Solar Carboreduction of Alumina under Vacuum

Main requirements for successful production of aluminum via carboreduction of alumina using solar vacuum reactors are sufficiently high reaction temperature, suitable low partial pressure of the product gases, fast heating and quenching at temperature low enough to prevent backward reaction. Based on these requests a batch solar reactor was modeled, designed, built and tested. Experimental results of the solar tests under different vacuum levels and temperature conditions will be presented. It will be shown that for reaction temperature, which is above the minimal temperature required for full conversion as predicted by thermodynamic calculations for appropriate pressure, the alumina to aluminum conversion is above 90%. Not reaching the full conversion can be explained by the byproducts formation during the initial preheating. At lower reaction temperatures and higher CO partial pressure by products can also be formed when reaching steady state condition both in the forward and backward reactions. This formation in the forward reaction is confirmed by the discovery of larger amounts of Al4C3, Al4CO4 solids as the residual byproducts in the reactants holder and higher alumina content in the deposits on the cold parts of the reactor that originated from the volatile Al2O produced in the forward reaction which during the deposition converts to alumina and aluminum. Decreasing the reaction temperature is accompanied by decreasing the temperature in the hot zone that causes the increasing of the deposit mass there with higher amount of Al4C3 and Al4CO4 produced in the backward reaction. Nano crystalline and amorphous morphology of the deposits in the cold zone caused by fast cooling will also be discussed