Tata Steel’s Haldia Plant Sets National Record with 25 Million Tonnes of Coke Production

Landmark Milestone: Non‑Recovery Coke Production Touches 25 Million Tonnes

Tata Steel’s Hooghly Met Coke (HMC) Division at Haldia has reached a remarkable production milestone—surpassing 25 million tonnes of metallurgical coke in a single campaign life without undergoing any major repair. This achievement makes it the first non‑recovery coke‑making plant in India to reach this level of uninterrupted output. The milestone was recorded on June 29, 2025, underscoring nearly two decades of operational excellence.

Operational Excellence & Sustainability: Behind the Numbers

Capable & Resilient: Commissioned over 17 years ago, HMC is Asia’s largest standalone coke-making facility, designed entirely as a non-recovery unit with a capacity of 1.6 million tonnes per annum.

No Downtime, No Overhauls: Despite environmental challenges such as monsoons, saline conditions, and cyclonic disturbances near the coast, the plant has maintained continuous production, with no major servicing or furnace downtime.

In‑house Power Generation: The plant harnesses 100 % of its flue gas to generate 120 MW of power, integrating it into Tata Steel’s broader sustainable operations.

What Sets HMC Apart: The Non‑Recovery Model

Unlike traditional coke plants that employ by‑product recovery units to capture and reuse gases and tar, HMC operates on a non-recovery heat-recovery (NRHR) model. It combusts coke oven gas internally to fuel its coking operations, eliminating separate gas recovery infrastructure and simplifying emissions control. This design promotes operational efficiency while reducing environmental footprint.

Voices from Operations

Chaitanya Bhanu, Vice President – Operations at Tata Steel Jamshedpur, commented:

“As the first non‑recovery coke making unit in India to cross 25 million tonnes, HMC’s uninterrupted operations for nearly two decades is a testament to Tata Steel’s ability to maximise asset life and manage processes with unmatched efficiency.”

Broader Impact: Industrial Leadership & Green Innovation

This achievement reflects Tata Steel’s long-term commitment to operational excellence, process innovation, and sustainable industrial practices. With a growing focus on efficient asset utilisation and minimized emissions, HMC’s performance positions Tata Steel as a benchmark for the global metallurgical coke industry.

The milestone also contributes to the company’s overarching sustainability goals, including its Net Zero by 2045 pledge and its recognition on global platforms such as the DJSI and the World Economic Forum’s Global Lighthouse program.

In Context: Capacity, Growth, and Future Prospects

Capacity & Scale: HMC’s 1.6 MTPA capacity makes it one of the most significant standalone coke plants in Asia. Its achievement of 25 million tonnes without major maintenance is unprecedented in India.

Environmental Clearances for Expansion: While the plant has operated efficiently over many years, Tata Steel has previously received environmental clearances to expand the facility to 2.2 MTPA, alongside increasing power generation from 120 MW to 165 MW. The expansion was approved with environmental safeguards including dust suppression, green belt development, rainwater harvesting, and social commitments.

By crossing the 25 million tonne threshold on a single uninterrupted production cycle, Tata Steel’s Hooghly Met Coke Division has not only reinforced its engineering and process strength but also set a new operational benchmark in India’s steel value chain. This feat exemplifies how strategic design, heat-recovery systems, and disciplined operations can drive both scale and sustainability in heavy industry.

As India marches toward cleaner, greener steel production, HMC’s milestone signals how innovation and resilience can coexist at scale—setting a model for future industrial excellence.