BALCO harnesses AI for enhanced ash management and safety

Bharat Aluminium Company Limited (BALCO), a renowned name in India's aluminium industry and a subsidiary of Vedanta Aluminium has taken a groundbreaking step in ash management. By introducing a state-of-the-art Digital Ash Control Tower (ACT), BALCO is set to revolutionise its ash management practices with real-time artificial intelligence (AI) monitoring, enhancing both operational efficiency and safety.

BALCO's Digital Ash Control Tower (ACT) is a pioneering solution aimed at transforming its extensive ash management network. Utilising advanced AI, the ACT provides real-time monitoring to ensure strict compliance with ash management guidelines. This cutting-edge technology significantly improves the management of the ash handling fleet, streamlining transportation, and ensuring road safety through enhanced traffic management.

Fly ash, a by-product of thermal power generation finds applications in diverse sectors such as brick manufacturing, road construction, infrastructure projects, and agriculture. In alignment with its circular economy agenda, BALCO has partnered with various industries to facilitate the sustainable use of fly ash. In FY24 alone, BALCO supplied over 4 million metric tonnes of fly ash, achieving an impressive 141% utilisation rate. These efforts underscore the company's dedication to resource efficiency, carbon emission reduction, and conservation of energy and water.

The ACT is equipped with a robust 24x7 monitoring system, featuring Advanced Driver Assistance System (ADAS) technology that enhances fleet safety. ADAS detects and alerts drivers to blind spots, reducing the need for manual checks and enabling proactive decision-making. The system's geofencing and camera capabilities support real-time AI-based Video Telematics, providing comprehensive visibility into driver behaviour and enhancing risk management.

BALCO's commitment to digital innovation extends beyond ash management:

- Finished Goods and Coal Control Towers: These towers offer a live 24x7 monitoring dashboard with real-time GPS tracking and speed monitoring, ensuring smooth operations.

- Advanced Safety Systems: Integration of AI-driven ADAS and Driver Monitoring Systems (DMS) enhances vehicular safety.

- Health, Safety, Security, and Environment (HSSE) Monitoring: T-Pulse HSSE System employs advanced AI models and cameras to monitor plant activities in real-time.

- Training and Workforce Connectivity: Augmented and Virtual Reality Training Centres, Video Analytics, a Sustainability Mobile App, E-learning courses, and digital workforce connectivity enhance safety practices.

- Centralised Security Operations Centre (CSOC): Leveraging digital intelligence for better decision-making in security, traffic, and supply chain management.

- Thermal Inspection and Safety Signage: Projects like the Hot Spot Detection System ensure strict safety adherence, while LED logo projectors enhance the visibility of safety messages in low-light and high-traffic areas.

Rajesh Kumar, CEO & Director of BALCO, exemplifies that digitalisation is at the core of BALCO's operations. By adopting innovative digital solutions, BALCO aims to achieve operational excellence and sustainable aluminium production, improving efficiency and fostering a robust safety culture.