REPORT ON INDUSTRIAL VISIT TO NALCO

7/30/2019 REPORT ON INDUSTRIAL VISIT TO NALCO

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REPORT ONINDUSTRIAL

VISIT TO

NALCO

GUIDED BY:

SUBMITTED BY:SEMESTER:ROLL NO. :


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PrefaceThis report is based on theIndustrial Tour to one of theAluminium producer of ORISSAthat is NALCO. It gives thereader an insight into the

aluminum industry of orissa,alumina production, theproducts manufactured byNalco. The various aspects ofNalco have also been presented

in the report. Again descriptionabout the CAPTIVE POWERPLANT which provides power tothe Nalco has also beenpresented.


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Best efforts have been done to

make this report a successfulone. It is a hope that the readersof this report will be benefited.

ACKNOWLEDGEMENT

I owe a debt of gratitude toR.K.Jena Sir, D.N.Mishra sir,Disha madam, Anjali madam,Sudhansu sir, Satyajit sir forproviding this greatopportunity to explore theoperations in the site of


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NALCO. Without them thisindustrial tour would not have

been a success. I also thankMr. Suresh Mishra the ChiefManager cum Technicalsecretary to the ExecutiveEngineer and the employees ofthe NALCO, Angul, Orissa for

extending their assistance forbetter perception of theprocesses being conducted inNALCO.


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CERTIFICATE

This is to certify that Mr.AdityaAnshuman Dash of 3rd semesteris a bona fide student fromD.A.V School of Business

Management, Bhubaneswar. Italso certifies that this project isof authentic nature and it hasbeen done by the studenthimself.


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Sign of studentSign of mentor

CONTENTSSLNO.

TOPIC

PAGE

1. INTRODUCTION

2. BAUXITE MINES3. ALUMINA REFINERY

4. ALUMINIUM SMELTER

5. CAPTIVE POWER PLANT

6. OBSERVATION

7. PRODUCTS

8. CONCLUSION


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9. BIBLOGRAPHY

IntroductionNational Aluminium CompanyLimited was incorporated in1981 as a public sectorcompany, under the ministry ofmines. The total capital cost ofRs. 2408 crore was fundedthrough contribution of theGovernment by Rs.1289 croreand a Euro dollar loan from aconsortium of internationalbanks of Rs.1119 crore.


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THE VISION:-To be a company of global

repute in Aluminium Sector.

THE MISSION:-To achieve growth in businesswith global competitive edge,

providing satisfaction tocustomers, employees,shareholders and community atlarge.

LANDMARK EVENTS:-

Foundation-stone laidbyLateSmt.IndiraGandhiMarch 1981


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Commissioning of theUnits: September

1985 -March 1987Commencem

ent of AluminiumSale May

1987

Commencementof AluminaExport January 1988

London MetalExchangeRegistration May 1989


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Dedicated to the Nationby LateShri RajivGandhi

June 1989

AchievedZero-debtStatus

September1998

Equity capital restructuredfrom Rs.1288.62

croretoRs.644.31 croreMarch1999

BAUXITEMINES


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Located onPanchpatmali Hills

in Koraput districtof Orissa

Fully mechanizedopen-cast mines, inoperation since

1985

Servefeedstoc

k toAluminaRefinery


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Ore transportationthrough 14.6 km long

cable belt conveyor

310milliontons depositestimated

InitialCapacity: 24,00,000 tpy

ExpandedCapacity: 48, 00,000 tpy

Alumina refinery

Located atDamanjodi inKoraput district


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Inopera

tionsince1986

3 productionstreams, each of5.25lakh tpy

3x18.5 mw

co-generationof power

Initial Capacity: 8,

00,000tpyExpanded Capacity: 15,75,000 tpy


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Aluminium smelter

Located at Angul inOrissa


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Integrated Casting &Rolling facilities

Energy-efficient State-of-the-art Pechineytechnology (France)

In operation since 1987

Initial Capacity: 2,18,000tpy

Expanded Capacity: 3, 45,000tpy


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Captive power plant

Located close to Smelter

Captive rail system forcoal transport from TalcherCoalfields

Feedsuninterrupted powerto Smelter

Connected to StateGrid for sale ofsurplus power

Initial Capacity:600 mwExpanded Capacity: 960 mw


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Almost a decade after the breaching ofthe National Aluminium Company Ltds

[Nalco] ash-pond a serious havoc in 26villages in Angul district, Indiasleading producer and exporter ofalumina and aluminium hascommissioned latest eco-friendly HighConcentration Slurry Disposal [HCSD]

System in its 1080 MW captive powerplant [CPP] at a cost of Rs 50 crore.

The embankment of one of the ashponds of Nalco's 720 MW ThermalPower Plant breached on 31.12.2000

forenoon resulting in a flash flood inNandira rivulet, a tributary ofBrahmani River. This has resulted insudden flooding of about 12 villages


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on the river bank. It is estimated thatabout 700 people have been affectedto some extent or the other.

Coming under serious criticism fromOrissa Pollution Control Board and civilsociety, Nalco raised the dykes of ashponds from 104 Meter Reduced Level(MRL) to 107 MRL to increase the lifeof the ponds. For ash disposal intoabandoned coal mines of MahanadiCoalfields Limited (MCL), Nalco alsoobtained provisional clearance fromMCL management to transport ash toBharatpur (South) abandoned coalmines, Talcher Coal Field, Angul.

The company acquired additional 46acre of land adjacent to ash pond 2 fordisposal of ash by high concentrationslurry disposal mode at a later date. Italso developed infrastructure todispose ash on the existing ash pondof CPP by HCSD system for the newunits No. 7 to 10 to accommodate


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more ash per unit land area, over theabove the disposal of ash by leanslurry method.


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Observations

ALUMINIUM PRODUCTION:-

ANODE MAKING :-Dry carbon materials are screened andcrushed to various sizes and mixedwith liquid pitch to make paste. The

paste is then vibro-compacted to formsolid green anodes. Green anodes arebaked in ring type furnace for twoweeks at 1100 Degree Celsius.

Baked anodes are then connected to

the stem bracket by pouring moltencast iron bye a process known asrodding. Rodded anodes are then sentto potlines through Anode TransportVehicles (A.T.V). Spent anodes frompotlines are crushed and recycled.

POTLINES:-Electrolysis is carried out in large steelvessels lined with semi-graphite


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cathodes in which an array of carbonbased anodes is suspended. Aluminais dissolved in an electrolytic bath ofmolten cryolite (sodium aluminiumfluoride) within a large graphite linedsteel container known as a pot.A pot has two parts:1. A block of carbon made of coke andpitch serves as an anode (positiveelectrode)2. A large rectangular steel box linedwith carbon made by baking a mixtureof metallurgical coke and pitch. Thislining is cathode (negative electrode).An electric current is passed throughat low voltage of 4.25V, but very highcurrent of 183000 amperes. Theelectric current electrolyses aluminaand produces aluminium at thecathode.

CAST HOUSE:-Molten metal is transferred fromfurnaces to Ingot Casting Machineswhich consists of water cooled moulds


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fitted on a moving conveyor thatdischarges cold ingots strapped instacks.

Molten metal is transferred fromfurnaces to a water cooled castingwheel from which cast bar emergesrolling into 9.5 mm diameter wire rods,that is strapped into tight coils.

Molten metal is transferred fromfurnaces to a Wag staff billet castingstation from where billets emerge andthey are cut into desired lengths.

There are 8 pot lines column wise. Ineach column there are 120 potstotaling up to 960 pots. There is arobot called Pot Tending Machine(PTM) which changes the used anodesto new ones after 72 shifts or 8 hours.

To control the pot there is a microchipbased MICRO POT. It controlsvarious aspects of the large pot andreports to 2nd level management.


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Products

ALUMINA:-

CALCINED ALUMINA

ALUMINA HYDRATE

SPECIALITY AND ALUMINA HYDRATES

DETERGENT GRADE ZEOLITE

ALUMINIUM METAL:-

STANDARD INGOTS

SOW INGOTS

WIRE RODS

BILLETS


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CAST STRIPS

COLD ROLLED SHEETS

CONCLUSION

CORPORATE RECOGNITIONS

A SuperStarTradingHouseRegistered with

London MetalExchangeAll Production Units ISO9002 & ISO 14001Certified

A Mini Ratna PSU

AWARDS ANDACCOLADES


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Indira PriyadarshiniVrikshamitra Award(1994)Indira GandhiParyavaranPuraskar(2000)CAPEXIL ExportAwards for last16 yearsTop ExportAward of EEPC forlast 3 yearsFIEOs NiryatShree Award forlast 2 yearsIndira Gandhi Rajbhasa Award(1993 & 1995)EnvironmentPromotion & PollutionControl Awardsfrom FIMI, FICCI & OrissaState Pollution ControlBoard


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With the above mentionedcorporate recognitions, awards and

accolades Nalco continues to beone the major producer of aluminaand aluminium products keeping inmind to decrease pollution ofenvironment, development of thelocal masses and the infrastructure

of Angul. The large ash pondscreated by the Captive Power Planthas also been taken care of so thatthe local people are not affected.The Company has done significant

progress over the years inproduction and has been exportingto other countries. Lastly due toexcellent management and trustedemployees the company isprogressing towards its VISON

and MISSION.


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BIBLOGRAPHY

1. Personal notes fromindustrial tour

2. Notes provided by NALCO3. Internet


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REPORT ON INDUSTRIAL VISIT TO NALCO

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