Apparatuses and systems for vertical electrolysis cells

Patent metadata

Field	Value
Publication number	US-11203814-B2
Application number	US-201715474934-A
Country	US
Kind code	B2
Filing date	Mar 30, 2017
Priority date	Mar 30, 2016
Publication date	Dec 21, 2021
Grant date	Dec 21, 2021

Abstract

In one embodiment, the disclosed subject matter relates to an electrolytic cell that has: a cell reservoir; a cathode support retained on a bottom of the cell reservoir, wherein the cathode support contacts at least one of: a metal pad and a molten electrolyte bath within the cell reservoir, wherein the cathode support includes: a body having a support bottom, which is configured to be in communication with the bottom of the electrolysis cell; and a support top, opposite the support bottom, having a cathode attachment area configured to retain a at least one cathode plate therein.

First claim

What is claimed is:

1. An electrolytic cell, comprising:
(a) a shell having a shell bottom and surrounding shell sidewalls;
(b) an insulating material on the shell bottom;
(c) a current collector bar extending through the shell and the insulating material;
(d) a carbon cathode block disposed on a portion of the current collector bar;
(e) a refractory material disposed adjacent to the carbon cathode block and one of the shell sidewalls;
(f) a cathode support located on the carbon cathode block;
(g) a plurality of vertical cathode plates disposed on the cathode support, wherein the cathode support comprises at least one cathode attachment configured to hold the plurality of vertical cathode plates in a vertical orientation;
(h) a plurality of vertical anode plates adjacent to and overlapping with the plurality of vertical cathode plates, wherein the plurality of vertically anode plates are at least partially disposed within the shell.

2. The electrolytic cell of claim 1 , wherein the at least one cathode attachment of the cathode support comprises surface grooves on an upper surface of the cathode support, wherein the surface grooves comprise a sufficient depth to retain at least one cathode plate of the plurality of vertical cathode plates.

3. The electrolytic cell of claim 1 , wherein the at least one cathode attachment of the cathode support comprises:
a first plurality of beams, wherein the first plurality of beams comprises one or more surface grooves, and wherein the one or more surface grooves are configured to retain the at least one cathode plate of the plurality of vertical cathode plates; and
a second plurality of beams connecting the first plurality of beams.

4. The electrolytic cell of claim 1 , wherein the plurality of vertical cathode plates comprise at least a first cathode plate and a second cathode plate, wherein an edge of the first cathode plate touches an edge of the second cathode plate, wherein the second cathode plate is located on an opposing side of the first cathode plate.

5. The electrolytic cell of claim 1 , wherein the at least one cathode attachment comprises a plurality of pins.

6. The electrolytic cell of claim 5 , wherein pin bottoms of the plurality of pins are retained by corresponding openings in the cathode support.

7. The electrolytic cell of claim 6 , wherein the plurality of pins are positioned in a spaced relation from one another and wherein at least some of the plurality of pins support at least one cathode plate of the plurality of vertical cathode plates in the vertical orientation.

8. The electrolytic cell of claim 5 , wherein the plurality of pins comprises a first set of pins and a second set of pins.

9. The electrolytic cell of claim 8 , wherein pin bottoms of the first set of pins are arranged in a first linear formation on the cathode support, and wherein pin bottoms of the second set of pins are arranged in a second linear formation on the cathode support.

10. The electrolytic cell of claim 9 , wherein the first linear formation is parallel to the second linear formation.

11. The electrolytic cell of claim 5 , wherein pin tops of the plurality of pins are configured to support a non-planar cathode plate of the plurality of vertical cathode plates in a vertical configuration.

12. The electrolytic cell of claim 8 , wherein a first pin of the first set of pins comprises a first top shape and wherein a second pin of the second set of pins comprises a second top shape.

13. The electrolytic cell of claim 12 , wherein the first top shape is different than the second top shape.

14. The electrolytic cell of claim 12 , wherein the first pin comprises a first top diameter and wherein the second pin comprises a second top diameter.

15. The electrolytic cell of claim 14 , wherein the first top diameter is different than the second top diameter.

16. The electrolytic cell of claim 12 , wherein the first pin and the second pin comprise a first bottom diameter and wherein the first pin and the second pin comprise a second top diameter.

17. The electrolytic cell of claim 16 , wherein the first bottom diameter is different than the second top diameter.

18. The electrolytic cell of claim 12 , wherein the first top shape and the second top shape comprise a laterally non-symmetrical shape.

19. The electrolytic cell of claim 5 , wherein at least some of the plurality of pins comprise titanium diboride.

20. The electrolytic cell of claim 5 , wherein a first pin of the plurality of pins comprises a varying radius.

21. The electrolytic cell of claim 5 , wherein at least some of the plurality of pins are embedded in the cathode support, wherein at least some pin tops of the plurality of pin comprise two prongs, and wherein at least one cathode plate of the plurality of vertical cathode plates is positioned between the two prongs.

22. The electrolytic cell of claim 1 , wherein at least two plates of the plurality of vertical cathode plates mechanically interlock together.

23. The electrolytic cell of claim 22 , wherein the plurality of vertical cathode plates comprise at least a first cathode plate and a second cathode plate, wherein both the first cathode plate and the second cathode plate comprise side edges configured to mechanically interlock with each other.

24. The electrolytic cell of claim 23 , wherein the side edges of the first cathode plate are concave side edges, wherein the side edges of the second cathode plate are convex side edges, and wherein the concave side edges are configured to interlock with the convex side edges.

25. The electrolytic cell of claim 24 , wherein side edges of the first and second cathode plates comprise a plurality of holes, wherein each hole of the plurality of holes is configured to accommodate a pin of a plurality of pins, wherein the plurality of pins mechanically interlock the first cathode plate to the second cathode plate.

26. An electrolytic cell, comprising:
(a) a shell;
(b) a plurality of anodes at least partially disposed within the shell;
(c) a cathode support at least partially disposed within the shell; and
(d) a primary cathode plate retained on the cathode support, wherein the primary cathode plate is configured to mechanically interlock with a plurality of adjacent cathode plates, wherein the plurality of adjacent cathode plates comprises a first adjacent cathode plate and a second adjacent cathode plate;
wherein at least one of the primary cathode plate, the first adjacent cathode plate and the second adjacent cathode plate overlap with at least one anode of the plurality of anodes; and
wherein the primary cathode plate comprises:
a top edge;
a bottom edge;
a first side edge; and
a second side edge, wherein the first adjacent cathode plate comprise a first adjacent side edge, wherein the second adjacent cathode plate comprises a second adjacent side edge, wherein the first side edge is configured to mechanically interlock with the first adjacent side edge, and wherein the second side edge is configured to mechanically interlock with the second adjacent side edge.

27. The electrolytic cell of claim 26 , wherein the first side edge, the second side edge, the first adjacent side edge and the second adjacent side edge comprise bevelled edges, wherein the bevelled edges are configured to mechanically interlock with each other.

28. The electrolytic cell of claim 2

Assignees

• Alcoa Usa Corp

Inventors

• Mosser Benjamin D
• Sworts Lance M

Classifications

• C25C3/08 Primary

  Cell construction, e.g. bottoms, walls, cathodes · CPC title

• C25C3/12

  Anodes · CPC title

• C25C7/005

  of cells for the electrolysis of melts (C25C7/02 - C25C7/06 take precedence) · CPC title

• C25C3/10

  External supporting frames or structures · CPC title

• C04B35/64

  Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F}) · CPC title