Massive Middle East aluminium smelters made efficient by ABB

ABB says it has helped two aluminium smelters in the Middle East increase their energy efficiency by 18%. ABB built and provided high power rectiformers as part of the power and automation solutions for the Sohar aluminium smelter in the Sultanate of Oman and the Qatalum smelter in Qatar. According to ABB, the large-scale smelters are setting new records for size and production capacity. Sohar started production in June 2008. It has the world’s largest potline, with 360 pots. The smelter produces up to 360,000t of aluminium per year. Qatalum is starting up in late 2009. It will be the world’s largest aluminium smelter with a production capacity of 585,000t a year and 704 pots. ABB provided the five large rectiformers which are at the heart of each smelter. These help the plants to operate in all conditions, including worst-case scenarios. Rectiformers are critical components in the aluminium production process. They control and convert the alternating current delivered by the power grid or onsite power plant into the required direct current that powers the electrolytic process and produces the molten aluminium in the pots. The potlines have to be constantly supplied with power. If the power conversion station fails, the lines will shut down and the molten aluminium in the pots will solidify and incur massive costs. While rectiformers have traditionally been limited to a voltage of 1200V DC, ABB has extended the voltage limit first to 1500V DC, then to 1650V DC for Sohar. Qatalum will go even farther, with 2000V DC. The upgraded rectiformers can convert and deliver substantially more power than was previously possible. As a result, each smelter requires only five rectiformers instead of the six that would have been necessary at the lower voltage limit. source:www.metalworker.com.au