ABOUT BIRLA COPPER AT DAHEJ

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
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 2010 was of Rs 1,25,364 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 5, 00,000 TPA in two more stages. The Company is also aggressively developing value-enhancing strategies for its existing products. Click on Hindalco for detailed information.

Birla copper is an ISO 9001, 14001 and OSHAS 18001 certified company, Registered on London Metal Exchange as Grade A Copper Brand and Certified as a Star Trading House having NABL accredited labs for chemical, mechanical and electrical testing and is the only manufacturer of 19.6 mm diameter Copper Rod in India, which is largely used for Overhead Copper Trolley wire and Rectangular Strips.

For over five decades, the Aditya Birla Group has been committed to the future of India. Its quality products and commodities reach out to the core sector in industries such as Aluminum, Copper, Cement, Viscose Staple Fiber, Textiles, Chemicals, Fertilizers, Carbon Black, Petroleum Refining, Power, Telecommunications and Financial Services - all plays vital role for the growth of the nation.

COMPANY PROFILE

1)VISION & MISSION

OUR VISION

TO BE A PREMIUM METALS MAJOR, GLOBAL IN SIZE AND REACH, WITH THE PASSION FOR EXCELLENCE.

OUR MISSION

TO RELENTLESSLY PURSUE THE CREATION OF SUPERIOR SHAREHOLDER VALUE BY EXCEEDING CUSTOMER EXPECTATIONS PROFITABLY, UNLEASHING EMPLOYEE POTENTIAL AND BEING A RESPONSIBLE CORPORATE CITIZEN ADHERING TO OUR VALU
ADHERING TO OUR VALUE.


OUR GOAL


TO REACH PRODUCTIVITY AND EFFICIENCY NORMS THAT ARE INTERNATIONAL BENCHMARKS FOR A COST CONSCIOUS MANAGEMENT OF BUSINESS OPERATIONS WHICH WILL NOT ONLY MAXIMISE SHAREHOLDER VALUE BUT ALSO CREATE COST EFFECTIVE OPTION FOR OUR CUSTOMERS. THESE WILL BE ACHIEVED BY ADOPTING HIGHEST BUSINESS VALUES AT ALL LEVELS.


OUR VALUES

      1.      INTEGRITY .

2. COMMITMENT.

3. PASSION.

4. SEAMLESSNESS.

5. SPEED

2)INFRASTRUCTURE

Plant Product  Rated Capacity ('000 TPA) Technology Provider Smelter Copper Anodes 500 1.Outokumpu Engg. Contractors Oy, Finland.   2. Ausmelt Technology, Australia Refinery Copper Cathodes 500 MIM, Australia. CCR Continuous Cast Copper Rods 120 Southwire, USA. Sulphuric Acid Sulphuric Acid 147 Monsanto-Environ, USA. Phosphoric Acid Phosphoric Acid 180 SNC - LAVALIN, Belgium. Di - Ammonium Phosphate Di - Ammonium Phosphate 400 Incro, Spain.

To ensure smooth operation, Birla Copper has committed substantial resources to the infrastructure development around the unit.
The Oxygen Plant has a production capacity of 2194 tonnes/day (TPD) of Oxygen ( 95% purity ). After providing for the captive requirement, some of the surplus liquid Oxygen and liquid Nitrogen is offered for sale in the open market.

                                                          Captive Jetty

A Jetty capable of berthing ships up to 70,000 DWT and equipped to handle 4.5 million tonnes per annum of solid cargo like copper concentrates, rock phosphates, coal and liquid cargo like phosphoric acid and ammonia.
Captive Power Plant has been installed as a vital step towards making the operation self-sufficient in its energy requirements. The combined power generation from coal based plants and waste heat boiler cogeneration is about 67.35 MW. 

                                               Captive Power Plant

 

PRODUCT PROFILE

COPPER CATHODS

Birla Copper Cathodes are square shaped with purity levels of 99.99% copper and made by Mount ISA electro-refining process. These cathodes meet international quality standards BSEN 1978:1998 Cu-Cath-1 / ASTM B-115 (1999), and are characterized by high grade with lowest level of various group elements and individual impurities. Birla Copper Cathode is a trusted brand name for high purity and consistent quality, and is registered as LME A Grade. They are characterized by a high grade with the lowest levels of various group and individual impurities.
Cathodes are largely used in the manufacture of copper rods for the wire and cable industry, and copper tubes for consumer durable goods. They are also used for making alloys such as brass, bronze and alloy steel, and find application in diverse areas like defense, mint and construction.

Logistic and transportation

BC Cathodes are delivered by road to the company's port storage and handling facilities for sale in export markets. A contracted fleet of containers carrying trucks for copper is used. An adequate trucking fleet is available. Copper is also shipped on break bulk cargo from the company's captive jetty at Dahej. Copper is delivered to our customers in India on a CIF basis.

                                                       Fl ash Furnace

  

                                                 Copper Smelter

                                             

                                               Anode Furnace

 

Anode Casting

 

                                                Electrolytic Refinery

Continuous Cast Copper Rods

                                   Continuous Cast Copper Rod Plant

Birla Copper Continuous Cast Copper Rod meets all the requirements of international quality standards. Available in 8, 11, 12.5, 16 and 19.6 mm dia.

	Excellent surface finish for processing to enamelled, Coated and Plated wires and strips.
	Its homogeneous structure and finer grain size leads to outstanding drawability. i.e. it can be drawn to ultra fine wire with high productivity. Due to its high quality, Birla Copper Rod is considered as the right choice for:
	·  Power and Communication Cables ·  Strips for power and distribution for Transformers ·  Magnet wire ·  Zari manufacturing
	Copper Rods with larger diameter (11, 12.5, 19.6 mm) is utilized for production of Profiles, Busbar and Rectangular strips for Transformer winding.

                                                              Dry Cargo Handling
                                  DAHEJ HARBOUR AND INFRASTRUCTURE LIMITED (DHIL)
                        ( Use the efficient and Customer Friendly Port and Feel the difference)

                               ( Latitude 21 degrees 42 North longitute 72 degrees 31.5 east )
      HIGHLIGHTS

• All weather deep water  direct berthing Jetty in GULF OF KHAMBHAT on West Coast of India
• Ideal location from geographical point of view. 50 Kms from Bharuch linked with two lane road with NH-8 and Broad gauge Rail connection at Bharuch with good Rake Loading facilities. Good availability of trucks well connected with Hinterland. Ideal place for users of Maharashtra, Punjab , MP , Gujarat, Rajasthan
• Ideal location from Hydrographical point of view. Draft Available 13 Mtrs
• Present  handling Capacity of 4.5 Million MT of solid bulk cargo
• Berthing Capacity of vessel up to 70,000 DWT in fair weather. Can Handle Gearless Vessel and thus contributing enormously in savings in Ocean Freight.
• State-of-the-art material handling equipment. Kangaroo type Unloaders with separate grabs to handle Coal, Copper Concentrate and Rock phosphate. Four Autos tension Winches of 120 T pull to hold the ship in position alongside berth. Pipe conveyor, which brings material from jetty to unloading area.
• Fast turnaround of vessels
• Well trained and efficient manpower.
• Round the clock security system

Sulphuric Acid

Birla copper produces Sulphuric Acid (also known as oil of vitriol, dipping Acid) of IS 266-1993 Technical Grade. It has great affinity for water, making it strong dehydrating agent, it is a valuable electrolyte and a strong oxidizing agent.

Three Sulphuric Acid plants are installed with a total capacity of 14, 70,000 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 3.5Km long pipeline feed sulphuric acid to vessel directly from storage tank.

Phosphoric Acid

The Phosphoric Acid plant is based on Prayon Mark IV Dihydrate Technology provided by SNC Lavalin (Belgium). Phosphoric acid is produced by reacting Rock phosphate with Sulphuric acid. The plant is debottlenecked to produce 1, 80,000 TPA of merchant grade Phosphoric Acid (52 - 54%). This plant also has a fluorine recovery section, which produces Hydro Fluosilicic Acid (18% to 20%) concentration.

 

Phosphoric Acid Plant

Fertilizer

The fertilizer plant has 400000 TPA capacity. Plant went on stream in October 2000, designed by Incro Spain. It is designed to produce DAP (Di-ammonium Phosphate) and NPK grades 12:32:16 & 10:26:26.

 PHOSPHO GYPSUM
(CaSO4.2H2O)

SOURCE:	From Phosphoric Acid Plant
PHYSICAL PROPERTIES:	Powder Form
SIEVE   ANALYSIS:	BSS Mesh	( % Passing)
	72 (211 Micron)	96
	170 (89 Micron)	64.3
CHEMICAL ANALYSIS: (On Dry Weight Basis)	CaSO4	92 to 95%
USES:	Cement manufacturing, Bricks manufacturing, Gypsum Board, Plaster of Paris (POP), Filler for fertilizers,

                                              COPPER SLAG
                                                                 (IRON SILICATE)

SOURCE:	Produced during Smelting of Copper
PHYSICAL PROPERTIES:	Granulated, Black in colour
	Hardness:	6 to 7 Moh's Scale
	Specific Gravity:	3.51
	Bulk Density:	1.87 (Kg/l)
	Electrical Conductivity:	2 (mS/m)
SIEVE   ANALYSIS:	SIEVE  SIZE(mm)	RANGE( % )
	-4.00  to +3.00	2 to 4
	-3 to + 2.36	3 to 12
	-2.36 to +1	40 to 55
	-1 to +0.5	15 to 30
	-0.5 to +0.212	6 to 12
	-0.212 below	0.2 to 1.0                                              MAJOR IMPORTS Item Short specification Copper concentrate 1.2 - 1.5 Million MT Floatation Sulphide Concentrate Rock Phosphate 5,00,000 MT For producing phosphoric acid Coal 5,00,000 - 6,00,000 MT For power generation. Ammonia 60,000 - 90,000 MT In liquid form through Ships Category Item Annual Quantity UOM Short specification Fuels Furnace Oil 18,000 KL     Naphtha 25,000 MT     Propane 9,000 MT   Bulk consumables/Chemicals Quartz 15,000 MT Size:10-40mm and 10-20 mm   Silica 180,000 MT SiO2 : 95% min, Size : 1 mm Phosphoric Acid MT P2O5 = 52%, Sea Tankers Coke Breeze 7,000 MT FC : 70% min., Size : 5-8mm Barium Sulphate 2200 MT BARIUM SULPHATE,92%PURITY, LOSS ON IGNITION:<0.2%, MESH SIZE:98% PASSING THROUGH 240 MESH SIZE Wax Microcrystalline 19 MT WAX (MICROCRYSTALLINE)BE SQUARE 175 BLACK VIS,SUS@210F,ASTM D88:79.0-111.0,MELTING - POINT, ASTM D-0127,F:177.0-187.0,PENETRATION ASTM D-1321,@77F:13.0-20.0,@110F:44.0-84.0 Borax (Anhydrous) 170 MT BORAX (ANHYDROUS), Na2O :30.66%, B2O3: 68.87% H2O : 00.47%,IMPURITIES : Chlorides : 0.0064% Sulphate :0.0345% Limestone Chips 1300 MT Size: 10-25 mm Limestone Powder 2300 MT Size: 1-3 mm Hydrated Lime 35000 MT Purity: 87% min. GRAPHITE ELECTRODE 140 MT 400MM X 1800MM NOMINAL LENGTH WITH SUITABLENOPPLES 03 NOS LIFTING PLUGS AVITONE A                  6,000 MT AVITONE A - HYDROCARBEN SODIUM SULFONATE FERRO SILICON                      75 MT FERRO SILICON AS PER IS 110/1981, Si:70-75% MIN, PHOSPHORUS: 0.02% MAX, CARBON: 0.15% MAX, SULPHUR:0.02% MAX, ALUMINIUM: 1.5% MAX, SIZE:25-150 MM Refractory Refractory Castable         55 % 1000 MT Al2O3 55% Refractory Castable         80 % 2500 MT Al2O3 80% Refractory Castable        97 % 600 MT Al2O3 97% Magchrome Refractories 1,600 MT MgO 55% etc. Magchrome Refractories 133,000 Nos. MgO 55% etc. REFRACTORY 620 MT TABCAST - 97,WTA, CASTABLES Engineering items/spares & Others Laddles for handling of hot metals 8 MT 8 m3 & 10 m3 for handling liquid metal Mouth Liners(Anode furnace/Converter) 20 MT ANODE FURNACE /CONVERTER MOUTH LINER (DRG), HI CHROME, WT. FROM 400GM TO 1900 GM Filter bags 1,658 MT Nomex  with membrane Size:116x3145 mm Oxygen Lancing Pipe 114 MT Size : 1/4" , MS ( 8 NB pipe, Each of  5.5 Mtr length) HL-Lance Pipe 3000 MT SIZE: 4.0B X 3000 / 2000 MM LONG, C: 0.5% MAX, SI: 2% MAX, MN: 1% MAX, P&S: 0.04% MAX, NI: 4.5% MAX CR: 26% MIN & 30% MAX, MO: 0.5% MAX. Casting Ring 12 MT CASTING RING,DRG:IDG 110-175-RO COPPER COOLING JACKET 35 MT FORGED/ROLLED ALTERANATELY CASTED CONVEYER BELTS 6000 MT Various types HDPE LINER 92000 MT HDPE LINER BOTH SIDE TEXTURED, 1.50 MM THICK, FOR POLLTION CONTROL TO PREVENT ACID SEEPAGE IN THE LAND BOILER PANEL 40 MT BOILER PANEL WITH INTEGRAL TUBING, DRG. PP Bags for filling DAP/ NPK Fertilizer 6000000 Nos. Cap. : 50 Kg, Wt : 120 gm   Q1 What are the various Copper Products manufactured by Birla Copper? A. Various copper products manufactured and marketed by Birla Copper are: Electrolytic grade Copper Cathodes conforming to BS-6017/ASTM B115 CC Rods of Diameter 8, 11, 12.5, 16, 19.6 mm conforming to ASTM-B49/98 or IS-12444. Trapezoidal Copper bars of 3220 mm2 cross section area having length of 600-1300 mm & corresponding weight of 18-40 kgs.   Q2 What are various CC Rod coil weights offered by Birla Copper? A. The minimum weight that can be offered is 1000 kgs, which are manually tailor made offline. The normal preferred coil size is 3000 kgs, loaded @ three coils in a standard truck having payload of 9.0 ton. On specific request from buyers, we can offer coils of 2250 kgs with a load pattern of 4 coils per truck having pay load of 9.0 tons. The maximum coil size that can be offered is 4000 kgs. Q3 How is the packing of the coils done at Birla Copper? A. We have a fully automatic compacting & packing line. Among the Indian rod producers, Birla Copper has only acquired such a unique & sophisticated system. The salient feature of this system are: A conveyor station feeds the pre-weighed wooden pallets. Thereafter the said coil is formed on a automatic platform lift, which discharges the formed coil on a automatic electronic weighing station. The coil then moves to compacting & strapping through a roller conveyor system. Hence the coil automatically compacted & strapped before discharging to the next station, where it is covered with HDPE sheet and secured through a stretch wrapping.   Q4 What are the different steps/measures that Birla Copper undertakes at their rod plant to improve Drawability? A. Drawability, being the ratio of the number of wire breaks to the length of wire drawn basically, is a composite of rod quality as well as wire drawing practices. Our experience, sustained interactions & joint exercises did prove that the following aspects in a CC rod are the most contributing factors for obtaining right quality rod & thereby enhancing the drawability. Use of high quality cathodes as the charge material, where minimum impurities are fully kept under control in line with the international practices & standards. Efficient process control for achieving metallurgical homogeneity across an individual coil length as well as across the batches. Accurate control over temperatures of the molten metal during casting for attaining better solidification & sound cast bar. Use of AMPS (Automatic Metal Pouring System) for uniform distribution of oxides in the cast bar. Maintaining correct reduction of the stock & minimum tension inside the mill for perfect No-twist rolling. Use of high-pressure sprays to prevent extra oxides from embedding into the cast bar during the rolling operation. Optimum temperature & application of suitable pickling media to obtain correct cooling & control over surface oxides. On-line defectomat for detection and prevention of surface imperfection like flakes, seams, slivers & iron inclusions in the rod. Q5 Could Birla Copper suggest some of the measures and precautions which a user of CC Rod should take to improve drawability at users' end? A. Efficient wire drawing practices coupled with CC Rod quality can drastically reduce the breaks and add the drawability & rod performance. The common saying in wire dawing parlance goes like this "A bad rod will perform well in good wire drawing machine & a good rod even fails to perform in a bad wire drawing practice." Some of the most essentials of good wire drawing practices are: Installing proper coil handling facilities. Undertaking good mechanical & electrical maintenance of drawing machine to ensure smooth & trouble free bearings, gearboxes, pulleys & capstans in a systematic manner. Timely replacement of worn out parts is a must. Maintaining correct lubrication system including emulsion, filtration, fat concentration, pH, Water quality. Using lubricant enriched with modern additives. Regular monitoring of the health of the lubricant. Using correct profiled 'dies' with proper blending of die angles & replacing them at predetermined intervals. Maintaining the required tension level within the drawing machine through adjustments in various guiding systems. Recording, analyzing & interpreting the wire breaks in a structured manner. This may call for support from suppliers of copper, Lubricant & dies etc. Maintaining a clean & Dust free environment. Proper training to the operating people at shop floor.                          MAP                  SOURCE http://www.birlacopper.com http://www.adityabirlaminerals.com.au/ http://www.adityabirla.com/