Vedanta Aluminium, India's largest aluminium producer, operates in a resource-intensive industry where efficiency, sustainability, and, most importantly, safety remain paramount. Under the leadership of Rajiv Kumar, CEO, the company has launched a comprehensive digital transformation initiative to implement AI, IIoT and advanced technologies across its value chain – from mining to metal production.
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“At Vedanta Aluminium, we’ve always believed that transformation begins with intent. As India’s largest aluminium producer operating in a high-risk, resource-intensive industry, our vision has been to lead not just in scale, but in intelligence, sustainability, and resilience,” says Kumar. “By embedding AI, IIoT, and advanced digital technologies across operations, we are optimising inventory management, resource planning, and demand forecasting in real time—reducing waste and ensuring seamless supply chain performance.”
This commitment can be seen in initiatives like digital smelters, predictive maintenance, and IoT-driven emissions monitoring. Even a one per cent improvement in energy efficiency can deliver annual savings of USD 4–5 million. These initiatives are transforming the conventional model of aluminium production into a model that is smarter, leaner and more resilient.
On February 13, 2025, Vedanta Aluminium took a major leap in mining safety with the launch of an AI-powered drone system at its Jamkhani coal mine in Odisha. The drone provides real-time monitoring for blasting clearance and danger zone safety.
Using sophisticated software, the system can automatically detect people, animals and vehicles within a blasting zone of up to 500 metres and stream live alerts to officials about detection. The system also enables audio communication between the officials, drone pilot, and blasting officer for safer and more efficient coordination. Additionally, the Time-in-Use Model (TUM) improves efficiency by recording coal exposure, tracking machine utilisation and assessing quality of stock.
“Safety is a key priority. The integration of AI-powered drones in our mining safety protocols is a significant step forward in ensuring a safer work environment while improving monitoring and compliance,” said Mr Rajiv Kumar.
These advances are not isolated. Through its Spark innovation platform, Vedanta is collaborating with over 70 startups on over 100 projects, from smart material handling to predictive diagnostics. Industry experts view this as a forward-looking blueprint for the metals sector, where human potential, AI and sustainability converge.
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