Investigations into innovative and sustainable processes for the carbothermic production of gaseous aluminum

Considerable efforts have been applied to produce aluminum by alternative ways. Two novel processes for the carbothermic reduction of alumina towards gaseous aluminum production in Electric Arc Furnace (EAF) and solar furnace have been investigated both theoretically and experimentally. The EAF process was tested at ambient pressures and temperatures above 2500°C in a customized 25 KW hollow electrode EAF, while the vacuum process was preliminary tested at 0.03–2.6 mbar absolute CO partial pressure and temperatures of 1400–1850°C in an induction furnace. Results of both processes confirmed that the full reaction and volatilization of alumina to produce metallic aluminum in the vapor condensers can be achieved only at proper matching of temperatures and pressures at reaction and condensation zones. The solar reactor concept was further explored in a concentrated solar radiation furnace on a 10 kW scale.