CA1053607A - Electrolytic cell including cathode busbar structure cathode fingers, and anode base - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE
A novel electrolytic cell comprising a novel cathode busbar structure, novel cathode fingers and a novel anode base structure which enable the novel electrolytic cell to be designed to operate as a chlor-alkali diaphragm cell at high current capacities of about 150,000 amperes and upward to about 200,000 amperes while maintaining high operating efficiencies. These high current capacities provide for high production capacities which result in high production rates for given cell room floor areas and reduce capital investment and operating costs. The cathode busbar structure comprises at least one lead-in busbar and a plurality of busbar strips which have different relative dimensions, and are fabricated from a highly conductive metal the cathode busbar structure is attached in electrical contact to at least one sidewall of a cathode walled enclosure fabricated from a conductive metal and having sidewalls, containing a plurality of cathode fingers. The cathode fingers comprise conductive reinforcing means, lengths of highly conductive metal positioned in the cathode finger structure, and foraminous conductive metal means attached to the reinforcing means thereby forming the exterior of the cathode finger structure and gas compartment space inside the cathode finger structure; cathode fingers extend substantially across the interior of the cathode walled enclosure and the cathode fingers are attached in electrical contact to at least one interior sidewall of the cathode walled enclosure the cathode busbar structure is attached in electrical contact to the exterior sidewall of the cathode walled enclosure on the sidewall adjacent to the attached cathode fingers. The anode base structure comprises a highly conductive metal means having a substantially flat and level surface and having a decreased cross-section as it extends away from the anode or intercell connecting busbar means to form the cross-sectional shape of a substantially stair-stepped truncated right triangle; the cathode busbar structure, cathode fingers and anode base structure each have a configuration so as to carry an electric current and to maintain a substantially uniform current density throughout without any significant voltage drop there across and with the most economical power consumption therein.

Description

~0536~7 BACKGROUND OF THE INVENTION
This invention relates to electrolytic cells suited for the electrolysis of aqueous solutions. More particularly, this invention relates to electrolytic cells suited for the electrolysis of aqueous alkali metal chloride solutions.
Electrolytic cells have been used extensively for many years for the production of chlorine, chlorates, chlorites, hydrochloric acid, caustic, hydrogen and other related chemicals. Over the years, such cells have been developed to a degree whereby high operating efficiencies have been obtained, based on the electricity expended.
Operating efficiencies include current, decomposition, energy, power and voltage efficiencies. The most recent developments in electrolytic cells have been in making improvements for increasing the production capacities of the individual cells while maintaining high operating efficiencies. This has been done to a large extent by modifying or redesigning the individual cells and increasing the current capacities at which the individual cells operate. The increased production capacities of the individual cells operating at higher current cap-acities provide higher production rates for given cell room floor areas and reduce capital investment and operating costs.
In general, the most recent developments in electrolytic cells have been towards larger cells which have high production capacities and which are designed to operate at high current capacities while maintaining high operating efficiencies. Within certain operating parameters, the higher the current capacity at which a cell is designed to operate, the higher is the production capacity of the cell. As the designed current capacity of a cell is increased, however, it is im-portant that high operating efficiencies be maintained. Mere enlargement of the component parts of a cell designed to operate at low current capacity and will not provide a cell which can be operated at high current capacity and still maintain high operating efficiencies.

~05;~607 Numerous design improvements must be incorporated into a high current capacity cell so that high operating efficiencies can be maintained and high production capacity can be provided.
The electrolytic cell of the present invention may be adapted to be used as different types of electrolytic cells of which chlor-alkali cells are of primary importance. The electrolytic cell of the present invention will be described more particularly with respect to chlor-alkali cells and most particularly with respect to chlor-alkali diaphragm cells. However, such descriptions are not to be understood as limiting the usefulness of the electrolytic cell of the present invention with respect to other types of electrolytic cells.
In the early prior art, chlor-alkali diaphragm cells were designed to operate at relatively low current capacities of about 10,000 amperes or less and had cQrrespondingly low production capacities.
Typical of such cells is the Hooker Type S Cell, developed by the Hooker Chemical Corporation, Niagara Falls, New York, U.S.A., which was a major breakthrough in the electrochemical art at its time of develop-ment and initial use. The Hooker Type S Cell was subsequently improved by Hooker in a series of Type S Cells such as the Type S-3, S-3A, S-3B, S-3C, and S-3D and S-4, whereby the improved cells were designed to operate at progressively higher current capacities of about 15,000, 20,000, 25,000, 30,000, and 40,000 and upward to about 55,000 amperes with correspondingly higher production capacities. The design and per-formance of these Hooker Type S cells are discussed in Shreve, Chemical Process Industries, Third Edition, Pg. 233 (1967~, McGraw-Hilli Mantell, Indust al Electrochemistry, Third Edition, Pg. 434 (1950), McGraw-Hilli and Sconce, Chlorine, Its Manufacture, Properties and Uses, A.C.S.
Monograph, Pp. 94-97 (1962), Reinhold. U.S. Patent 2,987,463 by Baker et al. issued June 6, 1961 to Diamond Alkali discloses a chlor-alkali diaphragm cell designed to operate at a current capacity of about 30,000 amperes which is somewhat different than the Hooker Type S
series cell. U.S. Patents 3,464,912 by Emery et al. issued Sept. 2, 1969 to Hooker and 3,493,487 by Currey et al. issued Nov. 2, 1971 to Hooker disclose chlor-alkali diaphragm cells designed to operate at a current capacity of about 60,000 amperes.
The above description of the prior art shows the development of chlor-alkali diaphragm cell design to provide cells which operate at higher current capacities with correspondingly higher production capa-cities. Chlor-alkali diaphragm cells have now been developed which operate at high current capacities of about 150,000 amperes and upward to about 200,000 amperes with correspondingly higher production capa-cities while maintaining high operating efficiencies.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a novel electrolytic cell. The novel electrolytic cell comprises a novel cathode busbar structure, novel cathode fingers having a novel cathode finger structure, and a novel anode base structure.
The novel cathode busbar structure comprises at least one lead-in busbar and a plurality of busbar strips which have different relative dimensions. The lead-in busbar or busbars and the plurality of busbar strips are fabricated from a highly conductive metal and are positioned in such a configuration wherein the lead-in busbar or busbars and the plurality of busbar strips are adapted to carry an electric current and to maintain a substantially uniform current density through the cathode busbar structure to electrical contact points adjacent to the cathode fingers without any significant voltage drop across the cathode busbar structure and with the most economical power consumption in the cathode busbar structure. The cathode busbar structure is attached to 10536(37 ~' at least one sidewall of a cathode walled enclosure. The cathode walled enclosure contains a plurality of cathode fingers which extend substantially across the interior of the cathode walled enclosure and the cathode fingers are attached in electrical contact to at least one interior sidewall of the cathode walled enclosure. The cathode busbar structure is attached in electrical contact to the exterior sidewall of the cathode walled enclosure adjacent to the attached cathode fingers.
The novel cathode busbar structure makes the most economic use of invested capital, namely, the amount of highly conductive metal used in the cathode busbar structure. The configuration and different relative dimensions of the lead-in busbar or busbars and the plurality of busbar strips significantly reduce the amount of highly conductive metal required in the cathode busbar structure as compared to the prior art. The lead-in busbar or busbars and the plurality of busbar strips by means of their configuration and different relative dimensions are a1so adapted to carry an electric current and to maintain a substantially uniform current density through the cathode busbar structure. ~ -The novel cathode busbar structure can be provided with means for attaching cathode jumper connector means when an adjacent electro-lytic cell is jumpered and is removed from the electrical circuit. The cathode busbar structure can also be provided with cooling means to prevent temperatures in the cathode busbar structure from rising to damaging levels and to further reduce the amount of highly conductive metal required in the cathode busbar structure. -The novel cathode finger structure comprises a conductive metal cathode finger reinforcing means, lengths of highly conductive metal positioned in the cathode finger structure and foraminous con-ductive metal means attached to the cathode finger reinforcing means thereby forming the exterior of the cathode finger structure and gas 10536~7 compartment space ins;de the cathode finger structure. The cathode finger reinforcing means can be provided with a suitable number of pegs, pins or protrusions. The foraminous conductive metal means can be attach-ed to these protrusions and thereby provide additional compartment space for gas, formed at the cathode during electrolysis, to be channeled to a collection chamber.
The highly conductive metal is preferably positioned on the cathode finger reinforcing means in the cathode finger structure and means is provided for attaching the highly conductive metal to the cathode finger reinforcing means. The highly conductive metal is po-sitioned in the cathode finger structure in such a configuration whereby the lengths of highly conductive metal are adapted to carry an electric current and to maintain a substantially uniform current density through the cathode finger structure without any significant voltage drop across the cathode finger structure and with the most economical power consumption in the cathode finger structure.
The novel cathode finger structure provides novel cathode fingers. The cathode walled enclosure contains a plurality of cathode fingers which extend substantially across the interior of the cathode walled enclosure and the cathode fingers are attached in electrical contact to at least one interior sidewall of the cathode walled en-closure. The cathode busbar structure is attached in electrical contact to the exterior sidewall of the cathode walled enclosure adjacent to the attached cathode fingers.
Means are provided for positioning the opposite ends of the cathode fingers adjacent to the interior sidewall of the cathode walled enclosure which is opposite to the interior sidewall where the cathode fingers are attached.
The novel anode base structure comprises a highly conductive metal means having a substantially flat and level surface and having a -, -- ... .
.. . .

10536~7 decreased cross-section as it extends away from the anode or intercell connecting busbar means to form the cross-sectional shape of a sub-stantially stair-stepped truncated right triangle. The highly conductive metal means can be a solid metal plate having a configuration as described above or can be two or more highly conductive metal shapes, such as plates, having different relative dimensions and positioned in such a configuration whereby their cross-sections form the cross-sectional shape of a sub-stantially stair-stepped truncated right triangle as described above.
The highly conductive metal means can be provided with means for attach-ing the anode blades. The highly conductive metal means has differentrelative dimensions and such a configuration whereby it is adapted to carry an electric current and to maintain a substantially uniform current density through the anode base structure to electrical contact points adjacent to the anode bladbs without any ~ignif$~t ~ltage drop across the anode base structure and with the most economical power con- ~`
sumption in the anode base structure.
The novel anode base structure can also comprise suitable ~ -structural support means for the highly conductive metal means and any other suitable structural support means to provide the anode base structure with sufficient means to support other components of the novel electro-lytic cell of the present invention.
U.S. Patent 3,432,422 by Currey issued Mar. 11, 1969 is herein cited to show a state of the prior art.
The anode base structure makes the most economic use of invested capital, namely, the amount of highly conductive metal used in the anode base structure. The configuration and different relative dimensions of the highly conductive metal means significantly reduce the amount of highly conductive metal required in the anode base structure as compared to the prior art. The highly conductive metal means by means of its configuration and different relative dimensions is also . . .
, , adapted to carry an electric current and to maintain a substantially uniform current density through the anode base structure.
The anode base structure can be provided with an anode ju~per busbar for attaching anode connector means when an adjacent electrolytic cell is jumpered and removed from the circuit. The anode base structure can also be provided with a cooling means to prevent temperatures in the anode base structure from rising to damaging levels and to further reduce the amount of highly conductive metal used in the anode base structure.
The novel electrolytic cell of the present invention may be used in many different electrolytic processes. The electrolysis of aqueous alkali metal chloride solutions is of primary importance and the electrolytic cell of the present invention will be described more parti-cularly with respect to this type of process. However, such description is not intended to be understood as limiting the usefulness of the electrolytic cell of the present invention or any of the claims covering the electrolytic cell of the present invention.
- DESCRIPTION OF THE DRAWINGS
The present invention will be more fully described by reference to the drawings in which:
FIGURE 1 is an elevation view of a typical electrolytic cell of the present invention and shows a typical cathode busbar structure;
FIGURE 2 is an enlarged partial sectional side elevation view of the cell of FIGURE 1 along plane 2-2 and shows another view of the cathode busbar structure;
FIGURE 3 is an enlarged partial plan view of the cathode walled enclosure of the cell of FIGURE 1 and shows the relative position of the cathode iingers;
FIGURE 4 is an enlarged partial sectional and elevation view of the cathode fingers and the cathode walled enclosure of the cell of FIGURE 3 along plane 4-4 and shows the relative position of the cathode ,. -: . , ~

lOS3t;07 fingers and anode blades as positioned at the end of the cathode walled enclosure;
FIGURE 5 is an enlarged sectional side elevation view of a cathode finger and the cathode walled enclosure of the cell of FIGURE 3 along plane 5-5 and shows the configuration of the highly conductive metal positioned on the cathode finger reinforcing means;
FIGURE 6 is a side elevation view of the opposite side of the cathode finger reinforcing means of FIGURE 5 and shows the visible con-figuration of the highly conductive metal positioned thereon;
FIGURE 7 is a side elevation view of another embodiment of a cathode finger reinforcing means and shows the configuration of the highly conductive metal positioned thereon;
FIGURE 8 is an end elevational view of the cathode finger re-. .... - . .
inforcing means of FIGURE 7 along plane 8-8 and shows the configuration of the highly conductive metal positioned thereon and the peg or pin means;
FIGURES 3, 4, 5, 6, 7 and 8, when viewed together, show typical embodiments of cathode finger structures;
FIGURE 9 is a plan view of an anode base structure which can be used in the cell of FIGURE 1. The anode blades are not shown for clarity;
FIGURE 10 is a side elevation view of the anode base structure of FIGURE 9 along plane 10-10 and shows the highly conductive metal plate configuration detail;
FIGURE 11 is a view of FIGURE 10 showing the addition of a structural cell base support means;
FIGURE 12 is a plan view of an anode base structure which can be used ~n the cell of FIGURE 1. The anode blades are not shown for clarity;
FIGURE 13 is a side elevation view of the anode base structure of FIGURE 12 along plane 13-13 and shows the highly conductive metal plate configuratiion detail; and , .

FIGURE 14 is a view of FIGURE 13 showing the addition of a structural cell base support means.
The different types of metals are used to fabricate most of the various components or parts which comprise the novel electrolytic cell of the present invention. One of these types of metals is a highly conductive metal. The other type of metal is a conductive metal which has good strength and structural properties.
The term highly conductive metal is herein defined as a metal which has a low resistance to the flow of electric current and which is an excellent conductor of electric current. Suitable highly conductive metals include copper, aluminum, silver and the like and alloys thereof.
The preferred highly conductive metal is copper or any of its highly conductive alloys and any mention of copper in this application is to be interpreted to mean that any other suitable highly conductive metal can be used in the place of copper or any of its highly conductive alloys where it is feasible or practical.
The term conductive metal is herein defined as a metal which has a moderate resistance to the flow of electric current but which is still a reasonably good conductor of electric current. The conductive metal, in addition, has good strength and structural properties. Suitable conductive metals include iron, steel, nickel and the like and alloys - thereof such as stainless steel and other chromium steels, nickel steels and the like. The preferred conductive metal is a relatively inexpensive low-carbon stee1, hereinafter referred to simply as steel, and any mention of steel in this application is to be interpreted to mean that any other sùitàble conductive metal can be used in the place of steel where it is feasible or practical.
The highly conductive metal and the conductive metal should have adequate resistance to or have adequate protection from corrosion during operation of the electrolytic cell.

1053~7 Referring now to FIGURE 1, electrolytic cell 11 comprises corrosion resistant plastic top 12, cathode walled enclosure 13 and cell base 14. Top 12 is positioned on cathode walled enclosure 13 and is secured to cathode walled enclosure 13 by fastening means (not shown).
A seal is maintained between top 12 and cathode walled enclosure 13 by means of a sealing gasket. Cathode walled enclosure 13 is positioned on cell base 14 and is secured to cell base 14 by fastening means (not shownJ.
A seal is maintained between cathode walled enclosure 13 and cell base 14 by means of an elastomeric sealing pad. Electrolytic cell 11 is positioned on legs 15 which are used as support means for the cell.
Cathode busbar structure 16 is attached in any suitable manner, as by welding, to steel sidewall 17 of steel cathode walled enclosure 13.
Cathode busbar structure 16 comprises copper lead-in busbar 18 and a plurality of copper busbar strips 19, 21 and 22 which have different relative dimensions and are positioned in such a configuration wherein lead-in busbar 18 and busbar strips 19, 21 and 22 are adapted to carry an electric current and to maintain a substantially uniform current density through cathode busbar structure 16 to electrical contact points on sidewall 17 of cathode walled enclosure 13.
Cathode busbar structure 16 can be provided with cooling means 23 which comprises steel plates 24, 25, 26 and 30 and steel entrance and exit ports 27 and 28 fabricated in any suitàble manner, as by welding, to form the said cooling means. Cooling means 23 is attached in any suitable manner, as by welding, to lead-in busbar 18 and busbar strip 19.
Coolant, preferably water, is circulated through cooling means 23 by passage through entrance and exit ports 27 and 28. Cooling means 23 is provided primarily for use when an electrolytic cell adjacent to electro-lytic cell 11 is jumpered and is removed from the electrical clrcuit.
The use of cooling means 23 permits considerably less copper to be used .",.

1053~;07 ~

in cathode busbar structure 16 which results in a substantial reduction in capital investment costs for cathode copper. While cooling means 23 is provided primarily for use when an electrolytic cell adjacent to electrolytic cell 11 is jumpered, cooling means 23 can be used during routine cell operation either to cool cathode busbar structure 16 during any periodic electric current overloads or to continuously cool cathode busbar structure 16, thereby permitting further reductions in the use of copper in cathode busbar structure 16 with an accompanying reduction in capital investment costs for cathode copper.
- Lead-in busbar 18 can be provided with steel contact plates 29 and 31 which serve as contact means. Steel contact plates 29 and 31 are attached to lead-in busbar 18 in any suitable manner, as by means of screws 32. Lead-in busbar 18 and steel contact plates 29 and 31 can be provided with holes 33 which can serve as means for attaching intercell connectors carrying electricity from an adjacent cell or leads carrying electricity from another source to lead-in busbar 18. Lead-in busbar 18 and busbar strip 19 can be used as a cathode jumper busbar when provided with holes 34 which can serve as means for attaching cathode jumper connectors when an adjacent electrolytic cell is jumpered and is removed from the electrical circuit. It is during this jumpering operation that cooling means 23 can provide its greatest utility by preventing the temperatures in cathode busbar structure 16 from rising to levels whereby damage to cathode busbar structure 16 or other components of electrolytic cell 11 occurs.
Referring now to FIGURE 2, cathode busbar structure 16 is shown in another view and the description of this figure further des-cribes cathode busbar structure 16 including the configuration and the different relative dimensions of the components or parts comprising cathode busbar structure 16 which were described in FIGURE 1.

~LO 5;3~;O 7 Cathode busbar structure 16 comprises copper lead-in busbar 18 and a plurality of copper busbar strips 19, 21 and 22. Busbar strips 19, 21 and 22 are attached to steel sidewall 17 of steel cathode walled enclosure 13 in any suitable manner, as by means of copper to steel welds 35, 37, 38 and 41, and to one another in any suitable manner, as by means of copper to copper welds 36 and 39. The weld metal is preferably of the same metal as the busbar str;ps, that is, copper. This means of attaching the busbar strips to sidewall 17 greatly decreases the required weld area and forms a lower electrical contact resistance to sidewall 17 or the cathode steel. Lead-in busbar 18 is attached to busbar strip 19 in any suitable manner, as by means of copper to copper weld 42, and lead-in busbar 18 is attached to sidewall 17 in any suitable manner, as by means of steel blocks 43. Lead-in busbar 18 is attached to steel blocks 43 in any suitable manner, as by a combination of screws (not shown), and steel blocks 43 are attached to sidewall 17 of cathode walled enclosure 13 in any suitable manner, as by means of steel to steel welds 40. Steel con-tact plates 29 and 31 are attached to lead-in busbar 18 in any suitable manner, as by means of screws 32.
The above means of attachment provides a cathode busbar structure wherein lead-in busbar 18 and the plurality of busbar strips 19, 21 and 22 are attached and electrically interconnected by means of welds 36, 37, 38, 39 and 42 and cathode busbar structure 16 is attached in electrical contact to sidewall 17 of cathode walled enclosure 13 by means of welds 35, 37, 38, 40 and 41.
Cathode fingers 44 are attached in electrical contact to sidewall 17 in any suitable manner, as by welding cathode finger reinforcing means 45 to sidewall 17. A typical cathode finger 44 is partially shown.
Cathode finger 44 comprises steel cathode finger reinforcing means 45 and perforated steel plates 46 which are attached in any suitable manner, as 10536(~7 by welding. Perforated steel plates 47 are attached in any suitable manner, as by welding, to perforated steel plates 46 and sidewall 17, thereby forming peripheral chamber 48.
The height of the plurality of the busbar strips at their points of attachment to sidewall 17 is usually substantially equal to the height of cathode finger reinforcing means 45 at their points of attachment to sidewall 17. This he;ght can be further defined as being of more than about one-half of the height of cathode walled enclosure 13. The thickness of busbar strips 21 and 22 are preferably less than those of lead-in busbar 18 and busbar strip 19.
The cathode finger reinforcing means are preferably corrugated structures fabricated from conductive steel sheet, however, other suitable reinforcing means such as conductive metal bars, plates, reinforced sheets and the like can also be used. The cathode finger reinforcing means serve the dual functions of first, supporting and reinforcing the perforated steel plates, and second, carrying electric current to all sections of the perforated steel plates with a minimum electrical resistance through the cathode finger reinforcing means.
The foraminous conductive metal means used to form the cathode fingers and the peripheral chamber are preferably perforated steel plates but can be steel screens. Other suitable foraminous conductive metal means which can be used to form the cathode fingers and the peripheral chamber include conductive metal grids, meshes, screens, wire cloth or the like.
Cathode walled enclosure 13 is positioned on cell base 14 and is secured to cell base 14 by fastening means (not shown). Cell base 14 comprises elastomeric sealing pad 49 and conductive anode base 51, and, if needed, structural support means 52. A seal is maintained between cathode walled enclosure 13 and cell base 14 by means of elastomeric sealing pad 49.

In a typical circuit of electrolytic cells, electric current is carried through intercell connectors (not shown) to lead-in busbar 18 of cathode busbar structure 16. Electric current is then carried and a substantially uniform current density is maintained through cathode busbar structure 16 without any significant voltage drop across cathode busbar structure 16 and with the most economical power consumption in cathode busbar structure 16. Electric current is carried and a sub-stantially uniform current density is maintained through cathode busbar structure 16 by means of the configuration and the different relative dimension of lead-in busbar 18 and busbar strips 19, 21 and 22. Electric current is thus carried through cathode busbar structure 16 to electrical contact points on sidewall 17 of cathode walled enclosure 13 where it is distributed to cathode fingers 44 and, under these conditions, the electric current is readily carried to all sections of perforated steel plates 46 with a minimum electrical resistance through cathode finger reinforcing means 45.
The novel cathode busbar structure makes the most economic use of invested capital, namely, the amount of copper or other suitable highly conductive metal used in the cathode busbar structure. The configuration and different relative dimensions of the lead-in busbar or busbars and the plurality of busbar strips significantly reduce the amount of copper or other suitable highly conductive metal required in the cathode busbar structure as compared to the prior art. The lead-in busbar or busbars and the plurality of busbar strips by means of their configuration and different relative dimensions are also adapted to carry an electric current and to maintain a substantially uniform current density through the cathode busbar structure.
The configuration and dimensions of the lead-in busbar or busbars and the plurality of busbar strips can vary depending on the 1053~07 designed current capacity of the electrolytic cell and also can vary depending on a number of factors such as the current density, the con-ductivity of the metal used, the amount of weld area, the fabrication costs and the like.
The novel cathode busbar structure provides improved elect-rical conductivity to the immediate area of the cathode fingers, thereby provid~ng a minimum or no significant voltage drop across the cathode busbar structure with a substantial reduction in copper or other suitable highly conductive metal expenditures as compared to the prior art.
The novel cathode busbar structure enables the electrolytic cell of the present invention to be designed to operate as a chlor-alkali - diaphragm cell at high current capacities of about 150,000 amperes and upward to about 200,000 amperes while maintaining high operating effi-ciencies. These high current capacities provide for high production capacities which result in high production rates for given cell room floor areas and reduce capital investment and operating costs. In addi-tion to being capable of operation at high amperages, the electrolytic cell of the present invention can also efficiently operate at lower amperages, such as about 55,000 amperes using the novel cathode busbar structure.
Referring now to FIGURE 3, cathode fingers 44 are enclosed by steel sidewalls 17, 54, 55 and 56 of steel cathode walled enclosure 13. The plurality of cathode fingers 44 can be any number from about 10 ` to about 50 or more, preferably the number is about 15 to about 40 and more preferably the number is about 20 to about 30. The anode blades (not shown) are positioned between cathode fingers 44. Perforated steel plates 46 are attached in any suitable manner, as be welding, to steel cathode finger reinforcing means 45. Steel plates 53 are also attached in any suitable manner, as by welding, to cathode finger reinforcing . : .

1053~ 7 means 45. Cathode fingers 44 are attached to steel sidewall 17 in any suitable manner, as by welding steel plates 53 and cathode finger re-inforcing means 45 to sidewall 17. Perforated steel plates 47 are attached to sidewalls 17, 54, 55 and 56 and to perforated steel plates 46 in any suitable manner, as by welding. Perforated steel plates 47 surround the inner sidewalls of cathode walled enclosure 13 and form peripheral chamber 48 which serves as a collection chamber for hydrogen gas formed at the cathode during electrolysis. Hydrogen gas formed at the cathode during electrolysis is channeled across cathode fingers 44 to peripheral chamber 48 from whence it proceeds to gas withdrawal means 57.
Referring now to FIGURE 4, perforated steel plates 46 are attached in any suitable manner, as by welding, to steel cathode finger reinforcing means 45. Steel plates 53 are attached in any suitable manner, as by welding, to cathode finger reinforcing means 45. Steel support means 58 are attached in any suitable manner, as by welding, to cathode finger reinforcing means 45 and to sidewall 56 of steel cathode walled enclosure 13. Perforated steel plates 47 are attached in any suitable manner, as by welding, to perforated steel plates 46 and to sidewalls 17 and 56 thereby forming peripheral chamber 48. Because of the larger dimensions of this figure, peripheral chamber 48 is more clearly shown. Cathode finger reinforcing means 45 can be provided with protrusions 59 and perforated steel plates 46 can be attached in any suitable manner, as by welding, to protrusions 59 thereby providing additional compartment space for hydrogen gas, formed at the cathode during electrolysis, to be channeled to peripheral chamber 48.
Steel tips 61 and steel plates 53 are attached in any suitable manner, as by welding, to copper rods 62. Steel tips 61 and steel plates 53 are attached in any suitable manner, as by welding, to cathode finger - 17 _ ~()53607 reinforcing means 45 thereby positioning copper rods 62 on cathode finger reinforcing means 45.
Cathode finger reinforcing means 45 are preferably corrugated structures fabricated from sheet steel, however, other suitable reinforcing means such as bars, plates, reinforced sheets and the like can also be used. Cathode finger reinforcing means 45 serve the dual functions of first, supporting and reinforcing perforated steel plates 46, and second, carrying electric current to all sections of perforated steel plates 46 with a minimum electrical resistance through cathode finger reinforcing means 45.
Referring now to FIGURES 2 and 4, cathode walled enclosure 13 is positioned on cell base 14 and is secured to cell base 14 by fastening means (not shown). Cell base 14 comprises conductive anode base 51 and, if needed, suitable structural support means 52. A seal is maintained between cathode walled enclosure 13 and cell base 14 by means of elasto-meric sealing pad 49.
Anode blades 72 are preferably metallic anode blades and are attached in electrical contact to conductive anode base 51 in any suitable manner, as by means of nuts and/or bolts, secured projections, studs, welding or the like. Cathode fingers 44 are spaced adjacent to each other at such a distance whereby anode blades 72 are centered between adjacent cathode fingers 44 and the desired alignment distance between anode blades 72 and cathode fingers 44 is provided.
Referring now to FIGURES 2, 3 and 4, electrolytic cell 11 is particularly useful for the electrolysis of alkali metal chloride solutions in general, including not only sodium chloride, but also potassium chloride, lithium chloride, rubidium chloride and cesium chloride. When electro-lytic cell 11 is used to electrolyze such solutions, electrolytic cell 11 is provided with diaphragm 71 which serves to form separate anolyte and ' 105;~;07 catholyte compartments so that chlorine is formed at the anode and caustic and hydrogen are formed at the cathode. Diaphragm 71 comprises a fluid-permeable and halogen-resistant material which covers steel plates 46 forming cathode fingers 44 and perforated steel plates 47 forming peripheral chamber 48. Preferably, diaphragm 71 is asbestos fiber deposited in place on the outer surfaces of perforated steel plates 46 and 47. Electrolytic cell 11 is adapted to permit the use of many types of diaphragms, including asbestos fabric, asbestos paper, asbestos sheet and other suitable materials known to those skilled in the art.
Perforated steel plates 46 forming cathode fingers 44 and per-forated steel plates 47 forming peripheral chamber 48 are foraminous conductive metal means. Other suitable foraminous conductive metal means which can be used to form the cathode fingers and the peripheral chamber include conductive metal grids, meshes, screens, wire cloths or the like.
Referring now to FIGURES 3 and 5, some of the details described in the foregoing figures are more clearly shown in these figures. Cathode busbar structure 16 is attached to outer sidewall 17 of cathode walled enclosure 13 and the ends of cathode fingers 44 adjacent thereto are attached to inner sidewall 17 of cathode walled enclosure 13 in a manner or manners described in the foregoing figures.
The other ends of cathode fingers 44 are preferably positioned as follows: Pos ~ ;ends 63 of steel cathode finger reinforcing means 45 are positioned adjacent to steel sidewall 55 of steel cathode walled enclosure 13 by means of steel support members 64, 65, 66 and 67.
Support members 64 and 65 are attached in any suitable manner, as by welding, to cathode finger reinforcing means 45 and rest upon support members 66 and 67 which are attached in any suitable manner, as by welding, to sidewall 55. Support members 64 and 65 can be attached or fastened to support members 66 and 67, respectively, however, it is preferred that 19 _ 10536(~7 support members 64 and 65 not be attached or fastened so that both linear and horizontal thermal expansion and/or contraction can be provided for cathode fingers 44.
Perforated steel plates 47 are attached in any suitable manner, as by welding, to sidewalls 17, 54, 55 and 56, respectively, and to adjacent perforated steel plates 46 thereby forming peripheral chamber 48.
Copper rods 62 are preferably of different lengths and are preferably positioned on cathode finger reinforcing means 45 as shown in FIGURE 5. Steel tips 61 are attached in any suitable manner, as by welding, to ends 68 of copper rods 62 and steel plate 53 is attached in any suitable manner,as by welding, to linear ends 73 of copper rods 62 thereby forming cathode copper assembly 69. Cathode copper assembly 69 is attached to cathode finger reinforcing means 45 in any suitable manner, as by welding steel tips 61 and steel plate 53 to steel cathode finger reinforcing means 45. Copper rods 62 can thus be positioned on cathode finger reinforcing means 45. Copper rods 62 are of sufficient length and preferably are of different lengths to maintain substantially uniform current density through cathode finger 44. Copper rods 62 do not necessarily have to be round or uniform in cross-section and can be square, rectangular, hexagonal, octagonal or the like in cross-section and can vary in cross-section along their lengths. It is important, however, that copper rods 62 be of sufficient length and cross-section to carry an electric current and to maintain a substantially uniform current density through cathode fingers 44 without any significant voltage drop across cathode fingers 44 and with the most economical power consumption in cathode fingers 44.
The use of a suitable highly conductive metal, such as copper, in cathode fingers 44 as shown in FIGURES 4, 5, 6, 7 and 8 is considered to be a novel use of a suitable highly conductive metal in the cathode fingers. The use of copper in the cathode fingers is disclosed in U.S.

. .
.. . . . .. .
.
'- ~, ' ' ' ' ' ' ~ ' ', lOS36(~7 "
Patents 3,464,912 by Emery et al. issued Sept. 2, 1969 to Hooker and 3,493,487 by Ruthel et al. issued Feb. 3, 1970 to Hooker, however, these disclosed uses of copper in the cathode fingers do not disclose, much less teach, the use of copper in the cathode fingers of an electro-lytic cell in the manner as taught herein.
qhepreferred method of positioning copper rods 62 on cathode finger reinforcing means 45 and in cathode fingers 44 is also novel.
Steel tips 61 are welded to ends 68 of copper rods 62 and steel plate 53 is welded to linear ends 73 of copper rods 62 thereby forming cathode copper assembly 69. Any warpage from the welding of steel tips 61 and steel plate 53 to copper ends 62 is corrected or compensated for before cathode copper assembly 69 is attached to cathode finger reinforcing means 45. Cathode copper assembly 69 is attached to cathode finger reinforcing means 45 by welding steel tips 61 and steel plate 53 to steel cathode finger reinforcing means 45. Copper rods 62 are thus positioned on cathode finger reinforcing means 45 and in cathode fingers 44. In this manner, all the copper to steel welds are made prior to the welding of cathode copper assembly 69 to cathode finger reinforcing means 45 and any metal warpage from welding is substantially eliminated.
The novel cathode fingers enable the electrolytic cell of the present invention to be designed to operate as a chlor-alkali diaphragm cell at high current capacities of about 150,000 amperes and upward to about 200,000 amperes while maintaining high operating efficiencies.
These high current capacities provide for high production capacities which result in high production rates for given cell room floor areas and reduce capital investment and operating costs. In addition to being capable of operation at high amperages, the electrolytic cell of the present invention can also efficiently operate at lower amperages, such as about 55,000 amperes using the novel cathode fingers.

1053bO7 Referring now to FIGURE 6, the opposite side of cathode finger reinforcing means 45 shown in FIGURE 5 is shown and the visible configuration of copper rods 62 positioned thereon is also shown. Cathode copper assembly 69 which comprises copper rods 62, steel plate 53 and steel tips 61 is shown positioned on cathode fingers reinforcing means 45. Cathode fingers reinforcing means 45 can be provided with protrusions 59 and perforated steel plates 46 can be attached in any suitable manner, as by welding, to protrusions 59 thereby providing additional compartment space for hydrogen gas, formed at the cathode during electrolysis, to be channeled to peripheral chamber 48. Protrusions 59 are positioned at spaced intervals on cathode finger reinforcing means 45 and only a representative portion are shown in this figure.
Referring now to FIGURES 7 & 8, another embodiment of a cathode finger reinforcing means is shown and a configuration of copper rods positioned thereon is also shown. In this embodiment, cathode finger reinforcing means 111 comprises steel plate 112 having steel peg or pin means 113 extending therefrom. Cathode copper assembly 69 which comprises copper rods 62, steel plate 53 and steel tips 61 is shown positioned on steel plate 112 of cathode finger reinforcing means 111 with a portion of steel plate 112 removed to accommodate steel plate 53. Cathode copper assembly 69 is attached to cathode finger reinforcing means 111 in any suitable manner, as by welding steel plate 53 and steel tips 61 to steel plate 112. Perforated steel plates 46 can be attached in any suitable manner, as by welding, to steel peg means 113 thereby providing compart-ment space for hydrogen gas, formed at the cathode during electrolysis, to be channeled to peripheral chamber 48.
Referring now to FIGURES 9 and 10, anode base structure 74 comprises copper plate 75 and copper plate 76 and can also comprise steel plates 77, 78, 79, 81 and 98 or any other suitable structural means.

lOS3~ 7 Copper plates 75 and 76 and steel plates 77, 78, 79 and 81 and 98 are connected in any suitable manner, as by bolting or welding, to provide a unitary structure having suitable structural support means. Anode base structure 74 can be protected from corrosion by elastomeric sealing pad 49. Copper plates 75 and 76 can be provided with anode blade attachment means 82 which can be used to attach anode blades 72 to copper plates 75 and 76.
Anode blades 72 can be fabricated from any suitable electri-cally conductive material which will resist the corrosive attack of the various cel1 reactants and products with which they may come in contact.
Anode blades 72 are preferably metallic anode blades. Typically, anode blades 72 can be fabricated from a so-called valve metal, such as titanium, tantalum or niobium as well as alloys of these in which the valve metal constitutes at least about 90% of the alloy. The surface of the valve metal may be made active by means of a coating of one or more noble metals, noble metal oxides, or mixtures of such oxides, either alone or with oxides of the valve metal. The noble metals which may be used include ruthenium, rhodium, palladium, irridium, and platinum. Particularly preferred metal anodes are those formed of ti~tanium and having a mixed titanium oxide and ruthenium oxide coating on the surface, as is described in U.S. Patent 3,632,498. Additionally, the valve metal substrate may be clad on a more electrically conductive metal core, such as aluminum, steel, copper, or the like.
Anode blades 72 can be attached to copper plates 75 and 76 in any suitable manner as by means of nuts and/or bolts, secured projections, studs, welding or the like. A typical method of attaching anode blades 72 to copper plates 75 and 76 can be found in U.S. Patent 3,591,483.
Anode busbar 97 can be provided by attaching steel contact plates 89 and 91 using means 85 to copper plate 75 and providing the said steel and copper plates with holes 83 which can serve as means for attaching ~05360'7 intercell connectors carrying electricity from an adjacent cell or leads carrying electricity from another source to anode busbar 97.
FIGURE 10 shows that the configuration of the cross-sections of copper plates 75 and 76 form the cross-sectional shape of a substantially stair-stepped truncated right triangle. Copper plates 75 and 76 have different relative dimensions and are positioned in such a configuration wherein copper plates 75 and 76 are adapted to carry an electric current and to maintain a substantially uniform current density through anode base structure 74 to electrical contact points adjacent to anode blades 72 without any significant voltage drop across anode base structure 74 and with the most economical power consumption in anode base structure 74.
Substantially uniform current density is achieved by the configuration of the different cross-sections of copper plates 75 and 76 which form the cross-sectional shape of a substantially stair-stepped truncated right triangle where electric current is removed from the copper plates in a substantially uniform manner as the cross-section of the copper plates is decreased.
In a typical circuit of electrolytic cell, electric current is :
carried through intercell connectors (not shown) to anode busbar 97 of anode base structure 74. Electric current is then carried and a sub-stantially uniform current density is maintained through anode base structure 74 without any significant voltage drop across anode base structure 74 and with the most economical power consumption in anode base structure 74. Electric current is carried and a substantially uniform current density is maintained through anode base structure 74 by means of the configuration and the different relative dimensions of copper plates 75 and 76. Electric current is thus carried through anode base structure 74 to electric contact points where it is distributed to anode blades 72 and, under these conditions, the electric current is readily carried to all sections of anode blades 72.

10536~37 The novel anode base structure makes the most economic use of invested capital, namely, the amount of copper or other suitable highly conductive metal used in the anode base structure. The configuration and different relat;ve dimensions of the copper plates significantly reduce the amount of copper or other suitable highly conductive metal required in the anode base structure as compared to the prior art. The copper plates by means of their configuration and different relative dimensions are also adapted to carry an electric current and to maintain a substantially uniform current density through the anode base structure.
The configuration and dimensions of the copper plates can vary depending on the designed current capacity of the electrolytic cell and also can vary depending on a number of factors such as the current den-sity, the conductivity of the metal used, the amount of weld area, the fabrication costs and the like.
The novel anode base structure provides improved electrical conductivity to the anode blades thereby providing a minimum or no significant voltage drop across the anode base structure with a sub-stantial reduction in copper or other suitable highly conductive metal expenditures as compared to the prior art.
The novel anode base structure enables the electrolytic cell of the present invention to be designed to operate as a chlor-alkali diaphragm cell at high current capacities of about 150,000 amperes and upward to about 200,000 amperes while maintaining high operating effi-ciencies. These high current capacities provide for high production capacities which result in high production rates for given cell room floor areas and reduce capital investment and operating costs. In addition to being capable of operation at high amperages, the electro-lytic cell of the present invention can also efficiently operate at lower amperages, such as about 55,000 amperes using the novel anode base structure.

' Anode base structure 74 can be provided with cooling means 92.
The coolant, preferably water, is circulated through cooling means 92 by entry through entrance port 93 and by passage through coolant conveying means 95. After entry through entrance port 93, the coolant is passed along steel plate 87 into and through cooling device 96 and then again along steel plate 87. The coolant is then passed along steel plate 88 and then along and around steel plate 89. The coolant is then passed along the opposite side of steel plate 89 and then along the opposite side of steel plate 88. The coolant is then passed along the opposite side of steel plate 87 and is discharged through exit port 94. Coolant conveying means 95 can be any suitable coolant conveying means such as copper tubing connecting cooling device 96 and coolant conveying channels positioned along the sides and ends of steel contact plates 87, 88 and 89. Cooling means 92 as shown in this figure and described herein is merely a typical cooling means and cooling means 92 should not be limited to the design as shown in this figure and described herein.
The use of cooling system 92 permits considerably less copper to be used in anode base structure 74 which results in a substantial -reduction in capital investment costs for anode copper. While cooling system 92 is provided primarily for use when an adjacent electrolytic cell is jumpered, cooling system 92 can be used during routine cell operation either to cool anode copper during any periodic electric current overloads or to continuously cool anode copper, thereby permitting further reductions in the use of copper in anode base structure 74 with an accompanying reduction in capital costs for anode copper.
Anode jumper busbar 99 can be provided by attaching steel contact plates 87 and 88 using means 86 to copper plate 75 and providing the steel and copper plates with holes 84 which can serve as means for attaching anode jumper connectors when an adjacent electrolytic cell is . ' : . . ' .

105360~7 jumpered and is removed from the electrical circuit. It is during this jumpering operation that cooling system 92 can provide its greatest utility by preventing the temperatures in anode base structure 74 from rising to levels whereby damage to anode base structure 74 or other components of electrolytic cell 11 occurs.
Referring now to FIGURE 11, anode base structure 74 is shown in another embodiment wherein anode base structure 74 is provided with structural support means 52 which can supply additional structural support for anode base structure 74. This embodiment would be advantageous and preferably where anode base structure 74 is fabricated from a highly conductive metal, such as copper, which has excellent electrical pro-perties but has relatively poor structural properties. Structural support means 52 can be fabricated from any number of suitable structural materials such as aluminum, iron, steel and the like and alloys thereof such as stainless steel and other chromium steels, nickel steels and the like which have sufficient strength to provide the needed support. Such structural materials can have the shapes of I beams, T beams, L beams, U beams and the like. Structural support means 52 does not have to be fabricated from a metal and can be fabricated from other suitable struc-tural materials such as concrete, reinforced concrete or the like.
Referring now to FIGURES 12, 13 and 14, another embodiment of anode base structure 74, shown in FIGURES 9, 10 and 11, is shown in FIGURES 12, 13 and 14. The description of FIGURES 9, 10 and 11 applies to FIGURES 12, 13 and 14. The difference in FIGURES 12, 13 and 14 from FIGURES 9, 10 and 11 is the addition of copper plates 101 and 102 and steel plates 103 and 104. There is also the addition of a fourth row of anode blades 72 and a slight modification in cooling means 92 and jumper busbar 99.
FIGURES 13 and 14 show that the configuration of the cross-sections of copper plates 75, 76, 101 and 102 form the cross-sectional 1053~;07 shape of a substantially stair-stepped truncated right triangle. Copper plates 75, 76, 101 and 102 have different relative dimensions and are positioned in such a configuration wherein copper plates 75, 76, 101 and 102 are adapted to carry an electric current and to maintain a sub-stantially uniform current density through anode base structure 74 toelectrical contact points adjacent to anode blades 72 without any signi-ficant voltage drop across anode base structure 74 and with the most economical power consumption in anode base structure 74, Substantially uniform current density is achieved by the con-figuration of the different cross-sections of copper plates 75, 76, 101 and 102 which form the cross-sectional shape of a substantially stair-stepped truncated right triangle where electric current is removed from the copper plates in a substantially uniform manner as the cross-section of the copper plates is decreased.
In a typical circuit of electrolytic cells, electric current is carried through intercell connectors (not shown) to anode busbar 97 of anode base structure 74. Electric current is then carried and a sub-stantially uniform current density is maintained through anode base structure 74 without any significant voltage drop across anode base structure 74 and with the most economical power consumption in anode base structure 74. Electric current is carried and a substantially uniform current density is maintained through anode base structure 74 by means of the configuration and the different relative dimensions of copper plates 75, 76, 101 and 102. Electric current is thus carried through anode base structure 74 to electrical contact points where it is dis-tributed to anode blades 72, and, under these conditions, the electric current is readily carried to all sections of anode blades 72.
The novel anode base structure makes the most economical use of invested capital, namely, the amount of copper or other suitable highly ~ - 28 -conductive metal used in the anode base structure. The configurationand different relative dimensions of the copper plates significantly reduce the amount of copper or other suitable highly conductive metal required in the anode base structure as compared to the prior art. The copper plates by means of their configuration and different relative dimensions are also adapted to carry an electric current and to maintain a substantially uniform current density through the anode base structure.
The configuration and dimensions of the copper plates can vary depending on the designed current capacity of the electrolytic cell and also can vary depending on a number of factors such as the current density, the conductivity of the metal used, the amount of weld area, the fabri-cation costs and the like.
The novel anode base structure provided improved electrical conductivity to the anode blades thereby providing a minimum or no significant voltage drop across the anode base structure with a sub-stantial reduction in copper or other suitable highly conductive metal expenditures as compared to the prior art.
Anode base structure 74 shown in FIGURES 9-14 can be an embodiment of conductive anode base 51 shown in FIGURES 2 and 4.
The novel anode base structure enables the electrolytic cell of the present invention to be designed to operate as a chlor-alkali-diaphragm cell at high current capacities of about 150,000 amperes and upward to about 200,000 amperes while maintaining high operating effi-ciencies. These high current capacities provide for high production capacities which result in high production rates for given cell room floor areas and reduce capital investment and operating costs. In addition to being capable of operation at high amperages, the electro-lytic cell of the present invention can also efficiently operate at lower amperages, such as about 55,000 amperes using the novel anode base structure.

- 28a -PREFERRED EMBODIM_NTS
The following Example illustrates the practice of the present invention and a mode of utilizing the present invention.
EXAMPLE
The following data is typical of the performance of the novel electrolytic cell of the present invention operating at a current capacity of 150,000 amperes. The performance is compared with the performance of a smaller electrolytic cell of the prior art, also equipped with metal anode blades, operating at a current capacity of 84,000 amperes.
Both electrolytic cells are chlor-alkali diaphragm cells.
84,000 Ampere Cell 150,000 Ampere Cell of the Prior Art of the Present Invention Current Efficiency 96.4 96.4 Average Cell Voltage (including busbars~ 3.84 3.83 Power - KWHDC/Ton C12 2735 2725 Cell Liquor Temperature - C. 100.5 100.7 Anolyte Temperature - C. 94.5 94.7 Percent NaOH in Cell Liquor 11.5* 11.5*
Chlorine Production - Tons/Day 2.83 5.06 NaOH Production - Tons/Day3.20 5.71 Brlne Feed - Grams/Liter 325 325 Current Density - Amperes/Sq. In. 1.5 1.5 * The cells can be operated at lower caustic content in the cell liquor. This will result in greater current efficiencies.
The above data show that the novel electrolytic cell of the present invention operates at essentially the same current efficiency, voltage and operating conditions as the smaller electrolytic cell of the prior art at the same anode current density. The novel electro-lytic cell of the present invention has a higher production rate for a given cell room floor area, uses less operating labor and also has a lower capital investment per ton of chlorine produced.

~ ~ 29 . . .
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~053~0~

This example shows that an electrolytic cell can be designed to operate at a high current capacity to provide a high production capacity and a high production rate while maintaining high operating efficiencies.
The novel electrolytic cell of the present invention can have many other uses. For example, alkali metal chlorates can be produced using the electrolytic cell of the present invention by further reacting the formed caustic and chlorine outside of the cell. In this instance, solutions containing both alkali metal chlorate and alkali metal chloride can be recirculated to the electrolytic cell for further electrolysis.
The electrolytic cell can be utilized for the electrolysis of hydro-chloric acid by electrolyzing hydrochloric acid alone or in combination with an alkali metal chloride. Thus, the novel electrolytic cell of the present invention is highly useful in these and many other aqueous processes.
While there have been described various embodiments of the present invention, the apparatus described is not intended to be understood as limiting the scope of the present invention. It is realized that changes therein are possible. It is further intended that each component recited in any of the following claims is to be understood as referring to all equivalent components for accomplishing the same results in substantially the same or an equivalent manner.
The following claims are intended to cover the present invention broadly in whatever form the principals thereof may be utilized.

_29a

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY OR
PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

An electrolytic cell comprising a cathode busbar structure, cathode fingers having a cathode finger structure, and an anode base structure wherein:
I) Said cathode busbar structure comprises at least one lead-in busbar and a plurality of busbar strips which have different re-lative dimensions, said lead-in busbar and said plurality of busbar strips are fabricated from a highly conductive metal and are positioned in such a configuration wherein the lead-in busbar and the plurality of busbar strips are adapted to carry an electric current and to maintain a substantially uniform current density through the cathode busbar structure to electrical contact points adjacent to the cathode fingers without any significant voltage drop across the cathode busbar structure and with the most economical power consumption in the cathode busbar structure, said cathode busbar structure is attached in elec-trical contact to at least one sidewall of a cathode walled enclosure fabricated from a conductive metal and having sidewalls, said cathode walled enclosure therein contains a plurality of cathode fingers;
II) Said cathode fingers having a cathode finger structure which comprises a conductive metal cathode finger reinforcing means, lengths of highly conductive metal positioned in the cathode finger structure, and foraminous conductive metal means attached to the cathode finger reinforcing means thereby forming the exterior of the cathode finger structure and gas compartment space inside the the cathode finger structure, said lengths of highly conductive metal are positioned in the cathode finger structure in such a a configuration wherein the lengths of highly conductive metal are adapted to carry an electric current and to maintain a substantially uniform current density through the cathode fingers without any significant voltage drop across the cathode fingers and with the most economical power consumption in the cathode fingers, said cathode finger structure provides a structure for the cathode fingers, said cathode walled enclosure contains plurality of cathode fingers which extend substantially across the interior of the cathode walled enclosure and the cathode fingers are attached in electrical contact to at least one interior sidewall of the cathode walled enclosure, said cathode busbar structure is attached in electrical contact to the exterior sidewall of the cathode walled enclosure on the sidewall adjacent to the attached cathode fingers;
III) Said anode base structure comprises a highly conductive metal means having substantially flat and level surface and having a decreased cross-section as it extends away from the anode or inter-cell connecting busbar means to form the cross-sectional shape of a substantially stair-stepped truncated right triangle, said highly conductive metal means has such a configuration and different relative dimensions whereby it is adapted to carry an electric current and to maintain a substantially uniform current density through the anode base structure to electrical contact points adjacent to the anode blades without any significant voltage drop across the anode base structure and with the most economical power consumption in the anode base structure.

The electrolytic cell of Claim 1, wherein the cathode busbar structure is provided with means for attaching cathode jumper connector means when an adjacent electrolytic cell is jumpered and is removed from the electrical circuit.

The electrolytic cell of Claim 1 wherein the cathode busbar structure is provided with a cooling means to prevent temperatures in the cathode busbar structure from rising to levels whereby damage to the cathode busbar structure or other components of the electro-lytic cell occurs.

The electrolytic cell of Claim 1, wherein the cathode lead-in busbar and the plurality of busbar strips are fabricated from copper.

The electrolytic cell of Claim 1 wherein the cathode walled enclosure contains about 10 to about 50 cathode fingers.

The electrolytic cell of Claim 1 wherein the cathode walled enclosure is fabricated from steel.

The electrolytic cell of Claim 1 wherein the height of the plurality of the busbar strips of said cathode busbar structure at their points of attachment to the sidewall of the cathode walled enclosure is usually substantially the same as the height of the cathode finger reinforcing means of the cathode fingers at their points of attachment to the sidewall of the cathode walled enclosure.

The electrolytic cell of Claim 1 wherein the conductive metal cathode finger reinforcing means comprises a corrugated conductive metal structure.

The electrolytic cell of Claim 8 wherein the corrugated con-ductive metal structure has foraminous conductive metal means attached to the outer surfaces of its protruding ridges thereby forming said exterior and providing compartment space for gas, formed at the cathode during electrolysis, to be channeled to a collection chamber.

The electrolytic cell of Claim 9 wherein the corrugated conductive metal structure is provided with protusions on the outer surfaces of its protruding ridges to which foraminous conductive metal means is attached to provide additional compartment space for gas, formed at the cathode during electrolysis, to be channeled to a collection chamber.

The electrolytic cell of Claim 10 wherein said foraminous conductive metal means is perforated metal plated.

The electrolytic cell of Claim 10 wherein the foraminous conductive metal means is screen.

The electrolytic cell of Claim 1 wherein the conductive metal cathode finger reinforcing means comprises a conductive metal plate, said plate having peg or pin means attached to said plate and foraminous conductive metal means attached to said peg or pin means thereby forming said exterior and providing compartment space for gas, formed at the cathode during electrolysis, to be channeled to a collection chamber.

The electrolytic cell of Claim 13 wherein the foraminous conductive metal means is perforated metal plate.

The electrolytic cell of Claim 13 wherein the foraminous conductive metal means is screen.

The electrolytic cell of Claim 1 wherein the lengths of highly conductive metal are positioned on the cathode finger reinforcing means in the cathode finger structure and are attached to the cathode finger reinforcing means.

The electrolytic cell of Claim 16 wherein the lengths of highly conductive metal are of different lengths.

The electrolytic cell of Claim 16 wherein the lengths of highly conductive metal have different cross-sections.

The electrolytic cell of Claim 16 wherein the lengths of highly conductive metal have different lengths and different cross-sections.

The electrolytic cell of Claim 1 wherein the highly conductive metal lengths are copper.

The electrolytic cell of Claim 1 wherein means are provided for positioning the cathode fingers to the sidewall opposite to that side-wall to which the fingers are attached.

The electrolytic cell of Claim 1 wherein the highly conductive metal means of the anode base structure is provided with means for attaching the anode blades.

The electrolytic cell of Claim 1 wherein said anode base structure comprise suitable structural support means for the highly conductive metal means.

The electrolytic cell of Claim 23 wherein said suitable support means for the highly conductive metal means comprises a configuration of metal shapes which form a unitary structure with said highly con-ductive metal means.

The electrolytic cell of Claim 24 wherein the metal shapes comprise steel plates.

The electrolytic cell of Claim 1 wherein said anode base structure is provided with sufficient means to support other components of the electrolytic cell.

The electrolytic cell of Claim 26 wherein the means to support other components of the electrolytic cell comprise structural metallic support means.

The electrolytic cell of Claim 26 wherein the means to support other components of the electrolytic cell comprise structural non-metallic support means.

The electrolytic cell of Claim 1 wherein the anode base structure is provided with a jumper busbar for attaching anode connector means when an adjacent electrolytic cell is jumpered and removed from the electrical circuit.

The electrolytic cell of Claim 1 wherein the anode base structure is provided with a cooling means to prevent temperatures in the anode busbar structure from rising to levels whereby damage to the anode busbar structure or other components of the electrolytic cell occur.

The electrolytic cell of Claim 1 wherein said highly conductive metal means of said anode base structure is copper.

The electrolytic cell of Claim 1 wherein the conductive metal cathode finger reinforcing means and the foraminous conductive metal means are fabricated from steel.

The electrolytic cell of Claim 1 wherein said cell is designed to operate at a current capacity of about 150,000 to about 200,000 amperes.