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provisions of companies act 2013 sd projects for sail 2015 16 citizen s charter careers there s a little bit of sail in everybody s life home plants and units rourkela steel plant about rourkela steel plantprint about rourkela steel plant link type none rourkela steel plant rsp the first integrated steel plant in the public sector in india was set up with german collaboration with an installed capacity of 1 million tonnes . subsequently its capacity was enhanced to 2 million tonnes of hot metal 1.9 million tonnes of crude steel and 1.67 million tonnes of saleable steel . after implementing a massive modernisation and expansion rourkela steel plant has enhanced its capacity to 4.5 million tonnes of hot metal and 4.2 million tonnes of crude steel . production capacity in million tonnes per annum pre expansion post expansion hot metal 2 4.5 crude steel 1.9 4.2 saleable steel 1.67 3.9 rsp was the first plant in india to incorporate ld technology of steel making . it is also the first steel plant in sail and the only one presently where 100 % of slabs are produced through the cost effective and quality centric continuous casting route . it is sail s only plant that produce silicon steels for the power sector and high quality pipes for the oil & gas sector . . its wide and sophisticated product range includes various flat tubular and coated products . details of modernisation and expansion of rsp please click link for details modernisation and expansion of rourkela steel plant rourkela steel plant has completed a massive modernization and expansion programme that is truly historic . with this the steel plant has doubled its capacity and augmented it to the level of 4.5 mtpa million tonne per annum of hot metal from the previous level of 2 mtpa . the crude steel making capacity has simultaneously increased from the level of 1.9 mtpa to 4.2 mtpa and production of saleable steel is all set to zoom from the level of 1.671 mtpa to 3.99 mtpa . it is worth mentioning here that apart from increasing the volume the other benefits envisaged from this phase of modernisation and expansion are increased economy of scale enlarged customer base enhanced quality reduced cost of production better market compatibility improved labour productivity stricter adherence to environment norms and superior techno economics . some key new units are raw material handling facilities post expansion the new raw material requirement of rsp has to go upto about 12 mtpa from the previous requirement of 5 mtpa . the augmentation facilities that have been added include receiving unloading reclaiming and finally transporting of raw materials required for blast furnce 5 base mix preparation for the new sintering complex transportation of flue dust mill scale etc. transportation of crushed fuel and flux for trimming addition to the new sinter unit conveyor line for transportation of calcining plant grade limestone and dolomite to consuming units automatic sampling system facilities equipment in new obbp unloading wagon tippler 1 no . track hopper 1 no . stacking & reclaiming 4 no of beds to stack the incoming raw materials 2 no . of beds for base mix equipments in the beds twin boom stacker 2 no . stacker cum reclaimer 1 no . barrel reclaimer 4 nos . bucket wheel reclaimer 1 no . other equipments flux crushers 8 nos . coke crushers 12 nos coke oven battery 6 the battery is top charged compound twin flue under jet regenerative heating with partial recirculation of waste gases . the 7 metre tall battery of 67 ovens has been installed to produce run of oven coke dry of 0.768 mt year . the computerized heating control system cohc has been installed for the battery operation for the process management system to improve reduction in environmental emission improve coke quality & productivity . a coal tower of 4000 ton useful capacity for storing coal leak proof doors water sealed ap covers hpla high pressure ammonical liquor aspiration door & frame cleaner high pressure water jet door cleaner land based pushing emission control pec system and effluent disposal and coke dry cooling plant cdcp have been provided for efficient environment management . some important components of the package are new coke dry cooling plant the principle of coke dry quenching is based on cooling of hot coke with inert gas circulating in close loop between the chamber of hot coke and the waste heat boiler . apart from ensuring environment friendly operation the cdcp is also designed to enhance the coke quality . technological parameters features of cdcp temperature of coke charged in the chamber 1050 c temperature of coke after cooling 200 c time of coke cooling in chamber 2.0 2.5 hr . temp . of circulating gas before cooling chamber 170 180 c temp . of circulating gas before waste heat boiler 750 800 c pressure of steam generated 66 ata temperature of steam generated 500 c generation of steam boiler 25 ton hr new coal handling plant the new coal handling plant can hold 15 days stock of coking coal for cob 6 3500 t day and cdi coal of 10 days stock 1500 t day . there are 24 nos . of rcc silos for stocking of coking coal and for cdi coal 6 nos of rcc silos each of capacity 2500 tons . new coal chemical department the new ccd has been installed to process coke oven gas generated from the new coke oven battery 6 . this cleans the raw coke oven gas by removing tar ammonia hydrogen sulphur sulphide and naphthalene . the coke oven gas is being cooled finally to 3000 c at the outlet of final gas cooler . there are naphthalene washer and benzole scrubber to have clean coke oven gas for use of the plant . sintering unit 3 the new single strand sinter unit has an effective suction area of 360 m and an annual production capacity of 3.70 mt of gross sinter with sinter productivity of 1.3 t m hr . the output stack emission is less than 50 mg nm by making the unit an environment friendly unit . the sintering unit is being provided with eirich type mixer and noduliser instead of the conventional mixing & balling drum . a circular cooler has been installed for sinter cooling . another new feature is pneumatic conveying of esp dust as a part of which the esp dust will be charged to the sinter raw mix bed after passing through an eirich type granulator . the eirich type mixer noduliser & granulator have been installed for the first time in sail plants . technical details of sp 3 sintering area 360 sq meter spec . productivity 1.3 t m hr under grate suction 1650 mmwc circular annular dip rail deep bed type sinter cooler 396 sq meter tumbler index 6.3 mm 75 % min . rdi 30 % max rated capacity of incoming raw material 1500 tph rated capacity of outgoing sinter 550 tph blast furnace 5 one of the biggest blast furnaces of the country the new blast furnace 5 with a useful volume of 4060 cubic metres is designed for a production capacity of 2.8 mtpa with a daily hot metal production of 7924 t avg . . the furnace operates at high intensification level and for a campaign life of 20 years . equipped with modern features such as pulverized coal injection system cast house fume extraction system cast house slag granulation system top gas recovery turbines of 14 mw capacity twin material bin blt system waste heat recovery system plate stave coolers and conveyor belt charging system this blast furnace has level ii automation . item unit values working volume m 3470 useful volume m 4060 hearth diameter m 13.2 no . of tuyers number 36 coke rate incl . 20 kg nut coke 8 34 mm kg thm 360 coal dust cdi coal kg thm 150 avg . ; 200 design blast volume n m min 6125 blast temperature oc 1200 oc avg . ; 1250 oc max blast oxygen enrichment % 4 6 bf top gas volume net & dry n m thm 1500 1550 bf top pressure kg c m g 2.5 max . slag rate kg thm 290 310 technical details and operating parameters of bf 5 the furnace has twin flat cast house with four tap holes . auxiliaries of bf 5 turbo blower station the 3 turbo blowers along with its all auxiliaries provides cold blast to the stoves of new bf 5 . boiler stg bptg & blowing station the unit comprising 3 boiler arrangements 2 steam turbo generators and 1 back pressure turbo generator generates power as well as cold blast to feed the blast furnace and the stoves . torpedo ladles & repair shop the 10 torpedo ladles with features like higher capacity and lesser scope of hot metal temperature loss are being used for transferring hot metal from the new blast furnace 5 to steel melting shop or pig casting machine . it is noteworthy that these torpedoes are being used for the first time in sail . the torpedo ladle repair shop handles jobs like refractory lining ladle inspection ladle heating and cooling . pig casting machine the twin strand 1500 tpd capacity pig casting machine has average strand speed 9 m min . augmentation of sms ii 3rd bof converter 1 x 150 t the new top blown basic oxygen furnace 3rd converter of sms ii of capacity 1.584 mt liquid steel per year is designed with provision for adoption of combined oxygen blowing from top and inert gas stirring with argon and nitrogen from bottom . the new rhob is also a first time feature of rsp that helps in producing higher strength and high quality special grade steel major design features of 3rd bof converter nominal heat size 150 t maximum heat size 165 t working volume with new lining 165 m3 tap to tap time 45 min . oxygen flow rate 500 nm3 min . avg . tilting angle 3600 tilting speed 0.1 1.0 rpm number of heats per day 32 avg . slab caster 3 conventional 1 x 1 strand with a capacity to produce slabs with width upto 2500 mm which makes it one of the widest in the country the main objective of the new slab caster 3 is to make slabs for the 4.3 metre wide new plate mill . it can handle slab tonnage up to 30 tonnes while the old casters have the capacity of 16 to17 tonnes . built with latest design and state of the art technology the caster is equipped with modern features such as ladle to tundish slag detection system vertical high speed mould with automatic width adjustment hydraulic mould oscillator automatic mould level controller break out prediction system air mist spray cooling system dynamic spray cooling system continuous straightening automatic torch cutting machine slab pusher cum piler arrangement transverse torch cutting machines and computerized process control system level ii to name a few . new plate mill the new 4.3 metre wide plate mill has