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Whole Smelter PDF
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0.6
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970 °C
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Anode Anode + Over- + Over- + Over-
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voltages voltages voltages voltages
voltages
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R1 R2 R3 R4 R5 R6 R7 1.5 V R7 R20
IPD IPD IPD IPD IPD IPD
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4.0% 4.27 V
2.0% 4.17 V
4.40 cm 4.50 cm 4.60 cm 4.70 cm 4.80 cm 4.90 cm 5.00 cm 5.10 cm
Interpolar Distance [cm]
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Superheat [°C]
960 30
940 20
920 10
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Material Temp Amount Total H Total H
Al2O3 (Gamma) 50 °C 1 kg -4.5 kWh
In -393.1 kWh
Na3AlF6 (l) 960 °C 100 kg -388.6 kWh
Al2O3 (l) 950 °C 1 kg -4.0 kWh
Out -393.1 kWh
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955 30
950 20
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940 0
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Al Ca Sr Ba
Atomic Weight 27.0 g/mol 40.1 g/mol 87.6 g/mol 137.3 g/mol
C'-7
!##
6
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Mass(SrCO3 ) * Purity(SrCO3 ) * A W ( )
SrCO3
C'/7 MassBath =
Conc.after (Sr ) − Conc.before (Sr )
#
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965
XRF Pressed Tablet 2 Phase XRF Pressed Tablet 2
800 1360
Sr Conc.[ppm]
Liquidus Temp. [°C]
1320
Sr Conc.[ppm]
955 760
1280
720
945
1240
680 1,240 1,280 1,320 1,360
935 680 720 760 800
945 955 965 975
Sr Conc. Wet Chemical [ppm] Sr Conc. Wet Chemical [ppm]
Bath Temp. [°C]
) C'876
F'',.#
-J/,#.
-/E %
&
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C1$*/,.
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O4) '
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1,600 17.6
XRF Pallet 1
XRF Pallet 2
ICP Method
Pseudo Resistance
Strontium Concentration [ppm]
]
1,200 17.4
Pot Pseudo Resistance [
800 17.2
400 17.0
0 16.8
6.8.04 13:00 6.8.04 15:00 6.8.04 17:00 6.8.04 19:00
) C'C73
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C '
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1,000 14.0
Sr Concentration [ppm]
950 13.5
Excess AlF3 [wt %]
900 13.0
850 12.5
Sr (PPM)
ALF3+
800 12.0
8:00 AM 10:00 AM 12:00 PM 2:00 PM 4:00 PM
) C'D7
3
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2.5%
Standard Deviation per Hour [%]
2.0%
1.5%
1.0% Sr (PPM)
ALF3+
0.5%
0.0%
8:00 AM 10:00 AM 12:00 PM 2:00 PM 4:00 PM
) C'97
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5 /;EE
0 0.0
-5 -0.2
-10 -0.4
-15 -0.6
Sr (PPM)
ALF3+
-20 -0.8
8:00 AM 10:00 AM 12:00 PM 2:00 PM 4:00 PM
) C'E7
)*F5 /;EE
1600 11.0%
Sr-Concentration [ppm]
1200 9.0%
800 7.0%
Sr (PPM)
ALF3+
400 5.0%
20.09.04 23.09.04 26.09.04 29.09.04
) C'27
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Development Sr-Concentration
1400
1200
Sr-Concentration [ppm]
1000
800
600
0 50 100 150 200 250
Time Since Addition [h]
) C'-;7F
3
3
-** %
&
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1.6%
Sampling and Analysing Standarddeviation
1.2%
0.8%
0.4%
y = -2E-06x + 0.0059
0.0%
0 500 1000 1500 2000
Strontium Concentration in Bath [ppm]
) C'--7
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50 18
AlF3 [kg]
AlF3 [wt %]
Aluminium Fluoride Concentr ation [wt %]
40 16
Aluminium Fluoride Additions [kg]
30 14
20 12
10 10
0 8
25. Aug. 1. Sep. 8. Sep. 15. Sep. 22. Se p. 29. Sep.
) C'-*7)*
/;E8
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&
50 18
AlF3 [kg]
Soda Ash
30 14
20 12
10 10
0 8
25. Aug. 1. Sep. 8. Sep. 15. Sep. 22. Sep. 29. Sep.
) C'-87)*
/;ED
&'
5hi,-228.!
C'8'
Ð
GÉÊÊ55GG :ËÌÍ 555L :ÎÍ 55$:ËÌÏ Ñ ÒÓÔ
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990 900
Bath Transfer
Liquidus
980 Temperature 600
970 300
960 0
950 -300
940 -600
930 -900
25. Aug. 1. Sep. 8. Sep. 15. Sep. 22. Sep. 29. Sep.
) C'-C763:F 3
6
/;E8
) C'-C
) C'-D' !
!
' /;E8
!
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' M
! 1
-*E %
&
!
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/2
'
990 900
Bath Transfer
Liquidus
Temperature
980 600
970 300
Temperatures [°C]
950 -300
940 -600
930 -900
25. Aug. 1. Sep. 8. Sep. 15. Sep. 22. Sep. 29. Sep.
) C'-D763:F 3
6
/;ED
#
'
-*2 %
&
) C'-9
) C'/-
/;E8
/;ED'
1800 6,000
Sr ppm
Strontium Concentration [ppm] / AlF3 Content [kg]
AlF3 Content
Bath Inventory
1500 5,500
900 4,500
600 4,000
300 3,500
0 3,000
25-Aug-04 01-Sep-04 08-Sep-04 15-Sep-04 22-Sep-04 29-Sep-04
) C'-976:)*3&
3
/;E8
&
?
&,
.'/;E8
C#-;;1
8#D;; 1
!
*- '
&&,A
.
8#D;;1
C#*;;1/;E8
8#C;;1C#D;;1/;ED'/;ED
-8; %
&
+
!
!
'
!
A
' A
!
1
' "
!
,
) C'-E
) C'-2.#
A ! '
! !
'
2
Potline Amperage 160 kA
Superheat 10.0 °C
Ledge Thickness 0.062 m
) C'//
) C'/*
= , =
.
'
&&=
#
A'
! !1
#
!
+ '
!+
-8- %
&
,&.
3
Potline Amperage 160 kA
Superheat 9.6 °C
Ledge Thickness 0.068 m
!
;'*D !H
;'*E !H
!
'
-8/ %
&
0.40
na2o_r2
na2o_r1
0.36
0.34
0.32
0.30
25/ Aug/ 1/ Sep/ 8/ Sep/ 15/ Sep/ 22/ Sep/ 29/ Sep/
) C'/;7 /$
&&&#
#
'
#
!
' $
!
' ! !
&?
!
!
'
/;E8
) C'-C'
$
-D
-E
-'8
!
/;E8'&
!
-*
/;
C'88'8'1
!
+
;'8'=
!
) C'//
!
E
//
/;E8! '&
=
! ! #
!
' /;ED !
!
/;E8'
-8* %
&
1800 6,000
Sr ppm
Strontium Concentration [ppm] / AlF3 Content [kg] AlF3 Content
Bath Inventory
1500 5,500
900 4,500
600 4,000
300 3,500
0 3,000
25-Aug-04 01-Sep-04 08-Sep-04 15-Sep-04 22-Sep-04 29-Sep-04
) C'/-76:)*3&
3
/;ED
400 970
CVD
Liquidus
390 960
Cathode Voltage Drop [mV]
380 950
370 940
360 930
350 920
25/ Aug/ 1/ Sep/ 8/ Sep/ 15/ Sep/ 22/ Sep/ 29/ Sep/
) C'//7=
F /;E8
/;ED
) C'/*' 5
-88 %
&
/;E8
/;ED
=
' &
=?
D
# !
!
' ) =? !
+
//
'
400 970
CVD
Liquidus
390 960
Cathode Voltage Drop [mV]
370 940
360 930
350 920
25/ Aug/ 1/ Sep/ 8/ Sep/ 15/ Sep/ 22/ Sep/ 29/ Sep/
) C'/*7=
F /;ED
-8C %
&
19.0 0.12
Pseudo Resistance [μOhm]
Sr-Concentration [wt %]
18.0 0.08
17.5 0.06
17.0 0.04
16.5 0.02
16.0 0.00
00
00
00
00
0
0
:0
:0
:0
:0
:0
:0
0:
6:
0:
6:
12
18
12
18
12
18
04
04
04
04
04
04
04
04
4
7/
7/
7/
7/
/0
/0
7/
7/
7/
7/
1/
1/
2/
2/
/6
/6
1/
1/
2/
2/
30
30
) C'/87 4
3
/;-8
+
'
!C'D
) C'/C'
!-E';μΩ'
+
/8 !
-';D'D
'
!-EH'
!
3
!
!
!
) C'*'
!
3'
-8D %
&
7,000
6,500
Bath Inventory [kg]
6,000
5,500
5,000
1/7/04 1/7/04 2/7/04 2/7/04 2/7/04 2/7/04 3/7/04
12:00 18:00 0:00 6:00 12:00 18:00 0:00
) C'/C76&
/;-8
14.0%
Liquidus Temp. [°C]
965
Bath Temp. [°C]
955
13.5%
955 945
13.0%
9R2CDR2D*R
/8 !
-;; ='
' A
!
+
#
! +
'
)*
, .'
-8'-H-/'9H'-'8H
A-;H
'
-89 %
&
# )*
D; 1 99C 1 E*C 1'
'
!
3
#
8R2C2R
+/8 '
!
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!
'
!
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'
:
,
.
,
! .
'
+
!
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&
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!
!
!
')
3
!
'
!Y*;;#Y/;;#Y-;;#3-;;#3/;;
(*;;='!+ !'
6
#
3
!
!
' +
)
C'/9
) C'/E' !
! #
: #
#
'
!
' ! 3
!
! '8E
!
+
3
'&
!
!+
!@
' !
'
-8E %
&
1,200 3.0
800 2.0
y = -0.5%x y = 4.28x
R² = 64.1% R² = 0.98
Delta Bath Inventory [kg]
0 0.0
-500 -400 -300 -200 -100 0 100 200 300
-400 -1.0
y = -1.2%x
y = 1.52x
R² = 79.5%
R² = 0.97
-800 -2.0
Bath Volume
-1,200 -3.0
AlF3 Concentration Delta Voltage [mV]
) C'/97 =%
6&
-82 %
&
Temperature 30
Liquidus y = 0.11x
R² = 0.98
Delta Temperature [°C] 20
10
y = 0.07x
R² = 0.89
0
-500 -400 -300 -200 -100 0 100 200 300
-10
y = 0.04x
R² = 0.86
-20
y = 0.08x
R² = 0.86
-30
Delta Voltage [mV]
) C'/E7 =%
6
'
!
+ )*
'
)*
'
C#;;;1!
+
-*'C !H# 8/E 1:-;;=
EH !
-'/ !H:-;;=
2H
'
*H
8H
+
-;;=
'
-C; %
&
1,000 14.5
900 14.0
Sr Concentration [ppm]
700 13.0
Sr (PPM)
ALF3+
600 12.5
8:00 AM 10:00 AM 12:00 PM 2:00 PM 4:00 PM
) C'/273
)*3
)
&
#!
+
Y:3;'C
!H'
!
#
#
+
'
!
'
!
8#*;;1
+
'
965 4.0%
Bath Temperature
Bath- Liquidus Temperature [°C]
960 3.5%
Al2O3 [wt%]
955 3.0%
Al2O3
950 2.5%
Liquidus
945 2.0%
8:00 10:00 12:00 14:00 16:00
) C'*;763
F
)
17.5 965
Bath Temperature
17.0 960
Pseudo Resistance [μΩ ]
Temperature [°C]
16.5 955
Resistance
16.0 950
15.5 945
Liquidus
15.0 940
8:00 10:00 12:00 14:00 16:00 18:00
) C'*-763
F
/;2;
!
) C'** /$* ,F $+
3
.
)* ,O4.# ! ! '
#
'
#
1
3
!
'
1
) C'**#)*
-';!H-/';!H--';!H
A
--';!H-/';!H@
'
3
!
'
-C* %
&
40 5,200
Superheat
Bath Inventory
30 5,000
20 4,800
10 4,600
0 4,400
8:00 10:00 12:00 14:00 16:00 18:00
) C'*/76&
/;2;
13% 6%
Al2O3
12% 4%
AlF3
11% 2%
10% 0%
8:00 10:00 12:00 14:00 16:00 18:00
) C'**7
3
)*3
/;2;
-C8 %
&
' A
600 300
AlF3
400 200
Al2O3
200 100
0 0
8:00 10:00 12:00 14:00 16:00 18:00
) C'*C' !
*'-
')*
)/!
O4 !
!
! F +
'
! !5 3$3'
#
*'C !H#
!
2C- R' "
#
'
C'D !H
! 8 R
'
A
# *';(*'C!H'
-'D!H
!8R!
'
-CC %
&
6.0% 965
Al2O3
Liq. calc.
Liq. meas.
5.0% 960
4.0% 955
3.0% 950
2.0% 945
1.0% 940
8:00 10:00 12:00 14:00 16:00 18:00
) C'*C7% ' F
/$*
'/;2;
-CD %
&
17.0
μΩ]
Pseudo Resistance [μΩ
μΩ 16.8
16.6
16.4
16.2
16.0
1.0% 2.0% 3.0% 4.0% 5.0% 6.0%
Alumina Concentration (Leco)
) C'*D7 34
'
/;2;
16.6
16.4
μΩ]
Pseudo Resistance [μΩ
μΩ
16.2
16.0
15.8
15.6
1.0% 2.0% 3.0% 4.0% 5.0% 6.0%
Alumina Concentration (Leco)
) C'*97 34
'
/;2/
-C9 %
&
40 5,200
Superheat
Bath Inventory
30 5,050
20 4,900
10 4,750
0 4,600
8:00 10:00 12:00 14:00 16:00 18:00
) C'*E76&
/;2/
+
!+!!
'&!
1
!
! 1
!
'
!
1
'&+
1
?
'
-CE %
&
!
! !
3
!
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,
.
!
1'!
!
1
'5
1
1#
'
1
#
1
1 A
'
' F!
! '
+'
'
'
F!
1
3
?
'
'
3
#
!
!
'
1
'F
!
!
'
!
'
-C2 %
&
-D; %
&
-
-
-
'
-D- %
&
&
#
!#
'
) D'-7
!%
=
-D/ %
&
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+
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'
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) D'*'
5
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.
'$
'/
'*
'
') D'/!
+
--#-/
-*'
1
-D
'
'--
C
-D* %
&
!
#! !'
' -/
*
D
!'
'-* !
C,
!
.'
) D'/76'F
) D'*7!
F
%
F
+
'!
!
/
/
$
/;;8' !
+
'
- -8
!
+
!
'
/,
.
C,
.'
$
-;!
!
'5
#
!
'
-D8 %
&
970 16
14 14
13
960 12 12
11
Bath Temp. [°C]
10 10 10
9
950 8 8
7
6 6
5
940 4 4
3
2 2
1
930 0
$
#
'
-; R !
'
)
D
'
!!!
/'
!
'
9*(*( ) % )
4
!
'
!
) D'C'
'
13
!
3 '!
'
-DC %
&
600
Anode Height [mm]
500
400
300
200 Outside
100
Inside
0
9 9 5 5 11 11 3 13 13 7 7 1 1
Inside
2 10 10 14 14 6 6 8 8 4 4 12 12 Outside
) D'C7474
965 955
Liquidus Temp. [°C]
Bath Temp. [°C]
960 950
Outside Outside
955 945
Inside Inside
950 940
9 9 5 5 11 11 3 13 13 7 7 1 1 9 9 5 5 11 11 3 13 13 7 7 1 1
2 10 10 14 14 6 6 8 8 4 4 12 12 2 10 10 14 14 6 6 8 8 4 4 12 12
) D'D76,.
F ,. 4
'
#
D
1
'
) D'9' &
#
D
,3 8R.
+
'$
#
-/
*R
#
3
!
'
-'ER'
4
Temperature Deviation from Average [°C]
-1
-2
-3
-4
1
10
11
12
13
14
) D'97
63 4
4
9*(*+ ) %
46,) D'E.!
'
' $
'
+ *;
!
@
/-; '
3
'
-D9 %
&
600
Anode Height [mm]
500
400
300
200 Outside
100
Inside
0
7 6 6 5 5 4 4 3 3 2 2 1 1
Inside
14 13 13 12 12 11 11 10 10 9 9 8 8 Outside
) D'E7467&
!
965 955
Liquidus Temp. [°C]
Bath Temp. [°C]
960 950
Outside Outside
955 945
Inside Inside
950 940
7 6 6 5 5 4 4 3 3 2 2 1 1 7 6 6 5 5 4 4 3 3 2 2 1 1
14 13 13 12 12 11 11 10 10 9 9 8 8 14 13 13 12 12 11 11 10 10 9 9 8 8
) D'276,.
F ,. 46
) D'2'
3
' 6
#
!'
'
!
) D'-;' "3
' !
8
--#!
-DE %
&
4
Bath Temp. Deviation from Average [°C]
-1
-2
-3
-4
10
11
12
13
14
1
) D'-;7
63 4
46
600
Anode Height [mm]
500
400
300
200 Outside
100
Inside
0
12 12 1 1 3 3 5 5 7 7 9 9 11 Inside
2 2 4 4 6 6 8 8 10 10 11 13 13 Outside
) D'--747&
-D2 %
&
970 957
965 952
Outside Outside
960 947
Inside Inside
955 942
12 12 1 1 3 3 5 5 7 7 9 9 11 12 12 1 1 3 3 5 5 7 7 9 9 11
2 2 4 4 6 6 8 8 10 10 11 13 13 2 2 4 4 6 6 8 8 10 10 11 13 13
) D'-/76,.
F ,. 4
4
Bath Temp. Deviation from Average [°C]
-1
-2
-3
-4
1
10
11
12
13
) D'-*7
63 4
4
-9; %
&
'"
#
'
100%
AC Rota 1
AC Rota 2
AC Rota 3 600
75% 300
200 Outside
Percentage of Pots [%]
100
Inside
0
7 6 6 5 5 4 4 3 3 2 2 1 1
14 13 13 12 12 11 11 10 10 9 9 8 8
92.3
93.6
50% 600 95.1
Anode Height [mm]
500
400
300
200 Outside
600
100
2 2 4 4 6 6 8 8 10 10 11 13 13 Outside 300
200 Outside
100
Inside
0
9 9 5 5 11 11 3 13 13 7 7 1 1
2 10 10 14 14 6 6 8 8 4 4 12 12
25%
0%
86% 88% 90% 92% 94% 96% 98% 100%
Current Efficiency [%]
) D'-87
4
) D'-8
' $
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3+'C;H
-,
.
2C'/H!
2C'-H'
4 / ,
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-9C %
&
Cryolite Cryolite
Enters Bath Enters Bath
'
1
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#-22EX
'#/;;-.'
-9D %
&
236+
#
-99 %
&
¨ reliable measurements
are important
) 9'/7 *)D()*,!/'CH/$*
8'CH)/.
) 9'*726+
-9E %
&
7 3 )* !
,8
.(
'
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23
+ +
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,6+C.
!1
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@
6+C'
-92 %
&
A lF 3 - c o n s u m p tio n in A lF 3 k g /m t re la tive
Na2O + CaO + F E m is s io n s 2 0 .0 kg /m t A l 100%
N a (a lu m in a ) 1 0 .2 kg /m t A l 51%
HF C a (a lu m in a ) 0 .6 kg /m t A l 3%
X 's A lF 3 (b a th ) 1 .8 kg /m t A l 9%
Na
N a to C a th o d e -5 .0 kg /m t A l -2 5 %
F (a lu m in a ) -1 9 .6 kg /m t A l -9 8 %
Net 8 .0 k g /m t A l
) 9'87)
)*
) 9'8
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+' "
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100 kg 967 °C
A: 90 D ays m a B: Na2O C om pensation C: Extra Additions
AlF3 Additions Liquidus 4 D ays m a
80 kg 957 °C
60 kg 947 °C
40 kg 937 °C
20 kg 927 °C
0 kg 917 °C
-20 kg 907 °C
2.
2.
2.
2.
2.
2.
2.
3.
3.
3.
3.
3.
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
01
05
09
13
17
21
25
01
05
09
13
17
) 9'C7
)
>*-*" #
6 236+
#
#
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&
#
1-;-/
'
970 30
Bath & Liquidus Temperature [°C]
Anode 17
Set
960 25
Superheat [°C]
950 20
940 15
930 10
Bath Temp.
920 5
Liquidus
Superheat
910 0
07:30
08:30
09:30
10:30
11:30
12:30
13:30
14:30
15:30
16:30
17:30
18:30
19:30
) 9'D7
Time to
Pot Anode Change
recover
2066 17 10 hours
2067 17 12 hours
2053 12 + 4 8 hours
2055 12 + 4 10 hours
9'-7
+
9'- ! +
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1 -/
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1
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6
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9-Box Control
activ
2C';
28';
$
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Gas Flow HF Concentration
Gas Flow HF [mg/m³]
Fluorination Cake
Fluoride [wt %]
4 2
2 1
0 0
-10 -8 -6 -4 -2 0
Filter Cake Thickness [mm]
5)
1
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R
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60 mBar
R1 R2 R3 R4 R5 R6 R20
filter filter filter filter filter filter 25 - 40 mBar filter
R 15 - 20 mBar
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Pots
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1,800,000
1,600,000
1,500,000
1,400,000
2
R = 0.8143
1,300,000
55 60 65 70 75 80 85 90 95
Offgas Temperature [°C]
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2.0
1.5
1.0
0.5
0.0
2
R2
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6
+
1
8
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3
10
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12
7
14
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16
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9
18
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11
20
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13
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19
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100% 100%
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40% 40%
20% 20%
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8 10 4 11 18 12 14 3 15 19 2 6 17 7 13 1 20 16 5 9
Filter Unit Number
5)
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11
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HF Concentration [mg/m³]
Reduce Fresh Alumina by 25 %
0.6
0.4
0.2
4:00 PM 5:00 PM 6:00 PM 7:00 PM 8:00 PM 9:00 PM
#
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HF Concentration [mg/m³]
0.6
0.4
Increase Recycled Alumina Flow
0.2
2:00 PM 2:30 PM 3:00 PM 3:30 PM
1 1
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0.6 2.0
0.4 1.8
0.2 1.6
8:00 AM 10:00 AM 12:00 PM 2:00 PM 4:00 PM
//C %
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75 1.6
Volume Flow
Volume Flow Rate [x1000 Nm³/h]
Filter Pressure Drop [mbar]
HF Concentration [mg/m³]
65 1.2
HF Concentration
55 0.8
45 0.4
Pressure Drop DP
35 0
PM
PM
PM
PM
PM
PM
PM
44
00
16
32
48
04
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2003
2004
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HF Concentration [mg/m³]
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Alumina in Dry Scrubber
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4%
75%
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2003 2004 2005
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Fresh Alumina:
Roof Na2O: 0.38 wt % Stack
Dry Scrubber
Fluoride: 1.91 kg/mt Al
Cryolite: 1.07 kg/mt Al
Enriched Alumina:
93 % Normal 7 % High Purity Fluoride: 26.67 kg per mt Al
Pot (EA) Pot (FA) Cryolite: 14.80 kg per mt Al
Na2O: 7.32 kg per mt Al
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Pot Age [Days)
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X-Ray Source
X-Ray Spectrum
Signal Processing
Detector
PC
Incident
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Fluorescent
X-Rays Results
Sample
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Solid state detectors have prevailed for the secondary X-rays measurement. In
particular, Si(Li) and HPGe detectors, operating under liquid nitrogen temperature, are
most commonly being used due to their high resolution. In recent years, the
development in semiconductors technology has furnished a number of small sized,
thermoelectrically cooled (Peltier effect) detectors, such as HgI2, Si-PIN, Si-DRIFT and
CdZnTe. Although their resolution is inferior to that of Si(Li) and HPGe crystals, their
convenient size and cooling requirements have rendered them popular in portable XRF
equipment.
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