Method for primary aluminum smelting integrated with a solid fossil-fuel fired power plant, with choice of technology allowing small size, minimal capital intensity, extra energy production available for a local grid, and competitive operating costs

Abstract

A method of processing aluminum combining an alumina reduction plant operating as per the Hall-Heroult process for electrolysis of alumina of the Vertical Stud Soderberg (VSS) type, with a fluidized bed boiler (FBB) or circulating fluidized bed boiler (CFBB) power plant consuming any solid fuel- or carbon-based fuel to produce aluminum metal in ingots or sows or in liquid form in ladles, and to generate electrical energy which is both used by the smelter itself in the alumina reduction reaction and available for a local energy grid.

1 . A method for co-producing primary aluminum and electricity, comprising a small scale Soderberg technology aluminum smelter with a solid fuel fired fluidized bed boiler power plant.  
     
     
         2 . The method of  claim 1  wherein the relationship between the power produced by the power plant is predetermined according to a cost/benefit scale exposed in computer model described in CD-Rom attached, so that energy traded to local market at market rates more than offsets energy costs, resulting in a low marginal energy rate for the smelting operation.  
     
     
         3 . The method of  claim 1  in which low-grade fossil fuel or other solid fuels can be used as the energy source, including municipal waste, etc.  
     
     
         4 . The method of  claim 1  in which, optionally, anode paste can be manufactured on site, from the solid fossil fuel, the fuel first being separated by any conventional separation process segregating the 10 percent of the highest purity fuel from the 90 percent of the residual fuel and utilizing the high-purity substrate to produce anode paste instead of procuring it from outside sources.