New Application of Thermal Insulation Coatings for Aluminum Electrolytic Cells

NegotiableUpdate on 02/28

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Overview

The electrolytic aluminum industry belongs to the high-energy consumption industry, and high electricity consumption and limited equipment life are common pain points faced by the industry. ZS-1 high-temperature resistant insulation coating is precisely applied to key parts of aluminum electrolytic cells based on their working conditions, achieving the core goals of energy conservation, cost reduction, quality improvement, and efficiency enhancement. Based on the structure and heat loss characteristics of aluminum electrolytic cells, ZS-1 thermal insulation coating (a new application of thermal insulation coating for aluminum electrolytic cells) is mainly used in key areas such as the side walls, bottom, gas collection hood, and cover plate of the electrolytic cell. These areas are the main channels for heat dissipation and the core areas that affect electrolysis efficiency and equipment life.

Product Details

Introduction of ZS-1 High Temperature Resistant Thermal Insulation Coating and Its Application Effect on Aluminum Electrolytic Cells（New Application of Thermal Insulation Coatings for Aluminum Electrolytic Cells）

1、 Introduction to the Core Characteristics of ZS-1 High Temperature Resistant Thermal Insulation Coating

（1） Product composition and core advantages

ZS-1 high temperature resistant thermal insulation coating is an inorganic single component functional coating developed by Beijing Zhisheng Weihua Chemical Co., Ltd. The core components are specially synthesized inorganic silicate solution, aluminum silicate fiber, heat reflecting substance, and selected hollow ceramic microspheres, which have significant characteristics of non-toxic and harmless, environmental protection and safety. This coating relies on special armor insulation technology to construct a dual insulation structure of "nano hollow ceramic microspheres+heat reflective fillers", which can effectively suppress more than 90% of thermal energy transfer. The insulation effect far exceeds traditional insulation materials, and it also has multiple characteristics such as waterproofing, crack prevention, sound insulation, fire resistance, wear resistance, acid and alkali resistance, and insulation, which can adapt to complex and harsh industrial high temperature environments.

（2） Working mechanism

The insulation mechanism of coating is similar to the insulation principle of a thermos bottle: firstly, the air inside the hollow ceramic microsphere cavity does not generate thermal convection in high temperature environments, and the three-dimensional air layer formed by the tightly arranged microsphere further blocks the thermal convection channel; Secondly, inorganic film-forming materials with low thermal conductivity serve as coating supports, forming a dense insulation shielding layer together with the air layer of microbeads; Thirdly, the added heat reflective material can effectively reflect infrared radiation heat, making the thermal conductivity of the coating close to the vacuum thermal conductivity, thereby achieving efficient insulation and heat preservation. At the same time, it can also have a good cooling effect on low-temperature objects, suppressing temperature rise caused by external heat sources.

（3） Core technical parameters

According to the product manual and actual test data, the key technical parameters of ZS-1 high-temperature resistant insulation coating are as follows:

Temperature resistance range: -81 ℃~1000 ℃, can work stably for a long time in a high temperature environment of 1000 ℃;
Thermal conductivity: only 0.033W/m · k (tested according to GB/T 10297-2015 standard), stable thermal conductivity, and less affected by temperature fluctuations and humidity;
Drying time: surface drying ≤ 2h, actual drying ≤ 24h (based on 1mm film thickness, GB/T1728-1989 standard);
Mechanical properties: The coating hardness reaches 5H (GB/T 6739-2006), the bonding strength is 8MPa (GB/T5210-2006), the tensile strength (after high temperature) is 8MPa, the compressive strength is ≤ 80MPa, and it can bear the extrusion of thick refractory bricks and castables;
Appearance and Density: Paste gray, coating density of 1.4g/cm ³, dry film density of 1.3g/cm ³;
Construction characteristics: Single component room temperature curing, can be used after stirring evenly in an open bucket, and can be applied by spraying, brushing (cross cross method), etc. It has strong adaptability to complex parts such as bends and valves;
Recommended film thickness: Adjust according to the working conditions, generally 0.3mm~20mm can meet the requirements, and a thickness of 2cm can cope with ultra-high temperature scenarios.

2、 Application Effect of ZS-1 High Temperature Resistant Thermal Insulation Coating on Aluminum Electrolytic Cells（New Application of Thermal Insulation Coatings for Aluminum Electrolytic Cells）

（1） Core application areas

Based on the structure and heat loss characteristics of aluminum electrolytic cells, ZS-1 coating is mainly applied to key parts such as the side walls, bottom, gas collection hood, and cover plate of the electrolytic cell. These parts are the main channels for heat dissipation and the core areas that affect electrolysis efficiency and equipment life. By forming insulation coatings in these areas, thermal bridges can be effectively blocked, heat loss can be reduced, and the internal temperature environment of the electrolytic cell can be stabilized.

（2） Key application effects

1. Significantly reduce energy consumption and improve energy utilization efficiency

The heat loss on the surface of the aluminum electrolytic cell during operation is an important reason for high energy consumption. ZS-1 coating, with its extremely low thermal conductivity and efficient insulation performance, can reduce the wall temperature of electrolytic cells by more than 40 ℃. Actual test data shows that the annual energy saving of a single tank can reach 1.32 million kWh, equivalent to reducing CO ₂ emissions by about 126 tons; At the same time, the coating can lock more than 90% of the thermal energy on the heat source side, significantly improving the temperature stability inside the electrolytic cell, increasing current efficiency by 5-8%, reducing comprehensive energy consumption by 10-15%, and significantly reducing production costs for enterprises. In addition, after being applied in the gas collection hood, cover plate and other parts, it can also reduce the heat loss of flue gas, optimize the emission conditions of flue gas, and avoid pipeline corrosion caused by condensation water.

2. Extend the service life of electrolytic cells and reduce equipment maintenance costs

The electrolytic cell is exposed to a harsh environment of high temperature and strong corrosion for a long time, and the thermal stress damage to the cell structure is the main factor leading to the shortened service life of the equipment. The dense coating formed by ZS-1 coating not only effectively isolates heat, but also resists corrosive media such as fluorine-containing flue gas generated during electrolysis, reducing thermal fatigue damage and corrosion damage to the tank structure. Practical application has shown that this coating can extend the service life of electrolytic cells by 2-3 years, while reducing equipment maintenance frequency and maintenance costs, and improving production continuity.

3. Optimize construction adaptability and enhance environmental safety

Compared to traditional insulation materials such as rock wool, ZS-1 coating has significant construction advantages: the coating is in slurry form and can be fully applied to confined spaces such as elbows and valves that are difficult to adapt to traditional insulation materials, achieving comprehensive insulation; The construction process does not require complex equipment and can be completed by curing at room temperature. The surface drying time is short and does not affect the production schedule; The coating thickness only needs 2-3mm to achieve the effect of traditional 15cm rock wool insulation layer, greatly reducing the load-bearing capacity of equipment. At the same time, the coating is made of pure inorganic materials with zero chloride ion content and no organic components. It does not produce harmful gases at high temperatures and complies with national environmental policies. It is harmless to human health and does not pollute water sources, ensuring the health of construction personnel and the safety of the production environment.

4. Stabilize the electrolysis process and improve product quality

The stability of the internal temperature of the electrolytic cell directly affects the efficiency of the electrolytic reaction and the quality of aluminum products. ZS-1 coating can effectively avoid excessive temperature fluctuations in the tank through precise temperature control, ensuring uniform and stable electrolytic reactions, and reducing problems such as abnormal anode consumption and fluctuations in aluminum liquid purity caused by temperature imbalance. Combined with the anode anti oxidation coating provided by Zhisheng Weihua, the anode loss rate can be further reduced by 40%, the phenomenon of oxidation and slag shedding can be eliminated, the pole changing cycle can be extended, and the overall production process stability and product qualification rate can be improved.

3. Summary

ZS-1 high-temperature resistant insulation coating, with its core advantages of efficient insulation, high temperature resistance, environmental protection and safety, and convenient construction, has achieved multiple goals of "energy saving and cost reduction, quality improvement and efficiency enhancement, and equipment life extension" in the application of aluminum electrolysis cells. With the transformation of the electrolytic aluminum industry towards "connotative growth", the demand for energy conservation, consumption reduction, and green development continues to increase. ZS-1 coating, as a key technological solution, provides important support for electrolytic aluminum enterprises to enhance their core competitiveness and achieve low-carbon development, and has broad application prospects.