What quality do the reprocessors expect?

Andy Doran

National Manager, Novelis Recycling

Our markets

    Novelis is the world leader in aluminum rolling and can recycling Spun off from Alcan Inc in January 2005 Became subsidiary of Hindalco Industries Ltd in May 2007 We are the only company of our size and scope focused on aluminum rolled products markets, including: Flexible and Semi-rigid Packaging Building and Construction Printing and Lithography Cans and Closures Automotive and Transportation

World leading UBC Recycler North America 480 kt United States Berea, KY Greensboro , GA Oswego, NY South America 125 kt São Paulo, Brazil Pinda Europe 220 kt Latchford, UK Asia 30 kt South Korea Ulsan

Latchford site UBC Plant Comm. 1991 GPP Plant Comm. 1942

Can body ingot

Weighs 27 tonnes Measures 9 x 1.8 x 0.5 metres Contains 1.5 million recycled drink cans Is transported to Germany to the rolling mill

Why quality matters in aluminium recycling and how to deliver it……

Novelis – Latchford used beverage can recycling plant

Dross Bay

Hot Metal Transfer from GPP

Argon dross coolers

Scraps charged direct to furnace Automatic Salt Feeders Scraps charged direct to furnace Capacity 16MT Cold Extraction System Shredder

Belt Conveyor

Off-site Aluminium Recovery

AJS

Melter 2 Capacity 90MT

   

Melter 1 Capacity 90MT

AJS

Decoater Extraction System

Scrap Receiving and Cold Fines Screen Screen

Decoater

Metal Transfer Launders Hopper 12MT

Off-site Al Recovery

Magnetic Separator

Hot (Furnace) Extraction System

DC Casting Centre 3 ingots per cast GSSD - Sidewell Stirrer AJS - Jet Stirrer RGI - Rotary Gas Injector ACD - Degasser DC - Direct Chill ABF - Bed Filter

Tilting Holder

ACD Holding and ABF Two point Grab Despatch Area RGI Class Scrap and UBCs

Sheet ingot to Alunorf

Impact of plastics

24 hrs

13 tph 8 tph

Series of line trips + reducing feedrate

Quality checks OUR AGGREGATION CENTRES:

 Visual before off loading    Visual after off loading Moisture test Magnet

AT THE RECYCLING PLANT:

 Visual before off loading  Visual after off loading  Moisture test - all deliveries  Breaking open of pallets / bales

Plastic

    Fire hazard and health and safety risk Every outage results in 10 minutes lost feed At 10 t/hr, this equates to 1.67 t lost feed Excessive melt loss

Lower quality equals lower value

Over a 1 year period, this supplier ‘lost out’ on more than £60,000 of revenue!

What makes for good quality aluminium?

Use good machinery and use it well

Simple technology and materials handling:  Avoid over compacting cans or cans and plastic fractions during collection  Tipping loose cans into wire baskets helps to filter out smaller contaminants, e.g. glass, and can make visual inspection easier  Controlling the rate of flow along conveyors with chains  Fit grilles in holding hoppers  Set conveyors at a high angle so that heavy objects fall back  Ensure eddy currents are well positioned and sufficient for the volumes handled  Check the positioning of skips. Use marks on the floor to ensure they are always replaced correctly after emptying

  

Use good people and treat them well

Housekeeping: Ensure balers are cleaned to remove traces of other materials (e.g. paper, plastic) before baling of UBCs starts Check the settings on eddy current separators regularly; for example is the splitter plate set to give the maximum sort? Pay regular attention to the cleaning of floors, skips etc. This not only reduces the opportunity for contamination to occur, it is also an important aid to maintaining health and safety in the work environment and improving staff motivation.   Staff training: Your staff are the key to successfully cutting contamination Contamination can be prevented by staff being more aware of the potential problems, and understanding the need to be vigilant

Open loop ‘multi-material’ collection and sorting schemes

In general it is difficult (and costly) to separate the small aluminium fraction from multi-material schemes. Therefore it is recommended to separate it early in the sorting process which in combination with improved separation techniques will result in higher yields, better quality and more value. There is the additional advantage of higher consumer involvement .

Glass household waste, including paper + ‘light fraction’ = plastic bottles (PET), metal containers (beverage cans, etc.) and beverage cartons (if necessary) Glass Paper + Light fraction Glass Paper fraction Light fraction

Thank you for your interest!

[email protected]

Tel: 01483 853 136 Mob: 07802 889 360

Thank you for your interest!

[email protected]

Tel: 01483 853 136 Mob: 07802 889 360