Light Metals 2009 Edited by: Geoff Bearne

TMS (The Minerals, Metals & Materials Society), 2009

AP50 PERFORMANCES AND NEW DEVELOPMENT

B.Benkahla1, O.Martin1, T.Tomasino1
1

Rio Tinto Alcan - LRF - BP 114 73303 Saint-Jean-de-Maurienne Cedex France

Keywords: AP50A, AP50B, ALPSYS, process control, power consumption, stability, MHD, ALUCELL

These goals have been reachable thank to a continuous improvement approach and a systematic use of powerful design and operating tools.

ABSTRACT
After 3 years of continuous improvement toward the version
which will be implemented in Jonquiere (Canada), the AP50 cell
has achieved very good technical performances on the LRF platform in Saint Jean de Maurienne (France).

Figure 1 shows the place where all these development are done in
LRF facilities.
Table 1 summarises the ultimate performances of the last AP50A
cell generation. The current efficiency, the specific power consumption, the anode effect frequency and the instability level
show that a very high level of performances is definitely achievable on AP50A technology. They still have been improved since
2007 [1].

The detailed technical results are presented: at the same time, high
amperage and low energy consumption have been reached. The
reliable ALPSYS control system has demonstrated low Anode
Effect rates and tighten thermal control. Pending availability of
the future Jonquiere development platform, an upgraded new
version of the AP50 able to cope with higher amperage has been
developed. The results of the first prototype cell are very promising.

Table 1: 2008 AP50A prototypes performance level

Line current
Current efficiency
Specific power consumption (DC)
Anode effect frequency
Instability level

kA
%
kWh/t
Ae/p/d
n

500
95.7
13250
0.02
20

Table 1 also shows our ability to feed a cell on a half million amps
basis combined with a current efficiency close to 96 % on a regular basis.
It is fundamental to keep the cell very stable thermally and magnetically but also to feed it efficiently with alumina at this amperage level to be able to maintain high current efficiency and low
specific energy consumption (see Figure 2).

Figure 1: General view of LRF AP50 R&D Development

Platform in Saint Jean de Maurienne

A powerful Magneto-Hydro-Dynamic (MHD) model was used to

optimize the MHD performances of the cell and its stability (see
paragraphs Numerical results with ALUCELL).

INTRODUCTION

As the AP50A cell operates with a good stability margin we have

decided to investigate new settings domains through the AP50B
technology.

Two main ways have been followed to develop the AP50 technology. The first one consisted in optimizing the AP50A technology
package: high amperage (500 kA), low specific energy consumption (13250 kWh/t), very low anode effect rate, industrially safe
and robust. The second one consisted in launching the AP50B
program with a very high amperage (>530 kA) coupled with low
energy consumption (13400 kWh/t).

Figure 2 shows the continuous improvement of the AP50A specific power consumption from 2006 until now.

It is the first time in aluminium industry that this amperage level

has been reached and fully controlled.

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AP50A specific power consumption @ 500 kA

13800

kWh/t

13600
13400
13200
13000

Figure 3: AP50A velocity field with ALUCELL

12800
2006

2007

2008

YEAR

The bath-metal interface deformation is relatively flat comparatively to the high amperage (see Figure 4 hereunder).
Figure 2: Specific power consumption of the AP50A prototypes

THE SUCCESS STORY OF THE AP50A CELL

The AP50A technology has fully confirmed its ability to be industrialized and by this way to be the basis of a high productivity
smelter.
The aim of this chapter is to present the design tools used for the
AP50A cell, the obtained technical results and a multiparameters
comparison with AP30 results in existing smelters.

AP50A Numerical results with ALUCELL

ALUCELL is a numerical model of the Magneto-HydroDynamic behaviour of the cell, whose object is to predict the
stability of the cell. It is also a full three-dimensional model of the
cell, including the busbars. It takes account of the effects of the
adjacent cells and the neighbouring lines.

Figure 4: AP50A bath-metal interface deformation with

ALUCELL

AP50A technical results

ALUCELL calculates the velocity fields in the bath and metal
pad caused by the interaction of the magnetic field generated by
the conductors inside the cell and the busbars with the electrical
currents in the bath and metal. It gives the stationary state of the
cell, i.e. the magnitude and direction of the metal movement at all
points as well as the shape of the bath-metal interface.

Figures 5 to 9 show respectively current efficiency, specific power

consumption, anode effect frequency, iron level in metal and
instability level on AP50A cells obtained in 2008 at 500 kA.
March results have been impacted by special works in LRF workshop with several pot shutdowns.

This steady state result serves as the basis for a linear stability
analysis that takes into account the Moreau-Evans viscosity term.

AP50A current efficiency @ 500 kA

Current efficiency (%)

The model gives the frequencies and amplitudes of the various

modes of oscillation the eigen frequencies - and makes it possible to plot the growth factor with increasing line current and so
predict the onset of oscillation and its frequency [2].
The AP50 model has been widely validated with generally a very
good agreement between measurements and numerical results [1].

AVERAGE

98
97
96
95
94
93
92
Jan-08

Figure 3 shows the steady state of the AP50A.

On the velocity field, two major eddies are seen. The maximum
magnitude is around 20 cm/s which is similar to the AP30 technology. It is located at the pot ends.

Feb-08

Mar-08

Apr-08

May-08

Months

Figure 5: AP50A prototypes current efficiency

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Jun-08

AP50A instability level @ 500 kA

AVERAGE

14000

Instability level (nOhm)

Specific power
consumption (kWh/t)

AP50A specific power consumption @ 500 kA

13500
13000
12500
12000
Jan-08

Feb-08

Mar-08

Apr-08

May-08

Jun-08

AVERAGE

40
30
20
10
0
Jan-08

Months

Feb-08

Mar-08

Apr-08

May-08

Jun-08

Months

Figure 6: AP50A prototypes specific power consumption

(Computed on a 336 cells smelter basis)

Figure 9: AP50A prototypes instability level

AP50A cell has got very good upstream and downstream protecting ledges. We can see on figure 10 that large joint and sides are
protected all along the cell.

AP50A anode effect frequency @ 500 kA

Anode effect frequency
(ae/pot/day)

AVERAGE

0,14
0,12
0,1
0,08
0,06
0,04
0,02
0

0,13

Detailed delining activities on young and old AP50A cells confirmed that AP50A life duration is expected at more than 60
months.

0,07
0,03

Jan-08

0,03

Feb-08

Mar-08

Apr-08

May-08

Jun-08

Months

Figure 7: AP50A prototypes anode effect frequency

Figure 10: AP50A cell at 500 kA:
Typical ledge profiles measurement

AP50 cell have been operated more than 3 months without any
anode effect. It shows among other things that alumina feeding is
totally under control.

The prototypes fluoride emissions are comparable to AP30

benchmark.
AP50A iron content in metal @ 500 kA

Iron content (ppm)

We also investigate numerous health and safety aspects linked to

AP50 technology. An example is the thermal working conditions
of operators who work close to the cells. Several W.B.G.T. (Wet
Bulb Globe Temperature) measures have been done showing than
temperature conditions during standard operations are aligned
with the international norms.

AVERAGE

800
600
400
200
0
Jan-08

Feb-08

Mar-08

Apr-08

May-08

ALPSYS and AP50, a powerful association

Compared results between AP50A and AP30

Jun-08

Months

In order to validate the AP50 technological package, we had to

compare it with a well-proven technology as AP30 through several parameters as pot stability level, anode effect frequency and
standard deviations of bath temperature, AlF3 excess and bath
height.

Figure 8: AP50A prototypes iron content in metal

Latest cell designs tend to increase the total surface area of the
anode in order to maximize productivity. This has the drawback
that it reduces the volume of the bath, tending to cause greater
fluctuations in the level of the bath. Moreover, the ratio between
power in the bath and bath weight in a AP50 cell induces a high

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thermal reactivity of this cell. At last, the introduction frequency

of alumina shots has to be highly reliable in order to ensure a
perfect dissolution in the bath.
Anode effect frequency
(Ae/pot/day)

AP50A vs AP30: compared

Anode effect frequency

The associated ALPSYS control system must be able to manage

this specific cell dynamics in order to keep an optimal control of
the cell.

AlF3 excess standard deviation

(%)

AP50A vs AP30: compared AlF3

excess standard deviation
4,0

1,6

1,5

Bath temperature standard

deviation (C)

0,11
0,04

0,02

0,00
AP30 (MIN) AP30 (MAX) AP30 (AVG)

AP50A
(PROTO.)

Figure 11: AP50A vs. AP30 multiparameters comparison

1,0
0,0
AP30 (MIN) AP30 (MAX) AP30 (AVG)

Figure 11 gives us the comparison between several critical operating parameters of AP50A and the well-proven AP30 technology.
Even if results obtained for AP50A are the consequence of a small
number of cells with very close cell monitoring, it highlights that
this technology is still not at its full potential: the very low instability level of this cell is a good example which shows that significative gains are still reachable.

AP50A
(PROTO.)

20,0

12,5

Chapter conclusion

8,0

5,7

5,1

These results fully confirm the very high performance level of the
AP50A technology cell.

0,0
AP30 (MIN) AP30 (MAX) AP30 (AVG)

AP50A
(PROTO.)

Moreover the robustness during all typical phases of an industrial

context (preheating, start-up, reduced amperage, outages of several hours and donor cell) has been tested successfully.

AP50A vs AP30: compared bath

height standard deviation
Bath height standard deviation
(cm)

0,20

2,4

AP50A vs AP30: compared bath

temperature standard deviation

The AP50A cell is ready to be implemented in Jonquiere pilot

plant for industrial development.

4,0

2,5
1,8
1,3

THE AP50B CELL

Thanks to the previous results, the AP50B technology has been

developed based on the AP50A reference cell.

0,0
AP30 (MIN) AP30 (MAX) AP30 (AVG)

AP50A
(PROTO.)

AP50B Numerical results with ALUCELL

AP50A vs AP30: compared

instability level
Instability level (nOhm)

0,30

Figure 12 shows the steady state of the AP50B.

The flow pattern is very similar to the AP50A cell but more
symmetrical. In addition, the maximum velocity is 10 % lower.

100

64
49
33

32

20

0
AP30
(MIN)

AP30
(MAX)

AP30
(AVG)

AP30
EQUIV @
500 kA

AP50A
(PROTO.)

Figure 12: AP50B velocity with ALUCELL

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Table 2: First 2008 AP50B cell performance level

The bath-metal interface deformation is a little bit higher than on

the AP50A but overall shape is still really good (see Figure 13
hereunder).

Line current
Current efficiency
Specific power consumption (DC)
Anode effect rate
Instability level

kA
%
kWh/t
AE/p/d
n

530
95.5
13600
0.03
20

The AP50B optimization is in progress and we are very confident

to reach a specific power consumption lower than 13400 kWh/t.
Two AP50B cells are currently into development.
Figure 15 demonstrates a good protection level of the AP50B
lining.

Figure 13: AP50B bath-metal interface deformation with

ALUCELL
Figure 14 compares the growth factors of the AP50A and AP50B
for the first 12 modes. The unstable area is represented at the
bottom of the figure.

Figure 15: AP50B cell at 530 kA:

Typical ledge profiles measurement

Chapter conclusion

Growth Factor

AP50A

Stable

AP50B

Rio Tinto Alcan is about to reach expected results on AP50B

basis thank to a continuous development of its AP technology
based on powerful design tools, control and tests philosophy.
Then the AP50B cell will confirm again the technological advance of Rio Tinto Alcan in Aluminium Reduction field.

Unstable
(1,0) (2,0) (3,0) (4,0) (0,1) (1,1) (2,1) (5,0) (3,1) (6,0) (4,1) (5,1)

THE AP50 JONQUIERE PROJECT

Modes

Figure 14: AP50A & AP50B stability diagrams (Growth Rate vs.
Modes)

Preliminary work has started for the AP50 pilot plant in Jonquiere
(Canada). Figure 16 shows the formwork intended to accept the
future Jonquieres substation.

The growth factors of the current operating point of the AP50A

are far from the critical instability threshold determined during the
measurement campaign. Then it is a very stable configuration
from a magnetic point of view.
In conclusion, AP50A & AP50B were numerically predicted to be
stable with a small bath-metal interface deformation, a good flow
pattern and reasonable velocity magnitudes.

AP50B first results

The typical results obtained on our first AP50B cell are given in
table 2. They will be followed by an important number of additional operating data as we are in the speed-up phase of the
AP50B technology development and optimization.

Figure 16: Picture of AP50 Jonquieres substation formwork

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The pilot plant will be equipped with 44 AP50 cells equivalent to

an annual production of 60,000 tons of aluminium. It will represent the symbol of Rio Tinto Alcan leading position in aluminium
industry. Figure 17 shows a 3D view of the pilot plant where
AP50 technology will be tested and developed at industrial scale.

References
[1] B.Benkahla, Y.Caratini, H.Mezin, S.Renaudier, S.Fardeau
Last development in AP50 cell Light Metals 2008, 451-455
[2] J.Descloux, M.Flueck, M.V.Romerio, Modelling of the
stability of the electrolysis cells for the production of aluminium.
Numerical methods in engineering and applied sciences, Ed.
Alder, Heinrich, Lavanchy, Ouate, Suarez, CIMME, Barcelona
1992, 30-38.

Figure 17: 3D view of the future AP50 Jonquiere pilot plant

Furthermore, since May 2008, Rio Tinto Alcan is going forward
with an accelerated pre-feasibility study for two additional phases
to the AP50 pilot plant. The on-going study is evaluating the
addition of another 140,000 tons of capacity to the pilot plant.
Representing a potential investment of between US$2 billion to
US$2.5 billion, the expanded plant would remain the platform for
future technological developments. The study is also considering
a possible subsequent expansion of up to a total of 400,000 tons.

CONCLUSIONS
The AP50 development program has made further advances since
last year:
- The AP50A design is now fully available with a high performance level at all point of views, ready to be implemented in the
Jonquiere pilot plant,
- The AP50B cell has been launched successfully. This very high
amperage pot needs to be optimized but the intrinsic stability level
of this cell combined with an important development program
allows looking forward quick important progresses.
The mastery of cell design activities together with a robust process control system and a rigorous pot follow-up are the pillars of
the AP50 attainment.
After the world success of the AP30 technology, our Vision is
clearly that the AP50 technology will be very soon the new Reference Technology in the world of Aluminium.

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