How to Improve the Environmental Efficiency of the Hall-Heroult Process While Producing and Using Carbon Anodes

Koulumies, Antti; Becerra, Ana Maria; Paul, M.; Piechowiak, Lasse; Zapke, Martin

doi:10.1007/978-3-030-36408-3_159

Cited by 3 publications

(3 citation statements)

References 1 publication

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Most of the actual pyrometallurgical processes used in the industry are based on relatively mature technologies: the injection of natural gas and oil via the tuyeres of blast furnaces used for the production of pig iron has been introduced in the 1960s 12 ; prebaked carbon anodes used in Hall–Héroult cells for the primary production of aluminum have been developed since the 1920s 13 and the environmental efficiency of this process was discussed. 14 The Noranda process implemented in Quebec and originally designed for the primary production of copper from a copper sulfide concentrate has also been processing electronic waste material since the 1980s 15 ; electric arc furnaces used in steelmaking to melt DRI pellets and iron scrap with a specific power that can reach power of 1000 kVA/ton were already available in the 1980s. 16 …”

Section: Pyrometallurgical Operations: Current Statementioning

confidence: 99%

Greener reactants, renewable energies and environmental impact mitigation strategies in pyrometallurgical processes: A review

Harvey

Courchesne

et al. 2022

MRS Energy & Sustainability

View full text Add to dashboard Cite

Metals and alloys are among the most technologically important materials for our industrialized societies. They are the most common structural materials used in cars, airplanes and buildings, and constitute the technological core of most electronic devices. They allow the transportation of energy over great distances and are exploited in critical parts of renewable energy technologies. Even though primary metal production industries are mature and operate optimized pyrometallurgical processes, they extensively rely on cheap and abundant carbonaceous reactants (fossil fuels, coke), require high power heating units (which are also typically powered by fossil fuels) to calcine, roast, smelt and refine, and they generate many output streams with high residual energy content. Many unit operations also generate hazardous gaseous species on top of large CO2 emissions which require gas-scrubbing and capture strategies for the future. Therefore, there are still many opportunities to lower the environmental footprint of key pyrometallurgical operations. This paper explores the possibility to use greener reactants such as bio-fuels, bio-char, hydrogen and ammonia in different pyrometallurgical units. It also identifies all recycled streams that are available (such as steel and aluminum scraps, electronic waste and Li-ion batteries) as well as the technological challenges associated with their integration in primary metal processes. A complete discussion about the alternatives to carbon-based reduction is constructed around the use of hydrogen, metallo-reduction as well as inert anode electrometallurgy. The review work is completed with an overview of the different approaches to use renewable energies and valorize residual heat in pyrometallurgical units. Finally, strategies to mitigate environmental impacts of pyrometallurgical operations such as CO2 capture utilization and storage as well as gas scrubbing technologies are detailed. This original review paper brings together for the first time all potential strategies and efforts that could be deployed in the future to decrease the environmental footprint of the pyrometallurgical industry. It is primarily intended to favour collaborative work and establish synergies between academia, the pyrometallurgical industry, decision-makers and equipment providers. Graphical abstract Highlights A more sustainable production of metals using greener reactants, green electricity or carbon capture is possible and sometimes already underway. More investments and pressure are required to hasten change. Discussion Is there enough pressure on the aluminum and steel industries to meet the set climate targets? The greenhouse gas emissions of existing facilities can often be partly mitigated by retrofitting them with green technologies, should we close plants prematurely to build new plants using greener technologies? Since green or renewable resources presently have limited availability, in which sector should we use them to maximize their benefits?

show abstract

Section: Pyrometallurgical Operations: Current Statementioning

confidence: 99%

Greener reactants, renewable energies and environmental impact mitigation strategies in pyrometallurgical processes: A review

Harvey

Courchesne

et al. 2022

MRS Energy & Sustainability

View full text Add to dashboard Cite

show abstract

“…The low sulfur petcoke is used as graphitic carbon and as an anode in the metallurgical industry, whereas the high sulfur petcoke is rendered useless because of the high sulfur emission associated with its combustion. 5,6 As petcoke possesses higher carbon content and heating value as compared to coal, its combustion leads to the generation of a higher CO 2 emission per unit energy produced. 7,8 Consequently, energy generation through petcoke combustion is detrimental for the environment and the costs associated with the flue gas cleanup for sulfur and carbon capture render the use of petcoke as a fuel economically unattractive.…”

Section: Introductionmentioning

confidence: 99%

“…Depending on the amount of sulfur present, petcoke can be classified as low sulfur coke and high sulfur coke. The low sulfur petcoke is used as graphitic carbon and as an anode in the metallurgical industry, whereas the high sulfur petcoke is rendered useless because of the high sulfur emission associated with its combustion. , As petcoke possesses higher carbon content and heating value as compared to coal, its combustion leads to the generation of a higher CO 2 emission per unit energy produced. , Consequently, energy generation through petcoke combustion is detrimental for the environment and the costs associated with the flue gas cleanup for sulfur and carbon capture render the use of petcoke as a fuel economically unattractive. Alternatively, petcoke can be gasified to produce partial oxidation products including CO and H 2 (syngas), which serve as building blocks in the petrochemical industry to produce a large number of value-added products such as methanol, acetic acid, dimethyl ether, and other liquid hydrocarbons …”

Section: Introductionmentioning

confidence: 99%

Acetic Acid Production Using Calcium Ferrite-Assisted Chemical Looping Gasification of Petroleum Coke With In Situ Sulfur Capture

2020

View full text Add to dashboard Cite

The global market size for acetic acid is expected to increase at a high compounded annual growth rate over the next few years due to an increased demand from the end-users such as the automobile, furniture, and construction industries. One of the key factors driving the acetic acid production is methanol formation, which in turn depends on syngas generation. The process simulation and reactor modeling study presented here explores the use of a novel petcoke-to-syngas process for acetic acid production where the petcoke is subjected to chemical looping gasification (CLG) using calcium ferrite (Ca 2 Fe 2 O 5 ) as the oxygen carrier. The underlying thermodynamics of petcoke partial oxidation are studied through the assessment of parameters such as the syngas purity, carbon deposition, and S# (an indicator of the syngas quality) using computational simulations carried out in Aspen. The effect of natural gas and steam co-injection along with petcoke has also been studied while also focusing on regeneration of the reduced carrier using steam and CO 2 . As sulfur is an integral part of the petcoke stream, its interaction with the oxygen carrier has also been analyzed and a process configuration is reported that allows the production of a sulfur-free syngas stream. Process simulations reveal an increase in the exergy efficiency of syngas production, syngas yield per mol of carbon, and acetic acid yield per mol of carbon by 32% points, 50, and 14%, respectively, using the Ca 2 Fe 2 O 5 -assisted CLG process as opposed to the conventional petcoke gasification route, thus rendering acetic acid production using the CLG route economically attractive.

show abstract

Aluminum-Based Fuels as Energy Carriers for Controllable Power and Hydrogen Generation—A Review

et al. 2022

View full text Add to dashboard Cite

Metallic aluminum is widely used in propellants, energy-containing materials, and batteries due to its high energy density. In addition to burning in the air, aluminum can react with water to generate hydrogen. Aluminum is carbon-free and the solid-phase products can be recycled easily after the reaction. Micron aluminum powder is stable in the air and enables global trade. Aluminum metal is considered to be a viable recyclable carrier for clean energy. Based on the reaction characteristics of aluminum fuel in air and water, this work summarizes the energy conversion system of aluminum fuel, the combustion characteristics of aluminum, and the recycling of aluminum. The conversion path and application direction of electric energy and chemistry in the aluminum energy conversion system are described. The reaction properties of aluminum in the air are described, as well as the mode of activation and the effects of the aluminum-water reaction. In situ hydrogen production is achievable through the aluminum-water reaction. The development of low-carbon and energy-saving electrolytic aluminum technology is introduced. The work also analyzes the current difficulties and development directions for the large-scale application of aluminum fuel energy storage technology. The development of energy storage technology based on aluminum is conducive to transforming the energy structure.

show abstract

How to Improve the Environmental Efficiency of the Hall-Heroult Process While Producing and Using Carbon Anodes

Cited by 3 publications

References 1 publication

Greener reactants, renewable energies and environmental impact mitigation strategies in pyrometallurgical processes: A review

Greener reactants, renewable energies and environmental impact mitigation strategies in pyrometallurgical processes: A review

Acetic Acid Production Using Calcium Ferrite-Assisted Chemical Looping Gasification of Petroleum Coke With In Situ Sulfur Capture

Aluminum-Based Fuels as Energy Carriers for Controllable Power and Hydrogen Generation—A Review

Contact Info

Product

Resources

About