Expanding Boundaries and Igniting Change: IFGL Refractories’ Strategic Vision

IFGL, the only true Indian MNC in the world of refractories, is poised to enhance its market presence, optimise processes and contribute to nation-building.

The following is an edited excerpt from the interview with Arasu Shanmugam, Director & CEO-India of IFGL Refractories, which appears in Iron & Steel Review’s September issue.

IFGL has outlined ambitious short-term and long-term plans. Can you share the key elements of these plans and the strategic milestones you aim to achieve?

We have embarked on a clear and ambitious short-term and long-term growth trajectory, initiated three years ago under the leadership of our new Managing Director, James Leacock McIntosh. Our strategy centres on strengthening our technology base, expanding our product portfolio, and modernising our relationships with stakeholders. We’ve built a state-of-the-art research centre and established new manufacturing units at Visakhapatnam for MGO-C bricks, RH degasser snorkels, large precast shapes, and casting flux. We’ve also expanded our ISO plant in Kandla and set up a tar impregnation plant at Rourkela.

Our executive team has been bolstered with key appointments, enhancing our managerial intellectual capacity. The IFGL website and social media platforms are fully aligned with industry standards, helping us communicate effectively with stakeholders and attract the best talents. We remain committed to improving workforce engagement through our ‘People First’ initiative.

Operational efficiency is being enhanced through SAP S4 HANA implementation, and we are expanding into the non-ferrous refractory market to serve sectors like cement and glass. Strategic partnerships and acquisitions will further strengthen our technological capabilities and market reach.

Research and innovation are critical in the refractory industry. Can you provide insights into the initiatives and breakthroughs coming out of IFGL’s research centre?

Since the inception of IFGL, like many companies that began without a dedicated research arm, our performance improvements were primarily driven by product development efforts within individual plants and the teams working there. However, recognising the need for a strategic shift, we identified research as a critical pillar for our future — focusing on intellectual property, material advancements, and product innovation.

Today, every initiative at IFGL is directed towards building a lasting legacy and enhancing the company, from executive decision-making to empowering each employee to contribute towards continuous improvement.

When we decided to establish the IFGL Research Centre in 2021, our vision was clear: we wanted a world-class facility that could be recognised globally for its capabilities, both in terms of cutting-edge equipment and the expertise of its people. Our journey into this exciting new phase is just beginning, and our initial focus is on achieving impactful results. For the first 12 to 18 months, we are prioritising benchmarking all our products from the Group worldwide, as well as our current domestic materials and products.

Once we have completed this benchmarking phase, we plan to transfer the best available technologies to our plants in India, enhancing our ability to serve domestic customers better. Following this, our research will expand to focus on raw materials, customer processes, new product development, and green technology. This approach will ensure that IFGL remains at the forefront of innovation in the refractory industry.

Iron & Steel Performance for July 2024

Production & Consumption Scenario

From April to July FY’25, India’s steel sector performed well. Crude steel production hit 48.88 Million Tonnes (MT), finished steel production was 46.66 MT, and finished steel consumption reached 47.75 MT.

Increase in Imports

During April-July FY’25, India was a net importer of finished steel, with imports exceeding exports by 11.2 Lakh Tonnes.

The leading source countries of finished steel imports during FY’25 (April-July) were China (29.9%), Japan (28.8%), Korea (26.9%), and Vietnam (2.6%).

Tata Steel Commissions India’s Largest Blast Furnace at Kalinganagar

Tata Steel successfully commissioned India’s largest blast furnace at Kalinganagar, Odisha. With a total investment of Rs. 27,000 Crores, the Phase II expansion at Kalinganagar will take the total capacity at the site from 3 million tonnes per annum (MTPA) to 8 MTPA.

The new facility was inaugurated by T. V. Narendran, CEO and Managing Director of Tata Steel, in the presence of senior leaders of the company.

The new blast furnace will significantly boost the plant’s overall production capabilities, allowing Tata Steel to meet the growing demands of various industries, including automotive, infrastructure, power, shipbuilding, and defence. It will also provide advantages in specific areas like oil & gas, lifting & excavation, and construction.

With the Phase II expansion, Odisha has emerged as the largest investment destination in India for Tata Steel, with a total cumulated investment of over Rs. 100,000 Crores in the last 10 years.

On this occasion, T. V. Narendran said, “The commissioning of India’s largest blast furnace at Kalinganagar is a momentous occasion for the steel industry, setting new benchmarks in capacity, technology, and sustainability. A key enabler of socio-economic development in the region, the expansion not only strengthens Tata Steel’s position as a leader in high-end, value-added steel segments but also showcases our advanced engineering prowess. It underscores our commitment to boosting private investment in India, aligning with the nation’s vision for self-reliance and sustainable industrial growth.”

The new blast furnace, with a volume of 5,870 m³, is equipped with state-of-the-art features for long campaign life and an eco-friendly design to optimise the steelmaking process. This blast furnace will utilise four top combustion stoves, the first in India, along with two preheating stoves for optimum specific fuel consumption in hot metal production. In a first for Tata Steel, a dry gas cleaning plant has been installed to maximise energy recovery from by-product gas. The world’s largest Top Gas Recovery Turbine (TRT) of 35 MW power generation capacity will help with the recovery of an additional 10% of energy. An evaporative cooling system is being employed for the first time in an Indian blast furnace, optimising space footprint while lowering specific water and power consumption by approximately 20% compared to conventional designs. The blast furnace will also have a zero-process water discharge plan with rainwater harvesting.

Key facilities in Phase II expansion at Kalinganagar also include a Pellet Plant, Coke Plant, and Cold Rolling Mill, each incorporating advanced technologies and sustainable practices. The new state-of-the-art steel plant incorporates modern technologies focused on value-added products, operational efficiency, and a significant reduction in carbon footprint.

Primetals Technologies to Provide Continuous Caster Maintenance for Outokumpu Stainless USA

Primetals Technologies has secured a five-year cost-per-tonne maintenance contract from Outokumpu Stainless USA, a leader in stainless steel manufacturing. The company will be responsible for the repair and maintenance of Outokumpu’s single-strand continuous casting machine in Calvert, Alabama.

This contract marks a significant shift from previous maintenance work. Primetals Technologies will apply its in-depth knowledge of the original equipment and introduce future process improvements. The company is committed to enhancing the performance and longevity of the continuous caster, which it supplied to Outokumpu in 2012. This includes implementing the latest advancements in mould coating and roll overlay technologies.

The maintenance work will be relocated to a nearby 40,000-square-foot facility in Calvert, operated by Primetals Technologies. This move will streamline maintenance operations and provide Outokumpu with additional space in its meltshop for other production activities. Throughout the transition, there will be no disruption to Outokumpu’s production in Calvert or the operation of the continuous casting machine.

Securing this contract, along with a recent caster maintenance agreement from ArcelorMittal Nippon Steel (AM/NS) Calvert, further strengthens Primetals Technologies’ upstream and downstream service offerings in the United States.

The contract covers a wide range of maintenance activities for continuous caster equipment, ensuring optimal equipment performance and longevity. This includes the repair and servicing of moulds, oscillators, as well as the bender, bow, straightener, and horizontal segments. Additionally, Primetals Technologies has been tasked with the upkeep of caster rolls (both new and reconditioned), spindles, table rollers, table drive shafts, and all spart-part management.

Primetals Technologies will also apply its innovative Hiper Coat technology to the mould coppers, which offers variable hardness to extend the life of these components. Similarly, its proprietary overlay technology will enhance the performance and durability of the caster rolls. The contract also entails bi-annual strand alignment and reporting, labour and supervision for core equipment maintenance and operational expert support services.

Another advantage that Primetals Technologies offers is the option for its customers to access remote assistance through its advanced operations-management platform called Through-Process Optimisation. Additionally, the m.space e-services platform allows operators to order spare parts online, access helpful training sessions, and centralise plant documentation.

Furthermore, the Maintenance and Asset Technology (MAT) platform offers a suite of tools for real-time tracking of mould copper and roll fleets. Developed by Primetals Technologies, MAT’s predictive maintenance scheduling employs reliability-centred maintenance strategies to address failure modes and optimise asset lifetime. MAT also includes graphical work order tracking, forecasting to boost overall productivity, and a KPI dashboard for insightful reporting. Designed for portability, MAT can be operated on tablets, ensuring on-site and offline accessibility.