What quality do the reprocessors expect?
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Transcript of What quality do the reprocessors expect?
What quality do the reprocessors expect?
Andy DoranNational Manager, Novelis Recycling
Our markets Novelis is the world leader in aluminum rolling and can recycling Spun off from Alcan Inc in January 2005 Became subsidiary of Hindalco Industries Ltd in May 2007 We are the only company of our size and scope focused on aluminum rolled products markets, including:
Automotive and Transportation
Building and
Construction Flexible and Semi-rigid Packaging
Cans and Closures Printing and Lithography
World leading UBC Recycler
São Paulo, Brazil
United States
UlsanUlsan
PindaPinda
Berea, KYBerea, KY
Europe 220 kt
North America 480 kt
South America125 kt
Asia30 kt
Greensboro , GAGreensboro , GA
Oswego, NY Oswego, NY
Latchford, UKLatchford, UK South Korea
Latchford site
UBC PlantComm. 1991
GPP PlantComm. 1942
Can body ingot
Weighs 27 tonnes
Measures 9 x 1.8 x 0.5 metres
Contains 1.5 million recycled drink cans
Is transported to Germany to the rolling mill
Why quality matters in aluminium recycling and how
to deliver it……
Novelis – Latchford used beverage can recycling plant
SurgeHopper12MT
Class Scrapand UBCs
to Alunorf
Sheet ingot
GSSD - Sidewell Stirrer
AJS - Jet Stirrer
DC - Direct Chill
ACD - Degasser
ABF - Bed Filter
RGI - Rotary Gas Injector
Hot Metal Transfer from GPP
DecoaterExtraction System
BeltConveyor
Shredder
Hygiene Extraction System
Off-site Al Recovery
MagneticSeparator
Cold Extraction System
DecoaterCold Fines
Screen
Hot (Furnace)Extraction
System
Metal TransferLaunders
Tilting HolderFurnace
Capacity 90MT
RGI
AJS AJS
AutomaticSalt Feeders
Melter 2 Melter 1Capacity
90MTCapacity
90MT
Sidew
ell
Sidew
ell GSSDs
Sow DrierCapacity 16MT
Scraps charged direct to furnace
Scraps charged direct to furnace
Hot Fines
Screen
DC CastingCentre
3 ingots per cast
ACD
ABF
DrossBay
Argon dross coolers
Off-site AluminiumRecovery
Two point Grab32MT Max. Load
Band Saw21-26MT Slab, 8300mm long
Scrap Receiving and Shredding Area
Decoating and Melting Area
Holding and Casting Area
Sawing and Despatch Area
8 tph
13 tph
24 hrs
Series of line trips + reducing feedrate
Impact of plastics
Quality checks
AT THE RECYCLING PLANT:Visual before off loadingVisual after off loadingMoisture test - all deliveriesBreaking open of pallets / bales
OUR AGGREGATION CENTRES: Visual before off loading Visual after off loading Moisture test Magnet
Plastic
Fire hazard and health and safety risk
Every outage results in 10 minutes lost feed
At 10 t/hr, this equates to 1.67 t lost feed
Excessive melt loss
Lower quality equals lower value
Over a 1 year period, this supplier ‘lost out’ on more than £60,000 of revenue!
What makes for good quality aluminium?
Use good machinery and use it well
Simple technology and materials handling:Avoid over compacting cans or cans and plastic fractions during collection
Tipping loose cans into wire baskets helps to filter out smaller contaminants, e.g. glass, and can make visual inspection easier
Controlling the rate of flow along conveyors with chains
Fit grilles in holding hoppersSet conveyors at a high angle so that heavy objects fall back
Ensure eddy currents are well positioned and sufficient for the volumes handled
Check the positioning of skips. Use marks on the floor to ensure they are always replaced correctly after emptying
Use good people and treat them wellHousekeeping: Ensure balers are cleaned to remove traces of other
materials (e.g. paper, plastic) before baling of UBCs starts Check the settings on eddy current separators regularly;
for example is the splitter plate set to give the maximum sort?
Pay regular attention to the cleaning of floors, skips etc. This not only reduces the opportunity for contamination to occur, it is also an important aid to maintaining health and safety in the work environment and improving staff motivation.
Staff training: Your staff are the key to successfully cutting
contamination Contamination can be prevented by staff being more
aware of the potential problems, and understanding the need to be vigilant
Open loop ‘multi-material’ collection and sorting schemes
Paper fraction
Glasshousehold waste, including paper + ‘light fraction’ = plastic bottles (PET), metal containers (beverage cans, etc.) and beverage cartons (if necessary)
Glass
Glass
Paper + Light fraction
Light fraction
In general it is difficult (and costly) to separate the small aluminium fraction from multi-material schemes. Therefore it is recommended to separate it early in the sorting process which in combination with improved separation techniques will result in higher yields, better quality and more value. There is the additional advantage of higher consumer involvement .
Thank you for your interest!
[email protected]: 01483 853 136Mob: 07802 889 360
Thank you for your interest!
[email protected]: 01483 853 136Mob: 07802 889 360