A Smart Management System for a 600KA Large Electrolyzer

Abstract

This application relates to the field of intelligent factory management technology, specifically to a smart management system for a 600KA large-scale electrolytic cell. The system includes: an electrolytic cell temperature monitoring system, an electrolytic cell insulation diagnostic system, an intelligent aluminum tapping system, an online current distribution monitoring system, a digital control system, and a digital twin system. This smart management system enables comprehensive digital management of the 600KA large-scale electrolytic cell, allowing managers to quickly grasp the production operation status, achieving seamless integration between the production environment and information systems. It significantly improves managers' on-site perception and monitoring capabilities and precise management capabilities, helping enterprises improve production efficiency, reduce production failures, lower employee workload, improve the employee working environment, and gradually achieve less-staffed or even unmanned production.

Description

Technical Field

[0001] This application relates to the field of intelligent factory management technology, specifically to an intelligent management system for a 600KA large-scale electrolytic cell. Background Technology

[0002] The statements in this section are merely to provide background information related to the technical solutions of this application to aid understanding, and do not necessarily constitute prior art for the technical solutions of this application.

[0003] The electrolytic aluminum industry is a typical high-energy-consuming industry, accounting for approximately 6% of the nation's total electricity consumption. With increasing national control over energy, environmental protection, and carbon emissions, and with increasingly stringent policies, electrolytic aluminum enterprises not only face the risks of rising energy and carbon emission costs and reduced profitability, but also the risk of closure and elimination. Therefore, it is necessary to systematically manage key data in the electrolytic aluminum production process to comprehensively and effectively reduce energy and raw material consumption, improve production efficiency, and lower production costs.

[0004] For 600KA large electrolytic cells, the electrochemical reactions are complex, there are few operating condition monitoring parameters, and the production equipment is greatly affected by environmental factors such as high magnetic fields and high temperatures. Traditional information acquisition equipment or methods have poor accuracy, short lifespan, and require a lot of manual intervention, which greatly affects the accuracy and real-time performance of parameter acquisition. They cannot provide comprehensive and timely operating status, operation information, and production management information for production operation, which brings challenges to the operation and management of electrolytic cells. Summary of the Invention

[0005] To achieve systematic and intelligent management of 600KA large-scale electrolytic cells, one aspect of this application provides a smart management system for 600KA large-scale electrolytic cells, which includes: an electrolytic cell temperature monitoring system, an electrolytic cell insulation diagnosis system, an electrolytic cell intelligent aluminum tapping system, an electrolytic cell online current distribution monitoring system, an electrolytic cell digital control system, and an electrolytic cell digital twin system.

[0006] The electrolytic cell temperature monitoring system includes a cell bottom temperature sensor, a temperature data processing device, and a temperature anomaly alarm device. The temperature data processing device processes the temperature data collected by the cell bottom temperature sensor and instructs the temperature anomaly alarm device to sound an alarm when there is an anomaly in the temperature data.

[0007] The electrolytic cell insulation diagnostic system includes multiple voltmeters for measuring the voltage of each of multiple electrolytic cells, a voltage data processing and analysis device, and an insulation abnormality alarm device. The voltage data processing and analysis device processes and analyzes the voltage data collected by the multiple voltmeters, and instructs the insulation abnormality alarm device to sound an alarm when the voltage data is abnormal. The processing and analysis of the voltage data collected by the multiple voltmeters includes: analyzing the voltage difference between multiple pairs of electrolytic cells; if the voltage difference between at least one pair of electrolytic cells is greater than a predetermined threshold, it is determined that the voltage data is abnormal. Each pair of electrolytic cells is symmetrical about a central electrolytic cell, which is a grounded electrolytic cell located in the middle of the electrolytic cell workshop.

[0008] The intelligent aluminum tapping system for the electrolytic cell includes an anode control system for the electrolytic cell and a voltmeter for measuring the voltage of the electrolytic cell. When aluminum tapping is completed, the anode control system controls the anode of the electrolytic cell to drop according to the voltage data collected by the voltmeter, so as to reduce the voltage of the electrolytic cell.

[0009] The online monitoring system for current distribution in the electrolytic cell includes multiple cathode sensing rings, multiple anode sensing rings, multiple cathode sub-distribution boxes connected to the multiple cathode sensing rings, multiple anode sub-distribution boxes connected to the multiple anode sensing rings, a current data processing and analysis device for receiving and processing current data from the cathode sub-distribution boxes and anode sub-distribution boxes, and a display screen for presenting the measurement and analysis results of the current.

[0010] The electrolytic cell digital management and control system includes electrolytic cell production and operation stage data acquisition equipment and electrolytic cell management and control equipment. The electrolytic cell production and operation stage data acquisition equipment is used to collect production and operation stage data of each electrolytic cell, and the electrolytic cell management and control equipment is used to analyze the production and operation stage data and provide solutions for electrolytic cells with poor operating conditions.

[0011] In one embodiment, in the electrolytic cell insulation diagnostic system, when an abnormality is detected in the voltage data, the voltage data processing and analysis device analyzes the voltage distribution characteristics of the electrolytic cells in the entire workshop based on the voltage data collected by the multiple voltmeters, and identifies electrolytic cells that may have insulation abnormalities.

[0012] In one embodiment, analyzing the voltage distribution characteristics of the electrolytic cells in the entire workshop includes comparing the voltage distribution characteristics with each voltage distribution characteristic in a pre-established electrolytic cell voltage distribution characteristic library, and determining electrolytic cells that may have insulation abnormalities based on the comparison results.

[0013] In one embodiment, in the intelligent aluminum tapping system of the electrolytic cell, the anode control system of the electrolytic cell determines the magnitude of the anode drop based on the voltage data collected by the voltmeter.

[0014] In one embodiment, in the intelligent aluminum tapping system of the electrolytic cell, the anode control system of the electrolytic cell receives real-time voltage data collected by a voltmeter during the process of controlling the descent of the anode of the electrolytic cell, and stops the anode descent when the real-time voltage data meets the requirements.

[0015] In one embodiment, the plurality of cathode sensing rings are disposed in the cathode portion of the electrolytic cell for measuring the cathode current distribution; the plurality of anode sensing rings are disposed in the anode portion of the electrolytic cell for measuring the anode current distribution; the plurality of cathode sub-distribution boxes are respectively connected to the plurality of cathode sensing rings via sensing ring tail wires for collecting and transmitting the current data measured by the cathode sensing rings; the plurality of anode sub-distribution boxes are respectively connected to the plurality of anode sensing rings via sensing ring tail wires for collecting and transmitting the current data measured by the anode sensing rings; each of the plurality of cathode sensing rings and the plurality of anode sensing rings includes a measuring head and a sensing optical fiber installed in the measuring head.

[0016] In one embodiment, the plurality of cathode sensing rings include a plurality of cathode sensing rings respectively disposed on a plurality of cathode pillars, a plurality of cathode sensing rings respectively disposed on a plurality of cathode busbars, a plurality of cathode sensing rings respectively disposed on a plurality of cathode steel bars, and a plurality of cathode sensing rings respectively disposed on a plurality of cathode flexible strips; the plurality of anode sensing rings include a plurality of anode sensing rings respectively disposed on a plurality of anode pillars, a plurality of anode sensing rings respectively disposed on a plurality of transverse anode busbars, a plurality of anode sensing rings respectively disposed on a plurality of anode busbar crossbars, and a plurality of anode sensing rings respectively disposed on a plurality of anode guide rods.

[0017] In one embodiment, the current data processing and analysis device processes and analyzes current data including any one or more of the following:

[0018] The current data is compared with preset reference current data for the electrolytic cell to determine whether there is an abnormality in the electrolytic cell. The preset reference current data includes preset reference current data for each of the plurality of cathode sensing rings and the plurality of anode sensing rings; and / or

[0019] The current data is compared with the current expected current data of the electrolytic cell to determine whether there is an abnormality in the electrolytic cell. The current expected current data of the electrolytic cell includes the current expected current data of each of the plurality of cathode sensing rings and the plurality of anode sensing rings. The current expected current data of the electrolytic cell is determined by: obtaining preset reference current data for the electrolytic cell, the preset reference current data including preset reference current data for each of the plurality of cathode sensing rings and the plurality of anode sensing rings; collecting production operation stage data of the electrolytic cell, the production operation stage data including the cumulative operating time, voltage, aluminum level, electrolyte parameters, and cell temperature of the electrolytic cell; determining the current expected current data of the electrolytic cell based on the preset reference current data, the production operation stage data, and the position of each of the plurality of cathode sensing rings and the plurality of anode sensing rings; and / or

[0020] Extract two or more data points that are correlated with each other from the current data, wherein the two or more data points are subject to preset constraints; analyze the two or more data points to determine whether they satisfy the constraints; if they do not satisfy the constraints, determine that the electrolytic cell is abnormal.

[0021] In one embodiment, the production operation stage data comes from the electrolytic cell production operation stage data acquisition device in the electrolytic cell digital control system.

[0022] In one embodiment, the functions of the electrolytic cell control equipment in the digital control system for electrolytic cells further include data query, abnormal cell management, overhaul cell management, data statistical analysis, and trend query.

[0023] The intelligent management system for the 600KA large electrolytic cell of this invention implements various subsystems for electrolytic cell management and integrates these subsystems into a complete organic whole, achieving comprehensive digital management of the 600KA large electrolytic cell. This intelligent management system enables managers to quickly grasp the production operation status, achieves seamless integration between the production environment and the information system, significantly improves managers' on-site perception and monitoring capabilities and precise management capabilities, and can help enterprises improve production efficiency, reduce production failures, reduce employee labor intensity, improve the employee working environment, and gradually achieve minimally staffed or even unmanned production sites. Attached Figure Description

[0024] The embodiments of the present invention will be further described below with reference to the accompanying drawings, wherein:

[0025] Figure 1 A smart management system for a 600KA large-scale electrolytic cell according to one embodiment is shown;

[0026] Figure 2 An electrolytic cell insulation diagnostic system according to one embodiment is shown;

[0027] Figure 3 An online monitoring system for current distribution in an electrolyzer is shown according to one embodiment. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0029] Figure 1 A 600KA large-scale electrolytic cell intelligent management system according to one embodiment is shown, which includes six subsystems: an electrolytic cell temperature monitoring system, an electrolytic cell insulation diagnosis system, an electrolytic cell intelligent aluminum tapping system, an electrolytic cell current distribution online monitoring system, an electrolytic cell digital control system, and an electrolytic cell digital twin system. The six subsystems included in the 600KA large-scale electrolytic cell intelligent management system are described in detail below.

[0030] (1) Electrolytic cell temperature monitoring system

[0031] The electrolytic cell temperature monitoring system integrates a cell bottom temperature sensor, temperature data processing equipment, and a temperature anomaly alarm device. The temperature data processing equipment processes the temperature data collected by the cell bottom temperature sensor and instructs the temperature anomaly alarm device to sound an alarm when abnormal temperature data is detected. Temperature sensors can be installed at selected locations on the cathode steel rods or side steel plates of a 600KA large electrolytic cell, enabling real-time and accurate monitoring of the cell bottom temperature and completing the real-time cell bottom temperature monitoring function adapted to 600KA large electrolytic cells.

[0032] In one embodiment, the bottom temperature sensor can be a wireless temperature sensor. The temperature data collected by the bottom temperature sensor can be wirelessly transmitted to a temperature data processing device. The temperature data processing device processes and analyzes the received temperature data to determine if there are any anomalies. When an anomaly is detected, the temperature data processing device can instruct a temperature anomaly alarm device to sound an alarm. Multiple temperature anomaly alarm devices can be deployed at the electrolytic cell site for rapid response by on-site personnel, or deployed in the control room to ensure that control room management personnel can understand the situation in real time and make decisions. The temperature anomaly alarm devices can use various feasible methods such as sound, light, and electricity to sound alarms, and can employ different alarm methods for different types of temperature anomalies or their severity to ensure effective information transmission and timely handling of emergencies.

[0033] (2) Electrolytic cell insulation diagnostic system

[0034] The electrolytic cell insulation diagnostic system detects the insulation status of each electrolytic cell to ground by collecting and analyzing voltage data. When an insulation failure to ground occurs, an alarm is triggered. This system replaces the traditional method of relying on manual experience, resolving issues such as grounding, current leakage, and zero-potential drift caused by damaged insulation or metal objects left over from operations. These issues also contribute to operator safety, structural corrosion at the leakage point, and current wastage.

[0035] In an electrolytic cell workshop, there are typically many electrolytic cells arranged side by side. The common practice is to ground the central electrolytic cell (also called a grounded electrolytic cell), with its voltage at zero. The voltage of the electrolytic cells on either side of the central electrolytic cell gradually increases, with the voltage higher for cells farther from the central cell. Under normal circumstances, two electrolytic cells symmetrical about the central electrolytic cell (i.e., these two electrolytic cells are located on either side of the central electrolytic cell and are spaced the same number of cells apart from it) have essentially the same voltage. For example, the first electrolytic cell on one side of the central electrolytic cell has essentially the same voltage as the first electrolytic cell on the other side, the second electrolytic cell on one side of the central electrolytic cell has essentially the same voltage as the second electrolytic cell on the other side, and so on.

[0036] If one of the electrolytic cells in the workshop, other than the intermediate electrolytic cell, is accidentally grounded (i.e., an insulation failure occurs), the voltage of that electrolytic cell will drop significantly (to zero). Furthermore, because of the accidental grounding of that electrolytic cell, it will affect the voltage of other electrolytic cells, ultimately resulting in a large voltage difference between the two electrolytic cells that are symmetrical about the intermediate electrolytic cell.

[0037] Figure 2 An electrolytic cell insulation diagnostic system according to one embodiment is illustrated. In this embodiment, the electrolytic cell insulation diagnostic system includes multiple voltmeters for measuring the voltage of each of a plurality of electrolytic cells, a voltage data processing and analysis device, and an insulation anomaly alarm device. The voltage data processing and analysis device processes and analyzes the voltage data collected by the voltmeters and instructs the insulation anomaly alarm device to sound an alarm when an anomaly is found in the voltage data. The voltage data processing and analysis device processes and analyzes the voltage data collected by the voltmeters, including: analyzing the voltage differences between multiple pairs of electrolytic cells, wherein each pair of electrolytic cells is symmetrical about a central electrolytic cell, the central electrolytic cell being a grounded electrolytic cell located in the center of the electrolytic cell workshop; if the voltage difference between at least one pair of electrolytic cells is greater than a predetermined threshold, then an anomaly is determined in the voltage data.

[0038] A suitable predetermined threshold can be set according to the actual conditions of the electrolytic cell workshop. In one embodiment, the predetermined threshold is a value between 30-50V.

[0039] When insulation abnormalities occur in different electrolytic cells, they will have different effects on the voltage of the electrolytic cells throughout the workshop, resulting in different voltage distribution characteristics. For example, if the first electrolytic cell on one side of the middle electrolytic cell experiences an insulation abnormality, the voltage of the electrolytic cells throughout the workshop will exhibit a first distribution characteristic; if the second electrolytic cell on one side of the middle electrolytic cell experiences an insulation abnormality, the voltage of the electrolytic cells throughout the workshop will exhibit a second distribution characteristic; and if the first electrolytic cell on the other side of the middle electrolytic cell experiences an insulation abnormality, the voltage of the electrolytic cells throughout the workshop will exhibit a third distribution characteristic. Therefore, in one embodiment, after determining that there is an abnormality in the voltage data, the voltage data processing and analysis device can further analyze the voltage distribution characteristics of the electrolytic cells throughout the workshop based on the voltage data collected by the multiple voltmeters, and determine the electrolytic cells that may have insulation abnormalities.

[0040] In one embodiment, corresponding voltage distribution characteristics can be established for various possible insulation abnormalities in electrolytic cells, and these voltage distribution characteristics can be used to form an electrolytic cell voltage distribution characteristic library. Thus, when the voltage data processing and analysis equipment analyzes the voltage distribution characteristics of electrolytic cells throughout the workshop, it can compare these voltage distribution characteristics with the various voltage distribution characteristics in the pre-established electrolytic cell voltage distribution characteristic library, and determine the electrolytic cells that may have insulation abnormalities based on the comparison results.

[0041] (3) Intelligent aluminum tapping system for electrolytic cells

[0042] During aluminum tapping in an electrolytic cell, the decrease in molten aluminum leads to a rise in the cell voltage, which negatively impacts the cell's efficient operation. To overcome this adverse effect, an intelligent aluminum tapping system for electrolytic cells has been implemented. This system includes an anode control system for the electrolytic cell and a voltmeter for measuring the cell voltage. The anode control system receives voltage data collected by the voltmeter and performs corresponding operations based on this data. In one embodiment, the voltmeter may be the same as that used in an electrolytic cell insulation diagnostic system; in another embodiment, the voltmeter may be a different type of voltmeter.

[0043] When aluminum tapping is complete in the electrolytic cell, the anode control system can control the descent of the anode based on voltage data collected by a voltmeter, allowing more of the anode to enter the electrolyte melt, thereby reducing the electrolytic cell voltage. In one embodiment, the anode control system determines the magnitude of the anode descent based on the voltage data collected by the voltmeter. In another embodiment, during the anode descent control process, the system can receive real-time voltage data collected by the voltmeter and stop the anode descent when the real-time voltage data meets the requirements.

[0044] (4) Online monitoring system for current distribution in electrolytic cells

[0045] Figure 3 An online monitoring system for current distribution in an electrolytic cell according to one embodiment is shown. The system includes multiple cathode sensing rings, multiple anode sensing rings, multiple cathode sub-distribution boxes, multiple anode sub-distribution boxes, current data processing and analysis equipment, and a display screen.

[0046] Multiple cathode sensing rings are disposed in the cathode portion of the electrolytic cell for measuring the cathode current distribution. Multiple anode sensing rings are disposed in the anode portion of the electrolytic cell for measuring the anode current distribution. The cathode and anode sensing rings can monitor the current in real time. Each of the cathode and anode sensing rings includes a measuring head and a sensing optical fiber installed within the measuring head. In one embodiment, both the cathode and anode sensing rings measure current based on the Faraday magneto-optical effect, enabling rapid and accurate measurement of large currents. In one embodiment, the measuring heads of the cathode and anode sensing rings are clamp-shaped structures. In one embodiment, the clamp-shaped structure of the measuring head has a handle, which can be pulled to separate the clamp-shaped structure, and the clamp-shaped structure automatically springs back after the handle is released, thereby allowing for rapid installation and deployment of the measuring head. In one embodiment, the measuring head has the ability to resist stray magnetic field interference, enabling it to measure only the conductor current passing through the measuring head, unaffected by other stray magnetic fields.

[0047] Multiple cathode sub-distribution boxes are connected to the multiple cathode sensing rings via sensing ring tail wires, for collecting and transmitting current data measured by the cathode sensing rings; multiple anode sub-distribution boxes are connected to the multiple anode sensing rings via sensing ring tail wires, for collecting and transmitting current data measured by the anode sensing rings.

[0048] The current data processing and analysis equipment is used to receive current data from the cathode sub-distribution box and the anode sub-distribution box, and to process and analyze the current data in real time to determine whether there is any abnormality in the electrolytic cell.

[0049] The display screen is connected to the current data processing and analysis equipment to display the measurement and analysis results of the anode and cathode currents of the electrolytic cell. The display screen can be located near the electrolytic cell for easy access by on-site personnel to view the measurement and analysis results, or it can be located in a remote location, such as a central control room, for remote monitoring personnel to monitor the electrolytic cell's operating status in real time. In one embodiment, multiple display screens can be located in multiple different locations.

[0050] In one embodiment, the plurality of anode sensing rings include a plurality of anode sensing rings respectively disposed on a plurality of anode pillars, a plurality of anode sensing rings respectively disposed on a plurality of transverse anode busbars, a plurality of anode sensing rings respectively disposed on a plurality of anode busbar cross links, and a plurality of anode sensing rings respectively disposed on a plurality of anode guide rods; the plurality of cathode sensing rings include a plurality of cathode sensing rings respectively disposed on a plurality of cathode pillars, a plurality of cathode sensing rings respectively disposed on a plurality of cathode busbars, a plurality of cathode sensing rings respectively disposed on a plurality of cathode steel rods, and a plurality of cathode sensing rings respectively disposed on a plurality of cathode flexible strips. In this way, the current distribution throughout the entire electrolytic cell can be comprehensively detected, providing a solid foundation for subsequent data processing and analysis.

[0051] After the current data of the electrolytic cell is collected through the cathode sensing ring and the anode sensing ring, the current data is sent to the current data processing and analysis equipment through their respective cathode sub-distribution boxes or anode sub-distribution boxes. The current data processing and analysis equipment can then process and analyze the current data to determine whether there is any abnormality in the electrolytic cell.

[0052] In one embodiment, the current data processing and analysis device can compare the collected current data with a preset reference current data for the electrolytic cell to determine whether there is an abnormality in the electrolytic cell. The preset reference current data includes preset reference current data for each of the plurality of cathode sensing rings and the plurality of anode sensing rings.

[0053] The reference current data can be determined through various feasible methods. In one embodiment, the reference current data for each of the cathode and anode sensing rings can be determined through theoretical calculations based on the actual conditions of the electrolyzer. In another embodiment, the current data can be measured when the electrolyzer is in good operating condition (e.g., when a new electrolyzer is officially started up), and this current data can be used as the reference current data. In yet another embodiment, the reference current data for each of the cathode and anode sensing rings can be determined empirically.

[0054] The preset reference current data for the electrolyzer can be a specific value or a range of values. When the reference current data is a specific value, it can be determined whether the deviation between the real-time detected current data and the reference current data is within a predetermined threshold. If not, the electrolyzer is considered to be malfunctioning. When the reference current data is a range of values, it can be determined whether the real-time detected current data falls within that range. If not, the electrolyzer is considered to be malfunctioning.

[0055] After setting a reference current for the electrolyzer, as the cell age increases (i.e., the cumulative operating time becomes longer), or as the cell's operating conditions change (such as voltage variations, aluminum level changes, electrolyte parameter changes, and cell temperature changes), the normal operating current or expected operating current at various points in the cell will change. In other words, even if the electrolyzer has no abnormalities or malfunctions, its normal operating current or expected operating current may have deviated from the reference current data. Comparing the collected current data with the preset reference current data in this case may produce erroneous analysis results.

[0056] In one embodiment, the current data processing and analysis device can determine the expected current data of the electrolytic cell under its current operating state, and compare the collected current data with the current expected current data of the electrolytic cell to determine whether there is an abnormality in the electrolytic cell. The current expected current data of the electrolytic cell includes the current expected current data of each of the plurality of cathode sensing rings and the plurality of anode sensing rings.

[0057] The desired current data for an electrolyzer in its current operating state can be determined by considering data from its production and operation phases. A method for determining the current desired current data for an electrolyzer, according to one embodiment, includes the following steps:

[0058] Step 1: Obtain the preset reference current data for the electrolytic cell. The preset reference current data includes preset reference current data for each of the plurality of cathode sensing rings and the plurality of anode sensing rings.

[0059] Step 2: Collect production and operation data of the electrolytic cell. The production and operation data includes the cumulative operating time, voltage, aluminum level, electrolyte parameters, and cell temperature of the electrolytic cell.

[0060] As the cumulative operating time of an electrolytic cell increases, some of its components gradually age, affecting the current distribution within the cell to some extent. During the operation of the electrolytic cell, its operating parameters, such as voltage (V), aluminum level (cm), electrolyte parameters (electrolyte temperature, density, molecular ratio), and cell temperature (°C), also change, influencing the current distribution. Therefore, it is possible to collect production operation data from the electrolytic cell and consider this data as a factor in determining the current desired current data. In one embodiment, the production operation data can come from the electrolytic cell production operation data acquisition device within the electrolytic cell digital control system described below.

[0061] Step 3: Determine the current desired current data of the electrolytic cell based on the preset reference current data, the production operation stage data, and the position of each of the plurality of cathode sensing rings and the plurality of anode sensing rings.

[0062] In one embodiment, the influence of production operation data of the electrolyzer on the current at various current detection locations (i.e., the locations of the cathode and anode sensing rings) of the electrolyzer can be analyzed to adjust the preset reference current data accordingly, thereby determining the current expected data for the electrolyzer. The impact of data from various production operation stages on the current distribution of the electrolyzer can be measured through theoretical calculations combined with experience. The current expected current data for the electrolyzer can be a specific value or a range of values.

[0063] In one embodiment, two or more current data points with a correlation can also be analyzed. For example, the currents of multiple anode rods connected to the same transverse anode busbar, the currents of two transverse anode buses and the currents of the anode busbar cross links between them, and the currents of a transverse anode busbar and the currents of all anode rods connected to that transverse anode busbar. Because these current data points are logically correlated, corresponding constraints can be preset for them. For example, constraints regarding the differences between the currents of multiple anode rods connected to the same transverse anode busbar, and constraints regarding the differences between the current of the transverse anode busbar and the sum of the currents of all anode rods connected to that transverse anode busbar.

[0064] A method for real-time processing and analysis of current data using a current data processing and analysis device according to one embodiment includes the following steps:

[0065] Step 1: Extract two or more data points that are correlated with each other from the current data, and the two or more data points are subject to preset constraints.

[0066] Step 2: Analyze the two or more data points and determine whether they satisfy the constraints.

[0067] Step 3: If the condition is not met, it is determined that the electrolytic cell is abnormal.

[0068] In one embodiment, after determining that there is an abnormality in the electrolytic cell, the current data processing and analysis device can analyze and determine the cause of the abnormality based on the specific circumstances of the abnormality (e.g., which sensor rings or which sensor rings detected the abnormal current data, the severity of the abnormality, etc.) and provide corresponding operation suggestions.

[0069] In one embodiment, when the current data processing and analysis equipment detects that the anode current is too low, it can instruct the adjustment of the anode height in the electrolytic cell, causing the anode to descend and allowing more of the anode to enter the electrolyte melt. The deeper the anode penetrates, the greater the current, and vice versa. This prevents anode detachment failures caused by abnormal anode current, improves the current efficiency of the 600KA large electrolytic cell, and reduces anode consumption.

[0070] In one embodiment, the online monitoring system for current distribution in the electrolytic cell further includes an alarm device connected to the current data processing and analysis equipment. When the current data processing and analysis equipment processes and analyzes the current data and determines that an abnormality exists in the electrolytic cell, it can instruct the alarm device to sound an alarm. There can be multiple alarm devices, which can be located at the electrolytic cell site or in the central control room. The alarm devices can use various feasible methods such as sound, light, and electricity to sound an alarm, and can employ different alarm methods according to different types or degrees of abnormality.

[0071] (5) Digital control system for electrolytic cells

[0072] The digital control system for electrolytic cells includes data acquisition equipment for the production and operation phases of electrolytic cells and electrolytic cell control equipment. The data acquisition equipment for the production and operation phases of electrolytic cells is used to collect data from each electrolytic cell during the production and operation phases. The electrolytic cell control equipment is used to analyze the data from each electrolytic cell during the production and operation phases, evaluate the cells as excellent, medium, and poor, analyze the main influencing parameters of poor cells, and provide solutions.

[0073] In one embodiment, the functions of the electrolytic cell control equipment also include data query, abnormal cell management, overhaul cell management, data (process data, technical parameters, technical indicators, etc.) statistical analysis, trend query, etc., thereby completing the digital control of the electrolytic cell.

[0074] (6) Electrolytic Cell Digital Twin System

[0075] The electrolytic cell digital twin system utilizes advanced 3D scene technology, with the 600KA large-scale electrolytic cell process and production data as the core and factory operations as the link, to achieve a step-by-step digital twin of the 600KA large-scale electrolytic cell production series of plants, production lines, and equipment. It integrates data and information between various process nodes to comprehensively monitor and analyze the production process. At the same time, it integrates data resources from other information systems in the plant to realize a digital twin workshop, providing data support for the production management and decision-making of the electrolytic cell.

[0076] The intelligent management system for the 600KA large electrolytic cell of this invention implements various subsystems for electrolytic cell management and integrates them into a complete organic whole, achieving comprehensive digital management of the 600KA large electrolytic cell. This intelligent management system enables managers to quickly grasp the production operation status, achieves seamless integration between the production environment and the information system, significantly improves managers' on-site perception and monitoring capabilities and precise management capabilities, and can help enterprises reduce energy consumption, improve current efficiency, extend electrolytic cell life, increase production efficiency, reduce production failures, reduce employee labor intensity, improve the employee working environment, and gradually achieve minimally staffed or even unmanned production sites.

[0077] References to “various embodiments,” “some embodiments,” “one embodiment,” or “embodiment” throughout this document refer to specific features, structures, or properties described in connection with said embodiments that are included in at least one embodiment. Therefore, the appearance of phrases such as “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” throughout this document does not necessarily refer to the same embodiment. Furthermore, specific features, structures, or properties can be combined in any suitable manner in one or more embodiments. Therefore, specific features, structures, or properties shown or described in connection with one embodiment can be combined, in whole or in part, with features, structures, or properties of one or more other embodiments without limitation, provided that such combination is not illogical or inoperable. Expressions such as “according to A,” “based on A,” “by A,” or “using A” appearing throughout this document are non-exclusive; that is, “according to A” can cover “according to A only” or “according to A and B,” unless specifically stated otherwise. In this application, some illustrative operational steps are described in a certain order for clarity, but those skilled in the art will understand that each of these operational steps is not essential, and some steps can be omitted or replaced by others. These steps do not necessarily have to be performed sequentially as shown. Instead, some of these steps can be performed in different orders or in parallel as needed, as long as the new execution method is not illogical or ineffective.

[0078] The foregoing descriptions have outlined some exemplary embodiments of the present invention. It is understood that these embodiments are merely illustrative and do not constitute a limitation on the scope of protection of the present invention. Features in these embodiments can be rearranged in suitable ways, and the resulting solutions remain within the scope of protection claimed by the present invention. All other embodiments obtained by those skilled in the art based on the foregoing embodiments without inventive effort, i.e., all modifications, equivalent substitutions, and improvements made within the spirit and principles of this application, fall within the scope of protection claimed by the present invention.

Claims

1. A smart management system for a 600KA large-scale electrolytic cell, characterized in that, include: Electrolytic cell temperature monitoring system, electrolytic cell insulation diagnostic system, electrolytic cell intelligent aluminum tapping system, electrolytic cell online current distribution monitoring system, electrolytic cell digital control system, electrolytic cell digital twin system. The electrolytic cell temperature monitoring system includes a cell bottom temperature sensor, a temperature data processing device, and a temperature anomaly alarm device. The temperature data processing device processes the temperature data collected by the cell bottom temperature sensor and instructs the temperature anomaly alarm device to sound an alarm when there is an anomaly in the temperature data. The electrolytic cell insulation diagnostic system includes multiple voltmeters for measuring the voltage of each of multiple electrolytic cells, a voltage data processing and analysis device, and an insulation abnormality alarm device. The voltage data processing and analysis device processes and analyzes the voltage data collected by the multiple voltmeters, and instructs the insulation abnormality alarm device to sound an alarm when the voltage data is abnormal. The processing and analysis of the voltage data collected by the multiple voltmeters includes: analyzing the voltage difference between multiple pairs of electrolytic cells; if the voltage difference between at least one pair of electrolytic cells is greater than a predetermined threshold, it is determined that the voltage data is abnormal. Each pair of electrolytic cells is symmetrical about a central electrolytic cell, which is a grounded electrolytic cell located in the middle of the electrolytic cell workshop. The intelligent aluminum tapping system for the electrolytic cell includes an anode control system for the electrolytic cell and a voltmeter for measuring the voltage of the electrolytic cell. When aluminum tapping is completed, the anode control system controls the anode of the electrolytic cell to drop according to the voltage data collected by the voltmeter, so as to reduce the voltage of the electrolytic cell. The online monitoring system for current distribution in the electrolytic cell includes multiple cathode sensing rings, multiple anode sensing rings, multiple cathode sub-distribution boxes connected to the multiple cathode sensing rings, multiple anode sub-distribution boxes connected to the multiple anode sensing rings, a current data processing and analysis device for receiving and processing current data from the cathode sub-distribution boxes and anode sub-distribution boxes, and a display screen for presenting the measurement and analysis results of the current. The electrolytic cell digital management and control system includes electrolytic cell production and operation stage data acquisition equipment and electrolytic cell management and control equipment. The electrolytic cell production and operation stage data acquisition equipment is used to collect production and operation stage data of each electrolytic cell, and the electrolytic cell management and control equipment is used to analyze the production and operation stage data and provide solutions for electrolytic cells with poor operating conditions.

2. The intelligent management system for a 600KA large-scale electrolytic cell according to claim 1, wherein, In the electrolytic cell insulation diagnostic system, when an abnormality is detected in the voltage data, the voltage data processing and analysis equipment analyzes the voltage distribution characteristics of the electrolytic cells in the entire workshop based on the voltage data collected by the multiple voltmeters, and identifies electrolytic cells that may have insulation abnormalities.

3. The intelligent management system for a 600KA large-scale electrolytic cell according to claim 2, wherein, The analysis of the voltage distribution characteristics of the electrolytic cells in the entire workshop includes comparing the voltage distribution characteristics with each voltage distribution characteristic in a pre-established electrolytic cell voltage distribution characteristic library, and judging electrolytic cells that may have insulation abnormalities based on the comparison results.

4. The intelligent management system for a 600KA large-scale electrolytic cell according to claim 1, wherein, In the intelligent aluminum tapping system of the electrolytic cell, the anode control system of the electrolytic cell determines the magnitude of the anode drop based on the voltage data collected by the voltmeter.

5. The intelligent management system for a 600KA large-scale electrolytic cell according to claim 1, wherein, In the intelligent aluminum tapping system of the electrolytic cell, the anode control system receives real-time voltage data collected by a voltmeter during the process of controlling the descent of the electrolytic cell anode, and stops the anode descent when the real-time voltage data meets the requirements.

6. The intelligent management system for a 600KA large-scale electrolytic cell according to claim 1, wherein, The plurality of cathode sensing rings are disposed in the cathode portion of the electrolytic cell and are used to measure the cathode current distribution. The plurality of anode sensing rings are disposed on the anode portion of the electrolytic cell and are used to measure the anode current distribution; The plurality of cathode sub-distribution boxes are respectively connected to the plurality of cathode sensing rings via sensing ring tail wires, for collecting and transmitting current data measured by the cathode sensing rings; The plurality of anode sub-distribution boxes are respectively connected to the plurality of anode sensing rings via sensing ring tail wires, for collecting and transmitting current data measured by the anode sensing rings; Each of the plurality of cathode sensing rings and the plurality of anode sensing rings includes a measuring head and a sensing optical fiber mounted within the measuring head.

7. The intelligent management system for a 600KA large-scale electrolytic cell according to claim 1, wherein, The plurality of cathode sensing rings include a plurality of cathode sensing rings respectively disposed on a plurality of cathode pillars, a plurality of cathode sensing rings respectively disposed on a plurality of cathode busbars, a plurality of cathode sensing rings respectively disposed on a plurality of cathode steel bars, and a plurality of cathode sensing rings respectively disposed on a plurality of cathode flexible strips. The plurality of anode sensing rings include a plurality of anode sensing rings respectively disposed on a plurality of anode columns, a plurality of anode sensing rings respectively disposed on a plurality of transverse anode busbars, a plurality of anode sensing rings respectively disposed on a plurality of transverse connecting rods of a plurality of anode busbars, and a plurality of anode sensing rings respectively disposed on a plurality of anode guide rods.

8. The intelligent management system for a 600KA large-scale electrolytic cell according to claim 1, wherein, The current data processing and analysis equipment processes and analyzes current data in the following ways: The current data is compared with preset reference current data for the electrolytic cell to determine whether there is an abnormality in the electrolytic cell. The preset reference current data includes preset reference current data for each of the plurality of cathode sensing rings and the plurality of anode sensing rings; and / or The current data is compared with the current expected current data of the electrolytic cell to determine whether there is an abnormality in the electrolytic cell. The current expected current data of the electrolytic cell includes the current expected current data of each of the plurality of cathode sensing rings and the plurality of anode sensing rings. The current expected current data of the electrolytic cell is determined by: obtaining preset reference current data for the electrolytic cell, the preset reference current data including preset reference current data for each of the plurality of cathode sensing rings and the plurality of anode sensing rings; collecting production operation stage data of the electrolytic cell, the production operation stage data including the cumulative operating time, voltage, aluminum level, electrolyte parameters, and cell temperature of the electrolytic cell; determining the current expected current data of the electrolytic cell based on the preset reference current data, the production operation stage data, and the position of each of the plurality of cathode sensing rings and the plurality of anode sensing rings; and / or Extract two or more data points that are correlated with each other from the current data, wherein the two or more data points are subject to preset constraints; analyze the two or more data points to determine whether they satisfy the constraints; if they do not satisfy the constraints, determine that the electrolytic cell is abnormal.

9. The intelligent management system for a 600KA large-scale electrolytic cell according to claim 8, wherein, The production operation stage data comes from the electrolytic cell production operation stage data acquisition equipment in the electrolytic cell digital management and control system.

10. The intelligent management system for a 600KA large-scale electrolytic cell according to claim 1, wherein, The functions of the electrolytic cell control equipment in the digital control system also include data query, abnormal cell management, overhaul cell management, data statistical analysis, and trend query.

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