ANNEXURE 1

KEY PLAN

BRIDGE
BHAKTI NAGAR
BUS STOP

MORBI MALIYA

IOC
FACTORY
Petrol
Pump 0.9 km

HARIPAR
KERALA
ROAD

Nelson Laminate Pvt.

Ltd

N
ANNEXURE 2 PLANT LAY-OUT
 ANNEXURE 3
MANUFACTURING PROCESS
Phenol Formaldehyde Resin:
Manufacturing Process
First all raw materials like phenol, formaldehyde & caustic will be added into closed
vessel.
Stirring & heating will be done upto 60 C. After 60C stop heating.
Reflux is done for 30 minutes upto 98 C.
Vacuum distillation will be started.
Water will be removed from the vessel as per the batch size.
Cooling down to 40 C.
Methanol will be added for dilution purpose.
Phenol Formaldehyde Resin will be ready for use in Laminate sheets as well as sell
purpose.

Reaction Chemistry
Process Flow Diagram

Phenol
Limped Reaction Vessel
Formaldehyde

Caustic Flakes
Stirring and heating up
to 60 C

Reflux for 30 Minutes

Vacuum Distillation Water

Cooling

Methanol Dilution

Product:
Phenol Formaldehyde
Resin
Melamine Formaldehyde Resin:

Manufacturing Process

First all the raw materials melamine, formaldehyde & caustic will be added in
Limped reaction vessel.
PH will be adjusted by adding Caustic.
Stirring & heating will be done upto 90 C for 1 Hr.
Cooling down to 40 C.
Add required quantity of Methanol
Melamine Formaldehyde Resin will be ready for use and for sell purpose.

Reaction Chemistry

N N
H2N NH2 fast
N N
+ H2C O
N N
NH2 H2C N CH2

melamine formaldehyde OH HO
melamine formaldehyde resin
Process Flow Diagram

Melamine
Limped Reaction Vessel
Formaldehyde

Caustic
Stirring and Heating up
to 95C for 1 hr

Cooling at 40C

Product:

Melamine Formaldehyde
Resin
 Urea Formaldehyde Resin:

Manufacturing Process
First all the raw materials Urea & Formaldehyde will be added in Limped reaction
vessel.
pH will be adjusted to pH 9.0 by adding acetic acid.
Stirring & heating will be done upto 95 C for 50 Minutes.
Heating will be continued until tolerance (10:40) is achieved.

pH will be adjusted to 9 by adding Caustic.

Cooling down to room temperature.

Urea Formaldehyde Resin will be ready for use and sale purpose.
Process Flow Diagram

Urea Limped Reaction

Vessel
Formaldehyde

pH adjusted to 9
Acetic Acid

Stirring and Heating up

to 95C for 50 Minutes

Caustic pH adjusted to 9

Cooling

Product: Urea
Formaldehyde Resin
 ANNEXURE 4

DETAILS OF SOLID WASTE

Sr. Quantity Per

Description Category Mode of Disposal
No. Month

1 ETP Sludge 34.3 11.28 MT Collection, storage and

Disposal at TSDF Site

Collection, storage and used

2 Used Oil 5.1 50 Lit. within premises as a lubricant
/ sold to registered recycler.

3 Discarded Plastic 33.3 13841Nos. Collection, storage & sell to

bags authorized vendor

Collection, storage & disposal

4 Resin waste 23.1 20 MT at common Incineration
facility
 ANNEXURE 5
DETAILS OF EFFLUENT TREATMENT PLANT

Collection & Holding Tank Primary Evaporator

Industrial
Neutralization Settling
effluent (Photo Fenton
Tank Tank
Reagent)

ETP PROCESS :
Industrial wastewater generated due to boiler blow down, cooling blow
down and resin manufacturing process and washing process will be
collected in Primary Collection tank and neutralized the effluent to make
homogeneous mixture.
Subsequently effluent from Primary Collection tank will be collected in
holding tank, where Photo Fenton Reagent (H2O2, FeSO4) will be added
and proper mixed with stirrer to destroy the Phenolic compounds.
Treated effluent from holding tank will be sent to primary settling tank to
remove the solid particle from the effluent.
Supernatant from Primary settling tank will be taken in to evaporation
system to evaporate the effluent.
Sludge will be collected in HDPE bags and sent to register TSDF site.
Thus the industry will achieve Zero discharge.

ETP UNIT DETAILS

No. Name of the units Volume (L) No. of Unit
1 Collection Tank 25000 2
2 Holding tank 20000 1
3 Primary Settling Tank 20000 1
4 Evaporator (Rating) 850 L/Hr. 1
 ETP FLOW-DIAGRAM

FeSO4.
H2O2
7H2O
Sun rays sun

H2O

Collection Tank
EFFLUEN (2 X 2500 L)
T FROM Water Inlet
THE
PLANT

Homogenizing tank or Photo Fenton process vessel

mixing tank (20000 L) (20000 L) O2 supply
Oxidation
Process
Coil for cooling
Heating Coil
purpose

SETTLING
TANK 20000 L

EVAPORATOR (850 L/hr)

Steam supplied from

Steam boiler & heater Sludge drying beds (1.5 x
1

1 2 3 4
1.5 x 1.5 (3.375 M3 each)
 ANNEXURE 6

WATER BALANCE DIAGRAM

Source: Bore well

Total: 26,424

Liter/ Day

Gardening Fresh Water 12642 L/D

10358 L/D Recycle
10166 L/D
15494 L/D

Domestic Use 25,200 L/D

5900 Lit/day Industrial Use
Recycle
48200 Lit/day

Recycle
7800 L/D
Drinking use 5650 Lit/day Washing Process
R. O.
250 Lit/Day goes to soak 200 L/D
48000 L/D Scrubbing &
pit through Nil
Cooling Dilution
septic tank 200 L/D Process
7800 4000 L/D
13860
Lit/day R.O. Reject Steam Boiler L/D
36000 L/D
12000 Scrubbed
Blow
methanol
Down
L/D sold to
400 L/D Expedio De- Authorized
scalar Condensate Boiler Blow-
recycler
down 3600
12000 L/D 25,200 L/D L/D
Sludge 40
Kg/day

ETP 18060 Lit/day

Note: * It may be noted that some raw materials are containing water which will be removed from the
process.
 ANNEXURE 7
DETAILS OF FLUE GAS STACK

Sr. Stack Height Fuel Type APC Expected GPCB

No. attached of the
System Pollutant Limit
to stack

In meter

1 Steam
Boiler

4 MT
30 Bag Filter PM As per
2 Thermic GPCB
(Common Coal SO2
Fluid Norms
Stack)
Heater 7.97 MT/Day NOx
(15,00,000
Kcal/Hr)

3 D. G. Set 6.7 43.2 lit/hr -- HC As per

GPCB
250 KVA CO
Norms
 ANNEXURE 8
LIST OF PRODUCTS FOR RESIN PLANT

Sr. No. Name of Product Quantity

1 Phenol Formaldehyde Resin 1100 MT/M

2 Melamine Formaldehyde Resin 500 MT/M

3 Urea Formaldehyde Resin 1200 MT/M

Note: Resin is use for manufacturing of Laminated Sheets (2, 00,000 no. /Month). Resin is
used for captive consumption as well as sells purpose.

LIST OF RAW MATERIALS REQUIRED FOR RESIN

PRODUCTION
Sr. No. Name of the Name of Raw Quantity in
product Materials MT/Month

1 Phenol Phenol 1037

Formaldehyde Resin
Formaldehyde 409

Caustic 6.05

Methanol 100

2 Melamine Resin Formaldehyde 300

Melamine 200

3 Urea Formaldehyde Urea 480

Resin
Formaldehyde 720

Caustic 6

Acetic Acid 6
 ANNEXURE 9

EXPECTED NOISE LEVEL

Sr. No. Location Noise level in dB(A)

1 Main Gate 60-63

2 Near Office 57-60

3 Process Area 70-73

4 Near Boiler 74-80

5 Near D.G. Set 74-80