УДК 669.

71
ББК 65.9 (2Р5) + 65.9 (2) 305.5
А 59

Edited by Professor Peter V. Polyakov

Issuing Officer: Marina Moiseyeva

А 59 Aluminium of Siberia – 2008: Proceedings / Krasnoyarsk: «Verso», 2008

Proceedings contain the materials of the XIV International Conference «Aluminium of

Siberia – 2008». They consist of the five parts: «Aluminium Reduction Technology», «Casting
and Secondary Aluminium Processing», «Alumina Production», «Ecology, labour protection,
waste processing», «Science and technology news». Each part includes the information about
the recent technical solutions and the latest developments in global aluminium industry.

The volume is intended for the experts of aluminium industry.

ISBN 5 - 85981 - 122 - 5

The reports maintain

the author's style © STC «Light metals», 2008
 ALUMINIUM OF SIBERIA – 2008. Edited by P.V. Polyakov. STC «Light мetals».

CONTENTS
Greeting . ........................................................................................................................ 3
Peter Polyakov
To the memory of Warren Haupin......................................................................................... 4
J. Johnson, P. Polyakov
90 th anniversary of Professor Mikhail Mikhailovich Vetyukov ................................................. 5
R.A. Mirzoev, P.V. Polyakov
Glory To The Hero of The Anniversary!................................................................................. 7

PART I. ALUMINIUM REDUCTION TECHNOLOGY

 Optimization of Cold Paste Ramming for Aluminium Electrolysis Cells By Means....................10

of Choice of Composition Elements and Recire
I.V. Rybyanetz, G.D. Apalkova, N.P. Nonishneva, С.K. Otroshenko

 Influence of Technological and Design Parameters on Cathode Bottom Integrity .....................12

at Electric and Flame Preheating
A.G. Arkhipov, P.V. Polyakov

 Influence of Durable Freezing on The Contact Between Cold Ramming Paste and Bottom Blocks... 28
G.M. Mikhailyuk, M.J. Babkin, O.V. Makovetskaya-Abramova

 Al-Cu Bimetal Produced By Explosive Welding for Current Conducting Units of Electrolysis Cells.31
A.Z. Bogunov, A.A. Kuzovnikov, E.N. Levaya, R.V. Valyntsev

 Global Tendencies and Experience In Arrangement of Service . ............................................ 37

of Processing Equipment at Metallurgical Enterprises of Russia
V. Bodrov

 Operation Efficiency Improvement of Graphization Furnaces By Means.................................41

of Development of Thermal Insulation
V.A. Vedin, S.K. Otroshchenko, V.I. Pirogov
 Negative Temperature Effect on Operating Characteristics ........................................................ 44
of Compacted Cold-Packed Bottom Paste
G.D. Vergazova

 Russian Automation System for Electrolysis and Raw Material Transport............................... 53

A.N. Kuptsov, P.A. Demykin, N.A. Galov, S.V. Tepikin

 The Use of Simulation Techniques for The Analysis of Production Processes and Systems.......... 56
А.G. Andreeva, А.B. Gladkikh, S.А. Esikov, L.А. Kukharyova, К.N. Parakhnevich

 Aluminum-Steel Electric Transition Joints,Effects of TemperatUre and Time .......................... 62

Upon Mechanical and Electrical Properties
D. Gauthier

 Deterioration of the Bottom Lining in Aluminium Reduction Cells ...................................... 69

Part I: Chemical Equilibria at 1100 K
A. Solheim, C. Schøning

 Deterioration of the Bottom Lining in Aluminium Reduction Cells .......................................76

Part II: Laboratory Data and Autopsies
C. Schøning, A. Solheim, E. Skybakmoen

 Implementation of Application Software for Electrolysis Technology Management.................... 83

А.А. Gridnev, V.G. Kostetskii, I.V. Kurilkin, V.V. ErosHchenkov

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 ALUMINIUM OF SIBERIA – 2008. Edited by P.V. Polyakov. STC «Light мetals».

 Application of Electrolysis Technology Statistical Monitoring and Analysis System ................. 86

to JSC «RUSAL Krasnoyarsk»
А.Е. Gridnev, Е.А. Sorokin, V.V. Eroshchenkov, N.N. Pitertsev, I.V. Kurilkin

 New Generation of Moeller Direct Pot Feeding System for A Smooth and Continuous.............. 94
Pneumatic Alumina Feed To The Electrolyte Cells
C. Duwe

 Laboratory Test of Vibrocompactor and Optimization of Anode Blocks ................................. 95

Vibrocompacting Parameters
S.S. Zhuchkov, Yu.A. Frantsev, N.N. Guryev, A.A. ChromoV, M.Yu. Perminov, S.A. Khramenko

 Modernization of Electrode Production Process Equipment................................................. 100

Eu.P. Kontsur, A.N. Kuptsov, V.V. Kirichenko

 Development and Application of Numerical Methods To Improve Aluminium Production.......... 102

V. Knizhnik

 Mechanism of Metal Agitation Initialization In Aluminium Cell.......................................... 105

A.V. Knizhnik, V.G. Grigoriev, A.A. Kuzakov

 Experience and Problems of Technology Masteringof Automated Alumina Feeding for Cells .... 109
with Self-Baking Anodes
V.А. Kryukovsky, P.V. PolyakoV, Е.N. Panov, М.P. Petukhov
The Graphitic Grade: A Performing But Too often Unknown Solution for Cathodes Linings........ 114
L. Rivoaland, S. Lacroix

 Some Ways to Increase Productivity of Existing Coke Calciners.......................................... 120

I.I. Lapaev, M.I. Krak, M.V. Golubev, A.D. Arnautov

 Study of Anode Effect In Industrial Cells........................................................................ 123

V.А. Lebedev, N.V. Yeltsov, О.G. Moiseyev, А.N. Palshin

 Physical Processes Modern Investigation Methods in Power-Intensive Industrial Equipments.... 124

E.N. Panov, A.Ya. Karvatsky, I.L. ShIlovich, G.N. Vasilchenko, T.B. Shilovich,
S.V. Leleka, S.V. Danilenko, V.V. Bilko, I.V. Pulinets, A.N. Chyzh

 Modernization of Cathode Assembly in Increased Amperage Soderberg Cell (185 kA) ............. 133
and Lowered Metal Level (25 cm)
I.Yu. Patrakhin, А.V. Popov, V.K. Frizorger, D.V. Tkachenko,
G.V.Arkhipov, Yu.A. Popov, V.V. Pingin

 Investigation of Thermal Destruction of Bottom Blocks for Aluminium Electrolysis Cells......... 137
С.K. Otroshenko, V.I. Pirigov, G. D. Apalkova, V.A. Vedin

 Pneumotronics in the Aluminium Industry....................................................................... 139

B.V. Pogorelov

 Essay of Usage of a Pitch with Higher Softening Temperature ............................................... 141

for Prebaked Anode Manufacturing
V.M. Polovnikov, I.V. Cherskih, E.A. Startsev

 Analysis of Thermal Insulation Properties of Materials Based on Vermiculite ........................ 148

of The Tatar Deposit
G.E. Nagibin, A.V. Proshkin, A.A. Levchenko, M.M. Kolosova,
A.G. Sbitnev, O.A. Rezinkina, A.Yu. Vshivkov

 Integrated Functionality with Advanced Crust Breaking Technology.................................... 154

P. Resmalm, P. Pålsson

 Estimation Method of Alumina Quality Effect on Technological State of a Cell.................... 156

О.О. Rodnov, V.N. Damov, Т.D. Pecherskaya, I.А. Kalachev, V.Ju. Buzunov

 Fuzzy Logic Application for AAFS Control...................................................................... 161

A.G. Rubtsov, C.F. Nikandrov, Ye.R. Shaidulin

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 ALUMINIUM OF SIBERIA – 2008. Edited by P.V. Polyakov. STC «Light мetals».

 Estimation of Permissible Current for Bottom Blocks......................................................... 165

G.M. Mikhailyuk, M.J. Babkin, O.V. Makovetskaya-Abramova, V.A. Sergeev

 Interaction Between The Cathode Metal Velocity Field and Cell Sludge ............................... 169
on 300 kA Amperage. Bath-Metal Interface........................................................................169
O.V. Sluchenkov, P.V. Polyakov, S.I. Akhmetov, A.G. Arkhipov

 Implementation of Graphical Description Methods of Processes in Aluminum Production......... 179

А.А. Soldatov, А.Е. Gridnev, V.А. Kolychev
Efficiency Improvement of Anode Lifting Mechanism of Aluminium Cell.................................. 186
L.N. Bagdasarov, V.V. Nelyubin

 Examination of Physical and Mechanical Properties of Relining Materials............................. 187

Before and After Operation
A.M. Ivanova, V.C. Timofeyev, D.Y. Nikitenko

 Technology of Colloid Anode Paste for Soderberg Anode.................................................... 194

V.K. Frizorger, C.A. Khramenko, A.N. Anushenkov, M.I. Krak, N.N. Gurjev,
E.N. Marakushina, P.M. Salamatova, A.A. Khromov, M.V. Golubev, A.A. Zabaluev

 Role of Anode Stud in Anode Technology ....................................................................... 198

I.V. Cherskikh, V.M. Polovnikov, O.E. Levi
 Laboratory System for Electrolyte Composition X-Ray Analysis...........................................203
I.S. Yakimov, P.S. Dubinin, A.N. Zaloga, O.E. Piksina,
S.D. Kirik, S.G. Ruzhnikov, A.F. Shimanskiy, M.A. Ozerskiy

 Condition Specification of The formation Ca–containing Crystalline Phases .........................206

in Cooled Electrolyte Samples
Y.N. Zaytseva, E.N. Lyndina, I.S. Yakimov, S.D. Kirik

 Evolution of Automated Alumina and Fluorides Feeding Systems, ....................................... 212

Centralized Alumina Feeding Systems on 300M1 Prebake Cells
A.N. Palshin, V.A. Lebedev, S.V. Tepikin

PART II. CASTING AND SECONDARY ALUMINIUM PROCESSING

 Quality Management System for Aluminum Production . ................................................... 222

D.A. Yegorov, V.F. Schwarzkopf

 Implementation of Methodology of Management Plan In Foundry of JSC «RUSAL Krasnoyarsk».223

I.М. Sergienko, А.Е. Gridnev, V.F. Drozdov

 Magneto-Hydrodynamic Technologies of Refining and Production of Aluminium ................... 227

Alloys In Conveying Ladles
R.M. Khristinich

 Modern Furnaces for Aluminum Scrap Recycling.............................................................. 232

K. Boeckenhauer, T. Kaczmarczyk

 Heat Exchanger and Low-Nox Burner Design for 30 t Aluminium Melting Furnace ...............238
Optimization: ESA H-EX6000 and ENM-9
F. Dentella, O. Lyubin

 Aluminium Tilting Furnaces Design................................................................................ 241

C. Emes

 New Design of Protected Type Heater.............................................................................246

V.F. Frolov, S.V. Soldatov, A.G. Pelevin, L.P. Trifonenkov

 Application Experience of Versatile Heat-Insulating Material of Silica..................................249

Needle-Punched Fiber in Foundry
I.А. Pikhutin

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 ALUMINIUM OF SIBERIA – 2008. Edited by P.V. Polyakov. STC «Light мetals».

 Study and Development of Composite Materials Based on A356 Alloy..................................254

S.V. Tepikin, V.F. Anosov

 Results of Industrial Tests of Flux Intended for Refining of Aluminium Alloys....................... 259
of Piston Group at OJSC «RUSAL Novokuznetsk»
P.N. Pominov, A.V. Kukharenko, N.A. Naidenov, O.V. Minaev

 Technological Innovations – Binary Base Metal Tablets with Silicon.................................... 261

D.V. Piskarev, А.V. Tikhonov, D.S. Ulyanov, M.G. ShevTsov

 Graphite-Free Release Agent for Aluminium Continuous Casting.........................................268

M. Shatrov

 Modern Effective Products of Refractory Fibres for High Temperature Isolation on Basis ........ 270
Inorganic Connectives
V. Soshkin, V. Gorbunov, M. Suhankin

 Optimization and Improvement of Technological Process of Water Circulation ...................... 275

at Aluminium Casting
L.N. Bagdasarov, V.V. Nelyubin

 The Analysis of Aluminum and Its Alloys Using Spectrolab................................................ 278

J. Carter

 Refractory Concretes for Lining for Melting-Casting Units of Aluminium Industry................. 281
D.E. Denisov, M.V. Maksimov

 Refractory Mixes, Castables and Shaped Products for Lining of Aluminium Smelters .............287
V.I. Sizov, А.М. Gorokhovsky, Е.V. Beklemishev,
L.А. Каrpets, М.N. Dunaeva, P.A. Кarpets

 Hydraulic Screwdown as a Perfect Rolling Mill Upgrade Solution........................................ 291

A. Polyakov

PART III. ALUMINA PRODUCTION

 Using The Method of Physicochemical Modeling in Technological Systems ...........................294

Production of Alumina
N.V. Golovnykh, V.A. Bychinsky, K.V. Chudnenko, I.I. Shepelev 

 Modelling of Behaviour of Organic Compounds During Physical.........................................297

and Chemical Transformations of Bauxites Into Bayer’s Cycle
I.I. Shepelev, N.V. Golovnykh, V.A. Bychinsky, A.G. Suss, A.V. Panov

 Pilot Project to Improve Evaporator Plants for Alumina Production ....................................300

V.M. Ronkin, V.M. Kovzel, A.B. Malyshev, S.I. Frolov

 Evaporators for Concentration of Crystallizable and Scale forming Solution.........................307

in Alumina Production
V.M. Ronkin, V.M. Kovzel, V.Yu. Shaburov

 Evaluation of Temperature Loss in Dawn-FalL Evaporators................................................. 314

V.M. Ronkin, V.M. Kovzel

 Commercial Operation of Four-Way Bauxite Slurry Heaters .............................................. 316

S.B. Zverev, V.A. Nikulin, Yu.G. Nikitin,
Yu.V. Pustynnykh, A.A. Molochkov, V.L. Podberezny

 Experience To Design and Operate Pilot High-Temperature Leaching Plant........................... 319

V.A. Nikulin, S.B. Zverev, Yu.G. Nikitin, V.L. Podberezny,
А.А. Molochkov, Ye.V. Pustynniykh

 The New Technology of Manufacture of Tricalcium Aluminate Hexahydrate with Gross Crystals .322
O.D. Linnikov, I.V. Rodina, V.A. NikUlin, M.A. Perestoronina

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 ALUMINIUM OF SIBERIA – 2008. Edited by P.V. Polyakov. STC «Light мetals».

 Behavior of Oxalates and Humates at Evaporation of Aluminate Liquors . ............................ 325

I.V. Rodina, O.D. Linnikov, V.M. Kovzel, V.M. Ronkin

 Study of Timan Bauxite Leaching Kinetics....................................................................... 326

I.V. Loginova, I.S. Zakusilov

 Particle Size Analysis from Lab to Line Survey of State-of-the-Art Technologies .................. 327
for the Aluminium Industry
A. Pankewitz, Ch. Behrens, U. Kesten

 Intensification of Aluminous Production Processes.............................................................333

A. Stepanenko, A. Bauman

PART IV. ECOLOGY, LABOUR PROTECTION, WASTE PROCESSING

 Energy and Environmental Concerns In AluminiUm Industry – A Review............................338

P.K. Narasimharaghavan

 Computerized Process Control for the Gas Scrubbing Unit of Potline V ...............................346
at the Irkutsk Aluminium Smelter
A.S. Burmakin

 Lasir® System and Its Application for Anhydrous Hydrogen Fluoride Measurement.................349
А.S. Kalashnikov

 The Influence of Gas Duct State on the Exhaust Rate From Soderberg Cells.........................356
S.G. Shakhrai, A.P. Rzhechitskiy, V.V. Kondratjev, A.A. Dekterev, D.V. Boiko

 Application of Rto Technology for Collecting Coal Tar Pitch Fumes by Manufacturing ..........360
of «Green» Anodes at New Rusal Smelters
V.V. Matveev, Yu.A. Frantsev, E.V. Sugak

 Comparative Estimation of Binding Pitches Carcinogenic Properties.....................................363

E.N. Marakushina, V. K. Frizorger, V. S. Burkat, S.A. Khramenko,
P. M. Salamatova, N.N. Guryev

 Development and Experimental-Industrial Tests of Technologies for Obtaining.......................366

Low Modular Cryolite from Aluminium Production Gases and Wastes
E.P. Rzhechitsky, V.V. Kondratyev, L.S. Kozlova, S.A. Sobolev,
E.V. SuGak, S.G. Shakhrai

 Reduction and Processing of Aluminum Production Electrolytic Pot Lining Waste ................369
N.V. Golovnykh, A.A. Shvets, S.B. Polonsky

 Matters of Water Body Protection From Smelters Sewage Pollution..................................... 372

Т.M. Pavlova, E.P. Rzhechitskii, V.V. Kondratjev

 Calculation of Optimal Periodicity of Maintenance Service of Potentially............................. 376

Hazardous Objects
Е.N. Okladnikova, Е.V. Sugak

PART V. SCIENCE AND TECHNOLOGY NEWS

 Promotion of «Schneider Electric» Equipment Into Non-Ferrous Metallurgy of Russia.............384

A.N. Kozyura

 Temperature Profiling Systems for Heat Treatment of Aluminium Plates .............................386

A.A. Ulanovskiy, A.V. Lyapin, S.L. Tsukrov, M. Taake

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ALUMINIUM OF SIBERIA – 2008. Edited by P.V. Polyakov. STC «Light мetals».  Part I. ALUMINIUM REDUCTION TECHNOLOGY

PHYSICAL PROCESSES MODERN INVESTIGATION METHODS

IN POWER-INTENSIVE INDUSTRIAL EQUIPMENTS

E.N. Panov, A.Ya. Karvatsky, I.L. Shilovich, G.N. Vasilchenko, T.B. Shilovich,
S.V. Leleka, S.V. Danilenko, V.V. Bilko, I.V. Pulinets, A.N. Chyzh
National Technical University of Ukraine «Kiev Polytechnic Institute», Kiev, Ukraine

INTRODUCTION
Producing of the primary aluminium by electrolytic method [1, 2] as well as a carbonaceous electrodes
graphitization in indirect heating kilns [3] are the most energy-intensive processes all over the industry.
These productions processes an electric power specific consumption (SPC) reaches 15500 ...16500 kW·h
per tonne of aluminum and 4500 ... 6500 kW·h per tonne of graphite electrodes. The power-intensive
equipment list can be continued by different kilns, stoves for the building materials producing, by mixers
for aluminium alloys producing et cetera High heat-intensivity and chemical aggressiveness of working
mediums these industrial processes results the electrolyser and kilns construction materials are operated
at limit of acceptable values of thermal and stress indexes, which are recommended for construction ma-
terials application. So, for example, chamotte, mullite and alumina refractories are used at temperatures
1300 oC and higher, and heat-insulation mix materials higher 2000 oC; aluminium cathode steel shell oper-
ating temperature level reaches up to 400 oC at the conditions of considerable flowages (limit of fluidity
for St.3 is 230 МPа). Values of this indexes are too high for normal operating and can cause remaining
deformations, reducing the operating life and eliminating possibility of the repeated shell application in
subsequent campaigns. Technological parameters of the indicated objects reach the followings values: pow-
er – 1.2–12 МW, electrical current – 100–320 kА, current density – 20–30А/сm2, electric field inten-
sity – 100–150 V/m, thermal flux density 10–15 kW/m2, mechanical tensions (for plastic materials, for
example, St.3 – 230МPа, for resilient materials, for example, carbide of silicon – 850 МPа) et cetera.
So the basic world progress trends of aluminium and electrode industry it is possible to take fol-
lowings:
– Soderberg technology (fig. 1) exchange for technology with the burnt anodes (BA) using (fig. 2).
Current output increasing: to 96 % through new technologies implementation; to 93–95 % by tradi-
tional technologies improvement;
– at operating electrolysers current increase and new powerful electrolysers design of 300 kA imple-
mentation. Electrolyser voltage drop decreasing at the proper adjustment of the heat mode;
– electric power specific consumption reducing to 12500 kW·h/t;
– graphitization kiln (Acheson design, fig. 3) power efficiency increasing by intensification of electric
power supply schedule, kiln loading geometry optimization and application of heat-insulation with
the improved thermophysical properties;
– specific electric power consumption at electrodes graphitization process reduction by direct heating
mode implement (Kastner design, fig. 4).

1. OBJECTIVES AND TASKS

General objectives and tasks of the development work are:
– to develop the complex of calculation-experimental high-efficiency methods for investigation
of physical fields of power-intensive high temperature industrial equipment of the coloured
metallurgy, building materials productions and so on;
– to create a modern software for high temperature experiments support at plant conditions and
at the automatic mode;
– to develop the complex of numerical models for the calculation of the physical fields of indus-
trial equipments, which is based on the fundamental laws of theory of potential, mechanics
of liquid and solid, with numerical models verification by experimental data and analytical
solutions application;
– to perform the complex of experimental and calculation investigations at operating industrial
equipment to obtain their energy and technology indexes which are necessary for comparison
with requirements of technological process, energy and resource savings potential;
– energy and resource saving measures and technical solution development in industry: scien-
tifically-grounded operating regimes schedules, designs on modernization of operating and
development of new constructions and so on;
– implementation of developed technical solutions.

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E.N. Panov, A.Ya. Karvatsky, I.L. Shilovich, G.N. Vasilchenko, T.B. Shilovich et al.Physical Processes Modern Investigation Methods ...

Fig. 1. ¼ of electrolyzer with upper current
supply system
1 – cathode bus-bar; 2 – counterforce cathode
shell|jecket; 3 – socle lining-up; 4 – cathode section;
5 – side wall block; 6 – melted metal; 7 – bath;
8 – scull and crust; 9 – self-burning anode; 10 – an-
ode shell jecket; 11 – anode bar; 12 – anode bus-bar
Fig. 2. ¼ of electrolyzer with burnt anode
1 – cathode bus-bar; 2 – carcass-frame cathode
shelljecket; 3 – socle lining-up; 4 – cathode section;
5 – side wall block; 6 – melted metal; 7 – bath;
8 – scull and crust; 9 – burnt anode; 10 – anode rod;
11 – anode bus-bar

Fig. 3. ¼ Acheson kiln Fig. 4. ¼ Kastner kiln

1, 3 – end and side walls; 2 – bottom; 4.5 – corner
and side columns; 6 – air channels; 7 – current bars;
8 – graphite-carbonaceous fire protective screen-
tube-face; 9 – graphite chips; 10 – heat insulation;
11 – core bulk materials; 12 – billets
1, 3 – end and side walls; 2 – bottom; 4 – air chan-
nels; 5 – shiftable current bar; 6 – shiftable cur-
rent bar breast; 7 – fixed current bar; 8 – billets;
9 – buffer; 10 – damping device gasket; 11 – heat
insulation

2. METHODOLOGY OF THE PHYSICAL FIELDS EXPERIMENTAL INVESTIGATION

Thermal and electric parameters experimental data, obtained at industrial equipments are used:
– for estimation of temperature level at different stages of technological process, descriptions of
heat transfer and heat losses into surrounding, energy balances calculation and SRC reserves
determination for it’s reduction;
– for boundary conditions true set up at numerical simulation;
– at numerical model of the physical processes verification at industrial equipment.

Methodical and device support for experiment running SRC «RT»

Specialists of SRC «RT» developed the multilevel complex method of high temperature measure-
ments at industrial equipment:
– to 1200 oC is a 1th level. Chromel-alumel thermocouples, infrared pyrometer Agema TPT 62;
– to 1800 oC is a 2th level. Tungsten-rhenium thermocouples;
– to 2500 oC is a 3th level. High-temperature brightness pyrometers;
– higher 2500 oC is a 4th level. Numerical simulation on verification models which are confirmed
by experiments.

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ALUMINIUM OF SIBERIA – 2008. Edited by P.V. Polyakov. STC «Light мetals».  Part I. ALUMINIUM REDUCTION TECHNOLOGY

To determine heat flux density at industrial equipment within temperatures to 750 oC sensors
of PTP-04 type by ITTF NANU, T500B-B, TW-C, TG-B, T750-C by Kyoto Electronics Manufac-
turing Co (Japan) are used. To measure air and waste gases flow rates the thermoanemometer of
TSI VelociCalc Plus 8388-M-GB is used. Chromel-alumel thermo-sensors views are represented on
a figure 5. Special vision tube for temperature measuring inside the kiln by a brightness pyrometer
is represented on a figure 6. The examples of thermo-sensors placement aluminium electrolysers
cathodes and electro-calcining kiln are represented on the figure 7.

Fig. 5. Thermocouple for temperature range up to 1200 oC with two pairs

1 – refractory tube; 2 – silicon tube; 3 – MgO filling; 4 – magnox and high temperature glue plug
5 – hot junction placed in alumina tubes; 6 – electrodes in mullit string; 7 – high temperature
resistance cambric

Thermophysical properties investigation

Experimental investigation of thermophysical properties (TFP) of bulk solids at temperatures
up to 1500 oC is performed with special laboratory rig. Conductivity coefficients and heat capacity
of bulk materials temperature dependence are calculated by conductivity reverse coefficient problem
numerical solution with using an experimental data [4]. изоляции

Fig. 6. Vision pipe setting up

1 – vision graphite tube; 2 – core; 3 – quartz glass; 4 – pipe for gas (argon); 5 – outlet valve;
6 – brightness-temperature pyrometer; 7 – billet; 8 – core bulk materials; 9 – wooden wall;
10 – heat insulation; 11 – kiln side wall; 12 – air channel

a b
Fig. 7. Thermo sensors installation chart:
a – in the aluminium electrolyser cathode; b – in electro calcinator

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E.N. Panov, A.Ya. Karvatsky, I.L. Shilovich, G.N. Vasilchenko, T.B. Shilovich et al.Physical Processes Modern Investigation Methods ...

Equipment of experiment computerization support

A measurement complex [5] (fig. 8) is built with modules: data capture of I-7018 (ICP_DAS compa-
ny production), which performs information output with frequency of measurement up to 10Hz through 8
separate analog inputs with cold shuts sensor (located near the terminal board of the module). The module
of I-7018 equipped with a galvanic upshot to 3000V and provides communication of digital data on the
half-duplex serial interface of suspension points of RS-485 on distance up to 1 km (transmission aids –
soaring pair). The amount of the modules in one network could be arrived at 254 pcs. At the complex
data from I-7018 after digital conversion into the serial interface of RS-232 is given on successive port of
the personal computer. Conversion of interfaces of RS-485-RS-232 is performed by conversion module of
I-7520 (ICP_DAS), which is supplied also with a galvanic upshot up to 3000 V. After successive port of
the personal computer input data are processed with SRC «RT». Software is used for:
– testing and the modules network creation;
– the modules query frequency setting up (up to 1Hz);
– election of the sensor type (Ch-A, Tng-Rh, PTP-04, tension) for every module input;
– data saving on an external or internal carrier with pointing of saving frequency;
– monitor data performance in a numeral and graphic type in real-time mode.

Fig. 8. Measurement complex device

Experimental investigations of the industrial equipment temperature fields and results of calcu-
lations energy balances based on the experimental data are represented on a figure 9, 10.

Burning Thermo sensors

graph

Automatic data measuring

and saving device

Fig. 9. Experimental temperature measurements at burning,

put into operation and working regimes of aluminium electrolyser

Fig. 10. Power balance of electrolyser with burnt anodes for current of 320 kА
(consumption items)

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3. PHYSICAL FIELDS NUMERAL SIMULATION

Thermo-electric mode of graphitization kiln
Mathematical formulation of the thermo-electric fields of Acheson kiln includes the system of two
differential equations in partial derivatives (unsteady – for heat conductivity and stationary – for
electrical conductivity) with initial and boundary conditions [6]. The examples of the physical fields
of Acheson graphitization kiln simulation results are represented on the figure 11. Software verification
for kiln physical fields simulation demonstrates a good concordance within the limits of error within
model experiment.

Kiln Billets and fire bricks

Time from kiln campaign start 55 hour (end of campaign)
Fig. 11. Temperature fields (К) of billets ∅ 400 mm graphitization kiln campaign
at enhancement current

Heat and electrical state of aluminium electrolyser

Design of the new or modernization of operating aluminium electrolysers energy balances infor-
mation is very important due to it’s valid for power efficiency estimation as well as opportunity of
energy saving resource determination [7]. To perform energy balance calculation it is necessary in
the beginning to obtain numerical simulation of thermal and electrical fields data. The examples of
calculations of the physical fields of aluminium electrolysers are represented on a figure 12.

a b
Fig. 12.  Results of numerical simulation of medium (C8-BM)
and large power (OA-320) electrolysers electric (а) and temperature fields (b) of potentials

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Forced air cooling systems of kiln and electrolysers heat-intensive elements. Basic fluid dy-
namic and complicated heat transfer equations
Fluid dynamic and complicated heat transfer system of equations based on standard model of tur-
bulence [8] for air flow includes continuity equation, motion equation, enthalpy subject to radiation,
turbulent energy, turbulent energy dissipation intensity and ideal gas equation:

(1)

where ρ
– density, kg/m3; t – time, s; V – velocity vector, m/s; P – pressure, Pa; m – dy-
namic viscosity, Pa ⋅ s; mt – turbulent viscosity, Pa⋅s; k – turbulent energy, m2/s2; e – dissipation
of turbulent energy intensity, m2/s3; g – gravity acceleration, m/s2; h – enthalpy, J/kg; E(X) –
volume density of radiant stream, W/m3.
For «grey environment» approach the volume density of radiant stream is represented by next
expression

, (2)

where K – absorption coefficient, m–1; I– intensity of radiation, W/(m2⋅rad); Ω – space angle,

sterad; n – index of refraction; σ – Stephen-Boltsmann, constant W/(m2⋅K4).
To close system (1,2) the initial and border conditions are used.
This system was used for heat transfer enhancement estimation at forced air cooling of the elec-
trolyser OA-300 cathode shell and electro-calcinator at put into operation regimes.

Deflected mode of kiln’s and electrolyser’s elements. Thermoelasticity basic equations.

Let’s consider unsteady disconnectedness problem of thermoelasticity mathematical setting up
[9, 10]
, (3)

(4)

where cp – specific isobaric heat capacity, J/(kg⋅K); r – density, kg/m3; t - temperature,  oC;
 = ∂t/∂t – temperature derivate on time, °C/m; t – time, s; λ – conductivity, W/(m⋅K); i =
∂2ui/∂t2 – 2nd derivate of moving on time, m/s2; ui – component of moving tensor, m; σij – com-
ponents of tension tensor, Pa; ƒi = rgi – components of volume forces, caused by gravity, Pa/m;
g – acceleration gravity, m/s2.
At the temperature influence the tension tensor is determined by Hooke generalized law of

, i, j, k = 1, 2, 3 (5)

where – shear modulus, Pa; Е – Young modulus, Pa; ν – Poisson coefficient;

  – Cauchies small deformations tensor; α - linear expansion coefficient, K–1;

δij – Kronecker character.

To close system (3–5) the initial and border conditions are used.

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ALUMINIUM OF SIBERIA – 2008. Edited by P.V. Polyakov. STC «Light мetals».  Part I. ALUMINIUM REDUCTION TECHNOLOGY

Thermoelasticoplastic equations
At the conditions of Mises isotropic approach of the deformation work-hardening of relation-
ships for tensions and deformations could be written in an apparent kind [10]:

i, j, k, l = 1, 2, 3 (6)

where – tension intensity , Pa; – stress deviator, Pa; H – module

of the plastic work-hardening, Pa.

Examples of aluminium electrolyser deflected mode simulationare represented at figure 13 and
in [9, 11].

Dangerous areas of plasticity with intensity of deformation > 0.1 % (grey color)
Fig. 13. Areas of flowage intensity on Mises of the electrolyser OA-320
carcass-frame cathode shell type

4. INVESTIGATION RESULTS IMPLEMENTATION

Scientific and technical approaches obtained by SRC «RT» team are implemented in companies:
UC «RUSAL», JSC «SUAL», JSC «SIBVAMI», JSC «Energoprom Management» on the follow-
ings factories: Zalk, BRAZ, KRAZ, SAAZ, VGAZ, KAZ, JSC «Novocherkasskiy electrode plant»,
SV  «Ukrgrafit». The examples of implementation some developments are represented on a figures
14, 15.

a – control cabinet b – block of gas-rings

Fig. 14. Equipment for cathode flame burning
(«Promgazapparat» and SRC «RT» mutual design)

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E.N. Panov, A.Ya. Karvatsky, I.L. Shilovich, G.N. Vasilchenko, T.B. Shilovich et al.Physical Processes Modern Investigation Methods ...

Equipment at cathode sections montage shop

Fig. 15. Equipment for cathode sections preheating before iron casting
(«Promgazapparat» and SRC «RT» mutual design)

CONCLUSIONS
1. On the base of high temperature experiments and numeral models developed methods a physical
fields investigation is performed in power-intensity industrial equipment. The detailed analysis
of the obtained data is conducted, on the basis of which technical solutions are developed
concerning energy saving problem at brunches of coloured metallurgy.
2. The results of scientific researches of NIC «RT» are imlemented in companies: UC «RUSAL»,
JSC «SUAL», JSC «SIBVAMI», JSC «Energoprom Management» on the followings
factories: Zalk, BRAZ, KRAZ, SAAZ, VGAZ, KAZ, JSC «Novocherkasskiy electrode plant»,
JSC «Ukrgrafit».
3. As a result of implementation the followings indexes are achieved: at Soderberg electrolysers
current is enhanced on 9…12.5% and in the same time the electric power specific consumption
is reduced on 2.3 %  kW·h/t; at Acheson graphitization kilns electric power consumption
is reduced on 5–8 % in the same time producing capacity is increased to 11 %.
4. Advanced researches. It is necessary to continue works in the followings directions:
– it is expedient to apply the developed methods of high temperature measurements for
technological objects of ferrous metallurgy and other industries with high temperature
heating is valid;
– thermophysical properties of bulk and solid materials investigations applied for colour and
ferrous metallurgy;
– numerical simulations: induction heating; burning processes; turbo-machines fluid mechanics;
electrolyte and melting metal magnetic hydrodynamics.

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