Microstructure and electrolysis behavior of self-healing Cu-Ni-Fe composite inert anodes for aluminum electrowinning

Ying Liu; Yong-an Zhang; Wei Wang; Dong-sheng Li; Jun-yi Ma

doi:10.1007/s12613-018-1673-9

Volume 25 Issue 10

Oct. 2018

Turn off MathJax

Article Contents

Article Navigation > International Journal of Minerals, Metallurgy and Materials > 2018 > 25(10): 1208-1216

Ying Liu, Yong-an Zhang, Wei Wang, Dong-sheng Li, and Jun-yi Ma, Microstructure and electrolysis behavior of self-healing Cu-Ni-Fe composite inert anodes for aluminum electrowinning, Int. J. Miner. Metall. Mater., 25(2018), No. 10, pp. 1208-1216. https://doi.org/10.1007/s12613-018-1673-9

Cite this article as:

Ying Liu, Yong-an Zhang, Wei Wang, Dong-sheng Li, and Jun-yi Ma, Microstructure and electrolysis behavior of self-healing Cu-Ni-Fe composite inert anodes for aluminum electrowinning, Int. J. Miner. Metall. Mater., 25(2018), No. 10, pp. 1208-1216. https://doi.org/10.1007/s12613-018-1673-9

Citation:

PDF( 2314 KB)

Research Article

Microstructure and electrolysis behavior of self-healing Cu-Ni-Fe composite inert anodes for aluminum electrowinning

+ Author Affiliations

Corresponding author:
Yong-an Zhang E-mail: zhangyongan@grinm.com
Received: 12 December 2017; Revised: 20 April 2018; Accepted: 17 May 2018

Abstract

Abstract

The microstructure evolution and electrolysis behavior of (Cu₅₂Ni₃₀Fe₁₈)-xNiFe₂O₄ (x=40wt%, 50wt%, 60wt%, and 70wt%) composite inert anodes for aluminum electrowinning were studied. NiFe₂O₄ was synthesized by solid-state reaction at 950℃. The dense anode blocks were prepared by ball-milling followed by sintering under a N₂ atmosphere. The phase evolution of the anodes after sintering was determined by scanning electron microscopy and energy-dispersive X-ray spectroscopy. The results indicate that a substitution reaction between Fe in the alloy phase and Ni in the oxide phase occurs during the sintering process. The samples were also examined as inert anodes for aluminum electrowinning in the low-temperature KF-NaF-AlF₃ molten electrolyte for 24 h. The cell voltage during electrolysis and the corrosion scale on the anodes were analyzed. The results confirm that the scale has a self-repairing function because of the synergistic reaction between the alloy phase with Fe added and the oxide phase. The estimated wear rate of the (Cu₅₂Ni₃₀Fe₁₈)-50NiFe₂O₄ composite anode is 2.02 cm·a^-1.
- aluminum electrolysis;
- inert anode;
- composites;
- aluminum electrowinning;
- corrosion

FullText(HTML)

Supplements(0)

References(27)

References

[1]	D.R. Sadoway, Inert anodes for the hall-héroult cell:The ultimate materials challenge, JOM, 53(2001), No. 5, p. 34.
[2]	J. Keniry, The economics of inert anodes and wettable cathodes for aluminum reduction cells, JOM, 53(2001), No. 5, p. 43.
[3]	B.J. Welch, Inert anodes-the status of the material science, the opportunities they present and the challenges that need resolving before commercial implementation, Light Met., 2009, p. 971.
[4]	T.R. Beck and R.J. Brooks, Non-consumable Anode and Lining for Aluminum Electrolytic Reduction Cell, U.S. Patent, No. 5284562, 1994.
[5]	T.R. Beck, A non-consumable metal anode for production of aluminum with low-temperature fluoride melts,[In] A. Tomsett and J. Johnson eds. Essential Readings in Light Metals, Springer, Cham, 2016, p.1104.
[6]	B. Assouli, M. Pedron, S. Helle, A. Carrere, D. Guay, and L. Roué, Mechanically alloyed Cu-Ni-Fe based materials as inert anode for aluminum production, Light Met., 2009, p. 1141.
[7]	I. Gallino, M.E. Kassner, and R. Busch, Oxidation and corrosion of highly alloyed Cu-Fe-Ni as inert anode material for aluminum electrowinning in as-cast and homogenized conditions, Corros. Sci., 63(2012), p. 293.
[8]	S. Helle, M. Pedron, B. Assouli, B. Davis, D. Guay, and L. Roué, Structure and high-temperature oxidation behaviour of Cu-Ni-Fe alloys prepared by high-energy ball milling for application as inert anodes in aluminium electrolysis, Corros. Sci., 52(2010), No. 10, p. 3348.
[9]	G. Goupil, G. Bonnefont, H. Idrissi, D. Guay, and L. Roué, Consolidation of mechanically alloyed Cu-Ni-Fe material by spark plasma sintering and evaluation as inert anode for aluminum electrolysis, J. Alloys Compd., 580(2013), p. 256.
[10]	T.R. Beck, C.M. Macrae, and N.C. Wilson, Metal anode performance in low temperature electrolytes for aluminum production, Metall. Mater. Trans. B, 42(2011), No. 4, p. 807.
[11]	S. Helle, B.Brodu, B. Davis, D. Guay, and L. Roué, Influence of the iron content in Cu-Ni based inert anodes on their corrosion resistance for aluminium electrolysis, Corros. Sci., 53(2011), No. 10, p. 3248.
[12]	R.P. Pawlek, Inert anodes:an update,[In] A. Tomsett and J. Johnson eds. Essential Readings in Light Metals, Springer, Cham, 2016, p. 1126.
[13]	J.Y. Liu, Z.Y. Li, Y.Q. Tao, D. Zhang, and K.C. Zhou, Phase evolution of 17(Cu-10Ni)-(NiFe₂O₄-10NiO) cermet inert anode during aluminum electrolysis, Trans. Nonferrous Met. Soc. China, 21(2011), No. 3, p. 566.
[14]	Y.Q. Tao, Z.Y. Li, D. Zhang, H.W. Xiong, and K.C. Zhou, Microstructure evolution of a nickel ferrite-copper alloy cermet during sintering and high-temperature oxidation, J. Am. Ceram. Soc., 95(2012), No. 10, p. 3031.
[15]	E. Olsen and J. Thonstad, Nickel ferrite as inert anodes in aluminium electrolysis:Part I Material fabrication and preliminary testing, J. Appl. Electrochem., 29(1999), No. 3, p. 293.
[16]	ASM International, ASM Metals Hand Book, Volume 3:Alloy Phase Diagrams, p. 1644.
[17]	S. Corso, P. Tailhades, I. Pasquet, A. Rousset, V. Laurent, A. Gabriel, and C. Condolf, Preparation conditions of pure and stoichiometric Ni_xFe_3-xO₄ bulk ceramics, Solid State Sci., 6(2004), No. 8, p. 791.
[18]	O.A. Lorentsen, Behaviour of Nickel, Iron and Copper by Application of Inert Anode in Aluminium Production[Dissertation], Norwegian University of Science and Technology, Trondheim, 2000, p. 265.
[19]	V. Deněk, Ø.T. Gaustavsen, and T. Ostvold, Structure of the MF-AlF₃-Al₂O₃ (M=La, Na, K) melts, Can. Metall. Q., 39(2000), No. 2, p. 153.
[20]	V. Lacassagne, C. Bessada, P. Florian, S. Bouvet, B. Ollivier, J.P. Coutures, and D. Massiot, Structure of high temperature NaF-AlF₃-Al₂O₃ melts:a multinuclear NMR study, J. Phys. Chem. B, 106(2002), No. 8, p. 1862.
[21]	G. Goupil, S. Helle, B. Davis, D. Guay, and L. Roué, Anodic behavior of mechanically alloyed Cu-Ni-Fe and Cu-Ni-Fe-O electrodes for aluminum electrolysis in low-temperature KF-AlF₃ electrolyte, Electrochim. Acta, 112(2013), p. 176.
[22]	S. Helle, M. Tresse, B. Davis, D. Guay, and L. Roué, Mechanically alloyed Cu-Ni-Fe-O based materials as oxygen-evolving anodes for aluminum electrolysis, J. Electrochem. Soc., 159(2012), No. 4, p. E62.
[23]	A.P. Khramov, V.A. Kovrov, Y.P. Zaikov, and V.M. Chumarev, Anodic behaviour of the Cu₈₂Al₈Ni₅Fe₅ alloy in low-temperature aluminium electrolysis, Corros. Sci., 70(2013), p. 194.
[24]	A.P. Apisarov, A.E. Dedyukhin, A.A. Red'kin, O.Y. Tkacheva, and Y.P. Zaikov, Physicochemical properties of KF-NaF-AlF₃ molten electrolytes, Russ. J. Electrochem., 46(2010), No. 6, p. 633.
[25]	X.Y. Yan, M.I. Pownceby, and G. Brooks, Corrosion behavior of nickel ferrite-based ceramics for aluminum electrolysis cells, Light Met., 2007, p. 909.
[26]	L. Ma, K.C. Zhou, Z.Y. Li, Q.P. Wei, and L. Zhang, Hot corrosion of a novel NiO/NiFe₂O₄ composite coating thermally converted from the electroplated Ni-Fe alloy, Corros. Sci., 53(2011), No. 11, p. 3712.
[27]	H.B. He, Y. Wang, J.J. Long, and Z.H. Chen, Corrosion of NiFe₂O₄-10NiO-based cermet inert anodes for aluminium electrolysis, Trans. Nonferrous Met. Soc. China, 23(2013), No. 12, p. 3816.