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Essar Steel (I) Ltd.

Hazira

Presentation on :

Technological conjunction of

Iron & Steel Making

at Essar Steel India Ltd.

By : Mr. Hitesh Sheth ([email protected])

Ms. Neeru Singh ([email protected])

2

• GDP projections indicate steel industry to reach 155-170 MTPA by 2025

• Benchmarking India's position in the steel growth curve, followed by other

countries indicates potential to go up to 250 MTPA by 2025

• Manufacturing vision laid down by government also translates into higher

steel intensity, indicating potential to go up to 250-300 MTPA by 2025

Increasing finished steel consumption lead to multiple secondary benefits

like creation of additional jobs, development of supply chain industry and

allied industries.

Pros : availability of plenty of iron ore reserves comparatively low wages

growing market human resources and strategic location for exports

act as supporting factors.

Cons : ore & coal availability fluctuating NG prices land availability

full capacity utilization because of varying parameters.

Hazira Steel Complex

Indian Steel Industry : Long Term Outlook

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Demand : India's inherent advantage is going to make it a natural choice / place

/ economy to become a 300 MT player by 2025 owing to following facts:

• Being globally 5th highest in iron ore reserves.

• Having lowest labor cost in the world

• Steel industry having a good mix of public & private firms with considerable

experience.

• Rising steel consumption in the sectors of :

• Construction

• Infrastructure

• Steel Intensive Industries

• Export



4


Cost of Bulk Raw Materials :

With current global scenario the prices of the commodities are dynamic

in nature. The viability of steel plant is highly dependent on the cost of

following key critical raw materials:

1. Iron ore; 2. Coal / Coke; 3. Natural Gas; 4. Electrical Power.

This needs promotion of flexibility in the process route wherein, cheaper

raw material utilization without affecting the productivity becomes the

key towards making steel business sustainable.


Strategically located manufacturing & distribution facilities bringing Essar close to raw materials & customer

Hazira facility

Vizag Pellet Plant

Kirandul Beneficiation Plant

Iron Ore Iron Ore

Deposits

Mahan

Beneficiation Plant

Slurry Pipeline

Pellet Plant

2

2

Bahadurgarh

Bhuj

Indore Kolkata

Chennai

Kirandul

Vizag

Paradeep

Hazira

Essar Port Limited

Essar Power Limited

Essar Shipping Limited

1

1

2

3 5

Hazira Steel Facility3

Pune Downstream Facility

Service Center

4

5

5

5

4 5

5

5

5

Pune

Dabuna

1

5

Material

Movement and

Supply Chain

Essar Steel India : Current Facilities


6

Hazira Steel Complex “Unique Facility”

State of the Art, Most Modern Integrated Steel Plant Complex

10 MTPA Capacity

Encompassing all fundamental technologies

All Weather Captive Port with Jetty – 1.5 KM.

Iron Making : BF, Corex & Midrex DRI Route

Steel Making : DC EAF & Conarc Route

Rolling – CSP, HSM, Plate Mill & CRM Complex

Pipe Mill.

Well Connected through Sea, Road and Rail.

Essar Steel – Hazira : Current Facilities

Product Range : Capital, White & Yellow Goods, Shipbuilding, Sweet &

Sour Gas Pipeline, Electrical Steel, Dual Phase Steel and prestigious

Automobile Sector.

Strategic location makes it an ideal gateway for meeting

the global demand for steel


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Current Facilities :

Hazira – Projects

Hazira Complex

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All the stated plants have developed in-built flexibilities and process

stabilization by using varieties of input materials –

• Iron Bearing Material – Ore / Pellets / Lump Ore with Fe content

ranging from 62.5 to 66 %, Wide ranging types of coal for Corex,

Innovative sources of Coke for BF and Operating Midrex at varying

levels as per NG availability.

• Steel Making – with Hot Metal, Pig Iron, DRI (Cold, Hot and

Briquettes), Scrap (internal / external), Pot Skull (BF / Corex / Steel

Plant returns), Oxides, fines etc.

• Casting – need base through conventional, vertical or strip caster.



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Iron Making - Midrex DRI Modules 1-6 : 7 MTPA

In-house design

engineering &

modification to achieve

the rated capacity from

57 tph to 100 tph. To

name the few as :

• Enhanced reforming

capacity.

• Increased the reaction

temperature in

furnaces – O2

Injection.

• Improving CCS of

pellets along with lime

spraying to withstand

higher reaction

temperature.

• Introduction of Corex

gas into Midrex

modules for full

utilization of Corex

gas from Corex

modules.


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• Day production :

6066 T

• Monthly production

: 170058 T

• Day productivity :

3.17 thm/m3/day

• Month Prod. : 2.88

t/m3/day

• Month O2

enrichment : 4.52%

• TRT power

generation : 6.93

MWh

• 18.5 MWh power

generation utilizing

surplus capacity of

BF boiler

Iron Making - Blast Furnace : 1.73 MTPA


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• Production of 116070

Tons.

• Lowest specific

oxygen consumption

rate of 503 Nm3/thm.

• Operated at lowest

coke rate of 102

Kg/thm.

• Achieved lowest fuel

Rate of 900Kg/thm.

• Usage of thermal

steam coal such as

South African coal

usage initiated within

a week of COREX 2

commissioning. The

usage of South

African Coal in Coal

mix is maximized up

to 85% - plant trial.

Iron Making - Corex 1-2 : 1.74 MTPA


13

Steel Making - DC Electric Arc Furnace : 4.6 MTPA


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Steel Making - Conarc Furnace : 5 MTPA


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SMPs Achievements :

1. Flexibility of iron bearing material usage with varied quality and proportion – HBI / Hot

DRI / Cold DRI, Hot Metal / Pig Iron, Scrap – Internal, Skull – from Blast Furnace /

Corex / Furnace / Ladle Return, Oxides. Operating profiles developed to manage

dynamics iron bearing material on heat to heat basis.

2. Heats made with 100 % Scrap or DRI or with 90 % of Hot Metal.

3. Zero Power Heat Making – Furnaces used as Convertor.

4. Redesign and master steel refining process for managing S, P, N2 arising due to

varied quality of Hot Metal.

5. As high quality steel maker, serving and meeting the need of all valued segments; be

it White & Yellow Goods, Capital Goods, Shipbuilding, Pipeline for Sweet & Sour Gas,

Electrical Steel, Dual Phase Steel and prestigious Automobile Sector. It has taken a

long stride in serving Defence Sector as well.

Steel Making - DC EAF + Conarc Furnace : 9.6 MTPA


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• Essar makes pipes and extra wide plates as well as hot rolled, cold rolled,

galvanized and color coated steel through Conventional or Compact Strip

Caster.

• All stated plants are backed-up by robust in-house developed Process

Monitoring and Controlling Automation System, Central Command Centre,

Planning Software’s like IMPS, Factory Link, i2 etc., SAP, RCM and many more,

facilitating to manage dynamics from varieties of input to quality outputs at an

optimum cost.

• Esteemed organisational objectives are achieved through highly talented,

enthusiastic, open minded and valuable team members, who are always striving

for achieving greater heights.

Hazira facility of Essar steel is a world class facility and a jewel in the crown for

Indian steel industry.

Other Facilities at Hazira :


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Steel Industry – Way Forward :

Challenge for the steel companies :

• Adopt technologies which use non coking coal as against coking coal for

steel making.

• Secure raw material availability globally.

• Partner with professional and technical institutions to develop the necessary

skill sets and competencies.

• Consolidate and enhance capacities to achieve economies of scale.

• Adopt cleaner and greener technologies.

• Need to create a strong infrastructure in terms of railways, roads and ports.

• Innovation to improve sustainability.


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Steel Industry – Way Forward :

Long and

promising road

ahead for the

steel sector.

Steel is the

foundation of

our future – it is

the pillar that

supports

industry,

infrastructure

and country’s

economic

growth.


THANK YOU

19Hazira Steel Complex

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