Numerical Simulations and Experimental Studies for Optimization of Anode Assembly in Aluminum Reduction Cell Using Cast Iron for Anode Fixation Thimble

This study examines the thermal–electrical–mechanical properties of high-phosphorus gray iron (HPGI) in anode assemblies for aluminum electrolysis cells, focusing on energy efficiency and sustainability improvements. Advanced simulations and comprehensive experimental analyses were conducted to evaluate temperature stability, voltage drop, and mechanical stability, optimizing element sizes from 24 to 36 mm. Our findings show significant improvements in energy efficiency, with a temperature stability of ~ 200 °C, voltage drop of ~ 12.8 mV, and stress of ~ 195 MPa being grid independent. Cast-iron thimbles exhibited minimal resistance (below 0.2%), leading to energy savings of up to 5% compared to current practices. Experimental data were obtained through anode current, voltage drop, and cell temperature measurements over the anode life cycle, alongside bench-scale evaluations of electrical resistivity and thermal expansion. By enhancing simulation accuracy using ProCAST and ANSYS tools, we demonstrate substantial contributions to energy conservation and process efficiency, which are essential for developing sustainable, high-performance anode assemblies.