Method for improving production quality of electrolytic aluminum based on electrolytic cell

Abstract

The invention discloses a method for improving the production quality of electrolytic aluminum based on an electrolytic cell. According to the invention, by systematically optimizing the structure and the production process of the electrolytic cell, the quality and the production sustainability of an electrolytic aluminum product are remarkably improved. In the aspect of environmental protection treatment, dry purification and carbon dioxide mineralization technologies are adopted, and a waste heat gradient utilization system is combined, so that emission of pollutants such as fluorides and carbon dioxide is greatly reduced, waste heat in the production process is converted into reusable steam energy, and enterprises are promoted to be transformed to be green and low-carbon. Meanwhile, the micro-grid integrates application of renewable energy sources, dependence on traditional energy sources is further reduced, an ecological chain of efficient resource circulation is formed, and the development bottleneck of high energy consumption and high pollution in the electrolytic aluminum industry is effectively relieved.

Description

Technical Field

[0001] The present invention belongs to the technical field of electrolytic aluminum, and specifically relates to a method for improving the production quality of electrolytic aluminum based on an electrolytic cell. Background Art

[0002] At present, domestic aluminum enterprises have used a variety of methods to improve the production quality of electrolytic aluminum, such as: Advanced electrolytic cell technology: Some domestic aluminum smelting enterprises have begun to adopt high-efficiency electrolytic cell technology, such as high-efficiency low-temperature electrolytic cells and long-life electrolytic cells, to improve the electrolysis efficiency of aluminum and reduce energy consumption. Improved electrolyte formula: Research and apply new electrolyte and flux formulas, optimize the performance of electrolytes, and improve the quality of aluminum liquid and electrolysis efficiency. Automated control: Some domestic enterprises have introduced automated control systems to monitor and adjust the electrolytic aluminum production process in real time, including precise control of parameters such as current, voltage, and temperature. Data analysis and prediction: Use big data and artificial intelligence technology to optimize and predict the process, improve production stability and aluminum product quality. High-efficiency power supply equipment: Introduce and develop high-efficiency power supply equipment to reduce energy consumption in the electrolysis process and improve the production efficiency of electrolytic aluminum. Energy-saving and emission reduction technology: Apply energy-saving technology and environmental protection equipment, such as high-efficiency gas recovery systems and waste heat utilization devices, to reduce energy consumption and environmental pollution in the production process.

[0003] However, the rough structural design of traditional electrolytic cells leads to uneven current distribution and severe heat loss, and the high impurity content in the electrolyte affects the purity and stability of the aluminum liquid; environmental protection treatment relies on inefficient wet processes, pollutant emission control is not up to standard and the resource recycling rate is low; production management lacks intelligent means, quality traceability relies on manual records, and the control accuracy of process parameters is insufficient, making it difficult to meet the high-end market's stringent requirements for product consistency and traceability. Summary of the invention

[0004] The object of the present invention is to provide a method for improving the production quality of electrolytic aluminum based on an electrolytic cell in order to solve the above-mentioned problems.

[0005] The technical solution adopted by the present invention is as follows: a method for improving the production quality of electrolytic aluminum based on an electrolytic cell, the method comprising the following steps:

[0006] Step S1: Use physical magnetic separation and acid chemical leaching synergistic process to deeply purify impurities such as iron and silicon in bauxite. By configuring gradient magnetic separation equipment (magnetic field strength ≥ 1.2T), ferromagnetic impurities are removed in stages, combined with sulfuric acid-hydrofluoric acid mixed leaching system (concentration 8% to 12%), and silicon is selectively dissolved under 80-90°C reaction conditions, and the leaching efficiency is increased to more than 95%. A raw material composition database is established simultaneously, integrating X-ray fluorescence spectrometer (XRF) and scanning electron microscope (SEM) detection data to achieve a raw material purity of ≥ 99.5%, providing high-purity alumina raw materials for the electrolysis process.

[0007] Step S2: Design a multi-level gradient insulation system, use nano-porous thermal insulation materials (thermal conductivity ≤ 0.03W / m·K) in the cathode area, configure an adjustable air-cooled heat dissipation module on the side wall, and combine the wavy cathode surface (amplitude 15-20mm) with a directional flow guide groove structure to optimize the aluminum liquid flow path. Through electromagnetic field finite element simulation analysis, the busbar network is re-arranged, the current distribution unevenness in the electrolytic cell is controlled within ±3%, the heat loss is reduced by 28%, the cell life is extended to 3000 days, and the stability of the electrolysis process is significantly improved.

[0008] Step S3: construct a quaternary composite electrolyte system of LiF (4-6wt%), AlF3, CaF2 (3-5wt%), and MgF2, add 0.5-1.2wt% CeF3 rare earth modifier, generate CeAlO3 protective film through high temperature melting reaction, and inhibit the anode effect. Introduce nano-Al2O3 suspension technology (particle size 50-80nm), use 40kHz ultrasonic dispersion device to increase the solubility of alumina by 15%, reduce the electrolyte primary crystallization temperature to 935±5℃, increase the current efficiency to 94.5%, and increase the conductivity of aluminum liquid to 3.1S / cm.

[0009] Step S4: Implement a three-stage purification process of electromagnetic purification (0.15T alternating magnetic field) - gas refining (Ar:Cl2 = 4:1 mixing ratio) - porous ceramic filtration (pore size 20μm). The electromagnetic field removes metal impurities such as Fe and Si, and the gas refining flow rate is controlled at 12-15m 3 / h, remove non-metallic inclusions to ≤50ppm. Equipped with a laser induced breakdown spectrometer (LIBS), it completes online detection of eight elements including Na, Ca, Fe, and Si every 30 seconds, and transmits data to the central control system in real time to ensure that the dynamic composition of the aluminum liquid meets the standard.

[0010] Step S5: Deploy an IGBT high-frequency pulse rectification system (switching frequency 5-20kHz), use a three-level topology to reduce the harmonic distortion rate to 2.8%, and dynamically adjust the output voltage (4.0-4.5V) in combination with an adaptive PID algorithm. Construct a current-temperature-pole distance multi-parameter coupling model, use digital twin technology to simulate the electrolytic cell state in real time, optimize the pole distance to 4.2-4.5cm, and reduce the DC power consumption to 12450kWh / t-Al, saving 18% of electricity compared to traditional processes.

[0011] Step S6: Install a 1000℃ high-temperature laser sensor array to monitor the electrolyte level in real time with an accuracy of ±2mm; deploy a multispectral thermal imager (0.1℃ resolution) to build a three-dimensional temperature field model of the electrolyzer. An integrated Fourier infrared gas analyzer (FTIR) continuously monitors the concentrations of 12 gases such as CF4 and CO, and combines the XGBoost-LSTM hybrid algorithm to predict the current efficiency deviation of ≤±1.5%, and generate energy efficiency optimization reports every day to guide production adjustments.

[0012] Step S7: Optimize the anode vibration forming process parameters (frequency 50Hz, amplitude 2mm, holding time 90s), use KCl solution (concentration 5%) to impregnate the modified coke particles, reduce the anode resistivity to 45μΩ·m. Match the high temperature roasting curve (1250℃ constant temperature 48h) to make the anode volume density reach 1.62g / cm 3 , compressive strength ≥32MPa, oxidation slag rate reduced by 40%, significantly reducing the pollution of carbon impurities to aluminum liquid.

[0013] Step S8: Apply Al(OH)3 nanosheet adsorbent (specific surface area ≥ 300m 2 / g) to build a dry purification system, with fluoride adsorption efficiency ≥ 98% and emission concentration ≤ 0.8 mg / m 3 . Equipped with a CO2 mineralization reactor (CaO / Al2O3 catalyst), the CO2 storage rate can reach ≥85% at 120℃ and 2MPa. The waste heat from electrolysis (flue gas temperature 450℃) is recovered simultaneously to produce 100,000 tons of saturated steam per year, and the proportion of renewable energy in the plant microgrid is increased to 30%.

[0014] Step S9: Establish a blockchain quality management system based on Hyperledger Fabric, and use RFID tags (read and write distance 8m) to trace the entire process from raw materials entering the factory to finished products leaving the factory, with a response time of <5 seconds. Formulate three industry standards such as "High-purity Electrolytic Aluminum Production Process Specifications", stipulating core indicators such as current efficiency ≥96% and DC power consumption ≤12500kWh / t-Al. Use the ANN-SVM hybrid model to predict the tensile strength of aluminum ingots (deviation ≤±2%), and promote product consistency to meet the AS9100 certification requirements for aviation aluminum.

[0015] In a preferred embodiment, in step S1, a physical magnetic separation and acid chemical leaching synergistic process is used to deeply purify impurities such as iron and silicon in bauxite. By configuring a gradient magnetic separation device, the magnetic field strength reaches more than 1.2 Tesla, and ferromagnetic impurities are removed in stages; combined with a mixed leaching system of sulfuric acid and hydrofluoric acid, the concentration of the leaching solution is 8% to 12%, and the silicon element is selectively dissolved under reaction conditions of 80 to 90 degrees Celsius, and the leaching efficiency is increased to more than 95%. The X-ray fluorescence spectrometer and scanning electron microscope detection data are synchronously integrated to establish a raw material composition database to ensure that the raw material purity is not less than 99.5%, providing high-purity alumina raw materials for the electrolysis process.

[0016] In a preferred embodiment, in step S2, the cathode area adopts nanoporous thermal insulation material, whose thermal conductivity does not exceed 0.03 watts per meter Kelvin, and the side wall is equipped with an adjustable air-cooled heat dissipation module. The wavy cathode surface structure is optimized, the amplitude is controlled at 15 to 20 mm, and the directional guide groove is used to improve the flow path of the aluminum liquid. The busbar network is rearranged through electromagnetic field finite element simulation analysis, the unevenness of current distribution in the electrolytic cell is controlled within plus or minus 3%, the heat loss is reduced by 28%, the cell life is extended to 3000 days, and the stability of the electrolysis process is significantly improved.

[0017] In a preferred embodiment, in step S3, a quaternary composite electrolyte system with a lithium fluoride content of 4% to 6% and a calcium fluoride content of 3% to 5% is constructed, and 0.5% to 1.2% of a cerium fluoride rare earth modifier is added to generate a cerium aluminate protective film through a high-temperature melting reaction to inhibit the anode effect. Nano-alumina suspension technology is introduced, and alumina particles with a particle size of 50 to 80 nanometers are used. A 40 kHz ultrasonic dispersion device is used to increase the solubility of alumina by 15%, and the electrolyte primary crystallization temperature is reduced to 935 degrees Celsius and a fluctuation of plus or minus 5 degrees Celsius is allowed. The current efficiency is increased to 94.5%, and the conductivity of the aluminum liquid is increased to 3.1 Siemens per centimeter.

[0018] In a preferred embodiment, in step S4, a three-stage joint operation of electromagnetic purification, gas refining and porous ceramic filtration is implemented. Electromagnetic purification uses a 0.15 Tesla alternating magnetic field to remove metal impurities such as iron and silicon; gas refining uses a 4:1 mixing ratio of argon and chlorine, and the flow rate is controlled at 12 to 15 cubic meters per hour to remove non-metallic inclusions to less than 50ppm. A laser induced breakdown spectrometer is used to complete online detection of 8 elements such as sodium, calcium, iron, and silicon every 30 seconds, and the data is transmitted to the central control system in real time to ensure that the dynamic composition of the aluminum liquid meets the standard.

[0019] In a preferred embodiment, in step S5, a high-frequency pulse rectifier system based on IGBT is deployed, the switching frequency covers 5 kilohertz to 20 kilohertz, and the total harmonic distortion rate is reduced to 2.8% by adopting a three-level topology structure. The output voltage is dynamically adjusted to 4.0 to 4.5 volts by combining an adaptive proportional integral differential algorithm, a multi-parameter coupling model of current, temperature and pole distance is constructed, and the electrolytic cell state is simulated in real time through digital twin technology to optimize the pole distance to 4.2 to 4.5 centimeters.

[0020] In a preferred embodiment, in step S6, a laser sensor array that can withstand a high temperature of 1000 degrees Celsius is installed to achieve an electrolyte level monitoring accuracy of plus or minus 2 mm; a multi-spectral thermal imager is deployed to construct a three-dimensional temperature field model of the electrolytic cell, with a temperature resolution of 0.1 degrees Celsius. An integrated Fourier infrared gas analyzer continuously monitors the concentrations of 12 gases such as carbon tetrafluoride and carbon monoxide, and generates an energy efficiency optimization report every day to guide production adjustments.

[0021] In a preferred embodiment, in step S7, the vibration frequency is set to 50 Hz, the amplitude is 2 mm, the holding time is 90 seconds, and the modified coke particles are impregnated with a 5% potassium chloride solution to reduce the anode resistivity to 45 micro-ohms. A high-temperature roasting curve is matched with a constant temperature of 1250 degrees Celsius for 48 hours, the anode volume density reaches 1.62 grams per cubic centimeter, the compressive strength is not less than 32 MPa, the oxidation slag rate is reduced by 40%, and the pollution of carbon impurities to aluminum liquid is significantly reduced.

[0022] In a preferred embodiment, in step S8, in the environmental emission management link, dry purification technology is used to replace the traditional wet treatment process, and the core is aluminum hydroxide nanosheet adsorbent, which has a specific surface area of ​​more than 300 square meters per gram, and efficiently adsorbs pollutants such as hydrogen fluoride and carbon tetrafluoride in the electrolytic flue gas to ensure that the fluoride emission concentration is stably controlled below 0.8 mg per cubic meter.

[0023] In a preferred embodiment, in step S9, a quality traceability system is constructed based on blockchain technology, and a distributed management system is developed using the Hyperledger Fabric framework. Ultra-high frequency radio frequency identification tags are used to store data such as raw material batches, electrolysis process parameters, and quality inspection results on the chain, thereby achieving full-process traceability from the entry of bauxite into the factory to the delivery of aluminum ingots, and the response time for a single query is shortened to less than 5 seconds.

[0024] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0025] 1. In the present invention, the quality and production sustainability of electrolytic aluminum products are significantly improved by systematically optimizing the electrolytic cell structure and production process. In terms of environmental protection, the use of dry purification and carbon dioxide mineralization technology, combined with the waste heat cascade utilization system, not only greatly reduces the emission of pollutants such as fluoride and carbon dioxide, but also converts the waste heat in the production process into reusable steam energy, promoting the company's transformation to green and low-carbon. At the same time, the microgrid integrates the application of renewable energy, further reduces dependence on traditional energy, forms an ecological chain of efficient resource circulation, and effectively alleviates the development bottleneck of high energy consumption and high pollution in the electrolytic aluminum industry.

[0026] 2. In the present invention, the deep integration of the full-process traceability system based on blockchain technology and radio frequency identification technology realizes accurate traceability from raw materials to finished products, ensuring that production data cannot be tampered with and can be checked in real time. By formulating strict process specifications and energy consumption standards, combined with intelligent algorithms to predict and optimize product performance, not only the mechanical properties and purity stability of aluminum ingots are improved, but also the products meet the stringent requirements of high-end fields such as aerospace, and the quality of products is improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the process of the present invention. DETAILED DESCRIPTION

[0028] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0029] Reference Figure 1 ,

[0030] A method for improving the production quality of electrolytic aluminum based on an electrolytic cell, the method comprising the following steps:

[0031] Step S1: Use physical magnetic separation and acid chemical leaching synergistic process to deeply purify impurities such as iron and silicon in bauxite. By configuring gradient magnetic separation equipment (magnetic field strength ≥ 1.2T), ferromagnetic impurities are removed in stages, combined with sulfuric acid-hydrofluoric acid mixed leaching system (concentration 8% to 12%), and silicon is selectively dissolved under 80-90°C reaction conditions, and the leaching efficiency is increased to more than 95%. A raw material composition database is established simultaneously, integrating X-ray fluorescence spectrometer (XRF) and scanning electron microscope (SEM) detection data to achieve a raw material purity of ≥ 99.5%, providing high-purity alumina raw materials for the electrolysis process.

[0032] Step S2: Design a multi-level gradient insulation system, use nano-porous thermal insulation materials (thermal conductivity ≤ 0.03W / m·K) in the cathode area, configure an adjustable air-cooled heat dissipation module on the side wall, and combine the wavy cathode surface (amplitude 15-20mm) with a directional flow guide groove structure to optimize the aluminum liquid flow path. Through electromagnetic field finite element simulation analysis, the busbar network is re-arranged, the current distribution unevenness in the electrolytic cell is controlled within ±3%, the heat loss is reduced by 28%, the cell life is extended to 3000 days, and the stability of the electrolysis process is significantly improved.

[0033] Step S3: construct a quaternary composite electrolyte system of LiF (4-6wt%), AlF3, CaF2 (3-5wt%), and MgF2, add 0.5-1.2wt% CeF3 rare earth modifier, generate CeAlO3 protective film through high temperature melting reaction, and inhibit the anode effect. Introduce nano-Al2O3 suspension technology (particle size 50-80nm), use 40kHz ultrasonic dispersion device to increase the solubility of alumina by 15%, reduce the electrolyte primary crystallization temperature to 935±5℃, increase the current efficiency to 94.5%, and increase the conductivity of aluminum liquid to 3.1S / cm.

[0034] Step S4: Implement a three-stage purification process of electromagnetic purification (0.15T alternating magnetic field) - gas refining (Ar:Cl2 = 4:1 mixing ratio) - porous ceramic filtration (pore size 20μm). The electromagnetic field removes metal impurities such as Fe and Si, and the gas refining flow rate is controlled at 12-15m 3 / h, remove non-metallic inclusions to ≤50ppm. Equipped with a laser induced breakdown spectrometer (LIBS), it completes online detection of eight elements including Na, Ca, Fe, and Si every 30 seconds, and transmits data to the central control system in real time to ensure that the dynamic composition of the aluminum liquid meets the standard.

[0035] Step S5: High-frequency pulse power supply and intelligent control technology

[0036] Deploy an IGBT high-frequency pulse rectification system (switching frequency 5-20kHz), use a three-level topology to reduce the harmonic distortion rate to 2.8%, and combine the adaptive PID algorithm to dynamically adjust the output voltage (4.0-4.5V). Build a current-temperature-pole distance multi-parameter coupling model, use digital twin technology to simulate the electrolytic cell state in real time, optimize the pole distance to 4.2-4.5cm, and reduce the DC power consumption to 12450kWh / t-Al, saving 18% of electricity compared to traditional processes.

[0037] Step S6: Install a 1000℃ high-temperature laser sensor array to monitor the electrolyte level in real time with an accuracy of ±2mm; deploy a multispectral thermal imager (0.1℃ resolution) to build a three-dimensional temperature field model of the electrolyzer. An integrated Fourier infrared gas analyzer (FTIR) continuously monitors the concentrations of 12 gases such as CF4 and CO, and combines the XGBoost-LSTM hybrid algorithm to predict the current efficiency deviation of ≤±1.5%, and generate energy efficiency optimization reports every day to guide production adjustments.

[0038] Step S7: Optimize the anode vibration forming process parameters (frequency 50Hz, amplitude 2mm, holding time 90s), use KCl solution (concentration 5%) to impregnate the modified coke particles, reduce the anode resistivity to 45μΩ·m. Match the high temperature roasting curve (1250℃ constant temperature 48h) to make the anode volume density reach 1.62g / cm 3 , compressive strength ≥32MPa, oxidation slag rate reduced by 40%, significantly reducing the pollution of carbon impurities to aluminum liquid.

[0039] Step S8: Apply Al(OH)3 nanosheet adsorbent (specific surface area ≥ 300m 2 / g) to build a dry purification system, with fluoride adsorption efficiency ≥ 98% and emission concentration ≤ 0.8 mg / m 3 . Equipped with a CO2 mineralization reactor (CaO / Al2O3 catalyst), the CO2 storage rate can reach ≥85% at 120℃ and 2MPa. The waste heat from electrolysis (flue gas temperature 450℃) is recovered simultaneously to produce 100,000 tons of saturated steam per year, and the proportion of renewable energy in the plant microgrid is increased to 30%.

[0040] Step S9: Establish a blockchain quality management system based on Hyperledger Fabric, and use RFID tags (read and write distance 8m) to trace the entire process from raw materials entering the factory to finished products leaving the factory, with a response time of <5 seconds. Formulate three industry standards such as "High-purity Electrolytic Aluminum Production Process Specifications", stipulating core indicators such as current efficiency ≥96% and DC power consumption ≤12500kWh / t-Al. Use the ANN-SVM hybrid model to predict the tensile strength of aluminum ingots (deviation ≤±2%), and promote product consistency to meet the AS9100 certification requirements for aviation aluminum.

[0041] In step S1, a physical magnetic separation and acid chemical leaching synergistic process is used to deeply purify impurities such as iron and silicon in bauxite. By configuring a gradient magnetic separation device, the magnetic field strength reaches more than 1.2 Tesla, and ferromagnetic impurities are removed in stages; combined with a mixed leaching system of sulfuric acid and hydrofluoric acid, the concentration of the leaching solution is 8% to 12%, and the silicon element is selectively dissolved under reaction conditions of 80 to 90 degrees Celsius, and the leaching efficiency is increased to more than 95%. The X-ray fluorescence spectrometer and scanning electron microscope detection data are synchronously integrated to establish a raw material composition database to ensure that the raw material purity is not less than 99.5%, providing high-purity alumina raw materials for the electrolysis process.

[0042] In step S2, the cathode area uses nanoporous thermal insulation material with a thermal conductivity of no more than 0.03 watts per meter Kelvin, and the side wall is equipped with an adjustable air-cooled heat dissipation module. The wavy cathode surface structure is optimized, the amplitude is controlled at 15 to 20 mm, and the directional guide groove is used to improve the flow path of the aluminum liquid. The busbar network is rearranged through electromagnetic field finite element simulation analysis, the unevenness of current distribution in the electrolytic cell is controlled within plus or minus 3%, the heat loss is reduced by 28%, and the cell life is extended to 3,000 days, significantly improving the stability of the electrolysis process.

[0043] In step S3, a quaternary composite electrolyte system with a lithium fluoride content of 4% to 6% and a calcium fluoride content of 3% to 5% is constructed, and a cerium fluoride rare earth modifier of 0.5% to 1.2% is added to generate a cerium aluminate protective film through a high-temperature melting reaction to inhibit the anode effect. Nano-alumina suspension technology is introduced, and alumina particles with a particle size of 50 to 80 nanometers are used. A 40 kHz ultrasonic dispersion device is used to increase the solubility of alumina by 15%, and the electrolyte primary crystallization temperature is reduced to 935 degrees Celsius and allows fluctuations of plus or minus 5 degrees Celsius. The current efficiency is increased to 94.5%, and the conductivity of the aluminum liquid is increased to 3.1 Siemens per centimeter.

[0044] In step S4, electromagnetic purification, gas refining and porous ceramic filtration are carried out in three stages. Electromagnetic purification uses a 0.15 Tesla alternating magnetic field to remove metal impurities such as iron and silicon; gas refining uses a 4:1 mixing ratio of argon and chlorine, and the flow rate is controlled at 12 to 15 cubic meters per hour to remove non-metallic inclusions to less than 50ppm. A laser induced breakdown spectrometer is used to complete online detection of eight elements such as sodium, calcium, iron, and silicon every 30 seconds, and the data is transmitted to the central control system in real time to ensure that the dynamic composition of the aluminum liquid meets the standard.

[0045] In step S5, a high-frequency pulse rectifier system based on IGBT is deployed, with a switching frequency covering 5,000 to 20 kHz, and a three-level topology is used to reduce the total harmonic distortion rate to 2.8%. The output voltage is dynamically adjusted to 4.0 to 4.5 volts by combining an adaptive proportional integral differential algorithm, and a multi-parameter coupling model of current, temperature and pole distance is constructed. The electrolytic cell state is simulated in real time through digital twin technology, and the pole distance is optimized to 4.2 to 4.5 cm.

[0046] In step S6, a laser sensor array that can withstand high temperatures of 1000 degrees Celsius is installed to achieve an electrolyte level monitoring accuracy of plus or minus 2 mm; a multi-spectral thermal imager is deployed to build a three-dimensional temperature field model of the electrolytic cell with a temperature resolution of 0.1 degrees Celsius. An integrated Fourier infrared gas analyzer continuously monitors the concentrations of 12 gases such as carbon tetrafluoride and carbon monoxide, and generates energy efficiency optimization reports every day to guide production adjustments.

[0047] In step S7, the vibration frequency is set to 50 Hz, the amplitude is 2 mm, the holding time is 90 seconds, and the modified coke particles are impregnated with a 5% potassium chloride solution to reduce the anode resistivity to 45 micro-ohms. A high-temperature roasting curve is matched with a constant temperature of 1250 degrees Celsius for 48 hours. The anode volume density reaches 1.62 grams per cubic centimeter, the compressive strength is not less than 32 MPa, and the oxidation slag rate is reduced by 40%, significantly reducing the pollution of carbon impurities to aluminum liquid.

[0048] In step S8, in the environmental emission management link, dry purification technology is used to replace the traditional wet treatment process. The core is aluminum hydroxide nanosheet adsorbent, which has a specific surface area of ​​more than 300 square meters per gram. It can efficiently adsorb pollutants such as hydrogen fluoride and carbon tetrafluoride in the electrolytic flue gas, ensuring that the fluoride emission concentration is stably controlled below 0.8 mg per cubic meter.

[0049] In step S9, a quality traceability system is built based on blockchain technology, and a distributed management system is developed using the Hyperledger Fabric framework. Ultra-high frequency radio frequency identification tags are used to store data such as raw material batches, electrolysis process parameters, and quality inspection results on the chain, thereby achieving full-process traceability from the entry of bauxite into the factory to the delivery of aluminum ingots, and the response time for a single query is shortened to less than 5 seconds.

[0050] From the above, it can be seen that: in the present invention, the quality and production sustainability of electrolytic aluminum products are significantly improved by systematically optimizing the electrolytic cell structure and production process. In terms of environmental protection, the use of dry purification and carbon dioxide mineralization technology, combined with the waste heat cascade utilization system, not only greatly reduces the emission of pollutants such as fluoride and carbon dioxide, but also converts the waste heat in the production process into reusable steam energy, promoting the company's transformation to green and low-carbon. At the same time, the microgrid integrates the application of renewable energy to further reduce dependence on traditional energy, form an ecological chain of efficient resource circulation, and effectively alleviate the development bottleneck of high energy consumption and high pollution in the electrolytic aluminum industry.

[0051] In this invention, the full-process traceability system based on blockchain technology and the deep integration of radio frequency identification technology have achieved accurate traceability from raw materials to finished products, ensuring that production data cannot be tampered with and can be checked in real time. By formulating strict process specifications and energy consumption standards, combined with intelligent algorithms to predict and optimize product performance, not only the mechanical properties and purity stability of aluminum ingots are improved, but also the products meet the stringent requirements of high-end fields such as aerospace, and the quality of products is improved.

[0052] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the term "comprises" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprises a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0053] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for improving the production quality of electrolytic aluminum based on an electrolytic cell, characterized in that: The method comprises the following steps: Step S1: using a physical magnetic separation and acid chemical leaching synergistic process to deeply purify impurities such as iron and silicon in bauxite; Step S2: design a multi-level gradient insulation system, use nano-microporous insulation materials in the cathode area, configure an adjustable air-cooling heat dissipation module on the side wall, combine the wavy cathode surface with the directional guide groove structure, and optimize the aluminum liquid flow path; Step S3: constructing a quaternary composite electrolyte system of LiF, AlF3, CaF2, and MgF2, adding 0.5-1.2wt% CeF3 rare earth modifier, and generating a CeAlO3 protective film through a high-temperature melting reaction to inhibit the anode effect; Step S4: Implement the three-stage purification process of electromagnetic purification - gas refining - porous ceramic filtration; the electromagnetic field removes metal impurities such as Fe and Si, and the gas refining flow rate is controlled at 12-15m 3 / h, remove non-metallic inclusions to ≤50ppm; Step S5: deploy an IGBT high-frequency pulse rectification system, use a three-level topology to reduce the harmonic distortion rate to 2.8%, and dynamically adjust the output voltage in combination with an adaptive PID algorithm; Step S6: Install a 1000°C high temperature laser sensor array to monitor the electrolyte level in real time with an accuracy of ±2mm; deploy a multi-spectral thermal imager to construct a three-dimensional temperature field model of the electrolytic cell; Step S7: Optimize the anode vibration forming process parameters, use KCl solution to impregnate the modified coke particles, reduce the anode resistivity to 45μΩ·m; match the high temperature roasting curve to make the anode volume density reach 1.62g / cm 3 , compressive strength ≥32MPa, oxidation slag rate reduced by 40%, significantly reducing the pollution of carbon impurities to aluminum liquid; Step S8: Use Al(OH)3 nanosheet adsorbent to construct a dry purification system, with fluoride adsorption efficiency ≥ 98% and emission concentration ≤ 0.8 mg / m 3 ; Step S9: Establish a blockchain quality management system based on Hyperledger Fabric, and use RFID tags to trace the entire process from raw materials entering the factory to finished products leaving the factory.

2. A method for improving the production quality of electrolytic aluminum based on an electrolytic cell as claimed in claim 1, characterized in that: In step S1, a physical magnetic separation and acid chemical leaching synergistic process is used to deeply purify impurities such as iron and silicon in the bauxite; By configuring gradient magnetic separation equipment, the magnetic field strength reaches more than 1.2 Tesla, and ferromagnetic impurities are removed in stages; combined with a mixed leaching system of sulfuric acid and hydrofluoric acid, the leaching solution concentration is 8% to 12%, and silicon is selectively dissolved under reaction conditions of 80 to 90 degrees Celsius, and the leaching efficiency is increased to more than 95%; the X-ray fluorescence spectrometer and scanning electron microscope detection data are simultaneously integrated to establish a raw material composition database to ensure that the raw material purity is not less than 99.5%, providing high-purity alumina raw materials for the electrolysis process.

3. A method for improving the production quality of electrolytic aluminum based on an electrolytic cell as claimed in claim 1, characterized in that: In the step S2, the cathode region adopts nano-microporous thermal insulation material, whose thermal conductivity does not exceed 0.03 watts per meter Kelvin, and the side wall is configured with an adjustable air-cooled heat dissipation module; the wavy cathode surface structure is optimized, the amplitude is controlled at 15 to 20 mm, and the directional guide groove is used to improve the flow path of the aluminum liquid; the bus network is rearranged through electromagnetic field finite element simulation analysis, and the current distribution unevenness in the electrolytic cell is controlled within plus or minus 3%, the heat loss is reduced by 28%, and the cell life is extended to 3000 days, which significantly improves the stability of the electrolysis process.

4. A method for improving the production quality of electrolytic aluminum based on an electrolytic cell as claimed in claim 1, characterized in that: In the step S3, a quaternary composite electrolyte system with a lithium fluoride content of 4% to 6% and a calcium fluoride content of 3% to 5% is constructed, and 0.5% to 1.2% of a cerium fluoride rare earth modifier is added to generate a cerium aluminate protective film through a high-temperature melting reaction to suppress the anode effect; nano-alumina suspension technology is introduced, and alumina particles with a particle size of 50 to 80 nanometers are used. A 40 kHz ultrasonic dispersion device is used to increase the solubility of alumina by 15%, so that the electrolyte primary crystallization temperature is reduced to 935 degrees Celsius and a fluctuation of plus or minus 5 degrees Celsius is allowed, the current efficiency is increased to 94.5%, and the conductivity of the aluminum liquid is increased to 3.1 Siemens per centimeter.

5. A method for improving the production quality of electrolytic aluminum based on an electrolytic cell as claimed in claim 1, characterized in that: In step S4, a three-stage combined operation of electromagnetic purification, gas refining and porous ceramic filtration is implemented; electromagnetic purification uses a 0.15 Tesla alternating magnetic field to remove metal impurities such as iron and silicon; gas refining uses a 4:1 mixing ratio of argon and chlorine, and the flow rate is controlled at 12 to 15 cubic meters per hour to remove non-metallic inclusions to below 50 ppm; a supporting laser induced breakdown spectrometer is used to complete online detection of eight elements such as sodium, calcium, iron, and silicon every 30 seconds, and the data is transmitted to the central control system in real time to ensure that the dynamic composition of the aluminum liquid meets the standard.

6. A method for improving the production quality of electrolytic aluminum based on an electrolytic cell as claimed in claim 1, characterized in that: In step S5, a high-frequency pulse rectification system based on IGBT is deployed, the switching frequency covers 5 kilohertz to 20 kilohertz, and a three-level topology structure is adopted to reduce the total harmonic distortion rate to 2.8%; The output voltage is dynamically adjusted to 4.0 to 4.5 volts by combining an adaptive proportional-integral-differential algorithm, and a multi-parameter coupling model of current, temperature and pole distance is constructed. The electrolytic cell state is simulated in real time through digital twin technology, and the pole distance is optimized to 4.2 to 4.5 centimeters.

7. A method for improving the production quality of electrolytic aluminum based on an electrolytic cell as claimed in claim 1, characterized in that: In step S6, a laser sensor array that can withstand high temperatures of 1000 degrees Celsius is installed to achieve an electrolyte level monitoring accuracy of plus or minus 2 mm; a multi-spectral thermal imager is deployed to construct a three-dimensional temperature field model of the electrolytic cell with a temperature resolution of 0.1 degrees Celsius; an integrated Fourier infrared gas analyzer continuously monitors the concentrations of 12 gases such as carbon tetrafluoride and carbon monoxide, and generates an energy efficiency optimization report every day to guide production adjustments.

8. The method for improving the production quality of electrolytic aluminum based on an electrolytic cell according to claim 1, characterized in that: In step S7, the vibration frequency is set to 50 Hz, the amplitude is 2 mm, the holding time is 90 seconds, and the modified coke particles are impregnated with a 5% potassium chloride solution to reduce the anode resistivity to 45 micro-ohms; a high-temperature roasting curve is matched with a constant temperature of 1250 degrees Celsius for 48 hours, the anode volume density reaches 1.62 grams per cubic centimeter, the compressive strength is not less than 32 MPa, the oxidation slag rate is reduced by 40%, and the pollution of carbon impurities to the aluminum liquid is significantly reduced.

9. A method for improving the production quality of electrolytic aluminum based on an electrolytic cell as claimed in claim 1, characterized in that: In step S8, in the environmental emission management link, dry purification technology is used to replace the traditional wet treatment process. The core is aluminum hydroxide nanosheet adsorbent, which has a specific surface area of ​​more than 300 square meters per gram. It can efficiently adsorb pollutants such as hydrogen fluoride and carbon tetrafluoride in the electrolytic flue gas, ensuring that the fluoride emission concentration is stably controlled below 0.8 mg per cubic meter.

10. A method for improving the production quality of electrolytic aluminum based on an electrolytic cell as claimed in claim 1, characterized in that: In step S9, a quality traceability system is constructed based on blockchain technology, and a distributed management system is developed using the Hyperledger Fabric framework. UHF radio frequency identification tags are used to store data such as raw material batches, electrolysis process parameters, and quality inspection results on the chain, thereby achieving full-process traceability from the entry of bauxite into the factory to the delivery of aluminum ingots, and shortening the response time of a single query to less than 5 seconds.

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