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SAIL
Company
Steel Authority of India Limited (SAIL) is the leading steel-making company in India. It is a fully integrated iron and steel maker, producing both basic and special steels for domestic construction, engineering, power, railway, automotive and defence industries and for sale in export markets.
Ranked amongst the top ten public sector companies in India in terms of turnover, SAIL manufactures and sells a broad range of steel products, including hot and cold rolled sheets and coils, galvanised sheets, electrical sheets, structurals, railway products, plates, bars and rods, stainless steel and other alloy steels. SAIL produces iron and steel at five integrated plants and three special steel plants, located principally in the eastern and central regions of India and situated close to domestic sources of raw materials, including the Company's iron ore, limestone and dolomite mines. The company has the distinction of being India’s largest producer of iron ore and of
having the country’s second largest mines network. This gives SAIL a competitive edge in terms of captive availability of iron ore, limestone, and dolomite which are inputs for steel making.
SAIL's wide range of long and flat steel products are much in demand in the domestic as well as the international market. This vital responsibility is carried out by SAIL's own Central Marketing Organisation (CMO) and the International Trade Division. CMO encompasses a wide network of 34 branch offices and 54 stockyards located in major cities and towns throughout India.
With technical and managerial expertise and know-how in steel making gained over four decades, SAIL's Consultancy Division (SAILCON) at New Delhi offers services and consultancy to clients world-wide.
SAIL has a well-equipped Research and Development Centre for Iron and Steel (RDCIS) at Ranchi which helps to produce quality steel and develop new technologies for the steel industry. Besides, SAIL has its own in-house Centre for Engineering and Technology (CET), Management Training Institute (MTI) and Safety Organisation at Ranchi. Our captive mines are under the control of the Raw Materials Division in Kolkata. The Environment Management Division and Growth Division of SAIL operate from their headquarters in Kolkata. Almost all our plants and major units are ISO Certified.
Major Units
Integrated Steel Plants
• Bhilai Steel Plant (BSP) in Chhattisgarh
• Durgapur Steel Plant (DSP) in West Bengal
• Rourkela Steel Plant (RSP) in Orissa
• Bokaro Steel Plant (BSL) in Jharkhand
• IISCO Steel Plant (ISP) in West Bengal
Special Steel Plants
• Alloy Steels Plants (ASP) in West Bengal
• Salem Steel Plant (SSP) in Tamil Nadu
• Visvesvaraya Iron and Steel Plant (VISL) in Karnataka
Subsidiary
• Maharashtra Elektrosmelt Limited (MEL) in Maharashtra
Click here for further details
Joint Ventures
SAIL has promoted joint ventures in different areas ranging from power plants to e-commerce.
• NTPC SAIL Power Company Pvt. LtdA 50:50 joint venture between Steel Authority of India Ltd. (SAIL) and National Thermal Power Corporation Ltd. (NTPC Ltd.), it manages the captive power plants at Rourkela, Durgapur and Bhilai with a combined capacity of 314 megawatts (MW). It has taken up expansion of its installed capacity by implementation of 500 MW (2 x 250 MW Units) power plant at Bhilai. Likely commercial generation of 1st Unit by Sept '08 and that of 2nd Unit by March '09.
• Bokaro Power Supply Company Pvt. LimitedThis 50:50 joint venture between SAIL and the Damodar Valley Corporation formed
in January 2002 is managing the 302-MW power generation and 1880 tonnes per hour steam generation facilities at Bokaro Steel Plant. BPSCL is currently expanding its capacity by installing 2x250 MW coal based thermal unit at Bokaro.
• Mjunction Services LimitedA joint venture between SAIL and Tata Steel on 50:50 basis, this company promotes e-commerce activities in steel and related areas. New added services includes E-Assets sales, Events & Conferences, Coal Sales & Logistics, Publications etc.
• SAIL-Bansal Service Center Ltd.SAIL has formed a joint venture with BMW industries Ltd. on 40:60 basis to promote a service centre at Bokaro with the objective of adding value to steel.
• Bhilai JP Cement LtdSAIL has also incorporated a joint venture company with M/s Jaiprakash Associates Ltd to set up a 2.2 MT cement plant at Bhilai. Likely to commence operations by March'2010.
• Bokaro JP Cement LtdSAIL has also incorporated a joint venture company with M/s Jaiprakash Associates Ltd to set up a 2.1 MT cement plant at Bokaro. Likely to commence operations by October'2010.
• SAIL&MOIL Ferro Alloys (Pvt.) LimitedSAIL has incorporated a joint venture company with M/s Manganese Ore (India) Ltd to set up ferro-manganese and silico-manganese plants at Nandini / Bhilai, of 1.0 lakh tonne capacity.
• A JV agreement signed with Tata Steel for joint development of coal blocks
Ownership and ManagementThe Government of India owns about 86% of SAIL's equity and retains voting control of the Company. However, SAIL, by virtue of its ‘Navratna’ status, enjoys significant operational and financial autonomy
Background & History
A Rich Heritage
The Precursor
SAIL traces its origin to the formative years of an emerging nation - India. After independence the builders of modern India worked with a vision - to lay the infrastructure for rapid industrialisaton of the country. The steel sector was to propel the economic growth. Hindustan Steel Private Limited was set up on January 19, 1954. The President of India held the shares of the company on behalf of the people of India.
Expanding Horizon (1959-1973)
Hindustan Steel (HSL) was initially designed to manage only one plant that was coming up at Rourkela. For Bhilai and Durgapur Steel Plants, the preliminary work was done by the Iron and Steel Ministry. From April 1957, the supervision and control of these two steel plants were also transferred to Hindustan Steel. The registered office was originally in New Delhi. It moved to Calcutta in July 1956, and ultimately to Ranchi in December 1959.
A new steel company, Bokaro Steel Limited, was incorporated in January 1964 to construct and operate the steel plant at Bokaro. The 1 MT phases of Bhilai and Rourkela Steel Plants were completed by the end of December 1961. The 1 MT phase of Durgapur Steel Plant was completed in January 1962 after commissioning of the Wheel and Axle plant. The crude steel production of HSL went up from .158 MT (1959-60) to 1.6 MT. The second phase of Bhilai Steel Plant was completed in September 1967 after commissioning of the Wire Rod Mill. The last unit of the 1.8 MT phase of Rourkela - the Tandem Mill - was commissioned in February 1968, and the 1.6 MT stage of Durgapur Steel Plant was completed in August 1969 after commissioning of the Furnace in SMS. Thus, with the completion of the 2.5 MT stage at Bhilai, 1.8 MT at Rourkela and 1.6 MT at Durgapur, the total crude steel production capacity of HSL was raised to 3.7 MT in 1968-69 and subsequently to 4MT in 1972-73.
Holding Company
The Ministry of Steel and Mines drafted a policy statement to evolve a new model for managing industry. The policy statement was presented to the Parliament on December 2, 1972. On this basis the concept of creating a holding company to manage inputs and outputs under one umbrella was mooted. This led to the formation of Steel Authority of India Ltd. The company, incorporated on January 24, 1973 with an authorized capital of Rs. 2000 crore, was made responsible for managing five integrated steel plants at Bhilai, Bokaro, Durgapur, Rourkela and Burnpur, the Alloy Steel Plant and the Salem Steel Plant. In 1978 SAIL was restructured as an operating company.
Since its inception, SAIL has been instrumental in laying a sound infrastructure for the industrial development of the country. Besides, it has immensely contributed to the development of technical and managerial expertise. It has triggered the secondary and tertiary waves of economic growth by continuously providing the inputs for the consuming industry.
SAIL Today
SAIL today is one of the largest industrial entities in India. Its strength has been the diversified range of quality steel products catering to the domestic, as well as the export markets and a large pool of technical and professional expertise.
Today, the accent in SAIL is to continously adapt to the competitive business environment and excel as a business organisation, both within and outside India.
SAIL - Into the Future
Modernisation and Expansion Plan of SAIL
The Corporate Plan was reviewed by Hon’ble Minister of Steel in Jul’06, wherein it was decided to take up the Expansion of Integrated Steel Plants and Special Steel Plant in one go based on Composite Project Feasibility Report (CPFR).
By that time Expansion of IISCO Steel Plant and Salem Steel Plant was already approved “in-principle” based on the Techno-Economic Feasibility Report (TEFR) of MECON. For the Expansion of other four integrated Steel Plants, MECON was assigned the job of Preparation of CPFR in Aug’06. The CPFR for the four integrated steel plants was prepared by MECON.
‘In principle’ approval has been accorded by SAIL Board for the expansion plans of IISCO Steel Plant (Jul’06), Salem Steel Plant (Jun’06), Bokaro Steel Plant (Dec’06), Bhilai Steel Plant (Apr’07), Rourkela Steel Plant (May’07) and Durgapur Steel Plant (Jul’07).
Item 2006-07(Actual)
Capacity as per Expansion Plans
Hot Metal 14.61 26.18
Crude Steel 13.51 24.59
Saleable Steel 12.58 23.13
Plant-wise Capacity Envisaged After Expansion (Mtpa)
Plant Hot Metal Crude Steel Saleable Steel
BSP 7.5 7.0 6.53
DSP 3.5 3.0 2.83
RSP 4.5 4.2 3.8
BSL 7.44 7.00 6.53
ISP 2.91 2.5 2.37
SSP - 0.18 0.34
ASP - 0.48 0.43
VISL 0.33 0.23 0.22
Total 26.18 24.59 23.13
Objective of Growth Plan
• 100% production of steel through Basic Oxygen Furnace (BOF) route • 100% processing of steel through continuous casting • Value addition by reduction of semi finished steel • Auxiliary fuel injection system in all the Blast Furnaces
• State-of-art process control computerisation/ automation • State-of-art online testing and quality control • Energy saving schemes • Secondary refining • Adherence to environment norms
The investment for modernization and expansion programme of SAIL is estimated at about Rs.54,333 crores.
Plant ExpansionSustenance/
on-goingTotal
BSP 11,262 1,716 12,978
DSP 5,549 114 5,663
RSP 7,668 1,121 8,789
BSL 8,952 2,167 11,119
ASP 49 49
SSP 1,902 - 1,902
VISL 121 121
ISP 12,743 494 13,237
MINES 195 195
OTHERS 280 280
TOTAL 48076 6257 54,333
% 88 12 100
Plant-wise Expenditure in Expansion (Rs. Crore)
Plant2006-07 2007-08
TotalActual RE Actual
BSP 12.66 35.95 66.63 79.29
DSP - 10.00 16.09 16.09
RSP - 20.00 36.85 36.85
BSL 12 11.17 28.92 40.92
ISP 72.69 340.00 495.70 568.39
SSP 3.26 40.00 35.75 39.01
ASP - - - -
VISL - - - -
TOTAL 100.61 457.12 679.94 780.55
VISION
To be a respected world class corporation and the leader in Indian steel business in quality, productivity, profitability and customer satisfaction.
CREDO
We build lasting relationships with customers based on trust and mutual benefit.
We uphold highest ethical standards in conduct of our business.
We create and nurture a culture that supports flexibility, learning and is proactive to change.
We chart a challenging career for employees with opportunities for advancement and rewards.
We value the opportunity and responsibility to make a meaningful difference in people's lives.
MOUs
:: MOUs :: JVs
• SAIL has signed an MoU with IL&FS IDC for forming a special purpose vehicle (SPV) to develop, operate and maintain a special economic zone (SEZ) for steel sector at SALEM.
• MOU signed with Rashtriya Ispat Nigam Ltd. (RINL) to jointly explore and develop low silica limestone mines in the Sultanate of Oman.
• SAIL has signed an MoU with Government of Kerala on 3rd May'08 wherein it has been agreed to jointly take necessary actions to increase production from the existing facilities at Steel Complex Limited (SCL), Calicut and also set up, develop & manage a 50,000 TMT Rolling Mill along with its balancing facilities and auxiliaries at SCL, Calicut.
• SAIL has signed an MoU with Shipping Corporation of India Limited (SCI) to promote a Joint Venture Company, which shall primarily provide shipping related services to SAIL for imported coking coal and also participate in world wide dry bulk shipping trade.
• MoU signed with the Korean steel giant, POSCO to collaborate in a wide range of strategic business and commercial areas of mutual interest.
• MOU with Mineral Exploration Corporation Ltd. (MECL) for exploration by MECL at all SAIL mines for assessing the reserves and quality of ore available. MECL has already started exploratory work in Gua and Chiria mines.
• MoU with M/s Heavy Engineering Corporation (HEC) for equipment/spares required for modernization/expansion.
• MoU with M/s Bisra Stone Lime Co. Ltd. (BSLC) for dolomite
• MoU with Indian Railways for procurement of high power locomotives
• MoU signed with Bangalore-based Bharat Earth Movers Limited (BEML) for supply of crucial equipment
• MoU with Rajasthan State Mines & Minerals Limited (RSMML) for long-term supply of low-silica limestone
• MoU signed with IIM, Ahmedabad and Management Development Institute (MDI), Gurgaon for knowledge sharing
• MoU signed with Larsen & Toubro Limited (L&T) to jointly set up, develop, manage and own captive/independent power plant (s) at suitable location/s to meet future power requirements of SAIL. The scope of agreement also includes exploration of opportunities to own captive thermal coal blocks to cater to the power plant requirements.
Product Mix
Product Wise
SemisBlooms, Billets & Slabs
Long ProductsStructuralsCrane RailsBars, Rods & RebarsWire Rods
Flat Products
HR Coils, Sheets & SkelpPlatesCR Coils & SheetsGC Sheets\ GP Sheets and CoilsTinplatesElectrical Steel
Tubular Products Pipes
Railway ProductsRailsWheels, Axles, Wheel Sets
Plant Wise
Bhilai Steel PlantBlooms, Billets & SlabsBeamsChannels, AnglesCrane Rails Plates Rails
Pig Iron, Chemicals & Fertilisers
Bokaro Steel PlantHR Coils & SheetsPlatesCR Coils & SheetsGP Sheets & Coils/ GC SheetsPig Iron, Chemicals & Fertilisers
Durgapur Steel PlantBlooms, Billets & SlabsJoists, Channels, Angles Bars, Rods & RebarsSkelp Wheels, Axles, Wheel SetsPig Iron, Chemicals & Fertilisers
Rourkela Steel PlantHR CoilsPlates CR Coils & SheetsGP Sheets/ GC Sheets TinplatesElectrical Steel PipesPig Iron, Chemicals & Fertilisers
Salem Steel Plant Stainless Steel
Other Products
Pig Iron
The mass of pig shall be either 45 kg having two notches or 22.5 kg having one notch, subject to mutual agreement between the purchaser and manufacturer.
Specification Grade Designation Si% Mn% P% S%max
IS 13502/ 1992
Steelmaking PG Si X Mn1 P40
See Note
1
<0.5 £ 0.4
0.06
PG Si X Mn3 P40
0.5-1.0
PG Si X Mn5 P40
1.0-1.5
NoteWhen ordering the integer given below shall be substituted for the symbol 'X' in the designation to the specific silicon range
Integer No Steelmaking Pig Iron
1 £ 0.75
2 > 0.75 but £ 1.25
3 >1.25 but £ 1.75
Other elements such as Cr, Mo, Ni, Ti, V etc. may be present in traces (total not exceeding 10%). The contents of these elements shall not be used in classification of pig iron.
Pig Iron is available in SAIL grade with silicon content of 1 - 1.5%.
Fertilsers
Ammonium Sulphate (20.6% N)
Brand name "Raja
Coal Chemical Benzene (NG) Toluene (NG & IG) Xylene Light Solvent Naptha Solvent Oil Heavy Solvent Naptha Benzol (IG) Still Bottom Oil Hard, Medium, Granulated and Liquid Pitch Extra Hard Pitch Hot Pressed Naphthalene/ Naphthalene Flakes Heavy Creosote Oil Anthracene Oil Light Creosote Oil Meta Para Creosole
Light Oil Sodium Phenolate Drained Naphthalene Oil Dephenolised Oil Heavy Benzol NG: Nitration Grade
IG: Industrial Grade
For purchase of coal chemicals customers may kindly contact the Marketing Managers of the plants at Bhilai, Bokaro, Durgapur and Rourkela
EXPORT
International Trade Division
International Trade Division (ITD) of SAIL at New Delhi – an ISO 9001:2000 accredited unit of CMO, undertakes exports of Mild Steel products and Pig Iron from SAIL’s five integrated steel plants. Ever ready to meet the exacting demands of its global customers, ITD maintains a close liaison with customers and the production units to cater to the customized requirements of its customers both in terms of quality and sizes. SAIL’s product basket includes products such as Rails, Structurals, Merchant Products, Wire Rods, Re-bars, Plate Mill Plates, Hot Rolled Coils, Hot Rolled Plates / Sheets, Cold Rolled steels, Galvanised steels, Cold Rolled Non Oriented (CRNO) coils, Chequered Plates, Slabs, Billets and Pig Iron besides cut-to-size Hot Rolled And Cold Rolled materials through its Joint Venture Service Centre. Our major products are also covered by stringent certifications such as CE marking, TUV and ‘U’ mark required by sophisticated end uses in European markets. ITD has successfully established SAIL’s brand name globally. Among the notable destinations for SAIL products are Japan, P.R. of China, Korea, Taiwan, Vietnam, Philippines, Singapore, Malaysia, Thailand, Indonesia, Australia, Mexico, Europe (UK, Germany, France, Belgium, Italy, Spain, Netherlands, Portugal), Sudan, Oman, UAE and the neighbouring countries such as Myanmar, Bangladesh, Sri Lanka and Nepal. The critical function of ensuring efficient shipment of export materials is performed by Transport &
Shipping Division (T&S) Headquartered at Kolkata. T&S has branch offices at Haldia, Paradip and Vizag ports .
SAIL - REACHING OUT TO GLOBAL MARKETSSteel Authority of India Limited (SAIL) is India’s largest steelmaker and one of the world’s leading steel producer with an annual turnover of Rs 45, 555 crore in 07-08. Annually it produces over 12 million tonnes of various steel products, to meet the exacting requirements of both domestic as well as overseas customers. Its vision for the future, encompasses a presence in major markets of the world.
Being a manufacturer of world-class steel products, SAIL offers to its customers a wide product profile matched with excellent service, and a choice ranging from widely traded items like Hot Rolled Coils to specialty products like CRNO steels.
SAIL’s products have found ready acceptance in about 75 countries the world over. Products exported to various countries include Mild Steel Billets, Slabs, Wire rods, Structurals, Hot-rolled Plates/Coils/Sheets, Cold-rolled Coils/Sheets, Rails, CRNO Steels and Pig Iron. SAIL’s Mild Steel and Pig Iron exports are undertaken by its International Trade Division (ITD) based in New Delhi.
Offers are subject to availability and confirmation of terms and conditions on case to case basis.
PRODUCTS
SL NO PRODUCT (* Please click the product for details. )
PLANT
1.
Billets Bhilai Steel Plant
Billets Durgapur Steel Plant
Billets IISCO Steel Plant
2. Cold-rolled Coils Bokaro Steel Plant
3. Cold-rolled Sheets Bokaro Steel Plant
4. Electrical Steels Rourkela Steel Plant
5. Galvanised Coils Bokaro Steel Plant
6.Hot-rolled Coils Bokaro Steel Plant
Hot-rolled Coils Rourkela Steel Plant
7.Hot-Rolled Plates/Sheets
Bokaro Steel Plant
8.. Pig Iron IISCO Steel Plant
9.Reversing Mill Plates Bhilai Steel Plant
Reversing Mill Plates Rourkela Steel Plant
10. Rails Bhilai Steel Plant
11. Wire Rods Bhilai Steel Plant
12. Customised Products Service Centre
International Trade Division
DETAILS REQUIRED FROM NEW CUSTOMERS
New customers desirous of starting import of Mild steel products of SAIL on sustained basis are requested to send the following details/documents for enlistment.
1. Customer profile (Details of the customer / Firm) who will establish the Letter of Credit.
2. Name, Address, Telephone & Fax number, e-mail of the Contact person overseas and the same of the representative in India (if any).
3. Last two years balance sheet of the company desirous of doing business with SAIL.
4. Name, address of the Bank through which the Letter of Credit will be established.
5. A certificate from the banker about business dealing with the customer.
:: CMO :: Regional Office
:: Branch Sales Offices - North Region-Eastern Region
-West Region-South Region
:: District Dealers ::-North Region-Eastern Region
-West Region-South Region
:: Warehouses ::-North-East
-West-South
:: International Trade Hindustan Times House
Division 13th Floor, 18-20, Kasturba Gandhi Marg, New Delhi - 110 001. Ph: (91-11) 2335 5733. Fax : 00-91-11-23739691, 23355276E-mail : [email protected]
Central Marketing Organisation
ISO 9001:2000 certified Central Marketing Organisation ( CMO ) is India’s largest industrial marketing set-up. It markets carbon steel produced by the five integrated steel plants of SAIL. Headquartered in Kolkata, it transacts business through its network of 37 Branch Sales Offices spread across the four regions, 25 departmental warehouses equipped with mechanised handling systems, 40 Consignment Agents and 25 Customer Contact Offices. CMO’s domestic marketing effort is supplemented by its ever widening network of rural dealers who meet the demands of the smallest customers in the remotest corners of the country. With the total number of dealers crossing 2,000 , SAIL has its presence in all the districts of the country. CMO through its joint venture partner M/s Metal Junction has simplified steel buying by providing net based facilities through its on line ‘e store’, providing door delivery facilities to small house-builders.
A strong IT support system enables real-time network connectivity within the entire CMO network. Extensive customer contact, product and segment specialization, close monitoring of order servicing and feedback analysis through a Customer Satisfaction index are established norms at CMO. The customer-friendly approach of CMO is backed by practical after-sales service. Through the process of Key Account management, CMO provides single-window service to key customers across the country for every business transaction from enquiry to order booking, order tracking to delivery, and even consultancy and after-sales service.
CMO’s International Trade Division
International Trade Division ( ITD), in New Delhi- an ISO 9001:2000 accredited unit of CMO, undertakes exports of Mild Steel products and Pig Iron from SAIL’s five integrated steel plants. Ever ready to meet the exacting demands of its global customers, ITD maintains a close liaison with customers and the production units to cater to the customized requirements of its customers both in terms of quality and sizes.
SAIL’s product basket includes products such as Rails, Structurals, Merchant Products, Wire Rods, Re-Bars, Plate Mill Plates, Hot Rolled Coils, Hot Rolled Plates/ Sheets, Cold Rolled Steels, Galvanised Steels, Cold Rolled Non Oriented ( CRNO ) coils, Chequered Plates, Slabs, Billets and Pig Iron besides cut-to-size Hot Rolled and Cold Rolled materials through its joint venture service centre. Our major products are also covered by stringent certifications such as CE marking TUV and ‘U’ mark required by sophisticated uses in European markets.
ITD has successfully established SAIL’s brand name globally. Among the notable destinations for SAIL products are Japan, P.R. of China, Korea, Taiwan, Vietnam, Philippines, Singapore, Malaysia, Thailand, Indonesia, Australia, Mexico, Europe (UK, Germany, France, Belgium, Italy, Spain, Netherlands, Portugal), Sudan, Oman, UAE and the neighbouring countries such as Myanmar, Bangladesh, Sri Lanka and Nepal.
The Transport & Shipping Division of CMO headquartered at Kolkata with its branch offices at Haldia, Paradip, Vizag and Kolkata ports, ensures timely import of the key ingredient in steel making, coking coal and handles its entire logistics. It also caters to other plant imports and ensures efficient dispatch of steel exports.
Both ITD and T&S are accredited with ISO 9001:2000 certification.
Headquarters
Ispat Bhavan 40, Jawaharlal Nehru Road, Kolkata - 700 071. Phone: (033) 2288 3810/12/14/17/18 Fax: (033) 2288 61838 E-mail: [email protected]
International Trade Division
Hindustan Times House 13th Floor, 18-20, Kasturba Gandhi Marg, New Delhi - 110 001. Phone: (0091-11) 2335 5733. Fax: 0091-11-2332 1018,2371 2774 E-mail: [email protected]
Regional Offices Northern Region Scope Minar
North Tower, 17th Floor, Distt. Centre Laxmi Nagar,
Delhi-110 092. Phone: (011)22467360, 22467384, 22467412,22467413, 22467414, 22467418
E-Mail [email protected] [email protected]
Eastern Region Jeevan Sudha 8th-9th Floors, 42-C, Jawaharlal Nehru Road, Kolkata - 700 071. Phone: (033) 2288 0970/0058/9339
Phone Fax E-Mail
FP Group 033-22880634/22888608
033-2288 0519 [email protected]
LP Group 033-22888556 033-2288 3960 [email protected]
Western Region The Metropolitan 8th & 9th floor, Bandra-Kurla Complex, Bandra (E), Mumbai- 400 051. Phone: (022) 2657 1493/96/97. Phone Fax E-Mail
FP Group 022-26572788/26571836
022-2657 1996 [email protected]
LP Group 022-26571819/26571827
022-2657 2042 [email protected]
Southern Region Ispat Bhavan 5 Kodambakkam High Road, Chennai - 600 034. Phone:044-2827 2091/2827 4105. Phone Fax E-Mail
FP Group 044-28257164/28274105
044-2827 1602/28242342
LP Group 044-28259660 044-2827 1602 [email protected]
Transport and Shipping Headquarters
Ispat Bhavan 40, Jawaharlal Nehru Road, Kolkata - 700 071. Phone: (033) 2288 3810/6151 Fax: (033) 2288 61808
BRANCH OFFICES Kolkata
Balmer Lawrie Building (ROBC),Netaji Subash Road, Kolkata - 700 071.
Phone: 033-22436013/22435668/22434236 Fax: 033-2243 5112
Haldia
Super Market Building (1st floor),DurgaChak, Haldia,Midnapore- 721 602. Phone: 03224-274218 Fax: 03224-274249
Paradip
Ispat Bhawan Paradip- 754 142. Phone: 06722-222631/222381 Fax: 06722-222730
Visakhapatnam
Harbour, Approach Road, Visakhapatnam - 530 035 Phone: 0891-256 3041/42/43 Fax: 0891- 256 3698 Email: [email protected] [email protected]
SRM OFFICES Bhilai
Equipment Chowk,Sector-1, Road-1,Bhilai - 490 001 Phone: 0788-2224177 Fax: 0788-222 3691 Email: [email protected]
Bokaro
CMO Complex,Mahatma Gandhi Road, Near Administrative Building, Bokaro Steel City - 827 001 Phone: 06542-240854 Fax: 06542-240860 Email: [email protected]
Durgapur
Surya Sen Sarani, Durgapur - 713 208 Phone: 0343-2546429 Fax: 0343-254 6431 Email: [email protected]
Rourkela
ED (Works) Building, Rourkela Steel Plant,Rourkela - 769 011
Phone: 0661-2508992 Fax: 0661-2506978 Email: [email protected]
Applications
Hot Rolled Coils, Sheets and Skelp
Hot rolled coils, sheets and skelp (narrow coil), are the largest product category of the company in terms of both sales volume and revenue. Hot rolled coils are primarily used for making pipes and have many direct industrial and manufacturing applications, including the construction of tanks, railway cars, bicycle frames, ships, engineering and military equip-ment and automobile and truck wheels, frames and body parts. Hot rolled coils are
also used as feedstock for cold rolling mills where they undergo further process-ing.Hot rolled coils are also delivered to the company's own cold rolling mills and silicon sheet mill and pipe plant in a wide range of widths and thicknesses as the feedstock for higher value-added steel products. The company is the largest producer of hot rolled coils, sheets and skelp in India.
Semi-Finished Products
The company produces semi-finished products, including blooms, billets and slabs, which are converted into finished products in the company's processing plant and, to a lesser extent, sold to rerollers for conversion to finished products.
Plates
Steel plates are used mainly for the manufacture of bridges, steel structures, ships, large diameter pipes, storage tanks, boilers, railway wagons and pressure vessels. The company also produces weatherproof steel plates for the construction of railcars. The company is currently the largest producer of steel
plates in India with a domestic market share of more than 80 per cent for these products. The company is the only producer of wide and heavy plate products in India.
Cold Rolled Products
Cold rolling of hot rolled products produces a superior surface finish, improves the physical properties of the steel, such as tensile strength, and reduces its thickness to precise gauges. As a result, cold rolled products generally command higher prices thanhot rolled products. The products of the cold rolling mill include cold rolled sheets and coils, which are used primarily for precision tubes, containers, bicycles, furniture and for
use by the automobile industry to produce car body panels. Cold rolled products are also used for further processing, including for colour coating, galvanising and tinning. The company also produces further processed cold rolled products, including galvanised sheets and tin plates.
Railway Products
Railway products, including rails, wheels and axles, sleeper and fish plates (which are used to connect and strengthen rails), are produced through a process of hot rolling blooms in the finishing mills and forging ingots and blooms in the forging press or hammer. Railway
products are used primarily to upgrade and expand the existing railway network in India.
Structurals
Structural steel products are produced through a process of hot rolling in the section or structural mills. They are long steel products with cross sections of various shapes. I-beams, channels and angle steel are used in mining, the construction of tunnels, factory structures, transmission towers, bridges, ships railways and other infrastructure projects.
Bars and Rods
The company produces steel bars and rods through a process of hot rolling billets in the finishing mills. Reinforcement steel and wire rods are primarily used by the construction industry. The company is one of the largest producers of reinforcement bars in India which are primarily sold to the construction industry.
Speciality Products
Speciality products, include electrical sheets, tin plates and pipes. Electrical sheets are cold rolled products of silicon steel for electrical machinery. Tin plates are cold rolled steel electrolytically coated with tin for food packaging.Pipes are longitudinally or spirally welded from hot rolled coils for conveying such things as water, oil and gas.
Alloy and Stainless Products
In addition to the steel products indicated above, SAIL produces a wide range of alloy steel products at ASP,SSP and VISL. Elements including chromium, nickel, vanadium and molybdenum are used in the alloy mixture to impart special properties to steel. These alloy steels are primarily used for sophisticated applications, including in the automobile, railway and defence industries.
A wide variety of alloy and stainless steel plates, hot rolled sheets, cold rolled sheets, bars, billets, blooms, forgings and die blocks are manufactured at ASP in an Electric Arc Furnace. SAIL is able to produce different qualities of alloy steels to meet the requirements of its customers. To increase steel's corrosion resistance properties, nickel and chromium are used in the making of stainless steel. SSP produces cold rolled stainless steel coils and sheets with thickness ranging from 0.3 mm to 6 mm and width ranging from 500 mm to 1,250 mm. These materials can be produced in a large number of grades for different applications. Stainless steel products are used for diverse applications including household utensils, automobile trims, conveyor belts, elevators, chemical and food processing equipment, building and interior decoration and pharmaceutical equipment
Bhilai Steel Plant
Bhilai Steel Plant
Seven - time winner of Prime Minister's Trophy for best Integrated Steel Plant in the country, Bhilai Steel Plant (BSP) is India's sole producer of rails and heavy steel plates and major producer of structural. The plant is the sole supplier of the country's longest rail tracks of 260 metres. With an annual production capacity of 3.153 MT of saleable steel, the plant also specializes in other products such as wire rods and merchant products. Since BSP is accredited with ISO 9001:2000 Quality Management System Standard, all saleable products of Bhilai Steel Plant come under the ISO umbrella.
At Bhilai IS0:14001 has been awarded for Environment Management System in the Plant, Township and Dalli Mines. It is the only steel plant to get certification in all these areas. The Plant is accredited with SA: 8000 certification for social accountability and the OHSAS-18001 certification for Occupational health and safety. These internationally recognised certifications add value to Bhilai's products and helps create a place among the best organisations in the steel industry. Among the long list of national awards it has won, Bhilai has bagged the CII-ITC Sustainability award for three consecutive years.
PRODUCT-MIX TONNES/ANNUM
Semis 5,33,000
Rail & Heavy Structural 7,50,000
Merchant Products(Angles, Channels, Round & TMT bars)
5,00,000
Wire Rods (TMT, Plain & Ribbed) 4,20,000
Plates (up to 3600 mm wide) 9,50,000
Total Saleable steel 31,53,000
Location : Forty kms west of Raipur, the capital city of Chhattisgarh, along the Howrah-Mumbai railway line and the Great-Eastern highway, stands Bhilai Steel Plant (BSP).
BHILAI STEEL PLANT:: Plant and Facilities
Captive mines
Iron-Ore - Dalli-Rajhara Iron Ore Complex, 80 kms from Bhilai
Limestone - Nandini, 23 kms from Bhilai
Dolomite - Hirri, 150 kms from Bhilai
Coke Ovens
BATT NO. NO. OF OVENS
OVEN HEIGHT(M)
COAL HOLDING CAPACITY PER OVEN
(T)
USEFUL VOLUME
PER OVEN CU.M.
SP.HEAT CONSPN.KCAL/KG
1-8 65 4.3 16.8 21.6 625-675
9&10 67 7.0 32.0 41.6 625-675
Blast Furnaces 3 of 1033 Cu m capacity each 3 of 1719 Cu m capacity each 1 of 2355 Cu m capacity
Hot Metal Capacity : 4.70 MT / year
Steel Melting Shop
Steel-making through BOF, VAD/Ladle Furnace/RH-Degasser and Continuous casting route
3 converters of 110/130 T VAD unit, 2 RH degasser,2 Ladle furnace 4 Slab Casters, 1 bloom caster, 1 Combi caster
Annual Capacity: 1.425 MT Cast steel
Converter Shop :
3 BOF 110/130 T Convertors Secondary Refining facilities : 1 VAD unit, 2 RH degassers, 2 Ladle furnaces,
1 Desulphurisation Unit
Continuous Casting Shop: 4 Slab Casters, 1bloom caster, 1Combi caster
Steel-making through Twin Hearth Furnace (THF) route :
4 THFs of 250 T capcity each Annual capacity 2.5 MT ingot steel
Blooming & Billet Mill
14 pairs of recuperative soaking pits Capacity to produce 2.14 MT/year of blooms Capacity to produce 1.50 MT/year of billets
Rail & Structural Mill
Capacity - 7,50,000 T
Products
Rails - R52 Kg/m & R60 Kg/m ; UTS 880 N/mm2 rails as per IRST-12/96 specifications , Euronorms and international standards.
Thick web asymmetric rail Zu 1-60 Beams - 600,500,450,400,350,300 & 250. Channels - 400,300 & 250. Angles - 200 & 150. Crossing Sleeper. Crane Rails - KP80, 100,120 & 140. Bhilai is the sole supplier of the country's longest rail tracks of 260 metres.
Bhilai Rails
Largest producer and leading rail maker of the world. Four and a half decades of experience in rail making. Produced over 15 million tonnes of rails; 2.7 lakh km in length. Indian Railways- World’s second largest rail company moves exclusively on
Bhilai rails. Bhilai rails are subjected to world’s highest traffic density and axle loads. Rails exported to 10 countries with exports to South Korea, New Zealand,
Argentina, Turkey, Iran, Egypt, Ghana, Bangladesh and Malaysia.
Technological Superiority
Steel from LD Convertor – Ladle furnace - RH Degasser – Concast route; achieving world best level of degassing/refining to less than 1.5 ppm of hydrogen in liquid steel in 100% of heats.
Capability to produce as rolled lengths of 80 meter and welded panels upto 260 meters
High degree of Straightness due to world’s most advanced and Laser straightness measurement based end straightening machine.
World class tested rails passing through state of art online NDT equipment; Laser straightness measurement, Ultrasonic and eddy current testing machines
Computer controlled automatic rail handling system and automatic yard mapping for rail storage.
Computerised Rail Tracking system for collection and storage of all process and testing related data of each rail.
Bhilai Rails- Universally Certified
RDSO, Indian Railways RITES Ltd
ISO-9001-2000 certified by LRQA (Lloyds Register Quality Assurance) ISO 14000 certified by BIS Crown Agents, London General Superintendence Company, Geneva Lloyds Register Of Shipping Robert W Hunt & Company Overseas Merchandise Inspection Company, Tokyo Egyptian Railways Inspection Team Tuboscope Vetco Gmbh, Deutcheland
Bhilai’s Special Purpose Rails
Copper Molybdenum Corrosion resistant rails High yield strength/ UTS vanadium micro-alloyed rails High conductivity metro rails Copper-Chromium alloyed High strength Rails
Merchant Mill
Capacity - 5,00,000 Tonnes
Products
Plain Rounds : dia 28, 32, 36,40, 50,53, 56, 63 & 67 TMT Bars : 25,28, 32, 36, 40 & 45 Lt. Structurals :Channel 100 x 50, 75 x 40 Angles : 50 x 50 x 5 upwards to 90 x 90 x 10
* Customised product campaigns are being taken up for shorter durations in case of light structurals and rounds for compliance of smaller quantity orders as per committed delivery within the month.
Wire Rod Mill
Capacity - 4,20,000 T
Wire Rods (Plain, Electrode Quality & TMT) in 5.5, 6, 7, 8 & 10 mm plain and ribbed, and 12 mm plain in coil form
8, 10, and 12 mm TMT
Plate Mill
Capacity - 9,50,000 T
Plates thickness - 8-120 mm
Width - 1500-3270 mm
Length - 5-12.5 M
The modern Plate Mill rolls out heavy and medium plates, as well as those for pipe manufacturers. Plates of wide variety, in any required size, and strength, chemical and physical properties, can be produced here. It has capacity to produce high pressure, boiler quality and high tensile steels. Shipbuilding plates, conforming to Lloyds specifications, and pressure vessel boiler plates, conforming to various ASTM, ASME standards, have withstood the challenges of nature and time. Some of the unique features of the mill are on-line finishing facilities and off-line normalising facilities. Bhilai has the widest plate mill in the country, and it uses continuously cast slabs as input. Liquid steel produced under controlled conditions in the LD Converters is rinsed with argon gas to homogenise the composition as well as to remove non-metallic inclusions before continuous casting so as to ensure the production of high quality feedstock for the Plate Mill. As per customers' requirement or specifications, plates are normalised in a roller hearth normalising furnace.
New Products
To cater to the changing needs of the customers and to increase the market share, various new products were developed and commercialised through process improvement and Research and Development.
1. 12 mm TMT Fe 500 - Wire rods : This will meet the requirement of construction sector which needs high strength wire rods for concrete reinforcement. These rods having the yield strength of 500 Mpa (Min.) would be able to take more load during service. These rods have improved ductility as well.
2. 12 mm TMT HCR Fe 500 - Wire rods : This will meet the requirement of Corrosion resistant wire rods for construction purpose in the Coastal areas as well as saline environment. The steel has been made using copper & chromium as the alloying elements to inhibit the corrosion action. The section meets the requirement of 500 Mpa (Min.) yield strength.
3. 32 mm EQR TMT Fe 500 - Rebars : This grade has been developed to meet the requirement of higher diameter of reinforcement bars for construction sector. The product has been rolled with TMT process. The properties of Fe-500 have been successfully achieved with higher tensile to yield strength ratio to make the product earthquake resistant.
4. 32 mm EQR HCR TMT Fe 500 - Rebars : For use of higher diameter rebars in the corrosion prone areas, this product has been developed using Copper & Chromium as the alloying element. By rolling through TMT process, yield strength of 500 Mpa(min.) has been successfully achieved with higher tensile to yield strength ratio.
5. 40 mm EQR HCR Fe 500 - Rebars : For high rise building, this section has been developed through TMT process. Use of Copper & Chromium as the alloying elements has made the product corrosion resistant and also giving
higher tensile to yield strength ratio. 6. Cu-Ni-Cr Corrosion resistant Rail : This grade of rail has been produced using
Copper, Nickel & Chromium as the alloying elements. These rails are being developed for use in the coastal sections which are corrosion prone.
7. 85 mm SAILMA 350 HI Plates : This section has been developed for use in the locomotives, where it will be used in the engine blocks. The product has been made with Niobium as micro-alloying element. The properties of SAILMA-350 HI have been successfully achieved.
8. HT 750 PLATES : Trail heat made succesfully, as substitute for Quench & Tempered plates for use in penstock of hydroelectric power projects.
9. High Tensile E 410 grade Angle 50 with V and Cu: The Steel, micro alloyed with V, has been successfully developed for Indian Railways. The steel grade has also been alloyed with Cu to impact atmospheric corrosion resistance.
10. EN 10028 P 275 NL I : 35 mm BQ plates for pressure vessels & storage tanks with high impact strength of 70 J at 0° C, Normalised and Ultrasonically Tested.
11. TMT 415 Wire rods through 'A' strand : Successful rolling of TMT through 'A' Strand of Wire rod Mill.
12. Fe 500 TMT-28 EQR Rebars: This is high strength TMT reinforcement bars having UTS/YS ratio of 1.18% min. These rebars could be used for earthquake resistant applications in the seismic prone areas.
13. Rock Bolt : This TMT profile that was developed in last financial year for application in construction purposes in hilly areas has been commercialized in this financial year.
The Cutting Edge Processes
Steel Making
Vacuum Arc Degassing: This unit ensures production of low sulphur steel with lower gas contents. Precise control of casting temperature, composition and improved steel cleanliness is achieved.
RH Degasser(2nos): A 130 T capacity RH (Ruhrstahi Heraus) Degassing Unit was installed mainly to remove hydrogen from rail steel. All rail heat produced in SMS-II have hydrogen level < 1.5 ppm.
Ladle Furnace(2nos): It is installed to process steel to reduce diversion due to chemistry and to process cold heats or return heats. The 130 T furnace also has benefits like reduction in tapping temperature of BOF, improvement in lining life of BOF, etc. It acts as a buffer between BOF & CCM for holding the heats, reduce consumption of ferro-alloys, carbonisers and deoxidiser and produce a cleaner steel.
Desulphurisation Unit : This has been installed to reduce hot metal sulphur for better steel-making
Finishing Mill
On line Ultrasonic testing machine in Plate Mill. - Mandatory on-line testing of API grade plates. - 100% scanning and edge testing of all plate surfaces.
Automatic thickness gauge and HAGC - Better quality assurance - Better dimensional and profile control - Improvement in yield by 2%.
Computerised tracking of plates in Plate Mill Plant-wide fiber optic cable networking
Environment Management
A conscious corporate citizen, BSP has accorded the highest priority to taking effective measures in the areas of resource conservation, pollution prevention, waste reduction and conversion of waste to wealth. Effective monitoring and analysis has ensured that BSP's compliance is well within the regulatory requirements.
ISO 14001 certificationhas been implemented in the entire Plant & township as well as in Dalli Mines. The plant has introduced environment friendly coal dust injection system in the Blast Furnaces, de-dusting system and electrostatic precipitators in other units. Besides, Clean Development Mechanisms for green house gas reduction, BSP has taken up the replacement of Ozone Depleting Substance CTC, aided by UNDP. The specific water consumption in BSP at 3.05 cu.m per tonne of crude steel in 2007-08 is one of the lowest in the country.
Green City
Contrary to the popular perception about industrial townships being dirty and polluted, a green canopy covers the township. A green-fingered population and a management aware of its obligations as a corporate citizen have come together for a massive tree-plantation drive over a period of years as a result of which afforestation sites and green expanses enrich the environment in mining and peripheral areas. There are five big gardens inside the plant and 15 gardens in the township. The cumulative plantation in the Works area and township is more than 30 lakhs while in the Mines, it is more than 22 lakhs. Spread over 167 acres, the sprawling Maitri Bagh that has the biggest musical fountain in the country, a zoo with 28 species of animals and birds, an artificial lake with boating facilities, a toy train etc., attracts over 5 lakh visitors every year.
The residential sectors of the steel city are kept clean and green by the Plant's Town Administration Department which also undertakes the civic amenities such as street lighting, cleaning and maintenance of the tree-lined carpeted roads. The water to the township is supplied from the Maroda water treatment plant having a capacity of over 30 million gallons per day. Water is distributed throughout the township through a system of underground reservoirs and overhead tanks.
Energy Consumption
Continuous monitoring
Apex Committee Inspection by HODs. Quarter review of Safety activities by ED(W) Fixing responsibility of line managers. Contractor workers safety - IPSS procedure enforcement, contractors' audit,
safety exhibitions Safety workshops
Regular inspections
Inspection of gas pipelines Inspection of structures, equipments and installations Risk Control Grading System implemented in Coke Ovens Battery 9 & 10,
Blast Furnace, SMS-1 and extended to BBM, Foundry Shop, and SMS-II.
Quality Assurance
ISO 9001 SEAL OF QUALITY
All major production units and marketable products in Bhilai Steel Plant are covered under ISO 9001:2000 Quality Management System. This includes manufacture of blast furnace coke and coal chemicals, production of hot metal and pig iron, steel making through twin hearth and basic oxygen processes, manufacture of steel slabs and blooms by continuous casting, and production of hot rolled steel blooms, billets and rails, structurals, plates, steel sections and wire rods.
Bhilai's products come with a complete assurance of quality.
This is achieved as a result of unrelenting attention and meticulous procedures at every stage of the process and upgrading of testing methods and equipment.
Right from selection of input material for steelmaking, the process parameters are kept under close control. Intensive checking of all quality parameters continues throughout the subsequent operations of casting, reheating and rolling. Express analysis with the help of sophisticated, direct-reading spectrograph and gas analyser ensures a narrow range of chemical composition. Intensive metallographic investigation with modern instruments like Scanning Electron Microscope, Image Analyser and Micro Hardness Tester is carried out to assess the quality of the product.
The key points of control are :
Chemical analysis of hot metal, liquid steel and final product. Inspection of surface and internal quality of the product by visual and
ultrasonic inspection. Monitoring and control of heating/reheating parameters. Dimensional and surface check during rolling and on finished product. Maintenance of cast identity throughout the process up to the end product
Human Resource Development :
Training need assessment is a continuing process. About 19,000 employees are imparted training every year. The focus is on need-based innovative programmes, such as Action
Collaboration. Multi-Skilling
Major HRD Interventions
PRODUCTION FACILITIES AT A GLANCE
Coke Ovens Batteries: 10 Nos.
8 batteries of 4.35m height consisting of 65 ovens each
2 batteries of 7m height consisting of 67 ovens each
Blast Furnaces : 7 Nos.
3 Blast furnaces each of 1033 cu.m volume 3 Blast furnaces each of 1719 cu.m volume
1 Blast furnace of 2355 cu.m volume Sintering Plants : 3 Nos.
SP-1 : 4x50sq.m hearth area SP-2 : 3x75sq.m hearth area
1x80sq.m hearth area
SP-3 : 1x320sq.m hearth area Steel Melting Shop-I
4 Twin Hearth Furnaces
Steel Melting Shop-II
Convertor Shop :
3 BOF 110/130 T Convertors Secondary Refining facilities : 1 VAD unit, 2 RH
degassers, 2 Ladle furnaces
Continuous Casting Shop:
4 Slab Casters, 1bloom caster, 1Combi caster
Mills
Blooming & Billet Mill Rail & Structural Mill Plate Mill Merchant Mill
Wire Rod Mill
Auxiliary Units
Two captive Power Plants - one captive and other in joint venture with 123 MW total power generation capacity
Two Oxygen Plants, Acetylene Plant, Propane Plant Refractory Materials Plants for production of Mag Carb
bricks, sinter, dolo, lime Foundry & Engg. Shops for captive manufacture of spares,
assemblies, mould, forging Coal Chemicals units for recovery of various by-products
from coal carbonization
Slag granulation plants
PRODUCT
PRODUCT-MIXTONNES/ANNUM
Semis 5,53,000
Rail & Heavy Structural 7,50,000
Merchant Products (Angles, Channels, Round & TMT bars)
5,00,000
Wire Rods (TMT, Plain & Ribbed)
4,00,000
Plates (up to 3600 mm wide) 9,50,000
Total Saleable steel 31,53,000
Prdouct Profile
The product range at Bhilai Steel Plant and their end use/consumers is as :
A. FINISHED PRODUCTS Product End use / consumers1. Rail & Structural Mill
Rails in 13m, 26m, 65/78 m length andwelded panels of 130m/260m length
Indian Railways, Export
Heavy Structurals Construction Crane Rails Cranes Crossing sleepers Broad gauge sleepers2. Merchant Mill Lt. Structurals
Engineering and Construction Med. Rounds (Plain & TMT) Heavy rounds (Plain)3. Wire Rod Mill Wire Rods- Plain
Construction Wire Rods- TMT EQ Wire Rods Electrodes4. Plate Mill
PlatesBoilers, Defence ,Railways, Ship building, LPG cylinders, Export
B. SEMIS Billets (from BBM)
Re-rollers Blooms (from BBM) Narrow width slabs CC Blooms Killed SlabsC. Pig Iron FoundryD. By Products
Coal Chemicals
Ammonium Sulphate (Fertiliser)Tar and tar products,(Pitch, Napthalene, Creosote Oil Road Tar,Anthracene oil, Dephenolised oil, PCM etc.), Benzol& its products (NG Benzene, Toulene, Xylene,Solvent oil, By. Benzol etc.)
Processed Slag Granulated slag from CHSG Plants & SGP for
cement manufacture