Unearthed is pleased to announce the launch of the ‘Crust Busters’ innovation challenge in partnership with South32, focused on eliminating and managing cryolite crust during molten aluminium transfer.
The Crust Busters Innovation Challenge invites global innovators to rethink how cryolite crust is managed during molten aluminium transport, a critical safety and efficiency factor for smelter operations at South32’s Hillside Aluminium.
Challenge Focus:
This open innovation challenge aims to identify better ways to:
- Eliminate cryolite fluid (electrolyte bath) from entering the ladle when tapping the molten aluminium at the Reduction potroom cells.
- Prevent, monitor, detect or manage the formation of electrolyte crust during the transportation of molten aluminium within a ladle.
- Enable safer and more efficient transfers of molten aluminium from the potroom to the Casthouse and into the furnace.
South32, in partnership with Unearthed, is calling on innovators inside and outside the mining and metals industry to share ideas and solutions that tackle this complex issue.
Why This Matters:
Once tapped from the reduction cells, the molten aluminium must be safely transported across the smelter to be transferred into the Casthouse furnace
As the molten aluminium is transported, typically over a ~35-minute window at Hillside, it begins to cool from its initial temperature of ~960°C. Due to its lower density, cryolite rises to the surface of the molten aluminium in the ladle, where it begins to harden as it separates from the metal below and forms an electrolyte crust.
The formation of an electrolyte crust can obstruct the ladle spout during pouring, particularly if there are delays at the weighbridge or casting area that causes transportation to take longer. This introduces a safety risk (primary focus) and also a production impact.
The Opportunity:
South32 Hillside Aluminium via their innovation program, Innovate32, have funding and an established pathway to support selected innovators from this challenge through:
- Studies
- Field trials
- Commercial agreements, where applicable and agreed.
Wider Market Opportunity:
It is worth mentioning that this challenge is not unique to Hillside – it is common in many smelting operations across the mining industry. There could be significant market potential for viable solutions beyond Hillside.
Challenge Timeline:
- Challenge Live: Tuesday 10 June
- Q&A Webinar: Tuesday 15 July – Register here for our technical webinar
- Challenge Closes: Friday 1 August
- Responses: September 2025
For more information, please contact:
Jake Harris
Innovation Delivery
jake@unearthed.solutions
Alexandra Dumas
Communications and Project Lead
alexandra@unearthed.solutions
