Although the REVEAL project has officially concluded, its partners continue to advance technologies with the aim of contributing to more sustainable energy systems. In its latest newsletter, consortium partner Arctus Aluminium provides further details on its Icelandic scale-up project, including plans for industrial-scale carbon-free aluminium production and the technology's potential to improve energy efficiency, reduce emissions and minimise hazardous waste.
Following the announcement of new funding in June 2026, Arctus continues to advance its DECAFAL demonstration project, with the aim to scale up their innovative aluminium smelting technology to a 25 kA electrolytic cell at Nordural Aluminium's industrial site in Grundartangi, Iceland.
The technology uses vertical inert electrodes and a low-temperature electrolyte operating at approximately 800°C, replacing conventional carbon electrodes to produce aluminium and oxygen without direct CO₂ emissions from electrolysis. The demonstration aims to validate electrode durability and the production of 99.8% purity aluminium.
According to Arctus, the technology could offer significant advantages over conventional aluminium smelting, including 20% lower energy consumption, 50% less space required, 30% lower investment costs and 15% lower operating costs.
Beyond these potential efficiency and economic benefits, Arctus estimates that the technology could avoid approximately 2.4 tonnes of CO₂-equivalent emissions per tonne of aluminium produced. The use of inert electrodes could also significantly reduce hazardous spent potlining waste and prevent cyanide formation associated with conventional carbon cathodes.
Building on the planned 25 kA demonstration, Arctus is also preparing a further scale-up to a 100 kA commercial-size cell, representing another step towards industrial deployment.
Advancing Research Beyond REVEAL
Within REVEAL, Arctus and IceTec contributed their expertise in carbon-free aluminium production to the development of a circular approach to long-duration renewable energy storage using aluminium as an energy carrier. Among the project's final achievements was a 4 kW aluminium-to-energy generator operating at the Eastern Switzerland University of Applied Sciences (OST), demonstrating progress towards the project's industrial-scale energy storage plan.
Arctus's continued work highlights the relevance of carbon-free aluminium production beyond REVEAL's lifetime. The company is scheduled to present its technology at the 4th European Green Aluminium Summit in Frankfurt on 18–19 November 2026.
For more information about Arctus's technology, industrial scale-up plans and other activities, click the button and read the full November newsletter.
