The Roll Shop Department of SAIL, Rourkela Steel Plant (RSP) has made significant strides in cost optimization and technical innovation during the financial year 2024–25. Through a series of in-house initiatives and process improvements, the department has not only achieved substantial savings but also contributed to enhanced reliability and sustainability in plant operations.
One of the standout achievements has been the reduction in roll consumption in Hot Strip Mill-2 (HSM-2). By adopting sustained process optimization and improved operational practices, the department successfully brought down roll consumption from 0.50 kg/T to 0.44 kg/T. This key improvement has led to an annual cost saving of Rs. 11 crores—demonstrating RSP’s commitment to enhancing productivity while reducing input costs without compromising on quality.
In another significant initiative, the team designed and implemented an in-house fabricated protective hood for the bottom back-up chock of the MHI Mill of HSM-2. This custom-engineered solution effectively prevents chronic water ingress, a long-standing maintenance challenge. As a result, equipment reliability has improved, and component life has been extended. This initiative highlights RSP’s ability to devise critical solutions internally, minimizing downtime and reducing reliance on external vendors.
The department also made notable contributions by salvaging 20 leveller rolls in Plate Mill that were previously deemed unserviceable. This successful recovery effort resulted in an additional cost saving of Rs. 3 crore and further reflects the department’s focus on resource efficiency, waste minimization, and sustainable practices.
Further enhancing its performance, the Roll Shop achieved zero roll neck bearing failures across Plate Mill, New Plate Mill (NPM), HSM-2, and the Silicon Steel Mill during the year. In addition, the team developed the capability to grind NPM work rolls using conventional roll grinding machines at Roll Shop-1—demonstrating both adaptability and technical skill.
Beyond technical milestones, the Roll Shop collective also contributed to improving the workplace environment by developing a beautifully landscaped garden in the department premises, showcasing their dedication to aesthetics and environmental consciousness.
These collective achievements underscore the skill, dedication, and innovative spirit of the Roll Shop team. With a continued emphasis on self-reliance, in-house engineering, and operational excellence, RSP is steadily setting new benchmarks in techno-economic performance.
