Dr. Ashok Nandi, President of the International Bauxite, Alumina & Aluminium Society (IBAAS), in an exclusive interview with AL Circle, discussed how India’s aluminium industry is shifting from efficiency gains to systemic transformation. He highlighted key drivers such as decarbonisation, circular economy practices, digitalisation, and the potential of nuclear energy for green aluminium. Dr. Nandi also emphasised IBAAS’s role in fostering collaboration, supporting emerging markets, and engaging young talent to advance sustainability across the aluminium value chain.

AL Circle: As President of IBAAS, how do you see the Indian aluminium industry evolving in terms of sustainability and green technologies over the next decade?

Dr. Ashok Nandi: India’s aluminium sector will move from incremental efficiency gains to systemic transformation — driven by decarbonisation of smelters, circular economy (recycling, dross-valorisation), and cleaner alumina refining. Although the basic Bayers process of alumina production and Hall-Héroult technology for electrolysis may remain the same, there will be continuous improvements to achieve the theoretical levels of raw materials and energy consumption.   

We’re already seeing the roadmap: sessions on low-carbon smelter pathways, calciners efficiency, and red-mud CCU/circularity show the community’s priorities. Implementation will be accelerated by near-term renewables integration, tighter ESG standards, and growing global demand for ‘responsible aluminium’. For making green aluminium, it may be necessary to set up small modular reactors (SMR) as India has limited hydel power. 

AL Circle: The theme for IBAAS 2025 highlighted “Green and Smart Aluminium Industry.” What are the most promising innovations or technologies that will drive this transformation?

Dr. Ashok Nandi: Concrete technologies to watch: (a) energy-efficiency and heat-recovery systems for alumina calciners (MVR / MVR compression, heat exchangers), (b) digital twins, AI/ML for potline longevity and process optimisation, and (c) dross recovery and red-mud valorisation technologies that create circular revenue streams.

The programme featured MVR/MVR-compression presentations, AI/ML pot-longevity models, and dross-to-value talks — a clear sign these are practical, near-term enablers. However, as mentioned above, the game changing development may be the use of nuclear power to generate electricity and run the Indian smelters with the green energy.

AL Circle: How the conference facilitated collaboration between global stakeholders, including producers, researchers, and technology providers?

Dr. Ashok Nandi: The event deliberately combined multinational technology vendors, Indian producers, research institutes and standards bodies in parallel technical tracks, sponsor presentations, an ASI panel and an exhibition — creating multiple points of contact: formal sessions, sponsor demos, ASI networking and plant visits. That mix (keynotes + exhibitor slots + ASI session + plant visit) is the practical architecture for collaboration: knowledge transfer in sessions, deal/tech discovery at exhibits, standards alignment in ASI panels, and operational learning on the NALCO plant visit.

AL Circle: Decarbonisation is a major focus for the aluminium sector. What are the biggest challenges and opportunities you foresee in achieving net-zero targets?

Dr. Ashok Nandi: Challenges: (i) high electricity intensity of primary aluminium and grid decarbonisation speed; (ii) capital intensity of low-carbon retrofits and access to green financing; (iii) integrating intermittent renewables into smelters reliably.

Opportunities: (i) switching to renewable/firmed power and electrified heat, (ii) cell-level efficiency gains and digital control (reducing energy per tonne), and (iii) circular feedstocks (recycling, dross recovery) that immediately lower lifecycle emissions. The programme’s focus on renewable integration, potline/energy topics and circularity reflects these realities. In case of alumina production, it may be necessary to set up pilot plant to demonstrate technologies to process high silica low grade bauxite and improve productivity by Sumitomo process and updated improved low temperature digestion process.  

AL Circle: How is digitalisation and automation reshaping production efficiencies and operational insights in the bauxite, alumina, and aluminium value chain?

Dr. Ashok Nandi: Digitalisation is moving from pilot to plant-floor reality: the programme included Vision-AI for bauxite stockpile measurement, ML models for pot longevity, IoT-based CBM sensors, and digital prescription models for steam optimisation — all examples where data + models are producing measurable OEE (overall equipment effectiveness), energy and material savings. Think of a digital twin as a highly detailed, living computer model of physical manufacturing plant. It's like having a virtual copy of the entire aluminum smelter that mirrors everything happening in the real facility in real-time.

AL Circle: Could you share some insights on how IBAAS supports developing countries or emerging markets in adopting sustainable aluminium production practices?

Dr. Ashok Nandi: IBAAS creates an affordable, practice-oriented platform: focused technical sessions (including case studies from Indian mines, refineries. smelters and downstream facilities), vendor demonstrations of costed solutions, ASI-led sessions on responsible sourcing, and release of market research reports tailored to India/region — all aimed at lowering the adoption barrier for emerging markets. By spotlighting implementable technologies (e.g., low-grade bauxite processing, heat recovery, flocculants, dewatering aids) and enabling networking with vendors and financiers, the conference accelerates practical uptake in developing contexts.

AL Circle: How does IBAAS plan to engage young professionals and researchers to sustain innovation momentum in the aluminium sector?

Dr. Ashok Nandi: We’re building pipelines via: student / research scholars presentations and technical posters, prize/ best-paper awards to recognise early-career work, and field visits that expose juniors to plant operations. The conference’s inclusion of academia-industry panels, and awards is an explicit strategy to surface and retain talent in the sector. Sustained engagement will add mentorship programmes. Further IBAAS organizes monthly online free lecture series for large number of aluminium industry professionals and research scholars / students.  

AL Circle: Can you highlight any standout research or technological breakthroughs showcased at this year’s conference?

Dr. Ashok Nandi: A few highlights from the programme: (a) technological approaches for utilising high silica bauxite (papers by Takuo Harato and George Bánvölgyi) and low-grade Indian bauxite (IB2 keynote) that can expand feedstock availability; (b) CCU concepts for red-mud turning waste into anthropogenic soils; (c) machine-learning models for pot longevity and predictive maintenance; and (d) dross recovery processes and new technologies turning by-products into saleable streams. Each of these demonstrates practical R&D moving rapidly toward commercialization. There was an award-winning paper on de-ironing of bauxite by carbo-chlorination process, which was highly appreciated by IBAAS delegates as this may lead to import substitution.

AL Circle: What is your outlook for the future of IBAAS?

Dr. Ashok Nandi: IBAAS will extend the momentum of this conference and exhibition through continuous webinars and technical dialogues on latest aluminium industry developments, decarbonisation, online lecture series, and partnerships with academia and start-ups to accelerate technology commercialisation. With the collective effort of government, industry and research institutions, India can lead the global transition toward a green, smart and inclusive aluminium industry.