An Approach for Estimation of Cathode Voltage Drop in an Aluminum Reduction Cell with an Inclined Carbon Block and a Copper Insert

Abstract

Numerical models of a cathode block assembly in a Hall–Heroult cell, comprising of liquid aluminium, carbon block, current collector, ramming paste and a copper insert were built and the finite element method simulations were carried out to model the cathode voltage drop (CVD), the current distribution and, the effect of geometrical parameters on the CVD. The objective of the study was to quantify the drop in the CVD for different cathode assembly design. Flat- and inclined-interface carbon block top-surface and a copper insert versus the conventional insert-free designs were simulated with a myriad of other geometrical parameters to optimise the design. The results informed about the optimum insert positioning to about 75 mm from the collector base and the energy saving possibilities due to reduction in the CVD with a cathode design with inclined-interface carbon block and copper insert in the collector bar.