A Detection Method of Metallic Impurities (V, Ni, Fe) in Coke and Carbon Anodes and Their Effect on Anode Reactivity =Méthode de détection des impuretés métalliques (V, Ni, Fe) dans le coke et les anodes en carbone et leur effet sur la réactivité de l'anode

摘要

Primary aluminum is produced by the electrolysis of alumina in the Hall-Heroult process. The anodes are the source of carbon required for the reduction process. They are made of calcined petroleum coke, butts, recycled anodes, and coal tar pitch. Carbon anodes constitute an important part of the aluminum production cost. During the production of aluminum, carbon anodes are consumed and CO 2 is produced. CO2 further reacts with the anode carbon to produce CO. Air also reacts with the exposed anode surface to produce CO 2. These reactions increase anode consumption and add to the cost of aluminum production. One of the key industrial goals is to minimize this excess consumption of anodes. The quality of prebaked carbon anodes, consumed in electrolysis during the primary aluminum production, has an important impact on the cell performance. The anode quality depends on the raw material quality and operating conditions in the anode plant. The most common metallic impurities found in cokes and anodes in aluminum industry are vanadium (V), nickel (Ni), and iron (Fe). The properties of the anode are influenced by these impurities. It is reported that they enhance the actual carbon consumption by catalyzing the air and CO2 reactivities in the electrolytic bath.;There are different standard methods to quantify the impurities. The American Society for Testing and Materials (ASTM) developed different test methods using Inductively Coupled Plasma Atomic Emission Spectrometry (ICP-AES), Atomic Absorption Spectrometry (AAS), and X-ray Fluorescence Spectroscopy (XRF). These standard methods require intensive sample preparation, highly skilled personnel, and costly reagents. The methods are usually time-consuming. Thus, a simple but effective tool is necessary to estimate the level of different impurities in the raw materials and the anode. In this study, colorimetric methods were developed to determine the levels of impurities (Fe, V, Ni) in cokes and anodes. In this method, the metallic impurities were extracted from the carbon sample by acids and/or electrophoresis. A certain amount of the extract was treated with reagents that can form specific color with a particular impurity. The color was analyzed using a custom-made image analysis software. The value of a particular component of the color was plotted against known concentrations of the impurities to prepare a calibration curve. The calibration curve was later used to estimate the concentration of impurity (Fe, V, Ni) in different samples with unknown concentrations. The colorimetric reagents used for the estimation of iron, vanadium, and nickel were potassium thiocyanate, N-benzoyl-N-phenylhydroxylamine, and dimethylglyoxime, respectively. It is possible to estimate the Fe, V, and Ni content in a carbon sample precisely with developed colorimetric methods in less than 30 minutes including sample preparation. In these methods, no costly ultrapure reagent was used, which reduced the cost of analysis.;Anodes were fabricated using known amounts of impurities (Fe, V, Ni). The density, electrical resistivity, and air and CO2 reactivities of the anode samples were measured. The effect of the above impurities on the air and CO2 reactivities were studied. It was observed that the impurities can catalyze the reactivities of the anode depending on the relative amount of other impurities. An artificial neural network method, which was previously developed by the carbon group, was trained using the experimental data; and the effect of the impurities on the reactivities was also analyzed. This study was carried out within the framework of the University of Quebec at Chicoutimi (UQAC) and Aluminerie Alouette Inc. (AAI) Research Chair on the Utilization of Carbon in Primary Aluminum Industry (UQAC/AAI Research Chair on Carbon).