Tata Steel BSL Meramandali steel plant

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Tata Steel BSL Dhenkanal plant, also known as Tata Steel Meramandali (TSM),Bhushan Steel Ltd (BSL); Tata Steel BSL Odisha; Tata Steel Angul steel plant, is a blast furnace-basic oxygen furnace (BF-BOF) steel plant operating in Meramandali, Odisha, India.

Location

The map below shows the exact location of the plant in Meramandali, Odisha, India:

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  • Location: Narendra Pur P.O. Shibapur, Meramandali, District - Dhenkanal - 759121, India
  • Coordinates (WGS 84): 20.796053, 85.260382 (exact)

Background

Bhushan Steel limited was established in 1989. The BSL Dhenkanal plant is an integrated steel plant with a capacity of 2.2 mtpa crude steel in 2009-10. With further expansion in stages using both primary and secondary steel production routes the plant now has a capacity of 5.6 mtpa.[1] On May 18, 2018, a subsidiary of Tata Steel acquired 72.65% stake in BSL.[2] On November 27, 2018, BSL was renamed Tata Steel BSL Ltd.[3] During the acquisition BSL was operating at 3.5 mtpa, much below its installed capacity.[4]

The Tata Steel BSL Dhenkanal plant is currently planning basic oxygen furnace (BOF) and electric arc furnace (EAF) expansions upto 12.8 mtpa for 2030.[5] The expansion is planned in two stages:

  • Stage I: Expansion from 5.6 mtpa to 8.2 mtpa. This involves installation of a third blast furnace and two 200 tons BOF, expected to begin commissioning by 2027.
  • Stage II: Expansion from 8.2 mtpa to 12.8 mtpa. This involves augmentation of existing blast furnace 1 and 2 to produce 3 mtpa additional hot metal, installation of a COG based Midrex Direct reduction plant of capacity 1.6 mtpa, two 100 tons EAF, and two 250 tons BOF.[1]

As of January 2025, there hasn't been many updates with regard to the expansion projects.

In February 2024, Tata Steel’s Kalinganagar and Meramandali plants received ResponsibleSteelTM Certification.[6]

Accidents

On 13 November, 2013, a deadly fire accident at the blast furnace 2 of the plant killed one worker and injured 19 others, following which the furnace was temporarily sealed by the Directorate of Factories and Broilers. According to a 2013 news article, BSL has witnessed several accidents and had so far claimed more than 100 lives since its inception.[7] According to government data, by 2013, 66 persons died in the plant since 2006, and the plant faces 70 criminal cases.[8]

On 13 June, 2023, 19 workers at the plant sustained burn injuries due to a mishap in one of the blast furnaces which lead to the escape of hot steam from a pipe.[9]

Plant Details

Table 1: General Plant Details

Phase Plant status Announced date Start date Workforce size Power source
Main plant Operating[10] – 2004[10] 1425[11] –
Expansion Announced[12] 2016[13] 2030[12] – Captive power plant (638 MW), Grid (994 MW)[13]
Expansion Announced[12] 2016[13] 2030[12] – Captive power plant (638 MW), Grid (994 MW)[13]

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 Tata Steel BSL Ltd [100%] 4295873662 [100%] E100000001753 [61.6%]; E100000121405 [32.4%]; E100001000520 [6%] Tata Steel BSL Ltd[14] 4295873662 E100001000862

Table 3: Process and Products

Phase Steel product category Steel products ISO 14001 Main production equipment Detailed production equipment
Main plant semi-finished; finished rolled[15] hot rolled coil, pipe, sheet, cold rolled[15] yes[16] BF, DRI, BOF, EAF, other[10] 1 coking plant (plant #1 began in 2010, plant #2 began in 2013); 3 sinter plants (plant #1 began in 2010, plant #2 began in 2013, plant #3 began in 2013); DRI plant (began in 2007; coal-based DRI); CONARC EAF (began in 2010)[10][17]
Expansion semi-finished; finished rolled[15] hot rolled coil, pipe, sheet, cold rolled[15] – BF, BOF[10] BF, BOF[12]
Expansion semi-finished; finished rolled[15] hot rolled coil, pipe, sheet, cold rolled[15] – BOF, EAF[10] DRI, EAF, BOF[12]

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 3000 TTPA[13][13] 422 TTPA[18] 5510 TTPA[13][13][18]
Expansion announced 2600 TTPA[12][12] – 2600 TTPA[12][12]
Expansion announced 3050 TTPA[13][13] 1550 TTPA[12][12][13] 4600 TTPA[13][13][12][12][13]

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 5700 TTPA[19][19] 1825 TTPA[20] 7525 TTPA[19][19][20]
Expansion announced 4300 TTPA[13] – 4300 TTPA[13]
Expansion announced – 1600 TTPA[13] 1600 TTPA[13]

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

Phase Sinter Coke Pellets
Main plant 6919.8 TTPA[13] >0 TTPA –
Expansion 4093.1 TTPA[13] – 7000 TTPA[13]
Expansion 4093.1 TTPA[13] 1645.5 TTPA[13] –

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

Year BOF Production Total (all routes)
2020 – 4080 TTPA[16]
2021 4900 TTPA[21] 4900 TTPA
2022 4950 TTPA[22] 4950 TTPA

Table 8: Actual Crude Iron Production by Year (thousand tonnes per annum)

Year BF Production Total (all routes)
2020 – –
2021 4590 TTPA[21] 4590 TTPA
2022 4600 TTPA[22] 4600 TTPA

Blast Furnace Details

Table 9: 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[19] unknown unknown 2010[10][17] MECON (Govt. of India); Paul Wurth Paul Wurth Blast Furnace Design[23][24][24] 3814 m³[23] 2500[19] unknown unknown[13]
2 operating[19] unknown unknown 2013[10][17] MECON (Govt. of India); Paul Wurth[23][24] 3400 m³[19] 3200[19] unknown unknown[13]
3 announced[12] 2016[13] unknown 2030[12] – 5800 m³[13] 4300[13] unknown 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. ↑ 1.0 1.1 "Pre-feasibility report for proposed expansion from 5.6 mtpa to 12.8 mtpa" (PDF). MoEF&CC. April 2016. Retrieved 11 October, 2023. {{cite web}}: Check date values in: |access-date= (help)CS1 maint: url-status (link)
  2. ↑ Tanya Thomas (2018-05-18). "Tata Steel buys Bhushan Steel, to settle dues of Rs35,200 crore". mint. Retrieved 2023-10-11.
  3. ↑ Hungama Digital Services. "Bhushan Steel Limited is Tata Steel BSL Limited now". www.tatasteel.com. Retrieved 2023-10-11.
  4. ↑ Ankit Gohel (2023-10-11). "HDFC AMC Q2 net profit may rise 11% to ₹404 crore; revenue seen up 15% YoY". mint. Retrieved 2023-10-11.
  5. ↑ "Latest Developments in Steelmaking Capacity 2021" (PDF). OECD. Retrieved 2022-04-08.{{cite web}}: CS1 maint: url-status (link)
  6. ↑ Services, Hungama Digital. "Tata Steel's Kalinganagar and Meramandali plants receive ResponsibleSteelTM Certification". www.tatasteel.com. Retrieved 2025-01-24.
  7. ↑ "Bhushan Steel's killer blast furnace sealed". Business Standard. 14 November, 2013. Retrieved 11 October, 2023. {{cite web}}: Check date values in: |access-date= and |date= (help)CS1 maint: url-status (link)
  8. ↑ "Dhenkanal plant faces 70 criminal cases | Bhubaneswar News - Times of India". The Times of India. Retrieved 2023-10-11.
  9. ↑ "19 injured in blast furnace mishap at Tata Steel's Dhenkanal plant in Odisha". The Indian Express. 2023-06-13. Retrieved 2023-10-11.
  10. ↑ 10.0 10.1 10.2 10.3 10.4 10.5 10.6 10.7 https://web.archive.org/web/20200801154548/http://tatasteelbsl.co.in:80/historynew.html. Archived from the original on 01 August 2020. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  11. ↑ https://web.archive.org/web/20210324055101/http://tatasteelbsl.co.in/know-us/tata-steel-bsl-at-a-glance/. Archived from the original on 24 March 2021. {{cite web}}: Missing or empty |title= (help)
  12. ↑ 12.00 12.01 12.02 12.03 12.04 12.05 12.06 12.07 12.08 12.09 12.10 12.11 12.12 12.13 12.14 12.15 (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)
  13. ↑ 13.00 13.01 13.02 13.03 13.04 13.05 13.06 13.07 13.08 13.09 13.10 13.11 13.12 13.13 13.14 13.15 13.16 13.17 13.18 13.19 13.20 13.21 13.22 13.23 13.24 13.25 13.26 13.27 (PDF) https://web.archive.org/web/20240119033914/https://environmentclearance.nic.in/writereaddata/Online/TOR/08_Apr_2016_144914843AB7KF4JBAnnexurePreFeasibilityReport.pdf. Archived from the original (PDF) on 19 January 2024. {{cite web}}: Missing or empty |title= (help)
  14. ↑ (PDF) https://web.archive.org/web/20220111172857/https://www.tatasteel.com/media/14540/tata-steel-corporate-brochure-fy20-21.pdf. Archived from the original (PDF) on 11 January 2022. {{cite web}}: Missing or empty |title= (help)
  15. ↑ 15.0 15.1 15.2 15.3 15.4 15.5 https://web.archive.org/web/20200716132754/http://tatasteelbsl.co.in:80/company.html. Archived from the original on 16 July 2020. {{cite web}}: Missing or empty |title= (help)
  16. ↑ 16.0 16.1 (PDF) https://web.archive.org/web/20220318084004/https://tatasteelbsl.co.in/Investor%20Relations%20pdf/Financial%20Reporting/Annual%20Report/Annual%20Report%20for%20FY%202020-21.pdf. Archived from the original (PDF) on 18 March 2022. {{cite web}}: Missing or empty |title= (help)
  17. ↑ 17.0 17.1 17.2 https://web.archive.org/web/20220326060904/http://spongeironindia.com/members.php. Archived from the original on 26 March 2022. {{cite web}}: Missing or empty |title= (help)
  18. ↑ 18.0 18.1 (PDF) http://environmentclearance.nic.in/writereaddata/Online/TOR/08_Apr_2016_144914843AB7KF4JBAnnexurePreFeasibilityReport.pdf. {{cite web}}: Missing or empty |title= (help)
  19. ↑ 19.0 19.1 19.2 19.3 19.4 19.5 19.6 19.7 19.8 (PDF) http://worldpetrocoal.in/download/WPCC-2020-PPT/KS-VII/Saroj-Banerjee.pdf. {{cite web}}: Missing or empty |title= (help)
  20. ↑ 20.0 20.1 https://tatasteelbsl.co.in/footprints/our-plants/. {{cite web}}: Missing or empty |title= (help)
  21. ↑ 21.0 21.1 (PDF) https://web.archive.org/web/20221108121601/https://www.tatasteel.com/media/15928/tata-steel-ir-2021-22.pdf. Archived from the original (PDF) on 08 November 2022. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  22. ↑ 22.0 22.1 (PDF) https://web.archive.org/web/20240125045719/https://www.tatasteel.com/media/18370/tata-steel-ir-2022-23.pdf. Archived from the original (PDF) on 25 January 2024. {{cite web}}: Missing or empty |title= (help)
  23. ↑ 23.0 23.1 23.2 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)
  24. ↑ 24.0 24.1 24.2 https://studylib.net/doc/5535054/design-features-of-indian-blast-furnaces. {{cite web}}: Missing or empty |title= (help)

Resources

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