Real Alloy plans to construct a zero-waste salt slag recycling facility in Wabash, Indiana, as part of the Zero-Waste Advanced Aluminum Recycling project (Project ZAAR). The project was selected to receive up to $67.3 million in funding from the Industrial Demonstrations Program, managed by the U.S. Department of Energy (DOE) Office of Clean Energy Demonstrations (OCED).
Salt slag is a hazardous byproduct of rotary furnaces used to recycle aluminum scrap due to the addition of salt flux to improve metal recovery. Salt slag recycling closes the loop by allowing all products generated from the recycling of aluminum scrap and dross to be reused, thereby eliminating waste and reducing carbon emissions.
The ZAAR project aims to build a processing plant on the backend of an existing aluminum recycling facility to enable salt slag components, which are typically sent to landfills, to be recycled back into the aluminum recycling process or beneficially used in other industries such as cement. This project aims to improve aluminum circularity and would strengthen the nation’s position as a world leader in secondary aluminum production.
Real Alloy is partnering with ALTEK, a subsidiary of Enviri Corp., on the construction of the salt slag recycling facility. The company will implement ALTEK’s AluSalt™ salt slag processing technology at the site to recycle metallics and salts and recover other non-metallic products.
“ALTEK is very excited to work with Real Alloy on this first-of-its-kind, milestone project for the U.S. aluminum industry as they work toward achieving aggressive sustainability goals,” said James Herbert, managing director of ALTEK. “Our AluSalt technology is designed to reduce carbon emissions, eliminate landfill associated with salt slag recycling, and generate byproducts that can be reused back in Real Alloy’s recycling process, as well as within the cement and steel industries.”
During Phase 1 of the ZAAR project, Real Alloy Recycling will conduct planning and design and prepare detailed analysis of expected project outcomes. The company will provide documentation and reports necessary for OCED to complete the National Environmental Policy Act (NEPA) review and will continue engagement activities with the community, project partners, and stakeholders.
The ZAAR project expects to generate approximately 100 construction jobs and nine permanent jobs at the Real Alloy Recycling facility. Real Alloy Recycling has a longstanding commitment to investing in its workforce and plans to offer comprehensive training and up-skilling opportunities in areas such as engineering, welding, autonomous systems, and manufacturing processes. Real Alloy Recycling also plans to implement diversity, equity, inclusion, and accessibility efforts to increase engagement with qualified applicants from underrepresented communities and those that face systemic barriers.