Session: 03-13-01: Manufacturing: General I

Paper Number: 165783

Solar Recycling: Induction Solar Foundry 

Induction heating is a process that utilizes material properties rather than heat transfer medians. Induction processes have gained popularity due to their efficiency and precision in applications. With electromagnetic induction, heating occurs in a localized area, capitalizing on the material properties of ferrous materials. Using the material properties of ferrous metals, energy loss from induction heating is minimized, creating efficient results. 

Aluminum, by nature, is non-ferrous as it does not contain iron. This material property makes it challenging to heat in the induction process. This material property does not mean induction heating has no merit in heating aluminum. The induction heating process generates large amounts of heat but is more efficient in ferrous materials 

This paper explores an approach to the induction heating of aluminum by utilizing solar energy to offset non-ferrous properties. Induction heating, known for its efficiency and precision, operates effectively on ferrous materials due to the iron inside. However, aluminum, a non-ferrous material, presents a challenge for traditional induction heating methods. This study proposes a hybrid process that combines induction heating with solar energy to achieve the necessary temperature to melt aluminum. The method minimizes reliance on fossil fuels by generating additional heat using solar power. A Fresnel lens system provides sufficient heat to offset the limitations of induction heating on aluminum, achieving the melting process without traditional sources. This research outlines the effectiveness of the combined heating process and discusses the potential implications for sustainable manufacturing practices, offering a promising alternative to traditional energy-intensive processes.  

The hybrid process demonstrates potential energy savings of 214% (based on the prices of power consumption of inductive heaters) compared to conventional aluminum melting methods. Based on previous research that introduced solar energy in a local recycling facility that uses traditional process for aluminum recycling, the new process could reduce CO2 emissions by 7.078 metric tons annually, based on general truck emissions from recycling transportation. Contributing to global sustainability goals and potentially generating income. Integrating solar energy into induction heating systems represents a significant advancement toward zero-emission recycling and sustainable material processing. Research benefits industrial-scale adaptations of this hybrid system and optimization of solar lens technology for enhanced efficiency and benefits for industries such as aerospace and automotive. By addressing these challenges, the research aims to provide a scalable solution that can be adopted globally to mitigate the environmental footprint of aluminum recycling. This innovative approach contributes to sustainability goals and paves the way for further advancements in green technology. 

Presenting Author: Basel Alsayyed Western Carolina University

Presenting Author Biography: Dr. Basel Alsayyed is the Engineering Technology program director and an assistant professor in the School of Engineering and Technology at Western Carolina University. Before joining WCU, Dr. Alsayyed was an Industrial Professor in the department of mechanical engineering, of University of Alberta (UofA), Canada. Prior to joining UofA, Dr. Alsayyed was an Associate Professor at the Department of Mechanical Engineering in UAE University. With over 21 years of experience in academia, and over 12 years of industrial experience, primarily in the American automotive industry, Dr. Alsayyed has a passion for innovation in education, teaching, research, and training. Integration of academia and industry goals and activities are paramount to Dr. Alsayyed. Sensing the industry needs and preparing future engineers to meet those needs and challenges is an important dimension of Dr. Alsayyed’s activities.
Dr. Alsayyed has published more than fifty articles in peer-reviewed journals and conference proceedings. He has seven granted patents. Research interests are in the areas of advanced manufacturing, additive manufacturing, design optimization, quality & reliability, engineering education, project management, and knowledge management.

Authors:

Basel Alsayyed Western Carolina University
Collin Tastet Western carolina Unversity