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Technical Program TECHNICAL PROGRAM The 128th TMS Annual Meeting & Exhibition T S The 128th TMS Annual Meeting & Exhibition Minerals • Metals • Materials San Diego Convention Center ✻ San Diego, California U.S.A. ✻ February 28 - March 4, 1999 MONDAY AM 9:10 AM PRODUCTIVITY INCREASE AT SORAL SMELTER: T. Johansen1; 1 2 1 ALUMINUM REDUCTION TECHNOLOGY: H. P. Lange ; R. von Kaenel ; Sor-Norge Aluminium A/S, Elektrolysen, AM MONDAY Smelter Technology P.O. Box 85, Husnes N-5460 Norway; 2Alusuisse Technology & Man- agement Ltd., Technology Center Chippis, CH-3965, Chippis, Switzer- Sponsored by: Light Metals Division, Aluminum Committee land Program Organizers: Georges J. Kipouros, Dal Tech, Dalhousie The Sør-Norge Aluminium AIS(Søral) smelter was started in 1985 University, NS B3J2X4 Canada; Mark P. Taylor, Comalco Alu- with Alusuisse 100 kA pre-baked anodes technology. In 1989 it was minium, Ltd., Brisbane, Queensland 4001 Australia decided to retrofit the plant as the operation had not changed since start-up. Goals for the modernization were initially rather modest. The current intensity should be increased from 115kA, the current effi- Monday AM Room: 6F ciency from 90 to 92% and energy consumption should be decreased March 1, 1999 Location: Convention Center from 15.3 to 14.7 kWh/kg Al. These goals should be reached by intro- ducing a new concept for cathode shell and lining, a minimum magnetic Session Chair: Geoff P. Bearne, Comalco, Comalco Research and compensation, and new process control and point feeding. These changes Technical Support, Melbourne, Victoria 3074 Australia explored new potentials. Today Søral is operating both pot lines at 126.5 kA with a current efficiency higher than 93.5%. Ten test cells have been operating for more than 17 months at 140 kA and in cooperation with the Alusuisse Technology Centre Chippis, Søral is exploring the possibilities to operate the cells at 150 kA. This paper 8:00 AM - SPECIAL LMD PRESENTATION presents the developments and methodology in details, shows the results and possible future developments. A REVIEW OF PAST ALUMINUM INERT ANODE RESEARCH LEADING TO A PLAN FOR FUTURE INVESTIGATION: Dr. H. 9:35 AM Wayne Hayden1; Dr. Greg Barthold2; Rodney Hanneman3; 1Oak Ridge NORDULAR FAST-TRACK ALUMINIUM MODULAR SMELTER National Labs, Bldg. 4500S, Rm C47, Oak Ridge, TN 37831; 2ASME, NORDURAL IN ICELAND: J. Lombard1; 1VAW Aluminium- 1828 L. Street NW, Suite 906, Washington, DC 20036; 33801 Old Gun Technologie GmbH, P.O. Box 101554, 41415 Neuss Germany Road West, Midlothian, VA 23113 Significant savings in capital expenditures for greenfield smelter can ASME has been asked by the Department of Energy's Office of be achieved by reducing the time needed from ground breaking to the Industrial Technology to assess past work on the development of an first hot metal. The construction of the Nordural Smelter in Iceland is inert anode for aluminum electrolytic reduction, and to suggest a path an example of such a fast-track smelter project with an outstanding for future research. ASME's Center for Research and Technology De- construction period of only 14 months. The process technology for this velopment is undertaking this task by forming a Technical Working smelter project was delivered by VAW Aluminium-Technologie GmbH, Group of recognized independent experts in the field of aluminum reduc- Germany. Nordural hf, a subsidiary of Columbia Ventures Corporation tion for the purpose of evaluating literature and patents and reviewing (CVC), has been designed and approved for a name plate capacity of presentations by private investigators. Their work is in the beginning 180,000 t/a in three phases. Phase 1 of this state-of-the-art smelter stages of review and assessment of both public and private information. consists of 120 VAW CA180 pots, a side-by-side prebake reduction cell A peer reviewed document is expected by early spring '99 for presenta- operating at 180,000 amps. The pots are equipped with center hoppers tion to DOE. This presentation at TMS will describe progress to date. for alumina and aluminum fluoride with crust breakers and point feeders The final report, when finished, will be made available to the public. incorporated in the hoppers. The cells are controlled by the VAW ELAS control system. Additionally there is an anode rodding shop, casthouse, fume treatment plant, alumina handling equipment, including harbour 8:30 AM off-loading equipment. AP21: A HIGH PERFORMANCE, HIGH PRODUCTIVITY AND LOW CAPITAL COST NEW CELL TECHNOLOGY: P. Homsi1; J. 10:00 AM Bos1; P. Herd1; 1Aluminium Pechiney, LRF - BP114, Saint-Jean-de- BUSBARS OPTIMIZATION USING CELL STABILITY CRITERIA Maurienne, Cedex 73303 France AND ITS IMPACT ON CELL PERFORMANCE: J. P. Antille1; R. von Based on the broad experience gained from the current generations Kaenel1; 1Alusuisse Technology & Management, Ltd., Technology Cen- of AP cell technology, the well known AP18 cell has been re-engineered ter Chippis, Chippis CH - 3965 Switzerland to create a new advanced cell operating at about 210 kA and called It is desirable to operate an aluminum reduction cell at the highest AP21. A range of numerical models, fitted to experimental results has possible level of current: the higher the current, the more aluminum per been used. The new design benefits from the latest improvements in unit time. Various factors limit the maximum current, among them the lining materials and design, anode and pin dimensions and sidewall ven- need to maintain an acceptable heat balance, which requires reducing tilation. Four test cells have been operating since September 1997 at the the anode-cathode distance as the current is increased. This tends to Saint-Jean-de-Maurienne smelter. Results are well in line with calcula- make the cell less stable: it becomes noisy, leading to reduced current tion predictions. Technical performances are presented and discussed. efficiency and increased energy consumption. The busbar configuration The main features of the new cell are a reduction of almost 15% in has a major effect on cell stability. A powerful mathematical model for capital cost per ton of installed capacity and improvements in operating predicting cell stability has been developed, and is in use for optimizing costs. The new cell technology is available for greenfield projects as well as for retrofitting of current AP18 potlines. 1 existing busbar systems. Applications at industrial scale are presented and the resulting performance improvements discussed. 8:30 AM INVITED PAPER 1 1 MONDAY AM MONDAY IS THE ALUMINUM CAR A FANTASY?: Firoze Katrak ; Charles 10:25 AM BREAK River Associates, Inc., 200 Clarendon St., T-33, Boston, MA 02116 USA 10:45 AM Over the last two decades, aluminum usage in cars has grown signifi- MODERNIZATION OF S 172 - M2 PREBAKED POTS: V. V. Geinze1; cantly, but mostly in cast forms. The bulk of these applications is in V. V. Bersteniov1; L. K. Krylov1; V. J. Orlov1; F. Zannini2; H. O. Bohner2; transmission, engine block, and suspension type components. Use of J. Ifju2; S. Deb3; 1OAO SaAZ, Sajanogorsk, Chakassia 662703; 2Techmo aluminum in body-in-white (BIW) has been limited and sporadic, and Car S.P.A., Via R. Colpi, Limena 15-17 - 3501 Italy; 3Hart Ltd - 13A steel continues to dominate in BIW applications. The use of polymers New Road, 700027 Calcutta, India has grown only in the interior, with some small successes in exterior AO Saianskij Aluminievyi Zavod (SaAZ) and Techmo Car/Techmo applications. Will usage of aluminum and polymers plateau, or will it Engineering SpA (Techmo) have decided to implement a modernization break through and grow rapidly in the next century? How will the battle project aimed at improving performance and ecology of the potline No among steel companies, polymer companies, and aluminum companies 2 comprising S-172 M2 type cells arranged in two rows in each potroom. affect this outcome? The paper will discuss key issues related to the Application of some elements of an up-to-date technology like mag- future of aluminum, steel, and polymers in the automotive industry. netic compensation, point feeding, process control and technology based on high acidic bath on 10 end-to-end 172 kA prebaked cells without 9:00 AM INVITED PAPER shutting them down provides an example on the ways of possible retro- OVERVIEW OF DOE’S PROGRAMS ON ALUMINUM AND MAG- fitting approaches. This paper describes the work done in the course of NESIUM FOR AUTOMOTIVE APPLICATIONS: Joe Carpenter1; 30-month preparation and pretest phase, as well as the results obtained 1U.S. Department of Energy, EE-32, 1000 Independence Ave., S.W., and approved during the 1-month control test period. Washington, D.C. 20585 USA This will be an update and review of the DOE programs on aluminum 11:10 AM and magnesium for automotive (including heavy duty) applications. DESIGN OF FEEDING BUSBAR SYSTEM: F. M. El-Dawi1; S. A. While the main programs focused on automotive applications are in the Mohamed1; U. H. Seha1; A. I. Hassanien1; 1The Aluminium Co. of Office of Transportation Technologies (OTT), there are contributory Egypt, Research and Design, Nage-Hammadi Egypt efforts in the DOE Office of Industrial Technologies and the Office of The annual production of the Aluminium Company of Egypt is Energy Research. The OTT efforts are programmatically divided into increased by adding a new pot line with prebaked anode 200 kA End to Automotive Materials and Heavy Vehicle Materials, but both have ef- End cells. Electrical, thermal and economic calculations are accom- forts on materials for the body/chassis and the powertrain, and there is plished. Different design alternatives are calculated and compared. The considerable synergism among the efforts. The bulk of the efforts are best design was the one which has lower cost and maintains certain on castings, sheet and alloys with lesser efforts on metal matrix com- requirements as safety.
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