Light Metals 2011

Front Matter....Pages i-xxxi
Front Matter....Pages 1-1
New Development Model for Bauxite Deposits....Pages 5-11
Study on the Characterization of Marginal Bauxite from Pará/Brazil....Pages 13-18
Resource Utilization of High-Sulfur Bauxite of Low-Median Grade in Chongqing China....Pages 19-22
Development of Bauxite & Alumina Resources in the Kingdom of Saudi Arabia....Pages 23-28
Digestion Studies on Central Indian Bauxite....Pages 29-32
Effects of Roasting Pretreatment in Intense Magnetic Field on Digestion Performance of Diasporic Bauxite....Pages 33-37
Application of Operation Integrity Management in the Alumina Industry....Pages 41-45
Influence of Solids Concentration, Particle Size Distribution, pH and Temperature on Yield Stress of Bauxite Pulp....Pages 47-50
A New Method for Removal of Organics in the Bayer Process....Pages 51-55
Alunorte Expansion 3 — The New Lines Added to Reach 6.3 Million Tons Per Year....Pages 57-62
One Green Field Megaton Grade Large Alumina Refinery with Successful Engineering & Operation Experience....Pages 63-67
Advanced Process Control in the Evaporation Unit....Pages 69-73
Improvements in Smelter Grade Alumina Quality at Clarendon Alumina Works....Pages 75-77
Application of Nanofiltration Technology to Improve Sea Water Neutralization of Bayer Process Residue....Pages 81-87
Caustic and Alumina Recovery from Bayer Residues....Pages 89-91
Investigation of Alumina Discharge into the Red Mud Pond at Nalco’s Alumina Refinery, Damanjodi, Orissa, India....Pages 93-96
Production of Ordinary Portland Cement (OPC) from Nalco Red Mud....Pages 97-102
Recovery of Metal Values from Red Mud....Pages 103-106
Red Mud Flocculants Used in the Bayer Process....Pages 107-112
Reductive Smelting of Greek Bauxite Residues for Iron Production....Pages 113-117
Front Matter....Pages 1-1
Effect of Technological Parameters on PSD of Aluminum Tri-Hydroxide from Seed Preciptation in Seeded Sodium Aluminate Solutions....Pages 121-123
Methods to Reduce Operating Costs in Circulating Fluidized Bed Calcination....Pages 125-130
Pressure Calcination Revisited....Pages 131-136
Dynamic Simulation of Gas Suspension Calciner (GSC) for Alumina....Pages 137-143
Physical Simulation and Numerical Simulation of Mixing Performance in the Seed Precipitation Tank with a Improved Intermig Impeller....Pages 145-150
Two Perspectives on the Evolution and Future of Alumina....Pages 151-155
Significant Improvement of Energy Efficiency at Alunorte’s Calcination Facility....Pages 157-162
Attrition of Alumina in Smelter Handling and Scrubbing Systems....Pages 163-168
Perspective on Bayer Process Energy....Pages 171-174
Optimization of Heat Recovery from the Precipitation Circuit....Pages 175-178
Alunorte Global Energy Efficiency....Pages 179-184
Opportunities for Improved Environmental Control in the Alumina Industry....Pages 185-190
Alumina Refinery Wastewater Management: When Zero Discharge Just Isn’t Feasible…....Pages 191-196
High Purity Alumina Powders Extracted from Aluminum Dross by the Calcining—Leaching Process....Pages 197-200
Effect of Calcium/Aluminium ratio on MgO containing calcium aluminate slags....Pages 201-204
Study on extracting aluminum hydroxide from reduction slag of magnesium smelting by vacuum aluminothermic reduction....Pages 205-209
Application of Thermogravimetric Analysis for Estimation of Tri-hydrate Alumina in Central Indian Bauxites — an Alternative for Classical Techniques....Pages 211-214
Determination of Oxalate Ion in Bayer Liquor Using Electrochemical Method....Pages 215-217
The effect of ultrasonic treatment on alumina leaching from calcium aluminate slag....Pages 221-225
Theory and Experiment on Cooling Strategy during Seeded Precipitation....Pages 227-230
Front Matter....Pages 1-1
Extraction of Alumina from Red Mud by Divalent Alkaline Earth Metal Soda Ash Sinter Process....Pages 231-236
Dissolution Kinetics of Silicon from Red Mud in Pure Water....Pages 237-240
The effect of cooling rate on the leachability of calcium aluminate slags....Pages 241-244
Preparing Polymerized Aluminum-Iron Chloride with Red Mud....Pages 245-249
Adsorption of Polyethylene Glycol at the Interface of Dicalcium Silicate — Sodium aluminate solution....Pages 251-254
Production of Hematite Ore from Red Mud....Pages 255-258
Front Matter....Pages 259-259
HF Measurements Inside an Aluminium Electrolysis Cell....Pages 263-268
Lasir™-R — the New Generation RoHS-Compliant Gas Analyzers Based on Tunable Diode Lasers....Pages 269-273
Use of Spent Potlining (SPL) in Ferro Silico Manganese Smelting....Pages 275-280
Reduction of PFC Emissions at Pot Line 70 kA of Companhia Brasileira de Alumínio....Pages 281-284
Towards Redefining the Alumina Specifications Sheet — The Case of HF Emissions....Pages 285-290
Design of Experiment to Minimize Fluoride and Particulate Emissions at Alumar....Pages 291-294
Innovative Distributed Multi-Pollutant Pot Gas Treatment System....Pages 295-300
Fluoride Emissions Management Guide (FEMG) for Aluminium Smelters....Pages 301-306
On Continuous PFC Emission Unrelated to Anode Effects....Pages 309-314
Monitoring air fluoride concentration around ALUAR smelter in Puerto Madryn (Chubut Province, Argentina)....Pages 315-317
Reduction of Anode Effect Duration in 400kA Prebake Cells....Pages 319-323
Sustainable Anode Effect Based Perfluorocarbon Emission Reduction....Pages 325-328
The Initiation, Propagation and Termination of Anode Effects in Hall-Héroult Cells....Pages 329-332
Towards Eliminating Anode Effects....Pages 333-337
Front Matter....Pages 259-259
Correlation between Moisture and HF Formation in the Aluminium Process....Pages 339-344
Particulate Emissions from Electrolysis Cells....Pages 345-350
Investigation of Solutions to Reduce Fluoride Emissions from Anode Butts and Crust Cover Material....Pages 351-356
PFC Survey in Some Smelters of China....Pages 357-360
Considerations Regarding High Draft Ventilation as an Air Emission Reduction Tool....Pages 361-366
Increasing the Power Modulation Window of Aluminium Smelter Pots with Shell Heat Exchanger Technology....Pages 369-374
New approaches to power modulation at TRIMET Hamburg....Pages 375-379
Some Aspects of Heat Transfer Between Bath and Sideledge in Aluminium Reduction Cells....Pages 381-386
Towards a design tool for self-heated cells producing liquid metal by electrolysis....Pages 387-392
Heat Recovery from Aluminium Reduction Cells....Pages 393-398
Effects of Composition and Granulometry on Thermal Conductivity of Anode Cover Materials....Pages 399-404
Restart of 300kA Potlines after 5 Hours Power Failure....Pages 405-406
Multiblock Monitoring of Aluminum Reduction Cells Performance....Pages 407-412
High Amperage Operation of AP18 Pots at Karmøy....Pages 415-419
Aluminium Smelter Logistics — Can These Bring Real Cost Savings?....Pages 421-423
Simultaneous Preheating and Fast Restart of 50 Aluminium Reduction Cells in an Idled Potline....Pages 425-430
SWOT Perspectives of Midage Prebaked Aluminium Smelter....Pages 431-436
Integrated Approach for Safe and Efficient Plant Layout Development....Pages 437-441
New Progress on Application of NEUI400kA Family High Energy Efficiency Aluminum Reduction Pot (“HEEP”) Technology....Pages 443-448
Improving Current Efficiency of Aged Reduction Lines at Aluminium Bahrain (Alba)....Pages 449-453
Front Matter....Pages 259-259
Development of NEUI500kA Family High Energy Efficiency Aluminum Reduction Pot (‘HEEP’) Technology....Pages 455-460
Current Efficiency for Aluminium Deposition from Molten Cryolite-Alumina Electrolytes in a Laboratory Cell....Pages 461-463
Retrofit of a Combined Breaker Feeder with a Chisel Bath Contact Detection System to Reduce Anode Effect Frequency in a Potroom....Pages 467-470
Anode Dusting from a Potroom Perspective at Nordural and Correlation with Anode Properties....Pages 471-476
The Application of Continuous Improvement to Aluminium Potline Design and Equipment....Pages 477-482
Alcoa STARprobe™....Pages 483-489
Active Pot Control using Alcoa STARprobe™....Pages 491-496
Technology & Equipment for Starting Up & Shutting Down Aluminium Pots under Full Amperage....Pages 497-502
Study on solution of Al2O3 in low temperature aluminum electrolyte....Pages 503-507
Applications of New Structure Reduction Cell Technology in Chalco’s Smelters....Pages 509-512
Transport Numbers in the Molten System NaF-KF-AlF3-Al2O3....Pages 513-516
Development and Application of an Ansys Based Thermo-Electro-Mechanical Collector Bar Slot Design Tool....Pages 519-524
Impact of Amperage Creep on Potroom Busbars and Electrical Insulation: Thermal-Electrical Aspects....Pages 525-530
Modern Design of Potroom Ventilation....Pages 531-535
A Preliminary Finite Element Electrochemical Model for Modelling Ionic Species Transport in the Cathode Block of a Hall-Héroult Cell....Pages 537-542
CFD Modelling of Alumina Mixing in Aluminium Reduction Cells....Pages 543-548
Bubble Transport by Electro-Magnetophoretic Forces at Anode Bottom of Aluminium Cells....Pages 549-554
Anodic Voltage Oscillations in Hall-Héroult Cells....Pages 555-560
Electrical Conductivity of the KF - NaF - AlF3 Molten System at Low Cryolite Ratio with CaF2 Additions....Pages 563-565
Study of ACD Model and Energy Consumption in Aluminum Reduction Cells....Pages 567-568
Front Matter....Pages 259-259
Modeling of Energy Saving by using Cathode Design and Inserts....Pages 569-574
Expermental Investigation of Single Bubble Characteristics in a Cold Model of a Hall-Héroult Electrolytic Cell....Pages 575-580
Large Gas Bubbles under the Anodes of Aluminum Electrolysis Cells....Pages 581-586
Initiatives to Reduction of Aluminum Potline Energy Consumption Alcoa Poços de Caldas/Brazil....Pages 587-590
Overview of High-Efficiency Energy Saving for Aluminium Reduction Cell....Pages 591-598
Cell Voltage Noise Reduction Based on Wavelet in Aluminum Reduction Cell....Pages 599-601
Human Factors in Operational and Control Decision Making in Aluminium Smelters....Pages 605-609
Front Matter....Pages 611-611
An Investigation of Deformation Behavior of Bimetal Clad Sheets by Asymmetrical Rolling at Room Temperature....Pages 615-619
Coil Build Up Compensation during Cold Rolling to Improve Off-line Flatness....Pages 621-624
Through process effects on final Al-sheet flatness....Pages 625-630
Front Matter....Pages 631-631
New Casthouse Smelter Layout for the Production of Small Non-Alloyed Ingots: Three Furnaces/Two Lines....Pages 635-639
Use of Process Simulation to Design a Billet Casthouse....Pages 641-646
Optimizing Scrap Reuse as a Key Element in Efficient Aluminium Cast Houses....Pages 647-651
Implementation of an Effective Energy Management Program Supported by a Case Study....Pages 653-656
Molten Metal Safety Approach Through a Network....Pages 657-662
Improved Monolithic Materials for Lining Aluminum Holding & Melting Furnaces....Pages 663-666
Cold Cracking During Direct-Chill Casting....Pages 669-674
Surface Defects on Direct Chill As-Cast 6XXX Aluminum Billets....Pages 675-680
Effect of Cooling Water Quality on Dendrite Arm Spacing of DC Cast Billets....Pages 681-686
Mould Wall Heat Flow Mechanism in a DC Casting Mould....Pages 687-691
Front Matter....Pages 631-631
Productivity Improvements at Direct Chill Casting unit in Aluminium Bahrain (ALBA)....Pages 693-697
The Coupling of Macrosegregation with Grain Nucleation, Growth and Motion in DC Cast Aluminum Alloy Ingots....Pages 699-704
Investment Casting of Surfaces with Microholes and Their Possible Applications....Pages 705-709
Using SEM and EDX for a Simple Differentiation of α- and β-Alfesi-Phases in Wrought Aluminum Billets....Pages 711-716
Oxidation of AlMg in Dry and Humid Atmospheres....Pages 719-724
Study of Early Stage Interaction of Oxygen with Al; Methods, Challenges and Difficulties....Pages 725-730
Quality Assesment of Recycled Aluminium....Pages 731-735
In-Line Salt-ACD™: A Chlorine-Free Technology for Metal Treatment....Pages 739-744
The Effect of TIB2 Granules on Metal Quality....Pages 745-750
Thermodynamic Analysis of Ti, Zr, V and Cr Impurities in Aluminum Melt....Pages 751-756
Current Technologies for the Removal of Iron from Aluminum Alloys....Pages 757-762
Electromagnetically Enhanced Filtration of Aluminum Melts....Pages 763-768
A Review of the Development of New Filter Technologies Based on the Principle of Multi Stage Filtration with Grain Refiner Added in the Intermediate Stage....Pages 769-774
Wettability of Aluminium with SIC and Graphite in Aluminium Filtration....Pages 775-782
Study of Microporosity Formation under Different Pouring Conditions in A356 Aluminum Alloy Castings....Pages 783-789
Hycast™ Gas Cushion (GC) Billet Casting System....Pages 793-796
Studies of Fluid Flow and Meniscus Behavior during Horizontal Single Belt Casting (HSBC) of Thin Metallic Strips....Pages 797-802
Development of Alba High Speed Alloy....Pages 803-807
Dissolution Studies of Si Metal in Liquid Al under Different Forced Convection Conditions....Pages 809-814
Modification and grain refinement of eutectics to improve performance of Al-Si castings....Pages 815-820
Front Matter....Pages 631-631
Production of Al-Ti-C Grain Refiners with the Addition of Elemental Carbon and K2TiF6....Pages 821-825
Effect of Mechanical Vibrations on Microstructure Refinement of Al-7 Mass% Si Alloys....Pages 827-830
Predicting the Response of Aluminum Casting Alloys to Heat Treatment....Pages 831-836
Front Matter....Pages 837-837
Determination of Coke Calcination Level and Anode Baking Level – Application and Reproducibility of L-Sub-C Based Methods....Pages 841-846
Operation of an Open-Type Anode Baking Furnace With a Temporary Crossover....Pages 847-852
Recent Developments in Anode Baking Furnace Design....Pages 853-858
Sohar Aluminium’s Anode Baking Furnace Operation....Pages 859-863
Meeting the Challenge of Increasing Anode Baking Furnace Productivity....Pages 865-870
Wireless Communication for Secured Firing and Control Systems in Anode Baking Furnaces....Pages 871-874
Full Control of Pitch Burn During Baking: It’s Impact on Anode Quality, Operational Safety, Maintenance and Operational Costs....Pages 875-880
High Performance Sealing for Anode Baking Furnaces....Pages 881-885
Property Profile of Lab-Scale Anodes Produced with 180 °C Mettler Coal Tar Pitch....Pages 889-893
Quality and Process Perforamnce of Rotary Kilns and Shaft Calciners....Pages 895-900
Sub-Surface Carbon Dioxide Reaction in Anodes....Pages 901-906
Paste Quality Improvements at Alcoa Poços de Caldas Plant....Pages 907-912
Prebaked Anode From Coal Extract (2) - Effects of the Properties of Hypercoal-Coke on the Preformance of Prebaked Anodes....Pages 913-916
New Generation of Vertical Shaft Calciner Technology....Pages 917-921
Historical and Future Challenges with the Vibrated Bulk Density Test Methods for Determining Porosity of Calcined Petroleum Coke....Pages 925-930
Prediction of Calcined Coke Bulk Density....Pages 931-936
Calcined Coke Particle Size and Crushing Steps Affect Its VBD Result....Pages 937-939
Front Matter....Pages 837-837
Bulk Density - Overview of ASTM and ISO Methods With Examples of Between Laboratory Comparisons....Pages 941-946
Improving the Repeatability of Coke Bulk Density Testing....Pages 947-952
ASTM D7454 Vibrated Bulk Density Method – Principles and Limitations....Pages 953-957
Vibrated Bulk Density (VBD) of Calcined Petroleum Coke and Implications of Changes in the ASTM Method D4292....Pages 959-963
Multivariate Monitoring of the Prebaked Anode Manufacturing Process and Anode Quality....Pages 967-972
Characterization of a Full-Scale Prebaked Carbon Anode Using X-Ray Computerized Tomography....Pages 973-978
Fem Analysis of the anode connection in aluminium reduction cells....Pages 979-984
Development of industrial benchmark finite element analysis model to study energy efficient electrical connections for primary aluminium smelters....Pages 985-990
Real time temperature distribution during sealing process and room temperature air gap measurements of a hall-héroult cell anode....Pages 991-996
Effects of high temperatures and pressures on cathode and anode interfaces in hall-heroult electrolytic cells....Pages 997-1002
New Apparatus for Characterizing Electrical Contact Resistance and Thermal Contact Conductance....Pages 1003-1008
Carbon Anode Modeling for Electric Energy Savings in the Aluminium Reduction Cell....Pages 1009-1014
Preheating Collector Bars and Cathode Blocks Prior to Rodding with Cast Iron by Passing an AC Current Through the Collector Bars....Pages 1017-1022
Development and Application of an Energy Saving Technology for Aluminum Reduction Cells....Pages 1023-1027
Study of Electromagnetic Field in 300kA Aluminum Reduction Cells with Innovation Cathode Structure....Pages 1029-1033
Evaluation of thermophysical properties of silicon carbide, graphitic and graphitized carbon sidewall lining materials used in aluminium reduction cell in function of temperature....Pages 1035-1040
Advanced numerical simulation of the thermo-electro-chemo-mechanical behaviour of hall-héroult cells under electrical preheating....Pages 1041-1046
Influence of Technological and Constructive Parameters on the Integrity of the Bottom of Aluminum Reduction Cells during Flame Preheating....Pages 1047-1052
Creep Behaviors of Industrial Graphitic and Graphitized Cathodes during Modified Rapoport Tests....Pages 1053-1057
Measurement of Cathode Surface Wear Profiles by Laser Scanning....Pages 1061-1066
Front Matter....Pages 837-837
Coke Selection Criteria for Abrasion Resistant Graphitized Cathodes....Pages 1067-1072
Determination of the Effect of Pitch-Impregnation on Cathode Erosion Rate....Pages 1073-1078
Simplifying Protection System to Prolong Cell Life....Pages 1079-1084
Aluminate Spinels as Sidewall Linings for Aluminum Smelters....Pages 1085-1090
A New Ramming Paste with Improved Potlining Working Conditions....Pages 1091-1096
Towards a Better Understanding of the Carburation Phenomenon....Pages 1097-1102
Characterization of Sodium and Fluoride Penetration into Carbon Cathodes by Image Analysis and Sem-EDS Techniques....Pages 1103-1107
Pressureless Sintering of TiB2-Based Composites Using Ti and Fe Additives for Development of Wettable Cathodes....Pages 1111-1116
Furan Resin and Pitch Blends as Binders for TiB2-C Cathodes....Pages 1117-1121
Influence of Cobalt Additions on Electrochemical Behaviour of Ni-Fe-Based Anodes for Aluminium Electrowinning....Pages 1123-1128
Effects of the Additive ZrO2 on Properties of Nickel Ferrite Cermet Inert Anode....Pages 1129-1134
Effect of sintering atmosphere on phase composition and mechanical property of 5Cu/(10NiO-NiFe2O4) cermet inert anodes for aluminum electrolysis....Pages 1135-1139
Influence of Ultrafine Powder on the Properties of Carbon Anode Used in Aluminum Electrolysis....Pages 1143-1147
Preparation NiFe2O4 Matrix Inert Anode Used in Aluminum Electrolysis by Adding Nanopowder....Pages 1149-1153
Cold Water Model Simulation of Aluminum Liquid Fluctuations Induced by Anodic Gas in New Type of Cathode Structure Aluminum Electrolytic Cell....Pages 1155-1160
Effects of Physical Properties of Anode Raw Materials on the Paste Compaction Behavior....Pages 1161-1164
Front Matter....Pages 1165-1165
Furnaces Designed for Fuel Efficiency....Pages 1169-1172
Latest Trends in Post Consumer and Light Gauge Scrap Processing to Include Problematic Processing Material such as UBC, Edge Trimmings and Loose Swarf....Pages 1173-1178
Investigation of heat transfer conditions in a reverberatory melting furnace by numerical modeling....Pages 1179-1184
Oxyfuel Optimization using CFD Modeling....Pages 1185-1187
Front Matter....Pages 1165-1165
Operational Efficiency Improvements Resulting from Monitoring and Trim of Industrial Combustion Systems....Pages 1189-1191
Technology for Electromagnetic Stirring of Aluminum Reverberatory Furnaces....Pages 1193-1198
Evaluation of Effects of Stirring in a Melting Furnace for Aluminum....Pages 1199-1203
Business Analysis of Total Refractory Costs....Pages 1205-1210
Improved Furnace Efficiency through the Use of Refractory Materials....Pages 1211-1216
Study on the Energy-Saving Technology of Chinese Shaft Calciners....Pages 1217-1219
Back Matter....Pages 1221-1232