Operating Costs, Material and Energy Consumptions for Aluminium Industry

Introduction

In today’s modern Aluminium industrial environment, the use of innovative cost management practices that can accurately allocate refined intermediate and product manufacturing costs may assist refiners to optimize their production, improve their profitability and competitiveness.

Cost management is concerned with the process of planning and controlling the budget of a project or business. Cost management can also be applicable to refinery management systems and it can be a very important part of the aluminium production processes. It must be appreciated however, that production costs are a synthetic index that can reflect the effectiveness of production planning and scheduling. How to successfully control and manage production costs is a complex set of issues for refineries, but it can be used to monitor and control refinery unit performance.

This training course on aluminium industrial cost management will assist in creating cost structures for aluminium process units and assist in allocating costs to individual aluminium intermediates and finished on-specification aluminium products. Important aspect of aluminium process plant optimization is related to aluminium system energy management and aluminium energy consumption reduction. Furthermore, aluminium process monitoring that includes advanced controls and new technologies also present opportunities for aluminium optimization.

This training course will assist in examining individual process equipment such as atmospheric and vacuum distillation equipment, catalytic and thermal processes, heaters, furnaces and steam boilers, heat exchanger integration, rotating equipment efficiency including pumps and compressors. Aluminium cost management will provide a comprehensive review of the various aspects of aluminium cost management, which is the cornerstone for a viable aluminium plant profitability and optimization.

Objectives

By the end of this training course, participants will be equipped with the knowledge to conduct the following activities in their refineries:

• Determine by various techniques the cost of individual streams in the aluminium and individual processes
• Use these costs to calculate the enhancement potential for blending lower cost, on-specification products
• Optimize aluminium utility systems such as cooling water, steam and power generation
• Apply energy saving techniques to develop energy saving projects
• Enhance the production planning activities of the aluminium via cost management

 

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This training course is suitable to a wide range of professionals but will greatly benefit:

• Aluminium Plants &Field Engineers
• Process Plant Energy Managers / Coordinators
• All Professionals involved in Production, Planning and Scheduling
• Blending Professionals
• Financial Analysts

Course Outline

DAY ONE: OVERVIEW OF COST MANAGEMENT

• Introduction to Aluminium Plants Cost Management
  • Resource Planning
  • Cost Estimating
  • Cost Budgeting
  • Cost Control
• Energy and its Effect on Aluminium Profitability
• Aluminium Material & Energy Balance
• Energy Benchmarking
• Fuel, Power and Steam Costing Methodology

DAY TWO: Aluminium Plants

• Types of Aluminium Plants
• Key Process Units
• Aluminium Plants & Process Utilization
• Global Aluminium Situation
• Aluminium Plants Costs
• Aluminium Plants Investment
• Size and Complexity
• Location and Logistics
• Maintenance Costs

DAY THREE: Aluminium Plants PROCESS UNIT OPERATIONAL COSTS

• Aluminium Unit Distillation
• Aluminium Product Enhancement
• Aluminium Process Simulations
• Advanced Aluminium Process Control and its Benefits
• Blending for Product Specifications
• Blending to Reduce Product Costs

DAY FOUR: ECONOMIC EVALUATION AND COST MANAGEMENT

• Cost Estimation
• Aluminium Complexity and Netback
• The Gross Refining Margin
• The Net Aluminium Margin
• Factors that Influence Margins
• Margins According to Region
• Aluminium Utility System
• Steam and Power System Optimization
• Energy Efficiency: The Effect of Energy on Aluminium Profitability
• Quantification of Loss, Aluminium Accounting

DAY FIVE: Aluminium PROCESS HEAT INTEGRATION & EQUIPMENT EFFICIENCY: EFFECTIVE ENERGY MANAGEMENT

• Aluminium Process Heat Integration
• How heat integration works?
• Introduction to Pinch Technology
• Heat Availability Curves and Energy Targeting
• Equipment Efficiency: Effective Energy Management
  • Fired Heaters
  • Rotating Equipment
  • Heat Exchangers
• Energy Focused Organisation