A Mathematical and Software Tool to Estimate the Cell Voltage Distribution and Energy Consumption in Aluminium Electrolysis Cells

Abstract

This work aims to deliver the objective of developing an appropriate set of mathematical models and a relevant software program to calculate the voltage distribution and energy consumption of a Hall–Héroult reduction cell, together with a deeper understanding of the complex physical and chemical phenomena underlying the alumina electrolysis process. The work involves an analysis of the basic principles governing the alumina reduction process, the presentation of the sets of the applied mathematical equations to predict the main electrolysis bath physicochemical properties related to the cell voltage, the mass balance of the main cell material inputs and outputs, the energy consumption of the electrolysis cell and the estimation of the cell voltage distribution along the various cells consisting of elements. All the mathematical models were included in an easy-touse software to enable the aluminium cell operators and engineers to introduce and retrieve all the necessary cell operational data and study the effect of the key process parameters on the cell energy performance.