PreZero Pyral - Sustainable aluminium recycling

Sustainable aluminium recycling

PreZero Pyral stands for resource-efficient industrial policy combined with green environmental policy. Thanks to a variety of innovative technologies, such as our proprietary Pyradec® pyrolysis technology, this site is capable of accepting any metal-containing waste. The process has been operated commercially for 15 years and recycles now approximately 60% of the lightweight aluminium packaging generated in Germany. With our modern aluminium treatment and aluminium recovery processes, we are able to obtain a finished product with an aluminium block yield of at least 90% (Pyralu®).

The recovery of light metals is possible regardless of composition, size, strength or impurity to produce single-grade products. These products and raw materials converted from supposed waste can thus be returned to the material cycle.

Aluminium recovery by pyrolysis

The amount of scrap and light metals, such as aluminium, is changing due to our fast-paced times. Products are replaced more quickly and the life cycle of scrap, metal and aluminium is becoming shorter and shorter. As a consequence, waste volumes are growing – and thus, from PreZero’s perspective, are the quantities of recyclable materials. This makes it all the more important to sustainably recycle and recover valuable materials from metal & aluminium waste through comprehensive aluminium recovery. In accordance with the principle of sustainability, the aluminium components are extracted and aggregated as raw materials. The by-products of production are used for energy recovery and recycled for treatment and pyrolysis process. Aluminium is thus extracted from commercially available waste, with economically efficient production combined with ecological consideration.

PreZero Pyral - Aluminium transport
PreZero Pyral - Aluminium falling

Recovering value by recovering aluminium

The unique, synergetic integrated concept of PreZero Pyral is based on sustainable principles. Thus, the recovery of valuable materials results not only in homogeneous, reusable metal products, but also in the sustainable thermal recycling of the organic admixtures to the metals without the use of oxygen and thus without incineration. In addition, for example, the pyrolysis gas, a by-product of process, is used to generate electricity from self-generated heat.

This innovative recovery of valuable materials is made possible by the combination of unique plant technology. At the Freiberg/Saxony site, PreZero Pyral operates an environmentally friendly and resource-efficient pyrolysis plant, an in-house developed fluidised bed system (Pyradec®) and a precise state-of-the-art laser sorting system. This combination enables extensive mechanical sorting and thermal recycling of materials. Among other things, organically or qualitatively contaminated materials can be cleaned and returned to the product cycle in homogeneous grain sizes. The specially developed non-ferrous metal sorting system recognises a large number of different types of metal simultaneously and sorts them according to type. Individual alloys are separated from a mixed material stream by laser. Fine metal fractions with sizes below 6mm can be separated and compacted by means of special density separation and granulation, so that they can still be recycled as granules or additive products. All of this enables the targeted processing of individual alloys, selected from mixed quantities of recyclable materials, in order to reuse them as equivalent materials in the cycle.

PreZero Pyral - Aluminum cycle
PreZero Pyral - Recovering value through aluminium recovery

Aluminium as raw material to meet customer specific needs

The result of this unique process transforms common waste and scrap into high quality aluminium raw material, which can be customised in shape and alloy according to customer requirements. Recycled material can be reintroduced into the product cycle in all forms, including ingots, dubs, pyramids, sows, or in the liquid state.

Recovering one ton of aluminium saves up to:

Tons of bauxite
Tons of chemicals
kW electricity
Tons of CO2