10 MTPA CAPACITY AUDIT REPORT, HAZIRA
ESSAR STEEL INDIA LIMITED

AEGIS LTD -ESSAR ENGINEERING SERVICES DIVISION

ESSAR STEEL INDIA LIMITED

HAZIRA FACILITY 10 MTPA CAPACITY AUDIT REPORT

ESSAR ENGINEERING SERVICES DIVISION.
HAZIRA
Document No: 2726-H000-ESTL/10MTPA/AUDIT-2013 APRIL 13

10 MTPA CAPACITY AUDIT REPORT, HAZIRA FACILITY
ESSAR STEEL INDIA LIMITED

AEGIS LTD -ESSAR ENGINEERING SERVICES DIVISION

INDEX

Contents
1. 2. 3. 4. 5. 6. 7. 8. INTRODUCTION .......................................................................................................... 3 METHODOLOGY OF STUDY ...................................................................................... 4 EXECUTIVE SUMMARY ............................................................................................ 11 DESIGN CAPACITY OF UNITS............................................................................... 27 PRESENT OPERATION AND PRODUCTION LEVELS ....................................... 90 LIST OF CONSTRAINTS ........................................................................................ 167 ANALYSIS & RECOMMENDATIONS AS PER RAMP UP PROGRAM ........... 172 CONCLUSION ........................................................................................................... 193

LIST OF ANNEXURE ANNEXURE 1 ANNEXURE 2 ANNEXURE 3 ANNEXURE 4 ANNEXURE 5 ANNEXURE 6 ANNEXURE 7 MATERIAL FLOW SHEET AT 6.0 MTPA MATERIAL FLOW SHEET AT 7.7 MTPA MATERIAL FLOW SHEET AT 8.2 MTPA MATERIAL FLOW SHEET AT 9.2 MTPA FUEL GAS CONSUMPTION 9.2 MTPA SCHEDULING CHART (EAF-LF-CASTERS) LIST OF CONSTRAINTS

10 MTPA CAPACITY AUDIT REPORT, HAZIRA FACILITY
ESSAR ENGINEERING SERVICES DIVISION, HAZIRA

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10 MTPA CAPACITY AUDIT REPORT, HAZIRA FACILITY
ESSAR STEEL INDIA LIMITED 1. INTRODUCTION

AEGIS LTD -ESSAR ENGINEERING SERVICES DIVISION

Essar Steel India Limited (ESTIL) is one of the leading producers of Steel in India. The steel plant at EStIL’s Hazira facility has a name plate production capacity of 10 MTPA. The Hazira facility is the largest flat product producer complex in a single location in India. The Hazira Steel Complex was set up in the year 1993 to produce hot rolled coils of 1.6 MTPA capacity. The plant was gradually upgraded to 3.0MTPA by executing modifications and improvements to the existing facilities. The Steel complex was further upgraded to 4.6 MTPA and then to 10 MTPA with addition of separate units to the facilities. At present, the Hazira Steel Complex has been declared as 10 MTPA integrated steel manufacturing unit. The 10 MTPA steel complex consist of two major units namely Plant A & Plant B. Plant A has been rated to 4.6 MTPA capacity with HSM and CRM units and it is in operation since 1993. The Plant B is of 5.0 MTPA rated capacity and is in operation since 2010. As the plant is ramping up towards the designed capacity, an audit was felt necessary to identify the potential obstacles that would impact the functioning of various production units and the means to be overcome them so as to achieve the envisaged capacity. Hence, ESTIL management requested EESD to conduct a study on the present operation and maintenance regime of the Hazira Steel complex. The study would include identifying constraints and problems and proposing probable strategic solutions to the management, to improve the production capacity. EESD has carried out the study on the operations of various units and prepared the audit report entailing the necessary actions to be implemented. The methodology adopted for study, analysis and recommendation, made as part of this report, is articulated in the following chapter.

10 MTPA CAPACITY AUDIT REPORT, HAZIRA FACILITY
ESSAR ENGINEERING SERVICES DIVISION, HAZIRA

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ESSAR STEEL INDIA LIMITED 2.