S4

Vijayanagar

• Commissioned the Coke Oven Battery A of capacity of 0.75 MTPA resulting in reduction of procurement of coke from third parties
• Reduction in coal rate at Corex-1 and Corex-2 due to better operating performance
• Increase in Pulverised Coal Injection (PCI) in Blast Furnace-1 and 4 thereby reducing the BF fuel rate
• Improvement in Zero Power Furnace and EAF yield resulting in reduction in operating cost
• Edge and Bar heater at HSM-2, to achieve uniform temperature across the width and length before rolling at finishing mill for improvement in quality of coils and reduce rejections
• Transportation of 6.3 MnT of iron ore through pipe conveyor resulting in lower logistics cost and an environment friendly and efficient solution for transportation of iron ore to the plant
• Usage of corex fines as a replacement of PCI coal resulting in lower hot metal costs
• Debottlenecking of BP-2 to enable handling of 50,000 tpd of low-grade iron ore resulting in usage of iron ore with lower Fe quality and consequent reduction in operating costs
• Produced in house LHF Slag Briquettes to replace the purchase of synthetic slag

Dolvi

• The cost of production from the newly expanded capacity of 5 MTPA is lower due to better operating efficiencies, lower fuel rate at Blast Furnace 2, lower operating costs at SMS 2 and lower power costs as the power is generated by harnessing the waste heat.
• Commissioned the 175 MW Waste Heat Recovery Boilers (WHRB) and a 60 MW captive power plant to harness flue gases and steam from CDQ. These power plants are catering to the power requirements of the Phase II expansion. These plants operate through the waste gases and heat generated from operations, an environmentally friendly and cost-efficient source
• Cost efficiencies have been achieved with increase in PCI rate per tonne of steel, resulting in savings in solid fuel rate
• Increased the use of pellets to sinter feed for better yield

Salem

• Higher coal fines usage in BF by optimising the process parameters resulting in lower operating costs
• Eliminating the delay in reversible mill manipulator resulting in increased productivity
• Reducing the return fines generation in SP#2
• Reducing fuel rate in BF#1 through process optimisation
• Improving the WHRP#5 steam generation
• Increasing PCI rate in BF through coal line modifications
• Reducing coal handling loss in coke oven plant