The Bratsk aluminum smelter is the largest enterprise by world and domestic standards, where 30% of the total domestic aluminum and 4% of the global metal production are produced.
History
The fraternal aluminum plant was launched in 1966, until 1973, additional capacities were launched. Energy supply to the enterprise is provided by the Bratsk hydroelectric station. In 1980, the company received worldwide recognition, having received the Golden Mercury Award, given for its merits in the field of international cooperation and the development of production.
The change in ownership took place in 1993: the company became an open joint stock company of Bratsk Aluminum Smelter OJSC. The total number of issued shares has not changed since that time and amounts to 5 505 305 units.
Until the beginning of the 21st century, the company changed owners several times. From 2000 until today, the enterprise has been managed by the RUSAL concern. The fraternal aluminum plant is one of the largest assets of Russian Aluminum. In 2001, BrAZ celebrated the anniversary smelting of aluminum, and 25 million tons of aluminum have been produced since the founding of the plant. Thirty millionth ton of metal was smelted in 2006.
Production
At the time of launch, the facilities of the enterprise were designed to produce 915 thousand tons of metal per year. Since 2007, a large-scale modernization has begun at the plant, the process is ongoing now. During this time, the Bratsk aluminum plant received the opportunity to produce a million tons of products per year; for the first time, new capacities were demonstrated in 2008.
Primary aluminum at the plant is obtained in electrolyzers using Soderberg technology. The company’s assets include 25 buildings, comprising three electrolysis workshops, anode paste workshops, fluorine salts and production areas for the production of crystalline silicon. As part of modernization and in order to produce competitive products, in 2008 a casting complex for the production of flat ingots was put into operation, its capacity is 100 thousand tons of products per year.
RUSAL Bratsk Aluminum Smelter OJSC receives energy from the Bratsk Hydroelectric Power Station and consumes up to 75% of the total generated capacity of the station. Raw materials for production are supplied from Kazakhstan, as well as from partners from Guinea, Italy and other countries.
The main types of products:
- Aluminum in high purity ingots weighing 15 kilograms (grade A995-A95).
- T-shaped bullion metal.
- Aluminum ingots, aluminum alloys marked AMg2, AMg3. Metal for rental companies.
All products are certified according to international standards and ISO and OHSAS protocols.
Production modernization and social policy
The main objective of the company is to increase the production of quality products in accordance with the requirements of the global consumption market. In 2012, the Bratsk Aluminum Plant began to produce more than ten new types of ingots and metal alloys. In the same year, new equipment was launched to achieve the best work results and the quality of the evaluation of the products received. The Wagstaff foundry complex received modern mixers, and the Limca plant began to evaluate the purity of aluminum during the smelting process.
In order to improve the ecological situation and reduce the environmental impact, the Bratsk Aluminum Plant implements the Ecological Soderberg program; in 2012, the installation of the latest gas purification unit in building No. 25 was carried out.
The social policy of the enterprise is implemented in compliance with all the norms of the Labor Code of the Russian Federation and the construction of housing for employees. It is expected that about 14.5 thousand people will take part in the housing program. Housing is purchased by employees of the company for preferential mortgage lending, part of the funds (about 50%) is repaid by RUSAL. In the summer, plant employees have the opportunity to send children for free to a camp located in the Krasnodar Territory.
Production management system
The leader in many endeavors was the Bratsk Aluminum Plant. The production system introduced at the enterprise is the result of a thorough study of world-class management standards, our own rich work experience and the capabilities of the Russian market. The main postulate of the program is a statement that the interests of the staff are priority. So there was a need to create a middle class at the enterprise, for which they determined the average level of wages - at least 2 thousand dollars a month, a high level of responsibility in its place, a quality education with the ability and desire to increase its level.
“Break the stereotype!” - The production system of the Bratsk aluminum plant. The book describing the system was released by the managing director of BrAZ in collaboration with several experienced managers of the company. The essence of the system is a step-by-step solution of tasks when moving towards a goal, 18 steps are described in total. According to the authors, each subsequent step can be realized only after understanding and obtaining a complete picture of the results of the previous ones. Based on a comprehensive analysis, the next step crystallizes to the ultimate goal.
System performance
After the introduction of a new type of management at the enterprise, profit increased noticeably, product quality improved, and the attitude of personnel towards their work and the company as a whole changed for the better.
Key achievements:
- Metal production increased to 1 million tons per year (it was 920 thousand tons).
- The increase in labor productivity up to 2.9 times, the optimization of the number of personnel occurred by reducing the staff from 11 to 4 thousand people.
- The overhaul period of equipment was reduced to 15%, which indicates its reliability.
- The quantity of stocks of raw materials in warehouses decreased by 10-30%.
- The quality of products does not depend on raw material indicators, remaining unchanged at their best.
- The number of industrial accidents has been reduced.
- Due to the introduction of new environmental protection systems, the amount of air emissions was reduced.
- The cost of production, which produces the Bratsk aluminum plant, is one of the lowest in the world.
- The company's production facilities are fully loaded, despite the crisis.
- Investments in the company were practically not carried out, efficiency was achieved due to operational activities.
Address
The Bratsk Aluminum Plant is a city-forming enterprise. The main facilities are located in the Irkutsk region, the city of Bratsk.