Aluminum is a light, soft metal that is the third most abundant element in the Earth's crust. It is widely used in everyday items. Hindalco is one of India's largest aluminum producers, operating across the aluminum value chain from bauxite mining to smelting to downstream products. Hindalco produces primary aluminum, flat rolled products, extrusions, and foils through processes like alumina refining using the Bayer process and aluminum smelting using the Hall-Héroult process in its facilities across India.

1. ALUMINIUM…..

2. ABOUT ALUMINIUM..
What is aluminum metal?
Aluminum (symbol Al) or alumium is a chemical
element or silvery-white, lustrous, low melting, soft
metal of Group 13 (IIIA) or boron family of
the periodic table uses widely in our everyday life.
Aluminum is the third most abundant chemical
element after oxygen and silicon.

4. .

5. .It is the most abundant metallic element in the
earth’s crust (8 percent by weight).
.Al differs from the first member of Group 13
(boron) due to its chemical properties, high
reactivity, and cationic chemistry in an
aqueous solution.
.It combines most of the nonmetallic elements
like nitrogen, sulfur, and halogens. It forms
intermetallic aluminum compounds with a large
number of metals.

6. Who discovered aluminum?
.British chemist Sir Humphry Davy failed to isolate the metal
but suggested the name of the element aluminum or alumium.
.In 1825 Denmark physicist Hans Christian Orsted first
discovered the metal by reducing aluminum chloride (AlCl3)
with potassium amalgam. Commercial production of the
element started in 1954 by electrolysis of NaAlCl4.

7. .aluminum usage in india

8. 1.Hindustan Aluminium Company (HINDALCO)
Mumbai, Maharashtra
2.Vedanta Limited
Jharsuguda, Odisha
3.India Foils Limited
Kolkata, West Bengal
4.Sacheta Metals
Mumbai, Maharashtra
5.Jindal Aluminium
Bengaluru, Karnataka
top player production of aluminum in
india

15. .Hindalco Aluminium Smelting operations are
located at Renukoot in Uttar Pradesh, Aditya
Aluminium in Odisha, Mahan Aluminium in
Madhya Pradesh and Hirakud in Odisha. All
these facilities combined produce around 1.3
Million tons of primary aluminium in a year.

16. Bauxite: Bauxite is an ore used in the production of alumina. In the mines located
in the eastern region, there are pockets of good quality bauxite that can be used for
various purposes in various industries, such as refractories, steel, polishing and for
manufacturing water-treatment chemicals.
India has sizeable deposits of bauxite and is home to the sixth largest bauxite
deposit in the world with a reserve base of over 2.20 billion tonnes. Indian bauxite
is of superior quality generally and is largely located on a single plateau, thus
making bulk mining possible and resulting in significant cost advantages in the
production of alumina and aluminium.

17. *Hindalco's captive bauxite mines in Jharkhand,
Chhattisgarh, Maharashtra and Odisha, provide
the raw material to our alumina refineries
located at Belagavi in Karnataka, Muri in
Jharkhand, Renukoot in Uttar Pradesh and
Utkal in Odisha.

21. Alumina Refining
Alumina is a white granular material, a little finer than table
salt, and is properly called aluminium oxide.
Aluminium does not occur as a metal but must first be refined
from bauxite into alumina. Approximately two tonnes of
alumina are required to produce one tonne of aluminium.

22. .
FUNCTIONAL DEPARTMENTS :
At HINDALCO the work is divided into the following
departments
*marketing
*production
*HR management
*Research and development
*Finance

23. .

24. PRODUCTION :--
In production department consists of …..
*ALUMINA REFINING
*SMELTING
*INGOT CASTING

25. The Bayer refining process used by alumina
refineries worldwide involves four steps:
1.digestion;
2.clarification;
3.precipitation; and
4.calcination.

26. Digestion:
.Bauxite is finely ground in mills, then mixed with a recycled caustic soda
solution and steam in digester vessels
operating at high temperature and pressure. This dissolves the alumina content
of the bauxite.
The solution is then cooled in a series of flash tanks.

27. Clarification
The impurities which remain undissolved are allowed to settle as a fine mud in
thickening tanks.
After several washing stages to recover caustic soda, the residue is pumped to
storage dams. The solution of alumina in caustic soda is further clarified by filtration.
The bauxite residue is safely stored, in ways which meet industry best practice and
required safety standards.
One technique used for bauxite residue storage in Australia is “dry stacking’”, which
involves depositing and drying
the residue in thin layers to a high density, thus making it very stable and unlikely to
flow in the event of a containment breach.

28. Precipitation
Alumina crystals are recovered from the caustic solution by mechanically
stirring the solution in
open-top tanks. Crystal growth is assisted by seeding with previously
precipitated alumina.

29. Calcination
The precipitated material (called hydrate) is washed and dried at temperatures
exceeding 1000 degrees
Celsius. This forms the dry white anhydrous aluminium oxide powder (alumina)
which is cooled and
conveyed to storage.
The caustic soda is recovered and returned to the start of the process and used
again.

31. Aluminium Smelting
. As electricity is a key input in aluminium smelting, smelters are usually located in areas with
reliable, historically low-cost electricity.
The HINDALCO industry continuously focuses on improving electricity efficiency, while also leading
the global industry in controlling direct greenhouse gas emissions.
The Hall- Héroult process is the main method of smelting aluminium used today and consists of five
steps:
1.adding bath and alumina;
2.anode;
3.electrolysis;
4.tapping; and
5.primary casting.

33. Adding Bath and Alumina
Inside a pot, alumina is dissolved in a “bath” of molten cryolite
(sodium aluminium fluoride) and
other materials.

34. Anode:
Anodes are used to conduct electricity into the smelting cells/pots in the pot
room. Anodes are
consumed in the smelting process and the remaining portions (known as
butts) are recycled.
Anodes are attached to rods and suspended into the electrolytic cells in the pot room
where they are
slowly consumed in the aluminium smelting process.
Carbon anodes, made from petroleum coke and pitch, are often manufactured on site.

35. Electrolysis:
A high electric current is passed through pots via the anode. The current flows
continuously from
the anode (positive) through alumina/cryolite mix to the lining of the pot (negative)
and then onto the next pot.
Electricity maintains the temperature of the process at about 950°C and enables
the alumina to split into aluminium and oxygen.

36. Tapping:
At regular intervals the molten aluminium is tapped from the pots and
transported to the casthouse.
Primary Casting
The molten aluminium is cast at a temperature of just over 700°C to form
ingots, slabs, billots and
t-bars.

37. PRODUCTS OF HINDALCO..
Hindalco Industries Limited is the metals flagship company of Aditya
Birla Group. It is one of Asia’s largest producers of primary aluminium
(excluding China), and with its subsidiary Novelis, a global leader in
flat rolled products and the world’s largest recycler of aluminium. In
India, Hindalco is the largest aluminium downstream player providing
customised solutions in flat rolled products and extruded
aluminium solutions.

40. .
Hindalco operates across the value chain, from
bauxite mining, alumina refining, coal mining, captive
power plants, and aluminium smelting to downstream
rolling, extrusions, and foils. It serves key sectors
such as aerospace and defence, building and
construction, electricals and electronics, automotive
and transport, beverage packaging, consumer
durables and kitchenware, pharmaceuticals and food
packaging, EV and renewables,
refractories, and ceramics.

41. Products of Aluminium:-
*Primary aluminium
Aluminium value added
Flat Rolled Products (FRP)
*ExtrusionsFoils and packaging
solutionsMetallurgical alumina