UC RUSAL Sustainability report 2016


Energy

Energy consumption

Approach

With more than 90% of UC RUSAL aluminium produced using renewable and environmentally friendly hydropower, the Company aims to keep the lowest carbon footprint in the industry through energy efficiency activities.

Electricity is a key element in the production of aluminium, so the Energy Efficient Production programme has the highest priority.

Targeted programmes and energy efficient projects are implemented at all production facilities of the Company without exception.

Massive introduction of energy-saving technologies, energy savings are achieved through optimisation of power regimes, cells design and technical and process parameters of production, such as reduction of thermal losses, use of slit-type and oblong anodes, modification of regulations for technological operations, reduction of amperage, etc.

Scientific developments to reduce energy consumption can play a key role.

Results

During the accounting period energy efficiency projects were successfully implemented at all smelters of the Aluminium Division. In the area of energy efficiency, at the three aluminium smelters – Sayanogorsk, Krasnoyarsk and Irkutsk – a project to implement the unified anode is implemented almost simultaneously.

The production facilities of the Company have achieved the following indicators of power consumption reduction:

          As a result of the use of the unified anode at the Sayanogosk aluminium smelter, the decrease in the unit energy consumption per tonne of aluminium was of 69 kWh. The production facility also has a pilot section of RA-550 section. It is planned to achieve the electricity consumption of less than 12,500 kWh per tonne over the next few years. The new reduction cells are operating with the amperage of more than 520 kA, which will reduce operating costs, primarily by improving environmental performance, increasing energy efficiency, and reducing labour costs for maintenance.

          IrkAZ – electricity consumption decreased by 46 kWh per tonne of aluminium, and on the upgraded cell line IrkAZ-5 – by 148 kWh. The savings of the burned anodes was of six kg per tonne.

          At the Krasnoyarsk aluminium smelter the specific electricity consumption per tonne of aluminium dropped by 143 kWh, and the savings of the burned anodes amounted to 7.5 kg per tonne. In potroom No 5 of the Krasnoyarsk aluminium smelter, experimental operation of energy-efficient cell developed by professionals of ETC began. Improved cell design allows to save up to 60 kw of process electricity in the production of each tonne of metal. In recent years, the production facility has achieved a reduction in the consumption of process electricity from 16100 to 15400 kWh per tonne of aluminium.

          Bratsk aluminium smelter reduced energy consumption for the production of a tonne of aluminium by 40 kWh, Novokuznetsk aluminium smelter by 30 kWh.

The aim is to reduce the annual energy consumption of aluminium smelters by 3,400 GWh by 2020 as compared to the 2011 level.

All the production facilities of the Alumina Division also participated in the energy saving programmes. Each of them prepared organisational and technical plans to change the operating systems of existing equipment and to replace obsolete equipment with energy efficient, contributing to the savings in fuel and energy resources.

UC RUSAL production sites continue to work on regular energy audits, the results of which serve as basis for the  action plans for efficiency optimisation.

The overall effect of lower electricity consumption was of approximately USD 5.8 mln.