Bauxite Processing via Chloride Route to Produce Chloride Products and Subsequent Electrolysis of Aluminium Chloride to Produce Aluminium Metal

Based in Mumbai, India, Gharda Scientific Research Foundation (GSRF) is working to produce aluminium chloride and primary aluminium via carbochlorination of bauxite followed by electrolysis step. In this paper, a literature review of the chloride route based on published literature and concept proof experiments in various small setups are discussed. Bauxite was chlorinated with calcined petroleum coke in an externally heated small bubbling fluidized bed reactor. Aluminium chloride thus produced was purified by reductive distillation in a small setup and used for aluminium chloride electrolysis in a 50 L cell. The study aimed to generate scale up data for optimizing the chloride conversion, recovery and purity as well as electrolysis efficiency. The findings are used for process scale up to a kg scale setup and then to a larger demonstration plant. Presently, GSRF is operating a demonstration plant for carbochlorination of bauxite.