The Carbon Department manufactures consumable prebake carbon anodes for use in the aluminium smelting process. The Department is made up of three major sections: Green Carbon, Carbon Bake, and Rodding Room.

Green Carbon:

Carbon anode is manufactured by processing Calcined Petroleum Coke (CPC), Coal Tar Pitch (CTP), and spent anodes (Butts) from the pot lines. The resulting aggregates are heated and mixed in batch mixers, compacted into anode blocks, cooled, and stored for use in Carbon Bake.

Carbon Bake:

The carbon blocks are baked at around 1150ºC for curing and hardening. Baked anodes are cooled and either stored or transferred to the rodding department.

Rodding Room:

The rodding department processes baked anodes and prepares them for use in the Cell Lines by rodding and casting the anodes to ensure proper electrical contact. They also clean spent anodes to be reused as butts in Green Carbon.

The Cell Lines Department is responsible for producing molten aluminum via the electrolytic Hall-Heroult process. In this process, alumina is reduced to aluminum. The Department is made up of three major sections: Cell Lines Operations, Cell Repairs Maintenance, and Cell Repairs Production and General Services.

Cell Lines Operations:

This section carries out the aluminum production using prebaked carbon anodes and an electrolyte composed of aluminum fluoride and cryolite. Electrolysis takes place in cells lined with refractory material and carbon cathodes. The resulting aluminum is extracted, and anodes are replaced as they are consumed by this section.

Cell Repairs Maintenance:

This unit handles repairs on damaged cell structures and superstructures, including minor repairs for other departments when needed. The unit also repairs or replaces components of the superstructure, like the ore feeding system and the anode suspension system.

Cell Repairs Production and General Services:

This unit focuses on rebuilding cells, cell insulation after repairs and managing tasks such as crucible repairs, super and cathode stripping, and crushing bath materials for reuse in the anode process.

The Cast House Department is the final production stage at VALCO, where molten aluminium is cast into shapes like sows, ingots, and billets based on customer specifications. This department plays a critical role in ensuring that products meet the highest quality standards, as it serves both local and international customers.

Metal Handling (Operations):

In this section, molten aluminium is transported from cell lines and cast into finished products. After being weighed and sampled for chemical analysis, the molten metal is either cast into sows, ingots, billets, rods or, depending on the demand, delivered in molten form to local customers.

Production Control and Shipping:

This section ensures that cast products meet customer specifications and prepares them for shipping. It manages customer communication, grades the products, and organizes shipping logistics to deliver the metal to customers worldwide.

The Docks, Engineering, and Maintenance (DEM) Department is the largest department in the plant, consisting of three main sections: Docks, Engineering, and Maintenance, each crucial for smooth plant operations.

Docks:

The Docks section handles the materials entering and exiting the plant. They receive and store raw materials such as Petroleum Coke, Coal Tar Pitch, Alumina, Aluminum Fluoride, and Cryolite. They are also responsible for shipping finished products like Sows and Billets from the Cast House to their destinations.

Engineering:

Engineering designs and installs equipment throughout the plant. The team handles conceptual designs and sources funds to execute projects. They also develop and audit preventive and predictive maintenance programs to minimize equipment failure.

Maintenance:

The Maintenance section is responsible for the upkeep and repair of all process units, equipment, instruments, and vehicles in the plant and housing units. Maintenance activities are categorized into overheads, shops, and operations.

These teams ensure the continuous functioning of the plant’s vital systems, including steam generation, compressed air supply, water distribution, and RFO supply for the Carbon Bake process.

The Technical Department, led by Mr. Daniel Tackie, is vital for ensuring the production of high-quality metal. Responsible for process and quality control, the department oversees every aspect of production, from raw material testing to final product delivery. Key functions include monitoring the health of production cells and approving the quality of anodes produced by the Carbon Operations.

Subsidiaries:

• Process Control Carbon: Analyzes data, prepares KPIs, conducts quality audits, and ensures compliance with regulations in the Carbon area. It monitors the production process and optimizes raw materials.
• Process Control Cell Lines: Provides technical services through accurate measurements, setting benchmarks, and implementing quality management practices in the Cell Lines area.
• Chemical Laboratory and Environmental: Conducts chemical and environmental analyses, monitors emissions, and ensures worker safety through regular tests and air quality checks.
• Metallurgy: Oversees cast house operations, audits product quality, and conducts metal sampling for analysis in the metallographic laboratory.

Overall, the Technical Department plays a crucial role in maintaining production standards and ensuring environmental safety throughout the plant's operations.

The Logistics Department is responsible for overseeing the flow of materials in and out of the plant. The department comprises three sections: Procurement, Warehouse, and Traffic.

Procurement Section:

The Procurement Section ensures:

• Cost-effective and ethical procurement.
• Timely purchasing of materials to prevent disruptions.
• Disposal of scraps and surplus materials at minimal cost.
• Strong supplier relations with multiple alternatives.

It includes an Overseas Purchasing Unit (mostly raw materials) and a Local Purchasing Unit, covering various local needs such as:

• Fabrications and fuel purchases.
• Service contracts (e.g., lunch, transport, janitorial).
• Medical and emergency purchases.

Traffic Unit:

The Traffic Unit, or Shipping Unit, performs:

• Outbound and inbound logistics arrangements.
• Self-clearing of all imports and exports.

Warehouse Operations:

The warehouse is where all inventory passes before the processing stages.

Warehouse Operations focuses on:

• RECEIVING: This involves accepting incoming shipments, checking them for accuracy and condition, and assigning them a place in the warehouse.
• INVENTORY Management : The warehouse must keep track of all items stored within it, including their quantity, location, and status (e.g. in transit, damaged, etc.), in a way that ensures accuracy of inventory records and good stock condition so that production will not be hampered by unavailability of materials when needed.
• ISSUING: Issuing of items to customers based on First In First Out basis.
• MRP: Materials Requirement Planning (MRP) is a computerized inventory management system that helps businesses manage and plan their production and inventory levels. MRP software uses data inputs such as production forecasts, lead times for raw materials and finished goods, and inventory levels to calculate the materials needed for production.

The Warehouse stocks over 35,000 different items and provides critical support to all internal customers in the plant.

The Human Resource Department manages all recruitment activities within VALCO. It oversees two employee categories: management and non-management, handling recruitment, compensation schemes, and employee conduct regulations. The department aims to ensure employees are well-informed about their employment terms and the rules guiding their conduct.

Sections:

• Employee Services: Manages recruitment and placement of management personnel and oversees the overall employee management process.
• Employee Relations: Focuses on the recruitment of non-management staff, administering salaries and benefits, and addressing employee grievances.
• Medical Services: Responsible for VALCO Hospital services for staff and their dependents.
• Learning and Development: Facilitates training and skill development for employees.
• Plant Protection: Ensures safety and security within the plant premises.

Recruitment Process:

Management employees are recruited through interviews and must hold a Bachelor’s degree, while non-management employees undergo interviews and tests, requiring a minimum of a Senior High School certificate.

Overall, the HR Department is essential in ensuring effective recruitment, employee welfare, and adherence to company regulations, contributing to a positive workplace environment.

The Finance Department handles financial planning, analysis, risk management, treasury management, and financial accounting. It supports the overall strategy and mission of the company through careful financial oversight and reporting.

Financial Analysis and Planning:

This section is responsible for financial planning, budgeting, and cost accounting to help the company stay financially viable and meet its objectives.

Financial Accounting:

This section focuses on payables, financial reporting, and ensuring compliance with statutory regulations and financial standards.

The Finance Department ensures efficient management of working capital, internal controls, budget monitoring, risk management, and liaising with external auditors.

The department supports VALCO’s Operation by leveraging ICT in providing safe, accurate, consistent and timely Information for Control, Operational, Tactical and Strategic decision making. This we do by formulating Policies, Provision of Resources, Training and Support.

There are Three (3) sectional areas within the department, namely:

1. Plant Computer Infrastructures and Communication Systems:

Interconnects all the computers and production control systems together using a variety of technologies for data gathering and information distribution to enhance decision making.

2. Plant Business Systems:

Provides services primarily provided from the IBM eServer comprises the following:

• Computerized Maintenance Management System.
• Financial System.
• Human Resource / Payroll System.
• Metal Accounting System.
• Other Systems.

3. Celtrol and Operational Technologies:

Celtrol: Control of production of Aluminium by feeding the cells with alumina, setting correct ACD via voltage control, managing anode effect control and alerting operators of exceptions.

Operational Technologies: Supporting specialized Computing systems for production equipment such as Quantometers, Green Carbon HMI and Metal Casting systems.