Combining AI with LP-LIBS, DTE's aluminum analysis cuts energy use and boosts efficiency.

In the face of surging global demand for aluminum and rising energy costs, an Icelandic company is pioneering a new solution with its real-time melt analysis technology that promises to revolutionize aluminum production by providing immediate insights into molten metal composition, significantly cutting down on energy usage and production times while ensuring higher efficiency and sustainability in meeting both economic and environmental targets.

While global aluminum demand continues to grow, largely fueled by the energy transition and the push for sustainable materials in industries such as automotive, construction, and packaging, Europe has faced challenges in maintaining a sufficient supply of this lightweight and versatile metal.

High energy prices, exacerbated by the Russian invasion of Ukraine, led to a nearly 4% reduction in European domestic aluminum production in 2023. As a result, Europe has become increasingly reliant on imports, which has made it more vulnerable to supply chain disruptions.

Amid these challenges, the International Aluminium Institute projects a 40% increase in aluminum demand by 2030, requiring an additional 33 million metric tons of production annually.

To better prepare for this anticipated increase, rising costs of primary aluminum production and global commitments to lower carbon emissions are pushing the industry toward greater reliance on secondary, or scrap, aluminum.

Recycling aluminum is significantly more energy-efficient, requiring only 5% of the energy used in primary production. However, with aluminum recycling already at about 76%, the competition for scrap supplies is expected to intensify, particularly between buyers in Europe, North America, and Asia.

To enhance efficiency and counter rising production costs, producers are focusing on improving recycling and recovery processes to maximize the return of aluminum into circulation. This has increased the focus on adopting new technologies that can streamline processes and reduce energy use.

Amid this evolving landscape, DTE is spearheading a transformation in aluminum production. By utilizing its real-time melt analysis technology, this innovative company seeks to improve production efficiency through rapid insights into molten metal composition.

This innovation aims to cut energy consumption, enhance operational processes, and address material shortages, as well as the stringent environmental standards that the aluminum industry faces today.

Immediate analysis

DTE

DTE's advanced LP-LIBS system conducts immediate, in-situ analysis of molten aluminum, providing instant data to optimize production processes and enhance material quality.

This is where DTE's real-time melt analysis technology comes in.

Utilizing advanced laser-induced breakdown spectroscopy (LIBS) coupled with artificial intelligence, DTE provides aluminum producers with immediate and precise data on the elemental composition of molten metal.

Unlike traditional methods, which require samples to cool and be sent to a lab for analysis – often leading to delays – DTE's technology provides results in less than 60 seconds.

Known as LP-LIBS or liquid-phase LIBS, this technology analyzes molten metal directly in the furnace, providing rapid feedback that enables immediate adjustments, thereby reducing the need for remelting and lowering energy consumption. The combination of LIBS with artificial intelligence-driven software provides not only elemental breakdowns but also predictive insights into how producers can improve process efficiency and reduce energy use.

Real-time analysis of aluminum melts addresses two significant issues in aluminum production – energy costs and carbon emissions.

Keeping aluminum in its molten state requires maintaining temperatures of approximately 700 degrees Celsius (1,292 degrees Fahrenheit), which demands substantial energy. By shortening the time aluminum needs to be held at these high temperatures, DTE's technology helps producers cut down on energy consumption.

DTE

Laser-induced breakdown spectroscopy provides precision elemental analysis, ensuring optimal aluminum melt quality with minimal energy use.

Additionally, this technology helps to lower carbon dioxide emissions associated with producing aluminum – a crucial factor as the industry strives to meet net-zero emissions targets by 2050. Major producers are increasingly seeking solutions that can decarbonize their production processes, and technologies like DTE's melt analysis fit squarely into that goal by improving efficiency and minimizing energy use.

"High energy prices and growing demand for low carbon aluminium will lead producers to seek energy savings through the adoption of new technologies," the company penned in a recent statement. "Real-time composition analysis offers significant energy savings to producers looking to reduce their consumption, by cutting the amount of time the aluminium needs to spend molten and reducing the chances of needing an energy-intensive remelt."

The aluminum industry faces mounting pressure to innovate, driven by ambitious carbon reduction targets and an ever-growing demand for sustainable materials. As a fundamental metal for the ongoing energy transition, aluminum's role is crucial, even as its supply faces uncertainties amidst increasing demand.

To navigate these challenges, companies are developing advanced methods for producing, recycling, and analyzing aluminum. This evolution highlights the increasing importance of aluminum in the transition toward cleaner energy.

By seamlessly integrating LP-LIBS with AI, DTE's melt analysis solution addresses the aluminum industry's pressing challenges – enhancing production efficiency, reducing energy consumption, and cutting carbon emissions. As demand for aluminum rises alongside ambitious sustainability goals, DTE's technology represents a critical step toward ensuring that the industry's growth remains both economically feasible and environmentally sustainable, positioning it as a new rising player in the energy transition.