Using ANSYS and CFX to Model Aluminum Reduction Cell since 1984 and Beyond
reach 5 cm. As the metal pad is around 20 cm thick, we are talking about a 25% variation, which will have
a significant impact on the heat loss distribution, the local ledge thickness, the local metal current density,
etc. As this is definitively not a weak coupling, the addition of that extra inaction effect on the numerical
scheme of step 4 will further increase the required computer resources one more time.
cell and external busbars model coupled with a 3D slice potroom
ventilation model:
to point out that the potshell temperature is also strongly influenced by the potroom ventilation pattern.
This type of coupling between the potshell heat loss and the potroom ventilation has already been modeled
by Ingo Eick (Reference 20). He combined ANSYS and FIDAP to build his model.
become quite important as potshell length continue to increase (References 22 and 23).
distribution and the heat loss partition. Adding the solid dispersed alumina phase and the physics of
alumina dissolution and sedimentation in the CFD model could become important in order to get a model
100% representative of the reality as everything else has already being considered.
drain cathode and inert anode/drain cathode R&D projects. In those innovative designs, the metal pad is
removed and the anode cathode distance is greatly reduced. In those designs, the alumina dissolution and
the sludge formation become an even more critical aspect of the process (Reference 24).
(Reference 42) but one of the model assumption is that the alumina fed is dissolving instantaneously so
there is undissolved dispersed alumina phase in that model. It is the opinion of the author that such a
simplified model representation cannot produce realistic results. Since model results validation would be
extremely difficult to do, it would take some time before the issue is settled.
years of continuous development, we are just pass half way through it and there are still as many years of
further model developments ahead of us. Not that that much time is required to actually do those
developments but simply because we need that many computer generations before a complete multi-
physics aluminum reduction cell model could become an affordable and efficient design tool for the
industry.
to pick up. For sure the current aluminum reduction cell technology developments (References 22, 23 and
24) could certainly greatly benefit from it. In addition to having to wait for the Moore law to continue to
take effect, the industry will probably need increased environmental pressure to produce aluminum with
less energy and with less greenhouse gas emission before it feels the need to modernize its smelting
capacity (Reference 25). The bottom line being that high tech computer models will become strategic assets
only after the aluminum industry massively shifts from operating old less efficient cell technologies
towards operating more efficient but also much more complex and challenging high amperage cell
technologies.