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ENVIRONMENT
CLEARANCE FORM-I FOR
PHENOL FORMALDEHYDE RESIN &
MELAMINE FORMALDEHYDE RESIN MANUFACTURING UNIT
OF M/S. MERINO INDUSTRIES LIMITED
Located at:
Plot No. D2/CH/36 DAHEJ GIDC PHASE-II,
Dist. Bharuch,Gujarat E- mail: [email protected]
Prepared by: Jyoti Om Chemical Research Center Pvt. Ltd.
Shed No. K- 1, 7705/2-4, GIDC Estate, Ankleshwar- 393002, Dist: Bharuch, Gujarat.
Phone: (02646)220293, Fax: (02646) 239454 E mail: [email protected]
CONTENT
Sr.
No. Content
Page
No.
1. Basic Information 1-2
2. Form – 1 3-11
3. Proposed Terms Of Reference Annexure-I 12
4. List of Directors Annexure-II 12-13
5. Plant Layout -Annexure-III (A) 14
6. Site Plan – Annexure - III (B) 15
7. List of Products - Annexure-IV 16
8. List of Raw Materials - Annexure-V 16
9. Brief Manufacturing Process - Annexure – VI 17-19
10. Details of Water Consumption, Wastewater
Generation - Annexure –VII 20-21
11. Energy and Fuel Consumption Details- Annexure –
VIII 21
12. Process gas emission- Annexure-IX 22-23
13. List of Hazardous Raw material-Annexure-X 23
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M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD. 1
FORM – 1 (I) BASIC INFORMATION
Sr. No. Item Details
1. Name of the Project M/s. Merino Industries Limited 2. Sr. No in the schedule 5 (f) 3. Proposed capacity/ area/length/
tonnage to be handled/command area/ lease area / numbers of wells to be drilled
Phenol Formaldehyde Resin: 312.5MT/M Melamine Formaldehyde Resin: 77.5MT/M
4. New/ Expansion/ Modernization New Unit 5. Existing Capacity/ Area etc. Not Applicable 6. Category of the project i.e. ‘A’ or ‘B’ B 7. Does it attract the general condition? If
yes, please specify No
8. Does it attract the specific condition? If yes, please specify
No
9. ♦ Location ♦ Plot/ Survey/ Khasra` No.
Village ♦ Tehsil ♦ District ♦ State
Plot No D2 CH 36, Dahej Phase II, Bharuch , Gujarat.
10. Nearest Railway station / Airport along with distance in Kms.
Dahej about 5 Km.
11. Nearest Town, City, District Headquarters along with distance in Kms.
Bharuch – Approx. 40 Kms.
12. Village Panchayat, Zilla Parishad, Municipal Corporation, Local Body (complete postal addresses with telephone numbers to be given).
Post Office: Dahej Taluka : Vagra District: Bharuch
13. Name of the Applicant M/s. Merino Industries Limited 14. Registered Address 5, Alexandra Court, 60/1, Chowringhee Road,
Kolkata – 700020, India 15. Address for Correspondence:
Name: Designation (Owner/Partner/CEO): Address: Pin Code: E- mail: Telephone No.:
Mr. Prakash Lohia Managing Director Merino Industries Limited Plot No D2 CH 36, Dahej Phase II, Dist. Bharuch , Gujarat.
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India 16. Details of alternative sites examined,
if any. Location of these sites should be known on the Topo Sheet.
No alternate site is examined.
17. Interlinked Projects No 18. Whether second application of the
interlinked project has been submitted?
Not Applicable
19. If yes, Date of submission Not Applicable 20. If no, Reason Not Applicable 21. Whether the proposal involves
approval/clearance under: if yes, details of the same and their status to be given. ♦ The Forest (Conservation) Act, 1980? ♦ The Wildlife (Protection) Act, 1972? ♦ Act, the C.R.Z Notification, 1991?
No
22. Whether there is any Government Order/ Policy relevant/ relating to the site?
No, it is GIDC Industrial Estate
23. Forest Land involved (Hectares) No 24. Whether there is any litigation
pending against the project and/ or land in which the project is proposed to be set up? ♦ Name of the Court ♦ Case No. ♦ Orders/ Directions of the Court, if
any and its relevance to the proposed project
No
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(II) ACTIVITY
1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc)
Sr. No.
Information / checklist conformation.
Yes / No.
Details thereof (with approximate quantities/ rates, wherever possible) with source of information data.
1.1 Permanent or temporary change in land use, land cover or topography including increase in intensity of land use (with respect to local land use plan.)
No New project: Project coming up in GIDC Estate, Dahej.
1.2 Clearance of existing land, vegetation and buildings?
No. Plots are already marked by the GIDC Estate.
1.3 Creation of new land uses. Yes Plot allotted to M/s Merino Industries Ltd. for setting up High Pressure Decorative plant in which manufacturing of Phenol Formaldehyde Resin and Melamine Formaldehyde Resin will be done for captive consumption only.
1.4 Pre-construction investigations e.g. bore house, soil testing?
No --
1.5 Construction works? Yes There will be construction work related to proposed expansion.
1.6 Demolition works? No No such work will be involved. 1.7 Temporary sites used for
construction works or housing of construction workers?
No Local construction workers will be hired.
1.8 Above ground buildings, structures or earthworks including linear structures, cut and fill or excavations.
Yes Section drawing of building plan attached. Section drawing attached in Annexure-III (A) & III (B).
1.9 Underground works including mining or tunneling?
No Not Applicable
1.10 Reclamation works? No Not Applicable 1.11 Dredging? No Not Applicable 1.12 Offshore structures? No Not Applicable 1.13 Production and manufacturing
processes? Yes Attached Manufacturing Process
details as Annexure No. VI
1.14 Facilities for storage of goods or materials?
Yes Mentioned in the layout plan. Drawing attached as Annexure III
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(A). 1.15 Facilities for treatment or disposal of
solid waste or liquid effluents? No There will not be any waste or liquid
effluent. 1.16 Facilities for long term housing of
operational workers? No Plot will be utilized for industrial
purpose only. 1.17 New road, rail or sea traffic during
construction or operation? No GIDC Dahej has well developed road
facility. 1.18 New road, rail, air waterborne or
other transport infrastructure including new or altered routes and stations, ports, airports etc?
No GIDC Dahej has well developed road facility. Not applicable
1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements?
No Proposed project is located in Notified area.
1.20 New or diverted transmission lines orpipelines?
No The proposed project is located in notified G.I.D.C. Industrial Estate.
1.21 Impoundment, damming, culverting, realignment or other changes to the hydrology of watercourses or aquifers?
No Not Applicable
1.22 Stream Crossing? No No such activity is involved in the proposed project.
1.23 Abstraction or transfers of water form ground or surface waters?
No The unit will use water from G.I.D.C water supply system.
1.24 Changes in water bodies or the land surface affecting drainage or run-off?
No The proposed project is located in notified GIDC Estate.
1.25 Transport of personnel or materials for construction, operation or decommissioning?
Yes There will be routine movement of construction material, labor, and raw material to the site by road trucks.
1.26 Long-term dismantling or decommissioning or restoration works?
No There is no such decommissioning work.
1.27 Ongoing activity during decommissioning which could have an impact on the environment?
No There will be no decommissioning activity for the proposed project.
1.28 Influx of people to an area in either temporarily or permanently?
No Local man power will be employed. The construction will be stage wise and hence not more than 50 people expected at a time.
1.29 Introduction of alien species? No No such activity is associated with
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the proposed project. 1.30 Loss of native species or genetic
diversity? No No such activity is involved which
can leads to loss of native species or genetic diversity.
1.31 Any other actions? No Not required other action 2 Use of Natural resources for construction or operation of the Project (such as land,
water, materials or energy, especially any resources which are non-renewable or in short supply):
Sr. No.
Information / Checklist conformation.
Yes / No.
Details thereof (with approximate quantities / rates, wherever possible) with source of information data.
2.1 Land especially undeveloped or agricultural land (ha)
No
Proposed project is situated in Dahej Industrial estate.
2.2 Water (expected source & competing users) unit: KLD
Yes
Details of water consumption are attached as Annexure No. VII.
2.3 Minerals (MT) No Not Applicable 2.4 Construction material – stone,
aggregates, sand / soil (expected source – MT)
Yes Material Qty. Source
Cement 5000 bags From local supply
Sand 2500 Cu. Mt. TMT Steel
300 MT
Gravel 2500 Cu. Mt.
2.5 Forests and timber (source - MT) No Not Applicable 2.6 Energy including electricity and fuels
(source, competing users) Unit: fuel (MT),energy (MW)
Yes Details of Energy & fuel consumption are attached as Annexure No. VIII.
2.7 Any other natural resources (use appropriate standard units)
No No other natural resources will be used.
3 Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.
Sr. No.
Information / Checklist Conformation.
Yes / No.
Details thereof (with approximate quantities / rates, wherever possible) with source of information data.
3.1 Use of substances or materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies)
Yes List of hazardous raw materials as per MSIHC rules is attached as Annexure No. X.
3.2 Changes in occurrence of disease or No Not Applicable. It is in the notified
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affect disease vectors (e.g. insect or water borne diseases)
Industrial Area.
3.3 Affect the welfare of people e.g. by changing living conditions?
Yes New employment will be generated.
3.4 Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderlyetc.,
No There will be no such effects due to the proposed project.
3.5 Any other causes. No None. 4. Production of solid wastes during construction or operation or decommissioning
(MT/month). Sr. No.
Information / Checklist conformation.
Yes / No.
Details thereof (with approximate quantities / rates, wherever possible) with source of information data.
4.1 Spoil, overburden or mine waste. No No such waste will be generated from the proposed activity.
4.2 Municipal waste (domestic and or commercial wastes)
Yes Will be disposed off as per MSW guide lines.
4.3 Hazardous wastes (as per Hazardous Waste Management Rules)
Yes There no generation of hazardous waste.
4.4 Other industrial process wastes Yes There is no generation of any industrial waste
4.5 Surplus product No Not Applicable 4.6 Sewage sludge or other sludge from
effluent treatment. No. --
4.7 Construction or demolition wastes Yes Any waste will be utilized in road
construction. 4.8 Redundant machinery or
equipment. No Not Applicable
4.9 Contaminated soils or other materials.
No New Project
4.10 Agricultural waste. No Notified GIDC Area. 4.11 Other solid wastes. No Nil 5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr) Sr. No.
Information / Checklist conformation.
Yes / No.
Details thereof (with approximate quantities / rates, wherever possible) with source of information data.
5.1 Emissions from combustion of fossil No There will not be any use of fossil
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fuels from stationary or mobile sources
fuel.
5.2 Emissions from Production Processes.
Yes VOC are scrubbed in water scrubber and details are attached as an Annexure No. IX.
5.3 Emissions from materials handling including storage or transport.
No --
5.4 Emissions from construction activities including plant and equipment
No Adequate measures will be taken to control emissions from construction materials including plant and equipment.
5.5 Dust or odors from handling of materials including construction materials, sewage and waste.
No
Adequate measures will be taken.
5.6 Emissions from incineration of waste. No Not Applicable 5.7 Emissions from burning of waste in
open air (e.g. slash materials, construction debris)
No No burning activity will be done in the unit.
5.8 Emission from any other sources. No No other emissions from any other source.
6. Generation of Noise and Vibration, and Emissions of Light and Heat: Sr. No.
Information / Checklist conformation.
Yes / No.
Details thereof (with approximate quantities / rates, wherever possible) with source of information data.
6.1 From operation of equipment e.g. engines, ventilation plant, crushers.
Yes DG set as stand by option. Adequate measures will be taken by the unit. The noise level will be within the prescribed limit.
6.2 From industrial or similar processes. Yes Noise proof equipments will be used for industrial processes.
6.3 From construction or demolition. Yes Noise will be generated from some activities such as drilling, digging, grinding etc. during construction which will be reduced by providing barricades. It will be ensured that the high noise creating activities will be performed during the day only.
6.4 From blasting or piling. No Nil 6.5 From construction or operational
traffic. No Adequate measures will be taken by
the unit. 6.6 From lighting or cooling systems. No Natural spray cooling towers are
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used. 6.7 From any other sources. No No emission from any other sources. 7. Risks of contamination of land or water from releases of pollutants into the
ground or into sewers, surface waters, groundwater, coastal waters or the sea: Sr. No.
Information / Checklist conformation.
Yes / No.
Details thereof (with approximate quantities / rates, wherever possible) with source of information data.
7.1 From handling, storage, use or spillage of hazardous materials.
Yes All the hazardous chemicals received will be stored in barrels in covered godown. Adequate measures will be taken during handling & use. Spillages will be cleaned with appropriate method and the waste generated will be disposed off as hazardous waste. PPE’s will be used by the operators when handling hazardous chemicals.
7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of discharge)
No Nil.
7.3 By deposition of pollutants emitted toair into the land or into water
No Proper air pollution control measures are taken and thus their deposition on land or water is not expected.
7.4 From any other sources. No No other sources will be there. 7.5 Is there a risk of long term build up
of pollutants in the environment fromthese sources?
No There will not be any long term build up of pollutants in the environment from these sources.
8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment.
Sr. No.
Information / Checklist conformation.
Yes / No.
Details thereof (with approximate quantities / rates, wherever possible) with source of information data.
8.1 From explosions, spillages, fires etc. from storage, handling, use or production of hazardous substances.
Yes Adequate control measures will be provided. Proper on site and off site emergency plans will be prepared.
8.2 From any other causes No All the causes have been covered in 8.1
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8.3 Could the project be affected by natural disasters causing environmental damage (e.g. floods, earthquakes, landslides, cloudburst etc)?
No Structures will be made earthquake proof and no possibility of flood is identified.
9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality.
Sr. No.
Information / Checklist conformation.
Yes / No.
Details thereof (with approximate quantities / rates, wherever possible) with source of information data.
9.1 Lead to development of supporting localities, ancillary development or development stimulated by the project which could have impact on the environment e.g.: • Supporting infrastructure (roads, power supply, waste or waste water treatment, etc.) • housing development • extractive industries • supply industries • other
Yes Local ancillary development like rewinding of motors, maintenance people, wiremen, etc. will be increased. It is the notified Industrial Area.
9.2 Lead to after – use of the site, which could have an impact on the environment.
No No negative impact identified.
9.3 Set a precedent for later developments.
No The project is not unprecedenent.
9.4 Have a cumulative effect due to proximity to other existing or planned projects with similar effects.
No It is in the industrial estate of Dahej.
(III) ENVIRONMENTAL SENSITIVITY. Sr. No.
Area. Name / Identity
Aerial distance (within 15 km.) Proposed project location boundary.
1 Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other related value.
No It is fully developed GIDC estate.
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2 Areas which are important or sensitive for ecological reasons – Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests.
No The Narmada river is approximately 7 km away from project site.
3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration.
No It is fully developed GIDC estate.
4 Inland, coastal, marine or underground waters
No It is fully developed GIDC estate.
5 State, National boundaries. No It is fully developed GIDC estate. 6 Routes or facilities used by the public
for access to recreation or other tourist, pilgrim areas.
No It is fully developed GIDC estate.
7 Defence installations. No It is fully developed GIDC estate. 8 Densely populated or built – up area. No Dahej is approx 5 Km away. Bharuch
City is Approx. 40 Km away. 9 Areas occupied by sensitive man-
made land uses (hospitals, schools, places of worship, community facilities)
Yes Nearest school is Vadadla Primary School which is 2Km from site. Hospital is 5Km from project site. .
10 Areas containing important, high quality or scare resources (ground water, surface resources, forestry, agriculture, fisheries, tourism, minerals)
No It is fully developed GIDC estate.
11 Areas already subjected to pollution or environmental damage. (those where existing legal environmental standards are exceeded)
No Environment standards of GIDC estate, Dahej are within the limits.
12 Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)
No It is fully developed GIDC estate.
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ANNEXURE-I
PROPOSED TERMS OF REFERENCE
Request is for B (2) Category. As there is no wastewater generation, no hazardous
waste generation, no fuel requirement and no process gas emission.
ANNEXURE-II LIST OF DIRECTORS
Sr. No.
Name & Designation
Designation Residential address Telephone/Fax/E-mail Nos.
1 Shri Champalal Lohia
Executive Chairman
House no.44, Road No.78 Punjabi Bagh, New Delhi-110026
01276-304900
2 Shri Rup Chand Lohia
Executive Vice-Chairman
Flat No. 4D, 4th Floor, 3, Mayfair Road, Kolkata-700 019
080-30216900
3 Shri Prakash Lohia- Managing Director
55/1, Kabi Bharati Sarani, 4th Floor, Vrindaban Apartments, PS-Lake, Kolkata-700 029
0122-2301620
4 Shri Prasan Lohia- Whole-Time Director
Flat No. 4D, 4th Floor, 3, Mayfair Road, Kolkata-700 019
033-22901214
5 Miss. Ruchira Lohia- Whole-Time-Director
Kasturi Bai Cold Storage Compound Buland Shahar Road, P.O. Hapur, Dist. Ghaziabad, U.P.
011-45557000
6 Shri Bikash Lohia - Whole-Time Director
House no.44, Road No.78 Punjabi Bagh, New Delhi-110026
011-45068300
7 Shri Madhusudan Lohia-
Whole-Time Director
55/1, Kabi Bharati Sarani, 4th Floor, Vrindaban Apartments, PS-Lake, Kolkata-700 029
0122-2301620
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8 Shri Nripen Kumar Dugar-
Whole-Time Director
Kasturi Bai Cold Storage Compound Buland Shahar Road, P.O. Hapur, Dist. Gaziabad, U.P.
0122-2301620
9 Shri Amar Nath Roy-
Director 10,Central Road, Kolkata-700 032
09830071093
10 Dr. Gautam Bhattacharjee-
Director 425/59, Golam Mohd. Shah Road, Panchjanya Golf Green, Kolkata-700 095
09830051479
11 Shri Sudatta Mandal Nominee Director (Nominee of Export-Import Bank of India)
Director (Nominee of Export-Import Bank of India)
Export-Import Bank of India Centre One Building, Floor 21, World Trade Centre, Cuffe Parade, Mumbai-400005
022-22172457
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ANNEXURE-III (A)
PLANT LAYOUT
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ANNEXURE-III (B) SITE PLAN
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ANNEXURE-IV
LIST OF PRODUCTS WITH THEIR PRODUCTION CAPACITY
ANNEXURE-V LIST OF RAW MATERIALS
Sr. No.
Name of Products Capacity in MT/Month
Name of Raw Materials
Quantity in MT/Month
1. Phenol Formaldehyde Resin
312.5 ( 508.384 on as is basis)
Phenol 244.4 Formaldehyde 150.0 Caustic 2.184 Sugar 20.8 Methanol 10.4 Para Formaldehyde
80.6
2. Melamine Formaldehyde Resin
77.5 (125.77 on as is basis)
Formaldehyde 67.27 Melamine 58.5
Sr. No. Product Name Capacity MT/Month
1 Phenol Formaldehyde Resin 312.5 MT/M
2 Melamine Formaldehyde Resin 77.5 MT/M
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ANNEXURE-VI MANUFACTURING PROCESS PHENOLFORMALDEHYDERESIN Production Process: Phenol, Formaldehyde, para formaldehyde and Caustic flake are added in the reaction vessel.
Then these are stirred and heated up to 90*C. After that refluxing starts and continues for 40
min., then cooling & dilution with methanol is done. Finally viscosity and water tolerance
been checked.
Reaction Chemistry
Process Flow Diagram of Phenol Formaldehyde resin
Reaction Vessel Phenol Formaldehyde Para Formaldehyde Caustic flakes and sugar Stirring and heating
up to 900 C
Reflux for 40 Minutes
Cooling
Dilution
Intermediate Product: Phenol Formaldehyde
Resin
Methanol
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Material Balance
Sr. No.
Raw materials QTY in KG/ Batch
Input 1 Phenol 2350
2 Formaldehyde 1440
3 Para Formaldehyde 775
Add
itive
s Caustic 21
Water 25
Sugar 200
4 Methanol 100
Total 4911
Output
Phenol Formaldehyde Resin 4911
Mass Balance of Phenol Formaldehyde Resin per Batch
(Batch size= 4.356 MT on dry basis)(4.91MT on as is basis) MELAMINE FORMALDEHYDE RESIN Production Process: Phenol and Formaldehyde are added in the reaction vessel. Then these are stirred and heated up to 950C for 1 hour. (After the achieving of required water tolerance), cooling and dilution with water is done and Melamine Formaldehyde Resin is manufactured. Reaction Chemistry
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Process Flow Diagram of Melamine Formaldehyde resin
Material Balance
Raw Materials Qty in KG per batch
Input
Formaldehyde 1150
Melamine 1000
Water 500
Final Total 2650
Output
Melamine formaldehyde resin
2650
Mass Balance of Melamine Formaldehyde Resin per batch (1batch = 2.650MT)
Reaction Vessel Melamine
Formaldehyde
Stirring and heating up to 950 C for 1 hr.
Cooling at 400C
Dilution
Intermediate Product: Melamine
Formaldehyde Resin
Water
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ANNEXURE-VII
DETAILS OF WATER CONSUMPTION AND WASTE WATER GENERATION
DETAILS OF WATER CONSUMPTION Sr. No.
Category Water Consumption (KL/Day)
1. Domestic -- 2. Industrial Processing 1.25 Boiler -- Cooling -- Gardening -- Total(Industrial) 1.25 Total
(Industrial + Domestic) 1.25
DETAILS OF WASTE WATER GENERATION Sr. No. Category Waste Water
Generation (KL/Day)
1. Domestic -- 2. Industrial Process -- Boiler -- Cooling -- Others -- Total(Industrial) -- Total
(Industrial + Domestic) --
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WATER BALANCE DIAGRAM
ANNEXURE-VIII
ELECTRICITY & FUEL CONSUMPTION
Sr. No.
Particulars Requirement Remark
1. Electricity connected load
1500 KVA DGVCL company
2. Steam 2 KL/Day Principle laminate manufacturing unit
GIDC WATER 1.25KLD
Water from Phenol (90%) and Formaldehyde (37%)
5 KLD
Process 6.25 KLD
Water Remaining in Resin 6.25 KLD
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ANNEXURE-IX
PROCESS GAS EMISSION
VOC will be scrubbed in water scrubber and that water will be used in process in next batch.
VOC
Spray
2 KL Chilled Water
Vent
Scrubbed Water is used in process in next batch
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Description:
The scrubbing system consists of a scrubber (packed column absorber), an exhaust blower and
scrubbing media. The vapor from the process vents enters the primary scrubber where they are
absorbed in water. Thus, the air leaving from the scrubber is clean. The details of scrubber system are
given below.
DETAILS OF WATER SCRUBBER SYSTEM
Sr. No.
Name of Units Capacity Quantity MOC
1 Water Scrubber 2 KL 1 HDPE/PP FRP
ANNEXURE-X
LIST OF HAZARDOUS CHEMICAL Sr.
No. Name of Chemical Storage Capacity for
proposed product ( resins) MOC 1 Phenol 100 Kl MS 2 Formaldehyde 150 Kl MS with FRP liner 3 Melamine 25 Ton Bags 4 Methanol 10 Kl MS
5 Caustic 01 MT Plastic bags on
pallets 6 DEG 200 Lit. Steel drum