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SUSTAINABLE DEVELOPMENT / ENVIRONMENT
/ ENVIRONMENTAL
INNOVATIONS / CREATION
OF RA 300 KA AND RA 400 KA SMELTING TECHNOLOGY
CREATION OF RA 300 KA AND RA 400 KA SMELTING
TECHNOLOGY
 In
Soviet times, aluminium reduction technology was designed by the Russian
Aluminium and Magnesium Institute (VAMI). At the time of RUSAL's founding in
2000, it was already failing to meet environmental and economic requirements.
At the same time, proprietary aluminium smelting technology was being
recognised by all modern aluminium businesses as a critical competitive edge.
Companies without this technology at their disposal are unable to successfully
develop existing operations or build new competitive plants.
There are only five companies in the world that have their own proprietary
aluminium smelting technologies - Alcoa, Alcan and companies from China. Their
best technologies are not for sale. In light of this, RUSAL decided to create
its own new technology to support its pursuit of a leading position in global
aluminium production. Today, having a unique technology for light metal
production is an essential prerequisite for UC RUSAL's consistent leadership in
its sector.
To achieve this, the Engineering & Technology Center (ETC) was opened in
Krasnoyarsk in 2002. Specialists from RUSAL's Siberian operations and
scientists from local institutes were invited to work for the ETC. Design,
engineering, and the commissioning of the RA 300 kA pot took one year and was a
major accomplishment of the ETC.
In December 2003, five pots of this type were brought online at the Sayanogorsk
aluminium smelter. Low energy consumption and longer pot life distinguishes the
RA 300 kA from other pots. The same technology was employed at the greenfield
Khakass aluminium smelter where it has demonstrated its competitive power and
effectiveness.
In the West, building new smelting capacities costs US $5,500 - 6,000 per tonne
of output, whereas at the Khakass smelter construction project the cost was
only US $2,500 per tonne of output.
In 2004, the ETC started development of a new 400 kA pot. Investment in the
project totaled US $11.3 million. RA 400 kA has become the most efficient pot
in Russia and was commissioned at the Sayanogorsk smelter (SAZ) on 24 December,
2005. In comparison to the RA 300 kA pot, the new pot has a lower metal
consumption level, a double anode, a better sealing of pot covers and the
height of the pot has been reduced due to an improved anode jacking system. The
pot's current efficiency is 93 % and power consumption is less than 13,900 kW
per tonne of aluminium. The installation of the RA 400 kA pot is designed to
produce 3 tonnes of aluminium per day and will enable UC RUSAL to increase its
productivity by 30%. At the same time, emissions will be reduced by 30%. The
new pots were designed on pre-bake technology and meet the highest
environmental standards.
At the beginning of January 2006 the second RA 400 kA pot was put into
operation and at the end of January a third commissioned. Installation of RA
400 kA pots is planned at UC RUSAL's new aluminium smelters. This technology
will be implemented at the Taishet aluminium smelter with a design capacity of
750, 000 tonnes. The Taishet smelter's construction was started in 2007.
At the moment the UC RUSAL's ETC is creating a new generation of pots, RA 500
kA, and developing a smelting technology based on higher current density. A
technical solution is being prepared and a pilot pot has been designed. Testing
of the RA 500 kA pot prototype is being carried out at the Krasnoyarsk smelter.
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