A framework for quality control of baked carbon anodes manufacturing plants

烘焙碳阳极制造厂的质量控制框架

• 批准号: 417576-2011
• 负责人: Duchesne, Carl
• 金额: $ 5.79万
• 依托单位: Université Laval
• 依托单位国家: 加拿大
• 项目类别: Collaborative Research and Development Grants
• 财政年份: 2011
• 资助国家: 加拿大
• 起止时间: 2011-01-01 至 2012-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=494590
• 关键词: framework; quality; control; baked; carbon

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.

该研究计划旨在提高原铝冶炼厂，特别是阳极制造商的工艺智能和敏捷性，以应对碳阳极原材料（焦炭和沥青）质量下降和变异性增加的问题。为了实现这一目标，提出了一个针对制造条件进行实时决策的框架，包括过程监控和质量控制。将开发新的成像和声学传感器来跟踪目前无法获得的关键原材料和工艺变量的变化。将根据阳极制造和冶炼厂的历史数据开发多元潜变量统计方法。这些工具将用于 1) 监控从原材料到最终产品（即烘烤阳极）的整个制造链，并及早发现异常情况，2) 计算过程变量的纠正措施，以减少烘烤阳极的变异性属性（即前馈/反馈质量控制），以及 3) 用于建立烘焙阳极属性的多变量规格区域，以帮助在还原电池中实现最佳性能。尽管原材料的变化越来越大，但将拟议的质量控制工具转移到行业将使他们能够生产出更一致的阳极。通过优化生产链，减少可变性可带来以下预期效益：节省成本、减少浪费、降低碳消耗和提高能源效率。事实上，通过生产质量更稳定的烘焙阳极以及在烘焙前拦截有缺陷的绿色阳极，实际上预计可以减少 5% 的碳过度消耗。减少碳过度消耗每年将减少1600吨二氧化碳的温室气体排放。运营成本的节省还将使加拿大铝冶炼厂在世界舞台上更具竞争力，从而通过出口和加工铝为加拿大经济做出贡献。巩固加拿大铝工业的领导地位将有助于维持操作员、技术人员和工程师以及专业供应商和工程公司的高薪工作。