Innovations in pot tending at the Qatalum smelter

Qatalum’s vision to install and operate the world’s most advanced Pot Tending Machines (PTM’s) has resulted in the 14 units functioning with over 95% efficiency, directly contributing to increased safety and productivity.

In the early 2000's, when Qatalum was still in its planning stage, equipment specified to operate the smelter would be cutting edge and capable of operating with minimal human contact. That vision has stood the test of time as Qatalum's investment in such advanced machinery is contributing to create one of the most advanced and efficient aluminium smelters in the world.

Of particular note are the Pot Tending Machines (PTM's) that operate within the 2 pot-lines at Qatalum in which liquid aluminium is produced. Their purpose is to take care of the critical anode changing process for all the 704 pots in an efficient and relentless manner. That accounts for 12 cranes operating in shifts for 24 hours.

Historically, the genesis of the PTM was initiated as part of a feasibility study conducted within Hydro, one of Qatalum's owners, to increase overall potline efficiency and therefore requiring a fully automated PTM solution. Called Su4, the project began on the 16 August, 2000.

The design basis for the Su4 project was based upon meeting several ambitious operational criteria. Several of the requirements were never before automated, such as anode changing; setting anodes according to their burn off method, without manual help, using laser guided alignment and finally vacuuming and cleaning the deck plate, added after successfully manipulating the side covers from the crane without support from floor operator.

A requirement tender with the new specifications was distributed to potential crane suppliers and NKM Noell submitted an offer that was accepted.

Early variants of the Su4 crane were delivered first to the Årdal smelter and then further modified variants were supplied to Sunndal, one of Hydro's five smelters in Norway. Both variants underwent testing and modifications during the testing and operational periods.

By the time Qatalum was to receive the cranes, collaboration between NKM Noell and Hydro contained lessons learned and improvements made during stages of the Su4 project timeline. Several tangible improvements included improved visibility from the crane cabin, a cover handler arm for lifting, off and on, the side covers and later the brush and vacuum solution for the deck plate minimising residual dust from the entire anode changing procedure.

The final cover handler and brush solution that was delivered to Qatalum was tested over a long period on one PTM at Sunndal. It was later dismantled, modified for Qatalum in the workshop at NKM Noell in France and delivered to Qatalum as PTM7 and is identical to the other 13 PTM's operating at Qatalum today.

Today, established as the most efficient method to tend aluminium pots, the PTM's role at Qatalum contribute to several real world safety, efficiency and cost advantages. Firstly there is the minimisation of human intervention on the potroom floor. Unlike other contemporary smelters, Qatalum, does without floor operators as there is automated pot side hood handling by the PTM cover handler device preceded by deck plate cleaning. This prevents unnecessary human traffic on the floor amongst several large potroom vehicles and exposure to potential atmospheric emissions within hot prevailing conditions.

Hans Petter Lange is satisfied that the overall PTM activity contributes to a safer and manning efficient anode changing routine with minimal human interaction.

The maintenance team, have over the last 3 years developed, using the Qatalum Production System, a more effective methodology for planned off line maintenance, increasing uptime of each PTM to over 95% and reducing planned maintenance costs. Between 2012 and today, Qatalum's business cash cost has reduced from number 12 to become the 4th most efficient smelter globally.

Copyright and Exemption Declaration :¢ÙAll articles, pictures and videos that are marked with "China Aluminum Network" on this website are copyright and belong to China Aluminium Network (www.alu.com.cn). When transshipment, any media, website or individual must list the source from "China Aluminium Network (www.alu.com.cn)". We seek legal actions against anyone that disobey this. ¢ÚArticles that marked as copy from others are for transferring more information to readers, do not represent or endorse their opinions or accuracy and reliability. When other media, website or individuals copy from our website, must keep the source. Anyone that changes the articles' sources will hold the responsibilities for copyright and law problems. We also seek legal actions against anyone that disobey this. ¢ÛIf any articles copied by our website concern the copyright and other problems, please contact us within one week.