Abstract: Apparatuses and methods for controlling electrode current density of an electrolytic cell during the electrolytic production of a metal, such as aluminum or aluminium, are disclosed. The cell has anodes and cathode plates vertically aligned and arranged in alternating rows. Each electrode defines a connecting region for connecting the electrode to the cell, a middle region, and an ACO (Anode-Cathode Overlap) region extending from the middle region for overlapping adjacent electrodes(s). The ratio of the ACO region's surface area to the middle region's surface area is superior to one. Alternatively, an average cross-sectional ACO region to the middle and connecting regions, is superior than one, preferably superior than 2. The present technology allows maximizing current density in the ACO region.

Abstract: New 6xxx aluminum alloy products and methods and systems of making the same are disclosed. A method may include heating a billet of a 6xxx aluminum alloy to a preheat temperature, holding the billet at the preheat temperature for a time sufficient to dissolve at least some precipitate hardening phases of the billet, extruding the billet into an extruded product wherein, during the extruding, both the billet and the extruded product are maintained at or above the preheat temperature, discharging the extruded product from the extrusion apparatus while maintaining the extruded product within 100° F. of a solvus temperature of the 6xxx aluminum alloy, and moving the extruded product from the heating shroud to a quenching apparatus.

Abstract: An insulation assembly is provided, including: a body of an insulating material with a lower surface configured to contact a sidewall an electrolysis cell; an upper surface generally opposed to the lower surface; and a perimetrical sidewall extending between the upper surface and the lower surface to surround the remainder of the body, the perimetrical sidewall including: an inner portion configured to face an anode surface of the electrolysis cell and provide a gap between the body and the anode surface of the electrolysis cell; wherein the body is configured to extend from the sidewall towards the anode surface.

Abstract: A method of monitoring an electrolytic cell including detecting information indicative of a thermite reaction, comparing the information indicative of a thermite reaction to a threshold, generating a thermite response signal according to the comparison, and reacting to the thermite response signal by adjusting the operation of the electrolytic cell.

Abstract: An insulation assembly is provided, including: a body of an insulating material with a lower surface configured to contact a sidewall an electrolysis cell; an upper surface generally opposed to the lower surface; and a perimetrical sidewall extending between the upper surface and the lower surface to surround the remainder of the body, the perimetrical sidewall including: an inner portion configured to face an anode surface of the electrolysis cell and provide a gap between the body and the anode surface of the electrolysis cell; wherein the body is configured to extend from the sidewall towards the anode surface.

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: 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.