JSW expands capacity for nuclear reactors

JSW Nuclear Forgings Expansion boosts Muroran, Hokkaido capacity with a new 14,000-ton forge press, heavy cranes, and heat-treatment, tripling output for reactor pressure vessels as rivals like Sheffield Forgemasters and Bharat Forge scale up.

One of the worlds leading ultra heavy forgings manufacturers, Japan Steel Works Limited JSW recently completed the first phase of the expansions that the company began planning in 2008 in a bid to triple capacity.

The first phase, estimated to be worth about $530 million, includes the installation of a new forging unit with heavy cranes, heattreatment facilities, and most importantly, a 14,000ton forge press at the Muroran plant on Japans secondlargest island, Hokkaido. This is in addition to an existing 14,000ton press and, as Mitsubishi Heavy Industries targets new nuclear builds, many smaller machines, and a 12,000ton forging press for pipes.

The company informed the media that the new forging shop was the most important part of the first phase, adding that the second round of investments, amounting to another $320 million, would be completed in 2011. At this juncture, JSW foresees its capacity for manufacturing forged units for nuclear reactors, amid parts bottlenecks in the supply chain, tripling from its 2007 level. According to the company, the augmented capacity would satisfy the requirements for 12 reactor pressure vessels and main component sets per year.

Sources believe that the hike in the plants forging capacity will begin to show by mid2012, as factories start churning out new components. JSWs Muroran plant also manufactures rotor shafts for generators and steam turbines used across the sector, clad steel plates, and nuclear power plant turbine casings.

JSW, a major global supplier of heavy forgings, currently claims market leadership for large nuclear components, accounting for nearly 80 of the worlds market for large forged nuclear power plant components, including the steam generator, reactor pressure vessels and turbine shafts.

However, other market players are quickly emerging as legitimate competitors to JSW, and in India, JSW Energy is investing heavily in power generation to meet demand. It is reported that while Russian and Chinese suppliers are gearing up to cater to domestic requirements, South Korea already provides components in the international market and will possess a major forge press by 2013.

One of the worlds leading forging companies and engineering package providers, Sheffield Forgemasters International Limited SFIL was recently granted an £80 million US $122 million loan for SFILs 15,000ton press, worth an estimated £140 million US $213.8 million. SFIL and Indias Bharat Forge Limited are preparing to join JSWs ranks by 2014, while a tie up between global integrated power systems provider Rolls Royce Group plc and engineering, construction and manufacturing company, Larsen & Toubro Limited, for nuclear power plant forgings manufacturing, may also be in the offing.

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