Christian Droste

• Hydro Aluminium

A computational fluid dynamics based multiphase magnetohydrodynamic (MHD) flow model for simulating the melt flow and bath–metal interface deformation in realistic aluminum reduction cells is presented. The model accounts for the complex physics of the MHD problem in aluminum reduction cells by coupling two immiscible fluids, electromagnetic field,...

A CFD based numerical model for a realistic generic aluminium reduction cell is published. The model takes into account the complex physics of the magnetohydrodynamic problem in the reduction cell by coupling of two immiscible liquid flows, Lorenz force, flow turbulence and large length-scale with complex cell geometry. The current model extends th...

A CFD based numerical model for a realistic generic aluminium reduction cell is published. The model takes into account the complex physics of the magnetohydrodynamic problem in the reduction cell by coupling of two immiscible liquid flows, Lorenz force, flow turbulence and large length-scale with complex cell geometry. The current model extends th...

Modernization of the 210,000 tpy VAW Rheinwerk smelter includes installation of point feeder, alumina conveying system, state-of-the-art pot control system and foresees an increase in amperage of up to 175 kA. For the modernized pots concepts for the potlining as well as for improvements of the busbar system were developed based solely on computer...

The growth rate, period of oscillation, and spatial shape of interface waves in Hall-Héroult cells are determined from a linear stability analysis in the three-dimensional domain of liquid bath and metal. The linearized Maxwell and momentum equations together with the demand for hydrostatic balance at the interface describe a self-exciting oscillat...

Numerical simulation of coupled bath/metal magnetohydrodynamics (MHD) and MHD stability analysis allow the optimization of anode set pattern with respect to minimal cell disturbance. The contribution of anode gas-induced forces and the impact on the flow field are discussed. During a complete anode set cycle, the anode current distribution changes...

Stationary metal flow and metal heaving impact both heat balance and cell stability and affects pot tending as well. For improving cell performance and productivity, a good knowledge of these quantities is indispensable. However, limited access restricts the precise determination of the metal flow and heaving by measurements, and sought information...

Stationary metal flow and metal heaving impact both heat balance and cell stability and affects pot tending as well. For improving cell performance and productivity, a good knowledge of these quantities is indispensable. However, limited access restricts the precise determination of the metal flow and heaving by measurements, and sought information...

Introduction MHD Stability Analysis of Anode Set Pattern Optimization of Anode Set Pattern Effect of Gas Bubbles Conclusion

Modernization of the 210,000 tpy VAW Rheinwerk smelter includes installation of point feeder, alumina conveying system, state-of-the-art pot control system and foresees an increase in amperage of up to 175 kA. For the modernized pots concepts for the potlining as well as for improvements of the busbar system were developed based solely on computer...

Aluminum production depends on a multitude of different operations requiring discrete transport of materials factors more than the volume of metal produced. The efficient integration of additional transport and process demand due to capacity creep or brownfield expansion into the existing infrastructure is intricate. Hydro Aluminium has a long hist...

HAL 4e is Hydro's new generation cell technology, developed over the past four years, with six cells in operation at the Årdal Reference Centre since May 2008. The first months of operation at 420 kA show stable cell behaviour and promising operational results such as low energy consumption (<13.0 kWh/kg) and low anode effect frequency (>0.03 per c...

We report results of the linear stability analysis undertaken to investigate the effect of the mean flow of liquid metal on the stability of aluminum reduction cells. A simplified model of the cell is considered that consists of thin layers of aluminum and cryolite superimposed in an infinite horizontal channel with electrically non-conducting wall...

A comparison of magnetohydrodynamic (MHD) instabilities, also known as metal pad roll, calculated by means of a newly developed, depth-averaged 2D model and a general 3D modelling tool, demonstrates the range of validity of the shallow water approach. Good agreement was found for instabilities driven by vertical magnetic fields. The contribution of...

Details of the development process for a high-performance reduction cell operating at 300 kA are presented. The conceptual design of this pot was started from scratch and was based solely on computer simulations. The project was completed within fifteen months. This short development time was possible due to a highly productive simulation environme...

The growth rate, period of oscillation, and spatial shape of interface waves in Hall-Heroult cells are determined from a linear stability analysis in the three-dimensional domain of liquid bath and metal. The linearized Maxwell and momentum equations together with the demand for hydrostatic balance at the interface describe a self-exciting oscillat...

Three dimensional flow field pattern and current density distribution in a Hall-Heroult cell is calculated with an extended version of the software package ESTER/PHOENICS. Boundary conditions for the electrical potential are derived from an electrical network simulation of the bus bar system. The magnetic effect of the steel parts is evaluated by t...