Aluminum Reduction Technology: Technology Development
Sponsored by: TMS Light Metals Division, TMS: Aluminum Committee
Program Organizers: Mark Dorreen, Light Metals Research Centre, The University of Auckland

Thursday 8:30 AM
March 2, 2017
Room: 2
Location: San Diego Convention Ctr

Session Chair: Till Reek, Trimet Aluminium SE

8:30 AM Introductory Comments

8:35 AM  
Implementation of D18+ Cell Technology at EGA Jebel Ali Smelter: Daniel Whitfield1; Sergey Akhmetov1; Jose Blasques1; Harishchandra Devadiga1; 1Emirates Global Aluminium (EGA)
    In March 2012, EGA started seven test cells to validate the new D18+ cell technology. Designed with the latest technological advances to upgrade the original D18 Potlines, the test cells quickly met their design targets with specific energy of 12.75 DCkWh/kg Al and AE frequency <0.02 /cell/day. After the successful validation, a project was commenced in August 2015 to upgrade the original D18 potlines to the newly developed D18+ cell technology. Unlike previous capacity expansion by EGA, the D18+ project required construction to occur within the existing potrooms, which continued to operate while the upgrade was underway.Despite the challenges that this involved, full potline conversion was successfully achieved ahead of schedule and without injury. Through increased amperage to 235 kA and higher efficiency EGA production capacity will be increased by 23.3 kT per annum. Further conversion of 272 cells to D18+ in Potline 3 will commence in September 2016.

9:00 AM  
Enabling Efficient Heat Recovery from Aluminium Pot Gas: Daniel Clos1; Trond Andresen1; Petter Nekså1; Sverre Johnsen2; Ragnhild Aune3; 1SINTEF Energy research; 2SINTEF Materials and Chemistry; 3Norwegian University of Science and Technology
    In the present work, previous studies carried out by the Norwegian aluminium industry and research centres with the aim of recovering heat from aluminium production off-gas, are reviewed. The main challenge in improving heat recovery is the fouling phenomena, which is due to the presence of particulate matter and corrosive gases in the off-gas. Fouling can occur due to particle deposition, condensation of corrosive acids and scaling reactions, which in turn can build up hard layers, particularly, on heat exchanger surfaces.The review focuses primarily on fundamental studies (theoretical and experimental), which address off-gas composition characterization, particle size distribution and particle deposition phenomena in laboratory and industrial environments. Moreover, it presents commercial concepts already implemented in industry applications. Upcoming activities in regards to the scaling phenomena, which include the design of a cold-finger for laboratory and industrial measurements, as well as mathematical modelling using CFD, are also discussed

9:25 AM  
DX+ Ultra – EGA High Productivity, Low Energy Cell Technology: Nadia Ahli1; Abdalla Zarouni1; Michel Reverdy1; 1Emirates Global Aluminium (EGA)
    After successful development and industrial implementation of DX and DX+ Cell Technologies, DUBAL (EGA Jebel Ali) launched several initiatives to lower CAPEX and cell energy consumption. The result is DX+ Ultra Cell Technology, installed in five demonstration cells, which were started up in March to May 2014 at 450 kA. The main new features of DX+ Ultra Cell Technology are: reduced cell-to-cell distance as well as proprietary novel-design split anode risers, collector bar copper inserts and cathode flexes. More than one year of excellent performance at 455 kA with 95 % current efficiency and net specific energy consumption of 12.8 kWh/kg Al has confirmed that the technology is ready for industrial implementation. DX+ Ultra Cell Technology has been selected for Alba Potline 6 expansion. Further optimisation of the cells is underway to deliver best-in-class technology to the client; this includes larger busbar cross-sections for even lower energy consumption.

9:50 AM Break

10:05 AM  Cancelled
Crane Electrical Isulation Monitoring in Potlines: New CANDI 4.0 Development: Serge Despinasse1; Eric Norel1; Fabienne Virieux2; 1Fives ECL; 2Fives Solios
    The still on-going productivity improvement achieved in potlines outlines the importance of the tending crane availability, which results from both their reliability and easiness to repair. In the field of the crane electrical isolation monitoring – essential for ensuring operator’ safety and avoiding equipment damage, it is now expected that preliminary incidents being quickly tracked and fixed, in order to minimize the investigation time. This paper presents the new Fives’ monitoring system: CANDI 4.0. It deals with a new modular architecture, which allows its implementation both on green field projects and retrofitting ones; it also focuses on the evolution of the scanning which is faster. It finally presents the information that operation or maintenance people will benefit thanks to a thoroughly redesigned human-machine interface and new data transmission abilities

10:30 AM  
The Successful Implementation of AP40 Technology at Kitimat: Patrice Desrosiers1; Martin Robitaille1; Pierre Luc Voyer1; Silvino Caetano1; René Gariépy1; Olivier Martin2; Pascal Robert1; 1Rio Tinto; 2Rio Tinto Alcan
    Positioned in British Columbia on the west coast of Canada, Kitimat smelter, is in operation for more than 60 years. A new era has started with the modernization of the smelter using the AP40 smelting technology. AP40 technology has already been successfully used in the Alma (Canada) smelter enabling operation above 400 kA. The new Kitimat potline, with its 384 pots, started production mid-2015 and reached full capacity in March 2016. The robust startup has been successfully concluded with a performance test achieving 96.1% Current Efficiency and 12800 kWh/t Specific Energy Consumption. Thanks to new AP40 potline, the Kitimat production increases by about 48 per cent to 420,000 tons annually while the smelter’s overall emissions have been halved. Kitimat smelter is now one of the most efficient, greenest and lowest-cost in the world.