Aluminium dross a once-ignored by-product of the aluminium industry, is now stepping into the spotlight. Formed as a thin, skin-like layer on molten aluminium during melting and processing, dross is the result of natural surface oxidation. For years, it was treated as industrial waste, routinely dumped into landfills. This not only posed serious environmental hazards but also led to the loss of valuable aluminium and other materials locked within the dross.
But times have changed. Today, with sustainability high on the industry's agenda, dross is no longer an afterthought. It's become a focal point in the push toward a circular aluminium economy. Thanks to cutting-edge technologies, recovery rates now exceed 95 per cent, turning what was once a liability into a high-value resource. Aluminium dross processing is no longer just a technical detail it's a game-changer in the industry's green transition.
Infact, in 2024, the aluminium industry generated approximately 4.78 million tonnes of dross. Of this, an estimated 3.5 million tonnes were recovered and processed—either within the in-house facilities of aluminium producers or through third-party recycling operations. This recovery effort yielded around 1.12 million tonnes of aluminium, highlighting the growing effectiveness and value of modern dross processing technologies. AL Circle’s comprehensive industry-focused market research report, “Aluminium Dross Processing: A Global Review” speaks indepth about the aluminium dross industry in details. Grab your copy now !
In 2024, the global aluminium industry, including primary smelters, recycled aluminium producers, and downstream metal processors, generated an estimated 4.78 million tonnes of dross. Now the question comes, which country or region generated the most amount of dross and recovered aluminium in the most amounts? This article speaks about it in detail –
China
In 2024, China's aluminium industry generated an estimated 2.26 million tonnes of dross, with primary smelters contributing 23 per cent, recyclers 50 per cent, and the downstream sector the remaining 27 per cent.
Yet only 1.678 million tonnes made it to recovery facilities, yielding around 587,000 tonnes of aluminium, a modest return given the scale. Despite leading in aluminium output, China still lags in advanced dross processing. Recovery technologies remain underdeveloped, and regulatory changes have added pressure.
Also Read: Recycling sector dominates aluminium dross output
Europe
In 2024, the European aluminium industry generated an estimated 669,000 tonnes of dross, with recycling operations making up the bulk at 63 per cent. Primary smelters contributed 13 per cent, while the downstream sector accounted for the remaining 24 per cent.
Of this total, around 573,000 tonnes were collected and processed, reflecting the region's growing focus on material recovery. The result? An estimated 166,000 tonnes of aluminium reclaimed showcasing the untapped potential of dross as a valuable resource in Europe's drive toward circularity and low-carbon production.
North America
In 2024, North America generated approximately 603,000 tonnes of aluminium dross, with remelters contributing the majority at 69 per cent, while primary smelters accounted for 8 per cent. The remaining dross came from downstream processing units. Out of this total, about 495,000 tonnes were collected and sent for further processing to extract valuable aluminium, but a portion still ended up in landfills or alternative uses. The region recovered an estimated 138,000 tonnes of aluminium from dross during the year.
Leading the charge in dross processing are key players like BPI Inc., Real Alloy, TST Inc., Glencore, and Scepter, driving North America's push toward a more circular, resource-efficient aluminium industry.
Asia Pacific region (excluding China)
In 2024, the aluminium industry across the Asia Pacific region (excluding China) generated an estimated 822,000 tonnes of dross. The lion's share of 72 per cent came from remelters, while primary smelters contributed just 10 per cent. The downstream sector added another 147,000 tonnes, highlighting the diverse sources of this once-overlooked by-product.
Despite growing awareness around resource recovery, only 454,000 tonnes of dross were sent for further recycling, with the remainder still ending up in landfills. The region managed to reclaim around 123,000 tonnes of aluminium, underscoring both the opportunity and the urgency for more efficient processing systems.
Middle East & Africa
The aluminium industry in the Middle East & Africa generated an estimated 210,000 tonnes of dross, with primary aluminium smelters accounting for nearly 45 per cent of this total. The recycling sector contributed about 33 per cent, while the downstream industry made up the remaining 22 per cent.
Out of this, approximately 160,000 tonnes of dross were collected and sent for further recycling, recovering around 68,000 tonnes of valuable aluminium—a testament to the region's growing commitment to circularity.
Leading the dross processing charge is TAHA International Corporation, with notable contributions from the Bahrain Recycling Plant and Crown Industries. Meanwhile, Harsco Metals & Minerals (now Enviri) has phased out its salt cake production in Bahrain, signalling a shift in how the region manages aluminium by-products as it pushes toward more sustainable practices.
South America
In 2024, South America's aluminium industry produced an estimated 215,000 tonnes of dross, with remelters contributing 65 per cent, primary smelters 8 per cent, and the downstream sector accounting for the remaining 27 per cent. Out of this, around 140,000 tonnes were recovered and sent for recycling, yielding approximately 38,000 tonnes of aluminium. Despite these efforts, the region's share of the global aluminium dross trade remains minimal.
Brazil's CBA (Companhia Brasileira de Alumínio) is leading the way in responsible dross management. The company processes onsite-generated dross to maximise aluminium recovery and actively collaborates with specialised external processors to recycle treated dross residue, aiming to close the loop and boost sustainability in its operations.
Conclusion – moving towards a sustainable future powered by dross
Aluminium dross has truly transformed from an overlooked industrial nuisance into a cornerstone of the aluminium industry's green revolution. In 2024 alone, nearly 4.78 million tonnes of dross were generated worldwide, with innovative recovery technologies now reclaiming over 95 per cent of this resource, turning waste into wealth. As global sustainability targets grow more ambitious and aluminium takes centre stage in clean energy, mobility, and infrastructure, aluminium dross processing is fast becoming a key driver of low-carbon growth. This renewed focus on dross recovery not only cuts down environmental impact but also unlocks immense economic value, proving that in the aluminium world, what was once discarded is now driving the future—lighter, greener, and smarter than ever before. The aluminium industry's journey from waste to resource is not just a technical upgrade; it's a bold statement of commitment to a cleaner, more circular planet.
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