Bhilai Steel Plant
Encyclopedia
Bhilai Steel Plant, located in Bhilai
, Chhattisgarh
, is India
's only producer of steel
rails, and is a major producer of steel plates and structural components.
This steel plant was set up with the help of the USSR in 1955. Nine - time winner of Prime Minister's Trophy for best Integrated Steel Plant in the country, Bhilai Steel Plant (BSP) is India's sole producer of rails and heavy steel plates and major producer of structural. The plant is the sole supplier of the country's longest rail tracks of 260 metres.The plant also specializes in other products such as wire rods and merchant products. Since BSP is accredited with ISO 9001:2000 Quality Management System Standard, all saleable products of Bhilai Steel Plant come under the ISO umbrella.The Plant is accredited with SA: 8000 certification for social accountability and the OHSAS-18001 certification for Occupational health and safety. Among the long list of national awards it has won, Bhilai has bagged the CII-ITC Sustainability award for three consecutive years. The company was more than 50 years old and is unique by means of their production techonology.
In the 2004-05 fiscal year, it was the Steel Authority of India Limited
's most profitable plant. It is the flagship plant of SAIL, contributing to the largest percentage of profit.
on 2nd march 1955, for the establishment of an integrated Iron and Steel works at Bhilai with an initial capacity of one million tones of ingot steel.
The main consideration which responsible for setting up the plant at Bhilai, was the availability of Iron ore at Delhi-Rajhara at a distance of about 90 Km from the site limestone from Nandini at 22 km and dolomite at HIRRI at 41 km. the plant was commissioned with the inauguration of the first blast furnace by the then president of India. Dr. Rajendra Prasad
on 4th February 1959. The plant was soon expanded to 2.5 Million tones in September 1967 and in further expansion to 4 MT was completed in 1988. The main focus in the 4 MT stage was on the continuous casting unit and the plate mill, a new technology in steel casting and shaping for any integrated steel plant to India during those times.
and to meet future requirement, BSP has decided to open up an iron ore mine at Rowghat which is located about 80 Kms from Rajhara
in Narayanpur District of Chhattisgarh
. Accordingly, BSP will develop the mine in Block-A of Deposit-F of Rowghat with a production capacity of 14.0 MT per year wef 2011-12. Due to environmental reasons, the beneficiation plant shall be of dry circuit type. However, grant of forest clearance under Forest (Conservation) Act, 1980 is still awaited.
It was in 1978 that BSP started sharing it prosperity with neighbouring villages through constructing additional rooms in village schools, making roads,bridges, culverts, Panchayat bhavans,Community halls, Cultural stages, digging bore well,deepening villages tanks/ponds, making ghats in the ponds for safe bathing and other such activities. Subsequently,activities involving community health were taken-up.
The Community &Peripheral Deptt. With the help of the medical Deptt.& public health department conducts eye camps, general OPD camps, ayurvedic Camps. BSP even holds veterinary camps for the benefit of the cattle of the region.
In order to preserve and promote the vast heritage of the local art, Bhilai Steel Plant organized the Lok Kala Mahotsav During May 2007. It was a grand success and appreciated highly by the artists as well as the people. These types of annual events give an opportunity to many local artists to perform on the stage.some of the artists such as Smt.Teejan Bai have won international acclaim for their art.
BSP managements adopts 20 tribal children every year belonging to below poverty line population of the state. Not only does the company take care of their boarding and lodging but also provides free education in one of the English medium schools of BSP.Bhilai Mahila samaj ,affliated to BSP, takes care of these children with a spirit of service. Bhilai has also adopted four girls from Aboojhmar area of Bastar for their education in Bhilai Nursing College.
Sports and Recreation
Over a hundred national and state championships have been organized in Bhilai since the formation of Chhattisgarh state. The mega-sports event that Bhilai has been organising in Narayanpur for Adivasi school-children for three consecutive years since 2006 attracts more than 1500 students from schools in remote areas of Bastar every year.
Maitree Bath which was established by BSP with Russian collaboration is the best example of recreational set up of BSP. It has country's biggest musical fountain well-laid lush lawns, biggest zoo in the region, boating in artificial lake, toy train and Pragati Minar offering a panoramic view of the steel plant and surroundings.
GREEN CITY
Contrary to popular perception about industrial city being polluted and dirty, Bhilai is totally opposite. Basically it’s a green city with large number of population actively taking part in massive tree plantation since many years. There are five big gardens inside the plant and 15 gardens in the township. The cumulative plantation in the Works area and township is more than 30 lakhs while in the Mines; it is more than 22 lakhs. Also the residential sectors of the green city are kept clean and green by Plant’s Town administration department. There is also a check on water supply by Maroda water treatment plant. This shows BSP’s systematic approach in keeping the city clean and healthy.
Apart from all these Effective monitoring and analysis has also been carried out just to ensure that BSPs is in compliance with the regulatory requirements.
ISO 14001 certification has been implemented in the entire Plant & township as well as in Dalli Mines. It is the only steel plant to get certification in all these areas.
Bhilai Steel Plant manages a well planned township (Bhilainagar) which as 13 sectors.
PRODUCT-MIX TONNES/ANNUM
Semis
5,33,000
Rail & Heavy Structural
7,50,000
Merchant Products
(Angles, Channels, Round & TMT bars)
5,00,000
Wire Rods (TMT, Plain & Ribbed)
4,20,000
Plates (up to 3600 mm wide)
9,50,000
Total Saleable steel
31,53,000
• Prime minister Trophy for best integrated steel plant in India Won seven times science its inception in the year1992-93, 1993-94, 1995-96, 1996-97, 1997-98, 2003-04 and 2004-05.
• National energy conservation award in the integrated steel sector won for 1994,1996,1998 & 1999.
• IIM National Quality awards winners in ferrous category during 1995-96, 1997-98 and 1999-2000.
• BIS Rajiv Gandhi National Quality award won twice in recent years.
• IOD Golden Peacock National Quality Award won therice in recent year.
• INSAAN Award for employee suggestions six times in last Seven year.
• SAIL paryawaran Award for all the six times (this ward was given from 1992-93 til 1997-98), for best environmentally managed Integreted Steel Plant. Several Paryawaran Awards have been also been won by captive mines and SMS-1 of BSP.
• Indo- German Green Tech. Environment Excellent Award for the year 1999-2000.
• Lal Bahadur shastri Memorial Award for the year 2000-01 for “Best Pollution Control Implementation Gold Award”.
• Dalli mines has bigged National Safety Award for a record seven times.
• National Award for best pay rolls the year 1999-2000 for outstanding social work won by Bhilai savings group in public sector for 1999-2000 and thrice earlier as best Sanchayika Award.
• Washeshari Devi Bhatia memorial Charitable Trust Award for Mahila Samaj.
• Steel ministers Trophy for the longest accident free period during 1995 -96 in the integrated steel plant category.
• BTI adjudged the best Training Establishment in northern zone by all India Regional Council several times.
• Padam Bhushan – Awarded to smt. Teejan Bai, Pandwani Singer.
• Prime Minister’s Shram Awards since inception of the award(1985)- Total 25 won as follows:-
Shram Ratan : 08
Shram Bhushan : 09
Shram vir : 04
Shram Shri : 04
Vishwakarma Rastriya puruskar : 188
Arjun Award : 02
• Apart from above, numbers individual group awards have been won time by BSP employees at National level in the field of Quality Circles, Management , Metallurgy, Sport & Cultural Activities etc.
• Strengths:
• Capacity of plant
• Product Mix
• Quality of Products
• Human Resource & Management
• Weakness:
• Supply of Raw Materials
• Demurrages
• Rigidity of Labor Law compared to other countries
• Opportunities:
• Upsurge in Indian Economy
• Technological Edge
• Human Resource Management
• Threats:
• Effect of Custom Duty
• International Competition
• Domestic Competition
• Increase in Oil Prices
• Depleting Mines
Bhilai
Bhilai or Bhilai Nagar is a city in the Durg district of Chhattisgarh, in eastern central India. As of 2001, it had a population of 753,837. The city is located west of the capital Raipur, on the main Howrah–Mumbai rail line, and National Highway 6...
, Chhattisgarh
Chhattisgarh
Chhattisgarh is a state in Central India, formed when the 16 Chhattisgarhi-speaking South-Eastern districts of Madhya Pradesh gained separate statehood on 1 November 2000....
, is India
India
India , officially the Republic of India , is a country in South Asia. It is the seventh-largest country by geographical area, the second-most populous country with over 1.2 billion people, and the most populous democracy in the world...
's only producer of steel
Steel
Steel is an alloy that consists mostly of iron and has a carbon content between 0.2% and 2.1% by weight, depending on the grade. Carbon is the most common alloying material for iron, but various other alloying elements are used, such as manganese, chromium, vanadium, and tungsten...
rails, and is a major producer of steel plates and structural components.
This steel plant was set up with the help of the USSR in 1955. Nine - time winner of Prime Minister's Trophy for best Integrated Steel Plant in the country, Bhilai Steel Plant (BSP) is India's sole producer of rails and heavy steel plates and major producer of structural. The plant is the sole supplier of the country's longest rail tracks of 260 metres.The plant also specializes in other products such as wire rods and merchant products. Since BSP is accredited with ISO 9001:2000 Quality Management System Standard, all saleable products of Bhilai Steel Plant come under the ISO umbrella.The Plant is accredited with SA: 8000 certification for social accountability and the OHSAS-18001 certification for Occupational health and safety. Among the long list of national awards it has won, Bhilai has bagged the CII-ITC Sustainability award for three consecutive years. The company was more than 50 years old and is unique by means of their production techonology.
In the 2004-05 fiscal year, it was the Steel Authority of India Limited
Steel Authority of India Limited
Steel Authority of India Limited from 116950 The company's current chairman is C.S Verma. With an annual production of 13.5 million metric tons, SAIL is the 14th largest steel producer in the world....
's most profitable plant. It is the flagship plant of SAIL, contributing to the largest percentage of profit.
History
Government of INDIA and USSR entered into an agreement signed at New DelhiNew Delhi
New Delhi is the capital city of India. It serves as the centre of the Government of India and the Government of the National Capital Territory of Delhi. New Delhi is situated within the metropolis of Delhi. It is one of the nine districts of Delhi Union Territory. The total area of the city is...
on 2nd march 1955, for the establishment of an integrated Iron and Steel works at Bhilai with an initial capacity of one million tones of ingot steel.
The main consideration which responsible for setting up the plant at Bhilai, was the availability of Iron ore at Delhi-Rajhara at a distance of about 90 Km from the site limestone from Nandini at 22 km and dolomite at HIRRI at 41 km. the plant was commissioned with the inauguration of the first blast furnace by the then president of India. Dr. Rajendra Prasad
Rajendra Prasad
Dr. Rajendra Prasad was an Indian politician and educator. He was one of the architects of the Indian Republic, having drafted its first constitution and serving as the first president of independent India...
on 4th February 1959. The plant was soon expanded to 2.5 Million tones in September 1967 and in further expansion to 4 MT was completed in 1988. The main focus in the 4 MT stage was on the continuous casting unit and the plate mill, a new technology in steel casting and shaping for any integrated steel plant to India during those times.
The Organisational Framework
Bhilai Steel Plant functions as a unit of SAIL with its corporate office at New Delhi.Over the years, Bhilai Steel Plant has developed an organizational culture that run forces its commitment to values and stimulates continuous improvements and higher levels of performance. the chief executive offficer (currently Mr.Pankaj Gautam) is in overall control of the operations of the plant, township and the mines CEO is assisted by his DRO’S i.e. the functional heads Executive directors General Manager concept of Zonal heads and HOD’S helps in integrating various functions with clear accountability for achieving corporate vision, company goals and objectives.Modernization and expansion programs
besides all other small and large projects , a new compressed air station and oxygen plant, new installation regarding power requirement and ore handling capacities expansion.Presently total requirement of iron ore of BSP is met from Dalli Rajhara, Iron Ore Complex. In view of fast depleting reserves at Iron Ore Complex, RajharaRajhara
Rajhara is a town in Palamu district in the Indian state of Jharkhand.-Geography:Rajhara is located at . It has an average elevation of .-Transport:Rajhara is the terminal point of NH 98 and lies about north of Daltonganj. Ranchi is about from Rajhara....
and to meet future requirement, BSP has decided to open up an iron ore mine at Rowghat which is located about 80 Kms from Rajhara
Rajhara
Rajhara is a town in Palamu district in the Indian state of Jharkhand.-Geography:Rajhara is located at . It has an average elevation of .-Transport:Rajhara is the terminal point of NH 98 and lies about north of Daltonganj. Ranchi is about from Rajhara....
in Narayanpur District of Chhattisgarh
Chhattisgarh
Chhattisgarh is a state in Central India, formed when the 16 Chhattisgarhi-speaking South-Eastern districts of Madhya Pradesh gained separate statehood on 1 November 2000....
. Accordingly, BSP will develop the mine in Block-A of Deposit-F of Rowghat with a production capacity of 14.0 MT per year wef 2011-12. Due to environmental reasons, the beneficiation plant shall be of dry circuit type. However, grant of forest clearance under Forest (Conservation) Act, 1980 is still awaited.
Product Profile
The product range at Bhilai Steel Plant and their end use/consumers is as :| Product Type | Product | End use / consumers |
|---|---|---|
| A. FINISHED PRODUCTS | Rail & Structural Mill | Rails in 13m, 26m, 65/78 m length and welded panels of 130m/260m length Indian Railways, Export Heavy Structurals Construction Crane Rails Cranes Crossing sleepers Broad gauge sleepers |
| Merchant Mill | Lt. Structurals Engineering and Construction Med. Rounds (Plain & TMT) Heavy rounds (Plain) | |
| Wire Rod Mill | Wire Rods- Plain Construction Wire Rods- TMT EQ Wire Rods Electrodes | |
| Plate Mill | Plates Boilers, Defence ,Railways, Ship building, LPG cylinders, Export | |
| B. SEMIS | Billets (from BBM) | Re-rollers |
| Blooms (from BBM) | ||
| Narrow width slabs | ||
| CC Blooms | ||
| Killed Slabs | ||
| C. | Pig Iron | Foundry |
| D. | By Products | Coal Chemicals Ammonium Sulphate (Fertiliser)Tar and tar products, (Pitch, Napthalene, Creosote Oil Road Tar, Anthracene oil, Dephenolised oil, PCM etc.), Benzol & its products (NG Benzene, Toulene, Xylene, Solvent oil, By. Benzol etc.) Processed Slag Granulated slag from CHSG Plants & SGP for cement manufacture |
Corporate Social Responsibility
The BSP leadership sincerely believes that existence of an organization depends upon long term sustainability and has always pursued CSR as a part of organization’s commitment towards the society. It also believes that society and industry are mutually interdependent and both can act to benefit each other mutually. This has successfully established BSP ,as a “caring and sharing” brand.It was in 1978 that BSP started sharing it prosperity with neighbouring villages through constructing additional rooms in village schools, making roads,bridges, culverts, Panchayat bhavans,Community halls, Cultural stages, digging bore well,deepening villages tanks/ponds, making ghats in the ponds for safe bathing and other such activities. Subsequently,activities involving community health were taken-up.
The Community &Peripheral Deptt. With the help of the medical Deptt.& public health department conducts eye camps, general OPD camps, ayurvedic Camps. BSP even holds veterinary camps for the benefit of the cattle of the region.
In order to preserve and promote the vast heritage of the local art, Bhilai Steel Plant organized the Lok Kala Mahotsav During May 2007. It was a grand success and appreciated highly by the artists as well as the people. These types of annual events give an opportunity to many local artists to perform on the stage.some of the artists such as Smt.Teejan Bai have won international acclaim for their art.
BSP managements adopts 20 tribal children every year belonging to below poverty line population of the state. Not only does the company take care of their boarding and lodging but also provides free education in one of the English medium schools of BSP.Bhilai Mahila samaj ,affliated to BSP, takes care of these children with a spirit of service. Bhilai has also adopted four girls from Aboojhmar area of Bastar for their education in Bhilai Nursing College.
Sports and Recreation
Over a hundred national and state championships have been organized in Bhilai since the formation of Chhattisgarh state. The mega-sports event that Bhilai has been organising in Narayanpur for Adivasi school-children for three consecutive years since 2006 attracts more than 1500 students from schools in remote areas of Bastar every year.
Maitree Bath which was established by BSP with Russian collaboration is the best example of recreational set up of BSP. It has country's biggest musical fountain well-laid lush lawns, biggest zoo in the region, boating in artificial lake, toy train and Pragati Minar offering a panoramic view of the steel plant and surroundings.
Environment Management
As a responsible corporate citizen, BSP has taken effective measures in the areas of waste management, effective resource utilisation, pollution control and also initiated several waste reduction mechanisms .Besides, undertaking different mechanisms for green house gas reduction, BSP has taken up the initiative of replacement of Ozone Depleting Substance CTC, aided by UNDP. BSP has earned Voluntary Emission Reduction (VER), (a sort of carbon credit) for two of its environment-friendly projects. Abiding by Corporate Responsibility for Environment Protection (CREP) guidelines & monitoring mechanism, it has taken adequate steps to check fugitive emissions from Coke Ovens and has installed Air cooled self sealing doors resulting in significant reduction in door emissions. The plant has also introduced de-dusting system, electrostatic precipitators and coal dust injection system in the Blast Furnaces and in other unitsGREEN CITY
Contrary to popular perception about industrial city being polluted and dirty, Bhilai is totally opposite. Basically it’s a green city with large number of population actively taking part in massive tree plantation since many years. There are five big gardens inside the plant and 15 gardens in the township. The cumulative plantation in the Works area and township is more than 30 lakhs while in the Mines; it is more than 22 lakhs. Also the residential sectors of the green city are kept clean and green by Plant’s Town administration department. There is also a check on water supply by Maroda water treatment plant. This shows BSP’s systematic approach in keeping the city clean and healthy.
Apart from all these Effective monitoring and analysis has also been carried out just to ensure that BSPs is in compliance with the regulatory requirements.
ISO 14001 certification has been implemented in the entire Plant & township as well as in Dalli Mines. It is the only steel plant to get certification in all these areas.
Bhilai Steel Plant manages a well planned township (Bhilainagar) which as 13 sectors.
PRODUCT-MIX TONNES/ANNUM
Semis
5,33,000
Rail & Heavy Structural
7,50,000
Merchant Products
(Angles, Channels, Round & TMT bars)
5,00,000
Wire Rods (TMT, Plain & Ribbed)
4,20,000
Plates (up to 3600 mm wide)
9,50,000
Total Saleable steel
31,53,000
Awards & Accolade
Bhilai Steel Plant has excelled in all walks of life, be it technology, quality, environment or socio-culture, some of the prestigious awards bugged by BSP are as follows.• Prime minister Trophy for best integrated steel plant in India Won seven times science its inception in the year1992-93, 1993-94, 1995-96, 1996-97, 1997-98, 2003-04 and 2004-05.
• National energy conservation award in the integrated steel sector won for 1994,1996,1998 & 1999.
• IIM National Quality awards winners in ferrous category during 1995-96, 1997-98 and 1999-2000.
• BIS Rajiv Gandhi National Quality award won twice in recent years.
• IOD Golden Peacock National Quality Award won therice in recent year.
• INSAAN Award for employee suggestions six times in last Seven year.
• SAIL paryawaran Award for all the six times (this ward was given from 1992-93 til 1997-98), for best environmentally managed Integreted Steel Plant. Several Paryawaran Awards have been also been won by captive mines and SMS-1 of BSP.
• Indo- German Green Tech. Environment Excellent Award for the year 1999-2000.
• Lal Bahadur shastri Memorial Award for the year 2000-01 for “Best Pollution Control Implementation Gold Award”.
• Dalli mines has bigged National Safety Award for a record seven times.
• National Award for best pay rolls the year 1999-2000 for outstanding social work won by Bhilai savings group in public sector for 1999-2000 and thrice earlier as best Sanchayika Award.
• Washeshari Devi Bhatia memorial Charitable Trust Award for Mahila Samaj.
• Steel ministers Trophy for the longest accident free period during 1995 -96 in the integrated steel plant category.
• BTI adjudged the best Training Establishment in northern zone by all India Regional Council several times.
• Padam Bhushan – Awarded to smt. Teejan Bai, Pandwani Singer.
• Prime Minister’s Shram Awards since inception of the award(1985)- Total 25 won as follows:-
Shram Ratan : 08
Shram Bhushan : 09
Shram vir : 04
Shram Shri : 04
Vishwakarma Rastriya puruskar : 188
Arjun Award : 02
• Apart from above, numbers individual group awards have been won time by BSP employees at National level in the field of Quality Circles, Management , Metallurgy, Sport & Cultural Activities etc.
SWOT Analysis
The primary function of Bhilai Steel Plant are derived from the functions of the mother organization SAIL. As a production unit of SAIL, BSP carries out the specific functions and task assign to it from time to time, both with regards to production and execution of other functions of SAIL, such as design consultancy, training and development etc.• Strengths:
• Capacity of plant
• Product Mix
• Quality of Products
• Human Resource & Management
• Weakness:
• Supply of Raw Materials
• Demurrages
• Rigidity of Labor Law compared to other countries
• Opportunities:
• Upsurge in Indian Economy
• Technological Edge
• Human Resource Management
• Threats:
• Effect of Custom Duty
• International Competition
• Domestic Competition
• Increase in Oil Prices
• Depleting Mines