Cars re­born

in a new alu­minium re­cy­cling scheme

DEMM Engineering & Manufacturing - - ENVIRONMENTAL -

Jaguar Land Rover is also ex­pand­ing the use of re­cy­cled alu­minium in its car bodies to cut waste and re­duce car­bon emis­sions.

The £2 mil­lion project, called RE­AL­ITY, has found a way to en­able the closed-loop re­cy­cling of alu­minium from end- of-life ve­hi­cles back into high- per­for­mance prod­uct forms for new ve­hi­cle body man­u­fac­ture in the UK by Jaguar Land Rover.

RE­AL­ITY builds on the REALCAR project al­low­ing tens of thou­sands of tonnes of alu­minium gen­er­ated in the man­u­fac­tur­ing process to be re­cy­cled and reused as a closed-loop. Alu­minium from other sources, in­clud­ing end- of-life ve­hi­cles, can now be graded and ‘ born again’ in the man­u­fac­ture of new cars.

This unique ‘closed-loop’ au­to­mo­tive re­cy­cling sys­tem helps to fur­ther de­velop the cir­cu­lar econ­omy model to de­liver both fi­nan­cial and en­vi­ron­men­tal ben­e­fits.

REALCAR be­gan as a part­ner­ship be­tween Jaguar Land Rover, In­no­vate UK, Novelis, Norton Alu­minium, Stadco, Brunel Univer­sity Lon­don, Zy­omax and In­no­val Tech­nol­ogy. The orig­i­nal project and sub­se­quent work with sup­pli­ers en­abled Jaguar Land Rover to re­claim more than 75,000 tonnes of alu­minium scrap and re-use it in the alu­minium pro­duc­tion process in 2016/17.

Im­ple­ment­ing closed-loop alu­minium re­cy­cling has in­volved cut­tingedge chem­istry, new in­fra­struc­ture and in­vest­ment of more than £13 mil­lion. It is driv­ing a new cul­ture that treats waste ma­te­rial as a high-value com­mod­ity. Qual­ity will re­main paramount, and the project has eval­u­ated alu­minium grades at chem­istry and mi­crostruc­ture level to in­crease tol­er­ance to re­cy­cling.

The project, part-funded by In­no­vate UK, has in­volved more than 10 press shops (Jaguar Land Rover and ex­ter­nal sup­pli­ers) with alu­minium be­ing remelted by Novelis.

The car man­u­fac­turer says work con­tin­ues to re­fine the process of turn­ing alu­minium from ‘end- of-life’ cars into new ve­hi­cles. The RE­AL­ITY project will con­tinue to de­liver sig­nif­i­cant sus­tain­abil­ity ben­e­fits, with alu­minium re­cy­cling re­quir­ing up to 95 per­cent less en­ergy than pri­mary alu­minium pro­duc­tion. In­no­vate UK1 awarded a grant of £1.3 mil­lion to the project in 2016 as part of its Man­u­fac­tur­ing and Ma­te­ri­als Round One fund­ing com­pe­ti­tion.

The new project will con­sider ad­vanced sort­ing tech­nolo­gies and eval­u­ate the next gen­er­a­tion alu­minium al­loys for greater re­cy­cla­bil­ity. In­no­va­tions in the sort­ing and sep­a­rat­ing tech­nolo­gies ap­plied to au­to­mo­tive end- of-life waste streams will also help other sec­tors, in­clud­ing pack­ag­ing and con­struc­tion. Re­source re­cov­ery spe­cial­ist Ax­ion has joined the project to de­velop the sort­ing tech­nolo­gies for re­cov­ery of a high grade re­cy­cled alu­minium. The project part­ners are Jaguar Land Rover, Ax­ion Re­cy­cling, In­no­vate UK, Novelis, Norton Alu­minium, Brunel Univer­sity Lon­don, WMG Univer­sity of Warwick and In­no­val Tech­nol­ogy.

RE­AL­ITY sup­ports ma­te­rial stew­ard­ship as part of the Alu­minium Stew­ard­ship Ini­tia­tive (ASI) Per­for­mance Stan­dard, to ac­tively en­cour­age the most ef­fec­tive re­cy­cling ap­proaches for alu­minium. Jaguar Land Rover is an ASI2 mem­ber. 1. In­no­vate UK is the op­er­at­ing name of the Tech­nol­ogy Strat­egy Board, the UK’s in­no­va­tion agency. It is a UK non- de­part­men­tal pub­lic body op­er­at­ing at arm’s length from the Gov­ern­ment re­port­ing to the De­part­ment for Busi­ness, En­ergy and In­dus­trial Strat­egy (BEIS). In the fi­nan­cial year 2016-2017 IUK dis­trib­uted up to £561m of pub­lic money in four sec­tor groups - Emerg­ing and en­abling tech­nolo­gies, Health and life sciences, In­fra­struc­ture sys­tems and Man­u­fac­tur­ing and ma­te­ri­als. The lat­ter has so far re­ceived £4.5 for Ad­di­tive man­u­fac­tur­ing; £2m for Man­u­fac­tur­ing readi­ness and all- up £28m for Man­u­fac­tur­ing & ma­te­ri­als Round 1 & 2. 2. The Alu­minium Stew­ard­ship Ini­tia­tive is the body stan­dard for an in­ter­na­tional ap­pli­ca­tion by the alu­minium value chain to en­able the alu­minium in­dus­try to demon­strate re­spon­si­bil­ity and pro­vide in­de­pen­dent and cred­i­ble as­sur­ance of per­for­mance; re­in­force and pro­mote con­sumer and stake­holder con­fi­dence in alu­minium prod­ucts; re­duce rep­u­ta­tional risks con­cern­ing alu­minium and alu­minium in­dus­try play­ers; and ad­dress the ex­pressed needs by down­stream in­dus­trial users and con­sumers for re­spon­si­ble sourc­ing of alu­minium. ASI’s stan­dards are de­signed to be ap­pli­ca­ble to all stages of alu­minium pro­duc­tion and trans­for­ma­tion, specif­i­cally: baux­ite min­ing, alu­mina re­fin­ing, pri­mary alu­minium pro­duc­tion, semi-fab­ri­ca­tion (rolling, ex­tru­sion, forg­ing and foundry), ma­te­rial con­ver­sion, and re­fin­ing and re- melt­ing of re­cy­cled scrap, as well as ma­te­rial stew­ard­ship cri­te­ria rel­e­vant to down­stream users of alu­minium. Two stan­dards will form the core of the ASI Cer­ti­fi­ca­tion pro­gram: • ASI Per­for­mance Stan­dard (Prin­ci­ples and Cri­te­ria launched De­cem­ber 2014) • ASI Chain of Cus­tody Stan­dard

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