3001 Alkali Electrolysis Adds KAlF4 Energy-saving Technology

Strategic Emerging Industries: Energy Saving and Environmental Protection

Advanced Technology Field: New Materials

Name of Institution: Shenzhen Xinxing Light Alloy Material Co., Ltd.

Nature of the company: Business

Contact: Zhou Zhi

contact number

Email: [email protected]

Unit URL:

Recommended Unit: China Nonferrous Metals Industry Association

Achievement profile:

Source of the project: enterprise independent project

Project title: Research and application of KAlF4 high-efficiency energy-saving technology in aluminum electrolysis

Project ID: STA-201105

Study start date: March 2011 - March 2014

The basic content of the project:

For decades, the main direction of development in the world's aluminum electrolysis industry has been energy saving. Due to technical breakthroughs in the areas of slot type, electrode structure, and computer control, China's aluminum electrolysis technology has made great progress, and it has now become the world's largest producer of aluminum, with tons of aluminum power consumption reaching the world's advanced level. However, the electricity price for aluminium in China is high, and the production cost of electrolytic aluminum is still not competitive. Achieving high-efficiency low-temperature electrolysis is a very important aluminum electrolysis energy-saving technology that further reduces the power consumption of aluminum electrolysis and improves the competitiveness of China's aluminum industry.

The main difficulty in reducing the temperature of aluminum electrolysis has been to develop an additive that can reduce the aluminum electrolysis temperature while improving the solubility and conductivity of Al2O3 and other important physicochemical performance indicators. The project unit worked with large-scale aluminum electrolysis plants, such as Henan Zhongfu Industry and Jiaozuo Wanfang Aluminum, and successfully developed a new energy-efficient and energy-saving technology for adding KAlF4 to aluminum electrolysis. And this technology achievement has successfully realized industrial application in large-scale aluminum electrolysis plants such as Zhongfu Industry and Jiaozuo Wanfang. With advanced technical specifications, the alumina dissolution performance has been significantly improved. The aluminum consumption has reduced the direct current electricity consumption of aluminum tons by about 500 kWh. The energy saving and emission reduction effect has been remarkable.

Achievements:

(1) For the first time, potassium is found in the aluminum electrolyte as a stable KAlF4 form. Through the study of the molten salt properties of the KAlF4 system, it has been proved that the KAlF4 is stable in the existing electrolyte molten salt system and the application is safe.

(2) For the first time, KAlF4 high efficiency and energy saving technologies have been developed for aluminum electrolysis. By systematically studying the main physicochemical properties of the KAlF4 aluminum electrolytic molten salt system, aluminum electrolytic addition of KAlF4 was developed, the alumina dissolution performance was improved, the electrolysis temperature was reduced, and the electrolytic cell production was stabilized.

(3) Innovative research and development of green synthesis technology for high-purity anhydrous KAlF4. Through the addition of an anti-agglomeration agent in the molten salt synthesis process, the high-frequency magnetic oscillation depolymerization reaction is performed to depolymerize the by-product mKF•nAlF3 macromolecules produced by aluminum titanium boron into high-purity anhydrous KAlF4.

This achievement is of great significance to the further energy conservation and emission reduction of aluminum electrolysis in China, and the utilization of waste resources formed in the production process of aluminum-titanium-boron series alloys has been realized. The economic and social benefits of this project are significant. It has obtained 7 domestic invention patents, 9 foreign and 2 copyrights.

Outstanding results:

The technical product “High-Purity Waterless KAlF4” of this project is produced by the “Multi-frequency multi-coil electromagnetic induction furnace”, a key equipment independently invented, designed and manufactured by the project entity and possessing independent intellectual property rights. The only equipment that can be used is aluminum titanium boron. The alloy by-products are purified into small-molecule-to-high-purity anhydrous KAlF4, and the equipment is currently only capable of manufacturing capacity in this project unit. Therefore, the project product “high-purity anhydrous KAlF4” can only be produced by this unit, and other units do not have the production capacity. At the same time, the project unit has obtained 12 domestic and foreign invention patents for the production and manufacturing technology of the project.

Profitability of results:

Through the above technical innovations, the project solved a major technical problem of improving alumina dissolution performance while reducing the aluminum electrolysis temperature. It not only eliminated the precipitation of crusts in the aluminum electrolytic cell, but also significantly reduced the anode effect coefficient, resulting in the addition of aluminum electrolytics. KAlF4 energy-efficient technology.

The addition of KAlF4 high-efficiency and energy-saving new technology in aluminum electrolysis has been applied in large-scale industrial applications in large-scale aluminum electrolysis plants. Tons of aluminum DC power consumption can be reduced by 400 ~ 600kWh, and achieved significant energy-saving emission reduction effect. The production of aluminum-titanium-boron alloy enterprises through the implementation of the technology, the byproducts of their own production process into aluminum electrolytic energy-saving additives, to achieve a full utilization of resources, increase the added value of the product. After the promotion of this industry-wide achievement, it can achieve annual electricity savings of 12 billion kWh, emission reduction equivalent CO2 8.6 million tons, annual economic benefits of 6.4 billion yuan, and significant economic and social benefits.

Sustainability of results:

The project unit is a national-level high-tech enterprise and key high-tech enterprise of the National Torch Plan. It has established Guangdong Aluminum Magnesium Titanium Engineering Technology Center, Guangdong Provincial Academician Workstation, Shenzhen Aluminum Magnesium Alloy Engineering Technology Center, and Shenzhen Aluminum Magnesium Titanium Alloy Project. Research and development platforms such as laboratories have applied for 158 domestic and foreign invention patents, obtained 98 domestic and foreign patents for inventions, won 4 provincial and ministerial science and technology awards (first prize), and won 3 municipal science and technology awards (1 Etc.) There is an efficient R&D team for project development.

In terms of technical reserves, the project unit conducted research and development of the “new production method to produce titanium metal” project, using a new safety and environmental protection production process to produce titanium metal products, while purifying the by-products produced, separated high purity anhydrous KAlF4 products. And can achieve aluminum electrolytic energy-saving additives "high-purity anhydrous KAlF4" product standards, through the implementation of this technology, to further protect the aluminum electrolytic industry additives KAlF4 source.

At the same time, in view of the application technology of the product in this project, if we can reduce the working temperature of aluminum electrolysis by 20-30°C on the basis of the existing working temperature, we predict that the energy-saving effect of the production of tons of aluminum will be a major breakthrough. It is estimated that tons of aluminum production can save about 1000kWh. Based on the experimental curve analysis of the effect of KAlF4 added to the electrolyte on the primary crystal temperature of the electrolyte, we can deduce that when the potassium content in the electrolyte is less than 3%, the effect of energy saving on the aluminum electrolysis process is not obvious, when the potassium content When the control reaches 3% to 5%, the energy saving effect of the tank body after 90 days of operation can reach about 500 kWh. When the potassium content is controlled at about 5% to 10%, we have conditions to reduce the operating temperature of the electrolytic cell by 20 to 30°C, and the energy saving effect can reach 1,000 kWh per ton of aluminum. When the electrolysis temperature drops by more than 20°C, it can be considered that the concept of the aluminum electrolysis technology initially enters into the category of low-temperature aluminum electrolysis. If we can achieve stable production of aluminum electrolysis at a temperature of around 900°C for a long period of time, we believe this is a major advancement in the low-temperature production technology of the aluminum electrolysis industry and a major advancement in energy-saving and emission reduction technologies in the aluminum electrolysis industry. At present, this research has made great progress and is expected to be completed and promoted in the industry within 1.5 years.

Achievements:

The addition of KAlF4 high-efficiency and energy-saving new technology in aluminum electrolysis has been applied in large-scale industrial applications in large-scale aluminum electrolysis plants. Compared with the pre-application production conditions and technical indicators, the addition of KAlF4 after the addition of KAlF4 had an effective treatment of the crust containing the bottom crust, and the electrolysis temperature decreased by 5 to 10°C. This resulted in the optimization of a series of aluminum electrolysis technology economic indicators: lower bottom pressure drop of 50 to 70 mV, current efficiency increase of 1% to 2%, anode effect coefficient reduction of 30% to 50%, and elimination of the slot for aluminum electrolysis The impact of tank operation and energy consumption, tons of aluminum DC power consumption can be reduced by 400 ~ 600kWh,

On October 15, 2014, 11 academicians and experts from the China Nonferrous Metals Industry Association organized the project to conduct scientific and technological achievements appraisal. The experts unanimously confirmed that the project has reached the world's leading technological level. The project technology optimizes the aluminum electrolyte system to achieve high-efficiency aluminum electrolysis at lower temperatures, providing an effective energy-saving and emission-reduction pathway for the aluminum electrolysis industry, providing technical support for the improvement of the core competitiveness of aluminum electrolysis companies.

Maturity: 12, profit level: start profit and profit exceeds 10% of total investment

Market analysis:

The product of this project is an intermediate product, which is an additive in the production process of electrolytic aluminum. By adding KAlF4 as an intermediate product in the process of aluminum electrolysis, the current efficiency can be effectively improved and the electrolysis temperature can be reduced. The aluminum can save 500 degrees of electricity. According to statistics from the China Non-Ferrous Metals Industry Association, China's annual output of electrolytic aluminum was 24 million tons in 2014, and the amount of this product added to the project was 5 to 10 kg per ton of electrolytic aluminum. The total annual demand was about 192,000 tons. Therefore, the market size of the project's products is very large.

Business model analysis:

The business model of this project is to provide customers with high-quality low-temperature aluminum electrolytic additives (KAlF4 products), and at the same time provide customers with technical advice on the use of this product, so as to achieve the profit of this project unit.

The product of this project is sold directly to the electrolytic aluminum enterprise by the unit and sold in a direct sales model with a return period of 45 days.

Marketing status:

As the product of this project is a new energy-saving material added during the electrolytic aluminum production process, the domestic electrolytic aluminum plant is a direct customer. After the product of this project is added to the electrolytic cell, the amount of aluminum fluoride added to the original electrolytic cell can be effectively saved, and the cost can be saved.

The price of the product is the same as the price of aluminum fluoride, and the product sales use the direct sales model.

The product of this project has been applied in Zunyi Yulong Aluminum Co., Ltd. for more than 2 years, and applied in Henan Zhongfu Aluminum Co., Ltd. and Jiaozuo Wanfang Aluminum Co., Ltd. for more than one year, and applied in Longgang Aluminum Co., Ltd. 0.5 years. The cumulative sales of 1,115 tons of products (the sales price of the product of this project is the same as the price of AlF3) are cumulatively used for the production of approximately 250,000 tons of electrolytic aluminum.

Since the product of this project is applied to the production of electrolytic aluminum, it can achieve the effect of energy saving and emission reduction (400-600kWh per ton of aluminum), and the aluminum production per ton is 5kg less than that of aluminum fluoride. The above-mentioned enterprises have created more products by applying the product of this project. Big economic benefits.

Intended conversion method: Other

Application of the investment has been invested: 35 million yuan

Capital requirement: 45 million yuan

Financing purposes: product development

Core Management Team Staff:

Core Team Leader: Chen Xuemin, male, 52 years old, Zhejiang Ningbo Personnel, master of engineering, senior engineer, enjoying Shenzhen special allowance experts.

Its main work experience is as follows:

1979.9--1983.7 Learning at the Department of Metallurgy, Central South University of Technology;

1983.9--1985.8 Worked at Fuchunjiang Smelter in Zhejiang Province;

1985.9--1988.6 studied in Fine Chemicals at Beijing University of Technology;

1988.8--1992.6 Worked at Beijing Chemical Reagent Research Institute;

1992.7--Now Shenzhen Xinxing Light Alloy Material Co., Ltd. served as chairman and general manager.

He has profound academic and research skills, and has many years of experience in the development and manufacturing management of non-ferrous metal composite materials and new alloy materials. During the work period, it applied for a total of 43 domestic invention patents, 90 international invention patents, led to the formulation of 3 industry standards, participated in the formulation of a national standard, won the first prize of China Nonferrous Metals Industry Science and Technology Award, and was awarded the title of Guangdong Province Science and Technology. There was 1 second prize, 1 Shenzhen Science and Technology Progress Award, 1 Shenzhen Industrial Invention First Prize, and 4 papers published.

Governance structure:

The project unit is a joint-stock company. The company intends to be a listed company. The ownership structure is 81% owned by the management team (of which the founder holds 57% shares), the investment institution (investors) holds 19% of the shares, and the equity structure is clear. It is a modernized shareholding. structure.

The shareholders' meeting is composed of all shareholders and is the highest authority and highest decision-making body of the company.

The internal organization of the company is composed of the board of directors, the board of supervisors and the general manager. It performs the company's strategic decision-making function, disciplinary supervision function, and management and management function respectively. Under the premise of mutual checks and balances of authority, the company conducts corporate governance objectively, impartially, professionally, and is responsible for the general meeting of shareholders. To maintain and win the company's best operating performance. The board of directors is the office of the general meeting of shareholders during the intersessional period. The general meeting of shareholders, the board of directors, and the board of supervisors all perform their functions in a formative manner. The general manager performs the functions with administrative decisions and execution power.

Management structure:

Leadership system: The entire company's operations are based on the "Company Law" and the company's articles of association, and establish an effective "three sessions" management system.

Teamwork: The project unit has established a close cooperation relationship with universities and scientific research institutes, and established a good teamwork relationship with university and institution scientific research workers. At the same time, the company has a solid management team. The management personnel have basically worked in the company for more than 8 years.

Management System: The project unit administers the enterprise according to the modern management system. The company has passed ISO9001, ISO14001, QC080000, OHSAS18001, TS16949 and other international management systems and specifications.

Internal Control: The project unit is a company to be listed. The company has established strict internal control regulations and established a full-time internal control department.

Main business name: High performance aluminum grain refinement alloy series

The main business income in the past three years: 19896.526 million yuan

Net profit: 1004.571 million yuan (2014)

Gross profit rate: 24.36%

Evaluation Agency: Ministry of Science and Technology, China Nonferrous Metals Industry Association; Zhang Long (tel.; 13601365478; fax)

Evaluation method: Identification

Review date: October 15, 2014

Evaluation comments:

1) The results have been successfully implemented in large-scale aluminum electrolysis plants such as Zhongfu Industry and Jiaozuo Wanfang. With advanced technical specifications, the alumina dissolution performance has been significantly improved. The aluminum consumption has reduced the direct current electricity consumption of aluminum tons by about 500 kWh. The energy saving and emission reduction effect has been remarkable.

2) The results are of great significance for the further energy saving and emission reduction of aluminum electrolysis in China, and the utilization of waste resources formed in the production process of aluminum-titanium-boron series alloys. The economic and social benefits of the project are significant.

3) The overall technology of this achievement has reached the international advanced level.

Award category: Social awards

Awarding Unit: China Nonferrous Metals Industry Association

Winning time: 2014-12

Award Name: Science and Technology Invention Award

Award Level: First Prize