Article

RUSAL is deploying non-formed materials (NFM) for electrolyzer assembly, developed using proprietary technology. This innovation simplifies installation, reduces costs, and allows for material reuse compared to traditional bricks and slabs.

The new materials, derived from coal processing by-products, have enabled RUSAL to halve both material and installation costs for electrolyzers. By the end of 2025, RUSAL plans to implement NFM in 5,100 electrolyzers across its Bratsk, Irkutsk, Krasnoyarsk, Novokuznetsk, and Sayanogorsk smelters, accounting for approximately 80% of its total electrolyzers.

The recycling of at least 50% of NFM during major repairs significantly minimizes waste and reduces disposal costs. RUSAL's technology, protected by 40 international patents, has already resulted in $13 million in savings.