Aluminum Extraction

The first step in obtaining aluminum is removing it from the earth through mining by which the
bauxite is then grinded into a powered form. Due to the reactivity of aluminum it is never found
naturally isolated in the earth, that is, it is bounded to other elements as compounds. Bauxite
(Al2O3 (S)) is the most common ore of aluminum containing oxides of silicon, titanium and iron as
impurities. The extraction of aluminum form its ore involves 3 steps:
(1) Purification of bauxite
(2) Electrolysis of alumina
(3) Refining of aluminum

(1) Purification of bauxite by leaching method

Leaching is a chemical method for the concentration of the ore. The ore is treated with a
suitable reagent in which the ore alone dissolves. The impurities are filtered off from the
solution and the ore is regenerated by precipitation.
The powdered ore of bauxite (Al2O3.2H2O (S)), is reacted with 45% sodium hydroxide
solution at 500 K and 35 atmospheric pressure. The bauxite forms a soluble sodium
aluminate and may form soluble sodium silicate.
Al2O3.2H2O + 2NaOH 2NaAlO2 + 3H2O
The solution is then filtered to remove insoluble impurities such as iron and titanium oxides.
This bauxite refining waste ( red mud) is highly alkaline and disposed of. The remaining
solution is then diluted with water and seeded with freshly precipitated aluminum hydroxide
Al(OH)3 , which induces the precipitation of aluminum hydroxide Al(OH)3 , from the
solution.
2NaAlO2 + 3H2O Al(OH)3 + NaOH
The solution is then filtered, washed, dried and heated at a temperature between 1100oC to
1200oC to give pure alumina Al(OH)3 while sodium silicate remains in the solution.
2Al(OH)3 Al2O3 + 3H2O

(2) Electrolysis of alumina

The alumina (Al2O3 ), is dissolved in a mixture containing mainly cryolite (Na3AlF3), with
fluorspar (CaF2), to lower the melting point. It is electrolysed in a rectangular steel container
lined with carbon which serves as a cathode and the anode comprise a set of thick carbon
rods made from baked bitumen suspended from the top into the fused alumina. At a high
temperature of the cell the anodes are oxidized quite rapidly by the oxygen given off and are
frequently replaced but, this is more economic anode than any other. This process is supplied
with a current of 120, 000 A and the temperature is kept between 1200 K to 1310 K. the
overall electrode reaction are:
At cathode: 2Al3+ + 6e- 2Al
At anode: 3O2- 1.5O2 + 6eAluminum formed at the cathode is collected at the bottom of the electrolytic cell where it is
periodically removed. The molten aluminum obtained by this method is 99% pure.

(3)Refining of aluminum
Further purification of aluminum is carried out by Hoopes electrolytic method. In Hoopes
electrolytic method of refining, three liquid layers with differing densities are used. The the
bottom layer is molten impure aluminum into which copper and silicon has been added to
increase its density. This molten layer is taken in a steel tank lined with carbon as the anode.
The electrolyte is a middle layer containing a molten mixture of AlF3, BaF2 and NaF. The
cathode is the upper layer containing pure molten aluminum above 99% . on electrolysis
aluminum dissolve at the anode and deposit at the cathode.

Hoopes electrolyte cell

Each mole of aluminum produced has a mass of only 27g but require 3 moles of electrons which
is approximately 300, 000 C. In order to produce large amounts of aluminum which are
demanded worldwide huge quantities of cheap electricity is necessary. Therefore, aluminum
production plants are usually sited on mountainous areas to make use of hydroelectric energy.

Environmental problems caused by the processes and waste involved in

the extraction of aluminum
(1)Mining and transporting of bauxite:

Extraction of bauxite from the earth, the strip mining process by which all native
vegetation in the mining region is removed resulting in the loss of habitat and food for
local wildlife as well as significant soil erosion. Also large amounts of chemicals are used

in processing resulting in air and noise pollution due to the grinding and transporting of
the bauxite.
(2)Extraction of aluminum from bauxite:

Loss of landscape due to the size of the chemical plant needed in the production and

transport of electricity.
Atmospheric pollution during the reduction of aluminum oxide to aluminum metal,
carbon dioxide from the burning of the anodes (greenhouse effect), carbon monoxide
(poisonous), fluorine and fluorine compounds lost from the cryolite during the
electrolysis process. These greenhouse gas emissions released during smelting and

processing have been found to blanket surrounding regions with toxic vapours.
Solid phase wastes which include bauxite refining waste (red mud) and reduction waste
from the refractory lining of the pots used to refine the aluminum are commonly
deposited into excavated mine pits where they ooze into aquifers contaminating local
water sources, grass lands and vegetation due to landslides, heavy tropical rains and
leakage.

(4)Landfills continue to be the resting place for large numbers of aluminum cans which, when
incinerated contaminate the air with toxic compounds and take up to 500 years to fully
decompose.

Solutions to environmental problems

(1) Reduction of air emissions from the mining and extraction of aluminum:

Particulates can be captured using air emission equipment to capture the

particulates which may be metal rich that is, if the metallic content is sufficient
the captured particulates can be re-melted to capture any remaining metals or it

may be otherwise reused or sold for its metallic content. If the dust collected is

not sufficiently metal rich then it should be landfilled.

The use of prebaked anodes which allow the electrolytic bath to be sealed,
allowing gas to be captured.

(2) Proper disposal of waste products from the extraction of aluminum:

The dumping site of red mud can be made more environmentally safe by use of
the dry disposal method, in which wet slurry undergoes several stages of filtration
and water is separated from it. Then the dry mud is disposed of at a pond site ( a
site which is built for the dumping of the red mud). The dry red mud is covered
by cotton soil and regularly water is sprinkled to prevent metallic dust pollution
in the air, livestock and crops around.

(3) Improving environmental performance:

It would be possible to make mining less destructive to the environment by

systematically examining environmental impacts and adopting measures to
mitigate these impacts.

Recommendations to environmental problems

(1) Recycling :

Raw materials and electrical energy can be saved by reducing the amount of
aluminum extracted from bauxite. Only 5% of energy is consumed with recycling
of aluminum as compared to producing virgin aluminum also, the quality is not
lost.

Avoids the environmental problems associated with the extraction of aluminum

from bauxite such as energy related emissions.

Dumping space for aluminum is not required and will therefore not emit toxic
compounds into the air by incineration at dumping sites.

(2) Economic measures:

Tax shifting can be introduced to provide incentives for practices like product

substitution and disincentives for poor environmental practices.

Tax measures to encourage a shift from mining virgin material to recycling.

(3) Legislation and regulations to reduce environmental impacts can be enacted

and enforced:

Governments can require mines to adopt increasing effective environmental

procedures and invoke penalties for failure to comply.

(4) Cleaning up abandoned mine sites:

Companies and government can be held accountable for abandoned mine sites
and be required to carry out an environmental cleanup.