A dynamic process model for predicting the performance of horizontal anode baking furnaces

Anode manufacturing is an important step during the production of primary aluminum, and baking is the costliest stage of the anode manufacturing process. The industrial challenge resides in obtaining a good anode quality while keeping the energy consumption, environmental emissions, and cost to minimum. A dynamic process model has been developed for horizontal anode baking furnaces. It covers all important phenomena such as fuel combustion, generation and combustion of volatiles (tar, methane, and hydrogen), air infiltration, and heat losses to the atmosphere and the foundation. The model was built using two coupled sub-models of the flue and the pit and was validated using the plant data. It simulates the dynamic behavior of the furnace and gives a prediction of its operation and performance. In this article, the modelling approach will be described, and the results of a number of case studies will be presented