Method for Producing Aluminum and Method for Producing a Gas-Tight Electrode for Carbothermic Reduction Furnace

Abstract

A method for producing aluminum and a method for producing a graphite electrode for a carbothermic reduction furnace, in which aluminum is produced by carbothermic reduction of alumina, render the graphite electrode substantially gas-impermeable. The graphite electrode is consumed during furnace operation and electrode columns connected by graphite pins are fed continuously fed in from the top into the furnace. The coating of the electrode withstands a temperature of up to 300° C. and more over a period of several hours without oxidation. Since the coating enters the furnace compartment at least partially, it is configured so that it will not contaminate the hot melt. That is, the chemistry of the coating materials is similar to the ingredients of the overall reaction or, at a minimum, the amount of foreign elements is very low. The coating is provided so that it does not increase the electrical contact resistance at the connection between the electrode columns and the electrode holding clamps. Where the electrode inlet area is cooled by water, the coating is insoluble in water.

1 . A method for producing aluminum by carbothermic reduction of alumina, the method comprising the following steps:
 placing a coating on a shaped graphite electrode body of a graphite electrode, the coating defining a CO permeability of the electrode body to less than 10 −6  cm 2 /sec and being substantially insoluble in water;   placing the graphite electrode having the shaped graphite electrode body in a furnace for producing aluminum by carbothermic reduction of alumina; and   producing aluminum by carbothermic reduction of alumina in the furnace.   
     
     
         2 . The method according to  claim 1 , wherein the coating is configured to withstand temperatures of up to 300° C. and above for several hours substantially without oxidation. 
     
     
         3 . The method according to  claim 1 , wherein the coating is configured to no more than negligibly increase an electrical resistance of the electrode body at a holding region at which the electrode body is held by electrode clamps in the furnace. 
     
     
         4 . The method according to  claim 1 , wherein the coating is configured not to contaminate a melt in the furnace containing alumina, aluminum carbide, carbon, and carbon monoxide. 
     
     
         5 . The method according to  claim 1 , wherein the coating is a thermally decomposed pyrolytic carbon coating. 
     
     
         6 . The method according to  claim 1 , wherein the coating is a glassy carbon coating. 
     
     
         7 . The method according to  claim 1 , wherein the coating is formed from a high-temperature-coked resin. 
     
     
         8 . The method according to  claim 1 , wherein the coating is formed of phenolic resin, novolak resin, formic aldehyde, or epoxy resin. 
     
     
         9 . The method according to  claim 1 , wherein the coating is a sodium silicate layer. 
     
     
         10 . The method according to  claim 1 , wherein the coating is formed from metallic Al applied on an Al-containing pre-coating layer. 
     
     
         11 . The method according to  claim 1 , wherein the coating is formed from a sol or gel coating layer based on Al or Al oxide particles. 
     
     
         12 . A method of producing a graphite electrode for a furnace for producing aluminum by carbothermic reduction of alumina, the method which comprises:
 providing a graphite electrode body; and   coating at least a part of the graphite electrode body to adjust a CO permeability thereof to less than 10 −6  cm 2 /sec.   
     
     
         13 . The method according to  claim 12 , which comprises coating the electrode body with pyrolytic carbon employing thermal decomposition techniques. 
     
     
         14 . The method according to  claim 12 , which comprises coating the electrode body with glassy carbon. 
     
     
         15 . The method according to  claim 12 , which comprises forming a coating by applying resins with high-temperature coking behavior on the electrode body, and coking the resins to form a substantially CO-impermeable coating. 
     
     
         16 . The method according to  claim 12 , which comprises coating the electrode body with sodium silicate. 
     
     
         17 . The method according to  claim 12 , which comprises coating the electrode body with an Al-containing pre-coating layer and applying metallic Al on the pre-coating layer. 
     
     
         18 . The method according to  claim 12 , which comprises applying a sol or a gel based on Al or Al oxide particles on the electrode body. 
     
     
         19 . The method according to  claim 18 , which comprises, prior to the applying step, applying a pre-coating layer based on 2 to 5% silicon in aluminum, and subsequently heat-treating the electrode in an inert atmosphere to approximately 900° C. 
     
     
         20 . A method for producing aluminum by carbothermic reduction of alumina, the method comprising the following steps:
 placing a coating on a shaped graphite electrode body of a graphite electrode for reducing a CO permeability of the electrode body to less than 10 −6  cm 2 /sec, the coating having a major constituent element selected from the group consisting of Al and C;   placing the graphite electrode having the shaped graphite electrode body in a furnace for producing aluminum by carbothermic reduction of alumina; and   producing aluminum by carbothermic reduction of alumina in the furnace.