Steel Authority of India Limited (SAIL) is the leading steel-making company

in India. It is a fully integrated iron and steel maker, producing both basic and

special steels for domestic construction, engineering, power, railway,

automotive and defense industries and for sale in export markets.

Ranked amongst the top ten public sector companies in India in terms of

turnover, SAIL manufactures and sells a broad range of steel products,

including hot and cold rolled sheets and coils, galvanised sheets, electrical

sheets, structurals, railway products, plates, bars and rods, stainless steel and

other alloy steels. SAIL produces iron and steel at five integrated plants and

three special steel plants, located principally in the eastern and central regions

of India and situated close to domestic sources of raw materials, including the

Company's iron ore, limestone and dolomite mines. The company has the

distinction of being India‟s largest producer of iron ore and of having the

country‟s second largest mines network. This gives SAIL a competitive edge in

terms of captive availability of iron ore, limestone, and dolomite which are

inputs of steel making in the every integrated plant of SAIL.

SAIL's wide range of long and flat steel products are much in demand in the to

clients world-wide domestic as well as the international market. This vital

responsibility is carried out by SAIL's own Central Marketing Organization

(CMO) and the International Trade Division. CMO encompasses a wide

network of 34 branch offices and 54 stockyards located in major cities and

towns throughout India .

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With technical and managerial expertise and know-how in steel making gained

over four decades, SAIL's Consultancy Division (SAILCON) at New Delhi

offers services. SAIL has a well-equipped Research and Development Centre

for Iron and Steel (RDCIS) at Ranchi which helps to produce quality steel and

develop new technologies for the steel industry. Besides, SAIL has its own in-

house Centre for Engineering and Technology (CET), Management Training

Institute (MTI) and Safety Organization at Ranchi. Our captive mines are under

the control of the Raw Materials Division in Kolkata. The Environment

Management Division and Growth Division of SAIL operate from their

headquarters in Kolkata. Almost all our plants and major units are ISO

Certified.

MAJOR UNITS

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

• IISCO Steel Plant (ISP) in West Bengal

Special Steel Plants

• Alloy Steels Plants (ASP) in West Bengal

• Salem Steel Plant (SSP) in Tamil Nadu

• Visvesvaraya Iron and Steel Plant (VISL) in Karnataka

Subsidiary

• Maharashtra Elektrosmelt Limited (MEL) in Maharashtra

Joint Ventures

SAIL has promoted joint ventures in different areas ranging from power plants

to e-commerce.

NTPC SAIL Power Company Pvt.Ltd

A 50:50 joint venture between Steel Authority of India Ltd. (SAIL) and

National Thermal Power Corporation Ltd. (NTPC Ltd.), it manages the captive

power plants at Rourkela, Durgapur and Bhilai with a combined capacity of 314

megawatts (MW).

Bokaro Power Supply Company Pvt.Limited

This 50:50 joint venture between SAIL and the Damodar Valley Corporation

formed in January 2002 is managing the 302-MW power generation and 1880

tonnes per hour steam generation facilities at Bokaro steel plant.

Ownership and management

The Government of India owns about 86% of SAIL's equity and retains voting

control of the Company. However, SAIL, by virtue of its „Navratna‟ status,

enjoys significant operational and financial autonomy

SAIL TODAY

SAIL today is one of the largest industrial entities in India. Its strength has been

the diversified range of quality steel products catering to the domestic, as well

as the export markets and a large pool of technical managerial and today, the

accent in SAIL is to continuously adapt to the competitive business

environment and excel as a business organization, both within and outside India

BOKARO STEEL PLANT

Bokaro Steel Plant (BSL), situated in the coal belt of Eastern India Symbolizes

India‟s advancement in the design; engineering and equipment suppliers have

played a major role in its construction, making it the first indigenous public

sector integrated steel plant in India.

History of the company

Bokaro Steel Plant - the fourth integrated plant in the Public Sector – started

taking shape in 1965 in collaboration with the Soviet Union. It was originally

incorporated as a limited company on 29th January 1964, and was later merged

with SAIL, first as a subsidiary and then as a unit, through the Public Sector

Iron & Steel Companies (Restructuring & Miscellaneous Provisions) Act 1978.

The construction work started on 6th April 1968.The Plant is hailed as the

country‟s first Swadeshi steel plant, built with maximum indigenous content in

terms of equipment, material and know-how. Its first Blast Furnace started on

2nd October 1972 and the first phase

of 1.7 MT ingot steel was completed on 26th February 1978 with the

commissioning of the third Blast Furnace. All units of 4 MT stage have already

been commissioned and the 90s' modernization has further upgraded this to 4.5

MT of liquid steel. The new features added in modernization of SMS-II include

two twin-strand slab casters along with a Steel Refining Unit. The Steel

Refining Unit was inaugurated on 19th September, 1997 and the Continuous

Casting Machine on 25th April, 1998. The modernization of the Hot Strip Mill

saw addition of new features like high pressure de-scalars, work roll bending,

hydraulic automatic gauge control, quick work roll change, laminar cooling etc.

New walking beam reheating furnaces are replacing the less efficient pusher

type furnaces.

A new hydraulic coiler has been added and two of the existing ones revamped.

With the completion of Hot Strip Mill modernization, Bokaro is producing top

quality hot rolled products that are well accepted in the global market. Bokaro is

designed to produce flat products like Hot Rolled Coils, Hot Rolled Plates, Hot

Rolled Sheets, Cold Rolled Coils, Cold Rolled Sheets, Tin

Mill Black Plates (TMBP) and Galvanized Plain and Corrugated (GP/GC)

Sheets. Bokaro has provided a strong raw material base for a variety of modern

engineering industries including automobile, pipe and tube, LPG cylinder,

barrel and drum producing industries. Bokaro Steel values its people as the

fulcrum of all organizational activities. The saga of Bokaro Steel is the story of

Bokaroans erecting a gigantic plant in the wilderness of Chhotanagpur, reaching

milestones one after another, staving off stiff challenges in the liberalized era,

modernizing its facilities and innovating their way to the top of the heap.Bokaro

Steel is working towards becoming a one-stop-shop for world-class flat steel in

India. The modernization plans are aimed at increasing the liquid steel

production capacity, coupled with fresh rolling and coating facilities. The new

facilities will be capable of producing the most premium grades required by the

most discerning customer segments. Brand Bokaro will signify assured quality

and delivery, offering value for money to the customers.

VISION & MISSION STATEMENT

VISION:

To be a respected world Class Corporation and the leader in Indian steel

business in quality, productivity, profitability and customer satisfaction.

MISSION:

Consistent with the corporate vision and core values, Bokaro steel plant

strives to create sustainable long term competitive advantages by

managing, mobilizing, inspiring and motivating its employees for

continuous growth in productivity, quality and profitability leading to

total customer satisfaction.

Bokaro steel plant recognizes that through the process of competences

building, people involvement, unleashing and leveraging the creative

energies of our people, we can create value for organization and exceed

the needs and expectation of our stakeholders.

Bokaro steel plant committed to safety, health and environment friendly

operation and practices for its people as well as personal touch in all

people initiative and interaction to bring since of togetherness and pride

we believes people create value when they feel valued.

TOTAL SALEABLE STEEL-3780 000 TONNES.

CORE VALUES

Customer satisfaction

Concern for people

Consistent profitability

Commitment to excellent

STEEL MAKING PROCESS IN BOKARO STEEL PLANT

The process of producing steel starts from extracting the iron ore and ends at

rolling the sheets of steel of various dimensions. In the process of production of

steel a major part of HUMAN RESOURCE of BOKARO STEEL PLANT is

used. In the plant there are a total of 5 blast furnaces for the purification of iron.

The capacity of 1 blast furnace is 2640-3000 tones for 1 day. So Bokaro Steel

Limited produces about 15000 tones of steel/day.

In the first step of production of steel first of all iron-ore (bauxite) is mixed

with sinter, lime-stone and coke. Now this mixture of iron – ore is being filled

in blast-furnace and from the lower part of the blast-furnace hot air is

blowed.Due to the effect of this hot air the coke which was being filled in the

blast-furnace starts to burn and at this burning of coke produces near about 1350

degree Celsius to 1400 degree Celsius temperature. Due to this huge

temperature the iron-ore which is inside the furnace starts to melt an dmany

chemical reactions takes place . Now due to this melting of iron-ore and by the

effect of chemical reactions the iron-ore is separated from the mixture and the

melted form of iron is taken out in the bottom of furnace.

The waste material which is present in the melted form of iron is called slag.

This slag is lighter than the iron and this slag is being separated by the process

of physical separation.

In the second step the melted form of iron is taken into a “V” shaped container

which is called LADLES. The capacity of these ladles is near about 100 tons

each. These ladles are attached to railway engines, in this step the ladles are

taken to SMS (STEEL MELTING SHOP).

Now in third step, the melted iron is being charged to a container which is

called CONVERTER. In these converters the iron is being mixed with oxygen

and the converter is rotated in 360 degree rotation, here the temperature is near

about 2000 degree Celsius. In Bokaro Steel Limited there are two steel melting

shops. These SMS‟s are known as SMS-1 and SMS-2.The capacity of steel

produced from SMS-1 is 400 MTand SMS-2 is near about double of SMS-

1.Here the steel which is being produced is called the crude steel. This crude

steel is now taken into containers which are called as ingots.

Now in fourth step, this steel which is produced till now from Steel Melting

Shop is in melted form. This melted form of steel is taken to strip yard where

the steel is being hardened by keeping the ingots in open atmosphere.

In the fifth step, the hardened steel is taken up to the Slabbing Mill. Here the

Slabbing Mill the ingots are being rolled and converted in the form of slabs. The

dimension of slab which we get from the Slabbing Mill is as follows:

a) Length: 200-210 meters

b) Thickness: 1.5 mm – 4.6 mm

c) Breadth: 7.5 mm-12 mm

In the sixth step now the steel which we get from the Slabbing Mill is being

shaped according to deemed of the customers. For example if the demand of the

steel is that whose thickness is 1mm – 4.5 mm.Then the slab of steel is being

taken to the Hot Strip Mill. Here the steel is being rolled and the dimension of a

single slab is charged into

a)Length:1.00 Kms – 1.5 Kms

b)Thickness:1.5 mm – 1.6 mm

c) Breadth: 7.5m – 12 m

Now, we get the steel which is saleable form and lastly the steel is being

transferred to the Marketing Department.

Raw Materials & Material Handling Plant

The Raw Materials and Material Handling Plant receives blends, stores and

supplies different raw materials to Blast Furnace, Sinter Plant and Refractory

Materials Plant as per their requirements. It also maintains a buffer stock to take

care of any supply interruptions.

Some 9 MT of different raw materials viz. Iron ore fines and lumps, Limestone

(BFand SMS grade), Dolomite lumps and chips, hard Coal and Manganese ore

are handled here every year. Iron ore and fluxes are sourced from the captive

mines of SAIL situated at Kiriburu, Meghahataburu, Bhawanathpur, Tulsidamar

and Kuteshwar. Washed coal is supplied from different washeries at Dugda,

Kathara, Kargali and Giddi, while raw coal is obtained from Jharia coalfields.

Coke Oven and By Product Plants

The Coke Oven Complex at Bokaro converts prime coking coal from Jharia,

Dugda and Moonidih and medium coking coal form Kargali, Kathara and

Mahuda, blended with imported coal, into high quality coke for the Blast

Furnaces, recovering valuable by-products like Anthracene Oil, Benzene,

Toluene, Xylene, Light Solvent Naphtha, Ammonium Sulphate and Extra-hard

Pitch in the process. Bokaro is situated in the prime coal belt of the country. The

Coke Oven battery has 8 batteries with 69 ovens each, maintained meticulously

in terms of fugitive emission control, use of phenolic water and other pollution

control measures.

Blast Furnaces

Bokaro steel plant has five 2000-cubic metre Blast Furnaces that produce

molten iron - Hot Metal - for steel making. Bell-less Top Charging, modernised

double Cast Houses, Coal Dust Injection and Cast House Slag Granulation

technologies have been deployed in the furnaces. The process of iroin-making is

automated, using PLC Charging System and Computer Controlled Supervision

System. The wastes products like Blast Furnace slag and gas are either used

directly within plant or processed forrecycling re-use.

Steel Melting Shops

Hot Metal from the Blast Furnaces is converted into steel by blowing 99.5%

pure Oxygen through it in the LD converter. Suitable alloying elements are

added to produce different grades of steel.Bokaro has two Steel Melting Shops -

SMS-I and SMS-II. SMS-I has 5 LD converters of 130T capacity each. It is

capable of producing Rimming steel through the ingot route. SMS-II has 2 LD

converters, each of 300 T capacity, with suppressed combustion system and

Continuous Casting facility. It produces various Killed and Semi-Killed steels.

Continuous Casting Shop

The Continuous Casting Shop has two double-strand slab casting machines,

producing high quality slabs of width ranging from 950 mm to 1850 mm. CCS

has a Ladle Furnace and a Ladle Rinsing Station for secondary refining of the

steel. The Ladle Furnace is used for homogenising the chemistry and

temperature. The concast machines have straight moulds, unique in the

country,to produce internally clean slabs.

Argon injection in the shroud and tundish nozzle prevent re-oxidation and

nitrogen pick-up, maintaining steel quality. The eddy current based automatic

mould level control, unique in the country, gives better surface quality. The air

mist cooling and continuous straightening facilities keep the slabs free from

internal defects like cracks. The casters are fully automated with dynamic

cooling, on-line slab cutting, de-burring and customised marking. The shop is

equipped with advanced Level-3 automation and control systems for

scheduling, monitoring and process optimisation.

CCS produces steel of Drawing, Deep Drawing, Extra Deep Drawing, Boiler

and Tin Plate quality. It also produces low alloy steels like LPG, WTCR,

SAILCOR and API Grade.

Slabbing Mill:-

Slabbing Mill transforms ingots into slabs by rolling them in its 1250 mm

Universal Four-High Mill. The rolling capacity of the Mill is 4 MT per annum.

The shop has Hot and Cold Scarfing Machines and 2800 T Shearing Machine.

Controlled heating in Soaking Pits, close dimensional accuracy during rolling

and hot and cold scarfing help produce defect-free slabs.

Hot Strip Mill

Slabs from CCS and Slabbing Mill are processed in the state-of-the-art Hot

Strip Mill. The fully automatic Hot Strip Mill with an annual capacity of 3.363

million tonnes has a wide range of products - thickness varying from 1.2 mm to

20 mm and width from 750 mm to 1850 mm. The mill is equipped with state-of-

the-art automation and controls, using advanced systems for process

optimisation with on-line real time computer control, PLCs and technological

control systems.

Walking Beam Reheating Furnaces provide uniform heating with reduction in

heat losses, ensuring consistency in thickness throughout the length. High-

pressure De-scaling System helps eliminate rolled-in scale. Edgers in the

roughing group maintain width within close tolerance. The roughing group has

a roughing train of a Vertical Scale Breaker, one 2-high Roughing Stand and

four 4-high Universal Roughing Stands. The finishing group consists of a

Flying Shear, Finishing Scale Breaker and seven 4-high Finishing Stands.

Hydraulic Automatic Gauge Control system in the finishing stands ensures

close thickness tolerance. The Work Roll Bending System ensures improved

strip crown and flatness. The rolling speed at the last finishing stand is between

7.5-17.5 metres per second. The Laminar Cooling System is a unique feature to

control coiling temperature over a wide range within close tolerance. The

Hydraulic Coilers maintain perfect coil shape with On-line Strapping system.

On-line Robotic Marking on the coil helps in tracking its identity.

Hot Rolled Coil Finishing

All the Hot Rolled coils from the Hot Strip Mill are received in HRCF for

further distribution or despatch. HR Coils rolled against direct shipment orders

are sheared and finished to customer-required sizes and despatched to

customers. The material is supplied as per Indian specifications and many

international/ foreign specifications. The shop has two shearing lines with

capacities of 6,45,000 Tonnes/ year and 4,75,000 Tonnes/ year respectively.

Cold Rolling Mill :

The Cold Rolling Mill at Bokaro uses state-of-the-art technology to produce

high quality sheet gauge material, Tin Mill Black Plate and Galvanised

Products. Cold rolling is done to produce thinner gauge strips of very smooth

and dense finish, with better mechanical properties than hot rolling strips.

Rolling is done well below re-crystallization temperature without any prior

heating of the material. The products of CRM are used for deep drawing

purposes, automobile bodies, steel furnitures, drums and barrels, railway

coaches, other bending and shaping jobs and coated steels. The CRM complex

comprises of two Pickling Lines (including a high speed Hydrochloric Acid

Pickling Line with re-generation facilities), two Tandem Mills, an Electrolytic

Cleaning Line, a Continuous Annealing Line, Bell Annealing Furnaces, two

Skin-Pass Mills, a Double Cold Reduction Mill (DCR), Shearing Lines, Slitting

Lines and a packaging and despatch section. The 5-stand Tandem Mill is

capable of rolling sheet gauges upto 0.15 mm thickness. It has sophisticated

Hydraulic Automatic Gauge Control, computerised mill regulation and

optimization control.

Hot Dip Galvanizing Complex

The Hot Dip Galvanizing Complex integrated with the CRM produces zinc-

coated Cold Rolled strips resistant to atmospheric, liquid and soil corrosion. The

Continuous Coil Corrugation Line in the HDGC produces corrugated sheets and

the Galvanised Sheet Shearing Line produces galvanised plain sheets for a

variety of applications. The first shop of Bokaro Steel to get the SO-9001

certification way back in 1994, this complex has maintained a high-standard of

coating quality and its SAILJYOTI branded products enjoy a loyal market.This

complex made certain innovations for higher productivity to help re-build

earthquake-ravaged Gujarat.

Services- a valuable support network

The service departments like Traffic, Oxygen Plant, Water Management and

Energy Management provide invaluable support to this gigantic plant. Bokaro

Steel has a vast networked of railway tracks and over 40 diesel locos to

smoothly run its operations. The Oxygen Plant provides Oxygen, Nitrogen and

Argon for processes like steelmaking and annealing. Water Management looks

after the huge water requirements of the plant and the township, providing

different grades of water and taking care of recycling needs. Energy

Management juggles the supply and demand of by-product gases and their

demand as process fuel.