– First of its type job in SAIL
In a pioneering effort, the enterprising Sintering Plant-3 (SP-3) collective of SAIL, Rourkela Steel Plant has successfully replaced the Direct Charge Transfer Chute (DCTC) of the Circular Sinter Cooler in SP-3 indigenously. Notably, the critical equipment was replaced for the first time since its installation in 2012. This crucial unit ensures the smooth transfer of sinter post-crushing, maintaining the quality required for Blast Furnace-5 operations.
Over the years, the DCTC had undergone severe wear and tear, particularly the ‘Flow Diverter’, which had become critically damaged. This resulted in increased disintegration of sinter into smaller, undesired sizes, adversely impacting product quality. The concept for DCTC replacement was initiated nearly two years ago. However, the execution posed formidable challenges due to the massive size of the component of over 17 tonnes and its installation at a height of more than 9 meters within the confined space of the Circular Sinter Cooler. The complex environment ruled out the use of mobile cranes and equipment, demanding an innovative and meticulously planned approach.
A comprehensive scheme was developed with support from the Design Department, including custom-engineered drawings for the DCTC and a 12-meter-long elevated rail system for mounting a trolley to facilitate the replacement. This robust structure enabled the removal and installation of Segment 3 & 4 of the DCTC during the Capital Repair of SP-3, conducted between 25th and 31st July 2025.
With precise micro-level planning and preparatory work, the entire replacement operation was successfully completed in just six days, between 25th and 30th July 2025. This is the first-ever replacement of the DCTC in any Sinter Plant within SAIL plants, marking a major milestone for RSP.
The initiative was conceptualized and technically guided from the outset in 2023 by Mr. B. R. Palai, the then CGM (Sinter Plants) and currently ED (Works), RSP. The successful execution was ably guided by Mr. Shekhar Narayan, CGM (Sinter), and the project was led by Mr. Kalyan Samajdar, GM In-charge and Head of Department, Sinter Plant-3.
