BALCO Reinforces Operational Excellence and Sustainability on Technology Day with Pioneering Digital Innovations
14th May 2025
Balconagar; 14th May 2025: Bharat Aluminium Company Limited (BALCO), a part of Vedanta Aluminium, reinforces commitment to operational excellence and sustainability through cutting-edge technological interventions across its value chain on National Technology Day. Aimed at enhancing efficiency, safety, and reliability, BALCO has introduced several advanced digital solutions, revolutionizing its operations.
To promote sustainable, energy-efficient operations, BALCO has introduced a new relining design in its potlines. This step, following 100% graphitization, aims at reducing energy consumption by 400 kWh/MT while improving current efficiency and lowering emissions.
Additionally, BALCO has integrated artificial intelligence (AI) simulators in the finishing line area to enable comprehensive analysis of process parameters, enhancing process efficiency. This targeted approach has helped in identification of optimal conditions for maximizing the production for rolled products.
Furthermore, the AI-driven advanced solutions have also played a pivotal role in enhancing product quality by improving anode making at BALCO’s furnace. This robot-based technology automates the assessment of refractory structures, swiftly detecting wear and tear of furnaces with precision, enhancing anode quality while ensuring secure operations.
The AI-powered Conveyor Belt Monitoring System deployed at BALCO’s 1200 MW power plant, further enhances both safety and efficiency. It conducts comprehensive conveyor health assessments, real-time fire alerts, and human presence detection near operational belts, reinforcing the company’s commitment to safe operations.
Speaking on the role of digitalisation, Mr. Rajesh Kumar, CEO & Director of BALCO, stated, “At BALCO, we are integrating digital innovation into every facet of our operations to drive efficiency, safety, and sustainability. Our digital interventions are setting new benchmarks in operational excellence, ensuring that we remain at the forefront of India’s aluminium industry while contributing to a more sustainable future.”
Technological interventions have become integral to the production of aluminium, the ‘Metal of the Future.’ The digital transformation at BALCO has strengthened safety, sustainability, and operational excellence across its line of operations. The digitization of 62 activities has replaced manual processes with real-time data collection, optimizing resource allocation, supporting data-driven decision-making, and maintaining a balance between human and machine interactions. Furthermore, cutting-edge technology being implemented at BALCO also include:
- The Finished Goods Tower, Ash Control Tower and Coal Control Tower facilitates a 24*7 live monitoring dashboard that offers real-time GPS tracking and speed monitoring, ensuring seamless operations round the clock.
- Integration of AI-driven Advanced Driver Assistance Systems (ADAS) and Driver Monitoring Systems (DMS) in internal vehicular operations enhances road safety.
- Augmented and Virtual Reality Training Centres, Video Analytics, Sustainability Mobile App, E-learning courses, and Digitalization of Workforce Connectivity to enhance leading indicators in safety practices.
- Centralized Security Operations Centre (CSOC) in the plant, which leverages digital intelligence and data insights for better decision-making in security, traffic & road safety, and supply chain security functions.
- Real-time data monitoring, facilitated by end-to-end digital dashboards, including projects like the Hot Spot Detection System at coal yard that uses thermal inspection to ensure strict adherence to safety.
- LED logo projectors in the plant, which are designed to illuminate safety signs on floors, ensuring clear and prominent display of safety messages in low-light conditions, especially in areas with dust accumulation and high vehicular traffic.
About BALCO:
Bharat Aluminium Company (BALCO) is a subsidiary of Vedanta Limited, operating a 0.57 million tonne per annum aluminium smelter in Korba, Chhattisgarh. It is part of Vedanta’s Aluminium Business, a division of Vedanta Limited, which is India’s largest producer of aluminium, manufacturing more than half of India’s aluminium, i.e., 2.42 million tonnes in FY25. It is a leader in value-added aluminium products that find critical applications in core industries. Vedanta Aluminium ranks 2nd in the S&P Global Corporate Sustainability Assessment 2024 world rankings for the aluminium industry, a reflection of its leading sustainable development practices. With its world-class aluminium smelters, alumina refinery and power plants in India, the company fulfils its mission of spurring emerging applications of aluminium as the ‘Metal of the Future’ for a greener tomorrow. For more information, please log on to www.balcoindia.com
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Disclaimer:
This press release contains “forward-looking statements” – that is, statements related to future, not past, events. In this context, forward-looking statements often address our expected future business and financial performance, and often contain words such as “expects,” “anticipates,” “intends,” “plans,” “believes,” “seeks,” “should” or “will.” Forward-looking statements by their nature address matters that are, to different degrees, uncertain. For us, uncertainties arise from the behaviour of financial and metals markets including the London Metal Exchange, fluctuations in interest and or exchange rates and metal prices; from future integration of acquired businesses; and from numerous other matters of national, regional, and global scale, including those of a political, economic, business, competitive or regulatory nature. These uncertainties may cause our actual future results to be materially different than those expressed in our forward-looking statements. We do not undertake to update our forward-looking statements.
About Vedanta Limited:
Vedanta Limited, a subsidiary of Vedanta Resources Limited, is one of the world’s leading Oil
& Gas and Metals company with significant operations in Oil & Gas, Zinc, Lead, Silver,
Copper, Iron Ore, Steel, and Aluminium & Power across India, South Africa, Namibia, and
Australia. For two decades, Vedanta has been contributing significantly to nation building.
Governance and sustainable development are at the core of Vedanta's strategy, with a strong
focus on health, safety, and environment. Giving back is in the DNA of Vedanta, which is
focused on enhancing the lives of local communities. Under the aegis of Vedanta Cares, the
flagship social impact program, Nand Ghars have been set up as model anganwadis focused on
eradicating child malnutrition, providing education, healthcare, and empowering women with
skill development. Vedanta and its group companies have been featured in Dow Jones
Sustainability Index 2020, and were conferred Frost & Sullivan Sustainability Awards 2020,
CII Environmental Best Practices Award 2020, CSR Health Impact Award 2020, CII National
Award 2020 for Excellence in Water Management, CII Digital Transformation Award 2020, ICSI
National Award 2020 for excellence in Corporate Governance, People First HR Excellence Award
2020, ‘Company with Great Managers 2020’ by People Business and certified as a Great Place
to Work 2021. Vedanta’s flagship Nand Ghar Project was identified as best CSR project by the
Government of Rajasthan. Vedanta Limited is listed on the Bombay Stock Exchange and the
National Stock Exchange in India and has ADRs listed on the New York Stock Exchange.
For more information, please visit www.vedantalimited.com
