and sales tax cost added). We can see that FDH prices are directly
proportional to its raw material price fluctuations
14650 14500 14500 14500 14650
17650 1800019500
22050 21333 21250
18125
14750 13983 13433 1300014000
14250 14500 1330013300
11167 1150014750
14000 1460013467 13700 13500
11450 10800 1060010200
9700
1373310950
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
April May June July Aug Sept Oct Nov Dec Jan Feb Mar
2015-16 2014-15 2013-14
0
10000
20000
30000
40000
50000
60000
70000
Apr May June July Aug Sept Oct Nov Dec Jan Feb Mar
2013-14 F
2013-14 M
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
13
The pricing of formaldehyde is a very sensitive affair because 80% of the cost of
production is of raw material. The basic raw material is Methanol and formaldehyde
pricing is mainly dependent upon on procurement of Methanol price. Normally the
industry accepts the model of cost + pricing. Pricing of the product is not affected by
seasonal changes.
The promoters of the project are already into sales & distribution of Formaldehyde,
Methanol, and Melamine & Urea for the last 20 years. The Promoters represent known
chemicals manufacturers such as Hindustan Organic Chemicals Ltd. (HOCL), Gujarat State
Fertilizers Corporation (GSFC), Gujarat Narmada Fertilizers Corporation (GNFC), and Atul
2447223942218912239821231
23266239932201521962
162481508617703
1475013983
1343313000140001425014500
1330013300
1116711500
14750
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
Apr May June July Aug Sept Oct Nov Dec Jan Feb Mar
2014-16 F
2014-15 M
19369
24194222332170622000
182821681815800156001459414767
17161
14000
14600134671370013500
11450108001060010200
9700
1373310950
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
Apr May June July Aug Sept Oct Nov Dec Jan Feb Mar
2015-16 F
2015-16 M
M/S SMT Organic Chemicals Pvt. Ltd
Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC, Plot No. E-127, Taluka Khalapur,
Dist. Raigad, Maharashtra
Pre-Feasibility
Report
14
Ltd. etc. The Promoters are already into Methanol trading for over 20 years, which is the
key raw Material for the manufacturing of Formaldehyde.
Now looking at the manufacturing opportunity, the promoter plans to set up its own
manufacturing factory for Formaldehyde (37%) for which the market and customers are
already established. Promoters are already into Methanol trading for over 20 years, which
is the key Raw Material for the manufacturing of Formaldehyde.
For FDH, major customers are located in and around Pune, Khapoli, Tarapur, Mahad,
Roha, Lote etc.This includes customers such as Clariant, BASF, IVP, Gargi, SI Group, Abelin
Polymers, Amines and Plasticizers, Aquapharma, Ask chemicals, Catapharma, Excel
Industries, Foseco, Golden Ply, HR Johnson, LRC speciality, Marvel thermoset, Resonance,
Romit Resin, Sunrise Polymer, Sunshield chemical, Titan organics, etc.
Looking at the increasing need of the proposed products in domestic market and having a
large number of customers we have planned to manufacture these chemicals. The new
project is expected to have 90% domestic sales and 10% export sales which will also
generate foreign revenues. Additional government revenue is expected from royalty,
taxes, duties and other fees
2.5 Imports Vs Indigenous Production
FDH and other products are not feasible for imports as FDH has 2/3rd water and are not
economically viable. Entire demand is being met from indigenous source.
2.6 Export Possibility
The project is mainly a domestic consumption project. Export could be in very small
quantities.
2.7 Domestic /Export Markets
For FDH, major customers are located in and around Pune, Khapoli, Tarapur, Mahad,
Roha, Lote etc. This includes customers such as Clariant, BSF, IVP, Gargi, SI Group
etc. For UF, PF & MF resins various resins consumers are located in the area as
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stated above
2.8 Employment Generation (Direct & Indirect)
The proposed project has a potential for employment of skilled, semi-skilled and unskilled
employees during construction phase as well as operational phase. The proposed project
provide direct employment to skilled workforce and indirect employment (transport,
services deliveries etc.) to semi-skilled and unskilled workers.
2.9 Manpower
o During Construction: 50 People
o During Operational: 20 People
2.10 Project Cost:
The capital cost of the project is Rs. 15.5 Cr
Sr. No. Description No. of Persons
1 Senior Management 02
2 Middle Management 03
3 Junior Management 05
4 Workers 10
Total 20
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3. Project Description
3.1 Project Site
The Project is to be located at Plot No. E-127, Additional Patalganga MIDC,Khalapur, Dist.
Raigad, Maharashtra.
Figure No. 3.1 Location of the project site
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Figure No. 3.2 MIDC MAP showing project site
Site Analysis & Infrastructure setup
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Table No. 3.1 Salient features of the project site and study area
Sr. No. Particulars Details
1 Location Plot No. E-127, Additional Patalganga MIDC , Khalapur, Dist. Raigad , Maharashtra
2 Land use of Project site 100% Industrial Land
Infrastructure Setup : (Distances mentioned below are aerial distances)
Nearest Habitation Nearest Village: Chavane 0.4 km
Highways National Highway No. 4 @ 5 km
Railway Station Rasyani @ 5 km, Panvel @ 20 km
Nearest Airport Chatrapati Shivaji, Mumbai – 35 km
3 Plot Area 3997.00 Sqm
4 Built up area
Terrace/ Roof top area/
office/Security Cabin:
2404 Sqm
5 Parking area 165 Sqm
6 Green Belt Area 1470 Sqm
Open Area 2701 Sqm
7 Water Supply By MIDC
8 Power Supply By MIDC
9 Protected area Karnala Bird Wildlife Sanctuary within 10 km radius study area
10 Displacement of Population None
11 Seismic Zone The area is falling in Zone- III
12 Availability of Raw Material Imported Methanol at Mumbai port as well as domestic suppliers such as RCF in Maharashtra.
13 Market Domestic
14 Manpower During Construction : 50 During Operation : 20
Area Statement and Project Layout
The total plot area for the unit is 3997.00 sqm.Out of total land available, 12% of the area is
parking area, 33 % of land as a green belt. Detailed break-up of the land is given in Table
3.2 & Plant Layout is shown in Figure No. 3.3
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Table No. 3.2 Breakup of Land
Area statement Area in Sq.m
Area of plot 3997.00 Sqm
Total built up area 2404 Sqm
1 Road Area 1066
2 Total Parking 165
3 Green Belt / RG 1470
4 Security & Weigh bridge room 18
5 Admin building: Office, Store, Canteen, Guest room, Terrace top (54m2x 3floor)
162
6 Formaldehyde Plant (240sqm x 2floor) 480
7 Resin Plant: all reactors, cooling tower, pilot plant, packing, dryer (264sqm x 3floor)
792
8 Utility: MCC Panel Room , control room, Compressor, terrace top (32m2 x 3floor)
96
9 Warehouse, LAB, Silver refining, urea store, terrace top (64sqm x 3floor)
192
10 ETP 45
11 Transformer & DG room 40
12 Boiler 30
13 Underground Water Tank 140
14 DM Water, RO, chiller, softening 40
15 Underground Methanol Tank 250
16 FD Tank Farm / Phenol storage tank 85
17 Ammonia cylinder store 34
Total Ground coverage 1336
Open Plot 2701
The location map of project site is shown in Figure No.3.1 and the area covering 10 km
radial distance from the project site is given as Figure No 4 & 5
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Figure No. 3.3 Plant Layout
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Figure No. 3.4 Google Image showing 10 km radius from project site
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Figure No. 3.5 Toposheet map showing 10 km radius from project site
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3.2 Details of Alternative Sites and Justification of Site Selection
The proposed project site is located in the MIDC area and the said area is 100% Industrial
land. MIDC provide basic facilities like availability of water, electricity, fuel, transport,
telecommunication systems etc. Since site alternative not studied.
3.3 Details of Manufacturing Process
1. Aqueous Formaldehyde (37% to 55% Concentration)
The formaldehyde production process we hereby propose (Off-gas Circulation Process
with Re-boiler) is based on the oxidation and/or dehydration over silver catalyst.
The basic principle of the production process: formaldehyde and oxygen of the air have
dehydrogenation and oxidation reaction with silver catalyst at high temperature of 630℃
to yield formaldehyde.
Main reactions:
Ag
CH3OH CH2 O + H2 - 85.27kJ/mol- -------- 1
(gas phase) 630℃ (gas phase)
Ag
CH3OH + 1/2 O2 CH2O + H2O + 156.557kJ/mol-------2
(gas phase) 630℃ (gas phase)
Side reactions:
CH3OH + 3/2 O2 CO2 + 2 H2O + 675.99kJ/mol -------3
(gas phase) (gas phase)
CH2O C O + H2 - 5.375kJ/mol ------- 4
(gas phase) (gas phase)
H2 + 1/2 O2 H2O + 241.83kJ/mol ------- 5
(gas phase) (air phase)
Seen from the reaction equation:
The formation reaction of formaldehyde:1, 2
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The consumption reaction of methanol:among which the(3)point is the loss reaction
of methanol
Oxygen consumption reaction:2, 3, 5
Methanol consumption reaction:4
The above reaction of (1) and (4) is the heat absorption reaction, others are the heat
releasing reaction, the whole reaction is with the condition of heat excess. The exist of
side reaction will decrease the reaction rate. Theoretically calculating, to produce a ton
of 100% formaldehyde, the consumption of 100% methanol 32/30 equals 1.067t, converted
into 37% formalin solution is 395kg/t, but actually the consumption is around 440kg/t,
mainly because of the side reaction. Thus 45kg/t methanol added is needed. Thus during
the production, silver catalyst with high performance and good reaction condition will be
chosen to decrease the side reaction as much as possible.
The oxygen used is from the air, and the mixture of air and methanol gas will be
flammable. The explosion range is under atmospheric pressure of 6.0~36.5%(V, namely
Air/Methanol is 1.7~15.7). The inert gas adding such as steam and nitrogen will reduce
the scope of its explosion and flammable range. The production process add steam and
off-gas to reduce the explosion and combustion ratio of air and methanol.
Steam and off-gas together will improve the proportion of air, that is, increasing the
heat releasing reaction of (2), (3), (5) The control of steam and off-gas to the proper scale
will increase the ratio of oxygen and methanol. The reaction of (2) is half oxygen
reaction. But the (3) (5) is the fierce combustion reaction, thus it needs to be controlled
to a certain proportion. The heat released by the (2)reaction can strengthen the reaction
(1) process , thus it decreases the residual of methanol, and the excess heat is aborted by
the make-up steam and off-gas to maintain temperature of the silver catalyst bed , and to
keep the continuous running of the reaction.
This process flow can be divided into the following 4 units: Evaporation, Oxidation,
Absorption, and Off-gas Treatment.
1 Evaporation Unit:
a. Methanol is fed to the unit of evaporator—reboiler, wherein methanol vapor at 80 C is
produced and then the vapor is charged to the mixer.
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b. The air is fed to the air heater for heating, the resulting 80 C air is then charged to the
mixer.
c. The off-gas is fed to the off-gas heater for heating, the obtained 80C off-gas is then
charged to the mixer.
d. In the mixer, the quaternary gas (air, off-gas, make-up steam and methanol vapor) is
homogeneously blended and heated to 110-130 C, then fed to the quaternary gas filter for
filtration.
2 Reaction Units
The gas mixture from the quaternary gas filter is charged to the oxidation reactor for
reaction. In the reactor, methanol is oxidized/dehydrated into formaldehyde under the
catalysis of silver at normal pressure (Reaction Pressure: 0.2MPa ). The crude product is
first quenched to 230-150oC( the released heat by the reaction is used to produce steam) ,
and then cooled to about 110oC before entering the Absorption Unit.
Gas feedstock to Reactor: quaternary gas mixture of methanol, air, make-up steam and
off-gas;
Gas product from Reactor: mixture of HCHO、CH3OH、HCOOH、H2O、CO2、CO、CH4,
O2、H2、N2
3 Absorption Unit
The absorption unit consist of two absorbers, the converted gas mixture from the
Oxidation Unit including HCHO、CH3OH、HCOOH、H2O、CO2、CO、CH4、O2、H2、N2
is fed to 1# Absorber, sprayed and absorbed by the dilute formalin from 2# Absorption
including HCHOCH3OH、H2O to give formalin product at 1# Absorber bottom while the
unabsorbed gas mixture is charged to 2# Absorber top, sprayed and absorbed by process
water to give dilute formalin and at the same time to discharge off-gas consisting of
HCHO、CH3OH、H2OCO2、CO、CH4、O2、H2、N2.
Due to its special design, the absorber can also function as the distillation column itself.
Thereby, no distillation column is included in the Commercial Proposal without
compromising the required methanol content in the finished formalin product.
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4 Off-gas Treatment Unit
In silver contact formaldehyde plant, the off-gas emitted from the Absorber top includes
18-21% hydrogen, and carbon oxide, carbon dioxide, nitrogen and methane, with the heat
enthalpy of 2000kJ/m3. Its burning heat can be made use of to generate steam, and also
the air pollution can be eliminated. Generated Excess Air & Water Vapor +Export Steam
will be sent to atmosphere through vent attached to Absorber & export steam will be
partially recycled in plant & partially exported
A Process & Instrumental diagram and Layout Plan are reported at the end of this
Technical Report.
Water requirement may lower significantly if we go for higher concentration & Recycling
from other products
Capacity: 36,000 MT/year. Production days - 300
Sr. No. Name of Raw Material Quantity Remarks
Kg/Kg of Product
MT/ Annum
Input
1 Methanol 0.454 16,344 Reactant
2 Air 0.814 29,304 Reactant
3 Water ( Fresh ) 0.4453 16,030.8 Absorbing + Cooling media of Reactor
Total 1.7133 61,678.8
Output
1 Aqueous Formaldehyde (37%) 1.000 36,000 Finished Product
Formaldehyde 0.37 13,320
Methanol 0.022 792
Formic Acid 0.001 36
Water 0.607 21,852
2 Excess Air & Water Vapor +Export Steam 0.71328 25,678.08
To atmosphere through vent attached to Absorber & export steam partially recycled in plant & partially exported
Total 1.7133 61,678.8
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Figure No. 3.6 Process flow sheet
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2. Hexamine
Hexamine is being produced by reaction of formaldehyde with Ammonia. The
Formaldehyde is taken in the form of Formaldehyde gas and is introduced in the reactor
containing saturated solution of Hexamine. Ammonia from the Ammonia Storage tank is
evaporated and purged in the reactor where it reacts with formaldehyde to produce
Hexamine as per the following reaction.
6HCHO + 4NH3 - (CH2) 6 N4 + 6H20
The reaction between Formaldehyde and Ammonia is exothermic in nature. The heat of
reaction is utilised in evaporating the water, which is formed during reaction. As the
reactions proceed and the upper saturation limit exceeds, the Hexamine starts
crystallizing in the mother liquor. This mother liquor, containing Hexamine crystals is
withdrawn though slurry pump and pumped to centrifuge where the crystals are
separated out. These crystals are dried in rotary drum drier and packed in jute bags for
dispatch.
The mother liquor from centrifuge is re-circulated back to the reactor.
This is a highly energy efficient process wherein the heat of gaseous Formaldehyde and
heat of reactions are utilised to evaporate water formed during reaction. No extra steam
is required in reactor and only a small quantity of steam is required for drying of
crystallized Hexamine.
Evaporation Losses during Drying & Crystallization will be sent to atmosphere through
vent attached to Spray Dryer.
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Figure No.3. 7 Process flow sheet of Hexamine
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Table No. 3.3 Material Balance & Chemical Composition (Chemical Reaction) –Hexamine
Reaction Chemistry
6 CH2O + 4 NH3→C6H12N4 + 6 H2O
Production Capacity: 3000 MT/year, 300 days of production
3 A. Urea Formaldehyde (UF) & Melamine Formaldehyde (MF) (Liquid Resin)
AND/OR
3 B. Urea Formaldehyde (UF) & Melamine Formaldehyde (MF) (Powder Resin)
Manufacturing process
The Manufacturing Process of UF and MF Resin are similar and involves two stages of
reaction as described below.
Sr. No.
Name of Raw Material Quantity Remarks
Kg/Kg of Product MT/Annum
Input
1
Aqueous Formaldehyde (AF-37) 3.600 10,800 Reactant
2 Ammonia 0.550 1650 Reactant
3 Wash Water 0.030 90
Water for Scrubber of Packing section 0.220 660
Scrubbed water will be fed to the spray dryer with product
Total 4.175 13,200
Output
1 Hexamine 1 3000 Finished Product
2
Evaporation Losses during Drying & Crystallization 3.4 10200
To atmosphere through vent attached to Spray Dryer
Total 4.175 13,200
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I) Chemical reaction stage
The production process between urea and formaldehyde or between melamine and
formaldehyde are very similar, only some few process conditions are different.
The selected process is a batch process.
Production of UF/MF resin involves an evaporation stage which is carried out in the
reactor.
The chemical reaction is carried out in a batch reactor, which is constructed of stainless
steel and equipped with an efficient agitator, coil heat exchangers or jacketed/Limpet
coils for heating and cooling of the resin batch as well as a reflux condenser.
The heating of the reactor is made by means of low pressure steam and the cooling by
means of cooling water from closed circuit cooling tower system or other suitable
source.
The reactor is fixed or mounted on Load cells which also acts as a weighing
scale.Charging of raw materials into the reactors is made in the following manner:
- Formalin of 37-50 % strength is charged into a service tank which is graded and then
discharged into the Reactor with the help of a pump.
- Urea is charged directly into the reactor from big-bags i.e. 1000 Kg or 500 Kg by crane
lift, or by means of a conveyor, chute and hopper arrangement. 50 Kg or 25 KG small
bags are also charged in the similar fashion.
The weighing system is electronic if reactor mounted on Load Cells and controls the
formaldehyde feed pump and it is used also for controlling the evaporation/dehydration
process.
The chemicals which are used in small amounts for adjustment of acidity/alkalinity of the
processed batch are charged into the reactor manually through measuring tanks.
The reactor has one discharge strainer, one discharge pump and one discharge filter.
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The acidity and progress of the reaction are monitored by determining the pH ON
LINE/manually of samples drawn from the reactor.
The progress of the reaction are monitored by determining the viscosity or cloud point of
the processed resin manually from samples drawn from the reactor.
II) Evaporation stage
The aforementioned solids content of UF/MF resin produced by chemical reaction, as
described above, depending on Formaldehyde concentration used is usually lower than
required for production of, for instance, particle board (i.e. 65% solids) for the consumers
requirement (higher concentration due to transport economical reasons and storage
handling).
The solids content of UF/MF resin is therefore increased by removing water by
evaporation from resin condensate.
The evaporation operation is carried out under vacuum to avoid high processing
temperatures of the resin, which would produce undesired types of molecules and
reduce the reactivity of the resin.
The removed liquid, distillate, contains mainly water but also methanol and small
amounts of formaldehyde.
The amount of water removed from the resin by evaporation can be monitored by
several ways. i.e. by means of the graded gauge of distillate tank, or by reactor weighing
system if such system is installed. Water recovery done through condenser will be
recycled to AF-37 Plant and Water Vapor Losses will be to the atmosphere.
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Table No. 3.4 Material Balance & Chemical Composition –UF Resin Liquid & Melanine
Formaldehyde (MF) Liquid Resin
UF Resin Liquid
Capacity, MT/Annum: 31,304 & 300 days of production
Sr. No Name Of Raw Material Quantity
MT/Annum
Remarks
Kg/Kg of Product
Input
Aqueous Formaldehyde
1 (AF-37) 1.15 36,000 Reactant
2 Urea (Granular or prilled) 0.6 18,782 Reactant
3 Caustic Soda 49% 0.003 94 For pH adjustment
4 Formic Acid 0.0002 6 For pH adjustment
Total 1.7532 54,882
Output
1 Urea Formaldehyde (UF) (liquid resin) 1 31,304 Finished Product
2 Water recovery through condenser 0.452 14,149
To be recycled to AF-37 Plant
3 Water Vapor Losses 0.3012 9,429 To atmosphere
Total 1.7532 54,882
Melamine Formaldehyde (MF) (Liquid Resin)
Capacity, MT/Annum: 31304 & 300 days of production
Sr. Quantity
No. Name of Raw Material Kg/Kg of Product MT/Annum Remarks
Input
1 Aqueous Formaldehyde (AF-37) 1.15 36,000 Reactant
2 Melamine 0.8 25,043 Reactant
3 Caustic Soda 49% 0.004 125 For pH adjustment
Total 1.954 61,168
Output
1 Melamine Formaldehyde (MF) (liquid resin) 1 31,304 Finished Product
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2 Water recovery through Condenser 0.576 18,031
To be recycled to AF-37 Plant
3 Water Vapor Losses 0.378 11,833 To atmosphere
Total 1.954 61,168
MANUGFACTURING PROCESS UF & MF POWDER RESIN
PROCESS DESCRIPTION
The fresh ambient air is filter through filter and heated across a direct Air Heater comes in
contact with the atomized spray. The air heater is designed for maximum process air
temperature of 200C.
Feed solution from your slurry holding tank is fed to the Atomization system through a
variable speed feed pump. The feed is sprayed in the spray chamber at controlled rate
through Rotary Disc Atomizer. The atomized particles get dried to the required level of
dryness in a co-current fashion. Dehumidified air broom arrangement is provided to
displace the powder from the chamber side walls and also simultaneously cool it as it falls
to the chamber bottom.
The product is separated in cyclone separated followed by Reverse Pulse Jet Bag Filter. The product is discharge through rotary air lock valves.
The dry product from cyclone and bag filter is then conveyed and cooled as it travels
pneumatically into the conveying Cyclone & Conveying Bag filter. The reverse pulse jet
bag filter is provided for pollution control. The exhaust air from the conveying bag filter is
recycled back at the inlet duct of main Cyclone separator and mixed with process air.
The entire operation of the plant is controlled through a Instrument panel cum MCC.
Urea Formaldehyde (UF) (Powder Resin)
Capacity, MT/Annum: 15652 & 300 days of production
Sr. No. Name of Raw Material Quantity Remarks
Kg/Kg of Product MT/Annum
1 Urea Formaldehyde (UF) (liquid resin) 2 31304 Liquid product
Total 2 31304
Output
1 Urea Formaldehyde (UF) (powder resin) 1 15652 Powder Product
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2 Evaporation losses during drying 1 15652
To atmosphere through vent attached to Spray Dryer
Total 2 31304
Melamine Formaldehyde (MF) (Powder Resin)
Capacity, MT/Annum: 15652 & 300 days of production
Sr. No. Name of Raw Material Quantity Remarks
Kg/Kg of Product MT/Annum
1 Melamine Formaldehyde (MF) (liquid resin) 2 31304 Liquid Product
Total 2 31304
Output
1 Melamine Formaldehyde (MF) (powder resin) 1 15652 Powder Product
2 Evaporation losses during drying 1 15652
To atmosphere through vent attached to Spray Dryer
Total 2 31304
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Figure No. 3.8 Process flow sheet of Urea Formaldehyde (UF) & Melamine Formaldehyde (MF) (Liquid Resin) AND/OR Urea Formaldehyde
(UF) & Melamine Formaldehyde (MF) (Powder Resin)
CONDENSATESTEAM
VAPOUR COLUMN
WATER OUTLET
STEAM INLET
STEAM INLET
WATER OUTLET
NRV
RESIN PLANT LAYOUT
VIEW GLASS
RECEIVER
HEAT EXCHANGER
WATER INLET
DISTILLATE
REFLUX LINE DRAIN
VALVE
LIMPET COIL
DRAIN
VACUUM PUMP
CATCH POT
G.L. ± 0.00
REACTOR
ELECTRICAL MOTOR
1ST FLOOR
ACID TANK
ALKALI TANKTEA TANK
HCHO
UREA
UREA
HOPPER
STAINER FILTER
TO RESIN HOLDING TANK
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4 A. Phenol Formaldehyde (PF) (Liquid resin)
AND/OR
4 B. Phenol Formaldehyde (PF) (Powder resin)
Manufacturing process
PF RESIN
There are two stages in the manufacture of the P F Resin.
I) Chemical reaction stage
The production process between Phenol and formaldehyde is a condensation type of
polymerisation.
The selected process is a batch process.
The chemical reaction is carried out in a batch reactor, which is constructed of stainless
steel and equipped with an efficient agitator, coil heat exchangers for heating and
cooling of the resin batch as well as a reflux condenser.
The heating of the reactor is made by means of low pressure steam and the cooling by
means of cooling water from closed circuit cooling tower system or other suitable
source.
The reactor is fixed.
Charging of raw materials into the reactors is made in the following manner:
- Formalin of 37 % strength is charged into a service tank which is graded and then
discharged into the Reactor.
- Phenol is solid at room temperature and has to be heated and maintained at 65 ° C for
which it is stored in an electrically traced storage tank. Phenol is then pumped to a
calibrated service tank in the resin plant and then down loaded by gravity into the
Reactor.
The chemicals which are used in small amounts for adjustment of acidity/alkalinity of the
processed batch are charged into the reactor manually.
The reactor has one discharge strainer, one discharge pump and one discharge filter.
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The acidity and progress of the reaction are monitored by determining the viscosity of
samples drawn from the reactor.
II) Evaporation stage
The solids content of PF resin is increased by removing liquid by evaporation from resin
condensate.
The evaporation operation is carried out under vacuum to avoid high processing
temperatures of the resin, which would produce undesired types of molecules and
reduce the reactivity of the resin.
The removed liquid, distillate, contains mainly water but also traces of methanol and
small amounts of formaldehyde. In case of PF there would be traces of Phenol also.
The amount of liquid removed from the resin by evaporation will be monitored by means
of the graded gauge of distillate tank or by reactor weighing system, if such system is
installed.
Table No. 3.5 Material Balance & Chemical Composition (Chemical Reaction) –Phenol
Formaldehyde (PF) (Liquid resin) AND/OR Phenol Formaldehyde (PF) (Powder resin)
Reaction Chemistry
C6H6O + HCHO → C7H8O2
Phenol Formaldehyde (PF) (Liquid resin)
Capacity, MT/Annum: 86,747
Sr. No. Name of Raw Material
Quantity Remarks
Kg/Kg of Product
MT/ Annum
Input
1 Aqueous Formaldehyde (AF-37) 0.415 36,000 Reactant
2 Phenol 0.212 18,390 Reactant
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3 Caustic Soda 49% 0.166 14,400 For pH adjustment
4 Water 0.207 17,957 Process requirement
Total 1 86,747
Output
1 Phenol formaldehyde Resin 1 86,747 Finished Product
Phenol Formaldehyde (PF) (Powder resin)
Capacity, MT/Annum: 43, 374 Production days:300
Sr. No. Name of Raw Material
Quantity Remarks
Kg/Kg of Product
MT/ Annum
Input
1 Phenol Formaldehyde (PF) liquid resins 2.273 98,589 Liquid Products
Total 2.273 98,589
Output
1 Phenol Formaldehyde (PF) liquid resins 1 43,374 Powder Product
2 Drying 1.273 55215 To Atmosphere through vent attached to Spray dryer
Total 2.273 98,589
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Figure No. 3.9 Process flow sheet of Phenol Formaldehyde (PF) (Liquid resin) AND/OR Phenol Formaldehyde (PF) (Powder resin)
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5. Silver Refining
Figure No. 3.10 Process flow sheet of Sliver Refining
High purity silver can be used as the catalyst for formaldehyde production from
methanol. The preparation procedures are given as below:
Briefly speaking, silver feedstock is electrolyzed by DC with aqueous AgNO3 solution as the electrolysis solution. Oxidation at anode: Ag-e→Ag+ Reduction at cathode: Ag++e→Ag
Ⅰ. Preparations before Electrolysis 1. Preparations for Silver:
Take the used and de-activated silver catalyst out of the oxidation reactor, and then
break the catalyst into small pieces using S. S. hammer (Iron hammer or other tools that
may bring iron impurities are strictly prohibited.)
Note: If the silver taken out of the oxidation reactor is coated with copper mesh or
impurities like black carbon, then before breaking them into small pieces, charge the
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silver directly to the resistance furnace for burning, where the temperature is controlled
at 680oC or so. 20 minutes after the silver is burned completely red, take it out and keep
it natural air cooled. (If black carbon is attached to the silver, open the door of the
furnace after the silver's becoming completely red to ensure a thorough combustion of
the carbon and other combustible in presence of sufficient oxygen gas.)
2、Immerse the resulted silver into acid solution (weak acid preferable, for instance
oxalic acid) for about 4 hours.
3、Cleaning. Flush the resulted silver from Step 2 with pure water to remove the acid and
other impurities like carbon to ensure the purity of the electrolysis solution, till the
washing liquid is certified that no Ag+ is remained by testing it with the aqueous solution.
If no white participate appears, the cleaning is completed.
④The un-electrolyzed silver can be electrolyzed directly without the above mentioned 3
steps.
Preparation of aqueous silver nitrate solution
1、Preparation from Silver Nitrate
Add 20Kg of silver nitrate (AR) into the electrolysis tank, then transfer pure water or
distilled water to dissolve it, and the water level shall be 1-2cm higher above the filter
plate. Start the circulation pump and keep it running for about 2 hours. After that, add
700mL of nitric acid and keep the circulation pump running for another 0.5 hour.
Determine the pH of the resulting liquid, and 1-2 would be acceptable, 1.5 preferred.
2、Preparation from Silver and Nitric Acid i. Concentrated nitric acid reacts with silver powder under heating to produce
aqueous silver nitrate solution of high concentration. (For each preparation, 18-
40Kg of silver power and 25-50Kg of nitric acid of Industrial Class is used.)
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ii. 4-4.5 hrs after preparation, determine the concentration of the resulted silver
nitrate solution to see whether it is about 12%. If higher than 12%, add more water
to dilute; if lower than 12%, add some silver nitrate powder.
3)The concentration of silver nitrate solution shall be determined as per the
followings:
Dissolve 3 ml of silver nitrate solution into 100mL of distilled water, add 5mL of 6N nitric
acid as well as 1mL of Ammonium Iron Sulfate indicating liquid, and homogenize. Titrate
the obtained solution with Standard Sodium Thiocyanate Solution to a red end point.
Calculation the weight percentage of silver nitrate as follows:
AgNO3% = C.V x 0.1079 C---Concentration of Standard KSCN Solution, mol/L V---Consumed volume of Standard KSCN Solution by titration, mL G ----AgNO3 G ----Weight of AgNO3 solution sample, g 0.1079----AgNO3 0.1079----Milliequivalent weight of AgNO3
The preparation of solutions required in the titration shall be conducted as the
followings:
1. Preparation of Aqueous Sodium Thiocyanate(NaSCN)Solution:
Weigh 8.2 g of sodium thiocyanate, and dissolve it into 1000mL of distilled water.
2. Preparation of 8% Ammonium Iron Sulfate Indicating Liquid:
Weigh 8g of ammonium iron sulfate, and dissolve it into 100 mL of distilled water.
3. Preparation of 6N Nitric Acid:
Dilute 384 mL of commercial concentrated nitric acid to 1000 mL.
Ⅱ. Electrolysis
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The voltage, current, and concentration, pH, temperature of electrolysis solution is very
crucial to control the size, shape of silver particle, as well as the electrolysis capacity.
According to our experiences, the above mentioned index shall be kept in the following
ranges:
Voltage: 3-5 V
Current: 65A or so
Concentration of electrolysis solution: 12% or so
pH of electrolysis solution: 1-2
Temperature of electrolysis solution: 30-40ºC
And the proportion of silver of different meshes shall satisfy the following requirement:
(8-24mesh) : (24-48 mesh); (48-60 mesh) = 5.5:2.5:1
Post Treatment
1、Take the electrolyzed silver out of the electrolysis bath with a S.S. shovel, then
transfer them to a water barrel. Wash them with a little amount of pure water, and the
washing liquid is returned them into the electrolysis bath.
2. Remove the AgNO3 solution completely from the silver by flushing them with pure
water and testing them with aqueous hydrochloric acid solution or aqueous sodium
chloride)
3. Transfer the clean silver into small S.S. tank, and then place these tanks in an oven for
drying (about 300ºC)
4. Screen out the silver of 8 mesh, silver of 24 mesh and silver of 60mesh using screening
sieve. Package the obtained silver catalyst and transfer them to a coffer.
Problems, Reasons & Eliminatory Methods
1、Disordered proportion of silver of different mesh
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When the current is too low, more silver of smaller mesh will be produced; while the
current is too high, more silver of larger mesh will be produced instead.
2、Silver tapes may be generated and inter wound with each other.
Control the pH in a proper range, neither too high nor too low.
3. Silver powder accumulates on the surface of the electrolyzed silver catalyst, which may
cause short circuit.
To avoid this phenomenon, water shall be added to immerse the silver on the cathode
plate.
When acicular impurities appear outside the silver bag, stop the electrolysis or stop
charging any silver feedstock.
Recovery of Silver from Waste Electrolysis Solution。
The silver ion in the waste electrolysis solution is reduced by copper to silver grain. And
the recovery is quite similar to the electrolysis of silver.
6 Urea Formaldehyde Concentrate (UFC- 85)
Manufacturing process
Whole process for the manufacturing of UFC-85 is same as manufacturing of aqueous
formaldehyde except the absorbing media. In case of UFC-85, Formaldehyde-rich gas
from the Reactor is fed to an Absorber where the Formaldehyde is absorbed in Urea
Solution.
Reaction Chemistry
H2N-CO-NH2 + 2 HCHO → HOCH2NH-CO-NHCH2OH
Urea Formaldehyde Concentrate (UFC- 85)
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Figure No.3. 11 Process flow sheet of Urea Formaldehyde Concentrate (UFC-85)
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Urea Formaldehyde Concentrate (UFC- 85)
Capacity: 20,000 MT/year. 300 days of production
Sr. No. Name of Raw Material Quantity Remarks
Kg/Kg of Product MT/Annum
Input
1 Methanol 0.252 5040 Reactant
2 Air (1.6 m3=1.92 Kg/kg of Methanol) 0.484 9680 Reactant
3 Urea (96% assay) 0.255 5100 Reactant
4 Caustic Soda 49 % 0.002 40 For pH adjustment
5 Water 0.1 2000 For absorption
Total 1.093 21,860
Output
1 UFC -85 1 20,000 Finished Product
2 Water vapor 1,860
To atmosphere through vent attached to Absorber
Total 1.093 21,860
7. Methylal
Manufacturing process
Methanol and Formaldehyde are pumped into the fixed bed Catalytic Reactor in
appropriate proportions. The reaction temperature is controlled at 60 ~85. The
obtained mixing solution of Methylal, Methanol and water is heated for evaporation
by the re-boiler steam at the bottom of distillation column. The compositions with
low volatility are collected at the top through screen packing, while the heavy
fraction remains at the column bottom. The azeotropic fraction of Methylal and
Methanol from the column top is condensed and sent to the reflux tank. Part of it
returns to the top of the tower for circulation, and part of it is collected as 92%
Methylal solution, which is pumped to multi-pressure Distillation Column with a
pressure range of 1.2 Mpa to 1.5 Mpa. The temperature at the top of the Distillation
Column is controlled at 120, while temperature at the bottom is controlled at 135.
High concentration Methylal can be withdrawn from the Column bottom, and
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fractions from the top are refluxed to reactor and pressure Distillation Column.
Table No. 3.6 Material Balance & Chemical Composition (Chemical Reaction) – Methyla
Reaction Chemistry
CH3OH + 2 HCHO → C3H8O2
Methylal (99.5%) Capacity, MT/Annum: 33,333. Production days : 300
Sr. No. Name of Raw Material Quantity Remarks
Kg/Kg of Product MT/Annum
Input
1 Aqueous Formaldehyde (AF-37) 1.08 36,000 Reactant
2 Methanol 0.86 28,666 Reactant
Total 1.94 64,666
Output
1 Methylal (99.5%) 1 33,333 Finished Product
2 Excess reaction water 0.94 31333 To be recycled to AF-37 Plant
Total 1.94 64,666
Table No. 3.7 Product wise unit process and Operations
Sr. No. Product Name
1 Formaldehyde (37% to 55% Concentration)
2 Hexamine
3 Urea Formaldehyde (UF) & Melamine Formaldehyde (MF) (Liquid/Powder Resin)
4 Phenol Formaldehyde (PF) (Powder resin)
5 Silver refining
6 Urea Formaldehyde Concentrate
7 Methylal (99.5%)
Table No. 3.8 Major Equipment’s and Machineries Details
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Sr. No. Name of the Products 1 2 3 4 5 6 7
Process
1 Absorption √ √ √ √
2 Blending √
3 Centrifuging √
4 Condensation √ √
5 Crushing/Grinding √
6 Crystallization √
7 Decolourization √
8 Drying √ √ √
9 Electrolysis √
10 Evaporation / Concentration √ √ √ √
11 Filtration √
12 Melting √
13 Mixing √ √
14 Neutralization √
15 Nitration √
16 Oxidation √ √
17 Pulverization √
18 Washing √ √
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Table No. 3.9 Major Equipment & Machinery Details of Formaldehyde Plant
S/N Particular Q’ty Specification Material Remark
I Equipment
1 Re-boiler 1 φ450×3750 Heat Transfer Area: 20m2
Tube Side: SS304 Shell Side: Q235-B
Pressure Vessel
2 Methanol Evaporator
1 φ900×5000 δ=4mm
304
3 Air Heater 1 760×760×1800 304 Pressure Vessel
4 Off-gas Heater 1 760×760×1800 304 Pressure Vessel
5 Ternary Gas Mixer 1 φ500×2700 δ=4mm
304/ Q235-B
6 Gas Mixture Filter 1 1400×1400×3100 304/ Q235-B With high efficiency filter materials With fire arrestor
7 Oxidation Reactor 1 Φ1500×5000 304/ Q235-B/1Cr18Ni9Ti
Pressure Vessel
8 1# Absorber 1 φ1500×11500 304/ Q235-B Including column internals
9 2# Absorber 1 φ1300×11500 304/ Q235-B Including column internals
10 Steam Filter 1 φ600×800 304/ Q235-B Pressure Vessel
11 Condensate Storage Tank
1 φ1600×1500 Q235-B
12 Steam Drum 2 φ1200×2200 Q235-B Pressure Vessel
13 Off-gas Filter 1 20锅 Pressure Vessel
14 Air Filter 1 900×900×1200 Q235-B With high efficiency filter materials
15 Liquid Sealing Tank for Off-gas
1 φ1200×1500 Q235-B
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II Machinery
1 Air Roots Blower 1 Q=76.1M3/min H=49kPa P=90kw
HT With silencers, and VFD controlled explosion proof motor
2 Off-gas Roots Blower
1 Q=36.4M3/min H=49kPa P=55kw
SS 304 With silencers, and VFD controlled explosion proof motor
3 Methanol Pump 2 Q=3.5m3/h H=20M n=2800 rpm N=1.5KW
Carbon Steel Explosion Proof
4 1# Circulating Pump 2 Q=150m3/h H=20M n=2800 rpm N=15KW
SS 304 Explosion Proof
5 2# Circulating Pump 2 Q=80m3/h H=20M n=2800 N=11KW
SS 304 Explosion Proof
6 3# Circulating Pump 2 Q=30m3/h H=20M n=2900 rpm N=5.5KW
SS 304 Explosion Proof
7 Water Feeding Pump for Boiler
2 Q=5.0m3/h H=96M n=2800 rpm N=4KW
Carbon Steel Explosion Proof
8 PHE 1 F=180M3 SS 304
9 PHE 1 F=130M3 SS 304
10 PHE 1 F=40M3 SS 304
11 Centrifuge Fan 1 4-72No 3.6A 2.2KW
HT
12 Chain Block 1
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Machinery and Equipment for Resins UF/MF/PF/UFC
Vaccuum Pump
Electric Motors
Catch Pot
Strainer
Filter
Limpet coil
Receiver
View Glass
Heat Exchanger
Drain Valve
Reactor
Vapor column
Acid Tank
Alkali Tank
Tea Tank
Hopper
Boiler
Cooling tower
Methylal Plant
Feed mixer SS 304 1
Catalytic reactors SS 304 1
Reaction tower SS 304 1
Reboiler
CS/SS304 1
Condenser SS 304 1
Finished product tank SS 304 1
Rectification tower SS 304 1
Reboiler for rectification tower SS 304 1
Cooling water pumps with motors CS 1
Product methylal storage tank SS 304 1
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Hexamine plant
Reactor with Agitator
Crystal Receiver
Filter
Separator
Bottom Drum Dryer
Lower,Upper Methanol Condensor
Deprecipitator
Mother Liquor Tank
Vaccuum Evaporator
Ammonia Evaporator
Separator - left, right
Separator after blower
Absorption column
Condensate Tank
Centrifuge
Mother Liquor Pump
Root Blower
Slurry Pump
Mother liquor Receiver
Heat Exchanger
Silencer
Silver Refining Equipment and Machinery
I Crystallizing Silver Electrolytic equipment
Electrolytic tank 1 set
High Frequency Power rectifier 1 set
Pulse Acid resistant magnetic pump 1
Cathode and Anode electrolytic bar 5
Anode titanium meshes, charge chutes and
filter bags
12
Anode plates 2 sets
II Sponger Silver Electrolytic Equipment
Electrolytic Tank 2 set
High Frequency Power rectifier 1 set
Cathode plates and Anode plates 2 sets for each
Anode tank and filter bag 4 pieces
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Auxiliary equipment and plastic bin for silver
fetching
1 set
III Washing Equipment
Small type laundry dryer 1 set
Filter bag and filter sieve basket 1 piece for each
IV Drawing Equipment
Muffle 1 set
Thermostatic Air dry oven 1 set
Stainless Steel Tray 4 pieces
Stainless Steel feeding boxes 2 pieces
V Power Building equipment
Small type grinder 1 piece
60-40 mess Complete set of stainless steel screen cloth, 7
pieces
VI Other tools
Complete set of connecting wire 1 set
Electrical Adhesive tape
Stainless Steel Spoon and Shovel 1 pieces for each
Acid Resistant gloves 1 pair
3.4 Raw Material Requirements
Various raw materials will be required for manufacturing of proposed products. Details of
raw material requirement for proposed products are given below in Table No. 3.10.
Table No. 3.10 Details of Raw Material (product wise) Requirements
Sr. No.
Products Name of raw material
Quantity in MT/annum
Physical form
Mode of transportation
Source
1 Formaldehyde Methanol 16,344
Liquid Tanker Lorries Import/Local
Air 29,304
Gaseous Through air blower
Natural
Water (DM-process) 16,030.8
Liquid Pipeline MIDC
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2 Hexamine OR
Ammonia 1650
Gaseous Cylinder-Local transport
Local
Gaseous Formaldehyde
10,800
Gaseous In Gas form through Pipe Line from Formaldehyde plant.
Finished Product
3 Urea Formaldehyde
Resin OR Melamine
Formaldehyde Resin OR
Liquid Formaldehyde
36000 Liquid Pipe line from Formaldehyde plant
Finished Product
UF resin liquid 31304 Liquid Pipeline Finished Product
MF resin liquid 31304 Liquid Pipeline Finished Product
Urea 18,782 Solid Lorries Local/Import
Caustic Soda 219 Solid Lorry Local
Formic Acid 6 Liquid Lorry Local
Melamine 25,043 Solid Lorries Local/Import
4 Phenol Formaldehyde
Resin
Formaldehyde 36,000 Liquid Pipe line from Formaldehyde plant
Finished Product
Phenol Formaldehyde liquid resins
98,589 Liquid Lorry Finished Product
Phenol 18,390 Liquid Lorry Local
Caustic Soda 14,400 Solid Lorry Local
5 Silver Refining Silver 5 Solid Lorry Local
Nitric Acid 4 Liquid Lorry Local
Water process 81 Liquid pipeline MIDC
6 Urea Formaldehyde Concentrate
OR
Methanol 5040 Liquid Tanker Import/Local
Urea 5100 Solid Lorry Local/Import
Air 9680 Gaseous Air Blower Natural
Caustic Soda 49% 40 Solid Lorry Local
7 Methylal (99.5 %)
Formaldehyde 36,000 Liquid Pipe line from Formaldehyde plant
Finished Product
Methanol 28,666 Liquid Lorry Import/Local
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Table No. 3.11 Inventory of the storage material
This is based on 7 days of storage.
Inventory for production of formaldehyde, Hexamine and Silver refining
Sr. No.
Raw material Max. qty.
stored mt. Mode of storage Tank /bag /drum
Packing size kg Remark Listed in SCH I
of MSIHC Rules 1989* MT/week
1 Ammonia 39 Cylinder 59 Kg Raw Material √
2 Caustic Soda 342 Bag 25 kg Raw Material √
3 Formaldehyde 840 Tank 850 Kl Raw Material & Finished goods √
4 Methanol 381 Tank 500 Kl Raw Material √
5 Water (MIDC) 1617 Underground Tank 3000KL Raw Material
6 Nitric Acid 0.1 Drum 200 l Raw Material √
7 Silver 0.12 Bag 5 kg Raw Material & Finished goods
Inventory for production of formaldehyde, UF resin and Silver refining
Sr. No.
Raw material Max. qty.
stored mt. Mode of storage Tank /bag /drum
Packing size kg Remark Listed in SCH I
of MSIHC Rules 1989* MT/week
1 Urea 438 Bag 25 kg Raw Material
2 Formic acid 0.14 Bottle 25 l Raw Material
3 Caustic Soda 342 Bag 25 kg Raw Material √
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Sr. No.
Raw material Max. qty.
stored mt. Mode of storage Tank /bag /drum
Packing size kg Remark Listed in SCH I
of MSIHC Rules 1989* MT/week
4 Formaldehyde 840 Tank 850 Kl Raw Material & Finished goods √
5 Methanol 381 Tank 500 Kl Raw Material √
6 Water (MIDC) 1617 Underground Tank 3000KL Raw Material
7 Nitric Acid 0.1 Drum 200 l Raw Material √
8 Silver 0.12 Bag 5 kg Raw Material & Finished goods
9 UF resin liquid 365 Drum 200 L Raw Material
Inventory for production of formaldehyde, MF resin and Silver refining
Sr. No.
Raw material Max. qty.
stored mt. Mode of storage Tank /bag /drum
Packing size kg Remark Listed in SCH I
of MSIHC Rules 1989* MT/week
1 Melamine 584 Bag 25 kg Raw Material
2 Caustic Soda 3 Bag 25 kg Raw Material √
3 Formaldehyde 840 Tank 850 Kl Raw Material & Finished goods √
4 Methanol 381 Tank 500 Kl Raw Material √
5 Water (MIDC) 1617 Underground Tank 3000KL Raw Material
6 Nitric Acid 0.1 Drum 200 l Raw Material √
7 Silver 0.12 Bag 5 kg Raw Material & Finished goods
8 MF resin liquid 365 Drum 200 L Raw Material
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Inventory for production of formaldehyde, PF resin and Silver refining
Sr. No.
Raw material Max. qty.
stored mt. Mode of storage Tank /bag /drum
Packing size kg Remark Listed in SCH I
of MSIHC Rules 1989* MT/week
1 Phenol 429 Tank 10 Kl Raw Material √
2 Caustic Soda 336 Bag 25 kg Raw Material √
3 Formaldehyde 840 Tank 850 Kl Raw Material & Finished goods √
4 Methanol 381 Tank 500 Kl Raw Material √
5 Water (MIDC) 1617 Underground Tank 3000KL Raw Material
6 Nitric Acid 0.1 Drum 200 l Raw Material √
7 Silver 0.12 Bag 5 kg Raw Material & Finished goods
8 Phenol Formaldehyde liquid resins
2024 Drum 200 L Raw Material
Inventory for production of formaldehyde, UFC 85 resin and Silver refining
Sr. No.
Raw material Max. qty.
stored mt. Mode of storage Tank /bag /drum
Packing size kg Remark Listed in SCH I
of MSIHC Rules 1989* MT/week
1 Urea 119 Bag 25 kg Raw Material
2 Caustic Soda 1 Bag 25 kg Raw Material √
3 Formaldehyde 840 Tank 850 Kl Raw Material & Finished goods √
4 Methanol 381 Tank 500 Kl Raw Material √
5 Water (MIDC) 1617 Underground Tank 3000KL Raw Material
6 Nitric Acid 0.1 Drum 200 l Raw Material √
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Sr. No.
Raw material Max. qty.
stored mt. Mode of storage Tank /bag /drum
Packing size kg Remark Listed in SCH I
of MSIHC Rules 1989* MT/week
7 Silver 0.12 Bag 5 kg Raw Material & Finished goods
Inventory for production of formaldehyde, Methylal and Silver refining
Sr. No.
Raw material Max. qty.
stored mt. Mode of storage Tank /bag /drum
Packing size kg Remark Listed in SCH I
of MSIHC Rules 1989* MT/week
Formaldehyde 840 Tank 850 Kl Raw Material & Finished goods √
Methanol 669 Tank 500 Kl Raw Material √
Water (MIDC) 1617 Underground Tank 3000KL Raw Material
Nitric Acid 0.1 Drum 200 l Raw Material √
Silver 0.12 Bag 5 kg Raw Material & Finished goods
Finished Products
Formaldehyde (37% to 55% Concentration) AND
840 Tank 850 Kl Finished goods
Hexamine OR 70 bag 25 kg Finished goods
Urea Formaldehyde (UF) & Melamine Formaldehyde (MF) (Liquid Resin) AND/OR
730 drum 200kg Finished goods
Urea Formaldehyde (UF) & Melamine Formaldehyde (MF) (Powder Resin)
365 bag 25 kg Finished goods
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Phenol Formaldehyde (PF) (Liquid resin) AND/OR
2024 drum 25 kg Finished goods
Phenol Formaldehyde (PF) (Powder resin)
1012 bag 25 kg Finished goods
Silver refining 0.58 drum --- Finished goods
Urea Formaldehyde Concentrate OR
467 drum 200kg Finished goods
Methylal (99.5%) 778 Drum 200kg Finished goods
Other Miscellaneous chemicals required for Silver refining plant in small quantities.
List of Chemical Reagent & Analysis Instrument for Silver Regeneration
Chemicals Specification Quantity
1 potassium thiocyanate (500g) AR (500g) 4 bottles
2 ammonium ferric sulfate (500g) AR (500g) 2 bottles 3 potassium acid phthalate (500g) AR (500g) 1 bottle 4 sodium hydroxide (500g) AR (500g) 4 bottles 5 phenolphthalein indicator 50g 1 bottle 6 bromophenol blue indicator 50g 1 bottle 7 potassium iodide 500g 1 bottle 8 ethanol (500ml) AR (500ml) 2 bottles 9 oxalic acid (500g) AR (500g) 20 bottles
10 sulfuric acid (500g) AR (500g)
2 bottles
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Water balance diagram – Per day consumption.
445 KL Total Water
consumption
3KL
Domestic
4 KL
Green Belt
0.5 KL Washing
231 KL RO Water
286.1 KL Utilities
1.5 KL
Drinking
1.5 KL
Sewage
161 KL
DM Water
70 KL
Reject Water
152.5 KL
Process Water
8.5 KL
Reject Water
152.5KL Formaldehyde
Domestic NIL Hexamine
NIL
NIL
Domestic
NIL UF/PF/MF resin
Domestic NIL
Methylal
Domestic NIL
UFC 85
Domestic NIL
Silver Refining
Domestic
123.6 KL
Boiler
162.5 kL
Cooling tower
6.18 KL Blow
down
8.12 KL Blow down
Domestic
ETP Capacity 15 KL
15
Domestic
2.5 KL
207.6 kl
78 kl
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3.5Resource Optimization / recycling and reuse envisaged in the project, if any, should
be given.
RO plant followed by DM Plant will be provided for raw water treatment. There will
not be any wastewater discharge from the manufacturing process.
Whatever wastewater will be generated from washing activities, DM Regeneration,
softener Regeneration, same will be collected, recycled into the plant as utilities or
used for gardening. Blow down from boiling and cooling will be treated in ETP.
Treated effluent water will be re-utilized.
Steam generated in the process will be partially exported to other areas of the plant
to generate heat and partially re-utilized within the process.
3.6 Recovery System
Solvent Recovery
We are converting Solvent [Methanol] to formaldehyde. Whatever Unreacted Solvent is
there, it goes along with Formaldehyde and it will not be recovered.
Raw Material Recovery
Formaldehyde No recovery
UFC No recovery
Hexamine No recovery
Urea formaldehyde resin [Liquid] Water Containing traces of
formaldehyde will be recycled to
formaldehyde plant
Urea formaldehyde resin [Powder] No recovery
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Melanine formaldehyde resin Water Containing traces of
formaldehyde will be recycled to
(liquid) formaldehyde plant
Melanine formaldehyde resin [Powder] No recovery
Phenol formaldehyde resin [Liquid] No recovery
Phenol formaldehyde resin [Powder] No recovery
Silver Refining No recovery
Methylal Water containing traces of
formaldehyde will be recycled to
formaldehyde plant
3.7 Utility Requirements & its Source
3.7.1 Land:
Sr. No. Particulars Area Details
1 Plot Area 3997 Sqm
2 Built up area : Terrace/ Roof top area/ office/Security Cabin: 2404 Sqm
3 Parking area 165 Sqm
4 Green Belt Area 1470 Sqm
5 Open Area /Road area 1066 Sqm
3.7.2 Water:
The water required for the project will be procured from MIDC. The total fresh water
Requirement for industrial use will be 439 KL/day. However, water required for domestic
activity will be 3 KL/day and that for green belt and washing will be 3 MT/Day. Thus the
total water requirement per day will be 445 KL/day
There will not be any wastewater discharge from the manufacturing process.
The industrial wastewater generation from the proposed project will be 15 KL/day.
This will go to the ETP plant. From water treatment plants i.e. D.M. Plant / RO will be
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78.5 KL/day which will be further utilized in the cooling tower. Washing wastewater
will be sent to ETP. Mode of treatment and disposal of these effluents will be carried
out as follows 15kl/day of effluent will be collected and treated in the ETP. Treated
water will be sent to CETP or reused.
RO Reject Water adhering to prescribed water will be used for utilities like cooling
tower
The Domestic wastewater will be discharged in to sewage and treated water will be
used for landscaping and gardening purposes
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3.7.3 Power & DG Set
Total connected load for the plant will be 890 KW power – 245 KW for FDH and
remaining for other products. The quantity would be double for spares and standby.
This will be will be procured from Maharashtra State Electricity Corporation Limited.
In addition to this, 1 D.G. Sets of 1000 KW or 750 KVA will be installed as stand-by
and captive source of power/to be used in case of power failure.
3.7.4 Fuel
For the proposed project, Furnace Oil will be required for the steam boiler (5 TPH)
and diesel will be required for stand-by D.G. Sets. The details of fuel requirement are
as follows:
Furnace oil (for 5 TPH boilers): 90 KL/month
Diesel (only for DG set in case of emergency): 251.8 ltr/hr
3.7.5 Manpower:
o During Construction :
o During Operation :
Cost: The capital cost of the project is Rs.15.5 Cr.
Sr. No. Description No. of Persons
1 Senior Management 02
2 Middle Management 03
3 Junior Management 05
4 Workers 10
Total 20
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3.8 Hazardous Waste Generation and Management (Liquid and Solid)
The main sources of hazardous waste generation from proposed unit will be ETP sludge
and ETP salt. The ancillary sources of hazardous waste generation will be discarded bags
& drums from storage and handling of raw materials and spent/used oil generation from
plant machineries. The unit is providing an adequate designated storage area for the
hazardous waste storage and will take appropriate membership of the TSDF site for
disposal. The details of hazardous wastes generation and its management are given in
Table below.
Table No. 3.12 Estimated Quantities of Solid waste and proposed disposal methods
Sr. No.
Type of Waste Source Estimated Quantity / Month
Method of disposal
1. Sludge & Silt ETP/STP 50 MT Collection, storage, Transportation at TMWM
2. Discarded bags Raw Material Storage & Handling
2,60,000 Stored in a store and then sold off as scrap
3. Spent /Used Oil Plant and Machineries
30 L Collection, Storage and used for lubrication within the premises OR sell to registered repressors
Wastes/ residues containing oil
0.2MT sold off as scrap
4. Spent Resin DM Plant 3KL sold as scrap
5. Old catalyst 50kgs/month regeneration
The unit will provide an adequate designated storage area for the hazardous waste
storage within premises having impervious floor and roof cover system and leachate
collection system. The unit will obtain necessary membership of MPCB approved Taloja
waste management /Mumbai waste management for the disposal of hazardous waste.
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4. Site Analysis
4.1 Connectivity
Proposed organic manufacturing plant will be located at Additional Patalganga MIDC, Plot
No. E-127, Taluka Khalapur, Dist. Raigad, Maharashtra.
RAIL: Rasayani railway station is a railway station on the Panvel - Roha route of Central
Railway. Approx. 6kms
ROAD: Tum-Tum from panvel railway station to Mohopada. ST Bus is also available at
regular intervals. Can be reached by private vehicle also.
Navi Mumbai International Airport is coming within 30Kms distance
4.2 Land Form, Land use and Land ownership
The proposed project site is at additional Patalganga MIDC & owned by proponent. The
present landuse of the proposed site is Industrial Use. Land agreement is enclosed as an
annexure.
4.3 Existing Infrastructure
The project is proposed since, does not have any existing infrastructure at site.
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4.4 Topography
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5. Planning Brief
5.1 Planning Concept (type of industries, facilities, transportation etc. ) Town and
Country Planning/Development authority Classification
The proposed project has been planned for the manufacturing of synthetic organic
chemicals. The entire development will take about 1 year for the completion of proposed
project. The construction activities and installation of plant & machineries will start after
obtaining Environmental Clearance from Ministry of Environment, Forests and Climate
Change (MoEF & CC) and Consent to Establish from State Pollution Control Board (SPCB).
Basic facilities of infrastructure like admin building, processing area, storage area,
internal roads etc. shall be developed on the project site. Transportation of raw material
and finished goods will be carried out through proposed internal roads and finally
through existing highway.
5.2 Population Projection
Chawane village has total houses 163 with a total population of 693 of which 349 are
Male and 344 are females as per census 2011.
5.3 Land Use Planning (breakup along with green belt etc.)
Land use of the project site is as below
Sr. No. Particulars Area Details
1 Plot Area 3997 Sqm
2 Built up area
Terrace/ Roof top area/ office/Security Cabin:
2404 Sqm
3 Parking area 165 Sqm
4 Green Belt Area 1470 Sqm
5 Open Area 2991 Sqm
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5.4 Amenities/Facilities
Basic Amenities like public transport, water supply, telecommunications, educational
institutions, hospitals etc. are available in nearby MIDC area.
5.5 Risk Assessment, HAZOP Study & Disaster Management Plan
Risk assessment, HAZOP study & DMP shall be carried out by as per technical EIA
guidance manual for synthetic organic chemicals and shall cover following aspects.
Hazard Identification
Failure Frequency Analysis
Consequence Analysis
Impact Assessment
Protective System And Hazard Analysis
Risk Mitigation Measures
DMP
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6. Proposed Infrastructure
6.1 Industrial Area (Processing Area)
The processing area is designed on a level difference of 5mtrs to create a better sense of
security.
There are two structures:
1) Resin Plant (UF/PF/MF/Hexamine/Methylal) –792 Sq.mtr
2) Formaldehyde Plant (Formaldehyde)– 480 Sq.mtr.
The industrial area shall comprise of following sections:
Batching section
Technical grade process area
Raw material storage
Packing material storage
Finished product storage
Scrubbing area
Solid & Hazardous waste storage area
ETP area
6.2 Residential Area (Non Processing Area)
Requirement of residential area will be developed as shown below
There are guest rooms in the proposed design, located in the Administration
building. Room has an attached toilet. Total area – 40 Sq.mtr
Administration building
Truck parking area
Security cabin
Utility area
Laboratory
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Canteen
6.3 Green Belt
The green belt is thoroughly divided throughout the site. Dense vegetation is provided
on the southern side of the site. Covers an area of 1470 sq.mt
6.4 Social Infrastructure
Chavane is the nearest habitation at an aerial distance of 0.4 Km in west direction from
project site having school, place of worship and community facility.
6.5 Connectivity (Traffic and Transportation Road/Rail/Metro/Water ways etc)
Rail: Rasayani railway station is a railway station on the Panvel - Roha route of Central
Railway. Approx. 6kms
Road: Tum-Tum from panvel railway station to Mohopada. ST Bus is also available at
regular intervals. Can be reached by private vehicle also.
Airport: Navi Mumbai International Airport is coming within 30Kms distance
6.6 Drinking Water Management (Source & Supply of water)
Drinking water to be supplied by MIDC. Also water rain harvesting potential shall be
calculated.
6.7 Industrial Pollution Details
6.7.1 Sewerage System/ ETP Details
Details of Water Requirement & Wastewater Generation
Based on the material balance and technical experience of the similar industries, the
water consumption and wastewater generation for all the products as well as for various
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categories have been calculated.
The product-wise water requirement & wastewater generation is given in Table No. 6.1
Table No. 6.1 Product-wise Water Requirement & Wastewater Generation
Product Stream
Water
Requirement, KL
Per Day
Wastewater
Generation,
KL Per Day Remarks
Formaldehyde
(37% to 55%
Concentration)
Process
(Fresh) 152.5 0 ----
Hexamine
Process
(Fresh)
…. 1.5KL
For Vent attached
to Packing
section
equipped with
cyclone
separator
followed by
water scrubber.
Scrubbed water
will be
Recycled in
Process.
Urea
Formaldehyde
(UF) & Melamine
Formaldehyde
(MF) (Liquid
Resin) Process(Fresh) --- 6.6KL
To be recycled to
AF Plant/Cooling
Tower
Silver refining APCM (Fresh) 0.02KL 0.02KL To ETP
Fresh 0.25KL 0.25KL To ETP
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(b) Wastewater Management System
There is no industrial wastewater generation from the process. From water
treatment plants i.e. D.M. Plant and RO plant will be 78 KL/day which is reutilized in
cooling tower. From industrial activities and utilities like washing, boiler blow down
& cooling purge 12.8 KL/day. RO reject will be 70 KL/day.
Mode of treatment and disposal of these effluents will be carried out as follows:
12.8 KL/day of effluent will be collected and treated in the ETP. Treated water will be
reused for the cooling tower and washing activities.
The Domestic wastewater 1.5 KL/day will be discharged in to sewage and treated
water will be used for landscaping and gardening purposes
Water Pollution: There will not be any wastewater discharge from the
manufacturing process. Whatever wastewater will be generated from washing
activities, cooling, DM Regeneration, softener Regeneration, same will be collected
and treated in the ETP. Treated effluent will be re-utilized.
RO plant followed by DM Plant will be provided for raw water treatment. Reject
water from RO will be used for Gardening purpose. Reject water of DM & Softener
plant will be used in utilities like cooling tower and the condensate water from ETP
will be reused for cooling.
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Figure No. 3.12 ETP Layout
Estimated Hydraulic Load – 150 KLD
CT1 CT2
PST
Dosing Chemicals
Blower line
Aeration
Tank
SST
Filter feed
sump
Treated Water
Tank
SDB / FP / Centrifuge
PSF ACF
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6.7.2 Air Pollution
The main sources of air pollution will be process gas emission and flue gas emission from
the proposed project. There will be also chances of fugitive emission due to
manufacturing activities and raw material handling and transportation. Various sources of
air pollution are described hereunder:
Coal LSHS Furnace Oil Natural gas other specify Fuel : Furnace Oil/Wood/Lignite
a) Fuel consumption: Off gas processor / steam generator/Incinerator
Boiler Capacity (TPH) STEAM GENERATOR 2 TPH
Feeding Rate 124 KG/HR.
(A) Details of stack (process& fuel stacks:) – Off gas processor / steam generator/Incinerator
a) Stack number(s) ONE
b) Attached to – STEAM GENERATOR
c) Capacity - 5 TPH
d) Fuel type: FURNACE OIL
e) Fuel quantity (Kg/hr.): 309 KG/HR.
f) Material of construction: CARBON STEEL
g) Shape (round rectangular): ROUND
h) Height. m (above ground level) APPROX. 30 MTR.
i) Diameter/size, in meters 600 MM
j) Gas quantity, Nm3/hr.: 7663 M3/HR.
k) Gas temperature oC: 230 DEG. CEN.
l) Exit gas velocity. m/sec 10 M/SEC.
m) Control equipment preceding the stack ONLINE OXYGEN ANALYSER
n) Nature of pollutants likely to present in the stack gases such as CO2. NOx, SOx, TPM etc.:
CO2-13.5-14%, O2-2.0-2.5%, SOx – 5000 Mg/Nm3(if Sulphur is 3%), NOx – 600 Mg/Nm3, TPM 400-600 ppm.
o) Emissions control system provided: OXYGEN TRIMMING WITH DIGITAL BURNER MANAGEMENT SYSTEM.
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(a) Process Gas Emissions
Table No. 6.2 Details of Gaseous Emissions from Process
Name of the Product Source of Emissions Probable Pollutants
Aqueous Formaldehyde (37% to 55% Concentration)
Formaldehyde Absorber Methanol/ FD Traces
Urea Formaldehyde Concentrate (UFC-85)
Formaldehyde Absorber Methanol/ FD Traces
Hexamine Spray Dryer Packing Section
Particulate Matter ((Hexamine Powder))
Silver refining Silver recovery vessel Nitrous fumes
Urea Formaldehyde (UF) (Powder Resin)
Spray Dryer Particulate Matter (Formaldehyde Powder)
Melamine Formaldehyde (MF) (Powder Resin)
Spray Dryer Particulate Matter (Formaldehyde Powder)
Resol type Phenol Formaldehyde (PF) (Powder Resin)
Spray Dryer Phenol
Table No. 6.3 Air Pollution Control Units
Sr. No.
Process Stack attached To Pollutant Concentration (mg/Nm3)
Air Pollution Control Unit
1 Absorber of Aqueous Formaldehyde Plant
Hydrocarbon as CH4 ≤15 Process Absorber
2 Absorber of Urea Formaldehyde Concentrate Plant
Hydrocarbon as CH4 ≤15 Process Absorber
3 Dryer of Hexamine Plant Particulate Matter ≤ 150 Cyclone Separator
4 Packing section of Hexamine Plant
Particulate Matter ≤150 Water Separator
5 Silver refining Nitrous gas ≤ 100 Alkaline Scrubber
6 Dryer of Urea Formaldehyde Powder Resin Plant
Formaldehyde ≤ 10 Cyclone Separator
7 Dryer of Melamine Formaldehyde Powder Resin Plant
Formaldehyde ≤ 10 Cyclone Separator
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Sr. No.
Process Stack attached To Pollutant Concentration (mg/Nm3)
Air Pollution Control Unit
8 Dryer of PF RESIN Powder Resin Plant
Formaldehyde ≤ 10 Hydrocarbon as Benzene ≤ 90
Cyclone Separator
b) Flue Gas Emission
Main source of flue gas generation will be steam boiler of 5 TPH capacity from the
proposed unit. Furnace oil will be used as a fuel in the boiler and adequate stack height
will be provided for the control of emissions. Unit will also install 1 nos. of D. G. Sets, of
750 KVA or 1000 KW capacity as stand-by units. The details of flue gas emission are given
hereunder in. The details of flue gas emission are given hereunder in Table No. 6.4. The
details of flue gas emission are given hereunder in Table No. 6.4
Table No. 6.4 Details of Flue Gas Stacks
Note: D.G. Set will be only used when power failure.
(c) Fugitive Emission
There will be a chance of fugitive emission from the manufacturing process as well
as due to storage & handling of raw materials and product. The unit will take
following adequate precaution for the control of fugitive emission:
Sr. Stack Type of Fuel Height Diameter Concentration Air
No. Attached To (m) of Pollutants Pollution
Control
1 Steam Boiler Furnace 30 600mm 400-600 TPM
Adequate
Stack
Oil
2
D.G.Set-1 (1000
Stand-by KVA) Diesel 6 0.2
PM ≤ 150 mg/Nm3
SO2 ≤ 100 ppm
NOx ≤ 50 ppm
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The entire manufacturing activities will be carried out in the closed reactors
and regular checking and maintenance of reactors will be carried out to avoid
any leakages.
All the motors of pumps for the handling of hazardous chemicals will be
flame proof and provided with suitable mechanical seal with stand-by
arrangement.
Control of all parameters on a continuous basis will be done by adequate
control valves, pressure release valves and safety valves etc.
All the flange joints of the pipe lines will be covered with flange guards.
All the raw materials will be stored in isolated storage area and containers
are tightly closed.
Precautionary measures will also be taken while handling various hazardous
chemicals.
There will also be provision of adequate ventilation system in process plant
and hazardous chemical storage area.
A regular preventive maintenance will be planned to replace or rectify all
gaskets, joints etc.
The unit will also develop green belt within the factory premises to control the
fugitive emission from spreading into surrounding environment
6.7.2 Noise & Vibration Control
The only source of noise generation may be from the D.G. Sets, which will be kept as
stand-by and no other source of noise and vibration in the proposed unit except
plant machineries. However, the following adequate precautions will be taken for
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control of noise & vibration:
The unit will install latest technology based low noise D.G. sets with acoustic
enclosures.
Proper and timely oiling, lubrication and preventive maintenance will be carried out
for the machineries and equipments to reduce noise generation.
The noise generation will be mitigated by installing noise barriers/absorbers around
stationery noise sources. Adequate noise control measures such as anti-vibration
pad for equipment with high vibration will be provided.
All the vibrating parts will be checked periodically and serviced to reduce the noise
generation. The equipment, which generates excessive noise, will be provided with
enclosures etc.
To minimize the adverse effect on the health, ear muffs / earplugs will be provided
to the working under high noise area.
To reduce the noise generation during the transportation activities; the vehicles will
be kept periodically serviced and maintained as per the requirement of latest trend
in automobile industry. Only those vehicles with PUC’s will be allowed for the
transportation.
The transport contractors will be informed to avoid unnecessary speeding of
vehicles inside the premises.
Green belt area will be developed to prevent the noise pollution inside and outside
the factory premises. Noise monitoring will be carried out regularly at different
parts of the plant.
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8. Rehabilitation and Resettlement (R and R) Plan
The intended use of land is for industrial activity and the land already has been allotted by
MIDC. So there are no issues related to displacement of people.
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9. Project Schedule & Cost Estimate
9.1 Schedule of Approval and Implementation
The proposed project has been planned for the manufacturing of chemical solutions. The
entire development will take about 1 year for the completion of proposed project. The
construction activities and installation of plant & machineries will start after
Environmental Clearance and obtaining Consent from Maharashtra Pollution Control
Board (MPCB).
9.2 Capital Investment
Capital investment for proposed units shall be of Rs. 15.5 crore and estimated cost of Rs.
40.0 Lakhs towards Environmental Protection Measures. Break-up of the capital cost is
given in Table No. 9.1
Table No. 9.1 Capital Cost
Sr. No. Description Rs. In Crore
1. Land 01.60
2. Building (civil) 00.90
3. Plant and machinery 10.00
4. Working Capital Margin (25% of Working Capital ) 03.00
Sub Total 15.5
6 Environment and Disaster Management Plan 00.40
Total 15.90
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10. Analysis of proposal (Final Recommendations)
The unit will provide adequate measures for the prevention and control of pollution.
With the execution and operation of such control measures along with proper
Environmental Management System, there will not be any major potential for
negative impact on the environment due to proposed project.
The proposed project will also boosts up ancillary industrial and commercial activity.
Thus, it will improve the economic condition of the area.
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