RU2641289C2 - Improved system of measurement and control of electric current for cell plants - Google Patents

Abstract

FIELD: electricity.SUBSTANCE: invention relates to a method and a system of electric current control (ECM) in at least one electrolysis cell having at least two electrodes in contact with an electrolytic medium, a plurality of touch sensitive measuring instruments for a current passing through one or more electrodes, besides the mentioned touch sensitive instruments are located within at least one ECM panel installed in one or more operating electrolysis cells. The system also includes the supporting means for supporting at least one ECM panel in electrolysis each cell, the supporting means being arranged to prevent disturbances in normal electrode movements and damage of the ECM panel. The system is executed with a possibility to measure an electric current passing through an electrode or a plurality of electrodes in the electrolysis cell. These improvements include means for minimization of impacts on measurement of current of variables of several types, for example, electromagnetic interference, electrolysis cell geometry and contact configuration, in order to provide a reliable approximation of the current passing through each electrode. In addition, the aforementioned improvements relate to maximizing the functionality, adaptability and manageability of the device, providing a complete upgrade of the metallurgical systems, in which it is important to provide reliable control of the electric current passing through the electrodes.EFFECT: increase in the accuracy of real-time monitoring of current magnitude passing through each cathode or anode contained in the electrolysis cell of electrolytic refining of metals, as well as optimisation of the electrolysis cells operation.31 cl, 13 dwg

Description

FIELD OF THE INVENTION

The present invention relates to metallurgical systems, in particular to electrometallurgical systems, and to improving the characteristics of the electrolyzer and / or electrolysis shop.

In particular, the present invention can be used for real-time monitoring of each cathode or anode that is part of an electrolytic cell for electrolytic production or electrolytic refining of metals, or another electrolytic cell with parallel electrodes.

BACKGROUND

The processes for recovering a metal, such as copper, often comprise the steps of electrolytic production or electrolytic refining. These steps have the advantage of real-time monitoring of the performance of each metal plate in order to obtain the optimum performance of the electrolysis shops.

During the electrolysis, a short circuit may occur if the electrodes are not aligned with each other, if due to physical defects the metal build-up on the surface is uneven, which, in particular, may be the result of working problems, for example, the presence of impurities, cathodic currents exceeding the permissible value, the presence of particles in the electrolyte, damage to the electrodes, or peeling of the electrolytic coating, which then comes into contact with an adjacent electrode. In addition, in the case of poor electrical contact between the anodes or cathodes and their current sources, a low current situation may occur, leading to a decrease in the efficiency of the system. In both cases, the result may be a poor quality product, or, as in the case of electrolytic refining of copper, the inability to achieve the required purity, and the result in these cases may also be a decrease in the current and energy utilization, which can reduce the productivity of the workshop and increase costs. In this context, control of the current passing through the electrodes of each electrolytic module is important to improve the processes, products, and performance of systems that use the above procedure.

The control problem of each cell is described in patent CL 44909 (J. Garcés Baron). This patent describes a control system for electric current passing through each cathode forming a set of electrodes, and this control system contains many non-contact electric current sensors connected to data exchange means, while said data exchange means are configured to communicate with the control device and data processing having a graphical user interface. Such proximity sensors are configured to measure the electric current passing through the electrode by measuring the magnitude of the magnetic induction generated by this passing current.

US7,445696 (Eugene You and others) also describes the principle on which the current sensor system used in electrolytic cells for electrolytic production and electrolytic refining of metals, and theoretical methods for compensating magnetic fields generated by adjacent electrodes are based. However, this patent does not describe important practical aspects of designing a touch panel, including means for sealing a panel, preventing electrical interference, practical aspects of calibration, limitations on the geometry of a touch panel embedded in many electrolysis systems, and maintaining such a panel in an electrolyzer. In particular, the presence of current measurement systems made in accordance with the prior art may cause difficulties in removing or replacing the electrode in the electrolyzer due to the fact that when lowering the electrodes, the electrodes can collide with the sensor system, causing damage and interfering with the effective loading of the electrodes into the cell. Neither in CL 44909, nor in US 7445696 solved the problem of the difficult movement of the electrodes in the cell due to the presence of a sensor system or the availability of means to protect the integrity of the sensors. The crane loading bale and powerful electrode hooks used to raise the cathodes and anodes can themselves cause damage to the sensor system. No. 7,445,969 also describes methods for attenuating interference from adjacent electrodes. Such a system does not provide the possibility of reliable measurement of the electric current passing through the electrode, since in practice “ideal” theoretical scenarios are rare. Thus, a method known from the prior art, based on a theoretical calculation, does not take into account the additional contribution made by the magnetic field. In addition, the solutions known from the prior art do not take into account external influences affecting the measurement, for example, temperature, which affects both the characteristics of magnetic fields and the measured electric current.

In addition, in electrolytic cells for electrolytic production or electrolytic refining of metals, very severe conditions are present. This may be, for example, chemical conditions, usually characterized by a high acidity of the electrolyte, the presence of drops of acid vapor and, possibly, halogens present in the airspace above the electrolyte. Such extreme operating conditions with frequent processes of removing and replacing the electrodes create a greater likelihood of damage to the sensors and the creation of interference by the sensors to move the electrodes. The options described in the documents known from the prior art do not provide stability in relation to these conditions, which leads to frequent breakdowns.

Moisture and chemical corrosion conditions present above the electrolyte electrolyzer require that the sensors be completely sealed inside the housing. There is an additional limitation that in many electrolytic cell systems, a panel having a round profile is not suitable for its installation under the electrode rods because of the thickness of its profile, which prevents the passage of electrodes when lowering them into the cell, and hooks for raising the electrodes, since they can be lowered under the rods to raise the electrodes by their rods. Thus, it is preferable to have non-circular profiles, since they are more used in practice and they allow you to position the sensors closer to the rods, which increases the accuracy of the sensor readings. Solutions known in the art do not affect this problem.

In addition, there is no clearly defined prior art regarding a method for sealing a non-circular cross section of non-circular shaped tubes suitable for such an application. Standard methods known from the prior art, for example, the use of flanges and threaded plugs, in the case of a non-circular profile, it is impossible to apply from the point of view of geometry. Internal sealing methods, for example, using o-rings, are not practical in practice due to bends of small radius that may be present at the corner or corners of non-circular shaped pipes. The applicant tried to apply bonding, epoxy, and a plug at the end of the pipe, but these attempts failed due to differences in the thermal expansion of the binder and the tubular body.

With regard to work in electrolysis workshops, the management of metal removal cycles (also known as metal removal cycles) in workshops for the electrolytic production or electrolytic refining of metals is usually carried out using a written schedule or a computer-controlled schedule to determine which electrolytic cells and what time it is necessary to carry out withdrawal. Such systems are inevitably based on paper documents or manually entered computer records about when it is necessary to carry out removal in electrolyzers. In order to accurately determine the current utilization factor, it is desirable to know the exact period of deposition time in individual electrolyzers. This requires the availability of custom-designed software systems and accurate operator records, which will ensure the correctness of the data. It is also important when changing the current settings in the electrolysis shop to determine and adjust the deposition time in accordance with the past ampere-hours, but this requires additional calculations for each cell. In addition, operator errors, for example, in the case of incorrect data recording and the absence of removal from the electrolytic cells at acceptable periods of time, lead to the appearance of inappropriate values of the cathode weight, poor structure, short circuits, damaged anodes and reduced current utilization factors.

If there are automatic cranes in the workshops, they can be made with the ability to record the exact time of removal from the electrolytic cells, however, such systems have a high cost, and most of the electrolysis shops are not equipped with such cranes.

Thus, the invention described in this application is intended to eliminate one or more of the aforementioned problems of the prior art by reliable measurement of current, which allows to optimize the corresponding processes through reliable hardware solutions.

SUMMARY OF THE INVENTION

The present invention relates to improvements in metallurgical systems, in particular electrometallurgical systems, related to improving the characteristics of the electrolyzer and / or electrolysis shop by improving one or more of the following characteristics of these systems: functionality, adaptability, controllability or user interface, the key factor is the control of electric current , that is, its measurement and control.

The present invention relates to an electric current management system (ECM) comprising at least one electrolyzer having at least two electrodes in contact with an electrolytic medium, a plurality of sensor means for measuring current passing through one or more electrodes, said sensor the means are located in at least one ECM panel installed in one or more operating electrolyzers, supporting means for maintaining at least one ECM panel in each electric oliser, and the supporting means are designed to prevent disruption of normal electrode movements and damage to the ECM panel.

Thus, the invention relates to a system for improving real-time monitoring of an electric current passing through each of a plurality of individual cathodes or anodes forming an electrolyzer. In this context, the present invention also provides improvements to various electric current measuring systems measuring electric current passing through an electrode or a plurality of electrodes inside an electrolyzer. These improvements include means to minimize the effects on the measurement of current of several types of variables, for example, electromagnetic interference, electrolyzer geometry and contact configuration, to ensure reliable approximation of the current passing through each electrode. In addition, the aforementioned improvements relate to increasing the functionality, adaptability and controllability of the device, providing a complete modernization of metallurgical systems, in which it is important to ensure a reliable approximation of the electric current passing through the electrodes. Therefore, this invention can be used in particular for real-time monitoring of each cathode or anode contained in an electrolytic cell for electrolytic production or electrolytic refining of metals, or another electrolytic cell with parallel electrodes.

As indicated above, the present invention in particular relates to the improvement of systems where a key factor is electric current control (ECM). In this context, the invention the availability of a reliable optimized system for measuring real-time electric current and / or provides for the modernization of existing measuring devices. This explains the adaptability of the invention, according to which solutions are widely adapted for various systems, devices, devices, devices used, developed, manufactured and / or not yet designed.

In view of the foregoing, the system according to the invention comprises a plurality of sensing means for measuring current, preferably corresponding to Hall effect sensors. These sensors are located on the touch panel, or electrode current control panel, which may contain means for processing and improving the measured current values, in particular, means for minimizing the effects of background magnetic fields on the current measurement. In addition, in one embodiment of the invention, such sensors are capable of exchanging data with central modules, preferably corresponding to at least one preprocessing module, said preprocessing modules being configured to communicate with a main controller module, which in turn is configured with the ability to exchange data with a central server module containing a user interface. The following modules and any other types of devices used to process, control and visualize data are referred to as central modules and display devices, respectively.

The present invention also relates to a method for more accurately measuring the current and controlling the current of each electrode (cathode or anode) in an electrolyzer by using a ferromagnetic device on both sides of the sensors to channel magnetic flux to provide direction and concentration of the influence of magnetic fields on the sensor means.

The invention also relates to a method for sealing a hollow panel using a mechanical seal assembly comprising a support plate, a gasket, an end cap and fasteners. After assembly, the assembly compresses the flexible seal (gasket) between the end cap and the support plate as a result of tightening the fasteners passing from the end cap through the gasket and end cap.

Preferably, the end cap may have threaded holes for said fasteners, nuts, or other fasteners.

The invention also relates to an ECM system having means for detecting metal removal cycles in order to improve control of the electrolysis shop. The removal cycles can be determined by pattern recognition, since the removal in each electrolysis workshop corresponds to a certain specific electrode lifting pattern. Since the system measures the current in each electrode, it can detect the position of the simultaneously raised electrodes and compare them with a template pre-programmed for the electrolysis shop.

Preferably, the ECM system provides a specific arrangement of one or more sensors for automatically detecting the displacement of the electrodes and the corresponding adjustment of the calculation of the electric current.

Preferably, the ECM system is designed to operate with a two-contact system containing at least one potential equalization bus, designed to improve the current distribution along the length of the cell.

Preferably, the ECM system is configured to control the voltage of each individual cell.

Preferably, the ECM system comprises a monitoring system for predicting conditions of poor contact and / or short circuit.

Preferably, the ECM system is configured to automatically adjust the current threshold values in accordance with actual conditions in the cell to prevent false indication of a short circuit and poor contacts.

Also, the ECM system preferably comprises means for prioritizing maintenance and repair of short circuits and poor contacts, for example, in accordance with the age and severity of the short circuits.

Preferably, the supporting means for the ECM panel contain protective means, which may be a deflector.

The deflector performs two tasks: preventing damage to the ECM panel due to removal / replacement of the electrode and the direction of the electrodes in the correct position.

In an alternative embodiment of the invention, the supporting means for the ECM panel are hinged supporting means located on the upper part of the cell.

Hinged support means provide the ability to rotate the ECM panel beyond the path of the electrodes when performing removal or when replacing electrodes in the cell. In one embodiment of the invention, the hinge system is configured to rotate the panel above the electrolyzer contact rail and position it near the rods in the adjacent electrolytic cell to perform measurements in the adjacent electrolytic cell.

Also, the hinged support means can preferably be made with the possibility of fastening to any available elements of the electrolyzer, including the accessories of the electrolyzer, the walls of the cell or the contact bus (1CCB) between the cells.

Supporting means for the ECM panel are preferably designed to be installed during modernization on existing cells. In an alternative embodiment, the supporting means is a rigid fastening of the accessories of the electrolyzer.

In an alternative embodiment of the invention, the supporting means for the ECM panel can be attached to the cathode ventilation caps located with emphasis on the upper part of the electrolytic cells, or to shields that can be attached to the side part of said caps. In this embodiment, the ECM panel or panels are configured to be lifted out of the electrolyser together with the ventilation caps during the removal operation in the electrolyzer.

Preferably, the ECM system comprises controllers for redirecting information from the ECM panels to a central server.

Also, each controller is preferably configured to communicate with one or more ECM panels.

The ECM system preferably contains additional sensors to monitor other parameters, including, but not limited to, pH, electrolytic concentration, and temperature.

Preferably, the ECM system is configured to calculate the overall performance of the electrolyzer in a relatively different monitored parameters.

Preferably, the ECM panel is made of one or more metallic or non-metallic materials. If the ECM panel is made of a metal material, preferably the ECM panel also contains a coating of insulating material. Insulation material is intended for safe movement of the panel in the electrolysis workshop, as well as to prevent unwanted short circuits when installing the panel.

Preferably, the ECM system comprises an electrode tracking system.

A tracking system helps the operator to monitor the effectiveness of metal buildup on a specific electrode of the electrolyzer during the removal, quality assessment, weighing and determination of the current utilization coefficient, which allows to identify the corresponding problems with specific cathode bases, electrolytic cells and the positions of the cathodes in the electrolyzer. Also, the electrode tracking system preferably includes, without limitation, radio frequency identification tags (RFID tags).

In addition, the tracking system preferably provides the ability to visually determine the status. Visual determination of the state can be used in addition to the electronic state to provide an opportunity for the operator in the workshop to immediately determine the state of the electrode, for example, by the color of the LED (normal, high current, low current).

Preferably, the ECM system contains energy-saving elements, and during the time intervals between consecutive readings of the sensors, part of the electronic circuit can be turned off or switched to low power mode, due to which, at any time, only one sensor operates in the entire panel in full load mode, which reduces requirements for both peak and average power.

Preferably, the ECM system includes an alarm system. Preferably, the alarm system is configured to automatically trigger upon detection of a malfunction.

BRIEF DESCRIPTION OF THE DRAWINGS

Other aspects of the invention will be better understood from the following detailed description of preferred embodiments thereof, which are given by way of example only and with reference to the accompanying drawings, in which:

in FIG. 1 shows a diagram of an electrolytic cell comprising basic devices according to one embodiment of the invention;

in FIG. 2 is a schematic view of a cell showing an ECM panel according to one embodiment of the invention;

in FIG. 3 is a schematic perspective view of an ECM panel protected by a deflector according to one embodiment of the invention;

in FIG. 4 is a schematic cross-sectional view of the deflector shown in FIG. 3;

in FIG. 5 shows an exploded view of a mechanical seal assembly at one end of an ECM panel according to one embodiment of the invention;

in FIG. 6 is a schematic perspective view of a pivotable ECM panel mounted on top of two adjacent electrolyzers, according to one embodiment of the invention;

in FIG. 7 is a schematic view of a first embodiment of ECM panel support means;

in FIG. 8 is a schematic cross-sectional view of the supporting means shown in FIG. 7;

in FIG. 9 schematically shows a detailed cross-sectional view of a second embodiment of ECM panel support means;

in FIG. 10 schematically shows a detailed view of a third embodiment of supporting means of an ECM panel;

FIG. 11 is a schematic view of an embodiment of the invention showing a channeling device or electrode current measuring system mounted above a cathode or anode rod;

in FIG. 12 is a schematic view of an embodiment of the invention showing a channeling device or electrode current measuring device mounted above a cathode or anode rod and above an anode or cathode plate, the network being a circuit used for computer simulation;

in FIG. 13 is a schematic view of a group of cathodes or anodes with a channeling device or device for measuring electrode current according to an embodiment of the invention, the network being a circuit used for computer simulation.

DETAILED DESCRIPTION OF THE INVENTION

As shown in FIG. 1, in one embodiment, the invention comprises an electrolytic cell (1) comprising a plurality of cathodes (4) and anodes (3) in an electrolytic medium arranged alternately relative to each other. In the present invention, the cathodes (4) and anodes (3) are plates arranged parallel to each other. Near each plate, preferably near each cathode plate, sensory devices (5) are mounted on the touch panel (2) or on the ECM. Such a touch panel, which is part of the ECM system according to the invention, is located near the output (or input) current-carrying bus from the cathode plate (or into the anode plate). Such a touch panel and such touch means should not be in direct contact with the electrodes. In addition, the ECM panel (2) can be located in one of many other places in the cell (1), for example, in the wall of the cell, in the cell (as shown in FIGS. 2-10), in the upper accessories of the cell or insulators, or it can be attached to electrodes or other elements. The geometry of the touch panel, in particular its housing, can have a different shape, for example, a hollow rectangular section profile (RHS), the length of which is approximately equal to the length of the cell, the shape of the pipe or other shape. In one embodiment of the invention, the touch panel may be located in the cell using one of the following possible supporting means, as shown in FIG. 6-10.

- Using hooks attached to the panel using stainless steel or plastic cable ties mounted over the wall of the cell under the contact rail between the cells, the lid between the cells or the fittings between the cells. To prevent the hooks from moving, they can be glued. For this, the cover or accessories of the electrolyzer can be removed to allow hooks to pass under them.

- Using brackets of a special shape glued to the inner surface of the electrolyzer, which makes it possible to remove or replace the sensor housing without the need to replace the support brackets. In addition, the brackets can be screwed to the wall, cover or upper insulation module of the cell or to other components of the equipment of the upper part of the cell.

- Hooks or brackets may be made of stainless steel, plastic, aluminum or other suitable material.

- Electrolyzers can be replaced or new electrolyzers manufactured with supporting means, for example, with a special protrusion, keyway or holder, providing built-in support and positioning capabilities. This design solves the problems existing in the prior art, as it eliminates the possibility of a direct impact of the ECM panel with electrodes, a bale of a crane or other mechanical objects when they are installed in or removed from the cell.

- The presence of these nodes provides advantages in comparison with the prior art, since such a design:

- allows to reduce the shock load, which must be maintained by the auxiliary parts of the cell;

- facilitates the work of the operator when installing electrodes in the cell;

- allows you to install the panel closer to the electrode rods, increasing the accuracy of the system;

- can be installed with minimal downtime of the electrolyzer.

All embodiments of the above mounting technologies have been designed to prevent damage to the sensor devices installed in the ECM.

The support brackets were designed to allow the ECM panel to be firmly fixed to the cell. This design provides physical strength sufficient to protect against mechanical stresses associated with the movement of the electrodes into and out of the cell, while at the same time preserving a narrow profile in order to avoid restrictions on the installation and removal of the electrodes. The key design elements of the supporting brackets are means for maintaining the position of the sensors in one line relative to each other in the panel and maintaining the given positions of the electrodes. This is achieved by means of a frictional connection between the support brackets and the ECM. Some embodiments of the invention also include the installation of deflectors used to protect the panel from physical damage and to assist operators in positioning the electrodes.

As shown in FIG. 1, in a preferred embodiment of the invention, the sensors (5) are connected to the data preprocessing modules (6) in order to improve the signal quality and facilitate its reading and interpretation in subsequent modules of the system, the preprocessing module (6) preferably being a microprocessor module. In this case, each individual sensor module (containing one or more sensor devices (5) and preprocessing module (6)) can communicate directly with the central server module. However, it is preferable to have separate sensors on the same touch panel that transmit data to a single main controller on the panel. In this case, the main controller (7) can transmit all the data from the panel to the central server module (9). If wireless communication (for example, Wi-Fi) is used to communicate with the central server module (9), this reduces the number of rather expensive wireless interfaces by about 60 times. To obtain cost advantages, other parts of shared sensor circuits, for example, voltage regulators, can also be located in the main controller (7). Finally, in a preferred embodiment of the invention, in the electrolysis workshop, it is advisable to have one or more places in which it is possible to control the currents of the electrodes. This helps the operator immediately see which electrode and in which cell has either weak or strong current, and, therefore, quickly correct this condition. Information from each cell (usually, but not necessarily, from the main controller, or from each sensor) can be transmitted to a central computing device, where this information is displayed.

If the information for display is received by the central computing device, then it can also be stored for subsequent further analysis. This analysis can provide information about the trend for the past period, which can help the operator identify the sources of deviations that reduce the overall quality of production. By detecting when deposition cycles begin (as a result of detecting the extraction of one third of the electrodes during removal), it is possible to help the operator determine when a given electrode (and therefore the electrolyzer) received a sufficient charge (in ampere-hours) so that it it was possible to remove metal. The system may include a table showing the preferred order in which withdrawals should be performed. In addition, the system can report the time elapsed since the electrolysis cell was cleaned, and thus make recommendations regarding the time and procedure for cleaning the electrolytic cells. Therefore, the system according to the invention not only manages the electric current, but also provides improvements in various fields of operation of electrolysis systems.

As for the main parts of the system, each of the sensor means (5) is configured to transmit data to the corresponding pre-processing module (6), which in turn is configured to transmit data to a data exchange channel, for example, to a data bus (13) sensors whose signals are received by the main controller (7) located on each of the touch panels (2). The aforementioned data transmission can be carried out by various means, including optical cable or bus. In addition, the signals from each main controller (7) enter the data exchange channel, which may be the main data bus (8), configured to transmit data to the central server module (9). The main function of the main controller (7) is to control the exchange of data between the central server module (9) and each of the pre-processing modules (6). In this regard, the transfer of data from the device, for example, data transmitted between the sensors (5) and the main controller (7), to the central server module (9), can be carried out using various means or wireless means, including Wi-Fi. Fi or Bluetooth, or using a licensed broadband wired connection when using a local area network (LAN). The aforementioned data transmission scheme is preferable, since it is possible to use any combination of components intended for other embodiments of the invention. In this sense, various topologies of data transmission tools can be used: bus, star, ring, wire mesh or other data exchange topologies, as well as various processing methods and various equipment. In this case, it is obvious to the person skilled in the art that there are many options for centralizing or distributing elements of computing devices, and that the data can be transmitted in analog or digital form, in raw or encoded form. In particular, any known or unknown means of processing and transmitting data may be used in the present invention. For this reason, the pre-processing module (6), the main controller (7), and the central server module (9) are referred to generally as central modules interacting with each other using available means of data exchange.

Sensor means (5) contain electric current sensors and any other type of sensors used to measure the characteristics of the process and electrodes in the electrolyzer. Preferably, the electric current sensors are magnetic sensors, known as Hall effect sensors, or any other sensors having a calibrated sensor response within the operating range of electrolyzers (1). In one embodiment of the invention, other types of sensory devices are provided to monitor the status of each individual cell, including with respect to electrolyte temperature, acid concentration, pH, ion concentration and conductivity. Although the ECM panel (2) may not be in contact with the electrolyte, it may have probes passing into the electrolyte to perform such measurements. These probes may have appropriate mechanical support and protective mechanisms to improve sensor response. In another embodiment of the invention, the touch panel may be configured to measure and report the magnitude of the voltage of the cell, alternatively, using wires connected between adjacent buses.

In addition, in order to protect the sensor means (5) and preferably the pre-processing modules (6), as well as any other necessary electronic equipment used in the invention, can be made enclosed in a housing made of a corrosion-resistant material. The enclosure enclosure is part of the aforementioned touch panel or ECM panel (2). In this context, a distinctive feature of the invention lies in its resistance to damage associated with acid electrolyte and acid fog. To implement this feature, electronic circuits are enclosed in a housing made of stainless steel, aluminum, fiberglass or other sealed corrosion-resistant material. In a preferred embodiment, one edge of the housing is welded and a molded polyvinyl chloride component is adhered to the housing from the other edge. The PVC component is installed where the wireless connection is located (since wireless communication through a metal case is not possible). When using a metal casing, it can be protected by a non-conductive protective shell, which can be made (for example, using heat-shrinkable insulating material) along the entire length of the panel. This provides some anticorrosive protection to the electrode current measuring instruments, as well as electrical insulation to prevent accidental short circuits in the cell or during installation (safety). In an alternative embodiment, wireless communications equipment may be installed outside the enclosure.

In this context, another embodiment of the invention comprises a magnetic channeling device that directs and concentrates the required magnetic flux through all the necessary sensor means, providing the opportunity to reduce interference during measurements, which, thus, allows for more accurate data, since this increases the signal-to-signal ratio. noise.

For sewage magnetic flux, there are many possible schemes of the channeling device. In this context, it is possible to use two parts of a ferritic material, a colorful coating or any other kind of material related to the direction and concentration of the magnetic flux, one part on both sides of the Hall effect sensors. An alternative circuit comprises a ferrite (or similar) ring or horseshoe (19) made of a material containing three of the four sides of the cathode rod (20) to direct and concentrate the magnetic field to the sensors under the open side of the horseshoe (19), as shown in FIG. . 11. In this sense, in FIG. 12 shows an embodiment of a channeling device in which a ferrite device (22) is used to channel the magnetic field above the electrode plate (21). In addition, in FIG. 12 and 13, a network (23) is shown representing a circuit used to model the properties of a sewer device, with FIG. 13 shows several rods of several electrodes used with the device. As mentioned above, with these devices at each cathode, interference with the magnetic flux generated by the adjacent cathode can be significantly reduced since they prevent the magnetic flux from propagating outside the ferritic material. In a preferred embodiment, the ferrite or horseshoe ring located around the rod is enclosed in a corrosion-resistant material, for example, polyvinyl chloride.

Therefore, it is important that all the sensors (5) are located inside the housing at the desired distance from each other, corresponding to the intervals between the electrodes inside the electrolyzer (1). In a preferred embodiment of the invention, this is accomplished by means of an extruded polyvinylchloride “carrier element” that holds along the length of all printed circuit boards (PCBs) in which the sensors are mounted together with other electronic components. The carrier has pin holes located at appropriate intervals for mounting individual sensor boards. In this case, the carrier is installed along the length of the housing.

Measurements by sensors can be affected by environmental variables, such as supply voltage or high frequency interference. In a preferred embodiment, the touch panel comprises means for detecting data of environmental variables and compensating for their effects to provide the most accurate resulting values.

According to the current measurement results, the state of each electrical module, in particular each cathode, with respect to predetermined threshold values, can correspond to any of the following three states:

(a) the current is less than the lower threshold value: the situation of cathode isolation or high resistance;

(b) the current between the lower and upper thresholds or the situation of normal functioning of the cathode; or

(c) current above the upper threshold value or an overcurrent situation. For the above conditions, it may be advisable to provide a tracking system for the total charge passing through a separate electrode during the deposition cycle, and compare it with the mass of the product, taken as a result of the electrode. This comparison gives the current efficiency of the electrode, which can usually be calculated as a composite value for the entire electrolysis shop or electrolysis module. However, it is desirable to detect the presence of problems with individual electrodes (for example, poor contacts) or individual electrolyzers. This means that it is necessary to record the charge of this electrode and track the mass of the product obtained from the same electrode. To do this, it is necessary to provide the ability to identify a single electrode. In this sense, this electrode during its service life can be used in various positions in various electrolyzers.

In order to enable the operator to accurately determine the location of malfunctions detected by the system, in a preferred embodiment of the invention, indicators (10) of the cathode state and the state of the cell in each pre-processing module (6), as well as in each main controller (7), which are a preferred embodiment of the present invention may be light indicators, for example, LEDs of different colors, corresponding to each of the above tional cathode states. Therefore, in addition to indicating the state of the cathode, which can be displayed on the screen of the central server module (9), it can be possible to generate a local visual indication for each cathode by means of indicators (10) of the cathode state, as well as by indicators of the state of the cell in front of each cell (1) )

If there is an indication of the state of the cell, the indication strategy in the above embodiment of the invention consists of the following types of indication:

- indication “normal cathode”, if each cathode is in this normal state; or

- indication of "weak current" if at least one of the cathodes is in this state (low current), and the remaining cathodes are in normal condition (one activated color); or

- indication “strong current”, if at least one of the cathodes is in this state (strong current), one activated color; or finally

- indication “low current and high current” if the current in one or more cathodes is lower than the lower limit, and also if the current in one or more cathodes is higher than the upper limit (two activated colors).

In another embodiment, the identification of the cathodes is accomplished by means of radio frequency identification tags (RFID tags), but this option may also include the presence of visual indicators, for example, colored or embossed stripes along the body of the device (for example, the aforementioned light indicators), numbers or other similar written designations on the device, electrolyzer or accessories of the electrolyzer (insulation panels). In addition, assistance is preferably provided to the operator in locating a particular cathode in a particular cell. For example, the system can identify that the cathode 47 in the cell 36 has a strong current. The operator needs to find this cathode, in this case, a count from 1 to 47 can be a tedious process, and an advantage may be the availability of a method for quickly determining which electrode has a problem. In addition, the housing may contain RFID tags, which, in order to identify individual cathodes or anodes, can be read using both the above and the following devices.

The information received from the server about the course of the deposition cycles at each cathode and in each electrolyzer regarding the elapsed time and ampere hours helps to inform operators about the most suitable sequence for removing deposited material from the electrodes. This information can also be used to automatically record times when electrolyzers were cleaned (when reading the zero current of the electrodes) and, therefore, to recommend the sequence and timing of future actions for cleaning the electrolyzer. Due to this, it is also possible at any time to obtain information on the general level of stocks of precipitated products in the electrolysis shop.

Since the main components of the present invention are defined, and using components known from the prior art, and components that are the subject of this patent application, it is possible to determine the method used in the new electric current control system. In this context, it is important to note that, since the current of each cathode is measured in the electrolyzer, by measuring the current of two cathodes (4) adjacent to one anode (3), it is possible to derive the value of the current passing through this particular anode (3). The advantage of this approach is that it provides the ability to identify poor contacts of the anode or anodes that do not work with the current value that is expected under normal conditions.

In a preferred embodiment, the sensor outputs are processed and sampled by pre-processing modules. These steps include amplification, correction of power effects, filtering, and analog-to-digital conversion.

As for the system’s power supply, there are many different sources, for example, batteries, a separate power connection (either mains power, or another type of power supply), power via Ethernet, connection to buses on both sides of the cell, connection to buses connected to other cells connection with buses, between which there are several electrolyzers (this option will provide a higher voltage, which can facilitate the operation of the device, and if necessary, can ensure continued operation of the device Twa, even if the local cell voltage is insufficient, for example in the purification of the cell), photovoltaic, thermoelectric, piezoelectric sources, induction, if direct current is smoothed enough, through the induction of a non-metallic body panel section or any other suitable power source.

According to a preferred embodiment of the method, the preprocessing module (6) receives data from the sensor modules and corrects the data signal to ensure optimal signal transmission to the following modules via the data transmission channel and to correct the current measurement due to the action of external variables, for which, based on fluctuations of the magnetic field, the aforementioned compensation can be made.

A conversion step may be required to compensate for various possible changes in the magnetic field sensor, amplifier, reference voltage, and digital-to-analog conversions. These changes can occur due to the effects of power, stray currents, the Earth’s magnetic field, manufacturing and installation tolerances, the geometrical location of the cell, magnetic fields from the currents of the electrodes of adjacent cells, magnetic fields of the contact bars between the cells, displaced electrodes, bent rods, and other influences.

The prior art knows a solution containing a theory-based calculation showing how to adjust the magnetic field of adjacent electrodes and electrolyzers. A preferred embodiment of the invention contains such calculations known in the art. It will be apparent to those skilled in the art that the calculation parameters will vary depending on the characteristics of the individual cells. In practice, it is necessary to simulate electrolyzers and adjust calculations.

Another source of possible changes is that the electrodes can not always be installed (by means of a crane) in the exact horizontal position on the electrolyzer tires. If the electrode is not directly above the sensor, then the contribution to the field of this sensor will be less than it should be. In a preferred embodiment, there is not one sensor (a pair of sensors), but a linear array of sensors or pairs of magnetic field sensors. A comparison of the output signals of these sensors can be performed to find the sensor with the maximum reading (after correction for the largest possible contributions from the currents of adjacent electrodes), which can be taken to correspond to the horizontal position of the electrode. This information can be used to compensate not only reduced field readings with the own sensor of this electrode, but (more importantly) and altered contributions to the fields measured by neighboring sensors.

Then, the measured currents are compared with the minimum threshold current Imin and the maximum threshold current Imax. In one embodiment of the invention, Imin and Imax for the entire system can be set in advance. In another embodiment, these values can be adjusted dynamically. For example, if there is a short circuit in the cell, then most of the cell current flows through this circuit, and the current through the other electrodes is less than the nominal value. If there were rather sensitive pre-set thresholds, then a short circuit in one electrode can lead to the fact that one or more other electrodes of the electrolyzer can be erroneously identified as having poor contact. However, with dynamic recalculation of the minimum threshold value this will not happen. These thresholds Imin and Imax can also be adjusted manually or automatically based on changes in rectifier current.

In one embodiment of the invention, the ECM panel is located under the anode rods at the anode connection with the side of the cell where the main contact bus is installed between the cells. Such a solution is preferable if the geometry provides a greater influence of the anode currents on magnetic fields than the influence of the cathodes. In one embodiment, short circuits and poor contacts are detected not by cathode currents, but by anode currents.

In this sense, the aforementioned embodiments of the invention and the following distinguishing features of the invention comprise the application of various improvements with respect to the functionality, adaptability, control and / or user interface of metallurgical systems, which systems are preferably electrometallurgical systems, for example, systems for electrolytic production or electrolytic refining of metal. In addition, such improvements can be applied in various types of systems in which control of the current passing through the electrodes is a key factor in the operation and productivity of the system.

Thus, in a preferred embodiment of the invention, the aforementioned improvements are applied in electrometallurgical systems having devices for measuring electric current, for example, Hall effect sensors designed to measure current passing through an electrode or a plurality of electrodes, for example, in an electrolytic cell or electrolysis shop. In this regard, these improvements are aimed at optimizing both the performance and operation of the at least one electrode, for example, in order to optimize the measurement of the current passing through it.

The following sections describe enhancements for systems, devices, and / or tools used to implement these enhancements. The following sections classify the main enhancements according to their main field of application for the purpose of description only, and it is important to keep in mind that in most cases the enhancements relate to several areas rather than one specific area. Therefore, the following description should not be construed as limiting the type of enhancement introduced by the various systems, devices, and / or means described herein. In addition, it is important to note that the following improvements can be applied to metallurgical systems individually or in the form of any possible combinations.

Functional Enhancements

As mentioned above, functional improvements are aimed at optimizing the operation of metallurgical systems by maximizing the reliability of these systems and, consequently, the finished product for the production of which these systems are intended.

Correct electrode placement and offset

As indicated above, in some electrolysis shops or electrolyzers, a system (crane, electrolytic fittings, insulation blocks) for installing anodes and cathodes in the electrolyzer may not always ensure the installation of these electrodes each time in the same location. That is, the electrodes are not physically located by fittings or similar devices. Therefore, if the change in the location of the electrode is significant, it may be appropriate to have at least one or more magnetic field sensors for measuring said changes. Then, by analyzing the magnetic fields detected by the sensors, it is possible to evaluate the most probable displacement of the electrode rod relative to its nominal position. Therefore, any sign of bias detected by a particular sensor means that the current in the corresponding rod has a slightly different effect on the field to which neighboring rods are exposed, which can affect the measurement of electric current. Therefore, if the aforementioned bias is known (or at least estimated), then this information can be used to modify the algorithms described by other persons in the prior art in order to better compensate for fields due to currents in adjacent electrodes.

The degree of bias can also be represented as a metric for use by operators of the electrolysis workshop.

Measurement in two-contact systems

In the simplest electrolytic cells, the anodes are connected to the busbar on one side of the cell (without loss of versatility, this side will be called the right side of the cell), and the cathodes are connected to the busbar on the other (left) side of the cell. The left end of the anode rod is insulated, and no current flows in this part. This means that when measuring the currents of the cathode rod, the only currents that, when flowing, affect the magnetic fields detected by the sensors are due to the cathode currents.

However, in some electrolyzers, commonly referred to as "two-contact electrolyzers", each electrode rod can be connected on both sides. Although the anodes are still “powered” on the right side, the left sides of all the anodes are connected via the anode “compensation bus,” sometimes called “equalization bus.” Similarly, the right sides of all cathode rods can also be connected to the cathode compensation bus. If there is a poor connection between this anode and the main anode bus, current can still flow to this anode, passing first through other anode rods, then along the anode compensation bus, and then into the anode rod of this anode. The same goes for cathodes. A two-contact system is described in US Pat. No. 7,993,501 (Freeport McMoRan Corporation) and US Pat. No. 7854825, the disclosures of which are incorporated herein by reference in their entireties.

In cases of using two-contact systems, the magnetic fields generated near the cathode rods can correspond not only to the currents in these rods, but also to the currents in the anode rods.

Further, in cases where a two-contact system is used, it is possible to install additional sensors located on the same line (bottom or top) with the anode rods. When applying a slightly more complex algorithm for compensating adjacent electrodes, it is possible to measure current in both cathode and anode rods. Regarding the calibration process, it will be useful to note that the sum of the currents in the anode rods (from the compensation bus side) is zero, that is, the currents will flow to the compensation bus from some anode rods, and from the compensation bus to other anode rods.

The use of sensors mounted on the same line with the anodes is advisable in two aspects: (a) it is possible to obtain a more accurate estimate of the current in the cathode rods, which is the most useful feature in operational terms; and (b) estimating the compensation busbar currents for the anode rods can help locate the poor connections between the anodes and the main busbar between the cells. So, the design of the EMC provides the ability to measure the current passing through adjacent electrodes along the compensation bus in order to correct the additional anode, which provides balancing of the current magnetic field and the availability of a method for assessing aspects of the current distribution in the cell.

Voltage measurement

Another improvement implemented by the present invention relates to multiple voltage measurements at various points in the electrical circuit of an electrolytic cell or electrolysis shop in which voltage measuring means are installed.

Voltage probes connected to the electrolysis circuit at different points, including the main busbar, main busbar risers and different points on different contact buses along the length of the contact bus between the electrolyzers, provide the ability to monitor individual electrolyzers and, therefore, various voltage drops in the circuit. This helps to improve the control of the entire circuit, since voltage drops and corresponding energy losses can be determined. Thus, as described below, the voltage drop in the electrolyzer can be used in combination with other measurements, for example, with measurements of temperature and metal concentration, as a means of assessing the quality of the deposition. Accurate control of the cell voltage is also important for monitoring the overall performance of anodes, such as titanium mixed metal oxide (MMO) anodes. MMO titanium anodes are used due to their low voltage requirements compared to conventional lead based anodes. A change in cell voltage may indicate a problem with coating the anodes in the cell. During maintenance and repair, the electrolyzer can generate voltage due to the reverse deposition of metal, in case of non-detection, this can lead to irreversible damage and a decrease in the performance of the MMO titanium anode.

Automatic correction of short circuit / bad contact thresholds

In its simplest form, the system can classify the cathode as being in a “short circuit” state as soon as the current exceeds a specific predetermined threshold value. However, such thresholds (for short circuits and poor contacts) are best calculated dynamically using various parameters.

During the removal cycle, a situation may arise when 1/3 of the electrodes are removed from the electrolyzer. This may mean that a current increased by 50% can pass through the remaining electrodes (assuming that the total current of the rectifier remains unchanged). This means that the threshold value of the short circuit should be increased so that this normal situation does not lead to a false indication of short circuits.

Similarly, if the rectifier current is reduced, a lower current must pass through each cathode. Even if the distribution is flawless (that is, there are no short circuits or bad contacts), this can, depending on the threshold value, lead to the classification of bad contacts.

Thirdly, if a short circuit exists in the cell, then a larger part of the total current of the cell flows through this short circuit than usual, and a smaller current flows along other paths. This may mean that some of the other electrodes are classified as bad contacts, although in fact they work normally, and there is no operational malfunction of these electrodes.

Then, according to the present invention, by means of computing means, threshold values for short circuits and poor contacts can be calculated as a function of (a) the total current of the cell, (b) whether electrodes are missing due to removal, and (c) from the presence of short circuits or poor contacts at other points in the cell. Therefore, the present invention sets dynamic threshold values depending on the above parameters, which improves the reliability of the system control due to the continuous calculation of threshold values.

Pattern detection to identify short circuits and bad contacts

The classification of the cathode as being in a short circuit state has been described as instantaneous comparison of the cathode current with a threshold value, even if this threshold value is not a constant number.

However, if the cathode has a slightly larger contact resistance on the bus or is located at a greater distance from the adjacent anode, then a slightly lower current may flow through the electrode, and nevertheless, a short circuit may occur in it. Observing a sequence of current measurement values that increase significantly over time, we can conclude that the cathode enters a short circuit state even before it reaches the actual threshold value for short circuits.

In addition, with the formation of short circuits, they can stop and then recover, leading to an oscillating current at an early stage of a short circuit. One embodiment of an ECM panel may be configured to detect such vibrations in order to classify the cathode as being in a short circuit state.

Therefore, in the present invention, pattern detection means are provided in order to have a reliable algorithm for evaluating short circuits and poor contacts, helping to improve system control.

Protective equipment for protection against physical damage and destruction when moving electrodes

A significant improvement provided by the present invention is the introduction of a protective device or several protective devices installed along the length of the ECM panel to protect it from mechanical damage and prevent disturbance of the normal movements of the electrodes, the ECM panel containing means for measuring electric current. In this context, in FIG. 3 and 4, one of the types of protective devices made in the form of a deflector (11) is shown in detail, and its design helps to avoid damage to the ECM panel (2) during normal operation of the crane on the electrolyzer, and is designed to push the electrodes in the direction of their correct position when lowering electrodes, for example during insertion of electrodes (3, 4), which can lead to damage to the ECM panel (2) as a result of the collision of the panel with the electrode. Accordingly, it is important to emphasize that the deflector structure shown in FIG. 3 and 4, does not limit the design of protective equipment, that is, any type of structure can be used that protects the panel from shock and other types of physical damage.

In addition, protective means can be attached to supporting means, a panel, or directly to any standard part of the cell. This may be, in particular, but without limitation, the accessories of the electrolyzer, the wall of the electrolyzer or the cover.

As indicated above, the prior art is not known design to prevent interference when moving the electrode and damage to the panel. The conditions in the cell are extremely harsh, and structural reliability is critical. A certain means to prevent violations of normal electrode movements and damage to the ECM panel for supporting devices is the presence of a deflector. The deflector must be able to cope with the weight of the electrodes when they are lowered at the speed with which the crane system lowers them at the appropriate load. The load should not be transferred to the touch panel, but should be absorbed as a result of transmission to the cell wall and minimized due to the angle of the surface of the deflector. In addition, the deflector must protect the brackets that support the ECM.

Mechanical seal

Electronic components can be sealed inside the material, so the panel may not have an outer casing. This sealing material may be an acid resistant epoxy resin or other sealing material.

Another improvement of the invention is the presence of sealing means at one end or both ends of the ECM panel (2), as shown in FIG. 5, wherein these sealing means protect the devices installed in the panel. In this sense, as shown in FIG. 8, the sealing means encloses a support plate (12), a gasket (13), an end cap (14), and fastening means (15), for example, screws or any other fixing device.

Further, the sealing assembly according to the invention seals one or both ends of the touch panel by connecting the support plate (12), the gasket (13) and the end cap (14), so that the gasket is sandwiched between the base plate and the end cap. After that, collecting the seal, the fastening means (15) are freely screwed into the base plate through the end cap and gasket. Said seal assembly is inserted in its correct position into the panel (2) or the housing. Finally, tighten the fastening means, reducing the gap between the end cap and the base plate, resulting in a decrease in the thickness of the gasket. In accordance with the Poisson's ratio, this leads to an increase in the width and height of the gasket. The increase in size creates the required seal between the seal assembly and the inner wall of the panel.

The main advantage in the presence of a mechanical seal assembly on one or both ends of the ECM panel is that it allows the panel to be sealed to protect internal components, for example, to prevent contact of electronic circuits located inside the panel with electrolyte or any other object that may damage specified components. In this sense, the mechanical seal assembly enables electronic circuits to enter the panel, seal the panel and pass the power cable through the cable entry to the panel or from the panel.

In addition, the seal assembly may also be removable for maintenance if necessary.

This sealing method can be used for panels of any profile, for example, square, round, rectangular and angular.

For the design of the ECM panel, it is necessary that the inside of the panel have a profile that does not interfere with the insertion of electronic circuits and the supporting element into the panel. The second limitation with respect to the panel profile is that it should be as narrow as possible to prevent interference when moving the valve / electrode into and out of the cell, and at the same time it must be designed so that the panel remains in close proximity to electrode rods. These two restrictions preclude the use of flanges or threaded fittings in order to seal against a harsh working environment and to seal the electronics located in the ECM. The use of a plate welded to the end of the panel was also impractical due to the heat generated during the welding process and the likelihood of damage during this process located in the electronics panel.

Multiple ECM panels per central module or controller

Another improvement is the use of control devices as a link in the exchange of data between each panel and the central server. For example, the central server can be configured to wirelessly exchange data with the controller, but the ECM can exchange data between the controller and the panel (s) by wire. This means that in another embodiment of the invention, one control device can be made common to several ECM panels. In this context, the control device may have separate communication buses for exchanging data with various ECM panels, or all panels may have one common bus.

The central server can be configured to exchange data directly with the ECM panels, without any intermediate controllers if such a connection topology and protocol are suitable for the workshop.

Electric current distribution measurement

In one embodiment of the invention, two ECM panels may be provided in each cell, said panels, in particular, being located on opposite sides of the cell. The objective of this embodiment of the invention is to enable the measurement of cathodic currents (and anode compensation currents in the case of a two-contact system) from the cathode contact side and anode currents (and cathode compensation currents in the case of a two-contact system) from the opposite side of the cell. Thus, this improvement provides the ability to measure all the influx and leakage currents passing through the respective cells, and to obtain a complete current distribution in the cell. The uniformity of the current distribution is a quality measure for the productivity of the cell, since a uniform current leads to a uniform deposition at each cathode, which maximizes the stability of the mass of deposits and the morphology of the surface of the deposits, minimizes the tendency to short circuits and maximizes the current utilization.

Concentration sensors and other sensors

In accordance with another improvement, the ECM panel according to the invention is configured to take into account the possibility of including concentration sensors and other sensors as part of the ECM system. In this sense, the ECM panel may contain tools for measuring temperature, concentration of metal, flow rate or level of electrolyte, concentration of additives, conductivity and so on in a particular cell.

The combination of measured values to determine the quality of the productivity of the cell or the quality of the electrolyte

The voltage of the cell increases with increasing total cathode current in the cell. In addition, the temperature of the cell is affected by the temperature of the cell, the composition of the electrolyte, the dosage of additives, the distance between the electrodes, as well as the age / condition / type of the anode. If these parameters are at predetermined levels, then the ratio between the voltage of the cell and the current is predictable, and it can best be determined for a particular electrolysis shop by performing a small-scale test. Any deviation from this predicted ratio indicates that the conditions in the cell are not optimal, and appropriate measures should be taken. The ECM system measures the total current of the cell and the voltage of the cell, and this measurement can be used as a measure of quality. If the ECM system measures any other parameter (for example, temperature, concentration), then it can use this data to provide further identification of possible problems leading to worse performance than optimal.

Assessment of current utilization and current stability for each electrode

Since the ECM measures electric current and detects the removal time for individual electrodes, in combination with a weighing system that is capable of weighing individual cathodes after removal (and, alternatively, before removal), the ECM can calculate the current utilization for individual cathodes. It can track the positions of individual electrodes in the cell to determine if the current utilization factor has a steady trend corresponding to that position, which may indicate problems with the adjacent anode, or, in combination with an RFID system (or other cathode identification system), it can determine whether a given trend is the result of problems with a particular cathode plate. In a simpler form, the system can track electric currents at specific electrode positions and determine if there is an obvious trend from one cycle to another, or (through a local RFID system or another cathode identification system) there is a current trend for a particular cathode, which may indicate to a problem with a specific electrode.

Adaptability improvements

As mentioned above, adaptability improvements are aimed at optimizing the adaptability of the metallurgical system, a key factor in which is current control. In this context, the following improvements are intended to maximize the flexibility of existing and / or new metallurgical systems.

ECM panel for measurement in two adjacent electrolyzers

One of the improvements regarding the adaptability of the system is the possibility of mounting one ECM panel on the upper part of the cell (or on any part of the cell, for example, but not limited to, on the accessories of the cell, the walls of the cell or the contact bus between the cells) so that it rests on brackets acting as hinges, and the ECM panel as a result of rotation to the appropriate position provides the ability to perform measurements in two adjacent cells. Due to this, it is possible to install one ECM panel on two adjacent electrolysers in order to reduce the cost of measuring electric current. In FIG. 6 shows an example of an ECM panel (2) mounted on top of two adjacent electrolyzers (16, 17), said panel being attached by means of support means (18) comprising rotary devices (19) for turning them about one axis, said supporting means (18 ) can be attached to any of the existing parts of the cell. This may be, for example, but not limited to, accessories of the electrolyzer, the walls of the electrolyzer or a contact bus between the electrolyzers. In addition, the ECM panel (2) may be attached to said supporting means (18) using cable ties or other means of attachment. Rotary means (19) provide the ability to move the panel from its position in the case when it is necessary to remove the electrodes from the electrolyzer or if it is necessary to change the position of the electrodes (thus, the hinge assembly also acts as a protective means for the ECM panel). This configuration makes it possible to position the ECM panel at one time over the electrode rods of one electrolyzer.

In addition, the ECM panel of the above configuration may include a device for determining the orientation of the panel, which contributes to the manifestation of the above adaptability improvements.

Material of the outer casing of the ECM panel

The outer casing of the ECM panel can be made of any material, including stainless steel, other metals, plastic or composite material. For example, it can be materials that contain a protective outer coating or shell, made with the possibility of replacement after a period of time or with a frequency depending on the conditions.

Integrated ECM

The ECM panel can be integrated in the electrolysis shop into the wall structure of the electrolyzer or the accessories of the electrolyzer. For the location of this device, it is necessary that there is a socket of sufficient volume either in the walls of the electrolyzer or in the accessories of the electrolyzer. This type of arrangement is suitable for new designs of electrolyzers, especially those intended for the integration of electric current measuring devices.

Support Tool Design

The ECM panel can be made to be supported by supporting means (18), for example, brackets or any other means that provide support to the panel, and these supporting means (18) can be attached to the accessories of the electrolyzer, as shown in FIG. 7 and 8 are mounted under the electrolyser cover, as shown in FIG. 9, and / or attached to the outer surfaces of the lid, as shown in FIG. 10. Accordingly, the supporting means (18) can be attached to the fittings of the electrolyzer using fastening means, or have a clamp type device that can be attached to the fittings of the electrolyzer, or a combination of these devices, as shown in FIG. 7 and 8. They can be attached to the upper part of the cell wall, or have a clamp-type device that fastens them to the back of the wall, or both, as shown in FIG. 9. Also, they can be attached to the open surface of the lid, or attached using fasteners, or both, as shown in FIG. 10.

The ECM panel can be located inside the channel of each of the supporting means, and for fixing the panel in the desired position, headless set screws can be used, and / or the ECM panel can be attached to the brackets using cable ties or other means of fastening.

The above details may depend on the type of cell that will be converted for use with ECM panels. In this context, in FIG. 7, 8, 9, and 10 show various support means (18) corresponding to the above description.

Portable ECM

Another improvement is the creation of a portable version of the ECM system, in which the panel is not permanently fixed to the electrolyzer, but is configured to move around the electrolysis shop and install electrodes on top or, alternatively, attach to the handle, so that the operator can move this tool to the appropriate a place. The portable panel may have the full length of the cell with the number of sensors sufficient for the number of electrodes in the cell, or be a short option for measuring the field, for example, around 5 or 10 electrodes, taking into account that the result of evaluating the currents in the electrodes at each end may be less accurate due to the influence of fields from neighboring electrodes that do not have sensors. In this context, the portable ECM panel allows to improve the adaptability of the system due to the possibility of using the specified panel as a tool in various electrolyzers.

ECM Modular Panel

In the same context, as described above, the ECM panel can be made of several smaller panels, which can either be physically connected to each other, or butt-mounted.

ECM panel. rod feed

Another improvement with respect to adaptability is to power the ECM panel not from the contact bars between the electrolyzers or from the mains, but from the electrode rods if a hinged type panel positioning unit is used. This helps reduce the use of various power sources, which improves system management.

Integration with other systems

Some electrolysis workshops have other systems that provide certain data on the operating mode of the electrolysis shop. For example, an optical inspection system evaluating the quality of the metal released at each cathode or a system weighing the metal removed from each cathode may be provided. If this data is combined with data obtained from the system according to the invention, then information of even greater importance can be obtained. For example, it can be determined that individual defects detected by optical inspection appear in some electrolytic cells more often than in others, or some electrolytic cells produce less production than others. Some electrolysis workshops may have cathodes with RFID tags, a barcode, or other identifiers that can be recognized by a crane, stripper, or other device. If this data is combined with information received from a system of current sensors, then (for example) it can be possible to detect that the current in a particular cathode changes to a greater extent, or poor contacts and short circuits occur more often in it than in other cathodes.

In this context, the current sensor system according to the invention can also be combined with other systems to create a single control system for the electrolysis shop, providing unified overall management and control of all (or many) aspects of the electrolysis shop. Other systems may include a cathode tracking system, a stripper, optical control, product weighing, flow control, electrolyte analysis, pump flow, schedule development, rectifier control and electrolyte additive management.

Control enhancements

As mentioned above, control improvements are designed to optimize the operation and maintenance of metallurgical systems, the key factor in which is the control of the electrode current. In this context, the following enhancements are intended to increase the reliability of control and the reliability of the system.

Prioritizing Short Circuits

In normal operations carried out in the electrolysis shop, operators can systematically scan electrolyzers, detecting and eliminating short circuits and poor contacts. By using a real-time current monitoring device, it is possible to spend more time on eliminating defects than on detecting short circuits and bad contacts.

In this context, the system has priority setting tools that are able to recommend the optimal procedure for eliminating short circuits using the following parameters: age and criticality of the short circuit, the distance the operator needs to go between short circuits, the number of operators per shift, and other parameters related to any of the above enhancements.

Calibration

1. The need for calibration. The magnetic fields detected by the sensors depend not only on the currents in the corresponding electrode rods, but also on the Earth’s magnetic field and, possibly, on the fields arising from currents in other conductors (for example, in buses), which can be directly connected or are not related to the operation of the electrolyzer. If there are fields due to the buses through which the current of the electrolyzer is supplied, then these fields can change with the change in the total current of the electrolyzer. In order to correct such fields, it is possible to derive their theoretical correction, or the empirical method (i.e. calibration) may be required.

Typically, the calibration includes measuring the current in each cathode rod along the length of the cell. In the case of an electrolyzer of a two-contact system, it may be necessary to measure the current in each anode rod, which can be a time-consuming operation.

2. Use removal for initial calibration and updates. To verify the calibration of the system, it is necessary to compare the current rating of the system with an independent current measurement. If there is any difference, then you can adjust the system parameters. For the most part, obtaining independent current measurements (for example, manually using clamp meters) is a time-consuming operation. However, during the removal cycle, the current flowing through some cathodes is definitely zero, since these cathodes are physically removed. This information can be used during the initial commissioning of the system, as well as during its maintenance, to establish and fine-tune some of the calibration parameters. Importing the rectifier current values manually or from local systems provides an additional known value that can be used during the initial commissioning of the system, as well as during its maintenance, to establish and fine-tune some of the calibration parameters.

User Interface Enhancements

As indicated above, improvements to the user interface of metallurgical systems are designed to optimize the visual display of information about electrodes, electrolyzers and / or electrolysis shops, which accordingly optimizes operator control and monitoring. In this context, they are intended to maximize ease of use, increase control reliability and system reliability.

Identification of short circuits and poor electrode contacts

Improvements obtained through the present invention include visualization means for visualizing the state of electrodes, electrolyzers and / or electrolysis shops. These tools also contain control tools, thanks to which the operator can take actions corresponding to the displayed status.

In one embodiment of this improvement, a method is provided for using a guided laser pointer mounted on the underside of the tap (s) of the electrolysis shop or having an independent support and designed to isolate electrodes operating outside their preferred range (short circuit or poor contact). Thus, this type of imaging tool allows the operator to easily identify a specific electrode in the electrolysis shop. In addition, this method may include determining a distance or location by means of a laser.

In another embodiment of the invention, visualization means, for example LED (s), are installed / located in the accessories of the electrolyzer or near the electrodes, which make it possible to identify the status of a particular electrode. The indicated status can represent normal operation, strong current (short circuit), weak current (poor contact) and, if necessary, other parameters.

Visualization of the status of electrodes and electrolyzers

Another embodiment of the invention also comprises status display means, thanks to which, as described above, it is possible to know the status of a particular electrode / electrolyzer. In this context, the present invention provides status display means for displaying relevant information to users of human-machine interface devices. This type of status display helps the operator take the right action in accordance with the operating status of the system.

In one embodiment of this improvement, augmented reality goggles are used in status displays, which allow operators to see the status of electrodes and electrolyzers as they move to the electrolysis shop. In this case, lasers, GPS or other location technologies can be used to determine the location of the user and, therefore, which electrolysis shop he is observing.

In addition, the present invention includes the use of pattern recognition software in a tablet or laptop personal computer with a camera or any other visualization device, said device configured to overlay the identification number of each electrode or the ECM status of each electrode on the electrolyzer image in real time. In one embodiment of this enhancement, GPS or other location capability may also be used in the system.

Alarms and / or Messages

Another improvement according to the present invention is that operators can configure one or more alarm mechanisms or emergency devices (including visual indicators, acoustic devices, email, pagers and short message service (SMS)) to enable the system to indicate occurrence short circuits or other operational faults.

Information can be provided by any type of visualization device, for example, by displaying on a screen a printed report, in the form of a text message, email or SMS, or even by voice generated by a computer.

With regard to the above improvements, optical indicators or visualization means on each electrode in each electrolysis cell of the electrolysis shop can be used to indicate the location of the fault. They can be light sources located close to the electrodes (for example, LEDs), as described above. As an alternative, a roof / wall mounted laser system can be used, for example, a system used during performances with lighting effects, which can be set to “draw” indications on the floor of the electrolysis shop, as described in one and previous embodiments of the invention. In the simplest embodiment of the invention, it can be just a status indicator light located at the end of each cell to provide alternative means of identifying the cell having a malfunction that needs attention.

Such an alarm system can also be compared with an automatically generated message giving an instant “snapshot” of the working state of the electrolysis shop, including a list of necessary corrections with the established order.

Automatic withdrawal detection

Finally, as indicated above, operators periodically must remove their metal from the cathodes. In the operations of electrolytic production, this is usually done by lifting 1/3 (or 1/2) of the cathodes completely coated with metal from the electrolysis cell, feeding them to the stripping machine, and then installing several clean (uncoated) cathodes in their place in the electrolyzer. The next 1/3 of the fully metal-coated cathodes is then removed and replaced with pure cathodes. Finally, the metal is removed from the last third. In accordance with this improvement, the measurement system according to the invention is capable of detecting, even in the presence of noise, the point in time when these events occur and recording them. In workshops with manual cranes and without a cathode tracking system, there may not be another record of when metal is removed from each cathode. This information can be useful for tracking problems in order to avoid situations in which the metal in the electrolytic cells is not removed at the appropriate time period, as well as for documenting and planning actions in the electrolysis shop.

Claims (46)

1. An electric current management system (ECM) for improving the working process in electrolysis shops, comprising: at least one electrolyzer having at least two electrodes in an electrolytic medium; - a plurality of sensor means for measuring the current passing through one or more electrodes, said sensor means being located inside at least one electric current control panel (ECM), in which a comparison of the measured current values with predetermined threshold current values and dynamic threshold adjustment are performed current values based on the total current of the cell; - one or more ECM panels installed in one or more working electrolyzers; - supporting means for supporting the ECM panel or ECM panels for each cell and - protective equipment for the ECM panel or ECM panels in each cell. 2. The electric current control system according to claim 1, wherein said sensor means of each ECM panel are located at a distance from each other corresponding to the intervals between said electrodes. 3. The electric current control system according to claim 2, wherein each electrode is provided with a rod, each ECM panel contains an elongated hollow body, which is a separate component installed near the electrode rods, each ECM panel is either directly below the electrode rod or directly above electrode rod, while supporting means are designed to support the ECM panel or ECM panels in each cell so that each ECM panel is rigidly fixed inside the cell, with em protective means intended to protect the panel from ECM damage during recovery or replacement of electrodes. 4. The electric current control system according to claim 1, wherein the protective means comprise a deflector mounted above the ECM panel. 5. The electric current control system according to claim 1, in which the supporting means and protective means are additionally installed in the electrolyzer or in which the supporting means and protective means are made in the form of rigid fasteners of the electrolyzer, accessories of the electrolyzer or insulators of the electrolyzer. 6. The electric current control system according to claim 1, in which the supporting means and protective means are attached to the cathode ventilation caps resting on the upper part of the electrolytic cells, or to shields that are attached to the side of these caps, the ECM panels being designed to lift them from the cell with the ventilation hood when it is necessary to carry out removal in the cells. 7. The electric current control system according to claim 1, wherein the ECM panel comprises a corrosion resistant and sealed enclosure containing sensor means and other electronic equipment. 8. The electric current control system according to claim 7, wherein said housing is protected by an electrical insulating sheath. 9. The electric current control system according to claim 1, further comprising one or more sensor means for measuring a change in the magnetic field resulting from improper positioning and / or displacement of the electrode in order to determine the deviation of the electrode rods from their nominal positions. 10. The electric current control system according to claim 1, wherein, in the case of using a two-contact electrolyzer, in which one end of the anode rod is connected to the bus and the other end is connected to the anode compensation bus, and one end of the cathode rod is connected to the bus, and its other end is connected to the cathode compensation bus, additional sensor means for measuring the magnetic field near both sets of electrodes are located on the line with the anode and cathode rods. 11. The electric current control system according to claim 1, further comprising an internal or external weighing system for measuring cathode weight values before and after removal. 12. The electric current control system according to claim 1, further comprising a tracking system configured to record a charge passing through a particular electrode. 13. The electric current control system according to claim 1, which is part of a single control system for the electrolysis shop. 14. The electric current control system according to claim 1, further comprising priority setting means for determining the priority for eliminating short circuits by considering the age and severity of the short circuit, the distance that the operator must travel between the places where the short circuits occur, and the number of operators. 15. The electric current control system according to claim 1, further comprising indicators of the state of the electrode and / or electrolyzer, such as light indicators suitable for indicating altered states of the electrode and / or electrolyzer and identifying the exact location of the altered state, the indicated state and location being visualized on display devices. 16. An electric current control system for improving the working process in electrolysis shops, comprising: - at least one electrolyzer containing at least two electrodes in an electrolytic medium; - a plurality of sensor means for measuring the current passing through one or more electrodes, said sensor means being located inside at least one electric current control panel (ECM), in which a comparison of the measured current values with predetermined threshold current values and dynamic threshold adjustment are performed current values based on the total current of the cell; - one or more ECM panels installed in one or more working electrolyzers; - supporting means for supporting the ECM panel or ECM panels in each cell and - magnetic canalization device made of a material that provides direction and concentration of the magnetic flux, located near the sensing means and intended for the canalization of the magnetic flux. 17. The electric current control system according to claim 16, wherein said sensor means of each ECM panel are located at a distance from each other corresponding to the intervals between said electrodes. 18. The electric current control system according to claim 17, in which each electrode is provided with a rod, each ECM panel contains an elongated hollow body, which is a separate component installed near the electrode rods, each ECM panel is located either directly below the electrode rod or directly above electrode rod, while supporting means are designed to support the ECM panel or ECM panels in each cell so that each ECM panel is rigidly fixed inside the cell, than protective means intended to protect the panel from ECM damage during recovery or replacement of electrodes. 19. An electric current control method for improving the working process in electrolysis shops, comprising the following steps: - measuring the current passing through one or more electrodes in contact with the electrolytic medium by means of a plurality of sensor means located inside an electric current control panel (ECM), which is part of the ECM system, said ECM system further comprising one or more ECM panels, installed in one or more working electrolysers, supporting means for supporting the ECM panel or ECM panels in each cell and protective means of the ECM panel; and - comparing the measured current values with the set threshold current values and performing dynamic adjustment of the threshold current values based on the total current of the cell. 20. The method of controlling electric current according to claim 19, wherein said sensor means of each ECM panel are located at a distance from each other corresponding to the intervals between said electrodes. 21. The method of controlling electric current according to claim 20, in which each electrode is equipped with a rod, each ECM panel contains an elongated hollow body, which is a separate component installed near the electrode rods, each ECM panel is either directly below the electrode rod or directly above electrode rod, while supporting means are designed to support the ECM panel or ECM panels in each cell so that each ECM panel is rigidly fixed inside the cell, with em protective means intended to protect the panel from ECM damage during recovery or replacement of electrodes. 22. The method of controlling electric current according to claim 19, further comprising the following steps: - transmission of measurement data to one or more central modules, which is a pre-processing module and / or the main controller and / or central server module, by means of data exchange; and - processing of measurement results in the specified central modules. 23. The method of controlling electric current according to claim 19, in which the readings of one or more sensor means are used to compensate for the incorrect location of one or more electrodes. 24. The electric current control method according to claim 19, wherein said threshold current values are dynamically adjusted based on the fact that there are no electrodes due to removal cycles, as well as the presence of short circuits or poor contacts at other points of the cell. 25. The electric current control method according to claim 19, further comprising the step of detecting patterns of short circuits and bad contacts in sequences of current measurement values for identifying short circuits and bad contacts. 26. The method of controlling electric current according to claim 19, further comprising the step of measuring all the flowing in and outgoing electric currents in order to obtain a complete current distribution in the cell. 27. The electric current control method according to claim 19, wherein the measurement step comprises measuring the cathode current of two cathodes adjacent to one anode, obtaining a magnitude of the current passing through said anode and, thus, detecting bad contacts of the anode or detecting anodes that are not operate at the required current level. 28. The method of controlling electric current according to claim 19, further comprising the step of weighing the individual cathodes before or after removal in order to measure the current utilization and current stability and to establish the presence of a trend in weight changes for a specific electrode position. 29. The method of controlling electric current according to claim 19, further comprising the step of establishing a sequence for eliminating short circuits based on the age and severity of the faults, the distance that an operator needs to go between faults, and the number of operators. 30. The electric current control method according to claim 19, further comprising the step of calibrating the electric current control system, the calibration step comprising using take-off cycles for initial calibration and updates. 31. The method of controlling electric current according to claim 19, further comprising transmitting alarms and / or messages to provide information about the operation of the electrolyzer or electrolyzers, said information being displayed using any type of display device, and additionally containing detection and recording of events of removal, cleaning of the electrolyzer and dressing of the electrodes.

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