Plants that run on what others throw away
Recycling economics turn on charge purity and yield. Both are decided by the plant design, long before the first scrap arrives.
A secondary plant has to cope with feedstock that changes week to week. Coating, moisture, density and contamination all move, and the melting process has to stay stable across that range. Design for the average and the plant will underperform for most of the year.
We have designed this plant type repeatedly across Europe, Asia and the Americas, which means the layout, the decoating and drying line, the furnace and the fume system get specified as one system rather than assembled from separate vendor packages.
Inside the scope
Scrap handling
Receiving, sorting, weighing, separation and charging logistics, designed so contamination is removed before the melt rather than diluted into it.
Aluminium recycling
Complete plant design: process, layout, melting furnaces, decoating and drying, dross handling and auxiliary systems.
Secondary metallurgy
Ladle treatment, alloying and the process control needed to hit grade from a variable charge.
Where we have done it
Hydro Cassopolis (USA) and Hydro Høyanger (Norway): process design, automation and detail design of decoating systems and melting furnaces. Novelis (USA) and Constellium (France): ingot dryer engineering with utilities distribution. Tesla Berlin (Germany): process design and detail design of a decoating system. Complete recycling plant design for Shandong Chuangxin, Shandong Yunnan and Shandong Suzhou (China), CCE and Interal (Azerbaijan), Yalcinlar (Turkey), Cazuca (Colombia), Omega (Brazil), and Exlabesa, Coralium and Aluind (Spain).
Is this the piece you are missing?
Send us the plant, the constraint and the timeline. You will get an engineer's answer, not a brochure.