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Chapter 6: The Disruption — AI, Green Hydrogen, and the Economics That Change Everything


In February 2025, Tata Steel’s Chief Technology Officer told a conference in Mumbai that the company had deployed over 550 AI models across its operations in the previous five to six years. The return on investment: 775 percent. The company had spent roughly Rs 1,200 crore on AI and data infrastructure and generated an estimated Rs 9,300 crore in cumulative value — through reduced energy consumption, improved yield, lower defect rates, and optimized logistics.

One specific example: a digital twin of a blast furnace at Jamshedpur, built using machine learning on years of sensor data — temperature, pressure, gas composition, coke ratio, hot metal chemistry — reduced the coke rate by 2.5 percent. That single optimization, applied to one furnace, saved Rs 45 crore per year. Across Tata Steel’s multiple blast furnaces, the cumulative savings from AI-driven coke optimization alone run into hundreds of crores.

This matters for Odisha’s story because of what it implies for the future of steelmaking — and, more broadly, for the economics of mineral value addition. The previous chapters established that Odisha sits at the bottom of the value staircase, capturing roughly 10 percent of the total value chain from its minerals. The barriers to climbing that staircase are formidable: decades of accumulated workforce expertise, massive capital requirements, established supplier ecosystems, and institutional infrastructure that takes generations to build.

Three technological disruptions are now changing the underlying economics in ways that could — could, not will — alter the calculus for states like Odisha. Each disruption addresses a specific barrier that has historically kept mineral-rich regions trapped in the extraction stage.


AI in Manufacturing: The Expertise Compressor

The traditional steelmaking knowledge stack looks like a pyramid. At the base: decades of accumulated shop-floor experience. A blast furnace operator with 30 years of experience can look at the flame color, listen to the furnace sounds, and feel the vibrations to know when something is wrong. A rolling mill operator with 20 years can tell from the strip’s surface finish whether the temperature profile is off. This tacit knowledge — impossible to document, impossible to transfer quickly, impossible to buy — is what makes Jamshedpur’s workforce irreplaceable.

Or rather, it was what made them irreplaceable.

What AI Actually Does in a Steel Plant

AI in steel manufacturing is not science fiction and not marketing hype. It is a set of specific, deployed technologies that are already changing production economics:

Blast furnace optimization: Machine learning models trained on thousands of operating parameters — burden distribution, hot blast temperature, coke quality, ore chemistry, tuyere conditions — can predict optimal operating points faster and more consistently than human operators. Tata Steel’s AI system processes data from over 10,000 sensors per furnace, making real-time recommendations that a human expert might take hours to reach. The digital twin predicts furnace behavior 2-4 hours ahead, allowing preemptive corrections rather than reactive ones.

Quality prediction and defect detection: Computer vision systems trained on millions of images of steel surfaces can detect defects as small as 0.1mm with 95-99 percent accuracy — far exceeding human visual inspection. Tata Steel reported a 68 percent reduction in quality deviations using AI. ArcelorMittal’s Sentinel AI platform achieved a 20 percent reduction in scrap at its Hamburg plant and 15 percent defect reduction company-wide.

Energy optimization: Steel plants consume enormous energy. AI optimizes energy use across the integrated plant — coordinating blast furnace gas recovery, coke oven gas distribution, power plant scheduling, and oxygen plant operations. The savings are typically 3-8 percent of total energy cost, which for a 5 MTPA plant translates to hundreds of crores annually.

Predictive maintenance: A rolling mill has thousands of bearings, motors, gearboxes, and hydraulic systems. A single unplanned shutdown of a hot strip mill costs Rs 5-10 crore per day in lost production. AI-driven predictive maintenance — analyzing vibration signatures, temperature trends, lubricant chemistry, and electrical parameters — can predict equipment failures days or weeks in advance. Tata Steel reported a 22 percent reduction in unplanned downtime.

Autonomous operations in mining: Rio Tinto operates over 300 autonomous haul trucks across its Pilbara iron ore operations in Australia, handling 80 percent of daily production. The trucks operate 24/7, need no rest breaks, never have fatigue-related accidents, and achieve 15 percent higher utilization than human-operated trucks. Komatsu has delivered the autonomous truck systems since 2008 — this is mature technology, not a pilot program.

The Implication: Expertise Can Now Be Compressed

Here is why this matters for Odisha and states like it. The traditional path to building a world-class steel industry required 30-50 years of accumulated workforce expertise. Jamshedpur has been making steel for over a century. Pohang (POSCO) needed 35 years. Even with technology transfer, you needed decades of workers learning on the job, making mistakes, developing intuition, passing knowledge to the next generation.

AI compresses this timeline. A new steel plant in Odisha — at Kalinganagar, at Angul, or at a greenfield site — can now deploy AI systems from day one that encode the equivalent of decades of operating experience. The blast furnace optimization model trained on Jamshedpur data can be adapted for a new furnace in months, not decades. Quality control AI doesn’t need 20 years of human inspectors developing visual acuity — it needs a camera, a server, and a trained model.

This does not eliminate the need for skilled workers. Someone still has to maintain the AI systems. Someone has to understand the metallurgy well enough to validate the AI’s recommendations. Someone has to manage the supply chain, the logistics, the customer relationships. But AI changes the ratio. Instead of needing 5,000 experienced operators for a 5 MTPA plant, you might need 2,000 operators plus 200 AI engineers plus the AI systems themselves. The total workforce skill level shifts upward — fewer people doing routine monitoring, more people doing exception handling and system management.

The cross-domain analogy is precise. What cloud computing did for software startups — eliminating the need to build your own data center before writing your first line of code — AI is beginning to do for manufacturing. It lowers the barrier to entry. A state that might have needed 50 years of workforce development without AI might build competitive manufacturing capability in 15-20 years with it.

I believe with roughly 65 percent confidence that AI will materially reduce the workforce-expertise barrier for new steel plants within the next decade. I would be wrong if the tacit knowledge component of steelmaking proves more resistant to AI compression than current evidence suggests — if, for example, AI optimization works well for routine operations but fails catastrophically for the rare-but-critical events (furnace breakouts, mill cobbles, power failures) where human expertise is most valuable.

SAIL’s situation illustrates both the potential and the gap. In March 2025, SAIL partnered with McKinsey to deploy AI across its plants, targeting Rs 1,000 crore in annual value creation within three years. This is a decade behind Tata Steel’s AI journey. SAIL’s Rourkela Steel Plant — in Odisha, processing Odisha’s minerals — is only now beginning the AI transformation that Jamshedpur started in 2018-19. The technology is available. The institutional speed of adoption varies enormously.


Green Hydrogen Steel: The Carbon Breakthrough

If AI compresses the expertise barrier, green hydrogen steel eliminates the coal dependency that has defined steelmaking for 250 years.

How Conventional Steelmaking Produces Carbon

A blast furnace uses coke (purified coal) for two purposes: as a fuel to generate heat, and as a chemical reducing agent to strip oxygen from iron ore. The chemical reaction is straightforward: Fe₂O₃ + 3CO → 2Fe + 3CO₂. For every tonne of steel produced through the blast furnace route, approximately 1.8-2.0 tonnes of CO₂ are emitted. The global steel industry accounts for roughly 7-8 percent of total CO₂ emissions — more than any single country except China, the US, and India.

This matters for Odisha because:

  1. The EU Carbon Border Adjustment Mechanism (CBAM) enters its definitive phase in January 2026. From that date, every tonne of steel exported to the EU will attract a carbon cost based on the embedded emissions. For Indian blast-furnace steel, the estimated cost increase is 15-22 percent. India bears 18 percent of total global CBAM exposure — the highest of any country. Odisha, as a major steel-producing state with plans to expand capacity, faces this cost directly.

  2. Blast furnace steel requires coking coal, which India imports at 85 percent dependency. This is a strategic vulnerability and a massive foreign exchange cost. Green hydrogen steel eliminates coking coal entirely.

How Green Hydrogen Steel Works

The alternative process is Direct Reduced Iron (DRI) using hydrogen instead of coal:

Step 1: Renewable electricity (solar, wind) powers an electrolyzer that splits water into hydrogen and oxygen.

Step 2: Green hydrogen replaces coal/gas as the reducing agent in a Direct Reduction shaft furnace. The reaction: Fe₂O₃ + 3H₂ → 2Fe + 3H₂O. The byproduct is water, not CO₂.

Step 3: The Direct Reduced Iron (sponge iron) is melted in an Electric Arc Furnace powered by renewable electricity, producing liquid steel with near-zero carbon emissions.

The process is technically proven. What remains is cost competitiveness.

Where It Stands

HYBRIT/SSAB (Sweden): The pioneer. A joint venture between SSAB (steelmaker), LKAB (iron ore miner), and Vattenfall (energy company), HYBRIT produced the world’s first fossil-free steel in 2021 using a pilot plant. SSAB’s commercial production at Gallivare is planned for 2026, starting at 1.2 MTPA.

Stegra / H2 Green Steel (Sweden): A greenfield plant at Boden, northern Sweden, with Phase 1 capacity of 2.5 MTPA. The plant includes an 800 MW electrolyzer — one of the largest in the world — powered by abundant Swedish hydroelectric power. Operations are ramping up in 2025-2026. The company has already pre-sold output to Mercedes-Benz and other automakers willing to pay a premium for green steel.

ThyssenKrupp (Germany): Planning a massive hydrogen DRI project at its Duisburg works — EUR 3.5 billion investment. However, in March 2025, ThyssenKrupp suspended its tender for green hydrogen supply, citing prices too high for competitive steel production. This is a reality check: the economics do not yet work everywhere.

ArcelorMittal: Operating a hydrogen DRI pilot at its Hamburg plant (100,000 tonnes capacity, EUR 110 million) and planning a 1.6 MTPA near-zero carbon plant at Sestao, Spain (EUR 1 billion investment).

The Cost Equation

Green hydrogen is currently expensive. In India, green hydrogen production costs approximately $3.5-6.7 per kg (roughly Rs 290-560/kg). At this cost, green hydrogen DRI steel is roughly $150-250 per tonne more expensive than conventional blast furnace steel.

India’s National Green Hydrogen Mission targets a production cost of $2/kg by 2032, with cumulative production reaching 5 million tonnes per year by 2030 from 125 GW of renewable energy capacity.

Global trajectory: Green hydrogen costs are declining along a learning curve similar to solar panels. Bloomberg New Energy Finance and ING project cost parity between green hydrogen steel and conventional steel by 2035-2040 — earlier if carbon pricing (like CBAM) is factored in.

The breakpoint: At $2/kg hydrogen and $40/MWh renewable electricity, green hydrogen DRI becomes cost-competitive with blast furnace steel even without carbon pricing. With EU CBAM adding $50-100 per tonne of CO₂ to conventional steel, green steel becomes cheaper for export markets well before 2035.

Why This Matters for Odisha Specifically

Odisha has a combination that very few places in the world possess simultaneously:

  1. Massive iron ore reserves (28% of India’s total) — the primary raw material for DRI
  2. Solar potential estimated at 170 GW by iFOREST — far more than current estimates, using wasteland and reservoir areas. Western districts (Bolangir, Boudh, Kalahandi, Nabrangpur) have strong solar irradiance.
  3. Wind potential of 12 GW at 150-metre hub height across 86 locations in 16 districts
  4. Offshore wind potential along the Bay of Bengal coastline — significant but not yet quantified at scale
  5. Existing port infrastructure (Paradip, Dhamra, Gopalpur) for export
  6. Existing DRI expertise — India is the world’s largest DRI producer, and Odisha has significant coal-based DRI capacity that could be converted to hydrogen-based

Green hydrogen DRI steel made in Odisha — iron ore from Keonjhar, reduced with hydrogen from solar-powered electrolyzers in western Odisha, melted in an EAF powered by renewable energy, and shipped through Paradip — would be among the lowest-cost green steel in the world. The iron ore proximity eliminates transport costs. The solar potential provides cheap renewable energy. The existing industrial infrastructure provides a foundation.

What’s already happening:

  • Tata Steel Kalinganagar is piloting green hydrogen DRI, with capacity expanding to 8 MTPA (and scope for 16 MTPA). The company established an AI Innovation Hub with IIT Bhubaneswar, combining AI optimization with green steel technology.
  • Gopalpur Industrial Park (in Tata Steel’s SEZ) has committed 2.6 MTPA of green hydrogen and ammonia capacity — one of the largest projects in eastern India.
  • JSW Steel is investing $1.2 billion in green hydrogen DRI at its Vijayanagar plant in Karnataka — using Odisha’s iron ore but processing it elsewhere. The question is whether the next generation of green steel plants will be built AT the ore source rather than 1,200 km away.

The Odisha Renewable Energy Policy 2022 targets 10 GW of renewable energy by 2030 — 68 percent solar, 18 percent wind, 11 percent pumped storage. This is a fraction of the total potential but a meaningful start. Floating solar across Odisha’s major reservoirs (Hirakud, Indravati, Rengali) alone could provide 5,000 MW.


Modular Manufacturing: The Capital Barrier Falls

The third disruption addresses the capital barrier. Traditional integrated steelmaking requires $3-5 billion for a world-scale plant — a 50-year payback bet that only the largest corporations and state-backed enterprises can make. This is why India’s steel industry is dominated by Tata, JSW, SAIL, and JSPL. No new entrant can afford to compete at the integrated scale.

Electric Arc Furnace (EAF) mini-mills change this equation.

The Nucor Model

Nucor Corporation, now America’s largest steelmaker, never built a single blast furnace. Founded in the 1960s as a nuclear instrument company (hence the name), it pivoted to steelmaking through EAF mini-mills — small plants that melt scrap steel and DRI using electric arcs at 3,000°C.

The Nucor model disrupted the American steel industry in the same way that software startups disrupted enterprise computing: by starting small, iterating fast, and scaling efficiently. A Nucor mini-mill could be built for $50-200 million (in historical terms) — a fraction of the $3-5 billion required for an integrated plant. Construction took 2-3 years instead of 5-7. The plants were profitable at 1-3 MTPA capacity, where an integrated plant needed 5+ MTPA to break even.

Today’s EAF mini-mills are more expensive — Nucor’s Brandenburg, Kentucky plate mill cost $1.7 billion for 1.2 MTPA — but still substantially cheaper than integrated blast furnace plants, with lower maintenance costs ($8-18 per tonne for EAF vs $14-28 for blast furnace) and far greater operational flexibility.

What This Means for Odisha

The conventional argument for steel in Odisha has always been: “We need a mega-project — a POSCO, a $12 billion integrated plant.” The history of mega-projects in Odisha is a history of MoU ceremonies, land acquisition battles, community displacement, environmental destruction, and frequent abandonment. POSCO spent 12 years and produced zero tonnes of steel. The announcement economy generated headlines but not factories.

Modular manufacturing offers a different path. Instead of one $5 billion plant, fifty $100-200 million EAF plants. Instead of displacing 20,000 people for a single mega-project, fifty smaller plants distributed across the mineral belt, each requiring 50-100 acres. Instead of a single point of failure — one anchor company deciding whether to invest or withdraw — a diversified ecosystem of smaller producers.

This is not theoretical. Chhattisgarh’s Raipur-Raigarh corridor has over 150 DRI/sponge iron units, most built by small and medium entrepreneurs at Rs 50-200 crore each. The environmental costs of these coal-based units are severe. But the entrepreneurial model — small capital, local sourcing, rapid buildout — demonstrates that value addition doesn’t require waiting for a global giant to choose your state.

The next generation would combine:

  • Green hydrogen DRI (instead of coal-based DRI) — clean process
  • EAF melting — flexible, lower capital
  • AI quality control — achieving premium product quality without decades of workforce expertise
  • Modular scale — 0.5-2 MTPA per unit, profitable at smaller volumes

A network of 20-30 such units across Odisha’s mineral belt — in Angul, Kalinganagar, Jharsuguda, Sundargarh, Jajpur — could add 20-40 MTPA of green steel capacity over 10-15 years, at a total investment of Rs 50,000-100,000 crore (roughly $6-12 billion), distributed across multiple entrepreneurs and companies, without any single project requiring the social and political upheaval of a POSCO-scale land acquisition.

I believe with roughly 60 percent confidence that modular green steel manufacturing will become the dominant mode of capacity addition in India by 2035-2040. I would be wrong if the economics of blast furnace steel improve through carbon capture, if green hydrogen costs fail to decline as projected, or if India’s renewable energy buildout falls significantly short of targets.


Critical Minerals: The New Value Chain

While the steel value chain gets most attention, a completely different mineral value chain is emerging — one that follows battery, semiconductor, and defense pathways rather than the iron-ore-to-steel pathway. And Odisha is positioned in this chain in ways that few states are.

What Odisha Has

Beyond its well-known iron ore, coal, bauxite, and chromite, Odisha holds deposits of minerals that are suddenly strategic:

  • Nickel: 175 million tonnes of India’s total 189 million tonnes — 92.6 percent. Located in the Sukinda ultramafic belt in Keonjhar, with nickel content of 0.15-1.2%. Not yet commercially exploited at scale, but nickel is essential for lithium-ion battery cathodes (NMC chemistry) and stainless steel.

  • Chromium (as chromite): Beyond stainless steel, chromium is critical for aerospace superalloys and defense applications.

  • Graphite: Active exploration in Rayagada (Khalpadar block, with 16 boreholes showing cumulative graphite thickness of 170 metres), Dhenkanal, and Koraput. Graphite is essential for lithium-ion battery anodes — every EV battery requires 50-100 kg of graphite.

  • Vanadium: Present in Odisha deposits, used in vanadium redox flow batteries for grid-scale energy storage and in high-strength low-alloy steels.

  • Platinum Group Elements (PGE): The Sukinda-Nausahi chromite complex contains platinum (up to 120 ppb), palladium (13 ppb), iridium (210 ppb), and ruthenium (630 ppb). PGEs are critical for hydrogen fuel cells and catalytic converters.

  • Lithium: Geological Survey of India is conducting drone-based and AI-assisted surveys in Mayurbhanj district, with preliminary results indicating presence. Commercial viability remains to be confirmed.

The China Problem

This is where geopolitics enters the mineral economics story.

China controls the midstream of virtually every critical mineral supply chain:

  • 91% of global rare earth separation and refining
  • 80% of global lithium processing
  • 80% of global battery cell production
  • 85% of cathode active material production
  • 90%+ of graphite processing
  • 90% of rare earth permanent magnet production

In October 2025, China announced export controls on lithium-ion battery supply chains — Phase Two of what has been described as rare earth statecraft. Phase One was the rare earth export restrictions that began in 2010 and have tightened progressively since.

This concentration gives China a strategic lever that no amount of downstream manufacturing in India can neutralize without building domestic processing capacity. You can assemble EVs in India. You can even manufacture battery cells in India (under the PLI scheme, though only 2.8% of the 50 GWh target has been achieved after four years — just 1.4 GWh by Ola Electric, with Hyundai withdrawing from its 20 GWh allocation). But if the cathode materials, anode graphite, and separator films all come from China, you have not built strategic autonomy. You have built strategic dependency with extra steps.

India’s Critical Minerals Strategy

The National Critical Mineral Mission, announced in January 2025 with a budget of Rs 34,300 crore ($4 billion) over seven years, identifies 30 critical minerals and targets:

  • 1,200 domestic exploration projects by 2030-31
  • Domestic production of at least 15 critical minerals
  • Four Critical Minerals Processing Parks: in Andhra Pradesh, Odisha, Maharashtra, and Gujarat (Rs 500 crore budget)
  • Rs 7,280 crore for 6,000 MTPA of Rare Earth Permanent Magnet manufacturing

Odisha has 34 mineral blocks lined up for auction in FY 2026-27, including 9 critical and strategic mineral blocks:

  • 2 standalone graphite blocks
  • 3 manganese + graphite composite blocks
  • 1 manganese + graphite + vanadium composite block
  • 1 polymetallic base metal block
  • 1 graphite block
  • 1 tin block

The first critical mineral auctions (November 2023) saw premiums of 13-400%, reflecting both the strategic value and the speculative interest. Agrasen Sponge Private Limited won two blocks in Odisha for graphite and manganese with combined resources of 4.57 million tonnes.

The Battery Value Chain: A Completely Different Staircase

The critical minerals value chain is not the iron-ore-to-steel staircase from Chapter 1. It is a different staircase entirely:

Mining → Processing/Refining → Cathode/Anode material → Cell manufacturing → Pack assembly → EV/Energy storage

The value concentration is different. Battery cells and packs represent 25-30 percent of total EV cost. The cathode is the most expensive single component. Cell manufacturing costs have declined from $10-20/kWh in 2020-21 to $3-6/kWh in 2022-24. Global battery demand is projected to grow from ~1 TWh (2024) to over 3 TWh by 2030 — a 4.5x increase in six years.

For Odisha, the opportunity is in the early and middle stages — mining and processing of graphite, nickel, manganese, and potentially lithium and rare earths. The downstream stages (cell manufacturing, pack assembly) require capabilities that India as a whole has not yet developed at scale, as the PLI experience demonstrates.

But the processing stage — where China captures 80-90% of global output — is precisely where India needs to build capacity, and it is precisely where Odisha’s mineral deposits position it as a natural location. A graphite processing facility in Rayagada, a nickel refinery near Sukinda, a manganese sulphate plant for battery-grade materials in Jajpur — these are not fantasy scenarios. They are the specific projects that the Critical Minerals Mission is designed to enable.

Community Conflict: The Recurring Tension

A reality check. GSI’s graphite prospecting in a community forest in Odisha has already triggered conflict with local tribal communities. The National Commission for Scheduled Tribes has initiated an inquiry. This is the Niyamgiri pattern replaying with different minerals: valuable deposits under tribal land, development imperative colliding with indigenous rights, and an institutional framework that has not resolved the fundamental tension.

The critical minerals story will be shaped by whether India can build processing capacity without repeating the displacement and environmental damage patterns of iron ore and coal mining. The stakes are higher this time — the minerals are strategically essential, the global competition is intense, and the window for building domestic capacity is measured in years, not decades.


The Window: 2025-2035

These three disruptions — AI, green hydrogen, and modular manufacturing — converge in a narrow window.

The Timeline That Matters

2025-2026: First commercial green steel from SSAB/Stegra in Sweden. EU CBAM definitive regime begins. Every tonne of Indian blast-furnace steel exported to the EU attracts a carbon cost.

2027-2028: ThyssenKrupp connected to hydrogen pipeline. Multiple hydrogen DRI plants operational in Europe. Indian steel exporters to the EU face 15-22 percent cost absorption without decarbonization.

2030: Green hydrogen target: $2-2.5/kg. Multiple MTPA-scale green steel plants running globally. India’s 5 million tonne hydrogen target. Odisha’s 10 GW renewable energy target. Battery demand at 3+ TWh globally.

2035-2040: Green steel achieves cost parity with conventional steel WITHOUT carbon pricing. With carbon pricing, it is already cheaper for EU-bound exports by 2030. India’s steel capacity reaches 300+ MTPA (from current 180+ MTPA). The question is whether the additional 120+ MTPA is conventional blast furnace (locking in 30-year carbon intensity) or green hydrogen DRI (future-proof).

Why the Window Closes

The plants being designed and permitted NOW — 2025-2027 — will be the ones producing in 2030-2035. A new steel plant takes 4-5 years from ground-breaking to production. A renewable energy installation takes 2-3 years. A green hydrogen electrolyzer takes 2-3 years. Working backwards from 2030 — when green steel needs to be competitive — the decisions need to be made in 2025-2027.

States and countries that build green steel capacity first will capture the export markets that blast-furnace states lose to CBAM. Critical mineral processing capacity being built NOW will supply the battery industries of 2030-2040. The companies that win critical mineral block auctions in 2025-2028 and build processing facilities will be the suppliers for India’s (eventual) domestic battery industry.

What Happens If Odisha Misses It

The default trajectory — the one that requires no decisions, no investment, no institutional change — is continuation of the current pattern:

  • Iron ore continues to leave as raw material or pellets
  • Green steel production shifts to states with renewable energy + hydrogen infrastructure (Gujarat, Rajasthan, possibly Andhra Pradesh)
  • Critical minerals are mined and exported unprocessed for refining elsewhere
  • CBAM makes Odisha’s existing blast-furnace steel increasingly uncompetitive for export
  • Other states capture the domestic battery and green steel value chain
  • The 90/10 value split becomes permanent

What Odisha Has That Others Don’t

If there is a single state in India positioned for the convergence of green steel and critical minerals, it is Odisha. The combination is remarkable:

  • 98.4 percent of India’s chromite
  • 92.6 percent of India’s nickel
  • 33 percent of India’s iron ore
  • 60 percent of India’s bauxite
  • 68 percent of India’s manganese
  • 170 GW solar potential + 12 GW wind potential
  • Coastline with existing ports for export
  • Designation as one of four Critical Minerals Processing Park locations
  • Tata Steel Kalinganagar already piloting AI + green hydrogen DRI
  • Gopalpur developing 2.6 MTPA green hydrogen/ammonia capacity

What Odisha Lacks

  • Domestic battery cell manufacturing (India-wide problem, not Odisha-specific)
  • Commercial-scale green hydrogen production (first plants commissioning 2026)
  • Rare earth processing capacity (none exists domestically at scale)
  • Graphite processing infrastructure (exploration phase, not production)
  • Renewable energy buildout sufficient for industrial-scale hydrogen (10 GW target by 2030, currently well below)
  • Speed. The mineral auctions, environmental clearances, land acquisition, and community engagement processes all take years. The window is measured in the same years.

The disruptions described in this chapter do not guarantee that Odisha will capture more value from its minerals. They guarantee only that the rules of the game are changing. A state that was locked out of value addition by the economics of the 20th century — by the capital barriers, the expertise barriers, the coal dependency, the mega-project model — faces a different set of economics in the 21st century. AI compresses expertise. Green hydrogen eliminates coal dependency. Modular manufacturing lowers the capital threshold. Critical minerals create entirely new value chains.

Whether Odisha seizes this or watches it pass — the way it watched the industrial revolution pass, courtesy of the Freight Equalisation Policy — depends on decisions being made now.


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  24. OXmaint. “EAF vs BOF Maintenance Comparison for Steel Producers.” https://oxmaint.com/industries/steel-plant/eaf-vs-bof-maintenance-comparison-steel-producers

  25. Odisha Department of Steel and Mines. “Mineral-Based Industries in Odisha.” https://odishaminerals.gov.in/MiningInOdisha/MineralBasedIndustries

  26. JMK Research. “Odisha Targets 10 GW of RE Capacity by 2030 Under New Renewable Energy Policy.” https://jmkresearch.com/odisha-targets-10-gw-of-re-capacity-by-2030-under-new-renewable-energy-policy/

  27. Business Standard. “In a First, Odisha Set to Auction Three Gold-Bearing Mineral Blocks.” March 2026. https://www.business-standard.com/industry/news/in-a-first-odisha-set-to-auction-three-gold-bearing-mineral-blocks-126032300838_1.html

Source Research

The raw research that informs this series.