Extraction and characterization of alumina nanopowders from aluminum dross by acid dissolution process

A significant amount of aluminum dross is available as a waste in foundry industries in Bangladesh. In this study, alumina was ex- tracted from aluminum dross collected from two foundry industries situated in Dhamrai and Manikgang, near the capital city, Dhaka. Alu- minum dross samples were found to approximately contain 75wt% A1203 and 12wt% SIO2. An acid dissolution process was used to recover the alumina value from the dross. The effects of various parameters, e.g., temperature, acid concentration, and leaching time, on the extrac- tion of alumina were studied to optimize the dissolution process. First, AI（OH）3 was produced in the form of a gel. Calcination of the AI（OH）3 gel at 1000℃, 1200℃, and 1400℃ for 2 h produced O-AlcOa, （t~＋O）-A1203, and u-alumina powder, respectively. Thermal charac- terization of the AI（OH）3 gel was performed by thermogravimetric/differential thermal analysis （TG/DTA） and differential scanning calo- rimetry （DSC）. The phases and crystallite size of the alumina were determined by X-ray diffraction analysis. The dimensions of the alumina were found to be on the nano level. The chemical compositions of the aluminum dross and alumina were determined by X-ray fluorescence （XRF） spectroscopy. The microstructure and morphology of the alumina were studied with scanning electron microscopy. The purity of the alumina extracted in this study was found to be 99.0%. Thus, it is expected that the obtained alumina powders can be potentially utilized as biomaterials.

Feasibility of aluminum recovery and MgAl_2O_4 spinel synthesis from secondary aluminum dross

The feasibility of aluminum recovery from secondary aluminum dross by extraction with NaOH solution and the subsequent synthesis of MgAl_2O_4 spinel by sintering the extracted slag were studied. The extraction percentage of soluble aluminum from the dross reached 80% at a temperature of 353 K, liquid-to-solid ratio of 12 mL·g^(-1), stirring speed of 300 r·min^(-1), and an extraction time of 15 min; the hydrolysis percentage of AlN reached 40% with an extraction time of 30 min. The activation energies of the soluble aluminum and AlN extracted from the dross were 7.15 and 8.98 kJ·mol^(-1), respectively, indicating that their kinetics were controlled by outer diffusion without a product layer. The extracted slag was sintered in the temperature range 1373–1773 K; MgAl_2O_4 spinel with a compressive strength as high as 69.4 MPa was produced in the sample sintered at 1673 K for 3 h. This value exceeds the threshold(40 MPa) prescribed by the National Standard for the Magnesia and Magnesia-alumina Refractory Bricks of China(GB/T 2275-2007). These results establish the effectiveness of aluminum recovery from secondary aluminum dross and subsequent MgAl_2O_4 spinel synthesis.

Effects of AlN hydrolysis on fractal geometry characteristics of residue from secondary aluminium dross using response surface methodology

The effects of aluminium nitride(AlN)hydrolysis on fractal geometry characteristics of residue from secondary aluminium dross were studied using response surface methodology.The results show that the fractal dimensions of the residue can be significantly influenced by the AlN hydrolysis from secondary aluminium dross.The hydrolysis of AlN in the dross was spontaneous under temperatures of303-373K.The actual fractal dimensions of residue were significantly affected by the liquid-solid ratio(p<0.05)and changed from1.16to1.80,which accurately aligned with those from the calculations.Moreover,the fractal dimensions of residue were significantly affected by the interactions between hydrolysis temperature and hydrolysis time,liquid-solid ratio and hydrolysis time,respectively(p<0.01).The minimum fractal dimensions of the residue reached1.15under the optimized conditions,which included a hydrolysis temperature of30℃,liquid-solid ratio of5mL/g and hydrolysis time of10min.The results suggest that response surface methodology can guide in optimizing the conditions of AlN hydrolysis in order to obtain the minimum fractal dimensions of residue for improving the reutilization of the dross.

Process of aluminum dross recycling and life cycle assessment for Al-Si alloys and brown fused alumina

In 2008,around 596 000 t of aluminum dross was generated from secondary aluminum industry in China;however,it was not sufficiently recycled yet.Approximately 95% of the Al dross was land filled without innocent treatment.The purpose of this work is to investigate Al dross recycling by environmentally efficient and friendly methods.Two methods of Al dross recycling which could utilize Al dross efficiently were presented.High-quality aluminum-silicon alloys and brown fused alumina(BFA) were produced successfully by recycling Al dross.Then,life cycle assessment(LCA) was performed to evaluate environmental impact of two methods of Al dross recycling process.The results show that the two methods are reasonable and the average recovery rate of Al dross is up to 98%.As the LCA results indicate,they have some advantages such as less natural resource consumption and pollutant emissions,which efficiently relieves the burden on the environment in electrolytic aluminum and secondary aluminum industry.

Multi-stage Electrostatic Separation for Recovering of Aluminum from Fine Granules of Black Dross

Separation of aluminum from fine granules of black dross, which is a waste by-product in secondary aluminum production, was investigated. The separation was performed by a multi-stage electrostatic separation method. There are three stages to complete the separation, including preliminary separation, pulse charging enhancement and secondary concentration. Chemical and mineralogical compositions of collection products were analyzed and determined by X-ray diffraction(XRD) and X-ray Fluorescence(XRF). After multistage electrostatic separation, the Al2O3 content of the collection products increases from 50.74% to 69.77%.The mineralogical phase analysis indicates that the final recovery of metallic aluminum phase increases from 8%to 37%, and the aluminum oxide phase increases from 20% to 26%. The research results show the multi-stage electrostatic separation method is effective for recovering of aluminum from fine granules of black dross, and upgrades the black dross to a recoverable material.

Removal of AlN from secondary aluminum dross by pyrometallurgical treatment

A new process of AlN removal from secondary aluminum dross(SAD)by pyrometallurgical treatment with added cryolite was applied for solving the problem of recycling the secondary aluminum dross.The response surface methodology(RSM)was used to design experiments and optimize parameters.The results show that adding the appropriate amount of cryolite can effectively promote the oxidation of AlN in the SAD,and too much cryolite will reduce the promotion effect.The effects of roasting temperature and cryolite on the denitrification rate are the most significant(p<0.0001)followed by holding time.Predicted values of the denitrification rate are found to be in good agreement with experimental values(R^(2)=0.9894 and R_(adj)^(2)=0.9775),which confirms the validity of the model employed.The optimum conditions of roasting temperature of 750°C,holding time of 194 min,mass fraction of cryolite of 17.7%are obtained according to the quadratic model.Under these conditions,the maximum actual denitrification rate reaches 94.71%and the AlN content in the SAD is only 0.55 wt%.The unfired brick with compressive strength of 18.62 MPa(GB/T 2542−2012)was prepared based on the roasted SAD.

Recycling of Secondary Aluminum Dross to Fabricate Porous <i>γ</i>-Al₂O₃Assisted by Corn Straw as Biotemplate

In the aluminum industry, secondary aluminum dross (SAD) is an inevitable solid residue, which usually contains 30 - 70 wt% Al2O3. In this work, Al(OH)3 was extracted from SAD through acid-leaching and alkali purification process. The as-obtained Al(OH)3 precipitation then was calcinated to synthesize porous γ-Al2O3 assisting by an agricultural waste biomass-corn straw as biotemplate. Effects of H2SO4 concentration, reaction temperature and time on the recovery of SAD were investigated. Furthermore, the dependence of calcination temperature on specific surface area, pore volume and content of porous γ-Al2O3 was analyzed. X-ray diffraction (XRD) and X-ray fluorescence (XRF) were used to inspect the phase compositions and their contents, respectively. Scanning electron microscopy (SEM) was employed to analyze the morphologies of the sintered porous γ-Al2O3. It was found that the highest recycle rate of aluminum from SAD was obtained under optimum conditions of 80&#176;C, acid concentration of 1.6 mol/l, and reaction time of 5 h by acid process. The porous γ-Al2O3 with specific surface area, 261.22 m2/g and average pore diameter, 52.64 nm, was obtained under calcination at 850&#176;C through mixing the as-obtained Al(OH)3 precipitation and corn straw.

Selective recovery of Sn from copper alloy dross and its heat-treatment for synthesis of SnO_2

Preliminary study on concentration and separation of tin(Sn) from copper alloy dross by selective dissolution method was conducted. The tin in the copper alloy dross did not dissolve in an aqueous nitric acid solution which could allow separation of tin from the copper alloy dross. The tin as H2SnO3(metastannic acid) phase was precipitated in the solution with centrifuging process and transformed to tin dioxide(SnO2) after drying process. The dried sample was heat-treated at low temperature and its phase characteristics, surface morphology and chemical composition were investigated.

Bottom dross defect and its transformation behavior during the galvannealing process

Bottom dross obtained from zinc bath and the typical bottom dross defects on galvanized and galvannealed coating were metallographically investigated.Galvannealing simulations with different holding time were conducted,and the bottom dross transformation behavior during the galvannealing process was revealed.The fast diffusion between bottom dross particles and the surrounding zinc occurs during the galvannealing process,resulting in the formation of an Al-containing Zn-Fe intermetallic outburst structure at the defect position.The thicker and harder coating will cause a shiny spot on the coating surface and a deep dent on the substrate after being temper rolled.

Zinc dross distribution and effects on the surface quality of steel sheet

Through sampling from different depth and different zones in the zinc bath, the size distribution of dross particles built during galvannealed （GA） production is analyzed and compared with that during galvanized （GI） production. The relationship between the dross formation during transitions from GA to GI and the effective Al of the melt is discussed. Finally, the characteristics of dross particles in GA coating and its effects on GA punching and painting performances are studied.

Phase Composition Analysis of TiN-AI_2O_3Synthesized from Aluminum-containing Dross and Rutile by Aluminothermic Reductionnitridation Method

TiN- Al2O3 composite powder was prepared by aluminothermic reduction- nitridation method with starting materials of aluminum-containing dross and rutile,and metallic aluminum in the aluminum-containing dross as reducer. The influences of synthesis temperature（600-1 400 ℃） and aluminum-containing dross addition（20% lower than theoretical value,theoretical value,20% higher than theoretical value,and 50% higher than theoretical value） on phase compositions and microstructure of the composites were investigated,and the reaction mechanism was analyzed. The results show that（1） TiN- Al2O3 composite powder can be synthesized under the experimental conditions; the main phases are TiN,α-Al2O3,a little bytownite,and MgAl2O4;（2）enhancing synthesis temperature or increasing aluminumcontaining dross addition favors the reaction of aluminothermic reduction- nitridation;（3） in the synthesized products,α-Al2O3 is platy or columnar; TiN is sub-micron granular,which reinforces and toughens the composite.

Dechlorination of zinc dross by microwave roasting

Traditional treatments of zinc dross have many disadvantages,such as complicated recovering process and serious environmental pollution.In this work,a new process of chlorine removal from zinc dross by microwave was proposed for solving problem of recycling the zinc dross.With better ability of absorbing the microwave than zinc oxide,the main material in zinc dross,chlorides,can be heated and evaporated rapidly during microwave roasting.Various parameters including roasting temperature,duration time and stirring speed were optimized.The microstructure of roasted materials was characterized by X-ray diffraction(XRD) and scanning electron microscope(SEM).The content of the chloride was analyzed by the method of chlorine ion selective electrode.The experiments indicate that the best duration time is 60 min with a stirring speed of 15 r/min during the microwave roasting process.The dechlorination rate reaches peak value of 88% at 700 ℃.The chlorine is removed as HCl gas when water vapor is used as activating agent,which means that it can be recovered into hydrochloride acid.

Research of Microstructure,Phase,and Mechanical Properties of Aluminum-Dross-Based Porous Ceramics

In this study,the effect of sintering temperature and the addition of kaolin,a sintering agent,on the microscopic,phase,and mechanical properties of ceramics were investigated using secondary aluminum dross(SAD)as the main component in the manufacturing of ceramics.The basic phases of the ceramics were Al_(2)O_(3),MgAl_(2)O_(4),NaAl_(11)O_(17),and SiO_(2)without the addition of kaolin.The diffraction peaks of MgAl_(2)O_(4),NaAl_(11)O_(17),and SiO_(2)kept decreasing while those of Al_(2)O_(3)kept increasing with an increase in temperature.In addition,the increase in temperature promoted the growth of the grains.The grains were uniform in size and regular in distribution,with a shrinkage of 2.2%,porosity of 72.5%,bulk density of 1.076 g/cm^(3),and compressive strength of 1.12 MPa.When the sintering temperature was 1450°C,the basic phases of the ceramic after the addition of kaolin were Al_(2)O_(3),MgAl_(2)O_(4),NaAl_(11)O_(17),and SiO_(2).With the increase of kaolin,the diffraction peaks of NaAl_(11)O_(17)and SiO_(2)decreased until they disappeared,while the diffraction peaks of Al_(2)O_(3)increased significantly.When kaolin was added at 30 wt.%,the ceramics obtained had shrinkage of 18%,a porosity of 47.26%,a bulk density of 1.965 g/cm^(3),and compressive strength of 31.9 MPa.Cracks existed inside the ceramics without the addition of kaolin,while the addition of kaolin significantly changed this defect.It is shown that SAD can obtain porous ceramics with good properties at a sintering temperature of 1450°C and a kaolin addition of 30 wt.%.

Intensifying recovery of metallic aluminum in secondary aluminum dross by alkali roasting−water leaching

An innovative process was proposed to recover metallic aluminum from secondary aluminum dross(SAD)by alkali roasting−water leaching.Thermodynamic calculations and experimental results were used to illustrate the phase transformation and reaction mechanism of the alkali roasting process.The leaching behaviors of roasted residue were also analyzed.Under optimal conditions,the aluminum extraction rate reached 93.08%.In addition,the kinetics of the water leaching of roasted products was studied through shrinking core model,and it was revealed that the leaching process of aluminum was in accord with diffusion control.The apparent activation energy of the leaching process was calculated to be 3.44 kJ/mol.Based on the above study,the underlying mechanism of the alkali roasting−water leaching was clarified.

铝灰资源化制备混凝剂研究进展

二次资源的有效利用和环境污染的防治逐渐成为关注焦点。作为一种潜在的二次资源,铝灰具有丰富的储量和利用潜力,其资源化利用备受关注。制备水处理混凝剂,不仅有利于节约资源、降低成本,还能有效解决铝灰无害处理的难题。总结利用铝灰制备铝系混凝剂的重要原料(铝酸钙)以及5种铝灰基混凝剂(硫酸铝、聚硫酸铝、聚硫氯化铝、聚硫酸铝铁和聚氯化铝)的特点、制备方法和研究进展,分析了铝灰基混凝剂生产的经济效益。发现铝灰基混凝剂的规模化应用仍面临一些挑战,需从提高产品核心竞争力和填补相关政策的空白入手,以实现水处理行业和铝工业的高质量、绿色和可持续发展,并带来显著的经济和环境效益。

Dissolution characteristics of black aluminum dross in Na_(3)AIF_(6)-AIF_(3)-Al_(2)O_(3)molten salt system

The dissolution performance of black aluminum dross(BAD)in cryolite electrolyte is key to its recovery by molten salt electrolysis.The stable operation of the electrolyzer depends mainly on the rapid dissolution of BAD in Na_(3)AlF_(6)-AlF_(3)-Al_(2)O_(3)electrolyte system.In this paper,the dissolution performance and behavior of BAD and its main components in the cryolite system were studied,and the saturation solubility of aluminum nitride in this system was determined.The dissolution performance of BAD in cryolite electrolyte before and after denitration was compared,and the effects of temperature,cryolite ratio,and the doping ratio of BAD and alumina on the dissolution rate were investigated.The obtained results showed that aluminum nitride was the main factor affecting the dissolution performance of BAD in the electrolyte.Aluminum nitride was partly converted toα-Al_(2)O_(3)after addition to the electrolyte,and the convertedα-Al_(2)O_(3)was partially dissolved in the cryolite electrolyte,while the remaining precipitated and accumulated at the bottom with aluminum nitride.Aluminum nitride was almost insoluble in the cryolite electrolyte,with 0.0022%solubility.A higher proportion ofα-Al_(2)O_(3)in BAD was negatively influenced its solubility in the cryolite electrolyte.The dissolution rate of BAD in cryolite electrolytes was effectively improved by mixing BAD withγ-Al_(2)O_(3).

Study on the cluster of floating dross before nucleating during hot-dipping process

During hot-dipping in molten Zn-55Al, the forming of “floating” dross is closely re- lated with the interaction between the Al and the Fe atoms. Utilizing the thita-thita X-ray diffraction and the Percus-Yevick hard sphere model, this paper investigates the structure of molten Al3Fe that is an approximant of partial melt in practical Zn-55Al alloy melt. It is found that in the melt there exist clusters that resemble the structure of intermetallic compound Al3Fe. The strong in- teraction between Al and Fe atoms is also indicated by the deficiency of the coordination number from 12 and the shrinkage of averaged atomic diameter. Based on such information, it is specu- lated that in the molten Zn-55Al, with the accumulation of Fe, Al3Fe-like clusters form with priority, then grow into dross. On the other hand, after deflating of the effective hard sphere diameter of pure Al atom and enlarging that of the pure Fe atom, the modified model can achieve reasonable fit to the experimental structure factor. Hard sphere modeling also gave a good estimation of the mass density 3.65 g/cm3 of liquid Al3Fe alloy at 1550℃. Compared with the density of 3.7 g/cm3 of Zn-55Al, the reason for dross floating is satisfactorily understood.

Fundamental research on recovering metals from hot-dip Zn-Al-Mg dross by supergravity separation

The dross generated in the hot-dip Zn–Al–Mg coating process is a valuable co-product,since it contains high quantities of recyclable alloy.A new method to recover Zn–Al–Mg alloy from the industrial Zn–Al–Mg dross was proposed using supergravity separation.The separation efficiency was analyzed as a function of gravity coefficient(G),separation time,and separation temperature.The separation of Zn–Al–Mg alloy from the dross can be achieved at G>100.The alloy content in the dross decreased gradually with an increase in the gravity coefficient,the separation time,and the separation temperature.The alloy ratio in the enriched dross decreased almost linearly as the gravity coefficient increased,and the recovery of Zn–Al–Mg alloy from the dross exceeded 78%;these results were consistent with the results of the FactSage software calculation.The purified alloy can be in-situ used in the hot-dip Zn–Al–Mg bath for production.The feasibility of supergravity separation as a promising process for efficiently recovering Zn–Al–Mg alloy from Zn–Al–Mg dross was thus demonstrated.

二次铝灰产品化方案及评价

综述了近年来以二次铝灰为原料制备氧化铝、净水剂、耐火材料、冰晶石、分子筛和陶瓷材料的现状,同时分析其产品及技术特点,对二次铝灰产品化利用给出评价和建议。

二次铝灰无害化处理和资源化利用研究进展

二次铝灰是铝熔渣经提取金属铝后得到的固体废弃物,含有氮化铝以及盐类精炼剂,二次铝灰具有污染和资源的双重属性,长期堆存会对环境构成威胁,而夹杂其中的铝化合物可用于二次回收利用,缓解环境危机。目前,二次铝灰的回收利用方法主要包括湿法冶金和火法冶金,湿法冶金主要是将二次铝灰进行溶解,提取里面的铝元素制备氧化铝、聚合氯化铝等;火法冶金主要是在高温条件下煅烧,制备微晶玻璃、耐火材料等。本文总结了二次铝灰的危害,概述了二次铝灰的无害化处理和资源化利用的现状,以期提高二次铝灰的资源化利用效率,降低二次铝灰对环境的污染。