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WO2018178509A1 - Mécanisme de dispositif de réglage des anodes d'une fonderie d'aluminium et procédé afférent - Google Patents

Mécanisme de dispositif de réglage des anodes d'une fonderie d'aluminium et procédé afférent Download PDF

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Publication number
WO2018178509A1
WO2018178509A1 PCT/FI2018/050212 FI2018050212W WO2018178509A1 WO 2018178509 A1 WO2018178509 A1 WO 2018178509A1 FI 2018050212 W FI2018050212 W FI 2018050212W WO 2018178509 A1 WO2018178509 A1 WO 2018178509A1
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WO
WIPO (PCT)
Prior art keywords
anodes
anode
adjustment device
adjustment
current
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/FI2018/050212
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English (en)
Inventor
Vesa Tarula
Markku RYTKÖNEN
Vesa Kumpulainen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kumera Oy
Original Assignee
Kumera Oy
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 Kumera Oy filed Critical Kumera Oy
Publication of WO2018178509A1 publication Critical patent/WO2018178509A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P5/00—Arrangements specially adapted for regulating or controlling the speed or torque of two or more electric motors
    • H02P5/46—Arrangements specially adapted for regulating or controlling the speed or torque of two or more electric motors for speed regulation of two or more dynamo-electric motors in relation to one another
    • 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
    • C25C3/08—Cell construction, e.g. bottoms, walls, cathodes
    • C25C3/10—External supporting frames or structures
    • 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
    • C25C3/08—Cell construction, e.g. bottoms, walls, cathodes
    • C25C3/12—Anodes
    • C25C3/125—Anodes based on carbon
    • 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 invention relates to an adjustment device mecha ⁇ nism for anodes of an aluminium smelter, and to a corresponding method for adjusting anodes of an aluminium smelter .
  • This invention relates to an anode-cathode electroly ⁇ sis cell typically used in a Hall-Heroult process for the production of aluminium, comprising a bottom of a tank serving as the cathode, and anodes suspended at a suitable distance from it, the anodes being adjusted by an adjustment apparatus.
  • each one of the anodes is provided with their own adjustment device for adjusting the anode independently of the other anodes. As the anodes are consumed during the process, they are adjusted lower so that the distance to the cathode remains suitable.
  • In one electrolysis cell there may be 20-40 anodes through which high electric current is conducted.
  • a common method of adjusting the anodes has been to fix them to an anode bridge transmitting the electric current, the bridge being then moved such that the an ⁇ odes move together.
  • the anodes are intended to be ar ⁇ ranged such that the system is formed by anodes con ⁇ sumed to different degrees, so that when one of them is consumed completely, they can be replaced one anode at a time, hindering the process as little as possi ⁇ ble.
  • the new anode is locked to the anode bridge so that the distance to the cath ⁇ ode is suitable, and the base of the anode is at the same level with the other anodes.
  • the point of attachment of the anode is higher than the other ones.
  • the consumption margin of the anodes is typically 2-3 fold compared to the movement range of the adjustment system moving the anode bridge.
  • the anodes are locked to be immovable with a separate locking device, and their locking to the anode bridge is opened, and the bridge is raised to the upper position with the adjustment apparatus, after which the anodes are again locked to the anode bridge and the next cycle begins.
  • Typical anode adjustment is carried out by driving all of them together, whereby it is important to keep them synchronized.
  • the difficulty of synchronization is due to the fact that the typical lifting device based on a screw jack and a worm gear is in practice an individu ⁇ al.
  • the lifting device is intended to be manufactured with low efficiency in order to be self-locking, so that it prevents back-rotation, i.e. the position of the anode does not change even if the device was not specifically braked.
  • the efficiency of lifting devices varies, and their efficiency is also improved with breaking in.
  • their moving speeds and stopping distances may be slightly different.
  • the typical adjustment cycle comprises several short adjustments one after the other, the inaccuracies caused by fric- tional differences begin to accumulate.
  • the adjusting accuracy may be improved by an apparatus that measures the position of the lifting devices, and by a support ⁇ ing control system. Motor control carried out in the normal way, however, results in a situation where, with slightly longer adjustments, the above-mentioned frictional differences cause deviation in the stopping positions, and a need for back-and-forth adjustment.
  • the motor power in anode systems is typically between 5-15 kW when one motor is used for adjusting all anodes at the same time.
  • each of the motors is considerably smaller, depending on the lower load, ranging between 0.3-1 kW .
  • the preferred induction motor typically used as the drive device moves at different speeds depending on the load. This is due to the slip that is inherent in the motor type.
  • the nominal speed of a 4-pole induction motor is 1500 rpm / 50 Hz, but with a nominal load it is typically 1425-1475 rpm when the motor size is 4-10 kW.
  • the speed varies according to load, being lower than the nominal speed at overload, and vice versa when operating at part load.
  • Overload protection is needed for the lifting devices in case of various disruptions. In collective motor systems, this is typically implemented with a current- based overload protector. This works in a satisfactory manner, even if the thermal relay does not react to the load of an individual anode. This is because the collective motor sized for driving all the lifting de- vices and anodes together operates at a relatively high loading range, which is 50-80% of the nominal load. Thus, the increase of electric current in the motor is quite linear, and overload situations can be easily estimated from it.
  • This invention intends to remedy the above-described defects of the prior art, and introduce additional features by means of which the ad ustability of the electrolysis process may further be enhanced.
  • the object of the invention is to dis ⁇ close an anode adjustment device mechanism and method that enable the anode effect to be removed as effi ⁇ ciently as possible.
  • an ad ⁇ justment device mechanism for anodes of an aluminium smelter wherein an aluminium production cell used in the smelter comprises a cathode forming the bottom of the production tank, and anodes that are held at a suitable distance from the cathode by lift ⁇ ing and lowering the anodes, the adjustment device mechanism comprising a control device having an algorithm, and for each of the anodes their own adjustment device that is independent of the other anodes and that includes its own power unit, arranged to control the power unit with the algorithm of the control de- vice in order to adjust the distance of the anode from the cathode independently of the other anodes or syn ⁇ chronously with the other anodes, and the adjustment device mechanism comprising a sensor for monitoring the movement or position of the anode or of a part that is proportional to its movement, and current measuring means for individually measuring the current of each of the anodes, and that the algorithm of the control device is
  • the invention relates to a method for adjust ⁇ ing anodes of an aluminium smelter.
  • a method for adjusting anodes of an aluminium smelter is disclosed, wherein an aluminium production cell used in the smelter comprises a cathode forming the bottom of the production tank, and anodes that are held at a suitable distance from the cathode by lifting and lowering the anodes, and an adjustment device mechanism comprising a control device having an algorithm, and for each of the anodes their own adjustment device that is independent of the other anodes and that includes its own power unit, for controlling the power unit with the algorithm of the control device in order to adjust the distance of the anode from the cathode independently of the other anodes or synchronously with the other anodes, in which method the position and speed of the anode or of a part that is proportional to its move ⁇ ment are monitored by a sensor, the current of each of the anodes is individually measured by
  • the invention relates to a method for driving an ad ⁇ justment device mechanism for anodes of an electroly ⁇ sis process separately for each of the anodes in alu- minium production, such that each individual anode is controlled by its own adjustment device having its own driving device for moving the anode up or down independently of the other anodes.
  • the corresponding appa ⁇ ratus is provided with technology enabling speed ad- justment of the driving device, for example with a frequency converter in connection with an electric motor.
  • the con ⁇ trol system may learn suitable drive control so as to compensate for differences in the mechanical efficien ⁇ cy of the adjustment devices due to manufacturing, such that the adjustment is accurate, and positioning adjustments back and forth can be minimized.
  • the object of the invention is possible to be carried out by providing each of the anode driving devices or motors with control by means of which the moving speed and the acceleration and deceleration ramps of the an- ode may be adjusted.
  • One such device is for example a frequency converter when the driving device an elec ⁇ tric motor.
  • the method may be provided, according to the inven- tion, with control measuring the moving speed of each individual by means of a position sensor. These data may be proportioned to the driving load that depends on the degree of consumption and moving direction of the anode. Based on these parameters, specific effi- ciency for different loads is calculated for the lift ⁇ ing device. Using these data, the adjustment is car ⁇ ried out such that an anode moving more heavily is driven, in case of a frequency converter, at a higher frequency, whereby the real moving speed remains as constant as possible.
  • Frequency converters also enable acceleration and deceleration ramps to be programmed, and they may be adjusted to further increase the posi ⁇ tioning accuracy. This kind of self-learning mode of control substantially reduces the need of additional back-and-forth adjustment in the positioning.
  • the advantages of using frequency converters may also be utilized more widely. Many times the need of ad ⁇ justment is very short, such that by using a short control pulse, the anodes are intended to be slightly twitched to a desired direction. When short controls are used in a situation where the movement has not yet reached full speed, the kinetic frictions are very nonlinear. This is seen such that when reaching for adjustment of 0.5 mm with a control pulse of 0.3 s, the real movement may be 0.3 mm, but when reaching for adjustment of 1 mm with a control pulse of 0.6 s, the movement may be up to 1.5 mm.
  • Using separate motors also enables reliable load meas ⁇ urement for the actuator based on the motor current, because each motor is sized to be suitable for the lifting device. Thus, the current range is more line ⁇ ar, and load estimation from it is sufficiently accu ⁇ rate. A suitable motor is furthermore not able to overload and damage the lifting device.
  • Using a fre ⁇ quency converter introduces automatic load measure- ment, and there is no need for a separate thermal fuse. The load may also be monitored remotely during driving with reasonable accuracy, taking into consid ⁇ eration the limitations imposed by the low efficiency (approximately 20%) of the lifting devices. Thus, timely alerts may be obtained for a malfunctioning de ⁇ vice that is expected to be damaged.
  • Load measurement using a weighing sensor is an expensive and unreliable method due to the special conditions of the aluminium production cell, high temperature and magnetic field. And it may not be used for detecting the condition of the lifting device seen as change of efficiency.
  • Using a self-learning frequency converter thus enables overload protection of the device, accurate positioning and condition monitoring based on monitoring of the development of specific efficiency.
  • the adaptive adjustment apparatus operates in the following way.
  • the position of each of the adjustment devices adjusting the position of the anode is measured by their own po ⁇ sition sensor, typically an absolute rotating position sensor connected to any of the rotating shafts of the adjustment device.
  • the resolution of the sensor is se ⁇ lected such that the accuracy is better than the re ⁇ quired anode positioning accuracy, which is typically +- 0.5 mm.
  • the position data given by the sensor are read to the anode cell control unit.
  • the anode control is primarily based on the position data given by the sensor and on a command given by the control unit for the desired change of position, which provides a new target value for the position of the adjustment de ⁇ vice.
  • a position adjustment algorithm is programmed for the control unit for starting the motor in the de ⁇ sired direction and stopping it at the given position target address. Because there are differences in the adjustment devices due to mechanical qualities and the anode load, the preferred typically used induction mo- tor is not able to drive the devices at the same speed due to the slip varying according to load, and thus due to the rotating speed.
  • the apparatus and method according to the invention it is the object to improve the accuracy of adjustment described above by means of a self-learning control logic using the measured position data and the real speed calculated from it, and if necessary, the motor loading torque measured with the frequency converter. Based on these values, correction factors for the speed command are calculated for up and down driving separately for each of the devices and loads. These data may also be updated at a suitable delay in order to compensate, for example, for the sensitization due to breaking in of the adjustment device.
  • the position measurement data may also include calculation of the stopping speed of the device in various situations, based on which a suitable deceleration ramp is defined for the frequency converter for stopping the devices as accurately as possible at a desired distance after the stopping command.
  • Stopping accuracy may also be improved with a creeping drive before stopping, during which the final precise adaptation of the positions may be carried out in a controlled manner.
  • the positioning may also be carried out as a creeping drive alone with short adjusting movements.
  • a quick and longer back-and-forth adjustment may be needed for a short time. This may be done by means of the frequency converters with a quicker-than-normal driving movement by changing the speed command.
  • the adaptive separate adjustment ac ⁇ cording to the invention also enables fine tuning sep ⁇ arately for each of the anodes according to how the electric current measured for each of the anodes sepa ⁇ rately deviates from the average value. This may be due to abnormal consumption of the anode or a local anode effect where undesirable gas bubbles insulating the electric current are formed at the lower surface of the anode. Normally, when they are present over the whole cell to such extent that the voltage drop ex- ceeds a specific limit, all anodes are lifted at the same time, and other bubble-removing operations are carried out in the bath. By means of separate adjust ⁇ ment and separate measurement, the removal of the bub- bles may be carried out locally at an earlier stage, thus increasing the efficiency of aluminium produc ⁇ tion .
  • control device gives a problematic anode a command for a new position, for example at a higher-than-normal speed, so as to increase a transversal flow of the electroly ⁇ sis bath below the rising anode, forcing gas bubbles away.
  • the separate adjustment also enables another an- ode to be lowered at the same time, such that the lev ⁇ el of the bath remains the same, and the process is disturbed as little as possible.
  • the pow- er unit is an electric motor arranged to have adjusta ⁇ ble speed and torque.
  • the electric motor is an induction motor arranged to be controlled by a frequency converter.
  • the sen ⁇ sor is an encoder measuring the rotation and/or position of a part.
  • the sen ⁇ sor is a linear potentiometer measuring the position of a part of a structure moving with the anode in a vertical direction.
  • the quantity of elec ⁇ tric current of an individual anode is measured, and the distance of the anode from the cathode is con- trolled based on the measurement.
  • the adjustment is car- ried out by adjusting the speed and torque of the electric motor serving as the power unit.
  • the position and move- ment of the anode re measured by measuring the move- ment and position f the adjustment device by one or more sensors.
  • parameters represent ⁇ ing the real movement are determined for the lifting device based on the current of the motor, the position and moving speed measured and calculated from the sen- sor, and the weight to be lifted according to the po ⁇ sition of the anode.
  • the driving parame ⁇ ters of movement control are corrected based on the real movement values, so that the following runs will be more accurate.
  • the anode effect is removed by lifting one or more anodes and correspond ⁇ ingly lowering one or more anodes at variable speeds to enhance the discharge flow of the gas bubbles in order to reduce the anode effect.
  • the anode effect is detected by measuring the electric current separately for each of the anodes.
  • the control device is used for verifying individual moving properties of in ⁇ dividual adjustment devices and predictively adapting the control parameters according to these properties, such that the separate adjustment devices substantial- ly move at the same speed and substantially stop at the same position when the anodes need to move in a synchronized manner.
  • Fig. 1 illustrates one aluminium production cell according to the invention
  • Fig. 2 shows an electric control diagram relating to the invention.
  • Fig. 1 illustrates a simplified version of an electro ⁇ lytic aluminium production cell with only three anodes.
  • This version comprises a cathode 2 serving as the bottom of the cell, and anodes 1 supported by an anode adjustment device 4 at a suitable distance from the cathode, depending on the thickness of a molten aluminium layer on the bottom.
  • the structure also comprises a busbar 3 supplying current to the anodes 1, and flexible current supply cables 5 connected to a central bar 6 of the anodes from the busbar.
  • the cur- rent supply cables are typically made from several thin aluminium strips having good flexibility and al ⁇ lowing the movement of the anode while conducting electric current through the anodes.
  • the adjustment devices 4 are connected to a frame 7 of the machine that stands on the floor.
  • Each of the anode adjustment devices 4 includes its own electric motor 8 and a sen ⁇ sor 9 monitoring the position of the device, which may typically be an encoder measuring the rotation and po- sition of a part, or a linear potentiometer measuring the position of a part of a structure moving with the anode in a vertical direction.
  • Fig. 2 shows a typical electric control diagram of the system.
  • the electric motor 8 driving the adjustment device 4 is connected with a cable 16 to a frequency converter 10.
  • the motor 8 also has typ ⁇ ically built-in thermistors 15 that protect the motor from overheating and are electrically connected via a cable 18 to the frequency converter 10.
  • the frequency converters 10 are controlled according to commands given by an algorithm of a control device 13.
  • the control device 13 is a control logic 13 having an algo ⁇ rithm. All of the frequency converters may be connect- ed to a same electric control bus 12, which is in turn connected to the control logic 13. Further, the con ⁇ trol logic 13 is connected to current measuring means 100 that individually measure the current of each of the anodes.
  • An I/O device 14 is connected to the con- trol logic 13 for monitoring the state of the system and changing the settings as needed. Also, manual ad ⁇ justment of individual anodes or programmed automatic driving may be switched on from the I/O device 14.
  • the I/O device is typically an industrial PC comprising a display, a central processing unit and an input de ⁇ vice.
  • a sensor 9 measuring the position of the adjustment is also connected to the adjustment device 4 for transmitting real-time data to the control logic 13 of the position of the adjustment.
  • the control log ⁇ ic 13 also calculates a speed on this basis and com ⁇ pares the value to other simultaneously moving anode adjustment devices 4 and, if necessary, gives the fre ⁇ quency converter 10 a different speed command so that the real speeds of the adjustment devices 4 moving at different speeds would correspond to each other.
  • These data are stored for each of the adjustment devices in a table of the control logic 13 separately for differ ⁇ ent types of driving situations. Thus, by using the corrected value further on, the devices will move more accurately at the same speed.

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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)
  • Power Engineering (AREA)
  • Electrolytic Production Of Metals (AREA)

Abstract

L'invention concerne un mécanisme de dispositif de réglage des anodes d'une fonderie d'aluminium et un procédé afférent. La cellule de production d'aluminium utilisée dans la fonderie comprend une cathode (2) formant le fond du réservoir de production, et des anodes (1) qui sont maintenues à une distance appropriée par rapport à la cathode, par levage et abaissement. Le mécanisme de dispositif de réglage comprend un dispositif de commande (3) opérant sous algorithme. Chacune des anodes (1) a son propre dispositif de réglage (4) qui est indépendant de celui des autres anodes et comprend sa propre unité d'alimentation (8), et le dispositif de réglage (4) est conçu pour amener l'unité d'alimentation (8) à l'aide de l'algorithme du dispositif de commande (13) à ajuster la distance de l'anode par rapport à la cathode, indépendamment des autres anodes ou de manière synchrone avec les autres anodes. Le mécanisme de dispositif de réglage comprend un capteur (9) qui surveille le déplacement ou la position de l'anode (1) ou d'une partie qui est proportionnelle à son déplacement, et des moyens de mesure de courant (100) qui mesurent individuellement le courant de chacune des anodes. L'algorithme du dispositif de commande (13) est conçu pour sélectionner, en fonction du mouvement et de la position surveillés par le capteur (9) et du courant de l'anode mesuré par les moyens de mesure de courant (100), en liaison avec le levage et l'abaissement de ladite anode, le mode optimal de réglage de l'accélération en début et en fin de mouvement.
PCT/FI2018/050212 2017-03-29 2018-03-22 Mécanisme de dispositif de réglage des anodes d'une fonderie d'aluminium et procédé afférent Ceased WO2018178509A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FI20175294 2017-03-29
FI20175294 2017-03-29

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WO2018178509A1 true WO2018178509A1 (fr) 2018-10-04

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2566674A (en) * 2017-08-01 2019-03-27 Dubai Aluminium Pjsc Electrolytic cell for aluminium production, with individual anode drives
CN112350319A (zh) * 2020-11-23 2021-02-09 云南电网有限责任公司 一种电解铝涉网紧急降功率系统及控制方法
CN115909017A (zh) * 2022-11-25 2023-04-04 四川启明星铝业有限责任公司 一种电解铝厂偏心阳极自动识别控制方法及系统

Citations (3)

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Publication number Priority date Publication date Assignee Title
GB2111082A (en) * 1981-12-08 1983-06-29 Pechiney Aluminium Adjustment of the anode plane of an aluminium production electrolysis cell
WO2001031086A1 (fr) * 1999-10-26 2001-05-03 Moltech Invent S.A. Cellule fonctionnant a faible temperature pour extraction electrolytique d'aluminium
AU2015208855A1 (en) * 2014-01-27 2016-07-28 Rio Tinto Alcan International Limited Electrolysis tank comprising an anodic assembly hoisting device

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2111082A (en) * 1981-12-08 1983-06-29 Pechiney Aluminium Adjustment of the anode plane of an aluminium production electrolysis cell
WO2001031086A1 (fr) * 1999-10-26 2001-05-03 Moltech Invent S.A. Cellule fonctionnant a faible temperature pour extraction electrolytique d'aluminium
AU2015208855A1 (en) * 2014-01-27 2016-07-28 Rio Tinto Alcan International Limited Electrolysis tank comprising an anodic assembly hoisting device

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Title
FIDRI / EIF200: "ACSM1 Motion Control Program Firmware Manual", ABB OY, 30 June 2015 (2015-06-30), XP055543113, Retrieved from the Internet <URL:https://library.e.abb.com/public/6eb2fea8f1da46609c57a06a71007e61/ACSM1-FW_motion_revH_screen_A4.pdf> [retrieved on 20180601] *

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2566674A (en) * 2017-08-01 2019-03-27 Dubai Aluminium Pjsc Electrolytic cell for aluminium production, with individual anode drives
CN112350319A (zh) * 2020-11-23 2021-02-09 云南电网有限责任公司 一种电解铝涉网紧急降功率系统及控制方法
CN112350319B (zh) * 2020-11-23 2023-04-11 云南电网有限责任公司 一种电解铝涉网紧急降功率系统及控制方法
CN115909017A (zh) * 2022-11-25 2023-04-04 四川启明星铝业有限责任公司 一种电解铝厂偏心阳极自动识别控制方法及系统

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