Method and device for electrolyte crust breaking by separation plasma cutting

Abstract

The present disclosure relates to aluminum production, more particularly, to a method of breaking an electrolyte crust in reduction cells of all types. According to a disclosed method for breaking electrolyte crust by means of separation cutting in a reduction cell for production of aluminum, the crust is cut and broken by means of the thermal melting of a crust material with a high-speed high-temperature concentrated flow of thermal plasma jet heat energy, for which a directed thermal plasma jet is generated and moved above the electrolyte crust along a predetermined path, a formed molten material is continuously removed from a zone of the thermal plasma jet impact to create in the electrolyte crust a slit with the thermal plasma jet, wherein the slit is enough for of crust continuous separation cutting and breaking. The technical effect in the addressing the mentioned object, reduction of the amount of broken electrolyte crust, avoiding the formation of electrolyte crust pieces during the breakage process and, consequently, reduction of power consumption for heating-up the covering material consisting of a mixture of alumina and crushed electrolyte used to form an electrolyte crust.

Claims

1. A method for breaking an electrolyte crust by a separation cutting in a reduction cell for production of an aluminum, the method comprising: (a) thermally melting a crust material with a high-speed high-temperature concentrated flow of a thermal plasma jet heat energy, wherein a directed thermal plasma jet is generated and moved above the electrolyte crust along a predetermined; and (b) continuously removing a formed molten material from a zone of the thermal plasma jet impact to create a slit in the electrolyte crust with the thermal plasma jet, wherein the slit is enough to perform the separation cutting and the breaking of the electrolyte crust.

2. The method according to claim 1, wherein a size of the slit are defined by technological processing operations for the reduction cell, and wherein the slit has a width of less than 25 mm.

3. The method according to claim 1, wherein a velocity of the thermal plasma jet above the electrolyte crust is from 0.5-2.5 m/min.

4. The method according to claim 1, wherein a distance from a point of plasma jet discharge to a surface of the electrolyte crust is 15 mm or less.

5. The method according to claim 1, wherein a width of the thermal plasma jet at the discharge point is 3-10 mm.

6. The method according to claim 1, wherein a discharge velocity of the thermal plasma jet is preferably 600-1500 mm/sec.

7. A system for plasma cutting an electrolyte crust in a reduction cell for production of an aluminum, the system comprising: an assembly of a plasma torch secured to a boom of an articulated manipulator comprising actuators configured to extend the boom with the plasma torch secured thereto from a transport position into a working position, and vice versa, to move the plasma torch at a pre-defined speed along a cutting path and to maintain a gap between a plasma torch tip and the electrolyte crust when moving the plasma torch over an electrolyte crust surface having a complex relief.

8. The system according to claim 7, wherein the assembly is mounted on a crane arm.

9. The system according to claim 7, wherein the system further comprises a unit for changing a tilt angle of the plasma torch with respect to the electrolyte crust surface.

10. The system according to claim 7, wherein the system further comprises an oscillator configured for contactless excitation of an electric arc and stabilization during the cutting process; a control and power supply element; and a cooling system for the plasma torch.

11. The system according to claim 7, wherein an arc plasma torch is used as the plasma torch.

12. The system according to claim 7, wherein the plasma torch is configured to perform separation cutting for an electrolyte crust while varying along the cutting path thickness and melt temperature.

13. The system according to claim 7, wherein the gap between the plasma torch tip and the electrolyte crust is formed by projections on a plasma torch body or by means of an element in the form of a movable skid or a roller secured to the plasma torch assembly, which in operation slides or moves directly on the crust creating a pre-defined distance between the plasma torch tip and the electrolyte crust.

14. The system according to claim 7, wherein the system further comprises an automated control system.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Some embodiments of the disclosure may be understood by referring, in part, to the present disclosure and the accompanying drawings, wherein:

[0026] FIG. 1 illustrates a side perspective of a disclosed device for aluminum production according to a specific example embodiment of the disclosure;

[0027] FIG. 2 illustrates a perspective of a plasma torch according to a specific example embodiment of the disclosure; and

[0028] FIG. 3 illustrates a cross-sectional view of a plasma torch and a cutting path for the plasma torch according to a specific example embodiment of the disclosure.

DETAILED DESCRIPTION

[0029] The present disclosure relates to aluminum production from molten salts, more particularly, to the process of breaking an electrolyte crust in reduction cells of all types with the use of a directed jet of thermal plasma.

[0030] The object of the present disclosure is to improve technical and economic characteristics of a reduction cell for production of aluminum by providing an effective method for breaking an electrolyte crust and a device for slit-type cutting of an electrolyte crust for the effective and economic crust breakage.

[0031] The technical effect provided by the disclosure is in addressing the mentioned object, reducing the amount of broken electrolyte crust, avoiding the formation of electrolyte crust pieces during the breakage process and, consequently, reducing power consumption for heating-up the covering material consisting of a mixture of alumina and crushed electrolyte used to form an electrolyte crust.

[0032] The technical effect is provided by that the method for breaking an electrolyte crust in a reduction cell for production of aluminum where the electrolyte crust is exposed to a high-speed high-temperature concentrated flow of heat energy of a thermal plasma jet which is moved above the electrolyte crust along a predetermined path includes a continuous removal of a formed molten material from a zone of jet impact, whilst in the electrolyte crust a slit is formed by means of the thermal plasma jet.

[0033] The difference of the present disclosure from the analogous solutions is in that the electrolyte crust in an aluminum reduction cell is broken by separation cutting of the electrolyte crust in the result of thermal melting and formation of a slit in the electrolyte crust by means of a thermal plasma jet.

[0034] There are two main categories of plasma cutting methods: 1) plasma-arc cutting used for metals and other conductive materials, 2) plasma jet cutting used for various non-conductive materials.

[0035] The main field of application of a plasma jet for cutting includes cutting of non-metal, sheet materials of small thickness (less than 5 mm), refractories, ceramics, etc. During cutting, a distance between a surface of a cut metal and an end face of a plasma torch tip must be constant. An arc is pointed downwards and typically at a right angle to the surface of a cut window. An electrolyte crust is non-conductive and it can be cut only with the plasma jet, however, currently, there are no instances of technological application of the plasma jet for the electrolyte crust breakage on existing reduction cells at aluminum plants (including plants in other countries).

[0036] The separation cutting of an electrolyte crust with a thermal plasma jet includes local heating an electrolyte crust material, melting and partial evaporation thereof to remove from a cutting zone in the form of a melt and vapor by the dynamic action of the jet. The process of separation cutting and breaking the electrolyte crust with the thermal plasma jet includes two stages: 1) melting a through-hole in a crust at an origin point of a path, 2) separation cutting a crust along a predetermined path.

[0037] The hole in the crust can be melted very quickly due to the local action of a high-speed high-temperature concentrated flow of the thermal plasma jet heat energy on the material. Plasma and path parameters are selected based on optimal cutting modes and power consumption. Products resulted from such action include a material melt and vapors which are removed from the hole region above the crust by the flow dynamic action. Immediately after the through-hole is formed, the separation cutting of a crust takes place performed by displacing the thermal plasma jet above a crust surface at a predetermined speed. A turbulent flow pattern of the thermal plasma jet and high temperatures (5,000-6,000 C.) provide highly intensive transfer of heat from the flow to the cut material by means of convective and radiant heat exchange. Rapid heating of the crust material results in its melting and partial evaporation with the continuous removal of the formed melt film and vapors from the area of the jet impact into a space under the crust due to the dynamic action of the high-speed high-temperature flow of the thermal plasma jet.

[0038] This method is characterized by specific preferred embodiments to obtain optimal modes of the effective crust cutting and breakage.

[0039] Sizes of slits formed in the electrolyte crust are defined by technological processing operations for a reduction cell, wherein the slit width is typically less than 25 mm. The speed of thermal plasma jet above the electrolyte crust is 0.5-2.5 m/min. The distance from a point of plasma jet discharge (a nozzle) to an electrolyte crust surface can be 1-15 mm, a thermal plasma jet width at the discharge point is 3-10 mm, and a jet discharge velocity is 600-1500 mm/sec. These parameters are selected by experiments and shouldn't be considered as limiting. All the disclosed parameters of the method and the exemplary device for implementing said method can be used in more broad or narrow ranges comprised within or outside said ranges.

[0040] In the method according to the present disclosure, a width of a slit formed with the thermal plasma jet in the electrolyte crust across the periphery and on a surface of a reduction cell anode is sufficient for separation cutting and breaking the electrolyte crust.

[0041] The above mentioned object is achieved by a device for slit cutting of an electrolyte crust which comprises a working member in the form of an arc plasma torch mounted at a boom end. The plasma torch is a cylindrical device comprising a body made of a heat-, electro- and arc-resistant material. The boom is extended from the plasma torch into a cutting area by means of an articulated manipulator. The manipulator is driven by two actuators or pneumatic cylinders, characterized by the efficient, reliable and accurate performance. The manipulator is configured so that a plasma torch tip follows a complex relief on the electrolyte crust surface. Also, the device can be equipped with alternative systems for contactless crust surface scanning. The surface relief can be followed with the use of a tip support, such as a skid or a roller.

[0042] In addition to attachments, any available alternative equipment can be used. As a facility where the present disclosure can be mounted to, a crane, a floor production machine or any other device allowing the use thereof for its intended purpose can be used. This includes automated and robotic complexes with programmed control of a motion, tilt, trajectory, and distance to crust with measurements of required crust parameters, such as a relief, temperature, thickness, chemical composition and so on performed at cutting, e.g., it can be the relief scanning. The idea is in the possible modification and improvement of the device.

[0043] Preferably, the plasma cutter of an electrolyte crust operates under unchanged energy parameters. The device operation is ensured by the power of 0.4 kV and compressed air with the pressure of no less than 4 bars. Plasma parameters are selected based on the cutting conditions for a crust having a specific thickness and chemical composition.

[0044] Aspects of device and plasma torch structures provide the following:

[0045] 1. When the plasma torch is moved across an electrolyte crust surface with a complex relief, the distance between a plasma torch tip and the crust is maintained in the range of 1 to 15 mm.

[0046] 2. A tilt angle of the plasma torch with respect to the electrolyte crust surface can be changed within 5.

[0047] 3. A thermal plasma jet generates in the electrolyte crust a slit with a width up to 25 mm at a velocity up to 2.5 m/min.

[0048] 4. The separation cutting can be performed for an electrolyte crust with various thicknesses along the cutting path (from 40 to 220 mm) and various melting temperatures (in the range of 950-2,000 C. depending on a percentage of alumina and electrolyte in the crust).

[0049] The distinctive and advantageous feature of the method and device of the present disclosure is in that melting and separation cutting processes with simultaneous formation of a split in an electrolyte crust save a lot of power required for electrolyte crust cutting and minimize the amount of recycled raw materials.

[0050] The present disclosure allows breaking the electrolyte crust without the risk of formation of cover material pieces which then can fall into an electrolyte melt. The use of the device according to the present disclosure reduces the negative impact of anode replacement operations on the MHD (magnetohydrodynamic) stability of reduction cells, reduces the time for clearing a place where a new anode is to be placed from cover material pieces, increases the efficiency of a reduction cell protection, reduces the amount of raw materials, and, consequently, reduces power consumptions for heating and melting the cover material consisting of a mixture of alumina and crushed electrolyte used to form an electrolyte crust across the periphery and on a surface of new anodes.

[0051] The implementation of the method is illustrated by the following examples with the use of a jet arc plasma torch as a thermal plasma jet generator.

EXAMPLES

[0052] Some specific example embodiments of the disclosure may be illustrated by one or more of the examples provided herein.

Example 1

[0053] A thermal plasma jet with a flow rate of a plasma air of 3.2 nm.sup.3/h, enthalpy of 12 MJ/kg, having a bulk temperature of 5,200 C., a diameter of a discharge nozzle of 6 mm and a discharge rate of 650 m/s. The crust thickness is 50 mm, an average temperature is 500 C. An electrolyte crust is through-cut by moving the nozzle of a plasma torch above a surface at a velocity of 0.5 m/min. The width of the resulted slit is about 10 mm. The path of motion is defined based on conditions for optimal cutting speed and energy consumption.

Example 2

[0054] A thermal plasma jet with a flow rate of a plasma air of 3.0 nm.sup.3/h, enthalpy of 16.5 MJ/kg, having a bulk temperature of 5,900 C., a diameter of a discharge nozzle of 4 mm and a discharge rate of 1500 m/s. The crust thickness is 70 mm, an average temperature is 500 C. An electrolyte crust is through-cut by moving the nozzle of a plasma torch above a surface at a velocity of 1.2 m/min. The width of the resulted slit is about 6 mm.

[0055] The rate of crust separation cutting with a thermal plasma jet is primarily defined by physical and chemical properties of a cut crust material, thickness and temperature. The main characteristics of a thermal plasma jet which determine the intensity of material impact include enthalpy of the thermal plasma jet (MJ/kg), jet discharge rate (m/s), jet width at a discharge point (mm), specific power per jet section (kW/m.sup.2) and a distance from the discharge point to a crust surface (mm). Said characteristics are defined by operation parameters of thermal plasma jet generators.

[0056] The use of the method according to the disclosure reduces the negative impact of such technological operation as the anode replacement on the MHD-stability of a reduction cell, reduces the time for rearranging anodes, increases the efficiency of a reduction cell cover, reduces the amount of recycled raw materials, reduces power consumptions for heating the cover material consisting of a mixture of alumina and crushed electrolyte used to form an electrolyte crust across the periphery and on a surface of new anodes.

[0057] The technical aspects and operating principles of the device according to the present disclosure are illustrated by drawings, where:

[0058] FIG. 1 is a view of a device according to the present disclosure,

[0059] FIG. 2 is a view of an exemplary plasma torch,

[0060] FIG. 3 is a view of a plasma torch with a cutting path.

[0061] An disclosed attaching device for plasma cutting an electrolyte crust in a reduction cell for production of aluminum comprises following units and parts: a plasma torch 1 secured to a boom of an articulated manipulator 5, actuators (electromechanical or pneumatic cylinders) 6 and 7 used for driving the manipulator 5 for cutting and extending the boom having the plasma torch 1 secured thereto from the transport position to a working position, and vice versa, respectively. The entire assembly is mounted on a support 8 rigidly secured to an arm of a crane 9. The crust cutting device also comprises: an oscillator 2 for contactless excitation of an electric arc and stabilization during the cutting process, a control and power supply cabinet 3 (ACSAutomatic Control System) and a cooling system 4 for the plasma torch 1. The ACS unit can comprise a controller and data acquisition modules which register signals from instrumentation sensors and control actuation devices, as well as power-supply circuits for the instrumentation and ACS. Also, the device comprises end-position sensors. Further, the device is provided with air flow sensors on the plasma torch, arc voltage sensors of the plasma torch, coolant flow rate sensors. For the secure operation of the device, the ACS system includes several automatic emergency stop commands:when the coolant flow is reduced to the pre-defined level for preventing the overheating and failure of a nozzle and plasma torch cathode; when the air flow is reduced below the pre-defined level; when the arc voltage is reduced below the pre-defined level for preventing the transition of arc burning to a mode where an insulator can be thermally degraded followed by the plasma torch failure.

[0062] For security purposes, it is also provided an external button for remote switching off the plasma torch arc in a manual mode which duplicates automatic commands.

[0063] FIG. 3 shows an example of the plasma torch movement over an electrolyte crust.

[0064] The device for separation plasma cutting of an electrolyte crust is used as follows:

[0065] The device mounted on a crane is transported to a reduction cell where a technological operationanode replacementmust be performed. A flap cover of the reduction cell is opened near a replaceable anode. Then, a crane arm 9 having a manipulator 5 secured thereto is lowered. An electromechanical actuator 7 extends a boom having a plasma torch 1 secured thereto from a transport position to a working position. Then, the device is moved into the reduction cell above an electrolyte crust surface and is placed into an initial point for cutting at a 1-2 mm distance from the crust surface. A crane operator transmits a command to turn on the device (arc ignition, supplying of plasma gas and coolant) using a remote control panel. Upon igniting a point at the origin of cutting, the plasma torch 1 is automatically moved across the crust surface of a solidified electrolyte along a programmed path. Upon cutting a longitudinal side of a butt, the device is rotated at 90 degrees and cuts a transverse side of the butt, therefore, the cutting path is sufficiently simple. The cutting process is continuously monitored. During the process of electrolyte crust cutting, following parameters are visually monitored: the progress of the cutting process, depth of crust cutting, voltage and current on the plasma torch, flow rate and pressure of compressed air, and pressure, temperature and flow rate of coolant in a cooling system. Monitoring may be carried out by means of corresponding sensors in an automatic mode. It is possible to use protective shields in a cutting zone, as well as supplemental equipment to accelerate and simplify the crust breaking process. The aluminum production process, which takes place in reduction cells having backed anodes, requires replacing the anodes. In order to replace the anode, it is necessary to separate it from a sintered portion of a cover material. Currently, it is usually carried out by means of a pneumatic hammer. The anode butt is cut off along a perimeter, then the butt is removed and arranged on a pallet. Next, butts are transported to a cleaning area where the remaining crust is separated from anode pack residues. The remaining crust is transported to a crushing area where it is ground and reintroduced into the electrolysis process. The area where the butt was located is cleaned from pieces of fallen electrolyte crust. The removed crust is transported to a crushing area, where it is ground and reintroduced into the production process. The anode pack residue is ground and introduced to a new anode production process. The main idea of developments in plasma cutting of electrolyte crust is to avoid using a breaker (a pneumatic hammer).

[0066] When an electrolyte crust is cut, the cutting progress and the crust cutting depth is visually or automatically monitored. During the plasma cutting process, a protective shield may or may not be used, because in the process, a plasma jet flow is directed to a space under the crust, and very small amount of particles are ejected. For security purposes, it is also provided an external button for remote switching off the plasma torch arc in a manual mode which duplicates automatic commands. The velocity of jet discharge is of the order 600-1500 mm/sec, wherein the higher the temperature and the thinner the crust is, the higher the velocity will be. Upon completion of a cutting program, the device is turned off and supplying the plasma gas and the coolant is stopped. The device is retracted into the transport position and removed from the cutting zone.

[0067] The practical implementation of the disclosure is tested using a prototype made on the base of the device mounted on the crane. The device according to the disclosure has passed the test in an operational facility for aluminum electrolysis at the applicant's plant. The tests have shown that the disclosure prevents the formation of pieces of solid cover material and penetration thereof into the electrolyte melt. The basic conditions for choosing the method for breaking an electrolyte crust were following: the absence of falling crust pieces into the melt; reducing the depressurization time of a reduction cell; lowering the power consumption for raw material melting.

[0068] In the context of technical and economic assessments of the project, the effectiveness of plasma cutting was analyzed in comparison with cutting by means of a jib and rotatory saw cutting, which has confirmed the effectiveness and the usage preference of the plasma cutting.

[0069] As will be understood by those skilled in the art who have the benefit of the instant disclosure, other equivalent or alternative compositions, devices, and disclosed systems for plasma cutting an electrolyte crust for production of aluminum can be envisioned without departing from the description contained in this application. Accordingly, the manner of carrying out the disclosure as shown and described is to be construed as illustrative only.

[0070] Persons skilled in the art can make various changes in the shape, size, number, and/or arrangement of parts without departing from the scope of the instant disclosure. For example, the position and number of actuators can be varied. In some embodiments, plasma torches can be interchangeable. In addition, the size of a device and/or system can be scaled up or down to suit the needs and/or desires of a practitioner. Each disclosed system, method, and method step can be performed in association with any other disclosed method or method step and in any order according to some embodiments. Where the verb may appears, it is intended to convey an optional and/or permissive condition, but its use is not intended to suggest any lack of operability unless otherwise indicated. Where open terms such as having or comprising are used, one of ordinary skill in the art having the benefit of the instant disclosure will appreciate that the disclosed features or steps optionally can be combined with additional features or steps. Such option may not be exercised and, indeed, in some embodiments, disclosed systems, compositions, apparatuses, and/or methods can exclude any other features or steps beyond those disclosed in this application. Elements, compositions, devices, systems, methods, and method steps not recited can be included or excluded as desired or required. Persons skilled in the art can make various changes in methods of preparing and using a composition, device, and/or system of the disclosure.

[0071] Also, where ranges have been provided, the disclosed endpoints can be treated as exact and/or approximations as desired or demanded by the particular embodiment. Where the endpoints are approximate, the degree of flexibility can vary in proportion to the order of magnitude of the range. For example, on one hand, a range endpoint of about 50 in the context of a range of about 5 to about 50 can include 50.5, but not 52.5 or 55 and, on the other hand, a range endpoint of about 50 in the context of a range of about 0.5 to about 50 can include 55, but not 60 or 75. In addition, it can be desirable, in some embodiments, to mix and match range endpoints. Also, in some embodiments, each figure disclosed (e.g., in one or more of the examples, tables, and/or drawings) can form the basis of a range (e.g., depicted value +/ about 10%, depicted value +/ about 50%, depicted value +/ about 100%) and/or a range endpoint. With respect to the former, a value of 50 depicted in an example, table, and/or drawing can form the basis of a range of, for example, about 45 to about 55, about 25 to about 100, and/or about 0 to about 100. Disclosed percentages are volume percentages except where indicated otherwise.

[0072] All or a portion of a disclosed devices can be configured and arranged to be disposable, serviceable, interchangeable, and/or replaceable. These equivalents and alternatives along with obvious changes and modifications are intended to be included within the scope of the present disclosure. Accordingly, the foregoing disclosure is intended to be illustrative, but not limiting, of the scope of the disclosure as illustrated by the appended claims.

[0073] The title, abstract, background, and headings are provided in compliance with regulations and/or for the convenience of the reader. They include no admissions as to the scope and content of prior art and no limitations applicable to all disclosed embodiments.