Tata Steel has commissioned India’s first-of-its-kind Coke Oven Gas (COG) Injection Project at Blast Furnace 1 of its Meramandali plant in Odisha, marking a significant step towards reducing fossil fuel consumption and carbon emissions in blast furnace-based ironmaking.
The initiative is aligned with Tata Steel’s Net Zero by 2045 target and is aimed at increasing the utilisation of process gases generated within an integrated steel plant. The technology enables coke oven gas to be used within the blast furnace process, reducing dependence on external fossil fuels.
Coke oven gas is a hydrogen- and hydrocarbon-rich by-product generated during the coke-making process. In an integrated steel plant, the gas is typically used for power generation and heating, or may be flared. Tata Steel has now deployed the gas directly in the blast furnace as a reductant, providing an alternative to conventional fossil fuel inputs.
With support from technology partner Paul Wurth-SMS and equipment supplier Kobelco, Tata Steel has implemented the COG injection system through tuyeres in the blast furnace. The process allows the gas to be injected directly into the furnace, where it can substitute a portion of fossil fuel used as a reductant.
The project is expected to lower fossil fuel consumption and CO₂ emissions while also providing Tata Steel with greater operational flexibility. The company said the technology creates an opportunity to operate the blast furnace with a three-fuel system, enhancing both operational efficiency and flexibility.
Subodh Pandey, Vice President – Technology, R&D, NMB and Graphene, Tata Steel, said the project demonstrates the potential to maximise the use of process gases and reduce dependence on external fossil fuels. He added that the company remains focused on demonstrating and scaling low-carbon technologies to accelerate its Net Zero 2045 journey.
Sudhir Kumar Mehta, Vice President – Operations, Tata Steel Meramandali, said the project combines operational efficiency with environmental benefits by finding a productive use for coke oven gas within the blast furnace process, making operations leaner and cleaner.
The initiative adds to Tata Steel’s ongoing efforts to deploy low-carbon technologies in blast furnace operations. The company has previously demonstrated the injection of coal bed methane, hydrogen and biochar in blast furnaces.
The commissioning of the COG injection project strengthens Tata Steel’s focus on improving resource efficiency and reducing the environmental impact of steelmaking, while exploring technologies that can support the transition towards lower-carbon iron and steel production.
