Norsk Hydro has patented a method for producing secondary aluminum through thermal processing. The process involves using carbon-containing scrap from electrolysis cells as fuel, which is crushed to a specific particle size, to thermally process aluminum-containing scrap in a rotary furnace, resulting in secondary aluminum production. GlobalData’s report on Norsk Hydro gives a 360-degree view of the company including its patenting strategy. Buy the report here.
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Method for producing secondary aluminium using scrap fuel
The granted patent US12043880B2 outlines a method for producing secondary aluminium through a thermal process that utilizes both aluminium-containing and carbon-containing scrap materials. The process begins with the provision of aluminium scrap, which may include dross or end-of-life aluminium, and carbon scrap sourced from electrolysis cells used in primary aluminium production. The carbon scrap is mechanically processed to create a scrap fuel with a specific particle size, which is then introduced into a rotary furnace. The thermal processing involves melting the aluminium scrap using energy generated from the combustion of the scrap fuel, which can be pneumatically transported into a burner flame or dispersed in a liquid fuel. The method emphasizes that at least 30% to 50% of the energy required for melting the aluminium is derived from the scrap fuel.
Additionally, the patent details various configurations and materials that can be incorporated into the process. For instance, the carbon scrap can originate from anodes or cathodes of the electrolysis cell, and the aluminium scrap may include fluorine-comprising bath material. The method allows for the adjustment of fluorine content in the rotary furnace by varying the ratio of bath material to other aluminium scrap. Furthermore, the process can include the introduction of chloride or fluoride salts, and off-gases from the melting process can be utilized for post-combustion in the burner. This closed-loop mass flow method not only enhances the efficiency of secondary aluminium production but also promotes the recycling of materials within the aluminium manufacturing industry.
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