EMERGING TECHNOLOGIES

IN
STEEL INDUSTRY
PAPER CODE – KMBN 252

MORADABAD INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MANAGEMENT
MORADABAD, UTTAR PRADESH
INDIA – 244001

Affiliated to Dr. A.P.J. Abdul Kalam Technical University Lucknow

MBA

SUBMITTED BY :- YAGINI SARASWAT

MBA Semester: II

ROLL NO. - 2200820700062

SIGNATURE OF FACULTY GUIDE

____________

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 ACKNOWLEDGEMENT
I have taken efforts in this report. However, it would not have been possible without the kind support
and help of many individuals and organizations. I would like to extend my sincere thanks to all of
them.
I also express gratitude towards our parents for their kind co-operation and encouragement which help
me in completion of this project. Our thanks and appreciations also go to our friends in developing the
project and people who have willingly helped me out with their abilities.

YAGINI SARASWAT

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 ABSTRACT

Indian steel production has grown strongly in recent decades and India is now the world's
fourth-largest steel producer. Nevertheless, India's consumption of steel relative to the size of
its economy is very low by international standards. As the economy develops further, steel
consumption is likely to increase. Indeed, Indian steelmakers have plans to expand capacity
substantially in order to meet the anticipated increase in demand. While India has relatively
large reserves of iron ore, its steelmakers import most of the coking coal they require. As
Australia is a major supplier of coking coal to India, these exports from Australia are likely to
expand further.

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 INDEX

Sr No. Table of Content Page No.

1 Introduction Of Industry 5-6
2 Issues And Challenges 7-10
3 Emerging Technologies In The Industry 11-14
4 3 Keys Ways to Improve O&M Results 15-16
in Steel Industries
5 Limitations 17

6 Conclusion 18

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 INTRODUCTION OF THE INDUSTRY

Today, the steel is considered as the backbone of Indian economy and has occupied a
dominant position in the socio-economic development of the country. The Indian steel
industry has entered into a new era of development since 2007-08, riding high on the
resurgent economy and robust demand for steel. Rapid rise in production has resulted in
India becoming the 4th largest producer of crude steel and the largest producer of sponge
iron in the world. The Indian steel industry has achieved significant milestones in terms of
growth in capacity, production and exports to become a major player in the global steel
industry.
Between FY2008 and FY2013, India’s steel production has grown at a compound annual
growth rate (CAGR) of about 7 percent. Today, besides achieving the rank of the 3 rdlargest
global crude steel producer against 8 thposition ten years back, India also made a mark
globally in the production of Sponge Iron. India is expected to become the second largest
producer of steel in the world by the year 2020. The country is likely to achieve a Steel
production capacity of nearly 110 million tonnes by the year 2019-20.
Though this is true, the problems in Indian steel industry cannot be neglected as they are now
affecting the pace as well as the prospects. The progress of Green field expansion
projects have almost halted due to problem in land acquisition, environmental clearances
and getting iron ore and coal allotments. Brownfield expansion projects are comparatively
going on well and these will surely take the industry further to some extent. But as every
body knows, there is a limit to this expansion mode and soon saturation may be reached.
Looking at the user industries, auto, infrastructure, white goods, engineering, all are
progressing quite well. Their appetite for steel is going to increase every year and if it is not
satisfied by the domestic steel producers, they will have to opt for imports. Analysts fear
that India can be a net long term importer post 2015-16 if the domestic steel making
capacity does not grow as projected added products such as cold rolled coils, galvanized
coils, angles, columns, beams and other re-rollers, and sponge iron units. Both sectors cater
to different market segments. On the basis of ownership, the Indian steel industry is broadly

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divided into private and public sector enterprises. The private sector dominates
production accounting for almost 85 percent of the finished steel output while the public
sector has higher capacity utilizations.

The steel industry releases more than 2 tons of CO2 per ton of steel manufactured, which
means that more than 6 tons of CO2 are emitted for every ton of slag. In terms of the total
worldwide greenhouse gas emissions, the steel industry contributes an excess of 5%. Iron and
steel slags have the potential to sequester about 0.4 tons of CO 2 per ton as a mineral
carbonate or up to 0.7 tons of CO 2 per ton via enhanced weathering. Mayes et al.
(2018) estimated, that over 37 years, atmospheric carbonation of steel slag deposits in the UK
is less than 1% of the maximum carbon sequestration potential of the deposit. This indicates
that uncontrolled management of slag residues in open waste dump sites is insufficient to
exploit carbon sequestration potential because substantial quantities of unreacted slag
deposits are unavailable for atmospheric carbon uptake. This means that the whole carbon
cycle of slag production processes and weathering is currently far from balancing the emitted
CO2 from the iron and steel industry.
To meet the greenhouse emission reduction goals (COP21; https://unfccc.int/process-and-
meetings/the-paris-agreement/the-paris-agreement), the iron and steel industry is under
increasing pressure to reduce emissions to the level of 0.3 ton of CO 2 per ton of steel and 0.5
ton of CO2 per ton of slag. This could be done via (a) mixing low carbon fuels into the blast
furnace; (b) utilizing renewable energy for power generation; (c) implementing
CO2 capture technologies at the production sites for reutilization within the plant as well as
for geological storage, and (d) exploiting mineral carbonation technology.
Proactive management of slag to accelerate carbon sequestration and mitigate potential
hazards to human health and the environment due to the hyper-alkalinity of discharged
leachates from disposal sites to the receiving watercourses, subsurface soils, and groundwater
could provide mutual benefits. Currently, there are some leachate management technologies,
such as (a) leachate aeration via CO2; (b) precipitation of calcium carbonate in settlement
lagoons; (c) use of wetlands to buffer alkaline leachate; and (d) recovery and reuse of the
high purity precipitated calcite.
In view of steel and iron slag carbonation, a pre treatment step (i.e., grinding) is required
(Bobicki et al., 2012), and the carbonation, in most cases, is carried out on an aqueous slurry
mixture (liquid-to-solid ratio greater than one on a weight basis) at ambient or elevated
pressure and temperature (Stolar off et al., 2005). The slag uptake of CO2 depends on the
number of operational parameters, such as particle size, CO2 pressure, CO2 concentration, and
temperature, similarly to the carbonation of natural Ca-silicates; however, it requires less
power (Huijgen et al., 2005). As expected, slags containing free CaO instead of Ca-silicates
were more reactive (Bonenfant et al., 2008). And, to accelerate the reaction process and
enhance carbonation efficiency, Santos, François, et al. (2013) used ultrasound and additives
such as MgCl2. The efficiency of CO2 sequestered was shown to vary widely from 1.7%-to-
28.9%, depending on slag composition, particle size, liquid-to-solid ratio, operation
conditions (temperature, gas flow rate and concentration, etc.), type of additives, type of
extracting agent, adopted mineral activation technique, nature of the reactor (static, rotating,
fluidized, etc.).
This chapter discusses the sources, characteristics, and utilization of slag.
Also, environmental impacts on the current utilization methods and possible mitigation
measures are evaluated. In addition, direct and indirect plans for slag carbonation are
discussed.

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 ISSUES AND CHALLENGES

1. Harsh environment and asset failure

The steel industry heavily relies on high-temperature thermal or chemical transformations to

achieve the desired final outcome. However, this kind of operational environment inherently
poses significant risks, making it exceptionally challenging to prevent unexpected accidents
and ensure worker safety.
Compounding these concerns, the inspection and maintenance of machinery and structures
within the industry present ongoing difficulties. These vital components are susceptible to
corrosion, wear, and tear, and structural integrity issues, often situated in hard-to-reach
locations. Furthermore, as we will delve into later, workers frequently navigate through
parallel processes, lacking clear insight into the real priorities of the operation.
Consequently, beyond the physical degradation of the plant infrastructure itself, the work
environment becomes inherently unsafe and stressful for employees. In certain cases, due to
the extreme temperatures associated with steel production, operators are subject to strict time
limitations, restricting their actions and overall efficiency. These restrictions further
exacerbate the challenges faced by workers, limiting their ability to perform critical tasks and
compromising their well-being.
Given these circumstances, it is imperative to prioritize the development and implementation
of innovative solutions that address the safety and efficiency concerns within these
operations. By embracing emerging technologies and process optimization, it becomes
possible to create a safer and more conducive work environment for operators.
For instance, leveraging advanced inspection techniques, such as non-destructive testing and
remote monitoring, can facilitate the timely detection of structural issues and corrosion,
enabling proactive maintenance. Additionally, the adoption of digital solutions, including
automation, robotics, and data analytics, can enhance worker safety by minimizing their
exposure to hazardous conditions and improving overall operational efficiency.
By investing in modernization and digital transformation, the steel industry can empower its
workforce with tools and technologies that alleviate safety concerns and reduce the stress
associated with demanding operational conditions. Ultimately, prioritizing worker well-being
and safety fosters a positive work environment, enhances productivity, and contributes to the
long-term sustainability and competitiveness of the industry.

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2. Process monitoring

The inspection and monitoring process within steel mills typically adheres to specific
procedures, necessitating workers to operate using conventional parallel methods.
Given the critical nature of the environment, halting production for corrective actions is often
impractical. Unfortunately, the current monitoring approach falls short of predicting failures
with the same level of accuracy as intelligent predictive models. This significant disparity
highlights an inherent gap that leaves room for potential errors and inefficiencies.
To address these challenges, it is crucial to transition towards a more advanced and proactive
approach to inspection and monitoring within steel mills. By embracing intelligent predictive
models, the industry can significantly enhance its ability to identify and anticipate potential
failures before they occur.
Adopting such intelligent predictive models allows for an accurate and efficient approach to
maintenance, reducing the reliance on reactive measures and minimizing unplanned
downtime. By identifying potential issues in advance, operators can schedule maintenance
activities during planned downtime or during periods of lower production demand,
optimizing the use of resources.

3. Maintenance
In addition to the inherent challenges mentioned earlier, conducting inspections itself
becomes a daunting task. However, the complexity doesn’t end there—maintenance of
encountered issues proves equally arduous.
Corrosion, a pervasive problem in these industries, significantly complicates the maintenance
of equipment and structures due to the unforgiving operating conditions previously

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mentioned. Moreover, the multitude of intricate processes within the industry further
exacerbates the issue by making it difficult to comprehend and utilize the extracted
operational data effectively. The improper management of this information across disparate
systems further hampers efficient maintenance of critical structures.
Consequently, the absence of precise management tools severely limits the ability to predict
failures within operations, resulting in unplanned shutdowns and an overreliance on
corrective maintenance methods. This approach not only disrupts production but also incurs
unnecessary costs and prevents optimal resource allocation.
To address these challenges, it is crucial to adopt comprehensive solutions that enable
effective inspection, streamlined maintenance, and robust data management within the steel
industry.
Understand in detail the predictive maintenance process aimed at containing the corrosion
and failure of Steel Industries.

4. Solid waste management and pollutant emissions

Another significant consequence stemming from the multitude of transformation processes

within the steel industry is the generation of substantial volumes of subproducts that currently
find no reuse within the operation. Consequently, a significant amount of waste is generated,
and regrettably, a portion of this waste is improperly released into the environment.
Moreover, the primary source of energy for these industrial processes predominantly relies on
the combustion of fossil fuels. This reliance directly contributes to the emission of polluting
gases into the atmosphere. Both the improper waste disposal and the high carbon emissions
associated with fossil fuel combustion pose severe environmental problems, effectively
categorizing the steel industry as one of the most environmentally polluting sectors.
To address these environmental challenges and promote sustainable practices within the
industry, embracing digital transformation is paramount.

5. Demand prediction

Yet another challenge of the steel industry is fluctuating demand. As it fluctuates from time
to time, it becomes difficult for steel makers to predict the demand and produce accordingly.
This results in delayed returns on investment.

6. Logistics related challenges

Like most other industries, logistics, and supply chain management remain key areas of
challenge for the steel industry. The main raw materials for making steel are iron ore and
coking coal. Both these are bulk materials while the finished product i.e., steel is also a bulk
material. Meaning, they are not regular goods to be transported and need to be handled
differently.

A report suggests that 80% of steel transportation takes place through railways in India.
Railways lack the modern infrastructure to handle bulk commodities. Road transport for bulk
commodities is often expensive and hence economically unfeasible. Many times, road
conditions are not suitable for transporting high-end steel products. Sea transport turns out to
be a cheaper and viable option provided the steel plant is closer to the port area. In simple

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terms, if the steel plant is located in a landlocked area, the railway turns out to be the most
feasible option however, it comes with its set of constraints.
Moreover, the cost of logistics is high for any industry in India, which is applicable to the
steel industry as well. Although the National Logistics Policy aims at bringing down the cost,
it is still to become a reality.

7. Disruptions in raw material supply

Key raw materials for steel production include iron ore and coking coal. Though iron ore is
available domestically, India needs to import coking coal and it is mainly imported from
Australia. Because of various factors, the supply chain of coal remains disrupted and hence
the supply of coal fluctuates. The same goes for coal prices too. While fluctuating supply of
coal affects steel production, fluctuating prices of coal impact the economics of production.
Hence, the produced steel becomes uncompetitive in the global market.

8. Low per capita consumption

Despite India being one of the largest producers of steel, India’s per capita consumption in
2020 was only about 75 kg. This restricts the demand for steel domestically. According to a
media report, the average per capita consumption is 224.5 kg while China records a per capita
consumption of a whooping 590 kg. The National Steel Policy 2017 aims at increasing per
capita consumption to 160 kg by 2030-31.

9.Lack of technology adoption

Although industry giants may have adopted digital technologies for supply chain
management, it is not the case for all steel producers. As a result, the supply chain
management team does not have access to real-time data. This translates into a lack of
capability in forecasting demand, grabbing short-term opportunities, etc. It may lead to losses
for the company.

10. Downtime and potential utilisation

All the challenges mentioned above culminate into yet another problem i.e., low capacity
utilisation. A report suggests that the potential capacity utilisation of the Indian steel plants
rarely reaches 80% because of various hurdles they face.
Some of the common constraints that affect capacity utilisation are: the non-availability of
raw materials, supply chain and logistics-related issues, labour relates problems like strikes,
energy crises, and so on. If these issues are eliminated, the plants can have better capacity
utilisation and hence, increased production of steel.

11. Increasing environment concerns

The steel industry is known to be an extremely energy-intensive industry. In fact, it is known

to be the second most energy-intensive industry after the chemical sector is the steel segment.
Hence, it has a high level of carbon footprint. On the other hand, increasing environmental
concerns is reducing the popularity of steel. Additionally, the industry has to adopt new
industry norms. Using modern energy management systems and the latest technologies can
help the steel industry to be more eco-friendly and more competitive.

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 EMERGING TECHNOLOGY IN THE INDUSTRY

In recent years, there have been several trends and technologies in metal fabrication that have
emerged to change the face of this industry. These include automation and robotics, 3D
printing, computer-aided design and manufacturing, additive manufacturing, advanced
materials, and the integration of IoT and Industry 4.0 technologies. These developments have
led to increased efficiency, precision, cost-effectiveness, and the ability to create complex
and unique designs in metal fabrication. As these trends continue to evolve and improve in
the next 202x (with an outlook for the next 8 years), we can expect to see even greater
advancements in the metal fabrication industry in the future.

1. Automation and Collaborative Robotics :-

The metal fabrication industry has been utilizing robotics for quite some time, mainly for
tasks that are deemed too dangerous for human workers. However, traditional robots were
large in size and required dedicated working spaces.
With the advancements in robotics technology, collaborative robots or cobots have emerged,
which can work alongside human workers to complete tasks safely. These cobots are
particularly useful for dangerous or repetitive tasks, and are increasingly being used to
address the labour shortage in the industry, which has been further exacerbated by the
COVID-19 pandemic.

Although cobots are still relatively new technology in the metal fabrication industry, they are
quickly proving to be a valuable asset. Soon, it is confirmed that automation is being
increasingly used in metal fabrication to improve efficiency, reduce costs, and increase
precision. Robots are being used to perform tasks such as welding, cutting, and drilling.

2. 3D Printing and Additive Manufacturing:-

3D printing, once considered a tool for hobbyists, has quickly become a valuable tool across
various industries, including metal fabrication. Additive manufacturing, also known as 3D
printing, provides unparalleled levels of customization in the metal fabrication industry.

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White 3D printing piece
3D printing is being used to create metal parts, casting molds and prototypes quickly and
cost-effectively. This technology allows for the creation of complex geometries and shapes
that would be difficult to produce using traditional manufacturing methods. One specific
method, Metal powder bed fusion, enables manufacturers to create complex designs with
minimal waste, as any unused powder can be recycled and reused. This technology is
revolutionizing the way metal fabrication is done and providing new opportunities for
innovation.

3. Implementing Automation and CNC Machines:-

Computer numerical control (CNC) machines are an integral part of the metal fabrication
industry, but until recently, they required human intervention and programming to function.
Incorporating automation into the CNC portion of metal fabrication can remove some
repetitiveness from this step, increasing efficiency and productivity in the long run.

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Eliminating repetition reduces the chance of employees developing repetitive stress injuries,
which also opens them up for better opportunities in their careers. CNC automation is
becoming more popular during 2020 and will continue to thrive as the industry moves into
the future.

4. Internet of things (IoT) and Industry 4.0:-

The Internet of Things (IoT) is becoming an increasingly important aspect of metal

fabrication equipment control. IoT devices and sensors can be integrated into metal
fabrication equipment to provide real-time data and monitoring of the equipment’s
performance and usage. This data can then be analysed to optimize equipment operation and
maintenance, leading to increased efficiency and cost savings. Additionally, IoT-enabled
equipment can be remotely monitored and controlled, allowing for greater flexibility and
improved collaboration between different teams and facilities. The integration of IoT
technology also enables Predictive maintenance, by using data from the machines and sensors
to predict when maintenance is needed, reducing downtime, and increasing the life of the
machines.

5. Computer-Aided Design (CAD) and Computer-Aided Manufacturing

(CAM):-

The use of Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM)

software in metal fabrication is becoming increasingly popular as it allows for greater
precision and efficiency in the design and manufacturing process. CAD software allows
designers and engineers to create detailed, accurate 3D models of the parts or products they

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want to fabricate. These models can then be simulated and tested before actual fabrication
begins, reducing the risk of errors and wasted materials.
CAM software, on the other hand, allows for the efficient programming of CNC machines to
perform the fabrication process according to the specifications of the CAD model. This can
lead to increased accuracy and consistency in the final product, and reduced lead time and
costs. Additionally, these software can be integrated with other digital technologies such as
IoT and simulation software, to enhance the overall efficiency and automation of the
fabrication process.

6. Embracing Digitisation:-

Despite the ongoing digital revolution in many industries, it has been relatively slow to adopt
new technologies in metal fabrication. However, it’s important to note that implementing
technology-based platforms doesn’t mean replacing human workers.
Rather, it’s a step towards increased efficiency and productivity. As business owners in the
metal fabrication industry, it is crucial to embrace digitization and leverage the tools available
to them. This includes not only the use of digitized technology but also the need for
cybersecurity measures to protect against potential threats. While the adoption of new
technologies in metal fabrication may come with some challenges, the benefits it brings to the
industry are well worth the effort.

7. Advanced materials:-

Advanced materials allow for greater strength, durability, and versatility in the final product.
These materials include, but not limited to:
High-strength steels: These steels have a higher yield strength and tensile strength compared
to traditional steels, allowing for thinner and lighter parts to be produced while maintaining
the same level of strength and durability.

Aluminium alloys: These alloys have a lower density than steels, making them ideal for
lightweight applications such as aerospace and automotive parts. They also have good
corrosion resistance and high thermal conductivity.

Titanium alloys: These alloys have an excellent strength-to-weight ratio and high corrosion
resistance, making them ideal for aerospace and medical applications.

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Copper alloys: Copper alloys have good electrical conductivity, thermal conductivity, and
corrosion resistance, making them ideal for electrical and electronic applications.

Composites: Composites are made of a combination of different materials such as fibres,

ceramics, and metals. These materials have unique properties that can be tailored to specific
applications, such as high strength, low weight, and corrosion resistance.

3 Key Ways to Improve O&M Results in Steel Industries

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1. Secondary production

Because of all the material waste throughout the production chain, managers of steel
industries need to develop plans for the gathering, sorting, and reuse of these raw materials.
This recycling process can even be thought by engineers so that these residues can be used in
a process of industrial symbiosis, where they become raw material for the production of
other products. Thus, it is possible to make the entire operation more profitable and with less
waste or damage to the environment.

2. Energy transition

To control the large greenhouse gas emissions from fuel-burning processes in steel industries,
many companies have already started or are charting a roadmap to implement energy
transition in the operation.
In this scenario, several structures and ideas need to be planned and installed, from
transporting and storing eventual CO2 emissions to completely switching to low-carbon
energy sources, such as hydrogen or renewable sources like solar and wind.

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3. Technology implementation

As a third, and probably one of the most important actions, is the implementation of new
technologies in the operation of steel industries. In order to solve all the complexity of data
management in these companies, the deployment of tools and softwares capable
of assimilating the data generated in the operation and transforming them into valuable
insights is one of the most important measures to really optimize processes.
This digital transformation journey has several fronts, and can help from predictive
maintenance of equipment and increasing their efficiency, to assertive monitoring of energy
production or emission of gases into the atmosphere by industrial processes, for example. In
other words, implementing new technologies also helps the other optimization actions
mentioned
above.

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 LIMITATIONS

Though India is an important producer of iron and steel in the world, we are not able to
perform to our full potential largely due to:

a) High cost: Limited availability of coking coal as the amount of coking coal is limited, its
cost in India is high therefore the industry faces difficulty in buying it.

b) Low productivity of labour: Lower productivity of labour and poor infrastructure also
remain a hindrance in many cases. Private entrepreneurs have made use of the liberalisation
and foreign direct investment policies of the government. These policies have given a boost
to steel production

c) Irregular supply of energy: There is an irregular supply of electricity in India, so that

work becomes more difficult.

d) Poor infrastructure: The technological development in India is less as compared to other

countries.

e) There is a need to allocate resources for research and development to produce steel more
competitively to raise their standards to meet international levels.

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 CONCLUSION

The rigidity of the steel industry’s processes makes it suffer from several problems as a
result. From the challenges in inspection and maintenance of the operation to the large
emission of pollutants into the environment, this sector needs to find ways to optimize its
processes to keep on satisfying the consumer’s and production demands, but in a more
efficient and sustainable way.

The reuse of residual materials, the energy transition, and the adoption of technologies in the
operation have been the three main paths adopted by this segment to overcome the
covered problems.

1.Secondary production
2.Energy transition
3.Technology implementation

Dealing with all the complexity of steel industries is not easy, which is why problems such as
low efficiency and waste are central challenges to managers.
To deal with this, making plans to optimize production with waste reuse, energy transition,
and implementation of new data intelligence technologies is more than essential.

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