The carbon slag produced by the aluminum electrolysis cell can reduce the electric efficiency by 3~5% when it is severe, resulting in the increase of the electricity consumption per ton of aluminum by 400~700 degrees, so it is very unfavorable to the electrolyzer, and the 200kA electrolyzer can be used to collect the carbon residue manually every day. More than 20 kilograms of carbon residue, 13 kilograms of aluminum, accounting for about 2.5% of tons of aluminum and carbon consumption. In order to better take effective measures to prevent the large amount of carbon slag, the following technical measures can be taken accordingly.
First, maintain a suitable thickness of insulation material
Practice has proved that the insulation material is too thin and easy to make the air contact with the anode surface, so that the surface of the carbon block oxidation slag; too thick can cause the far tank temperature should generally be maintained at 14 ~ 18cm. In addition, the finer the particle size of the crushed noodle shell is, the better, and if most of the particle size diameter exceeds 5 cm, it is easy to cause the phenomenon of air-permeable oxidation and dregs.
Second, maintain proper electrolyte levels
The level of electrolyte is one of the main factors that determine the oxidation residue of carbon block. Electrolyte level is too low will reduce the storage tank heat, is not conducive to stable tank conditions, but the electrolyte is too high, especially more than the residual pole (refers to two days to change the pole) plane, and about 950 degrees of electrolyte solution circulating in the carbon When the surface of the block is dissolved, the solid insulating material melts into a fluid, so that the surface of the carbon block will increase oxidation and the amount of carbon slag will increase sharply. Therefore, the electrolyte level is kept at a height of 19~21cm.
Third, the use of no lower edge anti-corrosion anode carbon block
The non-undercut carbon block transforms the transition angles of the sides and bottom surface of the carbon block from 90 degrees to a chamfered or arc shape. After the slot is closed, the new pole is carefully observed in the first two days. The new pole is basically non-conductive, but the lower edge changes from a right angle to an arc shape. This shows that the main reason for forming the arc angle at this time is to flush the anode with electrolyte. Carbon blocks are used to reduce the use of carbon slag, which has become useless underneath the ribs. It is reported that an aluminum plant in Norway has adopted the scheme and the transition angle is arc-shaped. The main advantages of the non-undercut carbon block are its strong resistance to scouring, which can effectively reduce the carbon slag in the tank and improve the electrical efficiency.
After calculation, the anode carbon block of 1450×660×570mm used on the 200kA electrolyzer is changed from right angle to chamfer angle of 50450. The weight of the single block is reduced by 12kg, and the carbon consumption per ton of aluminum can be reduced by 8kg, pressing 2500 per ton. In yuan calculations, the cost per ton of aluminum is reduced by 20 yuan. Since the carbon slag is reduced, the slot resistance is reduced, so that the slot voltage can be reduced, which can increase the electrical efficiency by more than 0.5%, reduce the electricity consumption per ton of aluminum by 75 degrees, and can reduce the cost per ton of aluminum by 30 yuan per 0.4 yuan. The sum of the two results can reduce the cost of aluminum production by 50 yuan. Taking China's small and medium-sized aluminum ingot enterprises with an annual output of 100,000 tons as an example, a net profit increase of 5 million yuan can be achieved each year.
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