Jharsuguda (Odisha): Vedanta Aluminium, India’s largest producer of aluminium, has deployed a state-of-the-art cooling system, termed the Forced Cooling Network (FCN), at its mega aluminium plant in Jharsuguda.
Developed inhouse, the innovation uses advanced 3D Computational Fluid Dynamics (CFD) modelling to enhance thermal management in aluminium reduction cells (commonly known as pots). The FCN technology has been recognised with a Certificate of Merit at the National Energy Conservation Awards 2025 by the Ministry of Power’s Bureau of Energy Efficiency.
CFD uses numerical algorithms to simulate fluid behaviour, such as airflow, pressure, and temperature, allowing engineers to optimise system performance without relying solely on physical testing. In aluminium smelting, this precision is critical for preventing sidewall overheating, maintaining protective layers, reducing energy loss, and en suring stable, efficient pot operations. Leveraging detailed digital replicas of pot structures, cooling ducts and airflow pathways, the FCN uses CFD simulations to optimise heat dissipation before installation.
The system has been commissioned on a section of a potline at Vedanta Aluminium’s Jharsuguda plant, with plans underway to scale it across the entire potline. By ensuring precise sidewall temperature control, the FCN enables stable highamperage operations, better thermal balance and enhanced overall performance. It has already delivered measurable gains, including energy savings of 15.3 kwhper tonne of aluminium produced.
Vedanta Jharsuguda CEO C. Chandru said,”Innovation is at the heart of everything we do at Vedanta Aluminium. By combining digital precision with practical engineering, we have not only strengthened the stability of our potlines but also improved the overall energy efficiency ofour operations. This achievement is a testament to the ingenuity of our teams and sets a new benchmark for sustainable aluminium production in India.”
