How Are Aluminium Cans Recycled? | How Do They Do It?

Summary

Novelis, the world's largest recycler of used beverage cans, transforms bales of aluminum cans into ingots at their factory in England. The recycling process involves shredding, sorting, and melting the cans, which not only saves energy but also highlights the versatility of aluminum. The ingots are then shipped to Germany for rolling into thin sheets, ultimately returning to the UK to be reconverted into cans. The script also humorously addresses the aluminum vs. aluminum debate and hints at the metal's potential use in aerospace, emphasizing the circular economy of aluminum.

Takeaways

• 🌍 Novelis is recognized as the world's largest recycler of used beverage cans, emphasizing the global scale of their operations.
• 🔄 The cans are compressed into bales, each weighing up to 1,000 kilograms and containing approximately 65,000 cans, showcasing the volume of recycling.
• ♻️ The energy saved from recycling aluminum is equivalent to powering the entire country of India, highlighting the environmental impact.
• 🚀 The process of recycling aluminum involves high-tech machinery, including a 340 horsepower shredder and an optical sorter using infrared sensors.
• 🧲 A powerful magnet is used to separate aluminum from other metals, as aluminum is not magnetic and requires different sorting methods.
• 🔠 The debate over the correct pronunciation and spelling of 'aluminum' versus 'aluminium' is humorously addressed, with a historical perspective.
• 🔥 Aluminum has a high melting point of 660 degrees Celsius, which is a critical factor in the recycling process.
• 🏗️ The ingots, each weighing 27 tons and made from 1.5 million recycled cans, are cast into large blocks before being transported for further processing.
• 🚚 The ingots travel a significant distance to a rolling mill in Germany, indicating the international nature of the aluminum industry.
• 🚀 The aluminum alloys used in beverage cans are similar to those used in rocket manufacturing, suggesting the versatility of aluminum in various industries.
• 🍺 The history of aluminum cans is briefly touched upon, noting that the first beverage in an aluminum can was beer in the US in 1959, and even then, recycling was encouraged.

Q & A

What is Novelis known for in the context of recycling?

Novelis is known for being the world's largest recycler of used beverage cans.

Where is the Novelis factory mentioned in the script located?

The Novelis factory is located in Warrington, England.

What is the weight and content of each compressed bale of cans at Novelis?

Each compressed bale weighs up to 1,000 kilograms and contains as many as 65,000 aluminum cans.

How much energy is saved annually through recycling aluminum, as mentioned in the script?

The energy saved through recycling aluminum is enough to run the whole of India.

What method is used to sort aluminum from other materials in the recycling process?

An optical sorter with infrared sensors at a rate of three meters per second is used to sort aluminum from other materials.

Why is aluminum tricky to sort using traditional methods?

Aluminum is tricky to sort because it cannot be separated out with a magnet, unlike some other metals.

What is the difference between the British and American pronunciation of the word 'aluminum'?

The British pronounce it as 'aluminium', while Americans pronounce it as 'aluminum'.

Who discovered aluminum and what were the different names he considered for it?

Sir Humphrey Davey discovered aluminum in 1807 and considered the names 'alumium', 'aluminum', and 'aluminium' for it.

What is the melting point of aluminum and how does it affect the recycling process?

The melting point of aluminum is 660 degrees Celsius, which is significant in the recycling process as it requires high temperatures to melt.

What is the term for the unwanted oxide that forms on the surface of molten aluminum?

The unwanted oxide that forms on the surface of molten aluminum is known as dross.

How are the aluminum ingots transported from the furnace to the casting area?

The aluminum ingots are transported to the casting area by tipping the entire furnace, allowing the molten metal to flow into molds.

What is the final product of the aluminum recycling process at Novelis and how is it used?

The final product is aluminum ingots, which are then transformed back into cans or used in other applications such as aerospace.

Outlines

00:00

🌍 Global Aluminum Recycling at Novelis

Novelis, the world's largest recycler of used beverage cans, receives cans from around the globe at its factory in Warrington, England. These cans are compressed into bales, each weighing up to 1,000 kilograms and containing approximately 65,000 cans. The energy saved from recycling aluminum is enough to power India annually. The recycling process involves shredding, sorting with an optical sorter using infrared sensors, and removing non-aluminum materials. The term 'aluminum' is a subject of debate, with the discoverer, Sir Humphrey Davey, having initially named it 'alumium' before settling on 'aluminium'. The melting process requires high temperatures, and the resulting aluminum is used to create ingots, which are then sent to a rolling mill in Germany for further processing.

05:03

🔨 Transformation of Aluminum Ingots into Cans

The aluminum ingots are transformed into cans through a series of processes. They are first heated to 525 degrees Celsius in a furnace to relax the aluminum bonds and release internal stresses. The ingots are then passed through a series of rollers, similar to rolling pastry, until the metal is thinned to a quarter of a millimeter and stretched to 10,000 meters in length. In the UK, at Ball Packaging, the aluminum is further processed into cans and other products. The process of making cans involves a rapid fire cupping press that forms shallow cups, which are then squeezed through a series of rings to form cylindrical cans. The first beverage in an aluminum can was beer in the US in 1959, and recycling has been a part of the process since then. The factory produces around 6.5 million cans daily, which are distributed worldwide.

Keywords

💡Recycling

Recycling is the process of collecting and processing materials that would otherwise be thrown away as trash and turning them into new products. In the context of the video, Novelis is highlighted as the world's largest recycler of used beverage cans, emphasizing the importance of recycling in conserving energy and resources. The script mentions that recycling aluminum cans, cars, tools, and planes saves enough energy to run the whole of India, illustrating the significant environmental impact of recycling efforts.

💡Aluminium Cans

Aluminium cans are containers made from aluminum, a lightweight and malleable metal, which are commonly used for packaging beverages. The video script discusses how these cans are collected, compressed into bales, and recycled at Novelis' factory. It also touches on the historical aspect, mentioning that the first beverage in an aluminum can was beer in the US in 1959, and the practice of recycling cans for a deposit was already in place at that time.

💡Shredder

A shredder is a machine used for reducing materials such as metal, wood, or paper into smaller pieces by cutting, tearing, or crushing. In the video, the bales of compressed cans are fed into a 340 horsepower shredder, which breaks down the aluminum cans into smaller pieces. This process is essential for recycling as it prepares the material for further sorting and processing.

💡Optical Sorter

An optical sorter is a device that uses a combination of cameras and sensors to sort materials based on color, shape, or material type. The script describes how the shredded scrap passes through an optical sorter that uses infrared sensors to identify and sort metal from non-metal materials. This technology is crucial for separating aluminum from other materials like plastic or glass in the recycling process.

💡Aluminium Oxide

Aluminium oxide, also known as alumina, is a chemical compound of aluminium and oxygen with the chemical formula Al2O3. When aluminum melts, it reacts with air to form a layer of aluminum oxide, which floats on top of the molten metal. In the video, furnace operators skim off this unwanted oxide, known as dross, to prepare the alloy for casting. This step is important to ensure the purity of the aluminum used in manufacturing new products.

💡Ingots

An ingot is a piece of relatively pure material, usually metal, that is cast into a shape suitable for further processing. In the context of the video, the clean aluminum chips are melted and cast into three towering blocks called ingots. Each ingot is ten meters long, weighs 27 tons, and is made up of 1.5 million recycled cans. Ingots are an essential intermediate product in the aluminum manufacturing process, from which various aluminum products, including cans, are made.

💡Rolling Mill

A rolling mill is a factory or a specific machine used to shape metal, such as aluminum, into various shapes by rolling it between rollers. The video script mentions that ingots are sent to a rolling mill in Germany, where they are heated and passed through a series of rollers to thin the metal into sheets. This process is essential for transforming the ingots into a form that can be used to manufacture cans and other products.

💡Cupping Press

A cupping press is a machine used in manufacturing that forms cups or other shapes from sheet metal. In the video, the aluminum sheets are fed into a rapid-fire cupping press that knocks out thousands of shallow cups. These cups are then transformed into cans through a process of squeezing, which shapes the aluminum into a cylindrical form. The cupping press is a critical component in the production line for making aluminum cans.

💡Aluminium Alloys

Aluminium alloys are materials composed of aluminum and other metallic or non-metallic elements, which are used to improve the properties of pure aluminum for various applications. The script highlights that the aluminum alloys used for beverage cans are very similar to those used in aerospace applications, suggesting the versatility and strength of these materials. This connection between everyday items like cans and advanced applications like rockets underscores the importance of material science in product development.

💡Dross

Dross is a term used to describe the unwanted oxide layer that forms on the surface of molten metals, such as aluminum. In the video, it is mentioned that when aluminum melts, it reacts with air to form a layer of aluminum oxide, known as dross, which is removed by furnace operators. Dross removal is a crucial step in the recycling process to ensure the purity and quality of the recycled aluminum.

💡Molten Metal

Molten metal refers to metal that has been heated to a high temperature, causing it to change from a solid to a liquid state. In the script, the process of pouring molten aluminum into molds to create ingots is described. The handling of molten metal requires special care due to its high temperature and the potential hazards it poses. This phase is a critical part of the aluminum recycling and manufacturing process.

Highlights

Novelis is the world's largest recycler of used beverage cans.

Cans arrive from all over the world, compressed into bales weighing up to 1,000 kilograms each.

Aluminium recycling saves enough energy annually to run the whole of India.

A 340 horsepower shredder processes the bales of compressed cans.

Aluminium cannot be separated with a magnet, unlike some metals.

An optical sorter uses infrared sensors to sort out metal and non-metal at three meters per second.

Jets of air remove plastic or glass, and a magnet extracts steel, leaving pure aluminium.

The origin of the word 'aluminium' is attributed to Sir Humphrey Davey, who discovered it in 1807.

Aluminium doesn't melt until it reaches 660 degrees Celsius.

Molten aluminium is handled in furnaces that reach 730 degrees, capable of handling up to 100 tons each.

Dross, a layer of unwanted aluminium oxide, is skimmed off by furnace operators.

Molten aluminium is cast into ingots, each made up of 1.5 million recycled cans.

Aluminium is the most common metal in the Earth's crust but was once more expensive than gold.

Ingots are transformed back into cans at a rolling mill in Germany.

Aluminium is rolled out to a quarter of a millimeter thick and 10,000 meters long at the rolling mill.

Aluminium alloys used for beverage cans are similar to those used in aerospace applications.

Ball Packaging converts aluminium into cans and other products, including those for aerospace.

Aluminium cans are made by a rapid fire cupping press and a series of rings that shape them into cylinders.

Beer was the first beverage to be canned in aluminium, in the US in 1959, with a recycling program in place from the start.

Novelis produces 6.5 million cans daily, showcasing the scale of aluminium recycling and production.

Transcripts

Novelis is the world's largest recycler of used beverage cans.

They arrive at its factory in Warrington, England from all over the world.

Compressed into bails, each weighing up to 1,000 kilograms and containing as many as

65,000 aluminium cans.

Every year we save enough energy recycling aluminium cans, cars, tools, even planes,

to run the whole of India.

The bales of compressed cans are loaded onto a conveyor and fed into a 340 horsepower shredder.

Aluminium is tricky to sort because unlike some metals, it can't be separated out with

a magnet.

So next, the shredded scrap passes through an optical sorter at a rate of three meters

per second.

The machine uses infrared sensors to sort out what's metal and what isn't.

Then blasts away any plastic or glass with jets of air.

A powerful magnet sucks up any scraps of steel, leaving just aluminium.

We Brits say aluminium.

And the Americans say aluminum.

But who's right?

Well, Sir Humphrey Davey, the British guy who discovered it in 1807, he wrote down the

name as alumium, which no one calls it.

Then he changed it to aluminum, and he changed it again to aluminium.

So, either he didn't know what to call it or he just couldn't spell.

It's aluminium.

Aluminum.

The next problem is, aluminium doesn't melt until 660 degrees.

The paint and laquer aren't so lucky.

They're instantly vaporised.

The clean aluminium chips are ready for the next stage, melting.

Two furnaces hit a blistering 730 degrees.

And handle up to 100 tons of aluminium each.

The trouble is, when the aluminium melts, it reacts with air forming a layer of aluminium

oxide that floats on top.

This unwanted oxide is known as dross.

A brave furnace operator skims it off with a giant, steel spatula.

And the alloy is ready for the casting area.

The only problem is getting there.

A river of molten metal flows downhill to a holding furnace that's the size of a double

decker bus.

Somehow, they need to pour the liquid metal into a mold.

Remarkably, the solution is to tip the entire furnace.

And a fountain of deadly metal pours into one of three molds set ten meters into the

ground.

Inside, they will be cast into three towering blocks of aluminium.

After two and a half hours they have three giant aluminium monoliths, called ingots.

Each one is ten meters long, weighs 27 tons and is made up of 1.5 million recycled cans.

Aluminium, or aluminum, is not expensive because it's rare.

In fact, it's the most common metal in the Earth's crust.

It's expensive because it's so hard to extract from the rock around it.

150 years ago, it was more expensive than gold.

Today, demand for aluminium is so high the ingots don't lie around.

Their transformation back into cans starts with a 900 kilometre journey to a rolling

mill in Germany.

Here, they're heated in another furnace to 525 degrees.

This relaxes the bonds between the aluminium atoms, releasing any stresses within the ingot.

Then it's passed back and forth through a series of rollers.

It's a bit like rolling pastry.

Each set of rollers thins out the metal until it's a quarter of a millimeter thick and 10,000

meters long.

That's 1,000 times its original length.

Massive reels of the aluminium arrive back in the UK at Ball Packaging to undergo reconversion

into cans and possibly something a little more out of this world.

We've got three basic product categories, beverage packaging, household metal packaging,

and we also have an aerospace division.

So, the interesting thing of course is manufacturing beverage cans is rocket science.

The aluminium alloys for rockets are very similar to the ones used for cans.

So theoretically, your old can could be on its way to space.

Meanwhile, on planet Earth, they feed the sheets of aluminium into a rapid fire cupping

press.

This heavyweight knocks out thousands of shallow cups.

The secret of turning them into cans is a tight squeeze.

Every cup is rammed through a series of rings, each narrower than the last.

Forcing the aluminium through the rings squeezes it into a cylinder and a new can is born.

The very first time anyone put a beverage in an aluminum can it was beer, it was in

the US, and it was 1959.

And even back then, they still recycled, you got a cent for every can you brought back.

They produce around 6 and a half million cans here every day, and send them all over the

world.

That's a whole lot of aluminium.

Luckily, there's plenty more where these came from.