PRE FEASIBILITY REPORT

FOR OBTAINING ENVIRONMENTAL CLEARANCE

For the Proposed Synthetic Organic Resin Manufacturing Unit of

M/S. PARIKSHIT DÉCOR PVT. LTD. Survey No. : 793, Village-Susvav,

Taluka: Halvad, District: Morbi, Gujarat.

Mob No.: 09537832532

Email: Parikshitdecor@gmail.com

Prepared By:

T. R. ASSOCIATES

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

S. G. Highway, Ahmedabad.

Mo. No.: 98253 71099

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

March 2015

1. Introduction M/s. Parikshit Decor Pvt. Ltd. is proposing to manufacture Phenol Formaldehyde Resin, Melamine Formaldehyde Resin & Urea Formaldehyde Resin at Survey No. 793 of Village Susvav in Halvad Taluka of Morbi District in State of Gujarat. Proposed products will be used for captive consumption in Laminated Sheet manufacturing as well as sell purpose. Proposed production details are given below:

Sr. No. Product Capacity

( MT/Month)

1. Phenol Formaldehyde Resin 500

2. Melamine Formaldehyde Resin 300

3. Urea Formaldehyde Resin 300

4. Laminated Sheets 2,00,000 Nos./Month

The proposed final product Laminated Sheets does not attract Environmental Clearance (EC) from Ministry of Environment and Forests (MoEF), New Delhi. However, the Intermediate products like Phenol Formaldehyde Resin, Melamine Formaldehyde Resin and Urea Formaldehyde Resin (being synthetic organic chemicals) falls under Category 5(f) as stated in Environment Impact Assessment Notification Published on 14th September, 2006. Further, the location of the proposed project is outside the notified industrial estate. Hence, the project proponent has to obtain the EC from the Ministry of Environment & Forests, New Delhi. M/s. T. R. Associates has been appointed to carry out EIA/EMP studies for Environmental Clearance.

The total land area of company is 18514.0 Sq. Mt. out of which 6009 Sq. Mt. (32.4% of total land) area will be used for greenbelt development. The estimated cost of the Resin project is 1.0 Crore. Total budget allocation towards Environmental Management Facilities will be Rs. 15 Lacs. Total 100 persons will be employed including skilled persons, unskilled persons and office staff.

2. Project Proponent and their back ground

Company is promoted by its directors namely Mr. Bhaveshbhai B Kalariya, Mr. Rajanbhai K Bhoraniya, Mr. Ishwar J Saravadiya and Mr. Rasikbahi M Kachrola having enough experience in field of manufacturing Resin.

3. Brief description of nature of the project: It is a small scale project for production of resin which will be used for manufacturing Laminated Sheets.

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

Formaldehyde resins are used predominantly in the wood products industry as adhesives. Growth of these resins is strongly correlated to construction/remodeling activity (which accounts for over 50% of consumption), and to a lesser degree, to the automotive industry.

The proposed products like Resins (Melamine Formaldehyde, Urea Formaldehyde and Phenol Formaldehyde) mainly used to produce Electrical Insulation Board and H.P. Decorative Laminated Sheets. These sheets have good market demand to develop the home and office for furniture.

Demand-Supply Gap:

The average production of decorative laminates has crossed approximately 130 million sheets inclusive of all thicknesses but the gap between installed capacity and demand is growing bigger. During FY 2011-2012 phases that gap narrowed with sudden demand in lower thickness segment but later capacities came in place and the Decorative laminate market became a pressure driven market. The below graph shows the gap which indicates more supply means pressure on pricing, profits etc. It is caution for any new comer that if he enters, he should be prepared for "More investments, more efforts and a long wait for margins".

The burgeoning market demands of urban and semi-urban India are estimated at Rs 5,00, 000 crore. The demand-supply gap has already attracted foreign players to India; and the e-retailing boom offers immense business opportunities. But a mere 15% of India's woodworking industry is organized. Its semi-skilled carpenters, self-styled interior decorators and small-scale local manufacturers will need to be trained and organized to meet future market demands and exploit business opportunities.

Imports v/s Indigenous production:

Indian market is open and big that is why every kind of import is booming. Indian plywood and panel trade has become global place as the consumption of different imported ply panels are on the rise. Unlike before Indians are now welcomed by plywood manufacturer of china. Earlier India was a self dependent country for commercial or high quality plywood, but sharp drop in domestic manufacturing output has resulted in material sourcing from countries like Burma, Malaysia, Indonesia, China, Vietnam etc. Now Indian plywood market is somehow curtailed or competed by incoming panel products from China. Be it film face, decorative, Laminate or MR plywood everything is now being imported partially or more and is sold. Indian industrialist must understand the fact that its no more a regional shift, it is a global shift. Indian technology should be upgraded an updated at par with international standards.

The working environment in India has changed tremendously. Earlier the trade fairs were hardly participated by foreign timber, lumber and plywood manufacturing companies where as now it is flooded with global suppliers.

Export Possibility:

There is only local market of resin. It is an intermediate product for manufacturing of Laminated Sheets. Liquid resins are quite expensive for export. So we have only local sale market for distribution.

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

This project will provide direct employment to 100 people whereas it will provide employment to many others indirectly. Plywood and Laminated sheet Industries provide employment to large number of people.

4. Project Description

(i) Type of project including interlinked and interdependent projects: Resins including P.F. resin, M.F. resin & U.F. resin are used in production of laminated sheets and plywood. So Plywood Industries and Laminated sheets Industries will be interdependent on resin Industries.

(ii) Location Proposed project is to be located at Survey No. 793 of Village Susvav in Halvad Taluka of Morbi District in State of Gujarat at Latitude: 23° 0' 45.60" N and Longitude: 71° 2' 48.03" E Satellite image showing proposed project site is given below; Satellite Image of Proposed Location:

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

Sr. No.

Important Features Description

1 Location Survey No.: 793, Village: Susvav, Ta.: Halvad , Dist.: Morbi, Gujarat.

2 Latitude 23° 0' 43.74" N 3 Longitude 71° 2' 47.79" E 4 MSL 40 m 5 Nearest power station PGVCL (Paschim Gujarat Vij Company Limited) 6. Directors Name Mr. Mr. Bhaveshbhai B Kalariya (Director)

Contact No. 09879418981 Mr. Rajanbhai K Bhoraniya (Director) Contact No. 9898510701 Mr. Ishwar J Saravadiya (Director) Contact No. 9825406238 Mr. Rasikbahi M Kachrola (Director) Contact No. 09979902150

7 Corporate office address Bunglow No.: 19, Uma Society, sara Road, Halvad, District: Morbi- 363341.

8 Temperature range 60 C to 440 C 9 Annual Rain fall 510 mm 10 Nearest Road SH 7 @ 0.13Km 11 Nearest Railway station Halvad @ 14 Km 12 Nearest city Halvad @ 13.55 Km 13 Nearest village Dhanala @ 1.86 Km 14 National HW NO NH 27 @ 26 Km 15 State HW No SH 7 @ 0.13 Km from Dhrangdhara to Malia. 16 Seismic Zone Zone-III (Less Active) 17 National Parks / Sanctuary None within 10 Km radius.

(iii) Project description with process details

a. Phenol Formaldehyde Resin:

Manufacturing Process First all raw materials like phenol, formaldehyde & caustic will be added into closed

vessel. Stirring & heating will be done up to 60 °C. After 60°C stop heating. Reflux is done for 30 minutes up to 98 °C. Vacuum distillation will be started. Water will be removed from the vessel as per the batch size. Cooling down to 40°C. Methanol will be added for dilution purpose. Phenol Formaldehyde Resin will be ready for use in Laminate sheets as well as sell

purpose.

Reaction Chemistry

Process Flow Diagram

H – CHO

Fast

OH OH

CH2OH

Phenol Phenol Formaldehyde Resin

Limped Reaction Vessel

Stirring and heating up to 60 °C

Reflux for 30 Minutes

Vacuum Distillation

Cooling

Dilution

Product: Phenol Formaldehyde Resin

Phenol Formaldehyde Caustic Flakes

Methanol

Water

b. Melamine Formaldehyde Resin:

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

vessel. Stirring & heating will be done upto 95 °C for 1 Hr. Cooling down to 40 °C. Melamine Formaldehyde Resin will be ready for use in Laminate sheets as well as sell

purpose.

Reaction Chemistry

N

N

N

NH2

NH2 NH2 + CH2 ON

N

N

N

OH

CH2

OH

CH2

fast

melamine formaldehyde

melamine formaldehyde resin

Process Flow Diagram

Limped Reaction Vessel

Stirring and Heating up to 95°C for 1 hr

Cooling at 40°C

Finish Product: Melamine Formaldehyde

Resin

Melamine Formaldehyde

c. Urea Formaldehyde Resin: Manufacturing Process First all the raw materials Urea & Formaldehyde will be added in Limped reaction vessel. pH will be adjusted to pH 9.0 by adding acetic acid. Stirring & heating will be done upto 95 °C for 50 Minutes. Heating will be continued until tolerance (10:40) is achieved. pH will be adjusted to 9 by adding Caustic. Cooling down to room temperature. Urea Formaldehyde Resin will be ready for use and sale purpose.

Reaction Chemistry

Process Flow Diagram

Stirring and Heating up to 95°C for 50 Minutes

Cooling

Product: Urea Formaldehyde Resin

Limped Reaction Vessel

Urea Formaldehyde

pH adjusted to 9

pH adjusted to 9 Caustic

Acetic Acid

List of Products for Resin Plant

Sr. No.

Name of Product Quantity (MT/Month)

1 Phenol Formaldehyde Resin 500 2 Melamine Formaldehyde Resin 300 3 Urea Formaldehyde Resin 300

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

List of raw materials required for resin production

Sr. No.

Name of Raw Material Requirement (MT/Month)

1 Phenol 471.5 2 Formaldehyde (37%) 546.0 3 Caustic 4.0 4 Melamine 120.0 5 Urea 120.0 6 Methanol 100.0 7 Acetic Acid 1.5

5. Resource optimization/ recycling and reuse envisaged in the project, if any, should be briefly outlined.

Latest Process technology will be adopted as available in market with optimum resources requirement with highest yield and less waste and pollution generation. For sewage water, sewage treatment plant will be provided and therefore treated water will be used in greenbelt development which will ultimately reduce the fresh water requirement. In addition to this, all the feasible cleaner production technologies will be adopted.

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

source should be given. Energy/power requirement will be 300 KVA which will be supplied through PGVCL (Paschim Gujarat Vij Company Limited). The total water requirement will be which will be fulfilled by own Borewell. Water balance diagram is given here under;

Source of Water Supply: Bore well Total: 50 KL/day

Domestic 12 KL/day

Gardening 11.5 KL/day

Industrial 41 KL/day

Sewage Treatment

Plant 11.5 KL/day

Boiler 10 KL/day

Cooling 38 KL/day

Effluent Treatment Plant followed by Evaporated condenser system 20.5 KL/day

ZERO DESCHARGE

RO Plant 60 KL/day

Process Nil

Floor Washing 0.2 KL/day

Permeate 48 KL/day

Reject 12 KL/day

Sanitary 3 KL/day

Recycled 19.2 KL/day

6.3 KL/day 0.2 KL/day

4.0 KL/day 1.0 KL/day

9.0 KL/day

40.8 KL/day

Fresh 9 KL/day

7. Quantity of wastes to be generated (liquid and solid) and scheme for their Management/disposal.

• SOLID WASTE GENERATION AND DISPOSAL

Sr. No.

Description Category Quantity Management

1 ETP Sludge + Evaporation residue

34.3 140 MT/Annum Collection, storage and Disposal at Approved TSDF Site

2 Used Oil 5.1 0.08 MT/ Annum Collection, storage and used within premises as a lubricant / sold to registered recycler.

3 Discarded Plastic bags / barrels 33.3 4 MT/Annum Collection, storage & sell to

authorized vendor.

4 Edge Cutting Waste 23.1 12 MT/Annum Collection, storage & disposal at

common Incineration facility • WASTE WATER GENERATION AND DISPOSAL FACILITY Total 20.5 KL/day of wastewater will be generated from the unit. For this unit will install two separate ETP as describe below; Industrial wastewater will be generated from process, boiler, cooling and washing activities. In addition to this, reject water will be generated from raw water (Borewell water) RO plant. Effluent Treatment Plant

• Wastewater will be generated from process, Boiler & cooling tower blow-down, Washing & R.O. reject.

• Wastewater (washing and process) will be collected collection tank. • Then wastewater will be given Photo Fenton treatment. • After completion of chemical treatment, wastewater will be taken to Filter Press for

chemical sludge separation. • Dried sludge will be stored in bags and ultimately disposed of at TSDF site. • Chemically treated water, Boiler blow down, RO rejected, cooling tower blow down

water will be collected in treated water collection tank and then will be evaporated in Steam based evaporation system followed by condenser.

• Bottom sludge from evaporator will be handled with ETP sludge. • Condensate water from condenser will be reused in cooling tower. • Thus, unit will maintain Zero Effluent Discharge.

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

Collection cum Neutralization Tank 7.0 1 Photo Fenton Treatment Tank 7.0 1 Nutch Filter 7.0 1 Treated Water Collection Tank 25.0 1 Steam based Evaporator followed by Condenser 1.4 m3/hr 1

ETP Flow Diagram:

Condensate to be used for CoolingActivities

ZERO DISCHARGE

Collection Tank

Photo Fenton Treatment

Tank

MOC: RCC

Nutch Filter

/Filter Press Holding Tank

Steam Based

Evaporation System with Condenser

ETP Sludge to be sent to TSDF site

Effluent from washing and

process

Effluent from R O rejected, Boiler blow down and cooling

8. Schematic representations of the feasibility drawing which give information of EIA purpose.

9. Site Analysis (i) Connectivity

(ii) Land Form, Land use and Land ownership

Industry wants proposed Manufacturing plant of Plywood sheets, flush doors, block

boards, phenol formaldehyde resin, melamine formaldehyde Resin, and urea

formaldehyde Resin for new product Resin.

Fig: 1 Land use pattern

There would not be any change in Land use/Land cover activity or Topography due to construction activity after implementation of the project, 37% area will be provided for greenbelt development.

Nearest Railway station Devliya Railway Station 6.1 Km in NW direction Nearest National highway NH 27 26 Km Nearest Airport Rajkot 123 Km in SSW direction Nearest State highway SH 7 0.13 km

(iii) Topography (along with map).

Fig: 2 legendry map of Valsad district

(iv) Existing land use pattern.

Existing land use pattern shown in fig no: 1

(v) Existing Infrastructure

(1) Nearest railway station: Devliya Railway Station is 6.1 Km from the project site (2) Nearest Highway: State highway 130 meter from the project site. (3) Nearest Airport: Rajkot is 123 Km from the project site. (4) Power: 300 HP from Paschim Gujarat Vij Corporation Ltd. (5) Water: Source of the water will be own borewell. (6) Basic amenities; Good Road connectivity with state and National highway. Site is

near to Halvad so there is good facility of Raw material and casual labour availability.

(7) Post Office: - India post office, Charadva is 16.3 km away from the project site.

(vi) Land Form, Land use and Land ownership. Proposed project site is an open area which is presently not being used for any purposes.

Project Site

(vii) Soil classification of Taluka Halvad

Halvad Taluka has found types of land vig. (1) alluvial soil (2) sandy land of thin layer (3) medium type black and loamy soil and (4) less fertile land with thin layer. Medium type black soil is found here and there. As the land is able to absorb moisture and sticky. It is suitable to cotton seed cotton-seals are cash crop of the Taluka. Soil in Dhrangadhra taluka is sandy and made of stone. Its layer is thin, sandy and easily washed away. Loamy soil is found in some parts of halvad and dhrangadra talukas. (viii) Social Infrastructure available.

• Temple: Small Shree Harikrushna satsangdham approx 7.0 km away from the project site.

• Post Office: India post office, Charadva is 16.3 km away from the project site. • Hospital: Government Hospital, Halvad 16 km away from the project site.

10. Planning Brief

(i) Planning Concept (type of industries, facilities transportation etc) Town and Country Planning/Development authority Classification.

It is Laminated sheet manufacturing industry located in Morbi district. Total available area is 18514.0 sq. meter out of it 6009.0 sq. meter area will be provided as a greenbelt area. Industry wants to manufacture different types of resin used in laminated sheets manufacturing plant.

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

Sr. No.

Particular Area (Sq. Mt.)

1 Built Up Area 8525.0 2 Green belt area 6009.0 3 Open/ Road area 3980.0

Total 18514.0

Plant Lay-out is given hereunder;

Plant Lay-out

(iii) Assessment of Infrastructure Demand (Physical & Social). Super Specialty and modern health facilities and medical stores are needed around.

(iv) Amenities/Facilities. Industry will contribute 2.5 % of total profit towards CSR (Corporate Social Responsibility) activity.

(v) Proposed Infrastructure a. Industrial Area

Industry will provide 8525.0 square meters built up area for industrial process activity. Which provide all needed facility including proper ventilation, safe handling system, etc.

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

c. Green Belt. 6009 Sq.m. area will be proposed for greenbelt development. In addition to this, project proponent will participate in greenbelt development programs in nearby areas under their CSR.

d. Social Infrastructure The Project proponent Industry will contribute 2.5 % of total profit towards CSR (Corporate Social Responsibility) activity like following in nearby villages;

• Education Facilities:- Facilities for village schools like game kits, drawing kits, table-chairs; school construction (classroom/toilet/school boundary), ceiling fans/ coolers or books for school library

• Health Facilities:-to provide assistance to existing health facilities in Nearest Hospital, for improvement in health facilities or services.

11. Project Schedule & Cost Estimates

(i) Likely date of start of construction and likely date of completion Start construction work: December, 2016 Completion of construction work: June, 2017

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

Total project cost of resin is around 1 crore