大型铝电解槽的安全设计优化

铝电解系列的本质安全设计对企业的安全生产至关重要,随着铝电解系列的大型化发展,大容量槽的安全生产更是尤为关键,合理的铝电解槽设计对电解系列的安全稳定生产起着决定性作用。本文从大型铝电解槽的本质安全设计入手,分析总结了近年来发生安全事故的大型槽的经验,对大型槽的槽壳结构、电热场、磁流体稳定性及母线风险点进行了优化设计,通过对合理的电解槽结构设计、先进磁流体稳定性计算平台及新型绝缘材料的使用,有效消除了铝电解槽生产过程中的安全隐患,确保了大型铝电解系列的安全生产,为大型铝电解系列的安全、稳定、高效生产提供了有力保障。     

600 kA级大型电解槽槽结构设计概述

为了降低吨铝投资,提高劳动生产率,增加企业经济效益,发展更大容量的铝电解槽技术已成为电解铝行业规模化发展的必然选择。近年来,国内已先后开发了350 kA、400 kA、500 kA、530 kA大型和600 kA超大型铝电解槽。为了进一步促进600 kA级以上超大型铝电解槽的稳步发展,笔者从设计角度对600 kA级大型铝电解槽槽结构进行了深入分析和探讨。     

我国大型预焙槽槽寿命达到2500天以上的研究

大型预焙槽槽寿命的研究是铝电解技术的一个重要课题 ,本文通过长寿命 (槽寿命超过 2 5 0 0天 )铝电解槽和早期破损槽进行对比研究分析 ,提出槽型基本设计定型后应注重筑炉材料、筑炉工艺和质量、提高焙烧启动质量、强化启动后期管理 ,同时在电解槽运行过程中确保正常生产技术条件和槽况平稳 ,将会有效地延长铝电解槽寿命     

大型铝电解槽在节能要求下的槽寿命探讨

随着大型铝电解槽节能技术的开展,电解槽的早期破损现象正逐渐引起电解铝企业的关注。本文通过分析电解槽槽寿命变化的原因,从电解槽设计的角度,在内衬设计、内衬材料选择、槽结构等方面进行了综合分析,找出了槽寿命降低的一些因素,并提出了相应的改进措施。     

采用优质阴极碳块开发大型高效节能长寿铝电解槽

我国大型预焙槽炼铝技术近年来有了很大的提高，但在单位面积产率和槽寿命等方面与国外先进水平相比还有较大的差距。采用优质阴极碳块是完善和提高我国大型预焙槽炼铝技术，增强铝电解工业竞争力的关键因素之一。本文对铝电解槽内衬应力和热平衡设计、阴极材料质量和焙烧方法等阴极技术问题进行了描述和分析。     

铁磁材料对铝电解槽内磁场影响规律研究

该文以一台简化的铝电解槽模型为对象,运用ANSYS仿真软件研究了铝电解槽的槽壳和摇篮架等铁磁物质对槽内磁场的影响规律。研究表明,随着槽壳厚度的增大,槽内X和Y向磁感应强度增大,Z向减小;随着摇篮架宽度增大,X向和Y向磁感应强增大,Z向减小。该研究结果能为大型铝电解槽磁场计算模型简化提供依据。     

一个新的磁流体稳定性评估方法及其应用

通过利用参数化程序设计语言APDL并加入自定义的程序代码,采用磁标量位法、k-ε两方程湍流模型以及数理统计相结合的方法分别计算了大型铝电解槽在不同立柱进电比母线配置下的电磁流场与波动界面以及电磁力场的方差分析,提出了一个新的磁流体稳定性分析方法,并应用于500kA大型铝电解槽的母线配置研究。研究结果表明自定义的磁流体稳定性评价指标能有效反映多物理场分布的优劣,对基于磁流体稳定性的大型槽母线配置的数值研究是简便易行的,能够有效用于铝电解槽生产和设计的物理场仿真计算分析。     

某500kA大型铝电解槽设计和测试情况概述

文章介绍了500 kA级大型铝电解槽的设计思路。母线设计采用了新型抗扰动稳流母线配置技术，解决了生产过程中当台槽不稳定时对上下游电解槽的扰动问题，并大幅度提高了端头槽的稳定性；内衬设计采用双平衡电解槽技术，采用区域保温，优化内衬结构，使电解槽形成了良好炉帮形状；槽壳采用整体焊接直角槽壳技术，明显改善了应力集中，槽壳变形小。并与测试和生产数据作比较，生产与设计形成了一个闭环，支撑了设计。     

某420 kA大型电解槽电热场测试和分析

针对某铝厂420 kA大型铝电解槽进行了全面的电、热场测试,对该槽型的运行情况进行分析。测试了该电解槽阳极、阴极、母线等各部分的欧姆压降,并和设计值进行了比较。测试并计算了立柱母线、阴极、阳极电流分布,比较了和设计值的偏差。测试了该槽型的炉膛形状,分析了高电流密度电解槽的炉膛形成规律。对电解槽的散热和能量平衡进行了详细的计算分析,为大型槽的内衬设计提供了依据。测试发现,该420 kA电解系列由于采用了保温型的设计,电解槽各部分散热比例和传统散热型电解槽有非常大的差异,特别是槽底部,只占电解槽散热的3%以内,比传统7%的散热比例要小得多。结合各项测试内容和生产情况,针对我国大型电解槽的设计提出改进建议。     

关于大型预焙阳极铝电解槽寿命问题

目前世界铝工业的发展趋势是采用大容量预焙阳极电解槽。国外这种电解槽的寿命一般为4～5年。我国大型预焙阳极电解槽的寿命,就某铝厂大型试验场所进行的四台槽七个槽次的试验来看,除2~#槽和1~#槽第二槽次寿命较长以外(2~#槽运行五年,1~#槽运行二年,在因故停槽及刨炉时均未发现破损);其它槽次寿命均较短,一般为一年左右。就系列化试验槽来看,在生产的两年半中,陆续破损的占73.9％,其中已停槽大修的占47.8％。上述情况说明:我国,大型预焙槽的寿命问题,是一个必须认真研究和解决的问题。     

350kA大型预焙阳极铝电解槽优化设计论述

随着铝工业技术的不断发展和对环保的更高要求 ,采用大型铝电解槽已成为当今铝工业发展的趋势。为了与世界铝工业接轨 ,我院新开发了 35 0kA铝电解槽。笔者从设计角度对 35 0kA铝电解槽的技术特点及优化设计方案 ,进行了较为详细的分析论述。     

我国现行铝电解槽散热状态及散热能力研究

经过对国内40多个系列、100多台铝电解槽进行了能量平衡测量,基本上掌握了我国现行工业铝电解槽的散热状态,在此基础上进行了进一步的数据处理和挖掘,得到了我国现行工业铝电解槽的两种极限散热状态,经过合理的推导,得到了能使我国现行铝电解槽正常运行的电压-电流可调配区间.在此区间内,只要能够合理的匹配铝电解槽的各项工艺技术参数、合理的调整能量平衡就能达到想要的最佳的电流-电压匹配关系,获得较大的经济效益.     

Updating a 1950s-generation aluminum smelter

Hindalco’s aluminum electrolysis cells were initially installed in 1962, and the technology was based on 1950s-generation pots. Although Hindalco expanded its aluminums melting capacity from 20,000 tonnes per year to 175,000 tonnes per year, the basic design of the pots remained unchanged. In view of energy price increases, and to keep pace with the latest developments in aluminum smelting technology, Hindalco undertook efforts to modernize its facilities. In spite of numerous constraints, the Hindalco smelter has been able to achieve performance nearly equivalent to that of 1980s-generation pots by retrofitting new technologies. This has resulted in considerable savings in electrical energy consumption and raw materials usage.     

Coupled computation method of physics fields in aluminum reduction cells

1　COUPLEDRELATIONOFPHYSICSFIELDINCELLSTherearesiximportantphysicsfieldsinalu minumreductioncells[13] ,suchaselectricfield ,magneticfield ,temperaturefield ,flowvelocityfield ,concentrationfieldandstressfield .Therelationsa mongthesephysics propertiesareshownasFig .1.　　　　Inregardtorelationofsixfields ,electricfield(electriccurrentandpotentialdistribution)istheen ergyfoundationofoperationandsourceoftheotherphysicsfieldsinreductioncells .Firstly ,electriccur rentcausesthemagne…     

铝电解槽热电场的有限元分析

运用大型有限元分析软件ANSYS中附带的APDL模块解决铝电解槽热非线性和炉帮形状的循环计算问题,充分考虑电解质发生相变时产生的潜热,建立了热电场数学模型,开发了准三维热电耦合模型.选择普通炭块和碳化硅作为侧部保温材料两种情况,对我国300 kA侧部五点进电预焙铝电解槽进行了热电耦合分析,绘出了热场等温线图.结果表明,300 kA侧部五点进电预焙电解槽的阴极和侧部炭块的设计是合理的.     

Numerical Simulation and Experimental Validation of Residual Stresses in Water-Quenched Aluminum Alloy Castings

Aluminum alloy castings are normally water quenched after solution treatment to improve mechanical properties. Rapid water quenching can result in high-residual stress and severe distortion which significantly affect functionality and performance of the products. To optimize product design and durability, one needs to model and predict residual stress and distortion produced in the water-quenched components. In this article, a finite element-based approach was developed to simulate the transient heat transfer and residual stress development during water quenching. In this approach, an iterative zone-based heat transfer algorithm was coupled with material constitutive model called mechanical threshold stress (MTS). With the integrated models, a good agreement was achieved between the numerically predicted and the experimentally measured residual stresses in the aluminum alloy frame-shape casting. The integrated FEA-based heat transfer and residual stress models were also applied to a water-quenched cast aluminum cylinder head with a great success.     

A Virtual Aluminum Reduction Cell

The most important component in the aluminum industry is the aluminum reduction cell; it has received considerable interests and resources to conduct research to improve its productivity and energy efficiency. The current study focused on the integration of numerical simulation data and virtual reality technology to create a scientifically and practically realistic virtual aluminum reduction cell by presenting complex cell structures and physical–chemical phenomena. The multiphysical field simulation models were first built and solved in ANSYS software (ANSYS Inc., Canonsburg, PA, USA). Then, the methodology of combining the simulation results with virtual reality was introduced, and a virtual aluminum reduction cell was created. The demonstration showed that a computer-based world could be created in which people who are not analysis experts can see the detailed cell structure in a context that they can understand easily. With the application of the virtual aluminum reduction cell, even people who are familiar with aluminum reduction cell operations can gain insights that make it possible to understand the root causes of observed problems and plan design changes in much less time.     

科技创新整合铝工业,煤电热铝实现一体化——试论铝工业可持续发展的最佳模式

铝产品能源消耗占成本近40％，煤水热电是主要能源形式。煤转化为热、电及在铝冶炼过程中的高最利用，体现在总能系统效率升高上。本文从氧化铝、电解铝生产所用的热电平衡和热电联产综合利用出发，从物耗能耗的关系及对成本的影响。论述了整合氧化铝厂和电解铝厂，实现煤电热铝一体化的意义。提出了一条铝冶炼一体化可持续发展的最佳模式。     

Integrated bottom up and top down approach to optimization of the extrusion process

Boal BV and the University of Twente participate in research projects focused on improvement of die design methods for aluminum extrusion dies. Within this research empirical knowledge is combined with insights gained from numerical process simulations. Design rules for improvements to the geometry and functionality of flat and porthole dies have been defined. For porthole dies this has led to enhanced die stability and significant reduction of scrap. For both flat and porthole dies an increase in production speed and a reduction of wear has been obtained. This paper will describe the scope of this research and present results achieved in industrial practice.     

基于BP神经网络的铝电解槽热平衡控制系统

本文阐明了基于BP神经网络的控制系统在大型铝电解槽生产过程中热平衡控制的开发和应用。由于电解槽存在大滞后、多变量的非线性作用的影响,因此很难用常规的基于数学模型来稳定地控制热平衡,而神经网络的专家系统是人工神经网络论对人工智能和专家系统的重大发展,它克服了传统专家系统欠缺,获得更佳效果。