Recently, Fushun Aluminum Factory has successfully developed a new safety alarm system for its newly built electrolytic aluminum plant, significantly enhancing the safety of the production process. This innovation ensures that the electrolysis operation runs smoothly and safely, reducing the risk of accidents caused by abnormal conditions.
The new electrolysis line at Fushun Aluminum Plant is controlled by a microcomputer system, managing the daily operations of 208 large-scale 200 kA prebake cells. These operations include shell breaking, block removal, anode lifting, and effect alarms. However, due to the presence of a groove cover plate in the electrolytic cell, when an effect occurs, the temperature inside the groove can rise dramatically, potentially melting the electrolyte shell. This could lead to molten aluminum (reaching up to 900°C) spilling out of the cell, damaging the cathode busbar and causing serious production accidents.
To address this issue, Qin Hongfei, an engineer from the microcomputer maintenance department, led the development of a safety alarm system. Using available data, technical drawings, old equipment, and even discarded trough gauges, he conducted over a dozen trials before finally creating a reliable alarm solution. The system is responsible for monitoring 52 electrolyzers in one production area, with a total of eight such areas in the plant. Each area has its own independent alarm, which immediately sounds and flashes a red light whenever an effect occurs in any cell.
After a month of trial operation, the system has proven to be highly effective. Its successful implementation has provided a strong foundation for ensuring the safe and stable operation of the new electrolysis process, marking a significant step forward in the factory’s safety management and technological advancement.
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