System and method for recycling aluminum scrap and related products

Abstract

The present invention is directed to a product and method for recycling aluminum scrap, the method including: (a) adding a feedstock including aluminum scrap to an aluminum refining cell, (b) purifying the feedstock to produce a refined aluminum stream and a raffinate stream, (c) separating components of the raffinate stream to produce at least a first by-product stream and a second by-product stream, and (d) combining at least a portion of the first by-product stream with at least a portion of the refined aluminum obtained from the refined aluminum stream to produce an aluminum alloy product.

Description

[Background technology]

[0001] REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 437,251, entitled "Systems and Methods of Recycling Aluminum Scrap and Associated Products," filed January 5, 2023, which is incorporated herein by reference in its entirety.

[0002] <Background> Aluminum metal has traditionally been produced by converting alumina (Al2O3), typically derived from bauxite ore. The conversion of alumina to aluminum is typically accomplished in an electrolytic cell by passing an electric current through an electrolyte containing alumina and cryolite. Carbon from the carbon anode reacts with oxygen in the alumina to produce carbon dioxide, which is discharged from the electrolytic cell, leaving molten aluminum as a by-product. The molten aluminum collects at the bottom of the electrolytic cell and is subsequently removed as relatively pure metallic aluminum. Various efforts have been made to purify metallic aluminum, including the "Hoopes process" (see U.S. Pat. No. 1,534,315) and the method described in commonly owned International Patent Application WO2016 / 130823. Summary of the Invention

[0003] <Summary of disclosure> Broadly, this disclosure relates to methods and systems for refining aluminum scrap in an aluminum refining cell, and products made therefrom. The continuous accumulation of impurities in aluminum scrap presents a challenge in aluminum recycling. Recycled aluminum scrap may only be usable for products with increasingly lower aluminum content. "Downcycling" to lower-value products results in products of decreasing purity and is an unsustainable process. While aluminum has high recyclability, there are currently no commercially viable processes that can remove unwanted impurities from aluminum scrap. This disclosure generally focuses on refining aluminum scrap so that it can be recycled without sacrificing the purity of the refined aluminum product. Aluminum recycling reduces energy consumption and carbon dioxide equivalent (CO ) emissions compared to traditional alumina smelting processes. 2e ) emissions can be reduced. In one embodiment, a closed loop process is used. In another embodiment, an open loop process is used.

[0004] In one embodiment, the method includes: (a) adding a feedstock containing aluminum scrap to an aluminum purification cell; (b) purifying the feedstock to produce a purified aluminum stream and a raffinate stream; (c) separating components of the raffinate stream to produce at least a first byproduct stream and a second byproduct stream; and (d) combining at least a portion of the first byproduct stream with at least a portion of the purified aluminum obtained from the purified aluminum stream to produce an aluminum alloy product. The produced aluminum alloy product has a predetermined composition and / or product morphology and is suitable for commercial use. In this manner, the aluminum scrap is refined and one or more of its constituent components are recycled to produce commercially usable products.

[0005] As described above, the method can include adding a feedstock to an aluminum purification cell. In some embodiments, the feedstock comprises at least 50% Al (aluminum) by weight. In one embodiment, the feedstock comprises at least 55% Al by weight. In another embodiment, the feedstock comprises at least 60% Al by weight. In yet another embodiment, the feedstock comprises at least 65% Al by weight. In another embodiment, the feedstock comprises at least 70% Al by weight. In yet another embodiment, the feedstock comprises at least 75% Al by weight. In another embodiment, the feedstock comprises at least 80% Al by weight. In yet another embodiment, the feedstock comprises at least 85% Al by weight. In another embodiment, the feedstock comprises at least 90% Al by weight. In yet another embodiment, the feedstock comprises at least 95% Al by weight. In another embodiment, the feedstock comprises at least 99% Al by weight. In yet another embodiment, the feedstock comprises at least 99.5% Al by weight.

[0006] In one embodiment, the raw material comprises 99.5% or less by weight of Al. In another embodiment, the raw material comprises 99% or less by weight of Al. In yet another embodiment, the raw material comprises 98% or less by weight of Al. In yet another embodiment, the raw material comprises 97% or less by weight of Al. In yet another embodiment, the raw material comprises 96% or less by weight of Al. In yet another embodiment, the raw material comprises 95% or less by weight of Al. In another embodiment, the raw material comprises 94% or less by weight of Al. In yet another embodiment, the raw material comprises 93% or less by weight of Al. In another embodiment, the raw material comprises 92% or less by weight of Al. In yet another embodiment, the raw material comprises 91% or less by weight of Al. In yet another embodiment, the raw material comprises 90% or less by weight of Al. In yet another embodiment, the raw material comprises 85% or less by weight of Al. In another embodiment, the raw material comprises 80% or less by weight of Al. In yet another embodiment, the raw material comprises 75% or less by weight of Al. In another embodiment, the raw material comprises 70% or less by weight of Al. In yet another embodiment, the raw material comprises 65% or less by weight of Al. In another embodiment, the raw material comprises 60% or less by weight of Al. In yet another embodiment, the feedstock comprises up to 55 wt% Al.

[0007] In one embodiment, the raw material contains 50 to 99 wt% Al. In another embodiment, the raw material contains 55 to 98 wt% Al. In yet another embodiment, the raw material contains 60 to 97 wt% Al. In another embodiment, the raw material contains 65 to 96 wt% Al. In yet another embodiment, the raw material contains 65 to 95 wt% Al.

[0008] In one embodiment, the raw material contains 5% by weight or less of alumina (Al2O3). In another embodiment, the raw material contains 4% by weight or less of alumina (Al2O3). In another embodiment, the raw material contains 3% by weight or less of alumina (Al2O3). In another embodiment, the raw material contains 2% by weight or less of alumina (Al2O3). In another embodiment, the raw material contains 1% by weight or less of alumina (Al2O3). In another embodiment, the raw material contains 0.5% by weight or less of alumina (Al2O3). In yet another embodiment, the raw material contains 0.25% by weight or less of alumina (Al2O3). In another embodiment, the raw material contains 0.1% by weight or less of alumina (Al2O3).

[0009] As noted above, the raw material can include aluminum scrap. The aluminum scrap can constitute part or all of the raw material. Therefore, the aluminum of the raw material can be based on the amount of aluminum in the aluminum scrap. In one embodiment, the aluminum scrap contains at least 5% Al by weight of the raw material (i.e., the aluminum content of the aluminum scrap accounts for at least 5% by weight of the total aluminum content of the raw material). In one embodiment, the aluminum scrap contains at least 10% Al by weight of the raw material. In another embodiment, the aluminum scrap contains at least 15% Al by weight of the raw material. In yet another embodiment, the aluminum scrap contains at least 20% Al by weight of the raw material. In another embodiment, the aluminum scrap contains at least 25% Al by weight of the raw material. In yet another embodiment, the aluminum scrap contains at least 30% Al by weight of the raw material. In another embodiment, the aluminum scrap contains at least 35% Al by weight of the raw material. In yet another embodiment, the aluminum scrap contains at least 40% Al by weight of the raw material. In another embodiment, the aluminum scrap contains at least 45% Al by weight of the raw material. In yet another embodiment, the aluminum scrap comprises at least 50% Al by weight of the raw material. In another embodiment, the aluminum scrap comprises at least 55% Al by weight of the raw material. In yet another embodiment, the aluminum scrap comprises at least 60% Al by weight of the raw material. In another embodiment, the aluminum scrap comprises at least 65% Al by weight of the raw material. In yet another embodiment, the aluminum scrap comprises at least 70% Al by weight of the raw material. In another embodiment, the aluminum scrap comprises at least 75% Al by weight of the raw material. In yet another embodiment, the aluminum scrap comprises at least 80% Al by weight of the raw material. In another embodiment, the aluminum scrap comprises at least 85% Al by weight of the raw material. In yet another embodiment, the aluminum scrap comprises at least 90% Al by weight of the raw material.In another embodiment, the aluminum scrap comprises at least 95% Al by weight of the raw material. In yet another embodiment, the aluminum scrap comprises at least 99% Al by weight of the raw material. In another embodiment, the aluminum scrap comprises at least 99.5% Al by weight of the raw material. In yet another embodiment, the aluminum scrap comprises at least 100% Al by weight of the raw material (i.e., the aluminum content of the aluminum scrap accounts for the entire aluminum content of the raw material).

[0010] As noted above, the method can include a purifying step (b), in which the feedstock is refined (e.g., in an aluminum refining cell) to produce a refined aluminum stream and a raffinate stream. In one embodiment, the purifying step includes passing an electric current through at least one anode and through an electrolytic cell to at least one cathode. In one embodiment, the density of the electrolyte is greater than the density of the aluminum to be refined. In one embodiment, the refined aluminum collects above the electrolyte. In one embodiment, the refined aluminum forms a refined aluminum layer. In one embodiment, the refined aluminum layer is positioned above the electrolyte in the aluminum refining cell.

[0011] The purified aluminum vapor typically contains more aluminum than the source material. In one aspect, the purified aluminum stream contains at least 95 wt. % Al and up to 99.999 wt. % Al. In one embodiment, the purified aluminum stream contains at least 95.5 wt. % Al. In another embodiment, the purified aluminum stream contains at least 96 wt. % Al. In yet another embodiment, the purified aluminum stream contains at least 96.5 wt. % Al. In another embodiment, the purified aluminum stream contains at least 97 wt. % Al. In yet another embodiment, the purified aluminum stream contains at least 97.5 wt. % Al. In another embodiment, the purified aluminum stream contains at least 98 wt. % Al. In yet another embodiment, the purified aluminum stream contains at least 98.5 wt. % Al. In another embodiment, the purified aluminum stream contains at least 99 wt. % Al. In yet another embodiment, the purified aluminum stream contains at least 99.5 wt. % Al. In another embodiment, the purified aluminum stream contains at least 99.75 wt. % Al. In yet another embodiment, the purified aluminum stream comprises at least 99.8 wt.% Al. In another embodiment, the purified aluminum stream comprises at least 99.85 wt.% Al. In yet another embodiment, the purified aluminum stream comprises at least 99.9 wt.% Al. In another embodiment, the purified aluminum stream comprises at least 99.95 wt.% Al.

[0012] As described above, the purification step can produce a raffinate stream. The raffinate stream generally contains less aluminum than the feedstock. In some embodiments, the raffinate stream contains 50 wt.% or less Al. In other embodiments, the raffinate stream contains 45 wt.% or less Al. In other embodiments, the raffinate stream contains 40 wt.% or less Al. In yet other embodiments, the raffinate stream contains 35 wt.% or less Al. In other embodiments, the raffinate stream contains 30 wt.% or less Al. In yet other embodiments, the raffinate stream contains 25 wt.% or less Al. In other embodiments, the raffinate stream contains 20 wt.% or less Al. In yet other embodiments, the raffinate stream contains 15 wt.% or less Al. In another embodiment, the raffinate stream contains 10 wt.% or less Al. In yet other embodiments, the raffinate stream contains 8 wt.% or less Al. In another embodiment, the raffinate stream contains 5 wt.% or less Al. In yet other embodiments, the raffinate stream contains 3 wt.% or less Al. In another embodiment, the raffinate stream comprises less than or equal to 1 wt. % Al.

[0013] In one embodiment, the raffinate stream comprises at least 3 wt% Si (silicon). In one embodiment, the raffinate stream comprises at least 3 wt% Fe (iron). In one embodiment, the raffinate stream comprises both at least 3 wt% Si and at least 3 wt% Fe. In one embodiment, the raffinate stream comprises 99 wt% or less Si. In another embodiment, the raffinate stream comprises 95 wt% or less Si. In one embodiment, the raffinate stream comprises 99 wt% or less Fe. In one embodiment, the raffinate stream comprises 95 wt% or less Fe.

[0014] As described above, the method includes (c) separating components of the raffinate stream to produce at least a first by-product stream and a second by-product stream. The method further includes (d) combining at least a portion of the first by-product stream with at least a portion of the purified aluminum obtained from the refined aluminum stream to produce an aluminum alloy product. In some embodiments, the aluminum alloy product has a composition identical to one of the 1xxx-8xxx aluminum alloys defined in the Aluminum Association's "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys." In some embodiments, the present disclosure relates to a method in which the aluminum alloy product has a composition identical to one of the 1xx-8xx aluminum alloys defined in the Aluminum Association's "Designations and Chemical Composition Limits for Aluminum Alloys in the Form of Castings and Ingots."

[0015] In one embodiment, at least a portion of the first by-product stream is used in combination with the purified aluminum vapor to produce the aluminum alloy product. In one embodiment, most or all of the first by-product stream is combined with the purified aluminum stream to produce the aluminum alloy product.

[0016] Additional by-product streams can also be combined with the refined aluminum stream to produce an aluminum alloy product. In one embodiment, portions of both the first and second by-product streams are combined with the refined aluminum stream to produce an aluminum alloy product. In another embodiment, a portion of the first by-product stream is combined with a portion of the refined aluminum stream to produce a first aluminum alloy product. In this regard, a portion of the second by-product stream can be combined with a portion of the refined aluminum stream to produce a second aluminum alloy product having a different composition than the first aluminum alloy product. Similar principles apply to third and subsequent by-product streams. This allows a variety of customized aluminum alloy product compositions to be produced from aluminum scrap.

[0017] The by-product streams can include, for example, one or more of silicon, iron, zinc, copper, and manganese. In one embodiment, the first by-product stream and / or the second by-product stream can include at least 12 wt.% Si, at least 3 wt.% Mn, at least 3 wt.% Fe, and combinations thereof. In one embodiment, the first by-product stream and / or the second by-product stream can include at least 5% of at least one of Si, Mn, Fe, Zn, Cu, and combinations thereof.

[0018] In addition to or instead of using the first by-product stream, the method may include using an additional component to facilitate production of a predetermined aluminum alloy product. In one embodiment, the method includes mixing an additional component with the refined aluminum stream to facilitate production of the aluminum alloy product. In one embodiment, the additional component includes at least one of Si, Fe, Cu, Ce, Cs, Mg, Mn, Cr, Ni, Zn, Ti, Co, Sn, Sr, Li, V, Zr, Sc, and combinations thereof. In one embodiment, the additional component includes one or more of aluminum scrap alloys, i.e., scrap containing aluminum alloys.

[0019] The first by-product stream and / or the precursor stream can be used to facilitate production of the feedstock. In one embodiment, the method can include adding at least one of the first by-product stream and / or the second by-product stream to the precursor stream to produce the feedstock.

[0020] In one embodiment, the method includes adding a predetermined metal to the precursor flow. In one embodiment, the predetermined metal is at least one of Si, Fe, Cu, Ce, Cs, Mg, Mn, Cr, Ni, Zn, Ti, Co, Sn, Sr, Li, V, Zr, Sc, and combinations thereof. In one embodiment, the predetermined metal is at least one of Cu, Ce, Cs, Sn, Zn, or combinations thereof. In one embodiment, the predetermined metal is Cu.

[0021] The produced aluminum alloy products can be in any suitable form, such as ingots, billets, powders, wires, ribbons, etc. Suitable wrought products (foils, sheets, plates, forgings, extrusions), shaped cast products (e.g., die cast products), and additively manufactured products (e.g., 3D printed products) can be produced from the aluminum alloy products.

[0022] Although the embodiments disclosed herein generally relate to the purification of aluminum, it is anticipated that embodiments of the present disclosure may also be applicable to the purification of other elements and / or compounds. For example, embodiments of the present disclosure may alternatively or additionally relate to the purification of magnesium. In some embodiments, the disclosed systems, apparatus, and / or methods relate to magnesium purification cells for producing purified magnesium from magnesium feedstock. The above embodiments are exemplary embodiments of the disclosed apparatus, system, or method and are not intended to limit the scope thereof, as the disclosed apparatus, system, and method are contemplated in other equally effective embodiments. [Brief explanation of the drawings]

[0023] [Figure 1] FIG. 1 illustrates one embodiment of a method for purifying a feedstock.

[0024] [Figure 2] FIG. 2 shows one embodiment of a process flow diagram according to the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0025] <Detailed explanation> Referring to FIG. 1 , one non-limiting embodiment of a method 100 for refining a feedstock is disclosed. Step 110 includes adding a feedstock to an aluminum purification cell. Step 120 includes purifying the feedstock through the aluminum purification cell. Step 120 includes producing a purified aluminum stream and a raffinate stream. Step 130 includes extracting the purified aluminum stream. Step 140 includes extracting the raffinate stream. Step 150 (optional) includes separating the raffinate stream into by-product streams. Step 160 (optional) includes combining the purified aluminum stream (e.g., the stream extracted in step 130) with at least one by-product stream (e.g., a by-product stream separated from the purified raffinate extracted in step 140) to produce a predetermined aluminum alloy product stream. In FIG. 1 , dashed boxes indicate that some steps are optional.

[0026] As used herein, "aluminum feedstock" refers to a feedstock suitable for producing purified aluminum in an aluminum refining cell. The aluminum feedstock can have any suitable aluminum content. Typically, the aluminum feedstock has at least 50 wt. % aluminum, although lesser amounts of aluminum can be used in some embodiments (e.g., at least 25 wt. % Al). In some embodiments, the aluminum feedstock includes aluminum and at least one other metal (e.g., one or more of Si, Fe, Cu, Ce, Cs, Mg, Mn, Cr, Ni, Zn, Ti, Co, Sn, Sr, Li, V, Zr, Sc). In some embodiments, the aluminum feedstock includes a transition metal. In some embodiments, the aluminum feedstock is substantially free of alumina (Al2O3) as described herein.

[0027] As used herein, "purified aluminum" means a material having at least 95% aluminum by weight.

[0028] FIG. 2 shows an exemplary flowchart of a process 200 according to some embodiments of the present disclosure. In the illustrated embodiment, process 200 includes adding a feedstock 210 to a refining cell 212. In some embodiments, refining cell 212 is an aluminum refining cell. In some embodiments, feedstock 210 includes aluminum scrap. Feedstock 210 can be refined by refining cell 212. After refining, refining cell 212 produces a refined aluminum stream 214 and a raffinate stream 216. Refined aluminum stream 214 is collected as refined aluminum product 250. Raffinate stream 216 can include impurities and / or other components not included in the refined aluminum stream. Raffinate stream 216 can be separated into one or more by-product streams (220, 222, 224). A by-product stream (eg, first by-product stream 220) from raffinate stream 216 is mixed with refined aluminum stream 214 to form a predetermined aluminum alloy product (eg, first predetermined aluminum alloy product 232).

[0029] In some embodiments, feedstock 210 can be fed to purification cell 212. In some embodiments, feedstock 210 is fed to purification cell 212 without modification (e.g., the feedstock is not mixed with other streams before being introduced into purification cell 212). The feedstock can be obtained from an external source or can be obtained as a result of the operation of the purification cell. In some embodiments, at least a portion of feedstock 210 is precursor 242. In other embodiments, at least a portion of feedstock 210 is recycled raffinate.

[0030] The feedstock 210 is fed to the refinery cell in an amount necessary to produce the refined aluminum product. In some embodiments, adding the feedstock 210 to the refinery cell 212 comprises continuously feeding the feedstock 210 while the refinery cell 212 is running. In some embodiments, adding the feedstock 210 to the refinery cell 212 comprises periodically or intermittently adding the feedstock 210 to the refinery cell 212. In some embodiments, adding the feedstock 210 to the refinery cell 212 comprises metering and feeding the feedstock 210 to the refinery cell 212 at a first feed rate. The first feed rate may be maintained constant or may vary and may include stopping and starting the feed of the feedstock 210 to the refinery cell 212.

[0031] Process 200 can include adding a by-product stream (e.g., first by-product stream 220) to feedstock 210 and prior to introduction into purification cell 212. In some embodiments, process 200 includes adding at least one of first by-product stream 220, second by-product stream 222, and / or third by-product stream 224 to precursor 242 to produce feedstock 210. While three by-product streams are illustrated, it will be understood that any number of by-product streams can be used. Typically, at least two by-product streams are used.

[0032] In some embodiments, feedstock 210 can be prepared by mixing 240 at least two streams. In some embodiments, at least a portion of feedstock 210 can be prepared by mixing at least two of the following streams: precursor 242, additional component 244, recycled raffinate 246, by-product stream (e.g., first by-product stream 220), or any combination thereof. In other embodiments, feedstock 210 is used without being mixed with other sources.

[0033] In some embodiments, additional component 244 includes a metal. In some embodiments, process 200 includes adding one or more predetermined metals to precursor 242 to produce at least a portion of feedstock 210. In some embodiments, the predetermined metal is at least one of Si, Fe, Cu, Ce, Cs, Mg, Mn, Cr, Ni, Zn, Ti, Co, Sn, Sr, Li, V, Zr, Sc, and combinations thereof. In some embodiments, the predetermined metal is at least one of Cu, Ce, Cs, Sn, Zn, and combinations thereof. In some embodiments, the predetermined metal includes at least Cu. Precursor 242 may be the same composition as that of feedstock 210, as described herein.

[0034] In some embodiments, feedstock 210 comprises at least 50% Al by weight. In one embodiment, feedstock 210 comprises at least 55% Al by weight. In another embodiment, feedstock 210 comprises at least 60% Al by weight. In yet another embodiment, feedstock 210 comprises at least 65% Al by weight. In another embodiment, feedstock 210 comprises at least 70% Al by weight. In yet another embodiment, feedstock 210 comprises at least 75% Al by weight. In another embodiment, feedstock 210 comprises at least 80% Al by weight. In yet another embodiment, feedstock 210 comprises at least 85% Al by weight. In another embodiment, feedstock 210 comprises at least 90% Al by weight. In yet another embodiment, feedstock 210 comprises at least 95% Al by weight. In another embodiment, feedstock 210 comprises at least 99% Al by weight. In yet another embodiment, feedstock 210 comprises at least 99.5% Al by weight.

[0035] In one embodiment, feedstock 210 comprises 99.5% or less by weight Al. In another embodiment, feedstock 210 comprises 99% or less by weight Al. In yet another embodiment, feedstock 210 comprises 98% or less by weight Al. In another embodiment, feedstock 210 comprises 97% or less by weight Al. In another embodiment, feedstock 210 comprises 96% or less by weight Al. In another embodiment, feedstock 210 comprises 95% or less by weight Al. In another embodiment, feedstock 210 comprises 94% or less by weight Al. In yet another embodiment, feedstock 210 comprises 93% or less by weight Al. In another embodiment, feedstock 210 comprises 92% or less by weight Al. In yet another embodiment, feedstock 210 comprises 91% or less by weight Al. In another embodiment, feedstock 210 comprises 90% or less by weight Al. In yet another embodiment, feedstock 210 comprises 85% or less by weight Al. In another embodiment, feedstock 210 comprises 80% or less by weight Al. In yet another embodiment, feedstock 210 comprises 75% or less by weight Al. In another embodiment, feedstock 210 comprises 70% or less by weight Al. In yet another embodiment, feedstock 210 comprises 65% or less by weight Al. In another embodiment, feedstock 210 comprises 60% or less by weight Al. In yet another embodiment, feedstock 210 comprises 55% or less by weight Al.

[0036] In one embodiment, feedstock 210 comprises 50-99 wt% Al. In another embodiment, feedstock 210 comprises 55-98 wt% Al. In yet another embodiment, feedstock 210 comprises 60-97 wt% Al. In another embodiment, feedstock 210 comprises 65-96 wt% Al. In yet another embodiment, feedstock 210 comprises 65-95 wt% Al.

[0037] In one embodiment, feedstock 210 comprises 5% by weight or less of alumina (Al2O3). In another embodiment, feedstock 210 comprises 4% by weight or less of alumina (Al2O3). In yet another embodiment, feedstock 210 comprises 3% by weight or less of alumina (Al2O3). In another embodiment, feedstock 210 comprises 2% by weight or less of alumina (Al2O3). In yet another embodiment, feedstock 210 comprises 1% by weight or less of alumina (Al2O3). In another embodiment, feedstock 210 comprises 0.5% by weight or less of alumina (Al2O3). In yet another embodiment, feedstock 210 comprises 0.25% by weight or less of alumina (Al2O3). In another embodiment, feedstock 210 comprises 0.1% by weight or less of alumina (Al2O3).

[0038] The feedstock 210 may contain impurities. In some embodiments, the impurities in the feedstock 210 may include Si, Fe, Cu, Ce, Cs, Mg, Mn, Cr, Ni, Zn, Ti, Co, Sn, Sr, Li, V, Zr, ScCr, Cu, Fe, Mg, Mn, Ni, Si, Ti, Zn, and combinations thereof. In some embodiments, the impurities in the feedstock 210 may include Cr, Cu, Fe, Mg, Mn, Ni, Si, Ti, Zn, and combinations thereof. In some embodiments, the feedstock 210 may contain aluminum and up to 2% Mg by weight, as well as other impurities. In some embodiments, the feedstock 210 contains between 0.5% and 50.0% impurities by weight of the feedstock 210. In some embodiments, the feedstock 210 contains between 5.0% and 50.0% impurities by weight of the feedstock 210. In some embodiments, the feedstock 210 contains impurities between 10.0% and 50.0% by weight of the feedstock 210. In some embodiments, the feedstock 210 contains impurities between 15.0% and 50.0% by weight of the feedstock 210. In some embodiments, the feedstock 210 contains impurities between 20.0% and 50.0% by weight of the feedstock 210. In some embodiments, the feedstock 210 contains impurities between 25.0% and 50.0% by weight of the feedstock 210. In some embodiments, the feedstock 210 contains impurities between 30.0% and 50.0% by weight of the feedstock 210. In some embodiments, the feedstock 210 contains impurities between 35.0% and 50.0% by weight of the feedstock 210. In some embodiments, the aluminum feedstock 210 contains impurities between 40.0% and 50.0% by weight of the feedstock 210. In some embodiments, feedstock 210 contains 45.0% to 50.0% impurities by weight of feedstock 210. In some embodiments, feedstock 210 contains 0.5% to 45.0% impurities by weight of feedstock 210. In some embodiments, feedstock 210 contains 0.5% to 40.0% impurities by weight of feedstock 210. In some embodiments, feedstock 210 contains 0.5% to 35.0% impurities by weight of feedstock 210. In some embodiments, feedstock 210 contains 0.5% to 30.0% impurities by weight of feedstock 210. In some embodiments, feedstock 210 contains 0.5% to 25.0% impurities by weight of feedstock 210.In some embodiments, feedstock 210 comprises impurities in an amount between 0.5% and 20.0% by weight of feedstock 210. In some embodiments, feedstock 210 comprises impurities in an amount between 0.5% and 15.0% by weight of feedstock 210. In some embodiments, feedstock 210 comprises impurities in an amount between 0.5% and 10.0% by weight of feedstock 210. In some embodiments, feedstock 210 comprises impurities in an amount between 0.5% and 5.0% by weight of feedstock 210.

[0039] In some embodiments, the feedstock 210 comprises aluminum scrap. In some embodiments, the aluminum scrap is aluminum alloy scrap, i.e., scrap comprising, consisting essentially of, or consisting of one or more aluminum alloys. In some embodiments, the aluminum alloy scrap comprises at least one of 1xxx-8xxx aluminum alloys and combinations thereof. In one embodiment, the aluminum alloy scrap comprises at least 1xxx series aluminum alloy scrap. In another embodiment, the aluminum alloy scrap comprises at least 2xxx series aluminum alloy scrap. In yet another embodiment, the aluminum alloy scrap comprises at least 3xxx series aluminum alloy scrap. In another embodiment, the aluminum alloy scrap comprises at least 4xxx series aluminum alloy scrap. In yet another embodiment, the aluminum alloy scrap comprises at least 5xxx series aluminum alloy scrap. In another embodiment, the aluminum alloy scrap comprises at least 6xxx series aluminum alloy scrap. In yet another embodiment, the aluminum alloy scrap comprises at least 7xxx series aluminum alloy scrap. In another embodiment, the aluminum alloy scrap includes at least 8xxx series aluminum alloy scrap.

[0040] In some embodiments, the aluminum alloy scrap comprises at least one of 1xx-8xx aluminum alloys or combinations thereof. In one embodiment, the aluminum alloy scrap comprises at least 1xx series aluminum alloy scrap. In another embodiment, the aluminum alloy scrap comprises at least 2xx series aluminum alloy scrap. In yet another embodiment, the aluminum alloy scrap comprises at least 3xx series aluminum alloy scrap. In another embodiment, the aluminum alloy scrap comprises at least 4xx series aluminum alloy scrap. In yet another embodiment, the aluminum alloy scrap comprises at least 5xx series aluminum alloy scrap. In yet another embodiment, the aluminum alloy scrap comprises at least 7xx series aluminum alloy scrap. In another embodiment, the aluminum alloy scrap comprises at least 8xx series aluminum alloy scrap.

[0041] In some embodiments, the aluminum scrap in the methods of the present disclosure comprises at least 5% Al by weight of feedstock 210 (i.e., the aluminum content of the aluminum scrap accounts for at least 5% by weight of the total aluminum content of feedstock 210). In one embodiment, the aluminum scrap comprises at least 10% Al by weight of feedstock 210. In another embodiment, the aluminum scrap comprises at least 15% Al by weight of feedstock 210. In yet another embodiment, the aluminum scrap comprises at least 20% Al by weight of feedstock 210. In another embodiment, the aluminum scrap comprises at least 25% Al by weight of feedstock 210. In yet another embodiment, the aluminum scrap comprises at least 30% Al by weight of feedstock 210. In another embodiment, the aluminum scrap comprises at least 35% Al by weight of feedstock 210. In yet another embodiment, the aluminum scrap comprises at least 40% Al by weight of feedstock 210. In another embodiment, the aluminum scrap comprises at least 45% Al by weight of feedstock 210. In yet another embodiment, the aluminum scrap comprises at least 50% Al by weight of the feedstock 210. In another embodiment, the aluminum scrap comprises at least 55% Al by weight of the feedstock 210. In yet another embodiment, the aluminum scrap comprises at least 60% Al by weight of the feedstock 210. In another embodiment, the aluminum scrap comprises at least 65% Al by weight of the feedstock 210. In yet another embodiment, the aluminum scrap comprises at least 70% Al by weight of the feedstock 210. In another embodiment, the aluminum scrap comprises at least 75% Al by weight of the feedstock 210. In yet another embodiment, the aluminum scrap comprises at least 80% Al by weight of the feedstock 210. In another embodiment, the aluminum scrap comprises at least 85% Al by weight of the feedstock 210. In yet another embodiment, the aluminum scrap comprises at least 90% Al by weight of the feedstock 210. In another embodiment, the aluminum scrap comprises at least 95% Al by weight of the feedstock 210.In yet another embodiment, the aluminum scrap comprises at least 99% Al by weight of the feedstock 210. In another embodiment, the aluminum scrap comprises at least 99.5% Al by weight of the feedstock 210. In yet another embodiment, the aluminum scrap comprises at least 100% Al by weight of the feedstock 210 (i.e., the Al content of the aluminum scrap accounts for all of the Al content of the feedstock 210).

[0042] In some embodiments, additional elements 244, such as additives (e.g., Cu, Ce, Cs, Sn, Zn, and combinations thereof), may be added to feedstock 210 to increase or maintain its density. These elements may be at least partially useful in retaining or maintaining the metals of feedstock 210 in the molten metal pad at or near the bottom of refining cell 212.

[0043] In some embodiments, feedstock 210 includes at least copper. In these embodiments, feedstock 210 includes at least 1% Cu by weight, and can include up to 50% Cu by weight. In one embodiment, feedstock 210 includes at least 5% Cu by weight. In another embodiment, feedstock 210 includes at least 10% Cu by weight. In yet another embodiment, feedstock 210 includes at least 15% Cu by weight. In another embodiment, feedstock 210 includes at least 20% Cu by weight. In yet another embodiment, feedstock 210 includes at least 25% Cu by weight. In another embodiment, feedstock 210 includes at least 30% Cu by weight. In yet another embodiment, feedstock 210 includes at least 35% Cu by weight. In another embodiment, feedstock 210 includes at least 40% Cu by weight. In yet another embodiment, feedstock 210 includes at least 45% Cu by weight.

[0044] In some embodiments, feedstock 210 includes at least cerium. In these embodiments, feedstock 210 includes at least 1 wt% Ce and can include up to 50 wt% Ce. In one embodiment, feedstock 210 includes at least 5 wt% Ce. In another embodiment, feedstock 210 includes at least 10 wt% Ce. In yet another embodiment, feedstock 210 includes at least 15 wt% Ce. In another embodiment, feedstock 210 includes at least 20 wt% Ce. In yet another embodiment, feedstock 210 includes at least 25 wt% Ce. In another embodiment, feedstock 210 includes at least 30 wt% Ce. In yet another embodiment, feedstock 210 includes at least 35 wt% Ce. In another embodiment, feedstock 210 includes at least 40 wt% Ce. In yet another embodiment, feedstock 210 includes at least 45 wt% Ce.

[0045] In some embodiments, feedstock 210 includes at least cesium. In these embodiments, feedstock 210 includes at least 1% Cs by weight and up to 50% Cs by weight. In one embodiment, feedstock 210 includes at least 5% Cs by weight. In another embodiment, feedstock 210 includes at least 10% Cs by weight. In yet another embodiment, feedstock 210 includes at least 15% Cs by weight. In another embodiment, feedstock 210 includes at least 20% Cs by weight. In yet another embodiment, feedstock 210 includes at least 25% Cs by weight. In another embodiment, feedstock 210 includes at least 30% Cs by weight. In yet another embodiment, feedstock 210 includes at least 35% Cs by weight. In another embodiment, feedstock 210 includes at least 40% Cs by weight. In yet another embodiment, feedstock 210 includes at least 45% Cs by weight.

[0046] In some embodiments, feedstock 210 includes at least tin. In these embodiments, feedstock 210 includes at least 1 wt% Sn, and can include up to 50 wt% Sn. In one embodiment, feedstock 210 includes at least 5 wt% Sn. In another embodiment, feedstock 210 includes at least 10 wt% Sn. In yet another embodiment, feedstock 210 includes at least 15 wt% Sn. In another embodiment, feedstock 210 includes at least 20 wt% Sn. In yet another embodiment, feedstock 210 includes at least 25 wt% Sn. In another embodiment, feedstock 210 includes at least 30 wt% Sn. In yet another embodiment, feedstock 210 includes at least 35 wt% Sn. In another embodiment, feedstock 210 includes at least 40 wt% Sn. In yet another embodiment, feedstock 210 includes at least 45 wt% Sn.

[0047] In some embodiments, feedstock 210 comprises at least copper. In these embodiments, feedstock 210 comprises at least 1 wt. % Zn, and can comprise up to 50 wt. % Zn. In one embodiment, feedstock 210 comprises at least 5 wt. % Zn. In another embodiment, feedstock 210 comprises at least 10 wt. % Zn. In yet another embodiment, feedstock 210 comprises at least 15 wt. % Zn. In another embodiment, feedstock 210 comprises at least 20 wt. % Zn. In yet another embodiment, feedstock 210 comprises at least 25 wt. % Zn. In another embodiment, feedstock 210 comprises at least 30 wt. % Zn. In yet another embodiment, feedstock 210 comprises at least 35 wt. % Zn. In another embodiment, feedstock 210 comprises at least 40 wt. % Zn. In yet another embodiment, feedstock 210 comprises at least 45 wt. % Zn.

[0048] In some embodiments, refined aluminum stream 214 is not mixed with any additional fluids. Refined aluminum stream 214 may be the same as refined aluminum product 250. In some embodiments, additional components (e.g., additional component 238 or additional component 244) are mixed with refined aluminum stream 214 to produce refined aluminum product 250 and / or aluminum alloy product 236.

[0049] In some embodiments, the refined aluminum product 250 comprises at least 95 wt% Al and up to 99.999 wt% Al. In some embodiments, the refined aluminum product 250 comprises an aluminum purity of at least 99.5 wt% and up to 99.999 wt% aluminum. In some embodiments, the refined aluminum product 250 comprises an aluminum purity of at least 99.9 wt% and up to 99.999 wt% aluminum. In some embodiments, the refined aluminum product 250 comprises an aluminum purity of at least 99.9 wt% and up to 99.999 wt% aluminum. In some embodiments, the refined aluminum product 250 comprises an aluminum purity of at least 99.98 wt% and up to 99.999 wt% aluminum. In one embodiment, the refined aluminum product comprises at least 95.5 wt% Al. In another embodiment, the refined aluminum product comprises at least 96 wt% Al. In yet another embodiment, the refined aluminum product comprises at least 96.5 wt% Al. In another embodiment, the refined aluminum product comprises at least 97 wt% Al. In yet another embodiment, the refined aluminum product comprises at least 97.5 wt% Al. In another embodiment, the refined aluminum product comprises at least 98 wt.% Al. In yet another embodiment, the refined aluminum product comprises at least 98.5 wt.% Al. In another embodiment, the refined aluminum product comprises at least 99 wt.% Al. In yet another embodiment, the refined aluminum product comprises at least 99.5 wt.% Al. In another embodiment, the refined aluminum product comprises at least 99.75 wt.% Al. In yet another embodiment, the refined aluminum product comprises at least 99.8 wt.% Al. In another embodiment, the refined aluminum product comprises at least 99.85 wt.% Al. In yet another embodiment, the refined aluminum product comprises at least 99.9 wt.% Al. In another embodiment, the refined aluminum product comprises at least 99.95 wt.% Al.

[0050] In some embodiments, refined aluminum product 250 is produced through refinement cell 212 at an energy efficiency of 1 to 15 kWh / kg of refined aluminum. In some embodiments, refined aluminum product 250 is produced through refinement cell 212 at an energy efficiency of 1 to 10 kWh / kg of refined aluminum. In some embodiments, refined aluminum product 250 is produced through refinement cell 212 at an energy efficiency of 1 to 8 kWh / kg of refined aluminum. In some embodiments, refined aluminum product 250 is produced through refinement cell 212 at an energy efficiency of 1 to 6 kWh / kg of refined aluminum. In some embodiments, refined aluminum product 250 is produced through refinement cell 212 at an energy efficiency of 1 to 4 kWh / kg of refined aluminum. In some embodiments, refined aluminum product 250 is produced through refinement cell 212 at an energy efficiency of 5 to 15 kWh / kg of refined aluminum. In some embodiments, refined aluminum product 250 is produced through refining cell 212 at an energy efficiency of 10-15 kWh / kg of refined aluminum. In some embodiments, refined aluminum product 250 is produced through refining cell 212 at an energy efficiency of 12-15 kWh / kg of refined aluminum.

[0051] In some embodiments, refining feedstock 210 to produce purified aluminum stream 214 and raffinate stream 216 includes passing an electric current through at least one anode, through an electrolyte (e.g., electrolytic solution), and into at least one cathode. In some embodiments, passing an electric current includes passing a direct current (DC) from the anode to the cathode through the electrolyte. In some embodiments, the anode and cathode can be partially disposed in the electrolyte, and the anode can be partially disposed in a molten metal pad. Directing aluminum metal from a molten metal pad in purification cell 212 toward the electrolyte includes flowing aluminum metal toward the electrolyte and providing an electric current to the anode.

[0052] In some embodiments, the refinery cell 212 includes a molten metal pad, an electrolyte, and refined aluminum. In one embodiment, the electrolyte separates the molten metal and the refined aluminum. In one embodiment, the refinery aluminum defines an upper liquid layer of the refinery cell 212, the electrolyte defines a middle liquid layer of the refinery cell 212, and the molten metal pad defines a bottom liquid layer of the refinery cell 212. The density of the refinery aluminum in the refinery cell 212 can be lower than the density of the electrolyte in the refinery cell 212. The density of the electrolyte can be lower than the density of the molten metal pad in the refinery cell 212. The electrolyte separates the upper layer of refined aluminum from the molten metal pad. In this regard, the composition of the electrolyte can be selected such that the electrolyte is less dense than the molten metal pad and more dense than the refined aluminum. In some embodiments, the electrolyte includes one or more molten salts. In some embodiments, the electrolyte includes at least one of a fluoride and / or a chloride. In some embodiments, the electrolyte comprises at least one fluoride and / or chloride of, among others, Na, K, Al, Ba, Ca, Ce, La, Cs, Rb, or combinations thereof. In some embodiments, the molten metal pad comprises at least one alloy containing one or more of Al, Si, Cu, Fe, Sb, Gd, Cd, Sn, Pb, and impurities.

[0053] In some embodiments, process 200 includes removing at least a portion of the purified aluminum from purification cell 212 to produce purified aluminum stream 214. In some embodiments, the purified aluminum is removed substantially continuously via purified aluminum stream 214 during operation of purification cell 212. In some embodiments, removing purified aluminum from purification cell 212 includes periodically removing purified aluminum from purification cell 212 via purified aluminum stream 214. In some embodiments, removing purified aluminum from purification cell 212 via purified aluminum stream 214 includes removing purified aluminum from purification cell 212 at a first removal rate. The first removal rate may be constant or may vary, for example, including stopping or starting the removal of purified aluminum from purification cell 212. In some embodiments, the first removal rate may be controlled, for example, based at least in part on the second removal rate. In some embodiments, the purified aluminum may be removed periodically via purified aluminum stream 214 during operation of purification cell 212. In some embodiments, the removing step is completed with equipment configured to remove the refined aluminum product 250 without contaminating the product (eg, alumina, graphite).

[0054] In some embodiments, the refined aluminum stream 214 comprises at least 95% by weight aluminum, for example, any of the amounts of aluminum described herein.

[0055] As previously discussed, the raffinate vapor can include elements such as silicon and iron. In some embodiments, the raffinate stream 216 comprises at least 0.5 wt% Si. In other embodiments, the raffinate stream comprises at least 1 wt% Si. In yet other embodiments, the raffinate stream comprises at least 2 wt% Si. In yet other embodiments, the raffinate stream comprises at least 3 wt% Si. In other embodiments, the raffinate stream comprises at least 5 wt% Si. In yet other embodiments, the raffinate stream comprises at least 7 wt% Si. In other embodiments, the raffinate stream comprises at least 10 wt% Si. In yet other embodiments, the raffinate stream comprises at least 15 wt% Si. In other embodiments, the raffinate stream comprises at least 20 wt% Si. In yet other embodiments, the raffinate stream comprises at least 25 wt% Si. In another embodiment, the raffinate stream comprises at least 30 wt% Si. In yet other embodiments, the raffinate stream comprises at least 35 wt% Si. In another embodiment, the raffinate stream comprises at least 40 wt% Si. In yet another embodiment, the raffinate stream comprises at least 45 wt% Si. In yet another embodiment, the raffinate stream comprises at least 50 wt% Si. In yet another embodiment, the raffinate stream comprises at least 55 wt% Si. In another embodiment, the raffinate stream comprises at least 60 wt% Si. In yet another embodiment, the raffinate stream comprises at least 65 wt% Si. In another embodiment, the raffinate stream comprises at least 70 wt% Si. In yet another embodiment, the raffinate stream comprises at least 75 wt% Si. In another embodiment, the raffinate stream comprises at least 80 wt% Si. In yet another embodiment, the raffinate stream comprises at least 85 wt% Si. In another embodiment, the raffinate stream comprises at least 90 wt% Si. In yet another embodiment, the raffinate stream comprises at least 95 wt% Si.

[0056] In some embodiments, the raffinate stream 216 comprises at least 0.5 wt% Fe. In one embodiment, the raffinate stream comprises at least 1 wt% Fe. In another embodiment, the raffinate stream comprises at least 2 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 3 wt% Fe. In another embodiment, the raffinate stream comprises at least 5 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 7 wt% Fe. In another embodiment, the raffinate stream comprises at least 10 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 15 wt% Fe. In another embodiment, the raffinate stream comprises at least 20 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 25 wt% Fe. In another embodiment, the raffinate stream comprises at least 30 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 35 wt% Fe. In another embodiment, the raffinate stream comprises at least 40 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 45 wt% Fe. In another embodiment, the raffinate stream comprises at least 50 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 55 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 60 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 65 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 70 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 75 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 80 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 85 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 90 wt% Fe. In yet another embodiment, the raffinate stream comprises at least 95 wt% Fe.

[0057] In some embodiments, the raffinate stream contains both silicon and iron, and the raffinate stream comprises at least 1 wt. % silicon and iron combined (i.e., Si + Fe > 1 wt. %). In other embodiments, the raffinate stream comprises at least 2 wt. % (Si + Fe). In yet other embodiments, the raffinate stream comprises at least 3 wt. % (Si + Fe). In other embodiments, the raffinate stream comprises at least 5 wt. % (Si + Fe). In yet other embodiments, the raffinate stream comprises at least 7 wt. % (Si + Fe). In other embodiments, the raffinate stream comprises at least 10 wt. % (Si + Fe). In yet other embodiments, the raffinate stream comprises at least 15 wt. % (Si + Fe). In other embodiments, the raffinate stream comprises at least 20 wt. % (Si + Fe). In yet other embodiments, the raffinate stream comprises at least 25 wt. % (Si + Fe). In another embodiment, the raffinate stream comprises at least 30 wt% (Si+Fe). In yet another embodiment, the raffinate stream comprises at least 35 wt% (Si+Fe). In another embodiment, the raffinate stream comprises at least 40 wt% (Si+Fe). In yet another embodiment, the raffinate stream comprises at least 45 wt% (Si+Fe). In another embodiment, the raffinate stream comprises at least 50 wt% (Si+Fe). In yet another embodiment, the raffinate stream comprises at least 55 wt% (Si+Fe). In another embodiment, the raffinate stream comprises at least 60 wt% (Si+Fe). In yet another embodiment, the raffinate stream comprises at least 65 wt% (Si+Fe). In another embodiment, the raffinate stream comprises at least 70 wt% (Si+Fe). In yet another embodiment, the raffinate stream comprises at least 75 wt% (Si+Fe). In another embodiment, the raffinate stream comprises at least 80 wt% (Si+Fe). In yet another embodiment, the raffinate stream comprises at least 85 wt% (Si+Fe). In another embodiment, the raffinate stream comprises at least 90 wt% (Si+Fe).In yet another embodiment, the raffinate stream comprises at least 95 wt% (Si+Fe).

[0058] In some embodiments, raffinate stream 216 comprises 95% or less by weight of Al (aluminum). In one embodiment, raffinate stream 216 comprises 90% or less by weight of Al. In another embodiment, raffinate stream 216 comprises 85% or less by weight of Al. In yet another embodiment, raffinate stream 216 comprises 80% or less by weight of Al. In another embodiment, raffinate stream 216 comprises 75% or less by weight of Al. In yet another embodiment, raffinate stream 216 comprises 70% or less by weight of Al. In another embodiment, raffinate stream 216 comprises 65% or less by weight of Al. In yet another embodiment, raffinate stream 216 comprises 60% or less by weight of Al. In another embodiment, raffinate stream 216 comprises 55% or less by weight of Al. In yet another embodiment, raffinate stream 216 comprises 50% or less by weight of Al. In another embodiment, raffinate stream 216 comprises 45% or less by weight of Al. In yet another embodiment, raffinate stream 216 comprises 40 wt% or less Al. In another embodiment, raffinate stream 216 comprises 35 wt% or less Al. In yet another embodiment, raffinate stream 216 comprises 30 wt% or less Al. In another embodiment, raffinate stream 216 comprises 25 wt% or less Al (Al). In yet another embodiment, raffinate stream 216 comprises 20 wt% or less Al. In another embodiment, raffinate stream 216 comprises 15 wt% or less Al. In yet another embodiment, raffinate stream 216 comprises 10 wt% or less Al. In another embodiment, raffinate stream 216 comprises 5 wt% or less Al.

[0059] Process 200 may include step 218 of separating raffinate stream 216 into a recycled raffinate stream 246, a by-product stream, or a combination thereof. In some embodiments, raffinate stream 216 is separated into only a by-product stream (e.g., first by-product stream 220, second by-product stream 222, or third by-product stream 224). In some embodiments, raffinate stream 216 is not further separated, and raffinate stream 216 is recycled raffinate 246. In some embodiments, recycled raffinate 246 does not contain the same components as the by-product stream. In some embodiments, recycled raffinate 246 contains the same components as at least one of the by-product streams. In some embodiments, recycled raffinate 246 is the same as all of the by-product streams.

[0060] Depending on the application, the number of by-product streams exiting separating step 218 may vary. As shown in Figure 2, raffinate stream 216 can be separated into at least one by-product stream, such as a first by-product stream 220, a second by-product stream 222, and a third by-product stream 224. In some embodiments, raffinate stream 216 can be separated into two or more by-product streams, such as two by-product streams, three or more by-product streams, four or more by-product streams, five or more by-product streams, six or more by-product streams, seven or more by-product streams, eight or more by-product streams, nine or more by-product streams, or ten or more by-product streams.

[0061] In some embodiments, the by-product streams may all be the same or all may be compositionally different from one another. In some embodiments, some of the by-product streams may be compositionally the same and some of the by-product streams may be different from one another. In some embodiments, two or more streams may be compositionally the same (e.g., first by-product stream 220 and second by-product stream 222) and different from other streams (e.g., third by-product stream 224). First by-product stream 220, second by-product stream 222, and third by-product stream 224 may be compositionally the same or all may be different from one another.

[0062] The by-product streams of the present disclosure (e.g., in the illustrated embodiment, first by-product stream 220, second by-product stream 222, and / or third by-product stream 224) can include at least one of silicon, manganese, iron, zinc, copper, and combinations thereof.

[0063] In some embodiments, at least one of the by-product streams comprises at least 1 wt% Si (silicon). In one embodiment, at least one of the by-product streams comprises at least 3 wt% Si. In another embodiment, at least one of the by-product streams comprises at least 5 wt% Si. In yet another embodiment, at least one of the by-product streams comprises at least 7 wt% Si. In another embodiment, at least one of the by-product streams comprises at least 10 wt% Si. In yet another embodiment, at least one of the by-product streams comprises at least 12 wt% Si. In another embodiment, at least one of the by-product streams comprises at least 15 wt% Si. In yet another embodiment, at least one of the by-product streams comprises at least 20 wt% Si. In another embodiment, at least one of the by-product streams comprises at least 25 wt% Si. In yet another embodiment, at least one of the by-product streams comprises at least 30 wt% Si. In another embodiment, at least one of the by-product streams comprises at least 35 wt% Si. In yet another embodiment, at least one of the by-product streams comprises at least 40 wt% Si. In another embodiment, at least one of the by-product streams comprises at least 45 wt% Si. In yet another embodiment, at least one of the by-product streams comprises at least 50 wt% Si. In another embodiment, at least one of the by-product streams comprises at least 55 wt% Si. In yet another embodiment, at least one of the by-product streams comprises at least 60 wt% Si. In another embodiment, at least one of the by-product streams comprises at least 65 wt% Si. In yet another embodiment, at least one of the by-product streams comprises at least 70 wt% Si. In another embodiment, at least one of the by-product streams comprises at least 75 wt% Si. In yet another embodiment, at least one of the by-product streams comprises at least 80 wt% Si. In another embodiment, at least one of the by-product streams comprises at least 85 wt% Si. In yet another embodiment, at least one of the by-product streams comprises at least 90 wt% Si.In another embodiment, at least one of the by-product streams comprises at least 95 wt.% Si.

[0064] In some embodiments, at least one of the by-product streams comprises at least 1 wt.% Mn (manganese). In one embodiment, at least one of the by-product streams comprises at least 3 wt.% Mn. In another embodiment, at least one of the by-product streams comprises at least 5 wt.% Mn. In yet another embodiment, at least one of the by-product streams comprises at least 7 wt.% Mn. In another embodiment, at least one of the by-product streams comprises at least 10 wt.% Mn. In yet another embodiment, at least one of the by-product streams comprises at least 12 wt.% Mn. In another embodiment, at least one of the by-product streams comprises at least 15 wt.% Mn. In yet another embodiment, at least one of the by-product streams comprises at least 20 wt.% Mn. In another embodiment, at least one of the by-product streams comprises at least 25 wt.% Mn. In yet another embodiment, at least one of the by-product streams comprises at least 30 wt.% Mn. In another embodiment, at least one of the by-product streams comprises at least 35 wt.% Mn. In yet another embodiment, at least one of the by-product streams comprises at least 40 wt% Mn. In another embodiment, at least one of the by-product streams comprises at least 45 wt% Mn. In yet another embodiment, at least one of the by-product streams comprises at least 50 wt% Mn. In another embodiment, at least one of the by-product streams comprises at least 55 wt% Mn. In yet another embodiment, at least one of the by-product streams comprises at least 60 wt% Mn. In another embodiment, at least one of the by-product streams comprises at least 65 wt% Mn. In yet another embodiment, at least one of the by-product streams comprises at least 70 wt% Mn. In another embodiment, at least one of the by-product streams comprises at least 75 wt% Mn. In yet another embodiment, at least one of the by-product streams comprises at least 80 wt% Mn. In another embodiment, at least one of the by-product streams comprises at least 85 wt% Mn. In yet another embodiment, at least one of the by-product streams comprises at least 90 wt% Mn.In another embodiment, at least one of the by-product streams comprises at least 95 wt.% Mn.

[0065] In some embodiments, at least one of the by-product streams comprises at least 1 wt. % Fe (iron). In one embodiment, at least one of the by-product streams comprises at least 3 wt. % Fe. In another embodiment, at least one of the by-product streams comprises at least 5 wt. % Fe. In yet another embodiment, at least one of the by-product streams comprises at least 7 wt. % Fe. In another embodiment, at least one of the by-product streams comprises at least 10 wt. % Fe. In yet another embodiment, at least one of the by-product streams comprises at least 12 wt. % Fe. In another embodiment, at least one of the by-product streams comprises at least 15 wt. % Fe. In yet another embodiment, at least one of the by-product streams comprises at least 20 wt. % Fe. In another embodiment, at least one of the by-product streams comprises at least 25 wt. % Fe. In yet another embodiment, at least one of the by-product streams comprises at least 30 wt. % Fe. In another embodiment, at least one of the by-product streams comprises at least 35 wt. % Fe. In yet another embodiment, at least one of the by-product streams comprises at least 40 wt.% Fe. In another embodiment, at least one of the by-product streams comprises at least 45 wt.% Fe. In yet another embodiment, at least one of the by-product streams comprises at least 50 wt.% Fe. In another embodiment, at least one of the by-product streams comprises at least 55 wt.% Fe. In yet another embodiment, at least one of the by-product streams comprises 60 wt.% or more Fe. In another embodiment, at least one of the by-product streams comprises 65 wt.% or more Fe. In yet another embodiment, at least one of the by-product streams comprises 70 wt.% or more Fe. In another embodiment, at least one of the by-product streams comprises 75 wt.% or more Fe. In yet another embodiment, at least one of the by-product streams comprises 80 wt.% or more Fe. In another embodiment, at least one of the by-product streams comprises 85 wt.% or more Fe. In yet another embodiment, at least one of the by-product streams comprises 90 wt.% or more Fe.In another embodiment, at least one of the by-product streams comprises 95 wt.% or more Fe.

[0066] In some embodiments, at least one of the by-product streams comprises at least 1 wt. % Zn (zinc). In one embodiment, at least one of the by-product streams comprises at least 3 wt. % Zn. In another embodiment, at least one of the by-product streams comprises at least 5 wt. % Zn. In yet another embodiment, at least one of the by-product streams comprises at least 7 wt. % Zn. In another embodiment, at least one of the by-product streams comprises at least 10 wt. % Zn. In yet another embodiment, at least one of the by-product streams comprises at least 12 wt. % Zn. In another embodiment, at least one of the by-product streams comprises at least 15 wt. % Zn. In yet another embodiment, at least one of the by-product streams comprises at least 20 wt. % Zn. In another embodiment, at least one of the by-product streams comprises at least 25 wt. % Zn. In yet another embodiment, at least one of the by-product streams comprises at least 30 wt. % Zn. In another embodiment, at least one of the by-product streams comprises at least 35 wt. % Zn. In yet another embodiment, at least one of the by-product streams comprises at least 40 wt.% Zn. In another embodiment, at least one of the by-product streams comprises at least 45 wt.% Zn. In yet another embodiment, at least one of the by-product streams comprises at least 50 wt.% Zn. In another embodiment, at least one of the by-product streams comprises at least 55 wt.% Zn. In yet another embodiment, at least one of the by-product streams comprises at least 60 wt.% Zn. In another embodiment, at least one of the by-product streams comprises at least 65 wt.% Zn. In yet another embodiment, at least one of the by-product streams comprises at least 70 wt.% Zn. In another embodiment, at least one of the by-product streams comprises at least 75 wt.% Zn. In yet another embodiment, at least one of the by-product streams comprises at least 80 wt.% Zn. In another embodiment, at least one of the by-product streams comprises at least 85 wt.% Zn. In yet another embodiment, at least one of the by-product streams comprises at least 90 wt.% Zn.In another embodiment, at least one of the by-product streams comprises at least 95 wt. % Zn.

[0067] In some embodiments, at least one of the by-product streams comprises at least 1 wt. % Cu (copper). In one embodiment, at least one of the by-product streams comprises at least 3 wt. % Cu. In another embodiment, at least one of the by-product streams comprises at least 5 wt. % Cu. In yet another embodiment, at least one of the by-product streams comprises at least 7 wt. % Cu. In another embodiment, at least one of the by-product streams comprises at least 10 wt. % Cu. In yet another embodiment, at least one of the by-product streams comprises at least 12 wt. % Cu. In another embodiment, at least one of the by-product streams comprises at least 15 wt. % Cu. In yet another embodiment, at least one of the by-product streams comprises at least 20 wt. % Cu. In another embodiment, at least one of the by-product streams comprises at least 25 wt. % Cu. In yet another embodiment, at least one of the by-product streams comprises at least 30 wt. % Cu. In another embodiment, at least one of the by-product streams comprises at least 35 wt. % Cu. In yet another embodiment, at least one of the by-product streams comprises at least 40% Cu by weight. In another embodiment, at least one of the by-product streams comprises at least 45% Cu by weight. In yet another embodiment, at least one of the by-product streams comprises at least 50% Cu by weight. In another embodiment, at least one of the by-product streams comprises at least 55% Cu by weight. In yet another embodiment, at least one of the by-product streams comprises at least 60% Cu by weight. In another embodiment, at least one of the by-product streams comprises at least 65% Cu by weight. In yet another embodiment, at least one of the by-product streams comprises at least 70% Cu by weight. In another embodiment, at least one of the by-product streams comprises at least 75% Cu by weight. In yet another embodiment, at least one of the by-product streams comprises at least 80% Cu by weight. In another embodiment, at least one of the by-product streams comprises at least 85% Cu by weight. In yet another embodiment, at least one of the by-product streams comprises at least 90% Cu by weight.In another embodiment, at least one of the by-product streams comprises at least 95 wt.% Cu.

[0068] In some embodiments, first by-product stream 220, second by-product stream 222, third by-product stream 224, or any combination thereof, can include at least one of at least 12 wt% Si, at least 3 wt% Mn, at least 3 wt% Fe, and combinations thereof, in any of the amounts recited above. In some embodiments, first by-product stream 220, second by-product stream 222, and / or third by-product stream 224 can include at least 5% of at least one of Si, Mn, Fe, Zn, Cu, and combinations thereof, in any of the amounts recited above.

[0069] As previously mentioned, additional elements 238 can be used in process 200. In one embodiment, additional elements 238 can include at least one of Si, Fe, Cu, Ce, Cs, Mg, Mn, Cr, Ni, Zn, Ti, Co, Sn, Sr, Li, V, Zr, Sc, and combinations thereof. In one embodiment, additional elements can include aluminum scrap alloy, as described herein. In one embodiment, additional elements can be added to any of the streams described herein (e.g., refined aluminum stream 214, refined aluminum product 250, first by-product stream 220, second by-product stream 222, and / or third by-product stream 224). The additional elements 238 are selected in an appropriate amount to achieve a desired aluminum alloy product composition.

[0070] In some embodiments, one or more streams of the present disclosure are mixed with additional component 238 and / or additional component 244. In some embodiments, additional component 238 and / or additional component 244 are not added to the streams. The step of mixing (e.g., mixing step 230 and / or mixing step 234) the by-product streams (e.g., first by-product stream 220 and second by-product stream 222) with refined aluminum stream 214 can include adding additional component 238. In the embodiment shown in FIG. 2, mixing step 234 includes adding additional component 238. In some embodiments, additional component 238 can be added to third by-product stream 224 and / or refined aluminum product 250.

[0071] The process 200 may include a step 230 of combining at least a portion of the first by-product stream 220 with at least a portion of the refined aluminum from the refined aluminum stream 214 to produce an aluminum alloy product, i.e., a first predetermined aluminum alloy product 232.

[0072] Process 200 may include a step 234 of combining at least a portion of second by-product stream 222 with at least a portion of the refined aluminum from refined aluminum stream 214, thereby producing an aluminum alloy product, second predetermined aluminum alloy product 236. The second predetermined aluminum alloy product may have a different composition than the first predetermined aluminum alloy product.

[0073] The first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 can have the same composition as any 1xxx-8xxx aluminum alloy product, such as any 1xxx-8xxx aluminum alloy product described in the Aluminum Association's "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys." The first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 can have the same composition as any 1xx-8xx aluminum alloy product, such as any 1xx-8xx aluminum alloy described in the Aluminum Association's "Designation and Chemical Composition Limits for Aluminum Alloys in the Form of Castings and Ingot." The first and second predetermined aluminum alloy products can be provided in any suitable form, such as ingot, billet, powder, wire, ribbon, etc. Suitable wrought products (foils, sheets, plates, forgings, extrusions), shaped cast products (e.g., die cast products), and additively manufactured products (e.g., 3D printed products) can be produced from the first and / or second predetermined aluminum alloy products.

[0074] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 can have the same composition as a 1xxx or 1xx aluminum alloy. In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 can include aluminum with an aluminum purity of 99.5% to 99.999% by weight. In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 can include aluminum with an aluminum purity of 99.6% to 99.999% by weight. In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 can include aluminum with an aluminum purity of 99.7% to 99.999% by weight. In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 can include aluminum with an aluminum purity of 99.75% to 99.999% by weight. In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 can include aluminum with an aluminum purity of 99.8% to 99.999% by weight. In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 can include aluminum with an aluminum purity of 99.85% to 99.999% by weight. In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 can include aluminum with an aluminum purity of 99.9% to 99.999% by weight. In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 can include aluminum with an aluminum purity between 99.95% and 99.999% by weight.

[0075] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 may have the same composition as a 2xxx aluminum alloy.

[0076] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 may have the same composition as a 3xxx aluminum alloy.

[0077] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 may have the same composition as a 4xxx aluminum alloy.

[0078] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 may have the same composition as a 5xxx aluminum alloy.

[0079] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 may have the same composition as a 6xxx aluminum alloy.

[0080] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 may have the same composition as a 7xxx aluminum alloy.

[0081] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 may have the same composition as an 8xxx aluminum alloy.

[0082] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 may have the same composition as a 2xx aluminum alloy.

[0083] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 may have the same composition as a 3xx aluminum alloy.

[0084] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 may have the same composition as a 4xx aluminum alloy.

[0085] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 may have the same composition as a 5xx aluminum alloy.

[0086] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 may have the same composition as a 7xx aluminum alloy.

[0087] In some embodiments, the first predetermined aluminum alloy product 232 and / or the second predetermined aluminum alloy product 236 may have the same composition as an 8xx aluminum alloy.

[0088] Although the methods described herein generally focus on refining aluminum and aluminum refining cells, the devices, systems, and methods described herein are applicable to the refining of other materials (e.g., magnesium) or different types of refining cells (e.g., magnesium refining cells). In some embodiments, the refining cell includes at least one electrode, such as a cathode or an anode.

[0089] While multiple embodiments of the present disclosure have been described, it is understood that these embodiments are illustrative and not limiting, and that numerous modifications will be apparent to those skilled in the art. The various steps can be performed in any order desired (and any steps can be added or omitted as desired). For example, a given aluminum alloy product can be produced by mixing all of the streams described herein (e.g., precursor 242 with refined aluminum stream 214). The exemplary embodiments of aluminum refinement are not meant to be exhaustive. The features and characteristics of the present disclosure can be combined in any manner.

[0090] Further, the present disclosure will be described with reference to the accompanying drawings, in which similar structures are designated by the same reference numerals in several views. The drawings constitute a part of this specification and include exemplary embodiments of the present disclosure, illustrating various objects and features thereof. Furthermore, the drawings are not necessarily to scale, and the details of certain components may be exaggerated to show details thereof. Furthermore, numerical values, specifications, etc. shown in the drawings are illustrative examples and are not meant to be limiting. Therefore, specific structural or functional details disclosed herein should not be meant to be limiting, but should be interpreted as representative examples for those skilled in the art to implement the present disclosure in various ways.

[0091] Among the benefits and improvements disclosed, other objects and advantages of the present disclosure will become apparent from the following description taken in conjunction with the accompanying drawings. While detailed embodiments of the present disclosure are described, it should be understood that the disclosed embodiments are merely exemplary demonstrating that the present disclosure can be embodied in various forms. Furthermore, the examples shown in connection with various embodiments of the invention are illustrative and not limiting.

[0092] Throughout this specification and the claims, the following terms shall have the meanings set forth herein unless a different meaning is clearly intended from the context. The phrases "in one embodiment" and "in some embodiments" do not necessarily refer to the same embodiment, but may. Additionally, the phrases "in another embodiment" and "in some other embodiments" do not necessarily refer to different embodiments, but may. Accordingly, as described below, various embodiments of the invention can be readily combined without departing from the scope or spirit of the invention.

[0093] Additionally, as used herein, the term "or" is an "or" operator and is equivalent to the term "and / or" unless the context clearly dictates otherwise. The term "based on" is non-exclusive and allows for additional unlisted factors to be based on, unless the context clearly dictates otherwise. Additionally, throughout this specification, the terms "a," "an," and "the" include plurals. Additionally, the term "in" includes "in" and "on."

Claims

1. (a) adding a feedstock comprising aluminum scrap to an aluminum refining cell; (b) refining said feedstock to produce a refined aluminum stream and a raffinate stream; (c) separating components of the raffinate stream, the separating components of the raffinate stream producing at least a first by-product stream and a second by-product stream; and (d) combining at least a portion of the first by-product stream with at least a portion of the purified aluminum obtained from the refined aluminum stream to produce an aluminum alloy product.

2. 10. The method of claim 1, wherein the feedstock comprises at least 50 wt% Al, or at least 55 wt% Al, or at least 60 wt% Al, or at least 65 wt% Al, or at least 70 wt% Al, or at least 75 wt% Al, or at least 80 wt% Al, or at least 85 wt% Al, or at least 90 wt% Al, or at least 95 wt% Al, or at least 99 wt% Al, or at least 99.5 wt% Al.

3. The aluminum scrap contains at least 5% Al by weight of the raw material, or at least 10% Al by weight of the raw material, or at least 15% Al by weight of the raw material, or at least 20% Al by weight of the raw material, or at least 25% Al by weight of the raw material, or at least 30% Al by weight of the raw material, or at least 35% Al by weight of the raw material, or at least 40% Al by weight of the raw material, or at least 45% Al by weight of the raw material, or at least 50% Al by weight of the raw material, or at least 55% Al by weight of the raw material, or at least 10% Al by weight of the raw material 10. A method according to any preceding claim, wherein the feedstock comprises at least 60% Al by weight of the feedstock, or at least 65% Al by weight of the feedstock, or at least 70% Al by weight of the feedstock, or at least 75% Al by weight of the feedstock, or at least 80% Al by weight of the feedstock, or at least 85% Al by weight of the feedstock, or at least 90% Al by weight of the feedstock, or at least 95% Al by weight of the feedstock, or at least 99% Al by weight of the feedstock, or at least 99.5% Al by weight of the feedstock, or at least 100% Al by weight of the feedstock.

4. 10. The method of any preceding claim, wherein the purifying step (b) comprises passing an electric current through at least one anode, through an electrolyte, and to at least one cathode.

5. 10. The method of any preceding claim, wherein the refined aluminum stream comprises at least 95 wt% Al.

6. 10. The method of any preceding claim, wherein the refined aluminum stream comprises at least 99.5 wt% Al.

7. 10. The method of any preceding claim, wherein the raffinate stream comprises up to 50 wt% Al.

8. 10. The method of any preceding claim, wherein the raffinate stream comprises at least 3 wt.% silicon.

9. 10. The method of any preceding claim, wherein the raffinate stream comprises at least 3 wt. % iron.

10. 10. A method according to any preceding claim, wherein the aluminium alloy product comprises one of the 1xxx-8xxx aluminium alloy compositions, or one of the 1xx-8xx aluminium alloy compositions.

11. 10. The method of any preceding claim, further comprising mixing an additional component with the refined aluminum stream.

12. 12. The method of claim 11, wherein the additional element comprises at least one of Si, Fe, Cu, Ce, Cs, Mg, Mn, Cr, Ni, Zn, Ti, Co, Sn, Sr, Li, V, Zr, Sc, and combinations thereof.

13. The method of claim 11 , wherein the additional component comprises at least one aluminum scrap alloy, the aluminum scrap alloy being aluminum alloy scrap.

14. 10. The method of any preceding claim, further comprising adding at least one of the first by-product stream and / or the second by-product stream to a precursor stream to produce the feedstock.

15. 10. The method of any preceding claim, further comprising adding a selected metal to the precursor stream to produce said feedstock.

16. 16. The method of claim 15, wherein the predetermined metal is at least one of Si, Fe, Cu, Ce, Cs, Mg, Mn, Cr, Ni, Zn, Ti, Co, Sn, Sr, Li, V, Zr, Sc, and combinations thereof.

17. 16. The method of claim 15, wherein the predetermined metal is Cu, Ce, Cs, Sn, Zn, or any combination thereof.

18. The method of claim 15 , wherein the predetermined metal comprises Cu.

19. 10. The method of any preceding claim, wherein the first by-product stream and / or the second by-product stream comprises at least one of at least 12 wt. % Si, at least 3 wt. % Mn, at least 3 wt. % Fe, and combinations thereof.

20. 10. The method of any preceding claim, wherein the first by-product stream and / or the second by-product stream comprises at least 5% of at least one of Si, Mn, Fe, Zn, Cu, and combinations thereof.

21. The raw material contains 5 wt. % or less of alumina (Al ２ O ３ 10. The method of any preceding claim, comprising:

22. 10. The method of any preceding claim, wherein the aluminum alloy product comprises one of an ingot, a billet, a powder, a wire, and a ribbon.

23. 10. The method of any preceding claim, wherein the aluminum refining cell includes a molten metal pad, a purified aluminum layer, and an electrolyte disposed between the molten metal pad and the purified aluminum layer.

24. 24. The method of claim 23, wherein the purified aluminum layer has a lower density than the electrolyte.

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