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In order to improve the fuel economy of internal combustion vehicles (ICEV) and the cruising range of electric vehicles (BEV), the automotive industry is actively seeking lightweight solutions for various body, chassis and power systems. In recent years, the gradual increase in the proportion of aluminum structural parts on passenger vehicles has brought about a paradoxical situation for environmental sustainability: on the one hand, a large number of lightweight aluminum-based materials can reduce greenhouse gas emissions during vehicle use; However, the more aluminum-based materials are used, the higher the carbon footprint of the vehicle manufacturer. This is because automotive aluminum structural parts are mainly produced using electrolytic primary aluminum, and the average carbon footprint per ton of electrolytic primary aluminum is about 12 - 16.5 tons of carbon equivalent (compared to this figure for steelmaking which is only about 2.2 tons).
In order to break through this dilemma, one of the solutions is to use post-consumer recycled aluminum (commonly known as old waste) to replace electrolytic primary aluminum to manufacture aluminum alloy structural parts. Remelting recycled aluminum into aluminum ingots consumes less than 7% of the energy consumed by electrolytic primary aluminum, and can reduce carbon emissions by more than 90%.
https://www.promisteel.com/galvanised-coated-steel/aluminized-steel/
In the automotive industry, one of the main barriers to the current use of post-consumer recycled aluminum is the large fluctuations in scrap composition and high levels of impurity elements due to immature recycling infrastructure. Industry and academia have been working to develop advanced waste sorting and pretreatment technologies to obtain waste with narrow composition range and low impurity content for relegation recycling applications. However, building an extensive and mature infrastructure in the short to medium term seems unlikely. In addition, the high costs associated with the use of complex sorting and pre-processing techniques will reduce the economics of using the scrap.
