Essential Readings in Light Metals: Volume 2 Aluminum Reduction Technology

Front Matter....Pages i-xxvi
Front Matter....Pages 1-1
Principles of Aluminum Electrolysis....Pages 3-11
The Solubility of Aluminum in Cryolite Melts....Pages 12-18
Viscosity of Molten NaF-AlF3-Al2O3-CaF2 Mixtures....Pages 19-24
On the Solubility of Aluminium Carbide in Cryolitic Melts — Influence on Cell Performance....Pages 25-32
Liquidus Curves for the Cryolite — AlF3 — CaF2 — Al2O3 System in Aluminum Cell Electrolytes....Pages 33-38
The Solubility of Aluminium in Cryolitic Melts....Pages 39-48
Dissolved Metals in Cryolitic Melts....Pages 49-56
Electrical Conductivity of Cryolitic Melts....Pages 57-64
Electrical Conductivity of Molten Cryolite-Based Mixtures Obtained with a Tube-type Cell Made of Pyrolytic Boron Nitride....Pages 65-72
Liquidus Temperature and Alumina Solubility in the System Na3AlF6-AlF3-LiF-CaF2-MgF2....Pages 73-82
Lithium-Modified Low Ratio Electrolyte Chemistry for Improved Performance in Modern Reduction Cells....Pages 83-88
Production of Aluminum with Low Temperature Fluoride Melts....Pages 89-95
The Structure of Alumina Dissolved in Cryolite Melts....Pages 96-104
The Dissolution of Alumina in Cryolite Melts....Pages 105-111
Further Studies of Alumina Dissolution under Conditions Similar to Cell Operation....Pages 112-118
Studies on Anode Effect in Aluminium Electrolysis....Pages 119-126
Direct Observation of the Anode Effect by Radiography....Pages 127-130
On the anode effect in aluminum electrolysis....Pages 131-138
Anodic Overpotentials in the Electrolysis of Alumina....Pages 139-146
Cathode Voltage Loss in Aluminum Smelting Cells....Pages 147-152
Back Matter....Pages 269-271
Front Matter....Pages 1-1
Interpreting the Components of Cell Voltage....Pages 153-159
Thermodynamics of Electrochemical Reduction of Alumina....Pages 160-165
Field Study of the Anodic Overvoltage in Prebaked Anode Cells....Pages 166-171
Current Efficiency and Alumina Concentration....Pages 172-176
Continuous Measurement of Current Efficiency, by Mass Spectrometry, on a 280 KA Prototype Cell....Pages 177-180
The Influence of Dissolved Metals in Cryolitic Melts on Hall Cell Current Inefficiency....Pages 181-187
The Interaction between Current Efficiency and Energy Balance in Aluminium Reduction Cells....Pages 188-194
A Laboratory Study of Current Efficiency in Cryolitic Melts....Pages 195-203
Current Efficiency Studies in a Laboratory Aluminium Cell Using the Oxygen Balance Method....Pages 204-210
Current Efficiency in Prebake and Søderberg Cells....Pages 211-216
Bath /Freeze Heat Transfer Coefficients: Experimental Determination and Industrial Application....Pages 217-221
Sludge in Operating Aluminium Smelting Cells....Pages 222-228
The Behaviour of Phosphorus Impurities in Aluminium Electrolysis Cells....Pages 229-233
See-through Hall-Heroult Cell....Pages 234-239
Metal Pad Velocity Measurements in Prebake and Soderberg Reduction Cells....Pages 240-250
Metal Pad Velocity Measurements by the Iron Rod Method....Pages 251-256
On the Bath Flow, Alumina Distribution and Anode Gas Release in Aluminium Cells....Pages 257-264
Bubble Noise from Søderberg Pots....Pages 265-268
Back Matter....Pages 269-271
Front Matter....Pages 273-273
Simulation of Thermal, Electric and Chemical Behaviour of an Aluminum Cell on a Digital Computer....Pages 275-278
Estimation of Frozen Bath Shape in an Aluminum Reduction Cell by Computer Simulation....Pages 279-285
Back Matter....Pages 445-447
Front Matter....Pages 273-273
A Water-Model Study of the Ledge Heat Transfer in an Aluminium Cell....Pages 286-293
Computation of Aluminum Reduction Cell Energy Balance Using ANSYS® Finite Element Models....Pages 294-302
Thermo-Electric Design of a 400 kA Cell Using Mathematical Models: A Tutorial....Pages 303-308
A Modelling Approach to Estimate Bath and Metal Heat Transfer Coefficients....Pages 309-314
Computer Model for Magnetic Fields in Electrolytic Cells Including the Effect of Steel Parts....Pages 315-321
The Effect of Some Operating Variables on Flow in Aluminum Reduction Cells....Pages 322-329
Magnetics and Metal Pad Instability....Pages 330-335
Stability of Aluminum Cells - A New Approach....Pages 336-341
Analysis of Magnetohydrodynamic Instabilities in Aluminum Reduction Cells....Pages 342-351
Magnetohydrodynamic Effect of Anode Set Pattern on Cell Performance....Pages 352-358
Stability of Interfacial Waves in Aluminium Reduction Cells....Pages 359-366
Using a Magnetohydrodynamic Model to Analyze Pot Stability in Order to Identify an Abnormal Operating Condition....Pages 367-372
Wave Mode Coupling and Instability in the Internal Wave in Aluminum Reduction Cells....Pages 373-378
Comparison of Various Methods for Modeling the Metal-Bath Interface....Pages 379-384
Physical Modelling of Bubble Behaviour and Gas Release from Aluminum Reduction Cell Anodes....Pages 385-395
Coupled Current Distribution and Convection Simulator for Electrolysis Cells....Pages 396-401
Effect of the Bubble Growth Mechanism on the Spectrum of Voltage Fluctuations in the Reduction Cell....Pages 402-408
Modeling the Bubble Driven Flow in the Electrolyte as a Tool for Slotted Anode Design Improvement....Pages 409-414
Planning Smelter Logistics: A Process Modeling Approach....Pages 415-420
CFD Modeling of the Fjardaal Smelter Potroom Ventilation....Pages 421-426
Back Matter....Pages 445-447
Front Matter....Pages 273-273
Heat Transfer Considerations for DC Busbars Sizing....Pages 427-432
The Impact of Cell Ventilation on the Top Heat Losses and Fugitive Emissions in an Aluminium Smelting Cell....Pages 433-438
Mathematical Modelling of Aluminum Reduction Cell Potshell Deformation....Pages 439-444
Back Matter....Pages 445-447
Front Matter....Pages 449-449
Development of Large Prebaked Anode Cells by Alcoa....Pages 451-456
Aluminium Pechiney 280 kA Pots....Pages 457-461
AP 50: The Pechiney 500 kA Cell....Pages 462-467
The Pot Technology Development in China....Pages 468-473
VAW Experience in Smelter Modernization....Pages 474-478
From 110 to 175 kA: Retrofit of VAW Rheinwerk Part I: Modernization Concept....Pages 479-484
From 110 to 175 kA: Retrofit of VAW Rheinwerk Part II: Construction & Operation....Pages 485-488
Productivity Increase at Søral Smelter....Pages 489-493
Reduction Cell Technology Development at Dubal Through 20 Years....Pages 494-499
Potline Amperage Increase from 160 kA to 175 kA during One Month....Pages 500-505
AP35: The Latest High Performance Industrially Available New Cell Technology....Pages 506-511
Tomago Aluminium AP22 Project....Pages 512-517
Development of D18 Cell Technology at Dubal....Pages 518-522
New Cathodes in Aluminum Reduction Cells....Pages 523-526
Dimensioning of Cooling Fins for High-Amperage Reduction Cells....Pages 527-533
Satisfying Financial Institutions for Major Capital Projects....Pages 534-538
Development and Deployment of Slotted Anode Technology at Alcoa....Pages 539-544
Back Matter....Pages 551-552
Front Matter....Pages 449-449
Innovative Solutions to Sustainability in Hydro....Pages 545-550
Back Matter....Pages 551-552
Front Matter....Pages 553-553
Current Pickup and Temperature Distribution in Newly Set Prebaked Hall-Héroult Anodes....Pages 555-561
Thermal effects by anode changing in prebake reduction cells....Pages 562-568
Considerations in the Selection of Alumina for Smelter Operation....Pages 569-573
Alumina Transportation to Cells....Pages 574-580
Study of Alumina Behavior in Smelting Plant Storage Tanks....Pages 581-589
New Aerated Distribution (ADS) and Anti Segregation (ASS) Systems for Alumina....Pages 590-595
Beryllium in Pot Room Bath....Pages 596-601
Hard Gray Scale....Pages 602-607
Aluminium Fluoride — A Users Guide....Pages 608-612
Crusting Behavior of Smelter Aluminas....Pages 613-621
On Alumina Phase Transformation and Crust Formation in Aluminum Cells....Pages 622-629
Heat Transfer, Thermal Conductivity, and Emissivity of Hall-Heroult Top Crust....Pages 630-638
Improving Anode Cover Material Quality at Nordural — Quality Tools and Measures....Pages 639-644
Appraisal of the Operation of Horizontal-Stud Cells with the Addition of Lithium Fluoride....Pages 645-651
Technical Results of Improved Soederberg Cells....Pages 652-658
Strategies for Decreasing the Unit Energy and Environmental Impact of Hall Heroult Cells....Pages 659-668
Operational and Control Improvements in Reduction Lines at Aluminium Delfzijl....Pages 669-673
Modeling Power Modulation....Pages 674-678
Smelters in the EU and the Challenge of the Emission Trading Scheme....Pages 679-682
Back Matter....Pages 735-736
Front Matter....Pages 553-553
Challenges in Power Modulation....Pages 683-688
Hibernating Large Soderberg Cells....Pages 689-693
Thermal Bake-Out of Reduction Cell Cathodes — Advantages and Problem Areas....Pages 694-698
The Economics of Shutting and Restarting Primary Aluminium Smelting Capacity....Pages 699-706
Brazil 2001 Energy Crisis — The Albras Approach....Pages 707-711
Potline Startup with Low Anode Effect Frequency....Pages 712-717
Cell Preheat/Start-up and Early Operation....Pages 718-722
Loss in Cathode Life Resulting from the Shutdown and Restart of Potlines at Aluminum Smelters....Pages 723-728
Simultaneous Preheating and Fast Restart of 50 Aluminium Reduction Cells in an Idled Potline....Pages 729-734
Back Matter....Pages 735-736
Front Matter....Pages 737-737
Overview of Process Control in Reduction Cells and Potlines....Pages 739-746
A Demand Feed Strategy for Aluminium Electrolysis Cells....Pages 747-751
Design Considerations for Selecting the Number of Point Feeders in Modern Reduction Cells....Pages 752-759
Pseudo Resistance Curves for Aluminium Cell Control - Alumina Dissolution and Cell Dynamics....Pages 760-766
Aiming for Zero Anode Effects....Pages 767-773
Reduction of CF4 Emissions from the Aluminum Smelter in Essen....Pages 774-781
The Initiation, Propagation and Termination of Anode Effects in Hall-Heroult Cells....Pages 782-785
Operation of 150 KA Prebaked Furnaces with Automatic Voltage Control....Pages 786-797
Bath Chemistry Control System....Pages 798-803
The Liquidus Enigma....Pages 804-807
Control of Bath Temperature....Pages 808-811
Back Matter....Pages 851-853
Front Matter....Pages 737-737
Noise Classification in the Aluminum Reduction Process....Pages 812-816
Increased Current Efficiency and Reduced Energy Consumption at the TRIMET Smelter Essen Using 9 Box Matrix Control....Pages 817-824
A Nonlinear Model Based Control Strategy for the Aluminium Electrolysis Process....Pages 825-829
Bath and Liquidus Temperature Sensor for Molten Salts....Pages 830-837
Anode Signal Analysis — The Next Generation in Reduction Cell Control....Pages 838-843
Alcoa STARprobe™....Pages 844-850
Back Matter....Pages 851-853
Front Matter....Pages 855-855
A Study of Factors Affecting Fluoride Emission from 10,000 Ampere Experimental Aluminum Reduction Cells....Pages 857-864
The Characterisation of Aluminium Reduction Cell Fume....Pages 865-869
Factors Affecting Fluoride Evolution from Hall-Heroult Smelting Cells....Pages 870-878
A Study of the Equilibrium Adsorption of Hydrogen Fluoride on Smelter Grade Aluminas....Pages 879-888
The Role and Fate of SO2 in the Aluminium Reduction Cell Dry Scrubbing Systems....Pages 889-897
Sulphur Containing Compounds in the Anode Gas from Aluminium Cells, A Laboratory Investigation....Pages 898-902
Mathematical Model of Fluoride Evolution from Hall-Héroult Cells....Pages 903-909
Factors Influencing Cell Hooding and Gas Collection Efficiencies....Pages 910-917
Sulfur and Fluorine Containing Anode Gases Produced during Normal Electrolysis and Approaching an Anode Effect....Pages 918-923
Understanding the Effects of the Hydrogen Content of Anodes on Hydrogen Fluoride Emissions from Aluminium Cells....Pages 924-929
Effect of Open Holes in the Crust on Gaseous Fluoride Evolution from Pots....Pages 930-935
Alumina Structural Hydroxyl as a Continuous Source of HF....Pages 936-941
Investigation of Solutions to Reduce Fluoride Emissions from Anode Butts and Crust Cover Material....Pages 942-947
Global Considerations of Aluminium Electrolysis on Energy and the Environment....Pages 948-955
Back Matter....Pages 1043-1045
Front Matter....Pages 855-855
The Surface Chemistry of Secondary Alumina from the Dry Scrubbing Process....Pages 956-961
SO2 Emission Control in the Aluminium Industry....Pages 962-967
Reduction of HF Emissions from the TRIMET Aluminum Smelter (Optimizing Dry Scrubber Operations and Its Impact on Process Operations)....Pages 968-974
Handling CO2EQ from an Aluminum Electrolysis Cell....Pages 975-980
Dry Scrubbing for Modern Pre-Bake Cells....Pages 981-986
Pot Gas Heat Recovery and Emission Control....Pages 987-992
The Applicability of Carbon Capture and Sequestration in Primary Aluminium Smelters....Pages 993-998
Dusting Properties of Industrial Aluminas....Pages 999-1006
Evaluation of Fluorocarbon Emissions from the Aluminum Smelting Process....Pages 1007-1014
Perfluorocarbon (PFC) Generation at Primary Aluminum Smelters....Pages 1015-1023
Factors Affecting PFC Emissions from Commercial Aluminum Reduction Cells....Pages 1024-1031
Protocol for Measurement of Tetrafluoromethane and Hexafluoroethane from Primary Aluminum Production....Pages 1032-1036
On Continuous PFC Emission Unrelated to Anode Effects....Pages 1037-1042
Back Matter....Pages 1043-1045
Front Matter....Pages 1047-1047
Impact of Alternative Processes for Aluminium Production on Energy Requirements....Pages 1049-1055
Alternate Smelting Processes for Aluminum....Pages 1056-1069
Technoeconomic Assessment of the Carbothermic Reduction Process for Aluminum Production....Pages 1070-1075
Solid State Carbothermal Reduction of Alumina....Pages 1076-1081
Production of Aluminum-Silicon Alloys from Sand and Clay in Hall Cells....Pages 1082-1088
Bench Scale Electrolysis of Alumina in Sodium Fluoride - Aluminum Fluoride Melts Below 900°C....Pages 1089-1094
Electrolysis of Alumina in a Molten Salt at 760°C....Pages 1095-1099
Back Matter....Pages 1107-1107
Front Matter....Pages 1047-1047
Aluminum Reduction via Near Room Temperature Electrolysis in Ionic Liquids....Pages 1100-1106
Back Matter....Pages 1107-1107
Back Matter....Pages 1109-1111