Speira Enhances Aluminium Recycling Capacity with Cutting-Edge Furnace Technology

Speira is modernizing its facilities in Grevenbroich and Töging by installing two new state-of-the-art furnaces at each location, replacing the old units. The addition of four new tiltable rotary furnaces will enhance the company's ability to handle "low grades"—heavily contaminated scrap and dross from the melting process. Ralf Köring, Head of Recycling Services, emphasizes Speira's commitment to a comprehensive approach to the circular economy: "We address not only the easily recyclable materials but also the more challenging lower grades and by-products. Our goal is to extract the maximum value from all aluminium materials and reintegrate them into the recycling loop." These recycling services are offered both for Speira's own operations and external clients, including those in the automotive and packaging industries.

Speira is investing approximately eleven million euros in four new furnaces, which includes additional infrastructure such as charging machines, suction hoods, thermal afterburners, and piping. The cutting-edge burner technology and automatic charging systems will enhance metal yield. The new units are designed to improve safety and ease of maintenance for employees: components are easily accessible, molten metal can be tapped with the furnace doors closed, and traffic in front of the furnaces is reduced due to the charging machines. The furnaces adhere to the highest environmental standards, featuring new suction and burner technologies that reduce CO2 emissions. Additionally, they are "H2 ready," meaning they can be adapted for hydrogen operation in the future.

The new furnaces deliver a threefold improvement in energy efficiency. First, their increased throughput means each tonne of recycled aluminum saves up to 95% of the energy needed to produce a tonne of primary aluminum. Second, the advanced burner and afterburner technology maximize energy yield from natural gas. Additionally, impurities from low-grade scraps are utilized as combustibles in the melting process, and the new furnaces handle a wider range of these grades. Third, the optimized furnace design reduces heat loss through features like automatic charging and tapping with closed furnace doors.

The four furnaces will be delivered and installed sequentially. Production is set to begin in May 2025 with the first furnace in Grevenbroich, followed by the first furnace in Töging in October 2025. The second furnace in Grevenbroich will start production in May 2026, and the second furnace in Töging is scheduled to commence in October 2026.

Speira's purpose is to create a functional circular economy. This fundamental belief drives the company's existence and is central to its mission, extending beyond merely expanding Speira's business. Speira is redefining the boundaries of aluminium rolling and recycling to develop innovative products and solutions, promoting circularity for both the planet's sustainability and the company's future.