Constellium Partners with OSR and Automaker to Enhance Aluminum Recycling with LIBS Technology

Revolutionizing Aluminum Recycling with LIBS Technology
Constellium SE, a leading aluminum manufacturer, has teamed up with a German automaker and OSR GmbH & Co. KG, a recycling company, to improve the efficiency of aluminum recycling through innovative Laser-Induced Breakdown Spectroscopy (LIBS) technology. The partnership focuses on sorting mixed aluminum scrap produced in automotive manufacturing processes. Traditionally, aluminum scrap, particularly from the 5000 and 6000 series, would be downcycled due to difficulty in sorting by alloy family. However, with LIBS, the scrap can be sorted with more than 95% purity, making it suitable for use in high-quality aluminum products, particularly in the automotive sector.

LIBS Technology Unlocks the Potential of Mixed Scrap
The primary advantage of LIBS is its ability to rapidly and accurately sort aluminum scrap by alloy family, enabling the efficient recovery of materials that would otherwise be discarded. Fanny Mas, a metallurgist at Constellium, explained that the scrap coming from automotive production is often mixed, making it difficult to reuse directly. Before the introduction of LIBS, this mixed scrap would be shredded and passed through a magnet to remove ferrous contamination, but it would still require significant processing to make it usable for high-quality products. With LIBS sorting, the aluminum can be efficiently separated into pure alloy streams, such as 5000 and 6000 series, which can then be remelted and reused in new products. This makes the recycling process more efficient and sustainable.

Achieving Closed-Loop Recycling for Automotive Products
The partnership allows Constellium to manufacture aluminum products with high scrap content without compromising the integrity of the material. The automotive scrap, which would typically be downcycled, can now be sorted and recycled back into the production of automotive components. Since 2023, Constellium has been melting several tons of the LIBS-sorted scrap at its Neuf-Brisach plant in France, significantly reducing the need for primary aluminum. By using preconsumer scrap in this process, Constellium is able to lower the carbon footprint of its products, aligning with the company’s commitment to sustainability and reducing the environmental impact of aluminum production.

Long-Term Goals and Future Developments in Recycling
The collaboration between Constellium, OSR, and the automaker is part of Constellium’s broader efforts to increase the use of recycled materials in its manufacturing processes. The company has set an ambitious target for 2030, aiming for 50% of its metal inputs to come from recycled aluminum. While the current focus is on preconsumer scrap, Constellium is also conducting research and development (R&D) into new technologies for recycling postconsumer scrap, including “twitch” – a mixed aluminum fraction from auto shredders. While LIBS technology has shown promise in sorting this scrap, there are challenges related to the cost-effectiveness and purity of recovered material. However, as more wrought aluminum is used in vehicles, Constellium expects the technology to become more viable for postconsumer scrap in the coming years, further enhancing aluminum’s circularity.

Overcoming Challenges in Postconsumer Scrap Recovery
While progress is being made with preconsumer scrap, the recovery of postconsumer scrap remains more challenging. “Twitch” scrap, a mixed fraction of aluminum derived from auto shredders, often contains impurities such as zinc, magnesium, and iron, making it difficult to reuse in high-quality applications. Although LIBS technology has shown potential in recovering wrought aluminum grades from this fraction, its cost-effectiveness is still under evaluation. Constellium is optimistic that as the amount of aluminum in vehicles increases, especially wrought aluminum, the technology will become more cost-effective, making the recycling of postconsumer scrap more efficient.