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RUSAL implements energy-efficient electrolyzer designs

RUSAL, one of the world's largest aluminum producers, is running a comprehensive program to develop and implement energy-efficient electrolyzer designs. To date, more than 5,500 electrolyzers have been upgraded under the program, saving more than 500 million kWh of electricity per year. Since 2017, RUSAL has been implementing the Low-Cost Energy Saving Solutions Program for electrolysers. Each year, between 300 and 1,300 electrolysers are converted to energy-efficient configurations. Currently, these designs have been implemented in over 5,500 electrolysers across RUSAL’s five aluminium smelting plants. By the end of 2024, the annual electricity savings from the upgraded designs exceeded 500 million kWh for the first time. This figure corresponds to a monetary value of over 21.2 million US dollars. Since the program’s inception, RUSAL has achieved total electricity savings of over 2.5 billion kWh. Yiğit Kasapoğlu, Rusal Turkey Representative Director, commented on the matter, stating: “The transition to energy-efficient electrolyzer designs directly improves both environmental sustainability and the economic performance of our facilities. Within the scope of the program, we have achieved annual savings of over 500 million kilowatt-hours. This amount is equivalent to the electricity consumption of a small city, demonstrating the program’s effectiveness. Moreover, these results were achieved without any capital investment. The solutions developed by our engineers are implemented during scheduled equipment maintenance and do not require production to be halted. This is one of the best examples of the immediate impact of RUSAL’s technological innovations.”