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Meeting 2023 TMS Annual Meeting & Exhibition
Symposium 60 Years of Taking Aluminum Smelting Research and Development from New Zealand to the World: An LMD Symposium in Honor of Barry J. Welch
Presentation Title Process Recovery to Unlock Power Efficiency Improvement at BSL
Author(s) Evan Andrews, Thomas Booby, Murray Ure, Hao Zhang
On-Site Speaker (Planned) Evan Andrews
Abstract Scope In February 2019, Boyne Smelters Limited (BSL) established a project team to recover Reduction Line 3 from a process excursion. The Line 3 operation had deteriorated progressively through 2018, with increasing levels of cell instability, anode spiking and work handed over between shifts had reached critical levels. By January 2019, average current efficiency had dropped to 91.7% and power efficiency had climbed to 13.45 DCkWhr/kgAl. The recovery project ran for 2 months and quickly achieved stable operation through a series of project clusters targeting exception cell recovery, new cell control and management of intergenerational cell designs. An average of 64mV was saved in 2019 compared to 2018, representing a power efficiency improvement of 0.24 DCkWhr/kgAl. Further stabilisation into 2020, resulted in full year performance of 94.2% and 12.96 DCkWhr/kgAl current efficiency and power efficiency respectively. This paper describes the fundamental approach taken to problem solve and deliver value quickly.
Proceedings Inclusion? Planned: Light Metals
Keywords Other, Other, Other


A Discussion on Thermal Impact of Anode Change in Aluminum Reduction Cell
A Dynamic Coupled Mass and Thermal Model for the Top Chamber of the Aluminium Smelting Cells
A New Strategy for Transient Heat Transfer Models with Phase Change for the Aluminum Electrolysis Industry
A Pragmatic Model for Bath Temperature Evolution during Alumina Feeding
A Smart Individual Anode Current Measurement System and Its Applications
Anode Quality Optimisation – Industry Learnings from the Research Supervised by Barry Welch
Barry Welch - A Mentor Driving Improvement in Industry Through Leadership and Technology
Barry Welch, Professor and Mentor for the Aluminium Industry
Barry Welch´s Honorary Keynote
Contribution of Professor Barry Welch to the Development of EGA’s Reduction Technologies
Development and Deployment Measures in PLC-based Pot Control System at Low Amperage Aluminium Reduction Cell
EGA’s First Holistic Mobile Application for Smelter Operations
Following Alumina Dissolution Kinetics with Electrochemical and Video Analysis Tools
Highlights of Aluminium Smelting Research Inspired by Barry Welch at UNSW from 1985 to Present
Impact of Aluminium Reduction Cell Parameters on Feeder Hole Condition
Light Metals Research at the University of Auckland
Meeting the Requirements of Potline Customers – the Largely Unmet Challenges Set by Barry Welch to Carbon Anode Producers
Monitoring Cell Conditions and Anode Freeze Dissolution with Model-based Soft Sensor After Anode Change
Process Recovery to Unlock Power Efficiency Improvement at BSL
Testing Feeding Alumina in Three Channels in a Wide Cell
The Need to Respect to the Interlink between Science, Physics, and Cell Design in an Environmentally Responsible Manner - The Next Big Challenge for Aluminium Smelting
What Makes TMS Special? Let Us Consider a Case Study in Volunteer Excellence: Barry J. Welch

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