1.0 EXECUTIVE SUMMARY

Transcription

1 1.0 EXECUTIVE SUMMARY M/s Merino Industries Limited has proposed for manufacturing Phenol Formaldehyde Resin, Melamine Formaldehyde Resin at Plot No D2 CH 36, Dahej Phase II, Dist. Bharuch, Gujarat. The details of products are given below table. TABLE: 1 LIST OF PRODUCTS Sr. No. 1 2 Product Name Phenol Formaldehyde Resin Melamine Formaldehyde Resin Capacity MT/Month MT/M 77.5 MT/M COST OF PROJECT The expected cost of project for production of Phenol Formaldehyde Resin and Melamine Formaldehyde Resin is Rs.625 lacs. The plot has been purchased by M/s, Merino Industries Limited from GIDC. The total plot area of the unit is sq. m. Out of this Phenol Formaldehyde Resin and Melamine Formaldehyde Resin plant has 880 sq. M area. The green belt area will be sq. m. UTILITY The steam consumption is 0.5 KL/Day from Laminated Sheet Plant. The connected electricity load will be 1500 KVA per annum from DGVCL. WATER CONSUMPTION The unit will use 1.3 KL/Day fresh water for Phenol Formaldehyde Resin and Melamine Formaldehyde Resin manufacturing. WASTE WATER GENERATION There will be 7KL/Day wastewater generation (Distillated Residue) from Phenol Formaldehyde Resin and Melamine Formaldehyde Resin manufacturing. Distillated Residue will be send to Incineration Plant. GASEOUS EMISSION 1

2 There will not be any gaseous emission from proposed project. HAZARDOUS WASTE MANAGEMENT There will be generation of distillate residue (7 KL/day). 2.0 INTRODUCTION 2.1 THE PROJECT M/s, Merino Industries Limited has proposed for manufacturing of Phenol Formaldehyde Resin and Melamine Formaldehyde Resin at Plot No: D2 CH 36, Dahej Phase II, Dist. Bharuch, Gujarat. The details of products are given below table PROJECT PROPONENT In Interior Solutions, plywood was first product of the unit in 1974 and it launched for reputation for product quality and company service. Merino then established its manufacturing unit for high pressure decorative laminates at Hapur near New Delhi. A second unit at Rohad was commissioned, as rapid growth evolved us into India's largest manufacturer and exporter of laminates. The Merino Group's facilities are state-of-the-art, geared for integration, and strategically well-located to serve the markets. Its two manufacturing facilities for High Pressure Laminates have a combined annual production capacity of 10 Lacs sheet per annum. M/s, Merino Industries Limited proposes to manufacture Phenol Formaldehyde Resin and Melamine Formaldehyde Resin which will be used as raw material for manufacturing high pressure decorative laminate. At Merino, quality is a tradition that is followed meticulously and in its entirety. Their commitment to the highest standards in manufacturing process has won certifications including ISO 9001, ISO and ISO 18001, for all facilities. Merino has integrated all the stages of its operation through ERP, ensuring transparency and on-time information to customers and service providers. A dedicated and focused Research and Development team works unremittingly towards 2

3 continuous innovation and improvement, resulting in an array of superior quality products. Moreover, experts from around the world are invited to strengthen their knowledge base. The list of directors is attached as Annexure-II. Directors of the company have good experience in handling the production management, financial management and all the allied areas. 2.3 NATURE OF PROJECT The unit has proposed manufacturing of MT/Month of Phenol Formaldehyde Resin, 77.5 MT/Month of Melamine Formaldehyde Resin. 2.4 MARKET FEASIBILITY PF resin and MF resin will be prepared by Merino for its own consumption and main reasons to manufacture resin for in house consumptions are listed below: 1. Manufacturing of resin is cheaper than purchasing of resin. 2. The unit can purchase standard resin but not customized resin to satisfy their requirements 3. The unit will prefer own resin manufacturing to maintain consistent product quality 4. Merino is manufacturing resin by its own formulation and they can t share their formulation with resin suppliers 5. The unit can t maintain and add product properties as per customer s requirement with the resin supplied by a vendor. 6. To impose better control on safety and environment issues linked with handling of hazardous chemicals and disposal of hazardous waste. 3.0 PROJECT DESCRIPTION 3

4 3.1 TYPE OF PROJECT The proposed project is not including any interlinked and interdependent projects. 3.2 PROJECT LOCATION The proposed project site is located at Plot No D2 CH 36, Dahej Phase II, and. It is approximately 40 km distance from Dist. Bharuch. The approximate geographical positioning of the project site is at Latitude: 21 42'46.56"N, Long: 72 34'55.23"E. The location of the project site can be identified from the location map shown in Figure -2. The salient features of the location of the project site are presented in below Table. TABLE: 2 SALIENT FEATURES OF THE PROJECT SITE Particulars Details Approx. Distance from Project Site Village Dahej 5 km Taluka/ Tehsil Vagra 35km District Bharuch 39.1 km Approx. Geographical positioning Latitude: 21 42'46.56"N 0 km Longitude:72 34'55.23"E Nearest City Bharuch 39.1 km Nearest Town Bharuch 39.1 km Nearest Highway National Highway No km Nearest State highway State Highway No km Nearest Railway line/ Railway Bharuch 39.2 km station Nearest Airport/ Airbase Vadodara 122 km 4

5 FIGURE: 1 LOCATION OF THE PROJECT SITE Project Site 5

6 FIGURE: 2 AERIAL VIEW OF THE 5 KM RADIAL PERIPHERY FROM THE PROJECT SITE 3.3 SITE SELECTION NEIGHBOURING INDUSTRIES The industry is proposed to be located in GIDC area. At present, there is no any industry nearby plot SIZE OF PROJECT The unit has proposed manufacturing of High Pressure Decorative Laminate Sheets and Laminated Particle Board and MDF. New Plant and machinery installations will also have to be acquired and installed. For captive consumption, the unit has proposed to manufacture resins. This application is for resin manufacturing activity. 6

7 Environment Protection and safety systems have also been considered in planning the Cost Projection. The unit will carry out maintenance and necessary modifications in proposed effluent treatment plant. The break-up of the proposed project cost is given in below table. TABLE: 3 CAPITAL COST PROJECTION Sr. No. Purpose Total (Rs. In Lacs) As Per CTE 1. Land Building Plant and Machinery Misc/Contingency Total For EC 1. Storage Cost VOC Control measurement 100 Equipment 3. Machinery Resin manufacturing Q.A. Lab set up Environmental Protection & Safety 40 a) Effluent treatment Plant 40 b) Green belt development 30 Total PROCESS TECHNOLOGY Process details like process description for each grade of products are covered separately in Annexure-VI. VOC control measure from reaction vent attached to water scrubber. 7

8 3.5 RAW-MATERIALS The proposed products are organic chemicals and the required raw materials will be purchased from the local/ Indian market. Details of raw-material consumption are covered in Annexure-IV. 3.6 RESOURCE REQUIREMENTS 3.6.1LAND The plot has been purchased by M/s, Merino Industries Limited from GIDC. The total plot area of the unit is sq. m. out of this Phenol Formaldehyde Resin and Melamine Formaldehyde Resin plant has 880 sq. m. FUEL & ELECTRICITY CONSUMPTION BUILDING The new building will be constructed. TABLE: 4 APPROXIMATE REQUIREMENT OF CONSTRUCTION MATERIALS Sr. No. Construction Material Proposed Quantity 1. Gravel 2500 cu mtr 2. TMT Steel 300MT 3. Cement Bags 4. Sand 2500 CFT 8

9 DETAIL OF UTILITY TABLE: 5 Utility Particulars Requirement Remark 1. Electricity connected 1500 KVA DGVCL company load 2.. Steam 0.5KL/day In-house WATER The unit will use 1.3 KL/Day fresh water for Phenol Formaldehyde Resin and Melamine Formaldehyde Resin manufacturing MANPOWER The manpower required for the project as well as during the construction/ commissioning activities will be employed from the local area. The preference will be given to local people. TABLE: 7 MAN POWER REQUIREMENT Phase of Project Type of Labor No. of Worker During construction Contractual 150 During commissioning Contractual 150 During operations Managerial 10 Skilled 12 Un-skilled MITIGATION MEASURES & EMP Based on overall manufacturing & operation activities, the mitigation measures have been proposed by the company for the control of the anticipated pollution load WASTEWATER MANAGEMENT WASTEWATER GENERATION There was 7KL/Day wastewater generation (Distillated Residue) from Phenol Formaldehyde Resin and Melamine Formaldehyde Resin manufacturing WATER BALANCE DIAGRAM 9

10 GIDC WATER 1.3KLD Process 14.3KLD Formaldehyde (37%) 13KLD Resin Production 1.3KLD Distillation 13KLD Recover water in cooling tower 6KLD (Distillate Residue) 7KLD WASTEWATER TREATMENT & DISPOSAL There will be 7KL/Day waste water generation (Distillate Residue) from Phenol Formaldehyde Resin and Melamine Formaldehyde Resin manufacturing. Distillate Residue will be send to Incineration Plant GASEOUS EMISSIONS & CONTROL FLUE GAS EMISSIONS There will not be any process emission for proposed resin manufacturing project HAZARDOUS/ NON-HAZARDOUS WASTE MANAGEMENT The following type of hazardous waste will be generated from the operational activities. All the waste will be stored separately in a designated storage area. TABLE: 12 10

11 DETAILS OF HAZARDOUS WASTE Sr. No. Name of Hazardous Waste Category Generation Quantity Mode Of Disposal 1 Distillation residue KL/Day In house incinerator In addition to the provision of above, the unit will ensure proper management for hazardous waste as below: Transportation of hazardous waste to the TSDF Site will be governed as per the guidelines and accompanied with Form-13. Annual returns of the disposal of wastes in Form-4 will be uploaded online and submitted regularly to the local office of the GPCB NOISE CONTROL & ODOUR The major noise generating installation will be the D.G. Set. It will be installed in a closed room, acoustic enclosure will be provided around it. Ear plugs will also be provided to the operating personnel in boiler room. The following steps will be taken for odour control. Raw-material feeding will be carried out by pumps. All reactions will be taken in closed reactor system. Roof top ventilation will be provided in the entire plant area. Regular monitoring will be done of piping and fittings for checking of any leakages STORAGE, HANDLING AND TRANSPORT OF HAZARDOUS CHEMICALS The storage and mode of transport of chemicals will be done as per detailed MSDS and Chemical hazards guide (NIOSH) for the hazardous chemicals. Few chemical to be used in the proposed activities are listed as Hazardous Chemicals as per the Schedule-1 of the MSIHC Rules, as amended in HEALTH AND SAFETY MEASURES Few chemical to be used in the proposed activities are listed as Hazardous Chemicals as per the Schedule-1 of the MSIHC Rules, as amended in

12 Physical hazards may manifest as fires, explosions, excessive temperatures, or the release of large volumes of gas or toxic or flammable gases or vapors. According to Schedule 2 & 3 of MSIHC Rules. Moreover transport activity will be through drums, so there will be manual loading and unloading and no unloading through pipe at the site. Hence, the risk of static charge generation during transfer of such chemicals is not significant. Below mentioned is the summary proposed safety measures to be taken at site for control of anticipated hazard. 4.0 SITE ANALYSIS 4.1 CONNECTIVITY Dahej industrial estate (chemical zone, engineer zone, service cum commercial zone) is spread over an area of 2700 hectares in close proximity to State Highway No. 6. National highway 8 passes through the district connecting it with Ahmadabad (182 km) and Mumbai (362 km). The Dahej is located at 40 km distance from Bharuch Railway station. The nearest domestic airport Vadodara is at an approx distance 116 km from Dahej. The nearest International airport Ahmadabad is at a distance 225 km. 4.2 LAND USE AND LAND OWNERSHIP The proposed project site is located at Plot No D2 CH 36, Dahej Phase II.. The total plot area of the unit is sq. m. Out of this Phenol Formaldehyde Resin and Melamine Formaldehyde Resin plant has 880 sq. M area. The green belt area will be sq. m. 4.3 LAND USE The proposed project site is located at Plot No D2 CH 36, Dahej Phase II, and Taluka. Vagra, Dist.Bharuch. The plot is notified by GIDC for industrial purpose. 4.4 EXISTING INFRASTRUCTURE The plant is located in a well-developed industrial zone, which will have all essential facilities such as internal roads, arrangement for supply of water and power to industries, effluent disposal facilities etc. 4.5 CLIMATE DATA 12

13 Vadodara is the nearest meteorological observatory station to the project site. The various meteorological details of Vadodara station for the year of March, 2014 to May, 2014 are given in below table. TABLE: 13 DETAILS OF THE METEOROLOGICAL CONDITIONS (OCTOBER TO DECEMBER 2012). Month Temperature( o C) Humidity (%) Rain fall (mm) Maximum Minimum Maximum Minimum Maximum Minimum March April May (Data from Indian Meteorological Department, Ahmadabad, Station:-Vadodara) (Data from Indian Meteorological Department, Baroda) Based on the above metrological data, wind rose has been prepared for the post monsoon season period from March, 2014 to May, As per the metrological data, it shows that the average wind speed in March, April and May, 2014 is 1.33 m/s with wind direction blowing to SW. The wind rose prepared from same data is shown in following Figure. 13

14 FIGURE: 4 WIND ROSE 4.6 SOCIAL INFRASTRUCTURE There are 67 villages in Vagra Taluka. Population density and sex ratio of Vagra Taluka was reported 94 persons/sq.km. And 913 females per 1000 males respectively in 2001 census report. Total literacy of Vagra Taluka was found %.The basic amenities like primary and secondary education schools, community health workers, primary health sub centre, private practitioners, primary health centre, maternity and child welfare, dispensaries, T.B clinic, family welfare centre, hospital, drinking water, transportation facilities, electricity, telephone etc. are available. 14

15 5.0 PLANNING BRIEF 5.1 PLANNING CONCEPT Details will be covered in EIA report. 5.2 POPULATION PROJECTION Population of Vagra Taluka was reported to be 82,647 in 2001, Census. Entire Vagra Taluka region and particularly Dahej area is all set for massive industrialization. There is large scale migrant population is anticipated in this area. The proposed project is relatively small in size and will be employing around 170 skilled and unskilled people all most 80% of this will be selected from local people. Even though the population of Vagra Taluka will have some increase due to this project. 5.3 LAND USE PLANNING Details will be covered in EIA report. 5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND The M/s, Merino Industries Limited shall get water from GIDC water supply scheme. So there will be no additional stress on ground water resources and there will be no adverse effect on the ground water resources available in the nearby area. The unit has proposed 1500 KVA per annum connected load from DGVCL. The transportation facilities will also expect to improve due to increase in the movement of workers and raw material and finished products. 5.5 AMENITIES There are 67 villages in Vagra Taluka. The available basic amenities are as under: All of the villages have primary schools, 3 villages have both primary and secondary education schools. 15 villages have community health workers, 4 villages have primary health sub centre, 4 villages have registered private practitioners, 1 village has primary health centre. Three maternity and child welfare, one child welfare centers, one dispensaries, one T.B clinic, two family welfare centre and six hospitals are also available in the impact zone. Primary source of water in villages are tap and well. Tank and hand pump are also used in 15

16 the village. Villages are connected with paved road. Some of the villages have navigable waterway facilities. Bus is the main source of transportation. Two villages have availability of railway facility. Most of the villages have post office and phones. Three villages do not have these facilities, but they can get within 5 km distance. All the villages have availability of electricity supply. The village has connectivity of mobile phone facility. All the surrounding area is covered with 108 emergency facilities. Source: 2001, Census Data. 6.0 PROPOSED INFRASTRUCTURE 6.1 PROCESSING AREA The process area will cover plant area, raw material storage area, Hazardous waste storage area, ETP, utilities etc. The process area covered by the unit at ground level will be sq. m. 6.2 NON PROCESSING AREA The non process area will cover water tank, green belt and security cabin etc. The non process area covered by unit at ground level will be around sq. m. 6.3 GREEN BELT The total plot area of the unit is sq. m. Out of this Phenol Formaldehyde Resin and Melamine Formaldehyde Resin plant has 880 sq. M area. The green belt area will be sq. m. 6.4 SOCIAL INFRASTRUCTURE The availability of basic amenities is covered as under: Training & Education: All the employees will be trained and educated periodically about the hazardous nature of chemicals used in the process. Also, training for fire fighting, work permits system, first aid, safe handling of hazardous chemicals and integrating safety, in all activities. 16

17 Medical facility: Pre-employment medical check up at the time of employment. In order to safe guard the health of the employees, all the employees undergo periodic health checkup. Drinking water: There will be provision of Aqua Guard/R.O. at different places to provide purified water for drinking purpose. Transportation: The unit will provide basic transportation facility for workers. Telegraph & Post: There will be provision of telephone, fax & internet facility. Power supply: There will be total connected load of 1500 KVA per annum from DGVCL. 6.5 CONNECTIVITY Dahej industrial estate (chemical zone, engineer zone, service cum commercial zone) is spread over an area of 2700 hectares in close proximity to State Highway No. 6. National highway 8 passes through the district connecting it with Ahmadabad (182 km) and Mumbai (362 km). The Dahej is located at 40 km distance from Bharuch Railway station. The nearest domestic airport Vadodara is at an approx distance 116 km from Dahej SEZ. The nearest International airport Ahmadabad is at a distance 225 km. 6.6 DRINKING WATER MANAGEMENT Average daily water consumption of unit will be 15 KL/Day for domestic purpose. The entire water requirement will be meeting through GIDC water supply system. 6.7 SEWERAGE SYSTEM The sewage will be treated with industrial effluent in ETP. 6.8 INDUSTRIAL WASTE MANAGEMENT The hazardous waste like used oil, ETP sludge and discarded containers /barrels/liner will be generated from proposed project activity. The hazardous waste management and disposal is shown in table SOLID WASTE MANAGEMENT The will not be any non hazardous waste management require due to proposed project. 17

18 6.10 POWER REQUIREMENT & SUPPLY The unit will use total 1500 KVA per annum electricity connected load from DGVCL for proposed expansion. 7.0 REHABILITATION AND RESETTLEMENT(R &R) PLAN The proposed project is located in Dahej Industrial Estate, Tal. Vagra, Dist.Bharuch. There will be no any human settlement affected by proposed project. So, there is no requirement of any R & R Plan. 8.0 PROJECT SCHEDULE & COST ESTIMATES 8.1 PROJECT IMPLEMENTATION SCHEDULE TABLE 14 PROJECT IMPLEMENTATION SCHEDULE Project implementation schedule after getting NOC from GPCB Sr. Activity Required Period No. 1. Civil work Immediately after getting NOC 2. Procurement of machinery 1 month after getting NOC 3. Erection & installation of Immediately after competition of activity no.2 machinery 4. Trial of machinery & Within 1 months after competition of activity no.3 equipments 5. Commercial activity 1 months after competition of activity no ESTIMATED PROJECT COST Details are already covered in table 3. 18

19 9.0 ANALYSIS OF PROPOSAL All the manpower is utilized from local region around Dahej. Company shall also try to provide indirect employment opportunities by availing local contract services during transportation during operational phase. The company intends to donate 2 % of the profit to agencies like NGOs or social welfare societies for projects carried out in nearby village for their welfare and upliftment. 5% of project cost will be utilized for CSR activity. 19