Recycling process
At Wasl Al Khayer, sustainability and resource optimization are at the core of our operations. Our aluminium and copper recycling process follows a streamlined, eco-conscious approach that ensures high-quality metal recovery while reducing environmental impact.
Sustainability & Environmental Stewardship
Our aluminium-and-copper operation is engineered around the principle that industrial growth and environmental care must advance together. Three pillars define our low-impact model:
Pillar | What we do | Why it Matters |
| 1. Zero-Smoke Melting | All furnaces are connected to an oversized multi-stage baghouse filtration system that strips > 99 % of particulate matter and acid gases before the exhaust reaches the stack. Continuous opacity monitors confirm “invisible-stack” performance, keeping visible smoke at 0 % during normal operation. | Modern baghouses cut PM, chlorides and fluorides at secondary aluminium plants to near-background levels, protecting air quality for workers and neighbouring communities. |
| 2. LPG-Fuelled Furnaces | We switched from heavy fuel oil/diesel to Liquefied Petroleum Gas (LPG) as our main energy source. LPG’s high hydrogen-to-carbon ratio means: <br>• ≈ 20 % lower CO₂ per tonne of metal <br>• Negligible SO₂ and ash <br>• Significantly less NOₓ and PM | LPG is widely recognised as a lower-carbon, clean-burning industrial fuel, helping us cut greenhouse gases and local pollutants simultaneously. |
| 3. Closed-Loop Recycling | 100 % of our aluminium and copper feedstock is post-consumer or post-industrial scrap. <br>• Dross and skimmings are returned to certified reclaimers. <br>• Process water is recirculated; solids are filtered and sent to cement kilns as raw material. | Recycling aluminium uses up to 95 % less energy than producing primary metal, and copper recycling saves ≈ 85 %—cutting energy demand and emissions at the source. |
Continuous Improvement Commitments
- Real-time emissions dashboard in the control room and quarterly third-party stack tests to guarantee compliance with local and EU standards.
- Energy-performance index (EPI) programme aiming to reduce LPG consumption by 3 % every year through burner tuning and furnace insulation upgrades.
- ISO 14001 environmental-management certification (audit underway for 2026).
- Community engagement: annual open-plant “Green Manufacturing Day” to showcase sustainability progress to schools, suppliers and regulators.
By integrating state-of-the-art filtration with cleaner combustion fuel and a circular-economy mindset, Wasl Al Khayer delivers high-grade aluminium and copper products with virtually zero visible emissions and a markedly smaller carbon footprint—proving that heavy industry can operate responsibly in a climate-conscious world.