CN114502777B - Preheating method for bottom of aluminum can - Google Patents
Preheating method for bottom of aluminum can Download PDFInfo
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- CN114502777B CN114502777B CN202080068514.4A CN202080068514A CN114502777B CN 114502777 B CN114502777 B CN 114502777B CN 202080068514 A CN202080068514 A CN 202080068514A CN 114502777 B CN114502777 B CN 114502777B
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
- C25C3/00—Electrolytic production, recovery or refining of metals by electrolysis of melts
- C25C3/06—Electrolytic production, recovery or refining of metals by electrolysis of melts of aluminium
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
- C25C3/00—Electrolytic production, recovery or refining of metals by electrolysis of melts
- C25C3/06—Electrolytic production, recovery or refining of metals by electrolysis of melts of aluminium
- C25C3/16—Electric current supply devices, e.g. bus bars
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Abstract
The method comprises the following steps: covering the bottom of the tank with a conductive material; placing a pre-baked anode having an anode rod assembly onto a conductive material and connecting the anode rod assembly to an anode busbar of a can anode busbar by a flexible electrical connection element; passing an electric current through the conductive material; and controlling the current load on the anode to perform preheating. The amount of conductive material under the anode is formed such that the amount of conductive material under the anode in the middle of the tank is smaller than the amount of conductive material under the anode in the vicinity of the endmost anode, and the amount of conductive material under the anode in the vicinity of the endmost anode is smaller than the amount of conductive material under the endmost anode. The method ensures that the bottom of the aluminum can is uniformly heated in the whole preheating process, ensures safe starting and ensures the prolonged service life of the aluminum can.
Description
Technical Field
The invention relates to the field of nonferrous metal metallurgy, in particular to an electrolytic reduction method of aluminum, namely a tank bottom preheating method of an aluminum tank with a prebaked or inert anode.
Background
Some processes used in the aluminum industry require a significant amount of thermal energy to preheat the equipment prior to start-up. In the past, liner preheating processes of equipment have tended to be overlooked, resulting in, for example, cold start-up of the tank and reduced life. Before starting the can, its cathode liner should be thoroughly and uniformly preheated to minimize potential damage due to excessive temperature differentials.
The high temperature differential and use of the coarse primer paste can cause thermal shock, cracking of the cathode block, and leakage when pouring the plating solution into the can, ultimately resulting in a shortened can life.
There are two basic tank bottom preheating methods:
Electric preheating;
The preheating is performed using a gaseous or liquid fuel.
During preheating with gaseous or liquid fuels, it is difficult to control the amount of heat energy generated and the heat distribution over the cathode surface and/or cathode liner thickness. It is also difficult, if not impossible, to properly heat the side and end walls, if necessary. There is a possibility that the cathode surface may be unevenly distributed, that part of the area is overheated, and that the temperature difference across the cathode lining is very significant.
The electric preheating process is based on the anode rod supplying an electric current to the cathode through the coke bed for heating the tank by electrical conduction and thermal radiation.
One common method of preheating the bottom of an aluminum can includes: placing a prebaked anode at the bottom of the tank; connecting the prebaked anode bar assembly to a busbar of an anode busbar; the prebaked anode is improved; pouring liquid aluminum, and immersing the prebaked anode into the liquid aluminum; and connecting the canister to an electrical circuit (G.Wolfson, V.Lankin., moscow: metallurgical, 1974, pages 55, 56).
One disadvantage of the usual aluminium can bottom preheating method is that the casting of liquid aluminium exposes the can bottom to thermal shock, which can lead to cracks forming in the cathode block and breaking upon further operation of the can. Another significant disadvantage is that the bottom of the can is in direct contact with liquid aluminum, which has the characteristics of low viscosity and low melting point, and the aluminum may flow into the bottom of the can before solidification, react with the insulation, thereby breaking the insulation, or creating a thermal shunt.
Yet another common method of preheating the bottom of an aluminum can (patent #ru 2215825,IPC C25C 3/06) includes: covering a can bottom made of a cathode block and an end peripheral joint with a layer of carbon filler; placing a prebaked anode on the anode rod assembly to enable the bottom of the prebaked anode to be in contact with the carbon filling layer in the whole area, wherein the rod of the anode rod assembly is adjacent to an anode bus of the anode bus; connecting the prebaked anode bar assembly to an anode bus of a can anode bus; a passage of current through the prebaked anode, the carbon-filled layer and the cathode block; and controlling the current load on the prebaked anode by controlling the turn-off.
One disadvantage of the usual aluminium tank bottom preheating method is that up to 50% of the pre-baked anodes are connected to the anode bus of the tank anode bus using a basic lock (rigid). Upon heating the tank bottom by natural combustion of the carbon material, the anode connected using the flexible element will drop, while the rigidly connected anode will remain in place, which will cause local overheating of the tank bottom.
The tank bottom preheating method with prebaked anode aluminum tank (patent No. # RU 2526351,IPC C25C 3/06) is the method closest to the present application in technology, and comprises: covering a tank bottom with a conductive material, wherein the tank bottom is made of a cathode block and reinforcing steel bars; placing a prebaked anode with a short rod; an anode busbar connecting the mounted prebaked anode bar assembly to an anode busbar; the current passes through the conductive material; and controlling the current load on the prebaked anode. In this case, the conductive material is a graphite filler arranged in truncated pyramid rows and positioned on the projections of the stubs, the height of each row being inversely proportional to the intensity of the current passing through the entire prebaked anode length, and all installed prebaked anode bar assemblies are connected to the anode bus of the can anode bus using flexible elements.
One disadvantage of this aluminum can bottom preheating method is that the graphite material is packed in multiple rows under projection of short bars over the entire length of all pre-baked anode blocks. This filling method of graphite material cannot uniformly heat the tank bottom in the first half of the preheating process because if the graphite material under the anode has the same cross section, current will flow to the middle of the tank during heating. Thus, the heating rate of the tank bottom will be slower, which will result in a significant temperature gradient.
Disclosure of Invention
The purpose of the invention is to ensure that the bottom of the aluminium can is heated uniformly throughout the preheating process.
The technical result solves the problem, not only is safe to start, but also prolongs the service life of the aluminum can.
The technical result achieved in the practice of the invention also includes a non-uniform current distribution at the tank bottom so that it is heated uniformly to 900 ℃ in less than 60 hours during preheating of the gas flame.
Drawings
Preferred embodiments of the present invention will be described in further detail below with reference to the attached drawing figures, wherein:
FIG. 1 shows the geometry of the conductive material (graphite "bed") -a top view of an embodiment with a can having 24 pairs of anodes;
FIG. 2 is a schematic diagram of a graphite "bed" knurling die of up to 200 kA;
FIG. 3 is a schematic diagram of a graphite "bed" knurling die above 200 kA;
FIG. 4 is a schematic illustration of knurling of a graphite "bed" at the end anode;
FIG. 5 is a schematic illustration of knurling of a graphite "bed" at the anode adjacent to the terminal anode;
FIG. 6 is a schematic illustration of knurling of a graphite "bed" on other anodes;
FIG. 7 is a schematic diagram showing an embodiment of a temperature pattern of the tank bottom prior to tank start-up wherein the tank bottom is unevenly heated due to non-optimal filling of graphite material;
FIG. 8 is a schematic diagram showing the surface temperature of the tank bottom within 1 hour prior to tank start-up;
FIG. 9 is a schematic illustration of the current intensity measured on the end anodes (1, 12, 13, 24) using "pliers" throughout the tank preheating process to change the graphite material structure (see FIG. 1);
FIG. 10 is a schematic view showing the heating trend of the can bottom at a check point;
FIG. 11 is a schematic illustration of a proposed flexible element for connecting an anode rod to an anode bus for independent preheating; and
Fig. 12, 13 are schematic views of alternative flexible elements.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments of the application. In the drawings, like reference numerals describe substantially similar components throughout the different views. Various specific embodiments of the application are described in sufficient detail below to enable those skilled in the art to practice the teachings of the application. It is to be understood that other embodiments may be utilized or structural, logical, or electrical changes may be made to embodiments of the present application.
Depending on the tank amperage, one of the proposed templates (fig. 2, 3) was used to install a graphite "bed" (fig. 1).
The knurling of the extreme anode of the graphite "bed" proceeds as follows.
The template (fig. 4) is placed on the can bottom of the knurled area of the graphite "bed" on the anodic projection. (arrangement of rods: # 1-side anodes; # 10-row spacing). The graphite material fills the spaces between the rails, flush to the upper surface (flush). The edges of the bars are used as supports, and graphite materials can be leveled without tamping. Excess graphite material is removed, for example, using a leveling blade. The form is removed from the bottom of the can and excess graphite material is removed.
The graphite "bed" was knurled at the anode near the end anode as follows.
Depending on the tank amperage, one of the proposed templates (fig. 2, 3) was used to install a graphite "bed". The template was placed on the can bottom of the knurled area of the graphite "bed" on the anodic projection (arrangement of bars: # 1-side anodes; # 10-row spacing). The graphite material fills the spaces between the rails, flush to the upper surface ('flush'). The raw material was not filled into the space between the 7 th and 8 th strips of the template (fig. 5). The edges of the bars are used as supports, and graphite materials can be leveled without tamping. Excess graphite material is removed, for example, using a leveling blade. The form is removed from the bottom of the can and excess graphite material is removed.
The knurling of the graphite "bed" on the other anodes is shown below.
Depending on the tank amperage, one of the proposed templates (fig. 2, 3) was used to install a graphite "bed". The template was placed on the can bottom of the knurled area of the graphite "bed" on the anodic projection (arrangement of bars: # 1-side anodes; # 10-row spacing). The graphite material fills the spaces between the rails, flush to the upper surface ('flush'). The raw material is not filled into the spaces between the third and fourth, seventh and eighth strips of the form (fig. 6). The edges of the bars are used as supports, and graphite materials can be leveled without tamping. Excess graphite material is removed, for example, using a leveling blade. The form is removed from the bottom of the can and excess graphite material is removed.
After all anodes were installed, a starter charge (cryolite, crushing hard tank, soda) was placed into the side anode space, and the top of the anode body was covered with cryolite.
All mounted pre-baked anode rod assemblies are connected to the anode bus of the tank anode bus, for example using a set of flexible aluminum strips, all current passing through the graphite material layers. The current load of the prebaked anode is controlled by turning off the anode at high load or when the local bottom is overheated.
Fig. 7 shows a schematic diagram of an embodiment of a temperature pattern of the tank bottom prior to tank start-up, wherein the tank bottom is heated unevenly due to non-optimal filling of the graphite material. It is evident that the middle of the tank is heated to 800-750 ℃ and the end temperature of the tank is below 400 ℃. In the latter half of the preheating process, the tank ends are heated by intermediate heat transfer, so that at the end of the preheating process the tank bottom temperature is uniform.
Figure 8 shows the surface temperature of the tank bottom within 1 hour prior to tank start-up. Fig. 9 shows the current intensity measured on the end anodes (1, 12, 13, 24) using "pliers" throughout the tank preheating process with graphite material configuration adjustment (see fig. 1), that is, it shows the current intensity trend on the end anodes. It is clear from the figure (fig. 9) that the current at these anodes is 20-25% higher than nominal (fig. 1) due to the more strips of graphite material.
As is clear from fig. 8, 9, the new graphite filling geometry enables us to:
1) Uniformly heating the bottom surface of the tank to a target value for 48 hours;
2) The current is redistributed to the end anodes.
Figure 10 shows the heating trend of the tank bottom at the inspection point. It is evident that the average temperature of the can bottom surface is achieved by checking the thermocouple at the following locations:
1. At line spacing-949 ℃ (target-over 900 ℃); a step of
2. -808 ℃ (Target-over 800 ℃) at the first stub on the "inlet" and "outlet" sides;
3. at the bottom of the tank-736 ℃ (target-over 550 ℃).
Thus, the proposed method for preheating the can bottom with prebaked anode aluminum can comprises: covering the bottom of the tank with a conductive material; placing a prebaked anode thereon; their connection to the anode bus of the tank anode bus; the current passes through the conductive material; and controlling the current load on the anode to preheat, which is inherent to the pilot model. In this case, uniform preheating is ensured by selecting a suitable amount of conductive material under the anode. That is, the amount of conductive material under the anode is selected such that the amount of material under the anode in the middle of the tank is less than the amount of material under the anode in the vicinity of the endmost anode, and the amount of material under the anode in the vicinity of the endmost anode is less than the amount of material under the endmost anode. The conductive material is preferably graphite, which is a segment of 0.1mm to 10 mm. It is reasonable to set the height and length of each row of conductive material under the anode to be inversely proportional to the current passing through. The mounted prebaked anode bar assembly typically uses an anode busbar (fig. 11) that is connected to the can anode busbar using flexible elements.
The "anode busbar-anode rod" flexible element has the following design solutions, distinguishing it from the alternatives:
Contact cross section, area and hold down pressure ensure current density: contact-no more than 0.6A/mm 2 for parts; for flexible conductors-no more than 1.2A/mm 2;
The overall dimensions and connection dimensions allow for unobstructed installation and disconnection of the flexible element;
the size and the screw pitch of the nut are uniform; the design of the screw allows the anode lock to be tightened using a transverse mechanism (wrench).
After all anodes are installed, a starting charge (e.g., cryolite, crushed hard tank, soda) is placed into the side anode space and the top of the anode body is covered with cryolite. At this point, all of the installed prebaked anode bar assemblies were connected to the anode bus of the can anode bus using a set of flexible aluminum strips, and current was passed through the graphite material layers. The current load of the prebaked anode is also controlled by turning off the anode when the load is high or the local bottom is overheated.
It should be noted that in view of the current economic situation, the smelter should take measures to monitor and eliminate the operating/general production costs affecting the various stages of commodity production without degrading the quality of the product. One aspect that directly affects the cost of raw aluminum production is the replacement of liners and process maintenance of metallurgical equipment by preheating.
The tank preheating phase before connection and start-up is one of the most important operations during its operation. The pot life, quality of aluminum produced, and key performance indicators are largely dependent on the quality of the preheating operation. During the preheating process, it is important to ensure that the can and cathode are heated uniformly and smoothly.
The preheating requirements for the tank body before starting are as follows:
-ensuring a smooth transition from cold to reduced temperature conditions;
-removing thermal "shocks", including shocks during the pouring;
-minimizing hot pressing of the cathode in the vertical and planar directions;
-ensuring proper heating of the priming paste;
after lining with liquid, ensure complete drying of the tank bottom base.
In actual practice, according to the heating principle, the following three basic tank preheating methods are used:
1. Preheating with an electric current, wherein the thermal radiation is defined by Joule-Roots law;
1.1. on finely divided and coarse carbon materials;
1.2. on liquid metal or aluminum flakes;
1.3. during the casting of the new anode (Sode Buerger);
2. heat preheating, wherein the heat transfer medium is natural gas or petroleum products;
3. starting without preheating, the tank and metal are immediately poured into a cold tank.
Prior to 1995, ha Kasi aluminum smelters used two methods for tank preheating:
on an S-175M2 tank-preheating by flame (preheating device designed by watt-meters);
On the S-255 pot-on the carbon particles ("seeds") the anode is firmly pressed against the anode bus with standard clamps after placement on the "seed" layer.
Since 1995, ha Kasi aluminum smelters took the following measures according to the pot life extension program to optimize the preheating process:
flexible connection of the anode bars to the anode bus bars, independent preheating with electric current in all types of tanks;
By opening the varistor shunt, the number of opening steps is increased from 2-3 to 6-8, thereby improving the control of the supply tank power and significantly improving the heating quality;
-arranging a dedicated team for tank preheating and starting operations.
During the electrical preheating on the carbon pellets, the anodes were pressed firmly against the anode bus with standard jaws. After 1995, flexible connection was adopted between the anode rod and the anode bus. The main drawbacks of this electrical preheating on coke are as follows:
-heating rate control problem (varistor shunt open);
Non-uniform heating of the can bottom due to the non-uniform connection of the raw material used (coke) and the anode bottom (knurling, design of the connecting band);
The tank start-up process is labor intensive (decoking).
Since 2004, all tanks of the sarhinogorsk aluminum smelter were preheated using gas flame after modification of the RA-300 technology and start-up Ha Kasi aluminum smelter. The existing warm-up and start-up procedures for RA-300 and RA-400 tanks are illustrated as follows:
Gas flame preheating= > watering= > connecting the tank to the circuit without disconnecting the tank line= > adjusting the parameter to the target value.
The disadvantages of the gas flame preheating method are as follows:
1) To batch preheat the liner and reach the target temperature, the preheat time should be increased from 72 hours to 96 hours (localized preheating in the cold season).
2) For long cans, the number of burners that are in heating operation is insufficient. The number of temperature checkpoints is small. Operational problems of the device during magnetic fields and heavy frost.
3) There is no data about the tank bottom temperature during preheating-the temperature of the gas-air environment was measured.
4) Fault operation of connection/start-up at full current:
-personnel safety;
-high probability of unexpected current drop;
long start-up duration (pouring more plating solution), high voltage anode effect during start-up.
Experience from the RA-400 pilot plant start-up tank has shown that during cold seasons, gas flame preheating does not meet process requirements (longer preheating times are required to reach the required minimum tank bottom temperature). Depending on climate parameters, the average ambient temperature for seven months per year for takent (russian Luo Siyi mol Coutts g area) is negative, and thus takent aluminum smelters cannot accept fast commissioning. In view of the capacity of the tower Xie Telv smelter, the main condition for connecting the electrolyzer is also to connect the RA-400 electrolyzer to the circuit without disconnecting the electrolyzer process load to eliminate the high loads of the siberian energy system.
The main technical solution to avoid the above drawbacks is to replace the gas flame preheating of the tank with electric current preheating. The application of an electrical preheating process will enable us to:
-connecting the tank reliably to the circuit without causing disconnection of the tank line or current drop;
Avoiding expensive preheating equipment and fuel costs (excluding the limiting factors of rapid commissioning of the smelter and environmental impact);
-shortening the duration of the tank preheating operation.
The key performance indexes realized are as follows:
1. The electrolytic tank is reliably and safely connected under the full current of the electrolytic tank.
2. The pot warm-up time was shortened from 72 hours to 54 hours.
3. Avoiding expensive preheating equipment and fuel costs (reducing environmental impact).
The basic differences of the proposed technical scheme are as follows:
1) Full current preheating of a varistor-free shunt;
2) The application of graphite materials;
3) Differential knurling of the graphite "bed";
4) Optimizing design of the flexible contact piece:
-anode degrees of freedom in three directions (X, Y, Z);
-immediate control by means of current distribution on the anode;
5) And (5) automatic temperature monitoring.
The above embodiments are provided for illustrating the present invention and not for limiting the present invention, and various changes and modifications may be made by one skilled in the relevant art without departing from the scope of the present invention, therefore, all equivalent technical solutions shall fall within the scope of the present disclosure.
Claims (7)
1. A method of preheating a can bottom of an aluminum can with a prebaked anode, the method comprising:
Covering the can bottom with a conductive material;
placing a pre-baked anode onto the conductive material, the anode having an anode rod assembly connected to an anode busbar of a can anode busbar by a flexible electrical connection element;
Passing an electrical current through the conductive material; and
The current load on the anode is controlled to preheat,
Wherein the conductive material under the anode is formed such that the amount of conductive material under the anode located in the middle of the tank is smaller than the amount of conductive material under the anode located in the vicinity of the endmost anode, and the amount of conductive material under the anode located in the vicinity of the endmost anode is smaller than the amount of conductive material under the endmost anode.
2. The method of claim 1, wherein the conductive material is a 0.1mm to 10mm piece of graphite material.
3. The method of claim 1, wherein the height and length of each row of conductive material under the anode is inversely proportional to the current passing therethrough.
4. A method according to claim 1, wherein the anode rod assembly of the mounted pre-baked anode is connected to the anode busbar of the tank anode busbar by using the flexible electrical connection element to ensure anode freedom in three directions (X, Y, Z).
5. The method of claim 1 wherein after all anodes are installed, a starting charge in the form of cryolite, broken up hard bath and soda is charged into the side anode space and covered with cryolite on top of all anodes.
6. The method of claim 1, wherein the anode rod assembly of the installed pre-baked anode is connected to the anode bus of the can anode bus by using a set of flexible aluminum strips and passing an electric current through the graphite material layers.
7. The method of claim 1, wherein the current load of the pre-baked anode is controlled by turning off the anode at high load or by turning off the anode in a locally overheated area of the tank bottom.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| RU2019130349 | 2019-09-24 | ||
| RU2019130349A RU2717438C1 (en) | 2019-09-24 | 2019-09-24 | Method for firing aluminum electrolyser bottom |
| PCT/RU2020/050204 WO2021061015A1 (en) | 2019-09-24 | 2020-08-26 | Method for baking a cell bottom of an aluminium electrolyzer |
Publications (2)
| Publication Number | Publication Date |
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| CN114502777A CN114502777A (en) | 2022-05-13 |
| CN114502777B true CN114502777B (en) | 2024-08-09 |
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| CN202080068514.4A Active CN114502777B (en) | 2019-09-24 | 2020-08-26 | Preheating method for bottom of aluminum can |
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|---|---|
| EP (1) | EP4039854A4 (en) |
| CN (1) | CN114502777B (en) |
| CA (1) | CA3154865C (en) |
| RU (1) | RU2717438C1 (en) |
| WO (1) | WO2021061015A1 (en) |
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| WO2021232147A1 (en) * | 2020-05-01 | 2021-11-25 | Elysis Limited Partnership | System and process for starting up an electrolytic cell |
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| FR2844811B1 (en) * | 2002-09-20 | 2004-10-22 | Pechiney Aluminium | METHOD FOR PREHEATING A TANK FOR THE PRODUCTION OF ALUMINUM BY ELECTROLYSIS |
| RU2318920C1 (en) * | 2006-04-26 | 2008-03-10 | Общество с ограниченной ответственностью "Русская инжиниринговая компания" | Method for firing hearth of aluminum cell with fired anodes |
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| RU2526351C1 (en) * | 2013-07-09 | 2014-08-20 | Общество с ограниченной ответственностью "Объединенная Компания РУСАЛ Инженерно-технологический центр" | Annealing of bottom of aluminium electrolytic cell with sintered electrodes |
| RU2593253C1 (en) * | 2015-04-22 | 2016-08-10 | Общество с ограниченной ответственностью "Объединенная Компания РУСАЛ Инженерно-технологический центр" | Method of burning of bottom of aluminium electrolytic cell |
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2019
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2020
- 2020-08-26 WO PCT/RU2020/050204 patent/WO2021061015A1/en unknown
- 2020-08-26 CA CA3154865A patent/CA3154865C/en active Active
- 2020-08-26 EP EP20867862.3A patent/EP4039854A4/en active Pending
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| CN101629304A (en) * | 2008-07-17 | 2010-01-20 | 沈阳铝镁设计研究院 | Coke particle baking startup method for pre-baked anode aluminum electrolytic cell and structure thereof |
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Also Published As
| Publication number | Publication date |
|---|---|
| EP4039854A1 (en) | 2022-08-10 |
| WO2021061015A1 (en) | 2021-04-01 |
| CN114502777A (en) | 2022-05-13 |
| CA3154865C (en) | 2024-01-09 |
| EP4039854A4 (en) | 2024-09-04 |
| RU2717438C1 (en) | 2020-03-23 |
| CA3154865A1 (en) | 2021-04-01 |
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