About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Aluminum Electrode Technology Symposium
|
| Presentation Title |
From Microstructure Control to Megawatt-Hour Savings: Industrial Validation of Anode ER Reduction via Forming Vacuum Optimization and Coke PSD Engineering |
| Author(s) |
Anamit Deb Gupta, Rafiqul Mirza |
| On-Site Speaker (Planned) |
Anamit Deb Gupta |
| Abstract Scope |
Electrical resistivity (ER) of baked anodes directly affects anode voltage drop and smelter energy consumption. This study presents an industrial two-pronged optimization at Aditya Aluminium: (a) forming-vacuum window engineering during vibro-compaction, and (b) coke PSD optimization via shaft–rotary blending using finer 10 mm coke in collaboration with suppliers. Reducing forming vacuum from >80 mbar to 50–60 mbar lowered ER from 59.33 to 57.08 μΩ·m and improved baked anode density (BAD) from 1.574 to 1.581 g/cc. Parallel blend trials identified a 40:60 shaft:rotary mix as optimal, achieving 57.27 μΩ·m ER with BAD >1.57 g/cc. Potroom trends showed reduced DC energy consumption in Jan 2026 versus the 2025 average, with stable current efficiency. Based on 7.12 kWh/MT per 1 μΩ·m ER reduction, savings are ~₹1.09 crore annually per μΩ·m at current operating scale, demonstrating clear linkage between microstructure control and energy efficiency. |
| Proceedings Inclusion? |
Planned: Light Metals |
| Keywords |
Other, Aluminum, Other |