Exploring Cheaper Coke Options for Aluminum Production Cost Reduction

The discussion focuses on the potential cost-saving strategies in aluminum production by considering two coke options: existing coke (coke E) and a blend of 2/3 coke E and 1/3 coke A. The blend offers cost savings but may lead to quality loss and increased Net Carbon Consumption. Additionally, improving baking processes by increasing temperature shows mixed financial impacts. The analysis includes potential gains, losses, and the impact of a current efficiency loss of 1% on production costs.

• Aluminum production
• Coke options
• Cost reduction
• Baking processes
• Efficiency loss

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Uploaded on Sep 28, 2024 | 0 Views

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1. Group Discussion 2 Cheaper coke to reduce aluminum production cost ? Presentation Choice between 2 options o Existing coke (coke E) o Blend : 2/3 coke E + 1/3 coke A Coke A characteristics o 50 $/t cheaper o High air reactivity Pilot anodes have been produced with the blend o Gives the key properties of the potential new anodes

2. Group Discussion 2 Cheaper coke to reduce aluminum production cost ? Potential gains Pitch = 90 kg/tAl Coke = 360 kg/tAl Butts = 140 kg/tAl Anodes = 560 kg/tAl NCC = 420 kgC/tAl Coke A required = 1/3 x 360 = 120 kg/tAl Expected gain = 0.12 x 50 = 6 $/tAl

3. Group Discussion 2 Cheaper coke to reduce aluminum production cost ? Potential loss Decrease in the anode quality Increase of the Net Carbon Consumption Fisher formula : link between anode properties and NCC Blend anode additional NCC = 20.8 kgC/tAl Anode price = 600$/kganode Financial summary o Gain : 6 $/tAl o Loss : 600 x 0.02 = 12 $/tAl o Balance : - 6 $/tAl NO GO !

4. Group Discussion 2 Cheaper coke to reduce aluminum production cost ? Improved baking Increase the baking temperature to 1150 C to reduce the air reactivity. o 4% gain on air reactivity residue o Slight reduction of CO2 reactivity o Increase of thermal conductivity New Blend anode additional NCC = 13 kgC/tAl Additional consumption o 1 liter oil 1 Nm3 gas 10 kWh 0.5 to 1 $ o + 50 C Tbaking 10% consumption increase o Baking consumption : 2 GJ/tanodeAnd 0.56 tanode/tAl o Financial impact : 1.6 to 3.2 $/tAl Financial summary o Gain : 6 $/tAl o Carbon Loss : 600 x 0.013 = 7.8 $/tAl o Baking loss : 1.6 to 3.2 $/tAl o Balance : - 3.4 to -5 $/tAl NO GO

5. Group Discussion 2 Cheaper coke to reduce aluminum production cost ? Current Efficiency Loss What about a current efficiency loss of 1% ? Loss of production of 0.01 tAl 0.01 t x (2200 $/t 2x400 $/t) = 14 $/tAl Financial summary o Gain : 6 $/tAl o Carbon Loss : 600 x 0.02 = 12 $/tAl o CE loss = 14 $/tAl o Balance : - 20 $/tAl