

India’s leading producer of aluminium, Vedanta Aluminium, has deployed an in-house developed Forced Cooling Network (FCN) at its mega smelter in Jharsuguda to strengthen energy efficiency and potline performance. The advanced system uses 3D Computational Fluid Dynamics (CFD) modelling to optimise thermal management in aluminium reduction cells, or pots, ensuring more stable and efficient operations.
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The innovation has already earned national recognition, receiving a Certificate of Merit at the National Energy Conservation Awards 2025 from the Bureau of Energy Efficiency under the Ministry of Power, underscoring its contribution to industrial energy optimisation.
CFD uses numerical algorithms to simulate airflow, pressure and temperature behaviour, enabling engineers to test and refine cooling performance virtually before deployment. In aluminium smelting, where even minor thermal imbalances can cause sidewall overheating and energy loss, such predictive modelling is critical. Byutilising detailed digital replicas of pot structures, ducts and airflow pathways, the FCN optimises heat dissipation prior to installation, reducing operational risk.
Commissioned on a section of a potline, the system is set for plant-wide expansion. Early results indicate energy savings of 15.3 kWh per tonne of aluminium, alongside improved thermal balance and stable high-amperage operations , key metrics for modern smelters striving to lower carbon intensity.
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.”
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