Aluminium is produced by electrolysis using alumina (Al₂O₃) as raw material and cryolite (Na₃AlF₆) as electrolyte. In this Hall–Héroult process, the energy consumption is relatively large, and solid wastes such as spent anodes and spent pot liner, flue gas and waste heat are generated. Therefore, this article discusses from the perspective of high energy consumption and high pollution and summarizes the methods to reduce energy consumption and solve pollution problems. The functions of carbon anode, carbon cathode, refractory material and sidewall in aluminium electrolysis cells are discussed in detail. The process of aluminium electrolysis and the ways to improve the current efficiency of aluminium electrolysis cells and reduce their energy consumption are outlined. The causes and treatment methods of spent anodes, spent cathodes, spent refractories and spent spot liner are reviewed. The research progress of waste heat recovery and aluminium electrolysis flue gas purification are analysed. And the future research directions of aluminium electrolysis flue gas are provided.

High-iron red mud presents a problem due to its alkalinity which leads to significant risks to the environment. In order to realize the harmless and large-scale utilization of high-iron red mud, the smelting reduction experiments were carried out to investigate the reaction mechanism for extraction iron from high-iron red mud. FactSage 6.4 software was used to conduct thermodynamic analysis of the carbon thermal reduction system. The results showed that the direct reduction with carbon involved a process of Fe₂O₃ → Fe₃O₄ → FeO → Fe, in which the theoretical required molar ratio of C/O (oxygen in Fe₂O₃) was 1:1. The maximum degree of iron extraction was 92.8% with anthracite as reductant and 88.8% without anthracite smelting at 1500 °C for 30 min in a graphite crucible. XRD was conducted to analyze the mineral phase of the samples and slags. The results showed that the minerals contained in high-iron red mud were hematite, quartz, rutile, and sodium aluminosilicate hydrate. The blank sample was consisted of hematite, nepheline quartz, and the reduced slag without quenching consisted of perovskite and gehlenite, indicating that the reaction processes occurred from sodium aluminosilicate hydrate to nepheline and then occurred from nepheline to gehlenite in slagging process. The overall smelting reduction process was described as three mass transfer steps and three chemical reaction steps. These results provide useful information for large-scale and harmless utilization of high-iron red mud.

Nano-CaCO₃ was producted by using carbide slag in the self-designed jet-reactor. The effect of different operating parameter such as CO₂ flow rate and concentration, liquid flow rate and concentration of Ca(OH)₂ on the CaCO₃ particle size and morphology has been investigated in this paper. The obtained calcite particle were characterized using x-ray diffraction (XRD) and scanning electron microscopy (SEM). The results showed that the calcite about 50–200 nm was obtained under the reaction conditions of the saturation of calcium hydroxide as 1, the flow rate as 1.5 l min⁻¹, the CO₂ flow rate as 50 ml min⁻¹, the concentration as 100%, and the SDS amount 2%.

The preparation of rhenium powder by a hydrogen reduction of ammonium perrhenate is the only industrial production method. However, due to the uneven particle size distribution and large particle size of rhenium powder, it is difficult to prepare high-density rhenium ingot. Moreover, the existing process requires a secondary high-temperature reduction and the deoxidization process is complex and requires a high-temperature resistance of the equipment. Attempting to tackle the difficulties, this paper described a novel process to improve the particle size distribution uniformity and reduce the particle size of rhenium powder, aiming to produce a high-density rhenium ingot, and ammonium perrhenate is completely reduced by hydrogen at a low temperature. When the particle size of the rhenium powder was 19.74 µm, the density of the pressed rhenium ingot was 20.106 g/cm³, which was close to the theoretical density of rhenium. In addition, the hydrogen reduction mechanism of ammonium perrhenate was investigated in this paper. The results showed that the disproportionation of ReO₃ decreased the rate of the reduction reaction, and the XRD and XPS patterns showed that the increase in the reduction temperature was conducive to increasing the reduction reaction rate and reducing the influence of disproportionation on the reduction process. At the same reduction temperature, reducing the particle sizes of ammonium perrhenate was conducive to increasing the hydrogen reduction rate and reducing the influence of the disproportionation.