Accelerate the innovation of primary aluminum extr

2022-08-15
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Accelerate the technological innovation of primary aluminum extraction in China

the technological innovation and R & D work of primary aluminum extraction industry are carried out around energy conservation and emission reduction, or its goals are to save energy and emission reduction, improve the working environment and safety guarantee, and extend the life of the tank, etc. In 2017, the average DC power consumption of primary aluminum in China was 13577kwh/ton, compared with 14100kwh/ton in the world. For each ton of primary aluminum extracted in China, 523kwh less power was used. In 2017, the power consumption of primary aluminum produced in China was about 1657mwh less than that of foreign countries, and greenhouse gas emissions were reduced accordingly. China's primary aluminum industry has ranked among the world's advanced in terms of power consumption, but the service life of China's aluminum reduction cells is much shorter than that of foreign countries

according to relevant data, the average life of prebaked cells in developed countries is 2435d at present, while that in China is only 1957d, which is about 478d shorter than that in foreign countries. This gap is still not small. At present, the longest tank life abroad is about 4000d, while the 160kA tank life of Chalco Guizhou branch has reached 4893d, 22.3% longer than that of foreign countries

China has become a major producer of primary aluminum in the world and a primary power of primary aluminum. It should also be the leader of energy conservation and emission reduction of primary aluminum in the world. Therefore, it is advisable to concentrate human, financial and material resources to carry out large-scale research on how to significantly reduce the energy consumption of primary aluminum and non carbon inert anode, and strive to reduce the average energy consumption of primary aluminum extraction in China to 12500kwh/tal in 2025, that is, 1077kwh/tal lower than 13577kwh/tal in 2017, That is to say, a reduction of 8%, if not 8%, then a reduction of 5% is also very remarkable

for this reason, the author suggests that a research and Development Institute for non carbon inert anodes can be established in the technical center of a large aluminum plant. The state is the major shareholder, and other aluminum plants and relevant units can take shares, so as to concentrate the best soldiers and strong generals in the country and hold a "ten thousand meter race" with the world's leading aluminum company

the following is a description of two recent milestones in the technology of the primary aluminum industry: one is the Hal 4E and Hal 4E ultra technology of hydro; The second is the non carbon anode aluminum electrolysis technology being developed by elysis

hal 4E and Hal 4E ultra tank

impact testing machine 1 is generally a complete set of equipment.

hal 4E and Hal 4E ultra technology are developed by hydro aluminum company. The former has been in pilot production, and the latter is under development. The pilot production line was built in the company's Kamo aluminum plant in Norway. In January 2017, the first batch of thick aluminum was produced, which is currently the most environmentally friendly and energy efficient in the world. Its energy consumption and CO2 emissions are 15% lower than the current world average, with only 11985kwh/ton of aluminum, which is very remarkable. In 2017, the world's average energy consumption was 14100kwh/ton of aluminum. At present, the primary aluminum production capacity of the pilot production line is 75kt/A, and hydro aluminum plans to increase the output of Hal 4E trough to 200kt/A in 2020. This is an unprecedented record level in the world. I'm afraid it will be difficult for other aluminum companies to achieve this level before 2025

hal 4E technology development

for a long time, hydro aluminum has placed the technological innovation of primary aluminum extraction process in a very important position. As early as the 1970s, it successfully developed asv170 technology with Aluminum Corporation of Canada. Since then, hydro aluminum has never stopped the pace of innovation. It not only has a strong technical innovation team, but also cooperates closely with the Norwegian University of science and technology. In 1981, it put hal220 tank into operation in hoyange aluminum plant in Norway; In 1988, hal230 trough was successfully developed in Venezuela Rena aluminum plant, and this trough was effectively operated in Slovak aluminum company in 1995; In 2009, Qatar Aluminum Corporation also adopted its hal300 groove

in 2004, hydro aluminum decided to develop Hal 4E and Hal 4E ultra tank technology, and transferred a number of technical funds from ADAR aluminum plant, Kamo aluminum plant, boshglen aluminum plant and neus aluminum plant in Germany to provide customers with the technical backbone of the spray free scheme specially developed for the household appliance industry, which fully mobilized the enthusiasm of each research center and gave full play to their expertise, some engaged in tank design, and some engaged in process control, Some are engaged in material science and engineering research, while others focus on model establishment and analysis

after several years of joint research with clear division of labor and concentration of all technical forces, such as whether the actions of sliding plate, thimble, tooth retraction structure and limit switch are accurate, the most remarkable achievements in the technological progress of primary aluminum industry in recent 20 or 30 years were finally achieved in 2008. The first batch of Hal 4E test tanks were selected and built in ADAR aluminum plant, which provides more advanced technology, higher efficiency The development of Hal 4E ultra tank with lower energy consumption and more environmental protection has laid the foundation, and the finalization of this tank will continue until 2016. Due to the precise control of magnetic field, the reduction of electrolyte resistance and the adoption of advanced control system, the anode spacing is reduced, and good comprehensive benefits are achieved

now researchers are continuing to carry out innovative work to make the model more reasonable, the process control more perfect, the process parameter regulation more effective and fast, and use new anodes to enter large-scale industrial production as soon as possible, creating the world's most energy-efficient aluminum electrolysis enterprise

construction of Hal 4E pilot electrolytic cell series in Kamo aluminum plant

hal 4E cell production plant is built next to the electrolysis workshop of Kamo aluminum plant. By 2017, Kamo aluminum plant has a history of 50 years. The raw aluminum production capacity of Kamo aluminum plant is 125kt/a, and the raw aluminum production capacity of pilot plant is 75kt/a. All the electricity used is green hydropower

the pilot electrolytic cell series was built on the site of the abandoned old self baking cell, and the self baking cell electrolytic line was discontinued in 2009 for environmental reasons. The new pilot line is composed of 60 new tanks, of which 48 are Hal 4E type that can be industrialized pilot production. The current intensity is 450ka, the current efficiency is 95%, and the energy consumption is 12.3kwh/kgal, which is much lower than the world average skill consumption of 14.1kwh/kgal that must be mastered in the advanced work examination of cable testing work and the average energy consumption of 13.8kwh/kgal of hydro aluminum. Compared with SU4 tank of sunndal aluminum plant of hydro aluminum and Hal 300 tank of Qatar aluminum, the primary aluminum output of each tank of the pilot test line of Kamo aluminum plant can be increased by 50%

the remaining 12 tanks are used to test Hal 4E ultra technology, and their current intensity is slightly lower, 415ka-450ka. Hydro aluminum hopes that the energy consumption of this technology can reach 11.5kwh/kgal-11.8kwh/kgal, which cannot be achieved by any other plant in the world in the near future

hal 4E tank's direct CO2 emissions are 0.8kg/kgal lower than the world average emissions, while the direct CO2 equivalent emissions can be reduced to 1.40kg/kgal - 1.45kg/kgal, Kamo aluminum plant can reduce emissions of 60ktco2 in a year. Hydro aluminum plans to upgrade all electrolytic cells in Kamo aluminum plant to Hal 4E and Hal 4E ultra, making it the most energy-saving, emission reduction and efficient raw aluminum production enterprise, and a banner of the world's aluminum electrolysis industry

the carbon free raw aluminum extraction technology of illix company

since the industrial production of aluminum in 1888, every 1kg of raw aluminum has been extracted by hall heroalt electrolysis. Electrolytic production of 1 ton of raw aluminum can release 15.4 tons of CO2, so the CO2 released by the aluminum electrolysis industry around the world every year is very amazing. In order to protect the environment, scientists are struggling to pursue the anode material for extracting raw aluminum without carbon anode electrolysis. However, it is a great pity that so far, a kind of non carbon anode material with very practical price has not been found. Illix company is a professional company established to develop this kind of non carbon anode material

elysis company

elysis company (elysis), founded earlier this year in Montreal, Quebec, Canada, is a joint venture between Alcoa and Rio Tinto Alcan, specializing in the research and development of carbon free electrolytic aluminum process. The company was established with the help of apple. The two companies plan to invest 55 million Canadian dollars in the next three years; Apple will also invest 13million Canadian dollars and provide technical support; Quebec and Montreal municipal governments will each invest $60million

Alcoa has successfully developed a new metal anode material that is not corroded by electrolyte. Since 2009, it has been tested in the company's Pittsburgh technology center and achieved reliable results. If all non carbon anodes are used in the aluminum electrolysis industry in Canada, the direct emissions of greenhouse gases can be reduced by 6500kt/a, which is roughly equivalent to the emissions of 1.8 million small passenger cars in one year, creating thousands of jobs for Canada and further prospering the aluminum industry in Quebec; This is a historic time for the aluminum industry

metal inert anode

inert anode is what we call non carbon anode, which can be divided into ceramic type and metal type. Alcoa developed the former, while meltech of Switzerland focused on the latter. After nearly 30 years of innovative research, it has made a lot of achievements and accumulated a lot of experience, but it has not made a historic breakthrough. Some scientific research institutions and colleges and universities in China have also carried out some research, but due to various reasons, mainly funding problems, little progress has been made. No matter what kind of non carbon anode, it must be coated with a layer of oxide on its surface, first, for conductivity, and second, to reduce the dissolution rate of metal in cryolite electrolyte. Meltech has also done a lot of research on metal inert anodes

the research and development of non carbon inert anodes are mostly concentrated in Ni Fe alloy and Ni Fe Co alloy, among which the representative is Dr. de Nora's Fe Ni Cu alloy, which is also known as Veronica alloy metal anode, and its surface is coated with a layer of cobalt oxide active crust

inert metal anode must have several conditions to have practical value: its life cost should be equivalent to that of carbon anode in the same period or even higher, but there are other measures that can be compensated; The elements dissolved in the electrolyte of metal inert anode have no effect on the quality of primary aluminum; The power consumption must be less than or at least equal to that of carbon anode; The electrolytic cell can directly replace the metal inert anode without large-scale transformation of the existing electrolytic cell

everyone knows more about ceramics, so there is no warning about ceramic inert anode

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