ABx Group announces the commencement of operations for ALCORE's state-of-the-art reactor

ABx Group, a prominent player in the aluminium industry, has recently unveiled its groundbreaking bath pilot batch reactor at its subsidiary, ALCORE, situated on the scenic New South Wales (NSW) Central Coast. 

This significant development signifies a major leap in the field of aluminium recycling and promises to have far-reaching implications. 

Key highlights:

• ALCORE, an 83 per cent owned subsidiary of ABx Group, has commissioned a cutting-edge bath pilot batch reactor.
• The reactor is significantly larger than its predecessor, providing the capacity to recover fluorine from excess bath.
• The excess bath, a waste product from aluminium smelting, produces hydrogen fluoride, a valuable chemical required in aluminium smelting.
• Initial operations with modified conditions have proven the reactor's potential, with hydrogen fluoride successfully produced.
• A hazard and operability (HAZOP) study was conducted to ensure safety and efficacy.
• Tests using standard process conditions are now underway, with results on reactor performance and bath process yield expected by December.

A Giant leap in reactor technology:

The centrepiece of this achievement is the state-of-the-art reactor, which is approximately ten times larger than its predecessor. This impressive size and scale are specifically designed to address a critical issue in the aluminium industry—the recovery of fluorine from what is known as "excess bath," a waste product generated during aluminium smelting.

The excess bath, often an overlooked byproduct of aluminium production, is a rich source of raw materials, particularly fluorine. ABx Group's innovative reactor has been engineered to harness the potential of this byproduct by converting the recovered fluorine into hydrogen fluoride. Hydrogen fluoride is an indispensable chemical compound in the aluminium smelting process, making it a high-value product sought after in the industry.

Innovative success with modified process conditions:

The initial operations of the reactor were conducted under modified process conditions, chosen for the safety and reliability of the reactor's performance. This phase has already yielded promising results, showcasing the reactor's potential to efficiently process excess bath and successfully produce hydrogen fluoride. The success of these preliminary operations is a significant milestone, demonstrating the technology's viability.

A focus on safety and efficacy:

Following the successful production of hydrogen fluoride, ABx Group conducted a hazard and operability (HAZOP) study. This comprehensive review assessed all processes undertaken during the initial operations to ensure the safety and effectiveness of reactor operations. The safety and integrity of the equipment and processes are paramount to ABx Group's commitment to responsible industrial practices.

Anticipated results and prospects:

With the modified conditions yielding promising results, the company has transitioned to tests under standard process conditions. These tests follow specific parameters, including temperature ranges, residence times, and precise quantities of acid, providing a more controlled environment for testing.

The upcoming test results conducted under standard process conditions are highly anticipated, with expectations to provide a more robust dataset. This data will be invaluable in guiding the next steps for ABx Group.

A bright future for aluminium recycling:

The successful commissioning of this state-of-the-art reactor and the subsequent production of hydrogen fluoride from excess bath marks a significant achievement for ALCORE, ABx Group, and the aluminium industry as a whole. The promising results obtained with modified conditions lay the technical foundation required for further advancements in processing.

The processing of bath using this new reactor, with its increased capacity (approximately ten times larger than the smaller laboratory reactor used in previous work), will provide critical insights into the potential for increased yields. This leap in scale positions ABx Group to make a substantial impact on the industry.

These results are expected to be pivotal in ABx Group's vision to scale up operations. The ultimate goal is to establish a continuous pilot plant and, eventually, a first-of-its-kind commercial plant in the field of aluminium recycling.

Mark Cooksey, Managing Director and CEO of ABx Group said, "Processing of bath using our new reactor will provide important data on our ability to produce greater yields, at roughly ten times the scale of our smaller laboratory reactor, where much of our work has been focused to date. Results from this new reactor are expected to provide more robust data which will be used to eventually scale-up operations to a continuous pilot plant and first commercial plant."

In conclusion, ABx Group's state-of-the-art reactor is a game-changer in the aluminium industry. It offers a sustainable and efficient solution to harness the full potential of excess bath and convert it into high-value hydrogen fluoride. With promising results already achieved and ambitious plans for the future, ABx Group's innovation promises to shape the future of aluminium recycling, contributing to a more sustainable and eco-friendly aluminium industry.