With Cell Lining Or Coating Patents (Class 204/247.4)
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Patent number: 11286574Abstract: An electrolytic cell for the production of aluminium including collector bars under the cathode, namely a copper collector bar whose external terminal end is connected by a conductor element providing electrical connection of the collector bar to an external bus. This conductor element comprises a flexible connector strip of the same or a different highly conductive metal as the conductor bar, such as copper.Type: GrantFiled: July 26, 2017Date of Patent: March 29, 2022Assignee: TOKAI COBEX GMBHInventors: Markus Pfeffer, René Von Kaenel
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Patent number: 11242604Abstract: A novel cathode assembly and its use for the production of aluminum in an electrolysis cell.Type: GrantFiled: July 26, 2017Date of Patent: February 8, 2022Assignee: COBEX GMBHInventors: Elaine Sum, Markus Pfeffer, Florian Pfefferer, Oscar Vera-Garcia, Mariusz Minkina, Seweryn Mielnik
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Patent number: 11060199Abstract: In one embodiment, an electrolytic cell for the production of aluminum from alumina includes: at least one anode module having a plurality of anodes; at least one cathode module, opposing the anode module, wherein the at least one cathode module comprises a plurality of cathodes, wherein the plurality of anodes are suspended above the cathode module and extending downwards towards the cathode module, wherein the plurality of cathodes are positioned extending upwards towards the anode module, wherein each of the plurality of anodes and each of the plurality of cathodes are alternatingly positioned, wherein the plurality of anodes is selectively positionable in a horizontal direction relative to adjacent cathodes, wherein the anode module is selectively positionable in a vertical direction relative to the cathode module, and wherein a portion of each of the anode electrodes overlap a portion of adjacent cathodes.Type: GrantFiled: September 16, 2019Date of Patent: July 13, 2021Assignee: ELYSIS LIMITED PARTNERSHIPInventor: Xinghua Liu
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Patent number: 11001931Abstract: The application is directed towards methods for purifying an aluminum feedstock material. A method provides: (a) feeding an aluminum feedstock into a cell (b) directing an electric current into an anode through an electrolyte and into a cathode, wherein the anode comprises an elongate vertical anode, and wherein the cathode comprises an elongate vertical cathode, wherein the anode and cathode are configured to extend into the electrolyte zone, such that within the electrolyte zone the anode and cathode are configured with an anode-cathode overlap and an anode-cathode distance; and producing some purified aluminum product from the aluminum feedstock.Type: GrantFiled: August 21, 2019Date of Patent: May 11, 2021Assignee: ALCOA USA CORP.Inventors: David H. DeYoung, Xinghua Liu, Brent L. Mydland, James Wiswall
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Patent number: 9822457Abstract: The invention relates to method and apparatus for lining the cathode of the electrolytic cell. The method comprises filling the cell's shell with powder material, leveling it with a rack, covering the fill material with a dust-proof film, and compaction. Compaction is performed in two stages: preliminary static and final dynamic treatment by consequent movement of static and dynamic work tools of compaction along the longitudinal axis of the cathode of the electrolytic cell through a cushion, which is made of at least 2 layers: a lower layer, which prevents pushing powder material forward in the direction of travel, and an upper layer, which provides for a coupling between the cushion and the static work tool. Static treatment unit of the apparatus, designed in the form of a roller with a drive, is connected to a dynamic treatment unit with a vibratory exciter by means of elastic elements.Type: GrantFiled: October 25, 2012Date of Patent: November 21, 2017Assignee: UNITED COMPANY RUSAL ENGINEERING AND TECHNOLOGY CENTRE LLCInventors: Aleksandr Vladimirovich Proshkin, Samuil Yakovlevich Levenson, Vitaliy Valer'evich Pingin, Aleksey Vasil'evich Morozov
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Patent number: 8980069Abstract: A high temperature electrolysis cell refractory system comprises at least one precast and predried monolithic refractory flooring module, precast and predried monolithic refractory wall modules, and at least one precast and predried monolithic refractory ceiling module, wherein the flooring module(s), wall modules and ceiling module(s) are configured for assembly to form a sealable electrolysis cell in which adjacent modules have interlocking surfaces. The refractory system is assembled within a steel containment shell to provide a high temperature electrolysis cell.Type: GrantFiled: November 17, 2011Date of Patent: March 17, 2015Assignee: Allied Mineral Products, Inc.Inventors: Timothy L. Hoyt, Christina Bernstein, Anthony S. Disaia, Herman Eslick, Dana G. Goski
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Publication number: 20140262808Abstract: Broadly, the present disclosure relates to sidewall features (e.g. inner sidewall or hot face) of an electrolysis cell, which protect the sidewall from the electrolytic bath while the cell is in operation (e.g. producing metal in the electrolytic cell).Type: ApplicationFiled: March 12, 2014Publication date: September 18, 2014Inventors: Xinghua Liu, Robert A. DiMilia, Joseph M. Dynys, Jeffrey S. Martello
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Publication number: 20140202873Abstract: An objective of the present invention is to provide a method and system for use for control of layer formation over an extended area in an aluminium electrolysis cell and exploitation of heat. A second object of the invention is to provide a method and system for use for control of layer formation suited for retrofitting to an aluminium electrolysis cell and maintainability during operations of the cell. The present invention attains the above-described objectives by a flat heat tube for attachment to the steel casing of an aluminium electrolysis cell. This heat tube can be a heat pipe or a thermosyphon. Preferably the heat tube is provided with a substantially flat surface. Preferably the heat tube has a meandering shape.Type: ApplicationFiled: October 5, 2012Publication date: July 24, 2014Applicant: Mitsubishi Electric CorporationInventors: Veroslav Sedlak, Dumitru Fetcu, John Salvador
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Publication number: 20130292259Abstract: Grid energy storage is very challenging due to its large scale, required quick response, versatility, round trip efficiency, and new system infrastructure. However, the benefit is also huge because it would enable utilisation of intermittent renewable energy, leverage load, and allow energy management in hours/diurnal to seconds/minutes. A new invention is described to store up to 4-6% the entire grid energy by aluminum production, while returning its baseload back to the grid by idling aluminum smelter cells. The round trip efficiency will be close to 100%; switching between storage and load release can be instantaneous.Type: ApplicationFiled: May 2, 2012Publication date: November 7, 2013Inventor: Xin Xiao
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Publication number: 20130199938Abstract: A system and method is provided for control of layer formation by use of sidelining provided with heat tube.Type: ApplicationFiled: September 20, 2011Publication date: August 8, 2013Inventors: John Paul Salvador, Veroslav Sedlak
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Patent number: 8440059Abstract: The invention relates to an electrolytic cell for obtaining aluminum, including a pot shell, at least one cathode block arranged at least partially in the pot shell, at least one anode suspended above the cell and dipping into the upper portion of the electrolytic cell, and an insulation at least partially covering the internal surface of the pot shell and located between the cathode block and the pot shell, the pot shell and the elements that it contains delimiting a crucible intended to receive an electrolytic bath in contact with the cathode block, characterized in that the insulation is at least partially made of carbon-based blocks having a heat conductivity lower than 1 W/m/K.Type: GrantFiled: April 25, 2007Date of Patent: May 14, 2013Assignee: Carbone SavoieInventor: Jean-Michel Dreyfus
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Patent number: 8425112Abstract: A measuring device is provided having a protective cover and a sensor arranged in the protective cover. The protective cover has a carrier tube made of metal and closed on one end. A first coating made of an aluminum non-wettable material is arranged on an outer surface of the carrier tube, and a further coating made of aluminum-wettable material is applied on the first coating.Type: GrantFiled: May 28, 2009Date of Patent: April 23, 2013Assignee: Heraeus Electro-Nite International N.V.Inventors: Paul Verstreken, Jozef Theodoor Aegten
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Patent number: 8273224Abstract: A collector bar for electrical connection to a busbar system of an electrolytic cell, the collector bar being received within a recess in a cathode block of the cathode of the electrolytic cell; wherein the collector bar comprises a first conductor which electrically connects to the busbar system, the first conductor having an external surface or surfaces which electrically contact the cathode block and at least one second conductor having a lower electrical resistance to the first conductor, the second conductor being positioned on at least one external surface of the first conductor in electrical contact with the first conductor.Type: GrantFiled: October 29, 2008Date of Patent: September 25, 2012Assignee: BHP Billiton Innovation Pty LtdInventors: Ingo Bayer, Bruce Ringsby Olmstead
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Calcium aluminate clinker as a refractory aggregate with and without barium addition and use thereof
Patent number: 8216435Abstract: A method of providing a safety lining in an industrial processing container, such as an aluminum electrolytic cell, is provided comprising providing a container having an interior and a at least one primary lining in juxtaposition to said interior of said shell, and adding a calcium aluminate clinker and/or castable layer between the primary lining and the shell of the container. Further, a method of trapping one or more gasses, elements or compounds produced from industrial processes is provided using the container having the calcium aluminate layer as herein described. An electrolytic cell is disclosed comprising a shell having an interior, one or more primary linings in juxtaposition to the interior of the shell, and one or more safety linings located between the primary lining and the shell, wherein at least one of the safety linings comprises a calcium aluminate clinker and/or castable.Type: GrantFiled: June 6, 2005Date of Patent: July 10, 2012Assignee: Westmoreland Advanced Materials, Inc.Inventor: Kenneth A. McGowan -
Patent number: 8206560Abstract: Disclosed is an aluminum electrolytic cell having profiled cathode carbon blocks structures, comprising a cell case, a refractory material installed on the bottom, an anodes and a cathode. The cathode carbon blocks include a profiled structure having projections on the top surface of the carbon blocks, that is, a plurality of projections are formed on a surface of the cathode carbon blocks. The aluminum electrolytic cell having the cathode structure according to the present invention can reduce the velocity of the flow and the fluctuation of the level of the cathodal molten aluminum within the electrolytic cell, so as to increase the stability of the surface of molten aluminum, reduce the molten lose of the aluminum, increase the current efficiency, reduce the inter electrode distance, and reduce the energy consumption of the production of aluminum by electrolysis.Type: GrantFiled: December 17, 2007Date of Patent: June 26, 2012Assignees: Northeastern University Engineering & Research Institute Co, Ltd., Northeastern University, Shenyang Beiye Metallurgical Technology Co., Ltd.Inventor: Naixiang Feng
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Patent number: 8123928Abstract: A process for shutting down an operating electrolytic cell for the production of aluminium is described. The process includes: lowering anodes until a lower portion of the anodes is immersed in an aluminium layer; allowing the aluminium layer and an electrolyte bath to cool down with the lower portion of the anodes immersed in the aluminium layer; determining if the electrolyte bath is solidified, and if the electrolyte bath is solidified, raising the anodes before solidification of the aluminium layer to create a space between the solidified electrolyte bath and the anodes and the aluminium layer.Type: GrantFiled: December 22, 2009Date of Patent: February 28, 2012Assignee: Rio Tinto Alcan International LimitedInventors: Robert Cayouette, Martin Bouchard, Jacques Fortin
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Patent number: 7928419Abstract: The present disclosure relates to a solid electrolyte device comprising an amorphous chalcogenide solid active electrolytic layer; first and second metallic layers. The amorphous chalcogenide solid active electrolytic layer is located between the first and second metallic layers. The amorphous chalcogenide solid active electrolytic layer is prepared by obtaining a solution of a hydrazine-based precursor to a metal chalcogenide; applying the solution onto a substrate; and thereafter annealing the precursor to convert the precursor to the amorphous metal chalcogenide. The present disclosure also relates to processes for fabricating the solid electrolyte device.Type: GrantFiled: July 30, 2007Date of Patent: April 19, 2011Assignee: International Business Machines CorporationInventors: Kailash Gopalakrishnan, David B. Mitzi, Rohit S. Shenoy
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Patent number: 7776191Abstract: Cathodes for aluminum electrolysis cells are formed of cathode blocks and current collector bars attached to those blocks. The cathode block has a cathode slot for receiving the collector bar and has a higher depth at a center than at both lateral edges of the cathode block. Additionally, the collector bar thickness is higher at the center than at both lateral edges of the cathode block. This cathode configuration provides a more even current distribution and, thus, a longer useful lifetime of such cathodes and increases cell productivity.Type: GrantFiled: October 14, 2008Date of Patent: August 17, 2010Assignee: SGL Carbon SEInventors: Frank Hiltmann, Philippe Beghein
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Patent number: 7749363Abstract: A cell for the electrowinning of aluminium by the electrolysis from an aluminium compound dissolved in a molten electrolyte (50), comprises: (I) a plurality of non-carbon anodes (10), each anode being suspended in operating in the molten electrolyte by an anode stem (11) that connects the anode (10) to a positive current source; and (II) a thermic insulating cover (60,60?) which covers the electrolyte (50) and through which each anode stem (11) extends from the positive current source to an anode (10). The insulating cover (60,60?) comprises a plurality of movable sections (60) that together cover a substantial part of the electrolyte (50). Each movable section (60) covers a corresponding portion of the electrolyte (50) that is located therebelow and that can be uncovered by moving the corresponding movable section (60).Type: GrantFiled: June 3, 2003Date of Patent: July 6, 2010Assignee: Moltech Invent SAInventors: Vittorio De Nora, Georges Berclaz
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Patent number: 7699963Abstract: An electrolytic cell for the production of metal by electrolytic reduction of a metal bearing material dissolved in a molten salt bath, the cell including a shell, and a lining on the interior of the shell, the lining including a bottom cathode lining and a side wall lining including a plurality of fluid ducts positioned against the interior surface of the shell for conducting fluid there through, the fluid ducts extending along the sides of the shell, and communicating with pump means to flow fluid through the fluid ducts.Type: GrantFiled: April 5, 2007Date of Patent: April 20, 2010Assignee: BHP Billiton Innovation Pty Ltd.Inventor: Ingo Bayer
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Patent number: 7658832Abstract: A method of stabilizing an electrolysis cell with a boundary, a liquid metal layer and an electrolyte layer having specific operational and geometric parameters, and comprises the steps of determining amplitude and frequency values for a desired external, time-varying and/or alternating magnetic field through wave reflection analysis on a theoretical wall whose parameters are representative of the cell wall's parameters; and imposing on said cell an external, time-varying and/or alternating magnetic field having substantially the same amplitude and frequency values determined in the wave reflection analysis so that the resultant magnetic field imposed on the cell tends to parametrically and dynamically desynchronize the occurrence of resonance instability near the cell's walls.Type: GrantFiled: July 11, 2008Date of Patent: February 9, 2010Assignee: Coventry UniversityInventors: Sergei Molokov, Alex Lukyanov, Gennady El
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Publication number: 20090321273Abstract: The present method relates to a method and a cell for electrolytic production of zinc from a salt melt comprising zinc chloride. The cell has at least one electrolysis chamber (2) containing an electrolyte and at least one adjacent chamber (1) separated from said electrolysis chamber by means of at least one partition wall (7, 8). The atmosphere(s) in the electrolysis chamber(s) is separated from the atmosphere(s) in the adjacent chamber(s) by the at least one partition wall. The electrolyte is directed to flow between the electrolysis chamber(s) and the adjacent chamber(s) through at least one opening in or at the partition wall(s) below the level of the electrolyte level. The Zinc metal produced is collected in the bottom of the cell. The electrolyte flow can be controlled in a substantial laminar manner.Type: ApplicationFiled: September 17, 2007Publication date: December 31, 2009Inventor: Christian Rosenkilde
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Patent number: 7628904Abstract: An electrochemical cell for electrochemical reduction of a metal oxide in a solid state is disclosed. The cell includes a molten electrolyte (14), an anode (10) formed from carbon in contact with the electrolyte, a cathode (20) formed at least in part from the metal oxide in contact with the electrolyte, and a membrane (28) that is permeable to oxygen anions and is impermeable to carbon in ionic and non-ionic forms positioned between the cathode and the anode to thereby prevent migration of carbon from the anode to the cathode. The membrane includes a body (32) and a lining (34) on the surface of the body on the cathode side of the membrane. The lining is formed from a material that is inert with respect to dissolved metal in the electrolyte and is impermeable to the dissolved metal. An electrochemical method based on the cell is also disclosed.Type: GrantFiled: October 15, 2003Date of Patent: December 8, 2009Assignee: Metalysis LimitedInventors: Les Strezov, Ivan Ratchev, Steve Osborn, Sergey Alexander Bliznyukov
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Patent number: 7618519Abstract: This invention relates to a cathode element for use in a pot of an electrolytic cell intended for production of aluminum. The cathode element comprises a cathode block and a steel connection bar. The connection bar includes at least one metal insert, whose electrical conductivity is greater than the electrical conductivity of the said steel. The presence of an insert according to the invention can simultaneously result in a very large drop in the global cathode voltage and a very strong reduction in the current density at the head of the block.Type: GrantFiled: April 1, 2005Date of Patent: November 17, 2009Assignee: Aluminum PechineyInventors: Delphine Bonnafous, Jean-Luc Basquin, Claude Vanvoren
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Publication number: 20090114547Abstract: A cell for the electrowinning of aluminium has a cavity for containing electrolyte (20) and one or more non emerging active anode bodies (5) that are suspended in the electrolyte. The electrolyte's surface (21,21?) has an expanse extending over the cavity and is substantially covered by a self-formed crust (25) of frozen electrolyte. The crust is mechanically reinforced by at least one preformed refractory body (30, 30?,30?). The electrolyte crust is formed against the preformed refractory body and bonded thereto so as to inhibit mechanical failure of the crust and collapse of the crust into the cavity.Type: ApplicationFiled: February 26, 2007Publication date: May 7, 2009Inventors: Thinh T. Nguyen, Rene Von Kaenel, Vittorio De Nora
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Patent number: 7527715Abstract: The invention relates to a cooling method of a igneous electrolytic cell for aluminium production wherein heat transfer fluid droplets (or “divided heat transfer fluid”) are produced, preferentially in a confined volume in contact with a specified surface of at least one wall of the shell of the pot of the electrolytic cell, so as to induce the evaporation of all or part of said droplets by contact with said surface and remove the heat from said surface. The invention also relates to a cooling system capable of implementing the cooling method. The invention makes it possible to obtain a high cooling efficiency due to the latent heat of vaporisation of the heat transfer fluid.Type: GrantFiled: July 7, 2003Date of Patent: May 5, 2009Assignee: Aluminum PechineyInventors: Laurent Fiot, Claude Vanvoren, Airy-Pierre Lamaze, Bernard Eygulnent, Jean-Luc Basquin
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Patent number: 7504010Abstract: The present invention relates to a dimensionally stable oxygen-evolving anode for use in an electrolytic cell for the production of aluminium. The anode comprises of a container made from an alloy comprising aluminium and at least one metal more noble than aluminium; a fluid bath in the bottom of the container having the ability to dissolve aluminium, said fluid having a density that is higher than the density of molten aluminium at the operating temperature of the cell, a pool of molten aluminium floating on top of the fluid bath in the bottom of the container; a refractory layer arranged on the inner sidewalls of the container at least in the area of the pool of molten aluminium, said refractory layer protecting the molten aluminium from contacting the inner sidewalls of the container.Type: GrantFiled: March 9, 2006Date of Patent: March 17, 2009Assignee: Elkem ASInventors: Jan Arthur Aune, Georg Frommeyer, Kai Johansen, Donald R. Sadoway, Gro Soleng, Elke William Thisted
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Publication number: 20080314738Abstract: The present disclosure relates to a solid electrolyte device comprising an amorphous chalcogenide solid active electrolytic layer; first and second metallic layers. The amorphous chalcogenide solid active electrolytic layer is located between the first and second metallic layers. The amorphous chalcogenide solid active electrolytic layer is prepared by obtaining a solution of a hydrazine-based precursor to a metal chalcogenide; applying the solution onto a substrate; and thereafter annealing the precursor to convert the precursor to the amorphous metal chalcogenide. The present disclosure also relates to processes for fabricating the solid electrolyte device.Type: ApplicationFiled: June 19, 2007Publication date: December 25, 2008Applicant: INTERNATIONAL BUSINESS MACHINES CORPORATIONInventors: Kailash Gopalakrishnan, David B. Mitzi, Rohit S. Shenoy
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Publication number: 20080314739Abstract: The present disclosure relates to a solid electrolyte device comprising an amorphous chalcogenide solid active electrolytic layer; first and second metallic layers. The amorphous chalcogenide solid active electrolytic layer is located between the first and second metallic layers. The amorphous chalcogenide solid active electrolytic layer is prepared by obtaining a solution of a hydrazine-based precursor to a metal chalcogenide; applying the solution onto a substrate; and thereafter annealing the precursor to convert the precursor to the amorphous metal chalcogenide. The present disclosure also relates to processes for fabricating the solid electrolyte device.Type: ApplicationFiled: July 30, 2007Publication date: December 25, 2008Applicant: International Business Machines CorporationInventors: Kailash Gopalakrishnan, David B. Mitzi, Rohit S. Shenoy
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Patent number: 7465379Abstract: An arrangement of one or more structural elements (3) in a cell lining, in particular for use as a side lining in aluminum electrolysis cells (5). The design of and choice of materials for side linings can be fitted in existing electrolysis cells, plus the design and production of the stated material is selected in view of the main purpose of the material, which is to utilize it for the purpose of energy recovery in electrolysis cells. Possible materials for use in the elements and production of these elements are disclosed.Type: GrantFiled: March 12, 2004Date of Patent: December 16, 2008Assignees: Cronus Energy AS, Norsk Hydro ASAInventor: Ole-Jacob Siljan
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Patent number: 6783656Abstract: 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.Type: GrantFiled: April 27, 2002Date of Patent: August 31, 2004Assignee: MoltechInvent S.A.Inventors: Vittorio De Nora, Jean-Jacques Duruz
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Patent number: 6692620Abstract: A drained cathode cell for the electrowinning of aluminium comprises a cell bottom (20) arranged to collect product aluminium and thermic insulating sidewalls (55,55′) lined with a molten electrolyte resistant sidewall lining (50) which is made of material liable to react with molten aluminium, in particular containing silicon carbide, silicon nitride or boron nitride. The thermic insulating sidewalls (55,55′) inhibit formation of an electrolyte crust on the lining (50), whereby the lining (50) is exposed to molten electrolyte. The cell bottom (20) has a peripheral surface from which the insulating sidewalls (55,55′) extend generally vertically to form, with the cell bottom, a trough for containing molten electrolyte and aluminium produced on at least one drained cathode (32).Type: GrantFiled: April 27, 2002Date of Patent: February 17, 2004Assignee: Moltech Invent S.A.Inventors: Jean-Jacques Duruz, Vittorio De Nora, Georges Berclaz
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Publication number: 20030221955Abstract: An aluminium-wettable protective coating on a substrate, for use at elevated temperature in an oxidising and/or corrosive gaseous and/or molten environment is disclosed. The coating (20A, 20B, 20C, 20D) is applied to protect the substrate (5, 15, 16) from liquid and/or gaseous attack. The coating comprises particles of at least one metal oxide and/or at least one partly oxidised metal in a dried and/or cured colloidal carrier and/or organic binder. The metal oxide and/or partly oxide metal is reactable with molten aluminium when exposed thereto to form an alumina matrix containing metal of said particles and aluminium. The coated substrate (5, 15, 16) may be used in an aluminium electrowinning cell an arc furnace for the recycling of steel or an apparatus for the purification of a molten metal such as aluminium, magnesium, iron or steel.Type: ApplicationFiled: June 3, 2002Publication date: December 4, 2003Inventors: Vittorio de Nora, Jean-Jacques Duruz
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Publication number: 20030209426Abstract: An aluminum production cell includes an inert anode and an insulating lid comprising alumina and at least one metal fluoride. The insulating lid preferably comprises about 35-90 wt. % of a mixture of sodium fluoride and aluminum fluoride and about 10-65 wt. % alumina.Type: ApplicationFiled: June 12, 2003Publication date: November 13, 2003Inventors: Michael L. Slaugenhaupt, Robert L. Kozarek
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Patent number: 6638412Abstract: A method of inhibiting dissolution of a transition metal alloy anode (40) of an aluminium electrowinning cell comprises providing a sodium-inert layer (11,20,50,50′) on a sodium-active cathodic cell material (15), such as carbon, and electrolysing alumina dissolved in a sodium ion-containing molten electrolyte (30). Aluminium ions rather than sodium ions are cathodically reduced on the sodium-inert layer to inhibit the presence in the molten electrolyte (30) of soluble cathodically-produced sodium metal that constitutes an agent for chemically reducing the anode's transition metal oxides and anodically evolved oxygen, thereby inhibiting reduction of the anode's transition metal oxides by sodium metal and maintaining the evolved oxygen at the anode at a concentration such as to produce at the alloy/oxide layer interface stable and coherent transition metal oxides having a high level of oxidation.Type: GrantFiled: March 30, 2002Date of Patent: October 28, 2003Assignee: Moltech Invent S.A.Inventors: Vittorio De Nora, Jean-Jacques Duruz
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Publication number: 20030102228Abstract: A cell of advanced design for the production of aluminium by the electrolysis of an aluminium compound dissolved in a molten electrolyte, has a cathode (30) of drained configuration, and at least one non-carbon anode (10) facing the cathode both covered by the electrolyte (54). The upper part of the cell contains a removable thermic insulating cover (60) placed just above the level of the electrolyte (54). Preferably, the cathode (30) comprises a cathode mass (32) supported by a cathode carrier (31) made of electrically conductive material which serves also for the uniform distribution of electric current to the cathode mass (32) from current feeders (42) which connect the cathode carrier (31) to the negative busbars.Type: ApplicationFiled: June 4, 2002Publication date: June 5, 2003Inventors: Vittorio de Nora, Jainagesh A. Sekhar
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Patent number: 6558525Abstract: 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.Type: GrantFiled: March 1, 2002Date of Patent: May 6, 2003Assignee: Northwest Aluminum TechnologiesInventors: Donald R. Bradford, Robert J. Barnett, Michael B. Mezner
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Publication number: 20030070937Abstract: A cell for the electrowinning of aluminium comprising one or more anodes (10), each having a metal-based anode substrate, for instance comprising a metal core (11) covered with an metal layer 12, an oxygen barrier layer (13), one or more intermediate layers (14; 14A, 14B) and an iron layer (15). The anode substrate is covered with an electrochemically active transition metal oxide layer, in particular an iron oxide-based outside layer (16) such as a hematite-based layer, which remains dimensionally stable during operation in a cell by maintaining in the electrolyte a sufficient concentration of iron species and dissolved alumina. The cell operating temperature is sufficiently low so that the required concentration of iron species in the electrolyte (5) is limited by the reduced solubility of iron species in the electrolyte at the operating temperature, which consequently limits the contamination of the product aluminium by iron to an acceptable level.Type: ApplicationFiled: November 25, 2002Publication date: April 17, 2003Inventors: Jean-Jacques Duruz, Vittorio De Nora, Olivier Crottaz
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Patent number: 6540887Abstract: A cell for the electrowinning of aluminium 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).Type: GrantFiled: July 2, 2001Date of Patent: April 1, 2003Assignee: Moltech Invent SAInventor: Vittorio de Nora
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Patent number: 6537438Abstract: The present invention is directed to methods for applying a protective layer (42) to the cathode (40) of an electrolysis cell (10), where the cell also contains inert anodes (50) and the protective layer (42) can comprise a plurality of layers (70, 72, 74) with an inner layer (70) of TiB2 being preferred, and the protective layer (42) protects the cathode (40)from hot gases (64) used to pre-heat the cell (10).Type: GrantFiled: August 27, 2001Date of Patent: March 25, 2003Assignee: Alcoa Inc.Inventor: Roy A. Christini
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Patent number: 6533909Abstract: A bipolar cell for the electrowinning of aluminium has bipolar electrodes each comprising a carbon cathode body having on one side an active surface on which aluminium is produced and connected on the other side through an oxygen impermeable barrier layer to an electrochemically active anode layer having an oxygen evolving iron oxide-based outer surface. The anode layer may comprise a metal-based anode substrate and a transition metal oxide-based outside layer, in particular an iron oxide-based outside layer, which either is an applied layer or is obtainable by oxidising the surface of the anode substrate which contains iron. During operation, the anode layer can be kept dimensionally stable by maintaining in the electrolyte a concentration of transition metal species which are present as one or more corresponding transition metal oxides in the electrochemically-active layer.Type: GrantFiled: January 29, 2001Date of Patent: March 18, 2003Assignee: Moltech Invent S.A.Inventors: Jean-Jacques Duruz, Vittorio de Nora
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Publication number: 20030010628Abstract: 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.Type: ApplicationFiled: April 27, 2002Publication date: January 16, 2003Inventors: Vittorio De Nora, Jean-Jacques Duruz
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Patent number: 6475358Abstract: A method of treating a carbonaceous cell component of an electrolyte cell for the production of aluminum, to impart protection against deterioration during operation of the cell. A liquid suspension of a refractory material dispersed in a lignosulfonate binder solution is prepared and applied as a protective coating to the surface of carbonaceous cell components and allowed to dry.Type: GrantFiled: February 6, 2001Date of Patent: November 5, 2002Assignee: Alcan International LimitedInventors: Amir A. Mirtchi, Jules Bergeron
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Patent number: 6436250Abstract: A refractory boride body or coating made of a boride of titanium, chromium, vanadium, ziconium, hafnium, niobium, tantalum, molybednum and cerium is produced from a slurry of the refractory boride or a precursor in a collidal carrier preferably composed of two more different grades of the same colloidal carrier selected from colloidal alumina, yttria, ceria, thoria, zirconia, magnesia, lithia, monoaluminum phosphate and cerium acetate. The slurry can also comprise an organic additive selected from polyvinyl alcohol; polyacrylic acid; hydroxyy propyl methyl cellulose; polythylene glycol; ethylene glycol, butyl benzyl phthalate; ammonium polymethacrylate and mixtures thereof. The retractory boride body or coated body is useful as a component of aluminum electrowinning cells.Type: GrantFiled: June 10, 1999Date of Patent: August 20, 2002Assignee: Moltech Invent S.A.Inventors: Jainagesh Akkaraju Sekhar, Jean-Jacques Duruz, James Jeng Liu
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Patent number: 6436272Abstract: 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.Type: GrantFiled: October 4, 2000Date of Patent: August 20, 2002Assignee: Northwest Aluminum TechnologiesInventors: Craig W. Brown, Patrick B. Frizzle
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Patent number: 6358393Abstract: A cell for the production of aluminium by the electrolysis of an aluminium compound dissolved in a molten electrolyte, in which an outer mechanical structure forming an outer shell (21) houses therein one or more inner electrically-conductive cathode holder shells or plates (31) which contain a cathode mass (32) and is/are connected electrically to the busbar. The cathode mass (32) has an aluminium-wettable top surface (37), preferably at a slope forming a drained cathode. The inner cathode holder shell or shells (31) is/are separated from the outer shell (21) by an electric and thermic insulation (40), the cathode holder shell(s) (31) also serving to distribute current uniformly to the cathode mass (32). The or each cathode (30) formed by the cathode holder shell (31) and cathode mass (32) is removable from the cell as a unit.Type: GrantFiled: March 30, 2000Date of Patent: March 19, 2002Assignee: Moltech Invent S.A.Inventors: Georges Berclaz, Vittorio de Nora
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Patent number: 6258246Abstract: A drained cathode cell for the electrowinning of aluminium comprises a cell bottom (20) arranged to collect product aluminium and thermic insulating sidewalls (40) lined with a molten electrolyte resistant sidewall lining (50), in particular containing silicon carbide, silicon nitride or boron nitride. The thermic insulating sidewalls (40) inhibit formation of an electrolyte crust on the lining (50), whereby the lining (50) is exposed to molten electrolyte. The cell bottom (20) has a peripheral zone from which the insulating sidewalls (40) extend generally vertically to form, with the cell bottom, a trough for containing molten electrolyte and aluminium produced on at least one drained cathode (32). The peripheral zone of the cell bottom (20) is arranged to keep the product aluminium from contacting and reacting with the molten electrolyte resistant sidewall lining 50).Type: GrantFiled: November 1, 1999Date of Patent: July 10, 2001Assignee: Moltech Invent S.A.Inventors: Jean-Jacques Duruz, Vittorio de Nora, Georges Berclaz
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Patent number: 6251237Abstract: An electrolytic pot for the production of aluminum by the Hall-Héroult electrolysis process includes a cooling device for blowing air with localized jets, advantageously with variable flow, in order to evacuate and dissipate thermal energy from the pot. An aluminum production plant using the Hall-Héroult electrolysis process has at least some pots which, either individually or in common, include at least one cooling device.Type: GrantFiled: November 18, 1999Date of Patent: June 26, 2001Assignee: Aluminium PechineyInventors: Jerome Bos, Benoit Feve, Pierre Homsi
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Patent number: 6245201Abstract: The aluminum smelting from alumina in the Hall-Heroult cells can be dramatically improved by using one or a combination of the following features together or in alternative to the Bayer alumina as feedstock: Al+++ alumina, sawtooth shaped electrodes, and lower temperatures. Laboratory experiments have shown that higher rates of dissolution of the Al+++ alumina in molten fluoride baths combined with lower voltage drops and improved design of electrodes can allow the operation of the cells at even higher current density, thus increasing overall productivity and efficiency of the cells.Type: GrantFiled: August 3, 1999Date of Patent: June 12, 2001Inventor: John S. Rendall