In 2004, Vedanta Aluminium Ltd. (VAL) started work on a major Greenfield Alumina Refinery with ore processing capacity of 1.4 MTPA at Lanjigarh, Orissa.

HDO was awarded the EPC for three packages:

• Settler-Washer package: This is one of the most important packages of any alumina refinery. HDO used the latest technology hi-rate thickeners for mud settling and washing circuits. Causticization package and Oxalate Removal System were part of this package as side streams.
• 10 TPH Milk of Lime package: HDO used its tried and tested in-house technology and proprietary equipment for this plant.
• Hydrate Seed Thickener package: HDO utilized state-of-art technology for efficient handling of hydrate fines in the spent liquor emanating from the overflow of the secondary cyclones. Cable torque thickeners of 35 meter diameter specially suited for handling heavy duty conditions were used for the hydrate settling circuit.

Despite difficult site conditions and unavailability of skilled work force HDO successfully completed this project and received commendation from the client for quality of work performed.

Accomplishments:

• HDO awarded Vedanta Preferred Vendor status after successful completion of this project
• Successfully delivered our first complete EPC project in Alumina industry within agreed performance guarantees
• Designed and delivered a robust system that handled ore from various sources from world over and not just the local ore for which it was initially designed and tested
• Client was extremely satisfied with HDOs role in this project and later awarded HDO INR 355 Crore worth of orders for the expansion of its Lanjigarh refinery to 5 MTPA slated for completion in 2010
• Nearly all equipment sourced in-house from HDO manufacturing facility at Vatva, Ahmedabad
• HDO did onsite fabrication of ten deep cone thickeners of 20 meter diameter for the Settler-Washer package. These are the largest deep cone thickeners ever used in any alumina refinery in India.