The present invention relates to a process for electrolytic production of aluminium from aluminium chloride, in an electrolysis cell with an electrolyte, where the aluminium chloride is produced by chlorination of an aluminium containing feedstock using chlorine gas and a carbonaceous reducing agent, CO and/or phosgene. The produced aluminium chloride is led to an absorption unit and partly absorbed by a molten salt liquid where some of the molten salt liquid in the absorption unit, enriched with aluminium chloride by the absorption, is transferred to the electrolysis cell wherein the aluminium chloride is electrolytically converted to aluminium metal and chlorine gas. The gases that are not absorbed by the liquid is led out of the absorption unit. The invention also relates to an apparatus for operating the process.

Integrated systems may be characterized by: (a) an aluminum production subsystem comprising an aluminum-producing electrolysis cell configured to electrolytically produce aluminum metal from an aluminum compound; and (b) a carbon dioxide reduction subsystem comprising a carbon dioxide electrolyzer, where the carbon dioxide reduction subsystem is configured to receive carbon dioxide produced by the aluminum production subsystem and provide the carbon dioxide to the carbon dioxide electrolyzer for reduction to a carbon-containing product.

Integrated systems may be characterized by: (a) an aluminum production subsystem comprising an aluminum-producing electrolysis cell configured to electrolytically produce aluminum metal from an aluminum compound; and (b) a carbon dioxide reduction subsystem comprising a carbon dioxide electrolyzer, where the carbon dioxide reduction subsystem is configured to receive carbon dioxide produced by the aluminum production subsystem and provide the carbon dioxide to the carbon dioxide electrolyzer for reduction to a carbon-containing product.

Systems and methods for feeding solid material and a gas into a container (e.g., electrolytic cell) are generally described. Certain methods comprise feeding solid material and a gas into an electrolytic cell through an inlet; wherein: the gas comprises an inert gas; and the inlet is positioned, relative to an anode of the electrolytic cell, within a distance that is less than or equal to 5 times the shortest cross-sectional dimension of the anode. Certain systems comprise a container configured for molten salt electrolysis; a passageway configured for feeding solid material and a gas into the container; an anode; a cathode; and an outlet configured for releasing a gas from the 10 container; wherein an inlet from the passageway to the container is positioned, relative to the anode, within a distance that is less than or equal to 5 times the shortest cross-sectional dimension of the anode.

Systems and methods for feeding solid material and a gas into a container (e.g., electrolytic cell) are generally described. Certain methods comprise feeding solid material and a gas into an electrolytic cell through an inlet; wherein: the gas comprises an inert gas; and the inlet is positioned, relative to an anode of the electrolytic cell, within a distance that is less than or equal to 5 times the shortest cross-sectional dimension of the anode. Certain systems comprise a container configured for molten salt electrolysis; a passageway configured for feeding solid material and a gas into the container; an anode; a cathode; and an outlet configured for releasing a gas from the 10 container; wherein an inlet from the passageway to the container is positioned, relative to the anode, within a distance that is less than or equal to 5 times the shortest cross-sectional dimension of the anode.

Apparatus and method for collecting and pretreating process gases produced in an electrolytic cell during aluminum production are disclosed. The apparatus comprises a collecting unit configured to draw off primary process gases from the electrolytic cell, for instance by drawing-off primary process gases from orifices purposely made over the electrolytic bath; and a pre-treating unit fluidly connected to the collecting unit and configured to receive a fluid bed of fluorinated alumina for pre-treating the primary process gases. The collecting and pre-treating units are within or immediately aside the electrolytic cell, in the potroom. The apparatus can be combine with a gas treatment center (GTC) located outside the potroom. Among other advantages, the technology allows collecting primary process gases directly at electrolytic bath level, separating primary process gases and hoodspace process gases to pretreat the primary process gases with alumina before the GTC, and using fluid bed reactors without filter bags.

Apparatus and method for collecting and pretreating process gases produced in an electrolytic cell during aluminum production are disclosed. The apparatus comprises a collecting unit configured to draw off primary process gases from the electrolytic cell, for instance by drawing-off primary process gases from orifices purposely made over the electrolytic bath; and a pre-treating unit fluidly connected to the collecting unit and configured to receive a fluid bed of fluorinated alumina for pre-treating the primary process gases. The collecting and pre-treating units are within or immediately aside the electrolytic cell, in the potroom. The apparatus can be combine with a gas treatment center (GTC) located outside the potroom. Among other advantages, the technology allows collecting primary process gases directly at electrolytic bath level, separating primary process gases and hoodspace process gases to pretreat the primary process gases with alumina before the GTC, and using fluid bed reactors without filter bags.

A carbo-chlorination process is disclosed for selectively producing AlCl.sub.3 from an alumina-containing feedstock, comprising introducing the following into a fluidized bed reactor maintained at 600-700 C.: (a) dried and calcined feed stream comprising the alumina-containing feedstock and a carbon feed; (b) chlorinating agent; (c) selectivity agent; (d) dried air; and optionally (e) off-spec AlCl.sub.3. The process further includes removing a vapor stream from the reactor in which preferably about 75-80%, of the alumina present in the reactor is converted to AlCl.sub.3; and also removing a solid raw pozzolan stream from the reactor, wherein about 90-99% of the silica present in the reactor remains unconverted and exits the reactor through the solid raw pozzolan stream. The vapor stream comprising AlCl.sub.3 is purified to create an AlCl.sub.3 product stream comprising preferably greater than about 99.99% AlCl.sub.3. The raw pozzolan product is classified to remove coke and create a final pozzolan product having a strength activity index (SAI) in the range of 80-160, per ASTM 618.

A carbo-chlorination process is disclosed for selectively producing AlCl.sub.3 from an alumina-containing feedstock, comprising introducing the following into a fluidized bed reactor maintained at 600-700 C.: (a) dried and calcined feed stream comprising the alumina-containing feedstock and a carbon feed; (b) chlorinating agent; (c) selectivity agent; (d) dried air; and optionally (e) off-spec AlCl.sub.3. The process further includes removing a vapor stream from the reactor in which preferably about 75-80%, of the alumina present in the reactor is converted to AlCl.sub.3; and also removing a solid raw pozzolan stream from the reactor, wherein about 90-99% of the silica present in the reactor remains unconverted and exits the reactor through the solid raw pozzolan stream. The vapor stream comprising AlCl.sub.3 is purified to create an AlCl.sub.3 product stream comprising preferably greater than about 99.99% AlCl.sub.3. The raw pozzolan product is classified to remove coke and create a final pozzolan product having a strength activity index (SAI) in the range of 80-160, per ASTM 618.

A carbo-chlorination process is disclosed for selectively producing AlCl.sub.3 from an alumina-containing feedstock, comprising introducing the following into a fluidized bed reactor maintained at 600-700 C.: (a) dried and calcined feed stream comprising the alumina-containing feedstock and a carbon feed; (b) chlorinating agent; (c) selectivity agent; (d) dried air; and optionally (e) off-spec AlCl.sub.3. The process further includes removing a vapor stream from the reactor in which preferably about 75-80%, of the alumina present in the reactor is converted to AlCl.sub.3; and also removing a solid raw pozzolan stream from the reactor, wherein about 90-99% of the silica present in the reactor remains unconverted and exits the reactor through the solid raw pozzolan stream. The vapor stream comprising AlCl.sub.3 is purified to create an AlCl.sub.3 product stream comprising preferably greater than about 99.99% AlCl.sub.3. The raw pozzolan product is classified to remove coke and create a final pozzolan product having a strength activity index (SAI) in the range of 80-160, per ASTM 618.