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 located at

Panchpatmali Hills of

Koraput District in

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:

2435

.596

2138

.344

2408

.472

2558

.002

2661

.557

2806

.288

2822

.464

2834

.189 35

22.0

59

4777.003 4816.762

2000

2500

3000

3500

4000

4500

5000

in '0

00M

T

1993-94 1995-96 1997-98 1999-00 2001-02 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 Environmental

features:

• Periphery barrier of 15m

width having green

cover around mines

• 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 world’s lowest cost

today. The production trend over the last ten years is shown

below:

753

770 80

7.1

840.

1

883.

3

894.

5

886 939

1113

1480.6 1550.1

700

900

1100

1300

1500

1700

in '0

00M

T

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

Nalco’s Damanjodi Refinery is globally sought after.

The export of alumina in the last ten years is shown below

417.

197

407.

405

415.

809

449.

831

481.

104 61

0.94

479.

314

495.

723

670.

12

1037.287

934.

874

300

500

700

900

1100

in '0

00M

T

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.

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 ISO-

14001 standards on February 10,1997, by M/s Aspects Moody

Certification, UK

Modernization/ De-bottlenecking/ Expansion of M&R

Complex

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 Nalco’s 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 1999-

2000 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 Dec’01.

Nalco’s 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 liquor is used for dilution of slurry before

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.

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 is known as liquor productivity. Lower

temperatures in precipitation helps achieving higher liquor

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 self-

sufficiency 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 pay and welfare amenities,

commensurate with the company's capacity to spend and the

governments guidelinesTo foster fellowship and sense of

belongingness among all sections of

employeethroughcloserassociation of employees with the

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 to develop the quality of training to new

employees.

2. Giving on the job training to those personnel who are already

in the organization.

3. More money spends on sales of promotion.

4. Organize more friendly atmosphere in the organization.

5. Development of infrastructure of some new technologies and

making new techniques as well as facilities.

6. Providing well services according to the employee’s

expectation.

7. Govt. should give subsidy to the organization in availing

finance, electricity and telecom sector.

8. To attract more no. of employees, the organization should have

to organize tour package through its own investment.

9. Recruitment of personnel relation officers for keeping good

relationship with the new employees.

10. Giving special holiday in off-season and giving special bonus /

incentive in running season.

11. At least one comedian will be given appointment for the

entertainment of the new employees.

12. At least one source of entertainment facility will be given for

the employees.

13. Opening of new cheaper or budget accommodation for

employees in special times.

14. Providing canteen facility for the employees to overcome their

requirement easily.

15. Providing foreign exchange facility or credit card facility to the

employees.

16. New and valuable plan or offer should be given to the

employees to develop their mentally as positive.

17. Providing the payment or salary through cheque / draft of

employees at proper time with 100% correct.

18. To establish more online facilities at the organization to reduce

the consumption of time and easy to access.

19. The organization should provide CPF & gratuity facility to the

employees.

20. Try to provide better service to an employee, so that he/she

will be motivated other persons towards the organization.

21. 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 to develop the quality of training to new

employees.

• 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 employee’s

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.