Continuous anode, manufacturing method and aluminum electrolysis cell

Abstract

The invention belongs to the technical field of aluminum electrolysis, and discloses a continuous anode, a manufacturing method and an aluminum electrolysis cell. The continuous anode comprises a metal frame body, a carbonization body, a carbon material and a plurality of conductors, the metal frame body is provided with a containing cavity, the carbonization body is arranged in the containing cavity of the metal frame body in a matched state, and the carbonization body is provided with an extending part exceeding the boundary of the containing cavity of the metal frame body; the carbon material is filled in the accommodating cavity of the metal frame body and covers the exposed surface of the carbonized body in the accommodating cavity; the conductors are inserted into the carbonized body and the carbon material, at least one conductor is provided with at least one expansion hole, and the conductors are connected with the metal frame body. According to the structure of the continuous anode expansion cavity, the warped head and the connecting bus, the key technical defects of anode material falling, corner damage, electrolytic bath resistance oscillation and the like in the prior art can be effectively overcome.

Description

Technical Field

[0001] The present application belongs to the technical field of aluminum electrolysis, and specifically relates to a continuous anode and a manufacturing method thereof, and an aluminum electrolysis cell. Background Art

[0002] In the aluminum electrolysis industry, the aluminum reduction cell is a core piece of equipment. Its performance and operational stability directly determine the efficiency of the electrolysis process, energy consumption, and the quality of the final aluminum product. As a key functional component of the aluminum reduction cell, the anode plays a core role in conducting current and participating in electrochemical reactions. Its performance has a decisive impact on the overall operation of the cell, making it the "heart" of the aluminum reduction cell.

[0003] Traditional aluminum electrolytic cell anode technology is mainly divided into two systems: pre-baked anodes and self-baked anodes. Pre-baked anodes use a prefabricated baking process outside the electrolytic cell, which has the advantages of low resistivity and high mechanical strength, but they need to be replaced regularly, resulting in high production costs and complex maintenance; self-baked anodes achieve continuous production through in-situ baking in the electrolytic cell. Although it can effectively reduce replacement costs, it has problems such as large fluctuations in baking quality and high energy consumption. In order to comprehensively balance the advantages and disadvantages of the two types of anode technologies, the industry has developed continuous anode technology. This technology integrates aluminum frames, conductors and carbon materials to form an integrated anode structure, and uses anode guide rods and anode busbars to achieve current conduction. During the electrolysis process, the anode busbar current is conducted to the conductor through the anode guide rods and aluminum frame. The conductor generates high temperature due to the resistive thermal effect, driving the carbon material to complete the heating, melting, solidification and baking process, and finally forming an anode with excellent conductive properties and high mechanical strength.

[0004] However, large-scale application of continuous anode technology has exposed significant technical bottlenecks. The conductor, carbon material, and carbon anode are made of inconsistent materials and exhibit significant differences in physical and chemical properties, particularly in thermal expansion and contraction, mechanical strength, and electrical conductivity. For example, under the high-temperature, high-current operating conditions of the electrolytic cell, the conductor experiences a sharp temperature increase or even melting due to continuous resistive heating, leading to dramatic volume expansion and accumulation of thermal stresses. Simultaneously, the carbon material undergoes coking, decomposition, and polycondensation, generating internal stresses of varying nature. These three components interact with each other to generate significant forces, resulting in a severe mismatch between the conductor, carbon material, and carbonized body. This leads to irreversible deformation of the anode structure, destructive damage such as chipping and chipping of the carbon anode, and ultimately, overall anode failure. Furthermore, destructive deformation of the anode structure significantly affects the flatness and integrity of the anode base, inducing high-frequency oscillations in the cell resistance (i.e., cell resistance needle vibration). This prevents precise control of the cell's inter-electrode spacing, significantly reducing current efficiency and significantly increasing energy consumption. This can also lead to a chain reaction of failures, such as loss of cell thermal balance and frequent anode effects, seriously threatening the safe and stable operation of the electrolytic cell.

[0005] While existing technologies have mitigated the anode deformation problem to some extent by optimizing the connection structure between the anode guide rod and the aluminum frame and adjusting the carbon material formulation, none of these technologies have fundamentally resolved the core contradiction of the mismatch between the conductor, carbon material, and carbonized body. Therefore, developing a continuous anode structure with a highly matched mechanism between the conductor, carbon material, and carbonized body to achieve long-term stable operation of the anode in high-temperature, high-current environments has become a key technical challenge that needs to be overcome in the field of aluminum electrolysis technology. Summary of the Invention

[0006] In response to the problem of poor matching between conductors, carbon materials and carbonized bodies faced by the existing continuous anode technology in the aluminum electrolysis industry, this application aims to provide a continuous anode structure with an efficient stress release mechanism.

[0007] This application is specifically implemented through the following technical solutions:

[0008] In one aspect of the present application, there is provided a continuous anode comprising:

[0009] A metal frame having a receiving cavity;

[0010] a carbonized body, the carbonized body being arranged in an adapted state in the accommodating cavity of the metal frame, the carbonized body having an extending portion exceeding a boundary of the accommodating cavity of the metal frame;

[0011] A carbon material is filled in the receiving cavity of the metal frame and covers the surface of the carbonized body exposed in the receiving cavity;

[0012] A plurality of conductors are inserted in the carbonized body and the carbon material, at least one of the conductors is provided with at least one expansion space, and the conductors are connected to the metal frame.

[0013] In one embodiment, the total volume of the expansion cavity accounts for 5-21% of the volume of the conductor.

[0014] In one embodiment, the total volume of the expansion cavity accounts for 8.9-14.3% of the volume of the conductor.

[0015] In one embodiment, the expansion cavity is provided inside or on the surface of the conductor.

[0016] In one embodiment, the shape of the expansion cavity includes but is not limited to a circle, a cuboid, a cube, a cone, a truncated cone, a cylinder, a prism, a truncated cone, a pyramid or other irregular shapes.

[0017] In one embodiment, the expansion space includes one or more of a closed expansion space, an open expansion space, and a through expansion space.

[0018] In one embodiment, the open expansion space and the opening through the expansion space are blocked with baffles, and the baffles are connected to the conductor.

[0019] In one embodiment, the expansion space is filled with a heat shrinkable material.

[0020] In one embodiment, the heat shrinkable material is selected from one or more of explosion-proof fibers, shrinkage films, foam materials, pearl cotton, plant fibers, cotton, and expanded polystyrene particles.

[0021] In one embodiment, a portion of the metal frame that accounts for more than 76% of its volume has the property of being melted or dissolved by the liquid electrolyte, or being oxidized and eroded by the high-temperature anode gas.

[0022] In one embodiment, the material of the metal frame is selected from one or more of metal, metal alloy, graphite, and graphene.

[0023] In one embodiment, a lug is connected to the inner wall surface of the metal frame, and the conductor is connected to the lug.

[0024] In one embodiment, the header is configured with at least one plug-in portion, and the conductor is connected to the header by being inserted into the plug-in portion.

[0025] In one embodiment, the metal frame has a power input surface and a power output surface, and the power input surface and the power output surface are arranged in a relative spatial position relationship.

[0026] In one embodiment, conductors are respectively connected to the power input surface and the power output surface of the metal frame.

[0027] In one embodiment, the portion of the conductor that accounts for more than 80% of its volume has the property of being melted or dissolved by the liquid electrolyte, or being oxidized and eroded by the high-temperature anode gas.

[0028] In one embodiment, the material of the conductor is selected from one or more of metal, metal alloy, graphite, graphene, and cryolite.

[0029] In one embodiment, a plurality of connecting busbars are arranged in the metal frame, one end of the connecting busbar is connected to the power input surface of the metal frame, and the other end is connected to the power output surface of the metal frame; or a connecting busbar is connected between the conductors of the power input surface and the power output surface.

[0030] In one embodiment, the connecting busbar includes a first rigid busbar, a second rigid busbar and a soft belt, and a tightening mechanism is arranged between the first rigid busbar and the second rigid busbar, and the tightening mechanism applies a pre-tightening force to the first rigid busbar and the second rigid busbar in the axial direction, so that: the first rigid busbar forms a continuous contact connection with the power input surface of the metal frame; the second rigid busbar forms a continuous contact connection with the power output end surface of the metal frame; and the two ends of the soft belt are respectively connected to the first rigid busbar and the second rigid busbar.

[0031] In one embodiment, the flexible belt has a preset deformation margin to accommodate the relative displacement between the metal frame and the first and second rigid busbars.

[0032] In one embodiment, the material of the carbonized body is selected from one or more of anode paste, prebaked blocks, bonding paste, graphite, biomass, and carbon-containing binders.

[0033] In one embodiment, the carbon material is selected from one or more of anode paste, prebaked blocks, bonding paste, graphite, biomass, and carbon-containing binders.

[0034] In one embodiment, the carbonized body is generated by a resistance heat roasting reaction of the carbon material generated by the conductor when the conductor is in an energized state.

[0035] In another aspect of the present application, a method for manufacturing the continuous anode is provided, comprising:

[0036] The power input panel and the power output panel of the metal frame are obtained by mold casting;

[0037] The metal frame is formed by connecting the power input panel and the power output panel of the metal frame with side panels;

[0038] Connecting conductors with expansion holes to the power input panel and the power output panel respectively;

[0039] Filling carbon material in the metal frame and between the conductors;

[0040] When the conductor is electrified, the carbon material is converted into a carbonized body under the action of the resistance heat of the conductor, and is integrated with the metal frame and the conductor to form a continuous anode.

[0041] In one embodiment, a metal frame power input panel and power output panel with warped heads are cast using a mold; and the conductors are connected to the warped heads of the power input panel and the power output panel, respectively.

[0042] In one embodiment, the header is configured with a socket and / or a slot, and the conductor is plugged into the socket or slot of the header.

[0043] In one embodiment, a connecting busbar is connected between the conductors of the power input panel and the power output panel, and the connecting busbar, the carbon material, and the carbonized body are located in different regions.

[0044] In one embodiment, a connecting busbar is connected between the power input panel and the power output panel, wherein one end of the connecting busbar is connected to the power input panel, and the other end is connected to the power output panel.

[0045] In another aspect of the present application, an aluminum electrolysis cell is provided, comprising: an electrolysis cell body; a cathode arranged at the bottom of the electrolysis cell body; and a continuous anode installed on the electrolysis cell body, wherein the continuous anode and the cathode form an electrical connection path through an electrolyte and / or aluminum liquid.

[0046] In one embodiment, the continuous anode includes a metal frame, a carbonized body, a carbon material, and several conductors; the metal frame has a accommodating cavity; the carbonized body is arranged in the accommodating cavity of the metal frame in an adapted state, and the carbonized body has an extended portion that exceeds the boundary of the accommodating cavity of the metal frame; the carbon material is filled in the accommodating cavity of the metal frame and covers the surface of the carbonized body exposed in the accommodating cavity; the conductor is inserted into the carbonized body and the carbon material, at least one of the conductors is provided with at least one expansion space, and the conductor is connected to the metal frame.

[0047] The beneficial effects of this application are:

[0048] 1. By reasonably setting the expansion void area in the conductor structure, during the current conduction process, the existence of the expansion void will not hinder the performance of the conductor in transmitting current to the interior of the carbon anode, and the current can be conducted stably and efficiently. The strength of the conductor meets the requirements of the continuous anode process. When the temperature of the conductor rises or even melts due to changes in working conditions, thermal expansion and corresponding stress will occur inside the conductor. At this time, the expansion void area can effectively release or absorb the expansion deformation and stress caused by temperature changes and / or melting of the conductor, carbon material and carbonized body, effectively avoiding the diffusion and penetration of stress to the surrounding anode area, ensuring that the anode structure can still maintain an intact, efficient and stable operating state under complex working conditions, and achieving a high degree of matching between the conductor, carbon material and carbonized body. It effectively solves the technical problems such as block falling, corner falling and severe slot resistance needle vibration in traditional anode structures, and significantly improves the performance and reliability of the anode.

[0049] 2. The expansion cavity is filled with a heat-shrinkable material with specific properties, and baffles can be installed at the opening of the expansion cavity to seal it, forming an effective protective structure. This structure prevents surrounding liquids, colloids, or pastes from entering the expansion cavity, releasing stress and maximizing the expansion cavity's ability to absorb stress efficiently. The heat-shrinkable material has corresponding shrinkage properties with temperature changes. Before the carbon material solidifies, it maintains the stability of the expansion cavity's volume, preventing the infiltration of external materials that would cause the expansion cavity to decrease in volume. This ensures that the expansion cavity can always perform its intended function during the operation of the conductor, safeguarding the normal operation of the conductor.

[0050] 3. The truss and metal frame are molded and manufactured using an integrated casting process, maintaining their shape and providing excellent structural strength, flatness, and stability. The metal frame and anode guide rod achieve good contact, with a large contact area, allowing the current on the anode guide rod to be efficiently and stably conducted to the interior of the anode. This effectively reduces the contact voltage between the metal frame and the anode guide rod, keeping the average cell voltage low and preventing problems such as premature melting of the conductor ends due to overheating, as well as melting of the metal frame and anode guide rod.

[0051] 4. The connecting busbar accurately conducts a portion of the current from the metal frame's input side to the metal frame's output side. This effectively solves the problem of traditional continuous anode current being difficult to conduct to the output side, meeting the specific current requirements of the output side. The connecting busbar evenly distributes the current within the anode, avoiding performance issues caused by localized excessive or insufficient current, improving the overall efficiency and stability of the anode, and ensuring the normal operation of the entire current conduction system.

[0052] 5. When the metal frame is made of recycled scrap metal materials such as scrap aluminum, it is energy-saving, environmentally friendly, low-cost, and has a controllable impact on quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Figure 1 This is a schematic structural diagram of a continuous anode in an embodiment of the present application;

[0054] Figure 2 This is a schematic structural diagram of a closed expansion chamber in an embodiment of the present application;

[0055] Figure 3 This is a schematic diagram of the structure of the through expansion space in the embodiment of the present application;

[0056] Figure 4 This is a schematic diagram of the structure of the open expansion cavity in the embodiment of the present application;

[0057] Figure 5 This is a schematic diagram of the structure of the baffle expansion cavity in the embodiment of the present application;

[0058] Figure 6 This is a schematic diagram of the structure filled with heat shrinkable material in an embodiment of the present application;

[0059] Figure 7 This is a schematic diagram of the connection between the warp head and the conductor in an embodiment of the present application;

[0060] Figure 8 This is a schematic structural diagram of the warp head in an embodiment of the present application;

[0061] Figure 9 is a schematic structural diagram of a conductor in an embodiment of the present application;

[0062] Figure 10 This is a schematic diagram of the structure of the busbar connection in an embodiment of the present application;

[0063] In the picture:

[0064] 1-metal frame, 11-power inlet surface, 12-power outlet surface, 13-head, 14-plug-in part; 2-carbonized body; 3-carbon material; 4-conductor, 41-expansion space, 42-baffle, 43-first conductor, 44-second conductor, 45-heat shrinkage material; 5-anode guide rod; 6-connecting busbar, 61-first rigid busbar, 62-second rigid busbar, 63-tightening mechanism, 64-soft belt. DETAILED DESCRIPTION

[0065] The present application is further described in detail below with reference to the embodiments described in the accompanying drawings, wherein like numbers in all figures represent like features. Although specific embodiments of the present application are shown in the drawings, it should be understood that the present application can be implemented in various forms and should not be limited by the embodiments described herein. Instead, these embodiments are provided to enable a more thorough understanding of the present application and to fully convey the scope of the present application to those skilled in the art.

[0066] In one embodiment of the present application, referring to Figures 1 to 10 As shown, a continuous anode is provided, comprising a metal frame 1, a carbonized body 2, a carbon material 3, and several conductors 4, wherein the metal frame 1 has a receiving cavity, the carbonized body 2 is arranged in the receiving cavity of the metal frame 1 in an adapted state, and the carbonized body 2 has an extension portion exceeding the boundary of the receiving cavity of the metal frame 1; the carbon material 3 is filled in the receiving cavity of the metal frame 1 and covers the surface of the carbonized body 2 exposed in the receiving cavity; the conductor 4 is inserted between the carbonized body 2 and the carbon material 3, at least one of the conductors 4 is provided with at least one expansion space 41, and the conductor 4 is connected to the metal frame 1.

[0067] During the operation of the continuous anode, the current is conducted through the metal frame 1 and flows through the conductor 4 and the carbonized body 2 in sequence, and then is conducted downward in a uniformly distributed manner to the lower electrolyte system (liquid electrolyte), the metal aluminum melt (aluminum liquid) and the negative electrode conductive structure (cathode), until it is transmitted to the continuous anode structure of the adjacent electrolysis unit (the next aluminum electrolysis cell). In this conduction path, the conductor 4 will produce thermal expansion effects and internal stress accumulation under high temperature conditions or when a melting phase change occurs and the carbon material 3 undergoes a coking reaction. To cope with this phenomenon, the conductor 4 is built with an expansion space 41 of a stress release structure. This structure effectively releases the volume change and internal stress caused by thermal expansion or phase change of the conductor 4 by providing a deformable space volume, and effectively absorbs the internal stress caused by the coking reaction of the carbon material 3 and the expansion and contraction of the carbonized body 2, thereby achieving a high degree of matching between the conductor 4, the carbon material 3 and the carbonized body 2, thereby suppressing the deformation expansion or material penetration of the conductor 4 to the surrounding anode structure, and avoiding destructive stress concentration on the surrounding anode structure. Through this stress release mechanism, the anode structure is able to maintain physical integrity, efficient conductivity and stable operating state, effectively solving key technical defects in the existing technology such as anode material shedding (block falling), edge and corner damage (corner falling) and electrolytic cell resistance oscillation (cell resistance needle oscillation).

[0068] In this application, the metal frame 1 provides the necessary structural support for the continuous anode, ensuring that components such as the carbonized body 2 and the conductor 4 maintain a relatively stable position and shape during the electrolysis process, preventing deformation or damage to the components due to factors such as the addition of the carbon material 3 and thermal stress. It also provides a sealed space for the melting, flow, solidification, and carbonization of the carbon material 3, preventing the escape of harmful gases generated during the carbonization of the carbon material 3, promoting secondary thermal decomposition of harmful gases, turning waste into treasure, improving anode performance, preventing the outflow of liquid carbon material 3 from the anode, reducing anode consumption, protecting the anode from oxidation, and further reducing anode consumption.

[0069] The metal frame 1 is made of metal materials, which should have good electrical conductivity, mechanical strength and corrosion resistance, including but not limited to pure aluminum, aluminum alloy, copper alloy, these materials have good electrical conductivity, thermal conductivity and certain mechanical strength, and can meet the needs of current conduction and structural support. The metal frame 1 has a regular or irregular geometric shape, including but not limited to a rectangle, a circle, a polygon (such as a hexagon, an octagon, etc.), etc., and its shape design can be optimized according to the specific application scenario and installation requirements of the continuous anode. When the metal frame 1 is made of recycled scrap metal materials such as scrap aluminum, it is energy-saving, environmentally friendly, low-cost, and has a controllable impact on quality. The part of the metal frame that accounts for more than 76% of its volume has the characteristics of being melted or dissolved by the liquid electrolyte, or being oxidized and eroded by the high-temperature anode gas.

[0070] In some embodiments, the metal frame 1 has a power input surface 11 and a power output surface 12, and the power input surface 11 and the power output surface 12 are arranged in a relative spatial position relationship. Specifically, the power input surface 11 and the power output surface 12 of the metal frame 1 are respectively located on two opposite side surfaces of the metal frame 1. Preferably, the two side surfaces are parallel to each other. The power input surface 11 serves as the input end of the current, receiving the current from the previous aluminum electrolysis cell, and the power output surface 12 serves as the other input end of the current, synchronously receiving the current from the previous aluminum electrolysis cell and / or the power input surface 11, together forming a current conduction path with dual inputs to the anode, and the current is transmitted to the metal frame 1 through the power input surface 11 and the power output surface 12. This dual input end design enables the current to be more evenly and stably distributed to the continuous anode.

[0071] In some embodiments, at least one anode guide rod 5 is provided on the outer surface of the metal frame 1. The anode guide rod 5 is electrically connected to the anode busbar of the electrolytic cell and is used to transmit the electrical energy provided by the previous aluminum electrolytic cell to the electrolytic cell to achieve an electrolytic reaction. The number of anode guide rods 5 is mainly determined by the size of the continuous anodes and can be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, etc. The current enters the carbonized body 2 from the power inlet surface 11 and the power outlet surface 12 through the anode guide rod 5, and after conduction inside the carbonized body 2, it flows out from the cathode and enters the power inlet end of the next aluminum electrolytic cell, thereby achieving series current conduction.

[0072] In some embodiments, the anode guide rod 5 can be made of a highly conductive, high-strength material, such as copper, aluminum, aluminum alloy, etc., to ensure low-impedance transmission of current, clamping and lifting the continuous anode assembly above the cathode. The shape of the anode guide rod 5 can be cylindrical, rod-shaped, or other shapes suitable for connection with the anode busbar and the metal frame 1, and its inner side and / or both sides are movably connected (such as being pressed) to the metal frame 1. At the same time, the anode guide rod 5 is connected to the anode busbar of the electrolytic cell, and the connection method can be welding, clamping, soft belt 64 connection, bolt connection, etc., to ensure the stability and reliability of the electrical connection. The anode guide rod 5 is connected to the anode hoist to control the lifting and lowering of the continuous anode and the cell voltage, as well as to lift the anode guide rod 5 separately to avoid being corroded by the liquid electrolyte.

[0073] In some embodiments, the connection position between the anode guide rod 5 and the metal frame 1 is specifically selected at or near the corresponding positions of the conductor 4 and the carbonized body 2 to ensure that the current can be directly and effectively transmitted to the conductor 4 and the carbonized body 2.

[0074] In certain embodiments, the material of the metal frame 1 is selected from one or more of metal, metal alloy, graphite, and graphene. Preferably, the metal frame 1 is made of aluminum, aluminum alloy, or recycled aluminum scrap. The low density of aluminum or aluminum alloy can reduce component weight, lower energy consumption and costs, improve operational convenience, and facilitate the production of high-purity primary aluminum. Its excellent electrical conductivity ensures efficient and stable current conduction, reducing energy loss. Its high mechanical strength ensures structural stability in complex environments, prevents the escape of harmful gases, and improves the physical and chemical properties of the anode.

[0075] In the present application, the carbonized body 2 is formed by high-temperature calcination of a carbon material 3. The carbon material 3 is selected from one or more of anode paste, pre-baked blocks, bonding paste, graphite, biomass, and carbon-containing binders. During this process, the carbon material 3 undergoes a series of physical and chemical changes, such as the generation of volatiles and thermal cracking, rearrangement of carbon structure, etc., thereby achieving conversion to a carbonized body 2. The anode paste is a paste-like material or solid granular material mixed with aggregate (such as petroleum coke, asphalt coke, etc.), a binder (such as coal tar) and a small amount of additives. The bonding paste is a paste-like material mixed with aggregate (such as petroleum coke, graphite, etc.), a binder (such as coal tar) and a small amount of additives. Graphite is an allotrope of carbon with a layered crystal structure. The carbon atoms in the layers are bound by covalent bonds, and the layers are bound by weaker van der Waals forces. Biomass refers to various organisms produced by photosynthesis using the atmosphere, water, land, etc., including plants, animals, and microorganisms. Carbonaceous binders are organic or inorganic compounds containing carbon, which serve to bind aggregate particles during the preparation of carbon materials. Common carbonaceous binders include coal tar, phenolic resin, etc.

[0076] In some embodiments, the carbon material 3 may also be a pre-baked block, which is obtained by high-temperature calcination of one or more of petroleum coke, graphite, biomass, and a carbon-containing binder.

[0077] In some embodiments, the carbonized body 2 may be replaced by a pre-baked block.

[0078] In some embodiments, the upper and lower ends of the metal frame 1 are open to form a through accommodating cavity, and the carbonized body 2 is arranged in the accommodating cavity of the metal frame 1 in an adapted state, and the bottom of the carbonized body 2 extends out of the bottom of the metal frame 1. Part or all of the extended carbonized body 2 serves as a current conduction path, and contacts with the electrolyte to form a conductive loop. The cross-sectional area of the accommodating cavity of the metal frame 1 (such as circular or square) matches the cross-sectional shape of the carbonized body 2, and the carbonized body 2 is constrained by the side wall of the accommodating cavity. The extension length of the extended part of the carbonized body 2 is determined according to the process parameters of the electrolytic cell (such as electrolyte height, electrolyte temperature, etc.), and is kept immersed in the electrolyte.

[0079] The carbon material 3 is filled in the accommodating cavity of the metal frame 1, and the filling position of the carbon material 3 is located in the exposed surface area (such as the top area) of the carbonized body 2. Preferably, a covering layer structure is formed on the surface of the carbonized body 2, so that the carbon material 3 and the carbonized body 2 are in continuous contact and fused into one.

[0080] In this application, conductor 4 is a substance or material with low resistivity that can efficiently conduct current. Such substances or materials contain a large number of free charge carriers (such as free electrons, ions, etc.). Under the action of an external electric field, these carriers can move in a directional manner, thereby forming an electric current. In this application, it is not limited to a specific material, form or application environment. As long as the substance or material can exhibit significant conductive properties under specific conditions, it is considered to be conductor 4 in this application.

[0081] In certain embodiments, conductor 4, comprising at least 80% of its volume, is capable of being melted or dissolved by the liquid electrolyte, or oxidized and eroded by the high-temperature anode gas. As carbonized body 2 is consumed, conductor 4 flows out of carbonized body 2 in liquid form and into the molten aluminum in the electrolytic cell, forming a slot at the bottom of carbonized body 2. Gas generated at the bottom of the anode can enter the slot and be discharged from the edge of metal frame 1, reducing anode overvoltage, lowering bubble resistance in the electrolyte, minimizing secondary aluminum reactions, and improving current efficiency.

[0082] In certain embodiments, the conductor 4 is made of at least one material selected from the group consisting of a metal material, a metal alloy material, a graphite material, a graphene material, or a cryolite material. When the conductor 4 is made of recycled scrap metal, such as scrap aluminum, it is energy-efficient, environmentally friendly, low-cost, and has a manageable impact on quality.

[0083] In certain embodiments, the conductor 4 is disposed within the carbonized body 2 and the carbon material 3 and connected to the metal frame 1. The conductor 4 is provided with an expansion cavity 41. During power-on, when current is transmitted through the metal frame 1 to the conductor 4, a resistive heating effect is generated, thereby achieving heat conduction heating of the carbonized body 2 and the carbon material 3. The expansion cavity 41, by reserving deformation space, achieves a high degree of matching between the conductor 4, the carbon material 3, and the carbonized body 2, effectively releasing the thermal expansion stress and material phase change stress of the continuous anode under high temperature conditions, preventing the conductor 4 from radially expanding or penetrating into the surrounding anode structure due to stress release, and ensuring that no destructive stress concentration is formed at the interface between the conductor 4 and the anode, thereby maintaining the integrity of the anode structure, functional effectiveness, and long-term operational stability.

[0084] In certain embodiments, at least one conductor 4 is provided in the carbonized body 2 and the carbon material 3. The number of conductors 4 can be flexibly set based on factors such as the conductive exhaust requirements in the actual application scenario, the size and shape characteristics of the carbonized body 2 and the carbon material 3, and the current uniformity requirements. The number range includes, but is not limited to, any positive integer such as 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. When there are multiple conductors 4, the relative positional relationship between the conductors 4 is not specifically limited, but meets the requirements of uniform current distribution within the continuous anode, rapid anode gas discharge, and no impact on the integrity of the continuous anode.

[0085] In certain embodiments, at least one expansion cavity 41 is provided per conductor 4. The specific number of expansion cavities 41 can be flexibly adjusted based on factors such as the length and cross-sectional area of the conductor 4, the operating environment, and the formulation of the carbon material 3. For example, the number of expansion cavities 41 can be 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10. The distribution of the expansion cavities 41 on the conductor 4 can also vary. The distribution can be uniform to ensure uniform stress release across the continuous anode, or non-uniform based on the stress distribution characteristics of the continuous anode, with more expansion cavities 41 being provided in stress-concentrated areas.

[0086] In certain embodiments, the size of the expansion cavity 41 is designed based on the material, size, and expected stress release of the conductor 4, carbonized body 2, and carbon material 3. A larger expansion cavity 41 may provide greater deformation space but may affect the mechanical strength and conductivity of the conductor 4; a smaller expansion cavity 41 may have limited effect on stress release.

[0087] In some embodiments, the expansion space 41 has a variety of shape structures, and its specific shapes include but are not limited to: circles, cuboids, and cubes with regular geometric shapes; cones, truncated cones, pyramids, and prisms with specific frustum characteristics; cylinders and prisms with column characteristics; and other irregular shapes composed of different curved surfaces or planes in addition to the above regular shapes.

[0088] In some embodiments, the total volume of the expansion space 41 accounts for 5-21% of the volume of the conductor 4. Preferably, the total volume of the expansion space 41 accounts for 8.9-14.3% of the volume of the conductor 4. Specifically, the total volume of the expansion space 41 accounts for 5%, 6%, 7%, 8%, 8.9%, 9%, 10%, 11%, 12%, 13%, 14%, 14.3%, 15%, 16%, 17%, 18%, 19%, 20% or 21% of the volume of the conductor 4.

[0089] When the total volume of the expansion space 41 accounts for a large proportion of the volume of the conductor 4, for example, greater than 25%, the effective area of the conductor 4 is reduced, the strength of the conductor 4 is reduced, and problems such as bending and deformation are prone to occur, which affects the current conduction of the conductor 4; or the cross-sectional area of the conductor 4 is further increased to improve the strength and conductivity of the conductor 4, but after the conductor 4 melts and flows out of the continuous anode, the current density of the continuous anode increases sharply, exceeding the safety range required by the process.

[0090] In one embodiment, referring to Figures 2 to 5 The expansion cavity 41 is provided inside or on the surface of the conductor 4. This ensures that the stress release function can be fully exerted when the conductor 4 undergoes thermal expansion or material phase change, and when the carbon material 3 undergoes a coking reaction. When the expansion cavity 41 is provided inside the conductor 4, it can be formed by a manufacturing process that includes casting, extrusion, or a combination of a conductor 4 with an open expansion cavity 41. When provided on the surface of the conductor 4, it can be processed by machining, casting, stamping, or connecting a baffle 42 with the expansion cavity 41. A good connection should be maintained between the expansion cavity 41 and the rest of the conductor 4 to ensure smooth current conduction.

[0091] In one embodiment, referring to Figure 2 and Figure 3 When the expansion space 41 is provided inside the conductor 4, the expansion space 41 includes a closed expansion space 41 and a through expansion space. The closed expansion space 41 refers to a cavity structure that is completely enclosed inside the conductor 4 and is not directly connected to the external environment of the conductor 4. The closed expansion space 41 has the ability to absorb stress in all directions, meeting the stress release requirements of the conductor 4, the carbon material 3 and the carbonized body 2, so that the above three are highly matched. The through expansion space 41 refers to a cavity structure that runs through the interior of the conductor 4 and has a communication channel with the external environment of the conductor 4. In addition to meeting the high matching of the conductor 4, the carbon material 3 and the carbonized body 2, it is easy to manufacture and has low cost.

[0092] In one embodiment, referring to Figure 4 When the expansion space 41 is provided on the surface of the conductor 4, the expansion space 41 comprises an open expansion space 41. The open expansion space 41 is a groove or hole of a certain shape and size opened on the surface of the conductor 4, and its opening portion is directly connected to the external environment. Common open expansion spaces 41 include linear open expansion spaces 41, spiral open expansion spaces 41, and grid-shaped open expansion spaces 41.

[0093] In one embodiment, referring to Figure 3 and Figure 4The open expansion space 41 and the opening through the expansion space 41 are blocked by a baffle 42, which is connected to the conductor 4. The baffle 42 is used to prevent liquid, gel, or paste from flowing into or penetrating the expansion space 41. The material of the baffle 42 should have good corrosion resistance and mechanical strength. The baffle 42 and the conductor 4 can be connected by bolts, welding, bonding, riveting, etc.

[0094] There are various ways to seal the opening of the open expansion space 41. The baffle 42 can be set in the internal space of the open expansion space 41 and directly cooperate with the inner wall of the open expansion space 41 to achieve sealing; it can also be set on the surface of the conductor 4 to seal the opening of the open expansion space 41.

[0095] The through expansion space 41 has through openings at both ends. To ensure a sealing effect, baffles 42 are provided at the through openings at both ends of the through expansion space 41. Similarly, the baffles 42 can be provided inside the through openings, tightly fitting with the inner walls of the through openings to complete the sealing, or they can be provided on the surface of the conductor 4 to seal the through openings.

[0096] Regardless of whether the baffle 42 is arranged inside the open expansion space 41 or on the surface of the conductor 4, or inside the through expansion space 41 or on the surface of the conductor 4, as long as it can meet the functional requirements of effectively sealing the corresponding opening, it is within the protection scope of this technical solution.

[0097] In one embodiment, referring to Figure 5 At least one surface of at least one conductor 4 is provided with at least one baffle 42, forming a closed expansion space 41 between the baffle 42 and the conductor 4. The baffle 42 can also be a profile with its own closed expansion space 41, connected to the surface of the conductor 4, providing a stress relief space for the conductor 4, the carbon material 3, and the carbonized body 2.

[0098] In one embodiment, the baffle 42 is made of one or more materials selected from the following: metal, metal alloy, cardboard, graphite, and plastic. The baffle 42's melting or disappearance characteristics under high-temperature conditions meet the following conditions: its melting or disappearance time is synchronized with, or delayed relative to, that of the conductor 4. Furthermore, the baffle 42 begins to melt, carbonize, or vaporize only after the carbon material 3 surrounding the baffle 42 has completed its solidification process, aligning with stress release and maintaining the expansion cavity's ability to release stress.

[0099] In one embodiment, the conductor 4 includes a first conductor 43 and a second conductor 44. The first conductor 43 includes at least one open expansion space 41 and a first covering portion, and the open end of the expansion space 41 has a predetermined contact area. The second conductor 44 includes at least one open expansion space 41 and a second covering portion. The second covering portion is complementary to the open end surface of the expansion space 41 of the first conductor 43, and the first covering portion is complementary to the open end surface of the expansion space 41 of the second conductor 44. When the first conductor 43 and the second conductor 44 overlap each other, the second covering portion completely covers the opening of the expansion space 41 of the first conductor 43, and the first covering portion completely covers the opening of the expansion space 41 of the second conductor 44. By overlapping the opening of the expansion space 41 with the first conductor 43 and the second conductor 44, liquid, colloid, or paste is prevented from flowing into or seeping into the expansion space 41. The first conductor 43 and the second conductor 44 can be connected to the power input surface 11 or the power output surface 12 of the metal frame 1 at the same time, or the first conductor 43 is connected to the power input surface 11 of the metal frame 1 and the second conductor 44 is connected to the power output surface 12 of the metal frame 1, or the first conductor 43 is connected to the power output surface 12 of the metal frame 1 and the second conductor 44 is connected to the power input surface 11 of the metal frame 1.

[0100] In one embodiment, the distribution of the expansion spaces 41 in the conductor 4 is not subject to specific restrictions, and any one or more of the following combinations may be adopted based on application requirements: axial distribution, the expansion spaces 41 are uniformly arranged or segmented along the axial direction (length direction) of the conductor 4 to form a linearly arranged axial cavity structure; radial distribution, the expansion spaces 41 are arranged along the radial direction (cross-sectional direction) of the conductor 4, including but not limited to annular cavities or layered cavity structures; grid distribution, the expansion spaces 41 form a three-dimensional grid structure inside the conductor 4, interwoven with the conductor 4 material to form a spatial mesh cavity system. The axially distributed expansion spaces 41 can be arranged at equal intervals or variable intervals, the radially distributed expansion spaces 41 can be designed as a single-layer or multi-layer structure, and the grid-distributed expansion spaces 41 form a honeycomb, cubic, or truss-like mesh structure.

[0101] In one embodiment, referring to Figure 6 At least one of the expansion spaces 41 is filled with a heat-shrinkable material 45. The heat-shrinkable material effectively prevents liquids, colloids, or pastes from entering or penetrating the expansion space 41, thereby relieving stress and maintaining the stress-absorbing capacity of the expansion space 41. Specifically, at least one of the open expansion space 41 and the through expansion space is filled with the heat-shrinkable material 45.

[0102] In one embodiment, the heat shrinkable material 45 is selected from any one or any combination of the following materials: explosion-proof fiber, a fiber material with high strength, high temperature resistance and heat shrinkage properties, which can shrink and carbonize or gasify after being heated, matching the stress release and playing the role of expansion space 41; shrinkage film, including but not limited to polyolefin, polyvinyl chloride or fluoroplastic film materials, which have heat shrinkage properties; foam materials, such as polyethylene foam, polyurethane foam, etc., which have heat shrinkage and cushioning properties and can be compressed and carbonized or gasified after being heated; pearl cotton EPE, a foamed polyethylene material, is lightweight, thermally insulating, and heat-shrinkable, allowing the expansion cavity 41 to absorb stress. Plant fibers, such as wood and bamboo fibers, can be modified to have heat-shrink properties and can be used in environmentally friendly sealing materials. Cotton, a natural fiber material, can also have heat-shrink properties after chemical modification or composite treatment. Expanded polystyrene particles prevent liquids, colloids, or pastes from entering or penetrating the expansion cavity 41 before shrinking and vaporizing. During the shrinkage and vaporization process, they release or absorb stress from the conductor 4, carbon material 3, and carbonized body 2. The heat-shrinkable material 45 can be used alone or in combination of two or more materials to achieve complementary functions. For example, explosion-proof fiber combined with shrink film can achieve both strength and sealing performance.

[0103] In certain embodiments, reference Figure 7 and Figure 8 At least one inner wall surface of the metal frame 1 is provided with at least one nose 13, and the bottom of the nose 13 is connected to the top of the conductor 4. The main function of the nose 13 is to serve as a bridge for current transmission, and to efficiently conduct current from the metal frame 1 to the conductor 4. When the anode at the bottom of the conductor 4 is consumed, the nose 13 and the conductor 4 will complete the conductive function, and begin to flow out of the anode in the form of liquid, enter the aluminum liquid in the electrolytic cell, and automatically form a groove in the carbonized body 2 at the original position of the nose 13 and the conductor 4, and the anode gas generated by the bottom of the anode quickly enters the groove. Since the nose 13 is located higher than the conductor 4, the depth of the groove formed by the liquid electrolyte burying the nose 13 is shallow, and the anode gas encounters little resistance when discharging from the nose 13 groove. The anode gas collected in the groove can be quickly discharged, promoting the dissolution of raw materials in the electrolyte, reducing the anode film resistance, and achieving energy saving.

[0104] In certain embodiments, the shape (e.g., cylindrical, rectangular, sheet-like, wedge-shaped, etc.) and dimensions (length, width, height) of the nose 13 are not strictly limited, and can be flexibly adjusted based on the process requirements of the electrolytic cell, the shape or structure of the conductor 4, the structure of the metal frame 1, and the anode consumption characteristics. Preferably, the contact area between the nose 13 and the metal frame 1 is greater than the cross-sectional area of the conductor 4. Increasing the contact area can reduce contact resistance, reduce energy loss during current transmission, and avoid the risk of melting or disconnection due to local overheating.

[0105] In some embodiments, at least one of the head 13 is provided on the power input surface 11 and the power output surface 12 of the metal frame 1. The head 13 is used as a connector to connect the conductor 4. The number and position of the head 13 can be reasonably arranged according to the actual current transmission requirements and structural design. The head 13 and the power input surface 11 or the power output surface 12 of the metal frame 1 are formed by integral casting. The integral casting process forms a seamless connection between the head 13 and the metal frame 1, avoiding the small conductive area and high voltage drop on the contact surface that may cause overheating or melting or outflow in the traditional connection method. At the same time, when the head 13 and the metal frame 1 are cast together, the metal frame 1 does not deform, ensuring that the contact area between the metal frame 1 and the anode guide rod 5 is maximized, the contact voltage between the two is reduced, the temperature at the contact point is low, and the contact point between the metal frame 1 and the anode guide rod 5 remains intact.

[0106] In some embodiments, the head 13 is configured with at least one plug-in portion 14, and the conductor 4 is connected to the head 13 by inserting the plug-in portion 14. The cross-sectional shape of the plug-in portion 14 is adapted to the cross-sectional shape of the connection portion of the conductor 4 to achieve stable plugging.

[0107] In some embodiments, the plug-in portion 14 and the conductor 4 are fixed by interference fit, a snap-on structure or fasteners (such as bolts), or welding, so as to ensure that the current on the plug-in portion 14 is smoothly transmitted to the conductor 4, keep the voltage drop at the contact point to a minimum, and avoid overheating of the contact point and premature melting.

[0108] In some embodiments, the plug-in portion 14 is a socket, which is a through hole or a blind hole that passes through the thickness of the head 13. The cross-sectional shape of the socket is adapted to the cross-sectional shape of the connection of the conductor 4, and the conductor 4 is inserted into the socket for connection.

[0109] In some embodiments, the plug-in portion 14 is a slot, which is a groove opened on the surface of the head 13, the depth of which matches the insertion depth of the connection of the conductor 4, and the cross-sectional shape of the slot is adapted to the cross-sectional shape of the connection of the conductor 4, and the conductor 4 is inserted into the slot for connection.

[0110] In some embodiments, the plug-in portion 14 may include both a socket and a slot to accommodate conductors 4 of different shapes or sizes.

[0111] In this application, busbar 6 refers to a conductive component used in an aluminum electrolysis cell to transmit and distribute current between the power input surface 11 and the power output surface 12 of the metal frame 1. Busbar 6 comes in a variety of forms to meet different connection requirements and installation environments. Common forms include straight lines, curved lines, and special-shaped structures customized to specific space and current distribution requirements.

[0112] In certain embodiments, reference Figure 9 , the power input surface 11 and the power output surface 12 of the metal frame 1 are respectively connected to the conductor 4, and a connecting busbar 6 is connected between the conductor 4 of the power input surface 11 and the power output surface 12. The connecting busbar 6 is made of a material with excellent electrical conductivity (such as high-purity copper, copper alloy, high-purity aluminum, aluminum alloy, etc.), and the connecting busbar 6 and the conductor 4 adopt a reliable electrical connection process, such as bolt connection or crimping. When the external current is introduced into the conductor 4 through the power input surface 11, part of the current on the conductor 4 can be conducted to the power output surface 12 through the connecting busbar 6, so as to achieve uniform current distribution between different conductors 4, avoiding problems such as overheating, melting, and huge thermal stress caused by local concentration of current.

[0113] In some embodiments, a lug 13 is provided on the power input surface 11 and the power output surface 12 of the metal frame 1 , respectively, and the conductor 4 is connected to the power input surface 11 or the power output surface 12 of the metal frame 1 through the lug 13 .

[0114] In certain embodiments, reference Figure 10 The metal frame 1 is provided with a plurality of connecting busbars 6. One end of each connecting busbar 6 is connected to the power inlet surface 11 of the metal frame 1, and the other end is connected to the power outlet surface 12 of the metal frame 1. The connecting busbars 6 achieve uniform current distribution between the power inlet surface 11 and the power outlet surface 12 of the metal frame 1, thereby reducing current concentration and overheating in local areas and lowering resistance losses. The connecting busbars 6 can be connected to the power inlet surface 11 and the power outlet surface 12 of the metal frame 1 using reliable connection methods such as welding, bolting, and crimping.

[0115] In certain embodiments, the connecting busbar 6 includes a first rigid busbar 61, a second rigid busbar 62, and a flexible strip 64. A tightening mechanism 63 is disposed between the first rigid busbar 61 and the second rigid busbar 62. The tightening mechanism 63 applies a pre-tightening force to the first rigid busbar 61 and the second rigid busbar 62 in the axial direction, so that: the first rigid busbar 61 forms a continuous contact connection with the power input surface 11 of the metal frame 1; the second rigid busbar 62 forms a continuous contact connection with the power output end surface of the metal frame 1; and the two ends of the flexible strip 64 are respectively connected to the first rigid busbar 61 and the second rigid busbar 62. The pre-tightening force applied by the tightening mechanism 63 ensures that the first rigid busbar 61 and the second rigid busbar 62 always maintain close contact with the power input surface 11 and the power output end surface of the metal frame 1, effectively avoiding the problem of loose connection caused by factors such as vibration, thermal expansion and contraction, and ensuring the stability of current transmission. Under the action of the tightening mechanism 63 , the elastic deformation and movement of the soft belt 64 enables the connecting busbar 6 to maintain a tight connection with the metal frame 1 , ensuring that the current on the first rigid busbar 61 is continuously and stably conducted to the second rigid busbar 62 .

[0116] As the anode at the bottom of the metal frame 1 participates in the electrochemical reaction and is continuously consumed, the corresponding metal frame 1 and conductor 4 are subsequently absorbed into the liquid aluminum below the anode in liquid form. To maintain the continuity of the anode, it is necessary to regularly connect a new metal frame 1 to the top of the metal frame 1, install a new conductor 4 in the new metal frame 1, and add new carbon material 3 between the conductor 4 and the metal frame 1. As the anode gradually descends, the carbon material 3 at the bottom is preferentially converted into a carbonized body 2 with good conductivity and high mechanical strength, which participates in the electrochemical reaction. When the anode guide rod 5 approaches the liquid electrolyte, it is raised to the highest position required by the process. Based on the new position of the anode guide rod 5, it is determined whether the connecting busbar 6 in the metal frame 1 needs to be raised.

[0117] When lifting the connecting busbar 6, first loosen the pressure of the tightening mechanism 63 on the connecting busbar 6, then lift the connecting busbar 6 to the specified position, restore the pressure of the tightening mechanism 63 on the connecting busbar 6, keep the two ends of the connecting busbar 6 in close contact with the inner side of the metal frame 1, and smoothly conduct part of the current from the power input surface 11 to the power output surface 12.

[0118] In some embodiments, the tightening mechanism 63 is selected from one or more of a worm gear mechanism, a telescopic cylinder mechanism, a wedge-shaped tightening mechanism 63, a spring mechanism, and a screw mechanism. The worm gear mechanism includes a worm wheel assembly and a worm assembly. The rotational motion of the worm drives the worm wheel to rotate, thereby realizing the tightening action. The self-locking characteristics of the worm gear mechanism are used to ensure that a stable preload state is maintained after tightening. The telescopic cylinder mechanism has a telescopic cylinder body and a piston rod. The piston rod is driven by hydraulic, pneumatic or electric means to perform linear telescopic motion to promote the relevant components to realize the tightening function. Its stroke can be adjusted according to actual needs. The wedge-shaped tightening mechanism 63 is composed of a wedge block and a driving component. The inclined surface principle of the wedge block is used to convert the smaller force generated by the driving component into a larger tightening force to achieve a reliable tightening effect. The spring mechanism uses a spring as a tightening element. The spring has good elastic deformation ability and can absorb vibration and impact energy within a certain range while providing continuous preload. The screw mechanism includes a screw and a nut assembly. The rotation of the screw drives the nut to move linearly, thereby tightening the relevant components.

[0119] Even better tightening effects can be achieved through combined applications. For example, combining a worm gear mechanism with a lead screw mechanism can leverage the self-locking properties of the worm gear mechanism to ensure stability after tightening, while also utilizing the high-precision transmission characteristics of the lead screw mechanism to precisely control the tightening stroke.

[0120] In another embodiment of the present application, a method for manufacturing a continuous anode is provided, comprising:

[0121] S1 uses a mold casting to obtain the power input surface 11 board and the power output surface 12 board of the metal frame 1

[0122] Pour the liquid metal material into the mold and perform casting molding to obtain the power input surface 11 plate and the power output surface 12 plate. After the metal material cools and solidifies, it is demoulded and taken out.

[0123] S2 uses side panels to connect the power-input side 11 and the power-output side 12 of the metal frame 1 to form the metal frame 1.

[0124] Place the power input surface 11 and the power output surface 12 of the metal frame 1 in parallel, use a side panel to connect one side edge of the power input surface 11 and the power output surface 12, and use another side panel to connect the other side edge of the power input surface 11 and the power output surface 12 to form the metal frame 1.

[0125] S3 connects the conductor 4 with expansion space 41 to the power input surface 11 board and the power output surface 12 board respectively.

[0126] A plurality of conductors 4 are connected to the power inlet surface 11 and the power outlet surface 12 respectively, and the conductors 4 extend toward the power inlet surface 11 or the power outlet surface 12 .

[0127] S4 Fill the carbon material 3 between the metal frame 1 and the conductor 4

[0128] The carbon material 3 is filled between the metal frame 1 and the conductor 4. During the filling process, the carbon material 3 should be continuously vibrated or pressure should be applied, or the carbon material 3 should sink due to its own weight to ensure the uniformity and density of the carbon material 3.

[0129] In step S5 , the conductor 4 is electrified, and the carbon material 3 is transformed into a carbonized body 2 under the action of the resistance heat of the conductor 4 , and is integrated with the metal frame 1 and the conductor 4 to form a continuous anode.

[0130] The above steps are in no particular order.

[0131] In one embodiment, referring to Figure 1 The mold should be designed to be able to cast the metal frame 1 with a head 13, the power input surface 11 plate and the power output surface 12 plate, select a suitable metal material, heat it to a molten state to form a molten metal, pour the molten metal into the mold, control the casting speed and temperature, ensure that the metal liquid can fully fill all parts of the mold, and form a complete power input surface 11 plate and power output surface 12 plate with a head 13, and connect the conductor 4 to the head 13 of the power input surface 11 plate and the power output surface 12 plate respectively.

[0132] In one embodiment, referring to Figure 7 and 8The head 13 is provided with at least one plug-in portion 14, and the conductor 4 is connected to the head 13 by inserting the plug-in portion 14. The cross-sectional shape of the plug-in portion 14 is adapted to the cross-sectional shape of the connection portion of the conductor 4 to achieve stable plugging.

[0133] In some embodiments, the plug-in portion 14 and the conductor 4 are fixed by interference fit, a snap-on structure or fasteners (such as bolts), or welding, so as to ensure that the current on the plug-in portion 14 is smoothly transmitted to the conductor 4, keep the voltage drop at the contact point to a minimum, and avoid overheating of the contact point and premature melting.

[0134] In some embodiments, the plug-in portion 14 is a socket, which is a through hole or a blind hole that passes through the thickness of the head 13. The cross-sectional shape of the socket is adapted to the cross-sectional shape of the connection of the conductor 4, and the conductor 4 is inserted into the socket for connection.

[0135] In some embodiments, the plug-in portion 14 is a slot, which is a groove opened on the surface of the head 13, the depth of which matches the insertion depth of the conductor 4, and the cross-sectional shape of the slot is adapted to the cross-sectional shape of the connection of the conductor 4, and the conductor 4 is inserted into the slot for connection.

[0136] In some embodiments, the plug-in portion 14 may include both a socket and a slot to accommodate conductors 4 of different shapes or sizes.

[0137] In certain embodiments, reference Figure 9 A connecting busbar 6 is connected between the conductors 4 of the power input surface 11 and the power output surface 12. The connecting busbar 6 and the conductor 4 adopt a reliable electrical connection process, such as bolt connection, welding or crimping.

[0138] In certain embodiments, reference Figure 10 A connecting busbar 6 is connected between the power input surface 11 board and the power output surface 12 board. One end of the connecting busbar 6 is connected to the power input surface 11 of the metal frame 1, and the other end is connected to the power output surface 12 of the metal frame 1.

[0139] Furthermore, the connecting busbar 6 includes a first rigid busbar 61, a second rigid busbar 62 and a soft belt 64, the first rigid busbar 61 is connected to the power input surface 11 board, the second rigid busbar 62 is connected to the power output surface 12 board, and a tightening mechanism 63 is connected between the first rigid busbar 61 and the second rigid busbar 62, and the tightening mechanism 63 applies a pre-tightening force to the first rigid busbar 61 and the second rigid busbar 62 in the axial direction, so that: the first rigid busbar 61 forms a continuous contact connection with the power input surface 11 of the metal frame 1; the second rigid busbar 62 forms a continuous contact connection with the power output end surface of the metal frame 1; one end of the soft belt 64 is connected to the first rigid busbar 61, and the other end of the soft belt 64 is connected to the second rigid busbar 62.

[0140] In another embodiment of the present application, an aluminum electrolysis cell is provided, comprising: an electrolysis cell body; a cathode arranged at the bottom of the electrolysis cell body; and a continuous anode installed on the electrolysis cell body, wherein the continuous anode and the cathode form an electrical connection path through an electrolyte and / or aluminum liquid.

[0141] In certain embodiments, reference Figure 1 The continuous anode includes a metal frame 1, a carbonized body 2, a carbon material 3, and several conductors 4; the metal frame 1 has a accommodating cavity; the carbonized body 2 is arranged in the accommodating cavity of the metal frame 1 in an adapted state, and the carbonized body 2 has an extending portion that exceeds the boundary of the accommodating cavity of the metal frame 1; the carbon material 3 is filled in the accommodating cavity of the metal frame 1 and covers the surface of the carbonized body 2 exposed in the accommodating cavity; the conductor 4 is inserted between the carbonized body 2 and the carbon material 3, at least one of the conductors 4 is provided with at least one expansion space 41, and the conductor 4 is connected to the metal frame 1.

[0142] The technical solution of this application is further described in detail below with reference to specific exemplary embodiments.

[0143] The method for measuring the actual contact area between the anode guide rod 5 and the metal frame 1 is as follows: a thin layer of easily removable black pigment is applied to the inner side of the anode guide rod 5 in contact with the metal frame 1, with the coating area being S1. Then, the anode guide rod 5 is pressed against the outer surface of the aluminum frame by 6000 kgf. After removing the anode guide rod 5, an area measuring instrument is used to measure the area S2 of the mark left by the anode guide rod 5 on the metal frame 1. That is, S2 is the actual contact area between the anode guide rod 5 and the metal frame 1. The actual contact area between the anode guide rod 5 and the metal frame 1 is expressed as the ratio of the contact areas, which is S2 ÷ S1 × 100%.

[0144] Example 1

[0145] Install 3 sets of continuous anodes in 160ka aluminum electrolytic cell, refer to Figure 1 and Figure 3 The single continuous anode comprises a metal frame 1, a carbonized body 2, a carbon material 3, and 32 conductors 4. The metal frame 1 has an oppositely disposed power inlet surface 11 and power outlet surface 12, as well as a receiving cavity between the power inlet surface 11 and the power outlet surface 12. The inner wall of the power inlet surface 11 of the single metal frame 1 is pre-set with 16 protrusions 13, and the inner wall of the power outlet surface 12 of the metal frame 1 is pre-set with 16 protrusions 13. The protrusions 13 of the power inlet surface 11 correspond to the protrusions 13 of the power outlet surface 12 in a one-to-one correspondence. Each of the conductors 4 has four expansion spaces 41, the openings of which are sealed with baffles 42. The four expansion spaces 41 are sequentially arranged along the length of the conductor 4.

[0146] The carbonized body 2 is connected to the accommodating cavity of the metal frame 1. The bottom of the carbonized body 2 extends out of the bottom of the metal frame 1. Sixteen conductors 4 located in the same plane are embedded in the carbonized body 2, of which eight conductors 4 are connected to the head 13 of the power inlet surface 11, and eight conductors 4 are connected to the head 13 of the power outlet surface 12. In the accommodating cavity of the metal frame 1, the top of the carbonized body 2 is filled with carbon material 3. Sixteen conductors 4 are embedded in the carbon material 3, of which eight conductors 4 are connected to the head 13 of the power inlet surface 11, and eight conductors 4 are connected to the head 13 of the power outlet surface 12. A slot is provided at the bottom of each head 13, and the upper front end of the conductor 4 is inserted into the slot of the head 13 and tightly connected. A connecting busbar 6 is connected between the power inlet surface 11 and the power outlet surface 12 of the metal frame 1. The connecting busbar 6 is located on the top of the carbon material 3 and corresponds to the anode guide rod 5. The power inlet surface 11 and the power outlet surface 12 of the metal frame are respectively connected to four anode guide rods 5 which are pressed tightly on the outer surfaces.

[0147] Among them, the metal frame 1 is made of recycled scrap aluminum, the nose 13 is made of recycled scrap aluminum, the conductor 4 is made of aluminum plate made of recycled scrap aluminum, the baffle 42 is made of thin aluminum sheet made of cold rolling, the expansion space 41 in the aluminum plate accounts for 12.8% of the volume of the aluminum plate, and the ratio of the contact surface between the anode guide rod 5 and the aluminum frame is 82~91%.

[0148] The electrolytic cell has been in operation for 6 months, with an electrolysis temperature of 925-938°C, an average cell voltage of 3.83V, and a current efficiency of 93.6%. There is no problem of anode falling off and corners falling off, and the cell resistance is stable without needle vibration, indicating that the expansion space 41 in the aluminum plate has absorbed the stress released by the aluminum plate, the warp 13, the carbon material 3 and the carbonized body 2. The above four are highly matched and consistent. The aluminum plate has not expanded or penetrated into the anode. The contact voltage drop between the aluminum frame and the anode guide rod 5 is 6-10mv, the contact temperature is 230-350°C, the contact between the aluminum frame and the anode guide rod 5 is intact without melting or damage, and the product quality aluminum content reaches 99.70% or above.

[0149] Example 2

[0150] Four sets of continuous anodes were installed in a 240ka aluminum electrolytic cell. The structure of the continuous anodes was the same as that of Example 1. The metal frame 1 was made of pure aluminum, the header 13 was made of pure aluminum, the conductor 4 was made of pure aluminum plate, and the baffle 42 was made of cold-rolled thin aluminum sheet. The expansion space 41 in the aluminum plate accounted for 12.8% of the volume of the aluminum plate, and the contact surface ratio between the anode guide rod 5 and the aluminum frame was 82-91%.

[0151] The electrolytic cell has been in operation for 6 months, with an electrolysis temperature of 925-938°C, an average cell voltage of 3.81V, and a current efficiency of 93.8%. There is no problem of anode block and corner falling off, and the cell resistance is stable without needle vibration, indicating that the expansion space 41 in the aluminum plate has absorbed the stress released by the aluminum plate, the warp 13, the carbon material 3 and the carbonized body 2. The above four are highly matched and consistent. The aluminum plate has not expanded or penetrated into the anode. The contact voltage drop between the aluminum frame and the anode guide rod 5 is 6-10mv, the contact temperature is 230-350°C, the contact between the aluminum frame and the anode guide rod 5 is intact without melting or damage, and the product quality aluminum content reaches 99.85% or above.

[0152] Comparative Example 1

[0153] Three sets of continuous anodes were installed in a 160ka aluminum electrolytic cell. The structure of the continuous anodes was the same as that of Example 1, except that the conductors 4 were not provided with expansion spaces 41 and were welded directly to the power inlet and outlet surfaces 11 and 12 of the metal frame 1. The metal frame 1 was made of recycled aluminum scrap, and the conductors 4 were made of aluminum plates made of recycled aluminum scrap. The ratio of the contact surface between the anode guide rods 5 and the aluminum frame was 21-33%.

[0154] The electrolytic cell was operated for 6 months, with an electrolysis temperature of 925-938°C, an average cell voltage of 3.96V, and a current efficiency of 92.3%. The anode pieces and corners fell off five times, and the cell resistance needle vibration time accumulated to 250 hours, indicating that the aluminum plate, the warp 13, the carbon material 3, and the carbonized body 2 were not matched, and they exerted forces on each other. The internal stress of the continuous anode was large, and the aluminum plate expanded or penetrated into the anode. The contact voltage drop between the aluminum frame and the anode guide rod 5 was 12-18mv, and the temperature at the contact was 320-460°C. Two melting and damage occurred at the contact between the aluminum frame and the anode guide rod 5. The end of the anode guide rod 5 connected to it melted and flowed out, emitting harmful gases. The portable VOC detector was used for detection, and the results showed that the VOC value was 36-52mg / NM 3 The aluminum content of the product quality reaches 99.70% or above.

[0155] Comparative Example 2

[0156] Four sets of continuous anodes were installed in a 240ka aluminum electrolytic cell. The structure of the continuous anodes was identical to that of Example 1, except that the conductors 4 were welded directly to the power inlet and outlet surfaces 11 and 12 of the metal frame 1, without expansion spaces 41. The metal frame 1 was made of pure aluminum, and the conductors 4 were made of pure aluminum plates. The contact surface ratio between the anode guide rods 5 and the aluminum frame was 21-33%.

[0157] The electrolytic cell was operated for 6 months, with an electrolysis temperature of 925-938°C, an average cell voltage of 3.93V, and a current efficiency of 92.5%. The anode blocks and corners fell off six times, and the cell resistance needle vibration time accumulated to 263 hours, indicating that the aluminum plate, the warp 13, the carbon material 3, and the carbonized body 2 were not matched, and they exerted forces on each other. The internal stress of the continuous anode was large, and the aluminum plate expanded or penetrated into the anode; the contact voltage drop between the aluminum frame and the anode guide rod 5 was 10-19mv, and the contact temperature was 322-468°C. The contact between the aluminum frame and the anode guide rod 5 was melted and damaged three times, and the end of the anode guide rod 5 connected to it melted and flowed out, emitting harmful gases. The portable VOC detector was used for detection, and the results showed that the VOC value was 32-55mg / NM 3 The aluminum content of the product quality reaches 99.85% or above.

[0158] In Comparative Examples 1 and 2, to improve the efficiency and safety of current conduction, an aluminum plate was welded to the inside of the aluminum frame. However, during the welding process, the aluminum frame deformed and could not remain flat, which deteriorated the contact between the anode guide rod 5 and the aluminum frame. When current was conducted to the aluminum frame through the anode guide rod 5, the small contact area and poor contact state caused an increase in the contact voltage drop, which in turn increased the temperature at the contact point, causing partial damage to the aluminum frame and anode guide rod 5, affecting the function of the aluminum frame and allowing the escape of harmful gases. Furthermore, due to thermal expansion and stress generated in the aluminum plate, the aluminum plate, the warp 13, the carbon material 3, and the carbonized body 2 did not match, resulting in the anode losing corners and pieces, and severe cell resistance vibration, affecting the smooth and efficient operation of the electrolytic cell.

[0159] Experimental example

[0160] Experimental Example 1

[0161] A continuous anode having the same structure as that of Example 1 was used, with an iron frame as the metal frame 1 and an aluminum block as the conductor 4.

[0162] A 200×200×200mm iron frame with open ends is placed in a 300×300×300 crucible. Anode paste is placed in the iron frame. An aluminum block conductor 4 with 8.9% expansion space 41 and a flat surface is embedded in the anode paste. The aluminum block conductor 4 has a size of 100×100×30mm and a mass of 738g. Filler is spread between the crucible and the iron frame, as well as above the anode paste. The crucible, container, anode paste, and aluminum block conductor 4 are placed in an electric furnace together. The crucible, container, anode paste, and aluminum block conductor 4 are baked to 700°C at a simulated actual heating rate and maintained for 6 hours before baking and cooling. The anode paste embedded with the aluminum block conductor 4 is dissected at room temperature, and the aluminum block conductor 4 is peeled off from the anode paste.

[0163] The results are as follows: the aluminum block conductor 4 is in contact with the anode paste but not bonded, and is easy to separate. The surface of the aluminum block conductor 4 is flat and intact, without bumps or concavities, and does not expand or penetrate into the anode paste. The mass of 738g remains unchanged, and the shape remains unchanged. The contact surface of the anode paste with the aluminum block conductor 4 is flat and intact, without bumps or concavities, and has no cracks.

[0164] Example 2

[0165] A continuous anode having the same structure as that of Example 1 was used, with an iron frame as the metal frame 1 and an aluminum block as the conductor 4.

[0166] A 200×200×200mm iron frame with open ends is placed in a 300×300×300 crucible. Anode paste is then placed in the container. A flat aluminum bulk conductor 4 with 14.3% expansion space 41 is embedded in the anode paste. The aluminum bulk conductor 4 measures 100×100×30mm and weighs 694g. Filler is placed between the crucible and the iron frame, as well as above the anode paste. The crucible, container, anode paste, and aluminum bulk conductor 4 are placed in an electric furnace and roasted to 950°C at a simulated actual heating rate. The temperature is maintained for 6 hours, followed by a cooling process. The anode paste containing the embedded aluminum bulk conductor 4 is dissected at room temperature, and the aluminum bulk conductor 4 is separated from the anode paste.

[0167] The results are as follows: the aluminum block conductor 4 is in contact with the anode paste but not bonded and can be easily separated. The surface of the aluminum block conductor 4 is flat and intact without bumps or concavities, and does not expand or penetrate into the anode paste. The mass of 694 g remains unchanged, and the shape remains unchanged. The contact surface of the anode paste with the aluminum block conductor 4 is flat and intact without bumps or cracks.

[0168] Experimental Example 3

[0169] A continuous anode having the same structure as that of Comparative Example 1 was used, with an iron frame as the metal frame 1 and an aluminum block as the conductor 4 .

[0170] A 200×200×200mm iron frame with open ends is placed in a 300×300×300mm crucible. Anode paste is then added to the container. A flat aluminum bulk conductor 4, measuring 100×100×30mm and weighing 810g, is embedded in the anode paste. Filler is then placed between the crucible and the iron frame, as well as above the anode paste. The crucible, container, anode paste, and aluminum bulk conductor 4 are placed in an electric furnace and roasted to 700°C at a simulated actual heating rate. The temperature is maintained for 6 hours, followed by a cooling process. The anode paste containing the embedded aluminum bulk conductor 4 is then dissected at room temperature, and the aluminum bulk conductor 4 is separated from the anode paste.

[0171] The results are as follows: the aluminum block conductor 4 and the anode paste are stuck together and difficult to separate. The shape of the aluminum block conductor 4 has changed, and irregular protrusions appear on the surface, expanding into the anode paste. The mass is 829g, an increase of 2.35%. The main reason is that some anode paste sticks to the protrusions of the aluminum block conductor 4 and cannot be cleaned off. The contact surface of the anode paste with the aluminum block conductor 4 has become uneven because the aluminum block conductor 4 has taken away a part of it, and a small crack has appeared at one corner.

[0172] Experimental Example 4

[0173] A continuous anode having the same structure as that of Comparative Example 2 was used, with an iron frame as the metal frame 1 and an aluminum block as the conductor 4 .

[0174] A 200 x 200 x 200 mm open-ended iron frame was placed in a 300 x 300 x 300 mm crucible. Anode paste was then added to the container. A flat aluminum bulk conductor (4) measuring 100 x 100 x 30 mm and weighing 810 g was embedded in the anode paste. Filler was then placed between the crucible and the iron frame, as well as above the anode paste. The crucible, container, anode paste, and aluminum bulk conductor (4) were placed in an electric furnace and heated to 950°C at a simulated actual heating rate. The temperature was maintained for 6 hours before the temperature was lowered. The anode paste with the embedded aluminum bulk conductor (4) was dissected at room temperature and the aluminum bulk conductor (4) was separated from the anode paste.

[0175] The results are as follows: the aluminum block conductor 4 and the anode paste are bonded together and difficult to separate. The shape of the aluminum block conductor 4 changes, and irregular protrusions appear on the surface, expanding and penetrating into the anode paste. The mass is 836g, an increase of 3.21%. The main reason is that the protrusions on the surface of the aluminum block conductor 4 take away some anode paste, and the contact surface of the anode paste in contact with the aluminum block conductor 4 becomes uneven, and small cracks appear at the corners in contact with the aluminum block conductor 4.

[0176] Experimental Example 5

[0177] A continuous anode with the same structure as Example 1 was used, with the metal frame 1 made from recycled aluminum scrap, the bumper 13 made from recycled aluminum scrap, the conductor 4 made from aluminum sheet made from recycled aluminum scrap, and the baffle 42 made from thin cold-rolled aluminum sheet. The differences were: the expansion space 41 in the aluminum sheet accounted for 4% of the aluminum sheet volume, and the contact surface ratio between the anode guide rod 5 and the aluminum frame was 82-91%.

[0178] The electrolytic cell operated for six months, with an electrolysis temperature of 925-938°C, an average cell voltage of 3.89V, and a current efficiency of 92.9%. Anode block and corner chipping occurred twice, and the cell resistance needle vibration time accumulated 95 hours. This indicates that the expansion cavity 41 in the aluminum plate absorbed some of the stress released by the aluminum plate, the warp 13, the carbon material 3, and the carbonized body 2. There was a lack of compatibility between these four elements, causing the aluminum plate to expand or penetrate into the anode. The contact voltage drop between the aluminum frame and the anode guide 5 was 5-10mV, and the contact temperature was 225-350°C. The contact between the aluminum frame and the anode guide 5 was intact, without melting or damage. The product quality aluminum content reached 99.70% or above.

[0179] In summary, when an aluminum block without expansion space is heated or melted, it expands and generates internal stress. These expansion effects and stresses are transmitted and permeated into the surrounding anode paste, exerting destructive stress on the paste. Combined with the internal stress generated by the anode paste coking process, these stresses ultimately lead to cracks in the anode paste structure, creating a mismatch and incompatibility between the aluminum block and the anode paste.

[0180] Although the embodiments of the present application are described above in conjunction with the accompanying drawings, the present application is not limited to the above-mentioned specific embodiments and application fields. The above-mentioned specific embodiments are merely illustrative and instructive, and not restrictive. A person of ordinary skill in the art, guided by this specification and without departing from the scope of protection of the claims of this application, may also devise various forms, all of which fall within the scope of protection of this application.

Claims

1. Continuous anode, including: A metal frame having a receiving cavity; a carbonized body, the carbonized body being arranged in an adapted state in the accommodating cavity of the metal frame, the carbonized body having an extending portion exceeding a boundary of the accommodating cavity of the metal frame; A carbon material is filled in the receiving cavity of the metal frame and covers the surface of the carbonized body exposed in the receiving cavity; A plurality of conductors are inserted in the carbonized body and the carbon material, at least one of the conductors is provided with at least one expansion space, and the conductors are connected to the metal frame.

2. The continuous anode according to claim 1, wherein the total volume of the expansion space accounts for 5 to 21% of the volume of the conductor; Preferably, the total volume of the expansion space accounts for 8.9-14.3% of the volume of the conductor.

3. The continuous anode according to claim 1, wherein the inner wall surface of the metal frame is connected to a head, and the conductor is connected to the head; Preferably, the tilt head is provided with at least one plug-in portion, and the conductor is connected to the tilt head by being inserted into the plug-in portion. 4 . The continuous anode according to claim 1 , wherein the expansion space is filled with a heat shrinkable material, and / or the opening of the expansion space is sealed with a baffle.

5. The continuous anode according to claim 1, wherein the metal frame has a power input surface and a power output surface, and the power input surface and the power output surface are arranged in a relative spatial position relationship; Conductors are respectively connected to the power input surface and the power output surface of the metal frame.

6. The continuous anode according to claim 5, wherein a plurality of connecting busbars are disposed in the metal frame, one end of the connecting busbars is connected to the power input surface of the metal frame, and the other end is connected to the power output surface of the metal frame; Or a connecting busbar is connected between the conductors of the power input surface and the power output surface.

7. The continuous anode according to claim 5, wherein the connecting busbar comprises a first rigid busbar, a second rigid busbar and a soft belt, and a tightening mechanism is arranged between the first rigid busbar and the second rigid busbar, and the tightening mechanism applies a pre-tightening force to the first rigid busbar and the second rigid busbar in the axial direction, so that: the first rigid busbar forms a continuous contact connection with the power input surface of the metal frame; the second rigid busbar forms a continuous contact connection with the power output end surface of the metal frame; and the two ends of the soft belt are respectively connected to the first rigid busbar and the second rigid busbar. 8 . The continuous anode according to claim 7 , wherein the flexible strip has a preset deformation margin to accommodate relative displacement between the metal frame and the first and second rigid busbars.

9. The method for producing the continuous anode according to any one of claims 1 to 8, comprising: The power input panel and the power output panel of the metal frame are obtained by mold casting; The metal frame is formed by connecting the power input panel and the power output panel of the metal frame with side panels; Connecting conductors with expansion holes to the power input panel and the power output panel respectively; Filling carbon material in the metal frame and between the conductors; When the conductor is electrified, the carbon material is converted into a carbonized body under the action of the resistance heat of the conductor, and is integrated with the metal frame and the conductor to form a continuous anode.

10. Aluminum electrolytic cell, including: electrolytic cell body; a cathode disposed at the bottom of the electrolytic cell body; And the continuous anode according to any one of claims 1 to 8 installed on the electrolytic cell body, wherein the continuous anode and the cathode form an electrical connection path through the electrolyte and / or aluminum liquid.

Images