Experimental Study of the Morphology and Dynamics of Gas-Laden Layers Under the Anodes in an Air–Water Model of Aluminum Reduction Cells

The bubble layer formed under an anode and the bubble-induced flow play a significant role in the aluminum electrolysis process. The bubbles covering the anode bottom reduce the efficient surface that can carry current. In our experiments, we filmed and studied the bubble layer under the anode in a real-size air–water electrolysis cell model. Three different flow regimes were found depending on the gas generation rate. The covering factor was found to be proportional to the gas generation rate and inversely proportional to the angle of inclination. A correlation between the average height of the entire bubble layer and the position under the anode was determined. From this correlation and the measured contact sizes, the volume of the accumulated gas was calculated. The sweeping effect of large bubbles was observed. Moreover, the small bubbles under the inner edge of the anode were observed to move backward as a result of the escape of huge gas pockets, which means large momentum transport occurs in the bath.