Impact · Towards more resource-efficient aluminium processing | DIGI-HSMC

THE IMPACT

Towards more resource-efficient aluminium processing

DIGI-HSMC is being developed to connect melt conditioning with process sensing and digital interpretation, with the aim of improving process visibility and supporting more resource-efficient aluminium processing.

  • ENERGY & EMISSIONS
  • RESOURCE EFFICIENCY
  • RECYCLING & CIRCULARITY

EXPECTED IMPACT · NOT ACHIEVED RESULTS

01 · SYSTEM EFFECT

How impact emerges

The intended impact of DIGI-HSMC does not come from a single component. It emerges from connecting physical melt conditioning with process information and digital interpretation.

IMPACT PATHWAYINTENDED PATHWAY · NOT A GUARANTEED RESULT
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Physical process and resource use Measurement and interpretation Intended, not yet demonstrated

02 · IMPACT AREAS

Three connected impact areas

01EXPECTED IMPACT

ENERGY & EMISSIONS

Reducing unnecessary furnace holding and re-processing could support lower energy demand and associated emissions.

Furnace holding time, re-melting and process uncertainty can contribute to energy use and operational burden. DIGI-HSMC is developing greater visibility of the melt-conditioning process as part of a potential route towards more efficient processing.

02EXPECTED IMPACT

RESOURCE EFFICIENCY

Better process visibility could support more efficient use of material, furnace time and process capacity.

Process uncertainty can contribute to scrap, re-processing and extended holding. DIGI-HSMC is intended to investigate whether integrated melt conditioning and process information can support more resource-efficient operation.

03EXPECTED IMPACT

RECYCLING & CIRCULARITY

More consistent processing of variable feedstock is part of the wider resource-efficiency challenge.

Recycled and secondary aluminium feedstocks can introduce variability in melt processing. DIGI-HSMC sits within this wider challenge by connecting melt conditioning with process visibility.

03 · CONTEXT

The industrial context

Documented figures describing the wider industrial challenge. The industrial challenge →

INDUSTRY CONTEXTNOT DIGI-HSMC RESULTS Source: DIGI-HSMC project documentation
Industry scrap rates
5–15%
Energy as a share of total production costs
20–30%
Potential annual loss for a typical SME processing 1,500–2,000 tonnes of aluminium per year through scrap, rework and avoidable furnace time
£150,000–£300,000
Increase in furnace operating costs since 2021
40%

04 · PROJECT TARGETS

What the project is working towards

PROJECT TARGETTARGET 01

10–20%

Potential reduction in furnace holding time

PROJECT TARGETTARGET 02

3–5%

Target reduction in scrap / material loss

TARGETS · NOT VERIFIED DIGI-HSMC RESULTS

How targets will be tested through validation →

05 · SCALE

From process to wider impact

IMPACT AT THREE SCALES · QUALITATIVE

  1. LEVEL 01 · PROCESS Better visibility of melt-conditioning conditions
  2. LEVEL 02 · INDUSTRIAL OPERATION Potential reductions in unnecessary holding, re-processing and material loss
  3. LEVEL 03 · WIDER SYSTEM Potential contribution to resource-efficient and lower-energy aluminium processing

No national-scale or verified carbon savings are claimed.

06A · ENERGY

Why furnace holding matters

  1. 01Longer holding
  2. 02More furnace energy
  3. 03Higher operational burden
  4. 04Potentially higher associated emissions
DIGI-HSMC RESPONSE Process visibilityMelt conditioningOperator-informed adjustment

Potentially more efficient processing

Energy, furnace time & cost →

06B · RESOURCE

Where resource efficiency can emerge

  1. 01Melt variability
  2. 02Process uncertainty
  3. 03Scrap / re-processing
  4. 04Material + energy use
DIGI-HSMC Physical melt conditioningSensingDigital interpretation

Potentially improved process efficiency

Scrap variability & circularity →

07 · EVIDENCE

Impact must be measured, not assumed

  1. 01

    INDUSTRY CONTEXT

    Documented information about the wider industrial challenge.

  2. 02

    PRIOR RESULT

    Evidence generated before or outside the current DIGI-HSMC project.

  3. 03

    PROJECT TARGET

    A defined outcome the project is working towards.

  4. 04

    EXPECTED IMPACT

    Potential contribution associated with successful development and validation.

  5. 05

    VERIFIED DIGI-HSMC RESULT

    Project evidence formally reviewed and approved for publication.

08 · INDUSTRIAL RELEVANCE

Potential industrial value

The potential industrial value of DIGI-HSMC depends on the evidence the project produces. Future industrial application will follow testing and validation.

  1. 01Evidence-led development
  2. 02Process visibility
  3. 03Resource-efficient processing
  4. 04Future industrial application

The project →The consortium →

Explore the evidence and impact pathway

Follow how DIGI-HSMC connects physical melt conditioning, process visibility and digital interpretation with the project's resource-efficiency and industrial objectives.