Electrode Technology: Operation/Practice
Sponsored by: TMS Light Metals Division, TMS: Aluminum Committee
Program Organizers: Houshang Alamdari, Laval University
Wednesday 2:00 PM
March 1, 2017
Location: San Diego Convention Ctr
Session Chair: Mario Fafard, Laval University
2:00 PM Introductory Comments
Xelios 2.0: Return on Experience for the Advanced Eco-designed Vibrocompactor: Vincent Philippaux1; Bastien Aymard1; 1Fives Solios
Amperage creeping projects are key milestones to improve productivity of aluminum smelters. They are also opportunities to upgrade vibrocompactors to the state of the art. In 2014, two smelters in the Gulf awarded to Fives contracts to upgrade their vibrocompactors to the most advanced eco-design standard. This paper details the return on experience (ROE) of these challenging and successful projects in terms of overall equipment effectiveness (OEE) and Environmental performances including: • Availability of the complete paste plant increased thanks to the reliability and space out maintenance requirements. • Best Quality Anodes produced with the incorporated features: Dynpac, Accurate Dosing system and integrated vacuum solution allowing high density and low standard deviation. • Shortest proven cycle time per former, demonstrating once more Fives' unique capacity of high throughput equipment. • Advanced eco-design solutions meeting also expectations in terms of noise and fume capture.
Hexapod Fleet Migration in Order to Upgrade to AP40LE Technology: Jonathan Reichelson1; Marc Gagnon2; 1Hatch Ltd; 2Aluminerie Alouette inc.
In order to meet an ambitious Strategic Growth plan, Aluminerie Alouette inc. decided to upgrade its smelting technology from AP30 to AP40LE. A portion of this upgrade was dedicated to the modification of their pots, while another portion was dedicated to reducing the electrical resistivity in the anodic assembly. The hexapod replacement was the most complicated portion of the anode upgrade. It required extensive testing in order to meet the AP40 technology requirements. The model also had to satisfy the need for a robust, long lasting product to minimize future operating costs. Once testing was complete, a logistical plan needed to be put into place to permit a seamless transition to the new technology without negatively impacting day to day operations. A fabrication process needed to be developed that would ensure a constant supply of the finished product to the plant so as to not put operations at risk.
The Impact of Increased Anode Size and Amperage Creep on Anode Management: James Anson1; René Trudel2; Bertrand Vincent2; 1Hatch; 2Alcoa, Deschambault Smelter
The Alcoa Deschambault smelter is investigating increasing anode size as part of a drive to continuously increase pot amperage (amperage creep). The new larger anodes will be both taller and longer and will impact the number of green and baked anodes, as well as the number of pallets, that can be stored within the smelter. Each of these storage areas have multiple functions: to link the operations of upstream and downstream plant areas, required due to differences in production rates, maintenance schedules, and working schedules; as a buffer for unplanned downtime; and to allow for anode or butt cooling before subsequent operations. The present article reviews the methodology used to evaluate the impact that a change in anode dimensions and amperage creep can have on storage areas and their ability to maintain their functions. The methodology includes layout reviews, mass and anode balance, functional analysis, and schedule optimization.
Anode Quality Improvement at INALUM Smelter: Edi Mugiono1; Firman Ashad1; Ade Buandra1; Sahala Sijabat1; 1PT Inalum (Persero)
INALUM used to mix high sulfur and low sulfur coke with 60:40 in ratio since 2004. INALUM made some efforts to increase anode quality, such as Blaine number stabilization, butt cleaning improvement, cone crusher utilization. By controlling fine fractions output in green paste mixing, the Blaine number variance reduced by 5%. Butt quality also become a big factor to the anode quality, by perform better butt cleaning process to reduce the impurities. The impurity is reduced and steady in level below 150 ppm from specification 300 ppm. In green paste mixing, coarse material also influence the green paste product. In butt crushing, coarse material composition shall reach 5%, that existing hammer mill cannot provide. INALUM install cone crusher to increase coarse material up to 10%. By perform those improvements, increase RRO2 by 2.5% and RRCO2 0.74%.