Tata Steel’s Ferro Alloys and Minerals Division has emerged as a trailblazer in water conservation within the mining sector. Faced with growing global water scarcity, the company has recognized the urgent need for sustainable water management practices. Mining operations, notorious for their high water consumption, often contribute significantly to the depletion of local water resources. In response to these challenges, Tata Steel has implemented a Smart Water Management system across its mining operations, using cutting-edge technology to optimize water usage and reduce waste.
This advanced system employs a combination of Internet of Things sensors, data analytics, and automation to monitor and control water flow, distribution, and consumption in real-time. By integrating sensors throughout its infrastructure, Tata Steel is able to gather actionable data on water usage, helping to identify inefficiencies and minimize wastage. The real-time monitoring is facilitated by an interactive web and mobile application, which provides immediate insights into the water management system. This allows for timely corrective actions, ensuring that water is used as efficiently as possible and minimizing the company’s reliance on increasingly scarce water resources.
In partnership with FluxGen Sustainable Technologies, a Bangalore-based industrial water management firm, Tata Steel has digitalized its water circuits. The collaboration has enabled FAMD to install sensors and water meters across its operations, providing detailed, real-time data about water consumption. These smart sensors not only track the flow and distribution of water but also help in reducing the overall water footprint by providing the necessary tools to fine-tune the water management process. Tata Steel’s commitment to environmental stewardship is underscored by the words of Pankaj Satija, Executive-In-Charge at FAMD, who emphasized the finite nature of water resources and the company’s responsibility to optimize water use for sustainable growth.
Beyond efficient water usage, Tata Steel is equally committed to ensuring the quality of water in its mining operations. To treat industrial discharge and surface runoff, the company has installed a state-of-the-art Effluent Treatment Plant with a capacity of 4500 KL/hr at its Sukinda Chromite Mine. This plant is designed to handle wastewater and ensure that it meets the stringent water quality standards set by the Odisha State Pollution Control Board. The treated water is then repurposed for non-potable uses such as horticulture and dust suppression, effectively reducing the environmental impact of the mining operations. Furthermore, Tata Steel has implemented an additional ETP at the Saruabil and Kamarda Chromite Mines, further enhancing its water management efforts.
The company also uses advanced technology to monitor the quality of water in real-time at its mines. With a sensor-based communication system in place, the company tracks key parameters such as hexavalent chromium (Cr+6), Total Suspended Solids (TSS), and pH levels. This constant monitoring ensures that the water quality remains within acceptable standards, reducing any potential environmental hazards. Tata Steel has also engaged a third-party agency, accredited by the National Accreditation Board for Testing and Calibration Laboratories, to conduct comprehensive environmental monitoring, further strengthening its commitment to responsible water management and sustainable practices.
In addition to its efforts in water treatment and quality management, Tata Steel has focused on minimizing water consumption at its Ferro Alloys Plant in Joda. Through innovative water conservation solutions, such as recycling treated effluent and scrubber pond water, the plant has managed to reduce its water usage by more than 40%. This has not only resulted in substantial cost savings for the company but has also contributed to reducing the environmental footprint of its operations. By reusing water within the plant’s processes, Tata Steel has made a significant step toward reducing its dependence on external water sources, which is crucial given the rising concerns about water scarcity in many regions.
Tata Steel’s commitment to sustainable water management is also evident in its initiatives aimed at treating domestic water waste. At the Sukinda Chromite Mine colony, the company has set up a 1000 KLD sewage treatment plant to treat the entire domestic wastewater generated in the colony. The plant is equipped with various treatment facilities, including grit chambers, aeration networks, pressure filters, and activated carbon filters, ensuring that all effluent meets the required water quality norms. The treated water is then used for plantation and gardening, contributing to the company’s efforts to enhance green spaces while reducing the impact on freshwater resources.
With these innovative technologies and practices, Tata Steel’s FAMD is not just addressing the immediate needs of its mining operations but is also setting a global standard for water management in the mining and steel industries. By leveraging smart technology and a holistic approach to water conservation, Tata Steel is making substantial progress toward its long-term sustainability goals. The company’s efforts in water management are an important part of its broader environmental stewardship strategy, which aims to minimize the ecological footprint of its operations while contributing to the well-being of the communities and ecosystems in which it operates.
Tata Steel’s approach to water management exemplifies the growing importance of technological innovation in addressing environmental challenges. With the integration of IoT-based systems, real-time data analytics, and sustainable water treatment technologies, the company is showing how the mining and industrial sectors can reduce their impact on vital natural resources while maintaining operational efficiency. This forward-thinking strategy ensures that Tata Steel remains a leader in both the steel industry and in corporate sustainability.
