ANODE BAKING: THE UNDERESTIMATED HUMAN ASPECT

In the framework of carbon plant auditing R&D Carbon Ltd. had the opportunity to investigate the operation of many different anode bake furnaces. As a striking result significant differences in the performance of bake furnaces with similar design were identified. Avoidable direct annual losses of one million USD and more per 100.000 tons of baking capacity have been identified. These direct costs do not take any indirect losses in the smelter into account, which result from substandard anode quality and which can easily be two to three times higher than the direct losses. Most of the problems creating financial losses could have been avoided. The key question, therefore, is why were these opportunities not explored? We identified four main reasons creating these losses: No well-defined objectives and goals set. Persisting errors regarding the anode baking process and misunderstanding of cause-effect chain. Organizational and motivational aspects underestimated. Inadequate data and information presentation. Propositions are made, how losses can be avoided and how management can react in order to optimize bake furnace efficiency while minimizing cost.