A device for monitoring leakage of molten aluminum in a vacuum ladle liner

Abstract

The utility model relates to electrolytic aluminium production equipment safety monitoring technical field, and disclose a kind of vacuum ladle lining aluminium liquid leakage monitoring device, including vacuum ladle shell, detection component, power supply component, detection display component, grounding component, temperature monitoring component and alarm component, the vacuum ladle shell is provided with lining refractory layer in, the detection component includes alarm steel wire net and is additionally installed in the ladle probe of vacuum ladle shell bottom, ammeter continuous display current data, thermocouple temperature display screen device synchronous update temperature data, without operating personnel frequent handheld equipment patrol inspection, substantially reduce the workload and subjective error of artificial monitoring, alarm steel wire net and ladle probe adopt 304 stainless steel material, cooperate the high-temperature insulation layer of electric wire outside, can adapt to the high temperature of vacuum ladle, cold and hot alternate working condition, ensure that monitoring element is stable in long-term use Performance, data transmission is reliable, avoid monitoring interruption due to element damage.

Description

Technical Field

[0001] This utility model relates to the field of safety monitoring technology for electrolytic aluminum production equipment, and more specifically, to a device for monitoring leakage of molten aluminum lining in a vacuum ladle. Background Technology

[0002] In the normal production process of an aluminum electrolytic plant, the vacuum ladle is a core piece of equipment used for aluminum tapping and transporting molten aluminum, and its operational stability is directly related to production safety and efficiency. However, with the increasing frequency of use of the vacuum ladle, it is prone to multiple structural damage problems due to its long-term exposure to high-temperature molten aluminum and alternating hot and cold conditions: on the one hand, the bottom of the ladle is prone to deformation due to the long-term weight and high temperature of the molten aluminum; on the other hand, the inner refractory lining will gradually break down under repeated thermal shocks, and the ladle wall will also corrode due to the erosion of molten aluminum.

[0003] The aforementioned structural damage will directly cause molten aluminum to seep into the insulation layer of the ladle, leading to an abnormal increase in local temperature at the bottom and walls of the ladle, resulting in a reddish appearance. If this anomaly is not detected in time, molten aluminum will continue to leak, eventually causing a serious ladle leakage accident. This will not only result in molten aluminum loss and equipment damage, but may also threaten the personal safety of on-site operators and even interrupt the production process.

[0004] Currently, the industry primarily relies on manual inspections to monitor abnormal temperatures at the bottom and walls of vacuum ladles. Operators periodically check the surface temperature of the ladle using handheld infrared thermometers or thermal imagers. This method has significant limitations: First, manual monitoring cannot achieve 24-hour continuous coverage, resulting in monitoring gaps and the potential to miss early-stage temperature anomalies in molten aluminum leakage. Second, the accuracy of manual detection is greatly affected by factors such as operator experience, inspection angle, and environmental interference, leading to the risk of misjudgment or missed detection. Third, even when temperature anomalies are detected, the leakage is often already quite severe, leaving very little time for on-site emergency response and making it difficult to effectively prevent the accident from escalating. Utility Model Content

[0005] In order to overcome the shortcomings of the existing technology, this utility model provides a device for monitoring the leakage of aluminum liquid lining in a vacuum lifting ladle.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a vacuum ladle lining aluminum molten metal leakage monitoring device, comprising a vacuum ladle housing, a leakage alarm device, a detection component, a power supply component, a detection and display component, a grounding component, a temperature monitoring component, and an alarm component. The vacuum ladle housing is lined with a refractory layer. The leakage alarm device is installed on one outer wall of the vacuum ladle housing. The detection component includes an alarm wire mesh and a bottom probe installed at the bottom of the vacuum ladle housing. The alarm wire mesh and the bottom probe serve as two detection electrodes. The wire mesh is made of 304 stainless steel with a wire diameter of 1-1.5mm and a mesh size of 14*14mm. The bottom probe is made of 304 stainless steel with a diameter of 8-10mm. The power supply component is a portable power supply, which is electrically connected between the two detection electrodes to form a circuit. The detection and display component includes an ammeter connected in series in the circuit. The alarm component includes an audible and visual alarm device and a protective relay connected in series in the circuit. The audible and visual alarm device and the protective relay are electrically connected.

[0007] In a preferred embodiment of this invention, the grounding component is a grounding wire, one end of which is connected to the circuit, and the other end of which is grounded.

[0008] As a preferred technical solution of this utility model, the temperature monitoring component includes a thermocouple, a connecting wire, and a thermocouple temperature display device. The thermocouple includes a second temperature measuring end and a first temperature measuring end, which are respectively disposed at the bottom and wall of the vacuum lifting shell. The thermocouple is electrically connected to the thermocouple temperature display device through the connecting wire.

[0009] As a preferred embodiment of this utility model, the leak alarm device includes a leak alarm device housing, an ammeter installed inside the leak alarm device housing, a thermocouple temperature display device installed inside the leak alarm device housing, and the leak alarm device housing is located below the ammeter.

[0010] As a preferred embodiment of this utility model, the audible and visual alarm device is installed on the top of the leaky package alarm device, and the housing of the leaky package alarm device is also provided with a control cabinet door handle.

[0011] As a preferred embodiment of this utility model, the alarm wire mesh is embedded in the inner refractory lining layer, and the lead-out end of the alarm wire mesh is electrically connected to the mobile power supply, ammeter and protection relay through wires.

[0012] As a preferred embodiment of this utility model, the bottom probe is vertically mounted at the center of the bottom of the vacuum lifting shell.

[0013] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0014] 1. In this utility model, compared with the traditional method of "manually monitoring temperature with an infrared thermometer / thermal imager", this device realizes early warning of aluminum liquid leakage through leakage current monitoring. When the inner lining is just damaged and the aluminum liquid has not yet leaked in large quantities to cause the bottom / wall of the bag to turn red, the leakage current can trigger an audible and visual alarm, giving the operator sufficient time for emergency response, effectively eliminating the risk of "leaking bag accident caused by untimely detection", and significantly improving the safety factor of vacuum bag lifting operation.

[0015] 2. In this utility model, the device realizes fully automatic real-time monitoring of leakage current and lifting temperature: the ammeter continuously displays current data, and the thermocouple temperature display device synchronously updates temperature data. There is no need for operators to frequently hand-hold the device for inspection, which greatly reduces the workload of manual monitoring and subjective errors. The alarm wire mesh and the bottom probe of the package are made of 304 stainless steel, and together with the high-temperature resistant insulation layer on the outside of the wire, it can adapt to the high temperature and alternating hot and cold working conditions of vacuum lifting, ensuring the stable performance of the monitoring elements and reliable data transmission during long-term use, and avoiding monitoring interruption due to component damage.

[0016] 3. In this utility model, the leakage alarm device adopts an integrated design: the ammeter and thermocouple temperature display device are built into the housing of the leakage alarm device, and the audible and visual alarm device is installed on the top of the device. The operator can open the housing through the control cabinet door handle to inspect the internal components, adjust parameters, or replace parts (such as replacing the damaged protective relay). There is no need to operate multiple scattered parts separately, which significantly improves the convenience of operation and maintenance. The bottom probe of the bag is sealed to the bottom of the bag through a high-temperature resistant seal. The alarm wire mesh is embedded in the inner refractory layer, which does not affect the normal aluminum output and transfer function of the vacuum bag lifting, and can also prevent aluminum liquid from leaking from the component installation point, reduce the interference of the device on the original structure of the bag lifting, and ensure the normal operation efficiency of the bag lifting. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of this utility model;

[0018] Figure 2 This is a schematic diagram of the structure of the leaky package alarm device of this utility model;

[0019] Figure 3 This is the circuit diagram for the leak alarm of this utility model;

[0020] Figure 4 This is the circuit diagram of the thermocouple of this utility model.

[0021] In the diagram: 1. Vacuum lifting bag housing; 2. Inner refractory lining; 3. Alarm wire mesh; 4. Bag bottom probe; 5. Leakage alarm device; 6. Audible and visual alarm device; 7. Ammeter; 8. Thermocouple temperature display device; 9. Leakage alarm device housing; 10. Control cabinet door handle; 11. Grounding wire; 12. Protective relay; 13. Portable power supply; 14. First temperature measuring end; 15. Thermocouple; 16. Second temperature measuring end. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0023] like Figures 1 to 4 As shown, this utility model provides a vacuum ladle lining aluminum molten metal leakage monitoring device, including a vacuum ladle housing 1, a leakage alarm device 5, a detection component, a power supply component, a detection and display component, a grounding component, a temperature monitoring component, and an alarm component. The vacuum ladle housing 1 is lined with a refractory layer 2. The leakage alarm device 5 is installed on one outer wall of the vacuum ladle housing 1. The detection component includes an alarm wire mesh 3 and a bottom probe 4 installed at the bottom of the vacuum ladle housing 1. The alarm wire mesh 3 and the bottom probe 4 serve as two detection electrodes. The alarm wire mesh 3 is made of 304 stainless steel. The device is made of wire with a diameter of 1-1.5mm and a mesh size of 14*14mm. The bottom probe 4 is made of 304 stainless steel with a diameter of 8-10mm. The power supply component is a mobile power supply 13, which is electrically connected between the two probe electrodes to form a circuit. The detection and display component includes an ammeter 7, which is connected in series in the circuit to continuously measure and display the leakage current in the circuit. The alarm component includes an audible and visual alarm device 6 and a protective relay 12, which are connected in series in the circuit and electrically connected to each other.

[0024] In actual use, the alarm component also includes a comparator. The comparator is electrically connected to the ammeter 7 to obtain leakage current data. The protection relay 12 is electrically connected to the comparator. When the comparator detects that the leakage current exceeds the set protection value, the comparator flips and triggers the protection relay 12 to operate. After the protection relay 12 operates, it can drive the audible and visual alarm device 6 to emit an audible and visual alarm. The comparator is not shown in the figure.

[0025] The grounding component is grounding wire 11. One end of grounding wire 11 is connected to the circuit, and the other end of grounding wire 11 is grounded to ensure the safety of the circuit's power supply.

[0026] The temperature monitoring component includes a thermocouple 15, connecting wires, and a thermocouple temperature display device 8. The thermocouple 15 includes a second temperature measuring end 16 and a first temperature measuring end 14, which are respectively located at the bottom and wall of the vacuum lifting shell 1 to collect temperature data of the bottom and wall. The thermocouple 15 is electrically connected to the thermocouple temperature display device 8 via connecting wires, and the thermocouple temperature display device 8 is used to receive and display the temperature data collected by the thermocouple 15.

[0027] The leakage alarm device 5 includes a leakage alarm device housing 9, an ammeter 7 installed inside the leakage alarm device housing 9, and a thermocouple temperature display device 8 installed inside the leakage alarm device housing 9, with the leakage alarm device housing 9 located below the ammeter 7.

[0028] In actual use, an insulating plate is provided at the contact point between the housing 9 of the leak alarm device and the vacuum lifting housing 1 to achieve insulation isolation between the device housing and the package body.

[0029] The sound and light alarm device 6 is installed on the top of the leaky package alarm device 5. The housing 9 of the leaky package alarm device is also equipped with a control cabinet door handle 10, which makes it convenient for operators to open the housing 9 of the leaky package alarm device to inspect and maintain the internal components.

[0030] The alarm wire mesh 3 is embedded in the inner fire-resistant lining layer 2, and the lead-out end of the alarm wire mesh 3 is electrically connected to the mobile power supply 13, the ammeter 7 and the protection relay 12 through the wire. In actual use, the wire is wrapped with a high-temperature resistant insulation layer to adapt to the high-temperature working environment of vacuum lifting.

[0031] The bottom probe 4 is vertically installed at the center of the bottom of the vacuum lifting housing 1, and the bottom probe 4 and the bottom of the vacuum lifting housing 1 are sealed together by a high-temperature resistant sealant to prevent molten aluminum from leaking from the installation point of the bottom probe 4.

[0032] Working principle and usage process of this utility model:

[0033] (I) Device initialization and parameter preset:

[0034] After the device is deployed, the operator opens the housing through the control cabinet door handle 10 on the housing 9 of the leak alarm device, checks the connection status of internal components such as ammeter 7, thermocouple temperature display device 8, and protection relay 12, and confirms that the lead-out lines of alarm wire mesh 3 (pre-embedded in the inner lining fire-resistant layer 2) and bottom probe 4 (vertically installed at the bottom center of vacuum lifting housing 1 and sealed by high-temperature resistant seal) are undamaged, and that the high-temperature resistant insulation layer on the outside of the wire is intact.

[0035] Turn on the mobile power supply 13 to power the entire monitoring circuit, so that a stable circuit is established between the two detection poles formed by the alarm wire mesh 3 (304 stainless steel, wire diameter 1-1.5mm, mesh size 14*14mm) and the bottom probe 4 (304 stainless steel, diameter 8-10mm); at the same time, preset the leakage current protection value of the comparator (based on the vacuum lifting safety operation standard) to complete the device initialization.

[0036] (II) Real-time monitoring phase

[0037] Leakage current monitoring: Ammeter 7 is connected in series in the detection electrode circuit to measure the leakage current between the two detection electrodes in real time and transmit the current data synchronously to the comparator; one end of grounding wire 11 is connected to the circuit and the other end is grounded, ensuring the safety of the circuit power supply throughout the process and avoiding additional risks caused by leakage.

[0038] Temperature monitoring: The first temperature measuring end 14 of thermocouple 15 (located on the wall of vacuum lifting shell 1) and the second temperature measuring end 16 (located on the bottom of the shell) synchronously collect temperature data of the shell wall and the bottom of the shell. The temperature signal is transmitted to the thermocouple temperature display device 8 through the connecting wire. The device displays the temperature value in real time to help the operator keep track of the temperature status of the lifting shell.

[0039] (III) Anomaly Detection and Alarm Triggering

[0040] The comparator continuously receives leakage current data transmitted by ammeter 7 and dynamically compares it with the preset protection value:

[0041] When the leakage current is less than or equal to the preset protection value, the comparator maintains its initial state, the protection relay 12 does not operate, the audible and visual alarm device 6 (installed on top of the leakage alarm device 5) remains closed, and the device remains in monitoring mode.

[0042] When the refractory lining 2 of the vacuum lifting bag is damaged and molten aluminum leaks into the alarm wire mesh 3, the molten aluminum acts as a conductive medium, increasing the leakage current in the detection electrode circuit. If the comparator detects that the leakage current exceeds the preset protection value, the level immediately flips, triggering the protection relay 12 to operate.

[0043] After the protection relay 12 is activated, it directly drives the audible and visual alarm device 6 to start. The device simultaneously emits an audible warning and a light signal to remind the on-site operators to pay attention to any abnormalities in lifting the bag.

[0044] (iv) Emergency response and device reset

[0045] After receiving the audible and visual alarm signal, the operator quickly locates the abnormal leakage point based on the temperature data of the bottom and wall of the ladle displayed on the thermocouple temperature display device 8 and the alarm location. The operator immediately stops the vacuum ladle lifting and aluminum unloading or transfer operation and takes emergency measures such as stopping the machine for inspection and emptying the molten aluminum to prevent the leakage accident from escalating.

[0046] After troubleshooting, the operator turns off the power bank 13, checks whether the alarm wire mesh 3 and the bottom probe 4 are damaged (if damaged, replace them), and after confirming that all components are normal, restarts the device and resets the comparator parameters, and the device returns to real-time monitoring status.

[0047] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0048] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A vacuum ladle lining aluminum molten leakage monitoring device, comprising a vacuum ladle housing (1), a leakage alarm device (5), a detection component, a power supply component, a detection and display component, a grounding component, a temperature monitoring component, and an alarm component, characterized in that: The vacuum bag lifting housing (1) is provided with an inner refractory lining (2). The bag leakage alarm device (5) is installed on one side of the outer wall of the vacuum bag lifting housing (1). The detection component includes an alarm wire mesh (3) and a bag bottom probe (4) installed at the bottom of the vacuum bag lifting housing (1). The alarm wire mesh (3) and the bag bottom probe (4) serve as two detection poles. The alarm wire mesh (3) is made of 304 stainless steel with a wire diameter of 1-1.5 mm and a mesh size of 14. 14mm, the bottom probe (4) is made of 304 stainless steel and has a diameter of 8-10mm. The power supply component is a mobile power supply (13). The mobile power supply (13) is electrically connected between the two detection poles to form a circuit. The detection display component includes an ammeter (7). The ammeter (7) is connected in series in the circuit. The alarm component includes an audible and visual alarm device (6) and a protection relay (12). The protection relay (12) is connected in series in the circuit. The audible and visual alarm device (6) and the protection relay (12) are electrically connected.

2. The vacuum ladle lining aluminum molten leakage monitoring device according to claim 1, characterized in that: The grounding component is a grounding wire (11), one end of which is connected to the circuit, and the other end of which is grounded.

3. The vacuum ladle lining aluminum molten leakage monitoring device according to claim 1, characterized in that: The temperature monitoring component includes a thermocouple (15), connecting wires, and a thermocouple temperature display device (8); the thermocouple (15) includes a second temperature measuring end (16) and a first temperature measuring end (14), the second temperature measuring end (16) and the first temperature measuring end (14) are respectively located at the bottom and wall of the vacuum lifting shell (1), and the thermocouple (15) is electrically connected to the thermocouple temperature display device (8) through connecting wires.

4. The vacuum ladle lining aluminum molten leakage monitoring device according to claim 3, characterized in that: The leak alarm device (5) includes a leak alarm device housing (9), an ammeter (7) installed inside the leak alarm device housing (9), a thermocouple temperature display device (8) installed inside the leak alarm device housing (9), and the leak alarm device housing (9) is located below the ammeter (7).

5. The vacuum ladle lining aluminum molten leakage monitoring device according to claim 1, characterized in that: The audible and visual alarm device (6) is installed on the top of the leaky package alarm device (5), and the housing (9) of the leaky package alarm device is also provided with a control cabinet door handle (10).

6. The vacuum ladle lining aluminum molten leakage monitoring device according to claim 1, characterized in that: The alarm wire mesh (3) is embedded in the inner lining fire-resistant layer (2), and the lead-out end of the alarm wire mesh (3) is electrically connected to the mobile power supply (13), ammeter (7) and protection relay (12) through wires.

7. The vacuum ladle lining aluminum molten leakage monitoring device according to claim 1, characterized in that: The bottom probe (4) is vertically installed at the center of the bottom of the vacuum lifting housing (1).

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