Techno-economic and life cycle assessment of aluminum electrorefining from mixed scraps using ionic liquid

Aluminum production from bauxite ore uses significantly high amounts of energy and capital expenditure. Recycle and reuse of aluminum can be economical and minimize the environmental impacts. Smelter-based recycling of aluminum is currently utilized; however, it also consumes high energy and incurs substantial production costs along with considerable life cycle impacts. In this study, aluminum electrorefining technology from mixed scraps using ionic liquid, developed by the University of Alabama, is assessed for its techno-economic viability and environmental sustainability. The methodology involves a comprehensive life cycle assessment (LCA) to compare the new electrorefining process with conventional smelting techniques. Findings illustrate that the ionic liquid electrorefining process not only reduces the overall energy consumption but also limits carbon emissions significantly when compared to traditional methods. Additionally, economic analysis indicates potential cost savings in aluminum processing, thereby encouraging the adoption of this innovative recycling approach. The results suggest that implementing this electrorefining technology could lead to a more sustainable aluminum industry while promoting circular economy principles. This study highlights the importance of advancing recycling technologies to improve resource efficiency and mitigate environmental impacts associated with aluminum production.