A Modeling Approach for Time-Dependent Geometry Applied to Transient Heat Transfer of Aluminum Electrolysis Cells

The thermal balance of aluminum electrolysis cells (AEC) have to be rigorously controlled in order to improve the efficiency and sustainability of this industrial process. A new modeling strategy is developed to consider the displacements of solid bodies and moving boundaries in finite element models. The transient thermal-electric modeling of the AEC demonstrates the effect of an increase in operating voltage on both the anode cover and the side ledge. With higher heat generation, the anode cover deteriorates and the side ledge thickness decreases. Since the anode cover is characterized by irreversible transformations, the top heat dissipation remains higher even when the operating voltage comes back to its typical value. For the first time, the transient temperature and electric fields throughout the anode life are simulated and validated by industrial measurements. The modeling predictions have been validated from instrumented anodes and manual measurements, all performed on operating AEC.