Use of recycled aluminium: challenges for metal enclosed parts in switchgears

Given that primary aluminium production is energy-intensive and dependent on the electricity mix, integrating recycled aluminium into switchgear enclosures offers a promising solution to further reduce greenhouse gas emissions.

This paper examines the role of aluminium in gas-insulated switchgear (GIS) and explores the practical integration of recycled aluminium through an industrial case study. It discusses the challenges related to material properties, supply chains, and environmental accounting. The objectives include assessing the feasibility of using recycled aluminium, identifying industrial challenges, and evaluating methodological issues in quantifying the environmental benefits within Life Cycle Assessments (LCAs). 1 The case study with the aluminium castings supplier demonstrated the feasibility of introducing recycled aluminium into cast enclosures, though it highlighted challenges such as material availability, traceability, and maintaining quality and durability standards. The aluminium tested had an 85% recycled content and an emission factor of 2.1 tCO₂eq per ton before foundry processing. Finding aluminium with 100% recycled content for this specific use remains difficult.

Methodologically, the paper explored the complexities of assessing the environmental benefits of recycled materials within LCAs. The mass balance approach, as outlined in ISO 22095:2020, was identified as the most appropriate method. Utilizing the IEC 63366 standard, the impact of recycling aluminium at the end of its life cycle was measured, showing significantly lower impacts than virgin aluminium. However, recycling also has limits due to emissions involved in various stages of the recycling process.

In conclusion, while the path to decarbonizing high-voltage switchgear using recycled aluminium is complex and challenging, the potential environmental benefits make it a priority.

Further research, industry collaboration, and methodological refinement are essential to achieving widespread adoption and minimizing impact on climate change.