Method and apparatus for separation of aluminum from aluminum-containing source materials

Abstract

Method and apparatus thereof to separate aluminum from aluminum-containing source material, such as fly ash, includes preparing a slurry of the source material and water in an agitation tank and adding a leaching reactant to the slurry in an amount dependent on the amount of aluminum in the source material. After agitation, transferring the mixture to a settling pond. After settling, transferring the liquid as a pregnant solution to an electric cell. Treating the pregnant solution in the electric cell by applying an electrical current that is periodically reversed as the pregnant solution passes between at least two metal plates in the electric cell. Collecting the treated solution in a cone bottom tank and separating aluminum particles from the treated solution using a filter press. Drying the particulate aluminum and pressing the aluminum into solid shapes. Another embodiment collects hydrogen generated in the electric cell from source material.

We claim: 
     
         1 . A method to separate aluminum-containing compounds from a solution, comprising:
 a. preparing a slurry comprising fly ash;   b. passing the slurry into an agitation tank;   c. preparing a pregnant solution by mixing the slurry in the agitation tank with water and sodium hydroxide;   d. agitating the pregnant solution in the agitation tank;   e. transferring the pregnant solution to a pond;   f. transferring the pregnant solution from the pond to an electric cell;   g. treating the pregnant solution in the electric cell to form particulate aluminum in the treated pregnant solution;   h. passing the treated pregnant solution to a tank;   i. separating a barren solution from the particulate aluminum and collecting the barren solution;   j. collecting elemental aluminum from the tank and into a filter press;   k. pressing the elemental aluminum to eliminate moisture and to concentrate the elemental aluminum into a wet aluminum powder;   l. drying the wet aluminum powder by a drier system to create dried aluminum powder; and   m. pressing the dried aluminum powder into briquettes by a pressing system.   
     
     
         2 . The method of  claim 1 , wherein preparing a pregnant solution by mixing the slurry in the agitation tank in a ratio of approximately 1 part fly ash to approximately 4 parts water and by adding approximately 2 fluid ounces of sodium hydroxide to approximately 1 pound of potential elemental aluminum yield, wherein the potential elemental aluminum yield is calculated as a percentage of aluminum in the fly ash. 
     
     
         3 . The method of  claim 1 , wherein the step of treating the pregnant solution in the electric cell comprises the steps of:
 a. introducing a controlled electrical current, which is periodically reversed,   b. passing the pregnant solution between two metal plates; and   c. collecting the treated pregnant solution in a cone bottom tank.   
     
     
         4 . The method of  claim 1 , further comprising: collecting unburned carbon from the slurry by a column flotation cell system before passing the slurry into the agitation tank. 
     
     
         5 . The method of  claim 1 , further comprising: removing iron from the slurry by a magnetic iron separator system before passing the slurry into the agitation tank. 
     
     
         6 . A method to separate aluminum from aluminum-containing source materials, comprising:
 a. preparing a slurry comprising fly ash;   b. passing the slurry into an agitation tank;   c. preparing a pregnant solution by mixing the slurry in the agitation tank with water and sodium hydroxide;   d. agitating the pregnant solution in the agitation tank;   e. transferring the pregnant solution to a pond;   f. transferring the pregnant solution from the pond to an electric cell;   g. treating the pregnant solution in the electric cell by introducing a controlled electrical current, which is periodically reversed, and passing the pregnant solution between at least two metal plates in the electric cell;   h. passing the treated pregnant solution to a tank;   i. separating a barren solution from particulate aluminum in the treated pregnant solution and transferring the separated barren solution to a pond;   j. collecting the particulate aluminum from the tank and into a filter press;   k. pressing the particulate aluminum to eliminate moisture and to concentrate the particulate aluminum into a wet aluminum powder;   l. drying the wet aluminum powder by a drier system to create dried aluminum powder; and   m. pressing the dried aluminum powder into briquettes by a pressing system.   
     
     
         7 . The method of  claim 6 , wherein preparing the pregnant solution by mixing the slurry in the agitation tank in a ratio of approximately 1 part fly ash to approximately 4 parts water and by adding approximately 2 fluid ounces of sodium hydroxide to approximately 1 pound of potential elemental aluminum yield, wherein the potential elemental aluminum yield is calculated as a percentage of aluminum in the fly ash. 
     
     
         8 . The method of  claim 6 , further comprising: collecting unburned carbon from the slurry by a column flotation cell system before passing the slurry into the agitation tank. 
     
     
         9 . The method of  claim 6 , further comprising: removing iron from the slurry by a magnetic iron separator system before passing the slurry into the agitation tank. 
     
     
         10 . A method of separating aluminum from a source material, comprising:
 mixing the source material and water and sodium hydroxide to form a slurry;   agitating the slurry for a first period of time;   settling the slurry for a second period of time to obtain a pregnant solution;   passing the pregnant solution between plates of an electric cell while passing an electrical signal through the plates to form aluminum particulate in the solution; and   separating the aluminum particulate from the liquid.   
     
     
         11 . A method as claimed in  claim 10 , wherein the electrical signal is a direct current that is reversed in polarity at a predetermined frequency. 
     
     
         12 . An apparatus for separating aluminum from a source material, comprising:
 an agitating tank that is operable to agitate a slurry comprising the source material, water, and a leaching reactant;   a holding containment that is connected to receive the agitated slurry from the agitating tank to separate a pregnant solution from settled solids;   a pump to transfer the pregnant solution from the holding containment;   an electric cell including at least two parallel conductive plates spaced apart by a distance to form a treatment space to receive the pregnant solution;   a power supply connected to the at least two parallel conductive plates and operable to apply an electrical signal to the at least two parallel conductive plates to form a treated solution comprising aluminum particulate; and   a separator connected to receive the treated solution and operable to separate the aluminum particulate from the treated solution.   
     
     
         13 . An apparatus as claimed in  claim 12 , wherein the separator includes a cone bottom tank and a filter press. 
     
     
         14 . An apparatus as claimed in  claim 12 , wherein the electric cell includes the at least two parallel conductive plates having an inlet for the pregnant solution at a lower position and an outlet for the treated solution at an upper position, and a gas outlet above the outlet for the treated solution. 
     
     
         15 . An apparatus as claimed in  claim 12 , wherein the at least two parallel conductive plates are of magnesium alloy, stainless steel, carbon, carbon-based material, or a combination thereof. 
     
     
         16 . An apparatus as claimed in  claim 12 , wherein the agitating tank includes a plurality of agitating tanks connected to receive the slurry; wherein the holding containment includes a plurality of ponds connected to receive the agitated slurry; and further comprising:
 a containment for barren solution separated from the aluminum particulate.   
     
     
         17 . A method for generating hydrogen gas, comprising:
 preparing a quantity of source material;   supplying the source material to treatment area of a high frequency electro induction cell;   applying a high frequency electrical signal to the treatment area of the high frequency electro induction cell, the high frequency electrical signal being applied to plates disposed on opposite sides of the treatment area;   connecting a vacuum to an outlet of the high frequency electro induction cell;   collecting hydrogen gas from the outlet.   
     
     
         18 . A method as claimed in  claim 17 , wherein the source material is sea water; and wherein the high frequency electrical signal is a signal that desalinates the sea water in the high frequency electro induction cell. 
     
     
         19 . A method as claimed in  claim 17 , wherein the high frequency electrical signal applied to the high frequency electro induction cell has a frequency range of 42,000-42,800 kHz.