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<p>The growing global demand for aluminum and the energy-intensive nature of its primary production highlight the importance of sustainable utilization of secondary resources and waste valorization strategies. Black dross (BD), a byproduct of aluminum smelting containing alumina, metal oxides, halides, and residual metallic aluminum, is a hazardous and compositionally complex industrial waste. This study proposes a simplified calcination-acid leaching-sintering route to convert BD into an alumina-rich raw material suitable for spinel-based ceramic applications, with improved process efficiency and industrial relevance. Sulfuric acid (H<sub>2</sub>SO<sub>4</sub>) was selected as an environmentally preferable and industrially viable leaching reagent for alumina enrichment. BD was calcined between 1000 and 1500&#xa0;°C to promote halide removal and oxidation of residual aluminum, followed by H<sub>2</sub>SO<sub>4</sub> leaching to enhance alumina concentration. Unlike previously reported multi-stage hydrometallurgical routes, the proposed process eliminates intermediate purification steps, reducing reagent consumption, process complexity, and chloride-rich wastes. The sample calcined at 1500&#xa0;°C, showing the most developed MgAl<sub>2</sub>O<sub>4</sub> spinel formation, was selected as the precursor for subsequent evaluation of sintering behavior at 1600&#xa0;°C. A screening life cycle assessment (LCA) identified thermal treatment and acidic leaching as the main environmental hotspots, indicating that energy-intensive calcination and process-related emissions are the primary constraints for further environmental optimization of the proposed route. Overall, the results demonstrate that aluminum black dross can be sustainably utilized as a raw material for spinel-based ceramics, contributing to circular material flows in the aluminum industry.</p> Graphical Abstract <p></p>

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Utilization of Aluminum Black Dross as a Raw Material of MgAl2O4-Based Ceramics through High-Temperature Calcination and Following Sulfuric Acid Leaching

  • 期刊论文

  • 发表日期：

    2026年6月24日

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  • İlayda Ozbag Togacar,
  • Umay Cinarli Yavas,
  • Arif Karaca,
  • Ahmet Turan

摘要

The growing global demand for aluminum and the energy-intensive nature of its primary production highlight the importance of sustainable utilization of secondary resources and waste valorization strategies. Black dross (BD), a byproduct of aluminum smelting containing alumina, metal oxides, halides, and residual metallic aluminum, is a hazardous and compositionally complex industrial waste. This study proposes a simplified calcination-acid leaching-sintering route to convert BD into an alumina-rich raw material suitable for spinel-based ceramic applications, with improved process efficiency and industrial relevance. Sulfuric acid (H2SO4) was selected as an environmentally preferable and industrially viable leaching reagent for alumina enrichment. BD was calcined between 1000 and 1500 °C to promote halide removal and oxidation of residual aluminum, followed by H2SO4 leaching to enhance alumina concentration. Unlike previously reported multi-stage hydrometallurgical routes, the proposed process eliminates intermediate purification steps, reducing reagent consumption, process complexity, and chloride-rich wastes. The sample calcined at 1500 °C, showing the most developed MgAl2O4 spinel formation, was selected as the precursor for subsequent evaluation of sintering behavior at 1600 °C. A screening life cycle assessment (LCA) identified thermal treatment and acidic leaching as the main environmental hotspots, indicating that energy-intensive calcination and process-related emissions are the primary constraints for further environmental optimization of the proposed route. Overall, the results demonstrate that aluminum black dross can be sustainably utilized as a raw material for spinel-based ceramics, contributing to circular material flows in the aluminum industry.

Graphical Abstract