Optimizing Anode Change in Aluminum Cells—A Digital Twin Approach
摘要
The anodesAnode in an aluminumAluminum cell must be periodically replaced, an operation which requires a way to position the new ones at a precise distance from the metalMetals pad. Some of our smeltersSmelter employ theoretical gauging, where the new position is calculated based on the carbon consumptionCarbon consumption rate. This method relies heavily on an accurate estimation of the consumption rate, and also on having mechanisms to detect and correct cells that deviate from the desired state. In this paper, we present a simple digital twinDigital twin that continuously estimates the anodeAnode position, setting offset, and consumption rate for each cell. It has been implemented in our smeltersSmelter, both as interactive tool to guide decision-making and as an automated correction algorithm directly connected to the production system. Our results show an improved coefficient of variationVariations of the anodic voltage dropVoltage drop, lower instability, and a reductionReduction in the number or pots drifting outside of the desired range.