Materials Engineering Department Extraction

Extraction of Aluminum

⮚ Introduction

Aluminum is a chemical element has Al symbol and atomic number equal 13, so
can be found in equivalent +3. Aluminum being an active metal, does not found in
free state. It is the third most abundant element of earth's crust (7.4%). It is found
only in combined state.

It is extracted by electrolysis. The ore is first converted into pure aluminum

oxide by the Bayer Process, and this is then electrolyzed in solution of molten
cryolite-another aluminum compound. The aluminum oxide has too high a
melting point to electrolyze on its own.

⮚ Aluminum ore

The usual aluminum ore is bauxite. Bauxite is essentially an impure aluminum

oxide. The major impurities include iron oxides, silicon dioxide and titanium
dioxide. There are many another aluminum ores, such as:

1. Oxide: Corundum (Al2O3)

2. Hydrate-Oxide: Bauxite (Al2O3.2H2O), Gibbsite (Al2O3,.), Diaspore
(Al2O3.H2O).
3. Fluoride: Cryolite (Na3AlF6)
4. Sulphate: Alunite [K2SO4.Al2(SO4)3.4Al(OH)3]
5. Aluminate: Spinel (MgO.Al2O3)
6. Silicates: Felspar (K2O.Al2O3.6SiO2), Chinaclay or kalolin
(Al2O3.2SiO2.2H2O).

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The Chief ore of aluminum is bauxite(Al2O3.2H2O)

⮚ Purifying the aluminum oxide-The Bayer Process

I. Reaction with sodium hydroxide solution

Crushed bauxite is treated with moderately concentrated sodium hydroxide

solution. The concentration, temperature and pressure used depend on the
source of the bauxite and exactly what form of aluminum oxide it contains.
Temperatures are typically from 140°C to 240°C; pressures can be up to about 35
atmospheres.

High pressures are necessary to keep the water in the sodium hydroxide
solution liquid at temperatures above 100°C. The higher the temperature, the
higher the pressure needed. With hot concentrated sodium hydroxide solution,
aluminum oxide reacts to give a solution of sodium tetrahydroxoaluminate.

𝐴𝑙2𝑂3. 2𝐻2𝑂 + 2𝑁𝑎𝑂𝐻 + 𝐻2𝑂 = 2𝑁𝑎𝐴𝑙(𝑂𝐻)4

The impurities in the bauxite remain as solids. For example, the other metal
oxides present tend not to react with the sodium hydroxide solution and so
remain unchanged. Some of the silicon dioxide reacts, but goes on to form a
sodium aluminosilicate which precipitates out.

All of these solids are separated from the sodium tetrahydroxoaluminate

solution by filtration. They form a "red mud" which is just stored in huge lagoons.

II. Precipitation of aluminum hydroxide

The sodium tetrahydroxoaluminate solution is cooled, then new aluminum

hydroxide was precipitated.

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𝑁𝑎𝐴𝑙(𝑂𝐻)4 = 𝐴𝑙(𝑂𝐻)3 + 𝑁𝑎𝑂𝐻

●
III. Formation of pure aluminum oxide

Aluminum oxide (sometimes known as alumina) is made by heating the

aluminum hydroxide to a temperature of about 1100 - 1200°C.

2𝐴𝑙(𝑂𝐻)3 = 𝐴𝑙2𝑂3 + 3𝐻2𝑂

⮚ Conversion of the aluminum oxide into aluminum by electrolysis

The aluminum oxide is electrolyzed in solution of molten cryolite, Na3AlF6.

Cryolite is another aluminum ore, but is rare and expensive, and most is now
made chemically.

I. The electrolysis cell

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The diagram shows a very simplified version of an electrolysis cell.

Raw materials for the electrolysis process:

● Bauxite ore of impure aluminum oxide (Al2O3 made up of Al3+ and O2- ions)
● Carbon (graphite) for the electrodes.
● Cryolite reduces the melting point of the ore and saves energy, because the
ions must be free to move to carry the current and less energy is needed to
melt the aluminum oxide obtained from the bauxite ore.
● Electrolysis means using DC electrical energy to bring about chemical
changes e.g. decomposition of a compound to form metal deposits or
release gases. The electrical energy splits the compound.
● At the electrolyte connections called the anode electrode (+, attracts - ions)
and the cathode electrode (-, attracts + ions). An electrolyte is a conducting
melt or solution of freely moving ions which carry the charge of the electric
current.

Although the carbon lining of the cell is labeled as the cathode, the effective
cathode is mainly the molten aluminum that forms on the bottom of the cell.
Molten aluminum is siphoned out of the cell from time to time, and new
aluminum oxide added at the top.

The cell operates at a low voltage of about 5-6 volts, but at huge currents of
100,000 amps or more. The heating effect of these large currents keeps the cell at
a temperature of about 1000°C.

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II. The electrode reactions

These are very complicated, I've looked at says that they aren't fully
understood. This is the simplification: Aluminum is released at the cathode.
Aluminum ions are reduced by gaining 3 electrons.
+3 −
𝐴𝑙 + 3𝑒 = 𝐴𝑙

Oxygen is produced initially at the anode.

−2 −
2𝑂 = 𝑂2 + 4𝑒

However, at the temperature of the cell, the carbon anodes burn in this oxygen
to give carbon dioxide and carbon monoxide. Continual replacement of the
anodes is a major expense.
−2 −
𝐴𝑛𝑜𝑑𝑒 𝐶 (𝑠) + 𝑂 (𝑚𝑒𝑙𝑡) = 𝐶𝑂 (𝑔) + 2𝑒

⮚ Uses of Aluminum

Pure aluminum isn't very strong, and alloying it adds to its strength. Aluminum
is usually alloyed with other elements such as silicon, copper or magnesium.

Aluminum is especially useful because it

● has a low density;

● is strong when alloyed;
● is a good conductor of electricity;
● has a good appearance;

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● resists corrosion because of the strong thin layer of aluminum oxide on its
surface. This layer can be strengthened further by anodizing the aluminum.

Anodizing essentially involves etching the aluminum with sodium hydroxide

solution to remove the existing oxide layer, and then making the aluminum article
the anode in an electrolysis of dilute sulphuric acid. The oxygen given of at the
anode reacts with the aluminum surface, to build up a film of oxide up to about
0.02 mm thick.

As well as increasing the corrosion resistance of the aluminum, this film is

porous at this stage and will also take up dyes. (It is further treated to make it
completely non-porous afterwards). That means that you can make aluminum
articles with the color built into the surface.

Some uses include:

Aluminum is used for Because

aircraft light, strong, resists corrosion
other transport such as ships'
superstructures, container vehicle bodies, light, strong, resists corrosion
tube trains (metro trains)
overhead power cables (with a steel core light, resists corrosion, good conductor
to strengthen them) of electricity
light, resists corrosion, good
saucepans
appearance, good conductor of heat

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