Abstract: New methods of producing aluminum fluoride from cryolite are disclosed. A method may include a step of reacting cryolite bath materials with aluminum sulfate, thereby producing a reactant product, the reactant product comprising aluminum fluoride. The method may further include a step of removing impurities from the reactant product, thereby creating a purified product comprising the aluminum fluoride. The removed impurities may comprise at least one of sodium (Na), magnesium (Mg), and calcium (Ca). In one embodiment, due to the removing step, the purified product contains not greater than 0.2 wt. % of calcium.

Abstract: System, method and apparatus for measuring electrolysis cell operating conditions and communicating the same are disclosed. The system includes a selectively positionable member coupled to an analytical apparatus, wherein the selectively positionable is configured to move the analytical apparatus into and out of physical communication with a bath. The system may also include a crust breaker for breaking the surface of a bath and an electronic device for measuring bath level.

Abstract: System, method and apparatus for measuring electrolysis cell operating conditions and communicating the same are disclosed. The system includes a selectively positionable member coupled to an analytical apparatus, wherein the selectively positionable is configured to move the analytical apparatus into and out of physical communication with a bath. The system may also include a crust breaker for breaking the surface of a bath and an electronic device for measuring bath level.

Abstract: System, method and apparatus for measuring electrolysis cell operating conditions and communicating the same are disclosed. The system includes a selectively positionable member coupled to an analytical apparatus, wherein the selectively positionable is configured to move the analytical apparatus into and out of physical communication with a bath. The system may also include a crust breaker for breaking the surface of a bath and an electronic device for measuring bath level.

Abstract: An analysis system for determining one or more operating conditions of a metal electrolysis cell and for facilitating a response is provided. The analysis system comprises a bath probe electrically interconnected to a portable computing device. The bath probe generates signals associated with temperature measurements produced from thermal communication with an electrolysis cell bath. The portable computing device may receive these signals and generate data based thereon. The data may be transformed into operating condition information relating to the electrolysis cell.

Abstract: Systems, methods and apparatus relating to evaluation of alumina feedstocks are disclosed. A system may include an alumina storage unit comprising an alumina feedstock, an alumina supply member in communication with the alumina storage unit and an aluminum electrolysis cell. The alumina feedstock of the alumina storage unit may periodically flow through the alumina supply member and to the aluminum electrolysis cell. A measurement device may be in communication with the alumina supply member, and may be configured to measure a supply member property and transmit a first signal to a processor. The processor may be configured to receive the first signal and produce supply member property data based, at least in part, on the first signal.

Abstract: System, method and apparatus for measuring electrolysis cell operating conditions and communicating the same are disclosed. The system includes a selectively positionable member coupled to an analytical apparatus, wherein the selectively positionable is configured to move the analytical apparatus into and out of physical communication with a bath. The system may also include a crust breaker for breaking the surface of a bath and an electronic device for measuring bath level.

Abstract: System, method and apparatus for measuring electrolysis cell operating conditions and communicating the same are disclosed. The system includes a selectively positionable member coupled to an analytical apparatus, wherein the selectively positionable is configured to move the analytical apparatus into and out of physical communication with a bath. The system may also include a crust breaker for breaking the surface of a bath and an electronic device for measuring bath level.

Abstract: System, method and apparatus for measuring electrolysis cell operating conditions and communicating the same are disclosed. The system includes a selectively positionable member coupled to an analytical apparatus, wherein the selectively positionable is configured to move the analytical apparatus into and out of physical communication with a bath. The system may also include a crust breaker for breaking the surface of a bath and an electronic device for measuring bath level.

Abstract: Systems, methods and apparatus for reducing impurities in electrolysis cells are disclosed. In one approach, a method includes feeding a particulate fines feed stream to a tank, mixing particulate fines (PF) with liquid, the liquid having a first liquid and a second liquid, and separating at least some of the first liquid from at least some of the second liquid. The particulate fines (PF) may include inlet carbon fines (CFI) and inlet recyclable fines (RFI). The first liquid may include a recovered recyclable fines portion (RF1), and the second liquid may include a waste carbon fines portion (CF1). The mass ratio of the recovered recyclable fines portion (RF1) to the inlet recyclable fines (RNI) may be at least about 0.5. The mass ratio of the waste carbon fines portion (CF1) to the inlet carbon fines (CFI) may be at least about 0.1.

Abstract: Systems, methods and apparatus relating to evaluation of alumina feedstocks are disclosed. A system may include an alumina storage unit comprising an alumina feedstock, an alumina supply member in communication with the alumina storage unit and an aluminum electrolysis cell. The alumina feedstock of the alumina storage unit may periodically flow through the alumina supply member and to the aluminum electrolysis cell. A measurement device may be in communication with the alumina supply member, and may be configured to measure a supply member property and transmit a first signal to a processor. The processor may be configured to receive the first signal and produce supply member property data based, at least in part, on the first signal.

Abstract: Systems, methods and apparatus for reducing impurities in electrolysis cells are disclosed. In one approach, a method includes feeding a particulate fines feed stream to a tank, mixing particulate fines (PF) with liquid, the liquid having a first liquid and a second liquid, and separating at least some of the first liquid from at least some of the second liquid. The particulate fines (PF) may include inlet carbon fines (CFI) and inlet recyclable fines (RFI). The first liquid may include a recovered recyclable fines portion (RF1), and the second liquid may include a waste carbon fines portion (CF1). The mass ratio of the recovered recyclable fines portion (RF1) to the inlet recyclable fines (RFI) may be at least about 0.5. The mass ratio of the waste carbon fines portion (CF1) to the inlet carbon fines (CFI) may be at least about 0.1.

Abstract: System and method for measuring alumina qualities and communicating the same are disclosed. In one example, a system includes an aluminum electrolysis cell, a feeder configured to supply a feed stock using a feed stream to the aluminum electrolysis cell, and a measurement device in communication with the feed stream, the measurement device adaptable to receive, release, and determine at least one attribute associated with the feed stock.

Abstract: Systems, methods and apparatus for reducing impurities in electrolysis cells are disclosed. In one approach, a method includes feeding a particulate fines feed stream to a tank, mixing particulate fines (PF) with liquid, the liquid having a first liquid and a second liquid, and separating at least some of the first liquid from at least some of the second liquid. The particulate fines (PF) may include inlet carbon fines (CFI) and inlet recyclable fines (RFI). The first liquid may include a recovered recyclable fines portion (RF1), and the second liquid may include a waste carbon fines portion (CF1). The mass ratio of the recovered recyclable fines portion (RF1) to the inlet recyclable fines (RFI) may be at least about 0.5. The mass ratio of the waste carbon fines portion (CF1) to the inlet carbon fines (CFI) may be at least about 0.1.

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: System, method and apparatus for measuring electrolysis cell operating conditions and communicating the same are disclosed. The system includes a selectively positionable member coupled to an analytical apparatus, wherein the selectively positionable is configured to move the analytical apparatus into and out of physical communication with a bath. The system may also include a crust breaker for breaking the surface of a bath and an electronic device for measuring bath level.

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 one inward slot (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 slot (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: A self-baking, Soderberg type carbon anode (40) for use in an aluminum electrolyses cell (1) to form product aluminum (11), where the anode (40) is consumable in molten electrolyte (12) in the cell, the anode having top, bottom and side surfaces and at least four layers of vertically disposed plate inserts (48) meltable in the molten electrolyte, the plate inserts (48) preferably made of aluminum and are capable of melting to create hollow vertical slots (52) at the bottom of the anode facilitating any gas bubbles (60) generated to channel to the side of the anode into the electrolyte (12).

Abstract: An analysis system for determining one or more operating conditions of a metal electrolysis cell and for facilitating a response is provided. The analysis system comprises a bath probe electrically interconnected to a portable computing device. The bath probe generates signals associated with temperature measurements produced from thermal communication with an electrolysis cell bath. The portable computing device may receive these signals and generate data based thereon. The data may be transformed into operating condition information relating to the electrolysis cell.

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.