1. Aluminum
Metal of the 21st Century

2. Assessment statement
Describe and explain the production of aluminum by electrolysis of alumina in molten cyrolite. (Include the use of cyrolite as a solvent because of the very high melting point of Al2O3 and the type of materials used for the construction of the cell and choice of electrodes.)

3. Al facts 8.13 wt.% of the crust Weighs about 1/3 of Cu or Fe
Malleable, ductile, easily cast and machined, corrosion resistant
Excellent conductor of electricity

4. History of Discovery Rubies and Sapphires 1809 recognized as alumina
Corundum
1809 recognized as alumina
1825 Al isolated value>>> Au
1886 Electrolytic process developed
Charles Hall U.S.
Paul Heroult France

5. History Con’d
1886 Chemical process of cleaning bauxite –Karl Bayer Austria
1947 First Al foil

6. Uses of Al Packaging Transportation Building Electrical wires
Al compounds
Petroleum industry, refractories, grinding and polishing, synthetic jewels

7. Ore Mineral of Al

8. Bauxite mining in Suriname

10. Production of Aluminum
Aluminum is primarily made by the electrolytic reduction of aluminum oxide.
Aluminum oxide or aluminum does not occur naturally.
The main ore of aluminum is bauxite.
Bauxite is in the form of mainly aluminum hydroxide Al(OH)3, and other impurities such as iron(III) oxide and titanium hydroxide, and other few oxides.

11. Bayer process
Bayer process is the process of extracting aluminum oxide from bauxite.
Bauxite is powdered prior to the process.
As aluminum oxide is amphoteric, it dissolves in sodium hydroxide solution.
Al(OH)3(s) + NaOH(aq)  NaAlO2(aq) + 2H2O(l)

12. The aluminate solution is filtered leaving behind the impurities.
Seeding with aluminum hydroxide then reverses the reaction.
The pure recrystallized aluminum hydroxide is then heated to produce aluminum oxide (alumina).
2Al(OH)3  Al2O3(s) + 3H2O(l)

13. Use of cryolite
To make the electrolysis happen, alumina has to be in aqueous state.
Alumina has a very high melting point of 2045°C.
Cryolite (sodium hexafluoroaluminate(III), Na3AlF6) melts at about 950°C and the solution can dissolve alumina sufficiently well.
Considerable energy is still required to heat cryolite and dissolve alumina, but it is much more energy-efficient than melting the alumina itself.

14. Natural cryolite is depleted long ago, thus synthetic cryolite is needed.
The aluminate solution (NaAlO2(aq)) from Bayer process is used in separate process to make synthetic cryolite.
Hydrogen fluoride and sodium carbonate is added to the solution to precipitate cyrolite.
NaAlO2(aq) + 6HF(g) + Na2CO3(aq)  Na3AlF6(s) +3H2O(l) + CO2(g)

15. Hall-Heroult process
Hall-Heroult process is an electrolysis process that extracts aluminum out of alumina (aluminum oxide).
Overall cell reaction is
Alumina + carbon = aluminum + carbon dioxide

17. COPY Hall Heroult process

19. Assessment statement
Describe the main properties and uses of aluminum and its alloys.

20. Properties of aluminum
Malleable and can be shaped easily
Excellent conductor of heat and electricity
Has much a lower density than iron, yet can form alloys that are stronger than steel
Resistant to corrosion due to its protective layer of aluminum oxide
The thickness of the oxide layer can be further increased by a process known as anodizing.

21. Uses of aluminum Use Examples Transport
Superstructures of trains, ships and airplanes. Alloy engines for cars.
Construction
Window frames, doors roofing
Power transmission
Overhead electricity cables, capacitor foil
Kitchen utensils
Kettles, saucepans
Packaging
Drink cans, foil wrapping
Chemical industry
Al(OH)3 – flame retarder, paper making
Al2(SO4)3 – flocculant in sweage treatment and to precipitate PO43-
Al2O3 – catalyst and catalytic support material, abrasive

22. Assessment statement
Discuss the environmental impact of iron and aluminum production.

23. Environmental impact
Smelting processes of aluminum requires enormous amount of electricity.
Also, the main process which is the electrolysis emits carbon dioxide which is greenhouse gas.
Recycling aluminum is an important method of saving energy and minimizing the environmental damage.
Recycling aluminum requires only 5% of the energy to produce the same amount of aluminum from bauxite.

24. Type of Mining OPEN Pit or STRIP Remove top soil and store
Break up bauxite into pieces
Clay removed by combination of washing and wet screening

25. Aluminium production starts with the BAYER process
Aluminium production starts with the BAYER process. This extracts aluminium oxide (alumina) from bauxite (aluminium ore)
The alumina (aluminium oxide) is then dissolved in cryolite. Once dissolved, the final process of metal extraction involves ELECTROLYSIS