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<p>Fluorine-containing waste electrolyte (WE) is a hazardous solid waste in electrolytic aluminum production. This study introduces a sustainable method for utilizing WE by substituting 10.15–24.95 wt.% of fluorite in CaO-Al<sub>2</sub>O<sub>3</sub>-based melts. High-temperature viscosity measurements demonstrate that WE reduces melt viscosity by 74% (from 0.85 to 0.22&#xa0;Pa·s) and lowers activation energy by 21.6% (from 94.06 to 73.77&#xa0;kJ/mol) compared to conventional fluxes. Structural analyses reveal network depolymerization, with FTIR/Raman spectra indicating the conversion of Q<sup>2</sup>/Q<sup>3</sup>(Si) to Q<sup>0</sup>/Q<sup>1</sup>(Si) units and the formation of [AlO<sub>3</sub>F]<sup>4−</sup> complexes. XPS results show aluminum coordination shifts from [AlO<sub>4</sub>]<sup>5−</sup> to [AlO<sub>6</sub>]<sup>9−</sup> through Al-F bonding, suggesting stable aluminate structures. The viscosity reduction responds sensitively to initial WE substitution, achieving 65% of the maximum decrease at 10.15 wt.%, while further increases provide diminishing returns. WE-modified fluxes exhibit comparable rheological performance to fluorite systems, significantly reducing hazardous waste generation and enhancing industrial symbiosis between the aluminum and steel sectors.</p> Graphical Abstract <p></p>

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Adjusting the Viscosity and Structure of CaO-Al2O3-Based Melts Using the Recycled Waste Electrolyte

  • 期刊论文

  • 发表日期：

    2025年8月29日

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  • Xiaocan Zhong,
  • Wanlin Wang,
  • Yang Yang,
  • Lejun Zhou,
  • Sibao Zeng,
  • Liwu Zhang,
  • Jianghua Qi,
  • Kui Chen

摘要

Fluorine-containing waste electrolyte (WE) is a hazardous solid waste in electrolytic aluminum production. This study introduces a sustainable method for utilizing WE by substituting 10.15–24.95 wt.% of fluorite in CaO-Al2O3-based melts. High-temperature viscosity measurements demonstrate that WE reduces melt viscosity by 74% (from 0.85 to 0.22 Pa·s) and lowers activation energy by 21.6% (from 94.06 to 73.77 kJ/mol) compared to conventional fluxes. Structural analyses reveal network depolymerization, with FTIR/Raman spectra indicating the conversion of Q2/Q3(Si) to Q0/Q1(Si) units and the formation of [AlO3F]4− complexes. XPS results show aluminum coordination shifts from [AlO4]5− to [AlO6]9− through Al-F bonding, suggesting stable aluminate structures. The viscosity reduction responds sensitively to initial WE substitution, achieving 65% of the maximum decrease at 10.15 wt.%, while further increases provide diminishing returns. WE-modified fluxes exhibit comparable rheological performance to fluorite systems, significantly reducing hazardous waste generation and enhancing industrial symbiosis between the aluminum and steel sectors.

Graphical Abstract