Slide 1: Hydro Technology
Hydro Technology Johannes Aalbu Vice President Head of Technology development 2015-01-16 (1)
Slide 2: Our long-term strategy for higher value creation
Our long-term strategy for higher value creation (2)
Slide 3: Hydro overall technology strategy
Hydro overall technology strategy The three pillars of Hydro’s technology strategy Operational excellence and 1 utilization of technology Electrolysis technology – 2 the heart of an Al company Product solutions supporting 3 future growth in Al demand and sustainability
Slide 4: Transforming the way we use energy
Transforming the way we use energy Energy efficient, Zero energy Increase solar Packaging that Recycling low-emission Lighter vehicles buildings energy efficiency reduces waste and reuse electrolysis Reduce energy Reduce fossil Reduce energy Reduce fossil Reduce GHG Reduce waste consumption, fuel co
Slide 5: Raw materials to produce 1 kg aluminium
Raw materials to produce 1 kg aluminium 4 - 5 kg Bauxite Al2O3, Electrolyte + x C 2 Al + mCO2 + nCO CO2 2 kg + 0.5 kg + 1,5-2 kg Aluminium oxide Carbon + + = 50 g 50 g 13 - 15 kWh 1 kg Aluminium fluoride Cryolite Electrical energy Aluminum Figures are approximate – depending on technology
Slide 6: Aluminium Reduction cell
Aluminium Reduction cell Alumina Electrolyte Carbon anode Liquid aluminium Carbon cathode (6)
Slide 7: Technology development for Hydro smelters
Technology development for Hydro smelters Traditionally strong focus on amperage increase Søderberg Sunndal 4 120 kA 250 - 316 kA Qatalum HAL4e 295 - 314 kA 400- 450 kA
Slide 8: Sunndal 390/515 kt Al pr. year
Sunndal (8) 390/515 kt Al pr. year
Slide 9: Qatalum site preparation
Qatalum site preparation 10 million tonnes of landfill
Slide 10: The world's largest aluminium plant built in one stage
The world’s largest aluminium plant built in one stage
Slide 11: R&D Organization
R&D Organization (11)
Slide 12: R&D Locations in decentralized structure
R&D Locations in decentralized structure Sunndal Raufoss Årdal Oslo Karmøy Porsgrunn Tønder Eupen Neuss Bonn RTD Reference Center, Ulm Sunndalsøra in Norway Toulouse HAL4e Reference Center, Årdal in Norway Holland, MI Doha Hydro's die innovation center, Eupen in Belgium Technal Brand Development Cen
Slide 13: Strategic University/R&D partners
Strategic University/R&D- partners NTNU SINTEF RWTH (Aachen) Qatar University Worcester Polytecnique Institute Indian Institute of Science, Bangalore MIT, Boston University of Illinois (ACRC) Universities of Toyama and Tokyo Shanghai Jiatong University Brazil University of Auckland
Slide 14: Academic network is part of R&D value creation and innovation
Academic network is part of R&D value creation and innovation • Active role in professorships • Funding PhD and master thesis • Summer jobs • Ownership in joint research programs • Knowledge sharing R&D • Access to plants Universities/ Operations/ institutes market
Slide 15: Energy & Climate: Greener
Energy & Climate Greener (15)
Slide 16: We have established industry's most ambitious climate strategy
We have established industry’s most ambitious climate strategy Supported by the three pillars of Hydro’s technology strategy Energy and primary production Reduce emissions, increase efficiency Aluminium in use Maximize user- phase benefits ‘End-of- life’ Increase recycling, back to the loop (16)
Slide 17: Emissions to air from electrolysis
Emissions to air from electrolysis -HF/SO2 -HF/SO2 -Dust -Dust 10% - CO2 90% -CO2 -CFx -CFx GTC Pot Room
Slide 18: Hydro meets climate challenge
Hydro meets climate challenge Major reductions in CO2e- and energy consumptions Lower emission from Hydro plants Lower energy consumption in Hydro plants Kg CO2e / Kg aluminium KWh / Kg Aluminium 7 16 6 5 -70% 15 4 14 3 13 2 12 1 0 11 1990 1995 2000 2005 2010 1993 1998 2003 2010 Qatalum HAL4e Averag
Slide 19: Fluoride emission to air, Norwegian smelters 1993-2013
Norwegian smelters 1993-2013 Fluoride emission to air Fluoride emission 0.8 0.7 0.6 0.5 kg/ton Al 0.4 0.3 0.2 HAL4e 0.1 0.0 1992 1996 2000 2004 2008 2012 Year (19)
Slide 20: Lifecycle perspective: Replacing steel with aluminium in vehicles
Lifecycle perspective: Replacing steel with aluminium in vehicles helps cut CO2 emissions Kg CO2 saved/kg aluminium replacing steel in cars* 25 20 15 10 5 No. years in use 0 0 1 2 3 4 5 6 7 8 9 10 11 -5 -10 100% primary metal 100% recycled metal * Incl. Full value chain CO2 emissions in production o
Slide 21: Production in Norway reduces global emissions
Production in Norway reduces global emissions Emission of climate gas per tonne aluminium Norway 2,2 CO2e Iceland 1,9 CO2e Russia Canada 15 CO2e 5,8 CO2e EU-27 10 CO2e USA China 12,8 CO2e 17 CO2e Middle- East 11 CO2e Brazil 4,5 CO2e Australia 16 CO2e Source: Institut für angewendte Ökologie (Öko-ins
Slide 22: Hydro Smelter Technology – Energy efficiency
Hydro Smelter Technology – Energy efficiency 17,5 Energy Consumption Development Historical Data Short Term Ambition 15.0 Medium Term Ambition 14.8 14.4 Long Term Vision kWh/kg Al 14.1 13.9 13.5 12.5 12.3 11.8-11.5 10 kW 10 Hydro Global Hydro HAL300 HAL4e HAL4e Hydro Karmøy Hydro Hydro HAL4e 2003 av
Slide 23: Systematic effort in order to reduce energy consumption
Systematic effort in order to reduce energy consumption
Slide 24: Targeting high productivity & low energy consumption
Targeting high productivity & low energy consumption Energy consumption (kWh/kg) HAL300 13 HAL4e High productivity 12 Low energy 11 Current density (24)
Slide 25: Better Cell Technology HAL4e
Cell Technology HAL4e Better (25)
Slide 26: Aluminium cell
Aluminium cell HYDRO
Slide 27: HAL4e in operation since May 2008 – now at 450 kA
HAL4e in operation since May 2008 – now at 450 kA (27)
Slide 28: Technology need to be implemented
Technology need to be implemented Bridging R&D and full production (28)
Slide 29: Towards 11 kWh/kg...
Towards 11 kWh/kg... ... and 10 kWh/kg − Millivolt chasing & bottleneck removal − Operate at shorter interpolar distance − Improved process control & stability Millivolt chasing Heat management − Improved feeding technology Heat management Millivolt chasing − Heat balance challenges Improve process
Slide 30: Magnetic Field Calculations
Magnetic Field Calculations
Slide 31: Hydro Double pot-room Technology
Hydro Double pot-room Technology Hydro’s Technology HAL250 potroom Competitors Technology Single row potroom
Slide 32: Double potroom Qatar
Double potroom Qatar (32)
Slide 33: HAL4e Pilot Plant Project
HAL4e Pilot Plant Project - Location on old Søderberg site at Karmøy Pilot Plant 74.000 tpy Existing 190.000 tpy (33) Confidential, 2013-10-30
Slide 34: Bigger: Growth and Improvements
Growth and Improvements Bigger (34)
Slide 35: Investing in developing our precision culture
Investing in developing our precision culture Tech 1 Tech2 Model based Tech 1 Prod limit Tech2 Model based Prod limit Performance World-class production requires stability Performance Fire fighting Stability 80 80 85 85 90 90 95 95 100100 105 105 Precision culture Process Control Technology step Lev
Slide 36: We have a history of continuous growth and improvements
We have a history of continuous growth and improvements: Metal volume from existing potlines has increased with more than 100.000 tons over some years (36)
Slide 37: Fully-owned smelters – increasing output from existing lines
Fully-owned smelters – increasing output from existing lines, gaining productivity Production development in Norwegian fully-owned smelters, indexed from 2005 130 125 ~100 000 mt1 120 ~100 000 mt1 115 Technology and competence 110 driven volume growth Larger anodes 105 New cathode technology Improve
Slide 38: The Pilot plant: Better, Bigger, Greener
The Pilot plant Better Bigger Greener (38)
Slide 39: HAL4e Pilot Plant – 60 cells, 74 ktpy
HAL4e Pilot Plant – 60 cells, 74 ktpy 48 cells: HAL4e 12 cells: HAL4eUltra 450 kA @ 12.3 kWh/kg 415 kA @ 11.8-11.5 kWh/kg
Slide 40: HAL4e Pilot Plant Project
HAL4e Pilot Plant Project - Location on old Søderberg site at Karmøy Pilot Plant 74.000 tpy Existing 190.000 tpy (40)
Slide 41: Infinite Aluminium – Hydro
INFINITE ALUMINIUM HYDRO