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1、Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 03:31:38 MDTNo reproduction or networking permitted without license from IHS -,-,- O O O O O O O O O O O Strong and lightweight Repeatedly rec
2、yclable for environmental sustainability Resistant to corrosion Good conductor of heat and electricity Tough and non-brittle, even at very low temperatures Easily worked and formed, can be rolled to very thin foil Safe for use in contact with a wide range of foodstuffs Highly reflective of radiant h
3、eat Highly elastic and shock absorbent Receptive to coatings Attractive in appearance Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 03:31:38 MDTNo reproduction or networking permitted with
4、out license from IHS -,-,- ALUMINUM INDUSTRY TECHNOLOGY ROADMAP 1 . Roadmap Background and Overview 1 2 . Primary Production 7 3 . Melting, Solidification, and Recycling 15 4 . Fabrication 27 5 . Alloy Development and Finished Products . 35 6 . Looking Forward: Implementation . 45 A . Acronyms 47 B
5、. References . 49 C . Roadmap Contributors 51 o Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 03:31:38 MDTNo reproduction or networking permitted without license from IHS -,-,- ALUMINUM IN
6、DUBTRY TECHMDLOQY ROADMAP I O0 Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 03:31:38 MDTNo reproduction or networking permitted without license from IHS -,-,- ALUMINUM INDUSTRY TECHNClLOB
7、Y ROADMAP A filuminum is one of the most versatile and sustainable materials for our dynamic global economy. The North American aluminurn industry charted a bold course for the future of this essentiai material in its 2001 publication Aluminum Industry Vlsion: Sustainable Solutionsfor a Dynamic Worl
8、d. In 2002, the industry created this updated Aluminum h d w q Technology Roadmap to define the specific research and development (R these activities are beyond the scope of this Roadmp. The aluminum industry has now defined a set of performance targets for assessing progress toward and achievement
9、of each of the strategic long-term goals involving technical solutions: Products and Markets, Sustainablity, and Energy and Resources (Exhibit 1- 1). To achieve these targets, the industry must pursue an organized, strategic technology agenda. This Roadmap outlines that agenda, organized according t
10、o the major aluminum processes. It presents detailed, sector-specific performance targets, technical barriers, research and development needs, and R these are also the R includes electricity losses at the plant). Hroult process is another priority for the industry. Even small efficiency gains in the
11、 energy-intensive smelting process can yield large cost savings, emissions reductions, and other benefits. While the most advanced cells can achieve an energy intensity of just under 13 kWhikg, the industry average is near 15 kWh/kg. Before primary aluminum producers can achieve their performance ta
12、rgets, the industry must develop solutions to several technological and institutional barriers. Exhibit 2-2 presents the technical barriers currently limiting primary aluminum smelting in four main categories: 0 Electrolytic Reduction Processes 0 Alternative Reduction Processes 0 Enabling Technologi
13、es 0 Institutional Barriers Technical limitations in existing reduction cells constrain improvements in their energy and production efficiencies, metal quality, and environmental performance. Enabling technologies such as sensors, controls, models, and materials can help to overcome these barriers;
14、however, these enablers are also limited in their accuracy, applicability, or effectiveness. Additionally, the lack of commercially viable alternatives to the Bayer and Hall Hroult processes hinders primary aluminum producers in their efforts to achieve revolutionary advances in cost and efficiency.
15、 Less than optimal coordination among industry, government, and academia also limits or slows the rate of technology development. Optimizing these working relationships can help increase the effectiveness of collaborative research and development. 1) Copyright The Aluminum Association Inc. Provided
16、by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 03:31:38 MDTNo reproduction or networking permitted without license from IHS -,-,- ALUMINUM INDUSTRY TECHNOLOGY ROADMAP ENA5LING TECHNOLOGIES e o Inadequate process tools, sensors, and contro
17、ls for reduction cells D inability to measure cell variables (other than resistance) in real time b lack of non-contact sensors o Lack of cost-effective metal-purification technologies o Inadequate process optimization models o Lack of materials (cathode, anode, and sensor tubes) that can withstand
18、exposure to molten aluminum and cryolite 1 ONSTITUTOmNAL BARRPERS c l o Government role in research is unclear; collaboration between government, academia, and industry is not o Low researcher awareness of the state of the technology and of previous and ongoing research optimized; limited cross-inst
19、itutional communication 1 o Lack of regulatory cooperation (e.g., spent potliner) I Exhibit 2-2. Technical Barriers: Primary Production (priorities in bold) ELECTROLYTIC REDUCTION PRQCESSES o Lack of mathematical models to predict the performance of cell design concepts Q Lack of robust bath chemist
20、ry (constrained by cryolite-based electrolyte) o Incomplete knowledge of how to raise thermal efficiency of reduction without negatively impacting the o Lack of economical method to retrofit older cells (including buswork) o Lack of economical technique to remove impurities from alumina in dry scrub
21、bers o High cost of reduction equipment o Large gap between theoretical and actual energy efficiency, and high associated power costs process ALTERNATIVE REDUCTION PROCESSES , Lack of feasible, economical electrolyte compositions that would require lower voltage without c1 Lack of systems approach t
22、o developing overall alternative processes o Difficulties maximizing use of chemical versus electrical energy in alternative processes compromising product quality The industry can overcome the barriers to improved primary production through research, development, demonstration, and other activities
23、 aimed at improving smelting technologies and processes. The R relative priority is shown by the arrows to the left of each R learn to cope with new anode materials (high sulfur, ash). (Ongoing) Develop advanced refractories for the cell. (Ongoing) Develop a cell capable of performing effectively wi
24、th power modulations (e.g,. off-peak power). Continue development of inert anodes (including materials development). (M-L) Refine method to extract impurities from alumina used in dry scrubbers. (N) Develop cost-effective, low-resistance, external conductors and connections for both the anode and ca
25、thode. (M-L) Develop extended-life pot lining ( 5,000-day life). (L) Improve waste heat recovery (from exit gases and from the cathode). (L) Perfect the continuous, pre-bake anode. (M) Priority Level R+w Moddte Higi Low if only goal is to reduce voltage, moderate when considering lifetime of the cat
26、hode 2003 2020 A I I I I I ihi I * I I I I Mid Term (3-10 years) Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 03:31:38 MDTNo reproduction or networking permitted without license from IHS
27、-,-,- ALUMINUM INDUBTRY TECHNOLOBY ROADMAP + Conduct scale-up a c t i e s on current * Develop metal purification techniques processes. (when starting with a metal with Develop the carbothermic reduction process on a commercial scale R O W I TECHNICAL R I S K - , savings, but on-site carbon emission
28、s will increase) mmm L H i g h technical risk I L m ? r n W N 0 W m- RUR shape casting is considered in detail in the Metalcasting Industry Tecbnology Roadmap (see references). New, clean energy sources may enable the industry to meet its energy needs for melting, solidification, and recycling while
29、 further minimizing its impact on the environment. Identiing ways to apply advanced energy technologies to aluminum processes would help ensure rapid adoption. Aluminum companies seeking alternative sources of energy may benefit from a variety of technologies as they become available and cost-effect
30、ive. Examples of such technologies include combined heat and power (CHI?), distributed generation (DG), hydrogen fuel, and induction melting using renewable electricity sources. The growing trend toward engineered material solutions implies that the scrap stream will contain an increased share of al
31、uminum-based composites and other materials with non- aluminum components. In the near term, all internai scrap generated during the processing and manufacture of these new, engineered materials must be captured and recycled. In the coming decades, when these materials enter the post-consumer scrap
32、stream at the end of their service life, they must also be recycled with no waste. By considering the entire life cycle of aluminum-based material solutions and designing them for easy and complete recycling, the aluminum industry can avoid creating products that are not fully recyclable. The origin
33、al industry roadmap called for improvements in furnace designs for the future, and furnace improvements in pursuit of this need have been broad and numerous. Flame image analysis has been useful in improving understanding of combustion, optimizing Copyright The Aluminum Association Inc. Provided by
34、IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 03:31:38 MDTNo reproduction or networking permitted without license from IHS -,-,- ALU MI NUM I N DUBTRY TECH N OLOOY ROAD MAP burner design, and improving temperature uniformity in furnaces. Im
35、proved burner designs, including low-NOx regenerative burners, oxy-fuel burners, and oxy-enriched burners have gained use throughout the industry, and pulsed and oscillating burners are being examined to further extend burner technology. Improved furnace sealing has helped to control the furnace atm
36、osphere, minimize dross formation, and improve overall energy efficiency. Additionally, improved furnace designs, charging techniques, and molten metal pumps all help to increase melt rates and further improve efficiencies. New heating and melting techniques continue to be developed and demonstrated
37、. The recent demonstration of reliable, high watt-density, immersion heaters that offer high energy efficiencies has pushed this promising technology closer to the market, while flotation, cupola-type melting and delacquering has been demonstrated at a prototype scale. Advances in filtration techniq
38、ues and knowledge have gone part of the way to addressing this priority need from the industrys original roadmap. Specifically, a more complete understanding of the role of surface chemistry in inclusion capture, unified depth capture based on computational fluid dynamics (CFD), and flow in reticula
39、ted foam media have all led to advances in filtration techniques. Inclusion sensor development has yielded several promising technologies. The proprietary liquid metal cleanliness analysis (LIMCATM) technology and subsequent refinements of molten metal analysis based on laser-induced breakdown spect
40、roscopy (LIBS) are at or near commercialization, while ultrasonic inclusion sensors and neutron adsorption technologies are being investigated. Scrap identification and sorting technologies have enjoyed similar success, with chemical, color, and LIBS-based sorting all achieving some degree of techni
41、cal success. X-ray absorption-based scrap sorting and neutron activation-based scrap stream analysis are other areas of ongoing investigation. Finally, exploration of ways to use non-metallic products resulting from aluminum melting in other applications has yielded some successes. Calcium aluminate
42、, used for iron and steel fluxing, has been commercially produced from non-metallic products (NMP), and a range of other applications have been developed, including low-density concrete formulations with NMP additions, thermal insulation fiber, abrasives, and sand blasting grit. PERFOWMANEE TARGETS
43、To guide R maximize the ability to deal with residual impurities in every step. To achieve its performance targets for secondary production and recycling, the aluminum industry must overcome a wide range of technical barriers. Some of the key barriers are shown in Exhibit 3-2, with the highest-prior
44、ity barriers displayed in bold text. These barriers have been organized into the following six process-related categories: 0 Melting and Recycling 0 Crosscutting Technologies 0 Metal Processing and Treatment 0 Skim and Dross 0 Casting 0 Continuous Processes Achieving the performance targets in this
45、area will require removal of the limitations on efficiency imposed by existing aluminum melting and recycling technologies and systems. Beyond melting and recycling technologies, however, the industry is lacking important crosscutting technologies that could eliminate wastes and improve the economic
46、s of recycling. Production and management of skim and dross create additional technical challenges for aluminum melters as the industry drives towards zero waste. Limited understanding of the solidification process and associated technologies hinders casting processes and limits the return secondary
47、 aluminum smelters can receive for their products. Additional barriers associated with the processing and treatment of metals center on fluxes, impurities, and fines. Finally, as the industry pushes productivity and efficiency higher, it will increasingly seek continuous operation, which is currentl
48、y limited by control and processing technologies. Copyright The Aluminum Association Inc. Provided by IHS under license with AA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 03:31:38 MDTNo reproduction or networking permitted without license from IHS -,-,- ALUMINUM INDU6TRY TECHNOLOBY ROADMAP Exhibit 3-2. Technical Barriers: Melting, Solidification, and Recycling (priorities in bold) MELTING AND RECYCLING I o Sub-optimal scrap melt rates o Low fuel efficiency in melting and holding furnaces; fu