Spent potlining material contains spent potliner from aluminium electrolysis cells, and at least one hydrophobic binder. The hydrophobic binder being selected from wax, a waxlike compound or mixtures thereof. A method for producing a spent potlining material includes the steps of (a) providing spent potliner from aluminium electrolysis cells, (b) comminuting the spent potliner in at least one comminuting apparatus, (c) fractionating the spent potliner through a separating apparatus, (d) mixing the spent potliner with at least one hydrophobic binder, selected from wax, a waxlike compound or mixtures thereof, in a mixing apparatus, (e) portioning the mixture obtained in step (d), (f) withdrawing the spent potlining material The steps (b) to (d) are carried out in an inert gas atmosphere. Also, spent potlining material is used as fuel in power stations and also in connection with the production of mineral wool, cement and steel.

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.

The invention relates to a method of providing an ore concentrate solution suitable for beneficiation processing, the method including the step of contacting an ore with one or more metal bases at elevated temperature. The one or more metal bases at elevated temperature may form a super-alkaline media that partially or fully dissolves the ore. Typically, the one or more metal bases are alkali metal bases, preferably chosen from lithium hydroxide, sodium hydroxide, potassium hydroxide, rubidium hydroxide or caesium hydroxide, or alkaline earth bases, preferably chosen from calcium hydroxide, barium hydroxide or strontium hydroxide. The one or more metal bases at elevated temperature may form a super-alkaline media that partially or fully dissolves the ore.

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.

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 method and system for producing cement using electrolysis is presented. Via an electric current, an electrolysis process may be performed on a melted oxide material, which may be anorthosite. Calcium oxide may be collected from the electrolysis process and mixed with silica and alumina to produce cement.

A method and system for producing cement using electrolysis is presented. Via an electric current, an electrolysis process may be performed on a melted oxide material, which may be anorthosite. Calcium oxide may be collected from the electrolysis process and mixed with silica and alumina to produce cement.

An integrated process contains the following steps of: (i) pyrolysis of hydrocarbons to carbon and hydrogen, (iia) removal of at least a part of the produced carbon in step (i) and at least partly further processing of said carbon into a carbon containing electrode, and (iib) removal of the hydrogen produced in step (i) and at least partly using said hydrogen for providing energy, preferably electric energy or heat, for the electrode production in step (iia). A joint plant is also useful, which contains (a) at least one reactor for a pyrolysis process, (b) at least one reactor for the production of electrodes for an aluminum process, (c) a power plant and/or at least one gas-fired burner, and optionally, (d) at least one reactor for the electrolysis for producing aluminum.