At Hira Ferro, we have implemented several sustainable practices that set us apart in terms of operational efficiency and environmental responsibility.

Vinay Agrawal
Director, Hira Group Of Industries

Could you provide a brief overview of Hira Ferro Alloys?

Hira Ferro Alloys (HFAL) is a key entity within the Hira Group of Industries, a conglomerate comprising 13 diverse businesses. Our operations span multiple sectors, including cement, iron ore mining, iron ore pelletisation, comprehensive steel production, and manganese-based ferro alloys. Additionally, we have a presence in the real estate sector. Expanding our reach, we have ventured into the automotive space with our two-wheeler startup, eblu. We are also exploring opportunities in other domains, particularly with a focus on heavy metals.

Could you shed some highlight of few key value-added Ferro Alloy products?

Our portfolio includes a range of key value-added manganese-based ferro alloy products, essential in the steelmaking process. These alloys play a crucial role in enhancing the properties of steel. Without the addition of manganese, steel remains as iron, lacking the essential characteristics needed for its strength and versatility. Manganese acts as a transformative element, providing steel with its flexibility, resilience, and overall structural integrity. Since 1985, we have been at the forefront of producing high-quality manganese-based ferro alloys in India, supporting the steel industry with a comprehensive and reliable product range.

Have there been any recent innovations in your production processes or product offerings?

The core technology behind steelmaking is quite old and dates back to the 19th century, remaining largely unchanged over time. However, with the rapid growth of digitization in recent years, significant advancements have been made in process control. Over the past few months, we have seen considerable progress in digital controls, automation, and technology-based analysis. The implementation of distributed control systems and other digital tools has significantly upgraded how the process is managed, marking a notable shift from traditional methods to more modern, efficient operations.

What are the measures that you have taken in HFAL in terms of environmental sustainability?

At Hira Ferro, we have implemented several sustainable practices that set us apart in terms of operational efficiency and environmental responsibility. One of the most significant achievements is the drastic reduction of our freshwater consumption by approximately 95%. We've achieved this by replacing our wet cooling systems, which require a constant supply of freshwater, with dry cooling systems. This innovative change ensures that the entire cooling process takes place in a closed-loop environment, where heat is dissipated without the need for water.

In addition, we have taken further steps to enhance our sustainability efforts. Any remaining freshwater used in our processes is being replaced with recycled water. Currently, we are tapping into a city drainage system located 7 kilometers away from our plant, where the government has set up a new recycling plant. We were the first to sign an MOU with the government and are laying a pipeline to bring this recycled water directly to our facility. This will enable us to use recycled water within our operations, further reducing our reliance on freshwater. Our long-term goal is to ensure zero liquid discharge in our operations, and we are committed to achieving this through advanced water management strategies, ensuring sustainability throughout our manufacturing process.

Environmental sustainability has become a major focus, and electric mobility is rapidly gaining traction everywhere. It’s a growing trend, and we’re particularly excited about the advancements in this space, especially in relation to electric wheel loaders. Can you share more about this development?

This is an exciting space, especially with battery technology. In our organization, we have been actively involved in the electric mobility sector. For instance, we produce electric two-wheelers and small electric loaders, which are in the passenger vehicle segment, with smaller batteries and different applications. However, after the pandemic, we saw a significant demand for transitioning our factory operations to newer, more sustainable equipment. We held off on upgrading our fleet because we were confident that, sooner rather than later, the heavy lifting and mobility segments would shift to electric.  The first significant change we made was with our Tata passenger vehicles, where we transitioned some of our operations to electric vehicles. Within a year, we learned about Liugong’s electric loaders, and we were thrilled. We immediately reached out to the local dealers, who provided us with the details. While they were confident in the product, we were even more confident in its performance. Our goal has always been to lead the way in transitioning from older, diesel-powered equipment to the new generation of electric mobility.

How do you evaluate the performance of the Liugong machines in your fleet?

Interestingly, we are not only satisfied with the performance of the Liugong machines, but we've also gained significant insights during our transition. We relocated from the older fleet, which included the 3-T diesel loaders from other OEM, to the new Liugong model, the electric loaders (Model 820 TE). In fact, we have shifted about 70% of our applications to 2-ton electric loaders, and the results have been outstanding. The 2-ton electric loaders have proven to be easier to operate and maneuver. The absence of diesel power results in less vibration, making the operation smoother. The smaller gearbox and transmission system have further simplified mobility, and the cabins, now equipped with air conditioning, enhance operator comfort. As a result, our operators prefer working with the electric variant over the diesel-powered models.

In terms of operator safety, given the challenging environmental conditions in India, how do you assess the machines you currently have?

This morning, during a site visit, I observed something noteworthy. I noticed that the diesel locomotives owned by other variants had a rather basic cabin design. The layout was relatively unchanged, with limited seating space and a somewhat cramped interior. In contrast, the Liugong machines we currently use have a significantly improved design. The driver's seat is positioned higher, offering a more comfortable, upright posture, and the cabin has large windows, providing better visibility. Overall, the cabin space is more spacious, and the driver's comfort has been greatly enhanced compared to other locomotives in this segment.

Are there any specific training programs or collaborations in place to upskill your operators for this transition?

When we decided to invest in electric vehicles (EVs), our head for automobile operations was initially apprehensive. He questioned why we needed to replace multiple vehicles all at once, suggesting we could start with just one. However, I didn’t want to delay the process, so we proceeded with the full transition. Once the machines arrived, the feedback I received from my on-site team was that these EVs were much faster and more efficient compared to their diesel counterparts. The drivers found it challenging to adjust to the quicker acceleration and operate the machines in the same way they were accustomed to with diesel-powered vehicles. Previously, in the diesel machines, the drivers had to push the gas pedal harder, relying on a rougher, more rugged operation. With EVs, however, the machines are much easier to maneuver and throttle. The team had to slow down their previous driving habits and relearn how to manage the more responsive electric machines.