Industrial Exposure

NALCO
Alumminium Smelter

WINTER PROJECT
BY
NIRMALYA PANIGRAHI
II year B.Tech , Mechanical Engineering,
IIT Kharagpur
NALCO
 NALCO
• National Aluminium Company Limited (NALCO) is a
Navratna CPSE under Ministry of Mines. It was
established on 7th January, 1981 in the Public Sector,
with its registered office at Bhubaneswar.
• The Company is a group ‘A’ CPSE having integrated and
diversified operations in mining, metal and power with
sales turnover of Rs 7,933 crore in financial year 2016-
17. Presently, Government of India holds 65.36% equity
of NALCO.
• With its consistent track record in capacity utilization,
technology absorption, quality assurance, export
performance and posting profits, NALCO is a bright
example of India’s industrial capability.
 NALCO
• The Company is low cost producer of metallurgical grade
alumina in the World as per Wood McKenzie report. With
sustained quality products, the Company’s export
earnings accounted for about 46% of the sales turnover
in the year 2016-17 and the Company was rated 2nd
highest net export earning CPSE in 2015-16 as per
Public Enterprise Survey report.
• Company’s long term security in terms of raw
materialsi.e bauxite and coal got a boost with allocation
of Utkal-D&E with a minable reserve of about 160 million
ton and commitmentfor Pottangi bauxite deposit with a
minable reserve of about 75 million ton.
 NALCO
• The Company pursues its R&D activities fervently and
has already filed 31 patents out of which 9 patents have
been granted and 5 have been commercialized. As a
part of its effort to convert waste to wealth, the Company
is endeavoring to salvage iron concentrate from red mud,
Gallium from spent liquor. The Company has also
successfully commissioned a first of its kind de-
fluoridation process based on nano-technology to de-
contaminate the effluent water of Smelter solving a long
standing fluoride contamination problem of the area.
 Alumina Refinery
• The Alumina Refinery is located at Damanjodi, Odisha,
approximately 14 KM from the bauxite mine at
Panchpatmali. The mined-out bauxite is transported from
captive mine to refinery by a 14.6 KM long single-light
multi-curve 1800 tonnes per hour (TPH) capacity cable
belt conveyor. The alumina produced is transported to
aluminium smelter at Angul (Odisha) and to Vizag
(Andhra Pradesh) port by rail.
• The present capacity of Alumina Refinery is 22.75 lakh
TPA. Alumina produced is used to meet Company's
requirements for production of primary aluminium at
smelter. The surplus alumina is sold to third parties in the
export markets.
Alumina Refinery
 Aluminium Smelter
 The present capacity of smelter is 4.60 lakh TPA.
 Alumina is converted into primary aluminium through a
smelting process by using electrolytic reduction. From
the pot-line, the molten aluminium is routed to either the
casting units, where the aluminium can be cast into
ingots, sow ingots, tee ingots, billets, wire rods, cast
strips and alloy ingots, or to RPU where the molten
aluminium is rolled into various cold-rolled products or
cast into aluminium strips.
 Aluminium products are sold in the domestic market and
also exported through Kolkata, Paradeep & Vizag ports.
 Aluminium Smelter
 Nalco acquired and subsequent merged International
Aluminium Products Limited (IAPL), the 50,000 tpa
export-oriented Rolled Products Unit with Nalco.
 The RPU is integrated with the Smelter Plant at Angul for
production of aluminium cold rolled sheets and coils from
continuous caster route based on the advanced
technology of FATA Hunter, Italy.
 It has also started production of another variety of rolled
product named as chequered sheet with thickness
ranging from 0.60mm to 3.0mm.
Aluminium Smelter
 The salient features:
• 180 KA cell technology
• Micro-processor based pot regulation system
• Fume treatment plant with dry-scrubbing system for pollution control and
fluoride salt recovery
• Integrated facility for manufacturing carbon anodes, bus bars, anode stems etc.
• Hyper Dense Phase System (HDPS) for alumina feeding.
• 4 x 35 Tonne and 4 x 45 Tonne furnaces and 2 x 15 TPH and 2 x 20 TPH ingot
casting machines
• 4 x 45 Tonne furnaces and 2 x 9.5 TPH wire rod mills
• 2 x 45 Tonne furnaces and 60/42 per drop billet casting machine
• 2 x 1.5 Tonne induction furnace with a 4 TPH alloy ingot casting machine
• 26,000 TPA strip casting machines
• 2 x 45 Tonne furnaces and 9 TPH tee ingot casting machine
• 2 x 45 Tonne furnaces and 20 TPH sow ingot casting facility are being installed.