AP30/AP40 - AP Technology

Fact sheet
AP Technology
March 2013
TM
AP30/AP40
The world’s benchmark
reduction technologies
Alma
AP30/AP40 smelters: delivering big benefits
Currently operating above 400kA, our high amperage
AP40 pots stand as the benchmark in reduction cell
technology. Fully integrated into an optimised smelter
design, AP40 technologies offer:
• Highest demonstrated amperage with development
ongoing at Saint-Jean-de-Maurienne and under
construction at Kitimat
• Lowest energy consumption (below 12,500kWh/t)
following the development of AP40LE at Alouette
and AP4X LE at Saint-Jean-de-Maurienne
• Lowest total cost of ownership with lowest combined
capital and operating costs
• Industry’s most bankable and dependable solution
• Most sustainable solution with the lowest energy
consumption and GHG emissions, backed by our
continuous improvement and innovation pipeline
• Unequalled productivity (above three tonnes/pot/
day) and return on capital invested
Our advanced AP3X
cell technologies
deliver unmatched
benefits to aluminium
producers worldwide.
Fact sheet
AP30/AP40
Number of pots
10
15
16
2
5
6
3
9
12
1 11
14
13
1
Alba
624
2
Alma
432
3
Alouette
594
4
Boyne
264
5
Deschambault
264
6
Dunkerque
264
7
Hillside
720
8
Mozal
576
9
Saint-Jeande-Maurienne
120
10
Fjardaal
336
11
Sohar
360
12
Ma’aden
720
Projects
Pots
13
Hindalco – Aditya
360
14
Hindalco – Mahan
360
15
Helguvik
16
Kitimat
4
8
7
90
384
Amperage (MWh/t)
AP30
AP4X
High
productivity
SEC (kWh/kg)
The AP Technology™
solutions available today
meet industry needs by
enabling very high
productivity or very low
energy consumption.
Continuous improvement
AP30 builds on more than three decades of intensive
research and a steady flow of breakthroughs and
enhancements. Continuous R&D will enable further
amperage increases in the very near future, ensuring
ongoing efficiency and productivity improvements in
AP30 potlines.
Leading edge AP30 and AP40 technology features include:
AP4X LE
Low energy
Proven global track record
Today more than six million tonnes of
annual capacity are equipped with our
innovative AP Technology™ cells. Our AP18
and AP30 solutions operate at amperages
ranging from 180 to above 400kA. In 2011,
4,554 AP30 pots produced approximately
4.5 Mt of aluminium around the world or
ten per cent of global production.
• Design amperage above 400kA
• Creeping potential over design values
• Latest ALPSYS process control system including
technical management of potlines
• Fully integrated alumina transport design including
point feeding system and HyperDense Phase System
(HDPS), automatic AlF3 and crushed bath feeding
Substantial savings
The latest AP40 technology reduces capital
investment and operation costs through:
•
•
•
•
•
•
•
•
•
Increased amperage over 400kA
Specific consumption below 12,500 kWh/t
Low anode effect rate below 0.03 per pot per day
High potline equipment productivity – Increased
number of pots per potline (above 400) – Reduced
number of PTAs
High environment, health and safety standards
including electrical safety
Improved building and equipment design
Comprehensive engineering packages and
training modules
Experienced support teams at all project stages
Reduced construction time and rapid start-up
Number of AP30 pots
Number of pots by potline
7,000
6,000
420 kt/y
Capital cost/
installed pot ($/t)
5,000
Potline
production
4,000
3,000
2,000
90 kt/y
1,000
0
1986
1990
1994
1998
2002
2006
2010
2014
2018
50
100
150
200
250
300
350
400
Start-up year
AP30 pot production increase (from older smelters to future projects and R&D potential)
t/pot/day
Initial design production
Existing smelters
2012 actual production
New projects
3.20
2.80
2.60
2.40
2.20
0
ik
AP
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at
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el
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Production
3.00
Fact sheet
AP30/AP40
Industry leading performance
Overall
AP30
Most productive
AP30
Mean results
Most energy efficient
AP30
Kitimat basic
data list – AP40
1988 to
Nov. 2012
2011
11 months
2012
2011
11 months
2012
2011
11 months
2012
17
17
17
1
1
1
1
1
Number of pots
4,554
4,554
4,554
360
336
330
330
384
Total production (kt)
52,187
4,453
3,737
373
315
308
285
420
Current (kA)
340
358
362
375
372
368
376
405
Current efficiency (%)
94.3
94.0
93.1
94.2
93.6
92.0
90.5
13,336
13,385
13,463
13,798
13,334
12,683
12,839
Anode effects per pot
and per day
0.20
0.22
0.24
0.14
0.12
0.18
0.18
Iron content in the
metal (ppm)
913
898
1,001
882
865
762
759
Periods
Number of potlines
kWh/t
Potline retrofit
At Rio Tinto Alcan, we’ve participated in numerous
pot modernisation projects. In each case, a complete
assessment of existing pots is conducted to evaluate
the potential gains including:
• Increased production and labour productivity
• Improved specific consumption (energy and
raw materials)
• Enhanced environmental protection and
working conditions
Leading edge AP Technology™ solutions are integrated
into the modernisation process: potshell and lining,
busbars, superstructure, anode system, alumina feeding,
environmental protection, assistance to operation and,
last but not least, the ALPSYS pot process control system.
AP Technology™: the industry’s leading
reduction package
Pot technology is only one aspect of a smelter’s
performance. At Rio Tinto Alcan, we’re committed
to developing advanced smelter technology solutions
that deliver exceptional performance and value today
and in the future.
•
•
•
•
•
•
Most comprehensive and advanced package
Lowest full economic cost
Unmatched industry and operating performance
Most environmentally friendly technology
Unrivalled credibility and unique bankability
Extensive integrator experience
Industry leading performance
Since 1988, AP30 pots have produced more than
52 million tonnes of metal, confirming daily their
reliability, robustness and performance. They’re
demonstrating the flexibility and full range of
AP Technology™ solutions, from high productivity
to low energy consumption.
Technology sales department
725, rue Aristide Bergès
Centr’Alp - BP 7 38341 Voreppe Cedex
France
Rio Tinto Alcan head office
1188 Sherbrooke Street West
Montreal, Quebec H3A 3G2
Canada
T +33 (0)4 76 57 85 00
F +33 (0)4 76 56 61 10
T +1 514 848 8000
F +1 514 848 8115
ap-technology.com
riotintoalcan.com
13,150
Mailing address
PO Box 6090
Montreal, Quebec H3C 3A7
Canada
Production: tmdesign.ca
© Rio Tinto Alcan