Recently, Fushun Aluminum Factory has made a significant breakthrough with the successful development of a new safety alarm system for its electrolytic aluminum plant, ensuring safer and more efficient production in the new electrolysis process.
The new electrolysis line at Fushun Aluminum Plant is controlled by a microcomputer system, managing the operation of 208 sets of 200 kA prebake electrolytic cells. This includes critical tasks such as shell removal, blanking, anode lifting, and effect alarms. However, due to the presence of a groove cover plate on the electrolytic cell, when an "effect" occurs—characterized by a sudden temperature rise—the high heat can melt the electrolyte shell. This may lead to molten aluminum (reaching up to 900°C) spilling out of the cell, potentially damaging the cathode busbar and causing serious production accidents.
To address this issue, Qin Hongfei, a maintenance engineer from the microcomputer section of the factory, took the initiative to develop a safety alarm system. Using available data, technical drawings, old equipment, and even discarded trough gauges, he conducted over a dozen trials before successfully creating the alarm. The system is now responsible for monitoring 52 electrolyzers in one production area, with a total of eight such systems installed across the factory’s eight production zones. Each alarm operates independently, and as soon as an effect is detected, it triggers an immediate audible alarm and flashes a red light.
After a month of testing, the system performed exceptionally well. Its successful implementation has significantly enhanced the safety of the new electrolysis process, providing a reliable safeguard against potential hazards. This innovation not only improves operational efficiency but also demonstrates the factory's commitment to continuous improvement and worker safety.
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