Moscow, Jan 29: RUSAL, a global leader in aluminium production, is rolling out non-formed materials (NFM) developed using its own patented technology for electrolyzer assembly. The new materials simplify installation, reduce costs, and allow the reuse of materials, compared to the usual bricks and slabs used in the industry.
Traditionally, lining an electrolyzer’s cathode shell is a lengthy and labor-intensive process involving multiple layers of bricks and slabs. To find a more efficient alternative, RUSAL’s Engineering Department developed proprietary technology to apply non-formed materials – a material derived from coal processing by-products – along with specialized compaction equipment.
This advancement has enabled RUSAL to replace a substantial quantity of traditional bricks and slabs, halving both material and installation costs for electrolyzers.
By the end of 2025, RUSAL had introduced non-formed materials across 5,100 electrolyzers at its Bratsk, Irkutsk, Krasnoyarsk, Novokuznetsk, and Sayanogorsk aluminium smelters. This constitutes about 80% of the company’s total, marking a decisive company-wide operational shift.
A key environmental benefit is that during major repairs, at least 50% of the non-formed materials can be processed and reintroduced into the production cycle. This recycling ыsignificantly reduces waste, cuts disposal fees by hundreds of thousands of dollars per plant, and advances a closed-loop economy.
Protected by 40 international patents, RUSAL’s technology has already delivered $13 million in savings through lower material costs and faster installation.