Alcoa Inc.

Alcoa USA Corp.

Aluminum Company of America

Elysis Limited Partnership

Robert A DiMilia

Xinghua Liu

Frankie E Phelps

Joseph M Dynys

Douglas A Weirauch, Jr

Siba P Ray

Mark Weaver

Lance M Sworts

Douglas A Weirauch

Alfred F LaCamera

James C McMillen

Andrew L Schnitgen

Jonell Kerkhoff

Frankie A Phelps

Brian J Tielsch

Jeffrey S Martello

Clement E Valchar

Kirk J Malmquist

Jeff Ward

Jr Douglas A Weirauch

Jeffrey R Ward

Jonell M Kerkhoff

Mark L Weaver

Compositions for making wettable cathodes to be used in aluminum electrolysis cells are disclosed. The compositions generally include titanium diboride (TiB) and metal additives. The amount of selected metal additives may result in production of electrodes having a tailored density and/or porosity. The electrodes may be durable and used in aluminum electrolysis cells.

Composition for making wettable cathode in aluminum smelting

A system is provided including an electrolysis cell configured to retain a molten electrolyte bath, the bath including at least one bath component, the electrolysis cell including: a bottom, and a sidewall consisting essentially of the at least one bath component; and a feed material including the least one bath component to the molten electrolyte bath such that the at least one bath component is within 30% of saturation, wherein, via the feed material, the sidewall is stable in the molten electrolyte bath.

Systems and methods of protecting electrolysis cell sidewalls

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).

A method to recycle TiB2 articles, and in particular, a method to recycle a TiB2 feedstock including TiB2 articles and Ti-ore and/or Ti-slag by chlorination.

Recycle of titanium diboride materials

A system is provided including an electrolysis cell configured to retain a molten electrolyte bath, the bath including at least one bath component, the electrolysis cell including: a bottom, and a sidewall consisting essentially of the at least one bath component; and a feeder system, configured to provide a feed material including the least one bath component to the molten electrolyte bath such that the at least one bath component is within 2% of saturation, wherein, via the feed material, the sidewall is stable in the molten electrolyte bath.

Systems and methods of protecting electrolysis cells

A composite anode assembly is provided, the assembly including a permeation resistant portion and a porous conductive portion circumscribing at least the bottom of the permeation resistant portion. The composite anode assembly reduces corrosion and restricts thermal expansion stresses.

Inert electrode assemblies and methods of manufacturing the same

Stable anodes comprising iron oxide useful for the electrolytic production of metal such as aluminum are disclosed. The iron oxide may comprise FeO, FeO, FeO or a combination thereof. During the electrolytic aluminum production process, the anodes remain stable at a controlled bath temperature of the aluminum production cell and current density through the anodes is controlled. The iron oxide-containing anodes may be used to produce commercial purity aluminum.

Stable anodes including iron oxide and use of such anodes in metal production cells

Ceramic inert anodes useful for the electrolytic production of aluminum are disclosed. The inert anodes comprise oxides of Ni, Fe and Al. The Ni&#x2014;Fe&#x2014;Al oxide inert anode materials have sufficient electrical conductivity at operation temperatures of aluminum production cells, and also possess good mechanical stability. The Ni&#x2014;Fe&#x2014;Al oxide inert anodes may be used to produce commercial purity aluminum.

Stable inert anodes including an oxide of nickel, iron and aluminum

An inert anodefor use in an electrolytic cellfor producing metals such as aluminum, is made by providing chemical source materialssuch as at least two of metal salts, metal particles, or metal oxides and dissolving them to form a solution or a slurryfollowed by adding a baseand adjusting the pH so that a gelis formed which is dried and calcinedto provide a blend of metal oxide powderwhich can be pressed and sinteredto form an inert anode

Synthesis of multi-element oxides useful for inert anode applications

Ceramic inert anodes useful for the electrolytic production of aluminum are disclosed. The inert anodes comprise an oxide of Ni and Fe having a controlled Ni/(Ni&plus;Fe) mole ratio which results in a single-phase structure at the operation temperatures of aluminum production cells. The Ni and Fe oxide material may also have a single-phase structure at the sintering temperature of the material. The single-phase inert anode materials maintain sufficient electrical conductivity at the operating temperatures of the cell, and also possess good mechanical stability.

Stable inert anodes including a single-phase oxide of nickel and iron

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.

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Greensburg, PA, United States of America

Robert A DiMilia