Issue 19

AP Technology newsletter

March 2015
aptechnology.com

AP Technology
Exceptional value delivery worldwide

AP60 Jonquire:
Well done!
In August 2014, the Arvida Aluminium Smelter, AP60 Technology
Centrepassed Rio Tinto Alcans rigorous internal certification confirming
thetechnologys effectiveness and reliability.
The performance test of the installed AP60 technology
was conducted over a 30-day period, with excellent
results, as summarised in the table below. The test
included a reinforced process and production follow-up
to assess thetechnologys full potential.

In parallel to the technological validation, some pots

equipped with a booster group are operating beyond
potline amperage. These AP60 pots will run at an
increased amperage to develop the next technological
step in industrial conditions and to validate new
benchmark in the aluminium industry.

The performance test results were excellent:

AP60 performance test results

Key indicator

Result

Metal production (kg/p/d)

4,407

Amperage (kA)

570.7

Current efficiency (%)

95.9

SEC (kWh/t Al)*

13,090

Anode effect frequency (AE/p/d)

0.02

Roof vent fluoride emissions

(kg F/t Al)

0.21

* SEC computed for an industrial plant

Cover picture:
Kitimat potline

02

The amperage of 600kA was reached on

22 January 2015, one month ahead of schedule.
In addition to the excellent pot performance, the test
showed outstanding environmental results. The fluoride
emission level of 0.21kg F/t Al is the result of the innovative
design of the pot gas collection system inside the
superstructure, specific pot tightness improvements
compared with previous pot generations, the very
stable pot behaviour and of course high work quality.
The anode effect frequency decreased to 0.02AE/p/d
during the performance test as the process and operation
teams adjusted to operating at full scale and as the
potfine-tuning advanced.
The performance of the AP60 cells monitored over the
past 12 months represents an all-time best in RioTinto
Alcans aluminium smelting technology. Optimised
frameworks such as busbars, shell and superstructure
allow for a very high level of cost effectiveness compared
with previous cell generations, by ensuring benchmark
productivity (production of 4,400kg/cell/day for AP60),
low energy consumption and record low emissions,
explained Claude Vanvoren, Vice President Technology
and Research and Development, Rio Tinto Alcan.

AP Technology newsletter

Issue 19
March 2015

Editorial
AP60 technology is a reality
After one year of operation, the AP60 technology
solution installed at Arvida Technological Centre in
Jonquire, Canada, shows outstanding technical results.
The performances have been above expectations on
allcounts and the threshold of 600kA was reached in
January earlier this year. APXe, the low energy version
of AP60 technology operating at the Laboratoire de
Recherche des Fabrications (LRF) in France, achieved
its targeted specific energy consumption of 12.0MWh/t
at amperage above 500kA, successfully delivering the
promised step change in energy reduction.
Vincent Christ
Vice president,
Technology R&D,
Equipment Sales
&Services and
Carbonproducts

In 2014 we also completed the final ramp-up of

1.5milliontpa at our clients new AP37 and AP36
smelters in Saudi Arabia and India. In November 2014
Sohar Aluminium became the first smelter to convert
toAP40 technology and today Rio Tinto Alcan Kitimat
Modernisation Project is mobilising for the final steps
towards first hot metal.

AP Technology products ALPSYS and MESAL have been

installed at new customer sites with constant effort going
into important innovations in both functionalities and
product characteristics. The fully automated anode change
operations at AP60 Jonquire has been proven.
Work continues to further develop new technology bricks
to allow fast and safe pot reengineering with enhanced
performances for amperage creep or energy reduction
on the existing AP18, AP30 and AP60 platforms.
While 2014 has been a challenging time for the
aluminium industry, AP Technology team remains
committed to supporting global customers by
delivering advanced solutions to optimise their
operations andensure their success. Please enjoy
reading the interesting updates and news in the
following pagesand stay tuned for another exciting
yearof APTechnology!

Routes to excellence
Aluminium smelters worldwide are working hard to keep
or improve their position on the industry cost curve.
Tolower expenditures in $/t, a plant can focus on costs,
overall production levels or both. One option is to launch
broad-based savings initiatives. While such programmes
are effective, their impact on the smelter's relative
position on the cost curve tends toremain limited.
Past experience has demonstrated that one of the best
ways to strengthen competitiveness is to improve pot
performances by implementing a pot modernisation
programme. Indeed, two smelters that initially used the
same pot technology can display very different targeted
pot performance, depending on factors such as:
Energy cost and availability
Bottlenecks in the carbon department
Remaining capacities in the gas treatment center,
substation andcarbondepartment

The AP Technology team is able to support any

smelter in the development of a clear vision of its
technical potential using our latest demonstrated
technology bricks, including:

Forced cooling
Low-energy lining
High-productivity lining
Magnetic compensation loops
Jet Induced Boosted Suction (JIBS)

Such technology bricks, associated with our simulation

tools, combined with our extensive experience in
assembling such elements and in supporting our clients
from the detailed engineering stage to the operation
ofthe solution, are key to your success.
On this journey to excellence, vision and goals are vital.
Equally important is ensuring they are supported and
managed. Some changes, such as lining design, take
years to fully implement. Properly managing the transition
from one technical design to the next is essential. The
AP Technology team brings you the expertise they have
developed over the last decades through their numerous
successful creeping projects.

We have the solutions that will make your

improvement dreams come true.
03

AP Technology newsletter

Issue 19
March 2015

Kitimat
The final countdown
At Kitimat, British Columbia, the new 384-pot potline,
installed in four separate rooms and hosting the latest
AP40 technology at 405kA and 13,150kWh/t, is gearing
up for action.
With an operation readiness plan established before
theproject kick-off and updated throughout the
construction phase, the Kitimat plant is ready for
thechallenge of stopping the remaining Soderberg
lines and starting the new AP40 line without any
additional external permanent manpower.
To support the transition over the coming months,
theAP Technology commissioning and start-up team
is mobilising on site to safely support the local teams
during the challenging months ahead.

We wish them all a safe

and very successful start-up.
Kitimat site

Fully operational Maaden

Aluminium Smelter
Key to a completely integrated supply chain

Ma'aden smelter site

The Saudi Arabian Mining Company (Maaden) was formed

by Royal decree in 1997, in keeping with the mandate
ofthe third pillar of the Saudi economy, which aimed
tofacilitate the development of the Kingdom of Saudi
Arabias mineral resources.
With benchmark safety standards and a 65% in-housetrained local Saudi workforce, Maaden Aluminium, the
joint venture developed between Maaden and Alcoa,
successfully achieved first hot metal at the smelter
onits target date of 12 December 2012. No lost-time
accidents were recorded. Today, Maaden has a fully
integrated supply chain, including a bauxite mine,
refinery, smelter and rolling mill.

04

The smelter uses AP37 technology across its two potlines

to produce 740,000 tonnes per year of aluminium and is
now fully operational, while the mine, refinery and rolling
mill are ramping up operations.
The successful completion of the smelters 720 pot
start-up was celebrated in July 2014, and the smelter has
since enjoyed excellent technical performances.
Maaden Aluminium will complete the ramp-up of all
itsfacilities in 2015 to become fully operational, with a
focus on safety and maintaining operational excellence
and quality across its fully integrated facility.

AP Technology newsletter

Issue 19
March 2015

The longest contract in the

history ofAP technology
The contract with NALCO, the longest ever with a company totally
independent of Aluminium Pechiney, is still in force, more than 30 years
after it was initially signed, following successive renewals.
In 1975 PUK (as Pechiney was known then) was informed
that the Indian Government intended to begin producing
aluminium in the State of Orissa (now Odisha), which
had rich bauxite and coal deposits.
The contract was signed on 9 January 1981 between
Bharat Aluminium Company, or BALCO (Bharat means
India), and PUK. It covered the entire range of operations
from the bauxite mines through to the production of
ingots, making it the most wide-ranging contract with a
third-party customer in terms of its fieldof application.
Odisha was one of the remotest states in India, and the
vast project also aimed to promote local development.
The government later set up a public company dedicated
to the project, which was independent of BALCO. It was
named NALCO (National Aluminium Company) and had
its head office in Bhubaneswar, the capital of Odisha.
Thecontract was reassigned to NALCO.

1 NALCO at a glance
A Situation:
The bauxite deposits are located at Damanjodi in a
beautiful plateau region. The 1,000 metre altitude is
high enough to avoid extreme heat, a major advantage
for both the staff and the machines.
Some of the alumina produced is sent by train to
Visakhapatnam inthe Bay of Bengal to be exported.
The smelter and captive power plant are situated
closeto coal deposits at Angul, a small rural town in a
rice-growing plain about 130 kilometres from the sea.
The main raw materials are carried there by train.

05

AP Technology newsletter

Issue 19
March 2015

Damanjodi: Alumina Plant

Damanjodi: Bauxite Mine

B Capacity:
NALCO was built and developed in three stages, each
involving essentially the same technologies witha
fewimprovements.

Capacity
Facility

Originally

After expansion 1

After expansion 2*

Bauxite mines

2,400,000t

4,800,000t

6,300,000t

Alumina refinery

800,000t

1,575,000t

2,100,000t

Smelter

218,000t

345,000t

460,000t

Captive
power plant

600MW

960MW

1,200MW

* In progress

NALCO port installations

at Visakhapatnam

Communication:
The plant was built and started up without any real
operating outside phone line, telex or fax. Telephoning
to France meant going to Bhubaneswar, a round trip
ofabout six hours by car.
Communication within the plant was also complicated
due to the many different languages and dialects spoken
by the staff.
Red tape:
At the time, management of the public sector in India
was characterised by a certain amount of administrative
red tape, which could make life at the plant difficult.
Total absence of small local firms:
There were no small firms in the Angul region able to
provide quality subcontracted services, without which
the life of a smelter such as this is very difficult.
3 Engineering and construction:

2 The challenges of the Angul plant at the time

ofthe project in the 80s:
The project had to face a number of challenges,
including the following:
Size and complexity:
The Angul plant is a sister plant to Tomago (a smelter
established in Australia in the early 80s), the most
modern at the time, with two potlines of 240 AP18 pots,
a complete anode sector with a paste plant, baking
furnaces and a rodding area, plus a casthouse equipped
with two ingot lines and two of the latest-generation
Properzi rod machines. It represented a huge increase
in terms of size, complexity and equipment automation,
as well as optimisation of the installations in comparison
with the Korba (BALCO) plant, from which most of the
NALCO managers were drawn.
For the operators, all local, it meant leaping into
anewworld.

06

For AP technology sales, the project was ably supervised

from Voreppe right from the start and up until 1990, well
beyond the end of construction of phase 1.
Engineering India Limited (EIL) was commissioned with
the engineering and construction aspects of NALCO
plants. The engineering work was carried out in Delhi,
with the support of an AP project manager sent there in
July 1982. He was the first in a long line of AP experts
involved in the NALCO project.
In 1984 the first AP team arrived on the smelter site.
They had to take a philosophical approach so as to
adapt to life at NALCO Nagar.
Construction was carried out according to local custom,
that is, with very few machines. The construction work
was long and difficult to complete, requiring great
determination from all the parties concerned and from
the AP experts, but the outcome was that its quality
was never challenged. The linings, for instance, had
some of the longest lifespans in their category in spite
ofconsiderable ill treatment in the following years.
Thisis all to the credit of EIL, the NALCO construction
teams, AP technology and its experts.

AP Technology newsletter

Angul: Captive Power Plant (CPP)

Issue 19
March 2015

Angul: Smelter

4 Operations:
NALCOs teams were trained in 1985 and 1986 essentially
at Vlissingen (Netherland) and at Tomago (Australia). The
courses went well, the trainees being well received by
the plants and making a good impression on their hosts.
The first pot was started up in potline 1 on 28 March 1987
but it was only in May 1993 that an operating rate of
nearly 90% was achieved.
The first few years were challenging. In spite of the
early difficulties, NALCO and its environment slowly
began to ramp up, improving its performance and

growing steadily. Potline 3 started in 2002 without any

major hitch. In the early 2000s NALCOs three potlines
were operating at about 183kA with current efficiencies
of nearly 94% and an excellent lining service life of
roughly 100 months.
Apart from a few periods of tension, these results were
achieved steadily thanks to the confident, friendly
relations built up between NALCO and AP staff. They
represent a great success for both companies.
Courtesy of IHA Marc de Zlicourt
(Translatedfrom the French and edited by Aluminium Pechiney)

Updates from
around the globe
BSL
The magnetic compensation
loop delivers
As mentioned previously, BoyneSmelterLtd in
Queensland, Australia, has installed an AP compensation
loop on its potline 2, with a view toimproving the
magnetic stability of its Sumitomo pots to unlock
furtheramperage increases.
One year after it was energised, the compensation
loophas successfully stabilised the pots, allowing
anamperage creep of over 16kA (equivalent to more
than7% in productivity), while maintaining and
insome cases improving all other technical KPIs.

Boyne Smelter
07

AP Technology newsletter

Issue 19
March 2015

Updates from around the globe

Hindalco

Aditya and Mahan AP36 smelters in operation

In India, the Aditya and Mahan smelters have continued
adding pots throughout the year. However, coal availability
is posing a significant challenge for ongoing pot ramp-up
at the growing Mahan and Aditya smelters.
There are currently 230pots in operation in Mahan
and152pots in operation at the Aditya smelter. Both
smelters are operating at 363-365kA. Each smelter
willeventually consists of 360pots of AP36 technology
powered by adjacent coal-fired captive power plants.
The AP Technology anode baking furnaces of both
units have also been commissioned and Aditya has begun
supplying baked anodes to Hindalcos neighbouring
smelter in Hirakud.

Aditya

Sohar Aluminium
Full conversion to AP40 technology

Sohar Aluminium

Sohar Aluminium, in operation since 2008 with

AP35technology, reached an important milestone
inNovember 2014: all of its pots were converted to
theAP40 design, unlocking creeping potential of the
smelter up to 400,000 tonnes of production (more
than25,000 tonnes above 2013 production levels).
The next two years will see further modernisations and
improvements in the plant workshops to accompany

08

the amperage increase, such as installing a compensating

loop, replacing the anode baking furnace flue walls
andadding a vacuum to the vibroformer.
The AP Technology team will actively continue
tosupport Sohar Aluminium in the implementation
ofthenew equipment and during the transition
phasesto ensure the success of the project.

AP Technology newsletter

Issue 19
March 2015

Alcoa Deschambault
Upgrading its AP anode baking furnace
After more than 20 years of operation, Aluminerie deDeschambault is implementing the latest
APTechnology improvements to renovate its twoanode baking furnaces and increase their capacity.
The renovation involves raising the concrete casing andincreasing the pit width to accommodate
the baking oflarger anodes, which will meet the needsof the reductionprocess.
The first bay of the first furnace was successfully rebuilt in 2014 and thesecond bay rebuild
isscheduled for the first half of 2015.

EMAL
New energy consumption benchmark achieved by the
APTechnology anode baking furnace at EGA Taweelah
The commissioning of the AP Technology Anode Baking
Furnace at EGA Taweelah (EMAL) was completed in 2014.
With four fires and 68 sections, the furnace has a
benchmark capacity of 330kt/year of baked anodes.
The technical performance evaluation showed that another
benchmark was set by the furnace as it achieved an energy
consumption as low as 1.53GJ/tonne.
This is the result of AP design efficiency, AP process
control principles and the excellent standard of operations
maintained by the EGA teams.

09

AP Technology newsletter

Issue 19
March 2015

Sustainable solutions
Assessment of GHG emissions
AP Technology deploys a wide range of sustainable solutions and services
toits clients. Below is a focus on the assessment of Green House Gases (GHG)
emissions in a smelter. Different approaches may be used to evaluate
GHGemissions inaccordance with IAI standards.

Technology specific
slope and overvoltage
coefficients for the
calculation of PFC
emissions per tonne
aluminium from AE
process data

Technology

Slope coefficient b,c

[(kg PFC/tAl) /
(AE-Mins/cell-day)]

Overvoltage coefficient b,c,d,e

[(kg CF4/tAl) / (mV)]

Weight fraction C2F6/CF4

SCF4

Uncertainty
(%)

OVC

Uncertainty
(%)

FC2F6/CF4

Uncertainty
(%)

CWPB

0.143

1.16

24

0.121

11

SWPB

0.272

15

3.65

43

0.252

23

VSS

0.092

17

NR

NR

0.053

15

HSS

0.099

44

NR

NR

0.085

48

a. C
 entre Worked Prebake (CWPB), Side Worked Prebake (SWPB), Vertical Stud Sderberg (VSS), Horizontal Stud Sderberg (HSS).
b. S
 ource: Measurements reported to IAI, US EPA sponsored measurements and multiple site measurements.
c. E
 mbedded in each Slope and Overvoltage coefficient is an asumed ernissions collection efficiency as follows: CWPB 98%, SWPB
90%, VSS 85%, HSS 90%. These collection efficiencies have been assumed based on measured PFC collection fractions, measured
fluoride collection efficiencies and expert opinion.
d. T
 he noted coefficients reflect measurements made at some facilities recording positive overvoltage and others recording algebraic
overvoltage. No robust relationship has yet been established between positive and algebraic overvoltage. Positive overvoltage
should provide a better correlation with PFC emissions than algebraic overvoltage.
e. O
 vervoltage coefficients are not relevant (NR) to VSS and HSS technologies.

The Tier 2 approach is used when the plant/smelter does

not have all the process data and, more importantly,
when it has not measured its own Perfluorocarbon (PFC)
emission factors. The standard Tier 2 coefficients, valid
for a block of technologies (CWPB, SWPB, VSS, HSS),
areprovided in the IAI table above.
The Tier 3 approach is used when these data exist
andare known to the plant.
With such a method the CF4 emissions are considered
tobe proportional either to the anode effect positive over
voltage and current efficiency (over voltage method) or
to the frequency and duration of the anode effects (slope
method). In both cases the C2F6 emissions are considered
to be a fraction of the CF4 emissions. The slope method
is becoming preponderant in the industry today.

10

Coefficients are determined by means of a measurement

campaign at the gas treatment centre inlet using
Fourier transform infra-red (FTIR) spectroscopy.
The Tier 2 approach is correct and accepted but may
lead to an overestimation of the PFC emission. In Europe
the EUETS (EU Emissions Trading System) deployment
requires that the plant emission coefficients be reassessed
every three years. These coefficients are used to establish
the yearly inventory of GHG emissions, which determines
the amount the plant must pay for these emissions.
This is why some smelters are interested in a measurement
campaign and its subsequent data analysis to determine
their specific Tier 3 coefficients.
The LRF in France and ARDC in Qubec, Rio Tinto
Alcan's two R&D centres, are now equipped with
measurement equipment and are able, on request, to
undertake the measurement campaign and subsequent
data analysis to determine the Tier 3 emission factors.

AP Technology newsletter

Issue 19
March 2015

ALPSYS @ ALBA

The switching of Lines 4 and 5 to the latest ALPSYS

version took place at the beginning of 2015.

With this ALPSYS project, ALBA will be operating all its

potlines with the same ALPSYS system within a few months.
ALBA will be able to improve pot performance and
efficiency via the use of the latest ALPSYS developments
incorporated into the installed system. Synergies will
also be generated between the process teams of ALBAs
different potlines, creating opportunities to share technical
resources and standardise procedures across the entire
plant, despite the differences existing between five
potlines operating three different pot technologies.

The factory acceptance test of Line 1, 2 and 3 systems

was successfully performed in December 2014.

With this upgrade, ALBA will become the largest

smelter fully operating on ALPSYS systems.

Having launched the ALPSYS upgrade of

Line 5, Line 4 and Line 3 in 2013, ALBA
decided in 2014 to also implement the
ALPSYS upgrade on Lines 1 and 2.
The overall ALPSYS project is now well advanced:

ALPSYS
More than a product: an array of opportunities!
Over the last 15 years, the ALPSYS team has shown
unwavering determination in developing the product
inorder to deliver ongoing performance improvement
opportunities in process and operation.
On the heels of the R&D work performed over the past
few years, 2014 saw the completion and validation of our
latest alumina control algorithm. With the new version
of the alumina feed procedure including the high/low
frequency instability treatment, the improved tracking
conditions and a broadened alumina control range on
unstable pots, the ALPSYS system isproviding concrete
and robust solutions to sustain optimal pot operation in
increasingly demanding operating conditions, typically
found in plants that arelowering their ACD.
Alongside the development of control procedures, 2014
was also a very successful year in consolidating our

active customer base. More than 25potlines can now

benefit from these improvements through evolution
services provided to plants running any version of ALPSYS.
The second release of RADAR, our process intelligence
solution, has now been installed in two plants; two others
will start using it in 2015.
To address the growing challenges of ageing IT equipment
and operating systems faced by some ofourclients, we
can now propose a range of upgrade options that provide
aflexible approach to hardware obsolescence without
the need to launch a complete system upgrade.
The plants under maintenance have also relied on the
support of our AP Technology partner RTA Alesa for
the repair of, and the supply of spare parts for, ALPSYS
parts and equipment.

Plants benefit from support and key developments

% of ALPSYS controlled
production capacity

100%
80%
60%
40%
20%
0%
Robust Al203
control

RADAR

High/low
frequency instability

4A

Maintenance/
warranty

11

AP Technology newsletter

Issue 19
March 2015

MESAL
Breaking news

Kitimat

MESAL 4.0
MESAL 4.0 is now fully deployed at the Kitimat smelter, British Columbia. The last key user
training session was held in late January 2015. MESAL is now up and running, ready for Day 1
ofthe commissioning phase ofeach of the smelter shops. This will bring strong technical
monitoring to the teams in charge of the smelter ramp-up.

Operational Excellence for Reduction

In early January Dunkerque started to deploy the newMESAL Operational Excellence module
inthe reduction sector. This new enhancement of MESAL version 4.0 enables a complete
follow-up of the quality of the operation made on the pots. Precise identification of any on
thefield operation that does not completely follow the standard operating procedures is then
made. Upon deployment of corrective plans, anticipated progress is checked by the module.
Other installed functionalities such as Pot Tending Assembly (PTA) follow-up and PTA transfer
management lead to a full view of the operations inpotline areas.

MESAL for Alumina

As a result of a major initiative conducted in 2014 with the active involvement of Rio Tinto
Alcan Bauxite and Alumina R&D and Technology teams, the MESAL framework for alumina
refineries is now available. This new framework is known as the Manufacturing Excellence
System for Alumina.
ONE MESAL now makes management of technical information related to operation
andprocess possible for both refinery and smelter.

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AP Technology newsletter

Issue 19
March 2015

2015 begins with strong innovation

initiatives on theAPTechnology
ITsolutions
Internet of Things : use case
Rio Tinto Alcan successfully achieved proof of concept
(POC) to define a use case based on the innovative
use of advanced collaboration tools, particularly mobile
and related tools, for field players operators that
provide a simple and natural connection to their control
centre while they perform their usual activities in the
field. Ultimately this functionality will be integrated within
the Mobile MESAL extension.
The goal of this POC was to equip an operator with
glasses and a tablet that are both connected to the
plant network. While working in the shops, the operator
isable to:
Take HD photos and send them in real time
toanapplication used by process engineers.

Scan a text with the glasses or the tablet to gain

access to the description of the equipment and
identity as well as visualise KPI operation of the
equipment or a process of intervention related
totheequipment.
Start an accurate and appropriate dialogue (audio and
video) with a technician or process engineer to describe
a situation, define a way to fix an issue or request
additional information to validate a critical operation.
Another phase is now being studied to complement
thisfirst POC with other technology bricks including:

Collaborative tools
Mobility (smartphone, tablet)
Real time
Advanced processing data
Cloud and big data

MESAL mobility extension

Rio Tinto Alcan has designed a mobile app that enables
remote access to KPI follow-up for a dedicated area or
the full plant. This app is available for IOS and Android
devices (smartphone and tablet) through local Wi-Fi
infrastructure or via 3G/4G access.
This version will be deployed initially in Q2 2015 at the
Kitimat smelter and will then be available from S2 2015
for all regions.
The design of this MESAL extension allows access to
the KPI database of external systems such as ALPSYS
orother applications (ERP, SCADA, Historian, other
MESsystems, etc.). Our goal is to offer a single point
ofaccess to a plant KPI repository to provide the plant
management team with a global view of production
andoperations.

13

AP Technology newsletter

Issue 19
March 2015

AP60 and APXe

A dual technology pot solution sharing one single platform

AP60 pot

The AP60 and APXe technologies use the same optimised framework
(busbars, shell and superstructure) and operating equipment, while
anode assemblies, cathodes and linings, ventilation and gas flow
differ to suit the needs of each.
Feature

14

AP60

APXe

Busbar

Common

Shell

Common

Superstructure

Common

Alumina feeding device

Common

Anode assembly

High productivity

Low energy

Cathode and lining

High productivity

Low energy

Shell ventilation

High productivity

Low energy

Gas flow

High productivity

Low energy

Pot control system (ALPSYS)

Common

Equipment (pot tending

assemblies, vehicles, ladles)

Common

Building

Common

Operation

Common

AP Technology newsletter

Issue 19
March 2015

While Jonquires new AP60 smelter is proceeding

withthe validation steps for the AP60 technology under
industrial conditions, the LRF is focussing on the full
validation of the low energy consumption APXe pots.
Toreduce pot specific energy consumption, the APXe
pot has a significantly lower electrical resistance and
considerably reduced heat dissipated through the pots
external surfaces. The pot must be able to operate
stably with a low ACD, very long anodes and limited
bath volume.
Several versions of the APXe pot have been tested at
LRF since 2011. The target is to achieve a potline SEC
of 12.3DCkWh/kg, including all external voltage drops,
which means that the pot energy consumption itself must
be below 12.0DCkWh/kg. Following the start-up of
thenew Jonquire smelter, the last AP60 pots operating
atthe LRF had been stopped by the summer of 2014
and were restarted with the APXe pot design to validate
operation in the range of 500-520kA at 11.8-12.0kWh/kg.
The table below shows the initial results of the more
recent optimised versions. These are very encouraging,
with higher amperage, high current efficiency and
reduced SEC.

Unit

Last
5 months
2014

Amperage

kA

507.0

Current efficiency

94.5

kWh/tAl

12,240

Potline energy
consumption

By sharing the same platform as AP60, APXe automatically benefits from the industrial validation
of the key components of the pot technology implemented at Jonquire, such as the busbars,
the potshells, the pot superstructures (including gas collection), the alumina handling equipment,
the pot process control system and main operating equipment such as pot tending assemblies,
metal and anode transport vehicles. Full validation results from a combination of industrial
validation of AP60 at Jonquire and validation of APXe specific items tested on the pots operating
at the LRF.

AP60
Time
to market

APXe

1st generation
(Jonquire 2014)

2nd generation
(2015)

2015

Current (kA)

570

600

500

Pot production (t/d)

4.3

> 4.5

3.7

Specific potline energy

consumption (MWh/t)

13.3

< 13.0

12.3

15

AP Technology newsletter

Issue 19
March 2015

AP30 Club
A unique forum for AP30 users

Club Members
visiting Muscat

16

The 11th AP30 Club meeting was held from

1to4December in Muscat, Oman. This
meeting, co-organised by APTechnology
and Sohar Aluminium, was attended by
representatives of all theAP30 plants now
in operation acrossthe world, totalling
anannual productionof 6 million tonnes.

The wide range of topics covered in the technical

sessions illustrated the diversity of plant dynamics
resulting from difficulties faced during unusual
situations or challenges such as: power restrictions,
anode dust or spikes, environmental issues, future
anddevelopment plans, steep relining program, pot
tending machine operating load, willingness to go fast
inrestarting pots, whole smelter start-up as well as
improvement and change programmes.

This unique forum enabled AP30 users to share their

technical experiences with their peers, review their HSE
best practices and exchange on their specific process
and operational constraints, as well as share successes.

The technical sessions held in Muscat and the tour of

the Sohar Aluminium smelter in Sohar also gave AP30
Club members a glimpse of beautiful Oman.

The meeting in numbers: 15 AP30 smelters,

35permanent guests at the technical session,
18technical presentations and Q&A sessions.

The meeting provided a great opportunity for members

to build their networks, share the challenges faced by
respective smelters, identify areas for improvement and
generate new ideas.

AP Technology newsletter

Issue 19
March 2015

The AP Technology
smelter of the future
New concepts and solutions for the smart smelter

BAC

The roadmap for the Smelter of the Futureis built to integrate

breakthrough technologies and solutions in AP Technology
smelters as well as in other existing and future smelters, smoothly
andcontinuously, creating value for allstakeholders.
As an example, ECL is developing the BAC (Fully
Automated Anode Change) best in class anode change
solution in a fully automated sequence as part of our
Smelter of the Future approach. The BAC program
consists of several bricks (tool positioning, hood handling,
hammering sequence and ALPSYS/PTA interfacing),
each of which can deliver value independently. The full
automation also includes safety solutions for manmachine
interference. Pilot tests in real industrial conditions
started in 2014 at Jonquiere on the AP60potline.
Another example is MAX, our autonomous heavy load
transport concept. This project targets the development
of a single, lean, unmanned vehicle. The vehicle fleet
will be fully integrated with Level 1 and Level 2 systems.
It will improve flexibility, logistic fluidity and inventory
management as well as mitigate risks associated with
human driving. MAX will also contribute to the goals
of zero emissions and low maintenance costs.

MAX

17

AP Technology newsletter

Issue 19
March 2015

TMS 2015

Walt Disney World, Orlando, Florida

At the TMS Light Metals Conference in Orlando from 16 to 19 March,

RioTinto Alcan will present or sponsor nine presentations.
Our focus on environmental issues will be reflected
inthree presentations:
The first paper Solution to Reduce Fluoride Emissions
from Anode Butts deals with an innovative and in-house
solution of fully enclosing the butts in a bell after the
anode change, dramatically reducing both fluoride roof
emissions and operator exposure with a measured
efficiency of nearly 100%.
Another very innovative approach will be presented with
the paper Use of the Life Cycle Assessment methodology
to support sustainable aluminium production and
technology developments. Life Cycle Assessment (LCA)
methodology has emerged as a standardised reference
for assessing the comprehensive environmental impact

18

from any product or process, and is applied to all steps

related to the product/process life, from cradle to grave.
As a smelting technology supplier, Rio Tinto Alcan
isnow deploying a simplified approach based on LCA
principles. The paper illustrates how this philosophy
can be used to design and operate sustainable smelter
technology solutions in a systematic way.
The third paper will be presented by Five Solios Inc.
andis coauthored by Rio Tinto Alcan: it overviews Fives
most advanced and eco-designed scrubbing technology
built around the Ozeos scrubbing modules with
integrated reactors in the context of the start-up and
early operation of Arvida Aluminum Smelter, AP60
Technological Centre.

AP Technology newsletter

Issue 19
March 2015

In the carbon domain, a paper will be presented to

demonstrate our commitment to improve anode quality
inthe context of degrading coke quality. We have
developed a coke separation process based on coke
density to maintain and even improve anode quality.
High density particles are used in coarse fractions,
whereas low density particles are crushed and used
asfines. Use of the coke separator has resulted in an
increase of the baked anode density by 0.015g/cm.
Results from the first six years of operation are presented.

thechallenge to reduce dramatically the electrical

resistance of the cell by increasing the electrical
conductivity of various components, while simultaneously
lowering heat loss by reducing the thermal conductivity
of certain materials.

In the analytical technology domain, three papers

willbe presented:
Rotary flux injector: (RFI) Recent development
towards an autonomous technology
Production and certification of metallic certified
reference materials for the analysis of aluminium alloys
Improvements in LiMCA technology: Introducing
theLiMCA III
And finally, in the reduction area, we will present
twopapers:
The first paper is about the start-up of the 38 cells
ofthe Arvida Aluminum Smelter, AP60 Technological
Centre at the end of 2013. This successful start-up
has established a new benchmark for the primary metal
aluminum industry in terms of productivity, robustness,
environmental performance and CAPEX/OPEX benefits.
The second paper presents the 3D modelling
developments coupled with MHD and thermo-electrical
modelling achieved at our R&D centres (LRF in France
and ARDC in Quebec), applied to the AP40 and AP60
pots. These developments improve the pots robustness
and performances as recently demonstrated at the
Arvida AP60 smelter.
These two presentations in the reduction area are built
uponcommunications made in recent months:
At the Australasian conference in November 2014,
wepresented for the first time the successful start-up
ofthe new Arvida smelter using the first generation
ofAP60 pots. The APXe low energy cell, the low energy
version of AP60 operating successfully at the LRF (using
the same basic design of busbars, shell, superstructure
and operating equipment), was also presented, with

We used high performance measurement and modelling

tools to successfully develop a reliable and high
performance low energy cell. The pots at the LRF in France
are operated at low anode-to-cathode distance with
alow volume of bath, and at low pot gas suction while
maintaining a high level of environment performance.
TheAPXe cells are now operating in the range of 500 to
520kA with energy consumption as low as 12.3kWh/kg.
The object of the next stage of development of these
high amperage and low energy consumption cells is to
achieve 11.7kWh/kg by 2016.
We also presented an article at the JOM (Feb.2015)
about the historical development of the AP Technology
pot series starting with the AP13 in the 1960s. This
development was historically based on a three stage
pattern, the first one being the pot modelling, followed
by the pot prototype stage and then the industrial stage
which fully validated the technology. This development
pattern has proven to be successful since it has led to
the very robust AP Technology pot design generations.
AP60 is the latest in this series. The development of
APXe, which is the low energy version of AP60 operating
successfully at the LRF and is also presented in the
paper. In addition to this historical pot technology pathway,
APTechnology also addressed the need for continuous
and fast improvement of pot performances adapted
toeach existing client or site. To meet this need, a new
development methodology recently emerged thanks to
very high modelling capabilities. This methodology, based
on the validation of technology bricks, is presented
inthe last section of this article.

Learning from the past, dedicated to innovation

and looking decidedly to the future, that is the
mindset ofthe AP Technology team!

19

Technology sales department

725, rue Aristide Bergs BP 7
38341 Voreppe Cedex
France

Rio Tinto Alcan head office

1188 Sherbrooke Street West
Montreal, Quebec H3A 3G2
Canada

T +33 476 578 500

F +33 476 566 110

T +1 514 848 8000

F +1 514 848 8115

aptechnology.com

riotintoalcan.com

Mailing address
PO Box 6090
Montreal, Quebec H3C 3A7
Canada

At Rio Tinto Alcan, we are committed to ramping up smelter

productivity and driving down energy consumption. From AP40
to AP60 for unprecedented productivity and from AP50to APXe
for dramatically lower energy use, our APTechnology platforms
continue to break new ground.
Contacts
You can reach our APTechnology sales force at:
Bernard Allais
Ivan Bauret
Franois Charmier
Benoit Feve
Claude Ritter
Christian Staub

bernard.allais@riotinto.com
ivan.bauret@riotinto.com
francois.charmier@riotinto.com
benoit.feve@riotinto.com
claude.ritter@riotinto.com
christian.staub@riotinto.com

ALPSYS
Patrick Richard

patrick.richard@riotinto.com

MESAL
Pierre Trouiller

pierre.trouiller@riotinto.com

XX%

Design and production: tmdesign.ca

Printed in Canada
Rio Tinto Alcan

Visit our website at

aptechnology.com