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The COVID-19 pandemic severely disrupted the global metalMetals sector, necessitating the temporary shutdown of Potline 3 at Hindalco’s Renukoot smelterSmelter. This paper outlines the strategic planning and execution employed to restart Potline 3 after a 1.5-year hiatus, prompted by improving market conditions and rising London MetalMetals Exchange prices. Key challenges included the simultaneous startup of 40 pots under rectifier constraints and securing critical materials. A dedicated task force of experienced managers and skilled workers successfully energized 40 pots within 10 h, achieving a significant operational milestone. This initiative resulted in a production gain. The following details the various efforts and obstacles encountered, highlighting the essential role of strategic planning, cross-functional teamwork (including Rectifier, Pot Room, CarbonCarbon, Services and Fire & SafetySafety teams), and accountability in overcoming industrial challenges and attaining operational excellence.

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Restart of Potline 3 at Hindalco Renukoot Smelter

  • 会议论文

  • 发表日期：

    2025年

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  • Piyush Mishra,
  • Gunakrithika Arumugam,
  • Manoj Kumar Dutta,
  • N. P. Singh

摘要

The COVID-19 pandemic severely disrupted the global metalMetals sector, necessitating the temporary shutdown of Potline 3 at Hindalco’s Renukoot smelterSmelter. This paper outlines the strategic planning and execution employed to restart Potline 3 after a 1.5-year hiatus, prompted by improving market conditions and rising London MetalMetals Exchange prices. Key challenges included the simultaneous startup of 40 pots under rectifier constraints and securing critical materials. A dedicated task force of experienced managers and skilled workers successfully energized 40 pots within 10 h, achieving a significant operational milestone. This initiative resulted in a production gain. The following details the various efforts and obstacles encountered, highlighting the essential role of strategic planning, cross-functional teamwork (including Rectifier, Pot Room, CarbonCarbon, Services and Fire & SafetySafety teams), and accountability in overcoming industrial challenges and attaining operational excellence.