A Multi-scale Mathematical Model of Growth and Coalescence of Bubbles Beneath the Anode in an Aluminum Reduction Cell

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.