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28 Jindal Steel & Power Limited Business Leadership Sustainable Operations Excellent Governance Robust FinancialsOperational ReviewAnnual Report 2011-1229Raigarh, ChhattisgarhJSPL’S STATE-OF-THE-ART STEEL MAKING PLANT HAS ACAPACITY OF UP TO 3 MTPA. THIS PLANT IS ALSO THEWORLD’S LARGEST COAL-BASED SPONGE IRONMANUFACTURING FACILITY.Research and development focusSuccessful commission of coal silo at coke oven; it can beused by different coal blends for coke production, reducingproduction costDeveloped ultra-low sulphur steel in 200 mm dia castStudy on root cause and remedial measures for occurrences offish cracks in plates in collaboration with IIT KanpurStudy on the effect of tundish argon gas diffuser on steelcleanlinessStudy on root cause and remedial measures on theformation of Rolled Burr Pits (RBP) in parallel flange beamsDeveloped newer structural gradesDeveloped sheet pile (Larson IV)Developed medium light structurals (Channel: 125-200 mm,Angle: 100-250 mm, Beam: 180 and 200 mm)Trial development of lead steel for wire rod applicationUse of non-coking coal in the blend of coking coal for cokeproduction without deteriorating the coke quality in miniblast furnaceStraightening of Columns at Rolling Mill (RUBM) at Raigarh, ChhattisgarhKey highlightsRecorded the highest ever steel production of 2.75 million tonCommissioned the casting of 320 and 350 Dia rounds inSMS III, the biggest diameter in round cast in IndiaFor the first time, JSPL manufactured ultra-low sulphur gradesteel for API applicationsDevelopment of boiler quality grade with impact guaranteePower Grid Corporation of India Limited has approved JSPLfor producing different sizes of Angle Irons for TransmissionTowersPrime yield for MLSM product increased by 1.5%, resulting insignificant cost savingsDeveloped a new variety of section anglesCommissioned India’s first automatic Fly Ash based brick plant(3,00,000 bricks per day)Commissioned a rail over-bridge and rail under pass forsmooth logisticsMLSM reheating furnace oil replaced by PGP Gas to saveconversion costDeveloped 23 new varieties of value-added steel productsProjects under implementationWidest Slab Caster (3,000 mm width) revamping at SMS IINew Fume Extraction System at SMS IIUp-gradation of Plate MillInstallation and commissioning of leveller at Plate Millto minimise rejection of plates and improve customersatisfactionTechnical aspects have been frozen for 600 TPD new Lime Kilnproject at JSPL, RaigarhInstallation and commissioning of CaCl 2spray system at thesinter plant to improve strength and reduce fines generationPollution control system (Dust Settling System) at RMH areacontrols fugitive emission during the loading and unloading ofvehiclesUpcoming projectsPulverised coal injection (PCI) mill: PCI coal will be used inthe blast furnace to reduce the consumption of coking coal,thus reducing the cost of conversion of hot metalInstallation of third turbo-blower: Existing two turboblowers are continuously running without any maintenance.If any of the two turbo blowers is shut down then thecontinuity of hot blast air in the blast furnace can be run bythe stand-by turbo-blowerCoal blending: Low-cost coal is blended into high-gradecoking coal to reduce the cost of cokePlate mill shed extension: Plate mill shed is being extendedto stock the finished goods inventory (as per thickness of aplate) to serve the customer better; also, the extended spacewill help increase the production from cut-to-length machineas the space availability for equipment will be moreService centre for MLSM: Standard length angles can beserviced as per customer requirementsLadle Refining Furnaces (LRF) II: Second LRF in SMS III willincrease the secondary steel-making capacity at SMS IIISlab caster up-gradation: Slab caster upgradation is beingdone to increase the width of the slabs to 3,000 mm and thusincreased width of plates which can be rolled from the plate millSlab Casting in progress at Raigarh steel plant in ChhattisgarhView of 1 MTPA Plate Mill at Raigarh, Chhattisgarh