The FECRI approach and the latest developments in the AP3X technology

More than 3800 AP30 cells are presently operating throughout the world, and 1500 more AP30 cells will start in the coming years. In order to continuously improve the AP30 technology, Alcan has launched an intensive technology development program. The aim of the program is to increase the amperage in the range 350-400 kA and to reduce specific energy consumption below 13000 kWh/t. Furthermore Alcan started in January 2005 an internal project aiming to reduce significantly the full economic cost for a new smelter: the Full Economic Cost Reduction Initiative (FECRI). This article describes the modelling of the AP3X cell including a major new development in coupling the thermoelectric and MHD models, the operational testing that lay behind the increase in amperage to more than 385 kA in the latest version, and some aspects of FECRI.