Comalco Aluminium Limited

Northwest Aluminum Technology

Comalco Aluminum Limited

The University of Melbourne

Northwest Aluminum Technologies

Plasma Technology Scientific and Engineering Centre of E O Paton

Comalco Aluminuim Limited

Drago Dragutin Juric

Raymond Walter Shaw

Richard J Brooks

Craig W Brown

Patrick B Frizzle

Geoffrey J Houston

Kevin D Watson

David Henry Solomon

Greg Guanghua Qiao

Ian A Coad

Alexander Ja Taran

Victor J Lakomsky

Boris Eu Paton

Ian G Stedman

Michael A Fridman

Gavan Joseph Stray

The invention relates to a composition suitable for the preparation of a carbon-containing material including: (i) a binder phase containing organic resin component or polymer composite; (ii) mesophase carbon; and (iii) optionally filler particles. The invention further relates to a method for preparing a carbon-containing material including the steps of: (a) mixing a binder phase containing an organic resin component or polymer composite with mesophase carbon and optionally filler particles; (b) curing the mixture; and (c) heating the cured mixture. The invention also provides an article which is wholly or partly manufactured from the carbon-containing material defined above.

Carbon-containing materials

A method of treating an electrolyte for use in the electrolytic reduction of alumina to aluminum employing an anode and a cathode, the alumina dissolved in the electrolyte, the treating improving wetting of the cathode with molten aluminum during electrolysis. The method comprises the steps of providing a molten electrolyte comprised of ALF and at least one salt selected from the group consisting of NaF, KF and LiF, and treating the electrolyte by providing therein 0.004 to 0.2 wt. % of a transition metal or transition metal compound for improved wettability of the cathode with molten aluminum during subsequent electrolysis to reduce alumina to aluminum.

Electrolyte treatment for aluminum reduction

An electrolytic bath for use during the electrolytic reduction of alumina to aluminum. The bath comprises a molten electrolyte having the following ingredients: (a) AlF 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. Removing sulfur from the bath can also minimize cathode deposits. Aluminum formed on the cathode can be removed directly from the cathode.

Bath for electrolytic reduction of alumina and method therefor

An electrolytic bath for use during the electrolytic reduction of alumina to aluminum. The bath comprises molten electrolyte having the following ingredients: AlF and at least one salt selected from the group consisting of NaF, KF, and LiF; and 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 is, a fluoride; oxide, or carbonate. The metal is nickel, iron, copper, cobalt, or molybdenum. The bath is employed in a combination including 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 instant bath during electrolytic reduction of alumina to aluminum improves the wetting of aluminum on a cathode by reducing or eliminating the formation of non-metallic deposits on the cathode.

Combination for electrolytic reduction of alumina

An electrolytic bath for use during the electrolytic reduction of alumina to aluminum. The bath comprises a molten electrolyte having the following ingredients: (a) AlF,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.

Cathode construction

Disclosed are methods for preparing carbon-containing materials resistant to alkali metal disruption, and compositions suitable for the preparation of carbon-containing materials resistant to alkali metal disruption. A composition in accordance with the invention comprises a mixture of (a) a binder phase having a viscosity of less than 10 Pascal seconds and a char yield in excess of 20% upon heating to a temperature of 800.degree.-1200.degree. C., and comprising at least one polymerizable resin and (b) particles of a solid material which is thermally stable at a temperature of 800.degree.-1200.degree. C., the particles having a granulometry wherein void spaces between the particles have a size of less than 20 .mu.m in diameter and the particles are coated with a layer of binder phase having a thickness of less than 2 .mu.m. When the composition is carbonized by heating to a temperature of 800.degree.-1200.degree. C., the composition forms a carbon-containing material resistant to alkali metal disruption.

Binder systems

An aluminium smelting cell comprising side walls (5) and a floor (2) defining an active cathode, an anode (3) overlying the cathode floor (2), some said side walls (5) being covered by a wetted cathode material (6), such as one contained TiB.sub.2, so that the covered side walls become active cathode surfaces on which a film of aluminium metal forms to protect the side wall parts against bath attack, thereby enabling the cell to operate at the desired temperatures without the usual protective side ledge of the frozen electrolyte material.

Ledge-free aluminum smelting cell

A support structure for supporting continuous prebaked anodes in an aluminium smelting cell comprises a pair of side plates (3) and a pair of end plates (4) connected together to form an enclosed superstructure. The supporting structure includes at least one pair of spaced cross-plates (8, 9) that are configured to provide wedging surfaces which act to support an anode (14) therebetween. Electrical current is fed to the anodes via the cross-plates. Respective pairs of cross-plates supporting adjacent anodes may be spaced to define heat exchange passages which can be used to control the temperature of the support structure. A method for operating an aluminium smelting cell at variable amperage by positive and controlled extraction of heat from the cell.

Continuous prebaked anode cell

Electrolysis cell and method for metal production

Method for operating a continuous prebaked anode cell by locating

A method of operating an aluminum smelting cell during the start-up phase of the cell is described. The method includes forming a layer of boron oxide on the exposed surface of the cathode of the cell, forming a layer of aluminum on the boron oxide layer, and starting the cell. This melts the boron oxide layer to form a barrier impervious to oxygen at a temperature from about 400.degree. C. to about 650.degree. C., and the aluminum layer is melted to form a barrier to oxygen at temperature above about 600.degree. C. to about 1000.degree. C. to reduce the development of oxidation products.

Cathode protection

An aluminum smelting cell comprising a cathode having an active upper surface, a plurality of anodes each having a lower surface spaced from the upper surface of the cathode, said cathode upper surface being sloped at an acute angle in a primary or longitudinal direction of each anode, and being formed with pairs of oppositely sloped surfaces extending in a transverse or secondary direction under each anode to cause complementary shaping of the lower anode surfaces to reduce the migration of bubbles between the anode and cathode along the anode surfaces in said primary or longitudinal direction to thereby reduce the path length of said bubbles whereby the turbulence caused by coalesced bubble disengagement from the bath electrolyte is significantly reduced while maintaining adequate bath circulation between the anode and cathode.

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Drago Dragutin Juric