Production of metallic nanopowders (Mg, Al) by solar carbothermal reduction of their oxides at low pressure

The carbothermal reduction of MgO and Al2O3 in argon flow at low pressure allows to lower the onset temperature of metal vapor formation. Thermodynamic calculations indicate that metal formation begins at 1400 and 1700 K for a primary vacuum (1000 Pa), respectively, for Mg and Al. In the experimental section, concentrated solar energy was used for the process heating in order to favor energy savings. The products of the reaction between MgO or Al2O3 and 2 varieties of carbon (graphite, carbon black) in flowing argon atmosphere at a total pressure of around 1000 to 1600 Pa were studied using X-ray diffraction, and microstructure observations revealed the formation of metallic nanopowders with some by-products. Metallic conversions close to 45 wt% and 52 wt%, respectively, for Mg and Al, were obtained. The low conversion yield of the carbothermal reduction of MgO can be attributed to a backward reaction reforming MgO powder and to a sintering process between oxide particles at high temperature. Aluminum production challenge is to avoid formation of undesired by-products: Al2O, Al4C3 and Al-oxycarbides. Advantages and weaknesses of the used process are described and some improvements are proposed to increase metallic yields.