Tata Steel Unveils India’s Largest Blast Furnace at Kalinganagar

Tata Steel Limited has successfully commissioned India’s largest blast furnace at its Kalinganagar facility in Odisha. This project, part of a Phase II expansion involving an investment of ₹27,000 crore, will increase the site’s capacity from 3 million tonnes per annum (MTPA) to 8 MTPA. The inauguration was led by T. V. Narendran, CEO and Managing Director of Tata Steel, along with senior company leaders.

The new blast furnace will significantly enhance the plant’s production capabilities, enabling Tata Steel to cater to the rising demands from various sectors, including automotive, infrastructure, power, shipbuilding, and defence. It will also benefit areas like oil & gas, lifting & excavation, and construction. With this expansion, Odisha has become the largest investment hub for Tata Steel in India, with total investments exceeding ₹1,00,000 crore over the past decade.

1. V. Narendran stated, “The commissioning of India’s largest blast furnace at Kalinganagar is a momentous occasion for the steel industry, setting new benchmarks in capacity, technology, and sustainability. A key enabler of socio-economic development in the region, the expansion not only strengthens Tata Steel’s position as a leader in high-end, value-added steel segments but also showcases our advanced engineering prowess.” 

He further added, “It underscores our commitment to boosting private investment in India, aligning with the nation’s vision for self-reliance and sustainable industrial growth. On behalf of Tata Steel, I thank the Government of Odisha for their unwavering support and applaud the collective efforts of our employees, suppliers and vendor partners, and all other stakeholders in enabling this significant milestone.”

The new blast furnace features a volume of 5,870 m³ and incorporates advanced technology for long operational life and an eco-friendly design to optimise the steelmaking process. It includes four top combustion stoves, a first in India, along with two preheating stoves for better fuel efficiency in hot metal production. Notably, a dry gas cleaning plant has been installed to enhance energy recovery from by-product gas. 

The facility also boasts the world’s largest Top Gas Recovery Turbine (TRT) with a capacity of 35 MW, contributing to an additional 10% energy recovery. An innovative evaporative cooling system is being utilised for the first time in an Indian blast furnace, optimising space while reducing specific water and power consumption by around 20% compared to traditional designs. Furthermore, the facility has a zero-process water discharge plan with rainwater harvesting.

Key components of the Phase II expansion at Kalinganagar include a Pellet Plant, Coke Plant, and Cold Rolling Mill, each featuring advanced technologies and sustainable practices. The new steel plant focuses on value-added products, operational efficiency, and a marked reduction in carbon emissions.

Beyond its industrial significance, the Kalinganagar plant plays a vital role in the socio-economic development of the region. Tata Steel has made substantial investments in community development initiatives focused on education, healthcare, and livelihood opportunities, positively impacting over 2,00,000 people in the surrounding areas. The success of Tata Steel Kalinganagar is also attributed to its dedicated workforce. The company’s ‘Safety First’ culture ensures adherence to the highest safety standards, making Kalinganagar one of the safest steel plants globally.

Tata Steel Kalinganagar is notable for being the first Indian manufacturing plant recognised as a Global Lighthouse by the World Economic Forum (WEF). In 2024, it also received the prestigious ResponsibleSteel™ Certification, marking a significant milestone in its sustainability journey.

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