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By Denis Legault, Ghyslain Dube, Ronald Morin, Jacques Bonneau, Daniel Guay, Keith Annett, Raymond Breault

"·The total recycling of all the constituents present in aluminum dross is now an industrial reality for Akan. This is made possible by the combination of two patented processes: the Alcan plasma dross treatment process, operating since 1990 at its Guillaume-Tremblay Works, and the calcium aluminate fabrication process, operating at AlumiCa's new plant in Thetford Mines. The latter process uses the total non-metallic content of the dross, thus rendering possible the complete recycling of aluminum dross.After describing the plasma dross treatment process, this paper will present the calcium aluminate fabrication process and how both processes contribute to close the recycling loop. The characteristics of Nova!™ by-product will also be described, as well as how they contribute to make a calcium aluminate with chemical and physical properties that are highly sought after. This calcium aluminate, produced by AlumiCa, is marketed under the trade name Kwikflux®. AlumiCa's total production is presently sold to a number of steel plants worldwide."

Jan 1, 2000

By Philip D. Wilson

AS thin most important and vital component of an airplane aluminum hay rapidly become the heart and tome- of the war program. Its production ham increased amt will continue to increase, in comparison with its pre-war position further than that of any of lie other important critical metals except magnesium. Compared with the 1939 production of tons of primary ingot coming from four plants, all owned by the Aluminum Company of America the 1942 figures are more than three timer as large. Including, recoverable scrap and contracted ingot from Canada the 191,, supply of aluminum for the United States will be over siren times dial of 1939- A substantial part of this increase has been achieved during the past year as total production in 1941 was only some 307,500 tons. During 1942 six great new ingot plants sponsored and owned by the Government have come into production and three others are nearing completion.

Jan 1, 1943

By B. Arsenault

Aluminum coatings can provide galvanic cathodic protection for several metals and alloys, In order to be a suitable protective solution on structural components, the mechanical integrity of the component must be preserved, In particular, fatigue properties are a challenge for thermal-spray protective coatings on mechanical structures, To address the issue of the fatigue integrity of 7075 aluminum alloy with an arc-sprayed protective coating, different surface preparations prior to arc spraying were considered, In the present work, a feasibility study was performed using laser ablation as a surface-preparation technique before or during arc spraying of coatings, This was collaborative effort between the LERMPS laboratory in France, the National Research Council Canada and the Royal Military College of Canada, Both fatigue and adhesive properties of aluminum coatings were evaluated in relation to substrate-surface-preparation techniques including laser ablation (Protal® process), grit blasting and shot peening. Results indicate that a combination of key conditions, including the use of nitrogen as the arc spray gas, shot peening, and proper laser energy density for ablation, provide high fatigue resistance of metallic coated 7075 alloy substrates. Specimens prepared under these conditions show a similar fatigue resistance to uncoated substrates.

Jan 1, 2005

By Turan Uysal, Ramazan Aydogmus, MURAT ERDEMOGLU

The paper investigates the effects of calcination for thermal activation and intensive milling for mechanical activation on aluminum recovery by acid leaching of pyrophyllite ore enriched via attrition scrubbing and froth flotation. The study compares these methods in terms of energy consumption and aluminum recovery, concluding that mechanical activation is more economical and environmentally friendly.

Nov 1, 2023

By Banqiu Wu, Ramana G. Reddy, Robin D. Rogers

Experimental studies on aluminum recycling via electrolysis in ionic liquids were carried out at the temperature of 105°C. Impure aluminum was dissolved at the anode and pure aluminum was deposited on a copper cathode. The products were characterized using an optical microscope, micro-image analyzer, X-ray diffraction, emission spectrometer, and atomic absorption analyzer. The electrorefining process with a current density of 310 - 730 AJm2, and current efficiency of about 99% was obtained. Impurities such as Si, Cu, Zn, Fe, Mg, Cr, Ni, Mn and Pb were removed as anode residue. Impure aluminum was purified from 79.8wt% to 99.9wt%. At a cell voltage of 1 volt, the energy consumption of about 3 kWh/kg-Al was obtained. The process has advantages of low energy consumption and low pollutant emissions, compared with the current industrial refining process.

Jan 1, 2000

By John A. S. Green, J. Gilbert Kaufman, Subodh K. Das

"The aluminum industry is a leading proponent of global sustainability and strongly advocates the use of recycled metal. As the North American primary aluminum industry continues to move offshore to other geographic areas, such as Iceland and the Middle East, where energy is more readily available at lower cost, the importance of the secondary (i.e., recycled metal) market in the U.S. will continue to increase. In the past, the recycling industry had been synonymous with the collection of aluminum beverage cans. However, as the opportunities for aluminum recycling have multiplied in motor vehicles, building and construction, and aerospace, these market are getting additional scrutiny for optimization of recycling strategies.Accordingly, the secondary industry can now draw upon a much wider range of product forms and alloys for its raw material, but this in turn brings issues of alloy sorting, impurity content, and control as the material is remelted and recycled into new product forms. The purpose of this paper is to take an integrated, industry-wide approach to look at the recovery of material from demolished buildings, shredded automobiles, and aging aircraft, as well as from traditional cans and other rigid containers. Attempts will be made to assess how the different alloys used in these separate markets can be recycled in the most energy efficient manner.IntroductionIn his recent book “Aluminum Recycling”[1], Mark Schlesinger points out that in traditional extractive metallurgy, the raw material used to produce a metal is mined from the earth and then is separated from other gangue minerals and impurities. In aluminum recycling, however, the ore body consists of scrap metal found on the ground, rather than in it. He further notes that scrap comes with its own variety of gangue and impurities such as painted coatings, other metal attachments, and even dirt and other contaminants. So, while the recycling process still requires some refinement and expenditure of energy, the effort and energy involved is much less than traditional mining."

Jan 1, 2008

By G. J. Shiflet

This paper will review work done in our laboratory on the formation, thermodynamics and crystallization of aluminum based metallic glass with the addition of rare earth elements. The results demonstrate that the metallic glasses are truly amorphous and not microcrystalline and that they are unusual in their formation because the alloys contain 90 at. % aluminum and there is no deep eutectic present in the phase diagram. Tensile strengths that exceed 900 MPa are obtained for several of the compositions and exceed 1000 MPa after partial crystallization.

Jan 1, 1992

By F. Kassabji

This publication presents the main experimental and theoretical results on the recovery of aluminum scrap (dross and Used Beverage Can) without use of any addition of fluxing salts. Dross and UBC's processing experiments have been conducted in a rotary plasma furnace operating in the transferred and non-transferred mode, using different plasma gases. The investigation involved the treatment of more than 100 kg of dross and other aluminum residues using plasma torches with less than 100 kW power. The experimental work showed that this process is .far more economical and kind to the environment than the conventional route using a salt flux. An equilibrium thermodynamic calculation at elevated temperature makes possible the prediction of by-products at various temperatures for different plasma gases.

Jan 1, 1994

By P. R. Bruggink

"A quantitative tool has been developed to assess the impact of changes in recycling rates on the environmental impact of aluminum supply. It has been applied to the USA to forecast sources of aluminum scrap and to examine the impact of an increase in Old Scrap recovery on the USA supply system and the subsequent effect on the Life Cycle Impact of aluminum supply. The reported data for primary, secondary and import/export supply and product shipments for aluminum in the USA show a fairly good balance between supply and demand on average over the years. Therefore, it is reasonable to use the data, along with published estimates of average product lives, recycling rates and recoveries to draw conclusions about future aluminum scrap generation· and recovery. The Life Cycle Impacts of increasing post-consumer recovery rates to recover an additional 450,000 MT/yr (1 billion lb/yr) has been estimated using the model.The spreadsheet model upon which this work was based was developed in U.S. Customary units. Converting the figures to Metric units would have required converting the entire model and rebuilding the figures. I have chosen to leave the figures in U.S. Customary units. I apologize for any inconvenience this may cause."

Jan 1, 2000

By T. Lamb

There are many honor stories about aluminum in the marine environment and many are not based on facts, so they are myths. Myths must be addressed before progress can be made. This paper attempts to dispel the myths and state the facts. A common perception is that aluminum ships cost significantly more than steel ships. This paper illustrates that even though the cost of the aluminum structure is over 50% more than the steel structure, an "equivalent" aluminum naval ship can be built within 7% of the acquisition price of a steel ship. This is possible because of the cascading benefits of the aluminum ship's significantly lighter weight. Aluminum ships also have a life-cycle cost advantage over steel ships because of reduced maintenance and fuel cost savings.

Jan 1, 2011

By Robert F. Jenkins

This document addresses the use of practical and basic engineering principles to develop a computer model for the analysis of the various issues which affect heat transfer in aluminum sidewell furnaces. These issues include furnace charge conditions, furnace operating conditions, furnace general arrangement, furnace combustion conditions, and furnace ambient heat loss. The engineering principles applied to this model were first put to test over 20 years ago. A prototype computer model developed 12 years ago has been in continuous use by Thorpe Technologies to determine the performance of sidewell furnaces for the aluminum industry. A new computer model has enhanced capabilities for more detailed performance analysis including regenerative and oxygen enriched combustion.

Jan 1, 2000

By Reza Kamali, Mohsen Bashiri, Hadi Fanisalek

"Nomenclature: A: area (m2), C: heat capacity (WIK), cp: specific heat (J/Kg K), d: internal tube diameter (in), F: correction factor for multi-pass and crossflow heat exchanger, h: convective heat transfer coefficient (W/m2K), k: thermal conductivity (W/mK), L: length (m), m: mass flow rate (Kg/s), W: flow rate, N: number, Q: heat rate (W), R: thermal resistance, T: temperature (°C), U: overall heat transfer coefficient (W/m2K), ;1,,P: pressure drop (Pa), ;1,,T: temperature difference (°C), p: density (lb/ft3), N: number of tube passes, U,: velocity in tubes, iJh: head loss in feet of flowing fluid, Up: velocity in the pipe leading to and from the heat exchanger (ft/sec), µ: viscosity ( cp ), Llpf frictional pressure loss (psi/l 00 equivalent ft of pipe) Subscripts: b: baffle, c: cold, cf counter flow, ex: exchanger, f: fouling, h: hot, i: inlet-inner, ib: inlet baffle, lm: logarithmic mean, m: mean, o: outlet-outer, s: shell, t: tube, w: wall AbstractThe main bottleneck for primary aluminum production industry is dealing with a huge amount of input energy. The fact is that part of provided energy to aluminum production smelters will be lost as waste heat and it never used for aluminum production. One part of waste heat is escaping from the potroom exhaust gases, which was studied for possible recovery in a desalination plant to produce distilled water and the paper was presented in 2011 TMS Annual Meeting. However, it was shown that waste heat recovery plant to produce distilled water is highly profitable but the main fact is that the exhaust gases from potroom are highly corrosive, abrasive and dusty. The main challenge for desalination plant construction, which is using aluminum smelter exhaust gases as the main heat source, is the highly corrosive environment that makes the situation difficult and complicated for equipments design and plant construction. In this paper, we are trying to study a detailed investigation regarding the heat exchangers fouling, corrosion in heat exchangers including heat exchangers' material, how often we need to shut down the plant for maintenance or cleaning, and plant thermal efficiency with considering fouling."

Jan 1, 2012

By Hannon, J. W. G.

Silicosis is today's most important industrial disease and probably dates back to the Stone Age. Since the industrial revolution, increasing attention has been paid to those occupations where mineral dust is present in the air breathed by the workers. For many years it was assumed that the inhalation of all mineral dusts was hazardous. but investigations conducted in several countries pointed the statistical finger of guilt at free silica in any of its numerous physical forms as a dust of outstanding toxicity. Recognition of silica as the chief hazard has resulted in widespread use of the term "silicosis." Depending upon the concentration of finely divided silica dust to which the individual is exposed and the duration of exposure, silicosis may become a disabling condition in from one to thirty years. The structure of the lung and respiratory passages is such that only minute particles of silica can gain entry to the air cells in the lung (5 microns or under are most toxic). When these minute particles gain entry to the lung tissues they stimulate certain protective cells in the lung to multiply at an excessive rate. The cell's undergo inflammatory changes which result in nodular scars and a low-grade inflammation of the lung tissue. These progressive changes in the lung structure gradually encroach

Jan 1, 1949

By Delahant A. B, Dworski M

From the Saranac Laboratory for the Study of Tuberculosis of the Edward L., Trudeau Foundation, Saranac Lake, New York:We are assembled to honor the memory of our friend and colleague, Donald Cummings, one of the founders and a past president of the American Industrial Hygiene Association. I deem it an Unusual privilege to have been asked to give this first memorial lecture and hope that what shall have to say may be worthy of the occasion. It is fitting that we should discuss here the subject of Silicosis to which he devoted such a large part of his life and it is doubly fitting, I think, that I should report to you an extended series of investigations carried on by his associates at the Saranac Laboratory.The subject of silicosis may seem hackneyed to this audience which is so familiar with the tried and accepted methods of prevention and control.But in spite of our efforts, the condition is still with us and unfortunately is still being produced in many places. In industries that now maintain good control of dust, fresh cases are appearing on annual re-examination, whose major exposure date back to the days before the hazard was recognized.A few new employees, with apparently ineffective upper respiratory protection against inhaled dust, develop silicosis precociously in environments that are comparatively harmless to their fellows. In plants that have relaxed their vigilance under the urgency of war production schedules, conditions again prevail that will produce, disease in the future.Silicosis acquired new interest with the announcement by Denny, Robson and Irwin(1) in 1937 that it could be prevented by the inhalation of powdered metallic aluminium. It so happened that without knowledge of their work, we at the Saranac Laboratory had for some months been conducting similar experiments with one of the hydroxides of aluminium.Quite independently we discovered that hydrated alumina would also protect animals against quartz. Our approach to the problem had been empirical; we were trying to neutralize quartz particles by coating their surfaces with an insoluble material following the lead of Kettle who in 1932 had shown that this could be accomplished with iron. He neglected to describe his method and the chemist who prepared his coated...

Jan 1, 1945

Following the experimental work of Denny, Robson, and Irwin, and the clinical investigation by Crombie and Blaisdell, an investigation of aluminium therapy was begun at Washington, Pa., which is situated In a very large industrial section of the State. Some of the men to be studied were from plants manufacturing silica brick, refractories used in steel and glass manufacturing, and semi-porcelain table-ware; others were workers in foundries, sand blasters, and men engaged in the quarrying of ganister rock.This group of workmen gave an opportunity to study the effects of aluminium on various types of silicosis which differed somewhat from that found in hard-rock miners.EXPOSUREIn their occupations, the men studied were exposed to silica dust concentrations ranging from 17 to 97 per cent free silica. In the silica brick industries, the unfired product averages 96 per cent silica in the form of quartz, whereas the fired brick contains 50 to 62 per cent. cristobalite plus 11 to 80 per cent. tridymite, forms of silica that, on account of their higher solubility, are more toxic than quartz. The operational dust counts in the plants varied from 15 to 9,500 particles per c.c., and the median particle size from the aerial samples was 1.0 micron for the green product and 2.0 microns for the fired product. The length of exposure varied with the occupation as well as with the individual plant, but disabling silicosis could be produced in less than four years in certain exposures. The average time needed to produce radiological silicosis in those susceptible to this disease was eight years. Some of the men in our series of cases have been treated as long as fifteen years after exposure had ceased, and have improved under treatment.The dust counts mentioned above had been reduced prior to the aluminium therapy studies and the presen.t exposures do not exceed '900 particles per c.c., the average being 370 particles. per c.c. This improvement in dust conditions was due to improved dust control apparatus, which was installed before aluminium therapy was instituted. Aluminium powder is not a substitute for dust control.PATHOLOGYThe pathological picture of silicosis in men engaged in the ceramic industry is somewhat different from that in hard rock miners." Due to exposure to high concentrations of dust containing high percentages of silica of varying degrees of solubility andvery small particle size, these men are subject to a relatively rapid type of silicosis, which sets up an acute...

Jan 1, 1945

By Jan Petter Maehlen

Solid H-absorbing materials are in focus of ongoing R&D to offer viable solutions for the hydrogen storage and supply systems aimed on use of hydrogen as energy carrier for automotive transportation. Low operating pressures, combined with high gravimetric and volumetric efficiencies, together with fast kinetics of hydrogen release at ambient temperatures (providing conditions for a low energy loss due to decomposition), are the most important features of the ?ideal? H storage material. Hydrides of the light elements are the only possible candidates to build systems with an overall efficiency similar to those accommodating liquid or compressed (700 bar) hydrogen. One promising material from this point of view is aluminium trihydride, alane AlH3 with a gravimetric storage capacity of 10 wt.% H. This work was focused on studies of the crystal structure and thermal decomposition of alane by application of powder synchrotron X-Ray diffraction.

Jan 1, 2006

This paper states how alloy and welding advances have made possible the rapid development of the use of aluminum in the construction of equipment for earth moving and off -highway rock hauling. The main details are given regarding the construction and field testing carried out on an aluminum prototype body. The test results of strain gauge readings are analysed, and a description is given of how these have been applied in subsequent designs. The increase in the number of aluminum units put into the various types of service in Canada, as well as the problems encountered, is described, and the experience gained from five years of field service is discussed in some detail. An assessment is also made of the durability of the e units. The economics of using aluminum, together with the current development position, are reviewed, and predictions are made for considerable future increases in the use of aluminum units in open-pit and off-highway operations.

Jan 1, 1964

Introduction One hundred years ago, a recent college graduate created the US aluminum industry. He found an economic way to crack the primeval bond that makes the metal so special. Aluminum doesn't "rust" - oxidize progressively. Rather, when exposed to air, it instantly forms a gem-hard but microscopic oxide coating. This seals off oxygen from the metal underneath. Scratch it and the seal reforms instantly. That tight chemical bond is the reason the metal is not found in nature; it exists only as a compound. The bond had to be broken to free the shiny metal. But once it is free, that self-sealing protection, alongside a remarkable strength-to-weight ratio, offers a marvelous material. Until 100 years ago, finding a way to do that economically was a challenge that defied science. Then it was solved, in a remarkable coincidence, on both sides of the Atlantic. And the way was paved for a material that would become the second most widely used metal in the world. Until that time, aluminum was a rare and precious metal. But then two young scientists independently invented the process that took aluminum outside the laboratory and into applications ranging from pots and pans to spacecraft. Discovery of aluminum Other major metals - copper, iron, lead, gold, and silver - had been used for thousands of years. But aluminum was entirely unknown until 1782, when French chemist Antoine Lavoisier suspected its presence. It was not actually discovered until Sir Humphry Davy, in England, detected it in clay in 1807. It was first isolated as a free metal only in 1825, by Denmark's Hans Christian Oersted. For years, laboratory methods yielded aluminum only in tiny amounts costing about $1200/kg ($545 per lb) - $13,333/kg ($6000 per lb) in today's dollars. Methods developed by French scientist Henri Sainte-Claire Deville in 1854 cut the cost to about $200/kg ($90 per lb). King Frederick VII of Denmark had a helmet of aluminum and gold. And Emperor Napoleon III of France reportedly served his most exalted guests at a state dinner with aluminum plates. He left the lower ranks to dine from pure gold. Deville and others continued to reduce production costs. But the price of aluminum still rivaled silver - $31/kg ($14 per lb) versus about $35/kg ($16 per lb) for silver. Then in 1884, a 2.8-kg (6.25-1b), 230-mm-tall (9-in.-tall) aluminum pyramid was cast as the tip of the Washington Monument. It was probably the first architectural use of aluminum. And it is still there after more than a century. The attractive properties of aluminum were obvious: it is lightweight but strong, conducts heat and electricity, reflects light and other electromagnetic radiation, and resists corrosion. But its commercial promise was blocked by its cost. In 1885, the price of aluminum was $17.70/kg ($8 per lb). It stayed there for the next couple of years until the Hall-Heroult process brought it down sharply. Hall-Heroult process lowers aluminum costs The characteristic that kept aluminum hidden so long continued to thwart chemists. Aluminum clings to oxygen so tightly that it is never found as a free metal in nature, and it is hard to break that bond chemically. The best chemical methods of the 1880s required sodium, and sodium itself was expensive. At Oberlin College in Ohio, chemistry professor Frank Fanning Jewett advised his students that anyone who could make aluminum inexpensive would do humanity a favor and get rich as well.

Jan 3, 1987

By W. L. Fink, R. S. Archer

THIS paper describes results obtained on aluminum-beryllium alloys and aluminum-beryllium-copper alloys in the preparation of which aluminum of 99.95 per cent. purity was used. The constitution and structure of the high purity binary alloys are given. The aluminum-beryllium eutectic occurs at 0.87 per cent. beryllium and 645° C. The solid solubility of beryllium in aluminum at 631° C. is 0.05 per cent. beryllium, and at room temperature is less than 0.013 per cent. beryllium. The densities of the alloys are substantially the same as the values calculated on the assumption that the densities of the elements are not changed by alloying. All of the alloys age-harden at room temperature after a solution heat treatment, and the chill cast aluminum-beryllium-copper alloys age-harden at room temperature without a prior solution heat treatment. Hardness and tensile properties are given. Salt spray corrosion tests on sheet specimens are described. It is shown that beryllium does not lower the corrosion resistance of aluminum to salt spray provided the alloy has received a solution heat treatment. COMMERCIAL POSSIBILITIES OF BERYLLIUM ALLOYS Beryllium has certain properties such as low density, high hardness, good corrosion resistance, low thermal expansion and fairly good electrical conductivity, which would indicate that it is worthy of consideration as an ingredient of light alloys. It was not until recently, however, that beryllium could be produced with sufficient ease to encourage research along this line. The production of beryllium by electrolysis from a fluoride bath has now developed to the stage where it could be used commercially if there were sufficient demand for the element. Claims made in certain newspapers and technical articles in regard to the strength and corrosion resistance of the aluminum-beryllium alloys are not justified by experimental results. Moreover, beryllium is an expensive metal ($200 a pound at the time this work was done) and, on account of the nature of its ore and the consequent difficulty of its extraction, it will in all probability continue to be a relatively expensive metal, although the cost would undoubtedly be a great deal less than $200 a

Jan 1, 1928

By R. S. Archer

BERYLLIUM has certain properties such as low density, high hardness, good corrosion resistance, low thermal expansion and fairly good electrical conductivity, which would indicate that it, is worthy of consideration as an ingredient of light alloys. It was not until recently, however, that beryllium could be produced with sufficient ease to encourage research along this line. The production of beryllium by electrolysis from a fluoride bath has now developed to the stage where it could be used commercially if there were sufficient demand for the element. Claims made in certain newspapers and technical articles in regard to the strength and corrosion resistance of the aluminum-beryllium alloys are not justified by experimental results. Moreover, beryllium is an expensive metal ($200 a pound at the time this work was done) and, on account of the nature of its ore and the consequent difficulty of its extraction, it will in all probability continue to be a relatively expensive metal, although the cost would undoubtedly be a great deal less than $200 a pound if the metal were produced on a large scale. It seemed, therefore, that low-beryllium alloys offered the greater commercial possibilities except for very special purposes. It was partly for this reason that in the present work emphasis has been placed on beryllium alloys of low beryllium content.

Jan 1, 1928