Reduction of environmental emissions and energy consumption of the primary aluminium production with improvements to the chemical, electrical and thermal synergy.

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Aluminum is produced from alumina dissolved in molten cryolite, by electrolysis at a temperature of about 940-970°C. As in any chemical reactor, in the aluminum electrolysis cell the optimal operational conditions require the homogeneous distribution of the intensive parameters like temperature, alumina concentration, current density, etc. Introducing, dissolving, and dispersing of the alumina powder uniformly in this shallow molten electrolyte layer represents a very important and difficult challenge. The alumina concentration gradients in the cell are strongly correlated with the cell chemical, thermal and electrical heterogeneities.The collaborative work described builds upon a previous partnership with Rio Tinto Aluminium that looked precisely at the alumina dissolution kinetics. The scope of the research program was extended in order to improve the understanding of the root causes of the chemical, thermal and electrical heterogeneities in an electrolysis cell. The work will directly lead to potential improvements and solutions to increase the homogeneity in an electrolysis cell. By doing so, the electrolysis cell will consume a lower amount of electrical energy as well as significantly reducing the frequency of process perturbations generating important amounts of greenhouse gases (GHG), specifically the perfluorocarbon gases (PFC). The different projects within the scope of this research will be based on mathematical modeling, simulations, experimental low-temperature analog systems, experimental high-temperature molten salt setups, data analytics of industrial data and in situ industrial measurements.The primary aluminum industry represents a very important sector in the Canadian economy. The Canadian smelters excel worldwide in their energy efficiency and low environmental impact. RTA, the third biggest producer of primary metal is also a technology leader. The expected results will help the Canadian aluminum industry to keep its leading position in the increasingly stronger international competition.