Forecasting global aluminium flows to demonstrate the need for improved sorting and recycling methods

Inertia of Technology Stocks: A Technology-Explicit Model for the Transition toward a Low-Carbon Global Aluminum Cycle

Low-carbon technologies are essential for the aluminum industry to meet its climate targets despite increasing demand. However, the penetration of these technologies is often delayed due to the long lifetimes of the industrial assets currently in use. Existing models and scenarios for the aluminum sector omit this inertia and therefore potentially overestimate the realistic mitigation potential. Here, we introduce a technology-explicit dynamic material flow model for the global primary (smelters) and secondary (melting furnaces) aluminum production capacities. In business-as-usual scenarios, we project emissions from smelters and melting furnaces to rise from 710 Mt CO2-eq./a in 2020 to 920-1400 Mt CO2-eq./a in 2050. Rapid implementation of inert anodes in smelters can reduce emissions by 14% by 2050. However, a limitation of emissions compatible with a 2 °C scenario requires combined action: (1) an improvement of collection and recycling systems to absorb all the available postconsumer scrap, (2) a fast and wide deployment of low-carbon technologies, and (3) a rapid transition to low-carbon electricity sources. These measures need to be implemented even faster in scenarios with a stronger increase in aluminum demand. Lock-in effects are likely: building new capacity using conventional technologies will compromise climate mitigation efforts and would require premature retirement of industrial assets.

A low-cost process for complete utilization of bauxite residue

Cost-effective treatment or even valorization of the bauxite residue (red mud) from the alumina industry is in demand to improve their environmental and economic liabilities. This study proposes a strategy that provides a near-complete conversion of bauxite residue to valuable products. The first step involves dilute acid leaching, which allowed the fractionation of raw residues into (1) an aqueous fraction rich in silica and aluminium and (2) a solid residue rich in iron, titanium and rare earth elements. For the proposed process, 91% of the original silicon, 67% of the aluminium, 78% of the scandium and 69% of the cerium were recovered. The initial cost evaluation suggested that this approach is profitable with a gross margin of 167 $US per tonne. This "Residue2Product" approach should be considered for large-scale practices as one of the most economical and sustainable solutions to this environmental and economic liability for the alumina industry.

Classification of Shredded Aluminium Scrap Metal Using Magnetic Induction Spectroscopy

Recycling aluminium is essential for a circular economy, reducing the energy required and greenhouse gas emissions compared to extraction from virgin ore. A 'Twitch' waste stream is a mix of shredded wrought and cast aluminium. Wrought must be separated before recycling to prevent contamination from the impurities present in the cast. In this paper, we demonstrate magnetic induction spectroscopy (MIS) to classify wrought from cast aluminium. MIS measures the scattering of an oscillating magnetic field to characterise a material. The conductivity difference between cast and wrought makes it a promising choice for MIS. We first show how wrought can be classified on a laboratory system with 89.66% recovery and 94.96% purity. We then implement the first industrial MIS material recovery solution for sorting Twitch, combining our sensors with a commercial-scale separator system. The industrial system did not reflect the laboratory results. The analysis found three areas of reduced performance: (1) metal pieces correctly classified by one sensor were misclassified by adjacent sensors that only captured part of the metal; (2) the metal surface facing the sensor can produce different classification results; and (3) the choice of machine learning algorithm is significant with artificial neural networks producing the best results on unseen data.

Insights into the evolution of cobalt use and implications through dynamic analysis of cobalt flows and stocks and the recycling potential of cobalt from urban mines in China during 2000-2021

Several countries regard cobalt as a critical material due to its extensive use in clean energy technology and high-tech industries. To comprehensively examine how China's cobalt industry developed and evolved from 2000 to 2021, our study quantified cobalt flows, stocks and the recycling potential of cobalt from China's urban cobalt mines using dynamic material flow analysis. In 2021, China's in-use cobalt stocks for cobalt-containing end products reached 131 kt, of which battery products and superalloys accounted for 83.8% and 8.1%, respectively. The theoretical cumulative recycling potential of cobalt from China's urban cobalt mines reached 204-356 kt between 2000 and 2021 under different scenarios. However, the actual cumulative exploitation of cobalt from urban cobalt mines was 46-80 kt, of which consumer electronics, cemented carbides, and superalloys were the main recycled products. The cumulative exports and imports of cobalt in all commodities reached 558 and 1117 kt, respectively. China exported a large quantity of cobalt chemicals, chemical derivatives and cobalt-containing end products produced from imported cobalt raw materials. China imported 84.7% of the cobalt raw materials consumed domestically, and 32.6% of the domestically produced cobalt-containing end products were exported. Over the entire life cycle of cobalt, cobalt losses totaled 288 kt, with 51.0% of losses coming from refining, and a 73.8% cobalt utilization efficiency was achieved. China recovered 76.7 kt of cobalt, and the recycling rate of cobalt from end-of-life cobalt-containing end products reached 20.0%. The findings can serve as a scientific basis for China's cobalt industry to develop efficiently and economically.

Adding Value to Secondary Aluminum Casting Alloys: A Review on Trends and Achievements

Aluminum is a critical element of the circular economy as it can be recycled several times. Moreover, Al recycling is a more economically and environmentally efficient procedure than the primary Al production from ores. Secondary aluminum alloys are mostly used in casting applications since it is possible to accommodate their chemical composition through secondary manufacturing processes. However, the quality of the alloys may be considerably altered during the different steps of the recycling process. Inadequate waste sorting might result in excessive contamination. Iron is the most dangerous contaminant because it causes brittle and fragile intermetallic phases, which significantly impacts the mechanical characteristics of alloys. In addition, the microstructure of the alloy changes significantly after multiple cycles of remelting. These issues lead to the downcycling of aluminum, i.e., in other words, the reduction in the overall quality of the alloys. Thus, it has been shown that a number of procedures, including ultrasonic melt treatment and microalloying with rare earths, can somewhat alter the shape of the Fe-rich phases in order to reduce the shortcomings of downcycling. However, a solid mechanical characterization is still missing in order to improve the Fe-rich phase alteration.

Synthesis and Characterization of Boehmite Particles Obtained from Recycling: Water Disinfection Application

We report on the synthesis of boehmite aluminum oxide hydroxide particles with lamellar structure (γ-AlO(OH)) obtained from the recycling of metallic can seals, with the addition of silver nanoparticles (Ag-NPs) reduced by Aloe Vera extract. X-ray diffractometry (XRD) confirmed the γ-phase, and scanning electron microscopy (SEM) showed the presence of Ag-NPs on the boehmite particle surface, confirming the efficiency of the synthesis to obtain the composite material. The samples were used to treat lake water, according to the Standard Methods for the Examination of Water and Wastewater. The results indicated that the elimination of total coliforms and Escherichia coli occurred, with excellent efficiency for the Ag-boehmite sample. The tests show the possibility of reuse (5×) of the sample, as it maintained the efficiency of disinfection for E. coli. The preparation, use, and reuse of boehmite obtained from metallic waste is a case of a circular economy, focused on sustainability and green chemistry.