Enhancing Sustainability in Aluminum Reduction Cells Through Cathode Repair Optimization and Numerical Simulations Study on Current Distribution and Erosion Hole Impact

• Published in: Journal of sustainable metallurgy 2024, Vol.10 (2), p.658-673
• Main Authors: Zhou, Sen, Diop, Mouhamadou A., Gao, Bingliang, Wang, Zhaowen, Hu, Xianwei, Yang, Youjian, Tao, Wenju
• Format: Article
• Language: English
• Subjects: Aluminum; Cathodes; Current density; Current distribution; Earth and Environmental Science; Electrical resistivity; Environment; Insulators; Material properties; Metallic Materials; Optimization; Research Article; Sustainable Development
• ISSN: 2199-3823; 2199-3831
• DOI: 10.1007/s40831-024-00803-8

The present study investigates the impact of erosion holes and subsequent repairs on the current distribution at the cathode-metal interface in aluminum reduction cells. The research focuses on examining the effects of erosion hole location, size, repair material properties, and the modification of cathode collector bars to optimize cathode repair strategies. The findings indicate that erosion holes lead to a localized concentration of current distribution in the metal at the erosion site. Notably, the maximum current density observed reaches 46125 A/m 2 , and the maximum horizontal current in the lateral cell direction at the cathode-metal interface increases with the depth of the erosion hole. Furthermore, the study reveals that the electrical conductivity of repair materials significantly influences current distribution. Materials with high resistivity behave similarly to insulators. Post-repair actions, including the cutting off of the collector bar, result in a noticeable reduction in current density, with a maximum horizontal current of 5860 A/m 2 . These results provide valuable insights into optimizing cathode repair processes, offering implications for enhancing aluminum reduction cells' efficiency, productivity, and cost-effectiveness. Graphical Abstract