Rusal starts the electrolysis production line of Boguhansky Aluminum Plant

SMM: according to the US magazine "light Metal Age", Russia United Aluminum Company has launched the first series of electrolysis production line of Boguhansky aluminum plant (Boguchansky aluminium smelter,BOAZ). Poguhansky Aluminum Plant is part of Boguhani Energy-Metal complex (BogyChany Energy and Meta1s Complx,BEMO), which relies on its advanced technology and full use of hydropower to provide remelting aluminum ingots with high quality and low carbon footprint. Company profile

In the first nine months of 2019, Rusal extracted 2.8 million tons of primary aluminum, more than 5 per cent of the world's total output, of which more than 50 per cent were exported to Europe, more than 20 per cent of which were exported to Russia and other CIS countries (CIS), 19 per cent to Asia and 8 per cent to the United States. The main customers are the transportation, structure and packaging industries, especially (VAP) customers with high value-added products, whose consumption will reach 1.1 million tons in 2019.

In the production process, the company gives priority to how to reduce greenhouse gas emissions (GHG) and improve production efficiency, so it adopts advanced technology and as much hydropower energy as possible. so far, more than 95% of the primary aluminum is extracted by hydropower. In 2019, the greenhouse gas emissions of the United Aluminum Electrolytic Aluminum Plant reached 2.8t CO2 e (equivalent) / t A1. In 2017, the company introduced to the market a low-carbon aluminum ingot under the brand name ALLOW, with an average carbon footprint of 2.5t CO2 e Al, and 12.5t for the aluminum industry.

Boguhani energy-metal complex (BEMO)

The construction of the BEMO project can be traced back to 2006, when Unilco planned to form a joint company with HJSC RUSHydro Hydropower Company, that is, to build a joint economic entity composed of a hydropower plant (hydropower plant,HPP) and an electrolytic aluminum plant in the (krasnoyarsk) area of Krasnoyarsk, which encountered many difficulties at the beginning of construction, and had to build measures and methods to solve the difficulties at the same time, and finally completed as scheduled.

The power plant is called PJS Boguhanskaya (Boguchanskaya) HPP Hydropower Station, a joint venture between Rusal and PJSC Russia Hydropower Station (Rushydro). It was put into production in December 2017. it is located on the Angara (Angara) River. It is one of the most advanced and efficient hydropower stations in the world. It is the fifth largest hydropower station in Russia, with a total installed capacity of 2997MW. The smooth commissioning of the hydropower station ensures that the primary aluminum of the aluminum plant becomes one of the lowest carbon footprints.

The completion of the hydropower station not only provides sufficient energy for the aluminum plant, but also provides a strong driving force for the clean economic development of the surrounding area. At present, the BEMO complex is the most labor-intensive economic entity in Siberia, with about 10000 employees. It is reported that the aluminum plant has been fully completed and put into operation, and the number of workers can reach more than 3500, of which more than 50% directly serve aluminum production. In addition, the construction of roads, hospitals, schools and other life services will provide more jobs.

Aluminum plant

Pogusky Aluminum Plant is a major member of the BEMO complex, covering an area of 2.3square kilometers, with two electrolysis workshops, a foundry workshop, an anode roasting assembly workshop and an electric power management department. The electrolysis workshop is divided into two phases, with an investment of US $1.6 billion in the first phase and put into production in March 2019. The primary aluminum extraction capacity is 300000 tons / year. After the second phase is put into production, the total capacity is 600000 tons / year. It is the third largest aluminum plant of Rusal Aluminium Company, after Krasnoyarsk (Krasnoyarsk) Aluminum Plant and Bratsk (Bratsk) Aluminum Plant.

The first phase has 336 electrolytic cells, using the RA-300 technology developed by the company, which is developed by the R & D center of Haakas (Khakas) Aluminum Plant. After the completion of the second phase, there are a total of 672 electrolytic cells with a raw aluminum output of 2.4t/d. The automation degree of electrolytic cell is the highest in United Aluminum Co., Ltd., all the process parameters are controlled, summarized, transmitted and reported by computer, and the safety work is also the best. in case of hidden trouble, it will give an alarm in time.

In the Russian aluminum industry, the environmental protection work of the plant is the best and can meet the requirements of ISO 14001 international environmental management standards. This can be done because the environmental management system and facilities are perfect, with four dust treatment centers and one circulating water treatment center, which uses alumina to absorb fluoride in dry flue gas, just like a filter, with a removal rate of about 99.8%. The fluoride-absorbing alumina is then added to the electrolytic cell.

The circulating water treatment center has the first set of equipment never used by the Russian aluminum industry, and the purified water is recycled back to the system like fresh water. The exhaust volume of the smoking fan can be doubled. When changing the anode, increasing the exhaust air volume can be doubled, which is beneficial to the protection of the environment and the health of workers.

The recently built foundry of Poguhansky Aluminum Plant has a production line for automotive remelting ingots with a production capacity of 120000 tons per year, which is a continuous casting machine of (Properzi) in Propez, Italy. The alloy ingots produced by this production line are used for casting LMZ SKAD automotive parts and for low-pressure casting wheels for export to Europe in the Krasnoyarsk Wheel Plant of Russian United Aluminium Co., Ltd. Rusal hopes that the remelting ingots produced will expand exports to Germany, Japan, the United States, Turkey, South Korea and other countries.