PROJECT PRE-FEASIBILITY...

Project Prefeasibility Report

Proposed expansion project for Manufacturing of Resin

Vijay Timber Ind. Pvt. Ltd.

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PROJECT PRE-FEASIBILITY REPORT

For

PROPOSED EXPANSION PROJECT

For

MANUFACTURING OF RESIN

At

Survey No 515/1 P, Village: Mithi-Rohar,

Taluka: Gandhidham,

Dist: Kutch-370 201, Gujarat, INDIA

Project proponent

M/s. Vijay Timber Industries Pvt. Ltd.




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CONTENTS

CHAPTERS

S.NO. PARTICULARS PAGE

NO.

CHAPTER 1 INTRODUCTION OF THE PROJECT 7-8

1.1 IDENTIFICATION OF THE PROJECT AND PROJECT

PROPONENT

7

1.1.1 IDENTIFICATION OF THE PROJECT 7

1.1.2 PROJECT PROPONENT 8

1.2 NATURE OF PROJECT 8

1.3 NEED OF PROJECT & DEMAND-SUPPLY GAP 8

1.4 EXPORT POSSIBILITY 8

1.5 EMPLOYMENT GENERATION DUE TO PROPOSED

PROJECT

8

CHAPTER 2 PROJECT DESCRIPTION 9-26

2.1 TYPE & LOCATION OF PROJECT 9

2.1.1 TYPE 9

2.1.2 LOCATION 9

2.2 DETAILS OF THE ALTERNATIVE SITE 12

2.3 SIZE & MAGNITUDE OF OPERATION 12

2.4 PROJECT DESCRIPTION WITH PROCESS DETAILS 12

2.4.1 EXISTING PRODUCTS 12

2.4.1.1 PLYWOOD, FLUSH DOOR, BLOCK BOARD & VENEER 12

2.4.1.1.1 MANUFACTURING PROCESS 12

2.4.1.1.2 FLOW CHART 13

2.4.2 PROPOSED PRODUCTS 14

2.4.2.1 PHENOL FORMALDEHYDE RESIN 14

2.4.2.1.1 CHEMICAL REACTION 14


2.4.2.1.3 MATERIAL BALANCE 15

2.4.2.2 UREA FORMALDEHYDE RESIN 15




2.4.2.3 MELAMINE UREA FORMALDEHYDE RESIN 17






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2.4.2.4 MELAMINE FORMALDEHYDE RESIN 19




2.5 RAW MATERIAL FOR FINISHED PRODUCTS 20

2.5.1 HAZARDOUS CHEMICAL STORAGE & HANDLING 20

2.6 RESOURCE OPTIMIZATION & AVAILABILITY 22

2.6.1 LAND & BUILDING REQUIREMENT 22

2.6.2 EQUIPMENTS 22

2.6.3 POWER AND FUEL REQUIREMENT 23

2.6.4 WATER REQUIREMENT 23

2.6.5 MAN-POWER REQUIREMENT 23

2.7 QUANTITY OF WASTE TO BE GENERATED 23

2.7.1 WASTE WATER GENERATION & MANAGEMENT 23

2.7.2 AIR EMISSION & CONTROL 24

2.7.2.1 PROCESS EMISSION 24

2.7.2.2 UTILITY EMISSIO 24

2.7.2.3 FUGITIVE EMISSION 24

2.7.3 HAZARDOUS/NON-HAZARDOUS WASTE MANAGEMENT 25

2.7.4 NOISE AND ODOUR CONTROL 26

2.7.5 HEALTH AND SAFETY MEASURES 26

2.7.6 ENVIRONMENTAL HEALTH & SAFETY CELL 26

2.7.7 POST PROJECT MONITORING PLAN 26

CHAPTER 3 SITE ANALYSIS 28-31

3.1 CONNECTIVITY 28

3.2 LAND FORM, LAND USE & LAND OWNERSHIP 28

3.2.1 LAND FORM 28

3.2.2 LAND USE PATTERN 28

3.2.3 LAND OWNERSHIP 28

3.3 TOPOGRAPHY 28

3.4 SALIENT FEATURES 28

3.5 EXISTING INFRASTRUCTURE 28

3.6 CLIMATE & METEROLOGY 28

3.6.1 TEMPERATURE 29

3.6.2 HUMIDITY 30

3.6.3 CLOUD COVER 30

3.6.4 RAINFALL 30

3.6.5 WIND PATTERN 30




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3.7 SOCIO INFRASTRUCTURE 30

3.7.1 EDUCATIONAL FACILITIES 30

3.7.2 MEDICAL FACILITY 30

CHAPTER 4 PLANNING BRIEF 32-33

4.1 PLANNING CONCEPT 32

4.2 POPULATION PROJECTION 32

4.3 AREA STATEMENT 32

4.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL

& SOCIAL)

32

4.5 AMENITIES/FACILITIES 32

4.5.1 DRINKING WATER FACILITIES 32

4.5.2 POWER SUPPLY FACILITIES 33

4.5.3 COMMUNICATION & BANKING FACILITIES 33

4.5.4 TRANSPORT FACILITIES 33

4.5.5 APPROACH TO VILLAGES 33

CHAPTER 5 PROPOSED INFRASTRUCTURE 34-34

5.1 INDUSTRIAL AREA 34

5.2 RESIDENTIAL AREA 34

5.3 GREENBELT 34

5.4 SOCIAL INFRASTRUCTURE 34

5.5 CONNECTIVITY 34

5.6 DRINKING WATER MANAGEMENT 34

5.7 SEWERAGE SYSTEM 34

5.8 INDUSTRIAL WASTE MANAGEMENT 34

5.9 SOLID WASTE MANAGEMENT 34

5.10 POWER REQUIREMENT & SOURCE OF SUPPLY 34

CHAPTER 6 REHABILITATION & RESETTLEMENT (R&R) PLAN 35-35

6.1 POLICY TO BE ADOPTED 35

CHAPTER 7 PROJECT SCHEDULE & COST ESTIMATES 36-36

7.1 TIME SCHEDULE OF THE PROJECT 36

7.2 ESTIMATED PROJECT COST 36

CHAPTER 8 ANALYSIS OF PROPOSAL 37-37

8.1 FINANCIAL & SOCIAL BENEFITS 37




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LIST OF TABLES

S.No. Particulars Page No.

TABLE 1.1 LIST OF PRODUCTS 7

TABLE 1.2 ADDRESSES OF DIRECTORS 8

TABLE 2.1 SALIENT FEATURES 9

TABLE 2.2 EXISTING AREA STATEMENT 12

TABLE 2.3(a) LIST OF RAW MATERIAL 20

TABLE 2.3(b) STORAGE, HANDLING & TRANSPORT OF HAZARDOUS CHEMICALS

20

TABLE 2.3(c) Applicability of MSIHC Rules, 1989 (As Amended in 2000) Regarding MAH Units

21

TABLE 2.4 LIST OF EQUIPMENTS 22

TABLE 2.5 DETAILS OF POWER & FUEL 23

TABLE 2.6 CATEGORY-WISE WATER REQUIREMENT (IN KL/D) 23

TABLE 2.7 CATEGORY-WISE WASTEWATER GENERATION (IN KL/D) 24

TABLE 2.8 DETAILS OF UTILITY EMISSION 24

TABLE 2.9 DETAILS OF HAZARDOUS WASTE GENERATION &

DISPOSAL

25

TABLE 2.10 POST PROJECT MONITORING PLAN 27

TABLE 3.1 SUMMARY METEOROLOGICAL DATA AT NEAREST IMD STATION –BHUJ

29

TABLE 3.2 DETAILS OF EDUCATIONAL FACILITIES 30

TABLE 3.3 DETAILS OF MEDICAL FACILITIES 31

TABLE 4.1 DISTRIBUTION OF POPULATION 32

TABLE 4.2 DRINKING WATER FACILITIES 33

TABLE 4.3 COMMUNICATION & BANKING FACILITIES 33




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LIST OF FIGURES


FIGURE 2.1 SATELLITE IMAGE OF THE PROJECT SITE 10

FIGURE 2.2 PROJECT SITE LAYOUT 11

LIST OF ANNEXURES


ANNEXURE-1(A) CC&A COPY 1-5

ANNEXURE-2 NA DOCUMENT 6

CHAPTER – 1

INTRODUCTION OF THE PROJECT




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1.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

1.1.1 IDENTIFICATION OF THE PROJECT

M/s. Vijay Timber Ind. Pvt. Ltd. is engaged in the commercial production of Ply wood sheets

& Face Veneer Sheets at its manufacturing facility located at Survey No. 515/1 P, Village:

Mithi-Rohar, Taluka: Gandhidham-370 201, Dist: Kutch, Gujarat.

The unit has acquired a consolidated consent & Authorization (CC&A) no. AWH-17366

dated 06/05/2015 for manufacturing of Ply wood sheets & Face Veneer Sheets. The existing

consent to operate-CC&A is attached as Annexure-1.

Presently Resin is being purchased from market. The resin is an important factor of quality of

the existing products as well as its cost. So, the firm experiences an urgent need of in-house

facility to maintain the desired quality level and to reduce the dependence on market. It also

intends to sell the same to other units in the vicinity.

Table 1.1: List of Products

Sr. No.

Name of Product, units Capacity per Month

Existing Proposed Total

Existing products/ processes

1 Plywood sheets 131250 m2 Nil 131250 m2

2 Face Veneer Sheets 4916500 m2 Nil 4916500 m2

Proposed products/ processes

2. Phenol Formaldehyde Resin

NIL

140 TPM 140 TPM 3. Urea Formaldehyde Resin

4. Melamine Urea Formaldehyde Resin

5. Melamine Formaldehyde

Note: CC&A No.AWH-17366 Dated 06/05/2015 is obtained for Plywood sheets and face veneer sheets.




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1.1.2 PROJECT PROPONENT

The company is promoted by 2 Directors. Name and Addresses of Directors is given below

in Table No. 1.2.

Table 1.2: Addresses of Directors

Sr. No.

Name of Directors Addresses

1. Mr. Gulabchand I. Shah Plot No 52, Sector 4, Gandhidham, Dist. - Kutch, Gujarat.

2. Mr. Ashvin G. Jain Plot No 52, Sector 4, Gandhidham, Dist. - Kutch, Gujarat.

1.2 NATURE OF THE PROJECT

The proposed expansion project involves the production of Resins, which falls under item no

5(f) i.e. synthetic organic chemicals.

As per the EIA notification, 14 September 2006 (as amended timely) small units with water

consumption less than 25 m3/day; fuel consumption less than 25 TPD; and not covered of

MAH units as per Management, storage, import of Hazardous Chemical Rules, 1989 are

covered under Category B and need to obtain the prior Environmental Clearance from State

Environment Impact Assessment Authority (SEIAA).

1.3 NEED OF PROJECT & DEMAND-SUPPLY GAP

Resin is key factor for manufacturing of Plywood industries. Presently, Resin is being

purchased from market. The resin is an important factor of quality of the existing products as

well as its cost. So, the firm experiences an urgent need of in-house facility for maintaining

the desired quality level and level to reduce the dependence on market. Moreover there are

also other plywood industries in the region to which the company can sale the resin, if

required.

1.4 EXPORT POSSIBILITY

No export possibilities analyzed for the proposed resin project.

1.5 EMPLOYMENT GENERATION DUE TO PROPOSED PROJECT

The proposed expansion project will provide direct employment opportunity to 5 persons and

indirect employment to few persons. The man-power required for the project will be

employed locally from the nearby areas.




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CHAPTER – 2

PROJECT DESCRIPTION

2.1 TYPE & LOCATION OF PROJECT

2.1.1 TYPE

The proposed expansion project involves the production of Resins, which falls under item no

5(f) i.e. synthetic organic chemicals.

2.1.2 LOCATION

The company is located at Survey No. 515/1 P, Village: Mithi Rohar, Taluka: Gandhidham,

Dist.: Kutch-370 201. The proposed project is to be sited within the existing premises of the

unit. The Satellite image of the site is shown in Figure -2.1 and plant lay-out is shown in

Figure 2.2.

Table 2.1: Salient Features of the Project Site

Particulars Details

Co-ordinates Approx. Center: 23° 7'18.90"N, 70° 9'39.85"E

Village Mithi Rohar ≈ 2.30 km (S)

Taluka/ Tehsil Gandhidham

District Kutch

Nearest Water body Rainwater Reservoir ≈ 3.35km (W)

National Highway/ State Highway NH 8 ≈ 0.6 km. (E)

Nearest Railway station & Railway line Gandhidham Railway Station ≈ 6.0 km (S)

Nearest Airport/ Airbase Kandala Airport ≈ 6.0 km (SW)

State/ National borders None within 10 km

National Park/ Wild life Sanctuary None within 5 km

Anganwadi/ School/ College/ Institute Anganwadi & primary school are located in nearest Village Mithi Rohar ≈ 2.30 km (S)

Note: All the above mentioned distances are the aerial distance from the project site.




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Figure 2.1: Satellite image of the project site




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Figure 2.2: Project Site layout




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Table 2.2: Existing Area Statement

S. No. Description Approx. Area (m2)

1. Total Plot Area 18717.0 m2

2. Built-up area 6941.0 m2

3. Greenbelt area 700.0 m2

4. Open Area 11076.0 m2

2.2 DETAILS OF THE ALTERNATIVE SITE

No alternative sites considered as the propose expansion is to be carried out in the existing

industrial plot.

2.3 SIZE & MAGNITUDE OF OPERATION

It is a small scale unit for manufacturing of ply wood and proposes to expand for

manufacturing of Resin.

2.4 PROJECT DESCRIPTION WITH PROCESS DETAILS

2.4.1 Existing Products

2.4.1.1 Plywood, Flush Door, Block Board & Veneer

2.4.1.1.1 Manufacturing Process

Log is cut by Saw cutter.

Log held on roller and being peeled with a sharp blade. The peeled sheet being rolled

in a roller.

Then log is cut in to sheets of required size with the slicing blade.

Sheets being fed onto a conveyor going inside the drying chamber. Heating is done

with help of Thermicfluid heater. Drying is done with help of inlet of air through air

blower.

Then glue is added. The glue is prepared by adding additives in the thick resin and

water in dilution vessels, depending on the thickness of resin to obtain desired

thickness for application.

After drying Grading and bundling is done to get the final product of Veneer.

Assembling of sheets is done to required thickness. Full sized sheets are put at top and

bottom. Small sized sheets are arranged horizontally and vertically in between.

In case of block boards, wood sticks are used. Fullandsmall sized sheets are put at top

and bottom. Wood sticks of required thickness are put in between.

Pressing of assembled boards is done by tonnage of weight.

Sheets arranged in separate layers inside the drying chamber. Heating is done with

help of Thermicfluid heater.

Sheets being fed through conveyor chain. Cutting of sides of the board.

Sanding (Finishing) of the surface of the boards.




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Sheets being fed by mounting on a pipe which is pushed for smoothening (finishing/

sanding) of the edges of the sheet. Local exhaust system has a blower used for suction

of the wooden dust.

Quality check is done by hitting the boards with hammer for any deviation in sound,

Labeling is done for the brand name and sticking of stickers and we get the final

product of Block Board, Flush door and Plywood.

2.4.1.1.2 Flow Chart




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2.4.2 Proposed Products

2.4.2.1Phenol Formaldehyde Resin

2.4.2.1.1 Chemical Reaction

2.4.2.1.2Manufacturing Process

Phenol (93%) solution to be charged into a Kettle followed by Formaldehyde (37-41%).

Stirring to be started followed by addition of Oxalic acid solution (13%).

Heating to be initiated through circulation of oil in coil, to raise the temperature to 60ºC,

until the exothermic reaction becomes strong enough to cause the batch to heat up

without further heating. The condensation reaction takes place at 92ºC - 95ºC to form

Novolac resin.

The intermediate product is to be cooled down the temperature to 45ºC - 50ºC by

jacketed cooling by circulation of water.

In the second stage, controlled addition of 33% solution of Sodium Hydroxide is done in

order to obtain alkaline resin solution.

Upon addition of Noah solution, the temperature rise to be controlled to 50-60ºC by

continuous circulation of water.

After achieving the desired temperature range, the ML to be kept for 30 minutes.

Further addition of Formaldehyde (37-41%), to again result in temperature raise to 75 to

80ºC, where the second condensation reaction takes place to obtain the final product -

Resole resin. During the exothermic reaction, the temperature to be controlled and

viscosity to be checked continuously, till the desired viscosity of the resin is achieved.

The resin becomes infinitely soluble in water and is to be further cooled by circulating

cold water. The product is ready to use.




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2.4.2.1.3 Material Balance

2.4.2.2Urea Formaldehyde Resin



First formaldehyde & poly Venyl alcohol is charged in SS reactor and mix it for half an

hour. Then caustic soda solution is to be added and to maintain pH up to 8.0. There

after add 1st batch of urea and start heating to maintain temp 95 0C for one hour. Acetic

acid is to be added for reduction of pH up to 4.5 to 5.0 and to check turbidity.

After obtaining turbidity, increase pH up to 7.0 to 7.5 by adding caustic soda solution for

getting desired viscosity. Add 2nd batch of urea for utilization of unreacted formaldehyde.

There after startdistillation and reflux. Cool the whole mass at 40 0C and maintain pH

8.0 by adding caustic soda solution and store it as final product. The water of reaction is

retained in the product.

Poly Vinyl Alcohol will be added for dilution purpose. It will not use to manufacture resin.

It will help to let down the viscosity of resin so it can float on the sheet while drying.




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2.4.2.3Melamine UreaFormaldehyde Resin 2.4.2.3.1 Chemical Reaction


Urea and formaldehyde are charged to reactor.

Than caustic soda solution is added to maintain pH. 9-9.5 with stirring.

Thereafter required quantity of Malamine is added and reaction temperature is

maintained at 95°C.

Reflux is done for 30 minutes.

After obtaining turbidity increase pH 9-9.5 by adding caustic soda solution. After getting

desired water tolerance 1:3-1:4,start cooling.

Add 2nd batch urea of 70°C & 3rd batch urea at 60°C.

Cool the whole mass at 40°C and maintain pH 8-8.5 and store it as final product.




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2.4.2.4 Melamine Formaldehyde Resin



All the raw materials Melamine and Formaldehyde will be added in limped reaction

vessel.

Stirring and heating will be done up to 95°C for 1 Hr.

Cooling will be started at 40°C.

Melamine formaldehyde resin will be ready for use.





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2.5 RAW MATERIAL FOR FINISHED PRODUCTS

The raw materials for range of products will be indigenously available.

Table 2.3(a): List of Raw Materials

2.5.1 HAZARDOUS CHEMICAL STORAGE & HANDLING

Hazardous chemicals are/will be used as raw material in the manufacturing process.

Storage, handling & transport of Hazardous Chemicals are given in table 2.2(b).

Table 2.3(b): Storage, Handling & Transport of Hazardous Chemicals

Raw Material/ finished goods

Source CAS No Means of storage

Means of transport

Max. Qty. stored MT

Phenol Local Market 108-95-2 Tank Tanker 3.0

Formaldehyde (37-41%) Local Market 50-00-0 Tank Tanker 4.0

Oxalic Acid Local Market 144-62-7 Bags Truck 0.5

NaOH Local Market 1310-73-2 Bags Truck 2.0

Urea (Tech grade) Local Market 57-13-6 Bags Truck 4.0

Poly vinyl Alcohol Local Market 9002-89-5 Bags Truck 0.5

Acetic Acid/Formic Acid Local Market 64-19-7/64-18-6 Drum Truck 0.1

Melamine Local Market 108-78-1 Bags Truck 3.0

Product Name of Raw Material Requirement (MT/Month)

Phenol Formaldehyde Formaldehyde (37-41%) 82.60

Phenol 50.26

Oxalic acid 0.77

NaOH 6.37

Or

Urea Formaldehyde NaOH 0.12

Polyvenyl alcohol 0.58

Urea (Tech.grade) 52.57

Formaldehyde (37-41%) 86.64

Acetic acid/Formic acid (25%) 0.09

Or

Urea Melamine Formaldehyde

NaOH 0.05

Melamine 12.35

Urea (Tech.grade) 37.04


Or

Melamine Formaldehyde Melamine 56.00





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Table 2.3(c): Applicability of MSIHC Rules, 1989 (As Amended in 2000) Regarding MAH Units. No.

Chemical Name Toxicity Flammable Limits Max. Storage (MT)

Physical form

Total Qty (MT)

Chemical Class (As per Shedule-1

Threshold Quantity as per Schedule 2 (MT)

Threshold Quantity as per Schedule 3 (MT)

LD50 Oral mg/Kg

LD50 Dermal mg/Kg

LC 50 mg/l

Flammable Gas @20 Deg. C (Y/N)

LEL %

UEL %

FP Deg. C

BP Deg. C

Part-1 Column 3 Column 3

1 Formaldehyde (37-41%)

42 15800 203 N 6.0 36.5 60 98 4.0 Liquid

4.1

Highly Flammable

10000 5

2 Acetic Acid 3310 1060 5620 N 4.0 19.9 43 118.1 0.1 Liquid Highly Flammable

10000 Not Specified

3 Phenol 270 630 125 N 1.7 8.6 85 182 3.0 Liquid 3.1

Flammable 15000 Not Specified

4 Formic Acid 700 NA 6200 N 18 57 NA 100 0.1 Liquid Flammable 15000 Not Specified

5 Melamine 3161 >1000 NA N NA NA 93.3 NA 3.0 Solid -- Not Specified Not Specified Not Specified

6 Poly vinyl Alcohol

14700 NA NA N NA NA 79 NA 0.5 solid -- Not Specified Not Specified Not Specified

7 Oxalic Acid NA NA NA N NA NA NA NA 0.5 solid -- Not Specified Not Specified Not Specified

8 Urea (Tech grade)

8471 NA NA N NA NA NA NA 4.0 solid -- Not Specified Not Specified Not Specified

9 NaOH NA NA NA N NA NA NA 1388 2.0 solid -- Not Specified Not Specified Not Specified

NA: NOT AVAILABLE




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2.6 RESOURCE OPTIMIZATION & AVAILABILITY The major resources for the proposed project are/will be raw-materials, water, man-power,

etc.

2.6.1 LAND & BUILDING REQUIREMENT

Total Plot area is 18717 m2 and total constructed area is 6941.0 m2. No additional land will

be required for proposed project expansion. No major construction except a base platform

will be constructed for Resin Plant. Rest all will be MS structure.

2.6.2 EQUIPMENT

Some additional equipment will be needed for the proposed expansion.

Table 2.4: List of Equipment

Sr. No. Equipment No

Existing (for plywood)

1 Side Sanding M/C 1

2 Chopping M/C 4

3 DD Saw M/C 1

4 Glue Spreader 2

5 Peeling lathe M 2750 2

6 Press daylight 12 1

7 Peeling Lathe M 1400 1

8 Grinding M/C 1

9 Wet clipper Veneer 4

10 Dryer 4 section 3 decks 2

11 Core Dryer 1

12 White belt sender 1

13 Deeping M/C 1

14 Scissor lift 2

15 Cooling Fan 2

16 Paddle chopper machine 10

17 Hand chopper Machine 2

18 Core Sanding 1

19 Glue Mixer 1

20 Glue jointer 1

Proposed (for resin)

29 Resin Kettles 1

30 Weighing Machine 1

31 Cooling Pump 2

32 Chemical Storage Tank 2

33 Resin Storage Tank 2




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2.6.3 POWER AND FUEL REQUIREMENT

Table 2.5: Details of Power & Fuel

Sr. No.

Particulars Requirement Source

Existing Proposed additional

Power

1 Power 180 kVA NIL PGVCL/ DG Set (125 kVA- 2 nos stand-by)

Fuel

1 Briquettes 250 kg/hr. NIL In-house generation, Local Traders

2. Diesel 15 Lit/hr. NIL Local petrol pumps

2.6.4 WATER REQUIREMENT

Necessary water requirement is fulfilled from Tanker water supply. For existing project, water

is required for domestic, process and utility purpose.

The category wise bifurcation of the water requirement is given in the Water Balance Data in

Table 2.6.

Table 2.6: Category-wise Water Requirement (in KL/D)

S.No. Particulars

Requirement (KLD)

Existing scenario Proposed scenario

1. Domestic 2.0 2.5

2. Gardening 1.50 2.0

3. Industrial

4. Process 0.0 0.0

5. Timber wetting 3.1 3.1

6. Washing 0.15 0.4

7. Glue Mixing 0.25 0.0

8. Cooling 0.0 0.5

9. Sub-Total: Industrial 3.5 4.0

10. Grand Total 7.0 8.5

2.6.5 MAN-POWER REQUIREMENT

The total number of man power for existing project is 100 persons, for proposed expansion

project additional 5 persons will be required. Hence the total man-power will be 105 persons.

The man-power required for the project is/ will be employed locally from the nearby areas.

Skilled as well as unskilled labour will be employed for the project.

2.7 QUANTITY OF WASTE TO BE GENERATED

2.7.1 WASTE WATER GENERATION & MANAGEMENT

The category wise bifurcation of the waste water generation is given in Table 2.7.




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Table 2.7:Category-wise Wastewater Generation (in KL/D) S.No. Particulars Waste Water Generation

Existing Scenario Proposed Scenario

1. Domestic 1.4 1.8

2. Industrial

3. Process water 0.0 0.0

4. Washing 0.15 0.4

5. Cooling 0.0 0.0

6. Other 0.0 0.0

7. Sub-Total: Industrial 0.15 0.4

8. Grand Total 1.55 2.2

Note: Waste water generated from washing having rich glue content and is/will be reused for Glue mixing purpose.

Domestic wastewater generated from the plant is/will be disposed off through septic

tank/soak pit. Waste water generated from washing having rich glue content and is/will be

reused for Glue mixing purpose. After proposed expansion, the reaction water generated

from the process will be retained in the product.

2.7.2 AIR EMISSIONS & CONTROL

2.7.2.1 Process Emission

There is/will be no process emissions from the manufacturing process.

2.7.2.2 Utility Emission

Details regarding utility emissions and control measures are mentioned in the below table

no. 2.7.

Table 2.8: Details of Utility Emission

Particulars Fuel &it’sQty Stack Details(m)

APCD Emission Norms

Existing

Thermicfluid heater (15 lakh kCal/Hr)

Briquettes: 250 kg/hr

H: 23.0 m D: 0.6 m

Multi Cyclone Dust-Collector

PM<150 mg/Nm3 SO2< 100 ppm NOx< 50 ppm

D. G. Set- 2 Nos (125 Kva each Stand-by)

Diesel: 15 lit/hr H: 5 m D: 0.1 m

- PM<150 mg/Nm3 SO2< 100 ppm NOx< 50 ppm

Proposed Additional

No additional Utilities are installed for proposed expansion.

2.7.2.3 Fugitive Emission




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In the existing plant, chances of fugitive emissions of wood husk/ dust arise during log

cutting and sanding/ finishing process.

From proposed resin plant, the fugitive losses of phenol & formaldehyde may occur during

the handling & transfer at their respective storage area, especially during the transfer of

phenol & formaldehyde solution.

Following measures are to be adopted for control of fugitive emissions:

Local Exhaust Ventilation System (LEV) provided to processes involving wood dust

generation.

Dust masks provided to working personnel.

Fly ash is stored near utility area and covered with tarpaulin. Regular water sprinkling

is also carried out to reduce fugitive dust emissions.

All production activities are to be carried out in closed conditions to minimize

possibility of fugitive emission.

Use of closed circuit system for all the process operations.

The plant set-up will be MS structure with shed, which can provide sufficient

ventilation to reduce work exposure.

The fugitive emissions in terms of formaldehyde & phenol will be controlled by proper

storage and handling method equipped with leak proof pipes.

Keen observations & supervision shall be done at time of transfer of phenol &

formaldehyde

Work place monitoring at storage area as well as production area shall be conducted

and necessary actions for keeping risk free workplace environment shall be taken by

the safety/ environment in-charge on regular basis.

Necessary PPEs like face mask with charcoal filter as well as emergency facility shall

be provided at storage area of Phenol & Formaldehyde.

2.7.3 HAZARDOUS/NON-HAZARDOUS WASTE MANAGEMENT

Table 2.9: Details of Hazardous Waste Generation & Disposal Type of waste & Category

Source Existing Proposed Additional

Total Disposal Method

Used Oil (Cat. 5.1)

Maintenance 0.24 Mt/Yr.

0.10 MT/Yr 0.34 MT/Yr. Collection, storage and disposal by re-use in plant machinery as a lubricant.




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Type of waste & Category

Source Existing Proposed Additional

Total Disposal Method

Discarded Bags (Cat. 33.3)

Raw material storage

3.84 MT/Yr

2500 Nos/Year

3.84 MT/Yr and 2500 Nos/Year

Collection, storage, Transportation & sold off to authorized re-conditioners.

Non Hazardous waste

Briquettes Ash Thermic fluid heater

18 MT/Yr NIL 18 MT/Yr It is given to farmers in neighbouring villages for use as manure.

2.7.4 NOISE AND ODOUR CONTROL

Noise is/will be generated from compressor, D.G. Set, plant machinery etc. However, Noise

level generation would be limited to 75 dB within plant premises. Diesel generator is

provided with acoustic enclosure. No offensive odor is/will be generated from the process.

The control measures to be taken for reduction in noise levels are as below:

D.G. Sets is provided with acoustic enclosure

Ear Plugs and Ear muffs are provided to the workers in Utility Section.

2.7.5 HEALTH AND SAFETY MEASURES

The following key safety measures shall be implemented in the proposed project:

The industry is responsible for health and safety of the workers.

The industry has provided first aid box containing cotton, bandage, soframycine tubes,

burnol, dettol, tincture iodine, eyes and eardrops. This is to cure the injuries from

chemical burns, eye injuries and electrical shocks.

Goggles, Gloves, Gum boots, Helmets, Earplugs, Face Masks, and clothing are provided to the workers.

The industry is taking all precautionary measures to control the hazardous associated with the industry.

The industry has provided good lighting and ventilation arrangements.

Fire buckets are provided and Foam ABC powder of various capacities is provided in all

the production units.

Emergency numbers are displayed at appropriate places for the communication at the

time of emergency condition.

Fire extinguishers will be installed wherever necessary.

Fire hydrant system will be installed. The pump will also attached to the DG Set.

Work place monitoring will be done on regular basis.

All storage tanks will be protected with Dyke wall.




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2.7.6 ENVIRONMENTAL HEALTH & SAFETY CELL

The company has an environment cell in order to keep a close watch on the performance of

the pollution control equipment, emissions from the sources and the quality of surrounding

environment in accordance with the monitoring program. The cell is also entrusted with the

responsibilities of regulating the safety measures inside the plant campus. The cell is also

responsible for maintaining the records of all data, documents and information in line within

the legislative requirement.

2.7.7 POST PROJECT MONITORING PLAN

Regular monitoring will be done by appointing external recognized/approved agencies. The

proposed post-project monitoring plan is given below:

Table 2.10: Post Project Monitoring Plan

Components Parameters Frequency of in house

monitoring Frequency of third party monitoring

Drinking water IS-10500:1991 -- Quarterly

Air-ambient PM10, PM2.5 SO2, NOx -- Quarterly

Stack monitoring SPM, SO2, NOx -- Quarterly

Noise monitoring dB(A) -- Quarterly




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CHAPTER – 3

SITE ANALYSIS

3.1 CONNECTIVITY

The site is well connected to other parts of the district through a well-developed road

network system. Gandhidham railway station is the nearest rail heads available on western

railway lines.

3.2 LAND FORM, LAND USE & LAND OWNERSHIP

3.2.1 LAND FORM

The proposed expansion is to be carried out in the existing industrial facility.

3.2.2 LAND USE PATTERN

The existing land is used for industrial purpose. No additional land will be required for

proposed plant.

3.2.3 LAND OWNERSHIP

Land is owned by the Company.

3.3 TOPOGRAPHY

The topography at site is relatively plain. The surrounding area is also flat with a gentle slope

towards the South towards the Gulf of Kutch.

3.4 SALIENT FEATURES

The salient features of the project site are given in Table no. 2.1 at chapter 2 of Pre-

feasibility report.

3.5 EXISTING INFRASTRUCTURE

Existing infrastructure includes provisions of appropriate water supply, power connection,

storage facilities for raw-material and products and production, utility sheds and

administrative office.

3.6 CLIMATE & METEROLOGY

The climate of Gujarat is varied, as it is moist in the southern districts and dry in the northern

region. The Arabian Sea and the Gulf of Cambay in the west and the forest-covered hills in

the east soften the region of climatic extremes, consequently reducing the temperature and

render the climate more pleasant and healthy.




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The climate is characterized by oppressive summer dryness in the atmosphere nearly

throughout the year, average south–west monsoon rainfall and a mild winter. The year can

be divided into four seasons. The cold season from December to February is followed by the

summer season from March to May. The south-west monsoon season is from June to

September. The post-monsoon season constitutes the months of October and November.

The Table 3.2 indicates the summary of meteorological pattern at the nearest observatory of IMD, Bhuj (Rudramata) published by IMD

Table 3.1: Summary Meteorological Data at nearest IMD Station –Bhuj

Location: Bhuj (Rudramata) ( Lat: N 23o 15’, Long: E69o 40’)

Aerial Dist. from Project Site: Approx.58.7 Km-NW

Height of installation: 80m above MSL

Month Temperature (oC) Relative Humidity

(%)

Cloud Cover (Oktas)

Mean Wind Speed

(km/h)

Pre-dominant Wind

Direction

Rainfall

(mm)

Max. Min. Mor. Eve. Mor. Eve.

January 26.7 9.0 66 28 1.4 1.4 7.7 NE 2.0

February 29.8 12.0 66 25 1.2 1.1 8.3 NE 1.1

March 34.9 17.6 64 23 1.6 1.6 9.9 W 2.9

April 38.7 22.1 64 25 1.6 1.8 12.1 W 0.7

May 39.5 25.2 70 37 1.3 0.8 18.4 W 1.7

June 37.1 27.0 76 54 4.1 3.4 20.9 SW 33.9

July 33.6 26.2 82 66 5.9 6.0 19.3 SW 136.3

August 32.5 25.2 85 69 6.1 6.2 17.1 SW 120.7

September 33.7 23.8 83 58 3.5 4.1 12.8 SW 54.2

October 35.9 20.6 71 34 1.3 1.9 7.9 W 15.4

November 32.4 15.5 65 31 1.4 1.5 6.9 NE 7.7

December 28.1 10.5 67 31 1.5 1.6 7.3 NE 1.6

Seasonal Average Values

Period Temperature (oC) Relative Humidity

(%)

Cloud Cover (Oktas)

Mean Wind Speed (km/h)

Avg. PDW Direction

Total Rainf

all (mm) Avg.

Max. Avg. Min.

Avg. Mor.

Avg. Eve.

Avg. Mor.

Avg. Eve.

Summer 37.7 21.6 66.0 28.3 1.5 1.4 13.5 W 5.3

Winter 28.2 10.5 66.3 28.0 1.4 1.4 7.8 NE 4.7

Monsoon 34.2 25.6 81.5 61.8 4.9 4.9 17.5 SW 345.1

Post monsoon 34.2 18.1 68.0 32.5 1.4 1.7 7.4 W/ NE 23.1

Annual Total or Mean

33.6 19.6 71.6 40.1 2.6 2.6 12.4 SW 378.2

Note: Winter: December, January & February, Summer: March, April & May, Monsoon: June, July, August & September, Post monsoon: October & November

(Source: Book “Climatological tables of Observatories in India (1951 - 1980)” published by IMD)

3.6.1 TEMPERATURE

Historical trend shows May as the hottest month and January as the coldest month in the

annual calendar. Maximum temperature is recorded to be 39.5°C in the month of May and

the minimum temperature is recorded to be 9°C in the month of January.




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3.6.2 HUMIDITY

Historical data shows the average relative humidity of 71.6% in mornings and 40.1% in

evenings. Daily relative humidity ranged from 23%-85%.

3.6.3 CLOUD COVER

During the South-west monsoon months, the skies are usually maximum clouded or

overcast. Cloud cover decreases during the post monsoon months. In the rest of the year

the skies are mostly clear.

3.6.4 RAINFALL

The annual rainfall in the district is received during the south-west monsoon season from

June to September. August is usually the month of highest rainfall. The average annual

rainfall of the region based on historical data of Bhuj, is noticed to be around 378 mm. The

recent years have however seen a better trend in the rainfall during monsoons.

3.6.5 WIND PATTERN

The historical data shows wind blowing pattern from North-East in the winter and from West

and South-West during summer and monsoon. Annual mean wind speed is 12.5 km/h.

3.7 SOCIAL INFRASTRUCTURE

The infrastructure available in the study area denotes the economic well-being of the region.

3.7.1 EDUCATIONAL FACILITIES

As per census 2001, Out of 67 villages, 61 villages have educational facilities, details of

which are given below.

Table 3.2: Details of Educational facilities

Sr. No.

Particulars Observed values in Anjar taluka

1 Primary Schools 78

2 Middle Schools 0

3 Secondary School 4

4 SeniorSecondary School 0

5 College 0 (Source: Primary Census Abstract – Census of India, 2001)

3.7.2 MEDICAL FACILITIES

As per census 2001, Details of medical facilities available in Anjar taluka are given below.




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Table 3.3: Details of Medical facilities

Sr. No.


1 Dispensaries 6

2 Primary Health Centers 3

3 Primary Health sub Centre 16

4 Allopathic Hospital 1

5 Allopathic dispensary 6

6 Maternity and Child welfare Centre 10

7 Community Health Workers 62 (Source: Primary Census Abstract – Census of India, 2001)




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CHAPTER – 4

PLANNING BRIEF

4.1 PLANNING CONCEPT


network system. Gandhidham railway station is the nearest station available on western

railway lines. Raw materials are/will be sourced locally and also imported from outside

country. The region is well planned with all the basic infrastructural facilities like internal

roads, water supply, arrangements for power, streetlights, etc.

4.2 POPULATION PROJECTION

As per census 2001, Out of 67 villages, 61 villages have educational facilities, details of

which are given below.

Table 4.1: Distribution of population

Sr. No. Particulars Observed values in Anjar taluka

1 Total Population 388927

2 No. of Households 83709

3 Avg. household size (person) 4.65%

4 Male population 200507

5 Male population (in %) 51.55%

6 Female population 188420

7 Female population (in %) 48.45%

8 Sex ratio 949.72 (Source: Primary Census Abstract – Census of India, 2001)

4.3 AREA STATEMENT

The details are elaborated in Table no. 2.2 at chapter no 2.

4.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

This is an expansion project which is to be developed in the existing premises. No additional

land or building is required for the proposed project except few installations and

modifications. So there will be no demand of major change in physical infrastructure and

social infrastructure.

4.5 AMENITIES/FACILITIES

4.5.1 DRINKING WATER FACILITIES

As per census 2001 following drinking facilities are available in study region.




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Table 4.2: Drinking Water Facilities

Sr.No. Particulars Observed values in Anjar taluka

1 Tap 63

2 Well water 18

3 Tank water 26

4 Tube well water 15

5 Hand pump 2

6 River 11

7 Canal 2

8 Lakes 0

9 Spring 1

10 Other drinking water sources 1 (Source: Primary Census Abstract – Census of India, 2001)

4.5.2 POWER SUPPLY FACILITIES

As per census 2001, Out of 68 villages, 64 villages have power supply facilities Anjar taluka.

4.5.3 COMMUNICATION& BANKING FACILITIES

As per census 2001, Distribution of facilities such as post office, post & telegraph office,

banks, telephone connections in Anjar taluka are illustrated in table below.

Table 4.3: Communication & Banking Facilities

Sr. No.


1 Post Office 42

2 Post and telegraph office 0

3 Telephone connection 1047

4 Commercial Bank 7 (Source: Primary Census Abstract – Census of India, 2001)

4.5.4 TRANSPORT FACILITIES

As per census 2001, Bus service is available in 64 villages of the Anjar taluka and most

preferable mode of transport in the region. Second option for transport is railway; railway line

is available in 2 villages. 57 Villages are connected with paved roads. 64 villages are

electrification in Anjar taluka

4.5.5 APPROACH TO VILLAGES

As per census 2001, there are 57 villages have paved road and 32 Villages have mud road

and 27 Villages have foot path.




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CHAPTER – 5

PROPOSED INFRASTRUCTURE

5.1 INDUSTRIAL AREA

The details are elaborated in Table no. 2.2 at chapter no 2.

5.2 RESIDENTIAL AREA

Provision is made for residence of workers within the site.

5.3 GREENBELT

Maximum possible open land is/will be allotted for green belt development. If required,

experts will also be consulted for selection of species for the development of the greenbelt.

5.4 SOCIAL INFRASTUCTURE

Existing infrastructure will be sufficient to accommodate the existing load from the proposed

project which is very low.

5.5 CONNECTIVITY


network system. Gandhidham railway station is the nearest rail heads available on western

railway lines.

5.6 DRINKING WATER MANAGEMENT

Drinking water is/will be sourced from Tanker Water Supplier for the project.

5.7 SEWERAGE SYSTEM

The details are elaborated in earlier chapter.

5.8 INDUSTRIAL WASTE MANAGEMENT


5.9 SOLID WASTE MANAGEMENT


5.10 POWER REQUIREMENT & SOURCE OF SUPPLY





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CHAPTER – 6

REHABILITATION &RESETTLEMENT (R &R) PLAN

6.1 POLICY TO BE ADOPTED

The proposed project is to be developed in the existing premises. Hence, no displacement of

any population is proposed for the project. Therefore, detailed Social Impact Assessment

studies or R&R action study has not been proposed.




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CHAPTER – 7

PROJECT SCHEDULE & COST ESTIMATES

7.1 TIME SCHEDULE OF THE PROJECT

The project is proposed to be implemented immediately after obtaining all the statutory

permissions from the respective authorities.

7.2 ESTIMATED PROJECT COST

The company has made budgetary provision for the recurring expenses for the

environmental issues while planning for the allocation of funds during the annual budgetary

planning. Environment Protection has also been considered in planning the cost projection.

Green belt development is also considered. The estimated project cost for proposed project

will be approximately Rs. 16 Lacs.




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CHAPTER – 8

ANALYSIS OF PROPOSAL

8.1 FINANCIAL & SOCIAL BENEFITS

Currently the company’s products are well accepted, by the local Indian Market. Today our

range of products and services has made rapid inroads in the processing world. We are

capable of not only understanding the customer’s needs, but also able to quickly tailor make

products suitable to their requirement at no extra cost.

For the proposed project, the company intends to spend 2% of the project cost in next 5

years for the social benefit as Corporate Social Responsibility.




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ANNEXURES




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Annexure-1 CC&A Copy




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Annexure-2 NA Document

PROJECT PRE-FEASIBILITY...

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