SAIL Rourkela steel plant

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SAIL Rourkela steel plant, also known as RSP, is a steel plant in Rourkela, Sundargarh, Odisha, India that operates blast furnace (BF) and basic oxygen furnace (BOF) technology.

Location

The map below shows the exact location of the plant in Rourkela, Sundargarh, Odisha, India:

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  • Location: Rourkela Steel Plant Area, Rourkela, Odisha 769011, India
  • Coordinates (WGS 84): 22.210804, 84.86895 (exact)

Background

SAIL has Maharatna CPSE (Central Public Sector Enterprise) status by the Government of India under the Ministry of Steel.[1] Air quality monitoring information provided on the SAIL website here.

Rourkela Steel plant is the first integrated steel plant in the public sector in India. It was set up with German collaboration with an installed capacity of 1 mtpa. The first blast furnace of the plant became operational on 03 February 1959. After subsequent phases of expansion the plant reached a hot metal capacity of 4.5 mtpa and crude steel capacity of 4.2 mtpa.[2] Under SAIL's Vision 2030 programme, the company plans to raise the plant's capacity to 8.8 mtpa.[3]

Expansion plans

On 30 March 2022, SAIL received environmental clearance for expansion of hot metal production capacity from 4.5 mtpa to 4.855 mtpa and crude steel production from 4.2 mtpa to 4.85 mtpa. This expansion involves installation of coke oven battery, a third steel meting shop, decommissionin gof two existing BOFs and augmentation of existing blast furnaces in addition to other auxiliary developments.[4]

As of May 2023, the project was indefinitely deferred owing to illegal encroachments and failure to rehabilitate the settlers.[5] In August 2024, Ministry of Steel announced that the capacity of the Rourkela Steel Plant will soon be enhanced to 9 mtpa from 4.5 mtpa.[6] The expansion will cost an estimated INR 30,000 crores.[7]

Decarbonization initiatives

In FY 2024-25, a waste heat recovery system was installed in BF-5 Stoves resulting in increase of Hot Blast Temperature by around 400°C, thereby leading to reduction in Coke rate by about 4 kg/thm.[8]

Primetals Technologies and RSP are collaborating on several initiatives, including, hydrogen-based steel production, digitalization, gas treatment, and CCUS.[8]

Ownership Tree

This ownership tree is part of the Global Energy Ownership Tracker, a project of Global Energy Monitor.

Low-emissions/green steelmaking

This steel plant is associated with a green steel project tracked in the Green Steel Tracker. Details about the project are included below.

Table 1: Green Steel Project Details

All references for the above data are available in the Green Steel Tracker.
Project 1
Project name SAIL Biochar Plant Odisha
Company Steel Authority of India Ltd. (SAIL)
Company has climate goals? Yes
Location Odisha, India
Project website Not available
Project scale Pilot
Project status Announced
Technology to be used Biomass for BF-BOF
Technology details Pyrolysis
Iron production capacity (million tonnes per year) Not stated
Steel production capacity (million tonnes per year) Not stated
CO2 capture (million tonnes CO2 per year) Not applicable
Hydrogen generation capacity (MW) Not applicable
Investment size (m USD) Not stated
Partners BHP
Date of announcement 8/29/2024

Plant Details

Table 2: General Plant Details

Announced date Start date Workforce size Power source Iron ore source Coal source
1953[9] 1959[10] 12938[11] Captive power plant #1 (1959, updated 1978), Rourkela Works-2 power station[12][13] SAIL Barsua Mine (P100000128517); SAIL Bolani Mine (P100000128461); SAIL Kalta Mine (P100000128480); SAIL Taldih Mine (P100000128525)[14] domestic[15]

Table 3: Ownership and Parent Company Information

State-owned entity status Parent company Parent company PermID Parent GEM entity ID Owner Owner company PermID Owner GEM entity ID
Partial Steel Authority of India Ltd [100.0%] 4295872623 [100.0%] E100001000703 [100.0%] Steel Authority of India Ltd [100%][16] 4295872623 E100001000703 [100%]

Table 4: Process and Products

Steel product category Steel products Steel sector end users ISO 14001 ISO 50001 Main production equipment
semi-finished, finished rolled[17] pipe, coil, sheet, plate[17] automotive, building and infrastructure, energy, steel packaging, tools and machinery, transport[17] yes[18] yes[19][9] BF; BOF

Table 5: Plant-level Crude Steel Production Capacities (thousand tonnes per annum)

1Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Capacity operating status1 Basic oxygen furnace steelmaking capacity Nominal crude steel capacity (total)
announced 6012[20][21] 6012[20][21]
operating 3282[22][23] 3282[22][23]
operating pre-retirement 918[22][23] 918[22][23]

Table 6: Plant-level Crude Iron Production Capacities (thousand tonnes per annum)

1Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Capacity operating status1 Blast furnace capacity Nominal iron capacity (total)
announced 6000[20][21] 6000[20][21]
operating 4500[24][25][26] 4500[24][25][26]

Table 7: Upstream Products Production Capacities (thousand tonnes per annum)

Sinter Coke Pellets
6776[12] 768[23] 2000[21]

Table 8: Actual Plant-level Crude Steel Production by Year (thousand tonnes per annum)

Year BOF production Total (all routes)
2019 3444[27] 3444[27]
2020 3500[28] 3500[28]
2021 3989[29] 3989[29]
2022 4039[29] 4039[29]
2023 4160[30] 4160[30]
2024 4040[31] 4040[31]

Table 9: Actual Plant-level Crude Iron Production by Year (thousand tonnes per annum)

Year BF production Total (all routes)
2019 3626[32] 3626[32]
2020 3455[32] 3455[32]
2021 4340[33] 4340[33]
2022 4040[34] 4040[34]
2023 4490[30] 4490[30]
2024 4340[31] 4340[31]

Unit Details

Table 10: Blast Furnace Details

Unit name Status Announced date Start date Furnace manufacturer and model Current size Current capacity (ttpa) Decarbonization technology Most recent relining
BF 1 operating[26] 1953[9] 1959[35][26] Danieli Corus[26] 1491.0[36][37] 1059[26] In Feb 2024, SAIL signed an MoU with Primetals to collaborate on projects and technologies related to decarbonization at the plant including but not limited to carbon capture and utilization (CCU), digitalization, hydrogen-based steel production, electric steelmaking, and advanced gas-cleaning solutions.; biochar trialed in 2024[38][39] 2018-05-08[40]
BF 4 operating[41] – 1967[42] – 1658.0[42] 641[24][25] unknown 2020-09-09[43]
BF 5 operating[44] 2008[45] 2013[46][26] Danieli Corus; Tata Projects Limited; MECON Hoogoven[44][47][48][26][44] 4060.0[49][44][48] 2800[26] unknown –
unknown BF (1) announced[50] – 2030[51] – – 6000[21][20] unknown –

Table 11: Basic Oxygen Furnace Details

Unit name Status Announced date Start date Furnace manufacturer and model Current capacity (ttpa) Current size
unknown BOF (1) operating[24] – 1996[52] LD Converter[52] 1094[22][23] 150.0 tonnes[53]
unknown BOF (2) operating[24] – 1996[52] LD Converter[52] 1094[22][23] 150.0 tonnes[53]
unknown BOF (3) operating[24] – 2014[54] Mecon Limited LD Converter[54][52] 1094[22][23] 150.0 tonnes[53]
unknown BOF (4) announced[55] 2020[51] 2030[51] – 4800[20] –[56][57][58]
unknown BOF (5) operating pre-retirement[21] – – – 481[22][23] 66.0 tonnes[53]
unknown BOF (6) operating pre-retirement[21] – – – 437[22][23] 60.0 tonnes[53]
unknown BOF (7) announced[21] 2021[21] – – 1212[21] 150.0 tonnes[21]

Articles and Resources

Additional data

To access additional data, including an interactive map of steel plants, a downloadable dataset, and summary data, please visit the Global Iron and Steel Tracker on the Global Energy Monitor website.

References

  1. ↑ Steel Authority of India Limited, Steel Authority of India Limited, Retrieved on: May 19, 2020
  2. ↑ "Rourkela Steel Plant | SAIL". sail.co.in. Retrieved 2023-10-11.
  3. ↑ "SAIL proposes to increase capacity to 49.6 mtpa by 2030 | The Financial Express". www.financialexpress.com. Retrieved 2023-10-11.
  4. ↑ "Grant of Environmental Clearance (EC) to the proposed Project Activity under the provision of EIA Notification 2006-regarding" (PDF). SAIL. 30 March 2022. Retrieved 06 November, 2023. {{cite web}}: Check date values in: |access-date= (help)CS1 maint: url-status (link)
  5. ↑ "SAIL defers expansion project for Rourkela mill until land is cleared". www.steelorbis.com. Retrieved 2023-11-06.
  6. ↑ "SAIL's Rourkela steel mill capacity to be expanded to 9 million mt per year". www.steelorbis.com. Retrieved 2025-01-23.
  7. ↑ "SAIL to scale up Rourkela Steel Plant capacity to 9 MT by 2030 at Rs 30,000 crore investment". The Economic Times. Retrieved 2025-10-16.
  8. ↑ 8.0 8.1 "Annual report 2024-25" (PDF). SAIL. 2025-08-25. Retrieved 2025-10-16.{{cite web}}: CS1 maint: url-status (link)
  9. ↑ 9.0 9.1 9.2 (PDF) https://qcin.org/public/uploads/ck-docs/1612535905.QCI_Magazine%20(Oct-Dec%202020).pdf. {{cite web}}: Missing or empty |title= (help)
  10. ↑ https://web.archive.org/web/20221018101223/https://en.wikipedia.org/wiki/Rourkela_Steel_Plant. Archived from the original on 2022-10-18. {{cite web}}: Missing or empty |title= (help)
  11. ↑ (PDF) https://www.sail.co.in/sites/default/files/2024-04/Sail%20Sustinability%20Report%202022-23.pdf. {{cite web}}: Missing or empty |title= (help)
  12. ↑ 12.0 12.1 https://web.archive.org/web/20200928010907/https://sail.co.in/rourkela-steel-plant/facilities. Archived from the original on 2020-09-28. {{cite web}}: Missing or empty |title= (help)
  13. ↑ https://web.archive.org/web/20210805091321/https://www.gem.wiki/Rourkela_Works-2_power_station. Archived from the original on 2021-08-05. {{cite web}}: Missing or empty |title= (help)
  14. ↑ https://web.archive.org/web/20231011114855/https://www.sail.co.in/plants/about-rourkela-steel-plant. Archived from the original on 2023-10-11. {{cite web}}: Missing or empty |title= (help)
  15. ↑ (PDF) https://environmentclearance.nic.in/writereaddata/Online/TOR/07_Nov_2019_1602038274GKO9G9QAnnexure-Briefsummaryofproject.pdf. {{cite web}}: Missing or empty |title= (help)
  16. ↑ https://web.archive.org/web/20220119143642/https://www.qcc.com/firm/dd1f8d7003b654e308bf075d383f6051.html. Archived from the original on 2022-01-19. {{cite web}}: Missing or empty |title= (help)
  17. ↑ 17.0 17.1 17.2 https://web.archive.org/web/20220204135619/https://sail.co.in/rourkela-steel-plant/products. Archived from the original on 2022-02-04. {{cite web}}: Missing or empty |title= (help)
  18. ↑ https://www.sail.co.in/en/plants/environment-management-division. {{cite web}}: Missing or empty |title= (help)
  19. ↑ https://www.linkedin.com/posts/sail-rourkela-steel-plant-502594284_33rd-national-energy-conservation-day-observed-activity-7141036969702195200-HGGv/. {{cite web}}: Missing or empty |title= (help)
  20. ↑ 20.0 20.1 20.2 20.3 20.4 20.5 https://web.archive.org/web/20220613185320/https://www.newindianexpress.com/states/odisha/2022/may/28/rsp-plans-double-expansion-as-land-hurdles-remain-to-be-solved-2458987.html. Archived from the original on 2022-06-13. {{cite web}}: Missing or empty |title= (help)
  21. ↑ 21.00 21.01 21.02 21.03 21.04 21.05 21.06 21.07 21.08 21.09 21.10 21.11 (PDF) https://web.archive.org/web/20230518232028/https://sail.co.in/sites/default/files/steel-plants/2022-04/Env-Clearance-issued-by-MoEFCC-30-03-2022.pdf. Archived from the original (PDF) on 2023-05-18. {{cite web}}: Missing or empty |title= (help)
  22. ↑ 22.0 22.1 22.2 22.3 22.4 22.5 22.6 22.7 22.8 (PDF) https://web.archive.org/web/20220108035637/https://www.teriin.org/sites/default/files/2020-03/Towards%20a%20Low%20Carbon%20Steel%20Sector%20Report.pdf. Archived from the original (PDF) on 2022-01-08. {{cite web}}: Missing or empty |title= (help)
  23. ↑ 23.00 23.01 23.02 23.03 23.04 23.05 23.06 23.07 23.08 23.09 https://web.archive.org/web/20211118113620/https://sail.co.in/en/plants/about-rourkela-steel-plant. Archived from the original on 2021-11-18. {{cite web}}: Missing or empty |title= (help)
  24. ↑ 24.0 24.1 24.2 24.3 24.4 24.5 https://web.archive.org/web/20220327143934/http://www.sail.co.in/rourkela-steel-plant/about-rourkela-steel-plant. Archived from the original on 2022-03-27. {{cite web}}: Missing or empty |title= (help)
  25. ↑ 25.0 25.1 25.2 (PDF) https://sail.co.in/sites/default/files/upload/2022-11/9_EC%20for%20%20RSP%204.2%20MTPA%2029-01-2008%20with%20clarifications%20and%20extension.pdf. {{cite web}}: Missing or empty |title= (help)
  26. ↑ 26.0 26.1 26.2 26.3 26.4 26.5 26.6 26.7 26.8 https://web.archive.org/web/20221111193631/https://www.steel-360.com/technology-next/innovation-is-at-core-of-rsps-expansion. Archived from the original on 2022-11-11. {{cite web}}: Missing or empty |title= (help)
  27. ↑ 27.0 27.1 (PDF) https://web.archive.org/web/20211117141829/https://steel.gov.in/sites/default/files/MoS%20AR%20Eng.pdf. Archived from the original (PDF) on 2021-11-17. {{cite web}}: Missing or empty |title= (help)
  28. ↑ 28.0 28.1 (PDF) https://web.archive.org/web/20220808195812/https://www.sail.co.in/sites/default/files/2022-02/Performance-highlights-Q3-FY-22.pdf. Archived from the original (PDF) on 2022-08-08. {{cite web}}: Missing or empty |title= (help)
  29. ↑ 29.0 29.1 29.2 29.3 (PDF) https://web.archive.org/web/20241007163656/https://sail.co.in/sites/default/files/upload/2023-06/2_%2520RSPs_HSM_SPP_Project_EC_implemntation_status_Oct-March,_2023.pdf. Archived from the original (PDF) on 2024-10-07. {{cite web}}: Missing or empty |title= (help)
  30. ↑ 30.0 30.1 30.2 30.3 (PDF) https://www.sail.co.in/sites/default/files/upload/2023-11/1_RSP-2019-Caster-4-EC-Implementation-report-October-March-2024.pdf. {{cite web}}: Missing or empty |title= (help)
  31. ↑ 31.0 31.1 31.2 31.3 (PDF) https://www.sail.co.in/sites/default/files/2025-08/Sail%20Annual%20Report_2025_%2825_08_2025%29.pdf. {{cite web}}: Missing or empty |title= (help)
  32. ↑ 32.0 32.1 32.2 32.3 (PDF) https://web.archive.org/web/20211127054741/https://sail.co.in/sites/default/files/2021-10/Sustainability-Report%202020_2021.pdf. Archived from the original (PDF) on 2021-11-27. {{cite web}}: Missing or empty |title= (help)
  33. ↑ 33.0 33.1 (PDF) https://web.archive.org/web/20230629235701/http://sail.co.in/sites/default/files/ticker/2022-09/Sail%20Annual%20Report_2021-22.pdf. Archived from the original (PDF) on 2023-06-29. {{cite web}}: Missing or empty |title= (help)
  34. ↑ 34.0 34.1 (PDF) https://web.archive.org/web/20250603183525/https://sail.co.in/sites/default/files/2023-09/SAIL_Annual-Report-2022-2023.pdf. Archived from the original (PDF) on 03 June 2025. {{cite web}}: Check date values in: |archive-date= (help); Missing or empty |title= (help)
  35. ↑ https://web.archive.org/web/20240115082233/https://sail.co.in/plants/about-rourkela-steel-plant. Archived from the original on 2024-01-15. {{cite web}}: Missing or empty |title= (help)
  36. ↑ https://www.slideshare.net/slideshow/case-study-on-sail-rourkela-steel-plant/263089936. {{cite web}}: Missing or empty |title= (help)
  37. ↑ https://www.danieli.com/en/news-media/news/top-bf-results-rourkela-steel-plant_37_547.htm. {{cite web}}: Missing or empty |title= (help)
  38. ↑ https://www.primetals.com/press-media/news/leading-indian-steel-producer-sail-partners-with-primetals-technologies-on-green-steel-transition-at-rourkela-plant. {{cite web}}: Missing or empty |title= (help)
  39. ↑ https://www.seaisi.org/details/25340?type=news-rooms. {{cite web}}: Missing or empty |title= (help)
  40. ↑ https://sail.co.in/en/sail-news/rebuilt-blast-furnace-1-parvati-sail-rourkela-steel-plant-blown, https://www.governancenow.com/news/psu/sails-rourkela-steel-plant-blast-furnace-blown-in, http://www.cspm.gov.in/ocmstemp/PROJ_SUMMARY?prcd=N12000084&stat=C https://sail.co.in/sites/default/files/upload/2022-11/2_%20RSPs%20implementation%20status%20of%20conditions%20of%20EC%20received%20for%203%20MTPA%20HSM%20other%20new%20projects%20April%20-%20September%202022.pdf, https://sail.co.in/en/sail-news/rebuilt-blast-furnace-1-parvati-sail-rourkela-steel-plant-blown, https://www.governancenow.com/news/psu/sails-rourkela-steel-plant-blast-furnace-blown-in, http://www.cspm.gov.in/ocmstemp/PROJ_SUMMARY?prcd=N12000084&stat=C. {{cite web}}: Check |url= value (help); Missing or empty |title= (help)
  41. ↑ (PDF) https://sail.co.in/sites/default/files/upload/2022-11/3_%20RSPs%20implementation%20status%20of%20conditions%20of%20EC%20received%20for%204.pdf. {{cite web}}: Missing or empty |title= (help)
  42. ↑ 42.0 42.1 https://odishabarta.com/annapurna-blast-furnace-4-of-sail-outperformed-its-metal-production/. {{cite web}}: Missing or empty |title= (help)
  43. ↑ https://twitter.com/sailrsp1/status/1303690740485124097?lang=en. {{cite web}}: Missing or empty |title= (help)
  44. ↑ 44.0 44.1 44.2 44.3 (PDF) https://web.archive.org/web/20190419111033/http://iim-delhi.com/upload_events/Danieli_Corus.pdf. Archived from the original (PDF) on 2019-04-19. {{cite web}}: Missing or empty |title= (help)
  45. ↑ https://www.aist.org/danieli-corus,-tata-projects-to-build-greenfield-blast-furnace-for-sail. {{cite web}}: Missing or empty |title= (help)
  46. ↑ https://abmproceedings.com.br/en/article/download-pdf/sail-rsp-blast-furnace-no-5-a-greenfield-project-in-a-brownfield-optimization-context. {{cite web}}: Missing or empty |title= (help)
  47. ↑ https://web.archive.org/web/20220525172438/http://www.meconlimited.co.in/Metals/Iron_Making.aspx. Archived from the original on 2022-05-25. {{cite web}}: Missing or empty |title= (help)
  48. ↑ 48.0 48.1 https://www.danieli.com/en/news-media/news-events/sail-rsp-blast-furnace-no-5-sets-new-standards-india_37_28.htm. {{cite web}}: Missing or empty |title= (help)
  49. ↑ https://www.sail.co.in/en/plants/about-rourkela-steel-plant-0. {{cite web}}: Missing or empty |title= (help)
  50. ↑ https://web.archive.org/web/20240916172132/https://www.steelorbis.com/steel-news/latest-news/sail-defers-expansion-project-for-rourkela-mill-until-land-is-cleared-1289254.htm. Archived from the original on 2024-09-16. {{cite web}}: Missing or empty |title= (help)
  51. ↑ 51.0 51.1 51.2 https://web.archive.org/web/20240119033254/https://www.financialexpress.com/business/industry-sail-proposes-to-increase-capacity-to-49-6-mtpa-by-2030-1911618/. Archived from the original on 2024-01-19. {{cite web}}: Missing or empty |title= (help)
  52. ↑ 52.0 52.1 52.2 52.3 52.4 https://imis.aist.org/store/detail.aspx?id=PR-RU2024-1. {{cite web}}: Missing or empty |title= (help)
  53. ↑ 53.0 53.1 53.2 53.3 53.4 https://web.archive.org/web/20220930100102/https://www.sail.co.in/en/plants/rourkela-steel-plant/facilities. Archived from the original on 2022-09-30. {{cite web}}: Missing or empty |title= (help)
  54. ↑ 54.0 54.1 http://www.meconlimited.co.in/Metals/steel_making.aspx. {{cite web}}: Missing or empty |title= (help)
  55. ↑ https://web.archive.org/web/20210227115638/https://www.financialexpress.com/industry/sail-proposes-to-increase-capacity-to-49-6-mtpa-by-2030/1911618/. Archived from the original on 2021-02-27. {{cite web}}: Missing or empty |title= (help)
  56. ↑ https://web.archive.org/web/20220111171832/https://www.daily-sun.com/post/227737/Star-Consortium-KISC-to-setup-steel-plant-at-Mirersharai. Archived from the original on 2022-01-11. {{cite web}}: Missing or empty |title= (help)
  57. ↑ (PDF) https://web.archive.org/web/20210929032946/https://www.oecd.org/industry/ind/latest-developments-in-steelmaking-capacity-2021.pdf (PDF). {{cite web}}: Check |archive-url= value (help); Missing or empty |title= (help)
  58. ↑ https://web.archive.org/web/20220112121226/https://starconsortiumbd.com/project_bci.php. Archived from the original on 2022-01-12. {{cite web}}: Missing or empty |title= (help)

Resources

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