A number of models for estimating the current efficiency of Hall-Heroult cells have appeared in the literature. Although these models can predict some current efficiency trends, their formulation is still too simplistic compared with the complex re-oxidation phenomena during aluminium electrolysis. A new current efficiency model for prebake cells is proposed; it is based on multiple zones, multiple mechanisms and combines the effects of gas induced flow, magnetohydrodynamic flow, surface tension flow and thermal flow. The model was evaluated by comparison with literature data from 13 different prebake cells with point feeding technology. The comparison led to suitable choices of metal solubility and metal diffusivity in the molten bath.
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