Extraction of Metals

from Oxides
Aluminium
Production

2
 Ancient Uses (Before 19th Century)
 Ancient Greece & Rome:
• Aluminum compounds, such as alum (KAl(SO₄)₂·12H₂O), were used for dyeing
textiles, tanning leather, and medicinal purposes.
 Discovery of Aluminum (18th-19th Century)
• 1808 – Sir Humphry Davy (England): Proposed the name "aluminum" after
attempting to isolate the metal using electrolysis.
• 1825 – Hans Christian Ørsted (Denmark): First successfully extracted aluminum
by reacting aluminum chloride (AlCl₃) with potassium.
• 1827 – Friedrich Wöhler (Germany): Improved Ørsted’s method using metallic
potassium to produce small amounts of aluminum.
• Wöhler is credited as the first scientist to obtain pure aluminum
 Aluminum Becomes a Precious Metal (Mid-19th Century)

 Mass Production & Industrial Revolution (Late 19th Century)

 Mass Production & Industrial Revolution (Late 19th Century)
 1886 – Hall-Héroult Process (USA & France): Charles Martin Hall (USA) and Paul
Héroult (France) independently invented the electrolytic extraction process using
molten cryolite.
 1888 – First Aluminum Plant (USA): Pittsburgh Reduction Company (later ALCOA)
started large-scale aluminum production.
 1890s – Growth in Usage: Aluminum became widely used in construction,
transportation, and packaging.
 This process made aluminum affordable for mass production.
 20th Century: The Age of Aluminum
 1903 – Wright Brothers’ Airplane: Used an aluminum engine in their first successful flight.
 1930s-40s – Expansion in Aviation & Military: Lightweight and strong, aluminum was crucial in
WWII aircraft production.
 1950s-70s – Household & Industrial Boom: Introduction of aluminum cans, foils, and household
products.
 1969 – Apollo 11 Lunar Module: The first Moon landing used aluminum alloys in spacecraft
construction.
 21st Century: Sustainability & Recycling:
 Today, aluminum is one of the most recycled metals, reducing energy consumption and
environmental impact.
 New developments in nanotechnology, aerospace, and electric vehicles continue to expand
Introduction
 Named after Alum (bitter salt) – X.Al(SO4)2. 12 H2O
 Most abundant metallic element in the earth crust ~8%
 Relatively new metal - 19th century
• 1827: Wöhler produced Al by reduction of AlCl3 with K
• 1854: Deville replaced K with Na – commercial process
 Expensive than gold in 19th century
 Properties
• Low melting ~660 0C
• Light weight. High strength to weight ratio
• Corrosion resistance
• Electrical and thermal conductivity
• Ductility (FCC structure)
• Non toxic
• Recyclable

5
 Extraction of Aluminium by
Details ofPyrometallurgical
Al: The most Processaluminium
common
Atomic Number: minerals are:
13  Alumina trihydrates as gibbsite

Atomic Weight: (Al2O3.3H2O)

 and Alumina monohydrates as diaspore
27 amu
(Al2O3.H2O).
Density: 2.702
 Bauxite (mixture of these two minerals.
gm/cm
Aluminium
3
(Al) is a lighter metal than copper,
zinc and lead The bauxite ores found in India normally
Melting Point:
contain 58–67% alumina. These ores
 Extraction of Aluminium by
At roomPyrometallurgical Process
temperature, aluminum has a specific gravity
of 2.7 as compared with 8.89 for copper and 7.8 for
iron. Its high strength-to-weight ratio is a distinct
advantage in many structural applications.

The metal exhibits good corrosion resistance and

electrical and thermal conductivity.

 The metal has high reflectivity of light and low

emissivity. Aluminium has a strong affinity for oxygen,
a film of oxide that forms spontaneously on any freshly
cut surface.
Application of Aluminium and its alloy

( In India)
Application of Aluminium and its alloy
 Aluminium is a good conductor of heat and electricity, and
it is also less expensive than copper; nowadays it is
replacing the copper in electrical applications. In India,
aluminium is gradually replacing the copper in the power
transmission lines and in other electrical applications.

 Due to very good ductility and flow properties of aluminium,

it is used for extrusion of vessels and containers.

 For kitchenware, chemical and food processing industries,

pure grade aluminium is used due to its corrosion resistance
and non-toxic properties.

 High reflectivity and low emissivity of aluminium explains

Sl. No. Alloy Application
1 1xxx (Pure) Used in electrical and chemical industries
2 2xxx (Cu) Aircraft and General Engineering
3 3xxx (Mn) Architectural and general purpose alloys
4 4xxx (Si) Cast components
5 5xxx (Mg) Boat Hulls, other components in marine application

6 6xxx (Mg & Si) Extruded product and automotive products

7 7xxx (Zn) Aircraft structural components , High strength
alloys

8 8xxx (Li/Sn/Fe Aircraft / Bearing etc.

9 9xxx (Reserved) Future Use
Producti
Indian Aluminium and Alumina Production
on
Global primary Al production ~ 65
million tons

11
 Aluminum Resources and Production
 Main Aluminum Ore: Bauxite
 Composition: Hydrated aluminum oxides (Al₂O₃·xH₂O) with iron oxides and silica as impurities.
 Major Producers: Australia, Guinea, China, Brazil, India.
 Largest Reserves:
 Guinea (~24% of global reserves)
 Australia (~19%)
 Vietnam (~12%)
 Brazil, Indonesia, India also have significant reserves.

China dominates production (~60% of global output) due to

cheap electricity and large infrastructure.
🔹 India, Russia, and Canada are other major contributors.
Aluminium
minerals
 Minerals
• Bauxite rock (1821, Les Baux (France)) – Primary ore
 Gibbsite (Al(OH)₃) Bauxite rock
 Boehmite (γ-AlO(OH)
 Diaspore (α-AlO(OH)
 Bauxite resources: 55 - 75 billion tons
• Africa (32%) (bauxite)
• Oceania (23%)
• South America and the Caribbean (21%) ,
• Asia (18%)
• elsewhere (6%)
 India (3.8 billion tons)

• Kaolinite and clays

• Alunite
• Anorthosite
• Fly ash
• oil shales etc.

12
 Extraction of Aluminium by
carbothermic reduction Pyrometallurgical Process
The aluminium oxide is very stable. The
of aluminium oxide is not
feasible because:
(1) It requires a very high temperature (above
2000°C),
(2) At that temperature, aluminium carbide is
formed,
(3) The refractory required, for such high
temperature, is readily available and very
Discharge potential of aluminium is
expensive.
higher than the discharge potential of
The extraction of aluminium by the electrolysis of
hydrogen. Thus, the aqueous solution
aluminium salts in an aqueous
containing Al3+ and H+ ions, when
medium is not feasible, due to the decomposition
electrolysed, the H+ ions rather
of the aqueous solution which results in the
than Al3+ ions are discharged at
evolution of hydrogen at a much lower voltage than
cathode and hydrogen is evolved.
that needed for the electro-deposition of aluminium
ions.
• Hence, the universally adopted process for the
extraction of aluminium is the
Hall-Heroult process
Bayer process
 Bauxite
Crushing Grinding Classification (-100 mesh)
Stea Leaching Caustic soda
m solution
Pregnant
(150-220˚C, 5-25
liquor
Bayer’s Starc Settling Red mud
atm.)
h
Process Washing
for Filtration Red mud cakes
Alumina Hot
Liquor
Production: Heat exchange Effluen
t
𝑨𝒍𝟐 𝑶𝟑 . 𝑯 𝟐 𝟎 + 𝟐 𝑵 𝒂 𝑶 𝑯 = 𝟐𝑵𝒂𝑨𝒍𝑶 𝟐 +
Cooled liquor

𝟐𝑯𝟐 𝑶
Precipitation

Thickening
Al2O3 hydrate
Rotary kiln
Anhydrous alumina
 Bayer process
 High purity alumina for Hall-Heroult process
 Raw material – Bauxite (40-55 % Al2O3)
• Mixture of Gibbsite, Boehmite and Diaspore
• Other minerals : hematite, goethite, Kaolinite,
quartz, rutile, anatase etc.
• Major oxides: Al2O3, Fe2O3, SiO2, TiO2, CaO etc.

 Milling
• After mineral beneficiation
• To increase the surface area
• Mixed with lime and spent liquor (alkali solution)
• Lime is added to convert Na2CO3 in the spent
liquor to NaOH
Bayer Process is for the preparation of pure A12O3 and known as the Bayer
Process. This process was concerned with leaching bauxite, discovered in
1821 in France in a small village called Les Baux, near Marseille, with
sodium hydroxide solution above its boiling point in a pressure reactor. After
separating the insoluble material, the pure solution was then seeded to
precipitate pure crystalline aluminum hydroxide which was filtered, washed,
dried, and calcined to pure M2O3 suitable for charging to the electrolytic
reduction cell
Bayer process - stages
 Clarification/Settling
• Settling: Flocculent to aid settling
• Washing: to recover caustic soda
• Filtering of pregnant solution : to remove solids
• Solids/slurry: bauxite residue disposal area
 Precipitation
• Pregnant solution : supersaturated sodium aluminate
(NaAlO2) solution
• Cooled down to around 70 0C
 Al(OH)4- + Na+ → Al(OH)3 + Na+ + OH-
• Addition of Al(OH)3 seeds (nuclei)
• Size and toughness are important
• Passed to thickeners followed by filtration
 Calcination
>1100 0C
 2 Al(OH)3 → Al2O3 + 3 H2O
 suspension calciners, fluidised bed calciners and rotary kilns
 Final product: PSD, surface area, α Al2O3 content etc. are
important 16
• The alumina trihydrate solution is then cooled, concentrated and stirred in open top
tanks until it forms into crystals. This part of the process can take several days. Pure
alumina is added to this mixture to assist with the formation of alumina trihydrate
crystals.

• Imagine a tank as tall as a six-story building. Now imagine row after row of those tanks
called precipitators. The clear sodium aluminate from the settling and filtering
operation is pumped into these precipitators. Fine particles of alumina - called “seed
crystals” (alumina hydrate) - are added to start the precipitation of pure alumina
particles as the liquor cools. Alumina crystals begin to grow around the seeds, then
settle to the bottom of the tank where they are removed and transferred to
“thickening tanks.” Finally, it is filtered again then transferred by conveyor to the
“calcination kilns.”
 Factors affecting Bayer Process
 Finer bauxite (wet grinding) increases the dissolution of alumina in leach liquor.

 Dissolution is accelerated by increasing temperatures; above 100°C water would be evaporated, hence high
pressures up to 25 atmospheres are applied to attain a temperature up to 220°C.

 The sensible heat, collected from hot liquid, is used for producing steam for dissolution.

 In the precipitation stage, complete precipitation of alumina is not allowed because this may lead to the
simultaneous precipitation of dissolved silica, as unsuitable for electrolysis.

 The rotary kiln should be able to attain a temperature as high as 1400˚C for efficient calcination of alumina.
 Contd…
In the Bayer process, high-purity alumina is produced from bauxite. The bauxite is leached by sodium hydroxide
under high pressure (25 atmospheres) and a temperature at 220°C to form soluble sodium aluminate, from which
Al(OH)3 is precipitated. The alumina is obtained by calcinations of Al(OH)3.

Initially, bauxite obtained from the mines is crushed and ground to a very fine size to separate silica from bauxite. By
comminuting, alumina can be enriched in the coarser fractions. The coarser fractions are further ground along with
caustic soda in a ball mill to form slurry, which is fed into an autoclave (at 220°C temperature and 25 atmospheres
pressure). The alumina, in the bauxite, is dissolved in caustic soda:

Al2O3.H2O+ 2NaOH = 2NaAlO2 + 2H2O

Al2O3. 3H2O+ 2NaOH = 2NaAlO2 + 4H2O

The dissolution of the alumina monohydrate requires a temperature of 230°C and a time of 3 h, whereas for the
alumina trihydrate requires a temperature of 180°C and a time of 1 h.
 Contd…
 At such high temperatures, a sufficiently high pressure (5–25 atmospheres) must be applied in order to retain
water in the liquid state. Then the liquid is cooled below 100°C, and the settling of red mud is speeded up by the
addition of starch. Any remaining red mud in the liquid is eliminated by washing with hot water. Finally, the liquid
is filtered; the filtrate obtained is a clear solution of sodium aluminate.

 The residue left behind after filtration consists mainly of ferric hydroxide, silica, and non-dissolved alumina.

 The hot liquid is extracted by heat exchanger for cooling the liquid below the critical temperature, which is
required for alumina precipitation.
 Very fine, freshly prepared aluminium hydroxide is added to create nuclei in order to accelerate the precipitation
of Al(OH)3. The precipitate is separated from the liquid in the thickener, and the product is calcined in a rotary
kiln to produce anhydrous alumina. Depending on calcinations temperature, resultant Al 2O3 is either a loose
hygroscopic γ-Al2O3 (800°C) or a more dense α-Al2O3 (1200°C), but generally the product is a mixture of both
components due to flow rate of transformation.

2NaAlO2 + 4H2O = 2Al(OH)3 + 2NaOH 2Al(OH)3 = Al2O3 + 3H2O

The filtered liquid is pumped through a series of six-story-tall precipitation tanks.
Seed crystals of alumina hydrate (alumina bonded to water molecules) are added
through the top of each tank. The seed crystals grow as they settle through the
liquid and dissolved alumina attaches to them
 Alumina
 Major part of alumina is used for Al
production
 Other application
• Ceramics
• Glasses (e.g. Gorilla)
• Filler for plastics
• Abrasives
• Refractories
• Aluminum oxide compound
for conversion of H2S to
sulphur in oil industry
Bauxite
residue
 Also known as red mud
 1.5 to 2.5 tons of residue per ton of alumina
 Storage is a concern – land and alkalinity
 Partly used in cement production - due to high sodium content and transportation costs
Other
wastes
 Fly ash

 Aluminum dross

 Spent pot lining

 Current research status on red mud (chinmayee)

 Environmental concern and recycling of Al indtustri waste like fly ash, Aluminum dross and spent pot lining (Era)

25
Aluminum
production
 Carbothermic reduction – not feasible
• 2000 0C temperature
• Carbide formation
• Limitations with refractories
 In 1886 Heroult from France and Hall from USA
independently patented a process
 Requisites
• High-purity alumina (>99.5%)
• Cryolite (3NaF.AlF3)
• Ashless carbon electrodes (0.4 to 0.5
kg/kg of Al)
• Electric power (cheap) (13 to 15 kWh/kg Al)
 Raw materials for Hall-Heroult
 Cryolite
process
• Alumina is not ionic. Limited solubility in many ionic melts.
• Cryolite dissolves 15% of alumina at 1000 C
• Available as mineral. Now exhausted
• Produced from sodium aluminate solution
6HF + NaAlO2 + 2NaOH = Na3AlF6 + 4H2O
 Electrolyte
• 75% Cryolite
• CaF2 – 4-8%
• Excess AlF3 – 5-15%
• Alumina – 2-6 % 5 meter long, 2 meter wide and 1 meter
deep.
• LiF – 0-5%
• MgF2 – 0-5%
• Additives lowers the melting point and increases the
current efficiency
• Addition of some of the above compounds required from
time to time to make up the losses by reactions and
evaporations 30
Why Cryolite Dissolves Alumina:
1.Ionic Compatibility: Cryolite is an ionic compound containing Al³⁺, Na⁺, and F⁻ ions,
which helps break the Al₂O₃ lattice and dissolve it.
2.Lowered Melting Point: Pure Al₂O₃ has a very high melting point (~2072°C), but in
molten cryolite, it dissolves at a much lower temperature (~1000°C), making the
electrolysis process energy-efficient.
3.Solvation Effect: The fluoride ions (F⁻) in cryolite interact with Al₂O₃, forming complex
ions like [AlF₆]³⁻, which enhances solubility.
4.Electrolytic Efficiency: The dissolved alumina provides Al³⁺ ions for the electrolysis
reaction, where aluminum is reduced at the cathode.
 Hall Heroult Process
• In 1886, Hall in the USA and Heroult in France
independently patented a process for the
commercial production of aluminium.
• This process is based on the electrolytic
decomposition of alumina dissolved in a liquid bath
of cryolite
• The primary requisite for the Hall-Heroult process,
which also requires high-purity alumina, cryolite, and
ashless carbon electrodes.
• The electrolytic cell contains a rectangular
refractory lined steel container which is 5 m long, 2
m wide and 1 m deep.
• The bottom of the container is conducting and acts
as a cathode which consists of refractory bricks of
carbon bonded by tar binder. Iron plate and iron bar
are embedded in the carbon mixed for good
conduction to form cathode.
https://www.youtube.com/watch?v=ktvTyccCIHo
 Hall Heroult Process
 Anodes are carbon electrodes that are replaced from time to time. The average life is 8–10 days. The
baked carbon anode and the lining cathode must be sufficiently strong (250–300 kg/cm2 of compressive strength)
and dense (< 25% porosity)

 A tap hole for the collection of molten aluminium metal is located on the bottom of the furnace. The density of the
bath must be less than that of liquid aluminium, or else the liberated metal will float and upset cell operation.
Molten aluminium is collected at the bottom, as its density (2340 kg/m3) is higher than that of the electrolyte (2030
kg/m3).

 Since alumina is not purely ionic compound, hence, very few ionic melts are capable of dissolving it to any
appreciable extent. However, cryolite (3NaF.AlF3), a naturally occurring mineral, can dissolve up to 15% alumina
at 1000°C. Cryolite has been successfully synthesized by passing hydrogen fluoride (HF) through sodium
aluminate (Na6Al2O6) solution,
 Hall Heroult Process
 Small amounts of CaF2 and NaF are added to the cryolite bath to enhance its conductivity and to improve the
metal recovery. Cryolite melts at 990°C, at this temperature it will dissolve 10% of alumina.

 At 1000°C, the density of the molten cryolite is approximately 2100 kg/m 3 and that of Al2O3 is 3960 kg/m3, which
sink at the bottom of the cell. When the bath containing about 10% CaF2, 80% cryolite, 5% Al2O3, and a small
amount of NaF is electrolyzed, the aluminium (density 2340 kg/m3) is liberated which is heavier than the bath and
collected at the bottom of the bath. In this way, the aluminium metal is protected against atmospheric oxidation.

 During operation, the cell is filled with cryolite and the anode is lowered into that. Current is passed through the
cell until the cryolite (melting point 990°C) melts. When the bath attains the molten state, then only alumina is
charged to the cell. The alumina decomposes to alunimium and oxygen, which is an endothermic reaction,
 Hall Heroult Process
 This oxygen reacts with carbon in anode to form CO and CO2 gases. The agitation of the bath takes place due to
evolution of CO and CO2 gases; as well as magnetic stirring due to the current flowing through the bath from
anode to cathode.

 If the alumina content of the bath (normally 5– 10%) decreases below 2%, then normal contact between the
anode and the bath is interrupted by a gas film which increases the resistance and causes the voltage to rise from
5–6 V to as much as 40–50 V. Fluorine gas is deposited at the anode surface where it forms a gas film which is
electrically insulating, causes rise in the voltage. As a result, normal operation is hampered. This effect is known
as the anode effect. With addition of sufficient alumina to the bath the voltage returns to its normal value.
Anode
effect
Decrease in alumina conc. below 2%
• Other reactions takes place
 Fluorocarbons (green house gases) generate at anode
• Forms gas layer on anode
• Decreases the contact area with electrolyte
• Voltage increases (10-50 volts)
 To overcome
• The alumina concentration must be restored to normal values
as quick as possible
• The layer of gas adhering to the anode bottom must be
removed by moving anodes up and down

37
During electrolysis, several reactions involving all the ions take place simultaneously in the melt
The NaF reacts with Al2O3 to form Na2O
The NaF is dissociated into Na
and F:
Factors influencing electrolysis
 Increase in temperature decreases the current efficiency
• every 4 oC decreases 1% CE
• Side reactions
• Metal dissolution in the flux increases
 The higher current density, the greater the current efficiency
 Decrease in density of the bath increases the CE
• High AlF3/NaF ratio decreases the density. However, it decreases the conductivity
and Al2O3 solubility
• Optimum – NaF/AlF3 slightly less than 3
 Distance between electrodes - highest (>90%) efficiency at ~65 mm
 CE is higher when Al2O3 content is higher than 4%

39
 Hall-Heroult Process
Factors affecting
Electrolysis
 Bath temp.: Increases in temp. decreases current efficiency due to increases
in side reactions. Decreases in temp. improves current efficiency upto
certain limit.

 Higher current density, greater current efficiency.

 Lower the density of bath, higher the rate of separation of metal liberated
from the bath. Density lowered by using high AlF3/NaF ratio.

 Cell efficiency can be improved by controlling the addition of alumina.

https://www.youtube.com/watch?v=4a1ptfTItXA
 Production of Al in india. (23)
 Production of Al in world scenario (24)
 Newer process for aluminium production Alcoa process (21),
toth process and Alcan process (22)
 Recovery of Al and Fe from red mud (50)
Raw
materials
 Electrodes
• cathode lining consists of refractive bricks is faced with
carbon mixed with a tar binder
• Anodes (petroleum coke +petroleum pitch)
 Prebaked
 Soderberg

 The process
• https://youtu.be/IaT9WWQA3pM
• https://youtu.be/JBso28su0G4?t=438

43
Anode
effect
 Decrease in alumina conc. below 2%
• Other reactions takes place
 Fluorocarbons (green house gases) generate at anode
• Forms gas layer on anode
• Decreases the contact area with electrolyte
• Voltage increases (10-50 volts)
 To overcome
• The alumina concentration must be restored to normal values
as quick as possible
• The layer of gas adhering to the anode bottom must be
removed by moving anodes up and down

44
Factors influencing
electrolysis
 Increase in temperature decreases the current efficiency
• every 4 oC decreases 1% CE
• Side reactions
• Metal dissolution in the flux increases
 The higher current density, the greater the current efficiency
 Decrease in density of the bath increases the CE
• High AlF3/NaF ratio decreases the density. However, it decreases the
conductivity and Al2O3 solubility
• Optimum – NaF/AlF3 slightly less than 3
 Distance between electrodes - highest (>90%) efficiency at
~65 mm
 CE is higher when Al2O3 content is higher than 4%

45
Requirement of
flux

46
Efficien
cy
• Theoretical energy
requirement based
on the below
reaction is ~6 -
kwh/kg
• Al2O3+1.5 C =
2Al + 1.5
CO2

• 1 kg Al price ~140
Rs
• Energy
consumption
per kg 18
kwh/kg
47
Carbon
consumption

48
Role of
Cryolite

49
Decomposition
potential

50
Decomposition
potential

51
Volta
ge

52
Electro-refining – three layer proce

53
 Electrolytic refining of Aluminium
 By the Hall-Heroult process purity is about
99.5%,
 for electrical applications and for canning,
a higher degree of purity is required. An
electrolytic method is used which is known
as the three layer process
 The graphite electrode is used as cathode
and carbon bottom acts as anode.
Electrolytic refining takes place in a cell in
which the anode is at the bottom, the
current travelling up through the bath and
being collected at the top by graphite
electrodes.
 A dense electrolyte (which consists of
36%
aluminium fluoride, 30% cryolite, 18%
barium fluoride, and 16% calcium fluoride)
forms the middle layer (density is 2800
kg/m3).
 The impure metal is alloyed with copper
(28–30% Cu), and this heavy alloy (density
is 4500 kg/m3) forms the bottom layer.
Three layer process
 28 to 30 percent copper that makes the density of the alloy about 4.5
 Electrolyte density is adjusted to 2.8 and pure aluminum 2.3
 aluminum fluoride 36 percent, cryolite only 30 percent
and barium fluoride (barium is a heavy), 18 percent, calcium fluoride 16
percent.
 Temperature -950 0C
 Energy consumption is high 12 kwh/kg
 Produces 99.99% purity (99.5% from Hall-Heroult)
Issues with Al
production
 High energy consumption
• Thermal power – CO2 generation
 Red mud (bauxite residue)
 Aluminum dross – generate ammonia and
poisonous gases when react with water
 Spent pot lining – cyanides and fluorides
 Land acquisition, deforestation, toxic
residues etc.

56
Primary aluminium smelting is the process of extracting aluminium
metal from aluminium oxide (also known as alumina). The process
takes place in electrolytic cells that are known as pots. The pots are
made up of steel shells with two linings, an outer insulating or
refractory lining and an inner carbon lining that acts as the cathode of
the electrolytic cell. During the operation of the cell, substances,
including aluminium and fluorides, are absorbed into the cell lining.
After some years of operation, the pot lining fails and is removed.
The removed material is spent pot lining (SPL)
 Production of Al in india. (23)
 Production of Al in world scenario (26)
 Newer process for aluminium production Alcoa process (19),
 Toth process and Alcan process (22)
 Recovery of Al and Fe from red mud (21)
 NEWER PROCESS FOR ALUMINIUM
PRODUCTION
 ALCOA Alumina from Bayer
PROCESS: process
Reaction: Coke
Chlorin Fluid bed chlorination 700-
Al2O3(c) + 2C (c) +
900˚C
3Cl2(g) e
AlCl3(g), CO(g), CO2(g)
2AlCl3(g) + CO(g) +
2CO2(g) Fluid bed condensation, 70˚C CO2, CO

AlCl3

Electrolysis NaCl-LiCl-AlCl3, molten

Chlorin bath 700˚C
e

Molten
aluminium
ALCOA BIPOLAR
CELL:

 Consist of several bipolar electrodes and each

behave like a cathode at the top and like anode
at the bottom surface.

 Continuous flow of electrolyte should be

maintained to prevent molten Al produced
upon electrolysis.

 1 bipolar cell is equivalent to 5 conventional

monopolar cell series.

 Productivity and cell voltage are 5 times

of conventional monopolar cell. ALCOA BIPOLAR
CELL
TOTH
PROCESS:
 Alumina is converted to AlCl3 by chlorination in the presence of carbon.
 AlCl3 reduced to Al by treating with manganese at 300˚C and pressure of 15
atm.

3Mn + 8 Al3Cl3 (l) 3 (MnCl2.2AlCl3) (l) + 2Al

ALCAN PROCESS:
 Bauxite is reduced to aluminium alloy contains Al = 50%, Fe = 30%, Si =
10%, Ti = 5% and C = 5%
 Reduction carried out at 2000˚C and reversed at 700˚C

 Reaction:
 2Al + 3AlCl (reversible
AlCl3 reaction)
 Alumina production – Bayer
process
 Alumina is an amphoteric oxide
 Acid leaching
• Not selective
• Reagent consumption
• Energy consumption
 Alkali leaching (Bayer process) is
economically viable
• Alkali regeneration
• Selective
• Crystalline Al(OH)3 product
 Karl Joseph Bayer invented the process in
1887 and modified it in 1892

13
Summa
ry
 Aluminum production by Hall-Heroult process
 Raw materials
 Flux
 Current efficiency and energy consumption
 Three layer process
 Energy and environmental issues

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