Various busbar configurations were built and modeled by the custom code based on the commercial package ANSYS for the 500 kA aluminum electrolysis cell.The configuration parameters,such as side riser entry ratio,numbe...Various busbar configurations were built and modeled by the custom code based on the commercial package ANSYS for the 500 kA aluminum electrolysis cell.The configuration parameters,such as side riser entry ratio,number of cathode bars connected to each riser,vertical location of side cathode busbar and short side cathode busbar,distance between rows of cells in potline,the number of neighboring cells,ratio of compensation busbar carried passing under cell and its horizontal location under cell along with large magnetohydrodynamic(MHD) computation based on the custom evaluation function were simulated and discussed.The results show that a cell with riser entry ratio of 11:9:8:9:11 and cathode busbar located at the level of aluminum solution,50% upstream cathode current passing under cell for magnetic field compensation,the distance between rows of 50 m is more stable.展开更多
Cell voltage is a widely used signal that can be measured online from an industrial aluminum electrolysis cell.A variety of parameters for the analysis and control of industrial cells are calculated using the cell vol...Cell voltage is a widely used signal that can be measured online from an industrial aluminum electrolysis cell.A variety of parameters for the analysis and control of industrial cells are calculated using the cell voltage.In this paper,the frequency segmentation of cell voltage is used as the basis for designing filters to obtain these parameters.Based on the qualitative analysis of the cell voltage,the sub-band instantaneous energy spectrum(SIEP)is first proposed,which is then used to quantitatively represent the characteristics of the designated frequency bands of the cell voltage under various cell conditions.Ultimately,a cell condition-sensitive frequency segmentation method is given.The proposed frequency segmentation method divides the effective frequency band into the[0,0.001]Hz band of lowfrequency signals and the[0.001,0.050]Hz band of low-frequency noise,and subdivides the lowfrequency noise into the[0.001,0.010]Hz band of metal pad abnormal rolling and the[0.01,0.05]Hz band of sub-low-frequency noise.Compared with the instantaneous energy spectrum based on empirical mode decomposition,the SIEP more finely represents the law of energy change with time in any designated frequency band within the effective frequency band of the cell voltage.The proposed frequency segmentation method is more sensitive to cell condition changes and can obtain more elaborate details of online cell condition information,thus providing a more reliable and accurate online basis for cell condition monitoring and control decisions.展开更多
Based on the commercial computational fluid dynamics software CFX-4.3, electrolyte flow fields in a 156 kA pre-baked anode aluminum electrolysis cell were investigated in three different cases where the electrolyte me...Based on the commercial computational fluid dynamics software CFX-4.3, electrolyte flow fields in a 156 kA pre-baked anode aluminum electrolysis cell were investigated in three different cases where the electrolyte melt was driven by different kinds of force, i.e. electromagnetic force only, the anode gas drag force only and both of the former two forces. The results show that when electromagnetic force was introduced only, most of the electrolyte moves horizontally; when anode gas drag force was introduced only, the electrolyte flows mainly around each anode with small circulation; when electromagnetic force and anode gas drag force were both introduced together, the structure of the electrolyte flow fields and the velocity of electrolyte are similar to that of the case where only anode gas drag force is used. The electrolyte flow fields are mainly determined by the anode gas drag force.展开更多
The standard k-ε model was adopted to simulate the flow field of molten metal in three aluminum electrolysis cells with different anode risers. The Hartman number, Reynolds number and the turbulent Reynolds number of...The standard k-ε model was adopted to simulate the flow field of molten metal in three aluminum electrolysis cells with different anode risers. The Hartman number, Reynolds number and the turbulent Reynolds number of molten metal were calculated quantitatively. The turbulent Reynolds number is in the order of 103 , and Reynolds number is in the order of 104 if taking the depth of molten metal as the characteristic length. The results show that the molten metal flow is the turbulence of high Reynolds number, the turbulent Reynolds number is more appropriate than Reynolds number to be used to describe the turbulent characteristic of molten metal, and Hartman number displays very well that electromagnetic force inhibits turbulent motion of molten metal.展开更多
The electrolyte circulations in monopolar cell and two-compartment bipolar cell with submerged electrodes were described by a hydraulic model.The influence of current density,electrode tilt,anode-cathode distance(ACD)...The electrolyte circulations in monopolar cell and two-compartment bipolar cell with submerged electrodes were described by a hydraulic model.The influence of current density,electrode tilt,anode-cathode distance(ACD)and immersion depth of electrodes on the electrolyte circulation velocities between electrodes had been studied.Results demonstrated that the flow rates in the two compartments of bipolar cell were very different,which provided important information for the structure design of bipolar cell.展开更多
Root cause analysis （RCA） of abnormal aluminum electrolysis cell condition has long been a challenging industrial issue due to its inherent complexity in analyzing based on multi-source knowledge. In addition, accur...Root cause analysis （RCA） of abnormal aluminum electrolysis cell condition has long been a challenging industrial issue due to its inherent complexity in analyzing based on multi-source knowledge. In addition, accurate RCA of abnormal aluminum electrolysis cell condition is the precondition of improving current efficiency. RCA of abnormal condition is a complex work of multi-source knowledge fusion, which is difficult to ensure the RCA accuracy of abnormal cell condition because of dwindling and frequent flow of experienced technicians. In view of this, a method based on Fuzzy- Bayesian network to construct multi-source knowledge solidification reasoning model is proposed. The method can effectively fuse and solidify the knowledge, which is used to analyze the cause of abnormal condition by technicians providing a clear and intuitive framework to this complex task, and also achieve the result of root cause automatically. The proposed method was verified under 20 sets of abnormal cell conditions, and implements root cause analysis by finding the abnormal state of root node, which has a maximum posterior probability by Bayesian diagnosis reasoning. The accuracy of the test results is up to 95%, which shows that the knowledge reasoning feasibility for RCA of aluminum electrolysis cell.展开更多
The Navier-Stokes equation with the "k-ε" two-equation turbulence model was employed to describe three-dimension flow of melt in aluminum electrolysis cells. For a 160 kA cell with two current risers, the s...The Navier-Stokes equation with the "k-ε" two-equation turbulence model was employed to describe three-dimension flow of melt in aluminum electrolysis cells. For a 160 kA cell with two current risers, the source, i.e. the electromagnetic force, in the momentum equations was solved based on the simulation results of magnetic and temperature fields. Numerical simulation on the three-dimension steady-state flow of melt was carried out. The results obtained about the velocities of molten metal on different planes, the metal/bath interface shape and the electromagnetic force distribution, were analyzed. An iron rod dissolution technique, which is based on the rate of dissolution of iron rods inserted into the melt, was used to measure the velocities of metal pad. The simulation and measurement show that there are two interaction vortexes in horizontal direction. The predictions are in well agreement with the measured results for flow pattern and velocities. It is worthwhile that in the three-dimension simulation, there is also a little change of metal velocities from level to level due to the difference of horizontal current on each level.展开更多
基金Project(20010533009) supported by the Specialized Research Fund for the Doctoral Program of Higher Education of China
文摘Various busbar configurations were built and modeled by the custom code based on the commercial package ANSYS for the 500 kA aluminum electrolysis cell.The configuration parameters,such as side riser entry ratio,number of cathode bars connected to each riser,vertical location of side cathode busbar and short side cathode busbar,distance between rows of cells in potline,the number of neighboring cells,ratio of compensation busbar carried passing under cell and its horizontal location under cell along with large magnetohydrodynamic(MHD) computation based on the custom evaluation function were simulated and discussed.The results show that a cell with riser entry ratio of 11:9:8:9:11 and cathode busbar located at the level of aluminum solution,50% upstream cathode current passing under cell for magnetic field compensation,the distance between rows of 50 m is more stable.
基金This work was supported by the Program of the National Natural Science Foundation of China(61988101,61773405,and 61751312).
文摘Cell voltage is a widely used signal that can be measured online from an industrial aluminum electrolysis cell.A variety of parameters for the analysis and control of industrial cells are calculated using the cell voltage.In this paper,the frequency segmentation of cell voltage is used as the basis for designing filters to obtain these parameters.Based on the qualitative analysis of the cell voltage,the sub-band instantaneous energy spectrum(SIEP)is first proposed,which is then used to quantitatively represent the characteristics of the designated frequency bands of the cell voltage under various cell conditions.Ultimately,a cell condition-sensitive frequency segmentation method is given.The proposed frequency segmentation method divides the effective frequency band into the[0,0.001]Hz band of lowfrequency signals and the[0.001,0.050]Hz band of low-frequency noise,and subdivides the lowfrequency noise into the[0.001,0.010]Hz band of metal pad abnormal rolling and the[0.01,0.05]Hz band of sub-low-frequency noise.Compared with the instantaneous energy spectrum based on empirical mode decomposition,the SIEP more finely represents the law of energy change with time in any designated frequency band within the effective frequency band of the cell voltage.The proposed frequency segmentation method is more sensitive to cell condition changes and can obtain more elaborate details of online cell condition information,thus providing a more reliable and accurate online basis for cell condition monitoring and control decisions.
基金Project (G1999064903) supported by the National Key Fundamental Research and Development Programof China
文摘Based on the commercial computational fluid dynamics software CFX-4.3, electrolyte flow fields in a 156 kA pre-baked anode aluminum electrolysis cell were investigated in three different cases where the electrolyte melt was driven by different kinds of force, i.e. electromagnetic force only, the anode gas drag force only and both of the former two forces. The results show that when electromagnetic force was introduced only, most of the electrolyte moves horizontally; when anode gas drag force was introduced only, the electrolyte flows mainly around each anode with small circulation; when electromagnetic force and anode gas drag force were both introduced together, the structure of the electrolyte flow fields and the velocity of electrolyte are similar to that of the case where only anode gas drag force is used. The electrolyte flow fields are mainly determined by the anode gas drag force.
文摘The standard k-ε model was adopted to simulate the flow field of molten metal in three aluminum electrolysis cells with different anode risers. The Hartman number, Reynolds number and the turbulent Reynolds number of molten metal were calculated quantitatively. The turbulent Reynolds number is in the order of 103 , and Reynolds number is in the order of 104 if taking the depth of molten metal as the characteristic length. The results show that the molten metal flow is the turbulence of high Reynolds number, the turbulent Reynolds number is more appropriate than Reynolds number to be used to describe the turbulent characteristic of molten metal, and Hartman number displays very well that electromagnetic force inhibits turbulent motion of molten metal.
文摘The electrolyte circulations in monopolar cell and two-compartment bipolar cell with submerged electrodes were described by a hydraulic model.The influence of current density,electrode tilt,anode-cathode distance(ACD)and immersion depth of electrodes on the electrolyte circulation velocities between electrodes had been studied.Results demonstrated that the flow rates in the two compartments of bipolar cell were very different,which provided important information for the structure design of bipolar cell.
文摘Root cause analysis （RCA） of abnormal aluminum electrolysis cell condition has long been a challenging industrial issue due to its inherent complexity in analyzing based on multi-source knowledge. In addition, accurate RCA of abnormal aluminum electrolysis cell condition is the precondition of improving current efficiency. RCA of abnormal condition is a complex work of multi-source knowledge fusion, which is difficult to ensure the RCA accuracy of abnormal cell condition because of dwindling and frequent flow of experienced technicians. In view of this, a method based on Fuzzy- Bayesian network to construct multi-source knowledge solidification reasoning model is proposed. The method can effectively fuse and solidify the knowledge, which is used to analyze the cause of abnormal condition by technicians providing a clear and intuitive framework to this complex task, and also achieve the result of root cause automatically. The proposed method was verified under 20 sets of abnormal cell conditions, and implements root cause analysis by finding the abnormal state of root node, which has a maximum posterior probability by Bayesian diagnosis reasoning. The accuracy of the test results is up to 95%, which shows that the knowledge reasoning feasibility for RCA of aluminum electrolysis cell.
文摘The Navier-Stokes equation with the "k-ε" two-equation turbulence model was employed to describe three-dimension flow of melt in aluminum electrolysis cells. For a 160 kA cell with two current risers, the source, i.e. the electromagnetic force, in the momentum equations was solved based on the simulation results of magnetic and temperature fields. Numerical simulation on the three-dimension steady-state flow of melt was carried out. The results obtained about the velocities of molten metal on different planes, the metal/bath interface shape and the electromagnetic force distribution, were analyzed. An iron rod dissolution technique, which is based on the rate of dissolution of iron rods inserted into the melt, was used to measure the velocities of metal pad. The simulation and measurement show that there are two interaction vortexes in horizontal direction. The predictions are in well agreement with the measured results for flow pattern and velocities. It is worthwhile that in the three-dimension simulation, there is also a little change of metal velocities from level to level due to the difference of horizontal current on each level.
