CN113337852A - Method for online production of aluminum intermediate alloy liquid by aluminum electrolysis cell - Google Patents
Method for online production of aluminum intermediate alloy liquid by aluminum electrolysis cell Download PDFInfo
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- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
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- C25C3/36—Alloys obtained by cathodic reduction of all their ions
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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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
- C25C7/00—Constructional parts, or assemblies thereof, of cells; Servicing or operating of cells
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- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/026—Alloys based on aluminium
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- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/03—Making non-ferrous alloys by melting using master alloys
Abstract
The invention relates to a method for producing aluminum intermediate alloy liquid on line by an aluminum electrolytic cell, belonging to the technical field of aluminum intermediate alloy preparation methods. The method for producing the aluminum intermediate alloy on line by the aluminum electrolytic cell takes the running electrolytic cell as a main body, materials are added into the electrolytic cell, part of aluminum oxide and an anode carbon block are subjected to electrochemical reaction under the action of direct current by utilizing high-temperature melting materials in the electrolytic production process, so that molten aluminum intermediate alloy liquid is obtained, and the intermediate alloy liquid can be uniformly mixed due to the disturbance action of a magnetic field. By adopting the method, the problems of internal segregation, surface quality defect, casting cost, remelting burning loss, remelting energy consumption, remelting labor cost, safety and the like of the components of the aluminum intermediate alloy can be effectively solved, the elastic production is realized, and the emission of waste gas pollutants is reduced, so that the purposes of energy conservation, emission reduction, energy conservation and consumption reduction are achieved, and the method has remarkable social benefits and environmental benefits.
Description
Technical Field
The invention relates to the technical field of online production of aluminum master alloy liquid by an aluminum electrolytic cell, in particular to a method for online production of aluminum master alloy liquid by an aluminum electrolytic cell.
Background
The traditional aluminum intermediate alloy is an alloy prepared by taking aluminum as a matrix and melting the aluminum and other metals or nonmetals through heating, and is widely applied to adjustment and control of chemical components and structures of cast aluminum alloy or wrought aluminum alloy. The mass fraction of the main alloying elements may exceed 50%. The aluminum intermediate alloy prepared by the traditional method has the problems of internal segregation of components, surface quality defects, increased casting cost, remelting loss, increased remelting energy consumption, increased remelting labor cost and high-temperature melting safety, wherein the internal segregation comprises intragranular segregation, gravity segregation and inverse segregation; and moreover, the emission of waste gas pollutants is increased, and the aims of energy conservation, emission reduction, energy conservation and consumption reduction of enterprises cannot be achieved. Meanwhile, the metal or nonmetal used for preparing the intermediate alloy has high purity and high price, and is not beneficial to reducing the production cost.
Disclosure of Invention
In order to solve the problems, the invention provides a method for producing an aluminum intermediate alloy liquid on line by using an aluminum electrolytic cell.
The technical scheme adopted by the invention is as follows:
a method for producing an aluminum intermediate alloy liquid on line by an aluminum cell takes an operating electrolytic cell as a main body, materials are added into the electrolytic cell after the initial metal content in the primary aluminum liquid is determined, and the materials added into the electrolytic cell are materials containing a certain amount of known metal element elements; the material is melted in the aluminum liquid, and after the aluminum liquid is taken again to analyze the content of metal elements, the weight of the primary aluminum liquid is calculated; calculating the weight of the materials to be supplemented according to the required target content of the metal elements in the aluminum intermediate alloy liquid, the weight of the primary aluminum liquid and the initial content of the metal elements in the primary aluminum liquid; adding materials to be supplemented into the electrolytic cell from an aluminum outlet or a flue end of the electrolytic cell to obtain molten aluminum intermediate alloy liquid, directly conveying the molten aluminum intermediate alloy liquid to a melting furnace at a casting position, and directly batching the molten aluminum intermediate alloy liquid into a subsequent batching process; wherein the material added into the electrolytic bath comprises at least one of metallic iron, metallic chromium, metallic manganese, industrial silicon, metallic copper, metallic strontium, metallic titanium, metallic zirconium, metallic vanadium, metallic magnesium and metallic zinc or waste metal containing the elements.
Preferably, the method for producing the aluminum master alloy on line by the aluminum electrolytic cell further comprises a process of confirming the composition of the master alloy liquid; if the actual content of the metal elements in the aluminum intermediate alloy liquid is larger than the target content of the metal elements, adding the original aluminum liquid for diluting; if the actual content of the metal elements in the aluminum master alloy liquid is less than the target content of the metal elements, the materials continuously added into the electrolytic cell are materials containing a certain amount of known metal elements.
Preferably, the method for producing the aluminum master alloy in the aluminum electrolysis cell on line further comprises the following supplementing process of metal elements; calculating the weight of materials to be supplemented every day according to the weight of the daily aluminum production intermediate alloy liquid of the electrolytic cell, the target content of metal elements in the aluminum intermediate alloy liquid and the content of metal elements in the additive materials, drying and removing water, and adding the materials into the electrolytic cell from an aluminum outlet or a flue end of the electrolytic cell for multiple times.
Preferably, the materials added into the electrolytic cell are dried and then added into the electrolytic cell from the aluminum outlet or the flue end of the electrolytic cell for multiple times.
Preferably, the current intensity of the electrolytic cell is 300-600 kA.
Preferably, the electrolytic reaction is carried out at 930-970 ℃, and the reaction temperature and the uninterrupted operation mode of the electrolytic cell provide enough heat for materials added into the electrolytic cell to meet the melting requirement of the added materials, which is equivalent to the process of gradually dissolving the solute in the solvent.
Preferably, the direction of the current is fixed and the magnetic field is fixed during the electrolysis of the electrolytic cell, and when the direction of the current is perpendicular to the magnetic field after the current is introduced through the anode, the molten aluminum master alloy solution can be uniformly mixed along with the movement and circulation of electrons according to Tesla's law.
An aluminum intermediate alloy liquid is prepared by the method for producing the aluminum intermediate alloy on line by the aluminum electrolysis cell, and the target content of metal elements in the aluminum intermediate alloy liquid is 1 or more than 1 of the following percentage of metal elements; 0-10% of iron element; 0-3% of chromium element; 0-3% of manganese element; 0-10% of silicon element; 0-10% of copper element; 0-2% of strontium element; 0 to 1.5% of titanium element; 0-2% of zirconium element; 0-2% of vanadium element; 0-5% of magnesium element; 0-6% of zinc element; wherein the percentage of the aluminum element is 50-95 percent, the total percentage of the aluminum element and the metal element is more than or equal to 95 percent, and the balance is inevitable impurities.
The invention has the beneficial effects that:
the method for producing the aluminum intermediate alloy on line by adopting the aluminum electrolytic cell can effectively solve the problems of internal segregation, surface quality defect, casting cost, remelting burning loss, remelting energy consumption, remelting labor cost, safety and the like of the components of the aluminum intermediate alloy, realizes elastic production, and reduces the emission of waste gas pollutants, thereby achieving the purposes of energy conservation, emission reduction, energy conservation and consumption reduction, and having remarkable social benefit and environmental benefit.
Detailed Description
The technical solutions in the embodiments of the present invention are clearly and completely described below. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without any inventive step, are within the scope of the present invention.
To further illustrate the specific addition mode and addition amount of the metal elements in detail, the present invention gives the following examples:
example 1:
A. selection of an electrolytic cell: an electrolytic cell which is normal in operation and has no damage phenomenon is selected, the current intensity is 400kA, and the temperature of the electrolytic cell is 950 ℃.
B. Inventory of aluminum liquid by weight: taking an aluminum sample in a selected electrolytic cell, analyzing chemical components, determining the original Cu element content of the primary aluminum liquid to be 0.0005%, adding 2kg of materials with the Cu element content of 99.9%, and calculating the weight of the added Cu elements as follows: 2kg × 99.9% =1.998 kg, and after 24 hours, the chemical composition of the aluminum sample is again analyzed to be 0.0059%, according to the change of the Cu element in the two chemical composition analysis results of the aluminum sample: changing the weight of the aluminum liquid in the electrolytic cell from 0.0005% to 0.0059%, and calculating the weight of the added Cu element to be 1.998 kg: 1.998 kg/kg (0.0059% to 0.0005%) =37000 kg/kg. Wherein, by utilizing high-temperature melting materials in the electrolytic production process, the alumina and the anode carbon block are subjected to electrochemical reaction under the action of direct current: alumina dissolves as charged particles in the electrolyte: 2Al2O3=4Al3++6O2-(ii) a Oxygen particles lose electrons on the surface of the carbon anode: 4O2- -4e-=O2×) ×; and (3) obtaining electrons from aluminum ions on the surface of the aluminum liquid cathode: al (Al)3++3e-=Al。
C. Calculating the weight of the materials required to be added: according to the target content of the Cu element in the intermediate alloy liquid of 0.2750 percent, the weight of the primary aluminum liquid of the electrolytic cell of 37000kg and the content of the Cu element in the aluminum liquid in the secondary sampling of 0.0059 percent, the weight of the Cu element to be added is calculated as follows: (0.275% -0.0059%) x 37000kg =99.567 kg, and the weight of the materials to be added is calculated according to the content of the Cu element in the materials to be added subsequently as 50%: 99.567 kg were divided by 50% =199.13 kg.
D. Adding materials: 199.13 kg of the required weight of the feeding materials are weighed and are dried and then fed into the electrolytic cell from the aluminum outlet or the flue end of the electrolytic cell for multiple times.
E. Confirmation of the composition of the master alloy liquid: and (4) after all the materials are added for 24 hours, taking an aluminum sample for chemical composition analysis, confirming whether the Cu content meets the requirement of 0.275 percent, and repeating C, D steps if the Cu content is less than the target value. If the Cu content exceeds the target value of 0.275%, selecting the raw aluminum liquid of the electrolytic cell with the Cu content of 0.0005% for dilution, specifically, calculating the weight of the required diluted aluminum liquid according to the excess value, the calculated aluminum amount of the intermediate alloy liquid and the Cu content of the electrolytic cell with the lower Cu content, and respectively mixing the intermediate alloy liquid and the diluted aluminum liquid during aluminum discharging. If the requirement is met, the aluminum is planned according to the aluminum discharge plan and transported to the use site.
F. Subsequent Cu element supplement: the subsequent daily output of the tank is 3100kg, the original Cu element content of the primary aluminum liquid is 0.0005%, the target value of the intermediate alloy liquid is 0.275%, and the Cu element content of the subsequent added materials is 50%, and the Cu content required to be added every day is calculated as follows: 3100kg x (0.275% -0.0005%)/50% =17kg, weighing the required weight of the additive, drying, adding into the electrolytic cell from the aluminum outlet or flue end of the electrolytic cell for multiple times, and keeping the Cu content at a stable state of 0.275%.
Example 2:
A. selection of an electrolytic cell: an electrolytic cell which is normal in operation and has no damage phenomenon is selected, the current intensity is 400kA, and the temperature of the electrolytic cell is 950 ℃.
B. Inventory of aluminum liquid by weight: taking an aluminum sample in a selected electrolytic cell, analyzing chemical components, determining the original Cu element content of the primary aluminum liquid to be 0.0005%, adding 2kg of materials with the Cu element content of 99.9%, and calculating the weight of the added Cu elements as follows: 2kg × 99.9% =1.998 kg, and after 24 hours, the chemical composition of the aluminum sample is again analyzed to be 0.0059%, according to the change of the Cu element in the two chemical composition analysis results of the aluminum sample: changing the weight of the aluminum liquid in the electrolytic cell from 0.0005% to 0.0059%, and calculating the weight of the added Cu element to be 1.998 kg: 1.998 kg/kg (0.0059% to 0.0005%) =37000 kg/kg.
C. Calculating the weight of the materials required to be added: according to the target content of Cu element in the intermediate alloy liquid of 0.275 percent, the target content of Fe element of 0.25 percent, the weight of the primary aluminum liquid of the electrolytic bath of 37000kg, the original content of Cu element in the primary aluminum liquid of 0.0005 percent and the original content of Fe element in the primary aluminum liquid of 0.07 percent, the weight of the Cu element to be added is calculated as follows: (0.275% to 0.0005%) x 37000kg =99.56 kg, and the weight of the materials to be added is calculated according to the Cu content of 50% in the subsequently added materials: 99.567 kg were divided by 50% =199.134 kg. Calculating the weight of Fe elements required to be added as follows: (0.25% -0.07%) x 37000kg =66.6 kg, and the weight of the materials to be added is calculated according to the content of the Fe element in the subsequently added materials as 80%: 66.6 kg were divided by 80% =83.25 kg.
D. Adding materials: weighing 199.134 kg of Cu-containing feeding materials and 83.25 kg of Fe-containing feeding materials, drying, and feeding into the electrolytic cell from an aluminum outlet or a flue end of the electrolytic cell.
E. Confirmation of the composition of the master alloy liquid: and (3) taking an aluminum sample 24 hours after the materials are added, carrying out chemical composition analysis, confirming whether the Cu content meets the requirement of 0.275 percent or not and whether the Fe content meets the requirement of 0.25 percent or not, and repeating C, D steps if the Cu content is less than the target value. If the Cu exceeds the target value of 0.275 percent, selecting the raw aluminum liquid of the electrolytic cell with the Cu content of 0.0005 percent for dilution, specifically, calculating the weight of the required diluted aluminum liquid according to the excess value, the calculated aluminum amount of the intermediate alloy liquid and the Cu content of the electrolytic cell with the lower Cu content, and respectively mixing the intermediate alloy liquid and the diluted aluminum liquid during aluminum discharging. If Fe exceeds 0.25%, selecting the raw aluminum liquid of the electrolytic cell with lower Fe content of 0.07% for dilution, and specifically, calculating the weight of the required diluted aluminum liquid according to the excess value, the calculated aluminum amount of the intermediate alloy liquid and the Fe content of the electrolytic cell with lower Fe content, and respectively mixing the intermediate alloy liquid and the diluted aluminum liquid during aluminum discharging. If the requirement is met, the aluminum is planned according to the aluminum discharge plan and transported to the use site.
F. Subsequent supplement of Cu and Fe elements: and calculating the Cu content required every day according to the daily output of the bath of 3100kg, the target Cu content of the intermediate alloy liquid of 0.275 percent and the Fe content of 0.25 percent, the Cu element content of the subsequently added materials of 50 percent and the Fe element content of the subsequently added materials of 80 percent: 3100kg x (0.275% -0.0005%)/50% =17kg, Fe-containing material required per day: 3100kg x (0.25% -0.07%)/+ 80% =6.98kg of the required weight of the added materials are weighed, dried and then added into the electrolytic cell from the aluminum outlet or the flue end of the electrolytic cell for a plurality of times, and the stable state of 0.275% of Cu and 0.25% of Fe is maintained.
Example 3
A. Selection of an electrolytic cell: an electrolytic cell which is normal in operation and has no damage phenomenon is selected, the current intensity is 400kA, and the temperature of the electrolytic cell is 950 ℃.
B. Inventory of aluminum liquid by weight: taking an aluminum sample in a selected electrolytic cell, analyzing chemical components, determining the original Cu element content of the primary aluminum liquid to be 0.0005%, adding 2kg of materials with the Cu element content of 99.9%, and calculating the weight of the added Cu elements as follows: 2kg × 99.9% =1.998 kg, and after 24 hours, the chemical composition of the aluminum sample is again analyzed to be 0.0059%, according to the change of the Cu element in the two chemical composition analysis results of the aluminum sample: changing the weight of the aluminum liquid in the electrolytic cell from 0.0005% to 0.0059%, and calculating the weight of the added Cu element to be 1.998 kg: 1.998 kg/kg (0.0059% to 0.0005%) =37000 kg/kg.
C. Calculating the weight of the materials required to be added: according to the target contents of Si, Fe, Cu, Cr and Mn in the intermediate alloy liquid of 0.7%, 0.25%, 0.275%, 0.28% and 0.12% respectively, the weight of the primary aluminum liquid of the electrolytic bath is 37000kg, the contents of the original Si, Fe, Cu, Cr and Mn in the primary aluminum liquid of 0.025%, 0.07%, 0.0005%, 0.0014% and 0.0011% respectively, the weight of the Si, Fe, Cu, Cr and Mn to be added is calculated as follows:
Si：（0.7%-0.025%）×37000㎏=249.75㎏
Fe：（0.25%-0.07%）×37000㎏=66.6㎏
Cu：（0.275%-0.0005%）×37000㎏=101.56㎏
Cr：（0.28%-0.0014%）×37000㎏=103.08㎏
Mn：（0.12%-0.0011%）×37000㎏=43.99㎏
and calculating the weight of the materials to be added according to the following conditions that the content of Si element in the subsequently added material A is 99.4%, the content of Fe element in the material B is 98%, the content of Cu element in the material C is 50%, the content of Cr element in the material D is 95%, and the content of Mn element in the material E is 95%:
material A: 249.75 kg of water are divided by 99.4% =251.26 kg of water
And (3) material B: 66.6 kg/98% =67.96 kg
And (3) material C: 101.56 kg of water are divided by 50% =203.12 kg of water
And (3) material D: 103.082 kg of water are divided by 95% =108.51 kg of water
Material E: 43.993 kg/95% =46.31 kg
D. Adding materials: weighing the material A, the material B, the material C, the material D and the material E with required weight, drying and then adding the materials into the electrolytic cell from an aluminum outlet or a flue end of the electrolytic cell for multiple times.
E. Confirmation of the composition of the master alloy liquid: and (3) taking an aluminum sample 24 hours after the material is added, carrying out chemical component analysis, confirming whether the contents of Si, Fe, Cu, Cr and Mn reach target values, and repeating C, D steps if the contents of Si, Fe, Cu, Cr and Mn are less than the target values. If a certain element or a plurality of elements exceed the target value, the raw aluminum liquid of the electrolytic cell with lower element content is selected for dilution, the specific steps are to calculate the weight of the required diluted aluminum liquid according to the element excess value, the calculated aluminum amount of the intermediate alloy liquid and the actual element content of the electrolytic cell with lower element content, and the intermediate alloy liquid and the diluted aluminum liquid are respectively mixed during aluminum production. If the requirement is met, the aluminum is planned according to the aluminum discharge plan and transported to the use site.
F. And (3) supplementing each subsequent element: and calculating the required material content containing the target elements every day according to the daily output of the bath of 3100kg, the target content of the metal elements in the intermediate alloy liquid, the initial content of the metal elements in the intermediate alloy liquid and the content of each metal element in the subsequently added materials:
material A: (0.7% -0.025%) x 3100kg of kilograms of water, 99.4% =20.06 kg of water
And (3) material B: (0.25% -0.07%) x 3100 kg/98% =5.59 kg/kg
And (3) material C: (0.275% to 0.0005%) x 3100 kg/50% =17.02 kg
And (3) material D: (0.28% -0.0014%) x 3100 kg/95% =9.09 kg/kg
Material E: (0.12% -0.0011%) x 3100 kg/95% =3.88 kg
During adding, weighing the added materials with required weight, drying the materials, adding the dried materials into the electrolytic cell from an aluminum outlet or a flue end of the electrolytic cell for multiple times, and keeping each target element near a target value.
Example 4
A. Selection of an electrolytic cell: an electrolytic cell which is normal in operation and has no damage phenomenon is selected, the current intensity is 400kA, and the temperature of the electrolytic cell is 950 ℃.
B. Inventory of aluminum liquid by weight: taking an aluminum sample in a selected electrolytic cell, analyzing chemical components, determining the original Cu element content of the primary aluminum liquid to be 0.0005%, adding 2kg of materials with the Cu element content of 99.9%, and calculating the weight of the added Cu elements as follows: 2kg × 99.9% =1.998 kg, and after 24 hours, the chemical composition of the aluminum sample is again analyzed to be 0.0059%, according to the change of the Cu element in the two chemical composition analysis results of the aluminum sample: changing the weight of the aluminum liquid in the electrolytic cell from 0.0005% to 0.0059%, and calculating the weight of the added Cu element to be 1.998 kg: 1.998 kg/kg (0.0059% to 0.0005%) =37000 kg/kg.
C. Calculating the weight of the materials required to be added: according to the target contents of Si, Fe, Cu, Cr and Mn in the intermediate alloy liquid of 0.7%, 0.25%, 0.275%, 0.28% and 0.12% respectively, the weight of the primary aluminum liquid of the electrolytic bath is 37000kg, the contents of the original Si, Fe, Cu, Cr and Mn in the primary aluminum liquid of 0.025%, 0.07%, 0.0005%, 0.0014% and 0.0011% respectively, the weight of the Si, Fe, Cu, Cr and Mn to be added is calculated as follows:
Si：（0.7%-0.025%）×37000㎏=249.75㎏
Fe：（0.25%-0.07%）×37000㎏=66.6㎏
Cu：（0.275%-0.0005%）×37000㎏=101.56㎏
Cr：（0.28%-0.0014%）×37000㎏=103.08㎏
Mn：（0.12%-0.0011%）×37000㎏=43.99㎏
and according to the Si and Fe contained in the subsequently added material A, respectively: 3 percent and 5 percent, the material B contains 50 percent of Cu element, the material C contains 95 percent of Cr element, the material D contains 95 percent of Mn element, and the material E contains 99.4 percent of Si element, because the material A contains two target elements, the maximum addition amount and the amount of the material E needing to be supplemented need to be calculated and determined firstly, and the calculation process is as follows:
the Si element needs the additive material amount: 249.75 kg/3% =8325 kg
The Fe element needs the additive material amount: 66.6 kg/5% =1332 kg
The maximum addition amount of the material A is 1332kg (if 8325kg of the material A is added, the Fe element exceeds the target value), the Fe element can reach the target value after the addition, the Si content is 1332kg multiplied by 3% =39.96kg, and the material E needs to be added for supplement, wherein the addition amount is that
（249.75㎏-39.96kg）÷99.4%=211.056kg
The weight of other materials to be added is respectively as follows:
and (3) material B: 101.56 kg of water are divided by 50% =203.12 kg of water
And (3) material C: 103.082 kg of water are divided by 95% =108.51 kg of water
And (3) material D: 43.993 kg/95% =46.31 kg
In conclusion, the feed rate of A was increased by 1332kg, the feed rate of B was increased by 203.12 kg, the feed rate of C was increased by 108.51 kg, the feed rate of D was increased by 46.31 kg, and the feed rate of E was increased by 211.056 kg.
D. Adding materials: weighing the material A, the material B, the material C, the material D and the material E with required weight, drying and then adding the materials into the electrolytic cell from an aluminum outlet or a flue end of the electrolytic cell for multiple times.
E. Confirmation of the composition of the master alloy liquid: and (3) taking an aluminum sample 24 hours after all the materials are added, carrying out chemical component analysis, confirming whether the contents of Si, Fe, Cu, Cr and Mn reach target values, and repeating C, D steps if the contents of Si, Fe, Cu, Cr and Mn are less than the target values. If a certain element or a plurality of elements exceed the target value, the raw aluminum liquid of the electrolytic cell with lower element content is selected for dilution, the specific steps are to calculate the weight of the required diluted aluminum liquid according to the element excess value, the calculated aluminum amount of the intermediate alloy liquid and the actual element content of the electrolytic cell with lower element content, and the intermediate alloy liquid and the diluted aluminum liquid are respectively mixed during aluminum production. If the requirement is met, the aluminum is planned according to the aluminum discharge plan and transported to the use site.
F. And (3) supplementing each subsequent element: and subsequently, respectively calculating the daily addition of the material A, the material B, the material C, the material D and the material E according to the daily yield of the bath 3100kg, the target value of the intermediate alloy liquid and the content of each target element in the material:
adding amount of material A:
the addition amount of Si element is 3100kg x (0.7% -0.025%)/3% =679.5kg
The addition amount of Fe element is 3100kg x (0.25% -0.07%)/5% =111.6kg
The maximum addition amount of the material a is 111.6kg (if 679.5kg of the material a is added, the Fe element will exceed the target value), the Fe element can reach the target value after the addition, but the content of the Si element is insufficient, 111.6kg × 3% =3.348kg, the material E needs to be added to supplement the Si element, and the addition amount of the material E is:
[3100kg×（0.7%-0.025%）-3.348kg]÷99.4%=17.68 kg
the addition amount of the material B is as follows: 3100kg of x (0.275% -0.0005%) + 50% =17.02 kg of
Adding amount of material C: 3100kg of x (0.28% -0.0014%) + 95% =9.09 kg of kg
Adding amount of material D: 3100kg of x (0.12% -0.0011%) + 95% =3.88 kg of kg
In conclusion, 111.6kg of the material A, 17.02kg of the material B, 9.09kg of the material C, 3.88kg of the material D and 17.68kg of the material E are required to be added every day. During adding, weighing the added materials with required weight, drying the materials, adding the dried materials into the electrolytic cell from an aluminum outlet or a flue end of the electrolytic cell for multiple times, and keeping each target element near a target value.
The specific adding mode and adding amount of the metal elements represent partial embodiments of the invention, and the metal elements with the following target content in percentage can be freely combined to produce the aluminum intermediate alloy liquid according to the actual production requirement by the method. The percentage of metal elements is as follows: 0-10% of iron element; 0-3% of chromium element; 0-3% of manganese element; 0-10% of silicon element; 0-10% of copper element; 0-2% of strontium element; 0 to 1.5% of titanium element; 0-2% of vanadium element; 0-5% of magnesium element; 0-6% of zinc element.
In addition, because direct current is used in the electrolysis process of the electrolytic cell, a clockwise magnetic field is formed when current flows from the anode at the upper part of the electrolytic cell to the cathode at the bottom of the electrolytic cell, and the molten metal rotates along with the direction of the magnetic field, so that the stirring effect is achieved, and the aluminum master alloy liquid is mixed more uniformly.
A comparison was made with example 1:
A. selection of an electrolytic cell: an electrolytic cell which is normal in operation and has no damage phenomenon is selected, the current intensity is 400kA, and the temperature of the electrolytic cell is 950 ℃.
And a comparison step A: if no electrolytic cell is selected: the safety risk management and control of the electrolytic cell has great hidden danger, the risk of leakage, abnormal fluctuation and electrolytic cell damage exists, and the calculated loss caused by the risk is not evaluated.
B. Inventory of aluminum liquid by weight: taking an aluminum sample in a selected electrolytic cell, analyzing chemical components, determining the original Cu element content of the primary aluminum liquid to be 0.0005%, adding 2kg of materials with the Cu element content of 99.9%, and calculating the weight of the added Cu elements as follows: 2kg × 99.9% equates to 1.998 kg, and after 24 hours, an aluminum sample was taken again with an analytical chemical composition of 0.059%, based on the Cu element change in the two chemical composition analyses for the aluminum sample: changing the weight of the aluminum liquid in the electrolytic cell from 0.0005% to 0.0059%, and calculating the weight of the added Cu element to be 1.998 kg: 2 kg/kg (0.0059% to 0.0005%) =37000 kg/kg.
And B, comparison: if the inventory step of the weight of the aluminum liquid is not available, the amount of the electrolytic aluminum liquid in the electrolytic bath cannot be known, the amount of the material containing Cu which needs to be added in the step C cannot be known, and the influence on the production of unqualified products caused by the subsequent production is avoided.
C. Calculating the weight of the materials required to be added: according to the target content of the Cu element in the intermediate alloy liquid of 0.275 percent, the weight of the primary aluminum liquid of the electrolytic bath of 37000kg and the original content of the Cu element in the primary aluminum liquid of 0.0005 percent, the weight of the Cu element to be added is calculated as follows: (0.275% -0.0059%) x 37000kg =99.567 kg, and the weight of the materials to be added is calculated according to the content of the Cu element in the materials to be added subsequently, which is as follows: 99.567 kg were divided by 50% =199.13 kg.
And C, comparison: if the step of calculating the weight of the materials to be added is not needed, the quantity of the materials containing Cu to be added is not known, the target value is not reached, and the influence on producing unqualified products caused by subsequent production is increased.
D. Adding materials: 199.13 kg of the required weight of the adding materials are weighed, potential safety hazards such as explosion caused by water brought into the electrolytic cell are eliminated through drying, and the adding materials are added into the electrolytic cell from an aluminum outlet or a flue end of the electrolytic cell for multiple times.
E. Confirmation of the composition of the master alloy liquid: and (4) taking an aluminum sample 24 hours after the materials are added, carrying out chemical composition analysis, confirming whether the Cu content meets the requirement of 0.275 percent, and repeating C, D steps if the Cu content is less than the target value. If the Cu content exceeds the target value of 0.275%, selecting the raw aluminum liquid of the electrolytic cell with the Cu content of 0.0005% for dilution, specifically, calculating the weight of the required diluted aluminum liquid according to the excess value, the calculated aluminum amount of the intermediate alloy liquid and the Cu content of the electrolytic cell with the lower Cu content, and respectively mixing the intermediate alloy liquid and the diluted aluminum liquid during aluminum discharging. If the requirement is met, the aluminum is planned according to the aluminum discharge plan and transported to the use site.
And E, comparison step: if the confirmation step of the components of the intermediate alloy liquid is not available, the components of the intermediate alloy liquid are unknown, the components are low and cannot reach the target value, and the influence on the production of unqualified products caused by the subsequent production is high.
F. Subsequent Cu element supplement: and then calculating 3100kg (0.275% -0.0005%) of Cu-containing material required every day by dividing 50% =17kg according to 3100kg of daily output of the cell, 0.275% of target value of the master alloy liquid and 50% of Cu element content in subsequent added materials, weighing the added materials with required weight, drying, adding the materials into the electrolytic cell from an aluminum outlet or a flue end of the electrolytic cell for multiple times, and keeping the stable state of the Cu content of 0.275%.
And F, comparison: if no subsequent Cu element replenishing step exists, the daily output of the electrolytic cell is 3100kg, and the Cu element content in the aluminum discharged from the electrolytic cell is gradually reduced along with the time and the aluminum discharged content. A steady state is not reached. Brings certain influence on the operation of the electrolytic cell and the quality of the aluminum liquid.
The comparative experiment developed in example 1 concluded that each step in the example is synergistic and none is necessary, and the method for on-line production of aluminum master alloy liquid by aluminum electrolysis cell in the present invention is the result of the whole operation of the electrolysis cell, and is a method for adding aluminum master alloy liquid by the weight of corresponding element material required in the production of aluminum alloy based on the whole operation of the electrolysis cell.
Compared with the aluminum intermediate alloy liquid prepared by the traditional method, the method for producing the aluminum intermediate alloy on line by the aluminum electrolytic cell has the following advantages:
1. the aluminum intermediate alloy liquid prepared by the method of the embodiment 1-2 has no casting process, and the aluminum intermediate alloy liquid is directly transported to a smelting furnace calculated by batching, so that the phenomena of intracrystalline segregation and inverse segregation do not exist; gravity segregation can be cycled with electron movement according to Tesla's law formed by the direction of current flow and the direction of magnetic field in the cell, namely: the disturbance effect of the magnetic field can lead the molten aluminum intermediate alloy liquid to be uniformly mixed.
2. The aluminum intermediate alloy liquid prepared by the method of the embodiment 1-2 has no casting process, the aluminum intermediate alloy liquid is directly transported to a smelting furnace calculated by batching, and the phenomenon of surface quality defect is zero defect.
3. The aluminum intermediate alloy liquid prepared by the method of the embodiment 1-2 has no casting process, the aluminum intermediate alloy liquid is directly transported to a smelting furnace calculated by batching, no secondary heating remelting process exists, and the emission values of waste gas and pollutants are zero.
4. The aluminum intermediate alloy liquid prepared by the method of the embodiment 1-2 has no casting process, the aluminum intermediate alloy liquid is directly transported to a smelting furnace calculated by batching, and the casting cost is zero.
5. The aluminum intermediate alloy liquid prepared by the method of the embodiment 1-2 has no casting process, the aluminum intermediate alloy liquid is directly transported to a smelting furnace calculated by batching, and the labor cost is zero.
In conclusion, the aluminum intermediate alloy prepared by the method for online producing the aluminum intermediate alloy by the aluminum electrolytic cell can effectively solve the problems of component internal segregation and surface quality defects of the aluminum intermediate alloy caused by process differences in the processes of stirring, smelting, refining, casting and cooling, can also improve the utilization rate of waste metals, and can reduce the production cost.
Claims (8)
1. A method for producing aluminum intermediate alloy liquid on line by an aluminum electrolytic cell is characterized by comprising the following steps: the method for producing the aluminum intermediate alloy on line by the aluminum electrolytic cell takes the running electrolytic cell as a main body, and after the initial metal content in the primary aluminum liquid is determined, materials are added into the electrolytic cell, and the materials added into the electrolytic cell are materials containing a certain amount of known metal elements; the material is melted in the aluminum liquid, and after the aluminum liquid is taken again to analyze the content of metal elements, the weight of the primary aluminum liquid is calculated; calculating the weight of the materials to be supplemented according to the required target content of the metal elements in the aluminum intermediate alloy liquid, the weight of the primary aluminum liquid and the initial content of the metal elements in the primary aluminum liquid; adding materials to be supplemented into the electrolytic cell from an aluminum outlet or a flue end of the electrolytic cell to obtain molten aluminum intermediate alloy liquid, directly conveying the molten aluminum intermediate alloy liquid to a melting furnace at a casting position, and directly batching the molten aluminum intermediate alloy liquid into a subsequent batching process; wherein the material added into the electrolytic bath comprises at least one of metallic iron, metallic chromium, metallic manganese, industrial silicon, metallic copper, metallic strontium, metallic titanium, metallic zirconium, metallic vanadium, metallic magnesium and metallic zinc or waste metal containing the elements.
2. The method for the on-line production of the aluminum master alloy liquid by the aluminum electrolytic cell according to claim 1, characterized in that: the method for producing the aluminum intermediate alloy on line by the aluminum cell also comprises a process of confirming the components of the intermediate alloy liquid; if the actual content of the metal elements in the aluminum intermediate alloy liquid is larger than the target content of the metal elements, adding the original aluminum liquid for diluting; if the actual content of the metal elements in the aluminum master alloy liquid is less than the target content of the metal elements, the materials continuously added into the electrolytic cell are materials containing a certain amount of known metal elements.
3. The method for the on-line production of the aluminum master alloy liquid by the aluminum electrolytic cell according to claim 1, characterized in that: the method for producing the aluminum intermediate alloy on line by the aluminum electrolytic cell also comprises the following supplement process of metal elements; calculating the weight of materials to be supplemented every day according to the weight of the daily aluminum production intermediate alloy liquid of the electrolytic cell, the target content of metal elements in the aluminum intermediate alloy liquid and the content of metal elements in the additive materials, drying and removing water, and adding the materials into the electrolytic cell from an aluminum outlet or a flue end of the electrolytic cell for multiple times.
4. The method for the on-line production of the aluminum master alloy liquid by the aluminum electrolytic cell according to claim 1, characterized in that: the materials added into the electrolytic cell are dried and then added into the electrolytic cell from an aluminum outlet or a flue end of the electrolytic cell for multiple times.
5. The method for the on-line production of the aluminum master alloy for the aluminum reduction cell according to claim 1, wherein: the current intensity of the electrolytic cell is 300-600 kA.
6. The method for the on-line production of the aluminum master alloy for the aluminum reduction cell according to claim 1, wherein: the electrolytic reaction is carried out at 930-970 ℃, and the reaction temperature and the uninterrupted operation mode of the electrolytic cell provide enough heat for materials added into the electrolytic cell, so that the melting requirement of the added materials is met, and the process is equivalent to the process that a solute is gradually dissolved in a solvent.
7. The method for the on-line production of the aluminum master alloy for the aluminum reduction cell according to claim 1, wherein: in the electrolytic process of the electrolytic cell, the current direction is fixed, the magnetic field is fixed, and after the current is introduced through the anode, when the current direction is vertical to the magnetic field, the molten aluminum intermediate alloy liquid can be uniformly mixed along with the movement and circulation of electrons according to Tesla law.
8. An aluminum master alloy liquid produced by the method for producing an aluminum master alloy on line of an aluminum electrolytic cell according to any one of claims 1 to 7, characterized in that: the target content of the metal elements in the aluminum intermediate alloy liquid is 1 or more than 1 of the following percentage metal elements;
0-10% of iron element;
0-3% of chromium element;
0-3% of manganese element;
0-10% of silicon element;
0-10% of copper element;
0-2% of strontium element;
0 to 1.5% of titanium element;
0-2% of zirconium element;
0-2% of vanadium element;
0-5% of magnesium element;
0-6% of zinc element;
wherein the percentage of the aluminum element is 50-95 percent, the total percentage of the aluminum element and the metal element is more than or equal to 95 percent, and the balance is inevitable impurities.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JPS61253163A (en) * | 1985-05-02 | 1986-11-11 | Asahi Malleable Iron Co Ltd | Device for adjusting composition of molten alloy for casting |
| CN103173622A (en) * | 2013-01-17 | 2013-06-26 | 北京科技大学 | Method for regenerating aluminum alloy with target ingredient from scrap aluminum |
| CN104164681A (en) * | 2014-07-22 | 2014-11-26 | 山西华泽铝电有限公司 | Novel electrolytic tank in-production aluminum inventory method |
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Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS61253163A (en) * | 1985-05-02 | 1986-11-11 | Asahi Malleable Iron Co Ltd | Device for adjusting composition of molten alloy for casting |
| CN103173622A (en) * | 2013-01-17 | 2013-06-26 | 北京科技大学 | Method for regenerating aluminum alloy with target ingredient from scrap aluminum |
| CN104164681A (en) * | 2014-07-22 | 2014-11-26 | 山西华泽铝电有限公司 | Novel electrolytic tank in-production aluminum inventory method |
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