The hottest small material makes a big brand. Alum

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"Small materials" build a big brand. The research and development record of impermeable materials for electrolytic aluminum of Chalco Zhengzhou Research Institute

based on the research and development of small materials for electrolytic aluminum, Aluminum Corporation of China has carried out quality improvement, efficiency increase and safety production work for electrolytic aluminum. At present, more than 20000 tons of impermeable materials independently developed and produced have been successfully offline and applied to some subordinate enterprises

anti seepage material for electrolytic aluminum is a kind of anti-seepage material laid under the cathode carbon block and above the thermal insulation material in the electrolytic cell. Its function is to prevent the electrolyte leaking through the cathode carbon block from damaging the thermal insulation material. This drain material is only a small material in the overhaul of the electrolytic cell, accounting for about 3.5% of the overhaul cost of the electrolytic cell. Its thickness is between 160mm and 200mm, and the consumption of a single cell ranges from 15 tons to 40 tons

despite this "small material", Ge Honglin, chairman of Aluminum Corporation of China, attached great importance to it, and personally approved and supervised the development and construction of a new anti-seepage material base for electrolytic aluminum in Zhengzhou non ferrous Metal Research Institute of Aluminum Corporation of China (hereinafter referred to as Zhengzhou Research Institute). Originally, this "small material" of impervious material can solve many problems in the production of electrolytic aluminum, such as reducing the damage of electrolytic cells, extending the life of cells, etc

as the research and development base of new technologies, new processes, new materials and new equipment in China's aluminum industry, Zhengzhou Research Institute has found in the process of long-term technical services for electrolytic aluminum enterprises that enterprises pay more attention to the indicators and performance of large-scale main equipment and materials in production, and often ignore the impact of impermeable materials on the production process. If the impervious material is improperly selected, the electrolytic cell will be damaged in the early stage, the thermal insulation material will be damaged, the thermal state of the electrolytic cell will become worse, and the economic indicators of the operation of the electrolytic cell will deteriorate, which will not only increase the power consumption, reduce the efficiency, but also greatly reduce the service life of the cell. At the same time, the overhaul cost will increase significantly, causing serious losses to the electrolytic aluminum enterprise

on this basis, Zhengzhou Research Institute conducted in-depth research on the materials in order to nip in the bud

after investigating the raw materials and production status of impervious materials, the Institute found that although there are many impervious material production enterprises at present, the price is very low, and the vicious competition in the market is serious. Basically, we don't use the raw material coke gem that should be used to produce impervious materials, but steal the beam and change the column, and use the tertiary alumina clinker and silica powder as the production raw materials. Some enterprises even use the crushing and mixing of various refractory corner wastes that are disclosed to the construction team at a low price, such as broken bricks, red stone slag raw materials, etc. to produce impervious materials. The cost is very low, and the impervious effect of the impervious materials produced is often very poor. This has caused huge losses to the life and economic production of aluminum reduction cells in Aluminum Corporation of China and even the whole industry

it is imperative to develop new impervious materials and build impervious material bases. Zhengzhou Research Institute has unique advantages in this regard: first, it has strong advantages in the research and development of new anti-seepage material technology and electrolytic aluminum technology service experience, and has a good understanding of the current situation of electrolytic cells in the company's electrolytic aluminum enterprises. Second, it is close to the origin of raw materials. The main raw material for producing high-quality impervious material for aluminum reduction cell is pyrogem. After high-temperature calcination, the composition is stable, the texture is uniform, the structure is dense, and has the characteristics of stable volume, high strength and low water absorption. It is mainly distributed in Qinyang and Jiyuan of Henan Province. The Qinyang high temperature alumina material factory under Zhengzhou Research Institute is located in Qinyang, which is very close to the main production area of raw materials, which can greatly save transportation costs. Third, there are idle electrolytic plants and some equipment, which can be reused after local reconstruction, which has good conditions for reducing investment and accelerating the progress of project implementation

Qinyang high temperature aluminum oxide material factory of Zhengzhou Research Institute was originally a national large-scale aluminum electrolysis test base and an original incubation base for China's large-scale aluminum electrolysis cell series technology and equipment. After completing the test task, due to market and other reasons, it stopped electrolytic aluminum production in 2007, carried out industrial transformation and upgrading, and turned to produce multiple varieties of aluminum oxide. There are still some waste plants and equipment that can be used. Fourth, relying on the platform of the national light metal quality supervision and inspection center attached to the Institute, it has incomparable advantages in raw material and product quality inspection and effect evaluation. Fifth, Henan Huahui Nonferrous Engineering design company, which has its own class a consulting and class a design qualification in the nonferrous metal industry, can design and construct by itself, which can not only reduce investment, but also shorten the construction period

in order to ensure the quality of impervious materials for aluminum electrolysis of Chinalco and try to avoid huge losses to the company's electrolytic aluminum production due to the quality of impervious materials, in July 2015, Zhengzhou Research Institute resolutely proposed to the company that it should develop and build a production base of impervious materials with an annual output of 20000 tons to ensure the company's needs. This coincides with the company's idea of fully promoting technological progress, improving quality and reducing consumption. Ge Honglin personally approved in the request report of Zhengzhou Research Institute: support the research institute to develop new impervious materials and build impervious material bases. Subsequently, the project has become a top-level project that Chairman Ge Honglin has been very concerned about and has been involved in many times. Chinalco and the joint stock company attach great importance to it, and the feasibility study, approval and other procedures have been completed rapidly

in accordance with the instructions of Ge Honglin and the requirements of Chinalco, Zhengzhou Research Institute soon established a leading group for the impervious material construction project, as well as four professional groups: technical research and development group, standard group, management group and on-site construction, construction and management group. They immediately took separate actions, formulated tips plans, and defined the project progress and relevant principals

on the basis of fully soliciting opinions from 30 enterprises inside and outside the company, such as refractories, design and research institutes, electrolytic aluminum, etc., the technology research and development group of Zhengzhou Research Institute has conducted 1800 groups of orthogonal experiments on the anti-seepage performance, thermal conductivity and tamping density of 8 formulas (chemical composition), 15 particle size ratios and 5 additive contents respectively. Through the analysis of experimental data and various influencing factors, The Institute's unique formula of anti-seepage material for electrolytic cell has been formed. It can not only resist the corrosion of cryolite electrolyte, but also have sufficient fire resistance, good volume stability and thermal insulation performance; Moreover, raw material resources are abundant and the price is relatively low

Zhengzhou Research Institute completed the design on its own in a short time based on the principle of making full use of old plants and equipment and reducing investment. During the construction, the idle electrolytic plant of the former Qinyang high temperature alumina material factory and the pit floor of the electrolytic cell were partially transformed, and the original crown block was repaired, which not only revitalized the idle assets, but also saved a total investment of 4.15 million yuan. The project began construction in September 2015, and was completed and put into operation in three months. With a self raised additional investment of 3.5551 million yuan, a production line of high-quality impervious materials for electrolytic cells with an annual capacity of 30000 tons was built, creating a new speed and miracle in the construction of the company's production line

with the strong support of the leaders of Chinalco, more than 20000 tons of impervious materials have been produced. After being used by enterprises in the company, through scientific testing, the anti electrolyte permeability is more than 4 times higher than that of the original market impervious material products. It not only solves the problem of the short board of the anti-seepage material for electrolytic aluminum, avoids the huge invisible economic losses caused to the company by the quality of the anti-seepage material, but also creates good economic and social benefits. Taking 400kA electrolyzer as an example, the overhaul cost is 800000-850000. With HTMi, the cost of impervious material is 30000 yuan. If the impervious material is improperly selected, the impervious effect will be poor, the thermal insulation material will be damaged, the thermal state of the electrolyzer will become worse, and the economic indicators of operation will deteriorate, which can increase the power consumption per ton of aluminum by more than 300 degrees, and even the electrolyzer will be damaged in the early stage. If it is used for 2-3 years, the electrolyzer will be stopped (calculated as 3 years). After using the impervious material, the normal cell life is calculated as 8 years, which can reduce the overhaul cost of electrolytic aluminum enterprises by about 100 yuan per ton of aluminum, and save more than 300 degrees of electricity per ton of aluminum. At the same time, Zhengzhou Research Institute, taking the overall situation into consideration, has made outstanding contributions to supporting the company in improving quality and efficiency by selling at almost cost price in the company

not only that, Zhengzhou Research Institute took this opportunity to make full use of the platform of the national light metal quality supervision and inspection center. On the basis of extensive consultation and internal discussion, its scientific name was polyurethane elastic fiber, and set a new standard of impervious material to meet the needs of electrolytic aluminum. Especially for the key anti-seepage performance indicators, we should also see that the samples are not clamped correctly, which is 3.5 times higher than the industry standard, forming the company's standard and setting a new benchmark for the company to improve quality and efficiency. At the same time, Zhengzhou Research Institute is also registering the company's unique trademark of impervious material to form a new brand of Chinalco

at present, the production capacity of new impervious materials has been in short supply. Zhengzhou Research Institute is improving the production line, striving to achieve 50000 tons, and strive to move towards the goal of 60000 tons per year, so as to meet the needs of the company and the industry for the overhaul of electrolytic cells, and make greater contributions to the company and China's aluminum industry

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