Cu-ni-fe anode for use in aluminum producing electrolytic cell

An improved anode for use in an electrolytic cell for producing aluminum from alumina dissolved in a molten salt electrolyte contained in said cell wherein aluminum is deposited at the cathode, oxygen is produced at the anode when electric current is passed through the cell, said cell containing at least one cathode and one anode disposed in said electrolyte, said anodes comprised of a Cu—Ni—Fe alloy having a single microstructural phase, said cathode having a surface, said anode having a surface for disposing opposite said cathode surface to provide an anode-cathode distance defining a region between said anode and said cathode surfaces, said anode having apertures therein to permit flow of electrolyte through said apertures to provide alumina-enriched molten salt electrolyte in said region between said anodes and said cathodes.

An improved anode for use in an electrolytic cell for producing aluminum from alumina dissolved in a molten salt electrolyte contained in said cell, said cell containing at least one cathode and one anode disposed in said electrolyte, said cathode having a flat surface, said improved anode comprising:

• two anode panels comprised of a Cu—Ni—Fe alloy having a single microstructural phase, said anode panels in electrical communication and separated to define a space between said panels for flowing molten electrolyte, each of said anode panels having a flat surface for disposing opposite said cathode surface to provide a region between the anode and the cathode surface, said panels having apertures to permit flow of alumina-enriched electrolyte contained in said space to said region between said anodes and said cathodes.

In an improved method of producing aluminum in an electrolytic cell containing alumina dissolved in an electrolyte wherein a molten salt electrolyte is maintained at a temperature of less than 900° C., the electrolyte having alumina dissolved therein, and alumina add to the electrolyte on a continuous basis to provide alumina-enriched electrolyte, and wherein a plurality of non-consumable anodes and cathodes are disposed in a vertical direction in said electrolyte, said cathodes having a flat surface, the improved method comprising:

• (a) providing anodes having a planar surface disposed opposite the flat surface of the cathode to define a region between the cathode flat surface and the planar surface of the anode, said anodes comprised of a Cu—Ni—Fe alloy having a single microstructural phase, the anode planar surface containing apertures permitting flow of electrolyte through the apertures to provide alumina-enriched electrolyte to the region between said anodes and said cathodes;
• (b) passing electrical current through said anodes and through said electrolyte to said cathodes, depositing aluminum at said cathodes and producing gas at said anodes.

An anode having increased anode active surface area for use in an electrolytic cell for producing aluminum from alumina dissolved in a molten salt electrolyte contained in the cell, the cell containing at least one cathode and one anode disposed in said electrolyte, said anode comprised of a Cu—Ni—Fe alloy having a single microstructural phase, said cathode having a surface, the anode having a first surface for disposing opposite said cathode surface to provide a controlled anode-cathode distance defining a region between said anode and said cathode surfaces, said anode having a second surface disposed from said first surface of said anode to provide said anode with a thickness dimension, said anode having apertures extending from said first surface to said second surface, said apertures defined by a wall of said anode, said wall providing additional anode active surface area during electrolysis of said alumina in said cell.

An anode having increased anode active surface area for use in an electrolytic cell for producing aluminum from alumina dissolved in a molten salt electrolyte contained in the cell, the cell containing at least one cathode and one Cu—Ni—Fe anode disposed in said electrolyte, wherein said anode is a cast anode heated to a temperature range of 950° to 1250° C. to provide a single microstructural phase, said cathode having a planar surface, the anode having a planar first surface for disposing opposite said cathode planar surface to provide a controlled anode-cathode distance of ¼ to 1 inch defining a region between said anode and said cathode surfaces, said anode having a second surface disposed from said first surface to provide said anode with a thickness dimension, said anode having apertures extending from said first surface to said second surface, said apertures defined by a wall of said anode, said wall providing additional anode active surface area during electrolysis of said alumina in said cell and providing for flow of alumina-enriched electrolyte to said region between said anode and cathode, the ratio of said anode active surface area to cathode active surface area being in the range of 1:1 to 5:1.