Aluminium is the world’s second most used metal. During aluminium extraction and recycling, salt slag is generated in vast volume and is a growing environmental problem. In Europe there are >270 known aluminium processing plants and only nine salt slag recycling facilities, this number is restricted due to economic viability of operation; there are very high initial capital cost and high operating costs. These costs create a high entry barrier for any new company to enter into the salt recycling business. EU countries such as Scandinavia and Eastern Europe transport many thousands of tonnes of salt slag p.a. thousands of kilometres for processing at the few locations available at enormous financial and environmental cost. This is a threat to the aluminium production industry as costs to process salt slag are becoming extremely high. Due to the monopolisation of re-processing options, it is a financial security issue for the aluminium recyclers as they are in the hands of the nine salt slag recyclers in operation. This highlights an industry need for aluminium recycling companies to manage in house all of their by-products and waste materials economically. ALTEK is a technology-based company with specialist expertise and experience in aluminium technology. With EC FP7 funding support, ALTEK have developed to TRL 6, ALUSALT, an in-house salt slag processing unit that offers aluminium recycling plants an economic solution to salt slag processing, reducing energy process requirements, transport costs and CO2 emissions. ALUSALT offers the industry a solution that complies with EU legislation, reduces environmental impact and can achieve cost savings of €1.95m p.a. (based on a 10,000 tonnes p.a salt slag producer). It is envisaged ALUSALT will revolutionise the industry saving €33.15m and 19,550 tonnes of CO2 p.a. based on 6.23% EU market penetration. With EU funding support ALTEK will embark on a significant new growth strategy aligned to the company’s mission.

Aluminium (Al) due to its properties is the 2nd most used metal after iron (C Krammer AlHandbook 1999). Al dross represents a residue from primary & secondary Al production. Drosses are classified according to their metal contents. White dross is higher metal Al content & is produced from primary & secondary Al smelters. Black dross has a lower metal content & is generated during Al recycling (secondary industry sector). White dross may contain from 15% to 70% recoverable metallic Al & it comprises a fine powder from skimming the molten Al. Black dross typically contains a 15% or less aluminium with a mixture of Al oxides & slag. (Hwang J Y et al 2006). Apart from Al metal, dross may also contain other chemical compounds eg Al203, AIN, Al4C3, MgF2, NaAlCl4, S102 MgO. With total global Al production at 62m tonnes (with close to 26m tonnes from recycled) increase to around 97m tonnes (39m from recycled) (Organisation of European Al Recycling Industry 2013) by 2020. Approximately, up to 4 million tonnes of white dross & more than a million tonnes of black dross are reported throughout the world each year, & around 95% of this material is landfilled (Journal of Minerals & Materials 2012 Vol 5). The problem for Al industry is to develop a means of recovering as much molten liquid from Al from the dross whilst still in the hot form (830°C-900°C) on removal from the furnace. Secondary recyclers are no longer providing acceptable value in dross recovery. Only about 40% of the metal recovery is passed on to the customer & is now common practice. In the Far East & BRIC Countries, secondary recycling services are often not available. Altek have identified a unique dual cycle stirring/pressing process which could dramatically increase the level of Aluminium recovery on site.

Altek is a world leader in the extraction of molten aluminium from dross either by direct draw off or through further rotary heating, Altek is proposing to research design & develop techniques & processes within a new press incorporating agitation & stirring to better extract the liquid aluminium bodies from the dross & salt slag at 70% either by weight as draw off or collected at the surface of the dross as a thin aluminium plate starving oxygen from the dross creating a process of rapid cooling making it easier to recover. This advancement would provide real economic, environmental & social benefits to primary and secondary aluminium producers and aluminium smelters & re-melters.

Altek is a world leader in the extraction of molten aluminium from dross either by direct draw off or through the use of rotary furnaces. The company are also world leaders in developing & applying electromagnetic stirring into furnaces & ladles & refining/holding furnace installations in the aluminium production industry. Altek is proposing to develop advanced & more compact electromagneto hydrodynamic technologies & devices for application in electromagnetic stirring technology that can deliver an advanced level of aluminium melting, pouring & semi-finished product processing performance providing circulatory benefits including higher productivity with reduced fuel consumption & dross generation. Additionally the electromagneto hydrodynamic) technologies would be utilised as a retrofit unit to be employed on continuous casting lines to modify the metallurgical grain structure & reduce alloy element segregation & porosity to provide improved performance in both high technical specification alloys for aerospace as well as proprietary alloys that require subsequent thermo-mechanical processing into final products ranging from extrusion to rolling. This advancement would provide real economic & environmental benefits to aluminium smelters, primary & secondary aluminium producers.