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Emirates Global AluminiumAluminium (EGA) executed a project to improve reliability of DX reductionReduction pot anode clampsAnode clamps which are used to clamp anodesAnode against anodeAnode beam. Applying proper clamping force is important to reduce electric current leakages, to improve efficiency, and avoid anodeAnode slippages in an aluminum smeltingAluminum smelting plant. Failure of anode clampsAnode clamps is also linked with employee safetySafety as falling of anode clampAnode clamps (weight 19 kg) from 2.5 m height is a potential threat that may lead to workplace injury. A total of 27,216 clamps are installed in EGA Al Taweelah (AT Site) smelterSmelter. These units are frequently undergoing tightening and loosening operation based on operational requirements during beam raising and anode changeAnode change. Main failure is due to shaft damages which require immediate replacement with the help of new spare to prevent pot voltageVoltage dropping and molten metalMolten metal spillage. To improve the clamp functionality and efficiency, the anode clampsAnode clamps were re-designed by introducing reliability improvement solutions. The new design improved the anode clampAnode clamps life and intervention of operation and maintenance personnel. It includes bigger diameter shaft of 50 mm, independent sleeves, centering device, and reinforcement rings. The new design has also a significant reductionReduction in maintenance cost. This paper details the initial challenges, phases of design, and the successful modification of an anode clampAnode clamps, which minimized the safetySafety concerns and operational issues. The modified clamps have features that reduce the load on operators, pot voltage dropVoltage drop and reliability.

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Anode Clamp Reliability Improvements in EGA DX Reduction Potlines

  • 会议论文

  • 发表日期：

    2025年

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  • Mohamed Al Dhanhani,
  • Balakrishnan Kunnathurampalayam Palanisamy,
  • Satish Kumar Rajput,
  • Ravindra Kumar Shinde,
  • Arogyanathan Sigamani,
  • Mohammed AlJaziri

摘要

Emirates Global AluminiumAluminium (EGA) executed a project to improve reliability of DX reductionReduction pot anode clampsAnode clamps which are used to clamp anodesAnode against anodeAnode beam. Applying proper clamping force is important to reduce electric current leakages, to improve efficiency, and avoid anodeAnode slippages in an aluminum smeltingAluminum smelting plant. Failure of anode clampsAnode clamps is also linked with employee safetySafety as falling of anode clampAnode clamps (weight 19 kg) from 2.5 m height is a potential threat that may lead to workplace injury. A total of 27,216 clamps are installed in EGA Al Taweelah (AT Site) smelterSmelter. These units are frequently undergoing tightening and loosening operation based on operational requirements during beam raising and anode changeAnode change. Main failure is due to shaft damages which require immediate replacement with the help of new spare to prevent pot voltageVoltage dropping and molten metalMolten metal spillage. To improve the clamp functionality and efficiency, the anode clampsAnode clamps were re-designed by introducing reliability improvement solutions. The new design improved the anode clampAnode clamps life and intervention of operation and maintenance personnel. It includes bigger diameter shaft of 50 mm, independent sleeves, centering device, and reinforcement rings. The new design has also a significant reductionReduction in maintenance cost. This paper details the initial challenges, phases of design, and the successful modification of an anode clampAnode clamps, which minimized the safetySafety concerns and operational issues. The modified clamps have features that reduce the load on operators, pot voltage dropVoltage drop and reliability.