Modelling of Coupled Mass and Thermal Balances in Hall-Heroult Cells During Anode Change

Abstract

As the most routine work practice in an aluminum reduction cell, anode change introduces substantial perturbations that adversely affect the mass and heat balance of the cell which may lead to loss of process efficiency and increased energy consumption. The literature lacks a dynamic mathematical model that describes the interactions among cell variables (e.g., electrolyte temperature and flow, anode current distribution, and cell heat loss) during and following this operation, which could otherwise be used to understand the process in greater depth and to develop changes that improve process operations and control. This paper presents a spatially-discretised dynamic model for anode replacement that integrates mass balance, thermal balance and cell voltage to describe and predict local cell variables. It was experimentally validated with an industrial cell undergoing an anode change procedure. This generic model can be applied to different cell design or process conditions by using appropriate parameters (e.g., heat transfer coefficients, conductivities, and flow patterns). The model can be used to improve existing process operations or control strategies for higher process efficiency, lower energy consumption, and lower emissions.