BHILAI STEEL PLANT OVERVIEW

Milestones Inside Steel Making

• Raw materials
• Steel • Flow Chart
• Steel Everywhere • Existing Facilities
• Steel Production • Glimpses
• History • Products
• Per-capita Steel co Plant
nsumption Overview
Trg. for
Vocational
Trainees
Modernisation
Discussions
• Steel consuming S • Becoming an Engineer
ectors • Learning from Audience
• Growth factors
• About SAIL
• Expansion Plans
If you are nothing without
it !
Teacher learned Pottery
Steel is an Alloy

of Iron and Carbon

with Carbon % < 2%

Word Steel Production 1950 MT + 3%

China 1032 MT + 4%

India 118 MT + 2%

Japan 96 MT - 3%
USA 86 MT - 2%
 Crude steel production (million metric tons):

Rank Country 2007 2022

World 1,190 1950

1 China 494 1032
2 India 53 118
3 Japan 53 96
4 United States 88 86
5 Russia 72 76
6 South Korea 51 70
7 Germany 48 35
8 Turkey 25 35
9 Brazil 33 31
10 Iran 26 29
Top Steel Producing Companies
Ranking Production Company

1st 115 MT Bao Steel

2nd 78 MT Arcelor Mittal

3rd 44 MT Hebei Steel

4th 43 MT Nippon Steel

5th 42 MT Shagang Steel

6th 41 MT POSCO Steel

7th 38 MT Ansteel
12th 28 MT TATA Steel
24th 15 MT SAIL
25th 14 MT JSW
 INDIA’s Steel production Historic Trends

45
87 MT
40 in 2015
1.25 mT
35
in 1948 6.6 mT
16.2 mT TH
in 1991 W
India gains independence in 1973 RO
30 in 1947 G
IGH
H
25

20
TH
OW
T GR
15
ODES
M
10 T H
L O W GROW
S
5

0
1949 1953 1957 1961 1965 1969 1973 1977 1981 1985 1989 1993 1997 2001 2008
 Steel Consuming Sectors

Construction & infrastructure contribute to more than 60% of steel consumption

Construction as a sector can broadly be divided into three major categories:

CONSTRUCTION

Infrastructure Real Estate Industrial

Metal Refineries
Roads, Railways, Commercial, Fertilizers,
Bridges, Ports, Retail, Petrochemicals,
Airports, Power, Housing Cement,
Irrigation
Oil & Gas
 Oppurtunities across Infrastructure Sector
Sector Key Opportunities
Power Government targets adding 100,000MW capacity. Both generation and
transmission capacities to be enhanced.
Oil & gas Pipeline network, city gas distribution, refinery infrastructure installation
& upgrading
Road & National Highway Development Program (NHDP) , PMGSY Plans to
highways construct and upgrade >50,000 km of National Highway

Railways Increase in overall freight and passenger movement.

Dedicated Rail Freight Corridor network expansion
Ports Port traffic is estimated to increase by a CAGR of about 12%.

Water & waste The Jawaharlal Nehru National Urban Renewal Mission is expected to
Mgmt (STP) increase steel consumption
Macro trends:

 Increasing urbanization

 Increase in population leading to increase in demand for housing /

affordable housing / House for all.

 Growth in household income

 Increase in height of buildings resulting in increase in overall steel-

cement ratio

 Regulations about earthquake resistance and building strength has

increased steel intensity.
Opportunities across Power sector
World Average Per Capita Consumption = 2500 kwh / Year

INDIA - INSTALLED CAPACITY DISTRIBUTION

Thermal 65%

Hydropower 25%

Nuclear 2.9%

Others 7.7%

Power sector is one of biggest steel user

 Indian Railways Vision
Category Short term target (10-11 to Long term target (12-13 to Total target
11-12) 19-20)
Doubling 1000 kms 11000 kms 12000 kms

Gauge conversion 2500 kms 9500 kms 12000 kms

New Lines 1000 kms 24000 kms 25000 kms

Electrification 2000 kms 12000 kms 14000 kms
New Wagons 33909 255227 289136
High Speed Corridors --- 2000 kms 2000 kms

The vision call for around $ 310 billion of investment over next 10 years
 Growth Factors of Steel Industry

Supply: With trade barriers having been lowered over the years, imports play an important role.

Demand: Demand is derived from sectors of infrastructure, consumer durables and automobiles.

Barriers to entry: High capital costs, technology.

Bargaining power of manufacturers: Monopoly.

Bargaining power of customers: Presence of a large number of suppliers and access to global markets.

Competition: Presence of a large number of players.

 Indian Potential for Steel

Huge Potential for Demand

• High GDP growth rate

• 1.2 billion population
• Low per capita steel consumption of 60 kg
(World av. 215 kg) China=510 kg

Growth factors for In- Abundant Iron Ore Reserves of 23

Skilled Human
dia billion tonnes
Resources

Government Policy

• • Encouraging trade relations with ASEAN and other countries

• Infrastructure building.
• Exploring new Energy resources
• Stable currency
 India having a potential for exponential growth in steel consumption

Peak Point
Point of
Saturation
Singapore Japan
EU
USA
Point of Inflection
Japan

EU 15

ain
Ch
Trigger Aus tralia

Point Singapore

USA

China

India India

0 100 200 300 400 500 600 700 800

Per capita in KG

India will be a part of the new Steel world …

 SAIL: MAHARATNA
•HSL incorporated as a company on 19-01-1954
•SAIL registered on 24-01-1973 (Foundation Day)

A) MAIN PLANTS / UNITS

Plant Start Collaborator

BSP 1959 USSR

RSP 1959 Germany
DSP 1960 UK
BSL 1964 USSR

27
 Units of SAIL
 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

 Special Steel Plants

 Alloy Steels Plants (ASP) and Intergrated Iron & Steel Company
(IISCO) in West Bengal
 Salem Steel Plant (SSP) in Tamil Nadu
 Visvesvaraya Iron and Steel Plant (VISL) in Karnataka

 Subsidiaries
 Maharashtra Electrosmelt Limited (MEL) in Maharashtra
 SAIL: MAHARATNA
 Steel production of 15 /14 /13 MT
 Expansion plan – 23.46 MTPA of HM
 2nd largest iron-ore mining operations in India
 Leadership in India: Flat Products, Non-Flat Products
 Large Land bank
 Relative self-sufficiency in Power
 Strong distribution & sales network: CMO
 RDCIS
 CET
 Steel consumption in 2021 (in KG per person)

1. South Korea 950 6 Germany 370

2. Taiwan, China 700 7 Austria 400

3. Czech Republic 600 8 Canada 300

4. China 700 9 Turkey 446

5. Japan 400 10 Sweden 340

World’s average steel consumption = 227 KG per person

World’s average steel consumption = 227

India’s average steel consumption = 65

Raw Materials
Raw Material Source State Consumer Unit
#

1. Iron Ore Fines Dalli Rajhara C.G. Sintering Plant

2. Iron Ore Lumps Dalli Rajhara C.G. Blast Furnace

3. Lime Stone Nandini C.G. Raw Material Plant

4. Dolomite Hirri Mines C.G. Raw Material Plant

Bhojudih,
5. Coal (Indigenous) Sudamdih,Nandan, Jharkhand Coke Oven
Rajarappa,Swan

Australia,
6. Coal (Imported) Abroad Coke Oven
New Zealand
33
 Tar Products, Benzol Products
Ammonium Sulphate
Rajhara Mines (90 KM)
Dalli Mines (96 KM)

Coal

Coal Preparation Bye Product Plant Iron Ore

Plant
Coke Oven
Gas
Coke Oven
Batteries

BF Coke

Raw Materials
Limestone
Nandini Mines (25 KM)
Hirri Mines (150 KM)
Dolomite

SP-1, 2 & 3

34
Blast Furnaces
 Slag Granulation Plant
Blast Furnaces
Granulated Slag

Foundry
Pig Casting Machine
Steel Melting Shop - 2
Steel Melting Shop - 3 Oxygen Blown
Cold Pig Iron Converters
Semis for Sale

Merchant Mill Slab

Casters

Continuous Casting M/c

Slabs
Wire Rod Mill Bloom Casters
Billets
Blooms

URM, RSM, BRM Plate Mill

To Rail & Structural Mill
CC Blooms

Plates 35
 Existing
Facilities
 Coke Ovens Batteries -11 Nos
 Batteries no. 1-8 - 4.35m height, 65 ovens each
 Batteries no. 9-10 - 7m height, 67 ovens each
 Battery no. 11 - 7m height, 67 ovens each

 Blast Furnaces: 8 Nos

 BF 1-3 – 1033 cu.m volume each
 BF 4-6 – 1719 cu.m volume each
 BF 7 – 2350 cu.m volume
 BF 8 – 4060 cu.m volume
 Sintering Plants:
 SP-1 : Dismantled
 SP-2 : 3*75 sqm hearth area + 1*80 sqm hearth area
 SP-3 : 1*320 sqm hearth area

 Steel Melting Shop:

 Steel Melting Shop-1 : Closed
 4 Twin Hearth Furnaces
 Steel Melting Shop-ll:
 3 Convertors
 Secondary Refining Facilities
 3 Slab Casters, 1 bloom caster,1 combi caster

 Steel Melting Shop-lll:

 3 Convertors
 Secondary Refining Facilities
 2 bloom Casters, 1 bloom cum billet caster, 1 beam blank cum bloom
caster
Finishing Mills
1. Blooming & Billet Mill - Closed
2. Rail & Structural Mill

3. Plate Mill
4. Merchant Mill
5. Wire Rod Mill

6. Rail & Universal Mill

7. Bar & Rod Mill
Auxiliary Units
 Power Plants:

1st captive Power Plant - 51 MW

2nd run under Joint Venture with NTPC - 104 MW
 Oxygen Plants
OP-I (Closed)
OP-II run by BSP
OP-III on BOO basis with Praxair
 Acetylene Plant
 Propane Plant
SAIL : ‘MAHARATNA

41
Won Prime Minister Trophy for 11 Times
For Best Integrated Steel Plant:
1) 1992 – BSP
2) 1993 – BSP
3) 1994 – TATA
4) 1995 to 1997 – BSP (03 times)
5) 1998 to 2001 – TATA (04 times)
6) 2002 – RINL
7) 2003 to 2004 – BSP (02 times)
8) 2005 – RINL
9) 2006 to 2007 – BSP (02 times)
10) 2008 – TATA
11) 2009 – BSP
12) 2010 – TATA
13) 2011 – BSP
14) 2012 – JSW
15) 2013 to 2020 – TATA (06 times)
FINANCES

YEAR NET LOSS / PROFIT

2004-05 (+) 6817 CRORES
2007-08 (+) 7537 CRORES
2009-10 (+) 6754 CRORES
2010-11 (+) 4905 CRORES
2011-12 (+) 3545 CRORES
2013-14 (+) 2616 CRORES
(-) 2800 CRORES
2016-17
(-) 480 CRORES
2017-18
(+) 3470 CRORES

43
Systems & Standards

Certified as per four international standards of:

1. ISO:9001 - Quality Management System

2. ISO:14001 - Environment Management System

3. OHSAS:18001 - Occupational Health Safety Assessment Series

4. SA:8000 - Social Accountability

44
Corporate Social Responsibility
136 Villages in 16 Km Periphery
RAW MATERIALS
WAGON
TIPLER
TRACK
HOPPER
Ore Handling Plant
Coke Making
SINTER PLANTS
 Iron Making Reactions

1 2Fe2O3+CO=Fe3O4+CO 7 SiO2+2C=Si+2CO

2 Fe2O3+8CO=2Fe+7CO2+C 8 FeS+CaO+C=Fe+CaS+CO

3 Fe3O4+CO=FeO+CO2 9 P2O5+5C=2P+5CO

4 FeO+CO=Fe+CO2 10 MnO+C=Mn+CO

5 CaCO3=CaO+CO2 11 H2O+C=H2+CO

6 C+CO2=2CO 12 2C+O2=2CO
STEEL MELTING SHOPS
Steel Plate
Products
 Slab size

 200X1300mm

 200X1500mm

 250 x 1500mm

Length from 1850-3350 mm

 Bloom size
 320 X 320 mm
 450 X 600 mm.
 Length of Bloom 4.0 – 6.0 Mts

Billet size

 150 X 150 mm
 Length – 5.0 -12.0 Mts
 SAIL: MAJOR PRODUCTS OF PLANTS / UNITS

Plant FLAT PRODUCTS / LONG PRODUCTS /SEMIS

BSP Rails, Plates,Blooms, Billets,Beams, light strucurals

RSP HR & CR coils, GP/GC Sheets, ERW & SW pipes

DSP Blooms, Billets,joists,bars,rods & rebars,Rail wheels & axles,

BSL HR & CR coils/sheets/plates,GP&GC sheets/coils,

ISP Steel structurals, Bulb bars sections

VISL High quality rolled & forged alloy, special steels
ASP Slabs,blooms,bars,CRM rolls,Crane wheels, springs, hammers,
hot saw blades
SSP CR stainless steel, HR carbon & stainless steel
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 SAIL after Expansion (Mtpa)

Plant Hot Metal Crude Steel Saleable Steel

BSP 7.5 4- 4.90- 7.0 3.15- 4.29- 6.56

DSP 2.45 2.2 2.12
RSP 4.5 4.2 3.99
BSL 5.77 4.61 4.18
ISP 2.91 2.5 2.39
SSP - 0.18 0.34
ASP - 0.48 0.43
VISL 0.33 0.23 0.22
Total 23.46 21.40 20.23