Bhilai Steel Plant
|Type||Central Public Sector|
|Headquarters||Bhilai, Chhattisgarh, India|
The Bhilai Steel Plant, located in Bhilai, in the Indian state of Chhattisgarh, is India's first and main producer of steel rails, as well as a major producer of wide steel plates and other steel products. The plant also produces and markets various chemical by-products from its coke ovens and coal chemical plant. It was set up with the help of the USSR in 1955.
The eleven-time winner of the Prime Minister's Trophy for best integrated steel plant in the country, Bhilai Steel Plant (BSP), has been India's sole producer of rails and heavy steel plates and major producer of structural steel. The plant is the sole supplier of the country's longest rail tracks, which measure 260 metres (850 ft). The plant also produces products such as wire rods and merchant products. Bhilai Steel Plant has been the flagship integrated steel plant unit of the Public Sector steel company, the Steel Authority of India Limited and is its largest and most profitable production facility. It is the flagship plant of SAIL, contributing the largest percentage of profit.
The governments of India and the USSR entered into an agreement, signed in New Delhi on 2 March 1955, for the establishment of an integrated iron and steel works at Bhilai with an initial capacity of one million tons of steel ingot.
The main consideration for choosing Bhilai was the availability of iron ore at Dalli Rajhara, about 100 km from the site; limestone from Nandini, about 25 km from the plant, and dolomite at Hirri, about 140 km away. The plant was commissioned with the inauguration of the first blast furnace by then president of India, Dr. Rajendra Prasad, on 4 February 1959. The plant was expanded to 2.5 million tons in September 1967 and a further expansion to 4 MT was completed in 1988. The main focus in the 4 MT stage was the continuous casting unit and the plate mill, a new technology in steel casting and shaping in India.
The organisational framework
Bhilai Steel Plant functions as a unit of SAIL, with corporate offices in New Delhi. Over the years, Bhilai Steel Plant developed an organizational culture that forces its commitment to values and stimulates continuous improvements and higher levels of performance. The chief executive officer (currently S.Chandrasekharan) controls operations of the plant, township and iron mines. The CEO is assisted by his DROs[clarification needed], i.e. the functional heads, executive directors, general Manager concept of zonal heads, and HODs who integrate functions with clear accountability for achieving corporate vision, company goals and objectives.
Modernization and expansion programs
Projects in progress include a new compressed air station, oxygen plant, new installations to support power requirements and ore handling capacities expansion. Presently, the total requirement of iron ore of Bhilai Steel Plant is met from Dalli Rajhara Iron Ore Complex (IOC). In view of IOC's rapidly depleting reserves, BSP is opening an iron ore mine at Rowghat, about 80 km from Dalli Rajhara in Narayanpur District of Chhattisgarh. Accordingly, Bhilai Steel Plant will develop the mine in Block-A of Deposit-F of Rowghat with a production capacity of 14.0 MT per year during 2011-12. For environmental reasons, the beneficiation plant shall be of dry circuit type. However, the grant of forest clearance under Forest (Conservation) Act, 1980 is still pending.
The product range at Bhilai Steel Plant and their end use/consumers is:
|Product Type||Product||End use / consumers|
|A. FINISHED PRODUCTS||Rail & Structural Mill||Rails in 13m, 26m, 65/78 m length and welded panels of 130m/260m length Indian Railways, Export Heavy Structurals Construction Crane Rails Cranes Crossing sleepers Broad gauge sleepers|
|Merchant Mill||Light structural engineering and construction, medium rounds (plain & TMT), heavy rounds (plain)|
|Wire Rod Mill||Wire rods - plain construction wire rods - TMT EQ wire rods electrodes|
|Plate Mill||Plates boilers, defence, railways, shipbuilding, LPG cylinders, export|
|B. SEMIS||Billets (from BBM)||Re-rollers|
|Blooms (from BBM)|
|Narrow width slabs|
|D.||By products||Coal chemicals, ammonium sulfate (fertiliser), tar and tar products, (pitch, naphthalene, creosote oil, asphalt, anthracene oil, dephenolised oil, PCM etc.), Be|
BSP has taken measures in the areas of waste management, resource utilisation and pollution control and has initiated several waste reduction programmes. Besides reducing greenhouse gas output, BSP is replacing the ozone-depleting CTC, aided by UNDP. BSP has earned Voluntary Emission Reduction (VER), (a sort of carbon credit) for two of its projects. Abiding by Corporate Responsibility for Environment Protection (CREP) guidelines and monitoring, it has taken steps to "check fugitive emissions from Coke Ovens and has installed Air cooled self sealing doors resulting in significant reduction in door emissions" The plant has introduced a de-dusting system, electrostatic precipitators and a coal dust injection system in the blast furnaces and in other units.
Bhilai Steel Plant manages Bhilainagar township which has 13 sectors.
2014 Gas leak tragedy
On June 12, 2014 a gas leakage in Bhilai Steel Plant, killed 7 people including 2 senior officials. Over 50 people got affected due to the accident. The Leakage occurred due to break down in water pump house.
Among dead were two Deputy General Managers while injured included CISF personnel, workers and officials of the public sector plant. The leak started at around 6.10 PM IST.
|Rail & heavy structural||750,000|
|Merchant Products (angles, channels, Rrund & TMT bars)||500,000|
|Wire Rods (TMT, plain & ribbed)||420,000|
|Plates (up to 3600 mm wide)||950,000|
|Total saleable steel||3,153,000|
- "The Bhilai Steel Plant". Field to Factory: Film and ethnography of industrialisation in Chhattisgarah, Central India. Jandarshan and LSE. Retrieved 24 June 2012.
- "BHILAI STEEL PLANT". Steel Authority of India Limited. SAIL, All Rights Reserved. Retrieved 24 June 2012.
- "Bhilai Steel Plant's Modernisation and Expansion Program Gains Momentum". Steel Authority of India Limited. SAIL. Retrieved 24 June 2012.
- "Bhilai Steel Plant gas Leak Accident kills 6 and injures 40". IANS. news.biharprabha.com. Retrieved 13 June 2014.