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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - PEA (aluminium Portable Element Analyzer)

Teaser

Summary

The PEA project is based on the industrialization and commercialization of the next generation of process analytical instrumentation, capable of performing in-line real-time chemical analyses of molten aluminium with optimum accuracy and repeatability. This will allow for precise adjustment of process parameters to their optimal limits. Our plan is to offer PEA systems to primary and secondary aluminium producers, who are constantly seeking solutions regarding process efficiency, operating costs, worker safety and environmental impact. Our revolutionary technology is set to change the entire industry, as it addresses the current limitations of a process known to be extremely energy intensive.

Work performed

DTE has worked on finalizing the design of the PEA prototype, with the analytical software as well as control software and protocols. We have designed the user interface for the equipment and how it will report to the users. We have started setting up testing procedures for the prototype to ensure compliance. This process has been documented and is being assessed against relevant regulations, standards and safety protocols. We have worked on dissemination and communication activities, both within the industrial and scientific community. We have introduced our product in exhibitions, trade fairs and other industry related events with good results.

Final results

DTE is introducing a breakthrough product with revolutionary technology which will create a new benchmark for aluminum production process control, through the application of laser-induced breakdown spectroscopy (LIBS) for on-line chemical analysis in primary aluminum smelters. To date, measurements have been performed for fourteen trace elements and correlated with laboratory measurements on corresponding solid samples. Real-time quantification of trace elements down to ppm levels directly in the molten aluminum has been demonstrated for a number of elements. For elements Fe and Si, typically present in elevated concentrations in primary aluminum, the average difference between concentration measurement carried out on the melt and laboratory results was found to be within 2.5% and 5% of the measured concentration, respectively. The observed differences can be partly related to uncertainties in the reference laboratory measurements, originating from the process of casting of solid samples from the melt. It can be concluded that for many technically important trace elements in primary aluminum, in-line LIBS analysis on the molten metal is fully competitive with off-line laboratory analysis of solid process samples in terms of accuracy and precision, in addition to improving worker safety and providing significantly faster measurement results. Once the PEA product is finalized and implemented, DTE will be able to quantitatively demonstrate the benefits of real-time analysis for product quality, process stability and workplace safety, with financial as well as environmental impacts.