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CHAPTER 1 Company Profile

Introduction History of the organization Special features

History
Of

The Organization

Introduction
With the discovery of the vast east coast Bauxite reserves at Panchpatmali hills, a new chapter in the history of alumina and Aluminum in India began in 1979. Government of India decided to set up a Mines & Refinery Unit, and accordingly the foundation stone was laid in 1981, by the then Prime Minister Mrs. Indira Gandhi. The Open Cast Mines was Koraput located District at in Panchpatmali Hills of Orissa, whereas the Alumina Refinery was located at Damanjodi, a flat land located about 15 kms away from the Mines. Together, the unit came up to be the largest open cast bauxite mine and the largest alumina plant in Asia.

Bauxite Mine
The fully mechanized opencast mine of 4.8 million tpa capacity is in operation since November, 1985, serving feedstock to Alumina Refinery at Damanjodi located on the foothills.

The salient features: Area of deposit - 16 sq. km. Resource - 310 million tonnes Ore quality - Alumina 45%, Silica 2% Mineralogy - Over 90% gibbsitic Over burden - 3 meters (average) Ore thickness - 14 meters (average) Transport - 14.6 km long single flight multicurve cable belt conveyor of 1800 tph

The Performance of the Mines has been exemplary. The last ten years production shown below:
4816.762

5000 4500

4777.003 3522.059 2001-02

in '000MT

2822.464

2435.596

3500 3000 2500 2000

1993-94

2138.344

1995-96

2408.472

2558.002

1997-98

2661.557

2806.288

1999-00

2834.189

4000

2003-04

Mines and the Environment


The Panchpatmali Bauxite Mines of NALCO has been well-known as one of the most Environment friendly mine today. Salient features: Periphery barrier of 15m width having green cover around mines Environmental

Garland drains and drainage control within the mines Dust suppression at source and sprinkling of water Total overburden excavated with top soil used for reclamation and rehabilitation of mined out areas with vegetation cover.

Studies Conducted on environment: Studies on effect of blasting on ground water table at Bauxite Mines Studies on water quality and water flow to assess the impact of mining on the perennial springs below.

Eco-genetic resources survey at Panchpatmali Mines.

The Environment Management Systems of Bauxite Mines certified to ISO-14001 standards on June 24th, 1996, by M/s Aspects Moody Certification, UK.

Alumina Refinery Complex

The 15, 75,000 tpa Alumina Refinery, having three parallel streams of equal capacity, is located in the picturesque valley of Damanjodi in Koraput district is in operation since Sep 1986.

The Refinery is designed to: Provide about 6,90,000 tons of Alumina to the Company's Smelter at Angul Export the balance Alumina to overseas markets through Visakhapatnam Port

The salient features: Atmospheric pressure digestion process Pre-desilication and inter-stage cooling for higher productivity Energy efficient fluidised bed calciners Co-generation of 3x18.5 MW power by use of back pressure turbine in steam generation plant Advanced red mud disposal system

Alumina Refinery has been consistently improving its performance from its inception and has proven to be one of the best in the business today, with consistently exceeding its capacity for the last three years, apart from producing Alumina at the worlds lowest cost today. The production trend over the last ten years is shown

below:

1700 1480.6 1500

1550.1

in '000MT

894.5

840.1

700 1993-94 1995-96 1997-98 1999-00 2001-02 2003-04

The Alumina Refinery has been earning hundreds of million dollars of valuable foreign exchange for the country through these years through export of its product, which consistently meets and exceeds the Quality requirement of the international market. Alumina from Nalcos Damanjodi Refinery is globally sought after. The export of alumina in the last ten years is shown below

753

900

770

807.1

886

939

1100

883.3

1113

1300

1100

1037.287

900

in '000MT

481.104

417.197

500

300 1993-94 1995-96 1997-98 1999-00 2001-02 2003-04

Environment and the Alumina Refinery


The Alumina Refinery has been both designed to be and later upgraded to be environment friendly in all respects.

407.405

415.809

449.831

479.314

495.723

700

610.94

670.12

934.874

Salient environmental features Highly efficient ESPs at Calciners and steam Generation Plant. Multistage washing of red mud and its storage in specially designed pond. Use of dust collectors at handling and transport areas of bauxite, coal, lime and alumina. Recycling of waste water.

The Environment Management Systems of Refinery certified to ISO14001 standards on February 10,1997, by M/s Aspects Moody Certification, UK

Modernization/ Complex

De-bottlenecking/

Expansion

of

M&R

The massive modernization/ de-bottlenecking & expansion program of M&R Complex has been completed. The methodology followed for the exercise was as follows: The constraints in production, quality and cost of production were studied in detail in-house as well by process licensors. This was followed up with identifying solutions for each constraint and choosing the most modern and economical techniques to achieve the objectives. Implementation of these techniques and installation/ commissioning of the new equipment on the earlier two streams rated at 800,000 MTPY enhanced the capacity to 10,50,000 MTPY.

Further, a de-bottlenecked and modernized stream of Alumina Plant was installed in the expansion stage, which raised the Plant Capacity to a staggering 15,75,000 MTPY. The Changes being incorporated are primarily as follows: Increase in speed of Cable belt to double that of the existing speed Pre-desilication of Bauxite, before digestion Double stage dilution, with second dilution after settling High concentration post-desilication and settling. Individual Kelly feed and lime dosing Improved Heat exchangers for better exchange rate with lower surface area Inter-stage cooling of precipitators Cyclone Classification and Spent-liquor solids separation Six-stage evaporation Utilizing conveying air in Calcination for combustion Nalco, which is already the largest player in the Alumina-Aluminium scene in the country, shall become a key player in the international arena after this modernization/ de-bottlenecking and expansion. The production cost will drop further, making its presently unchallenged position as the leader, even more unassailable.

BRIEF OVERVIEW OF ALUMINA REFINERY PROCESS


Nalcos Alumina Refinery, was set up with the technical collabaration of Aluminium Pechiney, France, having an installed capacity of 0.8 million MTPY with two streams each of 0.4 million MTPY rated capacity. The plant was commissioned in the year of 1987. Debottlenecking of the alumina refinery was done in the year 19992000 to increase plant capacity from 0.8 to 1.05 million MT per year, by making necessary changes at various units to realise higher liquor productivity and increased flow throughput. In expansion of alumina refinery, one more stream of debottlenecked hydrate circuit was added up to the existing two streams, having capacity of 5,25,000 MTPY. Hence, after expansion, plant installed capacity reached to 15, 75,000 MTPY.Third stream under expansion was commissioned in the month of Dec01. Nalcos alumina plant was designed with atmospheric pressure digestion (due to its primarily Gibbsitic bauxite), being the second plant with such type of digestion after Frigua plant in Africa. After digestion the design provided removal of coarse sand particle in sand separation, dilution followed by desilication, before settling in flat bottomed settlers and a continuous European high solid nucleation based precipitation. It also incorporates Circulating Fluid Bed (CFB) type energy efficient Calcination to produce sandy type Smelter grade alumina. Besides the above, the alumina plant has a coal based Steam generating plant and co-generating backpressure type cost effective Turbogenerators.

The process in its original form is now primarily limited to basic chemistry. The major reactions involved in the process are as follows: Digestion reaction: Al (OH)3 + NaOH NaAl(OH)4 Silica Dissolution: Al2O3, 2SiO2, 2H2O + 6NaOH 2NaAl(OH)4 + 2Na2SiO3 + H2O Desilication Reaction: 6NaAl(OH)4 + 6 Na2SiO3 3(Na2O,Al2O3,2SiO2,2H2O),Na2X + 12NaOH Where X = CO3-2, 2AlO2-, 2OH-, 2Cl-, SO3-2 etc. or a mixture of these anions Precipitation reaction: NaAl(OH)4 Al(OH)3 + NaOH Carbonation reaction: 2NaOH + CO2 Na2CO3 + H2O Causticisation reaction: Na2CO3 + Ca(OH)2 CaCO3 + 2 NaOH Brief description of the process units are as follows: Bauxite handling & crushing: Run off Mine (ROM) Bauxite, crushed in primary crusher in Mines to a size of 150 mm, is received at Alumina plant and stacked in stock piles with the help of a Stacker. This bauxite is then reclaimed from pile with the help of Bucket Wheel Reclaimer and fed to Vibrating screen & Hammer Crushers (secondary crushing unit) to get a size of D(85) = 30 mm and to store in day silos for feeding to process.

Grinding & Pre-desilication Bauxite is wet ground with hot and diluted caustic (Spent Liquor having caustic concentration around 150 gm/litre) in closed circuit Ball mill. In the grinding coarse grinding has been adopted so that sand separation could be introduced saving energy for grinding and at the same time optimizing settler/ washer capacity.The ground slurry is heated to 100- 102oC and sent to a series of 3 tanks, where at the conditions maintained, a part of the silica that has already dissolved in the caustic solution during grinding precipitates out as sodalite. A part of hot and concentrated caustic (Green liquor having concentration around 225 gpl) is then added to the pre-deslicated slurry and the resultant slurry is classified in Hydrocyclones. Coarser fraction is sent back to the mill and cyclone overflow, slurry with finer fraction after addition of balance Green liquor are fed to the digestors. Digestion In digestors (vigorously agitated steam heated tanks), bauxite slurry (ground & classified) is retained at a temperature of 105 deg C & kept under constant agitation for a period of about 2-3 hours for dissolution of tri-hydrate alumina (gibbsite) in caustic. During this process, along with alumina, the kaolinite (reactive silica) remaining after pre-desilication also gets dissolved in liquor to form sodium silicate. Desired level of saturation (Al2O3/Na2O), called Ratio Ponderal (RP) is maintained by adjusting Bauxite to Green liqour ratio in Ball Mills.

Sand separation, Sand washing and Dilution: After digestion, slurry is stripped of coarse particles (known as sand) by passing it through hydrocyclones to avoid excessive abrasion in the equipment & piping as well as to avoid quick settling in Settlers/washers. Segregated sand is washed in multistage cyclones to recover entrained soda.The comparatively high concentration of caustic in slurry after sand separation is disadvantageous to the downstream operations like desilication, settling, filtration and precipitation. Hence, after removal of sand, slurry is diluted to about 145 gpl with low caustic liquor generated in mud washer train while washing mud with water for recovering impregnated liquor.

Desilication: After dilution, slurry is fed to desilicator for removal of reactive silica, which got dissolved during digestion step and detrimental to product quality and also causes scaling of equipment & piping throughout the plant. Desilication is carried out in a series of agitated steam heated tanks at a temperature of 103 deg C for a period of about 8 to 10 hours. Almost all the dissolved silica precipitates out as a complex compound called Sodalite making the liquor part of slurry free from undesirable silica which would have otherwise contaminated the product during precipitation step. Settling & Mud washing, Causticisation and Flocculation: After desalination, slurry is fed to settlers for separation of solid (digestion residue & desilicated product known as red mud) from liquor saturated with alumina in large flat bottomed tanks

with rake mechanism. Flocculants are added to facilitate settling. In the settlers, liquor is collected in over flow and mud in the under flow.

The underflow of the settlers, called Mud containing considerable amount of entrained soda, is washed with pond return water in 6 stages of counter current washing. These washers are mechanically identical to settlers, only with a different function to perform. Washed mud withdrawn from the sixth washer is pumped to Mud disposal tanks from where along with sand it is pumped to TTD (Thickened tailing Disposal) tanks for further washing and disposal to red mud pond. The recovered low concentration desilication. In the washer train, 3rd washer overflow is allowed to react with lime slurry for causticisation of carbonate formed in the circuit. The reaction with lime decomposes sodium carbonate into sodium hydroxide and precipitates out other impurities like V2O5, P2O5 etc as their calcium salts. The causticised slurry is fed to a settler as the overflow and the underflow mud is sent to mud washing circuit. Flocculation unit is to prepare flocculant solution from wheat bran to use as settling aid in settlers & washers. During the process of desilication and settling, substantial amount of dissolved alumina precipitates out due to high residence time, low caustic concentration and high alumina to caustic ratio. Precipitated alumina gets lost with red mud. liquor is used for dilution of slurry before

Security filtration: The traces of solid present in settler over flow, commonly known as pregnant liquor, is still not acceptable as it upsets product quality in terms of Fe2O3 content. Hence it is filtered in pressure filters to remove traces of mud particles and to get clear sodium aluminate liquor. Lime slurry is used as filter aid. As this unit essentially secures product quality from impurities, the unit is also called Security filtration unit. Heat exchange The temperature of clear aluminate liquor is still about 100 deg.C, does not allow recovery of alumina in precipitation. Hence, it is passed through plate heat exchangers to bring down temperature close to 60 deg C in three stages. The first stage exchanges heat with 3rd washer overflow, Second stage with spent liquor and in the third with cooling water for precise temperature control. The control on this unit is a prime factor influencing both productivity and grain size of the product. Seeding, Precipitation, Classification and Hydrate filtration: Cold pregnant liquor is then mixed with seed hydrate already available in precipitators. Hydrate, thus mixed with pregnant liquor, acts as seed and enhances precipitation process when fed into the precipitators. Precipitators are a series of agitated high volume tanks containing about 700-750 gpl solids in suspension. The seeded slurry continuously flows from one precipitator to another by gravity flow. A portion of the slurry from 4 or 5 precipitators are fed to Inter stage Coolers (exchangers) for cooling with water. The cooled slurry is then discharged to the next tank. Interstage coolers have helped in improving the liquor productivity due to reduced temperature across the precipitation

even with higher feed temperature to reduce soda content in product alumina. Aluminate liquor, which attains high degree of supersaturation after cooling, hydrolyses in precipitators, accelerated by the presence of seed hydrate. The process yields Alumina Hydrate in crystallised form. The yield of Hydrate (as Al2O3) in Kg/M3 of aluminate liquor in is known as liquor productivity. higher Lower liquor temperatures precipitation helps achieving

productivity, wheras it also leads to a finer granulometry and higher soda content in product. A part of the precipitated hydrate slurry is classified in classifiers to get 45 micron size particle of 3-4% in the coarse underflow slurry. Classification is facilitated by injection of spent liquor and dilution of feed, if required. The classified slurry is filtered in vacuum disc filters. The cake is known as first stage product Hydrate.Balance part of precipitated hydrate slurry is filtered in vacuum precipitation.Filtrate obtained from the vaccum disc filters, commonly known as spent liquor, is passed through cyclones (spent liquor solid separation cyclones) for recovering fine suspended hydrate particles and then heated up with exchange of heat from aluminate liquor and sent to evaporation unit for further use. Second stage filtration & Calcination: The Product hydrate obtained from disc filter after classification of precipitated slurry and filtration is again repulped, filtered on rotary vacuum drum filter, washed with sodic condensate to make hydrate free from soluble soda. The wash filtrate taken out from washing zone of the filter is used for repulping of first stage product hydrate and main filtrate is sent to mud washing circuit after separation of solid. The cake known as product hydrate is sent to Calcination or Hydrate storage depending on requirement.

Product hydrate is calcined in Circulating Fluid Bed type Calciners between 900-1000 deg C using heavy fuel oil. Apart from surface moisture, the water of crystallisation in Hydrate is also drivenoff during Calcination, leaving behind sandy, metallurgical grade alumina. Evaporation: The spent liquor preheated through Plate Heat Exchangers (PHE) is concentrated in six effect evaporators, to raise its concentration from about 150 gpl to 225 gpl. The output liquor called as Green liquor is sent to Ball mills for grinding & digestion of Bauxite thereby, completing the circuit. Soda lost in the process is made up with addition of fresh caustic soda in this unit. steam & Power Plant Four Coal fired boilers with three back pressure type turbo generators have been installed to supply steam and power to the plant. The boilers and the TGs are of 200 TPH and 18.5 MW capacity respectively. At any point of time three boilers & three TGs are kept in service. Steam is generated at 68 Kg/cm2 and the process requirement is met by passing through the TGs and supplying at two different pressures, i.e. 11 Kg/cm2 and 6 Kg/cm2. During the reduction in pressure, power is generated. This is a proven method of power generation at the lowest cost. The plant power requirement is mostly met through Captive generation. However, generation is kept synchronized with the state grid and a small amount of power is drawn from the grid. During minor fluctuations and in some major failures of the grid for short duration, some of the non-critical loads are thrown off through load shedding scheme and the plant is automatically operated on Island mode.

Introduction
About The Organization

Organization Profile
National Aluminium Company Ltd. (Nalco) is considered to be a turning point in the history of Indian Aluminium Industry. In a major leap forward, Nalco has not only addressed the need for selfsufficiency in Aluminium, but also given the country a technological edge in producing this strategic metal to the best of world standards. Nalco was incorporated in 1981 in the Public Sector, to exploit a part of the large deposits of bauxite discovered in the East Coast. The philosophy of Nalco in the field of human resources and management has been: To attract competent personnel with growth potential and develop their skills and capabilities in a congenial work and social environment through opportunities for training, recognition career advancement and other incentives. To develop and nurture favorable attitude among employees and to obtain their best contribution to the organization by providing stable employment, safe working conditions, job satisfaction, quick redress of grievances and through good foster pay and welfare and sections employees with amenities, sense of of the commensurate with the company's capacity to spend and the governments belongingness guidelinesTo among fellowship all of

employeethroughcloserassociation

management and by encouraging healthy trade union practices.

Aluminum industry profile: 1. Aluminum in India 2. Company profile 3. Current Scenario Aluminum in India: India enter ed the field of aluminum smelting in 1943 with the setting of 2500 tones capacity smelter by Indian Aluminum company at Alupuram, at Kerala. The production of Aluminum in 1943 was 1292 tones only, but it was after 1960 that aluminum industry in India made a rapid growth when HINDALCO was established in and INDAL expanded its capacity by putting up more smelters. The 1991 policy changes for opening up economic and liberalization, since 1991has brought about considerable opportunities for Indian industry and has generated lot of interest by multinational companies to participate in joint ventures with Indian companies by way of technology, investment, marketing and franchise arrangements with the present opportunities. Indian Aluminum industry has already entered the world arena and registered its presence in global market after the entry of NALCO Alumna and Aluminum on the world market. Government of India entered in the field of Aluminum with setting up BALCO in 70s. However till1980, Indian Aluminum production was not sufficient to meet its domestic demand and there was not sufficient for domestic demand and there was no global presence of Indian aluminum industry. In 1981 National Aluminum Company in public sector was set up as a largest integrated alumina aluminum company in Asia. It is only NALCO came up in 1987 with its world class Aluminum and metal capabilities, India could enter the global arena in aluminum and alumnae.

CONCLUSION ON WORK
To describe the term Impact of T & D on work culture is very much large. Proper training and well development is the next meaning of customer satisfaction. Training and Development is very much essential and a vital part for an organization and to maintain itself in present scenario. To bridge up the gap between present and future, training and development is a systematic tool, but very often we find that, sometimes people in the organization are hesitate to involve themselves in the process of change or we can say they are not interested to change the work culture because of various fear i.e. Loss of Job, fear of replacement etc. In this situation proper moralsuation is essential to success the total system. A proper training and development system not only help the organization to make in a right path but also prepare the

organization to face the future changes. So to adopt the process of change the proper training and development is very much needed.

Therefore, here we conclude that training and development is an important weapon to modify the work culture and has great impact to develop the society. So, a proper and valuable planning is essential for its success and development.

RECOMMENDATION
After an exploratory research has been done and looking into the growing perception of the society, training and development towards employees are so necessary. So the following are the sources of my suggestion to an organization to win the heart of each and every person of the nation or the society. 1. Recruitment of well trained and experienced personnel in the organization employees. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Giving on the job training to those personnel who are already in the organization. More money spends on sales of promotion. Organize more friendly atmosphere in the organization. Development of infrastructure of some new technologies and making new techniques as well as facilities. Providing well services according to the employees expectation. Govt. should give subsidy to the organization in availing finance, electricity and telecom sector. To attract more no. of employees, the organization should have to organize tour package through its own investment. Recruitment of personnel relation officers for keeping good relationship with the new employees. Giving special holiday in off-season and giving special bonus / incentive in running season. At least one comedian will be given appointment for the entertainment of the new employees. to develop the quality of training to new

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

At least one source of entertainment facility will be given for the employees. Opening of new cheaper or budget accommodation for employees in special times. Providing canteen facility for the employees to overcome their requirement easily. Providing foreign exchange facility or credit card facility to the employees. New and valuable plan or offer should be given to the employees to develop their mentally as positive. Providing the payment or salary through cheque / draft of employees at proper time with 100% correct. To establish more online facilities at the organization to reduce the consumption of time and easy to access. The organization should provide CPF & gratuity facility to the employees. Try to provide better service to an employee, so that he/she will be motivated other persons towards the organization. Continuous discussion should be done among the Managing Director and the development officer, so that the feedback of the employees will fully reach in the management.

22.

The organization should have on opportunity for the employees to improve the local market as well as the demand of the organization.

At last, in an organization the employees must be trained properly so that they may contribute to the well being of the organization. So the following are the sources of my suggestion to an organization to win the heart of each and every person of the nation or the society.

Recruitment of well trained and experienced personnel in the organization employees. to develop the quality of training to new

Giving on the job training to those personnel who are already in the organization. More money spends on sales of promotion. Organize friendlier atmosphere in the organization. Development of infrastructure of some new technologies and making new techniques as well as facilities. Providing well services according to the employees expectation. Govt. should give subsidy to the organization in availing finance, electricity and telecom sector. To attract more no. of employees, the organization should have to organize tour package through its own investment.

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