Thermodynamic and physical property models for the production of greener aluminum alloys

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This R&D project to produce greener aluminum and advanced aluminum alloys is a partnership between Polytechnique Montréal, Alcoa, Constellium, Elysis, Hydro Aluminium and Rio Tinto with CRITM and NSERC funding. It aims to provide these partners with thermodynamic phase equilibrium models and multi-scale physicochemical models based on the calibration of equations derived from physical relations by first principles simulations and by the critical analysis of experimental results in order to be integrated into advanced simulation tools for the production processes of aluminum and its alloys. The project is divided into 2 research axes: 1) « alumina reduction processes for greener aluminum », and 2) « metallic alloys, liquid metal treatment and recycling ». The models developed within the framework of the 1st axis aim to 1) better simulate the behavior of electrodes (carbon or inert), 2) better simulate the behavior of detrimental impurities (Fe, P, carbon dust) during electrolysis, all in order to improve the energy performance of electrolysis and reduce harmful emissions (CO2 & fluorine). The models of the 2nd axis aim to improve the casting and thermal transformation simulations of aluminum alloys in order to develop new alloys with better properties, more able to support multiple recycling cycles, while improving our fundamental understanding at the atomistic level of these alloys. The training of highly qualified personnel is essential to establish a new generation of engineers and researchers. The anticipated outcomes of the project are that, by using state-of-the-art models that this project will supply, our industrial partners will be able to 1) improve the development and solve key issues pertinent to implement new oxygen evolving aluminum reduction technologies for new smelters, 2) reduce the carbon consumption and CO2 emissions of current smelters, 3) map in a non trial-and-error approach the design of new high performance Al alloys and 4) design a next generation recycling technology for advanced Al alloys (with Li, Fe, Ti, Zr, Cr, etc.). As Canada is a top aluminum producer, and Al smelting emits a lot of CO2, this project can potentially improve the long term viability of this important industry.