1. SUMMER INPLANT TRAINING
PRESENTED BY:-
AKSHANSH MISHRA
1021310334

2. ABOUT NALCO
 NALCO is a public sector enterprise of ministry
of mines.
 It has units in Odisha at places like Angul and
Damanjodi.
 It is Asia’s largest and the sixth largest
integrated aluminium complex,
encompassing bauxite mining, alumina
refining, aluminium smelting and casting,
power generation, rail and port operations.

3. OPERATIONS CARRIED OUT IN
NALCO
 The various operations carried out in
NALCO are divided in three major areas :-
1)CARBON AREA
2)POTLINE AREA
3)CASTING AREA

4. 1)CARBON AREA
 It consists of Green Anode Plant (GAP) , baking
oven and rodding shop.
 Green Anode Plant involves the production of
Green anodes. The word “GREEN” signifies that it is
fresh or raw.
 Raw materials used in preparation of green
anodes are Calcined petroleum coke (60-65%) ,
recycled material consisting of butts (22-25%)
returned from pot room and green scrap (5%) of
various sizes in definite proportions with coal tar
pitch used as binder. These fractions are drawn as
per defined recipe

5.  Processes carried out in GAP are
following:-
- Crushing and classification of dry
aggregates.
- Mixing in proportion of dry aggregates.
- Addition of pitch and paste forming.

6. In Crushing process the Calcined petroleum coke are crushed
and are classified according to their sizes:-
Very coarse dry aggregates (22%)
Coarse dry aggregates (20%)
Medium dry aggregates (22%)
Fines (25%)
Other recycled (11%)
Green recycle (4%)

7.  The carbon materials are continuously
mixed to produce homogenous paste
before moulding it into green anode
blocks on vibro compacting machines
simply known as VIBROCOMPACTORS .

8. In the furnace the green anodes are slowly
heated up to the range of 1100-
1120(degree Celsius) and slowly cooled
down again. The objective of green anode
baking is to transform its binder pitch into
pitch coke so as to produce the baked
anodes

9.  The water sprayed to cool down anodes
is collected under the cooling tunnel and
routed to the settling tank where it is
cleaned from the coke particles and dust
before being sprayed again on anodes.

10. EQUIPMENTS USED IN GAP
 1) BUCKET ELEVATORS

11.  2) BALL MILL is a type of grinder used to
grind the materials into extremely fine
powder for use in mineral dressing
processes

12.  3) HAMMER MILL
 . The material is crushed or shattered by
the repeated hammer impacts, collisions
with the walls of grinding chamber as well
as particle on particle impacts.

13.  4) SCREENING
 Screening of the calcined petroleum
cokes are done to separate in
accordance with their sizes i.e. very
coarse dry aggregates, coarse dry
aggregates, medium dry aggregates and
fines.

14.  5) DYNAMIC CLASSIFIERS
 Dynamic classifier separates the coarse
from fine coal by allowing the fine coal to
pass and rejecting the coarse particles for
regrinding. If the centrifugal force
experienced by the particle is greater
than the drag force than the particle is
rejected for regrinding.

16.  6) CYCLONE SEPERATOR
 A high speed rotating flow is generated
within a cylindrical or conical container
called a cyclone. Rotational effects and
gravity are used to separate mixtures of
solids and fluids