Alcoa Inc.

Alcoa USA Corp.

Elysis Limited Partnership

Xinghua Liu

Siba P Ray

Douglas A Weirauch, Jr

Robert A DiMilia

Joseph M Dynys

Frankie E Phelps

Alfred F LaCamera

Robert A Dimilia

David H DeYoung

Jonell Kerkhoff

James Wiswall

Douglas A Weirauch

Brent L Mydland

Jeffrey S Martello

Mark Weaver

Robert L Kozarek

Jerry L Roddy

Kirk J Malmquist

Jeff Ward

Alfred F Lacamera

Jonell M Kerkhoff

Jr Douglas Weirauch

Jr Douglas A Weirauch

Jeffrey R Ward

An electrolytic cell for producing aluminum metal is disclosed. The electrolytic cell comprises at least one anode module having a plurality of anodes and being supported above a corresponding at least one cathode module having a plurality of cathodes, the at least one anode module being supported by a positioning apparatus configured to move inside the cell for selectively positioning the plurality of anodes within the electrolytic cell relative to adjacent cathodes in order to adjust an anode-cathode distance (ACD) and/or an anode-cathode overlap (ACO). Preferably, the anodes are inert or oxygen-evolving electrodes for an eco-friendly or 'green' production of a metal, such as aluminum (or aluminium).

Electrode configurations for electrolytic cells and related methods

In some embodiments, an electrolytic cell includes: an one anode module having a plurality of anodes; a one cathode module, opposing the anode module, and comprising a plurality of vertical cathodes, wherein each of the plurality of anodes and each of the plurality of vertical cathodes are vertically oriented and spaced one from another; a cell reservoir; and a cell bottom supporting the cathode module, wherein the cell bottom comprise an first upper surface, a second upper surface, and a channel, wherein the plurality of vertical cathodes extends upward from the upper surfaces, wherein at least one cathode block is located below the plurality of vertical cathodes, wherein the first upper surface and the second upper surface are configured to direct substantially all of the liquid aluminum produced in the electrolytic cell to the channel, and wherein the channel is configured to receive liquid aluminum from the upper surfaces.

Advanced aluminum electrolysis cell

In some embodiments, an exemplary electrolytic cell includes: a cathode structure disposed within an electrolysis cell, wherein the electrolysis cell is configured to produce metal on a surface of the cathode structure, wherein the cathode structure is configured to fit along a floor of the electrolysis cell, wherein the cathode structure has a sloped surface when compared to a generally horizontal plane, and wherein via the sloped surface, the cathode structure is configured to drain a metal product from the sloped surface towards a lower end of the cathode structure.

Systems and methods of electrolytic production of aluminum

In one embodiment, an electrolytic cell for the production of aluminum from alumina includes: at least one anode module having a plurality of anodes; at least one cathode module, opposing the anode module, wherein the at least one cathode module comprises a plurality of cathodes, wherein the plurality of anodes are suspended above the cathode module and extending downwards towards the cathode module, wherein the plurality of cathodes are positioned extending upwards towards the anode module, wherein each of the plurality of anodes and each of the plurality of cathodes are alternatingly positioned, wherein the plurality of anodes is selectively positionable in a horizontal direction relative to adjacent cathodes, wherein the anode module is selectively positionable in a vertical direction relative to the cathode module, and wherein a portion of each of the anode electrodes overlap a portion of adjacent cathodes.

The application is directed towards methods for purifying an aluminum feedstock material. A method provides: (a) feeding an aluminum feedstock into a cell (b) directing an electric current into an anode through an electrolyte and into a cathode, wherein the anode comprises an elongate vertical anode, and wherein the cathode comprises an elongate vertical cathode, wherein the anode and cathode are configured to extend into the electrolyte zone, such that within the electrolyte zone the anode and cathode are configured with an anode-cathode overlap and an anode-cathode distance; and producing some purified aluminum product from the aluminum feedstock.

Systems and methods for purifying aluminum

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 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

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

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Murrysville, PA, United States of America

Xinghua Liu