Energy savings in aluminum electrolysis cells: Effect of the cathode design

Abstract

Non uniform current distribution inside aluminum electrolysis cells is responsible for energy losses, a phenomena impacting on both the economy and the environment. Indeed, non uniform distribution induces premature wear of the cathode surface and triggers magneto-hydro-dynamic instabilities in the molten aluminum of the cell. The present study addresses this problem by examining the effect of the cathode shape and design on the current distribution. A computational methodology based on a finite element method is developed. It is then employed to determine the optimal cathode design, i.e., the design that minimizes the energy losses and maximizes the lifetime of the cell. The effect of various design parameters on the current distribution is highlighted. Their economic impacts on the operation of the cell are also assessed.