Chen Dai, MPI student, presented her master thesis, “Reuse of Aluminum Dross as Engineered Products,” at TMS 2012 this month in Florida. The objective of her thesis, which is also one of the completed projects in CR3, is to eliminate “refurbishing the waste“, by utilizing the dross in a natural cycle (closed loop) as an engineered material. At present, dross is processed in rotary kilns to recover the Al, and the resultant salt cake byproduct is sent to landfills, posing a significant potential to harm the environment. Furthermore, recovering the Al from the dross is energy intensive. This project has proved that dross can be applied directly, or with a simple conditioning process, to manufacture refractory components. Mechanical properties reveal the possibility for dross waste to be utilized as filler in concrete, resulting in up to 40% higher flexural strength and 10% higher compressive strength, comparing to pure cement and cement with sand.