Alcoa Inc.

Elysis Limited Partnership

Alcoa USA Corp.

Leroy E D'Astolfo

Robert L Kozarek

Yimin Ruan

James T Burg

William J Steiner

Eric C Moreland

Alfred F LaCamera

Thomas R Hornack

Mark Ripepi

Calvin Bates

Raymond Miller

R Lee Troup

Richard M Beeler

Steven A Czekaj

Derrick Lucey

Robert C Moore

Giuseppe Lazzaro

Roy A Glisan

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

Systems and methods for preventing thermite reactions in electrolytic cells

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

Insulation assembly for electrolysis cell

In one embodiment, a feed system for distributing fluidized feed material, comprises: a distribution unit configured to fluidize feed material; and a control unit fluidly coupled to the distribution unit, wherein the control unit comprises: a chamber configured to hold the feed material provided from the distribution unit; and a feeder unit fluidly coupled to the chamber: and a second gas inlet configured to provide gas to the chamber; and a material discharge pipe fluidly coupled to the chamber and the second gas inlet.

Feeding systems and methods of using feeding systems

The instant disclosure provides an electrolysis cell, which includes: an anode; a cathode block; and a current collector bar configured to be at least partially disposed adjacent to and in electrical communication with the cathode block, wherein the bar comprises: at least one sidewall; an inner void enclosed by the sidewall; and an expandable material retained in the inner void via the at least one sidewall, wherein the expandable material is configured to exert pressure on the wall of the inner void while the bar is at operating temperature, such that the bar is conformed to the cathode block.

Current collector bar apparatus, system, and method of using the same

An electrolytic cell anode, including an encasing conductive material configured to encase a dense conductive material and define the electrolytic cell anode, wherein the dense conductive material has an electrical conductivity greater than that of the encasing conductive material.

Inert electrodes with low voltage drop and methods of making the same

A method of protecting an inert anode assembly () operating in an electrolysis cell () for producing metal when an adjacent assembly (') is removed exposing remaining assemblies to low ambient temperatures () by utilizing heat radiation shields () which can circumscribe every inert anode assembly (), where the shields () remain intact and in place in the cell () while operating in molten electrolyte () at about 850&#xb0; C.

Cermet inert anode assembly heat radiation shield

An improved electrical connection between an inert anode and a conductor rod is disclosed. The conductor rod has a smaller diameter than a hole in the anode such that a gap is provided between the conductor rod and the anode. The gap is filled with an electrically conductive particulate material, such as Cu, Ni and/or Ag. The particulate conductor material is at least partially sintered before or during operation of the anode. To ensure a good connection between the conductor rod and the anode, the particle size distribution of the particulate connector material may be controlled.

Inert anode electrical connection

A method for protecting anode assemblies in an electrolytic cell from thermal shock is disclosed. The method generally involves applying a thermal insulating layer () to the anode () prior to preheating the anode assembly in a furnace, where the layer () protects the anode () from thermal shock during transfer from the preheat furnace to the electrolytic cell. In a preferred embodiment the anode () is attached to a castable plate () that is also protected from thermal shock by an insulating layer.

Protecting an inert anode from thermal shock

A sintered electrode assembly is made of an inert electrode () containing a sealed metal conductor () having a surface feature () such as a coating or wrapping which aids in bond formation with the inert electrode () at their interface (), where the metal conductor () is directly contacted by and is substantially surrounded by the inert electrode () without the use of metal foam or metal powders.

Sinter-bonded direct pin connections for inert anodes

A solid material ( &prime;) circumscribing an anode system ( ) in an electrolysis apparatus is made from a mixture of cryolite and/or alumina (Al O ), where the solid material ( &prime;) contacts and surrounds the anodes ( &prime;).

Inert anode assembly

An inert anode ( ) for use in an electrolysis process to make metals such as aluminum, contains a hollow interior with an open top portion ( ), an interior closed bottom ( ) and interior walls ( ) where the top interior side walls ( ) have at least one interior groove ( ) which helps relieve stress on the anode material and helps provide locking and support of the anode.

Mechanical attachment of electrical current conductor to inert anodes

Insulation assemblies provide reduced heat loss from electrolytic metal production cells such as inert anode aluminum production cells. The insulation assemblies may be located at the end, side and/or center aisles of the cell, and may be supported by the anodes and deckplate of the cell. The assemblies reduce heat loss and bath vaporization losses, and permit stable operation of the inert anode cell.

Insulation assemblies for metal production cells

A method is provided for retrofitting conventional aluminum smelting cells with inert anode assemblies which replace the consumable carbon anodes of the cell. The inert anode assemblies are pre-heated prior to introduction into the operating cell. Insulation may be installed for reducing heat loss during operation of the retrofit cells.

Method of converting Hall-Heroult cells to inert anode cells for aluminum production

Conventional aluminum smelting cells are retrofitted with inert anode assemblies which replace the consumable carbon anodes of the cell. The inert anode assemblies may include multiple inert anodes, and may also include insulation for reducing heat loss during operation of the retrofit cells.

Growing community of inventors

Lower Burrell, PA, United States of America

Leroy E D'Astolfo