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Monitoring individual anode currentsIndividual anode currents in Hall-Héroult cells is essential for optimizing aluminum productionAluminum production, enabling early detection of anodeAnode problems, improving current efficiency, etc. Traditional manual methods, such as voltage measurementsMeasurements using handheld voltmeters, are labor-intensive and provide only intermittent data. To address these limitations, Alcoa has developed and implemented a contactless monitoring system using magnetic fieldMagnetic fields sensorsSensors. These sensorsSensors continuously measure the magnetic fieldMagnetic fields generated by the current flowing through individual rods. Integrated into a robust data acquisition system, the sensorsSensors enable real-time monitoring without disrupting operations. Advanced algorithms, enhanced by machine learningMachine learning and statistical analysisStatistical analysis, process the data to detect anomalies and trigger alarms based on anodeAnode setting performance. Problematic anodeAnode load-ups are now detected within 4 h after the anode changeAnode change. With over 2,800 sensorsSensors deployed across 33 pots, the system showed that operational responsiveness can be improved, leading to better pot stability.

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Anode Setting Performance in the Hall-Héroult Process Using Physical Contactless Sensors

  • 会议论文

  • 发表日期：

    2026年

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  • Samuel Duplessis,
  • Marcel Guerreiro Neiro,
  • Patrice Doiron,
  • Julien Lauzon-Gauthier,
  • Dany Gauthier

摘要

Monitoring individual anode currentsIndividual anode currents in Hall-Héroult cells is essential for optimizing aluminum productionAluminum production, enabling early detection of anodeAnode problems, improving current efficiency, etc. Traditional manual methods, such as voltage measurementsMeasurements using handheld voltmeters, are labor-intensive and provide only intermittent data. To address these limitations, Alcoa has developed and implemented a contactless monitoring system using magnetic fieldMagnetic fields sensorsSensors. These sensorsSensors continuously measure the magnetic fieldMagnetic fields generated by the current flowing through individual rods. Integrated into a robust data acquisition system, the sensorsSensors enable real-time monitoring without disrupting operations. Advanced algorithms, enhanced by machine learningMachine learning and statistical analysisStatistical analysis, process the data to detect anomalies and trigger alarms based on anodeAnode setting performance. Problematic anodeAnode load-ups are now detected within 4 h after the anode changeAnode change. With over 2,800 sensorsSensors deployed across 33 pots, the system showed that operational responsiveness can be improved, leading to better pot stability.