Aluminium Production

Introduction
The aluminium production process
Hall-Hroult
Prebake Cell
Pechiney technology
Inert anode
Aluminium Production: intro
Aluminium can be produced by using anodes and cathodes in the aluminium
smelter.
The main components of anodes are petroleum coke, a product from the distillation
of oil, and coal tar pitch, a distillation product extracted from the tar that is obtained
in coking plants. A part of the anode material, the so-called anode butts, is returned
by the aluminium smelters to be reused as raw material. Petroleum coke and anode
butts are crushed, dried if necessary, graded, ground, heated and mixed with an
exact amount of pitch and finally kneaded. An optimal composition is yet another
prerequisite for good anode quality. Depending on the anode format the compound
will be moulded to a 'green anode' either in a press or in a vibrating machine. After
forming, the anodes are baked at approx. 1150C to carbonize the pitch binder and
eliminate the volatile parts of the pitch. After cleaning, inspecting and packaging,
the anodes are ready for delivery. Anodes can be produced in all shapes and sizes.
Click here for a picture of the Anode production process steps. Click here for a short
overview of the aluminium production process.
the Hall-Hroult-Electrolysis
Anode production process steps
1) Petroleum coke storage
2) Butt storage
3) Liquid pitch storage
4) Sampling
5) Drying
6) Grading
7) Crushing
8) Grinding
9) Sifting
10) Intermediate storage
11) Metering
12) Preheating
13) Mixing and kneading
14) Homogenizing/cooling
15) Pressing
16) Vibrating
17) Baking
18) Inspecting
19) Packaging, storage
20) Dispatch
Cathode blocks
Cathodes in aluminum electrolysis - content
Production of primary aluminium
Aluminium electrolysis
Electrolysis cell lining
Aluminium electrolysis cell
Electrolysis cell - General data
Western world cathode demand
Cathode block production
Classification of cathode blocks
Cathode blocks - selection criteria
Graphite layer structure
Chemical / structural changes during heat treatment
Advantages of graphite
Rapport expansion curves
Disadvantages of graphite
Graphitized cathodes: Pot results vs semi-graphitic blocks
Graphitized cathodes: Positive impact on technical results
Graphitized cathodes: Achieved potlife (published data)
Wear Reduction
Cathodes made from carbon and graphite are applied for the production of primary aluminium.
Cathodes in aluminum electrolysis -
content
Electrolysis cell
Cathode blocks
Graphitized blocks
Aluminium electrolysis
General chemical reaction
2 Al
2
O
3
(dissolved) + 3 C (s) = 4 Al (liquid) + 3 CO
2
(gas)
Cathode reaction:
4 Al
3+
(bath) + 12 e
-
= 4 Al (liquid)
or 4 AlF
4
-
(bath) + 3 e
-
= Al (liquid) + 4F
-
Anode reaction:
3 C (solid anode) + 6 O
2-
= 3 CO
2
(gas) + 12 e
-
Electrolysis cell bottom lining
Requirements to the cell lining
electrically conductive
resistant against high temperature
low chemical reaction with bath components
no alloy-formation with liquid aluminium
= Single candidate: CARBON/GRAPHITE
Technological challenge
Tremendous increase over past century in
Cell size
Efficiency
Productivity
Demand for substantial cathode carbon developments
Main targets Reduction in power consumption
Increase in potlife
Cell Cathode:
C Cathode Blocks
C Sidewall Blocks
C Ramming Paste
C Glues/Cements
C Refractory Insulation
Carbon Anode
C Molten Cryolite
Liquid Aluminium

Aluminium electrolysis cell

Electrolysis cell - General data
Cathode Block 10 - 20 blocks/pot = 8 - 26 t/pot
Sidewall Blocks 2 - 7 t/pot
Ramming Paste 2 - 10 t/pot
Steel Shell 8 - 15 m long; 3 - 4 m wide
Pot Amperage 100 330
+
kA
Pot Voltage 4 - 5 V
Potline 100 - 300 cells connected in series
Potlife 1500 - 3000 days
Western world cathode demand
(*cathode = bottom blocks and sidewall blocks)
37 kt 23 kt 10 kt
8 kt 11 kt
Total Total world world: 101 : 101 kt kt
12 kt
Cathode block production
Extrusion Extrusion
Anthracite Anthracite
Graphite Graphite
Petrolcoke Petrolcoke
Binder Binder
pitch pitch
Baking Baking
Graphitization Graphitization
Machining Machining
Classification of cathode blocks
Anthracitic / Semi-graphitic
based on anthracite (gas or electrically calcined)
with or without additions of graphite; baked at ~1200 C
Graphitic
based on 100% graphite aggregate; baked at ~1200 C
Graphitized
based on petroleum/pitch coke; baked at ~ 800 C
followed by graphitization at over 2500 C
Cathode blocks - selection criteria
Low sodium expansion
Low electrical resistivity
High thermal conductivity
Graphite layer structure
Chemical / structural changes during heat
treatment
Marsh and Griffiths, Int. Symp. on Carbon, Japan 1982
Advantages of graphite
1) Low electrical resistivity
Lower cathode voltage drop
Less energy consumption
2) High thermal conductivity
Uniform temperature distribution
Less sludge deposition on cathode surface
3) High thermal shock resistance
No rodding cracks
4) Low sodium uptake
No cathode laminations
Result: Higher pot amperage / pot metal productivity
Rapport expansion curves
0
0,1
0,2
0,3
0,4
0,5
0,6
0 30 60 90 120
time (min)
e
x
p
a
n
s
i
o
n

(
%
)
amor phous
gr aphitic
gr aphite
Disadvantages of graphite
Mechanical data lower than anthracite
Mechanical wear
High thermal conductivity
Longer electrical preheating time
Dissipation of more heat into ramming paste
Change in current distribution
Increased horizontal currents in the metal pad
Larger differential expansion
Collector bars can move in the slot after cooling
Graphitized cathodes
Pot results vs semi-graphitic blocks

Plant A Plant B Plant C
(180 kA) (280 kA) (300 kA)
Production increase (%) + 2.3 + 3.2 + 4.8
Cathode drop () - 0.25 - 0.25 - 0.26
Energy from cath. drop (kWh/t) - 142 - 221 - 246
Energy from red. ACD (kWh/t) + 48 - - 154
Total energy (except C.E.) - 94 - - 400
Instability (n.ohm) + 1 + 4 - 11

(P. Homsi; 6
th
Australasian Aluminium Smelting Technology
Conference & Workshop)
Graphitized cathodes
Positive impact on technical results
Enhanced production output
- higher current efficiency
- increased pot amperage
Lower cathode drop
Constant or improved specific energy consumption
Improved pot stability,
allowing a reduction of the anode-to-cathode distance (ACD)
Graphitized cathodes
Achieved potlife (published data)
130 kA pot (low amperage pot) 114 months
180 kA pots up to 84 months
300 kA pots 65 months
Wear Reduction of graphitized cathodes
Approach
Create a 'harder' cathode by e.g.
Improved raw materials
Optimized composition / formulation
Densification
Use of Refractory Hard Material (RHM)
Reduced degree of graphitization
The aluminium
production process
The raw material for the extraction of aluminium is aluminium oxide, also called alumina,
produced from bauxite. Direct current of a very high intensity is passed through the
anodes in the process. The anodes are part of the chemical reaction. For the production of
1 ton of aluminium, approximately 400 kg anodes ton of Aluminium metal is required.
The aluminium production process is also called the Hall-Hroult-Electrolysis.
Picture of the general process
Overview of the aluminium production
4 t
Prebake Cell:
Pre-bake technology uses multiple anodes in each cell which are pre-baked in a separate
facility and attached to "rods" that suspend the anodes in the cell. New anodes are
exchanged for spent anodes - "anode butts" - being recycled into new anodes.
picture
Sderberg technology
Sderberg technology uses a continuous anode which is delivered to the cell (pot) in the form of a paste,
and which bakes in the cell itself.
An electrolytic cell or pot is an electro-chemical reactor with anodes arranged horizontally or vertically.
In case Sderberg anodes are used, the anode is delivered to the cell as a paste that is baked in-situ. In
Sderberg cells the power supply is either horizontal, as with HSS (horizontal stud Sderberg) cells or
vertical, as is the case with VSS (vertical stud Sderberg) cells.
picture
Pechiney technology
The Pechiney anode technology covers all steps of anode manufacturing:
- Raw materials selection and anode characterization
- Green process
- Baking process
- Anode handling and rodding
- Recycling
The anodes are baked in open type bake ovens, using the following technology:
- low gas consumption (2300 to 2600MJ/t)
- low packing coke consumption
- consistent level of baking
- low tar and fluoride emissions
- long fluewall life (130 to 160 cycles)
For the brickwork maintenance, the fluewalls can continuously be replaced without reducing
the production of the furnace.
copyright website Pechiney www.ap-technology.com
Inert anode/wettable cathode
The aluminium industry has employed the Hall-Heroult process for more than 100 years to
produce aluminium. The new inert anode technology is believed to reduce the anode,
labor, maintenance and environmental costs associated with running a smelter. The
wettable cathodes also holds potential for reduced costs and increased operating
efficiencies. Due to the fact that inert anodes would not use carbon, the smelting process
would not create carbon dioxide, carbon monoxide or other greenhouse gases.
(from An Aluminium Revolution Thomas Van Leeuwen, CFA)
Inert anode/wettable cathode
Technology:
The inert anode/wettable cathode invention relates to production of a metal by electrolytic
reduction of a metal oxide to a metal and oxygen. A preferred embodiment relates to
production of aluminum by electrolytic reduction of alumina dissolved in a molten salt
bath. An electric current is passed between an inert anode and a cathode through the salt
bath, thereby producing aluminum at the cathode and oxygen at the anode. The inert
anode preferably contains at least one metal oxide and copper, more preferably the oxides
of at least two different metals and a mixture or alloy of copper and silver.
(from An Aluminium Revolution Thomas Van Leeuwen, CFA)
Inert anode/wettable cathode
Technology (2):
The cermet materials used in anodes are deemed inert because, unlike carbon, they do not
react with oxygen generated by electrolysis of alumina. The cermet materials also have
relatively low solubility in the electrolyte. However, inert electrodes are subject to
corrosion through several different mechanisms. Aluminum droplets floating or suspended
in the molten salt bath may rapidly attack all components of the anodes. This problem is
more likely to occur at temperatures below 900C than at higher temperatures because
lower operating temperatures are generally associated with higher electrolyte densities that
can cause aluminum droplets to float. Secondly, aluminum and sodium dissolved in the
molten salt bath may also attack the ceramic or dissolve the metallic components of the
anode. The solubility of aluminum and sodium in cryolite drops rapidly from 960C to
910C, probably by about a factor of five. Further reduction in temperature below 910C
will reduce the solubility even more, but the benefit is small compared with other
mechanisms such as electrochemical corrosion of the anode metal phase.
(from An Aluminium Revolution Thomas Van Leeuwen, CFA)
Inert anode/wettable cathode
Technology (3):
The electrolytic cell operates at a temperature in the range of about 700-940C,
preferably about 900-940C, more preferably about 900-930C, and most preferably
about 900-920C. An electric current is passed between the inert anode and a cathode
through a molten salt bath comprising an electrolyte and alumina. In a preferred cell, the
electrolyte comprises aluminum fluoride and sodium fluoride, and the electrolyte may also
contain calcium fluoride, magnesium fluoride and/or lithium fluoride. The weight ratio of
sodium fluoride to aluminum fluoride is preferably about 0.7 to 1.1. At an operating
temperature of 920C, the bath ratio is preferably about 0.8 to 1.0 and more preferably
about 0.96. A preferred molten salt bath suitable for use at 920C contains about 45.9 wt.
% NaF, 47.85 wt. % AIF,, 6.0 wt. % Cap, and 0.25 wt. % MgF.
(from An Aluminium Revolution Thomas Van Leeuwen, CFA)