JSW Steel Vijayanagar steel plant

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JSW Steel Vijayanagar steel plant, also known as JSW Steel Toranagallu, Vijayanagar Works, JSW Karnataka steel plant, JVSL, is a steel plant in Toranagallu, Sandur, Bellary, Karnataka, India that operates ironmaking, blast furnace (BF), basic oxygen furnace (BOF), electric arc furnace (EAF), and direct reduced iron (DRI) technology.

Location

The map below shows the exact location of the plant in Toranagallu, Sandur, Bellary, Karnataka, India:

Loading map...
  • Location: Sandur Taluk, Vijyanagar Post, Bellary, Toranagallu, Karnataka 583275, India
  • Coordinates (WGS 84): 15.180423, 76.663134 (exact)

Background

The JSW Steel Vijayanagar steel plant began operating in 1994 and is the world sixth-largest steel plant. It was expanded in 1999, 2004, 2006, and 2009. According to the JSW Steel website, the plant reuses more than 95% of its process waste.[1]

In 2011, the blast furnaces at the plant were briefly shut down due to the unavailability of iron ore after an iron ore mining scam in Karnataka.[2]

In 2012, three workers were killed with another receiving serious injuries after an accident involving hot iron ore residue.[3]

Expansion

In 2018, original expansion plans were announced it would invest Rs 7,500 crore from then until March 2020 for expansions, in the effort to increase capacity to 18 million tonnes per year.[4]

In 2020, JSW Steel announced that it was planning to establish a new EAF at the Vijayanagar plant, which would be commissioned by March 2021.[5] However, no updates have been published regarding the commissioning of this EAF as of February 2022.

According to 2021 JSW Corporate Presentation, the expansion of the plant capacity from 12 mtpa to 13 mtpa at a cost of INR 380 crore by augmenting existing facilities was ongoing.[6] According to the 2023 JSW Corporate Presentation, debottlenecking of existing facilities completed in FY23 resulted in a capacity expansion of 0.5 mtpa, further 0.5 mtpa expansion through debottlenecking is expected to be completed in FY25. The presentation also mentioned expansion of existing facilities by 1.5 mtpa in FY25.[7]

In January 2022, JSW Steel announced it would invest ₹15,000 crore to expand its Vijayanagar Works Integrated Steel Facility in Ballari, Karnataka, to 18 million tonnes per year by 2024.[8] They began the construction for this expansion later that month as well.[9] This brown-field expansion is being undertaken through JSW Vijayanagar Metallics Ltd, a wholly owned subsidiary of JSW Steel Ltd.[10][11] It is unclear whether the two BF/BOF expansions they have planned (one 400 ttpa expansion planned for 2022 and another 1500-1800 ttpa expansion planned for 2026) will be part of this plan.

As of January 2025, the expansion was not completed.

Financing

The Japan Bank for International Cooperation (JBIC) signed a USD30 million loan for JSW Steel on January 9, 2020 in order to expand JSW Steel Vijayanagar. The funds from JBIC are intended to be used to purchase a wire rod mill from Primetals Technologies Limited.[12]

Decarbonization

JSW Steel has partnered with JSW Energy to set up a 3,800 tpa green hydrogen plant using 25 MW of renewable energy to be supplied to the DRI plant in JSW Steel Vijayanagar steel plant.[13]

JSW Steel Limited and JFE Steel Corporation in July 2024, commenced pilot demonstration of cloud-based Cyber-Physical System technologies for blast furnace operations at JSW Steel Vijayanagar Works. Through this digital project, JSW Steel will leverage data science technologies in a cloud environment to enhance efficiency of its blast furnace operations in the manufacturing of steel and reduce carbon emissions.

Low-emissions/green steelmaking

This steel plant is associated with a green steel project tracked in the Green Steel Tracker. Details about the project are included below.

Table 1: Green Steel Project Details

All references for the above data are available in the Green Steel Tracker.
Project 1
Project name BHP x JSW Steel CycloneCC
Company JSW Steel Limited
Company has climate goals? Yes
Location Not stated, India
Project website Not available
Project scale R&D partnership
Project status Announced
Year to be online 2026
Technology to be used CCU for BF-BOF
Technology details CycloneCC
Iron production capacity (million tonnes per year) Not stated
Steel production capacity (million tonnes per year) Not stated
CO2 capture (million tonnes CO2 per year) 0,1
Hydrogen generation capacity (MW) Not stated
Investment size (m USD) Not stated
Partners BHP, Carbon Clean
Date of announcement 2024-10-10

Plant Details

Table 2: General Plant Details

Start date Workforce size Power source Iron ore source Coal source
1994[14] 929[15] JSW Vijayanagar Toranagallu power station; 860MW power plant in Vijaynagar consisting of 2 130MW units in SBU I (2000) and 2 300MW units in SBU II (2009), 76 MW captive power plant. Also recycles 96% of coke oven gas for power generation.[16][17][14][18] Captive mines in Odisha and Karnataka[19] unknown

Table 3: Ownership and Parent Company Information

State-owned entity status Parent company Parent company PermID Parent company GEM ID Owner Owner company PermID Owner company GEM ID
Partial JSW Steel Ltd 4295872888 E100001000516 JSW Steel Ltd[20] 4295872888 E100001000516

Table 4: Process and Products

Steel product category Steel products Steel sector end users Main production equipment
semi-finished, finished rolled[20] galvanized, wire rod, bar, cold rolled, special, hot rolled[20] building and infrastructure[21] BF; DRI; BOF; EAF; Iron other/unspecified

Table 5: Plant-level Crude Steel Production Capacities (thousand tonnes per annum)

1Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Capacity operating status1 Basic oxygen furnace steelmaking capacity Electric arc furnace steelmaking capacity Nominal crude steel capacity (total)
announced 1500[22] 1500[22]
operating 10399[23][21] 1500[24] 11899[24][23][21]

Table 6: Plant-level Crude Iron Production Capacities (thousand tonnes per annum)

1Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Capacity operating status1 Blast furnace capacity Sponge iron/DRI capacity Other/unspecified iron capacity Nominal iron capacity (total)
operating 8500[25][26][23][21] 1200[27][28][21] 1700[23] 11400[25][23][21][27][26][28]
operating pre-retirement 2170[25][23][29] 2170[25][23][29]

Table 7: Upstream Products Production Capacities (thousand tonnes per annum)

Sinter Coke Pellets
12950[30] 6500[21][23] 9200[30]

Table 8: Actual Plant-level Crude Steel Production by Year (thousand tonnes per annum)

Year BOF production EAF production Total (all routes)
2019 unknown[31] unknown[31] [31]
2020 8600 1240 9840
2021 9334[19] 1346[19] 10680[19]
2022 9180[32] 1350[32] 10530[32]
2023 9387[33] 1380[33] 10767[33]

Table 9: Actual Plant-level Crude Iron Production by Year (thousand tonnes per annum)

Year BF production DRI production Other/unknown iron production Total (all routes)
2019 unknown unknown unknown
2020 unknown unknown unknown
2021 unknown unknown unknown
2022 unknown unknown unknown
2023 11196[33] 1104[33] 1564[33] 13864[33]

Unit Details

Table 10: Blast Furnace Details

Unit name Status Construction date Start date Furnace manufacturer and model Current size Current capacity (ttpa) Decarbonization technology Most recent relining
BF 1 operating[21] 2004[34][25] MECON (Govt. of India)[30][35] 2300.0 m3[29] 2500[23] unknown[36] 2016-02-08[37]
BF 2 operating pre-retirement[38] 2006[25] MECON (Govt. of India), Daniel Corus[30][35] 1250.0 m3[35] 2170[29][25][23] unknown[36]
BF 3 operating[21] 2006[39] 2009[40] Primetals Technologies, Siemens VAI Primetals Technologies Blast Furnace Design[30][40][40] 4019.0 m3[41][21] 3000[26][21][25] Trialing waste plastic injection at the unit[36][42] 2026[43]
BF 4 operating[21] 2011[40] Primetals Technologies, Siemens VAI Primetals Technologies Blast Furnace Design[30][40][40] 4019.0 m3[29] 3000[21][25] unknown[36]

Table 11: Direct Reduced Iron Furnace Details

Unit name Status Start date Furnace manufacturer and model Furnace type Current capacity (ttpa) Reductant
unknown DRI (1) operating[23] 2014[44] Midrex[44] shaft furnace[44] 1200[27][21][28] methane[45][46]

Table 12: Electric Arc Furnace Details

Unit name Status Announced date Start date Furnace manufacturer and model Current capacity (ttpa) Current size (tonnes)
unknown EAF (1) operating[47] 2016[48] 1500[24] 150.0[49][14][50][27][51][21][28]
unknown EAF (2) announced[22] 2022[22] 2025[22] ZPF[52] 1500[22] 160.0[26][24]

Table 13: Electric Arc Furnace Feedstock Details

Unit name Scrap-based % scrap % DRI % HBI % sponge iron (unknown if DRI or HBI) % basic/merchant pig iron % granulated pig iron % pig iron (unknown if basic/merchant or granulated % other iron
unknown EAF (1) yes[53][54] 8.00[53][54] >0[53] >0[53] 92.00[53]
unknown EAF (2) yes[54] 8.00[54] unknown unknown unknown >0 unknown unknown 92.00

Table 14: Basic Oxygen Furnace Details

Unit name Status Announced date Start date Furnace manufacturer and model Current capacity (ttpa) Current size
unknown BOF (1) operating[47] 1994[55] 2001[48] SMS Demag LD Converter[30][56] 1333[21][23] 130.0 tonnes[49][14][50][27][51][21][28]
unknown BOF (2) operating[47] 2004[48] SMS Demag LD Converter[30][56] 1333[21][23] 130.0 tonnes[49][14][50][27][51][21][28]
unknown BOF (3) operating[47] 2006[48] SMS Demag LD Converter[30][56] 1333[21][23] 130.0 tonnes[49][14][50][27][51][21][28]
unknown BOF (4) operating[47] 2009[57] SMS Demag LD Converter[30][56] 1600[21][23] 180.0 tonnes[49][14][50][27][51][21][28]
unknown BOF (5) operating[47] 2009[48] SMS Demag LD converter[30][56] 1600[21][23] 180.0 tonnes[49][14][50][27][51][21][28]
unknown BOF (6) operating[47] 2011[48] SMS Demag LD Converter[30][56] 1600[21][23] 180.0 tonnes[49][14][50][27][51][21][28]
unknown BOF (7) operating[47] 2011[48] SMS Demag LD Converter[30][56] 1600[21][23] 180.0 tonnes[49][14][50][27][51][21][28]

Articles and Resources

Additional data

To access additional data, including an interactive map of steel power plants, a downloadable dataset, and summary data, please visit the Global Iron and Steel Tracker on the Global Energy Monitor website.

References

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