Anurag Udayabhanu
Chemical Engineering Intern @National Aluminium Company Limited - Nalco
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WORK HISTORY
Chemical Engineering Intern @National Aluminium Company Limited - Nalco
Angul, IN
Worked in the Potline Operations Department at NALCO, Angul, gaining detailed exposure to industrial aluminium smelting using AP-18 prebaked anode Hall–Héroult technology. Studied electrolytic reduction of alumina dissolved in a cryolite-based bath across ~960 pots operating at ~180 kA DC and ~4.25–4.30 V. Learned the impact of anode–cathode distance (ACD), bath composition (Na₃AlF₆–AlF₃–CaF₂), excess AlF₃ control, and alumina concentration on pot voltage, current efficiency, energy consumption, and metal quality.Actively observed potline operations including alumina feeding (point feeding), skimming, metal tapping using vacuum ladles, bath correction, anode changing, anode beam raising, anode gauging, and covering practices. Performed data-based material and energy balance calculations using Faraday’s law, accounting for alumina consumption, carbon consumption, CO₂/CO generation, and bath chemistry corrections.Gained strong understanding of pot abnormalities such as anode effect, hot and cold pots, sludging, metal/bath turnover, clad failure, mushroom formation, and fallen anodes, along with corresponding corrective actions involving ultra-fast feeding, RC/RS adjustment, bath chemistry tuning, and SOP-driven interventions.Studied carbon anode manufacturing across the Green Anode Plant, baking furnace, and rodding shop, covering coke grinding and classification, kneading with coal tar pitch (~85:15 CPC:pitch), vibro-compaction, baking up to ~1150°C, rodding, and recycling of butts and bath via CRS.Focused on environmental control systems including Fume Treatment Plants (FTP/GTC), dry scrubbing with alumina adsorption, baghouse filtration, HF capture, and reuse of fluorinated alumina. Completed a technical study on chimney design and advanced dust-control strategies, evaluating high-efficiency bag filters, ceramic filters, and hybrid ESP–baghouse systems for emission reduction in smelter operations.
EDUCATION
Saraswati Vidya Mandir,Neelakanthanagar,Berhampur(2020-2022)
12th passout (CHSE.ODISHA)
Mohan Subudhi High school.Badamba (2018-2020)
10th passout (BSE ODISHA)
Veer Surendra Sai University Of Technology (VSSUT,Formerly UCE), Burla
Bachelor of Technology - BTech, Chemical Engineering
ABOUT ANURAG UDAYABHANU
I am a Chemical Engineering undergraduate with a strong interest in process industries, energy systems, and sustainability. I had completed an industrial internship at NALCO, Angul (Potline Department), where I gained practical exposure to large-scale aluminium production through electrolytic reduction of alumina. My learning included handling of calcined alumina from the NALCO Damanjodi, fluorination at the Fume Treatment Plant (FTP), real-time application of Faraday’s laws in high-current (~180 kA) potline operations, and a clear understanding of carbon anode manufacturing from raw material proportioning (≈85% calcined petroleum coke and ≈15% coal tar pitch) to green and baked anode production in the carbon area.Alongside industrial exposure, I have worked on core academic projects including plastic waste pyrolysis for fuel production with a data-driven approach, CO₂ conversion to methane (CH₄) using photoelectric film-based concepts, and advanced wastewater treatment processes such as Advanced Oxidation Processes (AOPs), ion exchange adsorption, electrocoagulation, and supercritical water oxidation.My academic foundation is built on strong core chemical engineering subjects—heat transfer, mass transfer, chemical reaction engineering, fluid mechanics, and process dynamics and control with instrumentation. I also have hands-on experience in process simulation and modeling using CHEMCAD, Aspen HYSYS, DWSIM, and MATLAB.I am keen to apply my technical knowledge and problem-solving skills in process, energy, materials, and sustainability-driven roles, and I am actively looking for opportunities that offer meaningful industrial exposure and real-world engineering challenges.
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