Welcome to Hospet Steels Limited

A joint venture of M/s Kalyani and M/s Mukand

Post Ginigera - 583228, Dist Koppal, Karnataka.
Efforts on environmental aspects.
Main gate with lush green background
Full view of the Plant

Admin building
 His Excellency, Sri. Veeren Shah
Governor of West Bengal, visited our factory
on 10th of July, 2004 along with Her Ladyship
and was received with great warmth.
Plantation in front of Admin building
Admin building, Scrap bay & boiler house
Greenery at south west water tank
 A view of clean road with
Greenery around & a “Parisara Vahini” vehicle
 Clean roads with
lush green road-divider,
environment slogan
& ornamental trees
Royal Palm flourishing amidst clean environment
South side road bund. A view from SMS stores
South side road. A view from LDO tank
A beautiful arial view of south side road and associated buildings.
(An Is-land of greenery amidst barren back-ground)
Close view of MBF-1
MBF-1 with land scape
Land scape by the side of
Boiler house
Furcaria sp seedlings raised at our nursery
 Forest seedlings kept ready for plantation.
We distribute this saplings to near by villages
on World Environment day, June 5th of every year.
 “ TEACH THEM YOUNG ”
We are creating awareness of environment even among youngsters
Cassia, sp at bloom near Admin building
Coconut plantation by the side of RMS
A close view of Land-scaping by the side of SMS yard
 15th August

A scene from Flag Hoisting Ceremony

at HSL housing colony on 15th August 2006.
Hygienically maintained canteen at our plant

Well maintained play ground.

Here we organise games & sports for local talents
Rescue team is ready to evacuate people
from a gas prone area during a mock-drill
 Mock-drill at MBF area
Evacuation of a casualty after first aid
 Sri. Navneeth Mohan, Sr. Asst. Director of Factories & Boilers,
Gulburga Div. addressing the gathering on the occasion of Mock-Drill
Periodical inspection of Fire-Fighting equipment by the Manager, Safety
Training on combating the fire by the security personal
An event of GRISD, organised by HSL

The procedure to revive a person who has just had a heart attack being demonstrated
on a mannequin by Dr. B.K. Sundar, a renowned cardiologist from Bellary
A view of neat open cast mines at SIOM-Sandur, A source of Iron ore.
Mined with conservation in view
Watering the roads to prevent dust while transportation of Iron ore-SIOM
Gully plug made to prevent soil erosion - SIOM
Plantation on hill slopes – SIOM.
Dignitaries observing the exhibits – GRISD-2005
TS 16949 – A symbol of our concern for Quality & care for our valuable customer
ISO 14001 – A symbol of our concern for environment
Our effort in participation at National level
Thank you for sparing your valuable time with us.

All Photos displayed here are the property of Hospet Steels Limited, Ginigera
Mr V.K.Goyal
- Secretary.Central Boiler Board.

Mr T.G.Manjunath
- Joint Director, Boiler Board, Karnataka

Mr K.Rengachari
- Sr. Deputy General Manager, Quality Control,
BHEL,Trichy.
HOSPET STEELS MUKAND LTD

TO THE LARGEST INTEGRATED

ALLOY STEEL PLANT
 HOSPET STEELS
MUKAND LTD

⇒ Green field project conceived in the year 1995.

⇒ Strategic Alliance between “Mukand” & “Kalyani” groups
to produce world class steel.
⇒ Both the groups are leaders in Alloy & Special Steels and
their individual strengths are complementary for achieving
management objectives.
⇒ Capacity : 4,00,000 MT /Annum to be shared in the
ratio of their respective investments.
 HOSPET STEELS
Milestones MUKAND LTD

¾ ISO 9000-2000 Certification

BY BVQI (Obtained on 8th Sept ,2001)

¾ ISO 14001 Certification

By BVQI ( Obtained in Nov.2003)

¾ TS16949 Certification
By BVQI (Target June 2004 )

¾ TPM Kicked off (14th Aug,2003)

¾ 5’ S Launched on (8th Nov,2003)

Implementation targeted by Nov-,2006.
 HOSPET STEELS
QUALITY POLICY MUKAND LTD

WE ARE COMMITTED TO IMPROVE MANUFACTURING

PROCESSES AND PRODUCTS ON CONTINUAL BASIS

THROUGH EFFECTIVE QUALITY MANAGEMENT

SYSTEMS FOR ACHIEVING CUSTOMER SATISFACTION

R.Sampath Kumar
Date : Jan 6th,2005 Chief Executive
 HOSPET STEELS
ENVIRONMENTAL POLICY MUKAND LTD

WE ARE COMMITTED TO MINIMIZE ON A CONTINUOUS BASIS, THE

IMPACT OF OUR MANUFACTURING ACTIVITIES ON THE ENVIRONMENT
BY:
™CONTROLLING ALL POLLUTANTS WITHIN THE STANDARD
LIMITS.

™COMPLIANCE WITH APPLICABLE ENVIRONMENTAL LAWS &

REGULATIONS.

™MINIMISING PROCESS WASTE,PROMOTING ITS RECOVERY BY

RECYCLING AND DISPOSAL OF WASTE MATERIALS.

™DEVELOPING AND REHABILITATING WASTE DUMPS

THROUGH AFFORESTATION AND LANDSCAPING.

R.Sampath Kumar
Date : Jan 6th,2005 Chief Executive
 HOSPET STEELS
TPM POLICY MUKAND LTD

R.Sampath Kumar
Date : Jan 6th,2005 Chief Executive
 HOSPET STEELS
SAFETY POLICY MUKAND LTD

We are committed to comply with

Legal, Economic & Moral obligation towards
Safety & Health of employees through safe working
practices for achieving organizational goals.

R.Sampath Kumar
Date : Aug 16, 2004 Chief Executive
 HOSPET STEELS
TRAINING POLICY MUKAND LTD

WE FIRMLY BELIEVE THAT HUMAN RESOURCES ARE OUR MAIN

ASSETS IN ORDER TO ACHIEVE THE BEST POSSIBLE RESULTS,

TRAINING FOR EMPLOYEES IS A CONTINUOUS PROCESS

TO ACHIEVE IMPROVED STANDARDS OF PRODUCTION

TO THE BEST SATISFACTION OF CUSTOMERS.

R.Sampath Kumar
Date : Jan 12, 2005 Chief Executive
 HOSPET STEELS MUKAND LTD

KEY INFORMATION

⇒Land Area : 372 Acres.

⇒Installed Capacity : 4,00,000 MT/Annum.
⇒Total Man Power : 780.
⇒Contract Demand : 22.1 MVA.
⇒Avg. Energy Consumption : 11.0 MU/ Month
⇒Avg. Electricity Bill : Rs 32 Million / Month
⇒Water Consumption : 3000 m3/day.
⇒Water Reservoir : 4.14 Lakh Cu M.
⇒Oxygen Plant (Praxair) : 115 TPD.
 HOSPET STEELS
MUKAND LTD

MAJOR FACILITIES
⇒ Mining Operation at
Subbarayanahalli Iron Ore Mines &
Jambunathanahalli Iron Ore Mines
of M/s Mysore Minerals Limited.
⇒ Mini Blast Furnace - 2 nos.
⇒ Energy Optimizing Furnace - 40 MT.
⇒ Ladle Furnace - 40 MT x 2 nos.
⇒ Vacuum Degassing Unit - 40 MT.
⇒ Bloom Caster - Two strands.
⇒ Billet caster - Three strands.
⇒ Blooming Mill.
 HOSPET STEELS
MUKAND LTD

Mining -Subbarayanahalli Iron Ore

⇒ Started in : Dec 1999.

⇒ Area : 160 Hectares.
⇒ Lease Period : 20 Years.
⇒ Iron Ore Reserves : 17. 5 Million Tons.
⇒ Calibrated ore Output : 50,000 MT/month
⇒ Size : 10-40 mm.
⇒ Fe. Content : > 65%.
⇒ Gangue Content : < 3%.
STAGE AT SUBBRARAYANAHALLI IRON ORE MINES
 HOSPET STEELS
MUKAND LTD

Mining -Jambunathanahalli Iron Ore

⇒ Started in : Apr-2003.
⇒ Area : 51.71 Hectares.
⇒ Lease Period : 10 Years.
⇒ Iron Ore Reserves : 7. 5 Million Tons.
⇒ Calibrated ore Output : 14,000 MT/month
⇒ Size : 10-40 mm.
⇒ Fe. Content : > 65%.
⇒ Gangue Content : < 3%.
 HOSPET STEELS
MUKAND LTD

MINI BLAST FURNACE

¾Technology : TKES/KTS
¾No. of MBF : 2 Nos.
¾Commissioning : I June 1998 - II Apr 2000
¾Working Volume : 250 m3
¾Hearth Diameter : 4.20 m
¾Working Height : 16.4 m
¾Top Pressure : 0.35 bar
¾Metallic Blast Preheater : 2 Nos, ( 800-900 o C)
¾Blowers : 6 Nos
¾Blower Volume : 40000 Nm3 / hr
¾GCP Capacity : 52000 Nm3 / hr
¾Pig Casting Machine : 2 Strands (80 MT/hr)
¾Slag Granulation Facility :
MINI BLAST FURNACE VIEW
Mini Blast Furnace View
 TRUCK TIPPLER AT GROUND HOPER
INSTALLED TO SAVE WASTAGE DURING HANDLING
TAPPING AT MINI BLAST FURNACE
PIG CASTING M/c VIEW AT MINI BLAST FURNACE AREA
 HOSPET STEELS
MUKAND LTD

ENERGY OPTIMISING FURNACE

⇒ Technology - KTS / TKES.

⇒ Commissioning - Aug 1998.
⇒ Capacity of EOF - 40 MT.
⇒ Shuttle Type Bottom change.
⇒ Water cooled roof & side walls.
⇒ Oxygen lancing through four tuyeres,
four atmospheric injectors & one supersonic
lance.
⇒ Automatic lime and ferro alloy addition system.
⇒ PLC process control.
 HOSPET STEELS
MUKAND LTD

LADLE REFINING FURNACE

⇒ No of LRF - 2 Nos.
⇒ Technology - ABB.
⇒ Commissioning - Aug 1998.
⇒ Transformer Capacity - 10 MVA.
⇒ Automatic lime & ferro-alloy feeding system.
⇒ Optimal alloy calculation program.
⇒ Argon Purging System.
⇒ Four strand Core Wire feeding system.
⇒ Heating rate 5 oC /min.
⇒ Level 2 Automation.
⇒ Oxygen Probe.
 HOSPET STEELS
MUKAND LTD

VACUUM DEGASSING
⇒Technology - ALD Germany.
⇒Commissioning - March 1999.
⇒Boiler Capacity - 14 Tons/hr.
⇒Vacuum System - 5 stage steam ejectors.
⇒Vacuum Level - 0.65 mbar.
⇒Suction Capacity - 200 Kgs/hr at 0.65 mbar
⇒Double alloying hoppers for trimming under vacuum.
⇒Level 2 Automation.
 HOSPET STEELS
MUKAND LTD

BLOOM CASTER
⇒Technology - Techint / Pomini.
⇒Commissioning - August 1998.
⇒No. of strands - 2
⇒Sections (mm) - 240X280, 160 , 200, 220 rounds.
⇒Multi Radius Machine - 10/18 m.
⇒Ladle Turret for quick change over.
⇒Auto Mould Level Control.
⇒Combi Electromagnetic Stirrer.
⇒Quality Tracking System.
⇒Automatic presetting of process parameters.
⇒Length Optimization.
⇒Synchronized Secondary Cooling System. BLOOM CASTER
 HOSPET STEELS
MUKAND LTD

BILLET CASTER
⇒Technology - Techint / Pomini
⇒Commissioning - March 1999
⇒No. of strands - 3
⇒Sections - 120X120 , 160X160, 200x200 mm sq
⇒Multi radius Machine - 9/16 m
⇒Ladle Turret for quick change over
⇒Auto Mould Level Control
⇒Combi Electromagnetic Stirrer
⇒Quality Tracking System
⇒Automatic presetting of process parameters.
⇒Length Optimisation
⇒Synchronized Secondary Cooling System
 HOSPET STEELS
MUKAND LTD

ROLLING MILL
⇒Technology - Danieli
⇒2 High Reversible Mill with 750 mm diameter rolls
⇒Maximum input section : 240X280 mm sq.
⇒High pressure descaler
⇒Slow cooling facility
⇒Bar straightening facility
⇒Magnetic particle inspection
⇒Rolled Bar Size
Rounds : 80, 83, 90, 97.5, 100, 105, 115, 125, 130 mm
RCS : 75, 90, 95, 100, 120,125 ,140,160 and 182mm sq.
Flats : 150X100,160X70,180X80,160X140
⇒Bar Length : 6.0 meters
 IRON ORE COKE LIMESTONE

MUKAND
IRON & STEEL MINI BLAST FURNACE
(250M³ X 2 Nos.) FLUX
SCRAP ( LIME &
(15–30%) DOLOMITE )
ENERGY OPTIMISING FURNACE
40 T CAPACITY O2 BLOWING
FERRO ALLOYS
FERRO ALLOYS
LF-1 LF-2
REFINING 40 T 40 T
REFINING
VACUUM
TRIMMING OF CHEMISTRY
DEGASSING
UNDER VACCUME
VD
CLOSED STREAM CASTING 40/45 T CLOSED STREAM CASTING

COMPUTERISED BLOOM CASTER COMPUTERISED

BILLET CASTER
PROCESS CONTROL 10/18 m Radius PROCESS CONTROL
9/16 m Radius

ROLLING MILL
750 mm, 2Hi
 HOSPET STEELS
TESTING FACILITIES MUKAND LTD

STEEL MELT SHOP & ROLLING MILL

⇒ Pneumatic sample carrier.
⇒ Electron emission spectrometers (2 Nos).
⇒ Hydrogen analyzer.
⇒ ‘C’ & ‘S’ analyzer.
⇒ Inverted Metallurgical Microscope.
⇒ Ultrasonic testing machine.
⇒ Universal testing machine.
⇒ BHN & Rockwell hardness tester.
⇒ Forging Hammer.
⇒ Jominy hardenability.
⇒ MPI sample testing facilities.
⇒ Mobile spectrometer
⇒Oxygen & Nitrogen Analyser
 HOSPET STEELS
MUKAND LTD

STEEL GRADES DEVELOPED

APPLICATION GRADES
COLD HEADING QUALITY
Low Carbon. SAE1010, VS14250.
Low Carbon Boron Steel. 10B21, 15B21.19MnB4
Medium Carbon Boron Steel. 15B41.
Alloy Steel. SAE 4140.
FORGING QUALITY
Gears. SAE8620,8627,SCM 420,SAE4120
Crown Wheel & Pinion. 20MnCr5, 16MnCr5,
EN353 ,EN 354
Rear Axles. EN15A.
Front Axles Beam. 1045(M),709M40(AL),SHAEM105(DANA),
40Cr4( C ) (TELCO)
Crank Shaft quality. EN18, EN19, SAE 4140, 42CrMo4.
Shock absorber shaft JIS S35 C, JIS S45 C, JIS S48 C
Steering Knuckle SAE4135(Meritor),SAR440
 HOSPET STEELS
MUKAND LTD

STEEL GRADES DEVELOPED

APPLICATION GRADES

BALL BEARING STEEL

Races SAE 52100, EN 31.

FREE CUTTING STEEL. EN1A , EN1A(Leaded)

SEMI FREE CUTTING STEEL. EN8M, SAE1141.

HIGH CARBON STEEL

High tensile wire rods/Needle wire 61/65, 66/70.

Low Relaxation Prestresed concrete. 78/82(V)

CATHODE BARS / LER ASTM A 36,ASTM A 663Gr.60,

LER.
 HOSPET STEELS
MUKAND LTD

STEEL GRADES DEVELOPED

APPLICATION GRADES
SPECIAL ELECTRODE QUALITY WR3

SPRING STEEL.
Leaf Spring. 65Si7
Helical Springs. 50CrV4,58CrV4,65Si7
SUP7, SUP9, SUP12V
SAE 9254
SEAMLESS TUBES.
Oil line Pipes. SAE1010, SAE1018, MSL–I/IA.
Casing & Tubing Pipe SAE 4042, SAE1541, MSL-II,MSL-IV
AP15CTQ 125,BS3059 Gr.440,MSL7 & 8
SAE1537(V).
HIGH TEMPERATURE BOILER SA210 Gr.A1,SA210 Gr.C,SA192,
APPLICATIONS (For BHEL) SA106 Gr.C

MICRO ALLOYED STEEL C38+N2 for crank shaft.

 IBR HEATS MADE FROM 21.11.2002 TO 31.01.2006
SL NO CUSTOMER GRADES SUPPLIED

1 Indian Seamless Metal Tubes Ltd. SAE 1026

MSL I
MSL IA
2 Maharastra Seamless Ltd.
MSL IC
MSL IV
ASTM-A105
3 MMF
SA 105

4 Echjay Industries Ltd. ASTM-A105

SA 105
SA106GrC
5 Bharat Heavy Electricals Ltd. SA210GrC
SA210GrA1
SA 192
 IBR HEATS MADE FROM 21.11.2002 TO 31.01.2006
SL NO CUSTOMER GRADES SUPPLIED

1 Indian Seamless Metal Tubes Ltd. SAE 1026

MSL I
MSL IA
2 Maharastra Seamless Ltd.
MSL IC
MSL IV
ASTM-A105
3 MMF
SA 105

4 Echjay Industries Ltd. ASTM-A105

SA 105
SA106GrC
5 Bharat Heavy Electricals Ltd. SA210GrC
SA210GrA1
SA 192
 HOSPET STEELS
PRODUCT DEVELOPMENT MUKAND LTD
FROM 2001-2005

¾Development of crank shaft quality grade with reduction ratio 1 : 4 for

Chinese application.
¾Development of crankshaft quality grade for heavy duty transport
vehicle (2 grade 2CrMo).
¾Development of micro-alloy crankshaft for Ford application.
¾Development of front axle beam material for Daimler Chrysler, Meritor,
Dana, Ashok Leyland & Telco application.
¾Development of steel for gear for Caterpillar application.
¾Development of Steering knuckle for Dana Corporation & Meritor
application.
¾Development of as cast seamless tube steel for high temperature boiler
application. ( BHEL)
 HOSPET STEELS
PRODUCT DEVELOPMENT MUKAND LTD
FROM 2001-2005

¾Development of as cast seamless tube steel for off shore drilling for
ONGC / OCTL application.
¾Development of Ball bearing (SAE 52100) steel for SKF application.
¾Development of Low & Medium carbon Boron steel for CHQ
application.
¾Development of alloy CHQ grade.
¾Development of steel for gear for Delphi automotive & GKN drive
shafts.
¾Development of helical springs steel for all prestigious passenger car
application.
¾Development of Leaded free cutting steel.
¾Development of steel for steering assembly application
 HOSPET STEELS
MUKAND LTD

PRESTIGEOUS CUSTOMER APPROVALS

CUSTOMER APPROVED IN
1 Bajaj Auto Ltd. 1999 July .
2 Delphi Automotive 1999 September .
3 Sundaram Fastners Ltd. 1999 September .
4 Motor Industries Co Ltd.(MICO) 1999 September .
5 LML 1999 October .
6 Kirloskar Oil Engines Ltd. 1999 October .
7 Mahindra & Mahindra 1999 November .
8 Bharat Forge Ltd 1999 November .
9 GNA 1999 November .
10 Tata Motors 2000 January .
11 Automotive Axles 2000 January .
12 Ashok Leyland 2000 February .
13 Shardlow (India) 2000 August .
14 M M Forgings Ltd. 2000 October.
15 Spicer India Ltd. 2000 November
 HOSPET STEELS
PRESTIGEOUS CUSTOMER APPROVALS MUKAND LTD

CUSTOMER APPROVED IN
16. Bharat Heavy Electricals Ltd(Trichy) 2001 May .
17. Bharat Gears Ltd. 2001 July.
18. Kalyani Forge 2001 September .
19. Gabriel India Ltd. 2001 September .
20. Hi- Tech Gears 2001 October .
21. Sona steering 2001 November .
22. Jamuna N.H.K 2001 December .
23. The Indian card clothing co. ltd. 2002 January .
24. DANA Corporation 2002 April.
25. CATERPILLAR INC. USA 2002 May.
26. G K N Drive Shafts (I) Ltd. 2002 June.
27. IBR Self Certification 2002 July.
28. Arvin Meritor 2002 August.
29. RDSO Approval 2002 September.
30. FM Billiton AL,South Africa 2003 February.
31. Wuxi Diesel Engine Works,China 2003 April.
32. Honda Motors & Scooters (I)Ltd. 2003 October.
33. Ford India Ltd, 2003 November.
34. SKF Ltd 2004 April
 HOSPET STEELS
SUBBARAYANAHALLI MINES MUKAND LTD

C.ORE PRODUCTION AT SIOM

700000
608540
600000

500000 456572
400629
QTY (MT)

400000
300806
300000
198052
200000

100000
16866
0
1999-2000 2000-2001 2001-2002 2002-2003 2003-2004 2004-2005

YEAR
 HOSPET STEELS
JAMBUNATHANAHALLI MINES MUKAND LTD

C.ORE PRODUCTION AT JIOM

130000 122396
120000
GENERATION (MTS)

110000

100000

90000 83813
80000
70000

60000
50000
2003-2004 2004-2005
YEAR
 HOSPET STEELS
MINI BLAST FURNACE MUKAND LTD

MINI BLAST FURNACE PRODUCTION

400000

350000

300000

250000
Qty(MT)

200000

150000

100000

50000

0
2000-01 2001-02 2002-03 2003-04 2004-05
Qty(MT) 234076 281266 300152 281608 363855
Year

Percentage increase over Previous best is 21.22%

 HOSPET STEELS
STEEL MELTING DIVISION MUKAND LTD

STEEL MELT SHOP PRODUCTION

400000

350000

300000

250000
Qty(MT)

200000

150000

100000

50000

0
2000-01 2001-02 2002-03 2003-04 2004-05
Qty(MT) 195463 250010 279869 273894 347810
Year
HEATS MADE 4973 6151 6787 6547 8224
Percentage increase over Previous best is
24.27%
 HOSPET STEELS
ROLLING MILL DIVISION MUKAND LTD

ROLLING MILL PRODUCTION

160000

140000

120000

100000
Qty(MT)

80000

60000

40000

20000

0
2000-01 2001-02 2002-03 2003-04 2004-05
Qty(MT) 36472 70573 90148 124170 140000
Year

Percentage increase over Previous best is

12.75%
 HOSPET STEELS
STEEL DESPATCHES MUKAND LTD

STEEL DESPATCHES

400000

350000

300000

250000
Qty(MT)

200000

150000

100000

50000

0
2000-01 2001-02 2002-03 2003-04 2004-05
Qty(MT) 192151 250585 275965 268470 338826
Year

Percentage increase over Previous best is

22.78%
 HOSPET STEELS
WELFARE SCHEMES MUKAND LTD

1. The Mediclaim facility is introduced in the company for the

benefit of employees to meet the medical expenses.

2. Benevolent fund scheme is introduced in the company to

help the employees in case of emergency.

3. Personal Group Accident Policy has been obtained wherein

all employees are covered. This policy ensures for a sum of up
to Rs. 3 lacs assured in case any employee succumbed to
accidental injuries.

4. Gratuity Policy : All the employees are covered under the

Gratuity scheme.
 HOSPET STEELS
WELFARE SCHEMES MUKAND LTD

5. Superannuation Policy: Employees are covered under

Superannuation scheme subject to the superannuation trust
rules wherein the Management will contribute on behalf of
the employee10% basic of the salary every month.

6. All employees are covered under provident fund rules wherein

the employee will contribute to the fund as per the rules of the
P.F. Act. Management also contribute equal amount to the fund
a/c deposited with P.F. Commissioner, Bellary.

7. Canteen: All the employees & contract workers avail the

canteen facility at subsidized rates.

8. Plant Medical Unit : There is periodical health check ups of

employees conducted and give feed back to employees about
their health.
 HOSPET STEELS
WELFARE SCHEMES MUKAND LTD

9. All the workmen department-wise sent for picnic with families

once in a year.

10. Training at all levels is a very integral part of operations at

Hospet Steels. The employees are given on-the-job technical
training, training for motivation, management skills, health care
and life enrichment.

11.At the end of the year, the employees are rewarded with annual
increments based on their performance, attendance and
discipline.

12.Every year, all workers are provided two pairs of uniform and
safety gear free of cost.
 HOSPET STEELS
COMMUNITY DEVELOPMENT MUKAND LTD

SOCIAL ACTIVITIES
1. Hospet Steels is supporting five schools in Ginigera and
Kanakapura villages by way of furniture, fixtures, sports goods,
etc., every year on 15th August. Cash prizes and trophies are
given to the 1st and 2nd rank holding boy & girl in middle school
as well as high school final examination. Trophies are also given
to the best sportsman of the school.

2. Eye camp was conducted at Ginigera along with Rotary Club of

Hospet in which 774 elderly men & women of the neighbouring
villages got their eyes tested. 74 patients were operated and 240
were given spectacles free of cost.

3. Street lamps worth of Rs.1.75 lakhs were provided in the

neighbouring villages.
 HOSPET STEELS
COMMUNITY DEVELOPMENT MUKAND LTD

SOCIAL ACTIVITIES
4. Rs.2.5 lakhs was donated for the land to build Primary Health
Centre at Ginigera.

5. Hospet Steels had sponsored five students of land sellers for ITI
course after which they were offered jobs in the company.

6. About 108 land sellers of Kanakapura, Ginigera, Hale

Kanakapura, Hosahalli, etc., were given jobs in the company
apart from the compensation paid for the land.

7. Sadguru Sri Sri Ravishankar Swamiji Maha Satsang was

organised at Hospet. People around Hospet, Torangallu,
Koppal attended the Maha Satsang programme in which they
were exposed to “The Art of Living”, Meditation and the
blessings of the Guruji.
 HOSPET STEELS
COMMUNITY DEVELOPMENT MUKAND LTD

SOCIAL ACTIVITIES
8. Company Doctor is available three days in a week at the
Community centre for two hours for free check up and
consultation for the residents of neighbouring villages.

9. Company has sponsored for the renovation of the Basket ball

court at the Vijayanagar College Ground at Hospet.

10. The company holds cricket tournament every year in which

fifteen teams participate from Hospet, Bellary, Koppal, Gadag
and Hubli regions.

11.To improve the environment inside the factory premises, the

company has planted more than 15,000 trees of different
species which is already making a positive impact to create the
green belt in the neighbourhood.
 HOSPET STEELS
COMMUNITY DEVELOPMENT MUKAND LTD

SOCIAL ACTIVITIES

12. Constructed class rooms for Ginigera High School and Hosa
Kanakapura primary school at a cost of Rs. 9 Lakhs. We have also
constructed compound wall for Primary school at Hosa Kanakapur
and Kanakapur Tanda at a cost of Rs. 3 Lakhs.

13. The company has been providing drinking water from its
borewells to the neighbouring villages whenever required.

14. The company has undertaken the task of providing street

lights in Jawahar Road, Koppal at a cost of Rs. 13 Lakhs.
 Energy Management
Organisation Structure at
HOSPET STEEL LTD
CHIEF EXECUTIVE

EXE.VP. (ENG)

GM – (E A & P)
CORPORATE COORDINATOR - ECC

SECRETORIES

MEMBERS
2
 Presentation Outline

• Introduction
• Background on Energy Management
Initiatives
• Energy Management Project
• Energy Management Team
• Success Factors
• Lessons Learned
 HOSPET STEELS LTD
Introduction

• Hospet Steels Ltd is the joint venture of

Mukand Ltd & Kalyani Steels Ltd
• Located in Ginigera, Koppal, Karnataka
• Largest Employer in City
• 386 Acres on Campus
• Units – MBF, SMS, PP, RMS, Admin Building,
SMS Office, Lab, Canteen, Colony, Utility etc.,.
• 8 Years - Average Age of Unit
• 792 Employees
 Background

• Energy Management was the unit

automation, computer system.

• FY05/06 Budget for Energy

Conservation Project – Rs.50 Lakhs
 Economic Review

• Approval for project Investment : Rs.50 lakhs

• Approx Annual Savings : Rs.100 lakhs
• Simple Payback : 5 months
 Reasons To Go Campus Wide
• More Shops, equipment & optimizing process
• Increasing utility cost year after year
• Management had confidence and know-how to
do energy conservation projects
• Because of number of shops, decided to seek
help with unit audits
 Audit Plan I: Four Groups

• Divided campus (HSL) into four units

[Iron Making – Kalyani Steeels Ltd (KSL),
Steel Melt Shop – Mukand Ltd (ML)
Rolling Mill – KSL
Power Plant – KSL].
• Invited Consultant (CII) to do an evaluation
• Unit wise Energy Management Groups
developed, one corporate coordinator had
been build up.
• Received suggestion from employees, started
feasibility study for effective implementation.
 CII Initial Audit Results

• Initial study took place

• Proposals specified.
• Overall project cost of Rs. 50 lakhs
• Potential annual saving was projected by
CII – Rs.150 lakhs p.a
• Decision made to buy out contract
 Management Approval
• Management Approval for investing Energy
conservation project - Rs.50 lakhs
– Installation of VFC drives in Compressed Air system –
Rs.12 lakhs
– Installation of VVVF drives – Rs.20 lakhs
– Replacing Steam Ejector valves – Rs.3 lakhs
– Installation of overhead pipes to arrest water leakage in
underground – Rs.15 lakhs.
– Energy meter for every individual feeder – Rs.25000
– Replacing 40W bulb by T5 series – Rs.25000
– Modification in Reheating Furnace air &
oil line actuators - Rs.50000
 The Steam Project

• Anticipated steam saving of Rs.36 lakhs

annually
– Reduced soft water consumption
– Reduced reheat due to control valve system
– Reduced FO consumption
– Heat recovery cycle
– Reduced Boiler power consumption cost
 The Water Project

• Anticipated water saving of ~ Rs.5

lakhs annually
– Installing overhead piping to arrest water
leakage in under ground.
– Closed loop cooling for water cooled air
compressors and lab equipment
– Reuse of pond water for road cleaning &
gardening instead of bore well
 The Electrical Project

• Anticipated electrical saving of Rs.57.25 lakhs

annually
– Replacing 40 W tube light by T5 - Rs.25000
& Individual switches with label.
– Energy meter in every feeder to monitor energy
reading.
– VVVF drives - Rs.12lakhs
– VFC drive - Rs.15 lakhs
– Automisation of air & line in RHF - Rs. 30lakhs
 Initial Strategy

• Identify easy-to-implement projects

• Go for “low hanging fruit”
• In-house labour and project
management
• Industry standard technology
• Internal control
 Team Concept

• Gather expertise from across the organization

(maintenance shops, engineering, utilities, project
management)
• Group discussion of unit problems leads to
new projects
• Group tours/examinations of high
consumption units to uncover opportunities
• Solutions address unit problems,
maintenance issues, customer complaint, as
well as energy
 HOSPET STEEL LTD
Energy Team

Team Composition:
Shop supervisors from Operation,
Electrical, Mechanical Engineer, QAD,
Project Managers, Energy
Management.
 Energy Solutions

• Arrest leakages in air, Oxygen, water

and steam lines/loops
• Use of waste heat / exhaust heats
where ever possible
• Variable speed drives
(slow fans/pumps for less than peak loads)
• Upgrade of VFC systems
• Closed loop water systems.
 Success Factors

• Team concept
• Pick the big consumers
• Start small, build credibility
• Keep control in-house - hire labour as
needed
• Involve shops and contract people
• Internal Financing
 Lessons Learned

• Planning
• Employee relations (contact, scheduling)
• Tried & true technologies
• Low hanging fruit
• In-house project management
• Select energy efficient and quality
products.
• Purchase in quantity - drive down unit
cost
• Set standardized prices for each activity
• Utilize your own people
 HOSPET STEELS LIMITED
ENERGY CONSERVATION POLICY (PROPOSED)

We are committed to minimize Energy Consumption on continual improvement

basis by,
™ Optimizing raw material consumption and conserving power, petroleum
fuels, oils, compressed air, water, steam, gases and other resources.
™ Adopting best available technology for energy management
™ Taking specific objective of energy conservation periodically through
process /technology change.
™ Conducting periodical energy audit for continual improvement
™ Creating awareness among employees

R.Sampath Kumar
June 01, 2006 Chief Executive