Basic Information

FORM 1

And

BASIC INFORMATION

FOR OBTAINING AMMENDMENT IN ENVIRONMENTAL CLEARANCE OF M/s. Windson Chemical Pvt. Ltd.

Block No. 1834/P1 & P2, Chikhli Vansda Road, Opp. Khodiyar Quary, At & Po.: Alipore - 396409, Tal. Chikhali, Dist: Navsari, Gujarat.

Vinodbhai T Patel: 9898872312 Email ID: [email protected]

Prepared By:

T. R. Associates A-401, S. G. Business Hub, B/w. Sola Bhagwat & Gota Overbridge, Near umiya Campus, S. G. Highway, Ahmedabad – 380060. M – 9825371099 Email – [email protected]

October - 2018

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 1 Index

No. of Annexure Description

Basic Information

Form Of Appendix – 1

Annexure – 1 Key Plan

Annexure – 2 Plant Lay-Out

Annexure – 3 Manufacturing Process & Flow Diagram

Annexure – 4 Details Of Solid Waste

Annexure – 5 Details Of Effluent Treatment Plant

Annexure – 6 Water Balance Diagram

Annexure – 7 Details Of Stack

Annexure – 8 List Of Product And Raw Material

Annexure – 9 List of Utilities

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 2 Appendix – I (See paragraph – 6) FORM 1

(I) Basic Information Name of the project : M/s. Windson Chemical Pvt. Ltd. Location / Site alternative : Block No. 1834/P1 & P2, Chikhli Vansda Road, Opp. Khodiyar Quary, At & under consideration Po.: Alipore - 396409, Tal. Chikhali, Dist: Navsari, Gujarat. Size of the Project * : Production capacity of product is shown in Annexure – 8. Expected cost of the project : 6 Crores Approx. Contact Information: : Vinodbhai T Patel: 9898872312 Email ID: [email protected] Address: Tejkarm, Gokuldham society, Gandevi Road, Opp. Shikh Camp, Ta: Devsar, Bilimora, Dist: Navsari, Gujarat – 396380. * Capacity corresponding to second activity (such as production capacity for manufacturing, mining lease area and production capacity for mineral production, area for mineral exploration, length for linear transport infrastructure, generation capacity for power generation etc.)

Sr. No. Item Details 1 Name of the project M/s. Windson Chemical Pvt. Ltd. 2 S. No. in the schedule 5(f) 3 Proposed capacity/area/length/tonnage to Sr. no Product Detail Quantity (MT/Annum) be handled/command area/lease area 1 Formaldehyde 1,34,400 2 Formaldehyde Based 10,800 /number of wells to be drilled Resin (Powder) 3 Formaldehyde Based 14,400 Resin (liquid) 4 Para Formaldehyde 10,800 5 Hexamine 3,600

4 New/Expansion/Modernization Amendment in latest Environmental Clearance wide no. J-11011/103/2014-IA II(I) dated 28-12-2017 5 Existing Capacity/Area etc As per above 6 Category of project i.e. “A” or “B” “A” 7 Does it attract the general condition? If yes, No please specify. 8 Does it attract the specific condition? If yes, There is no SEZ, Export processing Zones, Biotech please specify. parks, industrial estate, complex 9 Location Tal. Chikhli, Dist: Navsari, Gujarat. Plot/Survey/Khasra No. Block No. 1834/P1 & P2, Chikhli Vansda Road, Village At & Po. Alipore Tehsil Chikhali District Navsari State Gujarat

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 3 10 Nearest railway station/airport along with Nearest Railway Station – distance in kms. Chikhli Road Railway Station – 4.24 km in NW direction

Gandevi Railway Station – 11.11 km in WNW direction

Bilimora railway station – 14.0 km in WSW direction

Nearest Airport – Surat Airport – 51.93 km in NW direction

11 Nearest Town, City, District Headquarters Nearest Taluka Headqaters: Chikhli – 3.87 km in SW along with distance in kms. direction

Nearest District Headqaters :Navsari – 22.55 km in NW direction

12 Village Panchayats, Zila Parishad, Municipal Nearest Village: Alipore – 3.48 km in WNW direction Corporation, Local body(complete postal) address with telephone nos. to be givan)

13 Name of the applicant Vinodbhai T Patel: 9898872312 14 Registered Address Block No. 1834/P1 & P2, Chikhali Vansda Road, Opp. Khodiyar Quary, At & Po. : Alipore - 396409, Tal. Chikhali, Dist: Navsari, Gujarat. 15 Address for correspondence Vinodbhai T Patel: 9898872312 Block No. 1834/P1 & P2, Chikhali Vansda Road, Opp. Khodiyar Quary, At & Po. : Alipore - 396409, Tal. Chikhali, Dist: Navsari, Gujarat. Name Mr. Vinodbhai T Patel Designation(Owner/Partner/CEO) Director Address Mr. Vinodbhai T Patel: 9898872312 Address: Tejkarm, Gokuldham society, Gandevi Road, Opp. Shikh Camp, Ta: Devsar, Bilimora, Dist: Navsari, Gujarat – 396380. Pin Code 396380 E-mail [email protected] Telephone No. 9898872312 Fax No. --- 16 Details of Alternative sites examined, if any Not Applicable location of these sites should be shown on a top sheet. 17 Interlined Projects Not Applicable 18 Whether separate application of interlined Not Applicable project has been submitted

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 4 If yes, date of submission Not Applicable If no, reason Not Applicable 19 Whether the proposal involves approval Vansada National Park is @ 40.0 km in East direction /clearance under: (a) The Forest (Conservation) Act,1980 (b) The Wildlife (Protection) Act,1972 (c) The C.R.Z Notification, 1991 20 Whether there is any Government Order/ Not Applicable Policy relevant/ relating to the site?

21 Forest land involved (hectares) Not Applicable 22 Whether there is any litigation pending Not Applicable against the project and/or land in which the project is propose to be set up (a) Name of the court (b) Case No. (c) Orders/directions of the court, if any and its relevance with the proposed project. (d) The following shall be inserted at the end, namely :-

(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.)

Details thereof (with approximate quantities / Information/Checklist Sr. No. Yes/No rates, wherever possible) with source of confirmation information data Permanent or temporary change in land use, land cover or There may be minor change in land use due to 1.1 topography including increase Yes construction work or some machineries in intensity of land use (with installation respect to local and use plan) Clearance of existing land, Not Applicable 1.2 No vegetation and buildings? 1.3 Creation of new land uses? No Not Applicable Pre-construction investigations Not Applicable 1.4 No e.g. bore houses, soil testing? Due to the construction activities & installation of 1.5 Construction works? Yes machineries there may be minor changes in topography and land use. Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 5 1.6 Demolition works? No Not Applicable No temporary sites or housing facilities will be Temporary sites used for provided since local contractors / workers will be 1.7 construction works or housing No given preference for various construction of construction workers? activities. 1.8 Above ground buildings, Yes Key plan & Plant lay-out is attached as Annexure – structures or earthworks 1 & 2 including linear structures, cut and fill or excavations

1.9 Underground works including No Not Applicable mining or tunneling?

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 Yes Manufacturing process with flow-chart is attached processes? as Annexure – 3.

Adequate environment management system will be provided in the plant.

Therefore, land use of the project site will not be impacted due to production and manufacturing process.

1.14 Facilities for storage of goods or Yes Covered sheds will be provided for storage of materials? goods & materials

1.15 Facilities for treatment or Yes A detail of solid waste/hazardous waste is attached disposal of solid waste or liquid as Annexure – 4. effluents? A detail of ETP for treatment of effluent is attached as Annexure – 5.

1.16 Facilities for long term housing Yes There will be provision of housing facilities for of operational workers? employees.

1.17 New road, rail or sea traffic No During operation phase, traffic will be momentary during construction or increased. However; existing transport routes are operation? adequate.

1.18 New road, rail, air water borne No No new roads and rails are envisaged. Existing or other transport transportation facilities will be used for the project. infrastructure including new or Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 6 altered routes and stations, Therefore, land use will not be impacted. ports, airports etc?

1.19 Closure or diversion of existing No Not Applicable transport routes or infrastructure leading to changes in traffic movements?

1.20 New or diverted transmission No Not Applicable lines or pipelines?

1.21 Impoundment, damming, No Not Applicable culverting, realignment or other changes to the hydrology of watercourses or aquifers?

1.22 Stream crossings? Yes Kaveri river - 2.35 km in South direction

1.23 Abstraction or transfers of Yes Water requirement is met through ground water. water form ground or surface waters?

1.24 Changes in water bodies or the No Not Applicable land surface affecting drainage or run-off?

1.25 Transport of personnel or No Transport of personnel or materials for materials for construction, construction or operation will not bring change to operation or decommissioning? topography, land use, water bodies etc. Also to be noted that local personnel will be employed for the operation work, hence no such impact due to transport of personnel or material is envisaged.

1.26 Long-term dismantling or No Not Applicable decommissioning or restoration works?

1.27 Ongoing activity during No Not Applicable decommissioning which could have an impact on the environment?

1.28 Influx of people to an area in Yes Local people will be given preference for almost all either temporarily or the temporary as well as permanent jobs. permanently? Therefore, no such impact due to influx of people to an area in either temporarily or permanently is

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 7 envisaged.

1.29 Introduction of alien species? No Not Applicable

1.30 Loss of native species or genetic No Not Applicable diversity?

1.31 Any other actions? No No additional actions will be implemented that would cause physical changes in land use, topography or water bodies.

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 Yes/No Details thereof (with approximate confirmation quantities/rates, wherever possible) with source of information data

2.1 Land especially undeveloped or No Total plot area = 21553 Sq. Mt agricultural land (ha)

2.2 Water (expected source & Yes Water balance diagram is attached as Annexure – 6. competing users) unit: KLD

2.3 Minerals (MT) No NOT APPLICABLE

2.4 Construction material – stone, Yes Locally available construction materials will be aggregates, and /soil (expected utilized for the construction work. source – MT)

2.5 Forests and timber (source – MT) Yes Open market of Timber is available for office building

2.6 Energy including electricity and Yes Total: 600 KVA fuels (source, competing users) Unit: fuel (MT), energy (MW) Source : Dakshin Gujarat Vij company (DGVCL) For details requirement of fuel; please see Annexure - 7

2.7 Any other natural resources (use No Not Applicable appropriate standard units)

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 8 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 Yes/No Details thereof (with approximate confirmation quantities/rates, wherever possible) with source of information data

3.1 Use of substances or Yes Phenol, Methanol, Formaldehyde, Ammonia & materials, which are Hexamine are hazardous chemical as per MSIHC rules. hazardous (as per MSIHC Industry will provide proper facility to deal with rules) to human health or the Hazardous chemical. environment (flora, fauna, and water supplies)

3.2 Changes in occurrence of No NOT APPLICABLE disease or affect disease vectors (e.g. insect or water borne diseases)

3.3 Affect the welfare of people No NOT APPLICABLE e.g. by changing living conditions?

3.4 Vulnerable groups of people No Not applicable due to the fact that our unit is set-up who could be affected by the on an open land area, this is away from residential project e.g. hospital patients, area. Thus, there will not be any adverse effect children, the elderly etc. occurred on vulnerable groups of people.

3.5 Any other causes No NOT APPLICABLE

4. Production of solid wastes during construction or operation or decommissioning (MT/month)

Sr. No. Information/checklist Yes/No Details thereof (with approximate confirmation quantities/rates, wherever possible) with source of information data

4.1 Spoil, Over burden or mine No No wastes

4.2 Municipal Waste (domestic Yes Details of solid waste are attached as Annexure – 4 and or commercial wastes)

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 9 4.3 Hazardous wastes (as per No Details of solid waste are attached as Annexure – 4 Hazardous Waste Management Rules)

4.4 Other industrial process Yes Details of solid waste are attached as Annexure – 4 wastes

4.5 Surplus product No Not applicable

4.6 Sewage sludge or other Yes Details of solid waste are attached as Annexure – 4 sludge from effluent treatment

4.7 Construction or demolition No Due to the construction activities & installation of waste machineries there may be generation of construction waste. Construction wastes will be inert in nature and will be collected and utilized in filling of low-lying areas within the unit. 4.8 Redundant machinery or No Not applicable equipment

4.9 Contaminated soils or other No Not applicable materials

4.10 Agricultural wastes No Not applicable

4.11 Other solid wastes No Not applicable

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

Sr. No. Information/checklist Yes/No Details thereof (with approximate confirmation quantities/rates, wherever possible) with source of information data

5.1 Emissions from combustion Yes Details of flue gas stack is shown in Annexure-7 of fossil fuels from stationery or mobile sources

5.2 Emissions from production Yes Details of process gas stack is shown in Annexure- processes 7

5.3 Emissions from materials Yes Fugitive emission will be there, but industry will handling including storage or provide PPE for Workers and provide basic

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 10 transport amenities.

5.4 Emissions from construction Yes Precaution will be taken for all workers. activities including plant and equipment

5.5 Dust or odors from handling No Due to handling of construction materials, of materials including concentration of particulate matter in ambient air construction materials, will slightly increase for that particular time. sewage and waste Nevertheless, water Sprinklers will be used during construction activity to nullify the effects of such dusting. There will not be any odour problem during the handling of construction materials. During construction and operation phase adequate sanitary facilities will be provided for the workers.

5.6 Emissions from incineration No Not applicable of waste

5.7 Emissions from burning of No Not applicable waste in open air (e.g. slash materials, construction debris)

5.8 Emissions from any other No Not applicable sources

6. Generation of Noise and Vibration, and Emissions of Light and Heat:

Sr. No. Information/checklist Yes/No Details thereof (with approximate confirmation quantities/rates, wherever possible) with source of information data

6.1 From operation of equipment Yes Source of noise pollution will be D. G. sets and hot e.g. engines, ventilation plant, air generator and Boiler. As far as noise is crushers concerned adequate sound enclosures will be provided to all the equipment & machineries generating high noise. However, ear protecting devices (like earmuffs, earplugs) will be provided to all workers working in such areas where noise levels will be high. Increase in greenbelt development will help to abate noise levels. The noise levels within plant are expected to remain Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 11 below 80 dB (A).

6.2 From industrial or similar Yes Sources of noise pollution from the plant are processes pumps and motors, machineries, cooling tower etc. All the equipment in the unit will be designed and operated to have the noise level not exceeding 75-80 dB (A) at a distance of 1.5 m. from the equipment. Also, all the measures will be taken to limit the noise level at the plant boundary within the stipulated limits.

6.3 From construction or Yes Ambient noise level will slightly increase during demolition construction phase / installation of machineries. However, effect of such noise would be temporary and negligible.

6.4 From blasting or piling No NOT APPLICABLE

6.5 From construction or Yes Ambient noise level will slightly increase due to operational traffic construction and operational traffic. However, effect of such noise would be temporary and negligible.

6.6 From lighting or cooling No Not applicable systems

6.7 From any other sources No Not applicable

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 12 7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, ground water, coastal waters or the sea:

Sr. No. Information/checklist Yes/ Details thereof (with approximate confirmation No quantities/rates, wherever possible) with source of information data

7.1 From handling, storage, use or Yes Dyke wall will be provided surrounding spillage of hazardous materials Formaldehyde tank storage area.

Water sprinkling system will be adopted for Ammonia storage tank.

Other all precaution will be taken as per considering safety features.

Methanol will be stored underground; unit will obtain Explosive license from the PESO department.

7.2 From discharge of sewage or other No The details of Effluent Treatment Plant is attached effluents to water or the land as Annexure - 5 (expected mode and place of discharge)

7.3 By deposition of pollutants emitted No No major impact is anticipated by deposition of to air into the land or into water pollutants emitted to air into the land or into water due to all the necessary Air Pollution Control Measures to be adopted for controlling the air pollution within the norms specified by Central/State Pollution Control Board.

7.4 From any other sources No Not applicable

7.5 Is there a risk of long term build up No Not applicable 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 Yes/ Details thereof (with approximate confirmation No quantities/rates, wherever possible) with source of information data

8.1 From explosions, spillages, fires Yes Risk Assessment study will be carried out to etc. from storage, handling, use or minimize any possible causes that would lead to an Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 13 production of hazardous substance accident. Based on the same, the industry will prepare an onsite emergency plan highlighting the steps to be taken at the time of emergency, key personnel to be contacted; phone numbers of the emergency help lines etc. Moreover, adequate storage facilities will be provided and special care will be taken for storage, handling, use and transport of hazardous materials.

8.2 From any other causes No Not applicable

8.3 Could the project be affected by No Floods are not likely to occur as water body is far natural disasters causing away. It may be noted that seismic forces will be environmental damage (e.g. floods, considered for the construction of proposed earthquakes, landslides, cloudburst structures/ buildings as the project site falls under etc)? the Seismic Zone - III.

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 Yes/No Details thereof (with approximate confirmation quantities/rates, wherever possible) with source of information data

9.1 Lead to development of supporting, utilities, ancillary development or development stimulated by the project which could have impact on the environment e.g.

 Supporting infrastructure No Not applicable (roads, power supply, waste or waste water treatment, etc.)  Housing development  Extractive industries  Supply industries  Other 9.2 Lead to after use of the site, No Not applicable which could have an impact

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 14 on the environment

9.3 Set a precedent for later No Not applicable developments

9.4 Have cumulative effects due No Not applicable to proximity to other existing or planned projects with similar effects

(III) Environmental Sensitivity

Sr. No. Information/checklist Yes/No Details thereof (with approximate confirmation quantities/rates, wherever possible) with source of information data

1 Areas protected under No Not applicable international conventions, national or local legislation for their ecological landscape, cultural or other related value

2 Areas with are important or Yes Kaveri river – 2.35 km in south direction sensitive for ecological reasons – Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests

3 Areas used by protected, No Not applicable important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration

4 Inland, coastal, marine or Yes Nearest coastal zone: 25 km W direction underground waters

5 State, National boundaries No Not applicable

6 Routes or facilities used by No Not applicable the public for access to

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 15 recreation or other tourist, pilgrim areas

7 Defense installations No Not applicable

8 Densely populated or built- Yes Navsari - 22.55 km in NW direction up area

9 Areas occupied by sensitive Yes Hospital – Anand Hospital, Chikhli, 3.87 km in SW man-made land uses direction, Alipore hospital & research centre, 3.9 km (hospitals, schools, places of in West direction worship, community facilities) School / College – School at Bamabvel – 1.18 km in South direction

School at Alipore – 3. 5 km in West direction Physical Health Centre – Government Health centre, Chikhli – 3.95 km in SW direction. 10 Areas containing important, No Not applicable high quality or scarce resources (ground water resources, surface resources, forestry, agricultures, fisheries, tourism, minerals)

11 Areas already subjected to No Not applicable pollution or environmental damage. (those where existing legal environmental standards are exceeded)

12 Areas susceptible to natural No Floods are not likely to occur as water body is away. hazard which could cause the It may be noted that seismic forces will be considered project to present for the construction of proposed structures/buildings environmental problems as the project site falls under the Sesmic Zone - III. (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 16 “I hereby given undertaking that data and information given in the application and enclosures are true to the best of my knowledge and belief and I am aware that if any part of data and information submitted is found to be false or misleading at any stage, the project will be rejected and clearance give, if any to the project will be revoked at our risk and cost.”

Date: 20/10/2018

Place: Dist.-Navasari, Gujarat

Mr. Vinodbhai T Patel Mo. No. (+91) 9898872312 Block No. 1834/1 &2, Chikhali Vansda Road, At & Po. : Alipore, Tal. Chikhali, Dist: Navsari, Gujarat.

Signature of the applicant with Name and Full Address Note:

1. The projects involving clearance under coastal regulation zone notification, 1991 shall submit with the application a C.R.Z map duly demarcated by one of the authorized agencies, showing the project activities, w.r.t C.R.Z and the recommendations of the state coastal zone management authority. Simultaneous action shall also be taken to obtain the requisite clearance under the provisions of the C.R.Z Notification, 1991 for the activities to be located in the CRZ.

2. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals , the project proponent shall submit the map duly authenticated by Chief Wildlife Warden showing these features vis-à-vis the project location and the recommendations or comments of the chief wildlife warden thereon”

3. All correspondence with the Ministry of Environment & Forests including submission of application for TOR/Environmental Clearance, subsequent clarifications, as may be required from time to time, participation in the EAC Meeting on behalf of the project proponent shall be made by the authorized signatory only. The authorized signatory should also submit a document in support of his claim of being an authorized signatory for the specific project.”

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 17 ANNEXURE – 1 KEY PLAN

Project site

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 18 ANNEXURE – 2 PLANT LAY-OUT

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 19 ANNEXURE – 3 MANUFACTURING PROCESS (1) Process of Formaldehyde - Formaldehyde Liquid Form

1. Feed Methanol, air, water vapour Catalyst: Silver

2. The methanol in the measuring storage tank is pumped up to an elevated tank by a methanol pump. After being controlled by measuring, the methanol coming out from the elevate tank flows into an evaporator for vaporization of which the temperature is controlled within 440C ~ 470C and the liquid level is controlled as 50%,then the vaporized methanol gets into a super heater. The heat for the vaporization of methanol is provided by the 700C circulating fluid in the 1# formaldehyde absorber. 3. The air is filtered by a filter before being delivered to the evaporator by a blower. It mixes with the methanol in the evaporator and enters into then super heater together. The air flow is regulated by the blower through frequency conversion to control the flow ratio of air to methanol (A/M=1.8 ~1.95). 4. When the pressure gets stable, the vapour (0.3 MPa) gets into a mist eliminator for dehumidification through the pipeline before entering into the superheat. The flow ratio of air to methanol shall be controlled at desired level. In the formaldehyde production technique using silver as catalysis, the water vapour is an inert gas which does not participate in chemical reactions. The added water vapour changes the explosive range of the methanol and air, the production of formaldehyde thereby becomes far from the explosive area and stays safe and reliable. 5. After the flow rates are regulated and proportioned, the methanol, air and water vapour enter into the super heater and the superheating temperature shall be controlled at 2000C. Then, these materials enter into a reactor. 6. In the reactor, under the catalysis of silver at 6500C, the methanol is dehydrated and oxidised, generating Formaldehyde. Dehydration reaction is an endothermic reaction and oxidation reaction is an exothermic reaction, but the heat release is more than that can adsorbed, therefore the reaction system is an state of heat energy surplus. The water vapour is not involved in reactions but it can absorb a lot of heat of reaction, maintaining the temperature at 6500C. Chemical Reaction

CH3OH CH2O + H2 - 20Kcal------1

CH3OH + ½ O2 CH2O + H2O + 38 Kcal------2

1-2=18Kcal

The 6500C reaction gas leaves the reaction and gets into heat exchanger. For the heat exchanger, the medium is water. The outlet temperature of heat exchanger is 1600C. The water

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 20 absorbs heat, forming the water vapour of 0.35 MPa which will be used to arranging the raw materials for production in the super heater after its pressure stabilized.

The generated gas of about 1600C enter into 1# and 2# formaldehyde absorber in proper order and gets absorbed by the cooled circulating fluid through spraying. The temperature of the circulating fluid at the bottom of 1# absorber shall be control at 700C and fluid is pumped to the evaporator by circulating pump to supply the heat for the evaporation of methanol. In the 1# absorber, the concentration shall be controlled as 37%, and temperature of the top shall be controlled at 450 to 500C. The circulating fluid is also a composition of the Formaldehyde product by this technique. The temperature of the top of 2# absorber shall be controlled at 300 to 350C and keep adding water from top to control the release of formaldehyde.

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 21 PROCESS FLOW DIAGRAM

Formaldehyde (0.2 – 0.5 ppm)

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 22 (2) Urea Formaldehyde Resin (Liquid / Powder)

 Manufacturing Process Stage: 1: Liquid Resin:-

 First all the raw materials Urea & Formaldehyde will be added in Limped reaction vessel.  pH will be adjusted to pH 9.0.  Stirring & heating will be done up to 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 will start  Liquid Urea Formaldehyde Resin will be ready for Packing.

Stage 2: Powder Resin:-

 The prepared Liquid resin stored in the MS storage tank carries out in the feed tank of the spray drier by means of SS pump.  The atomizer is located at the top side of the spray Drier it rotates the resin in to very high speed so the resin scattered in micro drops. Also hot air at the temperature 200 0C - 220 0C in very high pressure comes from the hot air generator to the top of the spray drier it contacts to the resin scattered micro drops.  So however the resin scattered in micro drops comes to the bottom side of the spray drier with contact of the hot air in pressure so it dries and removes the water contents in the liquid resin. So when it reaches at the bottom valve of the spray drier it totally converts in to the powder form and then it cool down by the cooled air from the cooling plant then after it collects directly in 25 kg. Polythene bags.

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 23

Chemical Reaction:

Process Flow Chart for Liquid / Powder Resin :

Urea Limped Reaction Vessel Formaldehyde

pH adjusted to 9

Stirring and Heating up to 95C for 50 Minutes

Caustic Storage Tank of Liquid

Resin

Spray Drier

Urea Formaldehyde Resin

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 24 (3) Melamine Formaldehyde Resin (Liquid / Powder) :

 Manufacturing Process

Step 1 : Liquid resin :

 First all the raw materials melamine, formaldehyde & caustic will be added in Limped reaction vessel.  Stirring & heating will be done up to 95 C for 1 Hr.  Cooling will start up at 30 C.  Melamine Formaldehyde Resin will be ready for packing.

 Reaction Chemistry

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

NH2 H2C N CH2

melamine formaldehyde OH HO melamine formaldehyde resin

Stage 2: Powder Resin:-

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 25  Process Flow Diagram (Liquid / Powder Resin)

Melamine Limped Reaction Vessel Formaldehyde & Caustic

Caustic Stirring and Heating up to 95C for 1 hr

Cooling up to 30C

Dilution

Storage of Melamine Formaldehyde Resin (Liquid)

Spray Dryer

Melamine Formaldehyde Resin (Powder)

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 26 (4) Phenol Formaldehyde Resin (Liquid / Powder) :

 Manufacturing Process Stage: 1: Liquid resin

 First all raw materials like phenol, formaldehyde & caustic will be added into closed vessel.  Stirring & heating will be done up to 60 C. After 60C stop heating.  Reflux is done for 30 minutes up to 98 C.  Cooling down to 40 C.  Phenol Formaldehyde Ready for Packing. Stage 2: Powder Resin:-

 Reaction Chemistry

OH OH

CH2OH H – CHO

Fast

Phenol Phenol Formaldehyde Resin

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 27  Process Flow Diagram (Liquid / Powder Resin)

Phenol Limped Reaction Vessel Formaldehyde

Caustic Flakes Stirring and heating up to 60 C

Reflux for 30 Minutes

Cooling

Dilution

Storage of Phenol Formaldehyde Liquid Resin

Spray Dryer

Phenol Formaldehyde Powder Resin

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 28 (5) Hexamine:

Hexamine is being produced by reaction of formaldehyde with ammonia. The Formaldehyde is taken in the form of formaldehyde gas and is introduced in the reactor containing saturated solution of Hexamine. Ammonia from the Ammonia storage tank is evaporated and purged in the reactor where it reacts with the Formaldehyde to produce Hexamine as per following reaction.

6HCHO + 4 NH3 (CH2)6 N4 + 6H20

The Reaction between Formaldehyde and Ammonia is exothermic in nature. The heat of reaction is utilized in evaporating the water, which is formed during reaction. As the reactions proceed and the upper saturation limit exceeds, the hexamine start crystallizing in the mother Liquor. The mother liquor containing hexamine crystal is withdrawn though slurry pumps and pumped to centrifuge where the crystals are separated out. These crystals are dried in rotary drum dried and packed in jute bags for dispatch.

The mother liquor from centrifuge is re-circulated back to the reactor.

This is a highly energy efficient process where in the heat of gaseous formaldehyde and heat of reaction are utilized to evaporate the water formed during the reaction. No extra steam is required in reactor and only a small quantity of steam is required for drying of crystallized hexamine.

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 29

Vacuum Mass Balance

Exhaust

950 kg

99% Water and traces of Ammonia

R e Formaldehyde a c t o r 1550 to 1575 kg of Methanol HEXAMINE

Ammonia 1000 kg

510 to 515 kg

Centrifuge

Spent Mother Liquor

140 kg output recycled into process

Input: 2090 KG Output: 2090 KG

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 30 (6) Para Formaldehyde

 Para formaldehyde is manufactured from Aqueous Formaldehyde (37%) solutions by the process involving distillation and concentration at a point at which solidification or precipitation of polymer takes place. The process of concentration is carried out by vacuum evaporation. The main sections of the PLANT are: a. Concentration of aqueous Formaldehyde b. Polymerization and drying c. Concentration of distillates for recycling. d. Conveying, pulverization and storage / packaging of the Product.

 Concentration of aqueous Formaldehyde (37% or 55% with predecided Formic acid content) to (65-75)% is carried out by feeding the material from a storage tank to proprietary concentration equipment (Evaporator – I). The distillate containing (10- 20) % Aldehyde content is condensed, sub cooled in heat exchangers and collected in an Intermediate Tank. Polymerization and Drying up to 96% Formaldehyde concentration is carried out in proprietary special drying equipment which operates in a cyclic manner for polymer precipitation, cooling and unloading formed Para formaldehyde lumps.

 The (20-20) % Formaldehyde Concentration distillate obtained from the Evaporator – I and the distillate from the drying section are fed to concentration Evaporator – II for concentration and recycling. Functionally Evaporator II is similar to Evaporator I with certain differences in construction features. Use of secondary evaporation step helps in achieving the following:

(1) Recovery of Formaldehyde to improve overall yield.

(2) Facilitation of continuous operation of the PLANT by feed recycles.

(3) Recovery of final distillates below (3-4) % Formaldehyde concentration grade which can be recycled to the Formaldehyde PLANT supplying AF-37 / AF-55 feed stock thereby virtually eliminating liquid effluents.

Depending on the Paraformaldehyde grade to be produced the solubility of the product, reactivity and pH requirements, a proprietary Liquid Catalyst is added before the polymer precipitation process.

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 31 Dilute Formaldehyde solution can be sent to Formaldehyde PLANT for recovery and to avoid effluent generation. Process Steam generation Package Boiler, D.M. Water Unit, Chilled Water Unit, Instrument Air System and Cooling Tower shall be required as Utilities.

Product from Drying Equipment is dumped onto the Belt Conveyor from where it is conveyed to a Precrusher. Crushed product is pneumatically conveyed to a Cyclone through a rotary air lock valve. The product from the cyclone is taken to a Sieve Shaker in which particles below 1mm size are separated and sent to mix Product Silo via pneumatic conveying system. The oversize material from sieve shaker goes to a Pin Pulverize for further grinding and then through same pneumatic conveying system to mixed Product Silo. The mixed product is separated in II Sieve Shaker and transferred to separate silos for powder and granular products.

Typically about 40% product is in powder form (particle passing through 65 mesh) and remaining 60% particles are in granular form (retaining on 65 mesh). In case required, almost 100% product can be in granular form, by compacting finer powder.

Two independent Dust Collection Systems are provided for the two conveying, and pulverizing sections. An Aspirator System with third bag filter and blower is installed for keeping the whole material handling system under slightly negative pressure. The aspirator system helps in collecting fine dust particles during conveying, crushing and sieving operations thus improving recovery and reducing pollution. The dust handling systems provide dust collecting for each set of cyclones / bag filters / blowers. Air from the three bag filters is passed through scrubbers for further cleaning before venting into open atmosphere.

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 32 Flow Diagram of Para Formaldehyde

Para Formaldehyde Flakes

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 33 ANNEXURE – 4 DETAI LS OF SOLID WASTE

Sr. Description Category Quantity Mode of Disposal No.

Collection, storage and used within premises as a 1 Used Oil 5.1 0.045 MT/Month lubricant / sold to registered recycler.

Discarded Collection, storage & sold 2 33.1 Plastic Bags 1.11 MT/Month to approved vendor.

ETP Sludge + Collection, storage & sent 3 Evaporation 35.3 3.75 MT/month to approved TSDF site. Residue

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 34 ANNEXURE – 5 EFFLUENT TREATMENT PLANT

Evaporator Collection cum Nutch Filter RO Reject 5 KLD Neutralization Tank

Sludge

Sludge Drying Bed

ZERO LIQUID DISCHARGE

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 35 ANNEXURE – 6 WATER BALANCE DIAGRAM

Source of Water Supply: Borewell

491.25

Raw water

491.25

487 4.25

Industrial Domestic Gardening

487 4.25

112 10 135 230 30 0.5 3.75 5 130 Cooling Para 260 Drinking Goes to (Hexamine) formaldehyde 254 Soak Pit DM process 135 Cooling/ 260 Boiler (Formalin) 75 60 Condensate 130 130 12 Boiler Cooling Formaldehy Reject 20 de Process

Condensed 36 water 10 Blow down Blow Down 36 20 10 Permeate 31 RO Raw Water Reject 5

Wastewater Evaporator

Recycle/reuse

Note: All values are in KLD

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 36 ANNEXURE – 7 DETAILS OF FLUE GAS STACK

Sr. Stack attached Height of Fuel Type APC Expected GPCB No. to the stack System Pollutant Limit In meter 1 Steam Boiler 30 Bio coal – 1.25 Multi PM As per

(600 kg/hr.) MT/M cyclone SO2 GPCB Dust NOx Norms Collector 2 D. G. Set 6 HSD - 35 L/Hr -- HC, CO As per (3 X 250 KVA) GPCB Norms 3 D. G. Set 6 HSD - 105 L/Hr -- HC, CO As per (2 X 350 KVA) GPCB (1 X 400 KVA) Norms 4 Hot Air 20 Waste Hydrogen Cyclone PM As per

Generator gas generated from Separator SO2 GPCB (8 Lac Kilo Formaldehyde NOx Norms Calories x 1) Plant 5 Hot Air 20 Waste Hydrogen Cyclone PM As per

Generator gas generated from Separator SO2 GPCB (10 Lac Kilo Formaldehyde NOx Norms Calories x 1) Plant 6 Hot Air 20 Waste Hydrogen Cyclone PM As per

Generator gas generated from Separator SO2 GPCB (10 Lac Kilo Formaldehyde NOx Norms Calories x 1) Plant 7 Hot Air 20 Waste Hydrogen Cyclone PM As per

Generator gas generated from Separator SO2 GPCB (10 Lac Kilo Formaldehyde NOx Norms Calories x 1) Plant

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 37 DETAILS OF PROCESS GAS STACK

Sr. Stack Height APC Expected GPCB No. attached of the System Pollutant Limit to stack In meter

Spray As per PM 1 Dryer (500 20 Bag Filter GPCB

Kg/Hr. x 1) Norms

Spray As per PM 2 Dryer (600 20 Bag Filter GPCB

Kg/hr. x 1) Norms

Spray As per 20 PM 3 Dryer (800 Bag filter GPCB

Kg/Hr. x 1) Norms

Spray As per 20 PM 4 Dryer (800 Bag filter GPCB

Kg/Hr. x 1) Norms

Fluid Bed Common As per PM 5 dryer (300 stack of Bag filter GPCB

Kg/Hr. x 2) 18 meter. Norms

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 38 ANNEXURE – 8 LIST OF PRODUCTS

Sr. Product Detail Quantity MT/Annum no. 1 Formaldehyde 1,34,400 2 Formaldehyde 10,800 Based Resin (Powder) 3 Formaldehyde 14,400 Based Resin (liquid)

4 Para Formaldehyde 10,800

5 Hexamine 3,600 Total 1,74,000

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 39 RAW MATERIAL CONSUMPTION

Sr. No. Name of raw materials Total Capacity (MT/Month) Formaldehyde 1 Methanol 4984 2 Water 4155.2 Urea Formaldehyde Resin-Powder 1 Formaldehyde (55%) 1238.86 2 Urea 145.75 3 Melamine 72.87 Melamine Formaldehyde Resin- Liquid 1 Formaldehyde (37%) 240 2 Melamine 160 Phenol Formaldehyde Resin- Liquid 1 Phenol 160 2 Formaldehyde (37%) 240 3 Caustic 2 Urea Formaldehyde Resin- Liquid 1 Urea 160 2 Formaldehyde (37%) 240 3 Caustic 2 4 Acetic Acid 2 Hexamine 1 Ammonia 149.4 2 Methanol 468.6 Para Formaldehyde 1 Formaldehyde (37%) 2432.43

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 40 ANNEXURE – 9 LIST OF UTILITIES

Sr. Name Of Machinery Utilities required for Amendment No.

1 Steam Boiler 1 x 600 Kg/Hr.

2 Hot ( air) generator 3 x 10 lac kilo calories 1 x 8 lac kilo calories

3 Spray dryer with Bag filter Evaporation capacity 2 x 800 kg/hr 1 x 500 kg/hr 1 x 600 kg/hr 4 D. G. Set 2 x 350 KVA 2 X 250 KVA 1 X 400 KVA 5 P. F., M.F., U.F. Reaction Vessel 2 X 15 MT 2 X 11 MT 2 X 10 MT 3 X 8 MT 2 X 3 MT 5 X 5 MT 6 Formaldehyde plant including all 373.33 MT/Day equipment 7 Hexamine plant including all 10 MT/Day equipment 8 Fluid bed Drier Evaporation capacity 2 x 300 kg/hr

9 Cooling Tower 6 x 350 TR

10 PARAFORMALDEHYDE plant 35 MT/Day including all equipment

Application Form – 1 for Amendment in Environmental Clearance for M/s. Windson Chemical Pvt. Ltd. 41