Hydro's proprietary electrolytic process is one of the most efficient in the world. The smelters in Sunndal, Norway, and Qatalum, Qatar, are using the newest technology. We work continuously to develop the next generation technology, HAL4e, emphasizing cell productivity as well as reduced energy consumption and climate gas emissions from the production process.
R&D in Primary Metal is important to strengthen the competitiveness through improving the cost position at our smelters. Prioritized tasks are operational support, implementation of new technology in existing activities as well as development of next generation electrolysis technology.
Our casthouses focus on process efficiency in terms of improved capacity utilization and improved process capability. Continuous improvement of product quality is an important part of our business concept, and is strongly linked to technical customer service. We develop our products together with customers, listening to their needs while improving our own casthouse processes.
In the area of recycling, we have lifted our budgets as a joint effort between our metal markets, rolled products and extruded products business areas. This includes funding for projects related to closed-loop recycling of downstream products, recycling-friendly alloys and products, upgraded scrap processing, and furnace technologies that help improve recycling rates and quality of scrap and metal produced. The scope of all our recycling-related projects also includes reduction of total waste and waste sent to landfill. Hydro participates in national and EU-funded projects to support our ambition as a company and industry.
Quenching anode effects
An important mean to reduce greenhouse-gas emissions from our smelters is to reduce the so-called anode effect, which generates PFC emissions. PFCs are high-potent greenhouse gases. At our newest potline in Sunndal, Norway, the implementation of automatic anode-effect quenching has reduced the duration of anode effects by about 75 percent. This implies an annual reduction of PFC emissions equal to about 80,000 metric tons CO2, and an energy reduction equal to about 4,000 MWh. The change has also helped increase the operational performance of the reduction cells, due to less process instability after anode effects.
More efficient anode replacement
Our primary metal business area wanted to develop a simpler, easier way to change anodes during the production process for primary aluminium. That included a need to automate the anode-change operation so the crane operator could do the sequence himself. The innovator developed a new method of anode replacement, which utilizes the old anode butt as a reference for the pot-tending machine crane. The method gives room for significant cost savings in manning and current efficiency, and less exposure of workers to fluorides, heat and dust.
