In the DRI plant, production of sponge iron using a solid reductant involves reducing iron ore (lumps/pellets) with carbonaceous materials like coal or lignite. The reduction is carried out in a rotary kiln (which is inclined and rotates at a predetermined range of speeds) at a stipulated temperature (850°C -1050°C). The inclination and the rotary motion of the kiln ensure that the raw materials move from the feed end to the discharge end of the kiln and during this movement the actual reduction of iron ore to iron takes place. The material discharged from the kiln is taken to a rotary cooler for cooling and the cooled product is separated from the coal char.

In the SMS plant, sponge iron along with pig iron in a close requisite ratio is charged in the furnace. The material gets melted at a temperature of 1500°C -1600°C. This hot metal is then tested for its chemical composition. Depending on the existing chemical components, various necessary Ferro Alloys are added to it. The hot metal is then oxidised and then sent to the Continuous Billet Casting plant. Here the molten steel is continuously casted into Billets.

The Billets thus manufactured are re-heated at a temperature of 1200°C in the re-heating furnace and are rolled into specific sections of finished material in the Rolling Mill Unit.

In case of manufacturing TMT bars, the "Thermex Process" is followed as explained below:

From the finishing stand of the rolling Mill, the Re-Bars are guided through a specially designed proprietary Thermex pipes in which water quenching is done under controlled conditions. The surface temperature of the hot Re-Bars falls drastically from 900°C to around 400°C on account of the intense and uniform cooling, whereas the core temperature remains the same.

At the Cooling Bed, temperature equalising takes place at round 600°C. This makes the surface of the Re-Bar a hardened structure called tempered martensite. The core remains soft and is known as ferite-perlite. This process increases the tensile strength of the material while keeping high ductility and weldability. This whole process is a patented technology from HSE, Germany under the brand name of "Thermex".

The Rolling Mill is one of the most advanced units in India equipped with latest machineries for quality manufacturing. The Quality Control Lab is also equipped with all the necessary equipments for high grade Quality Control.

In the Howrah plant of the company, the Billets produced in its Durgapur unit are rolled into a variety of structural steel products like M.S. Round bars, M.S. Angles, M.S. Joists, M.S. Channels, M.S. Flats Bars and Window Sections.

Being ISO: 18001 certified, the company considers safety and environment prevention an integral part of its responsibilities. Hence, proper care is taken of the Health and Safety of its workers in the plant as mentioned in the company's health and safety policy.

To abide by its Environment Prevention Plan, the company has an ESP setup by Elex AG Switzerland, in its DRI unit. This serves a dual purpose of filtering particles like coal ash and also reducing the amount of suspended particles in the gases emitted out by the plant. The company also maintains lush gardens and landscapes around the plant contributing to the Green Belt Revolution. The company is ISO: 14001 certified and follows the principles of its Environment Management policy in full spirit.

The quality products manufactured in its plant ensure to provide its customers with the 'Best Value for Money', and therefore to loyally abide by its promise to provide them with 'Complete Customer Satisfaction'.

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