Development of advanced models for reducing energy and material consumption in the primary production of aluminium industry

加拿大是世界上最大的原铝生产国之一，每年生产近300万吨铝。在大部分生产完成的魁北克省，铝的初级生产支持着3万个直接和间接的就业机会。提高能源效率(千瓦时/千克[铝])和降低原材料消耗(主要是千克[碳]/千克[铝])是保持冶炼厂运营并减少其环境足迹的关键。本项目建立在拉瓦尔大学和美国铝业公司之间的长期合作基础上。它的重点是开发铝生产中涉及的关键工艺的先进型号。铝型材被业界广泛使用，以改进铝材生产工艺和设备性能。根据目前文献中的空白和行业的需要，选择了四个建模优先事项：-阴极设计：开发集成蠕变、扩散和侵蚀的热机电模型，以优化考虑其整个寿命的设计。-阳极焙烧：开发用于实时炉膛优化的阳极焙烧炉的数字孪生模型；-振动压实：开发考虑高频和与模具的摩擦的流变学模型，以及阳极成型模型；-阳极反应性：开发包括地壳存在的现场3D阳极反应性模型。将使用不同的实验设置来获取用于校准和验证模型的数据。结果将有助于该行业改进他们的工艺和他们使用的设备。

Canada is among the top world producers of primary aluminum, with close to 3 M ton of aluminum per year. In the province of Quebec, where most of the production is done, the primary production of aluminum supports 30,000 direct and indirect jobs. Improving energy efficiency (kWh/kg [Al]) and reducing raw materials consumption (mainly kg [C]/kg [Al]) are the key to keep smelters in operation and reduce their environmental footprint.The present project builds on a long-term collaboration between Université Laval and ALcoa. It is focused on the development of advanced models of key processes involved in aluminum production. Models are used extensively by the industry to improve the aluminum making process and the performance of equipment. Four modeling priorities have been chosen based on the current gaps in literature and on the needs of the industry: -Cathode design: Develop thermo-electromechanical models that integrate creep, diffusion and erosion to optimize the design considering its entire lifetime.;-Anode baking: Develop a digital twin model of an anode baking furnace for real-time furnace optimization;-Vibrocompaction: Develop rheological models that consider high frequencies and friction with mould, as well as anode forming models;-Anode reactivity: Develop in situ 3D anode reactivity models including the presence of the crust.Different experimental setups will be used to acquire data for calibrating and validating the models. Results will help the industry to improve their processes and the equipment that they use.