TECHNOLOGY OVERVIEW

 THE METAL
Aluminium is the most abundant metallic element (8.1
mass %) in the earth’s crust. Due to its strong affinity to
Oxygen, Aluminium does not occur in nature in its pure
elemental state and is found in combined forms such as
oxides and silicates. In order to produce the pure metal
a Reduction reaction must take place.
THE PROCESS
 Most smelting processes involve direct reduction of the
ore by Carbon to metal and Carbon dioxide. The
process of extracting a metal from its oxide is in general
referred to as smelting. Some of the subsequent steps
involved have been outlined below -
 The Aluminium produced by the electrolytic reduction
of alumina (Al2O3) dissolved in an electrolyte (bath)
mainly containing cryolite (Na3AlF6) sinks to the
bottom of the Cell from where it is collected and sent
to a melting or holding furnace, that is used to hold
the hot metal and maintain desired temperature for
casting.
 2 Al2O3 (dissolved) + 3C(s) ------> 4Al(l) +3CO2(g)
 The molten Aluminium is then mixed with desired
alloys to obtain specific characteristic and cast
into Ingots for transport to fabricating shops.
 In the Fabrication Shops, the molten Aluminium or
Aluminium alloys are re-melted and poured into casts
and cooled.
 Molten Aluminium may be further heated to remove
oxides, impurities and other active metals such as
Sodium and Magnesium, before casting.

 Chlorine may also be bubbled through the

Aluminium to further remove impurities.
ALUMINIUM PRODUCTION PROCESS FLOWCHART:-
MINING
BALCO has two captive Bauxite mines in Chhattisgarh
state - one at Mainpat with capacity 7,50,000 TPA &
another at Bodai Daldali (Kawardha) with capacity of
12,50,000 TPA and a Coal mine at Chotia with capacity
of 1 MTPA.
Both the Bauxite mines are situated at an elevated
plateau; the area is flat and covered with soil / lateritic
boulders. The Bauxite ore is available as pocket deposit
with 1.5 metre average thickness and is normally
available below 3 - 5 metres from ground level.
 SMELTING

BALCO has its operations at Korba in the state of

Chhattisgarh with a smelter capacity of 570 ktpa
with capabilities to produce ingots, Alloy ingots,
wire-rods, busbars and rolled products.
 FABRICATION

The molten metal (Aluminium) is fabricated

into saleable products by adapting different
processes. Fabrication SBU is broadly divided
in three units operating as separate profit
centres – Cast House, Foundry and Sheet
Rolling Shop.
 POWER
CAPTIVE POWER PLANT I
Capacity: 1200 MW (CPP -2 X 300MW & IPP - 2 X 300 MW)
Location: Balco Plant, Korba
Source of Coal: Gevra, Kusmunda & Manikpur Mines of South Eastern
Coalfields Ltd. (SECL) in Korba.
Source of Water: Hasdeo River
Operation & Maintenance: BALCO's own operation

CAPTIVE POWER PLANT II

Capacity: 540 MW (4 X 135 MW)

Location: BALCO Plant, Korba
Source of Coal: Gevra & Kusmunda mines of South Eastern
Coalfields Ltd (SECL) in Korba.
Source of Water: Hasdeo River
Operation & Maintenance: BALCO’s own operation
POT ROOM