Specific Energy Reduction Through Design Modifications at Aditya Aluminium Smelter
摘要
A new cathodeCathode liningCathode lining was developed and tested at Aditya aluminiumAluminium smelter to reduce the specific energyEnergy consumptionSpecific energy consumption. The copperCopper insertCopper insert in the collector bar was modified for uniform cathodeCathode current distributionCurrent distribution and lesser resistance. The uniform current distribution and lower resistance helped to reduce the overall cellCell voltage. The modified shape and size of the sidewall resulted in greater ledgeLedge thickness. Additionally, insulation bricks of lesser conductivity were used around the cathodeCathode. The thicker ledgeLedge and increased insulation maintain the desired cathodeCathode temperature at a lesser voltage. The process control parameters were modified to account for the increased bath mass. The standard operating procedure (SOPs) for pot relining, cathodeCathode preheatPreheat time, and start-upStart-Up parameters were modified to account for the increased pot cavity and lesser cathodeCathode resistance. Extra cooling arrangements were made to facilitate the quick build-up of the ledge at the sidewall during early cellCell life. The pilot pots have achieved reduced specific energyEnergy by ~150 DC-kWh/T.