Electrolysis: processes – compositions used therein – and methods – Electrolytic synthesis – Utilizing fused bath
Reexamination Certificate
2002-04-22
2004-04-20
Valentine, Donald R. (Department: 1742)
Electrolysis: processes, compositions used therein, and methods
Electrolytic synthesis
Utilizing fused bath
C205S394000, C204S244000, C204S293000
Reexamination Certificate
active
06723222
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to electrolytic production of aluminum from alumina and more particularly, it relates to an improved anode for use in a cell for the electrolytic production of aluminum.
In the electrolytic production of aluminum, there is great interest in utilizing an anode substantially inert to the electrolyte and which does not react with oxygen during cell operation. Anodes of this type are described in U.S. Pat. No. 4,399,008 which discloses a composition suitable for fabricating into an inert electrode for use in the electrolytic production of metal from a metal compound dissolved in a molten salt. The electrode comprises at least two metal oxides combined to provide a combination metal oxide.
Also, U.S. Pat. No. 5,284,562 discloses an oxidation resistant, non-consumable anode for use in the electrolytic reduction of alumina to aluminum, which has a composition comprising copper, nickel and iron. The anode is part of an electrolytic reduction cell comprising a vessel having an interior lined with metal which has the same composition as the anode. The electrolyte is preferably composed of a eutectic of AlF
3
and either (a) NaF or (b) primarily NaF with some of the NaF replaced by an equivalent molar amount of KF or KF and LiF.
U.S. Pat. No. 5,069,771 discloses a method of electrowinning a metal by electrolysis of a melt containing a dissolved species of the metal to be won using a non-consumable anode having a metal, alloy or cermet substrate and an operative anode surface which is a protective surface coating of cerium oxyfluoride preserved by maintaining in the melt a suitable concentration of cerium. The anode is provided with an electronically conductive oxygen barrier on the surface of the metal, alloy or cermet substrate. The barrier layer may be a chromium oxide film on a chromium-containing alloy substrate. Preferably the barrier layer carries a ceramic oxide layer, e.g. of stabilized copper oxide which acts as anchorage for the cerium oxyfluoride.
U.S. Pat. No. 3,957,600 discloses anodes of alloys, which may be fragmented and used in baskets, of passive film-forming metals and elements having atomic numbers 23-29 for use in electrowinning metals, methods of using such anodes, and electrowinning cells incorporating such anodes.
Further, U.S. Pat. No. 5,529,494 discloses a monolithic bipolar electrode for the production of primary aluminum by molten salt electrolysis composed of a cermet anodic layer, a conductive and diffusion-resistant intermediate layer, and a refractory hard metal cathodic layer, with the edges covered by an electrolyte-resistant coating. The intermediate conductive layer has a coefficient of thermal expansion intermediate to the anodic and cathodic layers.
U.S. Pat. No. 4,620,905 discloses an electrolytic process comprising evolving oxygen on an anode in a molten salt, the anode comprising an alloy comprising a first metal and a second metal, both metals forming oxides, the oxide of the first metal being more resistant than the second metal to attack by the molten salt, the oxide of the second metal being more resistant than the first metal to the diffusion of oxygen. The electrode may also be formed of CuAlO
2
and/or Cu
2
O.
U.S. Pat. No. 4,871,438 discloses cermet electrode compositions comprising NiO—NiFe
2
O
4
—Cu—Ni, and methods for making the same. Addition of nickel metal prior to formation and densification of a base mixture into the cermet allows for an increase in the total amount of copper and nickel that can be contained in the NiO—NiFe
2
O
4
oxide system. Nickel is present in a base mixture weight concentration of from 0.1% to 10%. Copper is present in the alloy phase in a weight concentration of from 10% to 30% of the densified composition.
U.S. Pat. No. 4,999,097 discloses improved electrolytic cells and methods for producing metals by electrolytic reduction of a compound dissolved in a molten electrolyte. In the improved cells and methods, a protective surface layer is formed upon at least one electrode in the electrolytic reduction cell and, optionally, upon the lining of the cell.
U.S. Pat. No. 5,006,209 discloses that finely divided particles of alumina are electrolytically reduced to aluminum in an electrolytic reduction vessel having a plurality of vertically disposed, non-consumable anodes and a plurality of vertically disposed, dimensionally stable cathodes in closely spaced, alternating arrangement with the anodes.
U.S. Pat. No. 4,865,701 discloses that alumina is reduced to molten aluminum in an electrolytic cell containing a molten electrolyte bath composed of halide salts and having a density less than alumina and aluminum and a melting point less than aluminum. The cell comprises a plurality of vertically disposed, spaced-apart, non-consumable, dimensionally stable anodes and cathodes. Alumina particles are dispersed in the bath to form a slurry. Current is passed between the electrodes, and oxygen bubbles form at the anodes, and molten aluminum droplets form at the cathodes. The oxygen bubbles agitate the bath and enhance dissolution of the alumina adjacent the anodes and inhibit the alumina particles from settling at the bottom of the bath. The molten aluminum droplets flow downwardly along the cathodes and accumulate at the bottom of the bath.
U.S. Pat. No. 6,248,227 discloses a non-carbon, metal-based slow-consumable anode of a cell for the electrowinning of aluminium self-forms during normal electrolysis an electrochemically-active oxide-based surface layer (
20
). The rate of formation (
35
) of the layer (
20
) is substantially equal to its rate of dissolution (
30
) at the surface layer/electrolyte interface (
25
) thereby maintaining its thickness substantially constant, forming a limited barrier controlling the oxidation rate (
35
). The anode (
10
) usually comprises an alloy of iron with at least one of nickel, copper, cobalt or zinc which during use forms an oxide surface layer (
20
) mainly containing ferrite.
U.S. Pat. No. 6,217,739 discloses a method of producing commercial purity aluminum in an electrolytic reduction cell comprising inert anodes. The method produces aluminum having acceptable levels of Fe, Cu and Ni impurities. The inert anodes used in the process preferably comprise a cermet material comprising ceramic oxide phase portions and metal phase portions.
U.S. Pat. No. 4,288,302 discloses novel dimensionally stable electrodes constituted by a film forming metallic material alloyed with at least one member of the group consisting of metal belonging to Groups VIB, VIIB, VIII, IIB, IB, IVA, lanthanum and lanthanide series of the Periodic Table, such as chromium, manganese, rhenium, iron, ruthenium, osmium, cobalt, rhodium, iridium, nickel, palladium, platinum, copper, silver, gold, zinc, cadmium, silicon, germanium, tin, lead and lanthanum having an electroconductive and corrosion resistant surface preactivated on the surface thereof, preparation of said electrodes, use of said electrodes as anodes for electrolysis in aqueous and organic solutions or in fused salts as well as for cathodic protection and electrolysis methods using said electrodes.
U.S. Pat. No. 4,620,905 discloses an electrolytic process comprising evolving oxygen on an anode in a molten salt, the anode comprising an alloy comprising a first metal and a second metal, both metals forming oxides, the oxide of the first metal being more resistant than the second metal to attack by the molten salt, the oxide of the second metal being more resistant than the first metal to the diffusion of oxygen. The electrode may also be formed of CuAlO
2
and/or Cu
2
O.
Additional anode compositions are described in U.S. Pat. Nos. 3,943,048; 4,049,887; 4,956,068; 4,960,494; 5,637,239; 5,667,649; 5,725,744 and 5,993,637.
There is still a need to improve the corrosivity and conductivity of the non-consumable anode to ensure an anode that provides satisfactory performance without dissolution in an electrolytic cell where alumina is reduced to aluminum.
SUMMARY OF THE INVENTION
It is an object of this inventi
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