PFR of NN Polymers PRE FEASIBILITY REPORT FOR OBTAINING ENVIRONMENTAL CLEARANCE For the Proposed Resins, Formaldehyde (37%) and Laminated Sheets Manufacturing Unit of M/s. NN POLYMERS Survey No. : 1458, Village: Panshina, Taluka: Limbdi, District: Surendranagar, Gujarat. Contact No.: 9824988993 email: [email protected] Prepared By: T. R. ASSOCIATES C‐605/A, Ganesh Meridian, Opp. Kargil Petrol Pump, S. G. Highway, Ahmedabad Contact No.: 98253 71099 email: [email protected]; [email protected] November 2016 Page 1 of 23 PFR of NN Polymers 1. Introduction M/s. NN Polymers is a proprietorship firm having it registered office at 7, Shree Complex, 1, Shree Nagar Society, Stadium Road, Ahmedabad – 380014. We are now proposing to set up a medium scale industrial unit at Survey No.: 1458, Village: Panshina, Taluka: Limbdi, District: Surendranagar, Gujarat. 2. Project Proponent and their back ground Company is promoted by its proprietor namely Ms. Tanya Naman Saraf having enough experience in field of manufacturing resins as well laminated sheets. 3. Brief description of nature of the project: M/s. NN Polymers is proposing to manufacture Formaldehyde (37%), Phenol Formaldehyde Resin, Melamine Formaldehyde Resin & Urea Formaldehyde Resin as well as Laminated Sheets at Survey No.: 1458, Village: Panshina, Taluka: Limbdi, District: Surendranagar, Gujarat. Proposed products will be used for captive consumption as well as for sell purpose. Proposed production details are given below: Sr. Product Capacity No. 1. Formaldehyde (37%) 3000 MT/Month 2. Melamine Formaldehyde Resin 300 MT/Month 3. Phenol Formaldehyde Resin 300 MT/Month 4. Urea Formaldehyde Resin 300 MT/Month 5. Laminated Sheets 1,50,000 Nos./Month The proposed final product Laminated Sheets does not attract Environmental Clearance (EC) from Ministry of Environment, Forest & Climate Change (MoEFCC), New Delhi. However, the proposed products like Formaldehyde (37%), 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, Forest & Climate Change, New Delhi. M/s. T. R. Associates has been appointed to carry out EIA/EMP studies for obtaining Environmental Clearance. Page 2 of 23 PFR of NN Polymers The total land area of company is 17,705 m2 out of which 5,345 m2 (30% of total land) area will be used for greenbelt development. The estimated cost of the proposed project is 11 Crores. Total budget allocation towards Environmental Management Facilities will be Rs. 75 Lakhs. Total 90 persons will be employed including skilled persons, unskilled persons and office staff. Need for the project and its importance to the country and or region: Formaldehyde (37%) is used as raw material for resins and adhesive manufacturing. Resins are used predominantly in the wood based product manufacturing industry as adhesives. Growth of the resin market 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 manufacture Laminated Sheets. These sheets have good market demand to develop the home and office for furniture. Demand-Supply Gap: The average production of laminated sheets 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 laminated sheets market became a pressure driven market. 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 Page 3 of 23 PFR of NN Polymers industrialist must understand the fact that its no more a regional shift, it is a global shift. Indian technology should be upgraded and 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 market of Formaldehyde (37%) and Resins is local market. Resins are intermediate products for manufacturing of Laminated Sheets. Formaldehyde (37%) and resins are quite expensive for export. So we have only local market for sale. Employment Generation (Direct and Indirect) due to the project: This project will provide direct employment to 90 persons whereas it will provide employment to many others indirectly. Plywood and Laminated sheet manufacturing industries provide employment to large number of people. 4. Project Description (i) Type of project including interlinked and interdependent projects: Formaldehyde (37%) is mainly consumed for production of resin products. Resins including P.F. resin, M.F. resin & U.F. resin are used in production of laminated sheets and plywood. So plywood industries, laminated sheets industries will be interdependent on resin industries. (ii) Location Proposed project is to be located at Survey No. : 1458, Village: Panshina, Taluka: Limbdi, District: Surendranagar, Gujarat. Geographic Coordinates Latitude: 22°34'9.72"N Longitude: 71°59'38.10"E Google image showing proposed project site is given below; Page 4 of 23 PFR of NN Polymers Google Image of Proposed Location: 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. : 1458, Village: Panshina, Taluka: Limbdi, District: Surendranagar, Gujarat. 2 GPS Coordinates Latitude: 22°34'9.72"N Longitude: 71°59'38.10"E 3 Temperature Range 22˚C to 43˚C (average) 4 Mean Sea Level 14 m 5 Annual Rain Fall 588 mm (average) 6 Nearest Railway Station Limbdi railway station– 21 km in West direction 7 Nearest Airport Ahmedabad airport – 85 km in NE direction 8 Nearest Town Limbdi – 18 km in West direction 9 Nearest Village Kanpara – 0.65 km in SW direction Panshina - 3 km in SW direction 10 Nearest National Highway NH 8A – 0.19 km in North direction Page 5 of 23 PFR of NN Polymers Sr. No. Important Features Description 11 Nearest River/Water body Bhogavo River - 2.2 km, SW Narmada Canal – 1.2 km, S Kanpara Village Pond – 0.85 km, SW Panshina Village Pond – 3.4 km, SW 12 National Parks / Sanctuary None within 10 km radius. (iii) Alternative Sites considered No other sites were selected. (iv) Size or magnitude of operation List of Proposed Products Sr. No. Product Capacity 1. Formaldehyde (37%) 3000 MT/Month 2. Melamine Formaldehyde Resin 300 MT/Month 3. Phenol Formaldehyde Resin 300 MT/Month 4. Urea Formaldehyde Resin 300 MT/Month 5. Laminated Sheets 1,50,000 Nos./Month Note: Formaldehyde (37%) and Resins will be used for captive consumption as well as sell purpose. Page 6 of 23 PFR of NN Polymers (v) Project description with process details 1. Melamine Formaldehyde Resin Manufacturing Process The Formaldehyde (37%) is charged into reaction vessel and raises its pH up to 8.5 – 9.0 by adding NaOH solution. Then Melamine is charged into vessel thoroughly to maintain the pH up to 8.5 – 9.0. Heat is supplied and raised temperature up to 82 °C. Maintain 82°C at pH 8.5 – 9.0 for 90 minutes till the precipitation is observed. Check the flow time in hot condition with B4 cup till it around 14.5 sec. Then take reaction at pH 9.0 by adding NaOH solution. The mixture is cooled at 60 °C and cooling continued up to 40 °C by circulating cold water. Finally, check viscosity, tolerance, pH, turbidity etc. to obtain desired product property. Process Flow Diagram Melamine + Reaction Vessel Formaldehyde (37%) + Caustic Soda Stirring and Heating up to 82C for 90 minutes Cooling down to 40C Finished Product Melamine Formaldehyde Resin Page 7 of 23 PFR of NN Polymers 2. Phenol Formaldehyde Resin Manufacturing Process Take required quantity of Phenol and Formaldehyde (37%) in the reaction vessel and start steam heating until the temperature reaches at 58°C to 60°C. Temperature will increase up to 90 °C. Once the temperature reaches up to 90 °C then cut the steam supply. Reflux process will be start at this point to achieve required water tolerance. After achieving required water tolerance, start cooling to decrease temperature up to 60 °C.