SAIL Bokaro steel plant

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SAIL Bokaro steel plant, also known as Bokaro Steel Limited, BSL, is a blast furnace-basic oxygen furnace (BF-BOF) steel plant operating in Bokaro Steel City, Jharkhand, India.

Location

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

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  • Location: Marafari, Bokaro Steel City, Jharkhand 827011, India
  • Coordinates (WGS 84): 23.671677, 86.106870 (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]

Plant Details

Table 1: General Plant Details

Phase Plant status Announced date Construction date Start date Workforce size Power source Iron ore source Coal source
Main plant Operating[10] 1964-01[11][12] 1968-04-06[13] 1972[10] 10781[14] BPSCL Captive power plant and balance from Damodar Valley Corporation (DVC)[15][12] Captive mines at Kiriburu, Meghahataburu, Bhawanathpur, Tulsidamar, and Kuteshwar.[16] Jharia coalfields, BCCL & imported from Australia
Expansion Announced[17] 2012-02[18] 2025[19] –[20] – BPSCL Captive power plant and balance from Damodar Valley Corporation (DVC)[15][12] Captive mines at Kiriburu, Meghahataburu, Bhawanathpur, Tulsidamar, and Kuteshwar.[17][16] Jharia coalfields, BCCL & imported from Australia

Table 2: Ownership and Parent Company Information

Phase State-owned entity status Parent company Parent company PermID Parent company GEM ID Owner Owner company PermID Owner company GEM ID
Main plant Partial Steel Authority of India Ltd [100%] 4295872623 [100%] E100001000397 [65%]; E100001000520 [9.4%] Steel Authority of India Ltd[21] 4295872623 E100001000703

Table 3: Process and Products

Phase Steel product category Steel products Steel sector end users ISO 14001 ISO 50001 Main production equipment Detailed production equipment
Main plant semi-finished; finished rolled[22] hot rolled coils, hot rolled plates, hot rolled sheets, cold rolled coils, cold rolled sheets, tin mill black plates, galvanised plain and corrugated sheets[22] automotive; building and infrastructure; steel packaging; tools and machinery; transport[23] Yes[24][25] Yes[24] BF, BOF[22] coking plant (8 batteries with 69 ovens each); sinter plant; 7 BOF (5 130-tonne BOF, 2 300-tonne BOF)[22][23][16]
Expansion semi-finished; finished rolled[22] hot rolled coils, hot rolled plates, hot rolled sheets, cold rolled coils, cold rolled sheets, tin mill black plates, galvanised plain and corrugated sheets[22] automotive; building and infrastructure; steel packaging; tools and machinery; transport[23] – – BOF[22] 2 BF; BOF (# unknown); Sinter plant; Pellet plant; Coke oven battery No.9[20]

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

*Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Phase Capacity operating status* Basic oxygen furnace steelmaking capacity Nominal crude steel capacity (total)
Main plant operating 4650 TTPA[10][26][17][10][26][17][10][26][17][10][26][17][10][26][17][10][26][17][10][26][17] 4650 TTPA[10][26][17][10][26][17][10][26][17][10][26][17][10][26][17][10][26][17][10][26][17]
Expansion announced 3000 TTPA[19][27] 3000 TTPA[19][27]

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

*Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Phase Capacity operating status* Blast furnace capacity Nominal iron capacity (total)
Main plant operating 5775 TTPA[28][18][28][18][28][18][28][18][28][18] 5775 TTPA[28][18][28][18][28][18][28][18][28][18]
Expansion announced 5600 TTPA[18][18] 5600 TTPA[18][18]

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

Phase Sinter Coke Pellets
Main plant 6900 TTPA[16] 4212 TTPA[17][15] –
Expansion 2000 TTPA[15][18] 1000 TTPA[18] 2000 TTPA[15]

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

Year BOF Production Total (all routes)
2020 3380 TTPA[29] 3380 TTPA
2021 – 0 TTPA
2022 4120 TTPA[25] 4120 TTPA

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

Year BF Production Total (all routes)
2020 4031 TTPA[30] 4031 TTPA
2021 4260 TTPA[25] 4260 TTPA
2022 4520 TTPA[25] 4520 TTPA

Blast Furnace 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
1 operating[16] unknown 1968-04-06[31] 1972-10-02[10] Heavy Engineering Corporation; the Soviet Union[32] 1758 m³[16][18] 1050[28][18] unknown 2016[33][34]
2 operating[16] unknown unknown 1974-01-31[35][36] Paul Wurth; Larsen & Toubro; Heavy Engineering Corporation (HEC)[32] 2250 m³[37][18] 1575[28][18] unknown 2010-07[37]
3 operating[16] unknown unknown 1978-02-26[38] Heavy Engineering Corporation; the Soviet Union[32] 1758 m³[16][18] 1050[28][18] unknown unknown
4 operating[16] unknown unknown unknown – 1758 m³[16][39] 1050[28][18] unknown 2022-09[40]
5 operating[16] unknown unknown 2012-03[41] Evo-Tech Hoogoven[41][41] 1758 m³[16] 1050[28][18] A top gas recovery system was installed on the unit to for power generation for the plant[42] unknown
unknown announced[18] 2012-02[18] 2025 unknown – 4060 m³[18] 2800[18] unknown unknown
unknown announced[18] 2012-02[18] 2025 unknown – 4060 m³[18] 2800[18] unknown unknown

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 Steel Plant 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. ↑ 10.00 10.01 10.02 10.03 10.04 10.05 10.06 10.07 10.08 10.09 10.10 10.11 10.12 10.13 10.14 10.15 10.16 https://web.archive.org/web/20220401064854/https://sail.co.in/en/plants/about-bokaro-steel-plant. Archived from the original on 01 April 2022. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  11. ↑ https://web.archive.org/web/20240119034814/https://sail.co.in/en/company/background-history. Archived from the original on 19 January 2024. {{cite web}}: Missing or empty |title= (help)
  12. ↑ 12.0 12.1 12.2 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 19 January 2024. {{cite web}}: Missing or empty |title= (help)
  13. ↑ https://web.archive.org/web/20231208164359/https://www.sail.co.in/plants/about-bokaro-steel-plant. Archived from the original on 08 December 2023. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  14. ↑ https://web.archive.org/web/20210706114009/https://www.telegraphindia.com/jharkhand/bokaro-steel-incurs-losses-in-day-long-protest-against-pay-revision/cid/1820693. Archived from the original on 06 July 2021. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  15. ↑ 15.0 15.1 15.2 15.3 15.4 https://web.archive.org/web/20240119052555/https://environmentclearance.nic.in/auth/ECGeneral_Report.aspx?pid=28411. Archived from the original on 19 January 2024. {{cite web}}: Missing or empty |title= (help)
  16. ↑ 16.00 16.01 16.02 16.03 16.04 16.05 16.06 16.07 16.08 16.09 16.10 16.11 16.12 https://web.archive.org/web/20211118112437/https://sail.co.in/en/plants/bokaro-steel-plant/facilities. Archived from the original on 18 November 2021. {{cite web}}: Missing or empty |title= (help)
  17. ↑ 17.00 17.01 17.02 17.03 17.04 17.05 17.06 17.07 17.08 17.09 17.10 17.11 17.12 17.13 17.14 17.15 17.16 (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 02 November 2021. {{cite web}}: Check date values in: |archive-date= (help); 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 18.25 18.26 18.27 18.28 18.29 18.30 18.31 18.32 https://web.archive.org/web/20240119051924/https://drive.google.com/file/d/16MIHkRpZFuME3mN0GWSO1NzOA6BiXBnw/view?pli=1. Archived from the original on 19 January 2024. {{cite web}}: Missing or empty |title= (help)
  19. ↑ 19.0 19.1 19.2 https://web.archive.org/web/20230607234950/https://www.thehindubusinessline.com/companies/sail-readying-100000-cr-capex-plans/article66912171.ece. Archived from the original on 07 June 2023. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  20. ↑ 20.0 20.1 https://web.archive.org/web/20210810174828/https://www.financialexpress.com/industry/sail-aims-to-start-next-phase-of-expansion-in-2023-24/2307559/. Archived from the original on 10 August 2021. {{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 19 January 2022. {{cite web}}: Missing or empty |title= (help)
  22. ↑ 22.0 22.1 22.2 22.3 22.4 22.5 22.6 https://web.archive.org/web/20220314024904/https://sail.co.in/bokaro-steel-plant/about-bokaro-steel-plant. Archived from the original on 14 March 2022. {{cite web}}: Missing or empty |title= (help)
  23. ↑ 23.0 23.1 23.2 https://web.archive.org/web/20220314024904/https://sail.co.in/bokaro-steel-plant/products. Archived from the original on 14 March 2022. {{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 01 October 2022. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  25. ↑ 25.0 25.1 25.2 25.3 (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 11 October 2023. {{cite web}}: Missing or empty |title= (help)
  26. ↑ 26.00 26.01 26.02 26.03 26.04 26.05 26.06 26.07 26.08 26.09 26.10 26.11 26.12 26.13 (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 08 January 2022. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  27. ↑ 27.0 27.1 (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 10 January 2024. {{cite web}}: Missing or empty |title= (help)
  28. ↑ 28.00 28.01 28.02 28.03 28.04 28.05 28.06 28.07 28.08 28.09 28.10 28.11 28.12 28.13 28.14 https://web.archive.org/web/20240115083007/https://environmentclearance.nic.in/DownloadPfdFile.aspx?FileName=Of5beKJ9Fbze6pWg171eSMhtZy6k1APKZQf0fQJ%2FAk3oZJpXnsOJCshijTzqOfijZS7566tYWtzQYemDxclquaHuQylUuLRsRF5qqz32Op8=&FilePath=93ZZBm8LWEXfg+HAlQix2fE2t8z%2FpgnoBhDlYdZCxzUeqEISsDpNmaozay3MPM7v. Archived from the original on 15 January 2024. {{cite web}}: Missing or empty |title= (help)
  29. ↑ (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 08 August 2022. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  30. ↑ Estimated by prorating across SAIL plants https://sail.co.in/sites/default/files/2021-10/Sustainability-Report%202020_2021.pdf
  31. ↑ (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 02 November 2021. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  32. ↑ 32.0 32.1 32.2 (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)
  33. ↑ (PDF) https://web.archive.org/web/20240322052726/https://sail.co.in/sites/default/files/steel-plants/2020-03/6_monthly_Compliance_6_monthly_Compliance_April_2014_Sept_2014.pdf. Archived from the original (PDF) on 22 March 2024. {{cite web}}: Missing or empty |title= (help)
  34. ↑ (PDF) https://web.archive.org/web/20230521222024/https://www.sail.co.in/sites/default/files/steel-plants/2020-03/6_monthly_Compliance%20April'2015-September'2015.pdf. Archived from the original (PDF) on 21 May 2023. {{cite web}}: Missing or empty |title= (help)
  35. ↑ 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 15 May 2021. {{cite web}}: Missing or empty |title= (help)
  36. ↑ https://eip.lntecc.com/homepage/common/p38.htm. {{cite web}}: Missing or empty |title= (help)
  37. ↑ 37.0 37.1 https://www.projectstoday.com/News/SAIL-commissions-Blast-Furnace-2-at-Bokaro. {{cite web}}: Missing or empty |title= (help)
  38. ↑ (PDF) https://serialsjournals.com/abstract/56198_ch_2_f_-_babita_paper_madhabendra.pdf. {{cite web}}: Missing or empty |title= (help)
  39. ↑ [https://drive.google.com/file/d/16MIHkRpZFuME3mN0GWSO1NzOA6BiXBnw/view?pli=1 https://drive.google.com/file/d/16MIHkRpZFuME3mN0GWSO1NzOA6BiXBnw/view?pli=1 https://drive.google.com/file/d/16MIHkRpZFuME3mN0GWSO1NzOA6BiXBnw/view?pli=1 https://drive.google.com/file/d/16MIHkRpZFuME3mN0GWSO1NzOA6BiXBnw/view?pli=1]. {{cite web}}: Check |url= value (help); Missing or empty |title= (help); line feed character in |url= at position 77 (help)
  40. ↑ https://web.archive.org/web/20220928131006/https://www.psuconnect.in/news/sail-chairman-lights-up-bsl-blast-furnace-equipped-with-new-features/34273. Archived from the original on 28 September 2022. {{cite web}}: Missing or empty |title= (help)
  41. ↑ 41.0 41.1 41.2 https://web.archive.org/web/20230303110138/http://www.bfscbokaro.com/clients.html. Archived from the original on 03 March 2023. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  42. ↑ https://web.archive.org/web/20220930100102/https://www.sail.co.in/en/plants/rourkela-steel-plant/facilities. Archived from the original on 30 September 2022. {{cite web}}: Missing or empty |title= (help)

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