Conference Agenda

Maintaining optimal thermal conditions within potlines is critical to operational efficiency of aluminum reduction cells. To address this, we have developed an advanced suite of tools and models specifically designed for monitoring and managing cell thermal performance. Our updated operating window model now integrates the impact of current efficiency and introduces adaptive limits that automatically adjust for essential variables, including anodes, cell age, metal volume, forced convection network (FCN), and cover materials. We present the "core power" concept and define new criteria to identify cells deviating from their thermal limits over time. Our interactive tools now allow for instant simulations of thermal windows and operational monitoring via a comprehensive dashboard. Efforts are currently underway to develop a "cell at risk" indicator, leveraging these developments to proactively mitigate tap out risks. These tools represent a leap in operational efficiency via improved thermal management, and have paved the way to the creation and ongoing testing of our complete "numerical thermal twin".

Increase in modern cell amperage and anode size has added a thermochemical stress on sidewall lining materials which could result in accelerated degradation. Variation in cell operating conditions due to routine and non-routine activities will apply various forces which will affect degradation rates of side wall lining material and affect its operating temperature and potentially cell life. In this paper, examples of various impacts of side wall lining material degradation is discussed as part of continuous improvement program. Emirates Global Aluminium has adopted advanced cell lining testing to evaluate material suitability for cell operating conditions. The work includes autopsies and side wall inspections. This has contributed to better cell performance.

In order to assist aluminum smelters to significantly reduce the energy consumption of primary aluminum production and promote the green transformation and high-quality development of the aluminum smelting industry, Shenyang Aluminum and Magnesium Engineering and Research Institute Co.,Ltd (SAMI) has developed a Deep Energy-Saving Aluminum Electrolysis Technology System. In 2022, SAMI successfully applied this technology system to the 240 kA potline upgrading project of Guangxi Baise Guangtou Yinhai Aluminum Industry Company, achieving integrated application of Networked Self-equalizing Busbar Technology (NSBT), New Conceptual Cathode Technology (NCCT), “Long Healthy Life” potlining technology, Energy-saving and Eco-friendly Superstructure Technology, and new pot control system on the 240 kA potline. After recommissioning of the upgraded potline, the technical team proposed and developed a refined control process of gas preheating of the pots. By utilizing electric-thermal balance simulation, “Three-Low and One-High” Production Process Management Technology was developed, successfully increasing the operating current of the potline from 240 kA to 260 kA. Thanks to the design upgrade and production process optimization, the potline now operates stably with excellent KPIs, with average voltage < 3.945V, the current efficiency > 94.5 %, and the DC power consumption < 12.450 kWh/kg Al. After the technical upgrading and optimization, the DC power consumption of the potline has been reduced by nearly 0.9 kWh/kg Al, and the annual primary aluminum production capacity has been increased by nearly 14 000 tonnes, with significant energy-saving and economic benefits.

Heat removal from the cell in aluminium smelter is very essential for temperature controlling. Sidewall cooling helps the formation of side ledge inside the cell. Many aluminium smelters including PT Inalum are currently using compressed air direct cooling to the sidewall of the pot. These air lances cool inefficiently as the cooling pattern is non-uniform and limited air to pot shell retention time that eventually required more compressed air to be utilized. On the other hand, compressed air is needed for other daily operational works so the pressure has to be kept as the requirement. Therefore, Shell Heat Exchanger (SHE) with air supply is introduced for sidewall pot cooling. This technology increases the pot cooling efficiency and eventually reduces the compressed air needed for cooling. Experiment results at PT Inalum show ±15% compressed air saving by using SHE compare to direct cooling.