Artificial Intelligence is transforming the steel industry

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Artificial Intelligence is transforming the steel industry

Thursday, 07 December 2023 | Alok Sahay

A step-by-step approach is the best to implement artificial intelligence. Scores of AI models are available for use in the steel units which can be tried without much hassle

Technology is ever-evolving. While it becomes difficult to keep pace with rapid technological advancements in all expanses of life, it is equally difficult to discount them because these are highly value-accretive. Artificial Intelligence (AI) is one such technology. The manufacturing sector, in general, and the steel sector, in particular, are integrating AI into their daily operations to improve productivity, health and safety, reduce operational costs and reap countless other operational and functional benefits. Survival will be at stake for those who will not.

In a developing nation or the Global South, cheaper availability of steel is a prequel to ensure sustainable development. Since raw materials for making steel are unlikely to be economical in the foreseeable future, adaptation of modern disruptive technologies and processes is the only way out. Estimates suggest that the proper adaptation of AI in the entire value chain of steelmaking can save between $60 and $100 per tonne. Apart from this, a key takeaway from the recently concluded ISA Steel InfraBuild Summit in Lucknow was that the use of AI in architecture will enable engineers and architects to design, plan, and build steel structures more efficiently, resulting in proper economics and savings in infrastructure and real estate.

In the steel sector, AI can be adopted from R&D and innovation to procurement, manufacturing and back-office process digitalisation to supply-chain inventory, marketing, and whatnot. All these can lead to a 60% growth in EBDITA in three years. Greenhouse gas emissions can also be reduced by 5-10%.

Maintenance is, as always, a difficult task. Each manufacturing unit has its maintenance plan tailored to its particularities. Proper implementation and use of AI can help predict the exact timing of maintenance, thereby reducing shutdown time, cutting maintenance costs, and enhancing the lifespan of the machinery. The Indian steel industry has been the early adopter of AI.

Adaptation of AI has the highest impact on steel manufacturing in the entire value chain. In the coke oven plant, sinter plant, blast furnaces, continuous caster and rolling, among others, the implementation of AI has multiple benefits ranging from 1-2% yield improvement to a 50-80% reduction in quality losses. Energy consumption also improved by roughly 10%. Autonomous or semi-autonomous data or content examination also makes predictions and recommendations easier. Integration of sales and production data improves revenue management and customer satisfaction.

With precise data, AI's ability to predict market data and price fluctuations helps manufacturers adjust production, manage inventories, and respond swiftly to changing market conditions. Enhancing safety is also another essential aspect. No wonder steel manufacturers worldwide are embracing AI to ensure faster delivery of business requirements. This is the age of intelligent manufacturing. Far from having a steel-producing smart factory, intelligent manufacturing encompasses all of it – sourcing raw materials to production to marketing products through an integrated intelligent supply chain.

Steel consumption mirrors the health of an economy. Aspiring to be in the league of a developed nation, India has miles to go to catch up with the global steel consumption average. The building, construction and infrastructure sector consumes nearly 70% of all steel in India. The growth of the steel sector will largely depend on the demand emanating from the infrastructure sector. While AI adaptation will benefit the steel sector, implementing AI in the infrastructure sector will help assess the sector's specific needs - such as identifying cost-effective high-strength steel structure-based designs and offering tailor-made products.

Adaptation, both in the steel and the infrastructure sector, is a challenging task. A mindset of experimentation and a determination to bring about positive changes are required. With AI, the ultimate goal is to implement an automated and unsupervised process linked with software and processes to improve performance over time. However, there is no substitute for human capital, and once integrated with AI, it will do wonders if used for the benefit of mankind and planet Earth. The apprehension that AI will displace jobs is unfounded. However, the dynamics of the job will change, requiring manpower with digital skills. It also warrants upskilling existing employees. A step-by-step approach is the best to implement AI. Building on the following line from the learnings of the first will yield the best results. Scores of AI models are in use in different steel manufacturing units in the country. The use of transformative technology will only go up in the days ahead. We need to be ready to adapt to the changes and implement it.

(The writer is the Secretary General of, the Indian Steel Association (ISA), views are personal)

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