Pre-Feasibility Report for Existing Project for Capacity Expansion Of

PRE FEASIBILITY REPORT

Pre-Feasibility Report

For

Existing Project for Capacity Expansion of Manufacturing of Formaldehyde from 1000 M.T per month to 2500 M.T per month

M/s Suchem Organics Pvt. Ltd.

Plot No. G1-787-788, RIICO Industrial Area, Tehsil Tijara, District Alwar, Rajasthan

Environment Consultant

Vardan Environet

(QCI and NABET/EIA/1619/RA 0037) Plot No. - 82 A,

Sector- 5, IMT Manesar, Gurugram (Haryana)

Contact no.-9810355569

Mail ID: [email protected]

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PRE FEASIBILITY REPORT Table of Contents

S.no. Chapters Page no

1 Executive Summary 2-4 2 Introduction of the Project / Background Information 5-7 3 Project Description 8-17 4 Site Analysis 18-21 5 Planning Brief 22-23 6 Proposed Infrastructure 24-25 7 Rehabilitation & Resettlement Plan 26 8 Project Schedule & Cost Estimates 27 9 Analysis of Proposal (Final Recommendation) 28

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PRE FEASIBILITY REPORT

1. EXECUTIVE SUMMARY

Project

M/s Suchem Organics Pvt. Ltd. is a partnership firm started with the objective to get involved in the business of manufacturing & trading in organic chemicals viz. Formaldehyde.

M/s Suchem Organics Pvt. Ltd. is an existing unit of Formaldehyde manufacturing with the production capacity of 1000 M.T per month since 1994 based on NOC/CTE. Now, industry comes under Capacity Expansion with the production from 1000 M.T per month to 2500 M.T per month. So, the proposal is for the existing project for Capacity Expansion of manufacturing of Formaldehyde from 1000 M.T per month to 2500 M.T per month at Plot No.- G1- 787-788, RIICO Industrial Area, Tehsil Tijara, District Alwar, Rajasthan. The Company has been registered by Directorate of Industries, Govt. of Rajasthan on 10/02/1994 (attached as Annexure-I). The existing plant was established based on CTE/NOC (attached as Annexure- II). The latest CTO was applied for renewal vide Application No.-185481, Dated- 03/06/2017 (attached as Annexure- III). The Rajasthan State Pollution Control Board has issued an Order No.-RPCB/RO/BWD/175/1488, Dated -19/08/2019 (attached as Annexure- IV) to apply for EC within 60 days from the date of issue of letter.

Location

The Existing project is located in a 1000 sq.m and is situated at Plot No.- G1- 787-788, RIICO, Industrial Area, Tehsil Tijara, District Alwar, Rajasthan. This is existing Project for Capacity expansion of manufacturing of Formaldehyde from 1000 M.T per month to 2500 M.T per month. As the land itself in industrial area of RIICO Industrial area, hence land use already been changed to industrial unit. There is no forest land involved in this 1000 sq.m of land. The geographical location of the Existing plant lies from Latitude- 28°12'22.82" N to Longitude- 76°51'25.99"E.

The Existing plant site is well connected with the rail and road connectivity. The project site is about 4.4 kms from SH-25 (Tijara-Delhi Highway) in West direction, 8.4 kms from MDR132 in ENE direction , is about 5.8 kms from NH-8 in NNW Direction (Delhi- Jaipur Expressway) and is 0.6 kms from NH71B in North Direction.

It is connected with the adjacent states and other parts of India as well, which facilitates transportation of goods, both inwards and outwards. This further facilitates the marketing of Formaldehyde all over India including Haryana, Punjab & Rajasthan & are nearby industrial areas having plywood and Sunmica/decorative laminate industry.

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PRE FEASIBILITY REPORT

Need for the project

The Formaldehyde is used by plywood and sunmica laminated sheets manufacturers,who make adhesives like Urea Formaldehyde, Phenol Formaldehyde, Malamine, Formaldehyde.

Plywood Boards and sun mica sheets market is growing very fast in India. The market is expected to continue to grow at the minimum rate of 10 to 15% per year. During the last decade, India has built a very strong position as sun mica sheets and ply wood boards for domestic consumption and for Exports to South Asian countries & Middle East.

Formaldehyde is used by ply wood and sun mica laminated sheets manufacturers, who make adhesives like Urea Formaldehyde and Phenol Formaldehyde products. So considering the above, the M/s Suchem Organics Pvt. Ltd. has setup an existing manufacturing unit of Formaldehyde with the capacity of production of 1000 M.T per month and now comes under Capacity Expansion from 1000 M.T per month to 2500 M.T per month.

Project Proponent

The present proposal is for the Capacity Expansion of Existing unit of Manufacturing of Formaldehyde from 1000 M.T per month to 2500 M.T per month which is being promoted by Mr. Sugam Gupta and Mrs. Khushbu Gupta, who are very experienced persons.

Process / Technology

The commercial production of Formaldehyde is manufactured from oxidation- dehydrogenation using a silver catalyst involving either the complete or incomplete conversion of methanol.

Methanol is vaporized and mixed with air and steam and it is then passed over a thin bed of silver catalyst at 650°C. Formaldehyde is formed by the dehydrogenation of methanol.

The heat required for the endothermic reaction is obtained by burning hydrogen content in the off gasses, produced from the dehydrogenation reaction.

Manpower Requirement

About 10-12 persons have been employed to the industry.

Water requirement (I) Existing Requirement:

Total water requirement is 25 KLD. For industrial purpose 16.7 KLD, for domestic purpose is 2 KLD, for Cooling Tower is 0.1 KLD, for Green Belt is 1 KLD & for other purpose is 5.2 KLD.

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PRE FEASIBILITY REPORT (II) Expansion Requirement:

Total water requirement will be 50 KLD. For industrial purpose 38 KLD, for domestic purpose will be 5 KLD, for Cooling Tower will be 1.5 KLD, for Green Belt will be 3 KLD & for other purpose is 2.5 KLD. Application for Groundwater Abstraction has been filed to CGWA.

Power Requirement

Maximum power requirement for the plant is 130 KVA (Total connected load). Average running load power requirement for the project is 80 KVA. The power is supplied from JVVNL (Jaipur Vidyut Vitran Nigam Limited). 1 DG set of capacity 125 KVA also exists as the backup power supply.

Raw Material Requirement

The only raw material is Methanol (99.9%) which comes in road tankers & stored in 60 KL underground 4 M.S tanks.

Capital Cost of the project

The fixed cost for the Existing project is 139.93 lacs and it will expands to 239.93 lacs including 100 lacs of Expansion which include land, building, plant & machinery and Capacity Expansion.

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PRE FEASIBILITY REPORT

2. INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION

(i) Identification of Project & Project Proponent

Project

M/s Suchem Organics Pvt. Ltd. is a partnership firm started with the objective to get involved in the business of manufacturing & trading in organic chemicals viz. Formaldehyde.

M/s Suchem Organics Pvt. Ltd. is an existing unit of Formaldehyde manufacturing with the production capacity of 1000 M.T per month since 1994 based on NOC/CTE. Now, industry comes under Capacity expansion from 1000 M.T per month to 2500 M.T per month. So, the proposal is for existing project for Capacity Expansion of manufacturing of Formaldehyde from 1000 M.T per month to 2500 M.T per month at Plot No.- G1- 787-788, RIICO Industrial Area, Tehsil Tijara, District Alwar, Rajasthan. The Company has been registered by Directorate of Industries, Govt. of Rajasthan on 10/02/1994 (attached as Annexure-I). The existing plant was established based on CTE/NOC (attached as Annexure- II). The latest CTO was applied for renewal vide Application No.-185481, Dated- 03/06/2017 (attached as Annexure- III). The Rajasthan State Pollution Control Board has issued an Order No.-RPCB/RO/BWD/175/1488, Dated -19/08/2019 (attached as Annexure- IV) to apply for EC within 60 days from the date of issue of letter.

Project Proponent

Process/Technology

M/s Suchem Organics Pvt. Ltd. has setup an manufacturing unit of Formaldehyde at Plot No.- G1- 787-788, RIICO Industrial Area , Tehsil Tijara , District Alwar, Rajasthan.

(i) Brief description of nature of project:

M/s Suchem Organics Pvt. Ltd. has setup an manufacturing unit of Formaldehyde with the capacity of production of 1000 M.T per month. Now, industry comes under Capacity Expansion with the production from 1000 M.T per month to 2500 M.T per month. The commercial production of Formaldehyde is manufactured from oxidation-dehydrogenation using a silver catalyst involving either the complete or incomplete conversion of methanol.

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PRE FEASIBILITY REPORT

As per EIA Notification dated 14th September, 2006, as amended on 25 June 2014, the project falls under activity ‘5(f)’ and the presence of interstate boundary of Rajasthan and Haryana within 5km from the project site in East direction makes the general condition applicable on the project which makes it category ‘A’ project. The project requires appraisal/approval at central level in the Ministry.

(ii) Need for the Project and its importance to the country and or region.

The Plywood Boards and sun mica sheets market is growing very fast in India. The market is expected to continue to grow at the minimum rate of 10 to 15% per year.

During the last decade, India has built a very strong position as sun mica sheets and ply wood boards for domestic consumption and for Exports to South Asian countries & Middle East.

Formaldehyde is used by ply wood and sun mica laminated sheets manufacturers, who make adhesives like Urea Formaldehyde and Phenol Formaldehyde products. So considering the above, the M/s Suchem Organics Pvt. Ltd. has setup an manufacturing unit of Formaldehyde with the capacity of production of 1000 M.T per month & now comes under Capacity Expansion from 1000 M.T per month to 2500 M.T per month.

(iii) Supply – Demand Gap

The project is envisaged to meet the demand supply gap in the domestic market, as the gap is created due to increase in growth of Formaldehyde for meeting increased demand of PLYWOOD and SUN MICA industries.

(iv) Imports V/s Indigenous Production

Company is making its Raw Material / Packing material procurement from the domestic market in big quantities more than as compared to its Import Purchases.

The Company in this manner and under statutory provisions and rules, is also utilizing the Import benefit policies allowed/ extended & allowed by the Govt. of India.

(v) Domestic Market

The Plywood Boards and sun mica sheets market is growing very fast in India. The market is expected to continue to grow at the minimum rate of 10 to 15% per year which makes the sufficient possibility to fulfill the domestic market demand. The Domestic supplies of the company will indirectly contribute to the growth of our nation.

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PRE FEASIBILITY REPORT

(vi) Employment Generation (Direct and indirect)

About 10-12 persons have been employed to the industry. Direct and Indirect employment is also likely to be generated with the Existing project which is economically beneficial for the development.

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3. PROJECT DESCRIPTION

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

Formaldehyde is a main constituent for manufacturing valuable chemical like melamine, urea and phenolic resins. It also acts as biocides, preservatives and used in many household & common products including medicines, health & beauty aids. It is available in 37% aqueous solution. It is identified by some of it properties like molecular weight about 30.3, boiling point -118 °C, melting point at - 19 °C and density of 0.815 at -20 °C.

The existing integrated facility is producing 1000 M.T per month of Formaldehyde & now comes under Capacity expansion from 1000 M.T per month to 2500 M.T per month.

The project is equipped with fully diversified processing facilities. The number of working days for the Existing project is 300 days. The Plant is operated 6 days in a week along with effective utilization of the resources.

(ii) Location (Map showing general location, specific location, and project boundary and project site layout) with coordinates :

The Existing project is located in 1000 sq.m and is situated at plot no. G1-787-788, RIICO Industrial Area, Tehsil Tijara, District Alwar, Rajsathan. The land is already under the possession of project proponent.

There is no forest land involved in this Existing project land. The geographical location of the Existing plant lies from Latitude- 28°12'22.82" N to Longitude- 76°51'25.99"E. The Existing plant site is well connected with the rail and road connectivity. The Existing project site is about 4.4 kms from SH-25 (Tijara-Delhi Highway) in West direction, 8.4 kms from MDR132 in ENE direction, is about 5.8 kms from NH-8 in NNW Direction (Delhi- Jaipur Expressway), is 0.6 kms from NH71B in North Direction.

The nearest settlement is Bhiwadi at a distance of 1.1 km (approx) in WNW direction. The nearest major railway station is Ichhapuri Railway Station at a distance of 18 km (approx) in NW direction. Pataudi Railway Station is 18.2 kms (approx.) in NW Direction, Khalilpur Railway Station is 18.9 kms (approx.) in WNW direction are also some routes from the project site. Indira Gandhi International Airport, Delhi is at a distance of 41.9 kms (approx.) in NE direction.

Project site falls in survey of India Toposheet no. H43W15, H43W16. Location map of the Project site is presented in Figure 1.

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Figure 1: Location Map

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Figure 2: Google Earth Image showing 500 m radius study area

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Figure 3: Layout Plan of Suchem Organics Pvt. Ltd.

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Figure 4: Key Plan showing 10 km radius study area

(iii) Details of alternate sites Considered and the basis of selecting the Existing site, particularly the environment consideration gone into should be highlighted.

No alternate sites have been examined for the existing project, as it is located within the industrial area. (iv) Size and Magnitude of Operation

M/s Suchem Organics Pvt. Ltd. has setup an manufacturing unit of Formaldehyde with the capacity of production of 1000 M.T per month at plot no. G1- 787-788, RIICO Industrial Area, Tehsil Tijara, District Alwar, Rajasthan and now comes under Capacity Expansion from 1000 M.T per month to 2500 M.T per month. The fixed cost for the Existing project is 139.93 lacs and it will expands to 239.93 lacs including 100 lacs of Expansion which include land, building, plant & machinery and Capacity Expansion.

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(v) Project description with process details: (a schematic diagram/flowchart layout, components of the project)

Formaldehyde Manufacturing Technologies & Process: Raw Material :1 Methanol (CH3OH) :2 Silver (Ag) :3 Water (H2O from tubewell) :4 Oxygen (O2 from atmosphere)

Finished Product : Formaldehyde (HCHO) Plant & Machinery (Main) : Evaporator, Mixing Tank, Super Heater, Reactor, Condenser, Absorption column, heat exchanger, pumps, pipe line

Methanol is converted into formaldehyde by oxidation process with Oxygen, silver & water at a temperature of 6500 C to 7000 C. It is an Exothermic reaction.

CH3OH + Ag+ H2O +O2------HCHO+ 2H2O+ AgO+ Inter Gas 6500 C To 7000 C

Step I: Methanol is pumped from the underground storage tanks to a mixing tank where water is added to dilute the solution.

Step II: Dilute Methanol solution I is then taken into evaporator where it is evaporated to proper stage at 700 C. Air also passed through the blower and applied steam. The mixture of vapours (AIR + METHANOL+ WATER) is passed to the reactor through silver bed where methanol is converted into formaldehyde gas at 6700 C (approx)

Step III: The temperature of formaldehyde gas is taken down upto 1100 C through condensers and then passed to absorption column to absorb the gases in water. We circular the formaldehyde solution till desired quality of formaldehyde liquid is obtained, and then the product is transferred to the storage tank. And after testing the quality, we dispatch the goods. This is a continuous chemical process. Normally, the ratio of methanol and formaldehyde is approx 1: 2, we get 2 kg of formaldehyde by 1 kg of methanol, if the quantity of raw material & product is OK . It 13 | Page

M/s Suchem Organics Pvt. Ltd. Existing Project for Capacity Expansion of Manufacturing of Formaldehyde from 1000 M.T per month to 2500 M.T per month at Plot No. G1- 787-788, RIICO Industrial Area, Tehsil Tijara, District Alwar, Rajasthan PRE FEASIBILITY REPORT depends on temperature, plant pressure and atmosphere climate also. On the demand of buyer, we produce the formaldehyde of different grade also, which is produced as per requirement of the party. The ratio of methanol and formaldehyde, sp. varies depends on the specification desired by the party.

Catalytic oxidation process is an optimized production method. Let us discuss about the technology in this process. It is a simple process as per the stoichiometric reaction steps along with material balance shown below.

1. Oxidation of methanol with oxygen present in air

CH3OH + ½ O2 HO + H20 = -37 Kcal

(32) (16→) HC (30) (18) ∆H(one mole of water is formed during reaction)

2. Pyrolysis endothermic reaction

CH3 HCHO + H2 = +20 Kcal

(32)OH → (30) (2) ∆H

3. Side reaction – complete combustion producing heat energy

CH3OH + 3/2 O2 2H2O +CO2 = -162 Kcal

Material Balanc→e ∆H (I) Existing Material Balance Material Balance for 1000 Ton capacity of Formaldehyde – 37%

2 MolesCH3OH + ½ Mole O2 Moles HCHO + 1 Mole H20 + 1 Mole H2

(64) (16) → 2 (60) (18) (2)

Concentration of HCHO formed during reaction

78 grams of HCHO solution formed is having 18 grams of water

Concentration of HCHO = (60/78) x 100 = 76.92 %

Water requirement for 37% Formaldehyde = 76.92-37.0 = 39.92 %

Water required for 1000 Ton of Formaldehyde = 39.92/100 x 1000,000= 399200 kg

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2 MolesCH3OH + ½ Mole O2 Moles HCHO + 1 Mole H20 + 1 Mole H2

(64) (16) → 2 (60) (18) (2)

Concentration of HCHO formed during reaction

78 grams of HCHO solution formed is having 18 grams of water

Concentration of HCHO = (60/78) x 100 = 76.92 %

Water requirement for 37% Formaldehyde = 76.92-37.0 = 39.92 %

Water required for 2500 Ton of Formaldehyde = 39.92/100 x 2500,000 = 998000 kg

Process Waste:

As per present scheme, domestic sewage generated 0.800 KLD which is treated in septic tank and further used for plantation. There is no discharge of waste water within or outside the premises, unit should maintain Zero Discharge Status.

Hazardous Waste:

Used oil from machineries/D.G. Set is carefully stored in HDPE drums in isolated covered facility. The used oil is sold to vendors authorized by Central Pollution Control Board for the treatment of the same. Suitable care is taken so that spills / leaks of used oil from storage could be avoided.

Air Emissions and Control:

All the exhaust gas emissions is channelized all through the process and is reused for various purposes like heating & remained chemical utilization. At the end the remaining gas will be exhausted through a boiler. 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 5 m is provided above the roof level of D.G. Set. Boiler have been installed based on coal fired fuel.

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Figure: 5 Process flow diagrams for Formaldehyde

(vii) Raw material required along with estimated quantity, likely source, marketing area of final products, mode of transport of raw material and Finished products. Raw Material requirement for production of Formaldehyde is Methanol (99.9%)

(viii) Resources optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined. M/s. Suchem Organics Pvt. Ltd. optimize utilization of resources including Land, Fuel, Water and Electricity.

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

Water Requirement

(I) Existing Requirement

Total water requirement is 25 KLD. For industrial purpose 16.7 KLD, for domestic purpose is 2 KLD, for Cooling Tower is 0.1 KLD, for Green Belt is 1 KLD & for other purpose is 5.2 KLD.

(II) Expansion Requirement

Power Requirement

(x) Quantity of waste to be generated (Liquid and solid) and scheme for their management.

Process waste

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4. SITE ANALYSIS

(i) Connectivity

The Existing plant site is well connected with the rail and road connectivity. The Existing project site is about 4.4 kms from SH-25 (Tijara-Delhi Highway) in West direction, 8.4 kms from MDR132 in ENE direction, is about 5.8 kms from NH-8 in NNW Direction (Delhi- Jaipur Expressway), is 0.6 kms from NH71B in North Direction. The nearest settlement is Bhiwadi at a distance of 1.1 km (approx) in WNW direction. The nearest major railway station is Ichhapuri Railway Station at a distance of 18 km (approx) in NW direction. Pataudi Railway Station is 18.2 kms (approx.) in NW Direction, Khalilpur Railway Station is 18.9 kms (approx.) in WNW direction are also some routes from the project site. Indira Gandhi International Airport, Delhi is at a distance of 41.9 kms (approx.) in NE direction.

(ii) Land form, Land Use, Land Ownership

Total area of the existing project is 1000 sq.m of land. The land is already under the possession on M/s Suchem Organics Pvt. Ltd.

(iii) Topography (along with map)

The site has been observed to be almost flat level in topography with an elevation of 291m

Figure: 5 Google Image of the Existing project site

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(iv) Existing Land use Pattern: 1000 sq.m of land is industrial for the existing project. No forest land is involved in the area identified for setting up of the existing project for manufacturing of Formaldehyde by M/s Suchem Organics Pvt. Ltd.

(v) Existing Infrastructure

The Existing project is under the possession of project proponent.

Road links: The Existing plant site is well connected with the rail and road connectivity. Existing project site is about 4.4 kms from SH-25 (Tijara-Delhi Highway) in West direction, 8.4 kms from MDR132 in ENE direction , is about 5.8 kms from NH-8 in NNW Direction (Delhi- Jaipur Expressway), is 0.6 kms from NH71B in North Direction.

(vi) Soil classification:

The area is occupied by Indo- Gangetic alluvium soil. Alluvium plains which forms a part of large Indo- Gangetic Quaternary basin comprises of thick sand and silty sand layers interbedded with silt and clay beds. The alluvium plains are of vital economic value as it supports the dense population of the district. The soils are mainly developed on alluvium under the dominant influence of climate followed by topography and time. The project site comes under Alluvial plain region. The major soil type of Alwar district is weakly solonized tropical arid brown soils. The soils of the district vary in texture generally from loam to silt clay. It may vary with the site location.

(vii) Climatic Data from secondary sources:

Climate: Alwar, Rajasthan has a semi-arid climate characterized with very hot summers and very cold winters with fairly good during south west monsoon period. In May and June, the maximum temperature may go upto 470 C. Normal annual rainfall of the district is 631mm.

Average temperature Summer: The temperature in summer may rise to a maximum of 48°C. Temperatures generally remain between 30°C to 40°C.

Autumn: In autumn, the temperature may rise to a maximum of 36°C. Temperatures usually remain between 16° to 27° in autumn. The minimum temperature is around 15°C.

Winter: Winters are quite cool. Average temperatures in winter (November to February) remains at (max)14°C to18 °C and (min) 0°C to 8°C.

Spring: The climate remains quite pleasant during the spring season. Temperature 19 | Page

Rainfall: The rainfall in the zone is caused by South-West monsoon. It starts in the month of July and extend upto the month of September. During this period the monsoon rainfall contribute about 75 to 80% of the total annual rainfall. The average annual rainfall is about 631mm.

Humidity: In summer months of April, May and June which is the driest part of the year, the afternoon humidity comes down to 28% to 35% while the relative humidity during monsoon months goes up to 75% to 80%.

Wind Speed/Direction: The wind direction in the area is mostly from North-West to South- East. During January to May the winds are quite strong while July to October is calm months.

Table 1.1: Summary of climate condition

Maximum temperature 44-45°C in the month of May Minimum temperature 10-14°C in the month of January Relative humidity 80-82% (Max.) Rainfall Annual – 450-458 mm Wind Speed 5.0 m/sec. Predominant Wind From South to West Seismic da ta Zone – IV as per IS-1893 (part-I)

(viii) Biodiversity:

The data of existing flora and fauna components in the study area has been collected through secondary sources. With the change in environmental conditions the vegetation cover as well as animal reflect several change in its structure, density and composition. The present study was carried out separately for floral & faunal community respectively.

Flora: Tree species which are most commonly found in the area are Azadirachta indica (Neem) Acacia arabica (Babool), Ficus religiosa (Peepal), Emblica officinalis (Amla), Dalbergia sissoo (Shishum), Mangifera indica (Aam), Prosopis juliflora (Vilayati babool) etc.

Fauna: Commonly found animal in the study area are Common mongoose (Herpestes edwardsi), Rat (R.rattus), Bull Frog (Rana tigrina), House crow (Corvus splendens), Common garden lizard (Calotes vesicolor) etc.

Crops: The major crops of the district are Wheat, Paddy, barley, gram mustard, etc. The Sugarcane & Sunflower crops are also cultivated in the district to some extent.

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Socio-economic status of the population is an indicator of development of the region. Any developmental project of any magnitude will have a bearing on the living condition and the economic bearing of the population in particular and the region as a whole. Similarly, the Existing project at plot no. – G1- 787-788, RIICO Industrial Area, Tehsil Tijara, Rajasthan is having its share of socio-economic influence in the study area. The section delineates the overall appraisal of the socially relevant attributes. The data on socio-economic aspects in the study area has been carried out through the analysis of the secondary data available for the study area. As per 2011 Indian census record, Alwar (Rajasthan) had a population of 1,939,026 Males constitute of the population and females constitutes 1,735,153. Alwar (Rajasthan) has an average literacy rate of 70.72%, male literacy is 83.75%, and female literacy is 56.25%.

(x) Other features:

Rivers Sahibi River is at 11.5 km in West direction

Interstate Boundary Presence of Interstate Boundary of Rajasthan- Haryana at a distance of 1.6 km in North direction. Road Connectivity SH-25 (Tijara-Delhi Highway) is 4.4 kms in West direction MDR132 is 8.4 kms in ENE direction NH-8 (Delhi- Jaipur Expressway) is 5.8 kms in NNW Direction, NH71B is 0.6 kms in North Direction. National Highaway NH-8 is at a distance of about 9.44 kms

Nearest Settlement Bhiwadi is at a distance of 1.1 kms (approx) in WNW direction.

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5. PLANNING BRIEF

(i) Planning concept

About 10-12 manpower has been employed to ensure smooth working of the plant. Direct and Indirect employment have also been generated from the Existing project during operation. The summary of direct employment estimate for the project is given in the table below: Table 1.2: Manpower Requirement

S.no. Description Manpower

1 Plant Manager 1 2 Environment health safety Officer(EHS) 1

3 Chemist 2

4 Assisstant to chemist & Plant Supervisor 2 5 Utility/Maintenance 2

6 Electrician 2

7 Store Keeper 1 8 Admin 1 Total 12

(iii) Land Use Planning

The Existing project is set up in an area of 1000 sq.m. The land use break up is as follows-

S.no. Type Of Use Area in sq. ft.

1 Green Belt Area 330.00 sq.m 2 Open Land 400.00 sq.m 3 Road/Paved Area 120.00 sq.m 4 Rooftop Area of Building/sheds 150.00 sq.m TOTAL LAND 1000 sq.m

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(iv) Assessment of Infrastructure demand

The following plants, machinery Existing for the project is given in the below table:

S.no. Machines & Equipment Quantity

1 Reactor 1

2 Evaporator 1 3 Heat Exchanger 3 4 Boiler 1 5 First Column 1 6 Second Column 1 7 Reactor Dome 1 8 Methanol Tank 2 9 Filters 3 10 FormaldehydeStorage Tanks 2 11 Condenser with sump 1 12 Mixing Vessel 1 13 D.M water plant 1

14 Air compressor 1

15 Absorption column 1

16 Silver (as catalyst) 60 kg

17 Cooling Towers 3

(v) Amenities/Facilities

Facilities like canteen, rest rooms and recreation facilities have been provided in the Existing project. No other additional facilities are existing.

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6. EXISTING INFRASTRUCTURE

(i) Total Area:

Total Plot area of M/s Suchem Organics Pvt. Ltd. is 1000 sq.m.

Residential Area:

There is no residential area falls under the existing project site.

(ii) Green Belt :

Total land area of the existing project is 1000 sq.m. The greenbelt has been developed at the site whose area is about 330 sq.m. Adequate green belt provision as per MoEFCC guideline has already been considered for existing project development. Further, unpaved areas, if any, within the plant boundary is provided with grass cover which will also improve the plant aesthetics.

(iii) Social Infrastructure

RIICO I.A Sub Post Office, Police Station- Bhiwadi, ESIC Hospital, Shiv Public School, Ayyappa Temple, SVR Girls College, Bhiwadi College of Polytechnic have been recognized nearby.

(iv) Connectivity

The Existing plant site is well connected with the rail and road connectivity. The Existing project site is about 4.4 kms from SH-25(Tijara-Delhi Highway) in West direction, 8.4 kms from MDR132 in ENE direction, is about 5.8 kms from NH-8 in NNW Direction (Delhi- Jaipur Expressway), is 0.6 kms from NH71B in North Direction. The nearest settlement is Bhiwadi at a distance of 1.1 km (approx) in WNW direction. The nearest major railway station is Ichhapuri Railway Station at a distance of 18 km (approx) in NW direction. Pataudi Railway Station is 18.2 kms (approx.) in NW Direction, Khalilpur Railway Station is 18.9 kms (approx.) in WNW direction are also some routes from the project site. Indira Gandhi International Airport, Delhi is at a distance of 41.9 kms (approx.) in NE direction.

Water requirement Existing Requirement

Total water requirement is 25 KLD. For industrial purpose 16.7 KLD, for domestic purpose is 2 KLD, for Cooling Tower is 0.1 KLD, for Green Belt is 1 KLD & for other purpose is 5.2 KLD.

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(vi) Drinking Water Management

Potable Drinking water is provided. Domestic water requirement includes drinking water is envisaged as 5 KLD.

(vii) Water Treatment System

(viii) Power requirement & Supply / Source

Maximum power requirement for the plant is 130 KVA (Total connected load). Average running load power requirement for the project is 80 KVA. The power is supplied from JVVNL ( Jaipur Vidyut Vitran Nigam Limited). 1 DG set of capacity 125 KVA also exists as the backup power supply.

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7. REHABILITATION & RESETTLEMENT PLAN

No agricultural land and habitation is present in the land and there is no displacement involved. Hence, no Land Acquisition, Resettlement and Rehabilitation is envisaged for this project.

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8. PROJECT SCHEDULE & COST ESTIMATES

(i) Project Schedule:

The construction of the project has already been done and the existing plant was established based on CTE & CTO from RSPCB. The latest CTO was applied for renewal vides Application No.- 185481, Dated- 03/06/2017. The Capacity Expansion will be done after EC receipt.

(ii) Total Project Cost

The fixed cost for the Existing project is 139.93 lacs and it will expands to 239.93 lacs including 100 lacs of Expansion which include land, building, plant & machinery and Capacity Expansion including preliminary & pre-operative expenses, electrical installation requirement and inclusive of cost of land as presented in the table below:

Total Fixed Cost Cost (Rs. in lakhs) Land & Building (Rented) 45.09 Plant & Machinery 70.30

MFA 13.11 Electrical Installation 11.43 Expansion Cost 100.00 Total 239.93

Table 1.5: Total Cost

Profit and Cost Benefit Analysis

Profit and cost benefit analysis can be estimated as the Raw Material cost per kg of product Methanol Consumption per kg product = 0.500 kg

Price of Methanol = Rs 20 per kg Cost of Formaldehyde Mfg.= Rs 20 x 0.500 = Rs 10.00 per kg

Sale price of Formaldehyde = Rs 13 per kg

Gross Contribution per kg = Rs 2 per kg Processing Charges per kg = Rs. 1.5

Daily Profit per kg = Rs 0.5( 0.5x 40,000=20000)

Monthly Profit = 20000 x 30 (days) = Rs 6 lacs

The manufacturing of Formaldehyde is economically viable.

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9. ANALYSIS OF PROPOSAL (Final Recommendation)

Formaldehyde is used by ply wood and sun mica laminated sheets manufacturers, who make adhesives like Urea Formaldehyde and Phenol Formaldehyde products. The commercial production of Formaldehyde is manufactured from oxidation- dehydrogenation using a silver catalyst involving either the complete or incomplete conversion of methanol.

The Plywood Boards and sun mica sheets market is growing very fast in India. The market is expected to continue to grow at the minimum rate of 10 to 15% per year which makes the sufficient possibility to fulfill the domestic market demand. Hence, the Domestic supplies of the company will indirectly contribute to the growth of our nation.

So considering above, M/s Suchem Organics Pvt. Ltd. has setup an manufacturing unit of Formaldehyde with the capacity of production of 1000 M.T per month at plot no.- G1- 787-788 , RIICO Industrial Area, Tehsil Tijara, District Alwar, Rajasthan which now comes under Capacity Expansion of Formaldehyde from 1000 M.T per month to 2500 M.T per month.

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