Finite Element Analysis of a Cylindrical Cathode Collector Bars Design

A new cathode design is investigated using the finite element method, in an attempt to improve the energy efficiency of a cell and reduce the premature wear of the cathode due to a non-uniform current distribution. This new design relies on cylindrical collector bars including copper inserts and eliminates the need of a cast iron interface in order to improve contact between the carbon blocks and the collector bars. The thermo-electro-mechanical model developed includes contact interfaces to simulate the contact between the different materials and is employed to determine the optimal configuration. Various geometry and design parameters are explored and their effect on both voltage drop and current distribution are highlighted. Simulation results indicate that a substantial voltage drop reduction and more uniform current distribution could be achieved.