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Operational Review

FERROCHROME

Ferro Alloys Corporation Limited (FACOR) is a key player in the Ferro Alloys industry, with a 140 KTPA Ferrochrome plant, an operational chrome mine, and a 100 MW captive power plant. In FY 2024-25, ore production reached 250 kt, ferrochrome production rose to 83 kt, and power generation touched 439 MU – all marking their highest level ever.

83 Kt RECORD FERROCHROME PRODUCTION

OPERATIONS
Production

Mining Division: ROM production from the Ostapal Mine reached 100% of the EC limit, i.e., 250 kt. EC for enhanced production of 1.5 MTPA was received in July 2024, and the CTO limit was increased to 300 kt in March 2025. Production at the Kalarangiatta mine has been temporarily halted due to pending statutory clearances; however, Stage - 1 clearance (CGWA NOC) has been obtained, with full-scale production expected to resume in FY 2025-26.

Charge Chrome Plant (CCP): We recorded a ferrochrome metal volume of 83 kt in FY 2024-25, with the highest-ever monthly production of 10,070 MT in June 2024.

Power Plant: We achieved full-capacity operations at 100 MW and the highest-ever annual power generation of 438 MU in FY 2024-25.

Projects Update
Expansion of Mines Project (1.5 MTPA)

The Underground Mines Project, with a capacity of 1.5 MTPA, is 23% complete. Development of two portals has been finalised, with 250 m of decline development completed, bringing the total underground development to 340 m.

Establishment of 600 KTPA Concentrator Plant

Progress on the 600 KTPA Concentrator Plant stands at 18%. Basic engineering is complete, and detailed engineering is 25% finished by the technology partner. Equipment manufacturing by the partner is 35% complete.

Expansion of Growth Capex Project (300 KTPA Ferrochrome Production)

The 300 KTPA Ferrochrome production project is 41% complete. Basic engineering has been finalised, and detailed engineering is 46% complete. Equipment manufacturing from the technology partner is 86% finished, with two lots of capital equipment from Metso already delivered to site. Civil construction for the furnace 1 structure erection is ongoing.

Awards and accolades
  • Recognised by HRAI for Employee Engagement & Experience
  • Honoured with the Odisha Best Employer Award for Excellence in HR through Technology and Strategy
  • Conferred with the People First HR Excellence Award
  • Won the FAME Award in the “Environment Management” Diamond category
  • Received the BSC International Safety Award in the Distinction Category for Power Plant safety
  • Honoured with the CII EHS Excellence Award for HSE Best Practices at Power Plant
  • Recognised with 5 awards for Systematic Development, Environment Monitoring, Mineral Beneficiation, Resettlement and Rehabilitation, and Overall Performance at MEMC Week Final Day Celebration
  • Awarded the FAME National Award for Excellence in Best CSR Practices
FINANCIAL PERFORMANCE

Revenue for the year was ₹ 921 crore, up 14% Y-o-Y, driven by higher sales volume and power generation, partly offset by lower realisation. EBITDA stood at ₹ 40 crore, a 65% Y-o-Y decline, mainly due to increased production costs from purchasing ore externally, delays in statutory clearances for Kalarangiatta Mines, and lower realisation as steel prices dropped, especially in the Chinese market, impacting ferrochrome demand.

ESG UPDATE
Environment
  • Completed installation of CAAQMS & CO sensor at CCP
  • Commissioned CEMS at 33 MVA GCP Stack
  • Deployed truck-mounted mist cannon system for dust suppression inside the plant
  • Installed 50 KLD STP at CCP colony and 14 KV Solar Panel at Ostapal Mines
  • Distributed 23,378 saplings and conducted plantation drives across the plant and mines
Occupational Health and Safety
  • Deployed Remote Racking Vehicle at 45 MVA Furnace
  • Introduced BLS Ambulance at the plant
  • Installed and commissioned two Safety Training kiosks at Power Plant and Mines
  • Organised state-level mock drill simulating a chemical disaster at CPP
  • Conducted onsite Mock Drill on Liquid Oxygen Leakage and Transformer Fire at CCP & Power Plant in the presence of government officials
  • Celebrated the 42nd Metalliferous Annual Safety Week at Osthpal Mines
  • Launched Specialised Visiting Doctors and Lady Doctor initiative (Gynaecologist, Paediatrician, Cardiologist, Orthopaedics) at OHC Plant & Mines
  • Conducted MEMC Week Flag Off ceremony and inspection at Mines
Strategic Priorities and Outlook
  • Revival of Kalarangiatta and Kathpal Mines
  • Expansion of Mines project of 1.5 MTPA
  • Expansion of Mines project of 1.5 MTPA
  • Expansion of Growth Capex project of 300 KTPA Ferrochrome Production