Abstract: Method and cell component for the electrowinning of aluminum by the electrolysis of alumina dissolved in a molten fluoride electrolyte comprises a porous micropyretic reaction product of nickel, aluminum, iron, copper and at least one additive element selected from silicon, tin zinc, vanadium, indium, hafnium, tungsten, elements from the lanthanide series starting from praesodymium, and misch metal. The micropyretic reaction product contains metallic and intermetallic phases, with a composite oxide surface produced in-situ by anodic polarization of the porous micropyretic reaction product in a molten fluoride electrolyte containing dissolved alumina, or by high temperature treatment in an oxidizing gas. The composite oxide surface usually comprises an iron-rich relatively dense outer portion and an aluminate-rich relatively porous inner portion.

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).

Abstract: This invention relates to a new family of materials that exhibits improved stability to the chemical environment used in metal ore reduction, and thus provides an opportunity for improving the energy use and efficiency of such processes by their use. More specifically, the inventions relates to an electrode, used in the construction and/or operation of a reduction cell use to produce metal from ore, which is comprised of a compound or compounds described by the chemical formulas M3NX2 or M2NX, where M is a transition metal, N is a group 3a, 4a or 5a element, and X is carbon or nitrogen; or a composite containing in part, at least one of such compounds.

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.

Abstract: A bipolar cell for the electrowinning of aluminum has bipolar electrodes each comprising a carbon cathode body having on one side an active surface on which aluminum 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.

Abstract: A method of producing commercial purity aluminum in an electrolytic reduction cell comprising inert anodes is disclosed. The method produces aluminum having acceptable levels of Fe, Cu and Ni impurities. The inert anodes used in the process preferably comprise a cermet material comprising ceramic oxide phase portions and metal phase portions.

Abstract: An inert anode for production of metals such as aluminum is disclosed. The inert anode comprises a base metal selected from Cu and Ag, and at least one noble metal selected from Ag, Pd, Pt, Au, Rh, Ru, Ir and Os. The inert anode may optionally be formed of sintered particles having interior portions containing more base metal than noble metal and exterior portions containing more noble metal than base metal. In a preferred embodiment, the base metal comprises Cu, and the noble metal comprises Ag, Pd or a combination thereof.

Abstract: The present invention includes uranium-bearing ceramic phase electrodes and electrolysis apparatus and electrolysis methods featuring same, including methods of metal production and the like by the electrolytic reduction of oxides or salts of the respective metals. More particularly, the invention relates to an inert type electrode composition, and methods for fabricating electrode compositions, useful in the electrolytic production of such metals. The present invention also includes an inert-type electrode composition, and methods for fabricating electrode compositions, used in processes for generating energy from fossil fuels.

Abstract: Components of electrolytic cells for the production of aluminum in particular by the electrolysis of alumina in a molten fluoride electrolyte, made of carbon or other microporous material which remains stable or may be consumed in the cell operating conditions, are conditioned to better resist in the cell operating conditions by impregnating them with colloidal ceria, cerium acetate, silica, alumina, lithia, yttria, thoria, zirconia, magnesia or monoaluminum phosphate containing ionic species of sodium, lithium, potassium, aluminum, calcium or ammonium, followed by drying and heat treatment.

Abstract: In aluminum smelting by electrolysis, a double salt of KAlSO.sub.4, as a feedstock, is heated with a eutectic electrolyte, such as K.sub.2 SO.sub.4, at 800.degree. C. for twenty minutes to produce an out-gas of SO.sub.3 and a liquid electrolyte of K.sub.2 SO.sub.4 with fine-particles of Al.sub.2 O.sub.3 in suspension having a mean size of six to eight microns. This is pumped into a cell with an electrolyte comprised of K.sub.2 SO.sub.4 with fine-particles of Al.sub.2 O.sub.3 in suspension, an anode and a porous cathode of open-cell ceramic foam material. The cell is maintained at 750.degree. C. and four volts of electricity applied between the anode and the cathode causes oxygen to bubble at the anode and liquid aluminum to form in the porous cathode.