Sadoway Labs Technology
Metal Recycling
The Challenge
Producing high-quality, climate-friendly aluminum from scrap alloy
Producing high-purity aluminum from impure alloy scrap presents significant environmental and economic challenges. Traditional processes for aluminum refining generate substantial COâ‚‚ emissions. As global industries move towards sustainable practices, the need for a cleaner, more cost-effective method of recycling aluminum has never been greater.
Space Overview
Aluminum is indispensable across industry
Aluminum is indispensable across various industries due to its recyclability and favorable properties. Secondary aluminum (aluminum from recycled sources) can be produced with 95% less CO2 emissions than primary aluminum production, making it a highly attractive alternative.
Recycling scrap aluminum alloys, which often contain silicon, magnesium, copper, and other metals, remains technically difficult. The market demands an innovative, low-carbon solution that reduces energy usage and reliance on fossil fuels.
Need for Innovation
Low-energy, carbon-neutral, renewable-electricity
The aluminum industry is seeking methods to produce pure aluminum from recyclables while lowering the carbon footprint and maintaining cost competitiveness. Innovations that address both the environmental and economic aspects are essential for transitioning to a sustainable aluminum supply chain.
A low-energy, carbon-neutral process would leverage renewable electricity to transform scrap aluminum alloys into high-purity aluminum. Such a process would need to operate at lower temperatures, avoid the production of greenhouse gases, and be integrated into existing aluminum manufacturing infrastructures.
The SLF Solution
Low-energy, carbon-neutral, renewable-electricity
The Sadoway Labs Foundation (SLF) is developing a breakthrough in aluminum recycling technology, offering a low-temperature electrolysis process that transforms impure aluminum scrap into high-purity aluminum without the production of COâ‚‚.
Low-Temperature Electrolysis (100-200°C)
​
Unlike conventional aluminum refining methods that require temperatures exceeding 900°C, SLF’s process operates at significantly lower temperatures. This reduces the energy consumption involved in extracting aluminum from scrap and enables the use of renewable electricity sources.
Efficient Aluminum Extraction
​
The process extracts elemental aluminum directly from solid alloy scrap. This innovative method avoids the complexity and waste associated with separating various alloying elements.
Purified Aluminum Deposition
The extracted aluminum is deposited onto blanks, which can then be melted into metal ingots. These ingots are suitable for existing production processes, making the solution compatible with today’s aluminum manufacturing infrastructure.
Interested in learning more about our technologies? Contact us at info@sadowaylabs.org