SAIL Bokaro steel plant

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SAIL Bokaro steel plant, also known as Bokaro Steel Limited, BSL, is a steel plant in Bokaro Steel City, Marafari, Bokaro, Jharkhand, India that operates blast furnace (BF), basic oxygen furnace (BOF), and steelmaking technology.

Location

The map below shows the exact location of the plant in Bokaro Steel City, Marafari, Bokaro, Jharkhand, India:

Loading map...
  • Location: Marafari, Bokaro Steel City, Jharkhand 827011, India
  • Coordinates (WGS 84): 23.671677, 86.10687 (exact)

Background

SAIL has Maharatna CPSE (Central Public Sector Enterprise) status by the Government of India under the Ministry of Steel.[1]

Bokaro Steel Limited (BSL) was incorporated in January 1964 for setting up a steel plant with capacity of 4 mtpa of ingot steel in collaboration with the erstwhile Soviet Union (USSR). On 1 May 1978, the plant was incorporated as a constituent unit of Steel Authority of India Limited (SAIL).[2] The construction work began on 6th April 1968. The first blast furnace started operating from 2nd October, 1972. The construction of the first phase was completed on 26th February 1978, with the commissioning of the third Blast Furnace, reaching a total capacity of 1.7 MT Ingot steel, at a total cost of Rs 981 crore.[3][2] The Cold rolling mill was commissioned in. November 1990. The proposal for modernisation of the plant was approved by the Government of India in July 1993 at a cost of Rs 1625.79 crores.[2]

Expansions

The upgradation of Blast Furnace-2 was completed in January 2013, as part of the expansion-cum-modernisation of the plant. The upgradation increased the working volume from 1758 m3 to 2250 m3.[4] Blast Furnace-4 was upgraded in May 2023, in order to enhance productivity and reducing carbon emissions.[5] According to the 2022-23 annual report of SAIL, the revamping of subsystems at BF-3 is in the execution phase.[6]

SAIL announced the expansion of BSL from 4.6 mtpa to 10.75 mtpa of crude steel capacity and hot metal production capacity to 11.375 mtpa, which involved the following:

  • Overall modernisation and capacity expansion of SMS-I in two stages:
    • Stage I: Replacement of BOF converter (5E) of 130 t heat size with addition and upgradation of allied facilities including new slag bay, new ladle furnace, new single strand slab caster and dismantling & re-routing of existing rail tracks, cable tunnel, utility pipelines, etc. in the location of proposed Continuous Casting Shop.
    • Stage II:Modernisation of 2 BOF converters and addition of ladle furnaces, degassing units etc. Stage-II modernisation is expected to be taken up after stabilisation of production from Stage-I modernisation.
  • Augmentation of Sinter plant production
  • Installation of 2000 tpd Oxygen plant
  • Installation of 2 mtpa pellet plant[7]

As of September 2023, a capacity expansion of 3000 ttpa was approved and would be taken up as part of the SAIL's vision 2030 programme.[8][9]

In October 2024, BSL unveiled plans for the establishment of two greenfield steel units, each with a capacity of 5 mtpa.[10] The company decided that the focus would be on brownfield expansion to increase capacity from 4.66 mtpa to 7.61 mtpa by 2030 which will begin execution from 2025 and the greenfield expansion will be taken up after boosting production in the next five years.[10][11]

Plant Details

Table 1: General Plant Details

Announced date Construction date Start date Workforce size Power source Iron ore source Coal source
1964-01[12][13] 1968-04-06[14] 1972[15] 11798[16] BPSCL Captive power plant and balance from Damodar Valley Corporation (DVC)[12][17] Captive mines at Kiriburu, Meghahataburu, Bhawanathpur, Tulsidamar, and Kuteshwar.[18] Jharia coalfields, BCCL & imported from Australia[19][20][17]

Table 2: Ownership and Parent Company Information

State-owned entity status Parent company Parent company PermID Parent company GEM ID Owner Owner company PermID Owner company GEM ID
Partial Steel Authority of India Ltd 4295872623 E100001000703 Steel Authority of India Ltd[21] 4295872623 E100001000703

Table 3: Process and Products

Steel product category Steel products Steel sector end users ISO 14001 ISO 50001 Main production equipment
semi-finished, finished rolled[20] coil, sheet, plate, galvanized coils and sheets, cold rolled, hot rolled[20] automotive, building and infrastructure, steel packaging, tools and machinery, transport[22] yes[23][24] yes[24] BF; BOF; Steel other/unspecified

Table 4: Plant-level Crude Steel Production Capacities (thousand tonnes per annum)

1Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Capacity operating status1 Basic oxygen furnace steelmaking capacity Other/unspecified steelmaking capacity Nominal crude steel capacity (total)
announced 3000[25][26][27] 10000[28] 13000[28][25][26][27]
operating 4652[29][30][15] – 4652[29][30][15]

Table 5: Plant-level Crude Iron Production Capacities (thousand tonnes per annum)

1Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Capacity operating status1 Blast furnace capacity Nominal iron capacity (total)
announced 5600[27] 5600[27]
operating 5775[31][27] 5775[31][27]

Table 6: Upstream Products Production Capacities (thousand tonnes per annum)

Sinter Coke
6900[18] 4212[30][17]

Table 7: Actual Plant-level Crude Steel Production by Year (thousand tonnes per annum)

Year BOF production Total (all routes)
2019 3813[32] 3813[32]
2020 3380[33] 3380[33]
2021 unknown –
2022 4120[23] 4120[23]
2023 4309[34][35] 4309[34][35]

Table 8: Actual Plant-level Crude Iron Production by Year (thousand tonnes per annum)

Year BF production Total (all routes)
2019 4230[36] 4230[36]
2020 4031[36] 4031[36]
2021 4260[23] 4260[23]
2022 4520[23] 4520[23]
2023 4725[34][35] 4725[34][35]

Unit Details

Table 9: Blast Furnace Details

Unit name Status Announced date Construction date Start date Furnace manufacturer and model Current size Current capacity (ttpa) Decarbonization technology Most recent relining
BF 1 operating[18] – 1968-04-06[37] 1972[15] Heavy Engineering Corporation; the Soviet Union[38] 2000.0[18][27] 1050[31][27] unknown 2016[39]
BF 2 operating[18] – – 1974[40][41] Paul Wurth; Larsen & Toubro; Heavy Engineering Corporation (HEC)[38] 2250.0[42][27] 1575[31][27] unknown 2010-07-20[43]
BF 3 operating[18] – – 1978[44] Heavy Engineering Corporation; the Soviet Union[38] 1758.0[18][27] 1050[31][27] unknown –
BF 4 operating[18] – – – – 1758.0[18][45] 1050[31][27] unknown 2022-09[46]
BF 5 operating[18] – – – Evo-Tech Hoogoven[47][47] 1758.0[18] 1050[31][27] A top gas recovery system was installed on the unit to for power generation for the plant[48] 2012-02[47]
unknown BF (1) announced[27] 2012-02[27] 2025 – – 4060.0[27] 2800[27] unknown –
unknown BF (2) announced[27] 2012-02[27] 2025 – – 4060.0[27] 2800[27] unknown –

Table 10: Basic Oxygen Furnace Details

Unit name Status Start date Current capacity (ttpa) Current size
BOF Converter A (4) operating[31][49][18] – 484[29][30][15] 130.0 tonnes[20][18][22]
BOF Converter B (3) operating[31][49][18] – 484[29][30][15] 130.0 tonnes[20][18][22]
BOF Converter C (2) operating[31][49][18] – 484[29][30][15] 130.0 tonnes[20][18][22]
BOF Converter D (1) operating[31][49][18] – 484[29][30][15] 130.0 tonnes[20][18][22]
BOF Converter E (5) operating[31][49][18] – 484[29][30][15] 130.0 tonnes[20][18][22]
unknown BOF (1) operating[31][49][18] 2012[50] 1116[29][30][15] 300.0 tonnes[20][18][22]
unknown BOF (2) operating[31][49][18] 2012[50] 1116[29][30][15] 300.0 tonnes[20][18][22]
unknown BOF (3) announced[25] 2032[25] 1500[25][26] 130.0 tonnes[27]
unknown BOF (4) announced[25] 2032[25] 1500[25][26][27] 130.0 tonnes[27]

Articles and Resources

Additional data

To access additional data, including an interactive map of steel power plants, a downloadable dataset, and summary data, please visit the Global Iron and Steel Tracker on the Global Energy Monitor website.

References

  1. ↑ Steel Authority of India Limited, Steel Authority of India Limited, Retrieved on: May 19, 2020
  2. ↑ 2.0 2.1 2.2 "Ministry of Steel: Steel Authority of India". CAG. Retrieved 21 September, 2023. {{cite web}}: Check date values in: |access-date= (help)CS1 maint: url-status (link)
  3. ↑ "Bokaro Steel Plant | SAIL". sail.co.in. Retrieved 2023-09-22.
  4. ↑ "SAIL Chairman commissions upgraded Blast Furnace at Bokaro Steel Plant". Business Standard. 20 January, 2013. Retrieved 22 September, 2023. {{cite web}}: Check date values in: |access-date= and |date= (help)CS1 maint: url-status (link)
  5. ↑ Current Bokaro (2023-05-08). "SAIL news: BSL's upgraded Blast Furnace-4 enhances productivity while reducing carbon emissions - Current Bokaro". Current Bokaro. Retrieved 2023-09-25.
  6. ↑ "SAIL: Anual Report: 2022-23" (PDF). SAIL. Retrieved 22 September, 2023. {{cite web}}: Check date values in: |access-date= (help)CS1 maint: url-status (link)
  7. ↑ "Concept Note, FR, DPR.pdf". Google Docs. Retrieved 2023-09-25.
  8. ↑ "Bengal to be big beneficiary as Steel Authority of India Ltd pushes capacity in Burnpur, Durgapur". www.telegraphindia.com. Retrieved 2023-11-06.
  9. ↑ "Steel Authority of India Limited Q1 FY 2024 Earnings Conference Call" (PDF). SAIL. 11 August, 2023. Retrieved 06 November, 2023. {{cite web}}: Check date values in: |access-date= and |date= (help)CS1 maint: url-status (link)
  10. ↑ 10.0 10.1 Oct 3, TNN /; 2024; Ist, 04:33. "Bokaro Steel Plant Announces Ambitious Expansion with Two Greenfield Steel Units | Ranchi News - Times of India". The Times of India. Retrieved 2025-01-23.{{cite web}}: CS1 maint: numeric names: authors list (link)
  11. ↑ Bokaro, Current (2025-01-01). "SAIL-BSL: डायरेक्टर इंचार्ज ने 2025 को ब्राउनफील्ड विस्तार के लिए अहम बताया, सेल चेयरमैन ने कहा मुस्कुराओ". Current Bokaro. Retrieved 2025-01-23.
  12. ↑ 12.0 12.1 https://web.archive.org/web/20240119034651/https://cag.gov.in/uploads/old_reports/union/union_performance/2002/Commercial/2002_book4/chapter6.htm. Archived from the original on 2024-01-19. {{cite web}}: Missing or empty |title= (help)
  13. ↑ https://web.archive.org/web/20240119034814/https://sail.co.in/en/company/background-history. Archived from the original on 2024-01-19. {{cite web}}: Missing or empty |title= (help)
  14. ↑ https://web.archive.org/web/20231208164359/https://www.sail.co.in/plants/about-bokaro-steel-plant. Archived from the original on 2023-12-08. {{cite web}}: Missing or empty |title= (help)
  15. ↑ 15.00 15.01 15.02 15.03 15.04 15.05 15.06 15.07 15.08 15.09 15.10 https://web.archive.org/web/20220401064854/https://sail.co.in/en/plants/about-bokaro-steel-plant. Archived from the original on 2022-04-01. {{cite web}}: Missing or empty |title= (help)
  16. ↑ (PDF) https://www.sail.co.in/sites/default/files/2024-04/Sail%20Sustinability%20Report%202022-23.pdf. {{cite web}}: Missing or empty |title= (help)
  17. ↑ 17.0 17.1 17.2 https://web.archive.org/web/20240119052555/https://environmentclearance.nic.in/auth/ECGeneral_Report.aspx?pid=28411. Archived from the original on 2024-01-19. {{cite web}}: Missing or empty |title= (help)
  18. ↑ 18.00 18.01 18.02 18.03 18.04 18.05 18.06 18.07 18.08 18.09 18.10 18.11 18.12 18.13 18.14 18.15 18.16 18.17 18.18 18.19 18.20 18.21 18.22 18.23 18.24 https://web.archive.org/web/20211118112437/https://sail.co.in/en/plants/bokaro-steel-plant/facilities. Archived from the original on 2021-11-18. {{cite web}}: Missing or empty |title= (help)
  19. ↑ https://web.archive.org/web/20240115072616/https://environmentclearance.nic.in/DownloadPfdFile.aspx?FileName=Of5beKJ9Fbze6pWg171eSCV942HaPOVCkyn7XqfJjmSQ0Cx6jGK7sowN1xV+w5CBWQCOeklXsSd+DszQ5tbubg==&FilePath=93ZZBm8LWEXfg+HAlQix2fE2t8z%2FpgnoBhDlYdZCxzXNvGkdT0PfxJ9apij6yL62I6BUeakiRSZ1RDw3zRMLfQ==. Archived from the original on 2024-01-15. {{cite web}}: Missing or empty |title= (help)
  20. ↑ 20.0 20.1 20.2 20.3 20.4 20.5 20.6 20.7 20.8 20.9 https://web.archive.org/web/20220314024904/https://sail.co.in/bokaro-steel-plant/about-bokaro-steel-plant. Archived from the original on 2022-03-14. {{cite web}}: Missing or empty |title= (help)
  21. ↑ https://web.archive.org/web/20220119143642/https://www.qcc.com/firm/dd1f8d7003b654e308bf075d383f6051.html. Archived from the original on 2022-01-19. {{cite web}}: Missing or empty |title= (help)
  22. ↑ 22.0 22.1 22.2 22.3 22.4 22.5 22.6 22.7 https://web.archive.org/web/20220314024904/https://sail.co.in/bokaro-steel-plant/products. Archived from the original on 2022-03-14. {{cite web}}: Missing or empty |title= (help)
  23. ↑ 23.0 23.1 23.2 23.3 23.4 23.5 23.6 (PDF) https://web.archive.org/web/20231011114647/https://sail.co.in/sites/default/files/ticker/2023-09/SAIL_Annual-Report-2022-2023.pdf. Archived from the original (PDF) on 2023-10-11. {{cite web}}: Missing or empty |title= (help)
  24. ↑ 24.0 24.1 https://web.archive.org/web/20221001234933/https://sail.co.in/en/right-information-act/brief-manuals/norms-set-bokaro-steel-plant-discharge-its-functions. Archived from the original on 2022-10-01. {{cite web}}: Missing or empty |title= (help)
  25. ↑ 25.0 25.1 25.2 25.3 25.4 25.5 25.6 25.7 (PDF) https://web.archive.org/web/20240110012111/https://sail.co.in/sites/default/files/2023-08/Transcript-Q1-FY24.pdf. Archived from the original (PDF) on 2024-01-10. {{cite web}}: Missing or empty |title= (help)
  26. ↑ 26.0 26.1 26.2 26.3 https://web.archive.org/web/20230607234950/https://www.thehindubusinessline.com/companies/sail-readying-100000-cr-capex-plans/article66912171.ece. Archived from the original on 2023-06-07. {{cite web}}: Missing or empty |title= (help)
  27. ↑ 27.00 27.01 27.02 27.03 27.04 27.05 27.06 27.07 27.08 27.09 27.10 27.11 27.12 27.13 27.14 27.15 27.16 27.17 27.18 27.19 27.20 27.21 27.22 27.23 27.24 https://web.archive.org/web/20240119051924/https://drive.google.com/file/d/16MIHkRpZFuME3mN0GWSO1NzOA6BiXBnw/view?pli=1. Archived from the original on 2024-01-19. {{cite web}}: Missing or empty |title= (help)
  28. ↑ 28.0 28.1 https://timesofindia.indiatimes.com/city/ranchi/bokaro-steel-plant-announces-ambitious-expansion-with-two-greenfield-steel-units/articleshow/113888096.cms. {{cite web}}: Missing or empty |title= (help)
  29. ↑ 29.0 29.1 29.2 29.3 29.4 29.5 29.6 29.7 29.8 (PDF) https://web.archive.org/web/20220108035637/https://www.teriin.org/sites/default/files/2020-03/Towards%20a%20Low%20Carbon%20Steel%20Sector%20Report.pdf. Archived from the original (PDF) on 2022-01-08. {{cite web}}: Missing or empty |title= (help)
  30. ↑ 30.0 30.1 30.2 30.3 30.4 30.5 30.6 30.7 30.8 30.9 (PDF) https://web.archive.org/web/20211102184841/https://sail.co.in/sites/default/files/steel-plants/2021-03/EC-for-Expansion-cum-Modernization-of-SAIL-Bokaro-Steel-Plantissued-on-17.03.2021.pdf. Archived from the original (PDF) on 2021-11-02. {{cite web}}: Missing or empty |title= (help)
  31. ↑ 31.00 31.01 31.02 31.03 31.04 31.05 31.06 31.07 31.08 31.09 31.10 31.11 31.12 31.13 https://web.archive.org/web/20240115083007/https://environmentclearance.nic.in/DownloadPfdFile.aspx?FileName=Of5beKJ9Fbze6pWg171eSMhtZy6k1APKZQf0fQJ%2FAk3oZJpXnsOJCshijTzqOfijZS7566tYWtzQYemDxclquaHuQylUuLRsRF5qqz32Op8=&FilePath=93ZZBm8LWEXfg+HAlQix2fE2t8z%2FpgnoBhDlYdZCxzUeqEISsDpNmaozay3MPM7v. Archived from the original on 2024-01-15. {{cite web}}: Missing or empty |title= (help)
  32. ↑ 32.0 32.1 (PDF) https://web.archive.org/web/20211117141829/https://steel.gov.in/sites/default/files/MoS%20AR%20Eng.pdf. Archived from the original (PDF) on 2021-11-17. {{cite web}}: Missing or empty |title= (help)
  33. ↑ 33.0 33.1 (PDF) https://web.archive.org/web/20220808195812/https://www.sail.co.in/sites/default/files/2022-02/Performance-highlights-Q3-FY-22.pdf. Archived from the original (PDF) on 2022-08-08. {{cite web}}: Missing or empty |title= (help)
  34. ↑ 34.0 34.1 34.2 34.3 "SAIL Annual report 2023-24" (PDF). SAIL.co.in. 2024. Archived from the original (PDF) on 2024-12-12. Retrieved 2024-12-12.
  35. ↑ 35.0 35.1 35.2 35.3 https://currentbokaro.com/milestone-achievements-sail-and-bokaro-steel-plant-set-new-records-in-fy-2023-24/. {{cite web}}: Missing or empty |title= (help)
  36. ↑ 36.0 36.1 36.2 36.3 (PDF) https://web.archive.org/web/20211127054741/https://sail.co.in/sites/default/files/2021-10/Sustainability-Report%202020_2021.pdf. Archived from the original (PDF) on 2021-11-27. {{cite web}}: Missing or empty |title= (help)
  37. ↑ (PDF) https://web.archive.org/web/20211102194149/https://sail.co.in/sites/default/files/publication/2020-06/SAIL%20CTB.pdf. Archived from the original (PDF) on 2021-11-02. {{cite web}}: Missing or empty |title= (help)
  38. ↑ 38.0 38.1 38.2 (PDF) https://www.jstor.org/stable/pdf/4378206.pdf?refreqid=excelsior%3Af3c4d4ec7831dae2573cd651290b4073&ab_segments=&origin=&initiator=&acceptTC=1. {{cite web}}: Missing or empty |title= (help)
  39. ↑ (PDF) https://sail.co.in/sites/default/files/steel-plants/2020-03/6_monthly_Compliance%20April%272015-September%272015.pdf https://sail.co.in/sites/default/files/steel-plants/2020-03/6_monthly_Compliance_6_monthly_Compliance_April_2014_Sept_2014.pdf, https://sail.co.in/sites/default/files/steel-plants/2020-03/6_monthly_Compliance%20April%272015-September%272015.pdf. {{cite web}}: Check |url= value (help); Missing or empty |title= (help)
  40. ↑ https://web.archive.org/web/20210515210627/https://www.thehindu.com/business/Industry/SAIL-chief-opens-upgraded-blast-furnace-2-at-Bokaro/article16203992.ece. Archived from the original on 2021-05-15. {{cite web}}: Missing or empty |title= (help)
  41. ↑ https://eip.lntecc.com/homepage/common/p38.htm. {{cite web}}: Missing or empty |title= (help)
  42. ↑ https://www.projectstoday.com/News/SAIL-commissions-Blast-Furnace-2-at-Bokaro. {{cite web}}: Missing or empty |title= (help)
  43. ↑ https://www.larsentoubro.com/media/31155/november-15-2007.pdf, https://www.sail.co.in/sites/default/files/2024-03/q3fy12.pdf, https://www.business-standard.com/article/press-releases/sail-chairman-commissions-upgraded-blast-furnace-at-bokaro-steel-plant-110072000097_1.html https://www.projectstoday.com/News/SAIL-commissions-Blast-Furnace-2-at-Bokaro, https://www.larsentoubro.com/media/31155/november-15-2007.pdf, https://www.sail.co.in/sites/default/files/2024-03/q3fy12.pdf, https://www.business-standard.com/article/press-releases/sail-chairman-commissions-upgraded-blast-furnace-at-bokaro-steel-plant-110072000097_1.html. {{cite web}}: Check |url= value (help); Missing or empty |title= (help)
  44. ↑ (PDF) https://serialsjournals.com/abstract/56198_ch_2_f_-_babita_paper_madhabendra.pdf. {{cite web}}: Missing or empty |title= (help)
  45. ↑ https://drive.google.com/file/d/16MIHkRpZFuME3mN0GWSO1NzOA6BiXBnw/view?pli=1https://drive.google.com/file/d/16MIHkRpZFuME3mN0GWSO1NzOA6BiXBnw/view?pli=1. {{cite web}}: Missing or empty |title= (help)
  46. ↑ https://www.psuconnect.in/news/sail-chairman-lights-up-bsl-blast-furnace-equipped-with-new-features/34273/ https://currentbokaro.com/sail-news-upgraded-bsls-blast-furnace-4-decrease-carbon-emission-enhance-productivity/, https://www.psuconnect.in/news/sail-chairman-lights-up-bsl-blast-furnace-equipped-with-new-features/34273/. {{cite web}}: Check |url= value (help); Missing or empty |title= (help)
  47. ↑ 47.0 47.1 47.2 https://web.archive.org/web/20230303110138/http://www.bfscbokaro.com/clients.html. Archived from the original on 2023-03-03. {{cite web}}: Missing or empty |title= (help)
  48. ↑ https://web.archive.org/web/20220930100102/https://www.sail.co.in/en/plants/rourkela-steel-plant/facilities. Archived from the original on 2022-09-30. {{cite web}}: Missing or empty |title= (help)
  49. ↑ 49.0 49.1 49.2 49.3 49.4 49.5 49.6 (PDF) https://web.archive.org/web/20240903170713/https://sail.co.in/sites/default/files/steel-plants/2023-06/Six-Monthly-EC-Condition-Compliance-SAIL-Bokaro-Oct-22-to-Mar-23.pdf. Archived from the original (PDF) on 03 September 2024. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  50. ↑ 50.0 50.1 (PDF) https://www.sail.co.in/sites/default/files/2024-03/q3fy12.pdf. {{cite web}}: Missing or empty |title= (help)

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