Carbon Anode Modeling for Electric Energy Savings in the Aluminium Reduction Cell

Abstract

The carbon anode geometrical design influences the energy consumption in aluminium production. A 2D finite element model (FE-model) of an anode immersed in an aluminium reduction cell has been developed to study how the anode geometry affects the variation in the anode to cathode distance (ACD). Large variation in ACD will prevent a systematic reduction of the average ACD and thereby hindering a reduction of electrical power loss in the bath. Another modeling example focuses on the large amount of energy loss occurring at the anode-cast iron interface due to the roughness-induced contact resistance. An analytical equation for the real contact area has been established to link the electrical power loss from the contact resistance with the pressure-dependent interface properties. The proposed contact model can be implemented in a full scale electrical FE-analysis of an anode, and used to optimize energy savings.