With a new Direct Reduction Plant and an electric melting furnace, Tata Steel in IJmuiden is undertaking one of the largest industrial transitions in the Netherlands. Engineering Manager Laura Buil is skilfully steering the design of this megaproject. During the knowledge event ‘Making existing plants more sustainable’, organised by ORAM and KH Engineering, she spoke about both the complexity and urgency of the green steel route.
‘When you’re deep in the project, you mainly see technology, planning and stakeholders. But sometimes it helps to step outside that bubble for a moment’, says Laura Buil, engineering manager of the Heracless project – Tata Steel’s green steel route. On 8 May, she spoke at the ORAM and KH Engineering knowledge event about sustainability in a brownfield environment. ‘It was striking to see how many companies are struggling with the same challenges, and it’s valuable to exchange experiences.’
transforming a running plant
The Heracless project involves the construction of a Direct Reduction Plant (DRP) and an electric furnace. The existing blast furnace and coke plant will eventually be decommissioned, enabling Tata Steel to drastically cut its CO₂ emissions. ‘We’re replacing the heart of our steel production’, Laura explains. ‘Instead of reducing iron ore with coal – a process that removes oxygen from the ore – we will soon be using natural gas, and eventually green hydrogen. That immediately results in CO₂ reduction. And with the electric furnace, we melt the reduced ore into steel – without coal.’ The technical complexity is immense, especially in a brownfield setting. ‘The plant keeps running while we build. The logistics are a real puzzle. That’s why we’re working with modular designs that can be built off site and integrated on location.’
from study to strategy
Laura has been involved as engineering manager since 2021. Her background in energy systems, project engineering and technology serves her well in the role. ‘I see myself as the technical lead of the project. I manage the engineering teams, engage with stakeholders, and act as the point of contact for everything technically linked to permits, communication and product development.’ Tata Steel’s approach is carefully considered. In recent years, the company focused on improving energy efficiency. Now, it is taking action at the core of the process. Laura explains: ‘We’re tackling the root cause – coal. That means using technologies other than those we’ve spent the past hundred years optimising. It’s a bold step, but a necessary one.’
Emissions and environment
Tata Steel is seizing this moment to go beyond CO₂ reduction alone. Laura explains: ‘We also want to reduce other emissions, such as particulate matter. That’s why we’re covering the ore storage, installing new dust extraction systems, and applying the ‘cleaner steel’ principle consistently across all new installations.’ The local community is also feeling the impact of the transition. ‘During meetings, I answer questions from nearby residents’, says Laura. ‘That openness is essential. The plant is located in the middle of a residential area. We need public support to realise a project of this scale.’
collaboration with KH Engineering
KH Engineering has been a trusted partner of Tata Steel for decades. While the engineering firm is not directly involved in the core of the Heracless project, it is contributing to sub-projects such as structural coverings and feasibility studies. The relationship is strong and constructive, with Tata Steel valuing KH Engineering’s expertise and approach.
Learning from one another
The knowledge event made it clear that many companies are facing similar sustainability challenges. Everyone is dealing with grid congestion, nitrogen regulations and investment uncertainty. There are many hurdles in this essential transition, while at the same time both producers and customers are seeking assurance about product quality. ‘Our customers expect the same quality of steel. But the production process is changing. That means we’re working with them to verify that the new steel is at least equivalent in quality’, says Laura. ‘Their trust is crucial.’
Tips for a successful transition
Does Laura have any advice for companies about to embark on a similar transition? ‘Make sure to involve your stakeholders at every step – management, local communities, government, customers, and your own employees. There’s often a wealth of knowledge within your organisation already. For example, we’ve set up Green Teams, where employees from different departments voluntarily contribute ideas on sustainability.’
the future of Tata Steel
In the coming years, Tata Steel will continue to shape the steel of the future. With the closure of the blast furnaces and the arrival of new installations, the site itself is also set to transform. For now, the focus is on execution. ‘It’s an exciting and unique opportunity’, says Laura. ‘We’re not only making steel CO₂-free – we’re also making the plant cleaner, quieter and more future-proof. That’s something to be proud of.’
For more information about Tata Steel Nederland: https://www.tatasteelnederland.com/en