QUESTIONS & ANSWERS

First of all, X-ECO is recycled aluminium. For circular aluminium we do not have to mine bauxite and less transport is needed. This leads to lower CO₂ emissions. In addition, we have invested in generating renewable energy with solar panels. We have also installed new melting furnaces in our aluminium foundry in Kerkrade. These furnaces use approximately 20% less energy than the old furnaces. We also monitor and manage energy consumption during the melting process. This also results in lower CO₂ emissions.

In addition, we have mapped our material flows thoroughly. We know the composition of the material we purchase so well that we only need to add a limited amount of primary aluminium during melting. We purchase that primary aluminium with proof of origin and CO₂ content.

Independent expert DNV has verified the CO₂ emissions of X-ECO. The carbon footprint is 2.03 tCO₂e per tonne of aluminium, calculated in accordance with ISO 14064-1 on a cradle-to-gate basis. For comparison: the average for primary aluminium production is 8 tCO₂e per tonne in Europe and 18 tCO₂e per tonne worldwide.

Colour differences in aluminium result in profiles that are too dark or too light. The oxide layer’s interaction with light determines the colour and lightness of an anodized profile.

Colour differences can be caused by too much variation in the alloy’s iron content or by variations in the thickness of the oxide layer.

1.    Colour differences can be prevented by adjusting various parameters of the etching process, such as temperature, duration, and current strength. 2.    Colour difference can also be prevented by making the alloy’s iron content more uniform (ideally 0.20% to 0.30% by weight).

Spangling is a surface effect that negatively impacts the appearance of aluminium profiles. Instead of a uniform finish, they have a spangled appearance.

Spangling results from an incorrect zinc/copper ratio in the alloy. Various etching-related factors can cause spangling. These include an incorrect zinc/copper ratio in the alloy, increases in grain size during extrusion, an excess of free zinc in the etching bath, or if post-etch residues are left on the profile for too long.

There are various ways of preventing spangling, at different times in the production process. Effective coordination of these elements is essential: 1.    Use an alloy with a zinc/copper ratio of 1 to 1. 2.    Fine tune the process parameters to produce small grains, ideally 0.05 mm to 0.1 mm in diameter. 3.    Add zinc catchers to the etching bath. 4.    Suspend and neutralize the profiles correctly.

Filiform corrosion has a thread-like appearance. It occurs on aluminium profiles between the paint and the underlying metal. This superficial form of corrosion does not impact the mechanical integrity of the product, but it does detract from its appearance.

Filiform corrosion typically develops in acidic environments, on cut surfaces or defects. It can also occur beneath the paint, around unprotected impurities or alloy elements. For instance, due to factors such as deep scratches, an insufficiently etched profile, post-etch residues (smut) deposited on the profile, a poor quality conversion layer, weak adhesion of the paint layer, or highly corrosive environments.

The key to preventing filiform corrosion is to properly prepare the surface and to carry out the coating process carefully, in line with the QUALICOAT, QUALIMARINE or GSB standards.

There are four different alloys available: X-ECO.22/ EN AW 6060 X-ECO.25/ EN AW 6063 X-ECO.27/ EN AW 6005 X-ECO.29/ EN AW 6061 We distinguish aluminium on the basis of CO2 impact. There are two main production methods that ultimately yield four types of aluminium. 1. The classic production method The classic production method provides: Classic aluminium produced using fossil fuels Classic aluminium produced using renewable energy 2. The circular production method The circular production method provides: Standard circular aluminium (containing 50 – 85% recycled material) Premium circular aluminium (containing over 85% recycled material) At E-MAX we produce circular aluminium with a maximum input of recycled aluminium. The 6060 and 6063 alloys consist of 80% recycled aluminium. The 6005 and 6061 alloys consist of 97% recycled aluminium. They are not only premium in terms of sustainability, but also in terms of quality.

Premium circular aluminium, with more than 85% recycled material, has a CO₂ emission of less than 1 to 2 tCO₂e per tonne of aluminium. We have supplied this aluminium at E-MAX since 2020.

The aluminium alloy X-ECO 6060 (X-ECO.22 / EN AW 6060) has a carbon footprint of less than 1 tCO₂e per tonne of aluminium. X-ECO 6060 always consists of more than 85% recycled material and contains trace elements of copper and zinc up to 0.05 wt%. These values are within the European standard EN AW 6060.

For comparison: aluminium produced with fossil fuels can emit more than 10 tonnes of CO₂ per tonne of aluminium. By way of illustration: an average car has to drive approximately 58,000 kilometres to emit 10 tonnes of CO₂.

The CO₂ impact of aluminium therefore differs per production method. These differences are amplified by the fuels used. Fossil fuels give a higher CO₂ impact than renewable energy, and a higher recycling percentage results in a lower CO₂ impact.

Climate change and environmental degradation are a threat to Europe and the world. Together we must ensure that this is reversed. A strategy is needed so that from 2050 Europe emits no net greenhouse gases and so that growth no longer depends on raw materials. It is therefore important that Europe becomes circular. Everyone, businesses, government institutions and individuals, must take responsibility for this.

In addition, the European Commission has developed the Green Deal. The goal is for Europe to be the first climate-neutral continent by 2050. The economy is stimulated, health and quality of life are improved and nature is protected. The Green Deal includes measures to use raw materials more efficiently in a circular economy. By 2030, net greenhouse gas emissions in the EU must be at least 55% lower than in 1990, by 2040 90% lower, and by 2050 Europe must be climate neutral. The European Green Deal covers all sectors of the economy. The aluminium industry will also have to make an important contribution to achieving these targets.

The X-ECO alloy compositions 6063, 6005, and 6061 do not differ from those of classic aluminium. The premium circular aluminium X-ECO 6060 differs from the classic alloys in terms of trace elements. That is because this 6060 alloy is subject to high surface requirements. Why is that? The classic alloy produced with high CO2 emissions only contains magnesium and silicon, to achieve the desired hardness. Only iron is added, to make matt anodizing possible. Other trace elements, such as manganese, zinc, and copper, are not necessary and therefore not present. These trace elements are present in circular aluminium. It used to be assumed that higher trace levels in 6060 alloys lead to reduced surface quality. We now know differently. Working with the Free University of Brussels, we at E-MAX have demonstrated that this does not negatively impact surface quality. Adaptations in the process make it possible to achieve high surface quality even with circular 6060 alloys. Even with the changes to the process, the X-ECO 6060 alloy remains in conformity with European standard EN AW.

With X-ECO, recycling does not come at the expense of quality. The properties of aluminium profiles are determined by the alloy composition and by how well the casting, extrusion and finishing processes are controlled. Research with Vrije Universiteit Brussel shows that circular aluminium can achieve the same quality with the right process control. In the industry it is rightly said: “Aluminium is born for recycling” and “Aluminium has no memory”.

There are no colour differences between circular and classic aluminium. This is prevented because we have good control of the materials and process. The iron (Fe) content of the alloy, in particular, is important in the anodizing process. We can therefore guarantee that there will be no difference in colour between circular aluminium and classic aluminium as long as: The iron (Fe) content of classic aluminium is between 0.2 and 0.3 wt% AND The thickness of the anodizing layer is accurately reproduced We have researched and demonstrated this extensively in cooperation with the Free University of Brussels. By the way, colour difference in aluminium does not only occur with circular aluminium. In the production of classic aluminium there is also a difference in colour after anodizing. Through years of extensive research, we are able to eliminate that colour difference. This also makes it easy to combine profiles from different batches.

Circular aluminium does not exhibit more spangling than classic aluminium. This is due to good control of the zinc and copper ratio as well as good control of the pre-etching step. Coarse-grained surface structure after anodizing is undesirable. Together with the Free University of Brussels, we at E-MAX conducted research that demonstrated the best solution to prevent this. The amount of zinc and copper in the alloy play an important role in this. In fact, the best ratio turned out to be 1:1. But that is not all. Zn-catchers must be used during the etching. This is also the case with the classic 7000 alloys. In addition, after etching, the dirty surface layer must be cleaned by thorough desmutting (with HNO3/nitric acid). This is also done for the classic 6005 and 6061 alloys.

During anodizing of circular aluminium, no streaks appear on the profile. Streaking is prevented by the excellent control of the extrusion and casting process. In this respect, circular aluminium does not differ from classic aluminium. Even when a very high anodizing quality is required, E-MAX never has streaks. This is because we use a good mechanical pre-treatment in combination with a short chemical pre-treatment. Why anodize aluminium? We anodize aluminium to protect it. This increases the corrosion resistance, and the aluminium remains attractive longer. Anodizing does not involve adding a coating but rather is a technique that hardens the surface of the existing aluminium. The crystal structure of the surface is strengthened. In addition to the practical application, anodizing is also useful as a method for colouring aluminium.

Circular aluminium does not give rise to filiform corrosion after powder coating. Filiform corrosion occurs with a copper content as low as 0.1 wt%. That is the same as for classic aluminium. In order to prevent filiform corrosion, good pre-treatment is required. This treatment results in a well-covering conversion layer. Process management is therefore of the utmost importance. We at E-MAX have conducted extensive research in this area in cooperation with the Free University of Brussels. That evidence is also provided in EA/ESTAL basic research. We are therefore able to achieve positive results in the salt spray test and the FFC test. But more importantly, we supply circular aluminium for which the user does not have to worry about filiform corrosion. Did you know that: Salt spray tests and the filiform corrosion test (FFC test) (>1000 h) show that X-ECO 6060 meets Qualicoat standards in all coating processes used in the Benelux? Along the sea coast, areas where lots of road salt is used, companies where lots of acids such as HCL are used, and swimming pools with high chlorine concentration: these are all highly corrosive environments. If aluminium (circular or classic) is used there, pre-anodizing is necessary. Pre-anodizing is by far the best conversion layer for powder coating.

Our CO₂ emission calculations are based on the methodology of European Aluminium, the European trade association for the aluminium industry. The carbon footprint of X-ECO, 2.03 tCO₂e per tonne of aluminium, has been independently verified by DNV in accordance with ISO 14064-1. In addition, Socotec has verified the CO₂ impact of our foundry and extrusion sites. The verification statement and the EPDs are available via our certificates page.

There are three important aspects to the environmental impact of aluminium: Extraction of bauxite ore and production of aluminium require a lot of energy (from fossil fuels). Bauxite extraction has an impact on the landscape. Most bauxite can be found in a broad band around the equator, in countries such as Australia, China, Brazil, Guinea, India, and Suriname. Aluminium transported to parts on the world such as North-West Europe must come a long way, and that produces high CO2 emissions.

Today it is possible to reuse a large part of the delivered material. First, the material is broken into smaller fractions in a fully automatic sorting installation. Then plastics are separated. Aluminium alloys can also be sorted by alloy type. Contaminants such as paint are sometimes also used as fuel for the pyrolysis process or even for the melting process. This further reduces the use of fossil fuels. An old painted and insulated window can serve as both fuel and raw material for the recycling process.

Next, the isolated aluminium is melted, after which the right alloy composition is achieved. This is done by diluting the aluminium with very low-alloy new aluminium or by adding the required elements, such as Mg, Si, Cu or Zn. In this way, circular aluminium meets the same EN standards as new aluminium.

E-MAX works on CO₂ reduction with targets for 2030 and 2050, set out in our CO₂ reduction plan. We produce X-ECO with a circular production method, generate our own energy with solar panels and a wind turbine and operate our own logistics centre with reusable packaging. We are investigating how we can move away from gas, for example with a hydrogen pipeline in cooperation with Chemelot and other companies.

Approximately 75% of all aluminium ever produced is still in use (source: European Aluminium). A large part of this will reach the end-of-life phase in the coming years, so that more and more aluminium becomes available for recycling.

The price of circular aluminium differs per alloy, quantity and market conditions. With strategic purchasing and a high share of recycled material, the price difference with conventional aluminium can be limited. Request a quote.

Circular aluminium can be used for the same applications as classic aluminium. This includes applications in construction, such as windows, doors, facade systems, and decorative applications, as well as many found in the automotive industry, aviation, tent, greenhouse and machine construction, and the production of climbing equipment.