CN112725840A - Digital twin control system of aluminum electrolysis cell - Google Patents
Digital twin control system of aluminum electrolysis cell Download PDFInfo
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- CN112725840A CN112725840A CN202011588070.5A CN202011588070A CN112725840A CN 112725840 A CN112725840 A CN 112725840A CN 202011588070 A CN202011588070 A CN 202011588070A CN 112725840 A CN112725840 A CN 112725840A
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- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 68
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 66
- 238000005868 electrolysis reaction Methods 0.000 title description 22
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 62
- 239000010959 steel Substances 0.000 claims abstract description 62
- 238000000034 method Methods 0.000 claims abstract description 33
- 230000008569 process Effects 0.000 claims abstract description 29
- 238000011217 control strategy Methods 0.000 claims abstract description 23
- 238000004364 calculation method Methods 0.000 claims abstract description 15
- 238000005265 energy consumption Methods 0.000 claims abstract description 8
- 238000005457 optimization Methods 0.000 claims abstract description 7
- 239000003792 electrolyte Substances 0.000 claims description 37
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 25
- 229910052799 carbon Inorganic materials 0.000 claims description 25
- 230000008859 change Effects 0.000 claims description 25
- 239000007788 liquid Substances 0.000 claims description 18
- 238000004458 analytical method Methods 0.000 claims description 15
- 239000004020 conductor Substances 0.000 claims description 15
- 238000006243 chemical reaction Methods 0.000 claims description 12
- 210000000078 claw Anatomy 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 9
- 238000009826 distribution Methods 0.000 claims description 8
- 239000000203 mixture Substances 0.000 claims description 3
- 238000013461 design Methods 0.000 abstract description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 16
- 230000005611 electricity Effects 0.000 description 15
- 238000004519 manufacturing process Methods 0.000 description 14
- 238000006722 reduction reaction Methods 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 4
- -1 oxygen ions Chemical class 0.000 description 4
- 239000002994 raw material Substances 0.000 description 4
- 230000009467 reduction Effects 0.000 description 4
- 229910002092 carbon dioxide Inorganic materials 0.000 description 3
- 238000010835 comparative analysis Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 238000003487 electrochemical reaction Methods 0.000 description 2
- 230000006870 function Effects 0.000 description 2
- 150000002500 ions Chemical class 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 238000004088 simulation Methods 0.000 description 2
- 238000011144 upstream manufacturing Methods 0.000 description 2
- KLZUFWVZNOTSEM-UHFFFAOYSA-K Aluminum fluoride Inorganic materials F[Al](F)F KLZUFWVZNOTSEM-UHFFFAOYSA-K 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
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- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 description 1
- 229910001634 calcium fluoride Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 239000003575 carbonaceous material Substances 0.000 description 1
- 238000012937 correction Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 238000003745 diagnosis Methods 0.000 description 1
- 230000003203 everyday effect Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000010801 machine learning Methods 0.000 description 1
- 229910001635 magnesium fluoride Inorganic materials 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 125000004430 oxygen atom Chemical group O* 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
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- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
- C25C3/00—Electrolytic production, recovery or refining of metals by electrolysis of melts
- C25C3/06—Electrolytic production, recovery or refining of metals by electrolysis of melts of aluminium
- C25C3/20—Automatic control or regulation of cells
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
- C25C3/00—Electrolytic production, recovery or refining of metals by electrolysis of melts
- C25C3/06—Electrolytic production, recovery or refining of metals by electrolysis of melts of aluminium
- C25C3/16—Electric current supply devices, e.g. bus bars
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- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
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- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Electrolytic Production Of Metals (AREA)
Abstract
The invention also provides a digital twin control system of the aluminum electrolytic cell, which constructs the twin equivalent model based on the aluminum electrolytic cell; calculating the resistance value of the anode equivalent circuit resistor in the twin equivalent model according to the process parameters; calculating each anode current, each upright post bus current, each cross-over bus current, each cathode steel bar current and tank voltage according to the twinning equivalent model with the determined resistance value by taking the series of currents as constraints; the method comprises the steps of determining a control strategy according to cell voltage and anode current of an electrolytic cell obtained in real time and cell voltage and anode current of the electrolytic cell obtained through calculation by taking the highest efficiency and the lowest energy consumption as optimization targets, and transmitting the control strategy to an electrolytic cell control system to implement optimal feeding control, so that the problem that the process parameters and the control strategy cannot be combined for optimal control in the prior art, and further the design target cannot be reached is solved.
Description
Technical Field
The invention relates to the technical field of intelligent manufacturing, in particular to a digital twin control system of an aluminum electrolysis cell.
Background
Cryolite-alumina molten salt electrolysis is the only industrial method for producing primary aluminumThe aluminum electrolysis cell is a container for raw aluminum production reaction. In an electrolytic tank, an alumina raw material is dissolved in a cryolite-aluminum fluoride melt with the temperature of about 950 ℃, and when direct current is introduced, oxygen ions lose electrons on the surface of an anode and are oxidized into oxygen atoms and react with carbon to generate CO2Gas is discharged, and aluminum ions in the melt are obtained on the interface of the cathode aluminum liquid to obtain electrons which are reduced into metallic aluminum, thereby realizing the production of the aluminum. In the cell, the current not only provides the power for alumina reduction, but is also the energy source for heating all materials through the electrolyte resistance. In a production plant, several hundred electrolytic cells are connected in series in a direct current power train, i.e. the electrolysis current is equal for all the cells. Currently, the current of the electrolytic cell series is between 300kA and 600 kA.
FIG. 1 shows a schematic diagram of a partial cell. The direct current of the upstream electrolytic cell is transmitted to the cell through an electricity inlet bus 1, transmitted to an A-side horizontal bus 3 through 4-7 upright post buses 2, and transmitted to a B-side horizontal bus 5 through a cross-over bus 4. An anode guide rod 6 lapped on the horizontal bus 3 at the side A and the horizontal bus 5 at the side B transmits current to an anode 8 through a steel claw 7, after the oxidation reaction of oxygen ions occurs on the interface of the anode 8 and an electrolyte melt 9, the current is transmitted to the interface of the electrolyte melt 9 and an aluminum liquid 10 through the electrolyte melt 9 in an ion transmission mode to carry out the reduction reaction of the aluminum ions, and then is sequentially transmitted to a cathode carbon block 11 and a cathode steel bar 12 through the aluminum liquid 10 in an electronic conduction mode, and then is collected on an electricity outlet bus 13 to enter the next electrolytic cell. The current is passed through the cell in the manner described above, creating a potential difference between point C on the incoming busbar 1 and point D on the outgoing busbar, the magnitude of this potential difference being the cell voltage V of the cell.
The aluminum oxide is used as a raw material for aluminum production, the aluminum oxide is continuously added into the electrolytic cell according to 4-7 areas at a time interval of about 90s through a control system of the electrolytic cell, and the cell voltage and series current are the only control signal sources for the aluminum electrolytic cell production. The pseudo resistance change of the electrolytic cell is obtained through the cell voltage and series current, and the concentration change of the alumina in the electrolyte is judged to adjust the adding amount of the alumina.
Due to the special environment of high temperature, strong corrosion and strong magnetic field, the process parameters such as the concentration of alumina, the electrolysis temperature, the two levels (the height of electrolyte and the height of aluminum liquid), the components of electrolyte and the like in the aluminum electrolysis production process cannot be monitored on line in real time, and are measured regularly in a routing inspection mode, and the working state of the electrolytic cell is judged manually based on the measurement result, so that the problem of inaccurate judgment is easy to occur.
In addition, the production process management of the current aluminum electrolysis cell, such as process adjustment, aluminum production and the like, is managed and operated by workshop technicians, workzone managers and the like more by experience, and process parameters and control strategies cannot be combined, so that the current production technical indexes of the current aluminum electrolysis cell are not ideal, for example, the current efficiency is generally 90-92%, the cell voltage is about 4.0V, the direct current power consumption is more than 13000kWh/t-Al, and the design target is not reached.
Disclosure of Invention
Based on the above, the invention aims to provide a digital twin control system for an aluminum electrolysis cell, which determines a control strategy by taking the highest efficiency and the lowest energy consumption as optimization targets and further controls the feeding of the aluminum electrolysis cell according to the control strategy.
To achieve the above object, the present invention provides a digital twin control system for an aluminum electrolysis cell, the system comprising:
the twin equivalent model building module is used for building a twin equivalent model based on the aluminum electrolytic cell;
the aluminum electrolytic cell includes: the system comprises an incoming bus, an A-side outgoing bus, a B-side outgoing bus, m upright buses, an A-side horizontal bus, a B-side horizontal bus, m bridging buses, 2n anode guide rods, 2n steel claws, 2n anodes, z cathode carbon blocks, 4z cathode steel bars and aluminum liquid; the power inlet bus is connected with the horizontal bus on the side A through m upright buses, m jumper buses are respectively connected with the horizontal bus on the side A and the horizontal bus on the side B, one end of the anode guide rod is connected with the anode through the steel claw, the other ends of n anode guide rods are respectively connected with the horizontal bus on the side A, the other ends of the remaining n anode guide rods are respectively connected with the horizontal bus on the side B, 2n anodes are connected with z cathode carbon blocks through the aluminum liquid, 1 cathode carbon block is embedded into 4 cathode steel rods, 2z cathode steel rods are connected with the power outlet bus on the side A, and the remaining 2z cathode steel rods are connected with the power outlet bus on the side B, wherein m, n and z are positive integers larger than 1;
the twin equivalent model includes: the device comprises m power-in bus resistors, m stand column bus resistors, n + m < -1 > A-side horizontal bus resistors, m cross-over bus resistors, n + m < -1 > B-side horizontal bus resistors, 2n anode equivalent circuit resistors, 4z cathode equivalent circuit resistors, 2z A-side power-out bus resistors, 2z B-side power-out bus resistors, a current source and a voltmeter, wherein the m power-in bus resistors are connected with the m stand column bus resistors;
the current source is respectively connected with the 2 z-th A-side power-out bus resistor, the 2 z-th B-side power-out bus resistor and the m-th power-in bus resistor, and the voltmeter is connected with the current source in parallel;
the power inlet bus bar between two adjacent upright post bus bars and the power inlet bus bar at one side end part are equivalent to a power inlet bus bar resistor;
the vertical column bus between the power inlet bus and the horizontal bus on the A side is equivalent to a vertical column bus resistance;
the horizontal bus bar on the A side between the adjacent anode guide rods and the horizontal bus bar on the A side between the upright post bus bar and the anode guide rods on the two adjacent sides are equivalent to the resistance of the horizontal bus bar on the A side;
the B-side horizontal bus between the adjacent anode guide rods and the B-side horizontal bus between the bridging bus and the anode guide rods on the two adjacent sides are equivalent to B-side horizontal bus resistance;
the bridging bus between the A-side horizontal bus and the B-side horizontal bus is equivalent to a bridging bus resistor;
the anode guide rod, the steel claw, the anode and the electrolyte melt with the volume between the anode and the aluminum liquid are equivalent to an anode equivalent circuit resistor;
one fourth of the cathode carbon blocks and one cathode steel bar are equivalent to a cathode equivalent circuit resistor;
the side A electricity outgoing bus between the adjacent cathode steel bars and the side A electricity outgoing bus at one side end are equivalent to side A electricity outgoing bus resistance;
the B side electricity outlet bus between the adjacent cathode steel bars and the B side electricity outlet bus at one side end part are equivalent to B side electricity outlet bus resistance;
the acquisition module is used for acquiring process parameters, series current, cell voltage of the electrolytic cell, each anode current, each cathode steel bar current and each upright post bus current in real time;
the first calculation module is used for calculating the resistance value of the anode equivalent circuit resistor in the twin equivalent model according to the process parameters;
the second calculation module is used for calculating each anode current, each upright post bus current, each cross-over bus current, each cathode steel bar current and the cell voltage according to the twin equivalent model with the determined resistance value by taking the series of currents as constraints;
and the control strategy calculation module is used for determining a control strategy according to the cell voltage and the anode current of the electrolytic cell obtained in real time and the cell voltage and the anode current of the electrolytic cell obtained by calculation with the highest efficiency and the lowest energy consumption as optimization targets, and transmitting the control strategy to the electrolytic cell control system for control.
Optionally, the system further comprises:
and the electrolytic cell running state determining module is used for comparing the obtained cell voltage with the calculated cell voltage to determine the whole electrolytic cell running state and the local electrolytic cell running state.
Optionally, the system further comprises:
and the frequency domain analysis module is used for carrying out frequency domain analysis according to the obtained anode currents and cell voltages and the calculated anode currents and cell voltages.
Optionally, the system further comprises:
and the fluctuation characteristic analysis module is used for carrying out fluctuation characteristic analysis according to the obtained anode currents and the calculated anode currents.
Optionally, the system further comprises:
and the aluminum leakage fault and positioning module is used for carrying out comparative analysis according to the obtained current on each cathode steel bar and the calculated current on each cathode steel bar, and predicting the position of the damage or aluminum leakage fault on the corresponding cathode carbon block.
Optionally, the system further comprises:
and the pole change analysis module is used for analyzing according to the obtained anode currents and the calculated anode currents, and determining the current increasing process of the new anode, the current change size of the adjacent anode in the pole change process and the anode current change size of the adjacent area in the pole change process.
Optionally according to
Calculating the bus current of each upright column, the anode current and the cathode steel bar current; wherein m, 2n and 4z respectively represent the number of upright buses, anodes and cathode steel bars on the electrolytic cell; i isLineRepresents a series of currents, IkRepresenting the current of the kth branch of node j.
Optionally, the anode circuit equivalent resistance is determined from anode stem resistance, anode resistance, bubble resistance, electrolyte resistance, reaction resistance, and over resistance.
Optionally, the anode guide rod resistance is sized by conductor material resistivity, temperature coefficient of resistance, geometry, and conductor temperature distribution.
Optionally, the process parameters include: the electrical resistivity of the carbon anode, the molecular ratio of the electrolyte, the electrolyte composition, the electrolyte temperature, and the anode on-time.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects:
the invention also provides a digital twin control system of the aluminum electrolytic cell, which constructs the twin equivalent model based on the aluminum electrolytic cell; calculating the resistance value of the anode equivalent circuit resistor in the twin equivalent model according to the process parameters; calculating each anode current, each upright post bus current, each cross-over bus current, each cathode steel bar current and tank voltage according to the twinning equivalent model with the determined resistance value by taking the series of currents as constraints; the method comprises the steps of determining a control strategy according to the cell voltage and the anode current of the electrolytic cell obtained in real time and the cell voltage and the anode current of the electrolytic cell obtained through calculation by taking the highest efficiency and the lowest energy consumption as optimization targets, and transmitting the control strategy to an electrolytic cell control system to implement optimal feeding control, so that the problem that the process parameters and the control strategy cannot be combined for control in the prior art is solved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
FIG. 1 is a schematic view of a partial structure of an electrolytic cell according to an embodiment of the present invention;
FIG. 2 is a partial structure diagram of a twin equivalent model according to an embodiment of the present invention;
FIG. 3 is a diagram of a digital twin control system for an aluminum electrolysis cell according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The invention aims to provide a digital twin control system for an aluminum electrolysis cell, which determines a control strategy by taking the highest efficiency and the lowest energy consumption as optimization targets and further controls the feeding of the aluminum electrolysis cell according to the control strategy.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
In an electrolysis plant, all cells are connected in series to a series of electric currents. The method comprises the steps of transmitting current of an upstream electrolytic cell to a current electrolytic cell through an incoming bus at the bottom of the cell, transmitting the current to horizontal buses at two sides of the current electrolytic cell through m upright buses and m bridging buses, namely an A-side horizontal bus and a B-side horizontal bus, then transmitting the current to a corresponding anode through 2n anode guide rods, generating carbon dioxide gas after anode reaction at an anode-electrolyte melt interface, transmitting the current to the electrolyte-aluminum liquid interface through an electrolyte melt in an ion conduction mode to perform cathode reaction to produce aluminum liquid and current, transmitting the current to a cathode steel bar through a cathode carbon block in an electron conduction mode, finally converging the current to an A-side outgoing large bus and a B-side outgoing large bus at the bottom of the cell, and then transmitting the current to a downstream electrolytic cell.
As shown in fig. 3, the present invention also provides a digital twin control system for an aluminum electrolysis cell, the system comprising: the system comprises a twin equivalent model building module 301, an obtaining module 302, a first calculating module 303, a second calculating module 304 and a control strategy calculating module 305.
The twin equivalent model building module 301 is used for building a twin equivalent model based on an aluminum electrolysis cell; the acquisition module 302 is used for acquiring process parameters, series current, cell voltage of the electrolytic cell, each anode current, each cathode steel bar current and each upright post bus current in real time; the first calculating module 303 is configured to calculate a resistance value of the anode equivalent circuit resistor in the twin equivalent model according to a process parameter; the second calculating module 304 is configured to calculate each anode current, each pillar bus current, each jumper bus current, each cathode steel bar current, and a cell voltage according to a twin equivalent model with a determined resistance value, with the series of currents as constraints; the control strategy calculation module 305 is used for determining a control strategy according to the cell voltage and each anode current of the electrolytic cell obtained in real time and the cell voltage and each anode current of the electrolytic cell obtained through calculation by taking the highest efficiency and the lowest energy consumption as optimization targets, and transmitting the control strategy to an electrolytic cell control system for implementing control. In this example, the series current was 500 kA.
In this embodiment, the aluminum electrolytic cell includes: the system comprises an incoming bus, an A-side outgoing bus, a B-side outgoing bus, m upright buses, an A-side horizontal bus, a B-side horizontal bus, m bridging buses, 2n anode guide rods, 2n steel claws, 2n anodes, z cathode carbon blocks, 4z cathode steel bars and aluminum liquid; the power supply system comprises a power supply bus, a column bus, an anode guide rod, a cathode carbon block, a bridge connection bus, a column bus, an upright bus, a B side horizontal bus, a bridge connection bus, a steel claw and 4 cathode steel bars, wherein the power supply bus is connected with the A side horizontal bus through m upright buses, m bridge connection buses are respectively connected with the A side horizontal bus and the B side horizontal bus, one end of the anode guide rod is connected with the anode through the steel claw, the other ends of n anode guide rods are respectively connected with the A side horizontal bus, the other ends of the remaining n anode guide rods are respectively connected with the B side horizontal bus, 2n anodes are connected with z cathode carbon blocks through aluminum liquid, 1 cathode carbon block is embedded into 4 cathode steel bars, 2z cathode steel bars are connected with the A side power supply bus, and the remaining 2z cathode steel bars are connected with the B side power supply bus, and m, n and z are. FIG. 1 discloses a partial structure diagram of an electrolytic cell, which comprises an incoming bus, an A-side outgoing bus, a B-side outgoing bus, 2 upright buses, 16 anode guide rods, 16 anodes, 16 cathode carbon blocks, 16 electrolyte melts and 32 cathode steel bars.
In this embodiment, the twin equivalent model includes: the device comprises m power-in bus resistors, m stand column bus resistors, n + m < -1 > A-side horizontal bus resistors, m cross-over bus resistors, n + m < -1 > B-side horizontal bus resistors, 2n anode equivalent circuit resistors, 4z cathode equivalent circuit resistors, 2z A-side power-out bus resistors, 2z B-side power-out bus resistors, a current source and a voltmeter, wherein the m power-in bus resistors are connected with the m stand column bus resistors; the current source is respectively connected with the 2 z-th A-side power-out bus resistor, the 2 z-th B-side power-out bus resistor and the m-th power-in bus resistor, and the voltmeter is connected with the current source in parallel; the power inlet bus bar between two adjacent upright post bus bars and the power inlet bus bar at one side end part are equivalent to a power inlet bus bar resistor; the vertical column bus between the power inlet bus and the horizontal bus on the A side is equivalent to a vertical column bus resistance; the horizontal bus bar on the A side between the adjacent anode guide rods and the horizontal bus bar on the A side between the upright post bus bar and the anode guide rods on the two adjacent sides are equivalent to the resistance of the horizontal bus bar on the A side; the B-side horizontal bus between the adjacent anode guide rods and the B-side horizontal bus between the bridging bus and the anode guide rods on the two adjacent sides are equivalent to B-side horizontal bus resistance; the bridging bus between the A-side horizontal bus and the B-side horizontal bus is equivalent to a bridging bus resistor; the anode guide rod, the steel claw, the anode and the electrolyte melt with the volume between the anode and the aluminum liquid are equivalent to an anode equivalent circuit resistor; one fourth of the cathode carbon blocks and one cathode steel bar are equivalent to a cathode equivalent circuit resistor; the side A electricity outgoing bus between the adjacent cathode steel bars and the side A electricity outgoing bus at one side end are equivalent to side A electricity outgoing bus resistance; and equivalently enabling the B-side electricity outlet bus between the adjacent cathode steel bars and the B-side electricity outlet bus at one side end part to form B-side electricity outlet bus resistance.
The twin equivalent model comprises a series of nodes, and specifically comprises the following steps: taking the incoming bus as a high potential node, taking the connecting position of the A-side outgoing bus and the B-side outgoing bus as a low potential node, and taking the aluminum liquid as a middle equipotential node; connecting points at which two ends of each upright post bus are respectively connected with the power inlet bus and the A-side horizontal bus are called nodes; connecting points of a plurality of bridging buses with the A-side horizontal bus and the B-side horizontal bus are called nodes; connecting points of all the anode guide rods which are lapped on the horizontal bus on the side A and the horizontal bus on the side B are called nodes; and connecting points of the cathode steel bars, the A-side power-off bus and the B-side power-off bus at the bottom of the cell are called nodes.
All the upright post bus resistors in the twin equivalent model are connected in parallel, and the sum of the currents on all the upright post bus resistors is equal to the series current; all the bridging bus resistors are connected in parallel; all the anode equivalent circuit resistors are connected in parallel, and the sum of the currents on all the anode equivalent circuit resistors is equal to the series current; all the cathode equivalent circuit resistors are connected in parallel, and the sum of the currents on all the cathode equivalent circuit resistors is equal to the series current; all the incoming bus resistors are connected in series; all the A side outgoing electric bus resistors are connected in series with each other, all the B side outgoing electric bus resistors are connected in series with each other, and the A side outgoing electric bus resistors are connected in parallel with the B side outgoing electric bus resistors.
FIG. 2 is a twin equivalent model of a part of a 500kA electrolytic cell corresponding to FIG. 1, according to an embodiment of the present invention, comprising: the power input bus 201, the A-side horizontal bus 202, the B-side horizontal bus 206, the aluminum liquid 204, the A-side power output bus 203 and the B-side power output bus 205 are divided into a plurality of nodes by the upright post bus 207, the crossover bus 208, the anode equivalent circuit resistor 209 and the cathode equivalent circuit resistor 210, and each node is marked by "·". On the aluminum liquid 204, because of its large cross-sectional size, the whole aluminum liquid is regarded as an equipotential body with equal potential, so that it means that there is no resistance between all nodes on the line of the aluminum liquid 204, and there is resistance between other nodes. The potential difference between the high potential node of the incoming bus and the low potential node of the outgoing bus is measured by the voltmeter 211, and the potential difference is the cell voltage of the current electrolytic cell.
The anode circuit equivalent resistance is determined according to the anode guide rod resistance, the anode resistance, the bubble resistance, the electrolyte resistance, the reaction resistance and the over-resistance, and specifically comprises the following steps:
the anode guide rod resistor comprises an anode guide rod and a resistor of a steel claw metal conducting part connected with the anode guide rod, and the size of the anode guide rod resistor is determined by the resistivity of a conductor material, the resistance temperature coefficient, the geometric structure and the conductor temperature distribution.
The anode resistance is a resistance formed by an anode, and the size of the anode resistance is determined by the resistivity of a carbon material, the resistance temperature coefficient, the anode geometric structure and the anode temperature distribution. Since the anode resistance is not only related to the resistivity and temperature distribution of the carbon anode, it is gradually consumed during the reaction and thus slowly varies with time.
The bubble resistance is the equivalent resistance formed by anode bubbles covering the surface of the anode in the anode reaction process due to the reduction of the effective working area of the anode and the reduction of the conductive part of the electrolyte, and the bubble resistance is formed by the generation of the anode bubblesShape change during formation, aggregation and detachment and electrolyte resistivity determination, and thus CO2The gas generation, accumulation and discharge are closely related to the shape of the bubbles, that is, the electrolyte composition, the alumina concentration, and the temperature.
The electrolyte resistance is formed by the electrolyte melt part between the anode and the cathode carbon block, the size of the electrolyte resistance is determined by the electrolyte resistivity and the distance between the anode and the cathode, and the electrolyte resistivity is determined by the electrolyte component and the temperature distribution.
The reaction resistance is an equivalent resistance formed by electromotive force required by electrochemical reaction for reducing the raw material aluminum oxide into aluminum, and the magnitude of the reaction resistance is determined by standard electromotive force of the electrochemical reaction, electrolysis temperature, aluminum oxide concentration in electrolyte and passing current. Since the reaction electromotive resistance is related to the concentration of alumina, it is varied during the electrolysis.
The over-resistance is an equivalent resistance formed by an over-potential required by the reduction of the alumina at a certain speed, and the magnitude of the over-resistance is determined by the current magnitude of the anode reaction and the alumina concentration.
The size of the bus bar resistance of the upright post is determined according to the resistivity and the geometric dimension of the conductor material. The cathode equivalent circuit resistance is determined by the resistivity of the material, the temperature distribution of the material and the geometric dimension.
In all of these resistors, except the anode equivalent circuit resistance, the other resistors are relatively fixed and are only related to the geometry, resistivity and temperature of the electrical conductor.
According to the above analysis, except the anode equivalent circuit resistance, other resistances are determined by calculation according to the material property, shape and conductor temperature, and the specific calculation formula is as follows:
wherein R is conductor resistance at conductor temperature T, L is conductor length, and S is conductor cross-sectional area，ρTIs the resistivity of the conductor material at temperature T, which is a function of temperature, as follows:
ρT＝ρ0[1+α(T-T0)] (2)；
where ρ is0Is a reference temperature T0The resistivity of (a) is a temperature coefficient of resistivity.
For the anode equivalent circuit resistance, the change characteristic of the anode in the whole life cycle of adding a new anode into an electrolytic cell for working and taking the anode out of the electrolytic cell when replacing is calculated according to field measurement or a computer numerical simulation method, the change characteristic is a complex function of electrolyte components, alumina concentration, electrolysis temperature, polar distance and time, the anode equivalent circuit resistance can be established based on process parameters by machine learning methods such as a neural network, a support vector machine and the like, and the specific formula is as follows:
wherein R isaeRepresenting the anode equivalent circuit resistance, RMRepresenting the resistance, p, of the metal part of the anode circuitCRepresents the resistivity of the carbon anode, rcrWhich represents the molecular ratio of the electrolyte,
cLiF、
respectively represent the excess AlF in the electrolyte3、CaF2、MgF2LiF and Al2O3Concentration of (d)acRepresents the pole pitch; t represents the electrolyte temperature and T represents the anode on time.
Because the pole changing operation exists almost every day, after the old anode is taken out, the equivalent circuit resistance of the anode does not exist; after the new anode is replaced, an insulating electrolyte solidified layer is formed on the surface of the anode, the solidified layer is dissolved out after several hours, the anode starts to conduct electricity, the conductivity of the anode is gradually increased along with the rise of the temperature, and the new anode works normally after about 20 hours. Therefore, the anode equivalent circuit resistance changes with time.
In the case where the equivalent resistance of the anode circuit is obtained by the expression (3), and the other resistances in fig. 2 are obtained, a current conservation equation system is established for all the nodes in fig. 2 according to kirchhoff's current law:
wherein n isjRepresenting the number of branches connected with the jth node in the twin equivalent model, IkRepresenting the current of the kth branch of node j.
Under the constraint condition of a known series current (500kA), the sum of all the upright post bus currents is equal to the series current, the sum of all the anode currents is equal to the series current, and the sum of all the cathode steel bar currents is equal to the series current, namely, an equation system is provided:
wherein m, 2n and 4z respectively represent the number of upright buses, anodes and cathode steel bars on the electrolytic cell; i isLineRepresents a series of currents, IkRepresenting the current of the kth branch of node j.
And obtaining the current on each upright post bus, the anode and the cathode steel bar and the current of any branch in the circuit network by solving a connected equation set formed by the equations (4) and (5).
Likewise, using kirchhoff's voltage law, a system of equations is established for each loop in the twinning equivalent model shown in fig. 2:
wherein p iscRepresenting the total number of resistors, V, on the c-th loopkRepresenting the voltage drop across the kth resistor on the c-loop. By solving equationsAnd (4) obtaining the cell voltage of the electrolytic cell and the voltage drop on each resistor.
Comparing the current and the cell voltage obtained by the calculation in the steps (4) to (6) with the current and the cell voltage measured on line or off line in real time, further verifying the correctness of the twin equivalent model and determining the state and the local fault of the electrolytic cell; the change of the anode current of the area can be judged and predicted by comparing the anode current and the measurement in the pole changing process (one electrolytic tank is provided with a plurality of feeding points, each feeding point provides alumina for a plurality of anodes, the electrolytic tank is generally divided into a plurality of areas according to the feeding points), and then a control strategy is determined to be given to an electrolytic tank control system according to the change of the anode current of the area, so that the electrolytic tank control system realizes the optimized control of feeding and the like according to the control strategy; the current on the corresponding branch on each node, particularly the current distribution on the anode and the change thereof, can be calculated by changing the size of the incoming bus, the layout and the size of the upright bus and the structure and the size of the horizontal bus, so that the structural design of the conductor of the cell can be optimized.
As an embodiment, the system of the present invention further includes:
and the electrolytic cell operation state determining module 306 is used for comparing the acquired cell voltage with the calculated cell voltage to determine the whole operation state and the local operation state of the electrolytic cell.
As an embodiment, the system of the present invention further includes:
and the frequency domain analysis module 307 is configured to perform frequency domain analysis according to the obtained anode currents and cell voltages and the calculated anode currents and cell voltages, diagnose a local fault state and a global fault state of the electrolytic cell entity, determine a fault diagnosis result, and provide a suggestion for solving a fault.
As an embodiment, the system of the present invention further includes:
and the correction module is used for performing comparative analysis according to the obtained anode current and cell voltage and the calculated anode current and cell voltage so as to correct the resistance value of the anode equivalent circuit resistor.
As an embodiment, the system of the present invention further includes:
the fluctuation feature analysis module 308 is configured to perform fluctuation feature analysis according to the obtained anode currents and the calculated anode currents, diagnose a low-voltage anode effect phenomenon occurring on the anode, coordinate the electrolytic cell control system to eliminate the low-voltage anode effect on the anode in a manner of feeding and sinking the anode, diagnose precipitation features of anode bubbles on the anode and a regional alumina concentration variation trend, further diagnose possible feeder faults in the region, prompt and warn maintenance of the feeder, and diagnose anode long-bag short circuit, anode breakage, and anode connection faults occurring on the anode, and prompt and warn and process the anode.
As an embodiment, the system of the present invention further includes:
and the aluminum leakage fault and positioning module 309 is configured to perform comparative analysis according to the obtained current on each cathode steel bar and the calculated current on each cathode steel bar, and predict a position of a damage or aluminum leakage fault occurring on the corresponding cathode carbon block and a position of a tank bottom precipitate.
As an embodiment, the system of the present invention further includes:
and the pole change analysis module 310 is configured to analyze each obtained anode current and each calculated anode current, determine a current increase process of a new anode in the pole change process, a current change size of an adjacent anode in the pole change process, and a change size of an anode current in an adjacent area, and provide a basis for adjusting an alumina charging strategy in the pole change process, ensuring uniform alumina concentration, pole change operation, and the like.
The invention can also compare, simulate and analyze the current of each anode, each steel bar and each upright post bus on the electrolytic cell according to the detected current of each anode, each steel bar and each upright post bus on the electrolytic cell and the calculated current of each anode, each steel bar and each upright post bus on the electrolytic cell, thereby realizing the rapid simulation calculation of the electrolytic cell entity, optimizing the control of the electrolytic production process, diagnosing the integral and local faults of the electrolytic cell, and providing suggestions for optimizing process parameters and production management, thereby improving the electrolytic current efficiency, reducing the energy consumption and the emission, and ensuring the safe operation of the electrolytic production.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other.
The principle and the implementation of the present invention are explained herein by applying specific examples, and the above description of the embodiments is only used to help understand the core idea of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (10)
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