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 CO_2e pa for coal based electricity) are possible through optimisation of the complex cast iron to carbon contacts within aluminium smelter anode and cathode assemblies. Finite element analysis is considered the tool of choice within industry for assessing potential improvements; however there are limitations with existing models regarding handling of contact resistance and carbon stress state. A study has been undertaken using thermoelectrical- mechanical finite element analysis of the cast iron to carbon contact for an anode assembly. The contact pressure and electrical resistance and its dependence on temperature have been derived from data available in the public domain. This paper presents development of the benchmark model including results. The benchmark model will be used as the reference point for the development of more advanced models in ongoing studies to assist primary aluminium smelters achieve these substantial savings in energy efficiency and reduced greenhouse gas emissions.