Alternative Al production methods: Part 1 – a review of indirect carbothermal routes

The production of Al from its ores at present relies on the Bayer (alumina production) and the Hall–

Heroult (Al production) process. The cost associated with alumina production and apparent

disadvantages of the Hall–Heroult process have led to intensive research to find alternative routes

for Al production. The direct carbothermal reduction process has been thoroughly investigated as

an alternative technique. Another alternative includes the indirect carbothermal reduction route

where alumina (or aluminous ores) is first reduced to intermediate Al compounds before reduced

further to Al. The present study reviews and provides systematic thermodynamic analyses of

alternative Al production routes. In this paper (Part 1), a comprehensive review of alternative Al

production techniques focusing on the indirect carbothermal reduction routes is presented. These

include carbochlorination, carbonitridation and carbosulphidation routes for the formation of

intermediate Al compounds, followed by various Al extraction processes.