Scope 3 Breakthrough: RIPL's Green Steel Revolution

In the industrial hub of Chhattisgarh, India, steel manufacturer Real Ispat and Power Ltd. (RIPL) is spearheading the future of green steel. Faced with rising energy costs and increasing pressure to reduce emissions, RIPL has partnered with ABB to embrace sustainable transformation. This has resulted in a remarkable increase in energy efficiency and highlights how innovation is critical to thriving in an increasingly eco-conscious and competitive world.
The sustainability imperative in steel production
The steel industry stands at a critical juncture, with sustainability becoming an unavoidable priority.
The balancing act is crucial given the steel sector's significant environmental impact. According to the International Energy Agency, steel production accounts for approximately 7% of global CO₂ emissions. In India, the world's second-largest steel producer, manufacturers face even greater pressure to enhance sustainability while meeting high industrial energy demands.
RIPL's sustainable transformation
RIPL's operations, which span iron ore processing to premium steel production, heavily rely on energy-intensive electric motors. Recognising the need for a solution that could cut energy costs, reduce emissions, and maintain competitiveness, RIPL turned to ABB, a global leader in sustainable motor innovation.
ABB's innovative technologies
ABB Motion provided RIPL with cutting-edge technologies designed to redefine energy efficiency while improving operational reliability:
- IE3 General and Process Performance motors (1.5kW to 710kW)
- Variable Frequency Drives (VFDs)
The precision-engineered motors excel under the demanding conditions of steel manufacturing, optimising energy use across critical tasks such as pumping, conveying and crushing. The introduction of VFDs allowed RIPL to fine-tune motor speeds, offering greater operational flexibility and significant energy savings.
Shiv Agrawal, Director of Real Ispat and Power Ltd., highlighted the impact of the partnership:
"ABB's solutions have been pivotal in driving sustainability and boosting productivity, truly masking them as a game changer for our business. We achieved remarkable energy optimisation by integrating motors with VFDs and leveraging ABB's high-efficiency motors. The energy savings were redirected into manufacturing new products, maximising operational efficiency and giving us a competitive edge in a demanding market while contributing positively to the environment."
Additional sustainable initiatives
Beyond motor and drive improvements, RIPL has embraced bold sustainable initiatives:
- Implementing hot charging of MS billets, eliminating energy-draining reheating processes
- Furnace coil modifications to maximise energy utilisation
- Adoption of Dolochar as fuel in boilers, enhancing circularity
Transformative results
The collaboration between RIPL and ABB has yielded impressive outcomes:
- Energy savings of approximately 3 million kWh annually
- Additional 600,000 kWh saved through a switch to energy-efficient LED lighting
- Significant reduction in CO₂ emissions
- Enhanced cost-effectiveness, freeing up resources for strategic reinvestment
Sanjeev Arora, President of ABB Motion India, celebrated the partnership on LinkedIn:
"A testimony of ABB's commitment to our customers in their sustainability journey! Thank you, Shiv Agrawal and REAL Group - GK TMT, for using our Energy Efficient Motors and Drives in your plant."
The future of green steel
RIPL's success demonstrates the potential of embracing innovation and sustainability in steel manufacturing. As energy efficiency regulations tighten and sustainability becomes a core pillar of industrial operations, collaborations like RIPL and ABB highlight the path forward for the global steel industry.
The transformation at RIPL aligns with broader industry trends. For instance, ArcelorMittal, another major player in the steel industry, has partnered with ABB to introduce XCarb steel, which is produced with high levels of recycled steel and 100% renewable energy.
The initiative has led to a 29% reduction in the manufacturing carbon footprint of ABB's Kabeldon power distribution systems.
Massimiliano Cifalitti, Smart Power President at ABB, highlighted the importance of such collaborations:
"ABB people are passionate about introducing circular business models that increase the lifetime of materials and products – and collaborating with supply partners to introduce more sustainable alternatives."
As the steel industry continues its journey towards sustainability, partnerships like those forged by RIPL and ArcelorMittal with ABB will be crucial in driving innovation, reducing emissions and shaping the future of green steel production.
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