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The paper presents a new nonstationary three-dimensional mathematical model of an aluminium reduction cell which makes it possible to perform coupled thermoelectric and magnetohydrodynamic calculations taking into account sideledge formation. The model considers the nonlinear dependence of material electrical conductivity and thermal conductivity coefficients on temperature, and the nonlinear dependence of magnetization on the magnetic field strength for ferromagnetic materials. Heat transfer coefficients on outer surfaces included the radiant and convective components of heat transfer and were functions of the ambient temperature and the local surface temperature. The energy equation took into account internal heat sources due to the electric current flow, exothermic reactions and additional thermal effects associated with the raw material loading and phase transitions. The control volume method was used to obtain a numerical solution. The developed mathematical model was experimentally tested at the S8BME aluminium reduction cell. The paper presents the calculated and experimental data of magnetic, electric, thermal and hydrodynamic fields. The comparison of calculation results with the results of industrial experiments showed that the developed model reflects physical processes taking place in the aluminium reduction cell with accuracy sufficient for engineering calculations. The calculated values of electrical voltage, magnetic induction and temperature practically coincide with the measured ones. Velocity directions in the metal and the sideledge profile shape obtained by calculation have insignificant differences from experimental values. The developed model can be used to estimate operation specifications and design parameters for new and modernized aluminium reduction cells. Further studies will be aimed at refining the calculated results by improving the developed mathematical model.
The paper presents a new nonstationary three-dimensional mathematical model of an aluminium reduction cell which makes it possible to perform coupled thermoelectric and magnetohydrodynamic calculations taking into account sideledge formation. The model considers the nonlinear dependence of material electrical conductivity and thermal conductivity coefficients on temperature, and the nonlinear dependence of magnetization on the magnetic field strength for ferromagnetic materials. Heat transfer coefficients on outer surfaces included the radiant and convective components of heat transfer and were functions of the ambient temperature and the local surface temperature. The energy equation took into account internal heat sources due to the electric current flow, exothermic reactions and additional thermal effects associated with the raw material loading and phase transitions. The control volume method was used to obtain a numerical solution. The developed mathematical model was experimentally tested at the S8BME aluminium reduction cell. The paper presents the calculated and experimental data of magnetic, electric, thermal and hydrodynamic fields. The comparison of calculation results with the results of industrial experiments showed that the developed model reflects physical processes taking place in the aluminium reduction cell with accuracy sufficient for engineering calculations. The calculated values of electrical voltage, magnetic induction and temperature practically coincide with the measured ones. Velocity directions in the metal and the sideledge profile shape obtained by calculation have insignificant differences from experimental values. The developed model can be used to estimate operation specifications and design parameters for new and modernized aluminium reduction cells. Further studies will be aimed at refining the calculated results by improving the developed mathematical model.
The article aims to determine the magnetohydrodynamic parameters of an aluminum electrolyzer in order to compare different types of bus arrangements used in baths with a Soderberg anode. The electrical parameters of the electrolyzer (current distribution across blooms and anode studs) and magnetic field parameters were computed using the Blums V5.07 program (Polyfem, Russia). Data on circulation rates and skew of the metal in the electrolyzer were obtained using the MHD-Valdis program (developed by V. Boyarevich, University of Greenwich, UK). In the course of the studies, mathematical models of the C-8BM (C-8B) electrolyzer with various bus arrangements were built. Three bus arrangements were selected for testing the installation of a bridge designed to close the current distribution in the anode bus arrangement of the electrolyzer. These types of bus arrangements were realized in two variants: with and without a bridge. The obtained circulation rates and skew of the metal were used to evaluate the possibility of modernizing baths with a Soderberg anode without significant capital costs. When using the first type of bus arrangement, the best current distribution was achieved for the blooms with limits of ~757 A (for the variant without a bridge) and ~656 A (for the modernized variant with closed series), as well as for the anode studs having limits of ~1754 A and ~1609 A, respectively. With the use of the third bus arrangement variant, the current distribution was shown to slightly decrease following the installation of a bridge between the anode bus bars. The obtained results suggest that in the modernization of a C-8BM (C-8B) electrolyzer with different types of bus arrangements, current distribution across blooms and anode studs, magnetic field characteristics (By and Bz components), as well as circulation rates and skew of the metal, have no significant impact on the efficiency of this electrolyzer, which contributes to a faster transition to EcoSoderberg bath electrolysis without significant economic costs.
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