CN103290431A - Aluminum electrolysis cell riser bus bar electrified repairing method - Google Patents
Aluminum electrolysis cell riser bus bar electrified repairing method Download PDFInfo
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- CN103290431A CN103290431A CN2013101750284A CN201310175028A CN103290431A CN 103290431 A CN103290431 A CN 103290431A CN 2013101750284 A CN2013101750284 A CN 2013101750284A CN 201310175028 A CN201310175028 A CN 201310175028A CN 103290431 A CN103290431 A CN 103290431A
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Abstract
The invention discloses an aluminum electrolysis cell riser bus bar electrified repairing method which comprises the following steps of: treating a damaged surface, mounting a graphite bar, calculating the addition amount of a flux for aluminum electrolysis cell riser bus bar electrified repairing, mounting a mould, welding, opening the mould and treating the metal surface of a weld seam. According to the aluminum electrolysis cell riser bus bar electrified repairing method disclosed by the invention, a riser bus bar and an insulation intersection can be repaired in an electrified manner without experiencing interference of the high-intensity magnetic field of an electrolytic plant; the fusion rate of the side wall of the weld joint of the riser bus bar is high, and the performance of the welded joint is similar to that of a parent material; and moreover, the method has safe and reliable technology, is simple and quick to operate and is suitable for popularization and application to the aluminum electrolysis industry.
Description
Technical field
The invention belongs to the aluminum smelting technology technical field, relate to the restorative procedure of aluminum electrolytic cell riser bus bar, relate in particular to the charged restorative procedure of aluminum electrolytic cell riser bus bar in a kind of strong magnetic field circumstance.
Background technology
In recent years, whole nation aluminium industry development is swift and violent, for improving the output of aluminium, aluminum cell current intensity also from before 100kA develop into present 300kA and 400kA, 38.8 ten thousand tons of electrolytic aluminum first phase project electric currents of annual output that Liancheng branch office of Chinese Aluminium Co., Ltd in April, 2011 goes into operation even reached record-breaking 500kA.The 600kA electrolyzer is also among research and development at present.The electrolyzer power consumption is big, and conductor configuration is comparatively complicated, and whole potroom produces powerful electromagnetic field.According to the strength of current difference, electrolyzer magneticstrength design maximum is 20～50GS, but the magneticstrength in the actual moving process is often than the design load of designing institute more than high ten times, and the highest field strength values of X-direction of testing when the actual motion such as the 300kA electrolyzer has reached 850GS.Even under the state that has a power failure, powerful remanent magnetism still is difficult to eliminate in short-term.
In cell room; riser bus bar and short-circuit busbar are subjected to unexpected injury and damage occurs through regular meeting; such as because short circuit mouth arc-over, insulcrete puncture the riser bus bar that causes and short-circuit busbar surface blow out seam broken, because the riser bus bar that bakie causes is washed out, because the anode rod surface imperfection pit that tribo-charging causes etc.; so that conductive area reduces; the current density of unit surface increases; cause the temperature of riser bus bar too high; energy consumption increases, and has potential major safety risks.For these damages that riser bus bar occurs, generally need to adopt arc welding method to repair.But, because the influence of powerful electric current, equipment is difficult to normal operation during welding, electric current and the voltage instability of welding set output, and liquid welding pool splashes everywhere, can't stack shaping, so can only adopt spot welding, there is more welding flaw, welding back connection resistance obviously increases, have a strong impact on welding quality, caused the significant wastage on the human and material resources.
For fear of the high-intensity magnetic field influence, carry out REPAIR WELDING after need having a power failure to whole potroom.At first the breach surface is adopted machine tool such as angle grinding machine, straight grinder, brush etc. to clean out, expose the cast aluminium true qualities.Coloured welder plays breach with one of welding machine, built-up welding in layer then, and exceeds former bus plane, uses argon welder melting aluminum welding rod or aluminium welding wire again, and the part that built-up welding is got up arrives together with former bus seam.Pincers worker with its surperficial equating, makes it to reach the requirement of bus Technology with instrument.Whole repair process needs repeatedly to have a power failure in short-term or the long period has a power failure continuously, not only causes the minimizing of electrolytic aluminum output, energy consumption significantly to increase, and also can increase noxious gas emission, causes environmental pollution.If have a power failure continuously when long, the aluminium liquid in the electrolyzer will solidify, and have a strong impact on the production of potroom aluminium liquid, cause heavy economic losses.
For fear of the destroying infection that has a power failure electrolyzer is brought, electrolytic aluminum producer attempts having taked the processing method of various charged welding riser bus bars both at home and abroad.Adopt and can avoid magnetic field to the welding effect of arc on the magnetic field shielding theoretical method, domestic Lanzhou University of Science ﹠ Technology, Yuncheng City, Guan aluminum equipment Materials Co., Ltd, Central Region, Henan aluminium manufacturer etc. have carried out some trials in this respect.Patent " a kind of diamagnetic interference arc welding plant " (patent No. ZL200820077927.5, publication number CN 201217122, open day 2009.04.08) a kind of diamagnetic interference arc welding plant is disclosed, comprise arc welding gun and nozzle thereof, arrange on the nozzle can shielding space magnetic field laterally, the magnetic head of longitudinal component, magnetic head is connected with excitation power supply; Magnetic head is made of annular core and magnetizing coil.In conjunction with measures such as three-dimensional combination shielding, electromagnetic shielding protection, safety operation protections; can solve existing arc-welding apparatus problems such as producing the magnetic blow phenomenon under the magnetic environment is being arranged; and the trough rim riser bus bar that attempt to adopt this technology that 190kA, 300kA electrolyzer original production damage in service are repaired carries out charged reparation, obtained certain effect.But these methods are of limited application, only be suitable for the simple occasion in magnetic field, and because the complicacy of aluminium cell ambient conditions, in the actual moving process the trough rim bus arbitrarily any magnetic field all be three-dimensional stereoscopic rotating magnetic field, and be to change over time; Magneticstrength is very big, there is distribution in magnetic field along all directions, be difficult to adopt conventional Technologies such as " cover, prevent, lead, dredge, disturb " to eliminate influence of magnetic field, especially perpendicular to the more difficult shielding of magnetic-field component of bead direction, and the demagnetization cost is very high, so can't in actual production, apply on a large scale.
In order to realize the good welds of magnetic field inner column bus, can adopt the strong or not affected by magnetic fields welding process of diamagnetic ability in theory.From present research and application present situation, conventional method is difficult to solve the interference problem in magnetic field.Resistance welding needs unit clamp, and is subjected to the restriction in riser bus bar position and space.Distribution of current is inhomogeneous simultaneously, and formation of weld and welding quality are difficult to be guaranteed.Gas welding is that the high hot melt weldment that utilizes inflammable gas and oxygen mix burned flame to produce carries out a kind of welding process that metal is connected with welding wire.During welding aluminum alloy materials, up to fusing, add aluminum solder (Repone K powder 50%+ sodium chloride powder 30%+ cryolite powder 20%) with gas welding heating welding position, finish welding by the filling of aluminum solder.Pressure gas welding is the same with gas welding, and pressure gas welding also is to be thermal source with the gas flame.After during welding the end of workpiece of two butt joints being heated to certain temperature, applying enough pressure again to obtain firm joint, is a kind of Solid-phase welding technology.Owing to be not subjected to magneticinterference, although gas welding and pressure gas welding can be used for the welding of riser bus bar, because its welding efficiency is lower and the restriction of pressing technology during pressure gas welding, the site welding that is not suitable for aluminium cell is operated.Friction stir welding connects means as a kind of solid phase, mainly forms joint under the combined action by the heat of friction of stirring-head and mechanical presses.It overcome melting welding in the past such as shortcomings such as pore, crackle, distortion, compare (strength of joint be about strength of parent 50%) during with traditional molten solder aluminium alloy, strength of joint improves greatly.Technology was very ripe when agitating friction was welded in the welding that is applied to the thin plate aluminium alloy, but still can not well be used for the welding of the long-pending aluminium bar bus in large section.
The casting welding is a kind of welding technique that foundry engieering and soldering tech combine.Domestic many aluminum smelting technology enterprise attempts in this respect.This method is to adopt refractory materials to make the damage breach that fusible pattern coats riser bus bar, injects molten aluminum liquid then in fusible pattern, and aluminium liquid is slowly heating mother metal in the process of cooling simultaneously, makes the mother metal fusing, thereby forms welding joint.There are three deficiencies in this method: (1) because the heating condition restriction, the temperature of aluminium liquid has only 900～1180 ℃, and only the fusing point than aluminium exceeds 250～400 ℃, topple over enter weld seam after mother metal dispel the heat rapidly, very difficult realization fuses preferably; (2) joint filling of aluminium liquid only relies on the trickling of gravity, and its joint filling effect is bad; (3) it is relatively poor add to soak into the wetting effect of element and mother metal in the aluminium liquid.Therefore, founding is welded the weld seam ubiquity that obtains and the bad problem of sidewall fusion effect like this.If be applied in the actual production, not only the welding joint consume electric power is more, and is that hidden danger has been buried in the normal operation of long-term safety.
Summary of the invention
The purpose of this invention is to provide the charged reparation of a kind of energy, be not subjected to that high-intensity magnetic field disturbs, the safe and reliable charged restorative procedure of aluminum electrolytic cell riser bus bar.
For achieving the above object, the technical scheme taked of the present invention is:
The charged restorative procedure of a kind of aluminum electrolytic cell riser bus bar may further comprise the steps:
A. injured surface is handled: cleaning riser bus bar injured surface, form riser bus bar groove to be welded, and at the riser bus bar injured surface shrinkage pool more than 2 is set;
B., graphite rod is installed: in the connecting hole of riser bus bar and short-circuit busbar, insert graphite rod;
C. calculate the addition that flux is used in the charged reparation of aluminum electrolytic cell riser bus bar: the size according to riser bus bar groove to be welded is calculated institute's expense;
D. installation mold: aluminum electrolytic cell riser bus bar reparation mould is installed at the riser bus bar damage location;
E. welding: the charged reparation of described aluminum electrolytic cell riser bus bar obtains high temperature aluminum mixture liquid after burning with flux, flows into described riser bus bar groove to be welded, finishes welding process, forms the weld metal face;
F. die sinking: welding is taken off aluminum electrolytic cell riser bus bar reparation mould after finishing;
G. the weld metal face is handled: remove the graphite rod that presets after the cooling, the processing connecting hole is to meeting the Technology requirement, and the redundance of trimming metal covering and welding slag carry out grinding and polishing to the surface and handle the riser bus bar that obtains repairing.
Described shrinkage pool among the step a comprises that the degree of depth is densely covered squamous hole recessed and the be separated by diameter of 15～25 mm, the shrinkage pool that the degree of depth is respectively 8～12mm of 4～6mm.
Described high temperature aluminum mixture liquid among the step e is temperature 1150-1180 ℃ aluminum mixture liquid.
Adopt the charged restorative procedure of aluminum electrolytic cell riser bus bar provided by the invention, riser bus bar and short circuit mouth can chargedly be repaired, be not subjected to the interference of cell room high-intensity magnetic field, the weld seam sidewall fusion rate of riser bus bar is higher, property of welded joint is near mother metal, and process safety is reliable, simple to operate rapid, be adapted at the electrolysis of aluminum industry and apply.
Description of drawings
Fig. 1 is the structural representation that mould is used in aluminum electrolytic cell riser bus bar reparation of the present invention.
Embodiment
Embodiment 1
The 200KA aluminium cell is because short circuit mouth insulcrete punctures, and seam broken is blown out on the riser bus bar that causes and short-circuit busbar surface, and the riser bus bar damage surface is of a size of: long 420mm, wide 150mm, 80mm deeply.
The charged restorative procedure of aluminum electrolytic cell riser bus bar, the reparation step is as follows:
1. injured surface is handled:
Adopt the short-circuit busbar of insulation paper parcel opposite side, insulcrete is laid on the grid ground in the electrolyzer side near riser bus bar, mainly is for insulating effect, guarantees personnel's safety.Operator stand in above the insulcrete, burn rub bar in riser bus bar and the short-circuit busbar connecting hole with oxygen-acetylene flame, amputate the aluminium block that solidifies of riser bus bar surface bulk with sawing machine, remove riser bus bar damage location and oxide skin all around with pneumatic polishing machine, clean out the riser bus bar injured surface with straight grinder and high speed brush, form riser bus bar groove to be welded.
At the riser bus bar injured surface, the densely covered squamous that adopts hammer to get degree of depth 5mm is cheated recessed, and drilling tool gets out the shrinkage pool of diameter 10mm, a degree of depth 10mm every 20 mm by hand.This uneven structure is in order to strengthen the welding fusion area of high temperature aluminum liquid and riser bus bar damage matrix, to make welding more solid and reliable.
2. installation graphite rod:
Inserting 4 length in the connecting hole of riser bus bar and short-circuit busbar is that 100mm, diameter are the graphite rod of 48 mm, adopts asbestos twine to wrap up around the graphite rod.The graphite rod end keeps concordant with the riser bus bar plane.The purpose of inserting graphite rod is in order to reserve the connecting hole of short circuit mouth after welding, not need to carry out secondary processing.Adopting asbestos twine that graphite rod is wrapped up is that graphite rod is taken out in convenient welding back.
3. calculate the addition that flux is used in the charged reparation of aluminum electrolytic cell riser bus bar:
Because the riser bus bar damage surface is of a size of: long 420mm, wide 150mm, dark 80mm, the volume that draws riser bus bar groove to be welded is: 42 * 15 * 8=5040cm
3
After melting welding agent welding, comprise weldering meat and welding slag two portions, weldering meat density is 3.2～4.0g/cm
3, calculate according to 50% the liquid rate that gets from the melting welding agent, get the percentage ratio that the liquid metal that obtains after the liquid rate refers to react accounts for original flux quality.Then required quality from the melting welding agent is between 32.3～40.3kg:
5040?cm
3×3.2?g/cm
3÷50%/1000=32.3?（kg）
5040?cm
3×4.0?g/cm
3÷50%/1000=40.3?（kg）
Consumption from the melting welding agent adopts the round numbers of big value, gets 40 kg from the melting welding agent.According to the mass percent meter, mixed by following raw materials according from the melting welding agent: 3% magnesium powder 1.2kg, 36% aluminium powder 14.4kg, 4% silicon calcium powder 1.6kg, 10% calcium sulfate 4.0kg, 22% copper powder 8.8kg, 22% tin protoxide 8.8kg, 3% Calcium Fluoride (Fluorspan) 1.2kg, use mixed powder machine or ball mill to carry out full and uniform mixing and form.
Wherein: the granularity of magnesium powder, aluminium powder, silicon calcium powder, calcium sulfate, copper powder, tin protoxide and Calcium Fluoride (Fluorspan) is 150 orders.
Wherein: copper powder refers to that the surface oxidation rate is 50% copper powder, the fine copper particle is placed in the oxidizing atmosphere of high temperature to handle, and makes its surface oxidation, and a kind of oxide compound by copper of formation coats the copper particle and forms composite particles.The surface oxidation rate is that 50% copper powder is that copper oxide surface amount mark is 50% copper powder.
This from the melting welding agent for other similar welding material, owing to adopted calcium sulfate instead of part oxide compound as oxygenant, with aluminium powder generation redox reaction, obtained sulfurated lime and aluminium sesquioxide, discharged a large amount of heats and be used for the excessive aluminium powder of fusing, so the aluminum mixture liquid temp is higher.In addition, because adopted silicon calcium powder as reductive agent, so chemical reaction is steadily controlled, slag liquid separates more abundant, and slag making is respond well.
The consumption of leading fiery powder according to the mass percent meter, is led fiery powder for covering the consumption from melting welding agent top layer fully: be 0.2:100 from the melting welding agent, get the fiery powder of leading of 8.0kg.
Lead fiery powder by 10% aluminium powder 0.8kg, 35% sulphur powder 2.8kg, 55% potassium permanganate 4.4kg, use mixed powder machine or ball mill to carry out full and uniform mixing and form.
Wherein: the granularity of aluminium powder, potassium permanganate and sulphur powder is 50 orders, the convenience of igniting like this, safety, quick.
4. installation mold: adopt the aluminum electrolytic cell riser bus bar reparation to surround with the damage location of mould with riser bus bar.
As shown in Figure 1, the aluminum electrolytic cell riser bus bar reparation comprises upper die and lower mould with mould, upper die 1 is the high strength graphite crucible of rectangular parallelepiped for the profile that is provided with dirty guide hole 2, be placed with in the dirty guide hole 2 from molten liner, be that thickness is the concavity aluminium flake of 1mm from molten liner, according to the depth Chengdu of riser bus bar damage location, select 2 from the molten stacked use of liner.Lower mould comprises the graphite cake 6 that is provided with chute 4, and the top of chute 4 offers pod apertures 3, and the bottom of chute 4 is provided with a plurality of fluid orifices 5 of continuous distribution, and the both sides of graphite cake 6 flexibly connect with baffle plate 7 respectively.Make the aluminum electrolytic cell riser bus bar reparation be fixed in the side of riser bus bar with mould by the anchor clamps clamping and with the iron wire binding.
The size of upper die 1 depends on the consumption of the required welding powder of welding of damage location and groove, and the volume of welding powder accounts for 2/3 to 4/5 of its capacity in the general upper die.Dirty guide hole 2 closely cooperates with pod apertures 3, is convenient to welding fluid in the upper die 1 by dirty guide hole 2 and pod apertures 3, flow in the riser bus bar damage location through fluid orifice 5.
Lower mould is by the baffle plate 7 of graphite cake 6 and both sides thereof, covers riser bus bar 9 damage locations fully and constitutes a welding die cavity.Slit between mould and the riser bus bar 9 seals with red soil up and down.The medullary ray of upper die and lower mould is positioned at the mid-way of riser bus bar damage location weld seam 8, and the pod apertures 3 of lower mould is near the bus surface of riser bus bar 9, apart from the about 1cm in upper die 1 crucible bottom edge.The central position of the continuous distribution fluid orifice 5 of lower mould is concordant with the top of the groove to be welded of riser bus bar weld seam 8.Fluid orifice 5 is the circular hole of diameter 8mm, and the spacing between the fluid orifice 5 is 12mm, and the quantity of fluid orifice 5 determines that according to the width of riser bus bar 9 these fluid orifices distribute and reconstruct a circular shower nozzle.
During use; add from the melting welding agent in the upper die 1 of mould and lead fiery powder in the aluminum electrolytic cell riser bus bar reparation; above upper die 1, place the conical smog protective guard of a both ends open then; protective guard requires up-small and down-big placement, covers from the melting welding agent fully and leads fiery powder region.
The aluminum electrolytic cell riser bus bar reparation has following characteristics with mould:
(1) upper die 1 is positioned at the mid-way of riser bus bar 9 levels damage, fully guaranteed to carry out to riser bus bar damage surface both sides from the formed high temperature aluminum liquid in melting welding agent fusing back evenly wetting and sprawl, avoid heat to scatter and disappear, dirty guide hole 2 is offered upper die 1 crucible bottom apart from the place of the about 1cm in edge, fully adapts to welding on-the-spot small space and narrow dimension.
(2) be not subjected to bevel for welding at riser bus bar position, shape, size and aspect effect, easily manufacturing, lower, the easy dismounting of cost.This reparation, life-span long point good with mold performance on average can weld 30～50 grooves.
(3) thickness of molten liner is 1mm certainly, according to the groove size, selects 2～3 stacked uses, has promoted welding to finish abundant come-up and the discharge of back welding slag, has guaranteed the pure of weld metal and not polluted by welding slag, has improved welding quality.
(4) use when the formed high temperature aluminum liquid in melting welding agent fusing back reaches preset temperature when welding, melt liner fusing automatically certainly, the flow velocity of high temperature aluminum liquid is even, and it is less to dispel the heat, and avoids a large amount of pores to occur.
5. welding:
Because riser bus bar itself has 100～200 ℃ of temperature, so need not carry out preheating by big electric current.Use lighter that the fiery powder of leading in the upper die is lighted a fire, ignite from the melting welding agent after leading fiery powder burning, obtain temperature and be 1150 ℃ high temperature aluminum mixture liquid), fusing is from molten liner through about 10 seconds, high temperature aluminum mixture liquid flows into riser bus bar groove to be welded by the pod apertures 3 in the lower mould chute 4 and fluid orifice 5, finish entire belt electric welding process in 20 seconds, form the weld metal face.
6. die sinking:
Welding finishes to take off aluminum electrolytic cell riser bus bar reparation mould after 5 minutes, the skull in the mould is removed clean.
7. the weld metal face is handled:
After the cooling, remove the graphite rod that presets from the riser bus bar outside, all can directly take out or break into pieces, the connecting hole of riser bus bar and short-circuit busbar is worked into reamer meets the Technology requirement.Adopt redundance and the welding slag of electric planer, flat chisel and angle grinding machine trimming metal covering, expose silvery white metalluster, adopt brush that grinding and polishing is carried out on the surface of described weld metal face and handle the riser bus bar that obtains repairing.
The 120KA aluminium cell is because the riser bus bar that bakie causes is washed out, and the riser bus bar damage surface is of a size of: long 300mm, wide 200mm, dark 120mm.
The charged restorative procedure of aluminum electrolytic cell riser bus bar, the reparation step is as follows:
1. injured surface is handled:
Adopt the short-circuit busbar of insulation paper parcel opposite side, insulcrete is laid on the grid ground in the electrolyzer side near riser bus bar, mainly is for insulating effect, guarantees personnel's safety.Operator stand in above the insulcrete, burn rub bar in riser bus bar and the short-circuit busbar connecting hole with oxygen-acetylene flame, amputate the aluminium block that solidifies of riser bus bar surface bulk with sawing machine, remove riser bus bar damage location and oxide skin all around with pneumatic polishing machine, clean out the riser bus bar injured surface with straight grinder and high speed brush, form riser bus bar groove to be welded.
At the riser bus bar injured surface, it is recessed that the employing hammer is got the densely covered squamous of degree of depth 6mm hole, and drilling tool gets out a diameter 12mm degree of depth 12mm shrinkage pool every 25mm by hand.This uneven structure is in order to strengthen the welding fusion area of high temperature aluminum liquid and riser bus bar damage matrix, to make welding more solid and reliable.
2. installation graphite rod:
Inserting 4 length in the connecting hole of riser bus bar and short-circuit busbar is that 100mm, diameter are the graphite rod of 48 mm, adopts asbestos twine to wrap up around the graphite rod.The graphite rod end keeps concordant with the riser bus bar plane.The purpose of inserting graphite rod is in order to reserve the connecting hole of short circuit mouth after welding, not need to carry out secondary processing.Adopting asbestos twine that graphite rod is wrapped up is that graphite rod is taken out in convenient welding back.
3. calculate the addition that flux is used in the charged reparation of aluminum electrolytic cell riser bus bar:
Because the riser bus bar damage surface is of a size of: long 300mm, wide 200mm, dark 120mm, the volume that draws riser bus bar groove to be welded is: 30 * 20 * 12=7200cm
3
After melting welding agent welding, comprise weldering meat and welding slag two portions, weldering meat density is 3.2～4.0g/cm
3, calculate according to 50% the liquid rate that gets from the melting welding agent, get the percentage ratio that the liquid metal that obtains after the liquid rate refers to react accounts for original flux quality.
Then required quality from the melting welding agent is between 46.1～57.6kg:
7200?cm
3×3.2?g/cm
3÷50%/1000=46.1?（kg）
7200?cm
3×4.0?g/cm
3÷50%/1000=57.6?（kg）
Consumption from the melting welding agent adopts the round numbers of big value, gets 58 kg from the melting welding agent.According to the mass percent meter, mixed by following raw materials according from the melting welding agent: 2% magnesium powder 1.16kg, 40% aluminium powder 23.2kg, 3% silicon calcium powder 1.74kg, 9% calcium sulfate 5.22kg, 18% copper powder 10.44kg, 24% tin protoxide 13.92kg, 4% Calcium Fluoride (Fluorspan) 2.32kg, use mixed powder machine or ball mill to carry out full and uniform mixing and form.
Wherein: the granularity of magnesium powder, aluminium powder, silicon calcium powder, calcium sulfate, copper powder, tin protoxide and Calcium Fluoride (Fluorspan) is 200 orders.
Wherein: copper powder refers to that the surface oxidation rate is 50% copper powder, the fine copper particle is placed in the oxidizing atmosphere of high temperature to handle, and makes its surface oxidation, and a kind of oxide compound by copper of formation coats the copper particle and forms composite particles.The surface oxidation rate is that 50% copper powder is that copper oxide surface amount mark is 50% copper powder.
This from the melting welding agent for other similar welding material, owing to adopted calcium sulfate instead of part oxide compound as oxygenant, with aluminium powder generation redox reaction, obtained sulfurated lime and aluminium sesquioxide, discharged a large amount of heats and be used for the excessive aluminium powder of fusing, so the aluminum mixture liquid temp is higher.In addition, because adopted silicon calcium powder as reductive agent, so chemical reaction is steadily controlled, slag liquid separates more abundant, and slag making is respond well.
The consumption of leading fiery powder according to the mass percent meter, is led fiery powder for covering the consumption from melting welding agent top layer fully: be 0.15:100 from the melting welding agent, get the fiery powder of leading of 8.7kg.
Lead fiery powder, mixed by following raw materials according: 15% aluminium powder 1.3kg, 25% sulphur powder 2.2kg, 60% potassium permanganate 5.2kg, use mixed powder machine or ball mill to carry out full and uniform mixing and form.The granularity of aluminium powder, potassium permanganate and sulphur powder is 50 orders, the convenience of igniting like this, safety, quick.
In the present embodiment, after reaction, the temperature that obtains 29 kg is 1160 ℃ high temperature aluminum mixture liquid to 58 kg from the melting welding agent.
4, weld mold is installed:
Adopt the aluminum electrolytic cell riser bus bar reparation to surround with the damage location of mould with riser bus bar.Aluminum electrolytic cell riser bus bar reparation usefulness mould is identical with embodiment's 1.
5. welding:
Because riser bus bar itself has 100～200 ℃ of temperature, so need not carry out preheating by big electric current.Adopt lighter that the fiery powder of leading in the upper die is lighted a fire, ignite from the melting welding agent after leading fiery powder burning, obtain temperature and be 1180 ℃ high temperature aluminum mixture liquid, fusing is from molten liner through about 15 seconds, high temperature aluminum mixture liquid flows into riser bus bar groove to be welded by the pod apertures 3 in the lower mould chute 4 and fluid orifice 5, finish entire belt electric welding process in 30 seconds, form the weld metal face.
6. die sinking:
Welding finishes to take off aluminum electrolytic cell riser bus bar reparation mould after 10 minutes, the skull in the mould is removed clean.
7. the weld metal face is handled:
After the cooling, remove the graphite rod that presets from the riser bus bar outside, all can directly take out or break into pieces, the connecting hole of riser bus bar and short-circuit busbar is worked into reamer meets the Technology requirement.Adopt redundance and the welding slag of electric planer, flat chisel and angle grinding machine trimming metal covering, expose silvery white metalluster, adopt brush that grinding and polishing is carried out on the surface of described weld metal face and handle the riser bus bar that obtains repairing.
Embodiment 3:
The 200KA aluminium cell is because short circuit mouth arc-over, and seam broken is blown out on the riser bus bar that causes and short-circuit busbar surface, and the riser bus bar damage surface is of a size of: long 250mm, wide 180mm, 100mm deeply.
The charged restorative procedure of aluminum electrolytic cell riser bus bar, the reparation step is as follows:
1. injured surface is handled:
Adopt the short-circuit busbar of insulation paper parcel opposite side, insulcrete is laid on the grid ground in the electrolyzer side near riser bus bar, mainly is for insulating effect, guarantees personnel's safety.Operator stand in above the insulcrete, burn rub bar in riser bus bar and the short-circuit busbar connecting hole with oxygen-acetylene flame, amputate the aluminium block that solidifies of riser bus bar surface bulk with sawing machine, remove riser bus bar damage location and oxide skin all around with pneumatic polishing machine, clean out the riser bus bar injured surface with straight grinder and high speed brush, form riser bus bar groove to be welded.
At the riser bus bar injured surface, it is recessed that the employing hammer is got the densely covered squamous of degree of depth 4mm hole, and drilling tool gets out the shrinkage pool of diameter 8mm, a degree of depth 8mm every 15mm by hand.This uneven structure is in order to strengthen the welding fusion area of high temperature aluminum liquid and riser bus bar damage matrix, to make welding more solid and reliable.
2. installation graphite rod:
Inserting 4 length in the connecting hole of riser bus bar and short-circuit busbar is that 100mm, diameter are the graphite rod of 48 mm, adopts asbestos twine to wrap up around the graphite rod.The graphite rod end keeps concordant with the riser bus bar plane.The purpose of inserting graphite rod is in order to reserve the connecting hole of short circuit mouth after welding, not need to carry out secondary processing.Adopting asbestos twine that graphite rod is wrapped up is that graphite rod is taken out in convenient welding back.
3. calculate the addition that flux is used in the charged reparation of aluminum electrolytic cell riser bus bar:
Because the riser bus bar damage surface is of a size of: long 250mm, wide 180mm, dark 100mm, the volume that draws riser bus bar groove to be welded is: 25 * 18 * 10=4500cm
3
After melting welding agent welding, comprise weldering meat and welding slag two portions, weldering meat density is 3.2～4.0g/cm
3, calculate according to 50% the liquid rate that gets from the melting welding agent, get the percentage ratio that the liquid metal that obtains after the liquid rate refers to react accounts for original flux quality.
Then required quality from the melting welding agent is between 28.8～36kg:
4500?cm
3×3.2?g/cm
3÷50%/1000=28.8?（kg）
4500?cm
3×4.0?g/cm
3÷50%/1000=36.0?（kg）
Consumption from the melting welding agent adopts the round numbers of big value, gets 36 kg from the melting welding agent.According to the mass percent meter, mixed by following raw materials according from the melting welding agent: 4% magnesium powder 1.44kg, 32% aluminium powder 11.52kg, 5% silicon calcium powder 1.8kg, 12% calcium sulfate 4.32kg, 25% copper powder 9.0kg, 20% tin protoxide 7.2kg, 2% Calcium Fluoride (Fluorspan) 0.72kg, use mixed powder machine or ball mill to carry out full and uniform mixing and form.
Wherein: magnesium powder, aluminium powder, silicon calcium powder, calcium sulfate, oxidation ratio are that the granularity of copper powder, tin protoxide and the Calcium Fluoride (Fluorspan) of 50% surface oxidation is 100 orders.
Wherein: copper powder refers to that the surface oxidation rate is 50% copper powder, the fine copper particle is placed in the oxidizing atmosphere of high temperature to handle, and makes its surface oxidation, and a kind of oxide compound by copper of formation coats the copper particle and forms composite particles.The surface oxidation rate is that 50% copper powder is that copper oxide surface amount mark is 50% copper powder.
This from the melting welding agent for other similar welding material, owing to adopted calcium sulfate instead of part oxide compound as oxygenant, with aluminium powder generation redox reaction, obtained sulfurated lime and aluminium sesquioxide, discharged a large amount of heats and be used for the excessive aluminium powder of fusing, so the aluminum mixture liquid temp is higher.In addition, because adopted silicon calcium powder as reductive agent, so chemical reaction is steadily controlled, slag liquid separates more abundant, and slag making is respond well.
The consumption of leading fiery powder according to the mass percent meter, is led fiery powder for covering the consumption from melting welding agent top layer fully: be 0.25:100 from the melting welding agent, get the fiery powder of leading of 9.0g.
Lead fiery powder, mixed by following raw materials according: 5% aluminium powder 0.45kg, 30% sulphur powder 2.7kg, 65% potassium permanganate 5.85kg, use mixed powder machine or ball mill to carry out full and uniform mixing and form.The granularity of aluminium powder, potassium permanganate and sulphur powder is 40 orders, the convenience of igniting like this, safety, quick.
In the present embodiment, 36kg after reaction, obtains 1180 ℃ the high temperature aluminum mixture liquid of 18kg from the melting welding agent.
4, weld mold is installed:
Adopt the aluminum electrolytic cell riser bus bar reparation to surround with the damage location of mould with riser bus bar.Aluminum electrolytic cell riser bus bar reparation usefulness mould is identical with embodiment's 1.
5. welding:
Because riser bus bar itself has 100～200 ℃ of temperature, so need not carry out preheating by big electric current.Adopt lighter that the fiery powder of leading in the upper die is lighted a fire, ignite from the melting welding agent after leading fiery powder burning, obtain temperature and be 1160 ℃ high temperature aluminum mixture liquid, fusing is from molten liner through about 12 seconds, high temperature aluminum mixture liquid flows into riser bus bar groove to be welded by the pod apertures 3 in the lower mould chute 4 and fluid orifice 5, finish entire belt electric welding process in 25 seconds, form the weld metal face.
6. die sinking:
Welding finishes to take off aluminum electrolytic cell riser bus bar reparation mould after 8 minutes, the skull in the mould is removed clean.
7. the weld metal face is handled:
After the cooling, remove the graphite rod that presets from the riser bus bar outside, all can directly take out or break into pieces, the connecting hole of riser bus bar and short-circuit busbar is worked into reamer meets the Technology requirement.Adopt redundance and the welding slag of electric planer, flat chisel and angle grinding machine trimming metal covering, expose silvery white metalluster, adopt brush that grinding and polishing is carried out on the surface of described weld metal face and handle the riser bus bar that obtains repairing.
Claims (3)
1. the charged restorative procedure of aluminum electrolytic cell riser bus bar is characterized in that, may further comprise the steps:
A. injured surface is handled: cleaning riser bus bar injured surface, form riser bus bar groove to be welded, and at the riser bus bar injured surface shrinkage pool more than 2 is set;
B., graphite rod is installed: in the connecting hole of riser bus bar and short-circuit busbar, insert graphite rod;
C. calculate the addition that flux is used in the charged reparation of aluminum electrolytic cell riser bus bar: the size according to riser bus bar groove to be welded is calculated institute's expense;
D. installation mold: aluminum electrolytic cell riser bus bar reparation mould is installed at the riser bus bar damage location;
E. welding: the charged reparation of described aluminum electrolytic cell riser bus bar obtains high temperature aluminum mixture liquid after burning with flux, flows into described riser bus bar groove to be welded, finishes welding process, forms the weld metal face;
F. die sinking: welding is taken off aluminum electrolytic cell riser bus bar reparation mould after finishing;
G. the weld metal face is handled: remove the graphite rod that presets after the cooling, the processing connecting hole is to meeting the Technology requirement, and the redundance of trimming metal covering and welding slag carry out grinding and polishing to the surface and handle the riser bus bar that obtains repairing.
2. the charged restorative procedure of aluminum electrolytic cell riser bus bar according to claim 1 is characterized in that, the described shrinkage pool among the step a comprises that the degree of depth is densely covered squamous hole recessed and the be separated by diameter of 15～25 mm, the shrinkage pool that the degree of depth is respectively 8～12mm of 4～6mm.
3. the charged restorative procedure of aluminum electrolytic cell riser bus bar according to claim 1 is characterized in that, the described high temperature aluminum mixture liquid among the step e is temperature 1150-1180 ℃ aluminum mixture liquid.
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| CN106541246A (en) * | 2016-09-27 | 2017-03-29 | 新疆众和股份有限公司 | The method that aluminum cell bus-bar sweat soldering is repaired under electromagnetic field environment |
| CN112458500A (en) * | 2020-11-11 | 2021-03-09 | 内蒙古大唐国际呼和浩特铝电有限责任公司 | On-line repair method for cathode bus of electrolytic cell |
| CN112458500B (en) * | 2020-11-11 | 2022-02-22 | 内蒙古大唐国际呼和浩特铝电有限责任公司 | On-line repair method for cathode bus of electrolytic cell |
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