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Manufactured Capital

At Tata Steel, we continuously strive to achieve excellence in ironmaking, steelmaking, rolling facilities, warehouses, as well as logistics. We are investing consistently in augmenting our capacities through both organic and inorganic routes and reinforcing Tata Steel’s leadership in the industry. Our integrated operations and continuous efficiency-enhancing efforts are helping us remain cost-competitive in the global markets.

19.06 MnT

Highest ever crude steel production at Tata Steel (India Operations), 13% Y-o-Y growth

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Sites of Tata Steel Group included in WEF’s Lighthouse network

MATERIAL ISSUES ADDRESSED

  • Business growth
  • Long-term profitability
  • Product and service quality
  • Technology, product and process innovation
Strategic Linkage

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Tata Steel, with an annual crude steel capacity of 34 MnTPA, is one of the world’s most geographically diversified steel producers. We are one of the few steel producers that are fully integrated – from mining to manufacturing and marketing of finished products. Tata Steel Group has operations in India, the United Kingdom, the Netherlands, Thailand and Canada. Our operations range across the steel value chain from mining to market. We are continuously building capability by improving the efficiency of our manufactured capital, viz. mines, ironmaking assets, steel-making assets, rolling facilities and warehouses, along with logistics operations, while ensuring the safety and reliability of operations. We have also been augmenting our operational capacity through a combination of organic and inorganic growth initiatives.

Raw material mines

The Company possesses and operates captive mines that bestow cost competitiveness through production efficiencies, ensuring an uninterrupted supply of assured quality raw materials. Our raw material operations are spread across India and Canada, which help us to improve raw material security. Tata Steel has four iron ore mines in Jharkhand and Odisha that enable 100% captive iron ore usage and coal mines in West Bokaro and Jharia which provide ~21% of coal requirement for our India operations. Additionally, Tata Steel India has three captive manganese mines in Odisha. With assured manganese ore availability from our mines, ferro-manganese is made available for 100% requirement of Indian steel plant operations. We are the lowest cost producer of ferromanganese alloys, thereby helping our steel plants to maintain the quality of steel with cost competitiveness. Tata Steel Mining Limited (a 100% subsidiary of Tata Steel) operates three chromite mines in Odisha. We are the largest producer of chromite ore in India and one of the largest producers of ferro chrome in the world, which is being exported to stainless steel producers worldwide.

Tata Steel India has the letter of intent for the Kalamang and Gandhalpada iron ore blocks in Odisha. We are in the process of obtaining statutory clearances for these blocks to commence mining.

Our manufactured capital can be classified into the following three categories:
  1. Raw material mines
  2. Manufacturing facilities (including downstream)
  3. Logistics, Distribution and Sales
    1. Steel Processing Centres
    2. Stockyards
    3. Sales offices

Panview of Tata Steel Kalinganagar Works

Steel manufacturing

Tata Steel’s India crude steel production capacity stands at 19.6 MnTPA with manufacturing facilities in Jamshedpur and Gamharia in Jharkhand, Kalinganagar and Meramandali in Odisha. The Meramandali steel plant of ~5.6 MnTPA capacity was acquired from Bhushan Steel (later renamed as Tata Steel BSL), the same has been amalgamated with Tata Steel in FY 2021-22. We have commenced the Phase-II expansion of Kalinganagar steel plant to increase crude steel capacity to 8 MnTPA, along with commensurate increase in Hot Rolling capacity and commissioning of the new Cold Rolling Complex of 2.2 MnTPA capacity.

Tata Steel Thailand (TSTH)

Downstream operations act as the ‘last mile connect’ between Tata Steel and its customers. With the acquisition of Bhushan Steel (later re-named as Tata Steel BSL), Tata Steel has become one of the largest producers of Cold Rolled Coil and Tube products in India. Tata Steel now has 1 MnTPA of Tubes capacity in India, making it the 2nd largest producer in India. With the upcoming Cold Rolling Mill Complex of 2.2 MnTPA capacity at Kalinganagar, we are poised to become the number one Cold Rolled steel producer in India.

In long products, we have Steel Processing Centres (SPCs) which are located across India and process the crude steel to finished steel products near the markets. We have a number of Service Centres to meet the processed steel requirements of customers such as auto OEMs or construction companies by providing ready-to-use steel.

In Europe, Tata Steel is one of the largest steel producers, with a crude steel production capacity of over 12.4 MnTPA. The manufacturing facilities in Europe comprise primary steel-making facilities in the Netherlands and in the UK, along with downstream operations in the Netherlands, the UK, Germany, France, Belgium, Sweden, Spain and Turkey. We supply high quality strip steel products to demanding markets such as automotive, construction, packaging, and engineering.

In South-East Asia, Tata Steel operations began in 2004 with the acquisition of NatSteel, Singapore. In 2005, we acquired a majority stake in Thailand-based long product manufacturer Millennium Steel, and renamed it as Tata Steel Thailand (TSTH). In FY 2021-22, we divested our stake in NatSteel, Singapore while we continue to run the TSTH operations.

A brief profile of our manufacturing assets is provided below:

Raw materials

Key minerals Asset / Location Production FY 2021-22
(million tonnes)
Highlights
Iron Ore
  • Noamundi (Jharkhand)
  • Joda (Odisha)
  • Katamati (Odisha)
  • Khondbond (Odisha)
  • Vijaya II (Odisha)
  • Labrador & Northern Quebec (Canada)
  • 12.41
  • 11.11
  • 1.99
  • 3.93
  • 2.5
  • 1.43 (on dry basis)
  • State-of-the-art mining and mineral processing technology
  • Tata Steel Minerals Canada Ltd. is a partnership between Tata Steel (82%) and the Government of Quebec (18%); it mines and processes hematite iron ore
Coking Coal
  • West Bokaro (Jharkhand)
  • Jharia (Jharkhand)
  • Clean Coal (Own + Purchased) - 2.05
  • Clean Coal (Own + Purchased) - 0.57
  • Coal washery at West Bokaro is 1st in the industry to beneficiate coal tailings to generate Clean Coal, resulting in value creation from by-products
  • Adopted new technology at West Bokaro for mining locked up coal at the mine boundaries through high wall mining, the performance of which is at world benchmark levels

Steel manufacturing

Geographies Asset / Location Production FY 2021-22
(million tonnes)
Highlights
India

Jharkhand:

  • Jamshedpur
  • Gamharia

Odisha:

  • Kalinganagar
  • Meramandali
  • 10.2
  • 0.7
  • 3.2
  • 4.9
  • Tata Steel India achieved highest ever annual crude steel production of ~19 MnT
Europe
  • Port Talbot (UK)
  • IJmuiden (Netherlands)
  • 3.4
  • 6.45
Thailand
  • NTS Plant, Chonburi Province
  • SISCO Plant, Saraburi Province
  • SCSC Plant, Rayong Province
  • 1.31 (total production of 3 units)

Downstream facilities

Downstream facilities (India)
  • Tubes Manufacturing
    • Jamshedpur (Jharkhand)
    • Khopoli (Maharashtra)
    • Sahibabad (UP)
    • Hosur (Tamil Nadu)
  • Wires Manufacturing
    • Jamshedpur (Jharkhand)
    • Tarapur (Maharashtra)
    • Pithampur (MP)
    • Indore (MP)
  • Bearings Manufacturing (Kharagpur, West Bengal)
Downstream facilities (UK business)
  • Corby
  • Hartlepool
  • Shotton
  • Lantern
  • Trostre
  • Catnic, UK
  • Skein (Norway)
  • Surahammars Bruk, (Sweden)
Downstream facilities (Thailand)
  • The Siam Industrial Wire Co. Ltd. (SIW), Rayong
  • TSN Wires, Rayong
Downstream facilities (Netherlands business)
  • Naantali, Finland
  • Fredrikstad, Norway
  • Halmstad, Sweden

Netherlands

  • IJmuiden,
  • IJsselstein,
  • Maastricht
  • Oosterhout
  • Zwijndrecht

Germany

  • Gelsenkirchen,
  • Düsseldorf
  • Niederaula
  • Netphen-Deutz
  • Wallau

Belgium

  • Duffel
  • Ivoz-Ramet

France

  • Chauny
  • Maubeuge
  • Corbeil-Essonnes

Switzerland

  • Villmergen

Turkey

  • Adapazari

Spain

  • Durango

USA

  • Bethlehem
  • Warren