WO2019226067A1 - Способ неразрушающей дефектоскопии анода алюминиевого электролизера - Google Patents
Способ неразрушающей дефектоскопии анода алюминиевого электролизера Download PDFInfo
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- WO2019226067A1 WO2019226067A1 PCT/RU2018/000489 RU2018000489W WO2019226067A1 WO 2019226067 A1 WO2019226067 A1 WO 2019226067A1 RU 2018000489 W RU2018000489 W RU 2018000489W WO 2019226067 A1 WO2019226067 A1 WO 2019226067A1
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- anode
- vectors
- induction
- electromagnetic field
- calculated
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/72—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
- G01N27/82—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/02—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance
- G01N27/04—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating impedance by investigating resistance
- G01N27/20—Investigating the presence of flaws
Definitions
- the invention relates to the field of flaw detection (non-destructive testing) of the anode of an aluminum electrolyzer and can be used in the metallurgy of non-ferrous metals, where electrically conductive electrodes are used.
- the patent of ALCOA, USA discloses a method and apparatus for measuring the electrical resistance of a carbon electrode.
- the device contains a plurality of current leads and voltage measurement sensors for an electrode surface electrically in contact with them.
- Current flows through the electrode along a plurality of paths between the current leads and the plurality of sensors.
- the total current along each path and the voltage drop in the electrode are measured to determine the electrical resistance of the electrode between the position on the contact surface of the current lead and the surface of the electrode in contact with the sensors. It is shown that in this way it is possible to measure the electrical resistance of the electrode at temperatures up to 960 ° C.
- a device for measuring the electrical resistance of a sample surface with an 8-point sensor improves the accuracy of measuring resistance in a region close to the edges of the anode body and to other inhomogeneities of the sample.
- the measurement result is the specific resistance [Ohm / m], which can only indirectly and integrally characterize the electrical resistivity in the volume of the anode.
- MIREA An on-line real time solution to check the electrical quality of anodes // Proceedings of 33rd International ICSOBA Conference, 2015, pp.455-466, a method for determining the quality of anodes using the MIREA installation is presented ( ⁇ - “Instant measurement of anode electrical resistance "). The system is based on non-destructive measurement of the electrical resistance of the anodes when simulating the current distribution in the anode during electrolysis.
- MIREA Magnetic Ink Radio
- the MIREA device is installed at the exit of the anodes from the kilns. After cooling and subsequent diagnostics, high-quality anodes enter the electrolysis production of diagnostics, while defective ones go to the processing line for processing.
- the technological measurement scheme includes the following steps: placing the anode in the installation, introducing the contacts into the anode nipple socket, measuring the voltage drop in the anode, removing the installation contacts from the anode nipple socket, removal of the anode from MIREA.
- MIREA is able to measure in 60-66 seconds.
- the MIREA installation is fully automated and requires limited maintenance.
- the MIREA installation takes into account the significant influence of the nipple zone on the anode electrical resistance, i.e.
- the main measuring element of MIREA is the plug of the nipple socket, which simulates the standard anode bracket through which current is supplied to the anode.
- the installation can also be used with a non-standard shape of the nipple socket.
- a voltmeter you can get a map of the voltage drop between the surfaces of the anode. The voltage drop is measured between the starting point at the top of the anode and predetermined positions on the surface of the anode (pattern).
- the template means taking measurements at points located on four columns along both sides on the surface of the anode and at 7 levels along the height of the anode, these columns are located between the nipple sockets. In total, 28 measurements are made at each anode.
- the ranking by the quality of the anodes is arbitrary, relying on the average analysis, i.e. the deviation of the voltage drop in the measured anode from the average voltage drop of the batch of anodes.
- the Mahalanobis distance is the distance between the data point representing the values of the potential difference of the anode and the midpoint in multidimensional space (the average value of the batch of anodes). This distance is used to identify outliers. The higher the Mahalanobis distance for a particular anode, the higher the voltage [mV] of this anode from the average batch value. Thus, this is an indicator of how the anode is different from the average batch anode. Anodes with a high Mahalanobis distance can be attributed to defective ones.
- the disadvantage of the MIREA method is the problem of instability of the transition resistance of the contact area in the nipple sockets of the anode, where a known current is supplied, because it is necessary to provide a vast contact area of the current lead in the nipple socket of the anode, moreover, the same in all the nipple sockets of the anode;
- the disadvantage is the problem with increased wear of the contacts of the sensors (measuring electric potentials on the side surfaces of the anode), the instability of the latter, reducing the overall reliability of the system.
- EMR electromagnetic induction
- at least one receiving coil is mutually inductively coupled to the electromagnetic field generated by the unit.
- the crude anode, or part of it, extends inside the receiving coil.
- the sensor is connected to the receiving coil, and generates an output signal, inducing a variation in the electromagnetic field obtained by this coil.
- the conductivity value of the anode is then calculated using a signal from the sensor and signals previously obtained using reference anodes.
- the patent also shows the dependence of the conductivity (1 / ( ⁇ cm)) on the percentage of pitch in the anode, the conductivity ( ⁇ cm) 1 on the amplitude of the signal variation in relative units.
- the disadvantage is the low accuracy of determining the location of defects, since it is possible to determine only the materiality of the deviation of the relative electrical resistance, for example, the right half of the anode from the left half of the anode, that is, the question of more precise determination of how the size and location of the defect (heterogeneity of electrical resistance, cracks, cavities) remains problematic to date.
- MIREA Magnetic Reassisted laser desorption spectroscopy
- the MIREA method (Guillaume Leonard, Ameline Bernard, Yann El Ghaoui, Marc Gagnon, Patrick Coulombe, Gontran Bourque and Stephane Gourmaud. MIREA - An on-line real time solution to check the electrical quality of anodes // Proceedings of 33rd International ICSOBA Conference, 2015, pp.455-466), based on the use of Ohm's law, which is simple, inexpensive, very productive (can reach about 60 anodes / hour).
- the MIREA method has the following disadvantages:
- the technical problem of electromagnetic defectoscopy of a calcined coal anode block of an aluminum electrolyzer is the lack of informational content of the measurement, low accuracy of determining the location of defects, reduced technological capabilities, and also reduced reliability of the method, which leads to insufficient accuracy of defectoscopy and determination of the quality of the anode block. Disclosure of invention
- the objective of the invention is to provide a method of non-destructive inspection of the anode of an aluminum electrolyzer with the exception of these disadvantages, including:
- the technical result of the invention is the solution of this problem, increasing the information content of determining the location of defects, caused, firstly, by measuring the magnetic field strength, the number and coordinates of the location of the current leads, as well as the number of coordinates and coordinate values of the sensors corresponds to the coordinate matrix of the sampling points of the surface of the upper face of the working anode block; secondly, by comparing the vector values of the magnetic field (or magnetic induction) of the working anode block measured in 3-dimensional space in the orthogonal coordinate system and the reference computer model, which, as a result, improves the accuracy of flaw detection and determining the quality of the anode block .
- the technical result of the invention is also the expansion of technological capabilities of the method by reducing the instability of the transition resistance of the contact area in the nipple sockets of the anode, because in the proposed method, there is no need to provide an extensive contact area of each current lead identical in all nipple sockets.
- the technical result is also to increase the reliability and reliability of flaw detection by measuring the magnetic field vectors of non-contact sensors.
- a method of non-destructive flaw detection of the anode of an aluminum electrolyzer includes building a design model of the anode or using a predetermined model with known data on the geometry and resistivity of the anode, geometry and coordinates of internal defects, in this case: 1) on the calculation model of the anode with given or known data, at least about the geometry, electrical resistivity of the anode, as well as the geometry and coordinates of the internal defect in the form of inhomogeneity of resistivity, cracks or cavities inside the anode, a numerical calculation of the spatial flow current through the anode, as well as the amplitudes and directions of the magnetic field strength (or induction) vectors at the outer surface of the anode, under the boundary condition of placement on external NOSTA anode, at least a pair of conductive contacts through the anode feeding a predetermined amount of electric current;
- step 2) perform a series of cyclic calculations in step 1) under the boundary conditions for placing at least a pair of electrically conductive contacts on the external surfaces of the anode, provided the contacts are moved with a sampling step not exceeding at least twice the length of the alleged defect;
- step 2) display the calculation results for step 2) in the form of a three-dimensional (3D) matrix of amplitudes and directions of the vectors of the calculated electromagnetic field strengths (or inductions) at the sampling points at the outer surface of the anode;
- the anode in this case, in the case of an acceptable deviation of the measured and calculated values of the amplitude and direction of the vectors at the same sampling points at the surface of the anode, the anode is recognized as high-quality, and in the case of a significant deviation, the anode is considered poor-quality.
- the Mahalanobis distance to determine defective anodes, i.e. the distance between the data point representing the values of the vector of intensity (or induction) of the electromagnetic field at the sampling point of the anode and the midpoint in multidimensional space (the average value of the batch of anodes), while the higher the Mahalanobis distance for a particular anode, the higher the value of the electromagnetic field strength (or induction) of this anode from the average batch value, anodes with a high Mahalanobis distance are considered defective.
- the comparison of the measured and calculated strengths or inductions of the electromagnetic field of the current is carried out at the same sampling points on the surface of the anode, with the same amplitude, shape and phase angle of a given magnitude of the alternating current.
- a combined sensor with three orthogonally located Hall sensors is usually used, in particular, to measure the amplitude and direction of the vectors of intensity or induction of an alternating electromagnetic field, at least one combined sensor with three orthogonal inductive windings covering a region of space centered at a sampling point at the outer surface of the anode.
- Also proposed is a method of non-destructive flaw detection of the anode of an aluminum electrolyzer including the construction of a calculation model of the anode with known data on the geometry and resistivity of the anode, the geometry and coordinates of internal defects, according to which, the operations obtained in steps 1), 2), 3) are used; values in the form of a three-dimensional matrix of amplitudes and directions of the vectors of the calculated strengths or inductions of the electromagnetic field at the sampling points at the outer surface of the anode.
- preset values for example, constructed on the basis of a set of experimental data.
- j j (r)
- dV is the volume element
- integration is performed over the entire space (or over all its regions, where j ⁇ 0), r - corresponds to the current point during integration (the position of the element dV).
- teslameters Devices for measuring magnetic induction and magnetic field strength (MF) are called teslameters (TM).
- TM teslameters
- Hall transducer ferromodulation
- nuclear resonance teslameter The most common instruments for determining the induction and magnetic field strength are: teslameters (TM) with a Hall transducer, ferromodulation and nuclear resonance teslameter.
- a TM with a Hall converter determines the parameters of medium (from 10-5 to 10 1 T) and strong (10 -1 to 10 2 T) magnetic fields (MP).
- the principle of operation of such teslameters is based on the appearance of EMF in semiconductors placed in a zone of influence of a magnetic field.
- the magnetic induction vector of the desired magnetic field (B) should be perpendicular to the semiconductor plate 1 (Fig. 1).
- EMF E x
- U The millivoltmeter scale is graduated in tesla.
- the EMF of the Hall depends on the design parameters of the semiconductor wafer (coefficient C), current strength and magnetic induction:
- the device is graduated in units of MP, provided that the current strength is constant.
- TMs with a Hall converter are easy to use, small in size, which allows them to be used for measurements in small gaps. With their help, the parameters of constant, variable and impulse fields are determined.
- the measurement range of a conventional device is from 2 10 ' to 2 T, with a relative error of ⁇ 1.5-2, 5%.
- FIG. 2 The operation of the method is illustrated in FIG. 2, where on a theoretical model of carbon anode 1 with known data on the geometry, electrical resistivity of the anode, as well as the geometry and coordinates of the internal defect 2 in the form of a cavity or crack, or the inhomogeneity of the electrical resistivity inside the anode, the calculation of volumetric current spreading is performed by the finite element method (I) through the anode 1, as well as the amplitudes and directions of the intensity vectors (Hi, H 2 , etc.) or magnetic field induction at the outer surface of the anode 1, with the boundary condition of placing at least a pair of electrically conductive contacts 3 on the outer surfaces of the anode 1 feeding through the anode 1 a known constant electric current (I).
- I finite element method
- At least one sensor 4 is placed on the outer surface of the flaw detector anode 1 and the amplitude and direction of the magnetic field or magnetic field vectors are measured at the same sampling points as in 1.1-1.3, and stored in the form of a 3D matrix of measured magnetic field vectors.
- the ST matrices of the calculated and measured vectors of intensity or magnetic field induction are compared at the same sampling points (Tj and T 2 ) at the outer surface of the anode 1.
- the measurements of the amplitude and direction of the vectors are due to the presence of measurement error.
- the Hall sensor has a relative measurement error of up to 2.5%
- the scatter of the anode electrical resistance parameters regulated by the production process cycle can lead to a relative measurement error of up to 12%
- the positioning error of the Hall sensors during automatic installation of the matrix of measuring sensors introduces an additional relative error of up to 2 , 5%
- the quality of contact when applying electric current can lead to a relative measurement error of up to 3%.
- the maximum value of the relative measurement error can be 20%, respectively, any deviation of the measured and calculated values of the amplitude and direction of the vectors at the same sampling points at the anode surface, which is less than 20%, is not a consequence of the defect, in which case the anode is recognized as a quality . Therefore, in the case of an insignificant deviation (less than 20%) of the intensity or induction measured from the calculated values of the amplitude and direction of the vectors (Hi, H 2 , etc.) at the same sampling points at the surface of the anode 1, the anode is recognized as qualitative.
- the anode In the case of a significant deviation (more than 20%) of the actual from the ideal values of the amplitude and direction of the vectors (Hi, H 2 , etc.) at the same sampling points near the surface of the anode 1, the anode is recognized as poor quality and rejected.
- FIG. Figures 3 and 4 show the current densities J [A / m] inside the carbon anode sample, both without internal defects and with a particular defect, for example, in the form of a horizontal cracks / cavities 200x200x10 (Fig. 4).
- the current goes around it (along the path of least resistance) and turns out to be closer to the side surface of the anode block, thereby introducing distortion into the picture of the magnetic field induction vectors (or intensity) B [T], due to an increase in the amplitude of these vectors at points located closer to the side surface of the anode, as shown in FIG. 5, 6.
- FIG. 4 shows the current densities J [A / m] inside the carbon anode sample, both without internal defects and with a particular defect, for example, in the form of a horizontal cracks / cavities 200x200x10 (Fig. 4).
- the current goes around it (along the path of least resistance) and turns out to be closer to the side surface of the anode block, thereby
- the lower and upper limits of the deviation range of the projections of the amplitudes and directions of the intensity or magnetic induction vectors can be set based on the technical and economic requirements of production, in which a cost-effective balance is achieved between the number and cost of rejected anodes and the economic effect of not using them in subsequent technological processes.
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Abstract
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Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
BR112020023705-1A BR112020023705B1 (pt) | 2018-05-21 | 2018-07-24 | Detecção de defeitos do ânodo por um método não destrutivo de célula de redução de alumínio |
AU2018424254A AU2018424254A1 (en) | 2018-05-21 | 2018-07-24 | Method for non-destructively examining an anode of an aluminium electrolysis cell |
US17/057,580 US11630081B2 (en) | 2018-05-21 | 2018-07-24 | Method for non-destructively examining an anode of an aluminium electrolysis cell |
CA3095712A CA3095712A1 (en) | 2018-05-21 | 2018-07-24 | Method for non-destructive inspection of anodes for aluminium reduction cells |
EP18919461.6A EP3748346B1 (en) | 2018-05-21 | 2018-07-24 | Method for non-destructively examining an anode of an aluminium electrolysis cell |
CN201880093073.6A CN112074733B (zh) | 2018-05-21 | 2018-07-24 | 用于对铝电解槽阳极进行无损检查的方法 |
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RU2018118713 | 2018-05-21 | ||
RU2018118713A RU2686570C1 (ru) | 2018-05-21 | 2018-05-21 | Способ неразрушающей дефектоскопии анода алюминиевого электролизера |
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WO2019226067A1 true WO2019226067A1 (ru) | 2019-11-28 |
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PCT/RU2018/000489 WO2019226067A1 (ru) | 2018-05-21 | 2018-07-24 | Способ неразрушающей дефектоскопии анода алюминиевого электролизера |
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US (1) | US11630081B2 (ru) |
EP (1) | EP3748346B1 (ru) |
CN (1) | CN112074733B (ru) |
AU (1) | AU2018424254A1 (ru) |
BR (1) | BR112020023705B1 (ru) |
CA (1) | CA3095712A1 (ru) |
RU (1) | RU2686570C1 (ru) |
WO (1) | WO2019226067A1 (ru) |
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CN110161913B (zh) * | 2019-05-23 | 2020-12-04 | 上海钇莹电器有限公司 | 一种铝电解槽控制机多路数据采集板及多路数据采集方法 |
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RU2189403C2 (ru) * | 2000-12-05 | 2002-09-20 | Закрытое акционерное общество "ТоксСофт" | Способ управления электролизерами для получения алюминия и устройство для его осуществления |
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RU2584726C1 (ru) * | 2014-12-29 | 2016-05-20 | Федеральное государственное унитарное предприятие "Научно-исследовательский институт стандартизации и унификации" | Способ измерения параметров трещин в немагнитных электропроводящих объектах |
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- 2018-05-21 RU RU2018118713A patent/RU2686570C1/ru active
- 2018-07-24 AU AU2018424254A patent/AU2018424254A1/en active Pending
- 2018-07-24 US US17/057,580 patent/US11630081B2/en active Active
- 2018-07-24 CA CA3095712A patent/CA3095712A1/en active Granted
- 2018-07-24 EP EP18919461.6A patent/EP3748346B1/en active Active
- 2018-07-24 CN CN201880093073.6A patent/CN112074733B/zh active Active
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Also Published As
Publication number | Publication date |
---|---|
EP3748346B1 (en) | 2023-02-22 |
CN112074733B (zh) | 2024-01-12 |
CN112074733A (zh) | 2020-12-11 |
EP3748346A4 (en) | 2021-12-01 |
BR112020023705B1 (pt) | 2024-01-30 |
EP3748346A1 (en) | 2020-12-09 |
AU2018424254A1 (en) | 2020-09-17 |
US11630081B2 (en) | 2023-04-18 |
CA3095712A1 (en) | 2019-11-28 |
BR112020023705A2 (pt) | 2021-02-09 |
RU2686570C1 (ru) | 2019-04-29 |
US20210208102A1 (en) | 2021-07-08 |
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