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ALAN TOMSETT, PhD, is Technical Director for the Pacific Technology Center, Pacific Aluminum, where he provides technical support and advice to the Pacific Aluminum smelters. Dr. Tomsett has more than twenty-five years of experience in carbon anode and cathode technology.
JOHN JOHNSON, MS, heads his own consulting business. He has forty-two years of experience in the aluminum industry, specializing in prebake and VSS anode technology as well as prebake cell design and development. Mr. Johnson was the Editor of Light Metals 2010.
Preface xv
Lead Editors xix
Editorial Team xxi
Part 1: Hall-Héroult Cell Carbon Anodes
Section Introduction 1
Raw Materials: Coke
Calcined Coke from Crude Oil to Customer Silo . 3
B. Vitchus, F. Cannova, and H. Childs
Refinery Feedstocks, Coke Structures and Aluminum Cell Anodes......11
P. Rhedey and D. DuTremblay
Coker Feedstock Characteristics and Calcined Coke Properties ....19
P. Rhedey and S. Nadkarni
Quality and Process Performance of Rotary Kilns and Shaft Calciners 24
L. Edwards
High Vanadium Venezuelan Petroleum Coke, A Rawmaterial for the Aluminum Industry?...30
U. Mannweiler, W. Schmidt-Hatting, D. Rodriguez, and A. Maitland
Use of Shot Coke as an Anode Raw Material....36
L. Edwards, F. Vogt, M. Robinette, R. Love, A. Ross, M. McClung, R. Roush, and W. Morgan
Influence of High Sulphur Cokes on Anode Performance42
S. Jones, R. Hildebrandt, and M. Hedlund
Carbon Raw Material Effects on Aluminum Reduction Cell Anodes ...53
P. Rhedey and S. Nadkarni
A Comprehensive Determination of Effects of Calcined Petroleum Coke Properties on Aluminum Reduction Cell Anode Properties ... 59
D. Belitskus and D. Danka
A Comprehensive Review of the Effects of Calcination at Various Temperatures on Coke Structure and
Properties _ Part 2....73
E. Hardin, C. Beilharz, P. Ellis, and L. McCoy
Influence of Coke Real Density on Anode Reactivity Consequence on Anode Baking....84
B. Coste and J. Schneider
Coke Calcination Levels and Aluminum Anode Quality .93
C. Dreyer, B. Samanos, and F. Vogt
Impact of Coke Calcination Level and Anode Baking Temperature on Anode Properties ....101
B. Samanos and C. Dreyer
Use of Under-Calcined Coke for the Production of Low Reactivity Anodes ....109
J. Lhuissier, L. Bezamanifary, M. Gendre, and M. Chollier
Anode Filler Coke Porosity Studies...114
P. Rhedey
Desulphurization and Its Effect on Calcined Coke Properties...... 119
R. Garbarino and R. Tonti
Influence of Petroleum Coke Sulphur Content on the Sodium Sensitivity of Carbon Anodes......123
S. Hume, W. Fischer, R. Perruchoud, J. Metson, and R. Baker
A Review of Coke and Anode Desulfurization 130
L. Edwards, K. Neyrey, and L. Lossius
Coke and Anode Desulfurization Studies .136
L. Lossius, K. Neyrey, and L. Edwards
Minimizing Impact of Low Sulfur Coke on Anode Quality ..142
A. Adams, R. Cahill, Y. Belzile, K. Cantin, and M. Gendron
Evaluating Calcined Coke for Aluminum Smelting by Bulk Density .148
D. Belitskus
Maintaining Consistent Anode Density Using Varying Carbon Raw Materials156
S. Wilkening
Coke Blending and Fines Circuit Targeting at the Alcoa Deschambault Smelter ....163
M. Gendron, S. Whelan, and K. Cantin
Raw Materials: Pitch
Worldwide Pitch Quality for Prebaked Anodes167
R. Perruchoud, M. Meier, and W. Fischer
Coal Tar Pitch _ Past, Present, and Future177
J. Baron, S. McKinney, and R. Wombles
Electrode Binder Pyrolysis and Bond-Coke Microstructure..182
S. Jones and R. Hildebrandt
Binder for the Ideal Anode Carbon....198
S. Jones and E. Bart
Binding Characteristics of Coal Tar Pitches for Prebaked Anode Mix - Choice Criteria: LRF Report 830 215
J. Pinoir and P. Hyvernat
The Influence of Solid Particles in Pitch on the Preparation and Baking of the Carbon Blocks ...225
G. Romovacek
Performance of Binder Pitches With Decreased QI-Content in Anode Making: Formation - Nature - Properties and
Substitution of Quinoline Insolubles .232
A. Alscher, R. Wildförster, and J. Sharp
Temperature Stability of Søderberg Anode Pitch ....239
M. Sørlie
Developing Coal Tar/Petroleum Pitches...246
R. Wombles and M. Kiser
Raw Materials: Spent Carbon
Investigation of the Quality of Recycled Anode Butts ...251
W. Schmidt-Hatting, A. Kooijman, and R. Perruchoud
Interdependence Between Properties of Anode Butts and Quality of Prebaked Anodes.267
W. Fischer and R. Perruchoud
Raw Material and Anode Characterization
New Methods for Testing Raw Materials for Anode Carbon Paste.....271
O. Bowitz, T. Eftestol, and R. Selvik
Standardization of a Calcined Coke Bulk Density Test..281
D. Belitskus
Reactivity Testing of Anode Carbon Materials 290
G. Houston and H. Øye
Characterization of Prebaked Anode Carbon by Mechanical and Thermal Properties....298
J. Brown and P. Rhedey
Green Anode Production
Aggregate Optimization Using a Y-Blender....307
R. Peterson
Soderberg Paste. Effect of Fine Fraction Variations313
P. Stokka and I. Skogland
Finer Fines in Anode Formulation.....318
F. Figueiredo, C. Cato, A. Nascimento, A. Marques, and P. Miotto
Process Adaptations for Finer Dust Formulations: Mixing and Forming...322
K. Hulse, R. Perruchoud, W. Fischer, and B. Welch
Effects of Mixing Variables and Mold Temperature on Prebaked Anode Quality...328
D. Belitskus
Improving Anode Quality by Separately Optimising Mixing and Compacting Temperature 333
B. Coste
Vibration Forming of Carbon Blocks 339
E. Sandvik, R. Blindheim, and H. Bø
Cooling of Green Anodes After Forming .351
W. Fischer, M. Meier, and M. Lustenberger
Recent Improvement in Paste Plant Design: Industrial Application and Results .....358
C. Vanvoren
Going Beyond SPC _ Why We Need Statistical Thinking in Operations Such as Carbon Plants .365
K. Sinclair and B. Sadler
Properties and Behaviour of Green Anodes.....371
S. Wilkening
Potentialities in the Paste Plant...378
S. Wilkening
Baked Anode Production
Mathematical Simulation of a Horizontal Flue Ring Furnace ...... 386
R. Bui, E. Dernedde, A. Charette, and T. Bourgeois
Flue Gas Management ..390
W. Leisenberg
Safe Operation of Anode Baking Furnaces......396
I. Holden, O. Saeter, F. Aune, and T. Naterstad
Anode Baking: The Underestimated Human Aspect ......403
F. Keller, P. Sulger, and W. Fischer
Specific Energy Consumption in Anode Bake Furnaces 408
F. Keller, P. Sulger, M. Meier, D. Severo, and V. Gusberti
Evaluation of the Uniformity of Baking in Horizontal and Vertical Flue Ring Furnaces414
D. Holdner, S. Nadkarni, and D. DuTremblay
Measurement and Control of the Calcining Level in Anode Baking Furnaces..418
T. Foosnaes, N. Kulset, H. Linga, G. Naeumann, and A. Werge-Olsen
The Equivalent Temperature Method for Measuring the Baking Level of Anodes.. 422
L. Lossius, I. Holden, and H. Linga
Baking Parameters and the Resulting Anode Quality.....427
W. Fischer, F. Keller, R. Perruchoud, and S. Oderbolz
Anode Desulphurization on Baking...434
M. Vogt, K. Ries, and M. Smith
The Effect of Prebake Anode Baking Temperature on Potroom Performance ..444
G. Bain, J. Pruneau, and J. Williams
Influence of Baking Temperature and Anode Effects Upon Carbon Sloughing450
E. Cutshall and V. Bullough
Influence on Anode Baking Temperature and Current Density Upon Carbon Sloughing......469
E. Cutshall
Anode Reactivity Influence of the Baking Process..478
C. Dreyer
Modern Anode Baking Furnace Developments......486
F. Keller and J. Disselhorst
Strategies for the Revision of Bake Furnaces ...492
F. Keller
Rodded Anode Production and Anode Design
Temperature and Voltage Measurements in Hall Cell Anodes.....500
R. Peterson
Studies of Stub to Carbon Voltage.....510
R. Peterson
Factors in the Design of Reduction Cell Anodes.....516
D. Brooks and V. Bullough
Anode Cast Iron Thickness Optimization.524
M. Ohlswager, G. Goeres, and R. Peterson
Drilling of Stub Holes in Prebaked Anodes.....529
B. Aga, I. Holden, H. Linga, and K. Solbu
Problems of the Stub-Anode Connection.. 534
S. Wilkening and J. Côté
Challenges in Stub Hole Optimisation of Cast Iron Rodded Anodes ..543
D. Richard, P. Goulet, O. Trempe, M. Dupuis, and M. Fafard
Real Time Temperature Distribution during Sealing Process and Room Temperature Air Gap Measurements of a Hall- Héroult Cell Anode549
O. Trempe, D. Larouche, D. Ziegler, M. Guillot, and M. Fafard
Effects of Carbonaceous Rodding Mix Formulation on Steel-Carbon Contact Resistance ....555
P. Rhedey and L. Castonguay
Anode Performance: Reactivity Fundamentals
Anode Carbon Reactivity.....564
S. Jones and R. Hildebrandt
Studies on Anode Reactivity to Oxidant Gases 580
J. Rey Boero
Some Practical Consequences of Analyses of the Carboxy and Airburn Reactions of Anode Carbons......589
N. Bird, B. McEnaney, and B. Sadler
A Porosimetric Study of Sub-Surface Carboxy Oxidation in Anodes .594
B. Sadler and S. Algie
Studies of the Impact of Vanadium and Sodium on the Air Reactivity of Coke and Anodes.606
J. Rolle and Y. Hoang
Anode Performance: Dusting
A Review of Factors Affecting Carbon Anode Consumption in the Electrolytic Production of Aluminum......611
P. Rhedey
Reflections on the Carbon Consumption of Prebaked Anodes .....623
S. Wilkening
Anode Dusting in Hall-Heroult Cells 633
T. Foosnaes, T. Naterstad, M. Bruheim, and K. Grjotheim
The Influence of Low Current Densities on Anode Performance.643
S. Hume, M. Utley, B. Welch, and R. Perruchoud
Dust Generation and Accumulation for Changing Anode Quality and Cell Parameters .649
R. Perruchoud, K. Hulse, W. Fischer, and W. Schmidt-Hatting
Anode Dusting from a Potroom Perspective at Nordural and Correlation with Anode Properties657
H. Gudmundsson
The Reduction in Anode Airburn with Protective Covers .....663
A. Fitchett, D. Morgan, and B. Welch
Reactivity and Electrolytic Consumption of Anode Carbon with Various Additives......667
T. Müftüo_lu and H. Øye
Bath Impregnation of Carbon Anodes ......673
R. Perruchoud, M. Meier, and W. Fischer
Anode Performance: Thermal Shock
Effects of Coke and Formulation Variables on Cracking of Bench Scale Prebaked Anode Specimens......680
D. Belitskus
Thermal Shock in Anodes for the Electrolytic Production of Aluminium..687
E. Kummer and W. Schmidt-Hatting
Operating Parameters Affecting Thermal Shock Cracking of Anodes in the Valco Smelter .694
N. Ambenne and K. Ries
Thermal Shock of Anodes _ A Solved Problem? ....700
M. Meier, W. Fischer, R. Perruchoud, and L. Gauckler
Extrinsic and Intrinsic Aspects of Anode Cracking.710
T. Liu, L. Edwards, C. Hughes, B. Mason, and R. McMellon
An Approach for a Complete Evaluation of Resistance to Thermal Shock (Part 1): Applying to the Case of
Anodes and Cathodes ...717
C. Dreyer and B. Samanos
Finite Element Modelling of Thermal Stress in Anodes.723
P. Cook
Recommended Reading 731
Part 2: Hall-Héroult Cell Cathodes
Section Introduction...... 739
Cell Lining: Cathodes
ISO Standards for Testing of Cathode Materials .....741
H. Øye
Laboratory Testing of Carbon Cathode Materials at Operational Temperatures ......747
M. Sørlie and H. Øye
Structural Changes in Carbon by Heat Treatment ...754
S. Brandtzaeg, H. Linga, and H. Øye
Low Electrical Resistivity and High Thermal Conductivity Carbon Products: The Solution for Cell Lining....762
D. Dumas and C. Michel
Aluminium Pechiney Experience with Graphitized Cathode Blocks ..773
D. Lombard, T. Béhérégaray, B. Fève, and J. Jolas
Some Experiments in Cathode Carbon .....779
S. Wilkening
How to Improve the Pig Iron Sealing of Metallic Bars in Cathode Carbon Blocks .787
I. Letizia, C. Bizzarri, and M. Lezzerini
Stress Analysis of Cathode Bottom Blocks ......793
B. Larsen and M. Sørlie
Experimental Comparison of Cathode Rodding Practices.....799
L. Caruso, K. Rye, and M. Sørlie
Cell Lining: Ramming Paste
Compaction of Room Temperature Ramming Paste ......804
M. Sørlie and H. Øye
Densification of Ramming Paste in Cathodes..814
M. Sørlie, B. Faaness , and J. Belmonte
Investigation into the Expansion/Contraction Behaviour of Cold Ramming Pastes during Baking Using a Horizontal
Dilatometer Method...... 821
B. Hocking
Ramming Paste Related Failures in Cathode Linings.....827
B. Faaness, H. Gran, M. Sørlie, and H. Øye
Cell Lining: Refractories
Corrosion and Behaviour of Fireclay Bricks of Varying Chemical Composition Used in the Bottom Lining of Reduction
Cells .. 834
F. Brunk
Experiences with Dry Barrier Powder Materials in Aluminium Electrolysis Cells .. 840
O.-J. Siljan, O. Junge, T. Svendsen, and K. Thovsen
Cathode Refractory Materials for Aluminium Reduction Cells....849
C. Schøning, T. Grande, and O. Siljan
Evaluation of Silicon Carbide Bricks 857
A. Tabereaux and A. Fickel
Quality Evaluation of Nitride Bonded Silicon Carbide Sidelining Materials ....866
E. Skybakmoen, L. Stoen, J. Kvello, and O. Darell
SiC in Electrolysis Pots: An Update ..872
R. Pawlek
Thermal Insulation Materials for Reduction Cell Cathodes ..876
A. Tabereaux
Cathode Performance: Failure Modes
Use of Cell Autopsy to Diagnose Potlining Problems ....888
R. Jeltsch
Processes Occurring in the Carbon Lining of an Aluminum Reduction Cell ....894
J. Waddington
A Study of Some Aspects of the Influence of Cell Operation on Cathode Life 903
C. Clelland, J. Keniry, and B. Welch
Potlining Failure Modes909
M. Dell
Design of Highly Reliable Pot Linings .....914
J. Peyneau
Early Failure Mechanisms in Aluminium Cell Cathodes ......921
M., J. Hvistendahl, and H. Øye
A Comparative Examination of Ageing of Cathodes: Amorphous Versus Graphitic Type ...931
E. Berhauser and J. Mittag
Property Changes of Cathode Lining Materials during Cell Operation......936
M. Sørlie, H. Gran, and H. Øye
Cathode Performance: Chemical Reactions
Reaction Between Carbon Lining and Hall Bath.....946
M. Dell
Penetration of Sodium and Bath Constituents into Cathode Carbon Materials Used in Industrial Cells..... 953
C. Krohn, M. Sorlie, and H. Øye
Chemical Resistance of Cathode Carbon Materials during Electrolysis.....960
M. Sørlie and H. Øye
The Effect of Current Density on Cathode Expansion during Start-Up......966
A. Ratvik, A. Støre, A. Solheim, and T. Foosnaes
Reactions in the Bottom Lining of Aluminium Reduction Cells ..972
A. Solheim, C. Schøning, and E. Skybakmoen
Chemical Degradation Map for Sodium Attack in Refractory Linings ......978
K. Tschöpe, J. Rutlin, T. Grande
Cathode Performance: Erosion
Physical and Chemical Wear of Carbon Cathode Materials ..984
X. Liao and H. Øye
Carbon Cathode Corrosion by Aluminium Carbide Formation in Cryolitic Melts...992
X. Liao and H. Øye
Erosion of Cathode Blocks in 180 kA Prebake Cells .....999
A. Tabereaux, J. Brown, I. Eldridge, and T. Alcorn
Graphite Cathode Wear Study at Alouette.....1005
P. Reny and S. Wilkening
Electrolytic Degradation within Cathode Materials......1011
P. Rafiei, F. Hiltmann, M. Hyland, B. James, and B. Welch
Influence of Internal Cathode Structure on Behavior during Electrolysis Part II: Porosity and Wear Mechanisms in
Graphitized Cathode Materials .1017
P. Patel, M. Hyland, and F. Hiltmann
Influence of Internal Cathode Structure on Behavior during Electrolysis Part III: Wear Behavior in Graphitic Materials...1023
P. Patel, M. Hyland, and F. Hiltmann
Spent Pot Lining
Formation and Distribution of Cyanide in the Lining of Aluminum Reduction Cells...1029
R. Peterson, L. Blayden, and E. Martin
Potlining Flux in Making Steel.1037
D. Augood, R. Schlager, and P. Belding
Thermal Treatment of Spent Potliner in a Rotary Kiln.1044
D. Brooks, E. Cutshall, D. Banker, and D. Strahan
Treatment and Reuse of Spent Pot Lining, an Industrial Application in a Cement Kiln ......1049
P. Personnet
Co-Processing at Cement Plant of Spent Potlining from the Aluminum Industry.. 1057
V. Gomes, P. Drumond, J. Neto, and A. Lira
Development Status of Processing Technology for Spent Potlining in China.1064
W. Li and X. Chen
Recommended Reading .....1067
Part 3: Inert Anodes and Wettable Cathodes
Section Introduction....1071
Inert Anodes
Solubilities of Oxides for Inert Anodes in Cryolite-Based Melts ......1073
D. DeYoung
Corrosion and Passivation of Cermet Inert Anodes in Cryolite-Type Electrolytes 1082
G. Tarcy
Testing of Cerium Oxide Coated Cermet Anodes in a Laboratory Cell ...1094
J. Gregg, M. Frederick, H. King, and A. Vaccaro
A Non-Consumable Metal Anode for Production of Aluminum with Low Temperature Fluoride Melts.1104
T. Beck
The Behaviour of Nickel Ferrite Cermet Materials as Inert Anodes .1110
E. Olsen and J. Thonstad
Tin Dioxide-Based Ceramics as Inert Anodes for Aluminium Smelting: A Laboratory Study...1119
A. Vecchio-Sadus, D. Constable, R. Dorin, E. Frazer, I. Fernandez, G. Neal, S. Lathabai, and M. Trigg
Inert Anodes: An Update ...1126
R. Pawlek
Wettable Cathodes
The Application of the Refractory Carbides and Borides to Aluminum Reduction Cells ....1134
C. Ransley
Use of TiB2 Cathode Material: Application and Benefits in Conventional VSS Cells..1145
L. Boxall, A. Cooke, and H. Hayden
Use of TiB2 Cathode Material: Demonstrated Energy Conservation in VSS Cells 1153
A. Cooke and W. Buchta
A Review of RHM Cathode Development .....1164
C. McMinn
Properties of a Colloidal Alumina-Bonded TiB2 Coating on Cathode Carbon Materials.....1171
H. Øye, V. de Nora, J. Duruz, and G. Johnston
Sodium and Bath Penetration into TiB2-Carbon Cathodes during Laboratory Aluminium Electrolysis ...1179
J. Xue and H. Øye
Wettable Cathodes: An Update.1185
R. Pawlek
Recommended Reading .....1191
Author Index. 1193
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