Direct suspension electrolysis of alumina in CaCl
2-BaCl
2 molten salt was performed as a new process for aluminum production in which alumina was directly reduced with calcium generated through electrolysis of the molten salt. The current efficiency of aluminum production in the molten salt at 1223K increases with an increase of CaCl
2 content up to 80%. It also increases with increases in alumina suspension concentration and cathode current density and with temperature rise up to 1223K. Produced aluminum grows spherically up to about 20mm in diameter in the upper part of the molten salt. The rate of alumina reduction in this process is well analysed in the viewpoint of consumption of calcium electrolytically generated in the molten salt.
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