In the process of aluminum smelting, direct current is used to generate molten aluminum and oxygen through a process known as the Hall- Héroult process. This process is used across North America as well as around the world as an effective, efficient and relatively simple process.
However, as in any type of chemical reaction, the need for precision control and quality material is always a factor. This includes all aspects of the aluminum smelting process, including the design and components of the electrolytic cells, the electrolytic bath as well as the use of specifically designed carbon electrodes.
A Brief Process Overview
The electrolytic cells, also known as pots, are constructed of a carbon-lined container that actually forms the cathode for the reaction. This pot is maintained at a consistent temperature of 960 degrees Celsius. In these pots is the solution, which includes salts and aluminum oxide. The carbon electrodes are suspended in the solution to function as the anode.
The current passes through the carbon electrodes into the solution and into the pot lining, which then transfers to the next in the series and so on through the process. As this occurs, the aluminum becomes a molten material and falls to the bottom of the pot where it is collected for further processing.
The Need for Quality
The carbon anodes are gradually consumed in the process, with low-quality electrodes being consumed much faster due to inconsistencies in the manufacturing that break down the material faster.
Not only does a rapid breakdown of these electrodes add to the cost of operation, but it also ultimately decreases production and results in increased downtime. Finding quality electrodes that are dependable as to their lifecycle is essential to keep the costs of aluminum smelting within the materials budget.