India’s iconic aluminium producer ‘BALCO’ reducing carbon footprint through next-generation technology

The iconic aluminium producer of India, Bharat Aluminium Company (BALCO) is a strong promoter of leveraging next-generation technology to model its manufacturing process sustainable and reducing carbon footprint.

BALCO has reduced its power consumption in its ‘potline 1’ at its aluminium smelter in Korba, Chhattisgarh to 12,862 KWH/MT which is at par with global standards. This potline ranks as the best performing amongst potlines in India and the Gulf countries in terms of specific power consumption and has thus lowered its carbon footprint significantly.

A smelter is a plant where aluminium is produced through the process of smelting, which involves extracting it from its oxide, alumina. A potline is a long building, or collection of buildings, which contain a series of “pots”, or large electrolytic cells, in which aluminium is made. BALCO has achieved this benchmark by deploying a smart combination of high-end technology and indigenous innovations.

Mr Abhijit Pati, CEO and Director, BALCO, while speaking on BALCO’s carbon footprint reduction in its manufacturing process said: “We are committed to sustainable development and across all our areas of operations using leading-edge technology, and judicious utilization of resources.”

“BALCO has been one of the early adopters in India to explore the field of smart technologies for heightened operational efficiencies. These investments and skills further bolster the culture of safety and productivity that we have meticulously fostered across the organization. We are conscious of our responsibility towards building a stronger and sustainable tomorrow and, therefore, are actively exploring innovations that help reduce carbon footprint as early as possible in the creation process. We are ensuring a future-ready organization for a self-reliant India.”

The company has integrated smart technologies and design modifications in its potlines progressively to lessen its specific power consumption by utilizing graphitized pot with thermal modelling and other digital interventions. The company relentlessly drives innovation and continuous improvement in its smelting technology.

The specific energy consumption of BALCO has been one of the lowest in the aluminium industries across the country. Presently the company has dropped down its specific water consumption by 170% from its previous specific water consumption levels, although it is also one of the lowest amongst its peers. These figures are a testimony to BALCO’s spirited endeavours towards environment and energy conservation which contribute to a greener and better planet.

BALCO has been the recipient of various awards and accolades for its environmental conservation efforts. For the year 2020, BALCO has won the ‘CII Energy Efficiency Award’, ‘Golden Peacock Sustainability Award’ and ‘CII HSE Excellence Award, Chhattisgarh’. BALCO has also achieved the ‘International Green Apple Award’ ‘CII Energy Excellence Award’, ‘Sustainable Business of the year Award’, ‘National Award for Excellence in Energy Management’ and ‘Energy & Environment Global Environment Award’ in recent years.

BALCO is owned 51% by Vedanta Limited and 49% by the Government of India and it operates a 0.57 million tonne per annum (mtpa) aluminium smelter. It is also a leader in value-added aluminium products that find critical applications in core industries. With its world-class smelter and power plants, the company fulfils its mission of spurring emerging applications of aluminium as the ‘Metal of the Future’ for a greener tomorrow.