mineral industry

Mineral Based Industry: Iron and Steel

  • Turning point in the history of iron and steel production in India.

  • India is currently the largest crude steel producer globally.

  • Key locations include Bhilai, Rourkela, and Visakhapatnam.

  • Major raw materials for iron and steel include:

    • Iron ore

    • Coal

    • Manganese (for hardening steel and impurity removal)

    • Limestone, silica, chromate, feldspar, scrap iron

    • Flux and fuel for steel production.

  • These industries provide essential components for various sectors including manufacturing machinery, electric machinery, and automobiles.

Steel Making Process

Ore Reduction

  • Ore and coal undergo reduction in a blast furnace

    • Limestone and dolomite are added as flux.

    • The slag (combined impurities) floats on molten iron, which is regularly collected as pig iron.

Steel Melting Furnaces

  • Pig iron, containing up to 5% carbon, is converted into steel by:

    • Removing impurities through deoxidation.

    • Adding carbon for desired hardness.

Rolling Mills

  • Steel is cast into ingots and rolled into various sizes for industrial use.

Major Integrated Iron and Steel Plants

Definition of Integrated Steel Plants

  • All processes from raw material supply to steel conversion and rolling occur in one location.

  • Contrast with mini steel plants which have separate handling.

Steel Authority of India (SAIL)

  • Largest public sector steel company in India.

  • Operates five integrated plants: Bhilai, Durgapur, Rourkela, Bokaro, Burnpur, and three special steel plants at Salem, Durgapur, Bhadravati.

Tata Iron and Steel Company (TISCO)

  • Historical significance being the oldest steel plant in India, established in 1907.

  • Located at Jamshedpur, ideal for raw material access:

    • Iron ore from nearby mines and manganese from Joda,

    • Coal from Jharia and Bokaro.

    • TISCO produces a variety of high-grade steel products (e.g., railway wheels, and special alloy steel).

Bhilai Iron and Steel Plant

  • Established in 1953 in collaboration with USSR.

  • Key products:

    • Heavy rails, structural products, and by-products like ammonium sulfate.

Rourkela Steel Plant

  • Built with German assistance (Krupp and Demag) in 1959.

  • Uses electric furnaces for mini steel plants, reliant on ferrous scrap.

Visakhapatnam Steel Plant

  • First shore-based steel plant established post-Independence.

  • Utilizes local high-grade iron ore, limestone from Bailadila, and coal from nearby fields.

Challenges Facing the Iron and Steel Industry

Capital Intensive

  • High initial investments required along with long gestation periods.

Obsolete Technology

  • Existing plants struggle due to outdated machinery and technology.

Limited Availability of Coking Coal

  • Availability of high-quality coking coal is limited, leading to reliance on imports.

Sick Industrial Units

  • Inadequate power supply and rising raw material costs have led many units to struggle or shut down.

Products of the Iron & Steel Industry

  • Products include:

    • Hot-rolled sheets

    • Cold-rolled sheets

    • Galvanised sheets

    • Electrical steel plates

    • Additional nitrogen as a by-product for fertilizers.

Key Facts about the Petrochemical Industry

Overview

  • Petrochemicals are derived from petroleum and are essential for various applications.

  • Major products include fertilizers, plastics, and synthetic materials.

Key Petrochemical Companies

  1. Herdillia Chemicals Ltd.

  2. National Organic Chemicals Industries Ltd.

  3. Petrofils Cooperative Limited (PCL)

  4. Indian Petrochemical Corporation Ltd.

  5. Reliance Industries

  6. Bongaigaon Petrochemicals Ltd.

Major Industries in India (Summary)

Iron and Steel

  1. TISCO - Jamshedpur, Jharkhand.

  2. Bhilai Iron and Steel Plant - Durg, Chhattisgarh.

  3. Rourkela Steel Plant - Sundargarh, Odisha.

  4. Visakhapatnam Steel Plant - Visakhapatnam, Andhra Pradesh.

  5. Others - Bokaro, Durgapur, IISCO, Vishvesvaraya Iron and Steel, Vijayanagar Steel Plant.

Petrochemical Industry

  1. Herdillia Chemicals - Chennai, Tamil Nadu.

  2. National Organic Chemicals - Mumbai, Maharashtra.

  3. PCL - Gujarat.

  4. Indian Petrochemical Corporation - Vadodara.

  5. Reliance Industries - Hazira, Gujarat.

Electronics Industry

  1. Indian Telephone Industries - Bengaluru, Karnataka.

  2. Electronics Corporation of India Ltd. - Hyderabad, Andhra Pradesh.

  3. Bharat Electronics Ltd. - Bengaluru, Karnataka.

Conclusion

  • The iron and steel industry plays a crucial role in India's economy, contributing to various sectors through its production processes and products. Despite challenges, it remains essential for industrial growth and development.