Research Projects

The proposed research focuses on developing and scaling up oxygen-evolving inert anodes for aluminum electrolysis, offering a sustainable alternative to the carbon-intensive Hall-Héroult process. Currently, aluminum production contributes significantly to global industrial CO2 emissions due to the consumption of carbon anodes, releasing CO2 and other greenhouse gases like CF4 and C2F6. By replacing consumable carbon anodes with inert ones, the proposed project aims to eliminate direct process emissions and improve energy efficiency. This research will target the synthesis and optimization of cermet-based inert anodes, leveraging their combined advantages of high electrical conductivity, chemical stability, and corrosion resistance in harsh fluoride-rich electrolytic environments. The project includes three major phases: Material development and characterization: Utilizing spark plasma sintering (SPS) and advanced surface coatings, the study will fabricate cermet anodes with enhanced thermal and chemical stability. Techniques like SEM, XRD, and electrochemical impedance spectroscopy will evaluate microstructure, phase stability, and conductivity. Laboratory-scale electrolysis testing: The anodes will be tested in a in-house-built electrolysis setup to optimize process parameters and evaluate short-term performance. Parameters like cell voltage, current density, and oxygen evolution will be monitored, alongside corrosion resistance and coating stability. Extended performance evaluation: Long-term testing under industrially relevant conditions will examine degradation mechanisms, dynamic load performance, and compatibility with renewable energy sources. This phase will also assess scalability and environmental impact, aiming to align with global carbon-neutrality goals. The project aligns with India's commitment to achieving net-zero emissions by 2070 and decarbonizing industrial sectors. Successful implementation will position India as a leader in sustainable aluminum production, reducing emissions by up to 2.3 tons of CO2 per ton of aluminum produced. This work not only addresses a critical industrial challenge but also facilitates economic and social benefits, including compliance with carbon regulations, cost savings, and technological advancements.