About Z-ONA4LIFE

Turning hazardous aluminium waste from secondary metallurgy into value

Z-ONA4LIFE is an EU-funded project that transforms hazardous aluminium industry waste into high-value synthetic zeolites for environmental and industrial applications. By combining circular economy principles, industrial innovation, and pilot-scale validation, the project demonstrates how waste can become a valuable resource while reducing environmental impact.

About Page background

The challenge

Every year, thousands of tonnes of aluminium salt slag are generated across Europe during aluminium recycling processes. This hazardous waste is difficult and expensive to manage, and only a limited number of treatment facilities are currently available in Europe. As a result, aluminium foundries often need to transport their waste over long distances, generating significant economic and environmental costs.

In Spain alone, aluminium recycling plants generate between 150,000 and 190,000 tonnes of salt slag every year. However, only one major operator currently manages most of this waste stream. Z-ONA4LIFE was created to address this challenge by demonstrating a more circular and sustainable alternative.

The solutions

Z-ONA4LIFE develops an innovative process that transforms aluminium salt slag and silica-rich waste into synthetic zeolites (Z-ONA zeolite) - versatile materials with strong adsorption and ion-exchange properties.

Our Z-ONA zeolite can be used in several environmental and industrial applications, including:

  • Wastewater treatment
  • Gas purification
  • Soil remediation
  • Fabrication of sustainable construction materials
  • Livestock and mining effluent treatment


 

The project also promotes a near-zero-waste process for the synthesis of the Z-ONA zeolite, by recovering by-products and recycling process water.

 

Main objectives

Demonstrate pilot-scale viability: Validate the technical and economic feasibility of producing synthetic Z-ONA zeolite at pilot scale.

Increase circularity in the aluminium industry: Recover and valorise hazardous aluminium salt slag and silica-rich residues.

Develop a near-zero-waste process: Recover valuable by-products and recycle water used during the process.

Support industrial uptake: Promote the adoption of the Z-ONA zeolite through pilot demonstrations and industrial validation.

Prepare replication across Europe: Develop a business strategy to replicate the Z-ONA4LIFE approach in Spain and across Europe.

Future Impact

145t

of salt slag recycled

95t

of silica waste recycled

220t

of synthetic zeolite produced

118m³

of landfill leachate treated 

100t

of zeolite used for industrial applications

25t

of enhanced compost produced

120t

of organic soil produced

Why Z-ONA4LIFE matters

Z-ONA4LIFE contributes to several European priorities, including:

  • Circular Economy Action Plan
  • European Green Deal
  • Resource efficiency objectives
  • Industrial decarbonisation
  • Sustainable waste management

The project demonstrates how industrial innovation can support a more circular and competitive Europe.