TWI894914B - Aluminum alloy deoxidizer with carbon compounds - Google Patents

Abstract

This invention provides an aluminum alloy deoxidizer with carbon compounds having several aluminum ingots, wherein the aluminum ingots mainly contain elemental aluminum and 0.1 wt% to 8 wt% cabon or organic matters.

Description

Deoxidized aluminum alloy containing carbon compounds

A deoxidized aluminum alloy material, particularly a deoxidized aluminum alloy material containing carbon compounds.

The circular economy has become a prominent concept in modern society. Unlike the traditional linear economic model, which follows a continuous process from resource extraction to production, consumption, and ultimately disposal, this economic model, based on resource recovery and reuse, aims to minimize resource consumption and waste. The circular economy encourages the circular use of resources, maximizing their value through recycling, regeneration, and reuse, ultimately achieving a sustainable economic development model.

The metal and related manufacturing industries are significant resource consumers and sources of environmental pollution, making the implementation of a circular economy crucial for this sector. Many relevant industries have long practiced metal recycling, as recycling can save significant amounts of raw materials and energy, reduce carbon emissions, and allow the recycled metal to be used to manufacture new products. However, today's aluminum recycling model requires smelting and tempering recycled aluminum, which consumes extremely high amounts of energy, requires numerous operations, and results in high operating costs. Oxidation caused by heating also results in significant yield losses and waste of aluminum, and the remelting of scrap aluminum produces toxic fumes, dust, and slag.

Furthermore, the current aluminum recycling model collects recycled aluminum materials such as aluminum cans, aluminum foil packages, or aluminum scrap generated after machining and cutting. Due to the use requirements and characteristics of the recycled aluminum materials before recycling, these recycled aluminum materials are mixed with a certain degree of organic matter. For example, aluminum cans have a resin coating on the interior surface and a printed coating on the exterior, or aluminum scraps contain cutting fluid. These organic substances attached to the recycled aluminum materials will produce organic pollutants such as dioxins during the remelting process of the recycled aluminum materials in the existing aluminum recycling process, causing serious environmental pollution and public hazards.

On the other hand, in the steel industry, deoxidizing materials are widely used during the steelmaking process to remove oxygen from molten steel, effectively improving its quality and properties, increasing its purity and uniformity, reducing defects, and enhancing its toughness and corrosion resistance. In particular, aluminum alloys, which react rapidly with oxygen, are used as deoxidizing materials. However, the cost of aluminum alloys is relatively high, and the energy consumption of existing technologies for producing aluminum alloy deoxidizing materials is also very high. In view of this, the development of aluminum alloy deoxidizing materials that can achieve a circular economy and reduce manufacturing costs has become a pressing goal in the relevant fields.

To address the environmental pollution caused by the generation of organic pollutants during the melting of scrap aluminum in existing aluminum recycling processes, as well as the high cost and energy-intensive production of deoxidizers required by the steelmaking industry, the present invention provides a carbon-containing aluminum alloy deoxidizer. The deoxidizer is composed of a plurality of aluminum particles, wherein the aluminum particles are primarily composed of elemental aluminum and contain 0.1 to 8 weight percent of carbon or organic matter.

The plurality of aluminum particles are cut from an aluminum bar. The cross-sectional area of the aluminum bar ranges from 0.2 square centimeters to 450 square centimeters. The cross-sectional area contains 20 to 500 carbon particles. The carbon particles are formed by carbonizing at least a portion of the organic matter and contain at least 50 weight percent of carbon.

The carbon particles contain 85 to 95 weight percent of carbon, 2 to 8 weight percent of oxygen, and 1 to 10 weight percent of aluminum.

The organic matter comprises alkanes, lipids, resins or polyesters.

The aluminum particles are made from recycled aluminum material.

The aluminum particles further contain 0.1 to 2 weight percent of silicon, 0 to 2 weight percent of copper, 0.1 to 30 weight percent of magnesium, 0.1 to 10 weight percent of manganese, and 0 to 10 weight percent of zinc.

The aluminum particles are in the shape of spherical particles, teardrops or polygons.

The aluminum particles contain one or more concave surfaces or hollow holes.

The carbon particles include chlorides, sulfides, nitrides, silicates or oxides.

The dioxin content of the aluminum pellets and the aluminum bars was lower than 0.1 ng I-TEQ/g.

From the above description, it can be seen that the present invention has the following features:

1. The carbon compound-containing aluminum alloy deoxidized material of the present invention does not require heating to melt the waste aluminum, which can significantly reduce air pollution and avoid the risk of pollutants escaping into the environment.

2. The carbon compound-containing aluminum alloy deoxidized material of the present invention does not require heating to melt the scrap aluminum, which can save a lot of energy and does not produce toxic fumes, dust and slag produced when melting scrap aluminum.

3. The method for producing a deoxidized aluminum alloy material containing carbon compounds does not require heating to melt the scrap aluminum, thus avoiding the loss of aluminum metal due to aluminum oxidation during the production process.

4. The carbon-containing aluminum alloy deoxidizing material of the present invention uses recycled aluminum as a deoxidizing material for steelmaking, thereby reducing the cost of deoxidizing materials and the loss of raw materials in the steelmaking process, and achieving the effect of resource recycling.

5. The production of the carbon-containing aluminum alloy deoxidized material of the present invention does not generate organic pollutants during the production process due to the organic matter contained in the recycled aluminum. This can simplify or even eliminate the previous processing of the recycled aluminum, saving time, resources and costs, and is more environmentally friendly.

7. The method for manufacturing the carbon compound-containing aluminum alloy deoxidized material of the present invention does not require the aluminum extrusion to be fixed with an adhesive as in the prior art, thereby saving costs and avoiding environmental pollution and resource waste caused by adhesives.

8. The method for producing the carbon compound-containing aluminum alloy deoxidized material of the present invention first converts the recycled aluminum into aluminum bars and then cuts them into a plurality of aluminum grains. Each cut surface is a new cut surface with an extremely thin aluminum oxide layer, thereby enhancing the deoxidation effect of the deoxidized material.

9. The carbon compound-containing aluminum alloy deoxidation material of the present invention has shapes including concave surfaces and hollow pores, which can increase the contact surface area and significantly improve the deoxidation efficiency.

10. The carbon compound-containing aluminum alloy deoxidizing material of the present invention can be further added with other elements to enhance the deoxidizing effect of the deoxidizing material by adjusting the redox capacity and specific gravity of the aluminum particles through the alloy composition.

11. The carbon-containing aluminum alloy deoxidized material of the present invention can be used to recycle aluminum waste materials that are difficult to process using existing technologies, such as aluminum chips generated by aluminum alloy cutting or used aluminum cans. This solves the problem that these aluminum chips have a large surface area to volume ratio, making them easily oxidized and often mixed with lubricant, cutting fluid, or beverage residue and coating, making them difficult to effectively recycle. It also improves the problems of recycling and remelting processing using existing technologies.

To more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the accompanying figures required for describing each embodiment. Obviously, the accompanying figures described below are merely examples or embodiments of the present invention. Those skilled in the art can apply the present invention to other similar scenarios based on these figures without inventive effort. Unless otherwise apparent from the context or otherwise indicated, the same reference numerals in the figures represent the same structure or operation.

As used herein and in the claims, unless the context clearly indicates otherwise, the terms "a," "an," "an," or "the" are not intended to refer to the singular but include the plural. Generally, the terms "comprises" and "include" indicate only the inclusion of the steps and elements specifically identified, and these steps and elements do not constitute an exclusive list; a method or apparatus may also include additional steps or elements.

Flowcharts are used throughout this disclosure to illustrate the operations performed by systems according to embodiments of the present invention. It should be understood that preceding or following operations do not necessarily need to be performed in exact order. Instead, the steps may be processed in reverse order or simultaneously. Furthermore, other operations may be added to these processes, or one or more operations may be removed from these processes.

Please refer to Figure 1, which is a diagram illustrating the manufacturing steps of some embodiments of the carbon-containing aluminum alloy deoxidized material of the present invention. The main manufacturing steps of the carbon-containing aluminum alloy deoxidized material of the present invention include steps S10 to S50.

Step S10: Place a plurality of recycled aluminum materials into a certain forming part and compact them until the recycled aluminum materials fill the forming part. In this step S10, the collected recycled aluminum materials are concentrated and placed into the forming part and continuously compacted. When the recycled aluminum materials shrink due to compression, more recycled aluminum materials can be placed into the forming part until the recycled aluminum materials completely fill the forming part. Preferably, the forming part is a hollow tube, and the hollow tube can be a tube with openings at both ends or only one end. The cross-section of the hollow tube is circular. In a preferred embodiment, the diameter of the cross-section circle of the hollow tube is 9 cm, and the length of the hollow tube is 60 cm.

The recycled aluminum can be various types of recycled aluminum scrap. For example, it can be aluminum shavings generated during the cutting process of an aluminum alloy block, or scraps from recycled aluminum cans and aluminum foil packages that have been pre-processed and shredded. The recycled aluminum can be scrap aluminum shavings of various sources and qualities. Preferably, the recycled aluminum placed in the hollow tube is recycled aluminum from a single source. A single source means that the recycled aluminum is aluminum alloy scrap generated or recycled from aluminum alloy products produced by the same alloy system, the same American Aluminum Association alloy number, or the same manufacturing process. In one embodiment, the recycled aluminum material is aluminum alloy aluminum chips produced by the same cutting process performed by the same machine tool. In another embodiment, the recycled aluminum material is all recycled aluminum alloy easy-opening can fragments.

The recycled aluminum may undergo a series of pre-treatments before being placed into the molded part for compaction and filling. In one embodiment, the recycled aluminum undergoes initial cleaning and air separation to remove larger impurities, followed by magnetic separation to remove ferromagnetic metals. However, these pre-treatments are not absolutely necessary; the appropriate pre-treatment method can be selected based on the source of the recycled aluminum. For example, in one embodiment, the recycled aluminum is aluminum shavings generated during a cutting process of an aluminum alloy block. In this case, the recycled aluminum only needs to be initially cleaned to remove the cutting fluid before it can be placed into the molded part for compaction and filling.

Therefore, the recycled aluminum material contains a plurality of residual organic compounds. Specifically, the recycled aluminum material contains 0.1 to 8 weight percent of organic components. More preferably, the recycled aluminum material contains 0.5 to 5 weight percent of organic components. In one embodiment, the recycled aluminum material is aluminum chips generated during a cutting process of an aluminum alloy block. The plurality of residual organic compounds in the recycled aluminum material are primarily cutting fluid, which may include mineral oil, emulsifier, water, anti-rust additives, defoaming agents, and other ingredients. In another embodiment, the recycled aluminum material is recycled aluminum cans and aluminum foil bag scraps. The multiple organic compounds remaining in the recycled aluminum material may be paper components contained in the aluminum foil bag, such as cellulose, hemicellulose, or lignin, or the incompletely removed printing layer on the aluminum can body and the coating layer on the aluminum can's inner layer. The coating layer may be composed of various lipids such as wax, various resins such as epoxy resins, or various polyesters such as acrylic copolymers or polycarbonates. These organic compounds are difficult to completely remove during pre-processing without consuming a considerable amount of time, energy, and resources. However, in step S10, the recycled aluminum material does not need to undergo a complex pre-treatment process before being placed into the molded part for compaction and filling to form an aluminum bag. In one embodiment, the untreated or minimally pre-treated recycled aluminum material is recycled from aluminum material with the American Aluminum Association alloy number 7075, which contains 1.5 to 8 weight percent of organic matter. In another embodiment, the untreated or minimally pre-treated recycled aluminum material is recycled from aluminum material with the American Aluminum Association alloy number 5000 series, which contains 2 to 5 weight percent of organic matter. In another embodiment, the untreated or simply pre-treated recycled aluminum material is recycled from aluminum of the American Aluminum Association alloy number 6000 series, which contains 0.5 to 1.5 weight percent of organic matter.

To further enhance the performance of the deoxidized aluminum alloy material formed by the present invention, elements with strong deoxidizing properties, such as magnesium, manganese, silicon, zinc, or copper, can be added to the aluminum clad during the step of placing the recycled aluminum into the cladding material for compaction. This further enhances the overall deoxidation efficiency and regulates the specific gravity of the deoxidized aluminum alloy material formed by the present invention. Preferably, different proportions of these elements can be added to achieve a specific ratio, depending on the recycled aluminum material. The aluminum clad contains 0.1 to 2 weight percent silicon, 0 to 2 weight percent copper, 0.1 to 30 weight percent magnesium, 0.1 to 10 weight percent manganese, and 0 to 10 weight percent zinc.

Step S20 (optional): Place the compacted recycled aluminum into a mold. In this step S20, when the recycled aluminum has been compacted to fill the forming part, the compacted recycled aluminum is taken out from the forming part and placed into the mold. This step S20 can take out the recycled aluminum from the forming part and place it into the mold. Since the recycled aluminum has been compacted, it will maintain the shape in the coating material when it is taken out without scattering or deforming. Preferably, the coating material is the hollow tube, and the compacted recycled aluminum is cylindrical or pie-shaped after being taken out. Place the compacted recycled aluminum into the mold. The mold is a long hollow cylinder, and its length and cross-section are both larger than the hollow tube. The mold bottom has a retaining ring positioned at the center of one of its long axes. This retaining ring is equal to or slightly larger than the cross-section of the compacted recycled aluminum, ensuring that the ring secures the compacted recycled aluminum at the center of the mold's long axis without shifting. The mold may also include one or more clamping devices to secure the compacted recycled aluminum within the mold. In a preferred embodiment, the mold opening has a diameter of 12.7 cm and is 60 cm long. The retaining ring, with a diameter of 10 cm and a depth of 1 cm, is located at the bottom of the mold. A clamping aluminum sheet and a screw are located at the top of the mold. In a preferred embodiment, the mold secures the compacted recycled aluminum with an aluminum alloy tube.

Furthermore, in step S20, the shaped part filled with the recycled aluminum can be placed directly into the mold without removing the recycled aluminum from the shaped part. In a preferred embodiment, the shaped part is the hollow tube, and the hollow tube is made of an aluminum alloy. This allows the recycled aluminum to be placed into the mold along with the aluminum alloy hollow tube after compaction, with the hollow tube serving as the clamping device. More preferably, the aluminum alloy hollow tube and the recycled aluminum have the same alloy composition, i.e., the hollow tube and the recycled aluminum have the same alloy system or the same American Aluminum Association alloy number.

Step S30 (optional): Pour an aluminum soup into the recycled aluminum and seal it to form a ladle. In this step S30, the recycled aluminum placed in the mold is poured with an aluminum soup, which completely covers and seals the recycled aluminum. After cooling and solidification, a ladle is formed. The aluminum soup is a molten aluminum alloy. Preferably, the aluminum soup and the recycled aluminum have the same alloy composition, that is, the aluminum soup and the recycled aluminum have the same alloy system or the same American Aluminum Association alloy number. In one embodiment, recycled aluminum alloy cans collected from a single source are shredded and placed into the hollow tube for compaction. The resulting recycled aluminum is then poured with aluminum broth of a similar alloy system, ensuring that the aluminum alloy within the ladle maintains uniform, homogeneous properties. Preferably, the aluminum sheet used for compaction also has the same alloy composition as the recycled aluminum. The aluminum broth completely encapsulates the recycled aluminum, thereby encapsulating the plurality of organic compounds within the ladle.

Step S40: The aluminum bag or cast is preheated and then hot extruded to form an aluminum bar A. In step S40, the cast is removed from the mold and preheated, then used as an aluminum blank for hot extrusion to form an aluminum bar A. The cross-sectional shape of the aluminum bar can be designed based on the extrusion die through which the cast passes, and the hot extrusion can be direct or indirect. Indirect extrusion can create a hollow structure within the aluminum bar A. Preferably, the hot extrusion temperature is between 360°C and 550°C, and the extrusion speed is between 0.2 mm and 20 mm per second. The extrusion speed is the travel speed of the hot extrusion machine's die. Preferably, the cross-sectional area ratio of the hollow tube to the aluminum bar is between 40:1 and 10:1. The cross-sectional area ratio of the hollow tube to the aluminum bar A is the extrusion ratio. The preferred extrusion ratio in step S40 is between 10 and 40. The resulting aluminum bar A has a porosity of less than 1%. Part of the organic matter in the aluminum bar A formed by hot extrusion is converted to carbon. The aluminum strip A contains 0.1 to 8 weight percent of carbon or organic components. More preferably, the aluminum strip A contains 0.5 to 5 weight percent of carbon or organic components.

Referring to Figures 2 and 8 , the aluminum bar A is preferably cylindrical, such that the shape and area of each of the plurality of cross-sections CS of the aluminum bar A are identical. In the present invention, the term "cross-section" refers to the surface formed by cutting the aluminum bar A along a plane perpendicular to the extrusion direction of the aluminum bar A. Preferably, the area of the cross-section CS is between 0.2 square centimeters and 450 square centimeters. Preferably, the aluminum bar A is a round bar, such that the cross-section CS is circular. Preferably, the diameter of the circle of the cross-section CS is between 0.5 centimeters and 2 centimeters.

Referring to Figure 7 , when aluminum strip A is heated, the organic compound attached to the aluminum-containing material further carbonizes, resulting in the inclusion of a plurality of carbon particles B within the strip A. The carbon particles B contain at least 50% by weight of carbon. These carbon particles B possess excellent high-temperature resistance, enhancing the strip A's heat resistance and allowing it to be processed in high-temperature environments. Furthermore, the presence of these carbon particles B improves the strip A's thermal conductivity, resulting in superior thermal conductivity even at high temperatures. Preferably, the cross-section CS of the strip A contains 20 to 500 carbon particles B.

Preferably, the carbon particles B contain chlorides, sulfides, nitrides, silicates, or oxides.

The carbon particles B may be composed of the following elements in weight percentage: 85% to 95% carbon, 2% to 8% oxygen, and 1% to 10% aluminum.

Referring to FIG. 7 , in a preferred embodiment, EDS analysis of the carbon particles B in the cross-section CS of the aluminum bar A reveals that the carbon particles B contain the following elements in weight percentage: 90.99% carbon, 4.22% oxygen, 0.64% magnesium, 2.79% aluminum, 1.16% silicon, 0.10% chlorine, and 0.11% iron.

Furthermore, the aluminum strip A exhibits anisotropic material mechanical properties. The aluminum strip A is in the shape of an elongated cylinder, defining an extrusion direction ED along the direction of extrusion of the elongated cylinder, and a radial direction perpendicular to the extrusion direction ED. The cross-section CS perpendicular to the extrusion direction ED (i.e., a normal vector of the cross-section CS is parallel to the extrusion direction ED) has a harder hardness than a longitudinal section LS perpendicular to the radial direction. Preferably, the ratio of the hardness of the cross-section CS perpendicular to the extrusion direction ED to the longitudinal section LS perpendicular to the radial direction is greater than 1.2, and more preferably, greater than 1.5. In a preferred embodiment, the Rockwell hardness test is performed using the HRF hardness scale, i.e., a steel ball with a diameter of 1.588 mm is measured at a load of 60 kgf. The measured value of the cross-section CS is between 23.9 and 42.5, while the measured value of the longitudinal section LS is between 63.1 and 76.7.

Referring to FIG5A , X-ray diffraction analysis was used to measure the cross-section CS of the aluminum strip A perpendicular to the extrusion direction ED. It was observed that the crystals of the aluminum strip A were mostly arranged in a (200) direction, as indicated by the Miller index. This was different from the X-ray diffraction results of the random structure of the standard aluminum powder, which were mostly arranged in a (111) direction. This indicates that the aluminum strip A has a preferred crystal orientation in the (200) direction. In addition, in some preferred embodiments, the aluminum strip A can also contain some carbon diffraction peaks (in the triangle), indicating that the carbon particles B after the carbonization of the organic compound are present in the aluminum strip A.

Please refer to Figure 5B. In another preferred embodiment, the recycled aluminum material is a mixed recycled aluminum material of the American Aluminum Association alloy number 6000 series and 7000 series. X-ray diffraction analysis is used to measure a surface of the aluminum bar A parallel to the extrusion direction ED and perpendicular to the cross-section CS. It can be observed that the crystals of the aluminum bar A have a relatively high strength (111) arrangement represented by the Miller index, which is similar to the (111) arrangement of the X-ray diffraction results of the random structure of the aluminum powder standard. The crystals of the aluminum bar A have a slight increase in the Miller index (200), indicating that in this embodiment, the aluminum bar A does not have an obvious preferential crystal orientation.

Please refer to Figures 6A and 6B , which are partial metallographic images of a cross-section CS of the aluminum bar A according to a preferred embodiment of the present invention. Preferably, the cross-section CS includes one or more cracks C or voids V at or near the center. These cracks C or voids V are defects generated during the extrusion process using recycled aluminum containing organic matter.

Step S50: Cutting the aluminum bar A into a plurality of aluminum pellets to produce a carbon-containing aluminum alloy deoxidized material. In step S50, the aluminum bar formed by hot extrusion is cut into a plurality of aluminum pellets, completing the production of the carbon-containing aluminum alloy deoxidized material. The aluminum pellets may be spherical, teardrop-shaped, or polygonal in shape. Preferably, the carbon-containing aluminum alloy deoxidized material further includes one or more concave surfaces or hollow holes to increase the surface area of the carbon-containing aluminum alloy deoxidized material, thereby enhancing the deoxidizing effect and improving deoxidation efficiency. In one embodiment, the aluminum bar A formed by indirect hot extrusion in step S40 includes a hollow portion along the axial direction, so that when the aluminum bar is cut into a plurality of aluminum grains, the aluminum grains have through-holes.

Preferably, step S50 can be performed in an oxygen-free environment, such as cutting the aluminum bar into a plurality of aluminum grains and packaging them in a nitrogen environment, thereby reducing the formation of aluminum oxide on the surface of the aluminum grains during cutting and increasing the deoxidation capacity and efficiency of the aluminum alloy deoxidation material.

＜Properties and Applications of Deoxidized Aluminum Alloys Containing Carbon Compounds＞

Please refer to the carbon compound-containing aluminum alloy deoxidized material 10 of the present invention, which is composed of a plurality of aluminum grains 20, wherein the aluminum grains 20 are primarily composed of elemental aluminum and contain 0.1 to 8 weight percent of carbon or organic matter. "Elemental aluminum" as used herein means that the aluminum element constitutes the largest percentage of the weight of the aluminum grains 20 compared to other components. Furthermore, the aluminum constituting the aluminum grains 20 is primarily elemental aluminum, not oxidized aluminum oxide. An oxide film, primarily composed of aluminum oxide, may form on the outer layer of the aluminum grains 20 that is in contact with the atmosphere. The oxide film tightly and completely coats the aluminum pellets 20, preventing further oxidation of inorganic matter within the pellets 20. This ensures that the aluminum in the pellets 20 is primarily elemental aluminum, rather than oxidized aluminum oxides, thus preventing a reduction in the deoxidation effectiveness of the pellets 20. Because the pellets 20 are not made by melting recycled aluminum, only the surface and some internal interfaces contain oxidized inorganic matter, resulting in an even better deoxidation effect for the pellets 20 of the present invention.

Furthermore, the aluminum particles 20 also contain 0.1 to 2 weight percent silicon, 0 to 2 weight percent copper, 0.1 to 30 weight percent magnesium, 0.1 to 10 weight percent manganese, and 0 to 10 weight percent zinc. The carbon particles B are formed by carbonizing an organic substance comprising an alkane, ester, resin, or polyester. In one embodiment, the organic substance primarily comprises cutting fluid, while in another embodiment, the organic substance primarily comprises the inner coating material of an aluminum can. After the carbon-containing aluminum alloy deoxidized material 10 of the present invention is manufactured, most of these organic substances are carbonized during the preheating and hot extrusion processes and distributed in the aluminum pellets 20 in the form of carbon particles B. When the aluminum pellets 20 are placed in a steelmaking furnace, the furnace temperature is much higher than the cracking temperature of the high-molecular organic substances, so the environmentally polluting or toxic organic substances are completely cracked, reducing waste problems and lowering the generation of harmful organic substances.

In one embodiment, the aluminum ladle and the cast ladle used to form the aluminum bar A, as well as the finished aluminum pellets 20, were tested for dioxin and furan. The test results were 0.013 ng I-TEQ/g and 0.00004 ng I-TEQ/g, respectively, which are significantly lower than the regulatory standard of 0.1 ng I-TEQ/g for bottom ash recycling products or soil. This confirms that neither the carbon compound-containing aluminum alloy deoxidized material 10 nor its manufacturing process generates dioxin pollution due to the organic matter present in the recycled aluminum.

To optimize the deoxidation performance of the carbon-containing aluminum alloy deoxidized material 10 of the present invention, the metal elements placed in the aluminum ladle or casting can be adjusted to achieve a specific ratio of metal elements within the aluminum granules 20 of the carbon-containing aluminum alloy deoxidized material 10. For example, the ratio of magnesium in the aluminum granules 20 can be increased to enhance deoxidation performance, or the ratio of copper in the aluminum granules 20 can be increased to increase the density of the aluminum granules, thereby improving the deoxidization performance caused by the deoxidized material floating on the molten steel surface. In one embodiment, the aluminum granules 20 contain 0.1 to 2 weight percent silicon, 0.1 to 2 weight percent magnesium, and 0.1 to 2 weight percent manganese. In another embodiment, the aluminum pellets 20 contain 0.1 to 2 weight percent silicon, 0.1 to 10 weight percent magnesium, and 0.1 to 2 weight percent manganese. In another embodiment, the aluminum pellets 20 contain 0.1 to 2 weight percent silicon, 1 to 2 weight percent copper, 0.1 to 1 weight percent magnesium, 0.1 to 1 weight percent manganese, and 0.1 to 10 weight percent zinc. In yet another embodiment, the aluminum pellets 20 contain 0.1 to 10 weight percent silicon, 0.1 to 10 weight percent magnesium, 0.1 to 2 weight percent manganese, and 0.1 to 10 weight percent zinc.

To achieve more efficient deoxidation in the carbon-containing aluminum alloy deoxidation material 10 of the present invention, each aluminum granule 20 is shaped like a spherical granule, a teardrop, or a polygon. Furthermore, to further enhance the deoxidation performance of the carbon-containing aluminum alloy deoxidation material 10, the aluminum granules 20 can be heat-extruded and cut to include one or more concave surfaces or hollow pores 30, significantly increasing the surface area of the aluminum granules 20. The low-porosity heat-extruded deoxidation material reduces the buoyancy of the aluminum granules 20, improving the traditional situation where aluminum granules merely float on the surface of the molten steel and enhancing the deoxidation effect.

The carbon-containing aluminum alloy deoxidizing material 10 of the present invention can provide the steel industry with a low-cost, high-efficiency, and environmentally friendly low-carbon deoxidizing material. In one embodiment, the carbon-containing aluminum alloy deoxidizing material can be used as an excellent deoxidizing material for molten steel. The temperature of the steelmaking furnace is far higher than 1000°C. Because the aluminum particles contain multiple residual organic substances, the various organic substances contained in the carbon compound aluminum alloy deoxidized material 10 can be completely carbonized and cracked at this temperature, thereby avoiding the emission of toxic organic pollutants such as dioxin. It can also effectively assist in the deoxidation of molten steel. Therefore, the carbon compound aluminum alloy deoxidized material 10 of the present invention can simultaneously recycle waste aluminum materials that are traditionally difficult to recycle and convert them into high-value-added carbon compound aluminum alloy deoxidized material 10 with low energy consumption and low metal loss, while avoiding environmental pollution caused by harmful organic substances.

From the above description, it can be seen that the present invention achieves the following effects:

1. The carbon compound-containing aluminum alloy deoxidized material of the present invention does not require heating to melt the waste aluminum, which can significantly reduce air pollution and avoid the risk of pollutants escaping into the environment.

2. The carbon compound-containing aluminum alloy deoxidized material of the present invention does not require heating to melt the scrap aluminum, which can save a lot of energy and does not produce toxic fumes, dust and slag produced when melting scrap aluminum.

3. The method for producing a deoxidized aluminum alloy material containing carbon compounds does not require heating to melt the scrap aluminum, thus avoiding the loss of aluminum metal due to aluminum oxidation during the production process.

4. The carbon-containing aluminum alloy deoxidizing material of the present invention uses recycled aluminum as a deoxidizing material for steelmaking, thereby reducing the cost of deoxidizing materials and the loss of raw materials in the steelmaking process, and achieving the effect of resource recycling.

5. The production of the carbon-containing aluminum alloy deoxidized material of the present invention does not generate organic pollutants during the production process due to the organic matter contained in the recycled aluminum. This can simplify or even eliminate the previous processing of the recycled aluminum, saving time, resources and costs, and is more environmentally friendly.

7. The method for manufacturing the carbon compound-containing aluminum alloy deoxidized material of the present invention does not require the aluminum extrusion to be fixed with an adhesive as in the prior art, thereby saving costs and avoiding environmental pollution and resource waste caused by adhesives.

8. The method for producing the carbon compound-containing aluminum alloy deoxidized material of the present invention first converts the recycled aluminum into aluminum bars and then cuts them into a plurality of aluminum grains. Each cut surface is a new cut surface with an extremely thin aluminum oxide layer, thereby enhancing the deoxidation effect of the deoxidized material.

9. The carbon compound-containing aluminum alloy deoxidation material of the present invention has shapes including concave surfaces and hollow pores, which can increase the contact surface area and significantly improve the deoxidation efficiency.

10. The carbon compound-containing aluminum alloy deoxidizing material of the present invention can be further added with other elements to enhance the deoxidizing effect of the deoxidizing material by adjusting the redox capacity and specific gravity of the aluminum particles through the alloy composition.

11. The carbon-containing aluminum alloy deoxidized material of the present invention can be used to recycle aluminum waste materials that are difficult to process using existing technologies, such as aluminum chips generated by aluminum alloy cutting or used aluminum cans. This solves the problem that these aluminum chips have a large surface area to volume ratio, making them easily oxidized and often mixed with lubricant, cutting fluid, or beverage residue and coating, making them difficult to effectively recycle. It also improves the problems of recycling and remelting processing using existing technologies.

It should be noted that, based on the explanations and elaborations in the above specification, those skilled in the art may further modify and alter the above-described embodiments. Therefore, the present disclosure is not limited to the specific embodiments disclosed and described above; equivalent modifications and variations of the present disclosure are also within the scope of protection of the claims of the present disclosure. Furthermore, while this specification employs certain terminology, these terms are used solely for convenience of explanation and do not constitute any limitation of the invention.

S10-S50: Steps 10: Deoxidized aluminum alloy containing carbon compounds 20: Aluminum particles 30: Hollow holes A: Aluminum bars B: Carbon particles C: Cracks CS: Cross-section ED: Extrusion direction LS: Longitudinal section V: Hollow holes

Figure 1 is a step diagram of a preferred embodiment of the present invention; Figure 2 is a schematic diagram of an aluminum bar according to a preferred embodiment of the present invention; Figure 3 is a schematic diagram of a plurality of aluminum grains according to a preferred embodiment of the present invention; Figure 4 is a schematic diagram of a plurality of aluminum grains according to a preferred embodiment of the present invention; Figure 5A is an X-ray diffraction analysis diagram of an aluminum bar according to a preferred embodiment of the present invention; Figure 5B is an X-ray diffraction analysis diagram of an aluminum bar according to a preferred embodiment of the present invention; Figure 6A is a partial metallographic image of a cross-section of an aluminum bar according to a preferred embodiment of the present invention; Figure 6B is a partial metallographic image of a cross-section of an aluminum bar according to a preferred embodiment of the present invention; Figure 6C is a partial metallographic image of a cross-section of an aluminum bar according to a preferred embodiment of the present invention; Figure 7 is a SEM image of an aluminum bar according to a preferred embodiment of the present invention; and Figure 8 is a schematic diagram of an aluminum bar according to a preferred embodiment of the present invention, showing the extrusion direction, a cross-section, and a longitudinal section.

A: Aluminum bars

B: Carbon particles

Claims (9)

A deoxidized aluminum alloy material containing a carbon compound is composed of a plurality of aluminum particles, wherein the aluminum particles are primarily composed of elemental aluminum and contain 0.1 to 8 weight percent of carbon or organic matter. The plurality of aluminum particles are cut from an aluminum bar, and each cut surface is a fresh cut surface. The dioxin content of the aluminum particles and the aluminum bar is less than 0.1 ng I-TEQ/g. The deoxidized aluminum alloy material containing a carbon compound as described in claim 1, wherein the plurality of aluminum particles are cut from the aluminum bar, the area of a cross-section of the aluminum bar ranges from 0.2 square centimeters to 450 square centimeters, and the cross-section contains 20 to 500 carbon particles, the carbon particles are formed by carbonizing at least a portion of the organic matter, and the carbon particles contain more than 50 weight percent of carbon. The deoxidized aluminum alloy material containing carbon compounds as described in claim 2, wherein the carbon particles contain 85 to 95 weight percent of carbon elements, 2 to 8 weight percent of oxygen elements, and 1 to 10 weight percent of aluminum elements. The deoxidized aluminum alloy material containing carbon compounds as described in claim 1, wherein the organic matter comprises an alkane, an ester, a resin or a polyester. The deoxidized aluminum alloy material containing carbon compounds as described in claim 1, wherein the aluminum particles are made from recycled aluminum material. The deoxidized aluminum alloy material containing a carbon compound as described in claim 1, wherein the aluminum particles further contain 0.1 to 2 weight percent of silicon, 0 to 2 weight percent of copper, 0.1 to 30 weight percent of magnesium, 0.1 to 10 weight percent of manganese, and 0 to 10 weight percent of zinc. The deoxidized aluminum alloy material containing carbon compounds as described in claim 1, wherein the aluminum particles are spherical, teardrop-shaped or polygonal. The deoxidized aluminum alloy material containing a carbon compound as described in any one of claims 1 to 6, wherein the aluminum particles contain one or more concave surfaces or hollow holes. The deoxidized aluminum alloy material containing a carbon compound as described in claim 2 or 3, wherein the carbon particles comprise chlorides, sulfides, nitrides, silicates, or oxides.