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DC2 confidential - (Garciaos)
READY TO USE CATHODE RUC®
General presentation
Oscar A. Vera GarciaWiesbaden, January 22nd , 2020
Page 2COBEX | RuC® for Hindalco Aditya| Novemberr 4th, 2019| Page 2TOKAI COBEX | RuC® General presentation| January 21st, 2020 |DC2 confidential - (Garciaos)
The aluminium production is a complex and expensive process
1 Supplied by Harbor Aluminum 2 Include steel bar and rodding process
How can Tokai COBEX help you increase your operational margin?
Alumina 38%
Anodes 16%
Other Raw Materials
3%
Labor & Administration
4% Energy29%
Other Operating
Costs
9%
Aluminum Smelting Costs Q1 - 20191Industry statistics
• Aluminium Production cost1: [$1 250 , $2 200] /t Al
• Electricity contribution: [$360 , $640] /t Al
• Rodding costs2: [$1 100 , $2 000] /block
• Cathodes have small cost but high impact on
energy consumption
Cathodes:
Only 1 → 2%
Page 3COBEX | RuC® for Hindalco Aditya| Novemberr 4th, 2019| Page 3TOKAI COBEX | RuC® General presentation| January 21st, 2020 |DC2 confidential - (Garciaos)
• In February 2016, Tokai COBEX & Novalum started an exclusive collaboration agreement for the next
generation cathodic solution.
• The Ready to use Cathode (RuC®) solution is protected by a patent application filed on May 2015
(PCT/IB2015/054325).
Towards the next generation of cathodic solutions
Cathodic solution without rodding
+
cost saving & productivity benefits
Page 4COBEX | RuC® for Hindalco Aditya| Novemberr 4th, 2019| Page 4TOKAI COBEX | RuC® General presentation| January 21st, 2020 |DC2 confidential - (Garciaos)
Towards the next generation of cathodic solutionsExample
Conventional cathode design compared
to RuC® solution:
• Same cathode dimensions
• Same external machining
• Same cross section of end of steel
bar
• Same end connection to flexibles
Same cathode assembly
design!
Page 5COBEX | RuC® for Hindalco Aditya| Novemberr 4th, 2019| Page 5TOKAI COBEX | RuC® General presentation| January 21st, 2020 |DC2 confidential - (Garciaos)
RuC® will increase your operational margin
• Rodding Elimination
• Significantly reduced health and
safety risks
• Installation & connection
unaffected
• Increased consistency of
cathodic assembly
• Reduced Specific Energy
Consumption (SEC)
• Reduced cathodic resistance whilst
maintaining thermal balance
• Improved current density
distribution enabling improved
Current Efficiency (CE)
• Increased production
• Additional cathode material and
more even current density
distribution extend pot life
Fields of
Improvement
Econom
ic
Benefits
Rodding Energy
Productivity Lifetime
Page 6COBEX | RuC® for Hindalco Aditya| Novemberr 4th, 2019| Page 6TOKAI COBEX | RuC® General presentation| January 21st, 2020 |DC2 confidential - (Garciaos)
Rodding and Installation
Ru
C®
Co
nv
en
tio
nal
Conventional Cathode Delivery Date
time
Delivery Date
Target Installation
date
Hazardous Rodding
process
RuC® Assembly
No Customer rodding! Customer’s rodding risks eliminated.
Significant improvement in time from Delivery to Installation.
Customer Scope
Customer Scope
Target Installation
dateConventional Cathode material
Supplier Scope
Page 7COBEX | RuC® for Hindalco Aditya| Novemberr 4th, 2019| Page 7TOKAI COBEX | RuC® General presentation| January 21st, 2020 |DC2 confidential - (Garciaos)
Energy Consumption – Measured Benefit example
CA ½
CVD and Pot voltage measurements
Reduced CVD and Pot Voltage → Lower Energy Consumption
• Example 3: 3.57 kA/bar, 36% CVD savings, average of 48 mV saved in the pot voltage after stabilization
-70.0
-60.0
-50.0
-40.0
-30.0
-20.0
-10.0
0.0
0 30 60 90 120 150 180 210 240
Savi
ngs
(mV
)
Age (d)
ΔPot Voltage savings
ΔPot V (RuC-Stnd)
50%
60%
70%
80%
90%
100%
110%
120%
130%
0 30 60 90 120 150 180 210 240 270 300
CV
D (%
)
Age (d)
CVD comparison
RuC Standard
Page 8COBEX | RuC® for Hindalco Aditya| Novemberr 4th, 2019| Page 8TOKAI COBEX | RuC® General presentation| January 21st, 2020 |DC2 confidential - (Garciaos)
Lifetime – Estimated Benefit example
Estimated extra 2 - 3 years lifetime
• More even current density distribution at the
cathode working surface
➢ Less localised erosion
➢ Lower average wear rate
• Additional cathode material between
aluminium and collector bar
➢ Leading to improved usage cycle
Fewer linings gives a reduced average annual lining cost
Standard cathode top view
RuC® solution top view
[A/cm2]
Modelling comparison of current density distribution
Δh
Δh: additional cathode material → extended lifetime!
Cross section showing differences in Collector bar dimensions
Page 9COBEX | RuC® for Hindalco Aditya| Novemberr 4th, 2019| Page 9TOKAI COBEX | RuC® General presentation| January 21st, 2020 |DC2 confidential - (Garciaos)
Productivity – Estimated Benefit example
• Better current density distribution
➢ Potential Current Efficiency (CE) improvement (0,5 – 1 %)
• Enables current creep
CA ½
max. 1,9 A/cm² max. 1,0 A/cm² (-45 %)
• Conventional current density distribution:
➢ Standard Current Efficiency (CE)
• Limited current creep
Conventional cathodic solution RuC® solution
Higher Current Efficiency (CE) → Additional metal production
Modelling shows current density
distribution v ectors
Page 10COBEX | RuC® for Hindalco Aditya| Novemberr 4th, 2019| Page 10TOKAI COBEX | RuC® General presentation| January 21st, 2020 |DC2 confidential - (Garciaos)
RuC® Benefit general estimation
* Estimated benefit based on Tokai COBEX cost assumptions of Al production, specifically; energy, alumina & Al LME price. Current creep not considered
Rodding Energy Lifetime Productivity
Full Rodding
avoidance
20-150 mV Pot
voltage reduction
Additional lifetime:
estimated 2-4 years
+0,5% up to +1%
CE Improvement
Significantly
reduced Health and
Safety risk
25 – 55 $/mt Al cost
saving in production
process
High Cu recycling
value
>80% of Cu-LME
Additional metal
output
Plug & Play solutionSpecific CO2
reductionPotential current
creep ~10%
Value creation → Overall SEC reduced by [100, 600] kWh/t Al
→ Range $6 000 - $15 000 of additional value per cathode block over lifetime*
Page 11COBEX | RuC® for Hindalco Aditya| Novemberr 4th, 2019| Page 11TOKAI COBEX | RuC® General presentation| January 21st, 2020 |DC2 confidential - (Garciaos)
Customer Specific SolutionsTypical RuC® project
Technical Exchange
Basic Design
Advanced Modelling*
Manufacture
Delivered Plug & Play RuC® solution
• Gathering of input data
• Estimation of potential
benefits with RuC®
benefit calculator
➢ Define targets
• Consideration of
basic input
parameters.
➢ Customer specif ic RuC®
design w ith benefits:
➢ No rodding.
Signif icantly reduced
health and safety risks.
➢ Extended lifetime
• Use of all input
parameters and lining
design
➢ Customer specif ic RuC®
design w ith further
benefits:
➢ Low er energy
consumption
➢ Additional metal
production
• Fully managed &
manufactured by
COBEX
• Assembly
Benefits:
• No rodding
• Lower energy
consumption
• Extended lifetime
• Additional metal
production
* Advanced modelling requires additional information from customer and a detailed thermo-electrical analysis of l ining design
Small package if lining
design is not given
Page 12COBEX | RuC® for Hindalco Aditya| Novemberr 4th, 2019| Page 12TOKAI COBEX | RuC® General presentation| January 21st, 2020 |DC2 confidential - (Garciaos)
Overview of RuC® worldwideStatus January 2020
▪ RuC® projects already in operation for a wide range of technologies (Söderberg, AP,
GAMI, Alusuisse, Kaiser, NEUI, VAW) and line currents (110 kA, 180 kA, 220 kA, 330 kA,
400 kA and coming soon 600 kA).
▪ >500 RuC® blocks delivered to 9 customers.
▪ Intermediate autopsy after 1.6 years confirmed the robustness of the design and the
good energy performance.
▪ Measured SEC savings up to 400 kWh/t, CVD savings up to 100 mV.
▪ Oldest RuC®-G1 cell: 3.5 years.
© Copyright SGL CARBON SE Registered trademarks of SGL CARBON SE®
© Copyright COBEX GmbHRegistered trademarks of COBEX GmbH®
DC2 confidential - (Garciaos)
© Copyright Tokai COBEX GmbHRegistered trademarks of Tokai COBEX GmbH®
DC2 confidential - (Garciaos)
Thank you for your attention!
This document is based on our best current knowledge a nd it is intended to provide information on specif ic properties of ourproducts and their applications. This information shall not be taken as guaranteeing specif ic properties , performance, or thesuitability of the product for a specific application under working conditions unknown to us. Pa rticularly, the data shall not betaken as a warranty for the lifetime or performance in the given applica tion. Tokai COBEX does not assume any lia bility withrespect thereto.