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decreasing the fraction of heat dissipated through the ledge, the exact same heat input
perturbation will have a much larger impact on the thermal response of the system. Since
exact measurements of these parameters were no longer possible, we had to estimate these
parameters.
Measured vs simulated bath temperature
910
920
930
940
950
960
970
980
04:48
09:36
14:24
19:12
00:00
Time in hours
Measured
Dyna/Marc
Figure 4: Comparison of the response thermal response (validated model)
After adjusting these parameters, the Dyna/Marc cell simulated thermal response almost
perfectly matched the real cell measured thermal response, as can be seen in Figure 4.
During the 3-hour power shutdown, two mechanisms characterizing the thermal and chemical
response of the pot were seen:
a) Without power no more heat generation in the anode, cathode and bath:
The remaining heat in the pot, however, still maintains the convection plume around the
pot so that the heat convection on the outside of the shell is almost unchanged.
Inside the pot, no more heat is generated in the anode and no more hot process gas is
emitted. The still-running exhaust gas extraction system starts to cool down the covering
and anodes.
b) The electro-magnetic stirring of the bath is disrupted and the metal pad flattens out under
gravity.
On shutting down the power, the magnetic field collapses and the metal pad levels out.
The stirring effect of the magnet field also breaks down, resulting in massive changes in
the heat transfer into the ledge.
At locations with a high metal and bath speed and a well-established ledge profile, the
speed-dependent heat transfer coefficient drops and less heat is conducted into the side /
end pier. The reduced heat flux results in a growing ledge thickness. This mostly occurs at
the centre of pot sides and ends.
At locations with low flow velocity, e.g. sludgy zones or stagnant areas, the changed
metal pad and slowed bath and metal movement can increase the heat transfer, resulting in
an increased heat flux into the lining. The effect can be seen often at the pot corners.
These effects are locally restricted and not covered by the lump model. However, with a 2D+
heat-transfer model running in parallel, these effects can be quantified and incorporated into
the global behaviour in the lump model.
After the heat generation and flow field have stopped, the cooling down of the bath begins.
This results in a drop in bath temperature and superheat, an increased concentration of excess
AlF3 through ledge formation and, depending on total bath acidity, reduced alumina
solubility, as shown in Figure 5a-c.