Energy Audit at Hindalco Thermal Power Plant, Hirakud, Sambalpur, Odisha

Hirakud Power Plant is a coal-based captive thermal power plant located near Hirakud in Sambalpur district, Odisha. The plant is owned and operated by Hindalco Industries Pvt. Ltd. The captive power plant commenced operation in 1993 with an initial installed capacity of 67.5 MW. Subsequently, the capacity was enhanced with the addition of 4 × 100 MW generating units to meet the power requirements of the Hirakud Smelter and FRP Plant. The total installed capacity of the Hirakud Captive Power Plant is 477 MW.

Coal is the primary fuel used for power generation, sourced from the Talabira captive coal mines. In addition, Electricity, Light Diesel Oil (LDO), and biomass fuel (rice husk) are also utilized as supplementary energy sources for various plant operations. The electrical energy generated is primarily used for plant auxiliary loads and process requirements.

The Hindalco Hirakud Power Plant is recognized for its outstanding environmental performance and holds the distinction of being Asia’s first ISO 14001 (BS 7750)-certified power plant. The facility’s environmental and occupational safety certifications (ISO 14001 and ISO 45001) reflect its commitment to maintaining the highest standards of sustainability and workplace safety. It has earned multiple awards for excellence in safety, environment, CSR, and sustainability, demonstrating how modern power plants are benchmarked on these key parameters. The plant has adopted comprehensive long-term environmental management practices, including achieving a high level of fly ash and bauxite residue utilization and implementing Zero Liquid Discharge (ZLD) systems. Additionally, the unit is widely recognized for its strict adherence to safety protocols and for undertaking socially responsible initiatives that contribute to the welfare of surrounding communities.

The objective of the present study is to conduct a comprehensive energy audit of the Hirakud Captive Power Plant. The audit was carried out during October 2025 to identify cost-effective energy efficiency measures that can help achieve the site’s specific energy consumption reduction goals and enhance overall operational efficiency.