Immediately over each vat is constructed a metal framework, through
which are inserted a large number of carbon rods about eighteen or
twenty inches long and from two to two and one-half inches in diameter.
This framework is electrically insulated from the iron crucibles. The
framework and the carbons are connected with the positive conductor of
the electric current, and the vat or crucible with the negative. These
conductors are very large, something like a foot in width and an inch in
thickness, and made of some good conductor of electricity. They have to
be very large because they carry a current equal to 3050 horse-power.
The current is one of great volume, but very low voltage; the
electromotive force at each vat or crucible being only about seven
volts. As the process is electrolytic, and not simply a heating process,
the direct current must be used, and therefore the current coming from
the power-house must be transformed twice; first to bring it to a
proper voltage and secondly to change it from an alternating to a direct
current. These iron vats or crucibles are connected up in series,
electrically, and then they are filled with the alumina and certain
other materials, which act either as a flux or as a means of increasing
the conductivity of the mixture; just what this substance is, is
probably one of the secrets of the process. When all of the crucibles
are filled with the mixture the current is turned on and is kept on
continuously night and day seven days in the week. All of the material
in the different crucibles is heated to redness, when the process of
separation takes place. The oxygen of the alumina is thrown off as a
gas, and other residuum floats to the top of the crucible and is skimmed
off.
Metallic aluminum in a melted state sinks to the bottom of the crucible,
where it is dipped out from time to time with large iron ladles and
poured into sand and molded into blocks similar to that of pig iron.
From time to time, as the metal is dipped out, fresh alumina with the
other substances are thrown in on top of the crucible, so that the
process is continually going on, day and night, week in and week out.
The heat in the process of reducing alumina, as we have before seen, is
not the chief factor; it simply serves to reduce the compound to a fluid
state so that the electrolytic action can readily take place.
Therefore it is not necessary to be brought to a white heat, as it is in
the case of the production of carborundum, described elsewhere.
Public-domain text, read in full here on John Shaqi.
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