Tata Steel Meramandali steel plant
From Global Energy Monitor
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Tata Steel Meramandali steel plant, also known as Tata Steel BSL Odisha, TSM, Bhushan Steel Ltd (BSL) (formerly), Tata Steel BSL Meramandali steel plant, Tata Steel Angul steel plant, is a steel plant in Meramandali, Shibapur, Dhenkanal, Odisha, India that operates steelmaking, blast furnace (BF), induction furnace (IF), basic oxygen furnace (BOF), electric arc furnace (EAF), and direct reduced iron (DRI) technology.
Location
The map below shows the exact location of the plant in Meramandali, Shibapur, Dhenkanal, Odisha, India:
- Location: Narendra Pur P.O. Shibapur, Meramandali, District - Dhenkanal - 759121, India
- Coordinates (WGS 84): 20.796053, 85.260382 (exact)
Background
Bhushan Steel limited was established in 1989. The BSL Dhenkanal plant is an integrated steel plant with a capacity of 2.2 mtpa crude steel in 2009-10. With further expansion in stages using both primary and secondary steel production routes the plant now has a capacity of 5.6 mtpa.[1] On May 18, 2018, a subsidiary of Tata Steel acquired 72.65% stake in BSL.[2] On November 27, 2018, BSL was renamed Tata Steel BSL Ltd.[3] During the acquisition BSL was operating at 3.5 mtpa, much below its installed capacity.[4]
The Tata Steel BSL Dhenkanal plant is currently planning basic oxygen furnace (BOF) and electric arc furnace (EAF) expansions upto 12.8 mtpa for 2030.[5] The expansion is planned in two stages:
- Stage I: Expansion from 5.6 mtpa to 8.2 mtpa. This involves installation of a third blast furnace and two 200 tons BOF, expected to begin commissioning by 2027.
- Stage II: Expansion from 8.2 mtpa to 12.8 mtpa. This involves augmentation of existing blast furnace 1 and 2 to produce 3 mtpa additional hot metal, installation of a COG based Midrex Direct reduction plant of capacity 1.6 mtpa, two 100 tons EAF, and two 250 tons BOF.[1]
As of January 2025, there hasn't been many updates with regard to the expansion projects.
In February 2024, Tata Steel’s Kalinganagar and Meramandali plants received ResponsibleSteelTM Certification.[6]
Accidents
On 13 November, 2013, a deadly fire accident at the blast furnace 2 of the plant killed one worker and injured 19 others, following which the furnace was temporarily sealed by the Directorate of Factories and Broilers. According to a 2013 news article, BSL has witnessed several accidents and had so far claimed more than 100 lives since its inception.[7] According to government data, by 2013, 66 persons died in the plant since 2006, and the plant faces 70 criminal cases.[8]
On 13 June, 2023, 19 workers at the plant sustained burn injuries due to a mishap in one of the blast furnaces which lead to the escape of hot steam from a pipe.[9]
Decarbonization initiatives
The began COG injection into Blast Furnace #1 in FY 2024-25, which is expected to increase hot blast temperature resulting in reduction of BF fuel.[10]
Ownership Tree
This ownership tree is part of the Global Energy Ownership Tracker, a project of Global Energy Monitor.
Plant Details
Table 1: General Plant Details
| Announced date | Start date | Workforce size | Power source | Iron ore source | Coal source |
|---|---|---|---|---|---|
| 2003[11] | 2007[11] | 1425[12] | Estimated overall power requirement after implementation of expansion- 1632 MW(638 MW to be met by CPP and remaining 994 MW to be drawn from theGrid)[13] | Captive iron ore mines in Odisha[14] | imported[13] |
Table 2: Ownership and Parent Company Information
| State-owned entity status | Parent company | Parent company PermID | Parent GEM entity ID | Owner | Owner company PermID | Owner GEM entity ID |
|---|---|---|---|---|---|---|
| Partial | Tata Steel Ltd [100.0%] | 4295872420 [100.0%] | E100001010018 [100.0%] | Tata Steel Ltd [100%][15] | 4295872420 | E100001010018 [100%] |
Table 3: Process and Products
| Steel product category | Steel products | ISO 14001 | Responsible steel | Main production equipment |
|---|---|---|---|---|
| semi-finished, finished rolled[16] | pipe, cold rolled, coil, sheet[16] | yes[17] | 2026-12-18[18][19] | BF; IF; DRI; BOF; EAF; Steel other/unspecified |
Table 4: Plant-level Crude Steel Production Capacities (thousand tonnes per annum)
| Capacity operating status1 | Basic oxygen furnace steelmaking capacity | Electric arc furnace steelmaking capacity | Induction furnace steelmaking capacity | Other/unspecified steelmaking capacity | Nominal crude steel capacity (total) |
|---|---|---|---|---|---|
| announced | 6070[20][13] | 1550[20][21] | – | – | 7620[20][21][13] |
| operating | 3000[20] | 422[13] | 288[20] | 1800[20] | 5510[20][13] |
Table 5: Plant-level Crude Iron Production Capacities (thousand tonnes per annum)
| Capacity operating status1 | Blast furnace capacity | Sponge iron/DRI capacity | Nominal iron capacity (total) |
|---|---|---|---|
| announced | 4300[20] | 1600[20] | 5900[20] |
| operating | 5700[22] | 1500[13] | 7200[22][13] |
Table 6: Upstream Products Production Capacities (thousand tonnes per annum)
| Sinter | Coke | Pellets |
|---|---|---|
| 8587[20] | 2100[23] | NF |
Table 7: Actual Plant-level Crude Steel Production by Year (thousand tonnes per annum)
| Year | BOF production | EAF production | Other/unknown steel production | Total (all routes) |
|---|---|---|---|---|
| 2019 | unknown[24] | 226[24] | 964[24] | 1190[24] |
| 2020 | 2222[17] | 312[17] | 1333[17] | 3867[17] |
| 2021 | 2668[25] | 375[25] | 1601[25] | 4644[25] |
| 2022 | 2695[26] | 379[26] | 1617[26] | 4691[26] |
| 2023 | 2809[27][28] | 395[27][28] | 1686[27][28] | 4890[27][28] |
| 2024 | 2831[29] | 398[29] | 1699[29] | 4928[29] |
Table 8: Actual Plant-level Crude Iron Production by Year (thousand tonnes per annum)
| Year | BF production | DRI production | Other/unknown iron production | Total (all routes) |
|---|---|---|---|---|
| 2019 | unknown | unknown | unknown | – |
| 2020 | unknown | unknown | unknown | – |
| 2021 | 3477[25] | 1113[25] | –[25] | 4590[25] |
| 2022 | 3484[26] | 1116[26] | –[26] | 4600[26] |
| 2023 | unknown | unknown | – | – |
| 2024 | 4700[29] | unknown[29] | –[29] | 4700[29] |
Unit Details
Table 9: Blast Furnace Details
| Unit name | Status | Announced date | Start date | Furnace manufacturer and model | Current size | Current capacity (ttpa) | Decarbonization technology |
|---|---|---|---|---|---|---|---|
| BF 1 | operating[22] | – | 2010[30][31] | MECON (Govt. of India); Paul Wurth Paul Wurth Blast Furnace Design[32][33][32] | 1681.0 m3[13] | 2500[22] | Installing Paul Wurth coke oven gas injection system, expected to be commissioned by Q1 2026[34][35][36] |
| BF 2 | operating[22] | – | 2013[30][31] | MECON (Govt. of India); Paul Wurth[32][33] | 3814.0 m3[33] | 3200[22] | unknown |
| BF 3 | announced[21] | 2016[20] | 2030[21] | – | 5800.0 m3[20] | 4300[20] | unknown |
Table 10: Direct Reduced Iron Furnace Details
| Unit name | Status | Start date | Furnace manufacturer and model | Furnace type | Current capacity (ttpa) |
|---|---|---|---|---|---|
| unknown DRI (1) | operating[31] | 2007[31] | Lurgi[37] | rotary kiln[38] | 150[13] |
| unknown DRI (10) | operating[31] | 2007[31] | Lurgi[37] | rotary kiln[38] | 150[13] |
| unknown DRI (11) | announced[20] | 2030[21] | Midrex[13] | shaft furnace[13] | 1600[20] |
| unknown DRI (2) | operating[31] | 2007[31] | Lurgi[37] | rotary kiln[38] | 150[13] |
| unknown DRI (3) | operating[31] | 2007[31] | Lurgi[37] | rotary kiln[38] | 150[13] |
| unknown DRI (4) | operating[31] | 2007[31] | Lurgi[37] | rotary kiln[38] | 150[13] |
| unknown DRI (5) | operating[31] | 2007[31] | Lurgi[37] | rotary kiln[38] | 150[13] |
| unknown DRI (6) | operating[31] | 2007[31] | Lurgi[37] | rotary kiln[38] | 150[13] |
| unknown DRI (7) | operating[31] | 2007[31] | Lurgi[37] | rotary kiln[38] | 150[13] |
| unknown DRI (8) | operating[31] | 2007[31] | Lurgi[37] | rotary kiln[38] | 150[13] |
| unknown DRI (9) | operating[31] | 2007[31] | Lurgi[37] | rotary kiln[38] | 150[13] |
Table 11: Direct Reduced Iron Furnace Reductant Details
| Unit name | Current or initial reductant | Gas reductant | Hydrogen reductant status |
|---|---|---|---|
| unknown DRI (1) | coal (solid)[20] | –[20] | – |
| unknown DRI (10) | coal (solid)[20] | –[20] | – |
| unknown DRI (11) | gas[20] | waste gas recovery (coke oven)[20] | incapable[39] |
| unknown DRI (2) | coal (solid)[20] | –[20] | – |
| unknown DRI (3) | coal (solid)[20] | –[20] | – |
| unknown DRI (4) | coal (solid)[20] | –[20] | – |
| unknown DRI (5) | coal (solid)[20] | –[20] | – |
| unknown DRI (6) | coal (solid)[20] | –[20] | – |
| unknown DRI (7) | coal (solid)[20] | –[20] | – |
| unknown DRI (8) | coal (solid)[20] | –[20] | – |
| unknown DRI (9) | coal (solid)[20] | –[20] | – |
Table 12: Electric Arc Furnace Details
| Unit name | Status | Announced date | Furnace manufacturer and model | Current capacity (ttpa) | Current size (tonnes) |
|---|---|---|---|---|---|
| unknown EAF (1) | operating[20] | – | CONARC | 422[13] | 60.0[30][31] |
| unknown EAF (2) | announced[21] | 2016[13] | – | 775[21] | 100.0[21][20] |
| unknown EAF (3) | announced[21] | 2016[13] | – | 775[21][20] | 100.0[21][20] |
Table 13: Electric Arc Furnace Feedstock Details
| Unit name | Scrap-based | % scrap | % DRI | % HBI |
|---|---|---|---|---|
| unknown EAF (1) | yes[20] | 2.83[20] | 79.38[20] | 17.79[20] |
| unknown EAF (2) | yes[20] | 9.16[20] | 90.84[20] | – |
| unknown EAF (3) | yes[20] | 9.16[20] | 90.84[20] | – |
Table 14: Basic Oxygen Furnace Details
| Unit name | Status | Announced date | Start date | Current capacity (ttpa) | Current size |
|---|---|---|---|---|---|
| unknown BOF (1) | operating[20] | – | – | 1500[20] | 200.0 tonnes[13][31] |
| unknown BOF (2) | operating[20] | – | – | 1500[20] | 200.0 tonnes[13][31] |
| unknown BOF (3) | announced[21] | 2016[13] | 2027[13] | 1485[13] | 200.0 tonnes[21][20][40] |
| unknown BOF (4) | announced[21] | 2016[13] | 2027[13] | 1485[13] | 200.0 tonnes[21][20][40] |
| unknown BOF (5) | announced[21] | 2016[13] | – | 1550[20] | 250.0 tonnes[21][20] |
| unknown BOF (6) | announced[21] | 2016[13] | – | 1550[20] | 250.0 tonnes[21][20] |
Table 15: Induction Furnace Details
| Unit name | Status | Current capacity (ttpa) | Current size |
|---|---|---|---|
| unknown IF (1) | operating[20] | 48[20] | 15.0 tonnes[20] |
| unknown IF (2) | operating[20] | 48[20] | 15.0 tonnes[20] |
| unknown IF (3) | operating[20] | 48[20] | 15.0 tonnes[20] |
| unknown IF (4) | operating[20] | 48[20] | 15.0 tonnes[20] |
| unknown IF (5) | operating[20] | 48[20] | 15.0 tonnes[20] |
| unknown IF (6) | operating[20] | 48[20] | 15.0 tonnes[20] |
Table 16: Induction Furnace Feedstock Details
| Unit name | Scrap-based | % HBI |
|---|---|---|
| unknown IF (1) | no | 100.00[20] |
| unknown IF (2) | no | 100.00[20] |
| unknown IF (3) | no | 100.00[20] |
| unknown IF (4) | no | 100.00[20] |
| unknown IF (5) | no | 100.00[20] |
| unknown IF (6) | no | 100.00[20] |
Articles and Resources
Additional data
To access additional data, including an interactive map of steel plants, a downloadable dataset, and summary data, please visit the Global Iron and Steel Tracker on the Global Energy Monitor website.
References
- ↑ 1.0 1.1 "Pre-feasibility report for proposed expansion from 5.6 mtpa to 12.8 mtpa" (PDF). MoEF&CC. April 2016. Retrieved 11 October, 2023.
{{cite web}}: Check date values in:|access-date=(help)CS1 maint: url-status (link) - ↑ Tanya Thomas (2018-05-18). "Tata Steel buys Bhushan Steel, to settle dues of Rs35,200 crore". mint. Retrieved 2023-10-11.
- ↑ Hungama Digital Services. "Bhushan Steel Limited is Tata Steel BSL Limited now". www.tatasteel.com. Retrieved 2023-10-11.
- ↑ Ankit Gohel (2023-10-11). "HDFC AMC Q2 net profit may rise 11% to ₹404 crore; revenue seen up 15% YoY". mint. Retrieved 2023-10-11.
- ↑ "Latest Developments in Steelmaking Capacity 2021" (PDF). OECD. Retrieved 2022-04-08.
{{cite web}}: CS1 maint: url-status (link) - ↑ Services, Hungama Digital. "Tata Steel's Kalinganagar and Meramandali plants receive ResponsibleSteelTM Certification". www.tatasteel.com. Retrieved 2025-01-24.
- ↑ "Bhushan Steel's killer blast furnace sealed". Business Standard. 14 November, 2013. Retrieved 11 October, 2023.
{{cite web}}: Check date values in:|access-date=and|date=(help)CS1 maint: url-status (link) - ↑ "Dhenkanal plant faces 70 criminal cases | Bhubaneswar News - Times of India". The Times of India. Retrieved 2023-10-11.
- ↑ "19 injured in blast furnace mishap at Tata Steel's Dhenkanal plant in Odisha". The Indian Express. 2023-06-13. Retrieved 2023-10-11.
- ↑ "Integrated report FY 2024-25" (PDF). Tata Steel. 2025. Retrieved 2025-10-15.
{{cite web}}: CS1 maint: url-status (link) - ↑ 11.0 11.1 (PDF) https://web.archive.org/web/20241206013325/https://www.ipaicmai.in/IPANEW/UploadFiles/Casestudy/Bhushan_Power.pdf. Archived from the original (PDF) on 2024-12-06.
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{{cite web}}: Missing or empty|title=(help) - ↑ 13.00 13.01 13.02 13.03 13.04 13.05 13.06 13.07 13.08 13.09 13.10 13.11 13.12 13.13 13.14 13.15 13.16 13.17 13.18 13.19 13.20 13.21 13.22 13.23 13.24 13.25 13.26 13.27 13.28 13.29 13.30 13.31 13.32 13.33 (PDF) http://environmentclearance.nic.in/writereaddata/Online/TOR/08_Apr_2016_144914843AB7KF4JBAnnexurePreFeasibilityReport.pdf.
{{cite web}}: Missing or empty|title=(help) - ↑ "TATA STEEL - Integrated report & annual accounts 2021-22". www.tatasteel.com. Archived from the original on 2024-12-06. Retrieved 2024-12-05.
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{{cite web}}: Missing or empty|title=(help) - ↑ 16.0 16.1 https://web.archive.org/web/20200716132754/http://tatasteelbsl.co.in:80/company.html. Archived from the original on 2020-07-16.
{{cite web}}: Missing or empty|title=(help) - ↑ 17.0 17.1 17.2 17.3 17.4 (PDF) https://web.archive.org/web/20220318084004/https://tatasteelbsl.co.in/Investor%20Relations%20pdf/Financial%20Reporting/Annual%20Report/Annual%20Report%20for%20FY%202020-21.pdf. Archived from the original (PDF) on 2022-03-18.
{{cite web}}: Missing or empty|title=(help) - ↑ (PDF) https://cdn.prod.website-files.com/653ed7060b01292cd4518d0e/66003bfc8ca92e548d01d31f_Tata-Steel-Limited-Meramandali-Final-Certificate-Responsible-Steel-combined.pdf.
{{cite web}}: Missing or empty|title=(help) - ↑ https://www.responsiblesteel.org/issued-certificates-and-ongoing-audits.
{{cite web}}: Missing or empty|title=(help) - ↑ 20.00 20.01 20.02 20.03 20.04 20.05 20.06 20.07 20.08 20.09 20.10 20.11 20.12 20.13 20.14 20.15 20.16 20.17 20.18 20.19 20.20 20.21 20.22 20.23 20.24 20.25 20.26 20.27 20.28 20.29 20.30 20.31 20.32 20.33 20.34 20.35 20.36 20.37 20.38 20.39 20.40 20.41 20.42 20.43 20.44 20.45 20.46 20.47 20.48 20.49 20.50 20.51 20.52 20.53 20.54 20.55 20.56 20.57 20.58 20.59 20.60 20.61 20.62 20.63 20.64 20.65 20.66 20.67 20.68 20.69 20.70 20.71 20.72 20.73 20.74 20.75 20.76 20.77 20.78 20.79 20.80 20.81 20.82 20.83 20.84 20.85 (PDF) https://web.archive.org/web/20240119033914/https://environmentclearance.nic.in/writereaddata/Online/TOR/08_Apr_2016_144914843AB7KF4JBAnnexurePreFeasibilityReport.pdf. Archived from the original (PDF) on 2024-01-19.
{{cite web}}: Missing or empty|title=(help) - ↑ 21.00 21.01 21.02 21.03 21.04 21.05 21.06 21.07 21.08 21.09 21.10 21.11 21.12 21.13 21.14 21.15 21.16 21.17 21.18 (PDF) https://web.archive.org/web/20210929032946/https://www.oecd.org/industry/ind/latest-developments-in-steelmaking-capacity-2021.pdf (PDF).
{{cite web}}: Check|archive-url=value (help); Missing or empty|title=(help) - ↑ 22.0 22.1 22.2 22.3 22.4 22.5 (PDF) http://worldpetrocoal.in/download/WPCC-2020-PPT/KS-VII/Saroj-Banerjee.pdf.
{{cite web}}: Missing or empty|title=(help) - ↑ (PDF) https://www.tatasteel.com/media/15101/environmental-clearance-for-56-mtpa-integrated-steel-plant-tsl-meramandali.pdf.
{{cite web}}: Missing or empty|title=(help) - ↑ 24.0 24.1 24.2 24.3 (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) - ↑ 25.0 25.1 25.2 25.3 25.4 25.5 25.6 25.7 (PDF) https://web.archive.org/web/20221108121601/https://www.tatasteel.com/media/15928/tata-steel-ir-2021-22.pdf. Archived from the original (PDF) on 2022-11-08.
{{cite web}}: Missing or empty|title=(help) - ↑ 26.0 26.1 26.2 26.3 26.4 26.5 26.6 26.7 (PDF) https://web.archive.org/web/20240125045719/https://www.tatasteel.com/media/18370/tata-steel-ir-2022-23.pdf. Archived from the original (PDF) on 2024-01-25.
{{cite web}}: Missing or empty|title=(help) - ↑ 27.0 27.1 27.2 27.3 (PDF) https://web.archive.org/web/20241206013536/https://www.tatasteel.com/investors/integrated-report-2023-24/pdf/tata-steel-limited-ir-2024.pdf. Archived from the original (PDF) on 2024-12-06.
{{cite web}}: Missing or empty|title=(help) - ↑ 28.0 28.1 28.2 28.3 https://avenuemail.in/tata-steel-produces-record-20-5-million-ton-steel-in-2023-24-fiscal-md-tv-narendran/.
{{cite web}}: Missing or empty|title=(help) - ↑ 29.0 29.1 29.2 29.3 29.4 29.5 29.6 29.7 (PDF) https://www.tatasteel.com/media/23971/ir-fy2024-25.pdf.
{{cite web}}: Missing or empty|title=(help) - ↑ 30.0 30.1 30.2 https://web.archive.org/web/20220326060904/http://spongeironindia.com/members.php. Archived from the original on 2022-03-26.
{{cite web}}: Missing or empty|title=(help) - ↑ 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 31.14 31.15 31.16 31.17 31.18 31.19 31.20 31.21 31.22 31.23 31.24 https://web.archive.org/web/20200801154548/http://tatasteelbsl.co.in:80/historynew.html. Archived from the original on 2020-08-01.
{{cite web}}: Missing or empty|title=(help) - ↑ 32.0 32.1 32.2 https://studylib.net/doc/5535054/design-features-of-indian-blast-furnaces.
{{cite web}}: Missing or empty|title=(help) - ↑ 33.0 33.1 33.2 https://web.archive.org/web/20220525172438/http://www.meconlimited.co.in/Metals/Iron_Making.aspx. Archived from the original on 2022-05-25.
{{cite web}}: Missing or empty|title=(help) - ↑ https://www.seaisi.org/details/24826?type=news-rooms.
{{cite web}}: Missing or empty|title=(help) - ↑ https://www.sms-group.com/press-and-media/press-releases/press-release-detail/tata-steel-selects-sms-group-to-spearhead-decarbonization-initiative-with-innovative-coke-oven-gas-injection-technology.
{{cite web}}: Missing or empty|title=(help) - ↑ https://web.archive.org/web/20240610162405/https://www.aist.org/news/steel-news/2024/june/3-7-june-2024/indian-mill-places-order-for-coke-oven-gas-injecti. Archived from the original on 2024-06-10.
{{cite web}}: Missing or empty|title=(help) - ↑ 37.0 37.1 37.2 37.3 37.4 37.5 37.6 37.7 37.8 37.9 https://web.archive.org/web/20220326060904/http://spongeironindia.com/members.php.
{{cite web}}: Missing or empty|title=(help) - ↑ 38.0 38.1 38.2 38.3 38.4 38.5 38.6 38.7 38.8 38.9 "2021 World Direct Reduction Statistics" (PDF). Midrex. 2022-09-01. Archived from the original (PDF) on 2022-10-08.
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{{cite web}}: Missing or empty|title=(help) - ↑ 40.0 40.1 https://web.archive.org/web/20220119232244/https://www.moneycontrol.com/news/business/tata-metaliks-kharagpur-plant-ramp-up-to-be-complete-by-fy21-4378351.html. Archived from the original on 2022-01-19.
{{cite web}}: Missing or empty|title=(help)
