ISSN 2581-6055 Vol. 20 • Issue No.

4 • January 2021 • `150

A Quarterly Journal

Aluminium in India

ALUMINIUM ASSOCIATION OF INDIA

Bengaluru - 560 001. India

JANUARY 2021
VOL. 20
ISSUE NO. 4
Published by
Aluminium
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Aluminium in India A Quarterly Journal
CONTENTS
1 ALUMINIUM METAL MATRIX COMPOSITE PROCESSING BY LIQUID METAL
INFILTRATION TECHNIQUES
7
T.P.D. Rajan - CSIR-NIIST & AcSIR, M.G. Akhil - CSIR-NIIST & AcSIR,
A.G. Arsha - CSIR-NIIST & AcSIR,K.M. Sree Manu, CSIR-NIIST & BCAST,
Visakh Manoj - CSIR-NIIST, H. Sundara Murthy - Fenfe Metallurgicals,
B.C. Pai - CSIR-NIIST
2 CELL LINING REDESIGN FOR SPL MINIMIZATION AT HIRAKUD SMELTER
Mahesh Sahoo - Hindalco Industries Ltd, Hirakud, Amit Gupta - Aditya Birla
15
Science & Technology Company Pvt. Ltd.,
S. K. Badajena - Veer Surendra Sai University of Technology, University of Burla
3 DESIGN & DEVELOPMENT OF HPC CONDUCTOR: A PERMANENT SOLUTION 18
FOR LONG SPAN RIVER-CROSSING– 400KV D/C QUAD
Prasad S, Rakesh Tripati, Ananthakumar R, Vishal Sharma, Saikrishna
Bendapudi - Sterlite Power Transmission Ltd.
4 CRU EXPLAINS HOW TO UNDERSTAND INDIA’S COMPLEX CARBON
EMISSIONS PROBLEM
22
Shankhadeep Mukherjee, Team Leader, CRU India
5 ALUMINIUM INDUSTRY NEWS 26
• Balco CEO, Abhijit Pati recognised amongst most promising business leaders of Asia 20-21
• Vedanta: Propelling India's growth & self-reliance story
• Hindalco Announces Resumption of Aluminium Capex Cycle with New Silvassa Plant
• Aluminium Demand Growth Will Soon Outpace Production Growth
• Jawaharlal Nehru Aluminium Research signs MoU with RUSAL
• Telangana new Electric Vehicle and Energy Storage Solution Policy to Woo Investments
• RAIN Water Company Launches Mountain Spring Water in Recyclable Aluminum Bottles
• Hindalco Ranked World’s Most Sustainable Aluminium Co: Dow Jones Sustainability Indices
2020
• Lighter Aluminum Wheels Outweigh Steel
• Extruded Elements Manufacturer with an Aluminum Solution Furnace from Seco/Warwick
• Kanfit3D Offers 3D Printed Aluminum Parts for Aerospace Industry
• Rectangular Aluminum Fins For PV Module Cooling
• Carbon Nanofibers Boost The Hardness Of 3D-Printed Aluminum
• Weiler Abrasives Expands Line of Aluminum Flap Discs
6 FORTHCOMING EVENTS 21
7 Aluminium Highlights
• Aluminium Statistics
34
• Japanese Aluminium Market
8 Archives 36
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 Editorial ALUMINIUM IN INDIA

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Vol.20 Issue No.4 JANUARY 2021 5 Aluminium Association of India

TECHNICAL PAPER

ALUMINIUM METAL MATRIX COMPOSITE PROCESSING

BY LIQUID METAL INFILTRATION TECHNIQUES
T.P.D. RAJAN1, 2*, M.G. AKHIL1, 2, A.G. ARSHA1, 2, K.M. SREE MANU1,3, VISAKH MANOJ1, H. SUNDARA MURTHY4 AND B.C. PAI1
1
Materials Science and Technology Division CSIR-National Institute for Interdisciplinary Science and Technology (NIIST),
Trivandrum - 695 019, Kerala, India.
2
Academy of Scientific and Innovative Research (AcSIR), Ghaziabad, New Delhi, India
3
Brunel Centre for Advanced Solidification Technology (BCAST), Brunel University, London, UK
4
Fenfe Metallurgicals, Bangalore, India
*Email: tpdrajan@niist.res.in, tpdrajan@rediffmail.com

Abstract
Metal matrix composites (MMC) are one of the advanced materials widely used for aerospace, automotive, defence and general engineering
applications. MMC can be tailored to have superior properties such as enhanced high temperature performance, high specific strength
and stiffness, increased wear resistance, better thermal and mechanical fatigue and creep resistance than those of unreinforced alloys. To
fabricate such composites with ideal properties, the processing technique has to ensure high volume fraction of reinforcement incorporation,
uniform distribution of the reinforcement and acceptable adhesion between the matrix and the reinforcing phase without unwanted
interfacial reactions which degrades the mechanical properties. A number of processing techniques such as stir casting/vortex method,
powder metallurgy, infiltration, casting etc. have been developed to synthesize MMC employing a variety of alloy and the reinforcement’s
combinations. Among these infiltration process is widely used for making MMC with high volume fraction of reinforcements and offers many
more advantages compared to other conventional manufacturing processes. The present paper describes various infiltration techniques
used for making the Aluminium MMC

1.INTRODUCTION matrix composites. From tribological perspective, the addition of

Liquid metal infiltration of ceramic preform is apparently the best
suited fabrication method to produce metal matrix composite
components with variety of complex shapes having high volume
fraction of reinforcement. Infiltration is a liquid state fabrication
method, in which a porous preform (reinforcement) such as ceramic
particles, fibers, woven etc are impregnated in a molten matrix
metal, which fills the pores between the dispersed phase inclusions.
Synthesis of porous ceramic preform with sufficient mechanical
strength, uniform pore distribution, pore size and porosity level
is one of the crucial steps involved in infiltration processing of
composites [1,2]. The captivating properties of these ceramic foams
such as thermal resistance, low density, controlled permeability,
low thermal conductivity, high surface area and high structural
uniformity make them potential candidates for multiple engineering
applications [3,4]. Some of the important fabrication methods for
porous ceramic foams are polymer replica techniques, gel casting,
direct foaming of suspensions and using pore forming agents (PFA)
[5-11]. Al, Mg and Cu based alloys have been successfully used as
matrices to contrive MMCs through liquid infiltration, as they can
be easily melted and handled in the liquid state. Difference from
one infiltration method to another is based on the technique that
is used to drive the molten metal to enter the preform. The present
paper gives the state of art knowledge on the various infiltration
processing methods of MMCs and their characteristics.
2. Metallic Composites
The inclusion of high strength and modulus ceramic reinforcements
to a ductile metal matrix forms the metallic composites having
unique combination of properties offering high resilience, high
temperature applications compared to polymer and ceramic
hard ceramic reinforcements increases the wear resistance of
the metallic matrix. Ultimate combination of properties of MMCs
depends on a number of factors related to matrix, reinforcement,
processing and heat treatment. Samer et al. recommended that the
young’s modulus, UTS and maximum elongation of the composite
depends on the particle size of the reinforcements and obtained
superior properties in composites containing nanoparticles
(~70nm) when compared to composites containing micrometre
range particles in Al/TiC system [12]. Aluminium, magnesium and
titanium alloys are the most commonly used matrix materials for
MMC processing due to their low specific gravity and those find
wide range of applications in automotive and aerospace sectors.
In metallic composites the thermal stress caused due to thermal
mismatch between matrix and reinforcement can be reduced
from the matrix plastic deformation phenomena [13]. Nowadays,
fabrication of MMC focuses on nanocomposites where the matrix
alloys are coupled with nanoparticle reinforcements like carbon
nanotubes, SiO2, Y2O3, SiC, Al2O3, graphene, etc [14,15].
3. Preform Materials
The porous ceramic preforms contemplate as scaffolding, are
considered to be the base of the composite materials processed by
infiltration technique. The properties of the composite depend upon
the strength, distribution, type and structure of the interconnected
pores in the porous body to facilitate the liquid metal infiltration.
Thus, the process parameters have to be optimized for synthesizing
quality composites. Assorted type of fundamental works by varying
the processing, pore former (NaCl, PEG, carbon fiber, tylose),
reinforcement (Al2O3, SiC, Si3N4) and binding agent (aluminum,
poly vinyl alcohol) have been carried out by several investigators.

Vol.20 Issue No.4 JANUARY 2021 7 Aluminium Association of India

TECHNICAL PAPER
However, the depth and speed of the infiltration is influenced by
the coefficient of permeability in the preform, which alters with the
volume fraction of reinforcement. Yamanaka et al. [16] concluded
that the temperature, wettability and the volume fraction of
reinforcement in the preform regulate the coefficient of permeability
in the system. An increase in the volume fraction of reinforcement
reduces the gaps and open porosity in the porous preform, which
reduces the ability of the liquid molten metal to get penetrated.
Based on the experimental studies it is found that the permeability
k of a porous preform is directly proportional to the square of the
mean diameter of the reinforcement [17].
k=aD2 (1)
where a is the constant which depends upon the reinforcement
morphology. Dobrzanski et al. [18] fabricated Al2O3 based preforms
using carbon fiber as the pore forming agent and observed the
increase of permeability with an increase in pore former content.
The strength of the porous preform is negatively affected by
increasing the pore former content because it increases the porosity
level and by randomness in distribution of pores. In accordance
with the above factor, non uniform distribution of pores in the
preform will create difference in the collateral wall thickness and
cause inability to withstand localized stress concentration resulting
in deformation [19]. The grain size of the particles has great impact
on the porosity hike and strength of the preform. Increase in the
grain size is inversely proportional to the mechanical strength of
the preform owing to low diffusion on grain boundaries [20]. The
morphology of the pores in the preform depends upon the kind and
type of pore former used in the system. Raddatz et al. [21] created
hollow channels in the ceramic preform by integrating cylindrical
shaped polymer fibers as pore forming agent. The binding agent in
the preform plays a dual role, which imparts strength to the green
body as well as the sintered porous structure by bridging between
the particles.
4. Processing Techniques
The liquid infiltration processes can be broadly classified into two
categories: a) spontaneous infiltration and b) forced infiltration
(Figure 1). When capillary action of the reinforcement phase acts
as a driving force for infiltration, the category of processes is
termed as spontaneous infiltration. In forced infiltration an external
pressure such as gaseous, mechanical, squeeze, electromagnetic
etc. are applied to the liquid matrix phase which accelerates the
infiltration of molten metal through the preforms. The processing
details are briefly discussed here.
Fig.1. Classification of infiltration process for the fabrication of
metal matrix composites.
Vol.20 Issue No.4 JANUARY 2021
4.1. Spontaneous / Pressure-less Infiltration
In spontaneous infiltration, the molten liquid metal invades
into the voids of the porous body without the application of any
external forces (Figure 2) [22-27]. This can be accomplished with
the help of controlled temperature and gas atmosphere ensuring
good wetting conditions are maintained for self-permeation [28].
Numerous studies in pressure-less infiltration have been carried
out using Al–Si, Al–Zn, Al–Mg alloys into porous SiC preform and
however there are some challenges that should be tackled to develop
spontaneous infiltration a very promising and industrially adaptable
method. Conventional drawback of the infiltration synthesis method
is the poor wettability between the matrix and the reinforcement
resulting from the formation of oxide layer on the melt surface
[29]. Poor wettability negatively influences the infiltration process
by slowing down the infiltration process leading to undesirable
reactions at the interface resulting in the formation of intermetallics
such as Al4C3 and Al3SiC4 in aluminium -SiC based systems [30].
Many researchers had investigated the effect of activator content
in pressure less infiltration of metal matrix composites [31]. Dwell
time and activator primarily controls the rate of infiltration. More the
activation more will be the infiltration depth. The amount of porous
areas and residual porosity also govern the infiltration quality
but this can be reduced by increasing the activator content [32].
The wettability of preform by liquid molten metal is an essential
parameter for processing composites by pressure-less infiltration
technique. Wittig et al. suggests that the addition of titanium in
the steel matrix composites reinforced with ZrO2 particles helps in
improving the wetting behaviour of liquid metal to ceramic preforms
[33]. Contreras et al. successfully infiltrated liquid magnesium into
TiC preforms by pressure-less technique [34]. Previous studies
suggest that the wettability can be improved by adding 3 - 4.7
mass percent of magnesium to the melt and also by using 100%
nitrogen atmosphere in the furnace.
Fig.2. Schematic diagrams showing the working principle of
spontaneous infiltration process: (a) infiltration takes place at
controlled atmosphere, (b) progressiveness of infiltration and (c)
final composite.
Magnesium is known to be a powerful surfactant that accumulates
oxygen from the surface of the melt and forms MgAl2O4 spinel at
8 Aluminium Association of India
TECHNICAL PAPER
the interface. The reaction results in attenuating the oxide layer
and act as driving force to promote wetting [35]. Schiroky et al.
reported the PRIMEX™ pressure less infiltration process of SiC
and alumina infiltration by Al-Mg alloy. During the pressure-less
infiltration process the Mg in the Al-Mg alloy at 800oC vaporizes
and react with the nitrogen gas used as atmosphere for the process
to form Mg3N2 and deposits on the reinforcement surface. During
aluminum alloy infiltration Al react with Mg3N2 to form AlN and Mg
which promotes better wetting with the reinforcement [36]. Even
though, the primary motive for the use of nitrogen during infiltration
is prevention of Al alloy oxidation it aids in reinforcement wetting
also. The effective chemical reaction between the constituents in
the molten metal and trapped gases in the porous preform cause
pressure drop in the preform and thereby improves the ease of
molten metal penetration. Nake et al. studies the spontaneous
infiltration mechanism of Al-Si-Mg alloy on SiC preform with the
addition of Fe2O3 in the preform as additives to improve wettability.
The pressure reduction in the preform improves the suction of the
molten metal which helps to break the oxide film present at the
interface between the metal and the preform formed due to the
reaction between the molten metal and the adsorbed moisture at
the infiltration front [37].
Generally, the wetting system of solid by a liquid is stipulated by
contact angle and the contact angle, θ, at the solid, liquid and gas/
vapour is related by the Young-Dupre’s equation [38].
(2)
where, are the liquid metal surface tension,
surface energies of solid/vapour and solid/liquid respectively. The
molten metal will wet the solid preform, if that is, when
θ < 900. Similarly, if the above process is reverse in the case of non-
wetting system a minimum pressure (threshold pressure) is to be
exerted for infiltration. As stated by Darcy’s law, the infiltration rate
of molten metal into porous preform is [39]
(3)
where, ν is the flow rate, k is the permeability which depends upon
the shape and sizes of the interconnected channels through which
the molten metal flows, µ is the viscosity of the molten metal, p is
the pressure (capillary pressure for spontaneous) correlated with
the size and shape of the pores that are in contact with the molten
metal and x is the infiltration distance. Surface modification of
reinforcements is also an effective method to circumvent interfacial
reactions and enhance wetting. Treatments include metallic
coatings like Cu, Ni, Zn, Ag, Si etc and high temperature treatment,
for example, of SiC leads to the formation of very stable surface
layer of amorphous silica [40, 41]. It has also been reported that
the coating of K2ZrF6, ZrO2 and Na2O in the fillers helps pressure-
less infiltration [42-44]. Continual investment and further process
optimization can ensure spontaneous infiltration techniques to
remain an attractive technique to synthesize composites in the time
to come.
Vol.20 Issue No.4 JANUARY 2021
4.2. Forced Infiltration
The infiltration process in which the aid of an external pressure
or mechanical force governs the infiltration of liquid metal into
the porous reinforcement is called forced infiltration. Poor wetting
between the molten metal and porous structure can be overcome
by endowing mechanical energy to force the metal in to the porous
preform. There are various types of forced infiltration methods and
these are described below.
4.2a. Gas Pressure Infiltration
An infiltration process in which pressurized gas (Figure 3) is used
as driving force for the penetration of molten metal into the porous
body. Gas infiltration process is normally carried out in combination
with vacuum at other end of the preform to get rid of entrapped
air to facilitate easy penetration at lower gas pressures [45]. Qi et
al. suggests that the anti-pressure of gas in the porous preform
significantly slowdown the rate of infiltration, which increases with
increase in infiltration depth and the temperature. As a result high
pressure is needed for complete infiltration of molten metal, hence,
anti-pressure of gases is to be considered during the analysis of
threshold pressure. With the ideal gas equation PV = nRT, the anti
pressure of gas can be expressed as [46]
(4)
where, p0 is the pressure of gas at initial time, T0 is the initial
time temperature, L is the preform total length and Tz is the
temperature of the gas when the infiltration attains a height z.
Enhance in the infiltration temperature and pressure during gas
pressure infiltration process improves the relative density of the
component, which shows an effect on the mechanical properties
of the final composite [47]. Joseph Blucher concluded that the
fabrication of MMC by hydrostatic gas pressure infiltration holds
certain advantages like low acquisition cost, high operational
flexibility for research purposes etc [48]. Al alloys reinforced with
Ni and Cu coated chopped, unidirectional carbon fibres and porous
graphite preforms were successfully fabricated using gas pressure
infiltration technique [49-51]. Non coated fibres can also be used in
gas pressure infiltration technique due to the short contact time of
the matrix with the reinforcement. Drawback of the gas infiltration
technique is the added cost of pressurized gas which usually is an
inert gas.
9 Aluminium Association of India
TECHNICAL PAPER
Fig. 3. Schematic illustrations of gas pressure infiltration process
for the fabrication of MMCs: (a) infiltration process carried out with
vacuum to remove the entrapped air in the preform to facilitate
easy molten metal penetration, (b) applying pressurized gas as a
driving force for metal infiltration and (c) final composite.
4.2b. Pressure Die Infiltration
Pressure die infiltration process involves placing a porous
preform inside a solid die and applying pressure with the help of a
movable piston to allow penetration of liquid metal in the porous
preform (Figure 4 (a and b)). Process parameters that are optimized
include speed, die temperature and pressure of the piston. Main
advantages of this process are low cost and ability to fabricate
components of high complexity and precision. The deformation
of preform due to the pressure of the molten metal before and
during infiltration will be high for pressure die casting compared
to squeeze casting owing to high compression rate of preform
during infiltration. Rasmussen et al. suggests that by increasing
the volume fraction of the reinforcement leads to stronger preform
which can prevent preform deformation, but at the same time it will
prohibit the ease of infiltration [52].
Fig.4. Schematic diagrams of pressure die infiltration process for
the fabrication of MMCs: (a) before applying pressure to molten
metal using plunger and (b) after applying pressure to molten metal
using plunger to form the composite.
4.2c. Centrifugal Infiltration
In centrifugal infiltration process, rotational / centrifugal force is
used to infiltrate porous preform with liquid molten metal. During
the fabrication of composites porous reinforcement material is
positioned inside a mould (at the end) having an elongated runner,
which was filled with molten metal. Large rotational velocities of the
runner initiate centrifugal force with required drive for infiltration to
overcome the threshold pressure for melt penetration and viscous
forces of the molten metal to flow in the preform. The molten metal
pressure exerted on the porous preform during centrifugal force is
given by [53]
(5)
Vol.20 Issue No.4 JANUARY 2021
Where, ρ is the density of molten metal, is the rotational
speed in rpm and L2 and L1 are the outer and the inner molten
metal's level from the rotation axis. To develop the near net
shape components and to avoid the material wastage typical
centrifugal infiltration technique is adopted. In order to achieve high
pressure centrifugal infiltration, a slight modification within the
same centrifugal system used for conventional process is made
by extending the inner molten metal level L1 from the rotational
axis (Figure 7b). In such cases liquid metal pressure acting on the
preform will be given by
(6)
Surface coated and non-coated carbon short fiber preforms were
successfully infiltrated by centrifugal process and the optimum
preform preheating temperature for non coated fiber for the
smooth penetration of molten metal is above 873 K (6000C),
whereas for nickel coated carbon fiber preform is 673 K (4000C)
[54]. In addition, surface pressure of the porous preform is reduced
perceptibly as the molten metal starts to infiltrate and once when
the metal gets penetrated into the preform the pressure of the
infiltrated region falls under the threshold pressure. The adhesion
between the molten metal and the reinforcement will not get
separated due to the fall of pressure in the infiltrated zone below
the threshold pressure. However, to achieve a complete infiltration
of molten metal throughout the porous preform, the pressure on the
infiltration front should exceed the threshold pressure [55].
4.2d. Lorentz Force Infiltration
Lorentz force infiltration process is a novel infiltration process in
which electromagnetic force is used to propel the molten metal
into the ceramic preforms. During the process, the preform gets
immersed in a liquid molten metal which is subjected to an high
frequency magnetic pulse. Simultaneously, eddy current persuaded
in the liquid metal gets interact with the magnetic pulse and develop
a Lorentz body force in the liquid molten metal causing the liquid
metal to enter into the ceramic preform at a high speed. Richard M.
Andrews and Andreas Mortensen had successfully fabricated void
free aluminum/Al2O3 fiber composite by Lorentz force infiltration
technique. They suggested that the infiltration depth depends upon
the nature and number of discharges [56].
4.2e. Ultrasonic Infiltration
In ultrasonic infiltration process, pressure waves generated by
the ultrasonic vibration assists in the penetration of the molten
matrix material in the ceramic preform. When ultrasonic vibration
is actuated through a horn in the liquid molten metal acoustic
cavitations (bubbles) are originated. The air entrapped in the porous
preform and the dissolved gas in the molten metal can become the
cavitations nuclei. When a bubble collapses shock wave originate
close to the molten metal resulting in infiltration process [57, 58].
The important process parameters considered for the ultrasonic
infiltration is ultrasonic power, hole in the horn and fabrication
speed. Increase in the diameter of the hole in the horn decrease
the infiltration ratio due to the depletion in the formation of acoustic
10 Aluminium Association of India
TECHNICAL PAPER
cavitations and studies shows that optimum diameter of the hole is
5 mm. Studies have shown that the infiltration can be made more
effective by the addition of 2.4 mass % magnesium to liquid Al metal
coupled with an ultrasonic power of 200 W. Similarly, infiltration
ratio decrease with increase in the fabrication speed, but at the
same time addition of magnesium in the molten metal for wettability
helps to increase the fabrication speed with better infiltration ratio
[59,60]. Gen sasaki et al. studied the effect of ultrasonic vibration
on the wettability during infiltration using contact angle technique
of polyester resin on glass substrate with and without ultrasonic
vibration (Figure 9). The system which undergoes ultrasonic
vibration shows reduction in contact angle due to heavy vibration
acceleration and thereby improving wettability [61].
4.2f. Vacuum Infiltration
Vacuum infiltration involves a negative pressure infiltration in which
matrix metal gets penetrated into the evacuated preform due to the
application of suction pressure. Process parameters like infiltration
temperature, infiltration time and applied vacuum (~300-500
mm Hg) plays a crucial role in this process [62]. Infiltration rate
gets increased with increasing the molten metal temperature and
by applying coating on the reinforcement, thereby reducing the
infiltration incubation period to avoid brittle interfacial reactions [63].
Low solidification rate of the final component during processing can
be stepped up as one of the disadvantage of vacuum infiltration
which enhances the grain growth of the matrix metal and interfacial
reaction between matrix and the reinforcement [64]. To avoid the
liquid molten metal getting into the vacuum pump by chance during
infiltration process one portion of the connection pipe is filled with
metal chips, so that the molten metal entering in to the pipe gets
solidified in that particular area without damaging the vacuum pump.
Studies have shown that Al and Mg based composite materials with
more than 50 vol. % reinforcement can be successfully fabricated
using vacuum infiltration technique [65].
4.2g. Squeeze Infiltration
Squeeze infiltration is one of the widely used methods for the
production of near net shape metal matrix composites with close
control over shape, volume fraction, chemistry and distribution of
reinforcement [66-72]. This process offers advantages over other
conventional methods for fabricating composite components which
are difficult to be machined. The process involves the formation of
porous preform as the reinforcement and its infiltration with the
molten matrix material under pressure (Figure 5) typically in the
range of 50-100 MPa [22]. The appropriate magnitude of applied
pressure ensures eradication of porosities, refined microstructure,
enhanced processing speed and termination of chemical reactions.
For the development of quality composites processing parameters
of squeeze infiltration have to be optimized.
Vol.20 Issue No.4 JANUARY 2021
(a) (b)
Fig.5. Schematic diagrams of squeeze infiltration process for the
fabrication of MMCs: (a) before the application of squeeze pressure
and (b) after applied squeeze pressure as a driving force to infiltrate
molten metal into the preform.
In light of the above, the application of higher squeeze pressure
accelerates the infiltration process but leads to crumpling or
cracking of the porous preform. Numerous studies regarding
infiltration pressure have been done by many researchers. Guan et
al. [73] investigated the threshold pressure and infiltration behaviour
of liquid metal into the porous preform. The infiltration rate can be
improved effectively by raising infiltration pressure, but the effect
will gradually diminish with the advancement in time. Increase in
infiltration pressure minimizes porosity, reduces the heat loss and
hinders the solidification of liquid metal front effectively. According
to Darcy’s law the expression for the square of infiltration height as
a function of infiltration time and difference in infiltration pressure
of the liquid metal is [74]
(7)
where p is the applied pressure, p0 is the threshold pressure for the
initiation of infiltration, infiltration time t, µ is the viscosity of molten
metal, vs is the volume fraction of solid and k is the permeability of
the porous solid. The threshold pressure p0 for infiltration can be
obtained as [75]
(8)
Where λ is a geometrical factor represent the deviations from
particle/fiber shape, surface roughness and actual particle/
fiber size distribution. The basic governing phenomenon for the
infiltration of metals, ceramics and polymers into the porous
preforms are fluid flow, capillarity and the behaviour of preform
deformation, which in turn are decided by preform permeability,
volume fraction of reinforcement, preform stress-strain behaviour,
pressure-dependant saturation of melt in the porous preform and
the melt viscosity.
The strength and stability of preform during infiltration depends
upon the mode of fabrication of preform, type of binder and the
reinforcement used. Reinforcements having lubrication nature
enhance the tendency of sliding over one another thereby
increasing the chance for deformation of the preform. Similarly
during the fabrication of layered preform equality in the stacked
layers reduces the preform compliance [76]. A new technique for
the direct measurement of capillary force is by drainage curve
11 Aluminium Association of India
TECHNICAL PAPER
method through which the corresponding volume fraction of
the molten metal in the porous preform as a function of applied
pressure is plotted and the method adopted is also suitable for
measuring contact angle and infiltration kinetics [77]. Higher
temperatures of liquid metal, preform and die initiate unwanted
chemical reactions at liquid metal/fibre interface and prolong the
solidification time [78]. Delaying the application of pressure after
pouring the molten metal above preform in the mould causes the
formation of oxide layer around the preform, which decelerates
the infiltration process [79]. Oxide inclusions, porosity and voids,
blistering, cold laps and cold shuts and sticking of casting with
the die surface are the major casting defects that occur in the
squeeze cast process [80]. Alhashmy et al. processed carbon fibre
reinforced aluminium matrix composite by squeeze infiltration
technique [81]. They suggested that the inclusions can be avoided
by using filters and turbulence must also be completely avoided
while pouring. Porosity can be avoided by increasing the squeeze
pressure. The main cause for blistering is the entrapment of
gas from the melt and can be avoided by reducing the pouring
temperature and degassing the melt. Die temperature and metal
pouring temperature can be increased to avoid cold laps and better
lubrication or die coating to avoid sticking of casting with the die
surface. Figure 6 shows the porous preform, squeeze infiltrated
Al composite, SEM micrograph of porous preform and the optical
micrograph of squeeze infiltrate Al-SiC composite at CSIR-NIIST.
The hardness of the as cast Aluminium alloy is 57 BHN and the
squeeze infiltrated Al-SiC composite with 50%SiC particle shows
remarkable increase in hardness to 147 BHN in as cast condition.
(a) (b) (c)
Figure 6: (a) The porous SiC preform and squeeze infiltrated Al
composite, (b) SEM micrograph of porous preform and (c) optical
micrograph of the squeeze infiltrated Al-SiC composite.
Acknowledgement
The authors would like to thank the Director and Members of
CSIR-NIIST for the support and encouragement, DST and IGSTC
(NearNetMAC) for the funding.
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13 Aluminium Association of India
TECHNICAL PAPER

CELL LINING REDESIGN FOR SPL MINIMIZATION AT

HIRAKUD SMELTER
MAHESH SAHOO1, AMIT GUPTA2 AND S. K. BADAJENA3
Hindalco Industries Ltd, Hirakud, Sambalpur, Odisha, India
1

2
Aditya Birla Science & Technology Company Pvt. Ltd, MIDC Taloja, Maharashtra, India
3
Veer Surendra Sai University of Technology, University of Burla, Odisha, India
Corresponding author: sahoo.mahesh@adityabirla.com

Abstract
Primary aluminium production process poses a threat to the environment due to generation of hazardous waste like the spent pot lining
(SPL). This has led the researchers to focus on 4R (Reduce, Recycle, Recover, Reuse) approaches to minimize the impact of SPL on the
environment. Worldwide aluminium smelters have been looking into ways to reduce the SPL generation per tonne of Al produced, such
as enhancing cell / pot operational life, as well as by reusing and recovering value from SPL by its utilization in both cement and ferrous
industries as well as coal-fired power plants. Hindalco’s Hirakud smelter has also been utilizing the 4R approaches with a goal to minimize
the SPL impact on the environment. This paper highlights the redesign approach adopted by Hirakud smelter, which has led to reduce the
SPL generation significantly. The paper describes the modification in the cell lining design and materials to enhance pot performance and
pot life, thereby reduce the SPL generation from 20.41 kg/t Al to about 15.55 kg/t Al. To enhance the energy efficiency of pot, copper-insert
collector bars have also been utilized, which are reported to enhance the pot life, thereby further potential of reducing the SPL generation
to the level of 14.14 kg/t Al. Apart from the redesign, other approaches such as recycle, recover and reuse have also been looked upon for
effective SPL management.
Keywords: 4R approach, Pot life, Cell lining, Spent pot lining (SPL), Aluminium smelter.

1.INTRODUCTION frost heave damage and a freezing isotherm too far down into the
Primary aluminium is produced using an electrolytic process, also insulation refractory layer results in damage of the insulation layer,
known as Hall-Héroult process, from the alumina dissolved in to the which is usually less dense and less salt resistant then the upper
molten cryolitic bath. The electrolytic process occurs in a steel pot, refractory layer. The thermal conductance of the sidewalls should
which is lined with refractories, to offers mechanical and chemical result in a proper ledge shape and thickness.
stability. The lining refractory is typically made of two layers, an
insulating refractory, which house a carbon cathode along with
collector bar to allow the current flow. The cell usually operates for
about 4 to 8 years before it fails. The life of the cell usually varies
from plant to plant based on the cell technology & operational
amperage. There are various factors, which affect cell operational
life, e.g., cell design, quality of lining materials, preheating, start-
up procedures and thermal disturbance during cell operational life.
Precise start-up procedures and efficient operation play key role in
attaining a satisfactory life of a cell. The thermal, mechanical and
chemical properties of cathode and lining materials may also lead
to failure, if the cell is not designed correctly to ensure isotherms
in proper locations. Figure 1 shows a typical cross-section of a
Hall-Héroult cell, highlighting cell-lining materials such as carbon
cathode, refectory and insulation materials. The cell lining design
should ensure that the electrolyte freezing isotherm in the lining
(~780 °C) should be just below the cathode blocks into the high Figure 1. Cross-sectional view of Hall Héroult cell.
dense refractory brick, made of silica and alumina. Due to capillary There are certain phenomena related to cathode and its properties
action, bath impregnation takes place after the sodium front has that may lead to pot failures, for instance, wear of cathode surface,
moved through the carbon and only through the porous network Na diffusion and intercalation, pothole formation etc. Wear rate of
formed by the volatilization & shrinkage of the binder during baking cathode is also dependent of current density [2]. Most of the current
[1]. A freezing isotherm inside the carbon blocks may result in tries to concentrate towards the end of cathode block due to the

Vol.20 Issue No.4 JANUARY 2021 15 Aluminium Association of India

TECHNICAL PAPER
least resistant path of electrical current, in such a way that the
cathode top surface acquires a W-shape pattern after completion of
its normal life. To avoid this, the collector bar assembly-to-cathode
block electrical resistances ratio may be modified by means of
altering both materials and design. Copper-insert collector bar
(CuCB) tends to provide (a nearly) uniform current distribution,
which aids in enhancing the pot life [3].
The Hirakud potline has end-to-end cells with upstream risers,
which offer uncompensated magnetic field, leading to higher metal
velocities and MHD instability [4]. These pots utilize semi-graphitic
cathodes (30% graphite) and old lining design with a tendency to
form a ledge toe extension under anode shadow, which increases
the chance for pothole formation. There were also operational
disturbances like anode spikes, bottom sludge and muck, which
may aggravate the pothole formation. These are the some of the
factors which have adversely affected the life of Hirakud pots,
resulting in higher SPL generation. In this study, these aspects
have also been looked upon carefully, while redesigning the cell
lining to enhance the performance and pot life thereby reducing
the SPL generation. These modifications have been discussed in
subsequent sections.
1.1 SPL Management
After the completion of cell operational life, the used lining of
the pot is classified as spent pot lining. The SPL is composed of
a first-cut (the carbon lining) and a second-cut (the remaining
refractory lining). During the production of one ton of aluminium,
a smelter produces about 25 kg of SPL waste with high content of
carbon fluorine compounds, alumina, various cyanides, aluminium
nitride, aluminium carbide, etc. [5]. In general, fluoride is present
in both carbon and refractory layers at around 1–2 wt. % whereas
cyanide (CN) content in SPL is low and varies across cuts, though
on average CN is around 60 ppm by weight [6]. The hierarchy of
SPL management focus first on reducing the generation itself, by
means of redesigning and enhancing the pot life. Subsequently,
the preference should be given in descending order to recycle,
recover and reuse. The last option is responsible disposal, in which
care must be taken on adoption of appropriate storage, handling,
treatment, transportation and disposal processes. Hence, the 4R
approach is adopted worldwide for SPL management to minimize
the impact on environment, which are described as follows:
a) Reduce or minimizing SPL generation through redesign of pot
and optimization of the process;
b) Recycle by using the part of the old pot lining material in a
new pot [7] or restarting a stopped or shunted pot by means of
patchwork, to utilize the same pot lining material;
c) Recover by conversion of carbonaceous part of SPL into useable
heat, electricity or alternate fuel, e.g., use of first-cut material in
coal-fired power plant;
d) Reuse by utilizing SPL waste into ferrous, non-ferrous and
cement industry. Example of using SPL in cement and ferrous
industry has been discussed in the following section.
Vol.20 Issue No.4 JANUARY 2021
2 SPL Management at Hirakud Smelter
Hirakud smelter had taken several strategic & sustainable initiatives
adopting the 4R approach for SPL management. The practices
followed at Hirakud smelter focus on protecting human health and
the environment from impacts associated with generation, storage,
handling, transportation and disposal of SPL. Following section
explains the modification in cell lining design, which resulted in
improving the pot life and reduction in SPL generation.
2.1 Redesign of Cell Lining
While redesigning the lining of a cell or pot, its thermal balance
needs to be analyzed critically with respect to isotherm location
in the refractory. Ledge toe extension underneath anode or hard
deposits on the cathode surface enhances the wear rate and chance
of pothole formation, thus affecting pot life. Presence of extensive
ledge and sludge can lead to an uneven current distribution in the
cell, resulting in MHD instability, which adversely affects the cell
operation and, consequently, requires higher anode-to-cathode
distance (ACD) [8]. Hence, for efficient cell operation at minimum
ACD, the cell lining design should ensure a nearly vertical ledge
profile along with the isotherm location at an appropriate position
in the refractory lining of the cell. This would not only prolong the
life of the cell but also improve its performance. A new lining design
was developed to reduce the SPL generation by means of reducing
the mass of lining materials used in a pot along with improving the
thermal balance of pot.
For this purpose, a thermo-electric model has been utilized to
analyze the cell lining design and material modification. Additional
information regarding thermo-electric model development for
Hirakud 85 kA cell and its validation with industrial measurements
can be found in literature [9]. In this study, simulations have been
performed for analyzing changes in cell lining materials, lining
design and CuCB. Desired thermal balance of the new cell was
obtained after performing multiple simulations where the results
yielded by proposed changes in design and materials were analyzed.
The cell lining design has been modified around the cathode block,
as shown in Figure 5, to alter the heat loss distribution from the
cell for improving the thermal balance of the cell and electrolyte
freezing isotherm placement in the refractory.
Figure 2. Cell lining modification. Left: old lining design, Right: new
lining design with CuCB.
The new lining design helped in attaining uniform current
distribution, a nearly vertical freeze profile with a smaller toe and
a thicker ledge at metal-bath interface, thereby providing energy
saving as well as potential for improvement in pot life. This design
16 Aluminium Association of India
TECHNICAL PAPER

modification was associated with changes in the quantities of lining found that the erosion rate of cathodes is much smaller when
materials. Table 2 shows the changes in the quantities of different compared to the old design pot. Based on this result, pot life is
lining materials for new cell lining design as compared to the old expected to exceed 2200 days, which would help in attaining a
one, excluding the collector bars. SPL generation of about 14.14 kg/t Al or a 30.7 % reduction with
respect to the original figure.
Table 2. Modification in cell lining materials quantities (in tonnes).
3. Conclusion
Cell Lining Materials Old Lining New Lining
Spent pot lining is a hazardous waste and a major threat to the
design (t) design (t)
environment. It is being managed by Hirakud smelter by adopting
First Cut Material Total = 8.60 Total = 7.80 4R (Reduce, Recycle, Recover & Reuse) approach. This work majorly
1. Cathode & Tamping Mix A 1. 6.20 1. 6.20 focuses on the first “R”, i.e., redesign of pot lining to reduce the
2. Carbonaceous Groove Mix-B 2. 0.40 2. 0.00 SPL generation. Pot lining was redesigned to improve the thermal
3. Carbonaceous Seam Mix 3. 2.00 3. 1.60 balance, ledge profile and isotherm location in the refractory by
Second Cut Material Total = 12.47 Total = 10.41 modifying the lining design and materials along with Cu-insert
collector bar. This has not only improved the pot performance
1. Dry Barrier Mix 1. 6.50 1. 5.50
with respect to the energy efficiency, but also improved the pot
2. High Strength Insulation Bricks 2. 1.73 2. 0.16
life. The new design pots are already running for the last 5.5 years
3. Low Strength Insulation Bricks 3. 0.12 3. 0.00
and offering an extended pot life of more than 200 days along with
4. High Strength Impervious 4. 1.40 4. 0.40
reduction in lining material quantity by about 3 tonne as compared
(Castable)
to old design. The new cell lining design reduces the SPL generation
5. Refractory Brick 5. 0.27 5. 1.35
from 20.41 kg/t Al to about 15.55 kg/t Al, or 23.8 %. Based on
6. Insulation Board 6. 0.27 6. 0.82
cathode surface measurement, the pot life is expected to exceed
7. Remaining Material Unchanged 7. 2.18 7. 2.18
2200 days, which provides further reduction potential in SPL
The simulation analysis incorporating the CuCB helped improving generation to about 14.14 kg/t Al or 30.7 % with respect to the
the current distribution in cathode block, hinting towards a positive original figure.
influence on pot life [3]. The simulation results also show that 4 References
cell lining modification has improved the ledge profile as well 1. M. Sorlie and H. A. Øye, Evaluation of cathode material properties
as cathode temperature profile, which would improve the cell relevant to the life of Hall-Héroult cells, Journal of Applied
operating condition. Table 3 shows the performance comparison Electrochemistry, Vol 19, (1989), 580-588.
between old and new lining designs, where both a 2.1 % reduction
2. Pretesh Patel, Margaret Hyland and Frank Hiltmann, Influence of
in specific energy consumption as well as a 13.6 % increase in pot
internal cathode structure on behaviour during electrolysis part III:
life have been effectively achieved. Wear behaviour in graphitic materials, Light Metals 2006, 633-638.
Table 3. Comparison of pot performance. 3. Amit Gupta et al., Energy Reduction Initiatives to Improve Low
Old Lining New Lining Amperage Cell Performance, Proceedings of 35th International
Design Design ICSOBA Conference, Hamburg, Germany, 2-5 October 2017, Paper
AL35, Travaux 46, 1135-1142.
Current (kA) 85 85
4. Amit Gupta et al., Electromagnetic and MHD Study to Improve Cell
Pot Voltage ex. Line Loss (V) 4.38 4.31 Performance of an End-to-End 86 kA Potline,” Light Metals 2012,
Current Efficiency (%) 93.0 93.5 853-858.
Cathode Voltage Drop (mV) 350 270 5. Rudolf P. Pawlek, Spent Pot lining: An Update, Light Metals
Pot Specific Energy 14 035 13 734 2012,1313-1317.
Consumption (kW.h/t Al) 6. Mohammad Al Jawi, et al., Environmental Benefits of Using Spent
Pot Lining (SPL) in Cement Production, Light Metals 2020, 1251-
Pot Life (Days) ~ 1760 ~ 2000
1259.
New design pots have been running efficiently over the period of 7. Aleksandr V. Proshkin et al., New Resource-Saving Technologies for
last 5.5 years. The new lining design offers a reduction of about Lining the Cathode with Un-shaped Lining Materials, Light Metals
3 tonne in the virgin lining materials (both carbon & non-carbon 2019, 573-581.
parts). However, the actual reduction in SPL quantity will be known
8. Amit Gupta and Biswajit Basu, Sustainable Primary Aluminium
only after completion of its operational life. Autopsy of an old design
Production – Technology Status and Future Opportunities,
pot revealed that SPL quantity was increased by about 8–9 % Transactions of the Indian Institute of Metals, Volume 72, Issue 8,
compared to virgin material. Therefore, a similar increase in weight (2019), 2135–2150.
has been assumed for the new cell lining design in such a way that
9. Amit Gupta et al., Investigation of Cathode & Collector Bar
the new design potentially offers a reduction in the SPL generation
Modification on Thermal Balance of Low Amperage Cell, Light
from 20.41 kg/t Al to about 15.55 kg/t Al, or 23.8 %. Measurement
Metals 2015, 747-752.
of cathode surface wear was performed in new design pots and

Vol.20 Issue No.4 JANUARY 2021 17 Aluminium Association of India

TECHNICAL PAPER

DESIGN & DEVELOPMENT OF HPC CONDUCTOR:

A PERMANENT SOLUTION FOR LONG SPAN
RIVER-CROSSING– 400KV D/C QUAD
PRASAD S, Manager – NPD, Sterlite Power Transmission Ltd.
RAKESH TRIPATI, Manager – NPD, Sterlite Power Transmission Ltd.
ANANTHAKUMAR R, Chief Manager – Technical, Sterlite Power Transmission Ltd.
VISHAL SHARMA, Operational Head, Sterlite Power Transmission Ltd.
SAIKRISHNA BENDAPUDI, Chief Operational Officer, Sterlite Power Transmission Ltd.

Abstract
Overhead line systems are dependent on a multitude of different factors. The lines must be capable of operating reliably in all environmental
conditions and should have as low an impact as possible on the environment. There are modifications, extensions and developments from
time to time in existing networks to manage & accommodate the continuous increase in power demand. River crossing involved in any
transmission line is most critical link of the line. It must be safe & sound from design considerations to be able to withstand field conditions
and any unexpected changes in climate resulting in cyclones/ storms, speedy winds, floods & changes in the course of rivers.
Keywords— HPC, High temperature low sag, AACSR, GZTACSR, ACCC, Sag-Tension, Ampacity, Electrical clearance.

1.INTRODUCTION
This paper is on the details of solution provided to a long river
crossing span 1099 mtr (i.e without intermediate tower) in the 400
kV DC- river crossing - Purina Bihar Sharif line. Due to change in
course of the river Ganga & high velocity water flow, pile foundations
were damaged on the towers of the 400 kV DC line in the middle
of Ganga river. As a result, the line was in a de-energized condition
for a prolonged period. This is non-navigable river where small
boats etc can’t be used. And waters were at the highest level due
to floods. To revamp the line, the feasibility of various technology
(AACSR, GZTACSR & ACCC-[1]) of High Peformance Condutor (HPC)
products were analysed. Post detailed deliberation, a new and Fig 1 : Existing line profile shows tower with either side of middle
permanent solution was provided - newly designed conductor & tower (intermediate tower) with 550 span & 549 span
earth-wire, considering all the key requirements like ampacity, sag
tension, RIV – Corona, phase & electrical clearance. 3. CHALLENGES IN RESTORATION
The possibility of line restoration was analysed by line diversion,
The product solution circumvents the need for intermediate towers/ enhancement of water level & other condition. In connection with
foundations and also there is no need to increase height of the this, if the fallen tower is bypassed, the total span would increase
tower. to 1099 mtr (i.e by connecting either side of the tower).
2. DESCRIPTIONS OF RIVER CROSSING Further, increase of the span challenged the sag clearance from
400kV Purnia-Bihar Sharif D/C line was out of service from 10th highest flood level (HFL). To cater to the present load demand, line
Aug 2018 due to the change in the course of the river Ganga and could be restored using special High Peformance Conductor (HPC),
heavy velocity of flow of water which led to tower collapse (pile which meets the sag with increased span without compromising the
foundation). Post flooding when water started receding, various power transfer requirements. These special conductor meets the
emergency restoration plans were proposed to ERPC[2] to charge high capacity needs & performance testing on some applications.
the line temporarily. The existing line conductor, quad AAAC 525 However, it’s the first case where such solution was provided for
mm2, in a double circuit tower can transfer 1600 MW per circuit. river crossing.

Vol.20 Issue No.4 JANUARY 2021 18 Aluminium Association of India

TECHNICAL PAPER

A unique solution with new design & development of both conductor
& earthwire for a critical long river crossing span, revamped the
EHV - 400 KV Purina Bihar Sharif line by the end of 2019.
Accomplishment Of Resolution
Initially the plan was to restore the line temporarily. It was with
single long span having not intermediate tower, single circuit
configuration. Various conductor technology & earth wire for
suitability were analysed. This imposed the challenge of meeting the
sag requirement in single circuit with long span. Sag requirement
fixed as 38 mtrs to ensure the 10 mtrs extra clearance from HFL.
Detailed mentioned below table 1.
4.SOLUTON
Planning for the permanent restoration of the line using special
high-performance low sag conductor ( i.e ACCC[1] Conductor)
between tower AP46/9A and AP47/1 as single long span of 1099
mtr. The critical sag requirement & power transfer for double circuit
configuration has been meet in newly designed conductor & earth
with respect to limitations as per below table 4.

Table 4. Unique Solution For Permanent Solution

Parameter Limitation ACCC GANGA Earthwire

In the initial plan, to meet the clearance, conductor technologies Circuit/

-- Double / Quad Single
were checked for suitability as mentioned in table 2. By taking Configuration
deviation on Max. loading (i.e horizontal loading) the limitation of
sag could be met. Mass of
-- 965 565
conductor
As per initial plan, existing tower design would have to be modified
and would have entailed additional cost. Meeting the
Sag
However, in the final permanent solution, the newly developed earthwire
requirement ≤28 28.0
conductor, made up of special annealed aluminium – was a key clearance w.r.t
for solution
component to ensure power transfer. The conductor also had a to conductor
specialised core. With this, 100% power transfer capacity was
Max. tension Not more than
restored on the line, by stringing the conductor for long single span Less than Less than
at full wind 70% UTS of
of 1099 mtr with double circuit configuration. This led to huge 70% 70%
condition the conductor
savings in time and capital, on the project. Refer to table 3.
Only design to meet the sag
Table 2. INITIAL DEISGN ANALYSIS FOR TEMPORARY
requirement other technology
SOLUTION with single circuit configuration. Remarks --
will not meet the critical
Parameter AAAC ACCC AACSR GAP requirements.
Double/ Single/ Single/ Single/
Circuit/ Configuration
Quad Quad Quad Twin On this crossing span solution, Phase to phase & phase to earth
Outer Dia. 29.79 27.40 28.62 28.60 clearance has been ensured with proposed HPC conductor from the
point of view of mutual inductance & flash over consideration. The
Mass of conductor 1448 1448 1958 2217
clearance between line conductor & the ground was also analysed
DC resistance 0.06396 0.0719 0.0929 0.1229
to maintain safety aspect as per provision of Indian Electricity Rules
Sag requirement for with all HPC conductor. These are taken care of by providing the
70.7 Sag
temporary solution 37.01 38.0 38.13 special steel core on earthwire to meet the electrical clearance for
deviation
(Less than 38 mtr)
this critical span.

Vol.20 Issue No.4 JANUARY 2021 19 Aluminium Association of India

TECHNICAL PAPER

Properties/ Design validation Requirements as per ASTM

Tensile test 
Densit 
Glass Transition 
Dimensions 
Heat Exposure (52 Weeks) 
Heat/ Stress test (1000Hrs) 
Bending test 
Fig 2 : Proposed solution without intermediate tower Dye penetrant test after bending 
( i.e1099 mtr span) Tensile test after bending test 
Galvanic protect barrier test 
5. FUNCTIONALITY, FEATURES & ITS SUSTAINABLITY 2. Conductor validation as per technical specification [6]
Innovation Product solution
Properties Requirements Results
ACCC[1]
DC resistance at As per IS 398 Part 2 Complied
20˚ C
UTS SMFL Guaranteed & as Complied
Carbon fibre composite per IS 398 part2
Stress strain As per IEC 61089 Complied
Corona 320 kv, rms Complied
a. Critical sag & power transfer requirement on long river crossing RIV Less than 1000 microvolts Complied
span of 1.1 km. for 1MHz
b. Lower weight, Higher strength to weight ratio & lower COE. COE for core 7.51 x 10-7 per deg.C Complied
c. Outer layer consists of Trapezoidal shaped Annealed aluminum Sheave test No damage of surface Complied
wire(1350 O Temper) resulting to meet the required power during 36 sheaves.100%
transfer. UTS of conductor
d. Innovative core comprises of Torsion ductility test No signs of loosening or Complied
damage
i. Ultra-high strength carbon fibre composite core (CFC)
Aeolian vibration test No damage of strands Complied
ii. Low coefficient of linear explanation
during vibration cycles
iii. High modulus of elasticity & 95% RTS during
iv. Low weight subsequent UTS test
v. Inner core comprises of CFC carbon fibre composite core Creep test at As per IEC 61395 Complied
ambient temp.
e. High strength to weight ratio
Radial crush test Min. 100% UTS of core Complied
f. Low sag after 350 kg load on
g. Addressing ROW issues by long span. compression portion
Strand brittle fracture Min. 100% UTS of core Complied
h. 100% power transfer
after 96 hrs acid exposure
Only technology of all HPC technology which is developed to meet Axial impact test Min. 100% UTS of core Complied
the critical sag without any changes in existing tower design/
heights & power transfer requirements. Validation of ACCC [1], earthwire & it accessories have been
completed successfully. Type test, Acceptance Test and routine
test are completed with respect to relevant standard[3] and HPC
6.VALIDATION TESTS: specification[4]. Stringing of ACCC has been completed using special
1. Core validation conducted as per ASTM B987 [5] tools & tackles.
Successfully commissioned the restoration of PB Line of ENICL
project at 19:09 hours on 29 Dec 2019.

Vol.20 Issue No.4 JANUARY 2021 20 Aluminium Association of India

TECHNICAL PAPER

7.IMPACT
a. Social Impact – Eliminating the requirement of prolonged
shutdown of the line and faster power transmission and permanent
solution
b. Cost & Time reduction –
i. No intermediate tower and its foundation (pile type).
ii. No need of any special tower type (i.e increased heights)
resulted into substantial cost & time saving.
c. Benefits – No derating of the line and 100% Power transfer
(1600 MW/Ckt)
8.CONCLUSION
The summary of outcome & benefit with these new developments
are as follows
1. Special characteristics of ACCC[1] conductor such as low thermal
expansion, high strength to weight ratio addressed the critical
challenges of sag & ampacity.
2. Newly Designed Earthwire with special steel results in less sag
& meets the electrical clearance whereas normal Earthwire &
OPGW cause electrical clearance issues.
3. Without reducing the power transfer for single long span, double
circuit solution provided by meeting critical clearance.
4. Need for intermediate tower & pile foundation eliminated
resulting in huge time & cost saving with implementation of
single long span.
5. Re-energizing the line will impact to social lives by quick transfer
of power
6. Application of ACCC[1] Technology first time in long single span.
7. Application of special high strength earthwire in long single span.
8. The line consists of two technology I,e. AAAC & ACCC conductor
connected by suitable jumpers have 75% DC Resistance of
conductor.
9.REFERENCE
[1] CORE – CTC F-730-532-F www.ctcglobal.com Date Produced:
3/29/2019.
[2] - Agenda for 162nd OCC Meeting date 22.10.2019, Eastern
Regional Power Committee.
[3] - Relevant standards are as mentioned below,
ASTMB609-Specification for Aluminium 1350 round wire, annealed
and intermediate tempers, for electrical purpose.
ASTMB857-Standard Specification for Shaped Wire Compact
Concentric-Lay-Stranded Aluminum Conductors Coated-Steel
Supported (ACSS/TW.
ASTM B987 Standard Specification for Carbon Fiber Thermoset
Polymer Matrix Composite Core (CFC) for use in Overhead
Electrical Conductors.
EN 50540- Aluminium Conductors Steel Supported (ACSS) for
overhead lines.
[4] - HPC specification in line with current test protocol of PGCIL
tender (CC-CS/912-NR1/TW-3957/3/G3.
[5] - core validation report No. 54264 , Qct 18, 2019.
[6] – Complete Conductor validation report No. CT/102/ 19-20 vide
dated Jan 01, 2020.

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Vol.20 Issue No.4 JANUARY 2021 21 Aluminium Association of India

TECHNICAL PAPER

CRU EXPLAINS HOW TO UNDERSTAND INDIA’S

COMPLEX CARBON EMISSIONS PROBLEM
SHANKHADEEP MUKHERJEE
Team Leader, CRU India
shankhadeep.mukherjee@crugroup.com

About the author: Shankhadeep is based in CRU's Mumbai office as team leader of CRU’s India office and works across the aluminium
and steel team and has over 12 years of experience in the metals and mining industry. He has worked in many countries across different
functions including strategy, market research, working capital management and corporate finance. He has a bachelor's degree in chemical
engineering from Jadavpur University, Kolkata and an MBA in finance and operations from Xavier Institute of Management, Bhubaneswar.

India’s coal-dependent power infrastructure gives the country a When we see Scope 1 and Scope 2 emissions in aluminium from
high-carbon intensity for metal production. CRU’s Global Carbon CRU’s Global Carbon emissions service (figure 2), we see that
Emissions Service will help to solve this complex power puzzle emissions from power generation used in aluminium is the most
Data from CRU’s Global Carbon Emissions Service shows the average significant source of aluminium carbon emissions. Elsewhere,
intensity of CO2 emissions from Indian aluminium production is 48% carbon emissions have been low where hydropower is available
higher than the global average. This is unsurprising as a significant for smelting.
proportion of India’s power production is coal-based. Hydropower generation is independent of market variations and
Indeed, India’s environmental and developmental context is visible provides relatively constant power tariffs, making it an attractive
in the country’s power mix. For example, hydropower, which power source for smelters. However, generation capacity can
globally reduces carbon emissions in aluminium production, is a vary largely with local meteorological conditions, like with other
power source which brings its own share of problems in India. And renewable energies. Hydropower may also provide significant cost
while India does not have a carbon tax as defined in the rest of the advantages. For example, smelters in Canada have the lowest
world, there are other ways in which India does tax carbon in coal. power cost partly due to Rio Tinto’s six smelters which benefit from
the world’s cheapest electricity rates from hydropower plants with
Indian aluminium producers can reduce their emissions, but the
long-term amortised capital charges.
approach may be very different to other parts of the world. In this
Insight, CRU explores the challenges and seeks to answer some of Figure 2: Hydropower and renewable energy helps reduce emissions
the most pressing questions.
Indian power generation growth will be primarily coal-based
The growth in power generation in India is expected to be primarily
driven by coal. While there is competition expected to come from
renewables – particularly from solar and wind – the share of coal
is expected to remain high. Though the share of power from coal
is expected to reduce only to 59% by 2030 (compared to 70% in
2019), actual power production from coal is expected to increase
from 1,166 TWhr in 2019 to 1,492 TWhr in 2030.
Figure 1: Coal will continue to be a major contributor to Indian
power production

DATA: CRU Aluminium Cost Model

Hydro will not be an important share of India’s power supply
As figure 1 shows, the share of Indian power production from hydro
is expected to remain at 10% over the medium term. The current
installed capacity for hydro is very low and few new projects are
under construction. This is because, in India, expanding hydropower
generation would bring with it its own challenges.
While the hydropower potential for India is around 145GW, only 28%
DATA: CRU of this capacity has been developed. Almost all current capacity

Vol.20 Issue No.4 JANUARY 2021 22 Aluminium Association of India

TECHNICAL PAPER
is government-owned (93% of installed capacity). Nearly half of
the present installed capacity (40GW) is in Northern India (19GW)
and almost 65% of the total hydro potential (94GW) is yet to be
developed and not under construction.
As far as potential hydro projects in India are concerned, they are
based on the Brahmaputra river route which flows from China
into the North Indian state of Arunachal Pradesh. However, since
1962, this area has been mired in border disputes between the
two countries. There are also occasional insurgent-related issues
in the region which can potentially disrupt project executions and
operations. This makes the region fraught with significant geo-
political risks, making it unattractive for private players in India (see
figure 3).
For this reason, we do not expect hydropower generation to become
an important share of India power supply. If Indian power emission
intensity in metal production is to be reduced, we think it must
be through other changes, and on incentives to do so. The other
important point for investors to understand is how CO2 emissions
costs are reflected in Indian power.
Figure 3: While most hydro potential is in the North East, aluminium
smelting is in the East.
DATA: CRU, CEA
How is coal taxed in India?
While there is no separate ‘carbon tax’ on power production in India,
there are a couple of ways where the cost of carbon is introduced in
the cost of thermal power production.
Clean energy cess: Purchase of coal in India (including imported
coal) as well as coal mined by captive producers attracts a cess
which is used to fund the development of cleaner power projects
in India. When introduced this was at INR50 /t of coal now it is
Vol.20 Issue No.4 JANUARY 2021
at INR400 /t of coal. Any user of coal (thermal power plants or
captive power plants) needs to pay this price over and above the
notified prices of Coal India Limited along with other royalties. This
is included in the cost of coal procurement in our cost models. With
India switching over to a uniform goods and service tax regime
from July 2017, this is now known as the compensation cess.
Renewable purchase obligation (RPO): Each state specifies
some obligated entities who need to procure part of their power
requirement in the form of renewable power – and this is split by
solar power and non-solar power. This percentage is specified for
the year the captive plant was established. In the state of Odisha,
where most of Indian aluminium smelters are based, captive power
plants are designated as obligated entities. There are two ways a
company in India can meet RPO levels:
a. Produce their own renewable power
b. Procure renewable energy certificates (REC) on the Indian
Energy Exchange
How are Indian aluminium producers handling this?
The source of power is a complex issue that the aluminium industry
faces in general: smelters cannot shift power source easily. In
India, this is even more complicated. Globally, 41 smelters produce
aluminium from 100% hydropower. However, only nine of them
have their own hydro production units. In fact, of the 180 smelters
in CRU’s aluminium cost model, 107 smelters operate on 100%
purchased power.
The situation in India is starkly different. All three aluminium
producers in India have captive power plants which can meet
100% of their power requirements, though a certain portion of grid
purchase is necessary to meet RPO obligations (alongside purchase
of REC). Along with captive power plants, all three primary producers
also have access to captive coal sources as well as assured coal
supply in the form of supply agreements with Coal India Limited,
though the extent of assurance is varied by company.
In fact, as we write this insight, coal block auctions for commercial
purposes are underway in India and both Hindalco and Vedanta have
won coal blocks in these auctions. As these blocks are auctioned
for commercial purposes without any end-use restrictions, both
the producers will get additional flexibility in sourcing coal for their
captive power plants. NALCO already has 100% captive / assured
coal supply.
It might also be worth noting that the Indian aluminium producers
could reduce their emissions by around 20% if they sourced
electricity from the grid (comparable to the 2020 mix shown in
figure 1), but that would result in an increase in power costs of
three to four times and expose the smelters to the instability of
the grid, which is an unacceptable compromise. The chart below
shows the performance of the grid in the state of Odisha over the
last few years.
23 Aluminium Association of India
TECHNICAL PAPER
Figure 4: Performance of the state grid makes it risky for smelter
operations
DATA: CRU, SLDC-Odisha
However, producers in India need to pay both the clean energy
cess as well as comply with RPO obligations as explained above.
Along with paying the charges, all three producers have invested
in renewable sources of power. NALCO has 198.4MW of installed
wind capacity and is in the process of expanding this further by an
additional 25.5MW.
Hindalco’s current renewable power generation capacity stands
at 45.2MW and the company intends to expand this by another
100MW by adding a solar power plant. In March 2020, just before
the lockdown in India, Vedanta floated a tender inviting interest
Invitation for Contributory
Technical Papers
The quarterly in-house journal “Aluminium-In-India” published by
Aluminium Association of India, which contains technical papers and
articles dealing with product development, process development and
other articles of general interest benefits the entire fraternity of Indian
Aluminium Industry.
We would like to invite you to contribute technical articles, case studies,
innovation & research papers, trends / technology perspectives and
news related to your area of work. You can also send in any other
communication requests, details about new product launches and
press releases for inclusion in the magazine.
The article can be around 1,000 to 1,500 words along with graphs,
tables and images (high-resolution) having captions + name of
author/s (author’s present designation and company name).
Your expertise and knowledge-share will indeed be a value-add for our
wide and varied readers.
Vol.20 Issue No.4 JANUARY 2021 24
from parties for developing 100MW solar power plant beside their
Aluminium smelter at Jharsuguda.
Alongside investments in renewable power, Indian producers
are also investing in recycling facilities which also help reduce
emissions as well as undertake regular internal projects to reduce
power consumption. In 2018, Hindalco signed a Memorandum of
Understanding with the State of Gujarat to invest in 300,000 t/y
scrap recycling facility (read here).
During FY2019-20, NALCO utilised graphitised cathode block in their
pot line and achieved the lowest power consumption (13.367Mwh
/t) in smelting operations since they started operations. Vedanta
also undertook similar process which resulting in power savings
for the company. The renewable power projects of Hindalco helped
reduce CO2 emissions by 0.25Mn tonnes during this period.
All countries utilise the natural resources present within their
respective borders and being abundant in coal, it is unlikely that
India’s dependence on coal will go away in the medium term.
However, Indian producers are taking various steps to reduce the
environmental impact of using this resource.
Instructions to Authors
1. All figures and tables to be captioned with title.
2. Table to be captioned at top and Fig. at bottom.
3. Source of data wherever required to be given, it should
be mentioned in bracket below the captions.
4. Title of articles to be in capital & bold with authors name
below it with 1st letter of each word capital.
5. All font to be Times New Roman & size 12, except title
whose size will be 14.
6. Any reference number intended to give, it should be
given as a superscript in the text body at appropriate
place and the details of reference to be given at the end
under sub heading- Reference.
Aluminium Association of India
 ALUMINIUM INDUSTRY NEWS

BALCO CEO, ABHIJIT PATI RECOGNISED AMONGST MOST

PROMISING BUSINESS LEADERS OF ASIA 20-21
Balconagar, Korba, December 17, 2020: Mr. Abhijit Pati, CEO &
Director BALCO has been recognised as ‘Most Promising Business
Leaders of Asia 2020-21, by The Economic Times in a virtual
ceremony on December 15, 2020. This award recognizes eminent
business leaders who are poised to make a significant impact in
shaping the business demographics of not just their country but also
beyond.
Mr. Pati with an illustrious career spanning over 30 years in the
Aluminium Industry, has served in several leadership profiles
delivering exponential growth. Under his leadership, BALCO
continues to deliver excellence. He is passionate about new ideas,
innovation, safety, sustainability, and digitalization across the entire
value chain. He is also a visionary in the areas of corporate social
responsibility and diversity & inclusion.
On receiving the prestigious award, Mr. Abhijit Pati, CEO and
Director of BALCO said, “Today we are living in a very exciting
transformed business environment, where India has emerged as the
change-maker in the global economic scenario. BALCO is amongst
the country’s top producers of the second most important metal
in the world – aluminium, firmly placing the country on the global
metal forum. BALCO has contributed in positioning aluminium as
the ‘Metal of the Future’ globally, through its best in class value-
added products. This award re-energizes us to serve our country,
customers and communities with even greater vigour.” Indian Affairs Business Leadership Awards. At the 3rd Corporate
Alumnus of the Calcutta University, Mr. Abhijit Pati started his career Excellence Award organized by Odisha Cultural Foundation, Mr.
as an engineer with Indian Aluminium Company (a subsidiary of Pati was awarded ‘Best CEO of the Year’ in 2017 for his efforts in
ALCAN, Canadian Major Aluminium Producer) in the year 1989. He driving the aluminium revolution in India as the CEO of Vedanta Ltd.,
served various leading aluminium companies with an exemplary Jharsuguda & ‘Best CEO of the Year’ in 2019 as the CEO of Bharat
track record until 2008. This is when he was offered senior leadership Aluminium Co. Ltd., where his professional acumen and leadership
position for leading one of the largest greenfield aluminium cum have resulted in nurturing one of the largest primary producers of
power complexes of the world at Jharsuguda, Odisha by the global aluminium.
natural resources conglomerate, Vedanta Ltd. He is a nominated representative of India for the Indo-Japanese
Subsequently, on March 16, 2015, Mr. Pati was elevated to the collaboration on PAT scheme for collaboration on energy sector
coveted position of President and CEO of Aluminium business and appointed by the Government of India. He has also taken the
headed the world’s largest single-location aluminium smelter at responsibility to co-chair the FICCI (Federation of Indian Chambers
Jharsuguda for a little over four years. Under his able leadership, of Commerce and Industry) Odisha State Council and is a nominated
Vedanta Ltd., Jharsuguda became a distinguished member of the member of the Board of Management of BPUT, Odisha for the past
prestigious ‘million tonne club’ of global aluminium producing 3 years.
companies. He is a Senior Management Executive Committee
Bharat Aluminium Company Limited (BALCO) is India’s iconic
member of Vedanta’s Global aspiration in its quest to emerge as
aluminium producer. It is owned 49% by the Government of India and
the frontrunner in global natural resource business. He is also the
51% by Vedanta Limited. Vedanta Limited is the world’s 6th largest
lead officio member of Governing Council of Aluminium Association
diversified natural resources company and the largest producer
of India (AAI).
of aluminium in India. BALCO operates a 0.57 million tonne per
He was felicitated with the ‘Technological Excellence Award 2016’ annum aluminium smelter in Korba, Chhattisgarh. It is also a leader
at the 20th National Conference on non-ferrous minerals & metals in value-added aluminium products that find critical applications
for his significant contribution as a frontline leader. in core industries. With its world-class smelter and power plants,
He was adjudged twice as the ‘India Affairs Professional CEO of the company fulfills its mission of spurring emerging applications
the year’ at the 8th and 9th Annual India Leadership Conclave and of aluminium as the ‘Metal of the Future’ for a greener tomorrow.

Vol.20 Issue No.4 JANUARY 2021 26 Aluminium Association of India

 ALUMINIUM INDUSTRY NEWS

ALUMINIUM ALLOY RESEARCH COULD BENEFIT MANNED

SPACE MISSIONS
Manned space missions in spacecraft made of aluminium that is environments’. A nuclear reactor is also an extreme environment,
light, yet resistant to radiation, could be a step nearer following as is the sun with solar cycles, but dynamic instabilities on the sun
research involving a facility at the University of Huddersfield. such as solar flares and coronal mass ejections are more extreme
The MIAMI-2 – Microscopes and Ion Accelerators for Materials than anything on Earth. The sun is a very efficient nuclear fusion
Investigations – facility has helped Dr Matheus Tunes investigate a reactor and high-energy particle accelerator.”
new alloy that will harden aluminium without increasing its weight Dr Graeme Greaves, Senior Research Fellow at the MIAMI Facility,
significantly. adds, “When Matt first came to us from Brazil as a postgraduate
Spacecraft launched from Earth need to be light, but still have the student, he was always looking for new projects and created a
right amount of fuel to see them achieve orbit. If too heavy, the number of new collaborations. I’m very happy that as he is starting
amount of fuel required would be prohibitive. Once outside of the the next part of his career in Austria and expanding into new areas,
Earth’s protective magnetic field, a vehicle may then be exposed to he is continuing to collaborate with us here at the MIAMI facility,
potentially destructive amounts of solar radiation, which becomes with this aluminium alloys project being just one example.”
more important for any long duration mission such as to Mars. Research could benefit deep space missions
Alloys that harden aluminium for space travel With manned missions to the moon and Mars currently being
Making spacecraft from aluminium is one solution, as aluminium is planned, the advantages of spacecraft that are light enough to
a light yet strong material. Alloys help aluminium become harder via launch and withstand radiation to protect their crews are clear. Next
precipitation strengthening, but the radiation encountered in space on the agenda for Matheus, Graeme and colleagues is to find out
can dissolve the hardening precipitates with potentially disastrous why the alloy behaves the way it does and what further benefits
and fatal consequences for astronauts. there could be.
But the research carried out at MIAMI-2, in partnership with “I am particularly proud that I finished my PhD in Huddersfield,
Montanuniversitaet Leoben (MUL) in Austria, has discovered I’ve now moved to Austria but still continue to work with Graeme,”
Matheus adds. “We have an active collaboration and 2021 will
that a particular hardening precipitate of a new aluminium alloy
be a busy year for the joint Huddersfield-Leoben space materials
– developed by a group of metallurgists led by Professor Stefan
research project.”
Pogatscher (MUL) – does not dissolve when bombarded with
particle radiation when compared with existing data on irradiation “We discovered the T-phase is radiation-tolerant, but we haven’t
of conventional aluminium alloys. discovered why that is. We have an idea which involves the
chemical complexity of the phase that we believe could lead to
The result is an alloy with a radiation resistant hardening phase
some very interesting research. We hope that we can make an
called a T-phase, which has a complex crystal structure of
important contribution to further human exploration of space.”
Mg32(Zn,Al)49. The research led to a paper that has been published
in Advanced Science.
“The idea of the paper was testing these
new alloys using the MIAMI facilities,
because we can subject the alloy to
energetic particle radiation and, at the
same time, monitor the effect of this
radiation on the alloy microstructure with
a transmission electron microscope”,
says Matheus.
“We monitored the crystallographic signal
of the T-phase as the radiation increased
and observed that compared with other
conventional aluminium alloys, the alloy
we developed was radiation tolerant –
meaning that the hardening phase does
not dissolve under high radiation doses.
“It sheds light on a very exciting new
field of research we call ‘prototypic
space materials for stellar-radiation

Vol.20 Issue No.4 JANUARY 2021 27 Aluminium Association of India

 ALUMINIUM INDUSTRY NEWS
VEDANTA: PROPELLING INDIA'S GROWTH & SELF-RELIANCE STORY
Vedanta Aluminium & Power business is the largest producer of
aluminium and the amongst the top three power producers in india.
Aluminium is a metal of supreme strategic importance and ranks
second in the list of priority metals in the world. The attributes
and versatility of aluminium make it a metal of choice and it finds
critical usage in key sectors like defence, aerospace, automobile
and infrastructure. It plays a vital role in the government's visionary
initiatives- Make in India, Smart Cities, Power for All, indigenous
space programs etc.The aluminium sector provides opportunities
for over 8 lakh people directly and indirectly. With such benefits,
it deserves to be considered as 'core industry',akin to the steel
industry.
Vedanta's efforts to increase itsproduction of aluminium is
propelling India towards self-sufficiency.In the last fiscal year,
Vedanta Aluminium has reached a peak production of 1.95 MT and
in the process emerged as the highest aluminium producer in the
country. With this achievement, the company moves a step closer
to supporting the government in its efforts to create a self-sufficient
domestic industry.
The biggest reason for this achievement is the way the business
has ramped up its capacity in its smelters at Jharsuguda( Odisha)
BALCO in Korba (Chhattisgarh), and its alumina refinery in Kalahandi
(Odisha). The organisation also operates an independent power
plant Talwandi Sabo Power Limited (TSPL) in Bhatinda (Punjab). But
HINDALCO ANNOUNCES RESUMPTION OF ALUMINIUM CAPEX
CYCLE WITH NEW SILVASSA PLANT
Hindalco Industries has announced plans to set up a 34,000-tonne
aluminium extrusion plant at Silvassa, in another round of capital
expenditure by the Aditya Birla group. The proposed `730 crore unit
is the first step towards reviving Hindalco’s downstream investment
plan, which had been pushed back because of covid-19.
Satish Pai, managing director, Hindalco Industries, said, “We are
seeing a revival in the economy, with demand picking in the building
and construction and automotive sectors. This has given us the
confidence to move forward. The Silvassa facility will enable us to
service our customers faster, with an offering of high-end quality
aluminium products."
The Silvassa plant will be fully-automated and will include three
extrusion presses and will enable Hindalco to service premium
customers in the building and construction, auto and transport,
electrical, consumer and industrial goods sectors. Aluminium has
been gaining ground as the preferred sustainable metal across these
sectors as it is infinitely recyclable and enables industries to integrate
circular economy models in their operations, the company said.
The aluminium extrusion market in India is expected to grow
exponentially – from the current 3,73,000 tonnes to reach about
850,000 tonnes by 2030, a press release from Hindalco said.
Western and southern regions of the domestic market account for
over 60% of the extrusion market. The Silvassa facility will allow
Hindalco to serve customers in these regions with superior quality,
faster service and shorter response times.
Vol.20 Issue No.4 JANUARY 2021
more importantly, this achievement will take Vedanta a step closer
to becoming a trusted partner of the government and providing
support to enable India attain self-sufficiency in aluminium.
Vedanta aluminium, well known for its superior product quality and
application of state-of-the-art technology in its production process,
is the leading player in the aluminium industry. The production
achievement has thrusted the company to the pinnacle and paved
the way for the company to develop a new business strategy with
a goal to create volume and achieve scale. To do so, Vedanta is
investing in the development of high-quality Value-Added Products
that enablesthe company to create a wide range of offerings –
from wire rods, billets, primary foundry alloy to rolled products and
ingots. The recently-launched primary foundry alloy, that is being
produced in India for the first time, and was hitherto only imported,
takes Vedanta a step closer to the end-customer in the value chain
and creates value for its stakeholders.
With the new business move, Vedanta will achieve operational
flexibility that will enable it to adapt itself meaningfully to evolving
customer requirements and changing market dynamics.
Vedanta will also continue to put safety and sustainability at the
core of its operations and remain committed to its Zero Harm, Zero
Waste, Zero Discharge culture. And all this will be carried out in
keeping with the larger obligation to people, planet and prosperity.
Satish Pai, managing director of Hindalco Industries.
"Over the next few years, as part of our downstream strategy, we
intend to enhance our capacity from over 300,000 tonnes currently,
to more than 600,000 tonnes with investments of around `7,000
crore," Pai said. “Our focus on downstream assets is part of our
sustainable business model with an emphasis on further de-risking
our business from LME (London Metal Exchange) volatility."
Hindalco’s existing extrusion plants in Renukoot in Uttar Pradesh
and Alupuram in Kerala cater mainly to auto, defence, aerospace,
and industrial segments. The Silvassa facility will add an additional
34,000-tonne capacity with focus on the B&C segment which
comprises over 60% of the extrusion market, apart from auto,
transport and other segments. Commercial production at the plant is
expected to start in 24 months.
28 Aluminium Association of India
 ALUMINIUM INDUSTRY NEWS
ALUMINIUM DEMAND GROWTH WILL SOON OUTPACE
PRODUCTION GROWTH
Research agency Fitch Solutions Country Risk & Industry Research
says the global primary aluminium market will remain largely in
oversupply, owing to absolute production remaining higher than
consumption this year, but the surplus is likely to start narrowing
from 2021.
This will remain the case up to 2024, before widening again from
2025. From 2025 onwards, Fitch expects the market oversupply
to widen again, as demand will benefit from construction industry
growth in key countries and the growing recognition of aluminium
as a lightweight substitute for steel in automotive.
Fitch further explains that global aluminium production will continue
to rise over the coming years as higher prices incentivise producers
to ramp up output. In the near term, the agency forecasts output to
grow by 2% year-on-year in 2021, compared with 2.7% in 2020, as
aluminium prices slowly recover from the slump during Covid-19,
which caused producers to reduce output.
The global aluminium demand picture will be stable over the coming
years, driven by steady demand growth in Asia and the growing
application of aluminium in industries such as automotive and
aerospace. Nevertheless, global demand growth will gradually slow
compared with preceding years as Chinese economic growth and,
therefore, demand for metals through automotive and infrastructure
ticks lower.
We forecast global aluminium consumption to increase from
64.2-million tonnes in 2021 to 78.4-million tonnes by 2029, averaging
2.6% annual growth. “Over 2021, we forecast consumption demand
to grow by 3.3% year-on-year up from a contraction of 1.2% year-
on-year in 2020,” the agency says. Protectionist policies in the US
increasingly threaten to disrupt global aluminium trade flows as the
US is the largest global importer of aluminium. Owing to ongoing
policy uncertainty, Fitch views these developments as downside
risks rather than a core view.
China’s aluminium production growth will slow down over the
coming years as the government’s push for consolidation and
stricter environmental regulations takes higher-cost and less
JAWAHARLAL NEHRU ALUMINIUM RESEARCH SIGNS MOU WITH RUSAL
Jawaharlal Nehru Aluminium Research Development and Design
Centre Nagpur signed a Memorandum of Understanding with Russian
Union of Producers, Suppliers and Consumers of Aluminium, the
second largest aluminium company in the world recently. The MoU
was signed for the co-operation in the development of aluminium
production, consumption and technology transfer between both
organisations.
As per the MOU, promoting exchange of experience in order to take
practical steps to increase aluminium consumption; Assistance
in information exchange and communications between the
representatives of Russian and Indian aluminium industry; Providing
assistance in the development of technoparks (clusters) for the
industry; Setting up joint ventures between Russian and Indian
Vol.20 Issue No.4 JANUARY 2021
efficient capacity offline. However, this will not result in an outright
decline in absolute output over the coming years and China will
remain the driving force behind global aluminium production.
This while Russia’s aluminium production will benefit next year from
United Company Rusal’s resumption of the ramp-up at its Taishet
smelter. The firm previously delayed activities owing to Covid-19
impacts. Fitch forecasts Russian aluminium production to grow
at an average 2% year-on-year in 2021, down from 2.3% in this
year. Meanwhile, Fitch expects China’s aluminium consumption to
rebound to 1.5% year-on-year growth in 2021, amid an uptick in
real estate and infrastructure investment, but may see a slow down
as the country’s economic growth loses steam in later years.
The agency predicts a rise in China’s total aluminium consumption
from 36-million tonnes in 2021 to 39.8-million tonnes by 2029. This
while US aluminium consumption is likely to grow by 1.2% year-on-
year in 2021 as automotive manufacturing resumes, recovering from
the 5% contraction recorded in 2020. Fitch says that India will be
the stand-out growth market for aluminium consumption in coming
years, since its long-term growth prospects in the construction
industry are supported by the country’s sizeable infrastructure
deficit and government driving investment in the sector.
The agency forecasts India’s aluminium consumption to increase
from 2.7-million tonnes in 2021 to 8.7-million tonnes by 2029.
The automotive and aerospace sectors will increasingly support
aluminium demand in key markets, as a lightweight – and therefore
environmentally preferable – alternative to steel. Several deals
between automotive or aircraft manufacturers and aluminium
producers highlight this trend over the past few years, such as
Arconic's multiyear supply deal with Toyota in 2017.
Aluminium integration will rise in more regulated automotive markets
such as the US, the EU and Japan, although developing markets
will also present growth opportunities. Additionally, the accelerating
shift towards electric vehicle adoption in select Asian and European
markets will add upside potential to aluminium consumption, as
automakers utilise the metal in structural parts and batteries.
enterprises, including facilities producing high level aluminium
products; Promoting contacts and information exchange in the field
of new and high technologies in the aluminium industry are some
agreements that signed during the MOU.
RUSAL is a leading company in the global aluminium industry,
producing metal with a low carbon footprint. Ninety per cent of
the Company's aluminium is produced from renewable electricity,
and by implementing innovative and energy-saving technologies
RUSAL is able to reduce greenhouse gas emissions at all production
stages. Both organisations intend to build their relations based on
the principles of mutually beneficial co-operation and common
interests.
29 Aluminium Association of India
 ALUMINIUM INDUSTRY NEWS
TELANGANA NEW ELECTRIC VEHICLE AND ENERGY STORAGE
SOLUTION POLICY TO WOO INVESTMENTS
Seeks to transform state into electric mobility hub
The Telangana Government has approved the new Telangana State
Electric Vehicle and Energy Storage Solution Policy seeking to
encourage green mobility while attracting investments in the sector.
The State Cabinet chaired by Chief Minister K Chandrasekhar Rao
took a number of decisions to attract investments into the State.
These include focusing on local job creation, encouraging production
of electric vehicles (EVs) in the state by giving them incentives, and
transforming the state into an e-hub for electric mobility.
Taking forward the Central government’s FAME II framework, the
new EV policy is aimed at making Telangana a preferred destination
for electric mobility and component manufacturing units, besides
making the State a major base for EV and energy storage sectors.
The policy framework seeks to attract investments and create
employment in the rapidly-growing sector, which is seen to have
immense potential.
The State government proposes to establish a couple of exclusive
parks — Energy Park and another EV Park. These will be supported
by the infrastructure created at the existing Electronic Manufacturing
Clusters at Raviryal and Maheshwaram for facilitating establishment
of the new EV manufacturing plants.
The State government plans to invest `1,425 crore towards
incentives and provide 775 acres of land for EV manufacturers by
promoting a hub.
The State expects to attract investments of `30,000 crore over the
next few years, apart from facilitating creation of 1.2 lakh direct and
2.5 lakh indirect employment opportunities.
RAIN WATER COMPANY LAUNCHES MOUNTAIN SPRING WATER IN
RECYCLABLE ALUMINUM BOTTLES
As plastic bottles become one of the major contributors of plastic
waste in the world, some companies are doing their part in
minimizing this problem. One of those is RAIN Water Company, a
spring water bottler. The company recently launched its new brand
of plastic-free mountain spring water in recyclable aluminum
bottles to help reduce plastic waste.
“Consumers have long been told that
plastic packaging is okay, provided that it
is recycled. With plastic recycling rates not
breaking single digits, it is quite difficult to
think that this act can help reduce plastic
waste. Aluminum is one of the most
recyclable materials on the planet and
reused repeatedly. Aluminum bottles, when
recycled, will be back on the shelf or made
into a pick-up truck like an F150 within 60
days – the opportunities are endless,” said
the representative at RAIN Water Company.
Vol.20 Issue No.4 JANUARY 2021
While releasing the policy, it proposes to develop an ecosystem
of shared mobility through battery charging and swapping
infrastructure, as well as supporting creation of EV charging
infrastructure.
As part of this policy move, the State government will provide
preferential market access to the companies which establish their
manufacturing plants in the State.
The State has decided to provide 100 per cent exemption of road
tax and registration fee for the first EVs to be purchased in the State
once the policy comes into force.
It is proposed to extend incentives to two lakh two-wheelers, 20,000
three-wheelers, 5,000 commercial passenger vehicles including
taxis and tourist cabs, 10,000 electric light goods carriers, 5,000
private cars and 500 e-buses.
The State has also decided to extend incentives and subsidies to the
manufacturers as well, as per the Electronics Policy 2016.
This includes 20 per cent capital investment subsidy, SGST
reimbursement, power tariff discount, electricity duty exemption,
interest subvention, transportation subsidy and other expenditures
like stamp duty, transfer duty, registration fee, lease rental assistance
and others.
E-bus manufacturer Olectra Greentech-BYD and electric three-
wheeler manufacturer Gayam Motor Works have already set up
their facilities in the state, while several other companies including
Mytrah Energy and battery manufacturer Exicom have expressed
interest in establishing their units.
According to the company, aluminum gets recycled at least 67%
of the time. Single-use plastics are recycled less than 10% of the
time. Aluminum also maintains its integrity when melted for an
infinite number of times. Recycled plastic must be mixed with new
plastic to make bottles. This scenario means more oil is needed,
leading to more waste. It is estimated that
over 75% of all aluminum ever produced is
still in use today.
With an aluminum body, spring water cools
in just 20 minutes. Plastic is not nearly as
thermally conductive as aluminum, so it
takes about two hours for water in cool in a
plastic bottle. In addition to that, aluminum
emits no microparticles whereas disposable
plastic containers have microparticles that
are harmful to health and ultimately the
environment.
30 Aluminium Association of India
 ALUMINIUM INDUSTRY NEWS
HINDALCO RANKED WORLD’S MOST SUSTAINABLE ALUMINIUM CO:
DOW JONES SUSTAINABILITY INDICES 2020
Hindalco is the DJSI Aluminium Industry Leader, globally, based on
its S&P Global CSA Score for 2020. Among 61 Industries, Hindalco is
the sole Indian company recognised as an ‘Industry Leader’
Hindalco Industries, the metals flagship of Aditya Birla Group, has
been ranked as the Aluminium Industry Leader for its sustainability
performance in the 2020 edition of the S&P Dow Jones Sustainability
Indices (DJSI) Corporate Sustainability Assessment (CSA) rankings,
the company said in a statement. Hindalco, the statement said, is
the only company from India to be recognised as an Industry Leader
this year. Industry Leaders are the top-performing companies in
each of the 61 industries represented in the DJSI. Hindalco got a
total score of 75 points as against the industry average of 51.
The ranking is an affirmation of Hindalco’s commitment to
operations under a Resilient, Responsible and Reliable business
model, it added.
According to the statement, Hindalco’s was scored in the
100th percentile in most aspects of all three dimensions of the
Environmental, Social and Governance (ESG) in the DJSI Corporate
Sustainability Assessment (CSA). The ESG assessment dimensions
included aspects like climate strategy, biodiversity, environment
and social reporting, water-related risks, policy influence, customer
relationship management, human capital development, among
others.
Hindalco had made its debut on the DJSI last year entering the
emerging markets index and had scored 60 points in 2019 placing it
at number 3 among in the aluminium industry globally.
Satish Pai, Managing Director, Hindalco Industries Ltd, said, “The
ranking is a profound affirmation of our commitment to our Resilient,
Responsible and Reliable business model. Achieving the position of
Industry Leader is a recognition of our pioneering initiatives and
consistent efforts to transform the global aluminium manufacturing
sector to a more sustainable one.
We are happy that we have shown significant improvement in our
overall sustainability scores from 60 to 75 in the past year, which is
both an indication that we are very much on the right path, as well
BALCO HAS BEEN RECOGNIZED
AS ONE OF
‘THE ECONOMIC TIMES BEST BRANDS 2020’
The prestigious recognition is synonymous with consumer trust and quality,
reiterates BALCO’s value as a brand that of being innovative, trustworthy,
unique, ethical, adaptable, and delivering the best quality products and
services to its consumers and channel partners. The “Best Brands 2020”
features successful brand stories and outlines the DNA of brands, their iconic
core values, and their commitment to socio-economic development.
Vol.20 Issue No.4 JANUARY 2021
as an inspiration for us to accelerate this journey.”
Manjit Jus, Global Head, ESG Research and Data, S&P Global, said,
“We congratulate Hindalco for being a DJSI Industry Leader in the
Aluminium Industry and a member of DJSI Emerging Markets. A
DJSI distinction is a reflection of being a sustainability leader in the
Aluminium industry.
With a record number of companies participating in the 2020
Corporate Sustainability Assessment and more stringent rules for
inclusion this year, this sets Hindalco apart and rewards its continued
commitment to people and planet.”
The aluminium industry has an important and significant role to
play in the circular economy. It can contribute to lower waste and
energy savings in the products it produces. Aluminium products
can contribute to energy savings in the production process and
use phase, as aluminium is lightweight and its recycling consumes
significantly less energy than most other materials.
Hindalco has taken a number of innovative steps on the
sustainability front. In a global-first initiative to create value out
of aluminium processing by-product, Hindalco has tied-up with
cement manufacturers to use red mud as a replacement for mined
resources. This is a pioneering effort in reducing the environmental
impact on both aluminium and cement sectors. Hindalco is the first
aluminium company in the world to achieve this breakthrough on
red mud utilization.
Hindalco’s efforts in product stewardship revolve around sustainable
transportation and logistics. India’s first lightweight aluminium trailer
and bulker, which helps transporters save up to 15,000 litres of fuel
per trailer, was developed and commercialised by Hindalco. Another
initiative is on sustainable packaging, a combination of aluminium
and jute bags, for food items.
The DJSI combine S&P DJSI’s transparent rules-based index
methodology with robust data from SAM’s Corporate Sustainability
Assessment (CSA), an annual evaluation of companies’ sustainability
practices. Each year, SAM evaluates more than 7,300 companies
around the world.
31 Aluminium Association of India
 ALUMINIUM INDUSTRY NEWS
LIGHTER ALUMINUM WHEELS OUTWEIGH STEEL
Spec’ing lighter weight forged aluminum wheels is a simple solution
to increasing overall fuel efficiency and oftentimes, more importantly,
reducing maintenance costs. Refuse collection and other similar
heavy-haul applications demand a tough wheel. Forged aluminum
wheels are not the aluminum cans that are shredded in the recycling
process.
The mechanical properties of forged aluminum wheels give the
wheels the high yield strength and the great elongation that make
them strong.
High load and refuse applications are adopting forged aluminum
wheels because of their mechanical property benefits. Also, as low
operating costs are critical, the urgency for refuse equipment to
find solutions that contribute to improved freight efficiency, reduced
maintenance costs and increased productivity becomes greater than
ever. Not only lighter in weight than steel, forged aluminum wheels
are also stronger and more durable
to increase freight capacity and
improve maintenance savings
for increased productivity and,
ultimately, lower lifetime operating
costs.
Fuel Efficiency and Weight Savings
Refuse equipment managers should consider overall lifetime
operating costs when spec’ing wheels on new equipment since forged
aluminum wheels can improve quick and continuous “payback” in fuel
savings or freight productivity combined with maintenance savings.
For added fuel savings to refuse equipment, wheel manufacturers
offer innovative technology, which assists in increased weight loss.
For example, forged aluminum wheels significantly reduce wheel
weight versus a comparable steel. It is no secret that the lighter the
truck, the more cargo it can legally carry. The weight of a forged
aluminum 22.5"x 8.25" hub piloted wheel is 39 lbs. versus an
equivalent steel wheel at 68 to 82 lbs. The upgrade takes advantage
of this significant weight reduction to further improve fuel efficiency.
Forged aluminum wheels’ strength, durability and low weight deliver
environmental advantages to complement their financial benefits.
With larger payloads due to the weight
savings, trips are reduced, and, since
forged aluminum wheels are infinitely
recyclable, they will never see a landfill.
Maintenance Advantages
Maintenance is also a hot topic among
equipment managers, especially as
it relates to refurbishing, curbing
damage, and tire and brake life. Aluminum wheels do not require
the continuous refurbishing for which steel wheels do such as
removing rust, re-painting, touch up or other labor-intensive steps.
In addition, aluminum wheels are not painted like steel wheels,
ultimately eliminating the need for spray paint and touch up. In
harsh environments, equipment managers are required to dismount
tires, paint or touch up and remount tires every year to avoid that
common rusty appearance found on so many steel wheels. Therefore,
additional maintenance can result in higher overall lifetime costs and
aluminum wheels can improve the appearance of the truck or fleet
over a rusty or paint chipped steel wheel.
By their very nature, wheels spend their entire lives in a hostile
Vol.20 Issue No.4 JANUARY 2021
environment. Several forged aluminum wheel manufacturers also offer
additional options for further lowering operating and maintenance
costs. Proprietary surface treatments from wheel suppliers can be
integral to the production process of the forged aluminum wheel so it
is durable from the start and built to last when properly maintained.
A comprehensive production process ensures that wheels will not
crack, chip or corrode. And since specially treated aluminum wheels
do not need to be polished, they work hard to lower maintenance
costs since they shine up quickly with a simple scrub and keep
the vehicle looking newer for longer. Combining the advantages of
lightweight forged aluminum wheels with these easy to clean benefits
helps to lower lifetime operating costs and provide value to equipment
managers.
Forged aluminum wheels offer the strength refuse equipment
can rely on, both improving maintenance and furthering the life of
the equipment. Additional surface treatments offer maintenance
advantages, such as those treated to reduce or eliminate rim flange
wear, common among refuse equipment. Some types of aluminum
wheels feature a specially treated rim flange that reduces wear and
extends wheel service life for heavy haul and shifting load applications.
This design feature makes these protected wheels most appropriate
for applications where loads are heavy and prone to shifting, causing
tire walls to rub against the wheel rims.
Improved heat dissipation leads to longer tire and brake life. It is a
fact: aluminum dissipates heat better than steel. When a refuse
truck stops-and-goes 600 to 800 times a day, often in already high
temperatures depending on the states it operates, the benefit of
aluminum giving up heat faster is key to dissipating heat away from
the brake thus keeping tires from wearing out. Steel holds onto the
heat and the heat continues to rise even after parking the trucks,
while aluminum wheels give up the heat faster, helping to quickly cool
down the system and prevent heat damage to the tire and brakes.
In any heat events like a fire or brake related incident, it is important
to understand the impact the heat has on the wheel. One aluminum
wheel manufacturer puts two heat indicator sensors on the wheel—
one at the end of the roll stamp and one in the middle of the wheel.
They will turn brown to inform you that heat is going through the
wheel, and when they become black, you know that too much heat
went through that wheel and the wheel should be removed from
service.
Enhanced Image and a Smoother Ride for the Operator
In addition to bringing an element of pride to both the fleet and the
operators, the enhanced image forged aluminum wheels provide also
offers operators a smoother ride. Forged aluminum wheels are 100
percent machined, which eliminates run-out and vibrations leading to
a smoother ride for the operator.
When considering wheel choices, value should always be the goal.
Forged aluminum wheels present lifetime advantages over steel
wheels. Although steel wheels are less expensive at the time of
purchase, they become more high maintenance over time. Decisions
come down to short-term
versus long-term planning
and navigating the available
choices to ensure value over
the life of the equipment for
the fleet or owner operator.
32 Aluminium Association of India
 ALUMINIUM INDUSTRY NEWS
EXTRUDED ELEMENTS MANUFACTURER WITH AN
ALUMINUM SOLUTION FURNACE FROM SECO/WARWICK
A Virginia manufacturer of high-quality plumbing tube recently
commissioned a new SECO/WARWICK solution heat treat furnace,
expanding the plant’s capabilities to include aluminum extrusions.
This is the first new aluminum processing equipment installation at
the plant.
Unique configuration of the furnace for the solution of aluminum from
SECO/WARWICK
The furnace configuration is unique. Tubing extrusions and other
shapes up to 26 feet in length are loaded horizontally at floor level into
a load carriage. The carriage containing the load is then pulled by a
hoist, from one end until it is vertical next to the furnace. The carriage
is then secured to the supporting structure, allowing the hoist to lower
the down, and out of the carriage. The load is lowered into a powered
rotating carousel, containing two (2) submerged drywells that extend
below the floor into the water-filled pit. The load is then supported
by the carousel, allowing the hoist to be released. The carousel then
rotates until the load is in a position directly below the furnace. The
furnace door opens, and a 2nd hoist retrieves the load, pulling it up
into the furnace chamber for heating.
After heating, the furnace door opens and the load is lowered into
one of two open positions in the carousel, allowing the load to quickly
cool in the water-filled pit below. The vertical orientation of the work
being heat-treated is what differentiates this unit from others. The
design allows the customer to maintain an efficient, semi-continuous
process with little downtime between batches by staging loads in the
drywells.
Rapid Quench Assures Highest Part Quality
The major benefit of this design is that it allows the customer to drop
extrusions into the quench within 10 seconds after heat treating and
soak. The rapid quench is done quickly to “lock-in” the hardening
elements of the alloy. By heating the work up to a temperature slightly
below the melting point, or solid solution (solvus), the hardening
elements will disperse throughout the cross section of the work.
After cooling is complete the load is raised up out of the water and
KANFIT3D OFFERS 3D PRINTED ALUMINUM PARTS FOR
AEROSPACE INDUSTRY
Kanfit Ltd announced that it now offers additive manufacturing
of aluminum parts through its sister company Kanfit3D. The new
SLM 280 system enables the production of medium to high volume
aluminum parts and prototypes using selective laser melting. The new
system is in addition to Kanfit3D's EOS M290 manufacturing machine
based on Direct Metal Laser Sintering for Titanium Alloy Ti64G5.
New SLM system has a state of the art high power laser system that
reduces the cost per part, while advanced sensors and additional
systems ensure best in class processing conditions to deliver highly
consistent, top performance additive manufacturing parts. Advanced
capabilities shorten delivery times for products from one month, for
example, to five days.
Together both Kanfit3D and Kanfit Ltd. hope to expand into new
Vol.20 Issue No.4 JANUARY 2021
released back to the carousel. The carousel then rotates until the load
is returned to the position under the load carriage. The 1st hoist then
pulls the load back up into the carriage, retrieving the carriage and
load simultaneously. The carriage is then lowered back down to the
plant floor, traversing from vertical to horizontal as it’s lowered. Once
back at floor level the finished load is removed from the carriage and
the next load to be treated is placed in the carriage. Loads can be
staged in the drywells as the furnace is cycling, so the furnace can be
unloaded and reloaded in just a few minutes.
“While SECO/WARWICK has patented many standard processes
related to aluminium heat treatment and controlled atmosphere
brazing, our strengths lie fundamentally in our ability to apply
innovative designs to custom requirements, something I believe we
do as well as anyone in the world. This is but one good example of
the type of work we excel in,” said Keith Boeckenhauer, Managing
Director SECO/WARWICK USA.
5x Better Temperature Uniformity
The new SECO/WARWICK furnace, designed and built in Pennsylvania,
was engineered to meet a minimum uniformity specification of +/-
10° F. Once the furnace was commissioned, the customer brought
in a third party to survey its performance and documented the
actual uniformity at +/- 1.5 – 2° F. So, by having the tight uniformity
capability, the temperature can be set closer to the solvus range
without concern for melting the work, allowing for optimum solution
treatment.
The customer stated that, as part of their initiative to diversify from
traditional HVAC products into more precision engineered components,
it was critical that they chose the right partner to implement this
expansion project with aluminum extrusions. They selected SECO/
WARWICK based on their proven track record with this type of furnace
and their ability to customize the project according to our needs. The
excellent and repeatable temperature uniformity achieved with this
furnace will allow the customer the ability to market products to the
aerospace and medical fields by meeting Class 1 requirements.
aerospace and medical sectors, including home defense, and custom-
made medical fixtures and devices.
Kanfit is a build-to-spec/print aerospace engineering company
offering full service solutions from product specification or 3D
model to prototype
to serial production.
Kanfit manufactures
and integrates primary
and detailed parts,
subassemblies and ready
to fly assemblies made
from composites and
metals.
33 Aluminium Association of India
 ALUMINIUM INDUSTRY NEWS

RECTANGULAR ALUMINUM FINS FOR PV MODULE COOLING

Scientists in Pakistan have proposed a new passive cooling
technique which they claim can improve a module’s open-circuit
voltage by up to 12.97% and its efficiency by up to 2.08%.
Researchers at Pakistan's U.S. Pakistan Center for Advanced Studies
in Energy (USPCASE) and the National University of Sciences &
Technology (NUST) have developed a new passive cooling technique
for PV modules, based on rectangular aluminium fins.
The scientists said they utilized hollow rectangular fins instead
of more commonly used solid rectangular bars as they wanted to
prevent the weight of the modified PV panel rising. “The hollow
rectangular shape of [the] fins, with open ends, also provides the air
flow channel, which can ultimately increase the cooling effect,” the
researchers also explained.
The new technique was tested on a PV system based on two 10 W
monocrystalline panels with a weight of 1kg each, one equipped
with the rectangular fins and one without them. The array is located
at the USPCASE, in Islamabad, with temperatures ranging during
daytime from 19.5 degrees Celsius to 26.4 degrees Celsius. Average
global horizontal irradiance during the experiment days was 570 W/
m2 with a maximum value of 718 W/m2 at around 1 p.m.
The panels used in the PV array have an efficiency of 15.3%, a
maximum voltage of 18 V and an open-circuit voltage of 21.24 V.
The eight aluminum fins applied to the rear side of the finned panel
have a length of 230mm, a wall thickness of 1.9mm, and an annular
area of 161.29mm2.
“All tubes are connected to the rectangular strips with a spacing
of 25.4mm, which provided
a frame-like structure,”
the academics explained.
“The frame is attached
to the back side of the PV
module, as a heat sink,
using self-tapping bolts and
rectangular strips.”
The measurements were
taken through temperature
data loggers, a multimeter,
a pyranometer, and an anemometer. “The results obtained from
experiments demonstrated that the attached fins reduced the
average temperature of the front and rear surfaces up to 8.97%
and 8.41%, respectively,” the Pakistani group stated. “The cooling
effect produced due to fins, improved the open circuit voltage up to
12.97% and the electrical output efficiency up to 2.08%.”
The adoption of the fins would increase the cost of a module by
around $0.20 per W, according to the scientists. The total weight
of the aluminum applied to the module is 0.6kg and its cost was
$2.33, while the cost of screws and washers was $1.08. “The total
cost of the prototype fabrication for thermal management in this
study is $2.96 for the PV area of 0.0929m2.”
The new technique is described in the paper Thermal management
of solar PV module by using hollow rectangular aluminum fins,
published in the Journal of Renewable and Sustainable Energy.

CARBON NANOFIBERS BOOST THE HARDNESS OF 3D-PRINTED ALUMINUM

While 3D-printed aluminum parts are becoming increasingly
common in the aerospace industry, any weaknesses in those parts
can cause them to fail catastrophically. A new additive could help, by
making the aluminum 1.5 times harder.
Developed by scientists at Russia's NUST MISIS university, the
additive is made up of tiny carbon nanofibers. These are produced
as a byproduct of the processing of natural gas, and would ordinarily
end up being disposed of – potentially becoming a form of pollution.
Instead, they're added to powdered aluminum. In an existing process
known as selective laser melting, a laser beam is used to melt that
powder in a specific pattern, building objects up one layer of melted
(and subsequently fused) aluminum at a time.
Ordinarily, temperature differences between those layers may cause
the microstructure of the finished product to be inconsistent, with
some layers ending up more porous than others. Because the carbon
nanofibers are very thermally conductive, however, they're reportedly
able to distribute the laser heat more thoroughly and evenly.
As a result, the 3D-printed aluminum has a uniform low porosity,
and is thus a claimed 1.5 times harder than aluminum printed from
powder without the added nanofibers.

WEILER ABRASIVES EXPANDS LINE OF ALUMINUM FLAP DISCS

Weiler Abrasives has expanded its aluminum abrasives offering to include Tiger aluminum flap discs
featuring a paired flap design. The design includes a top flap with a coating that prevents loading,
provides a high cut rate, and eliminates the need to apply wax or lubricant before grinding aluminum,
says the company. Alternating flaps of self-sharpening zirconia aluminum grains offer aggressive
material removal.
The 4-1/2-in. flap discs are offered in Type 27 or Type 29 with either 7/8 or 5/8-11 arbor holes and two
grit options. The 36-grit disc is a good choice for chamfering, weld removal, and stock removal, while the
60-grit disc is suitable for weld blending, finishing, and cosmetic detail work.

Vol.20 Issue No.4 JANUARY 2021 34 Aluminium Association of India

HIGHLIGHTS

ALUMINIUM STATISTICS Source: Japan Aluminium Association

PRODUCTION OF ALUMINIUM AND ITS FABRICATED PRODUCTS (Thousand Metric Tons)
2019 2020 2020 2020 2020 2020 2019
Total %Chg
2019 19/18 %Chg 9 9 %Chg
QIV QI QII QIII September
(20/19) Months Months
Primary Aluminium 0 0 0 0 0 0 0 0 0 0 0
Secondary Aluminium 795.4 -3.8 199.4 194.2 130.4 161.4 63.2 -5.1 486.0 596.0 -18.5
Semi-fabricated products
F.R.P.* 1,150.9 -5.6 276.8 263.3 263.4 253.1 91.6 -6.4 779.8 874.2 -10.8
Extrusion 755.5 -3.7 193.1 172.5 150.2 156.8 58.1 -9.2 479.5 562.4 -14.7
Die-Castings 1,001.4 -4.8 245.2 238.4 128.2 208.2 81.5 -4.8 574.8 756.2 -24.0
Castings 437.5 -3.6 109.2 102.5 52.4 86.2 33.4 -13.6 241.1 328.3 -26.6
Electrical Conductor 33.8 0.3 7.9 10.4 7.2 8.7 2.3 -22.9 26.2 25.9 1.3
Foil 108.1 -9.7 26.5 25.4 26.6 25.4 8.8 -0.6 77.3 81.6 -5.2
Aluminium Windows 157.3 -3.0 41.1 33.6 32.5 34.1 12.0 -10.0 100.2 116.3 -13.8
Aluminium Cans 364.4 1.1 85.4 84.7 96.4 96.0 29.6 -5.6 277.2 279.0 -0.7
*including foil stock

IMPORTS AND EXPORTS

(Thousand Metric Tons)
2019 2020 2020 2020 2020 2020 2019
Total %Chg
HS %Chg 9 9 %Chg
2019 19/18 QIV QI QII QIII September
(20/19) Months Months
IMPORTS
Aluminium waste &
scrap 7602 44.6 -26.9 10.1 12.3 10.6 11.0 4.1 25.4 33.9 34.5 -1.6
Unwrought aluminium

Aluminium not alloyed 7601-10 1,418.5 -11.2 376.6 329.3 324.3 246.4 73.3 -31.8 900.0 1,041.9 -13.6

Aluminium alloyed 7601-20 1,169.7 -8.8 282.2 258.6 216.1 148.3 67.0 -24.0 623.0 887.4 -29.8
Wrought aluminium
Plates, sheets & strip 7606 142.5 31.9 35.6 36.1 35.1 26.9 9.5 -23.2 98.2 106.9 -8.2
Bars, rods & profiles 7604 31.1 15.7 8.3 8.4 7.6 4.9 1.3 -56.9 21.0 22.9 -8.5
Tubes & pipes 7608 4.4 13.1 1.0 1.0 0.9 0.7 0.3 -24.3 2.6 3.3 -21.2
Wire 7605 12.8 42.9 3.4 3.0 3.5 2.4 0.8 -38.7 8.9 9.4 -5.8
Foil 7607 60.3 5.5 13.8 12.3 15.2 13.8 4.2 -9.0 41.3 46.6 -11.3
Rolled prod. sub total   251.1 22.5 62.0 60.9 62.4 48.7 16.2 -25.8 171.9 189.1 -9.1
EXPORTS
Unwrought aluminium 7601  
Not alloyed, alloyed -10,-20 18.1 -14.9 5.4 6.9 4.9 4.1 1.7 -12.3 15.9 12.7 25.5

Plates, sheets & strip 7606 179.9 -8.0 42.1 31.3 31.3 33.6 11.4 -21.3 96.2 137.8 -30.1
Bars, rods & profiles 7604 16.4 -22.3 4.4 4.2 3.5 2.9 1.0 -17.7 10.6 12.0 -11.7
Tubes & pipes 7608 4.8 -11.7 1.1 1.1 0.8 0.9 0.3 -18.4 2.8 3.7 -24.6
Wire 7605 6.2 -21.4 1.7 1.5 1.4 1.5 0.4 0.8 4.3 4.5 -4.4
Foil 7607 66.1 -0.3 19.1 16.5 14.5 13.5 3.8 -32.9 44.5 47.0 -5.2

1. Detail may not add to the each quarter and year totals due to rounding
2. The figures of ‘Total 2019’ are final ones of 2019. It might be different from the total figure of each quarter of 2019, because the data of
each quarter is based on temporary statistics for preliminary release.

Vol.20 Issue No.4 JANUARY 2021 35 Aluminium Association of India

HIGHLIGHTS

JAPANESE ALUMINIUM MARKET

Source: Nalk Report, Vol.360 November 2020
ALUMINUM PRICE TRENDS IN OCTOBER 2020
In October 2020, the three-month LME aluminium price maintained a steady level around $1,850 after recovering to the $1,800
level on October 8. The rise in the spot aluminum price in Japan was restrained due to the effects of the strong yen. However,
the price remained at a high level of ¥225,000-227,000/ton in mid-October. In November, from the results of the US presidential
election and out of expectation for the Covid-19 vaccine development by Pfizer, both stock and product markets rose and the
three-month LME price also rose to the $1,900 level on November 6.

Domestic Spot Market Prices

LME Three-Month Prices
Source : The Daily Light Metals News

However, the outlook for the presidential election and vaccine hope remains unclear and may be a factor hindering price increase.
The three-month LME price was $1,934.5 on November 13 and Japan’s spot price was ¥233,000/ton. According to data from The
Daily Light Metals News, aluminum stocks at the three major Japanese ports at the end of October 2020 totaled 286,1000 tons,
32,500 tons less than a month earlier, marking a decline for 4 months in a row.
Selling prices of secondary aluminum alloys shipped in small lots in October 2020 rose ¥7-11/kg from the previous month. This
may have been reflected by the tight supply and demand as well as the shortage of the raw scrap ingredients. Prices of ADC12
sold in small lots in the Tokyo area were between ¥284~289/kg as of November 10, up ¥10/ kg from the previous month, according
to the Japan Metal Bulletin.

PRODUCTION AND SHIPMENTS OF SECONDARY ALUMINUM AND SECONDARY

ALUMINUM ALLOYS IN SEPTEMBER 2020
Production of secondary aluminum and secondary aluminum alloys dropped 5.1% year on year to 63,170 tons, the Japan Aluminium
Alloy Refiners Association announced. Shipments fell 7.0% to 64,032 tons. Production and shipments fell below the previous year’s
standard for 21 straight months and 12 straight months, respectively.
Shipments to the key demand sector of die castings remained at the previous year’s level with an 0.1% increase, but posted positive
results for the first time in 6 months. Shipments to the casting sector fell 14.4%, recording a decline for 12 straight months. All other
sectors exceeded the previous year’s level.

Shipments of Secondary Aluminum and Secondary Aluminum Alloys by Market in September 2020 (tons)
Castings Die Castings Rolled Products Extruded Products Steel Alloys Exports Others Total
15,891 37,575 4,363 1,357 2,742 1,983 32 89 64,032
Y-on-Y% Chg 85.6 100.1 96.2 74.2 75.5 79.1 32.3 46.8 93.0

Vol.20 Issue No.4 JANUARY 2021 36 Aluminium Association of India

ARCHIVES

The following papers/articles were published in Aluminium-in-India in

the last four issues
• BUILDING A SUSTAINABLE FUTURE WITH ‘GREEN METAL’ ALUMINIUM
Mr. Ajay Kapur, CEO – Aluminium & Power Business, Vedanta Ltd.
• OPTIMIZATION OF BATH SHOP CRUSHING CIRCUIT FOR SUITABLE PARTICLE SIZE
Mr. Maheswar Behera, Consultant – Aluminium Industry
• ALUMINIUM INDUSTRIES DURING COVID-19 AND ACTION PLAN POST COVID
Dr. B.K Satpathy, Visiting Scientist, Indian Institute of Technology, Bhubaneswar
• INDIAN ALUMINIUM INDUSTRIES REVITALIZING GROWTH OPPORTUNITIES
Prof. K.S.Sreenivasa Murthy, Founder & Former General Secretary,
Aluminium Association of India
Vol. 20
• FRICTION STIR WELDING OF ALUMINUM ALLOYS: OPPORTUNITIES AND POTENTIAL - Issue No. 3,
Dr. Partha Sarathi De, Assistant Professor, School of Minerals, Metallurgical and Materials
October 2020
Engineering, Indian Institute of Technology Bhubaneswar
• ALUMINIUM –THE WAY AHEAD - Mr. Apte Ashish, Segment Manager, Fronius India Pvt.
Limited
• FORCED CONVECTION NETWORK IN POTS – A DESIGN ASPECTS FOR INSTALLATION - Mr.
Maheswar Behera, Consultant – Aluminium Industries
• METALLURGI CAL INVESTIGATION OF CRACK IN JACK BODY OF RUDDER PCU OF A MILITAR
Y AIRCRAFT - V. Ram Prasad, Vaisakhi Nandi & Dr. R R Bhat - Central Materials & Processes
Laboratory, Foundry & Forge Division, Hindustan Aeronautics Limited (HAL)
• PROVIDING EXPERIENCE FOR BIG PROJECTS - Mr. Carmelo Maria Brocato,,Head of the
Vol. 20
Aluminium Division, GMS/Engitec Group
Issue No. 1 & 2,
• FUTURE OF ALUMINIUM DIE CASTING INDUSTRY IN INDIA
Hetvi Sheth, CEO, Director, Hetpan Die Lubricants Pvt. Ltd.
April & July 2020
• BREAK THROUGH PATENTED TECHNOLOGY ULSONIK™© - THE ULTRASONIC TREATMENT
FOR ALUMINUM ALLOYS CASTING - Kedar Bhojak, Naresh Jain – Redshift Engineering LLP
• HERTWICH ENGINEERING – PREFERRED PARTNER OF ALUMINUM CASTHOUSES - Stefan
Pelech, HERTWICH, SMS group
• ANALYSIS OF KEY-HOLE/EXIT-HOLE AND ITS ELIMINATION TECHNIQUES IN FRICTION STIR
WELDING (FSW) PROCESS - Himansu Mishra, Biswajit Rout, Truptimayee Patra, Barsa Nanda
Hrudananda Prusty, Gourahari Behera, Nilakantha Sahu, B. K. Barik – Veer Surendra Sai
University of Technology Burla
• OPPORTUNITIES AND CHALLENGES OF INDIAN ALUMINIUM INDUSTRY - Mr. Bibhu Mishra,
Vol. 19
Head - Manufacturing Centre of Excellence, Hindalco Industries Ltd.
Issue No. 4,
• ALUMINIUM DOWNSTREAM OPPORTUNITIES - Mr. Utsav Agarwal, Director, Bhoruka Fabcons
January 2020
Pvt. Ltd.
• ALUMINIUM MARKET OUTLOOK - Mr. Shankhadeep Mukherjee, Team Leader, CRU Analysis
and Company Private Limited
• ALUMINIUM EXTRUSIONS: CHALLENGES AND OPPORTUNITIES - Dr. Pratapaditya Mishra,
Additional Director General, Aluminium Association of India
• EFFECTIVE LOGISTICS MANAGEMENT: FUTURE CHALLENGE FOR ALUMINIUM INDUSTRY IN
INDIA - Mr. Sadashiv Samantaray, Executive Director (Marketing)I/c, National Aluminium Co
Ltd.
• ROLE OF DOWNSTREAM ALUMINIUM IN ENHANCING ALUMINIUM CONSUMPTION IN INDIA -
Mr. B.K. Das, GM (CP, SM & Projects), NALCO Vol. 19
• TREATMENT OF DIFFERENT FUMES IN ALUMINIUM SMELTER: A REVIEW OF PITCH FUMES IN Issue No. 3,
GREEN ANODE PLANT - Mr. Maheswar Behera, Consultant – Aluminium Industries October 2019

Vol.20 Issue No.4 JANUARY 2021 37 Aluminium Association of India

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