At GME Recycling, we bring over 40 years of experience in designing and building systems for the recycling of aluminum and non-ferrous metals. Our commitment to innovation and sustainability has driven our Research and Development (R&D) team to develop a groundbreaking aluminum decoating system that enhances recycling efficiency while significantly reducing environmental impact.
Our new UBC decoating process is a closed-loop, auto-thermal system optimized for the removal of impurities from aluminum scrap. This system operates with no natural gas usage for organic loads above 5%, reducing energy consumption and lowering operational costs. When the organic content is below 5%, our process still consumes up to 60% less natural gas than traditional systems, setting a new standard for eco-friendly recycling.
Why Choose GME’s Aluminum Decoating Technology?
Our aluminum decoating technology stands out in the market due to its unique features that address key challenges in the recycling industry. Here are some of the primary benefits of our system:
- No natural gas usage for organics over 5%: traditional decoating systems require significant amounts of natural gas to process organic residues. Our system is engineered to operate efficiently without natural gas for organic loads over 5%, resulting in major cost savings and a reduced carbon footprint.
- Zero oxidation of metallic fractions: oxidation is a common problem in aluminum recycling that affects the quality and yield of the recycled material. GME’s decoating technology minimizes oxidation, ensuring a cleaner, higher-quality output.
- Lower consumption of natural gas: for organics below 5%, our system uses between 20 to 28 Nm3/ton of natural gas. In contrast, the industry average ranges from 55 to 65 Nm3/ton, meaning we achieve a net saving of approximately 55-60% in natural gas consumption.
Our system is also designed to handle oversized scrap, which enhances processing flexibility and further reduces the need for pre-shredding, lowering energy usage even more. Below, we explain the three main phases of our new decoating process and how they contribute to a cleaner, more sustainable aluminum recycling solution.
The New De-Coater Phases
Our decoating process is structured into three main phases, each designed to optimize the removal of impurities and maximize efficiency. Here’s an overview of each phase:
- Closed-Loop Auto-Thermal Process: in the first phase, our system utilizes an auto-thermal process that operates within a closed-loop. Aluminum scrap materials, including UBC (Used Beverage Cans), profiles, lithographic overlays, laminates, and chips, often contain oils, solvents, and carbon residues, known as organics. These organics are carbon-based substances that are gasified and combusted at 550°C in the kiln. The combusted gases are then sent to the after-burner, where they are transformed into natural combustion carbon fossil fuel in a controlled environment of oxygen, pressure, and temperature. This fossil fuel is filtered and redirected back into the kiln, heating the scraps without using any additional burners. This closed-loop system not only conserves energy but also ensures the process is entirely self-sustaining and environmentally friendly.
- Oversized Scrap Allowed: unlike many other decoating systems, GME’s technology can handle scrap pieces up to 250 mm in size. This capability greatly simplifies the recycling process by reducing the need for extensive pre-shredding, saving both time and energy. The kiln is equipped with a specialized GME paddle design that optimizes the movement and surface contact of the scrap, ensuring thorough removal of organic materials. The larger scrap size also allows for a greater lapse of organic agents, which results in higher organics evaporation and therefore more natural fuel. This reduces the consumption of natural gas while maintaining high efficiency. The ability to handle oversized scrap further minimizes wear on shredding machinery, contributing to lower maintenance costs and energy consumption.
- Zero Oxidation: oxidation is a major concern in aluminum decoating because it affects the purity and brightness of the recycled material. During the decoating phase, our system is engineered to rapidly heat the surface of the aluminum scrap, promoting the molecular breakdown and evaporation of organic agents responsible for oxidation. The unique GME paddle shape agitates the scrap effectively, ensuring that any metallic oxides in the paint are removed and directed toward the after-burner. At the end of this phase, the aluminum scrap is clean, warm, and shiny, free from any oxidation residues. The exhaust gases are continuously monitored and sent back to the after-burner for complete de-oxidation, resulting in a bright, white scrap that is ideal for further processing.
Key Benefits of GME’s Decoating System
Our aluminum decoating technology brings several unique advantages to the recycling industry:
- Improved Environmental Impact: By reducing natural gas usage and operating on a closed-loop system, our decoating process minimizes greenhouse gas emissions, contributing to a more sustainable recycling process.
- Cost-Effective Operation: With up to 60% less natural gas consumption compared to industry standards, our technology lowers operational costs, making it economically advantageous for recycling facilities.
- Enhanced Quality of Recycled Aluminum: Our zero-oxidation process ensures that the recycled aluminum is free from impurities and retains a bright, shiny appearance, which is crucial for downstream applications and improves the overall value of the recycled material.
- Reduced Need for Pre-Shredding: The ability to handle oversized scrap simplifies the recycling process and reduces the energy consumption associated with shredding, while also extending the life of shredding equipment.
GME – Leading the future of aluminum recycling
At GME Recycling, we are committed to advancing the aluminum recycling industry with our innovative decoating technology. Our closed-loop, auto-thermal process provides a sustainable solution for the removal of impurities from aluminum scrap, all while reducing natural gas consumption and minimizing oxidation. Our ability to handle oversized scrap further distinguishes us in the market, making recycling more efficient and cost-effective.
As environmental regulations become stricter and the demand for sustainable practices increases, GME’s aluminum decoating system is positioned to lead the way in eco-friendly recycling solutions. With decades of expertise and a passion for innovation, we are proud to offer a technology that not only enhances operational efficiency but also contributes positively to the environment.
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