PRE FEASIBILITY REPORT

FOR OBTAINING ENVIRONMENTAL CLEARANCE

For the Proposed Synthetic Organic Resin

Manufacturing Unit of

M/s. HIGHBORNE LAMINATES PVT. LTD. Survey No. : 326p1, NH-27, Ravapar Nadi, Tal-Dist-Morbi 363 642

Mob No.: 9825211603 Email: highbornelaminates@gmail.com

.

Prepared By:

T. R. ASSOCIATES

C-605/A, Ganesh Meridian, Opp. Kargil Petrol Pump, S. G. Highway, Ahmedabad.

Mo. No.: 98253 71099 Email ID: trassociates@hotmail.com; trassociates@ymail.com

February 2016

1. Introduction M/s. HIGHBORNE Laminates Pvt. Ltd. is proposing to manufacture Phenol Formaldehyde Resin, Melamine Formaldehyde Resin & Urea Formaldehyde Resin as well as Laminated Sheets at Survey No. : 326p1, NH-27, Ravapar Nadi, Tal-Dist-Morbi 363 642, Gujarat. Proposed products will be used for captive consumption in manufacturing of Resins and Laminated Sheets as well as sell purpose. Proposed production details are given below:

Sr. No. Product

Capacity ( MT/Month)

1. Phenol Formaldehyde Resin 450

2. Melamine Formaldehyde Resin 225

3. Urea Formaldehyde Resin 225

4. Laminated Sheets 1,50,000 Nos./Month

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

The total land area of company is 13,962 Sq. Mt. out of which 4,610 Sq. Mt. (33% of total land) area will be used for greenbelt development. The estimated cost of the proposed project is 1 Crore. Total budget allocation towards Environmental Management Facilities will be Rs. 25 Lacs. Total 70 persons will be employed including skilled persons, unskilled persons and office staff.

2. Project Proponent and their back ground

Company is promoted by its directors namely Mr. Anilbhai Govindbhai Sitapara, Mr. Udaykumar Anilbhai Sitapara, Mr. Vishal Rameshbhai thoriya and Mr. Jigarkumar Ratanshibhai Sitapara having enough experience in field of manufacturing Resins as well laminated sheets.

3. Brief description of nature of the project: It is medium scale projects for productions of synthetic organic resins which will be used for captive consumption as well sell purposes.

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

Formaldehyde (37%) is used as raw material for resins, Resins are used predominantly in the wood products industry as adhesives. Growth of these resins is strongly correlated to construction/remodeling activity (which accounts for over 50% of consumption), and to a lesser degree, to the automotive industry.

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

Demand-Supply Gap:

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

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

Imports v/s Indigenous production:

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

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

Export Possibility:

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

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

This project will provide direct employment to 70 people whereas it will provide employment to many others indirectly. Plywood and Laminated sheet Industries provide employment to large number of people.

4. Project Description

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

(ii) Location Proposed project is to be located at Survey No. : 326p1, NH-27, Ravapar Nadi, Tal-Dist-Morbi, and Gujarat at

Latitude: 22° 56' 26.26" N and Longitude: 70° 48' 37.21" E Google image showing proposed project site is given below; Google Image of Proposed Location:

Proposed Project Site

Macchu River 2.95 km

National Highway 27 -1.36 Km

Nearest Village -0.60 KM

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

Sr. No.

Important Features Description

1 Location Survey No. : 326p1, NH-27, Ravapar Nadi, Tal-Dist-Morbi, and Gujarat- 363 642.

2 GPS Coordinates Latitude: 22° 56' 26.26" N Longitude: 70° 48' 37.21" E

3 Mean Sea Level 32 m

4 Nearest power station Uttar Gujarat Vij Company Ltd., Prantij

5 Proponent Name Mr. Anilbhai G Sitapara (Director)

Contact No. 9825211603

6 Corporate office address Bhabha Ceramic

8-A National highway, Lakhdhirpur Road,

Orson Ceramic zone, Morbi.

7 Temperature range 180Cto430C8 Annual Rain fall 500‐1000mm9 Nearest Road NH 27 @ 1.36 Km, E

10 Nearest Railway station Nazarbaug-Morbi @ 14.18 Km, NNW

11 Nearest city Nearest City: Morbi @ 11.35 km, SSE

12 Nearest village Shakatinagar @ 0.60 Km, SE

13 National Highway NH 27 @ 1.36 Km, E

14 State Highway There is State highway & NH 27 @ 1.36 Km, E

15 Nearest River/water body Machchhu River is about 2.95 Km

Godadhari river is about 4.30 Km E

16 Seismic Zone Zone-III (Less Active)

17 National Parks / Sanctuary None within 10 Km radius.

(iii)

List

Sr. No.1 2 3 4

Notewell

Project d

t of Propos

.

e: Formal as sell pu

A

C

description

sed Produc

Nam

Phenol FMelamine

Urea FoLam

aldehyde (urpose.

23° 56'

70° 48'

22° 56'

70° 48

n with proc

cts

me of Prod

FormaldehydFormaldehy

ormaldehydeminated She

(37%) and

' 30.69" N

' 34.94" E

' 22.08" N

8' 39.41" E

cess detai

duct

de Resin yde Resin e Resin

eets

d Resins w

B

D

ls

will be us

23° 5

70° 4

22° 5

70° 4

452222

1,50,0

sed for ca

56' 31.30" N

48' 36.48" E

56' 21.23" N

48' 37.90" E

Quantity

50 MT/Mont25 MT/Mont25 MT/Mont000 Nos./M

ptive cons

N

E

N

E

th th th onth

sumption as

List of raw materials  

Sr. No. Name of the product Name of Raw Materials

Quantity in MT/Month

1 Phenol Formaldehyde Resin Phenol 180

Formaldehyde (37%) 270

Methanol 75

Caustic 2.5

2 Melamine Formaldehyde Resin

Formaldehyde (37%) 135

Melamine 90

3 Urea Formaldehyde Resin Urea 135

Formaldehyde (37%) 90

Acetic Acid 1.5

Caustic 1.5

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

Latest Process technology will be adopted as available in market with optimum resources requirement with highest yield and less waste and pollution generation. Treated sewage from sewage treatment plant will be reused in greenbelt development which will ultimately reduce the fresh water requirement. Treated industrial effluent will be reused in cooling and washing activities. In addition to this, all the feasible cleaner production technologies will be adopted.

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

source should be given. Energy/power requirement will be 300 KVA which will be procured through Uttar Gujarat Vij Company Limited. The total water requirement will be 60 KL/day which will be fulfilled by own Borewell. Water balance diagram is given here under;

Water balance diagram

Source of Water Supply: Bore well Total: 60 KL/day 

Domestic  7 KL/day 

Gardening 8 KL/day 

Industrial 51 KL/day 

Sewage Treatment 

Plant 6 KL/day 

Boiler 9.6 KL/day 

Cooling 38.8 KL/day 

Effluent Treatment Plant followed by Evaporated condenser system 23.93 KL/day 

ZERO DESCHARGE 

RO Plant 60.5 KL/day 

Process Nil 

Floor Washing 1.3 KL/day 

Permeate 48.4 KL/day 

Reject 12.1 KL/day 

Sanitary 6 KL/day 

Recycled 20.8KL/day

5.67 KL/day

1.3 KL/day

3.9 KL/day 0.96 KL/day 

 

39.7 KL/day 

Scrubber 10 KL/D 

Scrubber water send to authorized 

recycler

7. Quantity of wastes to be generated (liquid and solid) and scheme

for their Management/disposal.

HAZARDOUS WASTE GENERATION AND DISPOSAL

Sr. No.

Description Category Quantity Mode of Disposal

1 ETP Sludge + Evaporation residue

34.3 11.56 MT/M Collection, storage and Disposal at Approved TSDF Site

2 Used Oil 5.1 0.004 MT/M Collection, storage and used within premises as a lubricant / sold to registered recycler.

3 Discarded Plastic bags / barrels

33.3 2.57 MT/M Collection, storage & sell to authorized vendor

4 Edge Cutting Waste

23.1 0.6 MT/M Collection, storage & disposal at common Incineration facility

WASTEWATER GENERATION AND DISPOSAL FACILITY

Effluent Treatment Plant: Wastewater will be generated from process, Boiler & cooling tower blow-down, Washing &

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

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

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

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

EFFLUENT TREATMENT PLANT DETAILS

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

Collection cum Neutralization Tank 10.0 1

Photo Fenton Treatment Tank 10.0 1

Nutch Filter / Filter press 7.0 1

Treated Water Collection Tank 25.0 1

Steam based Evaporator followed by Condenser

1.4 m3/hr 1

ETP Flow Diagram:

Stream-wise Quality of Effluent:

Particular Unit Process WashingComposite

Effluent (Before Treatment)

After Chemical Treatment &

Sludge RemovalQuantity KL/day 5.67 1.3 6.97 6.97

pH -- 3.0-5.0 6.0-7.0 3.0-6.0 6.5-8.0

Total Suspended Solids mg/l 100-200 200-300 120-220 40-50

Total Dissolved Solids mg/l 6000-8000 400-500 5500-7500 6000-8000

Chemical Oxygen Demand mg/l 15000-20000 100-150 14000-19000 400-500

Particular Unit

Process & washing effluent

after chemical treatment

Cooling & Boiler blow

down

RO Reject

Composite Effluent

Quantity KL/day 6.97 4.86 12.1 23.9

pH -- 6.5-8.0 6.5-7.5 6.5-7.5 6.5-7.5

TSS mg/l 40-50 70-80 20-30 30-40

TDS mg/l 6000-8000 2000-2500 6000-8000 6000-8000

COD mg/l 400-500 40-50 10-20 200-300

CondensatetobeusedforCoolingActivitiesZERO

DISCHARGE

CollectionTank

PhotoFentonTreatmentTank

MOC:RCC

NutchFilter/FilterPress HoldingTank

SteamBased

EvaporationSystemwithCondenser

ETPSludgetobesenttoTSDFsite

Effluentfromwashingandprocess

Effluent from R O rejected, Boiler blow down and cooling tower blow down

Domestic Wastewater: Total 6 KL/day sewage will be generated which will be treated in Sewage Treatment Plant designed based on the electro coagulation system. Treated sewage will be reused for greenbelt development. Quality of sewage and flow diagram of STP is given below;

Quality of Sewage:

Sr. No.

Parameter Unit Untreated Sewage

Treated Sewage

GPCB Norms

1 pH ---- 6.5 – 8 6.5 – 7.5 6.5 – 8.5 2 Biochemical Oxygen Demand mg/l 300 – 350 < 20 < 20 3 Total Suspended Solids mg/l 200 – 300 < 10 < 30 4 Total Dissolved Solids mg/l 1200 – 1400 1200 – 1400 -- 5 Residual Chlorine mg/l -- 0.8 – 1.0 Min 0.5

STP Flow Diagram:

Collection cum

Equalization Tank with

Screen Chamber

Electro Coagulation

Tank

Tube Deck

Settling Tank

Chlorine Dosing Tank

Multi Media Filter

followed by Activated

Carbon Filter

Treated Sewage

Tank

Sludge Drying Beds

Sludge to be used as manure

Treated sewage to be

reused for greenbelt

development

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

9. Site Analysis  (i) Connectivity

Nearest Railway station Nazarbaug-Morbi 14.18 Km Nearest National highway NH 27 1.36 Km Nearest Airport Rajkot 69.75 Km

(ii) Existing Infrastructure

(1) Power: 300 KVA from PGVCL. (2) Water: Source of the water will be own borewell. (3) Basic amenities; Good Road connectivity with state and National highway.

(iii) Land Form, Land use and Land ownership. Proposed project site has already been procured by proponent and it is an open area which is presently not being used for any purposes. (iv) Soil classification of Taluka Prantij The sub soil condition below the existing ground level are almost uniform in nature. Sub soil is composed of Clay mixed with little fine grained silty sand, moram and Kankar with low resistivity due to clay and soil moisture. The area is covered with recent to sub recent alluvial deposits comprising of brownish clay mixed with little fine grained sand, silty sand. The Soil below ground level consist of top silty low plastic soil layer having no swelling nature. Blockish brown to yellowish brown clayey silt or sand silt layer extends to the depth of 2 to 3 mts.

(v) Social Infrastructure available. Lukhdhirji Engineering College is about 14.06 km away from the project site. Post Office: at Kerala which is 3.68 km away from project site. Hospital: Dalwadi Hospital which is 14.65 km away from project site.

(vi) Climate data from Indian Meteorological Department

Month

Air Temperature oC Humidity % Monthly Rainfall

Total, mm

Mean Wind Speed kmphDaily Max. Daily Min. Max. Min.

March 42.9 12.2 100 11.0 0.5 10 April 44.3 22.0 92.0 06.0 0.0 14 May 44.4 24.7 93.0 07.0 0.0 18 Annual 43.9 19.6 95.0 8.0 0.16 14 Source: IMD, Rajkot

10. Planning Brief

(i) Planning Concept (type of industries, facilities transportation etc) Town and

Country Planning/Development authority Classification.

Proposed Project site is located on edge of State highway and closely connected to the NH 8 which is well connected to the Himatnagar as well Gandhinagar & Ahmedabad having all the infrastructural and transportation facilities. There are some large industries located in nearby area.

There will be provision of labor rooms in premises for some labors and other labors will be come from nearby areas.

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

Sr. No.

Particular Area (Sq. Mt.)

1 Built Up Area 5218.0 2 Green belt area 4610.0 3 Open/ Road area 4134.0

Total 13962.0

Plant Lay-out is given hereunder;

Plant Lay-out

(iii) Assessment of Infrastructure Demand (Physical & Social). Surrounded villages in 10 km area from the project site are having all the necessary physical and social infrastructure facilities due to agricultural activities, animal husbandry and industrial development within the area as well nearby Prantij and Himatnagar City.

(iv) Amenities/Facilities. Surrounded villages in 10 km area from the project site are having all the necessary physical and social infrastructure facilities due to agricultural activities, animal husbandry and industrial development within the area as well nearby Prantij and Himatnagar City.

(v) Proposed Infrastructure a. Industrial Area

Industry will provide 5218 Sq mt. built up area for industrial process activity. Which provide all needed facility including proper ventilation, safe handling system, etc.

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

c. Green Belt. 4610 Sqmt. area will be proposed for greenbelt development. In addition to this, project proponent will participate in greenbelt development programs in nearby areas under their CSR.

d. Social Infrastructure The Project proponent Industry will contribute annually 2% of total profit towards CSR (Corporate Social Responsibility) activity like following in nearby villages;

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

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

11. Project Schedule & Cost Estimates

(i) Likely date of start of construction and likely date of completion Start construction work: 1st August, 2016 Completion of construction work: 31st August, 2016

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

Total project cost is around 1 Crores