After a power outage for 1 hour, the series of electrolytic tanks needs at least 8 hours to calculate, and its influence is considerable. The reduction in aluminum production caused by the power outage is calculated as follows: A) Less aluminum production in a little time: S=166×0.3355×303/1000=16.87 tons (166 units in the production slot) B) Total aluminum production for 4 to 6 hours: S total = 16.87 × (4 ~ 6) = 67.5 ~ 101.2 tons After the power failure, the series electrolyzers should establish energy balance as soon as possible, and the electrolyzers can only increase the burst effect. According to the influence of the electrolysis tanks that stopped electrolysis in the past, the electrolyzer efficiency coefficient will reach 0.35 or more after each power transmission. The daily effect control is targeted at 0.2, and the number of additional effects will reach: N=166×(0.35 to 0.2)×(4-6)=100 to 149 Each effect is controlled at an average of 3 minutes. When the voltage is 20V, the waste of power is: Q = (100 ~ 149) × 303 × 20 × 3/60 = (3.03 ~ 4.5) million degrees Calculated at 0.3 yuan/kWh, equivalent to RMB ¥=(3.03～4.5)×0.3=0.91～13,500 Therefore, from the above two sets of data alone, the effect of a series of electrolytic cells on the electrolysis cell by welding is not desirable. With reference to the successful experience of Pingguo Aluminum and Baotou Aluminum Plant, in order to avoid series of blackouts and reduce economic losses, the pre-repair conference will study the decision to use the electrified casting repair method to repair on April 24. First, pre-repair situation: The sectional dimension of the broken aluminum bus bar is 160×220mm and the fracture length is 300-350mm. See the figure below. Second, repair process 1, fracture grinding, clean oxide scale, pistol drilled at the two ends of the aluminum busbar broken hole honeycomb, in order to facilitate the casting of aluminum block and bus bar bite and improve the conductivity. 2. Install a cast iron mold, preheat it with a baking gun, heat the aluminum busbar break to 500-600°C, and then cast. Third, the casting process 1, preparations, everyone's focus. 2, Pour aluminum, using the assembly shop hot metal small lifting aluminum water about 100Kg. 3, check the aluminum water, slag, remove the oxide film and other slag skin. 4, ready to cast, because the construction unit personnel are not familiar with the casting of aluminum water, from the electrolysis workshop, a district chief Chen Qian and Chen Dong responsible for casting. 5. Start casting. 5, aluminum water splash: After the casting began, unexpected things happened: due to the electromagnetic force generated by the current and the electromagnetic field, causing the aluminum water to splash upwards, such as aluminum water explosion in general (in case of dodge, the molten aluminum water will inevitably The scald personnel), the follow-up scene is very thrilling, everyone's heart is hanging in the field, the author in the dodge process because of the magnetic field on the camera can not take these scenes, the following picture is the scene of the beginning of the splash of aluminum. 6. Cast again: The splashed aluminum water makes the staff feel redundant. Manager Lu personally operates the knife, but fortunately, the first secondary casting of aluminum water has condensed the aluminum bus bars together to form a conductive path, and the cast aluminum water has no splashes. phenomenon, 7, Finish casting 8, Repair effect (about 20 minutes from preparation of aluminum water to complete casting) Fourth, the effect of evaluation 1. After repairing, the balance bus line detection data of 135# groove bottom. 2. Compared with the undisturbed 105# groove bottom balance bus test data: Busbar temperature 98°C, 500mm equidistant pressure drop 22mv. Note that the equidistant pressure drop of the balance bus at the bottom of the 135 slot is the same as that of the normal slot. 3, because the mold does not need to remove, it is not convenient to measure the pressure drop at the section, according to the fracture die length 500mm, both ends of the pressure drop 48mv, 50mm distance measurement cross-section pressure drop = 48/(500/50)=4.8mv< 5mv (5mv for the discussion of the proposed standard, the lower the pressure drop the better) to achieve the desired effect. V. Experience summary 1. Since the casting work is for the first time, the preparation work is slightly insufficient. For example, if the preheating bake gun is used, it is not necessary to be prepared. There is a waste of time for the preparation of these baking guns. The bake gun used later is not applicable. Fortunately, The construction unit has a suitable baking gun and a large torch that can be used instead. 2. At the beginning of the casting, aluminum water splash caused by the influence of current and magnetic field was not taken into consideration. The operator may burn the personnel with carelessness. The conductive measures shall be strengthened beforehand. The aluminum wire rod shall be used for conduction or other effective bypass measures. On the one hand to speed up the conduction, on the other hand to avoid the large current through the aluminum water to reduce the aluminum liquid splash. 3. The safety measures are not enough. The aluminum busbars at the bottom of the trough are powered for a long time. The temperature of the busbars is close to 100°C. In order to avoid electric shock and scald, the bamboo springboards should be prepared and laid well. Other safety preparations must also be in place, such as insulation and heat protection materials, anti-hot clothing, and masks. 4. The repair has achieved the expected results, and it is recommended to improve the use of various work procedures to promote the use of aluminum as the preferred method of repair. When faced with the same problem later, it is necessary to fully collect the data, such as the busbar temperature (before and after casting) and the temperature and pressure drop of the adjacent busbars of the busbars, in order to take appropriate measures to ensure the long-term production of the electrolytic cell.
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The 135# tank on March 31 due to the shell shell melted through the aluminum leakage caused by aluminum water to break a balanced aluminum busbar bottom, such as the use of welding repair method requires a series of blackouts, all electrolytic tanks must be blackout, with 16 10mm thick The aluminum plates are welded one by one to the fractures. Due to the influence of the magnetic field in the field, the time required for welding four aluminum plates is more than one hour, and the time required to repair the fractures is between 4 and 6 hours. To ensure the normal production of the series of electrolyzers, without major impact, each power outage time should be controlled in about 1 small time, so all repaired sections should be completed, the series electrolyzers must be outages in 4-6 times, and can not be concentrated in one or two Within a day, so it has a great impact on the power grid and production.