Analysis of Energy Sustainability and Problems of Technological Process of Primary Aluminum Production

This paper is devoted to the problem of magnetohydrodynamic stability (MHDS) in the energy-intensive process of primary aluminum production by electrolysis. Improving MHDS control is important because of the high costs and reduced efficiency caused by the instability of magnetic and current fields. In this work, a methodological analysis of modern theoretical and numerical methods for studying MHDS was carried out, and approaches to optimizing magnetic fields and control algorithms aimed at stabilizing the process and reducing energy costs were considered. This review identified key challenges and proposed promising directions, including the application of computational methods and artificial intelligence to monitor and control electrolysis in real time. In this paper, it was revealed that wave MHD instability at the metal–electrolyte phase boundary is a key physical obstacle to further reducing specific energy costs and increasing energy stability. The novelty of this paper lies in an integrated approach that combines modeling and practical recommendations. The purpose of this study is to systematically summarize scientific data, analyze the key physical factors affecting the energy stability of electrolyzers, and determine promising directions for their solution. The results of this study can be used to improve the energy efficiency and environmental friendliness of aluminum production.