PRE-FEASIBILITY REPORT M/S APCOLITE POLYMERS PVT ...

M/s Apcolite Polymers Pvt. Ltd.

Formaldehyde Manufacturing Unit with production capacity 130 TPD at Village Ghespur, Radaur, District

Yamuna Nagar, Haryana

PRE FEASIBILITY REPORT

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PRE-FEASIBILITY REPORT

FOR

FORMALDEHYDE MANUFACTURING UNIT

WITH PRODUCTION CAPACITY 130 TPD

BY

M/S APCOLITE POLYMERS PVT. LTD.

AT

VILLAGE GHESPUR, RADAUR,

DISTRICT YAMUNA NAGAR,

HARYANA

Annexure 3





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Table of Contents

S.no. Chapters Page no

1 Executive Summary 3-4

2 Introduction of the Project / Background Information 5-6

3 Project Description 7-12

4 Site Analysis 13-15

5 Planning Brief 16

6 Existing Infrastructure 17

7 Rehabilitation & Resettlement Plan 18

9 Analysis of Proposal (Final Recommendation) 19

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1. EXECUTIVE SUMMARY

1.1 BRIEF OF PROJECT

M/s. Apcolite Polymers Pvt. Ltd. is a proprietor firm started with the objective to get

involved in the business of manufacturing & trading in organic chemicals viz.

Formaldehyde. Land Documents of the firm is attached as Annexure 1.

The unit is established for manufacturing of 130 Ton per Day Capacity of Formaldehyde

based on Consent to Establish (CTE) granted by Haryana State Pollution Control Board vide

Letter HSPCB/YMN/2242 dated 31.03.2010. (attached as Annexure 2). The plant came in

operation after securing Consent to Operate (CTO) vide HSPCB/YMN/DLC/2011/4027

dated 16.01.2012 (attached as Annexure 3) and renewable of CTO vide Letter

HSPCB/Consent/:2846616YAMCTO2630 dated 13.03.2016 which is valid till 31.03.2026

(attached as Annexure 4).

Applicability of EIA Notification 2006 and Implementation

As per EIA Notification 2006 and its subsequent amendments the project falls under

schedule 5 (f) “Synthetic Organic chemical Project”. This project was established after EIA

Notification 2006 without securing Environmental Clearance; hence the project has violated

the conditions of said Notification. Considering this, we are applying the proposal under

EAC (Violation).

1.2 Location

Project is established on 1.10 hectares land falling under Khasra No.- 1//18/3, 24,25 and is

situated at Village- Ghespur, Radaur, District Yamuna Nagar, Haryana. The land is already

under the possession of project proponent. The project site falls under uncontrolled area,

hence no CLU is required. Copy of NOC from Department of Town & Country Planning is

attached as Annexure 5.

The geographical location of the plant is Latitude- 30°1'9.39"N Longitude- 77°7'53.65"E.

Nearest Highway is SH-6 at 50 m distance from the project site in West direction.

Nearest town is Radaur at a distance of 2.05 km in NE direction.

Nearest railway station is Yamuna Nagar Railway Station at a distance of approx.

~18.5 Kms in NE direction.

Nearest Airport is Sarsawa Airport at a distance of 28.08 Kms (approx.) in E 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 are nearby industrial

areas having plywood and sunmica/decorative laminate industry.

1.3 Project Proponent

Apcolite Polymers Pvt. Ltd. is a Non-govt company. Company is registered in Delhi (Delhi)

Registrar Office. Registered address is C-344, Saraswati Vihar New Delhi 110034. Directors

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of Apcolite Polymers Pvt. Ltd. are Sumeet Pahwa, Jyoti Pahwa.

1.4 Process / Technology

The commercial production of Formaldehyde is manufactured from oxidation-

dehydrogenation using a silver catalyst involving the complete 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.

1.5 Manpower Requirement

About 9 persons have been employed to the industry. Indirect employment has also

generated while development of the project.

1.6 Water requirement

Total water requirement is 50 KLD for which the application is yet to be submitted to CGWB.

1.7 Power Requirement

Maximum power requirement for the plant will be 320 kW. The power is supplied from

UHBVNL (Uttar Haryana Bijli Vitran Nigam Limited)

2 D.G.Sets of capacities 180 KVA and 250 KVA also exist as the backup power supply.

1.8 Raw Material Requirement

The only raw material is Methanol which comes in road tankers from Kandla Port, Gujarat

& stored in underground M.S tanks.

1.9 Capital Cost of the project

The capital cost for the existing project is Rs. 2.25 Crores which include land, building, plant

& machinery.

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2. INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION 2.1 Identification of Project & Project Proponent M/s Apcolite Polymers Pvt. Ltd. is a proprietor firm started with the objective to get

involved in the business of manufacturing & trading in organic chemicals viz.

Formaldehyde.

The unit is established for 130 Ton per Day Capacity of Formaldehyde based on Consent to

Establish (CTE) granted by Haryana State Pollution Control Board vide Letter

HSPCB/YMN/2242 dated 31.03.2010. The plant came in operation after securing Consent to

Operate (CTO) vide HSPCB/YMN/DLC/2011/4027 dated 16.01.2012 and renewable of

CTO vide Letter HSPCB/Consent/:2846616YAMCTO2630 dated 13.03.2016 which is valid

till 31.03.2026.

2.2 Brief description of nature of project As per EIA Notification 2006 and its subsequent amendments the project falls under

schedule 5 (f) “Synthetic Organic chemical Project”. This project was established after EIA

Notification 2006 without securing Environmental Clearance; hence the project has violated

the conditions of said Notification. Considering this, we are applying the proposal under

EAC (Violation).

2.3 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 Apcolite Polymers Pvt. Ltd. has setup a manufacturing unit

of Formaldehyde with the capacity 130 TPD at Village Ghespur, Radaur, District Yamuna

Nagar, Haryana.

2.4 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.

2.5 Imports v/s Indigenous Production

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Company is making its Raw Material/Packing material procurement from the domestic

market in big quantities more than as compared to its Import Purchases.

Since Company is also doing Exports and hence its majority of Export supplies are against

the schemes and benefits allowed/extended by the Hon’ble Ministry of Commerce/

Hon’ble Ministry of Finance of Government of India, to the Exporters, so as to promote the

Export business in India.

Thus, 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 to the

Exporters.

2.6 Domestic/Export 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. Both the Domestic & Export

supplies of the company will indirectly contribute to the growth of our nation.

2.7 Employment Generation (Direct and indirect)

About 9 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.

2.8 Legal Framework under violation

The unit is in operation phase since 2010 without obtaining Environment Clearance

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3. PROJECT DESCRIPTION 3.1 Type of Project including interlinked and interdependent projects, if any

This is a Formaldehyde manufacturing project of 130 TPD Capacity and is purely

independent project and does not interconnect with any other project.

3.2 Location (Map showing general location, specific location, and project boundary

and project site layout) with coordinates

The project is established on 1.10 hectares land falling under Khasra No1/18/3,

24, 25 and is situated at Village Ghespur, Radaur, District Yamuna Nagar, Haryana.

Project site falls in Survey of India Toposheet no. H43R5 & is attached as Figure 1.

Layout plan of the plant is attached as Figure 1 and Figure 2.

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Formaldehyde Manufacturing Unit with production capacity 130 TPD at Village Ghespur, Radaur, District Yamuna

Nagar, Haryana


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Figure 1: Toposheet Map of the plant

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Figure 2: Layout Plan of M/s Apcolite Polymers Pvt. Ltd

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3.3 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 project.

3.4 Size and Magnitude of Operation

M/s Apcolite Polymers Pvt. Ltd. has setup a manufacturing unit of Formaldehyde with the

capacity of production of 130 TPD at Khasra No.- 1//18/3, 24,25 at Village Ghespur,

Radaur, District Yamuna Nagar Haryana. The total project cost is Rs. 2.25 Crores.

3.5 Project description with process details: (a schematic diagram/flowchart layout,

components of the project)

Formaldehyde is the oxidation product of methanol with oxygen in the presence of silver

catalyst. A fixed quantity of methanol and water is introduced into mixing vessel, from

where this mixture is taken into evaporator. Air is also purge introduced into the

evaporator. Temperature of evaporator is maintained at 70 deg cents, which facilitate the

evaporation of mixture. The vapor of mixture is then further heated to 110 deg cents in the

super heater and then introduced in reactor where in presence of silver catalyst, the

oxidation reaction take place at temperature of 650-700deg cents as per following

chemistry.

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.

1. Oxidation of methanol with oxygen present in air

CH3OH + ½ O2 → HCHO + H20 ∆H = -37 Kcal

(32) (16) (30) (18) (one mole of water is formed during reaction)

2. Pyrolysis endothermic reaction

CH3OH → HCHO + H2 ∆H = +20 Kcal

(32) (30) (2)

3. Side reaction – complete combustion producing heat energy

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

Detailed Process

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The Formaldehyde is manufactured as per the following process for the proposed project:

Unit Process:

The basic raw material for the manufacturing of Formaldehyde is Methanol. Controlled

oxidation of methanol forms Formaldehyde as per the following reaction

CH3OH + ½ O2 → HCHO + H20

Silver Granules are used as catalyst in the reactor. The catalyst is exhausted in 3 to 4

month’s time which is regenerated & reused in the process after reactivation.

Unit Operations:

1). Firstly, methanol is subjected to methanol vaporizer, where the compressed air is fed

into the bottom of the methanol vaporizer. The ratio of the methanol and air is maintained

between 35%-45%.

2).This mixture is heated to the reaction temperature with the help of pre-heaters, before

entering into silver catalyst reactor.

3).The catalyst reactor is a fixed bed type filled with silver catalyst. The production stream is

sent to rectification and recovery station. Unreacted methanol is fed back to the process to

methanol vaporizer.

4). Recycled stream contains 15% unreacted methanol, which is fed into methanol vaporizer

as started above.

5). Stripping column is used to separate Formaldehyde. The product is stored in aqueous

form in the storage tank.

Material Balance Material Balance for 100 Ton capacity of Formaldehyde – 37% 2 MolesCH3OH + ½ Mole O2 → 2 Moles HCHO + 1 Mole H20 + 1 Mole H2

(64) (16) (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 130 Ton of Formaldehyde = 39.92/100 x 130,000 = 51896 kg Process Waste: There is no solid and liquid waste generated through the manufacturing process of

Formaldehyde.

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Hazardous Waste: The following hazardous waste identified for the proposed project. 19.2 – Spent catalyst. 33.1 – Empty barrels/containers/liners contaminated with Hazardous chemicals/wastes. 33.3 – Discarded containers/barrels /drums Schedule 4 –Used oil from DG set will be sold to the authorized recyclers as per HSPCB.

Domestic Waste:

Approximately 1.0 KLD of domestic waste will be generated and will be treated in Septic Tank.

Air Emissions and Control:

There are no significant process emissions generated. The only source of Air emissions is

through D.G sets and Boiler of 1 TPH Capacity which is based on HSD.

To control the air emissions from D.G. Set, stack height of 6 m is provided above the roof

level of D.G. Set.

3.6 Raw material required along with estimated quantity, likely source,

marketing area of final products, mode of transport of raw material and Finished

products.

The Raw Material requirement for production of Formaldehyde is Methanol (60 TPD) along

with a catalyst, Silver Granules. 3.7 Resources optimization/recycling and reuse envisaged in the project, if any, should

be briefly outlined.

M/s Apcolite Polymers Pvt. Ltd. will optimize utilization of resources including Land,

Fuel, Water and Electricity.

3.8 Availability of Water its source, Energy/Power requirement and source Water Requirement

Total water requirement for Project will be 50 KLD for which the Ground water abstraction

application will be filed to CGWB.

Power Requirement


UHBVNL (Uttar Haryana Bijli Vitran Nigam Limited)

2 D.G.set of capacity 180 KVA and 250 KVA are also installed as the backup power supply.

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4. SITE ANALYSIS 4.1 Connectivity

SH-6 50 m in West direction. Nearest town Radaur is at a distance of 2.05 km in NE

direction. Yamuna Nagar Railway Station is at a distance of approx. ~18.5 Kms in NE

direction. Sarsawa Airport is at a distance of 28.08 Kms (approx.) in E direction.

4.2 Land form, Land Use, Land Ownership

Total area of the project is 1.10 Hectares. The land is already under the possession on

project proponent. 4.3 Topography (along with map)

The site has been observed to be almost flat level in topography with an elevation of 874 ft.

4.4 Existing Infrastructure

The manufacturing unit for formaldehyde is already established based on Consent to

Establish (CTE) granted by Haryana State Pollution Control Board vide Letter

HSPCB/YMN/2242 dated 31.03.2010, Consent to Operate (CTO) granted vide

HSPCB/YMN/DLC/2011/4027 dated 16.01.2012 and renewable of CTO on 13.03.2016

which is valid till 31.03.2026.

4.5 Soil classification

The district area is occupied by Indo-Gangetic alluvim. The soils are non-calcareous and

sandy loam on the surface, and loam to clayey loam at depth, and placed under the

classification of soil as Udipsamments/Udorthents. The area is occupied by Indo- Gangetic

alluvium soil. Alluvium plains which forms a part of large Indo- Gangetic Quaternary basin

comprises of 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 Yamuna Nagar district is solemnized tropical arid brown soils. High potassium, medium

phosphorus and low nitrogen occur in soil of Yamuna Nagar. The soils of the district are

sandy loam in texture generally. It may vary with the site location.

4.6 Climatic Data from secondary sources

The climate of Yamuna Nagar district can be classified as subtropical monsoon, mild & dry

winter, hot summer and sub-humid, that is mainly dry with very hot summer and cold

winter except during monsoon season when moist air of oceanic origin penetrate into the

district. The hot weather season starts from mid March to last week of the June followed by

the south west monsoon which lasts up to September. The transition period from September

to November forms the post monsoon season. The winter season starts late in November and

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remains up to first week of March.

Yamuna Nagar , Haryana has a sub-tropical continental monsoon climate characterized by a

seasonal rhythm: hot and sub-humid summers, mild & dry winters, unreliable rainfall and

great variation in temperature (7°C to 40.5 °C). In winter, sometimes frost also occurs during

December and January. The average annual rainfall is recorded to be 592 mm. The city

also receives occasional winter rains from the west.

Average temperature Summer: The temperature in summer may rise to a maximum of

40.8°C. Temperatures generally remain between 30°C to 40°C.

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

varies between (max) 22°C to 30°C and (min) 6.8°C 7°C to 15°C.

Rainfall: The rainfall in the zone is caused by South-West monsoon. It starts in the month of

June and extends up to the month of September. During this period the monsoon rainfall

contribute about 81% of the total annual rainfall. The average annual rainfall is 560 mm. The

annual number of rainy days on average is about 44 in a year.

Humidity: In summer months of May and June which is the driest part of the year, the

afternoon humidity comes down to 40% to 45% while the relative humidity during

monsoon months goes up to 55%.

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: Summary of climate condition

Maximum temperature 40-42°C in the month of May

Minimum temperature 8-12°C in the month of January

Relative humidity 70-72% (Max.)

Rainfall Annual – 450-458 mm

Wind Speed 5.0 m/sec.

Predominant Wind Direction From South to West

Seismic data Zone – IV as per IS-1893 (part-I)

4.7 Biodiversity

Flora: Tree species which are most commonly found in the area are Azadirachta indica

(Neem) Acacia (Babool), Ficus religiosa (Peepal), Emblica officinalis (Amla),

Dalbergia sissoo (Shishum), Mangifera indica (Aam), Prosopis juliflora (Vilayati babool)

etc.

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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 & Maize. The Sugarcane &

Sunflower crops are also cultivated in the district to some extent.

4.8 Socio-Economic Environment

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 Village Ghespur, Radaur, District Yamuna Nagar, Haryana

will have 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, Yamuna Nagar (Haryana) had a

population of 12.14 lakhs out of which males constitute 6.46 lakhs of the population and

females constitutes 5.67 lakhs.

Yamuna Nagar (Haryana) has an average literacy rate of 77.99 %, male literates are 8.32

lakhs, and female literates are 3.57 lakhs.

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5. PLANNING BRIEF 5.1 Planning concept As per EIA Notification 2006 and its subsequent amendments the project falls under

schedule 5 (f) “Synthetic Organic chemical Project” and EC was required to secured before

starting construction work. This project was developed after EIA Notification 2006 without

securing Environmental Clearance; hence the project has violated the conditions of said

Notification. Now in this situation; the Environmental Clearance will be granted from

Expert Appraisal Committee for the proposal involving violation of EIA Notification, 2006. 5.2 Employment & Population projection About 9 persons have been employed to ensure smooth working of the plant. Direct and

Indirect employment will also be generated from the project during operation. The

summary of direct employment estimate for the project is given in the table below: Table 1: Manpower Requirement

S.no. Description Manpower

1 Plant Manager 1

2 Plant Supervisor 1

3 Chemist 1

4 Environmental Health & Safety Supervisor 1

5 Utility/Maintenance 2

6 Electrician 1

7 Store Keeper 1

8 Admin 1

Total 9

5.3 Land Use Planning The project is set up in an area of 1.10 ha. The land use break up is as follows-

5.4 Amenities/Facilities Facilities like canteen, rest rooms and recreation facilities will be provided in the

plant. No other additional facilities are present.

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6. EXISTING INFRASTRUCTURE 6.1 Total Area Total plant area of M/s Apcolite Polymers Pvt. Ltd. is 1.10 Hectare which include Process

area, Admin Building, Storage area, Road, Open Space, Greenbelt area etc.

6.2 Residential Area Ghespur village is located at approx. 1 kms from the plant.

6.3 Green Belt

Total land area of the project is 1.10 hectares. The greenbelt will also be developed at the site

in 0.36 hectares area covering 33% of total area. Green belt will be developed as per

MoEFCC and CPCB guideline. Further, unpaved areas, within the plant boundary will be

provided with grass cover which will also improve the plant aesthetics.

6.4 Connectivity

The geographical location of the plant is:

SH-6 at 50m in West direction. Nearest town Radaur is at a distance of 2.05 km in NE

direction. Yamuna Nagar Railway Station is at a distance of approx. ~18.5 Kms in NE

direction. Sarsawa Airport, is at a distance of 28.08 Kms (approx.) in E direction.

6.5 Water Requirement

Total water requirement for project will be 50 KLD which is sourced from ground water for

which the Ground water abstraction application will be filed to CGWB.

6.6 Water Treatment System

The industry has provided septic tank for disposal of domestic effluent of 1.0 KLD. There is

no discharge of trade effluent outside the factory premises and thus it has maintain zero

discharge & complying the consent conditions. Separate drainage line has been developed

for storm water and waste water.

6.7 Power requirement & Supply / Source


UHBVNL (Uttar Haryana Bijli Vitran Nigam Limited).

2 D.G. Sets of capacity 180 KVA and 250 KVA are also installed 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 are envisaged for

this project.

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8. ANALYSIS OF PROPOSAL

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 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. 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. Both the Domestic & Export

supplies of the company will indirectly contribute to the growth of our nation.

So considering above, M/s Apcolite Polymers Pvt. Ltd. has setup a manufacturing unit of

Formaldehyde with the capacity of production of 130 TPD at Village Village Ghespur,

Radaur, District Yamuna Nagar, Haryana.

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Annexure 3

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