INDUSTRIAL producers in all sectors nowadays aim to reduce their energy consumption.
EPIQ Machinery, an equipment solutions provider, knows how it can affect results and profitability of its primary aluminium producer customers.
High energy costs and variable metals prices have forced them to adapt their processes. One being that since 2003, anode sizes have grown significantly, resulting in larger carbon blocks and surfaces, and electrolysis gas resistance results in energy losses and reduced performance.
Over the last decades, studies have shown that moulded or slotted anodes can improve pot conductivity. However, there are significant advantages to lean towards slotted anodes compared to the moulded ones.
Early anode slot cutting machines (ASCM) were typically set up in a conventional cutting configuration, which was and is better for machine start-up and tool life. Machine operators prefer conventional cutting for rough cuts that do not require a surface polish or precise tolerance.
Slotting anode alleviates thermal stress and limits cracking. It reduces electrical cell resistance and improves pot stability by allowing continually produced gas to escape. Slots also reduce aluminium production power usage. Slotsâ depth ensures that benefits last throughout anode life, whereas slotsâ narrow width decreases carbon removal and increases cycle duration.
Most aluminium companies who explore slot cutting for their operating facilities establish a business case that shows the efficiency, environmental and cost reductions outweigh the CAPEX and OPEX expenses.
The depth of slots can decrease voltage losses across pots, resulting in lower energy expenses, or enhance amperage, hence boosting the production of aluminium.
For those practising anode slot cutting, equipment manufacturers, such as EPIQ Machinery, were challenged to narrow and deepen the slots for a longer life. Climb milling comes into play offering narrower slot width along with a maximum slot depth.
The current generation of ASCM systems with climb milling technology can cut deeper and thinner slots in various geometries, including interrupted slots. Existing machines from the early 2000s may be able to be converted to climb milling to get deeper slots.
Any ASCM upgrade can incorporate high-level self-diagnostics, predictive maintenance and remote monitoring for alarm/abnormal conditions. This lets operators monitor equipment performance and predict blade and other faults.
When upgrading an ASCM from conventional to climb milling, incorporating Industry 4.0 technologies can reduce OPEX costs, boost uptime, and improve productivity. This can optimise machine performance and provide maintenance features for predictive fault finding. Anode slots have demonstrated significant economic advantages and long-lasting deep slots increase anodesâ cycle lifetime which is a significant added value.
In conclusion:
The industry trend of deepening and narrowing slots aims to optimise productivity, financial and environmental performance in aluminium production.
Sawing slots instead of creating them in anodes enables deeper slots.
When narrow slots are requested, climb milling is favoured over conventional cutting.
While climb milling is tougher in demanding applications, the process and technology are now well-established in the market.
Converting a traditional cutting process to climb milling can improve slot cutting practices and provide a profitable business case for existing smelters.
The return on investment is less than two years based on energy savings and less than one year if the project has infrastructure to improve aluminium throughput.
The type of objectives the EPIQ team likes to obtain for its customers: greater outputs, energy costs savings and greener production processes.
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