Case Study #69 1. Headline: Recovery and recycling of aluminum scraps and its alloys coming from aluminum machining by direct extrusion using a technology called CONFORM. 2. Background: See Description of Cleaner Production Application. 3. Cleaner Production Principle: New technology 4. Description of Cleaner Production Application: This case study, carried out in 1992, involves a new technology, CONFORM, that allows the recovery and recycling of aluminum and aluminum alloy machining scraps by direct extrusion without remelting. The process set-up, when compared to the conventional one, reduces the extrudate production steps from 9 to 4 with a high level of energy efficiency. The plant is constituted by a crushing system, a prill drying furnace and an UKAEA modified design extrusion machine which is used for the wire rod production. The plant can process 3,000 t/y of billets sawing shavings (chips) and rolling ingots scalping. Because of direct conversion of shavings into extrudates, without the traditional re-melting, the losses of metal can be reduced by 10%. The process is less energy intensive: consumption is lower by 73% compared to the traditional one. The production of air pollutants from combustion process are virtually eliminated (the reduction is about 9,5 million m3/y of metallurgical fumes). Re-melting drosses elimination are approximately of 200 k/t corresponding to 600 t/y. The plant currently operating can process 3000 t/y of trimmings produced by Alumix group. So far the demonstration plant is the first of its kind. There is, however, a great potential for this technology to be adapted throughout Europe by similar manufacturing industries. 5. Economics: 2.5 x 10(9) lire refers to a 3,000 t/y plant. Compared to the traditional technology (re-melting) the extrusion technology (CONFORM machine) permits a reduction of 900 lire per kilo of product processed. There is an estimated payback time of between 1.5 and 2 years. 6. Advantages: It is an environmentally friendly technology because it eliminates problems arising from aluminum recovery by re-melting. The key features are: -elimination of the usual side products like drosses; -elimination of gaseous emissions and metallurgic fumes from combustion; -lower consumption of resources, (10% of aluminum raw material recovered and recycled) -increased energy efficiency, (energy consumption is reduced by approximately 73% compared with traditional remelting process). 7. Constraints: No information provided. 8. Contacts: Information taken from the documents that accompany Italian patent (No. 1208583) and European patent (No. 0241668) . Mr G Lazzaro ALARES Spa- Centro Tecnico Processi ALUMIX Group PO Box 44 I 09010 PORTOSCUSO (Cagliari) Italy TEL: 39 781 5031 FAX: 39 781 509464 Mr G Bardone ENEA CRE Casaccia Dip Ambiente Via Anguillarese 301 00060 - S Maria di Galeria ROME Italy TEL: 396 3048 6662 FAX: 396 3048 3220 9. Keywords: Italy, metal, aluminum, machining, extrusion, new technology, recycling, CONFORM, energy saving 10. Reviewer's comments: The case study passed the ENEA Committee for technical investigation for "European Better Environment Award for Industry." This case study was submitted to UNEP IE in 1994 by Italy's ENEA. It was reviewed and edited by UNEP IE in July 1995. It has not undergone a formal technical review.