TFP Bureau, Korba, May 15, 2025: On the occasion of National Technology Day, Bharat Aluminium Company Limited (BALCO), a unit of Vedanta Aluminium, reaffirmed its commitment to operational excellence, sustainability, and digital transformation by unveiling a series of pioneering technological innovations across its operations.
These advanced interventions—ranging from artificial intelligence-based systems to smart monitoring tools—aim to enhance efficiency, safety, and environmental responsibility across the company’s aluminium production value chain.
A major innovation this year is the introduction of a newly designed potline relining process, following 100% graphitization. This development is projected to reduce energy consumption by 400 kWh per metric tonne, while also improving current efficiency and lowering overall emissions—strengthening BALCO’s push toward more energy-efficient and sustainable aluminium production.
To improve process efficiency and product quality, BALCO has deployed AI simulators in its finishing line area. These tools analyze process parameters in real time, enabling the identification of optimal conditions for maximizing output in rolled products. Additionally, AI-driven robot technology has been introduced in anode manufacturing to automate refractory structure assessments in furnaces, helping detect wear and tear with precision, thus enhancing both safety and anode quality.
Further enhancing plant safety, BALCO has rolled out an AI-powered Conveyor Belt Monitoring System at its 1200 MW power plant. This system provides real-time fire alerts, monitors conveyor health, and detects human presence near moving belts—safeguarding both personnel and operations.
“At BALCO, we are integrating digital innovation into every facet of our operations to drive efficiency, safety, and sustainability,” said Mr. Rajesh Kumar, CEO & Director of BALCO. “These initiatives are setting new industry benchmarks and reaffirm our commitment to staying at the forefront of India’s aluminium industry while building a sustainable future.”
BALCO’s digital transformation journey includes the digitization of 62 core activities, replacing manual processes with real-time data systems that improve resource utilization, decision-making, and safety. Other key advancements unveiled include:
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Live Monitoring Towers: The Finished Goods Tower, Ash Control Tower, and Coal Control Tower now feature 24×7 dashboards with real-time GPS tracking and speed monitoring for seamless operations.
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AI-Enhanced Road Safety: Integration of Advanced Driver Assistance Systems (ADAS) and Driver Monitoring Systems (DMS) in internal logistics vehicles to reduce accident risks.
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Immersive Training and Safety Tech: Augmented and Virtual Reality Training Centres, e-learning platforms, video analytics, and a sustainability-focused mobile app to promote safety best practices.
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Centralized Security Operations Centre (CSOC): A state-of-the-art hub using digital intelligence for real-time decision-making in plant security, road safety, and supply chain management.
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Thermal Monitoring and Safety Signage: Hot Spot Detection Systems at coal yards using thermal inspection for safety compliance, and LED logo projectors that illuminate safety signs in low-visibility, high-traffic areas.
As aluminium—hailed as the “Metal of the Future”—becomes increasingly integral to global industrial and environmental goals, BALCO’s digital-first strategy places it firmly on the path of responsible and innovative manufacturing leadership.
