UC RUSAL Sustainability report 2015


Energy

Energy

Approach

As UC RUSAL produces 90% of its aluminium using renewable and environmentally friendly hydroelectricity, the Company endeavours to have the smallest possible carbon footprint in the industry as part of its energy efficiency measures.

Electrified energy is the key element for aluminium production, therefore the Energy Efficient Production Program is of the highest priority.

Targeted Programs and energy efficiency projects are being implemented at all enterprises of the Company, without exception.

Energy saving technology is being installed on a mass scale, with energy savings being achieved through measures to optimise energy control arrangements, electrolysis cell designs, and drafting engineering and technical parameters for production (in particular, a reduction in heat losses, the use of slotted and linear anodes, amendment of the regulations on the performance of process operations, and a reduction of current strength.)

Scientific advancements in reducing energy consumption could play a key role.


Results

During the reporting year, energy efficiency projects were successfully implemented at all Aluminium Division smelters, and all Alumina Division refineries participated in major energy saving Programs.

The projects included optimization of electrolysis cells controlled in conditions of work at the minimum voltage and ACD which led to a reduction of time required for reaching the operating parameters by electrolysis cells after start-up. To increase energy efficiency in the aluminium production process, new designs of electrolysis cells which enabled a reduction in energy consumption by 300–500 kWh/t Al were developed and tested at pilot sites of KrAZ, SAZ, KhAZ and IrkAZ.. It was resolved to introduce energy efficient electrolysis cells of various designs at other production facilities of the Aluminium Division.

Special measures to improve energy efficiency in 2015 made it possible to reduce the overall specific electricity consumption of smelters at all production sites of the Aluminium Division by 85 KWh/t compared to the previous year.

Company enterprises achieved the following energy saving indicators:

·         SAZ: average electricity consumption to produce a tonne of aluminium fell from 14,636 KWh/t to 14,627 KWh/t;

·         IrkAZ: electricity consumption fell by 101 KWh per tonne of aluminium, and on the updated lines of electrolysis cells IrkAZ-5 –by 238 KWh.

·         KkAZ: process electricity consumption made 15,492 KWh per tonne of aluminium, which is 75 KWh less than the year before;

·         BrAZ: electricity consumption to produce a tonne of aluminium was reduced by 51 KWh, NkAZ – by 37 KWh.

UC RUSAL enterprises continue work to perform regular energy audits. The results of these are used to prepare plans for optimising energy efficiency parameters.

The overall effect of reducing the power consumption made approximately USD 5 million.

The Company has established a goal to reduce annual energy consumption at aluminium smelters by 3,400 GWh by the year 2020 as compared to the 2011 level.