The case study on SAIL Rourkela Steel Plant typically examines the operations, challenges, and achievements of the steel plant located in Rourkela, Odisha, India. It may cover topics such as its history, production processes, technological advancements, environmental initiatives, economic impact on the region, and management strategies. Such a case study provides valuable insights into the steel industry and its role in the development of the local economy and the broader industrial landscape.

1. Case Study :- SAIL- Rourkela Steel Plant
-YASH SHINDE

2. ROURKELA STEEL PLANT

3. INTRODUCTION
► Today is the first day of case study and I was allocated SAIL -
Rourkela steel plant. It was the first plant in India to incorporate
LD technology of steel making. It is also the first steel plant in
SAIL and the only one presently where 100% of slabs are produced
through the cost-effective and quality-centric continuous casting
route. It is SAIL’s only plant that produce silicon steels for the
power sector and high quality pipes for the oil & gas sector.. Its
wide and sophisticated product range includes various flat,
tubular and coated products

4. HISTORY
► The present day industrial capital of Odisha, Rourkela was initially a part
of the Nagara Sub-divisions of Odisha which used to be a part of Ex-
princely province of Gangapur at the time of British kingdom. The
headquarters of sub division of Nagara was constituted in the year 1945
by King Uditya Prataapa Shakher Deo at the Panposh. The historical
Vedavyas which is situated on the banks of river Brahmani is also one of
the famous religious places. It is also believed that the holy Mahabharata
was written at this place by Mahaa Rishi Vyash and hence the name of the
river is also on his name. In late 19th century there used to be a huge
festival which was being celebrated here on the occasion of Maha
Shivratri by then kings and Jamindaar of Kuanramunda which is still
being celebrated here.

5. HISTORY
► After India's independence from the British rule, the government realized
a prime requirement which was industrialization of the country that could
support economy of the nation. After lot of research, Rourkela was
selected as the city for setting up of industries. That's how Rourkela
became one of the most important industrial towns of the country.
Rourkela is better known as Rourkela Steel Plant.

6. ABOUT US
► Rourkela Steel Plant (RSP), the first integrated steel plant in the public
sector in India, was set up with German collaboration with an installed
capacity of 1 million tonnes. Subsequently, its capacity was enhanced to 2
million tonnes of hot metal, 1.9 million tonnes of crude steel and 1.67
million tonnes of saleable steel. After implementing a massive
modernisation and expansion, Rourkela Steel Plant has enhanced its
capacity to 4.5 million tonnes of Hot Metal and 4.2 Million Tonnes of
Crude Steel.

7. MILESTONE
❖ 1) Steel Authority of India’s (SAIL) Rourkela Steel Plant (RSP) has crossed 92 million
tonnes (MT) of crude steel production on March 21. On this achievement, Plant’s
CEO Dipak Chattaraj congratulated all the stakeholders of the Steel Plant on RSP
crossing this milestone.
► RSP is the first integrated steel plant under public sector undertaking (PSU) to
commence production in independent India. Since the very beginning, RSP has
functioned with a three-pronged strategy, viz. strengthening the Nation with the
might of steel, supporting the economy and steering progress in the entire region.
► Rourkela Steel Plant has never been about steel only. The Plant has changed the
very face of this part of the country by ushering in waves of progress and prosperity
that have touched and shaped the lives of millions of people in innumerable ways.
The first major industry in the state of Odisha, Rourkela Steel Plant epitomizes the
industrious, enterprising and innovative spirit of the people of this land.

8. MILESTONE
► 2) Rourkela Steel Plant (RSP) has surpassed a historic milestone of 100
Million Tonne (MT) Hot Metal production on July 5, 2021. With this the
unit of Maharatna Company SAIL has entered into the elite club of Steel
Industries with such a distinction. The journey that had commenced on
February 3, 1959, entered a higher orbit.
► RSP has consistently reinforced its commitment by providing one of the
strongest metals available on planet earth for use in every aspect of life
and living, right from household items to infrastructure and defence
applications in the last more than 62 years.
CONTINUED…..
.

9. MILESTONE
► It is noteworthy that the last 50 MT Hot Metal production was achieved in
only 18 years. Moreover, the last 10 million tons of hot metal was tapped
in a matter of 2 years 8 months, while the last one year witnessed 4.3
Million Tonnes of Hot Metal even with two furnace operation for few
months, which conveys the resilience and very high level of commitment
in the RSP Collective.
► Dipak Chattaraj, CEO, RSP visited the Blast Furnaces department along
with Top Management of the Plant, to congratulate the collective for the
remarkable achievement

10. PLANTS
1)Bhilai steel Plant:-
The Bhilai Steel Plant (BSP), located in Bhilai, in the Indian state of Chhattisgarh,
is India's first and main producer of steel rails, as well as a major producer of wide
steel plates and other steel products. The plant also produces steel and markets
various chemical by-products from its coke ovens and coal chemical plant. It was set
up with the help of the USSR in 1959.[1]
Bhilai Steel Plant (BSP) is eleven-time winner of the Prime Minister's Trophy for best
integrated steel plant in the country.[2] The plant is the sole supplier of the country's
longest rail tracks, which measure 260 metres (850 ft).[3] The 130 - meter rail, which
would be the world's longest rail line in a single piece, was rolled at URM, Bhilai Steel
Plant(SAIL) on 29 November 2016.[4] The plant also produces products such as wire
rods and merchant products. Bhilai Steel Plant has been the flagship integrated steel
plant unit of the Public Sector steel company, the Steel Authority of India Limited and
is its largest and most profitable production facility. It is the flagship plant of SAIL,
contributing the largest percentage of profit

11. PLANTS
2) Durgapur steel plant:-
DSP is situated about 158 km from Kolkata, its geographical location is
defined as 23° 27' North and 88° 29' East. It is situated on the banks of
the Damodar River in the Paschim Bardhaman district in the growing
industrial city of Durgapur. The Grand Trunk Road and the main Kolkata-
Delhi railway line pass through Durgapur. Durgapur Steel Plant (DSP) set up
in late fifties is a leading producer of long products and is the pioneer in
manufacturing and supply of forged Railway Wheels & Axles in the country.
DSP started production with an initial crude steel capacity of 1 MPTA (million
ton per annum) in 1959, which has been progressively increased to 1.8 MTPA
during the modernization in nineties and further to 2.2 MTPA during recently
completed Modernization & Expansion Plan (MEP).

12. PLANTS
3) Bokaro Steel Plant:-
is located in the Bokaro district of Jharkhand. It is the fourth integrated public sector steel
plant in India built with Soviet help. It was incorporated as a limited company in 1965.[1] It
was later merged with the state-owned Steel Authority of India Limited (SAIL).[2]
Currently it houses five blast furnaces with a total capacity to produce 5.8 MT of liquid
steel.[3] The plant is undergoing a mass modernisation drive after which its output capacity
is expected to cross 10 MT.
An upgrade of the plant was also done in the 1990s in its steel refining units and continuous
casting machines. The plant has recently taken expansion plan along with Korean Steel
Company, Pohang Iron and Steel Company (POSCO)[1] Initially, about 64 moujas (a mouja
may have several village units) had been acquired for the plant. Of the total land acquired,
only 7,765 ha was used to set up the steel plant. The rest has been given by SAIL to the
private parties without government’s approval.
The plant's yearly profit stood at ₹11.2 billion (US$160 million) for the financial year 2003–04
and has increased every year since then reaching to 84.26 billion INR in the financial year
2007–08.

13. PLANTS
4) Salem Steel Plant (SSP):-
A unit of Steel Authority of India Limited (SAIL), is a steel plant involved in the
production of stainless steel.[1] It is located along the Salem — Bangalore National
Highway 44 in the foothills of Kanjamalai in Salem district, Tamil Nadu,
India.[2][3] The plant has an installed capacity of 70,000 tonnes per annum in its
cold rolling mill and 3,64,000 tonnes per annum in the hot rolling mill.[1] It also has
the country's first stainless steel blanking facility.
5)Burnpur steel plant:- Burnpur is a captive township of SAIL, the area covered
by IISCO Steel Plant and its surroundings in Asansol of Paschim Bardhaman
district, in the heart of the mining-industrial belt in the western periphery of the
state of West Bengal, India. It is governed by Asansol Municipal Corporation

14. UNITS
1)Mines:-
SAIL is operating 8 iron ore mines and 2 flux mines spread over Jharkhand, Odisha
and Madhya Pradesh to supply Iron ore, Limestones and Dolomite to SAIL steel plants
in eastern sector of the country.SAIL iron ore mines are located at Kiriburu,
Meghahatuburu, Gua and Chiria in Jharkhand, and at Bolani, Barsua, Taldih and
Kalta in Odisha. Flux mines are located at Tulsidamar in Jharkhand, and at Kuteshwar
in Madhya Pradesh. SAIL is operating 8 iron ore mines and 2 flux mines spread over
Jharkhand, Odisha and Madhya Pradesh to supply Iron ore, Limestones and Dolomite
to SAIL steel plants in eastern sector of the country.SAIL iron ore mines are located at
Kiriburu, Meghahatuburu, Gua and Chiria in Jharkhand, and at Bolani, Barsua, Taldih
and Kalta in Odisha. Flux mines are located at Tulsidamar in Jharkhand, and at
Kuteshwar in Madhya Pradesh.

15. UNITS
2) Growth Division (GD):-
Functions as a nodal agency for manufacture and supply of various spare parts
and equipment to the SAIL Plants by utilizing available in-house facilities and
vendor base. GD functions focus on effective utilization of the engineering shops
in the steel plants. Main objectives of GD are:
∙ Effective utilization of captive engineering facilities of each steel plant.
∙ Providing technical help to manufacture specified equipment to cater to
present requirement as well as long-term expansion and modernization.
∙ Undertake projects within SAIL plants or outside.

16. UNITS
3) SAIL Safety Organization:-
SAIL Safety Organization (SSO), a Corporate Unit set up in 1988 at Ranchi,
monitors and guides the safety Promotional, fire and Occupational Health Services
activities undertaken at different steel Plants/Units/Mines/Stockyards. To
accomplish the above mentioned functions, SSO formulates and prepares
appropriate safety policies, procedures, systems, action plans, guidelines etc.
and follows up for their implementation and thereby helps in providing accident
free work environment. Consistent efforts are also being made by SSO for
competence building in the area of safety management through HRD
interventions covering heads of shops, line managers, safety personnel & trade
union leaders.
CONTINUED….

17. UNITS
A multi-disciplinary safety Engineering Departments exists in each of the
steel plants and mines to look after their safety needs. The emphasis is
now on Systematic Approach to safety Management. SSO is managing the
secretariat of the Joint Committee on Safety, Health & Environment in the
steel Industry (JCSSI), a bipartite forum which addresses steel plant
safety, health & environment issues with active involvement of
management and central & plant level trade unions and provides
guidelines to the member organizations like SAIL, TISCO, RINL, HSCL,
Dastur Co., etc., on promoting safety. Occupational health and pollution
control measures.

18. UNITS
4) Environment Management Division (EMD):-
Established on 23rd June 1988, is the corporate unit certified with ISO 9001 Standard.
The unit plays a pivotal role in consolidation of the efforts of the plants, mines and
units towards environment protection and resource optimization through its
multifarious activities involving:
• Proactive interface between the SAIL units and the regulatory agencies,
• Monitoring and assessment,
• Technology dissemination,
• Awareness campaigns and skill up-gradation.
In addition to these, EMD with constant co-operation from plants, mines and units, is
paving its way for propagation of EMS linked to ISO 14001 for various shops and units,
including warehouses.

19. UNITS
5) Central Coal Supply Organization :-
Central Coal Supply Organization (CCSO) is situated in Dhanbad District of
Jharkhand and has branch offices at Kolkata, Asansol, Adra and Bilaspur.
CCSO with its skilled man-power looks after the daily movement of Indigenous
washed coking coal and boiler coal to SAIL steel plants; BSP, RSP, DSP, BSL and
ISP by continuous follow up and liaison with the CIL subsidiaries such as Bharat
Coking Coal Limited (BCCL), Dhanbad, Central Coalfields Limited(CCL), Ranchi,
Western Coalfields Limited (WCL), Nagpur, Eastern Coalfields Limited (ECL),
Sanctoria (W.B), South Eastern Coalfields Limited (SECL), Bilaspur, Mahanadi
Coalfields Limited (MCL), Sambalpur (Orissa) and different Railway Zones.

20. VISION
► To be a respected world class corporation and the leader
in Indian steel business in quality, productivity,
profitability and customer satisfaction. Apart from vision,
SAIL has the following Credo: * We build lasting
relationships with customers based on trust and mutual
benefit.

21. MISSION
► To be a respected world class corporation and the leader
in Indian steel business in quality, productivity,
profitability and customer satisfaction.

22. PROCESS DETAILS
❖ Rourkela Steel Plant has completed a massive modernization and expansion
programme that is truly historic. With this the Steel Plant has doubled its
capacity and augmented it to the level of 4.5 MTPA (Million Tonne per Annum)
of Hot Metal from the previous level of 2 MTPA. The Crude Steel making
capacity has simultaneously increased from the level of 1.9 MTPA to 4.2 MTPA
and production of Saleable Steel is all set to zoom from the level of 1.671 MTPA
to 3.99 MTPA.
► It is worth mentioning here that, apart from increasing the volume the other
benefits envisaged from this phase of modernisation and expansion are
increased economy of scale, enlarged customer base, enhanced quality,
reduced cost of production, better market compatibility, improved labour
productivity, stricter adherence to environment norms and superior Techno-
economics.

23. PRODUCT AND SOLUTION
► Rourkela steel plant, the name indicates the company is specialised for
manufacturing of steel. Rourkela Steel Plant (RSP), the first integrated steel
plant in the public sector in India, was set up with German collaboration. It is
SAIL's only plant that produce silicon steels for the power sector and high
quality pipes for the oil & gas sector. Its wide and sophisticated product with
the capacity of after expansion with huge crude steel and saleable 4.2 and 3.9
million tonnes per annum respectively.
► The Raw Material circuit of the Ore Bedding and Blending Plant Phase-II
commissioned and
CONTINUED….

24. PRODUCT AND SOLUTION
► inaugurated by Chairman, SAIL on 11th August. The augmentation facilities include:
∙ Receiving, unloading, reclaiming and finally transporting of raw materials required for Blast
Furnce-5
∙ Base mix preparation for the New Sintering Complex
∙ Transportation of Flue dust, Mill scale etc.
∙ Transportation of crushed fuel and flux for trimming addition to SP-III
∙ Conveyor line for transportation of Calcining Plant grade limestone and dolomite to consuming
units
∙ Automatic sampling system

25. REASERCH AND DEVELOPMENT
► The Research & Development Centre for Iron & Steel (RDCIS) at Ranchi is
the corporate R&D unit of SAIL. Set up in 1972, the Centre has ISO: 9001
certification to its credit. It undertakes R&D projects in diverse realms of
Iron & Steel Technology under the categories of Plant Performance
Improvement (PPI), Product Development (PD), Scientific Investigation
and Development (SID), Basic Research (BR) and Technical Services (TS).
► RDCIS has around 180 dedicated and competent scientists and engineers
and its laboratory is equipped with around 300 sophisticated diagnostic
research equipment and 5 pilot plant facilities.
CONTINUED….

26. REASERCH AND DEVLOPMENT
► RDCIS provides customers with prompt, innovative and cost-effective R&D
solutions; develop and commercialize improved processes and products;
continually enhance the capability of its human resources to emerge as a
centre of excellence. The major efforts are directed towards cost reduction,
quality improvement and value-addition to products of SAIL plants and
providing application engineering support to SAIL’s products at customers’
end. RDCIS, along with steel plants, takes initiatives to develop special steel
products utilizing the modernized production facilities at steel plants.
► RDCIS also offers technological services to various organizations in the form of
Know-how transfer of technologies developed by RDCIS; Consultancy
services; Specialized testing services; Contract research; Technology
Awareness Programmes.

27. TECHNOLOGY
► FIRST COIL PROCESSED AT ROURKELA STEEL PLANT OF SAIL ON HOT STRIP
MILL LINE SUPPLIED BY PRIMETALS TECHNOLOGIES
∙ Three million metric tons per year capacity
∙ Plant produces high quality steels for automotive industry and API grades
∙ Pair cross technology ensures optimum control of profile and flatness
∙ Fast start-up
► At the production facility of India steel maker Rourkela Steel Plant of Steel
Authority of India Limited (SAIL), a hot strip mill with an annual production
capacity of three million metric tons, processed the first coil on January 31, 2020.
The hot strip mill was supplied by Primetals Technologies and produces high
quality steel for the automotive industry and API grades. It is equipped with pair
cross technology to ensure optimum control of profile and flatness. The first coil
was produced within two days of the start of hot trials.

28. TECHNOLOGY
► SAIL, in which the Indian state is a majority stockholder, has been engaged in an
ambitious expansion program that aims to boost production capacity from14 to 24
million metric tons of steel a year. The Rourkela Steel Plant, established in 1955 as
the first integrated steelworks in India, will increase its production capacity from
the current level of 5.6 million tons to 10.8 million tons of steel
► The order was awarded to a consortium of Mitsubishi Corporation (MC) and Larsen
& Toubro (L&T). MC was responsible for the project management as a consortium
leader, and L&T undertook civil construction, erection and local supply. Primetals
Technologies undertook designing and engineering of the hot strip line as well as
supply of main mechanical equipment as a main technology supplier. This
includes a reheating furnace, a single-stand roughing mill, a seven-stand finishing
mill, two down coilers, auxiliary systems and equipment for the roll workshop.
Hitachi Limited undertook to design, engineer, and supply electrical
equipment/automation system.
CONTINUED….

29. TECHNOLOGY
► The hot strip mill, one of the largest of its kind in India, is able to produce coils in
thicknesses between 1.2 mm and 25.4 mm and in widths between 725 mm and
2,150 mm. Maximum coil weight is 35 metric tons. The range of products includes
carbon steels for the construction industry, low and medium-carbon steels, LPG
cylinder steel and API grade steels, including X100, up to high-grade products that
meet the requirements of the automotive industry.
► Four stands of the finishing mill are equipped with pair cross technology. This
permits optimum adjustment of the roll gap contour and thus a fine control of the
strip profile. Depending on the angle set, the crown of the strip can be varied in a
wider range than can be achieved in a conventional 4Hi mill with work roll bending
only.
► First coil produced on January 31, 2020 on the new hot strip mill of SAIL in
Rourkela. The mill was supplied by Primetals Technologies.

30. INNOVATION
1) Boosting Capacity
RSP has adopted several measures to raise cost efficiency and attain superior
standards in terms of environmental performance. It was the first integrated steel
plant in the public sector set up with German collaboration with an installed capacity
of 1 million tonnes (MnT). Subsequently, its capacity was enhanced to 2 MnT of hot
metal, 1.9 MnT of crude steel and 1.67 MnT of saleable steel.
After implementing a mammoth modernisation and expansion programme, RSP
augmented capacity to the level of 4.5 MnT per year of hot metal from the previous
level of 2 MnT. The crude steel-making capacity has increased from the level of 1.9
MnT to 4.2 MnT and production of saleable steel has increased to 3.99 MnT per
annum.
CONTINUED….

31. INNOVATION
RSP was the first plant in India to incorporate the Linz-Donawitz (LD) technology of steel-making.
It is also the first steel plant in SAIL, and till now the only one, where 100% of slabs are produced
through the cost-effective and quality-centric continuous casting (CC) route instead of the old ingot
process. However, close to 90% of SAIL’s production today happens through the CC route.
Moreover, it is the only plant that produces silicon steels for the power sector and high-quality API
grade pipes for the oil and gas sector. Its wide and sophisticated product range includes various
flat, tubular and coated items.
Apart from increasing the volume, the other benefits envisaged under the modernisation and
expansion programme (MEP) are increased economies of scale, expanding customer base, quality
upgradation, reduced cost of production and better market compatibility, not to mention improved
adherence to environmental norms.
CONTINUED…

32. INNOVATION
2) Blast Furnace Modernisation
The core of the modernisation programme were two blast furnaces (BFs) that were designed and
rebuilt under a technological collaboration with Danieli Corus.
“BF 1 was built and commissioned in May 2018. The previous working volume was 995 cubic
meters (m3) and current working volume is 1,491 m3,” a senior RSP official told Steel360.
“The hot metal production capacity previously was 1,200 tonnes per day. The present capacity
stands at 2,900/tonnes per day,” he informed.
One of the biggest BFs of the country, the new blast furnace 5 with a useful volume of 4,060 m3 is
designed for a production capacity of 2.8 MnT per annum with an average daily hot metal
production of 7,924 tonnes per day. It, too, was designed and developed by Danieli Corus and was
commissioned in 2013.

33. INNOVATION
The furnace operates at a high intensification level and for a campaign life of 20
years. Equipped with modern features such as pulverised coal injection system,
cast house fume extraction system, cast house slag granulation system, top gas
recovery turbines of 14 MW capacity, heat recovery system, plate/stave coolers
and conveyor belt charging system, this BF has Level II automation.
“The ancillary plant equipment of BF 1 that were revamped and rebuilt by
Danieli Corus are a) the furnace proper with the bell less top charging
equipment, b) the flat cast house with twin tap hole, c) ramp for easy access to
cast house, d) the new gas cleaning unit (GCP), and d) the new coal direct
injection (CDI) unit,” said the RSP official.
CONTINUED….

34. INNOVATION
These new features and modifications apart, there has been overall “optimisation and operating
parameters of the furnace,” he informed, adding that “furnace availability has increased by
optimising the maintenance activities.”
Likewise, among the many new auxiliaries of BF 5 are the twin flat cast house with four tap holes,
three turbo blowers along with all the auxiliaries that provide cold blast to the stoves of BF 5.
The unit comprising three boiler arrangements, two steam turbo generators and one back pressure
turbo generator generates power as well as cold blast to feed the furnace and the stoves.
The 10 torpedo ladles with features like higher capacity and lesser scope of hot metal temperature
loss are being used for transferring hot metal from the new furnace to the melt shop or the pig
casting machine. These torpedoes are being used for the first time in SAIL. The torpedo ladle
repair shop handles jobs like refractory lining, ladle inspection, ladle heating and cooling.
CONTINUED…..

35. INNOVATION
3) New Converter
The main feature of the modernisation of the steel melt shop is the new third basic oxygen
furnace (BOF) converter. The new top blown third converter of SMS-II) of capacity 1.584
MnT of liquid steel per year is designed with the provision for adoption of combined oxygen
blowing from top and inert gas stirring (with argon and nitrogen) from the bottom.
The new Ruhrstahl Heraeus-Oxygen Blowing (RHOB) is also a first time feature of RSP that
helps in producing higher strength and high quality special grade steel.
CONTINUED….

36. INNOVATION
4) Raw Materials Handling
Post-expansion, the new raw material requirement of RSP has to go up to about 12 MnT per
annum from the previous requirement of 5 MnT. The ore bedding and blending plant
(OBBP) has a base mix preparation system with on-ground bedding, blending and conveying
facilities.
The facilities in OBBP include major installations like wagon unloading (tipplers and track
hoppers), iron ore crushing and screening system, raw material storage yard, rod mills and
roll crushers for flux and coke crushing, proportioning bins and elaborate conveying
systems.
CONTINUED….

37. INNOVATION
RSP has five old and one new coke oven batteries (COBs) that produce coke as the input for the furnaces.
The coke ovens are equipped with wagon tipplers, automatic handling and conveying facilities, coal
blending provisions, coke wharfage crushing together with screening and conveying systems.
The new battery 6 is top charged, compound twin flue, under jet and with regenerative heating for
provisions for partial recirculation of waste gases. The 7-metre tall battery of 67 ovens has been installed
to produce run of oven coke (dry) of 0.768 MnT per year. The computerised heating control system has
been installed for the process management system to improve reduction in environmental emission,
improve coke quality and productivity.
“The principle of coke dry quenching is based on cooling of hot coke with inert gas circulating in close
loop between the chamber of hot coke and the waste heat boiler. Apart from ensuring environment-
friendly operation, it is also designed to enhance coke quality,” said the senior official.
CONTINUED….

38. INNOVATION
The new coal handling plant can hold 15 days stock of coking coal for the new coke oven battery 6
at the rate of 3,500 tonnes per day and CDI coal of 10 days stock at the rate of 1,500 tonnes per day.
There are 24 silos for stocking of coking coal and for CDI coal there are six silos, each with a
capacity of 2,500 tonnes.
The new coal chemical department (CCD) has been installed to process coke oven gas generated
from the new battery 6. This cleans the raw coke oven gas by removing tar, ammonia, hydrogen,
sulphur, sulphide and naphthalene. The coke oven gas is cooled finally to 3,000 degree C at the
outlet of the final gas cooler. There are naphthalene washer and benzole scrubber to have clean
coke oven gas for use in the plant.
The RSP official informed: “The CDI rate per tonne of hot metal for BF 1 is 100 kg per tonne of hot
metal (THM) on an operating basis while on a design basis it is 150 kg/THM. The CDI rate in
January 2020 was 98 kg/THM. In February too the rate was 98 kg/THM.”
CONTINUED….

39. INNOVATION
5) Downstream Operations
The 4.3 metre wide new plate mill has a capacity to produce one of the widest plates in
the country, set up to cater to the customised plate market. The mill can produce a
wide range of plates with close tolerances to meet stringent international standards
and heavy and wide plates for the rising ship-building and boiler sectors.
While the cold rolling mill produces about 678,000 tonnes of cold rolled sheets per
annum, RSP’s silicon steel unit produces steel for the electrical industry through
various operations carried out in sophisticated, continuous/semi-continuous
processing lines and a reduction mill. Advanced process control and product testing
facilities ensure product quality.
CONTINUED….

40. INNOVATION
A highly sophisticated spiral welded (SW) pipe plant is equipped with
submerged arc welding process and produces large diameter pipes. Hydrostatic
pressure testing, ultrasonic testing and eddy current testing are some of the
features which ensure quality control.
The electric resistance weld (ERW) pipe plant caters to smaller diameter pipe
consumers. This plant has been recently upgraded to enable it to produce API
grade pipes for meeting the rising demand from the country’s oil and gas sector.

41. TESTING FACILITIES
1) Ore Bedding and Blending Plant
RSP’s Ore Bedding & Blenblending and conveying facilitiesding Plant (OBBP) has a
base mix preparation system with on-ground bedding,.The facilities in OBBP include
major installations like wagon unloading (tipplers & track hoppers), iron ore crushing
and screening system, raw material storage yard, rod mills and roll crushers for flux
and coke crushing, proportioning bins and elaborate conveying systems.
2) Coke Oven
RSP has five old and one new coke oven batteries (COBs) that produce coke as the
input for blast furnaces. The coke ovens are equipped with wagon tipplers, automatic
handling and conveying facilities, coal blending provisions, coke wharfage crushing
together with screening and conveying systems

42. TESTING FACILITIES
3) Sintering Plant
The Sinter plants feed sinter to the blast furnaces. The two old Sinter
plants have a combined capacity of 3.07 MT per annum, while the new
Sinter Plant has a capacity of 3.7 MTPA.
4) Blast furnaces
The five blast furnaces of RSP, with a combined capacity of 4.5 MTPA,
produce hot molten metal for steel production
CONTINUED…

43. TESTING FACILITIES
5) Steel Melting Shops
SMS-I
In early sixties SMS-I was commissioned with LD converters and later on a
Secondary Steel Making unit and a Continuous Casting unit were added to it. Hot
Metal from different Blast Furnaces are transferred to Hot Metal Mixers of SMS-I
by locomotives. Using oxygen from Tonnage Oxygen Plants and Lime & Dolomite
from LDBP, hot metal is converted to steel. Apart from a computerised LD process
which has enhanced shop capability, the LA Vacuum Metallurgy Technique has
been also adopted for secondary refining of steel. This facilitates production of
special steels for application in electrical machines, pipe making, tin plate,
boilers and auto chassis members.
CONTINUED….

44. TESTING FACILITIES
► SMS-II
The two old and one new Basic Oxygen Furnaces (150 Tonnes capacity
each) make steel from the inputs namely Hot Metal, scrap, Ferro alloys
and flux with the help of Oxygen that is blown into them from the top.
The two old and one new Continuous Slab Casters mould the molten Steel
and produce Steel Slabs. The shop is equipped with automation through
three levels of computerised control, LD gas cleaning and recovery,
power distribution system, water and utility services.
CONTINUED….

45. TESTING FACILITIES
6) Plate Mill
RSP’s old 3.1 meter wide, 4 high reversing mill is equipped with online thickness
measurement facilities. The mill has a production capacity of 299,000 tonnes per
annum. The 4.3 metre wide New Plate Mill has a capacity to
A New 4.3 Metre Plate Mill, which is one of the widest in the country has been set
up to cater to the customised plate market is one of the most important
components of this phase of Expansion. The Mill can produce a wide range of
plates with close tolerances to meet stringent international standards and heavy
and wide plates for the rising ship building and boiler sectors.
CONTINUED….

46. TESTING FACILITIES
7) Hot Strip Mill
The HSM supplies Hot Rolled Coils as input materials to its downstream customers such as
Cold Rolling Mills, Silicon Steel Mill, and Pipe Plants and also to Dividing Line. It also
caters to the requirements of external customers. The facilities of the 1.44 MT per annum
mill include, Two walking beam type reheating furnace (225 TPH), Roughing/sizing stand
RoVo with automation, an Automated coil box, Quick roll change system in Roughing Stand-
1 and finishing mills and Coil marking, sampling and conveying systems.
8) Cold Rolling Mill
Produces about 678,000 tonne of cold rolled sheets per annum, RSP’s Cold Rolling Mill has a
5-stand tandem mill and a 4-high 1700-mm reversing mill. The tandem mill is equipped with
automatic gauge control, x-ray gauge, data logging and thyristorisation.

47. TESTING FACILITIES
9) Galvanising Lines
Two continuous hot-dip galvanising lines are equipped with jet-coating facilities.
There are 2 multi-roller-corrugating machines as well which produce corrugated
sheets.
10) Silicon Steel Mills
This unit produces steel for the electrical industry through various operations
carried out in sophisticated, continuous/semi-continuous processing lines and a 4-
high reduction mill. Advanced process control and product testing facilities
ensure product quality.

48. BUSINESS
1) The Metals and Mining business unit successfully completed engineering
consultancy for a blast furnace for a steel plant in Rourkela, India. A showcase project
for Tata Consulting Engineers, marked by timely completion of project and innovative
solutions. Tata Consulting Engineers undertook turnkey execution of the project. The
Metals and Mining business unit rendered civil and structural works comprising
furnace foundation, 4-poster structure, equipment foundation, roads, railway tracks,
drawing and sewerage. Utilities and auxiliaries comprised furnace cooling system,
compressed air, nitrogen, steam, oxygen for blast furnace proper, gas cleaning plant,
cast house, bell-less top charging system, stove valve cooling, air-conditioning and
ventilation systems.
The plant construction and commissioning was done in record time and in line with
international standards.This project had several innovative engineering solutions
such as – design and engineering of 4-poster structure, thereby eliminating the need
for pouring concrete into hollow structures; and the engineered sequence of
installation of the downcomer connecting blast furnace and gas cleaning plant.

49. BUSINESS
Blast furnace foundation was designed, critically examined and approvals for construction
procured to suit site conditions such that no re-engineering required. Design/engineering of
systems and sub-systems were critically examined to enable problem-free construction and faster
execution. Design inputs from various agencies were compiled and integrated into the design for
construction in record time. State-of-the-art safety solutions were also provided in the design.
Basic engineering inputs, operational maintenance, extensive fire fighting systems and fire
detection systems were incorporated and gratings were provided to ensure accident-free
operations.
The innovation, safety measures and timely delivery provided cost-efficiencies to the client and
the quality standards were benchmarked to international standards. The success of this project
attributed to the Metals and Mining business unit’s understanding of the steel manufacturing
process, familiarity with international quality norms and, most of all, the capability to work with
multiple entities handling complex assignments.

50. BUSINESS
2) Rourkela Metal Plant mulls capability enlargement:- The Rourkela Metal Plant (RSP) is
planning to extend its annual sizzling steel manufacturing capability from the present
degree of 4.5 to 4.855 million tonne every year (MTPA), an official launch mentioned.
The crude metal manufacturing at its plant in Odisha’s Sundargarh district may also go up
from 4.2 MTPA to 4.85 MTPA and saleable metal manufacturing from 3.880 to 4.325 MTPA,
the discharge issued on Saturday mentioned.
The brand new items which have been deliberate as a part of the mission are a coke oven
battery, a metal melting store, oxygen plant and adoption of technological measures for
enhancing capability of the present blast furnaces, it mentioned.
A proposed normalising furnace with 0.3 MTPA capability may also be put in inside the
brand new plate mill to cater to area of interest market segments.
CONTINUED….

51. BUSINESS
The RSP is planning to utilise pure fuel in numerous items and it has deliberate a
pipeline community, which can reduce the usage of fossil fuels like coal and make the
steel-making course of cleaner and greener.
The proposed tasks, which can be taken up throughout the present boundary of the
RSP, are designed with state-of-the-art environment-friendly applied sciences based
mostly on the idea of zero discharge.
Several types of air air pollution management methods can be put in to minimise the
air air pollution and no slicing of bushes can be required.
The proposed enlargement is not going to solely improve the manufacturing capability
of the metal plant however may also additional strengthen the economic system of the
area and enhance the standard of life of individuals residing in and round Rourkela.

52. CAREER
SAIL Rourkela a Central Public Sector Enterprises (CPSE) is India’s largest steel producer with around
17.43 MT of Hot Metal and 16.15 MT of Crude Steel production. With Annual Turnover of more than Rs.
61000 crores in 2019-20, SAIL is one of the ‘Maharatna CPSE’ of country and has been the pivot of the
domestic steel industry has continuously moved with the times to carve a niche for itself among the
leading steel producers of the World.
SAIL Plants together produce the widest spectrum of steel products in the country, covering both flat and
long product segments, providing cost-effective and superior quality of products and services.
SAIL has completed a massive expansion plan and increased its crude steel production capacity to 21
million tonnes (MT) enabling its steel plants to produce 100% steel through the basic oxygen furnace-
continuous casting route and an expanded product mix with a larger proportion of value-added items. A
long term strategic plan has been worked out to steer the company towards a target of 50 MT of hot metal
production by 2031, thereby meeting the strategic objectives of maintaining leadership position in Indian
steel sector and a position amongst the top steel companies globally and makes its steel available at

53. FUTURE PLAN
1) The Rourkela Steel Plant (RSP) is planning to increase its annual hot metal
production capacity from the current level of 4.5 to 4.855 million tonne per annum
(MTPA), an official release said.
The crude steel production at its plant in Odisha's Sundargarh district will also go
up from 4.2 MTPA to 4.85 MTPA and saleable steel production from 3.880 to 4.325
MTPA, the release issued on Saturday said. A proposed normalising furnace with
0.3 MTPA capacity will also be installed inside the new plate mill to cater to niche
market segments.
The RSP is planning to utilise natural gas in various units and it has planned a
pipeline network, which will minimize the use of fossil fuels like coal and make
the steel-making process cleaner and greener.
CONTINUED….

54. FUTURE PLAN
The proposed projects, which will be taken up within the existing boundary of the RSP,
are designed with state-of-the-art environment-friendly technologies based on the
concept of zero discharge.
Different types of air pollution control systems will be installed to minimise the air
pollution and no cutting of trees will be required.
The proposed expansion will not only enhance the production capacity of the steel
plant but will also further strengthen the economy of the region and improve the
quality of life of people residing in and around Rourkela.
CONTINUED….

55. FUTURE PLAN
2) Steel Authority of India Limited (SAIL) is set for a big expansion, as Prime Minister Modi, who
will be visiting the steel plant on April 1st, likely to announce a Rs. 36,000 crore capacity expansion
plan. PM Modi will inaugurate the recently completed modernized unit of the plant.
SAIL has spent Rs. 12,000 crore in modernizing and expanding the plant, increasing its production
capacity to 4.5 mtpa from 2 mpta.
In a maiden visit to the Rourkela steel plant, located in Odisha state, PM Modi likely to make key
announcements on SAIL’s future plans, including SAIL’s ‘Vision 2025’.
As per sources, SAIL prepared a blueprint on future expansion, aiming 50 mpta installed capacity
by 2025, requiring a whopping Rs. 1.5 lakh crore in investment.
SAIL is going through a Rs. 72,000 crore ongoing expansion program that will increase its capacity

56. FUTURE PLAN
"The Prime Minister is very hopeful of the potential that can be tapped in the iron
and steel sector of the Eastern region. He may deliberate upon the need and his
government's commitment to unfurl that potential in his speech after inaugurating
the expanded facility of RSP on April 1," ET quoted an unknown source as saying.
SAIL is seriously working to increase the capacity of its Durgapur, IISCO, Bokaro
and Bhilai steel plants.
And coming to Rourkela Steel Plant, it is the country’s first public sector’s
integrated steel factory, set up back in 1960 with German collaboration. It is the
SAIL’s only steel plant in the country that produces steel specifically for the
power, packaging, oil and natural gas sectors.

57. AWARDS
1) Greentech Energy conservation Award 2021:- The 'Greentech Energy
Conservation Award 2021' has been presented to the SAIL's Rourkela Steel Plant
(RSP) in the Platinum category presented by Greentech Foundation SAIL’s
Rourkela Steel Plant (RSP) has won the ‘Greentech Energy Conservation Award
2021 in Platinum’ category presented by Greentech Foundation for outstanding
initiatives and practices adopted to conserve energy.
The steel Plant, under the guidance of its CEO Dipak Chattaraj who possess in-
depth knowledge about energy management, Rourkela Steel Plant has forayed
into various ventures for reducing energy consumption by adopting renewable
energy sources and ensuring a pollution-free environment.

58. AWARDS
The competition was organised in 2 phases, i.e. submission of application
followed by a presentation and question-answer round. The presentation session
was handled by the team from Energy Management Department led by DGM
(EMD) BP Pandey and Business Excellence Department led by GM (BE) Chaitali
Das under the overall supervision of GM In-Charge (EMD) KK Pandey.
The jury profusely praised Rourkela Steel Plant for achieving the highest Blast
Furnace Gas yield since inception, increased power generation from Power
Blowing Station and minimisation of low uncontrolled BF Gas pressure to Coke
Ovens Battery – 6.

59. AWARDS
2) Prakriti Bandhu Award:- DGM (Horticulture) and In-charge, Zoo Development Programme of
SAIL, Rourkela Steel Plant (RSP) Dr Avijit Biswas has bagged the prestigious ‘Prakriti Bandhu’
Award.
Notably, the award given by the Forest and Environment Department of Government of Odisha
comprises Rs 10,000 cash award and a citation from the Additional Chief Secretary, Forest and
Environment Department and Collector, Sundargarh.
The award has been conferred as a recognition for Dr Biswas’s noteworthy contributions in field of
conservation of nature and environment protection. It is worth mentioning here that veterinarian
has a notable record of dedicated service spanning over more than 25 years at Zoological Garden,
Alipore, West Bengal and Indira Gandhi Park and Zoo, Rourkela. Dr Biswas, who started his career
in 1989 from Zoological Garden, Alipore joined Indira Gandhi Park Zoo of Rourkela Steel Plant in
2006. His persistent efforts in breeding of native species resulted in increasing population and
saving precious wild lives. He has also been instrumental in rescuing as well as successful
treatment of a number of critically injured or seriously-ill animals.

60. THANK YOU