Extremely high corrosion resistance of Zn_xNi_1–xCr₂O₄ spinel as sidewalls in the aluminum electrolyte

The sidewall material is a key component in new electrolytic cell with an inert electrode for the aluminum electrolysis industry. The continuous development of novel sidewall materials with excellent corrosion resistance in molten salts electrolyte is an important topic. Herein, a new system of sidewall material, spinel structured Zn_xNi_1–xCr₂O₄ (x = 0 – 1), is prepared by solid-phase reaction and the corrosion-resistance enhancement is investigated. The results prove that Zn²⁺ plays two roles in the Zn_xNi_1–xCr₂O₄ spinels. Firstly, Zn²⁺ tunes the surface energies of spinels resulting in the octahedral grains, which suppresses the cation diffusion in the corrosion process. Secondly, Zn²⁺ stabilizes the Cr³⁺ in the spinels. As a result, the Zn_0.5Ni_0.5Cr₂O₄ spinel displays an extremely low corrosion rate ∼0.007 cm·a^–1 in NaF-KF-AlF₃ bath at 800 °C comparing with other sidewall materials. The as-obtained spinel shows great potential as a novel sidewall material for the new electrolytic cell.