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| {{ToolTemplate|ToolName=Aluminum Extractor}} | | {{OrigLang}} |
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| {{Category=Materials}} | | {{Category=Materials}} |
| [[Category:Chemical_engineering_for_OSE_use]] | | [[Category:Chemical_engineering_for_OSE_use]] |
| Aluminum extraction from clay - we are not talking about energy intensive smelting (requires fuel consumption on the order of 1 gallon of fuel oil for 1 kg of metal) with bauxite as aluminum ore, but a thermal and chemical process based on clay- not bauxite. Aluminum is not smelted, but leached out with hydrochloric acid: http://www.freepatentsonline.com/4388280.html. This is remarkable news to anyone interested in a better world - formerly strategic metals can be made anywhere. I need not emphasize the ranges of use of aluminum.
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| Kaolin clay is composed of aluminum and silicon (Si2Al2O5(OH)4). Reduction of Kaolin would then result in an aluminum/silicon alloy. In practice, carbides (usually SiC) resist further reduction except at very high temperatures (2050°C). Thus, the smelted product is likely some aluminum-rich alloy with various highly refractory simple and complex carbides.
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| Parent material is reduced ''carbothermically'', that is, it is reduced in the presence of carbon and the absence of oxygen at high temperatures. The carbon is oxidized to produce carbon mon- and di-oxide and the metal oxides are reduced.
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| The paper [http://www.sciencedirect.com/science?_ob=ArticleURL&_udi=B6V2S-4PF0X6V-1&_user=521384&_rdoc=1&_fmt=&_orig=search&_sort=d&view=c&_acct=C000059563&_version=1&_urlVersion=0&_userid=521384&md5=beeacd8e14dee1a7cb0059b6bb739790 carbothermal reduction of alumina] by m.halmann (at) weizmann.ac.il describes the carbothermic reduction of alumina rich material in an atmosphere of methane gas at high temperatures. Internal copy of this paper: [[File:halman.pdf]]
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| Such temperatures could be produced with a point focusing solar collector (see [[Metal Refining]] for more)
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| Page 66 in this online book talks about a plant in the Ukraine that smelts kaolin into an aluminum/silicon alloy: [http://books.google.com/books?id=XlmAKOjvnrgC&pg=PA66&lpg=PA66&dq=reduction+kaolin+aluminum&source=web&ots=2vF1okG5iX&sig=oh_J4JdI6XQDxZ68-j2i-b767Tw&hl=en#PPA65,M1 The Handbook of Aluminum] by George E Totten, D Scott MacKenzie
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| At temperatures below 2000°C, I assume aluminum metal may be separated from silicon carbide (SiC).
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| Low-temperature electrolytic refining ''(speculative)'': Conventional aluminum refining is a lot like electroplating; since the aluminum is above H2 in the electrochemical series, water can't be used as an electrolyte and high temperature molten salts are used instead. Recent developments in Ionic Liquids ([http://www.rsc.org/Education/EiC/issues/2005_Jan/salty.asp IL]) and Deep Eutectic Solvents ([http://en.wikipedia.org/wiki/Deep_eutectic_solvent DES]) have shown that they can be used for aluminum electroplating ([http://www.ionmet.eu/fileadmin/ionmet/training/20090324_Munich/2_Ryder_Al.pdf Ionmet], [http://www.jproeng.com/qikan/manage/wenzhang/208139.pdf Yu et al]). Perhaps AlCl3 could be extracted from clay by hydrochloric acid leaching (as cited above), redissolved in an IL per the electroplating process, and electrolyzed to plate out aluminum and release Cl for regeneration of the HCl.
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| =Collaboration=
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| ==Review of Project Status==
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| ==Aluminum - Current Work==
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| [[Metal_Refining]]
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| == Aluminum - Developments Needed==
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| === Aluminum - General===
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| ==links==
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| all about aluminium:
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| http://sam.davyson.com/as/physics/aluminium/siteus/index.html
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| how aluminum is made
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| http://findarticles.com/p/articles/mi_gx5205/is_1997/ai_n19124810/
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| http://www.rocksandminerals.com/aluminum/process.htm
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| http://science.howstuffworks.com/aluminum3.htm
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| aluminum recycling and processing for sustainability
| | [[Image:AluminumExtractor.png|thumb|400px|Aluminum Extractor]] |
| http://books.google.at/books?id=t-Jg-i0XlpcC&pg=PA197&lpg=PA197&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=dyGaESjSJu&sig=uhSUFo2Bc9UYzCGMKFII7OmpqF8&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=3
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| environmental chemistry of aluminum
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| http://books.google.at/books?id=lNxltQeVP9UC&pg=PA253&lpg=PA253&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=7Akaax7fNZ&sig=Q6v9n37jOf_FEDAjaN4aaqpSJZY&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=6
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| environmental guidelines for aluminum manufactoring
| | =Overview= |
| http://www.miga.org/documents/AluminumManufacturing.pdf
| | The Aluminum Extractor extracts raw aluminum from alumina common clay (alumina silicate). |
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| http://www.ifc.org/ifcext/enviro.nsf/AttachmentsByTitle/gui_alummfg_WB/$FILE/alum_PPAH.pdf
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| (world bank and investment guarantee agency) | |
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| pollution prevention in manufactoring aluminunm
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| http://www.p2pays.org/ref/21/20400.htm
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| why aluminum smelting is not good
| | =Detail= |
| http://planet.wwu.edu/archives/2006/articles/fall/popping-the-top.php
| | Using a closed-loop cycle involving hydroflouric acid and a large amount of electricity, it is possible to extract raw aluminum directly from clay deposits. This is in contrast to the typical aluminum extraction technique from strategic bauxite mineral reserves. |
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| national environmental health report on aluminium
| | There is posibility also to produce bauxite from very common feldspar mineral (sand) and carbon dioxide. This is natural process that produce clays, but it is posible to speed up usable level with increasing carbon dioxide partial pressure. Easy source for carbon dioxide are biogas reactors. Biogas cleaning produce large amounts pressurized carbon dioxide water solution. It is even posible to directly feed pressurized biogas through feldspar sand column and combine both process. |
| http://enhealth.nphp.gov.au/council/pubs/pdf/alumin.pdf
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| Handbook of corrosion engeneering
| | Alumium electrolyze process should be combined to localized power grid and its power consume should be tied to grid frequency after 50.5Hz or 60.5hz it should start itself and come full power until 51.0Hz or 61Hz so alumium making can be used to dump excess energy. Very useful combined with windpower. |
| http://www.scribd.com/doc/9402306/Handbook-of-Corrosion-Engineering-
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| extraction of aluminum
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| http://www.tms.org/pubs/Books/4062.chapter2.pdf
| | <iframe src="https://player.vimeo.com/video/18095549?title=0&byline=0&portrait=0" width="400" height="233" frameborder="0"></iframe> |
| | </html> |
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| the evolution of the world aluminum industry
| | =Product Ecology= |
| http://books.google.at/books?hl=de&lr=&id=1NS2ja36QckC&oi=fnd&pg=PA39&dq=aluminum+production+from+clays&ots=dQn5uYR_vZ&sig=Afp24-4CYgPIkWPhM0UjSF-4iXw
| | {{Product Ecology| |
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| aluminum alloy castings
| | |From= |
| http://books.google.at/books?id=JM0u1vwrS5UC&pg=PA21&lpg=PA21&dq=intitle:aluminum+production+clays+-patent&source=bl&ots=VwQAbCkL-o&sig=vMXAQovuSJOIYroY8VfQJYFfKE4&hl=de&ei=Cr9hSt79O5qOnAONxKz4Dw&sa=X&oi=book_result&ct=result&resnum=9
| | * {{Induction Furnace}} |
| | * {{Torch Table}} |
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| article: hydrolysis products of solution and exchangeable aluminum in acidic soil
| | |Uses= |
| http://scholar.google.at/scholar?q=info:VxZNUwsol1IJ:scholar.google.com/&output=viewport&pg=1&hl=de
| | * [[Power]] |
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| === Aluminum - Specific===
| | |Creates= |
| ==== Aluminum - Background Debriefing====
| | * [[Aluminum]] |
| ==== Aluminum - Information Work====
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| ==== Aluminum - Hardware Work====
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| | |Enables= |
| | * {{Induction Furnace}} |
| | }} |
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| ==Related Links== | | =Components= |
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| | =See Also= |
| | *[http://blog.opensourceecology.org/2010/12/open-source-aluminum/ Blog Post] |
| | *[[Aluminum Extraction From Clays]] |
| | *[https://www.bostonmetal.com/moe-technology/ Molten Oxide Electrolysis - carbon free process that goes directly from ore to pure metal with pure oxygen as a byproduct] |
| | *[https://www.nasa.gov/feature/molten-oxide-electrolysis/ NASA's page on MOE] |
| | *[https://www.youtube.com/watch?v=pg5M5WjGx5M Youtube: Donald Sadoway at EmTech MENA 2019: Steel Production without Co2 Emissions] |
| | *[[Metal Refining]] |
| | *[[Aluminosilicate chemistry]] |
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| | *[http://en.wikipedia.org/wiki/Aluminium Wikipedia: Aluminum] |
| | *[http://en.wikipedia.org/wiki/Clay Wikipedia: Clay] |
| | *[http://en.wikipedia.org/wiki/Hydrofluoric_acid Wikipedia: Hydroflouric Acid] |
| | *[http://en.wikipedia.org/wiki/Hall%E2%80%93H%C3%A9roult_process Wikipedia:Hall–Héroult process] |
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| == Aluminum - Sign-in==
| | {{GVCS Footer}} |
| =Development Work Template=
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| #[[Aluminum - Product Definition]]
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| ##[[Aluminum - General]]
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| ##[[Aluminum - General Scope]]
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| ##[[Aluminum - Product Ecology]]
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| ###[[Aluminum - Localization]]
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| ###[[Aluminum - Scaleability]]
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| ###[[Aluminum - Analysis of Scale]]
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| ###[[Aluminum - Lifecycle Analysis]]
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| ##[[Aluminum - Enterprise Options]]
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| ##[[Aluminum - Development Approach]]
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| ###[[Aluminum - Timeline]]
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| ###[[Aluminum - Development Budget]]
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| ####[[Aluminum - Value Spent]]
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| ####[[Aluminum - Value available]]
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| ####[[Aluminum - Value needed]]
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| ##[[Aluminum - Deliverables and Product Specifications]]
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| ##[[Aluminum - Industry Standards]]
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| ##[[Aluminum - Market and Market Segmentation]]
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| ##[[Aluminum - Salient Features and Keys to Success]]
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| #[[Aluminum - Technical Design]]
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| ##[[Aluminum - Product System Design]]
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| ###[[Aluminum - Diagrams and Conceptual Drawings]]
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| ####[[Aluminum - Pattern Language Icons]]
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| ####[[Aluminum - Structural Diagram]]
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| ####[[Aluminum - Funcional or Process Diagram]]
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| ####[[Aluminum - Workflow]]
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| ###[[Aluminum- Technical Issues]]
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| ###[[Aluminum - Deployment Strategy]]
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| ###[[Aluminum - Performance specifications]]
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| ###[[Aluminum - Calculations]]
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| ####[[Aluminum - Design Calculations]]
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| ####[[Aluminum - Yields]]
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| ####[[Aluminum - Rates]]
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| ####[[Aluminum - Structural Calculations]]
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| ####[[Aluminum - Power Requirements]]
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| ####[[Aluminum - Ergonomics of Production]]
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| ####[[Aluminum -Time Requirements]]
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| ####[[Aluminum - Economic Breakeven Analysis]]
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| ####[[Aluminum - Scaleability Calculations]]
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| ####[[Aluminum - Growth Calculations]]
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| ###[[Aluminum - Technical Drawings and CAD]]
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| ###[[Aluminum - CAM Files]]
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| ##[[Aluminum - Component Design]]
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| ###[[Aluminum - Diagrams]]
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| ###[[Aluminum - Conceptual drawings]]
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| ###[[Aluminum - Performance specifications]]
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| ###[[Aluminum - Performance calculations]]
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| ###[[Aluminum - Technical drawings and CAD]]
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| ###[[Aluminum - CAM files whenever available]]
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| ##[[Aluminum - Subcomponents]]
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| #[[Aluminum - Deployment and Results]]
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| ##[[Aluminum - Production steps]]
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| ##[[Aluminum - Flexible Fabrication or Production]]
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| ##[[Aluminum - Bill of materials]]
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| ##[[Aluminum - Pictures and Video]]
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| ##[[Aluminum - Data]]
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| #[[Aluminum - Documentation and Education]]
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| ##[[Aluminum - Documentation]]
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| ##[[Aluminum - Enterprise Plans]]
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| #[[Aluminum - Resource Development]]
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| ##[[Aluminum - Identifying Stakeholders]]
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| ###[[Aluminum - Information Collaboration]]
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| ####[[Aluminum - Wiki Markup]]
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| ####[[Aluminum - Addition of Supporting References]]
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| ####[[Aluminum - Production of diagrams, flowcharts, 3D computer models, and other qualitative information architecture]]
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| ####[[Aluminum - Technical Calculations, Drawings, CAD, CAM, other]]
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| ###[[Aluminum - Prototyping]]
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| ###[[Aluminum - Funding]]
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| ###[[Aluminum - Preordering working products]]
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| ###[[Aluminum - Grantwriting]]
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| ###[[Aluminum - Publicity]]
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| ###[[Aluminum - User/Fabricator Training and Accreditation]]
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| ###[[Aluminum - Standards and Certification Developmen]]
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| ###[[Aluminum - Other]]
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| ##[[Aluminum - Grantwriting]]
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| ###[[Aluminum - Volunteer grantwriters]]
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| ###[[Aluminum - Professional, Outcome-Based Grantwriters]]
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| ##[[Aluminum - Collaborative Stakeholder Funding]]
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| ##[[Aluminum - Tool and Material Donations]]
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| ##[[Aluminum - Charitable Contributions]]
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