Current distribution in a drained aluminum reduction cell is critical due to its influence on the current efficiency, electrolysis stability, anodes and cathodes integrity. A finite element model was developed to simu...Current distribution in a drained aluminum reduction cell is critical due to its influence on the current efficiency, electrolysis stability, anodes and cathodes integrity. A finite element model was developed to simulate the electric field in a 75 kA drained aluminum reduction cell. The current distribution and influences of the cathode inclination angle and anode-cathode distance (ACD) were studied. The results show that relatively large horizontal current density appears in the aluminum film, and the maximum value reaches 600 kA/m2. As the cathode inclination angle increases from 2° to 15°, the maximum current density of the metal pad increases by 15%, while the maximum current density of the aluminum-wettable coating layer decreases by 27%. The influence of the ACD on the current distribution is not obvious.展开更多
Region partition(RP) is the key technique to the finite element parallel computing(FEPC),and its performance has a decisive influence on the entire process of analysis and computation.The performance evaluation index ...Region partition(RP) is the key technique to the finite element parallel computing(FEPC),and its performance has a decisive influence on the entire process of analysis and computation.The performance evaluation index of RP method for the three-dimensional finite element model(FEM) has been given.By taking the electric field of aluminum reduction cell(ARC) as the research object,the performance of two classical RP methods,which are Al-NASRA and NGUYEN partition(ANP) algorithm and the multi-level partition(MLP) method,has been analyzed and compared.The comparison results indicate a sound performance of ANP algorithm,but to large-scale models,the computing time of ANP algorithm increases notably.This is because the ANP algorithm determines only one node based on the minimum weight and just adds the elements connected to the node into the sub-region during each iteration.To obtain the satisfied speed and the precision,an improved dynamic self-adaptive ANP(DSA-ANP) algorithm has been proposed.With consideration of model scale,complexity and sub-RP stage,the improved algorithm adaptively determines the number of nodes and selects those nodes with small enough weight,and then dynamically adds these connected elements.The proposed algorithm has been applied to the finite element analysis(FEA) of the electric field simulation of ARC.Compared with the traditional ANP algorithm,the computational efficiency of the proposed algorithm has been shortened approximately from 260 s to 13 s.This proves the superiority of the improved algorithm on computing time performance.展开更多
Considering importance of study on physics fields and computer simulation for aluminum reduction cells so as to optimize design on aluminum reduction cells and develop new type of cells, based on analyzing coupled rel...Considering importance of study on physics fields and computer simulation for aluminum reduction cells so as to optimize design on aluminum reduction cells and develop new type of cells, based on analyzing coupled relation of physics fields in aluminum reduction cells, the mathematics and physics models were established and a coupled computation method on distribution of electric current and magnetic field, temperature profile and metal velocity in cells was developed. The computational results in 82 kA prebaked cells agree well with the measured results, and the errors of maxium value calculated for three main physics property fields are less than 10%, which proves that the model and arithmetic are available. So the software developed can be not only applied to optimization design on traditional aluminum reduction cells, but also to establishing better technology basis to develop new drained aluminum reduction cells.展开更多
The method of numerical simulation was applied to investigate gas preheating and start-up process in a drained aluminum reduction cell. The transient temperature and velocity fields of a 156 kA drained aluminum reduct...The method of numerical simulation was applied to investigate gas preheating and start-up process in a drained aluminum reduction cell. The transient temperature and velocity fields of a 156 kA drained aluminum reduction cell were numerically calculated. The results show that the method of gas preheating and bake-out can basically meet the technical requirements of the start-up process for the drained cell. If the same distributing scheme of gas nozzle as that in the general cells is used, there are problems of great temperature gradients and low temperature zone at the top of cathode near the side of nozzles. In order to promote the effect of gas preheating and baking the drained cell, the jetting angle of end nozzle is adjusted and the temperature distribution in the drained cell is obviously improved. By means of simulating the temperature field in the case that jetting angle varies from 0? to 30?, it is concluded that better temperature distribution can be obtained if the jetting angle of end nozzle is approximately 15?.展开更多
The resistance arrangements of the flexes connecting with the cathode bus bar in aluminum reduction cells were generalized as three modes. In each mode the universal method to select proper resistivity of the flexes w...The resistance arrangements of the flexes connecting with the cathode bus bar in aluminum reduction cells were generalized as three modes. In each mode the universal method to select proper resistivity of the flexes was induced respectively to insure that the current in local group of flexes was equal. Furthermore, a 350 kA aluminum reduction cell based electric field model was developed by finite element method to evaluate the effect of the method. Suggestions on selection of three modes were also put forward. The results show that the methods of resistance optimization can reduce the current variation about 180 A compared with that in original case.展开更多
Based on principles of electromagnetic fluid dynamics the exerted forces and movement states of melted aluminum in the traditional reduction cells and the drained cells were compared and analyzed in this paper. And ba...Based on principles of electromagnetic fluid dynamics the exerted forces and movement states of melted aluminum in the traditional reduction cells and the drained cells were compared and analyzed in this paper. And based on the theory of slow movement, a formula in respect of the drained angle was derived, i.e. θ≥(J zB x-J xB z)ρg-(J xB y-J yB x ). It can be seen that the drained slope can be decided by respectively multiplying the area current densities and magnetic induction intensities in three coordinate directions in aluminum reduction cells, and the drained slope is approximate to 0.6% derived from typical data based on measurement and calculation, which implies that the key parameter is obtained in designing of drained cells. The results can be used for a designing basis for drained cathodes.展开更多
Based on the commercial computational fluid dynamics software CFX-4.3, electrolyte flow fields in a 156 kA pre-baked anode aluminum electrolysis cell were investigated in three different cases where the electrolyte me...Based on the commercial computational fluid dynamics software CFX-4.3, electrolyte flow fields in a 156 kA pre-baked anode aluminum electrolysis cell were investigated in three different cases where the electrolyte melt was driven by different kinds of force, i.e. electromagnetic force only, the anode gas drag force only and both of the former two forces. The results show that when electromagnetic force was introduced only, most of the electrolyte moves horizontally; when anode gas drag force was introduced only, the electrolyte flows mainly around each anode with small circulation; when electromagnetic force and anode gas drag force were both introduced together, the structure of the electrolyte flow fields and the velocity of electrolyte are similar to that of the case where only anode gas drag force is used. The electrolyte flow fields are mainly determined by the anode gas drag force.展开更多
Two full 3D steady mathematical models are developed by finite element method （FEM） to calcalate coupled physics fields. the electro-magnetic model is built and solved first and so is the fluid motion model with the...Two full 3D steady mathematical models are developed by finite element method （FEM） to calcalate coupled physics fields. the electro-magnetic model is built and solved first and so is the fluid motion model with the acquired electromagnetic force as source body forces in Navier-Stokes equations. Effects caused by the ferromagnetic shell, busbar system around, and open boundary problem as well as inside induced current were considered in terms of the magnetic field. Furthermore, a new modeling method is found to set up solid models and then mesh them entirely with so-called structuralized grids, namely hex-mesh. Examples of 75kA prebaked cell with two kinds of busbar arrangements are presented. Results agree with those disclosed in the literature and confirm that the coupled simulation is valid. It is also concluded that the usage of these models facilitates the consistent analysis of the electric field to magnetic field and then flow motion to the greater extent, local distributions of current density and magnetic flux density are very much dependent on the cell structure, the steel shell is a shield to reduce the magnetic field and flow pattern is two dimensional in the main body of the metal pad.展开更多
基金Project(2005CB623703) supported by the National Basic Research Program of China
文摘Current distribution in a drained aluminum reduction cell is critical due to its influence on the current efficiency, electrolysis stability, anodes and cathodes integrity. A finite element model was developed to simulate the electric field in a 75 kA drained aluminum reduction cell. The current distribution and influences of the cathode inclination angle and anode-cathode distance (ACD) were studied. The results show that relatively large horizontal current density appears in the aluminum film, and the maximum value reaches 600 kA/m2. As the cathode inclination angle increases from 2° to 15°, the maximum current density of the metal pad increases by 15%, while the maximum current density of the aluminum-wettable coating layer decreases by 27%. The influence of the ACD on the current distribution is not obvious.
基金Project(61273187)supported by the National Natural Science Foundation of ChinaProject(61321003)supported by the Foundation for Innovative Research Groups of the National Natural Science Foundation of China
文摘Region partition(RP) is the key technique to the finite element parallel computing(FEPC),and its performance has a decisive influence on the entire process of analysis and computation.The performance evaluation index of RP method for the three-dimensional finite element model(FEM) has been given.By taking the electric field of aluminum reduction cell(ARC) as the research object,the performance of two classical RP methods,which are Al-NASRA and NGUYEN partition(ANP) algorithm and the multi-level partition(MLP) method,has been analyzed and compared.The comparison results indicate a sound performance of ANP algorithm,but to large-scale models,the computing time of ANP algorithm increases notably.This is because the ANP algorithm determines only one node based on the minimum weight and just adds the elements connected to the node into the sub-region during each iteration.To obtain the satisfied speed and the precision,an improved dynamic self-adaptive ANP(DSA-ANP) algorithm has been proposed.With consideration of model scale,complexity and sub-RP stage,the improved algorithm adaptively determines the number of nodes and selects those nodes with small enough weight,and then dynamically adds these connected elements.The proposed algorithm has been applied to the finite element analysis(FEA) of the electric field simulation of ARC.Compared with the traditional ANP algorithm,the computational efficiency of the proposed algorithm has been shortened approximately from 260 s to 13 s.This proves the superiority of the improved algorithm on computing time performance.
文摘Considering importance of study on physics fields and computer simulation for aluminum reduction cells so as to optimize design on aluminum reduction cells and develop new type of cells, based on analyzing coupled relation of physics fields in aluminum reduction cells, the mathematics and physics models were established and a coupled computation method on distribution of electric current and magnetic field, temperature profile and metal velocity in cells was developed. The computational results in 82 kA prebaked cells agree well with the measured results, and the errors of maxium value calculated for three main physics property fields are less than 10%, which proves that the model and arithmetic are available. So the software developed can be not only applied to optimization design on traditional aluminum reduction cells, but also to establishing better technology basis to develop new drained aluminum reduction cells.
基金Project(G1999064903) supported by the National Basic Research Program of China
文摘The method of numerical simulation was applied to investigate gas preheating and start-up process in a drained aluminum reduction cell. The transient temperature and velocity fields of a 156 kA drained aluminum reduction cell were numerically calculated. The results show that the method of gas preheating and bake-out can basically meet the technical requirements of the start-up process for the drained cell. If the same distributing scheme of gas nozzle as that in the general cells is used, there are problems of great temperature gradients and low temperature zone at the top of cathode near the side of nozzles. In order to promote the effect of gas preheating and baking the drained cell, the jetting angle of end nozzle is adjusted and the temperature distribution in the drained cell is obviously improved. By means of simulating the temperature field in the case that jetting angle varies from 0? to 30?, it is concluded that better temperature distribution can be obtained if the jetting angle of end nozzle is approximately 15?.
基金Project(60634020) supported by the National Natural Science Foundation of China
文摘The resistance arrangements of the flexes connecting with the cathode bus bar in aluminum reduction cells were generalized as three modes. In each mode the universal method to select proper resistivity of the flexes was induced respectively to insure that the current in local group of flexes was equal. Furthermore, a 350 kA aluminum reduction cell based electric field model was developed by finite element method to evaluate the effect of the method. Suggestions on selection of three modes were also put forward. The results show that the methods of resistance optimization can reduce the current variation about 180 A compared with that in original case.
文摘Based on principles of electromagnetic fluid dynamics the exerted forces and movement states of melted aluminum in the traditional reduction cells and the drained cells were compared and analyzed in this paper. And based on the theory of slow movement, a formula in respect of the drained angle was derived, i.e. θ≥(J zB x-J xB z)ρg-(J xB y-J yB x ). It can be seen that the drained slope can be decided by respectively multiplying the area current densities and magnetic induction intensities in three coordinate directions in aluminum reduction cells, and the drained slope is approximate to 0.6% derived from typical data based on measurement and calculation, which implies that the key parameter is obtained in designing of drained cells. The results can be used for a designing basis for drained cathodes.
基金Project (G1999064903) supported by the National Key Fundamental Research and Development Programof China
文摘Based on the commercial computational fluid dynamics software CFX-4.3, electrolyte flow fields in a 156 kA pre-baked anode aluminum electrolysis cell were investigated in three different cases where the electrolyte melt was driven by different kinds of force, i.e. electromagnetic force only, the anode gas drag force only and both of the former two forces. The results show that when electromagnetic force was introduced only, most of the electrolyte moves horizontally; when anode gas drag force was introduced only, the electrolyte flows mainly around each anode with small circulation; when electromagnetic force and anode gas drag force were both introduced together, the structure of the electrolyte flow fields and the velocity of electrolyte are similar to that of the case where only anode gas drag force is used. The electrolyte flow fields are mainly determined by the anode gas drag force.
基金the National High Technical Reasearch and Development Programme of China （No. 2003AA327140） the National Natural Science Foundation of China （No. 50374081）.
文摘Two full 3D steady mathematical models are developed by finite element method （FEM） to calcalate coupled physics fields. the electro-magnetic model is built and solved first and so is the fluid motion model with the acquired electromagnetic force as source body forces in Navier-Stokes equations. Effects caused by the ferromagnetic shell, busbar system around, and open boundary problem as well as inside induced current were considered in terms of the magnetic field. Furthermore, a new modeling method is found to set up solid models and then mesh them entirely with so-called structuralized grids, namely hex-mesh. Examples of 75kA prebaked cell with two kinds of busbar arrangements are presented. Results agree with those disclosed in the literature and confirm that the coupled simulation is valid. It is also concluded that the usage of these models facilitates the consistent analysis of the electric field to magnetic field and then flow motion to the greater extent, local distributions of current density and magnetic flux density are very much dependent on the cell structure, the steel shell is a shield to reduce the magnetic field and flow pattern is two dimensional in the main body of the metal pad.
