IDEAS home Printed from https://ideas.repec.org/a/gam/jsusta/v16y2024i18p8061-d1478597.html
   My bibliography  Save this article

Simulation and Application of a New Type of Energy-Saving Steel Claw for Aluminum Electrolysis Cells

Author

Listed:
  • Jinfeng Han

    (School of Materials Science and Engineering, Zhengzhou University, Zhengzhou 450001, China)

  • Bing Feng

    (Zhengzhou Light Metallurgy Technology Co., Zhengzhou 450001, China)

  • Zejun Chen

    (School of Materials Science and Engineering, Zhengzhou University, Zhengzhou 450001, China)

  • Zhili Liang

    (Zhengzhou Light Metallurgy Technology Co., Zhengzhou 450001, China)

  • Yuran Chen

    (School of Materials Science and Engineering, Zhengzhou University, Zhengzhou 450001, China)

  • Xuemin Liang

    (School of Materials Science and Engineering, Zhengzhou University, Zhengzhou 450001, China)

Abstract

Aluminum electrolysis is a typical industry with high energy consumption, and the energy saving of aluminum electrolysis cells is conducive to the sustainable development of the ecological environment. The current density distribution on the steel claws of conventional aluminum electrolysis cells is uneven, resulting in a large amount of power loss. Therefore, a new type of current-equalized steel claw (CESC) is designed in this paper. The ANSYS simulation study shows that the CESC can achieve a more uniform current density distribution and reduce the voltage drop by about 36 mV compared with the traditional steel claw (TSC). In addition, the use of CESC optimizes the temperature distribution of the steel claws and reduces the risk of cracking and deformation. The results of the industrial application tests are highly consistent with the simulation results, confirming the accuracy of the simulation results. The economic benefit analysis shows that using CESC saves 114.1 kWh of electricity per ton of aluminum produced. If this technology can be promoted throughout China, it is expected to save up to 4.75 billion kWh of electricity annually. The development of CESC is promising and of great significance for improving the overall technical level of the aluminum electrolysis industry.

Suggested Citation

  • Jinfeng Han & Bing Feng & Zejun Chen & Zhili Liang & Yuran Chen & Xuemin Liang, 2024. "Simulation and Application of a New Type of Energy-Saving Steel Claw for Aluminum Electrolysis Cells," Sustainability, MDPI, vol. 16(18), pages 1-15, September.
    • Handle: RePEc:gam:jsusta:v:16:y:2024:i:18:p:8061-:d:1478597
    as

    Download full text from publisher

    File URL: https://www.mdpi.com/2071-1050/16/18/8061/pdf
    Download Restriction: no
    File URL: https://www.mdpi.com/2071-1050/16/18/8061/
    Download Restriction: no
    ---><---

    References listed on IDEAS

    as
    1. Haraldsson, Joakim & Johansson, Maria T., 2018. "Review of measures for improved energy efficiency in production-related processes in the aluminium industry – From electrolysis to recycling," Renewable and Sustainable Energy Reviews, Elsevier, vol. 93(C), pages 525-548.
    2. Ning Ding & Ning Liu & Bin Lu & Jianxin Yang, 2021. "Life cycle greenhouse gas emissions of aluminum based on regional industrial transfer in China," Journal of Industrial Ecology, Yale University, vol. 25(6), pages 1657-1672, December.
    3. Tian, Shuoshuo & Di, Yuezhong & Dai, Min & Chen, Weiqiang & Zhang, Qi, 2022. "Comprehensive assessment of energy conservation and CO2 emission reduction in future aluminum supply chain," Applied Energy, Elsevier, vol. 305(C).
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Shen, Angxing & Zhang, Jihong, 2024. "Technologies for CO2 emission reduction and low-carbon development in primary aluminum industry in China: A review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 189(PA).
    2. Liu, Weipeng & Zhao, Chunhui & Peng, Tao & Zhang, Zhongwei & Wan, Anping, 2023. "Simulation-assisted multi-process integrated optimization for greentelligent aluminum casting," Applied Energy, Elsevier, vol. 336(C).
    3. Hu, Xueyue & Wang, Chunying & Elshkaki, Ayman, 2024. "Material-energy Nexus: A systematic literature review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 192(C).
    4. Zheng Huang & Laisuo Su & Yunjie Yang & Linsong Gao & Xinyu Liu & Heng Huang & Yubai Li & Yongchen Song, 2023. "Three-Dimensional Simulation on the Effects of Different Parameters and Pt Loading on the Long-Term Performance of Proton Exchange Membrane Fuel Cells," Sustainability, MDPI, vol. 15(4), pages 1-22, February.
    5. Joakim Haraldsson & Simon Johnsson & Patrik Thollander & Magnus Wallén, 2021. "Taxonomy, Saving Potentials and Key Performance Indicators for Energy End-Use and Greenhouse Gas Emissions in the Aluminium Industry and Aluminium Casting Foundries," Energies, MDPI, vol. 14(12), pages 1-26, June.
    6. Shao, Tianming & Pan, Xunzhang & Li, Xiang & Zhou, Sheng & Zhang, Shu & Chen, Wenying, 2022. "China's industrial decarbonization in the context of carbon neutrality: A sub-sectoral analysis based on integrated modelling," Renewable and Sustainable Energy Reviews, Elsevier, vol. 170(C).
    7. Joakim Haraldsson & Maria T. Johansson, 2019. "Barriers to and Drivers for Improved Energy Efficiency in the Swedish Aluminium Industry and Aluminium Casting Foundries," Sustainability, MDPI, vol. 11(7), pages 1-27, April.
    8. Sgouridis, Sgouris & Ali, Mohamed & Sleptchenko, Andrei & Bouabid, Ali & Ospina, Gustavo, 2021. "Aluminum smelters in the energy transition: Optimal configuration and operation for renewable energy integration in high insolation regions," Renewable Energy, Elsevier, vol. 180(C), pages 937-953.
    9. Senka Gudić & Ladislav Vrsalović & Jure Krolo & Aleš Nagode & Ivana Dumanić Labetić & Branimir Lela, 2024. "Corrosion Behaviour of Recycled Aluminium AlSi9Cu3(Fe) Machining Chips by Hot Extrusion and Thixoforming," Sustainability, MDPI, vol. 16(4), pages 1-19, February.
    10. Golmohamadi, Hessam, 2022. "Demand-side management in industrial sector: A review of heavy industries," Renewable and Sustainable Energy Reviews, Elsevier, vol. 156(C).
    11. Mikhail A. Averbukh & Nikolay A. Zhukov & Stanislav V. Khvorostenko & Vasiliy I. Panteleev, 2019. "Reducing Electric Power Losses in the System of Power Supply Due to Compensation of Higher Harmonics of Currents: Economic and Energy Efficiency Outcomes," International Journal of Energy Economics and Policy, Econjournals, vol. 9(4), pages 396-403.
    12. Ren, Yi-Shuai & Liu, Pei-Zhi & Klein, Tony & Sheenan, Lisa, 2024. "Does the low-carbon pilot cities policy make a difference to the carbon intensity reduction?," Journal of Economic Behavior & Organization, Elsevier, vol. 217(C), pages 227-239.
    13. Yunfeng Huang & Shenghui Cui & Bing Gao & Wei Huang & Shuangying Han & Yuanchao Hu, 2023. "Driving reactive nitrogen emissions in China: Competition between scale and efficiency," Journal of Industrial Ecology, Yale University, vol. 27(3), pages 951-963, June.
    14. Li, Shupeng & Wang, Zhe & Yue, Qiang & Zhang, Tingan, 2022. "Analysis of the quantity and spatial characterization of aluminum in-use stocks in China," Resources Policy, Elsevier, vol. 79(C).
    15. Shuang Li & Liao He & Bo Zhang & Yan Yan & Wentao Jiao & Ning Ding, 2022. "A Comprehensive Evaluation Method for Soil Remediation Technology Selection: Case Study of Ex Situ Thermal Desorption," IJERPH, MDPI, vol. 19(6), pages 1-16, March.
    16. Liu, Weipeng & Peng, Tao & Kishita, Yusuke & Umeda, Yasushi & Tang, Renzhong & Tang, Wangchujun & Hu, Luoke, 2021. "Critical life cycle inventory for aluminum die casting: A lightweight-vehicle manufacturing enabling technology," Applied Energy, Elsevier, vol. 304(C).
    17. Shaktipada Bhuniya & Biswajit Sarkar & Sarla Pareek, 2019. "Multi-Product Production System with the Reduced Failure Rate and the Optimum Energy Consumption under Variable Demand," Mathematics, MDPI, vol. 7(5), pages 1-20, May.
    18. Xue, Mingfu & Razzaq, Asif & Afshan, Sahar & Yang, Xiaodong, 2023. "Fiscal pressure and carbon intensity: A quasi-natural experiment based on education authority reform," Energy Economics, Elsevier, vol. 126(C).
    19. Joakim Haraldsson & Maria T. Johansson, 2019. "Energy Efficiency in the Supply Chains of the Aluminium Industry: The Cases of Five Products Made in Sweden," Energies, MDPI, vol. 12(2), pages 1-25, January.
    20. Bandeiras, F. & Gomes, M. & Coelho, P. & Fernandes, J., 2020. "Towards net zero energy in industrial and commercial buildings in Portugal," Renewable and Sustainable Energy Reviews, Elsevier, vol. 119(C).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:gam:jsusta:v:16:y:2024:i:18:p:8061-:d:1478597. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: MDPI Indexing Manager (email available below). General contact details of provider: https://www.mdpi.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.