Overview
Alcoa’s Massena facility is one of the largest energy users in New York and operates in a highly energy-intensive aluminum manufacturing environment. With energy costs playing a major role in plant economics, Alcoa needed a demand response partner that could help maximize revenue, reduce operational burden, and support reliable participation in NYISO programs.
Rodan helped Alcoa improve participation across multiple demand response programs, combining automation and manual curtailment to create strong financial returns and more efficient operational execution.
The Challenge
Aluminum smelting is one of the most energy-intensive manufacturing processes in the market. For Alcoa, controlling energy cost per kilogram produced is critical. Because the facility is such a large energy user, even small improvements in demand response strategy or curtailment execution can create meaningful economic impact.
Alcoa needed a partner that could help it navigate NYISO demand response programs, reduce operational complexity, and improve both execution and revenue outcomes without compromising reliability.
Our Solution
Aluminum smelting is one of the most energy-intensive manufacturing processes in the market. For Alcoa, controlling energy cost per kilogram produced is critical. Because the facility is such a large energy user, even small improvements in demand response strategy or curtailment execution can create meaningful economic impact.
Alcoa needed a partner that could help it navigate NYISO demand response programs, reduce operational complexity, and improve both execution and revenue outcomes without compromising reliability.
Implementation
- Rodan worked with Alcoa to align curtailment strategy with its highest-energy processes, particularly the facility’s potlines. For the 10-Minute Spinning Reserve (DSASP) program, Rodan’s automated signals were interpreted by Alcoa’s system to reduce pot room power within seconds. For SCR, Alcoa manually curtailed power during scheduled events, typically reducing 55 MW over a four-hour block.
- Rodan supported both the technical and commercial side of participation, helping ensure consistent delivery, timely payments, and responsive support throughout the program lifecycle.
Key Takeaways
- This case demonstrates that sophisticated industrial facilities can generate significant value from demand response when the participation model matches operational reality. Alcoa’s success came from combining automation, manual flexibility, and program expertise rather than relying on a one-size-fits-all strategy.
- This case demonstrates that sophisticated industrial facilities can generate significant value from demand response when the participation model matches operational reality. Alcoa’s success came from combining automation, manual flexibility, and program expertise rather than relying on a one-size-fits-all strategy.
Rodan has consistently delivered excellent customer service. The revenue split is outstanding, payments are always timely, and they’re highly responsive to any technical issues. It’s been a game-changer for us. Our experience with Rodan Energy has been the best of any third-party provider we’ve partnered with during our 20 years in the demand response market. The service, support, and financial returns have exceeded our expectations.
