Improved aluminum purification cells with horizontally extending cathodes

Abstract

New aluminum purification cells are disclosed. An aluminum purification cell may include a cathode partially positioned within an electrolyte that is disposed above a molten anodic metal pad. The cathode may include a cathode post extending from a top of the aluminum purification cell. The cathode may also include a horizontal cathode member extending horizontally from the cathode post toward sidewalls of the aluminum purification cell. Aluminum ions may be produced within the electrolyte from aluminum of the molten anodic metal pad and metallic aluminum may be produced from the aluminum ions at a surface of the cathode.

Description

Attorney Ref. No.: 169593-120017 / WQIMPROVED ALUMINUM PURIFICATION CELLS WITH HORIZONTALLY EXTENDING CATHODES CROSS-REFERENCE TO RELATED APPLICATION

[0001] This patent application claims priority to U. S. Provisional Patent Application No. 63 / 756,557, entitled, “IMPROVED ALUMINUM PURIFICATION CELLS WITH HORIZONTALLY EXTENDING CATHODES,” filed February 10, 2025, which is incorporated herein by reference in its entirety.BACKGROUND

[0002] Aluminum metal has traditionally been made by converting alumina (Al2O3), which typically originates from bauxite ore. The conversion of alumina to aluminum is typically carried out in an electrolytic cell by passing an electric current through an electrolyte having alumina and cryolite. Carbon from the carbon anode reacts with the oxygen component in the alumina to produce carbon dioxide, which is expelled from the cell, leaving molten aluminum. The molten aluminum gathers on the bottom of the electrolytic cell and is subsequently removed as relatively pure metallic aluminum. Various efforts have been made to purify metallic aluminum, including the “Hoopes process” (see U. S. Patent No. 1,534,315) as well as those methods described in commonly owned International Patent Application Publication No. WO2016 / 130823.SUMMARY OF THE DISCLOSURE

[0003] Broadly, the present disclosure relates to aluminum purification cells and methods pertaining to the same, The aluminum purification cell may be useful, for instance, in purifying a feedstock comprising metallic aluminum or aluminum alloys. In one embodiment, the feedstock may comprise aluminum scrap. The scrap may include metallic aluminum, one or more aluminum alloys, and / or other additives, in one embodiment, an aluminum purification cell includes (a) a molten anodic metal pad, wherein the molten anodic metal pad is absent of solid anodic electrodes, (b) an electrolyte disposed above the molten anodic metal pad, and (c) a cathode positioned within the electrolyte and separated from the molten anodic metal pad. Aluminum ions may be produced at an interface of the molten anodic metal pad and an electrolyte disposed above the molten anodic metal pad in the aluminum purification cell. The cathode may be positioned at a selected distance relative to the molten anodic metal pad so as to supply a direct current that is suitable for producing aluminum ions at the interface between the molten anodic metal pad and the electrolyte in the absence of any solid anodes disposed within the molten anodic metal pad and / or the electrolyte.Attorney Ref. No.: 169593-120017 / WQ

[0004] In some embodiments, the cathode comprises a cathode post and a horizontal cathode member extending horizontally from the cathode post. In some embodiments, the horizontal cathode member is uncoated. In some embodiments, the horizontal cathode member has a greater density than the electrolyte. In some embodiments, the horizontal cathode member has a plate shape.

[0005] In some embodiments, the horizontal cathode member defines at least one passage extending through the horizontal cathode member. In some embodiments, the at least one passage extends from an upper surface of the horizontal cathode member to a lower surface of the horizontal cathode member. In some embodiments, the at least one passage comprises at least one channel extending through a portion of the horizontal cathode member. In some embodiments, the at least one passage extends vertically.

[0006] In some embodiments, the horizontal cathode member comprises at least one recess defined at the lower surface of the horizontal cathode member, wherein the at least one recess extends to the at least one passage. In some embodiments, at least a portion of the horizontal cathode member comprises a porous region. In some embodiments, the porous region provides fluid communication between two or more surfaces of the horizontal cathode member. In some embodiments, the porous region comprises a plurality of voids. In some embodiments, the voids are randomly dispersed within the porous region. In some embodiments, the voids are arranged in a preconfigured pattern within the porous region. In some embodiments, the porous region comprises a plurality of apertures extending at least partially through the porous region. In some embodiments, the horizontal cathode member comprises a non-porous region. In some embodiments, the non-porous region surrounds at least a portion of the porous region. In some embodiments, the porous region is located in a central portion of the horizontal cathode member.

[0007] In some embodiments, the horizontal cathode member comprises at least one recess defined at the lower surface of the horizontal cathode member. In some embodiments, the at least one recess extends along the lower surface of the horizontal cathode member. In some embodiments, the at least one recess extends horizontally. In some embodiments, the at least one recess extends in a non-horizontal direction. In some embodiments, the at least one recess extends to a lateral periphery of the horizontal cathode member.

[0008] In some embodiments, the horizontal cathode member is movable with respect to the molten anodic metal pad. In some embodiments, the horizontal cathode member is movable in a vertical direction. In some embodiments, the cathode post is movably coupled at an upper portion of the aluminum purification cell to position the horizontal cathode memberAttorney Ref. No.: 169593-120017 / WQwithin the electrolyte, in some embodiments, the horizontal cathode member is located at or near a distal end of cathode post.

[0009] In some embodiments, a bottom surface of the horizontal cathode member faces the molten anodic metal pad. In some embodiments, at least a portion of the lower surface of the horizontal cathode member extends in a horizontal direction. In some embodiments, at least a portion of the lower surface of the horizontal cathode member slopes in a non-horizontal direction. In some embodiments, the horizontal cathode member is wider than the cathode post in a horizontal direction. In some embodiments, the cathode post extends vertically. In some embodiments, the aluminum purification cell includes at least one additional cathode post extending to the horizontal cathode member. In some embodiments, the cathode post is electrically coupled to a cathodic current source.

[0010] In some embodiments, the aluminum purification cell includes at least one baffle disposed at least partially in the molten anodic metal pad. In some embodiments, a portion of the at least one baffle is in contact with the electrolyte. In some embodiments, the at least one baffle is separated from the electrolyte. In some embodiments, the at least one baffle comprises a material that is not electrically conductive or essentially not electrically conductive. In some embodiments, the at least one baffle comprises an insulator material. In some embodiments, the insulator material comprises at least one of a cerme t and a ceramic. In some embodiments, the insulator material comprises at least one of alumina and boron nitride. In some embodiments, the alumina comprises fused cast alumina. In some embodiments, at least a portion of the at least one baffle has a vertical plate shape. In some embodiments, at least a portion of the at least one baffle has a horizontal plate shape. In some embodiments, the at least one baffle comprises a horizontal portion and a vertical portion. In some embodiments, the vertical portion of the at least one baffle comprises at least one vertical support that extends between the horizontal portion and a cell bottom of the aluminum purification cell. In some embodiments, the at least one baffle has a cross-sectional T-shape. In some embodiments, a portion of the at least one baffle is attached to at least one sidewall of the aluminum purification cell. In some embodiments, the at least one baffle is supported by the at least one sidewall of the aluminum purification cell.

[0011] In some embodiments, the cathode comprises a solid material. In some embodiments, the cathode comprises a non-carbonaceous material. In some embodiments, the non-carbonaceous material comprises at least one of TiB2, ZrB2, and HfB2. In some embodiments, the cathode comprises a cross-sectional T-shape. In some embodiments, the electrolyte comprises a density greater than a purified aluminum metal layer (or zone). In someAttorney Ref. No.: 169593-120017 / WQembodiments, the electrolyte comprises at least one of fluoride salts and chloride salts. In some embodiments, a cation of the fluoride salts or the chloride salts is one or more of Li, Na, K, Al, Ba, Ca, Mg, Ce, La, Cs, Rb and combinations thereof. In some embodiments, the electrolyte comprises both (a) at least one of BaF2and LaF3, and (b) at least one of AlF3, KF, MgF2, and NaF. In some embodiments, a temperature of the electrolyte is from 700 to 980 degrees Celsius. In some embodiments, the molten metal pad comprises at least one of Al, Si, Cu, Fe, Sb, Gd, Cd, Sn, Pb, Mg, Zn, Ti, and B. In some embodiments, the molten metal pad comprises aluminum. In some embodiments, the molten metal pad comprises at least 20 wt. % Al.

[0012] In one embodiment, an aluminum purification cell includes (a) a molten anodic metal pad, (b) at least one anode positioned at least partially within the molten anodic metal pad, the at least one anode comprising a solid material, (c) an electrolyte disposed above the molten anodic metal pad, and (d) a cathode positioned within the electrolyte and separated from the molten anodic metal pad and the at least one anode, wherein the cathode comprises a horizontal cathode member that extends horizontally above the at least one anode. The horizontal cathode member may extend over multiple anodes and / or anodes having various shapes and configurations, lire horizontal cathode member may be adjustably positioned at a selected distance relative to the at least one anode and / or an upper surface of the molten anodic metal pad so as to supply a direct current that is suitable for producing aluminum ions at a surface portion of the at least one anode and / or at an interface between the electrolyte and the molten anodic metal pad.

[0013] In some embodiments, the cathode comprises a cathode post that extends between the horizontal cathode member and an upper portion of the aluminum purification cell above the electrolyte. In some embodiments, the cathode post extends vertically. In some embodiments, the cathode post is movably coupled at the upper portion of the aluminum purification cell to position the horizontal cathode member within the electrolyte. In some embodiments, the horizontal cathode member is movable with respect to the at least one anode.

[0014] In some embodiments, the at least one anode comprises a plurality of anodes and the horizontal cathode member is disposed above each of the plurality of anodes. In some embodiments, the at least one anode extends into the electrolyte (i.e., the at least one anode is in direct liquid communication with the electrolyte). In other embodiments, the at least one anode is separated from the electrolyte (i.e., the at least one anode is not in direct liquid communication with the electrolyte). In some embodiments, at least a portion of the at least one anode has a vertical plate shape.Attorney Ref. No.: 169593-120017 / WQ

[0015] In some embodiments, at least a portion of the at least one anode has a horizontal portion. In some embodiments, an upper surface of the horizontal portion is positioned at an interface between the molten anodic metal pad and the electrolyte. In some embodiments, the at least one anode comprises a horizontal portion and at least one support. In some embodiments, the at least one support extends between the horizontal portion and a cell bottom of the aluminum purification cell. In some embodiments, the at least one support comprises an anodic post. In some embodiments, the at least one support extends vertically. In some embodiments, the at least one anode has a cross-sectional T-shape. In some embodiments, a portion of the at least one anode is attached to at least one sidewall of the aluminum purification cell. In some embodiments, the at least one anode comprises an aluminum wettable material,

[0016] In some embodiments, at least a portion of the at least one anode comprises a porous region. In some embodiments, the at least one anode comprises a horizontal portion that includes the porous region. In some embodiments, the porous region comprises a plurality of voids. In some embodiments, the voids are randomly dispersed within the porous region. In some embodiments, the voids are arranged in a preconfigured pattern within the porous region. In some embodiments, the porous region comprises a plurality of apertures extending at least partially through the porous region. In some embodiments, the at least one anode is electrically coupled to an anodic current source.

[0017] In one embodiment, an aluminum purification cell comprises (a) a molten anodic metal pad, (b) an electrolyte disposed above the molten anodic metal pad, and (c) a cathode positioned within the electrolyte and separated from the molten anodic metal pad, wherein the cathode comprises a cathode post and a horizontal cathode member extending horizontally from the cathode post. In some embodiments, a horizontal dimension of the horizontal cathode member is greater than a horizontal width of the cathode post. In some embodiments, the horizontal cathode member overlaps a majority of a horizontal profile of the electrolyte (i.e., a horizontal profile of the horizontal cathode member overlaps a majority of a horizontal profile of the electrolyte between cell sidewalls of the aluminum purification cell). In some embodiments, the horizontal cathode member overlaps at least 60% of the horizontal profile of the electrolyte. In some embodiments, the horizontal cathode member overlaps at least 70% of the horizontal profile of the electrolyte. In some embodiments, the horizontal cathode member overlaps at least 80% of the horizontal profile of the electrolyte.

[0018] In one embodiment, a method for making purified aluminum comprises (a) producing aluminum ions from an aluminum-based feedstock, wherein the aluminum ions are produced at an interface between a molten anodic metal pad and an electrolyte located aboveAttorney Ref. No.: 169593-120017 / WQthe molten anodic metal pad, wherein the aluminum ions are produced in the absence of any electrodes located in the molten anodic metal pad, (b) forming metallic aluminum by reducing the aluminum ions on a portion of a cathode positioned within the electrolyte and separated from the molten anodic metal pad, and (c) transporting at least a portion of the metallic aluminum to a purified aluminum metal layer located above the electrolyte.

[0019] In some embodiments, the transporting step (c) comprises moving at least a portion of the metallic aluminum along a surface of the cathode that extends to the purified aluminum metal layer. In some embodiments, the transporting step (c) comprises moving at least a portion of the metallic aluminum from the cathode through the electrolyte to the purified aluminum metal layer. In some embodiments, the transporting step (c) comprises forming droplets of at least the portion of the metallic aluminum at the cathode. In some embodiments, the transporting step (c) comprises passing at least a portion of the metallic aluminum through a porous portion of the cathode. In some embodiments, the passing step comprises passing at least the portion of the metallic aluminum through the porous portion to an upper surface of the cathode. In some embodiments, the transporting step (c) further comprises transporting droplets of the metallic aluminum from the upper surface of the cathode through the electrolyte to the purified aluminum metal layer. In some embodiments, the cathode comprises a cathode post and a horizontal cathode member extending horizontally from the cathode post. In some embodiments, the method further comprises moving the cathode to adjust a distance between the cathode and the molten anodic metal pad,

[0020] In some embodiments, the method further comprises dampening instabilities in the molten anodic metal pad (e.g., molten metal waves, such as physical movement of the molten anodic metal pad predominantly in the horizontal direction, which may be considered a type of sloshing of the molten metal). In some embodiments, the dampening step comprises dampening the instabilities by at least one baffle positioned at least partially within the molten anodic metal pad. In some embodiments, the at least one baffle is in direct liquid communication with the electrolyte,

[0021] In one embodiment, a method for making purified aluminum comprises (a) producing aluminum ions from an aluminum-based feedstock, wherein the aluminum ions are produced at an interface between a molten anodic metal pad and an electrolyte located above the molten anodic metal pad, (b) forming metallic aluminum by reducing the aluminum ions on a horizontal cathode member of a cathode, wherein the horizontal cathode member is positioned within the electrolyte and is separated from the molten anodic metal pad, wherein the horizontal cathode member extends horizontally above the molten anodic metal pad, andAttorney Ref. No.: 169593-120017 / WQ(c) transporting the metallic aluminum to a purified aluminum metal layer located above the electrolyte.

[0022] In some embodiments, the transporting step (c) comprises moving at least a portion of the metallic aluminum along a surface of a cathode post of the cathode, wherein the cathode post extends from tire horizontal cathode member to the purified aluminum metal layer. In some embodiments, the transporting step (c) comprises forming droplets of the metallic aluminum at the horizontal cathode member. In some embodiments, the transporting step (c) comprises moving the droplets of the metallic aluminum through the electrolyte to the purified aluminum metal layer. In some embodiments, at least one solid anode is at least partially disposed in the molten anodic metal pad. In some embodiments, the horizontal cathode member overlaps the at least one solid anode. In some embodiments, the at least one solid anode is in direct liquid communication with the electrolyte.

[0023] These and other aspects, advantages, and novel features of this new technology are set forth in part in the description that follows and will become apparent to those skilled in the art upon examination of the following description and figures, or may be learned by practicing one or more embodiments of the technology provided for by the present disclosure.BRIEF DESCRIPTION OF DRAWINGS

[0024] FIG. 1 is a process flow diagram illustrating one embodiment of a method for purifying aluminum in accordance with the present disclosure.

[0025] FIG. 2A is a cross-sectional side view of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0026] FIG. 2B is a cross-sectional side view' of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0027] FIG. 3 is a cross-sectional side view of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0028] FIG. 4 is a cross-sectional side view of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0029] FIG. 5 is a cross-sectional side view' of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0030] FIG. 6 is a cross-sectional side view of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0031] FIG. 7 is a cross-sectional side view of one embodiment of an aluminum purification cell in accordance with the present disclosure.Attorney Ref. No.: 169593-120017 / WQ

[0032] FIG. 8 is a cross-sectional side view of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0033] FIG. 9A is a cross-sectional side view of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0034] FIG. 9B is a cross-sectional side view of one embodiment of a horizontal cathode member for an aluminum purification cell in accordance with the present disclosure.

[0035] FIG. 9C is a cross-sectional side view of one embodiment of a horizontal cathode member for an aluminum purification cell in accordance with the present disclosure.

[0036] FIG. 10 is a cross-sectional side view of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0037] FIG. 11A is a cross-sectional side view' of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0038] FIG. 11B is a cross-sectional side view of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0039] FIG. 12A is a cross-sectional side view of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0040] FIG. 12B is a cross-sectional side view of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0041] FIG. 13 is a cross-sectional side view of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0042] FIG. 14A is a cross-sectional side view' of one embodiment of an aluminum purification cell in accordance with the present disclosure.

[0043] FIG. 14B is a cross-sectional side view' of one embodiment of a horizontal baffle member for an aluminum purification cell in accordance with the present disclosure,

[0044] FIG. 14C is a cross-sectional side view of one embodiment of a horizontal baffle member for an aluminum purification cell in accordance with the present disclosure.

[0045] FIG. 15 is a cross-sectional view of one embodiment of an aluminum purification cell in accordance w'ith the present disclosure.

[0046] FIG. 16 is a cross-sectional view' of one embodiment of an aluminum purification cell in accordance with the present disclosure.DETAILED DESCRIPTION

[0047] As noted above, the present disclosure relates to aluminum purification cells and methods pertaining to the same, and, in particular, metal collection features relating to aluminum purification cells and methods of collecting metal in aluminum purification cells.Attorney Ref. No.: 169593-120017 / WQi. Methods of Making Purified Aluminum

[0048] In one approach, an aluminum purification cell includes at least one cathode in fluid communication with an electrolyte and a molten anodic metal pad in spaced relation from the at least one cathode and also in fluid communication with the electrolyte. In one embodiment, the electrolyte includes aluminum ions. The aluminum ions may be reduced, resulting in formation of molten metallic aluminum. Due to a density difference between the electrolyte and the metallic aluminum, a molten metal layer of metallic aluminum may form proximal the electrolyte. In one embodiment, the molten metal layer is less dense than the electrolyte and may form above or on top of the electrolyte. The molten metal layer may be periodically removed from the aluminum purification cell, such as by tapping.

[0049] One non-limiting embodiment of an exemplary method for purifying aluminum is illustrated in FIG. 1. In the illustrated embodiment, the method comprises producing (1000) aluminum ions from an aluminum-based feedstock at an interface between a molten anodic metal pad and an electrolyte. The aluminum ions may be formed in an aluminum purification cell that includes at least one cathode, such as a cathode that includes a cathode post and a horizontal cathode member extending from an end of the cathode post over the molten anodic metal pad. The aluminum ions may be produced in the electrolyte by supplying an electric current to the molten anodic metal pad, with the electric current being removed at the cathode of the aluminum purification cell. Aluminum may be oxidized from a surface of the molten anodic metal pad, thereby producing the aluminum ions in the electrolyte.

[0050] The method may additionally comprise forming (2000) metallic aluminum by reducing the aluminum ions on a cathode within the electrolyte. In some embodiments, the metallic aluminum may be formed on the cathode, where the aluminum ions are reduced onto a surface of the at least one cathode and form aluminum metal. In some embodiments, the aluminum metal may be in purified form. In some embodiments, metallic aluminum may remain on or near a surface of the cathode and / or may be present within the electrolyte in regions separate from the cathode,

[0051] The method may further comprise transporting (3000) the metallic aluminum through the electrolyte to a purified aluminum metal layer or zone disposed above the electrolyte. In one embodiment, at least a portion of the metallic aluminum may be conveyed along a surface of the cathode that passes through the purified aluminum metal layer above the electrolyte. In one embodiment, at least a portion of the metallic aluminum may pass through the electrolyte (e.g., as droplets) to the purified aluminum metal layer above the electrolyte.Attorney Ref. No.: 169593-120017 / WQii. Aluminum Purification Cells

[0052] Referring now to FIG. 2A, one embodiment of an aluminum purification ceil is illustrated. In the illustrated embodiment, the aluminum purification cell (200) includes a cell bottom (204), sidewalls (206), and a top cover (238). In some embodiments, the aluminum purification cell (200) may include thermal insulation (not shown) surrounding at least a portion of cell bottom (204), sidewalls (206), and / or top cover (238) to facilitate high energy efficiency of the aluminum purification cell (200) and / or to decrease heat loss from interior regions of the aluminum purification cell (200).

[0053] The cell sidewalls (206), the cell bottom (204), and the top cover (238) at least partially define a cell chamber (219) within the aluminum purification cell (200). In some embodiments, the cell side walls (206) may be made of a heat-stable material (e.g., a refractory material) that is generally inert to the liquid / molten conditions of the aluminum purification cell (200), In some embodiments, the aluminum purification cell (200) may include an outer shell (not shown), which may comprise steel or other suitable materials. In some embodiments, the outer shell may include a shell floor located beneath the cell bottom (204) and / or may include shell sidewalls spaced apart from and at least partially surrounding the cell sidewalls (206). Thermal insulation may be located in a region between the outer shell and cell bottom (204) and / or cell sidewalls (206). The thermal insulation may facilitate high energy efficiency of the aluminum purification cell (200).

[0054] In some embodiments, the cell chamber (219) contains a molten anodic metal pad (208) or zone, an electrolyte (210) layer or zone, and a purified aluminum metal (216) layer or zone. In the illustrated embodiment, the electrolyte (210) separates the purified aluminum metal layer (216) from the molten anodic metal pad (208). Inner surfaces of the cell sidewalls (206) may contact the molten anodic metal pad (208), the electrolyte (210), and in some embodiments, the purified aluminum metal layer (216) formed above the electrolyte (210). Tire molten anodic metal pad (208) may be in contact with an upper surface (205) of the cell bottom (204) of the aluminum purification cell (200). In one embodiment, the cell bottom (204) may be connected to an external anodic power source by an anode connector (239). In some embodiments, an anodic current may be supplied to molten anodic metal pad (208) via the cell botom (204), which contacts and extends along a lower portion of the molten anodic metal pad (208).

[0055] In some embodiments, the upper surface (205) of the cell bottom (204) is sloped. In some embodiments, the slope comprises an angle of less than 10 degrees. In some embodiments, the slope comprises an angle of about 3 to 5 degrees. In some embodiments, theAttorney Ref. No.: 169593-120017 / WQaluminum purification cell (200) may include a cell access channel (230) penetrating the cell chamber (219), thereby providing access to the lower portion of the cell chamber (219). The cell access channel (230) may have an access port (232). Aluminum feedstock (234) may be added to the aluminum purification cell (200) via the access port (232). The aluminum feedstock (234) may include, for instance, aluminum scrap, primary aluminum, and / or secondary’ aluminum. Purified aluminum metal ofthe purified aluminum metal layer (216) may be extracted from the aluminum purification cell (200) via a separate extraction port, such as an extraction port in the top cover (238). The aluminum feedstock (234) may be introduced to the cell access channel (230) as a solid material and / or as a melted mixture that has been heated above a melting point prior to delivery’. When the aluminum feedstock (234) is introduced to the cell access channel (230) in solid form, the aluminum feedstock (234) may be heated and melted within the cell access channel (230) and / or in a portion of molten anodic metal pad (208) at or near the cell access channel (230). In some embodiments, the aluminum purification cell (200) may also include an inert gas inlet (not shown) formed, for example, in the top cover (238) to provide an inert atmosphere to the cell chamber (219). Examples of inert gases include helium, argon, nitrogen, and carbon dioxide, among others. In some embodiments, a method includes purging the cell chamber (219) with an inert gas. In some embodiments, the method may include adding aluminum feedstock (234) into the cell chamber (219) via the cell access port (232). In some embodiments, the aluminum feedstock (234) may be added essentially continuously during operation ofthe aluminum purification cell (200), In some embodiments, the aluminum feedstock (234) may be added by metering the aluminum feedstock (234) at a first feed rate, in some embodiments, the aluminum feedstock (234) may be added periodically.

[0056] In some embodiments, sludge (236) may be produced as a by-product of the aluminum purification. As used herein, “sludge” means waste material precipitated during aluminum purification. In some embodiments, sludge (236) comprises highly viscous or solid material. The sludge (236) may have a higher density than the molten anodic metal pad (208). As described above, the upper surface (205) of the cell bottom (204) may be sloped. In some embodiments, the slope may run from a cell sidewall (206) down towards the cell access channel (230). In some embodiments, the sludge (236) may drain along the upper surface (205) of the cell bottom (204) towards the cell access channel (230). In some embodiments, the sludge may be removed from the cell chamber (219) via the cell access channel (230). In some embodiments, impurities may tend to collect in the molten anodic metal pad (208). In some embodiments, the cell access channel (230) may facilitate removal of at least a portion of the molten anodic metal pad (208).Attorney Ref. No.: 169593-120017 / WQ

[0057] As described above, in the illustrated embodiment, the electrolyte (210) separates the purified aluminum metal layer (216) from the molten anodic metal pad (208). As used herein, ‘‘electrolyte” means a medium in which the flow' of electrical current is primarily or entirely carried out by the movement of ions / ionic species. In one embodiment, an electrolyte may comprise one or more molten salts. In one embodiment, a composition of the electrolyte (210) may be selected such that the electrolyte (210) has a lower density than the molten anodic metal pad (208) and a higher density than the purified aluminum metal layer (216). In some embodiments, the electrolyte (210) may comprise salts of at least one of fluorides and / or chlorides of lithium (Li), sodium (Na), potassium (K), aluminum (Al), barium (Ba), calcium (Ca), cerium (Ce), lanthanum (La), cesium (Cs), rubidium (Rb), and combinations thereof, among others. In one embodiment, the electrolyte (210) comprises at least one of BaF₂ and AlF₃. In one embodiment, the electrolyte (210) comprises from 5 wt. % to 70 wt, % BaF2. In another embodiment, the electrolyte (210) comprises from 0.5 to 30 wt. % AlF₃. In yet another embodiment, the electrolyte (210) comprises from 5 to 70 wt. % BaFc and from 0.5 to 30 wt. % AlF₃. In one embodiment, the electrolyte (210) also includes at least one of KF and NaF in addition to at least one of BaF₂ and AlF₃.

[0058] The aluminum purification cell (200) may be operated or maintained at any suitable temperature. In one embodiment, a temperature of the electrolyte is from 700 to 980 degrees Celsius. In one embodiment, a temperature of the electrolyte (210) is at least 750 degrees Celsius. In another embodiment, a temperature of the electrolyte (210) is at least 800 degrees Celsius. In another embodiment, a temperature of the electrolyte (210) is at least 850 degrees Celsius. In another embodiment, a temperature of the electrolyte (210) is at least 900 degrees Celsius. In one embodiment, a temperature of the electrolyte (210) is not greater than 970 degrees Celsius. In another embodiment, a temperature of the electrolyte (210) is not greater than 960 degrees Celsius. In another embodiment, a temperature of the electrolyte (210) is not greater than 950 degrees Celsius. In one embodiment, a temperature of the electrolyte (210) is from 900 to 950 degrees Celsius,

[0059] As used herein, “purified aluminum” means a material having at least 95.0 wt. % aluminum, which aluminum is in metallic or alloyed form, in one embodiment, a purified aluminum material includes at least 96.0 wt. % aluminum. In another embodiment, a purified aluminum material includes at least 97.0 wt, % aluminum. In yet another embodiment, a purified aluminum material includes at least 97.5 wt. % aluminum. In another embodiment, a purified aluminum material includes at least 98.0 wt. % aluminum. In yet another embodiment, a purified aluminum material includes at least 98.5 wt. % aluminum. In another embodiment,Attorney Ref. No.: 169593-120017 / WQa purified aluminum material includes at least 99.0 wt. % aluminum, in yet another embodiment, a purified aluminum material includes at least 99.5 wt. % aluminum. In another embodiment, a purified aluminum material includes at least 99.6 wt. % aluminum. In yet another embodiment, a purified aluminum material includes at least 99.7 wt. % aluminum. In another embodiment, a purified aluminum material includes at least 99.8 wt. % aluminum. In yet another embodiment, a purified aluminum material includes at least 99,9 wt. % aluminum, or more. In one embodiment, the purified aluminum is in the form of a molten metal layer of an aluminum purification cell. In one embodiment, the purified aluminum is in the form of a solid material (e.g., a material formed due to extraction of the molten metal layer of the aluminum purification cell),

[0060] In some embodiments, the purified aluminum metal in the purified aluminum metal layer (216) has 99.5 wt. %to 99.999 wt. % aluminum. In some embodiments, the purified aluminum metal has 99.6 wt. %to 99.999 wt. % aluminum. In some embodiments, the purified aluminum metal has 99.7 wt. %to 99.999 wt. % aluminum. In some embodiments, the purified aluminum metal has 99.8 wt. %to 99.999 wt. % aluminum. In some embodiments, the purified aluminum metal has 99.9 wt. %to 99.999 wt. % aluminum. In some embodiments, the purified aluminum metal has 99.95 wt. % to 99.999 wt. % aluminum. In some embodiments, the purified aluminum metal has 99,98 wt. % to 99.999 wt. % aluminum. In some embodiments, the purified aluminum metal has 99.5 wt. % to 99.99 wt. % aluminum. In some embodiments, the purified aluminum metal has 99.5 wt. % to 99.95 wt. % aluminum. In some embodiments, the purified aluminum metal has 99.5 wt. % to 99.9 wt. % aluminum. In some embodiments, the purified aluminum metal has 99.5 wt. % to 99.8 wt. % aluminum. In some embodiments, the purified aluminum metal has 99.5 wt. %to 99.7 wt. % aluminum.

[0061] As used herein, “molten anodic metal pad” means a volume of molten metal material containing molten aluminum metal and impurities. In one embodiment, a molten anodic metal pad (208) includes some aluminum and a significant volume of impurities (e.g., from 1-75 wt. % impurities), A molten anodic metal pad may comprise any suitable metallic elements, including, by way of example, aluminum (Al), silicon (Si), copper (Cu), iron (Fe), antimony (Sb), gadolinium (Gd), cadmium (Cd), tin (Sn), lead (Pb), and magnesium (Mg). Impurities may include zinc (Zn), titanium (Ti), and / or boron (B).

[0062] In one embodiment, the molten anodic metal pad (208) comprises aluminum. In one embodiment, the molten metal pad (208) comprises at least 20 wt. % Al. In one embodiment, the molten metal pad (208) comprises at least 25 wt. % Al. In another embodiment, the molten metal pad (208) comprises at least 30 wt. % Al. In yet anotherAttorney Ref. No.: 169593-120017 / WQembodiment, the molten metal pad (208) comprises at least 35 wt. % Al. In another embodiment, the molten metal pad (208) comprises at least 40 wt. % Al. In yet another embodiment, the molten metal pad (208) comprises at least 45 wt. % Al. In another embodiment, the molten metal pad (208) comprises at least 50 wt. % Al. In yet another embodiment, the molten metal pad (208) comprises at least 55 wt. % Al. In another embodiment, the molten metal pad (208) comprises at least 60 wt, % Al. In yet another embodiment, the molten metal pad (208) comprises at least 65 wt. % Al. In another embodiment, the molten metal pad (208) comprises at least 70 wt. % Al. In yet another embodiment, the molten metal pad (208) comprises at least 75 wt. % Al. In another embodiment, the molten metal pad (208) comprises at least 80 wt, % Al, In one embodiment, the molten metal pad (208) comprises copper (Cu), which may be present in aluminum feedstock used to produce the molten metal pad (208) and / or which may be added to the molten metal pad (208) as a densifying aid. In one embodiment, the molten metal pad (208) comprises at least 0.3 wt. % Cu. In one embodiment, the molten metal pad (208) comprises from 15 to 60 wt.% Cu. in one embodiment, the molten anodic metal pad (208) comprises not greater than 90 wt. % Al. In another embodiment, the molten anodic metal pad (208) comprises not greater than 85 wt, % Al. In another embodiment, the molten anodic metal pad (208) comprises not greater than 80 wt. % Al.

[0063] In some embodiments, the aluminum purification cell (200) includes at least one cathode, such as cathode (214) illustrated in FIG, 2A. As illustrated, the cathode (214) extends downward through the purified aluminum metal layer (216) and terminates in the electrolyte (210) such that the cathode (214) is separated from the molten anodic metal pad (208) by a portion of the electrolyte (210). The cathode (214) may have a density that is greater than the electrolyte (210) such that the cathode (214) is not subject to buoyant forces in the electrolyte (210). In some embodiments, the cathode (214) is electrically connected to an external power source that supplies a cathodic current (e.g, a negatively charged current) to the cathode (214). For example, one end of a cathode connector may be coupled to the external power source and an opposite end of the cathode connector may be in electrical communication w ith the cathode (214). At least one of the cathode (214) and a cathode connector to which the cathode (214) is connected may pass through an upper portion of the aluminum purification cell (200) (e.g., through an opening defined in the top cover (238)).

[0064] One embodiment of a method for purifying aluminum includes supplying an electric current to the molten anodic metal pad (208). Molten material (including molten aluminum) from the molten anodic metal pad (208) may contact the electrolyte (210) at anAttorney Ref. No.: 169593-120017 / WQinterface (226) where a top surface of the molten anodic metal pad (208) contacts a bottom surface of the electrolyte (210). At least some of the aluminum ions may be transported through the electrolyte (210) onto surfaces of the cathode (214) positioned within the electrolyte (210). At least some of the aluminum ions in the electrolyte (210) may be reduced via electrical current at the cathode (214), thereby producing metallic aluminum (i.e., purified aluminum metal) on the surface portions of the cathode (214) and / or within the electrolyte (210). Without being bound by a particular mechanism or theory, it is hypothesized that at least some of the metallic aluminum moves along surface(s) of the cathode(s) (214) in an upward direction due to a buoyancy of the purified aluminum metal in the electrolyte (210). In some embodiments, at least some of the purified metallic aluminum within the electrolyte (210) may also collect in droplets that move upward through electrolyte (210) to the purified aluminum metal layer (216) due to buoyancy of the metallic aluminum in the electrolyte (210). In some embodiments, purified aluminum metal in the purified aluminum metal layer (216) may tend to collect above the electrolyte (210). Based on differences in density between the purified aluminum metal layer (216), the electrolyte (210), and the molten anodic metal pad (208), which may include feedstock with aluminum metal, impurities, and / or densifying aids, such as additives to increase density, the molten anodic metal pad (208) is configured to have a density’ greater than the electrolyte (210), with the molten anodic metal pad (208) disposed below the electrolyte (210). In some embodiments, the molten anodic metal pad (208) may include at least one additive (e.g., to increase its density), such as at least one of Cu, Pb, Sn, Ga, Zn, and Ag,

[0065] In some embodiments, the purified aluminum metal of the purified aluminum metal layer (216) may be produced via the aluminum purification cell (200) at an energy efficiency of 1 to 15 kWh / kg of purified aluminum metal. As used herein, “energy efficiency’’ means the amount of energy (in kilowatt hours) consumed by an aluminum purification cell per kilogram of purified aluminum metal produced by the aluminum purification cell. In some embodiments, tire purified aluminum metal may be produced via the aluminum purification cell (200) at an energy efficiency of 1 to 10 kWh / kg of purified aluminum metal. In some embodiments, the purified aluminum metal may be produced via the aluminum purification cell (200) at an energy efficiency of 1 to 8 kWh / kg of purified aluminum metal. In some embodiments, the purified aluminum metal may be produced via the aluminum purification cell (200) at an energy efficiency of 1 to 6 kWh / kg of purified aluminum metal. In some embodiments, the purified aluminum metal may be produced via the aluminum purification cell (200) at an energy efficiency of 1 to 4 kWh / kg of purified aluminum metal.Attorney Ref. No.: 169593-120017 / WQ

[0066] In some embodiments, the purified aluminum metal may be produced via the aluminum purification cell (200) at an energy efficiency of 5 to 15 kWh / kg of purified aluminum metal. In some embodiments, the purified aluminum metal may be produced via the aluminum purification cell (200) at an energy efficiency of 10 to 15 kWh / kg of purified aluminum metal. In some embodiments, the purified aluminum metal may be produced via the aluminum purification cell (200) at an energy efficiency of 12 to 15 kWh / kg of purified aluminum metal. In some embodiments, the purified aluminum metal may be produced via the aluminum purification cell (200) at an energy efficiency of 2 to 10 kWh / kg of purified aluminum metal. In some embodiments, the purified aluminum metal may be produced via the aluminum purification cell (200) at an energy efficiency of 2 to 8 kWh / kg of purified aluminum metal. In some embodiments, the purified aluminum metal may be produced via the aluminum purification cell (200) at an energy efficiency of 2 to 6 kWh / kg of purified aluminum metal.

[0067] In some embodiments, aluminum feedstock may be added to the molten anodic metal pad (208) continuously, essentially continuously, or periodically during operation of the aluminum purification cell (200). As used herein, “aluminum feedstock” means a feedstock having metallic aluminum and / or one or more aluminum alloys. The aluminum feedstock may include, for instance aluminum scrap, primary aluminum, and / or secondary aluminum. In one embodiment, an aluminum feedstock comprises at least 20 wt. % aluminum. In another embodiment, an aluminum feedstock comprises at least 25 wt. % aluminum. In another embodiment, an aluminum feedstock comprises at least 30 wt, % aluminum. In yet another embodiment, an aluminum feedstock comprises at least 35 wt. % aluminum. In another embodiment, an aluminum feedstock comprises at least 40 wt. % aluminum. In yet another embodiment, an aluminum feedstock comprises at least 45 wt. % aluminum. In another embodiment, an aluminum feedstock comprises at least 50 wt. % aluminum. In yet another embodiment, an aluminum feedstock comprises at least 55 wt. % aluminum. In another embodiment, an aluminum feedstock comprises at least 60 wt. % aluminum. In yet another embodiment, an aluminum feedstock comprises at least 65 wt. % aluminum. In another embodiment, an aluminum feedstock comprises at least 70 w t. % aluminum. In yet another embodiment, an aluminum feedstock comprises at least 75 wt. % aluminum. In another embodiment, an aluminum feedstock comprises at least 80 v>f.. % aluminum. In one embodiment, an aluminum feedstock comprises not greater than 98 wt, % aluminum. In another embodiment, an aluminum feedstock comprises not greater than 95 wt. % aluminum. In yet another embodiment, an aluminum feedstock comprises not greater than 90 wt. % aluminum.Attorney Ref. No.: 169593-120017 / WQ

[0068] In one embodiment, the aluminum feedstock is substantially free of alumina (Al2O3) having not greater than 5 wt. % alumina therein. In another embodiment, the aluminum feedstock comprises not greater than 4 wt. % alumina. In yet another embodiment, the aluminum feedstock comprises not greater than 3 wt. % alumina. In another embodiment, the aluminum feedstock comprises not greater than 2 wt. % alumina. In yet another embodiment, the aluminum feedstock comprises not greater than 1 wt. % alumina. In another embodiment, the aluminum feedstock comprises not greater than 0.5 wt. % alumina. In yet another embodiment, the aluminum feedstock comprises not greater than 0.1 wt. % alumina.

[0069] In some embodiments, at least some of the purified aluminum metal layer (216) may be removed from the aluminum purification cell (200). In some embodiments, purified aluminum metal of the purified aluminum metal layer (216) may be removed continuously, essentially continuously, or periodically during operation of the aluminum purification cell (200), In some embodiments, the removing step is completed with equipment configured to remove the purified aluminum metal without contaminating the purified aluminum metal product (e.g., using alumina, graphite, and / or boride -based tapping equipment).

[0070] In some embodiments, an inert atmosphere may be introduced to the cell chamber (219) via, for example, a gas inlet. In this regard, the cell chamber (219) may be sealed from the ambient atmosphere by, for example, the top cover (238). Examples of inert gases include helium, argon, and nitrogen, among others.zzz. Horizontal Cathode Member

[0071] Referring to FIG. 2A, the cathode (214) includes at least one cathode post (218) and a horizontal cathode member (220) extending horizontally from the cathode post (218). As used herein, the vertical direction is represented by the y-axis illustrated in FIG. 2A and the horizontal direction is a direction perpendicular to the y-axis (e.g,, a direction parallel to the x-axis illustrated in FIG. 2A). In some embodiments, the cathode post (218) may be secured to an upper portion of the aluminum purification cell (200), such as the top cover (238). In some embodiments, an upper end of the cathode post (218) may be secured at a location above the top cover (238). The upper end of the cathode post (218) may be electrically connected to a cathodic power source via, for example, a cathode connector. In one embodiment, the cathode post (218) may extend from the top of the aluminum purification cell (200), passing through the purified aluminum metal layer (216) and extending partially into the electrolyte (210). In some embodiments, the cathode post (218) may include at least one rod, pole, elongated plate, and / or any other suitable elongated member.Attorney Ref. No.: 169593-120017 / WQ

[0072] The horizontal cathode member (220) may be attached to the cathode post (218) at any suitable location, such as a location at or near a bottom end of the cathode post (218). In one embodiment, the cathode may have a cross-sectional T-shape formed by the combination of the cathode post (218) and the horizontal cathode member (220), as illustrated in FIG. 2A. The horizontal cathode member (220) may extend horizontally from the cathode post (218). In one embodiment, the horizontal cathode member (220) may extend horizontally outward from the cathode post (218) toward the cell sidewalls (206). In some embodiments, the cathode post (218) may be located at or near a central portion of the horizontal cathode member (220), as illustrated in FIG. 2A, or at any other suitable portion of the horizontal cathode member (220). In one embodiment, the cathode (214) may include a plurality of cathode posts (218) and / or a plurality of horizontal cathode members (220). For example, the cathode (214) may comprise a plurality of cathode posts (218) attached at different portions of the horizontal cathode member (220). In one embodiment, the horizontal cathode member (220) may extend in a horizontal direction so as to be parallel or essentially parallel to the interface (226) between the molten anodic metal pad (208) and the electrolyte (210).

[0073] The horizontal cathode member (220) may extend within the cell chamber (219) between cell sidewalls (206) so as to overlap a substantial portion of a horizontal profile of the electrolyte (210). For example, as illustrated in FIG. 2B, the electrolyte (210) has a horizonal profile (HPE) between the cell side walls (206) of the aluminum purification cell (200) and the horizontal cathode member (220) has a horizontal profile (HPC) between the cell sidewalls (206). As illustrated, the HPC of the horizontal cathode member (220) overlaps a substantial portion of the HPE of the electrolyte (210) (i.e., the horizontal cathode member (220) extends over or along a substantial portion of the electrolyte (210) in a horizontal direction). In one embodiment, the HPC of the horizontal cathode member (220) overlaps a majority of the HPE of the electrolyte (210). In one embodiment, the HPC of the horizontal cathode member (220) overlaps at least 50% of the HPE of the electrolyte (210). In one embodiment, the HPC of the horizontal cathode member (220) overl aps at least 60% of the HPE of the el ectrolyte (210). In one embodiment, the HPC of the horizontal cathode member (220) overlaps at least 70% of the HPE of the electrolyte (210). In one embodiment, the HPC of the horizontal cathode member (220) overlaps at least 80% of the HPE of the electrolyte (210). In one embodiment, the HPC of the horizontal cathode member (220) overlaps at least 90% of the HPE of the electrolyte (210). In one embodiment, the HPC of the horizontal cathode member (220) overlaps at least 95% of the HPE of the electrolyte (210). In one embodiment, the HPC of the horizontal cathode member (220) entirely or essentially entirely overlaps the HPE of the electrolyte (210).Attorney Ref. No.: 169593-120017 / WQ

[0074] Returning to FIG. 2A, the horizontal cathode member (220) may have an upper surface (222) and a lower surface (223). The upper surface (222) and the lower surface (223) may each have any suitable shape and size and may extend in any suitable directions. In one embodiment, as shown in FIG. 2A, the upper surface (222) and / or the lower surface (223) may extend in the horizontal direction. For example, the lower surface (223) may comprise a planar or essentially planar surface that is parallel to the interface (226). In this example, a distance between the lower surface (223) of the horizontal cathode member (220) and an upper surface of the molten anodic metal pad (208) may be constant or essentially constant along the horizontal cathode member (220). Additionally, a distance between the upper surface (222) of the horizontal cathode member (220) and a lower surface of the purified aluminum metal layer (216) at the interface (228) between electrolyte (210) and purified aluminum metal layer (216) may be constant or essentially constant along the horizontal cathode member (220). In some embodiments, at least a portion of the upper surface (222) and / or the lower surface (223) may extend at one or more angles with respect to the horizontal direction. For example, the upper surface (222) and / or the lower surface (223) may include one or more slanted and / or curved portions that are not horizontal.

[0075] FIGS, 15-16 show embodiments of aluminum purification cells having more than one cathode. For example, FIGS. 15-16 show an aluminum purification cell (800) having a first cathode (814) that includes a first cathode post (818) and a first horizontal cathode member (820) extending horizontally from the first cathode post (818). The aluminum purification cell (800) also includes a second cathode (845) that includes a second cathode post (848) and a second horizontal cathode member (850) extending horizontally from the second cathode post (848). The aluminum purification cell (800) includes a cell bottom (804) and cell sidewalls (806) surrounding a cell chamber (819), Tire cell chamber (819) contains a molten anodic metal pad (808), an electrolyte (810) bath, and a purified aluminum metal layer (816).

[0076] In some embodiments, a plurality of cathode posts (e.g., first cathode post (818) and second cathode post (848)) and / or a plurality of horizontal cathode members (e.g., first horizontal cathode member (820) and second horizontal cathode member (850)) may be positioned at the same or different elevations within the aluminum purification cell (e.g., extend different distances into the electrolyte, from the cell bottom, from the cell top, from a side of the cell, from an interface). For example, the first horizontal cathode member (820) can be at a first height position that is relatively closer, or relatively further away from the cell bottom (e.g., cell bottom (804) of FIG. 15) than the second horizontal cathode member (850) located at a second (different) height position in tire same aluminum purification cell (800).Attorney Ref. No.: 169593-120017 / WQ

[0077] In some embodiments, the position of the various horizontal cathode members (e.g., first horizontal cathode member (820) and second horizontal cathode member (850)) can be adjusted to maintain a uniform, or substantially uniform, distance between the various horizontal cathode members and, for example, an interface (e.g., interface (826) of FIG. 15). In some embodiments, as shown for example in FIG. 2A, tire interface between the electrolyte and the anodic metal pad (e.g., interface (226)) may be consistent (e.g., a uniform distance from the cell bottom (204)), or essentially consistent, throughout the aluminum purification cell. However, in some embodiments, as shown in FIG. 15, the interface (826) can be inconsistent (e.g., sloped, non-linear). In some embodiments, the interface (826) can be inconsistent because of imperfections in mixing, and build-up of impurities (e.g., sludge (236) of FIG, 2A), among other reasons. In some embodiments, the position of the various horizontal cathode members can be adjusted to increase the uniformity in the distance between the various horizontal cathode members and the interface. For example, the position of the various horizontal cathode members can be adjusted such that tire first horizontal cathode member (820) and the second horizontal cathode member (850) can be the same distance, or substantially the same distance, from the interface (e.g., interface (826) of FIG. 15).

[0078] Additionally, in some embodiments, the distance from a first end of a horizontal cathode member to an interface may be different than a distance to a second end of the same horizontal cathode member to the same interface. For example, as shown in FIG. 15, a first end (821) of the first horizontal cathode member (820) can be closer to the interface (826) than a second end (825) of the first horizontal cathode member (820). In some embodiments, to increase the uniformity in distance between various ends of a single horizontal cathode member and the interface, the horizontal cathode member can be slanted (e.g., sloped). For example, as shown in FIG. 16, the first horizontal cathode member (820) can be sloped such that the first end (821) and tire second end (825) may be the same distance, or substantially the same distance, from the interface (826). In some embodiments, a horizontal cathode member may be sloped such that it may be parallel, or substantially parallel, to the interface (e.g., within 5 degrees of perfectly parallel). In some embodiments, a horizontal cathode member may be sloped such that it may be non-parallel (e.g., more than 5 degrees away from perfectly parallel) to tire interface.

[0079] In some embodiments, the position of various horizontal cathode members (e.g., first horizontal cathode member (820) and second horizontal cathode member (850)) can be adjusted to maintain a uniform, or substantially uniform, electrical property (e.g., voltage drop, electrical resistance). In some embodiments, an electrical property may relate to a cathode. InAttorney Ref. No.: 169593-120017 / WQsome embodiments, an electrical property may relate to an anode, in some embodiments, an electrical property may relate to both a cathode and an anode. In some embodiments, an electrical property may be, for instance, a voltage drop across a cathode (e.g., the first horizontal cathode member (820)) and an anode (e.g., metal anodic metal pad (808) of FIG.15). For example, an electrical characteristic (e.g., voltage, current, resistance, power, capacitance, inductance) at an anode and / or a cathode can be detected. Based on the detected electrical characteristics, one or more electrical properties (e.g., voltage drop, electrical resistance) can be determined. In some embodiments, adjusting the position and / or orientation of one or more cathodes can affect one or more electrical properties. For example, in some embodiments, adjusting the distance between an anode (or a portion of an anode) and one or more cathodes can increase or decrease, as applicable, the voltage drop and / or the electrical resistance between the anode (or a portion of the anode) and one or more cathodes.

[0080] In some embodiments, the positioning and / or orientation of the cathodes (e.g., the elevation, the slope of the horizontal cathode member) may be controlled by adjusting one or more of the length of a cathode post, the relative position of a horizontal cathode member on a cathode post, the orientation of a horizontal cathode member, the shape of a horizontal cathode member, an amount of cathode post extending into an aluminum purification cell, and combinations thereof, among other factors. In some embodiments, a controller can control the positioning and / or orientation of one or more cathodes. In some embodiments, an operator can provide instructions to a controller to adjust the position and / or orientation of one or more cathodes. In some embodiments, a controller (e.g., a controller that is external to the aluminum purification cell) is operably coupled to one or more mechanisms. In some embodiments, one or more mechanisms can be mechanically coupled to one or more cathodes. In some embodiments, a mechanism may include a bridge. In some embodiments, a bridge may be directly coupled to one or more cathode posts. In some embodiments, a bridge may be indirectly coupled to one or more cathode posts (e.g., additional elements may be mechanically coupled between the bridge and one or more cathode posts). In some embodiments, a bridge may be coupled to one or more other devices (e.g., a support structure, guardrails, fasteners) to assist in supporting and / or positioning the cathodes. In some embodiments, a mechanism can be positioned above or on the cell cover (e.g., cell cover 238 of FIG. 2A). In some embodiments, a mechanism can be positioned below the cell cover.

[0081] In some embodiments, a controller can send signals (wired or wireless signals) to a mechanism to cause the mechanism to move from a first position to a second position. In some embodiments, a controller can cause the mechanism to move in a vertical direction (e.g.,Attorney Ref. No.: 169593-120017 / WQalong the y-axis illustrated in FIG. 15 and / or within 5 degrees of perfectly vertical), in some embodiments, a controller can cause a mechanism to move in a horizontal direction (e.g., along the x-axis illustrated in FIG. 15, or along an axis perpendicular to both the x-axis and the y-axis of FIG. 15 and / or within 5 degrees of perfectly horizontal). In some embodiments, the controller can cause a mechanism to move in a diagonal direction.

[0082] In some embodiments, a controller can adjust the position and / or orientation of a cathode. In some embodiments, a controller can adjust the position and / or orientation of a cathode by causing a mechanism coupled to a cathode to move (e.g., move in a predetermined and / or controlled direction). For example, in some embodiments, when a mechanism moves from a first position to a second position, one or more cathodes can also be moved from a first position to a second position (e.g., because the one or more cathodes are mechanically coupled to the mechanism). In some embodiments, the movement of a mechanism can be directly related to the movement of a cathode. In some embodiments, a controller may seek to move one or more cathodes via a mechanism in a predetermined direction and / or to a predetermined location. In some embodiments, a controller may move one or more cathodes to facilitate achievement of a predetermined electrical property, such as any of the electrical properties described previously (e.g., a predetermined voltage drop, a predetermined anode-cathode distance). In some embodiments, the movement of a mechanism can be proportional to the movement of the cathode.

[0083] In some embodiments, each individual cathode may be mechanically coupled to a separate mechanism. For example, a first cathode may be mechanically coupled to a first mechanism and a second cathode may be mechanically coupled to a second mechanism. In some embodiments, a controller can adjust the position and / or orientation of each mechanism, and thus each cathode associated with its respective mechanism, independently. For example, a controller can adjust the position and / or orientation of one or more selected cathodes by sending instructions to move a mechanism that is coupled to the one or more selected cathodes.

[0084] In some embodiments, a plurality of cathodes may be mechanically coupled to one mechanism. In some embodiments, a controller can adjust the position of multiple cathodes by moving a single mechanism (e.g., sending instructions to move the mechanism). For example, a first cathode and a second cathode can be mechanically coupled to the same mechanism. In some embodiments, a controller can adjust the position of a single mechanism which can cause the position and / or orientation of multiple cathodes to move at the same time, in some embodiments, when multiple cathodes are moved at the same time using a single mechanism, the change in the position and / or orientation of the multiple cathodes can be theAttorney Ref. No.: 169593-120017 / WQsame. For example, a first cathode and a second cathode can move the same distance in the same direction from a single movement from a mechanism.

[0085] In some embodiments, multiple mechanisms can be coupled to a single cathode (e.g., different cathode posts of the same cathode). In some embodiments, a controller can provide instructions to one or more of the mechanisms to adjust the position and / or orientation of the single cathode. In some embodiments, a controller can instruct multiple mechanisms to move in the same direction at the same time to adjust the position and / or orientation of a single cathode.

[0086] In some embodiments, the position and / or orientation of various cathodes can be adjusted during startup of the aluminum purification cell. In some embodiments, a position and / or orientation of various cathodes can be adjusted during operation of (e.g., steady-state operation of) the aluminum purification cell. In some embodiments, positioning and / or orientating various cathodes can be predetermined to achieve a predetermined property (e.g., a predetermined aluminum purification cell property). In some embodiments, a predetermined property can include one of more of a predetermined anode-cathode distance, a predetermined cell efficiency, a predetermined cathode-interface distance, a predetermined electrical property’, and combinations thereof, among other properties. In some embodiments, a range of allowable values can be determined for a predetermined property. In some embodiments, during operation of the aluminum purification cell, a predetermined property can fall outside of an allowable range (e.g., outside of a predetermined allowable range). In some embodiments, a position and / or orientation of one or more cathodes can be adjusted in an effort to cause a predetermined property to realize a measurement within an allowable range.

[0087] In some embodiments, one or more detection devices can detect one or more operating conditions of an aluminum purification cell. In some embodiments, suitable detection devices can include a multimeter, a clamp meter, a voltmeter, an ammeter, an ohmmeter, a galvanometer, a wattmeter, an electrometer, a magnetometer, an EMF meter, a thermocouple, a thermistor, a resistance temperature detector (RTD), a heat flow meter, a barometer, a manometer, a viscometer, and a pH meter, among other detection devices. In some embodiments, one or more detection devices can communicate with other devices in the system (e.g., a controller, a mechanism). In some embodiments, if a detection device indicates that a property (e.g., a predetermined property') is outside of an allowable range, a controller can adjust a position and / or orientation of one or more cathodes to cause a predetermined property to realize a measurement within an allowable range. For example, if during operation of an aluminum purification cell, the voltage drop increases above a desirable range, theAttorney Ref. No.: 169593-120017 / WQposition and / or orientation of a cathode can be adjusted (e.g., the cathode can be moved to reduce the anode to cathode distance) to cause the electrical property to realize an allowable voltage drop. In some embodiments, an operator can analyze the outputs from one or more detection devices and determine whether an adjustment is necessary. In some embodiments, the system can analyze the outputs from one or more detection devices and automatically determine whether an adjustment is necessary. In some embodiments, the system can automatically (e.g., without user intervention) adjust the position and / or orientation of one or more cathodes to cause a predetermined property to realize a measurement within an allowable range.

[0088] The horizontal cathode member (220) may be porous or non-porous and, in some embodiments, may include a combination of porous and nonporous regions. In one embodiment, porous features may be randomly distributed within a porous region. In one embodiment, porous features may be distributed in a preconfigured manner having a selected spacing, pore size, and / or orientation. In one embodiment, the horizontal cathode member (220) may include one or more apertures (224) extending between the upper surface (222) and the lower surface (223), as shown in FIG. 2A. The apertures (224) may comprise holes, slots, voids (e.g,, open voids), and / or other types of openings that extend at least partially through horizontal cathode member (220). For example, one or more of the apertures (224) may extend from the lower surface (223) to the upper surface (222), providing at least one passage extending through a portion of the horizontal cathode member (220) in a thickness direction. In some examples, the horizontal cathode member (220) may include surface features, such as recessed channels or grooves, that extend along portions of the horizontal cathode member (220), such as the lower surface (223).

[0089] One embodiment of a method for purifying aluminum includes supplying an electric current to the molten anodic metal pad (208). Molten material (including molten aluminum) from the molten anodic metal pad (208) may contact the electrolyte (210) at the interface (226) where a top surface of the molten anodic metal pad (208) contacts a bottom surface of the electrolyte (210). At least some of the aluminum ions may be transported through the electrolyte (210) onto surfaces of the cathode (214), such as external and / or internal surfaces of horizontal cathode member (220) positioned within the electrolyte (210). At least some of the aluminum ions in the electrolyte (210) may be reduced via electrical current at the cathode (214), thereby producing metallic aluminum (i.e., purified aluminum metal) on the surface portions of the horizontal cathode member (220) and / or within the electrolyte (210). At least some of the metallic aluminum may collect on the surface portions of the horizontalAttorney Ref. No.: 169593-120017 / WQcathode member (220), including the lower surface (223) and / or surfaces of apertures (224) within horizontal cathode member (220). At least some of the metallic aluminum may move along the surface(s) of the cathode(s) (214) and may be drawn in an upw ard direction through apertures (224) toward the upper surface (222) of the horizontal cathode member (220) due to a buoyancy of the purified aluminum metal in the electrolyte (210).

[0090] In some embodiments, at least some of the purified metallic aluminum on surfaces of the horizontal cathode member (220) and / or within the electrolyte (210) may collect in droplets that move upward from the horizontal cathode member (220) through the electrolyte (210) to the purified aluminum metal layer (216) due to the buoyancy of the metallic aluminum in the electrolyte (210). In some embodiments, the purified aluminum metal layer (216) may tend to collect as atop layer above the electrolyte (210). In one embodiment, at least some of the purified metallic aluminum may remain on surfaces of the horizontal cathode member (220) and may move upward along, for example, a surface of the cathode post (218) toward the purified aluminum metal layer (216) above the electrolyte (210).

[0091] In some embodiments, the cathode (214) comprises a solid material that is aluminum wettable. As used herein, ‘ wettable” (e.g., “aluminum wettable"’) means having a contact angle with molten metal (e.g., aluminum) of not greater than 90 degrees. In some embodiments, the cathode (214) may comprise anon-carbonaceous material, such as a boride material (e.g., one or more borides of titanium, zirconium, and / or hafnium), a carbonaceous material, and combinations thereof. In some embodiments, the cathode (214) comprises or consists essentially of titanium diboride (TiB₂). In one embodiment, the cathode (214) is configured to be wettable by a wetting metal from the electrolyte (210). In one embodiment, the wetting metal comprises aluminum. In one embodiment, the cathode (214) comprises a base material (e.g., graphite or carbon) coated with an aluminum wettable material (e.g., a boride of titanium, zirconium, and / or hafnium). The aluminum wettable coating may cover a portion of (e.g., a majority of), or all of, the base material.

[0092] In three-layer cells, such as the aluminum purification cell (200) illustrated in FIG. 2A, a substantial amount of power may be required due to the high resistivity of the electrolyte (210) and the relatively long path that electricity must travel through the electrolyte (210) between anodic and cathodic regions. Decreasing distances between the anodic and cathodic regions of the aluminum purification cell (200) by, for example, decreasing an anode to cathode distance (ACD) between the molten anodic metal pad (208) and the cathode (214), may reduce the total voltage needed to power the aluminum purification cell (200). As used herein, “anode to cathode distance” (ACD) means the distance (e.g., vertical distance)Attorney Ref. No.: 169593-120017 / WQseparating an anodic element (e.g., the molten anodic metal pad (208), a solid anodic electrode) from a cathodic element (e.g., a portion of the cathode (214) closest to the anodic element). A minimum A CD may be maintained to ensure sufficient separation between anodic metal from the molten anodic metal pad (208) and the cathode (214) to prevent contamination of any purified aluminum metal that may migrate to the purified aluminum metal layer (216). Contact between anodic metal from the molten anodic metal pad (208), which includes significant quantities of non-aluminum metals and impurities, and purified aluminum metal may quickly result in contamination of the purified aluminum metal layer (216) with impurities from the anodic metal. In some embodiments, the ACD between the molten anodic metal pad (208) and the cathode (214) may also be selected to lower voltage requirements and / or to lower energy consumption of the aluminum purification cell (200). In some embodiments, the ACD may additionally be selected to achieve a thermal balance in the aluminum purification cell (200). In some embodiments, as noted above multiple cathodes can be used in a single aluminum purification cell. In some embodiments, the ACD of a first cathode and the molten anodic pad can be the same as, or different than the ACD of a second cathode and the molten anodic pad.

[0093] In some embodiments, the cathode (214) may be periodically removed from the cell chamber (219). For example, the cathode (214), including the cathode post (218) and the horizontal cathode member (220), may be removed from the cell chamber (219) during operation. In one embodiment, the cathode (214) may be readily accessed via the top of the aluminum purification cell (200), facilitating cathode changes during operation. Additionally, the cathode (214) may be located outside the aluminum purification cell (200) during a preheating cycle at the startup of the aluminum purification cell (200). Following preheating, the cathode (214) may be positioned in the aluminum purification cell (200) once a desired temperature has been reached. Accordingly, a variety of preheating techniques, including conventional heating technique, may be used to heat the aluminum purification cell (200) without causing damage to the cathode (214).zv. Baffles

[0094] Referring to FIGS. 3 and 4, an aluminum purification cell (300) / (400) may include at least one baffle, such as a horizontal baffle and / or a vertical baffle, at or near the interface (226) between the molten anodic metal pad (208) and the electrolyte (210). For example, as shown in FIG. 3, the baffle (340) may include a horizontal portion (342) and a vertical portion (344). In one embodiment, the horizontal portion (342) may include a horizontally extending member, such as a plate, that extends parallel to the horizontal cathodeAttorney Ref. No.: 169593-120017 / WQmember (220) and / or the interface (226). In one embodiment, the horizontal portion (342) is supported by one or more vertical portions (344) extending between the horizontal portion (342) and the cell bottom (204). Supports having any other suitable shape and / or orientation may be utilized to support and / or position the horizontal portion (342). In one embodiment, the horizontal portion (342) may be positioned at or near the interface (226) to dampen instabilities in the molten anodic metal pad (208) (e.g., molten metal waves) at or near the interface (226).

[0095] In one embodiment, as shown in FIG. 3, the horizontal portion (342) of the baffle (340) is positioned in the electrolyte (210) such that the baffle (340) is in direct liquid communication with the electrolyte (210). The bottom surface (341) of the horizontal portion (342) may be positioned at or near the interface (226) with the bulk of the horizontal portion (342) disposed in the electrolyte (210) above the molten anodic pad (208). In another embodiment, as shown in FIG. 4, the horizontal portion (342) is positioned in the molten anodic metal pad (208) so that a top surface (343) of the horizontal portion (342) is positi oned at or near tire interface (226) with the bulk of the horizontal portion (342) disposed in the molten anodic metal pad (208).

[0096] The baffle (340) may be electrically conductive, non-conductive, or essentially non-conductive. In some embodiments, the baffles may also function as solid anodes when, for example, the baffles comprise a conductive material and / or a conductive coating. In some embodiments, a baffle may be porous or may include a porous portion to enable passage of a liquid material, such as molten metal or electrolyte, through at least a portion of the baffle. In the embodiments shown in FIGS. 3 and 4, at least part of the horizontal portion (342) may be porous to permit passage of anodic metal from the molten anodic metal pad (208) and / or electrolyte from the electrolyte (210) zone through the horizontal portion (342). Accordingly, anodic metal from the molten anodic metal pad (208) may contact electrolyte (210) via the horizontal portion (342) of the baffle (340). The positioning of the horizontal portion (342) at the interface (226) may dampen instabilities in the molten anodic metal pad (208) at or near the interface (226) between the electrolyte (210) and the molten anodic metal pad (208). In some embodiments, at least a portion of the baffle (340), such as the horizontal portion (342), may be electrically conductive and wettable (e.g., aluminum wettable) so as to promote production of aluminum ions on external or internal surfaces of the horizontal portion (342).

[0097] The baffle (340) may comprise any suitable material or combination of materials. In one embodiment, the baffle (340) may comprise an electrically conductive material, such as graphite, titanium diboride (TiB₂), zirconium diboride (ZrB₂), and / or hafnium diboride (HfB₂). In one embodiment, the baffle (340) may comprise an insulator material,Attorney Ref. No.: 169593-120017 / WQincluding at least one of an electrically insulative ceramic and / or cermet material, such as an oxide, a boride, a nitride, and / or a carbide. In one embodiment, the baffle (340) may include an insulator material that includes boron nitride. In one embodiment, the baffle (340) may comprise an alumina material, such as a fused cast alumina.

[0098] The baffles (340) may dampen instabilities in the molten anodic metal pad (208) at or near the interface (226) between the molten anodic metal pad (208) and the electrolyte (210). In one embodiment, the baffles (340) may dampen instabilities in the molten anodic metal pad (208) (e.g., molten metal waves) at or near the interface (226). In some embodiments, the baffles (340) may also restrict anodic material from the molten anodic metal pad (208) from contacting and mixing with purified aluminum metal in the electrolyte (210) and / or on the cathode (214).

[0099] Referring to FIGS. 5 and 6, an aluminum purification cell (500) / (600) may include a plurality' of vertical baffles (540) positioned within the molten anodic metal pad (208). The vertical baffles (540) may extend from the cell bottom (204) to a location at or near the interface (226) between the molten anodic metal pad (208) and the electrolyte (210). For example, as shown in FIG. 5, vertical baffles (540) may be in direct liquid communication with the electrolyte (210), with ends of the vertical baffles (540) extending above the interface (226) into the electrolyte (210) so as to cross the interface (226). The vertical baffles (540) may dampen instabilities in the molten anodic metal pad (208) (e.g., molten metal waves) at or near the interface (226). In some embodiments, as shown in FIG. 6, the vertical baffles (540) may be located fully within the molten anodic metal pad (208) such that the vertical baffles (540) are not in direct liquid communication with the electrolyte (210). Distal ends of the vertical baffles (540) may be disposed in sufficient proximity to tire interface (226) to dampen instabilities at or near the interface (226). In some examples, the vertical baffles (540) may have an elongated plate shape or other suitable shape. In one embodiment, the vertical baffles (540) may be elongated in a horizontal direction so as to extend along the cell bottom (204).v. Alternative / Other Embodiments

[0100] FIGS. 7 and 8 show an aluminum purification cell (700) having a cathode (714) that includes at least one cathode post (718) and a horizontal cathode member (720) extending horizontally from the cathode post (718). The aluminum purification cell (700) includes a cell bottom (704) and cell sidewalls (706) surrounding a cell chamber (719). Tire cell chamber (719) contains a molten anodic metal pad (708), an electrolyte (710) bath, and a purified aluminum metal layer (716).Attorney Ref. No.: 169593-120017 / WQ

[0101] As illustrated in FIG. 8, the horizontal cathode member (720) may include at least one porous region that is permeable to metallic aluminum and / or the electrolyte mixture. In one embodiment, the horizontal cathode member (720) may include a porous region along its entire horizontal extent (or a substantial portion thereof), as illustrated in FIG. 8. In additional embodiments, the horizontal cathode member (720) may include one or more porous regions and one or more nonporous regions. In some embodiments, metallic aluminum may be formed on external surfaces and / or internal surfaces of the horizontal cathode member (720). In one embodiment, metallic aluminum formed at or near a lower surface (723) of the horizontal cathode member (720) may pass through the porous region to an upper surface (722) of the horizontal cathode member (720). The metallic aluminum may collect within the porous region and / or on the upper surface (722) of the horizontal cathode member (720).

[0102] When a sufficient amount of metallic aluminum has collected on the horizontal cathode member (720), portions of the metallic aluminum may be drawn upward from the horizontal cathode member (720) into the electrolyte (710) as droplets (746) under buoyant forces exerted by the denser electrolyte (710). The droplets (746) of metallic aluminum may rise upward from the horizontal cathode member (720) through the electrolyte ( 10) to the layer of purified aluminum (716) above the electrolyte (710). Additionally, in one embodiment, some metallic aluminum formed on tire horizontal cathode member (720) may collect on an exterior surface of cathode post (718) and may move upward along the surface of the cathode post (718) toward the purified aluminum (716). As shown, the cathode post (718) may pass through the purified aluminum (716) such that purified aluminum on the surface of the cathode post (718) is conveyed from the horizontal cathode member (720) to the purified aluminum (716).

[0103] Referring to FIG, 9A, in one embodiment, an aluminum purification cell (900) includes a liquid metal collector (950). In one embodiment, the liquid metal collector (950) is located at an upper portion of the aluminum purification cell (900) and surrounds the cathode post (718) of the at least one cathode (714). In some embodiments, the liquid metal collector (950) may have an inverted cup or funnel shape and may comprise a collector top (952) and at least one collector wall (954) at or near a periphery of the collector top (952). The liquid metal collector (950) may have any suitable shape and size. For example, the liquid metal collector (950) may comprise one or more collector walls (954) having planar, arcuate, and / or other suitably shaped exterior and / or interior surfaces. The inner surfaces of the at least one collector wall (954) and the collector top (952) may define a recessed collection region (956) for collecting purified aluminum metal of a purified aluminum metal layer (916) within the liquidAttorney Ref. No.: 169593-120017 / WQmetal collector (950). A lower portion of the liquid metal collector (950) may be open to the electrolyte (710) to allow metallic aluminum in the electrolyte (710) to pass into the interior of the liquid metal collector (950). For example, the liquid metal collector (950) may collect metallic aluminum moving upward from the horizontal cathode member (920) as droplets through tire electrolyte (710) and / or as a layer along the cathode post (718). As shown in FIG.9 A, the cathode post (718) may pass from the collector top (952) through the interior of the liquid metal collector (950) and the purified aluminum metal layer (916) within the liquid metal collector (950). As shown in FIG. 9A, the purified aluminum metal layer (916) is disposed at an upper region of the liquid metal collector (950) above a zone of the electrolyte (710) located within the liquid metal collector (950).

[0104] The liquid metal collector (950) may be spaced apart from the cell sidewall (706) of the aluminum purification cell (900) such that collector walls (954) and / or other portions of the liquid metal collector (950) do not contact the cell sidewall (706). Additionally, the liquid metal collector (950) may restrict purified aluminum metal from the cell sidewall (706) of the aluminum purification cell (900) and / or from other regions of the aluminum purification cell (900) located outside the liquid metal collector (950). In some embodiments, collecting the purified aluminum metal within the collection region (956) of the liquid metal collector (950) may also facilitate extraction of the purified aluminum metal from the aluminum purification cell (900) by collecting the purified aluminum metal of the purified aluminum metal layer (916) within the defined collection region (956), which is narrower than the cell chamber (719).

[0105] In some embodiments, the cathode (714) may include a horizontal cathode member (920) that includes at least one porous region (958) and at least one nonporous region (960). For example, as shown in FIG. 9A, the horizontal cathode member (920) comprises a porous region (958) (e.g., a central porous region) surrounded by a nonporous region (960). The horizontal cathode member (920) may include various features to guide aluminum toward a central region at or near cathode post (718), In one embodiment, the porous region (958) may be located at or near the cathode post (718) to convey metallic aluminum toward the cathode post (718). in some embodiments, the nonporous region (960) may include a sloped lower surface (964) that slopes inw ard toward the porous region (958). In one embodiment, metallic aluminum collected on the sloped lower surface (964) of the nonporous region (960) may be funneled upward and inward along the sloped lower surface (964) toward tire porous region (958). Metallic aluminum collected at or near the central porous region (958) of the horizontal cathode member (920) may pass through the porous region (958) to the upper surface (962) ofAttorney Ref. No.: 169593-120017 / WQthe horizontal cathode member (920). The metallic aluminum may then move upward along the surface of the cathode post (718) and / or may be drawn upward from the horizontal cathode member (920) into the electrolyte (710) as droplets under buoyant forces exerted by the denser electrolyte (710).

[0106] Referring to FIG. 9B, in some embodiments, the cathode (714) may include a horizontal cathode member (920A) that includes at least one slanted channel (966), In one embodiment, the at least one slanted channel (966) may include an internal passageway that slopes from an outer portion of the horizontal cathode member (920A) inward toward a central portion of the horizontal cathode member (920A). For example, the at least one slanted channel (966) may slope from a peripheral portion of a lower surface (964) and / or from a peripheral surface (967) of the horizontal cathode member (920A). In one embodiment, metallic aluminum collected on the lower surface (964) and / or the peripheral surface (967) of the horizontal cathode member (920A) may be conveyed upward and inward through the at least one slanted channel (966) toward a central region of the upper surface (962). Tire metallic aluminum collected at the upper surface (962) of the horizontal cathode member (920A) may be collected near a cathode post (718) attached to the horizontal cathode member (920A) (see, e.g. FIG, 9A), The metallic aluminum collected on the upper surface (962) of the horizontal cathode member (920A) may then move upward along the surface of the cathode post (718) and / or may be drawn upward from the horizontal cathode member (920) into the electrolyte (710) as droplets,

[0107] Referring to FIG. 9C, in some embodiments, the cathode (714) may include a horizontal cathode member (920B) that includes a central porous region (958B) that extends through the horizontal cathode member (920B) from the lower surface (964) to the upper surface (962). Additionally, the horizontal cathode member (920B) includes a nonporous region (960B) at least partially surrounding the central porous region (958B). In one embodiment, as shown in FIG. 9C, the horizontal cathode member (920B) also includes an outer channel region (968) overlapping the nonporous region (960B) and at least partially surrounding the central porous region (958B). In some embodiments, the outer channel region (968) may include channels, slots, recesses, or other suitable features to guide metallic aluminum formed on or near the low er surface (964) of tire horizontal cathode member (920B) toward the central porous region (958B). In one embodiment, the central porous region (958B) may be located at or near the cathode post (718) (see FIG. 9 A) to direct metallic aluminum toward the cathode post (718). In some embodiments, the nonporous region (960B) may include a sloped lower surface that slopes inward toward the central porous region (958B).Attorney Ref. No.: 169593-120017 / WQMetallic aluminum collected at or near the central porous region (958B) of the horizontal cathode member (920B) may pass through the porous region (958B) to the upper surface (962) of the horizontal cathode member (920B). The metallic aluminum may then move upward along the surface of the cathode post (718) and / or may be drawn upward from the horizontal cathode member (920B) into the electrolyte (710) as droplets.

[0108] FIG. 10 shows an aluminum purification cell (900) that includes a liquid metal collector (950) and a cathode (714) comprising a cathode post (718) and a horizontal cathode member (920) (see, e.g., FIG. 9A). In some embodiments, metallic aluminum collected at or near the central porous region (958) of the horizontal cathode member (920) may pass through the porous region (958) to the upper surface (962) of the horizontal cathode member (920). The metallic aluminum collected at or near the cathode post (718) may be conveyed upward along the surface (972) of the cathode post (718) as an aluminum layer (970) that extends from the horizontal cathode member (920) to the purified aluminum metal layer (916) within the liquid metal collector (950).

[0109] Referring to FIGS. 11A and 11B, an aluminum purification cell (1100) includes a cathode (714) that is adjustably positioned within the cell chamber (719). In some embodiments, the cathode post (718) of the cathode (714) maybe movably coupled to an upper portion of the purification cell (1100) or at a location above the purification cell (1100) so that cathode post (718) may be moved in a vertical direction to adjust a depth at which the horizontal cathode member (720) is disposed within the electrolyte (710). In some embodiments, the position of cathode (714) may be adjusted to modify the ACD be tween the lower surface (723) of the horizontal cathode member (720) and the upper surface of the molten anodic metal pad (708) at the interface (726) between the molten anodic metal pad (708) and the electrolyte (710). For example, the cathode (714) maybe positioned so that the horizontal cathode member (720) is located at a first ACD (ACD1) with respect to the interface (726). The cathode (714) may then be moved so that the horizontal cathode member (720) is located at a second ACD (ACD2) with respect to the interface (726). In the embodiment illustrated in FIGS. 11A and 11B, the second ACD (ACD2) is less than the first ACD (ACD1), with the distance between the lower surface (723) and the interface (726) being less in FIG. 11B.

[0110] In some embodiments, a minimum ACD may be maintained to ensure sufficient separation between anodic metal from the molten anodic metal pad (708) and the cathode (714) so as to avoid contact between metal from the molten anodic metal pad (708) and purified aluminum metal in the electrolyte (710) and / or on the cathode (714). In some embodiments, the ACD between the molten anodic metal pad (708) and the cathode (714) may also beAttorney Ref. No.: 169593-120017 / WQadjusted to lower voltage requirements, to lower energy consumption, and / or to achieve a thermal balance in the aluminum purification cell (1100). In some embodiments, conditions within the aluminum purification cell (1100) may change during operation. For example, the composition of the molten anodic metal pad (708) and / or the electrolyte (710) may change as metallic elements and / or compounds accumulate within the molten anodic metal pad (708) and / or the electrolyte (710), In some embodiments, surface portions of the cathode (714) and / or optional baffle members and / or anodes included in the molten anodic metal pad (708) and / or the electrolyte (710) may become corroded or otherwise degraded from buildup of metallic elements and / or compounds. The ACD may be adjusted as needed to account for these and other changes within the aluminum purification cell (1100).

[0111] In some embodiments, the level (i.e., the vertical location) of the interface (726) between the molten anodic metal pad (708) and the electrolyte (710) may change as feedstock is added to the molten anodic metal pad (708) and / or as aluminum is removed from the molten anodic metal pad (708). The position of the cathode (714) may be adjusted to maintain a selected ACD in conjunction with changes in the level of the interface (726) within the aluminum purification cell (1100).

[0112] Referring to FIGS, 12A and 12B, an aluminum purification cell may include at least one baffle, such as a horizontal baffle and / or a vertical baffle, at or near the interface (726) between the molten anodic metal pad (708) and the electrolyte (710). For example, as shown in FIG. 12A, an aluminum purification cell (1200A) may include a baffle (1240) comprising a horizontal baffle, such as a plate-shaped baffle, that extends parallel to the horizontal cathode member (720) and / or a surface portion of the horizontal cathode member (720). In one embodiment, the baffle (1240) is positioned within the molten anodic metal pad (708) at a position near the interface (726). In some embodiments, the baffle may be positioned within the molten anodic metal pad (708) so that a top surface of the baffle (1240) is located at or near the interface (726). In some embodiments, an upper portion of the baffle (1240) may extend into the electrolyte (710) and a lower portion of the baffle (1240) may be disposed in the molten anodic metal pad (708). In some embodiments, the baffle may be positioned within the electrolyte (710) so that a bottom surface of the baffle (1240) is located at or near tlie interface (726). The baffle (1240) may be disposed at the interface (726) or in sufficient proximity to the interface (726) to dampen instabilities in the molten anodic metal pad (708) (e.g., molten metal waves) at or near the in terface (726). In one embodiment, the baffle (1240) is supported by one or more portions of the cell sidewall (706). For example, one or more ends of the baffle (1240) may be attached to the cell sidewall (706). In one embodiment, the baffle (1240) may beAttorney Ref. No.: 169593-120017 / WQsupported by one or more supports, such as vertical supports that extend between the baffle (1240) and the cell bottom (704).

[0113] In one embodiment, as shown in FIG. 12B, the aluminum purification cell (1200B) may include a baffle (1276) comprising a horizontal portion (1280) and at least one vertical portion (1278). In some embodiments, the horizontal portion (1280) is located at or near the interface (726) between the molten anodic metal pad (708) and the electrolyte (710). In one embodiment, as shown in FIG. 12B, the horizontal portion (1280) may be positioned at the interface (726) so that a lower portion of the horizontal portion (1280) is located within the molten anodic metal pad (708) and an upper portion of the horizontal portion (1280) is located in the electrolyte (710). In one embodiment, the at least one vertical portion (1278) comprises vertical supports that position the horizontal portion (1280) at a selected location. Supports having any other suitable shape and / or orientation may be utilized to support and / or position the horizontal portion (1280).

[0114] In some embodiments, the baffle ( 1276), including the horizontal portion (1280) and / or the at least one vertical portion (1278), may comprise an electrically conductive material and / or may be coated with an electrically conductive material. In one embodiment, the horizontal portion (1280) may be porous. In one embodiment, external and / or internal surfaces of the horizontal portion (1280) may be wettable with metal in the molten anodic metal pad (708). In some embodiments, anodic metal from the molten anodic metal pad (708) may be drawn through the porous horizontal portion ( 1280) to an upper region of the horizontal portion (1280) surrounded by the electrolyte (710). Aluminum may be oxidized from external surfaces and / or internal surfaces (e.g., pore surfaces) of the horizontal portion (1280) surrounded by the electrolyte (710), thereby producing aluminum ions in the electrolyte (710). The horizontal portion (1280) disposed at the interface (726) may dampen instabilities in the molten anodic metal pad (708) at or near the interface (726).

[0115] Referring to FIG. 13, an aluminum purification cell (1300) may include a plurality of vertical baffles (1340) positioned within the molten anodic metal pad (708). Different representative heights of vertical baffles (1340), including first vertical baffles (1340 A) and second vertical baffles (1340B), are shown for purposes of illustration. In some embodiments, the aluminum purification cell (1300) may include any combination and distribution of the first and second vertical baffle (1340A) and (1340B). The vertical baffles (1340) may extend from the cell bottom (704) to a location at or near interface (726). For example, as shown in FIG.13, ends of the first vertical baffles (1340A) may be located fully within the molten anodic metal pad (708) such that the first vertical baffles (1340A) are not in direct liquidAttorney Ref. No.: 169593-120017 / WQcommunication with the electrolyte (710). Distal ends of the first vertical baffles (1340A) may be disposed in sufficient proximity to the interface (726) to dampen instabilities in the molten anodic metal pad (708) at or near the interface (726). Ends of the second vertical baffles (1340B) may extend above the interface (726) into the electrolyte (710) such that the second vertical baffles (1340B) are in direct liquid communication with the electrolyte (710). The second vertical baffles (1340B) may cross the interface (726) and may dampen instabilities in the molten anodic metal pad (708) at or near the interface (726). In some examples, the vertical baffles (1340) may have an elongated plate shape or other suitable shape.

[0116] Referring to FIGS. 14A and 14B, an aluminum purification cell (1400) includes one or more baffles (1476) at or near the interface (726) between the molten anodic metal pad (708) and the electrolyte (710). For example, as shown in FIG. 14 A, a plurality of baffles (1476) may be disposed in molten anodic metal pad (708) overlapping horizontal cathode member (720) of cathode (714). A baffle (1476) may comprise a horizontal portion (1480), such as a plate-shaped baffle, that extends parallel to the horizontal cathode member (720) and / or a surface portion of the horizontal cathode member (720). Each horizontal portion (1480) may have any suitable shape, such as a rounded shape (e.g., circular, elliptical) as shown in the top view of horizontal portion (1480A) illustrated in FIG, 14B, or an angular shape (e.g., rectangular, square) as shown in the top view of horizontal portion (1480B) illustrated in FIG.14C.

[0117] In one embodiment, the baffle (1476) is positioned within the molten anodic metal pad (708) so that the horizontal portion (1480) is located at or near the interface (726). In one embodiment, a plurality ofbaffles (1476) may be disposed at the interface (726) or in sufficient proximity to the interface (726) to dampen instabilities in the molten anodic metal pad (708) at or near the interface (726). In one embodiment, each horizontal portion (1480) is supported by at least one vertical portion (1478), such as a vertically extending support post or plate, that extends between the horizontal portion (1480) and the cell bottom (704). In one embodiment, the vertical portion (1478) of each baffle (1476) may be connected at a di stal end to the corresponding horizontal portion (1480) at or near a central location of the horizontal portion (1480). In one embodiment, the baffles (1476) may each have a cross-sectional T-shape formed by the combination of tire vertical portion (1478) and the horizontal portion (1480), as illustrated in FIG. 14A.Attorney Ref. No.: 169593-120017 / WQvi. Miscellaneous

[0118] The present disclosure is explained with reference to the attached drawings, wherein like structures may be referred to by like numerals throughout the several views. Tire drawings shown are not necessarily to scale, with emphasis instead generally being placed upon illustrating the principles of the present disclosure. Further, some features may be exaggerated to show details of particular components.

[0119] The figures constitute a part of this specification and include illustrative embodiments of the present disclosure and illustrate various objects and features thereof. In addition, any measurements, specifications and the like shown in the figures are intended to be illustrative, and not restrictive. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present disclosure.

[0120] Among those benefits and improvements that have been disclosed, other objects and advantages of this disclosure will become apparent from the following description taken in conjunction with the accompanying figures. Detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative of the disclosure that may be embodied in various forms,

[0121] Throughout the specification and claims, the following terms take the meanings explicitly associated herein, unless tire context clearly dictates otherwise, lire phrases “in one embodiment” and “in some embodiments” as used herein do not necessarily refer to the same embodiment(s), though it may. Furthermore, the phrases “in another embodiment” and “in some other embodiments” as used herein do not necessarily refer to a different embodiment, although it may. In some embodiments, as described below, various embodiments of the disclosure may be readily combined, without departing from the scope or spirit of the disclosure.

[0122] In addition, as used herein, the term "or" is an inclusive "or" operator, and is equivalent to the term "and / or," unless the context clearly dictates otherwise. Tire term "based on" is not exclusive and allow s for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of "a," "an," and "the" include plural references. Hie meaning of "in" includes "in" and "on."

[0123] While various embodiments of the present disclosure have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present disclosure.

Claims

Attorney Ref. No.: 169593-120017 / WQCLAIMSWhat is claimed is:

1. An aluminum purification cell, comprising:(a) a molten anodic metal pad, wherein the molten anodic metal pad is absent of solid anodic electrodes;(b) an electrolyte disposed above the molten anodic metal pad; and(c) a cathode positioned within the electrolyte and separated from the molten anodic metal pad.

2. The aluminum purification cell of claim 1, wherein the cathode comprises a cathode post and a horizontal cathode member extending horizontally from tire cathode post.

3. The aluminum purification cell of claim 2, wherein the horizontal cathode member is uncoated.

4. The aluminum purification cell of claim 2 or 3, wherein the horizontal cathode member has a greater density than the electrolyte.

5. The aluminum purification cell of any of claims 2-4, wherein the horizontal cathode member has a plate shape.

6. The aluminum purification cell of any of claims 2-5, wherein the horizontal cathode member comprises at least one passage extending through the horizontal cathode member.

7. The aluminum purification cell of claim 6, wherein the at least one passage extends from a upper surface of the horizontal cathode member to a lower surface of the horizontal cathode member.

8. The aluminum purification cell of claim 7, wherein tlie at least one passage is slanted relative to at least one of the upper surface and the lower surface of the horizontal cathode member.Attorney Ref. No.: 169593-120017 / WQ9. The aluminum purification cell of any of claims 6-8, wherein the at least one passage extends through the horizontal cathode member in a thickness direction.

10. The aluminum purification cell of any of claims 6-9, w herein the at least one passage comprises at least one channel extending through a portion of the horizontal cathode member.

11. The aluminum purification cell of any of claims 6-10, wherein the at least one passage extends vertically.

12. The aluminum purification cell of any of claims 6-11, wherein the horizontal cathode member comprises at least one recess defined at the lower surface of the horizontal cathode member, wherein the at least one recess extends to the at least one passage.

13. The aluminum purification cell of any of claims 2-12, wherein at least a portion of the horizontal cathode member comprises a porous region.

14. The aluminum purification cell of claim 13, wherein the porous region provides fluid communication between two or more surfaces of the horizontal cathode member.

15. The aluminum purification cell of claim 13 or 14, wherein the porous region comprises a plurality of voids.

16. The aluminum purification cell of claim 15, wherein the voids are randomly dispersed within the porous region.

17. The aluminum purification cell of claim 15, wherein the voids are arranged in a preconfigured pattern within the porous region.

18. The aluminum purification cell of any of claims 13-17, wherein the porous region comprises a plurality of apertures extending at least partially through the porous region.

19. The aluminum purification cell of any of claims 13-18, wherein the horizontal cathode member comprises a non-porous region.Attorney Ref. No.: 169593-120017 / WQ20. The aluminum purification cell of claim 19, wherein the non-porous region surrounds at least a portion of the porous region.

21. The aluminum purification cell of any of claims 13-20, wherein the porous region is located in a central portion of the horizontal cathode member.

22. The aluminum purification cell of any of claims 2-21, wherein the horizontal cathode member comprises at least one recess defined at the lower surface of the horizontal cathode member.

23. The aluminum purification cell of claim 22, wherein the at least one recess extends along the lower surface of the horizontal cathode member.

24. The aluminum purification cell of claim 22 or 23, wherein the at least one recess extends horizontally.

25. The aluminum purification cell of claim 22 or 23, wherein the at least one recess extends in a non-horizontal direction.

26. The aluminum purification cell of any of claims 22-25, wherein the at least one recess extends to a lateral periphery of the horizontal cathode member.

27. The aluminum purification cell of any of claims 2-26, wherein the horizontal cathode member is movable with respect to the molten anodic metal pad.

28. The aluminum purification cell of any of claims 2-27, wherein the horizontal cathode member is movable in a vertical direction.

29. The aluminum purification cell of any of claims 2-28, wherein the cathode post is movably coupled at an upper portion of the aluminum purification cell to position the horizontal cathode member within the electrolyte,30. The aluminum purification cell of any of claims 2-29, wherein the horizontal cathode member is located at or near a distal end of cathode post.Attorney Ref. No.: 169593-120017 / WQ31. The aluminum purification cell of any of claims 2-29, wherein a lower surface of the horizontal cathode member faces the molten anodic metal pad.

32. The aluminum purification cell of claim 31, wherein at least a portion of the lower surface of the horizontal cathode member extends in a horizontal direction,33. The aluminum purification cell of claim 31, wherein at least a portion of the lower surface of the horizontal cathode member slopes in a non-horizontal direction.

34. Tire aluminum purification cell of any of claims 2-33, wherein the horizontal cathode member is wider than the cathode post in a horizontal direction.

35. The aluminum purification cell of any of claims 2-34, wherein the cathode post extends vertically.

36. The aluminum purification cell of any of claims 2-35, comprising at least one additional cathode post extending to the horizontal cathode member.

37. The aluminum purification cell of any of claims 2-36, wherein the cathode post is electrically coupled to a cathodic current source.

38. The aluminum purification cell of any of the preceding claims, comprising at least one baffle disposed at least partially in the molten anodic metal pad.

39. The aluminum purification cell of claim 38, wherein a portion of the at least one baffle is in contact with the electrolyte.

40. The aluminum purification cell of claim 38, wherein the at least one baffle is separated from the electrolyte.

41. The aluminum purification cell of any of claims 38-40, wherein the at least one baffle comprises an insulator material.Attorney Ref. No.: 169593-120017 / WQ42. The aluminum purification cell of claim 41, wherein the insulator material comprises at least one of a cermet and a ceramic.

43. The aluminum purification cell of claim 41 or 42, wherein the insulator material comprises at least one of alumina and boron nitride.

44. The aluminum purification cell of claim 43, wherein the alumina comprises fused cast alumina.

45. Tire aluminum puri fication cell of any of claims 38-44, wherein at least a portion of the at least one baffle has a vertical plate shape.

46. The aluminum purification cell of any of claims 38-45, wherein at least a portion of the at least one baffle has a horizontal plate shape.

47. Ihe aluminum purification cell of any of claims 38-46, wherein the at least one baffle comprises a horizontal portion and a vertical portion,48. The aluminum purification cell of claim 47, where in the vertical portion of the at least one baffle comprises at least one vertical support that extends between the horizontal portion and a cell bottom of the aluminum purification cell.

49. Ihe aluminum purification cell of any of claims 38-48, wherein the at least one baffle has a cross-sectional T-shape,50. The aluminum purification cell of any of claims 38-49, wherein a portion of the at least one baffle is attached to at least one sidewall of the aluminum purification cell,51. The aluminum purification cell of claim 50, wherein the at least one baffle is supported by the at least one sidewall of the aluminum purification ceil.

52. Tire aluminum purification cell of any of the preceding claims, wherein the cathode comprises a solid material.Attorney Ref. No.: 169593-120017 / WQ53. The aluminum purification cell of any of the preceding claims, wherein the cathode comprises a non-carbonaceous material.

54. The aluminum purification cell of claim 53, wherein the non-carbonaceous material comprises at least one of TiB2, ZrB2, and HfB2.

55. The aluminum purification cell of any of the preceding claims, wherein the cathode has a cross-sectional T-shape.

56. Tire aluminum purification cell of any of the preceding claims, wherein the electrolyte comprises a density greater than a purified aluminum metal layer disposed above the electrolyte.

57. The aluminum purification cell of any of the preceding claims, w'herein the electrolyte comprises at least one of fluoride salts and chloride salts.

58. Tire aluminum purification cell of claim 57, wherein a cation of the fluoride salts or the chloride salts is one or more of Li, Na, K, Al, Ba, Ca, Mg, Ce, La, Cs, Rb and combinations thereof.

59. The aluminum purification cell of any of the preceding claims, w'herein the electrolyte comprises both (a) at least one of BaF₂ and LaF₃, and (b) at least one of AIF3, KF, MgF₂, and NaF.

60. Tire aluminum purification cell of any of the preceding claims, wherein a temperature of the electrolyte is from 700 to 980 degrees Celsius.

61. The aluminum purification cell of any of the preceding claims, wherein the molten metal pad comprises at least one of Al, Si, Cu, Fe, Sb, Gd, Cd, Sn, Pb, Mg, Zn, Ti, and B.

62. Tire aluminum purification cell of any of the preceding claims, wherein the molten metal pad comprises aluminum.Attorney Ref. No.: 169593-120017 / WQ63. The aluminum purification cell of any of the preceding claims, wherein the molten metal pad comprises at least 20 wt. % Al.

64. An aluminum purification cell, comprising:(a) a molten anodic metal pad;(b) at least one anode positioned at least partially within the molten anodic metal pad, wherein the at least one anode comprises a solid material;(c) an electrolyte disposed above the molten anodic metal pad; and(d) a cathode positioned within the electrolyte and separated from the molten anodic metal pad and the at least one anode, wherein the cathode comprises a horizontal cathode member that extends horizontally above the at least one anode.

65. The aluminum purification cell of claim 64, wherein the cathode comprises a cathode post that extends between the horizon tal cathode member and an upper portion of the aluminum purification cell above the electrolyte.

66. Tire aluminum purification cell of claim 65, wherein the cathode post extends vertically.

67. The aluminum purification cell of claim 65 or 66, wherein the cathode post is movably coupled at the upper portion of the aluminum purification cell to position the horizontal cathode member within the electrolyte.

68. The aluminum purification cell of any of claims 64-67, wherein the horizontal cathode member is movable with respect to the at least one anode,69. The aluminum purification cell of any of claims 64-68, wherein:the at least one anode comprises a plurality of anodes; andthe horizontal cathode member is disposed above each of the plurality of anodes.

70. The aluminum purification cell of any of claims 64-69, wherein the at least one anode is in direct liquid communication with the electrolyte.

71. The aluminum purification cell of any of claims 64-70, wherein the at least one anode extends into the electrolyte.Attorney Ref. No.: 169593-120017 / WQ72. The aluminum purification cell of any of claims 64-69, wherein the at least one anode is separated from the electrolyte.

73. The aluminum purification ceil of any of claims 64-72, wherein at least a portion of the at least one anode has a vertical plate shape,74. The aluminum purification cell of any of claims 64-73, wherein at least a portion of the at least one anode has a horizontal portion.

75. Tire aluminum purification cell of claim 74, wherein an upper surface of the horizontal portion is positioned at an interface between the molten anodic metal pad and the electrolyte.

76. The aluminum purification cell of any of claims 64-75, wherein the at least one anode comprises a horizontal portion and at least one support.

77. Tire aluminum purification cell of claim 76, wherein the at least one support extends between the horizontal portion and a cell bottom of the aluminum purification cell.

78. The aluminum purification cell of claim 76 or 77, wherein the at least one support comprises an anodic post.

79. Ihe aluminum purification cell of any of claims 76-78, wherein the at least one support extends vertically.

80. The aluminum purification cell of any of claims 64-79, wherein the at least one anode has a cross-sectional T-shape.

81. The aluminum purification cell of any of claims 64-80, wherein a portion of the at least one anode is attached to at least one sidewall of the aluminum purification cell.

82. Tire aluminum purification cell of any of claims 64-81, wherein the at least one anode comprises an aluminum wettable material.Attorney Ref. No.: 169593-120017 / WQ83. The aluminum purification cell of any of claims 64-81, wherein at least a portion of the at least one anode comprises a porous region.

84. The aluminum purification cell of claim 83, wherein the at least one anode comprises a horizontal portion that includes the porous region.

85. The aluminum purification cell of claim 83 or 84, wherein the porous region comprises a plurality of voids.

86. Tire aluminum purification cell of claim 85, wherein the voids are randomly dispersed within the porous region.

87. The aluminum purification cell of claim 85, wherein the voids are arranged in a preconfigured pattern within the porous region.

88. Ihe aluminum purification cell of any of claims 83-87, wherein the porous region comprises a plurality of apertures extending at least partially through the porous region.

89. The aluminum purification cell of any of claims 64-88, wherein the at least one anode is electrically coupled to an anodic current source.

90. An aluminum purification cell, comprising:(a) a molten anodic metal pad;(b) an electrolyte disposed above the molten anodic metal pad; and(c) a cathode positioned within the electrolyte and separated from the molten anodic metal pad, wherein the cathode comprises a cathode post and a horizontal cathode member extending horizontally from the cathode post.

91. The aluminum purification cell of claim 90, wherein a horizontal dimension of the horizontal cathode member is greater than a horizontal width of the cathode post.

92. Tire aluminum purification cell of claim 90 or 91, wherein the horizontal cathode member overlaps a majority of a horizontal profile of the electrolyte.Attorney Ref. No.: 169593-120017 / WQ93. The aluminum purification cell of claim 92, wherein the horizontal cathode member overlaps at least 60% of the horizontal profile of the electrolyte.

94. The aluminum purification cell of claim 92 or 93, wherein the horizontal cathode member overlaps at least 70% of the horizontal profile of the electrolyte.

95. The aluminum purification cell of any of claims 92-94, wherein the horizontal cathode member overlaps at least 80% of the horizontal profile of the electrolyte.

96. A method, comprising:(a) producing aluminum ions from an aluminum-based feedstock, wherein the aluminum ions are produced at an interface between a molten anodic metal pad and an electrolyte located above the molten anodic metal pad, yvherein the aluminum ions are produced in tire absence of solid anodic electrodes located in the molten anodic metal pad;(b) forming metallic aluminum by reducing the aluminum ions on a portion of a cathode positioned w ithin the electrolyte and separated from the molten anodic metal pad; and (c) transporting at least a portion of the metallic aluminum to a purified aluminum metal layer located above the electrolyte.

97. The method of claim 96, yvherein the transporting step (c) comprises moving at least a portion of the metallic aluminum along a surface of the cathode that extends to the purified aluminum metal layer.

98. The method of claim 96 or 97, wherein the transporting step (c) comprises moving at least a portion of the metallic aluminum from the cathode through the electrolyte to the purified aluminum metal layer.

99. The method of any of claims 96-98, wherein the transporting step (c) comprises forming droplets of at least the portion of the metallic aluminum at the cathode.

100. Tire method of any of claims 96-99, wherein the transporting step (c) comprises passing at least a portion of the metallic aluminum through a porous portion of the cathode.Attorney Ref. No.: 169593-120017 / WQ101. The method of claim 100, wherein the passing step comprises passing at least the portion of the metallic aluminum through the porous portion to an upper surface of the cathode.

102. Tire method of any of claims 96-101, wherein the transporting step (c) comprises transporting droplets of the metallic aluminum from the upper surface of the cathode through the electrolyte to the purified aluminum metal layer.

103. The method of any of claims 96-102, further comprising moving the cathode to adjust a distance between the cathode and the molten anodic metal pad.

104. Tire method of any of claims 96-103, wherein the cathode comprises a cathode post and a horizontal cathode member extending horizontally from the cathode post.

105. The method of any of claims 96-104, further comprising dampening instabilities in the molten anodic metal pad.

106. Tire method of claim 105, wherein the instabilities comprise molten metal waves,107. The method of claim 105 or 106, wherein the dampening step comprises dampening the instabilities by at least one baffle positioned at least partially within the molten anodic metal pad.

108. The method of claim 107, wherein the at least one baffle extends into tire electrolyte.

109. A method, comprising:(a) producing aluminum ions from an aluminum-based feedstock, wherein the aluminum ions are produced at an interface between a molten anodic metal pad and an electrolyte located above the molten anodic metal pad;(b) forming metallic aluminum by reducing the aluminum ions on a horizontal cathode member of a cathode, wherein the horizontal cathode member is positioned within the electrolyte and is separated from the molten anodic metal pad, wherein the horizontal cathode member extends horizontally above the molten anodic metal pad; and(c) transporting the metallic aluminum to a purified aluminum metal layer located above the electrolyte.Attorney Ref. No.: 169593-120017 / WQ110. The method of claim 109, wherein the transporting step (c) comprises moving at least a portion of the metallic aluminum along a surface of a cathode post of the cathode, wherein the cathode post extends from the horizontal cathode member to the purified aluminum metal layer.

111. The method of any of claim 109 or 110, wherein the transporting step (c) comprises forming droplets of the metallic aluminum at the horizontal cathode member.

112. The method of claim 111, wherein the transporting step (c) comprises moving the droplets of the metallic aluminum through the electrolyte to the purified aluminum metal layer.

113. The method of any of claims 109-112, wherein at least one solid anode is at least partially disposed in the molten anodic metal pad,114. The method of claim 113, wherein the horizontal cathode member overlaps the at least one solid anode.

115. The method of claim 113 or 114, wherein the at least one solid anode extends into the electrolyte.

116. An aluminum purification cell, comprising:(a) a molten anodic metal pad;(b) an electrolyte disposed above the molten anodic metal pad; and(c) a first cathode positioned within the electrolyte and separated from the molten anodic metal pad, wherein the first cathode comprises a first cathode post and a first horizontal cathode member extending from the first cathode post; and(d) a second cathode positioned within the electrolyte and separated from the molten anodic metal pad, wherein the second cathode comprises a second cathode post and a second horizontal cathode member extending from the first cathode post.

117. The aluminum purification cell of claim 116, wherein the aluminum purification cell comprises a cell bottom.Attorney Ref. No.: 169593-120017 / WQ118. The aluminum purification cell of claim 117, wherein a distance between the first horizontal cathode member and the cell bottom is a first distance, and a distance between the second horizontal cathode member and the cell bottom is a second distance.

119. The aluminum purification cell of claim 118, wherein the first distance is equal to tire second distance.

120. The aluminum purification cell of claim 118, wherein the first distance is different than the second distance.

121. The aluminum purification cell of any of claims 116-120, comprising an interface between the molten anodic metal pad and the electrolyte.

122. The aluminum purification cell of claim 121, wherein the interface is a consistent distance from the cell bottom throughout the aluminum purification cell.

123. Tire aluminum purification cell of claim 121, wherein the interface is at least one of sloped, or non-linear with respect to the cell bottom throughout the aluminum purification cell.

124. The aluminum purification cell of any of claims 121-123, wherein the first cathode is positioned such that a distance betw een the first cathode and the interface is equal to a distance between the second cathode and the interface.

125. The aluminum purification cell of any of claims 117-124, wherein the first horizontal cathode member is parallel to the cell bottom and the second horizontal cathode member is parallel to the cell botom.

126. Tire aluminum purification cell of any of claims 117-124, wherein at least one of the first horizontal cathode member or the second horizontal cathode member is sloped relative to the cell bottom,127. Tire aluminum purification cell of claim 126, wherein the first horizontal cathode member is sloped relative to the cell bottom, and in part due to the slope of the horizontal cathodeAttorney Ref. No.: 169593-120017 / WQmember, the distance between the first horizontal cathode member and an interface is uniform across tire first horizontal cathode member.

128. The aluminum purification cell of any of claims 116-127, wherein the position of the first cathode and the position of the second cathode are adjusted to achieve a predetermined property,129. The aluminum purification cell of claim 128, wherein the predetermined property is selected from the group consisting of, a predetermined anode-cathode distance, a predetermined cell efficiency, a predetermined cathode-interface distance, a predetermined electrical property, and combinations thereof.

130. The aluminum purification cell of claim 129, wherein the predetermined electrical property is selected from tire group consisting of a voltage drop, an electrical resistance, and combinations thereof.

131. The aluminum purification cell of any of claims 116-127, comprising a mechanism coupled to at least one of the first cathode and the second cathode.

132. Tire aluminum purification cell of claim 131, wherein the mechanism comprises a bridge.

133. Tlie aluminum purification cell of any of claims 131-132, wherein the mechanism can control at least one of the position or orientation of at least one of the first cathode and the second cathode.

134. The aluminum purification cell of any of claims 116-133, comprising a detection device configured to detect a property of the aluminum purification cell.

135. The aluminum purification cell of claim 134, wherein the detection device is selected from the group consisting of a multimeter, a clamp meter, a voltmeter, an ammeter, an ohmmeter, a galvanometer, a wattmeter, an electrometer, a magnetometer, an EMF meter, a thermocouple, a thermistor, a resistance temperature detector (RTD), a heat flow meter, a barometer, a manometer, a viscometer, a pH meter, and combinations thereof.Attorney Ref. No.: 169593-120017 / WQ136. The aluminum purification cell of any of claims 131-135, comprising a controller communicatively coupled to the mechanism.

137. The aluminum purification cell of claim 136, wherein the controller is configured to instruct the mechanism to adjust at least one of the position or orientation of at least one of the first cathode or the second cathode.

138. The aluminum purification cell of claim 137, wherein the controller is communicatively coupled to the detection device, wherein the controller is configured to receive information from the detection device relating to the property of the aluminum purification cell, and wherein the controller is configured to instruct the mechanism to adjust at least one of the position or orientation of at least one of the first cathode or the second cathode based on the property detected by the detection device,139. A method, comprising:(a) producing aluminum ions from an aluminum-based feedstock, wherein the aluminum ions are produced at an interface between a molten anodic metal pad and an electrolyte located above the molten anodic metal pad, wherein the aluminum ions are produced in the absence of solid anodic electrodes located in the molten anodic metal pad;(b) forming metallic aluminum by reducing the aluminum ions on a portion of a cathode positioned within the electrolyte and separated from the molten anodic metal pad; and (c) transporting at least a portion of the metallic aluminum to a purified aluminum metal layer located above the electrolyte.

140. The method of claim 139, wherein the cathode includes at least one cathode.

141. The method of any of claims 139-140, comprising, prior to the producing step (a), adjusting at least one of the position or orientation of the cathode.

142. The method of any of claims 139-141, comprising adjusting at least one of the position or orientation of the cathode during the forming step (b).

143. The method of any of claims 141-142, wherein the adjusting comprises moving the cathode in a vertical direction.Attorney Ref. No.: 169593-120017 / WQ144. The method of any of claims 141-143, wherein the adjusting comprises moving the cathode in a horizontal direction.

145. The method of any of claims 141-144, comprising adjusting the position or orientation of the cathode with a mechanism.

146. The method of claim 145, wherein the mechanism comprises a single mechanism and the method comprises adjusting the position of multiple cathodes using the single mechanism.

147. The method of claim 145, wherein the mechanism comprises multiple mechanisms, wherein each mechanism is coupled to an individual cathode, and the method comprises adjusting the position of multiple cathodes using the multiple mechanism s.

148. The method of any of claims 142-147, comprising adjusting at least one of the position or orientation of the cathode to achieve a predetermined property.

149. The method of claim 148, wherein the predetermined property is selected from the group consisting of a predetermined anode-cathode distance, a predetermined cell efficiency, a predetermined cathode-interface distance, a predetermined electrical property, and combinations thereof.

150. The method of any of claims 148-149, comprising detecting a property during at least one of the producing step (a), the forming step (b), and the transporting step (c).

151. The method of claim 150, wherein the detecting comprises detecting the property using a detection device.

152. The method of claim 151, wherein the detection device is selected from the group consisting of a multimeter, a clamp meter, a voltmeter, an ammeter, an ohmmeter, a galvanometer, a wattmeter, an electrometer, a magnetometer, an EMF meter, a thermocouple, a thermistor, a resistance temperature detector (RTD), a heat flow meter, a barometer, a manometer, a viscometer, a pH meter, and combinations thereof.Attorney Ref. No.: 169593-120017 / WQ153. The method of any of claims 148-152, comprising determining a detected property is outside of an allowable range of the predetermined property and adjusting at least one of the position or orientation of the cathode to achieve the predetermined property.

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