Alumina and Aluminium Production Processes
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Questions and Answers

What is the typical daily output of the largest and most productive cells in terms of aluminium?

  • 4000 kg (correct)
  • 1000 kg
  • 6000 kg
  • 2000 kg
  • What is the average current efficiency of the most productive aluminium cells?

  • 98%
  • 95% (correct)
  • 85%
  • 90%
  • Which ions are probable current-carrying ions in the electrolytic reaction?

  • K+ and AlF6^2-
  • Na+ and AlCl3
  • Mg^2+ and Al3O8^3-
  • Na+ and AlF4- (correct)
  • What is produced at the cathode during the electrolytic reduction of aluminium?

    <p>Aluminium metal and F- ions (D)</p> Signup and view all the answers

    How much thermal energy is required to produce one tonne of aluminium?

    <p>30,000 kWh (D)</p> Signup and view all the answers

    What form of alumina is produced in the temperature range of 400–600°C?

    <p>γ -alumina (C)</p> Signup and view all the answers

    What is the primary benefit of using cryolite in the production of aluminium?

    <p>It allows for electrolytic dissolution of alumina. (B)</p> Signup and view all the answers

    Which country experienced the highest increase in alumina production from 2005 to 2015?

    <p>China (C)</p> Signup and view all the answers

    What is the typical composition of the electrolyte used in the Hall–Héroult process for aluminium production?

    <p>80–90% cryolite and 2–8% alumina (D)</p> Signup and view all the answers

    What is the purpose of the gas collection system in an electrolytic-reduction cell?

    <p>To prevent fumes from escaping into the atmosphere. (A)</p> Signup and view all the answers

    At what typical temperature is a modern electrolytic-reduction cell operated?

    <p>950°C (A)</p> Signup and view all the answers

    What is the average world price for alumina in 2015?

    <p>$250 per tonne (D)</p> Signup and view all the answers

    What role do carbon anodes play in the Hall–Héroult process?

    <p>They are consumed and require regular replacement. (A)</p> Signup and view all the answers

    Flashcards

    What is a potline?

    A unit of aluminum production, typically consisting of 150-300 cells connected in series.

    What is electrolysis?

    The process of using electricity to break down a compound into its elements, in this case, extracting aluminum from its ore.

    What is the cathode?

    The negatively charged electrode in an electrolytic cell, where aluminum is deposited.

    What is the anode?

    The positively charged electrode in an electrolytic cell, where oxygen is released as a byproduct.

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    What is the overall reaction of aluminum production?

    The chemical reaction where aluminum oxide is transformed into aluminum metal and carbon dioxide. This reaction occurs in the electrolytic cell during aluminum production.

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    Bayer Process

    The process of extracting aluminum from bauxite ore. This involves dissolving the ore in a sodium hydroxide solution, separating impurities, and then precipitating aluminum hydroxide. This hydroxide is then calcined into alumina (aluminum oxide).

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    Gamma Alumina (γ-Al2O3)

    A type of aluminum oxide that is chemically active and is produced during the calcination of aluminum hydroxide in the Bayer process.

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    Alpha Alumina (α-Al2O3)

    A type of aluminum oxide that is relatively inert and is produced by further heating of gamma alumina to higher temperatures.

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    Hall-Héroult Process

    The process of producing aluminum by electrolysis of alumina dissolved in molten cryolite. This process involves passing an electric current through the molten electrolyte, causing aluminum ions to be reduced at the cathode, resulting in molten aluminum.

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    Cryolite

    A molten salt mixture primarily composed of sodium aluminum fluoride (Na3AlF6), used as the electrolyte in the Hall-Héroult process. It acts as a solvent for alumina and allows for its electrolysis.

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    Sodium Aluminum Fluoride (Na3AlF6)

    The main component of the electrolyte in the Hall-Héroult process, which is a molten salt mixture composed of sodium aluminum fluoride (Na3AlF6).

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    Electrolytic Reduction Cell (Pot)

    An electrolytic cell used in the Hall-Héroult process to produce aluminum. It consists of carbon anodes, a molten electrolyte, a pool of liquid aluminum, a carbon-lined container, and a gas collection system.

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    Carbon Anodes

    Carbon materials used in the Hall-Héroult process as anodes, which are consumed during the electrolysis process due to oxidation reactions. They need to be replaced regularly.

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    Study Notes

    Alumina Production

    • Alumina production, typically 99.3-99.7% Al₂O₃, is created using the Bayer process.
    • The Bayer process removes alumina from bauxite, with crystallization occurring between 400°C and 600°C.
    • Further heating to up to 1200°C converts the alumina to α-alumina (relatively inert).
    • World alumina production increased from 64.6 million tonnes to 115.2 million tonnes between 2005 and 2015, with China's output increasing to 51% of the total.
    • The average world price of alumina was approximately US$250 per tonne in 2015.

    Aluminium Production (Hall-Héroult Process)

    • Alumina (high melting point, poor electrical conductor) is dissolved in molten cryolite (Na₃AlF₆) in the Hall-Héroult process.
    • Electrolyte typically contains 80-90% cryolite, 2-8% alumina, and additives like AlF₃ and CaF₂.
    • Cryolite, initially obtained from Greenland, is now made synthetically.
    • Electrolytic-reduction cells (pots) use baked carbon anodes (which need replacing regularly), molten cryolite-alumina electrolyte, molten aluminium, and a carbon-lined container.
    • These cells operate at around 950°C, 500 kA, and ~0.7 A cm⁻² anode current density.
    • The anode and cathode are separated by 4-5 cm, with a voltage drop of 4-4.5 V per cell.
    • Modern cells operate with around 95% current efficiency and around 4,000 kg of aluminium daily.
    • Potlines comprise 150-300 cells connected in series.
    • Cells have frozen cryolite protection for carbon linings and an alumina crust on the electrolyte surface.
    • Aluminium is siphoned out and cast into ingots while alumina is replenished.
    • The electrolytic reaction mechanisms involve Na⁺, AlF₄⁻, AlF₆³⁻, and ternary complex ions like AlOF₃²⁻.
    • At the cathode, fluoroaluminate anions produce aluminium metal and fluoride ions.
    • At the anode, oxofluroaluminate ions release oxygen, forming CO₂.
    • The overall reaction simplifies to: 2 Al₂O₃ + 3 C → 4 Al + 3 CO₂

    Magnesium Production (not detailed in this section)

    • A separate section discusses magnesium production in more detail.
    • Energy consumption is mentioned, but this information isn't detailed in this part.

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    Description

    Explore the processes of alumina and aluminium production, focusing on the Bayer and Hall-Héroult methods. Learn about the chemical properties, production statistics, and the role of electrolytic processes in aluminium manufacturing. This quiz will test your knowledge on both production methods and their significance in the global market.

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