Remi Claeys Aluminium N.V., a company that specializes in manufacturing high-frequency welded aluminum tubes used in various high-end applications, ordered a complete, new aluminum recycling plant for production of rolling ingots at its facility in Lichtervelde, Belgium. This investment enables the processing of heavily contaminated aluminum scrap while improving production effectiveness.
As the supplier of the complete rolling ingot plant, Hertwich Engineering will deliver the entire plant as a turnkey solution — from scrap feeding to the finished rolling ingots. The scope of supply includes a customized complete rolling ingot foundry. The order includes a state-of-the-art Ecomelt PS120 preheat-shaft melting furnace, a holding furnace, a vertical casting machine with rolling ingot molds, and an efficient flue gas cleaning system.
The Ecomelt PS120 melting furnace processes a wide variety of scrap types, including both process scrap and heavily contaminated post-consumer scrap, thanks to its integrated preheat charging shaft and integrated pyrolysis system. Two charging containers (each capable of being loaded with up to five tons of aluminum scrap) are alternately fed into the charging shaft, which can accommodate up to four container loads.
At a temperature of 550°C, pyrolysis begins within the charging shaft. Any organic compounds are broken down and completely combusted. The resulting pyrolysis gas serves as fuel, significantly reducing external energy demand of the furnace.
During the melting process, aluminum is recovered using an especially resource-efficient immersion melting method. Direct heat transfer minimizes metal losses and optimizes energy use. At the same time, a modern flue gas cleaning system filters dust and pollutants from emissions — a crucial contribution to an economically and environmentally friendly process.
In the next production step, molten aluminum is transferred from the melting furnace to the casting furnace. The vertical casting machine enables the simultaneous casting of multiple rolling ingots in three molds. With a daily capacity of more than 100 tons, the new foundry enhances process stability and overall efficiency.
Alltogether, the line ensures a fully digitized material flow. All of the components — from scrap loading systems and melting and casting technology to process visualization — follow a unified operating concept. This makes plant operation more intuitive, reduces training requirements, and ensures smooth interaction between all process steps. Without third-party interfaces, all components work seamlessly together, significantly simplifying commissioning, maintenance, and long-term optimization.
This investment strengthens Remi Claeys’ sustainability and competitiveness through cutting-edge recycling technology, energy efficiency, and a fully integrated production process. Being able to produce its own rolling ingots, which the company will then roll and further process into precision tubes for horticulture, scaffolding, medical technology, household appliances, DIY products, outdoor furniture, sports and leisure equipment, ladders, heat exchangers, and many other applications.
The new aluminum recycling plant is scheduled to start operations in spring 2026.