Proceedings ofthe technical sessions presented

by the TMS Aluminum Committee

at the TMS 2011 Annual Meeting & Exhibition,San Diego, California, USA

February 27-March 3, 2011

Edited by

Stephen J. Lindsay

®WILEY TiilSAJohn Wiley & Sons, Inc., Publication

TABLE OF CONTENTS

Light Metals 2011

Preface xix

About the Editor xxi

Program Organizers xxiii

Aluminum Committee xxix

Alumina and Bauxite

Bauxite Resources and Utilisation

New Development Model for Bauxite Deposits 5

P. ter Wear

Study on the Characterization of Marginal Bauxite from Para/Brazil 13

F. Silva, J. Sampaio, M. Medeiros, andF. Garrido

Resource Utilization of High-sulfur Bauxite of Low-median Grade in Chongqing China 19

J. Yin, W.Xia, andM. Han

Development ofBauxite and Alumina Resources in the Kingdom of Saudi Arabia 23

A. Al-Dubaisi

Digestion Studies on Central Indian Bauxite 29

P. Raghavan, N. Kshatriya, and Dasgupta

Effects ofRoasting Pretreatment in Intense Magnetic Field on Digestion Performance of Diasporic Bauxite 33

Z. Ting-an, D, Zhihe, L. Guozhi, L. Yan, D. Juan, W. Xiaoxiao, andL. Yan

Bayer Process I

Application of Operation Integrity Management in the Alumina Industry 41

C. Suarez, D. Welshons, J. McNerney, andJ. Webb

Influence of Solid Concentration, Particle Size Distribution, Ph And Temperature on Yield Stress

ofBauxite Pulp 47

C. Barbato, M. Nele, andS. Franga

A New Method for Removal Organics in the Bayer Process 51

B. Yingwen, L. Jungi, S. Mingliang, and Z. Fei

Alunorte Expansion 3 - The New Lines Added to Reach 6.3 Million Tons per Year 57

D. Khoshneviss, L. Corria, J. Ribeiro Alves Filho, H. Berntsen, andR. Carvalho

One Green Field Megaton Grade Large Alumina Refinery with Successful Engineering & Operation Experience...63L. Xianqing, and Y. Xiaoping

Advanced Process Control in the Evaporation Unit '. 69

C. Kumar, U. Giri, R. Pradhan, T. Banerjee, R. Saha, andP. Pattnaik

v

Improvements in Smelter Grade Alumina Quality at Clarendon Alumina Works

R. Shaw, A. Duncan, andM, Crosdale

75

Red Mud

Application of Nanofiltration Technology to Improve Sea Water Neutralization of Bayer Process Residue 81

K. Taylor, M. Mullett, L. Fergusson, H. Adamson, and J. Wehrli

Caustic and Alumina Recovery from Bayer Residue 89

S. Gu

Investigation on Alumina Discharge into the Red Mud Pond at Nalco's Alumina Refinery,Damanjodi, Orissa, India 93

B. Mohapatra, B, Mishra, and C. Mishra

Production of Ordinary Portland Cement( OPC) from NALCO Red Mud 97

C. Mishra, D. Yadav, M. Alii, andP. Sharma

Recovery ofMetal Values from Red Mud 103

P. Raghavan, N. Kshatriya, and K. Wawrynink

Red Mud Flocculants used in the Bayer Process 107

S. Moffatt, F. Ballentine, andM. Lewellyn

Reductive Smelting of Greek Bauxite Residues for Iron Production 113

A. Xenidis, C. Zogrqfidis, I. Kotsis, andD. Boufounos

Precipitation, Calcination and Properties

Effect of Technological Parameters on PSD of Aluminum Tri-Hydroxide from Seed Precipitation in Seeded SodiumAluminate Solutions 121

Y. Wu, L. Mingchun, and Q. Yanping

Methods to Reduce Operating Costs in Circulating Fluidized Bed Calcination 125C. Klett, M. Missalla, B. Reeb, andH. Schmidt

Pressure Calcination Revisited 131

F. Williams, and C. Misra

Dynamic Simulation ofGas Suspension Calciner (GSC) for Alumina 137

B. Raahauge, S. Wind, M. Wu, and T. Jensen

Physical Simulation and Numerical Simulation of Mixing Performance in the Seed Precipitation Tank with a

Improved Intermig Impeller 145Z Ting-an, L. Yan, W. Shuchan, 2. Hongliang, Z. Chao, Z. Qiuyue, D. Zhihe, and L. Guozhi

Two Perspectives on the Evolution and Future ofAlumina 151

L. Perander, J. Metson, and C. Klett

Significant Improvement ofEnergy Efficiency at Alunorte's Calcination Facility 157

M. Missalla, H. Schmidt, J. Ribeiro, and R, Wischnewski

Attrition ofAlumina in Smelter Handling and Scrubbing Systems 163

S. Lindsay

vi

Energy and Environment

Perspective on Bayer Process Energy 171

D. Donaldson

Optimization of Heat Recovery from the Precipitation Circuit 175

R, Singh, S. Hial, and M. Simpson

Alunorte Global Energy Efficiency 179

A. Monteiro, R. Wischnewski, C. Azevedo, and E. Moraes

Opportunities for Improved Environmental Control in the Alumina Industry 185

R. Mimna, J. Kildea, E. Phillips, W. Carlson, B. Keiser, andJ. Meier

Alumina Refinery Wastewater Management: When Zero Discharge Just Isn'tFeasible 191

L. Martin, and S. Howard

High Purity Alumina Powders Extracted from Aluminum Dross by the Calcining—Leaching Process 197

L. Qingsheng, Z. Chunming, F. Hui, andX. Jilai

Effect ofCalcium/Aluminium Ratio on MgO Containing Calcium Aluminate Slags 201

W. Bo, S. Hui-Lan, G. Dong, andB. Shi-Wen

Study on Extracting Aluminum Hydroxide from Reduction Slag ofMagnesium Smelting by Vacuum

Aluminothermic Reduction 205

W. Yaowu, F. Naixiang, Y. Jing, H. Wenxin, P. Jianping, D. Yuezhong, and W. Zhihui

Application of Thermo-gravimetric Analysis for Estimation of Tri-hydrate Alumina in Central Indian Bauxites—An

Alternative for Classical Techniques 211

Y. Ramana, and R. Patnaik

Determination of Oxalate Ion in Bayer Liquor Using Electrochemical Method 215

S. Turhan, B. Usta, Y. Sahin, and O. Uysal

Alternative Alumina Sources - Poster Session

The Effect ofUltrasonic Treatment on Alumina Leaching from Calcium Aluminate Slag 221

5. Hui-lan, W. Bo, G. Dong, Z. Xue-zheng, andB. Shi-wen

Theory and Experiment on Cooling Strategy during Seeded Precipitation 227

Z. Liu, W. Chen, and W. Li

Extraction of Alumina from Red Mud by Divalent Alkaline Earth Metal Soda Ash Sinter Process 231

S. Meher, A. Rout, andB, Padhi

Dissolution Kinetics of Silicon from Sintering Red Mud in Pure Water 237

X. Li, K. Huang, and H. Zhu

The Effect ofCooling Rate on the Leachability of Calcium Aluminate Slags 241

W. Bo, S. Hui-lan, Z. Xue-zheng, and B. Shi-wen

Preparing Polymerized Aluminum-ferrum Chloride with Red Mud 245

L. Guilin, Y. Haiyan, and B. Shiwen

Adsorption of Polyethylene Glycol at the Interface ofDicalcium Silicate - Sodium Aluminate Solution 251

Y. Haiyan, X. Pan, Z. Lu, and T. Ding

vii

Production of Hematite Ore from Red Mud 255

P. Raghavan, N. Kshatriya, and K. Wawrynink

Aluminum Reduction Technology

Enviroment- Emissions/ Anode Effect I

HF Measurements Inside an Aluminium Electrolysis Cell 263

K. Osen, T. Aarhaug, A. Solheim, E. Skybakmoen, and C. Sommerseth

LasIRTM-R - The New Generation RoHS-Compliant Gas Analyzers Based on Tunable Diode Lasers 269

J. Gagne, J. Pisano, A. Chanda, G. Mackay, K. Mackay, and P. Bouchard

Use of Spent Potlining (SPL) in Ferro Silico Manganese Smelting 275

P. von Krilger

Reduction of PFC Emissions at Pot Line 70 kA of Companhia Brasileira de Alumfnio 281

H. Santos, D. Melo, J. Calixto, J. Santos, and J. Miranda

Towards Redefining the Alumina Specifications Sheet - The Case of HF Emissions 285

L. Perander, M. Stam, M. Hyland, andJ. Metson

Design ofExperiment to Minimize Fluoride and Particulate Emissions at Alumar 291

E. Batista, P. Miotto, E. Montoro, and L. Souza

Innovative Distributed Multi-Pollutant Pot Gas Treatment System 295

G. Wedde, O. Bjarno, andA, Sorhuus

Fluoride Emissions Management Guide (FEMG) for Aluminium Smelters 301

N. Tjahyono, Y. Gao, D. Wong, W. Zhang, andM. Taylor

Enviroment- Emissions/ Anode Effect II

On Continuous PFC Emission Unrelated to Anode Effects 309

X. Chen, W. Li, J. Marks, Q. Zhao, J. Yang, S. Qiu, and C. Bayliss

Monitoring Air Fluoride Concentration around ALUAR Smelter in Puerto Madryn

(Chubut Province, Argentina) 315

J. Zavatti, C. Moreno, J. Lifschitz, and G. Quiroga

Reduction of Anode Effect Duration in 400kA Prebake Cells 319

W. Zhang, D. Wong, M. Gilbert, Y. Gao, M. Dorreen, M. Taylor, A. Tabereaux, M. Soffer, X. Sun,C. Hu, X Liang, H. Qin, J. Mao, andX Lin

Sustainable Anode Effect Based Perfluorocarbon Emission Reduction 325

N. Dando, L. Sylvain, J. Fleckenstein, C. Koto, V. Van Son, andL. Coleman

The Initiation, Propagation and Termination of Anode Effects in Hall-Heroult Cells 329

G. Tarcy, andA. Tabereaux

Towards Eliminating Anode Effects 333

A. Al Zarouni, B. Welch, M. MohamedAl-Jallaf, and A. Kumar

Correlation between Moisture and HF Formation in the Aluminium Process 339

C. Sommerseth, K. Osen, T. Aarhaug, E. Skybakmoen, A. Solheim, C. Rosenkilde, andA. Ratvik

viii

Particulate Emissions from Electrolysis Cells 345

H. Gaertner, A. Ratvik, and T. Aarhaug

Investigation of Solutions to Reduce Fluoride Emissions from Anode Butts and Crust Cover Material 351

G. Girault, M. Fame, J. Bertolo, S, Massambi, and G. Bertran

PFC Survey in Some Smelters of China 357W. Li, X. Chen, Q. Zhao, S. Qiu, andS. Zhang

Considerations Regarding High Draft Ventilation as an Air Emission Reduction Tool 361

S. Broek, N. Dando, S. Lindsay, andA. Moras

Cells Thermal Balance

Increasing the Power Modulation Window of Aluminium Smelter Pots with Shell Heat Exchanger Technology ...369P. Lavoie, S. Namboothiri, M. Dorreen, J. Chen, D. Zeigler, and M. Taylor

New Approaches to Power Modulation at TRIMET Hamburg 375

T. Reek

Some Aspects of Heat Transfer Between Bath and Sideledge in Aluminium Reduction Cells 381A. Solheim

Towards a Design Tool for Self-heated Cells Producing Liquid Metal by Electrolysis 387iS". Poizeau, andD. Sadoway

Heat Recovery from Aluminium Reduction Cells 393Y. Ladam, A. Solheim, M. Segatz, and O. Lorentsen

Effects of Composition and Granulometry on Thermal Conductivity of Anode Cover Materials 399

H. Wijayaratne, M. Hyland, M. Taylor, A. Grama, and T. Groutso

Restart of 300kA Potlines after 5 Hours Power Failure 405

X. Zhao, B, Gao, H. Han, J, Liu, J. Xiao, J. Qian, J. Yan, andD. Wang

Multiblock Monitoring ofAluminum Reduction Cells Performance 407J. Tessier, C. Duchesne, and G. Tarcy

Cells Technology, Development and Sustainabilitv

High Amperage Operation ofAPI8 pots at Karm0y 415

M Bugge, H. Haakonsen, O. Kobbeltvedt, andK. Paulsen

Aluminium Smelter Manufacturing Simulation - Can These Bring Real Cost Savings? 421M. Meijer

Simultaneous Preheating and Fast Restart of50 Aluminium Reduction Cells in an Idled Potline - A New Soft Re¬start Technique for a Pot Line 425

A. Mulder, A. Folkers, M, Stam, andM. Taylor

SWOT Perspectives of Midage Prebaked Aluminium Smelter 431

P. Choudhury, andA. Sharma

Integrated Approach for Safe and Efficient Plant Layout Development: 437R. Pires, R. Baxter, L. Tikasz, and R. McCulloch

ix

New Progress on Application ofNEUMOOkA Family High Energy Efficiency Aluminum Reduction Pot ("HEEP")

Technology 443

D. Lu, J. Qin, Z. Ai, and Y. Ban

Improving Current Efficiency of Aged Reduction Lines at Aluminium Bahrain (Alba) 449

A. Ahmed, K. Raghavendra, H. Hassan, and K. Ghuloom

Development ofNEUI500kA Family High Energy Efficiency Aluminum Reduction Pot ("HEEP") Technology ..455

D. Lu, Y. Ban, X. Qi, J. Mao, Q. Yang, andH. Dong

Cells Process Control

Current Efficiency for Aluminium Deposition from Molten Cryolite-alumina Electrolytes in a Laboratory Cell....461

G. Haarberg, J. Armoo, H. Gudbrandsen, E. Skybakmoen, A. Solheim, and T. Jentoftsen

Improvement in Cell Equipment and Design

Retrofit of a Combined Breaker Feeder with a Chisel Bath Contact Detection System to Reduce Anode Effect

Frequency in a Potroom 467

J. Verreault, R. Gariepy, B. Desgroseilliers, C. Simard, X Delcorde, C. Turpain, S. Simard,andS. Dery

Anode Dusting from a Potroom Perspective at Nordural and Correlation with Anode Properties 471

H. Gudmundsson

The Application of Continuous Improvement to Aluminium Potline Design and Equipment 477

W. Paul

Alcoa STARprobe 483

X. Wang, B. Hosier, and G. Tarcy

Active Pot Control using Alcoa STARprobe 491

X. Wang, G. Tarcy, E. Batista, andG. Wood

Technology & Equipment for Starting Up & Shutting Down Aluminium Pots under Full Amperage 497

Y. Tao, L. Meng, C. Bin, and Y. Xiaobing

Study on Solution of A1203 in Low Temperature Aluminum Electrolyte 503

H. Kan, N. Zhang, andX. Wang

Applications of New Structure Reduction Cell Technology in Chalco's Smelters 509

F. Liu, S. Gu, J. Wang, andH. Yang

Transport Numbers in the Molten System NaF-KF-AlF3-Al203 513

P. Fellner, J. Hives, andJ. Thonstad

Cells Process Modeling

Development and Application of an ANSYS Based Thermo-electro-mechanical Collector

Bar Slot Design Tool 519M. Dupuis

Impact of Amperage Creep on Potroom Busbars and Electrical Insulation: Thermal-Electrical Aspects 525A. Schneider, D. Richard, and O. Charette

x

Modern Design of Potroom Ventilation

A. Vershenya, U. Shah, S. Broek, T, Plikas, J. Woloshyn, and A. Schneider

531

A Preliminary Finite Element Electrochemical Model for Modelling Ionic Species Transport in the Cathode Block

ofaHall-HeroultCell 537

F. Gagnon, D. Ziegler, and M. Fafard

CFD Modelling of Alumina Mixing in Aluminium Reduction Cells 543

Y. Feng, M. Cooksey, and P. Schwarz

Bubble Transport by Electro-Magnetophoretic Foces at Anode Botttom of Aluminium Cells 549

V. Bojarevics, and A, Roy

Anodic Voltage Oscillations in Hall-Heroult Cells 555

K. Einarsrud, and E. Sandnes

Energy Savings by Cell Design Improvements

Electrical Conductivity of the KF-NaF- AlFj Molten System at Low Cryolite Ratio with CaF2 Additions 563

A. Redkin, A. Dedyukhin, A. Apisarov, P. Tin'ghaev, and Y. Zaikov

Study ofACD Model and Energy Consumption in Aluminum Reduction Cells 567

T. Yingfu, and W. Hang

Modeling of Energy Savings by Using Cathode Design and Inserts 569R. von Kaenel, andJ. Antille

Experimental Investigation of Single Bubble Characteristics in a Cold Model of a Hall-H6roult

Electrolytic Cell 575S. Das, Y. Morsi, G. Brooks, W. Yang, and J. Chen

Large Gas Bubbles under the Anodes ofAluminum Electrolysis Cells 581

A. Caboussat, L. Kiss, J. Rappaz, K. Vekony, A. Perron, S. Renaudier, and O. Martin

Initiatives to Reduction of Aluminum Potline Energy Consumption Alcoa Pocos de Caldas/Brazil 587

A. Abreu, M. Salles, and C. Kato

Overview of High-Efficiency Energy Saving for Aluminium Reduction Cell 591

X. Canming, and Y. Xiaobing

Cell Voltage Noise Reduction Based on Wavelet in Aluminum Reduction Cell 599

B. Li, J. Chen, X. Zhai, S. Sun, and G. Tu

Poster Session

Human Factors in Operational and Control Decision Making in Aluminium Smelters 605

Y. Gao, M. Taylor, J. Chen, andM. Hautus

xi

Aluminum Rolling

Session I

An Investigation of Deformation Behavior ofBimetal Clad Sheets by Asymmetrical Rollingat Room Temperature 615

L. Xiaobing, Z. Guoyin, and D. Qiang

Coil Build Up Compensation during Cold Rolling to Improve Off-line Flatness 621

L. Almeida Neto, and T. Ayhan

Through Process Effects on Final Al-sheet Flatness 625

S. Neumann, and K. Karhausen

Cast Shop for Aluminum Production

Casthouse Productivity and Safety

New Casthouse Smelter Layout for the Production ofSmall Non-Alloyed Ingots: Three Furnaces/Two Lines 635J. Berlioux, A. Bourgier, and J. Baudrenghien

Use ofProcess Simulation to Design a Billet Casthouse 641G. Jaouen

Optimizing Scrap Reuse as a Key Element in Efficient Aluminium Cast Houses 647

T. Schmidt, J. Migchielsen, D. Ing, andH. Grab

Implementation of an Effective Energy Management Program Supported by a Case Study 653R. Courch&e

Molten Metal Safety Approach through a Network 657

C. Pluchon, B. Hannart, L. Jouet-Pastre, J. Mathieu, R. Wood, J. Riquet, F. Fehrenbach,G. Ranaud, M. Bertherat, and J. Hennings

Improved Monolithic Materials for Lining Aluminum Holding & Melting Furnaces 663A. Wynn, J. Coppack, T. Steele, andK. Moody

Direct Chill Casting

Cold Cracking during Direct-chill Casting 669

D. Eskin, M. Lalpoor, and L. Katgerman

Surface Defects Structures on Direct Chill Cast 6xxx Aluminium Billets 675M. Erdegren, and T. Carlberg

Effect of Cooling Water Quality on Dendrite Arm Spacing ofDC Cast Billets 681S. Mohapatra, S. Nanda, andA. Palchowdhury

Mould Wall Heat Flow Mechanism in a DC Casting Mould 687

A. Prasad, andI. Bainbridge

Productivity Improvements at Direct Chill Casting Unit in Aluminium Bahrain (ALBA) 693A. Noor, S. Chateeriji, andA. Ahmed

xii

The Coupling of Macrosegregation with Grain Nucleation, Growth and Motion in DC Cast Aluminum

Alloy Ingots 699M. Zaloznik, A. Kumar, H. Combeau, M. Bedel, P. Jarry, and E. Waz

Investment Casting of Surfaces with Microholes and Their Possible Applications 705

T. Ivanov, A. Buehrig-Polaczek, U. Vroomen, C. Hartmann, A. Gillner, K. Bobzin, J. Holtkamp,N. Bagcivan, and S. Theiss

Using SEM and EDX for a Simple Differentiation of?- and ?-AlFeSi-Phases in Wrought Aluminum Billets 711

M. Rosefort, C. Matthies, H. Buck, and H. Koch

Dross Formation, Control and Handling

Oxidation of AlMg in Dry and Humid Atmospheres 719A. Kvithyld, D. Stevens, S. Wilson, and T. Engh

Study of Early Stage Interaction of Oxygen with Al; Methods, Challenges and Difficulties 725B. Fateh, G. Brooks, M. Rhamdhani, J. Taylor, J. Davis, and M. Lowe

Quality Assessment of Recycled Aluminium 731D. Dispinar, A. Kvithyld, andA. Nordmark

Melt Quality Control

In-Line Salt-ACD: A Chlorine-Free Technology for Metal Treatment 739P. Robichaud, C. Dupuis, A. Mathis, P. Cote, andB. Maltais

The EffectofTiB2 Granules on Metal Quality 745M. Mohamed Al-Jallaf, M. Hyland, B. Welch, A. Al Zarouni, andF. Abdullah

Thermodynamic Analysis of Ti, Zr, V and Cr Impurities in Aluminium Melt 751A. Khaliq, M. Rhamdhani, G. Brooks, and J. Grandfield

Current Technologies for the Removal ofIron from Aluminum Alloys 757L. Zhang, J. Gao, andL. Damdah

Electromagnetically Enhanced Filtration ofAluminum Melts 763M Kennedy, S. Akhtar, R. Aune, and J. Bakken

A Review of the Development ofNew Filter Technologies Based on the Principle ofMulti Stage Filtration WithGrain Refiner Added in the Intermediate Stage 769

J. Courtenay, S. Instone, andF. Reusch

Wettability of Aluminium with SiC and Graphite in Aluminium Filtration 775S. Bao, A. Kvithyld, T. Engh, and M. Tangstad

Study of Microporosity Formation under Different Pouring Conditions in A356 Aluminum Alloy Castings 783L. Yao, S. Cockcroft, D. Maijer, J. Zhu, and C. Reilly

Grain Refinement, Alloying, Solidification and Casting

Hycast Gas Cushion (GC) Billet Casting System 793/ Steen, andA. Hakonsen

xiii

Studies of Fluid Flow and Meniscus Behavior during Horizontal Single Belt Casting (HSBC)of Thin Metallic Strips 797

D. Li, J. Gill, M. Isac, and R. Guthrie

Development ofAlba High Speed Alloy 803

A. Ahmed, J. Hassan, G. Martin, andK. Ghosh

Dissolution Studies of Si Metal in Liquid Al under Different Forced Convection Conditions 809

M. SeyedAhmadi, S. Argyropoulos, M. Bussmann, and D. Doutre

Modification and Grain Refinement of Eutectics to Improve Performance of Al-Si Castings 815

M. Felberbaum, and A. Dahle

Production of Al-Ti-C Grain Refiners with the Addition ofElemental Carbon and K2TiF6 821

F. Toptan, I. Kerti, S. Daglilar, A. Sagin, O. Karadeniz, andA. Ambarkutuk

Effect ofMechanical Vibrations on Microstructure Refinement of Al-7mass% Si Alloys 827

T. Tamura, T. Matsuki, andK. Miwa

Predicting the Response of Aluminum Casting Alloys to Heat Treatment 831

C. Wu, andM. Makhlouf

Electrode Technology for Aluminium Production

Anode Baking

Determination of Coke Calcination Level and Anode Baking Level - Application and Reproducibility of L-sub-c

Based Methods 841

S. Rmrvik, L, Lossius, andA. Ratvik

Operation of an Open Type Anode Baking Furnace with a Temporary Crossover 847

E. Cobo, L. Beltramino, J. Artola, J. Rey Boero, P. Roy, and J, Bigot

Recent Developments in Anode Baking Furnace Design 853

D. Severo, V. Gusberti, P. Sulger, F. Keller, and M. Meier

Sohar Aluminium's Anode Baking Furnace Operation 859

S. Al Hosni, J. Chandler, O. Forato, F. Morales, C, Jonville, andJ. Bigot

Meeting the Challenge ofIncreasing Anode Baking Furnace Productivity 865

F. Ordronneau, M. Gendre, L. Pomerleau, N. Backhouse, A. Berkovich, andX. Huang

Wireless Communication for Secured Firing and Control Systems in Anode Baking Furnaces 871

N. Fiot, and C. Coulaud

Full Control ofPitch Burn during Baking: It's Impact on Anode Quality, Operational Safety, Maintenance and

Operational Costs 875

D. Maiwald, D. Di Lisa, and P. Mnikoleiski

High Performance Sealing for Anode Baking Furnaces 881

P. Mahieu, S. Neple, N. Fiot, I, Ofico, andM. Eufrasio

xiv

Anode Raw Materials and Green Carbon

Property Profile of Lab-scale Anodes Produced with 180°C Mettler Coal Tar Pitch 889W. Boenigk, C. Boltersdorf, F. Lindner, andJ. Stiegert

Quality and Process Performance of Rotary Kilns and Shaft Calciners 895L. Edwards

Sub-surface Carbon Dioxide Reaction in Anodes 901D. Ziegler

Paste Quality Improvements at Alcoa Pocos de Caldas Plant 907B. Vry, C. Kato, J. Araujo, F. Ribeiro, andA. Abreu

Prebaked Anode from Coal Extract (2) - Effects of the Properties of Hypercoal-coke on the Preformance ofPrebaked Anodes 913

M. Hamaguchi, N. Okuyama, N. Komatsu, J. Koide, K. Kano, T. Shishido, K. Sakai, and T. Inoue

The New Generation of Vertical Shaft Calciner Technology 917J. Zhao, Q. Zhao, and Q. Zhao

Petroleum Coke VBD

Historical and Future Challenges with the Vibrated Bulk Density Test Methods for Determining Porosity ofCalcined Petroleum Coke 925

J. Panchal, M. Wyborney, and J. Rolle

Prediction of Calcined Coke Bulk Density 931

M. Dion, H. Darmstadt, N. Backhouse, F, Cannova, andM. Canada

Calcined Coke Particle Size and Crushing Steps Affect Its VBD Result 937F. Cannova, M. Canada, andB. Vitchus

Bulk Density - Overview of ASTM and ISO Methods with Examples of Between Laboratory Comparisons 941L. Lossius, B. Spencer, andH. 0ye

Improving the Repeatability of Coke Bulk Density Testing 947L. Edwards, M. Lubin, and J. Marino

ASTM D7454 Vibrated Bulk Density Method - Principles and Limitations 953F. Laplante, andh. Duchesneau

Vibrated Bulk Density (VBD) ofCalcined Petroleum Coke and Implications of Changes in the ASTM MethodD4292 959

B. Spencer, L. Johnsen, D. Kirkpatrick, D. Clark, and M. Baudino

Anode Quality and Rodding Processes

Multivariate Monitoring ofthe Prebaked Anode Manufacturing Process and Anode Quality 967J. Lauzon-Gauthier, C. Duchesne, J. Tessier, K. Cantin, audi. Petit

Characterization ofa Full Scale Prebaked Carbon Anode using X-Ray Computerized Tomography 973D. Picard, H. Alamdari, D. Ziegler, P. St-Arnaud, and M. Fqfard

xv

FEM Analysis ofthe Anode Connection in Aluminium Reduction Cells 979

S. Beier, J. Chen, M. Fafard, andH. Fortin

Development of Industrial Benchmark Finite Element Analysis Model to Study Energy Efficient Electrical

Connections for Primary Aluminium Smelters 985

D. Molenaar, K, Ding, andA. Kapoor

Real Time Temperature Distribution During Sealing Process and Room Temperature Air Gap Measurements of a

Hall-H6roult Cell Anode 991

O. Trempe, D. Larouche, D. Ziegler, M. Guillot, andM. Fafard

Effects of High Temperatures and Pressures on Cathode and Anode Interfaces in a Hall-Heroult

Electrolytic Cell 997

L, St-Georges, L. Kiss, J. Bouchard, M. Rouleau, andD. Marceau

New Apparatus for Characterizing Electrical Contact Resistance and Thermal Contact Conductance 1003

N. Kandev, H. Fortin, S. Chenard, G. Gauvin, M. Martin, and M. Fafard

Carbon Anode Modeling for Electric Energy Savings in the Aluminium Reduction Cell 1009

D. Andersen, and Z. Zhang

Cathode Design and Operation

Preheating Collector Bars and Cathode Blocks Prior to Rodding with Cast Iron by Passing an AC Current Throughthe Collector Bars 1017

E. Jensen, H. BjBrnstad, andJ. Hansen

Development and Application of an Energy Saving Technology for Aluminum Reduction Cells 1023

P. Jianping, F. Naixiang, F. Shaofeng, L. Jun, and Q. Xiquan

Study of Electromagnetic Field in 300kA Aluminium Reduction Cells with Innovation Cathode Structure 1029

B. Li, X. Zhang, S. Zhang, F. Wang, andN. Feng

Evaluation of the Thermophysical Properties of Silicon Carbide, Graphitic and Graphitized Carbon Sidewall LiningMaterials Used in Aluminium Reduction Cell in Function of Temperature 1035

A. Khatun, and M. Desilets

Advanced Numerical Simulation of the Thermo-Electro-Mechanical Behaviour ofHall-H6roult Cells under

Electrical Preheating 1041

D. Marceau, S. Pilote, M. Desilets, L. Hacini, J. Bilodeau, and Y. Caratini

Influence ofTechnological and Constructive Parameters on the Integrity ofthe Bottom of Aluminum Reduction

Cells during Flame Preheating 1047

A. Arkhipov, G. Arkhipov, and V. Pingin

Creep Behaviors ofIndustrial Graphitic and Graphitized Cathodes during Modified Rapoport Tests 1053

W. Wang, J. Xue, J. Feng, Q, Liu, L. Than, H. He, andJ. Zhu

Cathode Materials and Wear

Measurement of Cathode Surface Wear Profiles by Laser Scanning 1061

E. Skybakmoen, S. Bervik, A. Solheim, K. Holm, P. Tiefenbach, and O. Ostrem

Coke Selection Criteria for Abrasion Resistant Graphitized Cathodes 1067

R. Perruchoud, W. Fischer, M. Meier, and U. Mannweiler

xvi

Determination of the Effect of Pitch-Impregnation on Cathode Erosion Rate

P. Patel, Y. Sato, and P. Lavoie1073

Simplifying Protection System to Prolong Cell Life 1079M. MohamedAl-Jallaf, M. Hyland, B. Welch, andA. Al Zarouni

Aluminate Spinels as Sidewall Linings for Aluminum Smelters 1085X. Yan, R. Mukhlis, M. Rhamdhani, and G. Brooks

A New Ramming Paste with Improved Potlining Working Conditions 1091B. Allard, R. Paulus, andG. Billat

Towards a Better Understanding of Carburation Phenomenon 1097M. Lebeuf, M. Coulombe, B. Allard, and G. Soucy

Characterization of Sodium and Fluorides Penetration into Carbon Cathodes by Image Analysis and SEM-EDS

Techniques 1103Y. Gao, J. Xue, J. Zhu, K. Jiao, and G. Jiang

Inert Anodes and Wettable Cathodes

Pressureless Sintering of TiB2-based Composites using Ti and Fe Additives for Developmentof Wettable Cathodes 1111

H. Heidari, H. Alamdari, D. Dube, andR. Schulz

Furan Resin and Pitch Blends as Binders for TiB2-C Cathodes 1117H. Zhang, J. Hou, X. Lil, Y. Lai, and J. Li

Influence ofCobalt Additions on Electrochemical Behaviour of Ni-Fe-Based Anodes for AluminiumElectrowinning 1123

V. Singleton, B. Welch, and M. Skyllas-Kazacos

Effects of the Additive Zx02 on Properties ofNickel Ferrite Cermet Inert Anode 1129X. Zhang, G. Yao, Y. Liu, J. Ma, andZ. Zhang

Effect of Sintering Atmosphere on Phase Composition and Mechanical Property of 5Cu/(10NiO-NiFe2O4) CermetAnodes for Aluminum Electrolysis 1135

Z. Zou, C. Wei, Z. Tian, K. Liu, H. Zhang, Y. Lai, andJ. Li

Poster Session - Electrode

Influence of Ultrafine Powder on the Properties of Carbon Anode Used in Aluminum Electrolysis 1143X. Jin, D. Songyun, L. Jie, L. Yanqing, andL. Yexiang

Preparation NiFe204 Matrix Inert Anode Used in Aluminum Electrolysis by Adding Nanopowder 1149Z. Zhang, G. Yao, Y. Liu, andX. Zhang

Cold Water Model Simulation of Aluminum Liquid Fluctuations Induced by Anodic Gas in New Tape of CathodeStructure Aluminum Electrolytic Cell 1155

Y. Liu, T. Zhang, Z. Dou, H. Wang, G. Lv, Q. Zhao, N. Feng, and J. He

Effects of Physical Properties of Anode Raw Materials on the Paste Compaction Behavior 1161K. Azari, H. Ammar, H. Alamdari, D. Picard, M. Fafard, and D. Ziegler

xvii

Furnace Efficiency - Energy and Throughput

Session I

Furnaces Designed for Fuel Efficiency 1169

D. White

Latest Trends in Post Consumer and Light Gauge Scrap Processing to include Problematic Materials such as UBC,

Edge Trimming and Loose Swarf 1173

F. Niedermair, and G. Wimroither

Investigation of Heat Transfer Conditions in a Reverberatory Melting Furnace by Numerical Modeling 1179

A. Buchholz, andJ. Rodseth

Oxyfuel Optimization using CFD Modeling 1185

T. Niehoff, and S. Viyyuri

Operational Efficiency Improvements Resulting from Monitoring and Trim of Industrial

Combustion Systems 1189

J. Oakes, and D. Bratcher

New Technology for Electromagnetic Stirring ofAluminum Reverberatory Furnaces 1193

J. Herbert, andA. Peel

Evaluation of Effects of Stirring in a Melting Furnace for Aluminum 1199

K. Matsuzaki, T. Shimizu, Y. Murakoshi, and K. Takahashi

Business Analysis of Total Refractory Costs 1205

C. Belt

Improved Furnace Efficiency through the Use of Refractory Materials 1211

J. Hemrick, A. Rodrigues-Schroer, D. Colavito, and J. Smith

Study on the Energy-saving Technology of Chinese Shaft Calciners 1217

G Lang, C. Bao, S. Gao, R. Logan, Y. Li, andJ. Wu

Author Index 1221

Subject Index 1227

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