My perspectives regarding a prospective Alumina refinery and some thoughts for conceptualization of world Class refinery.

1. By
SANDEEP GUPTA
Dated 28 .07.2017

2. Related experience
 Strong aspiration and preparations to deliver world class alumina refinery .Co developer of
the model ore dressing plant and hydro smelter plant and project concept and action plan at
HZL.
 Experience of working with EIL at Mahan and Aditya alumnium smelter projects as a
client. Mega projects (Each $ 2 billion in 2010). Alumina refinery project most likely to be
with same metallurgical division of EIL.
 Implemented many best Practices of project engineering and management at Mahan and
Aditya smelter projects. Creative construction methodology and strategy benchmarking.
Vendor development and cost management. Work breakdown structures, contract
management and Commissioning etc.
 A SWOT analysis of the technology package(from world best technology provider -AP,
France ), EPCM consultant(EIL) specifications – gap analysis lead to ‘better the best”.
Double digit improvements at process, sub process and equipment level suggested and
accepted by AP.
 Experience at Integrated aluminium complex, Hindalco, Renukoot with alumina refinery.
 Self driven experiences such as 30+ internal audits for Integrated management systems
(EHSEQ), waste management at alumina Plant and various projects. Aluminium smelter
IMS system coordinator role and Leadership role at Safety excellence journey has been
handy to develop management and control systems and MIS etc. Awareness campaign
leader and assessor for CII EXIM Business excellence has provided world class
approaches.

3. Related experience
 HO role at HZL : common engineering and capex for smelters, CPP and mines
 Hydrometallurgical Zinc smelter experience – capex and engineering . Alumina refinery
has high similarity to Alumina refinery.
 Tailings dam, water management and innovations –Thickening /paste tailings. Similar to
Red mud waste management and sustainability concerns.
 Experience of structural health management and structural integrity at HZL. This shall
help prevent ground upheaval problems in almost all alumina refineries.
 Transformation project to upgrade obsolete technology aluminum smelter into ‘at par ‘
with modern technology smelter.
 Headed aluminum smelter maintenance- this shall help to achieve high maintainability
and opera ability of projects.
 Leadership position on Process safety management . Major risk management.
 Experience of assimilating a body of Knowledge and contemporary approaches for
business development in minerals and metals sector at L&T IES and HZL.

4. Approaches for Alumina project (and others)
 Learning of Hindalco-Muri project shortcomings- major being gap of bauxite quality forecasting
between mine planning and project specifications .
 Active innovations such as neutralisation of the redmud by sea water. Deep sea disposal of redmud
exploration,
 Improved Design basis innovations to optimise the design plant life 40-50 years+ (chemical plants
start strugling after 25 years due to corrosion and detrition).
 LEAN PLANT and process design.
 Usage to the hilt of dynamic simulations in project stage ( to be included in specifications and scopes)
 Digitalization and IOT.
 Design of refinery for extreme conditions of Kutch.
 Benchmark project not only against othe alumina refineries but also parallel of oil refinery. Apply
TRIZ and ‘Design thinking’ concepts.
 Explore possibilities of modular and portable constructions.
 Online analysers for the silica and other impurities development.
 Layouts and detail engineering that supports optimised cost of capacity expansion.
 Prevention of caustic imbrettlement of equipment and structures.
 Major projects Services benchmarking ( with Worley Parsons/ Advisian etc. )
 There are many projects in pipeline in metals sector with Hindalco, Adani and Vedanta etc. Prior
preparations can help deliver superior value

5. Self Professional Position
 Positioned for providing Engineering, technical and Project
management directions at Major projects.
 Immediately available for engagements.

6. THANKS