JSW Steel Vijayanagar steel plant

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JSW Steel Vijayanagar steel plant, also known as JSW Karnataka steel plant; JSW Projects Ltd.; Vijayanagar Works; JVSL, is a blast furnace-basic oxygen furnace (BF-BOF), direct reduced iron (DRI) and electric arc furnace (EAF) steel plant operating in Toranagallu, Karnataka, India.

Location

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

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  • 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.

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.

Plant Details

Table 1: General Plant Details

Phase Plant status Announced date Start date Workforce size Power source Iron ore source
Main plant Operating[14] – 1994[15] 928[16] 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.[15][17][18] Captive mines in Odisha and Karnataka[14]
Expansion Announced[19] 2022[20] 2025[19] – – –

Table 2: Ownership and Parent Company Information

Phase Parent company Parent company PermID Parent company GEM ID Owner Owner company PermID Owner company GEM ID
Main plant JSW Steel Ltd [100%] 4295872888 [100%] E100000001753 [53.2%]; E100001010147 [15%]; E100001010148 [11%]; E100001000520 [7.5%]; E100001000521 [5.9%]; E100001010037 [0.9%]; E100001010033 [0.8%]; E100001010034 [0.7%]; E100001010036 [0.6%]; E100001010035 [0.6%]; E100001001119 [0.6%] JSW Steel Ltd[21] 4295872888 E100001000516

Table 3: Process and Products

Phase Steel product category Steel products Main production equipment Detailed production equipment
Main plant semi-finished; finished rolled[21] hot rolled, cold rolled, bar, galvanized, wire rod, specialty steel[21] BF, BOF, DRI, EAF[15] coking plant; sinter plant; pelletizing plant; 1 Midrex DRI plant (1.2 MTPA, began in 2014); 2 Corex BF-DRI plants (2 C-2000 + Midrex DRI (1.6 MTPA total, began in Aug. 1999 and Apr. 2000)); 7 BOF (3x130-tonne, 4x175-tonne);1 EAF (150-tonne)[15][22][23][24][25][26][27]
Expansion semi-finished; finished rolled[21] hot rolled, cold rolled, bar, galvanized, wire rod, specialty steel[21] EAF[28] ZPF[29]

Table 4: Crude Steel Production Capacities (thousand tonnes per annum)

*Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Phase Capacity operating status* Basic oxygen furnace steelmaking capacity Electric arc furnace steelmaking capacity Nominal crude steel capacity (total)
Main plant operating 10200 TTPA[30][30][30][30][30][30][30] 1500 TTPA[29] 11700 TTPA[30][30][30][30][30][30][30][29]
Expansion announced – 1500 TTPA[19] 1500 TTPA[19]

Table 5: Crude Iron Production Capacities (thousand tonnes per annum)

*Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Phase Capacity operating status* Blast furnace capacity Sponge iron/DRI capacity Nominal iron capacity (total)
Main plant operating 12170 TTPA[30][30][31][32][27][32][33][27][32] 1200 TTPA[24][25][27] 15070 TTPA[30][30][31][32][27][32][33][27][32][24][25][27]
Expansion announced – – –

Table 6: Upstream Products Production Capacities (thousand tonnes per annum)

Phase Sinter Coke Pellets
Main plant 12950 TTPA[34] 6500 TTPA[30][27] 9200 TTPA[34]
Expansion – 3000 TTPA[35][19] –

Table 7: Actual Crude Steel Production by Year (thousand tonnes per annum)

Year BOF Production EAF Production Total (all routes)
2020 – – 9840 TTPA
2021 – – 10680 TTPA[14]
2022 9180 TTPA[36] 1350 TTPA[36] 10530 TTPA

Blast Furnace Details

Table 8: Blast Furnace Details

Unit name Status Announced date Construction date Start date Furnace manufacturer and model Current size Current capacity (ttpa) Decarbonization technology Most recent relining
1 operating[27] unknown unknown 2004[32] MECON (Govt. of India)[37] 2300 m³[31] 2500[30] unknown[38] 2016-02-08[39][40]
2 operating[27] unknown unknown 2006[32] MECON (Govt. of India)[37] 1250 m³[37] 2170[30][31][32] unknown[38] unknown
3 operating[27] unknown unknown 2009-02[41] Primetals Technologies Primetals Technologies Blast Furnace Design[41][41] 5560 m³[27] 4500[27][32][33] Trialing waste plastic injection at the unit[38][42] 2020[33]
4 operating[27] unknown unknown 2011-07[41] Primetals Technologies Primetals Technologies Blast Furnace Design[41][41] 4019 m³[31] 3000[27][32] unknown[38] unknown

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 Steel Plant Tracker on the Global Energy Monitor website.

References

  1. ↑ "Vijayanagar Works - Overview". JSW Steel. Retrieved 2022-02-26.{{cite web}}: CS1 maint: url-status (link)
  2. ↑ "JSW shuts down 2 blast furnaces in Vijayanagar plant". The Economic Times. 2011-08-03. Retrieved 2022-02-26.
  3. ↑ "Three killed in Bellary steel plant accident | Mysuru News - Times of India". The Times of India. Retrieved 2022-02-26.{{cite web}}: CS1 maint: url-status (link)
  4. ↑ Energy World (2018-11-03). "JSW Steel to expand Vijayanagar plant capacity to 18 mn tonnes a year: Sajjan Jindal - ET EnergyWorld". Energy World. Retrieved 2022-02-26.{{cite web}}: CS1 maint: url-status (link)
  5. ↑ "Latest Developments in Steelmaking Capacity" (PDF). OECD. 2021. Retrieved 2022-02-26.{{cite web}}: CS1 maint: url-status (link)
  6. ↑ "JSW Corporate Presentation" (PDF). JSW Steel. December 2021. Retrieved 12 December, 2023. {{cite web}}: Check date values in: |access-date= (help)CS1 maint: url-status (link)
  7. ↑ "JSW Steel Corporate Presentation" (PDF). JSW Steel. May 2023. Retrieved 12 December, 2023. {{cite web}}: Check date values in: |access-date= (help)CS1 maint: url-status (link)
  8. ↑ Livemint (2022-01-07). "JSW Steel to invest ₹15,000 cr expand Vijayanagar facility to 18 MTPA". mint. Retrieved 2022-02-26.
  9. ↑ "Steel Minister lays foundation stone for 5 MTPA project at JSW Steel Vijayanagar works". Free Press Journal. 2022-01-07. Retrieved 2022-02-26.{{cite web}}: CS1 maint: url-status (link)
  10. ↑ "Steel Minister lays foundation stone for 5 MTPA project at JSW Steel Vijayanagar works". Free Press Journal. Retrieved 2023-12-12.
  11. ↑ Iyengar, Suresh P. (2022-01-07). "JSW Steel to invest ₹15,000 cr in expanding Vijayanagar capacity by 5 mtpa". BusinessLine. Retrieved 2023-12-12.
  12. ↑ Loan for JSW Steel Limited in India, Japan Bank for International Cooperation, Retrieved on: May 7, 2020
  13. ↑ "JSW Steel to use green hydrogen for steelmaking at Vijayanagar plant". pv magazine India. 2023-07-28. Retrieved 2023-12-11.
  14. ↑ 14.0 14.1 14.2 (PDF) https://web.archive.org/web/20221030083808/https://www.jsw.in/sites/default/files/assets/industry/steel/IR/Financial%20Performance/Annual%20Reports%20_%20STEEL/JSW%20Steel%20Integrated%20Report%202021-22.pdf. Archived from the original (PDF) on 30 October 2022. {{cite web}}: Missing or empty |title= (help)
  15. ↑ 15.0 15.1 15.2 15.3 https://web.archive.org/web/20210521050200/https://www.jsw.in/steel/vijayanagar-works-overview. Archived from the original on 21 May 2021. {{cite web}}: Missing or empty |title= (help)
  16. ↑ https://web.archive.org/web/20211207143423/https://www.jswsteel.in/about-us. Archived from the original on 07 December 2021. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  17. ↑ https://web.archive.org/web/20220411041249/https://www.jsw.in/energy/jsw-energy-vijaynagar-plant. Archived from the original on 11 April 2022. {{cite web}}: Missing or empty |title= (help)
  18. ↑ https://web.archive.org/web/20220313164012/https://www.jsw.in/groups/jsw-projects-limited. Archived from the original on 13 March 2022. {{cite web}}: Missing or empty |title= (help)
  19. ↑ 19.0 19.1 19.2 19.3 19.4 (PDF) https://web.archive.org/web/20230614200208/https://www.jsw.in/sites/default/files/assets/industry/steel/IR/JSW_Steel_Investor_Presentation/JSW%20Steel_Corporate%20Presentation_May-23_vF-2.pdf. Archived from the original (PDF) on 14 June 2023. {{cite web}}: Missing or empty |title= (help)
  20. ↑ https://web.archive.org/web/20230710085207/https://www.livemint.com/companies/news/jsw-steel-to-invest-rs-15-000-cr-expand-vijayanagar-facility-to-18-mtpa-11641548454792.html. Archived from the original on 10 July 2023. {{cite web}}: Missing or empty |title= (help)
  21. ↑ 21.0 21.1 21.2 21.3 21.4 https://web.archive.org/web/20220111143937/https://www.jsw.in/steel/jsw-steel-facilities. Archived from the original on 11 January 2022. {{cite web}}: Missing or empty |title= (help)
  22. ↑ https://web.archive.org/web/20220127005011/https://www.jsw.in/steel/vijayanagar-works-technology. Archived from the original on 27 January 2022. {{cite web}}: Missing or empty |title= (help)
  23. ↑ https://web.archive.org/web/20220207220810/https://www.fastmarkets.com/events. Archived from the original on 07 February 2022. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  24. ↑ 24.0 24.1 24.2 https://web.archive.org/web/20211215074837/https://www.primetals.com/portfolio/ironmaking/corexr. Archived from the original on 15 December 2021. {{cite web}}: Missing or empty |title= (help)
  25. ↑ 25.0 25.1 25.2 https://web.archive.org/web/20220320173526/https://www.midrex.com/about-midrex/midrex-plants/. Archived from the original on 20 March 2022. {{cite web}}: Missing or empty |title= (help)
  26. ↑ (PDF) https://web.archive.org/web/20220425141258/https://www.primetals.com/fileadmin/user_upload/content/01_portfolio/1_ironmaking/corex/COREX.pdf. Archived from the original (PDF) on 25 April 2022. {{cite web}}: Missing or empty |title= (help)
  27. ↑ 27.00 27.01 27.02 27.03 27.04 27.05 27.06 27.07 27.08 27.09 27.10 27.11 27.12 27.13 27.14 http://environmentclearance.nic.in/DownloadPfdFile.aspx?FileName=06q8VIacOJ6k/TU4rr1vtejKtXw+7m2bS5EY+gZhQCxwbQgA5bVT+4CF0Lrm+XbBmQBbuFi8Jf360z2wnR6KmBVIsJfDGJBVlmXDS+i+c8yfDzdLb1BZH/UVYqvSZfnLgVfAeV65WCurkx1heG2DyOkVfMtLipIlH4MP4kUpJuE=&FilePath=93ZZBm8LWEXfg+HAlQix2fE2t8z/pgnoBhDlYdZCxzXmG8GlihX6H9UP1HygCn3pCkAF2zPFXFQNqA4krKa1Aw==. {{cite web}}: Missing or empty |title= (help)
  28. ↑ (PDF) https://web.archive.org/web/20220111173338/https://www.oecd.org/industry/ind/latest-developments-in-steelmaking-capacity-2021.pdf. Archived from the original (PDF) on 11 January 2022. {{cite web}}: Missing or empty |title= (help)
  29. ↑ 29.0 29.1 29.2 (PDF) https://web.archive.org/web/20220629095453/https://www.jswsteel.in/sites/default/files/assets/industry/steel/IR/Share%20Holder's%20Information/Investors%20site%20visit%20to%20Vijayanagar%202022.pdf. Archived from the original (PDF) on 29 June 2022. {{cite web}}: Missing or empty |title= (help)
  30. ↑ 30.00 30.01 30.02 30.03 30.04 30.05 30.06 30.07 30.08 30.09 30.10 30.11 30.12 30.13 30.14 30.15 30.16 30.17 30.18 30.19 30.20 (PDF) https://www.jsw.in/sites/default/files/assets/downloads/steel/IR/Environmental%20Clearances/Env%20statement%20FY%2022%20Final.pdf. {{cite web}}: Missing or empty |title= (help)
  31. ↑ 31.0 31.1 31.2 31.3 31.4 http://environmentclearance.nic.in/DownloadPfdFile.aspx?FileName=06q8VIacOJ6k/TU4rr1vtejKtXw+7m2bS5EY+gZhQCzZoNCdmnow8wfiEOjv6kEw56Hoq/K7DsfhEAzwVYJ0sZ/CT8RkH+IjyWEdkCVg+0w=&FilePath=93ZZBm8LWEXfg+HAlQix2fE2t8z/pgnoBhDlYdZCxzUI4D0y0DyH4SbeEYqwvEmbzJ93uSdf1XR4VVIsqocs0Q==. {{cite web}}: Missing or empty |title= (help)
  32. ↑ 32.00 32.01 32.02 32.03 32.04 32.05 32.06 32.07 32.08 32.09 32.10 (PDF) https://web.archive.org/web/20221206051431/https://www.nexi.go.jp/environment/info/pdf/19-013_EAR.pdf. Archived from the original (PDF) on 06 December 2022. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  33. ↑ 33.0 33.1 33.2 33.3 https://www.jsw.in/sites/default/files/assets/downloads/steel/IR/Financial%20Performance/Annual%20Reports%20Steel/jsw-steel-19-20/strategic-growth.html. {{cite web}}: Missing or empty |title= (help)
  34. ↑ 34.0 34.1 https://web.archive.org/web/20240110020507/https://www.jswhotrolledsteel.in/manufacturing/vijayanagar-works.aspx. Archived from the original on 10 January 2024. {{cite web}}: Missing or empty |title= (help)
  35. ↑ (PDF) https://web.archive.org/web/20211004131951/https://www.jsw.in/sites/default/files/assets/downloads/steel/IR/Financial%20Performance/Annual%20Reports%20Steel/20-21/AR%202020-21.pdf. Archived from the original (PDF) on 04 October 2021. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  36. ↑ 36.0 36.1 (PDF) https://web.archive.org/web/20240111064236/https://www.jswsteel.in/sites/default/files/assets/industry/steel/IR/press-release-Q4-2023.pdf. Archived from the original (PDF) on 11 January 2024. {{cite web}}: Missing or empty |title= (help)
  37. ↑ 37.0 37.1 37.2 https://web.archive.org/web/20220525172438/http://www.meconlimited.co.in/Metals/Iron_Making.aspx. Archived from the original on 25 May 2022. {{cite web}}: Missing or empty |title= (help)
  38. ↑ 38.0 38.1 38.2 38.3 https://www.jsw.in/sites/default/files/assets/downloads/steel/IR/Financial%20Performance/Annual%20Reports%20Steel/jsw-steel-20-21/environment.html. {{cite web}}: Missing or empty |title= (help)
  39. ↑ (PDF) https://www.sevenrefractories.com/wp-content/uploads/2021/12/Reference-List_BF_Repair_EXTERNAL.pdf. {{cite web}}: Missing or empty |title= (help)
  40. ↑ https://www.metec-tradefair.com/en/Media_News/News/Restart_of_blast_furnace_after_major_reline_project. {{cite web}}: Missing or empty |title= (help)
  41. ↑ 41.0 41.1 41.2 41.3 41.4 41.5 (PDF) https://web.archive.org/web/20210718151818/https://www.primetals.com/fileadmin/user_upload/content/01_portfolio/1_ironmaking/blast-furnace/JSW_TORANAGALLU_-_BLAST_FURNACE_NO3_AND_NO4.pdf. Archived from the original (PDF) on 18 July 2021. {{cite web}}: Missing or empty |title= (help)
  42. ↑ https://furnaces-international.com/news/jsw-steel-successfully-completes-waste-plastic-injection-trials. {{cite web}}: Missing or empty |title= (help)

Resources

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