DEVELOPMENT OF INDUSTRIAL BENCHMARK FINITE ELEMENT ANALYSIS MODEL TO STUDY ENERGY EFFICIENT ELECTRICAL CONNECTIONS FOR PRIMARY ALUMINIUM SMELTERS

摘要

Process improvements of 5 MW per plant (50,000 t CO2e pa forcoal based electricity) are possible through optimisation of thecomplex cast iron to carbon contacts within aluminium smelteranode and cathode assemblies. Finite element analysis isconsidered the tool of choice within industry for assessingpotential improvements; however there are limitations withexisting models regarding handling of contact resistance andcarbon stress state. A study has been undertaken using thermoelectrical-mechanical finite element analysis of the cast iron tocarbon contact for an anode assembly. The contact pressure andelectrical resistance and its dependence on temperature have beenderived from data available in the public domain. This paperpresents development of the benchmark model including results.The benchmark model will be used as the reference point for thedevelopment of more advanced models in ongoing studies toassist primary aluminium smelters achieve these substantialsavings in energy efficiency and reduced greenhouse gasemissions.