Essential Readings in Light Metals, Volume 4, Electrode Technology for Aluminum Production (The Minerals, Metals & Materials Series)

This compilation is the most comprehensive historical collection of papers written on primary aluminum science and technology. It is a definitive reference in the field of aluminum production and related light metals technologies and contains a strong mix of materials science and practical, applied technology. Written for materials scientists and engineers, metallurgists, mechanical engineers, aerospace and automobile engineers, electrical and electronics engineers, this volume is a valuable resource for the global aluminum and light metals industries. Front Matter....Pages i-xxv Front Matter....Pages 1-1 Calcined Coke from Crude Oil to Customer Silo....Pages 3-10 Refinery Feedstocks, Coke Structures and Aluminum Cell Anodes....Pages 11-18 Coker Feedstock Characteristics and Calcined Coke Properties....Pages 19-23 Quality and Process Performance of Rotary Kilns and Shaft Calciners....Pages 24-29 High Vanadium Venezuelan Petroleum Coke, A Rawmaterial for the Aluminum Industry?....Pages 30-35 Use of Shot Coke as an Anode Raw Material....Pages 36-41 Influence of High-Sulfur Cokes on Anode Performance....Pages 42-52 Carbon Raw Material Effects on Aluminum Reduction Cell Anodes....Pages 53-58 A Comprehensive Determination of Effects of Calcined Petroleum Coke Properties on Aluminum Reduction Cell Anode Properties....Pages 59-72 A Comprehensive Review of the Effects of Calcination at Various Temperatures on Coke Structure and Properties Part II....Pages 73-83 Influence of Coke Real Density on Anode Reactivity Consequence on Anode Baking....Pages 84-92 Coke Calcination Levels and Aluminum Anode Quality....Pages 93-100 Impact of Coke Calcination Level and Anode Baking Temperature on Anode Properties....Pages 101-108 Use of Under-Calcined Coke for the Production of Low Reactivity Anodes....Pages 109-113 Anode Filler Coke Porosity Studies....Pages 114-118 Desulfurization and Its Effect on Calcined Coke Properties....Pages 119-122 Influence of Petroleum Coke Sulphur Content on the Sodium Sensitivity of Carbon Anodes....Pages 123-129 A review of Coke and Anode Desulfurization....Pages 130-135 Coke and Anode Desulfurization Studies....Pages 136-141 Minimizing Impact of Low Sulfur Coke on Anode Quality....Pages 142-147 Back Matter....Pages 731-737 Front Matter....Pages 1-1 Evaluating Calcined Coke for Aluminum Smelting by Bulk Density....Pages 148-155 Maintaining Consistent Anode Density Using Varying Carbon Raw Materials....Pages 156-162 Coke Blending and Fines Circuit Targeting at the Alcoa Deschambault Smelter....Pages 163-166 Worldwide Pitch Quality for Prebaked Anodes....Pages 167-176 Coal Tar Pitch-Past, Present, and Future....Pages 177-181 Electrode Binder Pyrolysis and Bond-Coke Microstructure....Pages 182-197 Binder for the Ideal Anode Carbon....Pages 198-214 Binding Characteristics of Coal Tar Pitches for Prebaked Anode Mix — Choice Criteria LRF Report — 830....Pages 215-224 The Influence of Solid Particles in Pitch on the Preparation and Baking of the Carbon Blocks....Pages 225-231 Performance of Binder Pitches with Decreased QI-Content in Anode Making Formation — Nature — Properites and Substitution of Quinoline Insolubles....Pages 232-238 Temperature Stability of Søderberg Anode Pitch....Pages 239-245 Developing Coal Tar/Petroleum Pitches....Pages 246-250 Investigation of the Quality of Recycled Anode Butts....Pages 251-266 Interdependence Between Properties of Anode Butts and Quality of Prebaked Anodes....Pages 267-270 New Methods for Testing Raw Materials for Anode Carbon Paste....Pages 271-280 Standardization of a Calcined Coke Bulk Density Test....Pages 281-289 Reactivity Testing of Anode Carbon Materials....Pages 290-297 Characterization of Prebaked Anode Carbon By Mechanical and Thermal Properties....Pages 298-306 Aggregate Optimization Using a Y-Blender....Pages 307-312 Søderberg Paste. Effect of Fine Fraction Variations....Pages 313-317 Back Matter....Pages 731-737 Front Matter....Pages 1-1 Finer Fines in Anode Formulation....Pages 318-321 Process Adaptations for Finer Dust Formulations: Mixing and Forming....Pages 322-327 Effects of Mixing Variables and Mold Temperature on Prebaked Anode Quality....Pages 328-332 Improving Anode Quality by Separately Optimising Mixing and Compacting Temperatures....Pages 333-338 Vibration Forming of Carbon Blocks....Pages 339-350 Cooling of Green Anodes after Forming....Pages 351-357 Recent Improvement in Paste Plant Design Industrial Application and Results....Pages 358-364 Going Beyond SPC — Why We Need Statistical Thinking in Operations Such as Carbon Plants....Pages 365-370 Properties and Behaviour of Green Anodes....Pages 371-377 Potentialities in the Paste Plant....Pages 378-385 Mathematical Simulation of a Horizontal Flue Ring Furnace....Pages 386-389 Flue Gas Management....Pages 390-395 Safe Operation of Anode Baking Furnaces....Pages 396-402 Anode Baking: The Underestimated Human Aspect....Pages 403-407 Specific Energy Consumption in Anode Bake Furnaces....Pages 408-413 Evaluation of the Uniformity of Baking in Horizontal and Vertical Flue Ring Furnaces....Pages 414-417 Measurement and Control of the Calcining Level in Anode Baking Furnaces....Pages 418-421 The Equivalent Temperature Method for Measuring the Baking Level of Anodes....Pages 422-426 Baking Parameters and the Resulting Anode Quality....Pages 427-433 Anode Desulfurization on Baking....Pages 434-443 Back Matter....Pages 731-737 Front Matter....Pages 1-1 The Effect of Prebake Anode Baking Temperature on Potroom Performance....Pages 444-449 Influence of Baking Temperature and Anode Effects Upon Carbon Sloughing....Pages 450-468 Influence of Anode Baking Temperature and Current Density Upon Carbon Sloughing....Pages 469-477 Anode Reactivity Influence of the Baking Process....Pages 478-485 Modern Anode Bake Furnace Developments....Pages 486-491 Strategies for the Revision of Bake Furnaces....Pages 492-499 Temperature and Voltage Measurements in Hall Cell Anodes....Pages 500-508 Studies of Stub to Carbon Voltage....Pages 510-515 Factors in the Design of Reduction Cell Anodes....Pages 516-523 Anode Cast Iron Thickness Optimization....Pages 524-528 Drilling of Stub Holes in Prebake Anodes....Pages 529-533 Problems of the Stub — Anode Connection....Pages 534-542 Challenges in Stub Hole Optimisation of Cast Iron Rodded Anodes....Pages 543-548 Real Time Temperature Distribution During Sealing Process and Room Temperature Air Gap Measurements of a Hall-Héroult Cell Anode....Pages 549-554 Effects of Carbonaceous Rodding Mix Formulation on Steel-Carbon Contact Resistance....Pages 555-563 Anode Carbon Reactivity....Pages 564-579 Studies on Anode Reactivity to Oxidant Gases....Pages 580-588 Some Practical Consequences of Analyses of the Carboxy and Airburn Reactions of Anode Carbons....Pages 589-593 A Porosimetric Study of Sub-Surface Carboxy Oxidation in Anodes....Pages 594-605 Studies of the Impact of Vanadium and Sodium on the Air Reactivity of Coke and Anodes....Pages 606-610 Back Matter....Pages 731-737 Front Matter....Pages 1-1 A Review of Factors Affecting Carbon Anode Consumption in the Electrolytic Production of Aluminum....Pages 611-622 Reflections on the Carbon Consumption of Prebaked Anodes....Pages 623-632 Anode Dusting in Hall — Heroult Cells....Pages 633-642 The Influence of Low Current Densities on Anode Performance....Pages 643-648 Dust Generation and Accumulation for Changing Anode Quality and Cell Parameters....Pages 649-656 Anode Dusting from a Potroom Perspective at Nordural and Correlation with Anode Properties....Pages 657-662 The Reduction in Anode Airburn with Protective Covers....Pages 663-666 Reactivity and Electrolytic Consumption of Anode Carbon with Various Additives....Pages 667-672 Bath Impregnation of Carbon Anodes....Pages 673-679 Effects of Coke and Formulation Variables on Cracking of Bench Scale Prebaked Anode Specimens....Pages 680-686 Thermal Shock in Anodes for the Electrolytic Production of Aluminium....Pages 687-693 Operating Parameters Affecting Thermal Shock Cracking of Anodes in the Valco Smelter....Pages 694-699 Thermal Shock of Anodes — a Solved Problem?....Pages 700-709 Extrinsic and Intrinsic Aspects of Anode Cracking....Pages 710-716 An Approach for a Complete Evaluation of Resistance to Thermal Shock....Pages 717-722 Finite Element Modelling of Thermal Stress in Anodes....Pages 723-729 Back Matter....Pages 731-737 Front Matter....Pages 739-739 ISO Standards for Testing of Cathode Materials....Pages 741-746 Laboratory Testing of Carbon Cathode Materials at Operational Temperatures....Pages 747-753 Structural Changes in Carbon by Heat Treatment....Pages 754-761 Low Electrical Resistivity and High Thermal Conductivity Carbon Products: the Solution For Cell Lining....Pages 762-772 Back Matter....Pages 1067-1069 Front Matter....Pages 739-739 Aluminium Pechiney Experience with Graphitized Cathode Blocks....Pages 773-778 Some Experiments in Cathode Carbon....Pages 779-786 How to Improve the Pig Iron Sealing of Metallic Bars in Cathode Carbon Blocks....Pages 787-792 Stress Analysis of Cathode Bottom Blocks....Pages 793-798 Experimental Comparison of Cathode Rodding Practices....Pages 799-803 Compaction of Room Temperature Ramming Paste....Pages 804-813 Densification of Ramming Paste in Cathodes....Pages 814-820 Investigation Into the Expansion/Contraction Behaviour of Cold Ramming Pastes During Baking Using a Horizontal Dilatometer Method....Pages 821-826 Ramming Paste Related Failures in Cathode Linings....Pages 827-833 Corrosion and Behaviour of Fireclay Bricks of Varying Chemical Composition Used in the Bottom Lining of Reduction Cells....Pages 834-839 Experiences with Dry Barrier Powder Materials in Aluminium Electrolysis Cells....Pages 840-848 Cathode Refractory Materials for Aluminium Reduction Cells....Pages 849-856 Evaluation of Silicon Carbide Bricks....Pages 857-865 Quality Evaluation of Nitride Bonded Silicon Carbide Sidelining Materials....Pages 866-871 SiC in Electrolysis Pots: An Update....Pages 872-875 Thermal Insulation Materials for Reduction Cell Cathodes....Pages 876-887 Use of Cell Autopsy to Diagnose Potlining Problems....Pages 888-893 Processes Occurring in the Carbon Lining of an Aluminum Reduction Cell....Pages 894-902 A Study of Some Aspects of the Influence of Cell Operation on Cathode Life....Pages 903-908 Potlining Failure Modes....Pages 909-913 Back Matter....Pages 1067-1069 Front Matter....Pages 739-739 Design of Highly Reliable Pot Linings....Pages 914-920 Early Failure Mechanisms in Aluminium Cell Cathodes....Pages 921-930 A Comparative Examination on Ageing of Cathodes: Amorphous Versus Graphitic Type....Pages 931-935 Property Changes of Cathode Lining Materials During Cell Operation....Pages 936-945 Reaction Between Carbon Lining and Hall Bath....Pages 946-952 Penetration of Sodium and Bath Constituents into Cathode Carbon Materials Used in Industrial Cells....Pages 953-959 Chemical Resistance of Cathode Carbon Materials During Electrolysis....Pages 960-965 The Effect of Current Density on Cathode Expansion During Start-Up....Pages 966-971 Reactions in the Bottom Lining of Aluminium Reduction Cells....Pages 972-977 Chemical Degradation Map for Sodium Attack in Refractory Linings....Pages 978-983 Physical and Chemical Wear of Carbon Cathode Materials....Pages 984-991 Carbon Cathode Corrosion by Aluminium Carbide Formation in Cryolitic Melts....Pages 992-998 Erosion of Cathode Blocks in 180 kA Prebake Cells....Pages 999-1004 Graphite Cathode Wear Study at Alouette....Pages 1005-1010 Electrolytic Degradation Within Cathode Materials....Pages 1011-1016 Influence of Internal Cathode Structure on Behavior During Electrolysis Part II: Porosity and Wear Mechanisms in Graphitized Cathode Material....Pages 1017-1022 Influence of Internal Cathode Structure on Behavior During Electrolysis Part III: Wear Behavior in Graphitic Materials....Pages 1023-1028 Formation and Distribution of Cyanide in the Lining of Aluminum Reduction Cells....Pages 1029-1036 Potlning Flux in Making Steel....Pages 1037-1043 Thermal Treatment of Spent Potliner in a Rotary Kiln....Pages 1044-1048 Back Matter....Pages 1067-1069 Front Matter....Pages 739-739 Treatment and Reuse of Spent Pot Lining, an Industrial Application in a Cement Kiln....Pages 1049-1056 Co-Processing at Cement Plant of Spent Potlining from the Aluminum Industry....Pages 1057-1063 Development Status of Processing Technology for Spent Potlining in China....Pages 1064-1066 Back Matter....Pages 1067-1069 Front Matter....Pages 1071-1071 Solubilities of Oxides for Inert Anodes in Cryolite-Based Melts....Pages 1073-1081 Corrosion and Passivation of Cermet Inert Anodes in Cryolite-Type Electrolytes....Pages 1082-1093 Testing of Cerium Oxide Coated Cermet Anodes in a Laboratory Cell....Pages 1094-1103 A Non-Consumable Metal Anode for Production of Aluminum with Low-Temperature Fluoride Melts....Pages 1104-1109 The Behaviour of Nickel Ferrite Cermet Materials as Inert Anodes....Pages 1110-1118 Tin Dioxide-Based Ceramics as Inert Anodes for Aluminium Smelting: A Laboratory Study....Pages 1119-1125 Inert Anodes: An Update....Pages 1126-1133 The Application of the Refractory Carbides and Borides to Aluminum Reduction Cells....Pages 1134-1144 Use of TiB2 Cathode Material Application and Benefits in Conventional VSS Cells....Pages 1145-1152 Use of TiB2 Cathode Material: Demonstrated Energy Conservation in VSS Cells....Pages 1153-1163 A Review of RHM Cathode Development....Pages 1164-1170 Properties of a Colloidal Alumina-Bonded TiB2 Coating on Cathode Carbon Materials....Pages 1171-1178 Sodium and Bath Penetration Into TiB2-Carbon Cathodes During Laboratory Aluminium Electrolysis....Pages 1179-1184 Wettable Cathodes: An Update....Pages 1185-1190 Back Matter....Pages 1191-1192 Back Matter....Pages 1193-1195 ONE OF A FOUR-BOOK COLLECTION SPOTLIGHTING CLASSIC ARTICLES Five decades of landmark original research findings and reviews Highlighting some of the most important findings reported over the past five decades, this volume features some of the best technical papers published on alumina and bauxite from 1963 to 2011. Papers have been divided into thirteen subject sections for ease of access. Each section has a brief introduction and a list of recommended articles for researchers interested in exploring each subject in greater depth. Only about fifteen percent of the alumina and bauxite papers ever published in Light Metals were chosen for this volume. Selection was based on a rigorous review process. Among the papers, readers will find landmark original research findings and expert reviews summarizing current thinking on key topics at the time of publication. From basic research to advanced applications, the articles published in this volume collectively represent our body of knowledge in alumina and bauxite. Students, scientists, and engineers should turn to this volume to discover the historical development of alumina and bauxite research as well as the current state of the science and the technology. Moreover, the papers published in this volume will serve as a springboard for future research and discoveries