Cylinders are used in an aluminum smelting process to break the crust of the aluminum dross in the reduction pot to create a hole where more alumina ore can be deposited. The cylinders are mounted vertically, rod end down, above the reduction pot and are in the retracted position approximately 80% of the time. Each cylinder is attached to a rod device that extends and breaks the crust.

Since the smelter had a long history of working with PHD and was familiar with PHD’s expertise in support and engineering, the company’s management sought out PHD to assist with solving the issues. PHD was able to design a drop-in crust-breaker cylinder that improved upon the competitor’s cylinder. PHD’s proprietary seals and rod bushing technology improved the cylinder’s heat tolerance and prevented alumina ingress, thus providing a more reliable, longer-life cylinder, and solving the expensive air leaks.

PHD’s customer has realized longer life from the cylinders, leading to increased uptime and reduced air consumption in its operation for optimal return on investment.