Towards Improved Current Efficiency of Hall–Héroult Cells by Using a Novel Cathode and Process Parameters

A novel cathode with rectangular protrusions has been tested and implemented by Chinese industrial electrolytic aluminum smelters. Measurements of the protrusion wear rate and average cell voltage were conducted. Some experience was acquired with the aim of achieving better current efficiency and longer cathode lifetime. Furthermore, to investigate the influence of the novel cathode after wear down, simulations were carried out to determine the variation of the metal flow for different metal levels and rectangular protrusion heights.