BALCO Reinforces Operational Excellence and Sustainability on Technology Day with Pioneering Digital Innovations

Balconagar; :Bharat Aluminium Company Limited (BALCO), a part of Vedanta Aluminium, reinforces commitment to operational excellence and sustainability through cutting-edge technological interventions across its value chain on National Technology Day. Aimed at enhancing efficiency, safety, and reliability, BALCO has introduced several advanced digital solutions, revolutionizing its operations.

To promote sustainable, energy-efficient operations, BALCO has introduced a new relining design in its potlines. This step, following 100% graphitization, aims at reducing energy consumption by 400 kWh/MT while improving current efficiency and lowering emissions.

Additionally, BALCO has integrated artificial intelligence (AI) simulators in the finishing line area to enable comprehensive analysis of process parameters, enhancing process efficiency. This targeted approach has helped in identification of optimal conditions for maximizing the production for rolled products.

Furthermore, the AI-driven advanced solutions have also played a pivotal role in enhancing product quality by improving anode making at BALCO’s furnace. This robot-based technology automates the assessment of refractory structures, swiftly detecting wear and tear of furnaces with precision, enhancing anode quality while ensuring secure operations.
The AI-powered Conveyor Belt Monitoring System deployed at BALCO’s 1200 MW power plant, further enhances both safety and efficiency. It conducts comprehensive conveyor health assessments, real-time fire alerts, and human presence detection near operational belts, reinforcing the company’s commitment to safe operations.

Speaking on the role of digitalisation, Mr. Rajesh Kumar, CEO & Director of BALCO, stated, “At BALCO, we are integrating digital innovation into every facet of our operations to drive efficiency, safety, and sustainability. Our digital interventions are setting new benchmarks in operational excellence, ensuring that we remain at the forefront of India’s aluminium industry while contributing to a more sustainable future.”

Technological interventions have become integral to the production of aluminium, the ‘Metal of the Future.’ The digital transformation at BALCO has strengthened safety, sustainability, and operational excellence across its line of operations. The digitization of 62 activities has replaced manual processes with real-time data collection, optimizing resource allocation, supporting data-driven decision-making, and maintaining a balance between human and machine interactions. Furthermore, cutting-edge technology being implemented at BALCO also include:

• The Finished Goods Tower, Ash Control Tower and Coal Control Tower facilitates a 24*7 live monitoring dashboard that offers real-time GPS tracking and speed monitoring, ensuring seamless operations round the clock.

• Integration of AI-driven Advanced Driver Assistance Systems (ADAS) and Driver Monitoring Systems (DMS) in internal vehicular operations enhances road safety.

• Augmented and Virtual Reality Training Centres, Video Analytics, Sustainability Mobile App, E-learning courses, and Digitalization of Workforce Connectivity to enhance leading indicators in safety practices.

• Centralized Security Operations Centre (CSOC) in the plant, which leverages digital intelligence and data insights for better decision-making in security, traffic & road safety, and supply chain security functions.

• Real-time data monitoring, facilitated by end-to-end digital dashboards, including projects like the Hot Spot Detection System at coal yard that uses thermal inspection to ensure strict adherence to safety.

• LED logo projectors in the plant, which are designed to illuminate safety signs on floors, ensuring clear and prominent display of safety messages in low-light conditions, especially in areas with dust accumulation and high vehicular traffic.