P11_The Current Situation of Chinese Smelter-Prof.Yao

1、The Current Situation of Aluminum Industry in China 中国铝工业的现状 GAMI Heraeus Electro-Nite ShanghaiProfessor Yao Shihuan Product Application Manager Dai Jun贵阳铝镁设计研究院 上海贺利氏电测骑士有限公司 姚世焕 教授 戴 军 产品应用经理 Content 内容Part . Aluminum Production,Capacity,Consumption and Forecast Demand Part .The Brief of Developme

2、nt for Chinese Reduction Technology and Typical PotlinesPart .Characteristics of the aluminium reduction technology and its Improvement in China 。1.中国铝产能、产量、消耗和需求预测.2.中国电解铝技术的发展和典型电解槽系列简介3.中国铝电解技术的特征及其改进Part Aluminum Production,Capacity,Consumption and Forecast 1.中国铝产能、产量、消耗和需求预测China Primary Alumin

3、um Production & Capacity中国原铝产能与产量Primary Al. production in 1990 was only 854 thousand of metric tons, it reached 6.70 million tonnes in 2004 and capacity reached 8.60 million tonnes.Primary aluminium consumption was increased from 760 thousand of metric tons in 1990 to 5.54 million tonnes in 2004.Ac

4、cording to the statistics ，since 1990， annual average growth rate of aluminium production and consumption have been up to 15.85% and 15.24respectively .1990年原铝生产85万吨,2004年670万吨,产能860万吨.原铝消费由1990年的76万吨增加到2004年的554万吨.根据统计,从1990年到2004年,原铝生产与消费分别增长15.85%和15.24%. The Al. industry in China is growing rapi

5、dly in the past 15 years . 中国铝工业在近15年飞速发展Aluminum Consumption in China Rising by the Annual Rate of 10.2% in the past 25 years（过去25年，中国铝消费年增长速度10.2%)Aluminum Industry Developed Greatly in China中国原铝高速度发展的时期是1998-2004年高达25% Al. output average increased rate is about 25% per year from 1998 to 2004.Alum

6、inum from import to export. 从进口变出口 Big Changes to Aluminum Consumption Structure in China compared with 20 years ago（1985-2002）（21年来中国铝消费结构发生巨大变化） 1985 2002Much more Fluctuations of Primary Aluminum Consumption than GDP Corresponding Changes（原铝消费波动远远大于同期GDP的变化）Forecast of Primary Aluminum Consumptio

7、n in China According to Rising Rate of GDP以增长速度来预测未来中国的铝消费量According to forecast of Chinas Academy of Social Science, from 2000, Chinas economy will continue to develop quickly in the next 1015 years, with annual rising rate between 7.0%-7.6 of GDP. It is found in Antaike Information Co. research th

8、at primary aluminum consumption will rise by 1.1-1.8 times as quickly as GDP. Based on the above, primary aluminum consumption during 2000-2010 will increase at the rate between 7.7% and 13.7%. 根据中国社会科学院预测，中国今后10-15年，GDP增长=7.0-7.6%.研究指出中国原铝消费增长速度是同期GDP增长速度的1.1-1.8倍.以此计算,2000-2010年原铝消费年增长速度在7.7-13.7%

9、之间.Estimated Consumption of Primary Aluminum in China among 8.812.6 Mt in 20102010年中国原铝消费量在8.8-12.6百万吨之间Forecast to Primary Aluminum Consumption in 2010 in China with Elasticity Coefficient(以弹性系数预测2010年中国原铝消费量）Primary aluminum consumed per GDP generated in China has been rising annually since 1990.

10、In 2003, 8.2 kg primary aluminum was consumed to create 10,000 RMB yuan of GDP.In the past 10 years, the elasticity coefficient has been rising by the average annual rate of 5.4%. It is estimated that the rising rate will not overcomes that figure in the next 5 years. 从1990年起，中国创造单位GDP所消耗的原铝数量逐年上升。2

11、003年，每万元GDP所消费的原铝数是8.2kg在过去十年中原铝弹性系数年平均增长速度为5.4%,以此推测未来5年铝的消费速度.Estimated Consumption of Primary Al in China =8.2-11.5 Mt in 2010 based on Various Elasticity Coefficients 按不同弹性系数预测2010年中国原铝消费8.2-11.5百万吨Therefore, We choose the mean among upper limit values and forecasts that in 2010, primary aluminu

12、m consumption will hit 10.5 Mt in China.所以 .到2010年,中国原铝消费将达到1050万吨是可能的. Price Ratio of SHFE / LME Continuing to Go Downward 深圳铝价与伦敦金属交易市场铝价之比开始下滑Part The Brief of Development for Chinese Reduction Technologyand Its Typical Potlines2. 中国电解铝技术发展和典型电解系列简介1st Step : From 60-80KA soderberg technology is

13、leaps to 160KA CWPB technology in 1980s第1步:80年代中国由60-80KA 自焙槽跃到160KA预焙槽In 1978, the aluminium output in China was only 300kt, consumption 447kt, import 212kt. In the spring of 1978, the Chinese government issued the order to build the modern 160kt aluminum reduction project of Guizhou Aluminium Smel

14、ter. The selection of which type (model) of technology was the major discussion of the related experts in China. At that time, Pechiney and AlCOA recommended proposals,respectivelyAt that time, The low energy consumption, low current intensity and high pollution in Chinese smelters . The government

15、requested to solve this problem quickly.1978年我国铝的产量只有300千吨，消费量447千吨，进口212千吨。1978年春国家下达贵州铝厂建设160千吨现代化铝电解项目的任务。采用什么电解技术就变成当时国内专家的主要议题。法国彼施涅和美铝推荐了不同的建议。当时中国存在的问题是；污染严重、能耗高和电流强度低，国家要求迅速解决这个问题。 Auzat France Instalco USA Omuta JapanSakaide JapanCurrent KA90133125132Anode Current density A/cm2072073068070D

16、C kwh/tAl1290013000-133001329513700Average voltage V38739-40-409C.E. %89589-89Side working pot type recommended by ALUMINIUM PECHINEY in 1976 /1977 当时法铝推荐的方案135KA边部加料预焙阳极电解槽Pot type Recommendation to China Import & Export Corp. (1976)Recommendation to China Metals Association (1977)Hooded central-fe

17、eding P-155Standard P-155Energy-saving P-155Standard P-225Energy-saving P-255 Current density A/cm2-0.880.780.850.78Current kA165170170155230200Average voltage V4.54.64.64.234.64.2C.E 90(91-92)-DC kWh/t.Al1480014990114990140002140003133002 The hooded central feeding prebake pot recommendation by AlC

18、OA 美铝推荐的方案为密闭式中间下料预焙阳极电解槽What kind of prebake types was adopted?采用什么类型的预焙阳极电解槽? During 1977-1978, the experts in China noticed that the side working pots in Europe were featured by low energy consumption (13000kwh/t), but this type of pot emitted large amount of gas in feeding with skylight scrubbin

19、g. For the hooded central feeding pots in North America, they didnt need skylight scrubbing, but the DC consumption of this type of pot was more than 14000kwh/t. so we must look for a kind of prebake pot which is hooded, central feeding and low power consumption.70% of power in Japan was dependent o

20、n the imported petroleum. Power cost took 60% of the primary aluminium cost. By the end of 70s, Japan had built a number of smelters, which were featured by low energy consumption and good environment protection. 1977-1978年间，我国专家注意到欧洲边部加料电解槽具有13000kwh/t低电耗特点，但是,此种槽加料时遗出大量气体.而北美式密闭式中间下料电解槽在解决环境保护方面优于

21、边部加工电解槽。但是此种槽当时直流电耗都超过14000kwh/t。为此，我们必须寻求一种密闭式、中间下料和低电耗的预焙槽当时，日本的电力有70%依赖进口石油，电费在原铝成本中占了60%。70年代末日本建成了一批铝厂，其特点是能耗低和环境保护好。Showa Aluminium Chiba Smelter 1997Sumitomo Aluminium Toyosmelter Tomakomai Smelter of J.L.M1977Quarter 1 of 1978Current kA163.05170162157Anode dimensions mm151058513759051350660

22、（1400mm）Anode number16182424Current density A/cm20.690.760.760.735（0.72）Average voltage V4.0554.104.154.033.98Current efficiency 87.5908888(87.5) DC kWh/t.Al13803137001373013560(13750) Feeding interval min.120(150kg/time)304560(90kg/time)Ditto Sky-light scrubbingYes Yes No No Crust breaker typeTooth

23、-type Big cutter-type Hammer-typeActual results of Sumitomo, Showa Al.and Light Metal prebake pots in Japan in 1977日本住友、昭和及轻金属预焙槽的实际效果 China selected the 160kA CWPB technology of the Nippon Light Metals in 1979 80年代初，日本中间下料和低电耗的160KA预焙槽被中国选择Combining the advantages of all the above , China selected

24、the 160kA CWPB of the Nippon Light Metals, which was featured by large current, magnetic field compensation at pot bottom and hitting bar and single pneumatic feeder. This was a good selection at the time. It was used in the 80kt/y phase 1 project in Guizhou Aluminium Smelter. After 1981, China has

25、a large prebake pots. Later, continuous improvements were made, and at present, there are about 1.0 million tons capacity which is produced by this type Its current efficiency is 93%，DC consumption 13300-13600kwh/t，fluoride emission 93%，直流电耗13300-13600kwh/t，氟的排放量100kt/y in 2004)200KA，240KA，280KA和300

26、-360KA典型电解槽系列（铝厂）图2004年中国年产量超过10万吨的23个铝厂见下表企 业 Smelter2004 Production tonsPot Type1中铝青海分公司 Chalco Qinghai Smelter286058PB 160KA + 200KA2青铜峡铝业集团有限公司 Qingtongxia Aluminum Co.247743 200KA+360KA+Soderberg3中铝贵州分公司 Chalco Guizhou smelter230001PB 160KA+200KA+230KA4包头铝业(集团)有限责任公司 Baotou Aluminum Co.228458 2

27、00KA+135KA+Soderberg5焦作市万方铝业股份有限公司 Jiaozuo Wanfang Aluminum Co.226289 PB 280KA6河南豫港龙泉铝业有限公司 Henan Yugong Longquan Aluminu Co.204090PB 300KA7河南万基铝业股份有限公司 Henan Wanji Aluminum Co.185443 PB 160KA+300KA8云南铝业股份有限公司 Yunnan Aluminum Co.182023 PB 200KA+300KA9山东信发铝电集团 Shandong Xinfa Aluminum Co.176433 PB 240

28、KA10抚顺铝厂 Fushun Aluminum Smelter162869 PB 200KA11兰州铝业股份有限公司 Lanzhou Aluminum Co. 155526PB 200KA+Soderberg12南山铝业公司 Nanshan Aluminum Co.154969 PB 160KA+300KA13峨眉山铝业(集团)有限公司 Emeishan Aluminum Group 153705PB 300KA14兰州连城铝业有限责任公司 Lanzhou Liancheng Aluminum Co.148673PB 200KA15白银红鹭铝业公司 Baiyin Honghe Aluminu

29、m Co.128000PB 160KA+210KA16青海桥头铝电股份有限公司 Qinghai Qiaotou Aluminum Co.124041 PB 240KA17河南豫联能源集团有限责任公司 Henan Yulian Power Goup.121623PB 160KA18四川广元启明星铝业有限责任公司 Sichuan Guanyuan Aostar Al. Co.117087 PB 200KA19商丘商电铝业集团公司 Shangqiu Shangdian Aluminum Co.116877PB 200KA20中铝广西分公司 Chalco Pingguo Aluminum Co.113

30、008PB 160KA+320KA21山西关铝股份有限公司 Shanxi Guanlv Co. 107095PB 200KA+300KA22四川启明星铝业有限责任公司 Sichuan Aostar Aluminum Co.106728PB 300KA23三门峡天元铝业集团有限公司 Sanmenxia Tianyuan Aluminum Goup.100417PB 200KA合计Total:： 3,638,183Production percentage of all kinds of cell account for total primary Al. production6.7 millio

31、n tons in 2004 2004年670万吨原铝产量中各种槽型的比例 HSS & SPB=60KA Soderberg & Small Prebake Cells80KA VSS Pot Converted into 200KA PB Anode Potline in GUIZHOU Smelter in 1997 中国的第一个186（200）KA电解系列在贵州铝厂诞生 QINGHAI QIAOTOU SMELTER(2 POTLINES,240KAPOTS, CAPACITY=300KT/Y)青海桥头240KA系列JIAOZUO WANFANG焦作万方280KA 2POTLINES27

32、0kt/yearBest Performances:No:1 5 YEARS OPERATIONPot Voltage=4.12VCE93%AE93%AE0.1 YICHUAN & AOSTAR 300KA Potline 伊川和启明星300KA系列 YICHUAN SMELTER 300KA POTLINE 伊川AOSTAR SMELTER 300KA Potline320KA POTLINE 320KA电解系列 ZHONGFU SMELTER 中孚HENAN ZHONGFU SMELTER 中孚BALCO SMELTER QINGTONGXIA 360KA POTLINE-250kt &

33、SHENHUO 350KA POTLINE-150kt 青铜峡350KA系列-250千吨和神火350KA系列-150千吨青铜峡QingtongxiaModern Smelters with Advanced Anode Plant中国现代化的铝厂均装备有先进的阳极生产厂Many advanced Equipments was Introduced Abroad : Outokumpu,Solios,Eirich,B&P, etc.Part Characteristics of the Chinese aluminium reduction technology and its improvem

34、ent 3.中国铝电解技术的特征及其改进Low cost of Technology,The low cost of equipment,The low cost of construction.Very low capital cost for a Greenfield or Brownfield project.Very low labor cost.Highest power cost.Alumina high price.技术费用较低，设备价格低，所以建设费用就低。新建或扩建，资本成本或建设回收的成本都较低。劳动成本非常低。电费非常贵。高价氧化铝。Principal of Develo

35、ping Aluminum Technology According to Chinese State Condition在中国开发铝冶炼技术的原则：适合国情 Characteristic NorthAmerica West / North Europe China Current Efficiency %DC k w h/kg.AlPot Voltage VAnode Current Density A/cm2Anode Consumption kg/kg.AlAE time/day/pot Type of Cathode BlockLabor wages in Operating Cost

36、Investment USD/ t.Al94%13.814.54.34.40.80.90.400-0.4100.03-0.05Amorphous /Graphitic/GraphitizedHigh(18%)4000-5000949613.013.24.054.150.760.820.395-0.4050.03 Graphitic/Graphitized Higher3500-4500939413.313.64.124.180.70.730.420-0.4500.1-0.3Amorphous/ Graphitic(contain6/30% graphite) Lower(3-4%)150018

37、00CHARACTERISTICS OF CHINESE ALUMINUM REDUCTION TECHNOLOGY中国铝电解技术的特征 Low current density, anode current density normally designed to be 0.72-0.73A/cm3.Bath Ratio:1.15-1.2, namely xsAlF3 is 8-10%，most of smelters dont feed additives such as LiF or MgF2。ACD-the distance between the cathodes and anodes

38、 is quite high.Cathode blocks are mainly made of anthracite，high cathode voltage drop .电流密度低:阳极电流密度一般设计为0.72-0.73A/cm3。电解质重量比（Bath Ratio）:1.15-1.2,即xsAlF3为8-10%，绝大部分铝厂不加添加剂，如LiF或MgF2。极距比较高。阴极炭块基本以无烟煤为基料，槽底电压降较高 Characteristics of Chinese reduction technology 中国的铝电解技术具有的特征Through years practice, I ha

39、ve had the following experience我们的经验Low current density: For a country with very high power cost, power consumption is the first issue to be considered because power cost takes up about 40% of the cost . The xsAlF3 in the western smelters is 12-13% and 95-96% CE. But the bath with low ratio makes th

40、e conductivity reduce .there are about 150 smelters in China, their alumina supply sources are very sophisticated and so the physical parameters changes greatly. Our experience is to use bath ratio of 1.15-1.2, this can not only avoid the sludge and control AE, most important of all, it can improve

41、the ACD and reduce voltage fluctuation. For China whose aluminium is developing rapidly, it is very easy for the operators to get known to it.低电流密度：对于电价十分高的国家，电费在成本中占约40%，应考虑电耗。西方铝厂电解质中xsAlF3=12-13%取得95-96%电流，但分子比低，导电率也降低。中国有150座铝厂，氧化铝的供应渠道复杂，性能变化大，用1.15-1.2，可以避免沉淀和控制AE、极距略高，有利减少电压摆动.这对于原铝发展迅速的中国而言，

42、操作者很容易掌握。 From the above two points :综合以上上两点:The large prebake pots in China are the most adaptable to the raw materials worldwide at present. It has not very high requirements on the skills of the workers and the lowest capital cost. It also provides space to further increase the current density fo

43、r the clients. Therefore, the large amperage prebake pots in China are the technology which has a great potentialityMore than 60% of pots operating at present in China is 200-350KA pots. Because China has selected to go along the appropriate technical route, there are no occurrence of cathode damage

44、s with large area and leakage on pot sides. 中国大型预焙槽是目前世界上对原料适应性最强的，对工人技术熟练程度要求不高的，以及国际上造价最低的铝电解技术。中国的电解技术为用户提供了继续提高电流密度的空间.具有很大潜力.中国今年运行的电解槽中约有60%以上是200-350KA级的电解槽，由于中国选用了合适的技术路线，大型预焙槽没有出现大面积的阴极破损和侧部漏槽的现象。Best Practice : 280KA Potline 182 CellsBath ratio = 1.15-1.2, LiF-=0.7-1.0%. Average voltage=4.

45、107;CE=93.64%中国铝厂280KA槽的最佳操作系列Jan.Feb.Mar.Apr.MayJun.Jul.Aug.Sep.Oct.Nov.Dec.Ave.KA281.3281.3280.9280.8280.8280.4280.4280.7280.9280.6280.7281.1280.8Vave.4.154.1274.1484.0884.114.0994.0954.0954.0974.0944.0934.0834.107CE%95.1793.9992.3994.5593.6693.6294.0794.2893.8392.1892.8593.0693.64DC12997130961338

46、612886130801304712972129441301213237131231309113072AlF3-22.66LiCO3-1.06AE 0.140.120.120.100.080.080.070.080.120.100.080.090.098AE” 0.5640.3840.4080.330.2320.2320.210.2080.180.120.0960.0990.273 AE” = Min./ day / potImprovements of Aluminum Reduction Technology for China Aluminum Industry中国铝电解技术的改进方向I

47、mprove pot unit area output: improve anode current density)（from 0.72 to 0.80 A/cm2)+ increase in anode surface。 Improve current efficiency : 93-94% to95- 96%, and decrease in power consumption。Control the acidity and temperature of bath, use low bath superheat, and remain good side wall ledge profi

48、le （to thicken ledge at bath-metal interface）。Bath ratio from 1.2 decrease to 1.1。Develop towards lower F emission and anode effect frequency 。AE from 0.1 reduce to 0.03。Strengthen the researches on the influencing factors on the pot stability, reduce and eliminate voltage fluctuations。Focus on ther

49、mal-mass balance control9-Box control strategy on pots提高电解槽单位面积产量 ,从0.72 到0.80 A/cm2 。提高电流效率从93-94%到95-96%，相应降低电耗。控制电解质的酸度和温度，使用低过热度，保持厚的侧部槽帮。向着更低的氟化物排放量和更低的效应系数(0.03)的方向迈进。控制电解槽的稳定性,减少电压波动采用热平衡和物质平衡控制技术9区控制技术Cell ParameterYear 1980Year2000Year 2020Line current (kA)225325500 - 600Cell voltage (V)4.1

50、04.103.9 - 4.0Current efficiency (%)94.095.5 96.0 - 97.0Energy consumption (kWh/kg Al)13.012.8 12.0 - 12.4Cell life (days)1500 2000 - 28003000Anodic current density (A/cm2)0.800.850.95 Forward to advanced world level : High CE ,High KA，Low V ,Low DC power，向世界铝电解技术方向看齐:高电流密度,低电压,低电耗,高电流效率Ref.: Thonst

51、ad et al., “Aluminium Electrolysis”, 3rd Edition, Aluminium-Verlag 2001We expect that Lowest DC Power( 12.6kwh / kg.Al )will be achieved as Japanese Sakaide Smelter in 1981我们希望能获得12.6kwh / kg.Al Improve Current Efficiency ，Increase in Anode Current density & Decrease AE are Difficulties in Chinese S

52、melters在中国提高阳极电流密度,提高电流效率以及降低效应系数遇到的困难 Lack in alumina supply and poor alumina quality parameters 氧化铝短缺,来源复杂,指标和性能差Anode quality should be improved阳极质量也需要大力改进48% of total demand of Al2O3 depend upon import氧化铝需求量的48%依靠进口 The Imported Alumina from 3346 increase to 5605ktin 2001 to 20032001-2003氧化铝进口量从

53、3346kt到5605kt200120022003ktMUSDktMUSDktMUSDUS/tAustralia2860522.863634588.164100998.23243.5India12424.3543569.91572124.90218.4Jamaica17133.7527648.72372105.26283.0Venezuela10015.74456.7119948.65244.5Kazakhstan7412.019717.67182.2Total Import334645715605 Comparison between QALs Al2O3 and Chinas Al2O3

54、standard 国外澳洲氧化铝性能与国内比较Alumina Parameter 指标或性能QAL Typical Value 昆斯兰厂Chinese Standard 中国标准 % +150m2.0 % 45 m8.012 ( Actually 30%) % 20 m1.2 SSA 比表面积7835Alpha Alumina1035 % LOI ( 3001000)0.90.8 Attrition 磨损指数23 % Na2O0.30.5 % Fe2O30.009 % SiO20.014 % CaO0.016 % TiO20.004 0.005 % P2O50.001 0.003Poor Di

55、ssolution of Al2 O3氧化铝溶解性极差In general ,smelters are requesting alumina that is low in impurities and dust content and that gives increased dissolution rates.The expectation is continually for more consistent alumina product. But, it is impossible in China causing different alumina sources. But, high fine particle size, high alpha AL2O3 content & low SSA in china ,therefore ultimately, poor dissolution (more sludge formed )can reduced cell control and current efficiency,and high frequency of AE etc.铝厂希望使用低杂质和含细粉少的氧化铝以加快氧化铝的溶解.希望长期供应品质一致氧化铝.但中国由于多渠道所以作不到.但是在中国由于本身生产的氧化铝质量就差,再加上进口氧化铝渠道太多,致使