Electrolytic aluminum anode replacement station method
Through employee number division of labor and multi-function trolley assistance to complete the anode replacement operation, the problem of high labor costs during the anode replacement process in electrolytic aluminum production is solved, and a more efficient anode replacement process is achieved, reducing labor intensity and cost.
Patent Information
- Application Number
- CN202310782024.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2023-06-29
- Publication Date
- 2024-12-31
AI Technical Summary
In the existing electrolytic aluminum production, the labor cost is high during the anode replacement process, and the staffing is mostly a problem of high labor intensity, poor quality and time-consuming.
By numbering and dividing labor to employees, multi-functional trolley assists in completing shell-plated, residual pole-pull-removing, residual pole-positioning, new pole-positioning and new pole-installation operations, reducing personnel configuration, and adding voltage to the electrolytic cell when changing pole-replacement Compensate for energy loss.
It effectively reduces labor costs, reduces employee labor intensity, improves work efficiency, reduces processing time, improves the quality of electrode replacement, reduces staffing, and saves personnel costs.
Smart Images
Figure CN119221040A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of electrolytic aluminum production, and in particular to a method for replacing an anode station for electrolytic aluminum. Background Art
[0002] In the prebaked aluminum electrolytic production, after the anode blocks used in the electrolytic cell have been consumed for a certain number of days, the thickness of the prebaked anodes gradually decreases due to continuous consumption. When the thickness is reduced to a certain extent, they need to be pulled out as residual anodes (i.e. residual electrodes) and replaced with a set of new anodes (i.e. new electrodes). The pole replacement operation in electrolytic aluminum production is a regular and necessary task.
[0003] The existing anode replacement workflow generally includes the steps of stripping, shelling, pulling out the residual anode, positioning the residual anode, positioning the new anode, fishing out the block, installing the new anode, and trimming, which are mainly completed manually and generally require 5 employees to complete the work. Currently, there is a problem of large labor demand and high employee costs.
[0004] There are schemes for replacing anode butts in existing patent documents. For example, the Chinese patent with application publication number CN102121122A discloses a method for replacing anodes during electrolytic aluminum production, wherein the cold anode butts are taken out of the heat exchange cabinet and shipped out of the electrolysis workshop, the hot anode butts are pulled out of the electrolytic cell, the hot anode butts are placed in the hot zone of the heat exchange cabinet for closed heat exchange with the cold new anode in the cold zone, the preheated cold new anode is taken out of the cold zone of the heat exchange cabinet and loaded into the electrolytic cell, and the cold new anode is placed in the cold zone of the heat exchange cabinet for preheating. The purpose of this scheme is to use the heat of the cold anode butts to preheat the cold new anode to reduce the impact of the anode replacement operation on the electrolytic cell, but this scheme does not consider how to reduce labor costs.
[0005] For another example, the Chinese patent with the authorization announcement number CN105177625B discloses a method for replacing anodes in an electrolytic cell of an aluminum smelter, which includes a residual anode, a new anode, an overhead crane, an anode replacement device of the overhead crane, and a measuring device on the anode replacement device, and also includes a vehicle-mounted measuring platform arranged on the overhead crane, and four steps of positioning and raising the measurement starting point, residual anode measurement, new anode measurement, and calculation of the thickness difference of the new residual anode. In this scheme, the residual anode and the new anode are kept suspended during measurement, and there is no need to operate the lifting or lowering operation. The measurement action is completed through the vehicle-mounted platform, which saves the labor intensity of the manual labor, but the staffing is not reduced. In other words, there is still the problem of high labor cost when replacing the anode.
[0006] In summary, the existing operation of replacing anodes has the problem of high labor costs. If the staffing can be reduced, the labor costs will be effectively reduced. However, how to successfully complete the replacement of anodes when the staffing is reduced is a technical problem that needs to be considered and solved. Summary of the invention
[0007] The purpose of the present invention is to provide a method for replacing anode work stations for electrolytic aluminum to solve the problems existing in the above-mentioned prior art. By numbering employees and dividing their work, different employees can operate according to set work stations, and the replacement of anodes can be successfully completed while reducing staffing, thereby effectively reducing labor costs.
[0008] To achieve the above object, the present invention provides the following solutions:
[0009] The present invention provides a method for replacing an anode station for electrolytic aluminum.
[0010] The employees are numbered and divided into different tasks, including (1), (2), (3) and (4), where (1) is a pole changer, (2) and (3) are material loaders, and (4) is a multifunctional overhead crane operator. The following steps are included:
[0011] S1, open the slot cover at the pole change location by (2) and (3), and open the U-shaped seal of the guide rod;
[0012] S2, (4) drives the multifunctional overhead crane to the pole-changing position, (1) directs (4) to operate the multifunctional overhead crane to slit the anode butts, (2) collects the generated material blocks, and (3) places a fixture on the anode butts;
[0013] S3, (1) directs (4) to operate the multifunctional overhead crane to pull out the residual poles, (4) positions the residual poles and places them on a tray, and drives the multifunctional overhead crane to the top of the pole changing position;
[0014] S4, (1) directs (4) to operate the multifunctional overhead crane to drive the grab bucket to remove the material blocks and slag that have fallen into the electrolytic cell and put them into the tray, and then position the new electrode. (1) directs (4) to install the new electrode and re-tighten the fixture;
[0015] S5. Enter the pole-changing area from (2) and (3) to carry out pole sealing operation, cover the slot cover, and cover the guide rod U-shaped seal.
[0016] Preferably, before S1, (1), (2), (3) and (4) check whether labor protection articles are fully worn, (1) check whether pole changing tools and materials are complete, then preheat the pole changing tools, place the short-circuit protection cover at the residual pole short-circuit, and measure the upper and lower levels of the anode electrolytic cell when replacing it.
[0017] Preferably, before S1 and while (1) is in progress, (2) and (3) check the new pole and clean the ferrophosphorus of the new pole, and then (2) and (3) place an aluminum dustpan on the corresponding flower comb of the residual pole and label the residual pole.
[0018] Preferably, in S1, after the cell cover is opened at (2) and (3), (1) a "pole change" signal is input to the electrolytic cell control box, and when changing poles, an additional voltage is applied to the electrolytic cell.
[0019] Preferably, in S1, (2) a floating material rake is brought in to scrape away the floating material on the residual anode.
[0020] Preferably, in S2, the multifunctional overhead crane drives the shell breaking device to perform a U-shaped slit on the residual pole.
[0021] Preferably, in S2, (2) when collecting the generated material blocks, the material blocks are scraped onto the aluminum dustpan.
[0022] Preferably, in S3, while (4) positioning the residual anode, (1) checking the furnace bottom, furnace side, legs, and adjacent anodes, and pushing away the sediment at the furnace bottom, (3) measuring and recording the aluminum liquid under the anode.
[0023] Preferably, in S5, (2) and (3) place the pole-changing tool on the pole-changing trolley and then enter the pole-changing location with a shovel to perform pole sealing operations, place material blocking plates to build a wall, direct the multifunctional overhead crane to add insulation material to the new pole and shape the insulation material. When adding the insulation material to the new pole, only a cover plate corresponding to the position of the new pole unloading material is opened.
[0024] Preferably, after S5, (2) and (3) lift out the aluminum dustpan and clean the pole-changing site. While (2) and (3) are being performed, (1) draws a line on the new pole and removes the short-circuit protection cover from the short-circuit, places it on the pole-changing trolley, checks whether the slot voltage is normal and whether there is needle vibration, and completes the pole-changing record.
[0025] Compared with the prior art, the present invention has achieved the following technical effects:
[0026] (1) The present invention numbers and divides the work among employees so that different employees can operate according to the set workstations, and the anode replacement can be successfully completed with reduced staffing, thereby effectively reducing labor costs;
[0027] (2) During the pole-changing operation, the present invention utilizes a multifunctional overhead crane to assist manual work in completing the shelling, pulling out the residual poles, positioning the residual poles, positioning the new poles, and installing the new poles. At the same time, the multifunctional overhead crane is used to drive the grab bucket to fish out the material blocks and slag that have fallen into the electrolytic cell, which can give full play to the function of the multifunctional overhead crane and effectively avoid the defects of high labor intensity, poor quality, and long time consumption caused by manual fishing, thereby reducing the processing time, improving the processing effect, reducing the labor intensity of employees, and reducing the working time of employees in a high temperature environment, thereby reducing the allocation of personnel on the basis of improving work efficiency;
[0028] (3) The present invention uses a multifunctional overhead crane to drive the shell breaking device to perform a U-shaped slit on the anode butts, which can remove obstacles (broken materials and hardened shells) around the anode butts, providing convenience for the subsequent removal of the anode butts; in addition, the generated material blocks are collected while slitting, reducing the amount of material blocks entering the electrolytic cell and reducing the difficulty of cleaning;
[0029] (4) The present invention adds voltage to the electrolytic cell during pole changing, thereby compensating for energy loss during pole changing. BRIEF DESCRIPTION OF THE DRAWINGS
[0030] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.
[0031] Figure 1 It is the work flow chart of the present invention;
[0032] Among them, (1) is the pole-changing personnel; (2) and (3) are the material loading personnel; and (4) is the multifunctional overhead crane operator. DETAILED DESCRIPTION
[0033] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
[0034] The purpose of the present invention is to provide a method for replacing anode work stations for electrolytic aluminum to solve the problems existing in the above-mentioned prior art. By numbering employees and dividing their work, different employees can operate according to set work stations, and the replacement of anodes can be successfully completed while reducing staffing, thereby effectively reducing labor costs.
[0035] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.
[0036] like Figure 1 As shown, the present invention provides a method for replacing an anode station for electrolytic aluminum.
[0037] The employees are numbered and assigned tasks, including (1), (2), (3) and (4), a total of four employees, of which (1) is a pole changer, (2) and (3) are material loaders, and (4) is a multi-functional overhead crane operator. The following steps are included:
[0038] Step S1: Open the slot cover at the pole change location by (2) and (3), and open the U-shaped seal of the guide rod.
[0039] Step S2, (4) drives the multifunctional overhead crane to the pole-changing position, (1) directs (4) to operate the multifunctional overhead crane to open the butt anode, (2) collects the generated material blocks, and (3) places the fixture on the butt anode. In the prebaked aluminum electrolysis production, there are broken materials and hardened crusts around the anode. When the anode is replaced, the multifunctional overhead crane is required to drive the shell breaking device to open the shell (i.e., open the seam). In this process, some material blocks and slag will enter the electrolytic cell. Usually, it is necessary to manually remove the material blocks and slag in the electrolytic cell, which leads to high labor intensity, long time consumption, and poor quality of manual cleaning.
[0040] Step S3, (1) directs (4) to operate the multifunctional overhead crane to pull out the residual poles, (4) positions the residual poles and places them on a tray, and drives the multifunctional overhead crane to the top of the pole replacement location.
[0041] Step S4, (1) directs (4) to operate the multifunctional overhead crane to drive the grab bucket to fish out the material blocks and slag that have fallen into the electrolytic cell, put them into the tray, and then position the new pole. (1) directs (4) to install the new pole and tighten the clamp. During the pole replacement operation, the multifunctional overhead crane is used to assist in manually completing the shelling, pulling out the residual pole, positioning the residual pole, positioning the new pole, and installing the new pole. At the same time, the multifunctional overhead crane is used to drive the grab bucket to fish out the material blocks and slag that have fallen into the electrolytic cell, which can give full play to the function of the multifunctional overhead crane, effectively avoid the defects of high labor intensity, poor quality, and long time consumption caused by manual fishing, reduce processing time, improve processing effect, reduce the labor intensity of employees, reduce the working time of employees in high temperature environment, and reduce staffing on the basis of improving work efficiency. When using the multifunctional overhead crane to fish out the material blocks and slag, the following points should be noted: 1) Operate the multifunctional overhead crane to drive the grab bucket to open the grab bucket to the maximum, and grab as many material blocks and materials as possible that fall into the electrolytic cell during anode replacement; 2) In addition to fishing out the material blocks, the grab bucket can also be used to fish out the carbon slag and material slag in the electrolytic cell: 3) The grab bucket used is made of high-temperature resistant stainless steel (16Cr25N). The size of the grab bucket is designed according to the slot area during the electrolytic anode replacement operation. The model is a multifunctional grab bucket with LK=28.5m to replace the ordinary grab bucket.
[0042] Step S5: Enter the pole-changing area from (2) and (3) to perform pole sealing operation, cover the slot cover, and cover the guide rod U-shaped seal.
[0043] Before step S1, preparatory work needs to be done, for example, (1), (2), (3) and (4) check whether labor protection equipment is fully worn, (1) check whether pole changing tools and materials are complete, then preheat the pole changing tools, place the short-circuit protection cover at the residual pole short-circuit, and measure the upper and lower levels of the replaced anode electrolytic cell.
[0044] Before step S1, while (1) is performing the above-mentioned inspection, preheating, measurement and other operations, (2) and (3) inspect the new electrode and clean the ferrophosphorus of the new electrode, and then (2) and (3) place the aluminum dustpan on the corresponding flower comb of the residual electrode and mark the residual electrode.
[0045] In step S1, after the cell cover is opened at (2) and (3), (1) a "pole change" signal is input to the electrolytic cell control box. When changing poles, an additional voltage is applied to the electrolytic cell to compensate for energy loss during pole change.
[0046] In step S1, (2) a floating material rake is brought in to scrape off the floating material on the residual anode.
[0047] In step S2, the multifunctional overhead crane drives the shell breaking device to make a U-shaped slit on the anode butt, so as to remove obstacles (broken materials and hardened crust) around the anode butt, thus facilitating the subsequent removal of the anode butt.
[0048] In step S2, (2) when collecting the generated material blocks, the material blocks are scraped onto the aluminum dustpan, that is, the generated material blocks can be collected by the aluminum dustpan while the slits are opened, which can reduce the amount of material blocks entering the electrolytic cell, thereby reducing the difficulty of cleaning.
[0049] In step S3, while (4) positioning the residual anode, (1) check the furnace bottom, furnace side, legs, adjacent anodes, and push away the sediment at the bottom of the furnace, and (3) measure and record the aluminum liquid under the anode.
[0050] In step S5, (2) and (3) place the pole-changing tool on the pole-changing trolley and then carry a shovel into the pole-changing area to perform pole sealing operations, place the material blocking plate to build a wall, and command the multifunctional overhead crane to add insulation material to the new pole and shape the insulation material. When adding insulation material to the new pole, only open a cover plate corresponding to the position where the new pole is unloaded to reduce material flying.
[0051] After step S5, (2) and (3) lift out the aluminum dustpan and clean the pole-changing site. While (2) and (3) are in progress, (1) draws a line on the new pole and removes the short-circuit protection cover from the short-circuit, places it on the pole-changing trolley, checks whether the slot voltage is normal and whether there is needle vibration, and completes the pole-changing record.
[0052] like Figure 1 As shown, the present invention provides a specific embodiment as follows:
[0053] The pole-changing workers are numbered and divided into different roles: (1) is the pole-changing worker, (2) and (3) are the material loaders, and (4) is the multi-functional overhead crane operator.
[0054] The pole changing process is as follows:
[0055] Step 1: Before changing poles, check (1), (2), (3), and (4) whether all labor protection equipment is worn properly.
[0056] Step 2, (1) Check whether the pole-changing tools and materials are complete, then preheat the pole-changing tools, place the short-circuit protection cover at the short-circuit of the anode to be replaced, and measure the upper and lower levels of the electrolytic cell when replacing the anode.
[0057] Step 3, while (1) is in progress, (2) and (3) check the new anode and clean the ferrophosphorus on the new anode. Then (2) and (3) place the aluminum dustpan on the corresponding grate of the anode to be replaced, label the anode to be replaced, open the four slot covers at the anode to be replaced, and open the U-shaped seal of the guide rod.
[0058] Step 4: After opening the tank cover at (2) and (3), (1) input the "change pole" signal to the electrolytic cell control box. When changing poles, add voltage to the electrolytic cell to compensate for the energy loss during the change of poles. (2) Bring in the floating material rake and scrape off the floating material on the anode to be replaced.
[0059] Step 5, (4) the multifunctional overhead crane is driven to the anode to be replaced, and (1) directs (4) to operate the multifunctional overhead crane to drive the shell breaking device to make a U-shaped slit on the anode butt to facilitate the subsequent removal of the anode butt. At the same time, (2) the material block is scraped onto the aluminum dustpan, and (3) the anode butt U-shaped clamp is placed on the anode butt to be removed. The U-shaped clamp is used to fix the anode butt so that the anode butt is not easy to shake when the anode butt is removed.
[0060] Step 6, (1) directs (4) to operate the multifunctional overhead crane to pull out the replaced residual pole, (4) positions the residual pole and places it on the tray, and drives the multifunctional overhead crane to the top of the pole replacement location.
[0061] Step 7, while (4) is positioning the residual anode, (1) uses a small hook to check the furnace bottom, furnace side, legs, and adjacent anodes, and uses a three-toothed rake to push away the sediment on the furnace bottom. (3) Measure the aluminum liquid under the anode and record it. (1) Command (4) to operate the multifunctional overhead crane to drive the grab bucket to pick up the material blocks and slag that have fallen into the electrolytic cell, put them into the tray, and then position the new anode. (1) Command (4) to install the new anode and tighten the clamp. The multifunctional overhead crane driven grab bucket to pick up the material blocks instead of manually picking up the material blocks can reduce the labor intensity of employees. The multifunctional overhead crane driven grab bucket picks up the material blocks more cleanly, reducing the fluctuation of the electrolytic cell caused by the failure to pick up the clean material blocks, so that the grab bucket can be used to pick up the material blocks to improve the quality of pole replacement, and the pole replacement qualification rate is increased from 80% to 90%.
[0062] Step 8, (2) and (3) put the pole-changing tools on the pole-changing trolley and then carry a shovel to the pole-changing site to perform pole sealing operations, place the material blocking plate to build a wall, and command the overhead crane to add insulation material on the new pole (only open a cover plate corresponding to the position of the new pole unloading to reduce the flying of materials), and shape the insulation material, (2) and (3) cover the slot cover, cover the guide rod U-shaped seal, lift out the aluminum dustpan and clean the pole-changing site. While (2) and (3) are working, (1) draw the new pole line and remove the short-circuit protective cover from the short-circuit, place it on the pole-changing trolley, check whether the slot voltage is normal and whether there is needle vibration, and complete the pole-changing record.
[0063] By reorganizing the pole-changing process, clarifying the pole-changing stations, and using the above method to change poles, employees can work closely together. On the one hand, the pole-changing speed is improved, and the pole-changing time is reduced from 40 minutes to 35 minutes; on the other hand, the number of pole-changing employees is reduced from 5 to 4, reducing personnel costs. According to the calculation of 8 shifts in the electrolysis area, each shift has 3 pole-changing groups, and the labor cost can be reduced by 24 people. The monthly labor cost of one person is 7,000 yuan, which can save 2.016 million yuan a year.
[0064] The present invention uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only used to help understand the method and core ideas of the present invention. At the same time, for those skilled in the art, according to the ideas of the present invention, there will be changes in the specific implementation methods and application scope. In summary, the content of this specification should not be understood as limiting the present invention.
Claims
1. A method for replacing anode stations for electrolytic aluminum, characterized in that: The employees are numbered and divided into different tasks, including (1), (2), (3) and (4), where (1) is a pole changer, (2) and (3) are material loaders, and (4) is a multifunctional overhead crane operator. The following steps are included: S1, open the slot cover at the pole change location by (2) and (3), and open the U-shaped seal of the guide rod; S2, (4) drives the multifunctional overhead crane to the pole-changing position, (1) directs (4) to operate the multifunctional overhead crane to slit the anode butts, (2) collects the generated material blocks, and (3) places a fixture on the anode butts; S3, (1) directs (4) to operate the multifunctional overhead crane to pull out the residual poles, (4) positions the residual poles and places them on a tray, and drives the multifunctional overhead crane to the top of the pole changing position; S4, (1) directs (4) to operate the multifunctional overhead crane to drive the grab bucket to remove the material blocks and slag that have fallen into the electrolytic cell and put them into the tray, and then position the new electrode. (1) directs (4) to install the new electrode and re-tighten the fixture; S5. Enter the pole changing area from (2) and (3) to carry out pole sealing operation, cover the slot cover, and cover the guide rod U-shaped seal.
2. The method for replacing anode stations for electrolytic aluminum according to claim 1, characterized in that: Before S1, (1), (2), (3) and (4) check whether the labor protection equipment is fully worn, (1) check whether the pole changing tools and materials are complete, then preheat the pole changing tools, place the short-circuit protection cover at the residual pole short-circuit, and measure the upper and lower levels of the replaced anode electrolytic cell.
3. The method for replacing anode stations for electrolytic aluminum according to claim 2, characterized in that: Before S1 and while (1) is in progress, (2) and (3) check the new pole and clean the ferrophosphorus of the new pole. Then (2) and (3) place an aluminum dustpan on the corresponding flower comb of the residual pole and mark the residual pole.
4. The method for replacing anode stations for electrolytic aluminum according to claim 3, characterized in that: In S1, after the cell cover is opened at (2) and (3), (1) a "pole change" signal is input to the electrolytic cell control box, and when changing poles, an additional voltage is applied to the electrolytic cell.
5. The method for replacing anode stations for electrolytic aluminum according to claim 4, characterized in that: In S1, (2) a floating material rake is brought in to scrape away the floating material on the anode butts.
6. The method for replacing anode stations for electrolytic aluminum according to claim 3, characterized in that: In S2, the multifunctional overhead crane drives the shell breaking device to make a U-shaped slit on the residual pole.
7. The method for replacing anode stations for electrolytic aluminum according to any one of claims 3 to 6, characterized in that: In S2, (2) when collecting the generated material blocks, the material blocks are scraped onto the aluminum dustpan.
8. The method for replacing anode stations for electrolytic aluminum according to claim 7, characterized in that: In S3, while (4) positioning the residual anode, (1) checking the furnace bottom, furnace side, legs, and adjacent anodes, and pushing away the sediment at the furnace bottom, (3) measuring and recording the aluminum liquid under the anode.
9. The method for replacing anode stations for electrolytic aluminum according to claim 7, characterized in that: In S5, (2) and (3) place the pole-changing tool on the pole-changing trolley and then carry a shovel into the pole-changing area to perform pole sealing operations, place a material blocking plate to build a wall, and command the multifunctional overhead crane to add insulation material to the new pole and shape the insulation material. When adding the insulation material to the new pole, only open a cover plate corresponding to the position where the new pole is unloaded.
10. The method for replacing anode stations for electrolytic aluminum according to claim 7, characterized in that: After S5, (2) and (3) lift out the aluminum dustpan and clean the pole-changing site. While (2) and (3) are working, (1) draws a line on the new pole and removes the short-circuit protection cover from the short-circuit, places it on the pole-changing trolley, checks whether the slot voltage is normal and whether there is needle vibration, and completes the pole-changing record.