Development of a new baking furnace design without headwall to increase anode production capacity

Abstract

Anode baking furnaces are a key component of the manufacturing process of prebaked anodes used for aluminium production. Green anodes are loaded into pits before being submitted to high temperature in order to meet resistivity and chemical reactivity specifications. These pits are separated from each other by fluewalls and headwalls made of dense refractory material. In order to answer to the need for productivity increase and cost reduction, a new generation of design for baking furnace without headwalls has been developed. From the proof of concept and the first tests realized in Rio Tinto Aluminium Grande Baie plant (UGB) to the industrial prototype implemented at Bell Bay Aluminium (BBA), this paper presents the different phases undertaken to successfully develop and test this breakthrough technology. The adaptations made to the operation sequences and the specific tools used to operate the industrial prototype will be described as well as the performance achieved to date at the two sites. Finally, the paper concludes with a summary of the benefits of this technology depending on the scenario of implementation on greenfield or brownfield projects.