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Chairman's Message Chairman's Message
CASE STUDY

Smelting Progress at BALCO

At BALCO, we continue to build on a legacy defined by industrial firsts, technical excellence and nation-building contribution. As one of India’s iconic aluminium producers, BALCO has supplied metal for strategic national programmes, operated India’s highest amperage smelter and established the country’s first 525 kA smelter. This progress reflects our focus on advanced technologies, process optimisation and continuous capability-building.

Impact statement

599 kt

BALCO’s highest-ever hot metal production during FY 2025-26 reinforcing our position as one of India’s most advanced and reliable aluminium producers

Key interventions
  • Advanced current creep by 3.7 kA year-on-year through a new relining design and thermal modelling
  • Developed India’s first Cu insert design and transformed 29% of the potline using this innovation
  • Completed RCC++ pot modelling and installed the pilot pot, marking a first-of-its-kind initiative in India
  • Implemented advanced pot modelling and design improvements to extend operating life and strengthen smelter reliability
  • Pioneered nano ceramic coating technology in India and shared this best practice across group smelters
  • Continued to enhance smelter performance through technical upgrades, process control and operational discipline
  • Integrated AI/ML powered pot reaction early alert control tool (PREACT) predicting pot health and improving pot availability
Milestones

~105.7%

Capacity utilisation achieved across the GAMI smelters in India

2,133 Days

Benchmark pot life reached

2,000+ Days

Pot life consistently sustained at BALCO

RCC++

Installed pilot pot, which is expected to increase pot life beyond 2,400 days

Strengthened BALCO’s role

as a hub of smelting innovation and capability-building within Vedanta

Way forward

We will continue to advance BALCO’s smelting performance through technology-led interventions, improved pot design, thermal efficiency and stronger process reliability. Our focus will remain on extending pot life, improving asset productivity and scaling proven innovations across our smelter network.