A framework for quality control of baked carbon anodes manufacturing plants

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This research program aims at improving process intelligence and agility of primary aluminum smelters, and anode manufacturers in particular, to cope with the declining quality and increasing variability of the carbon anode raw materials (coke and pitch). To achieve this, a framework for real-time decision making on manufacturing conditions is proposed, involving process monitoring and quality control. New imaging and acoustics sensors will be developed to track variability of key raw materials and process variables that are currently unavailable. Multivariate latent variable statistical methods will be developed based on historical anode manufacturing and smelter data. These tools will be used 1) for monitoring the entire manufacturing chain, from raw materials to final products (i.e. baked anodes), and early detection of abnormal situations, 2) for computing correcting actions for process variables in order to reduce variability in baked anode properties (i.e. feedforward/feedback quality control), and 3) for establishing multivariate specification regions for baked anode properties to help achieve optimal performance in the reduction cells. Transferring the proposed quality control tools to the industry will allow them producing more consistent anodes in spite of the increasing variability of raw materials. By enabling the production chain to be optimized, reducing variability leads to the following expected benefits: costs savings, waste reduction, lower carbon consumption, and higher energy efficiency. Indeed, a 5% reduction in carbon overconsumption is realistically expected through producing baked anodes of more consistent quality and by intercepting faulty green anodes before baking them. Such a reduction in carbon overconsumption would reduce green house gas emissions by 1600 tons CO2/year. Savings in operating costs would also enable Canadian aluminum smelters to be more competitive on the world scene and hence contribute to the Canadian economy by exporting and transforming aluminum. Consolidating the leadership position of the Canadian aluminum industry would help maintain highly paid jobs for operators, technicians and engineers, and specialized suppliers and engineering firms.