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With a Push From Apple, Rival Aluminum Makers Team Up Against CO2

Thursday April 22, 2021. 05:30 AM , from Slashdot
An anonymous reader shares an excerpt from a Bloomberg article, written by Joe Deaux: As David DeYoung, then a director of business technologies at Alcoa, walked into Apple's Cupertino, Calif., headquarters in September 2015, he knew that the stakes were high. DeYoung led a group of engineers who'd spent decades pursuing the holy grail for the notoriously dirty aluminum industry: a way to smelt the metal without producing any direct carbon emissions. Apple, which Harbor Intelligence analyst Jorge Vazquez estimates uses almost 15,000 metric tons of aluminum annually for its electronics gear, had invited DeYoung to explain a potentially revolutionary carbonless manufacturing process for aluminum that his group was developing. Alcoa was on the verge of ending the DeYoung team's yearslong search. To make the tension even worse, moments before DeYoung stepped into a roundtable with Apple engineers, he received word Alcoa was splitting into two publicly traded companies -- casting another cloud on his unit's project. So Apple's interest in reducing the carbon footprint of its metal casings looked to be key to saving the funding.

But it wasn't until later in 2015 that the payoff from that meeting came, with help from an unexpected source. That's when Vincent Christ, a manufacturing information technology expert from Rio Tinto Group Plc, flew to Cupertino for a similar visit. The London-based company, one of Alcoa's biggest rivals, was also struggling to develop a way to produce aluminum through a process that would emit oxygen instead of carbon dioxide. While heading back to the airport after an hourslong confab with Apple engineers, Christ received a call. Apple had an idea: Rio Tinto and Alcoa were both close to the answer they were looking for, but neither company seemed able to do it on its own. So why not combine efforts? 'We had the engine, but we didn't have the wheels, chassis, or body, and Rio brought that all to the party,' says DeYoung, who holds a Ph.D. from MIT. '[Apple] said, 'You guys really ought to talk to Rio,' and we were like, 'Yeah, we have already.' But then we said we'll talk to them again, and Apple actually facilitated that second contact.'

The result was the creation of Elysis, a joint venture between Alcoa and Rio Tinto with investments from Apple, the government of Canada, and the provincial government of Quebec, which is one of the biggest aluminum-producing regions in the world. The venture has developed a technology that makes so-called green aluminum, whose production doesn't emit carbon dioxide. If the partners can make the process work at commercial scale, it could be used to retrofit existing smelters, transforming them from some of the dirtiest industrial polluters into the kind of green manufacturing facilities business and government are shifting toward. 'Elysis has developed a process that substitutes carbon with inert materials -- it won't say what they are -- to make the anode that conducts the electricity causing the chemical reaction,' reports Bloomberg. 'Elysis' operating costs are about 15% lower than those of conventional smelting, in part because the carbon anodes used in the chemical reaction must be replaced after 25 days, while Elysis' inert material lasts two years. The carbonless process also requires fewer workers, since there's no need to frequently change out the cathodes sitting in the pots of molten alumina.'

The immediate hurdle for Elysis is to prove it can crank up the amperage used during carbonless smelting to industrial-strength power levels, which would allow higher daily production rates, says CRU Group analyst Greg Wittbecker. 'Elysis announced on April 20 it will begin installing commercial inert anode prototype cells on a smelter in Quebec in an effort to prove it can retrofit existing smelters,' adds Bloomberg. 'A pivotal moment will be if or when governments implement carbon credit or carbon tax programs that would penalize low-cost aluminum made in plants in China and India that use power from coal-fired plants.'

Read more of this story at Slashdot.
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