• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
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    • 专利摘要:
    In one embodiment, An electrolytic cell for producing aluminum metal, the electrolytic cell comprising at least one anode module (12) having a plurality of anodes (12E) and being supported above a corresponding at least one cathode module (14) having a plurality of cathodes (14E), the at least one anode module (12) being supported by a positioning apparatus configured to move inside the electrolytic cell for selective positioning of the plurality of anodes within the electrolytic cell relative to adjacent cathodes in order to adjust an anode-cathode distance (ACD) and/or and an anode-cathode overlap (ACO).
    公开号:DK202070550A1
    申请号:DKP202070550
    申请日:2020-08-25
    公开日:2020-08-31
    发明作者:Liu Xinghua
    申请人:Alcoa Usa Corp；
    IPC主号:
    专利说明:

    [0001] [0001] This application claims priority to U.S. provisional patent application Serial No. 62/313,266, filed March 25, 2016.FIELD
    [0002] [0002] The present invention relates to apparatus and methods for producing aluminum metal and more particularly, to apparatus and methods for producing aluminum metal by the electrolysis of alumina.BACKGROUND
    [0003] [0003] Hall-Héroult electrolytic cells are utilized to produce aluminum metal in commercial production of aluminum from alumina that is dissolved in molten electrolyte (a cryolite "bath”) and reduced by a DC electric current using a consumable carbon anode. Traditional methods and apparatus for smelting alumina utilize carbon anodes that are consumed slowly and generate CO2, a “greenhouse gas.” Traditional anode shapes and sizes also limit electrolysis of the reactant (dissolved alumina), which travels to the middle of the anode bottom for reaction. This leads to a phenomenon called, “anode affect” that results in the generation of CF, another regulated “greenhouse” gas. Besides the traditional commercial aluminum smelter, the prior art also includes aluminum smelter designs where the anodes and cathodes have a vertical orientation, e.g., as described in U.S. Patent No. 5,938,914 to Dawless, entitled, Molten Salt Bath Circulation Design For An Electrolytic Cell. Notwithstanding, alternative electrode and aluminum smelter designs remain of interest in the field.SUMMARY
    [0004] [0004] Generally, the various embodiments of the present disclosure are directed towards vertical electrode configurations for electrolytically producing non-ferrous metal (e.g. aluminum) in an electrolysis cell. As described herein, anode modules (e.g. each module configured with a plurality of vertically oriented, inert anodes) is configured (e.g. attached) to a longitudinal beam, where the beam is configured to span across the open, upper end of the electrolysis cell. The longitudinal beam is configured to be attached to or otherwise coupled to components /lift 1
    [0005] [0005] The disclosed subject matter relates to an electrolytic cell for the production of aluminum from alumina that has: at least one anode module having a plurality of anodes, wherein each of the plurality of anodes is an electrode configured to produce oxygen during electrolysis; at least one cathode module, opposing the anode module, wherein the at least one cathode module comprises a plurality of cathodes, wherein the each of the plurality of anodes and each of the plurality of cathodes have surfaces thereon that are vertically oriented and spaced one from another, wherein the cathodes are wettable, and wherein the at least one cathode module is coupled to a bottom of the electrolytic cell; a cell reservoir; an electrolyte disposed — within the cell reservoir; and a metal pad disposed within the cell reservoir, wherein the plurality of anodes are at least partially immersed in the electrolyte and suspended above the cathode module and extending downwards towards the cathode module, wherein the plurality of cathodes are completely immersed in the electrolyte, wherein the plurality of cathodes are positioned in the cell reservoir extending upwards towards the anode module, wherein each of the plurality of anodes and each of the plurality of cathodes are alternatingly positioned within the cell reservoir, wherein the plurality of anodes is selectively positionable in a horizontal direction relative to 2
    [0006] [0006] In another embodiment, the plurality of anodes form an least one row on the anode module.
    [0007] [0007] In another embodiment, the plurality of cathodes form an at least one row on a cathode module.
    [0008] [0008] In another embodiment, adjacent anodes in the at least one row of anodes have a gap therebetween. — [0009] In another embodiment, adjacent cathodes in the at least one row of cathodes have a gap therebetween.
    [0010] [0010] In another embodiment, a horizontal distance between the anode and the cathode is in a range of 1/4” to 6”, about 0.64cm to about 15.24cm.
    [0011] [0011] In another embodiment, a vertical overlap of the anode and the cathode is in the range of 1” to 100”, about 2. 54cm to about 254cm.
    [0012] [0012] In another embodiment, the anode is a plate with a rectangular cross-sectional shape that is 1” to 75” (about 2.54cm to about 191cm) in width, 5” to 100” (about 12.7cm to about 254cm) in height and 1/4” to 10” (about 0.64cm to about 25.4cm) in thickness.
    [0013] [0013] In another embodiment, the anode is a plate with a rectangular cross-sectional shape — with radiused corners having a width in the range of 1” to 75” (about 2.54cm to about 191cm) in width, 5” to 100” (about 12.7cm to about 254cm) in height and 1/4” to 10” (about 0.64cm to about 25.4cm) in thickness and a corner radius of 1/8” to 1” (about 0.32cm to about 2.54cm).
    [0014] [0014] In another embodiment, the anode is a plate with a rounded rectangular cross- sectional shape with radiused ends having a width in the range of 1” to 75” (about 2.54cm to about 191cm) in width, 5” to 100” (about 12.7cm to about 254cm) in height and 1/4” to 10” (about 0.64cm to about 25.4cm) in thickness and an end radius of 1/8” to 3” (about 0.32cm to about 7.62cm).
    [0015] [0015] In another embodiment, the anode has an elliptical cross-sectional shape with a major axis in the range of 1” to 30” (about 2.54cm to about 762cm), a minor axis in the range of 1/4” to 57 (about 0.64cm to about 12.7cm) and a height in the range of 5” to 50” (about 12.7cm to about 127cm). 3
    [0016] [0016] In another embodiment, the anode has a circular cross-sectional shape with a radius in the range of 1/4” to 6” (about 0.64cm to about 15.2cm) and a height in the range of 5” to 75” (about 12.7cm to about 191cm).
    [0017] [0017] In another embodiment, the cathode is a plate with a rectangular cross-sectional shape having a width in the range of 1” to 75” (about 2.54cm to about 191cm) in width, 5” to 100” (about 12.7cm to about 254cm) in height and 1/8” to 5” (about 0.32cm to about 12.7cm) in thickness.
    [0018] [0018] In another embodiment, the cathode module includes a plurality of cathodes forming at least one row on the cathode module with adjacent cathodes in a row having a gap therebetween and wherein the plurality of cathodes have a rectangular cross-sectional shape having a dimensions in the range of 1” to 40” (about 2,54cm to about 102cm) in width, 5” to 75” (about 12.7cm to 191cm) in height and 1/8” to 5” (about 0.32cm to about 12.7cm) in thickness and a gap in the range of 1/16” to 5” (about 0. 16cm to about 12.7cm) therebetween.
    [0019] [0019] In another embodiment, the cathode module includes a plurality of cathodes forming at least one row on a cathode module with adjacent cathodes in a row having a gap therebetween and wherein the plurality of cathodes have a circular cross-sectional shape having a radius in the range of 1/8” to 3” (about 0.32cm to about 7.62cm), a height in the range of 5” to 75” (about
    [0021] [0021] In another embodiment, the cathode module includes a plurality of cathodes forming at least one row on a cathode module with adjacent cathodes in a row having a gap therebetween and wherein the plurality of cathodes have an elliptical cross-sectional shape having a minor axis in the range of 1/4” to 3” (about 0.64cm to about 7.62cm) a major axis in the range of 1” to 8” (about 2.54cm to about 20.3cm) and a height in the range of 5” to 75” (about 12.7cm to about 191cm) and a gap in the range of 1/16” to 3” (about 0. 16cm to about 7.62cm) therebetween.
    [0022] [0022] In another embodiment, the anode module includes a plurality of anodes disposed on the anode module in an array forming a plurality of rows and the cathode module includes a plurality of cathodes disposed on the cathode module in an array forming a plurality of rows, wherein the plurality of rows of anodes and the plurality of rows of cathodes are interleaving, and wherein the plurality of anodes have a cross-sectional shape of at least one of rectangular, rectangular with radiused edges, rounded rectangular, circular, or elliptical, and the plurality of cathodes have a cross-sectional shape of at least one of rectangular, rectangular with radiused edges, rounded rectangular, circular, or elliptical.
    [0023] [0023] In another embodiment, the anode module has a profile in a plane perpendicular to a — direction of extension of the anodes with a first dimension larger than a second dimension, the plurality of rows of anodes are disposed either parallel or perpendicular to the first dimension.
    [0024] [0024] In another embodiment, a vertical distance between an upper surface of the electrolyte and an upper end of the cathode is in a range of 1/8” to 10” (about 0.32cm to about
    [0027] [0027] In another embodiment, the feed material is electrolytically reduced into a metal product.
    [0028] [0028] In another embodiment, the metal product is drained from the cathodes to the cell bottom to form a metal pad. — [0029] In another embodiment, a metal product is produced having a purity of P1020.
    [0030] [0030] In another embodiment, adjusting the anode module comprises raising the at least one anode module to decrease an overlap of the portion of each of the anode electrodes relative to the portion of adjacent cathodes.
    [0031] [0031] In another embodiment, adjusting the anode module comprises lowering the at least one anode module to increase an overlap of the portion of each of the anode electrodes relative to the portion of adjacent cathodes.
    [0032] [0032] In another embodiment, a method for producing aluminum metal by the electrochemical reduction of alumina, comprises: (a) passing current between an anode and a cathode through an electrolytic bath of an electrolytic cell, the cell comprising: (1) at least one anode module having a plurality of anodes, wherein each of the plurality of anodes is an anode configured to produce oxygen during electrolysis, (11) at least one cathode module, opposing the anode module, wherein the at least one cathode module comprises a plurality of cathodes, wherein each of the plurality of anodes and each of the plurality of cathodes have surfaces thereon that are vertically oriented and spaced one from another, wherein the cathodes are wettable, and wherein the at least one cathode module is coupled to a bottom of the electrolytic cell, (111) a cell reservoir, (iv) an electrolyte disposed within the cell reservoir, and (v) a metal 6
    [0033] [0033] In another embodiment, adjusting the plurality of anodes comprises adjusting the plurality of anodes in a horizontal direction such that a horizontal spacing is substantially similar on either side of the anodes in the anode module.
    [0035] [0035] In another embodiment, the metal product is drained from the cathodes to the cell bottom to form a metal pad.
    [0036] [0036] In another embodiment, a metal product is produced having a purity of P1020.BRIEF DESCRIPTION OF THE DRAWINGS
    [0037] [0037] For a more complete understanding of the present disclosure, reference is made to the following detailed description of exemplary embodiments considered in conjunction with the accompanying drawings.
    [0039] [0039] FIG. 2 is a perspective view of a pair of interleaved anode and cathode modules in accordance with an embodiment of the present disclosure.
    [0040] [0040] FIG. 3 is a side view of a portion of interleaved anode and cathode modules in accordance with an embodiment of the present disclosure.
    [0041] [0041] FIG. 4 is a partially cross-sectional, perspective view of an electrolytic cell in 7
    [0042] [0042] FIG. 5 is a perspective view of an array of interleaved anode and cathode modules in accordance with another embodiment of the present disclosure.
    [0043] [0043] FIG. 6 is a partially phantom plan view of an anode-cathode module within an electrolytic cell in accordance with another embodiment of the present disclosure.
    [0044] [0044] FIG. 7 is a series of diagrammatic cross-sectional views of a variety of anodes in accordance with embodiments of the present disclosure.
    [0045] [0045] FIG. 8 is a series of diagrammatic cross-sectional views of a variety of cathodes in accordance with embodiments of the present disclosure.
    [0046] [0046] FIGS. 9-13 are a series of diagrammatic plan views of a variety of interleaved anode and cathodes, in accordance with embodiments of the present disclosure.
    [0047] [0047] FIG. 14 is a partially cross-sectional, perspective view of an exemplary positioning apparatus coupled to an electrolytic cell for the production of aluminum. — [0048] FIG. 15 is a partially cross-sectional, perspective view of an exemplary positioning apparatus coupled to an electrolytic cell for the production of aluminum.DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
    [0049] [0049] FIG. 1 shows a schematic cross-section of an electrolytic cell 10 for producing aluminum metal by the electrochemical reduction of alumina using an anode and a cathode. In some embodiments, the anode is an inert anode. Some non-limiting examples of inert anode compositions include: ceramic, metallic, cermet, and/or combinations thereof. Same non-limiting examples of inert anode compositions are provided in U.S. Pat. Nos. 4,374,050, 4,374,761, 4390 008, 4455211, 4,382,585, 4,584,172, 4,620,905, S279.715, 5,794,112 and 5,855,980, assigned to the assignee of the present application. In some embodiments, the anode is an electrode configured to produce oxygen during electrolysis. The cathode is a wettable cathode, In some embodiments, alumioum wetiable materials are materials having a contact angle with molten aluminum of not greater than 90 degrees in the molten electrolyte. Some non-limiting examples of wettable materials may comprise one or more of 115, ZB, HIB; 5B; carbonaceous materials, and combinations thereof
    [0050] [0050] The cell 10 has at least one anode module 12. The anode module 12 has at least one 8
    [0051] [0051] Figure 14 depicts a perspective view of an exemplary apparatus 100 for the — production of aluminum. The at least one anode module 12 having a plurality of anodes 12E is supported above the corresponding at least one cathode module 14 having a plurality of cathodes 9
    [0052] [0052] The span beam 102 has a first end 104 and an opposing second end 106. In some embodiments, the span beam 102 is supported by a first supporting apparatus 108 at the first end 104 and by a second supporting apparatus 110 at the second end 106. Each of the supporting apparatuses 108, 110 are positioned on a deck 140 of the sidewall 142. The span beam 102 is oriented perpendicular to the sidewall 142. In some embodiments, the supporting apparatuses 108, 110 are coupled to the deck 140. In some embodiments, the span beam 102 can be raised or lowered by lifts 130 coupled to the supporting apparatuses 108, 110.
    [0053] [0053] The anode module 12 is coupled to the span beam 102 via a connector apparatus 116. The connector apparatus 116 comprises a first portion 118 in contact with and connected to a — surface 120 of the anode module 12. In some embodiments, the first portion 118 is connected to the surface 120 at a plurality of connection points. The connector apparatus 116 further comprises a second portion 124. The second portion 124 has a first end and an opposing second end. The first end of the second portion 124 is coupled to, or integrally formed with, the first portion 118. The second portion 124 extends vertically from the first portion 124 toward the span beam 102. The connector apparatus 116 further comprises a third portion 126. The third portion 126 is coupled to the second end of the second portion 124. In some embodiments, the third portion 126 is clamped to the span beam 102. In some embodiments, the third portion can be unclamped and allowed to move freely along the length of the span beam 102 (i.e. in the direction shown by arrow 128) to allow for selective positioning of the plurality of anodes in a — horizontal direction relative to adjacent cathodes.
    [0054] [0054] Figure 15 depicts a perspective view of another exemplary apparatus 200 for the production of aluminum. The at least one anode module 12 having a plurality of anodes 12E is supported above the corresponding at least one cathode module 14 having a plurality of cathodes 14E. In some embodiments, the at least one anode module 12 is supported by a positioning apparatus as depicted in Figure 15. In some embodiments, the positioning apparatus comprises at least one bridge 202. 10
    [0055] [0055] The bridge 202 has a first end 204 and an opposing second end 206. In some embodiments, the bridge 202 is supported by a supporting apparatus 210 at the first end 204 and at the second end 206. The supporting apparatus 210 comprises a plurality of vertical supports 240, positioned on opposing decks 242 of the endwall 216. The bridge 202 is oriented perpendicular to the endwall 216 and parallel to the sidewalls. In some embodiments, each vertical support 240 is coupled to each corresponding deck 242. During operation of the exemplary apparatus 200 for the production of aluminum, the exemplary apparatus can be heated to a temperature sufficient to result in expansion of the apparatus. In some embodiments, the vertical supports at one deck 242 are unlocked (i.e. free floating), thereby allowing the deck 242 of the apparatus 200 to expand without deforming any portion of the apparatus 200.
    [0056] [0056] The anode module 12 is coupled to the bridge 202 via a connector apparatus 244. The connector apparatus 244 comprises a first portion 246 in contact with and connected to a surface 222 of the anode module 12. In some embodiments, the first portion 246 is connected to the surface 222 at a plurality of connection points. The connector apparatus 244 further comprises a second portion 224. The second portion 224 has a first end and an opposing second end. The first end of the second portion 224 is coupled to, or integrally formed with, the first portion 246. The second portion 224 extends vertically from the first portion 246 toward the bridge 202. The connector apparatus 244 further comprises a third portion 226. The third portion 226 is coupled to the second end of the second portion 224. In some embodiments, the third portion 226 can be raised or lowered to adjust the anode module in a vertical direction relative to the cathode module.
    [0057] [0057] In some embodiments, the connector apparatus 244 can be adjusted along the length of the bridge 202 (i.e. in the direction shown by arrow 228) to allow for selective positioning of the plurality of anodes in a horizontal direction relative to adjacent cathodes.
    [0059] [0059] FIG. 3 shows an anode module 112 and a cathode module 114 with the electrodes 112E and 114E thereof in an interleaved relationship. The height of the bath 122 relative to the cathodes 114 may be called the “bath-to cathode distance” or BCD. In one embodiment, the BCD may be in the range of 1/8” to 10” (about 0.32cm to about 25.4cm) and in another embodiment, 1/2” to 6” (about 1.27cm to about 15.2cm). The anode module 112 can be raised and lowered (i.e. selectively positionable) in height relative to the position of the cathode module 114, as indicated by double ended arrow V. In some embodiments, the anodes 112E are not completely submerged in the bath and extend across the bath-vapor interface during metal production. This vertical adjustability allows the “overlap” Y of the anodes and the cathodes to be adjusted. The level of the electrolytic bath 22 (FIG. 1), the height of the anodes electrodes 112E and the cathode elements 114E may require the adjustment of the anode module 112 position relative to the cathode module 114 in the vertical direction, to achieve a selected anode- cathode overlap (ACO) Y, as well as depth of submersion in the electrolyte 22. In some embodiments, as shown in FIG.3, the anode electrodes 112E are at least partially immersed in the electrolyte and the cathode electrodes 114E are completely immersed in the electrolyte. Changing the ACO Y can be used to change the cell resistance and maintain stable cell temperature.
    [0061] [0061] The dimensional range of the spacing Z for the combination of anodes 112E and cathodes 114E depends upon the thickness of the anodes 112E and cathodes 114E, as well as the anode-cathode distance (ACD). The dimensional range of the spacing for X1 and X2 for the anodes 112E and cathodes 114E having the above described dimensional ranges will be 1/4” to 6” (about 0.64cm to about 15.2cm), in some embodiments, 1/4” to 5” (about 0.64cm to about
    [0062] [0062] The anodes 112E may be monolithic or composite, having an internal portion made from a metallic conductor and an outer portion that is formed from a material adapted to resist oxidation and corrosion due to exposure to the molten electrolyte 22 in a cell 10. The anodes —112E may be ceramic-based, e.g., oxides of iron, titanium, zinc, cobalt, and copper, ferrites (nickel ferrites, copper ferrites, zinc ferrites, multi-element ferrites) and mixtures thereof; metallic-based, e.g., copper, nickel, iron, cobalt, titanium, aluminium, zinc, tin, and/or alloys of one of more of these metals; or cermet based (mixtures of oxides and metals, i.e., a composite material comprising at least one ceramic phase and one metallic phase). The cathodes 14E may be made from corrosion resistant, molten aluminium-wettable materials, such as titanium diboride, zirconium diboride, hafnium diboride, strontium diboride, carbonaceous materials and 13
    [0063] [0063] The opposed, vertically oriented electrodes 112E, 114E permit the gaseous phases (Oy), generated proximal thereto to detach therefrom and physically disassociate from the anode 112 due to the buoyancy of the O, gas bubbles in the molten salt electrolyte 22. Since the bubbles are free to escape from the surfaces of the anode 112 they do not build up on the anode surfaces to form an electrically insulative/resistive layer allowing the build-up of electrical potential, resulting in high resistance and, high energy consumption. The anodes 112E may be arranged in rows or columns with or without a side-to side clearance or gap between them to create a channel that enhances molten electrolyte movement, thereby improving mass transport — and allowing dissolved alumina to reach the surfaces of the anode module 112. The number of rows of anodes 112E can vary from 1 to any selected number and the number of anodes 112E in a row can vary from 1 to any number. The cathodes 114E may be similarly arranged in rows with or without side-to-side clearance (gaps) between them and may similarly vary in the number of rows and the number of cathodes 114E in a row from one to any number.
    [0064] [0064] FIG. 4 shows the cell 10 of FIG. 1 in an orientation allowing the visualization of the ACD (X1, X2) and overlap Y.
    [0065] [0065] FIG. 5 shows two rows of an anode array of anode modules 212 and cathode modules 214 like those shown in FIGS. 1 and 2. For anode modules 212 and cathode modules 214 having the range of dimensions described above in reference to FIGS. 1 and 2, the number of anode — modules 212 and cathode modules 214 in the array may be in the range of 1 to 64, in some embodiments 2 to 48 and in some embodiments 8 to 48 that would be accommodated in a reservoir 16 (FIG. 1).
    [0066] [0066] FIG. 6 shows an anode-cathode module 412 positioned within a cell 410 in accordance with another embodiment of the present disclosure. The anode module 412 has five rows of anodes 412E that are closely spaced or touching side-to-side on the longer dimension of the anode module 412. Three center rows of anodes have nine anodes 412E and two exterior rows have eight anodes 412E to accommodate chamfered edges 412C. The chamfered edges 412C may be used to allow adding alumina or aluminum metal tapping. Four rows of cathodes 414E, each four in number, are interleaved with the rows of anodes 412E.
    [0067] [0067] The anode cathode distance (ACD) is both consistent and the same on either side of the anodes 412E and cathodes 414E, 1.e., X1 and X2 are approximately equal and may range in 14
    [0068] [0068] FIG. 7 shows a series of diagrammatic cross-sectional views of a variety of anodes S12E, 612E, 712E, 812E and 912E in accordance with embodiments of the present disclosure. Anode 512E has a rectangular cross-sectional shape and may have dimensions in the range of 1” to 75” (about 2.54cm to about 191cm) in width (W), 5” to 100” (about 12.7cm to about 254cm) — in height (into and out of the plane of the drawing) and 1/4” to 10” (about 0.64cm to about
    [0070] [0070] Anode 712E has a rounded, rectangular cross-sectional shape with radiused ends and may have dimensions in the range of 1” to 50” (about 2.54cm to about 127cm) in width, 5” to 75” (about 12.7cm to about 191cm) in height (into and out of the plane of the drawing), 1/4” to 6” (about 0.64 cm to about 15.2cm) in thickness and radius of curvature R2 of 1/8” to 3” (about
    [0071] [0071] Anode 812E has an elliptical cross-sectional shape with a major axis Al in the range of 1” to 30” (about 2.54cm to about 76.2cm), a minor axis A2 in the range of 1/4” to 5” (about
    [0073] [0073] While each of the anode 512E-912E cross-sections shown in FIG. 11 may be consistent along the length of the respective anode 512E-912E, the cross-section may also vary along the length (height) of the anode, e.g., the anode may taper in any given direction, execute a periodic variance, or otherwise vary in thickness and/or width cross-section along the length (height) thereof.
    [0074] [0074] FIG. 8 shows a series of diagrammatic cross-sectional views of a variety of cathodes 17
    [0075] [0075] Cathodes 1114E have a rectangular cross-sectional shape and may have dimensions in the range of 1” to 40” (about 2.54cm to about 102cm) in width (W), 5” to 75” (about 12.7cm to about 191cm) in height (into and out of the plane of the drawing) and 1/8” to 5” (about 0.32cm to about 12.7cm) in thickness. They are spaced side-to-side by a gap G1 having dimensions in a range of 1/16” to 5” (about 0.16cm to about 12.7cm). In some embodiments, the rectangular cross-sectional shape may have a width of 1” to 30” (about 2.54cm to about 76.2cm), 1” to 20” (about 2.54cm to about 50.8cm), 1” to 10” (about 2.54cm to about 25.4cm), 10” to 40” (about
    [0076] [0076] Cathodes 1214E have a circular cross-sectional shape and may have dimensions in the range of 1/8” to 3” (about 0.32cm to about 7.62cm) in radius and 5” to 75” (about 12.7cm to about 191cm) in height (into and out of the plane of the drawing). They are spaced one from another by a gap G2 having dimensions in a range of 1/16” to 2” (about 0.16cm to about —5.08cm). In some embodiments, the circular cross-sectional shape may have a radius of 1/8” to 2” (about 0.32cm to about 5.08cm), 1/8” to 1” (about 0.32cm to about 2.54cm), 1” to 3” (about
    [0077] [0077] Cathodes 1314E have a rounded rectangular cross-sectional shape and may have dimensions in the range of 1/4” to 3” (about 0.32cm to about 7.62cm) in width (W), 5” to 75” (about 12.7cm to about 191cm) in height (into and out of the plane of the drawing) and 1/8” to 3” (about 0.32cm to about 7.62cm) in thickness. They are spaced one from another by a gap G3 having dimensions in a range of 1/16” to 3” (about 0.16cm to about 7.62cm). In some embodiments, the rounded rectangular cross-sectional shape may have a width of 1/4” to 2” (about 0.64cm to about 5.08cm), 1/4” to 1” (about 0.64cm to about 2.54cm), 1/4” to 1/2” (about
    [0078] [0078] Cathodes 1414E have an elliptical cross-sectional shape and may have dimensions with a major axis in the range of 1” to 8” (about 2.54cm to about 20.3cm), a minor axis in the range of 1/4” to 3” (about 0.64cm to about 7.62cm) and a height in the range of 5” to 75” (about
    [0080] [0080] FIG. 10 shows two anode cathode configurations A and B, each featuring rectangular thermal insulation layers 1712B, 1812B with chamfers C. Anode module 1712 has six rows of anodes 1712E with circular cross-sectional shape. Each row, which extends across the smaller dimension of the anode module 1712, has eight anodes 1712E, except the row near the chamfers C, which has six. The anodes 1712E are spaced along the shorter dimension of the anode module 1712. Five rows of cathodes 1714E with a generally rectangular cross-sectional shape, each row having four cathodes 1714E, are interleaved with the rows of anodes 1712E. Anode module 1812 has four rows of anodes 1812E having circular cross-sectional shape, each with either twelve (center rows) or eleven anodes (end rows near chamfer) per row, that are closely spaced along the longer dimension of the anode module 1812. Three rows of cathodes 1814E, each with three cathodes 1814E in number, are interleaved with the rows of anodes 1812E.
    [0081] [0081] FIG. 11 shows two anode-cathode configurations A and B, each featuring rectangular thermal insulation layers 1912B, 2012B with chamfers C. Anode module 1912 has six rows of anodes 1912E with circular cross-sectional shape. Each row, which extends across the smaller — dimension of the anode module 1912, has eight anodes 1912E, except the row near the chamfers C, which has six. The anodes 1912E are spaced along the shorter dimension of the anode module 1912. Five rows of cathodes 1914E with a generally rectangular cross-sectional shape, each row having six cathodes 1914E, are interleaved with the rows of anodes 1912E. Anode module 2012 has four rows of anodes 2012E with a circular cross-sectional shape, each with — either twelve (center rows) or eleven anodes (end rows near chamfer) per row, that are closely spaced along the longer dimension of the anode module 2012. Three rows of cathodes 2014E, each with nine cathodes 2014E in number, are interleaved with the rows of anodes 2012E.
    [0082] [0082] FIG. 12 shows two anode-cathode configurations A and B, each featuring rectangular thermal insulation layers 2112B, 2212B with chamfers C. Anode module 2112 has six rows of anodes 2112E with circular cross-sectional shape. Each row, which extends across the smaller dimension of the anode module 2112, has eight anodes 2112E, except the row near the chamfers 21
    [0084] [0084] The above-described electrodes in the dimensional ranges disclosed may be used to produce P1020 or better aluminum metal. The increased surface area of the electrodes per unit of cell volume may lead to higher rates of production. The above described electrode structures — may elimination or reduction of CO, generation and reduce pollutants generated by Hall-Héroult smelting, such as CF4 and SO.
    [0085] [0085] In some embodiments, a method for producing aluminum metal by the electrochemical reduction of alumina, comprises: (a) passing current between an anode and a cathode through an electrolytic bath of an electrolytic cell, the cell comprising: (1) at least one anode module having a plurality of anodes, wherein each of the plurality of anodes is an anode configured to produce oxygen during electrolysis, (11) at least one cathode module, opposing the 22
    [0086] [0086] In some embodiments of the above described method, the feed material is electrolytically reduced into a metal product. In some embodiments of the above described method, the metal product is drained from the cathodes to the cell bottom to form a metal pad. In some embodiments of the above described method, a metal product is produced having a purity of P1020. In some embodiments of the above described method, adjusting the anode module comprises raising the at least one anode module to decrease an overlap of the portion of each of the anode electrodes relative to the portion of adjacent cathodes (e.g. decrease the anode- cathode overlap (ACO)). In some embodiments of the above described method, adjusting the anode module comprises lowering the at least one anode module to increase an overlap of the portion of each of the anode electrodes relative to the portion of adjacent cathodes. (e.g. increase the anode-cathode overlap (ACO)).
    [0087] [0087] In some embodiments, a method for producing aluminum metal by the electrochemical reduction of alumina, comprises: (a) passing current between an anode and a cathode through an electrolytic bath of an electrolytic cell, the cell comprising: (1) at least one anode module having a plurality of anodes, wherein each of the plurality of anodes is an anode 23
    [0088] [0088] In some embodiments of the above described method, the plurality of anodes is adjusted in a horizontal direction such that a horizontal spacing (e.g. the anode-cathode distance (ACD)) is the same, or substantially similar, on either side of the anodes in the anode module (i.e. when measuring the ACD on either side of an anode in the anode module to cathodes positioned on opposite sides of the anode). In some embodiments of the above described method, the feed material is electrolytically reduced into a metal product.
    [0089] [0089] In some embodiments of the above described method, the metal product is drained — from the cathodes to the cell bottom to form a metal pad. In some embodiments of the above described method, a metal product is produced having a purity of P1020.
    [0090] [0090] The adjustment of the vertical or horizontal position of the anode module as described in embodiments above provides for increased electrical efficiency in electrolytic metal production. The adjustment of the vertical or horizontal position of the anode module as — described in embodiments above also provides for reduced cell voltage drop (e.g. reduced electrical resistance). The adjustment of the vertical or horizontal position of the anode module 24
    DK 2020 70550 A1 as described in embodiments above also provides for modified cell temperature; modified feed rate of feed material, and or optimized cell operating parameters.
    权利要求:
    Claims (23)
    [1] 1. An electrolytic cell for producing aluminum metal, the electrolytic cell comprising at least one anode module (12) having a plurality of anodes (12E) and being supported above a corresponding at least one cathode module (14) having a plurality of cathodes (14E), the at least one anode module (12) being supported by a positioning apparatus configured to move inside the electrolytic cell for selective positioning of the plurality of anodes within the electrolytic cell relative to adjacent cathodes in order to adjust an anode-cathode distance (ACD) and/or and an anode-cathode overlap (ACO).
    [2] 2 The electrolytic cell according to claim 1, wherein the positioning apparatus comprises a connector assembly (116) for connecting the at least one anode module (12) to a span beam (102) located above the at least one anode module (12), the connector assembly (116) being configured to move freely along a length of the span beam (102) to allow for selective positioning of the plurality of anodes in a horizontal direction relative to adjacent cathodes in — order to adjust said anode-cathode distance (ACD).
    [3] 3. The electrolytic cell according to claim 2, wherein the span beam (102) has a first end (104) and an opposing second end (106), the span beam (102) being supported by a first supporting apparatus (108) at the first end (104) and by a second supporting apparatus (110) at the second end (106), each of the supporting apparatuses (108, 110) being positioned on a deck — (140) adjacent of a sidewall (142) of the electrolytic cell.
    [4] 4. The electrolytic cell according to claim 3, wherein the span beam (102) is oriented perpendicular to the sidewall (142).
    [5] 5. The electrolytic cell according to claim 3 or 4, wherein the supporting apparatuses (108, 110) are coupled to the deck (140).
    [6] 6. The electrolytic cell according to any one of claims 3 to 5, wherein the span beam (102) is configured to be raised or lowered by lifts (130) coupled to the supporting apparatuses (108, 110). 26
    DK 2020 70550 A1
    [7] 7. The electrolytic cell according to any one of claims 2 to 6, wherein the connector assembly (116) comprises a first portion (118) in contact with and connected to an upper surface (120) of the anode module (12).
    [8] 8. The electrolytic cell according to claim 7, wherein the first portion (118) is connected to — the upper surface (120) at a plurality of connection points.
    [9] 9. The electrolytic cell according to claim 7 or 8, wherein the connector assembly (116) further comprises a second portion (124) comprising a first end and an opposing second end, the first end of the second portion (124) being coupled to, or integrally formed with, the first portion (118), the second portion (124) extending vertically from the first portion (124) toward the span beam (102).
    [10] 10. — The electrolytic cell according to claim 9, wherein the connector assembly (116) further comprises a third portion (126) coupled to the second end of the second portion (124), the third portion (126) being configured to slide along the length of the span beam (102).
    [11] 11. The electrolytic cell according to claim 10, wherein the third portion (126) 1s configured to be clamped to the span beam (102) in order to fix a position of the positioning module on the span beam, or unclamped when the third portion (126) is moved freely along the length of the span beam (102) to change the potion of the positioning module on the span beam.
    [12] 12. The electrolytic cell according to any one of claims 2 to 10, wherein in accordance with a number of anode modules (12) and cathode modules (12) in the electrolytic cell, the electrolytic — cell comprises more than one of said span beam (102) in parallel configuration, each span beam (102) supporting one or more anode module (12) along the length of each span beam, each anode module (12) comprising one of said positioning apparatus.
    [13] 13. The electrolytic cell according to claim 1, wherein the positioning apparatus is connected to at least one bridge (202) oriented perpendicular to endwalls (216) and parallel to sidewalls of — said electrolytic cell, the positioning apparatus being configured to raise or lower to the anode module in a vertical direction relative to the cathode module (14) in order to adjust said anode- cathode overlap (ACO).
    27
    DK 2020 70550 A1
    [14] 14. The electrolytic cell according to claim 13, wherein the at least one bridge (202) comprising a first end (204) and an opposing second end (206), the bridge (202) being supported by a supporting apparatus (210) at the first end (204) and at the second end (206).
    [15] 15. The electrolytic cell according to claim 14, wherein the supporting apparatus (210) comprises a plurality of vertical supports (240) positioned on opposing decks (242) of each endwall (216).
    [16] 16. The electrolytic cell according to claim 15, wherein each vertical support (240) is coupled to each corresponding deck (242).
    [17] 17. The electrolytic cell according to claim 15 or 16, wherein during operation of the electrolytic cell for the production of aluminum, the electrolytic cell is heated to a temperature sufficient to result in expansion of the electrolytic cell, the vertical supports at one deck (242) are unlocked for free floating, thereby allowing the deck (242) of the electrolytic cell to expand without deforming any portion of the cell.
    [18] 18. The electrolytic cell according to any one of claims 13 to 17, wherein the anode module (12) is coupled to the bridge (202) via a connector apparatus (244) comprising a first portion (246) in contact with and connected to an upper surface (222) of the anode module (12).
    [19] 19. The electrolytic cell according to claim 18, wherein the first portion (246) is connected to the upper surface (222) at a plurality of connection points.
    [20] 20. The electrolytic cell according to claim 18 or 19, wherein the connector apparatus (244) further comprises a second portion (224) having a first end and an opposing second end, the first end of the second portion (224) being coupled to, or integrally formed with, the first portion (246).
    [21] 21. The electrolytic cell according to claim 20, wherein the second portion (224) extends vertically from the first portion (246) toward the bridge 202, the connector apparatus (244) — further comprises a third portion (226) coupled to the opposite second end of the second portion (224), the third portion (226) being configured to raise or lower the anode module in the vertical direction relative to the cathode module (14) in order to adjust the anode-cathode overlap (ACO).
    28
    DK 2020 70550 A1
    [22] 22. The electrolytic cell according to any one of claims 18 to 21, wherein the connector apparatus (244) is further configured to move along a length of the bridge (202) to allow for selective positioning of the plurality of anodes in a horizontal direction relative to adjacent cathodes.
    [23] 23. The electrolytic cell according to any one of claims 1 to 21, further comprising an adjustment system coupled to the at least one cathode module (14) for moving said at least one cathode module, thereby adjusting said anode-cathode distance (ACD).
    29
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    公开号 | 公开日
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    BR112018069046A2|2019-01-29|
    WO2017165838A1|2017-09-28|
    EA202091993A1|2021-03-31|
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    AU2017238837B2|2020-05-14|
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    DK201870674A1|2019-01-07|
    EA201892174A1|2019-02-28|
    EP3875635A1|2021-09-08|
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    法律状态:
    2020-08-31| PAT| Application published|Effective date: 20200825 |
    优先权:
    申请号 | 申请日 | 专利标题
    US201662313266P| true| 2016-03-25|2016-03-25|
    DKPA201870674A|DK180286B1|2016-03-25|2018-10-16|Electrode configurations for electrolytic cells and related methods|
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