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Meeting 2027 TMS Annual Meeting & Exhibition
Symposium Aluminum Reduction Technology
Presentation Title Smart Smelter Technologies in Aluminium Electrolysis: China’s Development Experience and Future Directions
Author(s) Beverley A. Pillay, Yan Zhou
On-Site Speaker (Planned) Beverley A. Pillay
Abstract Scope As the aluminium industry accelerates its transition toward Industry 4.0, the development of intelligent electrolysis equipment and digitally integrated smelter operations has become a key driver of productivity, safety, asset longevity, and sustainability. This paper examines the evolution of smart technologies within China’s primary aluminium sector, highlighting advancements in electrolysis equipment, automation, digital control systems, and data-driven operational practices. The presentation explores the industry’s progression from isolated technological innovations to increasingly integrated smart smelter ecosystems, demonstrating how intelligent equipment and real-time analytics are being used to enhance process stability, reduce manual intervention, improve workplace safety, optimize energy consumption, and extend equipment service life. Emerging trends, including artificial intelligence, predictive maintenance, digital twins, and autonomous operations, are discussed as technologies shaping the next generation of aluminium production.
Proceedings Inclusion? Planned: Light Metals
Keywords Aluminum, Aluminum, Aluminum

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A Dynamic Soft-Sensing Model for Alumina Concentration Distribution Based on Zone Currents and Equivalent Circuit with CFD-Derived Mass Transfer in a 500 kA Cell
Actual measurement evaluation of perfluorocarbon(PFC) emissions from pre-aluminum reduction cells, calculation deviations, and process-based emission reduction strategies
Aluminium Deposition from a NaCl-KCl-AlCl3 Melt Containing Calcium Oxide and Chlorine Gas
Analyzing Pots Stability Around a Booster Section
Analyzing Pots Stability Around a Booster Section: Part 2
Anode Effect Detection in Aluminum Reduction Cells Based on Pruned Spectral Graph Clustering and Multi-Zone Collaboration
AP61 Technology: A Milestone in the Evolution Toward 600+ kA Smelters
Assessment of Anode Current as an Indicator of Alumina Concentration and Pot Conditions in Aluminum Reduction Pots
Cathodic Efficiency Loss in Aluminium Electrolysis: Mechanisms, Peripheral Cathodic Deposits, and Driving Forces – A Comprehensive Review
Cell Design for Beyond-400 kA Operation at Mahan Smelter: A Case Study
Chemical Corrosion Pathways in Materials for the Hall-Héroult Process: Lessons from Metals, Ceramics and Cermets
Comparison of Performance and Application Characteristics Between Aluminum Electrolysis Full-Graphite and Graphitized Cathode Under Operating Conditions
Comprehensive Inspection and Repair Strategies for Aluminum Reduction Cell Associated with Restart Methodologies
Computational Analysis of Abnormal Operating Conditions in Aluminium Reduction Cells
Development of a Thermal-Electrical-Electrochemical Model of the Anode, Bath, and Metal in Aluminum Reduction Cells
Dynamic Response Behavior and Online Monitoring Potential of Cathode Currents in a 600 kA Aluminium Reduction Cell
Effect of Current Density on Cermet Inert Anode Corrosion Behavior in Low-Temperature Aluminum Electrolysis
Effect of Electrolyte Composition and Temperature on Current Efficiency of 500 kA Electrolysis Cell
Effect of Particle Size Distribution on Pressed Pellet Preparation and X-Ray Diffraction Results for Electrolytic Bath Samples
Energy Consumption of an Aluminum Reduction Cell with Inert Electrodes at Low Anode to Cathode Distance
Enhancement of Pot Feed System Reliability for EGA DX+ Ultra Pots
Evolution of the Carbon Footprint of Primary Aluminum Production
Experiments on the Formation of Anode Spikes in Laboratory Scale Electrolysis Cells
Impact of increased sulfur levels in alumina on cell and dry scrubber dynamics
Implementing C-Plate Aluminum on Anode Busbar Sparks to Enhance Work Efficiency and Optimize Production Performance
Increasing Inalum Operational Performance by Implementation of Operational Excellence
Integrated Closed Tapping and Electromagnetic Stirring for In-Transit Treatment of Primary Aluminum
Knowledge Diffusion in Aluminium Production, and the Impact on Innovation
Linking Refractory Degradation and Failure Modes in Hall–Héroult Cells through Integrated Autopsy and Machine Learning Analysis
Numerical Analysis of Voltage Drop Reduction in a Low-Energy Anode Assembly
Numerical Investigation of the Thermal, Electrical and Mechanical Behaviour of an Aluminum Reduction Cell During Start-Up
On the Evolution of Adhesion Between Ramming Paste and Cathode Blocks During the Preheating and Start-up Phases
Operation of Restarted and Survival Pots, Highlighting the Successful and Safe Extension of Pot Life
Operational Strategy and Thermal Balance Optimization to Reduce Sidewall Force Cooling Utilization in Potline 1 at INALUM
Optimization of Cathode Sealing Plant for Diverse Cathode Block technologies
Pot operations management without anode change for 13 days.
Potential Impacts and Control Requirements for Large Primary Aluminum Smelters
Process-Dependent PFC Formation During Alumina Reduction – Insights from a Multi-Method Industrial Measurement Campaign
Production Practice of Fully Graphitized Cathode Electrolytic Cells
Real-Time Variation and Simulation Analysis of Electrolyte Temperature
Reliability-Oriented Power Supply Planning for a Greenfield Aluminum Smelter: A 300 ktpa Case Study
Research Advances in Aluminum Chloride Electrolysis Technology
Research and Practice on a Novel Connection Structure Between Steel Yoke and Anode Rod of Prebaked Anode for Aluminum Electrolysis
Research progress of low-temperature electrolytic aluminum molten salt system
Robust Alumina Feeding Optimization Using Physics-Based Deep Learning Surrogates: An Industrial Proof-of-Concept for PFC Emission Reduction
Sensitivity of metal transport to particle size in aluminum smelter fugitive emissions
Smart Smelter Technologies in Aluminium Electrolysis: China’s Development Experience and Future Directions
Solubility of Aluminum Oxide in Low Melting Cryolitic Electrolytes
Systematic Reduction of Specific DC Energy Consumption in Aluminium Smelting through Integrated Design and Process Optimization
Task Monitoring: A Real-Time Digital Decision Platform for Aluminum Reduction Operations
The thermal decomposition process of AlF1.5(OH)1.5·H2O
Transforming Maintenance and Reliability - Digital Services for Power Conversion in the Metals Pro-duction
Transient Electro-Magnetic-Flow Simulation of Current Fluctuations in Industrial Aluminum Reduction Cells and Their Effects on Interface Stability and Cathode Wear
Upcycling highly contaminated aluminium scrap by electrorefining
Welding Repair Methodology for Intercell Busbars in Series Aluminum Electrolysis

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