炭碗结构对预焙铝电解槽阳极压降影响的仿真研究

采用有限元仿真计算的方法计算铝电解槽的阳极压降,以经电流强化后的某电解槽阳极部分为研究对象,在ANSYS平台上建立了含钢爪与炭碗结构的半阳极有限元模型,考察了磷生铁与阳极炭块间接触电阻对阳极压降的影响,并使用该模型研究了炭碗结构参数对阳极压降的影响.结果表明:磷生铁与阳极炭块间接触电阻对阳极压降有较大影响,接触压降约60mV左右,约占整个阳极压降的17％;增大钢爪直径、炭碗深度、磷生铁浇铸厚度以及炭碗凹槽深度均可不同程度地降低阳极压降,而炭碗凹槽的倾斜角度对阳极压降几乎没有影响.     

基于增碳脱硫的降低磷生铁压降技术试验研究

本文通过考虑表面接触电阻确定铁-碳接触电阻系数,建立了考虑接触电阻的阳极物理场,计算获得了磷生铁热膨胀系数与阳极压降规律,结合增碳脱硫实际需要确定磷生铁复合改性剂配方,并进行工业试验。工业试验表明,阳极铁-碳压降有效降低了15mV左右,且试验极表现稳定,未发生脱极,钢爪发红等现象,且使用复合改性剂后浇铸的磷生铁铁水流动性更佳,浇铸铁环裂纹明显减少,大规模应用经济效益十分可观。     

有浇铸口的预焙炭阳极的生产应用

使用有浇铸口的预焙炭阳极,消除组装阳极时磷生铁水向炭碗外流失和阳极钢爪粘铁现象,延长阳极钢爪使用寿命,降低磷生铁消耗、电耗和修理费用.     

预焙铝电解槽阳极导电装置研究与工业试验

研发一种新型铝电解槽阳极导电装置,采用铜炭结合过渡连接的方式,将铝导杆的电流通过阳极导电卡具传导给阳极炭块,降低阳极导电装置电压降;采用阳极导电卡具组装的方法,简化阳极炭块的组装工艺,替代现有的阳极钢爪和磷铁环与阳极炭块组装构造的连接方式,取消阳极组装车间和阳极残极清理工序,达到减少电解铝生产工艺成本和降低电耗的目的.     

非同径腿安全节能型阳极钢爪

非同径腿安全节能型阳极钢爪可明显减少磷生铁浇铸后出现的钢爪活动或晃动现象,大大降低电解工艺过程中的脱极事故。     

预焙阳极电解槽夹持式阳极导电卡具新技术的开发与应用

预焙阳极铝电解槽采用夹持式阳极导电卡具替代传统钢爪磷生铁浇铸阳极,吨铝节电120kWh以上,通过实践应用证明完全可行.     

电解铝炭素阳极用氧化铝溶胶抗氧化复合涂层

提出采用在炭素阳极表面原位固化制备以氧化铝溶胶为基本粘结相、相对致密的氧化铝涂层(膜)的方法,达到减少阳极氧化、降低阳极过量消耗的目的。在阳极炭块上制备了氧化铝溶胶复合涂层,并检测了其基本性能。结果表明,由室温至900℃,涂层阳极试样的热失重率比裸阳极降低了50%;涂层较为致密,即使是放大2000倍,也未见孔洞和裂纹;平均孔径只有几个纳米,且高温时涂层的平均孔径比低温时要小,900℃时涂层的平均孔径比600℃时小了近1/3;涂层不仅在不同的温度下都能对炭素阳极起到较强的保护作用,而且还能起到提高炭素阳极初始剧烈氧化温度点的作用。     

电解铝阳极钢爪修复新技术的应用实践

目前电解铝企业使用的阳极钢爪经过多次循环使用后,钢爪出现冲蚀、磨损,钢爪直径逐渐变细,从而导致铁-碳压降增加,增加了电解槽脱极风险,同时也增加了磷生铁消耗。现通过采用电解铝阳极钢爪修复设备对其进行全截面熔焊修复,替代人工电焊修复,可以使修复后的阳极钢爪达到新铸造钢爪的使用效果,修复效率高,质量好,满足电解生产要求。     

铝用炭素市场分析

铝用炭素主要分为炭素阴极和炭素阳极两大类。铝电解槽阳极有阳极糊和预焙阳极之分,前者用于自焙阳极电解槽,后者用于预焙阳极电解槽。阴极炭块又分为无烟煤炭块、半石墨质炭块、石墨质炭块和石墨化炭块。     

铝用炭素市场分析

铝用炭素主要分为炭素阴极和炭素阳极两大类。铝电解槽阳极有阳极糊和预焙阳极之分,前者用于自焙阳极电解槽,后者用于预焙阳极电解槽。阴极炭块又分为无烟煤炭块、半石墨质炭块、石墨质炭块和石墨化炭块。     

阳极钢爪保护环在生产中的应用

阳极刚爪保护环在许多电解铝厂都使用过。主要用来保护阳极钢爪不被电解质侵蚀,延长阳极钢爪使用寿命,维持正常的原铝质量。延长阳极使用周期。     

Possibility of High Phosphorus Pig Iron as Sacrificial Anode

Cathodic protection is an effective method to control the corrosion of underground pipelines and submerged structures. In the present work, high phosphorus containing pig iron was utilized as sacrificial anode for cathodic protection of underground mild steel plates and the results were compared with that of a commercially pure magnesium sacrificial anode. Driving potential and current between the galvanically coupled sacrificial anodes and mild steel plates were continuously monitored in real time for one month. Microstructure and morphology of the corrosion products formed on the surface of pig iron, magnesium sacrificial anodes and mild steel plates were observed with the help of optical microscope and scanning electron microscopy, and phase identification were performed using x-ray diffraction, Raman spectroscopy and Fourier transform infrared spectroscopy. The distribution of phosphorus in the pig iron matrix and soluble rust formation on the surface of pig iron under buried condition were critical from the point of sacrificial effect, indicating the possible scientific reasons for high phosphorous pig iron to be used as sacrificial anode.     

海绵钛镁电解石墨阳极工艺探索及实践

针对镁电解石墨阳极复合铸造过程中存在的石墨块开裂、石墨本体与铸铁底座熔接不良、导电性能差、阳极几何尺寸超差的问题,采用水平造型、预留收缩缝、一次浇注、二次填充工艺、定型工装夹具及专用砂箱设计、电弧热喷涂铝替代镀铝法等工艺手段生产石墨本体.经检测石墨本体和铸铁底座结合紧密,结合面电阻＜10 μΩ,阳极平面度及垂直度±2 mm,各项技术指标均达到甚至优于进口产品,目前使用状况稳定.     

Galvanic Series of Metals and Effect of Alloy Compositions on Corrosion Resistance in Sanya SeawaterEI北大核心CSCD

With the development of ocean engineering, various metallic materials have been applied to the marine environment. It is an urgent requirement to study the galvanic series and alloy composition optimization of metallic materials in the tropical marine environment. In this work, open circuit potentials (OCP) and galvanic series of 36 kinds of metallic materials in Sanya seawater were studied. By considering the response of OCP to tidal changes, the anti-corrosion effects of alloying elements were also ana lyzed. The results show that the OCP of metallic materials in Sanya seawater has a large range. The galvanic series order of metallic materials from high to low in Sanya seawater is: nickel alloy, duplex stainless steel, austenitic stainless steel and pure copper, ferritic stainless steel, martensitic stainless steel, copper alloy, low alloy steel, carbon steel, cast iron, aluminum alloy and aluminum anode. Low-carbon high-alloy content carbon steel and high Cr, Ni contents stainless steel have higher OCP. The potential fluctuations of carbon steel with tidal changes involves two phases: (1) under the dynamics control, the OCP of carbon steel is more negative at high tide; (2) under the diffusion control, the OCP is more positive at high tide. The potential fluctuations of metallic materials reflect the effect of the corrosion product film on the change of ionization balance, and metals with less potential fluctuations have better inhibition on ion diffusion. In Sanya seawater, the carbon steel, which has more alloying content and less carbon content, has less potential fluctuations with the tidal changes and has good oxygen diffusion resistance. The potential fluctuations of austenitic stainless steel with tidal changes are less than that of ferritic stainless steel and martensitic stainless steel. After 2700 h immersion, austenitic stainless steel and martensitic stainless steel, which have a higher content of Mo, have more stable OCP. In other words, the corrosion film gets a better corrosion resistance. The OCP of aluminum anode in Sanya seawater environment increases when the oxygen content is brought up. The OCP of Zn-containing or Ga-containing aluminum anode remains relatively stable. Al bronze and T2 copper have less potential fluctuations with tidal changes, and perform good corrosion resistance in Sanya seawater.     

电解铝炭素阳极消耗研究评述

电解铝过程中，炭素阳极的实际消耗远高于其理论消耗，直接影响原铝的生产成本。本文在分析铝用炭素阳极消耗机理的基础上，评述了阳极生产和电解铝生产中的诸多因素对炭素阳极消耗的影响，这些因素包括：阳极电流密度、石油焦煅烧温度、阳极焙烧温度、电解槽操作温度、阳极硫含量、阳极金属杂质、残极和灰分、阳极添加剂、电解质添加剂、阳极配方的沥青用量和阳极保护措施等。     

铝电解用阳极爪架的消失模铸造工艺

针对铝电解用阳极爪架的结构特点,从模型制备、涂料、干砂振动紧实、熔炼及浇注等方面分析了铸件的消失模铸造工艺。经实际生产验证,采用消失模工艺可提高生产效率,降低生产成本,并减少对环境的污染。     

Ambient temperature cured TiB_2 cathode coating for aluminum electrolysis

1　INTRODUCTIONAluminumindustryhasbeendevelopingrapidlyinChinainrecentyears ,soderbergcellshavebeenre placedwithmodernprebakecellsinmanyaluminumsmelters,theaveragecelllifehowever ,forprebakecellsinourcountrywasonlyabout130 0d ,muchlowerthantheaveragecelllife ,i.e .above 2 5 0 0d ,forthecellsindevelopedcountries .TiB2 cathodecoating (TCC)couldbeoneofthesolutionstoreducegreatlytheopportunitytotheearlyfailureofcellsandextendthecelllifeofprebakecell[14 ] .Theconceptoftitaniumdiboride (TiB2 …     

熔盐电解法渗铝的研究

在钢铁和高温合金上渗铝,可以大大提高这些材料抗高温氧化和热腐蚀的能力。目前工业上常用的渗铝方法有固体包装法和热浸法。固体包装法是将工件埋在含有铝铁合金粉和氧化铝粉的混合物中,加热到850°至1000℃,保温5至24小时而获得渗铝层。此法不需特殊技术,但要先制备铝铁合金,而装箱、进炉出炉,卸出工件劳动较多,因为连箱加热,渗铝速度慢,因之所需时间很长,为其缺点。热浸法是将工件浸于熔融铝浴中而获得渗铝层,速度较快且操作简便,但铁在铝液中有一定程度的腐蚀溶解,工件渗铝后表面常不均匀,有铝堆集,而且由于金属铝的蒸发和氧化,铝的损耗也较大,此外渗铝层脆性较大.需要进行渗后热处理,这些都是热浸法不足之处。 熔盐电解法渗铝是在坩埚(石墨或金属)中盛金属铝(可用铝屑),上面放1:1(分子比)的NaCl+KCl混合盐,另加少量冰晶石。坩埚和铝接为阳极,工件接为阴极。在惰性气氛保护下加热使盐熔化,然后通电流,铝作为阳极被熔盐腐蚀而生成铝离子,在阴极(工件)上沉积。由于工件不在铝浴中,故不被铝溶解,且受到阴极电流的保护作用,故不被熔盐腐蚀。铝上有熔盐复盖,蒸发和氧化均较小,故铝的损耗亦小。渗铝层较均匀,渗后不必另行热处理.沉积的铝量主要决定于电流密度与时间,服从法拉第定律,与温度无关.电流效率约在82约91％间,平均约85％。沉积的铝在高温下与底金属相互扩散而形成渗铝层,其厚度决定于温度、时间及电流密度。用电子探针分析、X-射线衔射分析及金相检查,得知纯铁上电解渗铝层最外表面有一薄层金属铝,往内为Al_3Fe、Al_5Fe_2、AlFe及AlFe_3。 钢铁经熔盐电解渗铝后,抗高温氧化性能大为提高。高温合金用此法渗铝后,抗热腐蚀性能亦显著改进。     

Adhesion of iron coatings with steel and cast iron

The iron-plating process in methyl sulfate chloride electrolytes was investigated. The conditions of iron plating ensuring the coating adherence with steel and pig iron required in the technological processes of reconditioning and strengthening of machine pieces are determined. Process conditions ensuring the high coating adherence with steels 45, 15HGT, 40H, and grey and high-strength pig iron are found; they include steps: powering on of the polarizing current with the initial density of 0.15–0.5 kA/m² immediately after insertion of pieces in the electrolyte and raising of the current density up to the working level with a rate of 4–5 A/m² s. Metallographic, polarizing, and other research show the influence of the initial electrolysis conditions on the formation of the first layers of coverings and the process of iron electrocrystallization on structural phases of tempered steel and grey and high-strength pig iron.     

铁酸镍基金属陶瓷惰性阳极材料的研究进展

惰性阳极铝电解技术的发展主要基于经济和环境的考虑,对铝电解工业的长远发展具有重要意义,已成为铝电解工业进步的关键技术。合金惰性阳极具有易加工成形、良好的抗热震性和导电性,金属陶瓷惰性阳极兼顾陶瓷的高温热稳定性及金属的高导电性和高韧性,二者已成为惰性阳极的主要候选材料体系,并进行了工程化铝电解试验研究。近年来,惰性阳极的研究集中在合金阳极表面保护膜形成与溶解的动态平衡控制、金属陶瓷组成与结构优化、惰性阳极的电解腐蚀机制及抑制技术等方面。综述了铝电解用合金阳极和金属陶瓷惰性阳极的近期研究进展,从材料学的角度介绍铁酸镍基金属陶瓷的组成优化、烧结、电解腐蚀特性等方面的最新研究成果。