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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

M/S. MERINO INDUSTRIES LIMITED.

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.



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



(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



(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



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.


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



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.


Yes / No.


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.


Yes / No.


5.1 Emissions from combustion of fossil No There will not be any use of fossil



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.


Yes / No.


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



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.


Yes / No.


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.


Yes / No.


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



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.


Yes / No.


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.



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.


4 Inland, coastal, marine or underground waters


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.


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)


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)




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



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



ANNEXURE-III (A)

PLANT LAYOUT



ANNEXURE-III (B) SITE PLAN



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



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



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



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



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) --



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



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



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

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