PRE-FEASIBILITY REPORT

FOR
100 MT/day Formaldehyde Plant
By M/s Bansal Chemicals industries
At
Plot no. B-12, Focal Point,
MandiGobindgarh,Dist: Fatehgarh Sahib
Punjab. Pin:147301

APPLICANT
M/s Bansal Chemicals industries
Kothi No. 15,22 Acers scheme,
Barnala, Punjab
Pin :148101

ENVIRONMENT CONSULTANT
VARDAN ENVIRONET
(QCI/NABET ACCREDITED NO. NABET/EIA/1619/RA0037)
D-142, SEC. 57 GURGAON (HARYANA)
E-MAIL: vardanenviro165@gmail.com
CONTACT: 0124-4291036, 09899651342
 PRE-FEASIBILITY REPORT
CHAPTER-1: INTRODUCTION

M/s Bansal Chemicals industries is proposing to develop a Formaldehyde Manufacturing Plant

of capacity 100 MTD Formaldehyde at Plot no. B-12, Focal Point, MandiGobindgarh, Dist:
Fatehgarh Sahib, Punjab.

Formaldehyde is an organic chemical having basic uses in core industries like

a) Plastic Industry in the manufacture of thermo set compounds like U.F;P.F. & M.F. Moulding
Powders

b) Plywood Industry where it is used as the bonding compound.

c) Pharmaceutical Industry where it is used for fumigation.

d) Explosive Industry also uses Formaldehyde in bulk.

e) Hexamine a blowing compound used in the Rubber Industry is produced by using

Formaldehyde as its main raw material.

The basic raw material used in the production of formaldehyde is Methanol. The basic process
used for the manufacture of formaldehyde involves oxidation of methanol in the presence of
Silver which works as catalyst. The chemical reaction involve is as follows:

CH3OH = H CHO + H2 (Endothermic Reaction)

H2 + 1/2 O2 = H2O (Exothermic Reaction)

CH3OH + 1/2 O2 = HCHO + H2O (Net Exothermic Reaction)

1.1 Profile of Bansal Chemicals Industries

Bansal Chemicals industries is a partnership firm with duly executed partnership deed dated
10.05.2017.The partners of the unit have proposed to set up a Formaldehyde continuous
Process Plant with a installed capacity of 100 MT per day at Focal Point,MandiGobindgarh.

The partners areengaged in plywood business since last 35 years. Satpal Bansal and his son
Bhupinder Bansal are running two industries by name Durga plywood industries situated in
Barnala city and other one is Shiv Shakti Plywood industries situated in Balachaur in Punjab
Indian manufacturing company is a leading Manufacturer & Supplier of Plywood board .
1.2 Need of the Project

Bansal Chemicals Industries have planned to set up an agro wood based project for
manufacturing Particle Board and MDF boards with value added products Management shall
take all necessary clearances related to environment & pollution control including
Environmental Clearance. The manufacturing of Particle board and MDF board requires
glue/adhesive /binder for binding the particles / fibres of wood. The major raw material for
manufacturing glue /binder/adhesive for particle board requires major quantity
of formaldehyde. Further for the quality production of final product particle board and MDF
board the quality of the formaldehyde used for glue/adhesive/binder should be as per the
standards. To achieve the quality production and the uninterrupted supply of the
formaldehyde, the company has proposed to develop their own formaldehyde unit all utilities
and storage within the main unit.

Details of Project Proponent

M/s Bansal Chemicals industries
Name :Satpal Bansal
Address :Plot no. B-12, Focal Point,
Mandi Gobindgarh,Dist: Fatehgarh Sahib
Punjab. Pin:147301
Mail Id: plywooddurga@gmail.com
Mob: 9872893429
 CHAPTER 2: PROJECT DESCRIPTION
Site Location

The proposed plant is to be installed at at Plot no. B-12, Focal Point, MandiGobindgarh, Dist:
Fatehgarh Sahib, Punjab on a land measuring 0.418 Ha.

The area details of this unit are given below:

S.No Plant area Area(Ha.)

1 Built up Area/Covered Area .150
2 Green Area .150
3 Open & Road area .118
Total area 0.418

SATELLITE IMAGERY OF THE PROJECT SITE

Fig1: Google Image of Project Site

Fig 2: Key Plan
Fig 3: Layout plan
 CHAPTER 3: PROJECT DESCRIPTION WITH PROCESS DETAILS

3.1 MANUFACTURING PROCESS

Formaldehyde is the oxidation/dehydrogenation product of methanol with oxygen in the

presence of Silver catalyst.

A fixed quantity of methanol and water is introduced in to a mixing vessel from where this
mixture is taken into an evaporator. Air is also introduced into the evaporator. A temperature
of 70o C is maintained which facilitates the evaporation of methanol. The air and methanol
vapour mixture is then further heated to 100 deg in the superheater and then introduced into
the reactor where in presence of silver catalyst maintained at temperature of 650 o C .The
oxidation/Dehydrogenation reaction takes place as per the following chemistry:

CH3OH = HCHO + H2 (Endothermic Reaction)

H2 + 1/2 O2 = H2 O (Exothermic Reaction)

CH3OH + 1/2 O2 = HCHO + H2O (Net Exothermic Reaction)

3.1.1 ABSORPTION

The Reaction is net Exothermic. In the Reaction 3 itself which is also a waste heat boiler the
temperature of the product gasses is brought down to 180 oCand then further to cooled to
about 95oCin the Reboiler. This is achieved by circulating the Solution in the Evaporator in the
Reboiler which cools down the Product gasses to about 95 oCand itself is heated up to 70 o
Cthus saving on energy.. The product gasses are further cooled to about 75 oCin the condenser
by circulation of cooling water from the cooling tower. Pre-Feasibility Report for Proposed
Formaldehyde Manufacturing Unit at Plot no. B-12, Focal Point, MandiGobindgarh, Dist:
Fatehgarh Sahib, Punjab by M/s Bansal Chemicals Limited .The reaction gas containing
Formaldehyde, unreacted Methanol and water vapour is then directed to Absorption column I
and escaping Formaldehyde gases are absorbed by circulating and cooling the Formaldehyde
solution in Plate Heat Exchanger from the absorber sump. The part of the circulation is taken
out as product.

Mostly the absorber is packed with pall rings. If proper packing size and cooling is maintained
more than 95% absorption is completed in the absorption column - I.
The unabsorbed gas from the absorption column - 1 is absorbed in the absorption column - II
and subsequently in Column III by circulating and cooling absorber sump dilute Formaldehyde
solution in Plate Heat Exchanger. Finally, the gas is washed with pure Chilled DM water at the
upper part of the column - III, provided with bubble cap trays, and then exhausted as tail gas to
the atmosphere.

The Exhaust gasses contain only Nitrogen, Hydrogen, Carbon dioxide, Carbon Monoxide and
traces of Formaldehyde and Methanol.

Table1: The plant and machinery being proposed to be used in the complex is given below:

ITEM NO MATERIAL OF Quantity

CONSTRUCTION/SPECIFICATION
Heat Exchanger Plate Type 5
Root Blower Alloy Steel Cast 1
Pumps Of various sizes for process 6
Pipelines SS304 and MS Of Different Sizes As per
requirement
Valves SS/MS Of Different Sizes As per
requirement
Rotameter Metallic/Glass Tube Type As per
requirement
Filters For Methanol,Methanol/water Mix 4
Gaugaes SS/MS temperature gauges As per
requirement
Structured packing+ Str.Pkg+ PP rings for Absorption column & As per
packing rings Air washer requirement
Electricals Electrical cables ,Motors etc As per
requirement
Hardware Items Steam Traps,Copper wire As per
Netting,packingGaskets,nuts,Bolts,washers requirement
etc
Baby Boiler 600 Kg capacity on and at 100 o C( vertical) 1
Cooling tower FRP/wooden forced draft 1
Laboratory Suitable for testing of Formaldehyde As per
Methanol as per standard requirement
Water treatment Plant For softener and RO water 1
 Fig 4: Process Flow Diagram

3.2 Finished products specification (Per Tonne of Formaldehyde)

Finished product specification

Formeldehyde: 37%-45%± 0.25%

Methanol content :1.0 %-3.0 %

Acidity: 0.01% Max (normally below 0.005%)

pH : 3.5-4.0

Iron : 2.0 PPM Max

Ash : 0.01 % max

3.3 Plant Automation summary

To establish efficient production & set concentration of Formaldehyde maintaining optimum
mix ratio of Methanol, Air, Steam/Water & tail gas at set catalyst temperature is critical to the
process.
The objective of the proposed plant automation is to maintain the process parameters under
tight closed loop controls so as to allow plant operations with least intervention/control from
the operator side. Apart from the above critical plant operations many equally important
process control functions have to be maintained by the system to ensure consistent product
quality, long plant running and catalyst life which in turn would increase the profitability of the
plant operations. To name some of these important functions:
 Catalyst bed temperature stability
 Constant steam pressure
 Level control in various process vessels to ensure stable process reaction
 Pressure and temperature monitoring
 For monitoring the plant efficiency in real time & on every day basis Methanol
consumption ,formaldehyde production & steam consumption in the process is
taken from the flow.
 transmitters & the same is recorded
 Ignition system for plant startup along with local control operation.
 Variable frequency drives for process control and energy saving.

3.4 Plant Capacity

 The Formaldehyde Plant Unit is designed for a capacity of 100 TPD

3.5 Raw Materials Required

S.No Raw Material Quantity used Kg/ Tonne HCHO

1. Methanol 460
2. Water(D.M water) 500
3. Air 900

Specification of Raw Material

Methanol :Clear ,free from suspended matters

Odour : Free of foreign odour

Sp. Gravity : 0.792-0.793 at 20 o C

Purity : 99.98 % Min weight by

Distillation loss : 95 % Vol. Min. Between 64.5-65.5 o C

Free acid : 0.35 MI Max

Non Volatiles : 0.005 % Max Wt

Acetone : 0.014 % max. Wt.

Per Magnate time : 30 Minutes min.

DM water

pH : 7.5 -8.0

TDS : less than 1.00 PPM

Chlorine ION : Less than 1.00 PPM

Silica : less than 1.00 PPm

Pressure : 2.5 Kg per Sq. Cm

Conductivity : Less than 1

Air

Pressure : 0.2 Kg per Sq CM

Temperature :40-45 o C

Source of raw material:

The main raw material methanol will be sourced from near by market

Mode of Transport: All the raw materials and products will be transported via road transport.

3.6 Water Management

Source of water supply

Approx 75 KLD of Ground Water by tubewell and the rest will be sourced from PSIEC. Process
water is 100 % reused within the process. The complex is zero discharge complex from process.
Consumption & discharge is given below:
 Total Water
Requirement
(75 KLD)
Horticulture/Green
Belt
1.2 KLD

DM Water Boiler Cooling

15 KLD
5 KLD
55 KLD 15 KLD

Wastewater Proccess
generated
50 KLD Wastewater
generated
5 KLD
1 KLD
Wastewater
generated
Wastewater 2 KLD
generated
10 KLD

Total Wastewater
generated
18 KLD
@90% Hence Zero Liquid
discharge is Achieved
Recycled/Treated water

(16.2 KLD

Fig 5: Water Flow Diagram

 Table 2 : Water Balance of the Process

Use Water Consumption per Loss/waste - water generation

dayKLD KLD
D.M. Water Production 55 5
Formaldehyde Process 50 10
Cooling Water (Make Up 15 2
Water)
Boiler 5 1
Domestic Water requirement 1 .80
Flushing Water Requirement 1 1
Water requirement in Green 1.2 NIL
Area

LIQUID WASTE
Proposed unit shall be a zero discharge unit

3.7 SOLID WASTE

Municipal Solid waste:-

It is estimated that from 10 persons around 12 Kg/day of MSW (garbage) shall be generated.
The closed color coded bins for biodegradable & non-biodegradable waste shall be placed in
each section. The waste from these bins will be collect in main bin at the complex. The
biodegradable waste bin shall be sent to approved solid waste management site. The waste
from non-biodegradable waste bin shall be given to recycler for recycling.

Table 3: The solid waste categories and disposal method is given below:

Category Type of Waste Color of Bins Disposal Method Total Waste

(Kg/day)
Bio Degradable Organic Waste Green Recycler 7.2
Non- Recyclable Blue Recycler 4.8
Biodegradable Waste
Total 12

3.8 Process waste: -

As per present scheme, no process waste will be generated, if in case generated shall be stored
and disposed off at Treatment Storage and Disposal Facility (TSDF) approved by Pollution
Control Board at Nimbuan, DeraBassi, Distt Mohali

3.9 Hazardous Waste

Used oil from machineries/D.G. Set will be carefully stored in HDPE drums in isolated covered
facility. The used oil will be sold to vendors authorized by Central Pollution Control Board for
the treatment of the same. Suitable care will be taken so that spills / leaks of used oil from
storage could be avoided.

3.10 Air Emissions and Control

All the exhaust gas emissions will be channelized all through the process and will be reused for
various purposes like heating & remained chemical utilization. At the end the remaining gas will
be exhausted through a chimney. Emissions from production processes will contain exhaust
gasses which shall contain only Nitrogen, Hydrogen, Carbon dioxide, Carbon Monoxide ,VOC
and traces of Formaldehyde and Methanol.
To control the air emissions from D.G. Set, stack height of 4.0 m shall be provided above the
roof level of D.G. Set. Multi fuel boiler shall be installed for heating load of the plant, this shall
be based on biomass combustion from local areas and waste wood chips of the plant.

3.11 Power Requirement and Source

Total Power Requirement of the plant is 160 KWA which will be sourced from Punjab state
power corporation limited.

DG Set Proposed: 152 KWA of DG is proposed

Details of Electricity and fuel charges

Particulars

Total power load:160 KW

No. of working days: 300 days
No. of hours per day:16 hours
Load factor: 160 x 300x 16x 0.80=614400
Rate per unit:7.00
Total power cost at different capacity utilization leve
At 70 % capacity utilization :30.11
At 75 % Capacity Utilisation: 32.26
At 80 % capacity utilization :34.41
At 85 % capacity utilization:36.56
At 90 % Capacity Utilization :38.71
3.13 Employment Generation

The plant installed is a continuous, automatic plant so labour requirement will be very less.
Overall there will be an employment of 10 manpower which will include the following:

Table 4: Manpower details

S.No Manpower No
1 Plant Manager 1
2 Purchase office 1
3 Formaldehyde plant operator 2
4 Store keeper 1
5 Labour 2
6 Water treatment plant operator(Equalization 2
tank ,MBBR, Extended Aeration and settling
tank units)
Total manpower 9
 Chapter 4
SITE ANALYSIS

S. No. Particulars Details

1 Location MandiGobindgarh
a) Village/ Town/Plot No. F-12
b) District Fatehgarh Sahib
c) State Punjab
d) Latitude 30°39'3.35"N
e) Longitude 76°17'59.78" E
f) Toposheet No. 53B/6, 53B/2, 53B/5, 53B/1
2 Land use at the project site Industrial Land
3 Nearest highway Srinagar Kanyakumari Highway NH-44, 0.75 Km E
4 Nearest Railway Station MandiGobindgarh Railway station ,2.15 Km N
5 Nearest airport Sahnewal Airport ,40 Km NW
6 Nearest city/settlement MandiGobindgarh,1.30 Km, N
7 Features with 10 km :
I. Archaeological important places Nil
II. Wild life sanctuaries Nil
III. Reserved/Protected forest Nil
IV. Rivers Nil
V. Hill ranges Nil
VI. State Boundary Nil

4.1 Land Use:

The new project is proposed in industrial area and the land is under agreement.

4.2 Soil Classification

sandy loam to clayey with pH value from 7.8 to 8.5

4.3 Existing Infrastructure

Infrastrure is available for water supply, backup power supply, lab, drinking water ,rest room,
toilets, medial units No additional facilities required.
4.4 Topography

The topography of the district is even. It is mostly a plain of alluvial type. It also has loam to
heavy loam and sand to sandy loam soils in certain parts of the district. Soil is rich in nutrients
and suitable for crops like wheat, Paddy, Oil seeds, Sugar Cane, Potato and vegetables etc.

4.5 Availability of Minerals

The district is poor as regards mineral wealth. A few minor minerals are, however, found in the
district like Ordinary Earth and Brick Earth . There is no sand , gravels and other minor minerals
found in this district. Sand and gravel

4.6 Groundwater.

Water bearing formations in the area mainly include fine to medium grained sand or sand with
little admixture of clay. At shallow depth the ground water occurs under unconfined water
table conditions and in deeper aquifers occurs under confined conditions. The depth to ground
water table in the area ranges from 4.05 m below ground level (mbgl) in the central to 18.10
mbgl in the north eastern parts. The quality of ground water in shallow aquifers confirm to
maximum permissible limits for drinking water standards except along western part where high
values of fluoride (1.5 to 2.10 ppm) have been noticed and in central Fatehgarh Sahib showing
high values of sodium, zinc, iron, sulphate, nitrate and chloride. The deeper waters in general
are found to be suitable for irrigation and domestic purposes.

4.7 CLIMATE AND RAINFALL

In Distt.Fatehgarh Sahib, the climate is warm and temperate. The summers are much rainier
than the winters. The average annual temperature in Fatehgarh Sahib is 24.03°C. Precipitation
here averages 770 mm. With an average temperature of 33.6°C, June is the warmest month.
The lowest average temperature in the year occur in January, when it is around 13.3°C. The
precipitation varies 252 mm between the driest month and the wettest month. The variation in
temperatures throughout the year is 20.3°C.
 Chapter 5 : PLANNING BRIEF

Planning concept (type of Industries, facilities, transportation etc) Town and country
planning/Development authority classification Specification of Utilities

Type of Industry
As per EIA Notification dated 14.09.2006 and as amended from time to time, the project falls in
Cat. ‘B’,S.No.5(f) Synthetic organic chemicals industry (dyes & dye intermediates) as the project
site is located in notified industrial area.

PROPOSED INFRASTRUCTURE
List of Plant & Machinery

S.No MATERIAL OF CONSTRUCTION/SPECIFICATION

1. Air washer

2. Mixed Vessel and Mixer

3. Evaporatio Vessel(With perforated air and Methanol feed

pipeline)
4. Steam coil (Seamless pipes)

5. Super heater (Seamless Pipes with MS jacket)

6. Vapour Filter

7. Seperator-I
Seperator-II
Seperator-III

8. Reactor-1( seamless tubes with MS Jackets)

Reactor-2
Reactor-3
9. Reboiler (seamless Pipes)

10. Absorption column-I

Absorption column-II
Absorption column-III
11. Process vessel

12. Feed Vessel

 13. Water Filter

14. Methanol filter

6 PROJECT BENEFITS
 The formaldehyde produced will be used as a binder/glue in agro wood based
project set up Bansal chemical Industries for manufacturing Particle Board and MDF
boards at Punjab.

 Formaldehyde also finds its uses in other industries like plastic industry,
Pharmaceutical Industry, explosive industry, rubber industry etc.

 The plant as designed by us is pollution free since there is no water discharge. So it’s
an eco friendly project

 The formaldehyde plant as designed is an Automatic Plant; therefore, labour

requirement is very small.

 The Formaldehyde market has been growing steadily and an efficient plant is bound
to be a success.

7.0 REHABILITATION & RESETTLEMENT PLAN

No rehabilitation or resettlement plan is proposed as there are no habitations in the in the Plant site.

8.0 PROJECT SCHEDULE & COST ESTIMATES

The project will start only after obtaining Environmental Clearance and all other required
clearance and will complete after 9 months of commencement if finance is no bar. The Capital
Cost of the project will be Rs.432.74 Lakhs.

9.0 ANALYSIS OF PROPOSAL (Final Recommendations)

With the implementation of proposed project, the socio-economic status of the local people will
improve substantially. This will help in upliftment of social status of the people in the area.
Educational institutes will also come up and will lead to improvement of educational status of the
people in the area. Primary health centers will also come up and medical facilities will certainly
improve due to the proposed project.