Sustainable fluoride removal with scrap aluminum: Co-producing cryolite and hydrogen

This study presents a novel continuous process for fluoride removal and re- source recovery as cryolite, using a scrap aluminum-packed column. Efficient aluminum dissolution in hydrofluoric acid (HF) generates hydrogen gas and provides cost-saving alkalinity. The process achieves high efficiency (Al/F molar ratio of 2/6) within short Empty Bed Contact Times (15 min) and at low HF concentrations (500 mg/L). Solution pH plays a crucial role, with Al/F ratios above 1 achievable at pH below 4. The exothermic reaction requires temperature control, with a strong correlation (R²=0.99) between HF concentration and heat generation. Hydrogen production matches theoretical predictions. Cryolite synthesis was confirmed at optimized pH (5–5.5) with a 1:1 bypass ratio, achieving 98 % fluoride removal. XRD and SEM- EDS analyses verified cryolite formation. This approach offers a promising solution for industrial fluoride management, resource recovery, and clean hydrogen production.