Secondary Aluminum Smelting is the process of recycling aluminum scrap into aluminum that can be used and recycled over and over again in a true closed loop process. Once collected and sorted, aluminum scrap is de-coated - typically through the use of a rotary kiln - to remove coatings and contaminants applied to aluminum products. From rotary de-coaters, the hot aluminum shreds (at about 500 °C) are then conveyed to the recycling furnace and turned into molten aluminum to be casted into ingots or billets, ready for subsequent processing into new aluminum products.
Magaldi developed and manufactured a Hot Shred Conveyor System to connect the rotary de-coaters with the downstream melting furnace.
The Magaldi Ecobelt® is the ideal conveyor to handle hot materials, aggressive chemicals and heavy or sharp products, ensuring a safe and environmentally friendly operation. Its key component, the Magaldi Superbelt®, is a steel belt conveyor successfully used to handle materials under the toughest process conditions in industries where high dependability is essential. It allows to overcome problems - such as sudden failures and frequent maintenance needs that lead to production losses and high O&M costs - encountered by conventional conveyors (e.g. drag chain conveyors, Apron, etc).
Designed completely enclosed in a steel casing, the Ecobelt® system is also suitable to prevent dust dispersion to the environment and ensure the lowest temperature drop, thus allowing to re-use thermal energy released from upstream processes.
Magaldi made its way into the aluminum recycling industry by supplying its dependable technology to two world giants operating in recycling and rolled aluminum production.
In June 2015, Novelis - leader in rolled aluminum products and recycling and the largest global producer of automotive and beverage can sheet - awarded Magaldi a contract for a turnkey installation of a complete Hot Shred Conveyor System in its largest aluminium recycling plant located in Germany.
Since December 2015, two complete lines are equipped with the Magaldi Ecobelt® technology.
The first conveying system is for the Can Line and delivers hot shreds from 2 rotary de-coaters to any of 3 melting furnaces; the second one is for the Flex Line and delivers hot shreds from 1 rotary de-coater to any of 3 melting furnaces. Working on three shifts, under severe conditions and high temperatures, the Ecobelt® technology has proven to be the best available solution for aluminium recycling plants.
A further confirmation of its reliability came from the request of Logan Aluminium Inc. - the leading manufacturer of flat rolled aluminium sheet for the beverage can market in US - to supply a Hot Shred Conveyor System for its new Recycling Centre located in Russelville (Kentucky). Logan was looking for a technology able to improve all aspects related to safety, reliability, process capability and spare parts demand. Equipped with the Magaldi Ecobelt® system, the can production lines have a continuous total production of 40 t/h. An additional line will be delivered at the end of this year and installed at the beginning of 2018.