ALUMINIUM

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Aluminium
 Aluminum is a chemical compound whose name is taken from the Latin
language, alum or alumen, which means ‘bitter salt’.
 Aluminium is the most abundant metal in the earth’s crust.
 The electric and heat conductors are very good, even better than copper.
 Forms a very thin layer of aluminum oxide when reacting with air which will
protect it from rust.
 Aluminium is a preferred metal of choice because it is corrosion resistant and
offers a very low density. Around the world people rely on it in multiple
industries including aerospace, manufacturing, and transportation -
capitalscrapmetal.com
Properties of Aluminium
 •
Bauxite is a rock
composed of aluminum
oxide and aluminum
hydroxide. The chemical
formula of bauxite is
Gibbsite (Al(OH)3),
Boehmite (γ - AlO(OH)),
Diaspore (α - AlO(OH)),
with impurities in the
form of Hematite (Fe2O3),
Goethite (FeO (OH)) and
Kaolinite (Al2Si2O5(OH)4)
Ore Aluminium and a little bit Ilmenite
(FeTiO3).
Bauxite Composition
• Different types of bauxite are distinguished by the
mineralogical form in which alumina is bound.
They are then called gibbsitic, boehmitic or bauxite
diaspora.
• Gibbsitic bauxite dominates. Geologically Gibbsitic
bauxite is the youngest and is located in the tropics
or subtropics, very close to the surface of the land.
The oldest deposits in Europe (France, Greece)
and in Asia mainly contain boehmite and diaspore.
Most are underground deposits.
Bauxite Distribution in Indonesia
 Ore Minerals of Aluminium
Bauxite Al2O3.3H2O
Diaspore Al2O3.H2O
Corundum Al2O3
Kaolinite Al2O3.2SiO2.2H2O
Cyanite Al2O3. SiO2
Leucite K2O. Al2O3.4SiO2
Alunite K2O. 3Al2O3.4SO3.6H20
 Aluminium
Producing Country in
the World

The world's largest

producer of bauxite from
2010 to 2017, with mine
production volumes (in
1,000 metric tons) *
Aluminium Price
Applications of Aluminium
Extraction of Aluminium
Generally, to obtain pure aluminium from bauxite is carried out in two
stages:

1. Bayer Process : bauxite is purified to obtain Aluminium Oxide.

2. Hall-Heroult Process: melting aluminum dioxide to get pure aluminium
metal.

Hall-Heroult
Bayer Process Process
Bauxite Alumina Aluminium
Bayer Process
Processing Bauxite

Bayer process is a refining process of alumina from bauxite (aluminum ore

containing 30-50% hydrated aluminum oxide) with selective extraction of pure
aluminum oxide mixed in sodium hydroxide.
Refined aluminum oxide (Al2O3) obtained from bauxite slurry by Bayer
Process which consists of four stages:
1. Digestion
2. Clarification
3. Precipitation
4. Calcination
1. Milling
Milling process is carried out to reduce the size of bauxite ore so that the high ore surface area is
obtained so that the digestion process runs faster.

2. Digestion / Leaching
The digestion process is carried out in an autoclave with operating conditions T = 140 – 250 oC and a
pressure of 3.5 MPa. This process is conditioned in an alkaline environment by adding NaOH about 50
- 55% by weight of NaOH. The reactions that occur are:
- Gibbsite : Al(OH)3 + NaOH  NaAl(OH)4 (135-150⁰C)
- Boehmite dan Diaspore: AlO(OH) + NaOH + H2O  NaAl(OH)4 (205-250⁰C)
In this process compounds that do not contain Al do not dissolve
3. Filtering
Because the impurity compounds do not dissolve, then the next process is to do filtering to
obtain impurities in the form of solid (mixture of Fe2O3, TiO2, SiO2 and CaO (called red
mud) and the filter passes in the form of NaAl(OH)4 solution. Thus we can separate the
impurities from Al compounds.

4. Classification
Crystals of Al(OH)3 vary in size. For this reason, it needs to be classified in size to facilitate
the next process. The process of classification of Al(OH)3 crystals is carried out using
cyclone.
5. Evaporation
By doing evaporation, NaOH will disappear and leave crystals of Al (OH)3.

6. Precipitation
After obtaining NaAl(OH)4 solution, the next process is to make precipitates
so that Na can be separated. This process can be done by recrystallizing
NaAl (OH)4 with the addition of Al (OH)3 periodically.
NaAl(OH)4(aq)  Al(OH)3(s) + NaOH(aq)

7. Calcination
Al(OH)3 was then calcined at T = 1100 – 1200 oC in the rotary kiln. So that Al2O3(s) is
formed, which contains around 95%.
Al(OH)3  Al2O3 + H2O
RESIDU (Red Mud)

In addition to producing alumina, at the end of the process Bayer also produces bauxite residue,
also known as red mud. The resulting red mud is still contained in aluminum in the form of Al2O3.
But the main component of the red mud is Fe2O3 with a range of 20-45%. Because of the large
iron content, it causes the red mud color to turn red. Red mud results from washing (tailings) in
the form of mud mixed with sand called bauxite washing waste
 The residue is then processed through roasting or sintering with soda-lime mixture (sintered lime-soda
 at a temperature of 800-1100OC.
 Sintered dissolved in dilute sodium carbonate solution produces a solution of sodium aluminate
(2NaAlO2) and dissolution residue.
 The solution was precipitated to produce deposits of aluminum hydrate (Al (OH) 3) which can be used
as raw material for synthetic zeolite.
 The dissolving residue is concentrated with iron minerals with 1000 separator magnetic separator,
 producing iron concentrate as a by-product.
 The results show that around 75-85% of alumina can be extracted or recovered from bauxite residue
with a grade of 98.7% Al2O3, and also produced iron concentrations of 66% Fe2O3 (46% Fe) with 40%
as a by-product.
Proses Hall-Heroult

The raw material for the Hall-Heroult

Process is Alumina

Alumina is obtained from bauxite ore

using the Bayer Process
 In general in this process, molten alumina is electrolyzed, wherein the melt is mixed
with molten cryolite electrolyte in the pot wherein the pot is tied to a series of carbon rods
at the top of the pot as the cathode. The anode carbon is at the bottom of the pot as a pot
layer, with a strong current of 4 - 5 V between the anode and the cathode the electrolysis
process occurs. Alumina experiences breaking of bonds due to electrolysis, aluminium melt
will go down the pot, which will periodically be accommodated towards cylindrical or slab-
shaped molds. Each pot can produce 66,000 - 110,000 tons of aluminum per year.
In general, 4 tons of bauxite will produce 2 tons of alumina, which will later
produce 1 ton of aluminium.
Chemical reaction in Hall-Heroult Process (generally):

2Al2O3(dissolved) + 3C(S) = 4Al(l) + 3CO2(g)

Melted alumina to become aluminum metal occurs in steel vat called a reduction pot.
The bottom of the pot is coated / bounded with carbon which acts as one of the
electrodes (conductors of electric current) of the system. His opponent's electrode
consists of a series of carbon rods hanging above the pot. These reduction pots are
arranged in such a way, in a row consisting of 50-200 pots that are connected to each
other to form electrical circuits.
The melting process is continued, with the addition of alumina in cryolite solution to
replace the decomposed compound. Constant electric current is flowing. Heat from
electricity keeps the contents of the pot in a liquid state. Pure aluminum melt collected
under the pot.
No Item Note

1 Cathode carbon (graphite, metallurgical coke, calcined antrachite)

2 Anode Prebaked anode : Baked Pet Coke

Soderberg Anode: Mixed Pet Coke – Coal tar (30% higher in resistivity)
3 Electrolyte Solution of Al2O3 inside cryolite.
Cryolite : 75%
CaF : 4 – 8%
AlF3 : 5 – 15%
Al2O3 : 1 – 6%
LiF : 0 – 5%
MgF2 : 0 – 5%
4 Current density 0,6 – 1,3 A/cm2

5 Temperature 980 – 10100C

operation
6 Efficiency of current 1 kA.h / 0,3356 kg Al
Usually only produce between 85% - 96% from value above.
Figure of reaction that happen in the cathode-
anode
Alumina is described in the Cryolite Temperature used 950-1000 oC.
In the cathode, alumina reduced becomes aluminium melt.
2 Al2O3 → 4 Al + 3 O2
In the anode, produce a CO2 gasses.
6 O + 3 C → 3 CO2
Final reaction that produced from cathode-anode.
2 Al2O3 + 3 C → 4 Al + 3 CO2
Pure aluminium will sedimenting in the bottom surface of cathode (bottom surface of
cryolite).
Pure aluminium be taken out from furnace through a gap that located in the bottom
furnace.
Electric current that used is 315.000 A.
Its process needs electric voltage 3-5 Volt.
Hall-Heroult Process and Aplication

• DURALUMIN

Bicycle’s Frame and Accesories

 Aluminum (AL) > 90 %

 Copper (Cu) = 4%
 Magnesium (Mn) = 0.5 – 1 %
 Manganese (Mg) <1%
1 KGOFALUMINIUM