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Production Process and Operational Practices of Large Prebaked Cell Aluminum Electrolysis Author: Li Qing ISBN: 7811051257 Pages: 235 Binding: Paperback Series Title: Publisher: Central South University Publication Date: Edition: 1 Word Count: Preface -------------------------------------------------------------------------------- Chapter 1 Basic Theory of Aluminum Electrolysis -------------------------------------------------------------------------------- · 1.1 Properties and Applications of Aluminum · 1.2 Basic Theoretical Knowledge of Aluminum Electrolysis Chapter 2 Overview of Aluminum Electrolysis Production -------------------------------------------------------------------------------- · 2.1 Electrolysis Production Process Flow · 2.2 Raw Materials Used in Electrolysis · 2.3 Layout of Aluminum Electrolysis Plant Facilities Chapter 3 Structure of Aluminum Electrolysis Cells -------------------------------------------------------------------------------- · 3.1 Development of Aluminum Electrolysis Cells · 3.2 Structure of Aluminum Electrolysis Cells Chapter 4 Preheating, Calcination, and Startup of Aluminum Electrolysis Cells -------------------------------------------------------------------------------- · 4.1 Purpose and Methods of Cell Preheating and Calcination · 4.2 Preparations Before Preheating and Startup of Newly Installed Cells · 4.3 Calcination and Startup of Large Prebaked Cells · 4.4 Startup of Aluminum Electrolysis Cells Chapter 5 Production Management During Abnormal Periods of Aluminum Electrolysis Cells -------------------------------------------------------------------------------- · 5.1 Management in the Early Stage of Startup · 5.2 Management in the Later Stage of Startup Chapter 6 Main Operations of Aluminum Electrolysis Cells -------------------------------------------------------------------------------- · 6.1 Anode Replacement Operations · 6.2 Aluminum Extraction Operations · 6.3 Suppressing Anode Effects · 6.4 Raising the Busbar Operations · 6.5 Edge Sealing Operations · 6.6 Carbon Slag Removal Operations · 6.7 Short Circuit Handling Operations · 6.8 Cell Shutdown Operations Chapter 7 Routine Measurements of Electrolysis Cells -------------------------------------------------------------------------------- · 7.1 Measurement of Aluminum Liquid and Electrolyte Levels · 7.2 Temperature Measurement of Electrolysis Cells · 7.3 Measurement of Initial Crystallization Temperature and Superheat · 7.4 Pole Pitch Measurement · 7.5 Measurement of Bottom Pressure Drop · 7.6 Measurement of Cathode Current Distribution · 7.7 Measurement of Anode Current Distribution · 7.8 Temperature Measurement of Bottom Steel Plate · 7.9 Temperature Measurement of Cathode Steel Rods · 7.10 Measurement of Furnace Shape · 7.11 Measurement of Bottom Bulging · 7.12 Sampling Operations Chapter 8 Normal Production Management of Aluminum Electrolysis Cells -------------------------------------------------------------------------------- · 8.1 Technical Conditions and Parameters for Normal Production · 8.2 Normal Production Management of Aluminum Electrolysis Cells Chapter 9 Treatment of Faulty Electrolysis Cells and Common Accidents -------------------------------------------------------------------------------- · 9.1 Common Faulty Cells and Their Treatments · 9.2 Common Accidents and Their Solutions Chapter 10 Damage and Maintenance of Aluminum Electrolysis Cells -------------------------------------------------------------------------------- · 10.1 Damage to Aluminum Electrolysis Cells · 10.2 Types of Damage to Cathode Liners in Electrolysis Cells · 10.3 Causes of Cathode Liner Damage · 10.4 Extending the Service Life of Cathode Liners · 10.5 Identification and Maintenance of Damaged Cells Chapter 11 Computer Control in Aluminum Electrolysis Production -------------------------------------------------------------------------------- · 11.1 Principles and Applications of Computer Control in Electrolysis Cells · 11.2 Control Actions of Computers Chapter 12 Current Efficiency in Aluminum Electrolysis Production -------------------------------------------------------------------------------- · 12.1 Electrochemical Equivalent of Aluminum and Theoretical Yield · 12.2 Current Efficiency in Aluminum Electrolysis · 12.3 Main Reasons for Reduced Current Efficiency · 12.4 Influence of Electromagnetic Phenomena on Current Efficiency · 12.5 Relationship between Current Efficiency and Process Parameters · 12.6 Relationship between Current Efficiency and Operational Management Chapter 13 Power Consumption and Energy Balance in Aluminum Electrolysis -------------------------------------------------------------------------------- · 13.1 Power Efficiency · 13.2 Voltage Balance in Aluminum Electrolysis Cells · 13.3 Energy Balance of Aluminum Electrolysis Cells · 13.4 Ways to Reduce Power Consumption Chapter 14 Economic Analysis of Aluminum Electrolysis Production -------------------------------------------------------------------------------- · 14.1 Economic Indicators for Aluminum Electrolysis Production · 14.2 Calculation of Raw Material Consumption in Electrolysis Production · 14.3 Calculation of Casting Production Indicators · 14.4 Cost Calculation of Aluminum Ingot Products · 14.5 Ways to Reduce Costs Chapter 15 Management of Aluminum Electrolysis Production -------------------------------------------------------------------------------- · 15.1 Management Principles for Aluminum Electrolysis Production · 15.2 On-site Management of Electrolysis Cells Chapter 16 Casting -------------------------------------------------------------------------------- · 16.1 Purification of Raw Aluminum · 16.2 Blending of Raw Aluminum · 16.3 Casting Process for Alloys Used in Remelting · 16.4 Machinery and Equipment for Raw Aluminum Casting Chapter 17 Dry Purification in Aluminum Electrolysis and Raw Material Transportation -------------------------------------------------------------------------------- · 17.1 Pollutants in Flue Gas from Aluminum Electrolysis Cells · 17.2 Methods of Flue Gas Purification · 17.3 Main Equipment for Dry Flue Gas Purification · 17.4 Raw Material Transportation and Feeding to Electrolysis Cells Appendix Requirements and Content for Vocational Skill Assessment -------------------------------------------------------------------------------- References
This book focuses primarily on large intermediate and lower-type pre-baked aluminum electrolysis cells. Its main contents include the production process of aluminum electrolysis, the operating procedures for aluminum electrolysis production, the stabilization and maintenance of the technical conditions in aluminum electrolysis production, the management of aluminum electrolysis production, the handling of common problems and accidents, current efficiency and power efficiency, as well as casting and flue gas purification. Based on the production practices of large prebaked electrolyzers built in China in recent years, with current intensities ranging from 160 kA, 200 kA, 300 kA to 350 kA, this article focuses on the production processes and operational practices for such large prebaked electrolyzers. In addition, in line with the **professional skill assessment standards and regulations, descriptions are also provided regarding the knowledge and skills required for junior workers, intermediate workers, senior workers, technicians, etc. During its compilation, the book focuses on the basic theories of aluminum electrolysis while also emphasizing practicality and applicability in the production process. It ensures coherence, universality, and systematicness in its content, and provides detailed explanations regarding the standardization, normalization, institutionalization, and informatization of production processes and operations. This book can serve as a reference for production technicians in aluminum electrolysis plants, as well as for vocational skill assessment and training, and as a teaching reference for colleges and secondary vocational schools.