Updating a 1950s-generation aluminum smelter

Abstract

Hindalco’s aluminum electrolysis cells were initially installed in 1962, and the technology was based on 1950s-generation pots. Although Hindalco expanded its aluminums melting capacity from 20,000 tonnes per year to 175,000 tonnes per year, the basic design of the pots remained unchanged. In view of energy price increases, and to keep pace with the latest developments in aluminum smelting technology, Hindalco undertook efforts to modernize its facilities. In spite of numerous constraints, the Hindalco smelter has been able to achieve performance nearly equivalent to that of 1980s-generation pots by retrofitting new technologies. This has resulted in considerable savings in electrical energy consumption and raw materials usage.