About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Aluminum Reduction Technology
|
| Presentation Title |
Characterization and Mitigation of Potshell Exfoliation in Aluminum Electrolysis Cells |
| Author(s) |
Patrice Doiron, Dany Gauthier, Mark Rheaume, Ketil Åldstedt Rye, Christian Gaudet |
| On-Site Speaker (Planned) |
Patrice Doiron |
| Abstract Scope |
Potshell exfoliation is a degradation mechanism in aluminum reduction cells, leading to the the detachment of oxidized steel layers from the inner potshell surface. Observed across several Alcoa smelters, this phenomenon could lead to significant degradation impact and safety risks. Accumulated iron oxides behind sidewall blocks generate mechanical stresses, leading to block cracking and compromising lining integrity. Critically, contact between these oxides and molten aluminum can trigger highly exothermic thermite reactions, threatening pot life and operational safety.
To address this issue, a structured approach has been developed to quantify exfoliation and evaluate mitigation strategies. Ultrasonic thickness measurements have been implemented across all sites, enabling detailed mapping of shell degradation and revealing patterns linked to pot design and thermal behavior. This paper presents the measurement methodology, field data, and analysis of exfoliation impacts, and introduces several mitigation solutions currently under evaluation. |
| Proceedings Inclusion? |
Planned: Light Metals |
| Keywords |
Aluminum, Process Technology, Electrometallurgy |