Minimization of resource use via flowsheet optimization: The case of Aluminum recycling

The integrated flow of primary and secondary resources in the loop is in the centre of the Circular Economy (CE) paradigm. To optimize the use of resources, a system-wide thinking, which links the primary and secondary production of the whole processing chain, is required. Digitalization and process simulation enable the linking of these relevant aspects together, optimising the resource use and minimising the environmental impact.

Aluminium’s reactivity poses a challenge for resource efficient recycling. In the re-melting of Al scrap, most of the impurities remain in the molten aluminium. This emphasizes the importance of the quality of the scrap in preventing contamination and reducing the need for dilution with primary aluminium in the alloying phase.

This paper analyses an aluminium recycling flowsheet that combines detailed physical separation models with re-melting and alloy production. The simulation model captures the impact feed quality and the efficiency of the physical separation stage have on specific alloy production. Optimum strategies for alloy production can be found for each specific feed type to minimise resource consumption. The paper demonstrates how digitalization allows more precise and efficient use of finite resources in the sense of CE.