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The University of Queensland THE UNIVERSITY OF QUEENSLAND Using Aluminium Smelters for Energy Stabilisation: A study of Demand Management for Aluminium Reduction Cells Student Name: Phillip TREW Course Code: MECH4500 Supervisor: Dr Peter Knights, Dr James Vaughan, Dr Alan Tomsett Submission date: 25 October 2018 Faculty of Engineering, Architecture and Information Technology Using Aluminium Smelters for Energy Stabilisation: A study of Demand Management for Aluminium Reduction Cells Abstract Demand for aluminium has increased over the last 60 years, this in conjunction with rising Australian energy prices has resulted in aluminium smelter electricity cost increasing. Additionally, within this overall energy price incline there are substantial demand and supply driven price variations for energy during each day. Smelters that rely on the electricity spot price can expect a larger variation in daily prices. Due to these factors, this thesis aims to investigate the impact an amperage reduction has on the heat, electrical and mass balance of a conventional aluminium cell. A specific focus is placed on the relationship between the reduction of electrical inputs and aluminium production. Furthermore, this thesis seeks to understand the suitable economic environment required for the amperage reduction, and the feasibility of the reduction as an energy stabilisation strategy. To achieve the aims of this project a quantitative strategy that involved the development of two models was adopted. One to simulate the heat, energy and mass balance of the cell, and the other to simulate to the economic impacts the reduction has on the cell. To analyse if amperage modulation is an effective energy stabilisation strategy, three types of reductions were tested; a step, staggered step and ramp reduction. These scenarios where tested for a reduction of 10, 15, and 20 kA. These scenarios were then compared by plotting the duration, opportunity cost and power saved. From this, the most viable reduction was selected with the use of weighted decision matrix. From this analysis the 10kA ramp reduction was deemed as the most suitable energy stabilisation strategy. As it saves 115.92 MWhr over a 3 hour period when applied to all 840 cells. Furthermore, this reduction only incurs an opportunity cost of $-33.6 over the same period of time. However, an average peak energy price of 90.17 $/MWhr was used for this analysis. By increasing the energy price and plotting the opportunity cost it was found that this strategy becomes viable when an energy price of 90.47 $/MWhr is reached. Finally, the following points where identified as areas of future study; Further optimisation of the model can be done by constructing a 3D model that simulates the cell dynamics in more detail. A similar study could be conducted with the use of heat exchangers to control the heat loss from the cell. 3 Using Aluminium Smelters for Energy Stabilisation: A study of Demand Management for Aluminium Reduction Cells i. Table of Contents i. Table of Contents ............................................................................................................................ 4 ii. List of Figures ................................................................................................................................. 6 iii. List of Tables ............................................................................................................................... 6 1. Abstract ........................................................................................................................................... 3 2. Introduction ..................................................................................................................................... 8 2.1. Scope ............................................................................................................................................ 8 2.2. Goals of the Project ...................................................................................................................... 9 2.3. Assumptions ................................................................................... Error! Bookmark not defined. 3. Literature Review ............................................................................................................................ 9 3.1. Hall-Héroult Aluminium Smelter ................................................................................................. 9 3.1.1. Anode .................................................................................................................................... 9 3.1.2. Cathode ............................................................................................................................... 10 3.1.3. Electrolyte Bath ................................................................................................................... 11 3.1.4. Faradays laws ...................................................................................................................... 12 3.1.5. Energy Balance of the Hall-Héroult Reduction Cell ........................................................... 13 3.2. The Need for Energy Stabilisation ............................................................................................. 13 3.3. Aluminium Smelter Cost Structure ............................................................................................ 16 3.4. Current Power Modulation Research ......................................................................................... 16 3.4.1. Shell Heat Exchanger .................................................................................................... 17 3.4.2. Impact of Amperage Reduction on the Cell .................................................................. 18 3.4.3. Energy stabilisation ....................................................................................................... 19 4. Methodology ................................................................................................................................. 20 4.1. Technical Model Development .................................................................................................. 20 4.2. Economic Model Development .................................................................................................. 25 4.3. Strategy to Analysis the Results ................................................................................................. 27 5. Results ........................................................................................................................................... 28 5.1. Technical Model ......................................................................................................................... 28 5.1.1. Results: Step ........................................................................................................................ 29 5.1.2. Results: Staggered Step ....................................................................................................... 30 5.1.3. Results Ramp ...................................................................................................................... 31 5.2. Economic Model ........................................................................................................................ 32 5.2.1. Results: Step ........................................................................................................................ 32 5.2.2. Results Staggered Step ........................................................................................................ 33 4 Using Aluminium Smelters for Energy Stabilisation: A study of Demand Management for Aluminium Reduction Cells 5.2.3. Results: Ramp ..................................................................................................................... 34 6. Analysis ......................................................................................................................................... 35 7. Sensitivity Analysis ....................................................................................................................... 39 8. Conclusion ..................................................................................................................................... 41 9. Reference List ............................................................................................................................... 42 10. Appendix ................................................................................................................................... 44 10.1. Appendix A: Example Technical Model Calculation .............................................................. 44 10.2. Appendix B: Example Economic Model Calculation .............................................................. 45 10.3. Appendix C: Weighted Decision Matrix .................................................................................. 45 5 Using Aluminium Smelters for Energy Stabilisation: A study of Demand Management for Aluminium Reduction Cells ii. List of Figures Figure 1 Side section view of Pre-baked Aluminium Cell Figure 2 Retail price index of electricity in Australian Capital cities Figure 3 Electricity Demand and Price Fluctuations Snapshot Figure 4 Aluminium Smelter cost break down Figure 5 Shell Heat Exchanger Figure 6 Conventional Cell Response to an 80 kA Amperage Reduction Figure 7 Aluminium Smelter response with Shell Heat Exchanger Figure 8 Simulated Cell Response to 80 kA
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