ABB India and Steel Authority of India Ltd (SAIL), a Maharatna central public sector enterprise, have signed a Memorandum of Understanding (MoU) to digitally optimize ironmaking and steelmaking operations at the Rourkela Steel Plant in Odisha. The collaboration aims to harness ABB’s expertise in automation and digitalization to create digital twins of the plant’s blast furnaces and basic oxygen furnaces in the steel melt shop areas.
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The initiative comes amid increasing challenges for the steel industry, including stringent environmental regulations, cost pressures, and the need to enhance competitiveness. With SAIL targeting a production increase at the Rourkela plant—from 4.08 million tonnes of saleable steel in FY 2024–25 to around 9 million tonnes by 2030—the digital transformation is intended to bolster operational efficiency and sustainability.
Under the agreement, SAIL will share plant data with ABB India to develop mathematical and data-driven models. These will be used to build digital replicas (twins) of core steelmaking equipment, allowing for real-time monitoring and data-driven decision-making.
“This partnership with ABB India is a significant step towards modernizing our operations and achieving greater efficiency and sustainability,” said Mr. Biswa Ranjan Palai, Executive Director (Works), SAIL. “The digital twin technology will provide real-time insights into furnace operations, enabling optimization of performance, improved product quality, enhanced asset longevity, and global competitiveness.”
Mr. Kapil Agarwal, Senior Vice President & Local Division Manager, Process Industries, ABB India, added, “This collaboration underscores our commitment to digital innovation in the steel sector. By integrating advanced data models and digital twin technologies, we aim to revolutionize steel production with greater efficiency and a reduced environmental footprint.”
India’s steel industry is experiencing rapid expansion, with domestic demand expected to rise by 9–10% in FY 2025, according to ICRA. Long-term growth is projected between 5% to 7.3% annually, as per Deloitte. In this context, the adoption of smart technologies and energy-efficient upgrades is increasingly critical for sustainable industrial progress.
This collaboration also coincides with ABB’s 75th anniversary in India, highlighting its long-standing contribution to sectors like steel, cement, mining, and energy. ABB continues to support India’s industrial modernization by delivering cutting-edge electrification, automation, and digital solutions aimed at boosting productivity and promoting a circular economy.
