- Joined
- 14 February 2005
- Posts
- 15,121
- Reactions
- 16,960
Aluminium smelting is indeed a very electricity price sensitive business.Some more gossip in the event of power cuts. The rumor is that some of the aluminium smelters have borderline/average profit margins & that if they were forced to shut down due to power outages (due to lack of water) that they might not start back up again. Don't know if it's true but sounds plausible.
Now, when does Costello's increased solar panel rebate come into effect?
In short, aluminium smelting is by far the largest industry that comes to the power rather than the reverse. Bell Bay (Tas) and Tiwai Point (NZ) are both classic examples. Import the ore, refine it, and export the metal. Electricity is the only local raw material and it is by far the largest component of the total cost.
To produce just one kilogram of aluminium metal takes enough power to run a 100 watt light bulb for a week. That's just one small block of aluminium.
The Bell Bay smelter actually uses more power than every house in Tasmania (and that's with very high domestic power use in Tas compared to the other states) or 25% of the state's entire load. Tiwai Point uses about 15% of NZ's power generation.
From a technical perspective, shutting one of these plants down isn't easy but it can be done. The main objective is to avoid ending up with solid (cold) metal in the pots - do that and the only solution is months of jack hammering out hundreds of pots (it won't melt - it's nowhere near as simple as it sounds).
So with sufficient (weeks) notice it's possible to do an orderly shutdown of part or all of a smelter. Just empty the pots one at a time (over 500 of these things at Bell Bay alone and they are massive - think something the size of a van (each) with over half a megawatt constantly pumped through it).
Bell Bay was partially shut during the mid-1990's due to a glut of aluminium on world markets. Also it was partially shut during the 1968 power crisis. In both cases the shutdown was orderly over a number of weeks and in both cases the smelter not only returned to full production, but went on to set new production records.
A short notice shut down is an entirely different problem however. A couple of hours without power is OK. But once the metal sets, it's game over unless the pots are mechanically dug (jack hammered) out and the plant restarted. A massive cost and months of lost production.
So if we're going to shut any smelters due to insufficient power, proper planning is essential otherwise the shutdown could well become permanent.
The smelters typically buy 5% or so, their "ripple" load, power on the spot market. They'll stop maximising production, just run at the baseload instead, if that gets too expensive. Not sure about individual smelters but Bell Bay's done that for ages (a spot price in Tas was basically invented for them years before anyone had heard the term "electricity market"). Tiwai Point does it too, not sure about those in Qld, NSW, Vic but I assume they maximise current through the pots when conditions allow.