THEBUSINESSBYTES BUREAU
JHARSUGUDA, FEBRUARY 17, 2026
Vedanta Aluminium, India’s largest producer of aluminium, has deployed a
state-of-the-art cooling solution, termed the Forced Cooling Network (FCN), at
its mega aluminium smelter in Jharsuguda, marking a significant step forward in
thermal management and energy efficiency. Developed in-house, the innovation
leverages advanced 3D Computational Fluid Dynamics (CFD) modelling to optimise
heat control in aluminium reduction cells, commonly known as pots. The FCN has
earned national recognition, receiving a Certificate of Merit at the National
Energy Conservation Awards 2025 presented by the Bureau of Energy Efficiency
under the Ministry of Power.
CFD technology uses sophisticated numerical algorithms to simulate fluid
behaviour — covering airflow, pressure and temperature — enabling engineers to
refine system performance with high precision before physical deployment. In
aluminium smelting, such accuracy is critical for preventing sidewall
overheating, preserving protective freeze layers, minimising energy losses and
maintaining stable, efficient pot operations.
By creating detailed digital replicas of pot structures, cooling ducts
and airflow pathways, the FCN enables pre-installation optimisation of heat
dissipation through CFD simulations. The system has already been commissioned
on a section of a potline at Vedanta Aluminium’s Jharsuguda facility, with
plans underway for phased expansion across the entire potline. Through precise
control of sidewall temperatures, the FCN supports stable high-amperage
operations, improves thermal balance and enhances overall process reliability.
The initiative has delivered measurable outcomes, including energy savings of
15.3 kWh per tonne of aluminium produced, reinforcing its role in advancing
energy-efficient and sustainable smelting practices. These tangible gains
contributed to its recognition at the National Energy Conservation Awards.
Commenting on the development, C. Chandru, CEO, Vedanta Jharsuguda, said,
“Innovation is at the core of Vedanta Aluminium’s operational philosophy. By
combining digital precision with practical engineering, we have strengthened
potline stability while significantly improving energy efficiency. This
achievement reflects the ingenuity of our teams and establishes a new benchmark
for sustainable aluminium production in India.”
Vedanta Aluminium continues to prioritise technology-led interventions
that enhance industrial safety, operational resilience and environmental
performance. The company is increasingly harnessing Industry 4.0 tools,
including Artificial Intelligence and Machine Learning, to drive data-driven
decision-making, optimise processes and achieve global standards of operational
excellence.
A business of Vedanta Limited, Vedanta Aluminium produces more than half
of India’s aluminium, with an output of 2.42 million tonnes in FY25. The
company is a leading manufacturer of value-added aluminium products that serve
critical sectors such as infrastructure, power, transportation and packaging.
It ranked second globally in the aluminium segment of the S&P Global
Corporate Sustainability Assessment 2025, underscoring its strong commitment to
sustainable development. With world-class smelters, an alumina refinery and
captive power plants across India, Vedanta Aluminium continues to advance its
vision of positioning aluminium as the ‘Metal of the Future’ for a greener and
more energy-efficient tomorrow.
