CN103290431B - The charged restorative procedure of aluminum electrolytic cell riser bus bar - Google Patents
The charged restorative procedure of aluminum electrolytic cell riser bus bar Download PDFInfo
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- CN103290431B CN103290431B CN201310175028.4A CN201310175028A CN103290431B CN 103290431 B CN103290431 B CN 103290431B CN 201310175028 A CN201310175028 A CN 201310175028A CN 103290431 B CN103290431 B CN 103290431B
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- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 116
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 110
- 238000000034 method Methods 0.000 title claims abstract description 54
- 238000003466 welding Methods 0.000 claims abstract description 132
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 35
- 239000010439 graphite Substances 0.000 claims abstract description 35
- 229910002804 graphite Inorganic materials 0.000 claims abstract description 35
- 230000008569 process Effects 0.000 claims abstract description 33
- 229910052751 metal Inorganic materials 0.000 claims abstract description 27
- 239000002184 metal Substances 0.000 claims abstract description 27
- 230000004907 flux Effects 0.000 claims abstract description 11
- 238000009434 installation Methods 0.000 claims abstract description 5
- 239000007788 liquid Substances 0.000 claims description 40
- 230000006378 damage Effects 0.000 claims description 24
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- 239000002893 slag Substances 0.000 claims description 16
- 230000000694 effects Effects 0.000 claims description 10
- 238000000227 grinding Methods 0.000 claims description 9
- 238000001816 cooling Methods 0.000 claims description 5
- 238000007517 polishing process Methods 0.000 claims description 5
- 238000012545 processing Methods 0.000 claims description 5
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- 238000004364 calculation method Methods 0.000 claims description 2
- 238000004140 cleaning Methods 0.000 claims description 2
- 230000005291 magnetic effect Effects 0.000 abstract description 23
- 230000004927 fusion Effects 0.000 abstract description 4
- 238000005868 electrolysis reaction Methods 0.000 abstract description 2
- 239000000843 powder Substances 0.000 description 58
- 238000002844 melting Methods 0.000 description 41
- 230000008018 melting Effects 0.000 description 41
- 239000004411 aluminium Substances 0.000 description 40
- 239000003795 chemical substances by application Substances 0.000 description 37
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 27
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 18
- 239000012530 fluid Substances 0.000 description 11
- 239000007789 gas Substances 0.000 description 10
- OSMSIOKMMFKNIL-UHFFFAOYSA-N calcium;silicon Chemical compound [Ca]=[Si] OSMSIOKMMFKNIL-UHFFFAOYSA-N 0.000 description 9
- 229910052802 copper Inorganic materials 0.000 description 9
- 239000010949 copper Substances 0.000 description 9
- 238000006243 chemical reaction Methods 0.000 description 8
- 238000005516 engineering process Methods 0.000 description 8
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 7
- 239000001301 oxygen Substances 0.000 description 7
- 229910052760 oxygen Inorganic materials 0.000 description 7
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 6
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 6
- 239000005864 Sulphur Substances 0.000 description 6
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 6
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical compound [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 6
- 239000010425 asbestos Substances 0.000 description 6
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 description 6
- 229910001634 calcium fluoride Inorganic materials 0.000 description 6
- 235000013372 meat Nutrition 0.000 description 6
- 239000011812 mixed powder Substances 0.000 description 6
- 239000002245 particle Substances 0.000 description 6
- 239000012286 potassium permanganate Substances 0.000 description 6
- 229910052895 riebeckite Inorganic materials 0.000 description 6
- 238000009826 distribution Methods 0.000 description 5
- 239000002994 raw material Substances 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 4
- 238000009413 insulation Methods 0.000 description 4
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- 229910000679 solder Inorganic materials 0.000 description 4
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- 238000010301 surface-oxidation reaction Methods 0.000 description 4
- 229910000838 Al alloy Inorganic materials 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- QPLDLSVMHZLSFG-UHFFFAOYSA-N Copper oxide Chemical compound [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 description 3
- 239000005751 Copper oxide Substances 0.000 description 3
- JNVCSEDACVAATK-UHFFFAOYSA-L [Ca+2].[S-]SSS[S-] Chemical compound [Ca+2].[S-]SSS[S-] JNVCSEDACVAATK-UHFFFAOYSA-L 0.000 description 3
- LNSPFAOULBTYBI-UHFFFAOYSA-N [O].C#C Chemical group [O].C#C LNSPFAOULBTYBI-UHFFFAOYSA-N 0.000 description 3
- 239000011246 composite particle Substances 0.000 description 3
- 150000001875 compounds Chemical class 0.000 description 3
- 229910000431 copper oxide Inorganic materials 0.000 description 3
- 238000005553 drilling Methods 0.000 description 3
- 238000003780 insertion Methods 0.000 description 3
- 230000037431 insertion Effects 0.000 description 3
- 229910001338 liquidmetal Inorganic materials 0.000 description 3
- 230000001590 oxidative effect Effects 0.000 description 3
- 238000005498 polishing Methods 0.000 description 3
- 238000006479 redox reaction Methods 0.000 description 3
- 230000002829 reductive effect Effects 0.000 description 3
- 210000003625 skull Anatomy 0.000 description 3
- 239000000758 substrate Substances 0.000 description 3
- 229940051851 sulfurated lime Drugs 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000010891 electric arc Methods 0.000 description 2
- 238000005265 energy consumption Methods 0.000 description 2
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- 241001604129 Polydactylus Species 0.000 description 1
- WCUXLLCKKVVCTQ-UHFFFAOYSA-M Potassium chloride Chemical compound [Cl-].[K+] WCUXLLCKKVVCTQ-UHFFFAOYSA-M 0.000 description 1
- 208000037656 Respiratory Sounds Diseases 0.000 description 1
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- 229910001610 cryolite Inorganic materials 0.000 description 1
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- 208000015181 infectious disease Diseases 0.000 description 1
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- 238000010583 slow cooling Methods 0.000 description 1
- 239000011780 sodium chloride Substances 0.000 description 1
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- Nonmetallic Welding Materials (AREA)
- Electrolytic Production Of Metals (AREA)
Abstract
The present invention discloses the charged restorative procedure of a kind of aluminum electrolytic cell riser bus bar, comprises the following steps: injured surface process, installation graphite rod, the addition calculating the charged reparation flux of aluminum electrolytic cell riser bus bar, installation mold, welding, die sinking and the process of weld metal face.Adopt the charged restorative procedure of aluminum electrolytic cell riser bus bar provided by the invention, riser bus bar and short-circuit opening can chargedly be repaired, not by 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 close to mother metal, and process safety is reliable, rapidly simple to operate, be adapted at electrolysis of aluminum industry and apply.
Description
Technical field
The invention belongs to aluminum smelting technology technical field, relate to the restorative procedure of aluminum electrolytic cell riser bus bar, particularly relate 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, annual output 38.8 ten thousand tons of electrolytic aluminum first phase project electric currents that Liancheng branch office of Chinese Aluminium Co., Ltd in April, 2011 goes into operation even reach record-breaking 500kA.Current 600kA electrolyzer is also among research and development.Electrolytic bath amount is large, and conductor configuration is comparatively complicated, and whole potroom produces powerful electromagnetic field.Different according to strength of current, electrolyzer magneticstrength design maximum is 20 ~ 50GS, but the magneticstrength in actual moving process is often than the design load more than high ten times of designing institute, the field strength values that the such as 300kA electrolyzer X-direction of testing when actual motion is the highest reaches 850GS.Even if under the state had a power failure, powerful remanent magnetism is still difficult to eliminate in short-term.
In cell room; riser bus bar and short-circuit busbar often can be subject to unexpected injury and occur damage; such as because short-circuit opening 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 etc. that causes of tribo-charging; 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 there are potential major safety risks.For these damages that riser bus bar occurs, generally need to adopt arc welding method to repair.But, due to the impact of powerful electric current, during welding, equipment is difficult to normal operation, the electric current that welding set exports and voltage instability, liquid welding pool splashes, cannot stack shaping, so can only adopt spot welding, there is more welding flaw, after welding, connection resistance obviously increases, have a strong impact on welding quality, cause the significant wastage on human and material resources.
In order to avoid high-intensity magnetic field impact, need to carry out REPAIR WELDING to after whole potroom power failure.First adopt machine tool such as angle grinding machine, straight grinder, brush etc. to clean out on breach surface, expose cast aluminium true qualities.Then coloured welder plays breach, and exceeds former bus plane with welding machine one, in layer built-up welding, then use argon welder melting aluminum welding rod or aluminium welding wire, and the part of built-up welding being got up is combined together with former bus weldering.Pincers worker instrument, by its surperficial equating, makes it to reach bus process specifications.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 that electrolytic aluminum output reduces, energy consumption significantly increases, and also can increase noxious gas emission, cause environmental pollution.If had a power failure continuously time long, the aluminium liquid in electrolyzer will solidify, and have a strong impact on potroom aluminium liquid and will produce, cause heavy economic losses.
In order to avoid the destroying infection brought electrolyzer that has a power failure, domestic and international electrolytic aluminum producer attempts the processing method taking various band electric welding riser bus bar.Adopting on magnetic field shielding theoretical method to avoid magnetic field on the impact of welding arc, and domestic Lanzhou University of Science & Technology, Yuncheng City, Guan aluminum equipment Materials Co., Ltd, Central Region, Henan aluminium manufacturer etc. have carried out some in this respect and attempted.Patent " a kind of magnetic disturbance resistant electric arc welding apparatus " (patent No. ZL200820077927.5, publication number CN201217122, publication date 2009.04.08) disclose a kind of magnetic disturbance resistant electric arc welding apparatus, comprise arc welding gun and nozzle thereof, nozzle is arranged the magnetic head of energy shielding space magnetic field transverse direction, longitudinal component, magnetic head is connected with excitation power supply; Magnetic head is made up 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 having under magnetic environment produces the problems such as magnetic blow phenomenon; and the trough rim riser bus bar damaged in attempting adopting this technology to run the original production of 190kA, 300kA electrolyzer and repair carries out charged reparation, achieves certain effect.But these methods are of limited application, be suitable only for the simple occasion in magnetic field, and due to the complicacy of aluminium cell ambient conditions, be all three-dimensional stereoscopic rotating magnetic field in the magnetic field of cell side busbar any point in actual moving process, and be change over time; Magneticstrength is very large, there is distribution in magnetic field along all directions, be difficult to adopt Technologies such as conventional " 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 demagnetization cost is very high, so cannot apply on a large scale in actual production.
In order to realize the good welds of magnetic field inner column bus, the welding process that diamagnetic ability is strong or not affected by magnetic fields can be adopted in theory.From current status quo, conventional method is difficult to the interference problem solving magnetic field.Resistance welding needs unit clamp, and is subject to the restriction in riser bus bar position and space.Distribution of current is uneven simultaneously, and formation of weld and welding quality are difficult to be guaranteed.Gas welding is the high hot melt weldment and welding wire that utilize inflammable gas and oxygen mix burned flame to produce and carries out a kind of welding process that metal is connected.During welding aluminum alloy materials, with gas welding heating welding position until fusing, add aluminum solder (Repone K powder 50%+ sodium chloride powder 30%+ cryolite powder 20%), complete welding by the filling of aluminum solder.Pressure gas welding is the same with gas welding, and pressure gas welding is also take gas flame as thermal source.During welding by two end heat of workpiece docked after certain temperature, then applying enough pressure to obtain firmly joint, is a kind of Solid-phase welding technology.Due to not by magneticinterference, although gas welding and pressure gas welding may be used for the welding of riser bus bar, due to its welding efficiency is lower and pressure gas welding time pressing technology restriction, be not suitable for the site welding operation of aluminium cell.Friction stir welding, as a kind of solid diffusivity means, forms joint primarily of under the heat of friction of stirring-head and the combined action of mechanical presses.Which overcome the shortcoming such as such as pore, crackle, distortion of melting welding in the past, compared with during conventional fused welding aluminum alloy (strength of joint is about 50% of strength of parent), strength of joint improves greatly.When agitating friction is welded in the welding being applied to thin plate aluminum alloy, technology is very ripe, but still well can not amass the welding of aluminium bar bus for large section.
Casting welding is a kind of welding technique that foundry engieering and soldering tech combine.Domestic many aluminium smelter enterprises are attempted in this respect.This method is the damage breach adopting refractory materials to make the coated riser bus bar of fusible pattern, and then in fusible pattern, inject molten aluminum liquid, aluminium liquid heats mother metal in Slow cooling process simultaneously, and mother metal is melted, thus forms welding joint.There are three deficiencies in this method: (1), due to heating condition restriction, the temperature of aluminium liquid only has 900 ~ 1180 DEG C, only exceeds 250 ~ 400 DEG C than the fusing point of aluminium, topples over mother metal after entering weld seam and dispel the heat rapidly, is difficult to realize fusion preferably; (2) joint filling of aluminium liquid only relies on the trickling of gravity, and its joint filling effect is bad; (3) do not add infiltration element in aluminium liquid, and the wetting effect of mother metal is poor.Therefore, such founding is welded the weld seam ubiquity obtained and the bad problem of sidewall fusion effect.If be applied in actual production, not only welding joint consume electric power is more, and has buried hidden danger for long-term safety is normally run.
Summary of the invention
The object of this invention is to provide the charged reparation of a kind of energy, not by high-intensity magnetic field interference, the safe and reliable charged restorative procedure of aluminum electrolytic cell riser bus bar.
For achieving the above object, the technical scheme that the present invention takes is:
The charged restorative procedure of a kind of aluminum electrolytic cell riser bus bar, comprises the following steps:
A. injured surface process: cleaning riser bus bar injured surface, forms riser bus bar groove to be welded, arrange the shrinkage pool of more than 2 at riser bus bar injured surface;
B. graphite rod is installed: in the connecting hole of riser bus bar and short-circuit busbar, insert graphite rod;
C. the addition of aluminum electrolytic cell riser bus bar charged reparation flux is calculated: according to the Size calculation institute expense of riser bus bar groove to be welded;
D. installation mold: install aluminum electrolytic cell riser bus bar reparation mould at riser bus bar damage location;
E. weld: after the charged reparation flux burning of described aluminum electrolytic cell riser bus bar, obtain high temperature aluminum mixture liquid, flow into described riser bus bar groove to be welded, complete welding process, form weld metal face;
F. die sinking: after welding terminates, take off aluminum electrolytic cell riser bus bar reparation mould;
G. weld metal face process: remove preset graphite rod after cooling, processing connecting hole is to meeting process specifications, and the redundance of trimming metal covering and welding slag, effects on surface carries out grinding and polishing process, obtains the riser bus bar repaired.
Described shrinkage pool in step a, comprises diameter that the degree of depth is the recessed and 15 ~ 25mm of being separated by the densely covered squamous hole of 4 ~ 6mm, shrinkage pool that the degree of depth is respectively 8 ~ 12mm.
Described high temperature aluminum mixture liquid in step e is the aluminum mixture liquid of temperature 1150-1180 DEG C.
Adopt the charged restorative procedure of aluminum electrolytic cell riser bus bar provided by the invention, riser bus bar and short-circuit opening can chargedly be repaired, not by 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 close to mother metal, and process safety is reliable, rapidly simple to operate, be adapted at electrolysis of aluminum industry and apply.
Accompanying drawing explanation
Fig. 1 is the structural representation of aluminum electrolytic cell riser bus bar reparation mould of the present invention.
Embodiment
embodiment 1
200KA aluminium cell punctures due to short circuit port insulation plate, and seam broken is blown out on the riser bus bar caused and short-circuit busbar surface, and riser bus bar damage surface is of a size of: long 420mm, wide 150mm, dark 80mm.
The charged restorative procedure of aluminum electrolytic cell riser bus bar, reparation step is as follows:
1. injured surface process:
Adopt the short-circuit busbar of insulation paper parcel opposite side, on the grid ground of riser bus bar, lay insulcrete in electrolyzer side, mainly in order to insulating effect, guarantee the safety of personnel.Operator stand in above insulcrete, the rub bar in riser bus bar and short-circuit busbar connecting hole is burnt with oxygen acetylene flame, with sawing machine amputate riser bus bar surface bulk solidify aluminium block, the oxide skin of riser bus bar damage location and surrounding is removed with pneumatic polishing machine, clean out riser bus bar injured surface with straight grinder and high speed brush, form riser bus bar groove to be welded.
At riser bus bar injured surface, the densely covered squamous adopting hammer to get degree of depth 5mm is cheated recessed, and drilling tool gets out the shrinkage pool of a diameter 10mm, degree of depth 10mm every 20mm by hand.This uneven structure, being fuse area in order to strengthen high temperature aluminum liquid with welding of riser bus bar damaging substrate, making welding more solid and reliable.
2. graphite rod is installed:
In the connecting hole of riser bus bar and short-circuit busbar, insert that 4 length are 100mm, diameter is the graphite rod of 48mm, around graphite rod, adopt asbestos twine to wrap up.Graphite rod end and riser bus bar plane keep concordant.The object of insertion graphite rod is the connecting hole in order to reserve short-circuit opening after welding, does not need to carry out secondary processing.Adopting asbestos twine to carry out parcel to graphite rod is take out graphite rod after convenience is welded.
3. calculate the addition of the charged reparation flux of aluminum electrolytic cell riser bus bar:
Because riser bus bar damage surface is of a size of: long 420mm, wide 150mm, dark 80mm, show that the volume of 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, from melting welding agent according to 50% liquid rate calculate, obtain the percentage ratio that the liquid metal obtained after liquid rate refers to reaction accounts for original flux quality.Then required from the quality of melting welding agent be between 32.3 ~ 40.3kg:
5040cm
3×3.2g/cm
3÷50%/1000=32.3（kg）
5040cm
3×4.0g/cm
3÷50%/1000=40.3（kg）
Adopt from the consumption of melting welding agent and be worth round numbers greatly, get 40kg from melting welding agent.According to mass percent, mixed by following raw materials according from 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 being uniformly mixed 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 Surface Oxygen rate is the copper powder of 50%, is placed on by fine copper particle in the oxidizing atmosphere of high temperature and processes, make its surface oxidation, a kind of oxide compound coated copper particle by copper of formation forms composite particles.Surface Oxygen rate be 50% copper powder and copper oxide surface amount mark be the copper powder of 50%.
This from melting welding agent for other similar welding material, replace partial oxide as oxygenant owing to have employed calcium sulfate, with aluminium powder generation redox reaction, obtain sulfurated lime and aluminium sesquioxide, release amount of heat for melting excessive aluminium powder, so aluminum mixture liquid temp is higher.In addition, because have employed silicon calcium powder as reductive agent, chemical reaction is steadily controlled, and slag liquid is separated more abundant, and slag making is respond well.
The consumption of leading fiery powder is cover the consumption from melting welding agent top layer completely, according to mass percent, leads fiery powder: be 0.2:100 from melting welding agent, and that gets 8.0kg leads fiery powder.
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 being uniformly mixed and form.
Wherein: the granularity of aluminium powder, potassium permanganate and sulphur powder is 50 orders, ignite so conveniently, safely, fast.
4. installation mold: adopt aluminum electrolytic cell riser bus bar reparation mould to be surrounded by the damage location of riser bus bar.
As shown in Figure 1, aluminum electrolytic cell riser bus bar reparation mould comprises upper die and lower mould, upper die 1 for the profile being provided with dirty guide hole 2 be the high strength graphite crucible of rectangular parallelepiped, be placed with from molten liner in dirty guide hole 2, from the concavity aluminium flake of molten liner to be thickness be 1mm, 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 being provided with chute 4, and the top of chute 4 offers pod apertures 3, and the bottom of chute 4 is provided with multiple fluid orifices 5 of continuous distribution, and the both sides of graphite cake 6 are flexibly connected with baffle plate 7 respectively.Bundling by holder and with iron wire makes aluminum electrolytic cell riser bus bar reparation mould be fixed on the side of riser bus bar.
The consumption of welding powder needed for the welding that the size of upper die 1 depends on damage location and groove, in general upper die, the volume of welding powder accounts for 2/3 to 4/5 of its capacity.Dirty guide hole 2 and pod apertures 3 closely cooperate, and are convenient to welding fluid in upper die 1 by dirty guide hole 2 and pod apertures 3, flow in riser bus bar damage location through fluid orifice 5.
Lower mould, by the baffle plate 7 of graphite cake 6 and both sides thereof, covers riser bus bar 9 damage location completely and forms a welding die cavity.Gap red soil between upper/lower die and riser bus bar 9 seals.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, and distance upper die 1 crucible bottom edge is about 1cm.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 fluid orifice 5 is 12mm, the width of the quantity basis riser bus bar 9 of fluid orifice 5 and determining, the distribution of these fluid orifices reconstructs a circular shower nozzle.
During use; add in the upper die 1 of aluminum electrolytic cell riser bus bar reparation mould from melting welding agent and lead fiery powder; then above upper die 1, place the conical smog protective guard of a both ends open; protective guard requires up-small and down-big placement, covers from melting welding agent completely and leads fiery powder region.
Aluminum electrolytic cell riser bus bar reparation mould has following characteristics:
(1) upper die 1 is positioned at the mid-way of riser bus bar 9 level lesions, fully ensure that the high temperature aluminum liquid formed after molten solder melts carries out uniform wet and sprawls to riser bus bar damage surface both sides, avoid heat loss, dirty guide hole 2 offers the place that upper die 1 crucible bottom distance edge is about 1cm, fully adapts to small space and the narrow dimension of welding scene.
(2) be not subject to bevel for welding at riser bus bar position, shape, size and aspect effect, easily manufacture, cost is lower, easily dismantle.This reparation mold performance is good, life-span long point, on average can weld 30 ~ 50 grooves.
(3) thickness of certainly molten liner is 1mm, according to groove size, selects 2 ~ 3 stacked uses, facilitates abundant floating and discharge that welding terminates rear welding slag, ensure that the pure of weld metal and do not pollute by welding slag, improve welding quality.
(4) when welding reaches preset temperature with the high temperature aluminum liquid formed after melting solder melts, can automatically melt from melting liner, the flow velocity of high temperature aluminum liquid is even, dispels the heat less, avoids a large amount of pore to occur.
5. weld:
Because riser bus bar is itself by big current, there are 100 ~ 200 DEG C of temperature, so do not need to carry out preheating.Lighter is used to light a fire to the fiery powder of leading in upper die, ignite from melting welding agent after leading the burning of fiery powder, obtain the high temperature aluminum mixture liquid that temperature is 1150 DEG C), through fusing in about 10 seconds from molten liner, high temperature aluminum mixture liquid flows into riser bus bar groove to be welded by the pod apertures 3 in lower mould chute 4 and fluid orifice 5, within 20 seconds, complete whole charged welding process, form weld metal face.
6. die sinking:
Welding end, after 5 minutes, takes off aluminum electrolytic cell riser bus bar reparation mould, is removed by the skull in mould clean.
7. weld metal face process:
After cooling, outside riser bus bar, remove preset graphite rod, directly take out or break into pieces, the connecting hole reamer of riser bus bar and short-circuit busbar is worked into and meets process specifications.Adopt redundance and the welding slag of electric planer, flat chisel and angle grinding machine trimming metal covering, expose silvery white metalluster, adopt the surface of brush to described weld metal face to carry out grinding and polishing process, obtain the riser bus bar repaired.
embodiment 2
The riser bus bar that 120KA aluminium cell causes due to bakie is washed out, and 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, reparation step is as follows:
1. injured surface process:
Adopt the short-circuit busbar of insulation paper parcel opposite side, on the grid ground of riser bus bar, lay insulcrete in electrolyzer side, mainly in order to insulating effect, guarantee the safety of personnel.Operator stand in above insulcrete, the rub bar in riser bus bar and short-circuit busbar connecting hole is burnt with oxygen acetylene flame, with sawing machine amputate riser bus bar surface bulk solidify aluminium block, the oxide skin of riser bus bar damage location and surrounding is removed with pneumatic polishing machine, clean out riser bus bar injured surface with straight grinder and high speed brush, form riser bus bar groove to be welded.
At riser bus bar injured surface, adopt hammer get degree of depth 6mm gather squamous hole recessed, drilling tool gets out a diameter 12mm degree of depth 12mm shrinkage pool every 25mm by hand.This uneven structure, being fuse area in order to strengthen high temperature aluminum liquid with welding of riser bus bar damaging substrate, making welding more solid and reliable.
2. graphite rod is installed:
In the connecting hole of riser bus bar and short-circuit busbar, insert that 4 length are 100mm, diameter is the graphite rod of 48mm, around graphite rod, adopt asbestos twine to wrap up.Graphite rod end and riser bus bar plane keep concordant.The object of insertion graphite rod is the connecting hole in order to reserve short-circuit opening after welding, does not need to carry out secondary processing.Adopting asbestos twine to carry out parcel to graphite rod is take out graphite rod after convenience is welded.
3. calculate the addition of the charged reparation flux of aluminum electrolytic cell riser bus bar:
Because riser bus bar damage surface is of a size of: long 300mm, wide 200mm, dark 120mm, show that the volume of 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, from melting welding agent according to 50% liquid rate calculate, obtain the percentage ratio that the liquid metal obtained after liquid rate refers to reaction accounts for original flux quality.
Then required from the quality of melting welding agent be between 46.1 ~ 57.6kg:
7200cm
3×3.2g/cm
3÷50%/1000=46.1（kg）
7200cm
3×4.0g/cm
3÷50%/1000=57.6（kg）
Adopt from the consumption of melting welding agent and be worth round numbers greatly, get 58kg from melting welding agent.According to mass percent, mixed by following raw materials according from 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 being uniformly mixed 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 Surface Oxygen rate is the copper powder of 50%, is placed on by fine copper particle in the oxidizing atmosphere of high temperature and processes, make its surface oxidation, a kind of oxide compound coated copper particle by copper of formation forms composite particles.Surface Oxygen rate be 50% copper powder and copper oxide surface amount mark be the copper powder of 50%.
This from melting welding agent for other similar welding material, replace partial oxide as oxygenant owing to have employed calcium sulfate, with aluminium powder generation redox reaction, obtain sulfurated lime and aluminium sesquioxide, release amount of heat for melting excessive aluminium powder, so aluminum mixture liquid temp is higher.In addition, because have employed silicon calcium powder as reductive agent, chemical reaction is steadily controlled, and slag liquid is separated more abundant, and slag making is respond well.
The consumption of leading fiery powder is cover the consumption from melting welding agent top layer completely, according to mass percent, leads fiery powder: be 0.15:100 from melting welding agent, and that gets 8.7kg leads fiery powder.
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 being uniformly mixed and form.The granularity of aluminium powder, potassium permanganate and sulphur powder is 50 orders, ignites so conveniently, safety, quick.
In the present embodiment, 58kg is from melting welding agent after reaction, and the temperature obtaining 29kg is the high temperature aluminum mixture liquid of 1160 DEG C.
4, erecting and welding mould:
Aluminum electrolytic cell riser bus bar reparation mould is adopted to be surrounded by the damage location of riser bus bar.Aluminum electrolytic cell riser bus bar reparation mould is identical with embodiment 1.
5. weld:
Because riser bus bar is itself by big current, there are 100 ~ 200 DEG C of temperature, so do not need to carry out preheating.Lighter is adopted to light a fire to the fiery powder of leading in upper die, ignite from melting welding agent after leading the burning of fiery powder, obtain the high temperature aluminum mixture liquid that temperature is 1180 DEG C, through fusing in about 15 seconds from molten liner, high temperature aluminum mixture liquid flows into riser bus bar groove to be welded by the pod apertures 3 in lower mould chute 4 and fluid orifice 5, within 30 seconds, complete whole charged welding process, form weld metal face.
6. die sinking:
Welding end, after 10 minutes, takes off aluminum electrolytic cell riser bus bar reparation mould, is removed by the skull in mould clean.
7. weld metal face process:
After cooling, outside riser bus bar, remove preset graphite rod, directly take out or break into pieces, the connecting hole reamer of riser bus bar and short-circuit busbar is worked into and meets process specifications.Adopt redundance and the welding slag of electric planer, flat chisel and angle grinding machine trimming metal covering, expose silvery white metalluster, adopt the surface of brush to described weld metal face to carry out grinding and polishing process, obtain the riser bus bar repaired.
embodiment 3:
200KA aluminium cell is due to short-circuit opening arc-over, and seam broken is blown out on the riser bus bar caused and short-circuit busbar surface, and riser bus bar damage surface is of a size of: long 250mm, wide 180mm, dark 100mm.
The charged restorative procedure of aluminum electrolytic cell riser bus bar, reparation step is as follows:
1. injured surface process:
Adopt the short-circuit busbar of insulation paper parcel opposite side, on the grid ground of riser bus bar, lay insulcrete in electrolyzer side, mainly in order to insulating effect, guarantee the safety of personnel.Operator stand in above insulcrete, the rub bar in riser bus bar and short-circuit busbar connecting hole is burnt with oxygen acetylene flame, with sawing machine amputate riser bus bar surface bulk solidify aluminium block, the oxide skin of riser bus bar damage location and surrounding is removed with pneumatic polishing machine, clean out riser bus bar injured surface with straight grinder and high speed brush, form riser bus bar groove to be welded.
At riser bus bar injured surface, adopt hammer get degree of depth 4mm gather squamous hole recessed, drilling tool gets out the shrinkage pool of a diameter 8mm, degree of depth 8mm every 15mm by hand.This uneven structure, being fuse area in order to strengthen high temperature aluminum liquid with welding of riser bus bar damaging substrate, making welding more solid and reliable.
2. graphite rod is installed:
In the connecting hole of riser bus bar and short-circuit busbar, insert that 4 length are 100mm, diameter is the graphite rod of 48mm, around graphite rod, adopt asbestos twine to wrap up.Graphite rod end and riser bus bar plane keep concordant.The object of insertion graphite rod is the connecting hole in order to reserve short-circuit opening after welding, does not need to carry out secondary processing.Adopting asbestos twine to carry out parcel to graphite rod is take out graphite rod after convenience is welded.
3. calculate the addition of the charged reparation flux of aluminum electrolytic cell riser bus bar:
Because riser bus bar damage surface is of a size of: long 250mm, wide 180mm, dark 100mm, show that the volume of 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, from melting welding agent according to 50% liquid rate calculate, obtain the percentage ratio that the liquid metal obtained after liquid rate refers to reaction accounts for original flux quality.
Then required from the quality of melting welding agent be between 28.8 ~ 36kg:
4500cm
3×3.2g/cm
3÷50%/1000=28.8（kg）
4500cm
3×4.0g/cm
3÷50%/1000=36.0（kg）
Adopt from the consumption of melting welding agent and be worth round numbers greatly, get 36kg from melting welding agent.According to mass percent, mixed by following raw materials according from 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 being uniformly mixed and form.
Wherein: magnesium powder, aluminium powder, silicon calcium powder, calcium sulfate, oxidation ratio are the copper powder of the surface oxidation of 50%, the granularity of tin protoxide and Calcium Fluoride (Fluorspan) is 100 orders.
Wherein: copper powder refers to that Surface Oxygen rate is the copper powder of 50%, is placed on by fine copper particle in the oxidizing atmosphere of high temperature and processes, make its surface oxidation, a kind of oxide compound coated copper particle by copper of formation forms composite particles.Surface Oxygen rate be 50% copper powder and copper oxide surface amount mark be the copper powder of 50%.
This from melting welding agent for other similar welding material, replace partial oxide as oxygenant owing to have employed calcium sulfate, with aluminium powder generation redox reaction, obtain sulfurated lime and aluminium sesquioxide, release amount of heat for melting excessive aluminium powder, so aluminum mixture liquid temp is higher.In addition, because have employed silicon calcium powder as reductive agent, chemical reaction is steadily controlled, and slag liquid is separated more abundant, and slag making is respond well.
The consumption of leading fiery powder is cover the consumption from melting welding agent top layer completely, according to mass percent, leads fiery powder: be 0.25:100 from melting welding agent, and that gets 9.0g leads fiery powder.
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 being uniformly mixed and form.The granularity of aluminium powder, potassium permanganate and sulphur powder is 40 orders, ignites so conveniently, safety, quick.
In the present embodiment, 36kg after reaction, obtains the high temperature aluminum mixture liquid of 1180 DEG C of 18kg from melting welding agent.
4, erecting and welding mould:
Aluminum electrolytic cell riser bus bar reparation mould is adopted to be surrounded by the damage location of riser bus bar.Aluminum electrolytic cell riser bus bar reparation mould is identical with embodiment 1.
5. weld:
Because riser bus bar is itself by big current, there are 100 ~ 200 DEG C of temperature, so do not need to carry out preheating.Lighter is adopted to light a fire to the fiery powder of leading in upper die, ignite from melting welding agent after leading the burning of fiery powder, obtain the high temperature aluminum mixture liquid that temperature is 1160 DEG C, through fusing in about 12 seconds from molten liner, high temperature aluminum mixture liquid flows into riser bus bar groove to be welded by the pod apertures 3 in lower mould chute 4 and fluid orifice 5, within 25 seconds, complete whole charged welding process, form weld metal face.
6. die sinking:
Welding end, after 8 minutes, takes off aluminum electrolytic cell riser bus bar reparation mould, is removed by the skull in mould clean.
7. weld metal face process:
After cooling, outside riser bus bar, remove preset graphite rod, directly take out or break into pieces, the connecting hole reamer of riser bus bar and short-circuit busbar is worked into and meets process specifications.Adopt redundance and the welding slag of electric planer, flat chisel and angle grinding machine trimming metal covering, expose silvery white metalluster, adopt the surface of brush to described weld metal face to carry out grinding and polishing process, obtain the riser bus bar repaired.
Claims (3)
1. the charged restorative procedure of aluminum electrolytic cell riser bus bar, is characterized in that, comprise the following steps:
A. injured surface process: cleaning riser bus bar injured surface, forms riser bus bar groove to be welded, arrange the shrinkage pool of more than 2 at riser bus bar injured surface;
B. graphite rod is installed: in the connecting hole of riser bus bar and short-circuit busbar, insert graphite rod;
C. the addition of aluminum electrolytic cell riser bus bar charged reparation flux is calculated: according to the Size calculation institute expense of riser bus bar groove to be welded;
D. installation mold: install aluminum electrolytic cell riser bus bar reparation mould at riser bus bar damage location;
E. weld: after the charged reparation flux burning of described aluminum electrolytic cell riser bus bar, obtain high temperature aluminum mixture liquid, flow into described riser bus bar groove to be welded, complete welding process, form weld metal face;
F. die sinking: after welding terminates, take off aluminum electrolytic cell riser bus bar reparation mould;
G. weld metal face process: remove preset graphite rod after cooling, processing connecting hole is to meeting process specifications, and the redundance of trimming metal covering and welding slag, effects on surface carries out grinding and polishing process, obtains the riser bus bar repaired.
2. the charged restorative procedure of aluminum electrolytic cell riser bus bar according to claim 1, is characterized in that, the described shrinkage pool in step a, comprises diameter that the degree of depth is the recessed and 15 ~ 25mm of being separated by the densely covered squamous hole of 4 ~ 6mm, shrinkage pool that the degree of depth is respectively 8 ~ 12mm.
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 in step e is the aluminum mixture liquid of temperature 1150-1180 DEG C.
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| CN104532296A (en) * | 2014-12-30 | 2015-04-22 | 贵州新峰机电设备有限公司 | Welding magnetic-reducing equipment for aluminum electrolysis cell under total current |
| CN104607616B (en) * | 2015-01-19 | 2017-01-18 | 阿坝铝厂 | Bus integral casting method under strong-current strong-magnetic-field conditions |
| CN104690255B (en) * | 2015-02-14 | 2016-08-24 | 山西华圣铝业有限公司 | A kind of aluminium bus of electrolyzer charged restorative procedure under strong magnetic field circumstance |
| CN105040031A (en) * | 2015-08-27 | 2015-11-11 | 武汉大学 | Non-power-outage repairing method for aluminum electrolysis cell short circuit busbar |
| CN105382483A (en) * | 2015-11-05 | 2016-03-09 | 郑州发祥铝业有限公司 | Electrolytic cell riser bus bar short circuit opening electrification repairing method |
| 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 |
| 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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Effective date of registration: 20191106 Address after: 100088 Aluminum Building, 62 Xizhimen North Street, Haidian District, Beijing Co-patentee after: WuHan University Patentee after: Aluminum Corporation of China Limited Address before: 730335, Gansu County, Lanzhou province Yongdeng County town bridge construction Ping Co-patentee before: WuHan University Patentee before: Lanzhou Liancheng Aluminum Industry Co., Ltd. |