Electrode Technology for Aluminum Production: On-Demand Oral Presentations
Sponsored by: TMS Light Metals Division, TMS: Aluminum Committee
Program Organizers: Stephan Broek, Kensington Technology Inc; Dmitry Eskin, Brunel University
Monday 8:00 AM
March 14, 2022
Room: Light Metals
Location: On-Demand Room
Assessment of Pre-baked Anodes Homogeneity Using Acousto-ultrasonic Testing and 3D Interpolation Methods: Daniel Rodrigues1; Carl Duchesne1; Donald Picard1; Julien Lauzon-Gauthier2; 1Laval University; 2Alcoa Canada
Many of the non-destructive testing technologies developed for the evaluation of pre-baked carbon anodes are based on measurements representing the response of the material contained along a specific pathway in their bodies. To assess anode homogeneity based on these data, some ways of interpolating the measurements within the anode volume are required. This paper presents a method to interpolate such measurements to estimate the distribution of properties at different points within an anode’s body, such as the speed of sound. The method is demonstrated first by testing it using a set of 2- and 3-dimensional toy examples, and then on a few full-scale anodes tested using acousto-ultrasound measurements. The resulting interpolations are cross-checked with the presence of external defects. The technique is suitable for understanding the level of isotropy, positioning defects and also enhancing the probes design for future implementation of NDT techniques.
Effect of Coke Type on the Partial Replacement of Coke with Modified Biocoke in Anodes Used in Primary Aluminum Production: Belkacem Amara1; Duygu Kocaefe1; Yasar Kocaefe1; Dipankar Bhattacharyay1; Jules Côté1; André Gilbert1; 1University of Quebec at Chicoutimi
The aluminum produced in Quebec is the greenest in the world since the electrical energy is produced by hydroelectric power. Nevertheless, aluminum industry continues its efforts for sustainable production and reduction in greenhouse gas (GHG) emissions. At the same time, it is dealing with the reduction in the anode raw-material quality. This necessitates the identification of new raw materials. One option is the partial replacement of petroleum coke with biocoke which is a renewable material. The biocoke utilization will add value to the side products and help wood industry diversify its operations. However, the biocoke addition decreases the anode quality according to published works. A method was developed to make this substitution possible by the UQAC researchers, and it was tested only with one type of coke. This article presents the effect of coke type on the anode quality when part of the coke is replaced with biocoke.
Ecofriendly Glue for the Aluminium Electrolysis Pot: Benedicte Allard1; Regis Paulus1; Nicolas Gros1; Herve Mezin1; Danny Gagnon2; Claude Fradet2; Gael Lambert3; 1TOKAI COBEX; 2EQUIBRAS; 3ALVANCE Aluminium Dunkerque
A new glue that does not contain any carcinogenic compound has been developed to be used at the sides of the aluminum electrolysis pots either against the shell or between silicon carbide sidewalls and preformed blocks. Such glue has been built to replace SiC mortars which usually exhibit poor sticking properties during ramming operation or even during pot life, and insure thermal efficiency. The different requirements and characteristics that are needed will be presented, and the final properties obtained on the new AD20+ glue will be given. AD20+ glue has been used at pilot scale with EQUIBRAS equipment, in comparison with some silicon carbide mortars. The trials performed with the EQUIBRAS machine relate to glue or mortar installation and to unsticking tests with pressure measurements. This AD20+ glue has already been installed in pots and some performance data will be given.
Blocked Fluewall Detection and Improved Safety for Anti-flooding Module, A New Approach for Safer Operations of Anode Baking Furnaces: Detlef Maiwald1; Frank Heinke1; Sandra Besson2; Diane Tremblay2; Lucas Ruel2; Alexandre Gagnon2; 1Innovatherm GmbH; 2Rio Tinto Aluminium
The carbon blocks used in the process for the primary aluminum production are baked in Anode Baking Furnaces. These furnaces have two combustion zones: volatile matters contained in the green anodes are emitted and burnt in the preheating zones, and natural gas or heavy fuel oil is injected and burnt in the heating zones. The control of both combustion zones constitutes a major challenge to ensure the safety of the operations, especially when deviations in the refractory condition, process or operations occur.In 2020 a Process Safety analysis identified two situations where the controls in place were judged insufficient to ensure the complete safety of operations: blocked flue walls and flooding situations. In 2021 Innovatherm and Rio Tinto decided to co-develop modules capable of automatically identifying those situations and raise alarms, or ultimately shut down the gas injection. The modules have been successfully implemented in Usine Grande-Baie in June 2021.
Cancelled
The Development of RUSAL’s Prebake Anode Production in Support of the Company’s Green Initiatives: Viktor Buzunov1; Viktor Mann2; Vitaliy Yakovlev2; Yuriy Frantsev1; Matvey Golubev1; Valeriy Polovnikov1; Mikhail Grinishin1; 1Rusal Etc; 2RUSAL
RUSAL’s prebaked anode production has increased considerably using underutilized green prebake anode production at Sayanogorsk, the design and installation of new prebake anode facilities at Taishet and Volgograd carried out by RUSAL’s technical team. The key project solutions are advance design Riedhammer furnaces with Solios oil (Taishet) and gas (Volgograd) along with a product Lifecycle Management System (LMS) for monitoring single anode lifecycle from raw materials, production, baking and the recycled spent anode (ETC Rusal). The new Volgograd carbon plant has 104 000 tons/year capacity. In 2019 64-pits, opened top type baking furnace was started in Taishet with 225 000 tons/year capacity. Currently green anodes are made in Sayanogorsk and Volgograd are shipped via rail to Taishet until the commissioning (or installation) of the Taishet Carbon complex. Longer term goals include increasing the Taishet prebaked anode facility capacity to 1 018 000 tons/year and Sayanogorsk furnace to 472 000 tons/year.