Across both projects, Primetals Technologies is delivering comprehensive plant design, process equipment, automation solutions, and advisory services.

New meltshop and continuous casters in Toranagallu

Primetals Technologies has successfully started up a new melt shop and two continuous casters at JVML’s facility in Toranagallu, Karnataka. The scope of supply included two 350-ton LD (BOF) converters, primary dedusting systems, two 350-ton ladle furnaces, secondary dedusting for the entire meltshop, and two 2-strand continuous casters, along with comprehensive Level 1 and Level 2 automation for the converters, ladle furnaces, and casters.

New benchmark for steelmaking

The first converter, commissioned in December 2024, achieved an exceptionally fast ramp-up, reaching more than 20 heats per day by the end of the commissioning month. It completed 220 heats in the first three weeks and over 400 heats within the first month of operation. The initial lining campaign reached more than 6,000 heats, setting a new benchmark in steelmaking. Primetals Technologies has received the final acceptance certificate (FAC) for the first converter, ladle furnace No. 1, and caster No. 1.

The second converter, commissioned in August 2025, achieved an even faster ramp-up, reaching more than 20 heats per day by the sixth day after commissioning. Primetals Technologies has also received the FAC for the second converter, ladle furnace No. 2, and caster No. 2.

First 350-ton primary dry dedusting system in India

This project marks Primetals Technologies’ first installation in India of 350-ton converters equipped with an advanced primary dry dedusting system. The system includes a steam-type heat recovery system, a dry electrostatic precipitator (ESP), and low-consumption axial-type ID fans, helping to improve energy efficiency, reduce water consumption, and meet environmental regulations. A gas cleaning plant with a gas recovery system, which significantly increases energy recovery, completes the dedusting solution.

For the LD converter (BOF) plants, Primetals Technologies supplied converter top lances, tilting drives, the Vaicon Stopper slag retention system, valve stands, and a material handling system. Vaicon Stopper minimizes slag carryover during tapping, allowing for shorter production cycles and improved steel quality. The vessel shell is equipped with top-cone water cooling and supported by the Vaicon Lamella suspension system inside an air-cooled trunnion ring, helping to extend equipment life.

Advanced automation solution

The automation scope includes the BOF Optimizer process optimization system, which improves hit rates for carbon content and steel temperature, reduces reblow rates, and increases efficiency. The tailor-made Lomas off-gas analysis system works with BOF Optimizer to enable automatic blow-end control and improve carbon hit rates. For the ladle furnaces, the fully automated Melt Expert electrode control system boosts productivity and reduces energy consumption.

Casting a wide variety of steel grades

The two continuous slab casters, each with two strands, produce slabs with widths ranging from 900mm to 1,650mm and thicknesses of 220mm or 260mm. They handle steel grades ranging from ultra-low-carbon to high-carbon, including deep-drawing, structural, peritectic, and HSLA grades, as well as microalloyed and low-alloy steels, strip grades, and high-silicon electrical steel.

Technology features include LevCon mold-level stability, DynaFlex mold oscillation, MoldExpert breakout prevention, DynaPhase phase-transformation modeling, and the LiquiRob robotic system for safe operation. Additional features include DynaGap Soft Reduction 3D, the Dynacs 3D cooling model, and Quality Expert for online slab quality assessment.

Two pelletizing plants in Paradeep

JSW Steel has placed an order with Primetals Technologies for two 8 MTPA pelletizing plants at its Paradeep facility in Odisha. Primetals Technologies is responsible for complete plant design, engineering services, key process equipment, complete process automation, and advisory services for construction and implementation.

The plant concept is based on a reliable, tried-and-tested 816 m² induration furnace, which will serve as the basis for a standardized pellet plant model for future capacity expansions at Paradeep and other JSW Steel production sites. Together, the two plants will deliver 16 MTPA of pellet production capacity, directly supporting JSW Steel’s rapid capacity expansion program.

Continuous improvements through long-term collaboration

In close collaboration with JSW Steel’s specialists, who operate some of India’s best-performing pelletizing plants, Primetals Technologies has developed several technical improvements to be incorporated into the new plant concept. These improvements will further optimize production capacity, pellet quality, and environmental performance.

The two partners have agreed to continue collaborating on process improvements after the new plants have been commissioned, reflecting a long-term technology partnership built on mutual expertise.

Advanced digitalization package for optimized process control

Smart sensors and advanced predictive control models form the core of the Primetals Technologies’ digitalization solution for the new pelletizing plants, enabling continuous monitoring of process conditions and transparent evaluation of the production process. The Level 2 automation system features a digital Pelletizing Optimizer, which enables automated adjustments to the green balling process to achieve a uniform pellet size distribution and consistently high pellet quality.

Primetals Technologies Austria GmbH

Turmstrasse 44, 4031 Linz/Austria

Tel.: +43 732 6592-0

marketing_support@primetals.com

www.primetals.com