Method of manufacturing aluminum in a Hall-Heroult cell

Claim 1

A method for manufacturing aluminum by the electrolysis of alumina in molten cryolite in a Hall-Heroult cell employing a non-consumable anode produced by the process of: (a) forming a first conductive ceramic material to produce a core having a substantially flat working surface and a non-working surface; (b) forming a physically adherent coating over said non-working surface of said core, on at least the portion thereof which is to be exposed to the electrolyte bath in the cell, said coating consisting of a second conductive ceramic material having, as compared to said first conductive ceramic material, (1) a coefficient of thermal expansion differing by no more than about 0.5%, (2) an essentially matched shrinkage during sintering, (3) a higher electrical resistivity, and capable of being chemical diffusion bonded thereto; and (c) sintering the coated core thus formed to produce a monolithic ceramic anode having a substantially flat working surface and a non-working surface, said non-working surface having an impervious coating thereon, at least in the portion thereof exposed to the electrolyte bath, of higher resistivity than the core and chemical diffusion bonded thereto, whereby substantially all of the current applied to said anode is conducted into the electrolyte bath through said flat working surface.

Claim 2

A method for manufacturing aluminum by the electrolysis of alumina in molten cryolite in a Hall-Heroult cell employing a non-consumable anode produced by the process of: (a) forming a first conductive ceramic material to produce a core having a substantially flat working surface and a non-working surface; (b) forming a physically adherent coating over said non-working surface of said core, on at least the portion thereof which is to be exposed to the electrolyte bath in the cell, said coating consisting of a second conductive ceramic material having, as compared to said first conductive ceramic material, (1) a coefficient of thermal expansion differing by no more than about 0.5%, (2) an essentially matched shrinkage during sintering, (3) a higher electrical resistivity, and capable of being chemical diffusion bonded thereto; and (c) sintering the coated core thus formed to produce a monolithic ceramic anode having a substantially flat working surface and a non-working surface, said non-working surface having an impervious coating thereon, at least in the portion thereof exposed to the electrolyte bath, of higher resistivity than the core and chemical diffusion bonded thereto, whereby substantially all of the current applied to said anode is conducted into the electrolyte bath through said flat working surface.

Claim 5

The method of claims 1, 2 or 3 wherein the anode coating consists of an Fe 2 O 3 -doped SnO 2 composition.

Claim 7

A method for manufacturing aluminum by the electrolysis of alumina in molten cryolite in a Hall-Heroult cell employing a non-consumable anode produced by the process of: (a) forming an elongated core having two ends from a first conductive ceramic material; (b) forming a physically adherent coating over said core with a second conductive ceramic material having, as compared to said first conductive ceramic material, (1) a coefficient of thermal expansion differing by no more than about 0.5%, (2) an essentially matched shrinkage during sintering, (3) a higher electrical resistivity, and capable of being chemical diffusion bonded thereto; (c) producing a substantially flat uncoated working surface on only one end of the coated core by removing the coating therefrom; and (d) sintering the coated core having a substantially flat uncoated working surface to produce an integral monolithic body with an impervious coating layer, thereby forming a ceramic anode having a substantially flat working surface and a non-working surface, said non-working surface having a coating of higher resistivity than said core and chemical diffusion bonded thereto, whereby substantially all of the current applied to said anode is conducted into said electrolyte bath through said flat working surface.

Claim 8

A method for manufacturing aluminum by the electrolysis of alumina in molten cryolite in a Hall-Heroult cell employing a non-consumable anode produced by the process of: (a) forming an elongated core having two ends from a first conductive ceramic material; (b) forming a physically adherent coating over said core with a second conductive ceramic material having, as compared to said first conductive ceramic material, (1) a coefficient of thermal expansion differing by no more than about 0.5%, (2) an essentially matched shrinkage during sintering, (3) a higher electrical resistivity, and capable of being chemical diffusion bonded thereto; (c) producing a substantially flat uncoated working surface on only one end of the coated core by removing the coating therefrom; and (d) sintering the coated core having a substantially flat uncoated working surface to produce an integral monolithic body with an impervious coating layer, thereby forming a ceramic anode having a substantially flat working surface and a non-working surface, said non-working surface having a coating of higher resistivity than said core and chemical diffusion bonded thereto, whereby substantially all of the current applied to said anode is conducted into said electrolyte bath through said flat working surface.

Claim 11

The method of claims 6, 7 or 8 wherein the anode coating consists of an Fe 2 O 3 -doped SnO 2 composition.

Claim 13

A method for manufacturing aluminum by the electrolysis of alumina in molten cryolite in a Hall-Heroult cell employing a non-consumable anode produced by the process of: (a) isostatically pressing a first conductive ceramic material to produce a core having a substantially flat working surface and a non-working surface; (b) isostatically pressing a second conductive ceramic material having, as compared to said first conductive ceramic material, (1) a coefficient of thermal expansion differing by no more than about 0.5%, (2) an essentially matched shrinkage during sintering, (3) a higher electrical resistivity, and capable of being chemical diffusion bonded thereto to form a physically adherent coating over said non-working surface of said core, on at least the portion thereof which is to be exposed to the electrolyte bath in the cell; and (c) sintering the coated core thus formed to produce a monolithic ceramic anode having a substantially flat working surface and a non-working surface, said non-working surface having an impervious coating thereon, at least in the portion thereof exposed to the electrolyte bath, of higher resistivity than the core and chemical diffusion bonded thereto, whereby substantially all of the current applied to said anode is conducted into the electrolyte bath through said flat working surface.

Claim 14

A method for manufacturing aluminum by the electrolysis of alumina in molten cryolite in a Hall-Heroult cell employing a non-consumable anode produced by the process of: (a) isostatically pressing a first conductive ceramic material to produce a core having a substantially flat working surface and a non-working surface; (b) isostatically pressing a second conductive ceramic material having, as compared to said first conductive ceramic material, (1) a coefficient of thermal expansion differing by no more than about 0.5%, (2) an essentially matched shrinkage during sintering, (3) a higher electrical resistivity, and capable of being chemical diffusion bonded thereto to form a physically adherent coating over said non-working surface of said core, on at least the portion thereof which is to be exposed to the electrolyte bath in the cell; and (c) sintering the coated core thus formed to produce a monolithic ceramic anode having a substantially flat working surface and a non-working surface, said non-working surface having an impervious coating thereon, at least in the portion thereof exposed to the electrolyte bath, of higher resistivity than the core and chemical diffusion bonded thereto, whereby substantially all of the current applied to said anode is conducted into the electrolyte bath through said flat working surface.

Claim 17

The method of claims 11, 12 or 13 wherein the anode coating consists of an Fe 2 O 3 -doped SnO 2 composition.

Claim 19

A method of manufacturing aluminum by the electrolysis of alumina in molten cryolite in a Hall-Heroult cell employing a non-consumable anode produced by the process of: (a) producing an elongated core having two ends by isostatically pressing a first conductive ceramic material; (b) forming a physically adherent coating over said core by isostatically pressing on the surface thereof a second conductive ceramic material having, as compared to said first conductive ceramic material, (1) a coefficient of thermal expansion differing by no more than about 0.5%, (2) an essentially matched shrinkage during sintering, (3) a higher electrical resistivity, and capable of being chemical diffusion bonded thereto; (c) producing a substantially flat uncoated working surface on only one end of the coated core by removing the coating therefrom; and (d) sintering the coated core having a substantially flat uncoated working surface to produce an integral monolithic body with an impervious coating layer, thereby forming a ceramic anode having a substantially flat working surface and a non-working surface, said non-working surface having a coating of higher resistivity than said core and chemical diffusion bonded thereto, whereby substantially all of the current applied to said anode is conducted into said electrolyte bath through said flat working surface.

Claim 20

A method of manufacturing aluminum by the electrolysis of alumina in molten cryolite in a Hall-Heroult cell employing a non-consumable anode produced by the process of: (a) producing an elongated core having two ends by isostatically pressing a first conductive ceramic material; (b) forming a physically adherent coating over said core by isostatically pressing on the surface thereof a second conductive ceramic material having, as compared to said first conductive ceramic material, (1) a coefficient of thermal expansion differing by no more than about 0.5%, (2) an essentially matched shrinkage during sintering, (3) a higher electrical resistivity, and capable of being chemical diffusion bonded thereto; (c) producing a substantially flat uncoated working surface on only one end of the coated core by removing the coating therefrom; and (d) sintering the coated core having a substantially flat uncoated working surface to produce an integral monolithic body with an impervious coating layer, thereby forming a ceramic anode having a substantially flat working surface and a non-working surface, said non-working surface having a coating of higher resistivity than said core and chemical diffusion bonded thereto, whereby substantially all of the current applied to said anode is conducted into said electrolyte bath through said flat working surface.

Claim 23

The method of claims 16, 17 or 18 wherein the anode coating consists of an Fe 2 O 3 -doped SnO 2 composition.

Claim 25

A method for manufacturing aluminum by the electrolysis of alumina in molten cryolite in a Hall-Heroult cell employing a non-consumable anode produced by the process of: (a) isostatically pressing a first conductive ceramic material consisting of a mixture of 98.5 wt. % SnO 2 , 0.5 wt. % CuO and 1.0 wt. % Sb 2 O 3 to produce a core having a substantially flat working surface and a non-working surface; (b) isostatically pressing a second conductive ceramic material consisting of 98.0 wt. % SnO 2 and 2.0 wt. % Fe 2 O 3 to form a physically adherent coating over said non-working surface of said core on at least the portion thereof which is to be exposed to the electrolyte bath in the cell; and (c) sintering the coated core thus formed to produce a monolithic ceramic anode having a substantially flat working surface and a non-working surface, said non-working surface having an impervious coating thereon, at least in the portion thereof exposed to the electrolyte bath, of higher resistivity than the core and chemical diffusion bonded thereto, whereby substantially all of the current applied to said anode is conducted into the electrolyte bath through said flat working surface.

Claim 26

A method for manufacturing aluminum by the electrolysis of alumina in molten cryolite in a Hall-Heroult cell employing a non-consumable anode produced by the process of: (a) isostatically pressing a first conductive ceramic material consisting of a mixture of 98.5 wt. % SnO 2 , 0.5 wt. % CuO and 1.0 wt. % Sb 2 O 3 to produce a core having a substantially flat working surface and a non-working surface; (b) isostatically pressing a second conductive ceramic material consisting of 98.0 wt. % SnO 2 and 2.0 wt. % Fe 2 O 3 to form a physically adherent coating over said non-working surface of said core on at least the portion thereof which is to be exposed to the electrolyte bath in the cell; and (c) sintering the coated core thus formed to produce a monolithic ceramic anode having a substantially flat working surface and a non-working surface, said non-working surface having an impervious coating thereon, at least in the portion thereof exposed to the electrolyte bath, of higher resistivity than the core and chemical diffusion bonded thereto, whereby substantially all of the current applied to said anode is conducted into the electrolyte bath through said flat working surface.