铝电解槽阴极的优化试验研究
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摘要
铝电解槽是铝电解工业中的核心设备,其性能直接影响着生产指标。电解槽寿命的长短,不仅关系到大修费用、铝的产量和质量,更关系到铝的成本和整个铝企业的效益。
本文介绍了铝电解槽的演变的历史及进程。通过对电解槽破损征状的特征及典型槽破损的类型的观察总结,深入对破损原因进行了分析,得出了电解槽破损主要是阴极内衬和槽体破损的结论,并对破损机理作了深入剖析。
根据中铝河南分公司1999年投产的85KA电解槽槽壳变形情况的观察,并对近期大修的部分电解槽槽壳变形尺寸进行了测量,据此描述了槽壳变形情况。对85KA电解槽槽壳结构进行了受力分析,并在此基础上,对现有槽壳的大修理提出了修补方案。
对中铝河南分公司铝电解槽内衬结构的逐步优化及所取得的良好效果作了介绍。在优化内衬结构中,中铝河南分公司采用了硅酸钙纤维板,干粉防渗料,异型侧部炭块等新型耐火材料,并对TiB2-C一体化复合阴极、氮化硅-碳化硅+碳(Si3N4-SiC+C)复合侧壁等进行了试验,对提高内衬热阻,降低侧壁热阻,取得了良好的效果。
根据国内阴极碳素材料产品现状,对阴极内衬筑炉施工工艺进行优化。应用了新型的FR-3Z捣固机和自制研发的覆盖式红外线阴极加热罩,提高了筑炉质量,保证了筑炉施工的稳定性。
实践证明,优化的铝电解槽阴极对保证85KA铝电解槽稳定生产,降低电耗,提高电流效率起到了积极的作用。直流电耗下降至13700kWh,电流效率稳定在92.05%。
Aluminum electrolysis cells is the core equipment in aluminum electrolysis industry, and its performs can affect the producing index directly. The cell life relates not only the funds for overhaul and the throughput and the quality of aluminium, but also the aluminum cost and the benefit of whole aluminium enterprise.
The paper introduced the develpment and history of aluminium cell. By observing the signs of cell breakage and the clasific cell breakage styles, and deeply analyzing the reasons of cell breakage, the paper got the conclusion that the cell breakage mainly is the breakage of cathode lining and cell body. Besides, it deeply analyzed the breakage mechanism.
Based on observing the pot shell deformation of 85KA cell which went into operation in smelting plant of Chalco Henan Branch,1999, we measured a part of pot shell deformation overhauled precently, and discribed the condition of pot shell deformation.
We analyzed the bearing pressure of the pot shell of 85KA cell, and based on it, the paper pointed out the reparation plan for overhauling the existing pot shells.
The paper introdued the gradual development of cell lining in smelting plant of Chalco Henan Branch and the good results. During optimizing the lining structure, the plant adopted calcium silicate fibreboard, dry powder impervious material, new style fireproofing material (such as deformed side cabon etc.), tested TiB2-C integrated cathode, Si3N4-SiC+C compound side wall and so on, improved the heat resistance of lining, reduced the heat resistance of side wall, and got good results.
According to the present condition of Chinese cathode cabon material, we optimzed the building furnace process of cathode lining, applied newFR-3Z tamping machine and covered infrared cathode heating coat which was invented by ourselves, advanced furnace quality, and ensured the stability of building furnace.
Through practices, we find that optimzing cathode is good for operating 85KA cell stably, reducing electricity consumption, and improving the current effectivity. When DC consumption reduces to 13700kWh, the current effectivity stably keeps 92.05%.
本文介绍了铝电解槽的演变的历史及进程。通过对电解槽破损征状的特征及典型槽破损的类型的观察总结,深入对破损原因进行了分析,得出了电解槽破损主要是阴极内衬和槽体破损的结论,并对破损机理作了深入剖析。
根据中铝河南分公司1999年投产的85KA电解槽槽壳变形情况的观察,并对近期大修的部分电解槽槽壳变形尺寸进行了测量,据此描述了槽壳变形情况。对85KA电解槽槽壳结构进行了受力分析,并在此基础上,对现有槽壳的大修理提出了修补方案。
对中铝河南分公司铝电解槽内衬结构的逐步优化及所取得的良好效果作了介绍。在优化内衬结构中,中铝河南分公司采用了硅酸钙纤维板,干粉防渗料,异型侧部炭块等新型耐火材料,并对TiB2-C一体化复合阴极、氮化硅-碳化硅+碳(Si3N4-SiC+C)复合侧壁等进行了试验,对提高内衬热阻,降低侧壁热阻,取得了良好的效果。
根据国内阴极碳素材料产品现状,对阴极内衬筑炉施工工艺进行优化。应用了新型的FR-3Z捣固机和自制研发的覆盖式红外线阴极加热罩,提高了筑炉质量,保证了筑炉施工的稳定性。
实践证明,优化的铝电解槽阴极对保证85KA铝电解槽稳定生产,降低电耗,提高电流效率起到了积极的作用。直流电耗下降至13700kWh,电流效率稳定在92.05%。
Aluminum electrolysis cells is the core equipment in aluminum electrolysis industry, and its performs can affect the producing index directly. The cell life relates not only the funds for overhaul and the throughput and the quality of aluminium, but also the aluminum cost and the benefit of whole aluminium enterprise.
The paper introduced the develpment and history of aluminium cell. By observing the signs of cell breakage and the clasific cell breakage styles, and deeply analyzing the reasons of cell breakage, the paper got the conclusion that the cell breakage mainly is the breakage of cathode lining and cell body. Besides, it deeply analyzed the breakage mechanism.
Based on observing the pot shell deformation of 85KA cell which went into operation in smelting plant of Chalco Henan Branch,1999, we measured a part of pot shell deformation overhauled precently, and discribed the condition of pot shell deformation.
We analyzed the bearing pressure of the pot shell of 85KA cell, and based on it, the paper pointed out the reparation plan for overhauling the existing pot shells.
The paper introdued the gradual development of cell lining in smelting plant of Chalco Henan Branch and the good results. During optimizing the lining structure, the plant adopted calcium silicate fibreboard, dry powder impervious material, new style fireproofing material (such as deformed side cabon etc.), tested TiB2-C integrated cathode, Si3N4-SiC+C compound side wall and so on, improved the heat resistance of lining, reduced the heat resistance of side wall, and got good results.
According to the present condition of Chinese cathode cabon material, we optimzed the building furnace process of cathode lining, applied newFR-3Z tamping machine and covered infrared cathode heating coat which was invented by ourselves, advanced furnace quality, and ensured the stability of building furnace.
Through practices, we find that optimzing cathode is good for operating 85KA cell stably, reducing electricity consumption, and improving the current effectivity. When DC consumption reduces to 13700kWh, the current effectivity stably keeps 92.05%.
引文
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3. 廖贤安,谢青松.铝电解槽内衬设计和破损机理若干问题的综合分析[J],轻金属,2002,7：29-31.
4. 郭龙,戢兆丰,顾敏.高效预焙阳极铝电解槽创新设计[J],轻金属,2002,3：35-37.
5. 廖贤安,陈保国,包崇爱.采用石墨化阴极炭块,提高我国大型预焙槽内衬设计水平和炼铝技术[J],河南有色金属,2005,(5)：43.
6. 沈泽方.铝电解[M],中国有色金属工业总公司职工教育教材编审办公室,1988,36-80.
7.Don Harris.冰晶石向铝电解槽干防渗耐火材料渗透的研究[J],Light Metals,2000: 419-427.
8. 邱竹贤.铝电解原理与应用[M],徐州：中国矿业大学出版社,1997,445-472.
9. Patel P, Hyland M, Hiltmann F, et al. Influence of internal cathode structure on behavior during electrolysis. Part 2:porosity and wear mechanisms in graphitized cathode material [J], Light Metals,2006:757-762.
10. Rafiei P, Hiltmann F. Electrolyte degradation within cathode materials[J], Light Metals,2001:747-753.
11. 强红江,李兵,乔贵林等.160KA预焙铝电解槽槽壳变形及摇篮架破损修复改造的探讨[C],第五届铝电解专业委员会2005年年会暨学术交流会论文集,2005：363-365.
12. 罗国平.预焙电解槽扎固施工温度控制[C],第五届铝电解专业委员会2005年年会暨学术交流会论文集,2005：367.
13. 冯乃祥.TiB2/C复合材料阴极的膨胀性的研究[C],第五届铝电解专业委员会2005年年会暨学术交流会论文集,2005：238-240.
14.刘敬穆.铝电解技术研究及发展方向探讨[J],轻金属,1995,(12)：43-46.
15.邱金山.铝电解槽使用寿命技术改进研究[J],甘肃有色金属,2001,3：19-21.
16.韩华,丁立伟,彭建平等.高效长寿命电解槽的技术问题[J],有色矿冶,2006,(5)：32-37.
17.刘世英,石忠宁,任必军等.铝电解槽用干防渗料的导热性与抗渗性[J],中国有色金属学报,1641-1646.
18.任必军.我国大型预焙槽寿命2500天以上的研究[J],轻金属,2002,(8)：32-36.
19.任必军.300 kA铝电解槽阴极破损机理研究[J],东北大学学报,2007,28(6)：843-846.
20.金秀岩.关于我国电解铝工业竞争力的思考[J],轻金属,2000,(4)：3-6.
21.张洪涛,温铁军.300KA系列电解槽阴极破损的现象、原因及对策[J],轻金属,2006,(5)：41-43.
22.王会全,孙春亮.电解槽干法刨炉的应用与推广[J],轻金属,2004,(4)：26-28.
23.赵无畏,段新国,田强等.提高槽寿命的工业试验研究[J],河南有色金属,2003,(4)：6-10.
24.李庆宏,王平甫,杨明生.铝电解槽炭质内衬材料与槽寿命的研究[J],河南有色金属,2003,(4)：19-22.
25. 刘建新.预焙阳极电解槽炉底破损的修补及维护方法[J],轻金属,2005,(5)：27-31.
26.王宝龙,赵俊国,王文武等.TiB2材料的特性及其在铝工业中的应用[J],轻金属,2004,(5)：23-27.
27.唐定品.铝电解槽阴极钢棒除锈、钝化新工艺[J],轻金属,2004,(5)：27-30.
28.李庆余,赖延清,李劫等.应用新一代常温固化TiB2阴极涂层技术提高我国预焙铝电解槽寿命[J],轻金属,2004,(10)：34-38.
29.王会全.85KA创新预焙阳极电解槽“电场”测试[J], 铝镁通迅,2005,(12)：18-19.
30. 高炳亮等.碳化硅耐火材料在铝电解槽中应用的可行性[J],轻金属,2001,(4)：40-43.
31.赵琳,刘风琴,毛继红等.铝电解用阴极炭块抗磨损性能研究[J],轻金属,2005,(12)：25-28.
32.尹书金,邵勇,曹继明等.大型预焙铝电解槽阴极内衬破损特征及检测[J],轻金属,2005,(12)：29-32.
33. 李广来.浅淡大型预焙阳极铝电解槽阴极结构制作与焊接[J],河南有色金属,2004,(1)：28-33.
34.廖贤安,段学良,赵忠明.我国阴极炭素材料发展中的若干问题[J],轻金属,2004,(11)：6-8.
35.周文田.155KA预焙槽寿命探讨[J],轻金属,2003,(1)：38-40.
36.项阳,李晓波.铝电解槽“过渡期”技术管理与槽寿命关系[J],河南有色金属,2004，(10)：26-33.
37.廖贤安.我国铝电解技术发展方向[J],轻金属,2006,(8)：23-40.
38. 熊维平.中国铝工业发展趋势探讨[J],轻金属,2006,(8)：29.
39.李方义,霍伟,翟书敏等.底部阴极炭块在物理档板和化学档板型内衬中变形差异的分析[C],第五届铝电解专业委员会2005年年会暨学术交流会论文集,2005：315.
40.成庚,吕增旭,王醒钟等.铝电解可湿润性阴极的研究开发与工业试验[J],包头钢铁学院学报,2002,(9)：288-292.
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45.李永正.干式防渗料在190KA大型预焙槽上的应用[J],轻金属,2002,(8)：47-49.
46.王化章,王惠林,刘业翔等.用于铝电解槽的TiB2基陶瓷阴极[J],轻金属,1993,(5)：28-31.
47.王兆文,高炳亮,邱竹贤等.改进的二硼化钛基惰性阴极耐腐蚀性的研究[J],轻金属,2001,(12)：35-37.
48.殷恩生著.160KA中心下料预焙铝电解槽生产工艺及管理[M],湖南：中南工业大学出版社,2004,1-6.
2. 冯乃祥.铝电解[M],北京：化学工业出版社,2006.
3. 廖贤安,谢青松.铝电解槽内衬设计和破损机理若干问题的综合分析[J],轻金属,2002,7：29-31.
4. 郭龙,戢兆丰,顾敏.高效预焙阳极铝电解槽创新设计[J],轻金属,2002,3：35-37.
5. 廖贤安,陈保国,包崇爱.采用石墨化阴极炭块,提高我国大型预焙槽内衬设计水平和炼铝技术[J],河南有色金属,2005,(5)：43.
6. 沈泽方.铝电解[M],中国有色金属工业总公司职工教育教材编审办公室,1988,36-80.
7.Don Harris.冰晶石向铝电解槽干防渗耐火材料渗透的研究[J],Light Metals,2000: 419-427.
8. 邱竹贤.铝电解原理与应用[M],徐州：中国矿业大学出版社,1997,445-472.
9. Patel P, Hyland M, Hiltmann F, et al. Influence of internal cathode structure on behavior during electrolysis. Part 2:porosity and wear mechanisms in graphitized cathode material [J], Light Metals,2006:757-762.
10. Rafiei P, Hiltmann F. Electrolyte degradation within cathode materials[J], Light Metals,2001:747-753.
11. 强红江,李兵,乔贵林等.160KA预焙铝电解槽槽壳变形及摇篮架破损修复改造的探讨[C],第五届铝电解专业委员会2005年年会暨学术交流会论文集,2005：363-365.
12. 罗国平.预焙电解槽扎固施工温度控制[C],第五届铝电解专业委员会2005年年会暨学术交流会论文集,2005：367.
13. 冯乃祥.TiB2/C复合材料阴极的膨胀性的研究[C],第五届铝电解专业委员会2005年年会暨学术交流会论文集,2005：238-240.
14.刘敬穆.铝电解技术研究及发展方向探讨[J],轻金属,1995,(12)：43-46.
15.邱金山.铝电解槽使用寿命技术改进研究[J],甘肃有色金属,2001,3：19-21.
16.韩华,丁立伟,彭建平等.高效长寿命电解槽的技术问题[J],有色矿冶,2006,(5)：32-37.
17.刘世英,石忠宁,任必军等.铝电解槽用干防渗料的导热性与抗渗性[J],中国有色金属学报,1641-1646.
18.任必军.我国大型预焙槽寿命2500天以上的研究[J],轻金属,2002,(8)：32-36.
19.任必军.300 kA铝电解槽阴极破损机理研究[J],东北大学学报,2007,28(6)：843-846.
20.金秀岩.关于我国电解铝工业竞争力的思考[J],轻金属,2000,(4)：3-6.
21.张洪涛,温铁军.300KA系列电解槽阴极破损的现象、原因及对策[J],轻金属,2006,(5)：41-43.
22.王会全,孙春亮.电解槽干法刨炉的应用与推广[J],轻金属,2004,(4)：26-28.
23.赵无畏,段新国,田强等.提高槽寿命的工业试验研究[J],河南有色金属,2003,(4)：6-10.
24.李庆宏,王平甫,杨明生.铝电解槽炭质内衬材料与槽寿命的研究[J],河南有色金属,2003,(4)：19-22.
25. 刘建新.预焙阳极电解槽炉底破损的修补及维护方法[J],轻金属,2005,(5)：27-31.
26.王宝龙,赵俊国,王文武等.TiB2材料的特性及其在铝工业中的应用[J],轻金属,2004,(5)：23-27.
27.唐定品.铝电解槽阴极钢棒除锈、钝化新工艺[J],轻金属,2004,(5)：27-30.
28.李庆余,赖延清,李劫等.应用新一代常温固化TiB2阴极涂层技术提高我国预焙铝电解槽寿命[J],轻金属,2004,(10)：34-38.
29.王会全.85KA创新预焙阳极电解槽“电场”测试[J], 铝镁通迅,2005,(12)：18-19.
30. 高炳亮等.碳化硅耐火材料在铝电解槽中应用的可行性[J],轻金属,2001,(4)：40-43.
31.赵琳,刘风琴,毛继红等.铝电解用阴极炭块抗磨损性能研究[J],轻金属,2005,(12)：25-28.
32.尹书金,邵勇,曹继明等.大型预焙铝电解槽阴极内衬破损特征及检测[J],轻金属,2005,(12)：29-32.
33. 李广来.浅淡大型预焙阳极铝电解槽阴极结构制作与焊接[J],河南有色金属,2004,(1)：28-33.
34.廖贤安,段学良,赵忠明.我国阴极炭素材料发展中的若干问题[J],轻金属,2004,(11)：6-8.
35.周文田.155KA预焙槽寿命探讨[J],轻金属,2003,(1)：38-40.
36.项阳,李晓波.铝电解槽“过渡期”技术管理与槽寿命关系[J],河南有色金属,2004，(10)：26-33.
37.廖贤安.我国铝电解技术发展方向[J],轻金属,2006,(8)：23-40.
38. 熊维平.中国铝工业发展趋势探讨[J],轻金属,2006,(8)：29.
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