1. Overview
Aluminum ash is a byproduct generated during the aluminum smelting process, typically accounting for about 3% of the total production. For large-scale aluminum plants, the annual volume of aluminum ash is substantial, leading to significant accumulation within plant areas. This waste not only represents a loss of valuable resources but also poses serious environmental risks. The primary components of aluminum ash include industrial residues formed during the casting and smelting of aluminum alloys. These materials consist mainly of aluminum oxide scale, magnesium oxide scale, and small quantities of aluminum and silicon. Among these, metallic aluminum makes up approximately 20–30%, while alumina constitutes over 70%. Currently, various methods are used to treat this type of industrial waste, but most of them come with environmental drawbacks. One common approach involves placing the waste into a large container, heating it, and repeatedly stirring to melt and separate solid aluminum. However, this method is inefficient, only recovering metallic aluminum, and generates harmful industrial gases and residue in the process. Additionally, improper treatment of aluminum ash can negatively impact the electrolytic aluminum production process if recycled without proper handling. To address these challenges, this paper explores a new manufacturing technology that directly integrates aluminum ash into the electrolytic production cycle for comprehensive utilization. This innovative approach uses a novel slag-forming agent, offering advantages such as a simplified production process, reduced environmental impact, and cost-effectiveness.2. Technical Process Plan
The technical process flow is illustrated in the accompanying diagram. The specific implementation plan includes several key steps, from the preparation of raw materials to the final integration of the treated ash into the electrolysis system. Each stage is designed to maximize resource recovery while minimizing pollution. The process ensures efficient separation of valuable metals and the formation of a suitable slag that can be safely reintroduced into the production line.
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