Development Status and Trends of PV DC-to-Electrolysis Integration for Aluminum Smelting

With the advancement of the "dual carbon" goal, energy saving, carbon reduction and energy transformation of electrolytic aluminum plants with high energy consumption have become urgent problems to be solved. Direct integration of photovoltaic (PV) DC power into the DC bus of aluminum electrolysis rectifier systems can reduce carbon emissions and increase green electricity penetration. Firstly, this study outlined energy consumption and carbon emission challenges facing the aluminum electrolysis industry, reviewed existing demonstration projects, and validated technical feasibility. Secondly, critical enabling technologies were discussed, including current stabilization control, high-capacity DC/DC converters, power quality mitigation measures, and DC microgrid control and protection strategies. Finally, future development trends of the technology were also identified. Results show that PV DC integration represents a pivotal approach for green transformation of the aluminum industry. Despite challenges regarding stability and economics, advancing critical equipment capabilities and intelligent control systems will further enhance green electricity ratios and energy efficiency.