专利摘要:
In some embodiments, an anode device comprises: (a) an anode housing comprising at least one outer wall, wherein the outer wall is configured to define a shape of the anode housing and to perimetrically enclose the hole in the anode housing, the hole comprising a top opening in an upper surface of the anode housing and the hole axially extending into the anode housing; (b) a plug comprising: a first end and a second end opposite the first end, the second end extending downwardly into the upper end of the anode housing and into the hole in the anode housing; and (c) a sealing material is configured to cover at least a portion of at least one of the following: (1) an interior side wall of the anode housing; (2) the upper surface of the anode housing; (3) the pin and (4) the anode holder.
公开号:DK201970168A1
申请号:DKP201970168
申请日:2017-09-19
公开日:2019-04-01
发明作者:Sworts Lance
申请人:Elysis Limited Partnership;
IPC主号:
专利说明:

ANODE DEVICE AND PROCEDURES RELATING TO THE SAME
CROSS REFERENCE TO RELATED APPLICATIONS [0001] The present application claims priority from U.S. Provisional Patent Application No. 62 / 396,583, filed September 19, 2016, which is incorporated herein by reference in its entirety
BACKGROUND An inactive anode is electrically connected to the electrolytic cell so that a conductor rod is connected to the inactive anode to conduct current from a power supply to the inactive anode, where the inactive anode carries the current into the electrolytic bath to produce iron metal (where the current leaves the cell via a cathode). In some embodiments, a corrosive bath and / or vapor during operation of the cell cooperates with the anode unit and may affect the efficiency and service life of the anode unit (e.g., by weakening the mechanical connection and / or increasing the electrical resistance of the electrical connection).
FIELD OF THE INVENTION In general, the present description is directed to a device with an inactive anode. More specifically, the present disclosure is directed to a device with an inactive anode configured to reduce, prevent and / or eliminate corrosion of the pin and / or anode material (e.g., by corrosive vapors and / or molten electrolyte) in a electrolysis cell.
SUMMARY OF THE INVENTION Without being bound by any particular mechanism or theory, it is believed that one or more embodiments of the anode stick-protecting sealant compound of the present disclosure provide improved corrosion resistance of the anode unit when
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It is measured in at least one of the following locations: (a) at the pin, inside the hole in the anode housing; (b) at the anode housing, along the inside diameter of the anode socket leg; and / or (c) in the vapor zone where the plug leg extends over the anode housing (i.e. over the bath, and / or in the refractory portion).
Without being defined by a particular mechanism or theory, it is believed that when the sealing material is used in the anode unit, it provides protection for (1) the mechanical attachment site on the anode of the connector and / or (2) the components of the anode unit (f. such as sockets, anode housing, filler material, cement material) as the sealing material is configured to accept reactive fluorides present on site in the bath and / or bath vapor. Without being delineated by a particular mechanism or theory, it is believed that by undergoing the chemical state change to accept the fluorides, the sealing material is converted (at least partially) from a solid into a liquid material. In some embodiments, a sealing material is configured to extend between the inner surface of the hole in the anode housing to the outer diameter of the pin.
In one aspect of the present disclosure there is provided an anode unit comprising: an anode holder; and an anode device mechanically attached to the anode holder, wherein the anode device comprises: (a) an anode housing comprising at least one outer wall, the outer wall being configured to define a shape of the anode housing, and to perimetrically enclose the hole in the anode housing, wherein the hole comprises an upper aperture in an upper surface of the anode housing and the aperture extending axially into the anode housing; (b) a plug comprising: a first end connected to a power supply and a second end opposite the first end, the second end extending downwardly at the upper end of the anode housing and into the hole in the anode housing; and (c) a sealing material comprising an additive and a matrix, wherein
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The 2019 70168 A1 sealing material is configured to cover at least a portion of at least one of the following: (1) an interior side wall of the anode housing; (2) the upper surface of the anode housing; (3) the pin and (4) the anode holder.
In some embodiments of the present disclosure, the sealing material comprises at least one of the following: water, polymers, organics, dispersants, or diluents.
In some embodiments of the present disclosure, a sealing material is configured to cover at least a portion of at least one of the following: (1) an interior sidewall of the anode housing; (2) the connector leg and (3) a filler material.
In some embodiments of the present description, the first end of the pin is configured to be retained in an anode holder.
In some embodiments of the present specification, the filler material is retained in the gap between the inner side wall of the anode housing and the connector leg.
In some embodiments of the present description, the sealing material is configured to enclose the conductive filler material in the anode housing between the inner side wall of the anode housing and the connector leg.
In some embodiments of the present description, the sealing material is molded in place.
In some embodiments of the present description, the sealing material is molded and screwed into the anode housing.
In some embodiments of the present disclosure, the sealing material is sintered in place during sintering of the green anode housing in the final anode housing.
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In some embodiments of the present specification, the sealing material is held over the upper surface of the anode housing.
In some embodiments of the present description, the sealing material is held in the hole.
In some embodiments of the present disclosure, it comprises over the upper surface of the anode housing that it extends along the connector leg.
In some embodiments of the present disclosure, it includes over the upper surface of the anode housing that it extends along the pin and into the anode holder. In some embodiments of the present disclosure, it comprises over the upper surface extending across the upper surface of the upper portion of the anode housing.
In some embodiments of the present disclosure, it comprises over the upper surface extending across the upper surface and down around the outer side wall of the anode housing.
In some embodiments of the present description, the sealing material is applied to the anode hole between the pin and the inner surface of the anode housing with a slope so that the concentration of the sealing material varies in a radial direction.
In some embodiments of the present description, the inclination is configured so that the concentration of the sealing material is higher in the immediate vicinity of the pin compared to the inner surface of the anode housing.
In some embodiments of the present description, the slope is configured so that the concentration of the sealing material is lower in the immediate vicinity of the pin compared with the inner surface of the anode housing.
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In some embodiments of the present description, the sealing material is applied to the anode hole between the pin and the inner surface of the anode housing with a slope so that the concentration of the sealing material varies in a lateral direction.
In some embodiments of the present description, the slope is configured so that the concentration of the sealing material is higher in the immediate vicinity of the upper end as compared to the lower end of the anode housing.
In some embodiments of the present description, the slope is configured so that the concentration of the sealing material is higher in the immediate vicinity of the upper end compared to the lower end of the anode housing.
In some embodiments of the present description, the sealing material is configured with a higher concentration at a position near the bath-vapor contact surface compared to either the upper end of the vapor phase or the lower end of the bath of the anode housing.
In some embodiments of the present disclosure, the concentration of the sealing material from a position just below the bath-vapor contact surface to a position near the upper end of the anode is higher than the portion of the sealing material in the submerged portion of the anode housing.
In one aspect of the present disclosure, an electrolytic cell comprising: a cell structure comprising a cell bottom and a cell side wall, wherein the cell side wall is configured to perimetrically enclose the cell floor and extend upward from the cell floor to define a control amount, wherein the amount of control is configured to hold a molten electrolyte bath; and an anode unit configured to conduct current into the molten electrolyte bath, the anode unit comprising: an anode holder; and an anode device that is
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DK 2019 70168 A1 mechanically attached to the anode holder, wherein the anode device comprises: (a) an anode housing comprising at least one outer wall, the outer wall being configured to define the anode shape and to perimetrically enclose the hole in the anode housing, the hole comprising a top opening in the upper part of the anode housing and the hole axially extending into the anode housing; and (b) a connector comprising: a first end connected to a power supply, and a second end opposite the first end, the second end configured to extend into the upper end of the anode housing and into the hole in the anode housing; and (c) a sealing material configured to cover at least a portion of at least one of the following: an interior side wall of the anode housing; the upper surface of the anode housing; the connector and the anode holder.
BRIEF DESCRIPTION OF THE DRAWINGS The embodiments of the present invention, briefly summarized above and discussed in more detail below, may be understood by reference to the illustrative embodiments of the invention depicted in the accompanying drawings. It should be noted, however, that the accompanying drawings illustrate only typical embodiments of this invention and should therefore not be considered as limiting the scope of the invention as the invention may allow for other embodiments of the same efficiency.
Figure 1 shows a block diagram of a generic anode unit according to an embodiment of the present description.
Figure 2 shows a schematic sectional side view of an anode device according to an embodiment of the present description.
Figure 3 shows a side sectional view of one embodiment of an anode device of the present description.
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Figure 4 shows a side sectional view of an embodiment of an anode device of the present description.
Figure 5 shows a side sectional view of one embodiment of an anode device of the present description.
Figure 6 shows a side sectional view of one embodiment of an anode device of the present description.
Figure 7 shows a side sectional view of one embodiment of an anode device of the present description.
Figure 8 shows a side sectional view of one embodiment of an anode device of the present description.
Figure 9 shows a side sectional view of one embodiment of an anode device of the present description.
Figure 10 shows a side sectional view of one embodiment of an anode device of the present description.
Figure 11 shows a side sectional view of one embodiment of an anode device of the present description.
Figure 12 shows a side sectional view of one embodiment of an anode device of the present description.
Figure 13 shows a side sectional view of one embodiment of an anode device of the present description.
Figure 14 shows a side sectional view of one embodiment of an anode device of the present description.
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Figure 201 shows a sectional side view of an embodiment of an anode device of the present description.
To facilitate understanding, identical reference numbers are used, where possible, to indicate identical elements common to the figures. The figures are not drawn to scale and may be simplified for the sake of clarity. It is contemplated that the elements and functions of one embodiment may advantageously be incorporated into other embodiments without further indication.
DETAILED DESCRIPTION Figure 1 shows a block diagram of a generic anode unit 10 according to an embodiment of the present description. In some embodiments of the present description, the anode unit 10 comprises an anode holder and an anode device. In some embodiments, the anode device is mechanically attached to the anode holder (e.g. refractory portion, support member, combination thereof). In some embodiments, the anode device comprises: an anode housing, a plug leg and a sealing material.
In some embodiments, the anode unit is part of an electrolysis cell comprising a cell structure comprising a cell bottom and a cell side wall. In some embodiments, the cell side wall is configured to perimetrically enclose the cell floor and extend in an upward direction from the cell floor to define a control amount. In some embodiments, the amount of control is configured to hold a molten electrolyte bath.
In some embodiments, the anode housing comprises at least one exterior sidewall. In some embodiments, the exterior side wall is configured to define a shape of the anode housing and to perimetrically enclose a hole in the anode housing. In some embodiments, the hole comprises one
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DK 2019 70168 A1 upper opening in the upper surface of the anode housing, and the hole extends axially into the anode housing. In some embodiments, the connector leg comprises a first end and a second end. In some embodiments, the first end is connected to a power supply. In some embodiments, the second end is opposite to the first end. In some embodiments, the other end extends downwardly into the upper end of the anode housing and into the hole in the anode housing. In some embodiments, the sealing material is configured to cover at least a portion of at least one of the following: an interior side wall of the anode housing; the upper surface of the anode housing; the connector and the anode holder. In some embodiments, the sealing material is configured to cover at least a portion of at least one of the following: an interior side wall of the anode housing; the socket leg and a filling material.
In some embodiments, the sealing material is configured to reduce, prevent, or eliminate corrosive constituents of the electrolysis process from contacting (and corroding) the (1) pin and / or (2) the mechanical attachment site of the pin anode housing. In some embodiments, the sealing material is configured to be specially designed (i.e., adapted) for the composition of the anode housing. In some embodiments, the sealing material is configured so that the additive in the sealing material is compositionally consistent with the composition of the anode housing. In some embodiments, the sealing material is configured to substantially overlap with the heat expansion coefficient of the anode housing.
In some embodiments, the sealing material is introduced into the anode housing (between the inside of the anode housing and the connector leg) as a particulate material. In some embodiments, the sealing material is introduced into the anode housing (between the inside of the anode housing and the socket leg) as a liquid / slurry applied to the anode housing or socket leg. In some embodiments, reviews
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A 201 chemical and / or thermal hardening material to form a solid sealing material as it is introduced / added into the anode housing. In some embodiments, the sealing material is placed between the connector leg and the anode housing.
In some embodiments, a sealing material is used around the upper end of the anode housing to enclose the outer surface of the pin and contact the anode housing (e.g., the inside of the hole in the anode housing, the upper surface of the anode housing, the upper part of the anode housing and / or combinations thereof). In some embodiments, the sealing material comprises a cement. In some embodiments, the sealing material comprises a cement slurry. In some embodiments, the sealing material is configured to prevent corrosive vapors from entering the interior surface of the anode housing, proximal to the portion of the pin held in the anode housing.
In some embodiments, cement includes additive and a binder or matrix. In some embodiments, the additive is replaced by a sealing material in accordance with the present disclosure (e.g., the use of the binder and / or matrix which can be purchased in stores). In some embodiments, the matrix or binder is replaced by a sealing material in accordance with the present disclosure (e.g., the use of the additive available in the stores). In some embodiments, the matrix or binder and additive are replaced by a sealing material according to the present disclosure. Some non-limiting commercial examples of binders, matrixes, additives and / or combinations thereof include: Al-O 2, SiO 2, MgO, CaO or the like.
In some embodiments, the sealing material includes at least one of the following: water, polymers, organics, dispersants, and / or diluents to promote a
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GB 2019 70168 A1 liquid sealing material so that the sealant can be formed / flowed liquid to the desired location (eg in the anode unit and / or the anode housing).
In some embodiments, the sealing material is configured to enclose the conductive filler material in the anode housing (i.e., between the inner side wall of the anode housing and the connector leg). In some embodiments, the sealing material is configured to provide a mechanical attachment of the anode housing to the connector. In some embodiments, the sealing material is configured to provide support for the anode assembly and / or anode assembly.
In some embodiments, the sealing material is molded in place. In some embodiments, a curing agent is used in conjunction with the sealing material to reduce the cure time. In some embodiments, the sealing material is molded and screwed into the anode housing (e.g., upper part of the anode housing). In some embodiments, the sealing material is sintered in place during sintering of the green molded anode housing in the final anode housing / anode assembly (anode housing, plugs and sealing material). In some embodiments, the sealing material is held over the hole, proximal to the upper surface of the upper end of the anode. In some embodiments, the sealing material is held in the hole (i.e., extends between the pin and the inner side wall of the anode housing) and over the upper surface of the anode housing.
In some embodiments, it comprises over the upper surface of the anode housing that it extends along the connector (i.e., portion of the connector extending from the anode housing). In some embodiments, it includes over the upper surface of the anode housing that it extends along the connector and into the anode holder (i.e., part of the connector extending into the anode holder where the connector is mechanically fixed). In some embodiments, it includes over the top surface that it extends across the top surface of the top portion of the
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DK 2019 70168 A1 anode housing. In some embodiments, it includes over the upper surface that it extends across the upper surface and down around the outer side wall of the anode housing (i.e., forms a collar around the upper end of the anode surface).
As used herein, "anode" means the positive electrode (or terminal) where current is introduced into an electrolysis cell. In some embodiments, the anodes (i.e., the anode housings) are made of electrically conductive materials. In some embodiments, the anode comprises an inactive anode (e.g., non-reactive, dimensionally stable, and / or at a dissolution rate (e.g., by the cell operating parameters) below the dissolution rate of a corresponding carbon anode).
[0060] As used herein, "anode housing" means the physical structure of the anode (e.g., including upper, lower and lateral wall (s)). Some non-limiting examples of anode materials include: metals, metal alloys, metal oxides, ceramics, ceramic metals and combinations thereof. In some embodiments, the anode housing is oval, cylindrical, rectangular, square, plate-shaped (generally flat), other geometric shapes (e.g., triangular, pentagonal, hexagonal, and the like) "Anode device" means the anode or positive electrode of the anode. In some embodiments, the anode device comprises: the anode housing and the plug leg. In some embodiments, the anode device comprises the anode housing, the anode connector leg and the filling / sealing materials (e.g., singly or in combination: conductive filling and / or sealing material).
As used herein, "anode unit" means at least one anode device (anode housing, plug, conductive filler material and / or sealing material) and an anode holder where the at least one anode device is connected (e.g., mechanical and / or electrical) to the anode holder.
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As used herein, "holder" means a component holding one or more objects in place. In some embodiments, the holder is the component that holds the anode (s) in place. In one embodiment, the holder promotes the electrical connection between the electric bus and the anode (s). In one embodiment, the holder is made of a material that is resistant to attack by the corrosive bath. The holder is e.g. made of insulating material, including e.g. refractory material. In some embodiments, several anodes (e.g., mechanical and electrical) are connected to the holder (e.g., removably attached), which can be adjusted and can be raised, lowered, or otherwise moved into the cell. In some embodiments, the anode holder includes a refractory material (e.g., block or unit) or materials that are resistant to baths, rail or beam holders, vertical adjustment components, and devices and / or electric buses.
As used herein, "electric bus" refers to the electrical connections on one or more components. For example, the anode, cathode and / or other cell components may have an electric bus to connect the components to one another. In some embodiments, the electric bus includes plugs for the anodes, wires for connecting the anodes and / or cathodes, electrical circuits for (or between) various cellular components, and combinations thereof. [0065] As used herein, "sidewall" means a surface which forms the wall of an object.
[0066] As used herein, "enclosing perimetrically" means enclosing the outer edge of a surface. As a non-limiting example, enclose perimetrically includes different geometries (e.g., concentric enclosure, boundary) and the like.
As used herein, "electrolyte bath" (sometimes referred to as bath) refers to a liquid bath in which at least one type of metal is to be reduced (e.g., via an electrolysis). A nonPage 13 of 38
Example 2019 70168 A1 limiting example of the composition of the electrolysis bath (in an aluminum electrolysis cell) includes: NaF-AlF3, NaF, AlF3, CaF2, MgF2, LiF, KF and combinations thereof - with dissolved alumina.
As used herein, '' melted '' means a liquid form (e.g., liquid) by virtue of the use of heat. As a non-limiting example, the electrolysis bath is in molten form (e.g., at least about 750 ° C). As another example, the metal product that forms the bottom of the cell (for example, sometimes called a 'metal plate') is in molten form.
[0069] In some embodiments, the operating temperature of the molten electrolyte bath / electrolysis cell is: at least about 750 ° C; at least about 800 ° C; at least about 850 ° C; at least about 900 ° C; at least about 950 ° C; or at least about 975 ° C. In some embodiments, the operating temperature of the molten electrolyte bath / electrolysis cell is: not higher than about 750 ° C; not higher than about 800 ° C; no higher than around
850 ° C; not higher than about 900 ° C; not higher than about 950 ° C; or no higher than about 975 ° C.
[0070] As used herein, "vapor" means a substance which is in the form of a gas species. In some embodiments, vapor comprises ambient gas mixed with caustic and / or corrosive discharge from the electrolysis process.
As used herein, the "steam room" refers to the space of an electrolytic cell, above the surface of the electrolyte bath.
[0072] As used herein, "contact surface" refers to a surface which is considered the common boundary between two masses, compartments or phases.
[0073] As used herein, the "bath-to-steam contact surface" refers to the surface of two-phase baths, the steam room and the liquid (molten) electrolyte bath.
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DK 2019 70168 A1 As used herein, "metal product" means the product produced by electrolysis. In one embodiment, the metal product is formed at the bottom of an electrolysis cell as a metal plate. Some non-limiting examples of metal products include: aluminum, nickel, magnesium, copper, zinc and rare earth metals.
[0075] As used herein, "at least" means greater than or equal to.
[0076] As used herein, "hole" means an opening into something.
[0077] As used herein, "pin" means a piece of material used to attach things to one another. In some embodiments, the connector leg is an electrically conductive material. In some embodiments, the connector leg is configured to electrically connect the anode housing to the electric bus to provide power to an electrolytic cell (via the anode). In some embodiments, a first end of the pin is configured to fit into / be retained in an anode holder (e.g., anode holder and at least one anode device is an anode unit). In some embodiments, the connector leg is configured to overlap with the anode housing. In some embodiments, the connector leg is configured to support the anode housing as it is attached to and suspended from the connector leg. In some embodiments, the connector is made of stainless steel, nickel, nickel alloy, Inconel or corrosion protected steel. In some embodiments, the connector leg is configured to extend into the anode housing (e.g., into a hole) to a particular depth to provide mechanical support and electrical communication to the anode housing. In some embodiments, the length of the connector is sufficient (long enough) to provide mechanical support to the anode housing and sufficient (short enough) to prevent corrosion of the connector inside the hole (i.e., placing the connector over the interface between bath and steam). the oblique, oval, cylindrical, rectangular, square, plate-shaped (generally flat), other geometric shapes (e.g., triangular, pentagonal, hexagonal, and the like).
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As used herein, "attach" means to connect two or more items to each other. In some embodiments, the connector leg is attached to the anode housing. In some embodiments, the connector leg is mechanically attached to the anode housing with: fastener (s), screw (s), a threaded configuration (e.g., on the connector), a corresponding threaded configuration (e.g., on the interior surface of anode housing holes, and on plugs) or the like. In some embodiments, the connector leg is attached to the anode housing by welding (for example, resistance welding or other types of welding). In some embodiments, the connector leg is attached to the anode housing by a direct sintering (i.e., direct sintering of the anode housing on the connector leg).
[0079] As used herein, "electrically conductive material" means a material having an ability to transport electricity (or heat) from one location to another.
As used herein, "filler material" means a material which fills a void or void between two other articles. In some embodiments, the filler material is configured to connect (e.g. electrically connect) the anode housing to the connector leg. In some embodiments, non-limiting examples of filler material include: a particle material, a liquid / slurry material and combinations thereof. In some embodiments, the filler material is incorporated into / disposed at the desired location in a liquid form, which then hardens over time to produce a solid filler material.
In some embodiments, the filler is a conductive material, also called conductive filler. In some embodiments, the filler material is configured to electrically connect the connector and the anode housing. Non-limiting examples of electrically conductive fillers include: iron oxides (hematite, magnetite, wustite), copper, copper alloys, nickel, nickel alloys, precious metals (e.g., Pt, Pd, Ag, Au) and combinations thereof.
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As used herein, "sealing material" means a substance used to close or secure an object or component (for example, to reduce, prevent and / or eliminate the transfer of vapor or liquid to the object or component). In some embodiments, the filler material is configured to block the hole in the upper portion of the anode housing from corrosive vapors in the steam room. Non-limiting examples of a sealing material include: castable cement, concrete, cement swelling, mortar and combinations thereof.
[0083] In some embodiments, the filler is a substance / material comprising at least two components: (1) additive and (2) matrix cement (e.g., cement slurry), wherein the additive comprises large and / or small total sizes. In some embodiments, the filler material is applied in an area to act as an adhesive as it is configured to adhere components after curing.
[0084] As used herein, "moldable" means a substance / material comprising at least two components: additive and cement, the additive comprising large and small overall sizes. In some embodiments, the molding compound is applied in an area to act as an adhesive since it is configured to adhere components after curing.
[0085] As used herein, "cement slurry" means a foundry mass and finer additive (as compared to concrete or cement). In some embodiments, the cement slurry has a viscosity configured to fill cracks and cracks in the anode assembly and / or anode assembly. In some embodiments, the cement slurry is configured as an on-site binder rather than being used to bond things together.
[0086] As used herein, "particle material" means a material consisting of particles. In some embodiments, the particle material is electrically conductive. In one embodiment, the particulate material is copper hail. Other non-limiting examples of particulate materials
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DK 2019 70168 A1 includes: precious metals (eg platinum, palladium, gold, silver and combinations thereof). As non-limiting examples, the particulate material includes: metal foam (e.g., copper foam), large or small hail (e.g. configured to fit between the pin and the anode housing and / or in the anode hole), paint and / or powder. Other sizes and shapes of particulate materials may be used provided they fill the void between the connector and the anode housing (or the portion below the connector, in the hole in the anode housing) and promote an electrical connection between the anode housing and the connector to provide power to the anode.
In some embodiments, the sealing material is configured to reduce, prevent, or eliminate corrosion from the anode device (e.g., pin, anode housing, conductive filler, and / or combinations thereof).
In some embodiments, the sealing material includes additive configured as an anode-adapted additive. In some embodiments, the sealant is configured as an exhaust-compatible additive (e.g., configured to react but not substantially impair the effectiveness of the sealant.
[0089] As used herein, "anode-adapted additive" (sometimes called exhaust-compatible additive) means an additive that has overlapping operating characteristics with the anode composition. In some embodiments, anode-adapted additive is an additive that has the same composition component as the anode housing (e.g., hematite, magnetite). In some embodiments, anode-matched additive is an additive having a composition compatible with at least one major species (or composition) present in the anode (e.g.,> 30% by weight). In some embodiments, anode-adapted additive is an additive that is a composition or component of a gas-compatible additive (e.g., NiFe2O4, NiO, CuAhO4, CuO). Some non-limiting examples of
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GB 2019 70168 A1 aggregating sealants include: spindle, magnetite, hematite, copper aluminate, nickel ferrite or tin oxide and combinations thereof.
In some embodiments, the sealing material comprises a moldable ceramic or metal ceramic plug, wherein the additives (or at least a portion thereof) are replaced by an anode-adapted additive and / or a gas-compatible additive as a primary seal. As a non-limiting example, the sealing material comprises a moldable ceramic or metal ceramic containing Al2O3, SiO2, MgO, CaO, Na2O and combinations thereof, wherein at least some of the silicates and / or aluminates are replaced with a specially designed / adapted additive to the material of the anode housing and / or connector leg, in accordance with the present description.
[0091] In some embodiments, the additive is about 40% by weight. of the sealing material (e.g., as cured). In some embodiments, the matrix / binder is about 60% by weight. of the sealing material (e.g., as cured). In some embodiments, the additive is from about 5% by weight. to 100% by weight of the sealing material. In some embodiments, the binder / matrix is from about 5% by weight. to 100% by weight of the sealing material.
In some embodiments, the percentage and / or amount of matrix or binder / matrix is quantified via SEM (scanning electron microscope) or EDS (energy dispersive spectroscopy), via viewing / observation of a polished cross section of the sealing material. In this embodiment, EDS is configured to provide the chemical composition of the cross section.
In some embodiments, the filler material is conductive filler material (e.g. configured to promote electrical communication between the connector and the anode housing).
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In some embodiments in the hole where the filler material is configured to extend between the inner side wall of the anode housing and the connector leg (for example, beneath the sealing material). In some embodiments, the sealing material comprises a thickness of: between 1 mm and not greater than 50 mm.
In some embodiments, the sealing material has a thickness of: at least 1 mm; at least mm; at least 3 mm; at least 4 mm; at least 5 mm; at least 6 mm; at least 7mm; at least 8 mm;
at least 9 mm or at least 10 mm.
In some embodiments, the sealing material has a thickness of: at least about 5 mm; at least about 10 mm; at least about 15 mm; at least about 20 mm; at least about 25 mm; at least about 30 mm; at least about 35 mm; at least about 40 mm; at least about 45 mm or at least about mm.
In some embodiments, the sealing material has a thickness of: not greater than 1 mm;
not greater than 2 mm; not greater than 3 mm; not greater than 4 mm; not greater than 5 mm; not greater than 6 mm; no larger than 7mm; not greater than 8 mm; not greater than 9 mm or not greater than 10 mm.
In some embodiments, the sealing material has a thickness of: not greater than about 5 mm; not larger than about 10 mm; not larger than about 15 mm; not larger than about 20 mm;
not larger than about 25 mm; not larger than about 30 mm; not larger than about 35 mm; not larger than about 40 mm; not larger than about 45 mm or no larger than about 50 mm.
In some embodiments, the sealing material has a thickness of: at least about 50 mm;
at least about 100 mm; at least about 150 mm; at least about 200 mm or at least about 250 mm. In some embodiments, the sealing material has a thickness of: not greater than about 50 mm; does not
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DK 2019 70168 A1 larger than about 100 mm; not larger than about 150 mm; not larger than about 200 mm or no larger than about 250 mm.
[00101] In some embodiments, the sealing material is configured as a coating applied to the anode socket leg. In some embodiments, the sealing material is configured as a coating on the inner surface of the anode housing. In some embodiments, the sealing material is configured as a coating applied to the upper surface (e.g., the upper end) of the anode housing.
In some embodiments, the sealing material is applied to one or more components of the anode device and / or the anode unit by rinsing (e.g., painting) the component directly with the material.
In some embodiments, the sealing material is applied to one or more components of the anode device and / or the anode unit by applying the sealing material to the component (s) as a slurry / suspension in combination with a binder or liquid.
In some embodiments, the sealing material is applied to one or more of the anode device and pin by applying / feeding the additive into the desired location (e.g. pouring powder, particles or beads), followed by mixing the matrix, mechanical stirring / bonding. , as the sealant is allowed to solidify / dry.
[00105] In some embodiments, the sealing material is applied to one or more of the anode device and the pin by spraying.
In some embodiments, the sealing material is applied to one or more of the anode device and the pin bone by spraying.
[00107] In some embodiments, the sealing material is applied to one or more of the anode device and the pin bone by licking molding. In some embodiments, it is applied
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DK 2019 70168 A1 sealing material on one or more of the anode device and the pin bone by pressure casting. In some embodiments, the sealing material is applied to one or more of the anode device and connector leg by vacuum casting. In some embodiments, the sealing material is applied to one or more of the anode device and connector leg by slurry pressing. In some embodiments, the sealing material is applied to one or more of the anode device and connector leg by gel casting. In some embodiments, the sealing material is applied to one or more of the anode device and connector leg by electrophoresis molding.
In some embodiments, the anode-adapted additive and / or the exhaust-compatible additive is present in mixed form with the sealant, the additive being from at least 1% by volume of the sealant to no more than 99.5% by volume of the sealant.
In some embodiments, the additive is present in mixed form with the sealing material, the additive being from at least 1% by volume of the sealing material to no more than 100% by volume of the sealing material.
As non-limiting examples, the additive comprises: at least 1% by volume; at least 5% by volume; at least 10% by volume; at least 15% by volume; at least 20% by volume; at least 25% by volume; at least 30% by volume; at least about 35% by volume; at least 40% by volume; at least 45% by volume; at least 50% by volume; at least 55% by volume; at least 60% by volume; at least 65% by volume; at least vol%; at least 75% by volume; at least 80% by volume; at least 85% by volume; at least 90% by volume or at least 95% by volume; or at least 99% by volume of the sealing material.
As non-limiting examples, the additive comprises: not more than 1 vol.
%; not more than 5% by volume; not more than 10% by volume; not more than 15% by volume; not more than 20% by volume; not more than 25% by volume; not more than 30% by volume; not more than about 35% by volume; does not
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DK 2019 70168 A1 greater than 40 vol%; not more than 45% by volume; not more than 50% by volume; no more than 55 vols.
%; not more than 60% by volume; not more than 65% by volume; not more than 70% by volume; not more than vol%; not more than 80% by volume; not more than 85% by volume; not more than 90% by volume or not more than 95% by volume or not more than 99% by volume of the sealing material.
In some embodiments, a mixture of anode-adapted additive and / or exhaust-compatible additive and sealing material comprises an amount of additive sufficient to maintain the ability of the sealing material to adhere components of the anode device (e.g., anode housing to the plug) and / or the anode unit. (eg anode holder plugs).
In some embodiments, the sealing material is applied in the anode hole (i.e., between the pin and the inner surface of the anode housing) with a slope such that the concentration of the sealing material (with anode-adapted additive and / or exhaust compatible additive) varies in a radial direction (i.e., differs). from a position near the connector leg compared to a position near the anode side wall).
In one embodiment, the slope is configured so that the concentration of the sealing material (with anode-matched additive and / or exhaust-compatible additive) is higher in the immediate vicinity of the pin compared to the inner surface of the anode housing.
In one embodiment, the slope is configured so that the concentration of the sealing material (with anode-matched additive and / or exhaust-compatible additive) is lower in the immediate vicinity of the pin compared to the inner surface of the anode housing.
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In some embodiments, the sealing material is applied in the anode hole (i.e. between the pin and the inner surface of the anode housing) with a slope such that the concentration of the sealing material varies in a radial direction (i.e., deviates from a position near the opening in the anode hole). the hole / upper surface of the anode housing compared to a position near the lower end of the anode housing).
In one embodiment, the slope is configured so that the concentration of the sealing material is higher in the immediate vicinity of the upper end as compared to the lower end of the anode housing.
In one embodiment, the slope is configured so that the concentration of the sealing material is higher in the immediate vicinity of the upper end as compared to the lower end of the anode housing.
In some embodiments, the sealing material is configured with a higher concentration at a position near the bath-vapor contact surface compared to either the upper end of the vapor phase or the lower end of the bath of the anode housing.
In some embodiments, the concentration of the sealant from a position just below the bath-vapor contact surface to a position near the upper end of the anode is higher than that of the (anode-adapted additive and / or exhaust compatible additive in) the sealing material in the submerged portion. of the anode housing (e.g., submerged below the bath-steam interface).
Figure 2-15 shows a schematic side sectional view of an example of an anode device according to some embodiments of the present disclosure. Figure 2 shows an anode device in which the sealing material 50 covers part of the pin 12 in the steam room 24, the opening 32 and the entire upper surface of the anode housing 30.
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DK 2019 70168 A1
Figure 3 shows an anode device in which the sealing material 50 covers the entire pin 12 in the steam compartment 24, the opening 32 and part of the upper surface of the anode housing 30. Figure 4 shows an anode device where the sealing material 50 covers a part of the pin 12 in the steam room 24, the opening. 32 and a portion of the upper surface of the anode housing 30. Figure 5 shows an anode device in which the sealing material 50 covers the entire connector leg 12 over the upper surface of the anode housing 30 (i.e., inside the steam compartment 24 and the refractory portion 18), the opening 32 and a portion. of the upper surface of the anode housing 30.
Figure 6 shows an anode device in which the sealing material 50 covers the entire pin 12 in the steam compartment 24, the opening 32 and the entire upper surface of the anode housing 30. In Figure 6, the sealing material 50 extends beyond a peripheral edge of the upper surface of the anode housing and Figure 7 shows an anode device in which the sealing material 50 covers a portion of the pin 12 in the steam compartment 24, the opening 32 and the entire upper surface of the anode housing 30. In Figure 7, the sealing material 50 extends beyond a peripheral edge of the upper surface of the anode housing and covering a portion of the side wall 40 of the anode housing 30.
Figure 8 shows an anode device in which the sealing material 50 covers the entire pin 12 in the steam compartment 24. The sealing material 50 covers the opening 32 and the entire upper surface of the anode housing 30. The sealing material 50 extends beyond a peripheral edge of the upper surface of the anode housing and covers a portion of the side wall 40 of the anode housing 30. The sealing material 50 is also disposed between the steam compartment 24 and the refractory portion 18 to prevent corrosive chemicals from corroding portions of the pin 12 (i.e., not covered by sealing material 50).
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Figure 201 shows an anode device in which the sealing material 50 covers part of the pin 12 in the steam compartment 24, the opening 32 and the entire upper surface of the anode housing 30. The sealing material 50 extends over a peripheral edge of the upper surface. of the anode housing and covering part of the side wall 40 of the anode housing 30. A portion of the pin 12 in the vapor phase 24 is not covered by the sealing material 50. The sealing material 50 is also disposed between the vapor space 24 and the refractory portion 18 to prevent corrosive chemicals from corroding parts. of the pin 12 in the refractory portion.
Figure 10 shows an anode device in which the sealing material 50 covers the entire connector leg of the steam compartment 24. The sealing material 50 covers the opening 32 and the entire upper surface of the anode housing 30. The sealing material 50 does not extend beyond a peripheral edge of the upper surface of the anode housing. to cover a portion of the side wall 40 of the anode housing 30. The sealing material 50 is also disposed between the steam compartment 24 and the refractory portion 18 to prevent corrosive chemicals from corroding portions of the pin 12 (i.e., not covered by sealing material 50).
Figure 11 shows an anode device in which the sealing material 50 covers a portion of the pin 12 in the steam compartment 24, the opening 32 and the entire upper surface of the anode housing 30. The sealing material 50 extends beyond a peripheral edge of the upper surface of the anode housing and covers a portion of the side wall 40 of the anode housing 30. The sealing material extends down the side wall 40 of the anode housing 30 close to the contact surface 22.
Figure 12 shows an anode device in which the sealing material 50 covers a portion of the plug leg 12 in the steam compartment 24, the opening 32 and the entire upper surface of the anode housing 30. Figure 13 shows an anode device where the sealing material 50 covers a part of the plug leg. 12 in the steam room 24, the opening 32 and the entire upper surface of the anode housing 30.
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DK 2019 70168 A1
The sealing material is also arranged in the hole 34 to cover a portion of the pin 12 in the anode housing 30. The sealing material 50 covers a portion of the pin 12 in the anode housing 30 which is above the contact surface 22.
Figure 14 shows an anode device in which the sealing material 50 is arranged in the hole 34 to cover a portion of the pin 12 in the anode housing 30. The sealing material 50 covers a portion of the pin 12 in the anode housing 30 which is above the contact surface 22.
Figure 15 shows an anode device in which the sealing material 50 is arranged in the hole 34 to cover a portion of the pin 12 in the anode housing 30. The sealing material 50 covers a portion of the pin 12 in the anode housing 30 which is over the contact surface 22. a filler material in the hole 34 below the sealing material 50.
Reference is now made in detail to prophetic examples which (in combination with the accompanying drawings and previous descriptions thereof) at least partially assist in illustrating various relevant embodiments of the present invention.
Example: Prophetic Anode Preparation:
Non-limiting examples of the anode housing manufacture include: press sintering, melt casting and casting disclosed in the corresponding U.S. Patent 7,235,161, the contents of which are fully incorporated by reference herein.
When the anode housing is formed, the connector leg and filler materials, if used, are incorporated into the anode housing. For example, if If filler material is used (eg conductive filler material), the plug leg is located in the hole of the anode housing and the filler material (eg in the form of particulate material) is introduced into the space between the plug leg and the inner surface of the hole in the anode housing. Then, the sealing material (i.e., to provide a mechanical fastener and / or sealing the pin and / or filler material in the hole in the anode housing) is added to the upper end of the anode housing. IN
Page 27 of 38
In some embodiments, the sealing material is configured to extend at least partially into the hole in the anode housing. In some embodiments, the sealing material is configured to be located on top of the anode housing, proximal to the upper end of the hole, and enclosing the connector leg as it extends upward from the anode housing. In some embodiments, the sealing material is located on top of the anode housing in a position enclosing the connector leg.
In some embodiments, the sealing material is configured to extend a bit into the hole at the upper end of the anode. In some embodiments, the sealing material is configured to cover the upper portion of the anode housing. In some embodiments, the sealing material is configured to contact at least a portion of the outer peripheral side wall of the anode housing. In some embodiments, the sealing material is configured to contact the pin, the inner portion of the anode housing (hole), the upper portion of / upper surface of the anode housing, and the upper portion of at least a portion of the outer peripheral wall of the anode housing.
While various embodiments of the present invention are described in detail, there is no doubt that those skilled in the art can devise modifications and adaptations of these embodiments. But it should be expressly understood that such modifications and adaptations are within the scope and scope of the present invention.
Prophetic comparative example:
Two anode assemblies (AA1 = prior art and AA2 = one embodiment of the present specification) are made with: the same anode housing dimensions and the same composition in accordance with the disclosures of U.S. Patent No. 7,507 .322 and 7,235,161; the same socket material (copper or copper alloy) and different sealing materials.
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DK 2019 70168 A1 In AA1 the first description (prior art) the sealing material is in accordance with the disclosure of US Patent 7,169,270. In the second description (the present description) the sealing material has 5% by weight. to 100% by weight the sealing material is moldable ceramic or metal ceramic containing Al2O3, SiO2, MgO, CaO, Na2O and combinations thereof, wherein at least some of the additives of silicate and / or aluminate in the sealing material (e.g. moldable ceramic) are replaced by a magnetite additive (f e.g., anode-matched / anode-compatible additive) configured with comparable sizing as the appropriate sizing of the additive as the additive of the prior art.
Both anode units are configured as the embodiment of Figure 2. Both anode units were incorporated into an aluminum electrolysis cell and functioned as electrodes (anodes) extending over the bath-vapor contact surface for a sufficient period of time to evaluate if reactions occurred. result of the interaction of the reactive species in the vapor compartment of the cell with the sealant and / or its constituents.
Anode units are pulled out of the cell and evaluated to evaluate and / or quantify the corrosion on various components of the anode device (e.g., sealing material). It will be seen that the sealing material in AA2, ie. sealant with additive specially designed (i.e., adapted) for the anode housing performed better (has less corrosion) than the known sealant. It is also evident that the socket in AA2 performed better (has less corrosion) than the socket in AA1 (the known anode device).
Without being bound by a particular mechanism or theory, it is believed that the silica (e.g., SiO2 present as an additive in the sealing material) under the operating conditions of the cell (i.e., at high temperature and in a corrosive environment of the vapor chamber). contains
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DK 2019 70168 A1 reactive fluoride gas, oxygen gas and / or other reactive vapors) forms pockets of reactive silicates which can affect the reactive substances in the steam room.
Without being bound by any particular mechanism or theory, it is believed that the reactive silicates in the additives in the sealant (i.e., AA1) will react with fluoride gas present in the vapor space of the cell which in turn forms silicon tetrafluoride which again can break down the connector. Without being bound by a particular mechanism or theory, it is believed that when the reactive silicon fluoride further affects / reacts with the pin, pockets or holes form in the sealing material (such as reducing the mechanical strength / support of the sealing material and providing pores / holes where the reactive materials can further penetrate and react with the sealing material or other components of the anode device, without being bound by a particular mechanism or theory, there are starting sites for corrosion on the socket when the silicon fluoride reacts with the socket materials, further reducing the structural integrity of the anode device and / or the electrical function of this component).
Without being bound by a particular mechanism or theory, it is believed that the silica (e.g. SiO2 present as an additive in the sealing material) under the operating conditions of the cell (i.e., at high temperature and in a corrosive environment of the vapor chamber). contains reactive fluoride gas, oxygen gas and / or other reactive vapors) forms the magnetite additive (e.g. SiO2 and / or Al2O3 replacement in the sealing material) additive pockets designed not to cause significant reaction with the reactants (and thus neither they pore in the sealing material and / or further contribute to corrosion of the connective bone). Without being bound by a particular mechanism or theory, it is believed that the reactive silicates in the additives in the sealing material (i.e., AA1) will react with
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DK 2019 70168 A1 fluoride gas present in the vapor compartment of the cell, which in turn forms silicon tetrafluoride, which in turn can break down the socket.
Various of the above aspects of the invention may be combined to obtain inactive anode devices with a connector providing a mechanical and electrical connection to the anode housing, the connector extending into the hole in the anode housing and positioned so that the lower end of the the pin is located above the interface between steam and steam. These and other aspects, advantages, and novel features of the invention will become apparent in the following description and will become apparent to those skilled in the art upon review of the following description and figures or may be experienced in testing the invention.
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DK 2019 70168 A1
reference numbers
Anode Unit 10
Socket legs 12
First End 14
Second End 16
Anode holder 18
Power supply 20
Bath / steam limit 22
Steam room 24
Bad 26
Anode Device 28
Anode housing 30
Top opening 32
Anode internal sidewall (delimiting hole) 34
Top end of anode 36
Lower end of anode 38
Anode exterior sidewall 40
Conductive filler 42
Particulate matter (conductive filler) 44
Liquid / slurry material (conductive filler) 46
Top surface of anode 48
Sealing material 50
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DK 2019 70168 A1
Additive 52 (large and / or small sizes, eg particles, powder)
Base / Binder 54
权利要求:
Claims (24)
[1]
(1) an interior side wall of the anode housing;
An anode unit comprising:
an anode holder and an anode device mechanically attached to the anode holder, the anode device comprising:
(a) an anode housing comprising at least one exterior sidewall, wherein the exterior sidewall is configured to define the shape of the anode housing and to perimetrically enclose a hole in the anode housing, the hole comprising a top opening in an upper surface of the anode housing, and wherein the hole extends axially into the anode housing;
(b) a connector comprising:
a. a first end connected to a power supply; and
b. a second end opposite the first end, the second end extending downwardly into the upper end of the anode housing and into the hole in the anode housing; and (c) a sealing material comprising an additive and a matrix, wherein the sealing material is configured to cover at least a portion of at least one of the following:
[2]
The anode unit of claim 1, wherein the sealing material comprises at least one of the following: water, polymers, organics, dispersants or diluents.
(2) the upper surface of the anode housing;
[3]
The anode unit according to 1, wherein a sealing material is configured to cover at least a portion of at least one of the following: (1) an interior side wall of the anode housing; (2) the connector leg and (3) a filler material.
(3) the pin and (4) the anode holder.
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DK 2019 70168 A1
[4]
The anode device according to claim 1, wherein the first end of the pin is configured to be retained in an anode holder.
[5]
The anode device according to claim 1, wherein the filler material is retained in the gap between the inner side wall of the anode housing and the connector leg.
[6]
The anode device according to claim 1, wherein the sealing material is configured to enclose the conductive filler material in the anode housing between the inner side wall of the anode housing and the connector leg.
[7]
The anode device of claim 1, wherein the sealing material is molded in place.
[8]
The anode device according to claim 1, wherein the sealing material is molded and screwed into the anode housing.
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DK 2019 70168 A1
[9]
The anode device according to claim 1, wherein the sealing material is sintered in place during sintering of the green anode housing in the final anode housing.
[10]
Anode device according to claim 1, wherein the sealing material is held over the upper surface of the anode housing.
[11]
The anode device according to claim 1, wherein the sealing material is retained in the hole.
[12]
The anode device of claim 10, wherein it comprises over the top surface of the anode housing extending along the connector leg.
[13]
The anode device of claim 10, wherein it comprises over the upper surface of the anode housing extending along the pin and into the anode holder.
[14]
The anode device of claim 10, wherein it comprises over the upper surface of it extending across the upper surface of the upper portion of the anode housing.
[15]
The anode device according to claim 10, wherein it comprises over the upper surface that it extends across the upper surface and down around the outer side wall of the anode housing.
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DK 2019 70168 A1
[16]
Anode device according to claim 10, wherein the sealing material is applied in the anode hole between the pin and the inner surface of the anode housing with a slope so that the concentration of the sealing material varies in a radial direction.
[17]
The anode device according to claim 16, wherein the inclination is configured so that the concentration of the sealing material is higher in the immediate vicinity of the pin compared with the inner surface of the anode housing.
[18]
The anode device according to claim 16, wherein the inclination is configured so that the concentration of the sealing material is lower in the immediate vicinity of the connector leg as compared to the inner surface of the anode housing.
[19]
The anode device according to claim 1, wherein the sealing material is applied in the anode hole between the pin and the inner surface of the anode housing with a slope so that the concentration of the sealing material varies in a lateral direction.
[20]
The anode device according to claim 19, wherein the slope is configured so that the concentration of the sealing material is higher in the immediate vicinity of the upper end as compared to the lower end of the anode housing.
[21]
Anode device according to claim 19, wherein the inclination is configured so that the concentration of the sealing material is lower in the immediate vicinity of the upper end as compared to the lower end of the anode housing.
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DK 2019 70168 A1
[22]
The anode device according to claim 19, wherein the sealing material is configured with a higher concentration at a position in the vicinity of the bath-vapor contact surface compared to either the upper end of the vapor phase or the lower end of the bath of the anode housing.
[23]
The anode device according to claim 19, wherein the concentration of the sealing material from a position just below the contact surface between bath and steam to a position near the upper end of the anode is higher than the portion of the sealing material in the submerged portion of the anode housing.
[24]
An electrolytic cell comprising:
a cell structure comprising a cell floor and a cell wall, wherein the cell wall is configured to perimetrically enclose the cell floor and extend upwardly from the cell floor to define a control amount wherein the control amount is configured to hold a molten electrolyte bath; and an anode unit configured to conduct current into the molten electrolyte bath, the anode unit comprising an anode holder and an anode device mechanically attached to the anode holder, the anode device comprising:
(a) an anode housing comprising at least one exterior sidewall, wherein the exterior sidewall is configured to define the anode shape and to perimetrically enclose a hole in the anode housing, the hole comprising a top opening in the top of the anode housing and the hole extending axially into the anode housing; and
Page 38 of 38
(201) a connector comprising: a first end connected to a power supply and a second end opposite the first end, the second end extending downwardly into the upper end of the anode housing and into the the hole in the anode housing; and (c) a sealing material configured to cover at least a portion of at least one of the following: an interior sidewall of the anode housing; the upper surface of the anode housing; the connector and the anode holder.
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同族专利:
公开号 | 公开日
CA3037199A1|2018-03-22|
BR112019005313A2|2019-09-17|
EP3516094A4|2020-07-15|
CN109715862A|2019-05-03|
WO2018053515A1|2018-03-22|
EA201990554A1|2019-07-31|
CA3037199C|2022-01-04|
EP3516094A1|2019-07-31|
US20200063279A1|2020-02-27|
AU2017327000A1|2019-04-18|
CN109715862B|2021-11-16|
引用文献:
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法律状态:
2019-04-01| PAT| Application published|Effective date: 20190318 |
优先权:
申请号 | 申请日 | 专利标题
US201662396583P| true| 2016-09-19|2016-09-19|
US62/396,583|2016-09-19|
PCT/US2017/052289|WO2018053515A1|2016-09-19|2017-09-19|Anode apparatus and methods regarding the same|
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