MetSol Technology Portfolio
MetSol’s product portfolio spans the full aluminium reduction cell — from pot control software to cathode and anode hardware — each technology engineered to deliver measurable efficiency gains and emissions reductions.
Product overview
01 — Advanced Process Control
Next-generation pot control for smarter, more stable operation
| Technology | Amperage | Type | % Reduction | |
|---|---|---|---|---|
| Power Consumption (MWh/t) |
CO2-equiv. Emissions (tCO2/tAl) |
|||
| AP-7 | 90 | PBSW | 1.5% | 88.7% |
| P-69 | 165 | PBPF | 4.7% | 58.8% |
| AP-CM | 135 | PBSW | 3.1% | 83.7% |
APC+™ is a PLC-based pot control system designed to manage and optimise alumina feed in a reduction cell for effective mass balance control. Unlike traditional timer-based controllers, it makes decisions based on real-time pot behaviour using high-resolution voltage sampling and resistance slope analysis.
Available as a supplement to existing microcomputers or as a standalone system. When combined with MPF™, additional savings and improved metal purity (P0202 or better) are achievable.
02 — Alumina Distribution
Multi-point feeding for improved pot stability
MPF™ is a proprietary multi-point feed system consisting of modular hopper, crust breaker and feeder units that can be retrofitted to existing pot superstructure. Process control logic manages improved heat and mass balance and advanced signal analysis for superior process stability.
The use of MPF technology makes it possible to increase anode length, facilitating current increases and achieving significant improvement in energy efficiency. Hardware is customised to each facility, maximising reuse of existing infrastructure.
03 — Cathode Technology
High performance cathode assemblies for lower voltage and longer pot life
HPCA™ is an electrically compensated cathode system developed to reduce cathode voltage drop and improve vertical current distribution. Delivered preassembled and ready to install, it simplifies relining while improving long-term performance. Developed in collaboration with Tokai Cobex, a leading producer of cathodic carbon material.
HPCA pots exhibit reduced metal velocity, lower cathode erosion, and effective ledge profile — translating to extended pot life and more stable operation.
04 — Anode Technology
High performance anode assemblies with copper-cored stub technology
HPAA™ consists of copper-cored anode assemblies constructed from scale-resistant alloy steel encapsulating a copper core. The HPAS™ (High Performance Anode Stubs) are an integral part of HPAA™ and inseparable from its performance characteristics.
The low resistance and high heat extraction of the copper core allow current to be increased further, enabling higher production rates. Significant voltage savings are achieved while further reducing carbon consumption.
05 — Bolted Connection Technology
Air cooled cathode tabs for reduced contact resistance
ACCT™ are used in bolted-connection settings to reduce resistance and lower energy consumption. The technology is designed to eliminate Green Ooze formation around the collector bar — a common cause of voltage increase and deterioration in bolted connection smelters.
ACCT™ is frequently marketed and sold as a stand-alone retrofit item, making it one of the fastest-to-deploy solutions in the MetSol portfolio.
06 — Collector Bar Technology
Copper cored collector bars for current increase and voltage reduction
CCCB™ is a proprietary technology capable of reducing cell operating voltage by over 100 mV and increasing operating current by at least 10%. The technology has been successfully piloted at a smelter for 3 years with excellent results — confirming 100 mV voltage reduction alongside decreased cathode erosion and increased pot life.
The primary focus of CCCB™ is facilitating current increase to enhance production from existing cells — without building new capacity. Engineering challenges of thermal cycling, creep resistance, and structural integrity at operating temperatures have been addressed in the proprietary manufacturing process.
Combined performance
Each MetSol product is engineered to deliver measurable gains independently — and greater gains when deployed together. The portfolio spans pot control, alumina distribution, cathode, anode, and connection hardware, covering every major pathway to lower energy consumption and reduced emissions.
Technologies are designed for retrofit compatibility, minimising capital expenditure and maximising return from existing smelter infrastructure.