Redesigning of Current Carrying Conductor—The Energy Reduction Initiative in Low Amperage Hall-Héroult Cell

To decrease specific energy consumption, we worked on Variable Stub and Solid Busbar project. In Variable Stub project, we changed the geometry of the stub, which decreased stub-to-carbon voltage drop. Our smelter has busbars of small cross-section. The busbar voltage drop is very high, which could be reduced by increasing the cross-sectional area. One pot has three sets of new welded busbars: one set on anode ring attached to the superstructure, two sets of half cathode ring welded to anode riser. This change-over requires shunting the next pot for 3–4 h which is taken back into the circuit after job completion. This paper will discuss the new modified pots, benefits, way forward, gain obtained after implementing the variable stub and solid busbar in the pots and also all the steps which are adopted to change the busbar without shunting the potline.