The Hall-Heroult Process

(STAGE 2)
• INPUT: Molten Aluminum Oxide or Alumina from Bayer Process

• OUTPUT: Molten Aluminum

• PROCESS: Electrolysis Process driven by electrical current

• Chemical Reaction : 2Al2O3 + 3C 4Al + 3CO2

The Hall-Heroult Process
• Alumina (Al2O3) is dissolved in a bath of electrolyte called Cryolite

• Cryolite is made up of Na3AlF6

• Anodes are made of carbon blocks

• Cathode is the carbon-lined Vessel

• Electrolysis takes place in a large carbon or graphite steel container called “Reduction
Pot” or “Cell”

• Uses only 5.25 V per pot but needs 100,000 – 320,000 amps

• Uses Direct Current or DC

The Chemical Reaction

Anode: Carbon
(positive electrode)
oxidation at anode
C(s) + 2O2-(l) → CO2(g) + 4e

Cathode: Carbon-lined
Vessel
(negative electrode) Al3+(l) + 3e → Al(l)
reduction at cathode

Overall Reaction: 2Al2O3(l) + 3C(s) → 4Al(l) + 3CO2(g)

Components for Hall-Heroult Process
The Hall-Heroult Process

• Liquid Aluminum or Molten Aluminum sinks at the bottom for it is denser

than the bath.

• Tapping is done to siphoned off the collected molten Aluminum.

• Silica, Water and Iron Oxides are considered to be impurities.

• Temperature reaches 950°C, use of cryolite

• Current efficiency is never 100% and 50% of electrical power goes to waste.
Pre-bake Cell VS. Soderberg Smelter

• Pre-bake Cell: SEVERAL single anodes made of carbon

• Soderberg Smelter: ONE huge anode made of carbon

• Pre-bake Cell: HIGHER Current Efficiency, LOWER Emissions and

LOWER Energy Consumption

• Soderberg Smelter: Require higher pot Voltage and Lower quantity

than that of Pre-Baked
Electrolyte Composition
Bath is composed of:
• AlF3; 10% to 13%
• Al2O3; 2.5% to 3.5%
• CaF2; 4% to 7%
• MgF2; 0% to 1%
• Rest is cryolite (Na3AlF6)
• Cryolite is used to dissolve oxides from the alumina
ELECTROLYTE PROPERTIES
1. Liquid Temperature (more additives, lower temperature)

2. Alumina Solubility (more additives, lower solubility)

3. Electrical Conductivity (CaF2, AlF3, MgF2, Al2O3 lowers conductivity)

4. Density (Al = 2.38 gr/cm³ and bath = 2.07 to 2.15 gr/cm³)

5. Viscosity (Increase in viscosity increases current efficiency)

6. Metal Solubility (Decrease aluminum from bath to increase efficiency)

7. Vapor Pressure (vapor pressure measures volatility)