High Density Prebaked Anode Blocks to Reduce Aluminium Production Cost

High Density Prebaked Anode Blocks to Reduce Aluminium Production Cost

Overview

Core Functions

1. Electric conductionWith low resistivity, anode blocks transmit heavy current into the electrolyte stably. Power cost occupies more than 40% of total aluminium production expenses, so low resistivity of carbon anodes directly cuts power loss and controls manufacturing costs for smelters.
2. Electrochemical reaction participantThe core chemical reaction of aluminium electrolysis relies on carbon anodes:

   Carbon from anodes is continuously consumed, which is the fundamental principle to separate metallic aluminium from alumina.

3. Thermal & structural stabilityInside high-temperature electrolytic cells (850℃–960℃), anodes withstand thermal cycling stress, electromagnetic vibration and erosion by molten electrolyte. Excellent mechanical strength prevents cracking, breaking and shedding carbon fragments, avoiding cell pollution and abnormal shutdowns.

Main Quality Specifications

1. Apparent density: 1.55~1.65 g/cm³Higher density slows air oxidation and reduces anode consumption rate.
2. Electrical resistivity: ≤55 μΩ·mLower resistivity means less power waste during current transmission.
3. Compressive strength: 35–42 MPaEnsures intactness during transportation, installation and cell operation.
4. Residual sulphur content: controlled strictlyExcessive sulphur will corrode cell equipment and cause harmful emissions.
5. Thermal expansion rate: low expansion designReduces cracking risk under frequent temperature changes.

Production Process

1. Raw material preparation: Calcined petroleum coke, recycled anode scraps and coal tar pitch are screened and proportioned according to formula.
2. Kneading: Solid coke particles are fully mixed with molten pitch under heating to form homogeneous carbon paste.
3. Forming: The paste is vibrated or extruded into standard rectangular anode blanks.
4. Roasting: Green anodes are baked at 1100–1200℃ in roasting furnaces to carbonize the binder and form a dense solid carbon structure.
5. Machining: Drill hanging holes on anode surfaces for connecting conductive steel stubs, finish trimming to unified dimensions.

Application Scenarios

1. Large-scale prebaked aluminium electrolysis cells (the main application field, accounts for over 95% consumption of carbon anodes).
2. Special electrolytic metallurgy production such as molten salt electrolysis of rare metals.
3. Conductive carbon components for high-temperature industrial furnaces.

Advantages of Our Carbon Anode Blocks

1. Stable density and uniform internal structure, low breakage rate during usage.
2. Ultra-low resistivity effectively lowers power consumption for aluminium factories.
3. Anti-oxidation performance is optimized to decrease anode consumption per ton of aluminium.
4. Strict dimensional tolerance, perfect matching with the assembly system of mainstream electrolytic cells worldwide.
5. Complete quality inspection system, each batch equipped with COA test reports to meet international aluminium industry standards.

Industry Trend

Conclusion