Optimization of the cathode block shape of an aluminum electrolysis cell

• A thermoelectric model of cathodes in aluminum electrolysis cells is proposed.
• A design optimization tool has been developed through an economical study.
• Results show a reduced CVD and a 20% increased lifetime of the optimized cathode.

A finite element/optimization model was developed to determine the optimum shape of the cathode block of an AP-30 aluminum electrolysis cell. The optimum shape is the design that makes the electric current density on the surface of the cathode block as uniform as possible so as to simultaneously prolong its lifetime, to minimize its energy consumption and to minimize the cost of material. Results indicate that by making some changes in the design of the collector bar, the cathode voltage drop can be reduced by 93 mV and the lifetime of the cell can be increased by 20%.