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<p>To address the challenge of low waste heat utilization in aluminum electrolysis cells, this study proposes a low-temperature waste heat recovery system based on thermoelectric generator (TEG) technology. The system comprises a thermoelectric generator device and an intelligent power management module. Firstly, Bi₂Te₃-based TEG1-199-1.4-0.5 thermoelectric generator modules, exhibiting superior Seebeck coefficients and power densities, were identified as the optimal option through comparative testing using one module. Secondly, to enhance heat exchange efficiency at the cold end, a series of experiments were conducted using 6 TEG modules with different cooling media. Transformer oil was ultimately selected as the cooling medium based on a comprehensive assessment of thermal performance and cost-effectiveness. Finally, an adaptive power management strategy, developed based on existing MPPT and charging techniques with additional multi-mode switching, was implemented, thereby ensuring stable power output and dynamic load matching. All experiments were performed on a laboratory-scale test bench designed according to field measurements of aluminum electrolysis cells, under a temperature gradient of approximately 100&#xa0;°C. A total of 12 TEG modules were installed for the power management experiments, and the intelligent power management circuit achieved a power conversion efficiency of up to 90%. Moreover, it is capable of autonomously adjusting its operating mode in response to fluctuations in heat input and load conditions. This study presents a laboratory-scale prototype directly derived from industrial conditions, demonstrating the feasibility of low-grade waste heat recovery, and may provide insights for future large-scale applications.</p>

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Design of intelligent power generation system for low temperature waste heat in aluminum electrolytic cells

  • 期刊论文

  • 发表日期：

    2025年11月3日

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  • Jiarui Li,
  • Ying Wang,
  • Yanqin Liang,
  • Shiming Gan

摘要

To address the challenge of low waste heat utilization in aluminum electrolysis cells, this study proposes a low-temperature waste heat recovery system based on thermoelectric generator (TEG) technology. The system comprises a thermoelectric generator device and an intelligent power management module. Firstly, Bi₂Te₃-based TEG1-199-1.4-0.5 thermoelectric generator modules, exhibiting superior Seebeck coefficients and power densities, were identified as the optimal option through comparative testing using one module. Secondly, to enhance heat exchange efficiency at the cold end, a series of experiments were conducted using 6 TEG modules with different cooling media. Transformer oil was ultimately selected as the cooling medium based on a comprehensive assessment of thermal performance and cost-effectiveness. Finally, an adaptive power management strategy, developed based on existing MPPT and charging techniques with additional multi-mode switching, was implemented, thereby ensuring stable power output and dynamic load matching. All experiments were performed on a laboratory-scale test bench designed according to field measurements of aluminum electrolysis cells, under a temperature gradient of approximately 100 °C. A total of 12 TEG modules were installed for the power management experiments, and the intelligent power management circuit achieved a power conversion efficiency of up to 90%. Moreover, it is capable of autonomously adjusting its operating mode in response to fluctuations in heat input and load conditions. This study presents a laboratory-scale prototype directly derived from industrial conditions, demonstrating the feasibility of low-grade waste heat recovery, and may provide insights for future large-scale applications.