Thermical™ technology represents a very significant breakthrough for the global aluminium industry. It has a number of key points of difference when compared with Alcoa/Elkem’s “ARP” process, including a number of critical elements:
1. In first stage of the process, Thermical™ technology efficiently produces highly reactive “charge” (i.e., Al2O3 intimately mixed with Al4C3, and entrained aluminium metal). This occurs without any CO production, unlike in the ARP process.
2. Then, in a second stage, the Thermical™ process undertakes solid-state reduction of the highly reactive charge to produce Al metal and CO - and it does so at a much lower operating temperature than does ARP.
3. As a result, the Thermical™ process -
• Dramatically
reduces Aluminium metal and Al2O vapour;
• Reduces refractory containment problems very significantly;
• Has a lower level of energy consumption;
• Handles the evolved CO gas in one stage; and,
• Has a much lower level of residual carbon in the Al product.
4. The diluent/carrier gas can either be an inert gas or a reactive hydrocarbon. If a hydrocarbon is used, then H2 by-production is achievable.
5. Power generation from the process is a major additional opportunity.
6. Aluminium
metal recycling can be conducted by using any of the following:
* Shredded aluminium
scrap;
* Shredded and/or granulated dross:
* Granulated aluminium (e.g., “UBC”s); and
* Granulated carbon
and/or different types of hydrocarbons
There are three key patent applications for the Thermical™ process. A book has been written encompassing all aspects of the technology/process. The requirements for the next stage of the Thermical™ process development have been fully identified, as has the broad scope of a semi-works plant scale development.