Steel Authority of India Limited (SAIL) has awarded a turnkey modernisation contract to SMS group for upgrading the billet casting facilities at its Durgapur Steel Plant (DSP) in West Bengal. The project involves the revamp of two existing six-strand, six-metre billet casters, originally supplied by SMS in the early 1990s.
The upgrade is aimed at strengthening DSP’s long product continuous casting capabilities and is expected to increase annual production capacity by more than 60 percent. As part of the scope, a new billet section of 150×150 mm, with provision for future expansion to 160 mm round billets, will be introduced to support the bar mill operations, including rebar and wire rod production.
The modernisation programme will be executed in two phases. Billet caster number one is scheduled for commissioning in the fourth quarter of 2027, followed by billet caster number two in the third quarter of 2028. The project has been structured to utilise the plant’s existing civil foundations, thereby limiting additional capital expenditure while improving operational efficiency.
The upgraded systems are expected to lower operating costs, enhance plant safety, and improve equipment availability and overall productivity. The move comes in response to rising market demand and the need for more efficient and reliable production processes.
Under the contract, SMS group will supply a comprehensive range of core casting technologies, including casting machines, ladle turrets, tundish systems, moulds, oscillation drives, and dummy bar and strand handling systems. The company will also provide process automation solutions and extend on-site technical support through its global delivery network, ensuring seamless project execution and lifecycle services.
Key technologies to be deployed include a butterfly-type ladle turret, CONDRIVE mould oscillation drive, close casting facilities, CONSTIR mould stirrers, rigid-type dummy bar systems, Level 2 automation, and advanced safety features.
Execution of the project will take place alongside ongoing plant operations. Each continuous casting unit will be commissioned within a defined shutdown period of five months, ensuring minimal disruption to production.
Bernhard Steenken, CSO for APAC & MEA at SMS group, stated that the project reflects the strength of the long-standing partnership between the two organisations. He noted that the upgrade demonstrates how focused modernisation using advanced technologies can deliver significant improvements in capacity and efficiency within tight timelines and controlled investment.
SMS group is a global leader in metallurgical plant engineering, with over 150 years of experience and a strong focus on innovation and digitalization. The company provides end-to-end solutions across the metals value chain, supporting customers in achieving efficient, resource-conscious, and future-ready operations.
