37 % less CO2


EBNER.blog | David Hazelett, HAZELETT

37 % less CO2.

Integrated melting, casting & rolling lines for production of continuous cast aluminum strip with reduced CO2 footprint.

In cooperation with Mino S.p.A. and other EBNER GROUP members, HAZELETT offers fully integrated lines for continuous casting of aluminum strip.

As mentioned in an article in the last issue of the HICON journal, HAZELETT offers a viable and tested solution to reduce the CO2 footprint of aluminum sheet. Compared to the conventional DC casting/conventional hot rolling process, which includes many processing steps and requires substantial electrical and thermal energy input, continuous casting processes (Twin-roll Casting/ TRC and Twin-Belt Casting/ TBC) are much shorter and consume significantly less energy.

With the assistance of HAZELETT and Gautschi, Mino has developed a model comparing the CO2 footprint of these three processes for the transformation of aluminum into common alloy sheet products. In the last issue we reported on the result for foil stock, and have since applied the model to common alloy sheet.

Application of the model revealed that, compared to the conventional DC casting/hot rolling process, the HAZELETT TBC process with in-line rolling provides a 37 % reduction in the CO2 footprint for the transformation of aluminum to common alloy sheet.

This conclusion was reached using a “cradle-to-gate” analysis. “Cradle-to-gate” refers to the carbon impact of a product, starting from its origin to the moment the product exits the gate of the plant.

All CO2 emissions required to transform the aluminum feedstock into coils of common alloy (0.5 mm thick, H14, 1750 mm wide) were considered. The feedstock is assumed to be a mix of 54 % primary ingot and 46 % scrap and alloying elements. The ADEMA Base Carbone database was used for the primary aluminum footprint. Because the CO2 emissions related to the primary production of aluminum dominates the analyses, the graphical comparison shown below begins with the feedstock.

37 % LESS CO2

With a CO2 footprint approx. 37 % smaller than a DC casting/conventional hot rolling process and a CO2 footprint 17 % smaller than that of a TRC process, the Hazelett Twin-Belt Process stands alone as the “greenest” process for the production of aluminum common alloy.

HAZELETT continues to refine and optimize its technologies to transform aluminum into an expanded range of aluminum sheet products with the lowest CO2 emissions.

CO2 emissions cradle-to-gate for 1 ton of common alloys/production route

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