Molten Flux Design for Solid Oxide Membrane-Based Electrolysis of Aluminum from Alumina

Compared with the current Hall –Héroult process for smelting aluminum, the Solid Oxide Membrane (SOM)-Based electrolysis process brings various advantages such as simplified design, lower cost, lower energy use, and many other environmental benefits. This work identifies cost-effective molten salt compositions and membrane materials/architecture along with electrodes and current collectors that are all chemically compatible and provide optimum electrochemical properties for efficient aluminum oxide electrolysis. The SOM-based electrolysis process utilizes an oxygen-ion-conducting solid oxide membrane to directly electrolyze desired metal oxides dissolved in a non-consumable molten salt, thus reducing various metal oxides to their respective metals, alloys, or intermetallics. The advantages of the SOM process over traditional processes highlight its potential for cleaner and more sustainable metal production. The research suggests that developing the necessary components that ensure compatibility and optimal performance is crucial for implementing this innovative electrochemical technology effectively.