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Sulphuric Acid on the WebTM Technical Manual DKL Engineering, Inc.

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Acid Plant Database  October 25, 2016

Owner Hindalco Industries Limited - Birla Copper

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Location AT & PO
Dist Bharuch Gujrat
Background Birla Copper is a unit of Hindalco Industries Limited www.hindalco.com
Part of the Aditya Birla Group
Website www.birlacopper.com
Plant Plant No. 1 Plant No. 2 Plant No. 3
Coordinates* 21° 42' 9" N, 72° 32' 19" E
Type of Plant Metallurgical
Gas Source Copper
Ausmelt Smelting Furnace and PS Converters
Plant Capacity 1,470,000 MTPA
Emissions - - -
Status Operating Operating Operating
Year Built - - -
Contractors MECS MECS MECS
Remarks - - -
Two-stage Dynawave Scrubber in gas cleaning system

Three Sulphuric Acid plants are installed with a total capacity of 1,470,000 TPA based on the DCDA process.  The plant design is provided by Monsanto Envirochem (USA).  The off gases from smelting furnace and PS converter containing Sulphur Dioxide (SO2) are delivered to the gas cleaning section-comprising two stages of reverse jet scrubbers.  Cleaned gases from final reverse jet scrubber are fed to two stage electrostatic precipitators to eliminate mist and residual dust particles from gases.  SO2 rich gases are further processed and converted into sulphuric acid of commercially acceptable quality.   Substantial storage capacity and a 3.5 km long pipeline feed sulphuric acid to vessel directly from storage tank.

Pictures Birla Copper 1.jpg (164077 bytes)
General Hindalco Industries Limited, through Birla Copper, has set up a mega Greenfield Copper Smelting and Refining complex at Dahej in Bharuch district of Gujarat, INDIA. The plant with an investment of Rs. 25,000 in Millions, Produces world class copper cathodes, continuous cast copper Rods & Precious Metals. Apart from Copper products, Sulphuric Acid, Phosphoric Acid, Di-Ammonium Phosphate and other Phosphatic Fertilizers are also produced. The plant has its own Power Plant and Jetty to meet its infrastructure requirement.

Hindalco Industries Limited, A flagship company of the Aditya Birla group. Birla copper is a unit of Hindalco Industries Limited. The Turnover of Birla copper for the year ended in March 2006 was of Rs 53,800 in Millions.

Hindalco's premier custom copper smelter with a capacity of 100,000 tones per annum commenced commercial production in May 1998. In less than a year of operation, it emerged as a market leader in the Indian copper industry. In the year 2001 the capacity was further increased to 150,000 TPA of   refined copper through debottlenecking. The production capacity has been further increased to 500,000 TPA in two more stages. The Company is also aggressively developing value-enhancing strategies for its existing products.

Reference -
News September 14, 2016 - Hit by oversupply and depressed prices of metals, the outlook for leading aluminium and copper producer Hindalco is "challenging" in the short term, its Chairman Kumar Mangalam Birla said today.  Besides, high imports will continue to impact sales of the flagship company of the USD 41 billion Aditya Birla Group, he added.  Speaking at Hindalco's annual general meeting, Birla said: "Notwithstanding the strong operational performance, the short term outlook is challenging given the structural oversupply and depressed pricing scenario. The sharp increase in imports will continue to impact sales."  However, on the positive side, he said demand in India is expected to be strong, as the firm sees an improved outlook on industrial and infrastructure growth.  "The government's thrust on the power sector works well for the aluminium and copper industry. We are also sharpening our thrust on downstream value added products in India, as these yield better realisation," Birla noted.  On the aluminium industry scenario in 2015-16, he said the industry witnessed significant challenges as the average realisations crashed.  The average aluminium London Metal Exchange (LME) price was 16 per cent lower than the previous year, while the premium was down by 68 per cent as compared to that of 2014-15.  Regardless, aluminium demand continued to remain strong. The cost deflation, especially energy costs coupled with depreciation of several local currencies vis-a-vis USD, resulted in a sharp decline in the aluminium cost curve.  "This exerted a lot of pressure on LME prices. Currently, though the prices appear to have bottomed out. In the Indian context, the demand scenario has been encouraging. The expected economic turnaround and improving industrial activity bode well for Hindalco," Birla said.  The decline in coal prices in India was a major relief. Depreciation of the rupee also helped Hindalco to an extent. However, the overcapacity in China and the consequent flooding of aluminium in the Indian market severely upset the balance, as imports surged in 2015-16, he added.  In the case of copper, Birla said 2015 was a challenging year. Refined copper consumption growth declined sharply from 5.5 per cent in 2013 and 4.6 per cent in 2014 to 1.6 per cent in 2015.  The global refined copper consumption in 2015 calendar was around 22 million tonnes (MT). This fall in consumption growth trajectory was primarily on account of slower growth in Chinese demand and de-growth in Japanese consumption, he said.  Copper demand is facing challenging times as China is moving away from an investment-led to a consumer-driven economy.  By-product prices, especially sulphuric acid and fertilisers, were also supportive as local demand was good, Birla said.  Birla opined that the expected revival in domestic demand, especially in the power and housing sector, portends well for Hindalco.  Given the improvement in Indian GDP, co-product prices are expected to be encouraging, which should bolster the copper business. With the increasing thrust on the agriculture sector, the demand for DAP and sulphuric acid should rise too, he added.  Talking about the company's performance, Birla said the aluminium business posted its highest ever production, crossing the 1 MT mark for the first time.  Hindalco's three greenfield projects -- Utkal, Mahan and Aditya Aluminium -- have now ramped up to their full capacity.  The copper business, a strategic component of Hindalco's portfolio, continued to deliver robust operational and financial performance, supporting the Indian business.  The company registered a consolidated turnover of USD 15 billion.  On Novelis, its wholly-owned subsidiary, Birla commented it faced significant head winds as the firm continued to ramp up production from the newly commissioned facilities.  A sharp decline in regional premium (which unlike the LME cannot be hedged) resulted in a metal price lag that adversely affected its financial performance throughout the year.  Operationally, Novelis clocked a strong performance. This was primarily achieved on back of a sharp focus on the product portfolio, which resulted in a higher realisation, he noted.  Going ahead, Birla said Hindalco's thrust will be on operational excellence and increasing the productivity of new assets, cash conservation and de-leveraging.  The firm has already secured around 25 per cent of its coal requirement in the recently concluded coal linkage auctions, he added.  This, along with the existing linkage for Renusagar power plant and captive coal mines, will provide adequate coal security and good visibility to power cost for aluminium production, he noted.

November 8, 2010
- Hindalco Industries Ltd has informed BSE that due to the breakdown of cooling tower of Sulfuric Acid Plant - 3 of the Copper Plant located at Dahej, Gujrat, there is a disruption of production in Smelter-3. The repair of the cooling tower is expected to be completed within a couple of weeks and after which normal production from Smelter-3 is expected to commence. This may cause loss of cathode production of around 8000MT.   The Company has adequate insurance policy covering the loss due to such breakdown and loss of profit.

MTPD - Metric Tonne per Day           STPD - Short Ton per Day
MTPA - Metric Tonne per Annum      STPA - Short Ton per Annum
SA - Single Absorption
DA - Double Absorption

* Coordinates can be used to locate plant on Google Earth