View the copper value chain (1) combined 1 (1) flipbook.
The Legal Handbook on Copper Manufacturing - A Hindalco Legal Publication Publication Date: Volume No.: I Revision Date:
Global Origins & Maritime Logistics: Copper Concentrates via Dahej Captive Jetty Mexico Congo Tanzania Brazil Peru Chile Australia Domestic Integration: Hindustan Copper Limited (HCL) supplements imports with 2000- 3000 tonnes/month via container delivery and aids inhomogenization.
Red Flag Identification and CAHRA Determination On three criteria namely, conflict, human rights and governance. It involves three levels: • Initial country level CAHRA determination based on TDI’s CAHRA map; • If country covered by Dodd Frank Act or identified as a high risk in the indicative list of CAHRAs provided by the European Commission. • If necessary, regional-level CAHRA determination. Track C Risk-based approach For low-risk or secondary/recycled material Track A External Industry Certification Third Party frameworks Internal SoPs The Track A Commitment Internally regulated only Track B
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Smelter 1 and Smelter 3 at the Dahej, Gujarat are powered by Metso Outotec Corporation’s Flash Smelting Technology and Mitsubishi Materials Corporation, respectively.
Both the Refineries at Dahej, Gujarat (1&2 and 3) are powered by M/S ISA (Australia) (presently, Xstrata Group).
Capacity: SAP-1 (1850 TPD) & SAP-3 (2800 TPD). The technical know-how for the Sulphuric Acid Plant at Dahej, Gujarat belongs to Outokumpu, Finland and the technology is supplied by Monsanto Inc.
SMS Technology, German based M/S Southwire, USA based CCR-3, 4 CCR-1 CCR-3, 4 Continuous Casting Rod (CCR) Process: Line 1 vs. Line 3, 4 Bottom Track for CCR- 3 and 4 Flow Top Track for CCR-1 Flow
Otto Junker CAF (Bright Annealing) Rolled Shell Mother tube Drastic reduction Cast shell 99.9% Copper Cathode SMS Channel Furnaces • Melting Temp.: 1200 – 1220 • Horizontal Continuous Casting Impurities peeled (1mm total) & Rolled SMS Surface Mill In- Order Double Cascade Uncoiled & Drawn twice Cold drawn via tungsten/steel plug & die In-Order Spinning Block Inductoheat (In-line Annealing) Induction heating softens metal; relieves stress Xing-Rong (Inner Grooving) Mechanical reshaping without heat Plain Tubes Eddy Current Testing (ECT) DHR Packing Magnified Cross Section: Inner Grooved Tube (IGT) • AC Refrigeration • Plumbing • Heat Exchangers The technology at IGT is called Cast and Roll Technology; supplied by four OEMs namely, SMS, In-Order, Inductoheat and Xing Rong. Inner Grooved Tubes (IGT)
The technology belongs to Rautomead Limited (a Scottish company). Copper Alloy Plant, Waghodia
The technology partner for the Precious Metals Recovery Plant at Dahej, Gujarat is Metso.
The technology partner for the E-waste and Secondary Copper Recycling Plant at Pakhajan, Gujarat is Metso.
Inspection and shredding E- waste (PCBs), fluxes (Fe, Silica), pure copper and secondary copper Melts & separates organics Black Copper (68-70% Cu) Black Copper, Scrap O2 oxidation of impurities Raw Copper (98-99% Cu) Slag from S/R Kaldo Coke reduction Pb-Sn/ Cu-Ni alloys Raw Copper Final reduction/oxidation Anode Copper (99.5% Cu) S-Kaldo (Smelting) R-Kaldo (Refining) Pb-Sn Kaldo (Recovery) Anode Furnace E waste recycling attracts the applicability of E-Waste (Management) Rules, 2022.
Birla Balwan A strategic pivot from local production to a tightly regulated, import-focused PHYSICAL SUPPLY CHAIN QUALITY, STANDARDS AND MORE Imports of fertilizers which arrive at Mundra Port from Morocco, Saudi Arabia, China, and Norway Cargo is unloaded and transferred to secure storage facilities Material is packed into standard 50 kg bags bearing the Birla Balwan brand Movement from wholesale networks to retail points The physical handover to the end consumer 1. Port unloading (Intratech/SGS). 2. Godown storage (IGA Labs/Bureau Veritas). 3. Dispatch check (Bright Maritime Services). Strict adherence to Fertilisers Control Order (FCO) 1985 specifications. Recourse protocols: 5 National Test Houses, 5 Central Labs POS Machine Integration + Aadhar Verification at the point of sale instantly triggers the Government of India subsidy payout.
Legal Framework Applicable to the Operational Legal Framework Applicable to the Operational Process This section outlines the key laws applicable to the process Environment Act, 1986 Explosives Act, 1884 Air act, 1981 & Water act 1974 Essential Commodities Act, 1955 Click on the Act for more details Legal Metrology Act, 2009 Boiler Act, 2025 (MARPOL), 1978 Protocol
Hindalco Industries Limited’s cop per division at Dahej, Gujarat, was commissioned in 1998 as part of the Aditya Birla Group’s vision to establish a world-class integrated cop per smelting complex in India. Originally developed under Indo Gulf Corporation, the plant was later amalgamated with Hindalco in 2 00 2 to consolidate the group’s metals business. Over the years, the Dahej facility underwent multiple expansions—from an initial cap acity of about 100,000 TPA to nearly 5 0 0 , 0 0 0 MTPA through the adoption of advanced technologies such as Outokumpu Flash Smelting, Ausmelt, and the Mitsubishi Continuous Smelting Process. Today, the Dahej complex is one of the largest single-location custom cop per smelters in the world, comprising cop per smelters, refineries, rod plants, captive power facilities, precious metals recovery units and captive port infrastructure through Dahej Harbour & Infrastructure Limited (DHIL). The plant plays a significant role in supplying cop per products for sectors such as power, railways, infrastructure, automobiles, and electric vehicles, while also contributing to India’s precious metals production and sustainable industrial development. Copper concentrate ( CC) for the Dahej Copper Smelter is received through the captive jetty operated by DHIL. It is a wholly owned subsidiary of Hindalco Industries Limited and is located on the coast of the Gulf of Khambhat (Arabian Sea) with geographical coordinates of latitude 21°42′ North and longitude 72°31.5′ East. Page 01/02
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ADITYA BIRLA RESPONSIBLE SUPPLY CHAIN POLICY Satish Pai, anaging Director Effective from: 28’h June, 2024* Version: 1.0 *Placed before the Managing Director and the Executive Committee and approved thereat. For internal reference and circulation only.
RESPONSIBLE SUPPLY CHAIN POLICY As a global metals business, we understand that risks of significant adverse impacts may be associated with the extraction, trading, handling and exporting of minerals from conflict- affected and high-risk areas (CAHRAs). At the same time, we recognise the valuable role that our business can play in advancing responsible business standards, both internally and in our supply chains. A. With the adoption of this Responsible Supply Chain Policy, we commit to: 1) Uphold our responsibility to respect human rights. 2) Refrain from any action which contributes to the financing of conflict. 3) Comply with relevant United Nations sanctions resolutions or, where applicable, domestic laws implementing such resolutions. 4) Neither tolerate nor by any means profit from, contribute to, assist with, or facilitate the commission by any party of serious abuses associated with the extraction, transport, or trade of minerals: a) any forms of torture, cruel, inhuman and degrading treatment;1 b) any forms of forced or compulsory Iabour;2 c) the worst forms of child Iabour;3 d) other gross human rights violations and abuses such as widespread sexual violence; e) war crimes or other serious violations of international humanitarian law, crimes against humanity or genocide.4 5) Not tolerate any direct or indirect support to non-state armed groups' through the extraction, transport, trade, handling or export of minerals, including but not limited to non-state armed groups or their affiliates who: a) illegally control mine sites or otherwise control transportation routes, points where minerals are traded and upstream actors in the supply chain; and/or b) illegally tax or extort money or minerals at points of access to mine sites, along transportation routes or at points where minerals are traded; and/or c) illegally tax or extort intermediaries, export companies or international traders. 6) Refrain from any direct or indirect support to public or private security forces that commit abuses or act illegally as described above. 7) Not offer, promise, give or demand any bribes; resist the solicitation of bribes; and support efforts, or take steps, to contribute to the effective elimination of money laundering. 8) Ensure that all taxes, fees, and royalties related to mineral extraction, trade and export from CAHRAs are paid to governments. 1 OFF As dehned by the Convention against Torture and Other Cruel, Inhuman, or Degrading Treatment or Punishment, adopted on 10 December 1984 by the UN General Assembly. 2 As defined by lhe ILO Convenlion No. 29 on Forced Labour 1930). 3 As defined by the ILO Convention No. 182 on the Worst Forms of Child Labour (1999). As defined by the Rome Statute of the International Criminal Court. As per relevant UN Security Council resolutions. For internal reference and circulation only.
B. We endeavour to uphold these commitments by implementing a due diligence system aligned to the 5-step framework of the OECD Due Diligence Guidance for Responsible Supply Chains of Minerals from Conflict-Affected and High-Risk Areas (“OECD Due Diligence Guidance”), which includes: 1) establishing a strong company management system; 2) identifying and assessing risks in the supply chain; 3) designing and implementing a strategy to respond to identified risks; 4) carrying out independent third-party audit of supply chain due diligence at identified points in the supply chain; and 5) reporting on supply chain due diligence; as articulated in internal Standard Operating Procedures. C We use our influence over the supply chain to catalyse positive change. To this end, we best endeavour to: 1) Engage with suppliers, as well as central or local governmental authorities, international organisations, civil society, and affected third parties, as appropriate, to design and adopt appropriate risk management plans, to improve and track performance with a view to preventing or mitigating risks through measurable steps taken in reasonable timescales. This includes building capacity within our supply chains through training and dialogue. 2) If we or any company in our supply chain contract public or private security forces: a) we endeavour to ensure or require that such engagement is in accordance with the Voluntary Principles on Security and Human Rights; b) we will support efforts, or take steps, to engage with authorities, international organisations and civil society organisations to contribute to improving transparency, proportionality and accountability in payments made to public security forces; and c) we will support efforts, or take steps, to avoid or minimise the exposure of vulnerable groups to adverse impacts associated with the presence of security forces, public or private, on mine sites. D. While committing to the above strategy of engagement, the following risk management strategies will be adopted where necessary: 3) 1) Regarding serious abuses associated with the extraction, transport or trade of minerals, we will immediately suspend or discontinue engagement with suppliers where we identify a reasonable risk that they are sourcing from, or linked to, any party committing serious abuses as defined in this Policy. 2) Regarding direct or indirect support to non-state armed groups, we will immediately suspend or discontinue engagement with suppliers where we identify a reasonable risk that they are sourcing from, or linked to, any party providing direct or indirect support to non-state armed groupFosr inatserndael rfeifnereednceinantdhciisrcuplaotiloicn yon.ly. Regarding public or private security forces, risk management of bribery and fraudulent misrepresentation of the origin of minerals, money-laundering, and non-payment of taxes, fees and royalties to governments, we will suspend or discontinue engagement with suppliers after failed attempts at mitigation within reasonable timelines.
Email ID Toll-free Hotline Web Portal abq.ethicshelpIirie(Ointeqrit y matters.in 1800- 102-6969 www.abqethicsheIpIine.inteq ritvmatters.in E. The commitments outlined in this Policy are integral to our broader responsibility to foster responsible supply chains, including respecting human rights and promoting environmental stewardship both internally and in our supply chains, as articulated in our dedicated policies (see Human Rights Policy, Rehabilitation, Resettlement and Protection of Indiqenous People Policy and Environment Policy). F. Any comments, questions, or grievances related to the topics covered in this Policy may be addressed via Hindalco's grievance mechanism: G. This Policy shall be communicated to all suppliers and other stakeholders, as appropriate, and be made publicly available on our website. 3 or3 For internal reference and circulation only.
Page 01/01 BERTHING Berthing is the process of safely positioning a vessel alongside the jetty for cargo operations. Upon arrival, tugboats provide the necessary thrust and directional control to guide the vessel safely into position, particularly in the presence of tides, currents, or adverse weather conditions. Typically, two tugboats per vessel are required for this purpose. Once aligned, the vessel is secured using mooring ropes fastened to bollards, while jetty-mounted winches regulate tension to ensure that the vessel remains stable and does not drift during operations. The jetty has a total of 4 winches with a capacity of 110 tonnes each and 16 ropes which come from the vessel. BERTHING Berthing is the process of safely positioning a vessel alongside the jetty for cargo operations. Upon arrival, tugboats provide the necessary thrust and directional control to guide the vessel safely into position, particularly in the presence of tides, currents, or adverse weather conditions. Typically, two tugboats per vessel are required for this purpose. O n ce aligned, the vessel is secur ed using mooring ropes fastened to bollards, while jetty-mou nted winches regulate tension to ensure that the vessel remains stable and d oes not drift during operations. The jetty has a total of 4 winches with a capacity of 110 tonnes each and 16 ropes which com e from the vessel. This process is supported b y continuous monitoring through syst em s such as the Vessel Traffic Monitoring Sy stem (VTMS), which provides real-time information on vessel movement and positioning. Operators simultaneously assess environmental factors, including wind speed, tide levels and draft requirements, to maintain optimal berthing conditions. The coordinated use of automatic and manual winch controls ensures gradual stabilization of the vessel, thereby minimizing sudd en movements and establishing a secure platform for subsequent unloading activities.
Unloading Following successful berthing, unloading operations are initiated through the deployment of cranes (Dalian and Figee) equipped with grabbers designed to handle bulk cargo such as copper concentrate. Each crane has a rated capacity of 26T, including a grab of approximately 9T, and under normal operating conditions, each crane handles about 300T to 400T per hour. Typically, around 4,000T of copper concentrate is unloaded in a day, and when both cranes operate together at higher efficiency, up to 8,000T can be unloaded. Unloa ding Following successful berthing, unloading operations are initiated through the deployment of cranes (Dalian and Figee) equipped with grabbers designed to handle bulk cargo such as copper concentrate. Each crane has a rated capaci ty of 26T, including a grab of approximately 9T, and under normal operating conditions, each crane handles about 3 0 0 T to 4 0 0 T per hour. Typically, around 4 , 000 T of copper concentrate is unloaded in a day, and when both cranes operate together at higher efficiency, up to 8 , 000 T can be unloaded. The grabbers lift material from the vessel’s hold and discharge it into hoppers, from where it is systematically transferred for further handling. The selection of grabbers is determined by the nature of the cargo, ensuring both efficiency and preservation of material integrity during the unloading process. In this context, two primary types of grabbers are utilized depending on the nature of the material being handled, namely mild steel (MS) grabbers and standard steel (SS ) grabbers. While MS grabbers are generally suited for handling coal due to their material properties, S S grabbers are specifically deployed for copper concentrate to ensure durability and operational efficiency. Subsequently, the discharged cargo is conveyed through an integrated system of belt and pipeline conveyors, beginning at the jetty and extending to the processing plant. This system operates in conjunction with structural and safety features, including fenders that absorb impact forces and reinforced concrete foundations that provide stability to the jetty infrastructure. The unloading pr ocess is calibrated to achieve high output within defined operational timelines, while maintaining safety standards and ensuring continuity in cargo transfer. Page 01/01
Conveyance and Preparation Conveyance and Preparation Page 01/04 The concentrate is lifted from the ship’s hatches and dropped into hoppers located on the jetty deck. From these hoppers, the material moves onto the R1 conveyor belt, which is roughly 180 meters long and runs along the jetty structure. The R1 conveyor transfers the material to Transfer Tower-1 (TT1), where the belt transitions into the long-distance pipe conveyor, R2. From TT1, copper concentrate is conveyed through the R2 pipe conveyor, which has a total length of about 3.2 km between the jetty and the plant, and uses a steel-cord rubber belt that closes into a pipe shape during movement. The pipe conveyor reduces dust, spillage, and rain ingress, with rollers enabling smooth pipe to flat belt transitions. R2 opens at Transfer Tower-3 (TT3), which is the interface between the jetty system and the Raw Material Handling (RMH) plant. At TT3, the copper concentrate is discharged onto a belt conveyor equipped with belt weighers to accurately measure the quantity received. This data is used for inventory accounting and reconciliation with shipping documents. From Transfer Tower 3 (TT3), coal discharged from the conveyor enters a movable hopper and is routed via the weighing system to Pipe Conve yo r 1. The coal is then conveyed through Transfer Towers 3 and 4 and transported directly to the Coal Plant for further processing.
Sampling is carried out at this stage, generally at a rate of one composite sample for every 50 0T , and a moisture laboratory located within the TT3 building supports routine testing and quality checks. Generally, moisture is checked to be around 8 to 9%. The sample is divided into four parts, and each is sent to corporate, precious metals recovery plant lab, the client, and one retained for internal records. After weighing and sampling, the concentrate is temporarily stored in 9 tons hoppers and conveyed to the RMH storage yard. The storage yard has a capacity of about 1 lakh metric tonnes and is divided into around sixteen bays. Shuttle conveyors distribute the concentrate into designated bays based on grade. The yard supplies material to dedicated hoppers for Smelter-1 and Smelter-3, from where it moves further to bedding plants and dryers for smelter 1 and 3. Bedding Plant: The bedding plant is responsible for blending copper concentrates from the storage yard to achieve a uniform and consistent feed quality for smelters. While the basic bedding operations such as weighing, stacking in layers, circular bedding, and reclaiming—remain similar for both smelters, the ca pa ci t y requirements and operational impor tance of the bedding plant differ significantly between Smelter 1 and Smelter 3. Page 02/ 04
In terms of capacity, the bedding plant serving Smelter 1 supports a comparatively lower throughput. Smelter 1 operates at a feed rate of around 6 8 tones per hour and requires a blended concentrate with a wide copper range of 15–30%. Due to this broader blending window and the batch nature of Smelter 1, the bedding plant can accommodate variability in concentrate quality. As a result, the capacity demand on the bedding plant is moderate, and minor fluctuations in blend composition do not critically impact plant performance. The bedding plant for Smelter 3, on the other hand, is designed for a much higher capacity and stricter quality control. Smelter 3 operates at approximately 110 tones per hour and requires concentration with a narrow copper range of 25–30%, with an ideal value of about 27%. Since Smelter 3 follows a continuous process, the bedding plant must deliver a steady and uninterrupted flow of uniformly blended concentrate. Any inconsistency in blending can directly affect continuous furnace operations, making the bedding plant far more critical in ensuring plant stability. A key difference therefore lies in the precision of blending. Smelter 1’s bedding plant emphasizes flexibility and accommodates variations in concentrate composition, whereas Smelter 3’s bedding plant demands high blending accur acy and consistency. Additionally, the higher throughput of Smelter 3 means the bedding plant must handle larger volumes of material continuously, increasing its operational intensity. Page 03 /04
Overall, while the physical bedding operations are similar, the bedding plant for Smelter 3 operates under greater capacity pressure, tighter quality constraints, and higher operational criticality compared to Smelter 1. Smelter 1’s bedding plant supports a flexible, batch-driven system, whereas Smelter 3’s bedding plant is optimized for high-capacity, continuous production with strict blend control. Dryer : For Smelter 1, before smelting, the material is mixed with silica flux to adjust slag and is fed to the steam dryer which reduces the moisture content to approximately 0.3%, producing a dry, free-flowing concentrate known as the “dry charge,” which is essential for stable and efficient flash smelting. For Smelter 3, from the wet feed tank, the copper concentrate reaches the rotary combustion dryer which uses Regasified Natural Ga s (RLNG) and oxygen to generate heat, reducing moisture to 0.3%. Page 0 4/ 04
The Captive Power Plant (CPP) at the Dahej Unit is a dedicated in-house power generation system designed to supply secure and reliable energy to both the copper plant and the township. A plant is called a “captive” plant because all the energy produced is used internally rather than being supplied to the public grid. The Dahej Unit operates three CPPs, where CPP 1 and CPP 2 have a combined capacity of 72 MW, and CPP 3 has a capacity of 6 0 MW, giving the entire facility a total generation capacity of 135 MW. Out of this, the plant consistently generates around 9 5 MW per hour, and the additional 25 MW required is sourced from the Gujarat Electricity Board (GEB). This CPP is also a cogeneration ( C o - Gen) plant because the same steam used for rotating the turbine is also used for pre-heating furnaces, improving energy efficiency. Alongside thermal energy, the unit also utilizes renewable energy sources such as wind, solar, and hydropower from a facility in Bhavnagar through an agreement between Aditya Birla Renewable Energy Limited and Unilink, which supplies renewable units into the GEB grid that the Dahej unit draws from. Coal Transportation From Jetty to Coal Storage Yard: The primary raw material for the CPP is coal, imported from South Africa, Australia, and Indonesia, due to its high G C V (Gross Calorific Value) which is compatible with the design of the boilers. Each year, 2.5–3 lakh tonnes of imported coal arrive at the captive jetty, where 6 0 , 0 0 0 tonnes are consumed every two months. Domestic coal is avoided because it has low G C V and high transportation costs. Once the imported coal arrives at the Dahej jetty, it is transported using a conveyor belt system known as R1 and R2 to Transfer Tower 3 (TT3). From there, coal separates from the concentrate conveyor and travels via Pipe Conveyor PC1 and PC2, each capable of carrying 1400–1500 tonnes per hour, to TT4 and TT5, finally reaching the Coal Storage Yard. The entire movement of coal from jetty to yard takes 4 – 5 days, covering a distance of 3 km. The coal yard is a large space measuring 120 × 2 20 meters, where coal is stored before being fed into the CPP. Page 01/03 ive Power Plant Captive Power Plant
Coal Feeding and Preparation From Coal Yard to Boilers: From the coal yard, the coal is loaded into two feeding syste ms with a combined capacity of 2 5 0 MT, after which it p asses through magnetic separators that remove metallic impurities. The coal then reaches the primary vibrating screen, where pi eces larger than 8 m m are sent to the crushers, and coal smaller than 8 m m directly moves to Junction Towers 1, 2, and 3, heading toward C P P - 1, C P P - 2, and C P P - 3. In C P P - 3, coal is stored in two coal bunkers of 3 5 0 m³ each, and one sand bunker of 75 m³. The boilers in C P P - 3 are Boiler 3 and Boiler 4, each with a capaci ty of 150 TPH (Tonnes per Hour). As coal enters the boilers, it reaches a temperature of 900 ° C , even though the ignition temperature of coal is 600 ° C , ensuring immediate and efficient combustion. The heat released from burning carbon in coal forms the primary thermal energy source for the steam cycle. Boiler to Turbine Working Steam Generation and Power Production: Inside the boiler, the heat from burning coal converts demineralised water (DM Water) into steam. The DM water, treated in the Water Treatment Plant (WTP), enters the boiler at a pressure of 0.075 bar and a temperature of 40°C. As the water circulates through boiler tubes, it absorbs heat and converts into high-pressure steam. This steam drives the turbine blades in C P P - 3, which has a 6 0 MW turbine. The turbine extracts kinetic energy from the steam, causing the turbine shaft to rotate. A turbo-alternator connected to this shaft converts mechanical rotation into electrical energy through electromagnetic induction. C P P - 3 turbine experiences maximum vibration at 2 63 0 RPM and 1650 RPM, and these RPM zones are carefully monitored. Page 02/03
Steam Condensation, Heat Recovery and Feedwater Cycle: After steam p asses through the turbine, it enters the surface condenser, where it is cooled and converted b ack into water. This condensed water flows into the hot well, and then the condensate extraction p ump pu sh es it through an ejector into the gland steam condenser. This device converts low-pressure exhaust steam into water and stores it in the hot well. From here, the water p asses through a low-pressure heater, then into a deaerator, which removes dissolved gases like oxygen (O₂) and carbon dioxide (CO₂). Removing oxygen prevents corrosion in boiler tubes. The water is then p ump ed into the high-pressure heater, after which it p asses through Economizer 1 and Economizer 2. Economizers recover heat from flue gases, improving fuel efficiency. These are con nected to the steam drum, completing the feedwater cycle. This cl os ed- loop system ensures continuous and efficient power generation. Power from the Grid and Power Distribution: The Dahej unit uses a 70:30 power ratio, where 70% of the electricity is generated internally through C P P s and 3 0 % from GE B grid, solar, and hydropower. The grid supplies electricity at a very high voltage of 11000 kV, which is stepp ed down to 11–33 kV for industrial use. The plant also consu mes about 5 MW as auxiliary power for operating boilers, pumps, conveyors, and control systems. The township requires only 0.8 MW, which is negligible compared to the plant load. Page 03/ 03
SMELTER-1 SMELTER-1 Page 01/02 Smelter-1 at the Dahej C oppe r Com plex is base d on Outotec (Finland) flash smelting technology and operates predominantly as a batch pr oce ss using a Lo ss in weight system which ensures a steady and consistent supply of concentrate (feed rate of 6 8 Ton/hour) to the smelter. C oppe r concentrate is received from the Raw Material Handling (RMH) system and routed to the bedding plant. The smelter requires concentrate of blended mixture with 15-30% coppe r of different grades and typically contains about 7–8% moisture. Before smelting, the material is mixed with silica flux to adjust slag and is fed to the steam dryer which reduces the moisture content to approximately 0.3%, producing a dry, free-flowing concentrate known as the “dry charge,” which is essential for stable and efficient flash smelting. Flash Smelting Furnace (FSF) and Settler: The dry charge is first sent to the Flash Smelting Furnace (FSF) through a Central J e t Distributor (C JD) . In the reaction shaft of the FSF, oxygen-rich air is injected along with the concentrate, leading to rapid oxidation of sulphur and iron contained in the concentrate. The se exothermic reactions release sufficient heat to smelt the charge, eliminating the need for continuous external fuel. The furnace operates at temperatures exceeding 1,200°C, resulting in the formation of two molten, immiscible portions – the coppe r matte and slag, along with off-gases. This mixture then de sce nd s into the settler part of the furnace, where separation occur s due difference in density, with the matte, containing around 6 0 to 63% copper, settles at the bottom of the furnace, while the slag layer floats above it.
Slag Cleaning and Copper Recovery: The molten slag is tapped from the FSF and sent to the Slag Cleaning Furnace ( SC F) for recovery of the 7-8 % copper therein. The S C F is an electric arc furnace, and slag is fed through ladles via an overhead crane. Coke is added to maintain heat and accelerate the process by increasing viscosity. Reduction occurs, due to which copper settles down in the form of high-grade matter from the S C F and is charged into the convertor. The slag from S C F is granulated and conveyed via rake classifier and belt conveyors to the dump yard. Off gases are carried through the uptake shaft to the Waste Heat Recovery Boiler (WHRB) and Electrostatic Precipitator (ESP) and directed to the Sulphuric Acid Plant. The heated furnace is cooled through extensive water-cooling jackets. The Converter: The copper matte collected from the FSF is periodically tapped and transferred by ladles to the converter to further increase the purity of copper. The Dahej Unit has 3 converters, of which 2 are operational at any given time. Oxygen enriched air is pa sse d through tuyeres submerged in liquid matter to oxidise iron and sulphur, and converting is carried out in two distinct stages. In the slag blow stage, iron sulphide is oxidized to iron oxide, which combines with silica to form slag and Copper Sulphide, while sulphur is released as sulphur dioxide gas. In the subsequent copper blow stage, remaining sulphur is from the Copper Sulphide compound is oxidized, producing blister copper with a typical purity of about 98.5%. The blister copper from the smelter is then transferred to the anode furnace for further refining and casting. Page 02/02
MELTER -3 SMELTER -3 Page 01/02 Smelter 3 at the Dahej Unit employs Mitsubishi continuous smelting technology from Japan. Unlike Smelter 1, it operates as a fully continuous process, integrating smelting, cleaning and converting into a seamless material flow system, and uses three interconnected furnaces - the Smelting Furnace (S Furnace), the Cleaning Furnace ( C L Furnace), and the Converting Furnace ( C Furnace), allowing molten material to flow without need for intermediate handling. The dry concentrate is then mixed with silica to reach the feed tank. There are 6 feed tanks with two lances each that reach the S Furnace. Smelting Furnace ( S Furnace) : The copper concentrate from the RMH, containing about 27% copper is mixed with silica flux is fed continuously into the S Furnace along with oxygen-enriched air, C - slag and coal on a need basis. It is a Bath Smelting Technology where oxidation reactions take place directly in the molten bath using top-blowing lances. The furnace operates at temperatures of approximately 1,220–1,250°C. During this stage, partial oxidation of sulphur and iron occurs, generating the heat required for smelting. Unlike flash smelting, there is no immediate separation of matte and slag in the S Furnace. Instead, the combined molten mixture flows by gravity into the next stage via launders.
Cleaning Furnace ( C L Furnace): The molten mixture from the S Furnace enters the C L Furnace, which is an Electric Arc Furnace fitted with multiple electrodes. It has a bath depth of about 1.2 meters, and the primary function of this furnace is separation of copper matte and slag based on density differences. Copper matte containing about 6 8– 69% copper settles at the bottom, while slag overflows from the top with copper levels reduced to around 0.7%. The electric heating allows precise temperature control, improving separation efficiency and minimizing copper losses. The discarded slag is either sold to cement manufacturers or disposed of. Converting Furnace ( C Furnace) : The high-grade copper matte from the C L Furnace flows into the C Furnace, which has 3 feed tanks with 10 lances distributed as 4, 2 and 4 respectively. In this stage, further oxidation reactions remove the remaining sulphur and iron from the matte. Fluxes su ch as limestone are added to make the slag less viscous and facilitate its movement out of the furnace via launders, and C - slag is introduced to control the temperature in the S furnace. The output of the C Furnace is blister copper with a purity of approximately 99.5%, which is carried out in launders at a rate of 40.3T per hour and C - slag containing 12-14% copper which is granulated and recycled back to the S Furnace through a feeding circuit. The C Slag adds as both a coolant and ensures recovery of some portion of copper contained therein. The blister copper from both the smelters is then transferred to the anode furnace for further refining and casting. Page 02/02
Anode casting is a critical operation in the copper smelting value chain at Dahej and is carried out after the production of blister copper in Smelter-1 and Smelter-3. The objective of this stage is to convert molten blister copper into solid anode plates of controlled weight, shape, and chemical composition, which serve as the feed material for electrolytic refining. Both smelters produce blister copper with a purity of 98.5%, which is transferred in molten form to the anode furnace for controlled refining to remove residual impurities and casting preparation. Oxidation and Reduction Proc ess : During the oxidation stage, oxygen-enriched air is blown into the molten copper bath to oxidise impurities such as sulphur and iron. Sulphur is removed in the form of sulphur dioxide gas. Cu₂S + O₂ → 2Cu + SO₂ ↑ Similarly, iron reacts with oxygen to form iron oxide. Fe + O₂ → FeO This then combines with silica or fluxes to form slag, which is skimmed off. ANODE CASTING A N O D E C A S T I N G Page 01/02
Next, reduction reactions are carried out to lower the oxygen level and prevent porosity in the anodes, by introducing hydrocarbons, mainly LNG propane (previously propylene was used ) into the melt. At the end of this stage, the copper achieves a refined purity of approximately 98.5%. Ca st ing Operation : O nce the molten copper reaches the required chemical composition and temperature, it is transferred through launders to the anode casting machine. At Dahej, a 24-mould rotary anode casting wheel is used, comprising an intermediate ladle and pouring spoon, where molten copper is poured into pre-shaped moulds arranged on a rotating carousel. The moulds are barite-coated to prevent sticking and are water-cooled to enable rapid and uniform solidification of copper. Each mould produ ces one anode plate weighing between 355 - 375 kg, and a total of 24 anodes per casting cycle. The anodes are picked up by forklift and stacked by cranes, after which they are transferred to the refinery for electrolytic refining. Page 02/02
REFINERY REFINERY Page 01/02 The copper refinery processes copper anodes produced at the smelting plants with approximately 99.5% purity, weighing 3 45 –3 5 0 kg, to produce high purity copper cathodes of 99.995–99.996% (LME Grade). The total refining capacity is 5 0 0 , 0 0 0 tonnes per annum (5 LTPA), divided equally between Refinery I & II and Refinery III, each with a capacity of 2.5 LTPA. Refinery I & II (commissioned in 1998) comprise 8 6 0 electrolytic cells arranged in 28 sections, while Refinery III (commissioned in 2 0 0 5 ) consists of 768 cells in 24 sections. Each section contains 32 cells, with every cell holding 54 anodes and 53 stainless steel cathodes. Electro refining enhances copper’s electrical and thermal conductivity and enables recovery of valuable precious metals. Anode Preparation and Cell Setup: Copper anodes are processed in the Anode Preparation Machine (APM), where they are straightened, pressed, and checked for dimensional and weight uniformity. Anodes that do not meet specifications are returned to the smelter for remelting. Prepared anodes are transported to the electro refining section using EOT cranes. In each electrolytic cell, anodes and stainless-steel cathodes are arranged with approximately 100 mm spacing to ensure current distribution, even anode dissolution, and smooth cathode deposition. Cells are filled with an electrolyte consisting of copper sulphate, sulphuric acid, and demineralized water, which continuously enters and exits through the cells one after another.
Electrolytic Refining Process: Electrolysis is carried out using direct current (D C) supplied by rectifiers (that convert Alternate current to DC). A total of nine rectifiers is installed—five for the main cell house and four for the liberator section. At 6 5 degrees Celsius, the copper in the anodes ionises and deposits on the cathode sheets. The anode cyc le lasts approximately 21 days, and the cathode harvesting cyc le is 9 – 10 days. The insoluble impurities such as gold, silver, selenium, and tellurium in the anodes settle at the bottom of the cell as anode slime, while soluble impurities remain in the electrolyte. This slime is the input for the Precious Metals Recovery Plant. Cathode Stripping and Anode Scrap Handling: After 9 – 10 days, cathodes are removed and processed in the cathode stripping machine. Copper sheets are stripped from stainless steel blanks, washed, and stacked for dispatch, while the S S blanks are reused. The stripping machines process about 5 0 0 plates per hour, yielding 2.5–2.8 tonnes of copper per hour. Spent anodes are washed in the anode scrap washing machine to recover slime and then sent back to the smelter for remelting. Final Product: The final product is a high purity copper cathode sheet (99.995% LME Grade), weighing 8 0 – 100 kg per sheet, ready for commercial and industrial applications. Page 02/02
Liberator Liberator Page 01/03 A Liberator is a special electro-refining unit used in copper refineries (such as Hindalco – Unit Birla Copper) to control and remove excess copper and harmful impurities from the electrolyte. During copper electro-refining, the electrolyte should ideally contain 2 5– 4 5 g/L of copper (Cu²⁺). Over time, copper concentration rises to 4 5 – 5 5 g/L, which can damage cathode quality and reduce refining efficiency. The liberator removes this excess copper and also helps in controlling impurities like Nickel (Ni), Arsenic (As), Bismuth (Bi), Antimony (Sb), and Tin (Sn). The main purpose of a liberator is: · To remove excess copper (Cu²⁺) · To maintain electrolyte purity · To enable reuse (circularity) of electrolyte · To protect cathode quality The electrolyte used is Copper Sulphate (CuSO₄) + Sulphuric Acid (H₂SO₄). The Liberator is used in the Electro-refining Section of a Copper Refinery. It is installed between the main tank house and the Effluent Treatment Plant (ETP).
Three Stages of Liberators First Liberator – Primary Copper Removal · Input copper concentration: 4 5– 5 5 g/L · Output copper concentration: ~4 0–28 g/L In this stage, maximum dissolved copper (Cu²⁺) is removed by electro-deposition onto cathodes. This stage mainly removes excess copper metal, preventing overload in the main refining cells. The recovered copper is reused in production. Second Liberator – Nickel and Further Copper Control · Input copper concentration: 28–4 0 g/L · Output copper concentration: 25 –12 g/L This stage further reduces copper and also removes Nickel (Ni²⁺), which dissolves completely in the electrolyte and can cause cathode contamination if not controlled. Nickel remains in solution longer than copper and is selectively managed here to protect cathode purity and electrical conductivity. Page 02/03
Third Liberator – Final Purification · Input copper concentration: 12–25 g/L · Final copper concentration: < 2 g/L This is the final polishing stage. It removes trace copper and allows impurities to separate: · Arsenic (As), Tin (Sn), Bismuth (Bi) form sludge · Antimony (Sb) deposits on liberator cells · Bismuth (Bi) forms floating slime · Calcium (Ca²⁺) precipitates as Calcium Sulphate (C aSO₄) · Tellurium (Te) dissolves and is recovered later in slime treatment The sludge from this stage goes to the Effluent Treatment Plant (ETP). In the Liberator stage, copper present in the electrolyte is deposited onto the anode scrap through the electrowinning process. The deposited copper is then manually removed from the scrap and charged into the smelter for further processing. The electrolyte contains approximately 2 – 5 g/L of copper. This electrolyte is sent to the Copp er Recovery Plant (CRP) for copper recovery, after which the treated solution is transferred to the Effluent Treatment Plant (ETP) for further treatment.In the Liberator stage, copper present in the electrolyte is deposited onto the anode scrap through the electrowinning process. The deposited copper is then manually removed from the scrap and charged into the smelter for further processing. The electrolyte contains approximately 2 – 5 g/L of copper. This electrolyte is sent to the Copp er Recovery Plant (CRP) for copper recovery, after which the treated solution is transferred to the Effluent Treatment Plant (ETP) for further treatment. Page 03/ 03
The Sulphuric Ac id Plants ( SAP 1 and S AP 3) serve a dual purpose: environmental protection by capturing S O₂ emissions from smelters and economic benefit by producing sulphuric acid for external sale. S O₂ gas from smelters, which must comply with emission norms of 4 0 0 – 4 5 0 ppm, is converted into H₂SO₄ through a four-stage process: 1. Ga s Cleaning 2. Converter 3. Absorption 4. Storage GAS CLEANING in the sulphuric acid plant removes heavy metals suc h as arsenic, bismuth, selenium, and lead. S O ₂ - rich gas (12–13% SO₂, 12–13% O₂, and trace impurities) from the smelter enters the Primary Reverse J et Scrubber (PRJS), it is cooled 3 4 0 ° C to 6 0 ° C without heat exchange. The Ga s Cooling Tower (GCT ), supported by a 9 0 MW plate-ty pe heat exchanger (PHE), the temperature reduces to 38°C. The Final Reverse J et Scrubber ( F RJS ) then removes 9 9% of remaining impurities, followed by five Electrostatic Precipitators (E SP) to eliminate residual dust, SO₃, and acid mist. Then Drying Tower removes moisture to prevent damage to the catalytic converter. The CONVERTER contains five catalyst beds 53 (Stainless Steel converter), with vanadium pentoxide, silica, and K₂O₂, totalling 4 0 0 m³ of catalyst. Ga s enters at 4 0 0 ° C and exits at 650°C, so 4 heat exchangers (HS01–H S0 4) are installed to manage temperature. Initially, the gas has 12% SO₂, 9 9% is transformed into SO₃. The first bed achieves the highest conversion through direct contact and leach reaction, while the remaining four beds complete the process. In S AP 3, all five beds are housed in a single vertical structure. In the converter, vanadium pentoxide catalyst oxidizes S O₂ to SO₃, which reacts with H₂SO₄ to form oleum; this oleum H2so7 is then diluted with water to produce sulphuric acid. Page 01/02 SULPHURIC ACID PLANT (SAP) SULPHURIC ACID PLANT (SAP)
The plant operates on the Double Contact Double ABSORPTION (DCDA) pr ocess to maximize conversion efficiency and minimize emissions. In the inter-p ass absorption stage, SO₃ is absorbed in concentrated sulphuric acid to form oleum (H₂S₂O₇), shifting the reaction equilibrium and enhancing further SO₂ conversion. In the final absorption stage, the remaining SO₃ is absorbed to produce 98.5% concentrated sulphuric acid. Oleum generated during the pr ocess is completely converted internally and is not released outside the system. STORAGE: After absorption, the produced acid is collected in a comm on pum p tank, where concentration and temperature are automatically controlled. It is then transferred to a product tank, diluted slightly to 98% commercial grade, cooled, and stored in dedicated storage tanks two tanks in S A P - 1 and three tanks in S A P - 3. The final product is dispatched safely through pipelines to external customers or downstream units. Impurities removed during gas cleaning are routed to the Effluent Treatment Plant (ETP) for environmentally safe disposal. Page 02/02
OXYGEN PLANT OXYGEN PLANT Page 01/02 The Oxygen Plant at HIL, Dahej is a critical utility facility designed to supply high purity oxygen for copper smelting and associated metallurgical processes. It was established in 1998 alongside the commissioning of first smelter (SM-1) to meet the oxygen demand for flash smelting technology. Over time, as production capacity expanded, additional oxygen plants were installed to cater to increased requirements for smelters. AIR FILTRATION: Air from the atmosphere is sucked in and filtered to remove dust and dirt. Clean air prevents damage to compressors and other equipment. Machine: Air Suction Filter House (ASFH) with 3 - stage filtration. AIR COMPRESSION: After the air is filtered to remove dust and moisture, it enters the compressors. The Base Load Air Compressor (BLAC) acts as the main unit, compressing the air to about 5.6 kg/cm² so it can be cooled and liquefied more easily. From there, part of the air moves to the Booster Air Compressor (BAC), which increases the pressure further to around 7.3 kg/cm². This higher pressure is essential for the next stage in the cold box, where the air is chilled to cryogenic temperatures for oxygen and nitrogen separation. COOLING AND MOISTURE REMOVAL: Compressed air is cooled in Direct Contact After Cooler (DCA)and Evaporative Cooler (EC). To remove water vapour and reduce temperature before purification.
PRE PURIFICATION: Onc e the air is cool, it goes to the Pre-Purification Unit (PPU). This is like a cleaning station where special materials (activated alumina and molecular sieves) remove water vapour, carbon dioxide (CO₂), and hydrocarbons. Because if these impurities stay, they would freeze inside the cold box and block the system. So this step ensures the air is completely clean before it is cooled to cryogenic temperatures for oxygen and nitrogen separation. CRYOGENIC COOLING: After the air is cleaned, it goes into the Co ld Box, an insulated chamber where it is cooled to very low temperatures (below – 150°C) so it can turn into liquid. This cooling happens in two ways: first, through heat exchangers that gradually remove heat by passing the air over very cold surfaces, and second, by a turbo-expander that rapidly expands the air, making it even colder. LIQUIFICATION: Air turns into liquid after passing through heat exchangers. Liquid form makes it easier to separate oxygen and nitrogen. DISTILATION: Liquid air is separated into oxygen and nitrogen using fractional distillation in two columns (Linde Double Column). Oxygen and nitrogen boil at different temperatures, so they separate naturally. Nitrogen is used for purging to remove unwanted gases and create a safe, inert environment inside equipment and pipelines. CONVERSION, STORAGE AND DELIVERY: Oxygen is converted back to gas or stored as liquid in tanks. To supply oxygen at required pressure for smelting Oxygen is mainly supplied as gaseous oxygen at the required pressures 0.8 bar for Smelter 1 and 4 bar for Smelter 3. Page 02/02
COPPER CASTING RODS (CCR) C O P P E R C A S T I N G R O D S ( C C R ) Co pper Casting Rods (CCR), also known as continuous c as t c opper rods, are s e m i- finished c opper products manufactured from c opper ca thodes through a continuous casting process. These rods exhibit high electrical conductivity, excellent ductility, and a uniform structure, making them highly suitable for further processing into wires used ac ross electrical, telecommunications, and industrial applications. Hindalco has its C C R plants in Dahej ( CC R 1 and C C R 3) and Asoj ( CC R 4) respectively. C C R plays a vital role in the c opper value chain and industrial ec os ys tem as they ac t as a primary raw material for the production of wires and cables. Thus, are essential for key sectors s uch as power, telecommunications, construction, and electronics. Further, they enable the production of high-quality and ultra-fine c opper wires required for adva nced applications. They form a crucial link in the c opper downstream value chain, connecting refined c opper to e n d - use industries. The proc es s is a continuous and integrated operation and begins with charging the c opper cathodes, along with recycled scrap, in a shaft furnace where it is melted at temperatures ranging between 1200–1300°C. The molten c opper is then c asted into solid cylindrical form at approximately 1125°C using specialized casting machines. This cylindrical c as t bar is subsequently pa s s ed through rolling mills, where it is gradually reduc ed to the desired rod diameters (such as 8 mm, 11 mm, etc.). The rods are then cooled using a water and alcohol spray sy stem to reduc e temperature and prevent oxidation. Finally, a wax coating is applied to enhance surface finish, improve shine, and protect the rods. The rods are then coiled, properly handled, and pac ked for safe storage and transportation. Page 01/02
C C R - 1: C C R - 1 i s o n e of t h e c o p p e r c a s t i n g r o d p r o d u c t i o n u n i t s l o c a t e d a t t h e D a h e j p l a n t . I t o p e r a t e s u s i n g S o u t h w i r e t e c h n o l o g y ( U S A ) a n d f o l l o w s t h e w h e e l b e l t c a s t i n g m e t h o d , w h e r e i n m o l t e n c o p p e r i s p o u r e d v e r t i c a l l y i nt o a r o t a t i n g c a s t i n g w h e e l t o f o r m t h e c a s t ba r. T h i s u ni t h a s a p r o d u c t i o n c a p a c i t y of 120 K T a n d i s p r i m a r i l y u s e d f or m a n u f a c t u r i n g r o d s of r e l a t i v e l y s m a l l e r d i a m e t e r s ( 8 m m, 11 m m, 12 . 5 m m, 1 6m m a n d 19.6 m m ) . C C R - 1 r e p r e s e n t s a n e a r l i e r g e n e r a t i o n of C C R t e c h n o l o g y a n d i s k n o w n f or i t s o p e r a t i o n a l r e l i a b i l i t y a n d s t a b l e p r o d u c t i o n , a l t h o u g h i t h a s c o m p a r a t i v e l y l ow e r c a p a c i t y a n d e f f i c i e n c y t h a n m o r e a d v a n c e d s y s t e m s . C C R - 3 : C C R - 3 i s a m o r e a d v a n c e d c o p p e r c a s t i n g r o d u ni t i n s t a l l e d a t t h e D a h e j p l a n t , w i t h s i m i l a r t e c h n o l o g y a l s o u s e d a t t h e A s o j p l a n t . I t o p e r a t e s u s i n g S M S t e c h n o l o g y ( G e r m a n y ) a n d e m p l o y s t h e t w i n b e l t c a s t i n g m e t h o d , w h e r e m o l t e n c o p p e r i s p o u r e d h o r i z o n t a l l y b e t w e e n t w o c o n t i n u o u s l y m o v i n g b e l t s t o p r o d u c e a u n i f o r m c a s t ba r. W i t h a h i g h e r p r o d u c t i o n c a p a c i t y of 2 4 4 KT, C C R - 3 i s t e c h n o l o g i c a l l y s u p e r i o r a n d o f f e r s g r e a t e r e f f i c i e n c y , h i g h e r o u t p u t , i m p r o v e d p r o c e s s c o n t r o l , a n d e n h a n c e d p r o d u c t q u a l i t y . I t c a n p r o d u c e l a r g e r d i a m e t e r r o d s ( 8 m m , 21 m m, 2 3 m m a n d 2 6 m m ) a n d i s c o n s i d e r e d a m o d e r n s y s t e m s u i t a b l e f or l a r g e - s c a l e , h i g h - q u a l i t y c o p p e r r o d m a n u f a c t u r i n g . C C R - 4: T h e C a t h o d e w h i c h i s t h e i n p u t f or C C R 4 c o m e s e x c l u s i v e l y f r o m D a h e j P l a n t a n d P o l y c a b I n d u s t r i e s a n d i s L M E G r a d e A. I t a l s o u s e s t h e s a m e t e c h n o l o g y a s C C R 3 a n d h a s a p r o d u c t i o n c a p a c i t y of 2 4 4 KT. T h e d i a m e t e r of t h e o u t p u t m a i n l y p r o d u c e d i s 8 m m, 21 m m, 2 3 m m a n d 2 6 m m r e s p e c t i v e l y . Page 02/02
The Inner Grooved Tubes (IGT) plant at Waghodia GIDC, Gujarat was established by Hindalco Industries Limited, under the PLI Scheme 2021 and the Atmanirbhar Bharat initiative, aimed at reducing India’s dependence on imported high-precision copper tubes used in air-conditioning, refrigeration, plumbing, and heat-exchange applications. The plant supports domestic requirements by producing these specialized tubes locally, aligning with the objectives of the PLI Scheme to strengthen indigenous manufacturing and promote self-reliance in critical industrial components. While both copper and aluminium may be used for the tubes in micro groove technology, copper fins are an attractive alternative to aluminium due to better corrosion resistance and its antimicrobial benefits. Further, copper is an antimicrobial material thus reducing bio -buildup and high levels of energy efficiency are maintained. Also known as “microfin tubes”, with a total investment of approximately ₹579 crore, the plant has a Phase-1 installed capacity of 2 5, 0 00 tonnes per annum Inner Grooved Tubes (IGT) Inner G r o o ve d Tu b e s (IGT) Page 01/03
Raw Material and Melting: T h e p r i m a r y r aw m a t e r i a l for t h e I G T p l a n t is L ME - g r a d e A c o p p e r c a t h o d e wi th a p u r i t y of m o r e t h a n 9 9 . 9 0 % , s o u r c e d f r o m H i n d a l c o ’ s D a h e j r ef in er y . E a c h b a t c h is c h e m i c a l l y v e r i f i e d u s i n g a s p e c t r o m e t e r b e f o r e c h a r g i n g . M el ti ng is c a r r i e d o ut in tw o c h a n n e l - t y p e i n d u c t i o n f u r n a c e s , e a c h wi th a t ot a l c a p a c i t y of 11 t o n n e s a n d an e f f e c t i v e u s a b l e m o l t e n c a p a c i t y of a r o u n d 8 t o n n e s . T h e f u r n a c e s o p e r a t e at t e m p e r a t u r e s of 1 2 0 0 – 1 2 2 0 ° C wi th a m e l t i n g r a t e of a p p r o x i m a t e l y 3 t o n n e s p e r ho ur p e r f u r n a c e . D u e to t h e f u r n a c e d e s i g n , a m i n i m u m of 3 . 5 t o n n e s of m o l t e n c o p p e r m u s t b e c o n t i n u o u s l y m a i n t a i n e d . To m i n i m i z e o x i d a t i o n d u r i n g c h a r g i n g , c o a l is a d d e d , a n d an o v e r h e a d e m e r g e n c y w at e r t a n k at 3 5 m e l e v a t i o n e n s u r e s s a f e o p e r a t i o n d u r i n g p o w er fa i lu r e s . Casting, Surface Milling, and Rolling: C a s t i n g is p e r f o r m e d t h r o u g h a h o r i z o n t a l c o n t i n u o u s c a s t i n g p r o c e s s , p r o d u c i n g fo ur h ol lo w c o p p e r s h e l l s s i m u l t a n e o u s l y a n d g i v e s a t ot a l o u t p u t of 4 t o n n e s p e r c a s t i n g c y c l e . T h e s h e l l s a re c u t at 2 0 - m e t r e l e n g t h s a n d h a v e s t a n d a r d d i m e n s i o n s of 9 7 m m o u t e r d i a m e t e r ( O D ) a n d 2 5 m m wall t h i c k n e s s ( W T ) . T h e s e s h e l l s f or m t h e b a s e m a t e r i a l for s u b s e q u e n t d e f o r m a t i o n p r o c e s s e s . T h e s h e l l s n e x t u n d e r g o s u r f a c e mi lli ng, w h er e a p p r o x i m a t e l y 0. 5 m m is r e m o v e d f r o m e a c h s i d e to e l i m i n a t e o x i d e s a n d s u r f a c e d e f e c t s . T h i s is f o l l o w e d b y ho t r ol li ng u s i n g a thr ee- r oll er a r r a n g e m e n t p o s i t i o n e d at 120°, wi th a m a n d r e l i n s e r t e d i n s i d e t h e t u b e to c o n t r o l i n t er n a l d i a m e t e r a n d wall t h i c k n e s s . Page 02/03
Double Cascade Li n e: A f t e r ro ll in g, t h e d i m e n s i o n s a r e r e d u c e d t o a p p r o x i m a t e l y 5 0 m m O D a n d 2 . 5 m m WT. T h e r o l l e d t u b e s a r e c o i l e d i n t o o n e - t o n n e c o i l s a n d p r o c e s s e d t h r o u g h a D o u b l e C a s c a d e L i n e ( D C L ) . I n i t i a l l y t h e c o i l i s u n c o i l e d ; t h e f i r s t r o ll i n g s t a n d s i z e r e d u c e s t h e s i z e t o 4 0 m m × 2 m m , a n d t h e s e c o n d s t a n d r e d u c e s i t f u r t h e r t o 3 0 m m × 1.6 m m , k n o w n a s t h e m o t h e r t u b e . F i n a l d i m e n s i o n r e d u c t i o n i s a c h i e v e d u s i n g a S p i n n e r B l o c k c o l d - d r a w i n g m a c h i n e , p r o d u c i n g t u b e s w i t h o u t e r d i a m e t e r s r a n g i n g f r o m 4 . 6 7 m m t o 2 2 . 2 2 m m a n d w all t h i c k n e s s e s b e t w e e n 0. 4 m m a n d 1. 2 m m . Annealing and Fi na l Inn er Grooving: S t r e s s r e li e f i s c a r r i e d o u t t h r o u g h in- l i ne i n d u c t i o n a n n e a l i n g , A f t e r t h e s p i n n e r b l o c k p r o c e s s , t h e t u b e s a r e d i v i d e d i n t o t w o c a t e g o r i e s : s t r a i g h t t u b e s a n d i n n e r g r o o v e d t u b e s ( I G T ) . B o t h t y p e s a r e p r o d u c e d , w i t h a t o t a l c a p a c i t y of 2 5 K TPA . In n e r g r o o v i n g i s p e r f o r m e d u s i n g X i n g R o n g m a c h i n e s , w h e r e a g r o o v e d m a n d r e l f o r m s p r e c i s e i n t e r n a l h e l i c a l g r o o v e s t h a t e n h a n c e h e a t - t r a n s f e r e f f i c i e n c y . S u b s e q u e n t l y , e d d y c u r r e n t t e s t i n g , s t r a i g h t l i ne c u t t e r a c t i o n s a n d w i n d i n g s e c t i o n f ollo w. T h i s i s f o l l o w e d b y f in a l Page 03/ 03 A n n e a l i n g F u r n a c e ( C A F ) s u p p l i e d b y O t t o J u n k e r , n i t r o g e n a t m o s p h e r e t o a c h i e v e f ina l m e c h a n i c a l h e a t t r e a t m e n t in a C o n t i n u o u s B r i g h t o p e r a t i n g a t a r o u n d 5 0 0 ° C u n d e r a p r o p e r t i e s . T h e f in a l p r o d u c t s i n c l u d e p l a i n a n d i n n e r - g r o o v e d t u b e s , s u p p l i e d a s s t r a i g h t l e n g t h s , p a n c a k e c o i l s , or l ev e l - w o u n d c o i l s , w i t h p a c k e d b u n d l e s w e i g h i n g a p p r o x i m a t e l y 2 5 k g. T h e p l a n t e x c l u s i v e l y p r o d u c e s D H P ( D e o x i d i z e d H i g h - P h o s p h o r u s ) c o p p e r t u b e s , o p t i m i z e d f or c o r r o s i o n r e s i s t a n c e a n d h e a t - e x c h a n g e p e r f o r m a n c e .
OXYGENFREECOPPER OXYGEN FREE COPPER T h e O x y g e n - F r e e C o p p e r ( O F C ) u ni t a t t h e A s o j f a c i l i t y i s d e s i g n e d t o p r o d u c e ultra- h i g h p u r i t y c o p p e r r o d s w i th e x t r e m e l y low o x y g e n c o n t e n t ( l e s s t h a n 10 p p m ) . U n li k e c o n v e n t i o n a l C C R p r o c e s s e s . T h e p r o c e s s f o c u s e s on m i n i m i z i n g o x y g e n p i c k u p f r o m f u r n a c e t o a c h i e v e s u p e r i o r e l e c t r i c a l c o n d u c t i v i t y a n d m a t e r i a l p e r f o r m a n c e , a n d a r e p r i m a r i l y u s e d in high- e f f i c i e n c y e l e c t r i c a l , e l e c t r o n i c s , p o w e r t r a n s m i s s i o n , a n d t e l e c o m a p p l i c a t i o n s , w h e r e e n e r g y l o s s a n d s i g n a l d e g r a d a t i o n m u s t b e m i n i m i z e d . T h e O F C p l a n t a t A s o j h a s a c a p a c i t y of 16 t o 2 0 t o n s p e r da y. T h e i n p u t m a t e r i a l i s h i g h - p u r i t y c o p p e r c a t h o d e s h e e t s , s o u r c e d f r o m H i n d a l c o ’ s D a h e j r e f i n e r y . T h e s e c a t h o d e s a r e c h a r g e d i n t o a c l o s e d i n d u c t i o n - b a s e d m e l t i n g f u r n a c e e m p l o y i n g B r i g h t R o d T e c h n o l o g y , w h e r e h e a t i s g e n e r a t e d i n t e r n a l l y t h r o u g h e l e c t r o m a g n e t i c i n d u c t i o n , e l i m i n a t i n g t h e n e e d f or a d d i t i o n a l o x y g e n f or c o m b u s t i o n . T h i s c l o s e d f u r n a c e d e s i g n s i g n i f i c a n t l y r e s t r i c t s t h e e n t r y of a t m o s p h e r i c o x y g e n d u r i n g m e l t i n g a s c o m p a r e d t o c o n v e n t i o n a l f u r n a c e s . To f u r t h e r m i n i m i z e o x y g e n c o n t e n t , g r a p h i t e f lu x or c h a r c o a l i s a d d e d o n t o p of t h e m o l t e n m e t a l p o o l w h i c h r e a c t s w i t h a n y r e s i d u a l o x y g e n p r e s e n t in t h e m o l t e n m e t a l , f o r m i n g g a s e o u s o x i d e s s u c h a s c a r b o n d i o x i d e a n d p r e v e n t i n g o x y g e n a b s o r p t i o n . B e c a u s e of t h i s c o n t r o l l e d m e l t i n g e n v i r o n m e n t , t h e o x y g e n c o n t e n t in O F C r o d s i s r e d u c e d t o b e l o w 10 p p m , a n d in s o m e c a s e s b e l o w 5 p p m , c o m p a r e d t o o x y g e n l e v e l s of u p t o 6 5 0 p p m p e r m i t t e d in s t a n d a r d C C R - p r o d u c e d r o d s . Page 01/02
A f t e r m e l t i ng , c a s t i n g in t h e O F C u ni t is c a r r i e d o u t u s i n g a d i e - b a s e d c o n t i n u o u s c a s t i n g s y s t e m . A c a s t i n g d i e is d i p p e d i nt o t h e m o l t e n c o p p e r , a n d a c o l d r o d is i n t r o d u c e d i nt o t h e m o l t e n m e t a l for i ni ti a l s t a r t u p . T h i s c r e a t e s a v a c u u m p r e s s u r e c a u s i n g t h e m e t a l to m o v e u p w a r d s , a l s o k n o w n a s u p c a s t i n g b e c a u s e of t h e v e r t i c a l m o v e m e n t . I t r e s u l t s in c h a r a c t e r i s t i c s u r f a c e p a t t e r n s on t h e r od. T h e d i s t a n c e b e t w e e n t h e s e m a r k i n g s c o r r e s p o n d s to t h e s p a c i n g m a i n t a i n e d b e t w e e n s u c c e s s i v e m o v e m e n t s of t h e u p c a s t e r . T h i s c r e a t e s a v a c u u m p r e s s u r e i n s i d e t h e d i e a n d d r a w s t h e m o l t e n c o p p e r u p wa r d . T h e t e m p e r a t u r e of t h e d i e is p r e c i s e l y c o n t r o l l e d u s i n g c o n t i n u o u s d e m i n e r a l i z e d w a t er c o o l i n g t h r o u g h t h e d i e ’s o u t e r j a c k e t . T h i s c o n t r o l l e d c o o l i n g e n s u r e s d i m e n s i o n a l s t a b i l i t y , s m o o t h s u r f a c e f in is h, a n d d e f e c t - f r e e r o d f o r m a t i o n . T h e s o l i d i f i e d c o p p e r r o d is t h e n g u i d e d to t h e c o i l i n g s e c t i o n , w h e r e i t is w o u n d i nt o c o i l s u s i n g a m ul t i - c o i l e r a r r a n g e m e n t , t y p i c a l l y c o n s i s t i n g of 16 c o i l e r s ( 8 u p p e r a n d 8 lo we r ) . T h e f ina l O F C r o d s e x h i b i t e x c e p t i o n a l e l e c t r i c a l c o n d u c t i v i t y , h i gh t h e r m a l c o n d u c t i v i t y , a n d e x c e l l e n t r e s i s t a n c e to h y d r o g e n e m b r i t t l e m e n t . Page 02/02
RodBreakdown( RBD)Process Rod Breakdown( RBD) Process Page 01/03 T h e R o d B r e a k d o w n ( R B D ) u n i t i s a p r o c e s s i n g f a c i l i t y i n t e g r a t e d w i th t h e C C R p l a n t at A s oj , d e s i g n e d to c o n v e r t s t a n d a r d c o p p e r r o d s i n t o sm al l er - d i a m e t e r c o p p e r w i r e s for s p e c i a l i z e d e l e c t r i c a l a n d i n d u s t r i a l a p p l i c a t i o n s . W h i l e C C R p l a n t s p r i m a r i l y f o c u s on t h e p r o d u c t i o n of l a r g er d i a m e t e r c o p p e r r o d s , t h e R B D s e c t i o n p e r f o r m s c o n t r o l l e d m e c h a n i c a l s i z e r e d u c t i o n to m e e t t h e r e q u i r e m e n t s of wire- dr a w i ng , s w i t c h g e a r , e l e c t r o n i c s , a n d c o n d u c t o r m a n u f a c t u r e r s . T h e R B D s e c t i o n at A s o j c o n s i s t s of t wo r o d b r e a k d o w n m a c h i n e s , w i th a c o m b i n e d c a p a c i t y of a p p r o x i m a t e l y 4, 0 0 0 t o n n e s p er m o n t h , h i g h l i g h t i n g i t s r ol e a s a h i g h - t h r o u g h p u t d o w n s t r e a m u ni t. T h e i n p u t m a t e r i a l for t h e R B D p r o c e s s i s 8 m m E l e c t r o l y t i c T o u gh P i t c h ( E T P ) c o p p e r r od , r e c e i v e d a s a c o i l f r o m t h e C C R p l a n t . T h e s e r o d s p o s s e s s h i g h e l e c t r i c a l c o n d u c t i v i t y a l o n g w i th a d e q u a t e d uc t i l i t y , m a k i n g t h e m i d e a l for f u r t h e r d r a w i ng .
In t h e R B D p r o c e s s , t h e 8 m m c o p p e r r o d i s d r a w n t h r o u g h a s e r i e s o f p r o g r e s s i v e l y s m a l l e r d i e s in m u l t i p l e s t a g e s t o a c h i e v e t h e f i n a l r e d u c e d d i a m e t e r . T h e p r o c e s s a t t h e R B D p l a n t r e d u c i n g t h e d i a m e t e r o f c o p p e r c o i l i s a s f o l l o w s : - 1 . T h e t y p i c a l r e d u c t i o n s e q u e n c e s i n c l u d e 8 . 0 m m → 6. 5 m m → 4. 5 m m → i n t e r m e d i a t e s i z e s , d e p e n d i n g o n r e q u i r e d s p e c i f i c a t i o n s . 2 . T h e f i na l wi re s i z e s p r o d u c e d b y t h e R B D u n it g e n e r a l l y r a n g e f r o m 1. 3 5 m m to 4. 5 m m in d i a m e t e r . T h i s g r a d u a l r e d u c t i o n a p p r o a c h i s e s s e n t i a l t o p r e v e n t s u r f a c e c r a c k i n g , i n t e r n a l s t r e s s b u i l d - up, or b r e a k a g e of t h e c o p p e r wir e d u r i n g d r a w i n g . To f a c i l i t a t e s m o o t h m e t a l f l ow t h r o u g h t h e d i e s a n d r e d u c e f r i c t i o n , a l u b r i c a t i o n s y s t e m i s e m p l o y e d t h r o u g h o u t t h e d r a w i n g p r o c e s s . D e s p i t e c o n t r o l l e d r e d u c t i o n , t h e d r a w i n g p r o c e s s i n t r o d u c e s i n t e r n a l s t r e s s e s in t h e c o p p e r d u e to e l o n g a t i o n a n d w o rk h a r d e n i n g . To c o u n t e r t hi s, t h e d r a w n w i r e s m a y u n d e r g o a n a n n e a l i n g p r o c e s s b a s e d o n c u s t o m e r r e q u i r e m e n t s , w h e r e t h e y a re e l e c t r i c a l l y h e a t e d a n d s u b s e q u e n t l y c o o l e d u s i n g s t e a m , w h i c h r e s t o r e s d u c t i l i t y , r e l i e v e s i n t e r n a l s t r e s s e s , a n d i m p r o v e s t h e m e c h a n i c a l f l e x i b i l i t y of t h e wire, m a k i n g i t s u i t a b l e for f u r t h e r p r o c e s s i n g or e n d u s e . T h i s s t e p i s c r i t i c a l to e n s u r e t h a t t h e wire d o e s n o t b e c o m e b r i t t l e a f t e r s i g n i f i c a n t c o l d w o r ki n g . Page 02/03
A f t e r a n n e a l i n g , t h e Page 03/ 03 t h r o u g h t e n s i o n a d a n c e r in i s m a i n t a i n e d w ire is w h i c h t h r o u g h p a s s e d c e r t a i n e x t e r n a l p r e s s u r e s o t h a t t h e f in a l d i a m e t e r of t h e w i r e i s m a i n t a i n e d . T h e f i n i s h e d w i r e s a r e c o i l e d o n c o i le r , w i n d e d in t h e b a s k e t or s o m e t i m e s in t h e b o b b i n s , p a c k e d in b o x c a r t o n s , a n d p r e p a r e d f or d i s p a t c h . T h e s e R B D p r o d u c t s a r e w ire m a n u f a c t u r i n gin PB r i b b o n s e g m e n t s , w i d e l y u s e d c o m p a n i e s , s w i t c h g e a r i n d u s t r i e s , a n d o t h e r p r e c i s i o n e l e c t r i c a l a p p l i c a t i o n s .
Introduction: Copp er concentrate is procured not only for the recovery of cop per as the primary metal but also for the extraction of valuable precious metals such as gold, silver and platinum, which are present as secondary constituents. These precious metals contribute significantly to the overall econ omic value of the concentrate and are therefore recovered through a dedicated Precious Metal Recovery (PMR) process. During electrolytic copper refining, precious metals are insoluble in the electrolyte and settle as anode slime. This slime, after removal of residual copper, bec om es the feedstock for the PMR plant. The resulting d e - copperised (DC) anode slime typically contains gold in the range of 0.7% to 1.5%, silver between 8% and 10%, and approximately 2% to 3% residual copper, along with selenium, lead and traces of platinum group metals (PGMs). The PMR pr ocess is a combination of pyro metallurgical and hydrometallurgical operations designed to recover these metals in a sequential and efficient manner. The pr ocess begins with selenium recovery through roasting, followed by smelting in a Tilting Rotating Oxyfuel Furnace (TROF) for dore metal generation. The metal is subsequently refined through silver electrolysis, after which gold and platinum group metals are recovered from the resulting anode mud using leaching and precipitation techniques. The final product slate of the PMR plant includes commercial-grade selenium, silver bars, gold bars, platinum–palladium sludge and dore slag, each routed to appropriate downstream industries. PMR (Precious Metal Recovery) P M R (P re ci o us Metal Recovery) Page 01/05
Selenium Roasting and Re cov ery Process: The first stage of precious metal recovery involves the removal of selenium and moisture from the d e - copperised anode slime. Selenium recovery is carried out in electrically heated roasting furnaces operated in batch mode, with eac h batch taking approximately 18 hours for completion. The D C slime is loaded into perforated trays, with ten trays forming a single batch weighing around 2,5 0 0 kilograms. These trays are charged into the roasting furnace, where the material is subjected to a temperature of about 3 5 0 °C in the presenc e of an oxygen-rich atmosphere. At elevated temperatures, elemental selenium present in the slime reacts with oxygen to form gaseous selenium dioxide. Continuous oxygen injection ensures complete oxidation and prevents incomplete conversion. In addition to selenium removal, this roasting stage also drives off residual moisture present in the slime, improving its suitability for subsequent smelting operations. The selenium dioxide ga s generated during roasting is conveyed to a wet scrubbi ng system, where it dissolves in water to form selenious acid. This absorption step is critical for preventing the release of selenium co mpounds into the atmosphere. The selenious acid solution is then reduced using sulphur dioxide, supplied from dedi cated tanks within the system. This reduction reaction regenerates elemental selenium in the form of a fine brown slurry and simultaneously produces sulphuric acid a s a b y - product. The sulphuric aci d is retained within the system and circulated ba ck as a reaction medium, ensuring proces s circularity and minimal reagent loss. Page 02 /05
The selenium slurry is subsequently subjected to filtration using filter presses to separate solid selenium from the liquid phase. The resulting selenium cake has a purity of approximately 99.3% and typically weighs between 5 0 0 and 6 0 0 kilograms per batch. The cake is then passed through drying units to reduce moisture content from around 20% to nearly 1%. Once dried, the selenium is packed in 10-kilogram buckets and sold commercially, primarily to the glass industry, where it is used as a colouring and decolourising agent. The roasted slime, now depleted of selenium and moisture, is discharged into a feed bin and conveyed to the smelting section of the PMR plant. TROF Smelting and Dore Metal Formation: After selenium extraction, the roasted anode slime is transferred to the Tilting Rotating Oxyfuel Furnace for smelting and metal separation. The TROF operates as a batch process, with each batch consisting of approximately 5 0 0 to 7 0 0 kilograms of roasted slime. Fluxes such as soda ash and borax are added to the charge to lower the melting point, promote slag fluidity and facilitate efficient separation of metal and slag phases. Smelting is conducted at a temperature of about 1,250°C and typically lasts for three to four hours. During this phase, the charge melts completely, allowing gold, silver, lead and traces of copper to separate from metal oxides. This is followed by a reduction phase lasting around two hours, during which met coke is added to the furnace. The met coke reacts with excess oxygen, forming carbon monoxide and carbon dioxide, thereby preventing oxidation of precious metals and ensuring they remain in metallic form. Page 03 /05
Once reduction is complete, the furnace is allowed to rotate and settle for approximately one hour. Due to differences in density, heavier precious metals such as gold and silver settle at the bottom of the furnace, while lighter impurities and oxides rise to the top as slag. The tilting mechanism of the TRO F enables controlled tapping of both slag and molten metal. The slag, known as dore slag, contains a high proportion of lead (around 2 5– 30%), small quantities of gold and trace silver. This slag is crushed and sold to the lead industry for further processing. The molten metal collected at the bottom of the furnace is referred to as dore metal, consisting primarily of gold and silver with minor base metal impurities. After 7 to 10 smelting batches, approximately 4 to 5 tonnes of molten dore accumulates, which is then ca st into anodes weighing about 10 kilograms each. These dore anodes serve as the feed material for silver electro refining. Off -gases generated during smelting, including lead fumes and acidic gases, are captured using hooding systems and treated in bag filters to ensure compliance with environmental standards. Silver Electro refining and Gold Recovery: The dore anodes produced from TRO F smelting are refined in silver electrolysis cells using a silver nitrate electrolyte. Stainless steel sheets are used as cathodes, while the dore anodes are placed inside fine mesh filter bags to retain insoluble residues. During electrolysis, silver dissolves from the anode and migrates through the electrolyte, depositing as high-purity silver crystals on the cathode surface. Gold and platinum group metals, being insoluble in the electrolyte, settle as anode mud within the filter bags. The deposited silver crystals are periodically sc ra ped from the cathodes, washed and dried. These crystals have a purity of about 99.9%. The dried silver is melted in an electric furnace and ca st into bars weighing approximately 2 0 kilograms each. Each casting produces 8 to 10 silver bars, which are sold in the bullion market and to authorised industrial consumers. Page 0 4/ 05
Gold and Platinum Group Metal Recovery: The anode mud collected from silver electro refining contains gold, platinum, palladium and traces of silver. This material undergoes hydrometallurgical treatment in a series of leaching drums. In the first leaching stage, hydrochloric acid is adde d to convert residual silver into silver chloride, which is filtered out. The remaining solution contains dissolved gold and platinum group metals. In the seco nd leaching stage, sodium metabisulfite is adde d to the solution, causing gold to precipitate as a fine metallic powder. This gold powder is filtered, dried and melted to produce gold bars weighing approximately one kilogram each, with a purity of around 99.9%. Residual solutions from gold precipitation are further treated using ferrous sulphate to recover additional gold, yielding impure gold of approximately 98% purity. The remaining solution is pr ocesse d in a final leaching stage, where zinc precipitation is used to recover platinum and palladium as a combined compound. This platinum-palladium sludge is sold directly to the platinum industry or sent to specialised refineries for further purification. The operation has an annual extraction capacity of approximately 12–15 tonnes of gold and around 120 tonnes of silver. Conclusion: The Precious Metal Recovery pr ocess plays a critical role in maximising the value of copper concentrates by enabling the efficient recovery of gold, silver, selenium and platinum group metals from refinery residues. Through a carefully integrated sequence of roasting, smelting, electro refining and hydrometallurgical operations, the PMR plant achieves high recovery efficiencies while maintaining environmental compliance. The recovery of marketable by products not only enhances overall plant econom ics but also supports sustainable resource utilisation within the copper refining value chain. Page 0 5/ 05
Hindalco Industries Limited is developing a pioneering electronic waste and se condary copper recycling facility, implemented in three phases. This project marks India’s first Printed Circuit Board (PCB) recycling plant and represents a major step towards promoting a circular economy and sustainable resource utilisation. Construction began in December 2024 following the groundbreaking ceremony on 16 December, and work is currently underway for the first phase. The plant is designed to recover copper from recycled sources such as e-waste, PCBs, and se condary copper. In its initial phase, it will pr ocess around 9 0 , 0 0 0 tonnes of raw material annually, including both e-waste P CBs and se condary copper, producing approximately 6 0 , 0 0 0 tonnes of copper anodes, which will be further refined into about 5 0 , 0 0 0 tonnes of cathode copper. On ce all three phase s are completed, the total capacity is expected to reach 2 0 0 , 0 0 0 tonnes of cathode copper per year, significantly contributing to India’s domestic copper supply. The facility is also envisaged to recover precious metals, with gold extraction of about 12–15 tonnes per year and silver extraction of around 120 tonnes per year. At the heart of the recycling pr ocess is the Smelting Kaldo Furnace, a rotating furnace operating at around 1,250°C with a capaci ty of 100 tonnes. Unlike conventional flash smelting furnaces, the Kaldo design ensures better mixing, faster reaction kinetics, reduced energy consumption, and more homogeneous smelting. Shredded e-waste is fed into the furnace along with pure copper, se condary copper and fluxes such as iron and silica, which aid in slag formation, while other recycled materials like dust and slag are charged through a skip hoist. During smelting, organic components comb ust at lower temperatures, and metals melt to form black copper of about 68 – 70% purity, accompanied by slag containing impurities and recoverable metals. Recycl ing Plant, Pakhajan Recycl ing Plant, Pa k h aj a n Page 01/02
The black copper is then transferred to the Refining Kaldo Furnace, where oxygen-enriched air oxidizes impurities such as lead, tin, and iron, producing copper of 9 8 – 99 % purity. Slag from this stage is treated in a PbSn Kaldo Furnace, where coke acts as a reducing agent to recover valuable metals including copper, nickel, lead, and tin, which are recycled back into the process. Off-gases generated during smelting, which may contain hazardous comp ounds like dioxins and NOx, are treated using Metso’s seven-stage Wet Gas Cleaning System. This system rapidly cools gases to prevent dioxin formation and ensures emissions remain within regulatory limits monitored by the Gujarat Pollution Control Board. Finally, refined copper is pr ocesse d in the Anode Furnace, where remaining impurities are removed before molten copper is cast into anodes weighing about 345 kilograms each. These anodes are then transported to Hindalco’s Dahej refinery for electrorefining into high-purity cathode copper, completing the recycling value chain. With its advanced technology and large-scale capacity, the Pakhajan facility represents a major step forward in India’s resource recovery sector, combining sustainability with industrial innovation. Page 02/02
BIRLABALWAAN:HINDALCO’ SFERTILIZERBUSINESS BIRLA BALWAAN: HINDALCO’ S FERTILIZER BUSINESS Page 01/03 Un t i l 2 0 2 0 t h e D a h e j Un i t , a l s o m a n u f a c t u r e d f e r t i l i s er s , s p e c i f i c a l l y , D i a m m o n i u m A m m o n i u m P h o s p h a t e ("DAP") at a d e s i g n a t e d f a c i l i t y , w h i c h w a s c o m m i s s i o n e d in t h e y e a r 2 0 0 0 . T h e S u l p h u r i c A c i d p r o d u c e d a s a b y p r o d u c t of t h e s m e l t i n g p r o c e s s at p l a n t w a s p a r t l y u t i l i s e d to m a n u f a c t u r e p h o s p h o r i c a c i d a n d f e r t i l i s e r s s u c h t h e S A P a s DA P. Since 2020 , H i n d a l c o I n d u s t r i e s Limited has c e a s e d d o m e s t i c f e r t i l i z e r m a n u f a c t u r i n g as t h e b u s i n e s s m o d e l s h i f t e d to i m p o r t , p a c k a g i n g a n d t r a d i n g of f e r t i l i z er s . A t p r e s e n t , H i n d a l c o i m p o r t s DA P, a m m o n i u m p h o s p h a t e , w a t e r - s o l u b l e f e r t i l i z e r s , a n d N P K ( N i t r o g e n P h o s p h o r u s a n d P o t a s s i u m ) v a r i a n t s f r o m o v e r s e a s s u p p l i e r s a n d m a r k e t s t h e m in I n d i a u n d e r t h e t r a d e m a r k “ B i r l a B a l w an ” . T h e f e r t i l i z e r s a r e s o l d i n d i r e c t l y to f a r m e r s t h r o u g h t h e g o v e r n m e n t r e g u l a t e d P o i n t of S a l e ( P O S ) s y s t e m , w h e r e p u r c h a s e s a r e a u t h e n t i c a t e d u s i n g A a d h a a r . G o v e r n m e n t s u b s i d y on f e r t i l i z e r s i s c r e d i t e d to H I L o n l y a f t e r t h e s a l e i s r e c o r d e d t h r o u g h t h e P O S m e c h a n i s m , e n s u r i n g t r a n s p a r e n c y , t r a c e a b i l i t y , a n d r e g u l a t o r y c o m p l i a n c e . F e r t i l i z e r s a r e n ot s o l d d i r e c t l y to f a r m e r s o u t s i d e t h i s s y s t e m .
T h e c o m p a n y i m p o r t s a p p r o x i m a t e l y 1 . 2 5 l a k h t o n n e s of f e r t i l i z e r s a n n u a l ly , p r i m a r i l y t h r o u g h M u n d r a P o r t , G a n d h i D h a m ( K a c h c h h , G u j a r a t ) . K e y s o u r c i n g c o u n t r i e s i n c l u d e M o r o c c o , S a u d i A r a b i a , C h i n a , a n d N or w a y , p a r t i c u l a r l y f or w a t e r - s o l u b l e f e r t i l i z e r p r o d u c t s . I m p o r t s a r e p l a n n e d a c c o r d i n g t o a g r i c u l t u r a l d e m a n d c y c l e s . T h e K h a r i f s e a s o n ( A p r i l – S e p t e m b e r ) a c c o u n t s f or p e a k d e m a n d , s u p p o r t i n g c r o p s s u c h a s r i c e , c o t t o n , s o y b e a n , a n d g r o u n d n u t , w h i le t h e R a b i s e a s o n ( O c t o b e r – M a r c h ) c a t e r s t o w h e a t , m u s t a r d , a n d p u l s e s . D A P f e r t il i z e r, w i t h a n u t r i e n t r a t i o of 18: 4 6 : 0, i s p r i m a r i l y u s e d a s a b a s a l or p r i m a r y d o s e , a p p l i e d b e f o r e s o w i n g t o s u p p o r t e a r l y c r o p d e v e l o p m e n t . A l o n g w i t h DAP, H i n d a l c o m a r k e t s a w i d e r a n g e of f e r t i l i z e r s , i n c l u d i n g m o n o a m m o n i u m p h o s p h a t e , s u l p h u r , p o t a s s i u m s u l p h a t e , c a l c i u m n i t r a t e , z i n c s u l p h a t e , b o r o n a t e d f e r t i l i z e r s , a n d N P K b l e n d s s u c h a s 19: 19: 19, a d d r e s s i n g d i v e r s e s o i l a n d c r o p n u t r i e n t r e q u i r e m e n t s . Page 02/ 03 U p o n a r ri v a l at t h e p o r t , t h e c o n s i g n m e n t s a re s t o r e d in p o r t g o d o w n s , w h e r e t h i r d - p a r t y a n d a f t e r s u c c e s s f u l t e s t r e s u l t s c o n f i r m i n g s a m p l i n g a n d q u a l i t y t e s t i n g a re c o n d u c t e d . S a m p l e s a re s e n t to l a b o r a t o r i e s , c o m p l i a n c e a re t h e f e r t i l i z e r s c l e a r e d for d i s p a t c h . T h i s p r o c e s s i s e s s e n t i a l a s all f e r t i l i z e r s m a r k e t e d in I n d i a m u s t a d h e r e s t r i c t l y t o s p e c i f i c a t i o n s u n d e r t h e F e r t i l i z e r C o n t r o l O r d e r ( F C O ) , 19 85. T h e F C O , 1 9 85 g o v e r n s all a s p e c t s of f e r t i l iz e r q u a l i t y c o n t r o l in In di a , i n c l u d i n g p r e s c r i b e d n u t r i e n t c o n t e n t , s a m p l i n g a n d t e s t i n g p r o c e d u r e s , l icensing r e q u i r e m e n t s , a n d m a n d a t o r y n o r m s f or p a c k a g i n g , m a r k i n g , a n d l a b e l l i n g . The t e s t i n g of f e r t i l i z e r s a m p l e s u n d e r t h e F C O f o l l o w s a t h r e e - t i e r m e c h a n i s m , as follows: -
1. In iti all y, s a m p l e s c o l l e c t e d b y f er t i l i z er i n s p e c t o r s ar e t e s t e d at S t a t e or R e g i o n a l F e r t i l i z e r Q u a l i t y C o n t r o l L a b o r a t o r i e s . 2. I f r e s u l t s ar e c o n t e s t e d , a s e c o n d a n a l y s i s c a n b e r e q u e s t e d at t h e N a ti on a l T es t H o u s e ( NT H) . 3. In c a s e of c o n f l i c t i n g r e s u l t s b e t w e e n t h e s t a t e l ab a n d NTH, a f inal a n d b i n d i n g d e c i s i o n is t a k e n b y t he C e n t r a l F e r t i l i z e r Q u a l i t y C o n t r o l I n s t i t u t e ( C F Q C I ) . Q u a l i t y v e r i f i c a t i o n i s c a r r i e d o ut t h r o u g h IGI L a b o r a t o r y at G a n d h i D ha m , w h i c h s e r v e s a s t he c o m p a n y ’ s t h i r d - p a r t y i n s p e c t i o n a g e n c y . IGI c o n d u c t s d i s c h a r g e p o r t t e s t i n g to c o n f i r m c o m p l i a n c e w i th F C O s t a n d a r d s p r i or to m a r k e t r el ea se . A d d i t i o n a l c h e c k s ar e c a r r i e d o u t b y H i n d a l c o ’ s i n t er n a l D A P t eam . F e r t i l i z e r s m u s t b e p a c k e d in s t a n d a r d 5 0 k g b a g s a n d d i s p l a y r e q u i r e d m a r k i n g s s u c h a s P ( C S ) ( c i t r a t e s o l u b l e p h o s p h o r u s ) a n d P( W S ) ( w a ter s o l u b l e p h o s p h o r u s ) , a l on g w it h n u t r i e n t c o m p o s i t i o n , b a t c h n um b er , a n d m a n u f a c t u r e r / i m p o r t e r d et a i l s . F or d i s p a t c h r e a d i n e s s , B r i g ht M ar i ne S e r v i c e s v e r i f i es b a g w e i g h t a c c u r a c y a n d p a c k a g i n g i n te gr i t y . F e r t i l i z e r s ar e s t o r e d at t h e M u nd r a P or t g od o w n , o w n e d b y A d a n i P or ts , w h i c h h a s a s t o r a g e c a p a c i t y of a b o u t 5 l ak h t o n ne s , w i th a n nu a l f er t i l i z er s a l e s r e a c h i n g u p to 4 l a kh t o n n e s d u r i n g p e a k p e r i o d s . Page 03/ 03
The diameter varies from 8mm to 30 mm. The Copper Alloy Plant: Alloys and Application