Aluminium Plant Inbound Logistics — Bauxite, Alumina & Coal Tracking India

India's aluminium industry runs on three inbound logistics streams: bauxite to the refinery, alumina from the refinery to the smelter, and thermal coal for the captive power plant. Each stream operates on a different corridor, with a different value density and a different risk profile.

Most aluminium companies track none of these in real time.

Stream 1: Bauxite to Refinery

Value: ₹800–2,500/MT Volume: 2.5–3 tonnes of bauxite per tonne of alumina produced Key corridors: Panchpatmali (Odisha) to Damanjodi refinery; Lanjigarh mines to Vedanta refinery; Muri to Hindalco operations Primary risk: Volume loss on long mine-to-refinery road hauls. Quality interference (silica addition) is a secondary risk that impacts refinery yield.

Stream 2: Alumina to Smelter

Value: ₹25,000–35,000/MT Volume: ~2 tonnes of alumina per tonne of aluminium produced Key corridors: Damanjodi → Angul, Lanjigarh → Jharsuguda, Muri → Renukoot Primary risk: Highest per-tonne value in the aluminium inbound chain. Even 1% loss on a 100,000 tonne/year smelter is 1,000 tonnes = ₹2.5–3.5 crore annually.

Stream 3: Coal for Captive Power Plant

Value: ₹3,000–5,000/MT for domestic coal Volume: 13,000–15,000 kWh per tonne of aluminium = 5–6 tonnes of coal per tonne of aluminium Key corridors: CIL collieries (MCL, SECL, WCL) to smelter CPP; port imports via Paradip, Vizag for coastal plants Primary risk: Highest volume stream. A 500,000 tonne/year smelter consumes 2.5–3 million tonnes of coal annually. At 5% pilferage: 125,000–150,000 tonnes = ₹37–75 crore/year.

Unified Platform for All Three Streams

Intugine tracks all three inbound streams on a single platform:

Unified dashboard: bauxite trucks, alumina trucks, and coal trucks visible together

Per-stream risk zone configuration: different hotspots for each corridor

Single transporter management module covering all vendors across all streams

Single SAP/ERP integration: GR posting for all commodities via one API

CPP Fuel Management Integration

For the coal stream feeding the captive power plant, Intugine integrates directly with CPP fuel management:

Real-time inbound coal inventory updated on every trip completion

Calorific value data (from LIMS) linked per trip for yield tracking

Transporter reliability scorecards for CPP fuel procurement reviews