Adversity to Opportunity:

The Tata Nirman Story

Fly Ash Utilization Conference 2018, Goa
28th February, 2019
Presented By: Aparajita Mridha
Manager, New Business Development
Tata Steel India
Content Flow

Tata Steel Overview

Industrial By Products Management Division (IBMD) Overview

Setting the Context: Adversity to Opportunity

LD Slag Processing and 3R Principle

Opportunity: Infrastructure Growth in India

LD Slag Application in Fly Ash Bricks and Cement Industry: Tata Nirman

Miles to Go
 Tata Steel Group Overview
A GLOBAL CONGLOMERATE

2nd most geographically diversified

steel producer in the world

23.88 million
tonnes of annual crude steel production

50 Countries with
commercial presence

(Source: Integrated Report and Annual Accounts 2016-17, TSL India

US $18.11 bn
As of March 31, 2017)
Turnover in FY 17
3
 TATA STEEL VALUE CHAIN

RAW IRON STEEL DOWNSTREAM MARKETING CUSTOMERS

MATERIALS MAKING MANUFACTURING PROCESSING & SALES

Enabling Raw Material Self Ensuring Driving Developing Solutions

Sufficiency Sustainability Profitability
• Tata Steel has embarked on
• Presence of captive mines enable • Tata Steel over the • Value-added a mission to provide
un-interrupted supply of raw years, has undertaken downstream dedicated distribution network
materials, and help to maintain extensive research in products such as and innovative product
cost competitiveness and making the process of hot rolled, cold solutions. Based on market
efficiencies steel making more rolled and coated requirements, Tata Steel has
• Reduction in the consumption of energy efficient, steel, rebars, wire innovated several solutions
iron ore, coal and fluxes and the economically viable rods, tubes and that have resonated with its
energy required for reducing each and environmentally wires make for growing customer base
tonne of hot metal is at the core of sustainable profits centres at
technological research in iron Tata Steel
making

Enabling Sustainability – Staying Green

4
Tata Steel Overview

Industrial By Products Management Division (IBMD) Overview

Setting the Context: Adversity to Opportunity

LD Slag Processing and 3R Principle

LD Slag Application in Fly Ash Bricks Industry: Tata Nirman

Miles to Go
Tata Steel’s Journey in By-Products Management

Sustainable Eco-system

By-Products Commercialization, Value

Value Enhancement through Creation & 2014
Downstream Forays
Value Selling Industrial By-Products
Management Division

Emergence of Profit Sales

Centre, By-Product Sales
Through 2008
Auction
Secondary Products
Disposal
Waste
Mode Management
No Structured
Organizational Setup

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 Industrial By-products Management Division, with its myriad products and
customer segments, open up opportunity for innovation and value enrichment..

Industrial By-products Management Division (IBMD)

handles all by-products across the steel value chain. Product Portfolio
IBMD handles more than 20+ product
Purpose of the Business categories spanning over 250+ SKU’s serving
Recover & Process metallics from Steel Slag 1500+ Customers
Major Products Gen (Vol in MnT
MnT))
Recycle and reuse waste & scrap
Total Gen: ~13 MnT Annually
Value enhancement of By-Products 0.5 0

Converting into marketable products 1

Moving downstream in the Value Chain 4.7 BF Slag

LD Slag
Volume Handled : ~ 13 MnTPA 4 Coal by-products
Scrap and Others
Net Revenue : ~ $ 500 Million 2.5 Pooled Iron

Vision : To be recognised as one of the most Innovative & Some other significant products include:
Enterprising By-Products Divisions of the World !
Ferroshots Coal Tar GGBS

Approach : Recover, Recycle, Re-Use Sulphur Zinc Iron Oxide

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… and address a multitude of industries and segments from infrastructure to
automotive

Products End Usage Customers

External Internal
Coal By-Products

Captive
Middlings Power Power Plant

Brick Kilns
Tailings
Cokeries

Captive
Rejects Power
Power Plant

BF Slag Cement Road making /

Mine stowing

Pooled Iron/
Steel By-Products

Ingot/Billets LD Shops
MRP Scrap

Sec Steel LD Shops

Steel Scrap
Products

Pellet Plant
CTP/ Naptha/
Coal Tar Blast Furnace
Creosote Oil
Sinter Plant
Various Blast Furnaces
LD Slag Applications LD Shops

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Tata Steel Overview

Industrial By Products Management Division (IBMD) Overview

Setting the Context: Adversity to Opportunity

LD Slag Processing and 3R Principle

LD Slag Application in Fly Ash Bricks Industry: Tata Nirman

Miles to Go
Significant generation of Solid By-Products – Worldwide and in India will
continue to be a challenge to deal with

Crude Steel Production Solid By-Products

WORLD
INDIA
Generation
2000
1100
1622.8
892.54
Million Tonnes

255 184
95 64.8

2015 2030 2015 2030

Solid By-Products Generation in Tons per Ton of Crude Steel
@ 0.55 across World @ ~0.72 in India World
India
References :-
1) International Journal on Solid Waste Management in Steel Industry – Challenges & Opportunities by World Academy of Science – Engineering & Technology (Pg 1);
2) Long Term Perspective – Ministry of Steel (Pg 12);
3) Annual Technical Volume of Metallurgy & Material Engg Board (Pg 30).
4)National Steel Policy 2017
5) Steel Demand Beyond 2030. Accenture Strategy. OECD 2017 10
Varied type of Solid By-Products Generation in Steel Industry will require
different approaches for utilisation

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Amongst the solid by-products LD Slag Remains the Major Concern in terms
of its utilisation!
Slag is a by-product generated during manufacturing of pig iron and steel. It is produced by
action of various fluxes upon gangue materials within the iron ore during the process of pig
iron manufacturing in blast furnace and steel manufacturing in steel melting shop
BF Slag LD Slag
Application in manufacturing of Portland Application in Steel Industry, Cement and
cement, Glass, mineral wool insulation, various civil engineering application
replacement of sand, etc.
Contains SiO2, CaO, MnO, Al2O3, S, TiO2 & Glass Contains Metallic Fe, CaO, SiO2, P, MgO, Al2O3,
TiO2, &Cr2O3

Adversity or Opportunity ?
At Jamshedpur Works
The BOTTLENECK
Generation

Other Solid
BF Slag LD Slag
(LD, HSI & LF Slag)
By-products
FY18

3700 KT 1860 KT 1000 KT

Utilization

99 % 59 % 98 %

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Tata Steel Overview

Industrial By Products Management Division (IBMD) Overview

Setting the Context: Adversity to Opportunity

LD Slag Processing and 3R Principle

LD Slag Application in Fly Ash Bricks and Cement Industry: Tata Nirman

Miles to Go
In Tata Steel LD Slag Processing undergoes various screening and weathering
processes to be made fit for use

Production of LD Metal Recovery Screening Plant

Slag in Steel Works Plant

QC for Weathered Dry & Wet Aging Transport to

Slag Process Stockyard

Weathered LD LD Slag Fines

Slag 6-65mm 0-6mm QC for LD slag
fines

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LD Slag Utilization – The 3R approach in Tata Steel

Recover Recycle Re-use

Developing new
Recover Metallics from Recycle for In-house Markets/applications of LD
Initiatives LD Slag consumption slag

Trials with BFs, Product development

Plant modifications
Enablers LD shops Statutory approvals
Benchmarking
Maximize Utilization at Sinter Plant,
De-phosphorization

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LD Slag Utilization – The Limiting Agent and The Lever

Nearing its Maximum Capacity Potential Lever

Recover Recycle Re-use

Developing new
Recover Metallics from Recycle for In-house Markets/applications of LD
Initiatives LD Slag consumption slag

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Re-Use: Favourable properties of LD Slag opens up Usage and Commercialization
in different applications

Properties of LD Slag Possible application areas

Commercialized

Physical Properties
• Highly angular in Commercialized Commercialized
shape Road
• Rough surface texture
• High bulk specific
gravity Fly ash
Clinker
bricks

Potential
Mechanical Properties
• Good abrasion
usage of
resistance LD slag Cement
• Good soundness
• High bearing strength Hardstand Rail ballast

Chemical Properties Agriculture

• Alkaline
Under Under
• Soluble silicate Development Development
content
Under
Development
Tata Steel Overview

Industrial By Products Management Division (IBMD) Overview

Setting the Context: Adversity to Opportunity

LD Slag Processing and 3R Principle

LD Slag Application in Fly Ash Bricks

Miles to Go
Indian Real Estate Story : Opportunity for LD Slag in Fly Ash Bricks

Source: Union Budget FY’18, Bloomberg, Economic Times, IBEF

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Fly ash brick is composed of Filler and Binder material in varying
proportion

Fly ash bricks manufacturing process

Fly Ash

Crusher
Dust
Filler
Bad Dust

Sand
Fly Ash
Bricks Mixer Control Unit
Gypsum

Lime
Binder
OPC/PSC

GGBS

Final Bricks Press Shop

Depletion of natural resources (sand) and expensive raw material (lime)

Source: Market vists

Tata Nirman : Branded Fine Aggregates made from LD Slag

• Superior Quality Bricks • Consistent Size (0-6mm)

• Conservation of Natural • Superior Quality

Resources
• Assured Delivery
• Cost Savings
• Ease of Ordering
• Ready Availability

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Properties of LD Slag enables us to replace sand & lime in the brick manufacturing
process….suggested Process – Fly ash (50-60 %), LD( upto 30%) and Lime & gypsum/cement
(upto 10 %)

Water sprinkling on Tata

Nirman for 10 days

Tata
Sand
Nirman

 Stronger bricks

 Lower production cost

 Zero environmental
impact

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Summary of Results obtained on testing of brick samples made using LD slag
LD +Lime + gypsum
LD + Cement

We tested different raw- The optimum 30 % slag and 6% binder

mix compositions viz-a- compressive strength gave the best results in
viz a refence brick of the was attained with a terms of water
manufacturer combination of 30% LD absorption
slag 23
Tata Steel Overview

Industrial By Products Management Division (IBMD) Overview

Setting the Context: Adversity to Opportunity

LD Slag Processing and 3R Principle

Opportunity: Infrastructure Growth in India

Miles to Go
Various initiatives has enabled Tata Steel to utilize LD Slag upto 98%...however
we have Miles to Go!

LD Slag utilization for major steel producing

% Utilization for LD Slag by Tata Steel
(at Jamshedpur Plant) companies across world ranges from 53%
to 72%.
98 100 Source: survey by LD Slag Association.

Average LD Slag Utilization in India ranges from

53 59 15% to 35%
44 43
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In view of its various initiatives to improve LD
Slag Utilization, TSL plans to achieve ~ 100%
Utilization by FY20 which is substantially above
FY14 FY15 FY16 FY17 FY 18 FY 19 EFY22 E other steel players in India.

240 KT of Tata Nirman sold is one of the initiatives that has helped us
achieve 98% Utilization in FY 19
As on date, ~ 1 Billion Tonnes of Solid By-products is generated worldwide which is expected to rise
substantially in view of the increasing Steel Production.
It is very important to find suitable ways to utilize this by aligning our
Policy Frame Work, Funds, Infrastructure, Technology and R&D with Sustainability

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 Tata Steel Launched
India’s First Branded LD Slag Product
for fly-ash bricks and Clinker making

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In Pictures

Our LD slag Puja EF Bricks Purulia RK Gupta Jamshedpur

Customer meet FY 18 Customer meet FY 19 Gandhari and Sons Ranchi

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Questions Please

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Back Up Pages

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Comparison of TSL’s Processed LD Slag with Natural Aggregates

Our Steel Slag Test Results by CRRI:

Test Results
Properties Tested MoRTH Specifications
Steel Slag Aggregate Natural Aggregate

Aggregate Impact Value 11.75% 15.64% Max 27 %

Los Angles Abrasion Value 11.26% 15.23% Max 30%

Water Absorption Value 1.08% 0.80% Max 2%

Specific Gravity 3.25 2.75 -

Combined
8.09% 24.2% Max 30%
(EI + FI) Index

Stripping 99% 98.5% Minimum retained coating 95%

Source:
CRRI: Central Road Research Institute of India

 Steel Slag found suitable for replacement of natural aggregates

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Tata Aggreto : Branded Road Aggregates made from LD Slag

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Tata Nirman : Branded Fine Aggregates made from LD Slag

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