About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Aluminum Reduction Technology
|
| Presentation Title |
Systematic Reduction of Specific DC Energy Consumption in Aluminium Smelting through Integrated Design and Process Optimization |
| Author(s) |
Anish Das, Sandeep Pratap Singh, Anup Kumar, Anshu Mangal, Kapil Kumar, Mukul Modak |
| On-Site Speaker (Planned) |
Anish Das |
| Abstract Scope |
Aluminium production is inherently energy intensive, and improving energy efficiency remains a key challenge in modern smelters, where operating limits are constrained by internal voltage losses, cell stability, and the need to maintain thermal balance. Specific DC energy consumption, a direct indicator of power cost, is governed by both cell voltage and current efficiency, making their simultaneous optimization critical.This paper presents a systematic approach implemented at Aditya Aluminium to reduce energy consumption through targeted engineering upgrades and process-control improvements. Key interventions included optimization of anode design and stable operation at reduced anode-to-metal distance without compromising current efficiency, supported by enhanced monitoring of cathodic voltage drop, improved process control, identification of low-performing cells, and tighter control of potline thermal balance.The integrated approach improved process stability and energy utilization, increasing current efficiency from 94.42% to 94.84% while reducing specific DC energy consumption by 121 kWh/t-Al. |
| Proceedings Inclusion? |
Planned: Light Metals |