Next Materials· 2026Q1
Mechanistic correlation between interfacial thermomechanical failure of ramming paste and electrical instability in Hall-Héroult cells: A combined numerical and industrial field study
- 0citations
- Q1SCImago
- 2026year
Short summary
High tensile stresses exceeding the failure threshold in ramming paste joints during preheating cause micro-cracking, disrupting current paths and leading to electrical instability in Hall-Héroult cells.
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Key points
- Ramming paste joints in Hall-Héroult cells experience high tensile stresses during preheating.
- These stresses exceed the failure threshold (Goldenblat-Kopnov criterion > 1), causing micro-cracking in the paste.
- Ramming paste micro-cracking disrupts current path uniformity.
- Disrupted current paths mechanistically link to electrical instability and cell resistance fluctuations.
AI-generated from the title and abstract; the full text is not read.
Abstract
Abstract The reliability of Hall-Héroult cells is often undermined by electrical instability during start-up, which is typically addressed through prolonged preheating schedules. This study identifies a fundamental thermomechanical material failure in the cathode structure as the primary root cause. Using a validated, fully coupled finite element model, we demonstrate that high tensile stresses are generated and concentrated specifically in the carbonaceous ramming paste joints during the preheating cycle. Applying the Goldenblat-Kopnov criterion for brittle materials confirms that these local stresses significantly exceed the failure threshold, leading to micro-cracking of the ramming paste (criterion value > 1). This predicted mechanical degradation directly disrupts the uniformity of current paths, establishing a quantifiable mechanistic link to fluctuations in cell resistance and, consequently, to electrical noise. This finding enables a paradigm shift in failure analysis, moving the focus from bulk cathode behavior or thermal gradients to the critical interfacial integrity of the ramming paste. This new perspective opens avenues for material-based design improvements.
The authors' abstract, as published at the source. Next Materials, 2026 · DOI ↗
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Fluid Flow and Transfer ProcessesChemical Engineering