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Effect of Using a Copper Insert on Stability and Energy Balance in an Aluminum Production Cell

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Abstract

Roughly half of the electrical energy input to a modern Hall–Héroult cell for the aluminum (Al) production is lost as heat. Naturally, significant efforts are currently directed toward increasing the thermal efficiency of the cell by a variety of means. In this work, a slice thermoelectric model of a Hall–Héroult cell was developed for a conventional base model (insert-free collector bar) as well as for a copper (Cu) insert model (cylindrical copper inserts in the steel collector bar). Finite element method-based simulations were carried out to determine the components of voltage drops, steady-state ledge profile, cell stability and the overall heat balance. Comparison of the specific energy consumption (SEC) and the cell current in all cases highlighted the advantages of copper insert collector bar assembly over the insert-free, base case. The use of a Cu insert can increase the plant productivity by over 5% at the same SEC as in the base case. Moreover, with the introduction of an insert, an increase in productivity with a concomitant decrease in the SEC could be achieved.

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Abbreviations

Q :

Ohmic heat source (W/m3)

J :

Current density (A/m2)

E :

Electric field strength (V/m)

σ :

Electrical conductivity (S/m)

\(\rho\) :

Density (kg/m3)

\(C_{p}\) :

Heat capacity (J/kg/K)

T :

Temperature (K)

t :

Time (s)

k :

Thermal conductivity (J/ m/K)

Q L :

Heat loss (J)

h :

Heat transfer coefficient (W/m2/K)

A :

Area (m2)

T s :

Temperature of surface (K)

T a :

Temperature of surrounding atmosphere (K)

L :

Characteristic length (m)

A * :

Cross-sectional area of electrolyte under anode (m2)

P :

Wetted perimeter (m)

U * :

Characteristic velocity (m/s)

K eff :

Effective thermal conductivity (J/m/K)

SEC:

Specific energy consumption (kWh)

U :

Cell potential (V)

CE:

Current efficiency

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Author notes

  1. Randhir Singh

    Present address: Department of Metallurgical Engineering, IIT (BHU), Rm No. 36, Varanasi, U.P, 221005, India

Authors and Affiliations

  1. School of Minerals, Metallurgical and Materials Engineering (SMMME), Indian Institute of Technology, Bhubaneswar, 751013, India

    Dipti Ranjan Parida

  2. Tata International Limited, P S Srijan Tech Park,13th Floor, DN 52, Sector V, Salt Lake City, Kolkata, 700091, India

    Nabakishore Kalo

  3. ANSYS Software Pvt. Ltd, Kabra Excelsior, 6A, 7th Main, 1st block, Koramangala, Bangalore, 560034, India

    K. V. S. Ravikrishna

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  1. Dipti Ranjan Parida
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  2. Randhir Singh
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This work has been carried out at IIT Bhubaneswar under the supervision of Dr. Randhir Singh.

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Parida, D.R., Singh, R., Kalo, N. et al. Effect of Using a Copper Insert on Stability and Energy Balance in an Aluminum Production Cell. Trans Indian Inst Met 74, 487–498 (2021). https://doi.org/10.1007/s12666-020-02182-6

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  • DOI: https://doi.org/10.1007/s12666-020-02182-6

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