ADVANCED ALUMINUM ELECTROLYSIS CELL

Abstract

The application is directed to products and methods related to an aluminum electrolysis cell with a non-carbonaceous substrate with a directing feature. The directing feature can be configured to direct a wettable material in a predetermined direction. The non-carbonaceous substrate can be at least partially covered with solid aluminum metal. The wettable material can be aluminum metal.

Claims

1. An aluminum electrolysis cell, comprising: a cell reservoir; at least one anode within the cell reservoir; at least one cathode within the cell reservoir, wherein the at least one cathode is at least partially below a bottom portion of the at least one anode; and a non-carbonaceous substrate, wherein the non-carbonaceous substrate comprises a directing feature; wherein the directing feature is configured to direct a wettable material in a predetermined direction, the wettable material comprising molten aluminum; and wherein at least a portion of the wettable material is located in and/or on the directing feature.

2. The aluminum electrolysis cell of claim 1, wherein a surface of the non-carbonaceous substrate is at least partially covered in solid aluminum metal.

3. The aluminum electrolysis cell of claim 1, wherein the directing feature comprises one or more slots, one or more grooves, pores, or combinations thereof.

4. The aluminum electrolysis cell of claim 1, wherein the directing feature comprises an oriented porous structure of inter-connected pores.

5. The aluminum electrolysis cell of claim 4, wherein the oriented porous structure comprises a porosity gradient.

6. The aluminum electrolysis cell of claim 1, wherein the non-carbonaceous substrate comprises a cermet or a ceramic.

7. The aluminum electrolysis cell of claim 1, wherein the non-carbonaceous substrate comprises or consists essentially of TiB.sub.2.

8. The aluminum electrolysis cell of claim 1, wherein the predetermined direction is a downwardly direction towards a molten metal pad of the aluminum electrolysis cell.

9. The aluminum electrolysis cell of claim 1, wherein the non-carbonaceous substrate is at least one of the at least one anode, at least one of the at least one a cathode; or both.

10. The aluminum electrolysis cell of claim 1, wherein the non-carbonaceous substrate comprises a surface area, wherein a first portion of the surface area comprises the at least one directing feature, and wherein a second portion of the surface area is absent of any directing feature, wherein the first portion of the surface area is at least partially covered by solid aluminum metal.

11. The aluminum electrolysis cell of claim 10, wherein the second portion of the surface area is at least partially covered by the solid aluminum metal.

12. The aluminum electrolysis cell of claim 1, wherein the non-carbonaceous substrate comprises a carbon-based material plated with TiB.sub.2.

13. The aluminum electrolysis cell of claim 1, wherein the non-carbonaceous substrate comprises a plated material that facilitates wetting.

14. The aluminum electrolysis cell of claim 1, wherein the directing feature comprises at least one channel defining a cross-section, and wherein the cross-section is substantially constant across a length of the at least one channel, or wherein the cross-section is variable across a length of the at least one channel.

15. A method using the aluminum electrolysis cell as claimed in claim 1, for restricting or preventing attack of the non-carbonaceous substrate via an electrolyte of the aluminum electrolysis cell, the method comprising: covering the non-carbonaceous substrate, at least partially, by the wettable material, when a temperature of the non-carbonaceous substrate is less than a melting point temperature of the solid aluminum metal in order to obtain a surface of the non-carbonaceous substrate that is at least partially covered in solid aluminum metal, and heating the non-carbonaceous substrate above a melting point temperature of the solid aluminum metal.

16. The method of claim 15, wherein the restricting or preventing comprises covering at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% of the surface area of the non-carbonaceous substrate by the wettable material.

17. The method of claim 15, further comprising: feeding an alumina feedstock into the aluminum electrolysis cell; passing current between the at least one anode and the at least one cathode through an electrolyte of the aluminum electrolysis cell, wherein the at least one anode and/or the at least one cathode is the non-carbonaceous substrate comprising the directing feature; and directing the wettable material via the directing feature in a predetermined direction.

18. The method of claim 17, further comprising: electrolytically reducing the alumina feedstock into a metal product.

19. The method of claim 18, further comprising: draining the metal product from the at least one cathode to a bottom of a cell reservoir of the electrolysis cell to form a metal pad.

20. A process for the manufacturing of a directing feature as claimed in claim 4 comprising an oriented porous structure of inter-connected pores, the process comprising: immersing a polyurethane foam having a pore size in an aqueous slurry comprising TiB.sub.2 particles therein to obtain a TiB.sub.2 infiltrated foam; compressing the TiB.sub.2 infiltrated foams, for instance between a set of parallel rollers with a defined gap thickness, to expel unwanted slurry; drying the compressed TiB.sub.2 foams; and sintering the dried compressed TiB.sub.2 foams by heating. preferably at a temperature of about 1850 C.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0067] FIG. 1A illustrates one embodiment of a method for directing a TiB.sub.2 wettable material in a predetermined direction using a directing feature.

[0068] FIG. 1B illustrates another embodiment of a method for directing a TiB.sub.2 wettable material in a predetermined direction using a directing feature.

[0069] FIG. 2A is a perspective view of an embodiment of a product with a TiB.sub.2 substrate having a plurality of slots as directing features.

[0070] FIG. 2B is a first side view of the embodiment shown in FIG. 2A.

[0071] FIG. 2C is an enlarged partial section view of the embodiment shown in FIG. 2A indicated by the circle of dashed lines in FIG. 2A.

[0072] FIG. 3A is a front view of an embodiment of a product with a TiB.sub.2 substrate having a slot as a directing feature.

[0073] FIG. 3B is a section view of a cross-section taken along the dashed line 3B shown in FIG. 3A.

[0074] FIG. 3C is a first side view of the embodiment shown in FIG. 3A.

[0075] FIG. 4A is a front view of an embodiment of a product with a TiB.sub.2 substrate having a plurality of grooves as directing features.

[0076] FIG. 4B is a first side view of the embodiment shown in FIG. 4A.

[0077] FIG. 4C is an enlarged partial section view of the embodiment shown in FIG. 4A indicated by the circle of dashed lines in FIG. 4A.

[0078] FIG. 4D is an alternative configuration of the plurality of grooves of the embodiment shown in FIG. 4C.

[0079] FIG. 5A is a side view of another embodiment of a product with a TiB.sub.2 substrate having a plurality of pores as directing features.

[0080] FIG. 5B is a close-up view of a portion of the embodiment shown in FIG. 5A indicated by dashed lines in FIG. 5A.

[0081] FIG. 6A is a perspective view of an embodiment of a product with a TiB.sub.2 substrate having a plurality of slots as directing features and a solid aluminum metal covering the TiB.sub.2 substrate.

[0082] FIG. 6B is a first side view of a cross-section taken along the arrows 6B shown in FIG. 6A.

[0083] FIG. 6C is an enlarged partial section view of the embodiment shown in FIG. 6A indicated by the circle of dashed lines in FIG. 6A.

[0084] FIG. 6D is a cross-sectional side view of an embodiment of a product with a TiB.sub.2 substrate having a plurality of slots as directing features and a solid aluminum metal covering an upper portion of the TiB.sub.2 substrate.

[0085] FIG. 6E is a partial cross-section taken along the dashed line 6E as shown in FIG. 6D where only one of the slots of the plurality of slots is shown. The cross-section is along the upper portion of the TiB.sub.2 substrate where there is solid aluminum metal.

[0086] FIG. 6F is a partial cross-section taken along the dashed line 6F as shown in FIG. 6D where only one of the slots of the plurality of slots is shown. The cross-section is along the lower portion of the TiB.sub.2 substrate where there is no solid aluminum metal.

[0087] FIG. 6G is a cross-sectional side view of an embodiment of a TiB.sub.2 substrate having a plurality of slots as directing features and a solid aluminum metal covering half of the TiB.sub.2 substrate, the front portion.

[0088] FIG. 6H is a partial cross-section taken along the dashed line 6H as shown in FIG. 6G where only one of the slots of the plurality of slots is shown.

[0089] FIG. 6I is a side view of an embodiment of a TiB.sub.2 substrate having a plurality of slots as directing features and a solid aluminum metal in the plurality of slots.

[0090] FIG. 6J is a partial cross-section taken along the dashed line 6J as shown in FIG. 6I where only one of the slots of the plurality of slots is shown.

[0091] FIG. 6K is a front view of an embodiment of a TiB.sub.2 substrate having a plurality of slots as directing features and a solid aluminum metal covering some or none of the slots.

[0092] FIG. 6L is a first side view of the embodiment shown in FIG. 6K.

[0093] FIG. 6M is a front view of an embodiment of a TiB.sub.2 substrate with a surface area having a first portion of the surface area with a plurality of slots as directing features and a second portion of the surface area being absent of any directing feature.

[0094] FIG. 6N is a first side view of the embodiment shown in FIG. 6M with the second portion of the surface area being absent of any directing feature.

[0095] FIG. 7A is a front view of an embodiment of a product with a TiB.sub.2 substrate having a slot as a directing feature and a solid aluminum metal covering the TiB.sub.2 substrate.

[0096] FIG. 7B is a cross-section taken along the dashed line 7B shown in FIG. 7A.

[0097] FIG. 7C is a first side view of a cross-section taken along the line 7C shown in FIG. 7A.

[0098] FIG. 7D is a front view of an embodiment of a product of a TiB.sub.2 substrate having a slot as a directing feature and a solid aluminum metal covering a portion of the slot.

[0099] FIG. 7E is a cross-section taken along the dashed line 7E shown in FIG. 7D.

[0100] FIG. 7F is a first side view of the embodiment shown in FIG. 7F.

[0101] FIG. 8A is a front view of an embodiment of a product with a TiB.sub.2 substrate having a plurality of grooves as directing features and a solid aluminum metal covering the TiB.sub.2 substrate.

[0102] FIG. 8B is a first side view a cross-section taken along line 8B shown in of FIG. 8A.

[0103] FIG. 8C is an enlarged partial section view of the embodiment shown in FIG. 8A indicated by the circle of dashed lines in FIG. 8A.

[0104] FIG. 8D is a rear view of an embodiment of a product of a TiB.sub.2 substrate having a plurality of grooves as directing features and a solid aluminum metal covering the front half of the TiB.sub.2 substrate.

[0105] FIG. 8E is a first side view of a cross-section taken along line 8B shown in FIG. 8D.

[0106] FIG. 8F is an enlarged partial section view of the embodiment shown in FIG. 8D indicated by the circle of dashed lines in FIG. 8F.

[0107] FIG. 9 is a close-up view of a portion of an embodiment with pores and solid aluminum metal, in accordance with some embodiments.

[0108] FIG. 10 is a frontal view of a TiB.sub.2 foam sintered end product that was used in lab-scale testing.

[0109] FIG. 11 is a frontal view of four TiB.sub.2 foam samples that were used in lab-scale testing, the samples having porosities of about 10, 20, 30, and 45 pores per inch (PPI).

[0110] FIG. 12 is a schematic cut-away side view of three crucibles that were used in lab-scale testing, each including four TiB.sub.2 foam samples submerged (partially or completely) in molten aluminum for 48 hours.

[0111] FIG. 13A is a frontal view of a TiB.sub.2 foam sample from a crucible that was used in lab-scale testing after it was fully submerged for about 48 hours in molten aluminum.

[0112] FIG. 13B is a frontal view of a TiB.sub.2 foam sample from a crucible that was used in lab-scale testing after it was partially submerged for about 48 hours in molten aluminum.

[0113] FIG. 14A illustrates one embodiment of a method for producing aluminum from an alumina feedstock in an aluminum electrolysis cell.

[0114] FIG. 14B illustrates one embodiment of a method for producing aluminum from an alumina feedstock in an aluminum electrolysis cell.

[0115] FIG. 15 is a partial schematic cross-sectional view of an electrolysis cell in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0116] This document includes several sections. Section i describes the electrolysis cells. Section ii describes substrates having directing features. Section iii describes the start-up of the aluminum electrolysis cell. Section iv describes the use of the substrates having directing features of Section ii in the electrolysis cells of Section i. Definitions are also included below.

[0117] The present disclosure will be further explained with reference to the attached drawings, wherein like structures are referred to by like numerals throughout the several views. The figures constitute a part of this specification and include illustrative embodiments of the present disclosure and illustrate various objects and features thereof. Further, the figures are not necessarily to scale, some features may be exaggerated to show details of particular components.

[0118] In addition, any measurements, specifications and the like shown in the figures are intended to be illustrative, and not restrictive. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present disclosure.

[0119] Among those benefits and improvements that have been disclosed, other objects and advantages of the present disclosure will become apparent from the following description taken in conjunction with the accompanying figures. Detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative of the present disclosure that may be embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the invention which are intended to be illustrative, and not restrictive.

[0120] Throughout the specification and claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrases in one embodiment and in some embodiments as used herein do not necessarily refer to the same embodiment(s), though it may. Furthermore, the phrases in another embodiment and in some other embodiments as used herein do not necessarily refer to a different embodiment, although it may. Thus, as described below, various embodiments of the invention may be readily combined, without departing from the scope or spirit of the invention.

Definitions

[0121] In addition, as used herein, the term or is an inclusive or operator, and is equivalent to the term and/or, unless the context clearly dictates otherwise. The term based on is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of a, an, and the include plural references. The meaning of in includes in and on.

[0122] As used herein, electrolysis means any process that brings about a chemical reaction by passing electric current through a material. In some embodiments, electrolysis occurs where a species of metal is reduced in an electrolysis cell to produce a metal product. Some non-limiting examples of electrolysis include primary metal production. Some non-limiting examples of primary metals include: aluminum, nickel, etc.

[0123] As used herein, electrolysis cell means a device for producing electrolysis. In some embodiments, the electrolysis cell includes a smelting pot, or a line of smelters (e.g., multiple pots). In one non-limiting example, the electrolysis cell is fitted with electrodes, which act as a conductor, through which a current enters or leaves a nonmetallic medium (e.g., electrolyte bath).

[0124] As used herein, electrode means a positively charged electrode (e.g., anode) or a negatively charged electrode (e.g., cathode).

[0125] As used herein, alumina feedstock includes alumina (Al.sub.2O.sub.3). In some embodiments, the alumina feedstock is smelting grade aluminum (SGA), or similar. In some embodiments, SGA includes at least 95 weight % aluminum oxide (i.e., alumina).

[0126] As used herein, molten means in a liquid form (e.g., liquid) through the application of heat. As a non-limiting example, the electrolyte bath is in molten form (e.g., at least about 750 C.). As another non-limiting example, the electrolyte bath is in molten form (e.g., not greater than about 1000 C.). As another example, the metal product (e.g., aluminum) that forms at the bottom of the cell (e.g., sometimes called a metal pad or a molten metal pad) is in molten form.

[0127] As used herein, metal product means the product which is produced by electrolysis. In one embodiment, the metal product forms at the bottom of an electrolysis cell as a molten metal pad (e.g., molten aluminum pad). Some non-limiting examples of metal products include: rare earth metals and non-ferrous metals (e.g. aluminum, nickel, magnesium, copper, and zinc). In some embodiments, the molten metal pad includes at least one alloy including one or more of Al, Si, Cu, Fe, Sb, Gd, Cd, Sn, Pb and impurities. In some embodiments, the metal product is an aluminum metal product. In some embodiments, the molten metal pad is an aluminum metal pad. In some embodiments, the aluminum metal product includes a high aluminum metal content having at least 99 weight % aluminum. In some embodiments, the aluminum metal product is selected from the group consisting of P1020, P0610, P0406, P0404, and P0302. In some embodiments, the metal product is drained from the cathodes to the bottom of the cell reservoir to form the metal pad.

[0128] As used herein, molten metal pad means a reservoir of molten material located below an electrolyte, and the molten material includes aluminum.

[0129] As used herein, aluminum-wettable means having a contact angle with molten aluminum of not greater than 90 degrees.

[0130] As used herein, wettable material means having a contact angle with a non-carbonaceous material of not greater than 90 degrees. In some embodiments, the wettable material is molten metal. In some embodiments, the wettable material includes metal. In some embodiments, the metal includes aluminum.

[0131] As used herein, electrolyte means a medium in which the flow of electrical current is carried out by the movement of ions/ionic species. In one embodiment, an electrolyte may include molten salt. As used herein, electrolyte bath refers to a liquefied bath of electrolyte (e.g., molten electrolyte) having at least one species of metal to be reduced (e.g., via an electrolysis process). In some embodiments, the electrolyte includes at least one of fluorides and/or chlorides. In some embodiments, the electrolyte contains at least one of fluorides and/or chlorides of Na, K, Al, Ba, Ca, Ce, La, Cs, Rb, or combinations thereof, among others. A non-limiting example of the electrolyte bath composition includes: NaF, AlF.sub.3, CaF.sub.2, MgF.sub.2, LiF, KF, and combinations thereofwith dissolved alumina.

[0132] As used herein, cryolite is Na.sub.3AlF.sub.6.

[0133] As used herein, producing (e.g., making) means: in some embodiments, one or more methods of the present disclosure include the step of producing a metal product (e.g., an aluminum metal product such as aluminum metal) from the electrolyte (e.g., a molten electrolyte bath). In one embodiment, the producing step includes producing aluminum metal from an alumina feedstock.

[0134] As used herein, anode-cathode overlap (ACO) means the vertical distance from the distal end of an anode (e.g., elongate vertical anode) to the distal end of a respective cathode (e.g., elongate vertical cathode).

[0135] As used herein, anode-to-cathode distance (ACD) means the horizontal distance separating an anode (e.g., elongate vertical anode) from a respective cathode (e.g., elongate vertical cathode).

i. Aluminum Electrolysis Cells Having Substrates Using Directing Features

[0136] The present disclosure relates to aluminum electrolysis cells having substrates that comprise one or more directing features. Such substrates are explained in detailed Section ii below and are further described in commonly owned U.S. Provisional Patent Application No. 63/276,892 which is incorporated by reference herein in its entirety. The aluminum electrolysis cells disclosed herein may include any of the substrates described in Section ii and in any combination. In some embodiments, the substrate is not an electrode. In some embodiments, the substrate is an electrode. For instance, a first electrode may comprise a substrate with at least one groove while a second electrode may comprise a substrate with one slot or porosity. As another example, a first electrode may comprise a substrate with no directing feature and a second electrode with a groove. As another example, a first electrode may comprise a substrate with a groove or porosity and a second electrode may comprise a substrate with no directing feature. As another example, a first electrode may comprise a substrate with a porosity and a second electrode may comprise a substrate with a porosity. Any of the substrates can be used in any combination with any carbonaceous electrode or non-carbonaceous electrode.

[0137] FIG. 14A illustrates one embodiment of a method for producing aluminum from an alumina feedstock in an aluminum electrolysis cell. In some embodiments, the method for producing aluminum in an aluminum electrolysis cell includes using an at least one electrode, such an anode or cathode. In some embodiments, the method includes feeding alumina feedstock to an aluminum electrolysis cell (the feeding step 10100), passing electrical current between anode(s) and cathode(s) (the passing electrical current step 10420), and directing wettable material (e.g., aluminum metal) via directing feature(s) of the electrode(s) (the directing step 10200). FIG. 14B illustrates one embodiment of a method for producing aluminum from an alumina feedstock in an aluminum electrolysis cell. FIG. 14B displays the method of FIG. 14A and includes an additional step: producing aluminum metal product (the producing step 10300) and/or collecting aluminum metal product 10500 (the collecting step 10500). In some embodiments, the method includes producing ions in the electrolyte.

[0138] FIG. 15 shows a schematic cross-section of an aluminum electrolysis cell 5000 for producing aluminum metal by the electrochemical reduction of alumina using electrodes (anodes 5104 and/or cathodes 5108). The aluminum electrolysis cell 5000 is an exemplary embodiment of an electrolysis cell for the apparatus, system, and methods described herein. In some embodiments, the anode 5104 is an inert anode. Some non-limiting examples of inert anode compositions include ceramic, metallic, cermet, and/or combinations thereof. Some non-limiting examples of inert anode compositions are provided in U.S. Pat. Nos. 4,374,050, 4,374,761, 4,399,008, 4,455,211, 4,582,585, 4,584,172, 4,620,905, 5,279,715, 5,794,112 and 5,865,980, assigned to the assignee of the present application. In some embodiments, the anode 5104 is an oxygen-evolving electrode. An oxygen-evolving electrode is an electrode that produces oxygen during electrolysis.

[0139] In some embodiments, the cathode 5108 is a wettable cathode. In some embodiments, aluminum wettable materials are materials having a contact angle with molten aluminum of not greater than 90 degrees in the molten electrolyte. Some non-limiting examples of aluminum wettable materials may comprise one or more of TiB.sub.2, ZrB.sub.2, HfB.sub.2, SrB.sub.2, carbonaceous materials, and combinations thereof.

[0140] In some embodiments, the electrodes (i.e., anodes 5104 and/or cathodes 5108) can be configured from an aluminum-wettable material. In some embodiments, the electrodes include one or more of TiB.sub.2, ZrB.sub.2, HfB.sub.2, SrB.sub.2, carbonaceous material (e.g., graphite), tungsten (W), Molybdenum (Mo), steel, or combinations thereof. In some embodiments, the electrodes are made from a non-carbonaceous material. In some embodiments, the electrodes are made from a cermet or a ceramic. In some embodiments, the electrodes are ceramic. In some embodiments, the electrodes are made from titanium. In some embodiments, the electrodes include TiB.sub.2. In some embodiments, the electrodes consist essentially of TiB.sub.2. In some embodiments, the electrodes are made of multiple layers.

[0141] The aluminum electrolysis cell 5000 has at least one anode module 5102. In some embodiments, the anode module 5102 has at least one anode 5104. The aluminum electrolysis cell 5000 further comprises at least one cathode module 5106. In some embodiments, the cathode module 5106 has at least one cathode 5108. In some embodiments, the at least one anode module 5102 is suspended above the at least one cathode module 5106. The cathode 5108 is positioned in the cell reservoir 5110. The cathodes 5108 extend upwards towards the anode module 5102. While anodes 5104 and cathodes 5108 of a specific number are shown in the various embodiments of the present disclosure, any number of anodes 5104 and cathodes 5108 greater than or equal to 1 may be used to define an anode module 5102 or a cathode module 5106, respectively. The cell reservoir 5110 typically has a steel shell 5118 and is lined with insulating material 5120, refractory material 5122 and sidewall material 5124. The cell reservoir 5110 is capable of retaining a bath of molten electrolyte (shown diagrammatically by dashed line 5126) and a molten metal pad (e.g., a molten aluminum metal pad) therein. In some embodiments, the density of the electrolyte should be less than molten aluminum, so that the molten aluminum separates from the electrolyte and settles properly to the bottom of the electrolysis cell, thereby forming the molten metal pad. Portions of an anode bus 5128 that supplies electrical current to the anode modules 5102 are shown pressed into electrical contact with anode rods 5130 of the anode modules 5102. The anode rods 5130 are structurally and electrically connected to an anode distribution plate 5132, to which a thermal insulation layer 5134 is attached. The anodes 5104 extend through the thermal insulation layer 5134 and mechanically and electrically contact the anode distribution plate 5132. The anode bus 5128 can conduct direct electrical current from a suitable power source 5136 through the anode rods 5130, the anode distribution plate 5132, anode elements, and a bath of molten electrolyte (shown diagrammatically by dashed line 5126) to the cathodes 5108 and from there through the cathode support 5112, cathode blocks 5114 and cathode current collector bars 5116 to the other pole of the power source 5136 of electricity. The anodes 5104 of each anode module 5102 are in electrical continuity. Similarly, the cathodes 5108 of each cathode module 5106 are in electrical continuity. The anode modules 5102 may be raised and lowered by a positioning apparatus to adjust their position relative to the cathode modules 5106 to adjust the anode-cathode overlap (ACO).

[0142] In some embodiments, the cathodes 5108 are supported in a cathode support 5112. In some embodiments, the cathode support 5112 is retained on a bottom of the cell reservoir 5110. In some embodiments, the cathode supports 5112 are fixedly coupled to the bottom of the aluminum electrolysis cell 5000. In some embodiments, the cathode support 5112 contacts at least one of a molten metal pad or a bath of molten electrolyte (shown diagrammatically by dashed line 5126) within the cell reservoir 5110. In some embodiments, the cathode support 5112 rests on cathode blocks 5114, e.g., made from carbonaceous material in electrical continuity with one or more cathode current collector bars 5116. In some embodiments, the cathode blocks 5114 are fixedly coupled to the bottom of the aluminum electrolysis cell 5000. In some embodiments, the cathode support 5112 is integrally formed with the cathode blocks 5114, wherein the cathode block 5114 is part of the cathode support 5112. In some embodiments, the cathode support 5112 is coupled to the cathode blocks 5114.

[0143] In some embodiments, the cathode support 5112 comprises a body having a support bottom. In some embodiments, the support bottom is configured to be in communication with the bottom of the aluminum electrolysis cell 5000. The body of the cathode support 5112 further comprises a support top, opposite the support bottom, having a cathode attachment area configured to retain a plurality of cathodes 5108 therein, each shown as a plate in FIG. 15.

[0144] In some embodiments, the anode 5104 overlaps the cathode 5108 thereby defining an anode-cathode overlap (ACO). The distal end of the anode 5104 and a distal end of the cathode 5108 partially overlap. In some embodiments, the distal end of the cathode 5108 is proximal a middle portion of the anode 5104, and a distal end of the anode 5104 is proximal a middle portion of the cathode 5108. In some embodiments, the anode-cathode overlap (ACO) is 0 to 50 inches. In some embodiments, the anode-cathode overlap is 1 to 50 inches. In some embodiments, the anode-cathode overlap is 5 to 50 inches. In some embodiments, the anode-cathode overlap is 10 to 50 inches. In some embodiments, the anode-cathode overlap is 20 to 50 inches. In some embodiments, the anode-cathode overlap is 25 to 50 inches. In some embodiments, the anode-cathode overlap is at least some overlap up to 12 inches of overlap. In some embodiments, the anode-cathode overlap is at least 2 inches of overlap to 10 inches of overlap. In some embodiments, the anode-cathode overlap is at least 3 inches of overlap to 8 inches of overlap. In some embodiments, the anode-cathode overlap is at least 3 inches of overlap to 6 inches of overlap.

[0145] The lateral spacing distance between the anode 5104 and the cathode 5108 can be specified as anode-to-cathode distance (ACD). In some embodiments, the anode-to-cathode distance is substantially perpendicular to the anode-cathode overlap. That is, the anode-to-cathode distance can extend substantially horizontally in the aluminum electrolysis cell 5000, and the anode-cathode overlap distance can extend substantially vertically in the aluminum electrolysis cell 5000. In some embodiments, the anode-to-cathode distance may be inch to 3 inches. In some embodiments, the anode-to-cathode distance may be inch to 2 inches. In some embodiments, the anode-to-cathode distance may be inch to 1 inch. In some embodiments, the anode-to-cathode distance may be inch to inch. In some embodiments, the anode-to-cathode distance may be inch to inch. In some embodiments, the anode-to-cathode distance may be inch to inch. In some embodiments, the anode-to-cathode distance may be inch to 1 inch. In some embodiments, the anode-to-cathode distance may be 1 inch to inch.

[0146] In some embodiments, the cell reservoir 5110 contains the electrolyte and a molten metal pad. The molten metal pad is in contact with the cathode support 5112. The anode 5104 extends downward and terminates in the molten electrolyte (the upper surface of which is shown diagrammatically by dashed line 5126). The cathode 5108 extends upward from the cathode support 5112 and terminates in the molten electrolyte such that the cathode 5108 overlaps the anode 5104 within the molten electrolyte. Thus, the cathode 5108 is separated from the anode 5104 by electrolyte.

[0147] In the illustrated embodiment, the metal product has a density greater than the electrolyte of the aluminum electrolysis cell 5000. The electrolyte has a density less than the molten metal pad of the aluminum electrolysis cell 5000. In this regard, the composition of the electrolyte may be selected such that the electrolyte has a lower density than the molten metal pad and lower density than the metal product including the produced aluminum.

[0148] In some embodiments, the electrolyte includes molten salt. In some embodiments, the electrolyte includes at least one of fluorides and/or chlorides. In some embodiments, the electrolyte contains at least one of fluorides and/or chlorides of Na, K, Al, Ba, Ca, Ce, La, Cs, Rb, or combinations thereof, among others.

[0149] In some embodiments, the molten metal pad is an aluminum metal pad with a purity of PI 020. In some embodiments, the molten metal pad includes at least one alloy including one or more of Al, Si, Cu, Fe, Sb, Gd, Cd, Sn, Pb and impurities.

[0150] The aluminum electrolysis cell 5000 includes the molten metal pad and the electrolyte. In some embodiments, the feeding step 10100 of the alumina feedstock includes flowing the alumina feedstock into the electrolyte.

[0151] In some embodiments, the feeding step 10100 includes feeding the alumina feedstock continuously during operation of the aluminum electrolysis cell 5000. In some embodiments, the feeding step 10100 includes periodically adding the alumina feedstock into the aluminum electrolysis cell 5000. In some embodiments, the feeding step 10100 includes metering alumina feedstock into the aluminum electrolysis cell 5000 at a first feed rate. The first feed rate may remain constant or may vary, including stopping and starting of the feeding of the alumina feedstock to the aluminum electrolysis cell 5000. In some embodiments, the feeding step 10100 includes adding the alumina feedstock periodically to the aluminum electrolysis cell 5000.

[0152] As noted above, the feeding step 10100 of the alumina feedstock may be through an aluminum electrolysis cell 5000. In some embodiments, the alumina feedstock is smelting grade aluminum (SGA), or similar. In some embodiments, the alumina feedstock includes alumina.

[0153] In some embodiments, the directing step 10200 includes moving aluminum along the electrode toward the molten metal pad. In some embodiments, before the directing step 10200, the method can include producing aluminum ions in the electrolyte and reducing at least some of the aluminum ions at or near at least one cathode 5108 of the aluminum electrolysis cell 5000, thereby producing 10300 aluminum metal product. For example, the method can include electrolytically reducing the alumina feedstock into a metal product.

[0154] The method of the present disclosure includes producing aluminum metal product from the alumina feedstock by passing electrical current into the anode 5104 through the electrolyte and into the cathode 5108. In some embodiments, the passing electrical current step 10420 includes passing direct current from the anode 5104 to the cathode 5108 through electrolyte. In some embodiments, the anode 5104 and/or the cathode 5108 can be partially disposed in the electrolyte and the cathode 5108 can be partially disposed in the molten metal pad. In some embodiments, the method of the present disclosure includes directing aluminum metal ions towards the cathode 5108 and supplying an electric current to the anode 5104.

[0155] In some embodiments, the method may include removing at least some of the aluminum metal product from the aluminum electrolysis cell 5000 (e.g., via the collecting step 10500). In some embodiments, the aluminum metal product is removed via a port (e.g., by vacuum). In some embodiments, the aluminum metal product may be removed essentially continuously during operation of the aluminum electrolysis cell 5000. In some embodiments, the first removal rate may be controlled, for example, based at least in part on the second removal rate. In some embodiments, the aluminum metal product may be removed periodically during operation of the aluminum electrolysis cell 5000. In some embodiments, the removing step is completed with equipment configured to remove aluminum metal product without contaminating the product (e.g., alumina, graphite, and/or TiB.sub.2 tapping equipment).

ii. Substrates Having Directing Features

[0156] As explained above, the present disclosure relates to aluminum electrolysis cells having substrates that comprise one or more directing features. Such substrates are described below in this section.

[0157] The present disclosure includes methods and products involving a titanium diboride (TiB.sub.2) substrate or a structure directing a TiB.sub.2 wettable material in a predetermined direction using a directing feature. In some embodiments, the TiB.sub.2 substrate structure can be covered with a solid aluminum metal before contacting the TiB.sub.2 wettable material. When the TiB.sub.2 wettable material contacts the TiB.sub.2 substrate, the directing feature directs the TiB.sub.2 wettable material in a predetermined direction. The directing feature can take many shapes and sizes. In some embodiments, the directing feature can be slots, grooves, pores, or combinations thereof. The TiB.sub.2 substrate with the at least one directing feature can be used in a variety of applications including moving fluid in a product. In some embodiments, the TiB.sub.2 wettable material may be any suitable metal for transfer via the TiB.sub.2 substrates. In some embodiments, the TiB.sub.2 wettable material is aluminum, such as aluminum alloy, metallic aluminum, and combinations thereof.

[0158] In one aspect, the present disclosure includes a product with a TiB.sub.2 substrate that includes a directing feature, wherein the directing feature is configured to direct TiB.sub.2 wettable material in a predetermined direction. In some embodiments, the TiB.sub.2 wettable material includes aluminum. In some embodiments, the aluminum is selected from the group consisting of an aluminum alloy, metallic aluminum, and combinations thereof. In some embodiments, a surface of the TiB.sub.2 substrate is at least partially covered in solid aluminum metal. In some embodiments, the directing feature is selected from the group consisting of slots, grooves, pores, and combinations thereof on the structure, e.g., the TiB.sub.2 substrate. In some embodiments, the TiB.sub.2 substrate has a solid geometric form. In some embodiments, the solid geometric form has at least one three-dimensional form of rectangle-shaped, square-shaped, triangle-shaped, oval-shaped, or oblong-shaped, among others. In some embodiments, the TiB.sub.2 substrate has a non-symmetrical form. In some embodiments, the TiB.sub.2 substrate is in the form of a plate.

[0159] In some embodiments, the TiB.sub.2 substrate is configured for use in an aluminum purification cell. In some embodiments, the directing feature directs the TiB.sub.2 wettable material via capillary action. In some embodiments, the directing feature includes pores. In some embodiments, the directing feature includes a porosity of the TiB.sub.2 substrate. In some embodiments, the porosity ranges from about 1 to about 200 pores per inch (PPI). In some embodiments, the porosity is at least about 5 pores per inch (PPI), or at least about 10 pores per inch (PPI), or at least about 15 pores per inch (PPI), or at least about 20 pores per inch (PPI). In some embodiments, the porosity is not greater than about 175 pores per inch (PPI), or not greater than about 150 pores per inch (PPI), or not greater than about 125 pores per inch (PPI), or not greater than about 100 pores per inch (PPI), or not greater than about 80 pores per inch (PPI), or not greater than about 60 pores per inch (PPI), or not greater than about 50 pores per inch (PPI).

[0160] In some embodiments, the directing feature includes a structure having at least one groove. In some embodiments, the at least one groove extends partially into the TiB.sub.2 substrate. In some embodiments, the dimensions of the at least one groove are predetermined. In some embodiments, a size and/or a shape of the at least one groove are predetermined. In some embodiments, a width (w) of the at least one groove ranges from about 10 m to about 20 mm. In some embodiments, a groove depth (gd) of the at least one groove ranges from about 1 mm to about 10 mm. In some embodiments, a length (l) of the at least one groove ranges from about 1 cm to about 1 m. In some embodiments, a thickness (t) of the TiB.sub.2 substrate ranges from about 5 mm to about 30 mm. In some embodiments, the directing feature includes at least two grooves in the TiB.sub.2 substrate. In some embodiments, an edge-to-edge distance (d) between the at least two grooves ranges from about 1 mm to about 20 mm.

[0161] In another aspect, the present disclosure includes a product having (a) a TiB.sub.2 substrate including at least one directing feature and (b) solid aluminum metal at least partially covering surfaces of the TiB.sub.2 substrate. In some embodiments, the solid aluminum metal is at least partially contained within the at least one directing feature. In some embodiments, the TiB.sub.2 substrate includes a structure having a surface area, wherein a first portion of the surface area includes the at least one directing feature, and wherein a second portion of the surface area is absent of any directing feature. In some embodiments, the first portion of the surface area is at least partially covered by the solid aluminum metal. In some embodiments, the first portion of the surface area is at least 1% covered by the solid aluminum metal. In some embodiments, the second portion of the surface area is at least partially covered by the solid aluminum metal. In some embodiments, the second portion of the surface area is at least 1% covered by the solid aluminum metal. In some embodiments, the solid aluminum metal covering the second portion of the surface area is in the form of a film. In some embodiments, the film includes a thickness of from 1 m to 500 m. In some embodiments, the second portion of the surface area is absent of the solid aluminum metal.

[0162] In some embodiments, at least one directing feature includes a void volume, and wherein at least 1% of the void volume contains the solid aluminum metal. In some embodiments, the at least one directing feature is a structure having a slot, and wherein the solid aluminum metal is at least partially contained within the slot. In some embodiments, the at least one slot includes a slot volume, and wherein the solid aluminum metal occupies at least 1% of the slot volume. In some embodiments, the at least one directing feature is a groove, and wherein the solid aluminum metal is at least partially contained within the groove. In some embodiments, the at least one groove includes a groove volume, and wherein the solid aluminum metal occupies at least 1% of the groove volume.

[0163] In another aspect, the present disclosure includes a product with (a) a web of TiB.sub.2 and (b) solid aluminum metal at least partially covering surfaces of the web of TiB.sub.2. In some embodiments, the web of TiB.sub.2 defines a porosity of the web of TiB.sub.2. In some embodiments, the solid aluminum metal includes porosity. In some embodiments, the porosity of the web of TiB.sub.2 defines a porous volume of the TiB.sub.2, and wherein the solid aluminum metal occupies at least 1% of the porous volume.

[0164] In another aspect, the present disclosure includes a method including producing a TiB.sub.2 product with at least one directing feature and directing a TiB.sub.2 wettable material in a predetermined direction via the at least one directing feature. In some embodiments, the producing step includes creating the TiB.sub.2 product having a plurality of pores. In some embodiments, the producing step includes creating a geometric feature. In some embodiments, the producing step includes machining the TiB.sub.2 product or a TiB.sub.2 product precursor to create the at least one directing feature. In some embodiments, the producing step includes extruding a TiB.sub.2 feedstock into a TiB.sub.2 product precursor wherein the TiB.sub.2 product precursor includes the at least one directing feature therein. In some embodiments, the TiB.sub.2 product precursor is a green TiB.sub.2 material. In some embodiments, the method includes exposing the green TiB.sub.2 material to an elevated temperature, thereby creating the TiB.sub.2 substrate. In some embodiments, the at least one directing feature in the TiB.sub.2 substrate may include grooves, slots, channels, or combinations thereof.

[0165] In another aspect, the present disclosure includes an aluminum purification cell having any of the TiB.sub.2 substrates described herein. In some embodiments, at least one of the TiB.sub.2 substrates is an electrode. In some embodiments, at least one of the TiB.sub.2 substrates is a directing apparatus, wherein the directing apparatus is configured to direct liquid aluminum metal (e.g., molten aluminum metal) in a predetermined direction in an absence of an applied electrical current.

[0166] As used herein, slot means a geometric feature that extends through a thickness of a TiB.sub.2 substrate

[0167] As used herein, groove means a geometric feature that extends partially through, but not all the way through, through a thickness of a TiB.sub.2 substrate

[0168] As used herein, geometric feature means a predetermined shape created in a TiB.sub.2 substrate. Examples include slots and grooves of any shape or size.

[0169] As used herein, TiB.sub.2 wettable material means having a contact angle with TiB.sub.2 of not greater than 90 degrees.

[0170] As used herein, TiB.sub.2 substrate means a substrate made of TiB.sub.2 that is capable of including at least one directing feature. Examples of TiB.sub.2 substrates include blocks, plates, rod, wires, and wools, among others, made of TiB.sub.2. In one embodiment, a TiB.sub.2 substrate consists essentially of TiB.sub.2.

[0171] As used herein, aluminum covered TiB.sub.2 substrate means a TiB.sub.2 substrate at least partially covered by aluminum metal, wherein the aluminum metal is metallic aluminum and/or an aluminum alloy. In one embodiment, the aluminum metal is at least partially contained in at least one directing feature of a TiB.sub.2 substrate. In one embodiment, the aluminum metal at least partially covers outer surfaces of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 5% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 10% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 15% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 20% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 25% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 30% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 35% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 40% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 45% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 50% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 55% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 60% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 65% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 70% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 75% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 80% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 85% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 90% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 91% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 92% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 93% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 94% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 95% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 96% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 97% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 98% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 99% of the surface area of a TiB.sub.2 substrate. In one embodiment, the aluminum metal covers at least 100% of the surface area of a TiB.sub.2 substrate.

[0172] As used herein, plated material and the like means a film, coating, or other thin covering in contact with at least a portion of an outer surface of a substrate, and irrespective how the plated material was produced on the substrate, i.e., plating includes all manners of applying a film, coating, or thin covering to a substrate.

[0173] FIG. 1A illustrates one embodiment of a method 100 for directing a TiB.sub.2 wettable material in a predetermined direction using a directing feature. Step 102 is an optional step as indicated by the dashed lines of the box in FIG. 1A. The step 102 includes covering a TiB.sub.2 substrate with solid aluminum metal. Varying amount of the TiB.sub.2 substrate can be covered with solid aluminum metal. In some embodiments, all of the TiB.sub.2 substrate can be covered. Some portions of the TiB.sub.2 substrate can be covered with solid aluminum metal while other portions of the TiB.sub.2 substrate are absent solid aluminum. The solid aluminum metal coverage can vary depending on the application of the TiB.sub.2 substrate. Step 104 includes contacting the TiB.sub.2 substrate with a TiB.sub.2 wettable material. Step 106 includes directing the TiB.sub.2 wettable material in a desired direction.

[0174] FIG. 1B illustrates another embodiment of a method 110 for directing a TiB.sub.2 wettable material in a predetermined direction using a directing feature. The producing step 112 includes producing a TiB.sub.2 product with at least one directing feature. The producing step 112 can include creating a TiB.sub.2 product structure having a plurality of pores. The producing step 112 can include creating a geometric feature. The producing step 112 can include machining a TiB.sub.2 product or a TiB.sub.2 product precursor structure to create at least one directing feature. The directing feature found in or on the product or product precursor structure can be slots, grooves, pores, and combinations thereof. The directing features can include a void volume. In some embodiments, at least 1% of the void volume contains the solid aluminum metal. The directing feature can direct the TiB.sub.2 wettable material via capillary action.

[0175] The producing step 112 can include extruding a TiB.sub.2 feedstock into a TiB.sub.2 product precursor wherein the TiB.sub.2 product precursor includes at least one directing feature therein. In some embodiments, the TiB.sub.2 product precursor is a green TiB.sub.2 material. The producing step 112 can include exposing the green TiB.sub.2 material to an elevated temperature, thereby creating the TiB.sub.2 substrate. The directing step 114 includes directing a TiB.sub.2 wettable material in a predetermined direction via the at least one directing feature.

[0176] FIG. 2A is a perspective view of an embodiment of a product 200 with a TiB.sub.2 substrate 202 having a plurality of slots 206 as directing features. The slots 206 are defined between prongs 204. The TiB.sub.2 substrate 202 also includes a base 208 and a tip 210. The slots 206 are configured to direct TiB.sub.2 wettable material in a predetermined direction. The TiB.sub.2 wettable material can include aluminum, such as an aluminum alloy, metallic aluminum, and combinations thereof.

[0177] FIG. 2B is a first side view of the embodiment shown in FIG. 2A. FIG. 2B shows a side view of the substrate 200 showing the prongs 204. The prongs 204 include a length (l) that extends from the top of the base 208 to the end of the tip 210. The tip 210 can have any of a variety of geometries including a point, a rounded curvature, or a jagged edge, among others.

[0178] FIG. 2C is an enlarged partial section view of the embodiment shown in FIG. 2A indicated by the circle of dashed lines in FIG. 2A. The partial top view only shows two of the prongs 204. That is, FIG. 2C shows a first prong 204A and a second prong 204B defining a first slot 206A. The first slot 206A is defined by an inner surface of the first prong 204A and an inner surface of the second prong 204B.

[0179] FIG. 3A is a front view of an embodiment of a product 300 with a TiB.sub.2 substrate 302 having a slot 306 as a directing feature. The slot 306 is defined by a first prong 304A and a second prong 304B (collectively, prongs 304). The TiB.sub.2 substrate 302 also includes a base 308 and a tip 310. The slots 306 are configured to direct TiB.sub.2 wettable material in a predetermined direction. A width (w) of one of the prongs is also shown.

[0180] FIG. 3B is a section view of a cross-section taken along the dashed line 3B shown in FIG. 3A. FIG. 3B shows a thickness (t) of the prongs 304 and a distance (d) the slot 306 extends between the inner surface of the first prong 304A and the inner surface of the second prong 304B. FIG. 3C is a first side view of the embodiment (e.g., the product 300) shown in FIG. 3A. FIG. 3C displays a length (l) of the prongs 304.

[0181] FIGS. 2A-2C and FIGS. 3A-3C will be described together, as they are similar. The embodiment of FIGS. 2A-2C differs from the embodiment of FIGS. 3A-3C in the number of prongs 204/304, the number of slots 206/306, and thickness (t) of the prongs 204/304.

[0182] The dimensions of the slots 206/306 are predetermined. In some embodiments, the slot 206A/306 extends an entire length (l) of the first prong 206A/306A and an entire length (l) of the second prong 206B/306B. The entire length (l) of the first prong 206A/306A and the entire length (l) of the second prong 204B/304B can range from about 0.01 meters to about 1 meter. A thickness (t) of the first prong 204A/304A and a thickness (t) of the second prong 204B/304B can range from about 1 mm to about 20 mm. The slot 206A/306 extends a distance (d) between the inner surface of the first prong 204A/304A and the inner surface of the second prong 204B/304B. In some embodiments, the distance (d) ranges from about 20 m to about 20 mm. A width (w) of the prongs 204/304 (e.g., first prong 204A/304A and the second prong 204B/304B) can range from about 1 mm to about 20 mm.

[0183] The prongs 204/304 can vary in dimension from one another. The prongs 204/304 can vary in length (l), thickness (t), and width (w) from one another. Similarly, the distance (d) of the slot 206/306 can vary from one another. In some embodiments, in comparison to the second prong 204B/304B, the first prong 204A/304A can have a larger length (l) and width (w) and a smaller thickness (t).

[0184] The slots 206/306 extend through a thickness of the TiB.sub.2 substrate 202/302. The number of slots can vary. In some embodiments, there can be one slot as shown in the examples of FIG. 3A, FIG. 3B, and FIG. 3C. There can also be two or more slots. The number of slots can vary depend on the intended application of the TiB.sub.2 substrate 202/302. In the example shown in FIG. 2A, FIG. 2B, and FIG. 2C, there are six slots

[0185] The TiB.sub.2 substrate 202/302 can be at least partially covered in solid aluminum metal. The slots 206/306 are the directing feature for the TiB.sub.2 substrate 202/302. Other directing features, such as grooves, pores, and combinations thereof, can be included with the TiB.sub.2 substrate 202.

[0186] The TiB.sub.2 substrate 202/302 can have any suitable structure, size, or shape depending on application. The TiB.sub.2 substrate 202/302 can have a solid geometric form. The geometric form surface can include at least one of rectangle-shaped, square-shaped, triangle-shaped, oval-shaped, or oblong-shaped surfaces, among others. The TiB.sub.2 substrate 202/302 can also be a non-symmetrical form. The TiB.sub.2 substrate 202/302 can also be in the form of a plate. The TiB.sub.2 substrate 202/302 can use the slots 206/306, the directing feature, to direct TiB.sub.2 wettable material via capillary action.

[0187] The TiB.sub.2 substrate 202/302 can be used in a variety of applications. In some embodiments, the TiB.sub.2 substrate 202/302 can be configured for use in an aluminum electrolysis cell. In an aluminum electrolysis cell, the cathode is at the bottom of the cell, the anode is at the top of the cell, and the metal product (e.g., the aluminum metal product) moves to the bottom of cell, thereby making the molten metal pad. One example of an aluminum electrolysis cell can be found in commonly owned U.S. Pat. No. 6,231,745, entitled Cathode Collector Bar, and filed on Oct. 13, 1999. Another example of an aluminum electrolysis cell can be found in commonly owned U.S. Pat. No. 11,203,814, entitled Apparatuses and Systems for Vertical Electrolysis Cells, and filed on Mar. 30, 2017.

[0188] FIG. 4A is a front view of an embodiment of a product 400 with a TiB.sub.2 substrate 402 having a plurality of grooves 406 as directing features. FIG. 4B is a first side view of the embodiment shown in FIG. 4A. FIG. 4C is an enlarged partial section view of the embodiment shown in FIG. 4A indicated by the circle of dashed lines in FIG. 4A. FIG. 4D is an alternative configuration of the plurality of grooves of the embodiment as shown in FIG. 4C.

[0189] The product 400 is similar to the product 200/300, including a tip 410. Differences are described herein. In some embodiments, the directing feature of the product 200/300 is slots 206/306; in contrast, the directing feature of the product 400 is at least one groove 406.

[0190] The grooves 406 extend partially into the TiB.sub.2 substrate 402. The dimensions of the grooves 406 are predetermined. In some embodiments, a size and/or a shape of the grooves 406 are predetermined. A width (w) of the grooves 406 ranges from about 10 m to about 20 mm. A groove depth (gd) of the grooves 406 ranges from about 1 mm to about 10 mm. A length (l) of the grooves 406 ranges from about 1 cm to about 1 m. A thickness (t) of the TiB.sub.2 substrate 402 ranges from about 5 mm to about 30 mm. An edge-to-edge distance (d) between the grooves 406 ranges from about 1 mm to about 20 mm.

[0191] As shown in FIG. 4C, the directing feature includes at least two grooves 406 in the TiB.sub.2 substrate 402. Specifically, the directing feature includes three grooves 406. FIG. 4C shows a first groove 406A, a second groove 406B, a third groove 406C (collectively, grooves 406).

[0192] The grooves 406 can be arranged in any pattern. The grooves 406 can also have the same dimensions as one another or have different dimensions from one another. The grooves 406 can also be located on the sides of the TiB.sub.2 substrate 402, not only on the front side and back side as shown in FIG. 4C. FIG. 4D shows a first groove 406A, a second groove 406B, a third groove 406C (collectively, grooves 406). FIG. 4D shows alternative dimensions and arrangement of the grooves 406 as compared to the grooves 406 of FIG. 4C. FIG. 4C shows the grooves having the same dimensions as one another and arranged in a pattern where the grooves 406 are positioned in an alternating pattern between a front side and back side of the TiB.sub.2 substrate 402. FIG. 4D shows that the grooves 406 can have different dimensions. In some embodiments, the second groove 406B is the largest groove with a groove depth that extends further than halfway through the TiB.sub.2 substrate 402. The third groove 406C is the smallest groove and extends less than halfway through the TiB.sub.2 substrate 402.

[0193] FIG. 5A is a side view of another embodiment of a product 500 with a TiB.sub.2 substrate 502 having a plurality of pores as directing features. FIG. 5B is a close-up view of a portion of the embodiment shown in FIG. 5A indicated by dashed lines in FIG. 5A. As shown in FIG. 5A, the TiB.sub.2 substrate is a web, e.g., a sponge-like structure, of TiB.sub.2. The pores 504 are defined by the TiB.sub.2 substrate 502, the web of TiB.sub.2. The directing features of the product 500 can be a porosity of the TiB.sub.2 substrate 502. The porosity of the TiB.sub.2 substrate 502 can range from about 1 pore to about 200 pores per square inch (PPI). In some embodiments, the porosity is at least about 5 pores per inch (PPI), or at least about 10 pores per inch (PPI), or at least about 15 pores per inch (PPI), or at least about 20 pores per inch (PPI). In some embodiments, the porosity is not greater than about 175 pores per inch (PPI), or not greater than about 150 pores per inch (PPI), or not greater than about 125 pores per inch (PPI), or not greater than about 100 pores per inch (PPI), or not greater than about 80 pores per inch (PPI), or not greater than about 60 pores per inch (PPI), or not greater than about 50 pores per inch (PPI).

[0194] The porosity of the TiB.sub.2 substrate 502 can have any suitable porous structure. The porosity of the TiB.sub.2 substrate 502 can be an interconnected porous structure, wherein at least some of the pores are in fluid communication with one another and facilitate movement of the wettable material from a first location to a second location (e.g., from a first predetermined location to a second predetermined location). Accordingly, the interconnected porous structure may be considered an open pore structure. In some embodiments, the porosity of the TiB.sub.2 substrate 502 has a random porous structure. In some embodiments, the porosity of the TiB.sub.2 substrate 502 can be an oriented porous structure. In some embodiments, the porosity of the oriented porous structure of the TiB.sub.2 substrate 502 can have a porosity gradient. In some embodiments, the porosity gradient of the oriented porous structure of the TiB.sub.2 substrate 502 can change along a three-dimensional gradient (i.e., the porosity gradient can change along the X-axis, Y-axis, and Z-axis of the TiB.sub.2 substrate 502). In some embodiments, the porosity gradient of the oriented porous structure of the TiB.sub.2 substrate 502 increases or decreases toward the center of the TiB.sub.2 substrate 502. In some embodiments, the porosity gradient of the oriented porous structure of the TiB.sub.2 substrate 502 can increase and/or decrease through the TiB.sub.2 substrate 502. For instance, the porosity gradient of the oriented porous structure of the TiB.sub.2 substrate 502 can increase, decrease, and then increase from one end of the TiB.sub.2 substrate 502 to another end of the TiB.sub.2 substrate 502.

[0195] FIG. 6A is a perspective view of an embodiment of a product 600 with a TiB.sub.2 substrate 602 having a plurality of slots 606 as directing features and a solid aluminum metal 612 covering the TiB.sub.2 substrate 602. A portion of the solid aluminum metal 612 is shown around or transparent in FIG. 6A to reveal the surface structure of the substrate 602. The product 600 includes prongs 604, a base 608, and a tip 610. FIG. 6B is a first side view of a cross-section taken along the arrows 6B shown in FIG. 6A. FIG. 6C is an enlarged partial section view of the embodiment shown in FIG. 6A indicated by the circle of dashed lines in FIG. 6A. The embodiments shown in FIGS. 2A, 2B, and 2C is the same or similar as the embodiment of FIGS. 6A, 6B, and 6C except for the differences described herein. In some embodiments, the embodiment shown in FIGS. 6A, 6B, and 6C includes solid aluminum metal 612 covering the TiB.sub.2 substrate structures shown in FIGS. 2A, 2B, and 2C (e.g., the TiB.sub.2 substrate 202). For FIGS. 6A, 6B, and 6C, similar features of FIGS. 2A, 2B, and 2C will not be repeated. FIG. 6A and FIG. 6B show the solid aluminum metal 612 completely covering the TiB.sub.2 substrate 602. FIG. 6C shows the solid aluminum metal 612 completely occupying the slot 606A between a first prong 604A and a second prong 604B.

[0196] In some embodiments, the solid aluminum metal 612 at least partially covers the surface of the TiB.sub.2 substrate 602 and/or the solid aluminum metal 612 is at least partially contained within the slot 606. In some embodiments, the solid aluminum metal 612 covers at least 1% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 5% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 10% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 15% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 20% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 25% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 30% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 35% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 40% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 45% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 50% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 55% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 60% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 65% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 70% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 75% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 80% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 85% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 90% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 95% of the surface of the TiB.sub.2 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 100% of the surface of the TiB.sub.2 substrate 602.

[0197] In some embodiments, the solid aluminum metal 612 is at least partially contained within the slot 606. In some embodiments, where the slot 606 has a slot volume, the solid aluminum metal 612 occupies at least 1% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 5% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 10% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 15% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 20% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 25% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 30% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 35% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 40% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 45% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 50% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 55% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 60% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 65% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 70% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 75% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 80% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 85% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 90% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 95% of the slot volume. In some embodiments, the solid aluminum metal 612 occupies at least 100% of the slot volume.

[0198] Varying amounts of the solid aluminum metal 612 are shown occupying the slots 606 and the TiB.sub.2 substrate 602 in the embodiments shown in FIGS. 6A-6N.

[0199] FIG. 6D is a cross-sectional side view of an embodiment of a product 600 with a TiB.sub.2 substrate 602 having a plurality of slots 606A as directing features and a solid aluminum metal 612 covering an upper portion of the TiB.sub.2 substrate 602. FIG. 6E is a partial cross-section taken along the dashed line 6E shown in FIG. 6D where only one of the slots 606A of the plurality of slots 606A is shown. The cross-section is along the upper portion of the TiB.sub.2 substrate 602 where there is solid aluminum metal 612. FIG. 6F is a cross-section taken along the dashed line 6F as shown in FIG. 6D where only one of the slots 606A of the plurality of slots 606A is shown. The cross-section is along the lower portion of the TiB.sub.2 substrate 602 where there is no solid aluminum metal 612.

[0200] FIG. 6G is a cross-sectional side view of an embodiment of a TiB.sub.2 substrate 602 having a plurality of slots 606A as directing features and a solid aluminum metal 612 covering half of the TiB.sub.2 substrate 602, the front portion. The solid aluminum metal 612 covers the front half of the base 608 and the tip 610. FIG. 6H is a partial cross-section taken along the dashed line 6H as shown in FIG. 6G where only one of the slots 606A of the plurality of slots 606A is shown. The solid aluminum metal 612 covers the front half of the slot 606A.

[0201] FIG. 6I is a side view of an embodiment of a TiB.sub.2 substrate 602 with a base 608 and tip 610 having a plurality of slots 606A as directing features and a solid aluminum metal 612 in the plurality of slots 606A. FIG. 6J is a partial cross-section taken along the dashed line 6J as shown in FIG. 6I where only one of the slots 606A of the plurality of slots 606A is shown. In the embodiment of FIGS. 6I and 6J, there is no solid aluminum metal 612 on the exterior surface of the TiB.sub.2 substrate 602. The solid aluminum metal 612 completely fills the slot volume of the slot 606A.

[0202] FIG. 6K is a front view of an embodiment of a TiB.sub.2 substrate 602 having a plurality of slots 606A, 606B, and 606B (collectively, slots 606) as directing features and a solid aluminum metal 612 covering some or none of the slots 606. FIG. 6L is a first side view of the embodiment shown in FIG. 6K. FIG. 6K shows the TiB.sub.2 substrate 602 with a base 608 and a tip 610. The slots 606 have varying lengths, thicknesses, and amounts of the solid aluminum metal 612.

[0203] For slot 606A, the slot length does not extend to the tip 610 of the TiB.sub.2 substrate 602. The top portion of the slot 606A does not contain the solid aluminum metal 612 The bottom portion of the slot 606A contains the solid aluminum metal 612. For slot 606B, the slot length extends from the top of the base 608 to the tip 610. The slot 606B does not contain the solid aluminum metal 612. Slot 606C does not start from the same place as slots 606A and 606B. The beginning of slot 606C starts further up the TiB.sub.2 substrate 602. Slot 606C has solid aluminum metal 612 at the bottom and top, but not in the middle of the slot 606C.

[0204] FIG. 6M is a front view of an embodiment of a TiB.sub.2 substrate 602 with a surface area 620 having a first portion 622 of the surface area 620 with a plurality of slots 606 as directing features and a second portion 624 of the surface area 620 being absent of any directing feature. Prongs 604 define the plurality of slots 606. FIG. 6N is a first side view of the embodiment shown in FIG. 6M with the second portion 624 of the surface area 620 being absent of any directing feature.

[0205] The TiB.sub.2 substrate 602 includes a surface area 620, wherein a first portion 622 of the surface area 620 includes the at least one directing feature, and wherein a second portion 624 of the surface area 620 is absent of any directing feature.

[0206] In some embodiments, the first portion 622 of the surface area 620 is at least partially covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 1% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 5% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 10% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 15% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 20% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 25% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 30% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 35% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 40% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 45% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 50% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 55% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 60% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 65% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 70% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 75% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 80% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 85% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 90% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 95% covered by solid aluminum metal. In some embodiments, the first portion 622 of the surface area 620 is at least 100% covered by solid aluminum metal.

[0207] In some embodiments, the second portion 624 of the surface area 620 is at least partially covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 1% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 5% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 10% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 15% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 20% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 25% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 30% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 35% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 40% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 45% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 50% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 55% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 60% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 65% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 70% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 75% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 80% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 85% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 90% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 95% covered by solid aluminum metal. In some embodiments, the second portion 624 of the surface area 620 is at least 100% covered by solid aluminum metal.

[0208] In some embodiments, the solid aluminum metal covering the first portion 622 and/or the second portion 624 of the surface area 620 is in the form of a film. In some embodiments, the film includes a thickness of from 1 m to 500 m. In some embodiments, the first portion 622 and/or the second portion 624 of the surface area 620 is absent of the solid aluminum metal.

[0209] FIG. 7A is a front view of an embodiment of a product 700 with a TiB.sub.2 substrate 702 having a slot 706 as a directing feature and a solid aluminum metal 712 covering the TiB.sub.2 substrate 702. A portion of the solid aluminum metal 712 is shown around or transparent in FIG. 7A to reveal the surface structure of the substrate 702. A first prong 704A and a second prong 704B define the slot 706 extending upward from the base 708. FIG. 7B is a cross-section taken along the dashed line 7B shown in FIG. 7A. FIG. 7C is a first side view of a cross-section taken along the 7C shown in FIG. 7A.

[0210] FIG. 7D is a front view of an embodiment of a product 700 of a TiB.sub.2 substrate 702 having a slot 706 as a directing feature and a solid aluminum metal 712 covering a portion of the slot 706. A first prong 704A and a second prong 704B extend upwards from a base 708, thereby defining the slot 706. FIG. 7E is a cross-section taken along the dashed line 7E shown in FIG. 7D. As shown in FIG. 7E, a middle portion 714 of the slot 706 is absent the solid aluminum metal 712. A front portion and a back portion of the slot 706 are shown as having the solid aluminum metal 712. FIG. 7F is a first side view of the embodiment shown in FIG. 7D.

[0211] The embodiment shown in FIGS. 7D, 7E, and 7F and the embodiment shown in FIGS. 7A, 7B, and 7C are the same or similar except for differences discussed herein. For example, the amount of solid aluminum metal 712/712 covering the TiB.sub.2 substrate 702/702 differs between the embodiments. For the embodiment of FIGS. 7A, 7B, and 7C, the solid aluminum metal 712 covers almost the entirety of the TiB.sub.2 substrate 702. Only a portion of the base 708 is covered with solid aluminum metal 712. The slot 706 is fully contained with solid aluminum metal 712. In contrast, the embodiment of FIGS. 7D, 7E, and 7F have no solid aluminum metal 712 on the exterior of the TiB.sub.2 substrate 702. Only a portion of the slot 706 is filled with solid aluminum metal 712.

[0212] The embodiments of FIGS. 7A, 7B, 7C, 7D, 7E, and 7F are the same or similar as the embodiment of FIGS. 3A, 3B, and 3C. One difference is that FIGS. 3A, 3B, and 3C are not shown with solid aluminum metal on the TiB.sub.2 substrate surfaces or covering at least portions thereof. The description of the solid aluminum metal from the embodiments of FIGS. 6A-6N also applies to the solid aluminum metal of FIGS. 7A-7F.

[0213] FIG. 8A is a front view of an embodiment of a product 800 with a TiB.sub.2 substrate 802 having a plurality of grooves 806 as directing features and a solid aluminum metal 812 covering the TiB.sub.2 substrate 802. A portion of the solid aluminum metal 812 is shown around or transparent in FIG. 8A to reveal the surface structure of the substrate 802. FIG. 8B is a first side view of a cross-section taken along line 8B shown in FIG. 8A. FIG. 8C is an enlarged partial section view of the embodiment shown in FIG. 8A as indicated by the dashed lines in FIG. 8A. FIG. 8C includes a view of a first groove 806A, a second groove 806B, and a third groove 806C.

[0214] FIG. 8D is a rear view of an embodiment of a product 800 of a TiB.sub.2 substrate 802 having a plurality of grooves 806 as directing features and a solid aluminum metal 812 covering the front half of the TiB.sub.2 substrate 802. FIG. 8E is a first side view of a cross-section taken along the line 8E shown in FIG. 8D. FIG. 8F is an enlarged partial section view of the embodiment shown in FIG. 8D indicated by the circle of dashed lines in FIG. 8F.

[0215] The embodiment shown in FIGS. 8D, 8E, and 8F and the embodiment shown in FIGS. 8A, 8B, and 8C are the same or similar except for differences discussed herein. For example, the amount of solid aluminum metal 812/812 covering the TiB.sub.2 substrate 802/802 differs between the embodiments. For the embodiment of FIGS. 8A, 8B, and 8C, the solid aluminum metal 812 is completely covering the TiB.sub.2 substrate 802. In contrast, the solid aluminum metal 812 in FIGS. 8D, 8E, and 8F only covers the front half of the TiB.sub.2 substrate 802.

[0216] The embodiments of FIGS. 8A, 8B, 8C, 8D, 8E, and 8F are the same or similar as the embodiment of FIGS. 4A, 4B, 4C and 4D. One difference is that FIGS. 4A, 4B, 4C, and 4D are not shown with solid aluminum metal on the TiB.sub.2 substrate. FIGS. 8A, 8B, 8C, 8D, 8E, and 8F are shown with solid aluminum metal 812/812 on the TiB.sub.2 substrate. The description of the solid aluminum metal 612/712 from the embodiments of FIGS. 6A-6N and 7A-7F also applies to the solid aluminum metal 812/812 of FIGS. 8A-8F.

[0217] For FIGS. 8A-8F, the at least one directing feature is a groove 806/806, and the solid aluminum metal 812/812 is at least partially contained within the groove 806/806. The at least one groove 806/806 includes a groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 1% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 5% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 10% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 15% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 20% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 25% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 30% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 35% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 40% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 45% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 50% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 55% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 60% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 65% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 70% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 75% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 80% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 85% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 90% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 95% of the groove volume. In some embodiments, the solid aluminum metal 812/812 occupies at least 100% of the groove volume.

[0218] FIG. 9 is a close-up view of a portion of an embodiment of a product 900 of a TiB.sub.2 substrate 902 with pores 904 and solid aluminum metal 906, in accordance with some embodiments. In some embodiments, the TiB.sub.2 substrate 902 is a web, e.g., a sponge-like structure, of TiB.sub.2.

[0219] In some embodiments, the product 900 includes a TiB.sub.2 substrate 902 of a web of TiB.sub.2 and solid aluminum metal 906 at least partially covering surfaces of the web of TiB.sub.2 substrate 902. The web of the TiB.sub.2 substrate 902 defines pores 904 within the web of TiB.sub.2.

[0220] In some embodiments, the solid aluminum metal 906 has a porosity. The solid aluminum metal 906 may be at an elevated temperature when the solid aluminum metal 906 is filled in the pores 904. When the solid aluminum metal 906 cools, there may be space (e.g., pores or voids) between the solid aluminum metal 906 and the pores of the TiB.sub.2 substrate 902. The pores 904 have a porosity of the TiB.sub.2 substrate 902 web defining a porous volume of the TiB.sub.2 substrate 902. In some embodiments the solid aluminum metal 906 occupies at least 1% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 5% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 10% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 15% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 20% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 25% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 30% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 35% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 40% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 45% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 50% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 55% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 60% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 65% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 70% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 75% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 80% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 85% of the porous volume. In some embodiments the solid aluminum metal 906 occupies at least 90% of the porous volume.

[0221] The porosity of the TiB.sub.2 substrate 902 can have any suitable porous structure. The porosity of the TiB.sub.2 substrate 902 can be an interconnected porous structure, wherein at least some of the pores are in fluid communication with one another and facilitate movement of the wettable material from a first location to a second location (e.g., from a first predetermined location to a second predetermined location). Accordingly, the interconnected porous structure may be considered an open pore structure. In some embodiments, the porosity of the TiB.sub.2 substrate 902 has a random porous structure. In some embodiments, the porosity of the TiB.sub.2 substrate 902 can be an oriented porous structure. In some embodiments, the porosity of the oriented porous structure of the TiB.sub.2 substrate 902 can be a porosity gradient. In some embodiments, the porosity gradient of the oriented porous structure of the TiB.sub.2 substrate 902 can change along a three-dimensional gradient (i.e., the porosity gradient can change along the X-axis, Y-axis, and Z-axis of the TiB.sub.2 substrate 902). In some embodiments, the porosity gradient of the oriented porous structure of the TiB.sub.2 substrate 902 increases or decreases toward the center of the TiB.sub.2 substrate 902. In some embodiments, the porosity gradient of the oriented porous structure of the TiB.sub.2 substrate 902 can increase and/or decrease through the TiB.sub.2 substrate 902. For instance, the porosity gradient of the oriented porous structure of the TiB.sub.2 substrate 902 can increase, decrease, and then increase from one end of the TiB.sub.2 substrate 902 to another end of the TiB.sub.2 substrate 902.

[0222] An aluminum electrolysis cell can include any of the TiB.sub.2 substrates described herein. In some embodiments, at least one of the TiB.sub.2 substrates is an electrode for the aluminum electrolysis cell. In some embodiments, at least one of the TiB.sub.2 substrates is a directing apparatus, where the directing apparatus is configured to direct liquid aluminum metal in a predetermined direction in an absence of an applied electrical current.

[0223] A product can include a TiB.sub.2 substrate, as described herein, with at least one directing feature and solid aluminum metal at least partially covering surfaces of the TiB.sub.2 substrate. The solid aluminum metal can be at least partially contained within the at least one directing feature. In some embodiments, at least one directing feature incudes a void volume. In some embodiments, at least 1% of the void volume contains the solid aluminum metal. In some embodiments, at least 5% of the void volume contains the solid aluminum metal. In some embodiments, at least 10% of the void volume contains the solid aluminum metal. In some embodiments, at least 15% of the void volume contains the solid aluminum metal. In some embodiments, at least 20% of the void volume contains the solid aluminum metal. In some embodiments, at least 25% of the void volume contains the solid aluminum metal. In some embodiments, at least 30% of the void volume contains the solid aluminum metal. In some embodiments, at least 35% of the void volume contains the solid aluminum metal. In some embodiments, at least 40% of the void volume contains the solid aluminum metal. In some embodiments, at least 45% of the void volume contains the solid aluminum metal. In some embodiments, at least 50% of the void volume contains the solid aluminum metal. In some embodiments, at least 55% of the void volume contains the solid aluminum metal. In some embodiments, at least 60% of the void volume contains the solid aluminum metal. In some embodiments, at least 65% of the void volume contains the solid aluminum metal. In some embodiments, at least 70% of the void volume contains the solid aluminum metal. In some embodiments, at least 75% of the void volume contains the solid aluminum metal. In some embodiments, at least 80% of the void volume contains the solid aluminum metal. In some embodiments, at least 85% of the void volume contains the solid aluminum metal. In some embodiments, at least 90% of the void volume contains the solid aluminum metal. In some embodiments, at least 95% of the void volume contains the solid aluminum metal. In some embodiments, at least 100% of the void volume contains the solid aluminum metal.

[0224] Although the present disclosure generally refers to TiB.sub.2 substrates, other ceramic and/or cermet substrates having directing features may be used. Any ceramic and/or cermet substrate having a directing feature can be used with any wettable metal. In some embodiments, any wettable metal can be any suitable metal for transfer via the ceramic and/or cermet substrates. In some embodiments, the suitable metal may be aluminum, such as aluminum alloy, metallic aluminum, and combinations thereof. In one aspect, the present disclosure relates to a product with a ceramic substrate or a cermet substrate having a directing feature, wherein the directing feature is configured to direct ceramic wettable material or cermet wettable material in a predetermined direction. In some embodiments, the substrate is a ceramic substrate. In some embodiments, the ceramic substrate is one of a TiB.sub.2 substrate, a ZrB.sub.2 substrate, or a HfB.sub.2 substrate. In some embodiments, the ceramic wettable material is aluminum, such as aluminum alloy, metallic aluminum, and combinations thereof.

[0225] While some of the above disclosures have been made relative to TiB.sub.2 and aluminum, the apparatus, systems, and methods described herein are applicable to other ceramic and/or cermet materials other than TiB.sub.2. For instance, the disclosures herein may be equally applicable to other metal borides (e.g., metal diborides) having metal wetting capabilities, such as ZrB.sub.2 and HfB.sub.2, just to name two, both of which are aluminum wettable materials.

iii. Start-Up of the Aluminum Electrolysis Cell 5000

[0226] During the start-up of the aluminum electrolysis cell 5000, the electrodes of the aluminum electrolysis cell 5000 (e.g., the anodes 5104 and/or cathodes 5108) can be damaged. When the electrodes are not protected, outside contaminants, such as the molten electrolyte (shown diagrammatically by dashed line 5126), can damage the electrodes. When the aluminum electrolysis cell 5000 is running at steady state, the wetting of the electrodes via the metal product can provide protection. In some embodiments, when the aluminum electrolysis cell 5000 is past the start-up phase and is running at steady state or close to running at steady state, the metal product can wet and cover the electrodes providing protection from contaminants.

[0227] In some embodiments, before the aluminum electrolysis cell 5000 can reach steady state, the electrodes of the aluminum electrolysis cell 5000 can be provided protection by other methods. For example, the electrodes can be covered in solid aluminum metal as described in Section ii. The solid aluminum metal on the electrodes can provide a barrier to outside contaminants. During start-up, the temperature of the electrodes of the aluminum electrolysis cell 5000 begins to increase. As the temperature increases past the melting point temperature of the solid aluminum metal on the electrodes, the solid aluminum metal will phase transition from a solid to a liquid. During the phase transition from solid to liquid, the liquid will begin to preferentially wet the electrodes and move in the predetermined direction via the directing feature(s) of the electrodes. The liquid aluminum metal that was previously solid and covering the electrodes will facilitate the flow of metal product. During steady state operation of the aluminum electrolysis cell 5000, the liquid metal from the solid aluminum metal and the metal product will cover the electrodes and provide protection from outside contaminants.

[0228] In some embodiments, the aluminum electrolysis cell 5000 is first heated up empty and then, liquid bath and alumina feedstock (e.g., liquid alumina) are added to the aluminum electrolysis cell 5000. In some embodiments, start-up of the aluminum electrolysis cell 5000 may include a dry bath (i.e., an un-melted bath) due to the electrodes being protected by the solid aluminum metal coverage at the initial start-up. During startup of the aluminum electrolysis cell 5000, the dry bath in the aluminum electrolysis cell 5000 can be melted during the cell preheat cycle.

[0229] In some embodiments, a method of using the aluminum electrolysis cell 5000 includes restricting or preventing attack of the anodes 5104 and/or cathodes 5108 (e.g., a non-carbonaceous substrate) via the molten electrolyte (shown diagrammatically by dashed line 5126) of the aluminum electrolysis cell 5000. In some embodiments, restricting or preventing includes at least partially covering the anodes 5104 and/or cathodes 5108 by the wettable material (e.g., the metal product). For example, the restricting or preventing includes covering at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% of the surface area of the anode 5104 and/or the cathode 5108 by the wettable material. The wettable material can restrict or prevent contacting of outer surfaces of the anodes 5104 and/or cathodes 5108 by the electrolyte and/or contaminants.

[0230] In some embodiments, restricting or preventing attack of the anodes 5104 and/or cathodes 5108 (e.g., a non-carbonaceous substrate) includes when a temperature of the non-carbonaceous substrate is less than a melting point temperature of the solid aluminum metal. In some embodiments, the restricting or preventing can be accomplished by at least partially covering the anodes 5104 and/or cathodes 5108 (e.g., a non-carbonaceous substrate) by the solid aluminum. For example, restricting or preventing can include covering at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% of the surface area of the anodes 5104 and/or cathodes 5108 (e.g., a non-carbonaceous substrate) by the solid aluminum. The solid aluminum can restrict or prevent contacting of outer surfaces of the anodes 5104 and/or cathodes 5108 (e.g., a non-carbonaceous substrate) by the electrolyte and/or contaminants.

iv. Using Substrates Having Directing Features in the Aluminum Electrolysis Cell

[0231] One embodiment of a method for producing aluminum includes feeding an alumina feedstock to the aluminum electrolysis cell 5000 and supplying an electric current to the anodes 5104. At least some of the aluminum ions from the alumina feedstock may be transported through the electrolyte onto the surface of the cathode 5108. At least some of the aluminum ions may be reduced via the cathode 5108, thereby producing a metal product, such as aluminum, on the surface of the cathode 5108.

[0232] Without being bound by a particular mechanism or theory, the produced aluminum metal product at the surface of the cathode 5108 flows down to the bottom of the cell reservoir due to the electrolyte having a density lesser than the aluminum metal product. Thus, the aluminum metal product may tend to collect and thus forming a layer below the electrolyte as the molten metal pad at the bottom of the aluminum electrolysis cell 5000. For example, based on differences in density between the aluminum metal product and the electrolyte, the molten metal pad is configured with a density greater than the electrolyte such that the molten metal pad zone is configured below the electrolyte zone.

[0233] In some embodiments, the anodes 5104 and/or cathodes 5108 can include directing features as described in Section ii. In some embodiments, at least one of the cathodes 5108 (e.g., all of the cathodes 5108) and/or at least one of the anodes 5104 (e.g., all of the anodes 5104) can have directing features. For example, some or all of the cathodes 5108 may be absent of directing features while some of the anodes 5104 have one or more directing features. For example, some or all of the cathodes 5108 may be absent of directing features while all of the anodes 5104 have one or more directing features. For example, some or all of the cathodes 5108 may be absent of directing features while some or all of the anodes 5104 may be absent of directing features. For example, some or all of the cathodes 5108 has one or more directing features while some of the anodes 5104 have one or more directing features. For example, some or all of the cathodes 5108 has one or more directing features while all of the anodes 5104 have one or more directing features. For example, some or all of the cathodes 5108 has one or more directing features while some or all of the anodes 5104 may be absent of directing features. These examples are exemplary and are not exhaustive. Other configurations are possible too.

[0234] The directing features can assist the flow of the aluminum metal product towards the bottom of the aluminum electrolysis cell 5000 to form the molten metal pad. In some embodiments, the directing feature directs the aluminum metal product in a predetermined direction that is vertical and/or horizontal. For example, the predetermined direction can be a downwardly direction towards the molten metal pad of the aluminum electrolysis cell 5000.

EXAMPLES

Example 1Lab-Scale Testing

Manufacture of Porous TiB.SUB.2 .Substrates (TiB.SUB.2 .Foams)

[0235] Four different TiB.sub.2 foam samples, each of dimension of about 3-inch (H) by 2-inch (W) by 0.5 inch (D), were manufactured to have a porosity of about 10, 20, 30 and 45 PPI, respectively. The TiB.sub.2 foam samples were manufactured by immersing polyurethane foams of different pore sizes in an aqueous slurry that had TiB.sub.2 particles therein. The TiB.sub.2 coated foams were then rolled between a set of parallel rollers with a defined gap thickness, which compressed the infiltrated foam and expelled unwanted slurry. The rolled TiB.sub.2 foams were then hung in a drying oven. In some cases, the process was repeated, wherein the coated foams were re-immersed in the aqueous slurry and then air dried. The final dried TiB.sub.2 foams were then sintered by heating at temperature of about 1850 C. FIG. 10 shows an example of a sintered end product. The sintered end products had continuous inter-connected pores with pore sizes of about 10, 20, 30, and 45 PPI corresponding to the respective polyurethane foam pore sizes. As shown in FIG. 10, the pore structure is an open pore structure allowing fluids to travel from one predetermined location to another predetermined location.

Water Wetting Test

[0236] As shown in FIG. 11, each of the four TiB.sub.2 foam samples (of about 10, 20, 30, and 45 PPI) was wrapped in two pieces of tissue paper, one piece of tissue paper at the top of the sample and one piece of tissue paper at the middle of the sample. The bottoms of the TiB.sub.2 samples were then placed in 0.25 inch of water, well below the middle part of the samples, to test the samples' abilities to promote water mass transfer through capillary action. After about 12 hours of time, the samples were evaluated. None of the tissues in the about 10 PPI sample were damp or wet, indicating that no capillary action had occurred. In the about 20 PPI sample, the middle tissue was damp and the top issue was dry, indicating that some capillary action had occurred. In both the about 30 and 45 PPI samples, the middle and top tissues were wet, indicating that substantial capillary action had occurred.

Infiltration of TiB.SUB.2 .Foams with Aluminum Metal

[0237] The sintered TiB.sub.2 foams were submerged in molten aluminum for 1 minute then air quenched. After cooling completely, each of the four TiB.sub.2 foam samples was then placed into about 0.5 inches deep slots of graphite carriers of three different crucibles (Crucible #1, Crucible #2, and Crucible #3, as further described below). Each of the three crucibles was installed in a furnace and heated in argon to 900 C. A purified molten aluminum composition (pure aluminum pellets-at least 99.5% pure) and a molten bath composition was added to each crucible. The molten bath composition was cryolite based and included NaF, AlF.sub.3, and CaF.sub.2 constituents.

[0238] The crucibles having the four TiB.sub.2 foam samples, molten aluminum, and cryolite, were held at 900 C. for about 48 hours. As shown in FIG. 12, in Crucible #1, the four TiB.sub.2 foam samples were completely submerged in the molten aluminum for the 48 hours. In Crucibles #2 and #3, the four TiB.sub.2 foam samples were partially submerged in approximately 1 and 2 inches of molten aluminum, respectively, with the remainder of the foams being exposed to the molten bath, for the 48 hours.

[0239] After 48 hours of testing at 900 C., as shown in FIG. 13A and FIG. 13B, no corrosion was observed for the four TiB.sub.2 foam samples in any of the crucibles, indicating that the samples had been wetted by molten aluminum via capillary action facilitated by the pores of the foams. The molten aluminum protects TiB.sub.2 from being corroded by cryolite.

Example 2Larger Lab-Scale Testing

Manufacture of TiB.SUB.2 .Foam Samples

[0240] Two different TiB.sub.2 foam samples, each of dimension of about 16-inch (H) by 2-inch (W) by 0.5 inch (D), were manufactured by the process for the foam samples from Example 1. The sintered end product of the two TiB.sub.2 foam samples had continuous inter-connected pores with pore sizes of about 20 and 30 PPI corresponding to the respective polyurethane foam pore sizes.

Infiltration of TiB.SUB.2 .Foams with Aluminum Metal

[0241] Two untreated TiB.sub.2 foam samples were placed into about 2-inches deep slots of a graphite carrier of a crucible. Prior to being placed in the graphite carrier, a purified molten aluminum composition (pure aluminum pellets) and a molten bath composition (cryolite based and included NaF, AlF.sub.3, and CaF.sub.2 constituents) was added to each crucible, then each crucible was then installed in a furnace and heated in argon to 900 C. After heating, each of the two TiB.sub.2 foam samples was then placed in a crucible. Each crucible, having a TiB.sub.2 foam sample, molten aluminum and cryolite, was then held at 900 C. After about 10 minutes of testing, the two TiB.sub.2 foam samples were then pulled from the crucibles and molten aluminum was detected at the top of the samples. Similar to Example 1, no corrosion was observed for either of the two TiB.sub.2 foam samples, indicating that the samples had been wetted by molten aluminum about 14 inches via capillary action facilitated by the pores of the foams. The molten aluminum protects TiB.sub.2 from being corroded by cryolite.

[0242] While a number of embodiments of the present disclosure have been described, it is understood that these embodiments are illustrative only, and not restrictive, and that many modifications may become apparent to those of ordinary skill in the art. The various steps may be carried out in any desired order (and any desired steps may be added and/or any desired steps may be eliminated). For example, the features and characteristics of the directing features (e.g., slots, pores, or grooves) can be used together or alone with any of the products and/or TiB.sub.2 substrates, including an aluminum electrolysis cell. The features and characteristics of the solid aluminum metal as described in any of the embodiments can be used in any other embodiment described herein. The exemplary embodiments of directing features and solid aluminum metal coverage are not meant to be exhaustive. The features and characteristics of the present disclosure can be combined in any manner.