The level of aluminum carbon consumption in aluminum electrolysis production is directly related to the economic benefits of the enterprise. Starting from the actual production, the following are specific ways to reduce the consumption of carbon per ton of aluminum in aluminum electrolytic cells, which can effectively help electrolytic aluminum enterprises to save energy and reduce consumption and improve economic benefits.
How to reduce the carbon consumption of electrolytic aluminum?
1. Improve current efficiency
Improving the current efficiency is an important way to reduce the consumption of aluminum and carbon. The current efficiency is improved, and the output is also increased, and the consumption of anode carbon block per ton of aluminum is less.
2. Improve the quality of anode carbon block
Anode quality affects anode consumption. Usually, high-quality anodes have better mechanical strength and anti-oxidation performance, and rarely occur oxidation and block drop. To improve the quality of anode carbon block, it is necessary to control the calcination temperature of raw materials, raw material formula, product forming process and roasting of green carbon block.
3. Ensure that the anode works normally
Improve the quality of the pole changing operation, set the correct anode height, prevent the anode current from biasing, and prevent the anode from overheating. During the pole changing process, remove the alumina crusts and furnace bottom deposits to prevent the anode from being long and avoid anode lesions. Adding anode insulation material during operation is the best way to block the contact between anode and air. Adding anode insulation material can prevent the anode above the electrolyte from contacting with air, reducing anodic oxidation and excessive consumption of anode.
4. Control the electrolyte temperature
The temperature of the electrolyte is affected by many factors such as the working voltage of the electrolytic cell, the level of molten aluminum, the thickness of the anode insulation material, the composition of the electrolyte, the anode effect coefficient and the working state of the anode. Production practice shows that when the electrolysis temperature changes by 10℃, the net consumption of anode can fluctuate in the range of 12kg/t-Al. Therefore, maintaining a suitable electrolyte temperature (925-935 °C) can effectively reduce anode carbon consumption.
5. Make the most of the stump
Whether the old tank is stopped or the new tank is started, there will be more thick residues, and making good use of these residues is also an important way to reduce the consumption of carbon per ton of aluminum in production. For the residual electrode that has been placed in the tank, the inspection of the anode should be strengthened, and the anode that is too thick should be replaced, and the life cycle of the anode should be extended as far as possible under the condition that the claws are not washed and the cake is not exposed.
6. Install anode protection ring
A small anode steel claw protection ring is installed on each steel claw of the anode, which can greatly reduce the carbon consumption. The test shows that the pole changing cycle and the carbon consumption per ton of aluminum have been extended and reduced respectively since the anode steel claw protection carbon ring was put into production and use in the electrolysis workshop.
7. Adopt anodic anti-oxidation coating technology
The coating material forms insulation protection on the side surface of the electrolytic aluminum prebaked anode carbon block by coating or spraying, preventing the erosion of surrounding air, CO2 and electrolyte steam, reducing the oxidation slag around the anode carbon block, and ensuring a series current. Under the same premise, the conductive area at the bottom of the anode carbon block is relatively increased, and the current density will decrease, so the height of the anode carbon block consumed every day will also decrease.
