Steel Authority of India Limited (SAIL), a Maharatna public sector enterprise, has formalized an agreement with ABB India to implement digital technologies aimed at optimizing operations at its Rourkela Steel Plant in Odisha. Under this collaboration, the two organizations will exchange data to develop advanced data-driven models and digital twins for blast furnaces and basic oxygen furnaces. This initiative will support process improvements in both ironmaking and steelmaking, aligning with SAIL’s strategy to enhance efficiency and sustainability as it prepares to increase annual output to 9 million tons by 2030.
The partnership responds to growing operational and environmental challenges faced by the steel sector, including rising cost pressures, evolving regulatory standards, and competitive global dynamics. In FY 2024-25, Rourkela Steel Plant recorded production of 4.08 million tons of saleable steel. With this digital initiative, SAIL is positioning the plant to meet higher production targets while reducing its environmental footprint and operational costs.
ABB will provide expertise in automation, data modeling, and process intelligence to support this transformation. The integration of real-time operational insights through digital twin technologies will enable predictive analysis, optimize furnace performance, extend asset life, and maintain product quality. These capabilities are expected to support more responsive and informed decision-making throughout the plant’s operations.
SAIL leadership has highlighted this initiative as a step toward modernization, aimed at elevating competitiveness and sustainability standards. ABB India’s involvement is in line with its broader mission to deliver industrial automation and digitalization across core sectors, including metals, cement, mining, and energy. The agreement with SAIL demonstrates ABB’s commitment to enabling operational excellence and responsible industrial growth.
India’s steel industry continues to expand, with domestic demand forecasted to grow by up to 10 percent in FY25, and a longer-term annual growth trajectory between 5 and 7.3 percent. As steel producers modernize their facilities, technologies such as digital twins and data analytics are expected to play a critical role in enhancing performance and supporting sustainability targets.
SAIL’s Rourkela Steel Plant, which commenced operations in 1959 as India’s first integrated public sector steel facility, offers a diverse range of flat, tubular, coated, and defense-grade products. With its current production capacity at 4.2 million tons per annum, RSP is now undergoing transformation to double its capacity. This digital initiative with ABB marks a new chapter in its evolution toward future-ready manufacturing.
ABB stands at the forefront of electrification and automation technologies, committed to driving a more sustainable and resource-efficient global economy. By leveraging its deep expertise in engineering and digital innovation, ABB empowers industries to operate at peak efficiency, improving productivity while reducing environmental impact. With a legacy spanning over 140 years and a global workforce of approximately 110,000 employees, ABB continues to shape the future of industrial performance.
The Process Automation division of ABB specializes in the automation, electrification, and digital transformation of industrial operations across vital sectors. From the distribution of energy, water, and raw materials to the manufacturing and delivery of finished products, ABB Process Automation delivers integrated solutions that enhance reliability and sustainability. With around 20,000 professionals and a strong foundation in cutting-edge technologies and services, this division supports process, hybrid, and marine industries in achieving cleaner and more efficient operations worldwide.
