Products, systems, and methods for transporting metals

Abstract

This disclosure relates to a product, system, and method for producing a refined liquid metal (e.g., refined aluminum) from a feedstock (e.g., an aluminum feedstock) in an electrolytic cell (e.g., a refining cell), by refining the feedstock and moving the refined liquid metal from a first position to a second position in the cell via at least one induction feature. The at least one induction feature is electrically neutral and can be located near the first position. The at least one induction feature may be in fluid communication with the refined liquid metal (e.g., refined aluminum) and the second position.

Description

Background Art

[0001] Aluminum has traditionally been produced from alumina (Al2O3) derived from bauxite ore. The conversion of alumina (Al2O3) to aluminum has typically been carried out by a smelting process that involves dissolving alumina (Al2O3) in cryolite, which is a molten solvent, and then passing an electric current through the mixture to cause carbon from a carbon anode to combine with the oxygen component in the dissolved alumina (Al2O3), producing aluminum and carbon dioxide as a byproduct. Various attempts have been made to purify aluminum by the "Hoopes process" (see U.S. Patent No. 1,534,315) and the method described in International Patent Application No. WO2016 / 130823 of the present applicant.

Summary of the Invention

[0002] Broadly speaking, the present disclosure relates to products, systems, and methods for transporting purified liquid metal. In one embodiment, the purified liquid metal is obtained by purifying a feedstock within an electrolytic cell to produce the purified liquid metal and moving the purified liquid metal from a first location to a second location different from the first location via one or more directing features. The purification step and the acquisition step may be performed in any order, sequentially, simultaneously, or contemporaneously. In one embodiment, the directing features include a wettable material with respect to the purified liquid metal. For example, liquid aluminum metal "wets" titanium diboride to form a contact angle of 90 degrees or less. Such a wettable material may be used to move the purified liquid metal from the first location to the second location by utilizing capillary action and / or a predetermined dripping arrangement, which will be described later.

[0003] The first location and the second location may be any suitable location related to the electrolytic cell. In one approach, the first location is a location related to the location of the first volume of purified liquid metal (e.g., the location where the purified liquid metal is produced within the electrolytic cell). In one embodiment, the first location is related to the cell chamber of the electrolytic cell.

[0004] As mentioned above, the second position is spaced apart from the first position. In one embodiment, the second position is a target position (desired position) for the refined liquid metal (for example, a position where the refined liquid metal is not produced in the cell, but it is desired to move the refined liquid metal to this position). The target position may be any position related to the electrolytic cell. In one embodiment, the target position may be located inside or partially inside the electrolytic cell. In other embodiments, the target position may be located outside the electrolytic cell. In one embodiment, the target position is related to one or more outlets of the electrolytic cell. In one embodiment, the target position is related to a refractory component of the electrolytic cell. In one embodiment, the target position may be in proximity to a refractory component of the electrolytic cell. In one embodiment, the refractory component is a refractory side wall of the electrolytic cell, a refractory cover of the electrolytic cell, or both. In one embodiment, the target position is a refined metal reservoir, which may be located inside, partially inside, or outside the electrolytic cell.

[0005] As described above, one or more guide features may be used to move the refined liquid metal from a first position to a second position. In one embodiment, the guide feature is in liquid communication with both the first and second positions. In one embodiment, the guide feature facilitates the movement of the refined liquid metal by capillary action (wicking) and / or a predetermined dropping configuration (e.g., via a tapered member), or a combination thereof. In one embodiment, the guide feature facilitates the movement of the refined liquid metal by capillary action. In another embodiment, the guide feature facilitates the movement of the refined liquid metal by a predetermined dropping configuration. In yet another embodiment, the guide feature facilitates the movement of the refined liquid metal by both capillary action and a predetermined dropping configuration.

[0006] In one embodiment, at least one guiding feature includes a material that is wettable to the refined liquid metal. For example, the first guiding feature may include a material that is wettable to the refined liquid metal, such as titanium diboride to refined aluminum metal. In one embodiment, at least one guiding feature includes a non-wetting material. For example, the first guiding feature may include a wettable material that can move the refined liquid metal in a predetermined direction by utilizing capillary action. The second guiding feature may include a non-wetting material so that different forces act on the refined liquid metal to move it in a predetermined direction. For example, a tapered member or other shape may be used to create a predetermined dropping arrangement without the surface of the tapered member (or other shape) being wetted by the refined liquid metal.

[0007] The guide feature may be any preferred shape that facilitates the movement of the refined liquid metal from a first position to a second position. Preferred shapes include one or more slots, one or more grooves, pores (porosity), one or more tapered members, and combinations thereof. In one embodiment, the guide feature includes a slot. In one embodiment, the slot defines a channel through which the refined liquid metal moves, for example, from the inlet to the outlet of the slot. In another embodiment, the guide feature includes a groove. In yet another embodiment, the guide feature includes a pore (e.g., porosity of a controlled size). In yet another embodiment, the guide feature includes a tapered member. Any combination of slots, grooves, pores, and tapered members may be used. Slots, grooves, pores, and / or tapered members may be of any suitable size and / or shape, insofar as their guiding features facilitate movement from a first position to a second position (e.g., via predetermined sizing and / or shape to produce a suitable capillary action and / or a predetermined dripping action with respect to refined liquid metal).

[0008] As described above, multiple guide feature sections may be used. In one embodiment, the spacing between guide feature sections is uniform. In other embodiments, the spacing between guide feature sections is non-uniform. In one embodiment, the first guide feature section is located near the second guide feature section. In one embodiment, the first guide feature section is located adjacent to the second guide feature section (for example, when the first and second guide feature sections work together to move the refined liquid metal). In one embodiment, the movement of the refined liquid metal through the first and second guide feature sections may be continuous movement, i.e., uninterrupted movement from a first position to a second position using the first and second guide feature sections. In one embodiment, the movement of the refined liquid metal through the first and second guide feature sections may be discontinuous movement, i.e., interrupted movement from a first position to a second position using the first and second guide feature sections. In other embodiments, the movement of the refined liquid metal through the first and second guide features may be discontinuous, i.e., a broken movement from a first position to a second position using the first and second guide features. In other embodiments, the first guide feature is positioned spaced apart from the second guide feature (for example, when the first and second guide features are not operating together to move the refined liquid metal). In one embodiment, the first and second guide features are separate components. In other embodiments, the first and second guide features are integral (for example, forming a single component and / or an integrated structure).

[0009] In one embodiment, the inductive feature section may be electrically neutral (as defined below). In another embodiment, the inductive feature section may be connected to the power supply of the electrolytic cell. Any number of electrically neutral inductive feature sections (if any) may be used in any combination with any number of powered inductive feature sections (if any).

[0010] Although not required, one or more induction features may be manifested via one or more substrates. In one embodiment, one or more induction features manifest via one or more substrates as voids which may be one or more slots, one or more grooves, pores, and combinations thereof. In other embodiments, one or more induction features manifest via one or more solid members, such as one or more tapered members. The substrate may contain any number of induction features in any combination. For example, the substrate may contain any number of slots, grooves, pores, tapered members, and combinations thereof. In one embodiment, the substrate contains one or more slots. In one embodiment, the substrate contains one or more grooves. In one embodiment, the substrate contains pores (porosity). In one embodiment, the substrate contains one or more tapered members. Thus, the substrate may be configured to allow the refined liquid metal to move from a first position to a second position via one or more induction features. In other words, the substrate may be configured such that the refined liquid metal is directed in a predetermined direction via one or more induction features through capillary action and / or predetermined dropping.

[0011] Slots, grooves, and tapered members may be of any suitable size and shape. For example, a slot may be columnar with any suitable cross-section (e.g., circular, elliptical, egg-shaped, or rectangular) that promotes capillary action. Slots may be linear (straight) or nonlinear (curved). Any number of slots may be used. Slots may be the same shape or different shapes. Slots may be the same size or different sizes. Slots may be adjacent to each other or spaced apart. Slots can partially or completely define channels through which the refined liquid metal moves. Other types of guiding features (grooves, porous, tapered members) may be used in conjunction with one or more slots. Such other guiding features may be positioned adjacent to or spaced apart from one or more slots.

[0012] Similarly, the grooves may be of any suitable size and shape. For example, the grooves may be columnar and have any suitable cross-section that promotes capillary action (e.g., any triangular, rectangular, pentagonal, hexagonal, heptagonal, octagonal, oval, elliptical, circular, or other geometric cross-section, the cross-section may be symmetrical or asymmetrical). The grooves may be linear (straight) or nonlinear (curved). Any number of grooves may be used. The grooves may be the same shape or different shapes. The grooves may be the same size or different sizes. The grooves may be adjacent to each other or spaced apart from each other. Other types of guiding features (slots, porous, tapered members) may be used with one or more grooves, and such other guiding features may be positioned adjacent to one or more grooves or spaced apart from them.

[0013] Similarly, porosity may be adjusted. For example, pore size may be adjusted to facilitate capillary action. Porosity may extend substantially linearly through the substrate or nonlinearly through the substrate to facilitate the movement of the refined liquid metal in a given direction. Any amount of porosity may be used, and different pore sizes may be used in different locations to facilitate capillary action / movement of the refined metal in a given direction. For example, a first porous volume may be located in part of the substrate, and a second porous volume may be located elsewhere on that substrate. The first porous volume may have substantially the same pore size as the second porous volume, or the first porous volume may have a different pore size than the second porous volume. The first porous volume may be located adjacent to the second porous volume or spaced apart. Other types of guiding features (slots, grooves, tapered members) may be used with one or more porous volumes, and such other guiding features may be located adjacent to or spaced apart from one or more porous volumes.

[0014] Similarly, the tapered member may be of any suitable size and shape, for example, a size and / or shape that facilitates the movement of the refined liquid metal in a given direction (e.g., by dripping at a given location). In one embodiment, the tapered member includes at least one inclined surface to facilitate the movement of the refined liquid metal in a given direction. In one embodiment, the tapered member includes a single inclined surface (e.g., trapezoidal shape). In other embodiments, the tapered member includes a configuration of multiple inclined surfaces (e.g., triangular, pentagonal, hexagonal, etc.). Any number of tapered members may be used. The tapered members may be the same shape or different shapes. The tapered members may be the same size or different sizes. The tapered members may be adjacent to each other or spaced apart from each other. Other types of guide features (slots, grooves, porosity) can be used with one or more tapered members, and such other guide features may be located adjacent to one or more tapered members or spaced apart from them.

[0015] When a substrate containing one or more induction features is used, the substrate may be of any preferred size and shape, and may be symmetrical or asymmetrical. The substrate may be curved or not. Examples of substrates include blocks, plates, rods, wires, and wool.

[0016] One or more induction feature units and / or substrates may be positioned at any suitable location within the electrolytic cell to facilitate the movement of the refined liquid metal from a first position to a second position. In one embodiment, the induction feature unit and / or substrate is positioned near the upper cover of the electrolytic cell (e.g., a fire-resistant upper cover). In one embodiment, the induction feature unit and / or substrate is positioned near the side wall of the electrolytic cell (e.g., a fire-resistant side wall). In one embodiment, the induction feature unit and / or substrate is positioned near, adjacent to, or at least partially inside the refined metal reservoir of the electrolytic cell. This refined metal reservoir may be positioned inside, partially inside, or outside the electrolytic cell. In one embodiment, the induction feature unit and / or substrate is positioned near, adjacent to, or at least partially inside the molten metal pad of the electrolytic cell. In one embodiment, the induction feature unit and / or substrate is positioned near or adjacent to the cell bottom of the electrolytic cell (e.g., the top surface of the cell bottom, such as the cathode block of a conventional aluminum electrolytic cell or other electrolytic cell structures). In one embodiment, the induction feature and / or substrate is located near or adjacent to one or more outlets of the electrolytic cell. In one embodiment, the induction feature and / or substrate is located near or adjacent to a cell access channel or supply port of the electrolytic cell. In one embodiment, the induction feature and / or substrate is located near, adjacent to, or at least partially inside an internal or external reservoir (e.g., a supply reservoir) of the electrolytic cell. In one embodiment, the induction feature and / or substrate is located near, adjacent to, or at least partially inside an overflow channel of the electrolytic cell.

[0017] One or more induction feature portions and / or substrates may be physically connected to an electrolytic cell. The physical connection may be made in any preferred manner, including one or more mechanical connections, one or more adhesive connections, and combinations thereof. In one embodiment, the physical connection is a mechanical connection. In another embodiment, the physical connection is an adhesive connection. In one embodiment, only a portion of the induction feature portion and / or substrate is physically connected to the electrolytic cell. In another embodiment, the entire surface area of ​​the induction feature portion and / or substrate may be physically connected to the electrolytic cell.

[0018] In one embodiment, at least 10% of the surface area of ​​the induction feature portion and / or substrate is connected to an electrolytic cell. In another embodiment, at least 20% of the surface area of ​​the induction feature portion and / or substrate is connected to an electrolytic cell. In yet another embodiment, at least 30% of the surface area of ​​the induction feature portion and / or substrate is connected to an electrolytic cell. In yet another embodiment, at least 40% of the surface area of ​​the induction feature portion and / or substrate is connected to an electrolytic cell. In yet another embodiment, at least 50% of the surface area of ​​the induction feature portion and / or substrate is connected to an electrolytic cell. In yet another embodiment, at least 60% of the surface area of ​​the induction feature portion and / or substrate is connected to an electrolytic cell. In yet another embodiment, at least 70% of the surface area of ​​the induction feature portion and / or substrate is connected to an electrolytic cell. In yet another embodiment, at least 80% of the surface area of ​​the induction feature portion and / or substrate is connected to an electrolytic cell. In yet another embodiment, at least 90% of the surface area of ​​the induction feature portion and / or substrate is connected to an electrolytic cell. In yet another embodiment, at least 95% of the surface area of ​​the induction feature portion and / or substrate is connected to an electrolytic cell.

[0019] In some embodiments, one or more induction feature units and / or substrates may not be physically connected to the electrolytic cell. For example, the induction feature units and / or substrates may be suspended in the purified liquid metal and / or electrolyte without being physically connected to the electrolytic cell (for example, utilizing buoyancy, the induction feature units and / or substrates float on or inside the purified liquid metal and / or electrolyte of the electrolytic cell). In one embodiment, the induction feature units and / or substrates are at least partially suspended in the purified liquid metal without being physically connected to the electrolytic cell.

[0020] As described above, the induction feature and / or substrate may be in liquid communication with the first position to facilitate the movement of the refined liquid metal in a predetermined direction. In one embodiment, at least one induction feature (or, if any, the corresponding substrate) is partially or completely immersed in the refined liquid metal. By partially or completely immersing the induction feature in the refined liquid metal, the induction feature can facilitate the movement of the refined liquid metal in one or more predetermined directions.

[0021] Similarly, in one embodiment, at least one induction feature (or, if any, a corresponding substrate) is partially or completely immersed in the electrolyte of the electrolytic cell. For example, the purified liquid metal may be adjacent to the electrolyte (e.g., above or below the electrolyte due to differences in density). By partially or completely immersing the induction feature in the electrolyte, fluid communication with the purified liquid metal can be achieved.

[0022] One or more induction feature portions and / or substrates may be oriented in any preferred orientation within the electrolytic cell. For example, the induction feature portions and / or substrates may be oriented horizontally and / or vertically, or at any angle between them (i.e., an inclined angle). In one embodiment, the induction feature portions and / or substrates are oriented vertically (e.g., ±3 degrees relative to perfect vertical). In another embodiment, the induction feature portions and / or substrates are oriented horizontally (e.g., ±3 degrees relative to perfect horizontal). In yet another embodiment, the induction feature portions and / or substrates are oriented in an inclined direction (e.g., 4 to 87 degrees relative to horizontal). Furthermore, if multiple induction feature portions and / or substrates are used, each may be oriented in any preferred orientation. For example, a first induction feature portion or first substrate may have a first orientation (e.g., horizontal), and a second induction feature portion or second substrate may have a second orientation (e.g., non-horizontal, vertical, or any relative angle between non-horizontal and vertical).

[0023] As described above, an electrolytic cell may be used to produce refined metal. In one embodiment, the electrolytic cell is an aluminum refining cell. An example of a suitable aluminum refining cell is described in the applicant's International Publication WO2016 / 130823A1. Another example of an aluminum refining cell is a hoops cell (e.g., described in U.S. Patent No. 1,534,315). Thus, the refined liquid metal may be refined liquid aluminum. In one embodiment, the feedstock is an aluminum-based feedstock. In one embodiment, the feedstock contains at least 50% by weight of metallic or alloyed aluminum. In one embodiment, the feedstock contains at least 5% by weight of copper (e.g., 5 to 25% by weight of copper). In one embodiment, the feedstock generally does not contain oxides and fluorides (e.g., it contains 10% by weight or less of fluorides and / or oxides). In one embodiment, the feedstock contains less than 10% by weight of alumina (aluminum oxide). In other embodiments, the feedstock contains less than 5% by weight of alumina (aluminum oxide). In other embodiments, the feedstock contains less than 3% by weight of alumina (aluminum oxide). In one embodiment, the feedstock contains less than 10% by weight of fluoride-containing material (e.g., cryolite). In other embodiments, the feedstock contains less than 5% by weight of fluoride-containing material (e.g., cryolite). In one embodiment, the feedstock contains less than 3% by weight of fluoride-containing material (e.g., cryolite).

[0024] In other embodiments, the electrolytic cell may be an electrolytic cell suitable for producing aluminum metal from alumina (Al2O3) feedstock (e.g., a Hall-Héroux cell or similar), regardless of whether the electrodes used in the electrolytic process are carbon-based (non-inert) or ceramic / cermet-based (e.g., inert electrodes). An example of an electrolytic cell that may benefit from the induction features and / or substrates described herein is described in the applicant's International Publication WO2017 / 173149.

[0025] Other electrolytic cells may be used. For example, an electrolytic cell for producing magnesium can benefit from the systems, methods, and apparatus disclosed herein, and the magnesium metal may be moved from a first position to a second position using one or more induction features.

[0026] The substrate and / or induced feature portion can be made from any suitable material. In one embodiment, the substrate and / or induced feature portion may include ceramics, cermets, or combinations thereof. In some embodiments, the ceramic is a metallic boride. In some embodiments, the ceramic includes one of titanium diboride (TiB2), zirconium diboride (ZrB2), hafnium diboride (HfB2), and combinations thereof. Such materials can be considered, for example, wettable to refined liquid metals, thereby promoting capillary action. In one embodiment, the substrate or induced feature portion includes titanium diboride. In one embodiment, the substrate or induced feature portion consists essentially of titanium diboride. In one embodiment, the substrate or induced feature portion includes zirconium diboride. In one embodiment, the substrate or induced feature portion consists essentially of zirconium diboride. In one embodiment, the substrate or induced feature portion includes hafnium diboride. In one embodiment, the substrate or induction feature portion is essentially made of hafnium diboride.

[0027] The substrate and / or inductive feature portion may include materials other than ceramics and cermets. In one embodiment, the substrate or inductive feature portion is carbonaceous (carbon-based). Such a substrate and / or inductive feature portion may be useful when capillary action is not required and / or when it is desired to impart a new / different force to a refined liquid metal. In one embodiment, the carbonaceous material contains graphite or is essentially composed of graphite.

[0028] Ceramics, cermets, carbonaceous, and non-carbonaceous materials can be used in any combination as a substrate, with a substrate, as an induction feature, or with an induction feature. For example, the substrate may include a carbonaceous base and a ceramic coating (e.g., a graphite substrate having a titanium diboride coating). The coating may be used to cover part or all of the substrate or the induction feature to facilitate the movement of the refined liquid metal in a predetermined direction.

[0029] These and other aspects of the present disclosure are provided in the following description and the accompanying drawings.

Brief Description of the Drawings

[0030] [Figure 1] FIG. 1 is a schematic cross-sectional side view of one embodiment of an electrolytic cell 1 for transporting liquid metal (e.g., refined aluminum of the refined aluminum layer 120) to a cell outlet position 370 via an induction feature 350 according to the present disclosure.

[0031] [Figure 2] FIG. 2 is a schematic cross-sectional side view of another embodiment of an electrolytic cell 1 for transporting liquid metal (e.g., refined aluminum of the refined aluminum layer 120) to a cell outlet position 370 via an induction feature 350 according to the present disclosure.

[0032] [Figure 3] FIG. 3 is an enlarged view of one embodiment of FIG. 2 according to the present disclosure, showing a method of transporting liquid metal (e.g., refined aluminum of the refined aluminum layer 120) to a cell outlet position 370 via an induction feature 350.

[0033] [Figure 4a] FIG. 4a is a partial view of one embodiment of FIG. 2 according to the present disclosure, showing a method of transporting liquid metal (e.g., refined aluminum of the refined aluminum layer 120) to a cell outlet position 370 via an induction feature 350.

[0034] [Figure 4b] Figure 4b is a partial view of another embodiment of Figure 2 relating to the present disclosure, showing a method of transporting liquid metal (e.g., refined aluminum of the refined aluminum layer 120) to a cell outlet position 370 via an induction feature section 350, and then transporting it through the cell outlet position to a refined metal reservoir 260.

[0035] [Figure 4c] Figure 4c is a partial view of yet another embodiment of Figure 2 relating to the present disclosure, showing a method for transporting liquid metal (e.g., refined aluminum in the refined aluminum layer 120) to the cell outlet position 370 via the induction feature section 350.

[0036] [Figure 4d] Figure 4d is a partial view of another embodiment of Figure 2 relating to the present disclosure, showing a method for transporting liquid metal (e.g., refined aluminum in the refined aluminum layer 120) through the cell well 130 to the cell outlet position 370 via the induction feature section 350.

[0037] [Figure 4e] Figure 4e, relating to the present disclosure, is a partial view of yet another embodiment of Figure 2 and illustrates a method for transporting liquid metal (e.g., refined aluminum of the refined aluminum layer 120) through the guide feature section 350 to and through the cell outlet position 370. As shown, the refined aluminum 120 drips from the tapered member 330 toward the molten metal pad and then moves to the refined metal reservoir 260. In some embodiments, one or more non-tapered members (not shown) may be used to facilitate the dripping of the refined aluminum toward the target source.

[0038] [Figure 5a] Figure 5a is a partial view of another embodiment of Figure 2 relating to the present disclosure, showing a method for transporting liquid metal (e.g., refined aluminum in the refined aluminum layer 120) to the cell outlet position 370 via the induction feature section 350.

[0039] [Figure 5b] Figure 5b is a partial view of yet another embodiment of Figure 2 relating to the present disclosure, showing a method for transporting liquid metal (e.g., refined aluminum in the refined aluminum layer 120) to the cell outlet position 370 via the induction feature section 350.

[0040] [Figure 5c] Figure 5c is a partial view of another embodiment of Figure 2 relating to the present disclosure, showing a method for transporting liquid metal (e.g., refined aluminum in the refined aluminum layer 120) through the induction feature section 350 to the cell outlet position 370 and through the cell outlet to the refined metal reservoir 260.

[0041] [Figure 5d] Figure 5d is a partial view of yet another embodiment of Figure 2 relating to the present disclosure, showing a method of transporting liquid metal (e.g., refined aluminum of the refined aluminum layer 120) to a cell outlet position 370 via an induction feature section 350 and then to a refined metal reservoir 260 through the cell outlet.

[0042] [Figure 6a] Figure 6a is a partial view of another embodiment of Figure 2 relating to the present disclosure, showing a method for transporting liquid metal (e.g., refined aluminum in the refined aluminum layer 120) to the cell outlet position 370 via the induction feature section 350.

[0043] [Figure 6b] Figure 6b is a partial view of yet another embodiment of Figure 2 relating to the present disclosure, showing a method for transporting liquid metal (e.g., refined aluminum in the refined aluminum layer 120) to the cell outlet position 370 via the induction feature section 350.

[0044] [Figure 6c] Figure 6c is a partial view of another embodiment of Figure 2 relating to the present disclosure, showing a method for transporting liquid metal (e.g., refined aluminum in the refined aluminum layer 120) to the cell outlet position 370 via the induction feature section 350.

[0045] [Figure 6d] Figure 6d is a partial view of yet another embodiment of Figure 2 relating to the present disclosure, showing a method for transporting liquid metal (e.g., refined aluminum in the refined aluminum layer 120) to the cell outlet position 370 via the induction feature section 350.

[0046] [Figure 7A] Figure 7A is a perspective view of one embodiment of a substrate 202 (for example, a TiB2 substrate) having a plurality of slots 206 as induction feature areas.

[0047] [Figure 7B] Figure 7B is a first side view of Figure 7A.

[0048] [Figure 7C] Figure 7C is a partial top view of Figure 7A, indicated by a dashed line in Figure 7A.

[0049] [Figure 8A] Figure 8A is a front view of one embodiment of a substrate 302 having a slot 306 as an induction feature portion.

[0050] [Figure 8B] Figure 8B is a top view of the cross-section along the dashed line 8B shown in Figure 8A.

[0051] [Figure 8C] Figure 8C is a first side view of Figure 8A.

[0052] [Figure 9A] Figure 9A is a front view of one embodiment of a substrate 402 having a plurality of grooves 406 as induction feature portions.

[0053] [Figure 9B] Figure 9B is a first side view of Figure 9A.

[0054] [Figure 9C]Figure 9C is a partial top view of Figure 9A, indicated by the dashed line in Figure 9A.

[0055] [Figure 9D] Figure 9D shows alternative configurations for the multiple grooves 406A', 406B', and 406C' shown in Figure 9C.

[0056] [Figure 10A] Figure 10A is a side view of another embodiment of a substrate 502 having a plurality of pores 504 as induction feature areas.

[0057] [Figure 10B] Figure 10B is an enlarged view of Figure 10A.

[0058] [Figure 11A] Figure 11A is a perspective view of one embodiment of a substrate 602 having a plurality of slots 606 as induction feature portions, and a solid aluminum metal 612 covering the substrate 602.

[0059] [Figure 11B] Figure 11B is a first side view of Figure 11A.

[0060] [Figure 11C] Figure 11C is a partial top view of Figure 11A, indicated by the dashed line in Figure 11A.

[0061] [Figure 11D] Figure 11D is a side view of one embodiment of a substrate 602' having a plurality of slots 606A' as induction feature portions, and a solid aluminum metal 612' covering the upper part of the substrate 602'.

[0062] [Figure 11E] Figure 11E is a partial top view of a cross-section along the dashed line 11E shown in Figure 11D, showing only one of the multiple slots 606A'. The cross-section is along the top of a substrate containing solid aluminum metal.

[0063] [Figure 11F] Figure 11F is a partial top view of a cross-section along the dashed line 11F shown in Figure 11D, showing only one of the multiple slots 606A'. The cross-section is along the bottom of the substrate 602' where the solid aluminum metal 612' is absent.

[0064] [Figure 11G] Figure 11G is a side view of one embodiment of a substrate 602'' having a plurality of slots 606A'' as induction feature portions, and a solid aluminum metal 612'' covering the front half of the substrate 602''.

[0065] [Figure 11H] Figure 11H is a partial top view of a cross-section along the dashed line 11H shown in Figure 11G, showing only one of the multiple slots 606A''.

[0066] [Figure 11I] Figure 11I is a side view of one embodiment of a substrate 602'''' having a base 608'''' and a tip 610'''', with a plurality of slots 606A'''' and solid aluminum metal 612'''' within the plurality of slots 606A'''' as induction feature portions.

[0067] [Figure 11J] Figure 11J is a partial top view of a cross-section along the dashed line 11J shown in Figure 11I, showing only one of the multiple slots 606A'''.

[0068] [Figure 11K] Figure 11K is a front view of one embodiment of a substrate 602'''' having a plurality of slots 606A, 606B, and 606C (collectively referred to as slots 606'''') as induction feature portions, and a solid aluminum metal 612'''' that covers or does not cover part of the slots 606.

[0069] [Figure 11L] Figure 11L is a first side view of Figure 11K.

[0070] [Figure 11M] Figure 11M is a front view of one embodiment of a substrate 602'''''' having a surface area of ​​620'''''', which includes a first portion 622'''''' having a surface area of ​​620'''''' with a plurality of slots 606'''''' as induction feature portions, and a second portion 624'''''' having a surface area of ​​620'''''' without induction feature portions.

[0071] [Figure 11N] Figure 11N is a first side view of Figure 11M in which the induction feature is absent in the second portion 624''''' of the surface area.

[0072] [Figure 12A] Figure 12A is a front view of one embodiment of a substrate 702 (e.g., a TiB2 substrate) having slots 706 as induction feature portions, and a solid aluminum metal 712 covering the substrate 702.

[0073] [Figure 12B] Figure 12B is a top view of a cross-section along the dashed line 12B shown in Figure 12A.

[0074] [Figure 12C] Figure 12C is a first side view of Figure 12A.

[0075] [Figure 12D] Figure 12D is a front view of one embodiment of a substrate 702' having slots 706' as induction feature portions, and a solid aluminum metal 712' covering a portion of the slots 706'.

[0076] [Figure 12E] Figure 12E is a top view of a cross-section along the dashed line 12E shown in Figure 12D.

[0077] [Figure 12F]Figure 12F is the first side view of Figure 12F.

[0078] [Figure 13A] Figure 13A is a front view of one embodiment of a substrate 802 (for example, a TiB2 substrate) having a plurality of grooves 806 as induction features, and a solid aluminum metal 812 covering the substrate 802.

[0079] [Figure 13B] Figure 13B is a first side view of Figure 13A.

[0080] [Figure 13C] Figure 13C is a partial top view of Figure 13A, indicated by the dashed line in Figure 13A.

[0081] [Figure 13D] Figure 13D is a front view of one embodiment of a substrate 802' having a plurality of grooves 806' as induction feature portions, and a solid aluminum metal 812' covering the front half of the substrate 802'.

[0082] [Figure 13E] Figure 13E is a first side view of Figure 13D.

[0083] [Figure 13F] Figure 13F is a partial top view of Figure 13D, indicated by the dashed line in Figure 13F.

[0084] [Figure 14] Figure 14 is an enlarged view of one embodiment of a substrate 902 (e.g., a TiB2 substrate) having pores 904 and a solid aluminum metal 906, according to several embodiments.

[0085] [Figure 15] Figure 15 is a front view of the final sintered product of the TiB2 foam used in the lab-scale test.

[0086] [Figure 16]Figure 16 shows front views of four TiB2 foam samples used in a lab-scale test, with porosity levels of approximately 10, 20, 30, and 45 pores per inch (PPI).

[0087] [Figure 17] Figure 17 shows schematic cross-sectional side views of three crucibles used in the lab-scale test, each containing four TiB2 foam samples immersed (partially or completely) in molten aluminum for 48 hours.

[0088] [Figure 18A] Figure 18A is a front view of a TiB2 foam sample from a crucible used in a lab-scale test, after being completely immersed in molten aluminum for approximately 48 hours.

[0089] [Figure 18B] Figure 18B is a front view of a TiB2 foam sample from a crucible used in a lab-scale test, after being partially immersed in molten aluminum for approximately 48 hours. [Modes for carrying out the invention]

[0090] <Detailed explanation> This disclosure is further described with reference to the accompanying drawings. In the drawings, similar structures are referenced by the same reference numerals throughout several drawings. The drawings constitute part of this specification and include exemplary embodiments of this disclosure, illustrating various purposes and features of this disclosure. Furthermore, the drawings are not necessarily to scale, and some features may be exaggerated to show details of the components. In addition, any measurements, specifications, etc., shown in the drawings are illustrative and not limiting. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but rather as merely representative grounds to teach those skilled in the art how to utilize this disclosure in various ways.

[0091] Among the advantages and improvements disclosed, other objectives and benefits of this disclosure will become apparent from the following description, which will be interpreted in conjunction with the accompanying drawings. While detailed embodiments of this disclosure are disclosed herein, it should be understood that the disclosed embodiments are merely illustrative examples of the disclosure, which can be embodied in various forms. Furthermore, each of the examples shown in relation to the various embodiments of this disclosure is intended to be illustrative and not limiting.

[0092] Throughout this specification and the claims, unless the context clearly indicates otherwise, the following terms mean as expressly associated herein. The phrases “in one embodiment” and “in some embodiments” as used herein do not necessarily refer to the same embodiment, but may refer to the same embodiment. Furthermore, the phrases “in other embodiments,” “in yet another embodiment,” and “in some other embodiments” as used herein do not necessarily refer to different embodiments, but may refer to the same embodiment. Thus, the various embodiments of this disclosure can be readily combined without departing from the scope or spirit of this disclosure, as described below.

[0093] 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 indicates otherwise. The term "based on" is not exclusive and allows for additional factors not mentioned unless the context clearly indicates otherwise. In addition, throughout this specification, the meanings of "a," "an," and "the" include multiple referents. The meaning of "in" includes "in" and "on."

[0094] As used herein, "aluminum feedstock" refers to material containing a sufficient amount of aluminum to produce refined aluminum products.

[0095] As used herein, "purified aluminum" refers to a material containing a greater amount of aluminum than the raw material used to supply it.

[0096] As used herein, "molten metal pad" refers to a reservoir of molten material located beneath the electrolyte, where the molten material includes aluminum.

[0097] As used herein, "wettable" means that a solid forms / has a static contact angle of 90 degrees or less with respect to the liquid in contact with its surface. In other words, the material is "philic" to the liquid in contact with its surface.

[0098] As used herein, "aluminum wettable" means that the contact angle with molten aluminum is 90 degrees or less.

[0099] As used herein, “electrolyte” refers to a medium through which the flow of electric current is carried out by the movement of ions / ionic species. In one embodiment, the electrolyte may include a molten salt.

[0100] As used herein, "electrically neutral" means that no intentionally applied current is present.

[0101] As used herein, “slot” means a geometric feature extending through the length, width, and / or thickness of a substrate. A slot may define a channel through which refined liquid metal moves, for example, a channel from the entrance of the slot to the exit of the slot.

[0102] As used herein, "groove" refers to a geometric feature that partially extends within the substrate but does not penetrate it.

[0103] As used herein, "geometric feature" means a predetermined shape created within a substrate, examples of which include slots, grooves, and pores having any shape or size. <i. Electrolytic cell having a non-electrical induction feature>

[0104] Refer to the accompanying drawings which at least partially aid in illustrating various relevant features of the products, systems, and methods disclosed herein. Referring to Figure 1, the electrolytic cell 1 includes one or more induction feature units 350 configured to transport liquid metal (e.g., refined aluminum of the refined aluminum layer 120) in the absence of an intentionally applied current. (The induction feature units 350 are described in further detail in Section II.) In some embodiments, one or more substrates include one or more induction feature units 350. These one or more substrates may be one or more of any substrates described herein (e.g., 202, 302, 402, 502, 602, 702, 802, 902). In one embodiment, the liquid metal includes the refined aluminum layer 120. In one embodiment, the refined aluminum layer 120 includes refined aluminum. In one embodiment, the electrolytic cell 1 is an aluminum refining cell. As shown in the illustration, the electrolytic cell 1 includes a base 10, an outer shell 20, a fire-resistant side wall 30, a fire-resistant upper cover 40, and a cell bottom 60 located near the base 10, the cell bottom 60 having an upper surface 80 and a lower surface 70. The electrolytic cell 1 includes an anode connector 50 that is electrically in communication with the cell bottom 60. The anode connector 50 is configured to connect to an external power supply. 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 near the fire-resistant upper cover 40, and at least one cathode 150 extending downward from the cathode connector 140. The cathode connector 140 has an upper connecting rod 146 configured to connect to an external power supply and a lower surface 142. In some embodiments, at least one cathode 150 or at least one anode 90 is generally oriented in a vertical direction. In some embodiments, at least one cathode 150 or at least one anode 90 is generally oriented horizontally. At least one cathode 150 may overlap with at least one anode 90.

[0105] Continuing to refer to Figure 1, the electrolytic cell 1 includes a cell chamber 240. The cell chamber 240 is configured to house a liquid metal (e.g., a refined aluminum layer 120), an electrolyte 110, and a molten metal pad 100. In one embodiment, the cell chamber 240 is at least partially defined by a fire-resistant upper cover 40, fire-resistant side walls 30, and a cell bottom 60 located near the base 10. The cell exit position 370 is located at least near one of the fire-resistant side walls 30 of the cell chamber 240. As used herein, “cell exit position” 370 means the position where the refined aluminum of the refined aluminum layer 120 exits the cell chamber 240 (e.g., facilitated by an induction feature 350).

[0106] Continuing to refer to Figure 1, the electrolytic cell 1 may include an extraction port 235, a cell access channel 160 penetrating the cell chamber 240, and a supply port 170. In some embodiments, the cell access channel 160 provides access to the bottom of the cell chamber 240. In some other embodiments, the cell access channel 160 provides access to the top of the cell chamber 240. Aluminum feed material 180 can be added to the cell chamber 240 of the electrolytic cell 1 via the supply port 170. The purified aluminum of the purified aluminum layer 120 may be extracted to the outside of 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 upper cover 40 and configured to provide an inert atmosphere.

[0107] Figures 2 and 3 show other embodiments of the electrolytic cell 1, which include an induction feature section 350 configured to transport liquid metal (e.g., refined aluminum in the refined aluminum layer 120) in the absence of an intentionally applied current. In one embodiment, the liquid metal includes the refined aluminum layer 120. As described above, in some embodiments, one or more substrates may include one or more induction feature sections 350. These one or more substrates may be one or more of any substrates described herein (e.g., 202, 302, 402, 502, 602, 702, 802, 902). In one embodiment, the refined aluminum layer 120 includes refined aluminum. In one embodiment, the electrolytic cell 1 is an aluminum refining cell. As shown, the electrolytic cell 1 includes a base 10, an outer shell 20, a fire-resistant side wall 30, a fire-resistant upper cover 40, and a cell bottom 60 located near the base 10, the cell bottom 60 having an upper surface 80 and a lower surface 70. The electrolytic cell 1 includes an anode connector 50 that is electrically connected to the cell bottom 60. The anode connector 50 is configured to connect to an external power supply. The electrolytic cell 1 includes at least one anode 90 extending upward from the cell bottom 60, a cathode connector 140 located near the fire-resistant upper cover 40, and at least one cathode 150 extending downward from the cathode connector 140. In some embodiments, at least one cathode 150 or at least one anode 90 is generally oriented vertically. In some embodiments, at least one cathode 150 or at least one anode 90 is generally oriented horizontally. At least one cathode 150 may overlap with at least one anode 90.

[0108] Continuing to refer to Figures 2 and 3, the electrolytic cell 1 includes a cell chamber 240. The cell chamber 240 is configured to house a liquid metal (e.g., a refined aluminum layer 120), an electrolyte 110, and a molten metal pad 100. In one embodiment, the cell chamber 240 is at least partially defined by a fire-resistant upper cover 40, fire-resistant side walls 30, and a cell bottom 60 located near the base 10. The cell outlet position 370 is located at least near the fire-resistant side walls 30 of the cell chamber 240.

[0109] Continuing to refer to Figures 2 and 3, in some embodiments, the electrolytic cell 1 includes an overflow channel 250 extending from the cell chamber 240 to a refined metal reservoir 260 located inside the electrolytic cell 1. The electrolytic cell 1 may also include a tapping port 230 and a supply port 170. One or both of the tapping port 230 and the supply port 170 may be located in a fire-resistant upper cover 40. The supply port 170 is connected to the supply reservoir 270. The tapping port 230 is connected to the refined metal reservoir 260. The refined metal reservoir 260 and the supply reservoir 270 are located within the sealed environment of the electrolytic cell 1. Aluminum feed material 180 may be supplied to the molten metal pad 100 of the electrolytic cell 1 via the supply reservoir 270. Refined aluminum from the refined aluminum layer 120 can be taken out of the refined metal reservoir 260 via the tapping port 230.

[0110] Referring to Figures 1 to 3, as described above, the electrolytic cell 1 includes one or more induction feature sections 350 configured to transport liquid metal (e.g., refined aluminum of the refined aluminum layer 120) in the absence of intentionally applied current. As described above, in some embodiments, one or more substrates may include one or more induction feature sections 350. Such one or more substrates may be one or more of any substrates described herein (e.g., 202, 302, 402, 502, 602, 702, 802, 902). In one embodiment, the liquid metal includes the refined aluminum layer 120. In one embodiment, the refined aluminum layer 120 includes refined aluminum. In one embodiment, the induction feature section 350 is aluminum wettable. In one embodiment, the induction feature section 350 transports the liquid metal in a predetermined direction. The induction feature section 350 can take many shapes and sizes. In some embodiments, the induction feature section may be a slot, groove, pore, or a combination thereof. In one embodiment, the induction feature section 350 is located in proximity to the refined aluminum 120. The induction feature portion may be in fluid communication with the refined aluminum 120 and the cell outlet position 370. The induction feature portion 350 may include ceramics, cermets, or a combination thereof. In some embodiments, the ceramic is one of TiB2, ZrB2, HfB2, or a combination or mixture of one or more of these. The induction feature portion 350 may be oriented in a horizontal, vertical, inclined, or combination thereof direction. The induction feature portion 350 may be partially immersed in the refined aluminum layer 120, fully immersed in the refined aluminum layer 120, or a combination thereof. The induction feature portion 350 may be partially immersed in the electrolyte 110, or not immersed in the electrolyte 110. In some embodiments, the induction feature portion 350 is in contact with at least one refractory sidewall 30. In one embodiment, the induction feature portion 350 is in contact with both refractory sidewalls 30. In one embodiment, the induction feature portion 350 is attached to at least one fire-resistant side wall 30. The induction feature portion may be attached to at least one fire-resistant side wall 30 mechanically, by adhesive, or a combination thereof.In some other embodiments, the induction feature portion 350 is not in contact with at least one fire-resistant side wall 30.

[0111] Although not bound by any particular mechanism or theory, it is assumed that when an electric current is supplied to at least one anode 90, and the potential generated by the current causes the current to flow through the molten metal pad (e.g., through an electrolyte), aluminum metal from the molten metal pad 100 rises to the surface of at least one anode 90 and is anodized via at least one anode 90. Aluminum ions are generated by anodization and may be transported through the electrolyte 110 to the surface of at least one cathode 150. At least a portion of the aluminum ions are reduced via at least one cathode 150, thereby generating purified aluminum 120 on the surface of at least one cathode 150. The purified aluminum 120 may be collected as the uppermost layer above the electrolyte 110. The purified aluminum layer 120 can be collected as the uppermost layer above the electrolyte 110 by being transported through the induction feature 350 or by rising to 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 in the purified aluminum layer 120 may be transported from the cell chamber 240 to the cell outlet position 370 via the induction feature section 350. The purified aluminum in the purified aluminum layer 120 may be extracted to the outside of the electrolytic cell 1 via the extraction port 235, or removed from the purified metal reservoir 260 via the tapping port 230.

[0112] Figure 4a shows another embodiment of the electrolytic cell 1, which includes a single substrate 125 having one or more induction feature sections 350 configured to transport liquid metal (e.g., refined aluminum from the refined aluminum layer 120) in the absence of an intentionally applied current. As shown, the single substrate 125 is generally oriented horizontally. As indicated by the arrows, one or more induction feature sections 350 transport the refined aluminum from the refined aluminum layer 120 to the cell outlet position 370. Additional pressure and / or additional induction feature material (not shown) may be used in conjunction with the overflow channel 250 to facilitate the movement of the refined liquid metal to the refined metal reservoir 260.

[0113] Figure 4b shows another embodiment of the electrolytic cell 1, which includes a plurality of substrates 125, each having an induction feature 350 configured to transport liquid metal (e.g., refined aluminum from the refined aluminum layer 120) in the absence of an intentionally applied current. As shown, one of the plurality of substrates 125 is generally oriented horizontally, and another of the plurality of substrates 125 is generally oriented vertically. As indicated by the arrows, one or more induction feature 350 transport the refined aluminum from the refined aluminum layer 120 to the cell outlet position 370, and through the cell outlet position to the refined metal reservoir 260.

[0114] Figure 4c shows another embodiment of the electrolytic cell 1, which includes a plurality of substrates 125, each having one or more induction features 350 configured to transport liquid metal (e.g., refined aluminum from the refined aluminum layer 120) in the absence of an intentionally applied current. As shown, the plurality of substrates 125 are generally oriented horizontally. As shown, at least a portion of one of the plurality of substrates 125 is immersed in the refined aluminum layer 120. As indicated by the arrows, one or more induction features 350 transport the refined aluminum from the refined aluminum layer 120 to the cell exit position 370.

[0115] Figure 4d shows another embodiment of the electrolytic cell 1, which includes multiple substrates 125, each having one or more induction features 350 configured to transport liquid metal (e.g., refined aluminum from the refined aluminum layer 120) in the absence of an intentionally applied current. As shown, the electrolytic cell 1 includes a cell wall 130. As shown, the multiple substrates 125 are generally oriented horizontally. As indicated by the arrows, one or more induction features 350 transport the refined aluminum from the refined aluminum layer 120 through the cell wall 130 to the cell outlet position 370. Additional pressure and / or additional induction feature material (not shown) may be used in conjunction with an overflow channel 250 to facilitate the movement of the refined liquid metal to the refined metal reservoir 260.

[0116] Figure 4e shows another embodiment of the electrolytic cell 1 having a substrate 125 having one or more induction features 350 / 330 configured to transport liquid metal (e.g., refined aluminum from the refined aluminum layer 120) in the absence of an intentionally applied current. As shown, the substrate 125 is generally oriented horizontally. As indicated by the arrows, one or more induction features 350 transport the refined aluminum from the refined aluminum layer 120 to and through the cell outlet position 370. As shown, the refined aluminum from the refined aluminum layer 120 then drips from one or more tapered members 330 (e.g., cones, finials, or similar objects) toward the molten metal pad 100 and then moves toward the refined metal reservoir 260. In one embodiment, the refined aluminum 120 drips from at least one tapered member 330. In one embodiment, the refined aluminum 120 drips from one tapered member 330. In one embodiment, refined aluminum 120 is dropped from a plurality of tapered members 330.

[0117] Continuing with reference to Figures 3 and 4e, one or more tapered members 330 (e.g., cones, finials, or similar objects) may be of any shape and / or size that facilitates the gravity-induced movement of the refined aluminum 120 toward the molten metal pad 100. One or more tapered members 330 may be formed from any material described herein for the induction feature 350 (e.g., ceramics, cermets, or a combination thereof). One or more tapered members 330 may be symmetrical or asymmetrical. If there are multiple tapered members 330, their dimensions (e.g., length, width, and height) may or may not be different from each other. Similarly, if there are multiple tapered members 330, the distances between them may or may not be different from each other. The dripping of the refined aluminum 120 from one or more tapered members 330 may be continuous or discontinuous. In one embodiment, refined aluminum 120 is dropped from one or more tapered members 330 to the cell outlet position 370.

[0118] Figure 5a shows another embodiment of the electrolytic cell 1, which includes a plurality of substrates 125, each having one or more induction features 350 configured to transport liquid metal (e.g., refined aluminum from the refined aluminum layer 120) in the absence of an intentionally applied current. As shown, four of the plurality of substrates 125 are at least partially immersed in the electrolyte 110 and are generally oriented in a vertical direction. As shown, one of the plurality of substrates 125 is generally oriented in a horizontal direction. As indicated by the arrows, one or more induction features 350 transport the refined aluminum from the refined aluminum layer 120 to the cell exit position 370.

[0119] Figure 5b shows another embodiment of the electrolytic cell 1, which includes a single substrate 125 having one or more induction features 350 configured to transport liquid metal (e.g., refined aluminum from the refined aluminum layer 120) in the absence of an intentionally applied current. As shown, four portions of the substrate 125 are oriented generally vertically and at least partially immersed in the electrolyte 110. As shown, one portion of the substrate 125 is oriented generally horizontally. As indicated by the arrows, one or more induction features 350 transport the refined aluminum from the refined aluminum layer 120 to the cell exit position 370.

[0120] Figure 5c shows another embodiment of the electrolytic cell 1, which includes a plurality of substrates 125, each having one or more induction features 350 configured to transport liquid metal (e.g., refined aluminum from the refined aluminum layer 120) in the absence of an intentionally applied current. As shown, five of the plurality of substrates 125 are oriented in a generally vertical direction, and four of the plurality of substrates 125 are at least partially immersed in the electrolyte 110. As indicated by the arrows, one or more induction features 350 transport the refined aluminum from the refined aluminum layer 120 to the cell outlet position 370 and through the cell outlet position to the refined metal reservoir 260.

[0121] Figure 5d shows another embodiment of the electrolytic cell 1, which includes a single substrate 125 containing one or more induction feature units 350 configured to transport liquid metal (e.g., refined aluminum from the refined aluminum layer 120) in the absence of an intentionally applied current. As shown, the five portions of the single substrate 125 are oriented in a generally vertical direction. As shown, four portions of the single substrate 125 are at least partially immersed in the electrolyte 110. As indicated by the arrows, one or more induction feature units 350 transport the refined aluminum from the refined aluminum layer 120 to the cell outlet position 370 and through the cell outlet position to the refined metal reservoir 260.

[0122] Figure 6a shows another embodiment of the electrolytic cell 1, which includes a plurality of substrates 125, each having one or more induction features 350 configured to transport liquid metal (e.g., refined aluminum from the refined aluminum layer 120) in the absence of an intentionally applied current. As shown, one of the plurality of substrates 125 has an irregular shape and is oriented in a tilting direction. As shown, one of the plurality of substrates 125 is generally oriented in a horizontal direction. As indicated by the arrows, one or more induction features 350 transport the refined aluminum from the refined aluminum layer 120 to the cell exit position 370.

[0123] Figure 6b shows another embodiment of the electrolytic cell 1, which includes a single substrate 125 having one or more induction features 350 configured to transport liquid metal (e.g., refined aluminum from the refined aluminum layer 120) in the absence of an intentionally applied current. As shown, the single substrate is generally oriented horizontally. As shown, the single substrate 125 is not in contact with one of the refractory sidewalls 30 of the electrolytic cell 1. In one embodiment, at least one substrate 125 is in contact with both refractory sidewalls 30 of the electrolytic cell 1. As indicated by the arrows, one or more induction features 350 transport the refined aluminum from the refined aluminum layer 120 toward the cell exit position 370.

[0124] Figure 6c shows another embodiment of the electrolytic cell 1 comprising a plurality of substrates 125, each containing one or more induction features 350 configured to transport liquid metal (e.g., refined aluminum from the refined aluminum layer 120) in the absence of an intentionally applied current. As shown, two of the plurality of substrates are generally oriented horizontally, and one of the plurality of substrates 125 is generally oriented vertically. As indicated by the arrows, one or more induction features 350 transport the refined aluminum from the refined aluminum layer 120 to the cell exit position 370.

[0125] FIG. 6d shows another embodiment of an electrolytic cell 1 including a plurality of substrates 125 having one or more inductive features 350 configured to transport liquid metal (e.g., refined aluminum of the refined aluminum layer 120) in a state where no intentionally applied current is present. As shown, one of the plurality of substrates 125 is generally oriented in a horizontal direction and one of the plurality of substrates 125 is oriented in an inclined direction. As indicated by the arrows, the one or more inductive features 350 transport the refined aluminum of the refined aluminum layer 120 to the cell outlet location 370.

[0126] Referring to FIGS. 1-6, the one or more substrates 125 may include one or more of any of the substrates described herein (e.g., 202, 302, 402, 502, 602, 602’, 602’’, 602’’’, 602’’’’, 602’’’’’, 702, 702’, 802, 802’, 902).

[0127] Referring to FIGS. 1-6, the one or more inductive features 350 may include one or more of any of the inductive 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).

[0128] <ii. Embodiments of Inductive Features> FIG. 7A is a perspective view of an embodiment of a substrate 202 (e.g., a TiB2 substrate) having a plurality of slots 206 as inductive 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 guide a wettable material in a predetermined direction. The wettable material may include aluminum such as aluminum alloys, metallic aluminum, and combinations thereof.

[0129] Figure 7B is a first side view of Figure 7A. Figure 7B shows a side view of the prong 204. The prong 204 includes a length (l) extending from the top of the base 208 to the end of the tip 210. The tip 210 may include various shapes, such as a point, a rounded bend, or a jagged edge.

[0130] Figure 7C is a partial top view of Figure 7A, indicated by a dashed line in Figure 7A. The partial top view shows only a portion of the prong 204. Specifically, Figure 7C shows the first prong 204A and the second prong 204B defining the first slot 206A. The first slot 206A is defined by the inner surfaces of the first prong 204A and the second prong 204B.

[0131] Figure 8A is a front view of one embodiment of a substrate 302 (e.g., a TiB2 substrate) having a slot 306 as an inductive feature. The slot 306 is defined by a first prong 304A and a second prong 304B (collectively, prong 304). The substrate 302 includes a base 308 and a tip 310. The slot 306 is configured to guide a wettable material in a predetermined direction. The width (w) of the prongs is also shown.

[0132] Figure 8B is a top view of the cross-section along the dashed line 8B shown in Figure 8A. Figure 8B shows the thickness (t) of the prong 304 and the distance (d) that the slot 306 extends between the inner surfaces of the first prong 304A and the second prong 304B. Figure 8C is a first side view of Figure 8A. Figure 8C shows the length (l) of the prong 304.

[0133] Figures 7A-7C and 8A-8C are similar and will be described together. The embodiments in Figures 7A-7C differ from those in Figures 8A-8C in the number of prongs 204 / 304, the number of slots 206 / 306, and the thickness (t) of the prongs 204 / 304.

[0134] The dimensions of slot 206 / 306 may be predetermined. In some embodiments, slot 206A / 306 extends over the entire length (l) of the first prong 206A / 306A and the 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 may range from about 0.01 meters to about 1 meter. The thickness (t) of the first prong 204A / 304A and the thickness (t) of the second prong 204B / 304B may range from about 1 mm to about 20 mm. Slot 206A / 306 extends over the 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) is in the range of about 20 μm to about 20 mm. The width (w) of the prongs 204 / 304 (e.g., the first prongs 204A / 304A and the second prongs 204B / 304B) may be in the range of about 1 mm to about 20 mm.

[0135] The prongs 204 / 304 may have different dimensions from each other. The prongs 204 / 304 may have different lengths (l), thicknesses (t), and widths (w). Similarly, the distances (d) between the slots 206 / 306 may have different lengths (d). In some embodiments, the first prongs 204A / 304A may have larger lengths (l) and widths (w) and smaller thicknesses (t) compared to the second prongs 204B / 304B.

[0136] Slots 206 / 306 extend through the thickness of substrate 202 / 302. The number of slots may vary. In some embodiments, there may be one slot, as shown in the embodiments of Figures 8A, 8B, and 8C. There may be two or more slots. The number of slots may vary depending on the intended use of substrate 202 / 302. In the embodiments shown in Figures 7A, 7B, and 7C, there are six slots, but any number of slots may be used.

[0137] The substrate 202 / 302 may be at least partially covered with solid aluminum metal (for example, before use in an electrolytic cell). Slots 206 / 306 may be induction features for the substrate 202 / 302. Other induction features may be included with the substrate 202, such as grooves, pores, and combinations thereof. The solid aluminum may be converted to liquid aluminum when the substrate is heated, for example, during startup and / or normal operation of the electrolytic cell. The solid and / or liquid aluminum may at least partially protect one or more surfaces of the substrate from attack by other materials. In one embodiment, the solid and / or liquid aluminum at least partially protected one or more surfaces of the substrate from attack by the electrolytic bath of the electrolytic cell.

[0138] The substrate 202 / 302 may be a solid geometric shape. The geometric shape may include at least one of a rectangle, square, triangle, ellipse, or oblong. The substrate 202 / 302 may also be asymmetrical. The substrate 202 / 302 may also be in the form of a plate. The substrate 202 / 302 may induce a wettable material by capillary action using slots 206 / 306 which are induction features.

[0139] Substrate 202 / 302 can be used in a variety of applications. In some embodiments, substrate 202 / 302 may be configured for use in an aluminum refining cell or an aluminum electrolytic cell. An example of an aluminum refining cell can be found in U.S. Patent No. 10,407,786, filed by the applicant on February 11, 2016, entitled "System and Method for Refining Aluminum." An example of an aluminum electrolytic cell can be found in U.S. Patent Application Publication No. 2017 / 0283968, filed by the applicant on March 30, 2017, entitled "Apparatus and System for Vertical Electrolytic Cell."

[0140] Figure 9A is a front view of one embodiment of a substrate 402 (e.g., a TiB2 substrate) having a plurality of grooves 406 as induction features. Figure 9B is a first side view of Figure 9A. Figure 9C is a partial top view of the portion shown by the dashed line in Figure 9A. Figure 9D is an alternative configuration of the plurality of grooves shown in Figure 9C.

[0141] The groove 406 extends partially into the substrate 402. The dimensions of the groove 406 can be predetermined. In some embodiments, the size and / or shape of the groove 406 can be predetermined. The width (w) of the groove 406 is in the range of approximately 10 μm to approximately 20 mm. The groove depth (gd) of the groove 406 is in the range of approximately 1 mm to approximately 10 mm. The length (l) of the groove 406 is in the range of approximately 1 cm to approximately 1 m. The thickness (t) of the substrate 402 is in the range of approximately 5 mm to approximately 30 mm. The edge-to-edge distance (d) between grooves 406 is in the range of approximately 1 mm to approximately 20 mm.

[0142] As shown in Figure 9C, the induction feature portion includes at least two grooves 406 within the substrate 402. Specifically, the induction feature portion includes three grooves 406. Figure 9C shows the first groove 406A, the second groove 406B, and the third groove 406C (collectively referred to as groove 406).

[0143] The grooves 406 can be arranged in any pattern. The grooves 406 may also have the same dimensions as each other or different dimensions as each other. The grooves 406 may also be arranged on the sides of the substrate 402 as well as on the front and back surfaces, as shown in Figure 9C. Figure 9D shows a first groove 406A', a second groove 406B', and a third groove 406C' (collectively groove 406'). Figure 9D shows alternative dimensions and arrangements of groove 406' in comparison to groove 406 in Figure 9C. Figure 9C shows grooves arranged in a pattern where they have the same dimensions as each other and are arranged in an alternating pattern between the front and back surfaces of the substrate 402. Figure 9D shows that grooves 406' may have different dimensions. In some embodiments, the second groove 406B' is the largest groove, having a groove depth that extends deeper than half the substrate 402. The third groove 406C' is the smallest groove, and its groove depth is less than half that of the substrate 402'.

[0144] Figure 10A is a side view of another embodiment of a substrate 502 (e.g., a TiB2 substrate) having a plurality of pores 504 as induction features. Figure 10B is an enlarged view of Figure 10A. As shown in Figure 10A, the substrate is a web of material (e.g., a web of TiB2). The pores 504 are defined by the substrate 502, i.e., the web of material. The induction features may also be the porosity of the substrate 502. The porosity of the substrate 502 may range from about 1 pore per inch (PPI) to about 200 pores per inch. 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 approximately 175 pores (PPI) or less per inch, or approximately 150 pores (PPI) or less per inch, or approximately 125 pores (PPI) or less per inch, or approximately 100 pores (PPI) or less per inch, or approximately 80 pores (PPI) or less per inch, or approximately 60 pores (PPI) or less per inch, or approximately 50 pores (PPI) or less per inch.

[0145] Figure 11A is a perspective view of one embodiment of a substrate 602 (e.g., a TiB2 substrate) having a plurality of slots 606 as induction feature portions, and a solid aluminum metal 612 covering the substrate 602. The substrate 602 includes prongs 604, a base 608, and a tip 610. Figure 11B is a first side view of Figure 11A. Figure 11C is a partial top view of the portion shown by dashed lines in Figure 11A. The embodiments shown in Figures 7A, 7B, and 7C are identical or similar to the embodiments in Figures 6A, 6B, and 6C, except for the differences described herein. In some embodiments, the embodiments shown in Figures 6A, 6B, and 6C include a solid aluminum metal 612. Features similar to those in Figures 7A, 7B, and 7C will not be repeated for Figures 11A, 11B, and 11C. Figures 11A and 11B show the solid aluminum metal 612 completely covering the TiB2 substrate 602. Figure 6C shows the solid aluminum metal 612 completely occupying the slot 606A between the first prong 604A and the second prong 604B.

[0146] In some embodiments, the solid aluminum metal 612 covers at least partially 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.

[0147] In some embodiments, the solid aluminum metal 612 is at least partially contained within the slot 606. In some embodiments, if 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.

[0148] In the embodiments shown in Figures 11A to 11N, it is shown that varying amounts of solid aluminum metal 612 occupy the slots 606 and the substrate 602.

[0149] Figure 11D is a side view of one embodiment of a substrate 602' having a plurality of slots 606A' as induction feature portions, and a solid aluminum metal 612' covering the top of the substrate 602'. Figure 11E is a partial top view of a cross section along the dashed line 11E shown in Figure 11D, showing only one of the plurality of slots 606A'. The cross section is along the top of the substrate 602' where the solid aluminum metal 612' is located. Figure 11F is a partial top view of a cross section along the dashed line 11F shown in Figure 11D, showing only one of the plurality of slots 606A'. The cross section is along the bottom of the substrate 602' where the solid aluminum metal 612' is not present.

[0150] Figure 11G is a side view of one embodiment of a substrate 602'' having a plurality of slots 606A'' as induction feature portions, and a solid aluminum metal 612'' covering the front half of the substrate 602''. The solid aluminum metal 612'' covers the base 608'' and the front half of the tip 610''. Figure 11H is a partial top view of the cross section along the dashed line 11H shown in Figure 11G, showing only one of the plurality of slots 606A''. The solid aluminum metal 612'' covers the front half of slot 606A''.

[0151] Figure 11I is a side view of one embodiment of a substrate 602''' having a base 608''' and a tip 610''', wherein the substrate has a plurality of slots 606A''' as guide features and solid aluminum metal 612''' within the plurality of slots 606A'''. Figure 11J is a partial top view of a cross section along the dashed line 11J shown in Figure 11I, showing only one of the plurality of slots 606A'''. In the embodiments of Figures 11I and 11J, the solid aluminum metal 612''' is not present on the outer surface of the substrate 602'''. The solid aluminum metal 612''' completely fills the slot volume of the slot 606A'''.

[0152] Figure 11K is a front view of one embodiment of a substrate 602'''' having a plurality of slots 606A, 606B, and 606C (collectively referred to as slots 606'''') as induction feature portions, and a solid aluminum metal 612'''' that partially covers or does not partially cover the slots 606. Figure 11L is a side view of Figure 11K, showing the substrate 602'''' having a base 608'''' and a tip 610''''. The slots 606'''' have solid aluminum metal 612'''' of varying lengths, thicknesses, and quantities.

[0153] For slot 606A, the slot length does not extend to the leading edge 610'''' of substrate 602''''. The upper part of slot 606A does not contain solid aluminum metal 612''''. The lower part of slot 606A contains solid aluminum metal 612''''. For slot 606B, the slot length extends from the top of the base 608'''' to the leading edge 610''''. Slot 606B does not contain solid aluminum metal 612''''. Slot 606C does not start in the same location as slots 606A and 606B. The beginning of slot 606C starts further above the TiB2 substrate 602''''. Slot 606C has solid aluminum metal 612'''' at the bottom and top, but not in the middle of slot 606C.

[0154] Figure 11M is a front view of one embodiment of a substrate 602''''' having a surface area of ​​620''''', comprising a first portion 622''''' of the surface area 620''''' having a plurality of slots 606'''''' as induction feature portions, and a second portion 624'''''' of the surface area 620''''' without induction feature portions. Prongs 604'''''' define the plurality of slots 606'''''. Figure 11N is a first side view of Figure 11M, where the second portion 624'''''' of the surface area 620'''''' does not have induction feature portions.

[0155] The substrate 602'''''' includes a surface area 620'''''', where a first portion 622'''''' of the surface area 620'''''' includes at least one induction feature portion, and a second portion 624'''''' of the surface area 620'''''' does not have an induction feature portion.

[0156] In some embodiments, a first portion 622''''' of the surface area 620''' is at least partially covered by solid aluminum metal. In some embodiments, a first portion 622''''' of the surface area 620''' is at least 1% covered by solid aluminum metal. In some embodiments, a first portion 622''''' of the surface area 620''' is at least 5% covered by solid aluminum metal. In some embodiments, a first portion 622''''' of the surface area 620''' is at least 10% covered by solid aluminum metal. In some embodiments, a first portion 622''''' of the surface area 620''' is at least 15% covered by solid aluminum metal. In some embodiments, a first portion 622''''' of the surface area 620''' is at least 20% covered by solid aluminum metal. In some embodiments, a first portion 622''''' of the surface area 620''' is at least 25% covered by solid aluminum metal. In some embodiments, a first portion 622''''' of the surface area 620''' is covered by solid aluminum metal by at least 30%. In some embodiments, a first portion 622''''' of the surface area 620''' is covered by solid aluminum metal by at least 35%. In some embodiments, a first portion 622''''' of the surface area 620''' is covered by solid aluminum metal by at least 40%. In some embodiments, a first portion 622''''' of the surface area 620''' is covered by solid aluminum metal by at least 45%. In some embodiments, a first portion 622''''' of the surface area 620''' is covered by solid aluminum metal by at least 50%. In some embodiments, a first portion 622''''' of the surface area 620''' is covered by solid aluminum metal by at least 55%. In some embodiments, a first portion 622''''' of the surface area 620''' is covered by solid aluminum metal by at least 60%. In some embodiments, a first portion 622''''' of the surface area 620'''' is covered by at least 65% of solid aluminum metal.In some embodiments, a first portion 622''''' of a surface area 620''' is covered by solid aluminum metal by at least 70%. In some embodiments, a first portion 622''''' of a surface area 620''' is covered by solid aluminum metal by at least 75%. In some embodiments, a first portion 622''''' of a surface area 620''' is covered by solid aluminum metal by at least 80%. In some embodiments, a first portion 622''''' of a surface area 620''' is covered by solid aluminum metal by at least 85%. In some embodiments, a first portion 622''''' of a surface area 620''' is covered by solid aluminum metal by at least 90%. In some embodiments, a first portion 622''''' of a surface area 620''' is covered by solid aluminum metal by at least 95%. In some embodiments, a first portion 622''''' of a surface area 620''' is covered by solid aluminum metal by at least 100%.

[0157] 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 covered by solid aluminum metal by at least 30%. In some embodiments, the second portion 624''''' of the surface area 620''' is covered by solid aluminum metal by at least 35%. In some embodiments, the second portion 624''''' of the surface area 620''' is covered by solid aluminum metal by at least 40%. In some embodiments, the second portion 624''''' of the surface area 620''' is covered by solid aluminum metal by at least 45%. In some embodiments, the second portion 624''''' of the surface area 620''' is covered by solid aluminum metal by at least 50%. In some embodiments, the second portion 624''''' of the surface area 620''' is covered by solid aluminum metal by at least 55%. In some embodiments, the second portion 624''''' of the surface area 620''' is covered by solid aluminum metal by at least 60%. In some embodiments, a second portion 624''''' of the surface area 620'''' is covered by at least 65% of solid aluminum metal.In some embodiments, the second portion 624''''' of the surface area 620''' is covered by solid aluminum metal by at least 70%. In some embodiments, the second portion 624''''' of the surface area 620''' is covered by solid aluminum metal by at least 75%. In some embodiments, the second portion 624''''' of the surface area 620''' is covered by solid aluminum metal by at least 80%. In some embodiments, the second portion 624''''' of the surface area 620''' is covered by solid aluminum metal by at least 85%. In some embodiments, the second portion 624''''' of the surface area 620''' is covered by solid aluminum metal by at least 90%. In some embodiments, the second portion 624''''' of the surface area 620''' is covered by solid aluminum metal by at least 95%. In some embodiments, the second portion 624''''' of the surface area 620''' is covered by solid aluminum metal by at least 100%.

[0158] 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 has a thickness ranging from 1 μm to 500 μm. In some embodiments, the first portion 622''''' and / or the second portion 624''''' of the surface area 620''''' is not covered by solid aluminum metal.

[0159] Figure 12A is a front view of one embodiment of a substrate 702 (e.g., a TiB2 substrate) having a slot 706 as an induction feature, and a solid aluminum metal 712 covering the substrate 702. The first prong 704A and the second prong 704B define the slot 706 extending upward from the base 708. Figure 12B is a top view of a cross-section along the dashed line 12B shown in Figure 12A. Figure 12C is a first side view of Figure 12A.

[0160] Figure 12D is a front view of one embodiment of a substrate 702' having a slot 706' as an induction feature portion, and a solid aluminum metal 712' covering a portion of the slot 706'. The first prongs 704A' and the second prongs 704B' extend upward from the base 708', thereby defining the slot 706'. Figure 12E is a top view of a cross section along the dashed line 12E shown in Figure 12D. As shown in Figure 12E, the solid aluminum metal 712' is absent in the central portion 714' of the slot 706'. The front and rear portions of the slot 706' are shown to have the solid aluminum metal 712'. Figure 12F is a first side view of Figure 12F.

[0161] The embodiments shown in Figures 12D, 12E, and 12F are identical or similar to those shown in Figures 12A, 12B, and 12C, except for the differences described herein. For example, the amount of solid aluminum metal 712 / 712' covering the substrate 702 / 702' differs between embodiments. In the embodiments of Figures 12A, 12B, and 12C, the solid aluminum metal 712 covers almost the entire substrate 702. Only a portion of the base 708 is covered with solid aluminum metal 712. The slot 706 is completely filled with solid aluminum metal 712. In contrast, in the embodiments of Figures 12D, 12E, and 12F, there is no solid aluminum metal 712' outside the substrate 702'. Only a portion of the slot 706' is filled with solid aluminum metal 712'.

[0162] The embodiments in Figures 12, 12B, 12C, 12D, 12E, and 12F are identical or similar to the embodiments in Figures 8A, 8B, and 8C. One difference is that Figures 8A, 8B, and 8C do not show solid aluminum metal. The description of solid aluminum metal from the embodiments in Figures 11A to 11N also applies to the solid aluminum metal in Figures 12A to 12F.

[0163] Figure 13A is a front view of one embodiment of a substrate 802 (e.g., a TiB2 substrate) having a plurality of grooves 806 as induction features, and a solid aluminum metal 812 covering the substrate 802. Figure 13B is a first side view of Figure 13A. Figure 13C is a partial top view shown by dashed lines in Figure 13A. Figure 13C includes a diagram of the first groove 806A, the second groove 806B, and the third groove 806C.

[0164] Figure 13D is a front view of one embodiment of a substrate 802' having a plurality of grooves 806' as induction features, and a solid aluminum metal 812' covering the front half of the substrate 802'. Figure 13E is a first side view of Figure 13D. Figure 13F is a partial top view of Figure 13D, shown by a dashed line in Figure 13F.

[0165] The embodiments shown in Figures 13D, 13E, and 13F are identical or similar to those shown in Figures 13A, 13B, and 13C, except for the differences described herein. For example, the amount of solid aluminum metal 812 / 812' covering the substrate 802 / 802' differs between embodiments. In the embodiments of Figures 13A, 13B, and 13C, the solid aluminum metal 812 completely covers the substrate 802. In contrast, the solid aluminum metal 812' in Figures 13D, 13E, and 13F covers only the front half of the substrate 802'.

[0166] The embodiments in Figures 13A, 13B, 13C, 13D, 13E, and 13F are identical or similar to the embodiments in Figures 9A, 9B, 9C, and 9D. One difference is that Figures 9A, 9B, 9C, and 4D are not shown with solid aluminum metal. Figures 13A, 13B, 13C, 13D, 13E, and 13F are shown with solid aluminum metal 812 / 812'. The description of solid aluminum metal 612 / 712 from the embodiments in Figures 11A-11N and 12A-12F also applies to solid aluminum metal 812 / 812' in Figures 13A-13F.

[0167] In Figures 13A to 13F, at least one guide feature is a groove 806 / 806', and the solid aluminum metal 812 / 812' is at least partially contained within the groove 806 / 806'. At least one groove 806 / 806' contains 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' accounts for at least 30% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' accounts for at least 35% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' accounts for at least 40% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' accounts for at least 45% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' accounts for at least 50% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' accounts for at least 55% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' accounts for at least 60% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' accounts for at least 65% of the groove volume. In some embodiments, the solid aluminum metal 812 / 812' accounts for 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.

[0168] Figure 14 is an enlarged view of one embodiment of a substrate 902 (e.g., a TiB2 substrate) having pores 904 and solid aluminum metal 906, according to several embodiments. In some embodiments, the substrate 902 is a mesh of material (e.g., a TiB2 mesh).

[0169] In some embodiments, the solid aluminum metal 906 covers at least partially the surface of the substrate 902. In some embodiments, the mesh of the substrate 902 defines the pores 904 of the material's mesh.

[0170] In some embodiments, the solid aluminum metal 906 is porous. When the solid aluminum metal 906 fills the pores 904, the solid aluminum metal 906 may be at a high temperature. When the solid aluminum metal 906 cools, spaces (e.g., pores or voids) may exist between the solid aluminum metal 906 and the pores of the TiB2 substrate 902. The pores 904 have a porous network in the TiB2 substrate 902 that defines the porous volume of the TiB2 substrate 902. In some embodiments, the solid aluminum metal 906 accounts for at least 1% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 5% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 10% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 15% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 20% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 25% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 30% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 35% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 40% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 45% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 50% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 55% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 60% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 65% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 70% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 75% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 80% of the porous volume.In some embodiments, the solid aluminum metal 906 accounts for at least 85% of the porous volume. In some embodiments, the solid aluminum metal 906 accounts for at least 90% of the porous volume.

[0171] An aluminum refining cell or aluminum electrolytic cell may include any substrate described herein. In some embodiments, at least one substrate is an electrode for the aluminum refining cell or aluminum electrolytic cell. In some embodiments, at least one substrate is an induction device, which is configured to guide liquid aluminum metal in a predetermined direction in the absence of applied current.

[0172] In some embodiments, the solid aluminum metal can be at least partially contained within at least one inductive feature. In some embodiments, the at least one inductive feature includes a void volume. In some embodiments, at least 1% of the void volume contains solid aluminum metal. In some embodiments, at least 5% of the void volume contains solid aluminum metal. In some embodiments, at least 10% of the void volume contains solid aluminum metal. In some embodiments, at least 15% of the void volume contains solid aluminum metal. In some embodiments, at least 20% of the void volume contains solid aluminum metal. In some embodiments, at least 25% of the void volume contains solid aluminum metal. In some embodiments, at least 30% of the void volume contains solid aluminum metal. In some embodiments, at least 35% of the void volume contains solid aluminum metal. In some embodiments, at least 40% of the void volume contains solid aluminum metal. In some embodiments, at least 45% of the void volume contains solid aluminum metal. In some embodiments, at least 50% of the void volume contains solid aluminum metal. In some embodiments, at least 55% of the void volume contains solid aluminum metal. In some embodiments, at least 60% of the void volume contains solid aluminum metal. In some embodiments, at least 65% of the void volume contains solid aluminum metal. In some embodiments, at least 70% of the void volume contains solid aluminum metal. In some embodiments, at least 75% of the void volume contains solid aluminum metal. In some embodiments, at least 80% of the void volume contains solid aluminum metal. In some embodiments, at least 85% of the void volume contains solid aluminum metal. In some embodiments, at least 90% of the void volume contains solid aluminum metal. In some embodiments, at least 95% of the void volume contains solid aluminum metal. In some embodiments, at least 100% of the void volume contains solid aluminum metal.

[0173] <iii. Examples> Example 1 - Laboratory Scale Test Manufacturing of porous TiB2 substrates (TiB2 foam) Four different TiB2 foam samples were prepared, each measuring approximately 3 inches (H) x 2 inches (W) x 0.5 inches (D), with porosity levels of approximately 10, 20, 30, and 45 PPI, respectively. The TiB2 foam samples were prepared by immersing polyurethane foam with different pore sizes in an aqueous slurry containing TiB2 particles. The TiB2-coated foam was then rolled between a pair of parallel rollers with a predetermined gap thickness, compressing the impregnated foam and removing excess slurry. The rolled TiB2 foam was suspended in a drying oven. In some cases, the process of re-immersing the coated foam in the aqueous slurry and then air-drying was repeated. Finally, the dried TiB2 foam was sintered by heating at a temperature of approximately 1850°C. Figure 15 shows an example of the sintered final product. The sintered final products had pore sizes of approximately 10, 20, 30, and 45 PPI, corresponding to the pore sizes of each polyurethane foam, and had continuously interconnected pores.

[0174] Water Wetness Test As shown in Figure 16, each of the four TiB2 foam samples (approximately 10, 20, 30, and 45 PPI) was wrapped in two pieces of tissue paper, with one piece placed on top of the sample and the other in the middle. The bottom of the TiB2 sample was then placed in 0.25 inches of water, well below the middle of the sample, to test the sample's ability to promote water mass transfer by capillary action. After approximately 12 hours, the samples were evaluated. The approximately 10 PPI sample showed that neither tissue was moist or wet, indicating no capillary action occurred. The approximately 20 PPI sample showed that the middle tissue was moist and the top tissue was dry, indicating some capillary action occurred. Both the approximately 30 and 45 PPI samples showed that both the middle and top tissues were wet, indicating substantial capillary action occurred.

[0175] Impregnation of TiB2 foam with aluminum metal The sintered TiB2 foam was immersed in molten aluminum for 1 minute and then air-cooled. After complete cooling, each of the four TiB2 foam samples was placed in a slot approximately 0.5 inches deep in the graphite carrier of three different crucibles (crucible #1, crucible #2, and crucible #3, which will be further described below). Each of the three crucibles was placed in a furnace and heated to 900°C in argon. A purified molten aluminum composition (pure aluminum pellets) and a molten bath composition were added to each crucible. The molten bath composition was cryolite-based and contained components of NaF, AlF3, and CaF2.

[0176] Crucibles containing four TiB2 foam samples, molten aluminum, and cryolite were held at 900°C for approximately 48 hours. As shown in Figure 17, in crucible #1, the four TiB2 foam samples were completely immersed in molten aluminum for 48 hours. In crucibles #2 and #3, the four TiB2 foam samples were partially immersed in approximately 1 inch and 2 inches of molten aluminum, respectively, with the remaining foam exposed to the molten bath for 48 hours.

[0177] After testing at 900°C for 48 hours, no corrosion was observed in any of the four TiB2 foam samples in any of the crucibles, as shown in Figures 18A and 18B, indicating that the samples were wetted with molten aluminum by capillary action facilitated by the pores of the foam. The molten aluminum protects the TiB2 from corrosion by cryolite.

[0178] Example 2 - Larger-scale laboratory testing Manufacturing of TiB2 foam samples Two different TiB2 foam samples, each measuring approximately 16 inches (H) x 2 inches (W) x 0.5 inches (D), were manufactured using the same process as the foam sample in Example 1. The final sintered products of the two TiB2 foam samples had pore sizes of approximately 20 and 30 PPI, corresponding to the pore sizes of their respective polyurethane foams, and possessed continuous interconnected pores.

[0179] Impregnation of TiB2 foam with aluminum metal Two untreated TiB2 foam samples were placed in slots approximately 2 inches deep in a graphite carrier in a crucible. Before placement in the graphite carrier, a purified molten aluminum composition (pure aluminum pellets) and a molten bath composition (cryocrystalline based, containing NaF, AlF3, and CaF2 components) were added to each crucible, and then each crucible was placed in a furnace and heated to 900°C in argon. After heating, each of the two TiB2 foam samples was placed in a crucible. Each crucible containing the TiB2 foam sample, molten aluminum, and cryolite was then held at 900°C. Approximately 10 minutes after the start of the test, the two TiB2 foam samples were withdrawn from the crucibles, and molten aluminum was detected at the top of the samples. Similar to Example 1, no corrosion was observed in either of the two TiB2 foam samples, indicating that the samples were wetted with molten aluminum over a length of approximately 14 inches due to capillary action facilitated by the pores of the foam. The molten aluminum protects the TiB2 from corrosion by cryolite.

[0180] While many embodiments of this disclosure have been described, these embodiments are illustrative and not limiting, and it will be understood that many modifications will be apparent to those skilled in the art. The various steps may be performed in any desired order (and any desired steps may be added, and / or any desired steps may be omitted). For example, the features and properties of induction features (e.g., slots, pores, or grooves) may be used with or alone in any product and / or TiB2 substrate. The features and properties of solid aluminum metal described in any embodiment may be used in any other embodiment described herein. The exemplary embodiments of induction features and solid aluminum metal coatings are not intended to be exhaustive. The features and properties of this disclosure may be combined in any way.

[0181] While the embodiments disclosed herein generally relate to the purification of aluminum, embodiments of the disclosure are intended to be equally applicable to the purification of other elements and / or compounds. For example, embodiments of the disclosure may, alternatively or additionally, relate to the purification of magnesium. In some embodiments, the systems, products, and / or methods of the disclosure relate to magnesium purification cells for producing purified magnesium from magnesium feedstock. As used herein, “magnesium feedstock” means material having a sufficient amount of magnesium to produce purified magnesium, and “purified magnesium” means material having a greater amount of magnesium than the magnesium feedstock. The embodiments described above are exemplary embodiments of the apparatus, systems, or methods of the disclosure, and therefore should not be considered limiting in scope, as the apparatus, systems, and methods of the disclosure may permit other equally effective embodiments.

Claims

1. It is a method, (a) Purifying the raw material in an electrolytic cell to produce purified liquid metal, (b) Moving the refined liquid metal from a first position to a second position in the electrolytic cell, The aforementioned movement includes transporting the refined liquid metal through the induction feature section. The induction feature section is positioned near the first position, The induction feature portion is in fluid communication with the refined liquid metal and the second position. method.

2. The method according to claim 1, wherein the induction feature portion is electrically neutral.

3. The method according to any one of the preceding claims, wherein the induction feature portion is at least partially immersed in the purified liquid metal.

4. The method according to any one of the preceding claims, wherein the induction feature portion is completely immersed in the purified liquid metal.

5. The method according to any one of the preceding claims, wherein the induction feature portion is realized within one or more substrates.

6. The method according to any one of the preceding claims, wherein one or more substrates have a regular or irregular shape.

7. The method according to claim 5 or 6, wherein one or more substrates are curved.

8. The method according to any one of claims 5 to 7, wherein the one or more substrates are oriented in a vertical direction.

9. The method according to any one of claims 5 to 7, wherein the one or more substrates are oriented in the horizontal direction.

10. The method according to any one of claims 5 to 9, wherein the one or more substrates are oriented in a tilting direction.

11. The method according to any one of claims 5 to 10, wherein the one or more substrates include at least one of ceramic or cermet.

12. The method according to any one of claims 5 to 11, wherein the one or more substrates are located in proximity to or adjacent to at least one fire-resistant component of the electrolytic cell.

13. The method according to claim 13, wherein one or more substrates are mechanically connected to the fire-resistant component.

14. The method according to claim 14, wherein the fire-resistant component is a fire-resistant cover.

15. The method according to claim 14, wherein the fire-resistant component is a fire-resistant side wall.

16. The method according to any one of claims 5 to 15, wherein the induction feature portion is partially immersed in an electrolyte.

17. The method according to any of the preceding claims, wherein the moving step (b) includes moving the refined liquid metal in a predetermined direction.

18. The method according to any of the preceding claims, wherein the induction feature portion includes a slot, a groove, a pore, a tapered member, or a combination thereof.

19. The method according to any one of the preceding claims, wherein the second position is a refined metal reservoir.

20. It is an electrolytic cell, (a) A cell chamber comprising a cell bottom, fire-resistant side walls, a fire-resistant upper cover, an electrolyte, and purified liquid metal, (b) an anode at least partially immersed in the electrolyte, (c) A cathode at least partially immersed in the electrolyte, (d) Cell exit position and (e) comprising an induction feature section, The induction feature portion is positioned in close proximity to the refined liquid metal. The induction feature portion is in fluid communication with the purified liquid metal and the cell outlet position. The induction feature is configured to guide the refined metal in a predetermined direction related to the cell outlet position. Electrolytic cell.

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