Introduction
Uploaded by
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Uploaded by
fhrsaaazaManaging Wastes from Aluminum
Smelter Plants
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Managing Wastes from
Aluminum Smelter Plants
B. Mazumder
and
B. K. Mishra
WOODHEAD PUBLISHING INDIA PVT LTD
New Delhi ● Cambridge ● Oxford
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Published by Woodhead Publishing India Pvt. Ltd.
Woodhead Publishing India Pvt. Ltd., G-2, Vardaan House, 7/28, Ansari Road
Daryaganj, New Delhi – 110002, India
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Woodhead Publishing Limited, Abington Hall, Granta Park, Great Abington
Cambridge CB21 6AH, UK
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First published 2011, Woodhead Publishing India Pvt. Ltd.
© Woodhead Publishing India Pvt. Ltd., 2011
This book contains information obtained from authentic and highly regarded
sources. Reprinted material is quoted with permission. Reasonable efforts have
been made to publish reliable data and information, but the authors and thepub
lishers cannot assume responsibility for the validity of all materials. Neither the
authors nor the publishers, nor anyone else associated with this publication, shall
be liable for any loss, damage or liability directly or indirectly caused oralleged
to be caused by this book.
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Woodhead Publishing India Pvt. Ltd. ISBN 13: 978-93-80308-13-5
Woodhead Publishing India Pvt. Ltd. EAN: 9789380308135
Woodhead Publishing Ltd. ISBN 13: 978-0-85709-010-2
Typeset by SD Infosystems, New Delhi
Printed and bound by Replika Press, New Delhi
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Contents
Preface vii
1 Introduction 1
1.1 Introduction 1
1.2 Extraction of aluminum metal (Hall-Heroult process) 2
1.2.1 Other aluminum extraction processes 6
1.2.2 ALCOA aluminum-chloride process 6
1.2.3 Carbothermic reduction of aluminous ores 6
1.2.4 The aluminum-carbide process 7
1.2.5 Reduced temperature aluminum production process 7
1.3 Wire-rod drawing plant 9
2 Wastes generated by aluminum smelter plants 11
2.1 Introduction 11
2.2 Spent pot liners 11
2.3 Anode butts 16
2.4 Red mud 18
2.5 Coal rejects/carbon dusts and coal ash 29
3 Treatment of the wastes and quality
of byproducts 32
3.1 Treatment of spent pot liner 32
3.2 Treatment of red-mud 48
3.3 Treatment of waste emulsion generated by wire-rod mills 55
4 Utilization of wastes (byproducts) 57
4.1 Byproducts from treatment of spent pot liner and anode-butts 57
4.1.1 Colloidal graphite and dry lubricants 57
4.1.2 Production of pyrogenic silica at relatively lower temperature 58
4.1.3 Preparation of pencil lead 59
4.1.4 Making dry cell electrodes 60
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vi Contents
4.1.5 Production of carbon refractories 62
4.1.6 Preparation of silicon-carbide from spent pot liner 62
4.1.7 Preparation of blast furnace tap hole and runner/trough mass 67
4.1.8 Preparation of aluminum plant anodes 74
4.1.9 Absorber for heavy metals, dyes and oils 76
4.1.10 Preparation of mould coating for batch casting of iron and steel 81
4.1.11 Recovery of fluorine as aluminum fluoride 81
4.2 Utilization of red-mud 82
4.2.1 Removal of ferric oxide 84
4.2.2 Forming electroceramic bodies 85
4.2.3 Making glazes 89
4.2.4 Utilization of iron filtrate solution 91
4.2.5 Extraction of titanium 92
4.3 Utilization of coal rejects/carbon dust/coal ashes 95
4.3.1 Utilization of coal rejects and coal dusts 95
4.3.2 Utilization of coal ash 98
5 Techno-economic feasibility of some selected
processes 100
References 103
Index 129
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Preface
Demand for aluminum metal in domestic as well as in industrial sector has
gone up leaps and bounds in last four decades, so is the generation of wastes
by these aluminum plants. Aluminum plants generate a number of wastes
amongst which red mud and spent pot liners are more prominent in terms of
volume of production and their toxicity. Even amongst these last two wastes,
spent pot liner is much more toxic than red mud. For these reasons there have
been a frantic effort by scientist and engineers in last few decades to develop
a process for safe disposal of these toxic wastes. This book depicts all the
work done in this area in last three decades and after analyzing these results
suggest a method for value addition to these toxic wastes in order to make
their decontamination process economically viable.
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