Home » Procedure » Green Steel EAF Manufacturing

Tata Tiscon’s Ludhiana EAF Plant Powers India’s Green Steel Revolution

Same trusted strength. Now produced through advanced Electric Arc Furnace (EAF) technology with lower CO₂ emissions.

Globally adopted across major steel-producing nations, EAF combines advanced refining technology, controlled production processes, and lower-emission steelmaking to support the future of modern construction.

INDIA’S BIGGEST EAF PLANT

How EAF Green Steel is Manufactured?

Tata Tiscon 550SD from the Ludhiana plant is manufactured via the Electric Arc Furnace (EAF) route at Tata Steel’s Hi-Tech Valley facility, the biggest EAF plant in the country dedicated to rebar production.

The process uses steel sourced from Tata Steel’s state-of-the-art recycling facility in Rohtak. The EAF plant operates with solar power integration, enabling cleaner and more responsible steel manufacturing. The resulting rebar meets IS 1786 specifications at Fe 550D (SD) grade, with carbon emissions below 0.5 tonnes of CO₂ per tonne of steel, up to 80% lower than traditional BF-BOF steelmaking routes.

Download Brochure

The process

How EAF Green Steel Manufacturing Works?

Recycle & Quality Control

Processed steel from Tata Steel’s Rohtak recycling facility first passes through best-in-class magnetic separation, screening out raw material.

Shred & procure

A captive in-house shredder (1st in industry) reduces impurities, and the FerroHaat platform ensures every batch is digitally procured.

Arc-furnace melt

The shredded charge is then melted in the Electric Arc Furnace, where hot oxidising slag at around 1,600°C pulls out sulphur, silicon, phosphorus and manganese.

Control chemistry

ECS, Q-One and Q-Melt systems monitor chemistry.

Cast & roll

The refined steel is cast on an Octacaster (1st in India, 7.5 m/min) and rolled into IS 1786 compliant TMT bars.

Key features

Why EAF Green Steel is the Future?

India’s own EAF Green Rebar

Produced at the state-of-the-art mill in the country, 4x bigger furnace than traditional IF plants.

Same strength you trust

Same earthquake resistance. Same mechanical strength. Same chemical purity.

New sustainability advantage

New sustainability advantage with lower carbon footprint.

Automated quality control

ECS, Q-One and Q-Melt automated chemistry control; Octacaster (1st in India, 7.5 m/min).

Applications

Uses of EAF Green Steel Rebar

Tata Tiscon 550SD from EAF Ludhiana is built for the same construction applications as primary-route:

Residential Homes

Commercial Buildings

Multi-Storey Structures

Infrastructure Projects

The Super Ductile (SD) variant, with a UTS/YS ratio of ≥1.15, is engineered for earthquake-prone regions. It is also positioned for LEED and GRIHA-rated buildings and is eligible for the Government’s Green Steel Public Procurement Policy from FY28.

Benefits

Advantages of EAF Green Steel Manufacturing

Low Carbon

Carbon emission below 0.5 tonnes of CO₂ per tonne, up to 80% lower than traditional BF-BOF steel.

Strength

Same strength and ductility as Tata Tiscon 550SD.

Design

Up to 6% steel savings via optimised design.

Manufacturing Standards

Quality Assurance in EAF Green Steel Manufacturing

Tata Tiscon 550SD from EAF Ludhiana is manufactured to IS 1786, Fe 550D (SD) grade, with the mandatory BIS / ISI Mark. The product exceeds IS code limits on every key parameter:

Parameters	Tata Tiscon EAF	IS Code
Yield Strength (min)	570 MPa	550
UTS / YS Ratio	≥ 1.15	≥ 1.08
Carbon Equivalent	≤ 0.50	≤ 0.61
Sulphur + Phosphorus (each)	≤ 0.035%	0.040%

Verifiable via

Mill Test Certificate

Ring Test

Weight Test

Frequently Asked Questions

What is Green Steel?

The Ministry of Steel defines Green Steel as steel produced with a CO₂-equivalent emission intensity of less than 2.2 tonnes per tonne of finished steel, with star ratings based on CO2 emissions. The highest 5-Star rating under this framework is reserved for steel with emissions below 1.6 tCO₂ per tonne of steel. At less than 0.5 tonnes of CO₂ per tonne of steel, Tata Tiscon 550SD manufactured through the EAF route at Ludhiana goes well beyond the 5-Star benchmark, setting a new standard for low-carbon steel manufacturing.

What is Electric Arc Furnace (EAF) Steel?

EAF steel is produced in an electric arc furnace using steel sourced from Tata Steel’s state-of-the-art recycling facility in Rohtak. The molten metal is then refined through hot oxidising slag at around 1,600°C, which actively pulls out impurities such as sulphur, silicon, phosphorus and manganese. This active refining step is what distinguishes EAF from simpler induction-furnace (IF) melting, which cannot remove these residuals effectively.

Is EAF Steel as Strong as Traditional Steel?

Yes. Tata Tiscon 550SD from EAF Ludhiana meets or exceeds IS 1786 on every parameter: Yield Strength minimum 570 MPa (IS code: 550 MPa), UTS/YS ratio ≥1.15 (IS code: 1.08), and tighter control on Sulphur and Phosphorus than the IS code requires. The quality can be verified on-site through the Ring Test, the Weight Test and the Mill Test Certificate.

Why is EAF Steel Considered Sustainable?

Tata Tiscon 550SD from EAF Ludhiana is sustainable on four counts. Tata Tiscon 550SD from EAF Ludhiana is sustainable on four counts. It uses steel sourced from Tata Steel’s state-of-the-art recycling facility in Rohtak. The plant operates on susbtantial solar power. Its embodied carbon is below 0.5 tonnes CO₂ per tonne of steel — up to 80% lower than traditional BF-BOF steel. And it operates with a Zero Effluent Discharge facility, backed by a ₹200 crore fume treatment plant that prevents harmful gases from being released into the environment.

What are the Benefits of Sustainable Steel Manufacturing?

Sustainable steel manufacturing reduces carbon emissions at the production stage, supports India’s commitment to Net Zero by 2070 and Tata Steel’s commitment to Net Zero by 2045, and makes construction eligible for green building certifications such as LEED and GRIHA, which now demand lower-carbon materials. From FY 28, the Government’s Green Steel Public Procurement Policy will mandate green steel in public projects — making this transition a regulatory imperative, not just an environmental choice.

What is the Difference Between Blast Furnace and EAF Steel Manufacturing?

The Blast Furnace (BF-BOF) route uses iron ore and coking coal as raw materials and emits around 2.5 tCO₂ per tonne of steel. The Electric Arc Furnace (EAF) route melts steel using electric arcs and refines it through hot oxidising slag, emitting below 0.5 tCO₂ per tonne at Tata Tiscon’s Ludhiana plant. Both routes can deliver IS 1786 compliant TMT rebar of the same grade specifications, but the EAF route enables a circular use of steel making with a far lower carbon footprint.

Can EAF Steel Be Used for Construction?

Yes. Tata Tiscon 550SD from EAF Ludhiana is built for the full range of construction applications — residential homes, commercial buildings, multi-storey structures and infrastructure projects. With the Super Ductile (SD) grade and a UTS/YS ratio of ≥1.15, it is suited for earthquake-prone regions. It is distributed through the Tata Tiscon’s official dealer network.

How is Tata Tiscon Supporting Sustainable Steel Manufacturing?

Tata Tiscon has commissioned India’s biggest EAF plant for rebars at Hi-Tech Valley, Ludhiana — a ₹3,500 crore facility with a furnace 4X larger than traditional IF plants. The plant is supported by a ₹200 crore fume treatment plant, a Zero Effluent Discharge facility, and substantial solar power. It is built around several industry firsts: a captive in-house shredder, FerroHaat digital procurement of steel from recycling facilities (unique to Tata Tiscon), best-in-class magnetic separation for radioactivity screening, and the ECS, Q-One and Q-Melt automated chemistry control systems.