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Review of measures for improved energy efficiency in production-related processes in the aluminium industry – From electrolysis to recycling

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  • Haraldsson, Joakim
  • Johansson, Maria T.

Abstract

The aluminium industry is facing a challenge in meeting the goal of halved greenhouse gas emissions by 2050, while the demand for aluminium is estimated to increase 2–3 times by the same year. Energy efficiency will play an important part in achieving the goal. The paper's aim was to investigate possible production-related energy efficiency measures in the aluminium industry. Mining of bauxite and production of alumina from bauxite are not included in the study. In total, 52 measures were identified through a literature review. Electrolysis in primary aluminium production, recycling and general measures constituted the majority of the 52 measures. This can be explained by the high energy intensity of electrolysis, the relatively wide applicability of the general measures and the fact that all aluminium passes through either electrolysis or recycling. Electrolysis shows a higher number of emerging/novel measures compared to the other processes, which can also be explained by its high energy intensity. Processing aluminium with extrusion, rolling, casting (shape-casting and casting of ingots, slabs and billets), heat treatment and anodising will also benefit from energy efficiency. However, these processes showed relatively fewer measures, which might be explained by the fact that to some extent, these processes are not as energy demanding compared, for example, to electrolysis. In many cases, the presented measures can be combined, which implies that the best practice should be to combine the measures. There may also be a future prospect of achieving carbon-neutral and coal-independent electrolysis. Secondary aluminium production will be increasingly important for meeting the increasing demand for aluminium with respect to environmental and economic concerns and strengthened competitiveness. Focusing on increased production capacity, recovery yields and energy efficiency in secondary production will be pivotal. Further research and development will be required for those measures designated as novel or emerging.

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  • Haraldsson, Joakim & Johansson, Maria T., 2018. "Review of measures for improved energy efficiency in production-related processes in the aluminium industry – From electrolysis to recycling," Renewable and Sustainable Energy Reviews, Elsevier, vol. 93(C), pages 525-548.
    • Handle: RePEc:eee:rensus:v:93:y:2018:i:c:p:525-548
    DOI: 10.1016/j.rser.2018.05.043
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    References listed on IDEAS

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    1. Ferretti, I. & Zanoni, S. & Zavanella, L. & Diana, A., 2007. "Greening the aluminium supply chain," International Journal of Production Economics, Elsevier, vol. 108(1-2), pages 236-245, July.
    2. Allwood, Julian M. & Ashby, Michael F. & Gutowski, Timothy G. & Worrell, Ernst, 2011. "Material efficiency: A white paper," Resources, Conservation & Recycling, Elsevier, vol. 55(3), pages 362-381.
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    5. Liu, Weipeng & Peng, Tao & Kishita, Yusuke & Umeda, Yasushi & Tang, Renzhong & Tang, Wangchujun & Hu, Luoke, 2021. "Critical life cycle inventory for aluminum die casting: A lightweight-vehicle manufacturing enabling technology," Applied Energy, Elsevier, vol. 304(C).
    6. Liu, Weipeng & Zhao, Chunhui & Peng, Tao & Zhang, Zhongwei & Wan, Anping, 2023. "Simulation-assisted multi-process integrated optimization for greentelligent aluminum casting," Applied Energy, Elsevier, vol. 336(C).
    7. Shen, Angxing & Zhang, Jihong, 2024. "Technologies for CO2 emission reduction and low-carbon development in primary aluminum industry in China: A review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 189(PA).
    8. Joakim Haraldsson & Maria T. Johansson, 2019. "Energy Efficiency in the Supply Chains of the Aluminium Industry: The Cases of Five Products Made in Sweden," Energies, MDPI, vol. 12(2), pages 1-25, January.
    9. Sgouridis, Sgouris & Ali, Mohamed & Sleptchenko, Andrei & Bouabid, Ali & Ospina, Gustavo, 2021. "Aluminum smelters in the energy transition: Optimal configuration and operation for renewable energy integration in high insolation regions," Renewable Energy, Elsevier, vol. 180(C), pages 937-953.
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    11. Mikhail A. Averbukh & Nikolay A. Zhukov & Stanislav V. Khvorostenko & Vasiliy I. Panteleev, 2019. "Reducing Electric Power Losses in the System of Power Supply Due to Compensation of Higher Harmonics of Currents: Economic and Energy Efficiency Outcomes," International Journal of Energy Economics and Policy, Econjournals, vol. 9(4), pages 396-403.
    12. Mitali Sarkar & Biswajit Sarkar & Muhammad Waqas Iqbal, 2018. "Effect of Energy and Failure Rate in a Multi-Item Smart Production System," Energies, MDPI, vol. 11(11), pages 1-21, October.
    13. Golmohamadi, Hessam, 2022. "Demand-side management in industrial sector: A review of heavy industries," Renewable and Sustainable Energy Reviews, Elsevier, vol. 156(C).
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    15. Joakim Haraldsson & Maria T. Johansson, 2019. "Barriers to and Drivers for Improved Energy Efficiency in the Swedish Aluminium Industry and Aluminium Casting Foundries," Sustainability, MDPI, vol. 11(7), pages 1-27, April.

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