Patent Application
20160002802
The present invention relates to a method of measuring electric current flowing in an individual electrode in an electrolysis system. Further, the invention relates to a current measuring arrangement for measuring electric current flowing in an individual electrode in an electrolysis system.
In electrorefining (ER) and electrowinning (EW) electrodes are immersed in an electrolyte and an electric current is passed between them. The anode is made positive and the cathode made negative so that an electric current passes through the electrolyte from anode to cathode.
In electrorefining (ER), the metal anode is soluble. That is to say that the metal enters into the electrolyte under the influence of the potential between the anode and cathode. For example, in the electrorefining of copper, the anode is made of impure metallic copper and copper ions enter the electrolyte from the anode. The copper ions, now in the electrolyte, are transported through or by the electrolyte to the cathode where they are deposited. The cathode may be of the same metal as the metal that is being deposited or it may be of a different metal. For example, in the electrorefining of copper it was at one time common to employ a cathode made of copper. However, a stainless steel permanent cathode is now commonly employed which quickly becomes coated with copper and which from then on essentially performs as a copper cathode. The deposited copper is mechanically removed or stripped from the permanent cathode and the permanent cathode reused. The copper deposited on the cathode is highly pure. Impurities that were in the impure anode may dissolve into the electrolyte or fall out as a solid as the anode is dissolved and may contain useful byproducts, for example, gold. Besides copper, metals purified by ER include gold, silver, lead, cobalt, nickel, tin and other metals.
Electrowinning (EW) differs from electrorefining in that the metal sought is imported into the cells and is already contained within the electrolyte. In the example of copper, sulphuric acid is typically employed to dissolve copper from an oxide form of copper ore and the resulting liquor, after concentration, is imported into an electrowinning cell to have the copper extracted. An anode and cathode are immersed in the electrolyte and a current is passed between them, again with the anode being positive and the cathode being negative. In electrowinning, the anode is not soluble but is made of an inert material. Typically a lead alloy anode is used in the case of copper electrowinning. The cathode may be of the same metal that is being extracted from the electrolyte or it may be of a different material. For example, in the case of copper, copper cathodes may be used although stainless steel cathodes are commonly employed which quickly become coated in copper. Under of the influence of an electric current, the metal to be won leaves the electrolyte solution and is deposited in a very pure form on the cathode. The electrolyte is circulated and concentrated by this process having given up a large proportion of its metal content. Besides copper, metals obtained by electrowinning include lead, gold, silver, zinc, chromium, cobalt, manganese, aluminium and other metals. For some metals, such as aluminium, the electrolyte is a molten material rather than an aqueous solution.
As an example of the voltages and current involved, in copper refining, the cell voltage is generally about 0.3V and in copper electrowinning is about 2.0V. In both cases the cathodic current density is about 300 A/m2 and the area of each side of the electrode at present is about 1 m2. These figures differ considerably for different metals and widely varying current densities may be used for the same metal but the invention applies to the electrorefining and electrowinning of all metals.
In ER and EW the starting point is an anode juxtaposed to a cathode in an electrolyte contained in a tank. But many cathode plates and many anode plates may be used, interleaved, with all the anode plates connected in parallel and all the cathode plates connected in parallel contained within a single tank of electrolyte. Electrically this still looks like a single cell and in the industry it is therefore commonly called a cell. In the ER and EW industry, “cell” is almost universally used to mean a tank filled with anodes and cathodes in parallel. In the ER and EW industry, “tank” can mean the same as “cell”, above, or it can mean the vessel alone, depending on the context. In tankhouses cells are connected electrically in series. A typical ER tankhouse might therefore require an electrical supply of the order of 36,000 Amps at 200 Volts.
The electrical circuit representing a typical tankhouse is shown in
More seriously, there is sometimes disruption to the operation of part of the cell when a short circuit develops between an anode plate and a cathode plate. This is typically due to a nodule or dendrite of metal growing from a cathode plate and increasing in size until it connects with the adjacent anode plate. The nodule of metal has to be physically removed to permit normal operation to continue.
Another disruption to normal production can occur when an individual cathode or individual anode becomes disconnected from the electrical circuit. As
A short circuit results in an unusually large amount of current flowing in the cathode 1 and the anode 2 which are electrically shorted together. Methods conventionally employed to detect short circuits are less than ideal. One method is to detect the overheating of the electrodes resulting from the short circuit. This is less than satisfactory because damage to the electrode, its hanger bars 13 or the busbar 4 may have resuited due to a time delay before the short is detected.
This method will become even less acceptable as new, expensive, high-performance anodes, are introduced into electrowinning processes. In electrowinning, inert lead anodes have been commonly used. In recent years mixed metal oxide (MMO) catalytically coated titanium anodes have been increasingly adopted because of their superior properties. However, the MMO coated titanium anodes are more expensive than lead based anodes and more easily damaged by the heat generated during shorting. It has therefore become imperative that problems with the process, in particular short circuits between electrodes, are identified very quickly. Furthermore it is desirable that circumstances likely to give rise to a short circuit are identified. One indicator of an incipient short circuit is a rise in cathode or anode current above its usual value. Hence current measurement with an accuracy and resolution suitable for detecting this rise in current is a tool for identifying dangerous situations and for prompting operator action to correct the situation.
Another method of detecting shorts is to have a worker patrol the tanks using a Gaussmeter to detect the high magnetic field produced by the short-circuit current. Due to restricted labor the patrol can often be organized only once per day or a maximum of few times per day. Therefore the short may go undetected for many hours, during which time production is lost, current efficiency decreases, the risk of decreased cathode quality increases and the electrodes, hanger bars and busbars may be damaged. This method has also proved very inefficient because the patrol needs to check every cell including the cells that do not have any problems. Unnecessary walking on top the cells during the patrol may also cause electrode movement and thus new short circuits. It also increases the risk of accidents. Infrared cameras are also used either by the worker patrols or in overhead cranes to detect short circuits due to heat caused by high current. The method has often proved not to give the desired results in the tankhouse environment because of the long time delay in detecting a short and also availability issues of the crane for the monitoring task.
In order to detect short circuits and bad (open) contacts there is a need to detect these problems at the level of individual cathodes or anodes by providing methods for measuring the current flowing in individual electrodes.
In prior art, U.S. Pat. No. 7,445,696 discloses an electrolytic cell current monitoring device and method, which detects not only short circuits, but open circuits as well. The apparatus comprises magnetic field sensors, e.g. Hall effect sensors, that measure magnetic field strength generated around a conductor adapted to carry electrical current to or from an electrolytic cell. The magnetic field current sensors for each cathode may be arranged on a rail car device which operates above the cells to detect the shorts and open contacts. Detection of current in all cathodes in the cell can be made simultaneously. The magnetic field sensor is brought at a distance above each electrode hanger bar aided by a capacitive proximity sensor.
Further prior art is disclosed in an article “Measurement of Cathodic Currents in Equipotential Inter-Cell Bars for Copper Electrowinning and Electrorefining Plants”. Industry Applications Conference, 2007. 42nd IAS Annual Meeting. Conference Record of the 2007 IEEE; 23-27 Sep. 2007; Wiechmann, E. P., Morales, A. S.; Aqueveque, P. E.; Burgos, R. P. pp. 2074-2079, proposes a measurement technique for the cathodic currents in a dog-bone type intercell bars using linear ratiometric Hall effect sensors and ferromagnetic flux concentrators. The article discloses that cathode currents may be measured by combining the magnetic flux sensors and flux concentrators.
Prior art solutions which are arranged to detect adverse conditions in the cells has focused on measuring the current flowing into or out of cathodes or anodes. The path which these currents take is through a hanger bar or lug, through a contact point between the hanger bar and busbar and then through a busbar. The path is one which changes direction or plane at least twice and after passing through the contact point its exact path is uncertain and variable. Hence the electrode currents are only realistically measurable in the hanger bars or at the contact point.
However, the measurement of the current in the hanger bars or at the contact point alone does not give the tankhouse operators sufficient information of the amount of current which actually flows in the electrode in the event there is a bad or open contact between the hanger bar of said electrode and the electric busbar due to that the equaliser busbar, which supports the other end of the electrode on the other side of the cell, is able to provide multiple pathways for the current so that current is conducted via the equaliser busbar from the adjacent other electrodes to the electrode which has the bad or open contact. Under ideal operating circumstances the equaliser bars connect points in the system which are at the same potential and the equaliser bar carries no current. When conditions are non-ideal, due to a variety of possible adverse circumstances such as said bad or open contacts, currents flow in the equaliser bars which tend to restore the system closer to its ideal operating condition. Currents flowing in the equaliser bars are therefore an indication that problems are arising with the process. Without the knowledge of the actual current flowing in the electrode it is not possible to detect or predict short circuits and open and bad contacts with a great certainty. Therefore, in order to obtain accurate current measurements for each individual electrode there is still a need for a measurement of the current which flows in the equaliser busbar between each contact point.
The objective of the invention is to eliminate the disadvantages mentioned above.
In particular, it is an objective of the present invention to provide a method and a current measurement arrangement which enables an accurate measurement of the current in the equaliser busbar between each contact point.
Further, the objective of the invention is to provide method and arrangement for measuring the current entering or leaving the electrodes (cathodes and/or anodes) which will permit operators to detect early the presence of short circuits or open circuits.
Further, the objective of the invention is to provide method and arrangement, which enable, due to the sufficiently accurate current measurement, that the growth of the metal nodules or dendrites which lead to a short circuit may be detected before the short circuit occurs, allowing action to be taken to prevent a short occurring.
Further, the objective of the invention is to provide method and arrangement, which enable, due to the sufficiently accurate current measurement, that high resistance contacts (between the hanger bar contacts and their respective busbars) can be identified and early corrective action can be taken.
Further, the objective of the invention is to provide method and arrangement which enable, due to the sufficiently accurate current measurement, that the measurement can be of use for process control, either through real time adjustment of current flow or by improvements in plant operation resulting from analysis of the data.
Further, the objective of the invention is to provide method and arrangement, which, due to the sufficiently accurate current measurement, permits process analysis, and if required, dynamic process control, as well as the detection of incipient short circuits and actual short circuits and the detection of open circuits.
The Table 1 below shows the estimated current measurement accuracy required for the various objectives mentioned above. This invention aims to make current measurements of the highest accuracy thereby permitting process analysis, and if required, dynamic process control, as well as the detection of incipient short circuits and actual short circuits and the detection of open circuits.
The Table 1 below shows the estimated current measurement accuracy required for the various objectives mentioned above. This invention aims to make current measurements of the highest accuracy thereby permitting process analysis, and if required, dynamic process control, as well as the detection of incipient short circuits and actual short circuits and the detection of incipient open circuits as well as actual open circuits.
According to a first aspect, the present invention provides a method of measuring electric current flowing in an individual electrode in an electrolysis system comprising a plurality of interleaved electrodes, cathodes and anodes, arranged in an electrolysis cell and immersed in electrolyte, said electrolysis system having a busbar arrangement disposed on a separating cell wall between each of the two adjacent cells, said busbar arrangement comprising an equaliser busbar to electrically connect anodes in one cell to cathodes in a next cell providing the current with multiple electrical pathways between electrodes, said electrical connection being formed by contact points between the equaliser busbar and hanger bars of the electrodes. According to the invention the electric current in the equaliser busbar is measured at measuring points located between each pair of the adjacently neighboring contact points.
According to a second aspect, the present invention provides a current measuring arrangement for measuring electric current flowing in an individual electrode in an electrolysis system comprising a plurality of interleaved electrodes, cathodes and anodes, arranged in an electrolysis cell and immersed in an electrolyte, said electrolysis system having a busbar arrangement disposed on a separating cell wall between each of the two adjacent cells, said busbar arrangement comprising an equaliser busbar to electrically connect anodes in one cell to cathodes in a next cell providing the current with multiple electrical pathways between electrodes, said electrical connection being formed by contact points between the equalizer busbar and hanger bars of the electrodes. According to the invention the current measuring arrangement comprises magnetic field sensing means for measuring the magnetic field induced by the electric current in the equaliser busbar, the magnetic field sensing means being arranged at measuring points located between each pair of the adjacently neighboring contact points.
The advantage of the invention is that the invention provides a method and arrangement for measuring the current entering or leaving the electrodes (cathodes and anodes) which will permit operators to detect the presence of short circuits or open circuits. Additionally, as the current measurement arrangement is of sufficient accuracy, the growth of the metal nodules or dendrites which lead to a short circuit can be detected before the short circuit occurs and corrective action taken to prevent a short occurring. Additionally, if the current measurement is of sufficient accuracy, high resistance contacts (between the hanger bars and their respective busbars) can be identified before they become open circuits and corrective action taken. Furthermore, if the current measurement can be made with even greater accuracy, the measurement can be of use for process control, either through real time adjustment of current flow or by improvements in plant operation resulting from analysis of the data. By use of a suitable algorithm and knowledge of the total current flowing through a cell, the currents flowing into or out of the cathodes and anodes can also be estimated. The invention is particularly applicable where a double-contact busbar arrangement is employed.
In an embodiment of the method, the electric current in the equaliser busbar is measured by sensing the magnetic field induced by said current flowing in the equaliser busbar.
In an embodiment of the method, the electric current in the equaliser busbar is measured by sensing magnetic field at the midpoint between each pair of the adjacently neighboring contact points.
In an embodiment of the method, the magnetic field of the electric current is sensed with a magnetic circuit being arranged to encircle the equaliser busbar.
In an embodiment of the method, the magnetic circuit is an open loop current sensor.
In an embodiment of the method, the magnetic circuit is a closed loop current sensor.
In an embodiment of the method, the magnetic circuit comprises a core of magnetic material formed as a ring surrounding the equaliser busbar.
In an embodiment of the method, the electric current in the equaliser busbar is measured at the measuring point by sensing the magnetic field with one or more Hall effect sensors arranged in proximity to the equaliser busbar.
In an embodiment of the method, the magnetic field induced by the current flowing in the equalizer busbar is sensed with an array of Hall effect sensors arranged in the vertical plane around the equalizer busbar at the measuring point.
In an embodiment of the method, the electric current in each electrode is measured by sensing the magnetic field induced by said current substantially at the level of the contact points to measure the current passing through the contact point.
In an embodiment of the method, the magnetic field at the contact point is sensed with a magnetic field sensor arranged in the vicinity of the contact point.
In an embodiment of the method, the magnetic field at the contact point is sensed with an array of magnetic field sensors arranged in three dimensional space around the contact point substantially in a plane of the contact point. The plane may be at an angle 0 to 75° in relation to horizontal.
In an embodiment of the method, a frame unit of insulating, non-magnetic material is arranged to hold the magnetic field sensors in a predetermined position with respect to equalizer busbar at measuring points and/or to hold the magnetic field sensors in a predetermined position with respect to the contact points.
In an embodiment of the arrangement, the magnetic field sensing means are arranged to sense the magnetic field at the midpoint between each pair of the adjacently neighboring contact points.
In an embodiment of the arrangement, the magnetic field sensing means comprise a magnetic circuit being arranged to encircle the equaliser busbar.
In an embodiment of the arrangement, the magnetic circuit is an open loop current sensor.
In an embodiment of the arrangement, the magnetic circuit is a closed loop current sensor.
In an embodiment of the arrangement, the magnetic circuit comprises a core of magnetic material formed as a ring surrounding the equaliser busbar.
In an embodiment of the arrangement, the magnetic field sensing means comprises one or more Hall effect sensors arranged in proximity to the equaliser busbar.
In an embodiment of the arrangement, the magnetic field sensing means comprises an array of Hall effect sensors arranged in the vertical plane around the equalizer busbar at the measuring point.
In an embodiment of the arrangement, the current measuring arrangement further comprises magnetic field sensing means arranged at the level of the contact points to measure the current passing through the contact point.
In an embodiment of the arrangement, the magnetic field sensing means comprises a magnetic field sensor arranged in the vicinity of the contact point.
In an embodiment of the arrangement, an array of magnetic field sensors arranged around the contact point substantially in the plane of the contact point.
In an embodiment of the arrangement, the array of magnetic field sensors is arranged in a three dimensional space around the contact point substantially in the plane of the contact point at an angle in the range 0 to 75° with respect to horizontal.
In an embodiment of the arrangement, the current measuring arrangement comprises a frame unit of insulating, non-magnetic material arranged to hold the magnetic field circuits and/or magnetic field sensors in a predetermined position with respect to the equalizer busbar.
In an embodiment of the arrangement, the frame unit is arranged to hold the magnetic field sensors in a predetermined position with respect to the to the contact points.
In an embodiment of the arrangement, the frame unit comprises a plurality of magnetic field sensors arranged to measure magnetic field from a plurality of measuring points along the equaliser busbar and/or from contact points.
In an embodiment of the arrangement, the frame unit comprises a plurality of magnetic field sensors arranged to measure magnetic field from a plurality of contact points.
In an embodiment of the arrangement, the frame unit comprises one or more notches, each of said notches being arranged to accommodate an end of an electrode hanger bar.
In an embodiment of the arrangement, the frame unit comprises one or more notches for one or more hanger bars of anodes.
In an embodiment of the arrangement, the frame unit comprises one or more notches for one or more hanger bars of cathodes.
In an embodiment of the arrangement, each notch is arranged to accommodate an end of a hanger bar with a play to allow installing of the frame unit by dropping it into position on the busbar without having to remove the electrodes and to allow lifting the electrodes without having to remove the frame.
In an embodiment of the arrangement, each notch is defined between two walls of the frame unit which are parallel and opposite and at a distance from each other, and that for measuring the current at the contact point, two magnetic field sensors spaced from each other are attached to each of the walls.
In an embodiment of the arrangement, the frame unit comprises notches for a number of hanger bars of cathodes and for a number of hanger bars of anodes.
In an embodiment of the arrangement, the arrangement comprises one frame unit extending substantially to the whole length of the cell.
In an embodiment of the arrangement, the arrangement comprises a plurality of frame units arranged in a row or queue on the busbar arrangement.
In an embodiment of the arrangement, the frame unit comprises a microprocessor for pre-analysis of the plurality of signals derived from the magnetic field sensing means.
In an embodiment of the arrangement, the microprocessors are arranged to connect and exchange information by digital, analog or wireless means.
In an embodiment of the arrangement, the frame unit comprises visual indicators which are arranged to indicate which electrodes have a problem associated with them which requires attention of the tankhouse operators.
In an embodiment of the arrangement, the visual indicators are controlled by the microprocessor which is arranged within the frame unit.
In an embodiment of the arrangement, the microprocessor is arranged to detect failure of a magnetic field sensor and to reorganise its analysis of the remaining magnetic field sensor signal so that the frame unit can continue to function.
In an embodiment of the arrangement, the microprocessor is arranged to provide a warning signal of the failure of a magnetic field sensor.
In an embodiment of the arrangement, the arrangement comprises a central processing unit arranged to receive signals from the microprocessors of the frame units.
In an embodiment of the arrangement, the microprocessors are arranged to connect and exchange information with the central processing unit by digital, analog or wireless means.
In an embodiment of the arrangement, the frame unit comprises temperature sensors arranged to measure the temperature of the electrode hanger bars.
In an embodiment of the arrangement, the frame unit comprises temperature sensors arranged to measure the temperature of the busbar arrangement.
In an embodiment of the arrangement, the frame unit is powered by an external unit or host.
In an embodiment of the arrangement, the frame unit comprises an electric energy storage device.
In an embodiment of the arrangement, the energy storage device is chargeable by energy harvesting from the ambient.
The accompanying drawings, which are included to provide a further understanding of the invention and constitute a part of this specification, illustrate embodiments of the invention and together with the description help to explain the principles of the invention. In the drawings:
One embodiment of the invention relates to the use of Hall effect sensors to measure the magnetic field induces by the current flowing in the equaliser bar.
In the embodiment of
A cross-section of the double-contact busbar arrangement is shown in
Referring to
Referring to
In the double-contact busbar arrangement 4B the on the right side (which is identical to busbar arrangement 4A), located between the cells 3B and 3A, the current incoming from anodes 2 (e.g. which belong to cell 3B) is conveyed to cathodes 1 (e.g. which belong to cell 3C) via the main intercell busbar 9 which can be called also as a main equaliser busbar. The first equaliser busbar 10 electrically connects together the left side ends of the hanger bars of anodes 2 which belong to cell 3C. The second equaliser busbar 11 electrically connects together the right side ends of the hanger bars of cathodes 2 which belong to cell 3B.
In ideal operation, as shown in
In
Reference is made to the
Again referring to
Further referring to the
Referring again to
A plurality of frame units 18 may be arranged in a row or queue on the busbar arrangement, as shown in
In the embodiment of
The frame unit 18, as shown in
Used in cooperation, the sum of the signal from these two sensors would have reduced sensitivity to their accidental displacement from their ideal position about the equaliser bar 11. This is a useful attribute when the sensors are not firmly attached to the equaliser bar support structure but rather are carried on a frame unit 18 which is separate from the busbar structure and which can be placed on top of the busbar structure subsequent to the building of the bus bar structure of when the frame units are fitted to an existing plant in a retrofit exercise.
Sensor 162 may have better rejection of flux generated by currents that flow orthogonally to the current in the equaliser bar 11. Sensor 162 could be used alone or in cooperation with sensors 161 and 163.
Referring also to
An algorithm optionally within the operating programme of the microprocessor contained within the frame unit can be arranged to create a record of each anode and/or cathode current against time and analyses said record to look for the profile of a short circuit in the process of developing.
The frame unit 18 may also comprise temperature sensors 24, 25 arranged to measure the temperature of the electrode hanger bars 13, busbar arrangement 4 or the frame unit 18. Temperature sensors 24, 25 can be connected to the microprocessor 21 of the frame unit 18 and hence also communicate with the central control facility 23. The temperature sensors 24 are preferentially located close to the electrode hanger bars 13. The hanger bars 13 are the most likely source of heating of the frame unit 18. This heating could damage the Hall effect sensors 16, 17. Hence an early warning of rising temperature will enable an operator to take corrective action and avoid damage to the Hall sensors and other electronic components within the frame unit. Additionally hot hanger bars are an indication of a short circuit between electrodes. Cold hanger bars could be an indication of an open circuit. Hence the temperature sensors are another source of information about the condition of the electrolysis cell. The Hall effect sensors and the temperature sensors may therefore cooperate to provide plant operators with a warning of actual or impending problems. Optionally, the signals from the Hall effect sensors and the temperature sensors may be analysed by the microprocessor in the frame unit to provide a simple warning of a problem at that location to the control room or via a visual indicator mounts on the frame unit. The frame unit may operate even if no current sensor is in operation so that it depends entirely upon temperature detection. Some characteristics of the Hall effect sensors are temperature dependent. The temperature readings sent to the microprocessor can therefore be used to correct for temperature the signals arriving from the Hall effect sensors. Thermistors, thermocouples, digital sensors or infrared sensors may all be used as temperature sensors.
Further, the frame unit 18 may comprise an electric energy storage device 26 which may be chargeable by energy harvesting from the ambient or externally via normal power supply. A typical Hall effect sensor will draw approximately 10 mA in operation. If a frame unit should encompass four cathodes and four anodes, each surrounded by four Hall effect sensors, the total number of Hall effect sensors employed will be 32. The total current drawn by the Hall effect sensors if all are operated continuously will be 320 mA. This may be inconveniently large. Each Hall effect sensor or array of Hall effect sensors may therefore be connected to its power supply by an electronic switch (for example, a MOSFET) which is under the control of the microprocessor in the frame unit. Hence only those Hall sensors for which a reading is required at any time are activated by the microprocessor.
Since electrolysis varies with time only slowly, readings of the current (and any other measurements) need only be taken at large intervals of time. Furthermore, readings can be obtained from the Hall sensors in fractions of a second. The microprocessor can be arranged to spend most of the time in sleep mode using only a tiny amount of power with all other electronics in the frame unit turned off. Hence the average power consumption of the electronics contained within the frame unit can be very low. The frame unit can spend nearly all the time in hibernation using only a few μW of power. If there is an energy storage unit within the frame units (for example a suitably sized capacitor or rechargeable battery) this can be trickle charged from a low power source or via a 4 normal power supply. It may be possible to obtain this trickle charge by energy harvesting. There are a number of ways this can be achieved (e.g. ripple current, photovoltaic source, thermal pile or Peltier generator using the heat from the electrolysis tank). In addition this stored energy may also be used to transmit the data obtained wirelessly if desired by activating a radio transmitter for a very short time (typically a fraction of a second).
A further embodiment may also be that on the base of the frame unit, spring contacts which press against the busbar conducting elements. The purpose of these contacts is twofold: they permit power for the frame unit electronics to be collected from the busbars elements, and they enable voltage measurements to be made on the busbar elements. More contacts can be provided than is strictly necessary for operation so that there is some redundancy which is useful if contamination prevents any one spring contact from making a good connection with the busbar element. The microprocessor can monitor the state of each spring contact and advise the operator if maintenance of the frame unit is required.
Frame units 18 may also be daisy-chained electrically with power and signaling wires connected from unit to unit using plugs and sockets. Instead of using a plugs-and-socket daisy-chain system to connect frame units, it is also possible to run cable, such as a twisted pair of wires, along the side of each tank and couple power into each frame unit in a non-contact fashion while coupling data again into and out of that cabling in a non-contact fashion. It is also possible to arrange an inductive coupling between frame units. The first frame unit can be powered with hard wiring and the power can then pass wirelessly via the inductive couplings down a daisychain of the frame units.
Within the frame units 18 are stabilised power supplies which give a suitable accurate voltage output to permit the use of ratiometric Hall effect sensors within the frame unit. The microprocessor 21 within the unit can be programmed with a start-up routine which allows compensation for offset voltages from the Hall effect sensors. The microprocessor 21 can be switched on before fitting the unit 18 to the ER or EW plant to accomplish this.
During assembly, calibration of the Hall effect sensors 16, 17 may be carried out to enhance accuracy. This will require the use of a calibration apparatus capable of generating a known set of currents in a suitable dummy busbar and hanger bar structure. The microprocessor can thereby acquire and remember a calibration factor for each Hall effect sensor.
Typically a calibrating apparatus will be used to test and calibrate the Hall sensors used in the frame unit. This calibrating unit would typically have a set of hanger bars resting on bus bars in a form which emulates the structure found in the electrolysis cell. Current sources are applied to this rig which are capable of applying a pattern of currents through the various conductors during calibration in a continuous, pulsed or varying manner. In coordination with this current pattern (which is predetermined or conveyed to the microprocessor of the frame unit) measurements are taken by the microprocessor of the Hall effect sensor readings at appropriate moments in time. These readings are used to calibrate the current readings produced by the microprocessor.
A typical calibration procedure might be as follows. Assuming that all the conductors (or contact points) are surrounded by an array of four Hall effect sensors, as previously described. A first test would be to apply a current to one conductor or contact point only. Readings would be taken from the four Hall effect sensors surrounding this conductor or contact point. From these readings a measure of the current in the conductor or contact point would be obtained. Additionally and simultaneously, readings would be obtained from all other Hall effect sensors in the frame unit. This process is then repeated for all conductors or contact points which the frame unit addresses and the currents in which it is responsible for reporting. Hence, when the current in a particular conductor or contact point is being measured, the microprocessor can correct the readings in the array of Hall effect sensors surrounding that array for the effects of any currents which may be flowing in any of the other conductors or contact points. Hence the calibration and learning process which the microprocessor goes through during calibration, forms an essential role in achieving high accuracy current measurements and this methodology and associated algorithm is a further aspect of the invention.
From each frame unit 18 current information can be transmitted via the data link to a control room or monitor screen to allow the current measurements to be observed, recorded and analysed. The current data link for each tank may be terminated in a frame unit already employed for returning current information to a control room so that the already established data links may be used for transmission of data from the frame units.
In summary, the present invention provides several advantages. High accuracy of the measurement results from measuring the current in each electrode at a location where it is concentrated in a point, i.e. at the contact point. The use of a plurality of magnetic field sensors to measure each current permits good signal strength while giving good immunity to unwanted signal intrusion. The inclusion of a microprocessor in unit frames and its ability to remember location with an ID and calibration factors for each Hall effect sensor allows low cost basic Hall sensors to be employed while achieving good accuracy for the unit. The presence of a microprocessor in the unit frame enables analysis of the Hall effect sensor signals within the frame unit permitting visual signaling to operators to be located on the frame unit. Appropriate design of the frame units permit the units to be installed whilst the ER or EW plant is operating. The frame units allow operation, including raising and lowering of electrodes to proceed unhindered.
While Hall effect sensors and temperature sensors have been disclosed, the frame unit may contain also other sensors or measuring equipment in addition to those described here and its measurement facilities are not limited merely to current and temperature.
While the present inventions have been described in connection with a number of exemplary embodiments, and implementations, the present inventions are not so limited, but rather cover various modifications, and equivalent arrangements, which fall within the purview of prospective claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 20135197 | Mar 2013 | FI | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/FI2014/050144 | 2/27/2014 | WO | 00 |
