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REPORT ON INDUSTRIAL VISIT TO NALCO

GUIDED BY:

SUBMITTED BY: SEMESTER: ROLL NO. :

Preface This report is based on the Industrial Tour to one of the Aluminium producer of ORISSA that is NALCO. It gives the reader an insight into the aluminum industry of orissa, alumina production, the products manufactured by Nalco. The various aspects of Nalco have also been presented in the report. Again description about the CAPTIVE POWER PLANT which provides power to the Nalco has also been presented.

Best efforts have been done to make this report a successful one. It is a hope that the readers of this report will be benefited.

ACKNOWLEDGEMENT I owe a debt of gratitude to R.K.Jena Sir, D.N.Mishra sir, Disha madam, Anjali madam, Sudhansu sir, Satyajit sir for providing this great opportunity to explore the operations in the site of

NALCO. Without them this industrial tour would not have been a success. I also thank Mr. Suresh Mishra the Chief Manager cum Technical secretary to the Executive Engineer and the employees of the NALCO, Angul, Orissa for extending their assistance for better perception of the processes being conducted in NALCO.

CERTIFICATE

This is to certify that Mr.Aditya Anshuman Dash of 3rd semester is a bona fide student from D.A.V School of Business Management, Bhubaneswar. It also certifies that this project is of authentic nature and it has been done by the student himself.

Sign of student Sign of mentor

CONTENTS SLN O. TOPIC 1. INTRODUCTION 2. 3. 4. 5. 6. 7. 8. BAUXITE MINES ALUMINA REFINERY ALUMINIUM SMELTER CAPTIVE POWER PLANT OBSERVATION PRODUCTS CONCLUSION

PA GE

9.

BIBLOGRAPHY

Introduction National Aluminium Company Limited was incorporated in 1981 as a public sector company, under the ministry of mines. The total capital cost of Rs. 2408 crore was funded through contribution of the Government by Rs.1289 crore and a Euro dollar loan from a consortium of international banks of Rs.1119 crore.

THE VISION:To be a company of global repute in Aluminium Sector. THE MISSION:To achieve growth in business with global competitive edge, providing satisfaction to customers, employees, shareholders and community at large.

LANDMARK EVENTS:Foundation-stone laid by LateSmt.IndiraGandhi March 1981

Commissioning of the Units: September 1985 -March 1987

Commencem ent of Aluminium Sale May 1987 Commencement of Alumina Export January 1988 London Metal Exchange Registration May 1989

Dedicated to the Nation by LateShri RajivGandhi June 1989 Achieved Zero-debt Status September 1998 Equity capital restructured from Rs.1288.62 croretoRs.644.31 croreMarch 1999

BAUXITE MINES

Located on Panchpatmali Hills in Koraput district of Orissa Fully mechanized open-cast mines, in operation since 1985 Serve feed stoc k to Alum ina Refin ery

Ore transportation through 14.6 km long cable belt conveyor 310million tons deposit estimated Initial Capacity: 24, 00,000 tpy Expanded Capacity: 48, 00,000 tpy

Alumina refinery Located at Damanjodi in Koraput district

In opera tion since 1986 3 production streams, each of 5.25lakh tpy 3x18.5 mw cogeneration of power Initial Capacity: 8, 00,000tpy Expanded Capacity: 15, 75,000 tpy

Aluminium smelter

Located at Angul in Orissa

Integrated Casting & Rolling facilities Energy-efficient Stateof-the-art Pechiney technology (France) In operation since 1987 Initial Capacity: 2, 18,000tpy Expanded Capacity: 3, 45,000 tpy

Captive power plant

Located close to Smelter Captive rail system for coal transport from Talcher Coalfields Feeds uninterrupt ed power to Smelter Connected to State Grid for sale of surplus power Initial Capacity: 600 mw Expanded Capacity: 960 mw

Almost a decade after the breaching of the National Aluminium Company Ltds [Nalco] ash-pond a serious havoc in 26 villages in Angul district, Indias leading producer and exporter of alumina and aluminium has commissioned latest eco-friendly High Concentration Slurry Disposal [HCSD] System in its 1080 MW captive power plant [CPP] at a cost of Rs 50 crore. The embankment of one of the ash ponds of Nalco's 720 MW Thermal Power Plant breached on 31.12.2000 forenoon resulting in a flash flood in Nandira rivulet, a tributary of Brahmani River. This has resulted in sudden flooding of about 12 villages

on the river bank. It is estimated that about 700 people have been affected to some extent or the other. Coming under serious criticism from Orissa Pollution Control Board and civil society, Nalco raised the dykes of ash ponds from 104 Meter Reduced Level (MRL) to 107 MRL to increase the life of the ponds. For ash disposal into abandoned coal mines of Mahanadi Coalfields Limited (MCL), Nalco also obtained provisional clearance from MCL management to transport ash to Bharatpur (South) abandoned coal mines, Talcher Coal Field, Angul. The company acquired additional 46 acre of land adjacent to ash pond 2 for disposal of ash by high concentration slurry disposal mode at a later date. It also developed infrastructure to dispose ash on the existing ash pond of CPP by HCSD system for the new units No. 7 to 10 to accommodate

more ash per unit land area, over the above the disposal of ash by lean slurry method.

ALUMINIUM PRODUCTION:ANODE MAKING:Dry carbon materials are screened and crushed to various sizes and mixed with liquid pitch to make paste. The paste is then vibro-compacted to form solid green anodes. Green anodes are baked in ring type furnace for two weeks at 1100 Degree Celsius. Baked anodes are then connected to the stem bracket by pouring molten cast iron bye a process known as rodding. Rodded anodes are then sent to potlines through Anode Transport Vehicles (A.T.V). Spent anodes from potlines are crushed and recycled. POTLINES:Electrolysis is carried out in large steel vessels lined with semi-graphite

Observations

cathodes in which an array of carbon based anodes is suspended. Alumina is dissolved in an electrolytic bath of molten cryolite (sodium aluminium fluoride) within a large graphite lined steel container known as a pot. A pot has two parts: 1. A block of carbon made of coke and pitch serves as an anode (positive electrode) 2. A large rectangular steel box lined with carbon made by baking a mixture of metallurgical coke and pitch. This lining is cathode (negative electrode). An electric current is passed through at low voltage of 4.25V, but very high current of 183000 amperes. The electric current electrolyses alumina and produces aluminium at the cathode. CAST HOUSE:Molten metal is transferred from furnaces to Ingot Casting Machines which consists of water cooled moulds

fitted on a moving conveyor that discharges cold ingots strapped in stacks. Molten metal is transferred from furnaces to a water cooled casting wheel from which cast bar emerges rolling into 9.5 mm diameter wire rods, that is strapped into tight coils. Molten metal is transferred from furnaces to a Wag staff billet casting station from where billets emerge and they are cut into desired lengths. There are 8 pot lines column wise. In each column there are 120 pots totaling up to 960 pots. There is a robot called Pot Tending Machine (PTM) which changes the used anodes to new ones after 72 shifts or 8 hours. To control the pot there is a microchip based MICRO POT. It controls various aspects of the large pot and reports to 2nd level management.

Products
ALUMINA:CALCINED ALUMINA ALUMINA HYDRATE SPECIALITY AND ALUMINA HYDRATES DETERGENT GRADE ZEOLITE ALUMINIUM METAL:STANDARD INGOTS SOW INGOTS WIRE RODS BILLETS

CAST STRIPS COLD ROLLED SHEETS

CONCLUSION CORPORATE RECOGNITIONS A Super Star Trading House Registered with London Metal Exchange All Production Units ISO 9002 & ISO 14001 Certified A Mini Ratna PSU
AWARDS ACCOLADES AND

Indira Priyadarshini Vrikshamitra Award (1994) Indira Gandhi Paryavaran Puraskar(2000) CAPEXIL Export Awards for last 16 years Top Export Award of EEPC for last 3 years FIEOs Niryat Shree Award for last 2 years Indira Gandhi Rajbhasa Award (1993 & 1995) Environment Promotion & Pollution Control Awards from FIMI, FICCI & Orissa State Pollution Control Board

With the above mentioned corporate recognitions, awards and accolades Nalco continues to be one the major producer of alumina and aluminium products keeping in mind to decrease pollution of environment, development of the local masses and the infrastructure of Angul. The large ash ponds created by the Captive Power Plant has also been taken care of so that the local people are not affected. The Company has done significant progress over the years in production and has been exporting to other countries. Lastly due to excellent management and trusted employees the company is progressing towards its VISON and MISSION.

BIBLOGRAPHY 1. Personal notes from industrial tour 2. Notes provided by NALCO 3. Internet