“Forging the Future” Utkal Alumina

 

 

 

Nestled in the Rayagada district of Odisha, Utkal Alumina International Limited (UAIL) stands as a beacon of excellence within the aluminum industry, serving as a 100 percent subsidiary of Hindalco Industries Limited—a metals flagship under the esteemed Aditya Birla Group.

Positioned as a leading alumina refinery, Utkal boasts a formidable infrastructure, including a 2.12 million metric tonnes per annum (MTPA) alumina refinery and the sprawling Baphlimali bauxite mines with a staggering capacity of 8 MTPA, secured by a valid lease title until February 2048. The facility is further augmented by a captive co-generation power plant generating 90MW, complemented by a 5MW solar power plant.

The genesis of Utkal dates back to 1992-93, conceived by four corporate juggernauts—Alcan, INDAL, Tata, and Norsk Hydro Aluminium of Norway—aiming to establish an alumina refinery with captive bauxite mines. In the evolution of corporate landscapes, INDAL merged with Hindalco in 2004, culminating in UAIL’s ascent to a 100 percent subsidiary of Hindalco by the fiscal year 2008.

Utkal prides itself on being a world-class refinery, leveraging state-of-the-art technology from the prestigious Rio-Tinto-Alcan. Blessed with the highest quality bauxite as its raw material, Utkal has devised an environmentally conscious logistics network, seamlessly transporting bauxite, raw materials, and the final product—alumina—through a network of conveyors and railways. A testament to its uniqueness, the 18km Long Distance Conveyor (LDC) transporting bauxite from the Baphlimali mines is unparalleled globally. UAIL’s supremacy extends across global benchmarks, encompassing product quality, energy efficiency, and cost-effectiveness.

Catering to a substantial 70 percent of Hindalco’s smelter alumina needs, Utkal’s reach extends beyond domestic borders, supplying its high-purity alumina to both national and international markets. The premium quality alumina supplied by Utkal plays a pivotal role in empowering modern smelters to produce specialized aluminum for critical sectors such as aviation, space exploration, defense, food and beverage, and transportation.

Utkal’s journey commenced with the commissioning of its greenfield plant in 2013-14, boasting an initial capacity of 1.5 MTPA. Over the years, the plant has undergone significant expansion, reaching a formidable 2.12 MTPA and achieving operational status in August 2021. Beyond mere production figures, Utkal consistently outperforms its own benchmarks in terms of efficiency, exceeding customer expectations, fulfilling societal responsibilities, and setting unprecedented standards within the industry year after year. In essence, Utkal Alumina International Limited is not just an industrial entity; it is a dynamic force shaping the trajectory of the aluminum sector with its commitment to excellence and continual innovation.

Navigating the complexities of positioning Utkal Alumina International Limited as a market leader is no small feat, but Mazhar Beig, armed with over 30 years of experience in the mining industry, proves himself a natural problem-solver. Having ventured into the Democratic Republic of the Congo in his early 40s as the Director of Projects at Chemaf, Mazhar not only set up a copper plant but also spearheaded the expansion of the cobalt project, relishing the freedom to push boundaries at the helm.

Assuming the role of CEO in 2020, Mazhar wasted no time in implementing his innovative ideas to enhance Utkal. “My focus was to recover the ground we lost because of COVID-19 and make a strategy to expedite the project,” he explains, emphasizing a prioritized approach to critical path items while streamlining operations. The results were nothing short of remarkable as Mazhar orchestrated a swift turnaround.

Situated amidst the hills, about 50 kilometers from its headquarters in Odisha’s Rayagada district, Utkal’s refinery project faces the imperative of safeguarding the ecosystem’s integrity. Mazhar, recognizing the mining industry’s responsibility, collaborates closely with the government and local administrations to uplift the lives of the community. “Utkal has a lot of goodwill in this place,” he notes proudly. The company’s initiatives, including the provision of alternative fuel sources, have rendered locals independent of firewood. Coupled with the Indian government’s Ujjwala scheme, these efforts contribute to the restoration of greenery in the hills, employing topsoil addition and tree planting in areas previously mined for bauxite.

Mazhar’s forward-thinking extends beyond environmental stewardship to innovative socio-economic projects. Seizing the advantage of high altitudes, he has initiated a coffee project, intending to establish cooperatives among local tribes. The revenue generated from coffee sales will be redistributed to benefit the community.

Yet, Mazhar’s visionary leadership encompasses not just environmental and social initiatives but also a keen eye on technological advancements for enhanced business efficiency. Embracing Industry 4.0 metrics, Utkal is on a journey to digitize its workforce.

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