The “current efficiency” of the aluminum smelting process (how much current it takes to convert alumina to aluminum) is the key cost element of production. Improving process efficiency, increasing process current, upgrading of power conversion equipment and industry consolidations make accurate measurements crucial for maintaining competitiveness. DynAmp focuses on two key parts of this process: 1) conversion of electrical power to be useable in the process and 2) delivery and consumption of power in the process.

Process Applications

With process efficiencies now exceeding 94% of the theoretical limit, tenths of percent significant impact on competitiveness. With individual pot-lines energy costs from $11m to over $75m at current levels approaching 600kA, even small measurement errors can hide large losses.

High accuracy measurement of voltage and current is needed to...

Suitable DynAmp Products

High accuracy total process current measurement utilizing fiber optic sensing technology
High accuracy total process current measurement

Power Conversion Applications

Aluminum processes require the highest stability and reliability from power conversion equipment. Current instability leads to numerous process efficiency problems which increase costs. Reliability of power is paramount. Short term disruptions increase costs by running the pot-line at less than optimum capacity. Long-term disruptions can be catastrophic requiring an entire pot-line to be rebuilt. Finally, catastrophic power conversion equipment failures are extremely hazardous and endanger both staff and facility.

Highly dependable and responsive measurement systems are needed to...

Suitable DynAmp Products

Rectifier output measurement, control, and balance with over/reverse current protection
High accuracy rectifier output measurement, control, and balance
Basic reverse current protection for rectifiers
Internal rectifier analysis and condition monitoring
Portable measurement