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OPERATIONS / ALUMINIUM
DIVISION / SAYANOGORSK
ALUMINIUM SMELTER
SAYANOGORSK ALUMINIUM SMELTER
 The Sayanogorsk Aluminium
Smelter is output-wise the third largest smelter of the United Company RUSAL.
In 2007 it produced over 534,000 tonnes of commodity aluminium.
The smelter was built in 1985, in the close vicinity of the Sayano-Shushenskaya
HPP, one of the world’s largest hydro power plants, and consumes around 30% of
the energy produced by the plant.
RUSAL Sayanogorsk employs over 2,500 people.
| Geography |
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Sayanogorsk is located in the Russian
republic of Khakassia. With a population of 55,100 people, the city stands on
the banks of the Yenisey river. Its main production facilities include the
Sayanogorsk aluminium smelter, the Khakas aluminium smelter, a stone works and
a house building factory. Two hydro power plants – Sayano-Shushenskaya and
Mainskaya – are located to the south of the city.
The Republic of Khakasia with its capital of Abakan, in the Siberian federal
district, covers an area of 61,900 square kilometres. It is home to 580,100
people. The republic’s main industries include mining, engineering and
non-ferrous metallurgy, as well as forestry and wood working.
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Technology
The smelter serves as the base for refining new technologies. The first five
RA-300 pots were started up here, with the consequent industrial testing of the
RA-300 technology at the Khakas Smelter. In 2007 eight RA-400 pots were mounted
at the smelter, which, like RA-300, are one of UC RUSAL's proprietary
technologies. Introduction of RA-400 pots allows the facility to reduce harmful
emissions and increase its productivity by 30%. Installation of RA-400T pots –
the baseline model of future pots at the Taishet smelter – has already started.
The facility also deploys S-175, S-190 and S-255 pre-baked anode cells.
The Sayanogorsk smelter also includes a pre-baked anode factory with an annual
capacity of 395,000 tonnes of anodes (as of 2007).
Certificates
The quality management system at the Sayanogorsk smelter complies with ISO
9001:2000 and ISO/TS 16949:2002 international standards. The compliance
certificates were issued by Det Norske Veritas (DNV), a Norwegian audit
company, which confirmed that all the finished products of the smelter,
including foundry alloys for car engineering, are manufactured in full
compliance with international requirements.
The Sayanogorsk smelter has also international compliance certificates in
environmental management (ISO 14001) and HSE (OHSAS 18001). Validity of the
certificates is confirmed by independent auditors from Det Norske Veritas on a
yearly basis.
Development
The principal objectives for the modernization of the Sayanogorsk Aluminium
Smelter (SAZ) in 2007 were:
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rise in aluminium output
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growth of value-added products (alloys) share
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advancing of the technology
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further automation of production processes.
SAZ has completed the modernisation of process equipment for production of
electrodes in order to raise the quality of pre-baked anodes. The project
enabled the smelter to improve the crucial industrial properties of pre-baked
anodes, which will underpin a reduction in the anode consumption rate during
the smelting process by not less than 10 kg/tonne of aluminium and help reduce
dust generation.
Within the investment programme, a coke dust recycle system was installed to
recover carbon contained in the generated and captured coke dust for secondary
use in the production process, decrease environmental fees payable for waste
disposal (aspiration fines) at the landfill and mitigate environmental
pollution.
The second installed Hertwich homo-line and casting pit No.3 with
HydroAluminium moulds have reached the installed capacity, an achievement that
allowed SAZ to augment its output of billets used in extrusions manufacturing,
the aircraft industry and car engineering, with a positive impact also observed
in the share of alloys - it leaped from 61% in 2006 to 73% in 2007.
Environment
The Sayanogorsk smelter is one of the cleanest smelters in the world. In
December 2002, RUSAL Sayanogorsk became the first aluminium smelter in Russia
to be certified under the ISO 14001 environmental management standard.
Management
Managing Director – Evgeny Nikitin
Contact information
(39042)7-45-06
saaz@sayan.rusal.ru
To learn more about the process of aluminium production, aluminium history and
use please visit http://www.aluminiumleader.com/en/
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