Design and Optimization Method of Controlled Heat Exchange Structure for Aluminum Electrolysis Cell Under Current Fluctuations

Under the carbon peaking and carbon neutrality goals, the aluminum electrolysis industry faces significant challenges in energy conservation, carbon reduction, and environmental protection. Utilizing new energy electricity is one of the most effective ways to reduce carbon emissions in primary aluminum production. This paper addresses the issue of uncontrolled thermal balance in electrolysis cells caused by large fluctuations in current during the absorption of new energy electricity. A multi-field solidification model of the electric-thermal-flow facing the side-controlled heat dissipation structure is constructed. The study investigates the impact of large current fluctuations, heat exchanger structure and different process parameters on the temperature field and the ledge shape of the electrolysis cell. The optimum process and corresponding heat dissipation structure of electrolysis cell under current fluctuations are summarized to provide theoretical guidance for aluminum electrolysis cells in absorbing fluctuating new energy electricity. The results indicate that the aluminum electrolysis cell with controlled heat exchange with standard rectangular carbon blocks, high-insulation irregular carbon blocks (inner lining type 2), and heat-conducting protrusions with a thermal conductivity of <tex xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">$120 \mathrm{W}\cdot \mathrm{m}^{-1}\cdot \mathrm{K}^{-1}$</tex> can effectively absorb current fluctuations ranging from −20% to +20% within a short period under collaborative control of side thermal regulation and processes. However, when maintaining a +20% current for prolonged periods, the cell may still experience uncontrolled thermal balance.