On November 21, 2024, Steel Authority of India Limited (SAIL), one of India’s largest state-owned steel producers, announced the commissioning of a newly rebuilt coke oven battery at its Rourkela Steel Plant (RSP) in Odisha. This significant step is part of SAIL's ongoing modernization efforts to enhance the efficiency and environmental sustainability of its operations. The newly rebuilt coke oven battery No. 2 is set to play a crucial role in meeting the growing demand for blast furnace coke, which is essential for hot metal production in the steelmaking process.
The newly commissioned coke oven battery comprises 70 ovens arranged in two blocks, and it has a maximum capacity of 93 pushes per day once it reaches full operational stability. The facility is designed to process 0.53 million metric tons of dry coal annually, producing approximately 0.363 million metric tons of blast furnace-grade coke each year. This ensures a stable and reliable supply of high-quality coke, which is essential for the production of molten iron in blast furnaces, an integral step in steelmaking.
A major challenge during the redevelopment of the coke oven battery was carrying out the construction work in a brownfield setting. This means that the project had to be completed without disrupting the operations of the existing plant, especially the nearby production areas. The execution of this task required careful planning and precision, ensuring that production in other sections of the plant remained uninterrupted during construction. This successful integration of new infrastructure into the existing setup reflects the high level of expertise and experience at SAIL.
The rebuilt coke oven battery features a modern, energy-efficient design that minimizes operational costs while maximizing productivity. The facility has been equipped with state-of-the-art environmental conservation technologies, which are designed to reduce emissions and improve the overall environmental footprint of the plant. These include advanced systems like a grit arrestor, a vapor spray system in the quenching tower, a dust suppression system in the guide car, and a hydro-jet door cleaning system. Together, these measures significantly reduce dust, smoke, and other pollutants, contributing to a cleaner and safer working environment.
Additionally, the project involved the use of approximately 13,000 metric tons of high-quality refractory bricks, which are essential for withstanding the extreme temperatures inside the coke ovens. These materials, combined with robust anchorage systems, ensure the longevity and stability of the facility, allowing it to operate efficiently under demanding conditions. Refractories play a critical role in the performance of coke oven batteries, as they protect the structural integrity of the ovens while ensuring consistent product quality.
With the commissioning of this rebuilt facility, SAIL’s Rourkela Steel Plant strengthens its position as one of India’s premier steel production hubs. The modernized coke oven battery is a key component of SAIL's larger strategy to upgrade its infrastructure, improve product quality, and reduce environmental impacts. By investing in cleaner, more efficient technologies, SAIL is aligning itself with global standards for sustainability and energy conservation.
The new coke oven battery is also expected to play a pivotal role in improving the competitiveness of the Rourkela Steel Plant in the highly competitive Indian steel market. As one of the leading producers of steel in the country, SAIL is committed to meeting the increasing demand for high-quality steel products, which are used in a variety of industries ranging from construction to automotive manufacturing. The reliable production of blast furnace coke is a critical component in ensuring the plant's ability to produce high-grade steel efficiently and economically.
This development also marks a significant step toward achieving SAIL’s sustainability goals. The company has been working to modernize its facilities, reduce energy consumption, and minimize its environmental impact. The implementation of advanced environmental technologies in the rebuilt coke oven battery reflects SAIL’s commitment to greener practices, ensuring that its steel production processes are more sustainable and less harmful to the environment.
In conclusion, the commissioning of the rebuilt coke oven battery at SAIL’s Rourkela Steel Plant marks a major achievement in the company’s modernization journey. With its improved energy efficiency, higher production capacity, and reduced environmental impact, the facility is set to play a crucial role in strengthening SAIL’s steel production capabilities, meeting market demands, and contributing to the company’s long-term sustainability goals.
