Industries- Major Industries - Iron and Steel

Iron and Steel Industry:

Pig Iron
Pig iron is the intermediate product of smelting of iron Ore with a high-carbon fuel such as coke and charcoal and is the basic raw material in Foundry and Casting Industry for the manufacture of various types of castings required for engineering sector. Pig iron usually has very high carbon content of 3.5% to 4.5%. The main sources of pig iron have traditionally been the integrated steel Plants of SAIL besides plants of Tata Steel and Rashtriya Ispat Nigam Ltd. The domestic production of pig iron did not keep pace with the demand. Efforts were, therefore, made to increase pig iron manufacturing facilities in the Secondary Sector
As a result of various policy initiatives taken by the Government, Private Sector did show considerable interest in setting up new pig iron units, specially in the post-liberalised period. Of the total 6.87 million tonnes production in 2012-13, the Private Sector accounted for over 90% of the total production for sale of pig iron in the country.
In 2012-13, 6.87 million tonnes pig iron was produced against 5.37 million tonnes in 2011-12. Location and capacity of principal pig iron units in Private Sector are furnished in Table-2. M/s Usha Martin Industries Ltd, M/s Jindal Steel & Power Ltd have integrated mini-blast furnaces (MBF) for manufacture of steel through Electric Arc Furnace (EAF). M/s Hospet Steel (a joint venture of Kalyani and Mukand) and M/s Southern Iron & Steel Co. Ltd had integrated their MBF with energy optimising furnace to produce steel.
Sponge Iron
Commercial production of sponge iron in India commenced in 1980. Sponge Iron India Ltd was first to set up a plant in 1980 at Palwancha of Khammam district in Andhra Pradesh with a capacity of 0.039 million tonnes/year.
In the last few years, combined use of hot Metal and sponge iron in electric arc furnace have been in practice for production of liquid steel, consequently production of sponge iron too went up substantially to meet the demands. The installed capacity of sponge iron increased from 1.52 million tonnes per annum in 1990-91 to 37.30 million tonnes per annum in 2012-13. The production also increased from 0.9 million tonnes in 1990-91 to 23.01 million tonnes in 2012-13

Industry:

Iron and steel is a basic industry and is the backbone of industrial development of any country.
The first unit, which was able to produce pig iron successfully, in the country came up at Kulti in 1874 and was named the Bengal Iron Work Country. Another plant came up at Sakchi (now Jamshedpur) in 1907, set up by the Tatas and called the Tata Iron and Steel Company (TISCO). In 1919, the Indian Iron and Steel Company (IISCO) plant was set up at Burnpur. In 1923, another plant came up, called the Mysore Steel Works (later named the Visveshwaraiya Iron and Steel Limited—VISL)
The plant at Durgapur, in Bardhman district of West Bengal started operating in 1962. It was set up with help from the United Kingdom. The Alloy steel plant at Durgapur produces ingot steel. Iron ore for the Durgapur steel plant comes from Bolani mines in Kendujhar; coal from Jharia, and power is supplied by the DVC. Limestone comes from Sundergarh and manganese from Kendujhar. Durgapur steel plant is situated on the Kolkata- Asansol rail line. This way, it is connected with Kolkata port and the major markets.
The Bokaro steel plant is situated in Hazaribagh district of Jharkhand at the confluence of Bokaro and Damodar rivers. It was established during the Third Plan, but started operating in 1972. It was set up with Soviet help. Iron ore for the plant comes from Kiriburu in Kendujhar district of Orissa and partly from Salem, Mangalore and Ratnagiri by sea route.
Coal comes from Jharia and power is supplied by the DVC. Limestone supplies are drawn from Bhavantpur and Daltonganj in the Palamau district, and dolomite from Bilaspur in Madhya Pradesh. The location of the steel plant is favourable, as it is nearest to the industrial region of southern Uttar Pradesh (Varanasi, Kanpur, Ferozabad, Mugalserai) and also has access to Delhi and Amritsar.
The plant at Salem in Tamil Nadu was planned during the Fourth Plan, but it could come into operation only in 1982. Earlier, due to lack of suitable raw materials in the area for making iron by the conventional blast furnace process, the proposal for a steel plant could not get materialised. Salem area is rich in iron ore and this iron ore is beneficiated to a higher grade concentrate, agglomerated and then smelted in electric furnace. The Salem plant produces stainless steel.
The Visakhapatnam Steel Plant, which came into operation in 1992, is the first plant in the shore region. It is also the most sophisticated modern integrated steel plant in the country. A number of modern technological features have been incorporated in the plant. Being located at a port site, the plant has the flexibility to opt for imported coking coal, thereby relieving the pressure on Indian coal mines.
Also, its products can be easily exported. Visakhapatnam is well connected with the coalfields of Damodar Valley. The iron ore deposits are obtained from Bailadila in Chhattisgarh. Fluxes like limestone, refractories and ferroalloys can be obtained from the adjacent areas.
Neelachal Ispat Nigam Ltd. and government agencies have set up Orissa’s second integrated iron and steel plant at Kalinganagar, in Jajpur district

Table of Contents

v Mini Steel Plants:

Apart from the integrated steel plants, steel is also produced by electric arc furnace units which are popularly known as mini steel plants, from steel scrap/sponge iron. The integrated steel plants mainly produce mild steel and alloy steel, including stainless steel. These plants are located in areas away from the integrated steel plants to meet the demand there. Their period of construction and gestation is short and they offer greater flexibility in operation.

v Copper Smelting Industry:

It was in the year 1857 that the Singhbhum Copper Company was formed to undertake mining operations at Saraikela. In 1924, the Indian Copper Corporation (ICC) was set up with concentration plant and smelter which produced copper at Ghatsila in Jharkhand (then in Bihar). In 1972, the ICC was taken over by the Hindustan Copper Limited (HCL), and now, the HCL is the sole producer of primary copper in India.
The Khetri Copper Complex at the foothills of Aravallis in Rajasthan erected by the HCL was formed to exploit the Khetri-Singhbhum ores. The unit consists of Khetri and Kolihan mines, a matching concentrator plant, smelter, electrolytic refinery and wire bar casting plants. The Khetri Copper Complex is an integrated copper mining- cum-metallurgical unit—by-product is sulphuric acid and fertiliser triple superphosphate is also manufactured.
The Malanjkhand copper project in Madhya Pradesh is the first large sized open cast mine and has been developed mainly to supply copper concentrates to Khetri to enable the plant to achieve the target capacity.
Other copper smelting projects include the Rakha copper project (Singhbhum-Maubhandar), Dariba Copper Project (Alwar) and Chandmari Copper Project (Jhunjhunu in Rajasthan).

Aluminium Industry:

Alumina

The production of alumina was 36.10 lakh tonnes in 2012-13. NALCO, accredited as one of the largest producers of alumina in Asia, has expanded its alumina refinery capacity to 1.575 million tpy. With further addition of capacity undertaken in the second phase by another 5,25,000 tonnes, the total capacity now stands at 2.1 million tpy. By 2014-15, after the 3 rd phase of expansion, the total capacity is expected to touch 2.975 million tonnes.

It was in the year 1938 that the country saw, for the first time, aluminium production at Alupuram Reduction Works of the Indian Aluminium Company. Later, this company was converted into a public sector company in 1944. By 1967, there were five smelters, one each at Jaykaynagar, Alupuram, Hirakud, Renukoot and Mettur
Besides mining of ore, the aluminium industry has four distinct stages, viz. production of alumina and aluminium; fabrication of aluminium ingots into sheets, circles, foils and various other types of structurals, and the production of articles from aluminium, like kitchenware’s, articles used in electrical transportation, building and construction, canning and packing material, furniture, etc.

Location:

The location of the aluminium industry is governed mainly by the availability of bauxite. It has been found that to produce – one tonne of aluminium of 50 per cent or more content, nine tonnes of bauxite, 0.44 tonne of petroleum coke, 0.26 tonne of caustic soda, 0.09 tonne of lime, very small quantities of cryolite, aluminium fluoride, soda ash and about 18,750 KW of electricity are required. Hence, the aluminium industry is mostly located in areas producing bauxite and having relatively cheap availability of hydro-electricity as in West Bengal, Uttar Pradesh, Maharashtra, and Tamil Nadu.
The Hindustan Aluminium Company (HINDALCO), a private sector company has its aluminium plant at Renukoot, Uttar Pradesh. In order to achieve the economics of scale, a second smelter was set up at Hirakud, Orissa.
HINDALCO, and the Bharat Aluminium Company (BALCO) set up two units at Korba and Ratnagiri to utilise bauxite ores of Amarkantak in Madhya Pradesh and of Udaigiri-Dhangarvadi region in Maharashtra, respectively.
A huge public sector aluminium company, the National Aluminium Company (NALCO) was set up with assistance from a French company at Damanjodi near Jaipur (Koraput district in Orissa). It also has a smelter at Angul, Orissa.
Cement Industry:
Cement, an important Infrastructure-2/”>INFRASTRUCTURE core industry, is one of the most advanced industries in the country. The country was deficient in cement and it had to resort to imports to fill the gaps in supplies until the complete decontrol of price and distribution on March 1, 1989 and introduction of other policy reforms; since then, the cement industry has made rapid strides.
Cement is made mainly from limestone and clay. Other raw materials include shale, coal and gypsum. Thus, cement factories are located near limestone deposits. Since coal and gypsum are brought generally from long distances and cement has to be dispatched to far-off consuming centres, the cement plants are located close to rail routes. Sludge from fertiliser plants, blast furnace slag and sea-shells are used instead of limestone in some cement plants.
For instance, the cement plants at Bhadravati (Karnataka) and Chaibasa (Jharkhand) use slag and the plant at Sindri uses sludge. Limestone is available at a number of places in most of the states of India, but basalt covered areas of Maharashtra and Chhattisgarh, and the northern alluvial plains are without limestone based cement manufacturing plants. At Dalmia Dadri in Haryana, there is a cement plant based on kanker (limestone nodules).
The major producer states of cement and major cement producing centres are given below.
Tamil Nadu:
TiruneFveli, Ramanathpuram, Tiruchchirappalli, Salem and Coimbatore.
Chhattisgarh:
Durg and Raipur.
Madhya Pradesh:
Jabalpur and Gwalior.
Gujarat:
Ahmedabad, Sikka, Sewree, Dwarka, Porbandar, Sewalia and Ankaleshwar.
Jharkhand:
Sindri, Ranchi, Palamau, Japla and Chaibasa.
Bihar:
Dalmianagar
Rajasthan:
Bundi, Sawai Madhopur, Chittor- garh, Udaipur.
Andhra Pradesh:
Karimnagar, Kurnool, Vijaywada, Krishna, Sullurpet and Anantpur.
Karnataka:
Shahbad, Wadi, Kurkunta, Bagalkot, Bhadravati and Tumkur.
The Indian cement industry not only ranks high in the production of cement in the world but also produces quality cement to meet global standards. The induction of advanced technology has helped the industry immensely to conserve energy and fuel and to save materials substantially. Apart from meeting the entire domestic demand, the industry is also exporting cement and clinker.
The working group on cement industry for the formulation of Tenth Five Year Plan and other studies on global competitiveness of the Indian cement industry highlighted constraints such as high cost of power, high freight cost, inadequate infrastructure and poor quality of coal. Additional capacity creation is hampered by the lack of long- term coal linkages.

In order to utilise the excess production capacity available with the cement industry, the government has identified the following thrust areas for increasing demand:

Further push to housing development programmes;
Promotion of concrete highways and roads;
Use of ready-mix concrete in large infrastructure projects; and
Construction of concrete roads in rural areas under Prime Minister’s Gram Sadak Yojana.

Lead arid Zinc Smelting Industry:
Lead
The total installed capacity of lead smelting was 1,85,000 tpy excluding secondary lead which was 24,000 tpy. Primary lead was produced entirely by HZL at lead-zinc smelter at Chanderiya, Chittorgarh district, and Rajpura-Dariba Plant, Udaipur district, Rajasthan. Tundoo lead smelter, Dhanbad district, Jharkhand with capacity of 8,000 tpy was decommissioned by HZL in May 2003 due to economic non-viability.
Secondary lead capacity is held by the Indian Lead Pvt. Ltd at its two units at Thane in Maharashtra and Kalipark in West Bengal. The installed capacity of these two plants is 24,000 tpy. There are a number of other secondary producing units in the Organised and Unorganised Sector. As per the estimates made in the recently published Market Survey on lead & zinc by IBM, production of 88,000 tonnes of lead has been estimated in 2010-11 as secondary lead.
Zinc
India has a total installed zinc capacity of 9,17,000 tpy distributed between HZL smelters at Debari, Visakhapatnam, Chanderiya, Dariba and Binani Zinc Ltd’s (BZL) plant at Aluva in Kerala. HZL’s Dariba hydro-zinc smelter with 2,10,000 tpy capacity was commissioned in March 2010. BZL has an annual installed capacity of 38,000 tonnes zinc along with 80 tonnes cadmium and about 53,000 tonnes sulphuric acid.
In India the main source of lead and zinc ores is the Zawar deposits of Rajasthan. The paucity of ore supplies has been largely responsible for the rather late and slow development of the lead-zinc smelting industry in the country.
The mines under production other than the Zawar mines are Agnigundla lead mines of Andhra Pradesh, Rajpura-Dariba mines in Udaipur, Rajasthan and Sargipalli lead mines of Orissa. Two smelters are under production: the Debari zinc smelters of Udaipur and the Vizag lead smelter plant at Visakhapatnam (Andhra Pradesh). The Debari plant was erected by the Hindustan Zinc Ltd (HZL) with technical assistance from Krebspenarroya of France and Lurgi of Germany.

The iron and steel industry is a major global industry that produces iron and steel products. Iron ore is mined and then processed into iron, which is then melted and refined into steel. Steel is used to make a wide variety of products, including buildings, cars, appliances, and machinery.

The iron and steel industry is a major source of EMPLOYMENT and economic activity in many countries. In the United States, the iron and steel industry employs over 100,000 people and generates over $100 billion in economic activity each year.

The iron and steel industry is facing a number of challenges, including rising energy costs, environmental regulations, and competition from low-cost producers. However, the industry is also investing in new technologies and processes to improve efficiency and reduce costs.

The future of the iron and steel industry is uncertain. However, the industry is likely to remain a major global industry for many years to come.

Iron ore mining

Iron ore is a mineral that is used to make iron. It is the most common metal in the Earth’s crust and is found in rocks and Minerals all over the world. Iron ore is mined in open-pit mines or underground mines. The ore is then crushed and ground into a fine powder. This powder is then mixed with coke and limestone and heated in a blast furnace to produce molten iron.

Steelmaking

Steelmaking is the process of converting iron into steel. Steel is a stronger and more durable material than iron. It is made by adding carbon to iron and then heating the mixture to a high temperature. The carbon reacts with the iron to form iron carbide, which makes the steel stronger.

Iron and steel products

Iron and steel are used to make a wide variety of products, including buildings, cars, appliances, and machinery. Steel is also used to make weapons and ammunition.

Iron and steel recycling

Iron and steel can be recycled many times. When iron and steel products are recycled, they are melted down and then re-formed into new products. Recycling iron and steel saves energy and Resources.

Iron and steel trade

The iron and steel industry is a global industry. Iron ore is mined in many countries, including Australia, Brazil, China, and India. Steel is produced in many countries, including China, Japan, the United States, and Russia. Iron and steel products are traded between countries.

Iron and steel industry associations

There are many iron and steel industry associations in the world. These associations represent the interests of iron and steel producers, suppliers, and users. They work to promote the iron and steel industry and to improve the efficiency of the industry.

Iron and steel industry research

There is a lot of research being done on iron and steel production. This research is aimed at improving the efficiency of the iron and steel industry and at developing new technologies for producing iron and steel.

Iron and steel industry sustainability

The iron and steel industry is working to reduce its environmental impact. The industry is investing in new technologies that will reduce emissions and improve Energy Efficiency. The industry is also working to recycle more iron and steel.

Iron and steel industry future

The future of the iron and steel industry is uncertain. However, the industry is likely to remain a major global industry for many years to come. The industry is facing a number of challenges, including rising energy costs, environmental regulations, and competition from low-cost producers. However, the industry is also investing in new technologies and processes to improve efficiency and reduce costs.

What is iron and steel?

Iron and steel are two of the most important materials in the world. Iron is a metal that is found in nature, while steel is a man-made alloy of iron and carbon. Steel is stronger and more durable than iron, and it is used in a wide variety of products, including buildings, cars, and appliances.

What are the different types of iron and steel?

There are many different types of iron and steel, each with its own unique properties. Some of the most common types of iron and steel include:

Carbon steel: This is the most common type of steel, and it is made by adding carbon to iron. Carbon steel is strong and durable, but it can rust easily.
Alloy steel: This type of steel is made by adding other Elements to iron and carbon, such as chromium, nickel, or manganese. Alloy steel is stronger and more durable than carbon steel, and it is resistant to rust.
Stainless steel: This type of steel is made by adding chromium to iron and carbon. Stainless steel is very resistant to rust, and it is used in a variety of products, including appliances, cookware, and jewelry.

What are the uses of iron and steel?

Iron and steel are used in a wide variety of products, including:

Buildings: Steel is a major component of many buildings, including skyscrapers, bridges, and Dams.
Cars: Steel is used in the bodies and frames of cars.
Appliances: Steel is used in a variety of appliances, including refrigerators, stoves, and washing machines.
Tools: Steel is used in a variety of tools, including hammers, saws, and screwdrivers.
Machinery: Steel is used in a variety of machinery, including engines, generators, and pumps.

What are the environmental impacts of iron and steel production?

The production of iron and steel is a major source of Air Pollution, Water Pollution, and greenhouse gas emissions. Iron and steel production also requires the use of large amounts of energy and water.

What are the future trends in the iron and steel industry?

The iron and steel industry is facing a number of challenges, including the need to reduce its environmental impact and the need to compete with low-cost producers from other countries. The industry is also facing the challenge of changing consumer preferences, as consumers are increasingly demanding products that are made from recycled materials.

What are some of the latest innovations in the iron and steel industry?

The iron and steel industry is constantly innovating in order to improve efficiency and reduce environmental impact. Some of the latest innovations in the industry include:

The use of new technologies to reduce emissions from iron and steel production.
The development of new types of steel that are stronger and more durable.
The use of recycled materials in the production of iron and steel.

The iron and steel industry is a major sector of the global economy, accounting for over 7% of global manufacturing output.
The industry is highly cyclical, with production and demand fluctuating in response to changes in the global economy.
The main raw materials used in the iron and steel industry are iron ore, coal, and limestone.
The main products of the iron and steel industry are iron and steel products, such as bars, rods, plates, and sheets.
The main markets for iron and steel products are the construction, automotive, and machinery industries.
The main producers of iron and steel are China, India, the United States, and Japan.
The main challenges facing the iron and steel industry are rising energy costs, environmental regulations, and competition from low-cost producers.

Here are some MCQs on the iron and steel industry:

Which of the following is not a raw material used in the iron and steel industry?
(A) Iron ore
(B) Coal
(C) Limestone
(D) Water
Which of the following is not a product of the iron and steel industry?
(A) Iron
(B) Steel
(C) Copper
(D) Aluminum
Which of the following is the main market for iron and steel products?
(A) Construction
(B) Automotive
(C) Machinery
(D) All of the above
Which of the following is the main producer of iron and steel?
(A) China
(B) India
(C) United States
(D) Japan
Which of the following is a challenge facing the iron and steel industry?
(A) Rising energy costs
(B) Environmental regulations
(C) Competition from low-cost producers
(D) All of the above
Which of the following is not a factor that affects the price of iron and steel?
(A) Demand
(B) Supply
(C) Cost of production
(D) Weather conditions
Which of the following is the most common type of iron ore?
(A) Hematite
(B) Magnetite
(C) Limonite
(D) All of the above
Which of the following is the most common type of coal used in the iron and steel industry?
(A) Bituminous coal
(B) Anthracite coal
(C) Lignite coal
(D) Peat coal
Which of the following is the most common type of limestone used in the iron and steel industry?
(A) Dolomitic limestone
(B) Calcitic limestone
(C) Marble
(D) Granite
Which of the following is the most common type of iron and steel product?
(A) Bar iron
(B) Steel rod
(C) Steel plate
(D) Steel sheet