Pathways to Reduce Carbon Footprint in Secondary Aluminum Melting

This technical report discusses various pathways to reduce the carbon footprint associated with secondary aluminum melting processes. It outlines the significant economic and environmental pressures that have led to the need for optimization in the aluminum industry, particularly in the context of recycling aluminum. The report details the advantages of using next-generation oxy-fuel burners and low carbon intensity fuels, such as hydrogen and ammonia, to minimize CO2 emissions. It presents the concept of smart oxy-fuel burners that allow for precise control of energy input based on real-time feedback from furnace sensors, enhancing energy efficiency and reducing greenhouse gas emissions. Additionally, the report highlights the role of computational fluid dynamics (CFD) in optimizing burner placement and operation within furnaces to achieve better heat distribution and lower emissions. The findings aim to assist manufacturers in selecting effective strategies for decarbonizing their melting operations while maintaining production efficiency.