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The Hall–Héroult process is the major industrial process for smelting aluminium. It involves dissolving aluminium oxide (alumina) (obtained most often from bauxite , aluminium 's chief ore, through the Bayer process ) in molten cryolite and electrolyzing the molten salt bath, typically in a purpose-built cell.
Efforts to find industrial use for spent anodes have led to proposals to use the anodes as a cost-effective alternative for coke in small-scale foundries that lack a ready supply of coke, and cannot afford modern electric furnaces.
The Hall-Héroult electrolysis process is the major production route for primary aluminium. An electrolytic cell is made of a steel shell with a series of insulating linings of refractory materials. The cell consists of a brick-lined outer steel shell as a container and support. Inside the shell, cathode blocks are cemented together by ramming ...
The Hall-Héroult process for aluminium production from alumina was invented in 1886 by Charles Hall and Paul Héroult. [17] Carl Josef Bayer created a multi-step process to convert raw bauxite into alumina in 1888. [18] As aluminium production rose with the use of these two processes, aluminium recycling grew too.
The electrolysis reaction will produce molten pure iron as a main product and oxygen as its by-product. Because this process does not add coke in the process, no CO 2 gas is produced. So no direct greenhouse gas emission. Moreover, if the electricity to run such cells comes from renewable sources, this process may have zero emissions.
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The Cowles process was the immediate predecessor to the Hall-Héroult process—today in nearly universal use more than a century after it was discovered by Charles Martin Hall and Paul Héroult and adapted by others including Carl Josef Bayer. Because of the patent landscape, the Cowles companies found themselves in court.
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