Hall-Heroult Centennial E-Book

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 247

Veröffentlichungsjahr: 2013

Beschreibung

A rich collection of insightful papers and photos gathered from the world's top aluminum companies highlight the important developments in the process metallurgy of aluminum from 1886-1986, including the electrolytic method of making aluminum, emission and waste control measures in plant operations, manufacture of carbon electrodes, methods of processing bauxite and alumina, technology for melting and casting process ingots, and processes for reclamation and recycling. Following the growth of the aluminum industry from infant to giant, this book features insight into the lives of Charles Hall and Paul HTroult, who devised a method of aluminum production that would revolutionize the industry, as well as descriptions of developments in technology, equipment, and practice in the various areas of aluminum process metallurgy.

Leseprobe

Contents

Cover

Title Page

Copyright page

Preface

Acknowledgements

Abbreviations

Pictorial Review

Reduction Technology

Carbon Technology

Coal Tar Pitch

Coke Calcination

Green Anode and Cathode Preparation

Anode Baking

Anode Developments

Alumina/Bauxite

Alumina

Bauxite

Cast Shop Technology

Melting

Metal Treatment

Direct Chill Casting

Electromagnetic Casting

Continuous Casting

Reclamation and Recycling

Safety

Environmental Control

Emission control systems at various locations from 1962 to 1982. Air Industrie.

Invited Papers

Charles Martin Hall The Young Man, His Mentor, and His Metal

Introduction

Professor and Student

Curricular and Extracurricular Studies

Electrolysis Experiments

Success

Commercialization

Recognition

The Person

References

Paul Héroult The Man Behind the Invention

History of Electrical Energy Consumption by Hall-Héroult Cells

Early History

Electrolyte Composition

Heat Balance

Electromagnetic Problems

Control

Summary

Evolution of Electrolytes for Hall-Héroult Cells

Baths of the Beginning

Characterization of Bath

More Recent Industrial Baths

References

Gaining That Extra 2 Percent Current Efficiency

Introduction

Better Understanding

Mass Transfer Control

Process Control & Operating Strategy

Cell Design

Advanced Through Communication

Future Utilization of Knowledge

Acknowledgements

References

Carbon Electrodes in the Hall-Héroult Cell: A Century of Progress

Abstract

Introduction

Carbon Technology Developments Prior To The Year 1886

Carbon Electrodes In The Early Years Of Commercialization Of The Hall-Héroult Process

State Of The Art And Developments In Manufactured Carbon Technology In The Late Nineteenth And Early Twentieth Centuries

A History Of Prebaked Anode Cell Development At One Smelter

Development Of The Soderberg Anode

Vibration Formed Anodes

Cathode Developments

Carbon Characterization Tests

State Of The Art Of Hall-Héroult Cell Electrode Technology

“The Proof Is In The Pudding”

Acknowledgments

References

Outlook of the Bayer Process

Plant Unit Sizes

Plant Capacities

Productivity

Plant Location

Quality

Energy

Equipment

Conclusions

Acknowledgement

Cast Shop Technology and Reclamation: 100 Years of Progress

Melting And Casting Process Ingot — Then And Now

Some Important Developments On The Way To The 1980’s

References

Fluoride Control in the Aluminum Industry 100 Years of Technology

References

Environmental Control in our Industry An Historical Overview

Introduction

Bayer Process Waste (Red Mud)

Calciners For The Production of Alumina

Carbonaceous Fumes

Potlining

Aluminum Remelting And Chlorine Fluxing

Explosions

Heat And Physical Stress

Noise

Disease And Damage To Vegetation

Ackowledgements

Appendix A Treating Cell Room Gaseous Effluent

References

A Publication of TMS (The Minerals, Metals & Materials Society) 184 Thorn Hill Road Warrendale, Pennsylvania 15086-7528 [phone]

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Preface

One hundred years ago, two young men, oceans apart, independently devised a new method of making aluminum. This discovery in 1886 by Charles M. Hall in the United States and Paul T. Héroult in France gave the world the shiny light metal at costs that made it competitive in the market place.

The Light Metals Committee of The Metallurgical Society is proud to celebrate the anniversary of this important event by publishing Volume I of Light Metals 1986 as a Centennial Edition.

This special edition has two parts: a pictorial section and a series of invited papers. The objective is to highlight with pictures and text the important developments in the past one hundred years in the process metallurgy of aluminum. This includes the electrolytic method of making aluminum, emission and waste control measures in plant operations, manufacture of carbon electrodes, methods of processing bauxite and alumina, technology for melting and casting process ingots and processes for reclamation and recycling.

Pictorial Review

This collection shows “how it was’ and “how it is now”, during the years in which the infant aluminum industry grew into a giant. Many companies from all over the world opened their archives to provide a large collection of photos from which to make selections. The Russians were invited, but, regrettably, did not respond.

Wherever possible, photographs were chosen which show people at work. This is fitting because this Centennial Edition is a tribute, not only to Hall and Héroult, but to all the men and women who have made contributions to the Aluminum Industry.

In addition to material from industry, we have drawn heavily upon the literature for drawings and photographs to provide a visual record of the changing nature and scale of the numerous processes involved in making aluminum and aluminum process ingots.

Invited Papers

An important part of this Hall-Héroult Centennial volume is a series of papers by experts in their fields. A pair of human interest reports tell us about the personal lives of Charles Hall and Paul Héroult at the time of their discovery. These reports are followed by papers describing developments in technology, equipment, and practice in the various areas of aluminum process metallurgy during the past one hundred years.

Ronald E. Miller, Chairman Light Metals Committee

Acknowledgements

Pictorial Review

This Pictorial Review is the result of efforts of many individuals and companies. Without their willingness to open their files and send photos, this Review could not have been assembled.

We are indebted to the following companies: Air Industrie, Alcan, Alcoa, Almeq, Alusuisse, Aluminum Association, Arco Metals, ASV, British Alcan, Consolidated Aluminum Company (Conalco), Commonwealth Aluminum Company (Comalco), Elkem, Granges Aluminum, Hazelett, Hunter Engineering, Intalco, Japan Aluminum Federation, Kaiser Aluminum and Chemical Corporation (KACC), KBI (Cabot Corporation), Loma Machine, Mitsui Aluminum, National Southwire Aluminum, Norsk Viftefabrikk (Flakt), Pechiney, Properzi International, Pyrotek, Reynolds Metals Company, Showa Aluminum K.K., Sumitomo Aluminum, Union Carbide (Linde Division), VAW, Wagstaff Engineering.

I will not list, but hereby, thank all contributors. A special acknowledgement is due to: Kjell Nielson (consultant); W.O. Stauffer (consultant); J. Peter McGeer, G.G.Robertson (Alcan); Vergi Sapp, Ronald E. Miller, Gordon Bell (Alcoa); Ulrich Mannweiler (Alusuisse); Andreas Anderson (ASV); David Williams, H. McDonald (Conalco); Gunnar Sem (Elkem); T. Pritchard, H.E. Miller, W. Kramer, B.J. Foster, R. Zabreznik (KACC); F.R. Mollard (KBI); A. Nussbaum (Loma Machine); N. Bjune (Mosal); E. Keul (Norsk Viftefabrikk); Prof. N. Craig (Oberlin College); Christian Bickert (Pechiney); A. Roy (Pyrotek); CM. McMinn, S. Levy, J. Creel (Reynolds Metals); T. Matshushima (Showa); K. Yamada (Sumitomo); G. Winkhaus (VAW); W. Wagstaff (Wagstaff Engineering).

Also, special appreciation and thanks to Elizabeth Luzar, Gayle Geddes and the TMS staff, and particularly to my wife.

Thanks to Interscience Publishers (Division of John Wiley & Sons), Aluminium Verlag, Journal of Chemical and Metallurgical Engineering, and The Metallurgical Society for permission to use materials from their publications.

Invited Papers

A special thanks is extended to Dr. Subodh K. Das of Arco Metals for soliciting the invited papers, and to each invited author who contributed to this volume: P. Atkins, D. Belitskus, C. Bickert, N. Craig, R. Friederich, W. Haupin, J. P. McGeer, N. Oberg, W. Peterson, N. Richards, B. Welch.

W.S. Peterson R.E. Miller

Abbreviations

Abbreviations used in the captions to the photos and figures include:

CWPB

center work prebake pot

DC

direct chill

EM

electromagnetic

HDC

horizontal direct chill

HSS

horizontal stud Soderberg

kA

kilo amperes

MW

mega watts

PBA

prebake anode

SWPB

side work prebake pot

VSS

vertical stud Soderberg

Pictorial Review

Reduction Technology

1. Charles Martin Hall. Born December 6, 1863 in Thompson, Ohio and later moved with his family to Oberlin, Ohio. Graduated from Oberlin in 1885. Worked in family woodshed on aluminum experiment. Died December 27, 1914 at the age of 51.

2. Original Hall patent. Alcoa.

3. Hall’s home in Oberlin, Ohio with wood shed in rear 1886. Alcoa.

4. Paul Louis Toussaint Héroult. Born April 10, 1863 in Saint Benin, Normandy. Worked in family tannery on aluminum experiment. Died May 9, 1914 at the age of 51.

5. Héroult cell for pure aluminum circa 1892. Alcoa.

6. The Héroult Tannery, Geulette, France, where Paul Héroult discovered the electrolytic process for producing aluminum. Alcoa.