### **Overview** **Vesuvius India Limited (VIL)** is a leading manufacturer and supplier of advanced molten metal flow engineering and refractory solutions in India. A subsidiary of **Vesuvius plc** (listed on the London Stock Exchange), the company brings over a century of global expertise from the Vesuvius Group to India’s rapidly growing industrial sectors. Incorporated in **1991** and commencing commercial production in **1994**, VIL has established itself as a technology-driven partner for high-temperature process industries, particularly in steel, aluminium, cement, foundry, and hydrocarbon processing. ### **Core Business & Market Position** - **Primary Industries Served**: Steel (core), aluminium, cement, foundry, refineries, power, and mineral processing. - **Key Offerings**: - Advanced refractory products (monolithic, pre-cast, and shaped) - Flow control systems (nozzles, shrouds, stoppers, slide gates) - Digital and robotic solutions for process monitoring and safety - Refractory management services and performance-based contracts - **Market Leadership**: - Holds **55% market share** in its specific refractory niche in India (per May 2023). - Serves only **~10% of the total available market**, indicating significant untapped potential for growth (Nov 2024). - Recognized as a **preferred vendor** for major integrated steel plants and a growing partner for mini mills. --- ### **Technological Differentiation & Innovation** Vesuvius India leverages the **global R&D strength** of Vesuvius Group, supported by a **Center of Excellence in Visakhapatnam** focused on monolithic and powder technologies. Its innovation strategy is quantified: - **New Product Sales** (products launched in the last 5 years) contributed **18% of total revenue in 2024**, up from 9–10% eight years ago. - Target: **>20% by 2026**, driven by high innovation in flow control and advanced refractories. **Key Product Innovations (2023–2025)**: | Product | Key Features & Impact | |--------|------------------------| | **Supergard OBL** | Oxygen Barrier Lining reduces steel contamination; critical for **electrical & ultra-low carbon steels**. | | **BASILITE QuickStart** | Sprayable tundish lining; eliminates 2–3 hour drying, reduces **CO₂ emissions by ~1.6 MT per tundish**, improves safety. | | **ATOM (Advanced Tundish Outlet Modifier)** | Reduces non-metallic inclusions; cuts bore erosion by **20%**, refractory consumption by **25–30%**. | | **Supermag** | MgO-C series for BOFs; enhances slag resistance, thermal stability, and furnace life. | | **ANTERIS 360** | Proprietary laser contouring system for real-time refractory wear monitoring and predictive maintenance. | | **Sigma 2SL** | Locally manufactured fused silica launder for aluminium; reduces lead time, machining, and inventory costs. | | **DuraPlate** | High-performance ladle slide gate; offers thermal shock resistance and durability for aggressive steels. | --- ### **Strategic Growth & Expansion** Vesuvius is executing a multi-phase capacity expansion aligned with India’s **steel capacity targets**: - **300 MTPA by 2030**, **500 MTPA by 2047** (government vision). - **35–40 MTPA of new steel capacity** expected in next 5–6 years, driving refractory demand. #### **Major Expansion Projects (2023–2025)** - **Parawada (Visakhapatnam) Industrial Complex**: - 32 acres acquired; two new plants planned (mould flux, basic monolithic). - Part of a **greenfield initiative** to meet rising demand for advanced refractories. - **New Manufacturing Plants Commissioned (2024–2025)**: - **Mould Flux Plant**, **Alumina-Silica (AlSi) Monolithic Plant**, and **Basic Monolithic Plant** in Visakhapatnam. - Collectively add **250,000 tonnes/year** of production capacity. - **Investments**: - **₹1,000 crores** planned over 3–5 years (more than doubled from initial ₹500 crores). - ₹360 crores already invested in 2.5 years. - Rs. 88 crores invested in 120,000 TPA AlSi plant, funded via internal accruals. **Strategic Philosophy**: - “**Make in India, sell in India**” – Localizing high-tech, imported products (e.g., flux, Sigma 2SL). - Focus on **value creation**, not volume or market share alone. - Organic growth prioritized; inorganic options evaluated strictly for **technology acquisition** and **price discipline**. --- ### **Customer-Centric & Service-Led Model** - **Long-term, performance-based partnerships** with steel plants, a rare model in the industry. - **Refractory Management Services** account for **~50% of sales**, growing steadily due to customer trust and value realisation. - Services include: installation, maintenance, digital monitoring, and predictive analytics. - Emphasis on **solving operational challenges** – improving **energy efficiency, yield, safety, and uptime**. --- ### **Manufacturing & Operational Footprint** - **5 Manufacturing Facilities**: Kolkata, Visakhapatnam (2 units), Mehsana. - **High-performance capabilities**: - Isostatic pressing, mechatronic systems, robotic lining, CFD-based design. - Digital integration via **Laser Contouring**, **Reveal CAST**, and **wireless temperature monitoring**. - **Recent Upgrades**: - 50% increase in isostatic & precast capacity at Kolkata & Vizag plants. - Expansion of drying ovens, casting lines, and material handling. --- ### **Sustainability & ESG Focus** - **BASILITE QuickStart** alone saves ~1.6 MT CO₂e per tundish. - **Local manufacturing** reduces logistics emissions and import dependency. - **Alternative fuels (AFR)** support in cement kilns via **Duraflo ZX** and **ONYX AFX** technologies. - **Pilot for returnable metal packaging** initiated to cut waste in distribution. - **Digital tools** (e.g., LCS, Reveal CAST) reduce defects, re-processing, and energy use. --- ### **Global Synergy & Technology Transfer** - Benefits from **Vesuvius Group’s global network**: - 54 manufacturing sites, 79 sales offices, 6 R&D centers. - Access to patented technologies, lean manufacturing, and pooled procurement. - Local R&D in **Visakhapatnam** adapts global innovations to Indian conditions. - Examples: - Surtap 500Z (tap hole clay) - DURAGUN series (low-rebound gunning) - **Import substitution** of VISO mixes (TS1127, TS1043) from US to India.