Gujarat-based Riona Laminate Pvt. Ltd intends to establish resin manufacturing plant for captive consumption. The proposed unit will have the capacities of 550 MT/month of phenol formaldehyde and 100 MT/month of melamine formaldehyde. These resins will be used for the laminate manufacturing plant of 180,000 sheets per month. The project cost is approximately Rs.85 lakhs and capital and recurring cost towards pollution control system is approximately Rs 15 lakhs.

Details on the project: The proposed project fall in category 5 (f): Synthetic Organic Chemicals Industry, of the schedule as per the EIA Notification, September 2006. The total project area is 13557 sq mtrs in which 4473 sq mtrs are dedicated for Green Belt and 355 sq mtrs for Labour Quarters. As raw materials, Phenol 220 MT/month, Formaldehyde 330 MT/month, Menthol 5.5 MT/month and Sodium Hydroxide 1.1 MT/month will be used for Phenol Formaldehyde Resin and for the another Resin, Melamine Formaldehyde, Formaldehyde 25 MT/month and Melamine 76 MT/month will be consumed. Manufacturing process for phenol formaldehyde resin The raw materials like Phenol, Formaldehyde and Sodium Hydroxide will be added into a closed vessel. The content in reaction vessels will be stirred and heated up to 60 degrees Celsius, then it will be refluxed for 30 minutes, then Vacuum distillation will start. The effluent will be removed from the vessel. Then, the material will be cooled up to 40 degrees Celsius. The next process is to add the Menthol for dilution purpose. Now the product, Phenol Formaldehyde Resin is ready for use in manufacturing of Laminate Sheets. Manufacturing process for melamine formaldehyde resin Both the raw materials like Melamine and Formaldehyde will be added in Limped reaction vessel. Then, the content will be stirred and heated up to 95 degrees Celsius for one hour, the next step is to be cooled up to 30 degrees Celsius. Now the product, Melamine Formaldehyde Resin is ready for use in Laminate sheets. Utilities As the utilities one Boiler (IBR) having capacity of 4 TPH, one cooling tower having capacity of 50 TR and one Diesel Generator set of 350 KVA will be used. The project would draw electricity from Gujrat Electricity Board in tune of 450 HP. Emergency capability The plant would maintain an updated copy of on-site emergency action plan providing details pertaining to hazards and risk associated with the process and raw materials and guidelines for handling emergency situations. Chemical storage would be done in accordance with the requirements mentioned in the respective MSDS. Raw water reservoir and storage tank with sufficient capacity resp. providing for fire fighting. The CO₂ type two 2.5 kg and three 6 kg fire extinguishers are proposed as a precaution for fire safety. Description of effluent treatment Trade effluent is collected in collection tank and pumped to mixing tank. The pH of effluent in mixing tank is adjusted between 3 to 3.5 by adding H₂SO₄, followed by FeSO₄. 7H₂O and H₂O₂ dosage. H₂O₂ dosage is 1:2 ratio with phenols and FeSO₄. 7H₂O dosage is 1:20 ratio of F⁺² to H₂O₂. The effluent is then transferred to Photo – Fenton Process Vessel for oxidation. The vessel is aided with air compressor pump for adequate aeration requirement, cooling system to maintain temperature range of 30 – 35 degrees Celsius. Phenol oxidation is accomplished in presence of sun light or UV lamp. For winter and rainy span, the process is accomplished in closed vessel with UV lamp. The effluent is then transferred to settling tank for solid liquid separation. The settled sludge is discharged to sludge drying beds and the filtrate from SDB is transferred to collection tank. The supernatant is transferred evaporation system for final evaporation. The evaporation system consists of electric heater for evaporation of treated effluent. Proposed Terms of Reference The scope of REIA study include the following • Justification of the project and Promoters and their background. • Regulatory frame work. • A map indicating location of the project and distance from severely polluted area. • Project location and layout plan. • Infrastructure facilities including power sources. • Total cost of the project along with total capital cost and recurring cost per annum for environmental pollution control measures. • Project site location along with the site map of 10 km area and site details providing various industries, surface water bodies, forest etc. • Present land use based on satellite imagery for the study area of 10 km radius. • Location of national park/wildlife sanctuary/reserve forest within 10 km radius of the project. • Details of the total land and break-up of the land use for green belt and other uses. • List of products along with the production capacities and list of solvents and its recovery plan. • Detailed list of raw material required and source, mode of storage and transportation. • Manufacturing process details along with the chemical reactions and process flow chart. • Action plan for the transportation of raw material and products. • Ambient air quality monitoring at 6 locations within the study area of 5 km, areal coverage from project site as per NAAQES notified on 16th September, 2009. Location of one AAQMS is downwind direction. • One season site specific micro-meteorological data using temperature, relative humidity, hourly wind speed & direction and rainfall and AAQ data (except monsoon) for PM₁₀, SO₂, NOₓ and VOCs to be collected. The monitoring stations to take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests. Data for water and noise monitoring to be included. • Air pollution control measures proposed for the effective control of gaseous emissions within permissible limits. • Design details of ETP and evaporator and boiler, scrubbers/bag filters etc. • Details of water and air pollution and its mitigation plan. • Action plan to control ambient air quality as per NAAQES standards notified by the ministry on 16th September, 2009. • An action plan to control and monitor secondary fugitive emissions from all the sources as per the latest permissible limits issued by the ministry vide GSR 414(E) dated 30th May, 2008. • Determination of atmospheric inversion level at the project site and assessment of ground level concentration of pollutants from the stack emission based on site-specific meteorological features. Air quality modeling for proposed plant. • Water balance chart including quantity of effluent generated, treated and evaporated. • Impact of ground water drawl on other users/ surroundings. Hydro-geological study of the area for availability of ground water should also be included. • Details of Effluent Treatment Plant (ETP). Characteristic of inlet effluent and treated effluent. • Details of technology to treat Phenols and Nitrogen in industrial effluent. • Action plan for zero discharge effluent as proposed to be included. • Ground water monitoring minimum at 6 locations to be carried out. Geological features and Geo-hydrological status of the study area and ecological status (Terrestrial and Aquatic). • The details of solid and hazardous wastes generation, storage, utilization and disposal particularly related to the hazardous waste calorific value of hazardous and detailed characteristic of the hazardous waste. Action plan for the disposal of fly ash generated from boiler to be included. • A copy of the Memorandum of Understanding signed with cement manufacturers indicating clearly that they will utilize all the organic solid waste generated. • Authorization/ Membership for the disposal of solid/hazardous waste at common facility of TSDF and incineration. • Ground water monitoring around the project. • Risk assessment for storage for chemicals/solvents. Action plan for handling and safety system. • An action plan to develop green belt in 33 percent area. • Action plan for rainwater harvesting measures at plant site to be included to harvest rain water from the roof tops and storm water drains to recharge the ground water. • Occupational health of the workers with elaboration including evaluation of noise, heat, illumination, dust, any other chemicals, metals being suspected in environment and going into body of workers either through inhalation, ingestion or through skin absorption and steps taken to avoid muscular-skeletal disorders (MSD), backache, pain in minor and major joints, fatigue etc. Occupational hazards specific pre-placement and periodical monitoring to be carried out. • Socio-economic development activities should be in place. • Note on compliance to the recommendations mentioned in the CREP guidelines. • Detailed Environment Management Plan (EMP) with specific reference to details of air pollution control system, water and wastewater management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure should be provided. • EMP to include the concept of waste-minimization, recycle/reuse/recover techniques, energy conservation and natural resources conservation. • Any litigation pending against the project and/or any direction/order passed by any court of law against the project, if so, details thereof. • Baseline data collection has been started in October 2011. Benefits of the project • The creation of the new project will bring direct employment for approximately 40 persons from the vicinity of Wankaner, Rajkot, Morbi and nearby villages. • The skills already available in areas of ITI scholars, fitters, mechanics etc. get a boost by being employed and further trained in respective skills. • The industry in association with local NGOs proposes to undertake welfare activities for the nearby community. • The proposed project is for manufacturing of Resin for captive consumption. • Considering the project size, the pollution scenario, the infrastructure to mitigate the impacts on environment and the benefits, the proposed project is feasible at the project location.