Abstract
The present disclosure relates to products, systems, and methods for producing purified liquid metal (e.g., purified aluminum) from a feedstock (e.g., aluminum feedstock) in an electrolytic cell (e.g., purification cell) by purifying the feedstock and moving the purified liquid metal from a first location of the cell to a second location via at least one directing feature. The at least one directing feature may be electrically neutral and may be located proximal the first location. The at least one directing feature may be in fluid communication with the purified liquid metal (e.g., purified aluminum) and the second location.
Claims
1. A method, comprising: (a) purifying a feedstock in an electrolytic cell, thereby producing a purified liquid metal; and (b) moving the purified liquid metal from a first location of the electrolytic cell towards a second location, wherein the moving comprises transporting the purified liquid metal via a directing feature, wherein the directing feature is located proximal the first location, wherein the directing feature is in fluid communication with the purified liquid metal and the second location.
2. The method of claim 1, wherein the directing feature is electrically neutral.
3. The method of claim 2, wherein the directing feature is at least partially submerged in the purified liquid metal.
4. The method of claim 3, wherein the directing feature is partially submerged in an electrolyte.
5. The method of claim 3, wherein the directing feature is fully submerged in the purified liquid metal.
6. The method of claim 1, wherein a substrate comprises the directing feature.
7. The method of claim 6, wherein the substrate is a regular shape or an irregular shape.
8. The method of claim 6, wherein the substrate is arcuate.
9. The method of claim 6, wherein the substrate is oriented in a vertical direction.
10. The method of claim 6, wherein the substrate is oriented in a horizontal direction.
11. The method of claim 6, wherein the substrate is oriented in a sloped direction.
12. The method of claim 6, wherein the substrate comprises at least one of a ceramic or cermet.
13. The method of any of claim 6, wherein the substrate is proximal or adjacent to at least one refractory component of the electrolytic cell.
14. The method of claim 13, wherein the substrate is mechanically connected to the at least one refractory component.
15. The method of claim 14, wherein the at least one refractory component is a refractory cover.
16. The method of claim 14, wherein the at least one refractory component is a refractory sidewall.
17. The method of claim 1, wherein the moving step (b) comprises moving the purified liquid metal in a predetermined direction.
18. The method of claim 1, wherein the directing feature comprises at least one of slots, grooves, pores, tapered members, or a combination thereof.
19. The method of claim 1, wherein the second location is a purified metal reservoir.
20. An electrolytic cell, comprising: (a) a cell chamber comprising a cell bottom, refractory sidewalls, a refractory top cover, an electrolyte, and purified liquid metal; (b) an anode at least partially submerged in the electrolyte; (c) a cathode at least partially submerged in the electrolyte; (d) a cell exit location; and (e) a directing feature, wherein the directing feature is located proximal the purified liquid metal, wherein the directing feature is in fluid communication with the purified liquid metal and the cell exit location, and wherein the directing feature is configured to direct the purified liquid metal in a predetermined direction associated with the cell exit location.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a schematic cut-away side view of an embodiment of an electrolytic cell 1 for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to a cell exit location 370, in accordance with the instant disclosure.
[0032] FIG. 2 is a schematic cut-away side view of another embodiment of an electrolytic cell 1 for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to a cell exit location 370, in accordance with the instant disclosure.
[0033] FIG. 3 is a close-up view of an embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to a cell exit location 370, in accordance with the instant disclosure.
[0034] FIG. 4a is a partial view of an embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to a cell exit location 370, in accordance with the instant disclosure.
[0035] FIG. 4b is a partial view of another embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to and through a cell exit location 370 and to a purified metal reservoir 260, in accordance with the instant disclosure.
[0036] FIG. 4c is a partial view of yet another embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to a cell exit location 370, in accordance with the instant disclosure.
[0037] FIG. 4d is a partial view of another embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to a cell exit location 370 through a cell well 130, in accordance with the instant disclosure.
[0038] FIG. 4e is a partial view of yet another embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to and through a cell exit location 370. As illustrated, the purified aluminum 120 drips from tapered member 330 towards the direction of the molten metal pad and then moves into the purified metal reservoir 260, in accordance with the instant disclosure. In some embodiments, one or more non-tapered members (not illustrated) may be used to facilitate dripping of purified aluminum towards a target source.
[0039] FIG. 5a is a partial view of another embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to a cell exit location 370, in accordance with the instant disclosure.
[0040] FIG. 5b is a partial view of yet another embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to a cell exit location 370, in accordance with the instant disclosure.
[0041] FIG. 5c is a partial view of another embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to and through a cell exit location 370 and to a purified metal reservoir 260, in accordance with the instant disclosure.
[0042] FIG. 5d is a partial view of yet another embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to and through a cell exit location 370 and to a purified metal reservoir 260, in accordance with the instant disclosure.
[0043] FIG. 6a is a partial view of another embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to a cell exit location 370, in accordance with the instant disclosure.
[0044] FIG. 6b is a partial view of yet another embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to a cell exit location 370, in accordance with the instant disclosure.
[0045] FIG. 6c is a partial view of another embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to a cell exit location 370, in accordance with the instant disclosure.
[0046] FIG. 6d is a partial view of yet another embodiment of FIG. 2 and illustrates a method for transporting liquid metal (e.g., purified aluminum of a purified aluminum layer 120) via a directing feature 350 to a cell exit location 370, in accordance with the instant disclosure.
[0047] FIG. 7A is a perspective view of an embodiment of a substrate 202 (e.g., TiB.sub.2 substrate) having a plurality of slots 206 as directing features.
[0048] FIG. 7B is a first side view of FIG. 7A.
[0049] FIG. 7C is a partial top view of FIG. 7A as indicated by the dashed lines in FIG. 7A.
[0050] FIG. 8A is a front view of an embodiment of a substrate 302 having a slot 306 as a directing feature.
[0051] FIG. 8B is a top view of a cross-sectional along the dashed line 8B as shown in FIG. 8A.
[0052] FIG. 8C is a first side view of FIG. 8A.
[0053] FIG. 9A is a front view of an embodiment of a substrate 402 having a plurality of grooves 406 as directing features.
[0054] FIG. 9B is a first side view of FIG. 9A.
[0055] FIG. 9C is a partial top view of FIG. 9A as indicated by the dashed lines in FIG. 9A.
[0056] FIG. 9D is an alternative configuration of the plurality of grooves 406A, 406B, 406C, as shown in FIG. 9C.
[0057] FIG. 10A is a side view of another embodiment of a substrate 502 having a plurality of pores 504 as directing features.
[0058] FIG. 10B is a close-up view of FIG. 10A.
[0059] FIG. 11A is a perspective view of an embodiment of a substrate 602 having a plurality of slots 606 as directing features and a solid aluminum metal 612 covering the substrate 602.
[0060] FIG. 11B is a first side view of FIG. 11A.
[0061] FIG. 11C is a partial top view of FIG. 11A as indicated by the dashed lines in FIG. 11A.
[0062] FIG. 11D is a side view of an embodiment of a substrate 602 having a plurality of slots 606A as directing features and a solid aluminum metal 612 covering an upper portion of the substrate 602.
[0063] FIG. 11E is a partial top view of a cross-sectional along the dashed line 11E as shown in FIG. 11D 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 substrate where there is solid aluminum metal.
[0064] FIG. 11F is a partial top view of a cross-sectional along the dashed line 11F as shown in FIG. 11D 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 substrate 602 where there is no solid aluminum metal 612.
[0065] FIG. 11G is a side view of an embodiment of a substrate 602 having a plurality of slots 606A as directing features and a solid aluminum metal 612 covering half of the substrate 602 the front portion.
[0066] FIG. 11H is a partial top view of a cross-sectional along the dashed line 11H as shown in FIG. 11G where only one of the slots 606A of the plurality of slots 606A is shown.
[0067] FIG. 11I is a side view of an embodiment of a 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
[0068] FIG. 11J is a partial top view of a cross-sectional along the dashed line 11J as shown in FIG. 11I where only one of the slots 606A of the plurality of slots 606A is shown.
[0069] FIG. 11K is a front view of an embodiment of a substrate 602 having a plurality of slots 606A, 606B, and 606C (collectively, slots 606) as directing features and a solid aluminum metal 612 covering some or none of the slots 606.
[0070] FIG. 11L is a first side view of FIG. 11K.
[0071] FIG. 11M is a front view of an embodiment of a 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.
[0072] FIG. 11N is a first side view of FIG. 11M with the second portion 624 of the surface area 620 being absent of any directing feature.
[0073] FIG. 12A is a front view of an embodiment of a substrate 702 (e.g., TiB.sub.2 substrate) having a slot 706 as a directing feature and a solid aluminum metal 712 covering the substrate 702.
[0074] FIG. 12B is a top view of a cross-sectional along the dashed line 12B as shown in FIG. 12A.
[0075] FIG. 12C is a first side view of FIG. 12A.
[0076] FIG. 12D, is a front view of an embodiment of a substrate 702 having a slot 706 as a directing feature and a solid aluminum metal 712 covering a portion of the slot 706.
[0077] FIG. 12E is a top view of a cross-sectional along the dashed line 12E as shown in FIG. 12D.
[0078] FIG. 12F is a first side view of FIG. 12F.
[0079] FIG. 13A is a front view of an embodiment of a substrate 802 (e.g., TiB.sub.2 substrate) having a plurality of grooves 806 as directing features and a solid aluminum metal 812 covering the substrate 802.
[0080] FIG. 13B is a first side view of FIG. 13A.
[0081] FIG. 13C is a partial top view of FIG. 13A as indicated by the dashed lines in FIG. 13A.
[0082] FIG. 13D is a front view of an embodiment of a substrate 802 having a plurality of grooves 806 as directing features and a solid aluminum metal 812 covering half of the substrate 802, the front portion.
[0083] FIG. 13E is a first side view of FIG. 13D.
[0084] FIG. 13F is a partial top view of FIG. 13D as indicated by the dashed lines in FIG. 13F.
[0085] FIG. 14 is a close-up view of an embodiment of a substrate 902 (e.g., TiB.sub.2 substrate) with pores 904 and solid aluminum metal 906, in accordance with some embodiments.
[0086] FIG. 15 is a frontal view of a TiB.sub.2 foam sintered end product that was used in lab-scale testing.
[0087] FIG. 16 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).
[0088] FIG. 17 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.
[0089] FIG. 18A 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.
[0090] FIG. 18B 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.
DETAILED DESCRIPTION
[0091] The present disclosure will be further explained with reference to the attached figures, 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 components. 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.
[0092] 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 present disclosure which are intended to be illustrative, and not restrictive.
[0093] 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 they may. Furthermore, the phrases in another embodiment, in yet another embodiment, and in some other embodiments as used herein do not necessarily refer to a different embodiment, although they may. Thus, as described below, various embodiments of the present disclosure may be readily combined, without departing from the scope or spirit of the present disclosure.
[0094] 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.
[0095] As used herein, aluminum feedstock means material having a sufficient amount of aluminum to produce a purified aluminum product.
[0096] As used herein, purified aluminum means material having a greater amount of aluminum than the aluminum feedstock.
[0097] As used herein, molten metal pad means a reservoir of molten material located below an electrolyte, wherein the molten material comprises aluminum.
[0098] As used herein, wettable means a solid creates/has a static contact angle of not greater than 90 degrees relative to a liquid in contact with its surface. That is, the material is philic relative to the liquid in contact with its surface.
[0099] As used herein, aluminum wettable means having a contact angle with molten aluminum of not greater than 90 degrees.
[0100] 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 comprise molten salt.
[0101] As used herein, electrically neutral means absent a purposefully applied electric current.
[0102] As used herein, slot means a geometric feature that extends through a length, width, and/or thickness of a substrate; a slot may define a channel for movement of purified liquid metal therethrough, such as movement from an entrance of the slot to an exit of the slot.
[0103] As used herein, groove means a geometric feature that extends partially into, but not through, a substrate.
[0104] As used herein, geometric feature means a predetermined shape created in a substrate; examples include slots, grooves, and pores of any shape or size.
i. Electrolytic Cells With Non-Electrical Directing Features
[0105] Reference will now be made to the accompanying drawings which at least partially assist in illustrating various pertinent features of the products, systems, and methods disclosed herein. Referring now to FIG. 1, an electrolytic cell 1 includes one or more directing features 350 configured to transport liquid metal (e.g., purified aluminum of a purified aluminum layer 120) in the absence of purposefully applied electric current. (The directing feature 350 is described in further detail below in Section ii.) In some embodiments, one or more substrates comprise the one or more directing features 350. Such one or more substrates may be one or more of any of the substrates described herein (e.g., 202, 302, 402, 502, 602, 702, 802, 902). In one embodiment, the liquid metal comprises a purified aluminum layer 120. In one embodiment, the purified aluminum layer 120 comprises purified aluminum. In one embodiment, the electrolytic cell 1 is an aluminum purification cell. As illustrated, the electrolytic cell 1 includes a base 10, an outer shell 20, refractory sidewalls 30, a refractory top cover 40, a cell bottom 60 located proximal the base 10, wherein the cell bottom 60 has an upper surface 80 and a lower surface 70. The electrolytic cell 1 includes an anode connector 50 in electrical communication with the cell bottom 60. The anode connector 50 is configured to connect to an external power source. In the illustrated embodiment, the electrolytic cell 1 includes at least one anode 90 extending upward from the cell bottom 60, a cathode connector 140 located proximal the refractory top cover 40, and at least one cathode 150 extending downward from the cathode connector 140. The cathode connector 140 has an upper connection rod 146 configured to connect to the external power source, and a lower surface 142. In some embodiments, the at least one cathode 150 or the at least one anode 90 are oriented in a generally vertical direction. In some embodiments, the at least one cathode 150 or the at least one anode 90 are oriented in a generally horizontal direction. The at least one cathode 150 may overlap the at least one anode 90.
[0106] With continued reference to FIG. 1, the electrolytic cell 1 includes a cell chamber 240. The cell chamber 240 is configured to hold the liquid metal (e.g., purified aluminum layer 120), the electrolyte 110, and the molten metal pad 100. In one embodiment, the cell chamber 240 is at least partially defined by the refractory top cover 40, the refractory sidewalls 30, and the cell bottom 60 located proximal to a base 10. A cell exit location 370 is located at least proximal to at least one refractory sidewall 30 of the cell chamber 240. As used herein, cell exit location 370 means a location at which the purified aluminum of the purified aluminum layer 120 exits the cell chamber 240 (e.g., as facilitated by the directing feature 350).
[0107] With continued reference to FIG. 1, the electrolytic cell 1 may include an extraction port 235, a cell access channel 160 penetrating the cell chamber 240, and a feeding port 170. In some embodiments, the cell access channel 160 provides access to the lower portion of the cell chamber 240. In some other embodiments, the cell access channel 160 provides access to the upper portion of the cell chamber 240. The aluminum feedstock 180 may be added into the cell chamber 240 of the electrolytic cell 1 via the feeding port 170. The purified aluminum of the purified aluminum layer 120 may be extracted external to the electrolytic cell 1 via the extraction port 235. In one embodiment, the electrolytic cell 1 includes an inert gas inlet formed in the refractory top cover 40 configured to provide an inert atmosphere to the cell chamber.
[0108] FIGS. 2 and 3 illustrate another embodiment of an electrolytic cell 1 that includes a directing feature 350 configured to transport liquid metal (e.g., purified aluminum of a purified aluminum layer 120) in the absence of a purposefully applied electric current. In one embodiment, the liquid metal comprises a purified aluminum layer 120. As noted above, in some embodiments, one or more substrates may comprise the one or more directing features 350. Such one or more substrates may be one or more of any of the substrates described herein (e.g., 202, 302, 402, 502, 602, 702, 802, 902). In one embodiment, the purified aluminum layer 120 comprises purified aluminum. In one embodiment, the electrolytic cell 1 is an aluminum purification cell. As illustrated, the electrolytic cell 1 includes a base 10, an outer shell 20, refractory sidewalls 30, a refractory top cover 40, a cell bottom 60 located proximal the base 10, wherein the cell bottom 60 has an upper surface 80 and a lower surface 70. The electrolytic cell 1 includes an anode connector 50 in electrical communication with the cell bottom 60. The anode connector 50 is configured to connect to an external power source. The electrolytic cell 1 includes at least one anode 90 extending upward from the cell bottom 60, a cathode connector 140 located proximal the refractory top cover 40, and at least one cathode 150 extending downward from the cathode connector 140. In some embodiments, the at least one cathode 150 or the at least one anode 90 are oriented in a generally vertical direction. In some embodiments, the at least one cathode 150 or the at least one anode 90 are oriented in a generally horizontal direction. The at least one cathode 150 may overlap the at least one anode 90.
[0109] With continued reference to FIGS. 2 and 3, the electrolytic cell 1 includes a cell chamber 240. The cell chamber 240 is configured to hold the liquid metal (e.g., purified aluminum layer 120), the electrolyte 110, and the molten metal pad 100. In one embodiment, the cell chamber 240 is at least partially defined by the refractory top cover 40, the refractory sidewalls 30, and the cell bottom 60 located proximal to a base 10. A cell exit location 370 is located at least proximal to a refractory sidewall 30 of the cell chamber 240.
[0110] With continued reference to FIGS. 2 and 3, in some embodiments, the electrolytic cell 1 includes an overflow passage 250 extending from the cell chamber 240 to a purified metal reservoir 260 located internal to the electrolytic cell 1. The electrolytic cell 1 may include a tapping port 230 and a feeding port 170. One or both of the tapping port 230 and the feeding port 170 may be located in the refractory top cover 40. The feeding port 170 connects to a feeding reservoir 270. The tapping port 230 connects to the purified metal reservoir 260. The purified metal reservoir 260 and the feeding reservoir 270 are located within a hermetically sealed environment of the electrolytic cell 1. The aluminum feedstock 180 may be fed into the molten metal pad 100 of the electrolytic cell 1 via the feeding reservoir 270. The purified aluminum from the purified aluminum layer 120 can be removed from the purified metal reservoir 260 via the tapping port 230.
[0111] With reference to FIGS. 1-3, as noted above, the electrolytic cell 1 includes one or more directing features 350 configured to transport the liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As noted above, in some embodiments, one or more substrates may comprise the one or more directing features 350. Such one or more substrates may be one or more of any of the substrates described herein (e.g., 202, 302, 402, 502, 602, 702, 802, 902). In one embodiment, the liquid metal comprises a purified aluminum layer 120. In one embodiment, the purified aluminum layer 120 comprises purified aluminum. In one embodiment, the directing feature 350 is aluminum wettable. In one embodiment, the directing feature 350 transports the liquid metal in a predetermined direction. The directing feature 350 can take many shapes and sizes. In some embodiments, the directing feature can be slots, grooves, pores, or combinations thereof. In one embodiment, the directing feature 350 is located proximal to the purified aluminum 120. The directing feature may be in fluid communication with the purified aluminum 120 and the cell exit location 370. The directing feature 350 may include a ceramic, a cermet, or combinations thereof. In some embodiments, the ceramic is one of a TiB.sub.2, a ZrB.sub.2, a HfB.sub.2, or a combination or mixture containing one or more of these. The directing feature 350 may be oriented in a horizontal direction, a vertical direction, a sloped direction, or combinations thereof. The directing feature 350 may be partially submerged in the purified aluminum layer 120, fully submerged in the purified aluminum layer 120, or combinations thereof. The directing feature 350 may be partially submerged in the electrolyte 110 or not submerged in the electrolyte 110. In some embodiments, the directing feature 350 is in contact with an at least one refractory sidewall 30. In one embodiment, the directing feature 350 is in contact with both refractory sidewalls 30. In one embodiment, the directing feature 350 is attached to the at least one refractory sidewall 30. The directing feature may be attached to the at least one refractory sidewall 30 mechanically, adhesively, or combinations thereof. In some other embodiments, the directing feature 350 is not in contact with the at least one refractory sidewall 30.
[0112] Without being bound by any particular mechanism or theory, it is believed that when an electric current is supplied to the at least one anode 90, which current flows through the molten metal pad (e.g., through electrolyte, etc.), due to potential caused by the electrical flow, aluminum metal from the molten metal pad 100 moves up the surface of the at least one anode 90 and is anodized via the at least one anode 90. Aluminum ions are produced by the anodization and may be transported through the electrolyte 110 onto the surface of the at least one cathode 150. At least some of the aluminum ions may be reduced via the at least one cathode 150, thereby producing the purified aluminum 120 on the surface of the at least one cathode 150. The purified aluminum 120 may collect as a top layer above the electrolyte 110. The purified aluminum layer 120 may collect as a top layer above the electrolyte 110 by being transported via the directing feature 350 or by moving up the surface of the cathode 150 due to the density of the purified aluminum 120 relative to the layer of electrolyte 110. The purified aluminum of the purified aluminum layer 120 may be transported via the directing feature 350 from the cell chamber 240 to the cell exit location 370. The purified aluminum of the purified aluminum layer 120 may be extracted external to the electrolytic cell 1 via the extraction port 235 or may be removed from the purified metal reservoir 260 via the tapping port 230.
[0113] FIG. 4a illustrates another embodiment of the electrolytic cell 1 that includes one substrate 125 comprising one or more directing features 350 configured to transport liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As illustrated, the one substrate 125 is oriented in a generally horizontal direction. As illustrated by the arrows, the one or more directing features 350 transports purified aluminum of the purified aluminum layer 120 to the cell exit location 370. Additional pressure and/or additional directing feature material (not illustrated) may be used with overflow passage 250 to facilitate movement of the purified liquid metal to the purified metal reservoir 260.
[0114] FIG. 4b illustrates another embodiment of the electrolytic cell 1 that includes a plurality of substrates 125 comprising directing features 350 configured to transport liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As illustrated, one of the plurality of substrates 125 is oriented in a generally horizontal direction, and one of the plurality of substrates 125 is oriented in a generally vertical direction. As illustrated by the arrows, the one or more directing features 350 transport the purified aluminum of the purified aluminum layer 120 to and through the cell exit location 370 and then to the purified metal reservoir 260.
[0115] FIG. 4c illustrates another embodiment of the electrolytic cell 1 that includes a plurality of substrates 125 comprising one or more directing features 350 configured to transport liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As illustrated, the plurality of substrates 125 are oriented in a generally horizontal direction. As illustrated, one of the plurality of substrates 125 is at least partially submerged in the purified aluminum layer 120. As illustrated by the arrows, the one or more directing features 350 transport the purified aluminum of the purified aluminum layer 120 to the cell exit location 370.
[0116] FIG. 4d illustrates another embodiment of the electrolytic cell 1 that includes a plurality of substrates 125 comprising one or more directing features 350 configured to transport liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As illustrated, the electrolytic cell 1 includes a cell wall 130. As illustrated, the plurality of substrates 125 are oriented in a generally horizontal direction. As illustrated by the arrows, the one or more directing features 350 transport the purified aluminum of the purified aluminum layer 120 to the cell exit location 370 through the cell wall 130. Additional pressure and/or additional directing feature material (not illustrated) may be used with overflow passage 250 to facilitate movement of the purified liquid metal to the purified metal reservoir 260.
[0117] FIG. 4e illustrates another embodiment of the electrolytic cell 1 that has one substrate 125 comprising one or more directing features 350/330 configured to transport liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As illustrated, the one substrate 125 is oriented in a generally horizontal direction. As illustrated by the arrows, the one or more directing features 350 transport the purified aluminum of the purified aluminum layer 120 to and through the cell exit location 370. As illustrated, the purified aluminum of the purified aluminum layer 120 then drips from one or more tapered members 330 (e.g., cones, finials, or similar type objects) and towards the direction of the molten metal pad 100 and then moves into the purified metal reservoir 260. In one embodiment, the purified aluminum 120 drips from at least one tapered member 330. In one embodiment, the purified aluminum 120 drips from one tapered member 330. In one embodiment, the purified aluminum 120 drips from a plurality of tapered members 330.
[0118] With continued reference to FIGS. 3 and 4e, the one or more tapered members 330 (e.g., cone, finial, or similar type object) may be of any shape and/or size that facilitates gravitational movement of the purified aluminum 120 towards the direction of the molten metal pad 100. The one or more tapered members 330 may be of any of the materials described herein for the directing feature 350 (e.g., ceramic, a cermet, or combinations thereof). The one or more tapered members 330 may by symmetrical or non-symmetrical. The dimensions (e.g., length, width, and height) of the plurality of tapered members 330, when present, may vary or may not vary from one another. Similarly, the distance between the plurality of tapered members 330, when present, may vary or may not vary from one another. The dripping of the purified aluminum 120 from the one or more tapered members 330 may be continuous or discontinuous. In one embodiment, the purified aluminum 120 drips from one or more tapered member 330 into the cell exit location 370.
[0119] FIG. 5a illustrates another embodiment of the electrolytic cell 1 that includes a plurality of substrates 125 comprising one or more directing features 350 configured to transport liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As illustrated, four of the plurality of substrates 125 are at least partially submerged in the electrolyte 110 and are oriented in a generally vertical direction. As illustrated, one of the plurality of substrates 125 is oriented in a generally horizontal direction. As illustrated by the arrows, the one or more directing features 350 transport the purified aluminum of the purified aluminum layer 120 to the cell exit location 370.
[0120] FIG. 5b illustrates another embodiment of the electrolytic cell 1 that includes a single substrate 125 comprising one or more directing features 350 configured to transport liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As illustrated, four portions of the substrate 125 are oriented in a generally vertical direction and are at least partially submerged in the electrolyte 110. As illustrated, one portion of the substrate 125 is oriented in a generally horizontal direction. As illustrated by the arrows, the one or more directing features 350 transport the purified aluminum of the purified aluminum layer 120 to the cell exit location 370.
[0121] FIG. 5c illustrates another embodiment of the electrolytic cell 1 that includes a plurality of substrates 125 comprising one or more directing features 350 configured to transport liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As illustrated, five of the plurality of substrates 125 is oriented in a generally vertical direction and four of the plurality of substrates 125 is at least partially submerged in the electrolyte 110. As illustrated by the arrows, the one or more directing features 350 transport the purified aluminum of the purified aluminum layer 120 to and through the cell exit location 370 and to the purified metal reservoir 260.
[0122] FIG. 5d illustrates another embodiment of the electrolytic cell 1 that includes a single substrate 125 comprising one or more directing features 350 configured to transport liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As illustrated, five portions of the single substrate 125 are oriented in a generally vertical direction. As illustrated, four portions of the single substrate 125 are at least partially submerged in the electrolyte 110. As illustrated by the arrows, the one or more directing features 350 transport the purified aluminum of the purified aluminum layer 120 to and through the cell exit location 370 and to the purified metal reservoir 260.
[0123] FIG. 6a illustrates another embodiment of the electrolytic cell 1 that includes a plurality of substrates 125 comprising one or more directing features 350 configured to transport liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As illustrated, one of the plurality of substrates 125 is of an irregular shape and is oriented in a sloped direction. As illustrated, one of the plurality of substrates 125 is oriented in a generally horizontal direction. As illustrated by the arrows, the one or more directing features 350 transport the purified aluminum of the purified aluminum layer 120 to the cell exit location 370.
[0124] FIG. 6b illustrates another embodiment of the electrolytic cell 1 that includes a single substrate 125 comprising one or more directing feature 350 configured to transport liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As illustrated, the single substrate is oriented in a generally horizontal direction. As illustrated, the single substrate 125 does not contact one refractory sidewall 30 of the electrolytic cell 1. In one embodiment, at least one substrate 125 contacts both refractory sidewalls 30 of the electrolytic cell 1. As illustrated by the arrows, the one or more directing features 350 transport the purified aluminum of the purified aluminum layer 120 towards the cell exit location 370.
[0125] FIG. 6c illustrates another embodiment of the electrolytic cell 1 that includes a plurality of substrates 125 comprising one or more directing features 350 configured to transport liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As illustrated, two of the plurality of substrates are oriented in a generally horizontal direction, and one of the plurality of substrates 125 is oriented in a generally vertical direction. As illustrated by the arrows, the one or more directing features 350 transport the purified aluminum of the purified aluminum layer 120 to the cell exit location 370.
[0126] FIG. 6d illustrates another embodiment of the electrolytic cell 1 that includes a plurality of substrates 125 comprising one or more directing feature 350 configured to transport liquid metal (e.g., purified aluminum of the purified aluminum layer 120) in the absence of a purposefully applied electric current. As illustrated, one of the plurality of substrates 125 is oriented in a generally horizontal direction, and one of the plurality of substrates 125 is oriented in a sloped direction. As illustrated by the arrows, the one or more directing features 350 transport the purified aluminum of the purified aluminum layer 120 to the cell exit location 370.
[0127] With reference to FIGS. 1-6, the one or more substrates 125 may comprise one or more of any of substrates described herein (e.g., 202, 302, 402, 502, 602, 602, 602, 602, 602, 602 , 702, 702, 802, 802, 902).
[0128] With reference to FIGS. 1-6, the one or more directing features 350 may comprise one or more of any of the directing features described herein (e.g., 206, 306, 406, 406A, 406B, 406C, 504, 606, 606A, 606B, 606C, 606A, 606A, 606A, 606, 706, 706, 806, 806, 904).
ii. Directing Feature Embodiments
[0129] FIG. 7A is a perspective view of an embodiment a substrate 202 (e.g., a TiB.sub.2 substrate) having a plurality of slots 206 as directing features. The slots 206 are defined by prongs 204. The substrate 202 also includes a base 208 and a tip 210. The slots 206 are configured to direct wettable material in a predetermined direction. The wettable material can include aluminum, such as an aluminum alloy, metallic aluminum, and combinations thereof.
[0130] FIG. 7B is a first side view of FIG. 7A. FIG. 7B shows a side view of 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 include a variety of geometries including a point, a rounded curvature, or a jagged edge, among others.
[0131] FIG. 7C is a partial top view of FIG. 7A as indicated by the dashed lines in FIG. 7A. The partial top view only shows some of the prongs 204. That is, FIG. 7C 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.
[0132] FIG. 8A is a front view of an embodiment of a substrate 302 (e.g., a TiB.sub.2 substrate) 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 substrate 302 also includes a base 308 and a tip 310. The slots 306 are configured to direct wettable material in a predetermined direction. A width (w) of the prongs is also shown.
[0133] FIG. 8B is a top view of a cross-sectional along the dashed line 8B as shown in FIG. 8A. FIG. 8B 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. 8C is a first side view of FIG. 8A. FIG. 8C displays a length (l) of the prongs 304.
[0134] FIGS. 7A-7C and FIGS. 8A-8C will be described together, which are similar. The embodiment of FIGS. 7A-7C differ from the embodiment of FIGS. 8A-8C in the number of prongs 204/304, the number of slots 206/306, and thickness (t) of the prongs 204/304.
[0135] The dimensions of the slots 206/306 may be 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.
[0136] 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).
[0137] The slots 206/306 extend through a thickness of the substrate 202/302. The number of slots can vary. In some embodiments, there can be one slot as shown in the examples of FIG. 8A, FIG. 8B, and FIG. 8C. There can also be two or more slots. The number of slots can vary depend on the intended application of the substrate 202/302. In the example shown in FIG. 7A, FIG. 7B, and FIG. 7C, there are six slots, although any number of slots may be used.
[0138] The substrate 202/302 can be at least partially covered in solid aluminum metal (e.g., prior to use in an electrolytic cell). The slots 206/306 may be the directing feature for the substrate 202/302. Other directing features can be included with the substrate 202, such as grooves, pores, and combinations thereof. The solid aluminum may convert to liquid aluminum as the substate is heated, such as during start-up and/or normal operations of an electrolytic cell. The solid and/or liquid aluminum may at least partially protect one or more surfaces of the substrate from attack by other material. In one embodiment, the solid and/or liquid aluminum at least partially protected one or more surfaces of the substrate from attack by an electrolytic bath of the electrolytic cell.
[0139] The substrate 202/302 can be a solid geometric form. The geometric form can include at least one of rectangle-shaped, square-shaped, triangle-shaped, oval-shaped, or oblong-shaped. The substrate 202/302 can also be a non-symmetrical form. The substrate 202/302 can also be in the form of a plate. The substrate 202/302 can use the slots 206/306, the directing feature, to direct wettable material via capillary action.
[0140] The substrate 202/302 can be used in a variety of applications. In some embodiments, the substrate 202/302 can be configured for use in an aluminum purification cell or for use in an aluminum electrolysis cell. One example of an aluminum purification cell can be found in commonly owned U.S. Pat. No. 10,407,786, entitled Systems and Methods for Purifying Aluminum, and filed on Feb. 11, 2016. One example of an aluminum electrolysis cell can be found in commonly owned U.S. Patent Publication No. 2017/0283968, entitled Apparatuses and Systems for Vertical Electrolysis Cells, and filed on Mar. 30, 2017.
[0141] FIG. 9A is a front view of an embodiment of a substrate 402 (e.g., a TiB.sub.2 substrate) having a plurality of grooves 406 as directing features. FIG. 9B is a first side view of FIG. 9A. FIG. 9C is a partial top view of FIG. 9A as indicated by the dashed lines in FIG. 9A. FIG. 9D is an alternative configuration of the plurality of grooves as shown in FIG. 9C.
[0142] The grooves 406 extend partially into the substrate 402. The dimensions of the grooves 406 may be predetermined. In some embodiments, a size and/or a shape of the grooves 406 may be 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 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.
[0143] As shown in FIG. 9C, the directing feature includes at least two grooves 406 in the substrate 402. Specifically, the directing feature includes three grooves 406. FIG. 9C shows a first groove 406A, a second groove 406B, a third groove 406C (collectively, grooves 406).
[0144] 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 substrate 402, not only on the front side and back side as shown in FIG. 9C. FIG. 9D shows a first groove 406A, a second groove 406B, a third groove 406C (collectively, grooves 406). FIG. 9D shows alternative dimensions and arrangement of the grooves 406 as compared to the grooves 406 of FIG. 9C. FIG. 9C 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 substrate 402. FIG. 9D 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 substrate 402. The third groove 406C is the smallest groove and extends less than halfway through the substrate 402.
[0145] FIG. 10A is a side view of another embodiment of a substrate 502 (e.g., a TiB.sub.2 substrate) having a plurality of pores 504 as directing features. FIG. 10B is a close-up view of FIG. 10A. As shown in FIG. 10A, the substrate is a web of material (e.g., web of TiB.sub.2). The pores 504 are defined by the substrate 502, the web of material. The directing features can be a porosity of the substrate 502. The porosity of the substrate 502 can range from about 1 pore 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).
[0146] FIG. 11A is a perspective view of an embodiment of a substrate 602 (e.g., TiB.sub.2 substrate) having a plurality of slots 606 as directing features and a solid aluminum metal 612 covering the substrate 602. The substrate 602 includes prongs 604, a base 608, and a tip 610. FIG. 11B is a first side view of FIG. 11A. FIG. 11C is a partial top view of FIG. 11A as indicated by the dashed lines in FIG. 11A. The embodiments shown in FIGS. 7A, 7B, and 7C 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 FIGS. 6A, 6B, and 6C includes the solid aluminum metal 612. For FIGS. 11A, 11B, and 11C, similar features of FIGS. 7A, 7B, and 7C will not be repeated. FIG. 11A and FIG. 11B 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.
[0147] In some embodiments, the solid aluminum metal 612 at least partially covers the surface of the 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 substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 5% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 10% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 15% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 20% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 25% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 30% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 35% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 40% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 45% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 50% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 55% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 60% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 65% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 70% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 75% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 80% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 85% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 90% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 95% of the surface of the substrate 602. In some embodiments, the solid aluminum metal 612 covers at least 100% of the surface of the substrate 602.
[0148] 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.
[0149] Varying amounts of the solid aluminum metal 612 are shown occupying the slots 606 and the substrate 602 in the embodiments shown in FIGS. 11A-11N.
[0150] FIG. 11D is a side view of an embodiment of a substrate 602 having a plurality of slots 606A as directing features and a solid aluminum metal 612 covering an upper portion of the substrate 602. FIG. 11E is a partial top view of a cross-sectional along the dashed line 11E as shown in FIG. 11D 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 substrate 602 where there is solid aluminum metal 612. FIG. 11F is a partial top view of a cross-sectional along the dashed line 11F as shown in FIG. 11D 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 substrate 602 where there is no solid aluminum metal 612.
[0151] FIG. 11G is a side view of an embodiment of a substrate 602 having a plurality of slots 606Aas directing features and a solid aluminum metal 612 covering half of the substrate 602, the front portion. The solid aluminum metal 612 covers the front half of the base 608 and the tip 610. FIG. 11H is a partial top view of a cross-sectional along the dashed line 11H as shown in FIG. 11G 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.
[0152] FIG. 11I is a side view of an embodiment of a 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. 11J is a partial top view of a cross-sectional along the dashed line 11J as shown in FIG. 11I where only one of the slots 606A of the plurality of slots 606A is shown. In the embodiment of FIGS. 111 and 11J, there is no solid aluminum metal 612 on the exterior surface of the substrate 602. The solid aluminum metal 612 completely fills the slot volume of the slot 606A.
[0153] FIG. 11K is a front view of an embodiment of a 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. 11L is a first side view of FIG. 11K showing the 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.
[0154] For slot 606A, the slot length does not extend to the tip 610 of the 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.
[0155] FIG. 11M is a front view of an embodiment of a 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. 11N is a first side view of FIG. 11M with the second portion 624 of the surface area 620 being absent of any directing feature.
[0156] The substrate 602 comprises a surface area 620, wherein a first portion 622 of the surface area 620 comprises the at least one directing feature, and wherein a second portion 624 of the surface area 620 is absent of any directing feature.
[0157] 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.
[0158] 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.
[0159] 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 comprises 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.
[0160] FIG. 12A is a front view of an embodiment of a substrate 702 (e.g., TiB.sub.2 substrate) having a slot 706 as a directing feature and a solid aluminum metal 712 covering the substrate 702. A first prong 704A and a second prong 704B define the slot 706 extending upward from the base 708. FIG. 12B is a top view of a cross-sectional along the dashed line 12B as shown in FIG. 12A. FIG. 12C is a first side view of FIG. 12A.
[0161] FIG. 12D, is a front view of an embodiment of a 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. 12E is a top view of a cross-sectional along the dashed line 12E as shown in FIG. 12D. As shown in FIG. 12E, 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. 12F is a first side view of FIG. 12F.
[0162] The embodiment shown in FIGS. 12D, 12E, and 12F and the embodiment shown in FIGS. 12A, 12B, and 12C are the same or similar except for differences discussed herein. For example, the amount of solid aluminum metal 712/712 covering the substrate 702/702 differs between the embodiments. For the embodiment of FIGS. 12A, 12B, and 12C, the solid aluminum metal 712 covers almost the entirety of the 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. 12D, 12E, and 12F have no solid aluminum metal 712 on the exterior of the substrate 702. Only a portion of the slot 706 is filled with solid aluminum metal 712.
[0163] The embodiments of FIGS. 12A, 12B, 12C, 12D, 12E, and 12F are the same or similar as the embodiment of FIGS. 8A, 8B, and 8C. One difference is that FIGS. 8A, 8B, and 8C are not shown with solid aluminum metal. The description of the solid aluminum metal from the embodiments of FIGS. 11A-11N also applies to the solid aluminum metal of FIGS. 12A-12F.
[0164] FIG. 13A is a front view of an embodiment of a substrate 802 (e.g., TiB.sub.2 substrate) having a plurality of grooves 806 as directing features and a solid aluminum metal 812 covering the substrate 802. FIG. 13B is a first side view of FIG. 13A. FIG. 13C is a partial top view of FIG. 13A as indicated by the dashed lines in FIG. 13A. FIG. 13C includes a view of a first groove 806A, a second groove 806B, and a third groove 806C.
[0165] FIG. 13D is a front view of an embodiment of a substrate 802 having a plurality of grooves 806 as directing features and a solid aluminum metal 812 covering half of the substrate 802, the front portion. FIG. 13E is a first side view of FIG. 13D. FIG. 13F is a partial top view of FIG. 13D as indicated by the dashed lines in FIG. 13F.
[0166] The embodiment shown in FIGS. 13D, 13E, and 13F and the embodiment shown in FIGS. 13A, 13B, and 13C are the same or similar except for differences discussed herein. For example, the amount of solid aluminum metal 812/812 covering the substrate 802/802 differs between the embodiments. For the embodiment of FIGS. 13A, 13B, and 13C, the solid aluminum metal 812 is completely covering the substrate 802. In contrast, the solid aluminum metal 812 in FIGS. 13D, 13E, and 13F only covers the front half of the substrate 802.
[0167] The embodiments of FIGS. 13A, 13B, 13C, 13D, 13E, and 13F are the same or similar as the embodiment of FIGS. 9A, 9B, 9C and 9D. One difference is that FIGS. 9A, 9B, 9C, and 4D are not shown with solid aluminum metal. FIGS. 13A, 13B, 13C, 13D, 13E, and 13F are shown with solid aluminum metal 812/812. The description of the solid aluminum metal 612/712 from the embodiments of FIGS. 11A-11N and 12A-12F also applies to the solid aluminum metal 812/812 of FIGS. 13A-13F.
[0168] For FIGS. 13A-13F, 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.
[0169] FIG. 14 is a close-up view of an embodiment of a substrate 902 (e.g., TiB.sub.2 substrate) with pores 904 and solid aluminum metal 906, in accordance with some embodiments. In some embodiments, the substrate 902 is a web of material (e.g., web of TiB.sub.2).
[0170] In some embodiments, solid aluminum metal 906 at least partially covers surfaces of the substrate 902. In some embodiments, the web of the substrate 902 defines pores 904 of the web of material.
[0171] In some embodiments, the solid aluminum metal 906 comprises a porosity. When a solid aluminum metal 906 is filled in the pores 904, the solid aluminum metal 906 may be at an elevated temperature. 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.
[0172] An aluminum purification cell or an aluminum electrolysis cell can include any of the substrates described herein. In some embodiments, at least one of the substrates is an electrode for the aluminum purification cell or the aluminum electrolysis cell. In some embodiments, at least one of the 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.
[0173] In some embodiments, 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.
iii. EXAMPLES
Example 1Lab-Scale Testing
Manufacture of Porous TiB.sub.2 Substrates (TiB.sub.2 Foams)
[0174] 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. 15 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.
Water Wetting Test
[0175] As shown in FIG. 16, 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 capitally action had occurred.
Infiltration of TiB.SUB.2 .Foams With Aluminum Metal
[0176] 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) 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.
[0177] 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. 17, 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.
[0178] After 48 hours of testing at 900 C., as shown in FIG. 18A and FIG. 18B, 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
[0179] 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
[0180] 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 TiB2 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.
[0181] 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. 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.
[0182] Although the embodiments disclosed herein relate generally to the purification of aluminum, it is anticipated that the embodiments of the present disclosure apply to purification of other elements and/or compounds as well. For example, the embodiments of the present disclosure can, alternatively or in addition to, relate to the purification of magnesium. In some embodiments, the systems, products, and/or methods of the present disclosure relate to a magnesium purification cell for producing purified magnesium from a magnesium feedstock. As used herein, magnesium feedstock means material having a sufficient amount of magnesium to produce a purified magnesium, and purified magnesium means material having a greater amount of magnesium than the magnesium feedstock. The foregoing embodiments are exemplary embodiments of the device, systems, or methods of the present disclosure and are therefore not to be considered limiting of its scope, for the device, systems, and methods of the present disclosure may admit to other equally effective embodiments.
