Since 2017, RUSAL has been implementing a Low-Cost Energy-Saving Solutions Program for electrolysers. Each year, between 300 and 1,300 electrolysers have been converted to energy-efficient configurations. As of now, these designs have been installed in more than 5,500 electrolysers across five of RUSAL’s aluminium smelters
By the end of 2024, annual electricity savings from the upgraded designs exceeded 500 mln kWh for the first time, which in monetary terms amounted to over $21.2 mln. Since the program’s launch, RUSAL has saved more than 2.5 billion kWh of electricity.
“The transition to energy-efficient electrolyser designs directly improves both the environmental sustainability and economic performance of our smelters. The program has proven highly effective: we’ve achieved annual savings exceeding 500 mln kilowatt-hours — equivalent to the yearly consumption of a small city. What’s more, these results have been achieved without capital investments: the solutions developed by our engineers are implemented during scheduled equipment maintenance and do not require production shutdowns. This is a prime example of how RUSAL’s technological innovations provide real-time impact,” said Head of RUSAL Engineering Department.