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Smarter Operations; Stronger Output

At Vedanta, we believe in doing more with what we have. Over the past year, our world’s largest single location smelter at Jharsuguda achieved a 2.3% increase in its production capacity – without any additional capital investment. This was made possible through targeted technical upgrades, advanced technologies, process optimisation, and operational excellence – reinforcing our focus on self-reliant, sustainable production in line with its ESG commitments.

Business

IMPACT STATEMENT

1,830 KTPA from 1,787 KTPA

Smelter’s design capacity increased through interventions aligned with global GAMI benchmarks

KEY INTERVENTIONS

Operated all potlines at 104% of their designed capacity

Enhanced potline stability and energy efficiency through advanced simulations

Implemented a monitoring system to manage pot health and minimise risks during capacity increases

Introduced In-house developed pot controller technology to improve pot life and increase capacity

Optimised anode coating and voltage for better performance and efficiency

MILESTONES ACHIEVED

43 KTPA

INCREASE IN DESIGN PRODUCTION VOLUME OF THE SMELTER

100%

GRAPHITISATION OF CATHODES LED TO REDUCTION IN SPECIFIC POWER CONSUMPTION

WAY FORWARD
  • Targeting full volume potential of 1,940 KTPA
  • 6% design capacity enhancement by FY 2027-28

Accelerating Exploration at KG Basin

In offshore exploration, identifying and de-risking high-impact prospects is crucial for maximising returns while minimising financial risks. The KG-DWHP-2017/1 block holds significant potential, and improving the accuracy of our subsurface imaging can increase the likelihood of success in future exploration.

Business

PROBLEM STATEMENT

To enhance our offshore exploration efforts, we needed advanced technology to improve the accuracy of subsurface mapping, identify potential hydrocarbon reservoirs, and minimise risks associated with deep-water exploration. the goal was to boost the success rate of high-impact prospects, ensuring higher returns while reducing financial uncertainties.

OUR SOLUTION
To address this challenge, we turned to Controlled Source Electromagnetics (CSEM), a cutting-edge geophysical technique that helps map the subsurface with high precision. here’s how we implemented the solution:

CSEM Technology : This technique uses electromagnetic signals to map resistivity in the earth’s subsurface, crucial for identifying hydrocarbon deposits. we partnered with EMGS's ASA, a leader in csem technology.

The system was developed through a joint project with global energy leaders Shell and Equinor, proving its reliability and effectiveness in offshore exploration.

Deep Blue Source System: EMGS's system, known as the Deep Blue Source System - 7500A, is capable of delivering up to 10,000 amps (for comparison, a typical household supply is around 5-15 amps). This technology enhances subsurface imaging, making it easier to locate potential hydrocarbon reservoirs.

Advanced Data Integration: By combining CSEM data with advanced 3D seismic data, we can make more informed decisions on where to focus exploration efforts and de-risk high-potential areas.

PROGRESS

281

RECEIVER NODES DEPLOYED USING THE VESSEL ATLANTIC GUARDIAN

Data Acquisition

COMMENCED IN APRIL 2025 AND COMPLETED BY JUNE 2025

WAY FORWARD
  • CSEM data will be processed, interpreted, and integrated with seismic interpretation
  • The prospect portfolio will be de-risked and re-ranked based on the findings
  • This will also create an opportunity to deploy horizontal deepwater wells

First Ever Women-Operated Smelter Line

At Vedanta, we believe that empowering women is not just a social commitment but a strategic priority for building a future-ready workforce. Aligned with our diversity, equity, and inclusion (DE&I) vision, we have taken a pioneering step by creating the world’s first fully and dedicated women-operated and maintained smelter potline at our Jharsuguda operations – setting a new benchmark in the global aluminium industry.

People

IMPACT STATEMENT

Guided by the philosophy of ‘Shakti Se Pragati’ (progress through empowerment), this initiative exemplifies vedanta aluminium’s commitment to driving diversity, equity, and inclusion by enabling women to lead across functions – from the shop floor to leadership roles.

OUR APPROACH

A dedicated smelter potline in the SEZ is being transitioned to a fully women-led operation

Women selected through internal postings, diversity outreach, and awareness programmes

Executed in three phases with over 100 identified roles across levels and skill sets

Intensive on-the-job training provided, supported by technical experts and senior leaders

WAY FORWARD
  • Promotes women’s participation in core manufacturing, challenging industry norms
  • Builds a future-ready, inclusive workplace
  • Strengthened by broader initiatives like:

Project Shree Shakti

Introduced night shifts for women – first in odisha’s industrial sector

Project Panchhi

Supports marginalised girls with higher education and job opportunities at vedanta

Accelerating industrial innovation through startup collaboration

Vedanta Spark is our flagship global corporate innovation, accelerator, and ventures platform that powers startup-led transformation across Vedanta’s industrial ecosystem. We connect emerging technology firms with real-world challenges across our mines, smelters, refineries, and power plants. This enables agile, scalable, and sustainable innovation. Spark delivers business impact by directly deploying cutting-edge solutions into core operations, supporting India’s broader vision of Atmanirbhar Bharat.

Technology

STRATEGIC RELEVANCE

Digital adoption in core sectors like mining, metals, and energy is complex, capital-intensive, and often slow. Yet, industrial transformation is critical to achieving higher productivity, safer operations, and stronger ESG outcomes. Vedanta Spark addresses this imperative by embedding innovation directly into operational workflows, enabling speed, scale, and sustainability across the Group.

OUR APPROACH
We collaborate with startups to address operational and sustainability challenges using next‑generation technologies.

AI, Iot, And Predictive Systems Real-time asset monitoring and AI-enabled fleet management have improved uptime, reduced energy use, and optimised emissions in mining. IoT solutions support predictive maintenance, minimising breakdowns and downtime across operations.

Digital Twins And SimulationDigital twins replicate plant conditions to support energy efficiency, waste reduction, and remote control. Deep learning aids predictive diagnostics and asset performance.

Immersive And Remote TechnologiesVR-based simulators enhance operator safety training, while drones conduct inspections for pre-extraction safety, asset integrity, and resource surveys across aluminium and oil & gas.

Computer Vision And Autonomous MiningAI-driven surveillance systems enhance safety and reduce manual monitoring. Integrated with digital twins, they support material flow and asset reliability. Tele-remote systems and autonomous vehicles are enabling safer, automated mining environments.

BUSINESS AND ESG IMPACT

US$ 18 million

OPERATIONAL COST SAVINGS

US$ 5 million

VOLUME GAINS

US$ 23 million

EBITDA IMPACT REALISED TO DATE

US$ 20 million

ORDER PURCHASE AWARDED TILL THE TIME-GENERATING TANGIBLE FINANCIAL IMPACT
MILESTONES

70+

AI-DRIVEN INITIATIVES IN PARTNERSHIP WITH OVER 30 STARTUPS

100+

INITIATIVES UNDER EVALUATION TO DEPLOY OVER THE NEXT YEAR

WAY FORWARD
Looking ahead, we aim to expand the deployment of autonomous and AI-integrated systems across additional sites, accelerating our journey toward intelligent operations. We are also focussed on broadening our startup ecosystem to address emerging sustainability priorities. As immersive technologies continue to redefine industrial training, we plan to integrate them more deeply into workforce skilling programmes.

Management Speak

Key Performance Indicators