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AluSalt Report Summary

Project ID: 674683

Periodic Reporting for period 1 - AluSalt (Efficient Aluminium Salt cake Recycling Technology)

Reporting period: 2015-09-01 to 2016-08-31

Summary of the context and overall objectives of the project

ALUSALT™ is an economically viable way of recovering and recycling materials to increase furnace efficiency, reduce transport and third party processing costs and reduce landfilling (especially regarding hazardous materials). End users will increase capacity without more furnaces and gain lower energy usage per tonne of aluminium produced. Reprocessing salt slag in house, extracting further aluminium, reusing salt and selling inert Non Metallic Products (NMP) extracted from salt slag maximise the value of salt slag allowing smaller companies to be competitively priced.

Depending on the quality of scrap or dross, 300kg - 1,000kg of salt slag is produced for each 1,000 kg processed. In a rotary furnace general aluminium recycling melting materials such as UBC, aluminium chips and turnings, engine blocks and irony scrap also generates approximately 500k tonne of salt slag each year. The salt ratio required is slightly lower than when treating dross (approximately 10%); however, they are often mixed in the same melting cycle.

The approach gives far greater flexibility and accountability to Al recycling plants, enabling them to meet increasingly stringent Global legislation, improve financial performance and reduce their environmental impact. We also believe it will encourage many other smaller operations who have struggled with the management and disposal of the salt slags when using a Rotary Salt Furnace, to invest in this type of technology and enter the market in recycling (possibly at local levels, leading to further reductions in transportation and CO2 emissions and better localized aluminium scrap sorting and collection.

The project objectives are to develop the work completed in FP7 and upscale the concept to a fully functioning demonstration plant. This will then operate within the confines of the project to provide detailed data for the marketing and dissemination of the plant design.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The upscale design and development has been completed with significant trial work being completed within the Pilot plant to provide data which has assisted the design and development of the full sized demonstration plant. Significant purchase activity has been conducted to provide key equipment for the building of the upscale plant. Detailed layouts have been agreed with the End user partner ( detailed pictures are shown)

Detailed chemical analysis of the process has been developed within Altek utilising various methods to clearly identify the phases of reaction throughout the process.

Detailed Gas analysis has been conducted during the processing of the Aluminium Salt Cake within the pilot plant which has clear defined the on-going development of the upscale project and given significant data to drive a industrialised design.

The generation of the dangerous off gasses had been a major concern at the commencement of the project, however after careful design and detailed laboratory testing these gases can be kept to a minimum of generation through control in the process parameters.

This work has enable the upscale design to be adopted to the foundry environment where it will be operated. Previously it needed a more chemical plant methodology.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

ALUSALT is the first aluminium salt cake processing plant of its kind to offer economic, efficient recycling of small to medium volumes at source.
ALUSALT Processing solution incorporates Crushing and separation of AL for reuse and then leaching and filtration for separation of soluble/insoluble components including Al2O3 and other non-metallic products. Running small to medium batches via multiple filtration stages, it is capable of full process control irrespective of salt slag composition. The ALUSALT intelligent control system achieves this via statistical process control to manage operating cycles, key for controlling reactivity in the residual NMP, and soluble quantities in the resulting filter cake. ALUSALT process is strictly controlled enabling the limiting of emissions to a trace amount. The Process system is engineered to meet ATEX requirements.

The resulting brine liquor is fed through a dedicated Patented recrystallization system.
NMP and aluminium oxides are extracted via filtering post leaching made safe for sale as by products providing a further source of revenue for clients and eliminate landfill.

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