Game-changing technologies in recycling leading towards aluminium’s green revolution

Technology and advancements are the backbone of progress, continuously reshaping how we live, work, and interact with the world. Both are like the invisible thread that connects the simplest tasks to the most extraordinary feats, shaping how we live, work, and explore, from the flick of a switch that brightens a room to the complex orchestration of a spaceship soaring beyond our atmosphere. It is the bridge between imagination and reality, transforming ideas into tools, machines, and systems that redefine human potential.

Technological progress is accelerating solutions to global challenges, from artificial intelligence optimising complex data analysis to renewable energy breakthroughs reducing our dependence on fossil fuels. In materials science, for instance, innovations in aluminium recycling and production are minimising waste, reducing carbon footprints, and creating stronger, more lightweight alloys that benefit industries ranging from automotive to aerospace.  Modern advancements, such as AI-driven sorting, low-carbon smelting, and high-purity recovery from industrial scraps, are redefining how we reclaim and refine this versatile metal. As per AL Circle’s report, recycled aluminium usage across the world increased from 27.1 million tonnes in 2022 to 28.3 million tonnes in 2023. Usage is expected to increase to more than 29 million tonnes in 2024. To know more about the industry, get your hands on our newly launched report, "Global Aluminium Industry Outlook 2025".

Below is a list of some of the technological advancements in the aluminium industry –

• New recycling process ShAPE

The U.S. Department of Energy’s Pacific Northwest National Laboratory (PNNL) in Washington has pioneered a process known as Shear Assisted Processing and Extrusion (ShAPE), enabling the transformation of 100 per cent post-consumer aluminium scrap into durable extrusions. Impressively, the resulting products meet or exceed the stringent strength and flexibility requirements set by the American Society for Testing and Materials (ASTM) for common building-grade alloys. One of the most remarkable benefits of this innovation is its potential to reduce energy consumption by up to 90 per cent in the production of aluminium building components. The ShAPE process applies intense shear forces to deform scrap aluminium billets or bricks, effectively ‘pulverising’ impurities and dispersing them uniformly throughout the material’s microstructure.

• LIBS Spectrometer from Avantes

Aluminium recycling presents several challenges, including efficient alloy sorting and maintaining the purity and quality of recycled materials. Laser-Induced Breakdown Spectroscopy (LIBS) from Avantes has emerged as a game-changing technology, addressing these critical issues with precision. Material Recovery Facilities (MRFs) handle vast volumes of aluminium scrap, requiring accurate identification and separation of different metal grades. Traditional sorting methods often fall short, leading to inefficiencies and reduced material quality. Avantes' spectrometers offer a cutting-edge solution by enabling real-time, in-line sorting of aluminium alloys. This ensures precise classification and separation of distinct aluminium grades, optimizing the recycling process for downstream applications.