Simulation and Application of a New Type of Energy-Saving Steel Claw for Aluminum Electrolysis Cells

Jinfeng Han, Bing Feng, Zejun Chen, Zhili Liang, Yuran Chen () and Xuemin Liang ()
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Jinfeng Han: School of Materials Science and Engineering, Zhengzhou University, Zhengzhou 450001, China
Bing Feng: Zhengzhou Light Metallurgy Technology Co., Zhengzhou 450001, China
Zejun Chen: School of Materials Science and Engineering, Zhengzhou University, Zhengzhou 450001, China
Zhili Liang: Zhengzhou Light Metallurgy Technology Co., Zhengzhou 450001, China
Yuran Chen: School of Materials Science and Engineering, Zhengzhou University, Zhengzhou 450001, China
Xuemin Liang: School of Materials Science and Engineering, Zhengzhou University, Zhengzhou 450001, China

Sustainability, 2024, vol. 16, issue 18, 1-15

Abstract: Aluminum electrolysis is a typical industry with high energy consumption, and the energy saving of aluminum electrolysis cells is conducive to the sustainable development of the ecological environment. The current density distribution on the steel claws of conventional aluminum electrolysis cells is uneven, resulting in a large amount of power loss. Therefore, a new type of current-equalized steel claw (CESC) is designed in this paper. The ANSYS simulation study shows that the CESC can achieve a more uniform current density distribution and reduce the voltage drop by about 36 mV compared with the traditional steel claw (TSC). In addition, the use of CESC optimizes the temperature distribution of the steel claws and reduces the risk of cracking and deformation. The results of the industrial application tests are highly consistent with the simulation results, confirming the accuracy of the simulation results. The economic benefit analysis shows that using CESC saves 114.1 kWh of electricity per ton of aluminum produced. If this technology can be promoted throughout China, it is expected to save up to 4.75 billion kWh of electricity annually. The development of CESC is promising and of great significance for improving the overall technical level of the aluminum electrolysis industry.

Keywords: aluminum electrolysis; steel claw; current equalization; temperature; simulation; energy saving (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2024
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (1)

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