International Course on Process Metallurgy of Aluminium

MAIN TOPICS

• The Principles of Aluminium Electrolysis
• Preheat and Start-up of Al-pots
• Pot-Line Operation. Pot Resistance Tuning
• Computer Control of Cells
• Electrolyte Composition. Options and Desirable Properties
• Anodes: The Impact of Raw Material Quality and Anode Manufacturing
• Parameters on the Behaviour in Electrolysis
• Søderberg Technology
• Safe Behaviour in the Pot Room
• Cathode Failure and Cell Service Life for Modern Cells
• Cell Voltage. Anode Effect
• Rectifier Operation During Aluminium Electrolysis
• Cell Dynamics
• Shut-Down and Restart of Cells
• Diagnosis and Correction of Irregularly Operating Cells
• Magnetic Compensation of Aluminium Cells
• Heat Balance
• Current Efficiency
• Alumina in Smelting
• Amperage Increase
• Electrical Safety in Potrooms
• Measurement Techniques for Pot Analysis
• Emission Control
• AP30 Pot Operation (movie)
• Group discussions will cover problems and improvements within the fields: Operation, Strategy for increased productivity, Cathode technology, Anode quality, Søderberg technology and Environmental aspects.

OBJECTIVE
The course has been given on an annual basis since 1981. It provides an updated, comprehensive review of the state of the art in aluminium production. The aim of the course is to "understand the process and act accordingly". Since 1981 the total attendance has been 2596 participants from 271 companies and institutions, representing 56 countries.

LECTURERS
Mr. Leif Hellebø (Senior Vice President Corporate Management, Norsk Hydro ASA, Norway)
Dr. George C. Holywell (President, Almagi Inc, Canada)
Dr. Bjørn Lillebuen (Technical Consultant, Norway)
Dr. Markus Meier (Director, R&D Carbon, Switzerland)
Mr. Bjørn P. Moxnes (Technical Consultant, Hydro Aluminium, Norway)
Mr. Tor Bjarne Pedersen (Technology Manager/Corporate Specialist, Alcoa Aluminium, Norway)
Dr. Jean-Michel Peyneau (Reduction Consultant, Rio Tinto – Europe, France)
Dr. Vinko Poto¿nik (Technical Consultant, formerly Alcan, Canada)
Dr. Michel Reverdy (Technical Consultant, DUBAL, formerly Pechiney, UAE, Dubai)
Dr. Ketil Rye (Potroom manager, Alcoa Mosjøen, Norway)
Mr. Daniel Sager (Business Development Manager, ABB Switzerland Ltd.)
Dr. Morten Sørlie (Corporate Specialist, Alcoa Norway ANS and Adjunct Professor, Dept. of Materials Science and Engineering, NTNU, Norway)
Dr. Alton T. Tabereaux (Technical Consultant, formerly Alcoa, USA)
Dr. Jomar Thonstad (Professor, Dept. of Materials Science and Engineering, NTNU, Norway)
Mr. Geir Wedde (Director, Alstom Power AS, Norway)
Dr. Harald A. Øye (Professor, Dept. of Materials Science and Engineering, NTNU, Norway)

COURSE FORMAT
The lectures are the backbone of the course, and the lecturers have been carefully chosen because of their expertise as well as their ability to communicate. Complete lecture notes will be handed out on arrival Monday morning together with the book "Cathodes in Aluminium Electrolysis" by Morten Sørlie and Harald A. Øye (Editors).

Group discussion is an integrated part of the course, and two such sessions are planned. Scenarios will be given, and the group will be asked for solutions. Active participation by the attendants is encouraged. The participants are free to choose discussion groups.

FOR WHOM INTENDED
The course is aimed at personnel working in the field of commercial aluminium electrolysis at all levels, including technical and project managers, supervisors, pot-room engineers as well as research metallurgists.

TIME SCHEDULE
The course starts on Monday, June 4th at 0830. There will be a bus pick up from the hotels each morning. On Friday, June 08th, the course is concluded at 11.40. Lunch on Friday will be at 11.45. A bus for the airport will leave at 1240, giving the participants time to catch planes to Oslo leaving from 1420 and later. From Oslo there will be further connection to major international flights the same day. The lectures will be held in Room 5, the Science building behind the Chemistry buildings at the Norwegian University of Science and Technology, Trondheim. For location, see the panorama on the rear. The course secretariat will also be located there. A welcome get-together reception will be held Monday evening. On Tuesday there will be a guided tour of the Archbishop Museum followed by an official receptionat the City Hall given by The City of Trondheim. Later the same evening there will be served a sea-food meal at Grenaderen Restaurant. Another place of interest Ringve Museum.

BACKGROUND INFORMATION
Aluminium smelting is a very important export industry in Norway, and there are substantial research activities at Department of Materials Science and Engineering supported not only by the Norwegian industry and government, but also by the international aluminium community. Department of Materials Science and Engineering has a long tradition in basic and applied research on aluminium electrowinning and was made a Strong Point Center at the Norwe-gian University of Science and Technology. Graduate teaching is a very important part of the activities. The research on aluminium electrowinning can be divided into four categories: Physicochemical studies for development of a reliable and accurate data base; new developments;laboratory and plant experiments associated with the present process; and participation in Norwegian and international industrial development work. A large number of scientific papers and several books have been published as a result of these activities. Relevant book titles are: «Aluminium Electrolysis», «Aluminium Smelter Technology», «Understanding the Hall-Héroult Process», «Carbothermal Production of Aluminium» and «Cathodes in Aluminium Electrolysis».

The present course utilizes the acquired knowledge as well as recent industrial experience. Speakers are renowned people from the international aluminium community. The course is revised and updated annually, according to the indus-trial development, and also according to suggestions and comments received from previous course participants.

ENROLLMENT AND FEE
The attendance is limited, and applications should be forwarded AS SOON AS POSSIBLE in order to get an immediate confirmation. All applications must be received by April 27, 2012. The fee is NOK 16 500. Hotel accommodation is NOT included in the fee, but hotel rooms may be booked by filling out the enrollment application.

 

• Please use the electronic Enrollment application form.
• OR make a printout of this application form, fill it in and send it EITHER by telefax to +47 735 93992 or by mail to this address:
  Department of Materials Science and Engineering
  Attn.: Ludmila Katylevskaya, Al-Course
  The Norwegian University of Science and Technology
  N-7491 Trondheim, NORWAY

 

 

The Norwegian University of Science and Technology with the Nidaros Cathedral and the center of Trondheim in the background.

1. Course entrance 2. Old Electrical Engineering Building

The hotels are located in the town center, about 20 minutes walking distance from the University.

3. Clarion Collection Grand Olav 4. Britannia Hotel 5. Rica Nidelven Hotel

The inner city of Trondheim and the course area have the wireless internet.

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, June 5th. 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 22 500. 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 28, 2013 for a refund.Cancellations received after April 28, 2013 are subject to NOK 1000 service charge.

SCHEDULE
1st week: May 28-29
Professor Dr. tech. Halvor Kvande: Chief Engineer at Hydro Aluminium in Oslo, Norway. Fundamental and Industrial Aspects of Aluminium Production

Introduction to the Hall - Héroult process

• Bath Composition and Properties
• Heat Balance in Al. Electrolysis Cells
• Current Efficiency
• Cell Voltage and Energy consumption
• Modernisation of Prebake Cells
• Challenges and opportunities for the process

1st week: May 30-31
Dr.ing. Ketil Rye, Technical Specialist, Alcoa Global Primary Products, Mosjøen, Norway.

Industrial Aspects of Aluminium Production

• Pot Design Concepts
• Bath Chemistry and Pot Performance
• Alumina in the Smelting Process
• Computer Control of Pots
• Basic Pot Operation
• Retrofitting
• Energy Recovery

2nd week: June 3-4
M.Sc. Per Stokka, Retired Chife Engineer at Hydro Aluminium AS, Porsgrunn, Norway.

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: June 5
Excursion to Hydro Aluminium Sunndal Plant / Excursion leader Professor Harald A. Øye

2nd week: June 6-7
Dr. ing. Morten Sørlie, Corporate Specialist at Alcoa Norway ANS in Kristiansand and Adjunct Professor at Department of Materials Science and Engineering, NTNU.

Cathode Technology

• Reling Rationale
• Pot Lining Materials
• Pot Lining Principles
• Practical Pot Relining
• Preheat, Start and Operation
• Chemical Attack on Cathodes
• Cathode Failures

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

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

Professor Harald A. Øye
Course Director