Energy Saving in Hall–Héroult Cell by Optimization of Anode Assembly Design

Over the past few decades, intensive research was carried out on developing anode assembly designs to reduce energy consumption in aluminum reduction cell. The present research work was carried out in the aluminum company of Egypt (Egyptalum) smelter. A new anode assembly design was developed by inserting multiple steel nails into stubhole. The total anode voltage drop of the current anode design and that of the proposed design have been studied using thermo-electrical analysis via ANSYS simulation software. The developed model was validated by comparing predictions with the measurements from in situ experiments. A significant improvement of the electrical contact resistance (ECR) between cast iron thimble and carbon was achieved by this new design. The mean voltage drop reduction reached 30 mV, which can achieve estimated annual cost saving of $1,228,800 USD/year for a smelter producing 320k tons of aluminum.