Module#1 Production of alumina

This modeule covers the basics of aluminium oxides, processing of Aluminium minerals, alumina
manufacturturing process, overview of the Bayer Alumina refinery (digestion, clarification, precipitation,
calcination), alumina microstructure, impurities and production of speciality aluminas.

Module#2 Production of primary aluminium

This covers basics of primary aluminum (alumina and aluminum), raw materials for aluminium production
process (bauxire, electric power), carbon anode energy efficiency, electro;yte materials (ionic structure of the
melt, electrolyre), cathode and cathode material, currnet efficiency (energy consumption helat balance, cell
amperage,increase (magneto hydrodymnamic, cell line (cell operation), inert anode and overview of the past
presetn and future primary alumium production process.

Module#3 Production of secondary aluminium

This module deals with the History of secondary aluminium, sources of raw materials (New production off-

cuts, post consumer scrap, swarf, dross) processing (sorting, baling and shearing, shredding,
drying and de-coating, milling and screening, melting and alloying), cost drivers and future trends

Module#4 Principles of aluminium Electrolysis

This module covers electrolysis cell or pot (potline, electrolyre or bath), chemical notaion,decompsosition and
deposition potential, chemical eequillibrium, ionic structure of bath, dissolution of Alumina, electrode reaction,
boundary layer, anode reaction, cell voltage, current efficiency, magnetics, anode effect.

Module#4 Bath Properties

This module broadly covers solubility of aluminiun in cryolite melts, structure of alumnia dissolved in cryolite melt,
dissolved metals in cyrolite melt, electrical conductivity of cryolite melt, unconventionla bath.

Module#5 Anode effect mechanism

This module will review and anlyse the anode effect inaluminum electrolysis, analysing anode effect by
radiography, anode effect in aluminiunm electrlysis, critical current densities, voltammetric investigations,
mechanism of the anode effect, control strtegies for anode effcet, anodic overpotentials in the electrolysis of
alumina.

Module#6 Components of Cell Voltage

This module deals with the determination of cell voltage components, equilibrium potential, activity of
alumina, voltage equivalent of energy of aluminum production, measurement of overvoltage’s, overvoltage,
concentration overvoltage at the anode, surface overvoltage al anode, bubble overvoltage, voltage
calculations, concentration overvoltage at the cathode, application to cell control, caveats

Module#7 Thermodynamics

The thermodynamics aspects of electrochemical reduction of alumina basically the cell voltage, reversible
potential, activity of alumina, energy efficiency.

Module#8 Current efficiency

This module deals with the interaction between mass transfer control of current efficiency, dynamic
energy balance, cell current efficiency, effect of process variables.

Module#9 Sludge In Operating Aluminum Smelting Cells

The operation of smelter cells requires sludge sampling, understanding sludge main phases, aluminum
carbide in sludge, sludge eutectic temperature, sludge electrical conductivity, slugging in an operating cell,
sludge influence on cathode wear, sludge effect on the current distribution sludge and aluminum carbide

Module#10 Process Control

this module deal with the pot line control strategy, critical operating variables (bath temperature, bath
composition cathode voltage drop and cathode surface condition), instability, metal and bath heights,
alumina content in the bath, metal purity, liquid bath and metal quantities, pot line target resistance,
adjustment of pot line amperage, automatic process control parameters, potline heat balance

Adapted from

1. Bearne, G., Dupuis, M., & Tarcy, G. (Eds.). (2017). Essential Readings in Light
Metals, Volume 2, Aluminum Reduction Technology. Springer.

2. Lumley, R. (Ed.). (2010). Fundamentals of aluminium metallurgy: production,

processing and applications. Elsevier.