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.
The H2020 ALUSALT full scale demonstration project has been a great success.
While the work will continue to further optimise the plant and the operation, we have fundamentally proved that the system developed from a small lab/pilot scale project under the FP7 programme in 2011-2014, has been possible to scale up to a full size, capable of meeting the requirements of normal production scenarios in the target market for exploitation, and meet the requirements of the European (and global) aluminium recyclers that require to locally and economically recycle their salt slag.
The initial commissioning and ramp up results we have obtained from the demonstration plant, have given full confidence that the equipment is scalable and all main process considerations are proven, allowing full commercialisation to start of the technology.
In summary we have proven that the three outputs of salt slag that is generated at the aluminium recycler; Aluminium, Salt and the remaining NMP (oxides) are fully re-useable at the recycling facility (aluminium recycled to produce new re-cycled aluminium, the salt re-used in the recycling facility, and the oxides (NMP) suitable as feed material to other external industrial processes (in this case steel and cement). Further work will be undertaken to further develop this aspect to widen the potential end use markets and value potential.
Due to the multiple client visits to investigate and verify the technology, who ultimately have been interested in purchasing the ALUSALT technology, and having now received our first commercial order for a mid-size (Model 3) system, and several Letters of Intent under discussion, ALTEK are very confident of their predictions for the commercialisation of this technology into the market.
Our ongoing commitment, at ALTEK’s own cost, to continue to further optimise and develop the demonstration plant, and the several recent articles in leading aluminium journals, press releases and invited conference presentations by leading aluminium conference organisers only further supports this situation.
To further support his position, ALTEK have now established a dedicated ALUSALT team, thoroughly re-affirms ALTEK’s commitment to fully exploiting this technology into the European and International aluminium industry.
The economic benefits through increased employment (both ALTEK and ALUSALT supply chains), massive potential reductions in CO2, reduced environmental impact, cost savings and competitive advantage for European aluminium operations, allowing for improved investment opportunities and growth/security of their operations are very significant.
