Systems and methods of protecting electrolysis cells

Abstract

Broadly, the present disclosure relates to sidewall features (e.g. inner sidewall or hot face) of an electrolysis cell, which protect the sidewall from the electrolytic bath while the cell is in operation (e.g. producing metal in the electrolytic cell).

What is claimed is: 
     
         1 . An apparatus, comprising:
 an electrolysis cell is provided, comprising:
 an anode; 
 a cathode in spaced relation from the anode; 
 a molten electrolyte bath in liquid communication with the anode and the cathode; 
 a cell body comprising a sidewall and a bottom,
 wherein the cell body is configured to retain the molten electrolyte bath; 
 wherein the sidewall comprises:
 a polarized sidewall portion, and 
 a non-polarized sidewall portion; wherein the non-polarized sidewall portion is configured to extend out from the sidewall and provide a stepped configuration, wherein the non-polarized sidewall portion comprises a stable material; 
 
 
   
       wherein the polarized sidewall portion and the non-polarized sidewall portion are adjacent to each other and wherein the non-polarized sidewall portion and the polarized sidewall portion are configured in liquid communication with the molten electrolyte bath. 
     
     
         2 . The apparatus of  claim 1 , wherein the polarized sidewall portion is one of:
 an anodically polarized sidewall, a cathodically polarized sidewall, and combinations thereof.   
     
     
         3 . The apparatus of  claim 2 , wherein the polarized sidewall portion comprises:
 a cathodically polarized sidewall, wherein the cathodically polarized sidewall is positioned below the bath-vapor interface and adjacent to the bottom of the cell body such that the cathodically polarized sidewall is in liquid communication with the bottom of the cell.   
     
     
         4 . The apparatus of  claim 1 , wherein the polarized sidewall portion comprises:
 at least 50% of surface of the inner sidewall.   
     
     
         5 . The apparatus of  claim 1 , further comprising:
 a non-polarized sidewall portion, wherein both the polarized sidewall portion and the non-polarized sidewall portion are adjacent to each other and in liquid communication with the molten electrolyte bath.   
     
     
         6 . The apparatus of  claim 1 , wherein the non-polarized sidewall portion is positioned above the cathodically polarized sidewall and is in communication with the bath-air interface. 
     
     
         7 . The apparatus of  claim 1 , wherein the non-polarized sidewall portion is selected from the group consisting of:
 a thermal conductor; a frozen ledge device, and combinations thereof.   
     
     
         8 . The apparatus of  claim 7 , wherein when the non-polarized sidewall portion comprises the thermal conductor, wherein the thermal conductor is adjacent to the polarized sidewall portion and in liquid communication with at least one of: (a) a metal pad and (b) a cell bottom, wherein the thermal conductor is configured to accept heat from the molten electrolyte bath adjacent to a thermal conductor contact point, wherein, via the thermal conductor, a frozen ledge is formed between the thermal conductor and molten electrolyte bath along the portion of the sidewall where the thermal conductor contacts the molten electrolyte. 
     
     
         9 . The apparatus of  claim 7 , wherein the non-polarized sidewall is configured to extend from the cell bottom to a height above a metal-to-bath interface, further wherein the non-polarized sidewall portion is configured adjacent to and in communication with an anodically polarized sidewall. 
     
     
         10 . The apparatus of  claim 7 , wherein the non-polarized sidewall portion is configured to extend out from the sidewall and provide a stepped configuration, wherein the non-polarized sidewall portion comprises a stable material. 
     
     
         11 .- 25 . (canceled)