Vedanta Aluminium deploys IoT technology for water conservation at its power plants

14th November 2022

New Delhi; 14th November 2022: Vedanta Aluminium, India’s largest producer of aluminium, has deployed Internet of Things (IoT) based technology for cooling water analysis and overall reduction in water consumption at its power plants at Jharsuguda, in Odisha. These power plants make use of a recirculating cooling system using water, and a cluster of natural draft cooling towers. The IoT technology deployed studies real-time operational data and recommends optimum water quality parameters that ultimately lead to water conservation through increase of CoC (or cycles of concentration i.e., reuse of the same water multiple times for cooling the condenser). This technology has started delivering reduced water consumption, improved water quality, reduced scaling and corrosion, and improved other operational parameters that have led to overall improvement in station heat rate (a measure of power plant efficiency).

Customised applications of leading-edge technologies across the value-chain are helping Vedanta Aluminium optimise processes, improve customer experience, and deliver new business models. This digital transformation is resulting in increased efficiency, greater business agility, and unlocking of new value for customers, employees, business partners, and stakeholders.

Speaking about the digital transformation underway at Vedanta Aluminium, Mr Rahul Sharma, CEO – Aluminium Business, Vedanta Ltd. said, “Being India’s largest producer of aluminium, we are manufacturing for the future. This is seeing us extensively use state-of-the-art technologies to make our operations more responsive, reliable, and future-ready. Accelerating our digitalisation programmes, intelligent automation and in-house innovations have enabled us to bolster our manufacturing excellence, use resources judiciously and boost workforce safety, making us agile in responding to market dynamics.”

Vedanta Aluminium is also focussed on building future-ready capabilities in its talent pool, from hiring talent in emerging tech-first specialisations and upskilling its talent base to become even more digital savvy. Some instances of how the company is leveraging digital solutions:

  • Deep learning algorithms and sophisticated modelling techniques allow Advanced Asset Performance Management at Vedanta Aluminium’s smelters and power plants
  • Digital twin technology for predictive and prescriptive maintenance helps ensure greater efficiency, and reduced safety risks with minimal or zero human touch
  • Machine learning based systems provide advance warning through surveillance cameras for real-time intervention to prevent mishaps
  • Video analytics for reduction in turnaround time of inbound trucks carrying raw materials into the plant
  • A robust Manufacturing Execution System provides visibility of all critical plant operations, allowing for remote decision-making

Vedanta Aluminium is now in a growth phase where it is poised to create the industry of the future. From assets to employees, to the vertical integration of operations, the company is geared up to bring a disruptive step-change.

Through Vedanta Spark, the company’s start-up incubator, Vedanta Aluminium is working with a host of new age start-ups, leveraging the power of innovation and digitalisation in manufacturing. The business cases where these start-ups are involved range from operational efficiency to energy storage solutions, water and waste management, smart inventory management, quality excellence, asset optimization and predictive maintenance, people safety and wellbeing, and many others.

Vedanta Aluminium, a business of Vedanta Limited, is India’s largest producer of aluminium, manufacturing more than half of India’s aluminium i.e., 2.26 million tonnes in FY22. It is a leader in value-added aluminium products that find critical applications in core industries. Vedanta Aluminium ranks 4th in the Dow Jones Sustainability Index (DJSI) 2021 world rankings for aluminium industry, a reflection of its sustainable development practices. With its world-class aluminium smelters, alumina refinery and power plants in India, the company fulfils its mission of spurring emerging applications of aluminium as the ‘Metal of the Future’ for a greener tomorrow.

About Vedanta Limited:

Vedanta Limited, a subsidiary of Vedanta Resources Limited, is one of the world’s leading Oil & Gas and Metals company with significant operations in Oil & Gas, Zinc, Lead, Silver, Copper, Iron Ore, Steel, and Aluminium & Power across India, South Africa and Namibia. For two decades, Vedanta has been contributing significantly to nation building. Governance and sustainable development are at the core of Vedanta's strategy, with a strong focus on health, safety, and environment. Vedanta has put in place a comprehensive framework to be the ESG leader in the natural resources sector. Vedanta is committed to reducing carbon emissions to zero by 2050 or sooner and has pledged $5 billion over the next 10 years to accelerate the transition to net zero operations. Giving back is in the DNA of Vedanta, which is focused on enhancing the lives of local communities. The company’s flagship social impact program, Nand Ghars, have been set up as model anganwadis focused on eradicating child malnutrition, providing education, healthcare, and empowering women with skill development. Under the aegis of the Anil Agarwal Foundation, the umbrella entity for Vedanta’s social initiatives, the Vedanta group has pledged Rs 5000 crore over the next five years on social impact programmes with a thrust on nutrition, women & child development, healthcare, animal welfare, and grass-root level sports. Vedanta and the group companies company have been featured in Dow Jones Sustainability Index 2020, and was conferred Frost & Sullivan Sustainability Awards 2020, CII Environmental Best Practices Award 2020, CSR Health Impact Award 2020, CII National Award 2020 for Excellence in Water Management, CII Digital Transformation Award 2020, ICSI National Award 2020 for excellence in Corporate Governance, People First HR Excellence Award 2020, ‘Company with Great Managers 2020’ by People Business and certified as a Great Place to Work 2021. Vedanta’s flagship Nand Ghar Project was identified as best CSR project by Government of Rajasthan. Vedanta Limited is listed on the Bombay Stock Exchange and the National Stock Exchange.

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About Vedanta Aluminium Business:

Vedanta Aluminium, a business of Vedanta Limited, is India’s largest producer of aluminium, manufacturing more than half of India’s aluminium at 2.26 million tonnes in FY22. Vedanta is a leader in value-added aluminium products that find critical applications in core industries. With its world-class Aluminium Smelters, Alumina Refinery and Power Plants in India, the company fulfils its mission of spurring emerging applications of aluminium as the ‘Metal of the Future’ for a greener tomorrow.

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For Further Information, Please Contact:

Ms. Sonal Choithani
Chief Communications Officer
Aluminium Business, Vedanta Ltd.


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