Ready-to-Use Cathodes for the Hall-Héroult Process

Ready-to-Use Cathode (RuC^®) blocks based on the use of copper inside the cathode have been implemented in many aluminum smelters since 2015. The concept and key performance parameters are presented, along with measurements of cathode resistance, collector bars current distributions and temperature at cell start-up and as function of cell age. Today more than 500 RuC^® cathodes are in operation and more RuC^® cells are started every day. Significant energy savings and improvement of the cell magneto-hydrodynamic state are achieved. The reduction of the maximum cathode surface current density should lead to longer cathode life. The concept allows the avoidance of cast iron rodding and recovery of copper at the relining time. A new generation of cathode is ready to be implemented.