A review of the upcycling of aluminum scrap and dross using molten salt electrolysis

Aluminum recycling must prioritize the development of high-usability products while addressing the challenges of circular waste accumulation. Traditional methods, constrained by compositional limitations, fail to meet these demands. Electrolysis technology presents a promising solution, with insights into this field possessing the potential to optimize existing technologies and inform future innovations, thereby supporting the sustainable development of the aluminum industry. This study provides a comprehensive review of recent advancements in aluminum recycling technologies using molten salt electrolysis. It critically assesses the improvements in the process, their impacts, and the industrial challenges faced during implementation. The analysis presented herein demonstrates that the electrolysis process significantly enhances the usability of recycled products. Molten salt electrolysis method is highly effective in waste treatment, enabling the processing of "dead" metals and secondary aluminum dross—materials typically excluded from conventional industrial practices. When recycling aluminum dross, the complexity of the dross composition and the sustainability of the recycling process need to be considered. Based on these considerations, we propose two novel strategies for aluminum dross recycling. Recycling waste through molten salt electrolysis to produce high-usability recycled products presents a promising alternative to the Hall-Héroult process, fostering sustainability in the aluminum industry.