Comparison of Various Methods for Modeling the Metal-Bath Interface

Severo, Dagoberto S.; Gusberti, Vanderlei; Schneider, Andre Felipe; Pinto, Elton C. V.; Potocnik, Vinko

doi:10.1007/978-3-319-48156-2_54

Cited by 10 publications

(13 citation statements)

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“…2000; Zikanov, Sun & Ziegler 2004; Sun, Zikanov & Ziegler 2004; Bojarevics & Pericleous 2006, 2008) which are quite economical to run (two-dimensional) or with direct numerical simulations of the full multiphase (three-dimensional) magnetohydrodynamics (Potocnik 1988; Gerbeau, Lelièvre & Le Bris 2003, 2004; Severo et al. 2005, 2008; Gerbeau, Le Bris & Lelièvre 2006; Munger & Vincent 2006 a , c ; Flueck et al. 2009; Steiner 2009; Flueck et al.…”

Section: Introductionmentioning

confidence: 99%

“…Once a cell has become unstable, we can still want to track the nonlinear evolution of the metal pad roll instability to find, for example, estimates of the maximal interface deformation. This can be done with nonlinear shallow models (Bojarevics & Romerio 1994;Zikanov et al 2000;Bojarevics & Pericleous 2006 which are quite economical to run (two-dimensional) or with direct numerical simulations of the full multiphase (three-dimensional) magnetohydrodynamics (Potocnik 1988;Gerbeau, Lelièvre & Le Bris 2003Severo et al 2005Severo et al , 2008Gerbeau, Le Bris & Lelièvre 2006;Munger & Vincent 2006a,c;Flueck et al 2009;Steiner 2009;Flueck et al 2010) that are numerically much more demanding. Experimental studies have been done to some extent in Hall-Héroult cells (Banerjee & Evans 1990;Potocnik & Laroche 2001) but due to the high temperatures and chemical aggressiveness of the cryolite, this is not simple.…”

Section: Introductionmentioning

confidence: 99%

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Perturbation theory for metal pad roll instability in cylindrical reduction cells

et al. 2019

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We propose a new theoretical model for metal pad roll instability in idealized cylindrical reduction cells. In addition to the usual destabilizing effects, we model viscous and Joule dissipation and some capillary effects. The resulting explicit formulas are used as theoretical benchmarks for two multiphase magnetohydrodynamic solvers, OpenFOAM and SFEMaNS. Our explicit formula for the viscous damping rate of gravity waves in cylinders with two fluid layers compares excellently to experimental measurements. We use our model to locate the viscously controlled instability threshold in cylindrical shallow reduction cells but also in Mg–Sb liquid metal batteries with decoupled interfaces.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Perturbation theory for metal pad roll instability in cylindrical reduction cells

et al. 2019

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“…This allowed to calculate the flow field and the aluminum-cryolite interface. Other commercial software packages have been used and have been accompanied by in-house software developed by Severo et al [3]. Their tools can also take into account the shape of the anode bottom to calculate the flow field and the metal pad heave.…”

Section: Introductionmentioning

confidence: 99%

Magnetohydrodynamic Analysis of Load Shifting in Hall-Héroult Cells

Gesell

Janoske

2023

J. Sustain. Metall.

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The research project SynErgie aims to adapt large scale industrial processes to a volatile supply of renewable energy which is expected for the future. The aluminum electrolysis process is one of the biggest consumers of electric energy in Germany. The aim is to vary its nominal process power by ± 25%. This numerical study focuses on the magnetohydrodynamic (MHD) behavior of the electrolysis cells of Trimet Aluminum SE in Essen. To capture the MHD driven flow and electrodynamics inside the electrolysis cells a computational fluid dynamics (CFD) model is developed in the OpenFOAM® framework. This accounts for the influence of neighboring electrolysis cells, the magnetization of ferromagnetic materials, a static ledge profile and the dynamic changes of anode shape caused by the carbon consumption. The simulation predictions show the heave of the aluminum cryolite interface for different line currents. To analyze the behavior of flexible process operation, shifts of the line currents are studied in detail. After shifting the line current, the interface heave changes directly whereas the shape of the anode bottom reacts with a delay in time. This leads to a locally uneven anode cathode distance (ACD) followed by a disturbed current distribution inside the electrolysis cell after shifting the line current. The anodic current distribution is quantified by the model, which can help process operators to identify whether increased anode currents are caused by the line current shift or potential abnormalities like spikes. Graphical Abstract

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“…Industrial aluminium electrolytic production cells are highly optimized for magnetic field and electric current distribution in order to avoid magneto-hydrodynamic (MHD) instabilities, increase the current efficiency and to maintain a stable electrolytic process during normal operation. The mathematical modelling of the cells and the prediction of unstable behaviour has reached certain maturity since the first principles of the MHD were introduced [1][2][3]. The modelling has become a primary design and optimization tool of aluminium electrolysis cells.…”

Section: Introductionmentioning

confidence: 99%

“…The specialised MHD code [4,5] using the 3-dimensional electromagnetic fields and the extended shallow layer turbulent fluid flow model permits to simulate real commercial cells accounting for a variety of their individual features (bus-bar network, ledge, bottom profile, cathode design, ferromagnetic parts, anode change, etc.). The code was extensively tested [4,5] and fully verified against the benchmark cases [3].…”

Section: Introductionmentioning

confidence: 99%

MHD Stability in Aluminium Electrolysis Cells – From Complex to Simple Analysis

Bojarevics¹

2021

14th WCCM-ECCOMAS Congress

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Numerical modelling has become a primary tool for design and optimization of commercial high amperage aluminium electrolysis cells. The design of industrial cells requires to account for a variety of their individual features: bus-bar network, cell bottom profile and side ledge, cathode bar design, ferromagnetic parts effect, operational adjustments due to the anode changes, etc. Analytical solutions in special cases provide benchmark tests and aid understanding of the basic physics. The commercial Trimet cell is analyzed using a simple theoretical, full numerical and advanced analytical problem solutions, which are compared with experimental measurements using wireless sensors to detect MHD instability onset.

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Comparison of Various Methods for Modeling the Metal-Bath Interface

Cited by 10 publications

References 1 publication

Perturbation theory for metal pad roll instability in cylindrical reduction cells

Perturbation theory for metal pad roll instability in cylindrical reduction cells

Magnetohydrodynamic Analysis of Load Shifting in Hall-Héroult Cells

MHD Stability in Aluminium Electrolysis Cells – From Complex to Simple Analysis

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