Tata Sponge is the first indigenous sponge iron technology. Established in the Keonjhar district in 1986, Tata Sponge, has its manufacturing facility at Bilaipada (in Joda Block of Keonjhar District in Odisha) and was initially set up as a joint venture company between Tata Steel and the Industrial Promotion and Investment Corporation of Orissa Limited (IPICOL). It has moved on since, becoming an associate company of Tata Steel following the former’s acquisition of IPICOL’s stake in 1991.
The origins of Tata Sponge can be traced to a groundbreaking effort by Tata Steel to industrialise a backward area of Odisha. Tata Steel proposed to do this by introducing an innovative technology for making Sponge Iron - Tisco Direct Reduction (TDR), developed by its Research and Development Division. The current capacity of the plant is 4 lakh TPA of Sponge Iron and 26 MW of co-generated power. The Plant’s modernisation and expansion plans envisage expansion of upto 8.5 lakh tonnes of sponge iron per annum and increasing power generation capacities upto 65MW. The process for implementing a 2 MTPA steel plant has been initiated.
Environment Sustainability initiatives
The ‘Precautionary Approach’ to environmental protection and balance at Tata Sponge Iron Limited is a subject of its own environmental policy and its Environmental Management System. The Company is among the greenest sponge iron companies in the world and was the first to receive ISO 9001 Quality and ISO 14001 Environment certifications. At the plant, best industry practices with proactive approaches are deployed for protection of environment. Initiatives in specific directions include:
Power Conservation
The Company is in the process of generating 26 MW power by utilization of waste heat, which emanates during sponge iron production. Once the internal power requirements are met, the excess power generated is sold to GRIDCO.
Consumption of energy at the Company’s facilities has been considerably reduced through upgradation of technology and instituting process improvement measures.
Carbon consumption per tonne of sponge iron production has been reduced considerably.
TSIL has optimized its coal consumption by importing low ash coal thereby bringing a definite reduction in emission of greenhouse gases.
TSIL is registered under UNFCC for its CDM project for combating climate change.
Waste Handling System
Clear water pump ensures continuous cleaning of contaminated water for its reuse in operations.
A large waste-dumping yard has been developed for disposal of waste materials generated during sponge iron production.
Continuous water spraying cleans the floors and helps the dust to flow into nearby drains from where the sludge is collected and disposed off in the waste yard.
Separate disposal yards have been earmarked for dumping biodegradable and non-degradable rejects.
Brick plants have been commissioned to convert the waste fly ash generated in the power plant into bricks, by adding sand, lime and gypsum.
Used oil and batteries are sold to parties authorised by the Central Pollution Control Board.
Water Conservation
Regular maintenance of water distribution network.
The quality of water is regularly checked and monitored.
Consumption of water has been optimised and surveys conducted regularly to check for leakage and other forms of wastage.
A water re-circulation system is in place to make the treated water from the plant available for other use.
Tree Plantation
At Tata Sponge Works, environmental consciousness is all-pervasive. A number of lawns, gardens and parks add beauty to the otherwise stark factory surroundings. The Company began planting trees annually and has since planted more than 150,000 trees turning the area lush green. After the initial ‘green belt’ with fast growing species like acacia, bakain, chakindi, etc. the plantation work was changed to fruit bearing plants and hard wood trees like sandalwood, rosewood, mahogany, teak & bamboo. These not only develop the soil quality but also help in recharging the ground water. More than 2500 sq. meter area inside the plant have been covered with picturesque gardens and parks.
The ‘Precautionary Approach’ to environmental protection and balance at Tata Sponge Iron Limited is a subject of its own environmental policy and its Environmental Management System. The Company is among the greenest sponge iron companies in the world and was the first to receive ISO 9001 Quality and ISO 14001 Environment certifications. At the plant, best industry practices with proactive approaches are deployed for protection of environment. Initiatives in specific directions include:
At Tata Sponge Works, environmental consciousness is all-pervasive. A number of lawns, gardens and parks add beauty to the otherwise stark factory surroundings. The Company began planting trees annually and has since planted more than 150,000 trees turning the area lush green. After the initial ‘green belt’ with fast growing species like acacia, bakain, chakindi, etc. the plantation work was changed to fruit bearing plants and hard wood trees like sandalwood, rosewood, mahogany, teak & bamboo. These not only develop the soil quality but also help in recharging the ground water. More than 2500 sq. meter area inside the plant have been covered with picturesque gardens and parks. 