How ABB Increases Energy Efficiency in Steel Manufacturing

In the bustling industrial region of Chhattisgarh, India, a significant revolution is underway.
Real Ispat and Power Ltd (RIPL), recognising the growing necessity for environmentally friendly practices, has joined forces with ABB, a giant in technological innovation, to spearhead a sustainable revolution in steel manufacturing to reduce emissions and boost energy efficiency.
This partnership has boosted energy efficiency at RIPL, marking a pivotal turn in the journey towards sustainability.
Challenges and changes in steel production
Now more than ever, steel manufacturers are urged to reassess their operations.
As Fred Esterhuizen, Global Business Line Manager for Metals, ABB Process Industries told Manufacturing Digital in 2024: "2025 will be a year of balancing acts for metals manufacturers."
This balancing act comes down to the need to pursue broader sustainability whilst managing operational challenges.
"As electric arc furnace usage rises globally and scrap recycling becomes more important and prominent, industry players must juggle regional demands, new tech and a pressing skills gap to continue to fuel sustainable, shared growth."
The steel industry is a major environmental detractor, traditionally known for substantial emissions and intensive energy demands. The International Energy Agency (IEA) says the steel sector is responsible for around 7% of global CO₂ emissions.
Nevertheless, steel continues to be indispensable across various sectors including construction, domestic appliances and automotive industries.
India, being the world's second-largest steel producer, faces immense challenges to boost sustainability within its expansive industrial energy landscape.
RIPL, whose operations stretch from converting iron ore into sponge iron to crafting top-tier steel goods, feels these challenges acutely.
Its heavy reliance on electric motors for essential tasks like milling and rolling, highlight an urgent need for solutions that not only reduce energy expenditures and emissions but also enhance competitiveness.
So RIPL naturally turned to one of the world's biggest leaders in sustainable motor innovation.
ABB's role in sustainable innovation
The collaboration led to the incorporation of ABB Motion's cutting-edge technologies, redefining energy efficiency and enhancing operational reliability at RIPL.
Among the innovations were ABB’s IE3 General and Process Performance motors, ranging from 1.5kW to 710kW, accompanied by Variable Frequency Drives (VFDs), crucial for tasks like pumping and conveying.
VFDs permit precision control over motor speeds, yielding significant improvements in energy efficiency.
"ABB's solutions have been pivotal in driving sustainability and boosting productivity, truly masking them a game changer for our business," says Shiv Agrawal, Director of Real Ispat and Power Ltd.
"By integrating motors with VFD's and leveraging ABB's high-efficiency motors, we achieved remarkable energy optimisation.
"The energy savings were redirected into manufacturing new products, maximising operational efficiency and giving us a competitive edge in a demanding market, all while contributing positively to the environment."
Further, RIPL adopted innovative measures like hot charging of MS billets, eliminating the need for reheating, thereby saving energy and reducing CO₂ emissions in one stroke.
Modifications to furnace coils further maximised every watt of energy used.
Transformative outcomes
The outcomes of RIPL’s collaboration with ABB have been transformative.
Annually, the company has managed to cut around three million kWh of energy, with an additional 600,000 kWh saved by transitioning to energy-efficient LED lighting.
Moreover, RIPL started using Dolochar as fuel in their boilers — a byproduct from the direct reduction of iron process.
This step not only fosters circularity but also marks significant strides in the company's sustainability agenda.
These strategic moves have proven economically beneficial too, freeing up resources for further investment into innovation and keeping RIPL competitive in a tough market landscape.
ABB's contribution to this transformation has been substantial, resonating with its commitment to supporting clients on their sustainability journeys.
"A testimony of ABB’s commitment to our customers in their journey of sustainability," Sanjeev Arora, President of ABB Motion India, says.
"Thank you Shiv Agrawal and REAL Group — GK TMT for using our Energy Efficient Motors and Drives in your plant."
As regulations tighten and sustainability becomes a crucial pillar of industrial operations globally, the partnership between RIPL and ABB exemplifies the invaluable role of collaborative innovation in shaping the future of green steel.
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