application for extension of validity of ......m/s. hindalco industries ltd renukoot –231217...

APPLICATION FOR EXTENSION OF VALIDITY OF

ENVIRONMENTAL CLEARANCE

FORM-I for

MODERNISATION & EXPANSION OF

ALUMINA REFINERY & SMELTER PLANT

at

RENUKOOT, SONBHADRA DISTRICT, UTTAR PRADESH

Submitted to:

Ministry of Environment and Forests New Delhi

Submitted by:

M/s. Hindalco Industries Ltd

Renukoot –231217

Dist.Sonbhadra U.P.

September, 2018

APPLICATION FOR EXTENSION OF VALIDITY OF ENVIRONMENTAL CLEARANCE (FORM-1) FOR THE

MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660 KTPA TO

900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA DISTRICT,

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FORM-I (I) BASIC INFORMATION S. No. Item Details

1. Name of the project/s Proposed Modernization and Expansion by

Hindalco Industries Ltd., Alumina Refinery

from 660 KTPA to 900 KTPA and Smelter

Plant from 356 KTPA to 472 KTPA at

Renukoot, Dist. Sonbhadra, Uttar Pradesh

as per the EC vide letter No. F. No. J-

11011/929/2008-IA-II(I) dated December

02,2011.

Through Modernization, we have enhanced

Alumina production from 660 KTPA to 720

KTPA and Aluminium Metal from 356 KTPA

to 420 KTPA by debottlenecking, improving

process, operation & maintenance

efficiency, increasing plant availability

factor and addition of balancing equipment

including 101 pots in the existing 11 pot

lines of smelter plant.

We are now seeking extension of

Environment Clearance for Alumina Plant


Plant from 420KTPA to 472 KTPA.

2. Sr.No. in the schedule 3 (a) 3. Proposed capacity /area/ length/ tonnage

to be handled/ command area/ lease area/number of wells to be drilled.3(a

Alumina Refinery- 660 KTPA to 900 KTPA

Alumina Smelter- 356 KTPA to 472 KTPA,

area about 9.25 hectare.

4. New/Expansion/Modernization Expansion 5. Existing Capacity/Area etc. Alumina Refinery- 720 KTPA

Alumina Smelter- 420 KTPA 6. Category of Project i.e. ‘A’ or ‘B’ ‘A’ Primary metallurgical industry –All

projects 7. Does it attract the general condition? If

yes, please specify. No

8. Does it attract the specific condition? If yes, please specify.

No

9. Location Plot/Survey/Khasra No. Village Tehsil District State

At Renukoot, Dist. Sonbhadra U.P.

Longitude :83003’ East

Latitude: 240 12’ North

No alternative sites considered, because it

is an expansion project within our existing

plant. 10. Nearest railway station/airport along with

distance in kms Renukoot Railway Station :2 km,SE Varanasi Airport :135km, N

11. Nearest Town, city, District Headquarters Dudhinagar 20km,E


PROPOSED MODERNISATION & EXPANSION OF ALUMINA REFINERY & SMELTER PLANTS FROM 660

KTPA TO 900KTPA AND FROM 356 KTPA TO 472 KTPA RESPECTIVELY AT RENUKOOT, SONBHADRA

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S. No. Item Details

along with distance in kms District HeadquartersRobertsgunj49km,N 12. Village Panchayats, ZillaParishad,

Municipal Corporation, Local body (complete postal addresses with telephone nos. to be given)

Project site is located in Renukoot, Sonbhadra District, Uttar Pradesh.

13. Name of the applicant M/s. Hindalco Industries Ltd ,Renukoot

14. Registered Address Shri S.N.Jajoo

Chief Operating Officer(COO)

Hindalco Industries Limited,

P.O. Renukoot,

Dist: Sonbhadra,

Uttar Pradesh – 231217, 15. Address for correspondence:

Name Designation (Owner/ Partner / CEO) Pin code E-mail Telephone No. Fax No.

Shri S.N. Jajoo

Chief Operating Officer (COO)

Hindalco Industries Limited,

P.O. Renukoot,

Dist: Sonbhadra,

Uttar Pradesh – 231217,

Phone: (05446)-252077/79, 254791/96

Fax : (05446)-252107, 252427

Email: [email protected] 16. Details of Alternative Sites examined, if

any. Location of these sites should be shown on a topo-sheet.

No alternative sites considered, because it is

an expansion project within our existing

plant The location map of the project site is enclosed as Annexure-1.

17. Interlinked Projects None

18. Whether separate application of interlinked project has been submitted?

Not applicable

19. If yes, date of submission Not applicable

20. If no, reason Not applicable

21. Whether the proposal involves approval/clearance under: if yes, details of the same and their status to be given. i. The Forest (Conservation) Act, 1980? ii. The Wildlife (Protection) Act, 1972? iii. The C.R.Z. Notification, 1991?

No

22. Whether there is any Government Order/Policy relevant /relating to the site?

No

23. Forest land involved (hectares)

Nil

24. Whether there is any litigation pending against the project and/or land in which the project is propose to be set up? a) Name of the Court b) Case No.

No




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S. No. Item Details

c) Orders/directions of the Court, if any and its relevance with the proposed project.

(II) ACTIVITY

1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)

Sr. No.

Information/Checklist Confirmation

Yes/ No

Details thereof (with approximate quantities/ rates, wherever possible) with source of

information data 1.1 Permanent or temporary change in

land use, land cover or topography including increase in intensity of land use (with respect to local land use plan)

No There will not be any major change in

landuse, land cover or topography.

The land required for the total project is

about 9.25 hectare.

The present land use at the project site is

industrial land.

The general elevation of site is about 330-

m above MSL.

The location map and Study area Map of

the site are enclosed as Annexure-I&

Annexure-II

1.2 Clearance of existing land, vegetation and building?

Yes At present, there is no vegetation and

building at proposed site. 1.3 Creation of new land uses? Yes The proposed Modernization and Expansion

of Alumina Refinery & Smelter Plant will be

established within the premises of the

existing plant. 1.4 Pre-construction investigations,

e.g., bore houses, soil testing? No Not required.

1.5 Construction works ? Yes Construction of Pot Cells, Baking Furnace,

Boiler, Calciner, liquor tanks, Rectifier,

compressor house, turbine, Coal Circuit

etc., will be done. 1.6 Demolition Works ? No Nil. There will not be any demolition works. 1.7 Temporary sites used for

construction works or housing of construction workers?

No The construction workers will be provided

housing with the existing colony

premises.ill be done by our own employees

who reside in colony and through the

contractors who will hired labor from local

area. Thus, there will not be any housing

requirement for the construction workers at




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Sr. No.


Yes/ No


information data

the project site. 1.8 Above ground buildings, structures

or earthworks including linear structures, cut and fill or excavations.

Yes Limited excavation work will be carried out

for construction of the structures. Minimum

cut and fill is required to make the land

suitable for constructions.

Construction of Pot Cells, Baking Furnace,

Boiler, Calciner, liquor tanks, Rectifier,

compressor house, Coal Circuit etc., will be

done. 1.9 Underground works including

mining or tunneling? No Not envisaged

1.10 Reclamation works? No Not Applicable 1.11 Dredging? No Not Applicable 1.12 Offshore structures? No Not Applicable 1.13 Production and manufacturing

Process? Yes Proposed Modernization and Expansion by

Hindalco Industries Ltd., Alumina Refinery


Plant from 356 KTPA to 472 KTPA at

Renukoot, Dist. Sonbhadra, Uttar Pradesh

as per the EC vide letter No. F. No. J-

11011/929/2008-IA-II(I) dated December

02,2011.

Through Modernization, we have enhanced

Alumina production from 660 KTPA to 720

KTPA and Aluminium Metal from 356 KTPA

to 420 KTPA by debottlenecking, improving

process, operation & maintenance

efficiency, increasing plant availability

factor and addition of balancing equipment

including 101 pots in the existing 11 pot

lines of smelter plant.

The process description of Alumina Refinery

& Smelter plant is enclosed as Annexure-

III, along with the process flow sheet.

1.14 Facilities for storage of goods or

materials? Yes Storage of goods or materials will be stored

in existing storage area.

1.15 Facilities for treatment or disposal of solid waste or liquid effluents?

Yes Red Mud is the solid waste generated from

Bauxite refining. Rotary vacuum drum

filters will be used to convert wet mud

slurry into cake form having a solid content

of about 70%. The well transportable mud

cake (70% solids) with negligible caustic

concentration will be disposed off in area




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Sr. No.


Yes/ No


information data specially earmarked surrounded by a

strong earthen dam.

The fly ash generated in the boiler by the

burning of coal will be dry fly ash and will

be supplied to various cement and cement

based industries.

We have patented process for utilization of

spent pot lining (SPL) by recovering its

fluorine values to produce valuable cryolite,

a raw material used in smelting process. Its

residue is efficiently used in our boilers as

fuel with coal. Thus we will treat & recycle

recycled total additional SPL generated.

We have an efficient Effluent Treatment

Plant and Sewage Treatment Plant which

has sufficient capacity to treat extra

effluent generated through this expansion. 1.16 Facilities for long term housing of

operational workers? No The existing township shall cater the

requirement of Refinery & Smelter. 1.17 New road, rail or sea traffic during

construction of operation? No Existing transport facilities will be used

during construction or operation. 1.18 New road, rail, air waterborne or

other transport infrastructure including new or altered routes and stations, ports, airports etc.?

No The plant is located adjacent to at a

distance of about 0.5 km of N.H. 76 E and

State highway connecting Varanasi and

Shakti Nagar is about 17 km. 1.19 Closure or diversion of existing

transport routes or infrastructure leading to changes in traffic movements?

No Not envisaged.

1.20 New or diverted transmission lines or pipelines?

No Not envisaged.

1.21 Impoundment, damming,

culverting, realignment or other changes to the hydrology of watercourses or aquifers?

No Not required.

1.22 Stream crossings? No Not applicable 1.23 Abstraction or transfers of water

from ground or surface waters? No No additional water will be drawn for

proposed project .The water requirement

for both Refinery and Smelter together will

be about 239.58 m3/hr and will be met

through recycled water from ETP and STP. 1.24 Changes in water bodies or the No No changes in water bodies or land surface




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Sr. No.


Yes/ No


information data land surface affecting drainage or run-off?

is envisaged and hence Existing drainage

network will not be affected.work. 1.25 Transport of personnel or materials

for construction, operation or decommissioning?

Yes Project site is within the existing plant.

Existing facilities will be used for all

activities. 1.26 Long-term dismantling or

decommissioning or restoration works?

No Not envisaged.

1.27 Ongoing activity during decommissioning which could have an impact on the environment?

No Not envisaged.

1.28 Influx of people to an area in either temporarily or permanently?

Yes The construction labor will be hired from

the local area which may lead to temporary

influx of the people. will be done by our

own employees who reside in colony and

through the contractors who will took labor

from local area.

The additional manpower requirement

during operation phase will be around

1200. 1.29 Introduction of alien species? No Not envisaged 1.30 Loss of native species or genetic

diversity? No Not envisaged

1.31 Any other actions? No -

2. Use of Natural resources for construction or operation of Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply).

Sr. No.

Information/ Checklist Confirmation

Yes/ No

Details thereof (with approximate quantities/ rates, wherever possible) with source of information data

2.1 Land specially undeveloped or agricultural land (ha)

No Proposed site is within the existing plant.

So no need to develop the new land.

2.2 Water (expected source &

competing users) unit KLD No No additional water will be drawn from

the source. The water requirement for

both Refinery and Smelter together will

be about 239.58m3/hr that will be met

through recycled water from ETP and STP.




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2.3 Minerals (MT) Yes

Minerals:

Bauxite –5,15,960MTPA

Lime –9,862 MTPA

Others –

C.P.Coke – 50,000MTPA

Aluminum Fluoride-1,740 MTPA

LDO - 26420 MTPA

Coal –2,00,000MTPA

Caustic Soda –12,869 MTPA

2.4 Construction material – stone,

aggregates, and/ soil (expected source - MT)

Yes Construction material such as sand,

aggregates, soil etc., will be used.

However, the quantification of the

materials will be made during detailed

engineering stage. These materials will be

sourced from surrounding 50-km radius

area. 2.5 Forests and timber (source-MT) No Not envisaged 2.6 Energy including electricity and

fuels (source, competing users) Unit: fuel (MT), energy (MW)

Yes The power requirement for the proposed

expansion will be 169.7 MW that shall be

sourced from the Co – generation unit,

Renukoot and captive power plant at

Renusagar.

LDO – 26, 420 MTPA

Coal – 2,00,000 MTPA 2.7 Any other natural resources

(use appropriate standard units) No Not envisaged

3.0 Use, storage, transport, handling or production of substances or materials, which

could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health

S. No. Information/Checklist

Confirmation Yes/ No


information data 3.1 Use of substances or

materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies)

No No such material will be used which are

hazardous as per MSIHC rules.

3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases)

No Not envisaged




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3.3 Affect the welfare of people, e.g., by changing living conditions?

No Not envisaged

3.4 Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderly etc.

No Not envisaged

3.5 Any other causes No Not envisaged 4.0 Production of solid wastes during construction or operation or decommissioning

(MT/month)

Sr. No. Information/ Checklist Confirmation

Yes/ No


4.1 Spoil, overburden or mine wastes

Yes The spoil and earthwork generated during

construction will be reused for

construction as well as for filling in low

lying ine area. 4.2 Municipal waste (domestic and

or commercial wastes) Yes 10 MT/month domestic solid waste is

being generated which will be vermi-

composted and used within the plant and

colony site for plantation as manure. 4.3 Hazardous wastes (as per

hazardous waste management rules)

Yes Used Oil –37.06 KL/month, ETP Sludge -

72 MT/month and SPL-59 MT/month

will be generated.

4.4 Other industrial process wastes Yes Red Mud is the solid waste generated

from Bauxite refining. Rotary vacuum

drum filters will be used to convert wet

mud slurry into cake form having a solid

content of about 70%. The well

transportable mud cake (70% solids) with

negligible caustic concentration will be

disposed of in an area specially

earmarked surrounded by a strong

earthen dam.

The fly ash generated in the boiler by the

burning of coal will be dry fly ash and will

be supplied to various cement and

cement based industries.

We have patented process for utilization

of spent pot lining (SPL) by recovering its

fluorine values to produce valuable

cryolite, a raw material used in smelting

process. Its residue is efficiently used in

our boilers as fuel with coal. Thus we




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Yes/ No

Details thereof (with approximate quantities/ rates, wherever possible) with source of information data recycled total SPL generated.

We have an efficient Effluent Treatment

Plant and Sewage Treatment Plant, which

have sufficient capacity to treat extra

effluent generated through this

expansion. 4.5 Surplus product No - 4.6 Sewage sludge or other sludge

from effluent treatment Yes Sludge from ETP and STP will be used for

plantation in red mud area. 4.7 Construction or demolition

wastes Yes This will be used internally for filling and

leveling of the sites within the plant site

area. 4.8 Redundant machinery or

equipment No Not envisaged

4.9 Contaminated soils or other materials

No Not envisaged

4.10 Agricultural wastes No Not envisaged 4.11 Other solid wastes No Not envisaged

5.0 Release of pollutants or any hazardous, toxic or noxious substances to air (kg/hr)

Sr. No. Information/Checklist Confirmation

Yes/ No


5.1 Emissions from combustion of fossil fuels from stationary or mobile sources

Yes SPM, SO2 and NOx are the major

emissions from the proposed Expansion of

Refinery and Smelter and will be

controlled through efficient pollution

control equipment.

5.2 Emission from production

processes Yes SO2, PM, Fluoride and NOx emissions will be

from Alumina Refinery and Smelter.

These emissions will be controlled by

installation of efficient Electrostatic

Precipitators, FTP and Advance Dry Scrubbing

System.

Fluoride emissions from pots < 0.8kg/ton

of Aluminium.

5.3 Emissions from material

handling including storage or transport

Yes Fugitive emissions.

5.4 Emissions from construction activities including plant and

Yes The construction activities would result in

an incremental increase in the SPM levels.




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Sr. No. Information/Checklist Confirmation

Yes/ No


equipment

However, this is restricted to the project

site only and would be marginal and

temporary in nature. 5.5 Dust or odors from handling of

materials including construction materials, sewage and waste

Yes The construction activities may cause

changes in the SPM levels. The impact

would however be marginal, reversible

and temporary in nature.

There will not be any odor generating

substances. 5.6 Emissions from incineration of

waste No Not Envisaged

5.7 Emissions from burning of waste in open air (e.g. slash materials, construction debris)

No Not Envisaged

5.8 Emissions from any other sources

No Not Envisaged

6.0 Generation of Noise and Vibration, and emissions of Light and Heat


Yes /No


6.1 From operation of equipment e.g. engines, ventilation plant, crushers

Yes Alumina Refinery - 90-105 dB(A)

Smelter plant- 91-95 dB(A)

Carbon plant- 80-95 dB(A)

Regular maintenance of the equipment

will help in reducing these noise levels.

Necessary PPEs shall be provided to

workers. 6.2 From industrial or similar

processes Yes The expected noise levels will be in the

range of 75-85 dB (A).

Regular maintenance of the equipment

will help in reducing these noise levels.

Necessary PPEs shall be provided to

workers




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6.3 From construction or demolition

Yes During construction, temporary.

No demolition process.

The range will be 65-80 dB(A). Regular

maintenance of the equipment will help in

reducing these noise levels. 6.4 From blasting or piling No Not envisaged 6.5 From construction or

operational traffic Yes During construction: temporary.

During operation: less to moderate.

The noise levels are expected to be in the

range of about 70-75 dB(A). 6.6 From lighting or cooling

systems No Not envisaged

6.7 From any other sources No Not envisaged

7.0 Risks of contamination of land or water from releases of pollutants into the ground or

into sewers, surface waters, groundwater, coastal waters or the sea

Sr. No Information/Checklist Confirmation

Yes/No Details thereof (with approximate quantities/ rates, wherever possible) with source of information data

7.1 From handling, storage, use or spillage of hazardous materials

No Not envisaged

7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of discharge)

No The sewage wastewater will be treated

and used for greenbelt development

The trade effluents will be treated and

recycled for process use. 7.3 By deposition of pollutants

emitted to air into the land or into water

No The incremental ground level

concentrations of air pollutants are likely

to be well within the permissible limits.

Hence, no impact on air is envisaged.

Hence, no risk of contamination of air,

land or water is envisaged. 7.4 From any other sources No Not envisaged 7.5 Is there a risk of long term

build up of pollutants in the environment from these sources?

No Not envisaged

8.0 Risk of accidents during construction or operation of the project, which could affect

human health or the environment






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8.1 From explosions, spillages, fires etc. from storage, handling, use or production of hazardous substances

No No hazardous substance will be used

during construction or operation of the

project, however existing facilities for fire

fighting and to handle any emergency will

be used. 8.2 From any other causes No Not envisaged 8.3 Could the project be affected

by natural disasters causing environmental damage (e.g. floods, earthquakes, landslides, cloud burst etc)?

No There is no record of occurrence of floods,

landslides, cloudbursts etc. The proposed

project site comes under Seismic Zone-III

as per IS 1893 (Part-I):2002

classification. Hence, seismically it is a

stable zone. 9.0 Factors which should be considered (such as consequential development) which could

lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality

Sr. No Information/Checklist

Confirmation Yes/No Details thereof (with approximate quantities/

rates, wherever possible) with source of information data

9.1 Lead to development of supporting, utilities, ancillary development or development stimulated by the project which could have impact on the environment e.g.: Supporting infrastructure (roads, power supply, waste or wastewater treatment, etc) Housing development Extractive industries Supply industries Other

No

No

No

Yes

No

Existing infrastructure is sufficient.

Existing township will accommodate all

the employees.

Not envisaged.

Caustic Soda manufacturer, Coal Mines

etc.

Not envisaged. 9.2 Lead to after use of the site,

which could have an impact on the environment

No No Major impacts are envisaged.

9.3 Set a precedent for later developments

No Not envisaged.




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9.4 Have cumulative effects due to proximity to other existing or planned projects with similar effects

No Not falling under critical polluting area

hence no pollution is envisaged.

(III) ENVIRONMENTAL SENSITIVITY

Sr. No Areas Name/ Identity

Aerial distance (with 15-km)

Proposed project location boundary

1 Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other related value

Nil in 15-km radius area.

N.A.

2 Areas which are important or sensitive of ecological reasons – wetlands, water courses or other water bodies, coastal zone, biospheres, mountains, forests

Reserve Forest near

Dudhi RF.

Muirpur RF

Water bodies:

- RihandReservoir

(4.5-km, E)

(5.0-kms, SE)

(2.5-km, W)

3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration

Detailed Flora and Fauna

Studies will be conducted

and incorporated in EIA

report.

-

4 Inland, coastal, marine or underground waters

Nil in 15-km radius area

5 State, national boundaries Nil in 15-km radius area.

-

6 Routes or facilities used by the public for access to recreation or other tourist, pilgrim areas


-

7 Defense installations Nil in 15-km radius area. - 8 Densely populated or built-up area Renukoot 0.5-km 9 Areas occupied by sensitive man

made land uses (hospitals, schools, places of worship, community facilities)

Yes Hospitals,

Mandir, Masjid,

Gurudwara,

Community

health centres

and schools exist

in 5 to 10-km




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Sr. No Areas Name/ Identity

Aerial distance (with 15-km)

Proposed project location boundary radius area

10 Areas containing important, high quality or scarce resources (ground water resource, surface resources, forestry, agriculture, fisheries, tourism, minerals)


-

11 Areas already subjected to pollution or environmental damage. (those where existing legal environmental standards are exceeded)


-

12 Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)

There is no record of

occurrence of floods,

landslides, cloud bursts etc.

The proposed project site

comes under Seismic Zone-

III as per IS 1893 (Part-I):

2002 classification. Hence,

seismically it is a stable

zone.

-




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ANNEXURE-I

LOCATION MAP OF THE PROJECT SITE




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ANNEXURE-II

10-KM RADIUS MAP OF THE PROJECT SITE




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ANNEXURE - III

PROCESS DESCRIPTION OF EXTRACTION OF ALUMINA FROM BAUXITE

Conventional Bayer’s process is used for the extraction of alumina from bauxite. Bauxite

from various mines is received and unloaded with the help of Wagon Tippler. It is

crushed to minus 100 mm lumps and stock piled. Bauxite from different sources get

mixed and blended in the stockpile itself. Occasionally, a dozer is also used for this

purpose. The minus 100 mm lump bauxite in the stock pile is further crushed to minus

12 mm in hammer mills and then again wet grinded in ball mills together with the Test

tank liquor from the process to form a 50% slurry. The slurry is fed into digestors and

the alumina content of bauxite is dissolved in caustic soda at a high temperature of

2480C and 36 Kg/cm2 pressure. The digested slurry is then sent for separation of red

mud from sodium aluminate liquor. After settling, the red mud is washed free from

caustic soda, filtered in drum filters and then dumped into the earmarked low lying areas

within the complex. The areas that have already been reclaimed in this manner have

been partly used for erection of new alumina plant and partly for green belt. The sodium

aluminate liquor is filtered using filter aid as tricalcium aluminate (TCA). The alumina

hydrate from this liquor is precipitated by agitating with seed alumina hydrate in the

precipitator tanks. The precipitated alumina hydrate is classified through Seed & Product

Hydro-cyclones.

The production hydrate from the Product Cyclone underflow is filtered and washed free

of caustic and calcined in gas suspension calciner at a temperature of 1150(C to produce

calcined alumina.




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ALUMINA PLANT PROCESS FLOW DIAGRAM




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FUMETREATMENT

SYSTEM

FUMES

BAKING

FURNACE POT ROOM

HANDLINGBUTT & BATH

TREATMENTPLANT

FUME

PLANTGREEN ANODE

CAST HOUSE

FUEL OIL BAKED

FUEL OIL

W ATER

PITCH C.P. COKE

GREEN ANODE

BUTTS (CRUSHED)

RODDING

ROOM

USEDRODS

ANODE

PACKING COKE

RODDED ANODE

BATH (CRUSHED)

ENRICHEDALUMINA

ALUMINAFRESH

ALUMINIUM FLUORIDE

SPENT ANODES

LIQUIDMETAL

DROSSFUEL OIL

ALLOYING ELEMENTS

MAKE UP W ATER

20 K

G IN

GO

T

WIR

E R

OD

S

BIL

LET

S/S

LAB

S

SPL

ALUMINIUM SMELTING PROCESS

Hall – Heroult process of Al. extraction is an extremely energy intensive process where

primary requisite is a source of economical electrical power. Furthermore, the process

uses great quantities of high purity Alumina, Cryolite and also very low ash carbon

electrodes. These source materials have to be prepared by fairly complicated methods.

Primary Aluminium is produced by electrolytic reduction of Alumina, the process is

commonly known as Hall-Heroult Process. Alumina is dissolved in molten cryolite bath

and electrolysis is carried out in specially designed Aluminium electrolysis cells

commonly known as 'pots'. “Faraday Law of Electrolysis” governs the electrolytic

process. Electrolytic cells consist of Anode, Cathode and electrolyte.

Anode (the +ve terminal) – Prebaked, made of CP coke and coal tar pitch Cathode (the –

ve terminal) – made of cathode carbon blocks in which steel collector bars are embedded

to make electrical connection Electrolyte – Medium for carrying out electrolysis,

consisting of mainly, cryolite, aluminium fluoride and calcium fluoride in which alumina is

dissolved for electrolysis

In an electrolytic cell when DC current is passed from anode to cathode through molten

electrolyte, alumina dissolved in electrolyte is dissociated into aluminium& oxygen.

Aluminium being positively charged goes to the cathode while oxygen being negatively

charged goes to anode. Aluminium continues to deposit at cathode, which is tapped out

periodically. The consumed anodes are replaced in certain sequence periodically with

new anode to continue the process.

Hindalco Smelter has its own Carbon Plant to produce prebaked anodes, which comprises

of three sections: Green anode making plant, Bake furnaces & Rodding shop.

Hot metal goes to different casting stations Billet Casting, Slab Casting, Wire Rod, Pig

casting etc.




DISTRICT, U.P.

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