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: $ 5.97万
• 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: 2012
• 资助国家: 加拿大
• 起止时间: 2012-01-01 至 2013-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=498799
• 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发性铝冶炼厂的过程智能和敏捷性，尤其是阳极制造商，以应对碳阳极原材料（可乐和俯仰）的质量下降和增加的变化。为了实现这一目标，提出了针对制造条件的实时决策框架，涉及过程监控和质量控制。将开发新的成像和声学传感器，以跟踪目前不可用的关键原材料和过程变量的可变性。多元潜在可变统计方法将根据历史阳极制造和冶炼器数据开发。这些工具将用于1）监视整个制造链，从原材料到最终产品（即烤制阳极），并尽早发现异常情况，2）用于计算过程变量的校正操作，以降低烘焙阳极属性的可变性，即在启动质量控制方面，以帮助建立多个效率范围，以帮助您实现多个型号的范围。细胞。尽管原材料的变化增加了，但将提议的质量控制工具转移到行业将使他们产生更一致的阳极。通过使生产链进行优化，可降低可变性会带来以下预期收益：节省成本，减少废物，较低的碳消耗和较高的能源效率。实际上，通过产生质量更一致的烘焙阳极并在烘烤之前拦截有缺陷的绿色阳极，碳过度减少了5％。这种碳过度减少的减少将使温室气体排放量减少1600吨二氧化碳/年。节省的运营成本还将使加拿大铝冶炼厂在世界各地更具竞争力，因此通过出口和转换铝来为加拿大经济做出贡献。巩固加拿大铝业行业的领导地位将有助于维持经营者，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。