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Aluminium Dross Recycling
Aluminium dross, a byproduct of the aluminium smelting process, can be mechanically recycled to separate the residual aluminium metal from the aluminium oxide. Thermo-mechanical metal extraction The mechanical process of recycling does not use any toxic chemicals previously used in the process of extracting the valuable aluminium in the dross. Hot dross processing is a system whereby the majority of metal is recovered without chemically reducing the aluminium oxides. The dross is first crushed then separated into aluminium rich particles and aluminium oxide rich particles based on density. The metal rich particles are then melted in a furnace to remove the remaining oxide particles. Mechanical extraction vs chemical The recovery of aluminium from dross has traditionally caused severe environmental issue with highly alkaline waste waters, a waste product that is rich in waste flux and that evolves ammonia gas on contact with water and can spontaneously combust if allowed to get ...
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Aluminium Dross2
Aluminium (or aluminum in North American English) is a chemical element; it has symbol Al and atomic number 13. It has a density lower than that of other common metals, about one-third that of steel. Aluminium has a great affinity towards oxygen, forming a protective layer of oxide on the surface when exposed to air. It visually resembles silver, both in its color and in its great ability to reflect light. It is soft, nonmagnetic, and ductile. It has one stable isotope, 27Al, which is highly abundant, making aluminium the 12th-most abundant element in the universe. The radioactivity of 26Al leads to it being used in radiometric dating. Chemically, aluminium is a post-transition metal in the boron group; as is common for the group, aluminium forms compounds primarily in the +3 oxidation state. The aluminium cation Al3+ is small and highly charged; as such, it has more polarizing power, and bonds formed by aluminium have a more covalent character. The strong af ...
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Explosives
An explosive (or explosive material) is a reactive substance that contains a great amount of potential energy that can produce an explosion if released suddenly, usually accompanied by the production of light, heat, sound, and pressure. An explosive charge is a measured quantity of explosive material, which may either be composed solely of one ingredient or be a mixture containing at least two substances. The potential energy stored in an explosive material may, for example, be: * chemical energy, such as nitroglycerin or Dust explosion, grain dust * pressure, pressurized gas compressor, gas, such as a gas cylinder, aerosol can, or boiling liquid expanding vapor explosion * nuclear weapon, nuclear energy, such as in the fissile isotopes uranium-235 and plutonium-239 Explosive materials may be categorized by the speed at which they expand. Materials that detonate (the front of the chemical reaction moves faster through the material than the speed of sound) are said to be "high ...
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Bauxite
Bauxite () is a sedimentary rock with a relatively high aluminium content. It is the world's main source of aluminium and gallium. Bauxite consists mostly of the aluminium minerals gibbsite (), boehmite (γ-AlO(OH)), and diaspore (α-AlO(OH)), Mixture, mixed with the two iron oxides goethite (FeO(OH)) and haematite (), the aluminium Clay minerals, clay mineral kaolinite () and small amounts of anatase () and ilmenite ( or ). Bauxite appears dull in Lustre (mineralogy), luster and is reddish-brown, white, or tan. In 1821, the French people, French geologist Pierre Berthier discovered bauxite near the village of Les Baux-de-Provence, Les Baux in Provence, southern France. Formation Numerous classification schemes have been proposed for bauxite but, , there was no consensus. Vadász (1951) distinguished Laterite, lateritic bauxites (silicate bauxites) from karst bauxite ores (carbonate bauxites): * The carbonate bauxites occur predominantly in Europe, Guyana, Suriname, and ...
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Aluminium Recycling
Aluminium recycling is the process in which secondary commercial aluminium is created from scrap or other forms of end-of-life or otherwise unusable aluminium. It involves re-melting the metal, which is cheaper and more energy-efficient than the production of virgin aluminium by electrolysis of alumina (Al2O3) refined from raw bauxite by use of the Bayer and Hall–Héroult processes. Recycling scrap aluminium requires only 5% of the energy used to make new aluminium from the raw ore. In 2022, the United States produced 3.86 metric tons of secondary aluminium for every metric ton of primary aluminium produced. Over the same time period, secondary aluminium accounted for 34% of the total new supply of aluminium including imports. Used beverage containers are the largest component of processed aluminium scrap, and most of it is manufactured back into aluminium cans. Recycling process Collection & sorting The first step in aluminium recycling is the collection and sorting of ...
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Ingot
An ingot is a piece of relatively pure material, usually metal, that is Casting, cast into a shape suitable for further processing. In steelmaking, it is the first step among semi-finished casting products. Ingots usually require a second procedure of shaping, such as cold/hot working, cutting, or milling to produce a useful final product. Non-metallic and semiconductor materials prepared in bulk form may also be referred to as ingots, particularly when cast by mold based methods. Precious metal ingots can be used as currency (with or without being processed into other shapes), or as a currency reserve, as with gold bars. Types Ingots are generally made of metal, either pure or alloy, heated past its melting point and cast into a bar or block using a mold chill method. A special case are polycrystalline or single crystal ingots made by pulling from a molten melt. Single crystal Single crystal ingots (called boule (crystal), boules) of materials are grown (crystal growth) using ...
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Aluminium Recycling
Aluminium recycling is the process in which secondary commercial aluminium is created from scrap or other forms of end-of-life or otherwise unusable aluminium. It involves re-melting the metal, which is cheaper and more energy-efficient than the production of virgin aluminium by electrolysis of alumina (Al2O3) refined from raw bauxite by use of the Bayer and Hall–Héroult processes. Recycling scrap aluminium requires only 5% of the energy used to make new aluminium from the raw ore. In 2022, the United States produced 3.86 metric tons of secondary aluminium for every metric ton of primary aluminium produced. Over the same time period, secondary aluminium accounted for 34% of the total new supply of aluminium including imports. Used beverage containers are the largest component of processed aluminium scrap, and most of it is manufactured back into aluminium cans. Recycling process Collection & sorting The first step in aluminium recycling is the collection and sorting of ...
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Thermite
Thermite () is a pyrotechnic composition of powder metallurgy, metal powder and metal oxide. When ignited by heat or chemical reaction, thermite undergoes an exothermic redox, reduction-oxidation (redox) reaction. Most varieties are not explosive, but can create brief bursts of heat and high temperature in a small area. Its form of action is similar to that of other fuel-oxidizer mixtures, such as gunpowder, black powder. Thermites have diverse compositions. Fuels include aluminium, aluminum, magnesium, titanium, zinc, silicon, and boron. Aluminum is common because of its high boiling point and low cost. Oxidizers include bismuth(III) oxide, boron(III) oxide, silicon(IV) oxide, chromium(III) oxide, manganese(IV) oxide, iron(III) oxide, iron(II,III) oxide, copper(II) oxide, and lead(II,IV) oxide. In a thermochemical survey comprising twenty-five metals and thirty-two metal oxides, 288 out of 800 binary combinations were characterized by adiabatic temperatures greater than 2000 K ...
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Fertilizer
A fertilizer or fertiliser is any material of natural or synthetic origin that is applied to soil or to plant tissues to supply plant nutrients. Fertilizers may be distinct from liming materials or other non-nutrient soil amendments. Many sources of fertilizer exist, both natural and industrially produced. For most modern agricultural practices, fertilization focuses on three main macro nutrients: nitrogen (N), phosphorus (P), and potassium (K) with occasional addition of supplements like rock flour for micronutrients. Farmers apply these fertilizers in a variety of ways: through dry or pelletized or liquid application processes, using large agricultural equipment, or hand-tool methods. Historically, fertilization came from natural or organic sources: compost, animal manure, human manure, harvested minerals, crop rotations, and byproducts of human-nature industries (e.g. fish processing waste, or bloodmeal from animal slaughter). However, starting in the 19th cen ...
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Concrete
Concrete is a composite material composed of aggregate bound together with a fluid cement that cures to a solid over time. It is the second-most-used substance (after water), the most–widely used building material, and the most-manufactured material in the world. When aggregate is mixed with dry Portland cement and water, the mixture forms a fluid slurry that can be poured and molded into shape. The cement reacts with the water through a process called hydration, which hardens it after several hours to form a solid matrix that binds the materials together into a durable stone-like material with various uses. This time allows concrete to not only be cast in forms, but also to have a variety of tooled processes performed. The hydration process is exothermic, which means that ambient temperature plays a significant role in how long it takes concrete to set. Often, additives (such as pozzolans or superplasticizers) are included in the mixture to improve the physical prop ...
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Aluminium Smelting
Aluminium smelting is the process of extracting aluminium from its oxide, alumina, generally by the Hall-Héroult process. Alumina is extracted from the ore bauxite by means of the Bayer process at an alumina refinery. This is an electrolytic process, so an aluminium smelter uses huge amounts of electric power; smelters tend to be located close to large power stations, often hydro-electric ones, in order to hold down costs and reduce the overall carbon footprint. Smelters are often located near ports, since many smelters use imported alumina. Layout of an aluminium smelter The Hall-Héroult electrolysis process is the major production route for primary aluminium. An electrolytic cell is made of a steel shell with a series of insulating linings of refractory materials. The cell consists of a brick-lined outer steel shell as a container and support. Inside the shell, cathode blocks are cemented together by ramming paste. The top lining is in contact with the molten metal a ...
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Paint
Paint is a material or mixture that, when applied to a solid material and allowed to dry, adds a film-like layer. As art, this is used to create an image or images known as a painting. Paint can be made in many colors and types. Most paints are either oil-based or water-based, and each has distinct characteristics. Primitive forms of paint were used tens of thousands of years ago in cave paintings. Clean-up solvents are also different for water-based paint than oil-based paint. Water-based paints and oil-based paints will cure differently based on the outside ambient temperature of the object being painted (such as a house). History Paint was used in some of the earliest known human artworks. Some cave paintings drawn with red or yellow ochre, hematite, manganese oxide, and charcoal may have been made by early ''Homo sapiens'' as long as 40,000 years ago. Paint may be even older. In 2003 and 2004, South African archeologists reported finds in Blombos Cave of a 100,000-y ...
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Aluminium Oxide
Aluminium oxide (or aluminium(III) oxide) is a chemical compound of aluminium and oxygen with the chemical formula . It is the most commonly occurring of several Aluminium oxide (compounds), aluminium oxides, and specifically identified as aluminium oxide. It is commonly called alumina and may also be called aloxide, aloxite, ALOX or alundum in various forms and applications and alumina is refined from bauxite. It occurs naturally in its crystalline Polymorphism (materials science), polymorphic phase (matter), phase α-Al2O3 as the mineral corundum, varieties of which form the precious gemstones ruby and sapphire,which have an alumina content approaching 100%. Al2O3 is used as feedstock to produce aluminium metal, as an abrasive owing to its hardness, and as a refractory material owing to its high melting point. Natural occurrence Corundum is the most common naturally occurring crystallinity, crystalline form of aluminium oxide. ruby, Rubies and sapphires are gem-quality forms o ...
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