Electrolytic tank system optimization index evaluation, learning and calculation technology for electricity metrology

Abstract

The application relates to an advanced device for determining the physical properties of an electrolytic cell. The device adopts an innovative energy collection mechanism, is ingenious in design, and can be firmly fixed around an anode bar or a bus of the electrolytic cell. The device is provided with at least one sensor, and key characteristics of the electrolytic cell can be accurately measured. In addition, the device further comprises a wireless transceiver unit for efficient data communication. One key aspect of the invention is that a distributed calculation function is utilized, and complex analysis and real-time data processing can be carried out on the sensor, so that the measurement precision is improved, and the electrolytic process can be deeply known and optimized. The combination of energy collection, accurate measurement and distributed calculation becomes an integral method for monitoring and analyzing the electrolytic cell, which marks a remarkable progress in the field.

Description

Technical Field

[0001] This application relates to the field of electrolytic cell analysis and monitoring, and particularly to an advanced electronic device and a computational method for evaluating, monitoring, and predicting the behavior and efficiency of electrolytic cells. This application encompasses integrated signal processing techniques, machine learning algorithms, and real-time data analysis to optimize the performance and diagnostic capabilities of electrolytic systems, including but not limited to applications in industrial electrolysis processes, energy storage systems, and electrochemical cell research. Background Art

[0002] Aluminum production is an energy-intensive industrial process that requires 12 kilowatt-hours of energy per kilogram of metal produced. Commercial aluminum electrolytic cells generally use the Hall–Héroult process to reduce alumina. For current smelters, the carbon dioxide emissions generated by this process are more than the output of aluminum itself, equivalent to nearly 1,500 kilograms of carbon dioxide emissions per ton of aluminum. In addition, if no decarbonization operation is carried out during power supply, additional carbon emissions will be generated, up to ten times the emissions of the above process itself.

[0003] Aluminum electrolytic cells need to be connected to a continuous current (CC) or direct current (DC) to generate an electrochemical reaction in the electrolytic cell to electrolyze aluminum. A smelter usually contains hundreds of such electrolytic cells, which are connected in series to form an electrolytic cell train. These electrolytic cells are powered by a transformer and a rectification system, providing a large current of up to 10 5 amps to all the electrolytic cells in the electrolytic cell train.

[0004] Over time, with continuous optimization, the length of the electrolytic cell production line is longer, the current density is higher, and the operation is more mechanized. Aluminum electrolytic cells have also achieved computer control. Modern aluminum electrolytic cell controllers can realize computer control of alumina feeding and other key processes, such as the raising of the anode beam or the adjustment of the anode-cathode distance, as well as anode replacement operations. At the same time, the improvement of the degree of automation of anode positioning has also facilitated the management of current cell operations.

[0005] However, there is limited electrolytic cell data such as bath acidity, temperature, and power input, and insufficient information for estimating key process variables. In addition, the electrolytic cell voltage is the only continuous signal used by the electrolytic cell controller to adjust the electrolytic cell target resistance and determine the precursor feeding intensity.

[0006] Modern Hall–Héroult electrolytic cell designs for large-scale aluminum production include a cathode located at the bottom of the electrolytic cell and a set of carbon anodes located above the electrolyte. The electrolytic cell anodes are connected in parallel. Various factors can cause current imbalance between individual anodes, thereby affecting the current efficiency and metal yield of the electrolytic cell. During the electrolysis reaction, the carbon in the anode reacts with the ions in the electrolyte, mainly generating carbon dioxide. Therefore, the consumable anodes of each electrolytic cell need to be replaced regularly within 36 - 48 hours.

[0007] Continuous monitoring of the parameters of the production electrolytic cell makes the operation process of the electrolytic cell visible, which requires the synchronous upgrade of instrument technology. Such a solution is cost-effective, has low or no maintenance costs, can provide accurate and reliable information, and has a wide range of applications, remaining effective even in heavy load and corrosive environments. In addition, a variety of energy harvesting mechanisms can be applied. However, the upgrade of the production solution requires cost optimization.

[0008] This application relates to an optimized energy harvester for powering sensing and computing devices. The energy harvester can operate under the strong static magnetic field of the electrolytic cell, thereby realizing the extended upgrade of the instrument's applicable range and providing a method for accurately monitoring and predicting the behavior of the electrolytic cell. Summary of the Invention

[0009] This application provides a device that includes at least one sensor for monitoring the physical quantities of the production electrolytic cell or its surrounding environment. The device includes an energy harvesting mechanism for powering the electronic devices of the device. The shown energy harvester can adopt an electromagnetic collector. The device may include two transceiver units. One transceiver can use the reactive magnetic field on the current-carrying infrastructure of the electrolytic cell production line for device-to-device communication, and the other is a short-range radio transceiver. Therefore, the device supports edge computing applications or edge artificial intelligence applications using machine learning models. These models can aggregate multiple readings of devices installed at different positions in the electrolytic cell and calculate the electrolytic cell parameters to assist in the optimization of the alumina reduction process. For example, anode current imbalance and surface current distribution of the electrolyte. By setting two transceivers, wireless communication can be carried out with the cellular radio network or the electrolytic cell controller according to the radio link.

[0010] The rectifier system of the power plant provides a feed current that can provide a constant current or a direct current with a residual and almost negligible alternating current component that has a wide energy spectrum originating from the rectifier circuit. The energy harvester can collect a part of the alternating current flowing through the battery anode bar or busbar to feed into the recovery circuit that powers the device including at least one sensor. The recovery circuit may include a transformer that captures magnetic energy using a toroidal coil arranged around the anode rod. The device stores the energy collected from the energy harvester coil in a supercapacitor to power the electronic devices of the device, thereby providing sufficient energy for the maintenance-free and long-term operation of the sensor.

[0011] The device for measuring at least one characteristic in an electrolytic cell can be installed in the anode rod. The device can provide continuous monitoring of at least one characteristic, such as anode current. In addition, the device can also be installed in the busbar element of the electrolytic cell, and the busbar element distributes current to multiple anodes. The sensor can be independent, self-powered, without external wiring, electrically isolated from the rest of the system, and can communicate wirelessly with other sensor node devices and external computing units.

[0012] Continuous sensor readings provide valuable information for optimizing the operation of the electrolytic cell under different process dynamic conditions, enabling early detection of electrolytic cell anomalies, such as unstable alumina feeding, abnormal foaming at the bottom of the anode and gas emission problems, anode consumption rate, current asymmetry, uneven anode wear, anode overheating, anode cracking and fracture. It helps to understand the magnetohydrodynamic process of the electrolytic cell, the anode positioning during anode replacement operations, and the optimization of the current efficiency of the electrolytic cell. Importantly, compared with simply measuring the electrolytic cell voltage, the anode effect of the electrolytic cell can be predicted earlier.

[0013] Since the device contains at most two transceiver units and a energy harvester, there is no need to set up wires to transmit data or power the device.

[0014] According to an embodiment of the present application, the device can install a voltage sensor on two adjacent ohmic contact points on the surface of the anode rod or busbar to determine the current flowing through each anode rod or busbar of the electrolytic cell. The part of the anode rod between the two ohmic contact points acts as a shunt resistor to measure the current. Separately monitoring the current flowing through each anode can provide important information about the state of the electrolytic cell. If the current flowing through all anode rods is equal or similar, it indicates that the electrolytic cell is operating stably and efficiently. If there is an imbalance in the current between one or more anode rods, further monitoring and certain corrective measures are required.

[0015] According to an embodiment of the present application, the device can include a sensor, such as a HE or TMR sensor, for measuring the static magnetic field generated when current flows through the anode rod or busbar in the electrolytic cell. As described above, it is particularly important to continuously monitor the characteristics of the electrolytic cell. Brief Description of the Drawings

[0016] The present application will be described in detail below with reference to the drawings: Figure 1 It is a schematic diagram of a device for measuring the characteristics of a busbar or anode rod in an electrolytic cell according to an embodiment of the present application.

[0017] Figure 2A and 2B Shown are cross-sectional schematic diagrams of two different projections of a device for measuring the characteristics of a busbar or anode rod in an electrolytic cell according to an embodiment of the present application.

[0018] Figure 3 A flowchart of different connections between different units in a device for measuring the characteristics of an electrolytic cell bus or anode rod.

[0019] Figure 4 A deployment diagram of sensor nodes on an aluminum production cell bus, through which synchronous distributed measurement of at least one characteristic of the electrolytic cell can be achieved. Detailed implementation mode

[0020] Figure 1 The present application provides an embodiment of a device 100, which is connected to the bus or anode rod 101 of an electrolytic cell and is used to measure one or more characteristics of the bus or anode rod, so as to determine one or more characteristics of the electrolytic cell. The device 100 can be used in electrolytic cells such as aluminum production cells, and can also be used in other electrolytic cells, such as liquid metal battery cells for large-scale power grid energy storage or production.

[0021] In one embodiment, the device may include three units: the first unit includes a sensor 102 for determining one or more characteristics of the electrolytic cell, the second unit includes an energy harvester 103 for extracting a part of the electrical energy flowing through the bus or anode rod 101 to supply power to the device 100, and the third unit includes a wireless communication device 104 for enabling wireless communication between the device and an external computing unit to transmit the data measured by the sensor 102.

[0022] An aluminum smelter generally includes multiple electrolytic cells (also called smelting pots), which are connected in series on an electrolytic cell production line and are driven by a constant current power supply device called a rectifier. The rectifier is a transformer with a three-phase primary winding and multiple secondary windings, which is combined with a solid-state rectifier to provide direct current for the electrolytic cell. Usually, before the current fed into the power grid reaches each primary winding of the rectifier, another device, namely a regulating transformer, is also required. The secondary winding of the regulating transformer may include a on-load tap changer for adjusting the range of its output voltage and feeding it to the rectifier.

[0023] The function of the regulating transformer is to provide sufficient margin for dynamically compensating the voltage changes of the feeding power grid and the load changes of the electrolytic cell production line, so as to maintain the constant current required by the electrolytic cell production line.

[0024] The system includes an integrated passive harmonic filter connected to the feeding power grid. The function of the passive filter is to absorb the high-frequency harmonic energy generated by the non-linear load current introduced by the solid-state polyphase rectifier in the circuit. In this way, the filter prevents the energy of these harmonics from flowing into the feeding power grid.

[0025] Aluminum smelting is a continuous industrial process that consumes hundreds of megawatts of electricity; traditional electrolytic cell power supply schemes consist of multiple rectifiers connected in parallel. This configuration aims to reduce harmonic currents at the coupling point, shorten the instantaneous current duration of each solid-state rectifier, facilitate harmonic elimination, increase power capacity, cope with operating limitations, and meet cost / space requirements. The higher the pulse order of a polyphase system, the higher the fundamental frequency of the pulsed continuous current.

[0026] The spatial distribution of components in the electrolytic cell production line circuit poses limitations on the design solution. Although the resistance of the busbar can be reduced by increasing the area through which the current passes, reducing the inductive component of the circuit is more challenging. Therefore, the electrolytic cell production line is mainly an inductive load for the power supply, represented as a resistor-inductor (RL) circuit.

[0027] Therefore, the current flowing through the electrolytic cell production line is mainly direct current, accompanied by relatively weak high-frequency harmonics. In addition to the hundreds of megawatts of direct current driving the reaction, there is at least several hundred watts of reactive power circulating in the electrolytic cell, which is caused by the amplitude variation (ripple) of the rectifier output voltage. Since the reactive magnetic field is related to the inductive reactance component of the circuit, its spatial distribution is relatively uniform.

[0028] Figure 1 Apparatus 100 including energy harvester 103 is shown. The energy harvester is designed to utilize a small portion of the reactive power flowing through the electrolytic cell. Such an energy harvester disclosed in the present application employs a toroidal transformer constructed around a busbar or anode rod to utilize this reactive energy. The apparatus operates in a strong static magnetic field and is effectively coupled to the weak reactive component in the magnetic field.

[0029] In one embodiment, the transformer design may include or not include a ferromagnetic material core. Therefore, the static magnetic field does not affect the function of the transformer. In this embodiment, not providing a ferromagnetic core simplifies the transformer design, reduces costs, and enables the energy harvester to be at least in the milliwatt range. The non-ferromagnetic core can be composed of air.

[0030] In another embodiment, the energy harvesting unit of the device provided by the present application includes a conductor coil having a number of turns, forming a hollow core, wherein the hollow core is filled with air or a metal compound. The conductor coil is a primary conductor coil, and the device further includes a secondary conductor coil, wherein both the primary conductor coil and the secondary conductor coil are used as transformers. The collection unit of the device includes the primary conductor coil of the transformer, and the transformer has an annular or linear geometry. The transformer resonates with one or, optionally, multiple harmonic components of the reactive magnetic field. A resonant LC circuit in the secondary winding of the transformer generates a large induced voltage. The device reflects the load as a more significant series resistance into the primary winding formed by the anode rod or the bus bar, and the anode rod or the bus bar passes through the annular coil or the linear coil, or is magnetically coupled with the annular coil or the linear coil.

[0031] In one embodiment, the transformer may use a specially designed ferromagnetic core to enhance the magnetic coupling with the reactive magnetic field present in the line and enhance the power capacity of the energy harvester. If the magnetic domains are forced to align with the static magnetic field, their magnetization no longer amplifies the strength of the time-varying reactive magnetic field when it stops changing. Magnetic core magnetic domain saturation is not desirable, and the static component of the magnetic field should be avoided. If the magnetic domains saturate, the effective magnetic permeability of the magnetic core will be affected and even disappear. Magnetically anisotropic materials or specially designed magnetic domain structures can overcome the limitations caused by the static magnetic field.

[0032] Engineered ferromagnetic cores designed for such applications can include a variety of magnetic materials. Materials with high coercivity and remanent magnetic fields, i.e., rare earth magnet alloys such as neodymium (NdFeB), can be used. Materials that significantly enhance the magnetic permeability of the magnetic core can also be used, i.e., nickel-iron cores, which have a high saturation magnetic flux density and a low loss rate. The combination of the two can achieve permanent magnetization while still exhibiting high magnetic permeability under a strong external static magnetic field. The permanent magnetization of NdFeB is opposite to the external static magnetic field, which can enhance the time-varying reactive magnetic field. Therefore, the obtained magnetic core can minimize the magnetic resistance of the reactive magnetic field, thereby maximizing the time-varying magnetic flux and enhancing the ability of the current transformer to utilize the non-functional energy field.

[0033] In one embodiment, the transformer includes an auxiliary coil for further reducing the static magnetic field component and making the operating point of the magnetic core closer to the origin of its hysteresis loop. The auxiliary coil can obtain excess energy from the energy harvester itself. Although the auxiliary coil dissipates energy in the form of heat under the Joule effect, at the same time, it maximizes the magnetic permeability of the magnetic core, promotes the magnetic coupling with the reactive magnetic field, and increases the net energy collected.

[0034] In a specific embodiment, the present application proposes to superimpose a high-frequency oscillation on the direct current flowing through the busbars in the electrolytic cell system to enhance the energy harvesting capability. This technology involves a sensor node with dual functions: firstly, as a power receiver, it directly obtains energy from the electrolytic cell voltage; secondly, as an additional sensing unit, it monitors the same electrolytic cell voltage. In addition, this node also acts as an energy distributor to power other nodes in the system.

[0035] To achieve this energy redistribution, the present application introduces a high-frequency oscillator, which is designed to be magnetically coupled to the busbars. When coupled to the magnetic field of the busbars, the oscillator releases energy, thereby introducing an alternating magnetic field component. This dynamic change in the magnetic field promotes more efficient energy harvesting by other sensor nodes. Such a configuration utilizes multiple energies in an active redundancy manner, thereby enhancing the stability and efficiency of the energy harvesting process of the entire system. At the same time, smooth functional degradation can be achieved even in the absence of all energy harvesting sources.

[0036] In one embodiment, the energy harvesting transformer and the static magnetic field sensor device for indirectly measuring the direct current flowing through the anode rod can be independent of each other but adjacent, thus simplifying the requirements for the magnetic core.

[0037] In one embodiment, the energy harvesting device further includes a capacitor for storing electrical energy from the secondary conductor coil. Such a capacitor is typically a supercapacitor and is used to supply electrical energy to at least one sensor. The secondary transformer powers a rectifier circuit, a boost circuit, a supercapacitor, and an electronic controller. The function of the controller is to maximize energy harvesting. For example, the resonant frequency of the transformer is adjusted to generate the harmonic component that produces the most energy.

[0038] In Figure 1 the illustrated embodiment, one or more sensors for measuring the characteristics of the electrolytic cell are located in Figure 1 unit 102. To obtain accurate direct current measurements from the anode beam, various devices can be used as alternatives. The devices disclosed in the present application can perform non-contact measurements using the static magnetic field generated by the direct current component of the current carried by the anode or the busbars. The sensing device can be a Hall effect (HE) or tunneling magnetoresistance (TMR) magnetic field sensor. This device provides sufficient bandwidth to measure current variations on the time scale related to the process variability of the electrolytic cell. An anode current sampling rate of 300 times per second or higher can capture the formation of anode bubbles, magnetohydrodynamics, and the effects of non-uniformity of the chemical composition of the electrolytic cell during the process. The information contained in these current signals is very valuable for improving the accuracy of producing a digital twin of the electrolytic cell.

[0039] Multiple HE or TMR sensing elements installed equidistant from a current-carrying conductor can improve accuracy. In the absence of ferromagnetic materials, the readings of each sensor can accurately estimate the current through multiple static field measurements. Only the current flowing through the intended conductor will produce the same magnetic field intensity on all sensor devices. Conversely, any other current distribution from nearby conductors will create a magnetic field gradient between the sensing devices. The number of sensing devices is optimized according to the foreseeable current distribution at the installation site. More than four of these devices can be symmetrically arranged to achieve sufficiently accurate anode current measurement.

[0040] In one embodiment, an annular air-gap ferromagnetic core confines the static magnetic field. By introducing magnetic resistance in the air-gap path, the air-gap can increase the saturation threshold of the core. The air-gap is small enough to keep the magnetic flux density (B) approximately constant between the opening and the core. HE or TMR magnetic field sensors are installed in the air-gap to detect B. Confining the magnetic field as described reduces the magnetic resistance and confines the contribution of the magnetic field in the core path to the current flowing through the inner loop of the annular core. This confinement does not amplify the magnetic field contributions from nearby currents, busbars, other anodes, etc., thereby improving the measurement accuracy.

[0041] In one embodiment, the device includes a series of sensors for measuring physical properties of the electrolytic cell or its surrounding environment. The at least one sensor may include a thermometer, a thermocouple, a thermal infrared temperature sensor, or a thermal imaging sensor for obtaining the temperature of the anode rod, the anode yoke, or a thermal image of the upper surface of the electrolytic cell. The temperature readings of these components can enhance the real-time thermal modeling of the electrolytic cell and the accuracy of the digital twin model of the electrolytic cell. Other sensors may include MEMS gas chemical composition measurement devices for analyzing the gases released by the electrolytic cell. The gas sensor may include a photoionization detector or a non-dispersive infrared sensor. Determining the concentration of volatile gases in the electrolytic cell can provide information about the redox reaction by-products for the digital twin, helping to quantify fugitive emissions harmful to human health and the environment, such as hydrogen fluoride and sulfur dioxide. It helps in the early detection or confirmation of anode effects in the electrolytic cell. Anode effects produce potent greenhouse gases (such as tetrafluoromethane and hexafluoroethane) and increase the formation of carbon monoxide.

[0042] In Figure 2A and 2BIn the illustrated embodiment, the device 200 includes a fixing mechanism 203 and 204, which are fixed around the anode rod or busbar 201 of the electrolytic cell by, for example, a pressurized mesh winding or a clamping mechanism. The fixing mechanism 203 and 204 may include a set of clamps for precisely positioning and fixing the device at an ideal height or position on the anode or busbar. The set of clamps may be of an open structure, thereby dividing the device into multiple components 202 and 205 and being detachable or replaceable; or it may be in a closed state to firmly fix the device around the anode or busbar 201. Figure 2B A cross-section of the device 200 and the anode rod or busbar 201 is shown, as Figure 2A indicated by the dashed line IIB in

[0043] The mechanisms of other fixing devices may include a mesh structure that winds around the anode or busbar, and the mesh structure applies a compressive force to fix the device in the desired position. This wound mesh structure has a relaxed structure where the fixing device does not apply a compressive force, facilitating the replacement of the device. The wound mesh structure may also have a fastening structure to fix the device in an ideal position around the anode or busbar. Those skilled in the art should understand that various modifications can be made to the clamping or fixing device to adapt to different configurations for fixing the device on the anode or busbar. These modifications include adjustable clamps, magnetic attachments, or other mechanical fixing methods known in the art. The above examples are not exhaustive and only illustrate how to develop modifications. All practical modifications that can effectively position the device in the described manner fall within the scope of protection of this disclosure.

[0044] The sensing device installed around the anode beam can directly measure the anode current. This arrangement facilitates the installation of other sensors to determine other quantities. Other relevant sensors include temperature, the concentration of various gases in the air, thermal imaging of the cell surface, and visual monitoring through an image sensor, etc.

[0045] In one embodiment, the toroidal coil constituting the energy harvester can also be made into an integral component in the shape of a bellows, and by fixing it around the anode and mechanically fixing both ends together using a latch, without any external electrical connection.

[0046] In one embodiment, at least one sensor and a wireless transceiver unit are electrically connected to the energy harvester. It is connected to an external computing unit through the wireless communication function of the device, and the computing unit is connected to a second wireless transmitter for communicating with the wireless transmitter of the device. The sensor unit installed in the electrolytic cell can measure the independent anode current. In this way, a multi-anode current model can be established and analyzed to obtain relevant indicators indicating the state of the electrolytic cell, such as anode current distribution, magnetohydrodynamics, and gas layer evolution.

[0047] In another embodiment, the reactive electric field in the busbar serves as a communication medium, providing an additional inter-node communication link, enabling dual communication channel telemetry, and making the system more robust. In addition to efficient data collection and processing, active communication redundancy also provides resilience and service degradation information. This feature also helps with diagnostics in the event of a final component failure.

[0048] By utilizing the reactive electric field in the busbar as a communication medium, a dedicated inductive link with short distance, low power consumption, and high data rate can be established between nodes. At the same energy cost, the reactive electric field in the busbar can provide higher bandwidth than radio, thus improving the energy efficiency of the sensor design. The data transfer rate of the inductive link depends on the available channel bandwidth, which is determined by factors such as the stray inductance and capacitance of the current-carrying structure, and the distance between nodes.

[0049] Depending on the physical design of the electrolyzer, the inter-node communication link can be realized by directly coupling the nodes through the busbar via a dedicated RF transformer, broadband near-field data transfer, or a combination of both.

[0050] The high bandwidth of the inductive link enables precise time synchronization between low-latency inter-node information and node clocks. Then, time-synchronized multi-node current measurements or other property measurements can further improve the predictability of the electrolyzer model. For example, in multi-anode current measurements, sub-microsecond time synchronization accuracy helps to map the instantaneous surface current density of the electrolyte, enabling anode-docking bubble formation and cell magnetohydrodynamics modeling that have not been achievable to date.

[0051] In one embodiment, the data link physical layer can rely on FSK / PSK / OFDM digital modulation techniques, which require one carrier or multiple subcarriers. Depending on the resulting channel, a carrierless data telemetry scheme (such as single-pulse harmonic modulation (SPHM)) helps to save power consumption. The latter utilizes the self-resonant pulse response and the relatively high-Q inductive link (with a resonant frequency up to several tens of megahertz) generated by the current-carrying structure of the electrolyzer. SPHM does not require a local oscillator or mixer in the transceiver, thus simplifying the circuit design and reducing the implementation complexity of providing a direct baseband inductive link.

[0052] In one embodiment, adaptive power transfer further reduces interference and improves the energy efficiency of inter-node inductive link communication. The selection of inductive link parameters should be highly scalable to improve the signal-to-noise ratio of the inter-node communication capacity within the electrolyzer while avoiding inter-electrolyzer node interference.

[0053] Figure 3It is a block diagram of two embodiments of the device, where units U1301, U2302, and U3303 are coupled to the current bar. All arrow lines represent signal and power flow. Unit U1301 includes at least one sensing element for measuring the current amplitude and works in cooperation with a measuring device 304 (which may include other sensors and signal conditioning electronics).

[0054] In one embodiment, the magnetic field operating point of a pulse transformer is set by a magnetic core control device 305, and the pulse transformer is part of device U2302. In another embodiment, since the magnetic core of the pulse transformer is air, there is no need to set up a magnetic core control device 305. The device U2302 is an energy harvester, including an energy scavenger 306. The energy harvester 306 can charge a supercapacitor 307 to store the collected energy. A power regulator 308 powers all active electronic circuits.

[0055] The communication unit U3303 is a transceiver unit based on an inductive link, includes a modem 309, and works in cooperation with a radio unit 310. The modem 309 enables direct communication between multiple similar devices installed on the same electrolytic cell. The modem 309 and the radio unit 310 interact through a CPU, and the radio unit includes an antenna 312, which can wirelessly transmit measurement information to an external processing unit.

[0056] In another embodiment, units U1 - U2 - U3 can be built into a single magnetic coupling circuit, similar to a multi - winding transformer installed on a current bar.

[0057] Signals from at least one sensor are processed by the CPU and transmitted to other devices for further data aggregation and processing. For example, to determine electrolytic cell metrics such as anode current imbalance. In this case, the modem of the inductive link transceiver can be used to send the signals to other similar devices.

[0058] The current sensor in U1301 samples the current of the anode bar at a fast enough speed (e.g., 300 times per second) to detect instantaneous current fluctuations in the anode bar, including minute changes that may be caused by the formation of bubbles at the bottom of the anode bar.

[0059] At least one sensor signal and the data processed by multiple devices can be transmitted to the controlled electrolytic cell through a wireless module. Or transmitted to another sensor node to process multiple signals measured at different locations from different or the same characteristics.

[0060] The inductive link transceiver and the wireless module can provide active redundancy and comprehensive communication functions for sensor nodes installed on the current bus.

[0061] In another embodiment, the disclosed system can be divided into three separate units that are electrically connected to form a complete node and measure the current flowing through a portion of the electrolytic cell, including the step of performing intra-node signal processing on the same current time series. This embodiment can be used to measure the physical characteristics of anodes in aluminum smelters by connecting them to any point along the length of the anode or busbar.

[0062] In one embodiment, Figure 4 As shown, the deployment of sensor nodes in an aluminum production electrolytic cell represents a complex monitoring network that is cleverly designed to provide a comprehensive view of the electrolytic cell and its surroundings.

[0063] These nodes are strategically connected to various parts of the electrolyzer busbar, and each node sequentially measures specific properties from different locations. The uniqueness of the system lies in its distributed signal processing capabilities. Each node is equipped with an ultra-low power microcontroller that collects data and performs preliminary processing using advanced machine learning algorithms.

[0064] Figure 4 The electrolyzer system is shown in detail, with particular emphasis on the configuration of multiple sensors installed at various key locations of the electrolyzer busbar. Each sensor, S1 (405), S2 (406), S3 (407), etc., is positioned to optimally monitor different operating parameters of the electrolysis process. For example, S1 and S2 can indirectly but accurately determine the current flowing through the anode rod (401) and anode support (409) located between them and flowing to the electrolyte.

[0065] This distributed approach enables efficient data processing even under low power constraints. In addition, the nodes can operate under complex communication protocols, ensuring accurate time synchronization across the network. This synchronization can establish a unified logical clock between all nodes, thereby improving the accuracy and reliability of data aggregation.

[0066] The key to this system is the advanced computing and communication platform provided by the application, which is designed specifically for electrolyzer monitoring. Synchronous multi-sensor signals can be used with high precision and high sampling rate to achieve accurate characterization of the electrolyzer environment. The machine learning model of the application can output composite characteristics from multiple signal sources, reflecting the synergy of distributed intelligence and high-fidelity data communication.

Claims

1. A device for determining at least one physical property associated with an electrolytic cell, characterized in that, Comprising: An energy harvesting device, the energy harvesting device comprising: A fixing mechanism, the fixing mechanism comprising: a conductor coil wound around a partial area of the upper part of the fixing mechanism for several turns, wherein the fixing mechanism is used for fixing around the anode rod or bus bar of the electrolytic cell; A sensor for measuring at least one physical property of the electrolytic cell; A microcontroller for calculating sensor values; A transceiver unit for transmitting information according to the at least one measured physical property.

2. The device according to claim 1, characterized in that, The electrolytic cell is a metal production cell, such as an aluminum production cell.

3. The device according to any one of the preceding claims, characterized in that, The electrolytic cell is an energy production cell and / or an energy storage cell, such as a liquid metal battery.

4. The device according to any one of the preceding claims, characterized in that, The fixing mechanism is fixed around the anode rod or bus bar of the electrolytic cell by means of a pressure net winding, a clamping mechanism or other methods.

5. The device according to any one of the preceding claims, characterized in that The at least one sensor, processor and wireless transceiver unit are electrically connected to the energy harvesting device.

6. The device according to any one of the preceding claims, characterized in that The primary conductor coil has an annular or linear geometry.

7. The device according to any one of the preceding claims, characterized in that, The conductor coil with several turns is defined as a hollow core, wherein the hollow core is filled with air or a metal compound.

8. The device according to any one of the preceding claims, characterized in that, The conductor coil is a primary conductor coil, and the device further comprises a secondary conductor coil, wherein both the primary conductor coil and the secondary conductor coil are used as transformers and can obtain energy from the change of magnetic flux density in the presence of a static magnetic field.

9. The device according to claim 8, characterized in that, The device comprises a capacitor, preferably a supercapacitor, for storing electrical energy from the secondary conductor coil.

10. The device according to claim 9, wherein the capacitor is configured to supply electrical energy to at least one sensor.

11. An electrolytic cell analysis method, characterized in that, The method comprises the following steps: Using at least one sensor to measure the physical properties of the electrolytic cell at a high sampling rate; Synchronously measuring the physical properties at multiple positions of the electrolytic cell; Processing the measurement results using signal processing techniques to obtain calculated properties, wherein the calculated properties are determined by performing mathematical operations on the measured physical properties, so as to be able to determine properties that cannot be directly measured.

12. The method according to claim 11, wherein The measurement results are transmitted to a microcontroller or a processor unit.

13. The method according to claim 12, wherein Processors on different nodes share a unique logical clock.

14. The method according to claim 13, wherein The processed data is transmitted to an additional node processor unit or an external processor (such as a cloud-based processor) for further aggregation and calculation.

15. The method according to claim 11, wherein The physical properties are measured by multiple sensors located at different positions of the electrolytic cell.

16. The device according to any one of the preceding claims, characterized in that, The at least one sensor is an ammeter for measuring the current flowing through the anode rod or bus bar in the electrolytic cell.

17. The device according to any one of the preceding claims, characterized in that, The at least one sensor is a magnetometer for measuring the magnetic field generated by the current flowing through the anode rod or bus bar in the electrolytic cell, such as a Hall effect device, a fluxgate or a magnetoresistive device.

18. The device according to any one of the preceding claims, characterized in that The at least one sensor is a thermometer of any unit including the electrolytic cell, such as a solid-state temperature sensor or a thermocouple.

19. The device according to any one of the preceding claims, characterized in that, The at least one sensor is a gas chemical composition measuring device for measuring the gas volatilized in the electrolytic cell, such as a photoionization detector or a non-dispersive infrared sensor.

20. A system, the system comprising the device according to any one of the preceding claims and a computing unit for receiving data from at least one sensor through a wireless transceiver unit.

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