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Secondary aluminum dross (SAD) is a hazardous solid waste discharged from aluminum electrolysis and processing and the secondary aluminum industries, which causes severe environmental pollution and public health disasters. The stable presence of the α-Al2O3 and MgAl2O4 phases in SAD makes it difficult for it to be efficiently utilized. A combined dry pressing and alkaline roasting process was proposed for extracting the valuable Al element from SAD. Two alkaline additives (NaOH and Na2CO3) were selected as a sodium source for extracting the aluminum source from SAD in order to perform the thermodynamic analysis and roasting experiments. The phase transition behavior and the leaching performance tests were conducted using X-ray diffraction, scanning electron microscopy, X-ray fluorescence, leaching kinetics and thermal analysis. The recovery of Al and Na reached the values of 90.79% and 92.03%, respectively, under the optimal conditions (roasting temperature of 1150 °C, Na2CO3/Al2O3 molar ratio of 1.3, roasting time of 1 h, leaching temperature of 90 °C, L/S ratio of 10 mL·g−1 and leaching time of 30 min). Meanwhile, the removal efficiency of N and Cl reached 98.93% and 97.14%, respectively. The leaching kinetics indicated that the dissolution of NaAlO2 clinkers was a first-order reaction and controlled by layer diffusion process. The green detoxification and effective extraction of the Al element from SAD were simultaneously achieved without any pretreatments.

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