M/S.Padmasree Steels Private Limited - OLD

M/S. PADMASREE STEELS PRIVATE LIMITED Survey No. 106/4,109/4, 6, 7, 110/1, 2, 3, 4 and 112, Devarapalli Village, Ravulapalem Mandal, East Godavari District, Andhra Pradesh

Updated Form I

1. FORM 1 2.Pre feasibility report

SUBMITTED BY STUDIES AND DOCUMENTATION BY M/s Padmasree Steels Private Limited, TEAM Labs and Consultants Devarapalli Village, B-115 to 117 & 509, Annapurna Block, Ravulapalem Mandal, Aditya Enclave, Ameerpet, East Godavari District - 533 223 Hyderabad-500 038 Andhra Pradesh Phone: 040-23748 555/616, Ph: +91 – 9849664455 Telefax: 040-23748666 E mail: [email protected] Email: [email protected]

SUBMITTED TO STATE LEVEL ENVIRONMENTAL IMPACT ASSESSMENT AUTHORITY ANDHRA PRADESH GOVERNMENT OF INDIA M/S. PADMASREE STEELS PRIVATE LIMITED Survey No. 106/4,109/4, 6, 7, 110/1, 2, 3, 4 and 112, Devarapalli Village, Ravulapalem Mandal, East Godavari District, Andhra Pradesh

FORM 1

SUBMITTED BY STUDIES AND DOCUMENTATION BY M/s Padmasree Steels Private Limited, TEAM Labs and Consultants Devarapalli Village, Ravulapalem Mandal, B-115 to 117 & 509, Annapurna Block, East Godavari District - 533 223 Aditya Enclave, Ameerpet, Andhra Pradesh Hyderabad-500 038 Ph: +91 – 9849664455 Phone: 040-23748 555/616, E mail: [email protected] Telefax: 040-23748666 Email: [email protected]

SUBMITTED TO STATE LEVEL ENVIRONMENTAL IMPACT ASSESSMENT AUTHORITY ANDHRA PRADESH GOVERNMENT OF INDIA Padmasree Steels Private Limited Form-1

APPENDIX I (See paragraph – 6) FORM 1 (I) Basic Information S. Item Details No 1 Name of the Project/s M/s. Padmasree Steels Private Limited 2 S. No in the Schedule 1(d) Power Plants 3(a) Secondary metallurgical processing industry 3 Proposed capacity/area/length/tonnage to be Capacity S.No Description Units handled/command area/lease area/number of Consented Proposed Total wells to be drilled 1 M S Ingots* / MS TPD 65 250 315 Billets 2 Steel rerolling rods TPD 72 250 322 of Various Sizes (Rebars) 3 Power generation MW 3 9 12 (Gas based) MW - 4* 4* *Standby Additional land of 1.73 ha is proposed for acquisition. 4 New/Expansion/Modernization Expansion Cost estimated for the project Rs. 21 Crores 5 Existing Capacity/Area etc. MS Ingots: 65 TPD, Steel Rerolling rods of various sizes (Rebars)- 72 TPD and Captive Power plant (Natural Gas)- 3 MW 6 Category of Project i.e 'A' or 'B' B 7 Does it attract the general condition? If yes, please No specify 8 Does it attract the Specific condition? If yes, please No specify. 9 Location Plot/Survey/Khasra No. 106/2,3,4,5,6,8,9 ,109/6,7,110/1,2,3 and 110/4 Village Devarapalli Tehsil Ravulapalem District East Godavari State Andhra Pradesh. 10 Nearest railway station/airport along with distance Railway Station: Tanuku- 19 km - NW in kms. Airport: Rajahmundry - 43 km- NW 11 Nearest Town, City, District Headquarters along Town: Ravulapalem – 4.0 km –NW with distance in kms. District headquarters: Kakinada – 45 km -SE 12 Village Panchayats, ZillaParishad,Municipal Village Panchayat: Devarapalli Corporation, Local body (complete postal address Ravulapalem Mandal, with telephone nos. to be given) East Godavari District 13 Name of the Applicant Sri C. Subba Rao 14 Registered Address M/s. Padmasree Steels Private Limited Devarapalli Village, Ravulapalem Mandal, East Godavari District - 533 223

F-1 Padmasree Steels Private Limited Form-1

S. Item Details No 15 Address for Correspondence: Name Sri C. Subba Rao Designation(Owner/Partner/CEO) Managing Director Address M/s. Padmasree Steels Private Limited Devarapalli Village, Ravulapalem Mandal, East Godavari Pin Code 533 223 E-mail [email protected] Telephone Number +91 9849664455, 0883-2445575. Fax No. 040-23748666 16 Details of alternative Sites examined, if any. Not Applicable Location of these sites should be shown on a topo sheet. 17 Interlinked Projects Not applicable 18 Whether separate application of interlinked -NA- project has been submitted? 19 If yes, date of submission -NA- 20 If no, reason 21 Whether the proposal involves approval/clearance -NA- under: if yes, details of the same and their status to be given. (a) The Forest (Conservation) Act, 1980? (b) The Wildlife (Protection) Act, 1972? (c) The C.R.Z Notification, 1991? 22 Whether there is any Government Order/Policy No relevant/relating to the site? 23 Forest land involved (hectares) No 24 Whether there is any location pending against the No 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.

F-2 Padmasree Steels Private Limited Form-1

(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 Information/Checklist S. No. Yes/No quantities /rates, wherever possible) with confirmation source of information data 1.1 Permanent or temporary change NO The proposal is for expansion of the existing in land use, land cover or plant. Additional land of 1.73 ha is proposed topography including increase in for acquisition. The present land use is intensity of land use (with respect Industrial use. Site area is 7.01 ha to local land use plan) 1.2 Clearance of existing land, NO The proposal is for expansion of the existing vegetation and buildings? unit. Additional land of 1.73 ha is proposed for acquisition. 1.3 Creation of new land uses? NO Existing land use – Industrial. 1.4 Pre-construction investigations YES Soil test done and soil load bearing capacity e.g. bore houses, soil testing? established 1.5 Construction works? YES Construction activity involves additional sheds, utilities, erection only. 1.6 Demolition works? NO No structures for demolition 1.7 Temporary sites used for NO The construction labor from local villages construction works or housing of shall be employed. construction workers? 1.8 Above ground buildings, YES Storage facilities for raw material and final structures or earthworks products shall be constructed. No major cut including linear structures, cut and fill or excavation is anticipated. and fill or excavations 1.9 Underground works including NO No underground works like mining and mining or tunneling? tunneling. 1.10 Reclamation works? NO 1.11 Dredging? NO 1.12 Offshore structures? NO 1.13 Production and manufacturing YES Enclosed in Annexure – I processes? 1.14 Facilities for storage of goods or YES Storage facility for raw materials (sponge materials? iron) is proposed. 1.15 Facilities for treatment or YES Domestic wastewater shall be sent to septic disposal of solid waste or liquid tank followed by soak pit. Solid waste is effluents? generated from the furnace but is minor in amount and sold to Cement manufacturers / reused. 1.16 Facilities for long term housing of NO Operational workers stay in surrounding operational workers? villages 1.17 New road, rail or sea traffic YES Construction materials shall be transported during construction or operation? to the site. There will be an increase of about 10 trucks per day. The traffic density of the existing connecting road is negligible.

F-3 Padmasree Steels Private Limited Form-1

Details thereof (with approximate Information/Checklist S. No. Yes/No quantities /rates, wherever possible) with confirmation source of information data 1.18 New road, rail, air waterborne or NO other transport infrastructure including new or altered routes and stations, ports, airports etc? 1.19 Closure or diversion of existing NO transport routes or infrastructure leading to changes in traffic movements? 1.20 New or diverted transmission NO lines or pipelines? 1.21 Impoundment, damming, NO culverting, realignment or other changes to the hydrology of watercourses or aquifers? 1.22 Stream crossings? NO 1.23 Abstraction or transfers of water YES Total water required shall be met from Bore form ground or surface waters? wells. Present permitted water consumption is 142 KLD. Total water required after expansion shall be 250 KLD.

1.24 Changes in water bodies or the NO land surface affecting drainage or run-off? 1.25 Transport of personnel or YES The construction material shall be drawn materials for construction, from local sources within 10 – 15 km. There operation or decommissioning? is no transport of personnel, as the construction workers shall be drawn from local villages. 1.26 Long-term dismantling or NO decommissioning or restoration works? 1.27 Ongoing activity during NO decommissioning which could have an impact on the environment? 1.28 Influx of people to an area in YES The proposed project shall increase either temporarily or employment potential and required persons permanently? will be employed locally. Hence the development may not lead to migration from surrounding villages. 1.29 Introduction of alien species? NO 1.30 Loss of native species or genetic NO There are no major losses of tree/shrub diversity? species. 1.31 Any other actions? NO

F-4 Padmasree Steels Private Limited Form-1

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): Yes Information/checklist Details thereof (with approximate quantities /rates, S.No / Confirmation wherever possible) with source of information data No 2.1 Land especially undeveloped No The proposal is for expansion of the existing unit. No or agricultural land (ha) additional land is required. 2.2 Water (expected source & YES Total water required shall be met from Bore wells. competing users) unit: KLD Present permitted water consumption is 142 KLD. Total water required after expansion shall be 250 KLD. (water balance enclosed in Annexure –II) 2.3 Minerals (MT) NA 2.4 Construction material– stone, YES Stone 20mm- 1500m3, stone 40mm- 800m3, and sand aggregates, sand/soil(expected -2000m3 sourced locally. source- MT) 2.5 Forests and timber (source – NO MT) 2.6 Energy including electricity and YES The required energy shall be drawn from existing fuels (source, competing users) Captive Power plant / APTRANSCO. Unit: fuel (MT), energy (MW) Gas based GG set and 1 x 1250 KVA GG set shall be provided in addition to the proposed 9 MW (Gas based) GG and 1 x 380 KVA GG set to cater to emergency load requirement during load shut downs. 2.7 Any other natural resources NO (use appropriate standard units)

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. Details thereof (with approximate Information/Checklist. Yes S.No quantities/rates, wherever possible) confirmation /No with source of information data 3.1 Use of substances or materials, which are YES Specific measures shall be taken for the hazardous (as per MSIHC rules) to human storage of raw materials. health or the environment (flora, fauna, and water supplies) 3.2 Changes in occurrence of disease or affect NO disease vectors (e.g. insect or water borne diseases) 3.3 Affect the welfare of people e.g. by YES Shall increase the employment potential changing living conditions? for locals and affect the living conditions for betterment.

3.4 Vulnerable groups of people who could be NO No sensitive receptors are present in the affected by the project e.g. hospital immediate vicinity of the site. The project patients, children, the elderly etc., shall not have any significant impact on vulnerable groups of people. 3.5 Any other causes NO

F-5 Padmasree Steels Private Limited Form-1

4. Production of solid wastes during construction or operation or decommissioning (MT/month) Details thereof (with approximate Information/Checklist S.No Yes/No quantities/rates, wherever possible) with confirmation source of information data 4.1 Spoil, overburden or mine NO wastes 4.2 Municipal waste (domestic and NO Wastes from canteen, other commercial or commercial wastes) wastes like paper, empty containers etc. The canteen wastes and commercial wastes shall be in the range of 40 kg/day. Biodegradable waste is sent to Vermi Compost and recyclable materials are sent to recyclers. 4.3 Hazardous wastes (as per YES The quantity of hazardous wastes generated Hazardous Waste during operation contains waste oils and Management Rules) batteries from GG set.

4.4 Other industrial process YES Solid waste is generated from the furnace but wastes is minor in amount and is sold to cement manufacturers. Enclosed in Annexure – III 4.5 Surplus product NO 4.6 Sewage sludge or other sludge NO from effluent treatment

4.7 Construction or demolition NO wastes 4.8 Redundant machinery or NO equipment 4.9 Contaminated soils or other NO materials 4.10 Agricultural wastes NO 4.11 Other solid wastes yes Slag is sent to cement industires

5.Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr) Details thereof (with approximate S.No. Information/Checklist Confirmation Yes/No quantities/rates, wherever possible) with source of information data 5.1 Emissions from combustion of fossil fuels YES Natural Gas shall be used as fuel for from stationary or mobile sources proposed 1 x 1250 KVA GG set. Emission details are enclosed in Annexure IV 5.2 Emissions from production processes YES The rerolling mill shall use Coal as fuel and the same shall result in emissions. Enclosed in Annexure – IV 5.3 Emissions from materials handling NO including storage or transport 5.4 Emissions from construction activities YES Dust may rise during transport of including plant and equipment material and construction activity.

F-6 Padmasree Steels Private Limited Form-1

Details thereof (with approximate S.No. Information/Checklist Confirmation Yes/No quantities/rates, wherever possible) with source of information data The dust emissions shall be mitigated by water spraying on the roads within the premises. 5.5 Dust or odours from handling of materials NO including construction materials, sewage and waste 5.6 Emissions from incineration of waste NO 5.7 Emissions from burning of waste in open NO air (e.g. slash materials, construction debris) 5.8 Emissions from any other sources NO

6. Generation of Noise and Vibration, and Emissions of Light and Heat: Details thereof (with approximate Yes quantities/rates, wherever possible) with S.No. Information/Checklist confirmation /No source of information data with source of information data 6.1 From operation of equipment e.g. YES Material transport and construction engines, ventilation plant, crushers equipment shall be source of noise, while GG sets are the source of noise during operation. 6.2 From industrial or similar processes YES Low Nox burners to GG sets.GG sets will be used in case of power failure. 6.3 From construction or demolition YES Noise during construction shall be due to construction equipment and emergency GG sets. 6.4 From blasting or piling NO 6.5 From construction or operational NO The increased traffic shall not have any traffic significant impact. 6.6 From lighting or cooling systems NO 6.7 From any other sources NO 7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal waters or the sea: Details thereof (with approximate quantities/rates, S.No. Information/Checklist confirmation Yes/No wherever possible) with source of information data 7.1 From handling, storage, use or spillage of No hazardous materials 7.2 From discharge of sewage or other effluents to No All the wastes from domestic water or the land (expected mode and place of operations are sent to septic tank discharge) followed by soak pit.

7.3 By deposition of pollutants emitted to air into the No land or into water 7.4 From any other sources No

F-7 Padmasree Steels Private Limited Form-1

Details thereof (with approximate quantities/rates, S.No. Information/Checklist confirmation Yes/No wherever possible) with source of information data 7.5 Is there a risk of long term build up of pollutants No 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 Details thereof (with approximate Information/Checklist S.No. Yes/No quantities/rates, wherever possible) confirmation with source of information data 8.1 From explosions, spillages, fires etc YES All in built Safety precautions will be from storage, handling, use or adopted and there will not be any production of hazardous substances damage to environment or human health 8.2 From any other causes NA 8.3 Could the project be affected by NO natural disasters causing Environmental damage (e.g. floods, earthquakes, landslides, Cloudburst etc)?

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 Details thereof (with approximate Yes / quantities/rates, wherever S. No. Information/Checklist confirmation No possible) with source of information data 9.1 Lead to development of supporting. YES The project shall enhance the socio facilities, ancillary development or development economic status of the area by stimulated by the project which could have improving the employment to the impact on the environment e.g.: local villagers. There are no major •Supporting infrastructure (roads, power supply, support industries required for this waste or waste water treatment, etc.) plant. •Housing development •Extractive industries • Supply industries • Other 9.2 Lead to after-use of the site, which could have an NO impact on the environment 9.3 Set a precedent for later developments NO 9.4 Have cumulative effects due to proximity to NO The baseline environmental status other existing or planned projects with similar of the surrounding areas is within effects the prescribed limits as observed from the secondary data.

F-8 Padmasree Steels Private Limited Form-1

(III) Environmental Sensitivity Name/ Aerial distance (within 15 km.) S.No. Areas Identity Proposed project location boundary 1 Areas protected under international NA conventions, national or local legislation for their ecological, landscape, cultural or other related value 2 Areas which are important or sensitive for YES Gautami Godavari River – 3.0 km – NE ecological reasons - Wetlands, watercourses Vasishta Godavari River – 6.2 km - SW or other water bodies, coastal zone, biospheres, mountains, forests

3 Areas used by protected, important or NA sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration 4 Inland, coastal, marine or underground NO waters 5 State, National boundaries NO Nil 6 Routes or facilities used by the public for NO access to recreation or other tourist, pilgrim areas 7 Defence installations NO

8 Densely populated or built-up area YES Devarapalle Village – 1.0 km – SW direction with population of 3293 9 Areas occupied by sensitive man-made land NA Place of worship and school at 1.0 Km uses (hospitals, schools, places of worship, away from site. community facilities) 10 Areas containing important, high quality or NO scarce resources (ground water resources, surface resources, forestry, agriculture, fisheries, tourism, minerals) 11 Areas already subjected to pollution or NO environmental damage. (those where existing legal environmental standards are exceeded) 12 Areas susceptible to natural hazard which NO could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)

F-9

ANNEXURES Annexure I

Figure A.1 Location of M/s . Padmasree Steels Private Limited.

A-1 BUND

N 11 KV ALTERNATIVE POWER LINE

GREEN BELT 35 37 36 20 12 38 BUND 21 22 34 17 18 16 19 7 5 4 ROAD 25 10 BUND 31 9 27 3 BUND CANAL 8 GREEN BELT 6 BUND 15 23

1 29 13 14 BUND ROAD

11 KV UNDERGROUND CABLE APPROXIMATELY 120 M ROAD 28 32 33 RAVULAPADU BRIDGE TO PALIVELA ROAD 24 BUND 30 ROAD

ROAD

GREEN BELT BUND G R E E N B E LT GREEN BELT

ALL DIMENSIONS ARE IN METERS M/S PADMASREE STEELS PVT LTD EXISTING LAYOUT PLAN: PROPOSED R.S NO:- 106/4; 109/4,6,7; 110/1,2,3,4; 112

G R E E N B E LT DEVARAPALLI VILLAGE, RAVULAPALEM MANDAL

E.G.Dt SCALE :- 1:765 Figure A.2 Site plan of M/s.Padmasree Steels Private Limited - OLD.,

A-2 Figure A.2 Site plan of M/s.Padmasree Steels Private Limited – New Layout.

A-3 Introduction

The project site is located at Survey No. 106/2,3,4,5,6,8,9 ,109/6,7,110/1,2,3 and 110/4 Devarapalli village, Ravulapalem mandal, East Godavari district, Andhra Pradesh. The site is situated at the intersection of 16°43'45.62"N Latitude, 81° 51'53.23"E Longitude. The site elevation above mean sea level (MSL) is in the range of 12-14 m. The site is surrounded by open lands in three directions except north direction which has Ravulapalem to Palivela Road. The nearest habitation from the site is Devarapalle located at a distance of 1.0 km in southwest direction from the site. The main approach road is Ravulapalem to Palivela adjacent to the site in north direction. The nearest railway station is Tanuku at a distance of 19 km in northwest direction. Gautami Godavari River is flowing from Northwest to southeast at a distance of 3.0 km in northeast direction, Vasishta Godavari River flowing from Northwest to Southwest at a distance of 6.2 km in Southwest direction. There is no forest, national park, wild life Sanctuary, ecologically sensitive area, critically polluted area and Interstate boundary within the impact area of 10 Km radius.

The manufacturing capacity is presented in table A-1. The manufacturing processes are presented as follows;

Table A-1 Manufacturing Capacity

Units Capacity S.No Description Consented Proposed Total 1 M S Ingots* / MS Billets TPD 65 250 315 2 Steel rerolling rods of Various TPD 72 250 322 Sizes (Rebars) 3 Power generation (Gas based) MW 3 9 12 MW - 4* 4* *Standby

A-4 Steel Making by Induction Furnace

The greatest advantage of the Induction Furnace is its low capital cost compared with other types of Melting Units. Its installation is relatively easier and its operation simpler. Among other advantages, there is very little heat loss from the furnace as the bath is constantly covered and there is practically no noise during its operation. The molten metal in an Induction Furnace is circulated automatically by electromagnetic action so that when alloy additions are made, a homogeneous product is ensured in minimum time. The time between tap and charge, the charging time, power delays etc. are items of utmost importance is meeting the objective of maximum output in tones/hour at a low operational cost. The disadvantage of the induction furnace is that the melting process requires usually selected scrap because major refining is not possible.

Manufacture of MS Ingots/Billets:

The process for manufacture of MS Ingots/billets may be broadly divided into the following stages:- i) Melting the charge mixed of steel & Iron scrap. ii) Ladle teeming practice for Casting (OR). iii) Direct teeming practice for Ingot Casting unladdable teeming machine. (i) Melting the Charge

The furnace is switched on, current starts flowing at a high rate and a comparatively low voltage through the induction coils of the furnace, producing an induced magnetic field inside the central space of the coils where the crucible is located. The induced magnetic fluxes thus generated out through the packed charge in the crucible, which is placed centrally inside the induction coil.

As the magnetic fluxes generated out through the scraps and complete the circuit, they generate and induce eddy current in the scrap. This induced eddy current, as it flows through the highly resistive bath of scrap, generates tremendous heat and melting starts. It is thus apparent that the melting rate depends primarily on two things (1) the density of magnetic fluxes and (2) compactness of the charge. The charge mixed arrangement has already been described. The magnetic fluxes can be

A-5 controlled by varying input of power to the furnace, especially the current and frequency.

In a medium frequency furnace, the frequency range normally varies between 150- 300 K cycles/second. This heat is developed mainly in the outer rim of the metal in the charge but is carried quickly to the center by conduction. Soon a pool of molten metal forms in the bottom causing the charging to sink. At this point any remaining charge mixed is added gradually. The eddy current, which is generated in the charge, has other uses. It imparts a molten effect on the liquid steel, which is thereby stirred and mixed and heated more homogeneously. This stirring effect is inversely proportional to the frequency of the furnace and so that furnace frequency is selected in accordance with the purpose for which the furnace will be utilized.

The melting continues will all the charge is melted and the bath develops a convex surface. However as the convex surface is not favorable to slag treatment, the power input is then naturally decreased to flatten the convexity and to reduce the circulation rate when refining under a reducing slag. The reduced flow of the liquid metal accelerates the purification reactions by constantly bringing new metal into close contact with the slag. Before the actual reduction of steel is done, the liquid steel which might contain some trapped oxygen is first treated with some suitable deoxidizer. When no purification is attempted, the chief metallurgical advantages of the process attributable to the stirring action are uniformity of the product, control over the super heat temperature and the opportunity afforded by the conditions of the melt to control de-oxidation through proper addition.

As soon as the charge has melted clear and de-oxidising ions have ceased, any objectionable slag is skimmed off, and the necessary alloying elements are added. When these additives have melted and diffused through the bath of the power input may be increased to bring the temperature of metal up to the point most desirable for pouring. The current is then turned off and the furnace is tilted for pouring into a ladle. As soon as pouring has ceased, any slag adhering to the wall of the crucible is crapped out and the furnace is readied for charging again.

A-6 As the furnace is equipped with a higher cover over the crucible very little oxidation occurs during melting. Such a cover also serves to prevent cooling by radiation from the surface heat loss and protecting the metal is unnecessary, though slags are used in special cases. Another advantage of the induction furnace is that there is hardly any melting loss compared with the arc furnace.

Continuous Casting Machine (CCM) – Proposed

The molten steel from the IF or the ladle metallurgical facility is cast in a continuous casting machine (4/7 2 stand Billet Caster) to produce cast shapes including billets. In some processes, the cast shape is hydraulic shear cut to length and transported hot to the hot rolling mill for further processing. Other steel mills have reheat furnaces. Steel billets are allowed to cool, and then be reheated in a furnace prior to rolling the billets into bars or other shapes.

The process is continuous because liquid steel is continuously poured into a 'bottomless' mould at the same rate as a continuous steel casting is extracted.

1) Before casting begins a dummy bar is used to close the bottom of the mould.

2) A ladle of molten steel is lifted above the casting machine and a hole in the bottom of the ladle is opened, allowing the liquid steel to pour into the mould to form the required shape.

3) As the steel's outer surface solidifies in the mould, the dummy bar is slowly withdrawn through the machine, pulling the steel with it.

4) Water sprays along the machine to cool/solidify the steel.

5) At the end of the machine, the steel is cut to the required length by hydraulic shear

cutter.

A-7 Rolling Mill Manufacturing Process

Hot Rolling Process (standby)

Re-Heating Furnace is fired daily 4 hours before start up time of Rolling Mill. Ingots/Billets, when in the heating zone a temperature of 650°C is achieved, which is measured through Thermo Couples & in Soaking zone a temperature of 1250°C is achieved some sized samples app. 1.5 Meter to 2 meter long are put in & fed in every mill. This is already in running condition with all water circuitry on, to check the sizes on every pass. If some minute adjustment is required it is made & again samples are fed to confirm size of pass in Rolls, then 1st piece of Ingot is passed through, leader and tail end is cut in on line Rotary Shears & final sized, which is put on cool Bed manual & again size is reconfirmed. Bar / Structural material is cut into 48 M length through on line Rotary Shear before cooling Bed.

In the meantime charging Grate helpers put manually cold ingot or, which was stacked on charging Grate by EOT Electromagnetic Crane from stock Yard, to conveyor table which brings the piece in front of pusher on the back side of Re- Heating Furnace from where on getting signal from Ejector operator the pusher operator pushes the piece into the Furnace. In front side the Roughing pull pot operator gives Electric operated signal to ejector operator for pushing next piece and rolling of second piece stars, if rolling is going on without hindrance which is observed upto 10 Approx. pieces the process become continuous. On an average when 8 MM size is being rolled & 3 meter billet is use approximately 65-70 pieces come in one hour. Production increases for high sized sections 10 mm & above on Cooling Bed when quantity is collected, one piece of 48 m length is pushed manually/automatically on pieces conveyor. Which when pass through cold shear is cut in to 12 m length & workers make bundles of these & stack these size wise for checking & dispatching.

A-8 Raw Material- Billets and Blooms

Billets and Blooms from Own Induction Furnaces/LRF are the main Raw material for the Plant. The Billets/Blooms are received in the Raw - Material Bay and unloaded with the help of Crane. The Billets/Blooms from the Concast Cooling Bed will be shifted to Billet storage shed. From the Billet storage it will be shifted to raw material storage by EOT Crane. The Billet is cut by the Billet shear into required length for rolling. Billets/Blooms are prepared for charging into the furnace as per the quality and size to be rolled. The Billets/Blooms are kept on the Charging Platform by means of Electric Crane. They are then pushed into the Re-heating Furnace with the help of Charging Roller Table and PUSHER.

*Re-heating in Furnace (standby)

The Billets/Blooms are heated to 1100 C in the Pusher type Re-heating Furnace as they are slowly advancing into the Furnace towards the burners. The Re-heating Furnace is equipped with low aircoal burners, Air Blower, Recuperator, Chimney and coal etc. The Furnace temperature is indicated by Pt-PtRh Thermocouple and Electronic Digital temperature Indicator. The Billet/Blooms is discharged out of the Furnace with the help of Mechanical Ejector. The Billet/Bloom is conveyed by a Roller Conveyor (RC) to the Main Roller Table and then automatically fed into the 1st Pass of Roughing Mill Stand No. I. daily consumption of coal is 20 TPD .

*stand by

Roughing In Roughing Mill

In Roughing Mill, there are 2 Stands driven with the help of Electric Motor, Flywheel and Gear Boxes. Several passes are cut into the Rolls to reduce the material in size and shape. There are also two passes in Intermediate Mill and two passes in Continuous Mill. The cutting of passes in the rolls is very important and it varies with the size, shape and quality of the material to be rolled. PASS DESIGN in a Rolling Mill is very important aspect and experienced FOREMAN or ENGINEER is appointed to take care of it. The material (Billet/Bloom) fed into the bottom passes with the help of Main Roller Table and Turning walls and in the top they are fed

A-9 with the help of Tilting Table. Approximately 4/6 passes have been provided in No. 1st Stand as per the size to be rolled.

After that the material is transferred by sliding rails and Skew Rolls to 2nd Stand and 1 pass is provided in the 2nd Stand. From Stand No. 2 the material is taken to 1st stand of Intermediate Mill via Roller Table and Y Table. Intermediate Mill has 2 Nos. Stands driven by Electric Motor. The 1st stand is opposite 2nd Stand of Roughing Mill. For top pass feeding `Y' Table is provided. Next the material is transferred to 2nd Stand of Intermediate Mill by sliding rails Skew Rolls. The material elongates each time it passes through the rolls and area reduction takes place. From Stand No. 2 of Intermediate Mill the material is taken to Continuous Mill No-1 via a Roller Table and then it’s going to Continuous Mill No-2 via a Roller Table.

Final shape is given in this Stand and accurate adjustment is required. The material is fed into the mill with the help of roller table automatically and it acquires the desired shape and size and further travels to Cooling Bed via a Roller Table. The temperature at finishing stage is 800/900 C approx. The rolls and guides and fiber bearings in the mill are cooled with the help of water re-circulation.

Natural Cooling On Cooling Bed

The Cooling Bed is Duplex type and fabricated with structural material and in the centre C.I. plates are provided with few individually driven rolls in between. After finishing pass the material comes to Cooling Bed via Roller Conveyor. Then it is shifted to one side of the Cooling Bed by Manual Shifting arrangement. When one side is filled up, the other side is used. The first side material is cleared while the other side is being used and vice a versa. The material is cleared via Roller Conveyor and cut into required specific length with the help of Shearing Press.

Inspection

Inspection is done at every stage of Production by Quality Assurance Department. First, the Raw Material is checked, Rolling temperature and finishing temperature is monitored and weight per meter of the rolled section is checked periodically.

From the finished material, samples are taken for Physical and Chemical Testing in

A-10 Laboratory. Care is taken so that sub-standard material is not supplied to customers. After the testing, material is kept ready for Dispatch. Loading in the truck will be done by Mobile or EOT Crane.

Stockyard and Dispatch

After cutting the inspected material to specific length it is transferred to stockyard and staked properly with the help of crane. Wherever, straightening is required, it is taken to a straightening M/C, and straightened and then properly staked. From the stacked material samples are taken for quality checks and suitable grading is done, as per Indian Standards. The material is then ready for dispatch.

Raw Materials Required

S.No Raw Material 1 Sponge Iron 2 M.S scrap, cast iron scrap and pig iron.

Utilities The utilities required for the proposed production capacity are presented in Table below. List of Utilities

S.No Description Capacity Consented Proposed Total 1 GG set 1 x 380 KVA 1 x 1250 KVA1 x 380 KVA 1 x 1250 KVA

A-11 Annexure – II

Water Requirement

Steel making is a heat intensive process wherein a considerable quantity of cooling water is required for control of metallurgical process. Water is mainly needed for cooling various furnace components and furnace transformer oil, drinking and Green belt development.

Water is not used in manufacture of Ingots, Rerolling Bars. Water is only used for cooling purpose, water circulation systems have been planned to cater extensive recycling and reuse of return water from plant processes is 250 KLD, there will be no process effluents. Blow downs from the cooling tower are sent to ETP for treatment.

Total Water Balance – Tentative

Quantity (KLD) Quantity (KLD) Input Output Consented Proposed Total Consented Proposed Total Cooling tower 14 7 63 Cooling blow down Tower 90 70 160 Losses 83 7 146 Scrubber 13 5 8 Effluent Scrubber 20 25 45 Losses 15 17 32 Domestic 13 10 3 wastewater Domestic 32 8 40 Losses 22 5 27 Green Belt - 5 5 Losses - 5 5 Total 142 108 250 Total 142 108 250

A-12 Annexure – III

Solid Waste

The solid waste generated from the plant is mill scales from CCM & Rolling Mill and slag from Induction Furnace will be sold to cement manufacturers. The solid waste quantities and disposal practices are presented in Table below.

Solid Wastes Generated and Mode of Treatment

Quantity Type of Solid S.No Consent Remarks Waste Proposed Total ed 1 Solid waste from 0.2 0.6 0.8 Reused as raw material in mill scales (TPD) MS ingots production / Sold to cement Manufactures 2 Induction 2 25 27 Sold to cement Manufactures Furnace Slag (TPD) 3 Used Batteries 3 9 12 Sent to Authorized recyclers (no/yr) 4 Waste Oil (l/yr) 200 2000 2200 Sent to Authorized recyclers

A-13 Annexure – IV

Air Emissions

The sources of air pollution from the proposed plant are Induction Furnace, Rolling mill, GG Sets (Natural Gas) and GG set of 1 x 1250 KVA capacity apart from the existing are Induction Furnace, Rolling mill, GG Sets (Natural Gas) and GG set of 1 x 380 KVA capacity. The furnace and rolling mill is fitted with control equipment. The emissions from the furnace and rolling mill are passed through a scrubber. Cleaned gases are then passed through chimney of sufficient height and diameter so as to ensure that the air emissions are safely let out into atmosphere. The stack of height 30m is provided with necessary infrastructure and porthole along with necessary power connection to monitor the pollutants. The emissions from the GG Set are safely let out into atmosphere by passing through a chimney of sufficient height above the ground level. A comprehensive green belt provided around the industry

to attenuate gaseous pollutants. The emission rates of SO2, NOx and PM are presented in Table 2.7

Stack Emission Details

Dia of Pollutant Emission Temp. of Exit Stack stack Rate (mg/Nm3) S.No Stack Connected to exhaust Vel, Ht, m at top, gases, 0C m/s m SPM SO2 NOx Consented 1. Induction Furnace 30 0.6 50 13.2 115 - -

2. Rolling mill Furnace 30 0.5 50 7.2 115 - -

3. 3 x 1 MW GG Sets 30 0.3 60 8.5 - - 100 (Natural Gas) 4. 1 x 380 KVA GG 5 0.2 60 14 115 - 100 Set(Natural Gas) Proposed 1. Induction Furnace 30 0.6 50 13.2 115 - -

2. GG Sets GG Sets (Natural Gas) 3 x 1 MW GG Sets 30 0.5 60 8.5 - - 100 (Natural Gas) 4 x 1.5 MW GG Sets 30 0.5 60 8.5 - - 100 (Natural Gas) or

A-14 Dia of Pollutant Emission Temp. of Exit Stack stack Rate (mg/Nm3) S.No Stack Connected to exhaust Vel, Ht, m at top, gases, 0C m/s m SPM SO2 NOx 6x 1.5 MW GG Sets 30 0.5 60 8.5 - - 100 (Natural Gas) or 4 x 2 MW GG Sets 30 0.5 60 8.5 - - 100 (Natural Gas) 1x1 MW GG set 30 0.5 60 8.5 - - 100 4. *2 x 2 MW GG Sets 30 0.5 60 8.5 - - 100 (Natural Gas) 5. 1 x 1250 KVA GG Set 9 0.3 60 16 115 100 100 (Natural Gas)* * *standby GG sets ** Auxilliary GG (spare)

A-15 7

Post [,r.No. SEIAA/ AP/ IiG/ IND/ 06-016 fitz Dt:13.07.2016 'fo N{/s. Padmasree Steels Private Limited, Sri C.Subba Rao, Managing Director, I)evarapalli (V), Ravulapalem (M), Ilasf ()odnvari District - 533223, Ph.r-91 981966,1455, e-nirti I : prrrlrnasrce555 rr grrrlri i.r.trnt

Sir.

Sub: sEAc - A.P. - NIis. Padmasree Steels private Limiterl at sun,ey l\o. 10614,70911, 6,'7, 110/1, 2, 3, 1 and 112, I)evarapalli (V), Rangampeta (M), East Gotiirvari iiistrict, Andhra Fraticsir - Expansion o{' thc eristing piiint - Terms of Rcference (TOIt) - Reg.

Ref: Your EC Application received on 01.06.2016.

In continuation of tire above, it is to infbrm that your application rvas examinecl by the State Expert Applaisal Committee (SEAC) in its meeting hetd on07.06.2016 and rhe Committee recommencled for Issue of Standard TOR for the expansion project.

In vier'v of the above, you are recluested to prepare EIA basecl on the standard TOR and submit to the SEAC for appraisal. T'he tems of the relerence are valid for a period of three years.

Yours faithfully,, sd/- MEMI}ER SECRETARY, SEAC. A.P.

ilT.C.E.B.O// M/S. PADMASREE STEELS PRIVATE LIMITED Survey No. 106/4,109/4, 6, 7, 110/1, 2, 3, 4 and 112, Devarapalli Village, Ravulapalem Mandal, East Godavari District, Andhra Pradesh

Studies and Documentation by: Team Labs and Consultants (An ISO 9001:2008 Certified Company) B-115 to 117 & 509, Annapurna Block, Aditya Enclave, Ameerpet, Hyderabad-500 038 Tel: 91-040-23748555, 23748616 Fax: 91-040-23748666. Email: [email protected] M/S. PADMASREE STEELS PRIVATE LIMITED Survey No. 106/4,109/4, 6, 7, 110/1, 2, 3, 4 and 112, Devarapalli Village, Ravulapalem Mandal, East Godavari District, Andhra Pradesh

Pre-Feasibility Report

SUBMITTED BY M/s Padmasree Steels Private Limited, Devarapalli Village, Ravulapalem Mandal, East Godavari District - 533 223 Andhra Pradesh Ph: +91 – 9849664455 E mail: [email protected]

SUBMITTED TO STATE LEVEL ENVIRONMENTAL IMPACT ASSESSMENT AUTHORITY ANDHRA PRADESH GOVERNMENT OF INDIA Padmasree Steels Private Limited.,

Pre – Feasibility Report

M/s. Padmasree Steels private Limited, Devarapalli village, Ravulapalem mandal, East Godavari district, Andhra Pradesh

DISCLAIMER The purpose and scope of this information memorandum is to introduce the subject matter and provide a general idea and information on the said area. All the material included in this document is based on data/information gathered from various sources and is based on certain assumptions. Although, due care and diligence has been taken to compile this document, the contained information may vary due to any change in any of the concerned factors, and the actual results may differ substantially from the presented information. M/s. Padmasree Steels private Limited., does not assume any liability for any financial or other loss resulting from this memorandum in consequence of undertaking this activity. Therefore, the content of this memorandum should not be relied upon for making any decision, investment or otherwise. The prospective user of this memorandum is encouraged to carry out his/her own due diligence and gather any information he/she considers necessary for making an informed decision.

1. Executive Summary

M/s. Padmasree Steels private Limited proposes to expand its existing steel plant with Survey no. 106/2,3,4,5,6,8,9 ,109/6,7,110/1,2,3 and 110/4 , Devarapalli village, Ravulapalem mandal, East Godavari district, Andhra Pradesh. The company has about 5.28 ha of land.

The site is located at the intersection of 16°43'45.62"N Latitude, 81°51'53.23"E Longitude. The site elevation above mean sea level (MSL) is in the range of 12-14 m. The site is surrounded by open lands in three directions except north direction which has Ravulapalem to Palivela Road. The nearest habitation from the site is Devarapalle located at a distance of 1.0 km in southwest direction from the site. The main approach road is Ravulapalem to Palivela adjacent to the site in north direction. The nearest railway station is Tanuku at a distance of 19 km in northwest direction. Gautami Godavari River is flowing from Northwest to southeast at a distance of 3.0 km in northeast direction, Vasishta Godavari River passing from Northwest to Southwest at a distance of 6.2 km in Southwest direction. There is no

P-1 Padmasree Steels Private Limited., forest, national park/wild life Sanctuary, ecologically sensitive area, critically polluted area and Interstate boundary within the impact area of 10 km radius.

2. Introduction of the Project / Background Information:

2.1 Identification of Project and Project Proponent:

The objective of this pre-feasibility study is to provide information for the proposed expansion Steel plant with production capacity of Ms Ingots*/MS Billets 250 TPD, Re rolling of various sizes 250 TPD and Captive Power: 9 MW.

The project proponent Mr. C Subba Rao is a Managing Partner of M/S. Padmasree Steels private Limited. His extensive experience in the area of steel plant, over last 30 years.

2.2 Brief Description of Nature of the Project:

2.3 Need for the project and its importance to the country and or region:

World population is growing at an alarming rate. In the Indian sub continent population growth is more than that of developed countries. To meet the needs and comforts of ever-growing population industrialization became inevitable. For the growing population the needs of infrastructure substitutes are also increasing

P-2 Padmasree Steels Private Limited.,

2.4 Demands-Supply Gap

The project is envisaged to meet the demand supply gap as demand is increasing day by day.

2.5 Imports Vs. Indigenous Production:

The project shall meet to reduce the imports products.

2.6 Domestic/export Markets:

The products shall cater to domestic market.

2.7 Employment Generation (Direct and Indirect) due to the project:

The present project for manufacturing of MS Ingots*/MS Billets, Captive Power (Natural Gas Based) and Rerolling of various sizes substantial handling of raw materials, goods in process and finished goods. The proposed expansion shall increase the employment potential to 200 peoples.

3.0 Project Description

3.1 Type of Project including interlinked and interdependent projects, if any:

The proposed project is falls in the B category of 1(d), 3(a) in the Schedule of EIA Notification, 2006.

3.2 Location

Location Details are enclosed in Annexure I.

3.3 Details of alternative sites considered and the basis of selection the proposed site, particularly the environmental considerations gone into should be highlighted

It is proposed to purchase additional land area of 1.73 ha.

3.4 Size or magnitude of operation:

List of products and manufacturing capacity

P-3 Padmasree Steels Private Limited.,

Manufacturing Capacity

Capacity S.No Description Units Consented Proposed Total 1 M S Ingots* / MS Billets TPD 65 250 315 2 Steel rerolling rods of Various TPD 72 250 322 Sizes (Rebars) 3 Power generation (Gas based) MW 3 9 12 MW - 4 * 4 * *Standby

3.6 Project Description with process details (a schematic diagram/flow chart)

Typical process description with process details is presented in Annexure I of Form I Application.

3.7 Raw material required along with estimated quantity likely source, marketing area of final product/s, mode of transport of raw material and finished product.

All the raw materials required for manufacturing mostly available in India.

3.8 Availability of water its source, energy/power requirement and source should be given

P-4 Padmasree Steels Private Limited.,

Total Water Balance – Tentative

Quantity (KLD) Quantity (KLD) Input Output Consented Proposed Total Consented Proposed Total Cooling tower blow down 7 63 70 Cooling Tower 90 70 160 Losses 83 7 90 Scrubber 5 8 13 Effluent Scrubber 20 25 45 Losses 15 17 32 Domestic 10 3 13 wastewater Domestic 32 8 40 Losses 22 5 27 Greenbelt - 5 5 Losses - 5 5 Total 142 108 250 Total 142 108 250 3.8.1 Electricity

Existing connected power load from CPP/AP Transco is max. 6 MW.

3.9 Quantity of wastes to be generated (liquid and solid) and Scheme for their Management/disposal

Wastewater Treatment Facilities

The sources of effluent generation in the cooling Tower and Scrubber Effluents plant. Domestic wastewater is sent to STP.

Solid Waste Generation and Mode of Disposal

Quantity Type of Solid S.No Consent Remarks Waste Proposed Total ed 1 Solid waste from 0.2 0.6 0.8 Reused as raw material in mill scales (TPD) MS ingots production / Sold to cement Manufactures 2 Induction 2 24 26 Sold to cement Manufactures Furnace Slag (TPD) 3 Used Batteries 3 9 12 Sent to Authorized recyclers (no/yr) 4 Waste Oil (l/yr) 200 2000 2200 Sent to Authorized recyclers

P-5 Padmasree Steels Private Limited.,

4. Site Analysis

4.1 Connectivity

The main approach road is Ravulapalem to Palivela adjacent to the site in north direction. The nearest railway station is Tanuku at a distance of 19 km in northwest direction.

4.2 Land form, Land use and Land ownership

The present usage of the Land is industrial land and the same is used for the proposal expansion.

5. Planning Brief:

The project is envisages to be completed by December 2019, and the production shall be initiated thereon. Consultants are identified for preparing the detailed project report.

6. Proposed Infrastructure:

6.1 Industrial Area

Utilities

List of Utilities

S.No Description Capacity Consented Proposed Total 1 GG set 1 x 380 KVA 1 x 1250 KVA1 x 380 KVA 1 x 1250 KVA * GG set will be used during load shut down.

P-6 Padmasree Steels Private Limited.,

Waste management

Liquid Effluents

The main sources of effluent generation from the plant are Scrubber, blow downs from cooling tower.

Air Pollution

The sources of air pollution in the plant are from the existing 2 x 8 MT IF, Reheating Furnace, 3 x 1 MW GG Sets (natural Gas), and backup GG sets of 1 x 380 KVA, and proposed 2 x 15 MT IF, Reheating Furnace, DG Sets (natural Gas), and backup GG sets of 1 x 1250 KVA, to cater to energy requirement during load shut downs. GG sets shall be provided with stack heights based on the CPCB formula for effective stack height.

Solid waste

The solid waste generated from the plant is mill scales from CCM & Rolling Mill and slag from Induction Furnace will be sold to cement manufacturers.

6.2 Residential Area (Non Processing Area)

No Residential colony is proposed, Local Villagers are employed.

6.3 Green belt

2.313 acres area is already developed for greenbelt.

P-7 Padmasree Steels Private Limited.,

6.4 Socio Infrastructure

Tanuku is the nearest town which has both educational and health facilities. Kakinada town, the district head quarters is located at a distance of 46 km from the site. The surrounding villages have primary and high schools, however the health facilities are observed to be inadequate. Drinking water source is mainly ground water in the surrounding villages, and ground water potential is observed to be good.

6.5 Connectivity

The main approach road is Ravulapalem to Palivela adjacent to the site in north direction. The nearest railway station is Tanuku at a distance of 19 km in northwest direction. Kakinada Port at a distance of 46 km in northeast direction.

6.6 Drinking water Management

Drinking water source is mainly ground water in the surrounding villages, and ground water potential is observed to be good.

6.7 Power Requirement and Supply/Source

Existing connected power load from Captive Power plant /AP TRANSCO is max. 3.0 MW and proposed connected power load is 9 MW.

7. Rehabilitation and Resettlement (R&R) Plan

Not applicable as the land area is only 7.01 ha already acquired.

8. Project Schedule & Cost Estimates

8.1 Likely date of start of construction and likely date of completion (Time schedule for the project to be given)

December 2019 and Completion by July 2020.

8.2 Estimated project cost along with analysis in terms of economic viability of the project

P-8 Padmasree Steels Private Limited.,

The estimated cost of the project is approximately Rs.21 crores.

Project Cost Rs. crores Plant, machinery 11 Civil buildings 2 Electricals & instrumentation 3 Erection & commissioning & painting 5 Project Cost 21

P-9 M/S. PADMASREE STEELS PRIVATE LIMITED Survey No. 106/4,109/4, 6, 7, 110/1, 2, 3, 4 and 112, Devarapalli Village, Ravulapalem Mandal, East Godavari District, Andhra Pradesh