铝电解槽电流强化与电热场仿真研究及应用
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摘要
电流强化是提高铝电解槽产量和经济效益的有效手段。我国现有的大部分铝电解槽阳极电流密度较低，有较大的电流强化潜力，因此研究电流强化方法及相应的配套技术措施对我国现阶段铝电解企业的增产、增效是有很重要的现实意义。
铝电解过程是一个多场耦合的复杂的物理化学过程，研究电流强化必须研究电流强化对三场的影响。本文采用工程测试手段利计算机仿真计算手段重点研究了电解槽电流强化后的热场变化情况及电流强化配套技术措施。
本文以龙祥铝业公司电解槽为电流强化研究对象，应用我院开发完善的铝电解槽热场仿真专用软件研究了阳极尺寸加大和加大阳极电流密度两种电流强化方案的优劣及工艺参数调整、槽结构材料改变对电流强化的影响。此外还研究了阳极电流分配不均匀性对槽膛内形的影响，并对阳极电流分配不均匀的原因进行了深入的分析，提出了改善阳极电流分配均匀性的技术途径。本文通过仿真计算和测试验证得出了如下结论：
1、现有的技术条件下，通过采用适当的配套技术措施，龙祥铝业公司154kA电解槽系列电流强化到160 kA是完全可行的，且增加阳极电流密度的强化方案比加大阳极的电流强化方案更经济。
2、槽底部使用防渗料代替耐火砖，有利于槽底部保温利延长电解槽的寿命。
3、槽侧部使用碳化硅砖代替普通碳砖，加强了侧部散热和抵抗电解质侵蚀的能力，有利于规整槽帮的形成、电解槽的电流强化和电解槽寿命的延长。
4、电解质的过热度影响着电解槽槽膛内形的的形成。研究得出：在龙样铝业公司现有技术条件下，电解质的过热度控制在12～15℃最为合适。
5、降低分子比，能有效地提高电解槽的电流效率，但同时带来了槽帮厚度的减薄和初晶温度线下移的不利影响。适当降低电解质过热度，能弥补降低分子比带来的不利影响。
6、阳极电流分配的均匀性对电解槽槽膛内形有决定性的影响，阳极电流分配的不均匀性增大对电流效率的提高和直流电耗的降低是不利的。本文研究认为极距的不同、各阳极碳块消耗的程度不同是影响阳极电流分配均匀性的主要因素。预热新更换的阳极碳块、在检测电流的基础上调节极距、加强磷生铁浇注质量检验，能有效地提高阳极电流分配的均匀性。
7、提出了与电流强化配套技术措施：增长阳极和阴极：适当降低极距和调低分子比等。经工业现场应用，取得了良好的成效。
Increasing current is one of the effective measures to increase products of aluminum reduction cells and economic profit in aluminum reduction plant. As the current density of the anode in most aluminum reduction cells is low comparatively in our country, improving current has great potential. It is significance to study ways of increasing current and relative technologies for increasing product and profit of aluminum electrolyte plants in China.
Aluminum electrolysis is a process of complicated physical chemistry reaction with multi-field coupled. It is indispensable to study increasing current influence on" three field " The variation of thermal field in the Based on and relative technologies after intensifying current are mainly studied in this paper by means of practical measure and computer simulation.
Aiming at the current increasing of the aluminum reduction cell of Longxiang Aluminum Ltd, based on the special simulation software of the thermal field of aluminum reduction cells, which is developed and perfected by school of Energy and Power Engineering, Central South University. The author studied excellence and disadvantage of two designs of enhancing current, optimization of technical parameters and variety of cell material in the cell, which are enhancing current density of anode and enlarging size of anode. Furthermore, asymmetry of current distribution influence on shape of profile ledge in the cell is studied and the reason is analyzed. The technical approach is put forward to improve the uniform distribution of anode current. The following conclusion has been achieved by means of simulation calculation and project test.
1. Under existing technical conditions, it is feasible to intensify current of the aluminum reduction cell of Longxiang Aluminum Ltd. from 154 kA to 160kA by means of appropriate technology measures. Furthermore, the current intensifying design of increasing current density of anode is superior to the one of enlarging anode in economy.
2. To Substitute anti-penetration material for the firebrick is beneficial to the heat
preservation in the bottom of aluminum reduction cells and the prolonging of the cells life.
3. To substitute ordinary brick made of carbon for brick made of Carborundum in the profile of the cells intensifies dispersion of heat in the profile of the cells and the capability of withstanding erosion of electrolyte. It is beneficial to the formation of optimized profile ledge, the increase of current and the prolonging of the cells life.
4. The super heat of electrolysis influences the shape of profile ledge in the cell.. This paper pointed out that the appropriate super heat of the electrolysis is between 12~15 C under present technology condition in the Longxiang Aluminum Ltd.
5. The decrease of molecule ratio can enhance current efficiency of aluminum reduction cells effectively, but simultaneously bring out some disadvantageous such as the decrease of profile ledge thickness and the moving down of the isotherm. Decreasing super heat properly can make up negative influences caused by lower molecule ratio.
6. The uniform distribution of anode current influences the shape of profile ledge in the cells definitively. Increasing asymmetry of anode current distribution is not beneficial to improving current efficiency and decreasing energy consumption The study indicated that the different distance between anode and cathode and the anode carbon consumption influence the uniformity of anode current distribution Heating new anode, regulating the distances between anode and cathode on the basis of measure of on-line of anode current, intensifying quality inspection of cast-material made of phosphor-iron can improve uniformity of anode current distribution effectively.
7. A serial of relative measures to increasing current have been put forward and applied. Such as to lengthen anode and cathode, to decrease distances between anode and cathode and reduce molecule ratio properly, and so on. Good effects have achieved the Longxiang Aluminum Ltd.
铝电解过程是一个多场耦合的复杂的物理化学过程，研究电流强化必须研究电流强化对三场的影响。本文采用工程测试手段利计算机仿真计算手段重点研究了电解槽电流强化后的热场变化情况及电流强化配套技术措施。
本文以龙祥铝业公司电解槽为电流强化研究对象，应用我院开发完善的铝电解槽热场仿真专用软件研究了阳极尺寸加大和加大阳极电流密度两种电流强化方案的优劣及工艺参数调整、槽结构材料改变对电流强化的影响。此外还研究了阳极电流分配不均匀性对槽膛内形的影响，并对阳极电流分配不均匀的原因进行了深入的分析，提出了改善阳极电流分配均匀性的技术途径。本文通过仿真计算和测试验证得出了如下结论：
1、现有的技术条件下，通过采用适当的配套技术措施，龙祥铝业公司154kA电解槽系列电流强化到160 kA是完全可行的，且增加阳极电流密度的强化方案比加大阳极的电流强化方案更经济。
2、槽底部使用防渗料代替耐火砖，有利于槽底部保温利延长电解槽的寿命。
3、槽侧部使用碳化硅砖代替普通碳砖，加强了侧部散热和抵抗电解质侵蚀的能力，有利于规整槽帮的形成、电解槽的电流强化和电解槽寿命的延长。
4、电解质的过热度影响着电解槽槽膛内形的的形成。研究得出：在龙样铝业公司现有技术条件下，电解质的过热度控制在12～15℃最为合适。
5、降低分子比，能有效地提高电解槽的电流效率，但同时带来了槽帮厚度的减薄和初晶温度线下移的不利影响。适当降低电解质过热度，能弥补降低分子比带来的不利影响。
6、阳极电流分配的均匀性对电解槽槽膛内形有决定性的影响，阳极电流分配的不均匀性增大对电流效率的提高和直流电耗的降低是不利的。本文研究认为极距的不同、各阳极碳块消耗的程度不同是影响阳极电流分配均匀性的主要因素。预热新更换的阳极碳块、在检测电流的基础上调节极距、加强磷生铁浇注质量检验，能有效地提高阳极电流分配的均匀性。
7、提出了与电流强化配套技术措施：增长阳极和阴极：适当降低极距和调低分子比等。经工业现场应用，取得了良好的成效。
Increasing current is one of the effective measures to increase products of aluminum reduction cells and economic profit in aluminum reduction plant. As the current density of the anode in most aluminum reduction cells is low comparatively in our country, improving current has great potential. It is significance to study ways of increasing current and relative technologies for increasing product and profit of aluminum electrolyte plants in China.
Aluminum electrolysis is a process of complicated physical chemistry reaction with multi-field coupled. It is indispensable to study increasing current influence on" three field " The variation of thermal field in the Based on and relative technologies after intensifying current are mainly studied in this paper by means of practical measure and computer simulation.
Aiming at the current increasing of the aluminum reduction cell of Longxiang Aluminum Ltd, based on the special simulation software of the thermal field of aluminum reduction cells, which is developed and perfected by school of Energy and Power Engineering, Central South University. The author studied excellence and disadvantage of two designs of enhancing current, optimization of technical parameters and variety of cell material in the cell, which are enhancing current density of anode and enlarging size of anode. Furthermore, asymmetry of current distribution influence on shape of profile ledge in the cell is studied and the reason is analyzed. The technical approach is put forward to improve the uniform distribution of anode current. The following conclusion has been achieved by means of simulation calculation and project test.
1. Under existing technical conditions, it is feasible to intensify current of the aluminum reduction cell of Longxiang Aluminum Ltd. from 154 kA to 160kA by means of appropriate technology measures. Furthermore, the current intensifying design of increasing current density of anode is superior to the one of enlarging anode in economy.
2. To Substitute anti-penetration material for the firebrick is beneficial to the heat
preservation in the bottom of aluminum reduction cells and the prolonging of the cells life.
3. To substitute ordinary brick made of carbon for brick made of Carborundum in the profile of the cells intensifies dispersion of heat in the profile of the cells and the capability of withstanding erosion of electrolyte. It is beneficial to the formation of optimized profile ledge, the increase of current and the prolonging of the cells life.
4. The super heat of electrolysis influences the shape of profile ledge in the cell.. This paper pointed out that the appropriate super heat of the electrolysis is between 12~15 C under present technology condition in the Longxiang Aluminum Ltd.
5. The decrease of molecule ratio can enhance current efficiency of aluminum reduction cells effectively, but simultaneously bring out some disadvantageous such as the decrease of profile ledge thickness and the moving down of the isotherm. Decreasing super heat properly can make up negative influences caused by lower molecule ratio.
6. The uniform distribution of anode current influences the shape of profile ledge in the cells definitively. Increasing asymmetry of anode current distribution is not beneficial to improving current efficiency and decreasing energy consumption The study indicated that the different distance between anode and cathode and the anode carbon consumption influence the uniformity of anode current distribution Heating new anode, regulating the distances between anode and cathode on the basis of measure of on-line of anode current, intensifying quality inspection of cast-material made of phosphor-iron can improve uniformity of anode current distribution effectively.
7. A serial of relative measures to increasing current have been put forward and applied. Such as to lengthen anode and cathode, to decrease distances between anode and cathode and reduce molecule ratio properly, and so on. Good effects have achieved the Longxiang Aluminum Ltd.
引文
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