Coated Electrode Patents (Class 205/384)
  • Patent number: 9978268
    Abstract: Traffic information is provided to an in-vehicle unit of a vehicle located in a shadow portion of a large-sized vehicle and to an in-vehicle unit of a vehicle at a location separated from an intersection 193. A UHF beacon unit 112 is installed at the intersection 193, thereby distributing the traffic information using a UHF beacon signal having a diffraction characteristic. The UHF beacon unit 112 transmits, to a plurality of concentric zones, UHF beacon signals with different traffic information set therein for the different zones, by time division. At this time, the UHF beacon unit 112 transmits the UHF beacon signals with the different traffic information set therein, with different transmission output powers.
    Type: Grant
    Filed: January 15, 2016
    Date of Patent: May 22, 2018
    Assignee: Mitsubishi Electric Corporation
    Inventor: Yoshiaki Tsuda
  • Patent number: 8480876
    Abstract: Low temperature cell for electrolytic production of aluminum.
    Type: Grant
    Filed: December 26, 2007
    Date of Patent: July 9, 2013
    Inventor: Theodore R. Beck
  • Patent number: 7976688
    Abstract: Method for manufacturing anodes used for the production of aluminium by fused bath electrolysis, said anodes comprising an anode stem made of a conducting metal and at least one block made of carbonaceous material called an anode block, said method including at least the following steps: a) obtain an anode stem; b) obtain a new anode block; c) fix one end of the anode stem onto the anode block, so as to give good mechanical attachment and good electrical connection between said stem and said anode block; said method being characterised in that before, during or after step c), but before placement of said anode in the electrolytic cell, a protective layer with a controlled thickness, typically between 5 and 25 cm composed of a material resistant to temperature and corrosion by the medium above the electrolytic bath is at least partially deposited on the upper surface of said anode block.
    Type: Grant
    Filed: May 10, 2007
    Date of Patent: July 12, 2011
    Assignee: E.C.L.
    Inventors: Ludovic Demeulenaere, Alain Van Acker, Didier Lescarcelle
  • Patent number: 7846308
    Abstract: An anode for electrowinning of aluminium from alumina comprises a cobalt-containing metallic outer part that is covered with an integral oxide layer containing predominantly cobalt oxide CoO. The integral oxide layer can be formed by surface oxidation of cobalt from the metallic outer part before use.
    Type: Grant
    Filed: March 18, 2005
    Date of Patent: December 7, 2010
    Assignee: Riotinto Alcan International Limited
    Inventors: Vittorio De Nora, Thinh T. Nguyen
  • Patent number: 7811425
    Abstract: An anode for electrowinning aluminium comprises an electrically conductive substrate that is covered with an applied electrochemically active coating comprising a layer that contains predominantly cobalt oxide CoO. The CoO layer can be connected to the substrate through an oxygen barrier layer, in particular containing copper, nickel, tungsten, molybdenum, tantalum and/or niobium.
    Type: Grant
    Filed: March 18, 2005
    Date of Patent: October 12, 2010
    Assignee: Moltech Invent S.A.
    Inventors: Vittorio De Nora, Thinh T. Nguyen
  • Patent number: 7740745
    Abstract: A cell for electrowinning aluminium from alumina, comprises: a metal-based anode having an electrochemically active outer part comprising a layer that contains predominantly cobalt oxide CoO; and a fluoride-containing molten electrolyte in which the active anode surface is immersed. The electrolyte is at a temperature below 950° C., in particular in the range from 910° to 940° C. The electrolyte consists of: 6.5 to 11 weight. % dissolved alumina; 35 to 44 weight % aluminium fluoride; 38 to 46 weight % sodium fluoride; 2 to 15 weight % potassium fluoride; 0 to 5 weight % calcium fluoride; and 0 to 5 weight % in total of one or more further constituents.
    Type: Grant
    Filed: March 18, 2005
    Date of Patent: June 22, 2010
    Assignee: Moltech Invent S.A.
    Inventors: Thinh T. Nguyen, Vittorio De Nora
  • Publication number: 20090250355
    Abstract: Method for manufacturing anodes used for the production of aluminium by fused bath electrolysis, said anodes comprising an anode stem made of a conducting metal and at least one block made of carbonaceous material called an anode block, said method including at least the following steps: a) obtain an anode stem; b) obtain a new anode block; c) fix one end of the anode stem onto the anode block, so as to give good mechanical attachment and good electrical connection between said stem and said anode block; said method being characterised in that before, during or after step c), but before placement of said anode in the electrolytic cell, a protective layer with a controlled thickness, typically between 5 and 25 cm composed of a material resistant to temperature and corrosion by the medium above the electrolytic bath is at least partially deposited on the upper surface of said anode block.
    Type: Application
    Filed: May 10, 2007
    Publication date: October 8, 2009
    Applicant: E.C.L.
    Inventors: Ludovic Demeulenaere, Alain Van Acker, Didier Lescarcelle
  • Publication number: 20090166215
    Abstract: Low temperature cell for electrolytic production of aluminum.
    Type: Application
    Filed: December 26, 2007
    Publication date: July 2, 2009
    Inventor: Theodore R. Beck
  • Patent number: 7431812
    Abstract: An anode for the electrowinning of aluminium by the electrolysis of alumina in a molten fluoride electrolyte has an electrochemically active integral outside oxide layer obtainable by surface oxidation of a metal alloy which consists of 20 to 60 weight % nickel; 5 to 15 weight % copper; 1.5 to 5 weight % aluminium; 0 to 2 weight % in total of one or more rare earth metals, in particular yttrium; 0 to 2 weight % of further elements, in particular manganese, silicon and carbon; and the balance being iron. The metal alloy of the anode has a copper/nickel weight ratio in the range of 0.1 to 0.5, preferably 0.2 to 0.3.
    Type: Grant
    Filed: March 12, 2003
    Date of Patent: October 7, 2008
    Assignee: Moitech Invent S.A.
    Inventors: Thinh T. Nguyen, Vittorio De Nora
  • Publication number: 20080237058
    Abstract: A method for producing aluminum and a method for producing a graphite electrode for a carbothermic reduction furnace, in which aluminum is produced by carbothermic reduction of alumina, render the graphite electrode substantially gas-impermeable. The graphite electrode is consumed during furnace operation and electrode columns connected by graphite pins are fed continuously fed in from the top into the furnace. The coating of the electrode withstands a temperature of up to 300° C. and more over a period of several hours without oxidation. Since the coating enters the furnace compartment at least partially, it is configured so that it will not contaminate the hot melt. That is, the chemistry of the coating materials is similar to the ingredients of the overall reaction or, at a minimum, the amount of foreign elements is very low. The coating is provided so that it does not increase the electrical contact resistance at the connection between the electrode columns and the electrode holding clamps.
    Type: Application
    Filed: June 9, 2008
    Publication date: October 2, 2008
    Applicant: SGL Carbon AG
    Inventor: Johann Daimer
  • Patent number: 7353185
    Abstract: An ETC system for a toll road includes a road-side device. The road-side device transmitting a polling signal. The road-side device receives a response of an on-vehicle device to the transmitted polling signal. A decision is made as to whether or not the response is received a plural number of times. In cases where it is decided that the response is received a plural number of times, next radio communications with the on-vehicle device are started.
    Type: Grant
    Filed: May 25, 2001
    Date of Patent: April 1, 2008
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventor: Seiji Fuyama
  • Patent number: 7255894
    Abstract: A method of manufacturing a component, in particular an aluminium electrowinning anode, for use at elevated temperature in an oxidising and/or corrosive environment comprises: applying onto a metal-based substrate layers of a particle mixture containing iron oxide particles and particles of a reactant-oxide selected from titanium, yttrium, ytterbium and tantalum oxides; and heat treating the applied layers to consolidate by reactive sintering of the iron oxide particles and the reactant-oxide particles to turn the applied layer into a protective coating made of a substantially continuous reacted oxide matrix of one or more multiple oxides of iron and the metal from the reactant-oxide. The metal-based substrate comprises at its surface during the heat treatment an integral anchorage-oxide of at least one metal of the substrate.
    Type: Grant
    Filed: April 15, 2003
    Date of Patent: August 14, 2007
    Assignee: Moltech Invent S.A.
    Inventors: Thinh T. Nguyen, Vittorio De Nora
  • Patent number: 7255893
    Abstract: A method of forming a dense and crack-free hematite-containing protective layer on a metal-based substrate for use in a high temperature oxidising and/or corrosive environment comprises applying onto the substrate a particle mixture consisting of: 60 to 99 95 weight %, in particular 70 to 95 weight % such as 75 to 85 weight %, of hematite with or without iron metal and/or ferrous oxide; 1 to 25 weight %, in particular 5 8 to 20 weight % such as 8 to 15 weight %, of nitride and/or carbide particles, such as boron nitride, aluminium nitride or zirconium carbide particles; and 0 to 15 weight %, in particular 5 to 15 weight %, of one or more further constituents that consist of at least one metal or metal oxide or a heat-convertible precursor thereof.
    Type: Grant
    Filed: September 9, 2003
    Date of Patent: August 14, 2007
    Assignee: Moltech Invent S.A.
    Inventors: Thinh T. Nguyen, Vittorio De Nora
  • Patent number: 7141148
    Abstract: A material suitable for use as the active anode surface in the electrolytic reduction of alumina to aluminium metal defined by the formula: A1+xB1+?CdO4 where A is a divalent cation or a mixture of cations with a relative preference for octahedral coordination, B is a trivalent cation or mixture of cations with a relative preference for tetrahedral coordination, C is a trivalent cations with a relative preference for octahedral coordination or a four-valent cation with a relative preference for octahedral coordination, O is the element oxygen: When C is trivalent x=0, 0.8<d<1, ?<0.2 and x+d+d is essentially equal to 1. When C is four-valent 0.4<x<0.6, 0.4<d<0.6, ?<0.2 and x+d+? is essentially equal to 1.
    Type: Grant
    Filed: February 13, 2002
    Date of Patent: November 28, 2006
    Assignee: Norsk Hydro ASA
    Inventors: Stein Julsrud, Turid Risdal
  • Patent number: 7118666
    Abstract: A method for protecting anode assemblies in an electrolytic cell from thermal shock is disclosed. The method generally involves applying a thermal insulating layer (8, 16) to the anode (2) prior to preheating the anode assembly in a furnace, where the layer (8, 16) protects the anode (2) from thermal shock during transfer from the preheat furnace to the electrolytic cell. In a preferred embodiment the anode (2) is attached to a castable plate (4) that is also protected from thermal shock by an insulating layer.
    Type: Grant
    Filed: February 25, 2003
    Date of Patent: October 10, 2006
    Assignee: Alcoa Inc.
    Inventors: Alfred F. LaCamera, Leroy E. D'Astolfo, James T. Burg
  • Patent number: 6998032
    Abstract: An anode of a cell for the electrowinning of aluminium comprises a nickel-iron alloy substrate having a nickel metal rich outer portion with an electrolyte pervious integral nickel-iron oxide containing surface layer which adheres to the nickel metal rich outer portion of the nickel-iron alloy and which in use is electrochemically active for the evolution of oxygen. The oxide surface layer has a thickness such that, during use, the voltage drop therethrough is below the potential of dissolution of nickel-iron oxide. The nickel metal rich outer portion may contain cavities some or all of which, after oxidation, are partly or completely filled with iron oxides to form iron oxide containing inclusions.
    Type: Grant
    Filed: June 3, 2002
    Date of Patent: February 14, 2006
    Assignee: Moltech Invent S.A.
    Inventors: Vittorio De Nora, Jean-Jacques Duruz
  • Patent number: 6913682
    Abstract: 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: Grant
    Filed: November 25, 2002
    Date of Patent: July 5, 2005
    Assignee: Moltech Invent S.A.
    Inventors: Jean-Jacques Duruz, Vittorio de Nora, Olivier Crottaz
  • Patent number: 6878247
    Abstract: An anode of a cell for the electrowinning of aluminium comprises a nickel-iron alloy substrate having an openly porous nickel metal rich outer portion whose surface is electrochemically active. The outer portion is optionally covered with an external integral nickel-iron oxide containing surface layer which adheres to the nickel metal rich outer portion of the nickel-iron alloy and which in use is pervious to molten electrolyte. During use, the nickel metal rich outer portion contains cavities some or all of which are partly or completely filled with iron and nickel compounds, in particular oxides, fluorides and oxyfluorides.
    Type: Grant
    Filed: June 3, 2002
    Date of Patent: April 12, 2005
    Assignee: Moltech Invent S.A.
    Inventors: Jean-Jacques Duruz, Thinh T. Nguyen, Vittorio De Nora
  • Patent number: 6855234
    Abstract: A sintered electrode assembly is made of an inert electrode (15) containing a sealed metal conductor (20) having a surface feature (30) such as a coating or wrapping which aids in bond formation with the inert electrode (15) at their interface (45), where the metal conductor (20) is directly contacted by and is substantially surrounded by the inert electrode (15) without the use of metal foam or metal powders.
    Type: Grant
    Filed: April 2, 2003
    Date of Patent: February 15, 2005
    Assignee: Alcoa Inc.
    Inventor: Leroy E. D'Astolfo, Jr.
  • Publication number: 20040216995
    Abstract: An anode of a cell for the electrowinning of aluminium has a nickel-iron alloy outer portion which during use is covered with an integral iron-based oxide surface layer. The nickel-iron alloy outer portion comprises one or more rare earth metals that are substantially insoluble in nickel and iron. These rare earth metals are present in the outer portion in an amount which provides during use controlled diffusion of iron from the outer portion to the integral iron-based oxide surface layer.
    Type: Application
    Filed: June 15, 2004
    Publication date: November 4, 2004
    Inventors: Thinh T Nguyen, Vittorio De Nora
  • Patent number: 6800192
    Abstract: 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 iron oxide-based outside layer (16), in particular a hematite-based layer, which remains dimensionally stable during operation in a cell by maintaining in the electrolyte a sufficient concentration of iron species. 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: Grant
    Filed: November 28, 2001
    Date of Patent: October 5, 2004
    Assignee: Moltech Invent S.A.
    Inventors: Jean-Jacques Duruz, Vittorio de Nora
  • Publication number: 20040144642
    Abstract: A cell for the electrowinning of aluminium comprises a horizontal carbon cathode bottom (11) having an aluminium-wettable surface coating (25) and a series of plates (21) made of aluminium-wettable reticulated porous material, typically foams, filled with aluminium and placed flat on the aluminium-wettable surface coating (25). During use, a thin bottom layer of aluminium (22) wets the aluminium-wettable surface coating (25) on top of the cathode bottom (11) and a bottom part of the porous aluminium-filled plates (21). A top layer of aluminium (23) is formed above the porous aluminium-filled plates (21). The cell may be operated with metal anodes (10) possibly protected with a cerium oxyfluoride coating when operated above about 910°-930° C.
    Type: Application
    Filed: March 1, 2004
    Publication date: July 29, 2004
    Inventor: Vittorio De Nora
  • Patent number: 6692620
    Abstract: 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: Grant
    Filed: April 27, 2002
    Date of Patent: February 17, 2004
    Assignee: Moltech Invent S.A.
    Inventors: Jean-Jacques Duruz, Vittorio De Nora, Georges Berclaz
  • Patent number: 6638412
    Abstract: 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: Grant
    Filed: March 30, 2002
    Date of Patent: October 28, 2003
    Assignee: Moltech Invent S.A.
    Inventors: Vittorio De Nora, Jean-Jacques Duruz
  • Patent number: 6607657
    Abstract: Carbon-containing components of cells for the production of aluminium by the electrolysis of alumina dissolved in a cryolite-based molten electrolyte are protected from attack by liquid and/or gaseous components of the electrolyte in the form of elements, ions or compounds, by a refractory boride coating applied from a slurry composed of pre-formed particulate refractory boride in a colloidal carrier which is dried and heated to consolidate the coating.
    Type: Grant
    Filed: July 25, 2001
    Date of Patent: August 19, 2003
    Assignee: Moltech Invent S.A.
    Inventors: Vittorio de Nora, Jainagesh A. Sekhar
  • Publication number: 20030127339
    Abstract: A method for protecting anode assemblies in an electrolytic cell from thermal shock is disclosed. The method generally involves applying a thermal insulating layer (8, 16) to the anode (2) prior to preheating the anode assembly in a furnace, where the layer (8, 16) protects the anode (2) from thermal shock during transfer from the preheat furnace to the electrolytic cell. In a preferred embodiment the anode (2) is attached to a castable plate (4) that is also protected from thermal shock by an insulating layer.
    Type: Application
    Filed: February 25, 2003
    Publication date: July 10, 2003
    Inventors: Alfred F. LaCamera, Leroy E. D'Astolfo, James T. Burg
  • Publication number: 20030106803
    Abstract: 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: Application
    Filed: June 27, 2002
    Publication date: June 12, 2003
    Inventors: Jainagesh Akkaraju Sekhar, Jean-Jacques Duruz, James Jeng Liu
  • Publication number: 20030102228
    Abstract: 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: Application
    Filed: June 4, 2002
    Publication date: June 5, 2003
    Inventors: Vittorio de Nora, Jainagesh A. Sekhar
  • Patent number: 6562224
    Abstract: A method of manufacturing an anode for use in a cell for the electrowinning of aluminium comprises oxidising before cell operation an iron-nickel alloy substrate in an oxygen-containing atmosphere, such as air, at a temperature which is at least 50° C., preferably 100° C., above the operating temperature of the cell to form on the surface of the iron-nickel substrate a coherent and adherent iron oxide-containing outer layer, in particular a hematite-containing layer having a limited ionic conductivity for oxygen ions and acting as a partial barrier to monoatomic oxygen. The outer layer is electrochemically active for the oxidation of oxygen ions and reduces also diffusion of oxygen to the iron-nickel alloy substrate when the anode is in use.
    Type: Grant
    Filed: January 29, 2001
    Date of Patent: May 13, 2003
    Assignee: Moltech Invent S.A.
    Inventors: Olivier Crottaz, Jean-Jacques Duruz
  • Publication number: 20030075454
    Abstract: 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: Application
    Filed: March 30, 2002
    Publication date: April 24, 2003
    Inventors: Vittorio De Nora, Jean-Jacques Duruz
  • Patent number: 6533909
    Abstract: 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: Grant
    Filed: January 29, 2001
    Date of Patent: March 18, 2003
    Assignee: Moltech Invent S.A.
    Inventors: Jean-Jacques Duruz, Vittorio de Nora
  • Publication number: 20030038039
    Abstract: A method for protecting anode assemblies in an electrolytic cell from thermal shock is disclosed. The method generally involves applying a thermal insulating layer (8, 16) to the anode (2) and the castable plate (4) prior to preheating the anode assembly in a furnace, where the layer (8, 16) protects the anode (2) and the plate (4) from thermal shock during transfer from the preheat furnace to the electrolytic cell.
    Type: Application
    Filed: August 27, 2001
    Publication date: February 27, 2003
    Inventors: Alfred F. LaCamera, Leroy E. D'Astolfo, James T. Burg
  • Patent number: 6521116
    Abstract: 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 species and dissolved alumina.
    Type: Grant
    Filed: January 29, 2001
    Date of Patent: February 18, 2003
    Assignee: Moltech Invent S.A.
    Inventors: Jean-Jacques Duruz, Vittorio de Nora, Olivier Crottaz
  • Patent number: 6521115
    Abstract: An anode of a cell for the electrowinning of aluminium comprises an iron-nickel alloy body or layer whose surface is oxidised to form a coherent and adherent outer iron oxide-based layer, in particular hematite, the surface of which is electrochemically active for the oxidation of oxygen ions and which reduces diffusion of oxygen from the electrochemically active surface into the iron-nickel alloy body or layer. The anode may be kept dimensionally stable during cell operation by maintaining a sufficient amount of dissolved alumina and iron species in the electrolyte to prevent dissolution of the outer oxide layer of the or each anode and by reducing the electrolyte operating temperature to limit dissolution of iron and by reducing the electrolyte operating temperature to limit dissolution of iron species in the electrolyte.
    Type: Grant
    Filed: January 29, 2001
    Date of Patent: February 18, 2003
    Assignee: Moltech Invent S. A.
    Inventors: Jean-Jacques Duruz, Vittorio de Nora, Olivier Crottaz
  • Publication number: 20020195350
    Abstract: The present invention is directed to methods for preheating a molten salt electrolysis cell having inert anodes (24) using recuperative gas heating by combusting a first gas outside the cell chamber (20) in a combustion chamber (2) and using to heat a second gas in recuperator (8) which second gas us passed to the cell chamber (20). The inert anode can be a cermet inert anode.
    Type: Application
    Filed: June 25, 2001
    Publication date: December 26, 2002
    Inventor: Roy A. Christini
  • Patent number: 6485628
    Abstract: An electrolytic bath for use during the electrolytic reduction of alumina to aluminum. The bath comprises a molten electrolyte having the following ingredients: (a) AlF3 and at least one salt selected from the group consisting of NaF, KF, and LiF; and (b) about 0.004 wt. % to about 0.2 wt. %, based on total weight of the molten electrolyte, of at least one transition metal or at least one compound of the metal or both. The compound may be, for example, a fluoride, oxide, or carbonate. The metal can be nickel, iron, copper, cobalt, or molybdenum. The bath can be employed in a combination that includes a vessel for containing the bath and at least one non-consumable anode and at least one dimensionally stable cathode in the bath. Employing the bath of the present invention during electrolytic reduction of alumina to aluminum can improve the wetting of aluminum on a cathode by reducing or eliminating the formation of non-metallic deposits on the cathode.
    Type: Grant
    Filed: November 25, 2000
    Date of Patent: November 26, 2002
    Assignee: Northwest Aluminum Technology
    Inventors: Craig W. Brown, Richard J. Brooks, Patrick B. Frizzle, Drago D. Juric
  • Patent number: 6475358
    Abstract: 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: Grant
    Filed: February 6, 2001
    Date of Patent: November 5, 2002
    Assignee: Alcan International Limited
    Inventors: Amir A. Mirtchi, Jules Bergeron
  • Patent number: 6447667
    Abstract: A cermet anode of an electrolytic cell is protected from thermal shock during cell start-up by coating an outer surface portion of the anode with a coating composition comprising carbon or aluminum or a mixture thereof. A particularly preferred coating composition includes an aluminum underlayer adjacent the outer surface portion of the anode, and a carbon overlayer overlying the underlayer. A support structure assembly supporting the cermet anode includes a high alumina ceramic material. In a preferred embodiment, the high alumina ceramic material is protected from thermal shock and corrosion by the coating composition of the invention.
    Type: Grant
    Filed: January 18, 2001
    Date of Patent: September 10, 2002
    Assignee: Alcoa Inc.
    Inventors: Calvin Bates, Patricia A. Stewart, Larry F. Wieserman
  • Patent number: 6436274
    Abstract: A non-carbon, metal-based slow-consumable anode of a cell for the electrowinning of aluminium self-forms during normal electrolysis an electrochemically-active oxide-based surface layer (20). The rate of formation (35) of the layer (20) is substantially equal to its rate of dissolution (30) at the surface layer/electrolyte interface (25) thereby maintaining its thickness substantially constant, forming a limited barrier controlling the oxidation rate (35). The anode (10) usually comprises an alloy of iron with at least one of nickel, copper, cobalt or zinc which during use forms an oxide surface layer (20) mainly containing ferrite.
    Type: Grant
    Filed: December 1, 2000
    Date of Patent: August 20, 2002
    Inventors: Vittorio De Nora, Jean-Jacques Duruz
  • Patent number: 6425992
    Abstract: A non-carbon, metal-based, high temperature resistant, electrically conductive and electrochemically active anode of a cell for the production of aluminum has a metal-based oxidation-resistant substrate to which an adherent multi-layer coating is applied prior to its immersion into the electrolyte and start up of the electrolysis by connection to the positive current supply. The multi-layer coating is obtainable from one or more applied layers selected from: a liquid solution, a dispersion in a liquid or a paste, a suspension in a liquid or a paste, and a pasty or non-pasty slurry, and combinations thereof, with or without heat treatment between two consecutively applied layers. At least one layer of the multi-layer coating contains a polymeric and/or a colloidal carrier. The coating is after final heat treatment electrically conductive and has during operation in the cell an electrochemically active surface for the oxidation of oxygen ions present at the surface of the anode.
    Type: Grant
    Filed: July 15, 2000
    Date of Patent: July 30, 2002
    Assignee: Moltech Invent S.A.
    Inventor: Vittorio de Nora
  • Publication number: 20020092774
    Abstract: A cermet anode of an electrolytic cell is protected from thermal shock during cell start-up by coating an outer surface portion of the anode with a coating composition comprising carbon or aluminum or a mixture thereof. A particularly preferred coating composition includes an aluminum underlayer adjacent the outer surface portion of the anode, and a carbon overlayer overlying the underlayer. A support structure assembly supporting the cermet anode includes a high alumina ceramic material. In a preferred embodiment, the high alumina ceramic material is protected from thermal shock and corrosion by the coating composition of the invention.
    Type: Application
    Filed: January 18, 2001
    Publication date: July 18, 2002
    Inventors: Calvin Bates, Patricia A. Stewart, Larry F. Wieserman
  • Patent number: 6416649
    Abstract: A method of producing commercial purity aluminum in an electrolytic reduction cell comprising ceramic inert anodes is disclosed. The method produces aluminum having acceptable levels of Fe, Cu and Ni impurities. The ceramic inert anodes used in the process may comprise oxides containing Fe and Ni, as well as other oxides, metals and/or dopants.
    Type: Grant
    Filed: April 16, 2001
    Date of Patent: July 9, 2002
    Assignee: Alcoa Inc.
    Inventors: Siba P. Ray, Xinghua Liu, Douglas A. Weirauch, Robert A. DiMilia, Joseph M. Dynys, Frankie E. Phelps, Alfred F. LaCamera
  • Patent number: 6413406
    Abstract: A non-carbon, metal-based high temperature resistant anode of a cell for the production of aluminum has a highly conductive metal-based substrate coated with one or more electrically conductive adherent intermediate protective layers and an outer layer which is electrically conductive and electrochemically active. The electrochemically active layer contains one or more electrocatalysts fostering the oxidation of oxygen ions as well as fostering the formation of biatomic molecular gaseous oxygen from the monoatomicnascent oxygen obtained by the oxidation of the oxygen ions present at the surface of the anode in order to inhibit ionic and/or monoatomic oxygen penetration. The intermediate layer(s) constitute(s) a substantially impermeable barrier to ionic, monoatomic and/or biatomic gaseous oxygen to prevent attack of the metal-based substrate. The electrocatalyst can be iridium, palladium, platinum, rhodium, ruthenium, silicon, tin, zinc, Mischmetal oxides and metals of the Lanthanide series.
    Type: Grant
    Filed: July 15, 2000
    Date of Patent: July 2, 2002
    Assignee: Moltech Invent S.A.
    Inventor: Vittorio de Nora
  • Patent number: 6402926
    Abstract: An adherent protective coating of a refractory material is produced on the surface of carbonaceous, refractory, ceramic, metallic or other materials serving as components of electrolytic cells operating at high temperature, by applying to such surfaces a well chosen micropyretic reaction layer from a slurry, which when dried is ignited to initiate a self-sustaining micropyretic reaction, along a combustion front, to produce condensed matter forming such refractory protective adherent coating. The slurry is preferably applied in several layers, the first layer(s) to facilitate adherence and the last layer(s) to provide protection, and may contain some preformed non-reactant materials. The electrolytic cells whose components require such coatings are especially those operating at high temperature with a molten salt electrolyte, particularly those for the production of metals, aluminium being the most important.
    Type: Grant
    Filed: June 17, 1996
    Date of Patent: June 11, 2002
    Assignee: Moltech Invent S.A.
    Inventors: Jaihagesh A. Sekhar, Vittorio de Nora
  • Patent number: 6379526
    Abstract: A non-carbon metal-based anode of a cell for the electrowinning of aluminium comprising an electrically conductive metal substrate resistant to high temperature, the surface of which becomes passive and substantially inert to the electrolyte, and a coating adherent to the metal substrate making the surface of the anode electrochemically active for the oxidation of oxygen ions present at the electrolyte interface. The substrate metal may be selected from nickel, cobalt, chromium, molybdenum, tantalum and the Lanthanide series. The active constituents of the coating are for example oxides such as spinels or perovskites, oxyfluorides, phosphides or carbides, in particular ferrites. The active constituents may be coated onto the substrate from a slurry or suspension containing colloidal material and the electrochemically active material.
    Type: Grant
    Filed: July 15, 2000
    Date of Patent: April 30, 2002
    Assignee: Moltech Invent SA
    Inventors: Vittorio de Nora, Jean-Jacques Duruz
  • Publication number: 20020043469
    Abstract: Carbon-containing components of cells for the production of aluminium by the electrolysis of alumina dissolved in a cryolite-based molten electrolyte are protected from attack by liquid and/or gaseous components of the electrolyte in the form of elements, ions or compounds, by a refractory boride coating applied from a slurry composed of pre-formed particulate refractory boride in a colloidal carrier which is dried and heated to consolidate the coating.
    Type: Application
    Filed: July 25, 2001
    Publication date: April 18, 2002
    Inventors: Vittorio de Nora, Jainagesh A. Sekhar
  • Patent number: 6361681
    Abstract: A method of coating an electronically conductive and heat resistant substrate of an anode of a cell for the electrowinning of metals, in particular a cell for the electrowinning of aluminium, to protect and make the surface of the anode active for the oxidation of the oxygen ions present in the electrolyte. The method comprises applying onto the substrate a slurry comprising at least one oxide or oxide precursor as a non-dispersed but suspended particulate in a colloidal and/or inorganic polymeric carrier. The applied-slurry is then solidified and made adherent to the substrate upon heat treatment to form an adherent, protective, predominantly oxide-containing coating. The colloidal and/or inorganic polymeric carrier may comprise at least one of alumina, ceria, lithia, magnesia, silica, thoria, yttria, zirconia, tin oxide and zinc oxide. The oxide of the coating may be a chromite or a ferrite, such as a ferrite selected from cobalt, copper, manganese, nickel and zinc.
    Type: Grant
    Filed: July 15, 2000
    Date of Patent: March 26, 2002
    Assignee: Moltech Invent S.A. Luxembourg
    Inventors: Vittorio de Nora, Jean-Jacques Duruz
  • Patent number: 6358393
    Abstract: 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: Grant
    Filed: March 30, 2000
    Date of Patent: March 19, 2002
    Assignee: Moltech Invent S.A.
    Inventors: Georges Berclaz, Vittorio de Nora
  • Publication number: 20020027069
    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).
    Type: Application
    Filed: July 2, 2001
    Publication date: March 7, 2002
    Inventor: Vittorio de Nora
  • Publication number: 20010027923
    Abstract: A non-carbon, metal-based slow-consumable anode of a cell for the electrowinning of aluminium self-forms during normal electrolysis an electrochemically-active oxide-based surface layer (20). The rate of formation (35) of the layer (20) is substantially equal to its rate of dissolution (30) at the surface layer/electrolyte interface (25) thereby maintaining its thickness substantially constant, forming a limited barrier controlling the oxidation rate (35). The anode (10) usually comprises an alloy of iron with at least one of nickel, copper, cobalt or zinc which during use forms an oxide surface layer (20) mainly containing ferrite.
    Type: Application
    Filed: June 15, 2001
    Publication date: October 11, 2001
    Inventors: Vittorio de Nora, Jean-Jacques Duruz