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The feasibility of layer-by-layer manufacturing through high-aspect-ratio (HAR) nozzles for microextrusion of paste to deposit planes has been investigated. Various conditions for paste extrusion, including nozzle moving speed, piston speed, extrusion rate, and distance between the nozzle tip and substrate, have been evaluated. By linking various microextrusion parameters together with the aid of...
In this work, a facile synthesis route was applied to fabricate nanoporous copper (NPC). As-sintered AlCu bulk alloys with (or without) NaCl that were fabricated by powder metallurgy were taken as precursors during the preparation of NPC via chemical dealloying. The effects of NaCl in the alloys on precursors and products were investigated. Scanning electron microscope (SEM) examinations showed that...
The industrial aluminum reduction cell is an electrochemistry reactor that operates under high temperatures and highly corrosive conditions. However, these conditions have restricted the measurement of key control parameters, making the control of aluminum reduction cells a difficult problem in the industry. Because aluminum electrolysis control systems have a significant economic influence, substantial...
Studies of magnetic field and magneto-hydro-dynamics are regarded as the foundation for the development of large-scale aluminum reduction cells, while due to the direct relationship between the busbar configuration and magnetic compensation, the actual key content is the configuration of the busbar. As the line current has been increased from 160 kA to 600 kA, the configuration of the busbar was becoming...
A real-time mathematical model for the two-dimensional temperature field of petroleum coke calcination in vertical shaft calciner was developed based on computational fluid dynamics. In the modeling process, the petroleum coke discharging process was described by the solid viscous flow, the dynamic heat flux boundary condition was adopted to specify the heat transfer between the flue wall and the...
There have been ongoing efforts into the study of the process signals of aluminum reduction cell control and operation. Anode currents provide one of the most valuable signals and the most likely to be measured. In this article, the commonly used methods of online anode current measurements are briefly introduced. Then, a new approach is proposed to improve measurements of anode currents based on...
The aim of this work was to establish a mathematical model for the analysis of calcining process of petroleum coke in a 24-pot calciner via computational fluid dynamics (CFD) numerical simulation method. The model can be divided into two main parts (1) heterogeneous reacting flow of petroleum coke calcination in the pot was simulated using a two-fluid model approach where the gas and solid phase are...
AlPd alloy slices with a thickness of 0.5 mm were taken as precursors during the fabrication of nanoporous palladium (np-Pd) using chemical dealloying in NaOH solution or electrochemical dealloying in NaCl solution. Scanning electron microscope photos and x-ray diffraction patterns demonstrate a full dealloying of Al out of the precursors and the formation of nP-Pd which is characterized by a three-dimensional,...
Anodic potential, morphology and phase composition of the anodic layer, corrosion morphology of the metallic substrate, and oxygen evolution behavior of Pb-Ag anode in H2SO4 solution without/with fluoride ion were investigated and compared. The results showed that the presence of fluoride ions contributed to a smoother anodic layer with lower PbO2 concentration, which resulted in lower double layer...
An extended computational fluid dynamics model combined with the driving forces of anode gas bubbles and electromagnetic forces (EMFs) was developed for the alumina-mixing process in aluminum reduction cells. A practical feeding scheme and the consuming rate of alumina depending on the local current intensity of the bath–metal interface were considered in the simulation. A comparative numerical study...
The mechanisms for magnetizing roasting of Fe2O3 into Fe3O4 under microwave heating and electrical heating have been studied through thermogravimetric analyses, x-ray diffraction (XRD) measurements, and reaction kinetic calculations. In the reduction process, activated carbon was used as a reducing agent and argon as the protective gas. The results of heating tests indicated that the temperature heating...
The new aluminum electrolysis technology based on inert electrodes has received much interest for several decades because of the environment and energy advantages. The key to realize this technique is the inert anode. This article presents China’s recent developments of NiFe2O4-based cermet inert anodes, which include the optimization of material performance, the joint between the cermet inert anode...
The most important component in the aluminum industry is the aluminum reduction cell; it has received considerable interests and resources to conduct research to improve its productivity and energy efficiency. The current study focused on the integration of numerical simulation data and virtual reality technology to create a scientifically and practically realistic virtual aluminum reduction cell...
A nonlinear shallow-water model combined with the effect of anode gas bubbles was derived for the melt flows and interface instability in aluminum reduction cells. Both the electromagnetic forces and the drag forces between the bath and gas bubbles, as the main driven forces for the melt flows, were taken into account in this model. A comparative numerical study was carried out using both the model...
The melt flow field and magneto-hydrodynamics (MHD) instabilities in aluminum reduction cells strongly affect the current efficiency and cell operation and a great deal of effort has gone into modeling melt flow and MHD instabilities. In this review, the progress of melt flow is presented: the successes and defects of modeling melt flow via k-ɛ model, Navier-Stokes equations due to different driving...
Application of inert anode and wet-table cathode technology for aluminum reduction will result in significant energy and environmental benefits, so it has been a research focus for several decades. The candidate as inert anode concentrates on oxide ceramic, cermet, and alloy. This paper reviews briefly the research progress and presents the achievements of Central South University, Changsha, China,...
Recent developments in the preparation, sintering process, mechanical properties, and thermal shock resistance of cermet inert anodes for aluminum electrolysis are reviewed in this paper. To obtain the desired technologies of low-temperature activated sintering of cermet inert anodes, the effects of material composition, sintering atmosphere, sintering temperature, and sintering aids on the densifi...
Titanium diboride wettable cathodes are regarded as ideal for aluminum reduction because of their excellent wettability with molten aluminum. The TiB2 inert wettable cathode materials for aluminum reduction may be divided into three groups: pure TiB2 ceramic cathode, TiB2 composite cathode, and TiB2 coating. This paper briefly describes international research progress on TiB2 inert wettable cathodes...
This article presents the use of an improved finite-element model to calculate the static electromagnetic field for an aluminum reduction cell. Consisting of three solid cells and their surrounding bus bars, the model can evaluate the non-uniformity of the current distribution in the inside conductors and bus bar system and couple the current into the sequential magnetic analysis through a conversion...
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