Recycling of aluminium scrapes include melting process. This melting process is very inefficient because the operation of larges furnaces is still mainly based on human decisions. Typically, a non-adequate door opening decreases the efficiency by ~5%. There is no tool to indicate the optimal times for door openings. Optimizing the melting efficiency by only 10% can save nearly 0.5 M€ / year operational costs of a medium-size furnace with a huge beneficial impact on energy saving and environment.
This process optimization enabler has a very positive impact of 5-10% CO2 emissions reduction, serving the society by reducing the energy consumption and the environmental impact of aluminium industry. The solution proposed for this problem is a disruptive technology in line with the global digitalization, thus contributing the worldwide efforts for industrial sustainable development.
Novamet develops SmartMelt, a unique and patented data-driven controlling system. SmartMelt solution includes a digital-twin furnace in which data coming from the furnace controller are analysed during the process and compared on-line to results coming from a very efficient numerical simulation software. Any operation such as door opening or melt skimming or stirring can be optimized on-line during the operations, while guiding the operator for future actions, in particular the end of the melting cycle, with the optimal timing.
The aim of feasibility study was: a) to identify the actual market opportunities for secondary Aluminium melting, b) evaluate and quantify the technical and financial benefit of introducing SmartMelt technology on medium range volume furnaces (=>30 tonnes), and c) validate the pertinence of an add-on software licensing business model.
Objectives:
O.1 Market viability: i) Evaluate the secondary Al melting furnaces capacity to confirm addressable target market share; ii) strengthen relationships with customers acting as partners.
O.2 Technological viability: Quantify the impact of the product utilization on productivity and energy saving.
O.3 Business model viability: i) Quantify the value added for the customer; ii) validate the licensing sales model through quotations and orders placed by customers; iii) generate specific value propositions for indirect sales.
O.4 Economic Viability: i) Consolidate the business growth timeline; ii) identify and apply to potential funding sources (Eurostars, SME Instrument II, World Materials Forum) and identify potential investors.
O.5 Organizational viability: i) Define a company structure; ii) integrate a project management engineer.
