ABB India and Steel Authority of India Limited (SAIL), a Maharatna Central Public Sector Enterprise, have signed a Memorandum of Understanding (MoU) to digitally optimise ironmaking and steelmaking processes at the Rourkela Steel Plant in Odisha, India. Under this agreement, SAIL will exchange operational data with ABB India to build data-based models and create digital twins of the blast furnaces and basic oxygen furnaces in the steel melt-shop.
This collaboration comes amid growing industry challenges—stricter environmental regulations, the imperative to reduce operational costs and the need to maintain competitiveness in a rapidly evolving market. In FY 2024–25, Rourkela Steel Plant produced 4.08 million tonnes of saleable steel, and SAIL aims to increase output to approximately 9 million tonnes by 2030. The partnership with ABB is a key step towards achieving the highest levels of operational efficiency and sustainability via digital transformation.
The plant will leverage ABB's expertise in automation and digitalisation—employing mathematical and data-driven models—to optimise both ironmaking and steelmaking processes. The objective is to deliver actionable insights and enable data-driven decision-making that supports optimal operations, paving the way for a more sustainable and cost-effective future in steel production.
"This partnership with ABB India is a significant step towards modernising our operations and achieving greater efficiency and sustainability," said Biswa Ranjan Palai, Executive Director (Works), SAIL. "The development of digital-twin technology will transform our steel-manufacturing processes by providing real-time insights into furnace operations, enabling us to optimise performance, improve product quality, extend asset longevity and remain competitive in the global market."
"This collaboration underscores our continued commitment to driving digital innovation and supporting the steel industry in its quest for excellence," said Kapil Agarwal, Senior Vice-President & Local Division Manager, Process Industries, ABB India. "By integrating advanced data-driven models and leveraging digital-twin technologies, we aim to revolutionise steelmaking processes, ensuring higher efficiency and reduced environmental impact."