Formation of Deposits on the Cathode Surface of Aluminum Electrolysis Cells

The efficiency of electrolysis cells for aluminum production is reduced when deposits are formed on the cathode block surface. Overfeeding of alumina or excessive heat loss in industrial cells leads to the formation of highly resistive deposits. In this study, the chemical composition of sludge, ledge toe, and thin deposits was investigated at the bottom of both industrial and experimental electrolysis cells. The formation of deposits in laboratory experiments was demonstrated in acidic, neutral, and basic electrolytic bath. A gradient of chiolite (Na₅Al₃F₁₄) and α-Al₂O₃ was observed in the deposits. The bath at the bottom of the experimental electrolysis cell had a higher cryolite ratio implying a higher liquidus temperature. The sludge formed at the bottom of the cell can lift the aluminum metal resulting in an important reduction of the contact surface between the aluminum and the cathode block. Moreover, the deposits disturb the current path and generate horizontal current components in the metal which enhance the motion and lower the current efficiency. A thin film of bath supersaturated in alumina was observed under the metal. This work provides clarification on the formation mechanisms of the various deposits responsible for the deterioration of the cathode surface.