Implementation of a $2.65 Million Project to Rebuild and Overhaul 18 Ingot Reduction Cells at Iran Alumina Company

The project to rebuild and overhaul aluminum ingot reduction cells was carried out with a total investment of $2.65 million and with the aim of addressing challenges arising from equipment wear, improving process performance, and increasing production line productivity.

As reduction cells age, lining wear and equipment efficiency decline, leading not only to reduced aluminum production but also to increased energy consumption; energy consumption has risen from 15 to 17 megawatt-hours per ton of aluminum, and cell efficiency has dropped from 93% to 85%. Given the standard lifespan of approximately 1,500 days for cell linings, rebuilding and overhauling this equipment plays an important role in maintaining production stability and controlling operating costs.

Under this project, 18 cells out of the total 70 cells in the ingot unit were rebuilt and overhauled since the beginning of the year 1405 (2026–2027). The cost of operations per cell is estimated at an average of $147,000, and with the implementation of this plan, cell efficiency increased by 8% and annual energy consumption decreased by approximately 32,700 megawatt-hours.

The implementation of this project, in addition to improving equipment performance and reducing energy loss, provides the basis for increasing the reliability of reduction cells, reducing the risk of production stoppages, and more effective use of existing infrastructure. Furthermore, improved efficiency and reduced energy consumption can play an effective role in lowering the finished cost of aluminum ingot production and strengthening the sustainability of this unit’s activities.

It is worth noting that Iran Alumina Company, within the framework of its new management approach after the transfer of management from the public sector to the private sector, pursues increasing productivity, optimizing energy consumption, safeguarding existing capital, and reducing operating costs as important axes of its activities. On this path, rebuilding and modernizing production equipment with a focus on enhancing technical performance and maximizing the use of existing capacities is considered an effective step toward production sustainability and strengthening the aluminum industry’s value chain.