The Refractories Engineering (Services) Department of SAIL, Rourkela Steel Plant (RSP) has delivered a stellar performance in the financial year 2024–25, setting multiple records in operational efficiency, cost-effectiveness, and technical innovation, bringing substantial savings for the plant.
In a national level accomplishment, RSP set a new record for torpedo ladle life. The Torpedo Ladle # 9 achieved a national record of 3009 heats in July’24, surpassing the previous National best of 2865 in March’24, also achieved by RSP.
The Continuous Casting Machine-I (CCM-I) steel ladle achieved the highest-ever yearly average life of 88.0 heats, surpassing the previous best of 84.90 heats recorded in FY 2023–24. This improvement exemplifies the department’s relentless focus on quality enhancement, process optimization, and meticulous maintenance practices.
Similarly, the RH-OB unit recorded its highest yearly average life at 143.56 heats, edging past the previous record of 142.10 heats. The consistent improvement in lining performance has significantly contributed to reducing downtime and improving productivity and helped in production of higher %age of special steel.
One of the most noteworthy achievements of the year has been the lowest-ever specific refractory consumption at 6.65 kg per Tonne of Crude Steel (TCS). This milestone not only reflects superior refractory management but also marks a step forward in cost reduction and sustainable operations.
The department also achieved a technical first at RSP with the successful grouting of Blast Furnace #5 Stove dome area using insulating pumpable castable. This innovative approach led to a dramatic reduction in shell temperature—from 250°C to just 70°C, thereby enhancing energy efficiency, prolonging equipment life, and improving operational safety.
These outstanding results underscore the Refractories Department’s commitment to excellence, innovation, and sustainability. The team continues to strive toward greater efficiency and cost-effectiveness, charting the path for future successes.
