The main objective of this research was to develop a new re-melting process for fine or light gauge aluminum scrap products that exhibits dramatic improvements in energy efficiency. Light gauge aluminum scrap in the form of chips, turnings, and borings has historically been underutilized in the aluminum recycling process due to its high surface area to volume ratio resulting in low melt recovery. Laboratory scale consolidation experiments were performed using loose aluminum powder as a modeling material as well as shredded aluminum wire scrap. The processing parameters necessary to create consolidated aluminum material were determined. Additionally, remelting experiments using consolidated and unconsolidated aluminum powder confirmed the hypothesis that metal recovery using consolidated material will significantly improve by as much as 20%. Based on this research, it is estimated that approximately 495 billion Btu/year can be saved by implementation of this technology in one domestic aluminum rolling plant alone. The energy savings are realized by substituting aluminum scrap for primary aluminum, which requires large amounts of energy to produce. While there will be an initial capital investment, companies will benefit from the reduction of dependence on primary aluminum thus saving considerable costs. Additionally, the technology will allow companies to maintain inhouse alloy scrap, rather than purchasing from other vendors and eliminate the need to discard the light gauge scrap to landfills.
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