http://en.wikipedia.org/wiki/Aluminium_smelting Some more info on the aluminum process for those that care to read.

Oh i was curious about the carbon recycling... looks like its not very recyclable http://www.bicycleretailer.com/news/newsDetail/4512.html and then what you need to do for say aluminum http://en.wikipedia.org/wiki/Aluminium_recycling So if you want to be Eco then make your bike out of some kind of metal WakiDesigns

I would say all the "metal" bikes are recyclable... I don't know about carbon bikes. During the process metal is cut, forged, cnc'd so its light industry... it does use electricity to power the machines but probably the same as an office building. The dirty stuff is probably the anodizing and painting but no dirtier then painting your house or changing the oil in your car...make sure you dispose of the crap properly and not down the drain. In the end nothing is totally green... electric cars a powered by electricity that comes normally from coal, oil, nuclear or...but its good to be aware and responsible as much as you can.

I can probably field this one. [jay@banshee] I love 853 and love 893 even more but when i talked to the Reynolds guy they didn't do the 893 in the tube sizes that we need. Also when we look at the BB shell/main pivot forging those parts would be very difficult to machine and break a lot of tools in the process. So if you want to make this bike in steel it would look very very much different and it would actually cost a lot more too. But steel definitely makes some beautiful bikes.

might have been this post you saw http://bansheebikes.blogspot.com/2009/08/why-doesnt-anyone-make-29er-downhill.html