Facilities

Major Units

Ore Bedding and Blending Plant

RSP’s Ore Bedding & Blending Plant (OBBP) has a base mix preparation system with on-ground bedding, blending and conveying facilities.
The facilities in OBBP include major installations like wagon unloading (tipplers & track hoppers), iron ore crushing and screening system, raw material storage yard, rod mills and roll crushers for flux and coke crushing, proportioning bins and elaborate conveying systems.

Coke Oven

RSP has five old and one new coke oven batteries (COBs) that produce coke as the input for blast furnaces. The coke ovens are equipped with wagon tipplers, automatic handling and conveying facilities, coal blending provisions, coke wharfage crushing together with screening and conveying systems

Sintering Plant

The Sinter plants feed sinter to the blast furnaces. The two old Sinter plants have a combined capacity of 3.07 MT per annum, while the new Sinter Plant has a capacity of 3.7 MTPA.

Blast furnaces

The five blast furnaces of RSP, with a combined capacity of 4.5 MTPA, produce hot molten metal for steel production.

Steel Melting Shops
SMS-I

In early sixties SMS-I was commissioned with LD converters and later on a Secondary Steel Making unit and a Continuous Casting unit were added to it. Hot Metal from different Blast Furnaces are transferred to Hot Metal Mixers of SMS-I by locomotives. Using oxygen from Tonnage Oxygen Plants and Lime & Dolomite from LDBP, hot metal is converted to steel. Apart from a computerised LD process which has enhanced shop capability, the LA Vacuum Metallurgy Technique has been also adopted for secondary refining of steel. This facilitates production of special steels for application in electrical machines, pipe making, tin plate, boilers and auto chassis members.

SMS-II

The two old and one new Basic Oxygen Furnaces (150 Tonnes capacity each) make steel from the inputs namely Hot Metal, scrap, Ferro alloys and flux with the help of Oxygen that is blown into them from the top.
The two old and one new Continuous Slab Casters mould the molten Steel and produce Steel Slabs. The shop is equipped with automation through three levels of computerised control, LD gas cleaning and recovery, power distribution system, water and utility services.

Plate Mill

RSP’s old 3.1 meter wide, 4 high reversing mill is equipped with online thickness measurement facilities. The mill has a production capacity of 299,000 tonnes per annum. The 4.3 metre wide New Plate Mill has a capacity to
A New 4.3 Metre Plate Mill, which is one of the widest in the country has been set up to cater to the customised plate market is one of the most important components of this phase of Expansion. The Mill can produce a wide range of plates with close tolerances to meet stringent international standards and heavy and wide plates for the rising ship building and boiler sectors.

Hot Strip Mill

The HSM supplies Hot Rolled Coils as input materials to its downstream customers such as Cold Rolling Mills, Silicon Steel Mill, and Pipe Plants and also to Dividing Line. It also caters to the requirements of external customers. The facilities of the 1.44 MT per annum mill include, Two walking beam type reheating furnace (225 TPH), Roughing/sizing stand RoVo with automation, an Automated coil box, Quick roll change system in Roughing Stand-1 and finishing mills and Coil marking, sampling and conveying systems.

Cold Rolling Mill

Produces about 678,000 tonne of cold rolled sheets per annum, RSP’s Cold Rolling Mill has a 5-stand tandem mill and a 4-high 1700-mm reversing mill. The tandem mill is equipped with automatic gauge control, x-ray gauge, data logging and thyristorisation.

Galvanising Lines

Two continuous hot-dip galvanising lines are equipped with jet-coating facilities. There are 2 multi-roller-corrugating machines as well which produce corrugated sheets.

Silicon Steel Mills

This unit produces steel for the electrical industry through various operations carried out in sophisticated, continuous/semi-continuous processing lines and a 4-high reduction mill. Advanced process control and product testing facilities ensure product quality.

Pipe Plants

A highly sophisticated Spiral Welded (SW) Pipe Plant is equipped with submerged arc welding process and produces large diameter pipes. Hydrostatic pressure testing, ultrasonic testing and eddy current testing are some of the features which ensure quality control.
The Electric Resistance Weld (ERW) Pipe Plant caters to the smaller diameter pipe consumers. This plant has been recently upgraded to enable it to produce API grade pipes.
The 3-LPE Pipe Coating Plant produces value-added pipes by providing 3-layers of Poly Ethylene coating on ERW and SW pipes of Rourkela Pipe Plants. Set up with technical knowhow from M/s Socotherm Spa, Italy, the unit is in strict compliance with the Pollution Control norms as per European standards.

Traffic & Raw Material

The Traffic & Raw Material Department deals with procurement and supply of raw materials to various user departments, internal movement of in-process and other material from one unit to another and despatch of finished products in railway wagons to outside parties or SAIL warehouses.

Environment Management

RSP is progressively adopting state of the art steel making technologies in for producing environment friendly steel. In the recently concluded 4.2 MTPA Expansion Project, RSP has successfully implemented clean technologies like Energy recovery and green power generation through Back Pressure Turbo Generator (6.4 MW) from Coke Dry Quenching facilities of Coke Oven Battery No.6, Energy recovery at top of Blast Furnace No.5 and green power generation (14 MW) through Top Recovery Turbo generator, recovery of BFc gases and its use for power generation (36 MW) in Power Blowing Station, secondary emission control system in BOF convertor#3 with Dog House etc.

Efforts are taken to minimize the pollution at their source of generation. End of pipe line treatments are provided to bring down the pollution levels below acceptable limits. Air Pollution Control technologies like Electro Static Precipitators, Bag Houses, Wet Scrubbers, Multi Cyclones, Dry Fog Dust Suppression Systems, Wet Fog Dust suppression Systems are provided to control air pollution. Dedicated Waste Water Treatment Plants (WWTPs) are provided in different departments for treating the effluent before recycling back to process leaving very little quantity as blow down to drain for further treatment at a polishing pond called Lagoon.

On renewable energy front, RSP has installed and commissioned 1 MW Solar Power Plant inside steel plant premises and installed Solar Water Heating Systems of 40,000 lit capacity in Ispat General Hospital of RSP. On greenery, RSP has established a green canopy by planting around 44.5 lakh trees since inception.

RSP has established a full-fledged Environmental Engg. Department, way back in 1989, along with Environment Laboratory which is certified with IS/ISO14001. RSP has adopted 4R (Reduce, Reuse, Recover & Recycle) principle for enhancing the utilization of solid wastes. With the dedicated efforts of RSP collective the pollutant levels have shown reduction.

The pollutant levels monitored during Apr.-Sept., 2017 are;

SN.

Environmental Indicator

Description

2015-16

2016-17

2017-18(Apr.- Sept.)

Norm/Target

1.

Ambient air quality (Levels monitored at 6 stations)

  • PM10(µg/m3)
  • Sulphur di Oxide(µg/m3)
  • Oxides of Nitrogen(µg/m3)
  • Ammonia(µg/m3)
  • Lead(µg/m3)

33 – 89
16 – 77
24 – 79
9.2 – 26.8
0.03 – 0.24

41 - 88
30 - 74
32  -  78
9.8 – 19.7
0 02 – 0.17

35 – 88
23 – 76
23 – 78
8.3 – 17.5
0.02 – 0.16

100
80
80
400
1.0

2.

Specific Dust Load on Environment

  • Cumulative dust load coming from different stacks(kg/TCS)

0.945

0.900

0.820

0.860

3.

Quality of finally  treated effluent discharged from Lagoon into  river Brahmani

  • pH
  • Suspended Solids(mg/lit)
  • Oil & Grease(mg/lit)
  • BOD3(mg/lit)
  • COD(mg/lit)

7.30 – 8.10
19 – 55
2 – 5
7 – 11
32– 85

7.10 – 7.85
13 - 55
2.75 – 4.75
7 - 9
23 - 36

7.37 – 7.90
23 – 38
3.3 – 4.00
8 – 9
31 – 39

6 – 8.5
100
10
30
250

4.

Total Solid Waste Utilization

  •  %

94.83

85.21

74.30

85%

RSP’s implementation status of action plan for Environment Clearance received for 4.2 MTPA Expansion (Half Yearly Report : Apr. – Sept., 2017)

Environment Clearance received for New HSM & Other projects, dated 15/12/2016

RSP’s Action Plan (04/04/2017) to comply with Special and General Conditions mentioned in EC dated 15-12-2016

Environment Statement

Computerisation

The Integrated Go-Live of the ERP system was carried out at RSP on 1st April 2012. The ERP system integrates all departments and functions across the organisation right from production and finance to dispatch.

Quality Management

Total Quality Management (TQM) that was adopted in RSP since January 1992 today forms the core of all our business strategies. Today the entire works zone as well as Personnel, Steel Township and Finance Department have been certified to ISO 9001: 2008 QMS.
Silicon Steel Mill and Environmental Engineering Department were the first departments to be certified with ISO 14001 Environment Management System (EMS) in the year 2000. Subsequently, SP-II, HSM, PM, SWPP, ERWPP, SPP and Steel Township were certified to ISO 14001:2004 EMS. RSP’s Steel Township is the first Township of SAIL to be certified for both ISO 9001 QMS and ISO 14001 EMS.
Entire RSP has been certified to internationally acclaimed Occupational Health & Safety Assessment Series (OHSAS 18001: 2007).
In order to have synergy and synchronization in implementation of various management systems, concept of Integrated Management System (IMS) has been initiated in RSP. An IMS Policy covering Quality, Environment, Occupational Health & Safety and Social Accountability of RSP has been introduced. RSP is the first unit in SAIL to adopt IMS policy.

Human Resource Development (HRD)

The Human Resources Development Centre (HRDC) of Rourkela Steel Plant was set up in the late 1950s. It consists of a Management Development Programme wing, auditoriums, well-equipped workshops, skill upgradation shops, lecture halls for apprentices and a well-equipped library on a plethora of technical and managerial subjects. The HRDC has received ISO 9001:2000 QMS certification.

Central Power Training Institute (CPTI)

RSP’s Central Power Training Institute (CPTI) is a CEA-certified category-1 institute that meets the statutory training needs of power engineers of SAIL. Certified with ISO 9001:2000 QMS, CPTI conducts training largely for operation and maintenance personnel of SAIL’s captive power plants and Power Distribution Network departments

Products

PRODUCT-MIX

TONNES/ANNUM

Plate Mill Plates

2,99,000 from old Plate Mill
10,00,000 from New Plate Mill

HR Plates

92,500

HR Coils

3,98,000

ERW Pipes

75,000

SW Pipes

55,000

CR Sheets & Coils

4,33,000

Galvanized Sheets (GP& GC)

1,60,000

Silicon Steel Sheets

73,500

 

 

Products

Applications

HR Coils

LPG cylinders, automobile, railway wagon chasis and all types of high strength needs.

Plates

Pressure vessels, ship building and engineering structures

Chequered Plates

Flooring & staircases in the industrial installations, railway platforms, etc.

Special Plates

Defence applications

CR Sheets & Coils

Steel furniture, white goods like refrigerators, washing machines, automobile bodies, railway coach panelling, drums, barrels, deep drawing and extra deep drawing, etc.

Galvanised Sheets

Roofing, panelling, industrial sheeting, air conditioner ducting and structural

Silicon Steel sheets & Coils

Small generators, stators for high efficiency rotating equipment and relays, etc.

Spiral Weld pipes

High pressure transportation of crude oil, natural gas and slurry transportation, water supply, sewage disposals, grain silos, civil engineering pilings, etc.

ERW Pipes

High pressure transportation of oil & water, sewage disposal, tube wells, etc.

Captive Power Plant #1

Captive Power Plant#1 was established in 1959 inside the premises of Rourkela Steel Plant with a main objective to generate captive power to meet the emergency requirements of Rourkela Steel Plant as well as supply of air to Blast Furnaces.  Medium Pressure Boilers were added during 1978 to meet the factory steam requirements of RSP.  Boiler coal is used along with BFc gas & Mixed gas for running the Turbo Alternators and Turbo Blowers in CPP#1.

During the  recently concluded Expansion Project, Power Blowing Station was added for gainful utilisation of BFc gas generated from Blast Furnace No.5.  As an environment friendly measure,  Top Recovery Turbo Generator was installed for generating power through  gainful utilization of high pressure generated from top of the Blast Furnace. Green Power is  being generated  through  Back Pressure Turbo Generator  by gainful utilistion of latent heat generated from dry quenching operations of Coke Oven Battery No. 6.

Good quality boiler coal is sparingly used in Captive Power Plant#1. The dry fly ash generated from the boilers is being given to Fly ash users free of cost. The availability of dry Fly ash from CPP#1 is given below;

The availability of dry Fly ash from CPP#1 (in Tonnes) is given below:

Stock as on

Fly Ash

Bottom Ash

Total Ash

01/06/2017

40 Tons

30 Tons

70 Tons

Community

Caring, Sharing and Spreading Smiles
Rourkela Steel Plant has imbibed a credo to make quality steel and spread lasting smiles amongst the people living in its neighbourhood. Going beyond the realms of philanthropy or charity, RSP has adopted a strategy of ushering in sustainable development in its peripheral villages. From education to women's empowerment, providing healthcare facilities to improving infrastructure, promoting advanced techniques of agriculture to skill enhancement, land and water management to livestock development – the multifaceted approach of RSP aims at touching and shaping every aspect of life and living of its community neighbours.
Taking a unique step forward, the plant has set up the Institute for Periphery Development that is functioning as the nerve centre of all the activities taken up under periphery development. Villagers from nearby areas are being trained in various income generation activities in this institute.
Adoption of 16 villages as Model Steel Villages is another significant stride taken up by RSP to create sustainable models of economic development.
One of the major focus areas of RSP’s CSR initiatives in educating and empowering rural women. As a part of this Project Kishori is playing a key role. Women Resource centres have been established in 50 villages to enhance the knowledge and skill of the women and ignite the spirit of entrepreneurship amongst them. A Handloom centre has been set up at Deepika Mahila Jagriti Sansthan in the heart of the Steel City. Women from various peripheral villages are being provided with training in handloom production and inputs pertaining to making it a source of income. A Sanitary napkin production centre and a Phenyl making unit are also being operated by the women in the same complex.
Partners in Progress
Rourkela Steel Plant has always considered the small scale industries (SSI) operating in its neighbourhood as its partners in progress. An exclusive wing – Peripheral Industries and Vendor Development (PIVD) – has been set up in RSP under its Materials Management Department for catering to the development needs of local SSI units.
Scenic Steel Township
Rourkela, the largest industrial town of Odisha is situated at an altitude of 219 metres above the sea level. The picturesque steel city of Rourkela is a connoisseur’s delight and a nature lover's dream come true. With a hill range girdling the city and number of parks and gardens, Rourkela presents a visage of greenery that will be the envy of many a garden city.
Rourkela’s Steel Township is a modern industrial habitation characterised by extensive green coverage and aesthetic installations. Efforts to beautify the township and upgrade its facilities never cease here. A number of artistically crafted monuments not only add significant grace to the sylvan landscape of the township but also showcase the innovative usage of steel for creating objects of art. The Indira Gandhi Park in the heart of the steel city is another effort made to highlight nature in all its glory and grandeur, and a musical fountain enthralling visitors. A zoo in the park is the second biggest of its kind in the state and is home for a diverse variety of animals and birds. The splendour of the sylvan and scenic Steel City of Rourkela has been further enhanced with the inauguration of the picturesque Ispat Nehru Park. The park boasts of a boating facility an XD Theatre as well as several other attractive features.
Creating a Healthy Environment
Rourkela Steel Plant’s concern for a healthy environment is symbolised by its wide network of Medical & Health Services. Ispat General Hospital (IGH), a 685-bed hospital run by RSP for its employees is a premier medical centre in the eastern region. The hospital has several exclusive facilities like a state-of-the-art Trauma Centre, Burn Centre, Blood Transfusion Centre, Intensive Care, Dialysis Unit, Nuclear Medicine, MRI Scan, Cardiac Clinic, CT Scan, Thyroid Clinic, Bio-Medical Waste Management System, etc. The hospital has a WHO-recognised Malaria Research Centre. It also has the distinction of imparting postgraduate DNB training in 9 disciplines.
Sports Hub
RSP strongly believes that one of the most fruitful investments that can be made in the present generation is in the field of sports. The Biju Patnaik Hockey Stadium in Rourkela is a full-fledged hockey stadium equipped with a state-of-the-art synthetic turf. The Steel Plant also runs the SAIL Hockey Academy (SHA) that is identifying and providing extensive training to the budding Hockey players of the region free of cost. The Academy has produced many nationally and internationally acclaimed Hockey players.
The huge Ispat stadium and a number of game specific facilities have played a key role in honing the talents of the youngsters. An Ispat Dhanurvidya Centre has been set up in the year 2015 to hone the intrinsic talents of the local youngsters in this game. Besides, the Steel Plant also maintains a number of other facilities like Ispat Indoor stadium, Ispat basketball complex, Ispat Chess Hall etc that promote sports and games in a big way amongst the youth. The Sports Department of Rourkela Steel Plant conducts several national, regional, steel plant, district and even school-level tournaments to impart a fresh impetus to sporting activities and make Rourkela a sporting hub.

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