Primetals Technologies has commissioned a new steelmaking complex at JSW Vijayanagar Metallic Limited’s (JVML) Toranagallu plant in Karnataka, featuring two 350-ton LD converters and two two-strand continuous casting machines. The company has also received an order from JSW Steel for two pelletizing plants, each with an annual capacity of 8 million tons, to be installed at JSW Steel’s Paradeep facility in Odisha.
Under both projects, Primetals Technologies will provide plant design, process equipment, automation solutions and consulting services. The company will also maintain a long-term technology partnership with JSW Steel focused on the continuous development of the pelletizing process.
New steelmaking complex commissioned in Toranagallu
Primetals Technologies has successfully commissioned a new steelmaking plant and two continuous casting machines at JVML’s Toranagallu facility in Karnataka.
The project included the supply of two 350-ton LD (BOF) converters, primary dedusting systems, two 350-ton ladle furnaces, a secondary dedusting system for the entire steelmaking plant and two two-strand continuous casting machines. Comprehensive Level 1 and Level 2 automation systems for the converters, ladle furnaces and casting machines were also included in the project scope.
The first converter, commissioned in December 2024, reached more than 20 heats per day by the end of its commissioning month. It completed 220 heats during the first three weeks, while the number exceeded 400 in the first month of operation. More than 6,000 heats were completed during the converter’s first lining campaign.
In addition to the first converter, Primetals Technologies received the Final Acceptance Certificates (FACs) for No. 1 ladle furnace and No. 1 continuous casting machine.
The second converter, commissioned in August 2025, reached more than 20 heats per day on its sixth day of operation. The company also received FACs for the second converter, No. 2 ladle furnace and No. 2 continuous casting machine.
India’s first dry dedusting system for 350-ton converters
The project marked the first installation in India of 350-ton converters equipped with an advanced primary dry dedusting system. The system consists of a steam-type heat recovery system, a dry electrostatic precipitator (ESP) and low-consumption axial-type ID fans.
The system is designed to improve energy efficiency, reduce water consumption and support compliance with environmental regulations. The dedusting solution also includes a gas cleaning plant with a gas recovery system that increases energy recovery.
For the LD converter facilities, Primetals Technologies also supplied converter upper shell pipes, tilting drives, the Vaicon Stopper slag retention system, valve stands and a material handling system.
The Vaicon Stopper system minimizes slag carryover during tapping, helping shorten production cycles and improve steel quality. The converter shell is equipped with an upper conical water cooling system, while the Vaicon Lamella suspension system, located inside the air-cooled trunnion ring, contributes to extending equipment life.
Production process digitally managed with BOF Optimizer
The project’s automation scope also included the BOF Optimizer process optimization system. The system is designed to improve the achievement of target carbon content and steel temperature, while reducing reblowing rates and increasing production efficiency.
A specially designed Lomas off-gas analysis system works together with BOF Optimizer to enable automatic blowing lance control and improve the achievement rate of carbon targets.
The ladle furnaces use the fully automatic Melt Expert electrode control system. The system was commissioned to increase production efficiency and reduce energy consumption.
Continuous casting machines to serve a wide product range
The two continuous slab casting machines, each equipped with two strands, can produce slabs ranging from 900 to 1,650 millimeters in width and 220 or 260 millimeters in thickness.
The machines can process a wide range of steel grades, from ultra-low-carbon to high-carbon steels. The product range includes deep-drawing, structural, peritectic and high-strength low-alloy (HSLA) grades, as well as micro-alloyed and low-alloy steels, strip grades and high-silicon electrical steels.
The technological equipment includes the LevCon mold level stabilization system, DynaFlex mold oscillation, MoldExpert breakout prevention system, DynaPhase phase transformation modeling and LiquiRob robotic system for safe operations. The facilities also use DynaGap Soft Reduction 3D, Dynacs 3D cooling model and Quali technologies.
Two 8 million-ton pelletizing plants to be built at Paradeep
JSW Steel has also placed an order with Primetals Technologies for two large pelletizing plants planned at its Paradeep facility in Odisha. Each plant will have an annual pellet production capacity of 8 million tons.
The new plants will feature advanced digitalization solutions as well as a 816-square-meter induration furnace technology. The cooperation between Primetals Technologies and JSW Steel will extend beyond commissioning the plants and include long-term technology initiatives aimed at continuously improving the pelletizing process.
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