Transforming Aluminium Waste: Sustainable Conversion to Commercial MOFs, Hydrogen Fuel, and Essential Aluminium Feedstocks

Aluminium dross waste is generated during the aluminium smelting process and has an annual production of nearly 5.3M tonnes worldwide. It is largely comprised of aluminium but also contains different metal oxides, silicates, and other impurities. We demonstrate how to make use of dross by producing high-value products (hydrogen gas, aluminium formate, aluminium acetate, aluminium hydroxide, MOF-303, Al-Fum) towards decarbonization of the aluminium industry. We produce hydrogen gas (1.1-1.2 Lg-1 of dross) by digesting it with NaOH, while further outlining methods to upcycle this encased aluminium into high value materials, and identify a route to pure amporhous Al2O3 via aluminium formate or aluminium acetate. We also demonstrate the production of the water harvesing MOF-303 and Al-Fum directly from processed dross as the aluminium source. This study highlights a complete overview of upcycling of aluminium dross to high value products towards a green energy shift, and industrial circircular economy.