Initiatives to reduction of aluminum potline energy consumption Alcoa Pocos de Caldas/Brazil

Abstract

Energy is one of the most important inputs for aluminum production and is responsible for approximately 40% of the cost of aluminum production (CAP) in Soderberg pots. Facing the 2008/09 global economic downturn, Alcoa Poços de Caldas Plant, Brazil, has focused its efforts on a planned project, counting on its personnel's potential, to reduce the energy consumption. Main initiatives taken along this process were: workshops on energy (thermal balance and energy consumption), STAR Probe measurements (pot control focused on thermal balance), new cathode design, financial model development and changes in automatic pot control. Through this project a reduction of 77mV/pot and 0.30 kWh/kg Al were achieved, the best ever result reached at the plant at the present load level. In financial terms, in 2008/09, US$ 1 million was saved without any extra investment.