SetConnect Case Study

Vedanta Aluminium Leverages AI to Boost Yields, Cut Emissions, and Enhance Alumina Production Efficiency

Aerial view of a large industrial complex with multiple factory buildings and smokestacks releasing steam or smoke into the sky. Surrounding areas include greenery and infrastructure such as roads and railways.

Vedanta Aluminium, India’s largest aluminium producer with a 41% market share, operates smelters in Jharsuguda & Korba (BALCO) and a refinery in Lanjigarh.

To stay ahead, Vedanta Limited - Aluminium Business aimed to leverage AI, Machine Learning, and Data Science to enhance efficiency, reduce costs, and drive innovation.

SetCONNECT GLOBAL partnered with Vedanta to turn this vision into reality.
With our Proprietary AI Playbook, a proven track record, and world-class experts, we are empowering enterprises to turn data into decisions and challenges into wins.

OUR ENGAGEMENT

SetCONNECT designed and delivered an Executive Immersion in Analytics, for senior executives across multiple Vedanta locations. The program focused on applying Al, ML, and Business Analytics to solve real world challenges. Identifying high-impact business problems, and developing data-driven solutions to enhance decision-making and efficiency.

SOLUTIONS

As part of this hands-on initiative, executives collaborated to define the scope of 15+ AI/ML-driven business challenges, achieving key outcomes like 10% lower coal transportation costs, optimized smelting for higher yield, reduced coil rejection from 24% to 6%.

BUSINESS IMPACT

The program delivered tangible business impact—

  • Optimizing production processes for higher yields

  • Reducing carbon consumption by 5 kg/MT minimizing pot leakages

  • Improving digestion efficiencies in alumina production.

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