Metalysis, a global manufacturer of metal and alloy powders — including lightweight and refractory high-entropy materials for space, aerospace, defence and other advanced manufacturing sectors — has contracted with clean tech firm
Gas Recovery and Recycle Ltd (GR2L) to install an ArgonØ argon-recycling system.
Metalysis uses argon to create an inert atmosphere throughout its patented production process and across all of its reactor sizes; these range from Gen 1, producing grammes of output per run to Gen 4, which produces ‘tens of tonnes per annum’ (being an inert gas, argon protects the metal and alloy powders from being contaminated by atmospheric gases — particularly oxygen, but also nitrogen and hydrogen).
Metalysis says installing this system will save the company 350 tonnes of argon each year, as 95% of the argon is recycled. The resulting reduction in energy used to process new argon and to transport it will result in annual savings of 1,000 tonnes of ‘Scope 3’ CO
2, as every tonne of argon purchased brings with it at least another 2-4 tonnes of Scope 3 CO
2 equivalent. Moreover, the ArgonØ recycling system has an energy footprint of less than 10% of conventional gas-recycling systems.
For Metalysis, which owns the Metalysis FFC process — originally developed as an energy-saving and efficiency-saving alternative to traditional titanium production and capable of producing metal and alloy powders across 49 elements of the Periodic Table — this project further demonstrates the company’s commitment to sustainability being built-in to the production process.
The Metalysis FFC process is already 50% more-energy-saving than traditional titanium production processes generating powders for additive manufacturing, as it reduces oxides in the solid state rather than being a melting technology.
As well as focusing upon capacitor grade tantalum powders; aluminium scandium alloys for semiconductors and lightweight structural applications, the development of refractory alloys such as niobium hafnium alloy (C103), and having an expertise in titanium, Metalysis also specialises in high-entropy alloys.
Nitesh Shah, Metalysis’ CEO, said: “Argon recycling achieves another milestone in the Metalysis sustainability story. We are already a highly energy-competitive process when compared to conventional melting technologies, while our ability to create lightweight alloys furthers the sustainability agenda of our end users.