We are a fully integrated flat carbon steel manufacturer – from iron ore to ready-to-market products – with a current capacity of 14 million tonnes per annum (MTPA). Our products find wide acceptance in highly discerning consumer sectors such as automotive, white goods, construction, engineering and shipbuilding.
Essar Steel is one of India's largest exporters of flat products, exporting to the highly demanding US and European markets, and to the growing markets of South East Asia and the Middle East.
A number of major client companies have approved our steel for their use, including Caterpillar, Hyundai, Swaraj Mazda, the Konkan Railway, and Maruti Suzuki. Essar Steel has acquired extensive quality accreditations and our lean team gives us one of the highest productivities and lowest manpower costs among steel plants internationally.
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. Our areas of operation include:
Iron ore beneficiation
We have an 8 MTPA plant at Bailadilla (Chhattisgarh) and a 12 MTPA plant at Dabuna (Odisha), both strategically established to leverage the rich iron ore deposits of the respective states. The plants pump the iron ore slurry to Essar Steel pellet plants at Visakhapatnam (Andhra Pradesh; 267 km pipeline) and Paradip (Odisha; 253 km pipeline) respectively.
We have an 8 MTPA pelletization plant at Visakhapatnam and a 6 MTPA pellet plant at Paradip, both of which provide vital raw material to our steel plant at Hazira (Gujarat).
Iron and steel
We have a fully integrated world-class facility at Hazira, housing the world's fourth largest single-location steel plant. It has a steel-making capacity of 10 MTPA, holds ISO: 9001:2000, IS 9002 and TUV, and ISO 140001 certification and is India Chiller Energy Efficiency Project (ICEEP) Protocol compliant.
The facility also houses a 6.8 MTPA sponge iron plant (the world's largest gas-based sponge iron plant in a single location); a 1.5 MTPA plate mill (the largest in India); a 0.6 MTPA pipe mill with with internal and external coating facilities of up to 2 million square meters annually; and a 1.4 MTPA cold rolling complex comprising two galvanizing lines, a batch annealing furnace and a skin pass mill.
We have a downstream capability hub at Pune (Maharashtra),which houses a 0.6 MTPA cold rolling plant, a 0.5 MTPA galvanizing plant, a 0.4 MTPA color coating plant, and a 0.65 MTPA pickling line.
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. Hypermart is the world's largest steel retail chain with a network of over 375 retail outlets across India, Indonesia, Nepal and the Middle East.
Essar Steel's processing and distribution facilities are the largest 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).
Essar Steel Algoma, Canada
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.
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.
Essar Steel Minnesota LLC, USA
Essar Steel is setting up a greenfield 7 MTPA integrated pellet plant on the Mesabi iron range in north-east Minnesota, along with a concentration plant and direct reduced iron plant.