The Minerals, Metals & Materials Series

Alan TomsettEditor

Light Metals 2020

123

EditorAlan TomsettRio TintoBrisbane, QLD, Australia

ISSN 2367-1181 ISSN 2367-1696 (electronic)The Minerals, Metals & Materials SeriesISBN 978-3-030-36407-6 ISBN 978-3-030-36408-3 (eBook)https://doi.org/10.1007/978-3-030-36408-3

© The Minerals, Metals & Materials Society 2020This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material isconcerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproductionon microfilms or in any other physical way, and transmission or information storage and retrieval, electronicadaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed.The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does notimply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws andregulations and therefore free for general use.The publisher, the authors and the editors are safe to assume that the advice and information in this book are believedto be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty,expressed or implied, with respect to the material contained herein or for any errors or omissions that may have beenmade. The publisher remains neutral with regard to jurisdictional claims in published maps and institutionalaffiliations.

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Preface

It is my honour to present to you Light Metals 2020 and welcome you to the 149th TMSAnnual Meeting and Exhibition in San Diego. Light Metals 2020 is a collaborative effort fromhundreds of authors plus session chairs, subject chairs, and TMS staff. It is their dedication thatmakes this meeting a success.

The global aluminum industry has gone through a period of rapid growth and change inrecent years. While growth is slowing, challenges such as low metal prices, decarbonisation ofenergy sources and processes, and deteriorating raw material quality remain. Light Metals2020 contains many innovative responses to these challenges for the industry. Our markets arealso changing with increasing demand for aluminum that has been produced responsibly andsustainably. These market changes are also reflected in this year’s volume where we havesessions dedicated to Bauxite Residue Reuse and Remediation, Spent Pot Lining, Recycling,Cast Shop Safety and Potroom Environment.

This year marks the 50th year of continuous publication of the Light Metals proceedings.Throughout that time, Light Metals has provided a repository for the combined knowledge ofresearchers and industry practitioners and today remains the pre-eminent reference work forour industry. It is timely that this year’s Light Metals keynote session will focus on attractingand growing the next generation of technical talent. Continuing to bring in new talent will becritical in developing the solutions required to meet the global industry challenges and toprovide the next generation of contributors and volunteers for the Light Metals proceedings.

These proceedings are the culmination of the efforts of many people, in particular, theSubject Chairs: James Vaughan, Dmitry Eskin, Jayson Tessier, Johannes Morscheiser, andDuygu Kocaefe. It has been a pleasure working with this team and I thank them for theirsupport and enthusiasm. They, along with the session chairs and reviewers, have volunteeredmany hours to ensure we have a full and high-quality program. In addition, I would like tothank Patricia Warren and the other the TMS staff working behind the scenes for their support,understanding, and flexibility in managing our requests. The help and advice from past editorsCorleen Chesonis and Olivier Martin are also greatly appreciated. Finally, the Light Metalsproceedings would not exist without the willingness of the authors to share their research andexperience with the broader community. We all owe them our deepest gratitude for continuingthe 50-year tradition of Light Metals.

Alan Tomsett

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Contents

Part I Alumina and Bauxite

Impacts of Mineralogy on Soluble Phosphorus Concentrations During LowTemperature Processing of Jamaican Bauxites . . . . . . . . . . . . . . . . . . . . . . . . . . 3Michael D. Coley, Anthony M. Greenaway, and Khadeen E. Henry-Herah

Effects of the Granular Properties of Bauxite Pisolithes on the Solid/LiquidSeparation in Liquid Fluidized Beds of Classifiers . . . . . . . . . . . . . . . . . . . . . . . . 12T. Grillot, G. Simard, R. Chesnaux, D. Boudeville, and L. Perrachon

Mineralogical Assessment of the Solid Phase Obtained on Leaching of BrazilianRed Mud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A. B. Botelho Junior, D. C. R. Espinosa, and J. A. S. Tenório

Low-Quality Aluminum-Containing Raw Materials: Experience, Problemsand Prospects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Vadim Lipin and Ekaterina Sofronova

Inhibition of Kaolinite Dissolution in Bayer Liquor Through LithiumAddition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Horace Ogilvie, James Vaughan, and Hong Peng

Ionic Effect of NaCl and KCl on the Flotation of Diaspore and KaoliniteUsing Sodium Oleate as Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Chaojun Fang, Shichao Yu, Hong Peng, Xiaowei Deng, and Jun Wang

Quantifying the Effect of Seeds on Gibbsite Crystallization—MathematicalModelling of Particle Size Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Thiago T. Franco and Marcelo M. Seckler

Experimental Study on Flow Field Characteristics in Seed PrecipitationTank and Influence on Physical Properties of Al(OH)3 Products . . . . . . . . . . . . . 54Xiangyu Zou, Yan Liu, Xiaolong Li, and Ting’an Zhang

Application of Advanced Oxidative Process for Organic Compounds Removalfrom Bayer Liquor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Miguel Antonio Soplin, Amilton Barbosa Botelho Junior,Marcela dos Passos Galluzzi Baltazar, Jorge Alberto Soares Tenório,and Denise Crocce Romano Espinosa

A Review of Comprehensive Utilization of High-Iron Red Mud of China . . . . . . 65Ting’an Zhang, Kun Wang, Yan Liu, Guozhi Lyu, Xiaofei Li, and Xin Chen

Conversion Behavior of Iron-Containing Minerals in the Process of DissolvingHigh-Iron Bauxite by Starch Hydrothermal Method . . . . . . . . . . . . . . . . . . . . . . 72Yongfei He, Yiyong Wang, Hun Jin, Ning Zhe, and Xingyuan Wan

vii

Disc Magnetic Separator Applied to the Extraction of Magnetitein Bauxite Residue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Y. Robert, G. Simard, and S. Fortin

Recovery of Iron from High-Iron Bayer Red Mud by Smelting Reduction . . . . . 92Kun Wang, Yan Liu, Guozhi Lyu, Xiaofei Li, Xin Chen, and Ting’an Zhang

Bayer Process Towards the Circular Economy—Metal Recoveryfrom Bauxite Residue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Paula de Freitas Marques Araújo, Patricia Magalhães Pereira Silva,Andre Luiz Vilaça do Carmo, Fernando Gama Gomes, Alex Mota dos Santos,Raphael Vieira da Costa, Caio César Amorim de Melo, Adriano Reis Lucheta,and Marcelo Montini

Bayer Process Towards the Circular Economy—Soil Conditioners fromBauxite Residue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Roseanne Barata Holanda, Patricia Magalhães Pereira Silva,Andre Luiz Vilaça do Carmo, Alice Ferreira Cardoso, Raphael Vieira da Costa,Caio César Amorim de Melo, Adriano Reis Lucheta, and Marcelo Montini

Brazilian Bauxite Residue Physical–Chemical Characterization and AcidicNeutralization Potential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Patricia Magalhães Pereira Silva, Andre Luiz Vilaça do Carmo,Roseanne Barata Holanda, Fernando Gama Gomes, Emanuele Nogueira,Raphael Vieira da Costa, Caio César Amorim de Melo, Adriano Reis Lucheta,and Marcelo Montini

Effect of Concentrations and Pressures of CO2 on Calcification–CarbonationTreatment of Bauxite Residue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Xi Chao, Ting-an Zhang, Guo-zhi Lv, and Yang Chen

Comprehensive Utilization of Red Mud Through the Recovery of ValuableMetals and Reuse of the Residue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Fei Lyu, Li Wang, Jiande Gao, Honghu Tang, Wei Sun, Yuehua Hu,Runqing Liu, and Lei Sun

A Review of Research on Alumina Extraction from High-Alumina Fly Ashand a New Method for Preparing Alumina by Electrotransformation . . . . . . . . . 136Xiu-xiu Han, Ting-an Zhang, Guo-zhi Lv, Xi-juan Pan, and Da-xue Fu

Effect of Sodium Alkali Concentration on Calcification–CarbonizationProcess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143Yang Chen, Ting-an Zhang, Guo-zhi Lv, and Xi Chao

Part II Aluminum Alloys, Processing and Characterization

Stress Characterization of Bore-Chilled Sand Cast Aluminum Engine Blocksin As-Cast and T7 Condition with Application of Neutron Diffraction . . . . . . . . 153J. Stroh, D. Sediako, G. Byczynski, A. Lombardi, and A. Paradowska

Molecular Dynamics Simulations of the Solidification of Pure Aluminium . . . . . 158Michail Papanikolaou, Konstantinos Salonitis, and Mark Jolly

Nanoindentation and Cavitation-Induced Fragmentation Study of PrimaryAl3Zr Intermetallics Formed in Al Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168Abhinav Priyadarshi, Tungky Subroto, Marcello Conte, Koulis Pericelous,Dmitry Eskin, Paul Prentice, and Iakovos Tzanakis

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In Situ Neutron Diffraction Solidification Analyses of Rare Earth ReinforcedHypoeutectic and Hypereutectic Aluminum–Silicon Alloys . . . . . . . . . . . . . . . . . 174J. Stroh, D. Sediako, D. Weiss, and V. K. Peterson

Influence of TiB2 Particles on Modification of Mg2Si Eutectic Phasein Al–Zn–Si–Mg–Cu Cast Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179Byung Joo Kim, Sung Su Jung, Yong Ho Park, and Young Cheol Lee

A Statistical Analysis to Study the Effect of Silicon Content, SurfaceRoughness, Droplet Size and Elapsed Time on Wettability of HypoeutecticCast Aluminum–Silicon Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185Amir Kordijazi, Swaroop Kumar Behera, Omid Akbarzadeh, Marco Povolo,and Pradeep Rohatgi

Aluminum Trace Elements Analyses Using Epsilon 1 Meso EDXRFTechnique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194Hussain Al Halwachi

Effect of Cooling Rate During Solidification of Aluminum–Chromium Alloy . . . . 204G. Muthusamy, S. Wagstaff, and A. Allanore

Effects of Si on the Electrical Conductivity, Microhardness, Microstructureand Hot Tearing of Al–0.8Fe–0.5Mg–0.4Ni Alloys . . . . . . . . . . . . . . . . . . . . . . . . 210Stephanie Kotiadis, Adam Zimmer, Abdallah Elsayed, Eli Vandersluis,and C. Ravindran

The Efficacy of Replacing Metallic Cerium in Aluminum–Cerium Alloyswith LREE Mischmetal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216Zachary C. Sims, David Weiss, Orlando Rios, Hunter B. Henderson,Michael S. Kesler, Scott K. McCall, Michael J. Thompson, Aurelien Perron,and Emily E. Moore

Effects of Sc and Y on the As-Cast Microstructure of AA6086 . . . . . . . . . . . . . . 222Sandi Žist, Varužan Kevorkijan, Matej Steinacher, and Franc Zupanič

Ternary Interactions and Implications for Third Element Alloying Potencyin Al–Ce-Based Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227Hunter B. Henderson, David Weiss, Zachary C. Sims, Michael J. Thompson,Emily E. Moore, Aurélien Perron, Fanqiang Meng, Ryan T. Ott, and Orlando Rios

Development and Analysis of Al7075 Alloy Materials Using Press and SinterProcessing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233Steven C. Johnson, Corey D. Clark, and Jason S. Alvarez

Formation of Rare Earth Intermetallics in Al–Cu Cast Alloys . . . . . . . . . . . . . . 241M. G. Mahmoud, A. M. Samuel, H. W. Doty, and F. H. Samuel

Retrogression Forming and Reaging of AA7075-T6 Alclad to ProduceStampings with Peak Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247Katherine E. Rader, Jon T. Carter, Louis G. Hector Jr., and Eric M. Taleff

High Cycle Fatigue Properties of the Zr-Modified Al–Si–Cu–Mg Alloyat Elevated Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253Guangyu Liu, Paul Blake, and Shouxun Ji

Effect of Mo on Elevated-Temperature Low-Cycle Fatigue Behavior of Al-Si356 Cast Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261S. Chen, K. Liu, and X.-G. Chen

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State Parameter-Based Simulation of Temperature- and Strain Rate DependentFlow Curves of Al-Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267Bernhard Viernstein, Philipp Schumacher, Benjamin Milkereit, and Ernst Kozeschnik

Coarsening-Resistance of a Severely Deformed Al-0.2 Wt% Sc Alloy . . . . . . . . . 272Yan Huang

The Effect of Modified Strain-Induced Melt Activation (Modified SIMA)Process on the Microstructure and Mechanical Properties of Al-7Si Alloy . . . . . 277Chandan Choudhary, K. L. Sahoo, and D. Mandal

Effect of Mg on Flow Behavior of Al–Mg Alloys and Its Constitutive ModelingUsing Finite Element Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283Shahin Ahmad, Vilas Tathavadkar, Alankar Alankar, and K. Narasimhan

Influence of Thermal Treatment and Design Parameters on the Fatigue Lifeof Automotive Control Arm Fabricated from A357 Semi-solid Alloy . . . . . . . . . . 289Mohamed Attia, Khaled Ragab, Mohamed Bouazara, and X. Grant Chen

The Formation of Al6(Fe, Mn) Phase in Die-Cast Al–Mg Alloys . . . . . . . . . . . . . 297Xiangzhen Zhu and Shouxun Ji

Spark Plasma Sintering of Graphene Nanoplatelets Reinforced Aluminium6061 Alloy Composites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301Mahmood Khan, Rafi Ud-Din, Abdul Wadood, Wilayat Husain Syed, Shahid Akhtar,and Ragnhild Elizabeth Aune

Effects of Mn and Mo Micro-additions on Al–Zr–Sc–Er–Si MechanicalProperties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312Shipeng Shu, Anthony De Luca, David N. Seidman, and David C. Dunand

Nanotreating High-Zinc Al–Zn–Mg–Cu Alloy by TiC Nanoparticles . . . . . . . . . . 318Jie Yuan, Min Zuo, Maximilian Sokoluk, Gongcheng Yao, Shuaihang Pan,and Xiaochun Li

Microstructure and Mechanical Response of an Artificially Aged Al–Mg–SiAlloy: Experiments and Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324Yoojin Kim and Sharvan Kumar

Effect of Zn Additions on the Mechanical Properties of High StrengthAl–Si–Mg–Cu Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331Sung Su Jung, Soo Been Hwang, Byung Joo Kim, Yong Ho Park,and Young Cheol Lee

Utilization of 3D Printed Materials in Expendable Pattern Casting Process . . . . 338Dika Handayani, Nicole Wagner, Victor Okhuysen, Michael Seitz,and Kyle Garibaldi

Hemming Evolution of 6xxx Aluminum Alloys in the Course of Natural AgingFollowing the Continuous Annealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345M. Lalpoor, E. Lambrechts, A. Miroux, C. Bollmann, and C. Yu

The Effect of Deformation Mode and Microstructure on the IGC Susceptibilityof Al–Mg–Si–Cu Alloys for Automotive Applications . . . . . . . . . . . . . . . . . . . . . 352R. Müller-Jena, J. Becker, T. Beyer, T. Hentschel, M. Rosefort, A. Stieben,and D. Zander

Evolution of Grain Refinement in AA5083 Sheet Metal Processed by ECAP . . . . 362Christian Illgen, Philipp Frint, Maximilian Gruber, Wolfram Volk,and Martin F.-X. Wagner

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Mechanical and Microstructural Behavior of Dissimilar AA2014-T6and AA7075-T6 Aluminium Alloys Joined by Friction Stir Welding . . . . . . . . . . 370Mohammad Adil and Jyoti Mukhopadhyay

High Strength Nanotreated Filler Material for TIG Welding of AA6061 . . . . . . . 380Maximilian Sokoluk, Gongcheng Yao, Shuaihang Pan, Chezheng Cao,and Xiaochun Li

Optimization of Thermo-Mechanical Processes of Continuous CastingProducts Using High Magnesium Aluminum Alloys in Automotive IndustryApplications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386Görkem Demir, Ali Ulaş Malcıoğlu, Sümbüle Sağdiç, Ali Ulus, Salim Aslanlar,and Erdinç İlhan

Plastic Flow of AA6013-T6 at Elevated Temperatures and Subsequent Reagingto Regain Full Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400Katherine E. Rader, Jon T. Carter, Louis G. Hector Jr., and Eric M. Taleff

Influence of Chemical Composition and Pre-deformationon the Age-Hardening Response of Al-Mg-Si Alloys . . . . . . . . . . . . . . . . . . . . . . 406A. Wimmer

Hot Deformation and Die-Quenching of 6000-Series Alloys—The Effectof Quench-Interruption Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412Tanja Pettersen, Benedikte Jørgensen Myrold, Calin Daniel Marioara,and Ola Jensrud

Descriptors and Predictors: New Tools for the Predictive Modellingof Production Paths and the Properties of Aluminum-Based End-Products . . . . . 419Varužan Kevorkijan

Effect of Extrusion Parameters on Microstructural and Mechanical Propertiesof EN AW 6063 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425Mehmet Buğra Güner, Cem Mehmetalioğlu, Osman Halil Çelik, Murat Konar,and Görkem Özçelik

Simulation Study on Equal Channel Right Angular Extrusion Processof Aluminum Alloy 6061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433Wenhuan Jiang, Liangying Wen, Huan Yang, Mengjun Hu, Meilong Hu,Jiahuan Jiang, and Paul K.-L. Song

Characterization of Dynamic Material Property of AlSi10 Mg Aluminum AlloyUnder High Strain Rate Compressive Loading . . . . . . . . . . . . . . . . . . . . . . . . . . 440Md Salah Uddin, Kristofer Kuelper, and Brahmananda Pramanik

Current Efficiency for Direct Production of an Aluminium–Titanium Alloyby Electrolysis in a Laboratory Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445Omar Awayssa, Rauan Meirbekova, Gudrun Saevarsdottir, Gudjon Atli Audunsson,and Geir Martin Haarberg

Corrosion Inhibition Effect of Aloe Saponaria Gel on the Corrosion Resistanceof Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452Malena Soledad Friedrich, Alicia Esther Ares, and Claudia Marcela Méndez

Experimental Investigation of MgAl2O4 Spinel Formation in Oxidationof Al–Mg Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460Young-Ok Yoon, Seong-Ho Ha, Bong-Hwan Kim, Hyun-Kyu Lim, and Shae K. Kim

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Impact of Dispersion Hardening by Alumina Nano Particles on MechanicalProperties of Al 1100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465Ilya Zhukov, Alexander Kozulin, Anton Khrustalev, Evgeny Moskvichev,Alexander Vorozhtsov, and Dmitry Lychagin

Investigation of Temperature Variation During Friction Drilling of 6082and 7075 Al-Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471Nadia Hamzawy, Mahmoud Khedr, Tamer S. Mahmoud, Iman EI-Mahallawi,and Tarek A. Khalifa

Study on the Anti-EMF of Al-Er Master Alloy Prepared by Er2O3

as Erbium Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478Hongguang Kang, Jidong Li, Chaogang Zhang, Qian Wang, Yiyong Wang,Zhe Ning, Jilin Lu, and Jing Li

Part III Aluminum Reduction Technology

Comparison Between Different Laminated Aluminum Busbars ExpansionJoints in Terms of Mechanical Performance and Relative Costs . . . . . . . . . . . . . 485André Felipe Schneider, Daniel Richard, David Leroux, Olivier Charette,and Francis Quintal

Demo Retrofit Study of a Chinese Inspired Cell Technology . . . . . . . . . . . . . . . . 495Marc Dupuis and Valdis Bojarevics

Mass Transport by Waves on the Bath Metal Interface in Electrolysis Cell . . . . 510L. Rakotondramanana, L. I. Kiss, S. Poncsák, S. Guérard, and J.-F. Bilodeau

Numerical Investigation of Flow Field Effect on Ledge Shape in AluminumReduction Cell by Coupled Thermo-Flow Model . . . . . . . . . . . . . . . . . . . . . . . . . 517Hongliang Zhang, Qiyu Wang, Shuai Yang, Jie Li, Jinding Liang, and Ling Ran

Study of Heat Distribution Due to ACD Variations for Anode Setting . . . . . . . . 527Choon-Jie Wong, Yuchen Yao, Jie Bao, Maria Skyllas-Kazacos, Barry J. Welch,and Ali Jassim

Anodic Incident Detection through Multivariate Analysis of Individual AnodeCurrent Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535David LaJambe, Éric Poulin, Carl Duchesne, and Jayson Tessier

Fault Detection and Diagnosis of Alumina Feeding System Using IndividualAnode Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543Yuchen Yao, Jie Bao, Maria Skyllas-Kazacos, Barry J. Welch, and Ali Jassim

Change of Anode Operation Pattern from Single to Double Staircaseat Albras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550Camila R. Silva, Vanderlei O. Fernandes, Nilton F. Nagem, and Ivar E. V. Sousa

An Advanced Nonlinear Control Approach for Aluminum Reduction Process . . . 556Jing Shi, Yuchen Yao, Jie Bao, Maria Skyllas-Kazacos, Barry J. Welch,and Ali Jassim

Model Based Approach for Online Monitoring of Aluminum ProductionProcess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566Lucas José da Silva Moreira, Gildas Besançon, Francesco Ferrante, Mirko Fiacchini,and Hervé Roustan

Predictive Analytics for Enhancing Productivity of Reduction Cells . . . . . . . . . . 572Shanmukh Rajgire, Abhijeet Vichare, Amit Gupta, and Devendra Pathe

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Restart of Shutdown Pots: Troubles, Solutions and Comparison with NormalPots to Improve Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579Ved Prakash Rai and Vibhav Upadhyay

Electrochemical Behaviour of Cu-Al Oxygen-Evolving Anodesin Low-Temperature Fluoride Melts and Suspensions . . . . . . . . . . . . . . . . . . . . . 591Andrey S. Yasinskiy, Sai Krishna Padamata, Peter V. Polyakov,Aleksandr S. Samoilo, Andrey V. Suzdaltsev, and Andrey Yu. Nikolaev

Alumina Concentration Measurements in Cryolite Melts . . . . . . . . . . . . . . . . . . . 600Luis Bracamonte, Karoline Nilsen, Christian Rosenkilde, and Espen Sandnes

The Influence of Polarisation on the Wetting of Graphite in Cryolite–AluminaMelts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608Henrik Åsheim, Ingrid A. Eidsvaag, Asbjørn Solheim, Henrik Gudbrandsen,Geir M. Haarberg, and Espen Sandnes

Oxidation Study of Zinc Sulfite on the Removal of Sulfur Dioxide fromAluminum Electrolysis Flue Gas by Zinc Oxide . . . . . . . . . . . . . . . . . . . . . . . . . 620Xuejiao Cao, Ting-an Zhang, Yan Liu, Weiguang Zhang, and Simin Li

Electrolysis of Low-temperature Suspensions: An Update . . . . . . . . . . . . . . . . . . 626Andrey Yasinskiy, Andrey Suzdaltsev, Sai Krishna Padamata, Petr Polyakov,and Yuriy Zaikov

Adapting Modern Industrial Operation Parameters in a StandardizedLaboratory Cell for Measuring Current Efficiency for Aluminium Deposition:Unexpected Challenges and Lessons Learned . . . . . . . . . . . . . . . . . . . . . . . . . . . 637R. Meirbekova, O. Awayssa, G. M. Haarberg, and G. Saevarsdottir

Aluminium Smelter Crust—Phase Distribution and Structure Analysis of TopZone Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644Shanghai Wei, Jingjing Liu, George Allan, Tania Groutso, John J. J. Chen,and Mark P. Taylor

Influence of Anode Cover Material Particle Size Composition on Its PhysicalProperty and Insulation Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653Changlin Li, Junqing Wang, Yunfeng Zhou, Bin Fang, Yanfang Wang,and Qingguo Jiao

Lab Scale Experiments on Alumina Raft Formation . . . . . . . . . . . . . . . . . . . . . . 659Sindre Engzelius Gylver, Asbjørn Solheim, Henrik Gudbrandsen, Åste Hegglid Follo,and Kristian Etienne Einarsrud

Mass- and Heat Transfer During Dissolution of Alumina . . . . . . . . . . . . . . . . . . 664Asbjørn Solheim and Egil Skybakmoen

The Rate of HF Formation During Addition of Alumina to NaF-AlF3 Melts . . . . 672Karen S. Osen, Dian Mughni Fellicia, Christian Rosenkilde, Camilla Sommerseth,and Ole Kjos

Validation of the Gravimetric Method to Properly Follow Alumina Dissolutionin Cryolitic Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680Jonathan Alarie, Thomas Roger, László I. Kiss, Sándor Poncsák, Sébastien Guérard,and Jean-François Bilodeau

Development of a Mathematical Model to Simulate Raft Formation . . . . . . . . . . 688T. Roger, K. Fraser, L. Kiss, S. Poncsák, S. Guérard, J. F. Bilodeau, and G. Bonneau

Contents xiii

Efficient Alumina Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696Jan Paepcke, Arne Hilck, Michael Altmann-Rinck,and Andrej Meinhardt

Status Analysis of Particle Size Distribution and Attrition Index of the SmelterGrade Alumina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704Youjian Yang, Xiaojuan Pang, Junfeng Qi, Wenju Tao, Zhaowen Wang,Fengguo Liu, Aimin Liu, Jiangyu Yu, Bingliang Gao, Zhongning Shi, and Xin Shu

The Effect of Hard Scale Deposition on the Wall Heat Flux of a Cold Finger . . . 710Daniel Perez Clos, Sverre Gullikstad Johnsen, Petter Nekså,and Ragnhild Elizabeth Aune

The Application of Intelligent Breaking and Feeding Technology forAluminium Reduction Pot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719Bo Hong, Qinghong Tian, Zhiyang Chen, Xiaotian Tan, and Shiping Yu

Reducing the Carbon Footprint: Aluminium Smelting with Changing EnergySystems and the Risk of Carbon Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726Gudrun Saevarsdottir, Halvor Kvande, and Barry J. Welch

Measurement System for Fugitive Emissions in Primary AluminiumElectrolysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735Håkon Aleksander Hartvedt Olsen Myklebust, Thor A. Aarhaug,and Gabriella Tranell

Validation of QCL CF4 Gas Analyzer for Sensitivity and Selectivity . . . . . . . . . . 744Thor Anders Aarhaug

A Laboratory Study of the HF Generation Potential of Particulate Fluoridesfrom Cell Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751Jenny H. Hung and James B. Metson

Method Development to Estimate Total Low Voltage and High VoltagePFC Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 758Luis Espinoza-Nava, Christine Dubois, and Eliezer Batista

Update on SO2 Scrubbing Applied in Primary Aluminium Smelters . . . . . . . . . . 766Stephan Broek

Optimization of a Gas Treatment Center Equipped with Extended Surface BagFilters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777Julie Dontigny, Stephan Broek, Philippe Martineau, Mario Dion,and Raymond Emond

Update on the Abart Gas Treatment and Alumina Handling at the KarmøyTechnology Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785Anders Sørhuus, Sivert Ose, Eivind Holmefjord, Håvard Olsen, and Bent Nilsen

The Australian Energy Crisis, Its Impact on Domestic Aluminium Smeltingand Potential Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791David S. Wong, Geoff Matthews, Alton T. Tabereaux, Tim Buckley,and Mark M. Dorreen

Recycling of the Flue Gas from Aluminium Electrolysis Cells . . . . . . . . . . . . . . . 803Asbjørn Solheim and Samuel Senanu

Utilization of Waste Heat for Pre-heating of Anodes . . . . . . . . . . . . . . . . . . . . . . 811Martin Grimstad, Kim Ronny Elstad, Asbjørn Solheim,and Kristian Etienne Einarsrud

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Toward Minimizing the of Co-evolution of PFC Emission in EGA Smelter . . . . . 817Ali Jassim, Najeeba Al Jabri, Sergey Akhmetov, Daniel Whitfield, and Barry Welch

Development and Application of GP500+ Energy Saving AluminumReduction Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 827Zhuojun Xie, Song He, and Hongmin Ao

Part IV Cast Shop Technology

Hands-Free Casting at AMAG Casting GmbH—It Is Possible! . . . . . . . . . . . . . . 837Bernd Prillhofer, Rudolf Dobler, and Thomas Mrnik

User-Friendly Surveillance Tools to Prevent Bleed-Out During Cast Start . . . . . 844M. Badowski, D. Krings, G. U. Gruen, W. Droste, Ph. Meslage, and B. Jaroni

Beryllium Reduction Potential in AlMg Cast Alloys . . . . . . . . . . . . . . . . . . . . . . 852J. Steglich, A. Basa, A. Kvithyld, N. Smith, and I. Zerbin

Accurate Real-Time Elemental (LIBS) Analysis of Molten Aluminumand Aluminum Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 860Sveinn Hinrik Gudmundsson, Jon Matthiasson, and Kristjan Leosson

Industrial Verification of Two Rotor Fluxing in Large Crucibles . . . . . . . . . . . . 865Terje Haugen, Arild Håkonsen, and Vegard Innerdal

Dynafeed: An Improved Crucible Transfer System . . . . . . . . . . . . . . . . . . . . . . . 868André Tremblay, Jean-Francois Desmeules, and Martin Dubois

Metal Transfer from Furnace to Furnace—A Case Study . . . . . . . . . . . . . . . . . . 873Olivier Dion-Martin, Pierre Jeanroy, Jean-Francois Desmeules, and Marek Varadinek

Heavily Loaded Areas in Aluminum Melting Furnaces and PossibleRefractory Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 879Thomas Schemmel, Rüdiger Pfaar, and Uwe Kremer

Mold Shape Control for Direct Chill Ingot Casting . . . . . . . . . . . . . . . . . . . . . . . 887Craig Cordill

Continuous Monitoring of Butt Curl Development During DCCasting—Development and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 892Werner Ewald Droste, Daniel Krings, Gerd-Ulrich Gruen, Mark Badowski,and Markus Hagen

Constellium’s Mould Technology for Al Alloy Slab DC Casting . . . . . . . . . . . . . 901Ph. Jarry, O. Ribaud, L. Jouët-Pastré, E. Waz, P. Delaire, P.-Y. Menet, M. Bertherat,and P. Celle

Fluid Flow Analyses and Meniscus Behavior During the Horizontal Single BeltCasting (HSBC) of Aluminum Alloy AA6111 Strips . . . . . . . . . . . . . . . . . . . . . . 909Roderick Guthrie, Mihaiela Isac, and Donghui Li

Effect of Water Flow Distribution on the Performance of AluminiumSmall-Form Ingot Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917Lei Pan, Eric Laplante, and Francis Breton

Small Scale Oxidation Experiments on AlMg Alloys in Various Gas FiredFurnace Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 923A. Johansson, E. Solberg, M. Skramstad, T. Kvande, J. Lodin, N. Smith,M. Syvertsen, and A. Kvithyld

Contents xv

Study of the Oxidation of an Al-5Mg Alloy in Various Industrial MeltingFurnace Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 930Johannes Lodin, Martin Syvertsen, Anne Kvithyld, Anders Johansson, Egil Solberg,and Thomas Kvande

Batscan™, Constellium In-melt Ultrasonic Inclusion Detector: IndustrialPerformance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 936Jean-Louis Achard, Nicolas Ramel, Guido Beretta, Pierre-Yves Menet,Jocelyn Prigent, and Pierre Le Brun

Benchmark and Practical Application of State of the Art HydrogenMonitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 944A. Pelss, J. Morscheiser, S. Radwitz, J. Kremer, and A. Gilles

Molten Aluminum Quality Evaluations for Thin Foil Products . . . . . . . . . . . . . . 951Çisem Doğan, A. Ulaş Malcıoğlu, Anıl Ozkaya, Eren Toraman, and Ali Ulus

Industrial Verification of One- and Two-Chamber Siphon Degassing . . . . . . . . . 959Arild Håkonsen and Terje Haugen

Evaluation of CFF and BPF in Pilot Scale Filtration Tests . . . . . . . . . . . . . . . . . 963M. Syvertsen, I. Johansen, A. Kvithyld, S. Bao, U. Eriksen, B. E. Gihleengen,S. Akhtar, A. Bergin, and A. Johansson

Dynaprime Filtration Technology Experience at Alcoa Baie-Comeau . . . . . . . . . 972Francis Caron and Jean-Francois Desmeules

Improving Ultrasonic Melt Treatment Efficiency Through Flow Management:Acoustic Pressure Measurements and Numerical Simulations . . . . . . . . . . . . . . . 981Tungky Subroto, Dmitry G. Eskin, Christopher Beckwith, Iakovos Tzanakis,Georgi Djambazov, and Koulis Pericleous

Impact of TiB2 Particle Size Distribution on Grain Refining Effectiveness . . . . . 988Akihiro Minagawa

Effect of Nucleant Particle Size Distribution on the Grain Refining Efficiencyof 7xxx Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 994G. Salloum-Abou-Jaoude, Ph. Jarry, P. Celle, and E. Sarrazin

Impact of Transition-Metal Elements on Grain Refiner Performancein AA6061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000Elli Tindall, Samuel R. Wagstaff, and Kathleen Bennett

Application Ultrasonic Technology Processing for Aluminum TreatmentWhile Casting Slabs on Industrial Equipment of UC RUSAL . . . . . . . . . . . . . . . 1007I. V. Kostin, A. Y. Krokhin, V. F. Frolov, S. G. Bochvar,I. V. Bobkov, and N. E. Laschukhin

Influence of Liquid Jet Stirring and In-Situ Homogenizationon the Intermetallics Formation During DC Casting of a 6xxxAl Alloy Rolling Ingot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1013S. Kumar, J. Cracroft, and R. B. Wagstaff

Digital Manufacturing for Foundries 4.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1019Prateek Saxena, Michail Papanikolaou, Emanuele Pagone, Konstantinos Salonitis,and Mark R. Jolly

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Integrating Fluid Simulation with Virtual Die Casting Machine for Industry 4.0and Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1026John Moreland, John Estrada, Edwin Mosquera, Kyle Toth, Armin K. Silaen,and Chenn Q. Zhou

Numerical Simulation of Wire Rod Casting of AA1370 and AA6101 Alloys . . . . 1032Dag Lindholm, Shahid Akhtar, and Dag Mortensen

Influence of Nozzle Shape on Near-Surface Segregation Formation DuringTwin-Roll Casting of Aluminum Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1039Olexandr Grydin, Mykhailo Stolbchenko, and Mirko Schaper

Effect of Ultrasonic Treatment on the Eutectic Phase and Cu Contentin the Al Matrix of Large-Scale 2219 Al Alloy Ingot . . . . . . . . . . . . . . . . . . . . . . 1045Li Zhang, Xiaoqian Li, Ripeng Jiang, Ruiqing Li, and Lihua Zhang

Influence of Alloying Additives on the Electrochemical Behavior of CastAl-5Zn Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052Mohamed Eissa Moussa, Hoda Elkilany, Shimaa El-Hadad, and Madiha Shoeib

Thermal Analysis and Microstructure of Al-12%Si-2.5%Cu-0.4%Mg CastAlloy with Ce and/or La Rare Earth Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056Mahmoud Tash, Waleed Khalifa, and Iman El-Mahallawi

Numerical Simulation of Temperature Field in 6061 Aluminum AlloyVertical Twin-Roll Casting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1063Chaopan Xie, Xiaoping Liang, and Yu Wang

Part V Cast Shop Technology: Recycling and Sustainability Joint Session

Constellium R&D Approach in Recycling, From Lab to Industrial Scale . . . . . . 1073A. Pichat, A. Vassel, P. Y. Menet, and L. Jouët-Pastre

Representative Sampling, Fractionation and Melting of Al-Scrap . . . . . . . . . . . . 1083Stefan Wibner, Helmut Antrekowitsch, and Barbara Falkensammer

Recycling of Aluminium from Mixed Household Waste . . . . . . . . . . . . . . . . . . . . 1091Sigvart Eggen, Kurt Sandaunet, Leiv Kolbeinsen, and Anne Kvithyld

An Assessment of Recyclability of Used Aluminium Coffee Capsules . . . . . . . . . . 1101Mertol Gökelma, Fabian Diaz, Ilayda Elif Öner, Bernd Friedrich,and Gabriella Tranell

Fractional Solidification for Purification of Recycled Aluminium Alloys . . . . . . . 1110Susanna Venditti, Dmitry Eskin, and Alain Jacot

A Rapid Method of Determining Salt Flux Melting Point and Composition . . . . 1119Ray D. Peterson

Recovery of Aluminium Metal Using Ultrasonic Technique and Productionof Al–Si Hypereutectic Alloys from 6063 Alloy’s Black Dross Using SiliconLumps and Flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1128G. M. Taha, Ahmed S. Aadli, and A. A. Ebnalwaled

Automatic Skimming Procedure for Reducing Aluminium Lossesand Maintaining the Uniform Quality of the Molten Metal . . . . . . . . . . . . . . . . . 1137Varužan Kevorkijan, Uroš Kovačec, and Sandi Žist

Contents xvii

Evaluation of the Effect of CO2 Cover Gas on the Rate of Oxidationof an AlMgSi Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1141Cathrine Kyung Won Solem, Kai Erik Ekstrøm, Gabriella Tranell,and Ragnhild E. Aune

Part VI Electrode Technology for Aluminum Production

The Development of Anode Shape, Size and Assembly Designs—Past, Presentand Future Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1151Barry J. Welch

10 Years of Anode Research and Development: Alcoa and Université LavalExperience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1161Jayson Tessier, Julien Lauzon-Gauthier, Mario Fafard, Houshang Alamdari,Carl Duchesne, and Louis Gosselin

Carbon Anode Raw Materials—Where Is the Cutting Edge? . . . . . . . . . . . . . . . 1163Les Edwards

Solids Flow Considerations and Their Impact in Smelter Carbon PlantOperations and Product Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1166Brian H. Pittenger and Andrés D. Orlando

How to Improve the Environmental Efficiency of the Hall-Heroult ProcessWhile Producing and Using Carbon Anodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1171Antti Koulumies, Ana Maria Becerra, Paul Merlin, Lasse Piechowiak,and Martin Zapke

Trends in Anode Carbon Production Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . 1174Derek Santangelo

Development of a Soft Sensor for Detecting Overpitched Green Anodes . . . . . . . 1176Adéline Paris, Carl Duchesne, Éric Poulin, and Julien Lauzon-Gauthier

Diffusion Measurements of CO2 Within Carbon Anodes for AluminiumSmelting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1183Epma Putri, Geoffrey Brooks, Graeme A. Snook, Lorentz Petter Lossius,and Ingo Eick

Testing of SERMA Technology on Industrial Anodes for Quality Controlfor Aluminum Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1189Yasar Kocaefe, Duygu Kocaefe, Dipankar Bhattacharyay, Abderrahmane Benzaoui,and Jean-François Desmeules

Modelling of Gas Injection on Anode Baking Furnace and Applicationto Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1196Sandra Besson, Solène Bache, Arnaud Bourgier, Jean-Philippe Schneider,and Thierry Conte

Higher Baking and Production Levels in Anode Baking Furnacesand Associated Challenges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1203SyedArif Ali, Charles Lebel-Tremblay, Pierre-Yves Brisson,and Alexandre Gagnon

xviii Contents

Major Reconstruction of Central Casing of Open Top Baking Furnacewith a View to Increase Its Lifespan and Reduce the Total Costs Comparingto Full Reconstruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1210Christos Zarganis, Eftychia Liantza, Harilaos Dolgyras, Giannakis Christos,Kosmetatos Dionysios, Christophe Molinier, and Arnaud Bourgier

Regulation and Management of Anode Baking Furnace Production CycleDuring Green Anode Crisis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1218Kalpataru Samal and Suryakanta Nayak

Sustainable Spent Pot Line Management Guidance . . . . . . . . . . . . . . . . . . . . . . . 1225Pernelle Nunez

Purification of Graphite by Thermal Vacuum Treatment of Spent Potlining . . . . 1231Kristin Sundby, Ulf Sjöström, Ellen Myrvold, and Morten Isaksen

The LCL&L Process: A Sustainable Solution for the Treatment and Recyclingof Spent Pot Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1237Laurent Birry and Stephane Poirier

Experimental Study on the Collecting Agent for Spent Potlining FlotationIndex Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1243Nan Li, Lei Gao, and Kinnor Chattopadhyay

Environmental Benefits of Using Spent Pot Lining (SPL) in CementProduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1251Mohammad Al Jawi, Chun Man Chow, Srinivasa Pujari, Michael Pan,Tanvi Kulkarni, Mohamed Mahmoud, Heba Akasha, and Salman Abdulla

Characteristic Analysis of Hazardous Waste from Aluminum ReductionIndustry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1261Mingzhuang Xie, Han Lv, Tingting Lu, Hongliang Zhao, Rongbin Li,and Fengqin Liu

Energy Saving in Hall–Héroult Cell by Optimization of Anode AssemblyDesign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1267Abdul-Mageed M. Shamroukh, S. A. Salman, William Berends, W. A. Abdel-Fadeel,and G. T. Abdel-Jaber

High Temperature Creep Behaviour of Carbon-Based Cathode Materialfor Aluminum Electrolysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1278Wei Wang and Kai Sun

Redesigning of Current Carrying Conductor—The Energy Reduction Initiativein Low Amperage Hall-Héroult Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1283Ved Prakash Rai and Vibhav Upadhyay

Ready-to-Use Cathodes for the Hall-Héroult Process . . . . . . . . . . . . . . . . . . . . . . 1291Markus Pfeffer, Oscar Vera Garcia, Louis Bugnion, and Laure von Kaenel

Mechanism Understanding of Sodium Penetration into Anthracite Cathodes:A Perspective from Diffusion Coefficients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1299Jiaqi Li, Hongliang Zhang, Jingkun Wang, and Yunrui Wang

Anhydrous Carbon Pellets—An Engineered CPC Raw Material . . . . . . . . . . . . . 1309Les Edwards, Maia Hunt, and Christopher Kuhnt

Influence of Particle Shape and Porosity on the Bulk Density of Anode GradePetroleum Coke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1319Frank Cannova, Mike Davidson, and Barry Sadler

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An EXAFS and XANES Study of V, Ni, and Fe Speciation in Cokes for AnodesUsed in Aluminum Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1327Gøril Jahrsengene, Hannah C. Wells, Camilla Sommerseth, Arne Petter Ratvik,Lorentz Petter Lossius, Katie H. Sizeland, Peter Kappen, Ann Mari Svensson,and Richard G. Haverkamp

Additive Selection for Coal Tar Pitch Modification in Aluminium Industry . . . . 1329Julie Bureau, Armita Rastegari, Duygu Kocaefe, Yasar Kocaefe, and Hans Darmstadt

Charcoal and Use of Green Binder for Use in Carbon Anodes in the AluminiumIndustry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1338Camilla Sommerseth, Ove Darell, Bjarte Øye, Anne Støre, and Stein Rørvik

Author Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1349

Subject Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1355

xx Contents

About the Editor

Alan Tomsett has been involved in research and industrialapplication of materials and metals for 40 years, with themajority of this time in the aluminium industry. He received hisB.Sc. and Ph.D. in Chemical Engineering from the Universityof New South Wales in Sydney, Australia and worked as aResearch Scientist at Kyoto University, Japan. He joined theComalco Research Centre in Melbourne, Australia in 1987 andhas held numerous technical and business improvement roles atComalco/Rio Tinto including Carbon R&D Manager, ProgramDirector for the global Rio Tinto Alcan Carbon R&D Team,and Carbon Technical Manager for the Rio Tinto AluminiumPacific Region. He is now Technical Manager—AluminiumSmelting for Rio Tinto Pacific Operations, where he providesstrategic direction, technical support and advice on carbon,aluminium reduction, casting, and raw material procurement tothe Rio Tinto aluminium smelters in the Pacific region.

He has been a member of TMS since 1996 and a regularattendee of the Annual Meeting since 2000. He has been amember of the Aluminum Committee since 2011 where hiscontributions include Electrode Symposium Chair (2011);Lead Editor of Essential Readings in Light Metals, Volume 4—Electrode Technology for Aluminum Production (2013); andSecretary (2011–2015). He has been an Electrode TechnologySession Chair on four occasions and has coauthored severalLight Metals and JOM papers. He was on the organisingcommittee of the successful 12th Australasian AluminiumSmelting Conference in Queenstown, New Zealand, has been aguest lecturer for the University of New South Wales/University of Auckland Graduate Program in AluminiumSmelting Technology, and a regular contributor to earlierAustralasian Aluminium Smelting Conferences.

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Program Organizers

Alumina and Bauxite

James Vaughan is Head of the University of QueenslandHydrometallurgy Research Group within the School ofChemical Engineering. He obtained a bachelor’s degree inMetallurgical Engineering at McGill University (2001) fol-lowed by Master of Applied Science (2003) and Ph.D.(2008) degrees in Materials Engineering at The University ofBritish Columbia. He recently served as Director of theUniversity of Queensland Rio Tinto Bauxite & AluminaTechnology Centre and previously worked as a researchengineer in extractive metallurgy with Placer Dome (gold) andBHP (nickel).

Aluminum Alloys, Processing and Characterization

Dmitry G. Eskin received his Engineering and Ph.D. degreesfrom Moscow Institute of Steel and Alloys (TechnicalUniversity, Russia) in 1985 and 1988, respectively. After that,he worked as a Senior Scientist in the Baikov Institute ofMetallurgy (Russian Academy of Sciences) with main researchfoci of alloy development and heat treatment and processing ofaluminum alloys. In 1999–2011, he was a Senior Scientist anda Fellow in Materials Innovation Institute and after 2008 alsoheld a position of an Associate Professor at Delft University ofTechnology (The Netherlands), where he conducted funda-mental and applied research on solidification processing ofmetallic materials, with major contributions to direct-chillcasting. In 2011, he joined Brunel University London (U.K.) asa Professor in Solidification Research. His current researchconcerns fundamentals and application of ultrasonic cavitationto melt processing as well as alloy development. He is awell-known specialist in physical metallurgy and solidificationprocessing of light alloys, and is author or co-author of morethan 250 scientific papers, 7 monographs, and a number ofpatents. Among his books are Iron in Aluminum Alloys (2002),Multicomponent Phase Diagrams: Applications for Commer-cial Aluminum Alloys (2005), Physical Metallurgy of Direct-Chill Casting of Aluminum Alloys (2008), Direct-Chill Casting

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of Light Alloys: Science and Technology (2013), and Solidifi-cation Processing of Metallic Alloys Under External Fields(2018). He has been a member of TMS since 2000, and is a currentmember of TMS Aluminum Committee, an organizer of a numberof symposia, and a regular speaker at TMS Annual Meetings.

Aluminum Reduction Technology

Jayson Tessier is Pilot Operation Manager at Alcoa Corpo-ration Aluminum Center of Excellence. After earning a Ph.D.in chemical engineering from Université Laval in Quebec City,Canada, he joined Alcoa in 2011 as a Research Engineerwithin the Aluminum Smelting Center of Excellence. Based ona mix of floor experience and research, he delivered differenttechnological improvements related to alumina feeding forHall-Héroult cells and worked on different process improve-ments and root cause analysis projects. In 2014, he took on therole of Pilot Operation Manager, leading a team carrying outtest programs within Alcoa smelters, aimed at creeping andimproving energy and metallurgical efficiency of reductioncells. He is also leading research activities between Alcoa andUniversité Laval.

Since 2004, he has contributed to TMS and other interna-tional conferences and scientific journals and has also acted assession chairperson for the TMS Annual Meeting. With otherAlcoa colleagues, he was the recipient of the Pr. Barry WelchBest Paper Award at the 10th Australasian Smelting Tech-nology Conference in 2011.

Cast Shop Technology

Johannes Morscheiser currently holds the position of R&DManager Casting at Aleris. In this function, he is responsiblefor the casting technology group at Aleris including the pilotcasting facility in Koblenz, Germany. After finishing his M.Sc.in metallurgy in 2008 at the RWTH Aachen University inGermany, he worked there as a research assistant and becamegroup leader for vacuum metallurgy with a focus on vacuuminduction melting, electroslag remelting and vacuum arcremelting. His work included extensive projects on superal-loys, titanium and titanium aluminides, refractory metals,precious metals, and special aluminium alloys like Al-Li. In2014, he graduated with a Ph.D. in Non-Ferrous Metallurgyfrom RWTH Aachen University after he had joined Aleris in2013 as a research engineer. Since 2018 he has held his currentposition as R&D Manager Casting. In his work, he focuses onthe global support of Aleris cast shops regarding questionsabout liquid metal processing, solidification, and homoge-nization of aluminium alloys. In this context, he has builtexpertise in the fields of melt cleanliness and respective

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measurement techniques, numerical process modelling, andin-depth analysis of technical processes. Other importantaspects of his work are molten metal safety and helping peopleinside and outside his team to develop their potentials.

Cast Shop Technology: Recycling and Sustainability Joint Session

Johannes Morscheiser (see above)

Electrode Technology for Aluminum ProductionDuygu Kocaefe is a Professor at the University of Quebec atChicoutimi (UQAC). She has more than 25 years of experiencein the fields of carbon, anode production, modelling andoptimisation of industrial processes, heat and mass transfer,and reaction kinetics. She has a B.Sc.E. (Middle East TechnicalUniversity (METU) in Turkey) and M.Sc.E. (University ofNew Brunswick (UNB) in Canada), and Ph.D. (UNB) inChemical Engineering. She has worked with several companieson various aspects of aluminium production including many oncarbon technology. She was the holder of the UQAC/Aluminerie Alouette Research Chair on Carbon. Currently,she is the UQAC Chair on Industrial Materials (Chaire insti-tutionnelle de recherche sur les matériaux industriels—CHIMI)and has many collaborative grants with industrial partners andgovernment institutions. She has published extensively in thefield of carbon, lectured in specialised conferences, and trainednumerous graduate students.

She is Director of Graduate Studies in Engineering(research) at UQAC, is responsible for the Production Axe ofRegroupement Aluminium (REGAL), is Scientific Advisor toFonds de recherche du Quebec-Nature et technologies(FRQNT), and is a Board member of the “Association de lafrancophonie à propos des femmes en sciences, technologies,ingénierie et mathématiques (AFFESTIM)”. Over the years,she has served The Minerals, Metals & Materials Society(TMS) as the session chair and the reviewer of many papers inthe Electrode Technology Symposium during annual meetings.She also has authored and coauthored a large number of paperspresented at these meetings.

Program Organizers xxv

Aluminum Committee 2019–2023

ChairpersonCorleen Chesonis, Metal Quality Solutions LLC, Pennsylvania, USA

Vice ChairpersonAlan David Tomsett, Rio Tinto Pacific Operations, Queensland, Australia

Past ChairpersonOlivier Martin, Rio Tinto, Saint-Jean, France

SecretaryStephan Broek, Hatch Ltd., Ontario, Canada

JOM AdvisorDavid Sydney Wong, University of Auckland, Auckland, New Zealand

Light Metals Division ChairEric Nyberg, Tungsten Parts Wyoming, Wyoming, USA

Members-at-Large Through 2020

Alexander Baker, Lawrence Livermore National Laboratory, California, USAHunter Henderson, Oak Ridge National Laboratory, Tennessee, USAOrlando Rios, Oak Ridge National Laboratory, Tennessee, USASugrib Kumar Shaha, University of Waterloo, Ontario, CanadaStephan Broek, Hatch Ltd., Ontario, CanadaMohamed Hassan Ali, Masdar Institute of Science & Technology, Abu Dhabi, UAEEdward McRae Williams, Arconic, Pennsylvania, USA

Members-at-Large Through 2021

Ali Jasim Banjab, Emirates Global Aluminium, Dubai, UAEKristian Etienne Einarsrud, Norwegian University of Science & Technology,Trondheim, NorwayJohn Griffin, ACT LLC, New Jersey, USAHoushang Alamdari, Laval University, Quebec, CanadaMark Doreen, Energia Potior Ltd., Auckland, New ZealandYanjun Li, Norwegian University of Science & Technology, Trondheim, NorwayArne Ratvik, SINTEF, Trondheim, NorwayBarry Sadler, Net Carbon Consulting Pty Ltd., Victoria, AustraliaZhang Tingan, Northeastern University, Shenyang, China

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Members-at-Large Through 2022

Mark Badowski, Hydro Aluminium Rolled Products, Bonn, GermanyPascal Lavoie, Alcoa, Quebec, CanadaOlivier Martin, Rio Tinto, Saint-Jean, FranceLinus Perander, Outotec Norway AS, Oslo, NorwayAndre Phillion, McMaster University, Ontario, CanadaXiyu Wen, Secat Inc, Kentucky, USA

Members-at-Large Through 2023

Corleen Chesonis, Metal Quality Solutions LLC, Pennsylvania, USAMarc Dupuis, GeniSim Inc, Quebec, CanadaSebastien Fortin, Rio Tinto, Quebec, CanadaJohn Grandfield, Grandfield Technology Pty Ltd., Victoria, AustraliaLorentz Petter Lossius, Hydro Aluminium AS, Ovre Ardal, NorwayPierre-Yves Menet, Constellium Technology Center, Voreppe, FranceHoromi Nagaumi, Soochow University, Jiangsu, ChinaNigel Jeffrie Ricketts, Altrius Engineering Services, Queensland, AustraliaAlan David Tomsett, Rio Tinto Pacific Operations, Queensland, AustraliaSam Wagstaff, Novelis Inc, Georgia, USA

xxviii Aluminum Committee 2019–2023