Abstract: The present disclosure concerns using microstructural engineering techniques to remove or reduce impurity elements from molten aluminum alloys, such as scrap. The impurities are removed by cooling molten aluminum, resulting in the formation of impurity-rich intermetallic compounds containing only one or more impurity elements as solid inclusions. Subsequent removal of impurity-rich intermetallic sediments by decantation, centrifuge, and filtration techniques can provide an economical method for removing the desired amount of impurities to meet the product specifications.

Abstract: Devices and methods for generating electricity in a direct carbon fuel cell are provided herein. The method includes heating and melting an alloy to obtain a liquid alloy anode; circulating the liquid alloy anode through a porous ceramic cathode, the cathode being a tubular structure and in communication with oxygen; reducing the oxygen at the porous cathode to obtain oxygen ions for diffusing through an electrolyte to the liquid alloy anode; and oxidizing the oxygen ions at the liquid alloy anode thereby generating electricity. The direct carbon fuel cells have high electronic conductivity, high carbon solubility with fast carbon diffusion, lower viscosity and eutectic temperatures, and rapid fuel dissolution kinetics.

Abstract: Devices and methods for generating electricity in a direct carbon fuel cell are provided herein. The method includes heating and melting an alloy to obtain a liquid alloy anode; circulating the liquid alloy anode through a porous ceramic cathode, the cathode being a tubular structure and in communication with oxygen; reducing the oxygen at the porous cathode to obtain oxygen ions for diffusing through an electrolyte to the liquid alloy anode; and oxidizing the oxygen ions at the liquid alloy anode thereby generating electricity. The direct carbon fuel cells have high electronic conductivity, high carbon solubility with fast carbon diffusion, lower viscosity and eutectic temperatures, and rapid fuel dissolution kinetics.

Abstract: A new method for the electrolytic production of aluminum, using a new electrolyte composition and low temperature operation, is provided. The electrolyte comprises a mixture of aluminum fluoride-potassium fluoride with from about 2 wt. % to 6 wt. % of alumina. The new electrolyte allows for the electrolytical reduction of alumina at temperatures as low as 700° C. The lower temperature allows for the use of inert anodes, and is conducive to the use of wetted cathodes. The new electrolyte mixture has a higher solubility for alumina and remains entirely liquid, even with 5 wt. % of alumina present in the electrolyte during electrolysis. Oxygen (O2) is the only gas generated during alumina electrolysis with the new electrolyte and the inert anodes, thus eliminating the production of greenhouse gases. Anodes and cathodes can be mounted in either a vertical, horizontal, or some other configuration.