Recycling

Recycling of aluminium and magnesium existed long before circular economy became a major trend. Used aluminium and magnesium parts, alloys and scrap are not only too valuable to dispose of, they are also great for reprocessing and remodelling. Recycling aluminium and magnesium is much more efficient than producing it from raw materials.

 

Remelting consumes only about 5% of the energy needed for primary production. In addition, both materials lose none of their properties through recycling. This has two advantages; the metal retains its value and can be reprocessed as often as is desired. Recycled alloys are therefore the logical choice for environmentally-conscious customers who want greater efficiency in their metal supply. With decades of experience, state-of-the-art technologies, and the constant development of new and environmentally-friendly processes, REAL ALLOY can provide the best possible aluminium and magnesium recycling solutions, while consuming as little energy and as few additives as possible.

 

The low-energy footprint, in comparison with primary metals, has also reduced the carbon footprint of our metal. Recycled aluminium and magnesium are therefore ideal for all customers aiming to reduce the carbon and climate impact in their supply chain. The light weight of these two metals bring about more of these advantages in the use phase of related products in most sectors.


Processes

REAL ALLOY’s mission is the recycling of aluminium and magnesium scrap and skimmings. Our sites are capable for recycling a wide variety of different scrap types and skimmings. Most of these raw materials are linked to manufacturing, but an increasing share is post-consumer and end-of-life-related.

 

Incoming scrap is inspected in our testing departments for further classification. Modified blending procedures for ensuring the appropriate specifications and economics are in place and continuously updated.

 

Efficient remelting is possible in dedicated furnaces, like single-chamber furnaces, two-chamber furnaces or tiltable rotary furnaces. Whilst single-chamber furnaces are mainly used for clean scrap remelting and refining, the two-chamber furnaces are also capable of remelting scrap, which is contaminated with lacquers or lubricants. Tiltable Rotary Furnaces are very well designed for highly-contaminated scrap and skimmings. All our furnaces are operated by highly-qualified and motivated teams. After melting, the liquid metal is either transferred into other furnaces for final refining, or casted through casting machines into moulds for solidification.

 

The refining of metal can be combined with degassing, filtration and other measurements which impact metal quality, in accordance with customer demands. The entire production process is closely controlled through the use of quality control systems.

 

A large proportion of our products is transferred as liquid metal directly into customer casthouses, in-line with their individual specifications; independent of whether foundry specification alloy or wrought alloy-related. Another share is casted into moulds for generating larger Remelt Secondary Ingots (RSI), small ingots or cones.


Foundry and Wrought Alloy

REAL ALLOY offers the full range of different alloys of aluminium or magnesium, whether they are related to foundry specification applications or wrought applications.

 

For foundry specification applications, REAL ALLOY has established two-stage operations at its sites which combine remelting and refining. Our specialty is the production of higher grade aluminium-silicon alloys, which are usually prime-related, but based on scraps and skimmings. Consequently, the CO2 footprint of these alloys is comparatively low. But in addition, other commodity alloys are in REAL ALLOY’s portfolio – basically, the entire range of alloys can be served, in accordance with customer requirements. Products are either transferred as a liquid or provided in the shape of small ingots.

 

For wrought applications, REAL ALLOY bases its production on one-stage operations, mainly linked to two-chamber operations or tiltable rotary furnace operations. Also in this segment, the entire range of alloys can be generated on the basis of various scrap types and skimmings, which also contributes to a low CO2 footprint. One specialty of REAL ALLOY is the ability to shift material flows between (and to) the various European sites, in accordance with customers’ demands – in a rather flexible way – and serves customers with recycling solutions for their production customer scrap, right across the European continent. Thanks to our market network, we can find the best raw materials for our customers, so adding the appropriate metal to their internal metal flows.