Aluminum Reduction Technologies

Potential

power reduction in smelting operations with anode nails

Potential

current-efficiency increase with anode nails

120–250%

more heat removed with magnetic mounted cooling fins

50–70%

more heat retained with magnetic mounted blankets

Challenges

Like most companies in the metals sector, primary aluminum producers face ongoing challenges to reduce costs and increase production. Reducing power consumption, improving current efficiency, increasing potline amperage and production, and extending potlife can all be strong incentives to streamline or upgrade operations.

Solutions

Anode nails

Saving some of the power that smelters use becomes possible with anode nails that reduce the electrical resistance of the anode assembly. Fine-tuning and improving anode current balance can add value to your aluminum reduction operation, increasing current efficiency, lowering costs, and improving production efficiency.

Mag-fin magnetic-mounted cooling fins

Sidewall life with extra frozen bath ledge may be extended by increasing the sidewall heat removal rate. With improved natural convection cooling, potshell hotspots may be reduced by the use of the magnetic cooling fins.

Mag-blanket magnetic-mounted insulation blankets

Proper or enhanced insulation reduces frozen-in anodes by insulating the external potshell side corners. By insulating the bottom corners of the potshell as well, the extent of frozen bath toe may be lessed. Magnetic-mounted insulation blankets can address both these issues.

Arc-cast cathode assembly

Cathode corrosion is known to be the result of high current density in the cathode and high metal velocity in the metal pad. Non-uniform current distribution between anode and cathode may also lead to current instability and unstable pot operation.

The arc-cast cathode/collector bar assembly provides more uniform electrical resistance over the cathode surface to reduce peak-current density, which can potentially extend potlife and reduce relining costs. By reducing horizontal electrical currents through the metal pad and cathode, current and pot stability are potentially improved.

Benefits

Power consumption (kWh/t) goes down when electrical resistance of the stub-to-carbon connection is reduced, in turn reducing ACD when using the arc-cast cathode assembly.
Increased current efficiency is achieved by reducing pot noise (current instability) through improved current distribution using anode nails.
Increased potline amperage and aluminum production is possible by increasing current stability and reducing peak current density by the arc-cast cathode connection.

Potlife can be extended by controlling frozen bath ledges by using magnetic-mounted potshell cooling fins or blankets.
Extended stub-life cycles through colder temperatures are achieved using anode nails.

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