The document discusses the three captive power plants owned and operated by BALCO (Bharat Aluminium Company) in Korba, India. BALCO operates three thermal power plants with a total capacity of 2,540 MW fueled by coal from local mines. The power plants supply electricity to BALCO's aluminum smelting facilities. BALCO also operates two aluminum smelting potlines using prebake anode technology with a total capacity of 570,000 tonnes per year.

1. Aluminium Industry
By :- Nikesh kumar manhar
BE , EEE 6TH sem

3. Captive power plants in balco
• CAPTIVE POWER PLANT I
• Capacity: 1200 MW (CPP -2 X 300MW & IPP - 2 X 300 MW)
• Location: Balco Plant, Korba
• Source of Coal: Gevra, Kusmunda & Manikpur Mines of South Eastern Coalfields Ltd. (SECL) in Korba.
• Source of Water: Hasdeo River
• Operation & Maintenance: BALCO's own operation
•
Salient Features
• Primary Fuel : Thermal Coal
• Startup Fuel : LDO, Burning Oil & HFO
• Pulverizing System : Primary air system medium speed mill
• Water Source - DM water
• Steam turbine : Subcritical pressure, single reheating type, single-shaft, two cylinders, condensing steam
turbine

4. • CAPTIVE POWER PLANT II
• Capacity: 540 MW (4 X 135 MW)
• Location: BALCO Plant, Korba
• Source of Coal: Gevra & Kusmunda mines of South Eastern Coalfields Ltd (SECL)
in Korba.
• Source of Water: Hasdeo River
• Operation & Maintenance: BALCO’s own operation
•
Salient Features
• Primary Fuel - Thermal Coal
• Start-up Fuel - LDO / HFO
• Pulverising System - Primary Air System with Vertical Roller Mills.
• Steam Turbine - Double cylinder, Impulse, Condensing and Nozzle & Throttle-
governed turbine
• Turbo Generator - Air Cooled, Direct Coupled Generator, Static Excitation

5. • CAPTIVE POWER PLANT III
• 1200 MW comprises of 4units of 300 MW each in which 2 Units are IPP and 2 Units are CPP.
• Capacity: 1200 MW (4 X 300 MW)
• Location: BALCO Plant, Korba
• Source of Coal: Gevra & Kusmunda mines of South Eastern Coalfields Ltd (SECL) in Korba.
• Source of Water: Hasdeo River
• Operation & Maintenance: BALCO's own operation
• Installation / O & M: Balco’s own operation from 01.05.2016 onwards.
•
Salient Features
• Primary Fuel : Thermal Coal
• Startup Fuel : LDO, Burning Oil & HFO
• Pulverizing System : 5 Mills, ZGM133G Bowl Mill (4 Working + 1 Stand By)
• Water Source - DM water
• Steam turbine : Subcritical pressure, single reheating type, single-shaft, two cylinders,
condensing steam turbine.
• CAPACITY : 1200 MW
• RAW MATERIAL : Coal, Water, Oil
• TECHNOLOGY : Thermal Power Plant with Pulverized coal fired boiler.

6. • BOILER :
• Manufacturer - HARBIN BOILER CO. LTD.
• Type - Natural Circulation, Sub critical, Reheat, Drum type & Corner firing.
• Capacity - 1025 TPH (BMCR),Operating SH Pr. 17.39 Mpa.
• TURBINE :
• Manufacturer - DONG FANG TURBINE FACTORY LTD.
• Type - Sub Critical, Reheat, Single Shaft. Double cylinder & Condensing Steam
Turbine
• Capacity - 300 MW (normal); 3000 RPM
• GENERATOR :
• Manufacturer - DONG FANG ELECTRICAL MANUFACTURING CO. LTD
• Type - 2 Pole, synchronous generator at 20 KV and 10189 amps rated current
with hydrogen cooled rotor and water cooled stator.
• Capacity - 300 MW (norma

7. • SEVERAL FIRSTS TO ITS CREDIT IN INDIA
• First integrated Aluminum Industry
• First to have Captive Power Plant
• First to venture into + 300 kA Prebake pots
• First to produce Alloy Rods for conductors used in power
transmission industry
• First to roll material for Aerospace in the Country
• First to produce largest Billet of diameter – 800 mm, length - 6 mt
• First to set up the widest Hot Rolling Mill

11. Process of smelting
• The process involves electrolytic reduction of Alumina (Al2O3) dissolved
in electrolyte (bath) mainly containing Cryolite (Na3AlF6).
• The mixture electrolysed causing the Oxygen ion of the dissolved Alumina
to discharge on positive electrode where it reacts with Carbon anode to form
gases like CO2 and CO.
• The Al3+ ion deposited at the negatively charged cathode converts into
liquid metal which sinks to the top of cathode from where it is periodically
collected and sent to casthouse or fabrication for further processing.
• Electrical resistance within the bath provides sufficient heat to keep the
Cryolite molten.
• The pot is thermally insulated from side and bottom to maintain the
optimum heat balance and sufficient ledge (frozen electrolyte) on the side of
the shell.
• A crust of bath and Alumina covers the anode to avoid anode oxidation.

12. • SALIENT FEATURES OF BALCO POTLINE - 1
• BALCO, Potline -1 works on Prebaked technology
• A total of 288 electrolytic cells are installed with potline-1 current of
320 kA
• All 288 pots are connected in a series circuit
• The name plate capacity of potline-1 is 245 ktpa

13. • SALIENT FEATURES OF BALCO POTLINE - 2
• BALCO, Potline -2 works on Prebaked technology
• A total of 336 electrolytic cells are installed with potline-2 current of
340 kA
• All 336 pots are connected in a series circuit
• The name plate capacity of potline-2 is 325 ktpa

15. THANKYOU…….