The e-Magazine "ALuminium Casting Industry: Focus 2024" by AL Circle delves into the significant impact of sustainability on the aluminium casting sector, shaping production methods, operational strategies, and overall industry standards. Firstly, there's a growing emphasis on reducing energy consumption and emissions during production. Aluminium casting companies are investing in energy-efficient technologies and processes to minimise their carbon footprint. Additionally, there's a heightened focus on recycling and reusing aluminium materials. The aluminium casting sector increasingly incorporates recycled aluminium into its production processes, reducing the need for raw materials extraction and minimising waste.
Moreover, sustainability considerations are driving innovations in material design and product development within the aluminium casting sector. Companies are exploring lightweight solutions to decrease products' environmental impact while maintaining performance and durability. Furthermore, there's a shift towards sustainable sourcing practices within the aluminium casting supply chain. Companies seek responsibly sourced aluminium to ensure ethical and environmentally friendly production practices from raw material extraction to final product delivery.
{alcircleadd}Hydro pioneers plasma technology
Hydro is intensifying its commitment to attaining zero CO2 emissions in aluminium production by integrating emission-free plasma technology into the Sunndal casthouse. The Norwegian Government had provided soft funding for this innovative project, acknowledging its potential to influence hard-to-abate industries worldwide profoundly. The conventional process of re-melting aluminium into new products typically involves an energy-intensive procedure demanding exceptionally high temperatures, often reliant on fossil energy sources like natural gas.
However, Hydro introduced a groundbreaking plasma technology that enabled the electrification of this process. By harnessing renewable energy sources—similar to those powering Hydro's primary smelters—the company is on the brink of revolutionizing aluminium re-melting, rendering it more sustainable and environmentally friendly. This advancement aligned with Hydro's overarching objective of diminishing its carbon footprint and advocating for cleaner practices across the aluminium industry.
Hydro aims to achieve the significant milestone of melting the inaugural batch of nearly emission-free aluminium in the Sunndal casthouse by the fourth quarter of 2025 in an unprecedented stride towards sustainable aluminium production. This groundbreaking pilot initiative is poised to have a substantial impact, reducing carbon emissions by over 500 tonnes annually. However, the ripple effect of this eco-friendly endeavour extends well beyond Sunndal, potentially cutting a staggering 11 million tonnes of CO2 emissions globally from aluminium casthouses and recyclers.
Rusal's new cast alloy with 25-30% recycled aluminium
Rusal, the world's largest aluminium company in primary aluminium output, announced the production of a cast alloy with an increased share of recycled aluminium content, ranging from 25 to 30 per cent. Specifically designed for the automotive industry, the new alloy matched Rusal's primary equivalent foundry alloys (PEFA), which comprised over a quarter of recycled aluminium. This marked an increase from the alloy's initial 20 per cent recycled metal content.
The newly developed cast alloy abided by all OEM requirements, addressing the demand for recycled content and a reduced carbon footprint. Notably, the scrap sourcing method for PEFA was more systematic than the approach for primary foundry alloys. This approach supported Rusal's commitment to carbon neutrality and bolstered its position in the circular economy. Furthermore, this strategy also aligned with Rusal's Climate Strategy, emphasizing its dedication to sustainable practices and environmentally friendly production methods.
ASI welcomes Shinhwa Auto USA
Aluminium Stewardship Initiative (ASI) announced the joining of Shinhwa Auto USA Corp. as the new Industrial User Member. Shinhwa Auto USA Corp. is a premier provider of aluminium die-cast, machining, and assembly components in the automotive industry. Shinhwa Auto excels in producing essential components like drive shafts and axle assemblies for automotive uses. With a wide range of services, including design, FEA, simulation, engineering, and manufacturing, the company comprehensively serves North American OEM and Tier 1 customers' requirements. Shinhwa Auto is committed to fulfilling its duties as a responsible corporate entity within its community.
Read more: https://www.alcircle.com/news/shinhwa-auto-usa-joins-asi-as-the-new-industrial-user-member-109151
ASI accredits Chongqing Millison Technologies
Chongqing Millison Technologies Inc., based in China, received official certification from the Aluminium Stewardship Initiative (ASI) under the ASI Performance Standard V3 (2022). The company's facility, located in the Banan District, Chongqing, underwent a successful certification process. SGS-CSTC Standards Technical Services conducted the independent third-party audit of Chongqing Millison Technologies Inc.'s facility.
Chongqing Millison Technologies Inc. specialised in manufacturing aluminium structural components for modern mobile network base stations and traditional vehicle systems. The company's primary production processes included remelting (smelting), die-casting, cleaning/shot blasting, and machining. With an impressive annual production capacity of 80,000 tonnes, they focused on producing components for engine, transmission, and steering, body, electric drive, and body systems for new energy vehicles.
Alro invests $15.9 million to reduce ecological impact
On October 10, Alro Group, a Romanian aluminium producer, revealed plans to invest 15 million euros ($15.9 million) in three initiatives to reduce its ecological footprint and boost competitiveness. One of these projects involved installing a 1,500 KW photovoltaic (PV) power station in Alro's parking areas to generate renewable energy. Additionally, the press release outlined that this investment will go towards expanding the fume treatment plant to meet new emission targets and acquiring new machinery to enhance the company's capabilities by broadening its product range. With an increased focus on sustainability, the company aimed to potentially reduce emissions across its molten metal treatment line, smelting, and casting units.
"The projects we are starting now have the role of reducing carbon emissions by generating a quantity of renewable energy that is so necessary for the company's activity but above all to considerably reduce the carbon footprint for our operations in the cast house,” said the CEO of Alro, Gheorghe Dobra.
Read more: https://www.alcircle.com/news/alro-invests-15-9-million-to-reduce-ecological-impact-100573
Evtec strikes a sustainable deal
Evtec Aluminium Limited, renowned for its expertise in crafting intricate aluminium castings, secured a significant supply agreement with Jaguar Land Rover. Under this arrangement, Evtec will supply automotive components for Jaguar's upcoming electric vehicle line. As a distinguished manufacturer of lightweight aluminium parts for electric vehicles and luxury automobiles, Evtec will be Jaguar's exclusive supplier for crucial components. This partnership is anticipated to generate more than $67 million in Evtec auto parts sales. Jaguar's forthcoming range of luxury electric vehicles will feature a four-door GT model and a luxurious sedan. These vehicles are expected to boast an impressive range of over 435 miles, with the ability to charge up to 200 miles in just 15 minutes rapidly.
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Assan Alüminyum’s move towards sustainability
Assan Alüminyum, a prominent producer of flat-rolled aluminium, is dedicated to diminishing its carbon footprint while striving for sustainable expansion. To fulfil this commitment, the company initiated a multi-year investment initiative bolstered by a $90 million green loan from the International Finance Corporation (IFC). A subsidiary of the Kibar Group, Assan Alüminyum aims to deploy an array of sustainable technologies, fostering efficiency and environmental stewardship.
The investment program included installing a cutting-edge, energy-efficient cold rolling line, introducing new continuous casting lines and upgraded filtration systems for current and upcoming operations. These investments are crafted to modernise production processes, augment the integration of renewable energy sources, and enhance the incorporation of recycled aluminium in manufacturing.
Top 10 low-carbon aluminium brands leading the sustainable revolution
The defining development of the twenty-first century is the global acknowledgement of climate change and its profound impact on Earth's delicate balance. Excessive carbon emissions and greenhouse gases are the chief culprits behind the gradual warming of our planet. This warming, in turn, poses a grave threat to our atmosphere's protective shield, the ozone layer, potentially leading to a dangerous escalation of temperatures. The rising heat presents a significant challenge for the Earth's troposphere, as it struggles to deflect and manage these intensified heat waves. This could transform our world into an inferno with devastating consequences if left unchecked. The consequences are stark: melting glaciers, cataclysmic floods, and a relentless rise in sea levels.
Amidst the increasing embrace of renewable and green energy sources, major aluminium companies actively seek collaborative ventures. This marks a significant shift towards sustainability and responsible practices. Leading the charge are global energy giants such as GenHydro in the USA, Statkraft in Europe, SPIC in China, Hydro in Norway, Phinergy in Israel, Adani in India, and Siemens in Germany. As these prominent aluminium producers connect with renewable energy grids, their primary operational facilities naturally transition towards greener, low-carbon production. This collective effort represents a pivotal moment in the industry's journey towards an environmentally conscious and sustainable future.
Conclusion
Investing in sustainable practices isn't just about preserving our planet; it's about securing a future where innovation, efficiency, and responsibility converge. Let's forge ahead with aluminium casting, knowing that our commitment to sustainability today will shape a brighter, greener tomorrow.
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