Light Metals 2011 (eBook)

Stephen Lindsay (Herausgeber)

eBook Download: PDF

2016 | 1st ed. 2016
MCCLXII Seiten
Springer International Publishing (Verlag)
978-3-319-48160-9 (ISBN)

Infos

The Light Metals symposia are a key part of the TMS Annual Meeting & Exhibition, presenting the most recent developments, discoveries, and practices in primary aluminum science and technology. Publishing the proceedings from these important symposia, the Light Metals volume has become the definitive reference in the field of aluminum production and related light metal technologies. Light Metals 2011 offers a mix of the latest scientific research findings and applied technology, covering alumina and bauxite, aluminum reduction technology, aluminum rolling, cast shop for aluminum production, electrode technology, and furnace efficiency.

The Minerals, Metals & Materials Society (TMS) is a member-driven international professional society dedicated to fostering the exchange of learning and ideas across the entire range of materials science and engineering, from minerals processing and primary metals production, to basic research and the advanced applications of materials. Included among its nearly 13,000 professional and student members are metallurgical and materials engineers, scientists, researchers, educators, and administrators from more than 70 countries on six continents. For more information on TMS, visit www.tms.org.

Inhalt

Cover 1
Title Page 3
Copyright Page 4
Table of Contents 5
Preface 21
About the Editor 22
Program Organizers 23
Aluminum Committee 29
Alumina and Bauxite 30
Organizers 30
Bauxite Resources and Utilisation 31
Session Chairs 31
New Development Model for Bauxite Deposits 32
Study on the Characterization of Marginal Bauxite from Pará/Brazil 39
Resource Utilization of High-sulfur Bauxite of Low-median Grade in Chongqing China 45
Development of Bauxite and Alumina Resources in the Kingdom of Saudi Arabia 49
Digestion Studies on Central Indian Bauxite 55
Effects of Roasting Pretreatment in Intense Magnetic Field on Digestion Performance of Diasporic Bauxite 59
Bayer Process I 64
Session Chairs 64
Application of Operation Integrity Management in the Alumina Industry 65
Influence of Solid Concentration, Particle Size Distribution, Ph And Temperature on Yield Stress of Bauxite Pulp 70
A New Method for Removal Organics in the Bayer Process 74
Alunorte Expansion 3 - The New Lines Added to Reach 6.3 Million Tons per Year 79
One Green Field Megaton Grade Large Alumina Refinery with Successful Engineering & Operation Experience
Advanced Process Control in the Evaporation Unit 90
Improvements in Smelter Grade Alumina Quality at Clarendon Alumina Works 95
Red Mud 98
Session Chairs 98
Application of Nanofiltration Technology to Improve Sea Water Neutralization of Bayer Process Residue 99
Caustic and Alumina Recovery from Bayer Residue 106
Investigation on Alumina Discharge into the Red Mud Pond at Nalco's Alumina Refinery, Damanjodi, Orissa, India 109
Production of Ordinary Portland Cement (OPC) from NALCO Red Mud 113
Recovery of Metal Values from Red Mud 119
Red Mud Flocculants used in the Bayer Process 123
Reductive Smelting of Greek Bauxite Residues for Iron Production 129
Precipitation, Calcination and Properties 134
Session Chairs 134
Effect of Technological Parameters on PSD of Aluminum Tri-Hydroxide from Seed Precipitation in Seeded Sodium Aluminate Solutions 135
Methods to Reduce Operating Costs in Circulating Fluidized Bed Calcination 138
Pressure Calcination Revisited 144
Dynamic Simulation of Gas Suspension Calciner (GSC) for Alumina 150
Physical Simulation and Numerical Simulation of Mixing Performance in the Seed Precipitation Tank with a Improved Intermig Impeller 157
Two Perspectives on the Evolution and Future of Alumina 163
Significant Improvement of Energy Efficiency at Alunorte's Calcination Facility 168
Attrition of Alumina in Smelter Handling and Scrubbing Systems 174
Energy and Environment 180
Session Chairs 180
Perspective on Bayer Process Energy 181
Optimization of Heat Recovery from the Precipitation Circuit 185
Alunorte Global Energy Efficiency 189
Opportunities for Improved Environmental Control in the Alumina Industry 195
Alumina Refinery Wastewater Management: When Zero Discharge Just Isn't Feasible– 201
High Purity Alumina Powders Extracted from Aluminum Dross by the Calcining-Leaching Process 207
Effect of Calcium/Aluminium Ratio on MgO Containing Calcium Aluminate Slags 211
Study on Extracting Aluminum Hydroxide from Reduction Slag of Magnesium Smelting by Vacuum Aluminothermic Reduction 215
Application of Thermo-gravimetric Analysis for Estimation of Tri-hydrate Alumina in Central Indian Bauxites-An Alternative for Classical Techniques 220
Determination of Oxalate Ion in Bayer Liquor Using Electrochemical Method 224
Alternative Alumina Sources - Poster Session 227
Session Chairs 227
The Effect of Ultrasonic Treatment on Alumina Leaching from Calcium Aluminate Slag 228
Theory and Experiment on Cooling Strategy during Seeded Precipitation 233
Extraction of Alumina from Red Mud by Divalent Alkaline Earth Metal Soda Ash Sinter Process 237
Dissolution Kinetics of Silicon from Sintering Red Mud in Pure Water 243
The Effect of Cooling Rate on the Leachability of Calcium Aluminate Slags 247
Preparing Polymerized Aluminum-ferrum Chloride with Red Mud 251
Adsorption of Polyethylene Glycol at the Interface of Dicalcium Silicate - Sodium Aluminate Solution 256
Production of Hematite Ore from Red Mud 260
Aluminum Reduction Technology 264
Organizers 264
Enviroment- Emissions/ Anode Effect I 265
Session Chairs 265
HF Measurements Inside an Aluminium Electrolysis Cell 266
LasIRTM-R - The New Generation RoHS-Compliant Gas Analyzers Based on Tunable Diode Lasers 272
Use of Spent Potlining (SPL) in Ferro Silico Manganese Smelting 277
Reduction of PFC Emissions at Pot Line 70 kA of Companhia Brasileira de Alumínio 283
Towards Redefining the Alumina Specifications Sheet - The Case of HF Emissions 287
Design of Experiment to Minimize Fluoride and Particulate Emissions at Alumar 293
Innovative Distributed Multi-Pollutant Pot Gas Treatment System 297
Fluoride Emissions Management Guide (FEMG) for Aluminium Smelters 303
Enviroment- Emissions/ Anode Effect II 309
On Continuous PFC Emission Unrelated to Anode Effects 310
Monitoring Air Fluoride Concentration around ALUAR Smelter in Puerto Madryn (Chubut Province, Argentina) 316
Reduction of Anode Effect Duration in 400kA Prebake Cells 319
Sustainable Anode Effect Based Perfluorocarbon Emission Reduction 324
The Initiation, Propagation and Termination of Anode Effects in Hall-Héroult Cells 328
Towards Eliminating Anode Effects 332
Correlation between Moisture and HF Formation in the Aluminium Process 337
Particulate Emissions from Electrolysis Cells 343
Investigation of Solutions to Reduce Fluoride Emissions from Anode Butts and Crust Cover Material 349
PFC Survey in Some Smelters of China 355
Considerations Regarding High Draft Ventilation as an Air Emission Reduction Tool 359
Cells Thermal Balance 365
Increasing the Power Modulation Window of Aluminium Smelter Pots with Shell Heat Exchanger Technology 366
New Approaches to Power Modulation at TRIMET Hamburg 372
Some Aspects of Heat Transfer Between Bath and Sideledge in Aluminium Reduction Cells 377
Towards a Design Tool for Self-heated Cells Producing Liquid Metal by Electrolysis 383
Heat Recovery from Aluminium Reduction Cells 389
Effects of Composition and Granulometry on Thermal Conductivity of Anode Cover Materials 395
Restart of 300kA Potlines after 5 Hours Power Failure 401
Multiblock Monitoring of Aluminum Reduction Cells Performance 403
Cells Technology, Development and Sustainability 409
High Amperage Operation of AP18 pots at Karmøy 410
Aluminium Smelter Manufacturing Simulation - Can These Bring Real Cost Savings? 415
Simultaneous Preheating and Fast Restart of 50 Aluminium Reduction Cells in an Idled Potline - A New Soft Re-start Technique for a Pot Line 418
SWOT Perspectives of Midage Prebaked Aluminium Smelter 424
Integrated Approach for Safe and Efficient Plant Layout Development 430
New Progress on Application of NEUI400kA Family High Energy Efficiency Aluminum Reduction Pot ("HEEP") Technology 435
Improving Current Efficiency of Aged Reduction Lines at Aluminium Bahrain (Alba) 441
Development of NEUI500kA Family High Energy Efficiency Aluminum Reduction Pot ("HEEP") Technology 446
Current Efficiency for Aluminium Deposition from Molten Cryolite-alumina Electrolytes in a Laboratory Cell 452
Improvement in Cell Equipment and Design 455
Retrofit of a Combined Breaker Feeder with a Chisel Bath Contact Detection System to Reduce Anode Effect Frequency in a Potroom 456
Anode Dusting from a Potroom Perspective at Nordural and Correlation with Anode Properties 460
The Application of Continuous Improvement to Aluminium Potline Design and Equipment 466
Alcoa STARprobeTM 472
Active Pot Control using Alcoa STARprobeTM 479
Technology & Equipment for Starting Up &
Study on Solution of Al2O3 in Low Temperature Aluminum Electrolyte 491
Applications of New Structure Reduction Cell Technology in Chalco's Smelters 496
Transport Numbers in the Molten System NaF-KF-AlF3-Al2O3 500
Cells Process Modeling 504
Session Chairs 504
Development and Application of an ANSYS Based Thermo-electro-mechanical Collector Bar Slot Design Tool 505
Impact of Amperage Creep on Potroom Busbars and Electrical Insulation: Thermal-Electrical Aspects 511
Modern Design of Potroom Ventilation 517
A Preliminary Finite Element Electrochemical Model for Modelling Ionic Species Transport in the Cathode Block of a Hall-Héroult Cell 522
CFD Modelling of Alumina Mixing in Aluminium Reduction Cells 528
Bubble Transport by Electro-Magnetophoretic Foces at Anode Botttom of Aluminium Cells 534
Anodic Voltage Oscillations in Hall-Héroult Cells 540
Energy Savings by Cell Design Improvements 546
Session Chairs 546
Electrical Conductivity of the KF-NaF- AlF3 Molten System at Low Cryolite Ratio with CaF2 Additions 547
Study of ACD Model and Energy Consumption in Aluminum Reduction Cells 550
Modeling of Energy Savings by Using Cathode Design and Inserts 552
Experimental Investigation of Single Bubble Characteristics in a Cold Model of a Hall-Héroult Electrolytic Cell 558
Large Gas Bubbles under the Anodes of Aluminum Electrolysis Cells 564
Initiatives to Reduction of Aluminum Potline Energy Consumption Alcoa Poços de Caldas/Brazil 570
Overview of High-Efficiency Energy Saving for Aluminium Reduction Cell 574
Cell Voltage Noise Reduction Based on Wavelet in Aluminum Reduction Cell 582
Poster Session 585
Session Chairs 585
Human Factors in Operational and Control Decision Making in Aluminium Smelters 586
Aluminum Rolling 591
Organizers 591
Session I 592
Session Chairs 592
An Investigation of Deformation Behavior of Bimetal Clad Sheets by Asymmetrical Rolling at Room Temperature 593
Coil Build Up Compensation during Cold Rolling to Improve Off-line Flatness 598
Through Process Effects on Final Al-sheet Flatness 602
Cast Shop for Aluminum Production 608
Organizers 608
Casthouse Productivity and Safety 609
Session Chairs 609
New Casthouse Smelter Layout for the Production of Small Non-Alloyed Ingots: Three Furnaces/Two Lines 610
Use of Process Simulation to Design a Billet Casthouse 615
Optimizing Scrap Reuse as a Key Element in Efficient Aluminium Cast Houses 621
Implementation of an Effective Energy Management Program Supported by a Case Study 626
Molten Metal Safety Approach through a Network 630
Improved Monolithic Materials for Lining Aluminum Holding & Melting Furnaces
Direct Chill Casting 640
Session Chairs 640
Cold Cracking during Direct-chill Casting 641
Surface Defects Structures on Direct Chill Cast 6xxx Aluminium Billets 647
Effect of Cooling Water Quality on Dendrite Arm Spacing of DC Cast Billets 653
Mould Wall Heat Flow Mechanism in a DC Casting Mould 659
Productivity Improvements at Direct Chill Casting Unit in Aluminium Bahrain (ALBA) 664
The Coupling of Macrosegregation with Grain Nucleation, Growth and Motion in DC Cast Aluminum Alloy Ingots 669
Investment Casting of Surfaces with Microholes and Their Possible Applications 675
Using SEM and EDX for a Simple Differentiation of Alpha- and Beta-AlFeSi-Phases in Wrought Aluminum Billets 680
Dross Formation, Control and Handling 686
Session Chairs 686
Oxidation of AlMg in Dry and Humid Atmospheres 687
Study of Early Stage Interaction of Oxygen with Al Methods, Challenges and Difficulties
Quality Assessment of Recycled Aluminium 699
Melt Quality Control 704
Session Chairs 704
In-Line Salt-ACDTM: A Chlorine-Free Technology for Metal Treatment 705
The Effect of TiB2 Granules on Metal Quality 711
Thermodynamic Analysis of Ti, Zr, V and Cr Impurities in Aluminium Melt 717
Current Technologies for the Removal of Iron from Aluminum Alloys 723
Electromagnetically Enhanced Filtration of Aluminum Melts 729
A Review of the Development of New Filter Technologies Based on the Principle of Multi Stage Filtration With Grain Refiner Added in the Intermediate Stage 735
Wettability of Aluminium with SiC and Graphite in Aluminium Filtration 741
Study of Microporosity Formation under Different Pouring Conditions in A356 Aluminum Alloy Castings 749
Grain Refinement, Alloying, Solidification and Casting 756
Session Chairs 756
Hycast Gas Cushion (GC) Billet Casting System 757
Studies of Fluid Flow and Meniscus Behavior during Horizontal Single Belt Casting (HSBC) of Thin Metallic Strips 761
Development of Alba High Speed Alloy 767
Dissolution Studies of Si Metal in Liquid Al under Different Forced Convection Conditions 0
Modification and Grain Refinement of Eutectics to Improve Performance of Al-Si Castings 778
Production of Al-Ti-C Grain Refiners with the Addition of Elemental Carbon and K2TiF6 784
Effect of Mechanical Vibrations on Microstructure Refinement of Al-7mass% Si Alloys 789
Predicting the Response of Aluminum Casting Alloys to Heat Treatment 793
Electrode Technology for Aluminium Production 799
Organizers 799
Anode Baking 800
Session Chairs 800
Determination of Coke Calcination Level and Anode Baking Level - Application and Reproducibility of L-sub-c Based Methods 801
Operation of an Open Type Anode Baking Furnace with a Temporary Crossover 807
Recent Developments in Anode Baking Furnace Design 813
Sohar Aluminium's Anode Baking Furnace Operation 819
Meeting the Challenge of Increasing Anode Baking Furnace Productivity 824
Wireless Communication for Secured Firing and Control Systems in Anode Baking Furnaces 830
Full Control of Pitch Burn during Baking: It's Impact on Anode Quality, Operational Safety, Maintenance and Operational Costs 834
High Performance Sealing for Anode Baking Furnaces 840
Anode Raw Materials and Green Carbon 845
Session Chairs 845
Property Profile of Lab-scale Anodes Produced with 180°C Mettler Coal Tar Pitch 846
Quality and Process Performance of Rotary Kilns and Shaft Calciners 851
Sub-surface Carbon Dioxide Reaction in Anodes 857
Paste Quality Improvements at Alcoa Poços de Caldas Plant 863
Prebaked Anode from Coal Extract (2) - Effects of the Properties of Hypercoal-coke on the Preformance of Prebaked Anodes 869
The New Generation of Vertical Shaft Calciner Technology 873
Petroleum Coke VBD 878
Session Chairs 878
Historical and Future Challenges with the Vibrated Bulk Density Test Methods for Determining Porosity of Calcined Petroleum Coke 879
Prediction of Calcined Coke Bulk Density 885
Calcined Coke Particle Size and Crushing Steps Affect Its VBD Result 891
Bulk Density - Overview of ASTM and ISO Methods with Examples of Between Laboratory Comparisons 894
Improving the Repeatability of Coke Bulk Density Testing 900
ASTM D7454 Vibrated Bulk Density Method - Principles and Limitations 906
Vibrated Bulk Density (VBD) of Calcined Petroleum Coke and Implications of Changes in the ASTM Method D4292 911
Anode Quality and Rodding Processes 916
Session Chairs 916
Multivariate Monitoring of the Prebaked Anode Manufacturing Process and Anode Quality 917
Characterization of a Full Scale Prebaked Carbon Anode using X-Ray Computerized Tomography 923
FEM Analysis of the Anode Connection in Aluminium Reduction Cells 929
Development of Industrial Benchmark Finite Element Analysis Model to Study Energy Efficient Electrical Connections for Primary Aluminium Smelters 935
Real Time Temperature Distribution During Sealing Process and Room Temperature Air Gap Measurements of a Hall-Héroult Cell Anode 941
Effects of High Temperatures and Pressures on Cathode and Anode Interfaces in a Hall-Heroult Electrolytic Cell 947
New Apparatus for Characterizing Electrical Contact Resistance and Thermal Contact Conductance 953
Carbon Anode Modeling for Electric Energy Savings in the Aluminium Reduction Cell 959
Cathode Design and Operation 965
Session Chairs 965
Preheating Collector Bars and Cathode Blocks Prior to Rodding with Cast Iron by Passing an AC Current Through the Collector Bars 966
Development and Application of an Energy Saving Technology for Aluminum Reduction Cells 972
Study of Electromagnetic Field in 300kA Aluminium Reduction Cells with Innovation Cathode Structure 977
Evaluation of the Thermophysical Properties of Silicon Carbide, Graphitic and Graphitized Carbon Sidewall Lining Materials Used in Aluminium Reduction Cell in Function of Temperature 982
Advanced Numerical Simulation of the Thermo-Electro-Mechanical Behaviour of Hall-Héroult Cells under Electrical Preheating 988
Influence of Technological and Constructive Parameters on the Integrity of the Bottom of Aluminum Reduction Cells during Flame Preheating 994
Creep Behaviors of Industrial Graphitic and Graphitized Cathodes during Modified Rapoport Tests 1000
Cathode Materials and Wear 1005
Session Chairs 1005
Measurement of Cathode Surface Wear Profiles by Laser Scanning 1006
Coke Selection Criteria for Abrasion Resistant Graphitized Cathodes 1012
Determination of the Effect of Pitch-Impregnation on Cathode Erosion Rate 1018
Simplifying Protection System to Prolong Cell Life 1024
Aluminate Spinels as Sidewall Linings for Aluminum Smelters 1030
A New Ramming Paste with Improved Potlining Working Conditions 1036
Towards a Better Understanding of Carburation Phenomenon 1042
Characterization of Sodium and Fluorides Penetration into Carbon Cathodes by Image Analysis and SEM-EDS Techniques 1048
Inert Anodes and Wettable Cathodes 1053
Session Chairs 1053
Pressureless Sintering of TiB2-based Composites using Ti and Fe Additives for Development of Wettable Cathodes 1054
Furan Resin and Pitch Blends as Binders for TiB2-C Cathodes 1060
Influence of Cobalt Additions on Electrochemical Behaviour of Ni-Fe-Based Anodes for Aluminium Electrowinning 1065
Effects of the Additive ZrO2 on Properties of Nickel Ferrite Cermet Inert Anode 1071
Effect of Sintering Atmosphere on Phase Composition and Mechanical Property of 5Cu/(10NiO-NiFe2O4) Cermet Anodes for Aluminum Electrolysis 1077
Poster Session - Electrode 1082
Session Chairs 1082
Influence of Ultrafine Powder on the Properties of Carbon Anode Used in Aluminum Electrolysis 1083
Preparation NiFe2O4 Matrix Inert Anode Used in Aluminum Electrolysis by Adding Nanopowder 1088
Cold Water Model Simulation of Aluminum Liquid Fluctuations Induced by Anodic Gas in New Tape of Cathode Structure Aluminum Electrolytic Cell 1093
Effects of Physical Properties of Anode Raw Materials on the Paste Compaction Behavior 1099
Furnace Efficiency - Energy and Throughput 1103
Organizers 1103
Session I 1104
Furnaces Designed for Fuel Efficiency 1105
Latest Trends in Post Consumer and Light Gauge Scrap Processing to include Problematic Materials such as UBC, Edge Trimming and Loose Swarf 1109
Investigation of Heat Transfer Conditions in a Reverberatory Melting Furnace by Numerical Modeling 1115
Oxyfuel Optimization using CFD Modeling 1121
Operational Efficiency Improvements Resulting from Monitoring and Trim of Industrial Combustion Systems 1124
New Technology for Electromagnetic Stirring of Aluminum Reverberatory Furnaces 1127
Evaluation of Effects of Stirring in a Melting Furnace for Aluminum 1133
Business Analysis of Total Refractory Costs 1138
Improved Furnace Efficiency through the Use of Refractory Materials 1144
Study on the Energy-saving Technology of Chinese Shaft Calciners 1150
Author Index 1153
Subject Index 1159

Produkt-Details

• Erscheint lt. Verlag: 23.12.2016
• Reihe/Serie: The Minerals, Metals & Materials Series
• Reihe/Serie: The Minerals, Metals & Materials Series
• Verlagsort: Cham
• Sprache: englisch
• Themenwelt: Technik ► Bauwesen
• Themenwelt: Technik ► Maschinenbau
• Schlagworte: Alumina and bauxite • aluminum alloys • cast shop • Light Metals • Materials Science
• ISBN-10: 3-319-48160-6 / 3319481606
• ISBN-13: 978-3-319-48160-9 / 9783319481609