Potroom Procedure POT0036 

Potline Startup Environmental Compliance Plan

 Document ID: POT0036 Revision: 0

Approved by: Brian Foster Page 1 of 2 Effective Date: 10/09/09

Printed 11/11/2011 3:42 PM If not printed on paper watermarked with “ISO”, this document expires 96 hours after print time.

noranda

Noranda Aluminum, Inc.

A. Definition

1. For the purpose of this plan, a potline startup is defined as the process of energizing the 

aluminum reduction cells of a potline that is presently out of operation. It also includes the 

startup of support systems such as fume scrubbing and alumina supply.

B. Purpose

1. The purpose of this plan is to ensure that the startup systems (reduction cells, fume scrubbing, 

and alumina supply) are kept in good running order and that the facility’s air emissions are 

minimized to the greatest extent which is consistent with safety and good air pollution control 

practices.

C. Responsibility

1. It is the responsibility of the Potline Superintendent to ensure the Potroom Procedure portion of 

this plan is adhered to.

2. It is the responsibility of the Air Control Superintendent to ensure the Air Control Procedure 

portion of this plan is adhered to.

3. It is the responsibility of the 136 Area (Anode Transport) Superintendent to ensure the Anode 

Transport portion of this plan is adhered to.

D. Potroom Procedure

1. All the affected ducts in the potline for the startup section shall be blanked off prior to startup 

except for the few pots that will be initially started. Blanking off the ducts forces the vacuum to 

the startup and operating pots where it is needed.

2. If draft settings are available, the pots shall be put on high draft at bath up and left on high draft 

until they are sufficiently stable and the crust well sealed.

3. Shielding, Anode Set, Tapping, Cutting Out a Pot, and Bake or Restart procedures shall be 

maintained or performed during the potline startup according to the following procedures:

a. POT0009 Shielding

b. POT0001 Anode Set

c. POT0004 Tapping

d. POT0022 Lines 1 and 2 Startup

e. POT0024 Line 3 Resistor Bake

f. POT0025 Cutting Out a Pot

g. POT0034 Lines 1, 2, and 3 Restart Procedures

4. Malfunction—Sick or Unstable Pot. In the event that a pot becomes sick or unstable, resulting in 

excessive emissions that are beyond the capture capability of the system, immediate measures 

shall be taken to bring the pot back under control and capture the emissions. Such measures 

include:

a. Proper adjustment of cell voltage

b. Proper adjustment of cell feeding

c. Monitoring anode current and adjusting as necessary

d. Monitor and adjust liquid levels if required
Potroom Procedure POT0036 

Potline Startup Environmental Compliance Plan

 Document ID: POT0036 Revision: 0

Approved by: Brian Foster Page 2 of 2 Effective Date: 10/09/09

Printed 11/11/2011 3:42 PM If not printed on paper watermarked with “ISO”, this document expires 96 hours after print time.

noranda

Noranda Aluminum, Inc.

e. Adding solid or liquid bath or metal to the cell to reduce temperature

f. Resealing pot crust when appropriate to reduce emissions

5. Rate of Startup—Pots shall be brought on at such a rate such that adequate control can be 

maintained of sick or unstable pots and emissions are kept within acceptable levels.

E. Air Control Procedure

1. Just prior to energizing the first cells of the potline startup process, two scrubbers will be brought 

on to provide a vacuum to the cells.

2. A minimum airflow of 3,100 ACFM per cell will be provided for Lines 1 and 2.

3. A minimum airflow of 3,650 ACFM per cell will be provided for Line 3.

4. Alumina shall be provided to the scrubbers at a rate to adequately scrub the pot gasses and 

considering alumina requirements to the cells and tank inventories.

5. In regard to the operation of potline reactors, the following procedures shall be used:

a. AC 3.03 Potline 1 and 2 Reactor Startup

b. AC 3.04 Potline 1&2 Reactor Shutdown

c. AC 3.05 Potline 3 Reactor Startup

d. AC 3.06 Potline 3 Reactor Shutdown

e. AC 3.12 Potroom Lines 1&2 Scrubber Normal Operations

f. AC 3.13 Potroom Line 3 Scrubber Normal Operations

6. Scrubber Malfunction. In the event that a scrubber malfunction occurs, the following procedures 

shall be followed which detail corrective actions that shall be made:

a. AC 3.12 Potroom Lines 1&2 Scrubber Normal Operations

b. AC 3.13 Potroom Line 3 Scrubber Normal Operations

F. Anode Transport Procedure

1. Anodes shall be added to and removed from the reduction cells during the potline startup 

according to the following procedures:

a. POT0001 Anode Set

b. 1360002 Anode and Butt Delivery and Transport

G. Startup Schedule

1. A startup schedule shall be determined by the Potline Superintendent.

2. A typical restart is on the order of 10-15 cells per week.

3. Projected cell startups will be reviewed on a daily basis.

H. Documentation

1. Reduction cell information is recorded in Celtrol.

2. Airflow and reactor conditions are recorded in Pi.