Quantitative Technoeconomic Assessment of Alumina Extraction from Aluminum Dross: Process Efficiency and Cost-Benefit Analysis
Year: 2025
Type: article
Abstract: Managing aluminum dross (AD) is essential due to its adverse impact on the environment. While utilizing AD in alumina production has gained attention, its economic sustainability evaluations remain inadequate despite a large amount of laboratory-scale work being published. Therefore, this study aims to assess the economic impact on an industrial-scale alumina production plant from AD in five scenarios using Aspen Plus simulation and technoeconomic analysis (TEA) based on previous experimental work utilizing the leaching-precipitation technique. The objective of this study is to evaluate different aluminum contents in AD and the number of leaching stages via production scale-up simulation and TEA. Simulation results showed a 10.2% variance in yield compared to experimental work, with consistent aluminum purity. Economic scale analysis suggested a batch size of 94 kg as the most cost-effective minimum selling price (MSP) for alumina, priced at 175.23 USD/kg based on Scenario AD-A (90.98 wt% Al). Discounted cash flow analysis identified 165.59 USD/kg as the lowest MSP for alumina, considering 90.98 wt% Al in AD and the two-stage leaching method. Sensitivity analysis revealed yield and annual batch number as key determinants affecting MSP. The study concludes that a circular economy for AD is feasible and economically viable, suggesting AD as an alternative resource, conserving primary resources for future use. Graphical Abstract
Authors: Yuan Xin Yeoh, Noor Intan Shafinas Muhammad, Shanmuga Kittappa, Malarvili Ramalingam, Mohamad Jamil Arif Mansor, Sumaiya Zainal Abidin
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: hybrid
Estimated APC paid: $3,190
Funder: Universiti Malaysia Pahang
OpenAlex ID: W4414986265