Numerical simulation, tools to design and optimize smelting technology

For many years, Aluminum Pechiney has been developing its extensive know-how in process modeling for smelting technology. The wide range of models developed has been valuable in designing equipment and facilities for new projects or for retrofitting, as well as in evaluating the performance of various process technologies. Thermo-electrical and magneto-hydro-dynamic analyses of the pot are well known by aluminium producers. The purpose of the paper is to present some other examples of numerical simulation addressing other less known fields. We first summarize the fundamental goals of numerical simulation and the main stages leading to efficient numerical models. Then, with the help of powerful software, we present animated results of numerical simulation. The first example deals with the cathode redding operation and illustrates the strong interaction between cathode bars and cathode blocks. The second example deals with the potroom ventilation and illustrates the aeraulic balance of the various flows which convey heat fluxes around the pots. The last example illustrates the use of numerical simulation to optimize the flue-wall design in an anode baking furnace regarding flow distribution.