One of the largest integrated primary producer of aluminium in Asia. With a pan-Indian presence that encompasses the entire gamut of operations, from bauxite mining, alumina refining, aluminium smelting to downstream rolling, extrusions and recycling, Hindalco enjoys a leadership position in aluminium and downstream value-added products in India.
Our Indian aluminium operations are integrated and consist of bauxite mining, alumina refining, smelting and converting primary metal into value-added products. We have dedicated sources for critical raw materials such as bauxite, power and coal. We also have committed supply sources for auxiliary chemicals.
Our finished products include alumina, primary aluminium in the form of ingots, billets and wire rods, value-added products such as rolled products, extrusions and foils. Metallurgical alumina is used for our own captive needs. Chemical alumina and hydrates are used in range of industries including water treatment, fillers in cables and plastics, refractories and ceramics, glass among others.
Our facilities are in regions close to raw material sources, low cost and available labour and demand markets. This helps in reducing costs and improving profit margins. The technology upgrade has resulted in higher utilisation rates at our plants and improved efficiency.
We believe implementation of superior technology not only reduces costs but also provides superior and customised products, thus, improving our sales.
Hindalco's integrated complex at Renukoot, in Uttar Pradesh, India, houses an alumina refinery, an aluminium smelter and facilities for the production of semi-fabricated products. Power is sourced from our Renusagar power plant, located about 45km from Renukoot. Our facilities also include an aluminium smelter and an aluminium FRP facility (for rolled products, extrusions products and wire rods) at Hirakud (Odisha) with a captive power plant and coal mine, and alumina refinery at Muri (Jharkhand). Our Chemical grade alumina plant is located at Belagavi (Karnataka), and rolling mills at Belur (West Bengal), Taloja near Mumbai and Mouda near Nagpur (Maharashtra). Foil rolling facility is situated at Mouda near Nagpur (Maharashtra) and our extrusion plant at Alupuram (Kerala).
Hindalco's new age smelters at Aditya (Odisha) and Mahan (Madhya Pradesh), operating on state-of-the-art AP36 technology, have not only resulted in expansion of our capacities but also improved cost-efficiency of our operations. These smelters have their own captive power plants and source alumina from Utkal, our 100% subsidiary.
Utkal Alumina (Odisha) is a world class refinery with one of the lowest cost structure in the world. The bauxite for Utkal is sourced from Baphlimali mines by a 18 kilometer long conveyor, one of its kind in the world
Hindalco manufactures coarse alumina hydrate, metallurgical alumina, special alumina and alumina hydrate. The chemicals business focuses on special alumina and alumina hydrates, which are products of in-house technological innovation by our Research & Development team at Hindalco Innovation Centre-Alumina(HIC-A). This research centre is recognised by the Department of Scientific & Industrial Research (DSIR), Government of India.
The chemicals business serves a wide range of customers across 32 countries around the world with special alumina and alumina hydrates. Alumina hydrates find use in applications like â?? alum, poly aluminium chloride (PAC), zeolites, aluminium fluoride, and as fire-retardant filler in polymer composites. Our special alumina finds a good suit in applications like refractory, ceramics, polishing compounds, abrasives and glass.
Hindalco's captive bauxite mines in the Indian states of Maharashtra, Jharkhand, Chhattisgarh, and Odisha, supply high quality raw material to our refineries located at Belagavi in Karnataka, Muri in Jharkhand and Renukoot in Uttar Pradesh, India. The alumina refineries at Belagavi, Muri and Renukoot have installed capacities of 350,000 TPA, 450,000 TPA and 700,000 TPA respectively. The state-of-the-art alumina refinery at Belagavi is dedicated to the manufacture of special alumina and alumina hydrates.
Utkal Alumina International Limited (UAIL), the fully-owned subsidiary of Hindalco Industries located in Rayagada district, Odisha, operates a most modern 1.5 MTPA alumina refinery.
During Hindalco's copper production process, by-products such as sulphuric acid and copper slag are formed. Sulphuric acid is partly converted into phosphoric acid, which is then made to react with ammonia to make di-ammonium phosphate (DAP) fertiliser. During the process of making phosphoric acid, phosphogypsum and hydrofluosilicic acid (HFA) are formed. HFA is partly utilised to make aluminium fluoride, and rest is sold in the market.
Sulphuric acid
Hindalco produces sulphuric acid of IS 266/1993 technical grade. The sulphuric acid plants use the double contact double absorption (DCDA) process, and are designed by Monsanto Envirochem (USA).
Phosphoric acid
Hindalco's phosphoric acid plant is based on the Prayon Mark IV dihydrate technology provided by SNC Lavalin (Belgium).
Phosphogypsum
Phosphogypsum is a by-product of Hindalco's phosphoric acid plant.
Copper slag (iron silicate)
Copper slag is produced during the smelting process at Hindalco's copper smelter located at Dahej.
Aluminium fluoride:
Hindalco produces aluminium fluoride by reacting HFA (a by-product of the phosphoric acid plant) with aluminium hydroxide (from Hindalc's aluminium manufacturing facilities).
Hindalco's copper division, Birla Copper, operates one of the largest single location custom copper smelters in the world. The custom copper smelter at Dahej in the state of Gujarat (west coast of India) houses three copper smelters, three refineries, two rod plants, a captive power plant, a captive oxygen plant, phosphoric acid plant, di-ammonium phosphate plant, precious metal recovery plant, captive jetty and other utilities. One of the new rod plants is under construction and will be operational by end FY18.
Hindalco produces LME grade copper cathodes, continuous cast copper rods in various sizes, and precious metals like gold and silver. Hindalco is one of the major manufacturers of 19.6mm diameter copper rods, which is used for railway electrification. The co-product, sulphuric acid, is partly utilised to produce phosphoric acid and fertilisers like di-ammonium phosphate (DAP).
Birla Copper's brands, Birla Copper and Birla Copper II, are recognized for their high purity and consistent quality in the domestic as well as global markets. Birla Copper is an ISO 9001, 14001, 27001, 50001 and OHSAS 18001 certified company, registered on the London Metal Exchange as Grade-A copper brand, and certified as a Star Trading House having labs for chemical, mechanical and electrical testing accredited by the National Accreditation Board for Laboratories (NABL).
Hindalco produces di-ammonium phosphate (DAP) fertiliser. It is the most popular phosphatic fertiliser because of its high nutrient content and good physical properties. The composition of DAP is 18% Nitrogen and P2O5 46%. Within the same facility, Hindalco can also produce nitrogen phosphorus potassium (NPK) complexes as value-added downstream products. It can manufacture NPK complexes such as 10:26:26, 12:32:16 and 20:20:0. Hindalco's DAP plant went on-stream in the year 2000, and has a capacity of 400,000 TPA.
Phosphoric acid is produced at Hindalco's phosphoric acid plant by the chemical reaction of sulphuric acid (generated as by-product from copper smelting process) and rock phosphate (imported). At the DAP plant, phosphoric acid and ammonia are reacted to form DAP. Imported potash is used to produce the NPK complexes.
The products are marketed under the well-known brand Birla Balwan, a name that commands preference among the farmers of Gujarat, Maharashtra, Rajasthan, Madhya Pradesh, Chhattisgarh, Haryana and Punjab, through a vast, established network of dealers, retailers and C&F agents. Operations are carried out through both private and institutional distribution channels. The products are packed in gusseted Lyril-green 50kg PP bags, and are transported to various destinations by rail and road, stored and then delivered to dealers, retailers, co-operative societies, and other customers in various marketing regions.
The customers are serviced through an experienced and qualified marketing team across all the seven states. Marketing, service-related activities, and farmer/retailer meets are regularly held at customers locations by well-trained field personnel.
Birla Phospho Gypsum is marketed in the agricultural field as a soil conditioner. The product contains 15-17 % sulphur, 20-22 % calcium and 1 % of P2O5. It is an economical input that adds nutrients to the soil and enhances its productivity, improvement and crop growth. Birla Phospho Gypsum is available in loose form, bulk and also in bags for convenience of handling and storage.
The popular brand, Birla Vishwas, caters to the market of diversified agricultural inputs.
