Abstract

 
 
 The results of the feasibility study of the complete aluminum chlorine production cycle in comparison with the conventional method, namely, the extraction of alumina by the Bayer method and subsequent electrolysis of cryolite-alumina melts are reported in this paper. The advantages of the proposed method are: using low-quality Al-containing raw materials and less scarce and aggressive chlorides instead of fluorides; reduction of specific electric power consumption by about 30%; elimination of high-quality carbon-containing materials consumption and harmful emissions into the atmosphere; reduction of capital investments; labor productivity improvement.
 
 
 
 Keywords: aluminum-containing raw material chlorination, electrolysis of aluminum chloride, electricity savings
 
 
 
 
 
Highlights
The results of the feasibility study of the complete aluminum chlorine production cycle in comparison with the conventional method, namely, the extraction of alumina by the Bayer method and subsequent electrolysis of cryolite-alumina melts are reported in this paper
The modern process of aluminum smelting is mainly based on alumina production according to the Bayer method followed by electrolysis of cryolite-alumina melts (Hall– Héroult process)
The aluminum chloride electrolysis is more particular about quality of raw materials, and there is a need for additional chlorination costs
Summary
The aluminum chloride electrolysis is more particular about quality of raw materials, and there is a need for additional chlorination costs. The estimated cost of aluminum chloride per 1 ton of metallic Al will be: (0.4 × 400 × 0.85 + 63) × 5 = $995 per ton Al (during chlorination of rough alumina). The cost of raw materials for aluminum chloride electrolysis is higher by $195 per ton Al than that of for the alumina electrolysis. Capital investments in the complete process cycle of aluminum production according to traditional technologies compared with the chlorine method are approximately the same and has been estimated at $6500 per 1 ton capacities for metal A1. Availability of inhouse facilities for aluminum chloride production protects the chlorine process from above-mentioned fluctuations in raw material prices
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