Secondary aluminum: Boosting proofits, reducing costs

Aluminum has a dual nature when it comes to sustainability. While its lightweight properties contribute to energy efficiency in various applications, the energy-intensive process of producing aluminum from bauxite ore (primary production) poses the need for sustainable alternatives. Aluminum obtained from recycled scrap (secondary production), also known as green aluminum, shifts the balance toward higher sustainability as the total energy required for production is reduced up to 95 percent compared with primary aluminum.

With the projected doubling of available aluminum for recycling by 2050, the metallurgical sector has a significant opportunity to move closer to a circular economy. Nevertheless, the recycling process comes with its own set of challenges. A large amount of the scrap available for recycling is post-consumer scrap, containing high levels of elemental contamination. 

The Magaldi family of companies, with its extensive expertise in demanding applications, has developed custom-engineered conveyor solutions that address scrap pre-treatment challenges. Their expertise extends from the balers to decoaters (cold area) as well as conveying hot shredded scrap downstream of decoaters (hot area). By improving material flow throughout the production line, these solutions maximize energy savings while minimizing costs and environmental impact.

Superbelt® technology: Efficiency and flexibility in aluminum scrap handling

In order to comply with the reduced CO2 requirements and reduce overall energy requirements, the ability to successfully process a wide range of post-consumer scrap must be developed. With this in mind, Magaldi developed the Superbelt® conveyor, which is designed to meet the demands of every scrap handling application, offering the necessary flexibility while ensuring the highest performance. Key features include:

• High dependability and uptime. The redundant patented mesh system ensures trouble-free continuous operation, eliminating any risk of sudden failure.
• Jam-free design. The unique overlapping pan design eliminates spots where material pinches and leaks, ensuring consistent material flow.
• Extremely low maintenance. With few moving parts and no critical wear points, maintenance requirements are minimal, translating to lower operational costs and downtime.
• High versatility. Designed to accommodate various material types and challenging geometries, the Superbelt® conveyor seamlessly integrates into existing processes, optimizing space utilization and operational efficiency.

The Ecobelt® conveyor system sets the standard in hot shredded scrap transport

Aluminum decoating is a pivotal stage in the recycling process as it enables the use of a broader range of scrap types. It consists of removing any surface layers (lacquer, paint, plastic, etc.) and other contaminants from aluminum products to obtain clean scrap, ready for melting.

Magaldi developed a unique, fully enclosed and insulated steel belt conveyor that connects the decoater with the downstream melting furnace(s), transporting shredded scrap at temperatures of approximately 500 C (932 F) without compromising efficiency or reliability. Coupled with the advantages of our Superbelt® technology, the Ecobelt® conveyor delivers additional benefits to aluminum scrap consumers:

• Increased melting rate and reduced energy consumption. The conveyor is fully enclosed in a thermally insulated casing that effectively minimizes thermal drop. This allows shredded scrap to be charged into the melting furnace while still hot, resulting in increased melting rate and, therefore, energy savings and reduced CO2 emissions.
• High resistance to abrasion and wear. The low-friction and innovative design minimize wear parts and eliminate often problematic chains, sprockets, hinges and rails that suffer from the heat combined with aluminum, alumina and silica dust. This minimizes maintenance requirements and downtime, thereby improving overall efficiency and profitability.

Engaging material handling expertise for sustainable success

Recycling has the potential to shift aluminum’s energy and carbon balance substantially toward greater sustainability. The key prerequisite for meeting the growing demand for green aluminum is using the highest scrap fractions, including low-quality post-consumer scrap. In this scenario, aluminum recyclers must invest in enhancing scrap treatment processes to remain competitive and achieve their sustainability goals.

Magaldi stands ready to support aluminum recyclers’ endeavors with tailor-made conveyor solutions that optimize material handling processes while minimizing environmental impact.

By harnessing Magaldi’s expertise and innovative technologies, aluminum recyclers can navigate the complexities of scrap handling with confidence, paving the way for a greener, more sustainable future.