The Impact of Cathode Material and Shape on Current Density in an Aluminum Electrolysis Cell

A finite element model was developed to determine the impact of cathode material and shape on current density in an aluminum electrolysis cell. For the cathode material, results show that increased electrical resistivity leads to a higher cathode voltage drop; however, the horizontal current is reduced in the metal. The horizontal current magnitude for six different cathode materials in decreasing order is graphitized, semi-graphitized, full graphitic, 50% anthracite (50% artificial graphite), 70% anthracite (30% artificial graphite), 100% anthracite. The modified cathode shapes with an inclined cathode surface, higher collector bar and cylindrical protrusions are intended to improve horizontal current and flow resistance. Compared to a traditional cathode, modified collector bar sizes of 70 mm × 230 mm and 80 mm × 270 mm can reduce horizontal current density component Jx by 10% and 19%, respectively, due to better conductivity of the steel. The horizontal current in the metal decreases with increase of cathode inclination. The peak value of Jx can be approximately reduced by 20% for a 2° change in inclination. Cylindrical protrusions lead to local horizontal current increase on their tops, but the average current is less affected and the molten metal is effectively slowed down.