Sankar Sankaranarayanan

S. Sankaranarayanan is a highly distinguished technical leader with over 43 years of experience in the aluminum industry, specializing in the Bayer process, specialty chemical grade alumina, and Alumina Trihydrate (ATH). A Gold Medalist from the Indian Institute of Science (IISc), he combines deep theoretical knowledge with extensive hands-on experience in designing, expanding, and retrofitting alumina refineries globally.
Sankar served as Vice President and Head of the Hindalco Innovation Centre, where he was responsible for the process and product technology development for four major alumina refineries and he was a primary resource for the technical due diligence for refineries and process audits. He led the conceptual process design and bauxite evaluation for greenfield projects across India (Utkal, Aditya, Samri), Cameroon, and Guinea. He spearheaded the technical conversion of two Hindalco refineries from standard LTD/HTD circuits to Double Digestion (DD) circuits. He directed the transition to pressure filtration for bauxite residue disposal across all Hindalco refineries, while simultaneously developing alternative industrial uses for red mud. He pioneered the development and commercial introduction of more than 100 grades of Chemical Grade Specialty Alumina and Alumina Trihydrate (ATH).
Throughout his career, Sankar has been deeply committed to building technical capability within the industry. He has delivered extensive training in Bayer process chemistry and operations, the formulation and application of Chemical Grade Specialty Alumina and ATH products and quality systems.

4N High Purity Alumina

4N High Purity Alumina: Driving Safety in EV Batteries and Precision in Sapphire Growth From Commodity Alumina to Critical Material Globally, alumina production is dominated by Metallurgical Grade Alumina (MGA), which accounts for more than 90% of output and feeds aluminum smelters via the Hall–Héroult process. A smaller but highly diverse segment—Chemical Grade Alumina (CGA)—serves […]

Alumina Trihydrate Facility Investment: up to 25–30% IRR

ATH production infographic showing Bayer process flow, price value ladder from $350 to $25,000 per tonne, and investment metrics.

Summary: By deliberately stopping the Bayer Process before the calcination stage, a vertically integrated alumina trihydrate facility eliminates a capital-intensive component of a conventional alumina refinery, reducing total CAPEX by an estimated 15–20% while positioning its output in structurally higher-margin market segments: flame retardants, solid-surface composites, EV battery separator coatings, and — in an expansion […]

Strategic Opportunities in Bauxite Residue Metal Recovery

Industrial sunrise scene showing a mound of bauxite residue with a glowing beam revealing metallic crystals labeled Sc (scandium), REEs (rare earth elements), and Fe (iron), in front of a modern alumina refinery.

Bauxite residue, the primary byproduct of alumina production, represents one of the world’s most significant untapped mineral resources. Globally, the aluminum industry generates over 180 million tonnes of this residue annually. While traditionally managed as a disposal liability, bauxite residue contains a concentrated suite of valuable metals, including rare earth elements (REEs), scandium, titanium, and […]

Aspects of Small-Scale Alumina Hydrate Plant Design

graphic outlining challenges facing small scale hydrate plant design

Introduction Designing an alumina hydrate plant—especially on a small scale—poses distinctive engineering and operational challenges. Both the fundamental process requirements and the realities of scale demand careful consideration to ensure sustainable operations and avoid costly mistakes. Below, we explore key challenges and the unique impacts of small-scale production, and strategies for building robust, flexible facilities […]