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Yield, another critical measure of operational success, also saw significant gains. Prior to modernization, the yield ranged from 97.48 % to 97.53 %, but post-upgrade, it increased to 97.56 % to 97.57 %. Though seemingly modest, this improvement translates into significant material savings by reducing defects and waste, directly supporting Tata Steel’ s sustainability objectives. By enhancing yield and minimizing production losses, ABB’ s solutions helped Tata Steel optimize resource utilization and further their commitment to environmentally responsible manufacturing.
Sustainability gains
A key outcome of the project was its contribution to Tata Steel’ s environmental initiatives. The modernization enabled the mill to reduce waste and energy consumption by improving yield and minimizing defects, as previously highlighted. The system’ s ability to prevent cobbles and rejects also reduced the energy required to recycle defective materials, indirectly contributing to energy savings.
Overall, the operational improvements resulted in a leaner, more efficient operation that aligns with Tata Steel’ s sustainability vision. The benefits of the
project are expected to last well into the future. Tata Steel anticipates that the upgraded control systems will continue to optimize plant operations for at least a decade, with the potential for further refinements over time. ABB remains committed to supporting Tata Steel, providing ongoing remote monitoring and support to ensure continued optimization of the bar mill.
While this project marks a major success, it is not the end of the collaboration between Tata Steel and ABB. As the two companies look to the future, their partnership will continue to drive innovation and efficiency within the steel industry, setting a standard for how technology can transform manufacturing operations in a sustainable and impactful way.
Endnotes
1 https:// www. zawya. com / en / world / indian-sub-continent / steel- production-in-india-soars-to-1443-million-tonnes-in-2023-24- lvv22rwz
2 https:// www. business-standard. com / industry / news / indiabecomes-net-importer-of-finished-steel-in-fy23-24-shows-govtdata-124040800471 _ 1. html
3 https:// www. theclimategroup. org / sites / default / files / 2024-02 / India % 20Net % 20Zero % 20Steel % 20Demand % 20Outlook % 20 report % 203. pdf
4 https:// www. tatasteel. com / corporate / our-value-chain / themaking-of-steel /#:~: text = Tata % 20Steel % 20has % 20undertaken % 20 extensive, the % 20Long % 20Product % 20Rolling % 20Mills.
5 https:// www. tatasteel. com / corporate / our-value-chain / themaking-of-steel /#:~: text = Tata % 20Steel % 20has % 20undertaken % 20 extensive, the % 20Long % 20Product % 20Rolling % 20Mills.
About ABB & Tata Steel
ABB’ s Process Automation business automates, electrifies and digitalizes industrial operations that address a wide range of essential needs – from supplying energy, water and materials, to producing goods and transporting them to market. With its ~ 20,000 employees, leading technology and service expertise, ABB Process Automation helps process, hybrid and maritime industries outrun – leaner and cleaner. Tata Steel group is among the top global steel companies with an annual crude steel capacity of 34 million tonnes per annum. It is one of the world’ s most geographically-diversified steel producers, with operations and commercial presence across the world. The group( excluding SEA operations) recorded a consolidated turnover of US $ 19.7 billion in the financial year ending March 31, 2020.
Green Steel World | Issue 17 | April 2025 19