Phinix LLC, a St. Louis-based company specializing in product and process development for the aluminium industry, has announced a groundbreaking $1.8 million project aimed at significantly improving the quality and sustainability of recycled aluminium. The two-year initiative will focus on developing a commercially viable process for removing iron and manganese, two common metallic impurities, from molten aluminium scrap.

The project, funded by the Remade Institute in Rochester, New York, addresses a critical challenge in aluminium recycling. Currently, recyclers manage impurities by diluting scrap with purer primary aluminium, a costly and energy-intensive process. Phinix's innovative approach, building on a 2024 Remade-funded R&D initiative and leveraging patent-pending technology, promises a more efficient and environmentally friendly solution.

The technology targets the removal of iron and manganese, which can negatively impact the properties of recycled aluminium. By effectively eliminating these impurities, Phinix's process will enable the production of high-purity recycled aluminium, a direct substitute for primary aluminium. This breakthrough has the potential to transform the aluminium industry, offering a cost-effective, low-carbon, and environmentally sound alternative to sourcing primary aluminium from bauxite.

"We are thrilled to collaborate with both existing and new secondary aluminium producers across the US," said Subodh Das, founder and CEO of Phinix LLC. "Our goal is to upgrade abundant, low-carbon domestic aluminium scrap—reducing reliance on costly, high-carbon imported primary aluminium while strengthening the sustainability of the aluminium supply chain."

The implications of this project are far-reaching. Increased availability of high-purity recycled aluminium will not only reduce the environmental footprint of aluminium production but also bolster domestic manufacturing. It will divert significant amounts of aluminium scrap from landfills and reduce the need to downcycle it into lower-value products. This, in turn, will contribute to a more circular economy for aluminium, minimizing waste and maximizing resource utilization.

To ensure the successful commercialization and refinement of the technology, Phinix has partnered with key players in the aluminium industry, including Audobon Metals, Real Alloys, and Spectro Alloys. These partnerships will provide valuable industry expertise and support the integration of the new process into existing recycling infrastructure. The collaboration will focus on developing high-value applications for the upgraded aluminium scrap in advanced manufacturing.

The Remade Institute, a public-private partnership focused on accelerating the circular economy for manufacturing, recognizes the importance of this project in achieving its mission. By funding initiatives like Phinix's, Remade is driving innovation in recycling technologies and promoting the adoption of sustainable manufacturing practices.