A method for early warning of abnormal operation of an aluminum electrolysis cell
By monitoring voltage changes during the roasting stage of aluminum electrolytic cells in real time, and using early warning analysis parameters to promptly identify abnormalities and output alarm signals, the safety issues during the roasting stage of aluminum electrolytic cells have been resolved, improving production safety and efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- ZHENGZHOU NON FERROUS METALS RES INST CO LTD OF CHALCO
- Filing Date
- 2023-06-01
- Publication Date
- 2026-06-26
AI Technical Summary
In the existing technology, the detection of abnormalities in the roasting stage of aluminum electrolysis cells mainly relies on manual monitoring, which poses a risk of safety accidents due to negligence and lacks an effective early warning mechanism.
By acquiring the voltage value of the electrolytic cell at preset time intervals during the roasting stage, the voltage value changes are monitored in real time using early warning analysis parameters. Abnormalities are judged according to the strategies of different operating stages, and alarm signals are output.
This has improved safety during the roasting stage of aluminum electrolysis cells, provided timely warnings of abnormal situations, prevented safety accidents, and increased production efficiency.
Smart Images
Figure CN116665415B_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of aluminum electrolysis cell technology, and more specifically, to a method for early warning of abnormal operation of aluminum electrolysis cells. Background Technology
[0002] Aluminum electrolysis is the main production process in aluminum smelting, and the electrolytic cell is the main equipment in aluminum electrolysis production. The safety and stability of the electrolytic cell's operation directly affect the actual output and operating efficiency of the enterprise. Calcination is a crucial stage before the electrolytic cell enters normal production, directly impacting its production efficiency, especially its lifespan. The temperature and current distribution during the electrolytic cell's calculation are important indicators of its condition. Uneven temperature distribution or anode misalignment can cause a strong current to concentrate on a particular anode or flexible connection, resulting in severe current deviation. Excessive current can melt the connection points, triggering a vicious cycle of current deviation, leading to successive disconnections of the connections, and in severe cases, even causing a short circuit and explosion.
[0003] Currently, to avoid abnormalities during the roasting stage, manual monitoring based on experience or reactive problem-solving is commonly used. Even slight negligence can lead to major accidents, causing casualties and significant economic losses for the company. Therefore, improving the operational safety of aluminum electrolysis cells during the roasting stage is an urgent technical problem to be solved. Summary of the Invention
[0004] The embodiments of this application provide an early warning method for abnormal operation of aluminum electrolytic cells. Based on the technical solution provided by this application, it is possible to provide timely early warning of abnormal situations that occur during the roasting stage, and to remind relevant technical personnel to understand and resolve the relevant abnormal situations in a timely manner, thereby improving the operational safety of aluminum electrolytic cells during the roasting stage and ensuring the smooth production of products.
[0005] Other features and advantages of this application will become apparent from the following detailed description, or may be learned in part from practice of this application.
[0006] According to an embodiment of this application, an early warning method for abnormal operation of an aluminum electrolytic cell is provided, applied in the roasting stage. The method includes: during the roasting stage, acquiring the voltage value of a target electrolytic cell at preset time intervals; determining early warning analysis parameters based on the acquired voltage values, wherein the early warning analysis parameters are parameters reflecting voltage value changes; determining whether the target electrolytic cell has an operational abnormality based on the early warning analysis parameters; and outputting an alarm signal if the target electrolytic cell has an operational abnormality.
[0007] In some embodiments of this application, based on the foregoing scheme, the roasting stage consists of multiple operating stages. The step of determining the early warning analysis parameters according to the obtained voltage values includes: when in a target operating stage, obtaining a target early warning strategy corresponding to the target operating stage, wherein the target operating stage is any one of the multiple operating stages; and determining the early warning analysis parameters of the target operating stage according to the voltage values obtained in the target operating stage and in accordance with the target early warning strategy.
[0008] In some embodiments of this application, based on the foregoing scheme, the target operating stage is a power-on stage. The step of determining the early warning analysis parameters of the target operating stage according to the various voltage values obtained in the target operating stage and in accordance with the target early warning strategy includes: determining the maximum value of the power-on impact voltage from the various voltage values obtained in the power-on stage as an early warning analysis parameter; the step of determining whether the target electrolytic cell has an operating abnormality based on the early warning analysis parameter includes: if the maximum value of the power-on impact voltage is greater than a first preset value, then determining that the target electrolytic cell has an operating abnormality.
[0009] In some embodiments of this application, based on the foregoing scheme, the target operating stage is a voltage ramp-up stage. The step of determining the early warning analysis parameters of the target operating stage according to the various voltage values obtained in the target operating stage and in accordance with the target early warning strategy includes: determining the maximum and minimum values from the various voltage values obtained in the voltage ramp-up stage, and using the difference between the maximum and the minimum values as the early warning analysis parameters; the step of determining whether the target electrolytic cell has an operating abnormality based on the early warning analysis parameters includes: if the difference between the maximum and the minimum values is greater than a second preset value, then determining that the target electrolytic cell has an operating abnormality.
[0010] In some embodiments of this application, based on the foregoing scheme, the target operating phase is a voltage drop phase. The step of determining the early warning analysis parameters for the target operating phase based on the voltage values obtained during the target operating phase and according to the target early warning strategy includes: determining a first difference between any two consecutive voltage values, a cumulative voltage drop value within a set time period, and a first duration of voltage fluctuation within a set range, and using the first difference, the cumulative drop value, and the first duration as early warning analysis parameters; the step of determining whether the target electrolytic cell has an operational abnormality based on the early warning analysis parameters includes: if the first difference is greater than a third preset value, then determining that the target electrolytic cell has an operational abnormality; if the cumulative drop value is greater than a fourth preset value, then determining that the target electrolytic cell has an operational abnormality; if the first duration is greater than a first preset time period, then determining that the target electrolytic cell has an operational abnormality.
[0011] In some embodiments of this application, based on the foregoing scheme, the method further includes: if the roasting stage of the target electrolytic cell is within a first preset time interval, then determining the number of voltage drops based on the obtained voltage values; and determining whether the target electrolytic cell has entered the voltage drop stage based on the number of drops.
[0012] In some embodiments of this application, based on the foregoing scheme, the method further includes: if a temporary voltage rise occurs during the voltage drop phase, determining a second duration of the temporary rise based on the voltage values obtained during the temporary rise, and determining a cumulative rise value of the voltage value during the second duration; using the second duration and the cumulative rise value as early warning analysis parameters; if the second duration is longer than a second preset duration and the cumulative rise value is greater than a fifth preset value, determining that the target electrolytic cell has an operational abnormality.
[0013] In some embodiments of this application, based on the foregoing scheme, the target operating stage is the split-chip voltage rise stage. The step of determining the early warning analysis parameters for the target operating stage based on the voltage values obtained during the target operating stage and according to the target early warning strategy includes: determining a second difference between any two consecutive voltage values and determining the number of voltage rises based on the voltage values obtained during the split-chip voltage rise stage, and using the second difference and the number of rises as early warning analysis parameters. The step of determining whether the target electrolytic cell has an operational abnormality based on the early warning analysis parameters includes: if the second difference is greater than a sixth preset value, then determining that the target electrolytic cell has an operational abnormality; if the number of rises is greater than a preset number, then determining that the target electrolytic cell has an operational abnormality.
[0014] In some embodiments of this application, based on the foregoing scheme, if the roasting stage of the target electrolytic cell is within a second preset time interval, then a third difference between any two consecutive voltage values and the number of times the voltage value rises are determined according to the obtained voltage values; and the target electrolytic cell is determined to have entered the split-flow voltage rise stage based on the third difference and the number of times the voltage value rises.
[0015] In some embodiments of this application, based on the foregoing scheme, the target operating stage is a voltage stability stage. The step of determining the early warning analysis parameters of the target operating stage according to the voltage values obtained in the target operating stage and in accordance with the target early warning strategy includes: determining the fluctuation difference between the voltage values and the set voltage values based on the voltage values obtained in the voltage stability stage, and using the fluctuation difference as the early warning analysis parameter; the step of determining whether the target electrolytic cell has an operating abnormality based on the early warning analysis parameter includes: if the fluctuation difference exceeds a preset range, then determining that the target electrolytic cell has an operating abnormality.
[0016] The technical solution of this application involves first acquiring the voltage value of the target electrolytic cell at preset time intervals during the roasting stage; then determining early warning analysis parameters based on the acquired voltage values, whereby these parameters reflect voltage value changes; furthermore, determining whether the target electrolytic cell is experiencing operational abnormalities based on these early warning analysis parameters; and finally, outputting an alarm signal if the target electrolytic cell exhibits an abnormality. Therefore, this technical solution enables real-time monitoring of the voltage value of the aluminum electrolytic cell during the roasting stage, and, based on early warning strategies corresponding to each operational stage within the roasting stage, timely determination of any abnormalities during the roasting stage based on voltage value changes. If an operational abnormality is detected in the aluminum electrolytic cell during the roasting stage, an alarm signal can be output, promptly alerting relevant technical personnel to resolve the abnormality, thereby improving the safety of the aluminum electrolytic cell during the roasting operation, preventing safety accidents, and increasing the production efficiency of the aluminum electrolytic cell.
[0017] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description
[0018] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort. In the drawings:
[0019] Figure 1 A flowchart illustrating an early warning method for abnormal operation of an aluminum electrolytic cell according to an embodiment of this application is shown.
[0020] Figure 2 A schematic diagram of multiple operating stages of a roasting stage according to an embodiment of this application is shown;
[0021] Figure 3A detailed flowchart illustrating the process of determining early warning analysis parameters based on the obtained voltage values, according to one embodiment of this application, is shown. Detailed Implementation
[0022] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the examples set forth herein; rather, these embodiments are provided to make this application more comprehensive and complete, and to fully convey the concept of the exemplary embodiments to those skilled in the art.
[0023] The flowcharts shown in the accompanying drawings are merely illustrative and do not necessarily include all content and operations / steps, nor do they necessarily have to be performed in the described order. For example, some operations / steps can be broken down, while others can be combined or partially combined; therefore, the actual execution order may change depending on the specific circumstances.
[0024] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such uses of these terms can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described.
[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.
[0026] The following detailed description of some embodiments of this application will be provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.
[0027] It should be noted that the early warning method of this application is applicable to monitoring whether abnormalities occur in the operation of aluminum electrolytic cells during the roasting stage.
[0028] See Figure 1 The diagram shows a flowchart of an early warning method for abnormal operation of an aluminum electrolytic cell according to an embodiment of the present application, specifically including steps S110 to S140.
[0029] S110, during the roasting stage, the voltage value of the target electrolytic cell is obtained at preset time intervals.
[0030] For example, once the target electrolytic cell enters the roasting stage, the voltage value of the target electrolytic cell can be acquired once every 1 minute or once every 1 second. Specifically, the preset time interval can be determined according to the actual situation, which is not limited in this application.
[0031] In some implementations, voltage data of a series of aluminum electrolytic cells can be read from a PLC system to obtain the voltage value of the target electrolytic cell.
[0032] It is understood that, in this embodiment, multiple voltage values can be obtained throughout the roasting stage of the target electrolytic cell.
[0033] S120, determine the early warning analysis parameters based on the obtained voltage values, wherein the early warning analysis parameters are parameters that reflect the changes in voltage values.
[0034] S130, determine whether the target electrolytic cell has an operational abnormality based on the early warning analysis parameters.
[0035] S140, if the target electrolytic cell malfunctions, an alarm signal is output.
[0036] It should be noted that any parameter that can reflect changes in voltage value can be used as the aforementioned early warning analysis parameter, including but not limited to the difference between two consecutive voltage values, the cumulative change in voltage value over a period of time; the slope between two consecutive voltage values; the trend of voltage value change (rising or falling) over a period of time; the number of times the voltage value rises; the number of times the voltage value falls; the fluctuation of voltage value over a period of time, etc. The choice of which parameter to use to reflect changes in voltage value as the early warning analysis parameter can be specifically designed according to the process characteristics and actual operating characteristics of the aluminum electrolysis cell, etc., and this application does not impose any limitations on this.
[0037] It should also be noted that the calcination stage of an aluminum electrolysis cell usually consists of multiple operating stages, which are generally related to the number of groups of diversion plates set in the process.
[0038] To help those skilled in the art better understand the operational stages included in the roasting process, the following will combine... Figure 2 Please provide an explanation.
[0039] It should be noted that in a complete firing stage, if the process includes several sets of wafer groups, there will be several stages of voltage rise during wafer splitting, such as... Figure 2 The diagram shows a scenario with five chip groups, five chip splits, and corresponding voltage rise stages during each split. Figure 2The location indicated by 1 is the voltage rise stage of the split-flow plate. In this application, the purpose of setting the split-flow plate during the aluminum electrolysis cell roasting stage is to ensure a stable temperature rise in the aluminum electrolysis cell.
[0040] It should also be noted that a complete roasting process involves multiple voltage drop phases, typically following a voltage ramp-up phase, such as... Figure 2 The voltage drop phase 1 shown; after the removal of a set of dynamometer modules, there will be a voltage drop phase, such as... Figure 2 The voltage drop phases 2 and 3 are shown. From... Figure 2 It can be seen that there are a total of 6 voltage drop stages, and the position indicated by 2 is also a voltage drop stage. Each voltage drop stage is an operational stage within the roasting stage, and the same early warning strategy is used to acquire and determine the early warning analysis parameters for each voltage drop stage.
[0041] Figure 2 In the process, after the aluminum electrolysis cell is energized, it begins the roasting stage. Therefore, the first stage of the roasting stage is the energizing stage, during which the instantaneous surge voltage must be within a safe range. After the energizing stage, the roasting stage enters the voltage ramp-up stage. During the voltage ramp-up stage, the voltage rises to a certain value and then enters the first voltage drop stage. After the voltage drop stage of the roasting stage runs for a certain period of time, the first splitting and sheet forming voltage rise stage begins, followed by the second voltage drop stage. This process then sequentially goes through the second splitting and sheet forming voltage rise stage, the third voltage drop stage, the third splitting and sheet forming voltage rise stage, the fourth voltage drop stage, the fourth splitting and sheet forming voltage rise stage, the fifth voltage drop stage, the fifth splitting and sheet forming voltage rise stage, the sixth voltage drop stage, and finally, the voltage stabilizes.
[0042] In summary, Figure 2 The voltage value change curves shown in the roasting stage diagram correspond to 14 operating stages.
[0043] In some embodiments, the specific implementation of determining the early warning analysis parameters based on the obtained voltage values can be as follows: Figure 3 The steps shown are performed, including S121 to S122.
[0044] S121, when in the target operation phase, obtain the target early warning strategy corresponding to the target operation phase, wherein the target operation phase is any one of the plurality of operation phases.
[0045] It is understood that in this application, an appropriate early warning strategy is formulated based on the operational characteristics of each operational stage in the roasting process, thereby enabling efficient monitoring of the operational status of each operational stage and whether any operational abnormalities occur.
[0046] See also Figure 3 S122, Based on the various voltage values obtained during the target operation phase, and in accordance with the target early warning strategy, determine the early warning analysis parameters for the target operation phase.
[0047] In this application, the roasting stage mainly includes the power-on stage, voltage ramp-up stage, voltage drop stage, splitting and fabrication voltage rise stage, and voltage stabilization stage. The specific early warning strategies employed in each stage, and the detailed implementation methods for determining early warning analysis parameters based on the various voltage values obtained during the stage, will be described in detail below, including the following five scenarios.
[0048] In the first scenario, when the target is in the power-on phase, the corresponding early warning strategy is as follows.
[0049] The specific implementation method for determining the early warning analysis parameters of the target operation phase based on the various voltage values obtained in the target operation phase and in accordance with the target early warning strategy is as follows: the maximum value of the energizing impulse voltage is determined from the various voltage values obtained in the energizing phase, and used as the early warning analysis parameter.
[0050] The specific implementation method for determining whether the target electrolytic cell has an operational abnormality based on the aforementioned early warning analysis parameters is as follows: if the maximum value of the energizing impact voltage is greater than a first preset value, then it is determined that the target electrolytic cell has an operational abnormality.
[0051] It should be noted that, in this embodiment, the first preset value can be set according to the actual situation such as the process characteristics, empirical values, operating characteristics, and preset time intervals of the aluminum electrolysis cell. This application does not limit the specific value of the first preset value. For example, the first preset value is set to 5V. When the maximum value of the energizing impulse voltage obtained during the energizing stage is greater than 5V, an alarm signal can be output to remind relevant technical personnel to pay attention.
[0052] The second scenario is when the target operating phase is the voltage ramp-up phase.
[0053] In some implementations, it can be determined whether the target electrolyzer has entered the voltage ramp-up stage by the following steps S10A to S11A.
[0054] S10A, if the roasting stage of the target electrolytic cell is within a preset time interval, then determine the first number of times the voltage value rises based on the obtained voltage values.
[0055] S11A, determine whether the target electrolytic cell has entered the voltage ramp-up stage based on the first number of rises.
[0056] For example, if the timing starts from when the target electrolytic cell is powered on, the target electrolytic cell will experience a voltage ramp-up phase during the calcination stage, which is between 1 and 8 hours. Therefore, the preset time interval can be set to 1 to 8 hours.
[0057] In some implementations, if it is determined that the first number of rises is greater than the set number of rises, then the target electrolytic cell can be considered to have entered the voltage ramp-up stage.
[0058] For example, assuming the target electrolytic cell is energized at 11:00, the preset time interval is set to 1 to 8 hours, and the preset number of rises is set to 3. After the roasting stage of the target electrolytic cell has run for 1 hour, i.e., after 12:00, it can be determined whether it has entered the voltage ramp-up stage based on the voltage value of the target electrolytic cell obtained per minute. Assuming the voltage value obtained at 12:10 is 3.1V, the voltage value obtained at 12:11 is 3.15V, and the voltage value obtained at 12:12 is 3.18V, then it is considered that the target electrolytic cell has entered the voltage ramp-up stage from 12:10.
[0059] In some implementations, the corresponding early warning strategy during the voltage ramp-up phase is as follows:
[0060] The specific implementation method for determining the early warning analysis parameters of the target operation phase based on the various voltage values obtained in the target operation phase and in accordance with the target early warning strategy is as follows: determine the maximum and minimum values from the various voltage values obtained in the voltage ramp-up phase, and use the difference between the maximum and the minimum values as the early warning analysis parameters.
[0061] The specific implementation method for determining whether the target electrolytic cell has an operational abnormality based on the aforementioned early warning analysis parameters is as follows: if the difference between the maximum value and the minimum value is greater than a second preset value, then it is determined that the target electrolytic cell has an operational abnormality.
[0062] It should be noted that, in this embodiment, the second preset value can be set according to the actual situation such as the process characteristics, empirical values, operating characteristics, and preset time intervals of the aluminum electrolysis cell. This application does not limit the specific value of the second preset value. For example, the second preset value is set to 0.5V. When the difference between the maximum and minimum voltage values obtained during the voltage ramp-up phase is greater than 0.5V, the target electrolysis cell is considered to have an operational abnormality, and an alarm signal is output.
[0063] The third scenario is when the target operating phase is the voltage drop phase.
[0064] In some implementations, it can be determined whether the target electrolyzer has entered the voltage drop stage by the following steps S10B to S11B.
[0065] S10B, if the roasting stage of the target electrolytic cell is within a first preset time interval, then determine the number of times the voltage value decreases based on the obtained voltage values.
[0066] It is understood that the target electrolytic cell will experience several voltage drop phases at different times during the roasting stage. The corresponding first preset time interval can be set based on empirical values of the target electrolytic cell, for example, such as... Figure 2 The first voltage drop phase adjacent to the voltage ramp-up phase is typically within the 1-8 hour time range of the calcination phase. Therefore, the first preset time range corresponding to the first voltage drop phase is set to 1-8 hours. The various voltage drop phases adjacent to the split-out wafer voltage rise phase are typically within the 8-55 hour time range of the calcination phase. Therefore, the first preset time range corresponding to the second, third, fourth, fifth, and sixth voltage drop phases can be set to 8-55 hours.
[0067] S11B, determine whether the target electrolytic cell has entered the voltage drop stage based on the number of voltage drops.
[0068] In some implementations, if the number of voltage drops exceeds a set number of voltage drops, the target electrolyzer is considered to have entered the voltage drop phase.
[0069] For example, suppose the target electrolytic cell is powered on at 11:00 and enters the roasting stage, suppose the first preset interval is 1 hour to 8 hours, and suppose the set number of voltage drops is 3. After the roasting stage of the target electrolytic cell has run for 1 hour, that is, after 12:00, it can be determined whether it has entered the voltage drop stage based on the voltage value of the target electrolytic cell obtained per minute. Suppose the voltage value obtained at 13:30 is 3.8V, the voltage value obtained at 13:31 is 3.799V, the voltage value obtained at 13:32 is 3.798V, and the voltage value obtained at 13:33 is 3.797V; then it is considered that the target electrolytic cell has entered the voltage drop stage from 13:30.
[0070] In some implementations, the corresponding early warning strategy during the voltage drop phase is as follows:
[0071] The specific implementation method for determining the early warning analysis parameters for the target operation phase based on the voltage values obtained during the target operation phase, according to the target early warning strategy, is as follows: Based on the voltage values obtained during the voltage drop phase, a first difference between any two consecutive voltage values is determined, as well as the cumulative voltage drop value within a set duration and the first duration of voltage value fluctuation within a set range are determined. The first difference, the cumulative drop value, and the first duration are used as early warning analysis parameters. Wherein, the set duration is less than the duration of the voltage drop phase.
[0072] The specific implementation method for determining whether the target electrolytic cell has an operational abnormality based on the aforementioned early warning analysis parameters is as follows: if the first difference is greater than the third preset value, then it is determined that the target electrolytic cell has an operational abnormality; if the cumulative decrease value is greater than the fourth preset value, then it is determined that the target electrolytic cell has an operational abnormality; if the first duration is greater than the first preset duration, then it is determined that the target electrolytic cell has an operational abnormality.
[0073] It should be noted that, in this embodiment, the third preset value, the fourth preset value, the setting duration, the setting range, and the first preset duration can be set according to the actual situation such as the process characteristics, experience value, operating characteristics, and preset time interval of the aluminum electrolysis cell. This application does not limit the specific values to be set here.
[0074] For example, suppose the third preset value is set to 0.002V; the set duration is set to 1h; the fourth preset value is set to 0.15V; the set range is set to ±0.0005V; and the first preset duration is set to 3min. If the target electrolytic cell enters the voltage drop stage at 13:30, the voltage value obtained at 13:30 is 3.8V; the voltage value obtained at 14:00 is 3.789V; the voltage value obtained at 14:01 is 3.7868V; the voltage value obtained at 14:30 is 3.64V; the voltage value obtained at 14:31 is 3.6396V; the voltage value obtained at 14:32 is 3.6403V; the voltage value obtained at 14:33 is 3.6401V; and the voltage value obtained at 14:34 is 3.6397V.
[0075] At 14:01, if the first difference is determined to be 0.0022V (3.789V-3.7868V), which is greater than 0.002V, then the target electrolytic cell will be considered to be operating abnormally, and an alarm signal will be output.
[0076] If it is determined at 14:30 that the cumulative voltage drop within 1 hour is 0.16V (3.8V-3.64V) which is greater than 0.15V, then the target electrolytic cell will be considered to be operating abnormally, and an alarm signal will be output.
[0077] At 14:34, it can be determined that the first duration of the voltage value of 3.64V fluctuating within ±0.0005V is 4 minutes. If it is greater than 3 minutes, it is considered that the target electrolytic cell has an operational abnormality and an alarm signal is output.
[0078] It should also be noted that, such as Figure 2 As shown, a brief, small increase in voltage during the voltage drop phase is not considered abnormal. However, a prolonged or significant voltage increase during the voltage drop phase is considered an operational anomaly. Therefore, the early warning strategy for a temporary voltage increase during the voltage drop phase is as follows, including S100 to S300:
[0079] S100, if a temporary voltage rise occurs during the voltage drop phase, a second duration of the temporary rise is determined based on the voltage values obtained during the temporary rise, and the cumulative rise value of the voltage value during the second duration is determined.
[0080] S200, the second duration and the cumulative increase value are used as early warning analysis parameters.
[0081] S300, if the second duration is greater than the second preset duration and the cumulative increase value is greater than the fifth preset value, then it is determined that the target electrolytic cell has an operational abnormality.
[0082] It should be noted that, in this embodiment, the fifth preset value and the second preset duration can be set according to the actual situation such as the process characteristics, experience value, operating characteristics, and preset time interval of the aluminum electrolysis cell. This application does not limit the specific values of the fifth preset value and the second preset duration.
[0083] For example, suppose the fifth preset value is set to 0.15V and the second preset duration is set to 5 minutes. If the target electrolytic cell enters the voltage drop phase at 13:30, the voltage value obtained at 13:30 is 3.8V; the voltage value obtained at 14:07 is 3.1V; the voltage value obtained at 14:08 is 3.13V; the voltage value obtained at 14:09 is 3.17V; the voltage value obtained at 14:10 is 3.20V; the voltage value obtained at 14:11 is 3.23V; the voltage value obtained at 14:12 is 3.26V; the voltage value obtained at 14:13 is 3.27V; and the voltage value obtained at 14:14 is 3.24V.
[0084] At 14:13, it can be determined that the second duration of the voltage rise is 6 minutes, which is greater than 5 minutes. If the cumulative rise value within the 6 minutes is 0.17 (3.27V-3.1V), which is greater than 0.15V, then the target electrolytic cell is considered to be operating abnormally, and an alarm signal will be output.
[0085] It should be noted that if the voltage value of the target electrolytic cell returns to normal within a short period of time, the alarm signal can be canceled. For example, in the above example, although the alarm signal is output at 14:13 because the voltage rise is considered to be too fast and the cumulative increase is too large, the voltage drops to 3.24V at 14:14, indicating that the voltage value has returned to normal, and the alarm signal will be canceled at 14:14.
[0086] It should also be noted that the early warning strategy corresponding to the third scenario above is applicable to situations such as... Figure 2 In each voltage drop phase shown, different parameter settings can be made according to the time interval in which the voltage drop phase occurs.
[0087] In this embodiment, by setting a corresponding early warning strategy during the voltage drop phase, timely alarms can be triggered when a series of operational anomalies occur, such as voltage drop being too rapid, voltage cumulative drop being too large, voltage rise being too rapid in a short period of time, voltage rise being too long, or voltage remaining unchanged for too long, so as to remind relevant technical personnel to pay attention.
[0088] The fourth scenario is when the target operating phase is the stage of rising voltage during the chip splitting process.
[0089] In some implementations, it can be determined whether the target electrolytic cell has entered the stage of rising split-sheet voltage by the following steps S10C to S11C.
[0090] S10C, if the roasting stage of the target electrolytic cell is within the second preset time interval, then based on the obtained voltage values, determine the third difference between any two consecutive voltage values, and the number of times the voltage value rises.
[0091] S11C, determine whether the target electrolytic cell has entered the split-chip voltage rise stage based on the third difference and the number of rises.
[0092] In some implementations, if the third difference is within a set difference range and the number of rises is greater than a set number, then the target electrolytic cell is considered to have entered the split-sheet voltage rise stage.
[0093] It should be noted that, in this embodiment, the second preset time interval can be determined based on empirical values. For example, under normal circumstances, aluminum electrolysis cells will split and flow into wafers within 8 to 55 hours during the roasting stage. During this time period, there will be one or more voltage rise phases and voltage drop phases during the split and flow phases. Therefore, 8 to 55 hours can be set as the second preset time interval.
[0094] It should also be noted that, in this embodiment, the set difference range and the set number of times can be set according to the actual situation such as the process characteristics, experience value, operating characteristics, and preset time interval of the aluminum electrolysis cell. This application does not limit the specific values of the set difference range and the set number of times.
[0095] For example, assuming the second preset interval is 8 hours to 55 hours, and the set difference range is set to [0.05V, 0.5V]; and the set number of times is set to 5. Assuming the target electrolytic cell is powered on at 11:00 to enter the roasting stage, and the voltage values obtained at 19:10 are 2.65V; at 19:11, 2.74V; at 19:12, 2.82V; at 19:13, 2.9V; at 19:14, 2.96V; and at 19:15, 3.03V, then it can be considered that the target electrolytic cell has entered the voltage rise stage of the wafer splitting process at 19:10.
[0096] In some implementations, the number of times the target electrolytic cell enters a split-flow voltage rise phase is recorded. Once the recorded number reaches a set number, it is considered that the target electrolytic cell has removed all the split-flow wafer groups. Therefore, after removing all the split-flow wafer groups, a voltage drop phase will be performed before entering the voltage stabilization phase.
[0097] In some implementations, the corresponding early warning strategy during the voltage rise phase of the chip splitting process is as follows:
[0098] The specific implementation method for determining the early warning analysis parameters of the target operation phase based on the voltage values obtained in the target operation phase and in accordance with the target early warning strategy is as follows: Based on the voltage values obtained in the split-chip voltage rise phase, determine the second difference between any two consecutive voltage values and the number of times the voltage value rises, and use the second difference and the number of times the voltage value rises as early warning analysis parameters.
[0099] The specific implementation method for determining whether the target electrolytic cell has an operational abnormality based on the aforementioned early warning analysis parameters is as follows: if the second difference is greater than the sixth preset value, then it is determined that the target electrolytic cell has an operational abnormality; if the number of rises is greater than the preset number, then it is determined that the target electrolytic cell has an operational abnormality.
[0100] It should be noted that, in this embodiment, the sixth preset value and the preset number of times can be set according to the actual situation such as the process characteristics, experience value, operating characteristics, and preset time interval of the aluminum electrolysis cell. This application does not limit the specific values of the sixth preset value and the preset number of times.
[0101] For example, assuming the sixth preset value is set to 0.5V and the preset number of times is set to 30, if the target electrolytic cell enters the splitting and wafer voltage rise stage at 19:10, the voltage value obtained at 19:30 is 2.9V, the voltage value obtained at 19:31 is 3.5V, the voltage value obtained at 19:32 is 3.1V, the voltage value obtained at 19:33 is 3.11V, the voltage value obtained at 19:34 is 3.12V...; the voltage value obtained at 20:02 is 3.4V, and the voltage value obtained at 20:03 is 3.43V.
[0102] If it can be determined at 19:31 that the second difference is 0.6V (3.5V-2.9V) which is greater than 0.5V, then the target electrolytic cell is considered to be operating abnormally, and an alarm signal is output.
[0103] At 20:03, it can be determined that the voltage value has risen 31 times. Since this number is greater than 30, the target electrolytic cell is considered to be operating abnormally, and an alarm signal is output.
[0104] It is understandable that by implementing corresponding early warning strategies during the voltage rise phase of the wafer splitting process, alarm signals can be promptly output when abnormalities occur in the aluminum electrolysis cell, such as excessively rapid voltage rise or prolonged voltage rise duration. This alerts relevant technical personnel and reduces the occurrence of safety accidents.
[0105] The fifth scenario is when the target operating phase is a voltage stability phase.
[0106] In some implementations, it can be determined whether the target electrolyzer has entered the voltage stabilization stage by the following steps S10D to S11D.
[0107] S10D, if the roasting stage of the target electrolytic cell is in the third preset time interval, and the target electrolytic cell has removed all the splitter groups, then the third duration of the voltage value within the set fluctuation range is determined according to the obtained voltage values.
[0108] S11D, determine whether the target electrolytic cell has entered the voltage stabilization stage based on the third duration.
[0109] In some implementations, if the third duration is longer than the third preset duration and the voltage fluctuates around a preset value (2V) without exceeding a threshold value (0.05V), the target electrolytic cell is considered to have entered a voltage stabilization stage.
[0110] In some implementations, the third preset time interval can be set based on empirical values. For example, typically, the calcination stage of an aluminum electrolysis cell will enter a voltage stabilization stage after running for 55 hours.
[0111] It should be noted that, in this embodiment, the set fluctuation range and the third duration can be set according to the actual situation such as the process characteristics, experience value, operating characteristics, and preset time interval of the aluminum electrolysis cell. This application does not limit the specific values of the set fluctuation range and the third duration.
[0112] For example, suppose the set fluctuation range is set to 1.95V to 2.05V; and the third duration is set to 3 minutes. If the third preset time interval is entered at 6:00, and the voltage value obtained at 6:30 is 2.01V, at 6:31 is 1.98V, at 6:32 is 2.00V, and at 6:33 is 2.02V, then it can be considered that the target electrolytic cell entered the voltage stabilization stage at 6:30.
[0113] In some implementations, the corresponding early warning strategy during the voltage stabilization phase is as follows:
[0114] The specific implementation method for determining the early warning analysis parameters of the target operation phase based on the various voltage values obtained in the target operation phase and in accordance with the target early warning strategy is as follows: Based on the various voltage values obtained in the voltage stabilization phase, determine the fluctuation difference between the voltage value and the set voltage value, and use the fluctuation difference as the early warning analysis parameter.
[0115] The specific implementation method for determining whether the target electrolytic cell has an operational abnormality based on the aforementioned early warning analysis parameters is as follows: if the fluctuation difference exceeds a preset range, it is determined that the target electrolytic cell has an operational abnormality.
[0116] It should be noted that, in this embodiment, the set voltage value and the preset range can be set according to the actual situation such as the process characteristics, experience value, and operating characteristics of the aluminum electrolysis cell. This application does not limit the specific values of the set voltage value and the preset range.
[0117] For example, assuming the set voltage value is set to 2V and the preset range is set to [-0.05V, +0.05V], if the target electrolytic cell enters the voltage stabilization stage at 6:30, the voltage value obtained at 6:40 is 2.02V, the voltage value obtained at 6:41 is 2.03V, and the voltage value obtained at 6:42 is 2.06V, then it can be determined that the target electrolytic cell experienced an operational abnormality at 6:42 and output an alarm signal.
[0118] To enable those skilled in the art to better understand the technical solutions of this application, examples will be provided below in conjunction with Embodiment 1 and Embodiment 2.
[0119] Example 1
[0120] Taking the 500KA series aluminum electrolytic cell as an example, the voltage value of the entire system is read. The state of cell 1001 starting to be energized and entering the roasting stage is read from the cell control system. The voltage value of cell 1001 is continuously analyzed. The operation analysis of the aluminum electrolytic cell starts from the energization of the electrolytic cell.
[0121] During the power-on phase, the impulse voltage is 4.1V, which does not exceed 5V, indicating normal operation.
[0122] During the voltage ramp-up phase, the ramp-up voltage rises from 3.2V to 3.6V, with the increase not exceeding 0.5V, and the operation is normal.
[0123] During the first voltage drop phase, the voltage began to decrease slowly, dropping to 2.8V, and then the system operated normally.
[0124] During the voltage rise phase before the first split-flow, the first set of wafers was split, and the voltage rose 7 times, reaching 3.15V, and the operation was normal.
[0125] During the second voltage drop phase, the voltage began to decrease slowly, dropping to 2.91V, and the operation was normal.
[0126] During the second phase of the chip splitting voltage rise, the second batch of chips was split, and the voltage rose 16 times, reaching 3.3V, and the operation was normal.
[0127] During the third voltage drop phase, the voltage began to decrease slowly, dropping to 2.89V, and the system operated normally.
[0128] During the third split-flow voltage rise phase, the third set of condenser chips was split, and the voltage rose 10 times, reaching 3.1V, and the operation was normal.
[0129] During the fourth voltage drop phase, the voltage began to decrease slowly, dropping to 2.9V, and the system operated normally.
[0130] During the fourth split-flow voltage rise phase, the fourth set of flow segments was split, and the voltage rose 23 times, reaching 3.23V, and the operation was normal.
[0131] During the fifth voltage drop phase, all shunts were removed, and the voltage began to drop slowly, eventually reaching 2.1V, after which it operated normally.
[0132] During the voltage stabilization phase, the voltage remains constant at 2V, indicating normal operation.
[0133] In Example 1, the entire roasting process did not exceed the threshold range, no alarm information was output, and the aluminum electrolysis cell operated normally.
[0134] Example 2
[0135] Taking the 300KA aluminum electrolysis cell series as an example, the voltage value of the entire system is read, and the state of cell 1619 starting to be energized and entering the roasting stage is read from the cell control system, and the voltage value data is continuously analyzed.
[0136] During the power-on phase, the impulse voltage is 4V, not exceeding 5V, and the operation is normal.
[0137] During the voltage ramp-up phase, if the ramp-up voltage rises from 3.2V to 4V and exceeds 0.5V, an alarm will be triggered indicating that the ramp-up voltage has increased too much.
[0138] During the first voltage drop phase, the voltage begins to decrease slowly from 2.81V to 1.08V, triggering an alarm for excessively rapid voltage drop. The voltage quickly recovers to 2.97V and continues to decrease slowly, at which point the alarm is canceled.
[0139] Before the first shunt split, the voltage rises and stabilizes. Then the shunt split begins, and the voltage rises several times as normal, followed by a slow voltage drop. Once all the shunts are removed, the voltage begins to drop slowly to 2V and then remains constant.
[0140] In Example 2, the aluminum electrolytic cell operated normally except for the voltage ramp-up phase and the first voltage drop phase, which triggered alarm signals. Because although alarm signals appeared during the voltage ramp-up and first voltage drop phases, the voltage quickly returned to normal, canceling the alarms, relevant technicians did not need to troubleshoot or handle the electrolytic cell.
[0141] In some embodiments of this application, the technical solutions provided involve the following steps during the roasting stage: First, the voltage value of the target electrolytic cell is acquired at preset time intervals. Then, early warning analysis parameters are determined based on the acquired voltage values. These parameters reflect changes in voltage values. Next, it is determined whether the target electrolytic cell is experiencing operational abnormalities based on these parameters. Finally, if an abnormality occurs in the target electrolytic cell, an alarm signal is output. Therefore, the technical solutions of this application enable real-time monitoring of the voltage value of the aluminum electrolytic cell during the roasting stage. Based on early warning strategies corresponding to each stage of the roasting process and changes in voltage values, it is timely determined whether an abnormality has occurred during the roasting stage. If an operational abnormality is detected in the aluminum electrolytic cell during the roasting stage, an alarm signal is output, promptly alerting relevant technical personnel to resolve the abnormality. This improves the safety of the aluminum electrolytic cell during the roasting stage, prevents accidents, and increases the production efficiency of the aluminum electrolytic cell.
[0142] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the embodiments disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein. It should be understood that this application is not limited to the precise steps described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.
Claims
1. A method for early warning of abnormal operation of an aluminum electrolytic cell, characterized in that, Applied to the roasting stage, the method includes: During the roasting stage, the voltage value of the target electrolytic cell is obtained at preset time intervals; Early warning analysis parameters are determined based on the obtained voltage values, and the early warning analysis parameters are parameters that reflect changes in voltage values; Based on the aforementioned early warning analysis parameters, determine whether the target electrolytic cell is experiencing operational abnormalities; If the target electrolytic cell malfunctions, an alarm signal will be output. The roasting stage consists of multiple operating phases, and the determination of early warning analysis parameters based on the obtained voltage values includes: When the target operation phase is in the target operation phase, obtain the target early warning strategy corresponding to the target operation phase, wherein the target operation phase is any one of the plurality of operation phases; Based on the voltage values obtained during the target operation phase, and in accordance with the target early warning strategy, the early warning analysis parameters for the target operation phase are determined. The multiple operating phases include the power-on phase, voltage ramp-up phase, voltage drop phase, chip splitting voltage rise phase, and voltage stabilization phase. The step of determining the early warning analysis parameters for the target operation phase based on the voltage values obtained during the target operation phase and in accordance with the target early warning strategy includes: The target operating phase is the power-on phase; the maximum power-on impulse voltage is determined from the various voltage values obtained during the power-on phase and used as a warning analysis parameter; The target operating phase is the voltage ramp-up phase; the maximum and minimum values are determined from the various voltage values obtained in the voltage ramp-up phase, and the difference between the maximum and the minimum values is used as an early warning analysis parameter; The target operating phase is the voltage drop phase; based on the voltage values obtained in the voltage drop phase, a first difference between any two consecutive voltage values is determined, as well as the cumulative voltage drop value within a set time period is determined, and a first duration of voltage value fluctuation within a set range is determined, and the first difference, the cumulative drop value, and the first duration are used as early warning analysis parameters; The target operating phase is the split-chip voltage rise phase; based on the voltage values obtained in the split-chip voltage rise phase, a second difference between any two consecutive voltage values is determined, as well as the number of times the voltage value rises, and the second difference and the number of times the voltage value rises are used as early warning analysis parameters; The target operating phase is the voltage stability phase; based on the voltage values obtained in the voltage stability phase, the fluctuation difference between the voltage values and the set voltage values is determined, and the fluctuation difference is used as an early warning analysis parameter.
2. The method according to claim 1, characterized in that, The target operating stage is the power-on stage. The step of determining whether the target electrolytic cell has an operational abnormality based on the early warning analysis parameters includes: if the maximum value of the power-on impact voltage is greater than a first preset value, then it is determined that the target electrolytic cell has an operational abnormality.
3. The method according to claim 1, characterized in that, The target operating phase is the voltage ramp-up phase. Determining whether the target electrolytic cell has an operational abnormality based on the early warning analysis parameters includes: if the difference between the maximum value and the minimum value is greater than a second preset value, then it is determined that the target electrolytic cell has an operational abnormality.
4. The method according to claim 1, characterized in that, The target operating phase is the voltage drop phase. Determining whether the target electrolytic cell has an operating abnormality based on the early warning analysis parameters includes: if the first difference is greater than a third preset value, then the target electrolytic cell is determined to have an operating abnormality; if the cumulative drop value is greater than a fourth preset value, then the target electrolytic cell is determined to have an operating abnormality; if the first duration is greater than a first preset duration, then the target electrolytic cell is determined to have an operating abnormality.
5. The method according to claim 4, characterized in that, The method further includes: If the roasting stage of the target electrolytic cell is within the first preset time interval, the number of times the voltage value drops is determined based on the obtained voltage values. The number of voltage drops determines whether the target electrolytic cell has entered the voltage drop phase.
6. The method according to claim 4, characterized in that, The method further includes: If a temporary voltage rise occurs during the voltage drop phase, a second duration of the temporary rise is determined based on the voltage values obtained during the temporary rise, and the cumulative rise of the voltage value during the second duration is determined. The second duration and the cumulative increase value are used as early warning analysis parameters; If the second duration is greater than the second preset duration and the cumulative increase value is greater than the fifth preset value, then it is determined that the target electrolytic cell has an operational abnormality.
7. The method according to claim 1, characterized in that, The target operating phase is the voltage rise phase of the split-chip fabrication process. The step of determining whether the target electrolytic cell has an operational abnormality based on the early warning analysis parameters includes: if the second difference is greater than the sixth preset value, then the target electrolytic cell is determined to have an operational abnormality; if the number of rises is greater than the preset number, then the target electrolytic cell is determined to have an operational abnormality.
8. The method according to claim 7, characterized in that, The method further includes: If the calcination stage of the target electrolytic cell is within the second preset time interval, then based on the obtained voltage values, the third difference between any two consecutive voltage values and the number of times the voltage value rises are determined. The target electrolytic cell is determined to have entered the voltage rise stage of the split-sheet process based on the third difference and the number of rises.
9. The method according to claim 1, characterized in that, The target operating phase is a voltage stability phase. Determining whether the target electrolytic cell has an operational abnormality based on the early warning analysis parameters includes: if the fluctuation difference exceeds a preset range, then determining that the target electrolytic cell has an operational abnormality.