Introduction: Recently, the "Electrolytic Cell Wireless Free-Point Shell Temperature Monitoring System" for the aluminum industry was successfully developed by Beijing Core Power Technology Co., Ltd. in Beijing. The advent of this monitoring system provides a new means of monitoring for the safe production and operation of electrolytic cells, becoming a safety guardian for electrolytic production.
The safety of electrolytic cells is crucial for electrolytic production. Once major accidents such as cell leakage or sidewall burn-through occur, they are accompanied by adverse consequences such as production stagnation, cell shutdown for maintenance, and restarting, all of which bring significant economic losses to aluminum electrolysis enterprises. Therefore, monitoring the shell temperature of electrolytic cells is an important part of safe electrolytic production and operation. In recent years, with the vigorous development of the aluminum electrolysis industry, continuous improvements in electrolytic technology, and increasing single-cell output, the pressure on safe electrolytic production and operation has also grown. Traditional methods using infrared thermometers and manual irregular inspections of shell temperature can no longer meet the safety requirements of modern aluminum electrolysis production. Moreover, their shortcomings, such as long monitoring cycles, significant influence from shell surface conditions, large measurement errors, inability to monitor in real-time, inadequate warning mechanisms, and inability to aggregate test data, pose considerable risks to the safe operation of electrolytic cells.
Measuring shell temperature is one of the important tasks in the production process of aluminum smelters. On one hand, it is necessary for observing the state of the electrolytic cell and ensuring safe production; on the other hand, it has high reference value for studying the shape of the cell cavity. The shape of the cell cavity directly affects the heat preservation and energy consumption of the electrolytic cell. The Electrolytic Cell Wireless Free-Point Shell Temperature Monitoring System uses advanced technological means to solve the problems of safe production and operation for aluminum electrolysis customers. This system accurately and reliably achieves real-time monitoring of shell temperature changes and real-time warnings for temperature exceedances. Due to its wireless control system, it improves resistance to harsh environments and various interferences around the cell shell; solves the problem of 24-hour continuous monitoring of electrolytic cells; and reduces labor input. The unique wireless design reduces the labor intensity of installation and wiring. The temperature measurement terminals can be freely placed and reused, providing support for management personnel to understand the operating status of electrolytic cells and explore the optimal state of the cells. The use of this system can effectively extend the life of electrolytic cells and reduce maintenance costs.
The Electrolytic Cell Wireless Free-Point Shell Temperature Monitoring System consists of terminal temperature measurement modules, wireless relays, wireless gateways, PC servers, and data analysis software, establishing a distributed measurement network in the electrolytic workshop. The terminal temperature measurement modules can be freely installed and reused. According to actual monitoring needs, by selecting suction cup or fixture installation modes, the terminal modules can be installed on the side, bottom, or cathode steel bar head of the electrolytic cell. The terminal modules measure the current temperature at the installation point through their built-in temperature-sensitive probes, and also have functions such as working status analysis, fault monitoring, and alarm. Wireless relays and wireless gateways are responsible for long-distance data transmission and wireless networking. The temperature data measured by the terminal modules and the working status of the modules are sent in real-time to the PC server via wireless relays and wireless gateways for data exchange. The data analysis software is responsible for saving, analyzing, and judging the real-time uploaded temperature data, directly indicating the location of temperature exceedance points and providing warnings for temperature points with trend changes. A large amount of monitoring data is stored in the data analysis software's built-in data storage, providing a substantial data foundation for viewing historical data, analyzing the impact of shell temperature changes on the cell temperature field, and studying the internal shape of the cell cavity.
The Electrolytic Cell Wireless Free-Point Shell Temperature Monitoring System has the following features: wireless automatic networking design, freely addable terminal temperature measurement modules, simple system and easy operation, continuous temperature measurement at a certain point on the shell under unattended conditions; use of intelligent temperature-sensitive components as temperature sensors, accurate temperature measurement, high reliability; the terminal modules provide two installation modes, plug-and-play, and can be easily relocated as needed; the system has multiple alarm methods such as automatic over-temperature alarm, status alarm, detachment alarm, and anti-theft alarm; uses various anti-interference technologies to suppress external electromagnetic interference, suitable for use in aluminum electrolysis sites; wireless design reduces installation and maintenance difficulty and ensures reliable insulation of the electrolytic cell.
Practice has proven that this system is easy to install and use, flexible and diverse in application, and has received praise from users. It is the best system for shell temperature monitoring in industrial aluminum electrolysis sites and the best solution for ensuring safe operation of electrolytic cells. Through years of research on safe operation protection of electrolytic cells, Beijing Core Power Technology Co., Ltd. has successfully launched the "Aluminum Electrolytic Cell Shell Temperature Wireless Real-Time Monitoring System." This system can achieve timed, on-demand, and special location temperature monitoring of the electrolytic cell shell, and has a comprehensive warning mechanism that can promptly respond to temperature exceedance points. Its excellent anti-interference ability, convenient and flexible installation modes, and multiple software service functions carried by the PC server provide new technical means and equipment support for safe electrolytic cell production, making it a new generation guardian for electrolytic cell production.
