PRE-FEASIBILITY REPORT FOR PROPOSED …environmentclearance.nic.in/writereaddata/FormB/TOR/PFR/07_Sep... · Additional Patalganga MIDC for M/s Balaji chemicals Pre-Feasibility Report

PRE-FEASIBILITY REPORT FOR PROPOSED

SYNTHETIC ORGANIC CHEMICALS MANUFACTURING

UNIT

For

Balaji Chemicals

N-32/1, Additional Patalganga MIDC

Tal : Khalapur, Dist : Raigad

(Maharashtra) (India)

Prepared By:

MITCON CONSULTANCY & ENGINERING SERVICES LTD. 1402/1403, Dalamal Tower, Free Press Journal Marg,

211, Nariman Point, Mumbai-400 021

M/S Balaji Chemicals

Prefeasibility study for proposed organic manufacturing plant at Additional Patalganga MIDC for M/s Balaji chemicals

Pre-Feasibility

Report

MITCON Consultancy and Engineering Services Ltd. , Pune 1

Contents 1. Executive Summary ........................................................................................................................ 2

1.1 General ....................................................................................................................................... 2

1.2 Salient Features of the plant site ......................................................................................... 2

1.3 Proposed Products & Co-Products ....................................................................................... 2

1.4 Resources Requirements ........................................................................................................ 4

1.5 Pollution Potential and Mitigation Measures ................................................................... 4

2. Introduction ..................................................................................................................................... 6

2.1 Background ................................................................................................................................ 6

2.2 Nature of the Project ................................................................................................................ 6

2.3 Project Proponent .................................................................................................................... 7

2.4 Need for the Project & Project Benefits ................................................................................ 7

3. Project Location & Site Analysis .................................................................................................. 9

3.1 Location ...................................................................................................................................... 9

3.2 Project site ............................................................................................................................... 10

3.3 Details of Alternative Sites and Justification of Site Selection ....................................... 10

4. Project Description ....................................................................................................................... 11

4.1 Details of Products and Production Capacity .................................................................... 11

4.2 Land and Project Layout........................................................................................................ 16

4.3 Resource Requirements ........................................................................................................ 17

4.4 Details of Manufacturing Process ........................................................................................ 18

4.5 Raw Material Requirements ................................................................................................. 36

5. Pollution Potential And Control Measures .............................................................................. 37

5.1 Water Pollution ....................................................................................................................... 37

5.2 Air Pollution ............................................................................................................................ 41

5.3 Hazardous Waste Generation and Management ............................................................. 46

5.4 Noise & Vibration Control ..................................................................................................... 48

6. PROJECT SCHEDULE & COST ESTIMATES ................................................................................. 49

6.1 Schedule of Approval and Implementation ....................................................................... 49

6.2 Capital Investment ................................................................................................................. 49

7. Rehabilitation And Resettlement (R&R) Plan ......................................................................... 50

8. Final Recommendations .............................................................................................................. 50



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1. Executive Summary

1.1 General

M/s. Balaji Chemicals is proposing to set up organic manufacturing unit at plot no.

N-32/1, Additional Patalaganga MIDC, Khalapur Dist. Raigad. The said unit is

designed to manufacture various chemicals like formaldehyde, resins etc.

As per new EIA Notification of Ministry of Environment & Forest (MoEF), dtd.

14/09/2006, the said project is being categorized as 5(f) and Therefore, unit

requires obtaining Environmental Clearance from Ministry of Environment & Forest

(MoEF), New Delhi.

1.2 Salient Features of the plant site

The project site is located in the Raigad District having all basic infrastructure

facilities like availability of water, electricity, fuel, transport,

telecommunication systems etc as the site is located in notified industrial

area.

Plant site is about 90 km away from Mumbai City and about 50 Km from JNPT.

which is well connected by road, rail and air to rest of India.

Availability of trained and skilled manpower in nearby areas.

There is no protected area notified under the Wild Life (Protection) Act

(1972) &

Eco-sensitive area notified under Section 3 of the Environment (Protection) Act-

1986 exists within 10 Km radius areas from the Plant Site.

1.3 Proposed Products & Co-Products

The unit proposes to manufacture following synthetic organic chemicals with total

production capacity of 254018 MT/Annum.



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No. Name of Product Capacity (MTPA)

1 Aqueous Formaldehyde (37% to 55% Concentration) – ( AF ) 150,000

2 Hexamine 6,000

3 Paraformaldehyde (91-96%) (PFD) 20,000

4-A Urea Formaldehyde (UF) & Melamine Formaldehyde (MF)

15,000

(Liquid Resin)

AND/OR

4-B Urea Formaldehyde (UF) & Melamine Formaldehyde (MF)

7,500

(Powder Resin)

5-A Phenol Formaldehyde (PF) (Liquid resin) 5,000

AND/OR

5-B Phenol Formaldehyde (PF) (Powder resin) 2,500

6 Silver refining 18

7 Urea Formaldehyde Concentrate (UFC) 20,000

8-A Sulphonated Naphthalene Formaldehyde (SNF)

20,000

Superplasticizers (Liquid)

AND/OR

8-B Sulphonated Naphthalene Formaldehyde (SNF)

7,000

Superplasticizers (Powder)

9 Methylal (99.5%) 18,000

Total (Maximum) 254018

Notes :

* Production capacity of 1,50,000 MT/year for Formaldehyde Plant is derived

considering 37% concentration of Formaldehyde.

The Plants mentioned at Sr. Nos. 4, 5,and 8 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 of

100% conversion of liquid product into powder form.

Details of Co-product

Due to neutralization stage in manufacturing gypsum (calcium sulfate) is generated

as by product (quantity 8900 MT/annum)



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1.4 Resources Requirements

Land: The total land acquired for the proposed unit is @ 15000 sqm. In MIDC,

Patalganga, Dist. Raigarh, Maharashtra, India.

Water: The total fresh water requirement for various domestic, gardening &

industrial activities will be 667 KL/day. The water will be supplied by MIDC.

Power: Total 4 MVA power will be required and same will be procured from

Maharsahtra State Electricity Corporation Limited. In addition to this, 2 D.G.

Sets of 1000 KVA will be installed as stand-by and captive source of power.

Fuel: Methanol / Furnace Oil @ 120 MT/Month will be required for the

steam boiler (5 TPH) &/or Hydrogen gas generated from Formaldehyde Plant

will also be used for boiler as a fuel. 0.5 KL/hr diesel will be required for

stand-by D.G. Sets.

Manpower: For the proposed unit about 85 personnel will be employed at

the different level with maximum people from local.

Finance: The capital cost of the project is 50 Cr

1.5 Pollution Potential and Mitigation Measures

Water Pollution: There will not be any wastewater discharge from the

manufacturing process, as well as air pollution control units like scrubbers as

this wastewaters will directly be utilized in the process again. Only 132

KL/day of wastewater will be generated from washing activities, boiler blow

down, cooling purge, DM & Softener Reject. This effluent will be collected and

treated in the ETP which includes multistage evaporator. Treated effluent

will be utilized for cooling & washing activities. RO plant / RO plant followed

by DM plant &/or softener Plant will be provided for raw water treatment.

Reject water from RO adhering to prescribed norms will be used for

Gardening Purpose. Reject Water of DM / RO / Softener plant will be treated

in ETP.

Hazardous Waste: The main sources of hazardous waste generation from

proposed unit will be dried sludge from ETP & inorganic salt from ETP. The



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ancillary source of hazardous waste generation will be discarded

bags/drums from storage and handling of raw materials and spent/used oil

generation from plant & machinery. The unit will provide an adequate

designated storage area for the hazardous waste storage and will become

member of nearby MPCB approved TSDF.

Greenbelt Development: The unit will develop green belt in about 5099.84

sqm are within the industrial premises with suitable plant species.

Additionally, 5166 sq.m. of area will be covered under internal road.



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2. Introduction

2.1 Background

M/s Balaji Chemicals is in a business of organic chemical manufacturing and has an

operational unit near Ahmedabad. Considering market potential they plan to set up

new facility in Additional Patalganga MIDC area by the name of Balaji Chemicals. M/s

Balaji Chemicals has already been allotted a land by MIDC.

The proposed project is covered under Category 5(f) as per new EIA Notification of

Ministry of Environment & Forest (MoEF), dtd. 14/09/2006. Therefore, unit

requires obtaining Environmental Clearance from Ministry of Environment & Forest

(MoEF), New Delhi. As a part of application for obtaining Environmental Clearance,

the unit requires to submit Form-1 and Pre-Feasibility Report of the proposed

project.

2.2 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

(MoEF) 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. N-32/1, Additional Patalganga MIDC , Raigad district.

Maharashtra.

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 endeavor for the pollution prevention and betterment of

environment.



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2.3 Project Proponent

The project proponent has long experience in formaldehyde manufacturing and the

details are as follows:

Mukesh Gupta- Director, (Balaji Formalin Ltd.)

Mahendra Gupta- Director

Ajay Bharatbhani Shah Director (Artemis Properties Pvt. Ltd.)

Email Id: [email protected] or [email protected]

Correspondence address of the promoter is as mentioned below -

Balaji Chemicals

C/o Balaji Formalin Pvt Ltd.

1398, Vill. Moti Bhoyan,

Ta. Kalol, Dist. Gandhinagar.

Gujarat- 382 721 (India)

2.4 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 national and international market and

response of the customers to the range of products as well as with a view to expand

rapidly in the field of synthetic organic chemicals, the unit has planned to

manufacture these specialty chemicals.

The unit is being set up also to achieve the critical mass of production and gain fair

market share in the international market for its range of products and to utilize the

increasing demand of the products in the international market. The new project is

expected to have 30% domestic sales and 70% export sales which will also generate

foreign revenues. Additional government revenue expected from royalty, taxes,

duties and other fees.

Balaji Chemicals will be employee friendly organization and it has discharged its

social commitments to the fullest ever since its inception. Balaji Chemicals will

encourages the employees to educate their children and will evolve several schemes

mailto:[email protected]

mailto:[email protected]



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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 85 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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3. Project Location & Site Analysis

3.1 Location

The Project is to be located at Plot No. N-32/1, Additional Patalganga MIDC,

Khalapur, Dist. Raigad, Maharashtra.

The location map of project site is shown in Figure-1 and the area covering 10 km

radial distance from the project site is given as Figure-2

Figure - 1: Location of Project Site

Location of Raigad District in Maharashtra



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3.2 Project site

Site Analysis & Infrastructure setup

The salient features of the project site and study area are given below:

1 Location :

Plot No. N-32/1, Additional Patalganga

MIDC , Khalapur, Dist. Raigad ,

Maharashtra

2 Geographical Locations : 18°52'24.0"N 73°10'06.7"E

3. Land use of Project site : 100% Industrial Land

4. Infrastructure Setup : (Distances mentioned below are aerial distances)

(a) Village / Habitation : Rasayani, Patalganga

(b) Town

Khalapur : @ 15.0 Km Panvel @20 km

approx.

(d) Highways : National Highway No. 4 @ 5 km

(e) Railway Station : Rasyani @ 5 km, Panvel @ 20 km

(f) Nearest sea Port : JNPT @ 30 km approx.

(g) Nearest Airport : Mumbai 100 km

5. Protected areas within 10 Km radius from the Plant Site (if, any) :

There is no protected area notified under the Wild Life (Protection) Act (1972) &

Eco-sensitive area notified under Section 3 of the Environment (Protection) Act-

1986 exists within 10 Km radius areas from the Plant Site

6. Displacement of population : None

7 Seismic Zone : The area is falling in Zone- II

3.3 Details of Alternative Sites and Justification of Site Selection

The proposed project site is located in the MIDC area and the said area is having

number of industrial estates, all basic infrastructure facilities like availability of

water, electricity, fuel, transport, telecommunication systems etc. MIDC plans to

further develop the infrastructure in the area.



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4. Project Description

4.1 Details of Products and Production Capacity

The unit proposes to manufacture various synthetic organic chemicals with total

production capacity of 254018 MT/Annum. Details of proposed products and co-

product along with production capacity are given hereunder in Table – 2(a) &

Table – 2(b) respectively.

Table – 2(a): List of Proposed Products with Production Capacity

Sr. Name of Product

Capacity

No. (MT/

Annum)

1 Aqueous Formaldehyde (37% to 55% Concentration) * 150,000

2 Hexamine 6,000

3 Paraformaldehyde (96%) 20,000

4-A Urea Formaldehyde (UF) & Melamine Formaldehyde (MF) (Liquid Resin) 15,000

AND/OR

4-B Urea Formaldehyde (UF) & Melamine Formaldehyde (MF) (Powder Resin) 7,500

5-A Phenol Formaldehyde (PF) (Liquid resin) 5,000

AND/OR

5-B Phenol Formaldehyde (PF) (Powder resin) 2,500

6 Silver refining 18

7 Urea Formaldehyde Concentrate 20,000

8-A Sulphonated Naphthalene Formaldehyde (SNF) Superplasticizers (Liquid) 20,000

AND/OR

8-B Sulphonated Naphthalene Formaldehyde (SNF)

7,000


9 Methylal (99.5%) 18,000

Total (Maximum) 254018

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 - 3.



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Table – 3: Details of Proposed Products

Name of Product CAS No. &

Purity % Use of product

No. Synonyms (wt)

1 Aqueous Mixture,

37% to 55% In Lamination industry, intermediate chemical for Oil field

Formaldehyde (37% Formalin

Formaldehyde formulations, raw material for Insulation/Fiberglass industry,

to 55% Concentration) Fumigant for Poultry Farms, basic chemical for Synthetic

Resins, Moulding Compounds, Powdered & liquid Resins,

Organic

dyestuff, Soil disinfection

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 Mixture 60% Used as Conditioning/anti caking agent for Urea Fertilizer,

Concentrate Formaldeh raw material for Amino Resins, Spray Coating Agent for



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yde

(UFC- 85)

and 25% Urea Urea Fertilizer, Slow Release Fertilizer, Urea Formaldehyde

liquid resins, UF powdered resins, UF moulding

compounds, UF glues & adhesives.

3 Hexamine 100-97-0, 98.2% Used in Rubber Industry, Explosives Industry, Fuel Industry,

Hexa Synthetic

Resin

Industry, Pharmaceuticals

Industry,

Methylene

Photographic Industry, Organic Synthesis Industry,

Metal

Tetra

Industry, Leather Industry. Paper/ Cellulose

Industry,

Amine Lubricants Industry & Fertilizer Industry.

4

Paraformaldehy

de 30525-89-4

Formald

ehyde

Resin manufacture (Phenolic/Amino Resins), Anti

caking

(91-96%)

Content

96%

Agent for Urea, manufacture of Surface coating

Resins,

Adhesives, Ion-exchange Resins, Friction Dust

Industry,

Formaldehyde

substit

ute

/Formaldehyd

e donor,

Disinfectants, Insecticides/Pesticides industry, manufacture

of Dyestuffs & special Plasticizers



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5

Urea

Formaldehyde 9011-05-6 Liquid:

UF Resin: Wood working Glues for MDF / Block / Ply /Chip

(UF) (Liquid &

Powder

40-50%

boards,

Moulding

Materi

als,

Surface

Coatings, Adhesives

Resins)

Powder:

Textiles and paper

Varnishes;

94-98%

6 Melamine 9003-08-1 Liquid:

MF Resin: Decorative

Lamina

tes,

Lamina

tes for special

Formaldehyde

(MF)

40-50%

electr

ical

applicatio

ns, Textiles and paper Varnishes,

(Liquid &

Powder

Powder:

Surface coatings, Moulding

Materials

Resins)

94-98%

7 Mixture Liquid:

Plyw

ood

/

Chipboar

d /

Fl

us

h Door manufacturing,

Phenol

Formaldehyde 45% Production of circuit Boards, moulded Products like Pool

(PF) Resins Powder: Balls, Laboratory counter tops, coatings, and Adhesives etc.

94-98%

8 Sulphonated Mixture Liquid: Water reducer in ready mix concrete, precast and

Naphthalene 42-45% prestressed concrete, marine concrete and special concrete



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Formaldehyde

(SNF) Powder: slabs, leather tanning, textiles’ wetting agents and dye stuffs

Superplasticizers 94-98% dispersants and dispersant / anti friction agents for oil

(Liquid &

Powder) Industry

9

Methylal

(99.5%) 109-87-5, 99.5%

Solvents, Perfumes, Resins, Adhesives, Paint strippers and

Dimethox

y-

Protective coatings

methane



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Table – 2(b): Details of Co-product

Sr.

No.

Name of Co-Product

Source

Generation

(MT/Annum)

1.

Gypsum

(Calcium Sulphate)

Neutralization stage in manufacturing

of Sulphonated Naphthalene

Formaldehyde (SNF)

8,900

4.2 Land and Project Layout

The total plot area for the proposed unit is 15,000 sqm Out of total land available,

the unit will develop approximately 33 % of land a s green belt.

The detailed break-up of the land is given in Table - 4 and Key Plan & Plant Layout

is shown in Drawing - 1.

Table - 4: Break-up of Built up area

Sr.

Particular

Area (Sqm)

No.

1 Process Plant 4278

2 Raw Material & Product Storage 1624

3 Utility 752

4 Administrative office and misc. 450

5 Road including parking 5166

6 Green Belt 5099.84



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Drawing - 1: Key Plan & Plant Layout

4.3 Resource Requirements

[A] Water

The water required for the project will be procured from MIDC. The total fresh water

requirement for various domestic, gardening & industrial activities will be 667

KL/day.

[B] Power

Total 4 MVA power will be required and same will be procured from Maharsahtra

State Electricity Corporation Limited. In addition to this, 2 D.G. Sets of 1000 KVA will

be installed as stand-by and captive source of power.

[C] Fuel

For the proposed project, Furnace Oil / Methanol 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 or methanol (for 5 TPH boiler) 120 MT/month

Diesel (only for DG set in case of emergency) 0.5 KL/hr

It is also proposed that the tail gas coming out from process will be used for fuel.

[D] Manpower

The manpower is one of the main resource requirements to operate and maintain

the plant in a better and efficient way. Approximately 85 personnel will be required

for the proposed project in the operation phase. Details of personnel requirement at

various cadres are as tabulated below



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Table - 6: Details of Manpower Requirement

S

r.

Description

No. of

Persons

N

o.

1 Senior Management 08

2 Middle Management 10

3 Junior Management 17

4 Workers 40

Total

85

4.4 Details of Manufacturing Process

1. Aqueous Formaldehyde (37% to 55% Concentration)

The process comprises the following steps:

Evaporation of Methanol.

Mixing of gaseous Methanol with air, steam and recycle gas

Oxidation of Methanol to Formaldehyde in an water cooled tubular catalytic

Reactor.

Absorption of Formaldehyde in De-Mineralized Water

Formation of Formaldehyde takes place in a Reactor filled with Catalyst. In this

process Silver is used as a Catalyst for the conversion of Methanol to Formaldehyde.

In the temperature range 600 - 680°C, conversion form Methnaol to Formaldehyde

takes place in presence of silver catalyst. The heat of reaction is removed by

circulating water on shell side of tubular reactor and in Heat Exchangers. The water

c i r c u l a t e d i n t a b u l a r r e a c t o r gets converted to steam.

The Formaldehyde-rich gas from the Reactor is rapidly cooled ensuring the

lowest possible formation of Formic Acid.



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The selectivity is the fraction of the converted Methanol which is transformed into

Formaldehyde. The Formaldehyde-rich gas from the Reactor is fed to an Absorber

where the Formaldehyde is absorbed in D.M. Water. By varying the amount of

Process Water fed to the Absorber, the strength of the Product can be varied.

b) Reaction Chemistry

CH3OH + ½ O2 HCHO + H2O

CH3OH HCHO + H2

Formaldehyde

Capacity, MT/month: 1,50,000 MT/Annum

Working Days per Annum: 330

Sr. No.

Name of Raw Material Quantity

Remarks Kg/Kg of

Product

MT/Annum

Input

1 Methanol 0.454

5

68175 Reactant

2 Air 0.814 122130 Reactant

3 Water ( Fresh ) 0.4453 66795 Absorbing + Cooling media of

Reactor

Total 1.7133 257100

Output

1 Aqueous Formaldehyde

(37%)

1.000 150000. Finished Product

Formaldehyde 0.37000 55500

Methanol 0.02200 3300

Formic Acid 0.00100 150

Water 0.60700 91050

2

Excess Air & Water Vapor

+Export Steam

0.714

107100

To atmosphere through vent

attached to Absorber &

export steam partially

recycled in plant & partially

exported

Total 1.7133 257100

Note : All the above calculations are based on the Formaldehyde 37% basis.



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Water requirement may lower significantly if we go for higher concentration &

Recycling from other products

2. Urea Formaldehyde Concentrate (UFC- 85)

a) Manufacturing process

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.


H2N-CO-NH2 + 2 HCHO → HOCH2NH-CO-NHCH2OH

Urea Formaldehyde Concentrate (UFC- 85)

Capacity, MT/Annum: 20,000


Sr.

No.

Name of Raw Material Quantity Remarks

Kg/Kg of

Product

MT/Annum

Input

1 Methanol 0.252 5,040.0 Reactant

2

Air (1.6 m3=1.92 Kg/kg of

Methanol)

0.484 9,680.0 Reactant

3 Urea (96% assay) 0.255 5,100.0 Reactant

4 Caustic Soda 49 % 0.002 40.0 For pH adjustment

5 Water 0.100 2,000.0 For absorption

Total 1.093 21,860.0

Output

1 UFC - 85 1.000 20,000.0 Finished Product

2

Water Vapor

0.093

1,860.0

To atmosphere through

vent attached to Absorber

Total 1.093 21,860.0



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3. Hexamine


Hexamine is produced by reaction of Formaldehyde and anhydrous Ammonia in

liquid phase. The main process consists of the following steps. The entire route is

non-catalytic.

Synthesis: The Formaldehyde is continuously fed to a circulating 25% wt/wt

Hexamine solution. Anhydrous liquid Ammonia is also fed to this circulating solution

at a point where Formaldehyde has already been added. The reaction thus takes

place in presence of the Hexamine solution which helps in absorbing the heat of

reaction. The synthesis loop is equipped with coolers which removes the heat of

reaction and maintains the required temperatures. In order to control the reaction,

aqueous Formaldehyde and Ammonia is charged in measured quantities

maintaining a small excess of Ammonia over the Stoichiometric requirement.

EVAPORATOR cum Crystallization: The Hexamine solution overflowing from the

synthesis loop requires concentration so that Hexamine crystallizes upon achieving

the saturation point. The solubility of Hexamine in water is about 45%wt/wt and

therefore deteriorate the quality of Hexamine the evaporation is done at low

temperatures by boiling the water under vacuum. The equipment design also takes

care to generate larger sized crystal which helps in subsequent operations.

Centrifuging: In order to provide continuous feed to centrifuge an intermediate tank

after the EVAPORATOR cum crystallizer has been designed which acts as a surge

tank. The centrifuge separates the mother liquor collected along with the fineness

escaping through the filter media of the centrifuge is recycled back to the

EVAPORATOR. The impurities and by-products formed during the evaporation cum

crystallization stage impart a yellowish colour to the mother liquor. The mother

liquor, therefore, is decolorized in pressure leaf filters and recycled to the system.

Drying: The wet cake from the Centrifuge is fed to the drying system through a

hopper and a screw conveyor. The wet cake is dried in the dryer. The product



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collected is bagged or pulverized to a finer mesh before bagging, depending upon

the requirements.


6 CH2O + 4 NH3

→

C6H12N

4 + 6 H2O


Sr.

No.

Name of Raw Material Quantity Remarks

Kg/Kg of

Product

MT/Annum

Input


(AF-37)

3.600 21600.0 Reactant

2 Ammonia 0.550 3300.0 Reactant

3 Wash Water 0.030 180.

0

4

Water for Scrubber of

Packing section

0.220 1320.0 Scrubbed water will be fed to

the spray dryer with product

Total 4.175 26400.0

Output

1 Hexamine 1.000 6,000.0 Finished Product

2

Evaporation Losses during

Drying & Crystallization

3.400 20400.0 To atmosphere through vent

attached to Spray Dryer

Total 4.175 26400.0

4. Paraformaldehyde (96%)


Paraformaldehyde is a Polymer which is obtained by Polycondensation of

Formaldehyde in aqueous solution. A unique process based on Vacuum

Concentrated and Drying of Product to produce Paraformaldehyde would be

applied.



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The main sections of the plant are:

Concentration of aqueous Formaldehyde (37 – 55%)

Polymerization and drying

Concentration of distillates for recycling

Conveying, pulverization and storage / packaging of the Product

Concentration of aqueous Formaldehyde (37%) to (65-75)% is carried out by

feeding the material from a storage tank to proprietary concentration equipment

(EVAPORATOR-I).

The distillate containing (10-20) % Aldehyde content is condensed, sub cooled in

heat exchangers and collected in an Intermediate Tank. Polymerization and Drying

up to 96% Formaldehyde concentration is carried out in proprietary special drying

equipment which operates in a cyclic manner for polymer precipitation, cooling and

unloading formed Paraformaldehyde lumps. The (20-20) % Formaldehyde

Concentration distillate obtained from the EVAPORATOR-I and the distillate from

the drying section are fed to concentration EVAPORATOR-II for concentration and

recycling. Functionally EVAPORATOR-II is similar to EVAPORATOR-I with certain

differences in construction features. Use of secondary evaporation step helps in

achieving the following:

Recovery of Formaldehyde to improve overall yield.

Facilitation of continuous operation of the plant by feed recycle.

Recovery of final distillates below (3-4) % Formaldehyde concentration grade

which can be recycled to the Formaldehyde plant supplying AF-37 feed stock

thereby virtually eliminating liquid effluents.

Product from Drying Equipment is dumped onto the Belt Conveyor from where it is

conveyed to a Precrusher. Crushed product is pneumatically conveyed to a Cyclone

through a rotary air lock valve. The product from the cyclone is taken to a Sieve

Shaker in which particles below 1mm size are separated and sent to mixed Product

Silo via pneumatic conveying system. The oversize material from sieve shaker goes

to a Pin



Pre-Feasibility

Report


Pulverizer for further grinding and then through same pneumatic conveying system

to mixed Product Silo. The mixed product is separated in II Sieve Shaker and

transferred to separate silos for powder and granular products.

An Aspirator System with bag filter and blower is installed for keeping the whole

material handling system under slightly negative pressure. The aspirator system

helps in collecting fine dust particles during conveying, crushing and sieving

operations thus improving recovery and reducing pollution. Air from the bag filters

is passed through scrubber for further cleaning before venting into open

atmosphere.


Add Tab Add Tabel Here

dddddddddddddddddddddddddddddddddddddddddd

Add Tabel Here dddddddddddddddddddddddddddddddddddddddddd

el Here dddddddddddddddddddddddddddddddddddddddddd

D

5. Urea Formaldehyde (UF) & Melamine Formaldehyde (MF) Resins


Urea Formaldehyde resins, Melamine Formaldehyde and Melamine Urea

Formaldehyde combination resins are manufactured in similar batch processes. The

equipment / machinery consists of jacketed steel Reaction Vessel equipped with an



Pre-Feasibility

Report


agitator and condenser, with a downstream Aging Tank / Blender followed by

Product

Storage tanks and Filling stations. Aqueous Formaldehyde, Amino compound (Urea

/ Melamine) and a Catalyst are charged to a stirred tank jacketed reactor commonly

referred to as a Resin Kettle. The pH is adjusted and the charge is heated. Since the

reaction is exothermic, close temperature control is necessary. The progress of

reaction is monitored by checking samples of viscosity. The equipment / machinery

for production of UF as well as MF liquid resins is identical and can have common

usage by running batches with downstream common Dryer in which powder

production campaigns can be run. One or more methylol groups per molecule are

produced, depending on the amount of formaldehyde used. The second step is the

condensation of the monomer units resulting in polymer chain formation and

elimination of water.

Melamine Formaldehyde resins are produced by condensation reaction of

Formaldehyde with the amino groups of Melamine. The chemistry is analogous to

that with Urea Formaldehyde as described above except that the three amino groups

of Melamine provide more possibilities for cross linking, are more reactive, and all

six atoms of Hydrogen will react.


H2N-CO-NH2 + 2 HCHO → HOCH2NH-CO-NHCH2OH

C3H6N6 + HCHO → C4H8N6O

c)

Summary of mass balance

Urea Formaldehyde (UF) (Liquid Resin)



Sr. No.

Name of Raw Material

Quantity Remarks Kg/Kg of

Product MT/Annum



Pre-Feasibility

Report


1

Aqueous Formaldehyde (AF-37)

1.1500

17,250.0

Reactant

2 Urea (Granular or prilled) 0.6000 9,000.0 Reactant

3 Caustic Soda 49% 0.0030 45.0 For pH adjustment

4 Formic Acid 0.0002 3.0 For pH adjustment

Total 1.7532 26,298.0

Output

1

Urea Formaldehyde (UF) (liquid resin)

1.0000

15,000.0

Finished Product

2

Water recovery through condenser

0.4520

6,780.0

To be recycled to AF-37 Plant

3 Water Vapor Losses 0.3012 4,518.0 To atmosphere

Total 1.7532 26,298.0

Melamine Formaldehyde (MF) (Liquid Resin)



Sr.


Quantity

Remarks

Kg/Kg of

No.

MT/Annum

Product


1.150 17,250.0 Reactant

(AF-37)

2 Melamine 0.800 12,000.0 Reactant


Total 1.954 29,310.0

Output

1 Melamine Formaldehyde

1.000 15,000.0

Finished Product

(MF) (liquid resin)

2

Water recovery through

0.576 8,640.0

To be recycled to AF-37

Condenser Plant

3 Water Vapor Losses 0.378 5,670.0 To atmosphere

Total 1.954 29,310.0

Urea Formaldehyde (UF) (Powder Resin)





Pre-Feasibility

Report


Sr.


Quantity

Remarks

Kg/Kg of

No.

MT/Annum

Product

1 Urea Formaldehyde (UF)

2.000 15,000

Liquid product

(liquid resin)

Total 2.000 15,000

Output

1 Urea Formaldehyde (UF)

1.000 7,500.0

Powder Product

(powder resin)

Evaporation losses during


2

1.000 7,500.0

vent attached to Spray

drying

Dryer

Total 2.000 15,000.0

Application for the Environmental Clearance

Proposed Project for Manufacturing of Synthetic Organic Chemicals

Melamine Formaldehyde (MF) (Powder Resin)



Sr.


Quantity

Remarks

Kg/Kg of

No.

MT/Annum

Product


2.000 15,000.0 Liquid Product

(MF) (liquid resin)

Total 2.000 15,000.0

Output


1.000 7,500.0

Powder Product

(MF) (powder resin)


To atmosphere through 2 1.000 7,500.0 vent attached to Spray



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Report


drying

Dryer

Total 2.000 15,000.0

6. Phenol Formaldehyde Resins


The Resol Resins are manufactured with Formaldehyde to Phenol molar ratio

greater than one, normally in the range 1.4 to 1.6. The resulting Resin has more than

one Methylol group attached to each aromatic ring and these can be used for cross

linking. Hence the Resin is a true Thermoset as manufactured. Resol Resins are made

by the simple condensation of the starting materials in a stainless steel or glass lined

vessel fitted with a condenser arranged both to reflux and distill. The usual catalyst

is an alkaline material and may be Caustic Soda, Ammonia, an Amine, Sodium

Carbonate, etc. Whilst the reaction will take place under either acid or alkaline

conditions, acid catalysis is generally too violent for commercial Resol production.

Temperatures used are up to boiling, much of the heat of reaction being taken away

by the condensers as well as a jacket on the reactor. The final product may be liquid,

a solution in an added solvent (Ketones and Alcohols are most common) or,

occasionally a solid. The production of solid Resols is a hazardous business since the

point at which the molecular weight is sufficiently high for the product to be solid

and that at which it is effectively cross-linked and intractable are very close. Solid

Resols are emptied from the reactor in the molten state into a box filled with chilled

plates, or a similar shock cooling device, where it freezes rapidly and the reaction

stops.

Novolac Resins, in which the Formaldehyde to Phenol molar ratio is less than one,

may be made using an acid catalyst although even then the acid would be a weak



Pre-Feasibility

Report


organic acid and not a mineral acid. Because there is insufficient Formaldehyde

present to crosslink the product, the resulting polymer is a thermoplastic and

usually solid, although, as with Resols, it may be supplied as a solution directly from

the plant. If solid, the Resin is poured from the reactor as a melt, either via small

holes to form ‘pastilles’ on a moving, cooled belt or as a continuous stream from

whence it is broken up into crude lumps. Either way the Resin is ground in a fine

grinding plant usually with the addition of a Formaldehyde donor such as Hexamine

Methylene Tetramine (Hexamine). The Resin, packed in bags or supplied as bulk

powder in tankers, is then ready for use. Hexamine provides the extra Methylene

bridges needed to complete the crosslinking reaction when the powder is heated to

a melt again in processing.


C6H6O + HCHO → C7H8O2

c) Summary of mass balance

Phenol Formaldehyde (PF) (Liquid resin)



Sr.

No.


Quantity Remarks

Kg/Kg of

Product

MT/Annum

Input

1

Aqueous Formaldehyde (AF-

37)

0.415 2,075.0 Reactant

2 Phenol 0.212 1,060.0 Reactant


4 Water 0.207 1,035.0 Process requirement

Total 1.000 5,000.0

Output

1 Phenol formaldehyde Resin 1.000 5,000.0 Finished Product



Pre-Feasibility

Report


Phenol Formaldehyde (PF) (Powder resin)



Sr.


Quantity

Remarks

Kg/Kg of

No.

MT/Annum

Product

Input

Resol type Phenol

1 Formaldehyde (PF) liquid 2.273 5,000.0 Liquid Product

resins

Total 2.273 5,000.0

Output

Resol type Phenol

1 Formaldehyde (PF) 1.000 2,200.0 Powder Product

powder resins


2

1.273 2,800.0

vent attached to Spray

Dryer

Total 2.273 5,000.0

7. Sulphonated Naphthalene Formaldehyde (SNF) Superplasticizers


The basic manufacturing stages in the five steps Process are:

Sulphonation

Condensation

Neutralization

Filtration

Storage & Handling



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Report


Sulphonated Naphthalene Formaldehyde is manufactured in a batch process by

sulphonation of molten Naphthalene with concentrated Sulphuric Acid under high

temperature and pressure. Naphthalene Sulphonic Acid thus formed is reacted with

Formaldehyde to give Poly Naphthalene Sulphonic Acid (PNS) Polymer which is

neutralized with Caustic Soda solution to achieve desired final product such as

Sodium Poly Naphthalene Sulphonate. Excess Sulphuric acid is neutralized by

addition of Lime.

Calcium Sulphate Salt formed is filtered out in a filter press.

SNF (Powder) is produced by drying SNF (Liquid) in a nozzle type Spray Dryer. The

drying process is carried out under vacuum. Air required for process is filtered

through an air filter before entering into Dryer for air heating. Air is passed through

an air heating system and hot air is sent to drying section for drying purpose. Feed

is sent to atomization system for uniform atomization. Feeding is done at controlled

rate. The feed material and hot air come in contact with each other and drying takes

place. The exhaust air carries the moisture removed from the product away. The

exhaust gas is then passed through cyclone separator for fines recovery. The product

is separated and collected at the bottom. Exhaust air is further passed through a

venturi scrubber. Clean air is then exhausted to the atmosphere. Product from

chamber and cyclone outlet is further pneumatically cooled and conveyed to bagging

off cyclone to separate the material from conveying air for packing / storing. The

entire operation of the PLANT is controlled through a local operating panel


C10H8 + H2SO4 + HCHO + NaOH → C11H7NaSO3 + 3 H2O


d) Sulphonated Naphthalen Formaldehyde (SNF) Superplasticizers (Liquid)



Quantity



Pre-Feasibility

Report


Sr.

No.

Name of Raw Material Kg/Kg of

Product

MT/Annum Remarks

Input

1

Aqueous Formaldehyde

(AF-37)

0.150 3,000.0 Reactant

2 Naphthalene 0.211 4,220.0 Reactant

3 Sulfuric Acid 0.172 3,440.0 Reactant

4 Caustic Soda 49% 0.127 2,540.0 Reactant

5 Lime Powder 0.022 440.0 Reactant

6 D.M. Water 0.700 14,000.0 Process requirement

7

2% Caustic solution for

Caustic Scrubber

0.059

1,186.4

Scrubbed liquid will be

recycled in next process step

i.e. Condensation

Total 1.441 28,826.4

Output

1

Sulphonated Naphthalene

Formaldehyde (SNF)


1.000

20,000.0

Finished Product 2 Gypsum 0.441 8,826.4 To be sold as co-product

Total 1.441 28,826.4

Sulphonated Naphthalene Formaldehyde (SNF) Superplasticizers (Powder)



Sr.


Quantity

Remarks

Kg/Kg of

No. MT/Annu

m

Product

Input


1 Formaldehyde (SNF) 2.857 20,000.0 Liquid Product


Total 2.857 20,000.0

Output


1 Formaldehyde (SNF)

1.000 7,000.0

Powder Product Superplasticizers



Pre-Feasibility

Report


(Powder)



2

1.857 13,000.0

vent attached to Spray drying

Dryer

Total 2.857 20,000.0

8. 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 fractions from the top are refluxed

to reactor and pressure Distillation Column.


CH3OH + 2 HCHO → C3H8O2




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Report


Methylal (99.5%)

Capacity, MT/Annum:

18,000 Working Days per Annum: 330

Sr.

No.

Name of Raw Material Quantity

Remarks Kg/Kg of

Product

MT/Annum

Input


(AF-37)

1.080 19,440.0 Reactant

2 Methanol 0.860 15,480.0 Reactant

Total 1.940 34,920.0

Output

1 Methylal (99.5%) 1.000 18,000.0 Finished Product

2 Excess reaction water 0.940 16,920.0 To be recycled to AF-37

Plant

Total 1.940 34,920.0

9. Process of Silver Refining

Stage-I -Process of making silver nitrate

In a vessel 50 Ltr. of water/dilute solution of Silver Nitrate is taken to which 16 Kg

of silver is added @ 50-55 Degree C, under constant stirring. Nitric Acid 9.3 Kg is

added in the same to convert silver to silver nitrate. During reaction nitrous fumes

are evolved which is absorbed in scrubber.

Stage-II

In a tank containing refining cells with hood, connected to scrubber, which can hold

silver.

Silver nitrate solution is added to tank in which current from 20 to 200 Amp & DC

voltage of 2 to 20 Volts is applied.

Silver crystals are deposited on silver cathode plate.

Silver crystals are removed from cathode plate by scrapping, then collected and

washed with DM water to remove silver nitrate. Water used in washing is recycled



Pre-Feasibility

Report


back to electrolysis tank.

Wet crystals are dried and sieved to obtain different sizes. The fumes generated are

absorbed in a scrubber.

In scrubber NaOH solution is circulated to absorb nitrus fumes. Neutralize solution

is taken to common ETP.

Stage-III

Melting

Process

Silver crystals to be reprocessed are melted in electric/gas furnace @ 900 Degree C

and converted into ingots / small pieces.

Silver Recovery From Silver Nitrate Solution

Silver nitrate solution is taken in SS vessel . Then addition of 10 % solution of caustic

soda solution with stirring.

Solution turns into brownish black of silver oxide. Quantity of caustic soda is nearly

half of the silver metal.

Reduction of silver metal from above alkaline solution by addition of Reducing Agent.

Always addn. of caustic soda and/or Reducing Agent are in slight excess to prevent

less yield of silver.

Quantity of reducing agent is half of Silver

Hksasssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssss



add Figure here



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4.5 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-7.

Table-7: Details of Raw Material Requirements

Sr.

No.

Name of raw

material

Quantity in

MT/annum

1 FORMALDEHYDE Methanol 68175

2 HEXAMINE AMMONIA 3300

FORMALDEHYDE 21600

3 PARAFORMALDEHYDE FORMALDEHYDE 56000

4 UREA FORMALDEHYDE

RESIN & MELAMINE

FORMALDEHYDE RESIN

FORMALDEHYDE 17250

UREA 9000

CAUSTIC SODA 600

FORMIC ACID 3

MELAMINE 12000

5 PHENOL

FORMALDEHYDE RESIN

FORMALDEHYDE 2075

PHENOL 1060

CAUSTIC SODA 830

WATER 1035

6 SILVER REFINING SILVER 18

NITRIC ACID 15

REDUCING AGENT 9

CAUSTIC 9

7 UREA FORMALDEHYDE

CONCENTRATE

METHANOL 5040

UREA 5100

CAUSTIC 40

WATER 2000

8 SULPHONATED

NEPHTHALENE

FORMALDEHYDE

FORMALDEHYDE 3000

NEPHTALENE 4220

SULFURIC ACID 3440

CAUSTIC SODA 2540

LIME POWDER 440

DM WATER 14000



Pre-Feasibility

Report


9 METHYLAL (99.5 %) FORMALDEHYDE 19440

METHANOL 15480

5. Pollution Potential And Control Measures

5.1 Water Pollution

(a) Details of Water Requirement & Wastewater Generation

The total fresh water requirement for various domestic, gardening & industrial

activities will be 667 KL/day and will be supplied by MIDC.

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 categories have been calculated. The fresh water requirement for industrial

activities will be 667 KL/day, which will be mainly used in the process, air pollution

control unit, washing activities and to make-up evaporation/blow down losses from

boiler and cooling tower. The water requirement for domestic activity will be 8.0

KL/day and for green belt development will be 10 KL/day.

The product-wise water requirement & wastewater generation is given in Table –

10(a). The water balance diagram is given in Diagram 10(b)

Table –10(a) Product-wise Water Requirement & Wastewater Generation

Product

Stream

Water Requirement, KL

Wastewater

Generation, KL

Remarks

Per Day Per Day

Aqueous Formaldehyd

Process (Fresh)

186.00 Nill

--



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Report


e (37% to 55% Concentration)

Urea Formaldehyde Concentrate (UFC- 85)

Process (Fresh)

6.1

Nil

--

Hexamine

Process (Fresh)

0.3

Nil

--

(Fresh)

4.5

4.5

For Vent attached to Packing section equipped with cyclone separator followed by water scrubber. Scrubbed water will be recycled in Process.

Paraformaldehy de (91-96%)

Process (Fresh)

Nil

98.2

To be recycled to AF Plant

APCM (Fresh)

8.00

8.40

For Vent attached to Dryer with bag filter followed by water scrubber.

Scrubbed water will be recycled

in EVAPORATOR-1 OF PFD.

*Urea Formaldehyde (UF) (Liquid Resin)

Process (Fresh)

0.00

20.55

To be recycled to

AF Plant

SILVER REFININF

Fresh

0.9 0.9 TO ETP



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Report


APCM (Fresh)

0.1 0.1 TO ETP



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Diagram 10(b)

(b) Wastewater Management System

The industrial wastewater generation from the proposed project will be 132

KL/day. From water treatment plants i.e. D.M. Plant / softener will be 61 KL/day &

from various industrial activities and utilities like washing, boiler blow down &

cooling purge 70 KL/day. 1 KL/day wasterwater will be generated from Silver

Refining Unit. Mode of treatment and disposal of these effluents will be carried out

as follows:

132 KL/day of effluent will be collected and treated in the ETP. 84 KL/day of treated

water will be reused for the cooling and washing activities.

RO Reject Water adhering to prescribed water will be used for Gardening Puprose

otherwise RO Reject Water will be taken to ETP.

The Domestic wastewater @ 8.0 KL/day will be discharged in to soak pit through

septic tank / MIDC Drainage Faciltiy.



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Water generated in various manufacturing process will be recycled to AF- 37 plant

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 pupose. Reject water of DM & Softener plant will

be treated in ETP and the condensate water from ETP will be reused for cooling.

Air Pollution: Adequate air pollution control units like Absorbers / Scrubbers are

provided for the control of process gas emission along with stack of adequate height

for the dispersion of the gases. There is also provision of D.G. Set as stand-by unit

and same is provided with adequate stack height as per prescribed norms.

Hazardous Waste: The main sources of hazardous waste generation from

proposed unit is dried sludge from ETP. The ancillary source of hazardous waste

generation will be discarded bags/drums from storage and handling of raw

materials and spent/used oil generation from plant & machinery. 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.

5.2 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:

(a) Process Gas Emissions

The sources of process gas emission from the proposed project will be SO2 &

Naphthalene generation from the manufacturing of SNF Superplasticizers, minute

traces of products during drying, etc. For the control of emissions, adequate air

pollution control systems and for proper dispersion of pollutants, adequate stack



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Report


heights will be provided. The details of gaseous pollutants to be emitted from the

manufacturing process of proposed products are given in Table – 13 (a) & details

of process gas stacks & air pollution control units are given in Table – 13 (b).

Table – 13(a): Details of Gaseous Emissions from Process

Name of Product Source of emissions Probable Pollutants Aqueous Formaldehyde Formaldehyde

Absorber Methanol

(37% to 55% Concentration)

Urea Formaldehyde Formaldehyde

Absorber Methanol

Concentrate (UFC- 85)

Spray Dryer

Particulate Matter

Hexamine

(Hexamine Powder)

Packing Section

Particulate Matter

(Hexamine Powder)

Particulate Matter Dryer (Paraformaldehyde

Paraformaldehyde (96%)

Powder)

Particulate Matter

Aspiration System (Paraformaldehyde Powder)

SILVER REFINING SILVER RECOVERY VESSEL NITROUS FUMES

Urea Formaldehyde (UF) Particulate Matter

Spray Dryer (Formaldehyde

(Powder Resin)

Powder)

Melamine Formaldehyde (MF) Particulate Matter

Spray Dryer (Formaldehyde

(Powder Resin)

Powder)

Resol type Phenol Formaldehyde (PF) (Powder Spray Dryer Phenol resin)



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Name of Product


Formaldehyde (SNF) SO2, Naphthalene


Sulphonated Naphthalene Particulate Matter

Formaldehyde (SNF)

(SNF Powder)


Particulate Matter

Polycarboxylates (Powder) (Polycarboxylate

Powder)

S

r

.

Pollutant

Concentrati

on

(mg/Nm3)

Air

Pollution

Control

Unit

Process Stack attached

To

1

Absorber of Aqueous

Hydrocarbon

as

Process

CH4 ≤ 15

Formaldehyde Plant mg/Nm3 Absorber

2

Absorber of Urea

Hydrocarbon

as

Process

Formaldehyde

Concentrate CH4 ≤ 15

Plant mg/Nm3 Absorber

3

Dryer of Hexamine

Particulate

Cyclone

Matter ≤ 150

Plant mg/Nm3 Separator

4

Packing section of

Hexamine

Particulate

Matter ≤ 150

Water

Scrubber

Plant mg/Nm3

5

Dryer of

Paraformaldehyde

Particulate Bag filter

Matter ≤ 150 followed by

Plant mg/Nm3

Water

Scrubber



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6

Aspiration System of

Particulate Bag filter

Matter ≤ 150 followed by

Paraformaldehyde Plant mg/Nm3

water

scrubber

7

. SILVER REFINING

Nitrous Gas <

100 mg/Nm3

ALKALINE

SCRUBBER

8

Dryer of Urea Formaldehyd

e

Cyclone

Formaldehyde Powder

Resin

≤ 10 mg/Nm3 Separator

Plant

9

Dryer of Melamine Formaldehyd

e

Cyclone

Formaldehyde Powder

Resin

≤ 10 mg/Nm3 Separator

Plant

Formaldehyd

e

1

0

Dryer of PF RESIN

≤ 10 mg/Nm3,

Cyclone

Hydrocarbon

as

Powder Resin Plant Benzene ≤ 90 Separator

mg/Nm3

SO2 ≤ 40

1

1

Sulphonator of SNF

(Liquid)

mg/Nm3, Caustic

Hydrocarbon

as

Plant Benzene ≤ 90 scrubber

mg/Nm3

1

2

Dryer of SNF (Powder)

Particulate Cyclone

Matter ≤ 150


1

2

Dryer of Particulate Cyclone

Polycarboxylates

(Powder) Matter ≤ 150


b) Flue Gas Emission

Main source of flue gas generation will be steam boiler of 5 TPH capacity from the

proposed unit. Furnace oil / Methanol/ Tail Gas will be used as a fuel in the boiler

and adequate stack height will be provided for the control of emissions. Unit will also



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install 3 nos. of D. G. Sets, each of 1000 KVA capacity as stand-by units. The details of

flue gas emission are given hereunder in Table - 14.

Table – 14: Details of Flue Gas Stacks

Sr.N

o.

Sta

ck

Att

ach

to

Typ

e o

f F

uel

Hei

ght

(m)

Dia

met

er

Co

nce

ntr

ati

on

of

Po

llu

tan

ts

Air

Po

llu

tio

n

Co

ntr

ol

Me

asu

res

1 Steam Boiler (5 TPH)

Fur

nac

e 20 0.35

PM ≤ 150

Oil

2 D.G.Set-1 (1000 KVA),

Die

sel 6 0.2 mg/Nm3

Adequa

te

Stand-by

SO2 ≤ 100

ppm

stack

height

3 D.G.Set-2 (1000 KVA),

Die

sel 6 0.2

Stand-by

NOx ≤ 50

ppm

(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:

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



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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.

5.3 Hazardous Waste Generation and Management

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 details of hazardous wastes generation

and its management are given in Table - 15.

Table –15: Hazardous Waste Generation and Management

Type of

Quantit

y

Source

per

Method of Disposal

waste

Annum

ETP Sludge &

300.0

MT Collection, Storage,

Salt Transportation & Disposal



Pre-Feasibility

Report


at

TSDF

Raw Discarded 5,00,000 Collection, Storage,

Material Bags Nos. Decontamination,

Storage

& Discarded 500 Nos.

Transportation and

Disposal

Handling Drums

by

selling/recycling/reusing

to

vendors.

Spent

/Used

100

Liters

Collection, Storage and

used

Oil for lubrication within the

premises OR sell to

Plant

and registered Reprocessors /

Machine

ries MoEF approved recyclers

Wastes/ 0.5 MT Collection, Storage,

residues

Transportation & Disposal

at

containing

oil CHWIF

D.M.

Plant Spent Resin 10 KL/ Collection, Storage,

10 Year

Transportation & Disposal

by

co-processing in cement

kiln

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

TSDF/CHWIF for the disposal of hazardous waste



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5.4 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

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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6. PROJECT SCHEDULE & COST ESTIMATES

6.1 Schedule of Approval and Implementation

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 approval from Ministry of Environment and Forests (MoEF)

and State necessary Pollution Control Board (SPCB).

6.2 Capital Investment

The proposed unit is a large Scale Unit with the capital investment of Rs. 50 Crores

and estimated cost of Rs. 1.5 Crores towards Environmental Protection Measures.

Break-up of the capital cost is given in Table - 16.

Table – 16: Capital Cost

Sr.

No. Description

Capital Cost Rs.

In Crore

1. Land & Site Development 5

2. Building 7

3. Plant & Machineries & Other Costs 36.5

4. Environmental Protection Measures 1.5

Total 50.0



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7. Rehabilitation And Resettlement (R&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.

8. 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.

There will be positive impact on the socio-economic environment since proposed

project will generate some permanent and secondary employment. The unit will also

establish Cordial relation with the nearby villagers and will carry out social welfare

activities according to their needs.

The proposed project will also boosts up ancillary industrial and commercial

activity. Thus, it will improve the economic condition of the area.

Documents

PRE-FEASIBILITY REPORT FOR PROPOSED …environmentclearance.nic.in/writereaddata/FormB/TOR/PFR/07_Sep... · Additional Patalganga MIDC for M/s Balaji chemicals Pre-Feasibility Report