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Hazira: Steel complex

Essar Steel Hazira, Gujarat, houses fully integrated world-class steel facility and is one of the most well-planned, sophisticated and environment-friendly steel complexes. Essar Steel Hazira complex is India's largest single-location flat steel plant.

Built with a total investment of over Rs. 300 billion, it has a steel-making capacity of 10 MTPA. This highly integrated and modern complex with a complete infrastructure set up is home to some of the most sophisticated manufacturing facilities and steel making processes. The Hazira complex is certified with ISO: 9001:2000, IS 9002 and TUV certifications, ISO 140001 and India Chiller Energy Efficiency Project (ICEEP) Protocol compliance.

Iron Making
The Hazira facility is the only plant in the world to have the three prominent ironmaking technologies at a single location – Blast Furnace, Midrex (DRI) and Corex. It houses the largest Direct Reduced Iron (DRI) plant in the world with six modules and a capacity of 6.8 MTPA. 2 Corex modules and a Blast furnace add to ironmaking capacity and bring diversity in technology. This technological diversity provides great operational flexibility and shields the business against the vagaries of the raw material market.
Hot Rolled Coils
The CONARC and EAF facilities provide liquid steel for the 8.6 MTPA hot rolled coil (HRC) plant, the first and the largest of India's new generation steel mills, and the most modern 3.5 MTPA Compact Strip Mill.

Essar Steel is the only Indian steelmaker with a 1.2 MTPA hot skin pass mill that enhances the steel's surface quality to match international standards such as API X-80. It has a wide thickness (1.6 mm – 20 mm) and width range (800 – 2000 mm). 

Three pickling lines with a combined capacity of 2.0 MTPA and turbulence technology ensure the production of a perfect steel strip with clean, scale-free surfaces without over-pickling the steel strip.
Cold Rolling
A sophisticated 2 MTPA Cold Rolling plant adds further muscle to the steel-making facilities. Equipped with a 0.2 MTPA reversing mill, a 1.2 MTPA tandem mill, a batch annealing furnace of 0.8 MTPA and a skin pass mill of 1.0 MTPA, the plant manufactures the finest cold rolled products.

The Essar Steel Hazira complex has two galvanising lines with an aggregate capacity of 1 MTPA. By applying a coating of molten Zinc to the surface of a Cold Rolled product, the lines manufacture galvanised coils that have excellent corrosion resistance and are used extensively in various industries.

Infrastructure facilities
The Essar Steel Hazira complex has a comprehensive infrastructure set up, including power plants, lime and oxygen plants, a township and a captive port that can handle capsize vessels, and is equipped with modern handling equipment. This inclusion makes the complex entirely self-sufficient eliminating dependency on external inputs and forms the core of Essar Steel's integrated processes. This ensures that Essar Steel is always able to maintain a strategic and competitive edge in an ever-changing and ever-growing market.

Essar Steel has a set-up of 30 MTPA, all-weather, deep draft dry bulk port at Hazira in Gujarat. Located on the western coast of India, the port is used for import of iron ore, pellets, limestone, other dry bulk cargos and export of finished steel. Existing facilities include a dedicated all-weather channel, a 550m long jetty, ship unloaders and storage facilities for finished products, conveyors for transporting raw materials to the stack house, a rail network, dredgers, tugs and mooring boats.

Power plant
The first power plant came up in Essar Steel Hazira, Gujarat, in 1997. The 515 MW power plant operated on a natural gas-fired combined cycle and has consistently set new standards of excellence in the Indian power sector since its commissioning. This environment-friendly, ISO 14001 and OHSAS 18001 certified power plant operates with a plant availability factor in excess of 94%.

Being India's first multi-fuel plant, it can operate simultaneously on Naphtha and gas. Essar Steel is one of the few companies to receive a safety rating by the International Safety Rating System (ISRS) and the elite 'Sword of Honour', the British Safety Council's highest award. A second power plant was established in Essar Steel Hazira in 2005 with a capacity of 500 MW.


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