Anode characterisation and gas diffusion behaviour in aluminium smelting

Over the past century, significant research on different aspects of the Hall-Héroult process has been conducted to increase energy efficiency. Bubble generation at the anode reaction and its contribution to the overall voltage drop in aluminium production holds significant potential for energy saving, yet the details of the gas transport mechanism for bubble nucleation behaviour are not completely understood. The multi-step electrochemical reaction releases predominantly CO2 gas along with CO gas, which is a reduction product formed by reaction of CO2 with the anode carbon. Complicating the reaction is the multiple paths by which the gas can diffuse (either through the porous anode or the electrolyte bath). There has been no detailed investigation of the correlation between gas diffusion as a function of anode and bath properties. In the present study, the porosity measurement techniques in the anode will be used to understand the relation of gas diffusion and anode properties. A porosimetric study was conducted for two different anode samples using mercury intrusion porosimetry (MIP) and hydrostatic method. The MIP method provides important anode properties information such as density, percent porosity, pore size distribution, permeability, and tortuosity factor which affect gas diffusion and anode performance. The Knudsen number obtained from MIP data shows both Knudsen diffusion and molecular diffusion need to be considered when predicting the effective diffusion.