Numerical Simulations and Thermal Diagnostic of Ledge Formation in Hall-Heroult Aluminum Electrolysis Cell with a Solidification Front at the Cryolite-Metal Baths Interface for Reduction of Heat Losses

摘要

This study presents a novel 0-D phase change model with ledge solidification implementation that explicitly tracks a two-dimensional interface and temperature profile on the solid. The model has been validated through 1-D and 2-D test cases, demonstrating its accuracy in predicting the phase change front and behavior in complex geometries. The model's efficiency and limitations have been compared to a 2-D model, highlighting the advantages of the new model in relevant industrial applications, particularly in the aluminum electrolysis cell. The new model's ability to be coupled with other models, such as those for multiphase fluid flow and electromagnetics, provides a more comprehensive understanding of the aluminum electrolysis process, enabling the development of advanced control strategies. The model's potential for investigating the effects of different process parameters on ledge formation and energy efficiency makes it a valuable tool for optimizing industrial processes, reducing energy consumption, and mitigating environmental impact. These results provide a solid foundation for future research in numerical modeling of phase change and heat transfer and highlight the potential of advanced computer models to improve industrial processes and reduce energy consumption.