Headquartered in Mumbai, India, Tata Steel is one of the largest steel producing companies globally, with manufacturing plants and mining operations in 26 countries. Tata Steel operates open cast coal mines in Jharkhand, Odisha.

Coal quality is a critical factor for various downstream industries, including the manufacturing of steel. Quality is measured by analysing parameters such as moisture, ash content, Gross Calorific Value (GCV), fluidity, dilation, CSN (Coke Strength after Reaction with Carbon Dioxide), and Sulphur content.

Currently, quality tests are performed offline in dedicated laboratories, resulting in significant delays in taking corrective actions during coal beneficiation or mining processes.

There are currently a range of challenges when seeking to accurately measure ash content, which holds the utmost importance to operators.

Manual analysis processes typically take around 4 hours, including sample preparation and analysis. This extended duration significantly impedes operational efficiency, especially when performed in Thermal Gravimetric Analysis (TGA) or a muffle furnace.

Laboratories lack an instantaneous monitoring system to precisely assess coal quality upon its arrival from mines or wash plants. The absence of such a reliable monitoring system poses substantial operational challenges, leading to delayed feedback and subsequent delays in implementing corrective actions.

At the plant level, a Prompt Gamma-Ray Neutron Activation Analysis (PGNAA) system is utilised to optimise process parameters and maintain the desired ash level in clean coal. However, this system primarily focuses on monitoring the final product and does not provide comprehensive real-time monitoring capabilities. Additionally, the PGNAA system’s results exhibit a high variation of ±0.6% with respect to the standard method due to various operational factors. As such, PGNAA is excluded as a solution for this opportunity.

There is currently no known technology available which can guarantee a tolerance of ±0.1% with respect to the standard method within the time frame of 10-30 minutes.

The current analysis cycle time of 4 hours is excessively long. The proposed system should facilitate rapid assessment, enabling prompt decision-making and immediate corrective actions.  

The solution should address the following goals:

1. Swift Assessment: Provide a quick assessment within 10-30 minutes, minimizing delays in decision-making and corrective actions. If sample preparation is necessary, it must also be completed within this 30-minute cycle time.
2. Accurate: Deliver results with an allowable tolerance of ±0.1% compared to laboratory analysis, ensuring reliable data for operational optimization. For example, if the standard sample yields a result of 40%, this device should provide a result within the range of 40±0.1%.
3. Compact and Portable: The system should be designed to be compact and portable, allowing for easy handling and transportation.
4. Reduce Calibration Frequency: The system should be engineered to minimize the need for calibration. If frequent calibration is necessary, it should be completed within a short timeframe of 5-10 minutes. However, if calibration takes a longer duration, it should only be performed at every 6-12 months to strike a balance between accuracy and operational efficiency.
5. Guaranteed Accuracy Range: The system's measurement range should be guaranteed within 10% - 60% ash content.

Submission Period

Suppliers are invited to submit their short-form solution to the challenge by 19 August 2023 for evaluation by Austmine and Tata Steel. 

A shortlisting process takes place and successful companies are invited to participate in phase 2. 

Phase 2

Shortlisted suppliers will be invited to a technical briefing, where each supplier will be able to gain more information about the challenge from Tata Steel. This allows suppliers to refine their proposed solution prior to pitching to Tata Steel. 

Following the technical briefing, suppliers will pitch their solution directly to Tata Steel online via Zoom breakout rooms. This provides the opportunity to ‘sell’ the solution, gain feedback from operational teams and field questions about the solution. 

Phase 3

Following the Pitch Session, a final shortlisting of suppliers takes place. The remaining suppliers are invited to submit a formal technical and economic proposal to solving the challenge.

Winner Announced

Tata Steel will select the best fit solution/s for the challenge and the supplier will work directly with Tata Steel to trial the technology and implement the solution. 

EOI Submission Deadline - 19 August 2023

Technical Briefing - 25 September 2023

Pitch Sessions - 29 September 2023

Final Proposal Deadline - 9 October 2023

Note that the above is an estimate and timelines can change.

Austmine is hosting this supply opportunity within the Australia-India Mining Innovation and Global Mining Challenge India Programs, supported by the Australia-India Council of DFAT and the Australian Government Department of Industry, Science & Resources.

Find more information about these programs here.