Abstract: Systems and methods for coating a metallic component are provided. In one embodiment, a metallic coating may be disposed in a plating bath comprising AlBr3. The metallic coating may be coupled with, or configured as, a working electrode. A counter electrode formed of aluminum may be disposed within the plating bath. An electric current may be applied between the two electrodes resulting in the electrodeposition of aluminum on the metallic component. In one particular embodiment, the plating bath may include LiBr, KBr and CsBr, with AlBr3 being present in an amount of approximately 80 percent or greater by weight. Various types of metals may be coated with aluminum using embodiments of the present disclosure. Additionally, the methods and systems described herein are amenable to coating of complex geometries.

Abstract: An apparatus and method for smelting has a smelting pot for containing electrolyte, alumina and a layer of liquid aluminum. A wall in the form of one or more TiB2 or alumina plates extends from the bottom of the pot to a height exceeding the height of the liquid aluminum layer formed in the bottom of the smelting pot during smelting. The wall partitions the bottom of the pot and impedes movement of the aluminum under the influence of MHD forces, diminishing the maximum crest height of waves in the aluminum and allowing a reduction in the ACD to reduce electrical resistance and power consumption. The wall may equal or exceed the height of the anode and may, when conductive, act as a cathode, drawing a horizontal current. The wall may be composed of alumina, e.g., in the form of blocks, undergoing electrolytic reduction and being replaced periodically.

Abstract: A cell for the electrowinning of aluminum (50) from alumina, comprises an inclined plate-like or grid-like open anode structure (25) which has a generally v-shaped configuration in cross-section. The anode structure (25) has a downwardly-oriented sloping electrochemically active surface that is generally v-shaped in cross-section and spaced above an upwardly-oriented corresponding sloping cathode surface (11) by an anode-cathode gap (40) in which alumina dissolved in a circulating electrolyte (60) is electrolysed. The anode structure (25) has a plurality of anode through-passages (45) distributed thereover for an up-flow of alumina-depleted electrolyte (60) from the anode-cathode gap (40).

Abstract: Disclosed is a method for the continuous production of aluminum from alumina including a first step of converting alumina (Al2O3) into aluminum sulfide (Al2S3) and a second step of separation of aluminum from aluminum sulfide in a separating reactor. Wherein in the first step in a conversion reactor alumina is dissolved in a molten salt to form a melt and a sulfur containing gas is fed through the melt whereby the sulfur containing gas acts as a reagent to convert at least part of the alumina into aluminum sulfide and at least part of the melt is used in the second step. Further the invention relates to an apparatus for operating the method.

Abstract: An electrolysis cell (10) contains a number of carbon anodes (12) having top, bottom and side surfaces, operating in molten electrolyte (17) in an aluminum electrolysis cell (10), where gas bubbles (28) are generated at the anode surfaces and where alumina particles (20) are added to the top of the molten electrolyte, where the carbon anodes (12) have at least two inward slots (21) passing through the carbon anode (12) along the longitudinal axis 40 of the carbon anode and also passing through only one front surface (25) of the carbon anode, where the height (32) of the slots (21) is from about 45% to 80% of the anodes thickness and the slotted front surfaces (25) are disposed toward the center of the electrolysis cell so that generated gas bubbles (28) are directed to the alumina particles.

Abstract: Low temperature cell for electrolytic production of aluminum.

Abstract: The invention provides efficient and effective processes for recovering metals such as aluminum, magnesium and lithium from mixed waste sources such as auto shredder residue, aluminum cans, waste particles of aluminum alloy and municipal waste. The metal-waste source is dissolved in a more noble metal solvent at a temperature at which contaminants do not dissolve. The purified metal is then recovered from the solvent, preferably by electrorefining.

Abstract: Process for early detection of an anode effect in an aluminum production cell based on molten salt electrolysis. The cell comprises at least one anode, at least one cathode and cathode connecting conductors and anode connecting conductors.

Abstract: An improved method is described for adding alumina to a Söderberg or pre-bake type electrolytic cell fed by schedule crust breaking. Instead of adding the full amount of alumina required following each crust breaking, as is traditional, the standard dose of alumina is now split into two smaller doses. Thus, a major proportion, e.g. about 50 to 90% by weight, of the theoretically required alumina to sustain the electrolysis between crust breakings is added following a crust breaking. The electrical resistance of the electrolyte is monitored between crust breakings, and if the resistance begins to rapidly increase indicating the approach of an anode effect, the anodes are activated into a pumping action thereby breaking the crust adjacent the anodes, allowing alumina to flow into the molten electrolyte, and also creating a stirring action within the molten electrolyte. This lowers the resistance such that any anode effect is avoided until the next full crust breaking.

Abstract: Electrolysis of alumina dissolved in a molten salt electrolyte employing inert anode and cathodes, the anode having a box shape with slots for the cathodes.

Abstract: An electrolytic cell for producing aluminum from alumina having a reservoir for collecting molten aluminum remote from the electrolysis.

Abstract: A method of producing aluminum in an electrolytic cell containing alumina dissolved in an electrolyte, the method comprising providing a molten salt electrolyte having alumina dissolved therein in an electrolytic cell. A plurality of anodes and cathodes having planar surfaces are disposed in a generally vertical orientation in the electrolyte, the anodes and cathodes arranged in alternating or interleaving relationship to provide anode planar surfaces disposed opposite cathode planar surfaces, the anode comprised of carbon. Electric current is passed through anodes and through the electrolyte to the cathodes depositing aluminum at the cathodes and forming carbon containing gas at the anodes.

Abstract: A drained-cathode cell for the electrowinning of aluminium comprises one or more anodes (14) suspended over one or more cathodes (16). The or each anode (14) and cathode (16) respectively have a sloped V-shaped active anode surface (22) and parallel sloped inverted V-shaped drained cathode surfaces (18) facing one another and spaced apart by two sloped inter-electrode gaps (20), arranged so the electrolyte circulates upwardly in the sloped inter-electrode gaps (20) assisted by anodically produced gas and then returns from a top part (22′) to a bottom part (22″) of each inter-electrode gap (20) along an electrolyte path (26,27,36,37).

Abstract: A method of producing aluminum in an electrolytic cell containing alumina dissolved in an electrolyte, the method comprising the steps of providing a molten salt electrolyte at a temperature of less than 900° C. having alumina dissolved therein in an electrolytic cell having a liner for containing the electrolyte, the liner having a bottom and walls extending upwardly from said bottom. A plurality of non-consumable anodes and cathodes are disposed in a vertical direction in the electrolyte, the cathodes having a plate configuration and the anodes having a flat configuration to compliment the cathodes. The anodes contain apertures therethrough to permit flow of electrolyte through the apertures to provide alumina-enriched electrolyte between the anodes and the cathodes. Electrical current is passed through the anodes and through the electrolyte to the cathodes, depositing aluminum at the cathodes and producing gas at the anodes.

Abstract: An improved method of producing aluminum in an electrolytic cell containing alumina dissolved in an electrolyte, the method comprising the steps of providing a molten salt electrolyte at a temperature less than 900° C. having alumina dissolved therein in an electrolytic cell having a liner for containing the electrolyte, the liner having a bottom and walls extending upwardly from the bottom, the liner being substantially inert with respect to the molten electrolyte. A plurality of non-consumable anodes and cathodes are disposed in the electrolyte and an electric current is passed through the anodes and through the electrolyte to the cathodes depositing aluminum on the cathodes and generating oxygen bubbles at the anodes, the bubbles stirring the electrolyte. Periodically, the electric current flow to the cell is reduced for extended periods.

Abstract: This invention relates to the use of bubble-driven flow to enhance the dissolution and distribution of alumina in an aluminum electrolysis cell operating with inert anodes. By harnessing the driving force of bubbles rising along the sides of a sloped anode to induce circulation in a cell and by using a group of anodes to amplify the effect, alumina distribution can be maintained close to or at saturation without formation of muck/sludge. Alumina fed through point feeders at specific locations can be distributed throughout the entire cell rather than sinking to the bottom of the cell below the feed location. For a given circulation pattern, feeder locations can be optimized.

Abstract: A cell for the electrowinning of aluminum using anodes (10) made from a alloy of iron with nickel and/or cobalt is arranged to produce aluminum of low contamination and of commercial high grade quality. The cell comprises a cathode (20) of drained configuration and operates at reduced temperature without formation of a crust or ledge of solidified electrolyte. The cell is thermally insulated using an insulating cover (65,65a,65b,65c) and an insulating sidewall lining (71). The molten electrolyte (30) is substantially saturated with alumina, particularly on the electrochemically active anode surface, and with species of at least one major metal present at the surface of the nickel-iron alloy based anodes (10). The cell is preferably operated at reduced temperature from 730° to 910° C. to limit the solubility of these metal species and consequently the contamination of the product aluminum.

Abstract: A method of producing aluminum in an electrolytic cell containing alumina dissolved in an electrolyte. A plurality of non-consumable anodes are disposed substantially vertically in the electrolyte along with a plurality of monolithic hollow cathodes. Each cathode has a top and bottom and the cathodes are disposed vertically in the electrolyte and the anodes and the cathodes are arranged in alternating relationship. Each of the cathodes is comprised of a first side facing a first opposing anode and a second side facing a second opposing anode. The first and second sides are joined by ends to form a reservoir in the hollow cathode for collecting aluminum therein deposited at the cathode.

Abstract: Cathode connector means for low temperature aluminum smelting cell for connecting titanium diboride cathode or the like to bus bars.

Abstract: A method of producing aluminum in an electrolytic cell containing alumina dissolved in an electrolyte. The method comprises the steps of providing a molten salt electrolyte in an electrolytic cell having an anodic liner for containing the electrolyte, the liner having an anodic bottom and walls including at least one end wall extending upwardly from the anodic bottom, the anodic liner being substantially inert with respect to the molten electrolyte. A plurality of non-consumable anodes is provided and disposed vertically in the electrolyte. A plurality of cathodes is disposed vertically in the electrolyte in alternating relationship with the anodes. The anodes are electrically connected to the anodic liner. An electric current is passed through the anodic liner to the anodes, through the electrolyte to the cathodes, and aluminum is deposited on said cathodes. Oxygen bubbles are generated at the anodes and the anodic liner, the bubbles stirring the electrolyte.

Abstract: A cell for the electrowinning of aluminum comprises at least one non-carbon metal-based anode (10) having an electrically conductive metallic structure (12, 13, 15) which is suspended substantially parallel to a facing cathode (20, 21, 22). Such metallic structure (12, 13, 15) comprises a series of parallel horizontal anode members (15), each having an electrochemically active surface (16) on which during electrolysis oxygen is anodically evolved. The electrochemically active surfaces (16) are in a generally coplanar arrangement to form the active anode surface. The anode members are spaced apart from one another by inter-member gaps forming flow-through openings (17) for the circulation of electrolyte (30) driven by the escape of anodically-evolved oxygen. The electrolyte (30) may circulate upwardly and/or downwardly in the flow-through openings (17) and possibly around the anode structure (12, 13, 15).