Innovative recycling and conversion of aluminum waste to hydrogen and aluminum chloride: Enhancing economic feasibility and sustainability in Saudi Arabia

The rapid industrialization and urbanization in Saudi Arabia have led to significant challenges in waste management, particularly in recycling aluminum waste. This study explores an innovative approach for converting aluminum waste, specifically beverage cans, into valuable products such as aluminum chloride (AlCl₃) and hydrogen (H₂). The process involves the chemical reaction of aluminum with hydrochloric acid (HCl), producing AlCl₃ and H₂, and is modeled using Aspen Plus software. Two scenarios are evaluated: one without recycling and one incorporating recycling processes. In the first scenario, the direct conversion process yields 355 tons of AlCl₃ and 9 tons of H₂ per day from 100 metric tons of aluminum waste. The minimum selling price (MSP) of AlCl₃ is calculated to be $764 per ton, with an annual profit of $25 million, assuming a market price of $1000 per ton. However, the economic viability of this scenario is highly sensitive to conversion efficiencies and market conditions. The second scenario integrates a recycling loop, processing 90 % of the aluminum waste back into aluminum, significantly enhancing economic stability. This scenario produces 35 tons of AlCl₃ and 1 ton of H₂ per day, with an MSP of $1068 per ton. Despite the higher MSP, the inclusion of recycled aluminum, sold at $2400 per ton, results in a higher annual profit of $38 million, demonstrating greater economic resilience and sustainability. This study provides a comprehensive techno-economic analysis, highlighting the dual benefits of waste reduction and resource recovery. By optimizing reaction conditions and incorporating recycling, the proposed process aligns with Saudi Arabia's Vision 2030 sustainability goals, offering a viable pathway for enhancing economic feasibility and environmental sustainability in aluminum waste management.