Long-term testing and evaluation of cathode components in a commercial aluminum cell

Technical Report · Tue Aug 01 00:00:00 EDT 1989

DOI:https://doi.org/10.2172/5099243· OSTI ID:5099243

Gee, J. T.; Tucker, K. W; Joo, L. A.; Stewart, D. V.; Alcorn, T.; Tabereaux, A.

Since 1886, essentially all primary aluminum has been produced in Hall-Heroult electrolytic cells which electrochemically reduce alumina to the metal in an energy/capital intensive process. Nearly five per cent of the electrical energy generated in the United States is consumed in this Hall-Heroult process, at the rate of 6--8 kwh/lb of aluminum produced. It has been in the aluminum industry's interest for the past several decades to utilize titanium diboride in some capacity as the cell cathode, either with conventional consumable carbon anodes or ultimately with nonconsumable, inert anodes. Eventual achievement of either or both of these goals will represent a technological breakthrough and make possible a significant reduction in the energy requirement to produce aluminum. The overall objective and achievement of this program was to better define the technical and economic viability of graphite-containing titanium diboride materials in low-cost shapes for use as cathodes in aluminum electrolytic cells as a precursor to subsequent demonstration and commercial application. Included are mathematical models for the prediction of cost-reducing cathode shapes, optimizing ratios of electrode areas, voltage reduction, and the effect on current efficiency from reduced anode-cathode distance. As part of the program, cathode shapes were produced using proprietary material processing technologies. Long-term commercial and medium-term pilot cell operations for data acquisition and cathode longevity determinations were completed, as were analyses of as-fabricated and as-tested cathodes, development of possible failure mechanisms, development of cathode holder/anode stops and an assessment of energy savings and technical/economic viability.

• Research Organization: Great Lakes Research, Elizabethton, TN (USA); Reynolds Metals Co., Sheffield, AL (USA). Energy Conversion Div.
• Sponsoring Organization: DOE/CE
• DOE Contract Number: AC07-87ID12689
• OSTI ID: 5099243
• Report Number(s): DOE/ID/12689-1; ON: DE90006064
• Country of Publication: United States
• Language: English

Related Subjects

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
36 MATERIALS SCIENCE
ALUMINIUM
FABRICATION
ELECTROLYTIC CELLS
ENERGY CONSUMPTION
ALUMINIUM OXIDES
ANODES
CARBON
CATHODES
ECONOMICS
MATHEMATICAL MODELS
PROCESS CONTROL
TITANIUM BORIDES
ALUMINIUM COMPOUNDS
BORIDES
BORON COMPOUNDS
CHALCOGENIDES
CONTROL
ELECTRODES
ELEMENTS
METALS
NONMETALS
OXIDES
OXYGEN COMPOUNDS
TITANIUM COMPOUNDS
TRANSITION ELEMENT COMPOUNDS
320303* - Energy Conservation
Consumption
& Utilization- Industrial & Agricultural Processes- Equipment & Processes
360101 - Metals & Alloys- Preparation & Fabrication
360201 - Ceramics
Cermets
& Refractories- Preparation & Fabrication