Dynamic Process Optimization in Paste Plant
Raja Javed Akhtar (1), Saleh Ahmad Rabba (1), Markus W. Meier (2)
(1) Dubai Aluminium Company Limited,
P.O. Box 3627, Dubai, United Arab Emirates
(2) R&D Carbon Ltd.
P.O. Box 362, 3960 Sierre, Switzerland
Abstract
U Lower raw material cost:
Dubai Aluminium Company (DUBAL) is one of the largest
single site aluminium smelters in the world producing
761,000 MT/year of high quality premium product. It has
its own carbon manufacturing plant with a production
capacity of 370,000 anodes/year of different sizes and
configurations.
As part of a management drive to optimise the current
assets, an exercise of Dynamic Process Optimization (DPO)
was carried out in the greenmill. R&D Carbon was chosen
as the technical partner and worked along with DUBAL
operational personnel during the three phases of the DPO.
The process parameters were optimised systematically to
reduce pitch content, increase paste throughput and increase
anode density. A mobile pilot press was utilised to prepare
samples for evaluation during the optimisation process.
The optimised parameter settings were implemented on both
anode production lines in the greenmill following a
successful 15 cell trial in the potrooms.
This paper describes the DPO methodology, highlights the
results achieved in the greenmill together with the
subsequent improvement in anode quality and performance.
Introduction
U
Prebaked anodes contribute as the biggest variable impact to
the aluminium production cost [1]. Reducing the production
cost is an ongoing process in every smelter. Optimization
goals may focus on the anode plant to produce cheaper
anodes with the same performance in the pots or on the
potrooms to use anodes of superior quality to produce metal
at reduced cost [2].
There are numerous optimization goals in the anode plant
that can lead to a reduction of the aluminium production
cost provided that the anode performance is not negatively
affected:
Lower conversion cost:
• Higher throughput
• Less scrap
• Fewer breakdowns
• Lower energy consumption
• Lower maintenance cost
• Coke / pitch
• Lower pitch content
Potroom related optimization goals focus on superior
anodes to produce metal at lower cost:
• Higher consistency of anode properties
• No anode cracking or slabbing
• No spikes or mushrooms
• Good anode current distribution
• Low anode voltage drop
• High metal purity
• Low consumption figures
• High current efficiency
In order to identify in a systematic manner the area(s) with
the greatest potential for optimization, DUBAL contracted
R&D Carbon to carry out an audit of the anode plant.
Therefore a technical assessment was carried out by
following the material stream from the raw material intake
all the way to the potrooms and the butts recycling station.
Every relevant processing step was investigated by
sampling the product, analysing its properties and
comparing them with the worldwide typical level and
benchmark.
The audit conducted by R&D Carbon concluded that
DUBAL produces anodes of high quality with limited
options for further improvements of their performance in
the pots. The high current efficiency of 95.1 % and low
anode net consumption of 406 kg/tAl in the CD-20 pots
underline this conclusion.
On the other hand the results of the audit showed that there
is a potential to reduce the pitch content without negatively
affecting baked anode quality, in particular apparent density
and air permeability. Prior to the DPO the pitch content in
green anode was 15.0 +/- 0.7 % depending on the coke type
used. The baked anodes exhibited an apparent density of
1.580 g/cc and an air permeability of 0.6 nPm.
Reduction of the pitch content without adversely affecting
the anode properties requires adjustments in the recipe and
also to the preheating, mixing and forming processes. A trial
and error approach on a full production scale was not
feasible due to a high risk of scrap generation and
potentially poor anode behaviour in the pots over an
extensive trial period. Instead, an approach on a pilot scale
was chosen which is described hereafter. hydraulic press, which took less than one hour. This allowed
the testing of many parameter combinations with the
The methodology of the Dynamic Process Optimization generation of a minimum amount of anode scrap. The short
(DPO) enabled the determination of the optimum production time reduced the effect of quality variations in
combination of processing parameters with negligible scrap the raw materials.
generation in a very short period of time. The
implementation of the optimization findings was made
within a few weeks. The optimization process was carried
out in 3 steps:

1. Plant capability check

2. Dynamic Process Optimization
3. Implementation of DPO recommendations in full
scale anode production following positive anode
performance confirmation in the potrooms.

DPO Approach, Experimental and Program

DPO Approach
U U

Prior to the actual DPO, a plant capability check was

conducted. The purpose of this check was to identify the
potential and limitations of the dry aggregate and paste
preparation operations and also the forming equipment. This
included the following:

• Consistency of the ball mill product during finer

fines production
• Capacity and reliability of the fraction scales
• Reliability of the sampling equipment and
procedures
• Stability and capability of the HTM system to
accommodate an increased coke preheating
temperature
• Spare capacity of the paste mixer and cooler in
terms of intensity and throughput
• Flexibility of the vibro-compactor in terms of
temperature, densification and throughput

The principal strategy to reach the target was to utilize the

maximum plant potential to increase anode density and then
to systematically reduce the pitch level. Accordingly, a new
recipe was chosen with a reduced fines content but with the
fines being of a finer sizing that has the advantage of less
variability in sizing from the ball mill and, as a
consequence, less pitch requirement. Finer fines require
more intense mixing, hence the mixing intensity needed to Figure 1: Production of pilot electrodes and monitoring of
be increased. With the implementation of these changes, the forming temperature
forming temperature could be increased, as the paste was
less sensitive with the reduced pitch content and better The pilot electrodes were baked under well controlled
homogeneity. The higher forming temperature allowed a conditions in a laboratory furnace to 1150°C with minimal
faster densification of the anode block and consequently a variations. From each pilot electrode, three cores of 50 mm
resultant higher density. diameter were then drilled. The quality of these cores
compared favourably with anodes produced with vibro
Experimental
U U compaction.

The actual procedure of the DPO [3] involved the
production of pilot electrodes with anode paste collected
directly after the cooler, (see figure 1). Only one parameter
was changed at a time while all others were kept constant.
For one set of parameters twelve pilot electrodes of
approximately 5 kg each were produced utilising a mobile
The resulting anode properties were determined according
to standardized test methods [4]. The evaluation of the
anode properties from each trial enabled the determination
of the optimum combinations of process parameters.
DPO Program Table II: Base line vs. optimized settings towards reduced
pitch and over-nominal throughput
Prior to the commencement of the DPO, a consistency test Optimization towards
was performed with standard conditions to verify stable Parameter / Property Unit Base Line
operation of the paste plant. This test was essential, as the Settings Reduced Over-
negative effect of process variations on the anode quality is Pitch level Nominal
Throughput
often underestimated.
Fines fineness Blaine No 2700 4000 4000
The best results were achieved when a combination of Fines content % 42 31 31
Pitch content % 15.6 14.4 14.4
parameters was optimised. However, several limitations Mixing temperature °C 177 187 187
were respected. The prime limitations were the capacity of Mixing power kW 260 280 280
the installed equipment, and their inherent operational Forming temperature °C 140 150 150
variations. These limitations were identified during the Throughput t/h 33 33 35
preliminary plant and capability check.
Green anode weight kg 1200 1204 1200
The sequence of optimization trials is summarized in table I. Green anode density g/cc 1.620 1.625 1.620
Due to the fast production procedure for the pilot electrodes, Baked anode weight kg 1145 1158 1155
the entire optimization program could be carried out in three Baked anode density g/cc 1.566 1.592 1.586
days. Air permeability nPm 0.50 0.49 0.54
Specific electrical m 57 58 59
resistance
Table I: DPO program principles Flexural strength MPa 10.5 9.5 8.6
Static elasticity modulus GPa 4.7 4.0 4.1
Seq. Focus Parameters Variations Thermal conductivity W/mK 3.89 3.48 3.38

Fines content 42%

Baseline 15.6 - 14.4 %
1 Pitch content By using the same raw materials, the pitch content was
Plant conditions Mixing conditions 177°C, 260 kW
145°c
reduced by 1.2 % abs. Even with the reduced pitch content,
Forming temperature
33t/h
the baked anode weight could be increased by 13 kg and the
Throughput
baked anode density by 0.026 g/cc. No significant change
Finer fines Fines content 31 - 37 % was measured for air permeability and specific electrical
2
Pitch content 15.0 - 13.8 % resistance.
3
Mixing power 220 - 280 kW
4 Forming temperature 140 - 150°C
5 Throughput 33 - 35 t/h
The optimized recipe resulted in a reduction of flexural
strength and elasticity modulus. These reductions may be
interpreted as deteriorations, but in fact, they were not. Due
Whilst the monitoring of the green anode density during the to the reduction of the elasticity modulus, the anodes
DPO gave an initial indication about potential optimal become less brittle and thus less susceptible to thermal
process parameter combinations, verification was obtained shock cracking [5]. The level of mechanical strength was
from the analysis and evaluation of the properties of the still capable of withstanding all arising stresses.
baked pilot electrodes.
Another positive aspect was the reduced thermal
DPO Results conductivity which has a positive impact on the net anode
consumption [6].
The comparison of properties of baseline anodes before
with DPO anodes revealed remarkable improvements, as Furthermore, the results in table II show that, with the
illustrated in table II. It has to be pointed out that for the knowledge gained from the pitch optimization trial, the
entire DPO program no investment in hardware equipment throughput could be increased by 10 % (ie. 3 t/h) over the
was made, ie. all improvements were achieved by the nominal level without any hardware modifications and
optimization of the process parameters with the existing without compromising anode quality.
equipment.
Hence the merit of the DPO was that it gives the option to
either generate savings by minimizing the pitch content or
maximizing the production capacity without investment on
equipment.
 Implementation in Routine Operation and Validation
U clear cycles in selected cell operation. No negative impact
in Pots U on pot parameters was recorded.

Following positive laboratory results as illustrated in table
11, the decision was taken to carry out a selected pots trial
in the potrooms before implementation of the recommended
revised settings for plant wide production. A batch of 2000
anodes each with the original parameters (control) and the
revised DPO settings (test) were produced utilising the same
raw materials in the Greenmill.
Table 111- Green Anodes Quality Data
The confidence gained as a result of the selected pots trial
helped in making the decision to implement the revised
DPO setting for plant wide production in March/2005.
The actual supply of anodes to the potrooms commenced in
May/2005. At the time of writing this article, these anodes
have completed four clear cycles of operation without any
adverse impact on pot operation.
Apparent density (g/cc)

Anode Production Anode Green Density Pitch % Ball mill product 1. 5 8 5

group line No (g/cc)

1. 5 8 0
Test 1 1987 Avg SD Avg SD Blaine SD
No.

1.628 0.005 14.30 0.12 3915 182 1. 5 7 5

Control 1 2000 1.625 0.008 14.89 0.12 2656 19

1. 5 7 0

A reduction of 0.59% binder level was observed without a

significant difference in green density. 1. 5 6 5
37 39 41 43 45 47 49 51 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 32

Y ear 2004 Y ear 2005

Both categories of anodes were baked under identical
operating conditions in the baking kilns.
Air permeability (npm)
Table IV - Baked Anode Quality Data
0 .9 0

Anode Group
Criteria Test Control 0 .7 5

Core density g/cc 1.580 1.577

0 .6 0

Real density g/cc 2.091 2.099

Air perme npm 0.44 0.58 0 .4 5

Elec. Resit. µΩm 52.28 51.79

Flex. Strgh. Mpa 14.89 14.01 0 .3 0

Mean Cryst-size 30.18 31.35 0 . 15

CRR % 95.85 98.73 3 7 3 9 4 1 4 3 4 5 4 7 4 9 5 1 1 3 5 7 9 11 13 15 17 19 2 1 2 3 2 5 2 7 2 9 3 2

CRL % 4.05 4.22 Y ear 2004 Y ear 2005

CRD % 0.10 0.06

ARR % 86.52 85.08
Figure II – Baked Anode Quality Indicators
ARL % 11.79 13.30
ARD % 1.69 1.63 Conclusions
U

Therm. Condition. w/mk 3.38 3.61

1. A reduction of 0.7% in binder was achieved
Test anode analysis was comparatively better with regards without compromising product quality. A
to flexural strength, real density, air permeability and air recurring saving of $400k/year.
reactivity loss.
2. It was not necessary to undertake any plant
15 pots each for test and control anodes were selected in modification to achieve the benefits.
potline-6 and the trial was carried out for 3 clear cycles.
3. Apparent density and air permeability improved
Table V - Butts parameters resulting in better anode performance.
Anode group
Criteria Test Control 4. Baking loss reduced from 5% to 4.5% - an
Reduction in area % 6.5 6.9 increase of 13kgs in baked anode weight.
Avg. Butt thickness (cm) 19.3 19.1
Top exidation (cm) 0.9 0.8 5. The throughput of each green anode marking
Carbon under stub (cm) 6.95 6.70 train could be increased from 33 tph to 35 tph – a
End burn (outer – cm) 2.65 2.70 benefit of additional 10,000 anodes/year.
End burn (Inner – cm) 3.10 3.05
Butt weight (kg) 259 241 6. Provided an opportunity to further increase the
Consumption per anode (kg) 883 900 anode density in the future.
18 kgs increase in butt weight was observed following three
 References

[1] M. Meier, T. Müller,”Influence of Anode Quality

on Aluminium Production Cost”, 3rd Rodding
Conference, Iceland, 2005

[2] R. Perruchoud, “Carbon Plant Optimization”,CII

Carbon Symposium XX, New Orleans, 2005

[3] U. Bühler, R. Perruchoud, “Dynamic Process

Optimization”, Light Metals 1995, 707 - 714

[4] R. Perruchoud, M. Meier and W. Fischer,

“Survey on Worldwide Prebaked Anode Quality”,
Light Metals 2004, 573 - 578

[5] M. Meier, “Cracking Behaviour of Anodes”,

R&D Carbon Ltd, 1996, 233 ff

[6] W. Fischer, F. Keller and R. Perruchoud,

“Interdependence between Anode Net
Consumption and Pot Design, Pot Operating
Parameters and Anode Properties, Light Metals
1991, 681 - 686