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Purpose <p>This study aims to evaluate the environmental performance of a novel Chlorination–Electrolysis Process (CEP) for producing primary aluminum from low-grade bauxite in China, where resource depletion and carbon constraints are intensifying. Using a life cycle assessment (LCA) approach, the research compares CEP with the conventional Sintering–Hall–Héroult Process (SHP), identifying system-level environmental trade-offs and decarbonization potential to support cleaner aluminum production pathways.</p> Methods <p>An attributional LCA following ISO 14040/44 was conducted to compare the environmental impacts of the CEP and the conventional SHP for primary aluminum production from low-grade bauxite. The system boundary encompassed cradle-to-gate stages, with a functional unit defined as 1 tonne of aluminum ingot. Impact assessment was performed using the ReCiPe 2016 method at both midpoint and endpoint levels. A quality-based allocation approach was applied for multi-output chlorination products. Sensitivity analysis was conducted to identify key input parameters influencing the global warming potential.</p> Results and discussion <p>The CEP demonstrates improved environmental performance compared to the conventional SHP in terms of carbon emissions and resource scarcity. Specially, the CEP reduces carbon emissions by 41.85% per tonne of aluminum, primarily due to improvements in electrolysis and refining stages. Electrolysis remains the largest contributor to environmental impacts, accounting for over 50% of damage across all endpoint categories. While CEP achieves lower impacts in climate change and resource scarcity, it exhibits relatively higher burdens in toxicity-related categories due to increased chemical inputs. Sensitivity analysis highlights the electricity mix and chlorine consumption as key drivers of global warming potential, emphasizing the importance of electrification efficiency and clean energy sourcing to maximize environmental benefits.</p> Conclusions <p>The findings highlight CEP’s potential to support the decarbonization of primary aluminum production, while also emphasizing the need for further technological refinement to realize its full benefits under industrial-scale conditions.</p>

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Life cycle assessment of Chlorination–Electrolysis and conventional aluminum production: environmental insights from low-grade bauxite utilization

  • 期刊论文

  • 发表日期：

    2026年3月31日

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  • Meng Zhao,
  • Boxue Sun,
  • Shiwei Du,
  • Mingyang Li,
  • Yu Liu,
  • Feng Gao,
  • Zuoren Nie

摘要

Purpose

This study aims to evaluate the environmental performance of a novel Chlorination–Electrolysis Process (CEP) for producing primary aluminum from low-grade bauxite in China, where resource depletion and carbon constraints are intensifying. Using a life cycle assessment (LCA) approach, the research compares CEP with the conventional Sintering–Hall–Héroult Process (SHP), identifying system-level environmental trade-offs and decarbonization potential to support cleaner aluminum production pathways.

Methods

An attributional LCA following ISO 14040/44 was conducted to compare the environmental impacts of the CEP and the conventional SHP for primary aluminum production from low-grade bauxite. The system boundary encompassed cradle-to-gate stages, with a functional unit defined as 1 tonne of aluminum ingot. Impact assessment was performed using the ReCiPe 2016 method at both midpoint and endpoint levels. A quality-based allocation approach was applied for multi-output chlorination products. Sensitivity analysis was conducted to identify key input parameters influencing the global warming potential.

Results and discussion

The CEP demonstrates improved environmental performance compared to the conventional SHP in terms of carbon emissions and resource scarcity. Specially, the CEP reduces carbon emissions by 41.85% per tonne of aluminum, primarily due to improvements in electrolysis and refining stages. Electrolysis remains the largest contributor to environmental impacts, accounting for over 50% of damage across all endpoint categories. While CEP achieves lower impacts in climate change and resource scarcity, it exhibits relatively higher burdens in toxicity-related categories due to increased chemical inputs. Sensitivity analysis highlights the electricity mix and chlorine consumption as key drivers of global warming potential, emphasizing the importance of electrification efficiency and clean energy sourcing to maximize environmental benefits.

Conclusions

The findings highlight CEP’s potential to support the decarbonization of primary aluminum production, while also emphasizing the need for further technological refinement to realize its full benefits under industrial-scale conditions.