Century Aluminum Upgrades Cooling Systems at South Carolina Smelter
Century Aluminum has upgraded the cooling tunnels at its Mt. Holly smelting plant in South Carolina, addressing operational challenges caused by outdated controls. The facility processes approximately 230,000 tonnes of aluminum annually, producing standard-grade ingots, extrusion billets, and other products. The modernization effort reflects broader trends in the aluminum industry as producers seek to enhance efficiency and reduce energy consumption.
The cooling tunnels at the plant play a crucial role in reducing billet temperatures from around 1,000°F to 90°F after homogenization. However, increased downtime due to aging controls had begun to impact production reliability. Sam Wilson, a technician at Century Aluminum, noted that the legacy equipment required extensive rebuilding and lacked the capability to provide detailed operational data. To tackle these issues, Century Aluminum collaborated with Electrical Equipment Company, a Siemens distributor, to retrofit the system with Siemens SINAMICS G120 drives and an Intelligent Operator Panel (IOP-2). The upgraded system now transmits real-time data such as current and torque, offering improved operational insights.
The modernization has led to a 50% reduction in downtime for the cooling tunnels and halved the cooling time for a 75-ton load. This improvement has increased daily processing capacity by 300,000 pounds while reducing energy consumption by optimizing motor operations. The upgrades also streamlined installation and maintenance processes through plug-and-play technology, allowing both control cabinets to be completed within eight hours without disrupting operations.
Century Aluminum’s investment in modernizing its casting equipment aligns with broader industry efforts to improve production efficiency amid rising demand for aluminum. Aluminum producers worldwide are increasingly adopting advanced technologies to address energy-intensive processes and meet sustainability goals. For example, Norsk Hydro recently announced plans to invest in low-carbon aluminum production using renewable energy sources like hydropower.
Additionally, global aluminum demand is being driven by its critical role in renewable energy systems and electric vehicles. The International Aluminium Institute estimates that demand for primary aluminum will rise by 40% by 2030 due to its use in lightweight materials and energy-efficient applications. This growth underscores the importance of modernizing production facilities like Century’s Mt. Holly plant.
Century Aluminum’s upgrades also reflect challenges faced by U.S. aluminum producers competing against lower-cost imports from countries like China. Rising energy prices and supply chain disruptions have made operational efficiency a priority for domestic producers aiming to remain competitive in global markets.
With these improvements now fully operational, Century Aluminum has enhanced its production capabilities while contributing to broader industry trends focused on efficiency and sustainability.
