TERMS OF REFERENCES (TOR) ASBESTOS CEMENT SHEET MANUFACTURING UNIT PROPOSED EXPANSION CAPICITY FROM 120,000 TPA to 320,000 TPA

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VISAKA INDUSTRIES LIMITED

TERMS OF REFERENCES (TOR)

ASBESTOS CEMENT SHEET MANUFACTURING UNIT

PROPOSED EXPANSION CAPICITY FROM

120,000 TPA to 320,000 TPA

Proposed Capacity : 200000 TPA

Phase 1 : 40000 TPA

Phase 2 : 160000 TPA

LOCATION:

Kannawan Village,

Bachharawan Gram panchayat,

Maharajganj Tehsil,

Raebareli District

U.P. state.

Registered Office

Visaka Towers,

69/3, S,P. ROAD,

Secunderabad – 500 003 AP

Submitted to

MINISTRY OF ENVIRONMENT & FORESTS

PARIYAVARAN BHAVAN,

LODHI ROAD, C.G.O. COMPLEX,

NEW DELHI – 110 003

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TERMS OF REFERENCES (TOR)

BY THE PROPONENT- VIL LIMITED ,

1.0 INTRODUCTION:

Location Kannawan Village,

Bachharawan Gram panchayat,

Maharajganj Tehsil, Raebareli District U.P. state. .

Size of the project : Manufacturing of Asbestos Cement

Sheets and Accessories Capacity from 120,000 TPA to 320,000 TPA

The expansion in productivity:

 No Additional land

 No Additional Building for Phase -1

 Additional Equipment

 Increase size of the Sheet

 Improved vacuum systems

 Improved waste recycling

ADVANTAGES TO THE PROJECT:

There is a positive impact on the environment due to the usage of fly ash of about 27% in the product which is a waste material of a nearby Thermal power station. The land is declared as industrial area by the government itself after a thorough study by expertise.

2.0 UTILITIES POWER

Connected maximum demand of 750 KVA which is under HT limits. The required power connection is obtained from APSEB. However, D.G sets of 2 X 500 KVA are installed. No Additional DG Sets required.

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MANPOWER

The regular manpower required for Existing administration, and production purposes around 50. Additional manpower (both regular and contract basis) for expansion will be up to 50.

WATER

Water requirement for Existing is 140 KLD, Proposed Phase -1 expansion will be 60KLD. Proposed Phase -2 expansion will be 200 KLD. Total water requirement for both existing and proposed will be 400 KLD (per day) for process + administrative purposes. It will be met by Existing bore wells within the project site.

3.0 SITE

The expansion Project will be implemented with in the VIL premises which is at 3.5

Kms from Bachharawan Gram panchayat, Tehsil Maharajganj, and District Rae-bareli.

State High way No.36 is coonecting Lucknow to Rae-Bareli The company has proposed to go for expansion operations in the existing premises of VIL. No Additional Land is required.

PLANT AREA SPLIT UP

Total Area 10.0 Hectares Plant facility 1.6 hectares Storage 0.8 hectares

Approach roads 0.4 hectares Green belt 6.0 hectares

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RM CONSUMPTION in TPM WATER CONSYUMPTION in KLD

EXISTING PROPOSED PROPOSED Existing Phase 1 Phase 2 Phase 1 Phase 2 Cement 4050 TPM 1320 TPM 5282 TPM Process 110 KLD 35 KLD 150 KLD Fly ash 2925 TPM 0872 TPM 3487 TPM Cure & cool 005 KLD 05 KLD 010 KLD Chrysotile +

other fibre

0810 TPM 0290 TPM 1159 TPM Domestic 015 KLD 15 KLD 020 KLD

Pulp 0063 TPM 0031 TPM 0123 TPM Gardening 010 KLD 10 KLD 015 KLD

Total 7848 TPM 2513 TPM 10051 TPM Total 140 KLD 65 KLD 195 KLD

Main reasons for initially selecting the site is that land is in existing premises of VIL. after a thorough study of negative/positive impact studies due to the major development in the area.

Easy to receive and importing material. Good transportation is possible as the site is situated near the highway. Man power availability. Nearer to raw material and market. Getting additional raw material for additional production capacity is also not a constraint. Sufficient raw material is available. Utilizing more Fly ash from the nearby Thermal Power Station as a major part of the raw material.

As for transportation of goods, there is already existing black topped roads from the State High way No 36 to the project site.

4.0 DESCRIPTION OF ENVIRONMENT

Khannawan village is a geographical part of Bachhranwan GP, Maharajganj Tehsil and Rae-Bareli District in Uttar Pradesh. The average annual rainfall is 700-900 mm. The maximum and minimum temperatures of the region are 45˚C and 2.5˚C. Area falls under semi- arid zone category. The area of interest for the REIA studies is 10 Km radius with Project site as its center.

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5.0 PROJECT DESCRIPTION

SALIENT FEATURES OF THE PROJECT SITE Location of Project

Village Tehsil District State

Kannawan Village, Bachharanwan GP, Maharajganj Tehsil, Raebareli District U.P. state. Altitude 381 feet Latitude 260 _{25’45.2” N} Longitude 810 _{07’ 47.5” E}

Soil Type Sandy loamsoils

Land Availability 10 hectares

General Climatic Conditions

Maximum Temperature (0_c) ₄₅

Minimum Temperature (0_c) _2.5

Relative Humidity(%) 24-89%

Annual Rainfall Average (mm) 800

Accessibility

Nearest Highway State Highway-36 – <1.0 km

Nearest Railway Station Bachharanwan – 3.5km

Nearest Airport Lucknow – 55 km

Nearest Town Rae-bareli – 27 km

Nearest Village Khannawan– 1.0km

Historical / Important Places

Water bodies Sai river – 4 km (S)

Reserved Forests NIL

Archaeological/ Historically important areas

None

Sanctuaries / National Parks None

Sensitive Places None

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RAW MATERIALS

The raw materials required are Asbestos fibre & other fibres (8 to 9%), Binders cement & flyash materials (45 to 47% and 27% respectively).

5.1. RAW MATERIALS- SOURCE Raw

Material Source

Cement Nearby sources

Fly ash Nearby Power station

Fibre Fully Imported from Canada,

Brazil,Russia

Pulp Local

Water Existing Bore wells of VIL LTD

As for transportation of goods, there is already existing black topped roads.

As for transportation of goods, there is already existing black topped roads from

the State High way No 36 to the project site. This is quite adequate for the

possible truck movement envisaged.

MANUFACTURING PROCESS OF A.C. PRODUCT

Asbestos Fiber of different grades are imported, mainly from Canada, Russia, Zimbabwe etc, and received in pressure packed condition in impermeable bags in palletized form. The fibre pallets are transported to the factory in closed containers through the trailer trucks. These palletized fiber bags are unloaded in fiber go-downs with the help of fork lifts. Fiber bag pallets are conveyed to the fiber feeding section by means of fork lifts. The fiber bags shall be slit open in closed automatic bag opening device. The empty bags shall be lifted by a hooking device attached within the bag opening device and carried to the attached bag shredder unit and the fiber after passing through the lump breaker shall be collected in the attached blender where some water shall be added to maintain the process in wet condition.. When all the bags in one charge empties the fiber

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on to the blender, the fiber in wet form shall be taken to the Edge Runner Mill via a screw conveyor and elevator which is also joined by the shredded bag pieces from the shredder unit. Here at ERM some more water is further added to the fibre for milling operation. The bag opening device & the edge runner mill shall be kept under negative pressure by tapping it on to a Bag Filter Type Dust Collector with pulse jet which again is connected to a Hydro-static Precipitator, connected to a blower (capacity _ 7500 m3/hr) driven by a 15 Hp motor. The delivery point of the blower is connected to the Air Wet Washer and through to a 18 m tall stack. The Hydro-static Precipitator works on the principle of tidal wave generation. Particles collected in hydro-static precipitator shall be periodically recycled in wet form. From this point onwards the total process operations involving fibre are carried out in wet condition with no possibility of dust generation during manufacturing process. The milled fiber is weighed in weigh hopper. The pre-requisite quantity of fiber which is about 8% of the product is mixed with required quantity of water in Wet Opener or fibre cone where it is re-circulated for about 3 to 4 minutes. The above slurry along with other fibers, if any, a small quantity (around less than 1%) of pulp and small quantities of homogenized solid waste + process sludge in slurry form (from sludge recycling tank/Wet Ball Mill) is taken to Beater tank. Cement is received and stored in go-down., from where it is conveyed to the Cement + Fly ash Mixing Tank via screw conveyor. Next, Fly ash is received and stored in closed go-down. Fly ash shall be pneumatically conveyed Pre-requisite quantity of Special binders - Fly ash (around 26 to 28 % of the product) is mixed with water, converted into slurry and sent to Storage tanks. A measured quantity of Fly ash slurry is taken to the Batch Hopper and then to the Cement + Fly ash Mixing Tank. The cement + FA slurry thus prepared in the Mixing tank is sent to Wet Rotary Sieve & thence to the Beater Tank, thus joining fiber slurry.

The RM slurry thus prepared is transferred to Storage Tank where it is under constant agitation. From here slurry is taken to the Dilution Tank(or Distribution Tank) and diluted further using recycled process water. Slurry from the Dilution

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Tank is taken to the sheet forming machine consisting of an assembly of 5 vats placed in series and with rotating sieve cylinders placed one in each of 5 vats. The sieve cylinders are fitted at its periphery, with the wire mesh of specific size (mostly 40 mesh on top surface and 5 mesh on bottom surface). An end-less felt made of synthetic woven fabric runs tangentially atop the sieve cylinders. The slurry through the sieve cylinders gets filtered out. The differential hydrostatic pressure thus created between the sieve cylinder and Vat causes an asbestos cement film to be formed and picked up by the sieve cylinder which in turn gets transferred to the moving felt. The gradually thickening slurry due to filtration is constantly diluted in the vats. The excess water in film is dehydrated by vacuum system. The wet film from the felt is then transferred on to the rotating sheet forming drum.

After the required thickness is achieved the wet sheet is cut by automatic cutter fixed on the sheet forming drum. The formed sheet is then trimmed widthwise with long cutters to the required width. The length of the sheet varies as per the market requirement from 1.5 M to 3 M. after cutting to the required length the sheet is transferred on to the profiling machine (Corrugator) by vacuum sucking. The formed sheets are stacked in between the steel moulds ( templates) which will be air cured for about 12 hrs in a closed chamber. After the air curing the sheets are separated out from the templates in destacker machine. The templates are cleaned and lubricated and sent back to profiling machine. The sheets then are inspected on-line, stacked on steel pallets and water cured for a minimum of 12 days before being finally inspected and then dispatched.

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6.0 PROPOSED SCOPE OF WORK FOR EIA STUDY:

OBJECTIVE:

Preparation of REIA/EMP Studies is a pre-requisite as per EIA-2006 Notification. The proposed Project expansion envisages setting up of 200,000 TPA ASBESTOS CEMENT SHEET PLANT in two phases of Phase -1 40000 TPA and Phase-2 160,000 TPA. EIA and EMP will be prepared to address these developmental activities.

The EIA study includes determination of baseline conditions surrounding to the proposed developmental facilities, assessment of the impacts on the environment due to the operation of the proposed expansion Project and making recommendations on the preventive measures to be taken, to minimize the impact on the environment to acceptable levels. The field data around proposed project will be collected within 10 Kms radius of Project Site.

6.1 COMPONENTS OF THE EIA STUDY:

The component of the EIA study includes:

 Determination of baseline conditions using primary data generation and

secondary data available from existing reports and studies and historical data from government published reports

 Detailed description of all elements of the project activities during the

pre-construction, construction and operational phases. The elements analyzed and included the infrastructures of the project including drainage features, roads, waste collection, disposal and management and utility requirements.

 Identifying the sources of pollution and assessing the impacts on the

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ensure environmental soundness, sustainability and regulatory compliance of the designs are studied.

 Preparation of EIA and EMP documents with recommendations on

preventive and mitigative measures for limiting the impact on environment to the desired level during various stages of project. Development of a suitable post study-monitoring program to comply with various environmental regulations also done; and

 Risk Assessment (RA) describing the probable risks and preventive &

precautionary measures to be followed in the event of emergency situations such as accidents, fire, oil spills, etc.

7.0 BASELINE ENVIRONMENTAL DATA GENERATION:

Field assessments of the physical, ecological, and socioeconomic aspects of the site and surrounding environs of the development facilities shall be conducted. These assessments shall be used to determine the potential impacts of the proposed expansion project. The survey includes a photo-inventory of the physical and biological features of the site and environs, and the areas viewed with respect to the suitability of the proposed facility.

The data generation will include:

Physical: Climate, air and noise quality, geology, topography,

groundwater/surface water hydrology and quality and hazard vulnerability.

Ecological: Terrestrial and aquatic communities; presence of rare, threatened,

and endangered species.

Socioeconomic: Demography, regional setting, location assessment, and land

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The baseline monitoring on physical parameters encompassing the entire developmental facilities are proposed to be carried out after TOR approval for assessing the environmental quality. A reconnaissance survey has been conducted prior to commencement of sampling to select the locations by a team of technical experts. The sampling requirements have been established based on the standard scientific methods.

The details of monitoring to be carried out on environmental attributes are presented in Table below:

Environmental Data Generation- Scope of work covered

SNo. Attributes Scope of Work

1 Ambient Air

Quality

10 Locations - 2 days/week for 12 weeks

(3 months) PM2.5 ,PM10, SO2, NOx, and CO

will be monitored as per CPCB guidelines. Design of ambient air quality sampling network with regard to topography, population, sensitive locations, emission sources, background concentrations and

possible impact zones, through

application of screening air quality models for assessing the maximum GLC zones prior to start of baseline study.

2 Meteorological

data

1 Location - 90 days

Wind speed, direction, temperature, humidity, cloud cover and rainfall will be monitored.

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meteorological data for the area of interest

from the nearest meteorological

observatory and Trend analysis of micrometeorological data generated at the site.

3 Water Quality 10 Locations- (Surface & Ground water

samples) – Once during the EIA study Parameters as per IS-10500, IS:2296 and EPA Act as applicable .

The survey also include estimation of water balance and assessment of impacts on regional water demand and availability of fresh water due to drawl of water for

plant, recommendations on water

conservation and rain water harvesting measures based on past experience on similar projects; and identification of suitable location and methodology for disposal of waste water form all sources.

4 Soil Quality 10 Locations once during EIA study.

Parameters related to afforestation,

nutrients, pollutants etc will be carried out.

5 Noise Levels 10 Locations (Residential, Commercial

and Sensitive areas) once during EIA study. Readings will be taken for 24-hr duration at each location

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handbooks as well as with the help of satellite imagery will be presented in 10-km radius study area.

7 Solid waste Characterization of all the solid wastes

generated from the plant operations and its disposal including impacts due to disposal.

8 Geology and

Hydro-geological aspects

These aspects will be covered for 10-km radius study area for proposed project site. The data will be compiled from the secondary sources only.

9 Socio-Economic

and Health

aspects

Socio-economic and health aspects will be covered for 10-km radius study area based on the Census documents and NIC database.

10 Ecological studies

(Terrestrial and

Aquatic)

Flora and fauna will be studied in 10-km radius study area. These studies will be based on primary as well as secondary sources.

The survey also includes assessment of the species diversity, density, abundance etc. in the study area and formulation of ecological indexes, assessment of likely changes on flora and fauna due to the project related activities, suggestions for conservation and protection of flora and fauna in the study area.

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LEGISLATION AND REGULATORY CONSIDERATIONS:

Government policies, legislation and regulations relevant to the proposal have been identified. Local plans and policies will also be evaluated. Project characteristics will be analyzed to ensure compliance with these policies, legislation and regulations. Appropriate recommendations will be provided to ensure regulatory compliance.

8.0 IDENTIFICATION OF SOURCES OF POLLUTION AND IMPACT ASSESSMENT:

8.1 Sources of Pollution in the Project Area

This includes the following:

 Identifying the sources of pollution of air, water, land, noise and solid

and hazardous wastes;

 Quantifying the emissions from the pollution generating sources; and

 Quantification of solid and HW wastes and likely disposal methods will be

suggested.

The proposed expansion project may have some impacts on the environment during construction, drilling and commercial production. The parameters likely to be affected are air quality, water quality, soil quality; noise levels, etc. on account of gaseous emissions, liquid effluent discharges, resultant particulates, generation of solid wastes, etc will be discussed.

The major pollution potential sources in the project are as under:

a) Construction Phase (If any)

 Approach road construction

 Laying pipelines

 Transport of men and material

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b) Development Phase

 Land acquisition and site preparation

 Disposal of construction waste

 Sewage from campsites

 Site restoration

c) Regular Operational Phase

 Transporting raw material

 Produce-water disposal

 Domestic wastewater disposal

 Disposal of solid waste

 Storage of materials

 Fire / Explosion

d) Decommissioning Phase

 Decommissioning of processing units

 Transport and disposal of waste

 Restoration of site

There are various qualitative as well as quantitative methods of conducting EIA studies, each having its own merits and demerits. We intend to use the best logical tool to assess the impact of the project.

The baseline data generated from the above studies will be analyzed and compared with applicable standards prescribed by the CPCB and MOEF. By this means, the impact whether positive or negative will be assessed and the environmental attributes requiring special attention for mitigating the

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negative impact, if any, will be identified. Also the areas, which fulfill the prescribed environmental norms and not requiring further improvements, will be specified. Both short-term and long term impacts particularly on sensitive targets such as habitat of endangered species of wildlife, crops, historically/culturally important sites/monuments, and centers with concentrated population in the study area will be established.

Mitigation measures to reduce adverse impacts will be suggested. The potential impacts due to the project could be as follows:

 Change in land use due to the proposed project

 Potential impact on soil and groundwater due to waste handling,

transportation and disposal

 Air quality and noise level impacts due to project activities.

 Potential impacts due to the Vehicular movement and emissions;

Storage of materials

Impact on socio-economic environment due to increased direct and indirect employment generation, and social welfare activities in the nearby villages The above impact assessment and proposed mitigative measures are described below

Impact on Land Use

 Impact Assessment

The land use impacts due to proposed project will be identified in terms of local land use planning efforts. The change in land use pattern of project site will also be identified. This includes visual impact, impact on forest, impact due to industrial growth and growth due to socio-economic factors.

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 Mitigation Measures

The mitigation measures will be addressed towards restoration of land disturbed by the proposed project activities to the extent possible.

Impact on Demography and Socio-Economics

On the basis of the compiled information and the proposed employment and other benefits to the people of the study area as well as others, the likely socio-economic impacts of proposed project in post-project scenarios for demography, facilities and services, agricultural sector, civic infrastructure and basic amenities, industrial sector, economic status and health status of people, etc will be assessed.

Strategies to mitigate the negative impacts of the project will be developed for areas where negative impacts are projected to occur. The potential actions considered will include both policy and planning actions. The roles of different bodies in mitigation measures will be identified.

Impact on Soil

Impacts on soil characteristics include destruction of soil profile, changes in soil productivity, increased erosion and subsequent loss of agricultural soils and land use changes. Details of solid and hazardous wastes likely to be generated from the operations and their treatment and disposal mechanism

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vis-à-vis the proposed treatment facilities in the project will be assessed and mitigation measures will be suggested accordingly.

Based on analysis, mitigation measures will be proposed which will avoid, minimize or compensate for significant adverse impact on soil characteristics.

Impact on Water Quality

We propose to address the impacts due to water requirement, Impacts due to the domestic sewage, treatment and disposal will also be addressed.

Considering the dependence of the people in the area on ground water as sources for drinking purposes, the prevailing quality and extent of contamination due to the proposed project activities, the mitigation measures will include and the treatment required for meeting the effluent discharge standards specified under the Environment Protection Rules and PCB will be addressed. The disposal arrangements will be conceptually indicated.

Impact on Meteorology

The climatologically factors, which play an important role in the environmental analysis of the process of transportation, dilution and dispersion of pollutants, will be analyzed. Meteorological data will be collected to ascertain wind roses, atmospheric stability conditions and prevalence of inversion levels around the project site. This will enable to

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define the atmospheric conditions likely to prevail in the study area and use it as a basis for air quality modeling studies.

Impact on Ambient air Quality

Emission inventory will be carried in the study area. A computer based internationally recognized mathematical air quality model (ISCST3) suitable for the region would be used to predict the concentration of SO2, NOx & SPM due to the operation of the proposed plant. The results will be presented for short-term (24-hourly) concentrations in and around the project site. The dispersion model results will be included in the report using isopleths or other graphical methods, over laying a land use map of the surrounding area. The predicted air quality results will be compared with existing regulations.

Potential mitigation measures include the control measures at the source level and providing adequate stack heights. The measures to control the fugitive dust emissions such green belt development and sprinkling will be suggested.

Impact on Noise

Sources of noise and its impact on the environment will be addressed. The noise level at varying distances for multi-sources will be predicted using Noise model. A comparison of measured noise (Leq) at monitoring locations

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to that of predicted noise levels (Leq) will be made and mitigatory measures will be recommended to conform to regulatory ambient air noise standards. Baseline noise levels in different zones like industrial, residential and sensitive areas like hospitals, wild life habitation etc will be monitored. The potential noise level exposure will be determined and evaluate for acceptable limits of exposure.

The potential mitigation measures will be addressed to reduce noise levels by control at source, provision of greenery to absorb noise during its propagation, isolation of high noise generating sources, use of protective measures especially in high noise areas.

Impact on Ecology

Impacts on terrestrial species especially during dry season will be assessed particularly those which are sensitive to the pollution. Recommendations will be made to mitigate such adverse impacts as soil erosion and habitat loss.

9.0 ENVIRONMENT MANAGEMENT PLAN

The Environment Management Plan (EMP) includes all the mitigatory measures proposed under each significant environmental attribute. For each potential negative impact identified, recommendations will be presented for

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avoidance, minimization or mitigation of impacts along with costs associated with potential mitigation. Further, a suitable green belt development plan for the project site will be included in the EMP report.

The EMP will addresses the following:

 Identify and summarize all anticipated significant adverse environmental

impacts:

 Identify and summarize all mitigation measures, including the type of

impact to which it relates and the conditions under which it is required;

 Define a set of policies and objectives for environmental performance and

continual enhancement of performance;

 Wastewater and produced water handling, treatment and disposal;

 Solid and hazardous waste handling and disposal;

 Green belt development plan;

 Recommend monitoring and reporting procedures including the

parameters to monitored, methods to be used, sampling locations, frequency of measurements, detection limits and definition of thresholds that will signal the need for corrective actions;

 Recommend capacity development and training requirements for

implementation of EMP; and

 Recommend an organizational structure for effective implementation of

the EMP;

An environmental monitoring and management plan have developed for the sensitive elements of the environment that may require monitoring during construction and production phase of the proposed project. Recommendations have made on the institutional arrangements that will be necessary to ensure effective monitoring and management.

A detailed management and monitoring program has developed to reduce the effects of potential negative environmental impacts. The EMP also reflects statutory requirements, M/s. VIL LIMITED