Hydrova ($1 million to recycle aluminum dross to produce hydrogen and valuable products)

Hydrova, an American cleantech company founded in 2020, develops an innovative  process to recycle aluminum dross and salt cake, which are waste byproducts of the aluminum recycling industry. The process produces valuable products of hydrogen, salt flux, and alumina-rich oxide solids. Hydrova’s technology offers a sustainable solution that addresses both waste management and decarbonization challenges in the aluminum industry.

Challenges: aluminum dross

Aluminum dross is a byproduct that is generated during the aluminum smelting and melting processes. This material is mainly composed of aluminum, aluminum oxide, and salts. During the melting process of aluminum dross in rotary furnaces, salt cake is formed. Salt fluxes are utilized in this process to enhance metal recovery and minimize oxidation. Once the processing is complete, the salt cake will retain a small amount of metal, along with significant amounts of metal oxides, salt, and various other elements and compounds.

Disposing of aluminum dross and salt cake through landfilling poses significant environmental challenges.

Improper disposal of aluminum waste can have negative impacts on the environment and human well-being. When aluminum dross ends up in landfills, it has the potential to contaminate the soil and groundwater, which can be harmful to ecosystems and human health. In addition, the incomplete recycling of dross results in the wastage of valuable resources and adds to the demand for new aluminum production, which requires a significant amount of energy and has a large carbon footprint.

Salt cake contains elevated levels of soluble salts and metals that have the potential to leach into groundwater and surface water sources. Salts and metals leaching from salt cake can contaminate the surrounding soil, rendering it unfit for plant growth or agriculture.

Hydrova Technology

Hydrova has developed an innovative process to produce hydrogen and valuable products from aluminum dross. The process involves reacting aluminum dross with water and alkaline solutions to produce gas, which contains hydrogen, methane, and ammonia. Methane and ammonia can be converted into hydrogen. Pure hydrogen is used for fuel cells. Other valuable byproducts, such as aluminum hydroxide and aluminum oxide, can be used in cement production.

How Hydrova turns aluminum dross into hydrogen

The diagram below depicts Hydrova’s process to produce hydrogen and other valuable products from aluminum dross salt cake.