Trimet adds 80,000T of German aluminium recycling capacity with hydrogen furnaces, laser sorting

GERMANY – Trimet has boosted recycled aluminium output by up to 80,000 tonnes annually at its Gelsenkirchen plant and will commission a new laser-sorting recycling facility in Hamm by the end of 2026 that identifies scrap by alloy composition for high-purity feedstock.

The Gelsenkirchen site has installed solar panels for electricity and will begin operating its melting furnaces with hydrogen-rich process gas from August 2026, which generates lower CO₂ emissions than natural gas. 

Dr Andreas Lützerath, Member of the Board of Trimet Aluminium, stated that the company is systematically aligning its strategy with growing demand for recycled aluminium and investing in capable structures that ensure a reliable, high-quality supply over the long term, even in a challenging market environment.

Laser Sorting Turns Mixed Scrap into Premium Feedstock

The new Hamm facility will use laser-based analysis technology to identify the metallurgical characteristics of scrap materials and separate them by alloy composition. 

Traditional scrap sorting cannot distinguish between different aluminium alloys, which have different metallurgical properties. 

Laser-based sorting enables alloy-specific separation, producing feedstock that can be directly remelted into new high-performance products without the energy penalty of refining mixed scrap down to purity. 

The facility will focus on sorting, processing, and logistics of aluminium scrap.

Expanding Capacity in Essen

Trimet has completed infrastructure work at its Essen site, expanding storage areas to allow alloy-specific separation and storage of aluminium scrap. 

The upgrades are expected to increase site capacity by around 16,000 tonnes, improving material quality, supporting process efficiency, and increasing the use of recycled aluminium in production. 

Aluminium recycling uses approximately 95 percent less energy than primary production, and each tonne of recycled aluminium saves about 11 tonnes of CO₂ emissions compared to primary production.

New Recycled Alloys for Automotive

Trimet currently offers Trimal-04, a high-pressure die-casting alloy with a high recycled content, as an alternative to its primary aluminium alloy Trimal-05. 

The company is also developing a recycled version of Trimal-38, an alloy used in battery housings, structural components, and other automotive applications where crash performance is important. 

Adjustments to alloy compositions allow a higher proportion of secondary aluminium to be used while maintaining the required mechanical properties. 

For automotive manufacturers, using recycled alloys reduces the carbon footprint of each vehicle, supporting corporate net-zero commitments.

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