China Nonferrous Metallurgy

Electricity consumption in the electrolysis process accounts for more than 50% of the total energy consumption ratio, and the electrolysis process is a coupling of multiple physical fields and electrochemical reactions with complex influencing factors. Currently, simulation of physical and electric fields can achieve the purpose of optimizing electricity consumption. This paper compiles the literature on numerical simulation of multi-physics fields such as electrolyte flow rate field, ion concentration field and electric field in zinc, copper, manganese and nickel electrolytic cells using COMSOL Multiphysics and ANSYS, and analyzes the research results to conclude that the energy consumption on electrolytic cells depends on the distribution of multi-physics fields in the cells, and by changing the electrolyte feeding method, anode material, electrolyzer geometry, temperature, plate spacing, electrode size, and plate placement, the current efficiency and energy consumption can be influenced; numerical simulation of the electrolysis process using simulation software can simulate the actual electrolysis process, which can help optimize the process and save costs. The current simulation mainly focuses on internal factors such as process parameters, electrode structure, electrolyzer structure, and electrolyte flow field in the electrolysis process, and the research results are very fruitful in controlling product impurities, improving productivity and current efficiency, improving surface quality and collecting sludge. However, the model is idealized, and in the future, more attention should be paid to the integration with reality, taking into account the effects of temperature, humidity, environment and other factors, provide more accurate simulation results.