Under Commissioning – Tata Steel Ltd., Kalinganagar, Odisha

Overview

Enecovery Waste Solutions Pvt. Ltd. is setting up an advanced Waste-to-Energy (WtE) plant at Tata Steel Ltd. (TSL), Kalinganagar, Odisha. The project aims to extract a hydrogen-rich syngas stream through Enecovery’s hybrid reforming technology, designed to be utilized directly within the steelmaking process at Tata Steel’s Kalinganagar facility. This initiative marks a major step forward in India’s industrial decarbonization journey—integrating waste valorization with green hydrogen generation for sustainable steel production.

Background

In steelmaking, carbonaceous materials (substances rich in carbon) are critical as reductants in the iron-making process. Traditionally, coal is the primary reductant but contributes heavily to CO₂ emissions—approximately 2.5 tons of CO₂ per ton of crude steel at Tata Steel Kalinganagar (TSK).

Large quantities of carbonaceous waste are also generated within and around the plant, including:

• Plot-2 Housing Complex
• DET Hostel
• REHAB (R&R Colonies)
• Labour Colony
• Packaging, canteen, and gardening waste from plant premises

These wastes, amounting to 9–10 tons per day, are currently dumped or landfilled, leading to energy loss, landfill stress, and methane emissions. Recognizing this, Tata Steel Kalinganagar partnered with Enecovery to reform waste into clean energy, cutting waste volume and greenhouse gas emissions.

Project Description

The 10 Tons Per Day (TPD) Waste-to-Energy Plant integrates two key Enecovery technologies:

• Thermo-Catalytic Conversion (TCC): Thermal reforming of organic waste into syngas and carbon.
• Molecular Separation Technology: Isolation and refinement of hydrogen-rich syngas for steelmaking applications.

The plant processes municipal solid waste and biomass, including food, crop residue, gardening, and packaging waste. The hydrogen-enriched syngas will serve as a sustainable reductant and energy source for green steel production.

Key Advantages

• Total Waste Capacity: 10 tons of mixed waste per day.
• Outputs:
  • Hydrogen-rich syngas for steelmaking.
  • Hydrocarbon gases for power generation.
  • Treated water for reuse and horticulture.
  • Green carbon for metallurgical applications.
• Carbon Footprint Reduction: ~8.5 million kg CO₂ offset annually (negative CFT achieved).
• Emission Control: No dioxins, furans, or toxic emissions — compliant with global standards.
• Energy Efficiency: Maximized circular resource use and energy recovery.
• Operational Sustainability: Zero effluent discharge, low maintenance, continuous operation.
• Socio-Economic Impact: Local job creation, regional energy self-sufficiency, biodiversity protection.

Implementation and Impact

The 10 TPD hybrid TCC plant is scheduled for commissioning in January 2026, making it Odisha’s first dedicated green steel WtE project. By integrating waste-derived hydrogen into production, Tata Steel Kalinganagar will significantly reduce carbon intensity, aligning with India’s Net-Zero 2070 goal and the Paris Agreement.

This pioneering initiative redefines waste-to-energy, proving that industrial waste can be converted into clean hydrogen — closing the loop between waste management and sustainable manufacturing.