Simultaneous extraction of Al, Fe, Si to prepare aluminum-based intermediate alloys from secondary aluminum dross by a high temperature electrochemical reduction method
Year: 2025
Type: article
Abstract: A short-process technology integrating hydrolysis-calcination and molten salt electrolysis was developed to recover Al, Si, and Fe from secondary aluminum dross (SAD). Thermodynamic and characterization studies elucidated the reaction pathways, phase transformations during pretreatment, and the dissolution behavior, electrolytic mechanism, and element migration (Al, Si, Fe) of pretreated SAD (P-SAD) in cryolite molten salts, overcoming its poor solubility. The research results show that the presence of Al 2 O 3 can promote the recovery of the Si element, and optimized electrolysis (30 wt.% P-SAD, 1000 °C, 1 A/cm 2 , 3 h) produced an Al-alloy containing 1.2 wt. % Si and 0.9 wt. % Fe with 76.7 % current efficiency. Microstructural analysis showed an Al matrix with Al-Si and Al-Si-Fe intermetallic phases, exhibiting uniform Si distribution and localized Fe enrichment. This study provides systematic insights into the electrolytic recovery process for high-value SAD utilization.
Authors: Biao Zeng, Jian Chen, Zegang Wu, Jingjing Zhong, Mingzhuang Xie, Hongliang Zhao, Fengqin Liu
Institution: University of Science and Technology Beijing
Language: English
Subfield: Fluid Flow and Transfer Processes
Field: Chemical Engineering
Domain: Physical Sciences
Open Access status: hybrid
Estimated APC paid: $5,270
Award: G6134328279
OpenAlex ID: W4414325932