annexure no. description
TRANSCRIPT
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
FORM-1, ENVIRONMENT CLEARANCE Page - 17 -
ANNEXURES
Annexure No. Description
1 Google image showing proposed project site
2 Plant Lay-Out
3 Manufacturing process details
4 Details of hazardous waste management
5 Details of Effluent Treatment Plant
6 Water Balance Diagram
7 Details of flue gas stacks
8 List of Products and Raw Materials
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
FORM-1, ENVIRONMENT CLEARANCE Page - 18 -
ANNEXURE-1
Google Image showing location of Proposed Project Site
A 23° 1' 59.38" N
70° 48' 26.33" E
B 23° 1' 58.87" N
70° 48' 24.11" E
C
23° 2' 4.95" N
70° 48' 22.44" E
D 22° 2' 4.24" N
70° 48' 25.11" E
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
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Google Image showing Project site and salient features:
Near Village-Sokhada-0.96 KM
Godhadhari
River-4.88 KM Machchhu
River-4.62KM
NH-27,
0.30 KM
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
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Google Image showing surrounding area within 5 Km radius from Project Site:
Google Image showing surrounding area within 10 Km radius from Project Site:
10 Km Circle
5.0 Km Circle
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
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ANNEXURE-2: Plant Lay-out
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
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ANNEXURE-3
Manufacturing Process Details
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 up to 60 C. After 60C stop heating.
Reflux is done for 30 minutes up to 98 C.
Vacuum distillation will be started.
Water will be removed from the vessel as per the batch size.
Cooling down to 40 C.
Methanol will be added for dilution purpose.
Phenol Formaldehyde Resin will be ready for use in Laminate sheets as well as sale
purpose.
Reaction Chemistry
H – CHO
Fast
OH OH
CH2OH
Phenol Phenol Formaldehyde Resin
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
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Process Flow Diagram
Limped Reaction Vessel
Stirring and heating up to 60 C
Reflux for 30 Minutes
Vacuum Distillation
Cooling
Dilution
Product: Phenol Formaldehyde Resin
Phenol Formaldehyde Caustic Flakes
Methanol
Water
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
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2. Melamine Formaldehyde Resin: Manufacturing Process
First all the raw materials melamine & formaldehyde will be added in Limped reaction
vessel.
Stirring & heating will be done up to 95 C for 1 Hr.
Cooling down to 40 C.
Melamine Formaldehyde Resin will be ready for use in Laminate sheets. as well as sale
purpose.
Reaction Chemistry
N
N
N
NH2
NH2 NH2
+ CH2 ON
N
N
N
OH
CH2
OH
CH2
fast
melamine formaldehyde
melamine formaldehyde resin
Process Flow Diagram
Limped Reaction Vessel
Stirring and Heating up to 95C for 1 hr
Cooling down to 40C
Finish Product: Melamine
Formaldehyde Resin
Melamine Formaldehyde
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
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3. Urea Formaldehyde Resin:
Manufacturing Process
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 and sale purpose.
Manufacturing Process
Urea Formaldehyde resin
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
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Process Flow Diagram
Stirring and Heating up to 95C for 50
Minutes
Cooling
Product: Urea Formaldehyde Resin
Limped Reaction Vessel
Urea Formaldehyde
pH adjusted to 9
pH adjusted to 9 Caustic
Acetic Acid
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
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ANNEXURE-4
DETAILS OF SOLID WASTE
There will be two types of Solid wastes generated from the project.
(a) Non Hazardous Solid waste. There will be two types of Non hazardous waste generated: (1) Municipal Solid Waste
The Municipal solid waste includes the paper wastes from Office as well as other domestic wastes. Paper wastes would be sold to scrap vendors, while other wastes would be disposed off in a proper manner.
(b) Hazardous Solid waste. The details different Hazardous wastes generated and its disposal is given in the table below.
Sr. No.
Description Category Quantity Mode of Disposal
1 ETP Sludge +
Evaporation
residue
34.3 8.5 MT/M Collection, storage and Disposal at Approved TSDF Site
2 Used Oil 5.1 0.004 MT/M Collection, storage and used within premises as a lubricant / sold to registered recycler.
3 Discarded Plastic
bags / barrels 33.3 0.32 MT/M
Collection, storage & sell to authorized vendor
4 Edge Cutting
Waste 23.1 0.6 MT/M
Collection, storage & disposal at common Incineration facility
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
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ANNEXURE-5
Details of Effluent Treatment Plants
Effluent Treatment Plant:
Wastewater will be generated from process, Boiler & cooling tower blow-down,
Washing & R.O. reject.
Wastewater (washing and process) will be collected in collection tank.
Then wastewater will be given Photo Fenton treatment.
After completion of chemical treatment, wastewater will be taken to Filter
Press/Nutch Filter for chemical sludge separation.
Dried sludge will be stored in bags and ultimately disposed off at TSDF site.
Chemically treated water, Boiler blow down, RO reject, cooling tower blow down will
be collected in treated water collection tank and then will be evaporated in Steam
based evaporation system followed by condenser.
Bottom sludge from evaporator will be handled with ETP sludge.
Condensate water from condenser will be reused in cooling tower.
Thus, unit will maintain Zero Effluent Discharge.
Condensate To be used For Cooling
Activities
ZERO DISCHARGE
Collection Tank
Photo Fenton Treatment
Tank
MOC: RCC
Nutch Filter
/Filter Press Treated water
Collection Tank
Steam Based
Evaporation System with Condenser
ETP Sludge to be Sent to TSDF site
Effluent from Washing and
Proces
Effluent from R O
rejected, Boiler blow
down and cooling tower blow down
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
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EFFLUENT TREATMENT PLANT DETAILS
Name of the units Volume (m3) No. of
Unit
Collection cum Neutralization Tank 25.0 1
Photo Fenton Treatment Tank 20.0 1
Nutch Filter / Filter press 10.0 2
Treated Water Collection Tank 25.0 1
Steam based Evaporator followed by
Condenser
1.5 m3/hr 1
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
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ANNEXURE-6
Water balance diagram
Source of Water Supply: Bore well
Total: 53.3 KL/day
Domestic
4.7 KL/day
Gardening
7 KL/day
Industrial
41.6 KL/day
4.4 KL/day Goes to soak pit through
septic tank
Boiler
9.6 KL/day
Cooling
29 KL/day
Effluent Treatment Plant followed by Evaporated condenser system
17.0 KL/day
ZERO DESCHARGE
RO Plant
31.4 KL/day
Process
Nil
Floor Washing
0.2 KL/day
Permeate
23.6
KL/day
Reject
7.8 KL/day
5 KL/day
0.2 KL/day
3 KL/day 1 KL/day
Scrubber
10 KL/D
Scrubber
water send to
authorized
recycler
Recycled
15 KL/day
14
KL/day
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
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ANNEXURE-7
Details of Flue Gas Stacks
Sr. No.
Stack attached to Stack Height
(m)
Fuel Requirement
APC System
Expected Pollutant
1
Steam Boiler (4 TPH)
30
Coal / Briquettes – 10
MT/Day
Cyclone separator
followed by Bag Filter
SPM 150 mg/Nm3
SO2 100 ppm
NOX 50 ppm
Thermic Fluid Heater (15 Lac Kcal/hr)
2 D.G. set (300 KVA)
6.7 HSD 50 L/Hr
Adequate stack height
MANUFACTURING OF SYNTHETIC ORGANIC RESINS, ABHAY LAMINATE LLP.
FORM-1, ENVIRONMENT CLEARANCE Page - 32 -
ANNEXURE-8
List of Products for Resin Plant
Sr.
No. Name of Product Quantity (MT/Month)
1 Phenol Formaldehyde Resin 400
2 Melamine Formaldehyde Resin 150
3 Urea Formaldehyde Resin 300
Note: Resin will be used for captive consumption (Laminates Sheets: 1, 50,000 NO. / Month) as
well as sell purpose.
LIST OF RAW MATERIALS REQUIRED FOR RESIN PRODUCTION
Sr.
No.
Name of the product Name of Raw Materials Quantity in
MT/Month
1 Phenol Formaldehyde
Resin
Phenol 377
Formaldehyde (37%) 149
Methanol 75
Caustic 2.0
2 Melamine Formaldehyde
Resin
Formaldehyde (37%) 90
Melamine 60
3 Urea Formaldehyde
Resin
Urea 120
Formaldehyde (37%) 180
Acetic Acid 1.5
Caustic 1.5