Description and Applications of a 3D Mathematical Model for Horizontal Anode Baking Furnaces

Abstract

In aluminum industry, carbon anodes are consumed continuously during alumina reduction in the electrolysis cells. Anodes are made of calcined coke, butt, and recycled anode particles and pitch as the binder. Green anodes are baked in large furnaces where they attain specific properties in terms of density, mechanical strength, and electrical conductivity. Baking is an important and costly step in carbon anode production. The proper operation of the furnace provides the required anode quality. Mathematical modeling allows the prediction of the heating profile of anodes during baking. Taking into account all the important phenomena, a 3-dimensional transient mathematical model was developed to reproduce numerically the different stages of the baking process in the furnace. The predictions give a detailed view of the furnace operation and performance. In this article, the 3D model is described, and the results on the impact of various parameters on furnace behavior are presented.

Effects of Mesh Generation on Modelling Aluminium Anode Baking Furnaces

“…Other studies have explored deformations of geometry. For instance, Baiteche et al [18] studied the effect of flue-wall deformation on anode temperature distribution. Comparing the temperature profiles on a line in the pit transverse direction for straight and deformed flue-walls, it was observed that after flue-wall deformation, the temperature profile is no longer symmetric, which indicates a non-uniform baking process.…”

Determination of optimum vibro-compaction time using sound analysis

“…The anode paste obtained by mixing all the raw materials is compacted in a vibrocompactor to produce green anodes. The green anodes baked in open-pit anode baking furnaces to produce the baked anodes [3][4]. Then, the baked anodes are cooled and rodded before sending them to electrolysis.…”

Structural and thermal analysis of an innovative baking furnace for carbon anode production

“…Zhou et al 34 studied the effects of the bricks arrangements and baffles on the flue flow characteristics of ABF. Baiteche et al 35 studied the temperature profile of anode blocks, and found that due to the flue‐wall deformation, the temperature distribution was no more symmetric with the result of a nonhomogeneity baking process.…”