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Light Metals 2009 Edited by: Geoff Bearne

TMS (The Minerals, Metals & Materials Society), 2009

IMPROVED CELL OPERATION BY REDISTRIBUTION OF THE ALUMINA FEEDING


Bjrn Moxnes1, Asbjrn Solheim2, Morten Liane3, Ellen Svinss1, and Anveig Halkjelsvik1
1

Hydro Aluminium Sunndal, NO-6600 Sunndalsra, Norway


SINTEF Materials Technology, NO-7465 Trondheim, Norway
3
Hydro Aluminium Technology Centre rdal, NO-6884 vre rdal, Norway
2

Keywords: Alumina, feeding, cell operation

There is reason to believe that at least some of the operational


problems mentioned above can be related to the increased alumina
consumption combined with the smaller cross-sectional area
available for alumina transport throughout the bath. This will
inevitably lead to a more non-uniform alumina concentration. It is
reasonable to believe, however, that technologies based on
sludge feeding will be less exposed to increased non-uniform
alumina concentration with increased amperage.

Abstract
The local anode-cathode distance in aluminum cells, as well as the
local superheat, depends strongly on the local concentration of
alumina dissolved in the bath. Based on the idea that it is
beneficial to have a uniform alumina concentration, a
measurement campaign aiming at a redistribution of the alumina
feeding was undertaken at the SU4 potline, Hydro Aluminium
Sunndal. By using AlF3 as a tracer, the path of each alumina dose
could be followed by measuring the current pick-up rate at each
individual anode. This enabled mapping of the connection
between each of the alumina feeders and anodes. Based on the
measurements, the rate of each individual alumina feeder was
optimised in test cells. The change turned out to be highly
successful with respect to improved operational results, such as
higher current efficiency, reduced anode effect frequency, and
less anode problems. Optimised alumina feeding has now been
implemented in the entire potline.

Measurements have shown that prior to an anode effect, the


distribution of the current to each individual anode is significantly
changed [3]. An anode effect normally starts at the anode that is
most starved in alumina, and from there, it spreads to the other
anodes like a domino. Some anode problems also seem to be
related to alumina distribution. The main reason for the initiation
of anode deformations appears to be locally too low alumina
concentration underneath the centre of the anode, in such a way
that consumption of alumina in that region takes place at the
limiting current density. A local low alumina concentration can be
achieved by a combination of a local low superheat, insufficient
transport of alumina underneath the anode, or carbon dust
blocking the surface of the anode. Furthermore, non-uniform
ACD, which may result from non-uniform alumina concentration,
gives lower current efficiency, as explained below.

Introduction
Increasing global competition gives a steady demand to reduce
production costs in all parts of aluminum smelters. In this context,
increasing the amperage in existing potlines represents the
cheapest way of producing more aluminum. Increasing the
amperage has therefore been a continuous and major activity in
most aluminum companies for the last two decades. It has been
claimed that the low-hanging fruits already have been taken [1],
and further success in increasing the amperage requires that
operational difficulties can be avoided. Typical problems
following amperage increase are loss of current efficiency (CE),
increased frequency of anode problems, increased anode effect
frequency, and increased cathode wear leading to shorter cell lives.

On this background, it was assumed that it might be beneficial to


have more uniform alumina distribution in the cells. The obvious
(and probably the only possible) way of achieving this is to
redistribute the amounts of alumina added from each individual
feeder in the cell.
Some Theoretical Considerations

There is no doubt that more efficient cell control has been a key
factor in the drive towards higher anode current density. Besides
needing more precise control, modern cells need quicker
intervention because the cell dynamics are faster than earlier. In
this context, the ratio between bath volume and amperage is a
relevant measure. Martin et al. [2] recently showed that this
parameter had decreased from about 13 l/kA at the introduction of
the AP30 technology to less than 8 l/kA in the present AP3X cells.
These numbers may be representative for other technologies as
well. The decrease in the bath volume can be attributed to the use
of larger anodes, as well as reduced anode-cathode distance (ACD)
to keep the net energy input to the cell constant.

Alumina Distribution and Anode-Cathode Distance


It is well known that the density of the bath decreases with
increasing alumina concentration. When there are gradients in the
alumina concentration in the horizontal direction, the
corresponding density gradients will influence the local vertical
position of the metal-bath boundary, as outlined in the following.
For the sake of simplicity, we assume that both the bath surface
and the bottom of the cell are horizontal (see Figure 1).
Furthermore, there are no static pressure gradients in the
horizontal direction. The static pressure is then given by the

461

0.23

Metal

Al

hAl

Figure 1. Schematic representation of anodes, bath and


metal in an electrolysis cell. The top of the bath is
assumed to be at the same level everywhere in the cell
(see text).

0.19

0.20

0.20

0.19

0.21

0.22
2

4
[Al2O3 ] / wt%

Figure 2. Local bath height as a function of the local


alumina
concentration.
Low
local
alumina
concentration gives high local bath height and
therefore a high ACD.

(1)

Anode-Cathode Distance and Current Efficiency

(2)

It is well known that the current efficiency (CE) decreases sharply


when the ACD becomes lower than a certain limit. According to
measurements made by Rolseth et al. [8] in the mid-eighties, this
limit appeared to be at 2-3 cm. Although the limit may have
shifted downwards due to better magnetic compensation and the
introduction of slotted anodes, there is reason to believe that
modern high current density cells contain a number of anodes that
operate below the critical limit, also due to the fact that the
average ACD has been steadily lowered with increased amperage.

Equation (1) can, therefore, be rearranged to give


Al av
Al

960 oC

0.21

where the average values are denoted by subscript av.


Furthermore (see Figure 1),
h h av = h Al(av) h Al

0.18

0.18

product of the height of a phase (h, [m]), its density (, [kgm-3]),


and the acceleration of gravity (g, [ms-2)]. With the simplifications
given above, the pressure at the bottom of the cell is constant,
regardless of the horizontal position. Therefore,
(h av av + h Al(av) Al ) g = (h + h Al Al ) g

[CaF2 ] = 5.0 wt%


r = 2.18
hav = 0.2 m
hAl(av) = 0.2 m

0.22

Local metal height / m

hAl(av)

Bath

Local bath height / m

hav

h = h av

0.17
[Al2O3 ] av = 3.5 wt%

(3)

Equation (3) tells us that the local metal height will be lower and
the local bath height will be higher (higher ACD) if the local bath
density is higher than the average value.

As illustrated in Figure 3, a more non-uniform ACD at a given


average ACD gives lower current efficiency, simply because a
larger number of anodes operate below the critical limit for the
current efficiency. This effect of course becomes more
pronounced if the ACD is already squeezed. Besides less variation
in the metal topography, a more uniform alumina concentration
gives less variation in the superheat and therefore smaller
variations in ACD due to variable time of re-melting of the freeze
formed on new anodes. One would therefore expect higher CE in
cells with uniform alumina concentration.

The density of a bath with a NaF/AlF3 molar ratio (r) of 2.18 and
5 wt% CaF2 was computed as a function of the Al2O3 content [4].
The average bath and metal heights were taken to be 0.2 m, and
the metal density was fixed at 2300 kgm-3. The data were then
inserted into Equation (3). From the result shown in Figure 2 it
appears that a small e.g., one percent variation in the alumina
concentration gives a change in the location of the metal-bath
interface that represents a large fraction of the ACD. This may
seem surprising, and it is likely that this effect has been
overlooked or neglected in the past.

Operational Background Information

It may be objected that the data in Figure 2 do not represent the


true variation in the ACD, since the current density-dependent
anode wear leads to an adaption to the metal topography and a
tendency towards the average ACD. Still, it is likely that the
alumina distribution changes with the feeding cycle, or after the
setting of a new anode. Upon setting, the new anode becomes
covered with frozen bath all the way down to the metal [5]. This
can change the flow pattern in the cell by blocking part of the area
available for bath flow. Moreover, the consumption pattern of
alumina will change, because new anodes draw little current.
Ideally, the alumina feeding pattern should compensate these
changes, but this is probably only possible after introduction of
continuous monitoring of the anodic current distribution [6, 7].

Kobbeltvedt and Moxnes [9] mapped the bath flow in the upper
part of the bath zone in modern prebake cells. They concluded
that the main bath flow is out of the centre channel and directed
towards the short ends of the cell. From operational practice in the
SU4 potline, the following was also known,

462

Relatively many newly set anodes in the central part of the


cell had to be lifted after setting due to too high current pickup rate, even when the anodes were positioned using an
accurate laser equipment (see figure 6).
There was a relatively high frequency of anode spikes in the
corners of the cell.

distribution of alumina from the individual feeders, hereafter


referred to as flow-adapted alumina feeding.
In addition to the experiments, the bath flow was modelled using
a commercial CFD code (Fluent). Unfortunately, the model was
not able to reproduce the measured flow patterns, and all changes
in the alumina feeding were therefore based on the measurements.

Non-uniform ACD, lower CE


Very non-uniform ACD,
catastrophic CE
Average ACD

Current efficiency

Uniform ACD, high CE

Anode-cathode distance

Figure 3. Current efficiency as a function of the anodecathode distance (see text).


Based on this knowledge, it was decided to try measuring the
alumina concentration underneath the anodes. It turned out that
direct measurement was a difficult task, however. Instead of a
direct absolute measurement, it was therefore decided to
measure the alumina concentrations in a relative way, by mapping
the bath flow underneath the anodes.
Preliminary Measurements of Bath Flow
Figure 4. Current pick-up rate at the individual anodes
in a cell at the Test Centre as a function of time during
addition of AlF3. The current scale is given in the bar
at the bottom of the figure (1 = average current).

Preliminary measurements were carried out at Hydro


Aluminiums Test Centre in rdal, in order to establish the bath
flow pattern in the cell. Inspired by earlier experience [10], it was
decided to add relatively large quantities of AlF3 to the bath at
different feeder locations. Since dissolution and increasing the
concentration of AlF3 give decreasing electrical conductivity in
the bath, the time course of the current distribution between the
individual anodes could be used to trace the bath flow from the
different feeder locations. In principle, alumina could also have
been used as a tracer, but not without the risk of depositing sludge
on the cathode, which would disturb the operational performance
of the cells. The extra amounts of AlF3 were later neutralized by
adding soda ash to the bath.

Measurements in Test Cells in SU4


Experiments
The alumina distribution in six normal cells in the SU4 line at
Sunndalsra was changed from a flat distribution to the flowadapted distribution shown in Figure 5. Modifications in the
process control system were needed in order to enable different
alumina feeding rates from the individual feeders. Before the test
started the weights of each individual alumina dump were
measured, and a recalculation of the feeding rate from each
individual feeder was made. The operational test on the six cells
was running for 10 months before the data were collected and the
results were evaluated. One of the reasons why the test had to last
for such a long period was that the metal volume was not
measured. Therefore, the calculation of the current efficiency (CE)
was based on the metal tapping weights only.

The entire anodic current distribution was measured continuously


before, during, and after the addition of AlF3. By adding the extra
AlF3 into the different feeder holes one after the other, different
current pick-up patterns for all the anodes could be mapped. The
experiments were carried out in periods when the test cells were
in a stable mode with low cell noise, and they were repeated at
different times and on different cells to get an as clear as possible
picture regarding the bath flow (mass and velocity) underneath the
different anodes in the cell.

The six test cells were not followed up in any special way during
the experiments, before collecting and analyzing the data.
Excessive attention may sometimes render an experiment
worthless; this is commonly known as the yellow pots
syndrome. The rest of the potline was used as reference cells.

Figure 4 shows a typical current pick-up plot. By analysing the


data it was possible to follow the AlF3 doses from the feeder hole
to the different anodes in the cell. The results clearly
demonstrated that each feeder in the cell has a number of anodes
where it will be the primary or secondary alumina supplier. This
is extraordinarily important, since it constituted the basis for
controlling the uniformity of the alumina concentration in the
cells. The result was used to figure out an optimised new

For convenience, the following discussion of the data obtained is


subdivided into anode operation and other operational data.

463

Original feeding

Feeding rate / percent

30

Flow-adapted feeding

20

10

number of anode adjustments has been reduced, due to the


more uniform alumina and superheat distributions in the cell
(see also Figure 6 below).
The difference in current pick-up rate between the anodes on
the upstream side of the cell and the downstream side was
significantly reduced. Furthermore, the test cells have a
significantly lower difference in the standard deviation in
current pick-up rate between the anodes on the upstream side
and anodes on the downstream side. This is again related to
the more uniform alumina concentration. Especially, the
current pick-up rate at the upstream side has increased.

Results Concerning Anode Operation

The measurement of the current pick-up was made on new anodes


(32 hours after setting). We expect that the difference between the
test cells and the reference cells would be smaller if the
comparison were made for older anodes. Still, according to the
theoretical considerations and discussion above, the standard
deviation in ACD as well as the standard deviation in butt
thickness between the individual anodes will be larger for the
reference cells than for the test cells.

The results concerning the anode operation are given in Table I


and commented below.

Results Concerning Other Operational Data

3
Feeder no.

Figure 5. Original and flow-adapted distribution of


alumina from each individual feeder.

The data given in Table II clearly indicate that the test cells with
flow-adapted alumina feeding operate more steadily than the
reference cells.

Table I. Some measured parameters concerning the


anode operation in the test cells and in the reference
cells. STD Standard deviation.
Measured parameter
Anode effect frequency (AEF,
# AE per cell and day)
Spikes/anode deformations
(# per cell day)
Anode adjustments*
(# per cell day)
Difference in current to the
upstream and downstream
sides (%)
Difference in STD in current
pick-up rate*, between the
upstream and downstream
sides (%)

Test
cells
0.076

Reference
cells
0.105

0.012

0.017

0.063

0.066

1.0

3.37

5.9

43.3

Table II. Some operational data of test cells and


reference cells. STD Standard deviation.
Measured parameter
Cell voltage (V)
Current efficiency (CE, %)
STD in CE (%)
Bath temperature (C)
STD in bath temperature (C)
Excess AlF3 (%)
STD in excess AlF3 (%)
Na in metal (ppm)
STD, Na in metal (ppm)
Cell noise* (Ohm)
STD in cell noise (Ohm)

*Action and measurements are related to new anodes,


measurements 32 hours after setting.

Test
cells
4.11
94.04
1.85
955.4
7.4
11.2
1.8
78.2
9.0
0.017
0.008

Reference
cells
4.11
93.57
2.27
955.8
7.2
11.2
1.8
76.7
9.4
0.017
0.010

*Daily average of 24 hours measurements.

Flow-adapted alumina feeding brought about a 28 percent


decrease in the anode effect frequency (AEF), which is a
very significant contribution in reducing the emission of
greenhouse gases. Reduced AEF was expected due to the
more uniform alumina concentration underneath the anodes.
33 percent reduction in the frequency of anode spikes and
deformations was obtained. Particularly, the corner anodes
got a strongly reduced frequency of anode deviations.
Theoretically, a higher alumina concentration increases the
superheat. This reduces the risk of spikes and deformation by
a more rapid re-melting of the frozen bath formed on newly
set anodes.
The number of height adjustments on newly set anodes was
reduced by 5 percent. The number of adjustments at the
upstream side and downstream side becomes more equal
after the change. More importantly, however, the total

The CE values, as calculated from the tapping weights, are in


average 0.46 percent higher for the test cells than for the reference
cells. Furthermore, the metal tapping weights of the test cells were
also significantly more constant (from tap to tap), and moreover
the difference in CE between the test cells was significantly less
than between the reference cells.
A higher CE in the test cells was also indicated by somewhat
higher sodium contents in the tapped metal. Lillebuen et al. [11]
have discussed the theoretical relationship between the sodium
level in the metal and the current efficiency. Even though 0.46
percent difference in CE is not very much, and possible changes
in the metal volume were not measured, there is reason to believe
that the difference is real. This is not only because the calculated
CE for the test cells was based on 1800 metal tappings, but also

464

other operational data (not shown here) that indicated that the test
cells should have the higher CE than the reference cells.
No. of anode adjustments per day

2.5

There were no differences in bath temperature or bath


composition between the test cells and the reference cells that can
explain the observed difference in CE. We believe that the most
important contribution to higher CE in the test cells is a more
uniform ACD, which means fewer anodes below the critical ACD,
as discussed earlier. However, the lower anode effect frequency
and the reduced number of spikes and anode deformations, as well
as a presumably more constant side ledge thickness and less
horizontal currents in the metal, would probably also contribute to
the improved CE.

Flow-adapted alumina distribution was implemented in the whole


SU4 line during a period of 40 days in December 2006 - January
2007. The organisation was informed about the individual
importance of the alumina feeders, i.e., the most important feeders
are the two end feeders. In connection with maintenance measures
should be taken so they can be shut down for only short periods.
A small modification to the sensors in the end alumina silos were
made, in order to ensure that they do not run empty of alumina. So
far (October, 2008), any operational problems that possibly could
be related to the flow-adapted feeding, have not been encountered.

Downstream

Original feeding
Flow-adapted feeding

2.0

1.5

1.0

0.5

Flow-Adapted Alumina Feeding in the Whole SU4 Line

Upstream

10
15
20
Anode position no.

25

30

Figure 6. Frequency of anode height adjustments in


SU4 10 months before (light columns) and 10 months
after (dark columns) implementing flow-adapted
alumina feeding.
Table III. Operational data in SU4 concerning anode
spikes and deformations. STD - standard deviation.
Measured parameter

Changes in CE for the whole potline after the implementation


have not been looked into. Increased amperage and periods with
bad anode quality may have disturbed the operation enough to
mask the effect of isolated changes like the introduction of flowadapted feeding. Since the potline is relatively new (started in
2002), a high number of new cells with an improved lining may
also have influenced the CE results.

Spike and deformation


frequency, all anode positions
Spike and deformation
frequency, corner anodes only
STD in spike/def. frequency,
between all anode positions

Percent reduction from


Period A* to Period B**
6.9
57.4
55.6

*Period A; 01.01.2006 - 01.07.2006,


** Period B; 01.07.2007 01.01.2008

Figure 6 shows the frequency of anode adjustments following the


current pick-up measurements 32 hours after the setting of a new
anode. When comparing data obtained 10 months after the
implementation of flow-adapted feeding with data recorded 10
months before the change, it is obvious that the number of
adjustments has been reduced significantly. Moreover, the
upstream side and the downstream side have become more equal.
This is in accordance with the previous discussion regarding the
test cell results in SU4. Still, the data in Figure 6 show that there
is still some room for improvement. It is possible that increased
amperage has changed the optimal feeding pattern, so even more
non-uniform feeding rates should be tried out.

Conclusion and Summary


The amperage in the SU4 potline has been increased by 20
percent since the start-up in 2002, and 6 percent of the amperage
increase has been after implementation of the flow-adapted
alumina feeding. Still, the specific energy consumption is
maintained at a low level. We regard the flow-adapted alumina
feeding pattern, i.e., moving away from a flat feeding, as an
important factor in enabling amperage increase without
compromising the operational performance.

The incidence of anode spikes and deformations decreased, as


was also observed in the test cells in SU4. The data given in Table
III clearly illustrate the relationship between local variations in the
alumina concentration and the frequency of anode spikes and
deformations. The introduction of flow-adapted feeding lead to
higher alumina concentration and thereby increased superheat
underneath the four corner anodes, and the frequency of spikes in
those positions went down significantly. The reduction in the
standard deviation with respect to the frequency of spikes and
deformations between all the anode positions also demonstrates
that the alumina concentration in the cells has become more
uniform.

The improvements in cell operation by introducing flow-adapted


feeding were substantial. The more uniform alumina distribution
in the cell has lead to improved current efficiency, reduced
frequency of anode adjustments, reduced numbers of anode spikes
and deformations, reduced cell noise, and reduced emission of
greenhouse gases by reduced anode effect frequency.
A more uniform alumina distribution in the cell will also make it
easier to adjust the average alumina concentration in the cell to
the optimum level (whatever it might be), without ending up with
an increased frequency of anode effects or increased amounts of
sludge residing at the cathode.

465

Based on the reduced spike frequency, there is reason to believe


that a more uniform alumina distribution in the cell has led to
reduced standard deviations in ACD, superheat, and butt thickness
between the individual anode positions. Data from Jentoftsen et al.
[12]
shows that differences of just 2-3 mm in ACD will have a
great impact on the frequency of spikes in the cells when the ACD
is close to the operational limit.

9.

O. Kobbeltvedt and B.P. Moxnes, On the Bath Flow,


Alumina Distribution and Anode Gas Release in Aluminium
Cells, Light Metals 1997, pp. 369/76.
10. K. . Rye, I. Solberg, T. Eidet, and S. Rolseth, Aluminium
Fluoride Dissolution and Distribution an Investigation of
the Dynamic Mass Balance when Adding Large Quantities to
the Cell, Light Metals 2001, pp. 529/33.
11 B. Lillebuen, M. Bugge, and H. Hie, Alumina Dissolution
and Current Efficiency in Hall Heroult Cells, Light Metals
2009 (this volume).
12 T. E. Jentoftsen, H. Linga, I. Holden, B.E. Aga, F. Hoff and
V. G. Christensen, Correlation Between Anode Properties
and Cell Performance, Light Metals 2009 (this volume).

Changes in the magneto-hydrodynamic (MHD) forces, changes in


the anode slot geometry, and changes in the channel dimensions
in the cell following adjustment of the anode dimensions may
require a re-tuning of the alumina feeding pattern.
Addition of AlF3 as a tracer to follow the bath and alumina
transport underneath the individual anodes appeared to be a
simple and efficient method in mapping the relationship between
individual feeders and anodes. The technique can probably also be
used to derive the optimum alumina feeder positions in the cell.
Acknowledgement
The SU4 organisation is thanked for its enthusiasm during the
entire test and implementation period. Special thanks are due to
Knut Solbu for allowing the authors to publish data from the
potline, and for being a driving force for implementing flowadapted alumina feeding in the line.
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1.
2.

3.

4.
5.
6.

7.

8.

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Developments in Alcan's AP3X and Alpsys Technologies,
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Technology Conference and Workshops, Terrigal, Australia,
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K.. Rye, M. Knigsson, and I. Solberg, Current
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A. Solheim, The Density of Molten NaF-LiF-AlF3-CaF2Al2O3 in Aluminium Electrolysis, Aluminum Transactions 2
(1) (2000), pp. 161/68.
R. degrd, A. Solheim, and K. Thovsen, "Current Pickup
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A. Solheim and B.P. Moxnes, Anodic Current Distribution
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International Conference Aluminium of Siberia-2007,
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J. Keniry and E.P. Shaydulin, Anode Signal Analysis the
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at the XIII International Conference Aluminium of Siberia2007, Krasnoyarsk, Russia, September 11-13, 2007
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