The challenge was to integrate two robots into a precise space to perform the cleaning operation of the anode butts without disrupting ongoing production. The space allocated for the installation of these robots was limited, which created constraints on the possible movements of the robots. This project required specialized expertise and strict operational management to avoid service interruptions. The installation and commissioning of the project also had to be done without disrupting the regular production operations of the facility.

Through in-depth 3D modeling, Norda Stelo evaluated various scenarios to ensure cleaning efficiency, trajectory synchronization and management of robot interference due to the limited space. This 3D modeling also allowed the clients to visualize the location of the robots within their facility and observe the range of movements, greatly reassuring them about the impact of such an installation and its effects on nearby activities.  

Since Norda Stelo has its own workshop, the installation of the robots, adjustments and operational tests could be carried out smoothly without interfering with the regular production at the smelter. The issue of robot interference was resolved by defining precise movement sequences, developed in collaboration with the clients and through workshop testing.

By eliminating the risks associated with this task, the automated anode butt cleaning project provides significant benefits for the health and safety of workers, who previously performed it manually, exposing them to the risks of musculoskeletal injuries and inhaling harmful dust particles. 

Moreover, better removal of residues from the anodes would enhance their efficiency in the electrolysis process, potentially reducing electricity consumption. The automation of the task by continuously operating robots also allowed for the reassignment of four employees to more value-added tasks at Aluminerie Alouette.  

More efficient cleaning would also extend the life of the infrastructure by reducing chemical reactions between sodium in the paste and refractories during the anode baking process, thus preventing swelling of the refractory walls and the need for subsequent replacements. 

By confining the cleaning process, it is now possible to capture a larger amount of dust using a dust collector, limiting its dispersion in the working environment.

• The automated anode butt cleaning process represents a first in the heavy aluminum industry.   

• The robotized cell is designed for continuous 24/7 operations. 

• Workshop testing validated the robot’s cleaning routes, reducing cleaning times in real-world conditions.

• The project eliminates potential risks of musculoskeletal injuries for operators. 

• Electricity
• Instrumentation, Controls and Robotics
• Industrial Mechanics
• Structure
• Health and Safety