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<p>This study presents the results of crystallization refining of aluminum containing high levels of iron (up to 3 wt%) and silicon (up to 0.5 wt%) impurities, which accumulate in electrolytic cells before major overhauls. A novel refining method for technical-grade aluminum based on fractional crystallization is proposed, involving the extraction of iron and silicon impurities from the melt through rapid cooling and the introduction of a crystallizer into the surface layer of the liquid. The study investigated the mechanisms of fractional crystallization and optimized process parameters to enhance refining efficiency. A mathematical model was developed to accurately describe the crystallization refining process. The optimal process conditions were determined as follows: aluminum melt temperature of 740–770&#xa0;°C, steel rod immersion time of 30–65&#xa0;s, and immersion depth of 0.3&#xa0;cm. The refining mechanism for iron and silicon removal was elucidated. Iron crystallization on the steel rod surface is driven by intensive heat extraction, leading to nonequilibrium solidification. The increased silicon content in the metal solidified on the rod is explained by inverse segregation, where the initially crystallized solid layer is enriched with eutectic components. The method’s effectiveness was confirmed by an 80% reduction in iron content (to 0.3 wt%) and a 66–72% reduction in silicon content (to 0.07 wt%).</p> Graphical Abstract <p></p>

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Mechanism and Optimization of Iron and Silicon Removal from Aluminum via Fractional Crystallization

  • 期刊论文

  • 发表日期：

    2026年3月12日

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  • Mikhail P. Kuz’min,
  • Marina Yu. Kuz’mina,
  • Alina S. Kuz’mina

摘要

This study presents the results of crystallization refining of aluminum containing high levels of iron (up to 3 wt%) and silicon (up to 0.5 wt%) impurities, which accumulate in electrolytic cells before major overhauls. A novel refining method for technical-grade aluminum based on fractional crystallization is proposed, involving the extraction of iron and silicon impurities from the melt through rapid cooling and the introduction of a crystallizer into the surface layer of the liquid. The study investigated the mechanisms of fractional crystallization and optimized process parameters to enhance refining efficiency. A mathematical model was developed to accurately describe the crystallization refining process. The optimal process conditions were determined as follows: aluminum melt temperature of 740–770 °C, steel rod immersion time of 30–65 s, and immersion depth of 0.3 cm. The refining mechanism for iron and silicon removal was elucidated. Iron crystallization on the steel rod surface is driven by intensive heat extraction, leading to nonequilibrium solidification. The increased silicon content in the metal solidified on the rod is explained by inverse segregation, where the initially crystallized solid layer is enriched with eutectic components. The method’s effectiveness was confirmed by an 80% reduction in iron content (to 0.3 wt%) and a 66–72% reduction in silicon content (to 0.07 wt%).

Graphical Abstract