Development and industrial tests of composite material based on TiB2 for repair of local destructions in electrolyzer bottom blocks

G. E. Nagibin, A. Zavadyak, I. I. Puzanov, A. Proshkin, E. Fedorova, S. S. Dobrosmyslov, I. Kirillova, N. V. Sukhodoeva
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Abstract

The paper presents the developed composition and technology for obtaining a repair mixture consisting of lumped corundum with a TiB2–C composite coating wettable with aluminum for restoration of local bottom block fractures without electrolyzer stops. The proposed technical solution made it possible to reduce bottom wear and increase aluminum electrolyzer service life by 6 months.A mixture of titanium diboride powder and a refractory powder-like binder in a ratio of 50 : 50 (wt.%) was used to obtain the repair mixture with an optimal composition. Then the lumped corundum was coated with the obtained mixture, dried at 150 °C and after that heat-treated under a carbon-bed at t= 700÷900 °C. As a result of reducing firing the TiB2–C composite material with a carbon content of 15–20 wt.% was formed on the surface of lumped corundum. A qualitative evaluation of the properties of the developed composite coating shows that the coating has a sufficiently high hardness, wear resistance and adhesion to the substrate after the heat treatment. For pilot testing, the repair mixture was covered with molten aluminum to obtain an Al–TiB2–C repair mass in the form of plates. The pilot testing of the repair mass on the 400 kA operating electrolyzer in the RUSAL-Sayanogorsk pilot shop showed that the bottom wear have slowed down 3 months after the local fractures were restored without electrolysis bath stops. This fact is evidenced by a 13 % decrease in the average depth of fractures with a stable current value of 4,7–4,8 kA/bloom after repair. Thus, the locallyused repair mass slowed that the overall wear of the cathode surface and allowed to extend the electrolyzer life.
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电解槽底块局部损坏修复用TiB2复合材料的研制与工业试验
本文研制了一种集总刚玉与可湿铝TiB2-C复合涂层组成的修复混合物,用于不停机修复局部底部块状断口。提出的技术解决方案使铝电解槽底部磨损减少,使用寿命延长6个月。将二硼化钛粉末与难熔粉状粘结剂按50:50 (wt.%)的比例混合,得到了具有最佳组成的修复混合物。然后用得到的混合物涂覆结块刚玉,在150°C下干燥,然后在t= 700÷900°C的碳床下热处理。通过还原烧成,在刚玉表面形成了碳含量为15 ~ 20wt .%的TiB2-C复合材料。对所研制的复合涂层的性能进行定性评价,表明该涂层热处理后具有足够高的硬度、耐磨性和对基体的附着力。为了进行中试,将修复液覆盖在铝液中,以获得板状的Al-TiB2-C修复体。在RUSAL-Sayanogorsk试验车间的400 kA运行电解槽上进行的修复质量试验表明,在没有电解浴停止的情况下修复局部裂缝3个月后,底部磨损有所减缓。修复后,裂缝的平均深度降低了13%,电流稳定在4,7 - 4,8 kA/bloom。因此,局部使用的修复质量减缓了阴极表面的整体磨损,并延长了电解槽的使用寿命。
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