Smelting

Simulation modelling of molten aluminium and casthouse operations to review options for the management of crucibles and crucible transport vehicles (CTVs). Parameters reviewed included the number of crucibles and CTVs, location of pickup points, quantity of and time taken for scrap melting in VDC furnaces, siphon downtimes, and continuous ingot casting. The option for a dedicated CTV in the furnace area was considered, along with a review of the crucible cleaning area and its impact on overall production.

Extensive modelling of anode handling supported the introduction of new technology. Issues addressed included the number and size of vehicles involved in the placement of trays on rodded anodes beside potlines preparatory to the changing out of anodes in individual cells; the collection of anode butts after change-out and their return to the rodding room; alternate schedules for anode changes; and interference of anode and butt transfers with other production activities.

As part of a study to review proposed changes to a casthouse operation, SMS modelled the collection, transportation and consumption of molten aluminium. The model helped to determine the number of furnaces required and the dependence of this upon the mix of products made.

A study of ingot mill operations was undertaken to assist with management of hot metal usage following a revision of operating procedures and increased production levels. The study was used to develop appropriate scheduling methodologies. It also highlighted some areas of concern with the proposed upgrade. This model was subsequently used to investigate further operational changes.

SMS modelled a nickel smelter to support a proposed upgrade in converter capacity. The model studied the impact of the upgrade on upstream and downstream processes and established the point at which interference between two overhead cranes became a limiting factor in throughput. SMS also provided advice on different work practices relating to crane operation.

SMS analysed raw materials handling and storage to assist with planning for a proposed third potline. The study looked at the arrival, ship unloading, transfer, storage and consumption of all raw materials, along with the circulation of the various recycled materials within the plant.

Other smelting projects have involved high purity model capture, butt cleaning, alloying furnaces, modelling of anode baking furnaces, aluminium bath delivery, rodding room simulation, carbon bake conversion, and continuous homogenising study.