Annexure No. Description

MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.

FORM-1, ENVIRONMENT CLEARANCE Page - 17 -

ANNEXURES

Annexure No. Description

1 Google image showing proposed project site

2 Plant Lay-Out

3 Manufacturing process details

4 Details of hazardous waste management

5 Details of Effluent Treatment Plant

6 Water Balance Diagram

7 Details of flue gas stacks

8 List of Products and Raw Materials



ANNEXURE-1

Google Image showing location of Proposed Project Site

A 23° 1' 59.38" N

70° 48' 26.33" E

B 23° 1' 58.87" N

70° 48' 24.11" E

C

23° 2' 4.95" N

70° 48' 22.44" E

D 22° 2' 4.24" N

70° 48' 25.11" E



Google Image showing Project site and salient features:

Near Village-Sokhada-0.96 KM

Godhadhari

River-4.88 KM Machchhu

River-4.62KM

NH-27,

0.30 KM



Google Image showing surrounding area within 5 Km radius from Project Site:

Google Image showing surrounding area within 10 Km radius from Project Site:

10 Km Circle

5.0 Km Circle



ANNEXURE-2: Plant Lay-out



ANNEXURE-3

Manufacturing Process Details

1. Phenol Formaldehyde Resin:

Manufacturing Process

First all raw materials like phenol, formaldehyde & caustic will be added into closed vessel.

Stirring & heating will be done up to 60 C. After 60C stop heating.

Reflux is done for 30 minutes up to 98 C.

Vacuum distillation will be started.

Water will be removed from the vessel as per the batch size.

Cooling down to 40 C.

Methanol will be added for dilution purpose.

Phenol Formaldehyde Resin will be ready for use in Laminate sheets as well as sale

purpose.

Reaction Chemistry

H – CHO

Fast

OH OH

CH2OH

Phenol Phenol Formaldehyde Resin



Process Flow Diagram

Limped Reaction Vessel

Stirring and heating up to 60 C

Reflux for 30 Minutes

Vacuum Distillation

Cooling

Dilution

Product: Phenol Formaldehyde Resin

Phenol Formaldehyde Caustic Flakes

Methanol

Water



2. Melamine Formaldehyde Resin: Manufacturing Process

First all the raw materials melamine & formaldehyde will be added in Limped reaction

vessel.

Stirring & heating will be done up to 95 C for 1 Hr.

Cooling down to 40 C.

Melamine Formaldehyde Resin will be ready for use in Laminate sheets. as well as sale

purpose.

Reaction Chemistry

N

N

N

NH2

NH2 NH2

+ CH2 ON

N

N

N

OH

CH2

OH

CH2

fast

melamine formaldehyde

melamine formaldehyde resin



Stirring and Heating up to 95C for 1 hr

Cooling down to 40C

Finish Product: Melamine

Formaldehyde Resin

Melamine Formaldehyde



3. Urea Formaldehyde Resin:


First all the raw materials Urea & Formaldehyde will be added in Limped reaction vessel.

pH will be adjusted to pH 9.0 by adding acetic acid.

Stirring & heating will be done upto 95 C for 50 Minutes.

Heating will be continued until tolerance (10:40) is achieved.

pH will be adjusted to 9 by adding Caustic.

Cooling down to room temperature.

Urea Formaldehyde Resin will be ready for use and sale purpose.


Urea Formaldehyde resin




Stirring and Heating up to 95C for 50

Minutes

Cooling

Product: Urea Formaldehyde Resin


Urea Formaldehyde

pH adjusted to 9

pH adjusted to 9 Caustic

Acetic Acid



ANNEXURE-4

DETAILS OF SOLID WASTE

There will be two types of Solid wastes generated from the project.

(a) Non Hazardous Solid waste. There will be two types of Non hazardous waste generated: (1) Municipal Solid Waste

The Municipal solid waste includes the paper wastes from Office as well as other domestic wastes. Paper wastes would be sold to scrap vendors, while other wastes would be disposed off in a proper manner.

(b) Hazardous Solid waste. The details different Hazardous wastes generated and its disposal is given in the table below.

Sr. No.

Description Category Quantity Mode of Disposal

1 ETP Sludge +

Evaporation

residue

34.3 8.5 MT/M Collection, storage and Disposal at Approved TSDF Site

2 Used Oil 5.1 0.004 MT/M Collection, storage and used within premises as a lubricant / sold to registered recycler.

3 Discarded Plastic

bags / barrels 33.3 0.32 MT/M

Collection, storage & sell to authorized vendor

4 Edge Cutting

Waste 23.1 0.6 MT/M

Collection, storage & disposal at common Incineration facility



ANNEXURE-5

Details of Effluent Treatment Plants

Effluent Treatment Plant:

Wastewater will be generated from process, Boiler & cooling tower blow-down,

Washing & R.O. reject.

Wastewater (washing and process) will be collected in collection tank.

Then wastewater will be given Photo Fenton treatment.

After completion of chemical treatment, wastewater will be taken to Filter

Press/Nutch Filter for chemical sludge separation.

Dried sludge will be stored in bags and ultimately disposed off at TSDF site.

Chemically treated water, Boiler blow down, RO reject, cooling tower blow down will

be collected in treated water collection tank and then will be evaporated in Steam

based evaporation system followed by condenser.

Bottom sludge from evaporator will be handled with ETP sludge.

Condensate water from condenser will be reused in cooling tower.

Thus, unit will maintain Zero Effluent Discharge.

Condensate To be used For Cooling

Activities

ZERO DISCHARGE

Collection Tank

Photo Fenton Treatment

Tank

MOC: RCC

Nutch Filter

/Filter Press Treated water

Collection Tank

Steam Based

Evaporation System with Condenser

ETP Sludge to be Sent to TSDF site

Effluent from Washing and

Proces

Effluent from R O

rejected, Boiler blow

down and cooling tower blow down



EFFLUENT TREATMENT PLANT DETAILS

Name of the units Volume (m3) No. of

Unit

Collection cum Neutralization Tank 25.0 1

Photo Fenton Treatment Tank 20.0 1

Nutch Filter / Filter press 10.0 2

Treated Water Collection Tank 25.0 1

Steam based Evaporator followed by

Condenser

1.5 m3/hr 1



ANNEXURE-6

Water balance diagram

Source of Water Supply: Bore well

Total: 53.3 KL/day

Domestic

4.7 KL/day

Gardening

7 KL/day

Industrial

41.6 KL/day

4.4 KL/day Goes to soak pit through

septic tank

Boiler

9.6 KL/day

Cooling

29 KL/day

Effluent Treatment Plant followed by Evaporated condenser system

17.0 KL/day

ZERO DESCHARGE

RO Plant

31.4 KL/day

Process

Nil

Floor Washing

0.2 KL/day

Permeate

23.6

KL/day

Reject

7.8 KL/day

5 KL/day

0.2 KL/day

3 KL/day 1 KL/day

Scrubber

10 KL/D

Scrubber

water send to

authorized

recycler

Recycled

15 KL/day

14

KL/day



ANNEXURE-7

Details of Flue Gas Stacks

Sr. No.

Stack attached to Stack Height

(m)

Fuel Requirement

APC System

Expected Pollutant

1

Steam Boiler (4 TPH)

30

Coal / Briquettes – 10

MT/Day

Cyclone separator

followed by Bag Filter

SPM 150 mg/Nm3

SO2 100 ppm

NOX 50 ppm

Thermic Fluid Heater (15 Lac Kcal/hr)

2 D.G. set (300 KVA)

6.7 HSD 50 L/Hr

Adequate stack height



ANNEXURE-8

List of Products for Resin Plant

Sr.

No. Name of Product Quantity (MT/Month)

1 Phenol Formaldehyde Resin 400

2 Melamine Formaldehyde Resin 150

3 Urea Formaldehyde Resin 300

Note: Resin will be used for captive consumption (Laminates Sheets: 1, 50,000 NO. / Month) as

well as sell purpose.

LIST OF RAW MATERIALS REQUIRED FOR RESIN PRODUCTION

Sr.

No.

Name of the product Name of Raw Materials Quantity in

MT/Month

1 Phenol Formaldehyde

Resin

Phenol 377

Formaldehyde (37%) 149

Methanol 75

Caustic 2.0

2 Melamine Formaldehyde

Resin


Melamine 60

3 Urea Formaldehyde

Resin

Urea 120


Acetic Acid 1.5

Caustic 1.5

Documents

Annexure No. Description