INTERNATIONAL CLEANER PRODUCTION INFORMATION CLEARINGHOUSE

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.