Kalliyath drives Kerala’s Green Steel Ambitions with Rs. 5 Billion Industrial Project

A ₹5 billion investment is made in the Palakkad district for a large-scale steel manufacturing project titled Green Core, positioning Kerala as an emerging hub for sustainable steel production. The project was developed by Kalliyath, a leading steel conglomerate with a long-standing presence in South India and a strong focus on environmentally responsible manufacturing.

Kalliyath’s Green Core project introduces advanced steelmaking technologies designed to significantly reduce energy consumption, fossil fuel use, water withdrawal, and carbon emissions when compared to conventional steel production routes. According to Kalliyath, the project represents a decisive shift towards low-carbon, resource-efficient industrial development in the state. Designed around best-in-class technologies and disciplined manufacturing practices, Kalliyath’s Green Core facility will deliver reinforcement steel of superior quality, built to serve the strength and scale of India’s growing infrastructure.

One of the key features of the Green Core project is the adoption of direct hot charging and rolling, which eliminates the need for fossil fuels. This process alone is expected to reduce energy consumption by 30–50 units per tonne of steel, translating to a minimum annual reduction of 3.54 million units of electricity consumption.

The Kalliyath’s Green Core project will employ IGBT-based voltage-fed induction furnaces, among the most energy-efficient melting technologies available today. Compared to conventional induction furnaces, this is expected to deliver further power reduction of 10–15 units per tonne, amounting to approximately 1.18 million units of electricity saved annually.

The project is designed to operate without fossil fuel inputs, resulting in the elimination of full life-cycle emissions linked to fuel handling, logistics, and combustion processes.

Water conservation forms another critical pillar of Kalliyath’s Green Core initiative. The facility will implement dry cooling systems, reducing process water consumption by nearly 99 percent compared to traditional cooling methods. In addition, the project incorporates a comprehensive rainwater harvesting system. With a total roof area of 14,100 square metres, rainwater from all factory sheds will be captured through durable gutter systems and stored for concurrent industrial use.

Further strengthening groundwater protection, the project includes the construction of a sub-surface dyke (SSD) along the southwest boundary of the site. Extending 100 metres in length and reaching depths of up to 8 metres, the SSD will help arrest groundwater outflow and enhance local aquifer recharge.

According to Kalliyath, the combined impact of these measures is expected to result in water savings of 1.87 lakh kilolitres annually when compared to conventional steel manufacturing practices.

Beyond environmental benefits, Kalliyath’s Green Core project is expected to contribute significantly to the regional economy. The project is projected to generate over 1,000 direct and indirect employment opportunities, while also strengthening local supply chains and ancillary industries.

Kalliyath stated that Green Core aligns with national priorities on sustainable manufacturing, circular economy principles, and self-reliance, by maximising the use of recycled steel, reducing dependence on virgin raw materials, and deploying clean, electrified processes that enhance both safety and efficiency.

With this investment by Kalliyath, Palakkad is set to play a pivotal role in Kerala’s industrial transition towards greener, future-ready manufacturing, reinforcing the state’s commitment to responsible economic growth

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