Overview

Hindalco Industries Ltd., a flagship company of the Aditya Birla Group, has consistently demonstrated leadership in environmental stewardship and sustainable industrial practices. At its Hirakud facility in Odisha, Hindalco became the first organization in the state to establish a Waste-to-Energy (WtE) plant based on Thermo-Catalytic Conversion (TCC) technology. This milestone initiative underscores Hindalco’s commitment to responsible waste management and carbon reduction.

Project Background

In alignment with its sustainability vision, Hindalco sought an advanced solution to manage and reform diverse waste streams — including industrial and municipal — through an eco-friendly process. Conventional disposal methods such as landfilling and incineration posed environmental and logistical challenges. To overcome these, Hindalco partnered with Enecovery to deploy TCC technology — a breakthrough process that converts heterogeneous waste into clean, reusable energy products while ensuring zero harmful emissions.

Implementation Phases

Phase I – Industrial Waste Reforming (2019)

The first TCC system was commissioned in 2019 at Hindalco’s industrial plant, designed to process industrial and process-generated waste, including:

• Mixed plastics and packaging residues
• Rubber waste from production activities
• Horticultural and organic residues from plant operations

Through the thermo-catalytic process, these waste materials were transformed into synthetic gas and carbon-rich char, which can be repurposed as alternative energy sources and material inputs, reducing dependency on fossil fuels.

Phase II – Residential Waste Reforming (2020)

Following the success of the first plant, a second TCC system was commissioned in 2020 within the Hindalco residential colony. This plant specifically handled Municipal Solid Waste (MSW) generated by the township, including household, kitchen, and garden waste. Its decentralized model minimized waste transport and landfill dependency, enhancing overall efficiency.

Key Achievements

• Total Waste Processed: ~400 tons (industrial + municipal)
• Carbon Footprint Reduction: Achieved negative Total Carbon Footprint (CFT) – equivalent to ~1 million kg of CO₂ offset
• Emission Control: No dioxins, furans, or toxic emissions — all parameters below global limits
• Energy Efficiency: Recovered energy and reusable by-products supporting circular economy
• Operational Sustainability: Zero effluent discharge, minimal maintenance, and full environmental compliance

Environmental and Social Impact

The implementation of the TCC Waste-to-Energy system at Hindalco, Hirakud, has set a benchmark for sustainable industrial waste management in Odisha. It has strengthened Hindalco’s internal environmental performance and encouraged neighboring industries and local authorities to explore advanced waste conversion technologies.

By adopting circular economy principles, Enecovery and Hindalco have proven that industrial progress and environmental responsibility can coexist — paving the way toward a cleaner, greener, and more sustainable future.