EGA team develops new system to cut power costs

A team of engineers at Emirates Global Aluminium (EGA), the fifth largest aluminium producer in
Cathodic Protection the world, has developed a unique cathode structure that could reduce
operating costs at the plants significantly.
Aluminium production is an energy-intensive industry, such that using less energy during the
production process reaps a number of benefits including lower operating costs and reduced
emissions levels.
Over the past 25 years or so, EGA has made substantial investments in developing technologies that
ensure continuous improvements in the companys operations, with energy-efficiency being at the top
of the agenda.
More recently, efforts have been launched to protect the companys inventions through applications
to patent EGAs proprietary technologies. Since 2014, EGA has worked closely with Takamul in
developing and submitting the required patent application documentation.
A case in point is the new tall cathode structure that has been developed by a team of engineers at
EGA subsidiary Dubai Aluminium (Dubal), also known as EGA Jebel Ali Operations, to improve
energy efficiency in the aluminium production process.
A patent application for the invention was filed by EGA in December 2014. After evaluation by
Takamuls Patent Review Committee, approval for financial support was granted in March 2015.
The project, launched in 2011, aimed to identify a structure that provided a barrier to metal flow
during the electrolysis process. The targeted result was lower metal velocity, which would help
improve electrolytic cell magneto-hydrodynamic (MHD) balance and enable the cell to be operated
at a lower voltage. The resulting improved energy-efficiency would reduce the operations carbon
footprint and save on energy-related costs.

Sergey Akhmetov, vice president, reduction, EGA

Jebel Ali Operations, said: The energy cost of
producing aluminium from alumina is considerable.
Typically, 12 kWh to 16 kWh is needed to produce
one kilogram of aluminium. Given that the cost of
electricity is approximately $0.05 to $0.10 per kWh
(equivalent of Dh0.18 to Dh0.36 per kWh), a
reduction in energy output can result in significant
cost-savings. For example, for a plant with an
annual production capacity of one million tonnes
such as Dubal an energy-efficiency solution could
result in savings of $6 million per year.
Ibrahim Baggash, director, smelter services, led the
project, supported by Alexander Arkhipov, manager,
modelling, and Akhmetov. The team began by
exploring existing structures in the industry internationally. However, following extensive research,
the conclusion was reached that a completely new solution had to be developed specifically for
Dubal's requirements.

Our cell design and anode to cathode alignment is unique,

so nothing readily available on the market would suit, says
Baggash. So we set out to develop a customised solution
for our purposes. We also committed to finding a solution
that could be manufactured simply and cost-efficiently; and
one that could be pre-heated using conventional methods.
Once the initial concept was devised, the final design was
chosen based on mathematical modelling results before construction of the appropriate solution was
completed. The overall project duration, from concept and construction to testing, took many
months. The invention a taller cathode structure is still undergoing a lengthy trial process.
The trials show that the tall cathode structure invented by the team is successfully reducing metal
velocity in the electrolytic cells, enabling the cells to be operated at lower voltage such that the
electrolysis process consumes less energy, explained Baggash.
Moreover, the new tall cathode structure entails an inherently simple adjustment to the former
cathode design. All that is required is to replace one or more standard cathode blocks with taller
ones, such that there is no significant change required to the electrolytic cell construction, the cell
pre-heating equipment or the cell start-up process. The additional cost in cell construction is
marginal, and is more than covered by the returns, he said. - TradeArabia News Service

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