In primary Aluminium industry , the energy control is a key , as in one aspect, it can largely increase the thermal efficiency, on the other , it can reduce the cost in an optimistic amount ,by reducing the energy wasting. Now in China, Siltherm has set up a milestone in the whole industry , by using its Microporous Insulation Product named Siltherm-Alu in the aluminium electrolysis cells. Siltherm Alu Panels can be easily installed in the wall and the bottom in the electrolysis cells.The primary aluminium production is carried out in electrolysis cells (pot cells), where alumina dissolved in cryolite is reduced electrolytically to metal aluminium.
State of the art is the insulation of pot cells with:
Microporous Insulation Panel/Vermiculite boards orMoler bricks
Siltherm Structure in the bottom of Electrolysis Cells
1st layer: 120-130mm dry seepage control material (Dry barrier insulation)
2nd layer:65mm Diatomite insulation brick (Moler Bricks)
3rd layer: 65mm Diatomite insulation brick (Moler Bricks)
4th layer 15mm Siltherm Alu Panel
5th layer 15mm Siltherm Alu Panel
Siltherm ALU panel in Side Wall Structure
1st layer: Si3N4-SiC Brick 2nd layer: 10mm Siltherm Alu Panel
Siltherm Alu Panel can be placed closely to the wall or the bottom in the cells , as a placement of conventional Ceramic Fiber / Calcium board.
Note: Since there are two operating methods in the cells while producing primary aluminium , one is using high electric current with high voltage , while the other one is opposite .Therefore, in the case of high voltage and high electric current cells, high capacity of the aluminium is a key parameter pursued ,enough better insulation is not suggested while a better formation of side ledge is necessary. Hence, Siltherm Alu panel is not instructed to be used in the wall , but only in bottom. Anyway, application in bottom / side wall /both will be optional based on real situation.
Siltherm Installation and Fabrication In Site: Bottom of Electrolysis Cells.
Siltherm Effects in Pot Cells: Pingguo Aluminium Cooperation / Yunan Aluminium Cooperation: (240KA Pot Cells)
|
Voltage No
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Voltage(Everage / V)
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With Insulation
|
Without Insulation
|
|
230
|
4.020
|
|
√
|
|
231
|
4.091
|
|
√
|
|
232
|
3.879
|
√
|
|
At the same time, it brings a 50 C decrease in the bottom cold surface, along with a as high as 95% thermal efficiency.
Cost Analysis using Siltherm ALU panel in pot cells.
Two Year’s in-site test shows application of Siltherm Alu in pot cells can bring a 50-100mv voltage decrease. Assuming that a 0.45 RMB(0.075 USD) cost for per KW electric power , and 50mV ≈ 150 KW (Electricity power) .
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Saving
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30 days (KW)
|
180 days (kw)
|
365 days (kw)
|
|
50mV can be Saved
|
4500
|
27000
|
54750
|
|
100mV can be Saved
|
9000
|
54000
|
109500
|
|
Money in RMB
50mV can be saved
|
0.45 x 4500
|
0.45 x 27000
|
54750 x 0.45
|
|
Money in RMB
100mV can be saved
|
0.45 X 9000
|
0.45 X 54000
|
0.45 X 109500
|
|
Money in USD
50mV can be saved
|
0.075 X 4500
|
0.075 X 27000
|
0..75 X 54750
|
|
Money in USD
100mV can be saved
|
0.075 X 9000
|
0.075 X 54000
|
0.075 X 109500
|
