AP Technology™

NEWSLETTER 2020
Sommaire

Edito P.3

Articles

AP Technology Customer Enquiry P.6

LRF: Celebrating 60 years of technical excellence in aluminium P.8

Max, the Self Driving Vehicles Designed for Smelters P.10

Smart Measurment : New Mobile Tool for Alpsys P.12

Anode Paste Plant Digital Twin P.14

Remote On-Line Process Support P.16

Anode Banking From OoM to commisionning P.18

Electrolysis News P.20

Carbon News P.28

Rio Tinto Aluminium articles at TMS 2020 P.32

Other Presentations during 2019 P.37

AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Jean-François FAURE
General Manager Aluminium Technology

2019 was another challenging year for the aluminium prima-

ry industry. The AP Technology™ team continued delivering
advanced solutions to optimize existing operations and drive
performance : low energy pot modernizations are being imple-
mented with constant improvements and important innova-
tions in both functionalities and product characteristics.

In September 2019, AP Technology launched a worldwide Customer Survey. Thanks to your

answers, we have now a precise image of how you perceive our activities, our products and so-
lutions and our capacity to fulfil your needs to your satisfaction. The results confirm our strong
brand position and is a very encouraging sign for our teams. This survey has also revealed
some points that require improvements to better serve our clients. Our teams are already wor-
king on them.

On 20th September 2019, LRF celebrated its 60 years. An official ceremony was held in the pre-
sence of French administration representatives, local stakeholders, AP Technology™ partners
as well as Rio Tinto senior leaders, employees and guests. For all these years LRF has been at
the forefront of smelter technology development and is home for the development of some of
the most advanced technology solutions. Important upgrading of the LRF reduction hall was
undertaken in 2019 to maintain its position as a core asset to further develop new technologies
allowing fast and safe pot reengineering with enhanced performances for amperage creep or
energy reduction on any existing platform including AP18, AP30 and AP60. We have also hired a
number of new employees to become our experts for tomorrow.

The new generation anode baking furnace without headwalls being demonstrated in our Rio
Tinto plant in Bell Bay, Tasmania, Australia and which confirmed the expected significant ca-
pacity and CAPEX advantages, has now more than two years of operation and is showing very
positive results on the OPEX.

I am very proud to announce that Rio Tinto MAX – the autonomous anode transport vehicle –
has now become an industrial reality. On 13 November 2019, MAX had a flawless start with its
first tour in Alvance Aluminium Dunkerque Smelter in France opening a period of operational
tests in the smelter. It is scheduled to be fully operative in the first quarter of 2020.

2019 was another challenging year for the aluminium primary industry and the AP Technolo-
gy™ team continued to support global customers by delivering advanced solutions to optimize
their existing operations and drive performance in line with their technology and site poten-
tial for amperage creep or energy reduction: Low energy pot modernizations tailored to sites
‘contexts are being implemented ; ALPSYS V15 and MESAL 4.0 have been installed at Clients’
sites with constant improvements and important innovations in both functionalities and pro-
duct characteristics.

We are starting 2020 with a change of our company name which is now Rio Tinto Aluminium
Pechiney. The company owns the AP Technology solutions and patents and will continue to
provide you with our services and products.

I want to thank all our customers for their longstanding support. Please enjoy reading the
interesting updates and news in the following pages. We also would like you to stay tuned with
us during the year at our renewed website ap-technology.com where regular posts keep you
informed of AP Technology™ activities.
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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

AP TechnologyTM Customer Enquiry

During the 3rd quarter 2019, we launched a satisfaction survey of AP Technology™ Clients.
More than 200 client representatives were contacted across the world on all 5 continents.
This is the first survey done since many years, period during which the aluminium industry
saw many changes and withstood events of strong impacts.

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

With the support of Praxis, a specialized research agency in conducting customer satisfaction
surveys, we gathered information that gives us robust results that are representative of our Clients
and activities.

The Survey Targeted three Objectives :

Evaluate our Clients’ level of Better understand

satisfaction for five activities our Clients’ expectations Identify the priority areas for
performed by AP over six improvement
themes and 31 criteria

Global Satisfaction

Question : « The note you have just given

corresponds to what level of verbal scale for you ? »

Balance : 30.8%
(Delighted / Dissatisfied)
A rate of « very satisfied »
(balance of delighted to diss
tisfied) at 26% much higher
than the average Services
Delighted Industry benchmark of 17%

Satisfied
64.4% A rate of dissatisfied of less
than 5% significantly lower
tha the Services Industry
Detractor (0 to 6) benchmark of 13% rate

4.8%

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« 30 % of our Clients are very satisfied of AP Technology »
AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Level of Recommendation
A NPS score of (+27 %) significantly higher that the Services benchmark (+ 11 %) coming from
a higher rate of promoters (37.5 % vs 30 %) and a lower rate of 19 % Detractors ( 11 % vs 19 %)

Question : « If a colleague or an acquaintance asked

you to recommend a supplier of Aluminium Production
Solutions how would you recommend AP Technology
on a scale of 0 to 10 ? »

10.6% 51.9% 37.5% + 26.9

Detractor (0 to 6) Passive (7 to 8) Promoter (9 to 10)

Diving in into the results, we can see that the satisfaction threshold is surpassed on all themes
but one and for twenty-eight of the selected criteria.

Our Client also singled out that they truly appreciated the technical training and the robustness
and efficiency of the solutions proposed by AP Technology. This very good result encourages our
AP Technology teams to continue to propose and deliver innovative and value creating solutions
to our Clients.

While we are still analysing and working on the action plans to consolidate our strengths, to
improve our products and services and to better deliver in the areas our Clients were calling for
improvements we have already identified action programs on three priority criteria :

• Resources availability and reactivity

• Commercial and contractual proposition
• Proactivity in solutions development

and three priority themes :

• Pre-project
• Technical support
• Innovation

« Thank you once again to all of our Clients for the time they
accepted to give to this survey and for their confidence
into AP Technology™ Solutions. »

« The global satisfaction score stands at 7.7 /10 » 7

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

LRF : Celebrating 60 years

of Technical Excellence in Aluminium

This year, Rio Tinto’s Laboratoire de Recherche des Fabrications (LRF) (Research & Development
Center) in France celebrated 60 years of creating innovative technologies for the aluminium
industry. On September 19 and 20, we celebrated this event with all our employees, Rio Tinto
group management, our partners, as well as local and national political figures and Philippe Varin,
President of France Industrie. Visitors had the opportunity to see the prototype pots, the state-of-
the-art control room and to exchange with LRF professionals on the latest developments and those
of the future.

Since 1959, LRF has been a dedicated aluminium research centre – designing, developing and
testing new aluminium smelting pot technologies. It has been the driving force behind Rio Tinto AP
Technology™ platform: smelting technology that gives us the lowest energy and carbon footprint
in the aluminium industry. Thanks to the pioneering LRF employees over the years, successive
generations of AP Technology™ smelting pots – AP18, AP30, APXe, AP60 – have been developed
here, each offering successive improvements in productivity and reductions in energy consumption
and emissions.

AP Technology™ solutions are in operation in our own Rio Tinto smelters and are licenced to
external customers. Today, the technology developed at the LRF over the past decades is integrated
into more than 10,000 reduction pots around the world, accounting for 17% of global primary
aluminium installed capacity.

With its prototype industrial-scale pots, LRF has been at the aluminium industry’s leading edge
for decades and today innovative projects being currently developed will shape tomorrow’s world
of aluminium. Today LRF is one part of Aluminium Technology Solutions (ATS) group of Rio Tinto
Aluminium which also includes the Aluval technology team in Voreppe, France, and the Arvida
Research and Development Centre (ARDC) in Quebec, Canada.
Strong relationships with industry partners, universities, equipment suppliers built over the years
have been essential in the LRF long term success. Within Rio Tinto it partners with aluminium
operations and Growth & Innovation group to integrate productivity and energy improvements.
Externally the network of industrial partners and academics that has been weaved is called upon
to bolster our knowhow.

LRF team’s skills are recognised around the world through the knowledge and expertise they bring
to our work with customers, and the technical assistance they provide.

The LRF team is also working closely with the Rio Tinto-Alcoa ELYSIS joint venture, which is advancing
breakthrough technology using inert anodes that eliminates all direct greenhouse gas emissions
from the aluminium smelting process – instead emitting pure oxygen.

“Sixty years is an opportunity to celebrate past achievements, but it’s also a chance to look ahead
to the future,” adds Jean-François Faure, general manager, ATS. “LRF is a key player in our industry’s
next technological revolution, both through developing 4.0 solutions thanks to new smart tools and
through its significant contribution to the Rio Tinto-Alcoa ELYSIS project.” LRF hasn’t finished adding
exciting chapters to the history of the aluminium industry and we wish a very happy birthday to LRF
and to all those who have contributed to its evolution during these sixty years.

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Five Things to know about LRF

• Today, LRF has 70 employees, who work at the R&D facility in Saint-Jean-de-Maurienne in the
French Alps, not far from the border with Italy. Over the last 10 years, LRF has generated €20
million in local economic benefits.

• LRF has a mini aluminium potline, with three industrial-scale pots used for testing new
technology packages and new pots. The potline uses AP Technology™ solutions developed
on-site, including the world’s most productive aluminium technology (AP60) and the most
energy-efficient technology (APXe).

• The site also has an engineering and modelling office that designs technological solutions for
Rio Tinto and third-party smelters.

• Increasing the amperage of reduction pots – the strength of electric current that flows
through them – is the key factor in improving their productivity. Since 1990, LRF has
increased the intensity of AP30 pots (which was initially at 300,000 amperes) to over 400,000
amperes. These new versions operate at Rio Tinto Alma and Kitimat smelters in Canada
and in 12 other smelters around the world. LRF also carries out R&D on process control, on
improving understanding of how reduction pots work and boosting their performance by
using new sensors and algorithms.

• For more than 30 years, LRF has run the Institut Paul Heroult a training facility named after
the 19th century French inventor of the aluminium reduction process. IPH offers training
courses for customers of AP Technology™ which focus on understanding

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

MAX, the Self Driving Vehicle

Designed for Smelters

Alvance Aluminium Dunkirk has become the first company to introduce MAX, the anode pallet
transport hybrid and autonomous vehicle, in an industrial environment.

The vehicle designed by AP Technology teams and developed by ECA Group has already successfully
completed a set of missions in various situations within the facilities of Alvance Aluminium in
Dunkirk. Its full and final deployment is scheduled for the first quarter 2020.

Thanks to its guiding technology based on Simultaneous Localization and Mapping, MAX can be
integrated to existing operations without any additional equipment or road modification.

From the first test of circulation between the hooking station and the storage of pallets, the vehicle
even demonstrated its ability to succeed in manoeuvers and docking perfectly. MAX demonstrated
as well its ability to circulate within the plant, whether indoor or outdoor, safely operating and
transporting heavy loads up to 12T.

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

In order to simplify maintenance, all of MAX’s actuators are electric. This includes steering, propulsion
and lifting of the pallets. MAX has also demonstrated the performance of its auto adaptive docking
functions, which allow you to pick up a pallet perfectly, even if it has been placed by a traditional
vehicle.

Another strength of the solution is the intelligent Fleet Management System, named LISA-FM,
a graphical user friendly HMI which manage the road network, the pallets locations, the smart
dispatching of transport mission, and of course the real time monitoring of the fleet.

MAX is a safe and environmental-friendly transportation solution aiming at optimizing aluminium

production operations. Its name refers to its key robotic features: M for Modular, A for Autonomous
and X (cross) for its capability to operate between the different parts of the plant.

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Smart Measurement :
New Mobile Tool for Alpsys

Smart Measurement aims to allow an operator to take a measurement with a probe connected
via Bluetooth to a smartphone. A dedicated application on the smartphone guides the operator
and checks how the measurement is taken. Then, the application transfers the measurement to
the ALPSYS system via a WiFi link. Based on the pot information, ALPSYS will possibly validate the
measurement or request an additional measurement or even to supplement the data collected.

This process makes it possible to highlight the measurement compared to the real situation of
the pot and thus give the possibility to understand the context of the pot associated with the
measurement. If WiFi is available in the potroom, measurement can be sent in real time to the
potmicro (APM3 or APM4) or to the level 2 (APM1 or APM2). If not, measurement can be downloaded
within the level 2 from the control room.

Key Elements

• Measurement device Modern & ergonomics for operators

• Cost effective replacement of former dedicated portable

device solution (same features: scheduled/exceptional
measurements & data inputs)

• improved data quality = Smart measure connected with L1

(APM3&4) or L2 (APM1&2)

• Detection & inputs of incidents (anodes, DPAA…) sent to

ALPSYS

• User defined custom measurements/inputs (linked to L2

generic data entries feature)

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Anode Paste Plant Digital Twin

During the last years, RIO TINTO has been involved in an UE research and
development program in the field of industry 4.0 called Monsoon.
This R&D programs aims at developing digital twin model with predictive functions
that could be used in a wide range of industries.

For the aluminium smelting industry, a digital twin model predicting the green anode quality was
developed and implemented in an operating paste plant. Presentations at different steps of this
project have been made at TMS and Forum Aluminium in 2019.

The objective of the digital twin model is to provide a support to paste plant technical staff to
improve green anode density. In other words, the objective is to always achieve the best possible
green anode density for a given set of raw materials.

The digital twin model operates in 3 steps:

1 – Classification
Real time detection of the 30 minutes’ periods of lower quality with two classes : low quality that
appears in red and good quality in red

2 – Identification
Identification of the main 5 variables that caused the lower quality and real time information of the
process engineer to help him to understand what is happening in the paste plant.

3 – Optimization
In case of low quality, recommendation on 3 actuators to improve the situation

Actuator 1 : Pitch temperature 159.6 => 176.9°C

Actuator 2 : Heater temperature 195.0 => 201.8°C
Actuator 3 : Mixer / cooler temperature 159.0 => 153.0°C

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

The recommendation is based on a list of 3 actuators with set point; the possible gain in density is
also given by the function.

To feed the algorithm, data is collected from an historian. The digital twin model is training itself
every 8 hours using the data from the last 6 months. This learning process allows the system to
self-adapt to changes in the physical world and to quickly take into account process step changes.

The project is well on tracks:

For the aluminium smelting industry, a digital twin model predicting the green anode quality was
developed and implemented in an operating paste plant. Presentations at different steps of this
project have been made at TMS and Forum Aluminium in 2019.

The objective of the digital twin model is to provide a support to paste plant technical staff to
improve green anode density. In other words, the objective is to always achieve the best possible
green anode density for a given set of raw materials.

The digital twin model operates in 3 steps:

• Successful implementation of a digital twin model in an aluminium smelter

• The tool is visual, simple and auto adaptive

• The paste plan digital twin opens optimization possibilities in paste plant

This project unlocks many possibilities for the use of digital twin models and their associated
predictive functions in every area of aluminium smelter.

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Remote on-line Process Support

Over the last decades, AP Technology™ has developed, flawless processes and methodologies
to provide our clients with the documentation, the know-how and the offsite and onsite support
needed to implement and operate their AP Technology™ solution. Today development of
communication network and business analysis tools allow us to implement a new approach based
on a combination of remote on-line process support and onsite short term missions that we call
Technical Assistance 4.0 or AT 4.0. We started to provide such service to a few smelters late 2016
and have continuously increase the number of clients supported by AT 4.0. In 2018, we created
the AT 4.0 team, bringing together AP Technology™ reduction process experts to deliver AT 4.0
services to our customers.

One team with multiple objectives

Bringing all our experts into one single team provides the opportunities to standardize and
improve our tools and methodology as well as to be able to ensure the continuity of the support
to our clients over time. Sharing and teamwork are the part of the DNA of our AT 4.0 team. RADAR
and ALPSYS dash-boarding tool are our key tools to facilitate data analysis and to create ready-to-
use standard reports and dashboard.
Our experts’ great knowledge of the reduction process and ALPSYS is unique and we are further
developing it for the benefits of our clients.

The Services

Now fully integrated with the implementation of AP Technology™ solutions’ the team supports
modernization or greenfield projects, roll-out of ALPSYS projects and provides technical assistance
to operating smelters.
Services combine on-site short-term missions to ensure a good knowledge of our clients’ facility
and to help build good relationships with the site teams with remote on-line process support
which takes place through period data analysis and conference calls, usually on a fortnightly basis.

Today six smelters are currently benefiting from our AT 4.0 services.

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Team AT 4.0

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Anode Baking - From OoM to Commissioning

Anode quality is crucial to the safe and optimal operation of any potline.
More specifically, consistently achieving the desired baking quality while
securing the anodes inventory at optimized costs is critical for the satisfactory
performance of any anode plant and ultimately aluminium smelter.

Pechiney developed and started in 1958 its first open-type anode baking facility in L’Argentière
in the French Alps. This new technology was firstly deployed internally in the 60’s and 70’s in
plants such as Aluminium of Greece (1967). The technology started to be sold in the 70’s with the
furnaces of Alro (Romania), Nalco (India) or Alcoa San Ciprian (Spain).

Since then, the design and operation have

been improved over the decades thanks to
innovation and the unique position of Rio
Tinto to be at the same time a designer and
an operator of baking furnaces. In 2020, 60
furnaces using AP design are in operation
and produce approximately 7.2 million tons
of baked anodes per year.

Today, AP TechnologyTM knowledge and experience in anode baking furnaces and the unique
source of feedback from over 60 years of design, erection, operation and retrofit is made available
through our engineering and technical services to support new projects and modernisation

Initially an anode baking furnace is designed for an anode format and a production output. When
time comes to modify the anode format, as homothetie does not work for thermal laws, the furnace
size and dimensions are adapted to the desired dimension and output through several modelling
phases using the latest technology improvements. Various options are analysed and compared in
terms of technical features, operability and costs leading to a first layout taking into account the
site main constraints and finding the best compromise with the following factors: number of pit
per section and number of sections per fire, number of fires, fire cycle. Thanks to the development
of dedicated modelling tools, AP Technology successfully increased pit and section size over the
years with a result of improved energy efficiency.

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Anode baking furnace design evolution over 30 years leading to a 30% reduction in GJ/t and an
anode refractory ratio of 0.7

With the global sizing of the furnace agreed among the various players of a project, the refractory
team enters into action with the proper detailed design of the furnace. Working hands in hands
with process and operation experts, the refractory experts define the detailed refractory design
of the furnace. Anode baking furnace is indeed a very unique and complex assembly of several
thousands of refractory bricks. Experience and expertise are a “must” at this stage to define the
detailed design of the fluewalls, headwalls, insulation and other parts of the furnace in order
to ensure the lifetime expectancy and the baking homogeneity. With nearly 20,000 fluewalls
currently in operation around the globe, AP Technology has unique experience and knowledge on
this phase.

Once all the detailed engineering is finalized, bricks can be produced by refractory suppliers.
The manufacturing quality, both the geometrical dimensions and the chemical and physical
properties, is of critical importance to ensure a satisfactory erection and sustainable operation of
the furnace. AP Technology supports its clients with the quality control at supplier premises for
the dense and isolating refractory. This is currently happening for the on-going revamping of Rio
Tinto Alma furnaces.

The furnace construction is another critical step. It involves an important workforce to correctly
assemble more than 1 million bricks within the allocated timeframe. AP Technology supports its
clients with expert resources delegated on site to follow on a day-to-day basis the erection of the
furnace. This ensures the right quality is applied until the furnace is ready to be started. At this
time the AP Technology operation and process team join the site to support the local team with
the start-up of the firing system and the daily operations. The aim here is to reach a sustainable
organization in terms of operational practices and knowledge to achieve the expected anode
baking performances.

Once the furnace operation reaches its steady state, AP Technology continues to support its client
through regular technical assistance activities such as audits, trainings and optimization mandates
until the next retrofit of the facility.

• Order of magnitude & Pre-feasibility studies

• Technology Transfer
• Basic engineering of the anode baking furnace building and its ancillary shops
• Detailed engineering of the baking furnace refractory, insulation and concrete casing
• Training at our Institut Paul Héroult
• Support during construction, commissioning and operation
• Refractory supply quality control services

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Electrolysis News

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Alro AP12LE

Alro, one of the largest aluminium smelters in Continental

Europe, and AP reached an agreement in April 2018 to
implement at Slatina a new low energy reduction pot
design (AP12LE) that will allow Alro to reduce the amount
of electricity needed to produce aluminium.

Mozal AP3XLE

The AP3XLE project targeting 378kA and 13.0MWh/t is

on track.

Since Sept. 2018, all stopped pots have been relined

using the AP3XLE technology.

In 2019, the strong process collaboration between

Mozal reduction team and AP Technology experts
continued thanks to missions on site and regular
phone conferences with our AT 4.0 team. The
combination of periodic onsite short missions and
regular remote process reviews demonstrates once
again the efficiency of our AT 4.0 support model.

At the end of 2019, 25% of the pots are converted and

the first step of amperage creep is planned for early
2020.

Interactive Online Advanced

Training

The Institut Paul Heroult (IPH), AP Technology™ training

centre, continues to develop and to improve AP
Technology™ training offer.

To answer the needs expressed by several smelters to

get access to more technical training material on very
specific subjects, a new advanced training format was
developed and successfully implemented in 2019.

On specific technical subjects, IPH organized a half-day

video conference session with participants located in one
or several smelters. The trainees are already experienced
in the domain. The trainer, a senior expert, presents
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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

the chosen subject and interact with the participants to The topics already covered by such Advanced Training
capture and share their experiences. The use of modern sessions are the following:
interactive tools like touch screen or klaxoon®makes
the format attractive. Substation : open circuit and Surmec settings
Alpsys: Robustness
The conference is recorded and IPH provides to the Alpsys: HF/BF
participants access to both the presentation used and And more will come in 2020….
the video for later use wit hin each plant.

Sohar Aluminium,
Benchmark Operations

2 years after the unexpected open circuit incident

that led to the complete stoppage of the Potline
(stoppage in August 2017 – full production resumed in
January 2018), Sohar Aluminium has been exhibiting
benchmark operational performance with its AP40
pots. Some of the benchmarks achieved by Sohar
Aluminium in 2019 are:

Safety: AIFR at 0.17 (Jan to Dec 2019).

Environment: Anode Effect Rate at 0.17 AE/PD (Jan to

Dec 2019).

Amperage at 395 kA and specific energy consumption

at 13,181 kWh/t Al, with Fe level below 600 ppm, and
Net Carbon at 408 kg/t Al.
Sohar Aluminium is now ready for its next amperage quality Aluminium, a 1,000 MW power plant and port
increase step, 400kA and beyond. facilities in Oman.

Sohar Aluminium was formed in September 2004 to Jointly owned by OQ Group, TAQA and Rio Tinto, Sohar
undertake a landmark Greenfield Aluminium Smelter Aluminium has won global acclaim for its superior,
and has an annual capacity of 390,000 tonnes of high- environmentally friendly technology.

Elysis

ELYSIS launched the construction of its R&D center in

Saguenay on August 16, 2019 where technical experts
will continue to advance the breakthrough technology
that eliminates all direct greenhouse gas emissions
(GHG) from the aluminum smelting process.

ELYSIS will continue to work closely with the Rio Tinto

Aluminium Pechiney technology design team in France
and Alcoa’s Technical Center (ATC), near Pittsburgh in
the United States, where this patented technology was
invented by Alcoa. Since 2009, Alcoa has been producing
research-scale metal at ATC with no direct carbon
emissions from the smelting process.

Late December Apple proceeded with the acquisition

of the first commercial batch of aluminium produced
using the breakthrough ELYSIS™ carbon-free smelting
technology.
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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

AP40 Alouette

18 months into the project which started mid-June

2018 more than 300 pots have been converted to
AP40 pots. As we go to print the installation of the
Forced Cooling Network (FCN) on Potline 1 is nearing
full completion and the Alouette teams are ready to
switch on the FCN leading the way to increase the
amperage on potline 1 in a matter of days.

The ALPSYS robustness module was rolled out

on both potlines and switched on mid-year. This
module allows for enhanced pot resistance and slope
calculations leading to reduction in the pot noise
level, a narrower alumina content range and less pot
additional resistance over target.

The Alouette and AP Technology teams have been

working very closely for the past 18 months on matters
ranging from potshells and conductors to operation
and process practices in order to be ready for the
amperage increase.

During 2019 following intense collaboration by all

involved, the Alouette teams achieved to restart up to
26 pots in a month, a level never reached before at
the plant.

APXE & AP60

Platforms during 2019

During 2019, RTA/AP continued to work on enhancing

the performances of both its platforms AP60 (Jonquière
–Canada) and APXe (LRF – France).

At AP60 Jonquière, considerable work has been

devoted to further increase the amperage and enhance
the performances of the AP60 pots. This required
implementing upgraded existing technology bricks such
as alumina feeding and process control procedures and
developing new ones for the pots that are in the boosted
sections. The results are that amperage on these pots
has been increased by nearly 10% while maintaining
operational results.

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At LRF, the APXe pots have been relined as well as

upgraded with the latest versions of existing technology
bricks in order to be able to support the development
of new technology bricks aimed at consolidating the
pot operations at very low energy consumption. to go
beyond 600 kA and below 12000 KWh/t.

To sum-up, AP technology teams having passed the

targets of 570kA and 12000kWh/t are now focusing
their effort on the next steps to deliver reduction
platforms going beyond 600kA and below 12000kWh/t.

Advanced Aluminium
Dunkerque: Support,
Modernize & Develop

As part of the on-going relationship with Alvance, AP

Technology teams performed on-site audits and held
quarterly operations reviews in the key sectors of
Reduction, Casting, Anode Baking, Environment and
Substation. AP Technology is also supporting the plant in
its implementation of the creeping project AD415 which
will see the plant operate at 415kA and below 13000
kWh/t. Furthermore, several development projects and
trials are being pursued jointly by AP Technology and
Alvance at the smelter targeting to improve the smelter
competitiveness with improved pot process control
procedures, enhanced pot equipment, alternative pot
designs as well as Anode Baking Furnace energy saving
and safety improvements.

Alpsys APM4: The new

generation
of potmicro is on track

This project aims to deliver the new generation of

potmicro that host ALPSYS Level 1 functionalities.
The new potmicro named APM4 will replace the
existing APM1, APM2 and APM3 models in plug
and play mode and includes new technological
advances (accessed by tablet, advanced management
of new sensors on pots, graphical HMI, …)

The APM4 project is on track with the APM4 prototypes:

• manufactured and assembled

• installed in the LRF environment
• having successfully passed all the hardware tests
in magnetic fields.
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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

APM4 is designed to work in a 200 Gauss environment Forthcoming steps are:

and following the tests have now been validated up to
500 Gauss (0.05 Tesla). • to perform the detailed validation of hardware &
software (process control) by implementing APM4
on live pot in LRF beginning of 2020.
• to install APM4 potmicros on a group of pot in a
potline during S1/2020 to complete the industrial
validation.

Alpsys V15 Go-Live

on 3 additional Smelters in
2019

The new Version V15 of ALPSYS has been implemented

in 3 sites in 2019.

• In February, UGB Rio Tinto smelter (Quebec) has

deployed ALPSYS V15 on 3 potlines (384 pots)
running P155 pot technology.
• In April, MOZAL (Mozambique) has deployed ALPSYS
V15 on 2 AP Technology™ potlines (576 pots)
• In November Sohar Aluminium (Sultanate of OMAN)
has deployed ALPSYS V15 on 1 potline of 360 AP40
pots

1600 pots are now operating with ALPSYS V15 which ALPSYS V15 is on track to be deployed in S1 2020 at
includes modern web HMI, embedded new IT features Tomago smelter (Australia) in 3 potlines (840 AP2X pots).
and new Process Control features such as Robustness.

New Features in
Development for Alpsys

Your production is facing changes and your process

engineers need to quickly test new approaches?
#HashTag allows them to create on the fly their own
process indicators. #HashTag is an additional ALPSYS
function that enables the user to create new data (the
“Tags”) based on existing ALPSYS data and on other
Tags.

This new module will therefore complement the

existing ALPSYS database and is develop with 3
objectives:

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

• intuitive language and ergonomic interface

• new indicators available immediately for present
and past values
• available everywhere when relevant in Alpsys &
Radar suite.

The goal is to allow ALPSYS users to create themselves

their customized indicator without need for IT
development or database configuration.

MESAL 4.0 is now

running in Middle East

The latest version 4.0 of MESAL™ has been successfully

deployed in two smelters in Middle East region.

• Sohar Aluminium (Sultanate of OMAN), initially the

first MESAL™ customer has upgraded the former
version 2 running in all the sectors of the smelter
(Reduction, Carbon, Casthouse and general Services)
in the new 4.0 version. With Kitimat (British Columbia
– Canada) Sohar is the second smelter to use MESAL
4.0 version in all the sectors of the smelter.
• At the same time, ALBA (Kingdom of BAHRAIN) has
started the MESAL™ 4.0 solution for its Carbon and
GTC areas within the L6 project.

MESAL™ 4.0 reinforce its position in smelting AP Technology™ team is currently developing new
management within the Middle East region. Other enhancements to come around mobile device to allow a
sites using MESAL™ 4.0 are the Rio Tinto smelters in MESAL™ usage on shop floor.
Quebec: Alma, UGB, AP60 Jonquière and Laterrière.

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Carbon News

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Bell Bay Aluminium

Smelter

2 years of successful operation of our new NG anode

baking furnace design

The industrial prototype is successfully operated by

Bell Bay Aluminium since December 2017. To date, the
converted zone (33 meters long pits) allowed Bell Bay
Aluminium to produce approximately 8000 additional
anodes (+ 15% productivity) with a confirmed 35%
reduction in gas consumption and with no impact on
anode quality. Operation and engineering teams are
now working on a possible extension of the zone in order
to increase further the Bell Bay anode baking capacity.

As a reminder, the NG Technology concept patented by

Rio Tinto is based on removing partially or totally the
headwalls to increase the anode loading ratio. The number
of headwalls to be removed is selected depending on the
anode dimensions in order to accommodate either an
extra set of anodes or an anode dimension increase.

Alma Aluminium Smelter

Anode baking furnaces retrofit works scheduled for

2020

Alma anode baking facilities (2 furnaces of 48

sections with 7 pits per section) designed by Alesa
were started in 2000. In 2020, the dense refractory
(fluewalls and headwalls) as well as the insulation and
the crossovers will be completely renovated. Both
furnaces will be raised by approximately 0.6m in order
to allow the baking of longer anodes. AP Technology™
baffleless fluewall design will be used to decrease the
renovation impact on the fume treatment facility and
the corresponding investments.

Since the preliminary studies, AP Technology™ Carbon

team is part of the integrated project team for the
supply of the refractory design. We also support Alma
team for refractory quality control at supplier premises
and we will be a key player for the construction and
the start-up of the renovated facilities.

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

AP TechnologyTM
Anode Baking User Club
2020

Coming conference in Sohar on March 10th and 11th

In 2020, there are more than 60 anode baking furnaces

of AP Technology design operating around the world.

With the belief that sharing and cooperation is one of

the keys to solve today’s and tomorrow’s challenges, we
are organizing the next AP Technology™ Anode Baking
User Club conference in Oman in March 2020. Realized
in partnership with Sohar Aluminium, it will gather
Anode Baking Furnace operators from all continents.
The conference will be framed around a benchmarking
exercise realized at the end of 2019 and numerous
presentations of the participants about anode baking
furnaces operation and maintenance.

Modeling Tools to
Optimize Anode Baking

It is well known that the process and operational

parameters of the anode baking furnace have
significant impacts on the anode quality and the
performance of the furnace. Among those parameters,
the gas injection is critical to achieve the targeted
baking level at optimized costs while respecting the
emissions limits. However industrial trials are often
long, costly and influenced by many uncontrolled
parameters.

AP Technology™ carbon team has been developing

and using for several years an entire set of modelling
tools to anticipate the impact of numerous operational,
design and process parameters.

Our latest model focuses on the behaviour of the

gas pulsed combustion in the heating zone. Through
sensitivity study, it is now used to support decision
making in the design phase of all projects in order to:

• Define the range of operation of existing and new/ • Identify the challenges/opportunities to maintain/
future firing ramps, improve anode baking performance and anode
quality,
• Adjust the internal design of fluewalls, for example
to check that the baking level will be maintained • Check the safety of our installations in degraded
for raised fluewalls, mode.
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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Rio Tinto Aluminium Articles TMS 2020

Rio Tinto Aluminium will deliver the following presentations at the TMS2020 Light Metals
Conference in San Diego, 24 February to 27 February 2020

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Validation of the Gravimetric Method to Properly

Follow Alumina Dissolution in Cryolithic Bath

A gravimetric method was developed to study alumina dissolution kinetic by following the evolution
of the apparent weight of alumina samples while immerged into a cryolithic bath. It is the change
of the gravity and buoyancy on the sample that can help to determine the dissolution rate. The
experimental results obtained by this method were compared to four other values; those found
in the literature, a CFD model developed by our team, the total mass difference over experience
time and finally to a boundary displacement method.

Optimization of a Gas Traitement Center Equipped

with Extended Surface Bag Filters:

Results of the test work that was conducted on the Gas Treatment Center installed at the Rio
Tinto AP60 Technology Center located in Canada on the GTC which was originally supplied with
standard filter bags except for one filtration module equipped with extended surface filter bags.
Back in 2017, the original bags were approaching the end of their useful life and the test work was
launched to acquire a deep understanding about control of process parameters to optimize the
GTC performances if ESB filters would be installed in all filtration modules.

Model Based Approach for Online Monitoring

of Aluminium Production Process

Model Based Approach for Online Monitoring of Aluminium Production Process: This article
presents a novel approach for estimating on line alumina concentration and the anode-cathode
distance (ACD) in a regular aluminium-reduction pot cell using a Linear Kalman Filter. This is done
by using an appropriate dynamical model for the pot, which is obtained by combining the first
principle modelling and experimental identification of alumina concentration behaviour from
irregular sampled data. Moreover, a dynamical model for the pot resistance is identified as a
function of the alumina concentration and ACD data. The proposed approach is validated on an
industrial platform.

Mass Transport By Waves on the Bath Metal

Interface in Electrolysis Cell

This paper reviews the literature on the works already done on the study of surface waves, interface
waves and Stokes drift (movement of waves on the surface of a fluid is always accompanied by
a displacement of the particles in the wave propagation direction) and presents estimates of the
mass transport induced by these waves for the case of the metal bath interface for material, such
as rafts of alumina and solidified bath, particles of undissolved alumina, cryolite snow.

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Development of a Mathematical Model

to Simulate Raft Formation

A Lagrangien model, called CuDEM and destined to simulate the alumina feeding process is presented
in this paper. The first part of this model focuses on the interaction between the spherical particles
and their environment by resolving the movement’s equation using discrete element method. The
second part uses the smooth particle hydrodynamics to simulate the flow and freezing of the bath
during raft formation.

Major Reconstruction of Central Casing of Open

top Baking Furnace

In cooperation with AP, Aluminium Company of Greece will present its major reconstruction of central
casing of open top baking furnace of more than 50 years old with a view to increase its lifespan and
reduce the total costs comparing to full reconstruction. The different phases undertaken in order
to successfully develop and safely realize the replacement of the casing walls in the central passage
as well as the anode conveyor supporting structure are detailed along with the technical challenges,
the innovative solutions and the project organization for this work which was completed without
any safety incident and in a strict schedule of ninety days.

Modeling of Gas Injection on Anode Baking

Furnace and Application to Operations

In this paper, a 3D model for the combustion of pulses of gas in the heating sections will be
presented, a model which focuses on the flame behavior in order to precisely represent the
gas pulses, the quality of the combustion, the heat transfer and the emissions. The effect of the
parameter variations on operation will also be presented.

Higher Baking and Production Levels

in Anode Baking Furnaces and Associated
Challenges

The paper describes projects that were simultaneously executed in two of Rio Tinto’s North
American smelters and describes the work performed to achieve both a higher baking level and
higher production. Optimisation of the baking curves is discussed, along with the issues that arose
during the project and the solutions that were put in place.

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Additive Selection for Coal Tar Pitch Modification

in Aluminium Industry

This paper describes the method undertaken to establish an additive selection method which
would yield improved coke wettability by modified pitch and presents the results for three different
additives. Non-modified and modified pitches were characterized by carrying out wettability tests
and FTIR analyses. Coking values of non-modified and modified pitches were also measured. The
results show that it is possible to improve coke-pitch interactions via the utilization of additives.

The LCL&L Process, a Sustainable Solution for the

Treatment and Recycling of Spent Potlining

In 2008, Rio Tinto inaugurated a new plant in Jonquière (Québec) for the treatment of 80 kt of
SPL annually, based on the low-caustic leaching and liming process (LCL&L) developed at Arvida
Research and Development Centre in the early 1990s. LCL&L process characteristics are described,
including valorisation routes for its by-products and some recent improvements of the process to
reduce treatment costs with better energy efficiency

Effect of Water Flow Distribution on the Perfor-

mance of Aluminium Small-Form Ingot
Continious Casting
This paper presents the effect of water flow distribution in the cooling basins on the ingot
solidification and ingots constraint stress. The water flow parameters at three sections in the
cooling basin were tested. The complete ingots cooling profiles, mould temperature profiles and
the demoulding rate in correlation with the water flow distribution were evaluated. To secure the
ingot quality and the casting performance, key process parameters and issues were identified and
the best practice was explored.

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

Other Presentations during 2019

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

January - At the Incal 2019 Conference held

in Bhubaneswar, India
We presented four technical papers covering a wide range of technical solutions:
http://www.meetingsnmore.com/incal%20third%20layout/#
Innovation and development in alumina refining capability (D Holmyard)
Low Caustic Leaching and Liming (LCLL) for the treatment and recycling of spent potlining material
(S Poirier). Expertise and methodology for improving aluminium smelter efficiency (B Feve)
Evolution and perspective of ALPSYS pot process control to support productivity improvement (P
Marcellin)

May - At the Future Aluminium Forum ICSOBA,

Warsaw
A Augé presented the predictive functions developed and implemented using big data analytics
applied to optimize green anode production and reduction processes on the operation platform
developed in the Alvance Aluminium Dunkerque smelter (France) during the Monson Project.
[Monsoon is a European project (European Union’s Horizon 2020), it means MOdel based coNtrol
framework for Site-wide OptimizatiON of data-intensive processes].

June - At Trondheim
B Allano participated to the 2019 International Course on Process Metallurgy of Aluminium in
Trondheim for a session on New Development in Computer Control of Aluminium Cells.

June - At the Air and Waste Management Asso-

ciation Meeting
At the Air and Waste management association meeting, we presented three papers covering:

Industrial process dust management, a short range LiDAR for fugitive emissions quantification
(Jonathan Bernier). The LCL&L process: a sustainable solution for the treatment and recycling
of spent potlining (Laurent Birry). Valorisation of synthetic anhydrite in blueberry fields (Marie-
Christine Simard)

September - At the 37th ICSOBA Conference in

Krasnoyarsk
R Chahine presented a paper on the design of magnetic solutions using MHD code to study the
stability of aluminium electrolysis pots and the role it can play in using boosters in smelters in order
to develop and test new AP technology pot improvements and in calculating the pot MHD stability
limit for creeping and designing solutions in case of unstable pots.

Christos Zarganis of AoG (Greece) made a presentation on the major reconstruction of the central
casing of its open top baking furnace with a view to increase its lifespan and reduce the total costs
comparing to full reconstruction. The article details the technical challenges and innovative solutions
as well as the project and operation organization put in place in order to realize the work without
any safety incident and in a strict schedule of ninety days. (in collaboration with AP).

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AP TechnologyTM newsletter ISSUE 22 - MARCH 2020

David Wong made a presentation on challenges and latest progress in IPCC methodology for
estimating the extent of greenhouse gases co-evolved in the aluminium reduction cell, covering
both anode effect and low voltage emissions – respectively termed ‘high voltage anode effect’
(HVAE) and ‘low voltage anode effect’ (LVAE) emissions (in collaboration with RTA).

September - At the Gulf Aluminium Council

Carbon Conference in Dubai
Arnaud Bourgier presented the latest development on modelling of gas injection on Anode Baking
Furnace with a focus on the behaviour of the flames during the gas injection and the understanding
of the phenomenon involved in the gas combustion and the effect of different burner parameters
on the operations.

Light Metals Award

This award recognizes an individual excellence of a paper presented the preceding year in a Light
Metals Division sponsored session at the Annual Meeting.

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 AP Technology™ Newsletter

Contacts

The AP Technology™ team is committed to delivering innovative proven products in many critical
fields to support increasing productivity and efficiency at your plant. Our technical platforms
get upgraded with new technology bricks and allow adaptations of AP Technology™ solutions to
best suit your own project configuration for unprecedented productivity and benchmark energy
consumption.

Rio Tinto Aluminium Pechiney Rio Tinto Aluminium head office

725, rue Aristide Bergès ‑ BP 7 400 -1190 av. Des Canadiens de
38341 Voreppe Cedex Montreal
France Montreal, Quebec H3B 0E3
Canada

T +33 476 578 500 T +33 476 578 500

F +33 476 566 110 F +33 476 566 110

ap technology.com ap technology.com

You can reach our AP Technology™ team at :

ALPSYS MESAL

Bernard Allais Julie Romano

bernard.allais@riotinto.com julie.romano@riotinto.com
Claude Ritter Antoine Garnier
claude.ritter@riotinto.com antoine.garnier@riotinto.com
Benoit Feve Gwenola Jaouen
benoit.feve@riotinto.com gwenola.jaouen@riotinto.com
Saliha Cherigui Pierre Trouiller
saliha.cherigui@riotinto.com pierre.trouiller@riotinto.com

ABF MAX

Arnaud Bourgier Stéphane Prodent

arnaud.bourgier@riotinto.com Stephane.prodent@riotinto.
Nicolas Tardy Berger com
nicolas.tardy-berger@riotinto. Pierre Trouiller
com Pierre.trouiller@riotinto.com