Electrode Technology for Aluminum Production: Carbon Anode Production – Where is the Cutting Edge? – A Focus on 4.0 and the Future
Sponsored by: TMS Light Metals Division, TMS: Aluminum Committee
Program Organizers: Derek Santangelo, Hatch
Monday 2:00 PM
March 15, 2021
Room: RM 30
Location: TMS2021 Virtual
Session Chair: Antti Koulumies, Outotec
2:00 PM
Introductory Comments: Electrode Technology for Aluminum Production: Derek Santangelo1; 1Hatch
Introductory Comments
2:05 PM Invited
Digitalization in the Carbon Area as a Means to Improve Productivity: Antti Koulumies1; Paul Merlin1; Ana Maria Becerra1; 1Metso Outotec
Industry 4.0 is visible in aluminium producers’ strategies, however, often lacking common terminology. We propose a framework for applications seen in the carbon area, ranging from Measuring and managing data, Sensing and diagnosing, Simulating and creating a “twin, Optimization, and Robotics and autonomous operation. We review what’s currently existing in the market, discussing some of the early adoptions of e.g. anode and rod tracking, and presenting what we currently see under development. Currently, there are four interesting avenues emerging: Process optimization in the carbon area, based on anode and rod tracking Predictive maintenance applications Increased autonomous operation Advanced rod shop process simulations In summary, digitalization is progressing in the industry. However, the conservative approach seen particularly in new greenfield investments is a hindrance– as adding new features would be easier than in retrofits. We encourage more cooperation between technology vendors, EPCMs and producers.
2:25 PM Invited
AMELIOS Suite or the Fives Digital Package for Carbon 4.0: Christophe Bouche1; Xavier Genin1; Sylvain Georgel1; Pierre Mahieu1; 1Fives
Over the last 10 years Fives has developed a comprehensive Carbon Digital Chain to reduce anode production costs and to better control the cost impacts to the reduction line. This solution, called “AMELIOS Suite”, is built using three packages that cover the whole value chain: Green Anode, Baked Anode and Anode Usage. These packages can be implemented in existing or new smelters to benefit customer with lower Net Carbon Consumption and maximum use of the carbon below stubs. Using an Anode Tracking System in combination with the existing on-line anode resistivity analyser MIREA and the newly implemented SOFIA butts scanning system, it allows us to create an anode ID card with all the key production parameters. This data, uploaded in the smelter knowledge management system, allows us to understand how anode characteristics impact the potline and therefore fine tune process parameters to optimize carbon production.
2:45 PM
Development and Applications of the Four Points Probe (4PP) Electrical Resistivity Measurements for Anode Process Optimization: Julien Lauzon-Gauthier1; John Secasan1; 1Alcoa Corporation
Electrical resistivity (ER) measurements for anodes have been around for more than 50 years. These measurements, as well as any other voltage drop measurement methods on green or baked anodes can be used for quality control (QC). However, correlations between these QC criteria, especially on green anodes, and their behavior in the pots have not been established. It is difficult to determine absolute pass/reject thresholds, and hence the benefits are hard to quantify. However, it is possible to use those methods for process control and monitoring. A non-destructive (NDT) measurement method of ER based on the 4PP technique was developed by Alcoa for that purpose. It can be used on both green and baked anodes. The development and the capabilities of the equipment for pitch optimization of the green anode is described. Observations on QC for green and baked anodes are also discussed based on the results obtained during the development and trial experiments.
3:05 PM Invited
The Readiness and Compatibility of a Modern Anode Handling and Cleaning System for Industry 4.0 Technologies: Kevin Williams1; 1Advanced Dynamics Corporation Ltd.
The world economy is keeping manufacturers of all products under continuous pressure to lower costs and improve quality. In addition, low metals prices are driving primary producers of aluminum to optimize their processes to stay competitive and profitable in a very tight market. In order to assure optimum technical and financial performance of the Carbon Plants and anode block manufacturing, Aluminium manufacturers are moving forward in the adoption and integration of Industry 4.0 technologies as part of their roadmap to the Aluminium plant of the future. This paper will present an overview of where current modern aluminium smelters are with their connectivity and readiness for Industry 4.0 integration and will explore the current technologies as they are being applied and as they may be applied in the future to the handling, cleaning, inspection and tracking of anode blocks through the anode manufacturing process.
3:25 PM Break
3:40 PM Panel Discussion