Proposed Organic Manufacturing Plant at Additional ... · PDF filePrefeasibility study for proposed organic manufacturing plant at Additional ... proposed organic manufacturing plant

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: [email protected]

Proposed Organic Manufacturing Plant at

Additional Patalganga MIDC, Plot No. E-

127, Taluka Khalapur, Dist. Raigad,

Maharashtra




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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




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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




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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




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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




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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.




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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.




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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




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Figure No. 1.1 Glimpses of the Project Site

Internal Road towards Factory Adjuscent area

Plot Showing Project site




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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.




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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.




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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.




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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.




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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.




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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




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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




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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


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


2015-16 F

2015-16 M




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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)




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


Total 2 31304

Melamine Formaldehyde (MF) (Powder Resin)




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


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)


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


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)


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



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


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



Input


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


6 3# Circulating Pump 2 Q=30m3/h H=20M n=2900 rpm N=5.5KW


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.





1 Urea 438 Bag 25 kg Raw Material

2 Formic acid 0.14 Bottle 25 l Raw Material





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Sr. No.










9 UF resin liquid 365 Drum 200 L Raw Material

Inventory for production of formaldehyde, MF resin and Silver refining

Sr. No.





1 Melamine 584 Bag 25 kg Raw Material







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.





1 Phenol 429 Tank 10 Kl Raw Material √







8 Phenol Formaldehyde liquid resins

2024 Drum 200 L Raw Material

Inventory for production of formaldehyde, UFC 85 resin and Silver refining

Sr. No.





1 Urea 119 Bag 25 kg Raw Material









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Sr. No.






Inventory for production of formaldehyde, Methylal and Silver refining

Sr. No.





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


(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 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



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



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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