风云年代米兰妮身份:俄罗斯铝厂

著名的俄罗斯铝业有限公司（RUSAL）所拥有的世界上最大的炼铝厂 - 萨亚诺戈尔斯克电解铝厂。由于附近就是著名的俄罗斯最大的萨扬舒申斯克水坝，该水坝建在叶尼塞河的上游，其水电站的装机容量高达640万KW。为电解铝工业提供了廉价、充足的电力。

该文不仅阐述了铝生产的历史及原理，还对前苏联和俄罗斯的铝工业发展进行了简要地介绍，是一篇图文并茂的好文章。

Русский алюминий

Russian Aluminum，俄罗斯铝业有限公司

我给俄罗斯铝业有限公司（RUSAL）写信，询问是否有可能参观该公司，了解他们的工厂是这样炼铝的。这个创作计划完全符合我的系列作品“这是怎么制造出来的”的要求。该公司立即同意了我的建议。我一直很疑惑，通过电解是怎样将铝矾土变成金属铝的。当然也非常好奇地想了解，俄罗斯除了能钻探石油外，还能生产哪些在世界上占有重要地位的产品。

该公司提出了我们可以参观工厂的清单和路线图，我们就开始了第一次访问，访问的是俄罗斯铝业公司的三个工厂之一，萨亚诺戈尔斯克电解铝厂。然后再去克拉斯诺亚尔斯克铝厂，这是目前世界上最大的铝熔炼厂之一。

在工厂里访问了四天，了解了炼铝的全部过程，我想我已经能在家里炼铝了。且让我慢慢道来。

铝是世界上第三位储量的元素，自然界以铝矾土及铝硅酸盐等形式存在。是元素周期表上处于原子序数第十三号的元素，其化学元素符号为Al。在自然界里我们只能遇见铝的化合物，而所有我们见到的金属铝都是通过工业的生产过程制造的，不像金、铂、铜等元素在自然界里有单质存在。

左：英国化学家汉弗里·戴维爵士，右：意大利物理学家亚历山德罗·伏特

（Sir Humphery Davy）                             （Alessandro Volta ）

曾经有一段时间，铝的价值比贵金属更昂贵。那时候只能从实验室里制造金属铝，人们称为铝是从粘土中提炼出来的银子。有两位科学家是导致金属铝成为我们常见的日用金属的重要人物。

另一位是英国化学家汉弗里·戴维爵士，他开始尝试用电解的方法制备铝，并于1808年以氧化铝为原料获得了少量银白色的金属，命名为“铝”（“Aluminum”）。汉弗里·戴维可以称为现代铝业之父，因为所有现代炼铝工艺均采用这种电解的过程。

1825年丹麦化学家汉斯·奥斯特成功用金属钾从氯化铝中还原出铝：

4 ALCl3 + 3 K = Al + 3 KAlCl4 

 由图波列夫设计的苏联首架全铝合金双座飞机，1920年。

俄罗斯成了世界上第三个进行工业化生产铝的国家。第一家铝厂是由俄罗斯工业家安东尼·诺奥维杰斯基（A. Nowowiejski）于1885年建成的，位于莫斯科北71公里的谢尔吉耶夫镇的谢尔盖圣三一修道院。1916年在季赫温（英文：Tikhvin，俄文：Ти?хвин，俄罗斯列宁格勒州东部的一个城市）周围发现铝矾土沉积矿。1929年在“Red Vyborzhets”建了六台炉子，5月27日用所建的设备产出了苏联第一炉铝，一共只有八公斤。该厂采用奥尔霍夫水电站产生的电能和完全国产化的原材料进行生产。该厂用制得的铝开始生产铝锅及铝制餐具。苏联电解铝的原型电解槽来自于法国。到1930年位于列宁格勒的炼铝实验工厂已经能生产九十吨铝。第二家铝熔炼厂建在第聂伯罗水坝附近这个总厂包括用年处理三万吨铝矾土生产电解铝所用的氧化铝提炼厂，15000吨/年生产能力的铝熔炼厂，具有自己生产电解所用的碳阳极的能力。

苏联开始在全国范围内探寻铝矾土资源，在乌拉尔的南部的巴什科尔托斯坦共和国境内发现大量铝矾土储量，在那里用高炉将铝矾土烧成氧化铝。当年铝的消耗量远远超过国内的产能，因此还需要从法国、挪威和美国进口。

卫国战争爆发之后，苏联几乎失去了全部的铝生产能力，奥尔霍夫和第聂伯的铝厂已经被转移。1941年斯大林曾经给美国总统罗斯福写信道：“给我三万吨铝，我就能赢得这场战争”。当时，苏联只有位于乌拉尔的炼铝厂依然能维持生产，为军工生产提供所需的铝。在整个卫国战争期间，乌拉尔铝厂一共生产二十四万四千吨铝材。

In the postwar years were built Kandalaksha, Nadvoitsky and Volgograd refineries. In 60-70 years, when the Soviet Union began to build a large hydroelectric power stations on the Siberian rivers, there Irkutsk, Krasnoyarsk and Bratsk smelters. There remained the problem of raw material - alumina had to buy abroad - in Guinea, Africa. The first plant for the processing of imported material was Nikolayev Alumina Plant (1980). It was designed to process high-quality African bauxite.

After the collapse of the Soviet Union the aluminum industry in Russia was in a difficult situation - the state stopped investing, broke relations with suppliers of raw materials in the former Soviet republics. The British Trans World Group, has received control over a large part of the Russian aluminum smelters in Russia has introduced a certain system of tolling, where imports of raw materials and export products made duty free, which brought huge profits to the owners, but the plants deprived of funds for production development. After the start of privatization in 1993, the industry began to receive criminal structures, hoping for a quick profit. Placed under the control of sea ports and factories were forced to pay for the shipment of goods thugs abroad. In the struggle for control over the industry criminal gangs tried to intimidate the leaders of those plants, which refused to cooperate with them. Those who refused to work on the gangsters brutally massacred.

In 1994, Oleg Deripaska, was elected Director General of the Sayanogorsk smelter. By this time he was its majority owner, together with the TWG (black brothers - well-known names). Three years after its establishment, headed by Oleg Deripaska, a group of "Siberian Aluminum" is among the ten leading manufacturers of aluminum products and Deripaska broke off relations with Trans World Group, finding additional funds for the development of additional shares of the plant. In 2007, the merger of aluminum and alumina assets of RUSAL, the third largest in the world aluminum producer, SUAL Group, part of the world's top ten producers of aluminum and alumina assets of Swiss company Glencore was created combined company "Russian Aluminium" - the largest in world producer of aluminum and alumina.

On Sayanogorsk aluminum smelter, which started the story of RUSAL, I went in the first place.

01. From Abakan, the capital of Khakassia, to Sayanogorsk - hour drive away. Along this road I've traveled two years ago, when the power plant accident occurred. The city is located in the very place where it ends and begins Khakasskaya steppe Sayan Mountains. Plant (and they are there three, actually) - ten miles from the city.

02. So Sayanogorsk aluminum looks out the window of the plant. I arrived on Sunday, people in almost was not, but the factory work - Aluminium production technology and continuous in all the shops work was, as usual.

03. It all starts here - in the electrolysis plant. It produces aluminum for the very technology developed by another Frenchman and an American Era Hall, about which I wrote above. True, it looks now is not the case, as in the XIX century. In Sayanogrske make aluminum in baths with so-called prebaked anodes. That brought them to a transport truck. These anodes are lowered into the electrolysis bath, to sleep and where alumina is converted to metal.

04. And here's what a burnt exhaust its anode. This is a consumable material, which the plant also produces its own. This technology allows the production on the stage of getting rid of many harmful substances. Anode with a coal cube already created more harmless, since the resinous substances are removed from the process of manufacture. Modern factories are being built with the expectation of just such anodes. There is a Norwegian technology Soderbergh, on which work, for example, the Krasnoyarsk aluminum plant, but on it I'll explain later.

05. Rows of pots go, it seems beyond the horizon. This new two shops in Sayanogorsk, built in 2004-2006 and dedicated to a single plant, called Khakassky - for the construction of a new plant because it was easier to find investors. In this shop quite sparsely populated, I met only one person. The production process is almost completely automated - from the top is filled alumina, after the end of the cycle comes off valve and a vacuum pump evacuates a large aluminum bucket.

06. Here is the design of the crane is pumping out three-ton aluminum reduction cells, and then poured into the bucket, which then be taken to the foundry. In order to produce a tonne of aluminum to nearly two tons of alumina, a half-ton of carbon (for the anode) and about 15 000 kWh of electricity. All equipment in the shop Russia, made in engineering and technology center of RUSAL, but the raw materials brought in imported - from Guinea, Jamaica.

07. Electrolysis plant - is not only harmful to human production, but also for photography. Each ton of aluminum - it is 280 000 cubic meters of gas emitted. And, if emissions have learned to fight through a filter system, here's a photo and video equipment, as I said, guides, better to close the electrolyzer not fit - there is a strong magnetic field.

08. What's next? Next to aluminum bucket placed on a cart and carry it to the foundry. There he was waiting for the furnace, which is made from a simple aluminum alloy required for the customer.

Photos foundry - from Sayanogorsk, which was built in Soviet times. Workshop of the two plants are near and look different only in color. By the way, two new shops Khakassia smelter (HAZ) - the first company to produce aluminum, built in Russia over the past 20 years. Well, most modern, of course.

09、在铸造厂里有许多熔炼炉，由于里面是温度高达700 °C的熔融铝，因此无法对着炉内拍照。在这些熔炼炉里根据用户对材料的要求配置不同组成的铝合金。

10、将从电解铝厂运来的熔融铝倒入熔炼炉，我不明白为什么熔融铝在照片上会显示出红色，而不是银灰色。

11、这些是生产铝合金所必要的添加剂，例如，金属硅、钛，锆等。

12. Here the master monitors the additives in the smelting of metal. After the furnace laid the components of the future of the alloy, the master takes a sample, makes it a little, the size of a hockey puck, bar and sends it in a chemical laboratory to check their work.

13、这里将熔融的金属铝铸成标准的铝锭，有些用户以这些标准铝锭为原料在他们自己的铸铝厂里铸造产品。

14、尽管从浇铸流水线上铝锭滚滚而来的，工人依然有足够的时间将铝锭运往堆场。

15、所生产的标准的铝锭，一种非常漂亮的金属。

16、阳光从车间顶篷和两侧的窗户中透射进来。但是工作面上还是有灯光照明的。

17、这里是专门为铝芯电缆工业生产柱状铝锭车间的控制室。

18、将熔融的金属铝浇铸到垂直放置的铸模中。

19、熔融的金属铝在这个铸模中结晶成型。

21、将生产出的铝棒码成堆。

24、挂上俄罗斯制造的标签。

译注：哈卡斯炼铝厂就是萨亚诺戈尔斯克电解铝厂，因为该厂建在俄罗斯联邦哈卡斯共和国境内。