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100 Pioneers for Efficient Resource Management PDF CRONIMET Ferroleg. 100 Pioneers for Efficient GmbH Resource Management Karlsruhe Examples of excellence in Baden-Württemberg from all parts of industry Best practice case of CRONIMET Ferroleg. GmbH www.springer.com/de/book/9783662567449 Recycling industry Development of systems and technology for aircraft engine and landing gear recycling in Baden-Württemberg CRONIMET Ferroleg. GmbH, Karlsruhe Technology/Process Technology: Aircraft recycling Measure: Secondary raw material extraction of economically critical raw materials Background and objectives The recycling (urban mining) of engines and Decommissioned aircraft are a source of high landing gear from old aircraft extracts numer- quality components and materials. Some of ous relevant technology metals and thus these engine and landing gear components serves particularly to ensure the availability of have a limited service life and must be raw materials. In the study analysing critical replaced after a defined number of revolu- raw materials for Baden-Württemberg’s state tions, operating hours and landings in aircraft strategy for resource efficiency, titanium, for maintenance hangars. Before the materials example, was classified as critical. Strategically can be introduced into the secondary raw important raw materials are to be recycled material cycle, the components must be ren- through the interventions. In concrete terms, dered unusable through a documented pro- high-temperature super alloys, titanium and cess. The reason for this process is to prevent high-quality aluminium and stainless steel suspected unapproved parts and inferior imi- super alloys are to be recovered from engines tations (bogus parts) from appearing on the and used to secure Baden-Württemberg‘s world market. The materials in question accu- raw materials supply. mulate continuously at aircraft maintenance hangars, so their documented dismantling Challenge and ultimate recycling can be scheduled. The greatest challenges lie in the procure- ment of the primary materials from the air- More than half of all commercial aircraft ever craft and engine maintenance hangars and in produced are still in operation. There are also creating an adequate, documented process large aircraft cemeteries in the arid regions of for rendering the serialised aircraft compo- Discs from the fan intake of the USA. The recovery of material from old nents (they are individually identified with an engine aircraft is all-in-all a promising field of activity. serial numbers up to that point) unusable. The Picture on the right: Engine recycling is a very interesting niche for aircraft recycling project for the recycling of Rolls Royce RB 211 engine the extraction of secondary raw materials such aircraft engines and landing gear is currently as technology metals, super alloys, titanium being carried out by CRONIMET Ferroleg. alloys and stainless steel alloys. However, the GmbH at its Karlsruhe site. environmental standards and recycling quotas in this field vary widely on a global basis. As When serialised aircraft components are ren- yet, only recommendations for the high- dered unusable, it is important to pay atten- quality recycling and recirculation of aircraft tion to ensure that the destruction of the materials exist on a global level, but no laws, materials is verifiably documented. This is such as the German End-of-Life Vehicles Act. necessary because these components have Beyond the rules of waste and aviation law, only been designed for a certain running time only the guidelines of the Aircraft Fleet or number of revolutions or landings and Recycling Association (AFRA) are available as must therefore be taken out of circulation legal guidelines. CRONIMET is also a member after the specified running time. of this association and works according to best management practice. Extract from M. Schmidt et al. (2019): 100 Pioneers in Efficient Resource Management – Best practice cases from producing companies. Springer-Verlag Berlin Heidelberg. Recycling industry created. A laboratory for the analysis of the secondary raw materials was set up in Karlsruhe, allowing comprehensive material analyses to be conducted. A nitrogen/oxygen analyser and a carbon/sulphur analyser from LECO Instrumente GmbH are among the devices used. An X-ray fluorescence spec- trometer and optical emission spectrometer are used to detect main-group and transition elements of the periodic table of elements and trace elements can be detected by glow discharge mass spectrometry. Savings The sustainability aspects of the process encompass the securing of high-quality tech- Delivery of an engine nological alloys as raw materials for the state of Baden-Württemberg, environmental relief through substitution of primary sources with Idea secondary sources of high-temperature alloys For the first time in Germany, CRONIMET is and other critical metals, securing the loca- offering a combination of service and tech- tion by creating new jobs and increasing the nology for the recovery and recirculation of quality and security of existing jobs at the the highest quality alloys from safety-related Karlsruhe site. Of the 21,000 commercial air- applications in aviation. This service includes craft with jet engines put into service world- securing a supply of secondary raw materials wide to date, around two thirds are still in through their worldwide business at the use, since the typical period of use before accumulation sites of aircraft maintenance they are decommissioned is around 26 years. hangars and engine recycling with plants in A commercially used engine has an average America, Europe and Asia. A safe, document- mass of around 3 t, so that a total of ed and service-oriented process for rendering 126,000 t of high-quality secondary raw sensitive secondary raw materials from the materials is potentially available. The potential aviation industry unusable and for recovering within the 15 largest airlines in Europe was the raw materials by recycling and upcycling examined and 7,265 engines with a com- can thus be guaranteed worldwide. bined weight of 22,000 t were found to be available. Implementation During implementation of the measures, strict The total potential of 126,000 t of high-qual- compliance with procedures is vital to ensure ity secondary raw materials from the engine the quality and safety of recycling. The task sector can be divided up in terms of time and Combustion chambers in of the aircraft maintenance hangars is the geographic location. Assuming a market pen- a military engine collection of parts and the corresponding etration of 10%, a potential of approx. 600 t documentation for further processing, then at of material per year can be expected, which CRONIMET the delivered parts are checked, can be used to close the cycle for the first sorted and dismantled. Finally, CRONIMET time at the site in Karlsruhe, Germany. recycles the remaining materials. In order to meet the safety requirements of the aviation Learning objective industry, all process steps must be verifiably Initial experience has already been gained documented. In addition, all CRONIMET even during the implementation of the pro- employees involved are checked for reliability cess for engine and landing gear recycling at in accordance with §7 of the German CRONIMET. Reliable information was com- Aviation Security Act. piled on the range of commercial and military engines available. This study was divided into After the process had been developed, suit- Europe (Karlsruhe collection point), North able machines were purchased, employees America and Asia. In addition, many tests were explicitly trained and instructed in their were carried out on the dismantling, analysis, use and storage and handling facilities were destruction and recycling of various engine Extract from M. Schmidt et al. (2019): 100 Pioneers in Efficient Resource Management – Best practice cases from producing companies. Springer-Verlag Berlin Heidelberg. CRONIMET Ferroleg. GmbH, Karlsruhe types. On the basis of these different disman- tling studies, recycling technologies were also tested for currently unusable substances or products, e.g. coatings in the high-tempera- ture range. Company CRONIMET has been a specialist in stainless steel scrap, ferroalloys and primary metals for four decades and is established on four con- tinents with over 60 subsidiaries, sharehold- ings and representative offices. The CRONIMET Group is a global leader in stainless steel raw materials, mining and recycling and has over 5,600 employees. The company combines many years of experience and expert knowl- edge with reliability, competence and cooper- High-temperature combustion area of a commercial engine ative partnership. CRONIMET responds to the needs of its suppliers and customers through daily, personal contact. The company has four foundational pillars: Trade & Sales, Recycling, Production and Services. Based on these, they have a com- prehensive offering, which ranges from pure metals and ferroalloys for primary raw materi- als, to processed stainless steel and metal scrap, to special and super alloys. CRONIMET guarantees its customers exact percentage analyses of all its raw materials, whether pure or in new, precise combinations. As required, all components can be supplied ready for charging into the smelting process. Technical dismantling discussion on a commercial engine CRONIMET Ferroleg. GmbH Südbeckenstraße 22 D-76189 Karlsruhe www.cronimet.de Gregor Zenkner [email protected] The project "100 Companies for Resource
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