In order to ensure the quality of barrier powder refractory, avoid losses caused by using poor quality barrier powder refractory, it is imperative to develop high quality barrier powder refractory. A new dry barrier powder refractory with reacting thickness less than 7mm in 960°X96h test was developed by optimizing the formula. In industrial test, after new dry barrier powder refractory used, electrolytic cell bottom outside surface temperature decreased 37°, cell bottom heat loss decreased 18mV, cell bottom kept clean and cell maintained stable in long term operation, cell voltage reduced 25mV, current efficiency increased 0.2 %, DC power consumption decreased 109 kWh/t-Al, a good energy saving effect was obtained.