Simulation of the Fluid Flow-Related Phenomena in the Electrolyte of an Aluminum Electrolysis Cell

A full-scale water model and mathematical simulation were used to study the fluid flow-related phenomena in a water model of an aluminum electrolysis cell. The time-dependent, multiphase fluid flow model was developed to represent the complex transient flow in the electrolysis bath. The accuracy of the mathematical model was validated by the ink dispersion and laser doppler velocimetry measurements in the water model. The shape, motion, release frequency of large-size bubbles, the fluid flow pattern, and the electrolyte–metal interface were predicted by the mathematical simulation. The design and operation of the anode were discussed, including the effect of the anode edge corner shape, the presence of a tilted bottom angle, and the magnitude of applied current density. The results indicated that coupling using a curved corner, with slot and with tilted angle at the anode, is effective for the release of bubbles and for the stability of the electrolyte–metal interface.