This study employs the finite element methodFinite element method (FEM) to examine the impact of copperCopper rods inserted into the cathode collector bars of aluminum reduction cellsAluminum reduction cells on the electromagneticElectro-magnetic-flow field flow fieldFlow field distributionDistribution at the metalMetals-cathode interface. The research focuses on the effects of varying copperCopper rod lengths and cross-sectional areas on the electric field and compares the flow fieldFlow field in cells with and without inserted copper rodsInserted copper rods. The results show that the inserted copper rodsInserted copper rods significantly reduce the horizontal currentHorizontal current at the metalMetals-cathode interface, with slight reductionsReduction correlated to increased rod’s length and marked reductionsReduction with increased rod's cross-sectional area. The insertion of copperCopper rods decreases the maximum current density at the interface from 16,420 to 15,543 A/cm2, thereby mitigating the electrochemical wear rate on the cathode surfaceSurface. Furthermore, the copperCopper rods improve the metalMetals flow fieldFlow field, reducing the maximum metalMetals velocity from 0.331 to 0.291 m/s, which lowers the cathode’s physical wear rate. The computational results were validated against industrial data, confirming the practical applicability of the findings.

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Numerical Simulations of Copper Rod Insertion Effects on Current Density, Flow Field Distribution, Cathode Wear, and Electrothermal Dynamics in Aluminum Reduction Cells

  • Sen Zhou,
  • Mouhamadou A. Diop,
  • Zhaowen Wang,
  • Xianwei Hu

摘要

This study employs the finite element methodFinite element method (FEM) to examine the impact of copperCopper rods inserted into the cathode collector bars of aluminum reduction cellsAluminum reduction cells on the electromagneticElectro-magnetic-flow field flow fieldFlow field distributionDistribution at the metalMetals-cathode interface. The research focuses on the effects of varying copperCopper rod lengths and cross-sectional areas on the electric field and compares the flow fieldFlow field in cells with and without inserted copper rodsInserted copper rods. The results show that the inserted copper rodsInserted copper rods significantly reduce the horizontal currentHorizontal current at the metalMetals-cathode interface, with slight reductionsReduction correlated to increased rod’s length and marked reductionsReduction with increased rod's cross-sectional area. The insertion of copperCopper rods decreases the maximum current density at the interface from 16,420 to 15,543 A/cm2, thereby mitigating the electrochemical wear rate on the cathode surfaceSurface. Furthermore, the copperCopper rods improve the metalMetals flow fieldFlow field, reducing the maximum metalMetals velocity from 0.331 to 0.291 m/s, which lowers the cathode’s physical wear rate. The computational results were validated against industrial data, confirming the practical applicability of the findings.