Formation and Utilization of Nanostructures Based on Carbon During Primary Aluminum Production

Results are given for comprehensive research concerning fields of metallurgy, nanomaterials, and ecology. Taking account of theoretical concepts and known practice of modifying gray cast iron, a new ultrafine modifier is considered containing carbon with increased chemical activity. It is established that carbon foam, electrolyzer dust from electric filters, and alumina passing through a dry gas cleaning system, have carbon nanostructures in their composition. Raw material composition for preparing modifying additive, procedures, and experimental materials are provided. Results are given from a series of cast iron melts with a different modifier content and a method for adding it with replacement of 50% of standard metallurgical graphite by the carbon-containing part of carbon foam. The effect of modifier on phase formation during gray cast iron solidification by means of cooling from a liquid condition is considered. A test cast iron sample and reference cast iron are analyzed chemically, and mechanical properties are analyzed. It is established that a modifier makes it possible to improve gray cast iron grade. Theories are proposed for carbon nanotube formation during aluminum production. A technology is provided for extracting carbon structures from starting raw material. It is shown that with preparation of one ton of aluminum using the production solutions developed for decontamination and utilization of industrial waste it is possible to produce modifier based on highly organized carbon nanostructures.