The paper analyzes the existing technologies of metallurgical production with minimal harmful effects on the environment. Emissions of carbon dioxide into the atmosphere can be eliminated using hydrogen as a reducing agent with iron oxide. The best results are realized when hydrogen is produced by electrolysis of water, but such technologies require serious investments. More realistic in terms of creating “green” technologies in metallurgical production is to reduce the consumption of natural gas, capture waste gases of metallurgical production and use them to produce electricity and new types of products: methanol, synthetic alcohol, fertilizers and polymers. An integral part of “green” technologies is also the implementation of the NoWASTE concept, aimed at minimizing waste to be disposed of. Examples of non‑waste technologies for the processing of aluminum waste at OOO NPF Metallon are given.

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It is shown that the amount of flux used in melting significantly influences the composition and volume of dust and gas emissions. Based on the results of the chemical analysis of dust a solution was adopted for the fluxless melting of aluminum waste. In this case, the proportion of chlorine-containing compounds is 1.4% at 75% of aluminum oxides, which makes it possible to use the formed dust to produce a deoxidizing mixture or a refiner slag. On the basis of balance melting, it is shown that with fluxless melting of aluminum waste, a waste-free processing technology is realized, ensuring ecological and economic effects.

The physicochemical interactions between components in the Al/SiO2aluminum matrix compositions under various temperature conditions of processing are studied. The synthesis of aluminum oxide ceramics in aluminum melts for the production of particulate reinforced Al-Si/Al2O3alloys was performed. The addition of dispersed particles of silicon oxide ceramics was carried out by mixing into aluminum melt in a liquid-solid state. At the temperature-time processing of the Al/SiO2compositions, alumina ceramic with a contact surface layer providing spontaneous wetting with liquid aluminum is realized.

The paper presents the results of research on the melting of aluminum chips and slag in a short-flame rotary furnace. Variants of the use of secondary waste products for out-of-furnace treatment of steel in the form of deoxidizers and diluents of refining slag are suggested.