The most typical thermal insulating materials used in the cathode lining in aluminium electrolysis cells are Moler, calcium silicate, or vermiculite. The thermal insulation is important for the overall thermal and dimensional stability of the cell. The chemical stability of the thermal insulating materials is important, especially in cases where the refractory layer above the thermal insulation layer becomes fully penetrated by sodium vapour. The chemical degradation of thermal insulating materials by sodium vapours has been investigated in a laboratory test resembling the environments in the cathode lining. The exposed materials were investigated with respect to changes in the microstructure and chemical and mineralogical composition by a combination of optical and electronic microscopy and powder X-ray diffraction. These investigations revealed different reaction patterns for the three materials and the formation of new mineralogical phases were identified. Finally, these findings were compared with chemical reactions with sodium based on computational thermodynamics.

The most common thermal insulating materials used in the cathode lining in aluminum electrolysis cells are Moler (diatomaceous earth), calcium silicate, or vermiculite based materials. The thermal insulation layer is critical for the overall thermal stability of the cell and is vulnerable to volatile species, such as sodium vapor, that may penetrate through the carbon cathode and refractory layer. Here, we present an investigation of the chemical degradation of typical thermal insulating materials by exposure to sodium vapor in a laboratory test. Changes in microstructure and chemical and mineralogical composition of the exposed materials were characterized by electronic microscopy and powder X-ray diffraction. The materials possess different reaction patterns, ranging from deformation by creep to formation of a glassy layer reducing further sodium penetration. The results from the laboratory test were compared with chemical reactions with sodium predicted by computational thermodynamics and discussed with respect to relevant ternary phase diagrams.