UK-based aluminium extrusion specialist Exlabesa announced that it would expand its aluminium recycling capacities by implementing an additional continuous homogenising plant from special aluminium machinery and equipment designer Hertwich Engineering.

Exlabesa is expanding production at its aluminium recycling plant in the province of A Coruña, in Spain, and is once again relying on technology supplied by Hertwich Engineering, an SMS group company.

Hertwich will deliver a continuous homogenising furnace, featuring an air-cooling station, long-billet stacker, and semiautomatic polyethylene terephthalate strapping system to complement the second melting furnace already installed for post-consumer scrap.

Exlabesa had already commissioned a continuous homogenising plant at the site back in 2018, and later a multi-chamber melting furnace, both of which were supplied by Hertwich.

With the expansion now agreed, the capacity for continuous homogenisation at the plant in north-west Spain will increase by 30 000 t/y to about 80 000 t/y. Further, Exlabesa will benefit from CO2 reductions achieved by recycling post-consumer aluminium scrap through the homogenising plants.

The advanced melting furnace, which was recently put into operation, is specifically focused on producing recycled billets sourced from post-consumer aluminium scrap that has reached the end of its lifecycle.

The subsequent expansion of the casthouse with the new continuous homogenising plant will significantly increase the capacity for processing production scrap, which enables Exlabesa to be less dependent on buying primary aluminium and so helps it to conserve resources.

These investments not only demonstrate Exlabesa’s commitment to sustainability and CO2 reduction by promoting a cleaner and more efficient industry based on the principles of the circular economy, but also consolidate Exlabesa’s ability to meet the increasing demand for this type of product with one of the most advanced foundries in the world.

“Finding solutions that are individually tailored to the needs of customers is one of our strengths,” says Hertwich Engineering CEO Gerold Keune.

He adds that the expansion at Exlabesa fits perfectly into the existing production environment. Moreover, it is an investment in the sustainability of aluminium production.

“This endeavour also underscores our commitment to long-term cooperation and partnership. We believe in forging strong alliances with our clients, built on trust and shared goals,” he says.

The new system is designed for aluminium billets with diameters of 178 mm to 406 mm and lengths of 7 m, it can also be used for all alloys within Exlabesa’s portfolio.

A major advantage of Hertwich's continuous system compared to chamber homogenisation is the uniform treatment of the billets: In the homogenising furnace, billets cast from melted aluminium scrap undergo continuous heat treatment at temperatures of up to 590 ˚C.

The precise temperature control when heating and retaining the heat in the furnace ensures that the billets have a uniform microstructure before they enter the air-cooling station.

This process guarantees high billet quality with optimal metallurgical properties, while at the same time reducing the energy required for billet homogenisation.

At the end of the production line, the billets are stacked and strapped with plastic straps.