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14 Xiao Y. Yan and Derek J. Fray The reversible cell voltage needed for the reduction reaction to occur at this temperature is 1.77 V at 700 °C and the cell voltage is about 3.3 V which can be compared with 4.5 V in the HHC, with the current density being 1.3 A/cm2. Under these conditions, power consumption is 11.4 kWh per kg Al, which yields an energy efficiency of 60 %. This cell design improves significantly the space-time yield over that of the HHC and compares quite favourably with that of the typical HHC which is due to the higher electrical conductance of the chloride electrolyte and the smaller anode-cathode separation, hence the lower voltage drop across the electrodes, make the electrolysis of AlCl3 more energy efficient than the HH process. This alternative chloride electrowinning technology promises to produce aluminium at around 4 kWh per 1b but requires a chemical plant to produce anhydrous AlCl3. The electrolysis unit offers higher efficiency and probably also lower capital costs than the HHC of the same capacity. However, these advantages are outweighed by the cost of the extra process step, i.e., chlorination of alumina and the problem of removing dioxins, making the overall process less attractive economically (see also section 2.5.3). Yang and Fray simulated electrowinning cells with anodes of large surface areas for electrolysis of alumina dissolved in a chloride melt [26]. Figure 5. Schematic diagram of Alcoa’s bipolar cell [3].PDF Image | MOLTEN SALT ELECTROLYSIS
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