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<p>The by-product of the aluminium recycling process, the black dross, is often processed to recover aluminium and then sent to the landfills. The existing techniques do not efficiently extract other materials from the dross. The present research introduces an innovative hydrometallurgical process using copper(II) chloride dihydrate to extract high-purity alumina by reprecipitation technique. The obtained alumina is then mixed with copper to form an alumina–copper composite from aluminium black dross. The copper for the process is obtained as a by-product of the reduction reaction between dross and copper(II) chloride dihydrate initial dissolution, the process precipitates aluminium hydroxide, which is subsequently purified through a reprecipitation step involving sodium hydroxide and aqueous ammonia. The final alumina, obtained after calcination at 1000&#xa0;°C, achieves a purity of 96.5%, as confirmed by ICP-OES analysis. The extracted alumina is then combined with copper in a 90:10 weight ratio, producing a composite with particle sizes ranging from 75 to 180&#xa0;nm, optimized for coating applications. This composite demonstrates a polydispersity index of 0.318, indicating uniform particle distribution. The overall extraction efficiency of alumina from aluminium black dross is 90.77%, significantly reducing waste and promoting resource efficiency. Additionally, the pH of various process stages was carefully controlled, with initial copper precipitation at pH 1.20, aluminium hydroxide precipitation at pH 7.46, and neutralization to pH 8.5 for final purification.</p>

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Hydrometallurgical Synthesis of Alumina–Copper Composite Using Waste Black Aluminium Dross for Novel Coating Application

  • 期刊论文

  • 发表日期：

    2025年4月18日

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  • G. Sathiyaseelan,
  • C. Bhagyanathan,
  • J. Gottmyers Melwyn,
  • P. Srinath

摘要

The by-product of the aluminium recycling process, the black dross, is often processed to recover aluminium and then sent to the landfills. The existing techniques do not efficiently extract other materials from the dross. The present research introduces an innovative hydrometallurgical process using copper(II) chloride dihydrate to extract high-purity alumina by reprecipitation technique. The obtained alumina is then mixed with copper to form an alumina–copper composite from aluminium black dross. The copper for the process is obtained as a by-product of the reduction reaction between dross and copper(II) chloride dihydrate initial dissolution, the process precipitates aluminium hydroxide, which is subsequently purified through a reprecipitation step involving sodium hydroxide and aqueous ammonia. The final alumina, obtained after calcination at 1000 °C, achieves a purity of 96.5%, as confirmed by ICP-OES analysis. The extracted alumina is then combined with copper in a 90:10 weight ratio, producing a composite with particle sizes ranging from 75 to 180 nm, optimized for coating applications. This composite demonstrates a polydispersity index of 0.318, indicating uniform particle distribution. The overall extraction efficiency of alumina from aluminium black dross is 90.77%, significantly reducing waste and promoting resource efficiency. Additionally, the pH of various process stages was carefully controlled, with initial copper precipitation at pH 1.20, aluminium hydroxide precipitation at pH 7.46, and neutralization to pH 8.5 for final purification.