Fundamentals and their application in aluminium production

ELECTRONIC APPLICATION FORM FOR THE PRE-COURSE

CONTENTS OF THE COURSE 2012
There has been a request from alumi-nium smelters for a more basic education and a more detailed introduction to aluminium electrolysis technology than it is possible to give during the one-week course: "The International Course on Process Metallurgy of Alumi-nium." As a response we are offering a two-week course in fundamentals and their application in primary aluminium production. The course will contain fundamental knowledge and thorough understanding through lectures, written exercises and laboratory demonstrations, and practical application to industrial problems.

The course is aimed at people working in the primary aluminium industry, but it isalso suitable for freshmen and for people working in related fields, who want tolearn about aluminium production technology. This course is also very suitable as a preparation for participation in the following one-week course.

The course material, which will be handed out on the first day of the course, includes the book: "Introduction to Aluminium Electrolysis" by K. Grjotheim and H. Kvande (Editors), as well as overhead notes on subjects not treated there. The course language is English.

AIM OF THE COURSE
The aim of the course is to give the participants theoretical and practical knowledge that they can use in their daily work. Group work and class discussion will be important parts of the course and will require active involvement of the participants. Experience from previous courses has shown that the opportunity of discussing practical problems with colleagues from other companies is greatly appreciated. The participants are encouraged to bring with them a problem or two that they would like to discuss in class during the course.

TIME AND PLACE
The course will be held at the Norwegian University of Science and Technology, Trondheim, Norway, in the Science Building, auditorium R9. There will be a bus pick-up from the hotels each morning. An excursion to Hydro Aluminium Sunndal Plant will be arranged on Wednesday, May 23d. This means 9 course days, including the excursion.

The university campus is located about 20-30 minutes walk south of the downtownarea. The course will start each morning at 08:30.

ENROLlMENT AND FEE
The fee will be NOK 19 500. The fee will cover course materials, the excursion to the Hydro Aluminium Sunndal smelter, lunches, beverage breaks and a course dinner, but no board or other meals. Breakfast is included in the hotel price.

The attendance is limited and applicants are accepted in the order of application receipt.

All applicants whose attendance has been confirmed by us will receive an invoice. Please, do not pay until you have received our invoice and refer to the invoice no. when paying.

The application may be cancelled before April 20, 2012 for a refund. Cancellations received after April 20, 2012 are subject to NOK 1000 service charge.

SCHEDULE
1st week: May 21-22
Professor Dr. tech. Halvor Kvande: Chief Engineer at Hydro Aluminium in Oslo. He has extensive experience in bath properties, cell start-up and operation.

Introduction to the Hall - Heroult process

• Electrolysis and electrochemistry
• Electrolyte properties
• Current efficiency
• Energy consumption
• The environment - carbon footprint
• Challenges and opportunities for the process

1st week: May 23
Excursion to Hydro Aluminium Sunndal Plant / Excursion leader Professor Harald A. Øye
 

1st week: May 24 - 25
Dr.ing. Ketil Rye, Technical Specialist, Alcoa Global Primary Products, Mosjøen, Norway.

Industrial Aspects of Aluminium Production

• Pot Design Concepts
• Basic Pot Operation
• Energy and Heat Balance, Energy Consumption
• Bath Chemistry, Current Efficiency and Cell Performance
• Alumina and its Properties in the Cells
• Computer Control
• Operating a Potline:
  - Routine Tasks
  - Carbon Setting and Consumption
  - Metal Tapping
  - Liquid Level Control
  - Operational Problems
  - Emission Control
  - Curtailment Scenarios
• Cell Retrofitting
• Energy Recovery

2nd week: May 28 - Whit Monday (no lectures)

2nd week: May 29 - 30
M.Sc. Per Stokka, Hydro Aluminium AS, Norway. He has extensive experience in handling of operational problems in aluminium electrolysis, specially on the anode side.

Production of Anodes

• Raw materials, petrol coke, coal tar pitch and butts
• Aggregate preparation, different type of aggregates
• Preheating and mixing, energy input, retention time, crushing
• Forming of green anodes

Analysis of properties of prebaked anodes

Anodes in operation

• Anode consumption, effect of anode prope 
• Amperage increase, voltage and heat balance problems
  •  Anode size
  • Slots, effect on voltage drop
  • Stubs, diameter and depth, effect on voltage drop
• Anode devitations
  • Carbon dusting, effect of anode properties and pot operation
  • Spikes, different types, how to create and avoid them
  • Cracks, anode properties and problems caused by pot operation

2nd week: May 31 - June 1
Dr. ing. Morten Sørlie, Corporate Specialist at Alcoa Norway ANS in Kristiansand and Adjunct Professor at Department of Materials Science and Engineering, NTNU. He has extensive expertise in cell and cathode technology.

• Cathode Materials Properties
• Design and Cathode Construction
• Start-up and Operation
• Cathode Failures and their Prevention
• How to make a better Cathode

The laboratory demonstrations will emphasize test procedures for carbon materials and structural studies.

The five lecturers also have extensive experience with several international projects.

Professor Harald A. Øye
Course Director