Abstract
The Hall–Heroult process to produce aluminum is more than 125 years old. Larger, more efficient cells have been developed, and process control has improved, but the process is basically unchanged. A new process has been under development since 1990 that promises 20% lower capital cost and 20% lower operating cost and no CO2 or fluorocarbon emissions. A new cell design, new anode and cathode materials, new electrolyte, and new operating conditions are based on experience over the past six decades. The evolution of this technology to its present state is described here.
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References
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Acknowledgements
Many people have contributed to the ideas and results in this paper. R. A. Lewis instructed the author in the art of Hall–Heroult technology at the Kaiser Aluminum laboratory. J. C. Withers introduced the concept of feeding alumina particles to the anode reaction site from the carbon anode side and using low-temperature electrolytes. Prof. J. Thonstad consulted on metal alloy anodes and contributed research on electrolyte properties. D. Bradford and Dr. C. W. Brown at NAT contributed much operating experience with 10-A to 300-A pilot cells. The National Laboratory, CSIRO, in Australia made electron probe microanalysis profiles of anode surfaces that led to quantitative understanding of metal anode performance. Support by the National Science Foundation and by the Department of Energy made this research possible. J. H. Magnusson of Arctus Metals in Iceland made economic studies of the technology and participated in obtaining further support by Vattenfall in Sweden. Dr. G. Andree and the group at Vattenfall in Sweden conducted outstanding work on testing the porous cathode concept within the time constraint.
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Beck, T.R. A New Energy-Efficient and Environmentally Friendly Process to Produce Aluminum. JOM 65, 267–271 (2013). https://doi.org/10.1007/s11837-012-0517-8
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DOI: https://doi.org/10.1007/s11837-012-0517-8