Inert Anode for the Primary Aluminum Industry 

The primary aluminum industry uses the Hall-Héroult process to produce aluminum. In this process, alumina is dissolved in molten cryolite and is then electrolytically decomposed. A carbon anode is consumed during the process, emitting large quantities of perfluorocarbons and CO2 which are significant greenhouse gases. Energy Research Company is developing the use of a novel inert anode to replace the consumable carbon anode. The result is the complete elimination of perfluorocarbons and CO2 emissions the combination of which leads to a greenhouse gas emissions reduction of 9.1 million metric tons of carbon equivalent in the US. Additionally, an energy reduction up to 25% would result, or 5.6 x 1010 kWhr annually. Operating costs reductions up to 10% and productivity improvements up to 5% will also occur.

In the USA the total primary aluminum market annual production was over 4 million metric tons for a value of $6.2 billion. Worldwide, the total primary aluminum annual sales are $37.2 billion.

The concept has been experimentally verified and its feasibility proven in a recently completed program in which nearly pure aluminum was made. The program was sponsored by the Office of Industrial technologies of DOE.

This project was initiated and managed by Energy Research Company (ERCo) with joint collaboration from CHEMIONIC/Rutgers University.

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