Copper Insert Collector Bar for Energy Reduction in 360 KA Smelter

Copper insert collector bar (CuCB) reduces the cathode voltage drop (CVD) along with reduction in horizontal currents in the cell. Intuitively CuCB becomes a preferred choice for cell voltage reduction, but reduced heat generation leads to shifting of liquidus isotherms towards cell centre which may affect the cell operation and will intensify the severity during power outage. Therefore, 3D models were used to analyse the thermal profile, voltage, current distribution, magnetic field and fluid flow for existing and CuCB cell. The CuCB was designed to have reasonable reduction in CVD and improved current distribution for reducing the inter-electrode gap. The cell lining was modified to avoid isotherm shifts at reduced heat generation and to have lesser cooling rate during power outages. Based on the new design, one pilot cell was started at Hindalco Mahan, which is offering good performance and substantial reduction in specific energy consumption.