Comparison of Various Methods for Modeling the Metal‐Bath Interface

Abstract

The correct evaluation of the stationary metal-bath interface in aluminum reduction cells is still a source of discussion and controversy. The objective of this paper is to present some calculations of the interface performed by different methods, used in software packages and to compare them with measured metalbath interface profile in a real cell. Our comparison includes Shallow Layer approach and 3D multiphase methods, such as: homogeneous and inhomogeneous volume of fluid (VOF) as well as floating grid method. Different boundary conditions on the top of bath channels are tested in VOF methods. Finally, a simple generic magnetic field and vertical current density are proposed for software benchmarking of this problem.

Towards a coupled multi-scale, multi-physics simulation framework for aluminium electrolysis

“…The proposed current density, centered in the centre channel, simulates the main characteristics of an aluminium reduction cell i.e. increasing current pick-up along the cathode block, corresponding in shape to that proposed by Severo et al [27].…”

An Overview of Opportunities for Waste Heat Recovery and Thermal Integration in the Primary Aluminum Industry

“…Considering the temperature and flow rate values reported in Ref. 7, it is concluded that if exfiltrations could be channeled in a single stream, then exfiltration heat could be available for thermal integration in the form of an airflow at $300°C. The amount of easily extractable heat is difficult to estimate since present furnaces are not designed to channel exfiltrations into a single stream; exfiltrations are currently dissipated into the surroundings.…”

“…Similar to exfiltration temperatures, top surface temperatures vary with furnace sections (between 100°C and 1100°C) based on Ref. 7. Using temperature and heat flux data from individual furnace sections, an average temperature of 700°C is obtained for this heat source.…”

“…We do not make an assumption with regards to extractable heat for this waste heat source since the best energy efficiency initiatives might be associated with furnace design alternatives that reduce this heat flux altogether. 7 In the cast house, high-temperature thermal waste originates from holding furnaces. The molten aluminum load first arrives to the ADQ cast house too hot for casting to begin (at about 860°C), and it is left to cool in ambient air until it reaches a 720°C temperature.…”

Probing the Numerical Convergence of a Commercial Finite Element Software in Electrochemical Simulations

“…Nanoelectrodes arrays are studied by Godino et al 18 Magnetohydrodynamics of aluminum electrolysis cells were modeled by Severo and coworkers. 19 Electrochemical machining processes were simulated by Hardisty and Mileham. 20 Dees et al modeled lithium polymer batteries.…”