ALUGREEN (Greener anodizing for cleaner nature)

Description

Alcomet AD is a Bulgarian leader in the production of flat-rolled and extruded aluminium products. The plant incorporates the entire downstream production cycle from billet- and coil-casting through extrusion and cold-rolling to prefabricated components on a single manufacturing site in Shumen, Bulgaria. Its production facilities have a total capacity of 100 thousand tons per year.

The main objective of the project ALUGREEN (Greener anodizing for cleaner nature) is to increase the company’s competitiveness through the implementation of new innovative green production processes in its anodizing shop. The implementation of innovative technical solutions for the main anodizing line and its adjacent wastewater treatment plant will contribute to optimize Alcomet’s production and straiten its market positions.  In addition, a positive environmental effect is expected by reason of a waste reduction, water and energy savings, a reduction of CO2 emissions due to chemical consumption’s optimization.

One of the challenges of the aluminium industry is its high carbon print in the initial production process. Alcomet has decided to put special emphasis on this problem and by implementing this project the amount of scrap in the re-melting operation will decrease, reduce cost and give Alcomet a competitive advantage since customers consider the usage of green aluminium a high priority next to competitive price and good quality. 

The implementation of green innovation investment in the anodizing production plant has been observed by Alcomet as a natural consequence of company’s institutional, economic and social sustainability direction. ALUGREEN project would strongly contribute to the company’s objective of economic development through environmental protection.

Summary of project results

The project aimed to address several challenges related to the outdated technology and environmental inefficiencies of the anodizing production line and wastewater treatment plant. These challenges included:

1. Outdated Technology Hindering Production Capacity: The anodizing production line was reliant on outdated technology, which limited the company’s production capacity. Despite improvements achieved under the ALUGREEN project, the existing setup was unable to fully utilize the potential of the newly implemented anodizing line, leaving significant production opportunities untapped.

2. Environmental Performance Limitations: The technology in use, while meeting existing environmental standards, was unable to achieve the more ambitious environmental performance levels attainable with modern solutions. This gap highlighted the need for advanced technology to enhance sustainability and reduce the company’s environmental footprint.

3. Inefficient Wastewater Treatment: The outdated equipment at the wastewater treatment plant resulted in inefficient processing of residual production waters. This inefficiency not only affected production processes but also generated excessive quantities of sludge—a byproduct of the physical-chemical processes used in industrial wastewater treatment. The high sludge volume posed significant waste management challenges.

4. Need for Further Expansion of Previous Achievements: Although the ALUGREEN project had achieved notable progress, including increasing production capacity from 200 to 300 tons per month through the investment in a modern anodizing line with 13 active tanks, further improvements were necessary. The project sought to build on these achievements by introducing an additional anodizing tank and enhancing the wastewater treatment plant’s drying system.

5. Untapped Production Potential: The anodizing line’s full capacity remained underutilized. The addition of a new anodizing tank was intended to enable the company to optimize the line’s operation, potentially increasing production to 400 tons per month. This expansion represented a significant opportunity to enhance operational efficiency and output.

6. Waste Reduction and Improved Air Quality: The drying system in the wastewater treatment plant was inadequate in terms of waste reduction and air quality improvements. By investing in a modern dryer, the project aimed to reduce the volume of sludge generated and improve the quality of steam emissions, contributing to better environmental outcomes and operational performance.

In summary, the project addressed pressing challenges related to production limitations, environmental impact, and operational inefficiencies. It built upon the foundation laid by the ALUGREEN project by incorporating additional capacity and adopting advanced technologies, ensuring enhanced economic and ecological sustainability.

The ALUGREEN Project focused on enhancing the environmental sustainability and efficiency of Alcomet AD’s anodizing and production processes through the application of innovative technologies and processes. The project involved several key activities and investments:

Technological Innovations and Process Enhancements:

• The company implemented a new anodizing line equipped with 13 active tanks, each designed to perform specific tasks within the anodizing process. This upgrade allowed the company to increase its production capacity from 200 tons to 300 tons per month. In the ongoing phase of the project, the company is working to integrate an additional anodizing tank, which will further increase the capacity, enabling a production level of up to 400 tons per month.
• As part of the project, Alcomet AD also invested in several other advanced systems, including an Acid Recovery system, a Demineralization Unit, a Die-Cleaning System, an Aspirator system, and a Wastewater Treatment Plant. These systems contributed to improving the overall efficiency and environmental performance of the production process.
• The wastewater treatment plant received significant upgrades, incorporating green, innovative solutions to improve the drying system at the end of the production cycle. These enhancements resulted in a reduction of waste generated and improved air quality by minimizing harmful emissions from the drying process.

Environmental Impact and Sustainability Measures:

• To reduce CO2 emissions, the newly purchased production equipment was designed to be more energy-efficient, helping to decrease the carbon footprint of the production operations.
• The equipment also helped in reducing VOCs emissions by using more environmentally friendly technologies that minimized the release of volatile organic compounds during production.
• As part of energy efficiency measures, the new anodizing line and other systems enabled the company to optimize its energy consumption, leading to a significant increase in energy efficiency across its operations.

Canceled Investment:

• Initially, the company had planned to invest in a Caustic Soda Recovery System, but this purchase was canceled during the first reporting period after the approval of Innovation Norway.

Overall, the ALUGREEN Project facilitated the implementation of innovative technologies that not only boosted production capacity but also contributed to enhanced environmental sustainability, energy efficiency, and reduced emissions.

The ALUGREEN Project achieved significant environmental, operational, and economic outcomes that benefited both the company and the broader community. The results were aligned with the project’s goals of reducing environmental impacts, improving resource efficiency, and increasing sustainability. These outcomes can be summarized as follows:

Reduction in CO2 Emissions

• The project led to a decrease in CO2 emissions per ton of aluminum produced. In 2019, the CO2 emissions were estimated at 0.6 tons per ton of aluminum, but after the project’s implementation, this was reduced to 0.49 tons per ton. This reduction represents a decrease of 0.11 tons of CO2 per ton of aluminum produced, helping to reduce the company''s carbon footprint and contributing to global efforts to mitigate climate change.
• The annual reduction in CO2 emissions is significant, benefiting not only the company’s environmental footprint but also contributing to the reduction of greenhouse gases at a local and global scale.

Waste Management and Recycling

• The project also focused on improving waste management practices. In 2019, the company generated 0.60 tons of waste per ton of aluminum produced. By 2023, the project aimed to reduce this to 0.26 tons per ton of aluminum, achieving a decrease of 0.34 tons per ton of aluminum. This reduction was achieved through innovative waste collection, reuse, and recycling measures.
• This result significantly enhanced the company’s resource efficiency, reduced the environmental impact of waste disposal, and promoted circular economy practices by ensuring that more materials were reused or recycled rather than disposed of.

Energy Efficiency Improvements

• The project led to a 13% reduction in energy consumption. In 2019, the energy consumed per ton of aluminum production was 1.07 MWh, which decreased to 0.93 MWh per ton by 2023. This reduction not only decreased operational costs but also had a positive impact on the local environment by reducing the energy demand and associated emissions from power generation.
• The decrease in energy consumption translated into both financial savings for the company and a lower environmental impact, benefiting the company’s bottom line and helping to meet sustainability goals.

Natural Gas Consumption Reduction

• The consumption of natural gas, a key energy input in aluminum production, was reduced by 55.6%. In 2019, the consumption rate was 52.5 m³ per ton of aluminum produced, and the goal was to reduce it to 23.3 m³ per ton by 2023. This reduction directly contributed to a more sustainable production process, decreasing the company’s dependency on fossil fuels and helping to lower greenhouse gas emissions associated with natural gas use.

Reduction in Chemical Consumption

• The project also focused on reducing the consumption of critical chemicals used in the anodizing process:
  • Caustic soda (Sodium hydroxide): In 2019, the company used 292 tons per year, which was reduced to 140 tons per year by 2023, marking a decrease of 152 tons per year.
  • Sulfuric acid: The consumption of sulfuric acid was reduced from 352.5 tons per year to 239.7 tons per year, achieving a reduction of 112.8 tons per year by 2023.
• These reductions in chemical usage not only lowered operational costs but also decreased the environmental impact of chemical production and disposal.

Air Quality and Emissions Reductions

• The improvements in the wastewater treatment plant and drying process resulted in the reduction of harmful emissions:
  • CO2 emissions from the drying process were reduced, contributing to a cleaner production cycle.
  • NOx emissions were also lowered, improving air quality and reducing the environmental impact of the production process.
• These measures benefited local air quality, reducing the environmental footprint of the facility and supporting the health and well-being of nearby communities.

The primary beneficiaries of the ALUGREEN Project’s results include:

• Alcomet AD: The company benefited from increased production capacity, operational cost savings, improved efficiency, and reduced environmental impact, positioning it as a more sustainable and competitive player in the aluminum industry.
• Local Environment: The surrounding community and local ecosystem benefited from the reduced emissions, improved air and water quality, and decreased waste generation. The environmental improvements also contributed to the local climate action efforts.
• Industry and Stakeholders: Industry partners, customers, and suppliers of Alcomet AD also gained from the improved environmental performance and sustainability of the company’s operations. Additionally, the project''s innovations set a benchmark for other players in the aluminum sector seeking to adopt more sustainable practices.

In conclusion, the ALUGREEN Project delivered tangible and significant results that aligned with its sustainability goals, enhancing both the company’s environmental performance and operational efficiency, while also benefiting the local community and the broader ecosystem.