1

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

2

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.

3

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 60 KLD.

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

4

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.

5

SITE LOCATION MAP WITH GOOGLE EARTH IMAGE PROJECT SITE

6

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 (0c) 45

Minimum Temperature (0c) 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

Seismic Zone(As per 1893) Zone I

6

7

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

8

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

9

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.

10

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

environment due to proposed project. Analysis and assessment of designs to

11

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

uses.

12

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.

This is to be further supported by the

13

SNo. Attributes Scope of Work

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

6 Land use Land use as per the district census

14

SNo. Attributes Scope of Work

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.

15

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

Construction of sheds & Buildings

16

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

Transport of men and material

Storage of materials

Fire / Explosion

d) Decommissioning Phase

Transport of men and material

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

17

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.

18

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

Impact Assessment

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.

Mitigation Measures

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

Impact Assessment

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

19

vis-à-vis the proposed treatment facilities in the project will be assessed and

mitigation measures will be suggested accordingly.

Mitigation Measures

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.

Mitigation Measures

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

Impact Assessment

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

20

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

Impact Assessment

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.

Mitigation Measures

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

Impact Assessment

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

21

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.

Mitigation Measures

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

22

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