Thermodynamic Analysis for the Refining Ability of Salt Flux for Aluminum Recycling

A New Strategy on Designing Fluxes for Aluminum Alloy Melt Refinement

With the aim of obtaining a refining flux that is stable and provides effective refining of aluminum melt, a new strategy of designing the flux composition has been proposed. Ten fluxes were designed, by selecting ten molten salt compounds according to their thermophysical parameters, physical properties, and thermodynamic analysis. The melting points of the ten fluxes, and the phases transformation of the fluxes after melting, were studied by DSC and XRD, respectively. The contact angles between four groups of fluxes and alumina at refinement temperatures were studied, and the effect of refinement was characterized by a metallographic microscope. The process of the fluxes removing inclusions and degassing was analyzed thermodynamically. The research findings indicate that flux #10 (11.0 wt.%NaF, 29.5 wt.%NaCl, 46.5 wt.%Na₂CO₃, 3.0 wt.%CaF₂, 10.0 wt.%Na₃AlF₆) has a melting point (562.2 °C) below the refining temperature. At the refining temperature (760 °C), flux #10 has the lowest contact angle, of 12.78°. In addition, compared to that of flux STJ-A3, currently used in practice, flux #10 has a better refining effectiveness, with the pores and inclusions content of the sample being reduced to 1.11% from 2.96%.

A solid-state electrolysis process for upcycling aluminium scrap

The recycling of aluminium scrap today utilizing a remelting technique downgrades the quality of the aluminium and the final sink of this down-graded recycled aluminium is aluminium casting alloys^1-9. The predicted increase in demand for high grade aluminium as consumers choose battery-powered electric vehicles over internal combustion engine vehicles is expected to be accompanied by a drop in the demand for low-grade recycled aluminium, which is mostly used in the production of internal combustion engines^2,7,10,11. To meet the demand for high-grade aluminium in the future, a new aluminium recycling method capable of upgrading scrap to a level similar to that of primary aluminium is required^2-4,7,11. Here we propose a solid-state electrolysis (SSE) process using molten salts for upcycling aluminium scrap. The SSE produces aluminium with a purity comparable to that of primary aluminium from aluminium casting alloys. Moreover, the energy consumption of the industrial SSE is estimated to be less than half that of the primary aluminium production process. By effectively recycling aluminium scrap, it could be possible to consistently meet our demand for high grade aluminium. True sustainability in the aluminium cycle is foreseeable with the use of this efficient, low energy-consuming process.

Thermodynamic criteria of the end-of-life silicon wafers refining for closing the recycling loop of photovoltaic panels

The collected end-of-life (EoL) silicon wafers from the discharged photovoltaic (PV) panels are easily contaminated by impurities such as doping elements and attached materials. In this study, the thermodynamic criteria for EoL silicon wafers refining using three most typical metallurgical refining processes: oxidation refining, evaporation refining, and solvent refining were systemically and quantitatively evaluated. A total of 42 elements (Ag, Al, Au, B, Be, Bi, C, Ca, Ce, Co, Cr, Cu, Fe, Ga, Gd, Ge, Hf, In, La, Mg, Mn, Mo, Na, Nb, Ni, Os, P, Pb, Pd, Pt, Re, Ru, Sb, Sn, Ta, Ti, U, V, W, Y, Zn, Zr) that are likely to be contained in the collected EoL silicon-based PV panels were considered. The principal findings are that the removal of aluminum, beryllium, boron, calcium, gadolinium, hafnium, uranium, yttrium, and zirconium into the slag, and removal of antimony, bismuth, carbon, lead, magnesium, phosphorus, silver, sodium, and zinc into vapor phase is possible. Further, solvent refining process using aluminum, copper, and zinc as the solvent metals, among the considered 14 potential ones, was found to be efficient for the EoL silicon wafers refining. Particularly, purification of the phosphorus doped n-type PV panels using solvent metal zinc and purification of the boron doped p-type PV panels using solvent metal aluminum are preferable. The efficiency of metallurgical processes for separating most of the impurity elements was demonstrated, and to promote the recycling efficiency, a comprehensive management and recycling system considering the metallurgical criteria of EoL silicon wafers refining is critical.

Melt fluxing to elevate the forming ability of Al-based bulk metallic glasses

Salt-fluxing treatment is an effective technique to improve the glass-forming ability (GFA) of bulk metallic glass (BMG)-forming melts, as demonstrated before in Pd- and Fe-based systems. However, it has been challenging to develop similar fluxing protocol for more reactive melts, such as Al-rich BMG-forming systems. Here we design new fluxing agents, from a thermodynamics perspective that takes into account combined effects of physical absorption and chemical absorption (reaction) between the fluxing agents and oxide inclusions. MgCl₂-CaCl₂ composite salts were selected, and their fluxing effects were systematically studied on an Al₈₆Ni_6.75Co_2.25Y_3.25La_1.75 alloy, the best BMG-forming composition reported thus far for Al-rich alloy systems. The oxygen content was found to continuously decrease in the master alloy with increasing cycles of salt-fluxing treatment, with chlorate products on the surface suggesting concurrent physical absorption and chemical reaction. The fluxing treatment developed has enabled a record critical size (diameter) of 2.5 mm for Al-based BMGs. Our finding is thus an advance in developing highly desirable Al-based BMGs, and also provides guidance for designing processing protocol to produce larger-sized BMGs in other reactive systems.

Deriving the Metal and Alloy Networks of Modern Technology

Metals have strongly contributed to the development of the human society. Today, large amounts of and various metals are utilized in a wide variety of products. Metals are rarely used individually but mostly together with other metals in the form of alloys and/or other combinational uses. This study reveals the intersectoral flows of metals by means of input-output (IO) based material flow analysis (MFA). Using the 2007 United States IO table, we calculate the flows of eight metals (i.e., manganese, chromium, nickel, molybdenum, niobium, vanadium, tungsten, and cobalt) and simultaneously visualize them as a network. We quantify the interrelationship of metals by means of flow path sharing. Furthermore, by looking at the flows of alloys into metal networks, the networks of the major metals iron, aluminum, and copper together with those of the eight alloying metals can be categorized into alloyed-, nonalloyed-(i.e., individual), and both mixed. The result shows that most metals are used primarily in alloy form and that functional recycling thereby requires identification, separation, and alloy-specific reprocessing if the physical properties of the alloys are to be retained for subsequent use. The quantified interrelation of metals helps us consider better metal uses and develop a sustainable cycle of metals.