Anode Carbon Block Stacking Overhead Crane for Aluminum Electrolysis Plants
The anode carbon block stacking overhead crane is a specialized transfer equipment used in the carbon block warehouses of carbon plants. The crane mainly consists of a bridge frame, trolley traveling mechanism, hoisting mechanism, guiding device, clamping device, control system, and electric hoist. It is used in anode carbon block storage yards for handling green and baked carbon blocks as well as other miscellaneous lifting tasks.
Equipped with its own clamping fixtures, the crane can grasp 19 or 21 longitudinally arranged anode carbon blocks at a time for shuttle stacking or loading operations. It can also remove defective blocks and insert qualified blocks as needed.
The anode carbon block stacking overhead crane is dual-driven, and the entire system is controlled via variable frequency drives and PLC. All crane operations are performed from the operator cabin, which is equipped with an air-conditioning system that can be adjusted for heating or cooling.
Features
- Operation Mode: Supports cabin operation, remote operation (wireless remote control), and dual-mode operation (cabin + remote control).
- Control System: PLC + VFD + HMI. PLC options include AB ControlLogix 5000 / Siemens S7-1500; VFD options include Emotron VFX48 / ABB ACS880 / Schneider ATV71. The industrial-grade HMI touch screen supports parameter setting and status monitoring.
- The crane can realize fully automatic operation, including automatic gripping, placing, destacking, and loading. It features a high level of automation and intelligent positioning, using precise laser/encoder alignment (±2 mm).
- Remote Monitoring and Data Management: Through wireless transmission, remote monitoring between the crane and the central control room can be achieved. Supports remote program upload and download, as well as data recording such as carbon block handling reports, fault log storage, and analysis.
- Mechanical Device and Energy-Saving Design: Pure mechanical structure with no electrical drive; variable-frequency speed regulation, environmentally friendly and energy-efficient; modular design for easy maintenance.
Specifications
| Span (m) | 16.5 | 19.5 |
| Number of Carbon Blocks (pcs) | 19, 21 | 19, 21 |
| Crane Weight (excluding clamp) (t) | 19–27 | 19–27 |
| Duty Classification | A7, A8 | A7, A8 |
| Clamp Lifting Speed (m/min) | 2.5–6 | 2.5–6 |
| Crane Traveling Speed (m/min) | 6–60 | 6–60 |
| Maximum Wheel Load (kN) | 265 | 285 |
| Total Power (kW) | 128 | 134 |
| Recommended Crane Rail | QU100 | QU100 |
| Operating Mode | Cabin operation (with heating & cooling A/C) | Cabin operation (with heating & cooling A/C) |
| Electric Hoist Lifting Capacity (t) | 5 | 5 |
| Electric Hoist Lifting Speed (m/min) | 8 | 8 |
| Electric Hoist Traveling Speed (m/min) | 20 | 20 |
| Drive Mode – Crane | VFD (Variable Frequency Drive) | VFD (Variable Frequency Drive) |
| Drive Mode – Hoisting Mechanism | VFD | VFD |
| Drive Mode – Clamp | Gravity type | Gravity type |
Mobile Clamp Device
- After the mobile combined clamp is connected to the hoisting mechanism and guiding device of the stacking crane, it can be moved to lift multiple longitudinally arranged anode carbon blocks, and it can also lift individual blocks for miscellaneous handling inside the warehouse.
- It can remove defective blocks and insert qualified blocks from/into a set of 19 longitudinally arranged anode carbon blocks, ensuring a stacking height of six layers.
- When the crane travels longitudinally back and forth inside the warehouse, it can not only grab and stack carbon blocks from the ground but also pick up blocks from the plate conveyor and place them onto the chain conveyor for outbound transfer.
- The mobile combined clamp in the clamping device adopts a gravity-type clamp, allowing it to adapt to carbon blocks of different specifications.
- Driven by its actuator, the clamp can move horizontally back and forth along the hanger beam track to achieve precise positioning and adjustable clamp spacing, enabling the handling of carbon blocks with different spacing requirements and realizing true multi-function capability with a single machine.
Applications
The anode carbon block stacking overhead crane is a specialized equipment for handling and stacking anode carbon blocks, primarily used in the carbon block warehouses of large prebaked anode aluminum plants.
Green carbon blocks produced from the vibration forming process are first transported to the anode baking workshop for baking. After baking, the finished (baked) carbon blocks are moved to the carbon block warehouse, and then to the anode assembly workshop for assembly. The anode carbon block stacking overhead crane unit is responsible for the transfer of carbon blocks throughout this production process.
Case
Project Overview
- Project: Carbon system green anode workshop in a coal-power-aluminum integrated industrial project.
- Production Capacity: Designed annual production of 500,000 t/a prebaked anodes.
- Equipment Purpose: The stacking crane serves as the core transfer equipment, used for handling and stacking green and baked anode carbon blocks in the warehouse, while also performing miscellaneous lifting tasks. It connects the full workflow from carbon block production, baking, to outbound storage.
- Operating Environment: High ambient temperature; air contains harmful substances such as carbon dust, hydrocarbons, and baking fumes.
- Workshop & Rails: Workshop span 18 m, rail gauge 16.5 m, using QU100 rails.
- Operating Schedule: Runs 365 days a year, with three shifts per day (8 hours per shift), and one 8-hour maintenance session per week.
- Lifted Objects:
- Green Anode Carbon Blocks: Dimensions 1770 mm × 745 mm × 663 mm, weight 1,350 kg per block.
- Baked Anode Carbon Blocks: Dimensions 1750 mm × 740 mm × 660 mm, weight 1,282 kg per block.
Equipment Configuration
- Quantity: 6 units.
- Stacking Capacity: Can grasp 19 longitudinally arranged anode carbon blocks per operation, with a maximum stacking height of 9 layers.
- Core Components: Frame, crane traveling mechanism, hoisting system, clamping device, guiding device, electric hoist, electrical system, control system, lubrication system, etc.
Key Technical Parameters
- Crane Traveling Mechanism:
- Rail gauge: 16.5 m
- Loaded traveling speed: 10–16 m/min
- No-load traveling speed: 7–50 m/min
- Variable-frequency speed control, duty class M8
- Traveling wheel wheelbase: 4.5 m, diameter: 500 mm; horizontal wheel wheelbase: 5.4 m, diameter: 238 mm
- Electric Hoist:
- Lifting capacity: 3 t
- Lifting height: 12 m
- Lifting speed: 10 m/min
- Traveling speed: 20 m/min
- Duty class: M4
- Winch:
- Lifting capacity: 25 t (excluding clamp)
- Lifting speed: 2.5–6 m/min
- Variable-frequency speed control, duty class M8
- Motor Protection: Insulation class F, protection class IP54.
- Electrical Control System: PLC-based electrical control system.
