A key accomplishment was the successful erection and commissioning of Belt Conveyor 501-X, designed for transporting metallurgical coke from Million Ton side to Blast Furnace-5 via the new Coke screening plant route. This installation has improved the coke supply to BF-5 and improved coke handling efficiency.

Throughout the year, several essential repair and maintenance activities were executed to sustain operational reliability. These included the safe replacement of a 40-meter Blast Furnace gas pipeline within the confined cellar area of Coke Oven Battery #1, bogie replacement on Reclaimers #1 and #2 to ensure uninterrupted coal lifting and removal of the load-lifting device on Battery-4 due to unsafe operating conditions. Additionally, a major repair campaign involving the full wall repair of 20 ovens in Battery-5B was completed successfully.

To enhance operational efficiency and ensure workmen safety, a CCTV-based surveillance system along with a RADAR-based proximity detection system was also commissioned for the Ram Cars and Guide Cars of Batteries #1, 3, 4, and 5. This upgradation has significantly improved visibility for operators and reduced safety risks during coke pushing and guiding operations.

Another pivotal initiative was the revival of the 10-ton boiler crane in the CDCP. Further in the hoists, VVVF drives were replaced and appropriately programmed, resulting in augmented production capability. Modifications to the trailing cable supporting structures on Lifter-1 and Lifter-4 were carried out, and additional hoist brake panels were erected on Lifter-3 and Lifter-4. This modification allows immediate switchover to a spare brake panel in case the hoist brake fails and a hot bucket gets stuck, thereby substantially reducing breakdown time.

A landmark achievement was the completion of capital repair on CDCP Chamber #4 within the scheduled timeframe. This repair marked the first-ever capital repair of its kind at Rourkela Steel Plant, establishing a new precedent for maintenance excellence in the plant’s operational history.

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SAIL, Rourkela Steel Plant (RSP) has registered outstanding performance in key units during April-July period of the current financial year 2025-26.

Blast Furnace-5 (BF-5) ‘Durga’ recorded its best-ever April–July performance, producing an impressive 10,37,844 tonnes of Hot Metal, surpassing its previous best of 9,67,097 tonnes achieved during the same period in 2023.

Similarly, Blast Furnace-1 (BF-1) ‘Parvati’ produced 3,61,774 tonnes, marking its highest April–July output, exceeding its earlier record of 3,16,199 tonnes from 2021. Notably, BF-1 also registered its best-ever July performance, tapping 94,015 tonnes of hot metal.

Caster-III of Steel Melting Shop-II made 5,25,213 tons of slabs to register its best April-July performance to date.

In the downstream, the Hot Strip Mill-2 rolled the highest ever 8,59,192 tons of slabs to produce 8,39,023 tons of HR Coils registering its best ever April-July performance. The earlier best April-July HR Coil production of 8,17,675 tons was achieved in 2024. The Sheet Shearing Line (SSL) of HSM-2 produced 95,876 tons of HR plates to set a new benchmark in the first four months. The New Plate Mill (NPM) rolled 3,30,789 tons of plates to clock its best April-July performance exceeding the earlier best figure of 3,10,317 tons achieved in 2021. NPM also recorded its best-ever July performance, rolling 92,099 tonnes of plates. Keeping pace, the Plate Mill also registered its best performance in the first four months by rolling 1,78,752 tons of plates improving upon the previous best figure of 1,77,226 tons achieved in 2023.

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The initial PCI injection rate of 150 kg/THM (Tons of Hot Metal) was proved insufficient, as inadequate nitrogen pressure and flow created challenges in sustaining the required injection rates. With the production at Blast Furnace -5 (BF-5) soaring from its designed capacity of 7929 Tons Per Day (TPD) to an impressive 9500 TPD, the existing PCI system faced limitations in meeting the increased demand.

To address this issue, the BF team implemented an innovative solution by constructing a new dedicated PCI line, designed to support the enhanced production requirements. The construction of the line began in mid-December 2024 and was completed within a short timeframe, by the end of the month. Integration of the new line into the existing system was successfully carried out during the scheduled shutdown of BF-5 on 4^th January, 2025.

This initiative has not only supported the increased production capacity of BF-5 but also aligned with the plant’s broader goals of operational excellence and cost reduction.

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