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WHAT
WE DO / OUR
OPERATIONS / ALUMINIUM
DIVISION / KRASNOYARSK
ALUMINIUM SMELTER
KRASNOYARSK ALUMINIUM SMELTER
 The Krasnoyarsk Aluminium
Smelter (KrAZ) was commissioned in 1964. The facility is the second largest
smelter in the world, with 1 mln tonnes of primary aluminium produced in
2008.
The smelter accounts for 24% of aluminium production in Russia and for 2.5% of
global output. It is located in the vicinity of the Krasnoyarsk Hydropower
Plant and consumes approximately 70% of its energy.
The smelter’s headcount is 4,700 employees.
| Geography |
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Krasnoyarsk is a Russian city
located along the Yenisey river, 3955 km east of Moscow. It is the capital of
the Krasnoyarsk region and has a large railway terminal on the Trans-Siberian
railway line providing good access for the supply of raw materials and delivery
of finished products. Krasnoyarsk was founded in 1628 and is now the home of
around 1 mln people. Its major industries include engineering, metal working,
energy, coal, defence, chemical, wood working, ferrous and non-ferrous
metallurgy.
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Technology
A number of potrooms at the smelter are equipped with pre-baked anode
technology, however the facility mainly uses Soederberg cells. In 2006, the
smelter completed the transition from the ‘semi-dry’ to a more environmentally
friendly ‘dry’ anode. Introduction of the new advanced technologies has enabled
the smelter to reduce its emissions of tarry matters and benz(a)pyrene, and
improve the working conditions in the potrooms.
Environmental modernisation
In September 2009 KrAZ completed a larde scale modernisation programme.
This was aimed at reducing the environmental impact of the smelter. The
construction of new dry gas scrubbers was he most important part of the
modernisation process. Currently, the smelter operates 23 gas treatment plants
that are equipped with an additional dry treatment stage. The modernisation
programme resulted in a reduction of KrAZ's emissions per tonne of aluminium
output, including a 1.5-fold reduction in HF, a 2.7-fold reduction in tar, and
a 2.5-fold reduction in benz(alpha)pyrene.
The Krasnoyarsk Aluminium Smelter has been the first aluminium smelter in
Russia based on Soederberg technology to install automatic alumina point
feeders. Alumina point feeding provides for better pot sealing and has enabled
the production facility to reduce its emissions of fluorides by 10%, tarry
substances - by 3%, and dust - by 30%. The use of the automatic alumina point
feeders reduces frequency of anode effects and subsequently dramatically cuts
greenhouse gas emissions.
In 2007, the Krasnoyarsk Aluminium Smelter started using six new
crane-manipulators, made by NKM Noel Siberia within the UC RUSAL’s project
Industrial Park Siberia. Eliminating manual work, these new cranes provide
maintenance of dry anodes, which were introduced at the smelter as part of the
modernisation programme which also included the installation of 13 advanced
hoisters.
The smelter was also the first in Russia to take measurements of
perfluorocarbons (greenhouse gases) in 2007. The monitoring was conducted by
Jerry Marks, a respected climate change researcher who is also a specialist
consultant for the International Aluminium Institute. The results of the
monitoring showed that the absolute level of perfluorocarbons emitted by the
smelter in 2007 was 78% lower than the level first recorded in 1990. In
addition, the level of emissions per tonne of aluminum produced decreased by
82% over the same period, indicating that the facility has achieved the
voluntary goal set by the International Aluminium Institute of reducing this
measure by over 80% before 2010.
Casthouse modernisation
As part of the modernisation of the casthouse, a new casting complex for can
stock alloys was launched. In 2008, the smelter produced 244,000 tonnes of can
stock alloys. A unique casting machine for the production of double-length
slabs (up to 11.5 m) was also built as part of the modernisation programme. The
machine has no equivalent in Russia. The planned capacity of the complex is
134,900 tonnes of foil alloys per year.
Two ingot cutting lines, produced by the French company Sermas, and a new
container terminal were also commissioned. In 2007, alloys accounted for 23.3%
of total production, and the smelter is planning to meet its strategic goal to
increase the share of alloys to 44% by 2011.
Efficiency Improvement at Krasnoyarsk Aluminium Smelter
In 2007, the Efficiency Improvement project, which is aimed to create and
implement a RUSAL’s own production system (RUSAL Business System or RBS), was
proliferated in all the potrooms of the Krasnoyarsk Aluminium Smelter. The
project is intended to standardise processes, bring them under control, shorten
duration of process operations, and implement best practices. Along with
improving technological and economic indices, the project significantly reduces
the environmental impact of the smelter.
Certificates
In 2004, the smelter’s environmental management system was certified under ISO
14001, and in 2006, the facility successfully completed an annual certification
audit and confirmed its compliance with the ISO 14001:2004 standard. It was
also certified under the ISO 9001, ISO/TS 16949, and OHSAS 18001 quality
management standards.
Management
Managing Director – Eugueny Nikitin
Contact information
Tel. +7 (3912) 56-38-98
AssistanceUD.KRAZ@rusal.com
To learn more about the process of aluminium production, aluminium history and
use please visit http://www.aluminiumleader.com/en/
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