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Operations

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Essar Steel's world-class, integrated steel facilities produce products that cater to leading global companies across sectors

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Essar Steel has fully integrated operations that span the entire value chain of steel making, from mining to retail, and a total production capacity of 14 MTPA. We hold the distinction of owning and operating the world's fourth largest single-location flat steel plant, located at Hazira (Gujarat). We also have a completely integrated distribution business consisting nine steel processing and distribution centers with an aggregate capacity of over 5 MTPA.

INDIA OPERATIONS
A major strategic advantage is our high level of forward and backward integration. We are totally integrated – from raw material to finished products – adding value at every stage of the manufacturing process.

Bailadilla facility: Iron ore beneficiation
At Bailadilla (Chhattisgarh), where some of the world's richest and finest ore is available, we have set up a beneficiation plant of 8 MTPA capacity, which ensures the highest quality iron ore. Iron ore slurry is pumped through a 267-km pipeline (the second longest in the world) to the pellet plant at Visakhapatnam (Andhra Pradesh), yielding advantages in quality, cost and real-time inventory management.

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Dabuna facility: Iron ore beneficiation
We have set up a 12 MTPA beneficiation plant in Dabuna (Odisha) which benefits from close access to the rich iron ore reserves in the state. A 253km slurry pipeline transports the raw material to the pellet plant at Paradip (Orissa).

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Visakhapatnam facility: Pelletization
Iron ore slurry is received at our pellet plant at Visakhapatnam, which has a capacity of 8 MTPA, providing vital raw material for our steel plant at Hazira (Gujarat).

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Paradip facility: Pelletization
A 6 MTPA pellet plant was commissioned in April 2012, which has an assured supply of high-quality iron ore from the beneficiation plant at Dabuna. The plant's proximity to the Paradip port ensures that the pellets are quickly shipped to our steel plant in Hazira. The plant is the first phase of the 12 MTPA integrated facility being set up in the state.

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Hazira facility: Sponge iron
Our steel complex at Hazira (Gujarat) houses a 6.8 MTPA sponge iron plant, the world's largest gas-based sponge iron plant in a single location. The plant provides raw materials for our state-of-the-art 7.5 MTPA hot rolled coil (HRC) plant, the first and largest of India's new-generation steel mills.

This plant is fed with inputs from four electric arc furnaces and three casters. The complex's sophisticated infrastructure includes independent water supply and power, oxygen and lime plants, a township and a captive port capable of handling up to 8 MTPA of cargo with modern handling equipment including barges and floating cranes.

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Hazira facility: Steel
Our steel complex at Hazira (Gujarat), houses a 10 MTPA steel plant, which is the largest single-location flat steel producer in India and the fourth largest single-location flat steel producer globally. The plant is supported by a complete infrastructure setup, including a captive port, power plant, lime plant and oxygen plant.

The plant's downstream facilities include:

Plate Mill
Essar Steel's state-of-the-art plate mill has a capacity of 1.5 MTPA, making it the largest in India. The plant produces plates in strength levels of 1,500 MPa and widths up to 5,000mm, which establishes it as one of the widest plate mills in the world. Essar plates undergo close process metallurgy and chemistry, keeping in mind the specific requirements of different application segments. The state-of-the art plant is not only capable of producing high-quality plates but also conforms to 'clean steel' norms prescribed by all leading international standards agencies.

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Pipe Mill
The Pipe Mill has a combined capacity of 0.6 MTPA of helical submerged arc welded (HSAW) and longitudinal submerged arc welded (LSAW) steel pipes along with internal and external coating facilities of up to 2 million square meters annually. This pipe making facility is backed by external and internal anti-corrosion coating facilities, including the country's first coating plant capable of coating pipes of up to 134" (11.16 ft) diameter.

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Cold rolling complex
At the other end of the value chain, our downstream facilities include a 1.4 MTPA cold rolling complex, which adds further muscle to our steel making facilities. The complex comprises two pickling lines of 1.4 MTPA capacity, a reversing mill and a 1.2 MTPA tandem mill, two galvanizing lines of an aggregate capacity of 0.5 MTPA, a batch annealing furnace of 0.7 MTPA, and a skin pass mill of 1.0 MTPA. This enables us to get into the genre of products that are tailor-made for the automotive, white goods, shipbuilding, agriculture and construction industries - segments that had been the exclusive domain of a few international manufacturers. Essar now holds leadership position in the cold rolling, galvanizing and pre-coated segments.

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Pune facility: Steel processing
We have a 0.6 MTPA cold rolling plant, 0.5 MTPA galvanizing plant, 0.4 MTPA color coating plant, and a 0.65 MTPA pickling line at Pune (Maharashtra).

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Distribution outlets
Essar Steel is the first steel company to set up an end user distribution chain for steel products under the brand names Essar Hypermart and Essar Expressmart. It has a strong network of over 600 steel retail outlets. These outlets are conveniently located across the length and breadth of the country to cater to the customized requirements of small and medium enterprises.

Hypermarts offer a comprehensive range of flat and long steel products for a variety of applications. Other product lines, such as structural and tubular products, are also being developed to make Essar Hypermart a one-stop shop for steel products.

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Services (across India)
Essar Steel has the largest steel processing and distribution facilities in India with an aggregate annual capacity of 4 million tonnes from its facilities in Pune (Maharashtra), Hazira (Gujarat), Bahadurgarh (National Capital Region), Chennai (Tamil Nadu), Bhuj (Gujarat) and Dubai (UAE).

INTERNATIONAL OPERATIONS
Essar Steel Algoma, Canada
Established in 1901, Essar Steel Algoma is a fully integrated steel producer based in Sault Ste. Marie (Ontario). With a current production capacity of 4 MTPA, the plant specializes in providing total steel solutions to North American flat roll customers.

The steelworks features a technologically advanced Direct Strip Production Complex (DSPC) – a continuous, thin slab caster coupled with direct hot rolling; a conventional two-strand slab caster capable of producing 8" thick slabs; a 106-inch strip mill that produces a broad range of products up to 96" wide including medium to high carbon grade families, HSLA formable grades, alloy products such as Corten and floor plate; a 166-inch plate mill that produces quality wide plate and features a heat treated plate facility offering a full range of high-quality heat-treated products for abrasion resistant, ballistic and other specialty plate applications; and a cold mill.

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PT Essar Indonesia
PT Essar located in West Java (Jakarta) is Indonesia's largest private sector flat products company, with a domestic market share of 35 per cent and a history of process and product innovation. After a major expansion drive, its cold rolling capacity has been enhanced to 0.4 MTPA and its newly set up galvanizing capacity is 0.15 MTPA. It has a steel processing center with the capacity of 0.2 MTPA and has also set up a Essar Hypermart steel retail outlet.

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Essar Steel Minnesota LLC, USA
Located in north-east Minnesota, the facility has access to some of the finest iron ore reserves in the world. Essar Steel is setting up a Greenfield 7 MTPA integrated integrated pellet plant on the Mesabi iron range, along with a concentration plant and direct reduced iron plant. Essar Steel's strategy is to develop it as an integrated pelletization facility.

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