I’m always looking for ways to produce-without-harm, especially because some of the digital technologies we love – like blockchain and generative AI – are environmentally unfriendly, to put it mildly. In this case it’s aluminum, which is everywhere from bicycle frames to everyone’s can of beer.
Part of my interest is the result of my undergraduate students complaining about what my generation has done to the environment: there’s no doubt we’re leaving them a mess. The other part is some guilt for letting all this happen on my – our – watch. In fact, we all bear some responsibility for the mess we’ve left everyone who will have to adapt to the changes our neglect has created.
Everyone Loves Aluminum
Aluminum’s magic lies in its perfect combination of lightness and strength, which makes it perfect for so many applications. Aluminum’s lightweight nature is crucial for fuel-efficient cars and airplanes. Lighter vehicles require less energy, which translates to fewer greenhouse gas emissions. Aluminum’s strength and resistance make it ideal for building facades, window frames and roofing, among similar applications. It creates lighter structures, reducing the amount of material needed for construction. It saves money. Food stays fresh in aluminum cans and foil because aluminum acts as a barrier, protecting food from spoilage and adding shelf life. It has almost infinite recyclability which makes it environmentally friendly – when produced sustainably. There’s lots to love, but there are also reasons to hate it.
Love, Hate
The problem is that the production of aluminum is not without problems. While aluminum is love, the process of producing it can leave environmentalists feeling pretty hateful. Why?
Aluminum comes from bauxite ore, which is mined from open pits. This leads to the loss of wildlife habitat, deforestation and soil and water contamination. Once bauxite is extracted, it’s refined into alumina. Then, through a process called smelting, alumina is transformed into aluminum metal. This final step is a major energy consumer, traditionally relying on fossil fuels like coal which releases harmful greenhouse gasses. Alumina refining also generates a toxic byproduct called red mud. This caustic waste is difficult and expensive to store safely. If not managed properly, red mud can leak into surrounding soil and water, causing environmental damage. There’s an infamous case about the island of Corsica worth reading. There’s another one about Marseille; and then there was Hungary.
Enter IB2
Companies are seeking ways to minimize their environmental impact with renewable smelting, recycling and red mud reusability. All good, all necessary and, candidly, all way overdue. IB2 – co-founded by Romain Girbal – innovates at a crucial stage of the aluminum production process: alumina refining. While others are focusing on the smelting stage or recycling, IB2 tackles the environmental concerns right at the beginning.
Here are three ways their technology contributes to sustainability:
1. Traditionally, aluminum production relies on high-quality bauxite deposits. These deposits are finite resources, and extracting them through open-pit mining can be environmentally destructive. IB2’s technology allows refineries to effectively utilize lower-grade bauxite ore. This not only reduces pressure on these high-quality reserves but also potentially minimizes the environmental impact of mining. Less mining translates to less deforestation and habitat loss. Utilizing lower-grade bauxite deposits extends the lifespan of existing bauxite reserves, (at least) delaying the need to explore and potentially disrupt new ecosystems.
2. The traditional alumina refining process relies heavily on caustic soda (sodium hydroxide), a chemical with its own environmental concerns. Caustic soda production can be energy-intensive, and its improper disposal can harm the environment. IB2’s technology minimizes the amount of caustic soda needed for alumina extraction. This translates to a lower environmental footprint associated with caustic soda’s production and disposal.
3. As described above, lumina refining generates a toxic byproduct called red mud. This caustic waste is difficult and expensive to store safely. If not managed properly, red mud can leak into surrounding soil and water, causing environmental damage. IB2’s technology significantly reduces the generation of red mud waste. This translates to less hazardous material to manage and store, minimizing the risk of environmental contamination. Reduced red mud volume enables lower storage costs for refineries.
While the specifics of IB2’s technology remain proprietary, the company refers to their process as a combination of “Improved Bauxite” and “Improved Bayer,” hinting at advancements in both the raw material (bauxite) and the traditional Bayer process used for alumina refining.
IB2’s technology holds significant promise. Ideally, the technology will be integrated into existing alumina refineries, as cheaply as possible. While utilizing lower-grade bauxite and less caustic soda offers potential cost savings, the full economic picture needs to be developed.
IB2 And Greener Aluminum
IB2 joins a growing number of companies committed to a more sustainable aluminum future. The focus on optimizing alumina refining complements companies concentrating on renewable energy for smelting and increased recycling rates. While challenges remain, IB2’s innovative approach offers a promising pathway towards a greener aluminum industry. With continued research, development, and industry collaboration, a truly sustainable aluminum life cycle might just be possible. The “sell”? IB2 can lower the CO2 emissions of refineries by 40%, can lower the use of water by 80%, and reduce production costs by 40%. It’s always persuasive when both the environment and bottom line are happy. According to Romain Girbal: “by being less energy-intensive and more ecological, our process reduces production costs by at least 40%, while reducing the production of toxic red sludge by 67%.”
The journey from bauxite ore to the aluminum beer can in your hand can be a complex one. However, with companies like IB2 pushing the boundaries of green technology, the future of aluminum production could be a cleaner shade of green. As consumers, we can also play a role by choosing products made from recycled aluminum and supporting companies committed to sustainable practices.
IB2 might just help me with my students. We need lots more companies like IB2 if we’re going to put a dent into the environmental crisis we’ve created. Here’s hoping.
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