EP2809833B1 - Procédé de fabrication d'un bloc cathodique pour une cellule d'électrolyse de l'aluminium - Google Patents

Procédé de fabrication d'un bloc cathodique pour une cellule d'électrolyse de l'aluminium Download PDF

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Publication number
EP2809833B1
EP2809833B1 EP13702626.6A EP13702626A EP2809833B1 EP 2809833 B1 EP2809833 B1 EP 2809833B1 EP 13702626 A EP13702626 A EP 13702626A EP 2809833 B1 EP2809833 B1 EP 2809833B1
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Prior art keywords
coke
hard material
layer
type
cathode
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Application number
EP13702626.6A
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German (de)
English (en)
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EP2809833A1 (fr
Inventor
Martin Kucher
Frank Hiltmann
Janusz Tomala
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Tokai Cobex GmbH
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Tokai Cobex GmbH
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    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
    • C25C3/00—Electrolytic production, recovery or refining of metals by electrolysis of melts
    • C25C3/06—Electrolytic production, recovery or refining of metals by electrolysis of melts of aluminium
    • C25C3/08—Cell construction, e.g. bottoms, walls, cathodes

Definitions

  • the present invention relates to a method for producing a cathode block as a multilayer block for an aluminum electrolytic cell.
  • a well-known process for the production of metallic aluminum is the Hall-Heroult process.
  • the bottom of an electrolytic cell is typically formed by a cathode surface, which consists of individual cathode blocks.
  • the cathodes are contacted from below via steel bars which are inserted into corresponding elongated recesses in the underside of the cathode blocks.
  • cathode blocks are conventionally carried out by mixing coke with carbon-containing particles such as anthracite, carbon or graphite, compacting and carbonizing. If necessary, this is followed by a graphitization step at higher temperatures, at which the carbon-containing particles and the coke are at least partially converted into graphite.
  • a carbon cathode is obtained which consists at least partially of graphite.
  • the service life of the cathode blocks is limited by a number of influences.
  • TiB 2 can obviously improve the wetting behavior of aluminum on the cathode and additionally contributes to higher hardness and wear resistance. Nevertheless, the wear resistance of a TiB 2 layer on a carbon cathode and a composite layer of carbon and TiB 2 is still too low, and thus the wear resistance of cathode blocks provided with corresponding layers is also too low.
  • the object of the present invention is therefore to provide an improved method for producing a cathode block as a multilayer block, this method reducing the production times and scrap rates of the cathode blocks and the cathode blocks produced having improved wear resistance and a longer service life.
  • the object is achieved by a method according to claim 1.
  • the carbonized green body is not impregnated prior to graphitization, in particular not impregnated with pitch, tar or synthetic resins.
  • the graphitization step at least a portion of carbon in the cathode block is converted into graphite.
  • a higher bulk density presumably contributes advantageously to a longer service life.
  • this can be due to the fact that there is more mass per unit volume of a cathode block, which for a given mass removal per unit of time leads to a higher residual mass after a given removal period.
  • it can be assumed that a higher bulk density with a corresponding corresponding lower porosity hinders the infiltration of electrolyte, which acts as a corrosive medium.
  • the two types of coke advantageously include a first type of coke and a second type of coke, the first type of coke having a greater shrinkage or expansion than the second type of coke during carbonization and / or graphitization and / or cooling.
  • the greater shrinkage and / or expansion is an advantageous embodiment of a different volume change behavior, which is probably particularly well suited to lead to greater compression than when coke types are mixed that have the same shrinkage and / or expansion.
  • the greater shrinkage and / or expansion relates to any temperature range. Thus, for example, there can only be a greater shrinkage of the first coke during carbonization. On the other hand, there can be, for example, additionally or instead a greater expansion in a transition area between carbonizing and graphitizing. Instead, or in addition, there may be different volume change behavior during cooling.
  • the shrinkage and / or expansion of the first coke type during carbonization and / or graphitization and / or cooling is preferably at least 10% higher in terms of volume than that of the second coke type, in particular at least 25% higher, in particular at least 50% higher.
  • the shrinkage from room temperature to 2000 ° C. for the second type of coke is 1.0% by volume, whereas for the first type of coke it is 1.1% by volume.
  • the shrinkage and / or expansion of the first type of coke during carbonization and / or graphitization and / or cooling is advantageously at least 100% higher in terms of volume than that of the second type of coke, in particular at least 200% higher, in particular at least 300% higher.
  • the expansion from room temperature to 1000 ° C. for the second type of coke is 1.0% by volume, whereas for the first type of coke it is 4.0% by volume.
  • the second type of coke may have greater shrinkage and / or expansion, as described above for the first type of coke, in at least any temperature range of the method according to the invention.
  • At least one of the two types of coke is preferably a petroleum or coal tar pitch coke.
  • the proportion by weight of the second type of coke in the total amount of coke is preferably between 50% and 90%, in particular between 50 and 80%.
  • Conceivable quantity ranges for the second type of coke can be 50 to 60%, but also 60 to 80% and 80 to 90%.
  • At least one further carbonaceous material and / or additives and / or pulverulent hard material are advantageously added to the coke. This can be advantageous both with regard to the processability of the coke and the subsequent properties of the cathode block produced.
  • the further carbon-containing material preferably contains graphite-containing material; in particular, the further carbon-containing material consists of graphite-containing material, such as graphite.
  • the graphite can be synthetic and / or natural graphite. Such a further carbonaceous material is achieved that the necessary shrinkage of the cathode mass, which is dominated by the coke, is reduced.
  • the further carbon-containing material is advantageously 1 to 40% by weight, in particular 5 to 30% by weight, based on the total amount of coke and further carbon-containing material.
  • Pitch can preferably be added in amounts of 5 to 40% by weight, in particular 15 to 30% by weight (based on the weight of the entire green mixture). Pitch acts as a binding agent and is used to create a dimensionally stable body during carbonization.
  • Advantageous additives can be oil, such as pressing oil, or stearic acid. These make it easier to mix the coke and, if necessary, the other components.
  • TiB 2 powder is used as the hard material in powder form.
  • the use of such a hard material increases the wettability of the cathode with respect to the aluminum melt.
  • the proportion of this hard material in the mixture of starting materials is between 15% by weight and 60% by weight, in particular between 20% by weight and 50% by weight.
  • the cathode block is produced as a multilayer block, a first layer containing coke as starting materials and possibly a further carbonaceous material and a second layer containing coke and a refractory hard material, in particular TiB 2 , as starting materials and optionally another carbonaceous material.
  • Hard material is also known as RHM (refractory hard material).
  • the further carbon-containing material can be present as described above for a monolithic cathode block.
  • the second layer always has a high density of more than 1.82 g / cm 3 after graphitization due to the addition of high-temperature resistant hard material, it is advantageous if the first layer also has a high density of more than 1.68 g / cm 3 after graphitization. cm 3 .
  • the small differences in the thermal expansion behavior and bulk densities during the heat treatment steps reduce production times and reject rates of the cathode blocks, since large differences in the layers can lead to thermal stresses during temperature treatment. Furthermore, the resistance to thermal stresses and the damage resulting therefrom in use is therefore also advantageously increased.
  • the multilayer block can optionally be advantageous for the multilayer block to have more than two layers.
  • any number of the layers of the more than two layers can be produced according to the invention, each with two types of coke with different volume change behavior.
  • the second layer can advantageously have a height which is 10 to 50%, in particular 15 to 45%, of the total height of the cathode block.
  • a small height of the second layer such as about 20%, can be advantageous since a small amount of more expensive hard ceramic material is required.
  • a large height of the second layer such as about 40%, can be advantageous, since a layer comprising hard ceramic material has a high wear resistance. The greater the height of this highly wear-resistant material in relation to the total height of the cathode block, the higher the wear resistance of the entire cathode block.
  • the hard material is in a monomodal particle size distribution, the mean particle size of the distribution d 50 being between 10 and 20 ⁇ m, preferably between 12 and 18 ⁇ m, more preferably between 14 and 16 ⁇ m.
  • the d 50 value indicates the mean particle size, with 50% of the particles here being smaller than the stated value. Accordingly, the d 10 or d 90 value indicates the mean particle size, with 10 or 90% of the particles being smaller than the specified value.
  • the hard material powder used according to the invention has particularly good flowability or pourability. This makes the hard material powder particularly easy to convey using conventional conveying devices, for example to a mixing apparatus.
  • the cathode blocks obtained have very good homogeneity with regard to the distribution of the hard material powder in the coke in the green body and in the graphite in the graphitized cathode body.
  • the d 90 of the refractory hard material is preferably between 20 and 40 ⁇ m, in particular between 25 and 30 ⁇ m. This has the advantageous consequence that the wetting and processing properties of the hard material powder are even better.
  • the d 10 of the refractory hard material is advantageously between 2 and 7 ⁇ m, in particular between 3 and 5 ⁇ m. This has the advantageous consequence that the wetting and processing properties of the hard material powder are even better.
  • the chip of the refractory hard material powder is advantageously between 0.65 and 3.80, in particular between 1.00 and 2.25. This advantageously has the consequence that The wetting and processing properties of the hard material powder are even better.
  • the graphitizing step is advantageously carried out at temperatures between 2550 and 3000 ° C., in particular between 2600 and 2900 ° C.
  • the graphitization process has progressed so far that the carbon-containing material has a high thermal and electrical conductivity.
  • the graphitization step is preferably carried out with an average heating rate between 90 K / h and 200 K / h. Alternatively or additionally, the graphitization temperature is maintained for a period between 0 and 1 hour. With these heating rates or this holding time, particularly good results are achieved with regard to graphitization and preservation of the hard material.
  • the duration of the temperature treatment up to the point in time at which cooling begins can advantageously be 10 to 28 hours.
  • a first and a second coke are ground separately from one another, separated into grain size fractions and mixed with one another with pitch.
  • the proportion by weight of the first coke in the total amount of coke can be, for example, 10 to 20% by weight or 40 to 45% by weight.
  • a cathode block can be made from the green mix by extrusion. Alternatively, the mixture can, for example, be poured into a mold that largely corresponds to the later shape of the cathode blocks and vibration-compacted or block-pressed.
  • the resulting green body is heated to a final temperature in a range of 2550 to 3000 ° C, with a carbonization step and then a graphitization step, without any intervening impregnation, for example with pitch, tar or synthetic resin, and then cooled.
  • the resulting cathode block has a bulk density of 1.71 g / cm 3 and is very wear-resistant to liquid aluminum and cryolite.
  • Fig. 1 shows a dilatometer measurement curve of the first type of coke (with dashed line) during the graphitization process.
  • Fig. 1 also shows a corresponding measurement curve (with a solid line) for the second type of coke. It can be seen that the two types of coke have different volume change behavior.
  • the first coke out Fig. 1 shows, starting from a zero line at the beginning of the temperature program up to a temperature of 2800 ° C, initially an expansion, with an increase in volume up to approx. 1200 ° C and a temporary decrease in volume after approx. 1400 ° C. Up to approx. 2100 ° C, a maximum increase in volume can then be seen compared to the initial volume.
  • two types of coke are used, the first of which already shrinks during the heating phase in the carbonization and / or graphitization step.
  • the second of the two types of coke has a significantly greater shrinkage (based on the shrinkage after carbonization, graphitization and cooling compared to the initial volume) than the other type of coke.
  • graphite powder or carbon particles are added to the coke mixture.
  • a mold 1 is first partially filled with a mixture 2 of the two types of coke, graphite and TiB 2 , and vibration-compacted, as in FIG Fig. 2a ) indicated. Subsequently, a mixture 5 of the two types of coke and graphite is poured onto the resulting starting layer 4, which in the later cathode will be the upper layer facing the anodes and will therefore have direct contact with the aluminum melt, and then compacted again (see Fig Figure 2b ). The resulting upper starting layer 6 represents the lower one in the later cathode Layer that faces away from the anode.
  • This two-layer block is carbonized and graphitized as in the first embodiment.
  • different types of coke can also include cokes from the same manufacturer but different pretreatment, such as differently calcined cokes.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Electrolytic Production Of Metals (AREA)
  • Ceramic Products (AREA)

Claims (9)

  1. Procédé de fabrication d'un bloc cathodique sous la forme d'un bloc multicouche, comportant les étapes de
    a) fourniture d'un mélange de matières de départ, comprenant du coke et du brai, le coke comprenant deux types de coke qui possèdent un comportement de changement de volume différent pendant la carbonisation et/ou la graphitisation et/ou le refroidissement, une première couche contenant éventuellement une autre matière carbonée comme matière de départ et une seconde couche contenant une matière dure réfractaire, en particulier le TiB2, comme matière de départ, et éventuellement une autre matière carbonée,
    b) formage des couches en un corps vert et
    c) carbonisation du corps vert et graphitation du corps vert carbonisé sans l'imprégner au préalable afin d'obtenir un corps graphité, ainsi que refroidissement après graphitisation, la matière dure de l'étape a) étant présente dans une distribution granulométrique monomodale, comportant un d50 compris entre 10 et 20 µm, et la première couche comportant, à l'étape c) après graphitisation, une densité brute d'une proportion de carbone supérieure à 1,68 g/cm3 et la seconde couche comportant une densité brute supérieure à 1,82 g/cm3.
  2. Procédé selon la revendication 1, caractérisé en ce que la seconde couche présente une hauteur qui représente 10 à 50 %, en particulier 15 à 45 %, de la hauteur totale du bloc cathodique.
  3. Procédé selon la revendication 1 ou 2, caractérisé en ce que le d50 de la matière dure est compris entre 12 et 18 µm, en particulier entre 14 et 16 µm.
  4. Procédé selon l'une ou plusieurs des revendications 1 à 3, caractérisé en ce que le d90 de la matière dure réfractaire est compris entre 20 et 40 µm, en particulier entre 25 et 30 µm.
  5. Procédé selon l'une ou plusieurs des revendications 1 à 4, caractérisé en ce que le d10 de la matière dure réfractaire est compris entre 2 et 7 µm, en particulier entre 3 et 5 µm.
  6. Procédé selon l'une ou plusieurs des revendications 1 à 5, caractérisé en ce que les deux types de coke comprennent un premier type de coke et un second type de coke, le premier type de coke présentant une contraction ou une expansion plus importante pendant la carbonisation et/ou la graphitisation et/ou le refroidissement que le second type de coke.
  7. Procédé selon l'une ou plusieurs des revendications 1 à 6, caractérisé en ce que la proportion de quantité en pourcentage poids du second type de coke dans la quantité totale de coke est comprise entre 50 % et 90 %.
  8. Procédé selon l'une ou plusieurs des revendications 1 à 7, caractérisé en ce que la matière dure, comme en particulier le TiB2, est présente dans le mélange des matières de départ dans une proportion comprise entre 15 % et 60 % en poids, en particulier entre 20 % et 50 % en poids.
  9. Procédé selon l'une ou plusieurs des revendications 1 à 8, caractérisé en ce que l'étape de graphitisation est réalisée à des températures comprises entre 2 550 °C et 3 000 °C, en particulier entre 2 600 et 2 900 °C.
EP13702626.6A 2012-02-01 2013-01-31 Procédé de fabrication d'un bloc cathodique pour une cellule d'électrolyse de l'aluminium Active EP2809833B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102012201468A DE102012201468A1 (de) 2012-02-01 2012-02-01 Verfahren zur Herstellung eines Kathodenblocks für eine Aluminium-Elektrolysezelle und einen Kathodenblock
PCT/EP2013/051940 WO2013113837A1 (fr) 2012-02-01 2013-01-31 Procédé de fabrication d'un bloc cathodique pour une cellule d'électrolyse de l'aluminium

Publications (2)

Publication Number Publication Date
EP2809833A1 EP2809833A1 (fr) 2014-12-10
EP2809833B1 true EP2809833B1 (fr) 2020-12-30

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EP (1) EP2809833B1 (fr)
JP (1) JP6018227B2 (fr)
CN (1) CN104126032A (fr)
CA (1) CA2862277C (fr)
DE (1) DE102012201468A1 (fr)
RU (1) RU2666806C2 (fr)
UA (1) UA112676C2 (fr)
WO (1) WO2013113837A1 (fr)

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Publication number Priority date Publication date Assignee Title
CA3179900A1 (fr) * 2020-04-24 2021-10-28 Norsk Hydro Asa Ensemble cathode pour une cellule hall-heroult pour la production d'aluminium et procede de fabrication associe
EP4143368B1 (fr) * 2020-04-30 2024-03-13 Norsk Hydro ASA Blocs cathodiques pour la production électrolytique d'aluminium et procédé pour la production de ceux-ci

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Publication number Publication date
DE102012201468A1 (de) 2013-08-01
CA2862277A1 (fr) 2013-08-08
JP6018227B2 (ja) 2016-11-02
CN104126032A (zh) 2014-10-29
JP2015511273A (ja) 2015-04-16
UA112676C2 (uk) 2016-10-10
RU2666806C2 (ru) 2018-09-12
CA2862277C (fr) 2016-10-25
WO2013113837A1 (fr) 2013-08-08
RU2014135212A (ru) 2016-03-27
EP2809833A1 (fr) 2014-12-10

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