Steel Authority of India Limited (SAIL) is set to transform raw material transportation for its Bokaro Steel Plant (BSP) by developing the longest slurry pipeline in India’s steel sector, enabling the plant to receive 8.3 million tonnes (MT) of iron ore annually directly from the company’s mines. The initiative forms a key component of Bokaro Steel Plant’s ₹15,000-crore expansion programme, aimed at significantly enhancing production capacity and operational efficiency.
The proposed pipeline will transport iron ore from SAIL’s Gua and Bolani mines. Under the new system, the ore will be finely ground and mixed with water to create slurry before being pumped through a dedicated pipeline. Ore from both mines will first be routed to Jamda, from where a 258-km main pipeline will carry the slurry directly to Bokaro Steel Plant. The infrastructure has been designed with future growth in mind and can eventually handle up to 16 MT of iron ore annually.
The project is expected to replace the existing rail-based transportation system, which depends on the availability of railway rakes and involves multiple stages of loading, transportation and unloading. By enabling the continuous movement of iron ore, the slurry pipeline is expected to ensure a more reliable supply of raw material, reduce transportation costs and ease pressure on the railway network.
As part of the expansion, Bokaro Steel Plant’s crude steel production capacity will increase from 4.65 million tonnes per annum (MTPA) to 7.25 MTPA, while hot metal production capacity will rise to 7.55 MTPA. According to SAIL, the slurry pipeline will play a crucial role in supporting the plant’s enhanced production requirements by ensuring an uninterrupted supply of iron ore.
The project also incorporates a sustainable water management system, under which the water used for transporting the slurry will be returned to the mines through a separate pipeline for reuse. The integrated infrastructure includes ore preparation facilities at the Gua and Bolani mines, pumping stations at both mining locations and Jamda, and dedicated slurry receiving facilities at the Bokaro Steel Plant. Designed for an operational life of around 30 years, the project is targeted for completion in approximately three and a half years.
SAIL said the expansion aligns with its Vision 2030 strategy to modernise the Bokaro Steel Plant with advanced manufacturing technologies and improved logistics. The programme includes the installation of a new 4,500-cubic metre blast furnace, a modern steel melt shop, a Thin Slab Casting and Direct Rolling (TSCDR) facility, an air separation unit, advanced raw material handling systems, energy recovery systems, and Industry 4.0-based digital automation and Digital Twin technologies. The company expects the expansion to create substantial opportunities across construction, engineering, logistics, equipment manufacturing, MSMEs and allied industries.