Transforming Tomorrow through Technology

May 11 marks National Technology Day, a celebration commemorating India’s successful nuclear tests at Pokhran in 1998 and recognising the country’s broader strides in science and technology. India’s technological progress reflects its commitment to self-reliance and innovation. From launching its first satellite, Aryabhata, in 1975 to leading low-cost space missions and Chandrayaan and building a robust digital economy through initiatives like Digital India and Startup India, the country has steadily strengthened its technological foundations.

Steel is a vital component of this journey and is the backbone of industrial growth and infrastructure. The global steel industry has embraced transformative technologies to improve efficiency, sustainability, and competitiveness. The shift from traditional blast furnaces to electric arc furnaces (EAF), which use scrap steel and electricity instead of iron ore and coal, aims to reduce carbon emissions. Direct Reduced Iron (DRI) processes, utilising natural gas or hydrogen to reduce iron ore, are gaining traction as cleaner alternatives.

Emerging technologies such as hydrogen-based steelmaking, which replaces coking coal, are a cornerstone of green steel production. Several pilot projects worldwide, including India, are assessing this method to decarbonise steelmaking. In parallel, Carbon Capture, Utilisation, and Storage (CCUS) is being explored to capture emissions from existing blast furnaces and repurpose them for industrial use or permanent storage. Alternative fuels like biochar and increasing scrap mix in blast furnaces are also being tested. Amid these developments, Tata Steel remains steadfast by actively integrating such technologies into its operations. It is building EAF-based steelmaking units in the UK and India. It has also conducted pilots for CCUS, waste heat recovery, hydrogen injection and biochar use in blast furnaces.

ULCOS (Ultra Low Carbon Dioxide Steelmaking), a European research initiative launched in 2004, focuses on fundamental changes to steel manufacturing processes rather than incremental improvements. HIsarna — a smelting reduction technology that converts iron ore and coal directly into molten iron without needing coke ovens and sinter plants — is one of the areas where Tata Steel Nederland is actively trialling through pilots. Once proven at scale, the technology can be deployed in India, thus accelerating the decarbonisation of the steel value chain.

The efficacy of technology can not only be evaluated based on its role in catalysing capacity growth and emission reduction. Safety is equally critical for heavy industries trying to reduce the man-machine interface while improving productivity and facilitating data-driven decision-making. Industry 4.0 technologies, including digital twins, predictive analytics, robotics, and AI-driven process optimisation, enable steelmakers to enhance operational efficiency, minimise downtime, and improve product quality. Electric and automated material handling systems, smart sensors, and real-time monitoring platforms further modernise production lines.

Tata Steel has invested in digital twin models for plant operations, AI-powered maintenance, robotics for hazardous tasks, and advanced data analytics to optimise its value chain efficiency. Its commitment to innovation extends to workplace safety, with the company adopting wearable devices, AI-driven safety analytics, and virtual reality-based training modules.

Technology has historically been transformational. From the first human flight to Blue Origin’s short space trips, scientists and engineers have turned what was once marvellous into mundane. Digital payments have changed how a large country like India transacts, increasing accountability and traceability. 3D printing has opened new gateways to sustainable, fast and low-cost construction. Gen AI has revolutionised education and media. Today, humans are limited only by their imagination. The steel industry is on the cusp of a similar and much-needed transformation that has the power to change the future of the planet and the human race.