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SPECIAL
ALUMINIUM SMELTING INDUSTRY
• A complete upper platform gives full access
to the grab hoist unit, to the top of
the storage hopper (sucking pipe elbow),
and to the top of the filter hopper to
perform filter bags changing
• A maintenance platform provides access
to the valve situated between the cyclone
and the filter hopper, and to the valve used
to control the de-dusting sucking during
the pit filling phase
• A platform is situated at the top of the
sucking pipe
• The 25-tonne hoist is now directly accessible
from a platform above the main
trolley
• A platform links the top of the FTA girder
to the long travel maintenance platform
• Lifting points and lifting rails installed directly
on the crane facilitate the dismantling
of heavy components not directly
accessible (moto-reducer, air condition
unit, hoist unit).
No effort has been spared in ensuring safety
of both the operator and the maintenance
staff. The large number of on-board platforms
makes obsolete any external mobile platform
which was often unavailable when needed,
and always cumbersome.
A New Concept FTA combining
reliability and greater performance
A double filling pipe: The new architecture of
the FTA is based on a double filling pipe assembly;
these pipes can be used individually
or simultaneously. Compared with a conventional
FTA (1 filling pipe, 1 grab and 1 sucking
pipe) this system of double filling pipe
increases by almost 10% the FTA utilisation
rate and therefore productivity. The utilisation
rate is carefully computed by ECL engineers
to match the customer’s production needs,
while keeping a capacity back-up of at least
25%. This approach ensures that the FTA is
not oversized (therefore not over-priced) and
reliably meets the anode production requirement.
ECL engineers also worked to make the
filling pipe more resistant to shocks, to variations
of coke temperature, and to the risks
of pipe blocking and falling. The pipe has
therefore become wider and shorter. Reducing
the pressure drop and consequently the
abrasion and maintenance costs for the suction
circuit. Stronger bumpers
have been installed. The
nozzle of the filling pipe has
been modified in order to ease
conical flow and to decrease
the time of filling. Regarding
the flexible de-dusting pipe located
on the filling pipe, it has
been replaced by an outside
mechanical pipe. This solution
eliminates all risk of friction between
lifting cable and de-dusting
system as well as any risk of
tearing the de-dusting pipe.
A powerful sucking pipe,
from 65 to 110 m 3 /h: this new
capacity of the sucking pipe
set up in the FTA almost doubles the suction
rate. Moreover, the sucking pipe is equipped
with a new shock absorption system, so avoiding
the risk of crushing the pipes.
Towards a fully automated FTA: What
about a crane in a few years time operating
on its own in this harsh environment? The
FTA is already equipped with some automatic
sequences, such as automatic positioning
over the pits, to assist the operator in his daily
tasks. The ECL R&D department is never at
rest, and is always looking for more automation
processes to include in the FTA.
ECL Training Academy
Training in a simulator
ECL has recently launched a customised training
programme dedicated to operators and
maintenance technicians. This programme is a
unique opportunity to improve skills, capabilities
and knowledge on crane operations and
maintenance of ECL equipment sub-assemblies
(hydraulic, pneumatic, mechanical and
electrical). The programme consists of five full
days of training session right on the doorstep
of our customers.
Two special technical containers allow
trainees to practice right after theory. The
first container is equipped with a multipurpose
driving crane simulator. In it trainees can
improve their accuracy and rapidity, and
can reach a suitable level of dexterity both
through PTM and FTA driving exercises. The
programme grades trainees after each exercise
in the simulator. Thus the trainer and the
trainee have a global view of the progress
achieved and of what competences still need
improvement.
In the second technical container the
trainees can practice on real devices (compressors,
etc.). Training is crucial for success, and
is fruitful for both employers and employees
of a smelter. When well trained, the operator
will become more efficient, productive and
a valuable asset to the smelter, needing less
supervision. This will lead to fewer accidents,
less equipment damage and consequently
costs, better productivity and better quality.
Technicians and operators from different
smelters can share their experience and learn
from each other’s know-how.
A first session was organised in Dubai in
2011 to meet with ECL customers from the
Middle East, and a second session in Canada
in 2012.
Here is the reality: produce more, faster,
at a lower cost and in a safer way. ECL is
constantly innovating, and both The New
Concept FTA and the ECL Training Academy
greatly help to achieve all this.
Author
Anne-Gaëlle Hequet is External Communication
manager at ECL, based in Ronchin, France.
Suppliers Directory – for your benefit
On pages 100 to 113, leading equipment suppliers to the aluminium industry present
their product portfolios and ranges of services. Take advantage of this useful information.
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