Cathode configuration, cathode block with a groove, and production method

Abstract

A cathode configuration for an aluminum electrolysis cell has at least one cathode block based on carbon and/or graphite. At least one groove is formed in the cathode block and the groove is lined with a graphite foil, at least in certain regions. At least one busbar is disposed in the groove and has an encasement of cast iron at least in certain regions. At least one recess is formed in the wall of the cathode block that delimits the at least one groove, and the encasement of cast iron engages into the at least one recess, at least in certain portions. A cathode block for such a cathode configuration is provided and also a process for producing a cathode configuration for an aluminum electrolysis cell.

1 . A cathode configuration for an aluminum electrolysis cell, the cathode configuration comprising:
 at least one cathode block based on at least one material selected from the group consisting of carbon and graphite;   said at least one cathode block having a groove formed therein lined with a graphite foil at least in certain regions thereof;   a wall of said cathode block delimiting said groove having at least one recess formed therein;   a busbar disposed in said groove, said busbar having an encasement of cast iron at least in certain regions thereof, said encasement of cast iron engaging into said at least one recess in said groove at least in certain portions thereof.   
     
     
         2 . The cathode configuration according to  claim 1 , wherein a portion of said encasement of cast iron engaging into said at least one recess is formed in a complementary shape to said recess. 
     
     
         3 . The cathode configuration according to  claim 1 , wherein a portion of said encasement engaging into said at least one recess and, if appropriate, said busbar encased thereby fill at least 70% of the recess. 
     
     
         4 . The cathode configuration according to  claim 1 , wherein said at least one recess extends continuously over at least 20% of a length of said groove. 
     
     
         5 . The cathode configuration according to  claim 1 , wherein said at least one recess has a depth of 2 mm to 40 mm. 
     
     
         6 . The cathode configuration according to  claim 1 , wherein said at least one recess has an opening width, based on a height of said cathode block, of 2 mm to 40 mm. 
     
     
         7 . The cathode configuration according to  claim 1 , wherein said at least one recess has a cross-sectional shape selected from the group consisting of substantially semicircular, triangular, rectangular and trapezoidal. 
     
     
         8 . The cathode configuration according to  claim 1 , wherein said recess extends substantially perpendicularly into the wall of said cathode block delimiting said groove. 
     
     
         9 . The cathode configuration according to  claim 1 , wherein, considered in a depth direction of said groove, said at least one recess is delimited at each end thereof by a transition region between said recess and an adjoining portion of the groove wall, wherein each of said transition regions has an angled configuration, wherein an angle between said wall of said recess and an adjoining portion of the groove wall, as seen from the inside said cathode block, amounts to between 90° and 160°. 
     
     
         10 . The cathode configuration according to  claim 1 , wherein, considered in a depth direction of said groove, said at least one recess is delimited at each end thereof by a transition region between said recess and an adjoining portion of the groove wall, wherein each of said transition regions has a curved configuration, wherein the radius of curvature of the transition region is at most 50 mm. 
     
     
         11 . The cathode configuration according to  claim 1 , wherein said wall delimiting said groove is formed with a bottom wall and two side walls, and wherein each of said side walls is formed with a respective said recess. 
     
     
         12 . The cathode configuration according to  claim 1 , wherein said at least one recess is formed at a substantially constant spacing distance from a bottom wall of said groove over a length of said recess. 
     
     
         13 . The cathode configuration according to  claim 1 , wherein said at least one recess is lined with said graphite foil, and said groove is lined over a full extent thereof with said graphite foil. 
     
     
         14 . The cathode configuration according to  claim 13 , wherein said graphite foil is pressed against a boundary of said recess by said encasement of said busbar formed of cast iron. 
     
     
         15 . The cathode configuration according to  claim 1 , wherein said groove has a variable depth over a length thereof. 
     
     
         16 . The cathode configuration according to  claim 15 , wherein longitudinal-side ends of said groove have a lesser depth than a center of said groove. 
     
     
         17 . The cathode configuration according to  claim 1 , wherein said graphite foil is inserted and/or adhesively bonded into the groove. 
     
     
         18 . A cathode block for a cathode configuration of an aluminum electrolysis cell, comprising:
 a carbon and/or graphite block having at least one groove formed therein for receiving a busbar;   a wall of said block delimiting said groove having at least one recess formed therein.   
     
     
         19 . A process for producing a cathode configuration for an aluminum electrolysis cell, the method which comprises the following steps:
 providing a cathode block based on at least one material selected from the group consisting carbon and graphite and formed with at least one groove for receiving a busbar, and with at least one recess formed in a wall of the cathode block that delimits the at least one groove;   lining at least a region of the at least one groove with a graphite foil;   inserting a busbar into the at least one groove;   pouring liquid cast iron into at least a portion of the at least one recess between the graphite foil and the busbar; and   allowing the cast iron to solidify.   
     
     
         20 . The process according to  claim 19 , which comprises inserting the graphite foil into the groove and/or adhesively bonding the graphite foil in the groove.