ABB Motion & RIPL: Green Steel Revolution in India

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Steel: both vital and energy intensive
In Indian state Chhattisgarh, where steel manufacturing drives economic growth, a leader in this field has partnered with ABB to drive sustainability

In the industrial state of Chhattisgarh, India, a remarkable transformation is underway at Real Ispat and Power Ltd (RIPL), a front-runner in the steel industry.

As global challenges around energy and environmental sustainability intensify, RIPL, in partnership with technology giant ABB, is turning the tide through innovative solutions that promise a greener future.

Steel industry's sustainability challenge

The demand for sustainable practices in steel production has never been more urgent.

As Fred Esterhuizen, Global Business Line Manager for Metals, ABB Process Industries told Manufacturing Digital in 2024:  "2025 will be a year of balancing acts for metals manufacturers."

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"As electric arc furnace usage rises globally and scrap recycling becomes more important and prominent, industry players must juggle regional demands, new tech and a pressing skills gap to continue to fuel sustainable, shared growth."

Despite steel's essential role in various industries — ranging from construction to automotive manufacturing — it accounts for approximately 7% of global CO₂ emissions according to the International Energy Agency (IEA).

This positions steel making among the least sustainable industrial activities.

Within India, the world's second-largest producer of steel, this issue is particularly pronounced given the country's high industrial energy demands.

The resulting environmental footprint and economic costs have driven RIPL to seek effective solutions.

Operational needs at RIPL's facilities, extending from the transformation of iron ore into sponge iron up to the fabrication of finished steel products, are energy-intensive.

Amid rising energy prices and stringent emissions standards the company turned to ABB, a global leader in electrical engineering and sustainable technological innovation.

Innovative solutions from ABB

ABB's involvement brought cutting-edge solutions to RIPL's manufacturing processes.

Using ABB Motion’s suite of products, the collaboration focused on integrating highly efficient IE3 General and Process Performance motors and Variable Frequency Drives (VFDs).

These devices excel under rigorous industrial conditions, optimising energy use across pivotal manufacturing operations such as pumping and milling.

A strategic deployment of VFDs allowed RIPL to adjust motor speeds with unmatched precision, directly leading to a substantial reduction in energy consumption.

Shiv Agarwal, Director of RIDL (Real Ispat and Power Ltd)

"ABB's solutions have been pivotal in driving sustainability and boosting productivity, truly masking them a game changer for our business," says Shiv Agrawal, Director of Real Ispat and Power Ltd.

"By integrating motors with VFD's and leveraging ABB's high-efficiency motors, we achieved remarkable energy optimisation.

"The energy savings were redirected into manufacturing new products, maximising operational efficiency and giving us a competitive edge in a demanding market, all while contributing positively to the environment." 

RIPL additionally spearheaded other sustainable initiatives like the hot charging of MS billets, which eliminated the need to reheat certain materials thus conserving energy further and reducing carbon outputs.

Modifications to the firm’s furnace coils ensured optimal energy use, illustrating a comprehensive approach to sustainability.

The path forward

The results of this innovative partnership have been transformative.

RIPL has managed to achieve an annual reduction of about 3 million kWh in energy usage, supplementing this saving with an additional 600,000kWh saved through the transition to energy-efficient LED lighting.

The company has also embraced the use of Dolochar as a biofuel in their boilers — a byproduct of the direct reduction of iron process in sponge iron production — enhancing circularity and reducing waste.

Through these concerted efforts, RIPL has dramatically lowered its CO₂ emissions while cutting costs and bolstering its market position.

The adoption of ABB's electric motors was a critical factor in supercharging RIPL’s sustainability objectives.

Sanjeev Arora, the President of ABB Motion

"A testimony of ABB’s commitment to our customers in their journey of sustainability," Sanjeev Arora, President of ABB Motion India said about the partnership on LinkedIn.

"Thank you Shiv Agrawal and REAL Group — GK TMT for using our Energy Efficient Motors and Drives in your plant." 


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