In an aluminum smelter, aluminum is produced in numerous electrolysis cells, also known as pots. Each cell has a limited lifespan and needs to be relined (replacing the cathode) to continue operating for a new cycle. Typically, the lifespan of a cell ranges from 5 to 7 years.

To withstand the intense heat of molten aluminum, which reaches approximately 960 degrees Celsius, the relining, preheating, and startup of the cell are critical processes. Additionally, the materials used for this purpose are expensive.

Challenge:

Proper preheating is a vital step in the startup process to ensure optimal performance and extend the cell's operational lifespan.
Both the lining material and cathode carbon within the cell must be gradually and carefully heated before the molten bath can be added.
Adding the bath to a cell that has not reached the proper temperature can cause thermal shock to the lining and cathode, which significantly increases the risk of crack formation, ultimately shortening the cell's lifespan.
Inadequate preheating also raises the risk of startup anode effects (AE), which can lead to an increase in harmful greenhouse gas emissions, such as PFC and CO2.
Therefore, it is essential to monitor the cathode temperature during startup. However, the measurement conditions are difficult due to the high heat and electromagnetic interference that the sensors face. Moreover, manual temperature readings are labor-intensive, requiring operators to spend considerable time connecting and disconnecting equipment for monitoring.

Solution

Using Neuron Thermocouple Type K sensors, temperature readings are accurately captured throughout the preheating phase.
Any deviation from the predefined temperature limits triggers an early warning.
This data can be used to optimize processes, such as adjusting the electrical load for efficient preheating.
Neuron Thermocouple Type K sensors deliver precise wireless measurements, ensuring minimal interference from electromagnetic noise, which is common with wired sensors.
The sensors can be easily integrated with the standard Type K probes that are already in use in most facilities.

What You Gain

Lower risk of thermal shock when the molten bath is introduced, which helps extend the life of the electrolysis cell.
Proper preheating reduces the occurrence of startup anode effects (AE), decreasing the release of harmful emissions such as PFC and CO2.
Achieving the optimal start temperature leads to quicker transition to normal operations, improving the overall efficiency and lifespan of the cell.
Immediate alerts when temperatures exceed predefined thresholds.
Continuous temperature monitoring provides a reliable data foundation, supporting further optimization and ensuring quality assurance with historical data.
Wireless sensors simplify installation and speed up sensor connectivity.
The sensors connect seamlessly with standard Type K measuring probes.