Simulation-Based Exergy and LCA Analysis of Aluminum Recycling: Linking Predictive Physical Separation and Re-melting Process Models with Specific Alloy Production

Recycling and process metallurgy are the main enablers of Circular Economy (CE). To assess the circularity of CE, a detailed understanding of the limits of the current recycling infrastructure is required. For this paper, a predictive physical separation model for Eddy Current Separator was developed using 3D particle-level detail acquired by Computed Tomography. The developed model was combined with re-melting and alloying models to create an aluminum recycling flowsheet in a simulation platform HSC Sim. Different simulation scenarios were considered, and the impact of the physical separation stage to resource efficiency was quantified by measuring the required additional resources to produce specific alloy types. The resource efficiency and environmental impacts were estimated through exergy analysis and Life Cycle Assessment based on the detailed physical and thermochemistry simulation models. The paper demonstrates how digitalization and exergy analysis allow more efficient use of resources in the sense of CE.