[NEDO] Developed new technology “vertical high-speed twin roll casting machine” to realize circular economy
*NEDO*
Press release: September 11, 2024
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We have developed a new technology, “Vertical high-speed twin roll casting machine,” to realize a circular economy.
*Aiming for the world’s first mass production of aluminum upgrade recycling* *
NEDO is working on the “Upgrade Recycling Technology Development Project for Aluminum Resources to Build a Resource Recycling-Oriented Society” (hereinafter referred to as the “Project”), and together with UACJ Corporation and the National University Corporation Tokyo Institute of Technology, has made a rapid solidification process possible. We have developed a “vertical high-speed twin roll casting machine” (hereinafter referred to as this casting machine). * *
With existing technology, it has been difficult to use recycled materials as raw materials for wrought material, which is a major aluminum (Al) product. The newly developed casting machine casts thin sheets directly from molten aluminum at high speed.By establishing a rapid solidification process, it solves the problems that had hindered the use of recycled materials and produces wrought materials for recycled aluminum products. Realize. The casting machine will be installed at UACJ’s R&D Center (located in Minato-ku, Nagoya City, Aichi Prefecture), where research and development is being conducted for this project, and will begin operation in October 2024. This is the world’s first initiative in casting technology aimed at mass production of aluminum. *
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In the future, by utilizing this casting machine, we will realize the mass production of high-quality recycled aluminum materials, and from 2030 onward, we will mass-produce high-quality recycled aluminum materials and significantly reduce carbon dioxide (CO2) emissions. We aim to *
Figure: Conceptual diagram of aluminum material advanced resource circulation system
* 1. Background*
In recent years, “circular economy” has been introduced in various economic activities.
As demand for aluminum is expected to grow significantly for the purpose of reducing CO2 emissions, such as by making transportation equipment lighter, aluminum is a material that is particularly expected to improve resource circulation. This is one of the. On the other hand, the large CO2 emission intensity during the production of new ingots is an issue, and recycled ingots, which consume less energy, are expected to be used as a production technology and utilized as an aluminum material with a low environmental impact.
Against this background, NEDO has been working on the “Aluminum Material Advanced Resource Recycling System Construction Project” since fiscal 2021. As part of this effort, NEDO is promoting this project*1 in collaboration with UACJ and Tokyo Institute of
Technology.
*2． Current results*
With existing technology, if impurities such as iron (Fe) or silicon (Si) are mixed into molten aluminum, coarse crystallized substances*2 will be generated, leading to a decline in the properties of the material. It has been difficult to use recycled materials as raw materials for expanded wood*3.
This newly developed casting machine is capable of casting thin plates directly from molten aluminum*4 at high speed. Compared to
conventional horizontal twin-roll casting machines, the cooling rate and casting speed for molten aluminum are improved several dozen times due to the long contact surface between the molten metal and the rolls, and the high thermal conductivity of the copper rolls. did. This creates a rapid solidification process, which makes it possible to refine and disperse crystallized substances caused by impurities mixed into the molten aluminum alloy, making it possible to
manufacture wrought aluminum recycled products. This casting machine will be installed at UACJ’s R&D Center, which is conducting research and development for this project, and will begin operation in October 2024. This is the world’s first*5 initiative in casting technology aimed at mass production of aluminum.
*3． Future plans*
In this project, we aim to mass-produce high-quality recycled aluminum materials using a vertical high-speed twin-roll casting experiment machine that uses new technology to realize a circular economy, and we will solve the necessary technical issues. We aim to achieve mass production after 2030 and reduce CO2 emissions by 18 million tons per year across the industry by 2050.
[Note]
*1 This project
Project name: Aluminum resource upgrade recycling technology development project towards building a resource recycling society Project period: FY2021-FY2025
Business overview: Aluminum material advanced resource circulation system construction project
https://www.nedo.go.jp/activities/ZZJP_100195.html
*2 Crystallized matter
It is a compound (intermetallic compound) that is different from the matrix aluminum.
*3 Expanded material
Aluminum materials are made of sheets, extrusions, cast materials, forged materials, foil materials, etc., and are used in cans, automobiles, air conditioners, IT equipment, aerospace, etc. *4 Molten metal
It is a product made by melting aluminum into liquid form.
*5 World’s first
Based on UACJ research.