Editor's Note

Dear Readers,
The April edition of the Iron & Steel Review newsletter brings intriguing insights straight from an exclusive interview with Luiz Simao, Senior Vice President of Elkem Carbon Solutions. In his discussion, Simao provides a compelling viewpoint on the carbon solutions industry and emphasises Elkem’s significant contributions to advancing sustainable practices in this field. The newsletter underscores the dynamic nature of the Indian steel sector in April-March, 2024-25.

In other news, Nagarnar Steel Limited celebrated remarkable operational achievements on April 13 and 14, 2025, setting new production records across all major units. On the global stage, Hoa Phat has signed a significant contract with Primetals Technologies. This month’s newsletter serves as a thorough exploration of these key developments and much more.

Santosh Mahanti, Editor & CMD

CONTENTS


“Today, we represent close to 10% of Elkem’s revenues, and we expect to double or triple our impact”

The following is an edited excerpt from an interview with Luiz Simao, Senior Vice President of Elkem Carbon Solutions, which appears in Iron & Steel Review’s April issue. With a diverse background in chemistry, industrial engineering, and finance, he offers a unique perspective on the carbon solutions industry and the pivotal role Elkem plays in driving sustainable practices within the sector.

Could you please share your professional journey and how you came to hold the position of Senior Vice President at Elkem Carbon Solutions?

I have a broad range of interests, with a bachelor’s degree in chemistry, a master’s in industrial engineering and an MBA in finance. I worked for 10 years in a large aluminium company, where I was responsible for quality and process improvements. I joined Elkem in 2005, working in different locations and holding several leadership roles, including CFO of the Carbon division and plant manager of Elkem Carbon Brazil, before being invited to accept the role of Senior Vice President of Carbon Solutions in 2020.

What attracted you to the carbon solutions industry, and how has your perspective on this sector evolved over the years?

Elkem Carbon has a unique quality of running what I call a “multi-local business”, with a strong core focus on R&D, innovation and technical service in Norway and local production units close to the customer, well-connected with their needs. We develop the highest quality products and deliver them as if we were “your neighbour”. I was fascinated by this business model and the possibility to work with and learn from so many different cultures.

Carbon materials play a crucial role in developing new and better materials, such as electrical steel for energy, copper and stainless steel for hydrogen transport, and aluminium and steel for transportation that drive sustainable development and energy transition, and we aim to lead in this area.

Can you provide an overview of Elkem Carbon Solutions and its role within Elkem as a whole?

The Carbon Solutions division has a rich history. In 1919, Elkem patented the Søderberg electrode, which revolutionised

the smelting industry and paved the foundation for growth in the ferroalloys industry. Over 100 years later, the invention still forms the foundation of the division, and Elkem is a world- leading player within the ferrosilicon and silicon industries.

The Carbon Solutions division has 490 employees working across our five plants in Norway, South Africa, Brazil, China and Slovakia. We also have R&I centres in Kristiansand, Norway and Shanghai, China, where our teams investigate innovative, circular and sustainable solutions, particularly replacements for fossil raw materials used in ECS products.

Today, we represent close to 10% of Elkem’s revenues, and we expect to double or triple our impact in the next five years. Of course, this is always dependent on finding the right opportunities, but we are working on that.

 


Performance of the Indian Steel Industry in April-March, 2024-25

Crude Steel Production: The industry produced 151.141 Million Tonnes (MT), reflecting a year-on-year growth of 4.7%.

Pig Iron Production: Recorded production reached 8.299 MT, marking a substantial increase of 12.7% compared to the previous year.

Hot Metal Production: Hot metal output was logged at 91.076 MT, achieving a year-on-year growth of 4.6%.

Finished Steel Production: The total production of finished steel amounted to 145.309 MT, with a year-on-year growth of 4.4%.

Finished Steel Imports: India imported 9.532 MT of finished steel, which represents an impressive year-on-year growth of 14.6%.

Finished Steel Exports: In contrast, the export figures for finished steel were recorded at 4.858 MT, showing a significant decline of 35.1% compared to last year.

Finished Steel Consumption: Domestic consumption surged to 150.234 MT, reflecting a robust growth of 10.2% year-on-year.

Trade Balance: Overall, India emerged as a net importer of finished steel during this period.


NSL Marks Historic Production Highs on April 13 and 14, 2025

Nagarnar Steel Limited (NSL) achieved historic operational milestones on April 13 and 14, 2025, delivering record-breaking production across all major units. This highlights the plant’s process excellence and growing strength in India’s steel sector.

On April 13, 2025, NSL’s Blast Furnace marked a significant milestone by producing 10,169 tonnes of hot metal in a single day. This output exceeded its designed maximum capacity, reaching a production rate of 2.26 tonnes/m³/day. Commissioned in August 2023, the furnace has a useful volume of 4,506 cubic metres and was originally designed for an average hot metal production of 9,500 TPD, with a rated peak of 9,900 TPD and a design rate of 2.2 tonnes/m³/day. Achieving this performance in such a short period underscores the technical excellence and operational discipline embedded in NSL’s processes.

On April 14, 2025, NSL achieved another record-breaking performance. The Sinter Plant registered its highest-ever daily production of 12,385 tonnes, the Hot Strip Mill reached a new benchmark with 8,260 tonnes of HR Coil production, and the Steel Melting Shop produced an impressive 47 heats and 8,600 tonnes of liquid steel in a single day, among other achievements. These results come at a time when NSL has consistently exceeded its rated performance levels, indicating a rising trajectory since its commissioning.

Amitava Mukherjee, Chairman and Managing Director (CMD) of NMDC Steel, said, “These historic performances by NSL mark a defining moment in our journey as a steel producer. Surpassing design capacities within months of commissioning demonstrates the extraordinary capabilities of our engineering, operations, and skilled teams. These achievements represent a bold statement of NSL’s readiness to take its place among India’s leading steelmakers.”

In line with its commitment to sustainable and cost-effective operations, NSL’s blast furnace is equipped with an advanced Pulverised Coal Injection (PCI) system designed to inject 150 kg of coal per tonne of hot metal (kg/THM). Notably, the company’s operations team has already achieved and stabilised injection rates beyond the design threshold, optimising fuel efficiency and reducing dependency on coke – a significant step toward greener steel production.

Overcoming delays and logistical hurdles, the team displayed exceptional planning, execution, and operational control to stabilise the plant and elevate NSL to a leading steel producer in India’s steel sector within months of commissioning.

NSL remains focused on pushing the boundaries of innovation and excellence in steel production. With each milestone, the company reinforces its commitment to world-class manufacturing, national self-reliance, and sustainable progress.


Hoa Phat Invests in High-Quality Long Casting and Rolling Line from Primetals Technologies

Hoa Phat has signed a contract with Primetals Technologies to supply and implement a long product caster with a capacity of 1 million tonnes per year, along with a rolling line that has an annual capacity of 500,000 tonnes. This new line will enhance Hoa Phat Group’s ability to manufacture high-quality steel. The rolling line is anticipated to start operations in the third quarter of 2026, while the casting line is expected to be operational in the fourth quarter.

Primetals Technologies will design, supply, and install a billet/bloom/beam blank casting machine. The caster will feature a wide range of advanced solutions, including DynaGap Soft Reduction, which ensures superior internal strand quality. The casting area includes a standby solution for large-section-size casting, enabling the production of blooms and beam blanks for steel profiles up to 800 mm wide, which is ideal for the structural steel industry.

A comprehensive Level 1 and 2 automation system will provide precise control over the entire casting process. DynaPhase, a thermodynamic phase transformation model, will calculate the behaviour of steel during solidification based on thermal enthalpy, conductivity, and density. This data will feed into Dynacs 3D, a secondary-cooling model that computes the full 3D temperature profile along the strand, facilitating optimal adjustments of secondary-cooling setpoints. DynaGap Soft Reduction 3D will then apply dynamic roll-gap control to minimise centerline segregation and enhance internal strand quality.

Primetals Technologies will also deliver a complete package of high-quality wire rod rolling line equipment for Hoa Phat. This technology features a state-of-the-art long rolling processing line, including 18 no-housing stands and mill shears, a 10-stand eDrive NTM, and a Morgan RSM with integrated single-family rolling to ensure high product quality.

This setup will enable Hoa Phat to consistently produce premium products while reducing alloying and energy costs. Additional benefits include optimised coil packages through metallurgical in-line heat treatment, Morgan Water Boxes, and a Morgan Stelmor Controlled Cooling Conveyor.

Upcoming Events

IBAAS-IMMT-IIM 2025

October 8-10, 2025

13th International Bauxite, Alumina & Aluminium Conference & Exhibition (IBAAS-IMMT-IIM 2025), Bhubaneswar, India
Website: http://www.ibaas.info/

3RD INDIAN STEEL CONFERENCE

September 9-10, 2025

HOTEL BABYLON INTERNATIONAL, RAIPUR
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