The development of secondary aluminum dross (SAD) has become a hot topic to deal with aluminum resource scarcity and landfill risk as hazardous waste. This study first compares the environmental impact, resource consumption, and economic performance of four emerging SAD reutilization methods with an integrated hybrid life cycle assessment (IHLCA). The results show that IHLCA captures larger environmental and economic impacts than process LCA (PLCA), especially for midpoint indicators, such as human toxicity potential, acidification potential, freshwater aquatic ecotoxicity. Furthermore, multi-component recovery from SAD is not always the best choice. The multi-component recovery scenario of SAD-to-alumina with alkali has the smallest environmental impact and resource consumption, while SAD-to-PAC with acid is the worst due to the massive use of HCl. Particularly, SAD-to-calcium aluminate with single-component recovery stands out due to its best economic performance. The given results provide new perspective on making a sustainable decision for SAD recovery industrialization.

再生铝渣（SAD）的开发已成为应对铝资源稀缺和危险废物填埋风险的热门话题。本研究首先将四种新兴的 SAD 再利用方法与综合混合生命周期评估 (IHLCA) 的环境影响、资源消耗和经济绩效进行了比较。结果表明，IHLCA 比过程 LCA (PLCA) 捕获更大的环境和经济影响，特别是对于中点指标，例如人体毒性潜力，酸化潜力，淡水水生生态毒性。此外，从 SAD 中恢复多组分并不总是最佳选择。SAD加碱制氧化铝的多组分回收场景环境影响和资源消耗最小，而SAD加酸制PAC由于大量使用HCl，环境影响和资源消耗最差。特别是单一组分回收的SAD制铝酸钙因其最佳的经济性能而脱颖而出。给定的结果为 SAD 恢复工业化的可持续决策提供了新的视角。