Aluminium recycling and its benefits for the aerospace industry, by Constellium Global Aerospace division

1. Aluminium recycling
and its benefits for
the aerospace industry
Bruno Chenal,
Technology & Innovation Director
Global ATI Division
Issoire, 29th March 2012

2. l’
Aluminium recycling and
its benefits for the
aerospace industry
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3. GREENWASHING?
aluminium
aerospace
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4. Recycling is already taking place
In 2011, 77% of the aerospace aluminium alloys produced by
Constellium were recycled products.
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5. 1- Aluminium is recycled
Why?
It is industrially
It’s part of its DNA possible on a large
scale
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6. Aluminium is naturally recyclable
Just like gold, platinum
and silver…
Aluminium retains its
properties even when
recycled
100% recyclable
Endlessly recyclable
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7. Aluminium is recycled because it is technically
possible on a large scale
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8. 2- Aluminium is recycled
Why?
How?
It is the responsible It is economically It is operationally
thing to do viable possible
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9. Aluminium is recycled because it is the
responsible thing to do
Every ton of recycled aluminium saves 4 tons of bauxite.
It takes 20 times less energy to produce recycled aluminium than
to manufacture new aluminium.
Every kg of recycled aluminium cuts 11.4kg of CO2 emissions.
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10. Aluminium is recycled because it is
economically viable
Optimized alloy
Lower energy costs requirements
(Cu, Zn, Li …)
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11. Aluminium is recycled because it’s
operationally possible
230 “internal”
Raw material
recycling
100 Recycling
Customer delivery
customer
scrap
Recycling at
10 Finished product the end of
the aircraft
lifecycle
A manufacturing process that creates raw materials.
A recycling circle organised by Constellium with its clients.
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12. Pre-machining, a solution for reducing the
quantity of scrap produced by clients
No pre-machining
Trans- Aircraft
Strong Aerospace
Foundry formation part
sheets client
≈10
100
Client scrap
≈90
Pre-machining
Strong Pre- Pre- Aircraft
Trans- Aerospace
sheets machin machin Machined plate – Framepart
Foundry formatio client
100 ing ed ≈10
n
sheet
Pre-machined 40
scrap
60
Client scrap
≈ 30
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13. The aerospace recycling circle
10% of the metal produced
90% of the metal
3-6 months 30-40 ans
30-40 years
2 boucles différenciées selon on the origin of:
2 different circles depending l’origine:
-- aircraft component/dismantling
- Pièces volantes/démantelées
-- production scraps
- Chutes de fabrication

14. The Aerospace recycling process
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15. A process co-developed with clients
 During the aircraft construction cycle
Phase 1 Phase 2 Phase 3
Establish contract Customer sorting Verification of scrap
and logistics on arrival at
Constellium
Cyclone
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16. A process co-developed with industry
stakeholders
 End of aircraft lifecycle
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17. A process co-developed with industry
stakeholders
 End of aircraft lifecycle: project PAMELA
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18. 3 – Recycling at the heart of innovation
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19. Recycling at the heart of innovation:
Innovative Products
AIRWARE™, an eco-design technology
A patented process for recycling mixed chips
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20. Recycling at the heart of innovation:
Innovative processes - OFELIA
An eco-efficient industry revolving around AIRWARE™
technology. A Viameca certified, Single Inter-Ministerial Fund
(FUI) project
OFELIA
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21. The Jules Verne Institute:
A commitment to aircraft of the future
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22. Aluminium recycling and its benefits for the
aerospace industry – 6 key messages
Aluminium is 100% recyclable – endlessly recyclable
 In 2011, 77% of the aluminium alloys manufactured by
Constellium for the aerospace industry were made from recycled
products. The objective is for 80% of products to be recycled.
 A responsible approach
 Of Economic value
 An operational industry
A process at the heart of innovation
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