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High Shear Processing of Recycled Aluminium Scrap for Manufacturing High Performance Aluminium Alloys

Objective

The EU wrought aluminium industry is based on the use of primary aluminium. Primary aluminium production is both energy and carbon intensive and EU production is rapidly declining. Secondary aluminium (post-consumer scrap) is either downgraded into low quality cast products, or exported.
This scrap could be transformed into a low cost, low carbon feedstock for wrought product and high quality castings by the adoption of High Shear Processing (HSP) technology. This innovative new technology is based on a novel physical melt conditioning process that can be applied both to batch and continuous metal processing. It is based on leading edge research into the heterogeneous nucleation and growth in aluminium alloys, and its promotion by dispersed oxides.
This research at Brunel University has demonstrated that the physical processing of liquid metals transforms oxides in melts from defects to active nuclei. This results in refined cast microstructures with significantly improved mechanical properties. The physically conditioned liquid can be used in all casting processes, including shape casting and the casting of rolling blocks or extrusion billets.
The project will bridge the gap to industrialization through the involvement of a research-capable SME who will design and manufacture a prototype small industrial-scale HSP unit and then make recommendations regarding improved equipment design and likely process costs. Other SME partners will assist with economic modelling, through a life cycle analysis, which will comprise the costs of the process and the energy savings together with the impact in the carbon footprint.
RecyCAL could have a major impact on the EU wrought and cast aluminium industry, leading to the consolidation of the primary and secondary industry sectors. The project could transform the EU aluminium metals cycle from one that is currently resource intensive to one that is sustainable.

Field of science

  • /natural sciences/chemical sciences/inorganic chemistry/inorganic compounds
  • /engineering and technology/environmental engineering/energy and fuels/renewable energy
  • /natural sciences/chemical sciences/inorganic chemistry/metals

Call for proposal

FP7-ENV-2013-two-stage
See other projects for this call

Funding Scheme

CP - Collaborative project (generic)

Coordinator

TWI LIMITED
Address
Granta Park Great Abington
CB21 6AL Cambridge
United Kingdom
Activity type
Research Organisations
EU contribution
€ 408 825,45
Administrative Contact
Adam Coventry (Mr.)

Participants (12)

BRUNEL UNIVERSITY LONDON
United Kingdom
EU contribution
€ 382 029,90
Address
Kingston Lane
UB8 3PH Uxbridge
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Teresa Waller (Ms.)
UNIVERSITY COLLEGE DUBLIN, NATIONAL UNIVERSITY OF IRELAND, DUBLIN
Ireland
EU contribution
€ 353 429,97
Address
Belfield
4 Dublin
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Donal Doolan (Mr.)
CENTRO RICERCHE FIAT SCPA
Italy
EU contribution
€ 268 519,37
Address
Strada Torino 50
10043 Orbassano
Activity type
Research Organisations
Administrative Contact
Maria Onida (Dr.)
ENGINSOFT SPA
Italy
EU contribution
€ 246 567,03
Address
Via Della Stazione 27
38100 Trento
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Carla Baldasso (Dr.)
AZCATEC TECNOLOGIA E INGENIERIA SL
Spain
EU contribution
€ 126 165,64
Address
Calle Historiador Juan Manzano 2 Edf Palmera Real 1 Mod 127
41089 Dos Hermanas
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Daniel Garcia (Mr.)
SULDOURO - VALORIZACAO E TRATAMENTO DE RESIDUOS SOLIDOS URBANOS SA
Portugal
EU contribution
€ 57 238
Address
Rua Conde Barao, Aterro Sanitario De Vng E Sta M F
4415 100 Vila Nova De Gaia Sermonde
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Maria Dores Mâncio (Ms.)
IBERICA DE ALEACIONES LIGERAS SL
Spain
EU contribution
€ 90 215,41
Address
Carretera Alagon Tauste Km 7600 7
50668 Pradilla De Ebro Zaragoza
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Fernando Lou (Mr.)
Quantal Laser Tecnologia SA
Portugal
EU contribution
€ 81 005,66
Address
Sao Cristovao 95
4480-430 Vila Do Conde
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Paula Ribeiro (Ms.)
GIF GESELLSCHAFT FUR INNOVATIVE FERTIGUNGSTECHNIK MBH & CO KG
Germany
EU contribution
€ 125 171,24
Address
Tronjestrasse 1
44319 Dortmund
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Rafael Bieker (Dr.)
F.O.M.T. FONDERIE OFFICINE MECCANICHE TONNO GIOVANNI DI TONNO SERGIO EC. SPA
Italy
EU contribution
€ 89 759,92
Address
Viale Lidice 8
10095 Grugliasco To
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Amelia Montedoro
INNOVAL TECHNOLOGY LIMITED
United Kingdom
EU contribution
€ 123 418,38
Address
Beaumont Close
0X16 1TQ Banbury
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Eoghan Mcalpine (Dr.)
UNIVERSIDAD PUBLICA DE NAVARRA
Spain
EU contribution
€ 43 863,03
Address
Campus De Arrosadia
31006 Pamplona
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Benigno Gomez (Mr.)