We operate an integrated steel manufacturing facility at Raigarh, Chhattisgarh, spread across 47.19 hectares — with the capability to manufacture a full range of semi-finished and value-added finished steel products, supported by a 67 MW captive power plant.
WHRB-based Power Generation
0 MW
AFBC-based Power Generation
0 MW
CFBC-based Power Generation
0 MW
Integrated Manufacturing Chain
From iron ore to finished steel, under one roof.
01
Raw Materials
Iron ore, iron ore pellets and coal form the foundation of our production process.
02
Sponge Iron
Raw materials are processed through rotary kilns to produce sponge iron.
03
Steel Melting
Sponge iron is processed in the SMS to produce billets and slabs.
04
Hot Charging
Billets and slabs are hot-charged directly into downstream rolling mills.
05
Rolling Mills
Integrated rolling processes transform semi-finished steel into value-added products.
06
Finished Products
HR Coils, Wire Rods, TMT Bars, ERW Pipes & Tubes.
Ferro Alloys
Manufacturing of Ferro Alloys
01
Raw material preparation and charging
Manganese ore, quartz (silica source), and carbonaceous reductants (coke/coal) are received, stored, and proportioned according to the target silico manganese composition. The raw materials are sized and blended before being charged into the submerged arc furnace.
02
Smelting in submerged arc furnace
The charged raw materials are smelted in a submerged arc furnace at high temperatures exceeding 1,400°C. The electric arc generates the thermal energy required to reduce the manganese and silicon oxides, producing molten silico manganese alloy.
03
Tapping, cooling and crushing
The molten silico manganese alloy is periodically tapped from the furnace and allowed to solidify and cooled under controlled conditions. The solidified alloy is subsequently crushed and screened to produce sized Ferro Alloy products conforming to customer specifications.
04
Quality testing and dispatch
The crushed and sized Ferro Alloy is sampled and tested for chemical composition (manganese, silicon, carbon, and phosphorus content) to confirm compliance with applicable BIS standards and customer specifications. The finished product is packaged. and dispatched either for captive consumption in our steel melt shop or for sale to external customers.
Proposed Greenfield expansion
Nawapara Facility
In addition, we are planning to commission the Nawapara Facility, a greenfield integrated steel manufacturing facility at Nawapara, Gharghoda, Raigarh, Chhattisgarh, India, to be executed in phases. Subject to receipt of the requisite approvals, including environmental approvals, implementation of the project as planned and completion of all the proposed phases, the Nawapara Facility, as on the date of this Draft Red Herring Prospectus, can have a maximum installed manufacturing capacity limit of 858,000 TPA of sponge iron, 792,000 TPA of Billets and Slabs and 160,000 TPA of Ferro Alloys, together with proposed production facilities for various value-added finished steel products, captive power plants with an aggregate installed capacity of 200 MW and a coal washery basis the TOR approved by the Ministry of Environment, Forest and Climate Change, Government of India, by way of its letter dated June 11, 2026. We have acquired 44.78 hectares of freehold land for the Nawapara Facility. We are yet to obtain the environmental clearance and the other approvals required for the construction and operation of the Nawapara Facility.
THE INTEGRATED DIFFERENCE
More Control. Less Dependence. Greater Operational Efficiency.
By controlling key stages within one facility, BS Sponge Limited can respond faster, optimise resources and maintain greater control over production.
Quality Control
Greater control over product quality at every stage.
Reduced Dependence
Less reliance on third-party suppliers for intermediate products.
Production Flexibility
Ability to adjust product mix based on market conditions.
Faster Delivery
Shorter production and delivery timelines.
Customer Responsiveness
Production planning supports timely response to customer specifications.
Resource Utilisation
Captive use of internally generated scrap reduces wastage.
key milestones
Building the Future of Steel, Together
From a single sponge iron kiln to an integrated steel manufacturing ecosystem, our journey reflects continuous growth, innovation and commitment.