Pre-Feasibility Report for Synthetic Resin Manufacturing...

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Pre-Feasibility Report

for

Synthetic Resin

Manufacturing Unit

at

Gandhidham, Kandla, Kutch,

Gujarat

Prepared for

Century Plywoods (I) Ltd.

Prepared By

SGS India Pvt. Ltd.

November 2014

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TABLE OF CONTENTS

Chapter 1.0:-INTRODUCTION .............................................................................................. 4

1.1 Project Background ................................................................................................... 4

1.2 Identification of Project and Project Proponent ...................................................... 4

1.3 Brief Description of the Project ................................................................................ 6

1.4 Need of the Project & Its Importance to the Country and or Region ...................... 6

1.5 Demand & Supply ...................................................................................................... 8

1.6 Employment Generation (Direct And Indirect) Due To The Project ........................ 9

Chapter 2.0: PROJECT DESCRIPTION ...............................................................................10

2.1 Type of Project ..........................................................................................................10

2.2 Location of the Project .............................................................................................10

2.3 Details of Alternate Sites ..........................................................................................11

2.4 Size or Magnitude of Operation ...............................................................................12

2.5 Process Description .................................................................................................12

2.5.1 Manufacturing of Phenol Formaldehyde (PF) resin ........................................ 12

2.5.2 Manufacturing of Urea Formaldehyde (UF) resin ........................................... 16

2.5.3 Manufacturing of Melamine Formaldehyde resin ............................................ 18

2.5.4 Manufacturing of MUF resin ............................................................................... 22

2.6 Raw Materials Details ...............................................................................................23

2.7 Equipments Details ...................................................................................................24

2.8 Resource Requirements ...........................................................................................25

2.9 Pollution Control Measures .....................................................................................26

3.1 Connectivity ..............................................................................................................28

3.2 Land Form, Land Use and Land Ownership ...........................................................28

3.3 Topography ...............................................................................................................28

3.4 Drainage: ...................................................................................................................28

3.5 Existing Infrastructure ..............................................................................................28

3.6 Soil Classification .....................................................................................................28

3.7 Climatic Data from Secondary Sources ..................................................................29

3.8 Social Infrastructure Available .................................................................................29

CHAPTER 4.0:-REHABILITATION & RESETTLEMENT (R&R) PLAN ................................30

CHAPTER 5.0:-PROJECT SCHEDULE & COST ESTIMATES ............................................31

5.1 Project Schedule .......................................................................................................31

5.1.1 Planning of Activities ............................................................................................31

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5.1.2 Pre Project Activities .............................................................................................31

5.1.3 Project Activities (Implementation Stage) ...........................................................31

5.1.4 Statutory Clearances .............................................................................................31

5.1.5 Project Schedule ...................................................................................................31

5.1.6 Strategies for Timely Execution of the Project ....................................................32

5.2 Project Cost ...............................................................................................................32

Annexure 1: Plant layout Map .............................................................................................34

Annexure 2: Vicinity Map ....................................................................................................35

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CHAPTER 1.0:-INTRODUCTION

1.1 PROJECT BACKGROUND

M/s. Century Plyboards (I) Limited (CPIL) has proposed to set-up synthetic resin

manufacturing unit within the existing ply board plant located at survey No. 145, 147

Paiky and 148, Village Motichirai, Bhachau Road, Gandhidham, District Kutch in

Gujarat State.

Plywood industries are the main users of synthetic resins. Its invention in early 19th

century brought revolutionary change in industrial field. Various types of resins are

being produced by addition or condensation polymerization of alcohols, phenols,

Aldehydes, amines, carboxylic acid etc. and are being used in various industrial and

engineering activities. Resin’s application largely depends on nature of the products.

Most commonly used resins are Urea Formaldehyde Resin, Phenolic Resin,

Melamine Resin and their derivatives.

1.2 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

The CPIL's products range includes almost all the varieties of plywoods, such as

commercial plywood, boiling water-proof plywood, decorative plywood, shuttering

plywood, block board, film face plywood etc.

After two years of rigorous R&D in the year 1998, Century introduced 100 percent

termite and borer proof plywood with 7 years comprehensive warranty and launched

the new product in the market with wide publicity and thereafter within a few months

it became the top selling brand of plywood in the country. As on date the borer proof

decorative plywood introduced by Century has become the minimum bench mark in

the plywood industry. Thereafter with the help of IPIRTI, Century undertook another

R&D project that is of making 100 per cent boiling water-proof decorative plywood.

So far decorative plywood was available without boiling water proof due to various

constraints in manufacturing the same. Century successfully concluded its R&D and

made a new mark with another innovative product i.e. 100 per cent boiling waterproof

decorative plywood - almost at the same price being charged by its competitors for

general products.

Since the last few years, CPIL is maintaining an annual growth of approximately 40

percent and has already reached No.1 status in the Indian Plywood Market and

selling more than everybody and atleast 30 per cent more than its immediate rivals

CPIL was incorporated on 5th January, 1982 as a private limited company. With effect

from company is having its registered and head office at Kolkata. CPIL is promoted

by Shri B. L. Agarwal, Shri H. P. Agarwal, Shri Sajjan Bhajanka and Shri Sanjay

Agarwal who are experienced and well-known businessmen.

In 1986, CPIL set up a unit at Bishnupur, 24 Parganas (S), West Bengal to

manufacture Plywood and Veneer with an initial installed capacity of 5000 CBM and

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12500 CBM per annum respectively, gradually, the installed capacity of the unit has

been increased to 25200 CBM and 50400 CBM respectively for plywood and veneer.

CPIL manufactures entire range of plywood such as commercial plywood, boiling Water-proof plywood, decorative plywood, shuttering plywood, block board, film face plywood etc. CPIL have the distinction of becoming the first ISO 9001 Company in India for Veneer and Plywood. The quality and durability of the product of CPIL sets its range apart from other brands. CPIL products are result of intensive research and development, use of best quality of raw materials, use of most sophisticated processing technologies and equipments and stringent quality control. CPIL sell its products under the well known brand name of “Century PF” Century is having an impressive growth and it has become the top selling brand of plywood in the country. CPIL has 17 branch offices and an extensive network of 388 Dealers all over India for marketing of its products. Promoters

Shri B. L. Agarwal, Shri H. P. Agarwal, Shri Sajjan Bhajanka and Shri Sanjay

Agarwal are promoter of CPIL.

Shri B. L. Agarwal, aged 69 years, is commerce and law graduate by

qualification. He has 46 years experience in various industries and businesses.

He is the Chairman of Century Plyboards (I) Ltd. and under his dynamic

leadership CPIL has become the highest plywood selling company in India. Shri

Agarwal also has active interest in various social activities.

Shir H. P. Agarwas, aged 55 years, is a Commerce Graduate. He is having

industrial and business experience of more than 30 years. He is the Vice-

Chairman of Century Plyboards (I) Ltd., the largest manufactures of Plyboard and

decorative veneer. He is also having keen interest in various social activities

through his active involvement in Marwari Relief society and Hospital, Indian Red

Cross Society, John’s Ambulance and various other social and cultural

organizations.

Shri Sajjan Bhajanka, aged 50 years, is a commerce graduate from Dibrugarh

University, Assam. He is having business and industrial experience of more than

25 years in the fields of Plywood. Ferro Silicon, export and import. He is

Managing Director of Century Plyboards (I) Ltd., the largest manufactures of

plywood and decorative veneers. He is also Chairman of Shyam Century Ferrous

Ltd., one of the leading manufacturers of Ferro Silicon. He is executive

committee member of Federation of Indian Plywood & Panel Industry and has

representation on various other committees. He is taking keen interest in various

social activities through Maharaja Agarsen Institute of Medical Research &

Education, Agroha (Hisar), Haryana, Vivekananda Kendra, Haryana Seva Sadan,

Tinsukia Education Trust and various other Institutions/Organisations. He is also

a trustee of Kalvan Bharti Trust which has set up “The Heritage School” and

“Heritage Institute of Technology” at Kolkata.

Shri Sanjay Agarwal, aged 41 years, is commerce graduate from Calcutta University.

Mr. Sanjay Agarwal is the Dy. Managing Director of M/s Century Plyboards (I) Ltd.

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He is the driving force behind the successful marketing of “Century” Ply Brand and its

distribution besides his contribution to general management aspects of the company.

Mr. Sanjay Agarwal is also a promoter.

1.3 BRIEF DESCRIPTION OF THE PROJECT

The Century Plyboards (I) Limited (Kandla Unit) started ply board plant in 2013.

Being inspired by the growth and demand of synthetic resin, CPIL proposed to set up

resin manufacturing plant with 12000 TPA capacity within the existing plant CPIL

plant at Kandla.

The proposed synthetic resin manufacturing plant of CPIL, Kandla, comes under Sr.

No. 5 (f) of EIA Notification, 14th September 2006 and subsequent amendments 25th

June 2014 SO 1599 (E) of Ministry of Environment, Forests and Climate Change

(MoEF&CC). The Proposed synthetic resin manufacturing plant of CPIL, Kandla is

falls in Category ‘B’ and requires Environmental Clearance from State

Environmental Impact Assessment Authority (SEIAA) of Gujarat State.

The proposed production capacities of the proposed plant are given in Table 1:

Table 1: Proposed Production Capacity

Sl. No

Name of the Product Total (Ton/Annum)

Storage

1 PF Resin 6000 40 MT

2 MF Resin 1500 10MT

3 UF Resin 1500 10 MT

4 MUF Resin 3000 20 MT

Total 12000 80 MT

1.4 NEED OF THE PROJECT & ITS IMPORTANCE TO THE COUNTRY AND OR

REGION

The wood and paper-based industry, that includes plywood, laminates and other

paneling materials clocked estimated revenues of Rs.12,000 Crores in 2011-12. Up

from Rs. 8,000 Crores in 2007-08, this 15% compounded growth has come at the

back of rising per capita income, demand for premium housing, office and

commercial space, and a boom in hospitality and healthcare sectors.

The industry is highly fragmented, with a major chunk of production coming from

small manufacturers, many of whom do not even possess a license to produce.

However, the market is driven by a few large companies who have plants at multiple

locations, invest heavily in brand building, offer ISI-marked products, and constitute

around 30% of the industry revenue.

Some of the bigger plywood companies in India and the brand names of their

plywood are listed (in random order) in the Table 2.

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Table 2: Plywood companies in India

Plywood

companies in India

Plywood brands in

India

More info.

Kitply Industries Ltd. Brand names: 'Kitply Gold', Kitply Curvy, Swastik MR grade, Vista (MR and BWR grade)

Kitply is a one of more famous plywood brand in India. The company started its operations in 1982. Other than plywood the company also manufactures block boards, decorative laminates, and it's 'KitCol' brand of wood adhesive.

Century Plyboards (India) Ltd.

Century Ply' The company also manufactures block boards, veneers, laminates, MDF and Prelaminated Particle boards.

Green Ply Industries Ltd.

Greenply plywood, 'Green Club Premium Ply, it's 'GreenLam' brand of decorative laminates and others.

GreenPly is a multi-national interior infrastructure company and has operations in several countries. The company also makes block boards, laminates, and decorative veneers, and MDF.

National Plywood Industries Ltd.

Brand name: 'National plywood'

The company manufactures plywood as well as laminates.

Sarda Plywood Industries Ltd.

DuroPly, DuroFlex, Duro-PumaPly as well as several other brands.

The company manufactures plywood, decorative plywood, block boards and flush doors etc.

Mayur Plywood Mayur ply The company has a Pan-India presence and also makes decorative plywood, veneers and doors.

The related products such as laminates, block boards and flush doors are also sold by most of the companies. Many of the bigger companies have also now ventured into the ready-made furniture market in India, as well as into the manufacture of newer engineered wood products such as Prelaminated Particle boards and MDF (Medium Density Fibre boards). The Indian market for particle board and plywood is estimated in value terms, at over Rs 17 billion. Of the total market, particle board accounts for over 30% of the market with the rest over 70% accounted by plywood segments. It is roughly presumed that the total size of Indian Plywood Market is around Rs.5000 Crores in value terms and around Rs 60 Crores sqm of plywood on 4mm basis in quantity terms. The market is divided between two categories i.e. (1) branded products and (2) non-branded products. Until 1970 the share of branded products was 90% in comparison to 10% of non-branded products but now the situation has been almost reversed and the branded products have only 10 per cent market share. Generally branded products are being manufactured by the plywood factories in the medium scale, who are paying all the taxes and excise duty, whereas non-branded products are mostly being manufactured by SSI units, most of whom are availing

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excise and sales tax exemptions. These SSI units generally are not fully integrated ones. They buy semi-processed raw material and do the pressing and finishing jobs in their factories. Thus excise duty collection is largely from the branded products. The total duty collection from plywood industry is estimated to be Rs.70 crores, out of which Century's contribution is likely to be more than Rs.7 crores i.e. around 10 percent of the total excise collection in the country from the plywood industry. When the excise contribution of Century is compared with other branded plywood manufacturers, Century is the highest excise contributor and the next contributor is 30 to 40 percent below it, followed by further lower contributors. In the western and southern markets, Century is the No. 1 selling brand, whereas in other markets it is among the top three. The company has achieved a considerable growth in turnover by 36 per cent in the year 1997-98, 48 per cent in 1998-99 and 52 percent in 1999 -2000. It has achieved a turnover of Rs.116 Crores during 2000-01 resulting in a growth of 20 percent.

1.5 DEMAND & SUPPLY

Plywood is made by glueing several layers of wood veneer (thin sheets of wood) over

each other with the grain pattern alternating at right angles in every subsequent

layer. During the plywood manufacturing process, the individual layers of veneer are

first obtained by rotary-cutting a log. For this the timber logs are rotated about their

longitudinal axis, while a cutter peels the log at the set thickness (each layer is

usually less than 2.5 mm in thickness). Later on, adhesives are spread on these

veneers using a glue-spreader machine. The machine helps in achieving a uniform

glue spread.

Demand of synthetic resins in the country is increasing day by day. These resins are

industrial additives used as bonding materials in plywood industries for

manufacturing of plywood, veneer sheets, particle board (composite wood core with

plastic laminate finish), panel products (fiber board), plywood made from both hard

and softwood (veneered panels and laminated woods), and medium density fiber

board etc. These resins are one of the most versatile chemicals and are a basic

building block to many important industries. The growth and demand of the ply board

largely play an important role for the growth and demand of synthetic resins. Since

last 2-3 years the Plywood, Laminate, Fabric items, Steel Industries and Engineering

products are growing at a remarkable space, which in turn increased the demand of

various industrial inputs. The market demand of synthetic resins is also filling the

upward growth tendency living a scope for further investments in these sectors,

especially because the existing capacities may not be sufficient to meet the new

demand. Some of the existing manufacturer of synthetic resins is in this line over a

long period and their plant capacities are at optimum level of utilization. Moreover,

the recently invented process technology for better quality product also needs further

investments and shall open new markets.

Since all the existing manufacturers are not in organized sector, country’s total

installed capacities vis-a-vis production for last few years are difficult to procure.

However, from the market trends the upward rise in demand of the product is being

felt by most of the manufacturers. The annual growth of steel, foundry, casting,

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laminate and plywood industries supports this upward trend in demand of synthetic

resins. Demand for resin is related to overall growth of other industries like ply

woods, particle board, laminates, housing, furniture, consumable durables, shipping

and railway sector.

1.6 EMPLOYMENT GENERATION (D IRECT AND INDIRECT) DUE TO THE PROJECT

The total requirement of manpower for the proposed resin manufacturing plant is

estimated at around 50 numbers. The required manpower is available locally.

Specialized training required for plant operation and maintenance will be carried out

by skilled personnel.

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CHAPTER 2.0: PROJECT DESCRIPTION

2.1 TYPE OF PROJECT

The proposed project is envisaged to manufacture different types of synthetic resins

as per market demands. PF resin, MF resin and other resin units are extend to meet

the demand for production of 12000 TPA products.

2.2 LOCATION OF THE PROJECT

This project is located on survey no. 145, 147 Paiky and 148, in village - Motichirai,

NH-8A Bhachau Road, Taluka – Bhachau, Gandhidham District - Kutch (Gujarat).

The Latitude and Longitude of the site is 23°14'7.50" N and 70°16'30.50"E,

respectively.

The site for proposed resin plant is within the CPIL’s existing plywood and veneer

unit. Indigenous raw materials & Chemicals are available nearby. Due to its nearness

with the Kandla & Mundra ports, the project will enjoy strategic advantages in import

of raw materials. The power and water required for the proposed resin plant is

already available at existing plant. Due to its nearness to the NH-8A the project will

enjoy good infrastructure and other facilities such as availability of skilled as well as

unskilled workforce, contractors, superior communication facilities, transportation

facilities etc.

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Figure 1: Plant Location

2.3 DETAILS OF ALTERNATE S ITES

It is proposed to set-up proposed unit within the existing ply board plant. Therefore,

no alternate site has been selected for the proposed plant. The existing site was

selected near in Moti Chirai village of Bhachau Tehsil, Kutch District of Gujarat State

based on the following considerations:

Nearby city – Gandhidham (22 km)

Availability of Infrastructure like power.

Land for proposed project does not involve any displacement of habitation nor

any diversion of forest/ vegetation,

Availability of land, with common approach road connected to NH 8A.

No forest land is involved in the project.

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Access to high growth domestic markets and future industrial and infrastructure

development has been planned.

2.4 S IZE OR MAGNITUDE OF OPERATION

The proposed plant will be engaged in manufacturing of synthetic resins. The

manufacture of different type of resins involves the following:

Manufacturing of Phenol Formaldehyde (PF) Resin,

Manufacturing of Melamine Formaldehyde (MF) Resin,

Manufacturing of Urea Formaldehyde (UF) Resin,

Manufacturing of Melamine Urea Formaldehyde (MUF) Resin.

The proposed synthetic resin manufacturing details are given in Table 3.

Table 3: Proposed Production Capacity

Sl. No

Name of the Product Total (Ton/Annum)

Storage

1 PF Resin 6000 40 MT

2 MF Resin 1500 10MT

3 UF Resin 1500 10 MT

4 MUF Resin 3000 20 MT

Total 12000 80 MT

The proposed resin plant will be located on the 254.25 sqm within the existing ply

board plant located on 98482.94 sqm land. The land is barren, non productive and

for industrial use.

2.5 PROCESS DESCRIPTION

The proposed synthetic resins manufacturing processes are summarized below:

2.5.1 MANUFACTURING OF PHENOL FORMALDEHYDE (PF) RESIN

It includes synthetic thermosetting resins obtained by the reaction of Phenol with

Formaldehyde. Phenol Formaldehyde Resin, as a group, is formed by a step - growth

polymerization reaction that can be either acid or base - catalyzed. Since

formaldehyde exists predominantly in solution as a dynamic equilibrium of Methylene

Glycol Oligomers, the concentration of the reactive form of formaldehyde depends on

temperature and pH.

Formation and structure:

Phenolic Resin is reaction products of phenol and/or substituted phenol with

formaldehyde. An unlimited variety of resin is possible depending on (1) the choice

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of phenols, (2) the phenol: formaldehyde molar ratio, (3) the type and amount of

catalyst used, and (4) the time and temperature of reaction.

The active positions on the phenol molecule are the two ortho and one para

positions. When more than one mole of formaldehyde is reacted with one mole of

phenol in the presence of an alkaline catalyst, the following initial products can be

formed:

Further heating of these initial reaction products results in condensation and an

increase in molecular weight. Condensation takes place between two methylol

groups to form a methylene ether link (a) or between a methylol group and an

active ortho or para hydrogen atom to yield a methylene link (b).

The amount of heating determines the final form of the product, e.g., whether the

resin is a low viscosity, water-soluble liquid, a higher viscosity liquid with little or no

water miscibility, or a grindable solid. Highly viscous forms may be dissolved in

solvent after the resin has been dehydrated. If the reaction is carried too far, the

resole can gel. Therefore the reaction is always conducted under carefully

controlled conditions of time, temperature, pH, and mole ratio of formaldehyde to

phenol.

Being thermostes, hydroxymethyl phenols will crosslink on heating to around

120°C to form methylene and methyl ether bridges. At this point the resin is a 3 -

dimensional network, which is typical of polymerized phenolic resins. The high

crosslinking gives this type of phenolic resin its hardness, good thermal stability,

and chemical imperviousness.

Manufacturing Process:

A typical phenolic resin is made by a batch process in a jacketed, stainless steel

reaction kettle, equipped with turbine-blade or anchor type agitator and condenser.

Molten phenol and formalin (37 – 40% formaldehyde) is charged to the kettle and

agitation begun.

To make a resole resin, an alkaline catalyst such as sodium hydroxide is added to

the phenol and formaldehyde before heating the batch to 80-100ºC. Reaction

temperatures below 100˚C are controlled with vacuum.

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Reaction times are generally 1-3 hr. Since a resole resin is capable of gelling in the

still, dehydration temperatures are kept below 105ºC by the application of vacuum.

Gel time on a 150ºC hot plate is a common test that is used to indicate the degree

of advancement of the resin and to determine when the batch should be

discharged.

Solid resoles are discharged to resin coolers, a series of parallel, internally cooled

metal plates that the resin flows between to be rapidly cooled.

The low molecular weight, water soluble resins are finished at as low a

temperature as possible, usually around 50ºC, whereas the less reactive para-

substituted resoles can be finished at temperatures as high as 120ºC.

Chemical Reaction:

Material Balance for PF resin per Batch

Input Quantity (in kg) Output Quantity (in kg)

Phenol 2550 PF Resin 8569

Formalin 4615 Process Loss 86

Para formalin

Caustic 384

Water 1020

Total Input 8569 Total Output 8483

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Figure 2: Process Flow Diagram of PF Resin

Raw Materials (Phenol, Formalin, Paraformaldehyde, Caustic)

and Water

Reaction

Vessel /

Kettle

String and Heating

Temperature up to 90-95° C

Water Circulation in

Coils

Pressure 3

kg/cm2

Digestion

Exothermic Reaction

Start

Product Testing:

Phenol Formaldehyde

Resin

Storage of PF resin

Con

den

ser

Distillat

e to

storage

for

reuse

Packing

Dispatch

Vacuum Pressure

700 mm 60ºC

Reflux

Cooling

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2.5.2 MANUFACTURING OF UREA FORMALDEHYDE (UF) RESIN

Urea formaldehyde resins are poly - condensation products of the reaction of

formaldehyde with urea. The relatively easy production of the UF resins, their good

solubility in water and absence of colour, make these thermosetting polymers

irreplaceable in the manufacture of many wood based products. Due to the UF resins

low resistance to humidity the panels obtain are suitable for interior use in dry

condition. The specifications of the resin product such as the molar ratio of

formaldehyde to urea, solids content, viscosity, reactivity etc. are adjusted in order to

meet any customer requirement.

Urea formaldehyde resin is prepared by reacting urea with formaldehyde in a

molar ratio of 1:1.8 generally. Urea reacts with formaldehyde under neutral or

alkaline condition to yield monomethylol urea, symmetrical dimethylol urea and

trimethylol urea depending on the ratio of the reactants.

The resinification process for urea formaldehyde occurs in two main stages,

addition or methylolation and condensation.

In the methylolation step, urea and formaldehyde are reacted under controlled

conditions using an alkaline catalyst. Typically, the methylolation step is carried

out at a pH of about 8.0. The methylolation stage usually results in a mixture of

methylolated species, monomethylol urea, and dimethylol urea and trimethylol

urea.

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This mono and dimethylol urea may be regarded as the monomer of the urea-

formaldehyde resin.

In the second stage these methylol urea undergo condensation to form low

molecular weight polymers. The rate of reaction depends on pH. Acid catalyses the

reaction in many ways:

Formation of Methylene Bridge in amino nitrogen facilities in acidic medium.

Methylene ether linkages also can be formed in acidic medium.

Two types of acid materials can be used, which are classified as (1) direct catalysts

& (2) latent catalysts.

Direct catalysts are inorganic and organic acids, acid salts. They are effective at all

temperatures. The latent catalysts are salts and esters which develop acidity upon

heating.

The solution is refluxed at 82-85ºC for about one hour to complete the formation of

Dimethylol – urea.

The condensation reaction proceeds to a predetermined end point, and the resin

intermediate is cooled.

At this stage reaction is arrested by raising the pH of the resin to about 7.0 to 8.0

by adding sodium hydroxide and cooled to ambient temperature by circulating

water in jacket and discharged from the vessel.

Chemical Reaction:

Material Balance for UF resin per Batch


Urea 1432 UF Resin 5149


Melamine 142

Caustic 9


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Fig 3: Process Flow Diagram of UF Resin

2.5.3 MANUFACTURING OF MELAMINE FORMALDEHYDE RESIN

Melamine formaldehyde is a hard, thermosetting plastic material made from

melamine and formaldehyde by polymerization. It is then used to cross-link with

alkyd, epoxy, acrylic, and polyester resins, used in surface coatings.

Reactor Vessel

At Atmospheric

Pressure

Catalyst

Urea Melamine

Formalin

Heating

82-85 ºC

Con

dens

er Cooling

WATER Circulation in

Jacket

Digestion

Exothermic Reaction

Start

Digestion time 2-3

hours Temp. Rise up to 85° C

Mixing of Raw Materials

Product Testing

Urea Formaldehyde

Resin

Storage of UF resin

Packing

Dispatch

Reflux

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Formation and Structure:

Methylol condensation occurs in a major extent. So, -CH2 – O – CH2 & -CH2- both

type linkages are formed.

All the six hydrogen atoms of melamine can be replaced by methylol groups upon

reaction with formaldehyde. However only 2 or 3 methylol groups are usually

introduce for production of thermosetting resin (insoluble and infusible). So in MF

resin preparation melamine and formaldehyde are taken in 1:2 to 1:3 molar ratios.

When melamine formaldehyde ratio crosses above 3 the pH of the reactants in

each step should be strictly maintained.

In the whole preparation, the temperature is controlled very much efficiently.

Because at elevated temperature curing of MF resin becomes very much facile and

occurs in a higher rate and 1st stage resin is prepared at elevated temperature. As

melamine has very poor solubility in water and aqueous formaldehyde at normal

temperature and during the preparation of 2nd stage resin for proper mixing of

compounding ingredients in 1st stage resin the temperature is required to raise to

some extent, at the time of milling temperature of the substance increases

somehow; so at any stage of above two there is a possibility of premature curing if

temperature goes out of control.

The effect of pH is not so great. Though at the time of 1st stage resin preparation

the medium should have neutral or slightly alkaline pH for good yield. But at the

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time of curing pH is not required to control in a continuous manner. Curing can

occur at any pH but the rate differs. Generally at pH 10-10.5 the rate of curing is

very slow but an increase or decrease of pH in any extent from this value will give

rise to a healthy rate of curing.

Manufacturing:

In MF resin preparation, melamine and formaldehyde are taken in 1:2 to 1:3 molar

ratio. For water soluble MF resin this ratio is 1:6 to get Hexamethoxymethylol

melamine (HMM).

It is manufactured by reacting melamine with formaldehyde in a jacketed reactor

under neutral or alkaline condition.

In first step melamine reacts with formaldehyde in aqueous solution (37 % w/w) to

form methylol compounds. The reaction is carried out under slightly alkaline

condition.

Since melamine is not soluble in water at room temperature. It is necessary to heat

the mixture to about 85°C for obtaining methylol compounds.

In the preparation of water soluble resins, the solution of methylol compound is

further heated under alkaline condition until the desired viscosity or solubility

characteristics are obtained from increased molecular weight.

Liquid formaldehyde is taken in the reaction vessel and melamine powder is added

slowly with stirring. After about 15 minutes caustic soda solution is added and the

mixture is heated by steam. The temperature is controlled at about 85°C.

Then the product is made alkaline by adding caustic soda solution (20% strength)

and subsequently cooled to room temperature. Finally, it is stored in a storage

barrel.

Chemical Reaction:

Material Balance for MF resin per Batch


Melamine 1690 MF Resin 4403


Caustic 8

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Water


Fig 4: Process Flow Diagram of MF resin

Reactor Vessel

At Atmospheric Pressure

Catalyst

Melamine

Formalin

Heating

82-85 ºC

Conde

nser

Cooling

Water Circulation In

Coils

Digestion Exothermic Reaction

Start

Digestion time

2-3 hours

Temp. rise up to 85° C

Product Testing

Melamine

Formaldehyde Resin

Storage of MF Resin

Packing

Dispatch

Reflux

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2.5.4 MANUFACTURING OF MUF RESIN

The MUF resin produced has unique characteristics and properties, which in many

ways are very different from the properties of MF or UF resin. Various MUF resin

formulations have different properties, performance and durability. The important

properties of MUF resin include the shelf life, solubility in water and curing period are

formulated according to its applications. MUF resin formulations are built up from a

combination of several factors. Among the important factors are the reaction period

for each stage, the efficiency of controlling the pH and the temperature throughout

the process, the mole ratio of formaldehyde to urea/melamine and the number of

stages in which amino compound is reacted. The combination and variation of these

factors produce different resin shelf life, degrees of solubility in water and curing

periods.

Manufacturing:

Formaldehyde is taken in a reaction vessel with Urea at pH 8.5 to form Formic

acid. The reaction is done at 60ºC temperature. Then to the mixture melamine

powder is added slowly and the mixture is then stirred well at a temperature of

88-90ºC.

The solution is refluxed at 88-90ºC for about one hour to complete the formation

of resin water (1:6.5). The pH is maintained to 8.5 by addition of caustic and then

addition of PVA.

The condensation reaction proceeds to a predetermined end point, and the resin

intermediate is cooled.

At this stage the product is cooled to ambient temperature (35ºC) by circulating

water in jacket and discharged from the vessel and the product is unloaded.

Total Batch time is about 5 hrs and evaporation loss of about 1%.

Chemical Reaction:

Material Balance for Furan resin per Batch


Melamine 874 MUF Resin 4954

Urea 583 Process loss 49

Formalin 3497


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Fig 5: Process Flow Diagram of MUF Resin

2.6 RAW MATERIALS DETAILS

The raw materials with quantity and mode of transport details are given in Table 4.

Dispatch

Reactor Vessel

At Atmospheric

Pressure

Formaline, Urea

Melamine

Addition of PVA

Cond

enser

Temp 60ºC

Distillate

to

storage

for reuse

Stirring and Heating

Temperature up to 88-90°

C

Water Circulation in

Jacket

Product Testing:

Furan Resin

Storage of

MUF Resin

Packing

Reflux (under

vacuum)

Digestion

Cooling at 35ºC

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Table 4: Raw materials details

Sl. No.

Raw Materials Form Quantity (Tonnes/ Month)

Mode of transport Source

1 Phenol Liquid 141.45 Shipment/ Truck Imported/ Local

2 Formalin Liquid 587.825 Shipment/Truck Imported/ Local

3 Urea TG Gr. Solid 64.950 Road Local

4 Melamine Solid 89.5 Shipment/ Truck Imported/ Local

5 Caustic Soda Solid 12.5 Road Local

5 Oxalic Acid Liquid 1.25 Road Local

6 Acetic Acid Liquid 0.625 Road Local

7 Borax Solid 1.5 Road Local

8 Polyvinyl

alcohol (PVA)

Solid 3.0 Road Local

2.7 EQUIPMENTS DETAILS

The equipment details for the proposed plant are as given in Table 5.

Table 5 : Equipment Details for the Proposed Plant

Equipment Qty Capacity

Kettle/ Vessel (fitted with condenser, temperature

indicator, glass window for visual inspection,

safety pressure valve, stirrer for mixing coupled

to a constant speed motor through reducing

gear, jacket for cooling/ coils, completely closed

lid, stem heating and water cooling inlet and out

lets, sampling valve, drainage valve).

Resin Kettle : 4 nos

Resin Kettle: 1 no.

Measuring tank :4 nos

6 MT each

6 MT.

3 MT each

Thermic Fluid Heater 1 no

Storage tank for PF resin 4 nos. 10 MT. each

Storage tank for MF resin 2 nos. 10 MT. each

Storage tank for UF resin 2 nos. 10 MT. each

Storage tank for MUF resin 2 nos. 10 MT. each

Cooling tower 2 nos. 50 TR

Weighing scale 1 no 750 kg

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Equipment Qty Capacity

Lab. Equipment :

Electronic Balance

Melting Point Apparatus

Refractometer

Universal Sand Strength Machine- Digital

Universal Sand testing Machine-Digital

pH meter

Sand Muller – Lab scale

Electric Oven – air circulated

Core Hardness tester

Sand Rammer

Core-gas determinator

Hot Plate

Ford Cup (B4, B5, B6)

Glass Reaction Kettle

Steel Reaction Kettle

2.8 RESOURCE REQUIREMENTS

Manpower Requirement

Total manpower requirement for operation of the proposed plant will be as given below:

Manpower Numbers

Manager 1

Supervisors 3

Workers (all shift) 8x2=16

Total 20

Energy Requirements

Total connected load is 2x1000 KVA. For proposed plant total load will be 100

kVA power will be required.

Electricity requirement will be met through existing grid supply by GSEB.

For back-up power existing DG Sets of 2 x 600 kVA capacity are available.

Page | 26

Fuel

Fuel (HSD) for DG set – Approx 1000 Litre/month Diesel will be required.

For fuel requirement of thermic fluid heater, about 12 ton/month wood waste will

be required.

Water Requirement

The total water requirement in the proposed plant will be 5 kld. Bore well is

available at the existing plant to abstract ground water. Ground Water withdrawal

permission has already been granted from the concerned authority.

For process 1 KLD, for cooling tower 2 KLD, domestic purpose 1 KLD and for

washing 1 KL water will be required.

About 1 KLD water will be required for domestic purposes and wastewater will be

discharged into the STP at existing ply board plant for treatment. Treated waste

water is used for greed belt development. So there will be zero discharge of

treated waste water outside the project premises.

Land Requirement

Total land area for the proposed project is 254.25 sqm, which is located within

existing CPIL plant comprising 98482.94 sqm.

Total green belt area shall be of 33% of total area. The main objective of the

greenbelt is to provide a barrier between the plant and the surrounding areas to keep

the environment clean.

2.9 POLLUTION CONTROL MEASURES

Air Environment – Mitigation Measures

There will be no process emission from the proposed plant.

DG sets are intermittent source of emissions. Pollution control in DG sets is

achieved by providing stack height as per Central Pollution Control Board

(CPCB) guidelines.

Wood waste fired thermic fluid heater is also source of dust emissions. For

control of dust from thermic fluid heater, bag filters have been fitted.

Water Environment

From the proposed plant, process effluent will not be generated.

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Domestic effluents (0.8 KL) generated from proposed plant will be treated in

existing STP at CPIL and treated waste water will be used for green belt

development at CPIL plant.

There will be zero discharge of treated waste water from proposed plant within

the existing plant.

Solid & Hazardous Waste Management

The proposed plant and existing plant will generate the following solid and hazardous

wastes from different production processes as given in Table 6.

Table 6: Solid & Hazardous Waste Generation and Management

Sl. No.

Item Source Quantity (Tones) Mode of Disposal

1 Glue sludge Process 100 kg/day TSDF Site

2 Cotton Waste Process 5 kg/day TSDF Site

3 Poly Bags Stores 50 kg/day Outside agency for Recycling

4 ETP sludge ETP 25 kg/day TSDF Site

5 Bottom Ash Boiler 50 kg/day Outside agency for Filling

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Chapter 3.0: SITE ANALYSIS

3.1 CONNECTIVITY

The project site is easily approachable by National Highway - 8A. The NH 8A is

about 0.5 Km away from the site. The nearest rail station is Bhachau Railway station

approx 10 Kms away from the project site. Hence no new transportation

infrastructure / alteration of existing routes will be required. Existing transport route is

already available. No closure or diversion is required for traffic movement.

3.2 LAND FORM , LAND USE AND LAND OWNERSHIP

The project site is located at survey No. 145, 147 Paiky and 148 in village Motichirai,

Tehsil Bhachau, District Kutch, Gujarat. The total plot area of existing CPIL is

98482.94 sqm. Synthetic resin manufacturing plant will be located on 254.25 sqm.

The current land use of land for proposed resin manufacturing is industrial. The

surrounding area of the project site is industrial land, waste land, salt pans,

habitation, coastal plain etc.

3.3 TOPOGRAPHY

Topography of the site and study area is coastal plain. The ground elevation at the

plant is 14 m above msl. The proposed project area comes in Seismic Zone-V, which

is high damage risk zone. The latitude and longitude of project site are 23°14'7.50"N

and 70°16'30.50"E, respectively.

3.4 DRAINAGE:

There is river or other water body in the vicinity of proposed plant. The coastal zone

is about 4 km from the proposed plant.

3.5 EXISTING INFRASTRUCTURE

Total plot area of the proposed unit is 254.25 sqm, which located with existing CPIL

plant. Site layout showing the proposed infrastructure is attached as Annexure -1.

The existing unit has raw material storage facility, utility facility, production area &

ETP facility, etc and same will be used for proposed resin plant. For proposed

project, unit will construct a building for resin manufacturing.

3.6 SOIL CLASSIFICATION

The soil of project site is sandy. The region is saline in nature due to the proximity

coastal zone. The coastal zone is about 4 km.

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3.7 CLIMATIC DATA FROM SECONDARY SOURCES

The region falls under the semi arid type of climatic conditions. The summer start

from March and last till ends of July. The period in between middle of May to the end

of August is the monsoon. The area do not experiences of very cold climate.

Meteorological factors such as wind speed, direction variation in temperature,

humidity etc. play a direct role in dispersion and dilution of pollutants atmospheric

pressure, rainfall and cloud cover also govern this activity. Other factors such as

terrain and local topography also impact the atmospheric dispersion.

3.8 SOCIAL INFRASTRUCTURE AVAILABLE

Social Infrastructure facilities (both public and private) such as schools, hospitals,

community halls, markets, colleges, railway station and religious buildings are

located at Bhachau, which is located at a distance of 10 km from the site.

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CHAPTER 4.0:-REHABILITATION & RESETTLEMENT (R&R) PLAN

The proposed resin plant will be located on 254.25 sqm land within the existing CPIL

plant. There is no displacement of people or property for proposed resin plant.

Therefore, rehabilitation and resettlement is not an issue in the proposed project.

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CHAPTER 5.0:-PROJECT SCHEDULE & COST ESTIMATES

5.1 PROJECT SCHEDULE

5.1.1 PLANNING OF ACTIVIT IES

Careful planning of all the activities is one of the pre-requisite for timely completion

of the project. Following activities will be given special attention.

5.1.2 PRE PROJECT ACTIVITIES

Management Approvals.

Selection of location

Statutory Clearances

Financial Approvals

Conceptual Design

Preparation of main machinery tender

Evaluation of tenders

5.1.3 PROJECT ACTIVITIES (IMPLEMENTATION STAGE)

Firm up basic design

Main Machinery Order placement

Detailed engineering of the project

Statutory approvals of Building Plans.

Preparation of tender, evaluation of tenders received and order placement for

balance machinery

Completion of procurement activities on time

Release of civil drawing for civil construction

Civil construction

Supply of mechanical & electrical equipment

Inspection of major machinery at supplier’s works

Erection of all plant & machinery

Commissioning of the plant

5.1.4 STATUTORY CLEARANCES

The proposed project will require various statutory approvals and clearances from

various authorities of the State and Central Government.

5.1.5 PROJECT SCHEDULE

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The total project implementation schedule is 15 months from zero date. The external

agencies such as consultant, machinery suppliers, contractors of civil construction

and equipment will be selected carefully well in advance. An effective project team

has been formulated with an experienced project manager as its leader.

5.1.6 STRATEGIES FOR T IMELY EXECUTION OF THE PROJECT

The following strategies would be adopted for smooth functioning as well as timely

execution of the project:

The task of implementing the project in time shall be achieved by ensuring a well

coordinated project implementation task force in-house and from external

agencies

A well chosen team of experienced personnel for project execution shall

coordinate the implementation of the project from in-house

Experienced engineering consultants with proven track records shall be selected

for detailed engineering of the project.

Reputed and experienced contractors with adequate resources of finance, men,

material and tools and tackles, will be engaged for execution of the construction

and erection work.

Effective project monitoring including project planning schedule and monitoring

shall be employed in this project. Timely execution and resources will be

monitored using computer based project monitoring tools. In case of deviations in

project progress, all possible corrective actions such as crashing of network etc.

will be carried out.

5.2 PROJECT COST

An estimated capital cost of the proposed plant is Rs. 105 Lakhs, including the pre-

operative expenses, contingency and interest during construction.

A broad break-up of the indicative estimate of the project capital cost is provided

below:

Project Cost (Rs. in Lakhs)

Particulars Total Remarks

Land & Site Development Expenses

Civil Works

Factory Building

Plant & Machinery

Pollution Control Equipment

-

-

30.00

40.00

17.00

Existing

Existing

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Particulars Total Remarks

Fire Fighting Equipment

Other Fixed Assets

Non Plant Building

5.00

8.00

5.00

Total 105.00

Means of Finance (Rs.in Lakhs)

Particulars Total

Promoters’ contribution:

- From Plywood Division

105.00

Total 105.00

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ANNEXURE 1: PLANT LAYOUT MAP

Page | 35

ANNEXURE 2: V ICINITY MAP

Pre-Feasibility Report for Synthetic Resin Manufacturing...

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