WO2015011665A1 - Système et procédé intelligents de perçage par électrolyse d'aluminium - Google Patents

Système et procédé intelligents de perçage par électrolyse d'aluminium Download PDF

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Publication number
WO2015011665A1
WO2015011665A1 PCT/IB2014/063356 IB2014063356W WO2015011665A1 WO 2015011665 A1 WO2015011665 A1 WO 2015011665A1 IB 2014063356 W IB2014063356 W IB 2014063356W WO 2015011665 A1 WO2015011665 A1 WO 2015011665A1
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WO
WIPO (PCT)
Prior art keywords
pike
drilling
module
signal
electrolyse
Prior art date
Application number
PCT/IB2014/063356
Other languages
English (en)
Inventor
Normand DAIGLE
Pierre Girard
Original Assignee
Aluminerie Bécancour Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Aluminerie Bécancour Inc. filed Critical Aluminerie Bécancour Inc.
Publication of WO2015011665A1 publication Critical patent/WO2015011665A1/fr

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Classifications

    • 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
    • C25C3/14—Devices for feeding or crust breaking
    • 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

Definitions

  • the process for producing aluminum has been well known in the art for the latest centuries.
  • the first step consists to extract bauxite from the ground or from a mine.
  • the bauxite is then refined to aluminum oxide (AI2O3), also known as alumnia.
  • AI2O3 aluminum oxide
  • the alumnia is separated through an electrolysis process, typically the well known Hall-Heroult process.
  • This process generally requires a tank having a cathode and at least one carbon anode within an electrolyte composed of mineral cryolite.
  • the oxygen atoms of the alumnia react with the carbon anode to form carbone dioxide.
  • a solid crust forms across the surface of the molten cryolite-alumina electrolyte, thus blocking the input of more alumina within the tank.
  • a drilling mean moving as a piston, is lowered with enough power to go through the crust.
  • Such drilling mean is generally embodied as a pneumatic drill or pike and requires huge quantity of energy to penetrate the crust.
  • One of the objects and advantages of the present invention is to reduce the quantity of energy required for drilling through the crust formed over the aluminum electrolyse tank of an aluminum smelter.
  • Another object and advantage of the present invention is to provide a system using the cable supplying electricity.
  • the aforesaid and other objectives of the present invention are realized by generally providing an intelligent system for controlling the drilling process of the intelligent aluminum electrolysis process.
  • the system typically comprises a tank, a receiver for each tank, a module, a pike, a dosing mean and at least one sensor.
  • the pike is connected to the module, to the tank and to the receiver through a cable.
  • the dosing mean is connected to the module, to the tank and to the receiver through a cable.
  • the cables are used alternatively as the dosing process is never executed during the drilling process.
  • tank also refers to a container allowing the electrolyse process commonly referred as a pot or electrolyse container or recipient.
  • the module is used to detect the event when the pike has drilled the crust. Upon detection of the completion of the drilling process by the pike, the module triggers the deactivation of the pike.
  • the main objective of this automated deactivation of the pike 105 is to prevent unwarranted wear of the pike and unnecessary consumption of compressed air.
  • the module comprises a circuit used as a transformer to convert alternative current (AC) to isolated direct current (DC), a circuit allowing controlling the pike, a central processing unit (CPU), a terminal or input triggering the end of the stroke of a pike and another circuit used to transmit the result to an automaton controller.
  • the module further comprises another circuit to synchronize the resulting signal which is picked up or read by a receiver located near the automaton controller.
  • Different results signals are used to identify the following results: soaking, end of the stroke, no detection (system idling or in default position). It shall be noted that the system is not limited to the present results as other result signals may be used to identify other status.
  • the receiver is generally mounted near the tank and is connected to the output connectors and of the pike and to the dosing mean using a parallel circuit.
  • the receiver unit generally comprises four current sensors, four detectors terminals, a timing circuit (R3 OP1), a CPU and two static outputs (RL1 RL2). Each detector allows the identification of a request to pike into the crust. In another embodiment, a different number of detectors may be used.
  • the present invention represents a module for intelligently controlling aluminum electrolyse drilling, wherein the module comprises a control sub module allowing the controlling of a stroke of a drilling pike, a central processing unit, a communication port adapted to receive a signal triggering the end of the stroke of a drilling pike and a transmitter to communicate drilling pike status to the central processing unit using a signal.
  • the module further comprises a sub module to transform alternative current to direct current.
  • the control sub module allowing the control of the stroke of a drilling pike allows at least one of the followings, lowering of the drilling pike, stopping the lowering of the drilling pike and raising of the drilling pike.
  • the communication port receives a constant signal during the lowering of the drilling pike and when no signal is received, the drilling pike has completely drilled a crust.
  • the status signal is a coded signal or may further be embodied as a series of information pulse transmitted and synchronized to a predetermined frequency.
  • the central processing unit is configured to process the status signal and to activate the output corresponding to the resulting signal.
  • the module further comprises a protection module configured to protect against excessive voltage from an anode effect.
  • the present invention comprises a receiver unit for detecting the status of a drilling pike in a process of aluminum electrolyse drilling.
  • the receiver unit comprises a plurality of sensors allowing the detection of a current threshold between the pike and the electrolyte, a plurality of communication ports each connected to a drilling pike or to a module for controlling the drilling, a central processing unit configured to process a status signal received from the module for controlling the drilling and to communicate an activation signal to a communication port connected to one or more drilling pikes based on the processing of the status signal.
  • the receiver unit may further comprises a synchronization module;
  • the intelligent aluminum electrolyse drilling system in accordance with the principles of the present invention comprises a tank containing an electrolyte, at least one pike for drilling, wherein the at least one pike is upwardly or downwardly movable and is linked to the controller module using a communication method at least one anode and at least one cathode, at least one sensor configured to communicate a status signal.
  • the system further comprises a controller module, wherein the controller module is linked to the drilling pike using a communication method and to the at least one sensor and wherein the controller module is configured to process data received from the at least one pike and/or the at least one sensor.
  • the system further comprises a receiver unit for each tank. The system allow the at least one pike to be linked to the controller module, to the tank and to the receiver unit using a communication method. Furthermore, the controller module is configured to process data from the at least one pike and the at least one sensor.
  • the further teaches that at least one pike is raised or lowered using a pneumatic system.
  • the communication method linked to the dosing mean one pike is used to communicate the status of the at least one sensor during the drilling process.
  • the at least one sensors may be attached to at least one of the drilling pike.
  • the communication method of each link may be embodied as an electric cable.
  • a method for intelligently controlling at least one pike during crust perforation of an aluminum electrolysis process comprising the steps to detect the event for which at least one pike has perforated the crust and to stop the lowering and start the raising of at least one pike upon detection of the crust perforation.
  • the detection of the perforation of the crust may use at least one sensor attached to the at least one pike.
  • Figure 1 is a schematic representation of an intelligent aluminum electrolyse drilling system in accordance with the present invention.
  • Figure 2 is a schematic representation of a system for controlling the drilling process of an aluminum basin in accordance with the present invention.
  • Figure 3 is a schematic representation of one circuit of the DPAA card in accordance with the present invention.
  • Figure 4 is a schematic representation of a second circuit of the DPAA card in accordance with the present invention.
  • the aluminum electrolysis system comprises a tank 200, at least one anode 210, at least one cathode 220 and at least one pike 230. Typically, an electrical current is generated between the at least one positive anode 210 and the at least one negative cathode 220.
  • the tank contains an electrolyte 202.
  • the cathode comprises a cable 211 connected to an electrical power source allowing the electrolyse process to occur.
  • the pike is raised and lowered using a pneumatic system which is powered using a cable 231.
  • the intelligent aluminum electrolysis drilling system and method control the lowering of at least one pike during the crust perforation process in order to stop the lowering and start the raising of the pike as soon as it touches the electrolyte, thus, considerably reducing the energy required for the drilling process.
  • the system comprises a tank 100, a receiver 101 for each tank, a module 102, a pike 105, a dosing mean 106 and at least one sensor 107.
  • the module 102 is generally installed over the pike 105.
  • the module 102 In order to resist to a large range of temperatures, the module 102 must be made in compliance with strict industrial standards. Typically, the module 102 and the receiver 102 must withstand temperature ranging from -40° Celsius to 85° Celsius.
  • HF hydrofluoric acid
  • the pike 105 is connected to the module 102, to the tank 100 and to the receiver through a cable 108.
  • the dosing mean is connected to the module 102, to the tank 100 and to the receiver through a cable 109.
  • the cable 108 and 109 are used alternatively as the dosing process is never executed during the drilling process.
  • the cable 110 acts as the neutral cable between the pike 105, the dosing mean 106 and the tank 100.
  • at least one sensor 107 is affixed on either or both the dosing mean 106 and on the pike 105.
  • the receiver 101 is generally mounted near the tank 100 and is connected to the output connectors 108 and 109 of the pike 105 and to the dosing mean 106 using a parallel circuit.
  • the receiver 101 comprises at least one output port that is connected to the module 102.
  • any type of circuit such as series, may be used for connecting the receiver 101 to the pike 105 and the dosing mean 106.
  • the module 102 comprises a controller 103 for processing data from the dosing mean 106, the pike 105 and the at least one sensor 107.
  • the output cable 109 of the dosing mean 106 is unused.
  • the present system uses the unused cable 109 to communicate the status of the at least one sensor 107 through an electrical impulse signal.
  • the output cable 108 of the dosing mean 105 is unused and may be used to communicate the status of the at least one sensor 107.
  • the electrical signal may be multiplexed in order to communicate the status of the plurality of sensors 107.
  • the signal shall be communicated through a series of 120 volt impulsions which are decoded by the receiver 101. In other embodiments, any voltage may be used.
  • the series of impulsion represents a binary signal.
  • the number of sensor 107 shall depend on the number of available input ports of the module 102 and on the possibility of multiplexing the impulsion signal.
  • the module 102 typically a controller card and also known as DPAA or ACCA, is used to detect the event when the pike 105 has drilled the crust. Upon detection of the completion of the drilling process by the pike 105, the module 102 triggers the deactivation of the pike 105.
  • the main objective of this automated deactivation of the pike 105 is to prevent unwarranted wear of the pike 105 and unnecessary consumption of compressed air.
  • the module 102 comprises a circuit used as a transformer to convert alternative current (AC) to isolated direct current (DC).
  • the transformer circuit comprises a resistance Rl, a bridge PI, a diode Dl, a tantalum capacitor CI and CV1.
  • the input AC voltage is 120V which is converted by the transformer to 5V DC.
  • the output DC voltage must be adapted to power and activate a processing unit (CPU).
  • CPU processing unit
  • the module 102 further comprises a circuit allowing controlling the pike 105.
  • a static electric relay RL1 conducts the electric signal to the "VALVE" terminal as the resistance R2 creates a current.
  • the "VALVE” terminal is active and allows the lowering of the pike.
  • the bath liquid typically cryolite
  • a protection circuit shall present to protect against excessive voltage from an anode effect.
  • the CPU is configured to detect when the voltage created by the electric potential difference reach a specific trigger level. When the CPU detects such trigger level, the CPU disables the "VALVE” output thereby raising the drill (or pike).
  • any other circuit allowing to control one or more pike in order to stop a stroke and retreat may be used.
  • the module 102 further comprises a terminal or input triggering the end of the stroke of a pike 105 (identified as "FIN DE COURSE” in Fig. 3).
  • the terminal "FIN DE COURSE” is powered by a constant signal.
  • the constant signal is stopped on the "FIN DE COURSE” terminal.
  • the CPU disables the "VALVE” output and the pike is brought back up.
  • the module 102 comprises another circuit used to transmit the result to an automaton controller (identified as PROT in Fig. 3).
  • such circuit comprises a relay RL2, a resistance R4 and an automaton controller PROT.
  • a relay RL2 a relay RL2
  • a resistance R4 a resistance
  • an automaton controller PROT any other circuit construction may be used.
  • the resulting signal is typically composed of information pulse series transmitted and synchronized to the line frequency (typically 120 half-cycles).
  • the result is synchronized by another circuit.
  • the pulse comprised in the resulting signal represents the risings curve of the current which are picked up or read by a receiver located near the automaton controller.
  • Different results signals are used to identify the following results: soaking, end of the stroke, no detection (system idling or in default position).
  • the circuit comprises a resistance R3 and an optical coupler OP1.
  • any other circuit construction allowing the synchronization of the result signal may be used.
  • the receiver unit 101 generally comprises four current sensors. In another embodiment, a different number of sensors may be used. Each sensor allows the detection of the current to detect. In the present embodiment, each sensor comprises an opto-coupler (OP3) and a resistor (R2), which allows the adjusting of the current threshold to be detected.
  • the receiver 101 further comprises the four detectors terminals, a timing circuit (R3 OP1), a CPU and two static outputs (RL1 RL2). Each detectors allows the identification of a request to pike into the crust. In another embodiment, a different number of detectors may be used.
  • the receiver 101 circuit is continuously powered by the current between a live terminal (identified as "VIVANT” in Fig. 4) and a neutral terminal (identified as "NEUTRE")-
  • a live terminal such as "VIVANT” in Fig. 4
  • a neutral terminal such as "NEUTRE"
  • the receiver CPU uses an opto-coupler (such as OP2) to detect the signal and activates or powers the corresponding pike 105 (such as PIQUEUR 1).
  • the module 102 of the corresponding pike is powered,
  • the VALVE terminal of the module 102 is then powered, thus creating current which is detected by a detector circuit (composed of R2 and OP3 in this example).
  • the VALVE terminal When the drilling process is completed, the VALVE terminal is turned off, thus the current falls below the detection threshold.
  • the receiver CPU awaits the result signal to be communicated by the module 102 as a series of current pulses. The receiver CPU then processes the resulting signal and activates the output corresponding to the resulting signal.
  • the output remains active as long as the demand is present for a specific length of time, typically a period of over one second, unless another detector terminal is activated by the automaton controller.

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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)
  • Processing Of Stones Or Stones Resemblance Materials (AREA)

Abstract

La présente invention concerne un système et un procédé intelligents de perçage par électrolyse d'aluminium, qui permettent de commander de façon intelligente la descente et la montée d'au moins une pointe pendant la perforation de croûte du processus d'électrolyse d'aluminium, afin d'arrêter la descente et de commencer la montée de la pointe aussitôt que celle-ci touche l'électrolyte, ce qui permet de réduire considérablement l'énergie requise pour le processus de perçage.
PCT/IB2014/063356 2013-07-23 2014-07-23 Système et procédé intelligents de perçage par électrolyse d'aluminium WO2015011665A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201361857445P 2013-07-23 2013-07-23
US61/857,445 2013-07-23

Publications (1)

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WO2015011665A1 true WO2015011665A1 (fr) 2015-01-29

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105256334A (zh) * 2015-10-30 2016-01-20 四川华索自动化信息工程有限公司 基于反馈信号调零处理的铝电解用智能打壳控制系统
CN105256335A (zh) * 2015-10-30 2016-01-20 四川华索自动化信息工程有限公司 一种铝电解用智能打壳控制系统
CN105369291A (zh) * 2015-10-30 2016-03-02 四川华索自动化信息工程有限公司 基于三极管自激式振荡电路的铝电解用智能打壳控制系统

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4377452A (en) * 1980-06-06 1983-03-22 Aluminium De Grece Process and apparatus for controlling the supply of alumina to a cell for the production of aluminum by electrolysis
US6436270B1 (en) * 1999-07-19 2002-08-20 Ab Rexroth Mecman Method and device for controlling the movement of a feeding and breaking chisel in an aluminum production cell
WO2007145590A1 (fr) * 2006-06-16 2007-12-21 Parker Hannifin Ab Système d'actionnement pneumatique
CN202492591U (zh) * 2012-03-05 2012-10-17 洛阳曦光气动液压元件有限公司 一种铝电解槽智能打壳控制系统

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4377452A (en) * 1980-06-06 1983-03-22 Aluminium De Grece Process and apparatus for controlling the supply of alumina to a cell for the production of aluminum by electrolysis
US6436270B1 (en) * 1999-07-19 2002-08-20 Ab Rexroth Mecman Method and device for controlling the movement of a feeding and breaking chisel in an aluminum production cell
WO2007145590A1 (fr) * 2006-06-16 2007-12-21 Parker Hannifin Ab Système d'actionnement pneumatique
CN202492591U (zh) * 2012-03-05 2012-10-17 洛阳曦光气动液压元件有限公司 一种铝电解槽智能打壳控制系统

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105256334A (zh) * 2015-10-30 2016-01-20 四川华索自动化信息工程有限公司 基于反馈信号调零处理的铝电解用智能打壳控制系统
CN105256335A (zh) * 2015-10-30 2016-01-20 四川华索自动化信息工程有限公司 一种铝电解用智能打壳控制系统
CN105369291A (zh) * 2015-10-30 2016-03-02 四川华索自动化信息工程有限公司 基于三极管自激式振荡电路的铝电解用智能打壳控制系统

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