Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari B CATEGORY
FORM – 1 With Basic Information
FOR OBTAINING ENVIRONMENTAL CLEARANCE
For Expansion of New Product ‐ Resin for
M/s. Sagar Veneer Industries.
Block No.: 1781, 1782 P‐3, Vansda Road, Nr. Bhavin Construction, Village: Alipore, Post: Bamanvel, Taluka: Chikhli, District: Navsari, Gujarat.
Mr. Ambalal Patel & Purushottam Patel Mob No.: 08469531018 & 09824180164 Email: [email protected]
Prepared By:
T. R. ASSOCIATES
C‐605/A, Ganesh Meridian, Opp. Kargil Petrol Pump, S. G. Highway, Ahmedabad. Mo. No.: 98253 71099 Email ID: [email protected]; [email protected]
June 2015
Form‐1 for Environmental Clearance 1
Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
Index
No. of Annexure Description
Form Of Appendix – 1
Annexure – 1 Key Plan
Annexure – 2 Plant Lay‐Out
Annexure – 3 Manufacturing Process & Flow Diagram
Annexure – 4 Details Of Solid Waste
Annexure – 5 Details Of Effluent Treatment Plant
Annexure – 6 Water Balance Diagram
Annexure – 7 Details Of Stack
Annexure – 8 List Of Product And Raw Material
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
Appendix – I (See paragraph – 6)
FORM‐1
(I) Basic Information Name of the project : M/s. Sagar Veneer Industries. Location / Site alternative under : Block no. 1781, 1782 P‐3, Vansda Road, Nr. consideration Bhavin Construction, Village : Alipore, Post : Bamanvel, Taluka : Chikhli, District : Navsari, Gujarat. Size of the Project * : Existing Project : Plywood – 1,15,000 Sq.M./Month Flush door – 25,000 Sq.M./Month Block Board ‐ 25,000 Sq.M./Month Proposed Project : Phenol Formaldehyde Resin – 20 MT/Month Melamine Urea Formaldehyde Resin – 70 MT/Month Urea Formaldehyde Resin – 50 MT/Month Expected cost of the project : Existing project cost : 30.5 Lacs Proposed resin project cost : 29.5 Lacs Total cost after proposed expansion project : 60 Lacs * Capacity corresponding to second activity (such as production capacity for manufacturing, mining lease area and production capacity for mineral production, area for mineral exploration, length for linear transport infrastructure, generation capacity for power generation etc.)
Sr. Item Details No. 1. Name of the Project/s M/s. Sagar Veneer Industries. 2. S. No. in the schedule 5(f) 3. Proposed capacity/area/length/tonnage Capacity Product to be handled/ command area/ lease (MT/Month) area/ number of well to be drilled. Phenol Formaldehyde Resin 20 Melamine Urea Formaldehyde 70 Resin Urea Formaldehyde Resin 50 4. New/ Expansion/ Modernization Expansion of new products 5. Existing Capacity/ Area etc. Plywood – 1,15,000 Sq.M./Month Flush door – 25,000 Sq.M./Month Block Board ‐ 25,000 Sq.M./Month 6. Category of Project i.e. ‘A’ or ‘B’ B, 5 (f) 7. Does it attract the general Condition? If No Yes, please specify. 8. Does it attract the specific Condition? If No Yes, please specify.
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
Sr. Item Details No. 9. Location Plot/Survey/Khasra No. 1781, 1782 P‐3 Village Alipore Tehsil Bamanvel (Chikhli) District Navsari State Gujarat 10. Nearest railway station/airport along Nearest Railway station – Chikhli Road Railway with distance in kms station– 4.03 Km Nearest Airport – Surat‐ 51 Km 11. Nearest Town, city, District Headquarters Nearest Village: Bamanvel – 0.98 Km along with distance in kms. Nearest Town: Chikhli – 4.64 Km Nearest District Headquarters: Navsari ‐25 km 12. Village Panchayats, Zila Parishad, Alipore Village Panchayat – 3.18 Km Municipal Corporation, Local body(complete postal) address with telephone nos. to be givan) 13. Name of the applicant Mr. Ambalal Patel 14. Registered Address 9, Ambika Park, Gokuldham Society, Gandevi Road, Devsar, Bilimora, District: Navsari, Gujarat. 15. Address for correspondence As above Name Mr. Ambalal Patel Designation (Owner/ Partner/ CEO) Partner Address As above E‐mail [email protected] Telephone No. 8469531018 Fax No. ‐‐ 16. Details of Alternative Sites examined, if No alternative site was examined. any. Location of these sites should be shown on a topo sheet. 17. Interlinked Projects. Not Applicable 18. Whether separate application of Not Applicable interlinked projects has been submitted? 19. If yes, date of submission Not Applicable 20. If no, reason Not Applicable 21. Whether the proposal involves approval/ Not Applicable clearance under: If yes, details of the same and their status to be given. (a)The Forest (Conservation) Act, 1980? (b)The Wildlife (Protection) Act, 1972? © The C.R.Z Notification, 1991? 22. Whether there is any Government Order/ Not Applicable Policy relevant/ relating to the site? 23. Forest land involved (hectares) Not Applicable 24. Whether there is any litigation pending Not Applicable against the project and/ or land in which the project is propose to be set up?
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
Sr. Item Details No. a) Its relevance with the proposed project.
(II) Activity
1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
Sr. Information/Checklist Yes/ Details thereof (with approximate No. confirmation No quantities / rates, wherever) with source of information data 1.1 Permanent or temporary change in Yes There is minor change in land use due to land use, land cover or topography construction work. including increase in intensity of land use (with respect to local and use plan) 1.2 Clearance of existing land, No ‐‐ vegetation and buildings? 1.3 Creation of new land uses? No ‐‐ 1.4 Pre‐construction investigations e.g. No ‐‐ bore houses, soil testing? 1.5 Construction works? Yes There is minor change in land use due to construction work. 1.6 Demolition works? No ‐‐ 1.7 Temporary sites used for No ‐‐ construction works or housing of construction workers? 1.8 Above ground buildings, structures Yes Key plan & Plant lay‐out is attached as or earthworks including linear Annexure – 1 & 2. structures, cut and fill or excavations 1.9 Underground works including No ‐‐ mining or tunneling? 1.10 Reclamation works? No ‐‐ 1.11 Dredging? No ‐‐ 1.12 Offshore structures? No ‐‐ 1.13 Production and manufacturing Yes Manufacturing process with flow‐chart processes? is attached as Annexure – 3 1.14 Facilities for storage of goods or Yes Covered sheds will be provided for materials? storage of goods & materials 1.15 Facilities for treatment or disposal Yes A detail of solid waste is attached as of solid waste or liquid effluents? Annexure – 4. A detail of ETP for treatment of effluent is attached as Annexure – 5. 1.16 Facilities for long term housing of No No operational workers? 1.17 New road, rail or sea traffic during No No construction or operation? 1.18 New road, rail, air water borne or No No other transport infrastructure including new or altered routes and stations, ports, airports etc? 1.19 Closure or diversion of existing No No
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
transport routes or infrastructure leading to changes in traffic movements? 1.20 New or diverted transmission lines No No or pipelines? 1.21 Impoundment, damming, culver No No ting, realignment or other changes to the hydrology of watercourses or aquifers? 1.22 Stream crossings? No No 1.23 Abstraction or transfers of water Yes Borewell form ground or surface waters? 1.24 Changes in water bodies or the No No land surface affecting drainage or run‐off? 1.25 Transport of personnel or No No materials for construction, operation or decommissioning? 1.26 Long‐term dismantling or No No decommissioning or restoration works? 1.27 Ongoing activity during No No decommissioning which could have an impact on the environment? 1.28 Influx of people to an area in either Yes Temporary erection workers. temporarily or permanently? 1.29 Introduction of alien species? No No 1.30 Loss of native species or genetic No No diversity? 1.31 Any other actions? Nil Nil
2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non‐renewable or in short supply):
Sr. Information/checklist Yes/No Details thereof (with approximate No. confirmation quantities/rates, wherever possible) with source of information data 2.1 Land especially undeveloped No Un developed area or agricultural land (ha) Total plant area: 14588 Sq. M. 2.2 Water (expected source & Yes Existing water consumption: 3.55 competing users) unit: KLD KL/Day. Water consumption after proposed expansion will be 14.3 KL/Day. Water balance diagram is attached as Annexure – 6. 2.3 Minerals (MT) No NOT APPLICABLE 2.4 Construction material – Yes For the erection purpose of plant and stone, aggregates, and /soil machinery. Balance will be sent to the (expected source – MT) land‐fill site. 2.5 Forests and timber (source – No No. MT) 2.6 Energy including electricity Yes Existing Demand loads 25 KW from and fuels (source, competing DGVCL
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
users) Unit: fuel (MT), energy Total demand load after proposed (MW) expansion 50 KW from DGVCL
2.7 Any other natural resources No No (use appropriate standard units)
3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.
Sr. Information/checklist Yes/No Details thereof (with approximate No. confirmation quantities/rates, wherever possible) with source of information data 3.1 Use of substances or No Phenol, Urea & Formaldehyde are materials, which are Hazardous as per MSIHC rules. hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies) 3.2 Changes in occurrence of No NOT APPLICABLE disease or affect disease vectors (e.g. insect or water borne diseases) 3.3 Affect the welfare of people No NOT APPLICABLE e.g. by changing living conditions? 3.4 Vulnerable groups of people No NOT APPLICABLE who could be affected by the project e.g. hospital patients, children, the elderly etc. 3.5 Any other causes No NOT APPLICABLE
4. Production of solid wastes during construction or operation or decommissioning (MT/month)
Sr. Information/checklist Yes/No Details thereof (with approximate No. confirmation quantities/rates, wherever possible) with source of information data 4.1 Spoil, Over burden or mine No No wastes 4.2 Municipal Waste (domestic Yes Domestic waste will be disposed through and or commercial wastes) soak pit system. 4.3 Hazardous wastes (as per Yes Details of solid waste are attached as Hazardous Waste Annexure – 4. Management Rules) 4.4 Other industrial process Yes Details of solid waste are attached as wastes Annexure – 4. 4.5 Surplus product No‐‐ 4.6 Sewage sludge or other Yes Details of solid waste are attached as sludge from effluent Annexure – 4. treatment 4.7 Construction or demolition No No waste 4.8 Redundant machinery or No No
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
equipment 4.9 Contaminated soils or other No No materials 4.10 Agricultural wastes No No 4.11 Other solid wastes No No
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
Sr. Information/checklist Yes/No Details thereof (with approximate No. confirmation quantities/rates, wherever possible) with source of information data 5.1 Emissions from combustion Yes Details of flue gas stack is shown in of fossil fuels from stationery Annexure‐7 or mobile sources 5.2 Emissions from production No No processes 5.3 Emissions from materials Yes There will be fugitive emissions for handling including storage or which proper Control measures will transport be provided. 5.4 Emissions from construction Yes ‐ Due to construction activities there activities including plant and may be chances of fugitive emission. equipment ‐ To avoid fugitive emission, proper Control measures will be provided. 5.5 Dust or odors from handling No No of materials including construction materials, sewage and waste 5.6 Emissions from incineration No No of waste 5.7 Emissions from burning of No No waste in open air (e.g. slash materials, construction debris) 5.8 Emissions from any other No No sources
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
Sr. Information/checklist Yes/No Details thereof (with approximate No. confirmation quantities/rates, wherever possible) with source of information data 6.1 From operation of equipment Yes < 80 dB e.g. engines, ventilation plant, crushers 6.2 From industrial or similar No NOT APPLICABLE processes 6.3 From construction or No NOT APPLICABLE demolition 6.4 From blasting or piling No NOT APPLICABLE 6.5 From construction or No NOT APPLICABLE operational traffic 6.6 From lighting or cooling No NOT APPLICABLE systems 6.7 From any other sources No NOT APPLICABLE
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, ground water, coastal waters or the sea:
Details thereof (with approximate Sr. Information/checklist Yes/ quantities/rates, wherever possible) No. confirmation No with source of information data 7.1 From handling, storage, use or Yes Fugitive emissions will be occurred. spillage of hazardous materials However, necessary precautionary measures will be taken. 7.2 From discharge of sewageor other No The details of Effluent Treatment Plant is effluents to water or the land attached as Annexure ‐ 5 (expected mode and place of discharge) 7.3 By deposition of pollutants emitted to Yes Multi cyclone dust collector & Bag Filter air into the land or into water will be installed for air pollution control 7.4 From any other sources No No 7.5 Is there a risk of long term build up of No No pollutants in the environment from these sources?
8. Risk of accidents during construction or operation of the project, which could affect human health or the environment
Details thereof (with approximate Sr. Information/checklist Yes/ quantities/rates, wherever possible) No. confirmation No with source of information data 8.1 From explosions, spillages, fires etc. No All the necessary precautionary measures from storage, handling, use or will be taken. production of hazardous substance 8.2 From any other causes No Not Applicable 8.3 Could the project be affected by No Not Applicable natural disasters causing environmental damage (e.g. floods, earthquakes, landslides, cloudburst etc)?
9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality
Details thereof (with approximate Sr. Information/checklist Yes/ quantities/rates, wherever possible) No. confirmation No with source of information data 9.1 Lead to development of supporting, lities, ancillary development or development stimulated by the project which could have impact on the environment e.g. Supporting infrastructure (roads, power supply, waste or waste No Not Applicable water treatment, etc.)
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
Details thereof (with approximate Sr. Information/checklist Yes/ quantities/rates, wherever possible) No. confirmation No with source of information data Housing development Extractive industries Supply industries Other
9.2 Lead to after use of the site, which No Not Applicable could have an impact on the environment 9.3 Set a precedent for later No Not Applicable developments 9.4 Have cumulative effects due to No Not Applicable proximity to other existing or planned projects with similar effects
(III) Environmental Sensitivity
Details thereof (with approximate Sr. Information/checklist Yes/ quantities/rates, wherever possible) No. confirmation No with source of information data 1 Areas protected under international No Not Applicable conventions, national or local legislation for their ecological landscape, cultural or other related value 2 Areas with are important or sensitive No Not Applicable for ecological reasons – Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests 3 Areas used by protected, important No Not Applicable or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration 4 Inland, coastal, marine or No Not Applicable underground waters 5 State, National boundaries No Not Applicable 6 Routes or facilities used by the public No Not Applicable for access to recreation or other tourist, pilgrim areas 7 Defense installations No Not Applicable 8 Densely populated or built‐up area No Navsari is about 25 km away from the project site. 9 Areas occupied by sensitive man‐ No Alipore Hospital is about 3.56 km away made land uses (hospitals, schools, from the project site. places of worship, community facilities) 10 Areas containing important, high No Not applicable quality or scarce resources (ground water resources, surface resources, forestry, agricultures, fisheries, tourism, minerals) 11 Areas already subjected to pollution No Proposed project site is about 10 km away
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
Details thereof (with approximate Sr. Information/checklist Yes/ quantities/rates, wherever possible) No. confirmation No with source of information data or environmental damage. (those from the Bilimora, Antalia GIDC. where existing legal environmental standards are exceeded) 12 Areas susceptible to natural hazard No Not applicable which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)
(IV) Proposed Terms of Reference for EIA studies:
1. Land documents shall be provided. 2. Details of surrounding Industries. 3. Layout plan of the factory premises. Provision of separate entry & exit and adequate margin all round the periphery for unobstructed easy movement of the emergency vehicle/fire tenders without reversing back. Mark the same in the plant layout. Mark also existing shed & proposed shed in the plant lay‐out. 4. Existing & Proposed monthly production and product wise monthly consumption of each raw material. 5. Existing & proposed products Manufacturing process along with chemical reactions & complete mass balance. 6. Assessment of source of the water supply with adequacy of the same to meet with the requirements for the proposed project. 7. Water balance diagram (including reuse‐recycle, if any) along with qualitative and quantitative analysis of the each waste stream to be generated. 8. Pucca flooring will be provided on the inner roads of the factory to control SPM concentration in ambient air. 9. Product wise water consumption and waste water generation for existing & proposed project. Justification of water consumption & waste water generation data submitted with application. 10. Detailed effluent treatment scheme and disposal method. Technical details of the proposed ETP including size of each unit, retention time etc. along with its adequacy report. 11. Plans for management and disposal of waste streams to be generated from spillage, leakages, vessel washing, used container washing etc. Measures proposed for preventing effluent discharge during unforeseen circumstances. 12. Details of provisions to be made for evaporation of industrial effluent. Technical details effluent evaporation system including evaporation capacity, steam required for evaporation adequacy of the boilers to supply steam for evaporation in addition to the steam required for the process etc. Techno‐economical viability of the evaporation system. Control measures proposed for the evaporation system in order to avoid/reduce gaseous emission from evaporation of industrial effluent. 13. Specific details of (i) Process emission from each unit process with its quantification (ii) Air pollution Control Measures proposed. (iii) Adequacy of the air pollution control measures to achieve the GPCB Norms. (iv) Details of the utilities required (v) Flue gas emission rate from the utilities along with stack height. (v) Air Pollution Control Measures proposed to the utilities along with its adequacy. 14. Specific details of fugitive emission from the along with its quantification and proposed measures to control it along with measures proposed to monitor VOC within work area.
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
Details of ventilation system proposed in the work area. Measures proposed to keep the work area environment as per the norms of GFR. 15. Details of measures proposed for noise pollution abatement & its monitoring. 16. Details of management of the hazardous wastes to be generated from the project stating detail of storage area for each type of waste, its handling and its disposal. How the manual handling of the hazardous wastes will be minimized? 17. Methodology of Common Environmental Infrastructure including the TSDF/Common Hazardous waste incineration facility along with an assessment to accommodate the additional quantity of waste to be generated. 18. Measures proposed to be taken for the work area ambient air quality monitoring as per Gujarat Factories Rules. 19. A detailed EMP including the protection and mitigation measures for preventing impacts on human health and environment as well as detailed monitoring plan with respect to various parameters and responsible head for the environmental management cell and environmental management cell proposed for implementation and monitoring of EMP. 20. A detailed Green Belt Development Program including annual budget, types & number of trees to be planted, area under green belt development [with map]; along with commitment of the management to carry out the tree plantation activities outside the premises at appropriate places in the GIDC area and elsewhere. 21. Details of hazardous characteristics and toxicity of raw materials and products to be handled and the control measures proposed to ensure safety and avoid the human health impacts. This shall include the details of Antidotes also. 22. Details of quantity of each hazardous chemical to be stored, Material of Construction of major hazardous chemical storage tanks, threshold storage quantity as per schedules of the Manufacture, Storage & Import of Hazardous Chemicals Rules of major hazardous chemicals. How the manual handling of the hazardous chemicals will be minimized? 23. Details of the separate isolated storage area for chemicals. Details of fire extinguishers, flame proof electrical fittings, DCP extinguishers and other safety measures proposed. 24. Specific safety details I provisions for various hazardous chemicals and detailed fire control plan for flammable substances. 25. Details of possibilities of occupational health hazards from the proposed manufacturing activities and proposed measures to prevent them. 26. MSDS of all the products and raw materials. Details of hazardous characteristics and toxicity of raw materials and products to be handled and the control measures proposed to ensure safety and avoid the human health impacts. This shall include the details of Antidotes also. Detailed material handling plan to avoid minimize human exposure. 27. Risk assessment including prediction of the worst‐case scenario and maximum credible accident scenarios should be carried out. The worst‐case scenario should take into account the maximum inventory of storage at site at any point of time. The risk contours should be plotted on the plant layout map clearly showing which of the facilities would be affected in case of an accident taking place. Based on the same, proposed safeguard measures including On‐Site Emergency Plan should be provided. 28. Submit checklist in the form of Do's & Don'ts of preventive maintenance, strengthening of HSE, mfg utility staff for safety related measures.
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
“I hereby given undertaking that the data and information given in the application and enclosures are true to the best of my knowledge and belief and I am aware that if any part of the data and information submitted is found to be false or misleading at any stage, the project will be rejected and clearance given, if any to the project will be revoked at our risk and cost.
Date: /2015 Place: Navsari Signature of the applicant With Name and Full Address
Mr.
M/s. Sagar Veneer Industries
Block no. 1781, 1782 P‐3, Vansda Road, Nr. Bhavin Construction, Village: Alipore, Post: Bamanvel, Taluka: Chikhli, District: Navsari, Gujarat..
Note:
1. The projects involving clearance under coastal regulation zone notification, 1991 shall submit with the application a C.R.Z map duly demarcated by one of the authorized agencies, showing the project activities, w.r.t C.R.Z and the recommendations of the state coastal zone management authority. Simultaneous action shall also be taken to obtain the requisite clearance under the provisions of the C.R.Z Notification, 1991 for the activities to be located in the CRZ.
2. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit the map duly authenticated by Chief Wildlife Warden showing these features vis‐à‐vis the project location and the recommendations or comments of the chief wildlife warden thereon”
3. All correspondence with the Ministry of Environment & Forests including submission of application for TOR/Environmental Clearance, subsequent clarifications, as may be required from time to time, participation in the EAC Meeting on behalf of the project proponent shall be made by the authorized signatory only. The authorized signatory should also submit a document in support of his claim of being an authorized signatory for the specific project.”
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
ANNEXURE – 1 KEY PLAN
Proposed project site M/s. Sagar Veneer Industries
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
Google image of project site
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
ANNEXURE – 2 PLANT LAY‐OUT
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
ANNEXURE – 3
EXISTING MANUFACTURING PROCESS OF PLYWOOD, FLUSH DOOR & BLOCK BOARD
PLYWOOD:
The main ingredients for manufacturing superfine quality of durable plywood are core and face. Face is placed on the core and the same is pressed by hot press machine under high temperature. Depending upon different size of plywood to be prepared, different size of core is used. In this process resin is used as bonding factor to stick the two layers: core & face.
The next & the last process are of cutting and finishing of plywood.
FLUSH DOORS / BLOCK BOARDS:
The main ingredients for manufacturing superfine quality of durable Flush doors / Block boards are core, wood and face. The first step is preparation of wooden frames from wood. Then core & face are placed on frames and the same is pressed by hot press machine under high temperature. In this process resin is used as bonding factor to stick the two layers : core & face.
The next & the last process are of cutting and finishing of plywood.
NOTE: Resin is procured from the outside agencies for the existing plant.
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
PROPOSED MANUFACTURING PROCESS OF RESIN
1. Phenol Formaldehyde Resin:
Manufacturing Process First all raw materials like phenol, formaldehyde & caustic will be added into closed vessel. Stirring & heating will be done upto 60 C. After 60C stop heating. Reflux is done for 30 minutes upto 98 C. Vacuum distillation will be started. Cooling down to 40 C. Phenol Formaldehyde Resin will be ready for captive consumption & as well as sale purpose.
Reaction Chemistry
OH OH
CH2OH
+ HCHO Fast
Phenol Formaldehyde Phenol Formaldehyde Resin
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
Process Flow Diagram
Phenol Limped Reaction Formaldehyde Vessel Caustic Flakes
Stirring and heating up to 60 C
Reflux for 30 Minutes
Vacuum Distillation
Product: Phenol Formaldehyde Resin
(2) Melamine Urea Formaldehyde Resin:
First of all Melamine, T. G. Urea & Formaldehyde will be added in the Reaction
vessel.
pH will be adjusted to neutral by homogeneous mixing.
Stir for 1 hr. & also maintain temperature between 70 oC to 80 oC.
Water will be circulated & temperature should be maintained at 40 oC.
Product Melamine Urea Formaldehyde Resin will be ready for captive consumption
as well as sale purpose.
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
Reaction Chemistry:
Process Flow Diagram
Melamine Formaldehyde Reaction Vessel T. G. Urea
pH will be adjusted to Neutral
Stirring for 1 Hr. and Heating up to 70C to 80
Cooling down to 40C
Product: Melamine Urea Formaldehyde Resin
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
(3) Urea Formaldehyde Resin: First all the raw materials Urea & Formaldehyde will be added in Limped reaction vessel. pH will be adjusted to pH 9.0 by adding acetic acid. Stirring & heating will be done upto 95 C for 50 Minutes. Heating will be continued until tolerance (10:40) is achieved.
pH will be adjusted to 9 by adding Caustic.
Cooling down to room temperature. Urea Formaldehyde Resin will be ready for use in captive consumption & as well as sale purpose.
Urea Formaldehyde Resin
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
Process Flow Chart
Urea Limped Reaction Formaldehyde Vessel
Acetic Acid pH adjusted to 9
Stirring and Heating up to 95C for 50
Caustic pH adjusted to 9
Cooling
Product: Urea Formaldeh yde Resin
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
ANNEXURE – 4
DETAILS OF SOLID WASTE
Total Quantity Sr. Existing Proposed Mode of Description Category after No. Quantity Quantity Disposal proposed Expansion ETP Sludge Collection, + 300 300 1 34.3 ‐‐‐‐ storage and Evaporation Kg/Month Kg/Month Disposal at TSDF Site Residue Collection, storage and 2 2 used within 2 Used Oil 5.1 ‐‐‐ premises as a Kg/Month Kg/Month lubricant / sold to registered recycler. Collection, 0.7 65 3 Discarded 33.3 65.7 Kg storage & sell to Plastic bags Kg/Month Kg /Month. /Month authorized vendor
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
ANNEXURE – 5
DETAILS OF EFFLUENT TREATMENT PLANT
To Atmosphere
Port Hole
Water from Floor washing Evaporator ZERO DISCHARGE
Nutch Filter Sludge to be Collection cum sent to TSDF Neutralization site Tank
ETP PROCESS:
Total 0.3 KLD effluent to be generated from Floor washing & cooling activities. It will be collected and chemically treated in Collection cum Neutralization Tank. Effluent will be then taken to Nutch Filter for sludge separation. Separated dried sludge will be collected, stored and disposed of at approved TSDF site. Filtrate water from Nutch Filter will be taken in the Evaporator. Here, effluent will be evaporated at controlled temperature of 110 to 120 C and vapor will be released from vent 3 “ diameter and 6 m height stack to atmosphere.
ETP UNIT DETAILS
Name of the units Volume (L) No. of Unit Collection Tank 500 1 Nutch Filter 200 2 Evaporator 50 L/hr. 1
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
ANNEXURE – 6
EXISTING WATER BALANCE DIAGRAM
Source of Water Supply: Bore well
TOTAL Raw Water consumption 3.55 KL/Day
Domestic 3.5 KL/D Industrial 0.05 KL/D
Sewage 3.0 KL/D Nil
Soak Pit Via Septic Tank
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
PROPOSED WATER BALANCE DIAGRAM AFTER EXPANSION
Source of Water Supply: Bore well
Total Raw Water consumption 14.5 KL/Day
Domestic 3.65 KL/D Gardening 8.6 KL/D Industrial 2.25 KL/D
Sewage 3.4 KL/D
Washing Cooling 0.2 KL/D 2.05 KL/D Soak Pit via Septic Tank
0.2 KL/D 0.1 KL/D
ETP followed by Evaporation 0.3 KL/D
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Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
ANNEXURE – 7
DETAILS OF EXISTING FLUE GAS STACK
Sr. Stack Height Fuel APC Expected GPCB No. attached to of the consumption System Pollutant Limit stack In meter Thermic Fluid Multi Wood waste : SPM As per Heater 30 Cyclone 1 1 SO GPCB (4,00,000 Dust 2 MT/Day NOx Norms Kcal/hr) Collector
DETAILS OF FLUE GAS STACK AFTER PROPOSED EXPANSION
Sr. Stack Height Fuel APC Expected GPCB No. attached to of the System Pollutant Limit stack In meter 1 Thermic Wood Multi Fluid Heater waste Cyclone (Existing) : 1MT/Day Dust (4,00,000 Collector 30 Kcal/hr) Bag Filter
2 Thermic Wood Multi (Common) SPM As per
Fluid Heater waste / Cyclone SO2 GPCB (Proposed) Briquettes Dust NOx Norms (4,00,000 : 1MT/Day Collector Kcal/hr) 3 D.G. Set 6 HSD : N.A. (65 KVA) 11 L/Hr
Form‐1 for Environmental Clearance 27
Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
ANNEXURE – 8
LIST OF PRODUCTS
Sr. Quantity Total quantity after Name of Product Quantity (Existing) No. (Proposed) proposed expansion
1 Plywood 1,15,000 M2/Month ‐‐‐‐‐‐‐ 1,15,000 M2/Month
2 Flush door 25,000 M2/Month ‐‐‐‐‐‐‐ 25,000 M2/Month
3 Block Board 25,000 M2/Month ‐‐‐‐‐‐‐ 25,000 M2/Month
Phenol Formaldehyde 20 4 ‐‐‐‐‐‐‐ 20 MT/MONTH Resin MT/MONTH
Melamine Urea 70 5 ‐‐‐‐‐‐‐ 70 MT/MONTH Formaldehyde Resin MT/MONTH
Urea Formaldehyde 50 6 ‐‐‐‐‐‐‐ 50 MT/MONTH Resin MT/MONTH
LIST OF EXISTING RAW MATERIALS
Sr. No. Name of the product Name of Raw Materials Quantity Face Veneer 2,00,000 M2 /M Plywood, Core Veneer 8,00,000 M2/M 1 Flush door , Block Board Resin 15 MT/M Wood 1900 M3/M
NOTE: Resin is procured from the outside agencies for the existing plant.
Form‐1 for Environmental Clearance 28
Expansion of New Product ‐Resin Manufacturing Sagar Veneer Industries, Chikhli, Navsari
LIST OF PROPOSED RAW MATERIALS REQUIRED FOR RESIN PRODUCTION
Sr. No. Name of the Name of Raw Quantity in product Materials MT/Month 1 Phenol Phenol 8 Formaldehyde Formaldehyde (37%) 12 Resin Caustic 0.1 2 Melamine Urea Formaldehyde (37%) 42 Formaldehyde Melamine 14 Resin Urea 14 3 Urea Formaldehyde Urea 20 Resin Formaldehyde (37%) 30 Caustic 0.25 Acetic acid 0.25
Form‐1 for Environmental Clearance 29