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Modeling of bubble shapes is challenging because of the wide range of length scales in aluminum reduction cells. A 3D multi-scale mathematical model was developed to understand the nucleation, growth and coalescence of bubbles beneath the anode and to investigate the transition of bubbles from the micro- to macro level. The motion of micro-bubbles is examined using the discrete bubble model (DBM) within a Lagrangian reference. An algorithm for the transition from discrete micro-bubbles to large bubbles, which are fully resolved by the volume of fluid (VOF) approach, is achieved using a user-defined function. The two-way coupling between discrete bubbles and continuous fluids is achieved by inter-phase momentum exchange. The model involves three kinds of bubble coalescence: micro-bubble coalescence is taken into account by the DBM; large bubbles swallowing up micro-bubbles are solved by the discrete-continuum transition model; the coalescence between large bubbles is handled by the VOF method. Numerical results show that the coverage and thickness of bubbles agree well with the experimental data in the literature. Bubble thickness stops increasing when the bubble elongates with the anode bottom, which is 4.0 to 4.5 mm. Meanwhile, two asymmetrical thick heads can be observed under the anode. Bubble release frequency increases with increasing current density. [ABSTRACT FROM AUTHOR]

In the aluminum reduction cells, gas bubbles are generated at the bottom of the anode which eventually reduces the effective current contact area and the system efficiency. To encourage the removal of gas bubbles, slotted anode has been proposed and increasingly adopted by some industrial aluminum reduction cells. Nonetheless, the exact gas bubble removal mechanisms are yet to be fully understood. A three-dimensional (3D) transient, multiphase flow mathematical model coupled with magnetohydrodynamics has been developed to investigate the effect of slotted anode on the gas bubble movement. The Eulerian volume of fluid approach is applied to track the electrolyte (bath)-molten aluminum (metal) interface. Meanwhile, the Lagrangian discrete particle model is employed to handle the dynamics of gas bubbles with considerations of the buoyancy force, drag force, virtual mass force, and pressure gradient force. The gas bubble coalescence process is also taken into account based on the O'Rourke's algorithm. The two-way coupling between discrete bubbles and fluids is achieved by the inter-phase momentum exchange. Numerical predictions are validated against the anode current variation in an industrial test. Comparing the results using slotted anode with the traditional one, the time-averaged gas bubble removal rate increases from 36 to 63 pct; confirming that the slotted anode provides more escaping ways and shortens the trajectories for gas bubbles. Furthermore, the slotted anode also reduces gas bubble's residence time and the probability of coalescence. Moreover, the bubble layer thickness in aluminum cell with slotted anode is reduced about 3.5 mm (17.4 pct), so the resistance can be cut down for the sake of energy saving and the metal surface fluctuation amplitude is significantly reduced for the stable operation due to the slighter perturbation with smaller bubbles. [ABSTRACT FROM AUTHOR]