Rourkela steel plant set to enter new era

 Rourkela Steel Plant (RSP) is all set to enter a new era of productivity, profitability and quality as the Board of Steel Authority of India Limited (Sail) has formally given approval in principle to a proposal for its modernisation and capacity expansion at an indicative cost of Rs 9,869 crore.
The objectives of expansion include increase in production of crude steel through state-of-the-art technology in order to meet the productivity level of international standards, improvement in quality of products, reduction in energy consumption, cut in cost of production and thereby increase in net sales realisation.
As per the approval, the hot metal production capacity of the steel plant will soar to 4.5 million tons per annum (MTPA). The massive modernisation programme of RSP includes setting up of a fifth blast furnace with working volume of 4,060 cubic meters and productivity of 2.3 tons per meter cube per day. This apart, blast furnace-1 will be reconstructed and upgraded to 1,250 meter cube useful volume with high top pressure and coal dust injection facilities, while in blast furnace-4, coal dust injection system will be incorporated, thereby more than doubling the present hot metal capacity of the plant.
In order to augment the steel producing capacity, RSP is going to install a new 150 ton converter and a new caster in its SMS-II. New RH-OB unit will be introduced in SMS-II to produce clean steel such as ultra low carbon steels. Two new matching ladle heating furnaces (LHF) are also on the cards, which will take the number of LHFs to three. One of the existing casters will also be upgraded. These augmentation measures will take the total crude steel capacity of RSP to the level of 4.2 MTPA.
In view of the increasing demand for high end products, the RSP will be going in for a new plate mill with a capacity of 1.8 MTPA that will roll out different grades of plates up to the width of 4,200 MM meeting the stringent specific customer requirements. In order to further improve the quality of hot rolled strips, the finishing mill train of HSM will be modernised to meet the customers’ requirement and to improve the operation and quality of downstream units.
An entirely new mill to produce 1,80,000 tons of CRNO steel will be coming up under this modernisation package, taking the total capacity of this superior grade steel to 2.55 lakh tons per annum.                                                                   



Tata Ryerson (TRyL) is in the business of steel processing and distribution and produces hot and cold rolled coils, strips, plates, sheets, blanks and structural. With the Ryerson plant in Mexico demonstrating the advantages of SAP’s ERP package, the selection of mySAP ERP at TRyL was a natural choice and Tata Technologies took on the responsibility of being the implementation partner. On one side transaction volumes were resulting in increased throughout putting pressure on the current hardware infrastructure that could not scale and the issue of an upgrade came up. Says C S Murthy, chief of Information management, TRyL, “With ERP, from the IT perspective, we do not need to know anything about the underlying operating system or database; we do not need experts because SAP provides all the support that we need—the warning signs, any drops in production and any other points that we need to address.”

TRyL adds substantial value to the material supplied by Tata Steel before it is dispatched to the customer. The ERP system shares all the information about material and customers online. For instance, the credit control limits of different customers can be checked before material is dispatched. Details of materials billed and shipments are shared from Tata Steel’s SAP system to TRyL’s. The implementation also made it possible for the company to change its production cycle as per customer requirements at any given time, altering its own production to suit their needs. This has translated into improved customer service and quality control.


Hardened and Tempered Steel Strip

Hardening and Tempering is a thermal process that strengthens steel through a controlled heating and cooling process Hardened and tempered steel strip, is used in many applications including saws, cutting tools as well as springs.

This process will result in improved mechanical properties and give a tougher more durable product. The hardening process involves heating the steel to above the critical transformation temperature for the given grade and then rapidly cooling. Whilst this process achieves the highest mechanical strengths and hardness’s, steel in this condition is extremely brittle and therefore requires further treatment in the form of tempering. This consists of reheating the steel to a lower temperature and holding the steel at the given temperature for a given period of time. As with traditional annealing (used to soften steels) this process is conducted in an inert atmosphere to avoid oxidation.

Weak dollars effecting steel exports

Dollars have highly depreciated in the past one year. From 46/- to 41/- in a matter of 12 months, has effected the exports a lot. This has drastically effected the steel exports.China is getting a huge benefit of this despite their poor quality.

In the present scenario, the import of steel is much more viable. From China small coils of 1000 kgs approx. can be bought at USD 545 per mt,CIF Kolkata Port.Thus the cost comes around 29000/- per MT after taking into consideration all the government levies. Whereas in India, prices of HR Coils are 27500/- basic.

It seems the balance of trade in steel will once again face a drastic change in the future .