A European research initiative is aiming to unlock more value from recycled aluminium by tackling one of the sector’s biggest challenges: alloy contamination.
Based in Vienna, Austrian Institute of Technology is leading the EU-funded RecAL project, which focuses on advanced aluminium recycling technologies and digital tools for a circular economy. The Horizon Europe initiative brings together 19 partners from nine European countries.
At the heart of the project is the planned ‘RecAL Hub’, described as a digital cockpit designed to improve the traceability, sorting and reuse of aluminium recyclates across Europe.
Tackling aluminium downcycling
Aluminium recycling already delivers major environmental benefits. Recycled aluminium requires just 5% of the energy needed to produce primary material. Nevertheless, recyclers still face major technical barriers.
One persistent issue is alloy mixing. End-of-life aluminium often contains multiple elements that are difficult to separate. Consequently, many recycled streams end up downgraded into lower-value applications.
The RecAL consortium wants to change that by developing 14 technological solutions for aluminium recycling up to technology readiness level 6. These innovations will cover the entire recycling chain, from sorting and remelting to alloy design and digital process monitoring.
‘RecAL aims to fully exploit the immense potential of secondary aluminium resources in Europe, revolutionise recycling processes, address key challenges in alloy development and promote sustainable practices,’ says project manager Gerald Prantl of LKR Leichtmetallkompetenzzentrum Ranshofen.
Europe plans to source nearly half of its aluminium production from secondary material by 2050. However, analysts argue the sector needs stronger coordination and better digital infrastructure to maximise recovery.
Strong recycling rates drive momentum
The project arrives as aluminium recycling rates continue to climb across several industries.
According to new figures from Metal Packaging Europe and European Aluminium, aluminium beverage can recycling reached 76.3% across the EU, UK, Switzerland, Norway and Iceland in 2023. Meanwhile, recycling volumes increased by 7% year-on-year.
The automotive sector is a strong performer. In both Europe and the US, more than 90-95% of automotive aluminium is reportedly recovered and repurposed.
As demand for lightweight materials grows in transport, construction and packaging, projects such as RecAL are expected to play an increasingly important role in securing Europe’s secondary raw material supply.
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