{"id":11902,"date":"2026-04-09T06:34:32","date_gmt":"2026-04-09T06:34:32","guid":{"rendered":"https:\/\/www.alcircle.com\/blog\/?p=11902"},"modified":"2026-04-17T10:59:00","modified_gmt":"2026-04-17T10:59:00","slug":"new-methods-to-recycle-aluminium-sorting-infrastructure-to-solid-state-recycling","status":"publish","type":"post","link":"https:\/\/www.alcircle.com\/blog\/new-methods-to-recycle-aluminium-sorting-infrastructure-to-solid-state-recycling","title":{"rendered":"New methods to recycle aluminium: Sorting infrastructure to solid state recycling"},"content":{"rendered":"\n

The dual role of aluminium recycling \u2013 economic viability and environmental sustainability – is widely recognised by the industry. From the environment perspective, recycling aluminium uses only 5 per cent of the energy and saves 95 per cent of carbon emissions in the environment, while from the economy lens, it requires only 10 per cent of the capital equipment costs compared to primary smelters. As many new recyclers are entering the market, buyers are showing greater interest in recycled aluminium. As a result, supplies are falling short in comparison with demand. The solution? Technology advancement is the way forward. Today, the aluminium recycling industry is witnessing several new methods and approaches to improve recovery and make the most of the available resources. Let’s learn about a few of these methods below.<\/p>\n\n\n\n

Shredded aluminium sorting<\/strong><\/h2>\n\n\n\n

Perhaps the most innovative aluminium recycling technology in recent years is the rise of sorting technology. Shredded aluminium, officially known as Zorba, is a by-product of shredding end-of-life cars. Once the ferrous material is separated from the mixture, it leaves behind non-ferrous materials such as aluminium, copper, zinc and traces of other metals. Many aluminium firms like Sortera Alloys, Hydro and Schupan, along with equipment suppliers Tomra and Steinert, use aluminium sorting methods to increase the value of shredded aluminium, commonly called upcycling. It allows companies to offer higher quality scrap packages to their customers, and could also enable sales of other metal scrap like copper and zinc.<\/p>\n\n\n\n

The aluminium sorting process uses various methods like X-Ray Transmission (XRT) and Laser Induced Breakdown Spectroscopy (LIBS) to identify the chemical composition of the mixed aluminium and separate different aluminium alloys. This is largely applicable to 5xxx, 6xxx, 2xxx and 7xxx series alloys, though technology is looking to identify more alloys as well. The importance of this technology is that instead of the Zorba being exported to Asia for hand sorting, it can be separated into different alloys and sold as high-quality aluminium packages to the rolling mills, thus raising its price considerably. For reference, Zorba may sell for $2,700 per tonne today, while a high-purity 6063 extrusions package may sell for $4,640 per tonne.<\/p>\n\n\n\n

Also read: Europe\u2019s 6.8% dross generation from aluminium recycling reflects global standard- how the continent is scaling its recovery efforts<\/mark><\/a><\/p>\n\n\n\n

The value of this method is not only in the economic benefit but also in the ability to find high-grade alloys that can be used to produce ingots or billets that are close to primary aluminium quality. In doing so, aluminium companies can make better use of the resources already available to them. A great example of this is Sortera Alloys, who supply both aluminium sheet and aluminium extrusions packages, which have been separated from Zorba. It explains that the material is low in copper, zinc and silicon and can be used in blending for primary billets and ingots like P1020. Sortera has estimated that about 1.8 million tonnes of Zorba is exported to Asia every year, a considerable amount of which could be recycled domestically through the use of sorting infrastructure.<\/p>\n\n\n\n

Solid State Recycling<\/strong><\/h2>\n\n\n\n

The traditional method of aluminium recycling consists of remelting scrap at 700-750\u00b0C primarily using natural gas as fuel in reverberatory or rotary hearth furnaces. This includes the addition of various compounds like chlorides, fluorides and primary aluminium like P1020 for chemistry balancing to ensure high-quality molten aluminium, which is then cast into secondary aluminium ingots. However, various universities across the world have studied Solid State Recycling (SSR) as an alternative to this traditional method. SSR uses 6xxx series alloy chips or turnings, which are generated during the machining process for various structural parts in the fabrication stage. These chips are considered mill-grade or primary scrap as they are high quality and close to new in chemical composition. However, they are usually sold at a lower price due to the difficulty in recycling them.<\/p>\n\n\n\n

SSR uses various methods, but the most common one is called hot extrusion. This method involves pressing the 6xxx series chips into a die and heating them to less than their melting point, usually 450-500\u00b0C. Soon after, pressure is exerted to create the desired form, leading to a new aluminium billet made from the chips. Higher heat reduces the amount of pressure required to form the new billets. The oxide layer on the chips is removed using high shear strain, improving the bonding between the exposed chips. This method considerably reduces energy consumption as it does not require a furnace to remelt the material. In some cases, it is also followed by hot rolling, where the billet is passed through a rolling pass several times to reach the desired sheet thickness. For example, the billet must be rolled seven times to reach a thickness of 1.5mm. A temperature of 490\u00b0C is maintained throughout the process.<\/p>\n\n\n\n

Another popular SSR method is cold compacting. In the pre-stage of this process, aluminium machine shop turnings, such as 6061 or 6063, are cleaned using ethanol in an ultrasonic bath. The cleaned chips are then dried in an oven at around 60\u00b0C for an hour to remove any residual moisture from the cleaning process. In the cold compression method, the chips are compressed using a force exceeding 300kN to compact them into briquettes. This process is repeated four times in order to ensure tight compacting and structural integrity of the resulting briquette. The novelty of this method is that the process does not use any heat but is instead conducted at room temperature. This substantially reduces energy requirements. These briquettes can then be used as feedstock for new aluminium products.<\/p>\n\n\n

\n
\"\"<\/a><\/figure>\n<\/div>\n\n\n

Batch Intelligence System<\/strong><\/h2>\n\n\n\n

The operations at Novelis and Speira\u2019s 50:50 partnership, the Alunorf plant in Nuess, Germany, take recycling efficiency a step further by using a Batch Intelligence System (BIS). The program was created specifically for the Alunorf plant, and is unique in the aluminium recycling industry. The BIS allows plant workers to calculate the maximum amount and type of scrap the furnace can handle at a given temperature and duration. In doing so, the plant can increase its scrap input rate and also reduce the use of primary aluminium. Novelis claims that it can reduce its annual carbon emissions at Alunorf by 500,000 tonnes a year using this process.<\/p>\n\n\n\n

The process uses the idea that the better the scrap mix used for the remelting process, the better the end product, such as aluminium ingots or billets, can be. The BIS system helps sort Alunorf\u2019s scrap into different batches, most of which are largely homogenous, to ensure high-quality melting. The scrap processed by the BIS includes both Novelis\u2019 mill-grade scrap that is generated during fabrication, as well as post-consumer scrap that is collected from customers and procurement strategies. The scrap is placed in large buckets and run through the BIS program, where it is weighed and sorted for alloys. Once the buckets are filled, the rest of the process is fully automated, from transport within the warehouse to the melting furnace operations.<\/p>\n\n\n\n

After approval, the buckets are either stored for future use or tipped into the charging stations, where they are pre-heated before being placed in the furnace for the new batch. The BIS may combine specific buckets for charging to create the optimal batch in order to reduce the amount of primary aluminium needed to maintain the chemistry of the desired product. It takes into account 100 different parameters to determine which buckets would work well together. The BIS system and automated working of the plant also raise operational safety standards since all the cranes that handle the buckets are operated remotely.  The BIS system also uses a light barrier system to ensure workers are not in the tipping area when the buckets are being turned over. This also reduces workplace accidents.<\/p>\n\n\n\n

Salt Cake Valorisation<\/strong><\/h2>\n\n\n\n

Aluminium salt cakes are a byproduct of the primary and secondary smelting process, and are derived from aluminium dross. In regular cases, these are considered to be toxic waste and discarded to landfills or dumped with other toxic waste. However, these salt cakes contain anywhere from 3-10% of aluminium by weight, suggesting that one tonne of salt cake can hold around 30-100 kg of metallic aluminium that can be recovered through valorisation. The process uses a combination of methods to ensure salt cakes are not discarded but instead, processed completely to recover valuable metals and other by-products.<\/p>\n\n\n\n

The first commercial application of salt cake valorisation was seen at Aluminz LLC based in Texas, USA. The company uses its own proprietary process to fully extract aluminium contained in salt cakes to ensure zero waste, resulting in products like aluminium ingots, salt flux, aluminium oxides and hydrogen gas. The company uses both salt cakes and aluminium turnings as input materials, including hard-to-recycle material which is painted, anodised, or oily in nature. The process of valorisation includes several steps that lead to aluminium recovery. It allows for a product that would be discarded to provide economic benefit not only in terms of aluminium recovery but also in the form of minerals and hydrogen gas that can be sold commercially. As an example, aluminium oxides can be used in cement manufacturing, while hydrogen gas is being used to substitute natural gas in the steelmaking process and in hydrogen fuel cells. This ensures zero waste and marketable new products from the salt cake.<\/p>\n\n\n\n

In stage one, the salt cakes are ground to a very fine powder, where the contained salts and other compounds break down into smaller pieces while the metallic aluminium remains in relatively larger chunks. The product is then screened in water using a DSM screen, where the salt and other minerals, which are easily soluble, dissolve in water, leaving behind the larger metallic aluminium particles.<\/p>\n\n\n\n

In stage two, electrostatic separation is used to recover around 70% of the contained metallic aluminium or aluminium scrap parts (in case of secondary aluminium dross). In further steps like flotation and dissolution in a strong alkali solution, almost all the aluminium contained in the salt cake can be recovered.<\/p>\n\n\n\n

Conclusion<\/strong><\/h2>\n\n\n\n

As aluminium scrap will continue to become an increasingly scarce resource in the long term, these technologies could ensure that the aluminium industry can efficiently extract the maximum value from the scrap they process. Systems like aluminium sorting are growing at a rapid pace, as aluminium companies realise that they cannot afford to downgrade the material they procure anymore, but must separate the high-value alloys and use them for better products. Solid state recycling still has some way to go in terms of testing and results, but it provides great opportunities to process 6xxx series aluminium scrap more efficiently and increase production of recycled billets. The reduced energy consumption could be a breakthrough for the industry.<\/p>\n\n\n\n

Novelis\u2019 Batch Intelligent System is apparently something the industry needed for many years, and a format most aluminium recyclers should adopt to reduce the use of primary aluminium and ensure energy efficiency. BIS must be considered since energy costs are a big part of any aluminium plant, whether primary or secondary. Salt cake valorisation is also a great way to reduce waste and recover aluminium from products we previously considered toxic or useless. The opportunity to market the by-products also increases the viability of the process.<\/p>\n\n\n\n

In all, technological innovation seems to be the best way for the aluminium industry to progress as we increasingly move from primary or virgin materials to recycling. If we consider the resources at hand finite, we must also strive toward ensuring we are reusing the available materials as mindfully and efficiently as we possibly can. Change is slow, but change is always driven by innovators, and in the aluminium industry, we see them cropping up now and then, trying to change the way business is done, and it is the distinction between just another company and a leader in the segment.<\/p>\n\n\n\n

Also read: Recycling as the seventh resource: How aluminium is powering the next metallurgical revolution<\/mark><\/a><\/p>\n","protected":false},"excerpt":{"rendered":"

The dual role of aluminium recycling \u2013 economic viability and environmental sustainability – is widely recognised by the industry. From the environment perspective, recycling aluminium uses only 5 per cent of the energy and saves 95 per cent of carbon emissions in the environment, while from the economy lens, it requires only 10 per cent […]<\/p>\n","protected":false},"author":53,"featured_media":11903,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[299],"tags":[13,700,699,701],"class_list":{"0":"post-11902","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-recycled-aluminium","8":"tag-aluminium-recycling","9":"tag-aluminium-scrap-recovery","10":"tag-aluminium-sorting-infrastructure","11":"tag-batch-intelligence-system-aluminium"},"yoast_head":"\nNew Methods to Recycle Aluminium | Sorting & SSR Guide<\/title>\n<meta name=\"description\" content=\"New methods to recycle aluminium through sorting infrastructure, solid state recycling, BIS systems and salt cake recovery.\" 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