PRE FEASIBILITY REPORT

FOR OBTAINING ENVIRONMENTAL CLEARANCE

For the Proposed Synthetic Organic Resin Manufacturing Unit of

M/S. PANARA LAMINATE PVT. LTD.

Survey No. : 341/P, Village-Chiyada,

Taluka: Bavla , District: Ahmedabad, Gujarat.

Mob No.: 09979902150

Email: viraji1967@gmail.com

Prepared By:

T. R. ASSOCIATES

C-605/A, Ganesh Meridian, Opp. Kargil Petrol Pump,

S. G. Highway, Ahmedabad.

Mo. No.: 98253 71099

Email ID: trassociates@hotmail.com; trassociates@ymail.com

March 2015

1. Introduction

M/s. Panara Laminate Pvt. Ltd. is proposing to manufacture Phenol Formaldehyde Resin,

Melamine Formaldehyde Resin & Urea Formaldehyde Resin at Survey No. 341/P of Village

Chiyada in Bavla Taluka of Ahmedabad District in State of Gujarat. Proposed products will be

used for captive consumption in Laminated Sheet manufacturing as well as sell purpose.

Proposed production details are given below:

Sr. No.

Product Capacity

( MT/Month)

1. Phenol Formaldehyde Resin 400

2. Melamine Formaldehyde Resin 400

3. Urea Formaldehyde Resin 400

4. Laminated Sheets 3,00,000 Nos./Month

The proposed final product Laminated Sheets does not attract Environmental Clearance (EC)

from Ministry of Environment and Forests (MoEF), New Delhi. However, the Intermediate

products like Phenol Formaldehyde Resin, Melamine Formaldehyde Resin and Urea

Formaldehyde Resin (being synthetic organic chemicals) falls under Category 5(f) as stated in

Environment Impact Assessment Notification Published on 14th September, 2006. Further, the

location of the proposed project is outside the notified industrial estate. Hence, the project

proponent has to obtain the EC from the Ministry of Environment & Forests, New Delhi. M/s. T.

R. Associates has been appointed to carry out EIA/EMP studies for Environmental Clearance.

The total land area of company is 11,890 Sq. Mt. out of which 4,000 Sq. Mt. (33.6% of total

land) area will be used for greenbelt development. The estimated cost of the Resin project is

1.0 Crore. Total budget allocation towards Environmental Management Facilities will be Rs. 15

Lacs. Total 80 persons will be employed including skilled persons, unskilled persons and office

staff.

2. Project Proponent and their back ground

Company is promoted by its directors namely Mr. Ashokbhai Panara and Mr. Hitendrabhai

Panara having enough experience in field of manufacturing Resin.

3. Brief description of nature of the project:

It is a small scale project for production of resin which will be used for manufacturing

Laminated Sheets.

Need for the project and its importance to the country and or region:

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.

The proposed products like Resins (Melamine Formaldehyde, Urea Formaldehyde and Phenol

Formaldehyde) mainly used to produce Electrical Insulation Board and H.P. Decorative

Laminated Sheets. These sheets have good market demand to develop the home and office for

furniture.

Demand-Supply Gap:

The average production of decorative laminates has crossed approximately 130 million sheets

inclusive of all thicknesses but the gap between installed capacity and demand is growing

bigger. During FY 2011-2012 phases that gap narrowed with sudden demand in lower

thickness segment but later capacities came in place and the Decorative laminate market

became a pressure driven market. The below graph shows the gap which indicates more supply

means pressure on pricing, profits etc. It is caution for any new comer that if he enters, he

should be prepared for "More investments, more efforts and a long wait for margins".

The burgeoning market demands of urban and semi-urban India are estimated at Rs 5,00, 000

crore. The demand-supply gap has already attracted foreign players to India; and the e-

retailing boom offers immense business opportunities. But a mere 15% of India's woodworking

industry is organized. Its semi-skilled carpenters, self-styled interior decorators and small-scale

local manufacturers will need to be trained and organized to meet future market demands and

exploit business opportunities.

Imports v/s Indigenous production:

Indian market is open and big that is why every kind of import is booming. Indian plywood and

panel trade has become global place as the consumption of different imported ply panels are

on the rise. Unlike before Indians are now welcomed by plywood manufacturer of china. Earlier

India was a self dependent country for commercial or high quality plywood, but sharp drop in

domestic manufacturing output has resulted in material sourcing from countries like Burma,

Malaysia, Indonesia, China, Vietnam etc. Now Indian plywood market is somehow curtailed or

competed by incoming panel products from China. Be it film face, decorative, Laminate or MR

plywood everything is now being imported partially or more and is sold. Indian industrialist

must understand the fact that its no more a regional shift, it is a global shift. Indian technology

should be upgraded an updated at par with international standards.

The working environment in India has changed tremendously. Earlier the trade fairs were

hardly participated by foreign timber, lumber and plywood manufacturing companies where as

now it is flooded with global suppliers.

Export Possibility:

There is only local market of resin. It is an intermediate product for manufacturing of

Laminated Sheets. Liquid resins are quite expensive for export. So we have only local sale

market for distribution.

Employment Generation (Direct and Indirect) due to the project:

This project will provide direct employment to 80 people whereas it will provide employment to

many others indirectly. Plywood and Laminated sheet Industries provide employment to large

number of people.

4. Project Description

(i) Type of project including interlinked and interdependent projects:

Resins including P.F. resin, M.F. resin & U.F. resin are used in production of laminated sheets

and plywood. So Plywood Industries and Laminated sheets Industries will be interdependent on

resin Industries.

(ii) Location

Proposed project is to be located at Survey No. 341/P of Village Chiyada in Bavla Taluka of

Ahmedabad District in State of Gujarat at

Latitude: 22° 45' 59.64" N and

Longitude: 72° 20' 30.37" E

Google image showing proposed project site is given below;

Google Image of Proposed Location:

Distance from

NH 8A: 2.1 KM

Proposed

Project Site

Salient features in the surroundings area of the proposed site within 10 km radius are as

follows:

Sr.

No. Important Features Description

1 Location Survey No.: 341/P, Village: Chiyada,

Ta.: Bavla , Dist.: Ahmedabad, Gujarat.

2 Latitude 22° 45' 30.37" N

3 Longitude 72° 20' 30.37" E

4 MSL 22 m

5 Nearest power station GEB (Gujarat Electricity Board)

6. Proponent Name Mr. Ashokbhai Panara (Director)

Contact No. 09979902150

7 Corporate office address A-301, Sepal Garnet, Opp. Anand Nagar, Behind

Platinum Residency,

Prahladnagar 100 Feet Road,

Satellite, Ahmedabad-380015

8 Temperature range 140 C to 430 C

9 Annual Rain fall 510 mm

10 Nearest Road NH 8 A @ 2.1Km

11 Nearest Railway station Bavla @ 8 Km

12 Nearest city Bavla @ 7 Km

13 Nearest village Chiyada @ 1.5 Km

14 National HW NO NH 8 A @ 2.1 Km

15 State HW No SH 47 @ 6.0 Km from Bavla to Dholka.

16 Seismic Zone Zone-III (Less Active)

17 National Parks / Sanctuary None within 10 Km radius.

(iii) Project description with process details

a. 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 40C.

Methanol will be added for dilution purpose.

Phenol Formaldehyde Resin will be ready for use in Laminate sheets.

Reaction Chemistry

Process Flow Diagram

H – CHO

Fast

OH OH

CH2OH

Phenol Phenol Formaldehyde Resin

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

Caustic Flakes

Methanol

Water

b. Melamine Formaldehyde Resin:

Manufacturing Process

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

vessel.

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

Cooling down to 40 C.

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

Reaction Chemistry

N

N

N

NH2

NH2 NH2

+ CH2 ON

N

N

N

OH

CH2

OH

CH2

fast

melamine formaldehyde

melamine formaldehyde resin

Process Flow Diagram

Limped Reaction Vessel

Stirring and Heating up

to 95C for 1 hr

Cooling at 40C

Finish Product:

Melamine Formaldehyde

Resin

Melamine Formaldehyde

c. Urea Formaldehyde Resin:

Manufacturing Process

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.

Reaction Chemistry

Process Flow Diagram

Stirring and Heating up

to 95C for 50 Minutes

Cooling

Product: Urea

Formaldehyde Resin

Limped Reaction Vessel

Urea Formaldehyde

pH adjusted to 9

pH adjusted to 9 Caustic

Acetic Acid

List of Products for Resin Plant

Sr.

No. Name of Product Quantity (MT/Month)

1 Phenol Formaldehyde Resin 400

2 Melamine Formaldehyde Resin 400

3 Urea Formaldehyde Resin 400

Note: Resin will be used for captive consumption as well as sell purpose.

List of raw materials required for resin production

Sr.

No. Name of Raw Material Requirement (MT/Month)

1 Phenol 377.2

2 Formaldehyde (37%) 628.8

3 Caustic 2.0

4 Melamine 160.0

5 Urea 160.0

6 Methanol 150.0

5. Resource optimization/ recycling and reuse envisaged in the

project, if any, should be briefly outlined.

Latest Process technology will be adopted as available in market with optimum resources

requirement with highest yield and less waste and pollution generation.

For sewage water, sewage treatment plant will be provided and therefore treated water will be

used in greenbelt development which will ultimately reduce the fresh water requirement. In

addition to this, all the feasible cleaner production technologies will be adopted.

6. Availability of water its source, Energy/ power requirement and

source should be given.

Energy/power requirement will be 320 HP which will be supplied through Gujarat Electricity

Board.

The total water requirement will be 20 KL/day which will be fulfilled by own Borewell. Water

balance diagram is given here under;

Source of Water Supply: Borewell Total: 20 KL/day

Domestic 4 KL/day

Greenbelt Development

4.5 KL/day

Industrial 15 KL/day

Sewage Treatment Plant

3.5 KL/day

3.5

KL/day

1

KL/day

Cooling 8 KL/day

Boiler (Make-up)

8 KL/day

Washing 0.5 KL/day

Process Nil

ETP-1 Effluent Treatment Plant

followed by Evaporator and condenser system

5.3 KL/day ZERO DISCHARGE

5.0

KL/day

RO Plant 15 KL/day

4.8 KL/day

1

KL/day

0.5

KL/day 1

KL/day

Reject 3.5

KL/day

Permeate

11.5 KL/day

Sludge to TSDF

ETP-2 Steam based Evaporator

5.5 KL/day ZERO DISCHARGE

Sludge to TSDF

3.0 KL/day

7. Quantity of wastes to be generated (liquid and solid) and scheme

for their Management/disposal.

SOLID WASTE GENERATION AND DISPOSAL

Sr.

No. Description Category Quantity Management

1 ETP Sludge 34.3 20

MT/Month

Collection, storage and disposal

at approved TSDF Site

2 Used Oil 5.1 50

Liters/ Month

Collection, storage and used

within premises as a lubricant /

sold to registered recycler.

3 Discarded bags 33.3 13000

Nos./ Month.

Collection, storage & sell to

authorized vendor

WASTE WATER GENERATION AND DISPOSAL FACILITY

Total 10.8 KL/day of wastewater will be generated from the unit. For this unit will install two

separate ETP as describe below;

Industrial wastewater will be generated from process, boiler, cooling and washing activities. In

addition to this, reject water will be generated from raw water (Borewell water) RO plant.

There will a segregation of streams and provision of two separate ETP. Details of these two

ETPs are as given below;

First ETP will be for wastewater generated from process and washing and second ETP will for

cooling and boiler blow down and RO reject.

Effluent Treatment Plant-1

This ETP will be for wastewater generated from process and washing. Wastewater will be

collected and neutralized in collection cum neutralization tank. Then wastewater will be given

Photo Fenton treatment. After completion of chemical treatment, wastewater will be taken to

Nutch Filter / Filter Press for chemical sludge separation. Dried sludge will be stored in bags

and ultimately disposed of at TSDF site. Chemically treated water will be collected in treated

water collection tank and then will be treated 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. Volumes of proposed ETP-1 units are given below;

Name of the units Volume (m3) No. of Unit

Collection cum Neutralization Tank 6.0 1

Photo Fenton Treatment Tank 6.0 1

Nutch Filter 4.0 2

Treated Water Collection Tank 6.0 1

Steam based Evaporator followed by Condenser 0.75 m3/hr 1

ETP-1 Flow Diagram:

Effluent Treatment Plant-2

This ETP will be for cooling and boiler blow down and RO reject. Wastewater will be collected in

collection tank and then completely evaporated in steam based Evaporator as this wastewater

will mainly contain high TDS. Bottom solids will be handled with ETP-1 sludge. Thus, unit will

maintain Zero Effluent Discharge. Volumes of proposed ETP-2 units are given below;

Name of the units Volume (m3) No. of Unit

Collection Tank 6.0 1

Steam based Evaporator 0.75 m3/hr 1

ETP-2 Flow Diagram:

Treated Water

Collection Tank

ZERO

DISCHARGE

Sludge to be sent to

TSDF site

Cooling Purge,

Boiler Blow

Down & RO

Reject

Steam Based

Evaporator

Condensate

to be used

for Cooling

Activities

ZERO

DISCHARGE

Collection cum

Neutralization

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

Water

from

Process &

Washing

8. Schematic representations of the feasibility drawing which give

information of EIA purpose.

9. Site Analysis

(i) Connectivity

Nearest Railway station Bavla 8 Km

Nearest National highway NH 8 A 2.1 Km

Nearest Airport Ahmedabad 45 Km

Nearest State highway SH 47 6 km

(ii) Existing Infrastructure

(1) Nearest railway station: Bavla Railway station is 8 Km from the project site

(2) Nearest Highway: state highway 47 is 6 km from the project site.

(3) Nearest Airport: Ahemadabad is 45.0 km from the project site.

(4) Power: 320 HP from Gujarat Electricity Board.

(5) Water: Source of the water will be own borewell.

(6) Basic amenities; Good Road connectivity with state and National highway. Site is

near to Kerala GIDC so there is good facility of Raw material and casual labour

availability.

(7) Post Office: - India post office, Bavla is 8.km away from the project site.

(iii) Land Form, Land use and Land ownership.

Proposed project site is an open area which is presently not being used for any purposes.

(iv) Soil classification of Taluka Bavla

The area forms part of North Gujarat Alluvial Plain. The area is under lain by post Miocene

alluvium comprising sand, gravel, silt and clay. The alluvium is about 400 m thick under lain by

tertiary formation. The alluvium mainly consists of palaeo deltaic, fluvial and Aeolian sediments,

comprising alternate bands of fine to course grained sand, gravel and yellowish brownish sticky

clay. The sub-soil condition below the existing ground level is almost uniform in nature. Sub soil

is composed of Clay mixed with little fine grained silty sand, moram and kankar with low

resistivity due to clay and soil moisture. The area is covered with recent to sub recent alluvial

deposits comprising of brownish clay mixed with little fine grained sand, silty sand. The Soil

below ground level consist of top silty low plastic soil layer having no swelling nature. Blackish

brown to yellowish brown clayey silt or sand silt layer extends to the depth of 2 to 3 m.

(v) Social Infrastructure available.

Temple: Small Swaminarayan Temple near Bavla approx 6.0 km away from the

project site.

Post Office: India post office, Bavla is 8.8 km away from the project site.

Hospital: Parekh Hospital 8 km away from the project site.

10. Planning Brief

(i) Planning Concept (type of industries, facilities transportation etc) Town and

Country Planning/Development authority Classification.

It is Laminated sheet manufacturing industry located in Ahmedabad district. Total available

area is 11890 sq. meter out of it 4000 sq. meter area will be provided as a greenbelt area.

Industry wants to manufacture different types of resin used in laminated sheets manufacturing

plant.

(ii) Land use planning (breakup along with green belt etc).

Sr.

No. Particular Area (Sq. Mt.)

1 Built Up Area 4873.0

2 Green belt area 4000.0

3 Open/ Road area 3017.0

Total 11890.0

Plant Lay-out is given hereunder;

Plant Lay-out

(iii) Assessment of Infrastructure Demand (Physical & Social).

Super Specialty and modern health facilities and medical stores are needed around.

(iv) Amenities/Facilities.

Industry will contribute 2.5 % of total profit towards CSR (Corporate Social Responsibility)

activity.

(v) Proposed Infrastructure

a. Industrial Area

Industry will provide 4873.0 square meters built up area for industrial process activity.

Which provide all needed facility including proper ventilation, safe handling system, etc.

b. Residential Area

Industry will provide labor quarter for their labors and provide all basic facilities to them.

c. Green Belt.

4000 Sq.m. area will be proposed for greenbelt development. In addition to this, project

proponent will participate in greenbelt development programs in nearby areas under their

CSR.

d. Social Infrastructure

The Project proponent Industry will contribute 2.5 % of total profit towards CSR (Corporate

Social Responsibility) activity like following in nearby villages;

Education Facilities:- Facilities for village schools like game kits, drawing kits, table-

chairs; school construction (classroom/toilet/school boundary), ceiling fans/ coolers or

books for school library

Health Facilities:-to provide assistance to existing health facilities in Nearest Hospital,

for improvement in health facilities or services.

11. Project Schedule & Cost Estimates

(i) Likely date of start of construction and likely date of completion

Start construction work: December, 2015

Completion of construction work: June, 2016

(ii) Estimated project cost along with analysis in terms of economic viability of the project.

Total project cost of resin is around 1 crore