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What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

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Page 1: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

What quality do the reprocessors expect?

Andy DoranNational Manager, Novelis Recycling

Page 2: What quality do the reprocessors expect? Andy Doran National 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

Page 3: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

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

Page 4: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

Latchford site

UBC PlantComm. 1991

GPP PlantComm. 1942

Page 5: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

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

Page 6: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

Why quality matters in aluminium recycling and how

to deliver it……

Page 7: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

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

Page 8: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

8 tph

13 tph

24 hrs

Series of line trips + reducing feedrate

Impact of plastics

Page 9: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

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

Page 10: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

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

Page 11: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

Lower quality equals lower value

Over a 1 year period, this supplier ‘lost out’ on more than £60,000 of revenue!

                                                    

Page 12: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

What makes for good quality aluminium?

Page 13: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

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

Page 14: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

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

Page 15: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

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 .

Page 16: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

Thank you for your interest!

[email protected]: 01483 853 136Mob: 07802 889 360

Page 17: What quality do the reprocessors expect? Andy Doran National Manager, Novelis Recycling

Thank you for your interest!

[email protected]: 01483 853 136Mob: 07802 889 360