Light Metals 2009 Edited by: Geoff Bearne

TMS (The Minerals, Metals & Materials Society), 2009

HAL 4e Hydros New Generation Cell Technology

Asgeir Bardal1, Bjrn Erik Aga1, Albert Berveling1, Christian Droste2, Markus Fechner2, Elin Haugland1
Morten Karlsen1, Morten Liane1, Sven Olof Ryman1, Tor Helge Vee1, Elmar Wedershoven2, Frank vstetun3
1
Hydro, Aluminium Metal, Verksvn 1, N-6884 rdal, Norway
2
Hydro, Aluminium Metal, Koblenzer Str 122, D-41468 Neuss, Germany
3
Present address: Norsun, Tangenvn 1, N-6885 rdalstangen, Norway
Keywords: Cell development, High amperage, Numerical modeling, Cell design, MHD

Abstract
HAL 4e is Hydros new generation cell technology, developed
over the past four years, with six cells in operation at the rdal
Reference Centre since May 2008. The first months of operation
at 420 kA show stable cell behaviour and promising operational
results such as low energy consumption (<13.0 kWh/kg) and low
anode effect frequency (<0.03 per cell day). The design is a
double-potroom concept with lean design solutions that will yield
low specific investment and operating cost.

Introduction

The technology organization in Hydro has focused over the past

decades on ambitious amperage increase programs and leading
environmental performance, and on development and verification
of in-house cell technologies. The Slovalco project (1995) was
based on the HAL230 technology, and later expanded (2003) [1],
Sunndal 4 (2002) was based on the HAL250/275 technology [2],
and Qatalum will be based on HAL275 (start-up 2009). A further
development of this cell technology family, the HAL300 is
currently operating well above 300 kA at the rdal Reference
Centre.

The CO2 project targets further reduction of GHG and

solutions to further lower fluoride emissions are being
developed.
Reduced energy consumption has already been demonstrated
through improvements in anode, cathode and busbar designs.
Magnetohydrodynamic and heat balance modeling is key to
realize a technology that can operate at low interpolar
distance and still has the desired heat-loss behaviour. Energy
recovery concepts in the pipeline are expected in the future to
contribute significantly to further reduction of specific
energy consumption, as are advances to improve process
stability.
Technology as an entry-ticket to partnership is a major
strategic reason for undertaken such ambitious technology
development programs. Cutting-edge cell technology
accompanied by operational competence and documented
project execution capabilities are important assets when
entering into joint ventures. An ambitious technology
development strategy enhances the need for undertaking
development programs together with selected suppliers, and
at the same time also makes you more attractive as a partner
in such cooperation.

From 2004, a dedicated effort has been undertaken to design,

construct, and operate a higher-amperage cell, resulting in the
start-up of six HAL4e cells during May 2008 at the rdal
Reference Centre. The cells, shown in Figure 1, are currently
operating at an amperage level of 420 kA. Continuous
improvement of technology elements over time, learnings and
solutions from HAL230 through HAL300 and early prototypes
dating back to the nineties constitute an important background for
the HAL4e.
The designation of the HAL4e technology hints at four important
aspects of the technology symbolized by the letter e:

HAL4e is our platform for emerging technology elements

that are still in the development pipeline. The technology has
been developed for easy adaptation of such elements as soon
as they have gained sufficient maturity. Examples of such
development include solutions for increasing the CO2 content
of the process off-gas to prepare for future CO2-capture [3],
several approaches to energy recovery [4, 5], and non-linear
model predictive control [6, 7].

The technology targets leading environmental performance.

In the version of the technology currently operating at the
rdal Reference Centre, design solutions and operational
practice have already been implemented that yield reduced
anode effect frequency and reduced anode effect duration.

Figure 1 HAL4e cells at rdal reference centre

Economic Assessments
An obvious reason for developing a new cell technology is the
aim for cost reduction. During the concept selection phase of the
HAL4e project, analysis of typical CAPEX breakdowns of
smelter projects was made, studying dependencies of smelter
capacity, amperage, and other technology-specific factors on
CAPEX. Technology elements with a good saving potential were
identified, and there was a strong cost-optimisation focus in
design of these elements. Increased amperage does of course
contribute to savings, but as important as amperage are lean
design solutions. Most notably, the HAL4e (like HAL300) is a

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double potroom concept where two rows of pots can be placed in

one potroom with a distance between the rows of only slightly
above 30 m. At amperages above 400 kA, this can only be
achieved by means of state-of-the-art magnetohydrodynamic
(MHD) modeling tools and competence and very careful busbar
system optimisation. Significant savings are associated with the
double potroom concept, both in terms of site preparation (less
area required) and civil engineering cost. The concept furthermore
yields flexible operation with easy interchange of auxiliary
potroom equipment such as pot tending machines and manning
between pot rows. Weight savings and constructability, as
discussed in more detail below, are other factors contributing to
lowering the specific CAPEX of the technology.

Although also stationary flow in the metal & bath and metal pad
heaving was checked, it was not used as a major design criterion.
This was the MHD stability resulting from the busbar design.
Hydro has made strong efforts during the latest years to constantly
improve the meaning of the MHD stability evaluation by
expanding geometry modeling by including ledge contour and
anode centre and cross channels and including more physical
effects [9]. Type 1 and type 2 instability mechanisms as described
in [10] and in addition other relevant effects like induced currents
and gas bubble resistance below the anodes are contained. A
typical 3-D geometry set-up is shown in Figure 2. The underlying
algorithm of the model is based on a linear stability analysis
resulting in a huge eigenvalue problem. From the resulting
eigenvectors and eigenvalues the relevant quantities are derived.
Computing time for such a complex problem is high. On the other
hand, for optimization of a busbar system a vast amount of
variants has to be tested. Therefore, a geometric simpler but
significantly faster MHD stability program [10] based on box
geometry was used up to a certain degree of development. Only
selected alternatives are finally checked with the full approach.

An analysis of technology-specific factors impact on operating

cost was also undertaken in the concept phase. Amperage
contributes modestly (more effective tapping, measurements), and
modest savings come from increased anode size (more effective
anode change). The most important technology dependent effects,
however, are related to decreased specific energy consumption,
decreased anode consumption, and increased cathode lifetime.
HAL4e development has targeted significant improvements along
these three dimensions. Novel smelter solutions are furthermore
being developed that are expected to contribute to lower cost.

Starting from predefined anode and cathode configuration, the

busbar system was developed basically from scratch. First for the
above mentioned pot line arrangement in a double potroom
building and in a seconded step the solution was adapted for the
magnetic environment of the reference center. The tricky part was
here to minimize the difference of the magnetic fields between
line arrangement and test center to guarantee the same MHD
performance. This was achieved to a high degree by an intricate
routing of external busbars with a variety of current loads.

Mathematical Modeling and Cell Design

The concept for the HAL4e busbar system, lining, pot shell and
superstructure was derived from mathematical modeling. Various
in-house developed simulation tools for busbars and lining are
integrated in a software package driven by a common graphical
user interface. Input/output data of the different routines are stored
in an Oracle database to ensure redundant free exchange of data
between the different software modules. ANSYS was used for
thermomechanical modeling of pot shell and superstructure
behaviour.
Magnetohydrodynamics (MHD)
Concept evaluation of a busbar system design is done in three
consecutive steps where each step depends on the results of the
previous ones:

Computation of the electrical potential, current and

temperature distribution of the busbars of a single cell.
External voltage drop, busbar weight and economical current
density [8] are the important figures for rating the design.

Magnetic field calculation based on the calculated current

distribution of the first step, but for a full line arrangement
where all current carrying parts of the site inside and out the
cells are contained with varying degree of details (distance
dependent). The important magnetic field contribution due to
magnetized ferromagnetic parts has to be taken into account
by including the pot shell at the investigated cell position and
the direct neighboring shells.

MHD stability analysis is based on the calculated magnetic

fields and the cathode current distribution as derived in the
first step. A consistent solution of a potential equation takes
care for the horizontal currents in the cell. Important result
for quantifying the MHD performance is the instability rate.
This name, a synonym for the previously called growth rates
[9], seems to be more adequate.

Figure 2 Geometry of stability model

Even for the double-potroom concept, with a pot row distance of

only slightly above 30 m, a busbar system could be designed that
exhibits only an approximately linear weight increase with
amperage compared to the HAL300. Normally one would expect
a stronger than linear weight increase with amperage. The
instability rates for the HAL4e design in comparison to the
HAL300 are shown as function of ACD in Figure 3. Over the full
anodecathode distance (ACD) range the MHD stability of
HAL4e surpasses that of HAL300. This was one of the goals for
the design. The high stability at the actual amperage opens
potential for significant amperage increase in the future. Already
after a few months of operation the predicted high MHD stability
was confirmed by a very low cell noise, cf. Figure 4. The noise
value is defined as the standard deviation of cell resistance based
on a sample of measurements taken at 0.5-second intervals over a

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period of 4 minutes. The curves shown in Figure 4 are

representative of daily average noise values for HAL4e and
HAL300. The lower value of HAL4e is partly due to the lower
basic resistance value of the larger cell, and partly to improved
MHD behaviour.

Figure 5 Typical temperature variation logged by thermocouple

in insulation brick layer during operation (displayed
period one week).

Anode

Metal

Figure 3 Instability rates versus ACD

Ledge
Lining

Figure 6 Typical ledge profile measured after 4 months of

operation

Mechanical design
As mentioned, weight savings have been sought in the design
work for the various cell elements, contributing to a low specific
CAPEX. In addition, the accumulated experience from previous
projects was used to also choose design solutions that are easy and
cheap from a constructability point of view. A HAL4e pot shell
was designed that weighs approximately the same as the shell
used for HAL300, and with improved shell ventilation.
Deformation behaviour in the early operational phase is according
to model simulations.

Figure 4 Typical noise variation for HAL4e (top) and HAL300

(bottom) over a period of three days. AC denotes anode
change.

Lining design
The pot lining of HAL4e was designed using a dedicated
thermoelectric model, and targeting low cell voltage, a ledge
profile of the right shape and thickness, and isotherm locations
that dont compromise the linings long-term thermal properties.
Our lining design strategy emphasizes to extensively check, verify
and tune model output based on measurement data. This includes
laboratory experiments investigating thermal properties and aging
characteristics of lining bricks, heat balance measurements on
operating cells determining heat fluxes through the various heat
sinks, on-line monitoring of temperatures, and autopsies.

The height of the HAL4e superstructure above the potroom floor

is essentially the same as for HAL300. Hence no increase in the
height of the potroom is required. Still, by thorough optimization
during design, and focus on effective use of the material in the
load-bearing structures (steel structure plus anode beam), we have
managed to keep the weight of the superstructure low, and almost
only increasing linearly with amperage compared to HAL300.
This was a challenging task, since for a simple linear structure of
constant height; a much stronger weight increase with length
would be required to maintain the bending stiffness. Mechanical
modeling has taken into account the relevant loads, and
temperature gradients corresponding to various situations of cell
start-up and operations. Bending stiffness during rack-raising, for
instance, needs special attention. Even more challenging is the
start-up, during which particularly high temperatures and
temperature gradients are encountered and all anodes are full-size.
Figure 7 shows an example of model output for this situation. The
maximum deformation shown in the figure is 14 mm, for a
superstructure of more than 15 m length, and with no support
structure midway between the ends of the cell. Measurements

The linings of the HAL4e pilot cells have been abundantly

equipped with thermocouples to allow for continuous monitoring
of temperature development in the various parts of the linings.
Figure 5 shows an example from the insulating brick layer from a
typical week of operation of one of the cells. The modeled
isotherm at the location of the thermocouple was 770 oC at the
average bath temperature of that week, illustrating a good
correspondence with modeling results. Figure 6 shows a typical
measured ledge profile, recorded 4 months after start-up of one of
the cells, and providing good protection of the lining.

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shortly after start-up show modeling results to be in good

agreement with reality.

with the new constructed alumina and fluoride distribution system

outside of the battery limit of the cell. Figure 10 shows an
example of a run-in curve for one of the HAL4e cells, with acidity
and bath temperature values well within predetermined bands of
variation.

Figure 8 Fluoride addition and acidity by power control (top) and

conventional control (bottom). Vertical grid (acidity) is
1% AlF3. A half-year period is shown.

Figure 7 Mechanical modeling results for a start-up case,

showing equivalent stress (top) and deformation
(bottom), with max values at ca. 280 MPa and 14 mm
respectively.

Process Control and Early Operational Performance

In higher-amperage cells with less specific bath volume,
deviations can cause large disturbances, and keeping a stable bath
chemistry and ledge, and controlling anode effects to a minimum
becomes more of a challenge. The process control system used for
the HAL4e is the HAL3000 system, which was used also for
Sunndal 4 and Slovalco and a number of other Hydro potlines,
and which undergoes continuous improvement with better
functionality added over time.
HAL3000 bath temperature- and fluoride control uses the power
control strategy [11]. The main difference from existing strategies
that focus on acidity is that this strategy focuses on achieving
constant mass of AlF3 in the cell by using an estimator and a
decoupler, and uses power input to control the bath temperature.
In addition a feed-forward strategy is used to react early on raw
material changes. The strategy has proven to give great cell
stability which is beneficial for achieving a high current efficiency
and low energy consumption. An example, taken from HAL300,
is shown in Figures 8 and 9.

Figure 9 Cell resistance and bath temperature by power control

(top) and conventional control (bottom). Vertical grid
(temperature) is 10 oC. A half-year period is shown.
Figure 11 shows typical bath temperature and acidity variation for
one of the HAL4e cells after completing the run-in period, and at
the stage of starting to tune the power control parameters.
Although decent thermal and bath chemistry stability is already
achieved, further improvement is expected when power control
tuning is completed, cf. Figure 8 and 9. The cells operate at low
voltage as predicted by thermoelectric modeling, Table 1. Reliable
current efficiency data are not yet available, due to the short
period in operations, but indications are promising.

Power control was not used during the first months of HAL4e
operation, during which instead an empiric run-in curve for bath
temperature and acidity was used, ensuring a controlled formation
of a stable ledge. Thermal control of the cells during this phase
proved to be well manageable, despite of some early challenges

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Outlook
Operational optimisation, further measurement of cell behaviour
and qualification of the technology will continue through 2009.
Given the promising early operational phase of the technology,
HAL4e is likely to become the base case technology for future
investment projects, currently in early development stages. The
major risk factor is related to cathode lifetime, which cannot
possibly be comprehensively understood within only a few
months (or first couple of years) of operation. Some
understanding can, however, be gained from information from
cathode prototypes of longer age, monitoring of lining behaviour
and mechanical deformation over time, and autopsies.

Acknowledgements
Figure 10 Run-in curves for one of the HAL4e cells, over 8
weeks. Vertical grids are 2% AlF3 and 20 oC.

The author list only reflects the topics addressed specifically in

this paper. Many other colleagues gave important contributions
during the development and early operation of the HAL4e and are
gratefully acknowledged. These colleagues include T.Berge,
M.Bugge, A.Dyry, I.Eick, N.J.Holt, J.Hop, H.Hie, S.Jarek,
E.Johnsen, R.Jrgensen, H.O.Kleiva, R.Kovac, D.Kroschinski,
E.Manger, B.P.Moxnes, S.Paulides, M.Segatz, S.Thrnblad
Mathisen, and N.Wrsted.

References
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M.Bugge, M.Koniar, K.Skladan, M.Stas, Expansion of the

Potline in Slovalco, Light Metals 2008, 261-265.
2
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O.-A.Lorentsen, A.Dyry, M.Karlsen, Dealing with CO2EQ
from an Aluminum Electrolysis Cell, Light Metals 2009,
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S.Kols and T.Stre, Bath Temperature and AlF3 Control of an
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B.P.Moxnes, A.Solheim, M.Liane, A.Halkjelsvik, Improved
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Figure 11 Bath acidity and bath temperature variation for HAL4e

cell over 3 weeks. Vertical grids are 1% AlF3 and 10
o
C. Arrow marks start of power-control tuning period.

Table 1 Anode effect frequency and cell voltage during the first
months of operation. Indicated specific energy
consumption is based on an assumption of 95% current
efficiency.
The alumina feeding system is an aereated distribution / aereated
feeding system optimized through several years of prototype
testing, with bath-sensing breakers, and functionality for reducing
pressurized air consumption. The first weeks of operation yielded
a steep learning curve as to tuning of this system, in terms of dose
sizes, spatial distribution of doses (see also [12]), early-operation
crust characteristics, and corresponding demand on breaker
equipment. Utilizing solid operational experience from several
potlines, procedures were established that brought the average
anode effect frequency down below 0.03 per cell day already from
the third month of operation, as shown in Table 1.

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