Manufacturing Unit

67 MW CAPTIVE POWER INFRASTRUCTURE

An integrated facility with captive Power.

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

How Our Ferro Alloys Are Manufactured

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

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.

Nawapara Facility

Proposed Greenfield expansion — Nawapara Facility

The proposed Nawapara Facility will be located in proximity to our existing Manufacturing Facility, enabling operational synergies and supply chain efficiencies.

We are planning to commission a greenfield integrated steel manufacturing facility at Village Nawapara Tenda, Tehsil Gharghoda, District Raigarh, 496111, Chhattisgarh (“Nawapara Facility”), to be executed in phases. Subject to receipt of the requisite approvals including environmental related approvals, implementation of the project as planned and completion of all the proposed phases, the Nawapara Facility is expected to have an installed manufacturing capacity of approximately 0.8 million TPA each of sponge iron and billets and slabs, and 160,000 TPA of silico manganese. The billets and slabs proposed to be manufactured at the Nawapara Facility are proposed to be utilised for the production of various value-added finished steel products as part of our integrated steel operations. We also intend to establish captive power plants with an aggregate installed capacity of 200 MW at the Nawapara Facility to meet its power requirements. In addition, we intend to establish a coal washery at the Nawapara Facility which we believe will enhance the quality of coal used in our manufacturing operations, improve operational efficiencies and further strengthen our integration.

We have acquired 44.78 hectares of freehold land for the Nawapara Facility. The terms of reference (“TOR”) for the proposed Nawapara Facility have been approved by the Ministry of Environment, Forest and Climate Change, Government of India, vide letter dated June 11, 2026. Further, the public hearing for the proposed project is scheduled to be held on September 28, 2026.

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.