The proprietary Hot DRI technology has been developed in-house at Essar Steel and has been deployed in the existing three modules resulting in enhancement of the production capacity from 1.76 mmtpa to 2.4 mmtpa. Besides helping maintain a consistent quality of metallics for the melt-shop, it brings about significant savings in the energy costs involved.

With the commissioning of the new module, the total DRI capacity has now reached 3.4 mmtpa, further consolidating Essar Steel's position as the world's largest gas based sponge iron producer. Subsequently, the company has become self sufficient in metallics, a first among the new generation steel companies in India. This will also meet the metallic requirement of the steel plant after expansion of steel making capacity from 2.4 mmtpa to 3.6 mmtpa.

Hot DRI (Direct Reduced Iron) is a technique used for generating the primary input across steel manufacturing melt shops. At Essar Steel, the Hot DRI manufactured is directly transported to the Electric Arc Furnaces (EAF) at a temperature upwards of 650º C. Transported through special vehicles with a capacity of 90 tons, this hot DRI is ideally suited for the melting process.

The high temperature at which the Hot DRI is introduced to the melt shop significantly reduces the power requirements to recharge the DRI. A reduced reheating process also increases production cycles at the melt shop translating in to increased productivity.

Essar Steel's design, project engineering and commissioning capabilities gives it a distinct advantage in execution of mega steel projects across the world.