SBIR Phase I: Rapid Fabrication of Titanium Boride (TiB2) Anodes for Electrolysis of Aluminum

9861522 这个小企业创新研究（SBIR）第一阶段项目将探索一种用于铝电解的非消耗性硼化钛（TiB 2）阳极的新型制造方法。 在常规Hall-Heroult工艺中，常规生产一吨铝需要约65 - 70吉焦耳的能量和约半吨碳（石墨）阳极。 由TiB2制成的非消耗性阳极可以降低能耗，并消除当今工业中实践的碳阳极的更换。 TiB 2是一种优良的导电体，对金属铝和熔融冰晶石具有高的耐腐蚀性。 此外，使用非消耗性阳极消除了有毒气体排放和多环芳烃。 不幸的是，TiB2由于其低自扩散性而需要在高温下长时间烧结。过度的晶粒生长在热压或无压烧结过程中产生内部缺陷，导致微裂纹。 为了克服这些困难，第一阶段将开发一种称为等离子体压力压实（P2C）的反应性固结方法。 TiB2的合成和致密化将在P2C工艺中通过使用新的场激活机制在15分钟的循环时间内实现。 反应固结的TiB 2预期具有高密度、小晶粒尺寸、均匀的微观结构和一致的机械性能。 通过P2C在一个步骤中合成和固结TiB2被预期应用于在初级金属工业中用于铝电解的TiB2阳极的制造。

9861522 This Small Business Innovation Research (SBIR) Phase I project will explore a novel fabrication method for a nonconsumable titanium boride (TiB2) anode used in the electrolysis of aluminum. The conventional production of one ton of aluminum requires about 65-70 gigajoules of energy and about one-half ton of carbon (graphite) anode in the conventional Hall-Heroult process. A nonconsumable anode made of TiB2 can reduce energy consumption and eliminate the replacement of carbon anodes as practiced in industry today. TiB2 is an excellent electrical conductor with high corrosion resistance against metallic aluminum and molten cryolite. In addition, the use of nonconsumable anodes eliminates toxic gas emissions and polycyclic aromatic hydrocarbons. Unfortunately, TiB2 requires a long sintering time at high temperatures due to its low self-diffusion. Exaggerated grain growth creates internal defects during hot pressing or pressure-less sintering that lead to microcracking. To counter these difficulties, Phase I will develop a reactive consolidation approach called Plasma Pressure Compaction (P2C). Synthesis and densification of TiB2 will be achieved in the P2C process within a 15-minutes cycle time by using novel field-activating mechanisms. Reactively consolidated TiB2 is expected to have high density, small grain size with uniform microstructure, and consistent mechanical properties. Synthesis and consolidation of TiB2 by P2C in a single step is anticipated to be applied in fabrication of TiB2 anodes for use in electrolysis of aluminum in the primary metals industry.