EFFICIENT USE OF ALUMINUM SCRAP IN EFFICIENT USE OF ALUMINUM SCRAP - PowerPoint PPT Presentation

EFFICIENT USE OF ALUMINUM SCRAP IN EFFICIENT USE OF ALUMINUM SCRAP IN BATCHING SECONDARY ALLOYS AND POTENTIAL BATCHING SECONDARY ALLOYS AND POTENTIAL FOR SENSOR-BASED SORTERS TO IMPROVE FOR SENSOR-BASED SORTERS TO IMPROVE RECYCLING SYSTEM EFFICIENCY RECYCLING SYSTEM EFFICIENCY Adam Gesing Hartmut Harbeck Gesing Consultants Inc TiTech GmbH REWAS 2008, Cancun esing onsultants Inc

Contents • Current light metal recycling system • Markets for secondary alloys • Recycling system needs and sustainability issues • Scrap separation and sorting technologies • Desirable separations that make financial sense REWAS 2008, Cancun esing onsultants Inc

Aluminum p Aluminum prod oduction and recycling uction and recycling Prime smelter Casting RSI scrap Oxides Dross Remelt and ingot Dross cast house Salts processor Fab Al Shredder Shredder scrap shred residues Sorter Shape Semi- caster fabricator Handsorted Al Manuf EoL & scrap scrap mixed Mixed Component metal manuf manufacturer scrap scrap Reject Foils components Assembly Chips Scrap Assembler Turnings scrap dealer Contaminated scrap EoL scrap Use Landfill Waste

Post-consumer light-metal recycling Post-consumer light-metal recycling • Primary steel shredders process ELVs commingled with other metal-containing scrap • Light-metal scrap can be effectively separated from the shredder residue as nonmagnetic metal concentrate (NMMC) • Mg is not separated from light metals at the shredder • Only a portion of the NMMC is treated by dense-media plants producing Al and Al + Mg alloy mixes • Remaining Mg scrap stays commingled with Al shred and is chlorinated out of Al foundry alloys • Al + Mg mix is handsorted in Asia and Mg desulphurizes Chinese steel • New particle-sorting technologies and processes under development have the ability to complete metal scrap separation by parent metal and by alloy REWAS 2008, Cancun esing onsultants Inc

Post-consumer light-metal scrap sources Post-consumer light-metal scrap sources Scrap source Scrap type LM in EoL Curbside recycling and UBC products recycling depots Packaging foil Municipal waste dirty Consumer durables – appliances MRFs and RDF plants C&D MRFs Building scrap, siding, windows, doors Scrap machinery, process vessels & piping WEEE recycling depots Electronic scrap – Al and Mg housings Scrap yards and ELV Flattened ELV hulks de-pollution dismantlers Handsorted & baled, categorized LM scrap LM commingled in Steel shredders NMMC (nonmagnetic metal concentrate) shredded scrap LM concentrate LM scrap products Dense media sink-float Al and Mg-Al mixes from shredder LM plants concentrate Alloy sorting/batching Al or Mg alloys batched from alloy mix plants Post-consumer scrap diverted from landfill and recycled reduces demand for the prime metal by secondary alloys and frees up prime for use in high-performance prime alloys REWAS 2008, Cancun esing onsultants Inc

Light metals in the car recycling system Light metals in the car recycling system Car in use ELV Deregistration Deregistration Deregistration Deregistration Deregistration fluids remanufactured reusable Depollution Depollution Depollution Depollution refrigerants Depollution Car repair Remanufacture Car repair Car repair Car repair Car repair Car repair Remanufacture Remanufacture Remanufacture Remanufacture Remanufacture parts components Dismantling Dismantling Dismantling Dismantling catalysts Dismantling Flattening Flattening Flattening Flattening toxics Flattening steel scrap steel Remanufacturing demolition scrap flattened shred scrap appliance scrap ELV hulk scrapped mixed metal scrap parts Al new & Si old scrap Zn Scrap yard Scrap yard Scrap yard Scrap yard Steel shredder Steel shredder Steel shredder Steel shredder Cu Al prime used consumer Al +(Mg) . ingot nonmagnetic scrap Al(Mg) + metal concentrate direct to Al refiner Al refiner Al refiner Al refiner Cl 2 used industrial Al(SiCuZn) Mg / Al(Mg) in remelt scrap MgCl 2 categorized nonmetal nonmetal residue in dross scrap residue Al Al 38X & 319 Sink-float Sink-float casting foundry ingot media plant scrap media plant Al Al shape casting Al shape casting dense shape casting metals wire Mg+Al Al castings mix REWAS 2008, Cancun esing onsultants Inc

Primary shredding plant Primary shredding plant white mixed metal ELVs goods dealer scrap CDW MSW 5,000-15,000 HP hammer mill oversize drum magnet steel light Z-box elutriator SR Oversize Cyclone & 5, 30 mm baghouse screens >5<30 mm >30<100 mm <5 mm fines Light SR Overbelt magnet steel (nonmetal) Nonmetal Eddy current lead, wire rotor circuit stainless steel Eddy current coil metal particle sorter circuit Nonmetal NMMC fines Al + Mg nonmagnetic Stainless Steel concentrate metal concentrate Nonmetal steel REWAS 2008, Cancun esing onsultants Inc

Nonmagnetic shredder fraction –NA supply ~ 1,000 kT of NF metal/ year, growing quickly –20-95% metal –60-70% Al in metal (~ 600 kT/ year) –30-50% wrought in Al (~ 200 kT/ year)

Sink-float dense Sink-float dense-media plant media plant NMMC from NMMC = NMMC from Nonmagnetic SDF SLF metal concentrate 1000-2000 HP dense hammer mill 100 mm Oversize 3 mm screens Process water treatment Overbelt magnet fines 3 mm screen Dewatered 1.0 g/cc wash sludge 2.0 g/cc float >9 mm 9 mm screen steel Overbelt magnet magnetite slurry Jig light headpulley magnet Cyclone separator Eddy current & baghouse rotor circuit 3.5 g/cc float light ferrosilicon slurry Eddy current Nonmetal Eddy current dense rotor circuit fines & rotor and shape foam dust sort circuit paper <9 mm foil Fe Dense metal steel Nonmetal Nonmetal Insul. textile attach. metal mix mix grain Al +Mg Wire Nonmetal Al +Mg mix Al alloy rock grain mix REWAS 2008, Cancun esing onsultants Inc

Al mix from HMF

Main markets for secondary Al Main markets for secondary Al and the most popular alloys for these markets and the most popular alloys for these markets Market Secondary alloy Compatible scrap sources Al 3X04 can body Old cans, can manufacturing scrap Non-can wrought manufacturing scrap packaging sheet Al- and Mg-based scrap mix from 2 g/cc float fraction of a dense-media sink-float plant Building 3105 painted Old Al siding Al siding and extrusion construction scrap Al sheet Mixed wrought manufacturing Al scrap with low copper content Old wrought scrap Automotive 38X.x casting Some 38X alloys can accept a mixture of the most common old scrap varieties without dilution, providing Al alloys the Mg concentration is controlled by chlorination 319.x casting Tighter concentration limits on 319 increase the dilution requirement and limit the types of old scrap that can be added to a 319 alloy batch Steel 95% Al This specification can be met by many mixtures of old wrought alloy scrap deoxidants REWAS 2008, Cancun esing onsultants Inc

Secondary die castings AA38X - Al Si9% Cu4% Z n3% F e Low Mg → Mg chlorinated out REWAS 2008, Cancun esing onsultants Inc

Alternative uses for prim Alternative uses for primary Al ingot & recycled Al ary Al ingot & recycled Al Primary imary Al ingot Al ingot Al in Mg Al 3XX UBC Al alloy- AZ91 Al in Mg particle Al alloy- segregated particle- alloy- segregated billet batched old Al in Mg ingot casting Mg +Al batched Al dross segregated shred casting alloy- fabrication & particle mix old shred and skim billet casting fabrication & Al 3XX alloy- segregated manufacturing old shred fabrication & manufacturing segregated Fe ingot casting scrap Al in Mg from light manufacturing scrap casting & contaminated fabrication & alloy- media float scrap manufacturing scrap manufacturing segregated Al 5/6XXX Al 3/5/6XXX scrap Al 3X04 scrap ingot and particle particle Al particle shape batched old machining batched old Al machining batched old chips & casting shred chips & shred shred turnings scrap turnings Al Mg Al Al sheet Al shape Al Mg shape Mg sheet secondary extrusion casting extrusion mill UBC casting mill remelt smelter mill remelt mill remelt remelt remelt remelt remelt Al Fe Mg deoxidant All good uses for Al-containing scrap; All free up prime Al for prime alloy applications REWAS 2008, Cancun esing onsultants Inc

For least-cost, sustainable recycling you need: For least-cost, sustainable recycling you need: a complete recycling system • • markets for all scrap-derived products • recyclable , relatively pure, PRIME alloys • Few, high volume SECONDARY alloys with high recycled content • low-cost technology and system for managing alloying elements in scrap and using these elements to alloy new metal • unrestricted flow of metal scrap between markets REWAS 2008, Cancun esing onsultants Inc