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SAIL, Rourkela Steel Plant registers excellent performance in key areas in Calendar Year 2025

Newsmantra — Mon, 05 Jan 2026 06:37:12 +0000

-Caster-4 of Steel Melting Shop-2 becomes operational

Rourkela Steel Plant (RSP), a flagship unit of Maharatna Steel Conglomerate, SAIL, concluded the calendar year 2025 with a string of remarkable achievements in key production units, demonstrating its best-ever performance for any calendar year. The year also witnessed commencement of slab casting from of Caster-4 of Steel Melting Shop-2 on 13^th October, 2025.

The Blast Furnace-5 ‘Durga’ produced 32,39,390 tons of Hot Metal in 2025 to register its best calendar year performance improving upon its earlier best figure of 30,72,786 tons achieved in 2024. Similarly, the Blast Furnace-1 tapped 10,62,722 tons of Hot Metal to clock its best annual performance with a growth of 8.9% over the previous calendar year 2024. The Hot Strip Mill-2 rolled 26,54,530 tons of HR Coils to achieve its best calendar year performance thereby improving upon its earlier best performance of 25,23,587 tons achieved in 2024. The Sheet Shearing Line also produced 3,16,582 tons of HR Plates to clock its best calendar year record with a growth of 39.3% over the previous year. The New Plate Mill registered its best calendar year performance by rolling 9,75,133 tons of plates and exceeding its earlier best figure of 9,47,778 tons achieved in 2024. The Sintering Plant-3 produced 37,45,069 tons of sinter to register its best annual performance surpassing the earlier best record of 37,30,532 tons achieved in 2021.

With 32,11,017 tons direct dispatch and 6,17,396 tons road dispatch, RSP achieved a growth of 11% and 19% over the previous year respectively.

In the techno-economics area also, RSP exhibited record performances with sustained focus on reducing input cost. The coal to hot metal ratio was all time best 0.882 while the shop coke rate stood at all time best figure of 385 Kgs. The Coke Rate of BF-5 was an all time best of 368 Kgs. The year also witnessed record improvements in different areas. A best yearly average ladle life of 147.5 heats was achieved in CCM-II. The SMS-2 Converters also achieved Best-ever yearly average life of 7,734.5 heats.

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Transformative solution by Safety Circle team of New Plate Mill enhances safety and accrues huge savings for Rourkela Steel Plant

Newsmantra — Tue, 05 Aug 2025 08:48:41 +0000

In a significant step toward enhancing workplace safety, the TEJAS Safety Circle of SAIL, Rourkela Steel Plant (RSP) has successfully executed a critical project to mitigate hazards caused by hot flying scales from the primary descaler of the New Plate Mill (NPM). The initiative, underscores the commitment of the plant to promote a culture of proactive safety, innovation, and operational excellence.

The five-member TEJAS team comprising Mr. Deepak Sahu, Engineering Associate, Mr. Gopabandhu Behera, Mr. Shirshananda Das and Ms. Supriya Bhoi, all Junior Engineering Associates along with facilitator Mr. Abhijit Patnayak, Senior Manager (NPM) carried out a detailed safety audit in the descaling zone. During their inspection, the team identified over 100 unsafe conditions and acts, related to the hazard of hot flying scales. This particular hazard had the potential to cause serious injuries, fire incidents, and significant equipment damage.

Using the DIMAC (Define, Measure, Analyze, Improve, Control) methodology, the team conducted an in-depth root cause analysis. The investigation revealed key vulnerabilities. To address these challenges, the team implemented a robust and multi-faceted action plan that included installation of multi-layer chain curtains to contain flying scales, Fire insulation of exposed cables and motor areas, Protective shields for essential equipment, and Deployment of visual caution signage to enhance hazard awareness.

Following the implementation, there has been a substantial improvement in workplace safety. The initiative not only prevented potential production losses valued at over Rs. 1.56 crores but also led to a monthly saving of 24 man-hours. More importantly, it contributed to a stronger culture of safety, morale, and teamwork among employees.

The team Tejas presented the innovative project at the 16th Integrated Safety Circle Convention at SAIL, Bhilai Steel Plant and bagged the Gold medal for the project.

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Team Building Football Match organised by NPM & SPP of SAIL, RSP

Newsmantra — Fri, 01 Aug 2025 06:09:56 +0000

A friendly football match among the executives of New Plate Mill (NPM) and Special Plate Plant (SPP) of SAIL, Rourkela Steel Plant was organised at Vikas Public School Ground, Sector-9 on 27^th July, 2025. The match, played under floodlights, witnessed enthusiastic participation from officers and their family members.

The match was held between Team One Million Tonnes and Team Near Miss, led by Mr. R. K. Bisare, CGM (NPM & SPP) and Mr. P K Padhi, GM (SPP). Both teams displayed commendable skill and sportsmanship, making the game an exciting affair. The match ended in a draw, celebrating camaraderie and fun.

Mr. S. Sudhakar, GM (NPM), Mr. R. Naveen, AGM (NPM), Mr. M. P. Prasad, Sr. Manager (NPM), and Mr. Abhijit Patnaik, Sr. Manager (NPM), were jointly declared Man of the Match. Mr. S. Gouda, Sr. Manager (NPM), playing for Near Miss, was adjudged the Best Goalkeeper. The awards were presented by Mr. R. K. Bisare.

The event was coordinated by Mr. K. C. Mohanty, AGM (NPM), Mr. Abhijit Patnaik, and Mr. Suman Kumar, DSO (NPM). Mr. Suman Kumar and Ms. P. Nath, ASO (NPM & SPP) anchored during the match. The match served as a welcome break from the daily routine and strengthened team spirit among the executives.

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Enterprising effort of ‘Tejas’ Quality Circle team of New Plate Mill helps accrue huge savings for SAIL, Rourkela Steel Plant

Newsmantra — Mon, 07 Oct 2024 06:54:49 +0000

An enterprising effort of ‘Tejas’ Quality Circle (QC) team of New Plate Mill (NPM) has helped accrue huge savings for SAIL, Rourkela Steel Plant (RSP). They have successfully implemented a project Modification of Cooling Line System to improve the heat capacity of Reheating Furnace’ which has led to significant cost savings and enhanced production efficiency. The enterprising team comprises Mr. Gopabandhu Behera (OCT), Mr. Shirshananda Das (SOST), Mr. Deepak Sahu (Assistant Roller), Mr. Asit Behera (SOST), and Mr. Deepak Kumar Sahoo (OCT), with Mr. Abhijit Patnayak, Manager (NPM), serving as the team’s facilitator.

It is noteworthy that the Reheating Furnace of NPM was facing intermittent issues such as maintain efficiency and prevent damage, water is circulated through horizontal beams to keep the temperature within safe limits. However, over time, the horizontal beams and skid posts experience oxidation, leading to gradual thinning and frequent replacements. In recent years, the frequency of punctures in the skid posts has become an alarming issue, causing interruptions in production and damage to vital components such as pipe support beams, refractory materials, and recuperators in the reheating furnaces. These malfunctions, operating at extreme temperatures, can result in significant production losses.

The Tejas QC took up the challenge to address the problem. The team after detailed study and brainstorming added an extra cooling line, sourced from the main water supply, to regulate temperatures at the skid posts that were exceeding safe limits. This additional cooling line helped to keep the skid posts within the permissible temperature range, converting potential breakdowns into scheduled maintenance shutdowns.

The QC team bagged the prestigious J K Das Memorial Trophy in the recently organised Chapter Level Quality Circle Competitions held at Rourkela securing highest grade amongst the 140 participating teams from various big corporate houses.

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