Aerial view of Essar's HBI plant at Hazira, India

Aerial view of Essar's iron ore beneficiation plant
at Bailadilla, India

Aerial view of Essar's pelletisation plant at
Visakhapatnam, India

Aerial view of Essar's port facilities at Hazira, India

Aerial view of Essar's steel plant at Hazira, India

Aerial view of Essar's steel plant at Algoma, Canada

Aerial view of Essar's steel plant at, Indonesia

No wonder we are India's largest exporter of flat products, selling almost one-third of our production to the highly demanding US and European markets, and to the growing markets of South East Asia and the Middle East. A number of major client companies have approved our steel for their use, including Caterpillar, Hyundai, Swaraj Mazda, the Konkan Railway and Maruti Suzuki. Essar Steel has acquired extensive quality accreditations. Our lean team gives us one of the highest productivities and lowest manpower costs among steel plants internationally.

Seamless integration

A major strategic advantage is our high level of forward and backward integration. We are totally integrated - from raw material to finished products, adding value at every stage of the manufacturing process.

Bailadilla Facility: Iron ore beneficiation

At Bailadilla, where some of the world's richest and finest ore is available, Essar has set up a beneficiation plant of 8 million tonnes per annum (MTPA) capacity, which ensures the highest quality iron ore. The iron ore slurry is pumped through a 267 km. pipeline (the second longest in the world) to the pellet plant, yielding advantages of quality, cost and real time inventory management.

Visakhapatnam Facility: Pelletisation

The slurry is received at our Pellet plant at Visakhapatnam, which has a capacity of 8 MTPA, providing vital raw material for the steel plant at Hazira.

Hazira Facility

Overview: Our steel complex at Hazira, Gujarat, houses a 5.0 MTPA sponge iron plant, the world's largest gas-based HBI producer. The plant provides raw materials for our state-of-the-art 4.6 MTPA hot rolled coil (HRC) plant, the first and largest of India's new generation steel mills. This plant is fed with inputs from three electric arc furnaces and three casters. The complex's sophisticated infrastructure includes independent water supply and power, oxygen and lime plants, a township and a captive port capable of handling up to 8 MTPA of cargo with modern handling equipment like barges and floating cranes.

Cold Rolling Complex: At the other end of the value chain, the Company's downstream facilities include a 1.4 MTPA Cold Rolling Complex, adds further muscle to our steel making facilities. The complex comprises two pickling lines of 1.4 MTPA capacity, a reversing mill and a 1.2 MTPA Tandem Mill, two Galvanizing lines of 0.5 MTPA, Batch Annealing Furnace of 0.5 MTPA, a Skin Pass Mill of 1.0 MTPA. This enables Essar Steel to get into the genre of products that are tailor-made for automotive, white goods, shipbuilding, agriculture and construction industries - segments that were the exclusive domain of a few international manufacturers.

Canada Facility: Essar Steel Algoma

Established in 1901, Essar Steel Algoma is an integrated steel producer based in Sault Ste. Marie, Ontario, Canada. The plant's current production capacity is 4 million tonnes per annum (MTPA). Some of the key equipment at the plant include a low-cost, technologically advanced Direct Strip Production Complex (DSPC), a slabcaster, a 106-inch strip mill (one of the widest in North America), a 166-inch plate mill, a cold mill and blanking facility that helps produce steel customised for client requirements, and a welded beam division.

Indonesia Facility: PT Essar Indonesia

PT Essar is Indonesia's largest private sector flat products company, with a domestic market share of 35% and a history of process and product innovation. After a major expansion drive, its CR capacity has been enhanced to 400,000 TPA and its newly set up galvanising capacity is 1,50,000 TPA.

Retail Initiatives

Essar Steel is the first steel company to set up the only retail chain for steel products under the brand name Essar Steel Hypermart. It has a strong network of over 80 Steel Hypermarts. The outlets are conveniently located across the length and breadth of the country to cater to the customised requirements of small and medium enterprises.

The Hypermarts offer a comprehensive range of flat steel products for a variety of applications. Other product lines, like longs, structural, and tubular, are also being developed to make Essar Steel Hypermart a one-stop-shop for steel products.

Essar Steel actively participates in the Essar Group's clickforsteel.com, an online Asian steel vortal through which we have been able to reduce multiple distribution layers, making transactions transparent and extending our reach to various small users across the country.