In recent years, the aluminum industry has faced various challenges. However, the Aluminum Ingot Production Unit of Iran Alumina Company, as one of the pioneers in this industry, has achieved remarkable successes by relying on technical knowledge, coherent planning, and continuous efforts, despite limitations arising from power energy supply resources and the supply of raw materials such as anodes, cathodes, cryolite, etc. In an interview with Engineer Bijan Ebrahimi, the company’s Ingot Production Manager, these achievements are discussed to learn more about the experiences and challenges in this industry.

1. What are the characteristics of the Aluminum Ingot Production Plant of Iran Alumina Company, and what role does it play in the country’s aluminum industry?

This unit is one of the key sectors of the aluminum industry and Iran Alumina Company. It became operational in 2018 (1397 SH) with the commissioning of two cells (pots) and includes the main stages of the reduction process in electrolysis cells, casting, and ingot production. Fortunately, we are proud that through targeted and sound planning and the efforts of experts in this field, Iran Alumina Company, as the only domestic smelter, has managed to achieve the highest purity level (99.90%) with 7-year-old cells and maintain an average purity of 99.8%.

2. Tell us about the successes achieved in the renovation and commissioning of the cells in the reduction hall, despite the harsh conditions in the country and the sanctions.

In a situation where the supply of raw materials was complicated by sanctions, with the support and continuous follow-up of Dr. Badkoubeh, the respected CEO, the process of supplying materials needed for the repair and renovation of the cells proceeded without interruption. For the first time, we carried out the demolition, refractories installation, and lining of the cells entirely within Iran Alumina Company and also designed and manufactured the necessary equipment in-house. In this regard, the complete renovation operation of the first cell has been finished, and 5 other cells have achieved over 70% progress. The remaining cells have completed about 50% of their renovation path due to limitations in execution space and the nature of the work. In total, out of the 70 cells in the reduction hall, 21 have been temporarily shut down so far, 7 cells have been renovated and brought back online, and according to the established plan, one cell is scheduled to be commissioned every 7 to 10 days until the desired stable condition is achieved.

3. You mentioned that the useful life of the cells in the reduction hall has been extended from 5 years to 7 years. How was this achievement accomplished?

This success is the result of the continuous efforts of our colleagues in the operations and production unit. By precisely controlling the electrolyte temperature and the thermal balance of the cell, optimizing the electrolyte composition and the alumina-to-cryolite ratio, improving the anode design and gas ventilation to reduce corrosion, and monitoring equipment status and implementing preventive maintenance, we have managed to extend the useful life of the cells. Furthermore, intelligent energy resource management and the use of innovations in operating methods have also played a significant role in this regard.

4. What impact has the localization of processes had on the unit’s performance?

In line with the company’s macro policies regarding the localization of processes and the utilization of domestic capabilities, we can confidently state that from the beginning of the current year (December 22nd), the renovation and lining of the cells will be carried out entirely by the company’s domestic specialists, without the presence of external contractors. The result of this valuable action, in addition to upgrading the skills and technical knowledge of domestic staff, will lead to a saving of approximately 500 million Tomans per cell. This great achievement is a symbol of trust in the capabilities of local forces, intelligent management, and true self-sufficiency in the Jajarm aluminum industry.

5. Tell us about the limitations of energy supply for production operations.

Energy supply limitations have truly created a major challenge for all factories in the country and have even halted the production of some of them. Aluminum production, which is a very energy-intensive process (13 to 15 MWh of electricity per ton of aluminum), has faced many challenges such as increased production costs and reduced competitiveness, reduced reduction line capacity or temporary shutdowns, decreased cell efficiency due to power fluctuations, disruption in the supply chain of downstream industries, and increased reliance on ingot imports. Fortunately, we were able to continue production operations with the minimum number of shut-down cells and without interruption. After the limitations were lifted, the cells were renovated and brought back online, which demonstrates innovation in operating methods and energy management—a valuable step towards sustainable production and knowledge transfer to local specialists.

6. Despite all these challenges and limitations, what were the factors for the success of the ingot production unit under the current circumstances?

Several factors have had the greatest impact on achieving this success, including reduced energy consumption, localization of parts, intelligent resource management, increased product purity, maintaining power flow during the summer, and precise cost control.

7. Is there anything else you would like to mention?

In closing, we sincerely thank the respected CEO, managers, heads, supervisors, experts, technicians, operators, and all dear colleagues at Alumina Company. With the valuable support, intelligent guidance, and unwavering cooperation of the respected management, the path of continuous production, productivity enhancement, and support for domestic forces will be successfully traversed. This cooperation and solidarity is a clear example of commitment, team spirit, and belief in domestic capability, and it plays a significant role in the sustainable development of the country’s aluminum industry. This conversation demonstrates the firm determination and relentless effort of the Aluminum Ingot Production Team at Iran Alumina Company to overcome challenges and achieve remarkable success in Iran’s aluminum industry under the current conditions.