Cell Materials - investigation and studies:
Anode cover and bath processing
- Best practices for anode covering and dressing during pot operation
- Optimum anode cover material definition and testing in laboratory and in smelters
- Heat balance studies to determine the alumina blend, cover characteristics and thickness for different required heat flows through the top of the pot
- Bath and alumina crust material properties including thermal conductivity and hardness – from point of view of bath processing
- Material structural studies to determine the reasons for “uncrushable” bath
- Definition of fit for purpose equipment for bath crushing handling, transport and blending with alumina
For Anode Cover Materials research flyer, please click here.
Anode plant
- Determine the optimum cast iron composition for anode rodding
- Best practices for maintaining fluidity and control of anode rod casting conditions for highest quality casting
- Troubleshooting anode dust formation and diagnosis of causes of reactive anode carbon from raw materials and plant recycling practices
- Effect of bath circuit and both level control on anode quality and dust formation in pots
- Analysis of baked anode core data to determine causes of low density and low strength in green and baking areas
Green anode
- Smelter audit of all anode processing and storage areas to determine the nature of scrap and anode height variation
- Diagnosis of trends in anode density due to forming problems associated with changes to granulometry or to slot implementation
- Anode cracking investigations using both baked and green data to determine origin of cracking and possible remedies
- Ball mill / classifier circuit investigations to determine the origin of variation in pitching and green anode density and permeability
- Baking furnace audits to improve practices with respect to refractory maintenance, draft control, firing control and anode loading/unloading
Pot sidewall and new cathode materials development
The materials and cell life are important factors in the operating economics of an aluminium smelter. The lifetime of the cells is increasingly driven by two components of the cell lining: the carbon cathode blocks and the sidewall refractories which are the primary containments of the metal and the electrolyte. Our studies regarding sidewall and cathode materials and new design include:
- Pot autopsies to determine failure conditions and protection of the sidewall against corrosion by the ledge Fundamental studies into the wear mechanisms of modern cathode blocks.
- Development of new carbon-based cathode materials for longer cell life.
- Investigations into emerging cathode materials and design technologies. eg. TiB2 coatings.