International 400-500KA aluminum electrolyzers
Thread Content
•First is PECHNEY: The AP-30 electrolyzer developed by this company has been improved over more than a decade, and its capacity has now increased from 350KA to 360KA, then to 370KA, and further to 385–400KA, with excellent performance. •PECHNEY’s 3 AP50 cells, namely 500KA electrolyzers, achieved an efficiency of 95.5% in 2007 with a direct current power consumption of 13,300 kwh/t. In 2008, the AP50B model was introduced, with a current capacity of 530KA. •RUSAL successfully tested the RA-400 electrolyzer; in June 2007, the Taishet aluminum plant using 400KA electrolyzers was built in the Irkutsk region, with a capacity of 750kt/y. •The newly developed RA-500 electrolyzer by RUSAL Joint Company was put into trial in Krasnoyarsk in October 2007. •Hydro has 6 400KA test cells that are expected to be put into operation at the Ardal aluminum plant in Norway by early 2008. •Dubai Aluminum added 40 340-350KA electrolyzers to Series 6. The company is considering building new large-scale aluminum plants in the future, and therefore is also actively exploring the development of larger electrolyzers. Test parameters of AP50B: Current intensity ω KA 530; Current efficiency % 95.5; DC power consumption Kwh/t Al 13600; Anode effect coefficient AE/cell/day 0.03; Instability level in ohms 20
RA-400 by Alrosa Joint Company: In 2004, Alrosa Joint Company’s research center (ETC) developed a new type of large electrolyzer. The first electrolyzer of this second-generation RA-400 model was put into operation in December 2005 at the Sayanogorsk aluminum plant； In January 2006, the second and third units were added. It is said to be more advanced than RA-300 in terms of environmental protection, technology, and economics; its design results in a 30% reduction in fluoride emissions compared to RA-300, with a current efficiency of 93% and a direct current power consumption of 13,900 kwh. This cell type differs from the RA-300 and features the following new elements: a new anode gas collection system with excellent sealing properties; dual anodes; a graphitic cathode using dual cathode rods; an improved anode lifting mechanism that reduces the overall height of the electrolyzer; and a new busbar design system. Russian RA-400 Sayanogorsk cell: Daily production capacity: 3060 kg of Al; Current efficiency: 95.0%; Electricity consumption: 13.65 kwh/kg of Al; Anode current density: 0.85 A/cm2; Cell voltage: 4.35 V; Anode gross and net consumption: 550 and 420 kg/t of Al; Anode effect coefficient: 0.05 AE/cell/day; Number of feeders: 6. In June 2007, RUSAL announced the construction of a new aluminum plant with an annual production capacity of 750 kt in the Taishet region of Irkutsk, at an investment of around $2 billion. The plant will have 2 production lines or 4 workshops, equipped with state-of-the-art RA-400 cells. It will employ 3000 people, with operations expected to begin in 2009 and full capacity likely to be achieved by the end of 2011.
RUSAL RA-500: In October 2007, RUSAL’s Engineering and Technical Center (ETC) was working on another new electrolyzer, designated RA-500. A test cell with a high anode current density was designed, and it is now being tested at the Krasnoyarsk aluminum plant. RUSAL’s inert anode electrolyzers: In line with ETC’s long-term plans, efforts have been made to develop inert anode electrolyzers, and a range of oxygen-based anode materials have been tested in laboratory conditions for many years. Currently, the aluminum electrolyzers we use have horizontal anodes and cathodes, while experts from RUSAL have developed a new type of electrolyzer with vertical electrodes. The material used for the vertical anodes is corrosion-resistant, which ensures a longer lifespan. Research is underway on inert or wettable cathode materials; the cost of such cathode materials is approximately $230–250 per square meter. It is estimated that the energy consumption of such electrolyzers could be less than 12,000 kwh/t. The electrolyte temperature is 800°C, thereby reducing the corrosion of the electrolyte on the cathode material. Due to the significant reduction in the size of the electrolyzers, investment costs have been reduced by 2–4 times; the capacity per unit area of the electrolyzers has increased from 10 KA/m2 to around 50–100 KA/m2. Additionally, the amount of busbars required has also been significantly reduced. This research is expected to be completed in 20012.
China is also rushing to develop large ones; I heard they are working on 600KA models.
China designs large electrolyzers; those with 350KA and 400KA capacities have many defects, are unstable, and have a short lifespan. I think the key to electrolyzer design lies not in size, but in how to improve overall design quality and narrow the gap with foreign technologies.
In my opinion, the key lies in energy conservation and environmental protection; the ultimate purpose of production is for humanity!
Was energy conservation taken into account in this design?
-- Does being large necessarily mean better performance? Is it definitely environmentally friendly? --
5# tyn_2001 has no points left; maybe I’ll give you 8 points! Well said.
Currently, the AP35 has the best economic and technical indicators, surpassing the AP50. PECHINEY value = direct recommendation 35.