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ALUMINIUM SMELTING INDUSTRY KPI Unit D18+, 1 June to 21 Nov 2012 D18 Difference Amperage kA 202 202 0 Current efficiency % 96.0 92.3 3.7 Metal production kg/pot-day 1,562 1,502 60 Volts per cell V 4.08 4.69 -0.61 DC specific energy kWh/kg Al 12.67 15.14 -2.47 Fe % 0.05 0.07 -0.02 Si % 0.02 0.03 -0.01 AE frequency AE/pot-day 0.02 0.44 -0.42 AE duration (V > 8 V) s 32 31 1 PFC emissions, CO 2 equivalent [4] kg/ t Al 12 247 -235 Table 4: D18+ and D18 performance comparison. D18+ is average of 5 middle pots tion from D18 to D18+ cell design. Additionally, the original potshell was modified to accommodate two more cathode blocks. Fig. 3 shows the seven test cells. Table 4 gives key performance indicators. The performance of the D18+ cells has now exceeded the original design targets, resulting in significant improvement over the existing D18 cells. The test cells are currently being fully evaluated before implementing throughout Dubal’s D18 potlines. Conclusions DX+ cell technology continues to give excellent performance with considerable amperage increase to 440 kA in DX+ pilot cells. The new DX+ Pot Control System is based upon standard market PLCs, which give increased HMI capabilities and ensure easy maintenance and future development. The successful test and validation of the D18+ cell technology has proven that it is both technically and practically possible to update and replace the cell technology within an existing operating potline. Study of the feasibility and optimal engineering pathway is currently in progress to enable replacing the remaining 513 D18 cells with the D18+ technology. References Fig. 4: Completed seven D18+ test cells in a D18 potline been developed to modernise the original Dubal D18 potlines and to improve their performance and economic competitiveness [8]. The objectives behind modernising the cells through new technology are to reduce the specific energy consumption to below 12.9 kWh/kg Al, reduce the anode effect frequency to below 0.10 per cell-day and to allow for a possible further amperage in-crease of 40 kA. The constraints were: to maintain the same cell-to-cell centerline distance and the same cell height, to keep the amperage availability limits within the same rectifiers and to use the same gas treatment centre. Seven D18+ cells were constructed and successfully startedup in March 2012. Table 3 gives a list of changes made during the transi- [1] Ali Al Zarouni et al., DX Cell Technology Powers Green Field Expansion, Light Metals 2010, 339- 343. [2] B.K. Kakkar et al., Commissioning of Emirates Aluminium Smelter Potlines, Light Metals 2012, 721-726. [3] Ali Al Zarouni et al., The Successful Implementation of Dubal DX Technology at Emal, Light Metals 2012, 715-720. [4] Ali Al Zarouni et al., DX+ an Optimized Version of DX Technology, Light Metals 2012, 697-702. [5] M. Reverdy et al., Advancements of Dubal High Amperage Reduction Cell Technologies, Light Metals 2013. [6] Abdalla Zarouni et al., Mathematical Model Validation of Aluminum Electrolysis Cells at Dubal, Light Metals 2013. [7] Abdalla Zarouni et al., Achieving Low Greenhouse Gases Emission with Dubal’s High Amperage Cell Technology, 19 th International Symposium IC- SOBA, Belem, Brazil, 25 Oct. to 2 Nov. 2012. [8] S. Akhmetov et al, D18+: Potline Modernisation at Dubal, Light Metals 2013. Author Michel Reverdy is Technology Transfer manager at Dubal. 22 ALUMINIUM · 1-2/2013
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Page 1 and 2: Special: aluminium smelting industr
Page 3 and 4: CONTENTS Volker Karow Chefredakteur
Page 5 and 6: CONTENTS Power upgrade of Isal Potl
Page 7 and 8: NEWS IN BRIEF Aluminium China’s b
Page 9 and 10: NEWS IN BRIEF 14 to 18 May 2013, Mi
Page 12 and 13: WIRTSCHAFT Produktionsdaten der deu
Page 14 and 15: ECONOMICS Five hundred participants
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Page 19 and 20: ANODE BAKING FACILITIES The Riedham
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TECHNOLOGY to transport and store.
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TECHNOLOGY mines the internal shapi
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COMPANY NEWS WORLDWIDE Aluminium sm
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COMPANY NEWS WORLDWIDE Suppliers Da
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RESEARCH 4 Al (l) + 3 C (s) → Al
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PATENTE obvious that more than one
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LIEFERVERZEICHNIS 1 Smelting techno
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LIEFERVERZEICHNIS • Rolling mill
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LIEFERVERZEICHNIS • Colour Coatin
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LIEFERVERZEICHNIS 4.13 Melt operati
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VORSCHAU / PREVIEW IM NÄCHSTEN HEF
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THE ULTIMATE SERVICE... FOR CARBON
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