Eccomelt LLC’s three-part webinar series concludes with great news for the aluminum industry, which has become increasingly involved in reducing its overall carbon footprint over the number of years, in anticipation of the targets set by the Paris Agreement and the European “Circular Aluminium Action Plan” for 2050. The highly anticipated final part of the Eccomelt series reveals, in a scientific study conducted by aluminum expert Martin Hartlieb, the exact calculations of the carbon footprint of different types of aluminum, in particular A356/AlSi7Mg, and explains how to create the ideal mix in foundries to emit the lowest possible carbon emissions overall.
At the outset, it is important to understand that the GHG Protocol Corporate Standard is proposing three scopes of carbon footprint disclosure, and many studies only publish the results for Scope 1 and 2, avoiding the critical, all-inclusive Scope 3. In particular, Scope 1 involves direct emissions of the company (facilities and mobile assets e.g. vehicles), Scope 2 includes indirect emissions from purchased energy (e.g. electricity), while Scope 3 includes indirect emissions from the entire value chain, including raw materials.
In the webinar entitled “Calculating and Minimizing Carbon Footprint in Foundries and Die Casters“, Mr. Hartlieb, who is also president of Viami International, reveals that eccomelt356.2, Eccomelt LLC’s direct, cost-effective substitute for A356.2, comes in at 0.11 t C02e/t Al in the Scope 1-3 category, which is far lower than RSI (secondary ingots) and any type of primary aluminum that is included in the comparative study. Specifically, the global average A356.2/AlSi7Mg has 16.65 t C02 e/t of Al, (even average “low carbon” primary A356.2/AlSi7Mg has typically 6.58 t C02e / t Al,) and most A356 remelt secondary ingots (RSI) have a minimum of 0.673 t C02 e/t of Al (cradle to gate). Clearly, as Mr. Hartlieb points out, eccomelt356.2 has by far one of the lowest carbon footprints of any aluminum alloy on the market today.
In this well-attended third and final webinar of the series, a general guide for foundry managers and technical people is presented to minimize carbon footprint in A356 /AlSi7Mg foundries. The main points in this guide encapsulate information from parts 1 and 2 of the webinar series, “Charging, Melting, and Alloying in Different Furnace Types” and “Melt Treatment and Melt Quality Control”, both of which provide extensive literature on best practices when melting 356 type aluminum. We learn that raw material is usually by far the main source of C02 in castings, and that melting is the most energy-intensive and C02 producing process. To minimize carbon footprint, recycle all internal scrap/returns if possible, using proper practices; maximize the use of the lowest carbon footprint material (eccomelt356.2); and maximize furnace efficiency. By reducing global average primary ingots to 50% and replacing them with 20% eccomelt356.2 and 30% with internally recycled runaround scrap, the carbon footprint diminishes from a high of 24.29 t C02 to an incredible low of 3.73 t C02 e/t Al. Indeed, by replacing a mere 20% of those primary ingots with eccomelt356.2 and recycling internal scrap, the carbon footprint of castings is reduced by approximately 50%, independent of the carbon footprint grade of the primary A356/AlSi7Mg.
The innovation of eccomelt356.2 lies mainly in its proprietary, non-thermal process, which eliminates one (carbon-producing) melting step. The process also provides an extremely clean metal, with minimal dross, and allows for high density to maximize furnace and transportation efficiency. Eccomelt LLC, located in both the US and Canada, is available to provide economical, extremely clean, chemically pure aluminum, which has now been scientifically calculated to have one of the lowest carbon footprints of any aluminum alloy on the market today. Alongside Alcan R&D, Eccomelt LLC has developed a patented process that produces a specification alloy from aluminum wheels at a lower cost than traditional methods and creates a CLEAN CHARGE. eccomelt356.2 is a direct substitute for A356.2 primary aluminum, used by OEMs, Tier 1s, foundries, and die casters who are using eccomelt356.2 to cast high-quality automobile parts. Eccomelt LLC ships products to automotive OEMs and foundries within North America including the United States, Canada, and Mexico, and worldwide, such as France, Ireland, Italy, Serbia, Spain, Hungary, and the Czech Republic.