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Evolution of Busbar Designs for Aluminium Reduction Cells.–

Typically a bus bar system for a modern smelter is made of aluminium, weighs 15,000t and costs $50m. As such it represents 10-15% of the potline cost. With increasing amperage the bus bar complexity must also increase in order to avoid high magnetic field

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Review of ASARCO El Paso Smelting Processes Figure 2 (shown on the following page) provides a process flow diagram for the early copper smelting process (1910-1992); Figure 3 (shown on the following page) provides the details of the process used after 1993.

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How Aluminum is Produced

The cost of building a typical, modern smelter is about $1.6 billion. Most smelters produce aluminum that is 99.7% pure – acceptable for most appliions. However, super pure aluminum (99.99%) is required for some special appliions, typically those where high ductility or conductivity is required.

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Ferrochromium Smelting Process Refining Diagram

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Aluminium Sector - Bureau of Energy Efficiency

Figure 15: Fertilizer plant Battery Limit block diagram 179 Figure 16: Overall Material and Energy balance 182 Figure 17: Ex- GtG boundary for Aluminium (Refinery sub sector) 192 Figure 18: Ex- GtG boundary for Aluminium (Smelter sub sector) 193

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