The capital repair of Sintering Plant-I (SP-I) of SAIL, Rourkela Steel Plant (RSP), carried out from 3rd to 14th November 2025, was completed successfully with high precision, stringent coordination, and strict adherence to safety standards. The extensive repair programme covered several critical technological and structural interventions essential for enhancing the sinter plant’s reliability and performance.

Key jobs executed during the shutdown included a comprehensive PLC upgradation to modernize process automation with key support from Instrumentation & Automation Department, PMD liner replacement, and the extension of the palletizing drum shell along with liner replacement in units 45A and 45B. All these tasks required meticulous engineering and planning. The team also replaced the impeller of Main Blower-2 to increase air capacity, renewed multiple material-handling belts, and installed a new cold screen deck plate. Replacement of the sinter breaker unit, cold screen equipment, and renewal of top and bottom beams further strengthened system stability.

Refractory relining was carried out in both furnaces to ensure sustained thermal efficiency. As part of the gas system revamp, 53 meters of 900-mm diameter and 50 meters of 350-mm diameter gas lines were replaced. The ESP emitting electrodes were changed, around 250 meters of pan conveyor rail were renewed, and several leakage points in suction lines were repaired, ensuring smooth and safe plant operations.

The repair activities were completed through the dedicated efforts of SP-1 executives, employees, and the contractor agencies. The jobs were executed in timely manner by the committed SP-I team led by Mr. Shubhrangsu Chakravarty, GM In-Charge (SP-I) under the continuous monitoring and guidance of Mr. Shekhar Narayan, CGM (Sinter).

Commissioned in 1965, SP-1 remains a vital unit of RSP’s sintering operations. With the latest equipment upgrades and automation improvements, SP-1 is now well-positioned for enhanced productivity, improved process control, and greater operational efficiency.