Research in the Iron and Ferro Alloys Group is carried out under the following domains of expertise:

Beneficiation
Demand of the manganese ore and chrome ore is increasing in line with increasing production of steel production and the reserve of the high grade ore is limited. Proper utilization of the available resources is therefore a major challenge. This subgroup is currently working to minimize the chrome ore losses in the tailings, recover values from chrome ore tailing pond, and also explore methods to utilize the low grade manganese ore fines.

Agglomeration
With the adoption of mechanized mining and close sizing of ore, the amount of fines generated in the mines has increased substantially, thereby emphasizing the need for their agglomeration. This subgroup focuses on the sintering and pelletizing techniques for agglomerating ore fines for metallurgical applications. Research work is carried out on sintering of iron ore and manganese ore fines and pelletization of iron ore, chromite ore and manganese ore fines for improved blast furnace and arc furnace smelting. Recently, new binders have been designed for cold bonded chromite pellets and briquettes of ferroalloys for use in SAF and direct steel making respectively.

Blast Furnace Iron making
Ironmaking process at Tata Steel India is primarily through the blast furnace route. In recent years, the major focus has been on installing large sized blast furnaces for a higher production level and this trend is expected to continue. Major challenges ahead are to sustain stable operation and higher productivity levels from large sized blast furnaces.

To address these challenges, this subgroup focuses its research activities (mathematical models as well as lab and plant scale experiments) in the areas of segregation and distribution of burden, pulverized coal injection, blast furnace internal state (process dynamics and kinetics) and slag-metal characteristics.

Ferro Alloys making
Ferro alloy processes are known to be energy and coke intensive. This subgroup carries out research work on smelt reduction of chromite and manganese ores. The group is currently working on the development of a new sponge chrome process to minimize the power and coke consumption in Ferrochrome production and a new slag regime for Ferromanganese production and on smelting of refractory grade chromite ores in more efficient manner.          

Energy and Environment
High energy intensity and emissions from the steel industry have put a question mark on its sustainability. This subgroup works on identifying the opportunities of reduction of emission/energy consumption from various installations, and benchmarking their performances with the best practices to identify grey areas. This subgroup is currently developing a technology demonstration plant on recovery of the sensible and chemical heat from slag generated in works and ferroalloys manufacturing unit.