PRE-FEASIBILITY REPORT

FOR

100 MT/day Formaldehyde Plant

By M/s Bansal Chemicals industries

At

Plot no. B-12, Focal Point,

MandiGobindgarh,Dist: Fatehgarh Sahib

Punjab. Pin:147301

APPLICANT

M/s Bansal Chemicals industries

Kothi No. 15,22 Acers scheme,

Barnala, Punjab

Pin :148101

ENVIRONMENT CONSULTANT VARDAN ENVIRONET

(QCI/NABET ACCREDITED NO. NABET/EIA/1619/RA0037) D-142, SEC. 57 GURGAON (HARYANA)

E-MAIL: vardanenviro165@gmail.com CONTACT: 0124-4291036, 09899651342

PRE-FEASIBILITY REPORT CHAPTER-1: INTRODUCTION

M/s Bansal Chemicals industries is proposing to develop a Formaldehyde Manufacturing Plant

of capacity 100 MTD Formaldehyde at Plot no. B-12, Focal Point, MandiGobindgarh, Dist:

Fatehgarh Sahib, Punjab.

Formaldehyde is an organic chemical having basic uses in core industries like

a) Plastic Industry in the manufacture of thermo set compounds like U.F;P.F. & M.F. Moulding

Powders

b) Plywood Industry where it is used as the bonding compound.

c) Pharmaceutical Industry where it is used for fumigation.

d) Explosive Industry also uses Formaldehyde in bulk.

e) Hexamine a blowing compound used in the Rubber Industry is produced by using

Formaldehyde as its main raw material.

The basic raw material used in the production of formaldehyde is Methanol. The basic process

used for the manufacture of formaldehyde involves oxidation of methanol in the presence of

Silver which works as catalyst. The chemical reaction involve is as follows:

CH3OH = H CHO + H2 (Endothermic Reaction)

H2 + 1/2 O2 = H2O (Exothermic Reaction)

CH3OH + 1/2 O2 = HCHO + H2O (Net Exothermic Reaction)

1.1 Profile of Bansal Chemicals Industries

Bansal Chemicals industries is a partnership firm with duly executed partnership deed dated

10.05.2017.The partners of the unit have proposed to set up a Formaldehyde continuous

Process Plant with a installed capacity of 100 MT per day at Focal Point,MandiGobindgarh.

The partners areengaged in plywood business since last 35 years. Satpal Bansal and his son

Bhupinder Bansal are running two industries by name Durga plywood industries situated in

Barnala city and other one is Shiv Shakti Plywood industries situated in Balachaur in Punjab

Indian manufacturing company is a leading Manufacturer & Supplier of Plywood board .

1.2 Need of the Project

Bansal Chemicals Industries have planned to set up an agro wood based project for manufacturing Particle Board and MDF boards with value added products Management shall take all necessary clearances related to environment & pollution control including Environmental Clearance. The manufacturing of Particle board and MDF board requires glue/adhesive /binder for binding the particles / fibres of wood. The major raw material for manufacturing glue /binder/adhesive for particle board requires major quantity of formaldehyde. Further for the quality production of final product particle board and MDF board the quality of the formaldehyde used for glue/adhesive/binder should be as per the standards. To achieve the quality production and the uninterrupted supply of the formaldehyde, the company has proposed to develop their own formaldehyde unit all utilities and storage within the main unit. Details of Project Proponent M/s Bansal Chemicals industries

Name :Satpal Bansal

Address :Plot no. B-12, Focal Point,

Mandi Gobindgarh,Dist: Fatehgarh Sahib

Punjab. Pin:147301

Mail Id: plywooddurga@gmail.com

Mob: 9872893429

CHAPTER 2: PROJECT DESCRIPTION

Site Location

The proposed plant is to be installed at at Plot no. B-12, Focal Point, MandiGobindgarh, Dist:

Fatehgarh Sahib, Punjab on a land measuring 0.418 Ha.

The area details of this unit are given below:

S.No Plant area Area(Ha.)

1 Built up Area/Covered Area .150

2 Green Area .150

3 Open & Road area .118

Total area 0.418

SATELLITE IMAGERY OF THE PROJECT SITE

Fig1: Google Image of Project Site

Fig 2: Key Plan

Fig 3: Layout plan

CHAPTER 3: PROJECT DESCRIPTION WITH PROCESS DETAILS

3.1 MANUFACTURING PROCESS

Formaldehyde is the oxidation/dehydrogenation product of methanol with oxygen in the

presence of Silver catalyst.

A fixed quantity of methanol and water is introduced in to a mixing vessel from where this

mixture is taken into an evaporator. Air is also introduced into the evaporator. A temperature

of 70o C is maintained which facilitates the evaporation of methanol. The air and methanol

vapour mixture is then further heated to 100 deg in the superheater and then introduced into

the reactor where in presence of silver catalyst maintained at temperature of 650o C .The

oxidation/Dehydrogenation reaction takes place as per the following chemistry:

CH3OH = HCHO + H2 (Endothermic Reaction)

H2 + 1/2 O2 = H2O (Exothermic Reaction)

CH3OH + 1/2 O2 = HCHO + H2O (Net Exothermic Reaction)

3.1.1 ABSORPTION

The Reaction is net Exothermic. In the Reaction 3 itself which is also a waste heat boiler the

temperature of the product gasses is brought down to 180 oCand then further to cooled to

about 95oCin the Reboiler. This is achieved by circulating the Solution in the Evaporator in the

Reboiler which cools down the Product gasses to about 95 oCand itself is heated up to 70 o

Cthus saving on energy.. The product gasses are further cooled to about 75 oCin the condenser

by circulation of cooling water from the cooling tower. Pre-Feasibility Report for Proposed

Formaldehyde Manufacturing Unit at Plot no. B-12, Focal Point, MandiGobindgarh, Dist:

Fatehgarh Sahib, Punjab by M/s Bansal Chemicals Limited .The reaction gas containing

Formaldehyde, unreacted Methanol and water vapour is then directed to Absorption column I

and escaping Formaldehyde gases are absorbed by circulating and cooling the Formaldehyde

solution in Plate Heat Exchanger from the absorber sump. The part of the circulation is taken

out as product.

Mostly the absorber is packed with pall rings. If proper packing size and cooling is maintained

more than 95% absorption is completed in the absorption column - I.

The unabsorbed gas from the absorption column - 1 is absorbed in the absorption column - II

and subsequently in Column III by circulating and cooling absorber sump dilute Formaldehyde

solution in Plate Heat Exchanger. Finally, the gas is washed with pure Chilled DM water at the

upper part of the column - III, provided with bubble cap trays, and then exhausted as tail gas to

the atmosphere.

The Exhaust gasses contain only Nitrogen, Hydrogen, Carbon dioxide, Carbon Monoxide and

traces of Formaldehyde and Methanol.

Table1: The plant and machinery being proposed to be used in the complex is given below:

ITEM NO MATERIAL OF CONSTRUCTION/SPECIFICATION

Quantity

Heat Exchanger Plate Type 5

Root Blower Alloy Steel Cast 1

Pumps Of various sizes for process 6

Pipelines SS304 and MS Of Different Sizes As per requirement

Valves SS/MS Of Different Sizes As per requirement

Rotameter Metallic/Glass Tube Type As per requirement

Filters For Methanol,Methanol/water Mix 4

Gaugaes SS/MS temperature gauges As per requirement

Structured packing+ packing rings Air

Str.Pkg+ PP rings for Absorption column & washer

As per requirement

Electricals Electrical cables ,Motors etc As per requirement

Hardware Items Steam Traps,Copper wire Netting,packingGaskets,nuts,Bolts,washers etc

As per requirement

Baby Boiler 600 Kg capacity on and at 100 o C( vertical) 1

Cooling tower FRP/wooden forced draft 1

Laboratory Suitable for testing of Formaldehyde Methanol as per standard

As per requirement

Water treatment Plant For softener and RO water

1

Fig 4: Process Flow Diagram

3.2 Finished products specification (Per Tonne of Formaldehyde)

Finished product specification

Formeldehyde: 37%-45%± 0.25%

Methanol content :1.0 %-3.0 %

Acidity: 0.01% Max (normally below 0.005%)

pH : 3.5-4.0

Iron : 2.0 PPM Max

Ash : 0.01 % max

3.3 Plant Automation summary To establish efficient production & set concentration of Formaldehyde maintaining optimum mix ratio of Methanol, Air, Steam/Water & tail gas at set catalyst temperature is critical to the process. The objective of the proposed plant automation is to maintain the process parameters under tight closed loop controls so as to allow plant operations with least intervention/control from the operator side. Apart from the above critical plant operations many equally important process control functions have to be maintained by the system to ensure consistent product quality, long plant running and catalyst life which in turn would increase the profitability of the plant operations. To name some of these important functions:

Catalyst bed temperature stability

Constant steam pressure

Level control in various process vessels to ensure stable process reaction

Pressure and temperature monitoring

For monitoring the plant efficiency in real time & on every day basis Methanol consumption ,formaldehyde production & steam consumption in the process is taken from the flow.

transmitters & the same is recorded

Ignition system for plant startup along with local control operation.

Variable frequency drives for process control and energy saving.

3.4 Plant Capacity

The Formaldehyde Plant Unit is designed for a capacity of 100 TPD

3.5 Raw Materials Required

S.No Raw Material Quantity used Kg/ Tonne HCHO

1. Methanol 460

2. Water(D.M water) 500

3. Air 900

Specification of Raw Material

Methanol :Clear ,free from suspended matters

Odour : Free of foreign odour

Sp. Gravity : 0.792-0.793 at 20 o C

Purity : 99.98 % Min weight by

Distillation loss : 95 % Vol. Min. Between 64.5-65.5 o C

Free acid : 0.35 MI Max

Non Volatiles : 0.005 % Max Wt

Acetone : 0.014 % max. Wt.

Per Magnate time : 30 Minutes min.

DM water

pH : 7.5 -8.0

TDS : less than 1.00 PPM

Chlorine ION : Less than 1.00 PPM

Silica : less than 1.00 PPm

Pressure : 2.5 Kg per Sq. Cm

Conductivity : Less than 1

Air

Pressure : 0.2 Kg per Sq CM

Temperature :40-45 o C

Source of raw material:

The main raw material methanol will be sourced from near by market

Mode of Transport: All the raw materials and products will be transported via road transport.

3.6 Water Management

Source of water supply

Approx 75 KLD of Ground Water by tubewell and the rest will be sourced from PSIEC. Process

water is 100 % reused within the process. The complex is zero discharge complex from process.

Consumption & discharge is given below:

Fig 5: Water Flow Diagram

Total Water

Requirement

(75 KLD) Horticulture/Green

Belt

1.2 KLD

DM Water

55 KLD

Proccess

50 KLD

Wastewater

generated

2 KLD

@90%

Hence Zero Liquid discharge is Achieved

Recycled/Treated water

(16.2 KLD

Boiler

5 KLD

Wastewater

generated

10 KLD

Total Wastewater

generated

18 KLD

15 KLD

Wastewater

generated

5 KLD

Cooling

15 KLD

Wastewater

generated

1 KLD

Table 2 : Water Balance of the Process

Use Water Consumption per dayKLD

Loss/waste - water generation KLD

D.M. Water Production 55 5

Formaldehyde Process 50 10

Cooling Water (Make Up Water)

15 2

Boiler 5 1

Domestic Water requirement 1 .80

Flushing Water Requirement 1 1

Water requirement in Green Area

1.2 NIL

LIQUID WASTE Proposed unit shall be a zero discharge unit 3.7 SOLID WASTE Municipal Solid waste:-

It is estimated that from 10 persons around 12 Kg/day of MSW (garbage) shall be generated. The closed color coded bins for biodegradable & non-biodegradable waste shall be placed in each section. The waste from these bins will be collect in main bin at the complex. The biodegradable waste bin shall be sent to approved solid waste management site. The waste from non-biodegradable waste bin shall be given to recycler for recycling.

Table 3: The solid waste categories and disposal method is given below:

Category Type of Waste Color of Bins Disposal Method Total Waste (Kg/day)

Bio Degradable Organic Waste Green Recycler 7.2

Non- Biodegradable

Recyclable Waste

Blue Recycler 4.8

Total 12

3.8 Process waste: - As per present scheme, no process waste will be generated, if in case generated shall be stored and disposed off at Treatment Storage and Disposal Facility (TSDF) approved by Pollution Control Board at Nimbuan, DeraBassi, Distt Mohali 3.9 Hazardous Waste Used oil from machineries/D.G. Set will be carefully stored in HDPE drums in isolated covered facility. The used oil will be sold to vendors authorized by Central Pollution Control Board for

the treatment of the same. Suitable care will be taken so that spills / leaks of used oil from storage could be avoided. 3.10 Air Emissions and Control All the exhaust gas emissions will be channelized all through the process and will be reused for various purposes like heating & remained chemical utilization. At the end the remaining gas will be exhausted through a chimney. Emissions from production processes will contain exhaust gasses which shall contain only Nitrogen, Hydrogen, Carbon dioxide, Carbon Monoxide ,VOC and traces of Formaldehyde and Methanol. To control the air emissions from D.G. Set, stack height of 4.0 m shall be provided above the roof level of D.G. Set. Multi fuel boiler shall be installed for heating load of the plant, this shall be based on biomass combustion from local areas and waste wood chips of the plant.

3.11 Power Requirement and Source

Total Power Requirement of the plant is 160 KWA which will be sourced from Punjab state

power corporation limited.

DG Set Proposed: 152 KWA of DG is proposed

Details of Electricity and fuel charges

Particulars

Total power load:160 KW

No. of working days: 300 days

No. of hours per day:16 hours

Load factor: 160 x 300x 16x 0.80=614400

Rate per unit:7.00

Total power cost at different capacity utilization leve

At 70 % capacity utilization :30.11

At 75 % Capacity Utilisation: 32.26

At 80 % capacity utilization :34.41

At 85 % capacity utilization:36.56

At 90 % Capacity Utilization :38.71

3.13 Employment Generation

The plant installed is a continuous, automatic plant so labour requirement will be very less.

Overall there will be an employment of 10 manpower which will include the following:

Table 4: Manpower details

S.No Manpower No

1 Plant Manager 1

2 Purchase office 1

3 Formaldehyde plant operator 2

4 Store keeper 1

5 Labour 2

6 Water treatment plant operator(Equalization tank ,MBBR, Extended Aeration and settling tank units)

2

Total manpower

9

Chapter 4

SITE ANALYSIS

S. No. Particulars Details

1 Location MandiGobindgarh

a) Village/ Town/Plot No. F-12

b) District Fatehgarh Sahib

c) State Punjab

d) Latitude 30°39'3.35"N

e) Longitude 76°17'59.78" E

f) Toposheet No. 53B/6, 53B/2, 53B/5, 53B/1

2 Land use at the project site Industrial Land

3 Nearest highway Srinagar Kanyakumari Highway NH-44, 0.75 Km E

4 Nearest Railway Station MandiGobindgarh Railway station ,2.15 Km N

5 Nearest airport Sahnewal Airport ,40 Km NW

6 Nearest city/settlement MandiGobindgarh,1.30 Km, N

7 Features with 10 km :

I. Archaeological important places Nil

II. Wild life sanctuaries Nil

III. Reserved/Protected forest Nil

IV. Rivers Nil

V. Hill ranges Nil

VI. State Boundary Nil

4.1 Land Use:

The new project is proposed in industrial area and the land is under agreement.

4.2 Soil Classification

sandy loam to clayey with pH value from 7.8 to 8.5

4.3 Existing Infrastructure

Infrastrure is available for water supply, backup power supply, lab, drinking water ,rest room,

toilets, medial units No additional facilities required.

4.4 Topography

The topography of the district is even. It is mostly a plain of alluvial type. It also has loam to

heavy loam and sand to sandy loam soils in certain parts of the district. Soil is rich in nutrients

and suitable for crops like wheat, Paddy, Oil seeds, Sugar Cane, Potato and vegetables etc.

4.5 Availability of Minerals

The district is poor as regards mineral wealth. A few minor minerals are, however, found in the

district like Ordinary Earth and Brick Earth . There is no sand , gravels and other minor minerals

found in this district. Sand and gravel

4.6 Groundwater.

Water bearing formations in the area mainly include fine to medium grained sand or sand with

little admixture of clay. At shallow depth the ground water occurs under unconfined water

table conditions and in deeper aquifers occurs under confined conditions. The depth to ground

water table in the area ranges from 4.05 m below ground level (mbgl) in the central to 18.10

mbgl in the north eastern parts. The quality of ground water in shallow aquifers confirm to

maximum permissible limits for drinking water standards except along western part where high

values of fluoride (1.5 to 2.10 ppm) have been noticed and in central Fatehgarh Sahib showing

high values of sodium, zinc, iron, sulphate, nitrate and chloride. The deeper waters in general

are found to be suitable for irrigation and domestic purposes.

4.7 CLIMATE AND RAINFALL

In Distt.Fatehgarh Sahib, the climate is warm and temperate. The summers are much rainier

than the winters. The average annual temperature in Fatehgarh Sahib is 24.03°C. Precipitation

here averages 770 mm. With an average temperature of 33.6°C, June is the warmest month.

The lowest average temperature in the year occur in January, when it is around 13.3°C. The

precipitation varies 252 mm between the driest month and the wettest month. The variation in

temperatures throughout the year is 20.3°C.

Chapter 5 : PLANNING BRIEF

Planning concept (type of Industries, facilities, transportation etc) Town and country

planning/Development authority classification Specification of Utilities

Type of Industry As per EIA Notification dated 14.09.2006 and as amended from time to time, the project falls in Cat. ‘B’,S.No.5(f) Synthetic organic chemicals industry (dyes & dye intermediates) as the project site is located in notified industrial area. PROPOSED INFRASTRUCTURE

List of Plant & Machinery

S.No MATERIAL OF CONSTRUCTION/SPECIFICATION

1. Air washer

2. Mixed Vessel and Mixer

3. Evaporatio Vessel(With perforated air and Methanol feed pipeline)

4. Steam coil (Seamless pipes)

5. Super heater (Seamless Pipes with MS jacket)

6. Vapour Filter

7. Seperator-I Seperator-II Seperator-III

8. Reactor-1( seamless tubes with MS Jackets) Reactor-2 Reactor-3

9. Reboiler (seamless Pipes)

10. Absorption column-I Absorption column-II Absorption column-III

11. Process vessel

12. Feed Vessel

13. Water Filter

14. Methanol filter

6 PROJECT BENEFITS

The formaldehyde produced will be used as a binder/glue in agro wood based project set up Bansal chemical Industries for manufacturing Particle Board and MDF boards at Punjab.

Formaldehyde also finds its uses in other industries like plastic industry, Pharmaceutical Industry, explosive industry, rubber industry etc.

The plant as designed by us is pollution free since there is no water discharge. So it’s an eco friendly project

The formaldehyde plant as designed is an Automatic Plant; therefore, labour requirement is very small.

The Formaldehyde market has been growing steadily and an efficient plant is bound to be a success.

7.0 REHABILITATION & RESETTLEMENT PLAN

No rehabilitation or resettlement plan is proposed as there are no habitations in the in the Plant site.

8.0 PROJECT SCHEDULE & COST ESTIMATES

The project will start only after obtaining Environmental Clearance and all other required

clearance and will complete after 9 months of commencement if finance is no bar. The Capital

Cost of the project will be Rs.432.74 Lakhs.

9.0 ANALYSIS OF PROPOSAL (Final Recommendations)

With the implementation of proposed project, the socio-economic status of the local people will

improve substantially. This will help in upliftment of social status of the people in the area.

Educational institutes will also come up and will lead to improvement of educational status of the

people in the area. Primary health centers will also come up and medical facilities will certainly

improve due to the proposed project.