Tutorial-1

Non-ferrous Industries in India

Prepared by: Dr.Bharati R.Rehani

Aluminium Production in India

• World's fifth largest aluminium producer

• Aluminium production competence of around 2.7 million tones

• 5% of the total aluminium production in the world

• Huge reservoir of Bauxite with a Bauxite reserve of 3 billion tones.

Aluminium Industries

• Companies under the India aluminum industry

• · Hindustan Aluminium Company (HINDALCO)

• · Indian Aluminum Co. Ltd (INDAL)

• · National Aluminum Co. Ltd (NALCO)

• · Bharat Aluminum Co. Ltd (BALCO)

• · Madras Aluminum Co. Ltd (MALCO)

HINDALCO

• Hindalco is Asia's largest integrated primary producer of aluminium

• Hindalco is the biggest aluminium industry in India with around 39% of market share

• An Aditya Birla Group flagship company, Hindalco has its aluminium plant at Renukoot in Uttar Pradesh

• Various aluminium products are primary aluminium, extrusions, rolled products, wheels and foils

Hindalco’s integrated complex at

Renukoot , Uttar Pradesh, India

• Alumina refinery

• Aluminium smelter

• Facilities for the production of semi-fabricated products.

• Power is sourced from our Renusagar power plant, located about 45 km from Renukoot.

Other facilities include

• Aluminium smelter at Hirakud (Odisha) with a captive power plant and coal mine

• Alumina refineries at Muri (Jharkhand), and Belgaum (Karnataka)

• Rolling mills at Belur (West Bengal), and Taloja, Mouda (Maharashtra)

• Foil rolling at Kalwa (Maharashtra) and Silvassa (Union Territory of Dadra and Nagar Haveli)

• Extrusions plant at Alupuram (Kerala).

Products: Primary aluminium • Ingots

produces high-purity ingots through smelting

• Alloy ingots of various grades are also produced and mainly used for the production of castings in the auto industry and in electrical applications.

• Wire rodsHindalco manufactures wire rods in a continuous

casting and rolling process. Electrical conductor (EC) wire rods are used for the production of cables and conductors.

• BilletsHindalco's aluminium billets are top-quality billets

with a smooth finish. They are used mainly to produce extrusions and forgings.

Aluminium extrusions

• Extrusions capacity stands at 31,000 tpa.• Two extrusion plants in India, Renukoot, Uttar Pradesh, and Alupuram, Kerala• Manufactured from high-quality billets • Offer the widest range of shapes and alloys• Hindalco Extrusions is a leading brand for a wide

spectrum of industries, including architectural, electrical, industrial, transport, defence and consumer durables industries.

Rolled products • Al-clad sheets / coils

-Automobile radiators

-Inter-coolers

• Building sheets -Cladding for roofs and walls

-Industrial buildings, warehouses, aircraft

hangers

Foil and packaging

Sterlite Industries• Aluminium business of Sterlite Industries Limited

comprises of Indian aluminium giants – BALCO

• BALCO is a partially integrated

• Sterlite has got a market share of around 32%.

BALCO• Korba in the state of Chhattisgarh with a smelter

capacity of 345 ktpa • The Hall-Heroult process is used • The molten metal (Aluminium) is fabricated into

saleable products by adapting different processes.

-Cast House continuous Casting and Rolling process is adopted in which hot metal, after being continuously cast as Cast Bars is rolled to Wire Rods

-Foundry Hot metal received from smelter is alloyed

-Sheet Rolling Shop slabs and caster coils are processed as semi -finished products for further rolling into sheets, coils and plates

NALCO• It is also one of the leading aluminium producers

in India

• Government of India has a stake of 87.15% in this company

• Its aluminium refinery is located at Damanjodi

• It also has a smelter located at Angul, Orissa.

Copper Industries in India

• Sterlite Industries Ltd.

• Hindalco Industries

• Hindustan Copper

Hindalco's copper division• Integrated facility at Dahej in the Bharuch district of Gujarat• The unit has the unique distinction of being the largest

copper smelter in the world at a single location with a 500,000 tpa capacity

• The facilities comprise copper smelters, captive power plants, utilities and a captive jetty.

• The company's copper product range includes copper cathodes and continuous cast copper rods. Birla Copper also produces precious metals, sulphuric acid, phosphoric acid, di-ammonium phospate (DAP) and other phosphoric fertilisers, and phospho gypsum.

Copper cathodes

Cathodes are largely used in the manufacture of

• copper rods for the wire and cable industry• copper tubes for consumer durable goods• used for making alloys such as brass,

bronze and alloy steel

Continuous cast copper rods• International quality standards. Their excellent surface

finish makes them suitable for processing to enamelled, coated and plated wires. They are available in diameters of 8, 11, 12.5, 16 and 19 mm.

• The homogeneous structure and fine grain size of the

continuous cast copper rod result in outstanding drawability. It can be drawn to an ultra-fine wire at a high yield rate.

• The Birla Copper rod is considered suitable for power and communication cables, strips for power and distribution for transformers, magnet wires, and zari manufacturing. Larger diameter rods — 11, 12.5 and 16 mm — are used to produce profiles and busbars.

• Birla Copper is the only manufacturer of the 19-mm-diameter copper rod in India. This rod is used for groove conductors and profiles.

• The Birla Copper rod is considered suitable for: power and communication cables, strips for power and distribution for transformers, magnet wires, zari manufacturing

A larger diameter rod —11, 12.5 and 16 mm — is used for producing profiles and busbars.

Precious metals

• Precious metals are extracted at our precious metals refinery located at Dahej. Gold and silver have an affinity to copper ore and are found in certain quantities in the concentrate supplies.

• The precious metals are extracted after copper refining to produce 99.9 per cent pure gold, silver and selenium. The residue contains traces of platinum and palladium, which are sold as platinum group metal mix, commonly known as PGM.

Hindustan Copper Limited

• INDIAN COPPER COMPLEX Ghatsila, Dist. – Singhbhum(E) , Jharkhand

• KHETRI COPPER COMPLEXDist. – Jhunjhunu Rajasthan

• MALANJKHAND COPPER PROJECT Malanjkhand, Dist. – Balaghat Madhya Pradesh

• TALOJA COPPER PROJECT Taloja, Dist. – Raigad, Maharashtra

INDIAN COPPER COMPLEX

• Facilities 1. Surda Copper Ore Mine

2. Concentrator Plant3. Smelter Plant4. Refinery Plant5. Wire Bar Plant6. Sulphuric Acid Plant7. Precious Metal Plant

KHETRI COPPER COMPLEX

• Facilities 1. Copper Ore Mines (Khetri, Kolihan)

2. Concentrator Plant3. Smelter Plant4. Refinery Plant5. Wire Bar Plant6. Sulphuric Acid Plant

MALANJKHAND COPPER PROJECT

1. Copper Ore Mine 2. Concentrator

TALOJA COPPER PROJECT

1. Continuous Cast Copper Rod Plant

Zinc and Lead Industries

Hindustan Zinc Limited

• Hindustan Zinc is the largest integrated Zinc producer in India

• It owns captive zinc mines that supply all of Hindustan Zinc’s Zinc concentrate requirements for its smelters

• Hindustan Zinc operates three underground mines (Sindesar Khurd, Rajpura Dariba, and Zawar Mines) and one open cast mine Rampura Agucha Mine being one of the most cost-efficient Zinc mines in the world

Zinc Smelters

• Hindustan ZincLtd. operates smelters using, Roast Leach Electro-Winning (RLE), hydrometallurgical (Debari, Vizag and Chanderiya Smelters),

• Pyrometallurgical (Chanderiya Lead Zinc Smelter)

• Ausmelt(Chanderiya Lead Smelter) process routes.

Chanderiya Lead Zinc Smelter Complex

• Products Range

•   Zinc -Slabs    (25 kgs)   

Jumbo (1,000 kgs) 

•  Lead-Slabs    (25 kgs) 

• Cadmium -Pencils  (160 gms) 

• Silver -Bricks (30 kgs) 

• Sulphuric Acid -+ 98.5% concentration

Magnesium Industries

• National Metallurgical Laboratory (NML)

Jamshedpur- 250 tons/year

• Central Electrochemical Research Institute,

Karikudi , Tamil Nadu

Nickel Industries

• Sukinada Nickel extraction Project, National Aluminium Co.Ltd.,

Orissa• Kolar, Karnataka• Jaduguda, Bihar• Hindustan Copper Limited, Khetri,

Rajasthan