CN113502508A - Control method for efficient production of aluminum electrolysis cell - Google Patents

Control method for efficient production of aluminum electrolysis cell Download PDF

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Publication number
CN113502508A
CN113502508A CN202110915257.XA CN202110915257A CN113502508A CN 113502508 A CN113502508 A CN 113502508A CN 202110915257 A CN202110915257 A CN 202110915257A CN 113502508 A CN113502508 A CN 113502508A
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aluminum
electrolytic cell
electrolyte
anode
cell
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葛贵君
惠憬明
祝元兵
朱跃强
周明珠
陈文军
刘玉轩
王斌
高涛
高艳军
赵亮
姜海超
张文明
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Inner Mongolia Hmhj Aluminum Electricity Co ltd
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Inner Mongolia Hmhj Aluminum Electricity Co ltd
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    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25CPROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
    • C25C3/00Electrolytic production, recovery or refining of metals by electrolysis of melts
    • C25C3/06Electrolytic production, recovery or refining of metals by electrolysis of melts of aluminium
    • C25C3/20Automatic control or regulation of cells

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Electrolytic Production Of Metals (AREA)

Abstract

The invention discloses a control method for high-efficiency production of an aluminum electrolytic cell, which is characterized in that in the stable production stage of electrolytic aluminum, the aluminum level is controlled to be 14-17cm, the anode covering material is 3-4cm, the molecular ratio is 2.2-2.45, the cell temperature is 930-950 ℃, the electrolyte level is 18-20cm, the superheat degree is 10-15 ℃, and the polar distance is 4.5-5.5 cm. The method for controlling the high-efficiency production of the aluminum electrolytic cell solves the problems of large labor capacity and high labor intensity of industrial workers; the long-term stable operation of the equipment is ensured, and the safety operation risks of industrial workers, such as maintenance and monitoring of a damaged groove and furnace leakage risks, are greatly reduced; the electrolytic cell has stable operation, less smoke generation amount, convenient collection of smoke and favorable environmental protection. The economic benefit is remarkable, the current efficiency is more than 94%, the alternating current consumption of the aluminum liquid is less than 13250kWh/t Al, and the service life of the electrolytic cell is more than 2600 days.

Description

Control method for efficient production of aluminum electrolysis cell
The technical field is as follows:
the invention relates to a control method for efficient production of an aluminum electrolytic cell, belonging to the technical field of aluminum metallurgy.
Background art:
after the economic crisis of 2008, the domestic electrolytic aluminum industry gradually pursued a low power consumption technical route (high molecular ratio, high alumina water, high insulating material, low voltage, low polar distance). The technical route is adopted by most of electrolytic aluminum enterprises by 2010, but the defects are not looked by industry experts and are not effectively solved for 10 years. The main body is as follows:
1. the molecular ratio is high, and the conventional molecular ratio is generally 2.35-2.5.
The main components of the electrolyte are aluminum fluoride and sodium fluoride, the molecular ratio is the molar ratio of the sodium fluoride to the aluminum fluoride, the aluminum fluoride has high volatility, the aluminum fluoride in the electrolyte decreases and the molecular ratio increases as the aluminum electrolysis progresses, and the aluminum fluoride needs to be added into the electrolyte periodically in order to maintain the components of the electrolyte.
In daily management, the electrolyte components are periodically tested to obtain the molar ratio of aluminum fluoride to sodium fluoride, and then the molecular ratio is determined to be increased or decreased according to the molecular ratio control standard. And increasing the molecular ratio, adding sodium carbonate (the sodium carbonate reacts in the electrolyte to generate sodium fluoride and aluminum fluoride), wherein the addition amount of the sodium carbonate is represented by the following formula: 0.631P (K)2-K1)/(2+K1) (ii) a And (3) adding aluminum fluoride when the molecular ratio is reduced, wherein the addition amount formula of the aluminum fluoride is as follows: p (K)1-K2)/K2/(2+K1)。
Note: in the above two formulas, P represents total electrolyte amount, K1In order to obtain the molecular ratio of the electrolyte,K2the adjusted electrolyte molecular ratio is obtained.
The molecular ratio is high, so that the electrolyte has good conductivity, the effective polar distance is large under the same set voltage, and the operation of the electrolytic cell is more stable; however, it is possible to use a single-layer,
1.1 the molecular ratio is high, the primary crystal temperature is high, and the formed crust can be melted at a higher temperature;
1.2 the molecular weight ratio is high, the wetting angle of the electrolyte to the graphite material is large, which is not beneficial to the emission of anode gas and leads to the increase of anode polarization;
1.3, the molecular ratio is high, so that the interfacial tension of the electrolyte and the aluminum liquid is reduced, the collection of aluminum from the electrolyte is not facilitated, and the separation of carbon slag is also not facilitated;
1.4 the viscosity of the electrolyte is high, which is not favorable for the circulation of the electrolyte.
2. The high alumina water means that the height of the molten aluminum is higher, and the traditional aluminum smelting can reach 18-30 cm.
2.1 because the heat conductivity of the aluminum is good, the heat dissipation of the bottom of the aluminum liquid is large when the aluminum level is high, the temperature of the electrolytic cell is reduced, the dissolution speed of the aluminum oxide is low, and the added aluminum oxide can not be dissolved in the electrolyte in time and is deposited on the bottom of the cell to form a precipitate on the bottom of the cell; if the aluminum level is too high, the temperature of the bottom of the tank is low, and the sediment at the bottom of the tank gradually becomes crusts;
2.2 the bottom sediment or crusting of the cell is unevenly distributed, the current has the characteristic of short-cut path, and the current flows to the position without sediment/crusting or with thin crusting in a concentrated manner, so that the cathode is unevenly conductive;
2.3 the cathode has uneven conduction, and the cathode has more conduction at the position without precipitation/crusting or with thin crusting, so that the heat generated by the cathode is large, meanwhile, the precipitation and the crusting at the bottom of the tank hinder the conduction of the heat in the tank to the cathode, the thermal stress of the cathode and the lining is unbalanced, the damage is easy to occur, and the service life of the cathode and the lining is shortened.
3. The heat preservation material is high, and the traditional aluminum smelting can reach 15-20 cm.
The heat preservation material plays a role in aluminum electrolysis, and has the function of reducing heat loss; secondly, the anode is covered on the surface of the anode to prevent the anode from contacting with oxygen in the air, thereby protecting the anode from being oxidized; and thirdly, covering the contact part of the anode steel claw and the anode, and properly increasing the temperature of the contact part of the anode steel claw and the anode so as to reduce the contact pressure drop at the contact part.
However, the heat insulation material is added to the surface of the anode through manpower and a multifunctional unit, and the high heat insulation material increases the labor capacity of workers and prolongs the occupied time of the multifunctional unit in the work; meanwhile, the shell surface formed by the high-heat-insulation material is thick, the shell surface is hard and is not easy to knock, a material block falling into the electrolytic tank in the process of replacing the anode is thick and large, and the material block cannot be melted in a short time at a low tank bottom temperature caused by a high aluminum level, so that the material block needs to be fished, the labor amount of workers is large, the labor intensity is high, and the equipment operation rate is high.
4. Low voltage and low pole pitch. Since 2008, in the domestic aluminum electrolysis industry, in order to pursue low power consumption, the voltage is generally controlled below 4.05V, and the polar distance is below 4 cm.
The polar distance is the distance from the bottom palm of the anode to the upper surface of the aluminum liquid, and under the condition that the electrolyte components are not changed, the polar distance is mainly controlled by adjusting the set voltage of the electrolytic cell. In the process of aluminum electrolysis, aluminum liquid in an electrolytic cell circularly flows under the action of a magnetic field force, the aluminum liquid can fluctuate up and down in the flowing process due to the vertical magnetic field force and the existence of precipitation or incrustation at the bottom of the cell, and if the polar distance is too low, the fluctuating aluminum liquid is easy to contact with the bottom palm of the anode, so that voltage fluctuation is caused, and the current efficiency is reduced.
In summary, the technical route of high-molecular-ratio, high-alumina water, high-heat-insulating material, low voltage and low pole pitch power consumption is adopted, and the existing problems comprise that: the method has the problems of production disorder, great labor capacity of workers and extremely high labor intensity, and does not have the condition of approaching to the intelligent manufacturing direction; secondly, although the energy consumption is low, the efficiency is low, the equipment operation rate is poor, the operation of the electrolytic cell is not stable, and the operation cycle of the electrolytic cell is short; thirdly, cost reduction and efficiency improvement are difficult to realize for enterprises.
The invention content is as follows:
the invention aims to provide a control method for high-efficiency production of an aluminum electrolytic cell, which realizes high-current-efficiency production of the electrolytic cell at a low energy consumption level on the basis of effectively improving the safety of an electrolytic cell series, reduces the labor amount and labor intensity of industrial workers, improves the operation efficiency of equipment, and is a biggest obstacle in cleaning the process of an intelligent factory, and meanwhile, the economic benefit and the social benefit are obvious.
The invention is implemented by the following technical scheme: a control method for high-efficiency production of an aluminum electrolytic cell is characterized in that in the stable production stage of electrolytic aluminum, the aluminum level is controlled to be 14-17cm, the anode covering material is 3-4cm, the molecular ratio is 2.2-2.45, the cell temperature is 930-950 ℃, the electrolyte level is 18-20cm, the superheat degree is 10-15 ℃, and the polar distance is 4.5-5.5 cm.
2. The method as claimed in claim 1, wherein the molecular ratio is controlled to be 2.2-2.3 in an electrolyte system containing no more than 5% of lithium and potassium; in an electrolyte system with the total content of lithium and potassium more than 5 percent, the molecular ratio is controlled to be 2.3-2.45.
3. The method as claimed in claim 2, wherein the temperature of the aluminum electrolytic cell is controlled to 935-950 ℃ in an electrolyte system with a total content of Li and K not more than 5%; in an electrolyte system with the total content of lithium and potassium more than 5 percent, controlling the temperature of the bath at 930-940 ℃.
The invention has the advantages that:
compared with the prior art, the invention has the following advantages:
1. the problems of large labor amount and high labor intensity of industrial workers are solved.
2. The long-term stable operation of equipment is guaranteed, and the safety operation risks of industrial workers, such as the maintenance, monitoring and furnace leakage risks of a damaged groove, are greatly reduced.
3. The electrolytic cell has stable operation, less smoke generation amount, convenient collection of smoke and favorable environmental protection.
4. The economic benefit is remarkable, the current efficiency is more than 94%, the alternating current consumption of the aluminum liquid is less than 13250kWh/t Al, and the service life of the electrolytic cell is more than 2600 days.
5. Is suitable for all electrolyte systems, and can solve the problem of high lithium and potassium content of the electrolyte system in the whole industry.
6. The future of the aluminum industry is certainly developed towards mechanization, intellectualization, informatization and digitization, and the implementation of the technical route can clean technical obstacles of an intelligent manufacturing factory for an electrolytic aluminum factory.
The specific implementation mode is as follows:
the technical solutions in the embodiments of the present invention are clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all 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.
Example 1:
the present example is based on the electrolysis parameters mentioned in the background, namely: the aluminum level is 18-24cm, the thickness of the anode covering material is about 17cm, the cell voltage is below 4.05V, the polar distance is 3.8-4.0cm, the electrolyte level is about 18cm, the molecular ratio is about 2.40 (the electrolyte system in the embodiment is an electrolyte system with the total content of lithium and potassium not exceeding 5%), the cell temperature is about 955 ℃, and the superheat degree is about 10 ℃.
Example 2:
in this example, after stable production of aluminum was achieved under the control conditions in example 1, the adjustment was made in the following manner:
the first stage is as follows: properly increasing the set voltage of the electrolysis series, gradually increasing the polar distance to 4.5-5.5cm, and improving the stability of the electrolytic cell; meanwhile, the thickness of the anode covering material is gradually reduced to about 10cm, the heat balance of the electrolytic cell is kept, and the falling of the anode caused by the thermal deformation of the anode steel claw due to the high thickness of the anode covering material is reduced, so that the labor amount and the labor intensity of workers are reduced;
and a second stage: gradually reducing the aluminum level to 14-17cm, reducing the heat dissipation of aluminum liquid while moving the heating area of the electrolytic cell downwards, increasing the temperature of the cell bottom, melting the crusting of the cell bottom, avoiding the enlargement of the extending legs, cleaning the cell bottom, enabling the cathode to conduct electricity uniformly, naturally reducing the damage of the cathode and the lining, and further prolonging the service life of the cell; meanwhile, anode bias current caused by crusting at the bottom of the tank is avoided, long corners and long bags of the anode are avoided, and the labor capacity of workers is further reduced;
the electrolyte level is increased to 18-20cm, the thermal stability of the electrolytic cell is enhanced, and the power supply side stop resistance and load risk reduction capability of the electrolytic cell are improved; meanwhile, the capability of dissolving alumina is improved, and the generation of sediment at the bottom of the tank is avoided.
Continuously reducing the thickness of the anode covering material to 3-4cm, ensuring that the anode is not oxidized, optimizing the temperature distribution of each part of the electrolytic cell, and stabilizing or establishing a firm hearth.
And a third stage: the molecular ratio is reduced to 2.20-2.30, the wetting angle of the graphite material is reduced, the discharge of anode gas is facilitated, and the anode polarization is reduced; the interfacial tension of the electrolyte and the aluminum liquid is increased, so that the aluminum can be collected from the electrolyte, and the separation effect of the carbon slag is improved; the viscosity of the electrolyte is reduced, and the circulation property of the electrolyte is improved; the current efficiency is improved, and the formed shell surface is loose and easy to break, thereby being beneficial to operation.
The low bath temperature is controlled to be 935-950 ℃, the diffusion, dissolution and reaction speed of the aluminum liquid to the electrolyte are slow, the re-loss of the aluminum liquid is reduced, and the current efficiency is improved; meanwhile, the limit of the ambient temperature on the use condition of the equipment and the influence of the service life are reduced, and conditions are created for implementation of intelligent manufacturing and realization of an intelligent factory.
The superheat degree is improved to 10-15 ℃, and the higher superheat degree is beneficial to the faster dissolution of the alumina by the electrolyte, the reduction of the generation probability of the bottom sediment of the electrolytic cell, the improvement of the stability of the electrolytic cell and the improvement of the current efficiency; the electrolyte has good fluidity, the aluminum oxide is uniformly dissolved in the electrolyte, and the anode gas is smoothly discharged, so that a bubble film is prevented from being formed by aggregation, the occurrence of an anode effect is reduced, and the current efficiency loss caused by the anode effect and the anode extinguishing effect is reduced; the carbon slag and the electrolyte are well separated, the material is not easily accumulated at the feed opening, the fire hole is smooth, the generated carbon slag is combusted at the fire hole, the carbon slag is not fished, the labor capacity of staff is reduced, and the generation of hazardous waste is avoided; the shell surface of the formed covering material is thin, and the pole changing operation is convenient.
Example 3:
the present example is based on the electrolysis parameters mentioned in the background, namely: the aluminum level is 18-24cm, the thickness of the anode covering material is about 17cm, the cell voltage is below 4.05V, the polar distance is 3.8-4.0cm, the electrolyte level is about 18cm, the molecular ratio is about 2.45 (the electrolyte system in the embodiment is an electrolyte system with the total content of lithium and potassium exceeding 5%), the cell temperature is about 948 ℃, and the superheat degree is about 10 ℃.
Example 4:
in this example, after the stable production of aluminum was achieved under the control conditions in example 3, the adjustment was performed in the following manner:
the first stage is as follows: properly increasing the set voltage of the electrolysis series, gradually increasing the polar distance to 4.5-5.5cm, and improving the stability of the electrolytic cell; meanwhile, the thickness of the anode covering material is gradually reduced to about 10cm, the heat balance of the electrolytic cell is kept, and the falling of the anode caused by the thermal deformation of the anode steel claw due to the high thickness of the anode covering material is reduced, so that the labor amount and the labor intensity of workers are reduced;
and a second stage: gradually reducing the aluminum level to 14-17cm, reducing the heat dissipation of aluminum liquid while moving the heating area of the electrolytic cell downwards, increasing the temperature of the cell bottom, melting the crusting of the cell bottom, avoiding the enlargement of the extending legs, cleaning the cell bottom, enabling the cathode to conduct electricity uniformly, naturally reducing the damage of the cathode and the lining, and further prolonging the service life of the cell; meanwhile, anode bias current caused by crusting at the bottom of the tank is avoided, long corners and long bags of the anode are avoided, and the labor capacity of workers is further reduced;
the electrolyte level is increased to 18-20cm, the thermal stability of the electrolytic cell is enhanced, and the power supply side stop resistance and load risk reduction capability of the electrolytic cell are improved; meanwhile, the capability of dissolving alumina is improved, and the generation of sediment at the bottom of the tank is avoided.
Continuously reducing the thickness of the anode covering material to 3-4cm, ensuring that the anode is not oxidized, optimizing the temperature distribution of each part of the electrolytic cell, and stabilizing or establishing a firm hearth.
And a third stage: the molecular ratio is reduced to 2.30-2.45, the wetting angle of the graphite material is reduced, the discharge of anode gas is facilitated, and the anode polarization is reduced; the interfacial tension of the electrolyte and the aluminum liquid is increased, so that the aluminum can be collected from the electrolyte, and the separation effect of the carbon slag is improved; the viscosity of the electrolyte is reduced, and the circulation property of the electrolyte is improved; the current efficiency is improved, and the formed shell surface is loose and easy to break, thereby being beneficial to operation.
The low bath temperature is controlled to be 930-940 ℃, the diffusion, dissolution and reaction speed of the aluminum liquid to the electrolyte are slow, the re-loss of the aluminum liquid is reduced, and the current efficiency is improved; meanwhile, the limit of the ambient temperature on the use condition of the equipment and the influence of the service life are reduced, and conditions are created for implementation of intelligent manufacturing and realization of an intelligent factory.
The superheat degree is improved to 10-15 ℃, and the higher superheat degree is beneficial to the faster dissolution of the alumina by the electrolyte, the reduction of the generation probability of the bottom sediment of the electrolytic cell, the improvement of the stability of the electrolytic cell and the improvement of the current efficiency; the electrolyte has good fluidity, the aluminum oxide is uniformly dissolved in the electrolyte, and the anode gas is smoothly discharged, so that a bubble film is prevented from being formed by aggregation, the occurrence of an anode effect is reduced, and the current efficiency loss caused by the anode effect and the anode extinguishing effect is reduced; the carbon slag and the electrolyte are well separated, the material is not easily accumulated at the feed opening, the fire hole is smooth, the generated carbon slag is combusted at the fire hole, the carbon slag is not fished, the labor capacity of staff is reduced, and the generation of hazardous waste is avoided; the shell surface of the formed covering material is thin, and the pole changing operation is convenient.
In examples 1 and 3, the electrolytic bath bottom precipitates more, which aggravates the fluctuation of the aluminum liquid, the secondary reaction of the aluminum liquid is aggravated due to the lower polar distance, the current efficiency loss is larger, and meanwhile, the current efficiency is further reduced due to the higher molecular weight and the higher bath temperature, which causes the current efficiency to be only 90% -92%, and the aluminum liquid alternating current power consumption 13280 + 13580kWh/t Al (the bath average voltage is 4.00V, and the rectification efficiency is 97.5%).
Because of higher aluminum level, lower tank voltage, cold bottom of the electrolytic tank, more sediment at the tank bottom, large extending legs, uneven cathode conduction and unbalanced thermal stress of the cathode and the lining, and meanwhile, under the erosion of the sediment and the extending legs, the cathode is easy to be damaged early, the service cycle of the cathode and the lining is reduced, and the service life of the tank is lower, about 2000 days to 2300 days.
In addition, because the aluminum level is higher and the bath voltage is lower, the electrolytic bath tends to be cold, the heat preservation management of the electrolytic bath (the thickness of a heat preservation material is increased) is required to be enhanced in order to keep the heat balance, so that the anode steel claw is deformed, the service life of the steel claw is shortened, the anode falling phenomenon is increased, and the labor intensity of workers is increased.
In examples 2 and 4, the bottom of the electrolytic cell is clean, the fluctuation of the aluminum liquid is small, the secondary reaction of the aluminum liquid is reduced due to the higher polar distance, the current efficiency reaches 94% -95% when the aluminum liquid is produced in the electrolyte with low molecular ratio and low cell temperature, the alternating current power consumption of the aluminum liquid 13190 and 13330kWh/t Al (the average cell voltage is 4.10V, and the rectification efficiency is 97.5%).
The bottom of the electrolytic tank is clean, the cathode is uniformly conductive, the thermal stress of the cathode and the lining is balanced, the service life of the cathode and the lining is prolonged, and the service life of the electrolytic tank is more than 2600 days.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.

Claims (3)

1. A control method for high-efficiency production of an aluminum electrolytic cell is characterized in that in the stable production stage of electrolytic aluminum, the aluminum level is controlled to be 14-17cm, the anode covering material is 3-4cm, the molecular ratio is 2.2-2.45, the cell temperature is 930-950 ℃, the electrolyte level is 18-20cm, the superheat degree is 10-15 ℃, and the polar distance is 4.5-5.5 cm.
2. The method as claimed in claim 1, wherein the molecular ratio is controlled to be 2.2-2.3 in an electrolyte system containing no more than 5% of lithium and potassium; in an electrolyte system with the total content of lithium and potassium more than 5 percent, the molecular ratio is controlled to be 2.3-2.45.
3. The method as claimed in claim 2, wherein the temperature of the aluminum electrolytic cell is controlled to 935-950 ℃ in an electrolyte system with a total content of Li and K not more than 5%; in an electrolyte system with the total content of lithium and potassium more than 5 percent, controlling the temperature of the bath at 930-940 ℃.
CN202110915257.XA 2021-08-10 2021-08-10 Control method for efficient production of aluminum electrolysis cell Pending CN113502508A (en)

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