Aluminium industry stares at critical coal shortage
COAL & MINING

Aluminium industry stares at critical coal shortage

The highly power-dependent aluminium industry is in for a tough time ahead. This is because of Coal India Limited’s (CIL) recent move to significantly reduce coal supplies and railway rakes for Captive Power Plants (CPPs), resulting in a coal crunch for the Indian aluminium industry.

Aluminium is a metal of strategic importance and an essential commodity for diversified sectors, crucial for the nation’s economy. Aluminium smelting requires uninterrupted and high-quality power supply for production which can be met only through in-house CPPs.

Hence, such drastic curtailment of coal supplies, without any advance notice, will bring the industry to a standstill as it has been left with no time to devise any mitigation plan to continue sustainable operations. Also, resorting to imports at such a short notice is not feasible.

The Aluminium industry CPPs have signed FSA (Fuel Supply Agreement) with CIL and its subsidiaries for assured long term coal supply. Any abrupt stoppage of this secured coal supply brings the industry to a grinding halt and has a severe impact on the SMEs in the downstream sector resulting in increased prices of finished products and burdening end consumers.

Aluminium is a continuous process based highly power intensive industry wherein coal accounts for around 40% of aluminium production cost. Huge investments of Rs 1.2 lakh crore ($20 billion) have been made to double the domestic production capacity to 4.1 mtpa to cater to the country’s increasing aluminium demand. The Indian Aluminium industry has set up approximately 9000 MW CPP capacity to meet its power requirement for the smelter and refinery operations and reduce dependence on power grids.

Any power outage or failure (2 hours or more) results in freezing of molten aluminium in the pots which leads to shutting down of the aluminium plant for at least six months rendering heavy losses and restart expenses, and once restarted it takes almost a year to get the desired metal purity. The Indian Aluminium industry is already struggling to remain globally competitive due increasing production costs in India primarily due to increased power cost over the past few years with rising coal prices, increase in various duties, cess and RPO. Also, the high incidence of unrebated Central and State taxes and duties, constitutes around 15% of aluminium production cost which is amongst the highest in the world. This is adversely impacting the sustainability and competitiveness of the Indian Aluminium industry.

Being a continuous process-based power intensive industry, The Aluminium Association of India has sought the following support from Coal India to continue sustainable operations and to reduce the load on the power grid:

  • Resumption of adequate coal supply against secured linkages for sustainable industry operations.
  • Allocation of railway rakes on priority for coal dispatch to the aluminium industry.
  • Allocation of coal dispatches through rakes in proportion of 75% (power) and 25% (non-power), as per MoC circular for auction linkage, dated 15 Feb, 2016.
  • Any decision for stopping or curtailing secured coal supplies should not be taken on an ad hoc basis. The CPP based industry should be given prior notice well in advance (2 to 3 months) to devise mitigation plans for coal or power imports.

"Join industry leaders at RAHSTA Expo, India's premier platform for roads, highways and traffic infrastructure. Register now to explore innovations, network with experts and shape the future of mobility."

The highly power-dependent aluminium industry is in for a tough time ahead. This is because of Coal India Limited’s (CIL) recent move to significantly reduce coal supplies and railway rakes for Captive Power Plants (CPPs), resulting in a coal crunch for the Indian aluminium industry. Aluminium is a metal of strategic importance and an essential commodity for diversified sectors, crucial for the nation’s economy. Aluminium smelting requires uninterrupted and high-quality power supply for production which can be met only through in-house CPPs. Hence, such drastic curtailment of coal supplies, without any advance notice, will bring the industry to a standstill as it has been left with no time to devise any mitigation plan to continue sustainable operations. Also, resorting to imports at such a short notice is not feasible. The Aluminium industry CPPs have signed FSA (Fuel Supply Agreement) with CIL and its subsidiaries for assured long term coal supply. Any abrupt stoppage of this secured coal supply brings the industry to a grinding halt and has a severe impact on the SMEs in the downstream sector resulting in increased prices of finished products and burdening end consumers. Aluminium is a continuous process based highly power intensive industry wherein coal accounts for around 40% of aluminium production cost. Huge investments of Rs 1.2 lakh crore ($20 billion) have been made to double the domestic production capacity to 4.1 mtpa to cater to the country’s increasing aluminium demand. The Indian Aluminium industry has set up approximately 9000 MW CPP capacity to meet its power requirement for the smelter and refinery operations and reduce dependence on power grids. Any power outage or failure (2 hours or more) results in freezing of molten aluminium in the pots which leads to shutting down of the aluminium plant for at least six months rendering heavy losses and restart expenses, and once restarted it takes almost a year to get the desired metal purity. The Indian Aluminium industry is already struggling to remain globally competitive due increasing production costs in India primarily due to increased power cost over the past few years with rising coal prices, increase in various duties, cess and RPO. Also, the high incidence of unrebated Central and State taxes and duties, constitutes around 15% of aluminium production cost which is amongst the highest in the world. This is adversely impacting the sustainability and competitiveness of the Indian Aluminium industry. Being a continuous process-based power intensive industry, The Aluminium Association of India has sought the following support from Coal India to continue sustainable operations and to reduce the load on the power grid: Resumption of adequate coal supply against secured linkages for sustainable industry operations. Allocation of railway rakes on priority for coal dispatch to the aluminium industry. Allocation of coal dispatches through rakes in proportion of 75% (power) and 25% (non-power), as per MoC circular for auction linkage, dated 15 Feb, 2016. Any decision for stopping or curtailing secured coal supplies should not be taken on an ad hoc basis. The CPP based industry should be given prior notice well in advance (2 to 3 months) to devise mitigation plans for coal or power imports.

Next Story
Resources

Jyoti Structures Launches Heat Safety Drive Across Sites

Jyoti Structures (JSL) has strengthened heat safety measures across its project sites and manufacturing facilities as temperatures rise across India. The company has implemented a Summer Safety Plan covering all transmission line projects to address risks related to heat stress, dehydration and worker fatigue.The initiative includes rescheduling work away from peak afternoon temperatures, provision of drinking water, ORS and lemon-salt solutions, and installation of rest shelters near work areas. Daily toolbox talks, worker health monitoring, first-aid preparedness, emergency transport arrange..

Next Story
Real Estate

MHADA Declares 82 Buildings Most Dangerous in Central and South Mumbai

The Maharashtra Housing and Area Development Authority (MHADA) has declared 82 buildings as most dangerous across Central and South Mumbai and has appealed to residents to vacate immediately. The list, prepared after structural assessments by the authority, identifies buildings judged to pose imminent risk to occupants and to passersby. Local civic bodies have been asked to coordinate evacuations and to make arrangements for temporary shelter and rehabilitation for displaced households. Officials said the authority prioritised buildings with visible structural distress, severe cracking, tiltin..

Next Story
Infrastructure Transport

Damage Reported At Halwara Airport Terminal After First Rains

Severe damage was reported at the terminal of Halwara Airport during the first major rain spell of the season, prompting immediate concern among aviation and local authorities. Images from the site showed water ingress and visible deterioration of the terminal interior, affecting passenger areas and ancillary services. The airport authority suspended certain operations temporarily to assess structural safety and ensure passenger wellbeing. Preliminary inspections have prioritised electrical systems and roof seals to prevent further water ingress. State aviation officials ordered a formal inqui..

Advertisement

Subscribe to Our Newsletter

Get daily newsletters around different themes from Construction world.

STAY CONNECTED

Advertisement

Advertisement

Advertisement