• CASE STUDY

Automated solution for the aluminum slag recovery line with reduced emissions

INDUSTRY:

Industrial waste treatment

FOCUS:

Automation of an aluminum slag processing line for safe material recovery and environmental protection.

OBJECTIVE:

Recover aluminum (5–6%), specific salts (30–35%), and alumina (68–70%) from slag for reuse in cement and refractory materials, while generating combustible gases to reduce energy consumption.

SOLUTION:

  • Siemens S7-1515  PN PLC;
  • Siemens G120 frequency inverters;
  • Siemens ET200-SP distributed IO ;
  • Phoenix Contact IPC, switches
  • Schneider protection devices;
  • Ignition SCADA;
  • Rittal Enclosure.

PROJECT DURATION:

Ongoing

THE PROJECT COMPRISED OF:

System Overview:

  • The project focuses on designing & building a processing line for aluminum slag;
  • Aluminum slag is classified as hazardous waste – it releases harmful gases like ammonia (NH3) and methane (CH4) when exposed to moisture;
  • The system aims to recover valuable raw materials from the slag and minimize the environmental damage.

Electrical Panels:

  • We developed the entire electrical infrastructure for the project, from e-design to PLC programming and SCADA visualization;
  • 2*MCC panel – S7 1515-2 PN PLC, ET200-SP distributed IO, Siemens G120 frequency

inverters, Schneider protection devices, Phoenix Contact IPC, switches, PS, etc.;

  • Bloc diagram of the entire automation system.

Automation:

  • PLC software development;
  • Developed and integrated SCADA Ignition software for real-time control;
  • Configured and commissioned numerous frequency converters Siemens Sinamics G120X;
  • Interfaced the system with the local automation via Profinet Communication;
  • The system ensures that the process complies with strict environmental regulations;
  • The electrical distribution system ensures efficient power distribution and protection for all stages of slag processing;
  • Providing a full solution for processing aluminum slag;
  • The system integrates mechanical, thermal, and chemical treatments for efficient material recovery;
  • The solution also includes advanced gas filtering and monitoring systems to ensure environmental safety made in SCADA Ignition.