WO1999036594A1 - Non-carbon metal-based anodes for aluminium production cells - Google Patents
Non-carbon metal-based anodes for aluminium production cellsInfo
- Publication number
- WO1999036594A1 WO1999036594A1 PCT/IB1999/000084 IB9900084W WO9936594A1 WO 1999036594 A1 WO1999036594 A1 WO 1999036594A1 IB 9900084 W IB9900084 W IB 9900084W WO 9936594 A1 WO9936594 A1 WO 9936594A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- anode
- coating
- nickel
- electrolyte
- metal substrate
- Prior art date
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
- C25C3/00—Electrolytic production, recovery or refining of metals by electrolysis of melts
- C25C3/06—Electrolytic production, recovery or refining of metals by electrolysis of melts of aluminium
- C25C3/08—Cell construction, e.g. bottoms, walls, cathodes
- C25C3/12—Anodes
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
- C25C7/00—Constructional parts, or assemblies thereof, of cells; Servicing or operating of cells
- C25C7/02—Electrodes; Connections thereof
- C25C7/025—Electrodes; Connections thereof used in cells for the electrolysis of melts
Definitions
- This invention relates to non-carbon metal-based anodes for use in cells for the electrowinning of aluminium by the electrolysis of alumina dissolved in a molten fluoride-containing electrolyte, and to methods for their fabrication and reconditioning, as well as to electrowinning cells containing such anodes and their use to produce aluminium.
- the anodes are still made of carbonaceous material and must be replaced every few weeks .
- the operating temperature is still not less than 950°C in order to have a sufficiently high solubility and rate of dissolution of alumina and high electrical conductivity of the bath.
- the anodes have a very short life because during electrolysis the oxygen which should evolve on the anode surface combines with the carbon to form polluting CO2 and small amounts of CO and fluoride-containing dangerous gases .
- the actual consumption of the anode is as much as 450 Kg/Ton of aluminium produced which is more than 1/3 higher than the theoretical amount of 333 Kg/Ton
- US Patent 4,614,569 (Duruz/Derivaz/Debely/ Adorian) describes non-carbon anodes for aluminium electrowinning coated with a protective coating of cerium oxyfluoride, formed in-situ in the cell or pre-applied, this coating being maintained by the addition of cerium compounds to the molten cryolite electrolyte. This made it possible to have a protection of the surface only from the electrolyte attack and to a certain extent from the gaseous oxygen but not from the nascent monoatomic oxyge .
- EP Patent application 0 306 100 (Nyguen/Lazouni/ Doan) describes anodes composed of a chromium, nickel, cobalt and/or iron based substrate covered with an oxygen barrier layer and a ceramic coating of nickel, copper and/or manganese oxide which may be further covered with an in-situ formed protective cerium oxyfluoride layer.
- Metal or metal based anodes are highly desirable in aluminium electrowinning cells instead of carbon-based anodes. Many attempts were made to use metal-based anodes for aluminium production, however they were never adopted by the aluminium industry because of their poor performance .
- An object of the invention is to substantially reduce the consumption of the active anode surface of an aluminium electrowinning anode which is attacked by the nascent oxygen by enhancing the reaction of nascent oxygen to biatomic molecular gaseous oxygen.
- Another object of the invention is to provide a coating for an aluminium electrowinning anode which has a high electrochemical activity and also a long life and which can be replaced as soon as such activity decreases or when the coating is worn out.
- a major object of the invention is to provide an aluminium electrowinning anode which has no carbon so as to eliminate carbon-generated pollution and reduce the cost of operation.
- the invention provides a non-carbon metal-based anode of a cell for the electrowinning of aluminium, in particular by the electrolysis of alumina dissolved in a molten fluoride-containing electrolyte.
- the anode comprises an electrically conductive metal substrate resistant to high temperature, the surface of which becomes passive and substantially inert to the electrolyte, and an electrochemically active coating adherent to the surface of the metal substrate making and keeping the surface of the anode conductive and electrochemically active for the oxidation of oxygen ions present at the electrolyte interface.
- This passivation property offers a self-healing effect, i.e. when the surface of the anode is imperfectly covered, damaged or partly worn out, parts of the metal substrate which come into contact with the electrolyte are automatically passivated during electrolysis and become inert to the electrolyte and not corroded.
- Metal substrates providing for this self-healing effect in molten fluoride-based electrolyte may be made of one or more metals selected from nickel, cobalt, chromium, molybdenum, tantalum and the Lanthanide series of the Periodic Table, and their alloys or intermetallics, such as nickel-plated copper.
- the coatings usually comprise:
- Coatings can be obtained by applying their active constituents and their precursors by various methods which can be different for each constituent and can be repeated in several layers.
- a coating can be obtained by directly applying a powder onto the passivatable metal substrate or constituents of the coating may be applied from a slurry or suspension containing colloidal or polymeric material.
- the colloidal material can be a binder solely or can be part of the active material.
- the colloidal material may include at least one colloid selected from colloidal alumina, ceria, lithia, magnesia, silica, thoria, yttria, zirconia, tin oxide, zinc oxide and colloid containing the active material .
- the dry colloid content corresponds to up to 50 weight% of the colloid plus liquid carrier, usually from 10 to 20 weight% .
- the coating can be applied on the substrate by plasma spraying, physical vapor deposition (PVD) , chemical vapor deposition (CVD) , electrodeposition or callendering rollers.
- PVD physical vapor deposition
- CVD chemical vapor deposition
- a slurry or a dispersion is preferably applied by rollers, brush or spraying.
- electrochemically active constituent (s) is/are selected from oxides, oxyfluorides, phosphides, carbides and combinations thereof.
- the oxide may be present in the electrochemically active layer as such, or in a multi-compound mixed oxide and/or in a solid solution of oxides.
- the oxide may be in the form of a simple, double and/or multiple oxide, and/or in the form of a stoichiometric or non- stoichiometric oxide.
- the oxides may be in the form of spinels and/or perovskites, in particular spinels which are doped, non- stoichiometric and/or partially substituted.
- Doped spinels may comprise dopants selected from Ti 4+ , Zr 4+ , Sn 4+ , Fe 4+ , Hf 4+ , Mn 4+ , Fe 3+ , Ni 3+ , Co 3+ , Mn 3+ , Al 3+ , Cr 3+ , Fe + , Ni 2+ , Co 2+ , Mg 2+ , Mn 2+ , Cu 2+ , Zn + and Li + .
- Such a spinel may be a ferrite, in particular a ferrite selected from cobalt, manganese, molybdenum, nickel and zinc, and mixtures thereof.
- the ferrite may be doped with at least one oxide selected from the group consisting of chromium, titanium, tantalum, tin, zinc and zirconium oxide.
- Nickel-ferrite or nickel-ferrite based constituents are advantageously used for their resistance to electrolyte and may be present as such or partially substituted with Fe 2+ .
- the coating may also contain a chromite which is usually selected from iron, cobalt, copper, manganese, beryllium, calcium, strontium, barium, magnesium, nickel and zinc chromite.
- a chromite which is usually selected from iron, cobalt, copper, manganese, beryllium, calcium, strontium, barium, magnesium, nickel and zinc chromite.
- the electrochemically active constituents of the coating may be selected from iron, chromium, copper and nickel, and oxides, mixtures and compounds thereof, as well as a Lanthanide as an oxide or an oxyfluoride such as cerium oxyfluoride, and mixtures thereof.
- an electrocatalyst is present in the coating it is selected preferably from noble metals such as iridium, palladium, platinum, rhodium, ruthenium, or silicon, tin and zinc, the Lanthanide series of the Periodic Table and mischmetal oxides, and mixtures and compounds thereof.
- noble metals such as iridium, palladium, platinum, rhodium, ruthenium, or silicon, tin and zinc, the Lanthanide series of the Periodic Table and mischmetal oxides, and mixtures and compounds thereof.
- Coatings can be formed with or without reaction at low or high temperature.
- a reaction can either take place among the constituents of the coating; or between the constituents of the coating and the passivatable metal substrate.
- the active constituents When no reaction takes place to form the coating the active constituents must already be present in the applied material, for example in a slurry or suspension applied onto the substrate.
- any electrically conductive and heat-resisting materials may be used.
- metals which do not offer the self- healing effect can only be used as metal cores which must be coated with a layer forming the passivatable metal substrate having this self-healing effect particularly when exposed to a fluoride-containing electrolyte, such as cryolite.
- the metal core may comprise metals, alloys, inter etallics, cermets and conductive ceramics, such as metals selected from copper, chromium, cobalt, iron, aluminium, hafnium, molybdenum, nickel, niobium, silicon, tantalum, titanium, tungsten, vanadium, yttrium and zirconium, and combinations and compounds thereof.
- the core may be made of an alloy comprising 10 to 30 weight% of chromium, 55 to 90 weight% of at least one of nickel, cobalt and/or iron and 0 to 15 weight% of at least one of aluminium, hafnium, molybdenum, niobium, silicon, tantalum, tungsten, vanadium, yttrium and zirconium.
- the core may be covered with an oxygen barrier layer.
- This layer may be obtained by oxidising the surface of the core when it contains chromium and/or nickel or by applying a precursor of the oxygen barrier layer onto the core and heat treating.
- the oxygen barrier layer comprises chromium oxide and/or black non-stoichiometric nickel oxide.
- the oxygen barrier layer may be covered in turn with at least one protective layer consisting of copper or copper and at least one of nickel and cobalt, and/or (an) oxide (s) thereof to protect the oxygen barrier layer by inhibiting its dissolution into the electrolyte.
- the oxygen barrier layer may be coated first with a nickel layer and then with a copper layer, heat treated for several hours in an inert atmosphere, such as 5 hours at 1000°C in argon, to interdiffuse the nickel and the copper layer, and upon heat treatment in an oxidising media, such as an air oxidation for 24 hours at 1000°C, the interdiffused and oxidised nickel-copper layer constitutes a good a protective layer.
- the invention relates also to a method of manufacturing the described non-carbon metal-based anode.
- the method comprises coating a substrate of electrically conductive metal resistant to high temperature the surface of which during electrolysis becomes passive and substantially inert to the electrolyte with at least one layer containing electrochemically active constituents or precursors thereof and heat-treating the or each layer on the substrate to obtain a coating adherent to the metal substrate making the surface of the anode electrochemically active for the oxidation of oxygen ions present at the electrolyte interface.
- the method of the invention can be applied for reconditioning the non-carbon metal-based anode when at least part of the active coating has been dissolved or rendered non-active or dissolved.
- the method comprises clearing the surface of the substrate before re-coating said surface with a coating adherent to the passivatable metal substrate once again making the surface of the anode electrochemically active for the oxidation of oxygen ions .
- Another aspect of the invention is a cell for the production of aluminium by the electrolysis of alumina dissolved in a fluoride-containing electrolyte, in particular a fluoride-based electrolyte or a cryolite- based electrolyte or cryolite, having non-carbon metal- based anodes comprising an electrically conductive passivatable metal substrate and a conductive coating having an electrochemically active surface as described hereabove .
- the cell comprises at least one aluminium-wettable cathode. Even more preferably, the cell is in a drained configuration by having at least one drained cathode on which aluminium is produced and from which aluminium continuously drains.
- the cell may be of monopolar, multi-monopolar or bipolar configuration.
- a bipolar cell may comprise the anodes as described above as a terminal anode or as the anode part of a bipolar electrode.
- the cell comprises means to improve the circulation of the electrolyte between the anodes and facing cathodes and/or means to facilitate dissolution of alumina in the electrolyte.
- means to improve the circulation of the electrolyte between the anodes and facing cathodes can for instance be provided by the geometry of the cell as described in co-pending application PCT/IB98/00161 (de Nora/Duruz) or by periodically moving the anodes as described in co- pending application PCT/IB98/00162 (Duruz/Bell ⁇ ) .
- the cell may be operated with the electrolyte at conventional temperatures, such as 950 to 970°C, or at reduced temperatures as low as 750°C.
- the invention also relates to the use of such an anode for the production of aluminium in a cell for the electrowinning of aluminium by the electrolysis of alumina dissolved in a fluoride-containing electrolyte, wherein oxygen ions in the electrolyte are oxidised and released as molecular oxygen by the electrochemically active anode coating.
- An non-carbon metal-based anode is prepared according to the invention by hot calendar rolling at 900°C of nickel ferrite particles having a particle size of 10-50 micron into a nickel metal sheet of 2 mm thickness used as an electrically conductive substrate for the anode.
- the nickel ferrite particles are coated onto the nickel sheet in an amount of 500 g/m 2 .
- the anode was tested in an electrolytic cell using cryolite with 6 weight% alumina as an electrolyte and a carbon cathode covered with molten aluminium.
- the anode was polarised at 1 A/cm ⁇ for 93 hours and sustained this current density during the entire test, the cell voltage remaining comprised between 5.5 and 5.8 Volts.
- the anode was dimensionally unchanged and no sign of corrosion could be detected at the anode surface.
- a non-carbon metal-based anode according to the invention was obtained from a nickel substrate which was coated with a slurry with subsequent heat-treatment .
- the slurry was made from a solution consisting of 10 ml of colloidal magnesia acting as a binder mixed with 20 g of nickel ferrite powder providing the electrochemically active constituents, as described in Example 1.
- the slurry was then applied onto the substrate by means of a brush. 15 successive layers were applied onto the substrate. Each time a layer had been applied onto the substrate, the layer was cured on the substrate by a heat treatment at 500°C for 15 minutes before applying the next layer.
- the anode After coating the substrate with the 15 successive layers the anode had a final coating of 0.6 to 1.0 mm thick.
- the anode was then tested in a laboratory scale cell for the electrowinning of aluminium. 10 minutes after immersing the anode into the electrolytic bath the anode was extracted from the cell. The parts of the anodes which were not protected by the coating had been passivated under the effect of the current by the formation of an inert and adherent nickel oxide layer formed on the uncoated surfaces which could be observed by optical microscopy and scanning electron microscopy of a cross section of the anode after test.
- Example 2 a coating was applied onto a nickel substrate in 10 layers, except that 0.2 g of iridium powder acting as a catalyst were added to the mixture of colloidal alumina with nickel-nickel ferrite.
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA002317800A CA2317800C (en) | 1998-01-20 | 1999-01-19 | Non-carbon metal-based anodes for aluminium production cells |
EP99900110A EP1049818B1 (en) | 1998-01-20 | 1999-01-19 | Non-carbon metal-based anodes for aluminium production cells |
AU17798/99A AU740270B2 (en) | 1998-01-20 | 1999-01-19 | Non-carbon metal-based anodes for aluminium production cells |
DE69922924T DE69922924T2 (en) | 1998-01-20 | 1999-01-19 | CARBON-FREE ANODES BASED ON METALS FOR ALUMINUM ELECTRICITY CELLS |
US09/616,328 US6379526B1 (en) | 1999-01-19 | 2000-07-15 | Non-carbon metal-based anodes for aluminium production cells |
NO20003701A NO20003701D0 (en) | 1998-01-20 | 2000-07-19 | Non-carbon metal-based anodes for aluminum production cells |
Applications Claiming Priority (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IBPCT/IB98/00080 | 1998-01-20 | ||
IB9800080 | 1998-01-20 | ||
US09/126,840 | 1998-07-30 | ||
US09/126,359 US6365018B1 (en) | 1998-07-30 | 1998-07-30 | Surface coated non-carbon metal-based anodes for aluminium production cells |
US09/126,206 | 1998-07-30 | ||
US09/126,840 US6113758A (en) | 1998-07-30 | 1998-07-30 | Porous non-carbon metal-based anodes for aluminium production cells |
US09/126,359 | 1998-07-30 | ||
US09/126,206 US6077415A (en) | 1998-07-30 | 1998-07-30 | Multi-layer non-carbon metal-based anodes for aluminum production cells and method |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/616,328 Continuation US6379526B1 (en) | 1999-01-19 | 2000-07-15 | Non-carbon metal-based anodes for aluminium production cells |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1999036594A1 true WO1999036594A1 (en) | 1999-07-22 |
Family
ID=27452016
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IB1999/000084 WO1999036594A1 (en) | 1998-01-20 | 1999-01-19 | Non-carbon metal-based anodes for aluminium production cells |
Country Status (7)
Country | Link |
---|---|
EP (1) | EP1049818B1 (en) |
AU (1) | AU740270B2 (en) |
CA (1) | CA2317800C (en) |
DE (1) | DE69922924T2 (en) |
ES (1) | ES2230828T3 (en) |
NO (1) | NO20003701D0 (en) |
WO (1) | WO1999036594A1 (en) |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2001031089A1 (en) * | 1999-10-27 | 2001-05-03 | Alcoa Inc. | Inert anode containing oxides of nickel, iron and zinc useful for the electrolytic production of metal |
WO2001031090A1 (en) * | 1999-10-27 | 2001-05-03 | Alcoa Inc. | Cermet inert anode for use in the electrolytic production of metals |
WO2001042168A1 (en) * | 1999-04-16 | 2001-06-14 | Moltech Invent S.A. | Aluminium-wettable protective coatings for carbon components used in metallurgical processes |
WO2001042534A2 (en) * | 1999-12-09 | 2001-06-14 | Moltech Invent S.A. | Metal-based anodes for aluminium electrowinning cells |
US6416649B1 (en) | 1997-06-26 | 2002-07-09 | Alcoa Inc. | Electrolytic production of high purity aluminum using ceramic inert anodes |
US7045250B2 (en) | 2000-11-13 | 2006-05-16 | Sanyo Electric Co., Ltd. | Non-aqueous electrolyte battery |
US8546046B2 (en) | 2009-11-20 | 2013-10-01 | Industrial Technology Research Institute | Method for fabricating bi-polar plate of fuel cell and bi-polar plate of fuel cell |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN101300700B (en) | 2005-10-27 | 2011-02-09 | 京瓷株式会社 | Heat resistant alloy member for fuel cell, power collecting member for fuel cell, cell stack and fuel cell |
DE102009016111B4 (en) * | 2009-04-03 | 2011-02-10 | Technische Universität Clausthal | Die castings from a hypereutectic aluminum-silicon casting alloy and process for its production |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4541912A (en) * | 1983-12-12 | 1985-09-17 | Great Lakes Carbon Corporation | Cermet electrode assembly |
EP0306101A1 (en) * | 1987-09-02 | 1989-03-08 | MOLTECH Invent S.A. | Non-consumable anode for molten salt electrolysis |
WO1993020026A1 (en) * | 1992-04-01 | 1993-10-14 | Moltech Invent Sa | Prevention of oxidation of carbonaceous and other materials at high temperatures |
-
1999
- 1999-01-19 WO PCT/IB1999/000084 patent/WO1999036594A1/en active IP Right Grant
- 1999-01-19 CA CA002317800A patent/CA2317800C/en not_active Expired - Fee Related
- 1999-01-19 DE DE69922924T patent/DE69922924T2/en not_active Expired - Fee Related
- 1999-01-19 ES ES99900110T patent/ES2230828T3/en not_active Expired - Lifetime
- 1999-01-19 AU AU17798/99A patent/AU740270B2/en not_active Ceased
- 1999-01-19 EP EP99900110A patent/EP1049818B1/en not_active Expired - Lifetime
-
2000
- 2000-07-19 NO NO20003701A patent/NO20003701D0/en unknown
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4541912A (en) * | 1983-12-12 | 1985-09-17 | Great Lakes Carbon Corporation | Cermet electrode assembly |
EP0306101A1 (en) * | 1987-09-02 | 1989-03-08 | MOLTECH Invent S.A. | Non-consumable anode for molten salt electrolysis |
WO1993020026A1 (en) * | 1992-04-01 | 1993-10-14 | Moltech Invent Sa | Prevention of oxidation of carbonaceous and other materials at high temperatures |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6416649B1 (en) | 1997-06-26 | 2002-07-09 | Alcoa Inc. | Electrolytic production of high purity aluminum using ceramic inert anodes |
WO2001042168A1 (en) * | 1999-04-16 | 2001-06-14 | Moltech Invent S.A. | Aluminium-wettable protective coatings for carbon components used in metallurgical processes |
WO2001031089A1 (en) * | 1999-10-27 | 2001-05-03 | Alcoa Inc. | Inert anode containing oxides of nickel, iron and zinc useful for the electrolytic production of metal |
WO2001031090A1 (en) * | 1999-10-27 | 2001-05-03 | Alcoa Inc. | Cermet inert anode for use in the electrolytic production of metals |
WO2001042534A2 (en) * | 1999-12-09 | 2001-06-14 | Moltech Invent S.A. | Metal-based anodes for aluminium electrowinning cells |
WO2001042534A3 (en) * | 1999-12-09 | 2002-01-17 | Moltech Invent Sa | Metal-based anodes for aluminium electrowinning cells |
US7045250B2 (en) | 2000-11-13 | 2006-05-16 | Sanyo Electric Co., Ltd. | Non-aqueous electrolyte battery |
US8546046B2 (en) | 2009-11-20 | 2013-10-01 | Industrial Technology Research Institute | Method for fabricating bi-polar plate of fuel cell and bi-polar plate of fuel cell |
US8841045B2 (en) | 2009-11-20 | 2014-09-23 | Industrial Technology Reserach Institute | Method for fabricating bi-polar plate of fuel cell |
Also Published As
Publication number | Publication date |
---|---|
ES2230828T3 (en) | 2005-05-01 |
EP1049818A1 (en) | 2000-11-08 |
CA2317800C (en) | 2008-04-01 |
AU740270B2 (en) | 2001-11-01 |
CA2317800A1 (en) | 1999-07-22 |
NO20003701L (en) | 2000-07-19 |
AU1779899A (en) | 1999-08-02 |
DE69922924D1 (en) | 2005-02-03 |
NO20003701D0 (en) | 2000-07-19 |
DE69922924T2 (en) | 2005-12-15 |
EP1049818B1 (en) | 2004-12-29 |
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