Compositions suitable for use in an electrolytic cell for producing aluminum are provided. The compositions can contain a powder blend of boron oxide, a titanium dioxide, aluminum, and titanium diboride. The powder blend can be compacted into tiles and arranged as a cathode surface. The boron oxide and the titanium dioxide in the tiles can be made to react under low temperature molten aluminum to produce titanium diboride in situ. The reaction yields a dense dimensionally stable wettable cathode substrate that can reduce the power consumption in the aluminum electrowinning process.

A raw gas collection system for collecting raw gas from a plurality of aluminium smelting pots is equipped with a plurality of branch ducts, each of which is arranged to channel a respective branch flow of raw gas from an aluminium smelting pot to a collection duct, which is common to and shared by the branch ducts. Each of said branch ducts is, near an outlet thereof, equipped with a curved section for aligning the branch flow with a flow direction of raw gas already present in the common collection duct, and a constriction for accelerating the branch flow through the branch duct outlet into the common collection duct. Furthermore, each of said branch ducts is equipped with a heat exchanger for removing heat from the respective branch flow of raw gas. The combined flow resistance of the constriction and the heat exchanger reduces the need for adjusting the respective branch flows using dampers, thereby reducing the power required to transport the raw gas.

A raw gas collection system for collecting raw gas from a plurality of aluminium smelting pots is equipped with a plurality of branch ducts, each of which is arranged to channel a respective branch flow of raw gas from an aluminium smelting pot to a collection duct, which is common to and shared by the branch ducts. Each of said branch ducts is, near an outlet thereof, equipped with a curved section for aligning the branch flow with a flow direction of raw gas already present in the common collection duct, and a constriction for accelerating the branch flow through the branch duct outlet into the common collection duct. Furthermore, each of said branch ducts is equipped with a heat exchanger for removing heat from the respective branch flow of raw gas. The combined flow resistance of the constriction and the heat exchanger reduces the need for adjusting the respective branch flows using dampers, thereby reducing the power required to transport the raw gas.

An integrated process contains the following steps of: (i) pyrolysis of hydrocarbons to carbon and hydrogen, (iia) removal of at least a part of the produced carbon in step (i) and at least partly further processing of said carbon into a carbon containing electrode, and (iib) removal of the hydrogen produced in step (i) and at least partly using said hydrogen for providing energy, preferably electric energy or heat, for the electrode production in step (iia). A joint plant is also useful, which contains (a) at least one reactor for a pyrolysis process, (b) at least one reactor for the production of electrodes for an aluminum process, (c) a power plant and/or at least one gas-fired burner, and optionally, (d) at least one reactor for the electrolysis for producing aluminum.

An integrated process contains the following steps of: (i) pyrolysis of hydrocarbons to carbon and hydrogen, (iia) removal of at least a part of the produced carbon in step (i) and at least partly further processing of said carbon into a carbon containing electrode, and (iib) removal of the hydrogen produced in step (i) and at least partly using said hydrogen for providing energy, preferably electric energy or heat, for the electrode production in step (iia). A joint plant is also useful, which contains (a) at least one reactor for a pyrolysis process, (b) at least one reactor for the production of electrodes for an aluminum process, (c) a power plant and/or at least one gas-fired burner, and optionally, (d) at least one reactor for the electrolysis for producing aluminum.

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.

There is provided a method of electrochemically reducing multiple metal oxide pellets simultaneously, the method comprising: contacting an anode and a cathode with multiple metal oxide pellets with an electrolyte, wherein the multiple metal oxide pellets are secured to the cathode; and applying an electrical potential between the anode and the cathode to reduce multiple metal oxides comprised in the multiple metal oxide pellets to its respective metals. There is also provided an electrochemical cell for electrochemically reducing multiple metal oxide pellets simultaneously.

Disclosed herein are methods for producing an aluminum-scandium alloy comprising 0.41-4 wt % of scandium which can be used in industrial production setting. The method is carried out by melting aluminum and a mixture of salts comprising sodium, potassium and aluminum fluorides followed by performing simultaneously, while continuously supplying scandium oxide, an aluminothermic reduction of scandium from its oxide and an electrolytic decomposition of the formed alumina. Periodically, at least a portion of the produced alloy is removed, aluminum is then charged, and the process of alloy production is continued while supplying scandium oxide. Also disclosed is a reactor for producing an aluminum-scandium alloy pursuant to the methods described herein.

Disclosed herein are methods for producing an aluminum-scandium alloy comprising 0.41-4 wt % of scandium which can be used in industrial production setting. The method is carried out by melting aluminum and a mixture of salts comprising sodium, potassium and aluminum fluorides followed by performing simultaneously, while continuously supplying scandium oxide, an aluminothermic reduction of scandium from its oxide and an electrolytic decomposition of the formed alumina. Periodically, at least a portion of the produced alloy is removed, aluminum is then charged, and the process of alloy production is continued while supplying scandium oxide. Also disclosed is a reactor for producing an aluminum-scandium alloy pursuant to the methods described herein.

In some embodiments, an electrolytic cell includes: an one anode module having a plurality of anodes; a one cathode module, opposing the anode module, and comprising a plurality of vertical cathodes, wherein each of the plurality of anodes and each of the plurality of vertical cathodes are vertically oriented and spaced one from another; a cell reservoir; and a cell bottom supporting the cathode module, wherein the cell bottom comprise an first upper surface, a second upper surface, and a channel, wherein the plurality of vertical cathodes extends upward from the upper surfaces, wherein at least one cathode block is located below the plurality of vertical cathodes, wherein the first upper surface and the second upper surface are configured to direct substantially all of the liquid aluminum produced in the electrolytic cell to the channel, and wherein the channel is configured to receive liquid aluminum from the upper surfaces.