PRE-FEASIBILITY REPORT 1. EXECUTIVE SUMMARYenvironmentclearance.nic.in/writereaddata/Online/...Pine Laminates Private Limited is incorporated on 21 January 2004. It is classified as

Project: Proposed Formaldehyde manufacturing unit

Promoters: Pine Laminates Pvt. Ltd. Pre-Feasibility Report

Gaurang Environmental Solutions Pvt. Ltd.

PRE-FEASIBILITY REPORT

1. EXECUTIVE SUMMARY

Pine Laminates Private Limited is incorporated on 21 January 2004. It is

classified as Non-govt Company and is registered at Registrar of Companies,

Jaipur.

They are into the business of Ply, plywood, laminated & decorative plywood,

water- proof plywood, boards, ply board, block boards, teak-ply & boards,

sunmica, laminates, flush doors, penal doors and marine plywood included in

class 19.

They are now proposing for manufacturing of Formaldehyde (80 MT per day)

for their own use at A-526, RIICO Industrial area, Chopanki, Bhiwadi, Tehsil-

Tijara, District Alwar (Rajasthan).

As per EIA Notification dated 14th Sept., 2006 and amended from time to time,

the proposed project falls under Category “A”, Project or Activity 5(f)Synthetic

Organic Chemicals Industry, due to presence of Interstate Boundary of Rajasthan

and Haryana at a distance of 3.22 Km , in NE direction and will require

environmental Clearance from MoEF&CC, New Delhi. This pre-feasibility report

has, therefore, been prepared by the consultant to assess the likely impact of the

proposed on various factors which may be affected with the implementation of

the program and to suggest remedial/precautionary measures, if any.

2. INFORMATION OF PROJECT/BACKGROUND INFORMATION

i) Identification of project and project proponent

Project Details

The project proposal is for manufacturing of 80 MT per day at A-526, RIICO

Industrial area, Chopanki, Bhiwadi, Tehsil-Tijara, District Alwar (Rajasthan).

Pine Laminates Pvt. Ltd. Is involved in the business of manufacturing Ply,

plywood, laminated & decorative plywood, water- proof plywood, boards, ply

board, block boards, teak-ply & boards, sunmica, laminates, flush doors, penal

doors and marine plywood. The purpose of proposing formaldehyde production

is for captive consumption only. Formaldehyde is used by ply wood and sun mica

laminated sheets manufacturers, who make adhesives like Urea Formaldehyde

and Phenol Formaldehyde products.

Project Proponent Details

Pine Laminates Private Limited is a Private incorporated on 21 January 2004. It

is classified as Non-govt Company and is registered at Registrar of Companies,

Jaipur.

They are into the business of Ply, plywood, laminated & decorative plywood,

water- proof plywood, boards, ply board, block boards, teak-ply & boards,

sunmica, laminates, flush doors, penal doors and marine plywood included in

class 19.




Details of Authorized Signatory are as follows:

Name: Manoj Aggarwal

Designation:

Address of Correspondence: Pine Laminates Pvt. Ltd. A-526, RIICO Industrial

area, Chopanki, Bhiwadi, Tehsil-Tijara, District Alwar (Rajasthan)-301019.

E-mail ID: [email protected]

ii) Brief Description of Nature of Project

The proposed project is for setting up the unit for manufacturing 80 MT/day of

Formaldehyde for captive use by Pine Laminates Pvt. Ltd at A-526, RIICO

Industrial area, Chopanki, Bhiwadi, Tehsil-Tijara, District Alwar (Rajasthan). The

project is listed under item Project or Activity 5(f) Synthetic Organic Chemicals

Industry, Category “A” due to presence of Interstate Boundary of Rajasthan and

Haryana at a distance of 3.22 Km, in NE direction.

iii) Need for the Project and it’s importance to Country and Region

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.

The Plywood Boards and sun mica sheets market is growing very fast in India.

The market is expected to continue to grow at the minimum rate of 10 to 15%

per year.

During the last decade India has built a very strong position as sun mica sheets

and ply wood boards for domestic consumption and for Exports to South asian

countries & Middle East.

Formaldehyde is used by ply wood and sun mica laminated sheets

manufacturers, who make adhesives like Urea Formaldehyde and Phenol

Formaldehyde products. As Pine Laminates are into the business of Ply,



doors and marine plywood, so considering the above they are proposing to setup

a manufacturing unit of Formaldehyde with the capacity of production of 80 M.T

per day.

iv) Demand & Supply Gap

Asia experiences 5% gap in its demand and supply. Moreover, World

consumption is forecasted to grow at an average annual rate of almost 5%

during2011–2016. 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 product




formaldehyde is mainly used to produce Laminated Sheets. These sheets have

good market demand to develop the home and office for furniture. The products

generated from Formaldehyde include Melamine Formaldehyde Resin, Phenol

Formaldehyde Resin etc. The textile industry use formaldehyde-based resins as

finishers to make fabrics crease-resistant. Also the seresins are used to produce

decorative laminate sheets. 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. The project proponent is already into the business of Ply,



doors and marine plywood so they are proposing to manufacture formaldehyde

for it’s captive use.

v) Import 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 and 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.

vi) Export Possibility

M/s. Pine Laminates Pvt. Ltd. is proposing the Formaldehyde production for it’s

captive use only, hence there is no export possibility.

vii) Employment Generation

During construction phase approx 10-12 persons will be required. Whereas it is

estimated that total 10-12 persons will be required for the proposed project

during operation phase.

Indirect employment is also likely to be generated with the proposed project

which will be economically beneficial for the development.

3.0 PROJECT DESCRIPTION

i) Type of Project including interlinked and interdependent projects, if any




Formaldehyde is used in production of laminated sheets and plywood. The

laminated sheets and plywood industries are dependent on formaldehyde

manufacturing industry.

ii) Location (Map showing general location, specific location, and project

boundary and project site layout) with coordinates

A-526, RIICO Industrial area, Chopanki, Bhiwadi

Tehsil-Tijara,

District Alwar

State: Rajasthan

Figure 1: Location Map Showing Project Site




Figure 2: Google Image Showing Project Site




Figure 3: Key Plan Showing 15 Km Radius of Study Area




Figure 4: Figure Showing Plant Layout




iii) Details of alternative sites considered and the basis of selecting the proposed

site, particularly the environment consideration gone into should be

highlighted.

No alternate sites have been examined for the proposed project as the project shall

be setup on the purchased land.

iv) Size or magnitude of Operation

The production capacity is as under:

Table 1: Plant Capacity

Particular Proposed Capacity

Formaldehyde 80 MT/day

The total area for setting up the formaldehyde unit is 1960 sq m.

v) Process Description (a schematic diagram/flow chart showing the project

layout, components of the project etc. should be given)

The catalytic oxidation process is an optimized production method. Let us discuss the

technology in this process. It is a simple process as per the stoichiometric reaction

steps as shown below:

1. Oxidation of Methanol with oxygen present in the air

CH3OH+1/2 O2 HCHO+H2O

2. Pyrolysis endothermic reaction

CH3OH HCHO+H2

3. Side Reaction-Complete combustion producing heat energy

CH3OH+3/2 O2 2H2O+CO2

Silver Catalyst Method

Initially Air compressed to pressure 0.2 atm by an air compressor and fed to the

bottom of methanol vaporizer. The ratio of methanol and air maintained about

35-45%. This mixture heated to the reaction temperature 550-6000C by series of

pre heater before entering into the silver catalyst reactor. The catalytic reactor is

fixed bed type filled with silver catalyst used for converting methanol to

formaldehyde. The fraction of conversion depends on the catalyst type and the

temperature of the reactor at fixed operating pressure. Advanced reactor controls

both reactions, exothermic combustion reaction and endothermic dehydration

reaction simultaneously in single step.

The product steam sent to purification and recovery section. Unreacted methanol

fed back to the process of methanol vaporizer. Recycle stream contains 15%

unreacted methanol of feed to the vaporizer. Formaldehyde obtained as the heavy

end of alcohol stripper column. It is in the form of aqueous containing 63% water.

The overall process has yield ranging from 85-90% on the weight basis.




Figure 5: Process Flow Chart

vi) Raw material required along with estimated quantity, likely source,

marketing area of final products, and mode of transport of raw material and

Finished products.

Raw Material requirement for production of Formaldehyde is methanol. Quantity of

methanol required will be 40 MT/day.

Table 2: Raw Material Requirement, it’s Source

S.No Name of the Raw

Material

Quantity Required Source

1 Methanol 40 MT/day Local Market




vii) Resources optimization/recycling and reuse envisaged in the project, if any,

should be briefly outlined.

M/s. Pine Laminates Pvt. Ltd. will optimize utilization of resources including Land,

Fuel, Water and Electricity.

viii) Availability of Water its source, Energy/Power requirement and source

Water Requirement

Total water requirement for the proposed project will be approx 52 KLD (Industrial

water: 50 KLD and Domestic water 2 KLD) which will be sourced ground water for

which the permission will be taken from CGWB.

Power Requirement

Maximum power requirement for the plant will be 0.25 MW. The power will be

supplied from J. V. V. N. L. Bhiwadi. One no. of DG set of capacity 250 KVA is also

proposed as the backup power supply.

ix) Quantity of waste to be generated (Liquid and solid) and scheme for their

management.

Process Waste

As per present scheme, no process waste will be generated. if in case generated shall

be stored and disposed off at Treatment Storage and Disposal Facility (TSDF)

approved by Pollution Control Board.

Waste Water Generation & their Management

There will be no waste water generation. The industrial waste water generated

will be recycled in the process itself. The domestic waste water will be managed by

the RIICO industrial area only. Thus, unit will maintain Zero Effluent Discharge.

4.0 SITE ANALYSIS

i) Connectivity

The proposed plant site is well connected with the rail and road connectivity.

The site is about 5.4 km W from SH-25, 5.5 Km N to Tauru Road and 10 km NW

to NH-8. The nearest settlement is Phalsa is at a distance of 0.7 km (approx) in

NNE direction. The nearest railway station is Pataudi Road Railway Station is at

a distance of 24.3 km (approx) in NNW direction. Rewari Railway station is at a

distance of 26.0 Km in WNW direction. Indira Ghandhi International Airport,

New Delhi is at a distance of 48.0 km (approx) in NNE direction from the project

site.

ii) Land form, Land Use, Land Ownership

The total area for setting up the formaldehyde unit is 1960 sq m. The land is

already under the possession on M/s Pine Laminates Pvt. Ltd.

iii) Topography (Along with Map)




The site has been observed to be almost flat level in topography with an elevation

of 281.33 m.

Figure 6: Google Image of Proposed Project Site

iv) Existing Land Use Pattern

The proposed project site lies in RIICO Industrial area. The land is already under

industrial use only, hence there will be no change in land use pattern after

coming up of the proposed project.

v) Existing Infrastructure

The proposed project is Greenfield project & the land is under the possession of

project proponent. M/s. Pine Laminates Pvt. Ltd. Have their laminates industry

just near to the proposed site, hence all the required infrastructure is available.

The site is about 5.4 km W from SH-25, 5.5 Km N to Tauru Road and 10 km NW

to NH-8.

vi) Soil Classification

The district is quadrilateral in shape. The Aravalli ranges form ridges of rocky

hills in most parts and are generally parallel. These make their appearance in the

district from north east in Tijara subdivision and run southwards forming

boundary of the district in the north east for about 24 km, terminating near

Naugaon. Another prominent hill range is at Mandawar, which passes through

Jindoli and Alwar towards the extreme south west corner of the district adjacent

to Jaipur district. The low hills cover almost entire Thanagaji and Rajgarh tehsils

& about one third of the Alwar tehsil 4 and form prominent feature in Bansur,

Kishangarh and Tijara tehsils. Mainly three major types of soils are found in the

Alwar District:




Lithosol & regosol of hills (Red Grey valley Soil) These are found in

the Aravalli hills of south western part of the district. These soils are

shallow with gravels found very near the surface, light textured, fairly

drained, reddish brown to grayish brown in colour.

Older alluvium (Older Alluvial Soils) These soils are derived from

alluvium and found mainly in western parts of the district. These soils are

non calcareous, semi-consolidated to unconsolidated brown soils, loamy

sand to sandy loam in texture. They are well drained and occupy gently

sloping terrains.

Recent alluvium (Red Sandy Soils) These soils are developed in

alluvium and found mainly in the eastern part of the district. These soils

are deep, well drained, sandy loam to loam in texture and noncalcareous.

vii) Climatic Data From Secondary Sources

Climate of the district can be classified as semi-arid. It is characterized by very

hot summer and very cold winters with fairly good rainfall during south west

monsoon period. In May and June, the maximum temperature may go up to

470C. The potential evapo transpiration rates are quite high especially during

May and June. Normal annual rainfall of the district is 631mm.

viii) Social Infrastructure Available

1. Railway Station

Rewari Railway station – 26.0 km WNW

Pataudi Road Railway Station – 24.3 km NNW

2. Road

SH 25 – 5.4 km W

Tauru Road - 5.5 km N

NH 8 – 10.0 km NW

3. Medical Facilities

SH 25 – 5.4 km W


NH 8 – 10.0 km NW

4. Educational Facilities

Quantum Kids - Play School 5.4 km NW

Modern Public School Adharshila 5.3 km NNW

U C S K M Public School 5.5 km NNW

Table 3 : Details of 10 Km Radius Study Area

S. No. Particulars Details

1. Geographical

location

Latitude : N

Longitude : E




2. Nearest town/city Bhiwadi, 6.2 Km NNW

3. Highways SH-25, 5.4 Km, W

NH-8, 10 Km, NW

4. Railway station Rewari Railway station – 26.0 km WNW


5. Airport IGI Airport – 48.0 km NNE

6. River/ Water body Indori Nala: 5.7 Km, NE

Sahibi River: 13 Km, W

5.0 PLANNING BRIEF

i) Planning Concept

Pine Laminates Pvt. Limited is into the business of ply, laminates etc. For these

products they require Formaldehyde as a resin, hence they are proposing for

manufacture of 80 MT/ day Formaldehyde unit for their captive use only.

As per EIA Notification dated 14th September, 2006, and as amended from time

to time, the project falls under activity ‘5(f)’ and the presence of interstate

boundary of Haryana and Rajasthan (3.22 Km, NE) within 5km from the project

site in North-East direction makes the general condition applicable on the

project which makes it category ‘A’ project. So the Proposed project will be

appraised at MOEF&CC.

ii) Employment & Population Projection

It is estimated that total 10-12 persons will be required during the construction

phase and 10-12 no. of skilled workers will be required for smooth working of

the plant. Indirect employment will also be generated from the proposed project

during construction and operation.

iii) Land Use Planning

The proposed project will be set up in an area of 1960 sq m. The land use break

up is as follows:

Table 4: Land Use Break up Details

S. No Type of Land Use Area in Sq m

1 Shed Area 882

2 Open /Paved Area 431.2

3 Green Belt Area 646.8

Total 1960

iv) Assessment of Infrastructure Demand (Physical & Social)




The road facility is available which is used and properly maintained. The project is

well connected with state highway and national highway. Clean drinking water and

medical facilities are made available at project area. The major plant & machinery

required for the proposed project is as given below:

Reactor

Condenser

Evaporator

ABS Column

Cooling Tower

Blower

Storage Tank

Steam Separator

Mixing Tank

Process water tank

Heat Exchanger etc.

v) Amenities/ Facilities

Facilities like canteen, rest rooms and recreation facilities will be provided in the

proposed project. No other additional facilities are proposed.

6.0 PROPOSED INFRASTRUCTURE

i) Total Area

The proposed project will be set up in an area of 1960 sq m. The greenbelt will also be

developed at the site whose area is estimated as 645 sq. m. Adequate green belt

provision as per MoEFCC guidelines will be considered for proposed project

development. Further, unpaved areas if any, within the plant boundary will be

provided with grass cover which will also improve the plant aesthetics.

ii) Social Infrastructure

The various infrastructure present are as follows:

1. Railway Station

Rewari Railway station – 26.0 km WNW


2. Road

SH 25 – 5.4 km W


NH 8 – 10.0 km NW

3. Medical Facilities

SH 25 – 5.4 km W





NH 8 – 10.0 km NW

4. Educational Facilities

Quantum Kids - Play School 5.4 km NW

Modern Public School Adharshila 5.3 km NNW

U C S K M Public School 5.5 km NNW

iii) Connectivity (Traffic and transportation Road/Rail/Metro/Water ways

etc.)

The project is located about 6.2 km from Bhiwadi city which is towards NNW

direction of the project site. Nearest railway station is Pataudi Road Railway

Station which is at a distance of 24.3 km towards NNW from the Project Site. SH

25 is at a distance of 5.4 km towards W and NH-8 Km is at a distance of 10 Km in

NW direction. Indira Gandhi International Airport, is at a distance of 48 km

towards NNE.

iv) Drinking Water Management (Source & supply of water)

Water required for industrial and drinking purpose and will be met through

ground water supply. Approx 50 KLD fresh water is required for trade as well

and 2 KLD for domestic purposes.

v) Industrial Waste Management

Detailed earlier in item no. 3.9

vi) Solid Waste

As per present scheme, no process waste will be generated. if in case generated

shall be stored and disposed off at Treatment Storage and Disposal Facility

(TSDF) approved by Pollution Control Board.

7.0 REHABILITATION & RESETTLEMENT PLAN

No agricultural land and habitation is present in the land and there is no displacement

involved. Hence, no Resettlement and Rehabilitation is envisaged for this project.

8.0 PROJECT SCHEDULE & COST ESTIMATES

i) Likely date of start of Construction and likely date of completion

(Implementation schedule) :

The construction of the project shall commence soon after receipt of

Environment Clearance from MoEF& CC and CTE from RPCB. The project

execution schedule shall be another 18 months after getting project clearance/

environment clearance.

ii) Estimated Project Cost

The cost of the proposed formaldehyde manufacturing unit will be 2.5 Crores.

9.0 ANALYSIS OF PROPOSAL (Final Recommendation)

Formaldehyde is used by ply wood and sun mica laminated sheets manufacturers, who

make adhesives like Urea Formaldehyde and Phenol Formaldehyde products. The




commercial production of Formaldehyde is manufactured from oxidation-

dehydrogenation using a silver catalyst involving either the complete or incomplete

conversion of methanol.

The project is envisaged to meet the demand supply gap in the domestic market, as the

gap is created due to increase in growth of Formaldehyde for meeting increased

demand of Plywood and Sun Mica industries.

The Plywood Boards and sun mica sheets market is growing very fast in India. The

market is expected to continue to grow at the minimum rate of 10 to 15% per year

which makes the sufficient possibility to fulfill the domestic market demand. Both the

Domestic & Export supplies of the company will indirectly contribute to the growth of

our nation.

A financial and social benefit has been considered while analyzing the proposal. The

proposed expansion is environmentally compatible and will helps to people improving

their financial status of the local people. Corporate Social Responsible (CSR) program

shall be executed on need base.

*********

Documents

PRE-FEASIBILITY REPORT 1. EXECUTIVE SUMMARYenvironmentclearance.nic.in/writereaddata/Online/...Pine Laminates Private Limited is incorporated on 21 January 2004. It is classified as