Process for manufacturing aluminium from bauxite or its residue

A process for obtaining at least one metal from a mixture comprising an aluminum compound and optionally, at least one compound selected from the group consisting of an iron compound and a titanium compound;

• said process comprising the following steps:
• a. pulverizing the mixture to obtain a powder and calcining said powder at a temperature ranging between 600° C. and 800° C. to obtain a calcined feed containing aluminum oxide and optionally, at least one oxide selected from the group consisting of titanium oxide and iron oxide;
• b. mixing the calcined feed with a carbonaceous material to obtain a blend;
• carbochlorinating the blend by using a stream of chlorine gas at a temperature ranging between 600° C. and 1000° C., to obtain a gaseous stream containing aluminum chloride and optionally, at least one chloride selected from the group consisting of iron (III) chloride and titanium chloride;
• c. condensing the gaseous stream to obtain a chloride condensate containing aluminum chloride constituent and optionally, at least one chloride selected from the group consisting of iron (III) chloride constituent and titanium chloride constituent;
• d. optionally, treating the chloride condensate to fractionally separate the aluminum chloride constituent and optionally at least one chloride constituent selected from the group consisting of iron (III) chloride constituent and titanium chloride constituent;
• and
• e. electrolyzing the aluminum chloride constituent in an electrolysis cell to obtain aluminum metal.