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Moving toward emission-free aluminum production

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Moving toward emission-free aluminum production

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Until now, aluminum production has generated significant greenhouse gas emissions. But a new process is emerging that produces aluminum without such emissions.

The current production method is 140 years old, and it is time to modernize it to reduce greenhouse gas emissions. Oct. 19 marked an important milestone in this direction at Hydro's Herøya aluminum research center in Norway.

"In very simple terms, this is an alternative process for producing aluminum," says Egil Skybakmoen, a research manager at SINTEF.

The technology currently used to produce aluminum was invented as far back as 1886. The process uses electricity to trigger a reaction between aluminum oxide—also known as alumina—and carbon through electrolysis, resulting in the formation of aluminum. The primary byproduct of this process is carbon dioxide (CO₂), which is released into the atmosphere.

In the traditional process, "you end up with very high emissions. For every kilogram (2.2 pounds) of aluminum produced, 1.5 kilograms (3.3 pounds) of CO₂ are released. This is a process that contributes a significant amount of CO₂ to the atmosphere," says Skybakmoen.

The technology developed for CO₂ capture is not well suited for use here. Current aluminum production methods result in CO₂ being mixed with large volumes of air.

Consequently, the CO₂ gas becomes so diluted that separating and collecting it would be extremely difficult and costly—although some projects are currently exploring this as well.


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