Bhilai Steel Plant (BSP), established in 1959 and operated by Steel Authority of India Limited, is a key public sector steel production unit with an annual capacity of 3.153 million tonnes of saleable steel, specializing in rails and plates. It has garnered multiple awards for its integrated steel production capabilities, achieving high-quality standards and environmentally sustainable practices. BSP is significant for supplying long rail tracks and has a comprehensive product range including structural and wire products, maintaining international certifications for quality and environmental management.

1. BHILAI STEEL PLANT
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2. CONTENTS
Steel Authority of India Limited (SAIL)
Introduction
Products Profile
Process flow
Rail and Structural Mill
Plate Mill
Steel Melting Shop 2
Achievements
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3. Steel Authority of India Limited (SAIL) is one of the largest state
Owned steel makers in India and one of the top steel makers in the
world, With a turnover of 8681crore (US $10.71billion), the company
is among top five highest profit earning corporate of the country
Type State owned enterprise public
Industry Steel
Founded 1954
Headquarters New Delhi, India
Products Steel, flat steel products, long steel
products, Wire Products, plates
Employees 275,580(2016 dec)
Website www.sail.co.in 3

4. Special Steel Plants
oSteel Authority of India Limited (SAIL), Kanpur, Uttar Pradesh
oAlloy Steels Plants (ASP), Durgapur, West Bengal
oSalem Steel Plant (SSP), Tamil Nadu
oVisvesvaraya Iron and Steel Limited (VISL), at Bhadravathi, Karnataka
Ferro Alloy Plant
oChandrapur Ferro Alloy Plant (CFP) in Maharastra
SAIL integrated Steel Plants
oBhilai Steel Plant (BSP) in Chhattisgarh setup with Soviet Collaboration
oRourkela Steel Plant (RSP) in Orissa setup with German Collaboration
oDurgapur Steel Plant (DSP) in West Bengal setup with British Collaboration
oBokaro Steel Plant (BSL) in Jharkhand setup with Soviet Collaboration
oIISCO Steel Plant (ISP) at Burnpur, West Bengal
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5. INTRODUCTION
Bhilai Steel Plant (BSP), a unit of Steel Authority of
India Ltd. Inaugurated at 1959 by the President of India Dr.
Rajendra Prasad with a production capacity of 1.0 million
tonne. A-public sector undertaking was conceived under
aegis of Indo-USSR Treaty in the 2nd Five year plan.
The captive mines of the plant located at Dalli-Rajahara
supplies iron ore and lime stone used to be available from
Nandini captive mines. At present lime stone is procured
from outside. The other major raw material, coal is
purchased from outside either through import or from
indigenous market.
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6. ELEVEN times of Prime Minister’s
Trophy for best integrated Steel Plant in the Country,
Bhilai Steel Plant is India’s sole producer for the rails
and heavy steel plates and major producer of
structural. The Plant is sole suppliers of the country’s
longest rail tracks of 260 meters. With an annual
production capacity of 3.153 MT of saleable steel,
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 Standards, all saleable steel
products of Bhilai Steel Plant come under The ISO
umbrella.
At Bhilai ISO:14001 has been awarded for
Environment Management System in the Plant,
Township and DALLI MINES. It is only Steel plant to
get certificates in all these areas.
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7. Company Profile
Type Central Public Sector
Industries Metallurgical process
Founded 1955
Headquarters Bhilai, Chhattisgarh, India
Products Rails, Plates, Structurals
Website https://www.sail-
bhilaisteel.com/
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8. PRODUCTS PROFILE
Product Type Product End use Productio
n
(Tonnes/a
nnum)
A. Finished Product Rail and
structural mill
Rails in 13m, 26m, 65/78 m
length and welded panels of
130m/260m length Indian
Railways, Export Heavy
Structural Construction Crane
Rails Cranes Crossing sleepers
Broad gauge sleepers
7,50,000
Merchant Mill Light structural engineering and
construction, medium rounds
(plain & TMT), heavy rounds
(plain)
5,00,000
Wire Rods
Mill
Wire rods - plain construction
wire rods - TMT EQ wire rods
electrodes
4,20,000
Plate Mill
(upto3600mm
wide)
Plates boilers, defence, railways,
shipbuilding, LPG cylinders,
export
9,50,000
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9. Product
Type
Products End Use Production
(Tonnes/ann
um)
B. SEMIS Billets (from BBM) Re-rollers 5,33,000
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,,
Anthracene oil, Dephenolised oil,
PCM etc.), Benzol & its products (NG
Benzene, Toulene, Xylene,solvent
oilslag,granulated slag from CHSG
plants & SGP for cement
manufacture
Total sealable steel 31,53,000
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10. PROCESS FLOW at BSP
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11. DEPARTMENTS WE VISITED..
oRail and Structural Mill
oPlate Mill
oSteel Melting Shop(SMS)
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12. RAIL AND STRUCTURAL MILL
Capacity - 7,50,000 T
Products
•Rails - R52 Kg/m & R60 Kg/m ; UTS 880 N/mm2 rails
as per IRST-12/96 specifications , Euronorms and
international standards.
•Thick web asymmetric rail Zu 1-60
•Beams - 600,500,450,400,350,300 & 250.
•Channels - 400,300 & 250.
•Angles - 200 & 150.
•Crossing Sleeper.
•Crane Rails - KP80, 100,120 & 140.
•Bhilai is the sole supplier of the country's longest rail
tracks of 260 metres.
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14. Bhilai Rails
Largest producer and leading rail maker of the world.
Four and a half decades of experience in rail making.
Produced over 15 million tonnes of rails; 2.7 lakh km in length.
Indian Railways- World’s second largest rail company moves
exclusively on Bhilai rails.
Bhilai rails are subjected to world’s highest traffic density and axle
loads.
Rails exported to 10 countries with exports to South Korea, New
Zealand, Argentina, Turkey, Iran, Egypt, Ghana, Bangladesh and
Malaysia.
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15. Technological Superiority
Steel from LD Convertor – Ladle furnace - RH Degasser –
Concast route; achieving world best level of degassing/
Refining to less than 1.5 ppm of hydrogen in liquid steel in
100% of heats.
Capability to produce as rolled lengths of 80 meter and
welded panels upto 260 meters.
High degree of Straightness due to world’s most advanced
and Laser straightness measurement based end
straightening machine.
World class tested rails passing through state of art online
NDT equipment; Laser straightness measurement, Ultrasonic
and eddy current testing machines
Computer controlled automatic rail handling system and
automatic yard mapping for rail storage.
Computerised Rail Tracking system for collection and
storage of all process and testing related data of each rail.
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18. Bhilai Rails- Universally Certified
RDSO, Indian Railways
RITES Ltd
ISO-9001-2000 certified by LRQA (Lloyds Register Quality
Assurance)
ISO 14000 certified by BIS
Crown Agents, London
General Superintendence Company, Geneva
Lloyds Register Of Shipping
Robert W Hunt & Company
Overseas Merchandise Inspection Company, Tokyo
Egyptian Railways Inspection Team
Tuboscope Vetco Gmbh, Deutcheland
Bhilai’s Special Purpose Rails
Copper Molybdenum Corrosion resistant rails
High yield strength/ UTS vanadium micro-alloyed rails
High conductivity metro rails
Copper-Chromium alloyed High strength Rails
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19. PLATE MILL
Capacity - 9,50,000 T
Plates thickness - 8-120 mm
Width - 1500-3270 mm
Length - 5-12.5 M
The modern Plate Mill rolls out heavy and medium plates, as well as
those for pipe manufacturers. Plates of wide variety, in any required
size, and strength, chemical and physical properties, can be produced
here.
It has capacity to produce high pressure, boiler quality and high tensile
steels.
Shipbuilding plates, conforming to Lloyds specifications, and pressure
vessel boiler plates, conforming to various ASTM, ASME standards,
have withstood the challenges of nature and time. Some of the unique
features of the mill are on-line finishing facilities and off-line normalising
facilities. 19

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23. Bhilai has the widest plate mill in the country, and
it uses continuously cast slabs as input. Liquid steel
produced under controlled conditions in the LD
Converters is rinsed with argon gas to homogenise
the composition as well as to remove non-metallic
inclusions before continuous casting so as to ensure
the production of high quality feedstock for the Plate
Mill. As per customers' requirement or
specifications, plates are normalised in a roller
hearth normalising furnace.
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24. STEEL MELTING SHOP II
• Steel Melting Shop-II (SMS-II) is designed to produce 1.5 MT of
Cast Steel in the form of Slabs and Blooms.
• With every passing day, the shop has improved its systems and
processes.
• Many in-house modifications along with acquisition of most modern
steel making equipments have helped in fulfillment of ever
increasing customer demands in terms of quality
• The revised production capacity SMS-II is equipped with secondary
steel making units like VAD, Ladle Furnaceand RH Degasser to
produce low hydrogen, low sulphur and micro-alloy steels.

25. STEEL BEING CARRIED IN LADDLES FOR
FURTHER PRODUCT ADDITION

27. SMS-II COMPRISES CONVERTER SHOP
& CONTINUOUS CASTING SHOP
• THE operation cycle of the convertor is
as follows :
• a) Charging - 5 min
• b) Oxygen blowing - 20 min
• c) Sampling & temperature measurement - 8
min
• d) Corrections before tapping - 5 min
• e) Tapping - 5 min
• f) Nitrogen splashing, coating- 7 min

28. The following Bulk Materials are
handled in SMS II
• 1) Lime.
• 2) Calcined Dolomite.
• 3) Lime stone.
• 4) Coke.
• 5) Raw Dolomite.
• 6) Iron Ore

29. CONTINOUS CASTING SHOP
• Continuous Casting Shop
comprises the following sections :
• 1) Argon Rinsing Bay
• 2) Tundish preparation Bay
• 3) Casting Bay
• 4) VAD (Vacuum Arc Degassing Unit)
• 5) Ladle Furnace

30. .
• 6) RH Degasser
• 7) Discharge Bay
• 8) Slab & Bloom Storage Yard (SBS)
• 9) Mould Repair Shop
• 10) Casting Powder Plant (SFMPP

31. .
CASTING FOR RAIL

32. Achievements
SAIL was featured in the 2008 list of Forbes Global 2000 companies at
position 647.
SAIL was adjudged best PSU and conferred with Business and Economy
Leadership and Excellence Awards 2008 by Planman Media.
BSP won CII Sustainability Award – 2008 in independent unit category.
Greentech Safety Gold Award by Greentech Foundation for outstanding
achievement in Safety Management to Bhilai Steel Plant.
Golden Peacock Award for Combating Climate Change – 2008 for BSP.
National Safety Award to Bhilai Steel Plant announced by the Ministry of
Labour & Employment, Government of India – 2008.
Ispat Bhasha Bharati. the Rajbhasha Journal of SAIL has been awarded with
the first prize under the All India House Journal Award Scheme - 2008-09.
Golden Peacock Award for Corporate Social Responsibility won by Bhilai
Steel Plant (BSP) for the third year in a row - 2009
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