Introducing an inert anode in the reduction process is recognised as revolutionary in metallurgy, and RUSAL is the world leader in creating this technology
Specialists at RUSAL's ETC created an advanced generation of Soderberg cells, effectively giving a new birth to the traditional method of aluminium production. The key advantage of the new technology is that, instead of traditional anode paste, the upgraded cells use a colloidal anode.
Reduction cells with an amperage of more than 500 kA, which were put into commercial operation at the Sayanogorsk Aluminium Smelter in 2017, have allowed RUSAL to set new standards in the global aluminium industry.
The launch of a RA-400 cell at the Sayanogorsk Aluminium Smelter in 2005 is proof of one of the Company's efforts to build its own technology base. The technology was created by specialists of the RUSAL Engineering and Technology Centre
RUSAL has competencies to provide a full cycle for the 3D printing of products with specified parameters and characteristics – from creating aluminium alloys for powders and wire rods, to developing production technologies for specific types of products.
RUSAL's line of innovative products is represented by dozens of advanced aluminium-based alloy types. Every allow created by Company process engineers has got the specified characteristics and parameters and is developed on the requirements of the market and specific customers.
Unique carbonisation technology for extracting scandium from red muds developed by RUSAL's ETC has resulted in the Company becoming one of the world leaders in the production of this rare earth metal.
An eco-friendly pitch away from charcoal was produced by the specialists at RUSAL's ETC who, together with scientists from the Siberian Federal University and a number of Russian institutes, worked on creating an alternative binder.
Developing and producing master alloys is a relatively new area of RUSAL's innovation activities, since its launch in 2017. The basis for this was the creation by the Company's process engineers of a new high-efficiency method for producing the aluminium-scandium master alloy.
The scientific and research units of RUSAL have accumulated extensive experience in developing and implementing various types of tooling for casting and heaters. These technologies have been implemented in the casting and rolling units of RUSAL’s aluminium smelters.
Fume treatment technologies
The FTC-RUSAL fume treatment system, which is being implemented at the Company's aluminium smelters, relates to equipment of the world's leading manufacturers in terms of its characteristics and functionality, but surpasses it in terms of reliability, manufacturability, and lower cost.
With the modelling technologies that are used at RUSAL plants, it is possible to calculate the optimal parameters of production processes and create digital twins of the main equipment.
RUSAL is the only company in the world that produces alumina from alkaline raw materials (nepheline). Wide competencies in this field have allowed Company specialists to create a unique technology to produce highly dispersed precipitated aluminium hydroxide (HDPAH).
Aluminium chloride process
Aluminium chloride process for producing metallurgical-quality alumina from high-silica raw materials created by specialists of RUSAL's ETC and VAMI has a number of undeniable advantages over traditional methods of producing alumina from bauxite.
Company engineers have created a number of unique patented solutions, which have got no analogues in world practice. In particular, one such solution was the combined casting, rolling and extrusion process (CREP), intended to produce electrical wire rod and welding wire.
Quality control system automation
RUSAL is improving production processes and finished product quality control systems using advanced technologies and control methods.
Virtual casting machine simulator
ETC created a virtual casting machine simulator – an interactive computer system for personnel training. The functionality of this system is implemented based on realistic 3D models of the machine using virtual reality technologies. Immersion in the simulator's virtual environment and working out actions with the machine is carried out using VR equipment.
Pilot Casting Complex
The Casting Centre of LLC RUSAL ETC on the basis of the Krasnoyarsk Aluminium Smelter created the Pilot Casting Complex, which accomplishes a number of the key production tasks.
EcoFriendly bulk lining materials
RUSAL created an innovative technology to install the basements of aluminium cells (ITME). The technology comprises unique bulk lining materials (BLM) created by LLC RUSAL ETC based on lignite semi-coke, which is capable of being recycled, barrier materials based on burnt clays (porcellanite), and graphite foil.