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Automated anode replacement system for aluminum production

Société des Technologies de l'Aluminium STAS Ltée

Primary aluminum production begins with the processing of bauxite into pure aluminum oxide, or alumina, before proceeding through the electrolytic reduction process. Electrolysis reduces the alumina into liquid aluminum in electrolytic cells, or "pots," connected in a series, or "potline," to a direct-current power source. Acting as electrical conductors for the low-voltage, high direct current, anodes manufactured from a mixture of petroleum coke and coal tar pitch are attached to rods and suspended into the electrolytic cells where they are slowly consumed in the aluminum process. Because they burn, the carbon anodes must be regularly replaced, but it is a manual process that lacks precision and can lead to "anode effects" - a condition that occurs when the level of the dissolved alumina in the cell drops too low and the electrolytic bath itself begins to undergo electrolysis - thereby lowering cell energy efficiency and increasing the release of polyfluourocarbon gases.

La Société des technologies de l'aluminium (STAS), with financial support from TEAM, has developed a fully automated anode changing system for use in the aluminum industry. Developed by STAS, the system uses remote-control and computer-driven technology to replace worn anodes. The technology was demonstrated at the Lauralco aluminum plant in Deschambault, Québec, which typically replaces 174 anodes every 12-hour shift.

By improving the anode replacement process, STAS has indicated that the automated system could reduce energy consumption by 94,500 gigajoules per year, per plant. Other benefits included reduced GHG emissions and heat losses, and the creation of a safer working environment through the elimination of workers' exposure to harmful gases. With the Canadian aluminum industry looking to maintain its competitive position through lower production costs and improved energy efficiency, STAS anticipates equipping one plant per year over the next 10 years with its new system.

Delivery Agent:
  CANMET Energy Technology Centre - Ottawa

Total Project Value ($,000):	6,528
TEAM Contribution ($,000):	1,155
Other Federal Contributions ($,000):	485

^*NOTE: Project amounts taken from Third TEAM Progress Report 2003-2005