The term downcycling is often used anecdotally to describe imperfections in recycling. However, it is rarely defined. Here, we identify six meanings of the term downcycling as used in scientific articles and reports. These encompass the material quality of reprocessed materials, target applications, product value, alloying element losses, material systems, and additional primary production. In a proposal for harmonized and more specific terminology, we define downcycling as the phenomenon of quality reduction of materials reprocessed from waste relative to their original quality. We further identify that the reduced quality can express itself thermodynamically, functionally, and economically, covering all perspectives on downcycling. Dilution, contamination, reduced demand for recycled materials, and design‐related issues can cause those downcycling effects. We anticipate that this more precise terminology can help quantify downcycling, keep materials in the loop longer, use materials more often and at higher quality, and therefore assist in reducing material‐related environmental impacts.

Better quality control for alloy manufacturing and sorting of post-consumer scraps relies heavily on the accurate determination of their chemical composition. In recent decades, analytical techniques, such as X-ray fluorescence spectroscopy (XRF), laser-induced breakdown spectroscopy (LIBS), and spark optical emission spectroscopy (spark-OES), found widespread use in the metal industry, though only a few studies were published about the comparison of these techniques for commercially available alloys. Hence, we conducted a study on the evaluation of four analytical techniques (energy-dispersive XRF, wavelength-dispersive XRF, LIBS, and spark-OES) for the determination of metal sample composition. It focuses on the quantitative analysis of nine commercial alloys, representing the three most important alloy classes: copper, aluminum, and steel. First, spark-OES is proven to serve as a validation technique in the use of certified alloy reference samples. Following an examination of the lateral homogeneity by XRF, the results of the techniques are compared, and reasons for deviations are discussed. Finally, a more general evaluation of each technique with its capabilities and limitations is given, taking operation-relevant parameters, such as measurement speed and calibration effort, into account. This study shall serve as a guide for the routine use of these methods in metal producing and recycling industries.

This study outlines a recycling initiative conducted at Rekular GmbH, focusing on the recycling of 100 refrigerators. The recycling process employed a combination of manual dismantling, depollution, and mechanical processing techniques. Manual dismantling followed a predefined protocol to extract various materials, while the mechanical and physical processes involved shredding, zigzag, magnetic, and eddy current separation (ECS) to liberate and separate different materials. The resulting ferrous, non-ferrous and polymer product fractions were analyzed and categorized, providing valuable insights into the quality of interim products in the refrigerator recycling process. Simulations were then performed using FactSage^TM version 8.2 and HSC Chemistry 10 version 10.3.7.1 software to simulate the recovery of metals from the ferrous and non-ferrous fractions using pyro metallurgical and hydrometallurgical methods. An electric arc furnace (EAF) was utilized for iron (Fe), while a re-smelter process for aluminium (Al), and the black copper route was simulated for copper (Cu) recovery. The recovery rates including metallurgical, mechanical, and physical processes are as follows: Fe (78%), Al (68.4%), and Cu (52.4%). In contrast, the recovery rates through metallurgical processes are as follows: Al (99%), Fe (79%), and Cu (88%). This discrepancy is attributed to losses of these elements resulting from incomplete liberation in mechanical processing. Additionally, a product/centric approach was applied and the recycling index reached 76% for recovery the Al, Cu, and Fe metals in a refrigerator recycling process. Turning to the environmental impact evaluation within the life cycle assessment (LCA), the process unit with the highest emissions per refrigerator in the recycling process was the use of nitrogen during the shredding process, accounting for 3.7 kg CO₂ eq/refrigerator. Subsequently, the consumption of medium voltage electricity from the German grid during mechanical and physical separations contributed to 0.6 kg CO₂ eq/refrigerator. The EAF, and electrolytic refining stages in the metallurgical recovery process also had a notable impact, generating 10.7 kg CO₂ eq/refrigerator.

“Waste is a resource, but not in the correct place” is a widely known proverb among scientists