SMS Siemag AG - ALU

Transcrição

SMS Siemag AG - ALU

Official media partner
of 17th Arabal Conference
Special: Aluminium
smelting industry
Achieving maximum
output when insulating electrolysis cells
The new ingot casting
plant at Trimet Aluminium
Amag
New melting and casting
furnace increases Amag’s
casthouse capacity
Volume 89 · July/August 2013
International Journal for Industry, Research and Application
CRU Conference 2013:
Key turning point
7-8
Sawing and Packing Plants
State-of-the-art BilletPr ocessing
Leading technology in the aluminum casthouse.
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Weinbergerstrasse 6
5280 Braunau, Austria
Phone: +43 7722 806-0
Fax:
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E-mail: [email protected]
Internet: www.hertwich.com
EDITORIAL
Volker Karow
Chefredakteur
Editor in Chief
Die Musik spielt in
Asien und am Golf
Asia and the Golf
region are where
it’s all happening
ALUMINIUM · 7-8/2013
Die jüngsten Quartalszahlen von Alcoa, speziell das operative Ergebnis, fielen besser aus
als von vielen Analysten erwartet – trotz des
anhaltenden Abwärtstrends bei den Aluminiumnotierungen. Was auf der Hüttenseite
belastet, wird in der Verarbeitung offenbar
überkompensiert. Der Konzern berichtet von
einer starken Nachfrage aus der Luftfahrt-,
Automotive- und Verpackungsindustrie. Auf
der Hüttenseite reagiert das Unternehmen,
wie andere Flagschiffproduzenten à la Rusal
und Chalco, mit Produktionskürzungen und
der Schließung von Werken. Über die bereits
brach liegenden Kapazitäten von einer halben Million Jahrestonnen hinaus prüft Alcoa
weitere Produktionsstilllegungen fast in gleicher Höhe. In der Baie-Comeau-Hütte in
Kanada werden zwei Søderberg-Linien bis
September stillgelegt, in Italien wird die Fusina-Hütte bei Venedig endgültig geschlossen.
Letzteres wirft erneut die Frage nach der
langfristigen Zukunft europäischer Hütten
auf, sollte aber nicht überbewertet werden,
diese Frage begleitet die europäische Aluminiumindustrie seit mehr als zwei Jahrzehnten.
Ohnehin sind die Produktionskosten, insbesondere die Stromkosten für Aluminiumhütten in den EU-Ländern recht unterschiedlich,
sodass die Frage nach der Zukunft der europäischen Hütten nicht pauschal beantwortet
werden kann. Immerhin handelt es sich allein
in Westeuropa um eine Jahresproduktion von
3,6 Mio. Tonnen Primäraluminium.
Die Erweiterung und der Neubau von
Hütten, das zeigt sich seit Jahren, findet vor
allem in China und den Golfstaaten statt.
China ist Selbstversorger, modernisiert seit
Jahren seine Hüttenstruktur, mustert kleine
und technologisch veraltete Betriebe aus
und ersetzt sie durch große, energieeffiziente Produktionsanlagen, die internationalen
Standards entsprechen. Möglicherweise entscheidet sich China dereinst, Hütten außerhalb der Landesgrenzen zu bauen oder sich
an entsprechenden Projekten zu beteiligen,
zumal rohstoff- und energieseitig Engpässe
bestehen. Von den großen Hüttenbetreibern
im Land wird eine Rückwärtsintegration in der
Wertkette erwartet, um sich beim Bauxit und
Oxid abzusichern.
Am Golf schreitet der Kapazitätsausbau
weiter voran. Er zielt, vorerst noch, stark auf
den Export und die Versorgung Asiens, aber
auch Amerikas und Europas mit Primäraluminium. Doch etabliert sich am Golf Schritt
für Schritt eine Downstream-Industrie. Die
Arabal-Konferenz im November in Abu Dhabi
wird ein Schlaglicht auf die Region und ihre
Entwicklungstendenzen werfen. Darauf darf
man gespannt sein.
Despite the continuing downward trend in
aluminium prices, the latest quarterly figures
from Alcoa were better than many analysts
had expected, especially operating income.
Difficulties on the smelter side (upstream) are
apparently being overcompensated for by the
processing side (downstream): the company
reported strong demand from the aerospace,
automotive and packaging industries. Upstream the company reacted à la Rusal and
Chalco and made cuts in production and closed
plants. Despite having already mothballed capacity totalling half a million tonnes a year,
Alcoa is now considering further production
closures of almost the same magnitude. Two
Søderberg lines at the Baie-Comeau smelter
in Canada will be shut down until September
and the smelter at Fusina near Venice in Italy
has been closed permanently.
The latter again raises the question of the
long-term future of European smelters but
too much should not be read into this: it is a
question that has been dogging the European
aluminium industry for more than two decades. Production costs, and especially electricity costs, differ quite markedly in the different
EU countries so that the question of the future
of European smelters cannot be answered in
a wholesale manner. After all, in Western Europe alone we are talking about some 3.6m
tonnes of primary aluminium a year.
It has been apparent for some years that
the expansion of existing smelters and the
erection of new ones are mainly taking place
in China and the Gulf Arab states. China is
self-sufficient in aluminium: production and
consumption are balanced to a large extent. It
has been modernising its smelter capacity for
years and is taking small and technologically
obsolete smelters out of service and replacing
them with large, energy-efficient production
plants that are on a par with international
standards. Someday China will possibly decide to build smelters beyond its borders or
participate in such projects, especially as there
are bottlenecks where raw materials and energy are concerned. The country’s large smelter
operators are expected to undertake a backward integration in the value chain in order
to safeguard supplies of bauxite and alumina.
The expansion of smelter capacity in the
Gulf Arab states is continuing apace and is
strongly oriented, at least at first, at exports
and supplying primary aluminium to Asia as
well as the USA and Europe. However, the
Gulf region is steadily establishing a downstream industry. The Arabal conference in
Abu Dhabi in November will highlight the
region and developments there. We can look
forward to that with anticipation.
3
I N H A LT
EDITORIAL
Di e Mu s i k s p i e l t i n As i e n u n d a m Go l f
A s i a a n d t h e Go l f re gi o n a re wh e re i t ’s a l l h a p p e n i n g ........................ 3
A KT U E L L E S • N E W S I N B R I E F • E V E N TS
A ma g s ch l i e ß t Gro ß ve rt ra g mi t E ADS
A ma g s i gn s ma jo r c o n t ra c t wi t h E ADS .......................................... 6/ 7
18
G DA s ch re i b t Al u -Dru ckgu s s -We t t b e we rb 2 014 a u s
I n t e rn a t i o n a l Al u mi n i u m P re s s u re Di e Ca st i n g Co mp e t i t i o n 2014 ....... 6/ 7
G e org Fi s ch e r re c e i ve s ma jo r o rde r fro m Au di ................................... 7
Hermann-Josef Hanny Vorsitzender des GDA-Fachverbands Alurecycling ... 8
Tr i m e t vo r Ü b e rn a h me z we i e r Al u mi n i u mwe rke i n Fra n k re i ch ............... 8
M a g n a e rh ä l t Su p p l i e r In n ova t i o n Awa rd vo n BMW ........................... 8
M uba da l a a n d ICD e st a b l i s h E mi ra t e s Gl o b a l Al u mi n i u m ..................... 9
E m al c e l e b ra t e s i n st a l l a t i o n o f st e e l st ru c t u re fo r P h a s e II potline ........ 9
E uro p e a n Al u mi n i u m Co n gre s s 2 013 – Th e p ro gra mme i s read y ......... 10
30
I C EB – In t l Co n fe re n c e o n E x t ru s i o n a n d Be n ch ma rk ........................ 10
Metef 2014 aiming to add new field of excellence to Italy’s three Fs ..... 11
A l umi n i u m Ch i n a 2 013 c e l e b ra t e s re c o rd a t t e n da n c e ........................ 11
WIRTSCHAFT • ECONOMICS
A l umi n i u mp re i s e ......................................................................... 12
Pro d u k t i o n s da t e n de r de u t s ch e n Al u mi n i u mi n du st ri e ......................... 14
„ M et a l l e p ro K l i ma “ -Ve ra n st a l t u n g b e i O t t o Fu ch s :
44
K l i ma s ch u t z du rch e n e rgi e e ffi z i e n t e P ro du k t i o n ............................... 16
S M S gro u p 2 012 : Au ft ra gs e i n ga n g z u rü ckge ga n ge n –
U m sa t z ge st i e ge n – st a b i l e s E rge b n i s • SMS gro u p i n
2 012: l owe r o rde r i n t a ke – h i gh e r s a l e s – st a b l e re s u l t .....................18
CR U ’s Wo rl d Al u mi n i u m Co n fe re n c e 2 013
i n L o n do n : Ke y t u rn i n g p o i n t s ..................................................... 22
New alumina project approach – dedicated design, compact capacity .. 24
L a g e de r Sch we i z e r Al u mi n i u mi n du st ri e we i t e rh i n a n ge s p a nnt ........... 29
52
ALUMINIUMHÜTTENINDUSTRIE
A L U M I N I U M S M E LT I N G I N D U S T R Y
Pr i ma ry a l u mi n i u m i n du st ry du ri n g t h e fi rst h a l f o f 2 013 , Par t I ......... 30
Latest News
www.alu-web.de
4
Ke op s Te ch n o l o gi e s de p l o ys a n e w
st an da rd a l u mi n i u m s me l t e r ME S s o l u t i o n .......................................37
„ Duro de n s e “ – Al u mi n i u mox i d-Fö rde rt e ch n o l o gi e fü r Du b a l erf olgreich
CONTENTS
i n B e t r i eb gen o mme n • ‘ Duro d e n s e’ – A l u mi n a fe e di n g
t ech n ol ogy su c c e s s f ul l y c o mmi s s i o n e d at Du b a l ............................... 38
O pt i m i sa t i on o f g rai n re f i n e m e n t i n a
ra n g e of ca st h o us e al umi n i um al l o ys . . . . . . ....................................... 40
Ach i e v i n g m a x i m um o ut p ut w h e n i n s ul at i ng e l e c t ro l ys i s c e l l s ............ 42
Di e neu e M a ss e l g i e ß an l ag e d e r Tr i me t A l u mi n i u m i m We rk
Esse n ra ng e of c ast h o us e a l um i n i um a l l o y s • Th e n e w i n go t
c a st i ng pl a nt a t t h e E s s e n wo r ks o f Tr i m e t Al u mi n i u m ...................... 44
56
T E CH N O LO G I E • T E CH N O LO GY
N eu e r S chm e l z - un d G i e ß o f e n d e r A ma g e rh ö h t Gi e ß e re i k a p a z i t ä t
New melting and casting furnace increases Amag’s casthouse capacity . 48
Al coa f u r t h er e x t e n d s s h e e t c a p a c i t y . . . . . . ........................................50
B esu cher woch e b e i A ch e n b a ch B us ch h üt t en
Vi si t or s’ we ek at A ch e n b a ch B us ch h üt t e n ........................................52
K a m pf e röf f n e t n e ue M o n t ag e h a l l e n a m St a n do rt Mü h l e n
K a m pf open s n e w a s s e mb l y h a l l s a t t h e Mü h l e n s i t e .........................54
62
HP I er r i cht e t Ho r i z o n t a l - S t ra n g g i e ß a n l a g e i n Sh a n gh a i ......................55
Al u m e c se t z t auf um we l t s ch o n e n d e n Ko r ro s i o n s s ch u t z
Alumec adopts to ecologically sound corrosion protection technology ....56
This issue contains
an enclosure from
R ecycl i n g of wro ug h t al umi n i um al l o ys f ro m p o st -c o n s u me d s c ra p ......58
Dryplus process drastically reduces sludge volumes from anodising lines ... 61
P rä z i se r S chn i t t aus A l umi n i um b l ö cke n . . . ........................................62
N ovel i s ü ber wa ch t M as ch i n e n s ch w i n g un g en mi t Co n di t i o n
Moni t or i n g vo n i b a • Novelis monitors machine vibrations with
GDA Gesamtverband
der Aluminiumindustrie
to which we draw
your kind attention.
iba Condition Monitoring . . . . . . . . . . . . . . . . . . . . . . ........................................63
C O M PA N Y N E W S W O R L D W I D E
Al u m i n i u m sme l t i n g i n d ust r y . . . . . . . . . . . . . . . . . ........................................66
B a u x i t e a n d a l um i n a ac t i vi t i e s . . . . . . . . . . . . . . . ........................................67
Seconda r y sm e l t i n g a n d re c yc l i n g . . . . . . . . . . ........................................68
Al u m i n i u m sem i s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................69
O n t h e m ove, S up p l i e r s . . . . . . . . . . . . . . . . . . . . . . . . ........................................70
D O C U M E N TAT I O N
Inserenten dieser Ausgabe
List of advertisers
ABB Switzerland
33
Coperion GmbH, Germany
37
Didion International Inc., USA
25
Dubai Aluminium, UAE
15
Emirates Aluminium, UAE
13
ECL, France
39
FLSmidth Hamburg GmbH, Germany
35
Hertwich Engineering GmbH, Austria
2
Inotherm Industrieofen- und
Wärmetechnik GmbH, Germany
11
Innovatherm Prof, Dr. Leisenberg
GmbH & Co. KG
31
Kasto Maschinenbau GmbH & Co. KG
29
I m pressu m • I mp r i n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................90
Messe Essen GmbH, Germany
21
Vor scha u • P re vi e w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................90
Micro-Epsilon Messtechnik
GmbH & Co. KG, Germany
19
Outotec, Germany
91
Pa t en t e . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................72
L I E F E R V E R Z E I C H N I S • S U P P L I E R S D I R E C T O R Y ............. 76
SDV-Santioli AG, Switzerland
41
SMS Siemag AG, Germany
92
5
AKTUELLES
Der Gesamtverband der Aluminiumindustrie
(GDA), Düsseldorf, schreibt den internationalen Wettbewerb für Aluminium-Druckguss
2014 aus. Partner bei der Durchführung des
Wettbewerbs sind der Bundesverband der
Deutschen Gießereiindustrie (BDG) und die
European Aluminium Association (EAA). Einreichungen für den Wettbewerb sind bis zum
31. Oktober 2013 möglich.
Der Wettbewerb ist seit vielen Jahren eine
bewährte Plattform, um die hohe Qualität
von Aluminium-Druckgussteilen aufzuzeigen.
Bisher wurde der Wettbewerb vom Verband
der Aluminiumrecycling-Industrie (VAR) durchgeführt, der zum 1. April 2013 als Fachverband
Aluminiumrecycling in den GDA aufgegangen
ist. Der Fachverband Aluminiumrecycling wird
zunächst das bisherige Leistungsspektrum des
VAR erhalten und mittelfristig weiter ausbauen. Hierzu gehört auch der Aluminium-Druckguss-Wettbewerb.
Kriterien für die Bewertung der teilnehmenden Gussstücke beim Wettbewerb 2014
sind die druckgussgerechte Konstruktion und
die Verwendung von Recyclingaluminium. Gießereien können beliebig viele Gussstücke einreichen. Das Gussteil sollte aus einer gängigen
Aluminiumgusslegierung hergestellt sein. Die
Gussteile, die den Anforderungen an Qualität,
Aktualität, innovative Lösungsansätze und
technischen Fortschritt entsprechen, werden
durch Urkunden ausgezeichnet.
Die Preisverleihung der besten Einsendungen erfolgt anlässlich der Euroguss 2014
(14. bis 16. Januar 2014) in Nürnberg. Die
prämierten Gussstücke werden dort und auf
weiteren Messen ausgestellt.
Die Wettbewerbsunterlagen können auf
den Websites der Verbände in deutscher und
englischer Sprache heruntergeladen werden:
www.aluinfo.de, www.bdguss.de
Produktion von Alufolie
legt auf breiter Front zu
Erstmals seit Mitte 2011 ist die Produktion
von Alufolie wieder in allen Dickenbereichen
gestiegen. Wie der europäische Alufolienverband EAFA mitteilte, legte die Produktion im
ersten Quartal dieses Jahres insgesamt um 3,7
Prozent auf 209.400 Tonnen zu (2012: 201.900
t). Auch der Export der europäischen Hersteller stieg um 10,3 Prozent an. Damit konnte
das Momentum von Ende 2012 in das erste
Quartal dieses Jahres mitgenommen werden.
6
Amag schließt Großvertrag mit EADS
Die Amag Austria Metall AG mit Sitz im österreichischen Ranshofen ist zum 1. Januar 2013
einen Großvertrag mit EADS eingegangen,
der die Lieferung von Aluminiumplatten und
-blechen für die Fertigung von Struktur- und
Außenhautteilen vorsieht. Das Auftragsvolumen beträgt bis zu 100 Mio. Euro. Die mehrjährige Vereinbarung umfasst die Lieferung
von Platten, Blechen und Bändern für alle
aktuellen Airbus-Flugzeugtypen.
Der Amag-Standort wird derzeit mit einem
Investitionsvolumen von 220 Mio. Euro ausgebaut, um vor allem das Geschäft im Transportbereich (Luftfahrt und Automobil) und
Leichtbau weiterzuentwickeln. Mit der Investition erweitert das Unternehmen sein Portfolio zu größeren Dicken und Breiten auch für
hochfeste Produkte in der Luftfahrtindustrie.
Für Amag-Chef Gerhard Falch ist der Auftrag
„ein weiterer Beweis für unsere hohe Kompetenz in der Luftfahrt.“ Beide Unternehmen
arbeiten bereits seit 2005 zusammen.
Aluminium ist nach wie vor der bevorzugte Basiswerkstoff in der Luftfahrt. Marktprognosen von Airbus zufolge werden bis 2031
mehr als 28.000 neue Passagier- und Frachtflugzeuge gebaut. Diese Zahl unterstreicht
die langfristigen Wachstumsaussichten für
die Luftfahrtindustrie und damit auch für den
Aluminiumbedarf. Das Marktforschungsinstitut CRU erwartet ein beständiges Wachstum
des Verbrauchs von Aluminiumwalzprodukten in der Luftfahrtindustrie von derzeit
390.000 Tonnen auf 536.000 Tonnen im Jahr
2017 allein für Nordamerika und Europa.
Durch die Investition in das neue Walzwerk
in Ranshofen schafft Amag die Voraussetzungen, um am wachsenden Alubedarf in der
Luftfahrtindustrie zu partizipieren.
© Amag
GDA schreibt Alu-DruckgussWettbewerb 2014 aus
Amag-Luftfahrtplatten bei der Ultraschall-Prüfanlage, die eine mehrfach schnellere Qualitätsprüfung
erlaubt
Die Bedeutung dieses Geschäftes für Amag
spiegelt sich auch darin wider, dass das Unternehmen auf der 50. Paris Air Show in Le
Bourget im Juni ihr Produktportfolio an hochfesten Blechen und Platten für die Luftfahrtindustrie der Fachwelt präsentierte.
Oetinger insolvent
Das Aluminiumschmelzwerk Oetinger mit
Standorten in Weißenhorn, Neu-Ulm, Hannover und Berlin hat Insolvenz angemeldet.
Zum vorläufigen Insolvenzverwalter wurde
der Düsseldorfer Rechtsanwalt Frank Kebekus
bestellt, der in der Sanierung von Aluminiumfirmen erfahren ist. Seine Aufgabe ist nun, Investoren zu finden um das Schmelzwerk mit
seinen 500 Arbeitsplätze zu retten.
Der Betrieb des Unternehmens wird derzeit
aufrechterhalten, Aufträge seien vorhanden,
zitiert die Regionalpresse Günter Frey von der
Gewerkschaft IG Metall. Probleme bereiteten
die niedrigen Preise für Gussteile aus Aluminium, die das Unternehmen vor allem an die
Automobilindustrie liefert. Als eine Ursache
dafür werden die darbenden Schmelzwerke
in Südeuropa ausgemacht, die angesichts freier Kapazitäten sehr niedrige Preise anbieten
können.
Oetinger zählt zu den größten Herstellern
von Aluminium-Gusslegierungen in Europa.
Der Standort in Gorcy in Frankreich ist von
der Insolvenz nicht berührt.
NEWS IN BRIEF
Amag signs major
contract with EADS
Amag aerospace plates at the ultrasonic inspection line where quality testing is completed several
times more quickly
Amag Austria Metall AG, based in Ranshofen,
Austria, concluded a multi-year contract with
EADS, effective 1 January 2013, for the supply of aluminium plate and sheet to manufacture structural and skin components. The order
volume is up to 100 million euros. The agreement covers the supply of aluminium plate,
sheet and strip for all current Airbus aircraft
types.
The Austrian factory is being expanded,
with an investment of 220 million euros,
primarily to drive the commitment in transportation (aircraft and automotive) and lightweight construction. The investment is aimed
at extending Amag’s portfolio to include
larger thicknesses and widths also for highstrength products for the aircraft industry.
Amag CEO Gerhard Falch commented: “This
order is further proof of our high level of expertise in products for the aircraft industry.
Amag and EADS have been cooperating since
2005.
Aluminium continues to be the preferred
principal material for aircraft applications.
According to Airbus’ market forecasts, the
demand for aircraft will rise to more than
28,000 new passenger and cargo planes by
2031. This forecast underlines the long-term
growth prospects for the aircraft industry. The
market research institute CRU (Commodity Research Unit) expects the consumption
of aluminium flat rolled products in the aircraft industry to steadily grow from currently
390,000 to 536,000 tonnes in 2017 in North
America and Europe. Due to the investment
in the new rolling mill, Amag is ideally positioned to participate in the growing consumption of aluminium in the aircraft industry.
As the aircraft business is of growing importance to Amag, the company presented its
product portfolio of high-strength sheet and
plate destined for the aircraft industry at the
50th International Paris Air Show at Le Bourget in June.
Georg Fischer receives major order from Audi
GF Automotive, a division of Georg Fischer,
has been awarded a major order from Audi,
worth more than CHF400 million. The light
structural parts for the German car manufacturer will be produced by aluminium pressure
die casting in Europe and China starting in the
next few years.
The order comprises suspension strut
domes, which will be built into several new
Audi models and replace conventional welded
sheet metal assembling. The new design features a better functionality and a much lower
number of components resulting in a weight
reduction of over 50 percent.
Ten production sites worldwide
GF Automotive, located in Switzerland, is
one of the leading automotive suppliers
worldwide and a development partner and
manufacturer for the automotive industry. It
manufactures some 600,000 tonnes of iron,
aluminium and magnesium at ten production
plants in Germany, Austria and China.
International Aluminium Pressure Die Casting Competition
The German Aluminium Association GDA announces the International Aluminium Pressure
Die Casting Competition 2014. Partners in
organising the competition are the Federation
of the German Foundry Industry (BDG) and
the European Aluminium Association (EAA).
Submissions to the competition can be made
until 31 October 2013.
For years the competition has been a
proven platform for showing off the high
standard of quality in aluminium pressure
die casting. The goal of the competition is to
strengthen interest in aluminium as versatile
working material and to demonstrate new
areas of application. Until now the aluminium
pressure die casting competition was held by
the German Association of the Aluminium
Recycling Industry (VAR), which disbanded in
March. As of 1 April the GDA puts its aluminium recycling division into action. Initially, they
will continue the former programme of activities of VAR, and expand it in the mid term.
This includes the die casting competition.
The evaluation criteria for cast pieces submitted to the competition include a proper
die cast construction and the use of recycled
aluminium. Foundries can submit any number
of die cast pieces, which should be made of
an aluminium alloy commonly used in die
casting. Pieces which meet the requirements
on quality, topicality, innovative approaches to
solving problems and technical advancement
will receive awards.
The award ceremonies for the best submissions will take place at Euroguss 2014 (14
to 16 January) in Nuremberg. The winning
pieces will be exhibited there and at other
trade fairs.
Competition forms can be downloaded in
German and English from the websites of the
associations: www.aluinfo.de, www.bdguss.de
Alufoil sees production
growth on all fronts
First quarter 2013 figures for aluminium foil
showed growth across all gauges for the
first time since mid-2011. Overall first quarter
production grew by 3.7% to 209,400 tonnes
(2012: 201,900 t). Meanwhile exports from
European manufacturers maintained the momentum seen in the later part of 2012 with
a first quarter growth of 10.3%, according to
figures released by the European Aluminium
Foil Association (EAFA).
7
AKTUELLES
Hermann-Josef Hanny (46), Commercial
Director Foundry Alloys und Bereichsleiter
Gusslegierungen bei der Aleris Recycling
(German Works) GmbH, Grevenbroich, ist
neuer Vorsitzender des Fachverband Aluminiumrecycling im Gesamtverband der Aluminiumindustrie (GDA), Düsseldorf.
Diplom-Kaufmann Hanny hat langjährige
Erfahrungen in der Aluminiumrecycling-Industrie und im Metallhandel. In den vergangenen 15 Jahren war er unter anderem bei
Bayer, Agfa-Gevaert, VAW-Imco, Honsel International Technologies und bei Oetinger in
diesem Marktbereich in verantwortlicher Position tätig.
Der GDA hat den Fachverband Aluminiumrecycling im April 2013 aktiviert. Mitglieder im Fachverband sind unter anderem
die Mitgliedsunternehmen des Verbandes der
Aluminiumrecycling-Industrie (VAR), der sich
zum 31. März 2013 aufgelöst hat. Die Aktivierung des neuen Fachverbands erfolgt vor
dem Hintergrund der wachsenden Bedeutung
des Aluminiumrecyclings, das in Deutschland
und Europa als Rohstoffquelle immer wichtiger wird. Um den Rohstoff in Deutschland
noch intensiver zu verwerten, investieren
deutsche Aluminiumbetriebe in den Ausbau
der Recyclingkapazitäten und greifen dabei
auf modernste Anlagentechnik zurück. Angesichts des fortschreitenden Abbaus von Hüttenkapazitäten in der EU wird die Nachfrage
nach Recyclingmaterial weiter wachsen.
Trimet vor Übernahme zweier
Aluminiumwerke in Frankreich
Trimet Aluminium hat ein verbindliches Angebot abgegeben, um zwei Produktionswerke
in Frankreich von Rio Tinto Alcan (RTA) zu
übernehmen. Mit der Übernahme der Aluminiumwerke in Saint-Jean-de-Maurienne und
Castelsarrasin will das Unternehmen weiter
wachsen und sein Portfolio spezialisierter
Produkte aus Leichtmetall erweitern. Die
mit RTA getroffene Vereinbarung sieht eine
Kooperation mit dem französischen Energieversorger EdF (Électricité de France) vor und
muss noch von den Aufsichtsbehörden genehmigt werden.
Während es sich bei dem Werk Saint-Jeande-Maurienne um eine Aluminiumhütte mit
einer Produktionskapazität von 140.000 Jahrestonnen handelt (RTA-Produktion 2012:
93.000 t), stellt das Werk Castelsarrasin Gießwalzdraht her (RTA-Jahresproduktion 8.000
t), der unter anderem zu elektrischen Leitungen in der Energiewirtschaft und zu Verbindungselementen in der Automobilindustrie
weiterverarbeitet wird. Die Hütte beschäftigt
480 Mitarbeiter, das Gießwalzdrahtwerk 35
Mitarbeiter.
„Die Standorte fügen sich hervorragend in
die strategische Ausrichtung der Trimet ein.
Die Konditionen der Übernahme erlauben
uns zudem eine verlässliche und langfristige
Investitionsplanung“, erklärte Heinz-Peter
Schlüter, Inhaber und Vorsitzender des Aufsichtsrates der Trimet Aluminium SE.
Die Übernahmevereinbarung sichert laut
Trimet die langfristige Versorgung mit Toner-
© Trimet
Hermann-Josef Hanny
Vorsitzender des GDAFachverbands Alurecycling
Die Essener Trimet-Gießerei hat Mitte Juni die
siebenmillionste Tonne Aluminium seit Bestehen
des Werks gegossen. Das „Jubiläums“-Aluminium
wurde als hochspezialisierter Walzbarren an den
langjährigen Kunden Constellium Singen geliefert.
Das Foto zeigt Trimet-Chef Martin Iffert (links) und
Robert Gabor, verantwortlich für Metallbeschaffung
bei Constellium Singen.
de (Aluminiumoxid) und elektrischem Strom,
den für die Aluminiumproduktion essenziellen Grundstoffen. Laut RTA wird Trimet eine
Mehrheitsbeteiligung von 60 Prozent an den
Produktionswerken halten, EdF übernimmt
35 Prozent der Anteile und die staatliche französische Fonds Stratégique d’Investisse (FSI)
fünf Prozent der Anteile.
Martin Iffert, Vorsitzender des Vorstands
der Trimet Aluminium, sagte: „Bei der weiterverarbeitenden Industrie in Europa besteht
ein großer Bedarf an Aluminiumdraht. Als
Anbieter komplexer Legierungen und maßgeschneiderter Lösungen stärken wir mit
dieser Produktgruppe auch langfristig unsere
Kernkompetenz als Spezialitätenanbieter.“
Magna erhält Supplier Innovation Award von BMW
Die Magna BDW technologies GmbH hat als
einer von acht Zulieferern den BMW Supplier Innovation Award für herausragende
Leistungen im Bereich Innovation und Entwicklung erhalten. Die BMW Group hat diesen Preis ihren Lieferanten 2013 zum zweiten
Mal verliehen und in München überreicht.
BDW technologies ist eine in Markt-Schwaben ansässige Einheit von Cosma International – der Gruppe, die im Magna-Konzern für
Karosserien zuständig ist. Sie bekam die Auszeichnung in der Kategorie „Leichtbau“ für
ein aus Aluminium gegossenes Hochvoltspeicher-Gehäuse für Batterien. Cosma ist es gelungen, eine Vielzahl komplexer Funktionen
in einem Bauteil zu vereinen und somit das
Gewicht der Batterie deutlich zu reduzieren.
8
Außerdem konnte der Produktionsprozess
um einige Schritte verschlankt werden.
Für die BMW Group sind die innovativsten
Zulieferer wichtige Partner, die bei der erfolgreichen Umsetzung neuer Entwicklungen eine
entscheidende Rolle spielen. Der Supplier Innovation Award wurde konzipiert, um diese
Leistungen zu würdigen.
Hauptgeschäftsführung
des BDG neu aufgestellt
Christian Wilhelm (56) ist seit dem 1. Juli
neues Mitglied in der Hauptgeschäftsführung
des Bundesverbandes der Deutschen Gießerei-Industrie (BDG), wo er den Bereich Tech-
nik übernimmt. Er war zuvor langjähriger Mitarbeiter der Mannheimer Eisengießerei von
Mercedes-Benz, zuletzt leitete er das Kompetenzzentrum Gießerei und war zugleich stellvertretender Gießereileiter.
Er übernimmt das Ressort von Erwin Flender, der interimsweise die technische Hauptgeschäftsführung des BDG seit April 2012 innehatte. Flender ist seit Oktober 2012 auch
Präsident des BDG und wird weiterhin die
Geschäftsführung des Vereins Deutscher
Gießereifachleute (VDG) wahrnehmen. Max
Schumacher leitet den Bereich Wirtschaft und
ist zum 1. Juli zum Sprecher der BDG-Hauptgeschäftsführung berufen worden. Gerhard
Klügge bleibt weiterhin für den Bereich Finanzen zuständig.
NEWS IN BRIEF
Mubadala and ICD establish Emirates Global Aluminium
the new company will look to expand along
the value chain, from aluminium smelting to
alumina refining and bauxite mining overseas.
Given its scale, Emirates Global Aluminium
will also continue to attract downstream manufacturing and ancillary businesses related to
aluminium smelting and alumina refining as it
grows, thereby indirectly creating additional
jobs.
Emirates Global Aluminium will be managed by a board of directors that will be chaired
by H. E. Khaldoon Khalifa Al Mubarak, current chairman of Emal, while H. E. Saeed Mohammed Ahmed Al Tayer, vice-chairman of
Dubal, will become its vice-chair. The board
will also include H. E. Sultan Al Jaber, Abdulla
Kalban, Khaled Al Qubaisi, Ahmed Yahia Al
Idrissi, Abdul Wahed Mohammad Al Fahim;
and Khalid Al Bakhit.
The new company will be led by two wellestablished leaders in the UAE, both veterans
in the aluminium industry. Abdulla Kalban,
president and CEO of Dubal with 28 years
of experience, will be managing director and
CEO; and Saeed Al Mazrooei, president and
CEO of Emal and leader of its rise in the industry, will become CEO of UAE Operations.
“The creation of a new global industrial champion anchored in the UAE is an important
step towards realising our vision for a diversified and sustainable economy. It is especially
inspiring that UAE technology contributed to
the success of this business and that it will continue to be led by UAE Nationals as it grows
locally and globally,” said Al Mubarak, CEO
of Mubadala. “Emirates Global Aluminium
will build on strong foundations of leadership, to become a major industrial champion
and engine of economic development for our
people.”
H. E. Mohammed I. Al Shaibani, the CEO
of ICD, said: “Today’s announcement builds
on what these two outstanding organisations
have created and reflects the UAE’s long-term
industrial strategy. Emirates Global Aluminium will accelerate employment with 2,000
direct jobs being created by 2020 adding to
more than 6,200 direct jobs already in existence. We also conservatively estimate that a
further 6,000 indirect jobs will be generated,
delivering total employment of over 33,000
people by the UAE aluminium sector through
the end of this decade.”
The agreement signed by Mubadala and
ICD unifies the Jebel Ali and Taweelah
smelter assets as well as interests in Guinea
Alumina Corp. and Cameroon Alumina Ltd.
Emal celebrates installation of steel structure
for Phase II potline
Emirates Aluminium (Emal) has recently celebrated the installation of the final steel structure for the potline of its Phase II expansion.
With the last of 120 specially designed steel
structures now in place, all the major civil
and mechanical work on the world’s longest
single potline of 1.7 km is now complete and
Emal remains on target to deliver its ambitious
expansion plans.
The first steel structure was raised in July
last year, which means that completion was
within the anticipated target of 12 months. The
project was also completed without a single
Lost Time Injury (LTI) – the industry standard
for measuring success in health and safety.
Emal’s Phase II expansion project will increase primary aluminium production to 1.3
million tonnes a year by the end of 2014, from
today’s 800,000 tonnes a year. Early works
on the estimated USD4.5 billion Phase II expansion began early in 2011, making Emal one
of the largest industrial projects in the United
Arab Emirates outside oil and gas and one of
the key projects leading to the diversification
of the UAE’s economy.
Emal has created 2,000 jobs with Emiratisation at the core of its employment strategy,
which will rise to approximately 3,000 upon
completion of Phase II.
© Emal
In a move that will form a new industrial giant in the United Arab Emirates, Mubadala
Development Company of Abu Dhabi and the
Investment Corporation of Dubai (ICD) have
announced the creation of Emirates Global
Aluminium – a jointly-held, equal-ownership
company that will integrate the businesses
of Dubai Aluminium (Dubal) and Emirates
Aluminium (Emal) – with plans for significant
local growth and international expansion.
Pending required approvals, the formal commencement of joint operations is expected to
be completed within the first half of 2014.
Emirates Global Aluminium will be the
fifth largest aluminium company by production when Phase II of Emal is completed mid2014, and will serve over 440 customers in 55
countries, with a joint production capacity of
2.4m tpy of aluminium on the completion of
Emal Phase II.
The accord builds on a successful partnership that started with the formation of Emal in
2006, a joint venture of Mubadala and Dubal.
Emirates Global Aluminium will have an aggregate enterprise value of more than USD15
billion and will be the fifth-largest global aluminium company by production once Emal
Phase II is complete in the first half of 2014.
Building on the heritage of Emal and Dubal,
All the major civil and mechanical work on the world’s longest single potline of 1.7 km is now complete
9
EVENTS
European Aluminium Congress 2013 – The programme is ready
The programme for the EAC – European
Aluminium Congress 2013 is ready. The
international congress with its theme
‘Aluminium Automotive
Applications –
Tomorrow’s Design and
Sustainable Performance’
will be held by the German Aluminium Association GDA in Düsseldorf
on 25 and 26 November
2013. The programme
of the EAC 2013 shows
presentations on possible
applications of aluminium
in motor vehicle manufacturing, but also presentations on further developments with potential for
making vehicles of the
future even lighter and
more energy efficient.
Aluminium has become an
indispensable material in the motor car: castings for engine housings, cylinder heads, and
gearbox housings or for structural parts in the
auto body. Today this is state-of-the-art. But
semi-finished products in the form of sheets,
extruded profiles and forgings
are also being used more and
more in vehicles. Some examples of this are car body structural parts, sheets for the outer
shell or crash-related parts,
such as bumper crossbeams or
longitudinal beam structures.
Even more examples can be
found in the form of extruded
profiles used as decorative
strips for visual enhancement,
or as safety related parts in the
area of the chassis.
The increasingly intensive
competition between the different materials has prompted
car manufacturers and aluminium suppliers to work
more closely together. With
its investments in application-oriented research and development, the
aluminium industry has repeatedly improved
the characteristics of its material, developed
new products, and optimised production processes. Innovations in processes and materials
are strong drivers behind the development of
efficient lightweight construction solutions
and their implementation in series production,
such as energy-saving components for chassis,
engine and gearbox.
The EAC congress ‘Aluminium Automotive Applications’ is divided into a total of
five sessions, dealing with the subjects design,
body structure, subframes, process technologies, joining technologies and surfaces as well
as markets, recycling and sustainability. Notable speakers from international companies
will offer information and real-life examples
in all the sessions of the congress.
Conference language is English. All presentations will be simultaneously translated into
German. More information on the congress
website at www.aluminium-congress.com.
Your contact at organiser GDA:
Georg Grumm
Phone: +49 (0)211 4796 160
ICEB – Intl Conference on Extrusion and Benchmark, 8-9 October 2013
The International Conference on Extrusion and Benchmark (ICEB) has become
the biggest event in Europe related to
the recent developments on extrusion
technologies and their analysis by FEM
simulation. The fourth edition is planned
for 8-9 October 2013 in Dortmund, Germany.
ference on the ‘Latest advances in the extrusion of light alloys’ with an industrial worldwide contest: ‘FEM codes Benchmark’.
• In the conference sessions invited papers
from academia as well as from industries will
describe the most recent developments in the
analysis, optimisation and research of the light
alloys extrusion processing.
More than 150 delegates attended the
2011 edition, with participants from over
27 countries including America and the Far
East. With two-thirds of the participants
coming from the industry and with representatives from all the multinationals of
aluminium, a strong interest was evidenced
in getting and sharing knowledge on these
topics of technological frontier. The aim of
the conference is to join together technical
and scientific experts, to widespread their
knowledge and to form an international
community for the discussion of state of
the art, as well as future developments, in
the field of extrusion and in its most powerful
tool, the numerical simulation.
ICEB is a two-in-one event, merging a con-
• In the benchmark sessions, participants
will be asked to simulate the extrusion of an
industrial case (a specially designed die for
emphasising selected process-related issues),
10
on the base of die geometries, material properties, ram speed and tools temperatures, as
they were monitored by the organisers. Only
during the conference the blind simulations
results will be discussed and compared to
the data recorded during experimental trials,
thus allowing a clear and equal comparison
of different FEM codes and simulating approaches.
This two-in-one event provides a unique
opportunity to:
• learn about innovation and simulation
capabilities in the extrusion of light alloys
• get guidelines for best process analysis
and product optimisation
• understand the potential of your current
simulation tool
• have the widest possible range of information on extrusion simulation today.
The conference heads toward extruders
(technicians, R&D divisions, production
managers), extruded profile users, academic and industrial researchers, die makers,
alloys specialists, software houses and software distributors, press and equipment builders. More information at www.ice-b.net. ■
EVENTS
Metef 2014 aiming to add new
field of excellence to Italy’s three Fs
Advertisement
The whole production chain for innovative materials will be presented at Metef 2014: from
primary and secondary production through
to the processing, machining and finishing of
extrusions, castings and rolled products, including surface treatment. The new addition
is expected to meet its ambitious target of covering the whole production chain for aluminium in the transport and transportation sector.
The organisers are hoping 2014 will be a
turning point for Metef. In 2012, Alfin-Edimet
signed a strategic agreement with Veronafiere
that saw Veronafiere acquire a 50% share in
a newly formed company that took over the
assets of Alfin-Edimet. This partnership gave
Metef Foundeq 2012 a global dimension
thanks to the presence of over 500 exhibitors
from 29 countries and of 15,000 visitors, nearly a third from 69 foreign countries. “The 2014
edition will represent the whole Italian aluminium and innovative material production chain
on the international arena, where competitiveness is more and more challenging,” said Veronafiere’s president Ettore Riello at a recent
press conference. “Veronafiere then becomes
a guide for the organisational management of
this exhibition in order to consolidate Metef as
b2b show and to represent the whole Italian
manufacturing sector,” he added.
Italy is world renowned for its three Fs:
fashion, food and furniture. Metef 2014 is
aiming to add a new field of excellence: a customised facility for the aluminium and innovative metals technologies that represent the
core of the country’s manufacturing industry.
This has enabled Italy to develop the design
and manufacturing skills needed to produce
high-value products and tailored solutions.
Mario Bertoli, president of Alfin-Edimet,
stressed that the market had changed; globalisation has altered where many goods are now
being produced and consumed, including in
the metals sector, but he said that this had
not affected Italian excellence. Customised
plants, machinery and technologies are still
Italy’s key strengths; they are well known and
highly regarded all over the world. He added
that Metef has been a major source of sector
growth over the last decade and more than
ever now provides a great opportunity for the
whole production chain to present itself internationally.
Metalriciclo-Recomat focuses on
recycling of industrial materials
Metalriciclo-Recomat will again deal with the
recovery and recycling of industrial materials
and will be offering specialist information on
products, machinery and technologies in this
sector. The show will benefit from Metef’s internationality and Veronafiere’s global organisation and contacts.
Despite the overall decline in the consumption and production of secondary materials in
Alumotive at Metef for first time
The Alumotive exhibition will present innovative solutions, components and technological
materials for original equipment in the transportation sector and will be part of Metef for
the first time in 2014. The show will promote
a sector that in terms of products and number
of employees is one of the traditional strengths
of the manufacturing industry in Italy. It will
be a welcome and useful addition to Metef.
Companies engaged as second and third
tier suppliers will constitute the largest sector
at Alumotive; their fields of activity include
innovative materials, design and production
of components, processing systems, robots,
engineering, mould making, machining and
finishing.
■
Aluminium China 2013 celebrates record attendance
Aluminium China 2013, Asia’s leading aluminium
exhibition, looks back on a record breaking
number of visitors from around the globe at the
Shanghai New International Expo Centre in July.
With 462 exhibitors (121 first-time participants)
from China, Asia and further abroad, the exhibition attracted more than 15,200 visitors, an
increase of 28% over last year. This development
in number of visitors reflects the rich potential
of Asia’s aluminium markets today driven by a
large number of exhibiting industry giants at
the show such as Kobe Steel, Shanghai Jieru,
Novelis, Wagstaff, Qatalum and SMS Group, to
mention just a few.
Aluminium China 2013 also presented two
new feature areas: semi-finished products for
transportation and other key industries, and
packaging products supported by the EAFA’s
Alufoil Trophy Award. Alongside the new
feature areas, the show also launched the Aluminium Downstream Processing Forum, where
the audience gained insights into latest develop-
© Reed Exhibitions China
The Metef trade fair, one of the leading
international events for aluminium and
innovative metals, will be held for the
tenth time from 11 to 13 June 2014 at
the Verona Exhibition Centre in Italy.
It will have a new format: it will be accompanied by Foundeq and MetalricicloRecomat as in previous years but will
include the new Alumotive fair for the
first time.
Italy in recent years, the quantity of recovered
and recycled materials is still high. The growth
in metals and materials recycling in all sectors has led to a significant development of
machinery, systems and technologies made
in Italy for the recovery and recycling of materials. Metef offers the industry’s players an
opportunity to present themselves internationally and open up new business opportunities.
The Metalriciclo-Recomat fair is aimed at
car breakers, metal collection and recovery
companies, scrap users for downstream hot
processing, waste disposers, recycled metal
traders as well as authorities, associations and
institutions involved in the recycling sector.
ments across closely related application sectors.
The EAFA’s display zone was also combined with
a forum on future opportunities for aluminium
packaging applications in China.
11
WIRTSCHAFT
Aluminium im Monatsrückblick
Ein Service der TRIMET Aluminium SE
Die LME 3-Monatsnotierung für High
Grade Aluminium erlebte Mitte Juni an
der LME einen regelrechten Ausverkauf
und rutschte auf ein neues 4-Jahrestief von USD 1.764,50. Gerüchte über
einen drohenden Liquiditätsengpass
Chinas, die Sorge über den Verlauf der
Euroschuldenkrise und die politische Entwicklung im Norden Afrikas sorgten für
die eher hastigen Verkaufsaktivitäten
im Metallmarkt. Dagegen stiegen die
LME-Lagerhausbestände erneut an und
markierten mit 5,45 Millionen Tonnen
ein neues Allzeithoch, allerdings werden
die Forderungen nach neuen LagerhausRegularien durch die LME immer lauter.
Auf- bzw. Abschlag für 3-Monatstermin
Letzten 6 Durchschnittswerte LME
Juni
Mai
April
März
Februar
Januar
2013
2013
2013
2013
2013
2013
30,36 Euro
24,80 Euro
25,22 Euro
30,79 Euro
31,22 Euro
27,92 Euro
50
0
–50
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
Aluminium High Grade, Kasse
Letzten 6 Durchschnittswerte LME
Juni
Mai
April
März
Februar
Januar
2013
2013
2013
2013
2013
2013
1.376,16 Euro
1.410,51 Euro
1.424,60 Euro
1.475,92 Euro
1.538,20 Euro
1.531,99 Euro
2.500
2.000
1.500
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
1.000
Aluminium Lagerbestände
Letzten 6 Monatsendwerte LME
Juni
Mai
April
März
Februar
Januar
2013
2013
2013
2013
2013
2013
5.435.600 t.
5.202.000 t.
5.157.625 t.
5.237.400 t.
5.162.050 t.
5.156.975 t.
6.000
5.000
4.000
3.000
2.000
1.000
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
0
Alle Angaben auf dieser Seite sind unverbindlich.
Quelle: TRIMET Aluminium SE – aktuelle LME-Werte unter www.trimet.de oder per TRIMET-App auf das iPhone.
12
WIRTSCHAFT
Produktionsdaten der deutschen Aluminiumindustrie
Primäraluminium
Sekundäraluminium
Walzprodukte > 0,2 mm
Press- & Ziehprodukte**
Produktion
(in 1.000 t)
+/in % *
Produktion
(in 1.000 t)
+/in % *
Produktion
(in 1.000 t)
+/in % *
Produktion
(in 1.000 t)
+/in % *
Mai
34,4
-7,4
54,3
-4,1
160,7
-4,5
48,9
-12,7
Juni
33,0
-8,0
54,6
6,9
161,0
20,6
49,1
-0,3
Juli
34,8
-5,0
56,0
7,1
166,4
0,9
46,9
-7,4
Aug
34,9
-5,8
47,2
2,9
161,4
1,2
44,9
-11,8
Sep
33,6
-4,4
52,5
-4,3
164,5
8,1
44,6
-17,2
Okt
35,2
-2,5
53,3
-0,3
162,5
9,4
46,1
-7,4
Nov
34,2
-2,9
53,4
-6,4
152,9
0,1
42,5
-20,1
Dez
35,1
-2,1
43,4
-7,0
117,2
7,4
23,3
-22,8
Jan 13
35,4
0,3
52,2
-3,5
159,3
9,5
42,8
-7,6
Feb
33,8
4,4
52,6
-5,3
158,9
6,5
44,3
-7,2
Mär
39,9
17,0
54,4
-5,0
163,1
-1,7
45,5
-9,8
Apr
40,3
20,2
53,9
1,0
173,1
17,6
48,7
8,2
Mai
42,3
23,1
51,5
-5,1
163,2
1,5
45,3
-7,4
* gegenüber dem Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf
Primäraluminium
Walzprodukte > 0,2 mm
14
Sekundäraluminium
Press- und Ziehprodukte
WIRTSCHAFT
„Metalle pro Klima“-Veranstaltung bei Otto Fuchs
Klimaschutz durch energieeffiziente Produktion
Das traditionsreiche Familienunternehmen
aus dem Sauerland hat in den zurückliegenden
zehn Jahren an den deutschen Standorten
mehr als 300 Millionen Euro investiert. Allein
im laufenden Jahr werden 40 Millionen Euro
für den Standort in Meinerzhagen aufgebracht.
Investitionen in energieeffiziente Maßnahmen
haben daran einen erheblichen Anteil. Mählmann sprach seine Erwartungen an die Politik
deutlich aus: „Wir setzen auf gute und verlässliche Rahmenbedingungen für die Industrie in
der Energie- und Steuerpolitik. Dazu gehört
auch der Ausbau und der Erhalt einer modernen, flächendeckenden Infrastruktur für das
Industrieland Deutschland.“
Martin Kneer, Hauptgeschäftsführer der
WirtschaftsVereinigung Metalle (WVM), unterstrich auf der Veranstaltung: “Die Grundstoffindustrie ist ein wesentlicher Faktor in
der Wertschöpfungskette und legt die Grundlagen für ein stabiles Bruttosozialprodukt, das
wir mehr denn je benötigen. Unser Ziel ist es,
mittels Best-Practice-Beispielen aus der industriellen Produktion einen offenen Dialog mit
Politik, Wirtschaft und Medien zu führen.“
Im direkten Gespräch mit Abgeordneten
aus Bundes- und Landtag, Kommunalpolitikern sowie zahlreichen Personen aus dem
öffentlichen Leben der Region stellten die
Experten der Otto Fuchs KG ihre Beiträge
zu Klimaschutz, Energie- und Ressourceneffizienz vor. Die Politiker, darunter der Wirtschaftsexperte Matthias Heider sowie die So-
16
„Dies ist für uns sowohl
ökologisch als auch
ökonomisch sinnvoll“,
erklärte Gießereileiter
Frank Vieweg bei der
Vorstellung von BestPractice-Beispielen zur
Ressourceneffizienz
und zum Klimaschutz.
Die Stranggießerei des
Unternehmens verarbeitet fast das gesamte
Kreislaufmaterial, das
in der Produktion im
Werk Meinerzhagen
anfällt. In insgesamt
acht Induktions- und
Draufsicht der beiden neu installierten Zweikammer-Schmelzöfen
drei
gasbeheizten
zialpolitiker Johannes Vogel und Petra Crone, Schmelzöfen wird das Material getrennt nach
sprachen einmütig ihre Unterstützung für den Legierungen erschmolzen und im Strangguss
Metallverarbeiter am Standort Meinerzhagen zu Rundbarren vergossen.
aus. Sie zeigten sich beeindruckt von den umIm Jahr 2010 wurden vier elektrisch begesetzten Maßnahmen zur klimaschonenden heizte Induktionsschmelzöfen nach 40 Jahren
und energieeffizienten Verarbeitung von Betrieb durch zwei gasbeheizte ZweikammerMetallen. Die Botschaft, dass Energie sicher, Schmelzöfen neuester Bauart ersetzt. Dies
sauber und bezahlbar sein müsse, sei ange- spare jährlich rund 6.000 Tonnen CO2 direkt
kommen.
auf der Energieseite von Otto Fuchs plus etwa
Kneer und Mählmann forderten mehr Ak- 3.000 Tonnen CO2 indirekt durch die Erhözeptanz in Gesellschaft und Politik für die Be- hung der Metallproduktion ein, hob Vieweg
lange der Industrie ein. „Schließlich hat uns hervor.
die Realwirtschaft durch die Krise geführt. Das
Die besonderen Merkmale des Zweikamsollte von einem Mentalitätswechsel begleitet mer-Schmelzofens liegen in der betont enerwerden, der letztlich zu ausbalancierten poli- giesparenden Schmelztechnik, die auch die
tischen Entscheidungen führt“, betonten sie.
am Einsatzmaterial anhaftenden organischen
Bestandteile als Energieträger nutzt. Gleichzeitig werden hohe Schmelzleistungen bei
Optimierte Schmelztechnik erhöht
flexibler Schrottart und -qualität erreicht.
Materialeffizienz bei Otto Fuchs
Die eingesetzten Öfen arbeiten nach fol„Metall wird bei der Otto Fuchs KG direkt gendem Prinzip: Zunächst wird das einzuzurück in den Produktionskreislauf geführt. schmelzende Material in die Chargierkam-
© Otto Fuchs
Die zwölfte Regionalveranstaltung der
Unternehmensinitiative „Metalle pro Klima“ fand Anfang Juli bei der Otto Fuchs
KG in Meinerzhagen statt. Hinrich Mählmann, persönlich haftender Gesellschafter des Unternehmens, betonte den Beitrag der Industrie für den Klimaschutz.
„Wir reduzieren unsere CO2-Emissionen
durch Energieeffizienz in der industriellen Produktion in beträchtlichem Umfang
und kontinuierliche Innovationen und Investitionen“, erklärte er. Welchen Beitrag
Otto Fuchs zu Klimaschutz, Energie- und
Ressourceneffizienz beiträgt, unterstrich
das Unternehmen mit mehreren BestPractice-Beispielen. Der Hersteller von
Produkten aus Aluminium, Titan, Magnesium, Nickel und Kupfer für die Luft- und
Raumfahrt, Automobil- und Bauindustrie
ist Mitglied der Initiative der NE-Metallindustrie.
Steuerzentrale (links) und Wärmerückgewinnungseinheit mit Rauchgaskamin (rechts)
WIRTSCHAFT
mer des Ofens gefüllt, dort vorgewärmt und Bei dem neuen, in Zusammenarbeit mit der
getrocknet. Nachdem die Kammer mit dem ONI Wärmetrafo GmbH aus Lindlar entwiRücklaufmaterial befüllt wurde, wird be- ckelten Verfahren wird das bis zu 900 °C
reits flüssiges Metall von der Hauptkammer heiße Rauchgas über einen frequenzgeregelin die Chargierkammer gepumpt. Der Füll- ten Heißluftventilator aus dem bestehenden
stand steigt an und das Einsatzmaterial wird Kamin angesaugt und über einen Wärmetaugeschmolzen. Gleichzeitig werden die beim scher geleitet. Die zurückgewonnene Wärme
Vorwärmen entstehenden energiehaltigen wird für die Warmwasserbereitung genutzt.
Schwelgase (am Rücklaufmaterial anhaftende Dadurch wird das Kesselhaus entlastet und
Schmierstoffe) in die Hauptkammer geführt Nutzenergie unabhängig von diesem bereitgeund dort als Energieträger genutzt. Anschlie- stellt. „Die Rückgewinnung thermischer Enßend wird die Aluminiumschmelze in einem ergie minimiert den Primärenergieverbrauch,
optimierten Übergabeprozess in den Gießofen reduziert überflüssige CO2-Emissionen und
überführt und vergossen.
erfüllt energiewirtschaftliche und ökologische
Der Energiebedarf für das Recycling der Ziele“, betonte Dewinklo.
Aluminiumlegierungen liegt
mit rund 600 kWh/t bei nur
etwa fünf Prozent des Energiebedarfes, der zur Herstellung
von Hüttenaluminium notwendig ist. Außerdem ist der
Logistikaufwand durch Transporte beim werksinternen Recycling vergleichsweise gering.
„Beides wirkt positiv auf den
Klimaschutz, da große Mengen
an CO2 eingespart werden“, so
Vieweg. Durchschnittlich fünf
Lkw-Fahrten je Woche zum
Transport des Rücklaufmaterials werden so vermieden.
Recycling ist in Deutschland mit etwa zwei Dritteln Schmiedeprozess von Alu-Rädern
des erzeugten Materials eine
der wesentlichen Rohstoffquellen für die hei- Die als Baukastensystem entwickelte Lösung
mische Industrie. Die Gießerei von Otto Fuchs kann als Grundkonzept für Betriebe mit verbezieht vier Fünftel des eingesetzten Alumi- gleichbaren Öfen und Warmwasserbetriebsniums aus Rücklaufmaterialien des internen netzen genutzt werden. Der flexible Aufbau
Fertigungsprozesses. Das „Inhouse“-Recyc- mit Regelkomponenten an den einzelnen Bauling von Überschüssen aus der Produktion – steinen ist beliebig kombinierbar.
Grate, Pressreste oder Späne – generiert neben den positiven Auswirkungen auf den Schmiederäder aus Aluminium
Klimaschutz auch erhebliche wirtschaftliche für klimaschonende Mobilität
Vorteile wie Absicherung der Vormaterialversorgung, Erhöhung der Flexibilität oder Die Begrenzung des CO2-Ausstoßes von Pkw
Senkung der Logistikkosten.
ist für eine klimaschonende Mobilität nicht
nur ein europäisches, sondern zunehmend
auch globales Thema. Der Kraftstoffverbrauch
Energieschonende Metallverarbeitung
von Pkw ist von zahlreichen Faktoren abhändurch Wärmerückgewinnung
gig, vor allem aber vom Gewicht: 36 Prozent
Das Wärmerückgewinnungssystem im Stamm- des Kraftstoffverbrauchs ist gewichtsbedingt.
werk ist ein weiteres Beispiel für die Steige- Leichtbau trägt daher entscheidend dazu bei,
rung der Energie- und Ressourceneffizienz. einen geringeren Verbrauch bzw. eine höhere
„Mit Hilfe der Wärmerückgewinnung aus Nutzlast bei Fahrzeugen zu erreichen und daRauchgas konnten wir seit September 2010 mit auch die Abgasbelastung zu reduzieren.
„Schmiederäder aus Aluminium sind ein
über vier Millionen Kilowattstunden Energie
einsparen und den Ausstoß um 985 Tonnen beliebtes Designelement an Fahrzeugen und
Kohlendioxid verringern“, erläuterte Harald leisten besonders bei großen Radabmessungen
Dewinklo, Prokurist und Leiter Einkauf bei einen signifikanten Beitrag zur Gewichtseinsparung und damit zur Minimierung der CO2Otto Fuchs.
Emissionen“, beschreibt Bernd Velten, Leiter
Technischer Vertrieb und Marketing bei Otto
Fuchs das verbindende Element von Mobilität,
Design und Klimaschutz.
Der Gewichtsvorteil eines Schmiederades
liegt bei etwa 15 Prozent gegenüber einem
Gussrad (durchschnittliches Gewicht ca. 11
kg), was zu einem Gewichtsunterschied von
netto 1,65 Kilogramm führt. Das bedeutet
eine Emissionsreduzierung von circa 0,165
Gramm CO2 je Rad und Kilometer Fahrleistung. Die Einsparung setzt sich aus zwei
Teilen zusammen, jeweils im Vergleich zu
gegossenen Alu-Rädern: zum einen aus der
direkten Verbrauchsminderung infolge der
Gewichtseinsparung, zum anderen aus der Einsparung an
Primärenergie zur Erzeugung
von Hüttenaluminium. Für
das auf die Herstellung geschmiedeter Alu-Räder spezialisierte Unternehmen Otto
Fuchs – Fertigungsvolumen
jährlich 1,6 Mio. Räder – errechnet sich bei einer durchschnittlichen Fahrleistung von
15.000 Jahreskilometern eine
direkte Einsparung von jährlich 4.000 Tonnen CO2 plus
weiteren 24.000 Tonnen CO2
dadurch, dass 2.600 Tonnen
weniger Hüttenaluminium benötigt werden.
In den 1960er Jahren erfand
Otto Fuchs die Kombination von sogenannten Gesenkschmieden und Fließdrücken als
wesentliche Voraussetzung für die Fertigung
einteiliger Schmiederäder. Bis heute ist diese
Technologie das technische Alleinstellungsmerkmal von Otto Fuchs im hart umkämpften
Markt der Pkw-Räder aus Aluminium.
Die Technologie der Schmiederadherstellung baut auf jahrzehntelangen Erfahrungen
auf. Im Zuge der politisch und öffentlich gewollten Gewichtsreduzierung bei der PKWHerstellung werden ihre Möglichkeiten deutlich höher bewertet. Ganz besonders gilt dies
für innovative Fahrzeuge mit Elektroantrieb,
denn die Reichweitenproblematik erfordert
maximale Anstrengungen bei der Gewichtseinsparung. Außerdem erlauben Schmiederäder die Herstellung aerodynamisch günstiger
und trotzdem leichter Räder und senken somit
im doppelten Sinne den Fahrwiderstand.
Hintergrundinformationen und BestPractice-Beispiele zu weiteren Anwendungen von NE-Metallen wie Aluminium,
Kupfer, Zink finden sich auf dem Internetportal von „Metalle pro Klima“ unter
www.metalleproklima.de.
■
17
WirtSChAft
SMS group 2012: Auftragseingang zurückgegangen –
Umsatz gestiegen – stabiles Ergebnis
In seinem Ausblick erklärte Weiss, der zum
1. Juli 2013 den Vorsitz der Geschäftsführung
niedergelegt und den Vorsitz im Aufsichtsrat
übernommen hat: „Wir gehen trotz einer wei
terhin zurückhaltenden Investitionsneigung
unserer Kunden bis zum Ende des Jahres von
einer leichten Erholung des Marktumfelds aus.
Vor dem Hintergrund unseres nach wie vor
hohen Auftragsbestands und unter Berück
sichtigung der Auswirkungen der erstmaligen
Konsolidierung von Paul Wurth im laufenden
Geschäftsjahr erwarten wir beim Umsatz eine
leichte Steigerung gegenüber 2012, aber ein
rückläufiges Ergebnis.“
SMS setzt weiterhin auf die Qualitätsfer
tigung der anspruchsvollsten Komponenten
der Maschinen und Anlagen in Deutschland.
Dazu wurde in den letzten Jahren erheblich
SMS group in 2012: lower order
intake – higher sales – stable result
© SMS group
Die SMS group musste 2012 gegenüber
dem Vorjahr einen Auftragseinbruch von
rund 17 Prozent auf 2,8 Milliarden Euro
hinnehmen. Der Umsatz stieg dagegen
um fünf Prozent auf 3,2 Mrd. Euro. Das
Gruppenergebnis vor Steuern in Höhe
von 258 Millionen Euro lag annähernd
auf Vorjahresniveau. Wie Heinrich Weiss,
Vorsitzender der SMS group auf der Jahrespressekonferenz erläuterte, spürten
beide Unternehmensbereiche – SMS Siemag und SMS Meer – die Zurückhaltung
der Kunden bei der Auftragsvergabe.
Fertigungswerkstatt der SMS Siemag in Hilchenbach
SMS Siemag’s manufacturing shop in Hilchenbach, Germany
The SMS group had to face a significant decline in orders intake in 2012 of about 17
percent to 2.8 billion euros. However, sales
increased by five percent to 3.2 billion euros, and the net group result of 258 million
euros was almost matching the previous
year’s level. At the company’s annual press
conference, Heinrich Weiss, chairman and
chief executive of the SMS group, stated
that both business areas, SMS Siemag and
SMS Meer, had clearly felt the impact of
customers’ restraint in placing orders.
Wechsel in Aufsichtsrat und
Geschäftsführung der SMS group
Changes in the supervisory and
managing board of SMS group
Heinrich Weiss, seit 45 Jahren für den Aufbau
und die Führung der SMS group verantwortlich,
hat sein Mandat in der Geschäftsführung zum 1.
Juli 2013 niedergelegt und den Vorsitz im Aufsichtsrat übernommen. Der bisherige Vorsitzende,
Manfred Bischoff, wird dem Unternehmen als
AR-Mitglied verbunden bleiben. Joachim Schönbeck, bisher bereits Mitglied der Geschäftsführung, wurde zum Sprecher des Unternehmens ernannt. Gemeinsam mit seinen Kollegen Burkhard
Dahmen und Eckhard Schulte wird er weiterhin
die Geschäftsführung der SMS GmbH bilden.
Joachim Schönbeck wird wie bisher primär für
SMS Meer zuständig sein und Burkhard Dahmen
für SMS Siemag (inkl. der Mehrheitsbeteiligung
Paul Wurth). Eckhard Schulte ist Finanzchef der
Gruppe.
With effect from 1 July, Heinrich Weiss, who has
been responsible for the development and leadership
of the group of companies for the last 45 years, has
resigned from his post on the managing board and
assumed the chairmanship of the supervisory board.
The present chairman, Manfred Bischoff, will retain
his commitment to the company as a member of
the supervisory board. Joachim Schönbeck, who is
already a member of the managing board, has been
appointed to represent the company externally with
effect from 1 July. Jointly with his colleagues, Burkhard Dahmen and Eckhard Schulte, he will continue
to constitute the management of SMS GmbH. Mr
Schönbeck will be primarily responsible for SMS Meer
as before, Mr Dahmen will be responsible for SMS
Siemag (including the Paul Wurth majority holding)
and Mr Schulte will be the CFO of the group.
18
Heinrich Weiss, seit 1. Juli Vorsitzender des Aufsichtsrates der SMS group
Heinrich Weiss, chairman of the supervisory board
of the SMS group since 1 July
Looking ahead Mr Weiss, who resigned from
his post on the managing board on 1 July and
at the same time assumed the chairmanship of
the supervisory board, commented: “Despite
a persistent reluctance of our customers to in
vest, we expect a slight recovery on the market
by the end of the year. Based on the contin
ued high level of orders in hand, and taking
into account the effects of the first full year
of consolidation of the Paul Wurth group this
year, we anticipate a modest increase in sales
compared to 2012, but a decline in profit.”
To ensure high quality, SMS remains com
mitted to producing the most complex compo
nents of its machinery and plants in Germany.
That is why the company invested heavily over
recent years in expanding and upgrading its fa
cilities in Hilchenbach and Mönchengladbach.
Yet, parallel to these measures, it expanded its
production capacity in China. Here it is mainly
about better customer service on the ground
as well as special products designed for the
Chinese market and produced at a lower price
locally: in view of the aluminium extrusion
business this, for example, applies to medium
standard presses up to 35 MN.
Overall, the aim is to further cut manufac
turing costs by focusing on productionopti
mised design, greater efficiency in logistics,
plus increased productivity in both engineer
ing and production. Using the same strategy as
that pursued in the years after the first finan
cial crisis, the company will make the most of
the weaker order intake to drive technological
development. Equally important to the man
agement is intensifying onthejob training and
qualification of experienced core personnel as
well as training new staff.
SMS is also expanding its presence outside
Europe by hiring qualified personnel as well
as building production and service facilities in
the key markets China and India. “This is how
we will be able to meet demands in China for
a locallyproduced share of supplies without
increasingly losing these types of orders to lo
cal competitors,“ said Mr Weiss, adding that
there was still an increased demand for plants
for the aluminium industry in China.
SMS Siemag – still high demand
for aluminium rolling mills
Already high in recent years, demand for alu
minium plants remained strong in 2012. SMS
Siemag was able to further increase both order
intake and sales. Another moderate increase
looks likely in 2013. Responding to the wishes
of many aluminium customers for a complete
supply package, SMS Siemag has developed
AluControl, an automation system specifi
in den Ausbau und die Modernisierung der
Betriebe in Hilchenbach und Mönchenglad
bach investiert. Parallel dazu sind aber auch
die Werkstattkapazitäten in China erweitert
worden. Hier geht es vor allem um einen bes
seren Kundenservice vor Ort und den Bau
von speziellen Produkten, die auf den chi
nesischen Markt zugeschnitten sind und dort
kostengünstiger hergestellt werden können,
im Aluminiumsegment beispielsweise mitt
lere Standardpressen bis 35 MN.
Insgesamt wird daran gearbeitet, die Her
stellkosten durch fertigungsoptimierte Kon
struktionen, eine höhere Effizienz in der
Logistik und Produktivitätssteigerungen bei
Engineering und Fertigung weiter zu senken.
Wie schon in den Jahren nach der ersten Fi
nanzkrise wird die schwächere Auftragsla
ge genutzt, um die technische Entwicklung
voranzutreiben und die Weiterbildung und
Qualifikation des Stammpersonals sowie die
Ausbildung der Nachwuchskräfte zu inten
sivieren.
Die Präsenz der Gruppe außerhalb Euro
pas wird durch die weitere Einstellung von
qualifiziertem Personal und den Bau von
Fertigungs und Serviceeinrichtungen in den
Hauptmärkten China oder Indien weiter aus
gebaut. „So können wir die in China gefor
derten lokalen Lieferanteile sicherstellen,
ohne die wir solche Aufträge zunehmend
gegen die Konkurrenzanbieter vor Ort ver
lieren würden“, sagte Weiss. In China beste
he weiterhin eine verstärkte Nachfrage nach
Anlagen für die Aluminiumindustrie.
MEHR PRÄZISION
BANDDICKE& PROFIL
laser-optisch mit
thicknessCONTROL
SMS Siemag – Nachfrage nach
Aluminiumanlagen hält an
Die seit Jahren anhaltend hohe Nachfrage
nach Aluminiumanlagen der SMS Siemag
hat sich 2012 fortgesetzt. Sowohl der Auf
tragseingang als auch der Umsatz legten zu.
Für das laufende Jahr 2013 rechnet SMS mit
einem weiteren, moderaten Anstieg.
Entsprechend dem Wunsch vieler Alumi
niumkunden nach einer vollständigen Liefe
rung hat SMS Siemag das speziell auf das
Aluminiumwalzen abgestimmte Automati
sierungssystem AluControl entwickelt. Mit
diesem System konnte der Anteil der Alu
Walzwerke, die komplett mit Elektrik und
Automatisierung geliefert wurden, 2012 auf
über 80 Prozent gesteigert werden.
Eines von mehreren Großprojekten für
die Aluminiumindustrie ist die Warmwalz
linie von Henan Zhongfu Industrial. Bereits
einen Monat vor dem vertraglich fixierten
Termin und nach einer nur sechswöchigen
Inbetriebnahmephase lief im Dezember
GESCHWINDIGKEIT
& LÄNGE
optisch mit
ASCOspeed
www.micro-epsilon.de
Micro-Epsilon Messtechnik
94496 Ortenburg · Tel. 0 85 42/168-0
[email protected]
WirtSChAft
2012 das Band mit einer
Breite von 1.330 mm und
einer Enddicke von 6 mm
aus der Anlage in Gongyi
in der Provinz Henan.
Künftig sollen auf der neu
en Anlage 760.000 Tonnen
Aluminiumwarmband im
Jahr für ein breites An
wendungsspektrum
wie
Folien, Verpackungen, Ge
tränkedosen, Automotive,
Fassadenbleche und die
Druckindustrie produziert
werden. Das Unternehmen
vergab an SMS Siemag zu
dem den Auftrag für eine
Farbbeschichtungslinie
für 70.000 Tonnen Dosen
band; die Anlage wird
2014 in Betrieb gehen.
Außerdem wurden zwei
Aufträge zur Lieferung von
GATVSchwebebandöfen
für AluminiumBandbe
handlungsanlagen herein 18-MN-Presse, in der Werkstatt von SMS Meer in Shanghai gebaut
geholt – ein Auftrag ist 18-MN press, being built at SMS Meer’s manufacturing shop in Shanghai
von Henan Zhongfu Indus
trial, ein weiterer vom Ma’aden Alcoa Joint oder TGV. Jilin Liyuan kann damit Bauteile
Venture, wo ab 2014 jährlich 50.000 Tonnen für einen Zugwaggon in einem Pressvorgang
Aluminiumband für die Automobilindustrie herstellen, was Zeit, Energie und Kosten spart.
geglüht und chemisch behandelt werden sol Außerdem sind das Leichtbaudesign und die
len. In beiden Linien überzeugt der GATV hohe Recyclingfähigkeit wichtige Antworten
Schwebebandofen durch ein kompaktes De auf ökologische Forderungen.
sign, eine gleichmäßige Erwärmung und Küh
lung des Bandes über den gesamten Quer Ecomelt-Schmelzöfen – hohe
schnitt sowie eine besonders hohe Energie Energieeffizienz und Metallausbeute
effizienz und Umweltfreundlichkeit.
Das Einschmelzen von Aluminiumschrotten
gewinnt seit Jahren an Bedeutung. Hier sind
SMS Meer profitiert weiterhin
die EcomeltSchmelzöfen der SMSTochter
von Nachholbedarf in China
Hertwich Engineering gefragt, die sich durch
Die Sonderkonjunktur in der Aluminiumin Energieeffizienz und geringe Metallverluste
dustrie setzte sich auch bei SMS Meer weiter auszeichnen. Aufträge zur Lieferung von Eco
fort. Hier ist – im Gegensatz zum Stahlmarkt – meltÖfen wurden 2012 von Novelis Italia,
infolge eines großen Nachholbedarfs die vom slowenischen Unternehmen Impol und
Volksrepublik China nach wie vor der Wachs von Constellium in Tschechien erteilt.
tumstreiber. Bei den hydraulischen Pressen
Aluminium Mostar, BosnienHerzegowina,
führte dies zu neuen Dimensionen in den Ab bestellte bei Hertwich eine Masselgießlinie.
messungen. So bestellte Jilin Liyuan Alumini Die Anlage umfasst einen Schmelz und Gieß
um aus Liaoyuan (Provinz Jilin) bei SMS Meer ofen sowie ein luftgekühltes Masselgießband.
zwei neue Pressen: ein 160MNFrontlader Trimet Aluminium nahm 2012 eine Massel
und eine 60MNDirekt/IndirektRohrpres gießanlage in Betrieb. Eine Beschreibung der
se. Die neue 160MNAnlage wird die größ Anlage findet sich auf den Seiten 44ff.
Aus den GolfStaaten erhielt Hertwich von
te moderne FrontladerStrangpresse sein, die
weltweit in Betrieb ist. Damit kann Jilin Liyian den Aluminiumhütten Dubal und Emal den
Profile bis zu einem Meter Breite herstellen. Auftrag über Ultraschallprüfanlagen zur Qua
Die Länge der Profile erreicht bis zu 28 Me litätskontrolle für Rundbarren. Emal bestellte
ter – das entspricht der Waggonlänge moder darüber hinaus auch zwei Kammerhomogeni
ner Hochgeschwindigkeitszüge wie dem ICE sierungsöfen.
■
20
cally designed for aluminium rolling. Due to
this system, the share of aluminium rolling
mills supplied complete with electrics and au
tomation could be increased to more than 80
percent in 2012.
One of several major projects for the alu
minium industry is the new hot rolling mill at
Henan Zhongfu Industrial. In midDecember,
a whole month before the contractual dead
line and after a commissioning phase of just
six weeks, the first 1,330 mmwide strip with
a final gauge of 6 mm rolled off the line in
Gongyi, Henan Province. In the future, the
new plant will produce 760,000 tonnes of hot
strip for a wide application spectrum such as
foil, packaging, beverage cans, automotive and
facade panels, and printing industry supplies.
for your benefit:
Suppliers Directory
On pages 76 to 89,
leading equipment suppliers
to the aluminium industry
present their product portfolios and ranges of services.
Take advantage of this
useful information.
ECoNoMiCS
The Chinese company also awarded SMS Sie
mag the contract for a colour coating line for
70,000 tonnes of strip in the form of can stock;
commissioning of the plant is scheduled for
the year 2014.
Moreover, SMS Siemag attracted two orders
for GATV strip flotation ovens for aluminium
strip processing plants – one order is, again,
from Henan Zhongfu while the other one is
from the Ma’aden Alcoa joint venture, where,
as from 2014, 50,000 tonnes of aluminium
strip a year will be annealed and chemically
treated for the automotive industry. Particu
larly impressive features of the GATV strip
flotation ovens in both lines are the compact
design, even strip heating and cooling over the
entire crosssection, plus extrahigh energy ef
ficiency and ecofriendliness.
SMS Meer benefits from
backlog of demand
The exceptional boom in the aluminium indus
try continued in 2012 and generated high de
mand, particularly in China which remains the
engine of growth because of its huge backlog
of demand. For the hydraulic presses this led
to new dimensions in product sizes. Jilin Liy
uan Aluminium in Liaoyuan (Jilin Province)
ordered two new presses from SMS Meer: a
160MN frontloading press and a 60MN di
rect/indirect tube press. The 160MN machine
will be the world’s largest modern extrusion
press of its type in operation today. It will en
able Jilin Liyuan to manufacture profiles up
to one metre in width. The maximum profile
length is 28 metres – equivalent to the railcar
length of modern highspeed trains such as the
ICE or the TGV. With the new machine, Jilin
will be able to manufacture railcar compo
nents in a single extrusion process. That saves
time, energy and money. Extra benefits are the
lightweight design and high recycling capabil
ity that meet green requirements.
Ecomelt furnaces – high energy
efficiency and low metal loss
The melting of aluminium scrap has been gain
ing in importance for years. Here Ecomelt
furnaces from Hertwich Engineering are in
demand as they consume much less gas than
conventional melting furnaces. The results are
lower energy costs, and the immersion melt
ing process reduces metal loss to below three
percent. Orders for the supply of Ecomelt
furnaces were placed by Novelis Italia, Impol
in Slovenia and Constellium in the Czech Re
public.
Aluminij Mostar, BosniaHerzegovina, or
dered a belttype billet casting line from Hert
wich to boost its productivity and flexibility.
The plant comprises a melting and casting fur
nace as well as an aircooled belttype billet
casting line. Trimet Aluminium in Germany
commissioned a billet casting line in 2012; a
detailed description of the plant is given on
pages 44ff.
Hertwich received orders from the alumin
ium producers Dubal and Emal for ultrasonic
testing facilities for the quality control of bil
lets. Furthermore, Emal awarded a contract
for the supply of two chamber homogenising
furnaces.
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ECoNoMiCS
CRU’s World Aluminium Conference 2013 in London
Key turning points
Principal issues that have been affecting
the aluminium industry over the past
couple of years are reaching key turning points. This sentiment was echoed by
a number of speakers at CRU’s World
Aluminium Conference in London this
year. Recurrent themes surrounding the
functionality of the LME and its warehouses, legislative impacts on the industry
and understanding where the value is in
the supply chain were among the hotly
debated topics engaging the conference’s
250 delegates.
the LME – help or hindrance?
The primary aluminium market is currently in
a state of gross oversupply. It is estimated that
approximately five million tonnes of metal is
stored in LME warehouses, whilst consumers
are waiting for access to their metal due to ex
cessively long queuing times. The link between
LME warehouses, price premiums and the
continuous state of oversupply brought into
question the role of the LME in the industry.
The consensus was that the situation is now
critical and needs to be addressed by major
players in the market to restore balance.
One of the keynote speakers, Oleg Muk
hamedshin, deputy CEO at UC Rusal, called
for greater transparency in LME pricing
mechanisms and a push for these prices to
greater reflect actual market fundamentals. A
question repeatedly raised by delegates was
why aluminium smelters were still producing
at historically high rates despite depressed
prices and an already plentiful stockpile in
warehouses. In addition to this, estimates that
20 to 30% of all producers (excluding China)
were making a loss at today’s price levels
fuelled further questions surrounding produc
er responsibility and controls on production.
Tim Reyes, president of Alcoa Minerals
Management, explained that the influence of
the financial community on the LME pricing
system was unlikely to change in the near
term. He believes that capital will continue
to flow through the industry, and that people
will be keen to hold onto their assets. Instead
of waiting for a turn in the financial markets,
the industry must look towards producers for
swift implementation of curtailments. Alcoa,
for example, are advancing their programme
to curtail capacity, with over 560,000 tonnes
of primary aluminium shutdown in 2012, and
22
plans to review additional curtailments over
the coming months. Other major producers in
cluding Rusal are thought to be implementing
similar strategies to counter market surplus.
In this context, CRU believes that if prices
fall a further 5 to 10% below current levels,
it could have a significant impact on the vol
ume of curtailments. The mutual dependence
of the power as well as aluminium industry
as one of the drivers behind escalating ware
house stocks is an alternative view on the situ
ation. With energy intensive industries such
as aluminium often providing an ideal outlet
for stranded power, an intimate relationship
has developed between the two. The result
has seen the power industry and governments
with surplus power dictating the construction
of aluminium smelters instead of the reverse.
In a market of significant surplus, consum
ers should be the winners, benefitting from
the low prices associated with plentiful supply.
This, however, is not the case for most con
sumers at present. The problem the consumer
faces in the current market is that LME ware
houses have made access to metal a difficult
and lengthy process. Not only are consumers
unable to hedge the premiums associated with
the metal, a large proportion of LME alumin
ium is held at two main locations: Vlissingen
in The Netherlands and Detroit in the United
States. Despite new legislation designed to
make access to the metal easier, long queues
persist at these locations.
Will China deliver?
Another potential solution to the market sur
plus seen today would be the realisation of
the long predicted ‘China effect’ taking hold of
the aluminium industry. For a number of
years, China has been singled out as a key con
tributor to booming commodity markets, fuel
ling unprecedented growth in industries such
as iron ore. The aluminium industry had, until
recently, been predicting similar increases in
demand and a drawdown of primary metal
to supplement domestic supply gaps. These
predictions have yet to materialise and it is
seemingly less likely that such significant sup
ply gaps with actually transpire.
CRU believes that while government poli
cies will favour the import of energy intensive
products such as aluminium, the current high
primary production levels and widespread
overcapacity leaves little scope for China to
increase imports. Despite this, there is some
hope that activity in China may provide some
support in restoring balance to the primary
aluminium market.
China’s recently elected government has
proposed four main options to deal with over
capacity: increasing demand for primary alu
minium, moving capacity to other countries,
encouraging greater industry consolidation
and closure of old, outdated capacity. By far
the least explored option, moving capacity,
has seen an increase in recent activity with
Rusal and Chalco signing an MoU to build
a Siberian smelter, following in the footsteps
of Rusal, China Xinfa Group and China’s
Citic who have also made steps to establish
themselves abroad. Whilst there is indication
of development in all of the aforementioned
options, the collective impact may do little
to the overall balance if China pushes ahead
with new smelter capacity in Xinjiang.
the raw materials challenge
China will need to look for alternative supply
for their booming smelter and refinery indus
try, especially with the Indonesian export ban
anticipated in 2014. With further evidence
of a push towards resource nationalism from
a number of countries, securing future feed
stock supply will be a key challenge not only
for China, but for primary producers across
the globe. Since the Indonesian government
made clear their intention to restrict raw
material exports back in 2009, resource na
tionalism has become a central theme of the
upstream aluminium industry.
An Indonesian ban on bauxite exports is
anticipated to heavily impact China as Indo
nesia is the country’s largest supplier of gibb
site bauxite. It is likely that traditional Chi
nese importers will look to secure resources
by investing in refining facilities in Indonesia.
In addition to the muchdiscussed Indonesian
bauxite ban, numerous other policies were
touched upon in key producing regions: MRRT
and carbon tax in Australia, bauxite export
bans in India, an export ban in Vietnam and
reviews for the royalty system in Brazil. The
push for these policies will greatly impact the
security of bauxite supply for producers and
led some to question if bauxite would become
the new iron ore.
The consensus amongst the panel for the
Raw Materials and Cost Trends Session was
that while there are some issues surrounding
access to bauxite and difficulty in bringing
projects online, the world’s bauxite resource
base is plentiful. Therefore, whilst prices are
expected to increase, the consensus is that it is
It‘s a pure waste of time
... if you make do with anything less!
unlikely to reach the levels that iron ore has.
Where is the value?
There was agreement that value is diverging,
with a movement upstream towards bauxite
and downstream towards rolled products.
The challenging environment developing
at the upper end of the value chain has con
tributed to the shift in profitability. As sup
ply of feedstock tightens and sources become
less clear, prices are expected to rise and
lesser known bauxite producing countries
will emerge as front runners of supply. It is
thought that this uncertainty in the upstream
industry could potentially be the production
constraint that the industry needs to curtail
primary production.
At the other end of the spectrum, the rolled
products market is benefitting from a surge in
demand driven by the transport and construc
tion sectors. Investments into research and
development for aluminium uses have been
prolific in recent years, and with the automo
tive and aerospace industries in particular
realising the benefits of aluminium, there is
scope for significant growth. Low primary
prices have benefitted the downstream in
dustry and increased the competitiveness of
aluminium as a substitute for other materials
in transport sector.
Aluminium is able to provide automo
tive manufacturers with significant weight
reductions and therefore better fuel savings
and lower emissions. For every 10% saving
in weight, a 5 to 7% saving can be made on
fuel. This has a number of beneficial knockon
effects for: (a) the consumer as cars require
less fuel, (b) the producer as weight saving im
proves performance and (c) the environment
as automotive emissions are reduced.
the demand for sustainability
With respect to ‘recycling’, there was agree
ment that legislation would, in time, need to
be revised to better represent the changes in
consumer usage today. Scrap was identified as
a major opportunity for Europe to retain alu
minium production while primary producers
suffer with tougher operating environments.
The demand for specialised alloys from sec
ondary material is also growing strongly, driv
en primarily by the automotive sector.
Europe has the opportunity to capitalise on
this growth to ensure that it is not merely a
scrap exporter, but that it is following in the
footsteps of other regions and ensuring that
value is being added to resources before
export. In this case, Europe’s resource is its
significant scrap pool, which, under current
forecast consumption rates will continue to be
a major source of aluminium for many years
to come.
Growing importance of sustainability with
in the industry is demonstrated by Novelis
Europe with an ambitious target for 80% of
their material to be from recycled products
by 2020.
All the very latest information in a single publication,
10 times a year, excellently researched,
direct from the source!
What does the future hold
for the aluminium industry?
The outlook for aluminium, according to many
industry experts, remains dependent on the
actions of the LME. Tackling the issues sur
rounding premiums and warehousing are in
tegral to improving the current imbalance in
the market. Others believe much of the
blame lies with producers who continue to
ignore ‘free market commercial signals’ that
call for greater control and curtailment in
production. In reality, it is perhaps the respon
sibility of both the aluminium producers and
the LME to take active steps towards a reso
lution. Producers must cut high cost capacity
and ensure that capacity is built in response
to demand instead of other industry factors.
Meanwhile the LME, facilitators of the current
surplus market, must look for a way to reduce
the influence of the financial community on
the LME price, and instead adopt a pricing
mechanism that better represents the funda
mentals of the market. The most recent com
mitments by companies to curtail production
will steadily reduce surplus, and this, paired
with strengthening demand across the value
chain, provides potential respite for the situ
ation.
Aluminium, unlike a number of other metal
markets, has never seen the commodities su
percycle reflected in its pricing. The boom in
commodities prices, partially fuelled by China,
had significant impacts on the iron ore and
copper markets but the fundamentals of the
aluminium market have worked against such
significant price escalation. With the easing of
Chinese growth, sentiment in such Chinacen
tric markets has suffered, and now the lack of
a supercycle in the aluminium industry can be
viewed as a benefit.
Over the next few years, as other industries
struggle with changes in market factors that
are essentially out of their hands, aluminium
is in a stronger position to make the necessary
changes from within the industry itself.
Author
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ECoNoMiCS
New alumina project approach –
dedicated design, compact capacity
P.-h. ter Weer, tWS Services & Advice
1. Synopsis
As discussed elsewhere the design / initial re
finery production capacity of greenfield alu
mina projects outside China has evolved from
about 0.51.0m tpy 25 to 30 years ago to about
1.53+m tpy for more recently constructed and
future planned projects [1]. Despite this large
scale increase economics did not structurally
improve, mainly as a result of large capital cost
increases for alumina projects in this period.
The increase in project scale had major con
sequences:
• Significantly increased project complexity:
planning and management, extensive govern
ment involvement, huge capital cost (multibil
lion USD, project financing, multiparty joint
ventures).
• Worldwide only a limited number of large
companies are left with the resources to de
velop greenfield projects, and only a few en
gineering firms with the skills and experience
to implement these projects.
• Typically a project life of 30+ years applies
to the significant investment of a greenfield
bauxite and alumina project. For projects with
a captive refinery this means that the bauxite
deposit on which they are based should sustain
refining operations for such a period of time.
Therefore only (very) large bauxite deposits
are developed, indicatively 200300 million
tonnes and more.
• Summarising: worldwide only a small num
ber of companies develop mostly very large
greenfield bauxite and alumina projects which
often takes a decade or more.
This paper describes a new twostage ap
proach to improve on the state of affairs
outlined above: first and foremost base any
greenfield project on a dedicated design and
layout for a specified production capacity, and
secondly apply this methodology to a compact
refinery capacity. Objectives are to improve
alumina project economics and to develop
an option of smaller greenfield bauxite and
alumina projects at acceptable economics.
The economic basis of the new approach is
discussed in section 3, technical aspects are
covered in section 4.
2. Commodities and
current refinery design
Commodities such as concrete, steel, mechani
cal bulks (e.g. valves), piping, wire and cable,
etc. represent a significant element (typically
~30%) of a refinery’s capital cost as illustrated
in the lefthand column (Current design) of
Table 1 (see next page) for a typical current
design 1.5m tpy ‘lowtemperature digestion’
alumina refinery.
Importantly commodity amounts and the
related capital costs reflect plant design and
layout. Current alumina refineries are designed
to accommodate additional future digestion
units (and all of the other required process
Fig. 1: Typical main piperack layout current-design 1.5m tpy alumina refineries
24
units – e.g. precipitation, evaporation), i.e.
plant design is not optimised for its initial pro
duction capacity. Plant layout is characterised
by an ‘open architecture’ as illustrated in Fig.
1 by the main piperack layout of recently
designed 1.5m tpy alumina refineries, which
represents at best a compromise between the
limited layout requirements for the initial /
design capacity and the more extensive re
quirements to accommodate future additional
process units. And at worst consists of a large
capacity plant part of which is built, resulting
in an inefficient plant layout for the design /
initial capacity. In summary plant design is
not optimised for its design / initial production
capacity.
3. New project approach
3.1 Step 1 – Dedicated design & layout
The new approach is based on a dedicated
refinery design and layout for a specified pro
duction capacity, i.e. tailoring the design to the
equipment and infrastructure requirements
(earth works, power, water supply, piperacks,
roads, cable trays) of the selected production
capacity. This approach enables optimising
plant layout for the targeted production ca
pacity e.g. with respect to positioning similar
equipment close to each other, and the use of
common spares; it impacts positively on com
modity volumes, and it focuses on a ‘lean’
design. Consequentially the design excludes
provisions for future expansions, which should
be justified on their own economic merits.
This more ‘closed’ layout architecture results
in a more efficient plant layout, reflected for
example in the design of the main plant pip
eracks as illustrated in Fig. 2 for a 1.5m tpy
refinery (compare with the piperack layouts
of Fig. 1 which are on the same scale).
This new approach impacts positively on
commodity volumes (refer to [2] for details):
for the same production capacity commodity
volumes for steel, concrete, piping, etc. for a
greenfield plant designed along this approach
are similar to that of a brownfield expansion
Fig. 2: Main piperack layout dedicated design 1.5m
tpy alumina refinery
ECoNoMiCS
owner’s costs, improving plant
capital cost indicatively by an
Current design Dedicated design
additional 10% relative to a
Direct costs
currentdesign plant of similar
1
244
234
Equipment
size.
Commodities2
558
474
Total direct costs
802
708
As illustration a produc
730
663
Total indirect costs3
tion capacity for a greenfield
Contingency
167
150
400,000 tpy dedicated design
Total refinery capital cost
1,699
1,521
plant is used here, and its re
USD/annual tA
1,133
1,014
lated capital cost (indicative
numbers) is shown in Table 2.
Table 1: 1.5m tpy greenfield refinery capital cost comparison
(indicative numbers)
Table 2 shows that the capi
tal cost per annual tA (1,347
Cost item
400,000 tpy
USD/AnntA) is higher than that of the much
in million USD
production capacity
larger 1.5m tpy dedicated plant (1,014 USD/
Dedicated design
AnntA – refer Table 1), however is at a level
Direct costs
which could result in a project with acceptable
1
Equipment
99
economics provided infrastructure capital cost
183
Commodities2
is limited (refer [2] for further details). At the
Total direct costs
283
same time a project based on a compact plant
Total indirect costs
196
Contingency
60
capacity has very limited infrastructural re
539
Total refinery capital cost3
quirements and has several advantages over a
USD/annual tA
1,347
large plant, particularly if the project is located
close to an existing port, e.g. it may be allowed
Table 2: 400,000 tpy dedicated design refinery capicloser to residential areas (i.e. is closer to exist
tal cost (indicative numbers)
ing infrastructure); the existing infrastructure
1 Incl. steam and power generation, sub stations, residue
may be sufficient for a small plant, but not
disposal, water supply, communication and info systems
2 Incl. concrete, steel, mechanical bulks, piping, wire and
for a big plant; a suitable location for a small
cable, etc.
residue disposal area is easier to find than for
3 Incl. freight, EPCM, temporary construction, start-up,
commissioning, owner’s engineering
a large one, etc. The table also shows that the
total capital cost is at a level which would en
of an existing refinery. In other words per able many more companies to develop such
annual tA production capacity significantly a project without necessarily requiring the
lower amounts of commodities are required formation of multiparty joint ventures, sim
for greenfield projects based on this approach plifying overall project management and thus
compared with current, resulting in lower enabling to decrease the capital cost further.
Note that the new approach is independent
costs. The effect on refinery capital cost is il
lustrated in the righthand column of Table of the selected refinery technologies.
1 for a dedicated design 1.5m tpy ‘low tem
perature digestion’ refinery: the capital cost 4. 400,000 tpy capacity alumina refinery
per annual tA capacity improves indicatively
by about 10%.
The above outlined DCS approach (Dedicated
Compact Sustainable – this last aspect is not
discussed here) has been applied by model
3.2 Step 2 – Compact production capacity
The second step of the new approach address ling a 400,000 tpy lowtemperature digestion
es the issues of complexity and huge capital refinery in a benchmark version of the Bayer
cost of current alumina projects: by applying process (refer [3] for further details). The
the dedicatedcapacity approach to a compact steam temperature and pressure required for
refinery capacity of about 300,000 to 600,000 lowtemperature digestion enables first using
tpy the resulting project has a simple and limit high pressure boiler steam for the cogenera
ed scope. The higher end of this range is limited tion of power. This results in an energy and
by the objective to end up with a total project capital efficient refining process.
capital cost well below USD1bn (mega pro
ject threshold); the lower end is determined 4.1 Equipment sparing
by logistical limitations (e.g. with respect to • Key role for equipment cleaning / descaling.
raw materials shipping). As a result some in • Substantial use of common spare equip
direct capital cost items decrease more than ment.
proportionately such as costs related to tempo • If an outage would result in an immediate
rary construction and startup support, camp alumina production loss, a spare or equipment
and other construction related items, and bypassing facilities are installed or extra ca
Cost item
in million USD
26
1.5m tpy production capacity
pacity in upstream / downstream equipment is
included. This also applies to frequently main
tained equipment.
• No sparing is included for the bauxite resi
due washers and flash vessels which can be by
passed, accepting transient process efficiency
reductions; a spare precipitator is installed and
the third precipitator in line can be used both
as agglomerating as well as growth precipitator.
• The refinery operates continuously, with
planned outages (accounted for in the overall
plant operating factor) being used to service
equipment. The sparing philosophy assumes
no scheduled extended total plant shutdowns.
• The sparing philosophy may require adjust
ing to a specific plant location.
4.2 Plant design elements
• The digestion and liquor evaporation areas
positioned next to each other, enabling shar
ing a common spare train of heat exchangers.
Advantages: equipment standardisation, sim
plified operations and maintenance, less (types
of) spare parts.
• The bauxite residue discharging from the
CCD wash train contains less than ~8 g/l
caustic soda in the adhering liquor, enhancing
disposal options.
• The last two online precipitators operate
with agitators allowing varying slurry levels,
thus accommodating volume takeup when
descaling a tank.
• Precipitators are mechanically cleaned /
descaled. Main advantages: no major plant
volume / plant liquor caustic concentration
fluctuations, i.e. better control of both. Put
differently: tank cleaning and plant volume /
liquor concentration control have been sepa
rated. Other advantages: no further spare pre
cipitators / tanks of similar size are required
and steam savings (caustic cleaning).
• The filters for hydrate to calcination, for
fine seed to precipitation and for oxalate re
moval are located in one building. Advantages:
equipment standardisation, operating proce
dures, etc.
• A hydrate storage facility between precipi
tation and calcination, enabling the Bayer
circuit to operate independently and as un
disturbed as possible from calcination. Two
calciners are installed, both normally in op
eration. By uncoupling the Bayer circuit from
calcination, product quality control can be
optimised.
4.3 Layout considerations
The key advantage of the DCS design is that
the plant layout is optimised. This may be re
alised in various ways, depending on bauxite
quality (boehmite, TOC, oxalate, etc.), select
ECoNoMiCS
Fig. 3: Layout of digestion / evaporation areas
Fig. 4: Layout of residue settling, washing and lime areas
Fig. 5: Layout of hydrate classification / filtration
and oxalate removal areas
ed process technolo
gies (digestion, impu
rity removal, equip
ment types – filters,
heat exchangers, etc.),
plant location specif
ics (rainfall – water
balance, legal require
ments, soil conditions,
gravity flow between
precipitators, etc.), and
operating and mainte
nance philosophies.
The following lay
out considerations are
based on the selected
refining process, de
sign, equipment spar
ing, operating param
eters and equipment.
However most of these
would (fully or partly)
apply also if other choices are made.
• Position the digestion and liquor evapora
tion areas next to each other (refer Fig. 3).
The causticiser feed heat exchanger is located
in the digestion / evaporation area because
evaporation export steam and digestion flash
condensate is used to heat the CCDwasher
overflow to causticisation. Attention should be
given to maintain the free caustic concentra
tion in the spent liquor through evaporation
at the hot end within acceptable levels.
• Place the bauxite residue settler and wash
ers in a horseshoe shape for easy access to
washer overflow standpipes and pumps, etc.
(refer Fig. 4). Lime related areas are positioned
next to each other (similar operating and
maintenance requirements) and close to the
washer train.
• Place the filters for hydrate to calcination,
fine seed for precipitation and oxalate remov
al, as well as the cyclone classification areas
in one building (similar equipment, operat
ing and maintenance procedures, spare parts,
sharing of common spare tanks and pumps,
etc.) (refer Fig. 5).
• Position security filtration related equip
ment close to each other for operating and
maintenance efficiency reasons; the heat in
terchange, precipitation and interstage cool
ing close to each other as these have many
interactions (minimising liquor / slurry pipe
line distances); and the main steam consum
ers (digestion and evaporation) and the steam
and power plant close to each other to mini
mise energy losses; and place if feasible the
bauxite crushing, grinding and predesilication
areas close to each other and to the digestion
area to minimise slurry pipeline distances.
• Construct in the centre of the plant a facil
ity accommodating the plant control room (in
cluding control of the steam and power plant),
operations office and plant laboratory.
• Create good crane access to all major equip
ment from 15 m wide plant roads, and if eco
nomically justifiable consider pipe trenches
instead of piperacks for road crossings (ease
of access).
4.4 Overall plant layout
An overall process plant layout for a 400,000
tpy DCS plant is shown in Fig. 6, showing that
the new approach leads to a compact, simple
and efficient layout with a small Bayer loop,
illustrating that the goal to tailor the design
to the equipment and infrastructure require
ments of the specified production capacity is
achievable: most of the infrastructure is inte
grated in the process areas and only limited
infrastructure is required outside those.
➝
27
ECoNoMiCS
5. Advantages of the new approach
The main advantages of the new approach
are:
• Reduced capital cost (lower risk) enabling
the development of bauxite and alumina
projects by smaller companies without a need
to form joint ventures, thus increasing the
number of companies potentially interested in
developing bauxite deposits. More competi
tion, more efficient use of (capital and bauxite)
resources.
• Small and simple projects carrying less risk
require less time to develop, construct and
startup, positively impacting economics.
• Alumina refining projects based on this
approach require a small bauxite deposit (a
deposit of about 40m tonnes could support a
400,000 tpy project for 30 years), i.e. world
wide the number of bauxite deposits lending
themselves to development increases, again
improving the use of resources.
• This new development model may also be
applied to the development of part(s) of a
large deposit.
• In some cases the new approach enables
value creation through alumina refining rather
than being limited to bauxite export (attrac
tive to the host country and to companies de
veloping bauxite & alumina projects).
• An adapted version of the new develop
ment model may in some cases enable baux
ite deposit development even in locations with
little existing infrastructure, albeit at a larger
than compact scale (see below).
bauxite and alumina projects in an adapted
version of this new development model – e.g.
a dedicated 1.5m tpy capacity project. Ex
ample: some of the Eastern Ghats deposits
in Orissa and Andhra Pradesh, India, e.g. the
Kutrumali deposit (with Visakhapatnam as po
tential alumina export port).
6. Possible project locations
7. references
Examples of bauxite deposits that may lend
themselves to development via the proposed
approach are (between brackets the potential
alumina export port):
• Haden, Queensland, Australia (Brisbane)
• Bindoon, Western Australia (Fremantle)
• Central Northern Tasmania (Devon Port /
Bell Bay)
• El Palmar, Venezuela (Ciudad Guayana)
• Trelawny, Jamaica (Discovery Bay)
• Kibi, Ghana (Tema).
In addition some bauxite deposits which in
view of their large size could support the cur
rent development approach with largecapac
ity alumina refining projects, may also lend
themselves to stagewise development apply
ing the new approach. In this case these depos
its could support several (smaller) greenfield
1. P.J.C. ter Weer, Significance of Increased Green
field Alumina Refinery Design Capacity, Interna
tional ALUMINIUM Journal, Jan/Feb 2011, Vol.
87, pp 2022.
2. P.J.C. ter Weer, New Development Model for
Bauxite Deposits (paper presented at Light Metals
2011, San Diego, California), pp 511.
3. P.J.C. ter Weer, New Development Model for
Bauxite Deposits – Dedicated Compact Refinery
(paper presented at Light Metals 2013, San Anto
nio), pp 97102.
Author
PeterHans ter Weer, TWS Services & Advice, Baux
ite Alumina Consultancy. For further information,
please contact P.J.C. ter Weer at +31.646143965,
email to [email protected] or visit www.
twsservices.eu.
Fig. 6: Overall 400,000 tpy DCS process plant layout
28
WirtSChAft
Lage der Schweizer Aluminiumindustrie weiterhin angespannt
„Den moderaten Zuwachs von gesamthaft 0,4 Prozent inklusive der
Exporte 2012 gegenüber dem Vorjahr verdankt unsere Industrie vor
allem einer stark gesteigerten Produktion von AluWalzerzeugnis
sen für den Transport und Automobilsektor. Dagegen mussten die
Presswerke Einbußen von bis zu 15 Prozent hinnehmen“, erklärte
Verbandsgeschäftsführer Marcel Menet.
Bei den Schweizer Leichtmetallgießern reduzierten sich die ver
arbeiteten Mengen im vergangenenJahr auf 17.970 Tonnen (14%).
Der LeichtmetallSandguss produzierte 2.740 Tonnen (37%), der
Druckguss 12.770 Tonnen (7%) und der Kokillenguss 2.460 Ton
nen (10%). Der gesamte Aluminiumeinsatz im Inland ging um 0,6
Prozent auf 207.900 Tonnen zurück.
Auftragseingänge im ersten Quartal rückläufig
Die Krise hat sich nicht entschärft: „Auch bei den Auftragseingängen
im ersten Quartal 2013 verzeichnen die Pressprodukte ein Minus von
rund 13 Prozent“, gab Menet an. Verantwortlich dafür sind in erster
Linie der weiterhin starke Franken, der auch 2012 die Margen ero
dieren ließ, sowie ausbleibende Bestelleingänge, verursacht durch
die schlechte Wirtschaftslage in den europäischen Ländern. „Auf
grund des tiefen Euros drängten zudem verstärkt ausländische An
bieter in den Binnenmarkt. Dies führte zu einem enormen Preisdruck
und zu zusätzlichen Auftragsverlusten für unsere heimische Indus
trie“, erläuterte Verbandspräsident Markus Tavernier die Situation.
Einbußen erlitt die Schweizer Aluminiumbranche vor allem durch
geringere Bestelleingänge seitens der Maschinen und Elektrotechnik
sowie des Textilmarktes. Diese Industriezweige reagierten vor allem
mit der Beschaffung einfacher, in großer Serie hergestellter Alumini
umBasisteile im günstigeren Euroraum.
Dagegen zählte für die Kunden im Verpackungsbereich, im Bau
wesen und Energiesektor sowie in der Medizinaltechnik auch 2012
die gewohnt hohe Schweizer Qualität, Flexibilität und Servicebereit
schaft mehr als der Preisdruck. Hier verhielten sich die Auftragsein
gänge nahezu konstant und auch im laufenden Jahr wird mit keinen
größeren Einbrüchen gerechnet.
Den größten Zuwachs bescherte erneut das Transportwesen. Dank
dem großen Knowhow und der ungebrochenen Investitionsbereit
schaft in neue Entwicklungen und Fertigungsanlagen konnte die
Schweizer Aluminiumindustrie 2012 Neuaufträge und Produktions
steigerungen für den Flugzeug und Schiffsbau sowie für Schienen
fahrzeuge, Nutzfahrzeuge und Automobile erzielen: mit komplexen
Konstruktionen im UltraleichtbauStrukturguss zur Reduzierung des
Gewichts und des CO2Ausstoßes genauso wie mit Walzprodukten
und hochwertig anodisierten Aluminiumteilen.
„Durch aufwändige Produktentwicklungen, Qualität und Liefer
zuverlässigkeit sowie erweiterte Dienstleistungsangebote wie die
© Aluminium-Verband Schweiz
Die im Aluminium-Verband Schweiz zusammengeschlossenen
Unternehmen blicken überwiegend auf ein unbefriedigendes
Ergebnis 2012. Die Auswirkungen der Frankenstärke und der
Schuldenkrise in Europa belasteten den Geschäftsverlauf der
zu 80 Prozent exportorientierten Schweizer Aluminiumindustrie. Dennoch konnten die Walz- und Presswerke ihre Gesamtproduktion inklusive der Ausfuhren leicht um 0,4 Prozent auf
184.850 Tonnen gegenüber 2011 steigern. Im laufenden Jahr
zeigt sich die konjunkturelle Entwicklung weiter verhalten.
Gesamtablieferungen von Walz- und Pressprodukten in der Schweiz, in Tonnen
verlängerte Werkbank für unsere Kunden haben sich unsere Mitglieds
firmen eine Alleinstellung erarbeitet“, so Tavernier. Auch für 2013
zeichnen sich hier bereits jetzt die größten Steigerungsraten ab.
Das Motto „Klasse statt Masse“ bringt die Überlebensstrategien der
Schweizer Branche auf den Punkt: Um die Wettbewerbsfähigkeit zu
erhöhen, wird zunehmend die Serienherstellung standardisierter Bau
teile in eigens dafür gegründete Fabriken im Ausland verlagert. Zahl
reiche Mitgliedsfirmen investieren aber auch zweistellige Millionen
beträge in ihre F&EAbteilungen und spezialisierten Fertigungsstätten
■
an den Schweizer Standorten, wie Tavernier weiter ausführte.
EMO Hannover | 16.-21.09.2013 | Halle 015 / Stand D26
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Lagern von Metall
sind wir Technologieführer. Als kompetenter Partner
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29
Primary aluminium industry during the first half of 2013, Part I
Rudolf P. Pawlek, Sierre
GUINEA: In March Russian aluminium giant
Rusal quietly abandoned plans for a multibillion-dollar aluminium smelter in Guinea.
NIGERIA: In mid-March, the Alscon board
of directors decided to suspend aluminium
Alcoa will close two Søderberg potlines at its Baie-Comeau smelter in Quebec
ing a 200,000-tonne alumina deficit and a
535,000-tonne aluminium surplus in 2013.
Given the size of these markets, however, the
figures show that supply and demand are essentially balanced. Alcoa also predicts a recovery in LME prices, linked more to the global economic situation than to market fundamentals.
Chinese output will reach 23.35m tonnes,
while its demand will be 23m tonnes, leaving
a small surplus which has grown from 100,000
30
production at the plant. Previously, Rusal had
covered the plant’s losses, expecting to find
a sustainable gas supply which would enable
Alscon to operate at its full capacity. Despite
all measures undertaken by Rusal, Alscon does
not have a reliable and continuous gas supply.
Aluminium production at the plant is deeply
loss-making, which renders it impossible to
fully utilise the existing capacities. However,
Alscon will continue to generate electricity.
During the suspension period, the main ef-
forts of Rusal will be focused on securing continuous gas delivery, obtaining judicial determination that Rusal is the rightful owner of
Alscon, and preparing to restart operations.
Smelting will resume as soon as the legal uncertainty has been resolved and the continuous power supply has been secured.
In July Nigeria’s supreme court ruled that
former state-owned Alscon should have been
sold to a US-based firm, not to Rusal, but did
not question Rusal’s ownership. Rusal acquired a 75% stake in Alscon in 2007 and now
owns 85% of its assets.
AMERICA
BRAZIL: In January Brazil announced it
would cut electricity costs by more than a
third across different sectors. Electricity tariffs for industry, agriculture and retail would
be reduced by 32% while the reduction was
18% for residences. The cut is larger than the
16.2% for residences and 28% for industries
announced in September 2012. The impact of
the reductions will amount to an additional
expenditure of 8.46bn Reais (USD4.14bn).
The energy cost for Brazil’s aluminium industry is 329 Reais per MWh (USD161/MWh)
on average, according to the industrial federation of Rio de Janeiro. This is much higher
than China’s average electricity rate, equivalent to 142 Reais per MWh (USD69/MWh).
Rates of 27 countries compared averages
about 215.5 Reais per MWh (USD105/MWh).
The country also plans to double its installed capacity over the next 15 years from
the present 121,000 MW. Last year, about
4,000 MW and 2,700 kilometres of transmission lines were installed. For 2013, the objective is to install another 7,500 kilometres of
transmission lines and generate additional
8,500 MW of energy.
CANADA: In May Alcoa announced the
permanent closure of two older potlines at
its Baie-Comeau smelter in Quebec, and to
postpone the construction of a new potline by
three years as it looks to cut costs. The two
Søderberg potlines, which have a capacity of
105,000 tpy, are scheduled to be closed by
August. Restructuring charges related to the
closures are forecast to be USD135-155m
after tax in 2013. The potline closures come
after Alcoa announced to cut as much as
460,000 tpy of smelter capacity globally over
the next 15 months in the face of low alu-
innovatherm 06/2013
AFRICA
© Alcoa
In January Alcoa announced it expects aluminium demand to increase by 7% to 49.4m
tonnes in 2013, up 1 percentage point from
the 6% growth seen in 2012. The bump in
global demand will be bolstered by an 11%
expansion in demand from China, as well as
strong growth from Brazil (3%), Russia (1%)
and India (3%). The change in demand from
North America and Europe should remain
relatively similar to 2012, with North America
seeing a 4% increase in demand (equal to the
2012 growth figure) and European demand,
which fell by 2% in 2012, declining by just
1% year-on-year in 2013. As a result of the
expected demand growth, Alcoa is project-
tonnes in 2012. In the rest of the world, production of primary aluminium output will be
26.61m, with demand forecast to be 26.42m
tonnes.
In May Alcoa announced that it will review 460,000 tpy of smelting capacity over
the next 15 months for possible curtailment
to secure the company’s competitiveness, as
aluminium prices have fallen more than a third
since their peak in 2011. Rusal and Chalco
have announced production cuts too. Rusal
will reduce primary aluminium production by
300,000 tonnes by year-end, and Chalco said
it would temporarily close 380.000 tpy of production capacity.
216 x 303
This overview covers the events of the
primary aluminium industry during the
first half of 2013. Part I focuses on the
regions Africa, America, Oceania and
Europe while Part II, which will be published in our next issue, will look at the
Middle East and Asia.
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216 x 303
One Design · One Technology · One Company
Primary aluminium smelters in Africa, America, Europe, Russia and Oceania:
Nameplate capacities and shutdown capacities on a temporary basis
Compiled by R. P. Pawlek, June 2013
Country
AFRICA
Cameroon
Egypt
Ghana
Mozambique
Nigeria
South Africa
AMERICA
Argentina
Brazil
Canada
USA
Venezuela
EUROPE & RUSSIA
Bosnia
France
Location
Nameplate
capacity
(tpy)
Shutdown
capacity
(tpy)
Edéa
Nag Hammadi
Tema
Maputo
Ikot Abasi
Richards Bay, Bayside
Richards Bay, Hillside
100,000
320,000
200,000
565,000
200,000
100,000
720,000
50,000
Puerto Madryn
Belem
Saramenha
Poços de Caldas
São Louis
Sorocaba
Santa Cruz
Arvida
Alma
Grande Baie
Kitimat
Laterrière
Shawinigan Falls
Bécancour
Sept-Îles
Deschambault
Baie Comeau
Sebree
Mount Holly
Evansville
Massena
Rockdale
Wenatchee
Ferndale
Hawesville
New Madrid
Hannibal
Ravenswood
St. Lawrence
Puerto Ordaz
Mantanzas
465,000
460,000
51,000
106,000
460,000
475,000
95,000
163,000
443,000
220,000
210,000
235,000
100,000
420,000
600,000
260,000
335,000
205,000
229,000
270,000
135,000
191,000
184,000
280,000
250,000
280,000
270,000
180,000
125,000
170,000
448,000
Mostar
Dunkirk
St. Jean de Maurienne
130,000
273,000
140,000
minium prices. Pushing back construction of
the new potline from 2016 to 2019 also comes
because of current market conditions.
In addition, Alcoa would invest USD100m
in the Baie-Comeau smelter over the next
three years, with USD30m of that money earmarked for upgrading the plant’s casthouse
operations as the company looks to support
growing demand from the automotive sector.
32
160,000
Germany
Greece
Iceland
200,000
Italy
Montenegro
The Netherlands
Norway
15,000
5,000
30,000
20,000
95,000
50,000
Romania
Slovenia
Slovkia
Spain
Sweden
United Kingdom
Ukraine
Russia
90,000
191,000
41,000
41,000
90,000
180,000
135,000
96,000
170,000
230,000
166,000
190,000
346,000
285,000
159,000
120,000
170,000
127,500
221,500
233,000
60,000
170,000
400,000
185,000
290,000
75,000
160,000
93,000
87,000
250,000
135,000
42,000
120,000
1,010,000
75,000
75,000
50,000
1,010,000
80,000
320,000
542,000
300,000
170,000
24,000
80,000
31,000
60,000
85,000
95,000
16,000
31,500
31,500
120,000
30,000
40,000
OCEANIA
Australia
123,000
270,000
29,000
60,000
Hamburg
Voerde
Essen
Neuss
St. Nicolas
Straumsvik
Fjardaal
Grundartangi
Portoscuso
Podgorica
Delfzijl
Lista
Mosjoen
Aardal
Hoyanger
Karmoy
Sunndalsora
Husnes
Slatina
Kidricevo
Ziar nad Hronom
Aviles
La Coruña
San Ciprian
Sundsvall
Fort William
Zaporozhye
Bratsk
Kamensk
Kandalaksha
Krasnoturinsk
Krasnoyarsk
Nadvoitsy
Novokuznetsk
Sayanogorsk
Sayanogorsk II
Volgograd
Volkhov
New Zealand
That money comes in addition to USD75m
already scheduled to be spent to rebuild the
plant’s port facilities.
PARAGUAY: In May, it was reported
that Paraguay’s new elected president, Horacio Cartes, is supportive of the USD4bn aluminium smelter project planned by Rio Tinto,
which had been opposed by the previous
president Fernando Lugo.
Point Henry
Portland
Boyne Island
Tomago
Bell Bay
Tiwai Point
190,000
358,000
550,000
540,000
180,000
351,000
30,000
The country is attractive for aluminium production, due to its partnership with Brazil in
the Itaipu hydro-electric dam project – one of
the biggest in the world – and with Argentina
in the Yacyreta hydro-electric plant. Itaipu
alone provides 17.3% of all the energy consumed in Brazil and 75.2% of that used by
Paraguay.
As the country does not use all of the en-
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ergy it generates with its hydro-electric plants,
it sells the surplus to its Latin American partners.
USA: In April Century Aluminum announced its Hawesville smelter in Kentucky
would close in mid-August if it cannot secure
competitively priced power. The 244,000 tpy
primary aluminium smelter has a power contract with Big Rivers Electric Corp. The contract expires on 20 August. Century remains
resolved to finding a solution that will support the plant’s continuing operations, and is
in discussions with the power provider.
At the end of April, the company entered
into a definitive agreement to acquire substantially all of the assets of the Sebree aluminium smelter from Rio Tinto Alcan (RTA).
Sebree, located in Henderson County, Kentucky, has production capacity of 205,000 tpy
of aluminium. Early in June Century completed the transaction with RTA to acquire all
of the assets of the Sebree smelter. The transaction is subject to certain closing conditions,
including the consent of Kenergy Corp. to the
assignment of the smelter’s existing power
contract, which will terminate on 31 January
2014.
In May Alcoa announced that it will review 460,000 tpy of smelting capacity over
the next 15 months for possible curtailment
to maintain the company’s competitiveness,
as aluminium prices have fallen more than
a third since their peak in 2011. The review
includes facilities across the Alcoa system,
and will focus on higher-cost plants and plants
that have long-term risk due to factors such
as energy costs or regulatory uncertainty. The
possible curtailments could affect 11% of Alcoa’s global smelting capacity. Up to then, Alcoa had 13%, or 568,000 tonnes of smelting
capacity idle.
When reviewing smelting capacity for possible curtailment, Alcoa will consider a wide
variety of alternative actions, ranging from
discontinuing pot relining to full plant curtailments and / or permanent shutdowns. Alcoa’s
alumina refining system will also be reviewed
to reflect any curtailments in smelting as well
as prevailing market conditions.
Alcoa’s review of its primary metals operations is consistent with its 2015 goal of
lowering its position on the world aluminium
production cost curve by 10% points and the
alumina cost curve by 7% points.
Early in June Alcoa released it is piloting
a new emissions reduction technology at its
baked anode and calcined coke facility in
Lake Charles, Louisiana, that will reduce sulphur dioxide, particulate matter and hydrogen
fluoride emissions at the plant by up to 90%.
34
The new technology also offers significantly
lower installation costs than more established
emission-cleansing technology, as well as lower operating cost, using half as much water and
30% less energy.
Whereas conventional wet scrubbers pump
a limestone or sodium-based solution to the
top of a 100-foot (31 metre) tower and spray it
onto flue gas, Alcoa’s in-duct scrubber moves
flue gas from the smelter or boiler into a horizontal chamber and sprays a sodium-based
solution in the same direction as the gas flow.
This high-velocity, horizontal scrubbing process allows up to three times more gas to be
treated than in an equivalent conventional
scrubber space, and it requires 30% less energy to operate. The technology treats upwards
of 90% of sulphur dioxide in less than onefifth of a second, compared to traditional wet
scrubbers, which could take 10-15 seconds.
Commissioning and testing of the new technology is expected to be complete by August
2014.
In May bankrupt aluminium company
Ormet was sold to an entity owned by private equity firm Wayzata (Minn) Investment
Partners. The Ohio-based company had originally been scheduled to go to auction, but the
auction was cancelled because no bids besides
that from stalking-horse bidder Smelter Acquisition, a Wayzata entity, were received.
The exact purchase price for Ormet was
not disclosed. The company reported assets of
USD407m and total liabilities of USD416m
when it filed for Chapter 11 bankruptcy. High
legacy and power costs as well as low aluminium prices pushed the company to seek
bankruptcy protection.
Ormet’s smelter in Hannibal can produce
up to 270,000 tpy of primary aluminium when
operating at full capacity, and its alumina refinery in Burnside, Louisiana, can produce
540,000 tpy of smelter-grade alumina.
In June, the US Bankruptcy Court for the
District of Delaware approved the sale of
substantially all of the assets of Ormet Corp.,
to Smelter Acquisition, LLC, a portfolio company owned by private investment funds managed by Wayzata Investment Partners LLC.
For this restructuring, the company received
aggregate commitments of USD90m of DIP
Financing, consisting of USD30m in Term
DIP financing from Wayzata, as well as a USD60m DIP facility from Wells Fargo, which
replaced its USD60m pre-petition revolver
with Ormet. The DIP financings provided the
Company with sufficient liquidity to meet its
ongoing obligations and to ensure that its operations continue without interruption during
the restructuring.
The purchase from bankruptcy by Smelter
Acquisition means that the business will shed
substantially all of its legacy liabilities and will
emerge with a much stronger balance sheet
and sole equity sponsor in Wayzata. The company does not anticipate that the acquisition
will impact Ormet’s ordinary course of operations.
In June Ormet’s sale to Smelter Acquisition was approved by the US Bankruptcy
Court in Delaware.
VENEZUELA: In February aluminium
producer CVG Alcasa said it will increase its
output to 170,000 tpy, using new machinery
obtained with a USD402m investment approved by President Hugo Chávez back in
2012. The new equipment was supplied by
China Aluminium International Engineering
Corp. (Chalieco), and will be incorporated
progressively over the next two years. It
represents the first technological adequation
process made by Alcasa in 25 years.
OCEANIA
NEW ZEALAND: In April Rio Tinto’s Pacific
Aluminium unit was still in talks with energy
supplier Meridian to renegotiate terms for
New Zealand’s only aluminium smelter, after
it rejected a short-term subsidy by the government to keep the plant running. Pacific Aluminium’s view is that a commercial agreement
can be reached through a NZAS electricity
supply contract, that is in the best interests of
NZAS, Meridian, the New Zealand Government and the people of Southland. Under the
existing contract, NZAS must operate until
2016, and can then be progressively closed,
and it would be expensive for Rio Tinto to
shut it down faster.
NZAS uses about 15% of the nation’s
electricity output. Closure of the plant would
mean a massive power surplus in the nation
that is looking to divest stakes in three stateowned electricity firms. About 90% of output
by NZAS is exported, with Japan being its
biggest market. NZAS contributes USD525m
to the Southland economy annually – about
3% of New Zealand’s GDP – and supports
more than 3,200 direct and indirect jobs in
Southland.
EUROPE
BOSNIA: Early in June Bosnian aluminium
smelter Aluminij Mostar announced to shut
down all operations in mid-June due to losses
made on high power costs and low aluminium
prices. On 20 June the company said that it
had decided to delay the closure by 17 July
Still in operation or shut down? A critical date for the future of loss-making Aluminium Mostar was
17 July (after editorial deadline).
“due to positive developments that occurred
after we had informed the public on our decision.”
CEO Ivo Bradvica’s proposal to close operations was unanimously approved by the
company’s supervisory board after reviewing a business report for the first four months
of 2103. This revealed losses of 9.7m marks
(USD6.5m) per month since the start of the
year.
The decision had been taken during a supervisory board session, which the leadership
of the independent trade union also attended.
These representatives of the plant’s employees also realised that there is no alternative to
the closure. Aluminij produces about 130,000
tpy of aluminium through a tolling agreement
with Glencore Xstrata, and employs around
900 people.
FRANCE: At the end of 2012, Rio Tinto Alcan was ordered to stop insisting that companies licensing its Aluminium Pechiney smelting technology must also buy pot-tending assembly handling equipment from its subsidiary
Electrification Charpente Levage (ECL). The
European Commission made legally binding
Rio Tinto’s promise in August 2012 to end the
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© DUBAL
© Aluminij Mostar
SPECIAL
practice as a condition of lifting a threat of
anti-trust fines in the European Union. Brussels had feared that Rio Tinto was potentially
dominating the aluminium smelter equipment
market through its licensing system, damaging
competition within the EU.
Under the agreement, users of Rio Tinto
Alcan’s technology can not only choose from
recommended suppliers, but Rio Tinto must
also provide competing pot-tending assembly
suppliers with technical specifications, to ensure their equipment can work in Aluminium
Pechiney smelters.
Brussels’ investigation began after Francebased crane manufacturer Réel complained
about the practice, for which Rio Tinto offered
commitments in August 2012, which have now
been accepted by the Commission and made
legally binding. If the company breaches the
conditions, the Commission could impose a
fine of up to 10% of Rio Tinto’s total turnover.
GERMANY: Trimet Aluminium, Germany’s largest producer of primary aluminium,
confirmed in March that the company was in
talks with Rio Tinto Alcan to acquire two aluminium plants in France, namely the sites at
Castelsarrasin and Saint-Jean de Maurienne.
The Saint-Jean de Maurienne plant in eastern France is an aluminium smelter of about
140,000 tpy. Talks are still underway.
ITALY: In June, Alcoa agreed to maintain
the shuttered Portovesme aluminium smelter
in Italy until the end of June 2014, rather than
just to the end of 2013, to allow more time
for a possible sale. However, the ministry does
not take for granted the failure of the deal
with Klesch, and reserves the right to contact the group again to further investigate the
terms of negotiation. Simultaneously, it said
it would continue scouting for other potential buyers at both the national and international level. The Portovesme smelter had fully
ceased production in November 2012, after a
possible sale to Glencore fell through.
After more than three years of reduced
production, Alcoa finally decided to permanently close its Fusina smelter in Venice. The
closure will reduce Alcoa’s global production
capacity of 4.2m tpy by 44,000 tonnes. This
tonnage is in addition to the 460,000 tonnes
of operating smelting capacity that Alcoa previously announced was under review. The
Alcoa Fusina rolling mill operates separately
from the smelter and is not affected by this
decision.
NORWAY: In March Hydro said it was developing new and energy-efficient aluminium
production technology as the foundation for
its long-term efforts. Hydro is therefore studying the potential for testing next-generation
electrolysis technology at a pilot plant with
a capacity of about 70,000 tpy at Karmøy in
Norway. If the pilot project is realised, Karmøy
will host the most energy-efficient aluminium
production in the world, according to Hydro.
There are a number of elements that must
fall into place before Hydro can break ground.
The power grid in the region must be dimensioned to meet the demands of the offshore
power industry and industrial development.
The company must also secure enough power
under competitive conditions and establish an
agreement with Enova on financing, in which
Enova can contribute considerable – and crucial – support. Enova is owned by the Norwegian Ministry of Petroleum and Energy and
has as its goal to promote environmentally
friendly alternatives in energy consumption
and energy production in Norway.
In June Hydro signed an agreement with
Rio Tinto Alcan to acquire its 50% ownership
share in the Vigeland Metal Refinery AS and
100% ownership share in the AS Vigelands
Brug hydropower station, located in southern Norway. Hydro held a 50 % ownership
share in Vigeland Metal Refinery AS prior to
the transaction, and was the sole off-taker of
its production of high-purity aluminium. High
purity aluminium plays a vital part in semiconductors and in several electronic applications
such as LCD screens for TVs, computers, cell
phones and tablets.
Located in Vennesla at the lower part of
the Otra River, the Vigeland Metal Refinery,
has a capacity of 8,500 tpy of high-purity aluminium.
The transaction will be notified to the Norwegian Competition Authority, and Hydro
will also apply to Norwegian authorities for
an approval to acquire the hydropower assets
in AS Vigelands Brug.
RUSSIA: In February Rusal announced
that it started pilot testing of inert anode technology in a 3 kA amperage cell at the Kras-
noyarsk aluminium smelter (KrAZ). For inert
anode technology Rusal has developed a completely new pot design. Following successful
pilot tests, Rusal will start industrial tests in
inert anode pots in 2015 at KrAZ. From 2017
Rusal may start shifting smelting capacities
to inert anode technology, starting at KrAZ.
The burning speed of an inert anode is 300
to 400 times slower than that of a traditional
carbon anode, and wears away only 1-2 cm
per year, compared to 1-2 cm per day with
the carbon anode. The project joined the
Skolkovo foundation in June 2011. Planned
co-financing of the inert anode aluminium
production research from the foundation
amounts to RUR750m (USD25m) until 2015.
To date, RUR130m (USD4.3m) has already
been spent by Skolkovo.
In June the first phase of the Boguchansky
aluminium plant (BoAZ) was 75% complete.
As of 1 May the partners had already invested
about USD862m in the construction, which
needs another USD749m to complete the
first phase of BoAZ’s production capacity of
298,000 tpy. The first metal is expected in Q4
2013. Full capacity of the first phase will be
reached by the end of this year.
Also in June Rusal and IES Holding announced an agreement on the sale of Rusal’s
Bogoslovsk aluminium smelter, which will enable Rusal to form a single production facility
in Krasnoturinsk. The deal will be closed in
August 2013. Creation of a single industrial
complex will enable Rusal to reduce the cost
of production of alumina in the Bogoslovsk
aluminium plant. Rusal will keep the alumina
refinery which will be part of the Alumina
division.
In June Rusal signed an agreement with
the Leningrad region and the trade union
committee Volkhov Aluminium Plant (VAZ)
concerning plans to reorganise production in
the industrial area VAZ. The reorganisation
involves changing from producing primary
aluminium to producing high value added
products such as aluminium automotive components. The parties signed an agreement in
order to save jobs, to create joint ventures with
potential investors producing end products
for mechanical engineering, and to establish
conditions for the long-term development of
industry in the region.
n
Suppliers Directory – for your benefit
On pages 76 to 89, leading equipment suppliers to the aluminium industry present their
product portfolios and ranges of services. Take advantage of this useful information.
36
!
!
w
t
s
m
SPECIAL
Keops Technologies deploys a new
standard aluminium smelter MES solution
Keops Technologies, Inc. is currently deploying a new standard aluminium MES
(Manufacturing Execution System) solution for the Ma’aden/Alcoa joint venture.
Encompassing the electrode, general
plant, and casthouse areas, the deployed
functionalities will enhance the ability of
the site to manage its production.
After months developing a standard MES application based on Alcoa smelter and casthouse
functionalities, Keops Technologies – a leading
provider of MES systems serving the aluminium industry – is presently on site, deploying
process and production control applications
with planning and scheduling functionalities
for managing daily operations.
The Ma’aden project represents specific
challenges given the integration with the rolling mill and high quantity of daily metal production. This increases the complexity of the
!compounding
& extrusion
!materials
handling
casthouse scheduling system that Keops has
designed, having to respond to a very shortterm demand. The coordination between upstream molten metal flows from the potline
and downstream remelt and cold scrap management from the rolling mill has been modelled to sequence all operations: pot tapping,
trip scheduling of crucibles to the casthouse
and shipments of casthouse products to the
rolling mill, while respecting quality, equipment and process constraints.
In addition, the MES tool supports managers, supervisors and engineers to optimise
their business processes by providing timely
information directly collected from the many
equipment and systems from the port to the
casthouse, through the carbon and reduction
areas. Connecting to PLC and external systems
– for example the LIMS – through proprietary
interfaces, the Keops MES solution provides
an integrated view of production information
to support critical decision-making processes.
The detailed execution plan or process data is
then interfaced in two directions: either downward to the production systems with production and process parameters, or upward towards the ERP or rolling mill MES. Production
information is also fed to the manufacturing
infrastructure, which plant personnel can use
as needed to monitor production performance
and to drill down into detailed data.
The deployment is concentrated over a
short period of time by taking advantage of
Keops’ experience in greenfield and brownfield projects, and its agility in quickly providing a wide range of subject matter experts
for each of the sectors and subsystems. Keops
also benefits from its large library of interfaces with third-party applications, accumulated with various industry vendors during its
over-30 years of experience in the aluminium
industry.
n
!service
!!Why we enjoy an unloading challenge. Because time is money and this is also very true
when it comes to alumina and petcoke unloading. With our Vacuum Ship Unloader VSU, featuring leading-edge technology and our deep process know-how, we can guarantee short
ship lay times and ensure gentle and reliable unloading of your product. That’s what we
mean when we say „confidence through partnership“ . !!www.coperion.com
! For unloading capacities up to 1.000 t/hr
! Double or single boom technology
„Durodense“ – Aluminiumoxid-Fördertechnologie
für Dubal erfolgreich in Betrieb genommen
Die Coperion GmbH, Weingarten, hat ihr Fördersystem „Durodense“ zur automatischen
Beschickung von Elektrolysezellen für die
Potline 1 der Aluminiumhütte von Dubai
Aluminium (Dubal), VAE, erfolgreich in Betrieb genommen. Das System versorgt 64
Elektrolysezellen vom Typ D18 und D18+ mit
Aluminiumoxid. Es ersetzt die bisherige Zuführung per Kran und erhöht dessen Verfügbarkeit für andere Anwendungen; außerdem
spart es Arbeitskräfte und vermeidet umweltbelastende Staubemissionen.
Mit der neuen Technologie vervollständigt
Coperion das Vorhaben von Dubal, den Energieverbrauch älterer Zellen durch höhere Effizienz zu verringern sowie die Emission von
Perfluorcarbon zu senken, um auch bei
der Umweltverträglichkeit den Stand
anderer fortschrittlicher Technologien
aufzuweisen. Einmal mehr hat Coperion als Spezialist für Schüttgutsysteme
in der Aluminiumindustrie mit diesem
Projekt gezeigt, dass das Unternehmen
ein kompetenter Partner ist, wenn es um
technologisch anspruchsvolle Modernisierungsprojekte in der Branche geht.
Mit Durodense bietet Coperion eine
nachhaltige Lösung für die Zuführung
von Aluminiumoxid zum Elektrolyseprozess. Das System erfüllt die hohen
Anforderungen bei neu errichteten
Aluminiumhütten sowie bei Modernisierungsprojekten in bestehenden Anlagen.
‘Durodense’ – Alumina feeding technology
successfully commissioned at Dubal
Coperion GmbH, located in Weingarten, Germany, has successfully commissioned their
automatically operating ‘Durodense’ pot feeding technology at Potline 1 in the smelter
of Dubai Aluminium (Dubal), UAE. The
system supplies primary and secondary
alumina to 64 cells of the Dubal D18 and
D18+ reduction cell technology. It replaces
the regular crane feeding operation thus
increasing its disposability for other operations, saving labour and avoiding dust emissions to the environment.
able solution to supply alumina to the reduction process in aluminium smelters. It meets
the requirements of new greenfield smelter
projects as well as of brownfield modernisation projects.
High operating reliability
© Coperion
Durodense is built of a modular system body
consequently using round shaped standard
piping with internal product fluidisation for
the most gentle product transport. Due to
such slim design the routing
of the system is very flexible
and as a consequence the installation at and the penetration through an existing pot
room wall structure is eased.
This is also advantageous especially at the pot superstructure compared to other, more
space requiring systems, says
Coperion. With the utilisation
of standard couplings the use
of standard piping minimises
problems with sealing and
thermal expansion.
The Durodense system has
its very high operating reliability due to the following facts:
• The main distribution pipe
along the potroom is constantHohe Betriebssicherheit
ly filled to almost 100 percent with alumina. The whole
Durodense ist aus einem modularen
system serves as an alumina
Systemkörper aufgebaut, der aus runbuffer located close to the
den Standardrohren besteht und mit
cells.
Through this fact very
interner Fluidisierung für einen äußerst Außenansicht auf die Anlage mit 64 Elektrolyezellen, die mit dem Fördersystem
Durodense
zur
automatischen
Beschickung
von
Elektrolysezellen
high
instantaneous
filling rates
schonenden Produkttransport sorgt.
aufgerüstet wurden
into
a
cell
hopper
are
possible.
Durch das schlanke Design ist die Stre- Exterior view of the plant with 64 electrolysis cells, upgraded with the
Even
cell
technologies
with a
ckenführung des Systems sehr flexibel. fully automatic pot feeding system Durodense for alumina
strong
fluctuating
filling
level
Dadurch wird auch die Montage an der
in
the
cell
hopper
can
be
filled
immediately.
bzw. die Führung durch die Wandstruktur der With this Coperion complements Dubal’s
Elektrolysehalle vereinfacht. Besonders vor- undertaking to retrofit their older potlines • The system is equipped with a special air
teilhaft ist dies auch im Hinblick auf den Ge- to optimise energy consumption with higher distribution system inside its fluidisation elsamtaufbau der Elektrolysezellen, weil andere efficiency and reduced perfluorcarbone emis- ements. These devices assure that in case of
Systeme einen größeren Platzbedarf haben, sions being environmentally par with other ad- plug formation the air cannot bypass the plug
hebt Coperion hervor. Die Verwendung von vanced technologies. With this project, Cope- but is forced into the alumina plug and disStandardkupplungen und -rohren minimiert rion has proven once again to be the compe- solves it.
Probleme in Bezug auf Dichtungen und ther- tent partner for a technologically driven mod- • The air consumption for the total system
from silo to pot during normal operation is
ernisation project in the aluminium industry.
mische Ausdehnung.
With Durodense, Coperion offers a sustain- less than 0.6 to 0.7 m3/min per pot and very
Das Durodense-System weist eine sehr
38
SPECIAL
constant. This leads to a very low material
velocity in the piping and avoids the risk of
scaling. The low and constant air consumption
causes a low impact on the gas balance of the
potroom, a low impact on the gas treatment
centre (GTC) and a low impact on the roof
emissions as well. This is a very important
benefit especially for revamping projects with
existing GTCs and related gas balances.
• The system does not need any sensor or actor (gates, valves) at the pots; it is completely
self-regulating. This eliminates the investment
cost for sensors, actors and related cabling
and control boxes compared to other existing
automatic systems.
These features of the Durodense pot feeding system provide clear benefits for new
smelter projects as well as for modernisation
projects.
After the successful realisation of the alumina and petcoke handling and storage facilities in the port of Qatalum and the bulk handling facilities in the courtyard areas of the
Ma’aden smelter, Coperion now completes
the material handling chain with the successful
operation of the Durodense pot feeding system in the Dubal smelter.
n
hohe Betriebssicherheit auf, denn
• das Hauptverteilerrohr entlang des Elektrolyseraumes ist permanent fast vollständig
mit Aluminiumoxid gefüllt. Das gesamte System fungiert als Oxidspeicher in unmittelbarer
Zellennähe. Dadurch sind verzögerungsfrei
hohe Füllraten in einen Zellenbehälter möglich. Sogar bei Zelltechnologien mit stark
schwankendem Füllstand ist eine sofortige
Nachbefüllung möglich.
• das System ist mit einem speziellen Luftverteilungssystem innerhalb seiner Fluidisierelemente ausgestattet. Diese Vorrichtung stellt
bei der Entstehung eines Pfropfens sicher, dass
die Luft diesen nicht umgehen kann, sondern
in den Pfropfen eingeblasen wird und ihn somit auflöst
• bei normalem Betrieb ist der sehr konstante Luftverbrauch des gesamten Systems vom
Silo zur Zelle geringer als 0,6 bis 0,7 m3/min
pro Zelle. Dies führt zu einer sehr geringen
Fördergeschwindigkeit in den Rohren und
vermeidet das Risiko von Anbackungen
(„scaling“). Durch den geringen und gleichmäßigen Luftverbrauch wird die Gasbalance
der Elektrolysehalle, der Gasreinigungsanlage
und ebenso die Dachemissionen kaum beein-
Innovation in motion
Innovation is in everything we do and in all
the equipment we design and build.
For over 60 years, ECL™ has been the
benchmark for reliable, high quality and
cost-effective equipment for aluminium
smelters, for all technologies.
We will maintain that focus now and in the
future.
www.ecl.fr
flusst. Dies ist ein großer Vorteil speziell bei
Umbauprojekten von existierenden Gasreinigungsanlagen und dem damit zusammenhängenden Gasgleichgewicht.
• Das System arbeitet vollständig selbstregulierend und ohne Sensoren oder Aktoren (z. B.
Schieber, Weichen) an den Elektrolysezellen.
Dadurch entfallen im Vergleich zu anderen
automatischen Systemen die Investitions,Betriebs- und Instandhaltungskosten für diese
Bauteile sowie für die sonst erforderlichen
Kabel und Schaltschränke.
Diese Merkmale des Durodense-Fördersystems zur Zellenbeschickung mit Aluminiumoxid bringen deutlichen Nutzen sowohl in
neuen als auch bei bestehenden Aluminiumhütten.
Nach der erfolgreichen Realisierung der
Förderung und Lagerung von Oxid und Petrolkoks im Hafen von Qatalum und der
Schüttgutaufbereitung auf dem Gelände der
Ma’aden-Aluminiumhütte hat Coperion seine Prozesskette in der Schüttgutaufbereitung
mit dem erfolgreichen Betrieb der Durodense-Zellenbeschickung bei Dubal nun vervollständigt.
n
Optimisation of grain refinement in a
range of casthouse aluminium alloys
M. Bryant, MQP
a best and worst case scenario. This means that
the calibration equation must be set up for the
upper of the two curves and is for the lower
one as well. The practical implication of this is
that there is much to gain if the grain refiners
used have a consistently high efficiency from
batch to batch.
© MQP
Optifine
Fig. 1: Instrumentation used in the Opticast system
MQP Ltd recently presented a paper at
the 2013 TMS Conference in San Antonio, Texas, about optimising the grain
refining process for aluminium alloys [1].
The article is based on that presentation,
including some new information, and
looks at
• the optimisation technique used
• a new powerful and consistent grain
refiner, Optifine
• and their combined effect on a range
of aluminium alloys currently being
produced at a casthouse involved in
the study.
casthouses by using data generated from sampling the melt in real time. Originally conceived
by Lennart Backerud [2] and co-workers at
Stockholm University, and since that time extensively developed, tested and refined, the
Opticast technology is today being used for
optimisation and control of grain refinement
practice in casthouses worldwide.
It produces rapid and reliable results so
that accurate conclusions can be quickly made
regarding implementation of optimised grain
refining practice.
Implementation of the Opticast system in
the casthouse entails the following steps: calibration and sampling in casting furnace.
Calibration involves establishing how a
Optimisation
specific alloy responds to addition of fresh
The Opticast system is proving to be an invalu- nuclei via the grain refining rod, in other
able tool in carrying out assessment and con- words establishing the equations for the grain
trol of grain refinement practice in industrial refinement curves as shown in Fig. 2. It shows
a test carried out with
two different batches of
the same grain refiner
in the same alloy melt.
Obviously one batch
is more efficient than
the other and it follows
that if both grain refiners are being used in a
casthouse, the calibration
must be done to handle
any variations in the grain
refiner efficiencies, that is
Fig. 2: Grain refiner curves for two master alloys with different efficiency
40
Establishing that grain refiner variability is an
important consideration factor in achieving a
fully optimised practice has led to the development of a consistently powerful titanium boron master alloy grain refiner, Optifine.
Optifine is produced via a special production route, which substantially optimises its
nucleation potential. In standard TiBAl grain
refiners only 1% of particles are active, and
large boride particles and agglomerates lead
to preferential formation of large grains
whereas studies have shown that particles in
the size range 1-3µ are optimum for nucleation.
Optifine has been found to have over six
times more active nuclei per ppm of boron
Fig. 3: Microstructure of a standard TiBAl
B
S
D
Fig. 4: Microstructure of Optifine
In
C
Te
Fa
w
SPECIAL
than standard grain refiners and promotes
fine equiaxed structures. Its efficiency as a
grain refiner is at least twice, sometimes up to
thirty times higher than standard Ti Bal refiners normally used.
An independent metallographic study also
shows that Optifine grain refiner has a very
in the typical standard Ti Bal grain refiner
(Fig. 3).
Casthouse trials at a
remelt casthouse – Hulamin
A trial programme carried out using the Opticast system in conjunction
with Optifine grain refiner
showed that adequate
grain refinement could be
achieved in all of theAA alloy
groups that Hulamin produces with additions in the
range 0.1 kg/t up to 0.24 kg/
t compared to the 0.34 kg/t
up to 0.78 kg/t previously
used with a standard TiBAl
(Fig. 5). Expressed in percentages this means reductions of 56-81% in addition
rates.
Following these trials
Fig. 5: Addition rates for standard TiBAl grain refiner (light blue-series
1) and Optifine (dark blue-series 2) for a range of AA alloys
Optifine usage has been implemented in full production
resulting
in
overall
grain refiner usage
uniform microstructure (Fig. 4) without debeing
reduced
to
45
tpy.
nuded zones or TiB2 clusters that can be seen
Conclusion
Optifine is a very potent grain refiner which
allows reduction of addition rates to extremely
low levels over a range of AA alloys. Since
Optifine has a consistent high potency, and the
grain refinement process can be closely monitored with the Opticast method, there is no
risk for cracking of ingots and billets.
Improvements in cast ingot quality can be
expected due to consistent grain size, lower
levels of borides, boride agglomerates and oxides introduced as a result of the substantial
reduction in grain refiner addition as well as
the uniform nature of the Optifine grain refiner microstructure.
References
[1] R. Vainik, J. Courtenay, B. Saglam: Optimisation
of grain refinement, Light Metals, 2013
[2] L. Backerud and R. Vainik: Method for optimised aluminium grain refinement, Light Metals
2001, 951-954
Author
Michael Bryant is marketing manager at MQP Ltd.
BRUSHING AND GRINDING MACHINES
SDV-Santioli AG/
DEMIS Wide Belt Processing Systems
Industriestrasse 10
CH-8157 Dielsdorf
Tel. +41 44 854 0908
Fax +41 44 854 0920
www.demis.ch
Material width up to 3000 mm
Material thickness up to 205 mm
Achieving maximum output when insulating electrolysis cells
A wide variety of insulating materials are
available on the market and it can be difficult to understand the benefits of one
material compared to another. However,
key factors to consider, when insulating
electrolysis cells in the aluminium industry, are the products’ impact on heat loss,
cell efficiency and installation process.
These factors can among other things improve performance efficiencies, prolong
the lifetime of the cells and increase time
between relining.
© Skamol
S. N. Bertel and H. R. Østergaard, Skamol A/S
It is the needle-like micro-structure of the calcium
silicate that provides significant strength to the
boards and maintains it at high temperatures
have a well-defined pore size – the smaller the
pores, the higher insulation value is obtained
when exposed to high temperatures. The structure of small pores with relatively short distances from fix point to fix point makes the
calcium silicate highly insulating compared to
fibre-based boards that are structured by large
pores and, as a result, have a lower insulation
value.
A prolonged lifetime of the cell
Besides finding a highly insulating solution,
another aspect to consider is the strength
and compressibility of the product in order
to avoid damages to the insulation material
from heaving cathode blocks. When infiltratOne of the challenges often faced in the aluing the cathode blocks, gas, bath and molten
minium industry is achieving a cost-efficient
aluminium can cause the blocks to heave and
electrolysis cell. This involves being able to
the insulation material becomes in danger of
keep a stable heat balance in order to reduce
compressing due to the increased pressure.
energy costs and to minimise the risks and the
When the insulation material is compressed,
effects of penetrating gasses, bath and molten
the insulation value of the product will be dealuminium. It also involves a more efficient
creased and the direct result is a significant
relining process, where time is the key factor,
increase in heat loss (cell voltage drop) and
but also a process that embraces the fact that
the electrolysis cell will be taken out of opthe physical environment in many work places
eration.
is becoming increasingly important. Insulating
The Super-Isol and Super 1100 E calcium
the electrolysis cells with highly efficient insusilicate
boards both have a compressive
lation materials can contribute to a solution
strength
of
2.6 MPa at room temperature makto these challenges by bringing benefits like
ing
them
700-800%
stronger than comparaan energy-efficient production with focus on
ble bio-soluble fibre-based boards that have
reducing heat loss, improving cell efficiency
a compressive strength of approx. 0.30 MPa.
and also contributing to an efficient relining
The reason for this difference is evident when
process.
looking at the structure of the products. To obtain strength to the fibre-based
Testing insulating materials
boards, an organic binder is
added in the manufacturing
There is a wide range of materials availprocess and the compressive
able on the market and among these
strength reaches approx. 0.30
are calcium silicate insulating boards
MPa. However, this binder
and fibre-based boards. These products
burns off at approx. 400 °C
are among some of the world’s most
and so the strength disappears
efficient materials when insulating elecwith the consequence of the
trolysis cells – their low thermal confibre-based boards compressductivity combined with their specific
ing and the insulating lining
product characteristics provides highly
becoming unstable. This is not
insulating solutions that are easily inthe case with calcium silicate
stalled thus ensuring an efficient produe to its microstructure and
duction with a minimum of heat loss.
the fact that the pores inside
this product are intertwined,
Low thermal conductivity contribwhich makes the use of binder
uting to a stable heat balance
unnecessary. Calcium silicate,
therefore, is able to maintain
Calcium silicate and fibre-based boards
Calcium silicate pot set from Skamol installed in an electrolysis cell. The pot
strength better than fibreare both highly insulating products and set was delivered according to the specific measurements of this cell, which
based boards.
the use of either product can contribute reduced installation time significantly.
Insulation – a key to
an efficient production
42
to reduced heat loss, energy savings and to an
improved control of the production process
by contributing to maintaining a stable heat
balance inside the cells. The calcium silicate
insulating boards, Super-Isol and Super 1100
E from Skamol A/S, both have a thermal conductivity of 0.14 W/(m*K) at 800 °C, which is
among the lowest in the industry. Recent independent tests conducted to ASTM C-201/182
in 2013 conclude that the thermal conductivity of these two calcium silicate insulating
boards is 27% lower than a leading bio-soluble fibre-based board between the operating
temperatures of 600 to 800 °C. The test was
conducted at several temperatures from 250
to 800 °C and the results vary from a difference of 18% at 600 °C to 27% at 800 °C – all
in favour of calcium silicate. The reason for
the low thermal conductivity of calcium silicate can be found in the structure of the product. To obtain a good insulation value at high
temperatures, the insulating product has to
SPECIAL
Increasing space and
enhancing protection
Efficient insulation not only means a highly
insulating and strong product, it also refers to
a product that is, to a certain extent, able to
resist the influences from destructive gasses,
etc. In the aluminium industry and especially
in electrolysis cells, the risk of fluoride and
sodium gasses, bath and molten aluminium
penetrating the cathodes, graphite blocks,
ramming paste and lining material is always
present. These facts make it important to have
a solid layer of barrier bricks that is able to
withstand this kind of aggressive environment
and underneath it, a strong insulation material that is able to withstand these substances
if these destructive forces should reach them,
thus avoiding damage to the entire cell.
The calcium silicate boards from Skamol
contain a lot of small pores, which provide
them with low gas permeability. These small
pores make it hard for the gasses to penetrate
the product and hence, the insulation value
remains intact. Combined with the low degree
of compressibility and the fact that they retain
significant strength up to approx. 900 °C with
only a 5% creep in compression, the calcium
silicate insulating boards will provide a stable
lining that is protected from gas attacks. The
fibre-based boards, however, consist of large
pores, making them vulnerable to e.g. gas attacks, because of the fact that the gasses condense and freeze inside the boards at 700 to
720 °C thus diminishing the thermal conductivity. Combined with the risk of creating gaps
inside the cell, due to the risk of the material
compressing, gas etc. can penetrate the lining
and a risk of damage to the lining and increasing heat loss is created.
Although carefully lined with a strong insulating product and highly resistant barrier
bricks, gas, bath or molten aluminium will
always, to some extent, be able to penetrate
the carbon / graphite. Therefore, many smelters are trying to figure out ways of increasing the protective layer of barrier bricks while
maintaining a highly efficient insulation of
their electrolysis cells in order to protect the
lining material. Even at small thicknesses,
the low thermal conductivity of the calcium
silicate insulation board opens up for the
possibility of decreasing the thickness of the
insulating lining – making more room for an
increased layer of barrier bricks. The calcium
silicate insulating board, Super-Isol and Super
1100 E from Skamol, can be delivered with
a single layer up to 100 mm thickness while
maintaining a low thermal conductivity of
0.14 W/(m*K). Besides being able to increase
the layer of barrier bricks, reducing the thickness of the insulating material also makes it
possible to install bigger cathodes. This can,
other things being equal, prolong the lifetime
of the cell due to the fact that most cells are
taken out of operation, when the cathode
block is worn down. A combination of a reduced refractory layer and bigger cathodes
is also possible – making the cell even more
efficient.
Using calcium silicate can not only provide
more space and protection of the electrolysis
cells, it can also be installed in combination
Calcium silicate boards are easily installed and dismantled without health risks
with castable material. In cases where castable
material is applied directly onto the back-up
lining material in order to e.g. even out gaps
between the materials, calcium silicate boards,
like the Super-Isol and Super 1100 E, can be
surface-treated to be water-repellent. The water repellent surface makes them unable to
absorb water from the castable material and
the risk of using this product, whether installing barrier bricks or applying castable material
directly onto the boards, is non-existent.
Shortening the installation process while
improving the physical environment
Relining electrolysis cells lasts approx. 5 to 7
days from when the cell is turned off to restarting it again including the cooling and relining
time, depending on the size of the cell and
the complexity of the process at the specific
aluminium smelter. This is done manually and
a contractor is often hired to do the work and
it is a process that is connected with many
costs. Combined with the pursuit of minimising
cost due to the decrease in aluminium prices,
these costs are often sought reduced.
Insulation materials like the calcium silicate
insulating boards and fibre-based boards are
mostly delivered as whole boards in standard
sizes making it necessary to cut the products
before installation as the electrolysis cells are
often shaped with round corners and conical walls. Although both products are easily
handled and cut, more and more smelters in
the aluminium industry see the advantages of
installing pre-cut boards ready for installation without further adjustments. This opens
up for the possibility of reducing installation
time significantly as no further measurements
and machining of the product is necessary and
the product can easily and quickly be installed.
The calcium silicate pot sets from Skamol can
be placed on the pallets according to the sequence that they will be used on site, reducing
the inventory and shortening the installation
process significantly.
Although relining can be done more efficiently and a long lifetime of the cell can
be achieved using the right combination of
production process and insulating material,
relining will continue to be a recurrent event
for aluminium smelters and so, protecting the
health of the people working with and around
the cells during relining is still an important
factor. The calcium silicate board, Super-Isol
and Super 1100 E, has been classified as nonhazardous by government bodies worldwide,
so there is no risk of handling the product.
This is due to the fact that the product is manufactured as 100% fibre- and shot-free and
therefore does not emit hazardous dust. This
is also the case during dismantling of the product opposed to fibre-based boards – though
easily managed and cut – the silica inside the
fibre boards crystallises over time and they
thereby pose a health risk especially during
dismantling which makes it important to wear
a lot of personal protective equipment. Calcium silicate is therefore a healthier solution.
Calcium silicate insulating
boards from Skamol
Calcium silicate insulating boards from Skamol
were developed and introduced to the market
in the 1980s. Since then, the material has been
used extensively throughout many industries,
including the aluminium industry, where it is
primarily used as sub-cathodic and sidewall
insulation to improve the thermal efficiency
of energy-intensive processes. Skamol is one
of the leading suppliers of insulation solutions
to the aluminium industry, and the Skamol
calcium silicate board is used by aluminium
smelters all over the world from Norway to
New Zealand, Canada and Abu Dhabi etc.
Authors
Søren Nørgaard Bertel is application manager, Aluminium Industry, Skamol A/S at Nykøbing Mors,
Denmark.
Holger Raun Østergaard is business director, Aluminium Industry, Skamol A/S at Nykøbing Mors,
Denmark.
43
Die neue Masselgießanlage der Trimet Aluminium im Werk Essen
H. Koch, D. Bramhoff, U. Kremer, Trimet Aluminium; F. Niedermair, Hertwich Engineering
Trimet Aluminium SE hat im Werk Essen
eine luftgekühlte Masselgießanlage errichtet. Die von Hertwich Engineering
gelieferte Einrichtung komplettiert das
Anlagenspektrum der Gießerei und erweitert die Liefermöglichkeiten des Unternehmens.
Das Geschäftsmodell der in Essen ansässigen
Trimet Aluminium hat es dem Unternehmen
erlaubt, unter den nicht einfachen Standortbedingungen in Deutschland erfolgreich
Aluminium zu produzieren. Dabei versteht
sich Trimet als Werkstoffpartner der Aluminiumverarbeiter, der mit maßgeschneiderten
Produkten auf seine Kunden zugeht. Im Sinne
dieses Anspruchs hat das Unternehmen sein
Lieferprogramm kontinuierlich erweitert.
Derzeit hat Trimet circa 150 verschiedene
Abmessungen in 450 Legierungen (auch
Glanzwerkstoffe) sowie Sonderqualitäten
nach Kundenspezifikationen im Programm.
Eine wichtige Rolle dabei spielen Produkte
zur Herstellung von Sicherheitsteilen für die
Automobilindustrie, die nach Prüfung auf
Europas modernster Ultraschallprüfanlage
mit Null-Fehler-Garantie ausgeliefert werden
können.
Gießereierweiterung für neue Produkte
H. Koch, D. Bramhoff, U. Kremer, Trimet Aluminium;
F. Niedermair, Hertwich Engineering
At its plant in Essen Trimet Aluminium
SE has set up an air-cooled ingot casting
unit. The installation, supplied by Hertwich Engineering, supplements the range
of equipment at the casthouse in Essen
and extends the company’s delivery options.
The business model of Trimet Aluminium has
made it possible for the company to produce
aluminium successfully even under the by no
means favourable local conditions that prevail
in Germany. Trimet regards itself as a materials partner for aluminium processors, offering
its customers tailor-made products. In support
of that claim the company has continually extended its product range.
Currently Trimet produces some 150 different formats in 450 alloys (including bright
materials) as well as special grades in accordance with customer specifications. In this, an
important role is played by products for the
manufacture of safety-relevant components
for the automotive industry, which can be supplied with a zero-defect guarantee after being
tested on Europe’s most modern ultrasonic
(US) testing unit.
Casthouse extension for new products
For its extensive product range the casthouse
in Essen has the following equipment in total:
• 14 furnace units and another furnace for
melting down swarf and chips
• nine vertical continuous-casting units for
semis in various formats
• one continuous-throughput and eight
batch homogenising furnaces
• a fully automatic US-testing unit for
round bars
• a horizontal continuous-casting unit for
ingot production, and
• an R & D continuous-casting plant,
including its own homogenising furnace.
The plant produces around 250,000 tonnes
a year, of which 160,000 tonnes come from
the company’s own primary production and
90,000 tonnes from recycled material.
Ingots of casting alloys can optionally be
produced by horizontal continuous casting
© Hertwich
Für dieses umfangreiche Lieferprogramm ver-
The new ingot casting plant at the
Essen works of Trimet Aluminium
Die neue Massel-Gießanlage von Trimet
44
The new ingot casting plant at Trimet
SPECIAL
or by casting into moulds. In Essen, until now
only one automatic, 24-strand horizontal casting machine was available for producing such
material for delivery. By supplying mould-cast
ingots Trimet can now satisfy the expectations
of many of its customers.
Another aspect of this is that Trimet anticipates increasing demand for casting alloys,
some of which, such as hypereutectic AlSi and
AlCu alloys, cannot be cast using a horizontal
continuous-casting unit.
New ingot casting plant with air cooling
For that reason too, among others, in 2011
Trimet decided to invest in a modern ingot
casting plant. As its equipment partner for the
project Trimet opted for Hertwich Engineering, a subsidiary of the SMS group and market
leader in the field of casthouse equipment for
the aluminium industry.
Hertwich produces
both horizontal continuous-casting
machines and batch-type
ingot casting units
(with metallic moulds).
The present-day mould
casting concept goes
back to the year 2000:
at that time Austria
Secondary Aluminium
(ASA) set Hertwich
the task of providing a
new type of ingot casting unit whose concept Cooling zone
differed from the versions then available on the market in a number
of particular respects. The criteria, among others, were:
• a plant fully automated from the pouring
of the metal to the bundle of ingots ready
for dispatch, having high performance and
being designed in a space-saving manner
• Primary cooling as far as complete solidification in the mould should be done with
air; until then water cooling was standard.
The result was the concept of an air-cooled and
water-cooled casting belt, with which the solidification can be controlled very precisely. This
design, which combines high product quality
with economical and environmentally acceptable operation, proved persuasive to Trimet in
its investment decision.
Plant and working method
The plant installed at Trimet for ingots weighing between six and ten kilograms achieves a
maximum casting rate of ten tonnes an hour.
fügt die Essener Gießerei über insgesamt
• 14 Ofenanlagen sowie einen Späneofen
• neun vertikale Stranggießanlagen für
Halbzeugformate
• eine Durchlauf- und acht Kammerhomogenisieranlagen
• eine vollautomatische Ultraschallprüfanlage für Rundbarren
• eine Horizontal-Stranggießanlage für die
Masselproduktion sowie
• eine F&E-Stranggießanlage einschließlich
Homogenisieranlage.
Die Jahresproduktion des Werkes beträgt derzeit etwa 250.000 Tonnen, die sich aus 160.000
Tonnen eigener Primärerzeugung und 90.000
Tonnen Recyclingmaterial zusammensetzt.
Gusslegierungsmasseln können wahlweise
im Horizontal-Strangguss oder im Formguss
erzeugt werden. In Essen stand für diese
Lieferform bisher ausschließlich eine automatische 24-strängige Horizontal-Stranggießan-
kille). Das moderne Kokillen-Gießkonzept
geht auf das Jahr 2000 zurück: Damals hatte
die Austria Sekundär Aluminium (ASA) Hertwich aufgefordert, eine neuartige Masselgießanlage anzubieten, deren Konzept sich von den
seinerzeit am Markt erhältlichen Bauformen
durch eine Reihe besonderer Merkmale unterschied. Kriterien waren unter anderem:
• eine vom Metalleinguss bis zum versandfertigen Masselbund voll automatisierte
Anlage mit hoher Leistungsfähigkeit und
in platzsparender Ausführung
• die Primärkühlung bis zur vollständigen
Erstarrung in der Form sollte mit Luft
erfolgen; bis dahin war die Wasserkühlung
Standard.
Im Ergebnis entstand das Konzept des luftund wassergekühlten Gießbandes, bei dem
sich die Erstarrung sehr präzise steuern lässt.
Diese Bauform, die eine hohe Produktqualität
mit wirtschaftlicher und umweltgerechter Betriebsweise verbindet, hatte auch Trimet bei
deren Investitionsentscheidung überzeugt.
Anlage und Arbeitsweise
Kühlstrecke
lage zur Verfügung. Mit der Lieferung von
Formgussmasseln entspricht Trimet nun den
Erwartungen vieler Gießereikunden.
Hinzu kommt ein weiterer Aspekt: Zukünftig werden nach Einschätzung der Trimet
verstärkt Gusslegierungen nachgefragt, die
nicht auf einer horizontalen Stranggießanlage
gegossen werden können, wie beispielsweise übereutektische AlSi- und AlCu-Legierungen.
Neue Masselgießanlage mit Luftkühlung
Auch aus diesem Grunde hat sich Trimet 2011
zur Investition einer modernen Masselgießanlage entschlossen. Als Ausrüstungspartner
entschied sich das Unternehmen für die österreichische Hertwich Engineering, ein Tochterunternehmen der SMS group und Marktführer
bei Gießereiausrüstungen für die Aluminiumindustrie.
Hertwich baut sowohl horizontale Stranggießanlagen als auch Masselgießanlagen (Ko-
An der bei Trimet installierten Anlage für
Masseln zwischen sechs und zehn Kilogramm
erreicht die Gießrate maximal zehn Tonnen
je Stunde.
Gießstation: Die abgebildete Gesamtanlage zeigt links zwei Gießöfen mit Durchflussregelung. Zwei unabhängige Ofenanlagen sind
zweckmäßig, um beim Legierungswechsel den
kontinuierlichen Betrieb aufrechtzuerhalten.
Über eine feuerfeste Gießrinne gelangt das
etwa 700 °C heiße Metall über einen Keramikfilter zum Gießtrog, der während des Gießprozesses synchron mit dem Gießband verfährt. Die höhenverstellbaren Gießöffnungen
gewährleisten dabei eine präzise Dosierung
und einen weitgehend turbulenzfreien
Schmelzefluss. Die abgebildete Einrichtung
füllt jeweils fünf (vorgewärmte) Kokillen
gleichzeitig.
Die Kokillen durchlaufen, auf einem umlaufenden Gießband montiert, die Kühlzone.
Der entscheidende Vorteil der neuen Masselgießeinrichtung ist die deutlich geringere
Oxidbildung. Dieser Aspekt gehört zu den
qualitätsbestimmenden Kriterien, da Oxideinschlüsse das Schmelzbad beim Wiedereinschmelzen verunreinigen. Als ein weiterer
Vorteil kommt die präzise Gießsteuerung
hinzu, die unterschiedliche Masselgewichte
ausschließt.
Primärkühlung mit Luft: Um Erstarrungsrisse zu vermeiden, kommt es zu Beginn der
Erstarrung darauf an, den Temperaturgradienten zwischen Kern und Randbereich gering
45
zu halten. Die erste Zone der Kühlstrecke ist der Masselgießanlage nicht erforderlich.
deshalb so ausgelegt, dass Temperaturschocks Stapeln, Verpacken, Umreifen: Am Ende des
oder Wellenbewegungen der Schmelzeober- Kühlprozesses schließlich stehen voll automatisierte Anlagen zum Stapeln, Markieren, Umfläche vermieden werden.
Die Primärkühlung erfolgt deshalb mit- reifen sowie zum Wiegen zur Verfügung.
Im ersten Arbeitsschritt werden die gekühltels Luft. Die Kühlluftkanäle sind zwischen
ten
Masseln stirnseitig signiert, paarweise (bei
dem Ober- und Untergurt des Gießbandes
Fußmasseln)
bzw. lagenweise zum Stapeln
angeordnet, sodass die Kühlluft nicht direkt
vorbereitet
und
schließlich von einem Indusauf die flüssige Metalloberfläche auftrifft.
trieroboter
im
anschließenden
VerpackungsDie erwärmte Luft wird mittels zusätzlicher
system
abgelegt.
Beim
Stapeln
werden
die LaVentilatoren über dem Gießband abgeführt.
gen
über
Kreuz
auf
den
zuvor
positionierten
Wenn die Oberfläche komplett erstarrt ist,
gelangen die Kokillen in einen Bereich inten- Fußmasseln abgelegt. Mit einem Tintenstrahlsiverer Luftkühlung. In diesem Bereich des drucker wird jede Massel markiert.
In der Umreifungsmaschine wird der MasGießbandes wird die Erstarrung vollendet.
Die Kühlintensität ist über die Ventilatorsteu- selstapel schließlich mit Umreifungsbändern
versehen. Dabei verfügt Trimet über mehrere
erung regulierbar.
Diese Art der Kühlung besitzt gegenüber optionale Möglichkeiten: So ist eine Auswahl
der Wasserkühlung metallurgische und wirt- zwischen verschiedenen Bandmaterialien, der
schaftliche Vorteile. Im Hinblick auf die Pro- Anbringung einer Querumreifung für gesteigerte Stabilität oder die Bildung von Doppelduktqualität sind dies unter anderem:
stapeln möglich.
• dichtes Masselgefüge durch gezielt
Im Rahmen der Versandvorbereitung wird
gesteuerte Kühlwirkung
der Stapel verwogen und etikettiert. Die Daten
• optimale Einstellung der Kokillenwerden vom Rechner an die Produktionssteutemperatur
erung und den Versand übermittelt.
• Kokillen kommen nicht mit Wasser in
Automatisierung: Der gesamte Ablauf vom
Kontakt.
Hinzu kommen bedeutende wirtschaftliche Eingießen in die Kokillen bis zur Entnahme
fertiger Stapel ist voll automatisiert. Jeder
Vorzüge der Luftkühlung:
einzelne Arbeitsschritt wird von speziellen
• Nahezu unbegrenzte Kokillenlebensdauer
Überwachungs- und Diagnoseprogrammen
(keine Temperaturschocks)
kontrolliert. Bei Abweichungen reagiert die
• kein zusätzlicher Kühlwasserverbrauch,
Steuerung unverzüglich. Es wird eine Fehlerkeine Nebenanlagen oder Maßnahmen
meldung generiert, die Aufschluss über die
zur Aufbereitung
Ursache der Störung sowie Vorschläge zur
• geringer Wartungsaufwand an Kokillen
Problemlösung enthält.
und Gießband.
Sekundärkühlung mit Wasser: Die
Masseltemperatur nach dem Gießband beträgt noch etwa 350 °C. Für
das weitere Handling – besonders für
das Farbmarkieren, für das Abbinden
mit Metall- oder Kunststoffband sowie
für das Etikettieren – muss die Temperatur unter circa 50 °C abgesenkt werden. Für diesen Kühlabschnitt setzt Trimet Wasser als Kühlmedium ein.
Dazu durchlaufen die zuvor ausgeformten Masseln einen Kühltunnel, in
dem Sprühdüsen installiert sind. Die
einstellbaren Sprühköpfe erlauben es,
die Kühlung für die jeweilige Aufgabe
zu optimieren. Am Ende des Kühltunnels werden die herunter gekühlten
Masseln mittels Druckluft getrocknet.
Die Kühlwasserversorgung ist Teil
des zentralen Wasserkreislaufes des
Werkes. Hinter dem Kühltunnel wird
das Wasser wieder in diesen Kreislauf
zurückgeführt. Besondere Einrich- Masselstapel vor der Umreifung
tungen sind für die Wasserversorgung Stack of ingots before strapping
46
Casting station: The overall view of the plant
pictured shows on the left two casting furnaces, each with throughput regulation. It is best
to have two independent furnace units in order
to maintain continuous operation even when
changing alloys.
By way of a refractory launder the metal, at
around 700 °C, flows via a ceramic filter into
the pouring trough. During the pouring process the pouring trough moves synchronously
with the casting belt. During this the pouring
openings, whose height is adjustable, ensure
precise metering and largely turbulence-free
flow of the melt. The equipment illustrated
fills five (preheated) moulds simultaneously.
Positioned on a circulating casting belt,
the moulds pass through a cooling zone. The
decisive advantage of the new ingot casting
equipment is that much less oxide is formed.
This is one of the quality-determining criteria,
since oxide inclusions contaminate the melt
bath when remelting. Another advantage is
the precise control of the casting process,
which prevents variation of the ingot weight.
Primary cooling with air: To avoid solidification cracks, at the beginning of solidification
the temperature gradient between the core
and edge areas must be kept small. The first
part of the cooling zone is therefore designed
to prevent thermal shock or wave movements
of the melt’s surface.
Accordingly, primary cooling is done with
air. The cooling air ducts are arranged between
the upper and lower strands of the casting belt
so that the air does not impinge directly on
the surface of the molten metal. The heated
air is drawn off by additional fans above the
casting belt. When the surface has solidified
completely, the moulds pass into a zone of
more intense air cooling. In this section of the
casting belt solidification is brought to completion. The cooling intensity can be regulated by
the fan control system.
Compared with water cooling, this cooling
method has both metallurgical and economic
advantages. As regards product quality these
are, among others:
• a compact ingot such that due to
selectively controlled cooling action
• optimum mould temperature adjustment
• no contact between the moulds and water.
To the above can be added some important
economic advantages of air cooling:
• virtually unlimited mould life
(no temperature shocks)
• no additional cooling water consumption
and no auxiliary plant or preparation
measures
• less maintenance effort and expense for
the moulds and the casting belt.
SPECIAL
Secondary cooling with water: After the cast- In accordance with the stored order data, up
ing belt, the ingot temperature is still around to three different orders can be processed in
350 °C. For the subsequent handling proce- a single batch. For each order the following
dures – particularly colour marking, binding parameters can be programmed individually:
with metallic or plastic strips and labelling – • ingot marking
the temperature has to be lowered to less than • stack type
around 50 °C. For the section in which this • stack weight
takes place Trimet uses water as the cooling • base-layer ingots
• printing and design of the weighing label
medium.
For this the ingots, previously removed • strapping pattern (number of strips) and
from their moulds, pass through a cooling • nature of strapping strip.
tunnel in which spray nozzles are fitted. The
adjustable spray heads enable the
cooling to be optimised for the
job concerned. At the end of the
cooling tunnel the ingots, now sufficiently cooled down, are dried by
compressed air.
The cooling water supply is taken from the plant’s central water
circuit. After the cooling tunnel the
water is returned to that circuit. No
special equipment is needed for the
supply of water to the ingot casting
plant.
Stacking, packing and strapping:
Finally, at the end of the cooling
process fully automatic machines
are available for stacking, marking,
strapping and weighing the ingots.
In the first work step the cooled
ingots are marked on their end
faces in pairs (in the case of baselayer ingots), prepared in layers for
stacking, and finally transferred by Moveable pouring trough during the filling process
an industrial robot to the nearby
packing station. During stacking the layers are Future prospects
laid cross-wise onto the previously positioned
base-layer ingots. Each ingot is marked by an The plant installed in Essen began operating
inkjet printer.
with no problems and is working to the cusIn the strapping machine the stack of ingots tomer’s satisfaction. With a yearly production
is then bound with strapping strips. For this volume of 35,000 tonnes, it is now already
Trimet has a number of options: a choice be- fully occupied.
tween various strip materials, the application
Clearly, the customers too appreciate this
of cross-strapping for greater stability or the new, additional supply form. Trimet answers
formation of double stacks are all possible.
questions about the plant’s workload ambiguAs part of the preparation for dispatch the ous: “200 percent!” Accordingly, it may well
stack is then weighed and labelled. The data prove necessary to increase the casting capacare relayed by computer to the production ity even more in the foreseeable future.
control and dispatch systems.
Automation: The entire sequence from Authors
pouring into the moulds up to the dispatch of
finished stacks is fully automated. Each indi- Dr. Hubert Koch is head of R&D at Trimet Aluminvidual work step is controlled by special moni- ium SE, Essen, Germany.
toring and diagnosis programs. In the event Dr. Dietmar Bramhoff is head of the casthouse at
Trimet Aluminium SE, Essen, Germany.
of any departure from the norm the control
Uwe Kremer is head of factory planning, maintesystem reacts immediately. An error message nance and projects at Trimet Aluminium SE, Essen,
is generated, which contains conclusions about Germany.
the cause of the disturbance and proposals for Franz Niedermair is managing director at Hertwich
Engineering, Braunau, Austria.
solving the problem.
Gemäß den gespeicherten Auftragsdaten können in einer Charge bis zu drei unterschiedliche Bestellungen produziert werden. Für
jede Bestellung lassen sich die folgenden Parameter individuell programmieren:
• Masselsignierung
• Stapelform
• Stapelgewicht
• Fußmassel
• Ausdruck und Gestalt des Wiegeetiketts
• Umreifungsbild (Anzahl der Bänder) und
• Art des Umreifungsbandes.
Verfahrbarer Gießtrog während des Füllvorganges
Ausblick
Die in Essen installierte Anlage ist reibungslos
in Betrieb gegangen und arbeitet zur Zufriedenheit des Kunden. Sie ist mit einem jährlichen Produktionsvolumen von 35.000 Tonnen derzeit bereits voll ausgelastet.
Offensichtlich schätzen auch die Kunden
diese neue, zusätzliche Lieferform. Trimet beantwortet die Frage nach der Auslastung vieldeutig: „200 Prozent“. Es könnte sich danach
als notwendig erweisen, die Gießkapazität in
absehbarer Zeit sogar noch zu erweitern.
Autoren
Dr. Hubert Koch, Leiter Forschung und Entwicklung, Trimet Aluminium SE, Essen.
Dr. Dietmar Bramhoff, Leiter Gießerei, Trimet Aluminium SE, Essen.
Uwe Kremer, Leiter Werkplanung, Instandhaltung
und Projekte, Trimet Aluminium SE, Essen.
Franz Niedermair, Managing Director, Hertwich
Engineering GmbH, Braunau, Österreich.
47
TECHNOLOGIE
Der gesamte Schmelz- und Gießofenkomplex im Bereich des neuen Ofens
The complete melting and casting furnace complex in the area of the new furnace
Neuer Schmelz- und Gießofen der Amag erhöht Gießereikapazität
Die Amag casting GmbH hat durch die
Investition in einen weiteren Schmelzofen mit integrierter Gießfunktion an der
Produktionslinie EMC II eine deutliche
Kapazitätserweiterung bei Walzbarren in
EMC-Technologie geschaffen. Mit der an
dieser Anlage erzeugten Produktqualität
und der Erweiterung des Produktspektrums wird die Position der Amag als
Premiumhersteller von Walzprodukten
weiter gefestigt.
Erstklassige Walzbarren sind die Grundvoraussetzung für hochwertige Walzprodukte.
Die Walzbarrengießerei der Austria Metall
AG (Amag) aus Ranshofen, Österreich, gießt
ausschließlich für den Bedarf des eigenen
Walzwerks. Die Vielfalt an Walzprodukten
stellt besondere Anforderungen an die Kompetenz und Flexibilität der Gießerei. Unter
einem Dach werden alle Al-Legierungsfamilien von 1xxx- bis 8xxx-Werkstoffen vergossen, wobei ein besonderes Knowhow in der
Verarbeitung von hoch- und höchstfesten
Legierungen der 2xxx- und 7xxx-Familien
aufgebaut wurde.
48
New melting and casting furnace
increases Amag’s casthouse capacity
By investing in an additional melting furnace with integrated casting function at
the EMC II production line, Amag casting GmbH has significantly increased the
capacity for rolling slabs using EMC technology. The product quality achieved at
this line and the extension of the product
range contribute to further strengthening
Amag’s position as a premium manufacturer of rolled products.
First-class rolling slabs are a basic requirement
for premium rolled products. The products
of Austria Metall AG’s rolling-slab casthouse
are solely intended for Amag’s own rolling
mill in Ranshofen. The wide range of rolled
products places special demands on the expertise and flexibility of the casthouse. All
families of aluminium alloys, from 1xxx- to
8xxx-materials, are cast at one location; specific know-how has been developed in the
processing of high-strength and super-high-
strength alloys of the 2xxx- and 7xxx-families.
Various continuous casting processes from
conventional vertical continuous casting and
LHC (Low Head Composite Casting) to EMC
(Electromagnetic Casting) are available to
meet the individual product requirements. As
Amag is continuously increasing the output
of rolled products, the company has to adapt
the casthouse capacity for rolling slabs. When
designing new facilities, the focus is always
on meeting quality requirements and increasing flexibility to satisfy customer needs.
The appropriate furnace technology
for different type of scrap
When scrap metal is melted that contains aluminium, it is essential to select the appropriate furnace technology for the different raw
materials. Therefore, the scraps must be exactly sampled and classified as soon as they
TECHNOLOGY
Entsprechend den Produktanforderungen
stehen unterschiedliche Stranggießverfahren
vom konventionellen Vertikalstrangguss über
LHC-Guss (Low Head Casting) bis hin zum
EMC-Guss (Elektro-Magnetic Casting) zur
Verfügung. Die kontinuierliche Steigerung der
Produktionsmenge bei Walzprodukten zieht
folglich auch eine Anpassung der Gießereikapazität für Walzbarren nach sich. Bei der
Planung der Neuanlagen stehen dabei immer
Qualitätsanforderungen und die Erhöhung der
Flexibilität zur Erfüllung von Kundenwünschen im Vordergrund.
© Amag
Die richtige Ofentechnologie
je nach Einsatzmaterial
are delivered. Covered storage of the scraps,
sorted by type, and batch planning based on
guidelines enable high-grade alloys and sizes
to be produced using raw materials in a costefficient manner. Standardised guidelines also
ensure that, out of the large number of different furnaces, the optimum melting technology
is selected for the individual scrap type.
The multi-chamber shaft melting furnace
technology is best suited for small-sized, thinwalled and highly contaminated scraps. The
single-chamber melting furnace has proven
successful for largesized, slightly contaminated scraps at Amag.
Capacity increase of the EMC machine
When a second electromagnetic casting machine (EMC II) and a multi-chamber shaft melting furnace were installed in 2009, the rolling slab production capacity was significantly
increased in the wrought-alloy casthouse. In
late 2012, a new single-chamber melting furnace with combined casting function, with a
bath capacity of up to 70 tonnes, was additionally put into operation and integrated into
the existing site in a particularly space-saving
manner. This additional capacity increase at
the same time provides more flexibility for
the alloy mix. The new casting unit also al-
Ein wesentlicher Punkt beim Schmelzen von
aluminiumhaltigen Metallabfällen ist die Wahl
der richtigen Ofentechnologie für die verschiedenen Einsatzmaterialien. Daher müssen die
Schrotte bereits bei Anlieferung genau bemustert und klassifiziert werden. Die sortenreine
Lagerung der Schrotte unter Dach und eine
auf Richtlinien basierte Chargenplanung ermöglichen die Produktion hochwertiger Legierungen und Formate mit wirtschaftlichem
Einsatzmaterial. Standardisierte Richtlinien
gewährleisten, dass aus der Vielzahl an unterschiedlichen Öfen die Wahl auf die optimale
Technologie zum Schmelzen der jeweiligen
Schrotte fällt.
Für kleinstückige, dünnwandige und stärker verunreinigte Schrotte wird der Mehrkammer-Schachtschmelzofen als die am besten geeignete Technologie betrieben. Bei Einsatz von grobstückigen, nur leicht verunreinigten Schrotten hat sich der EinkammerSchmelzofen bei der Amag bewährt.
an wiederverwerteten Schrotten abzudecken.
Der neue Ofen ist kippbar und mit Regenerativbrennern sowie einer elektromagnetischen Pumpe ausgestattet. Dadurch kann das
Erschmelzen und Reinigen des Schrotts sowie
das anschließende Gießen des flüssigen Metalls in einem Aggregat erfolgen. Die Regenerativbrenner gewährleisten eine optimale
Schmelzleistung bei geringem Energieverbrauch und stark reduzierten CO2-Emissionen. Die patentierte Brennertechnologie und
die dem Ofen angepasste Anordnung der
Brennerlanzen verhindert zudem die Bildung
von Stickoxiden. Die deutliche Senkung des
Energieverbrauchs gegenüber herkömmlichen
Brennern reduziert Kosten und CO2-Emissionen.
Eine zusätzliche Regelung des Gas-LuftVerhältnisses in Abhängigkeit vom Restsauerstoffgehalt im Abgas macht den Energieinhalt
von geringfügigen organischen Schrottverunreinigungen für den Prozess nutzbar. Dadurch
werden Abgase auf ein Minimum reduziert.
Selbstverständlich wurde mit dem Ofen auch
eine hoch moderne Filteranlage errichtet. Damit liegen die Emissionswerte des Ofens bezüglich aller relevanten Schadstoffe weit unter
den gesetzlichen Vorschriften.
Die Ofenanlage besitzt zusätzlich eine elektromagnetische Rohrpumpe mit Zwischenbehälter, der seitlich angebracht ist. Dies ermöglicht neben dem Rühren auch ein effizientes
Auflegieren von Legierungsmetallen bei geringer Oxidbildung. Ein weiterer Vorteil der
Schmelzehomogenisierung ist die Vermeidung
von Überhitzungen an der Oberfläche (HotSpots) und der verbesserte Wärmeaustausch
innerhalb der Schmelze.
Kapazitätserhöhung der EMC-Gießanlage
Amag erhält EnergiemanagementZertifikat ISO 50001
Mit der Installation einer zweiten elektromagnetischen Gießanlage (EMC II) und eines
Mehrkammer-Schachtschmelzofens im Jahr
2009 wurde in der Knetlegierungsgießerei
die Produktionskapazität für Walzbarren signifikant erhöht. Gegen Ende 2012 wurde nun
ein neuer Einkammerschmelzofen mit kombinierter Gießfunktion mit einem Badinhalt
von bis zu 70 Tonnen ergänzend in Betrieb
genommen und besonders platzsparend am
bestehenden Standort integriert. Mit dieser neuerlichen Kapazitätserhöhung wurde
gleichzeitig auch die Flexibilität in Hinblick
auf den Legierungsmix gesteigert. Die neue
Gießgruppe erlaubt es auch, die neuen größeren Barrenformate für das in Bau befindliche
Warmwalzwerk zu fertigen und ein breites
Legierungsspektrum mit einem hohen Anteil
Seit Mai darf Amag ein besonderes Zertifikat
ausweisen: Als Vorreiter unter den metallerzeugenden Unternehmen Österreichs erfüllt
Amag die weltweit gültige Norm ISO 50001
für den Bereich Energiemanagement. Die
Zertifizierung erfolgte durch die renommierte
Lloyd’s Register Quality Assurance.
Ziel dieser energiespezifischen Norm ist
es, Systeme und Prozesse im Unternehmen
aufzubauen, die den Energieverbrauch, die
Energiekosten, die Klimagasemissionen und
andere Umweltbelastungen reduzieren. Maßgeblich für die erfolgreiche Zertifizierung der
Amag war die Optimierung der Energiebilanz
in allen Unternehmensteilen. Dabei wurden
neben Energieaspekten auch Umweltfaktoren
wie Wasser, Abfall, Chemikalien und Gebäude-Energiemanagement berücksichtigt.
Ý
49
TECHNOLOGIE
Amag setzt durch die ressourcenschonende
Erzeugung von Primäraluminium mit Strom
aus Wasserkraft im kanadischen AlouetteWerk sowie durch das Recycling mit modernsten energie- und emissionsoptimierten
Schmelztechnologien in Ranshofen bereits
Industriestandards beim Energieeinsatz und
bei den CO2-Emissionen. Dies gilt auch für
die Großinvestition „Amag 2014“ mit einem
Projektvolumen von 220 Mio. Euro am Hauptsitz in Ranshofen.
Im Gesamtaudit 2013 bescheinigte die Zertifizierungsgesellschaft Lloyd’s der Amag einen hohen Standard sowohl im
• QM allgemein – ISO 9001 als auch bei der
• QM Automobilindustrie – ISO TS 16949
• QM Luftfahrtindustrie – AS /EN 9100
• Umweltmanagement – ISO 14001 und
• Arbeitssicherheit – OHSAS 18001.
n
lows producing new, larger slab sizes for the
rolling mill under construction and covering a
broad range of alloys with a large proportion
of recycled scrap.
The new furnace can be tilted and is
equipped with regenerative burners and an
electromagnetic pump, so scrap can be melted
and cleaned and the liquid metal be cast in
one unit. The regenerative burners provide
for an optimum melting capacity, while at the
same time minimising power consumption
and CO2 emissions. Moreover, the patented
burner technology and burner lance arrangement adjusted to the furnace prevent formation of nitrogen oxides. The significant reduction of power consumption compared to
conventional burners results in a reduction of
costs and CO2 emissions.
The gas-to-air ratio is additionally control-
led as a function of the residual oxygen content in the waste gas, so the energy content
of minor organic scrap contaminants can be
utilised for the process. Accordingly, waste
gases are minimised. It goes without saying
that a state-of-the-art filter system was installed together with the furnace. As a result,
the emission values of the furnace with respect to all of the relevant pollutants are well
below the legal limit values.
The furnace is additionally equipped with
an electromagnetic pump, which is provided
with an intermediate tank mounted at the
side, to enable stirring and efficient alloying
of alloying materials to be performed at a
low oxide formation rate. Another advantage
of melt homogenisation is that hot spots are
avoided and heat exchange in the melt is improved.
n
Alcoa further extends sheet capacity
Investment addresses North American auto demand
Alcoa has announced its plans for a second major expansion in North America
to meet what it sees as a growing demand
for light, durable and recyclable aluminium sheet used in automotive production.
a tenfold increase by 2025.”
Alcoa’s Tennessee expansion will add 200
full-time, high-value jobs upon completion. In
addition, more than 400 jobs will be created
during the construction phase of the expansion, welcomed by the state in its continued
growth in the automotive sector. The project
will convert some of the plant’s can sheet
capacity to high-strength automotive production, as well as installing incremental automotive capacity. The expansion project is
scheduled to begin shortly and be completed
© Alcoa
The company is to invest USD275 million over
the next three years to expand and convert
capacity at its rolling mill in Tennessee to
support automotive manufacturers’ plans for
using more aluminium sheet to increase fuel
efficiency, safety, durability and performance
of cars and light trucks. This latest development follows Alcoa’s previously announced
USD300 million expansion of its Davenport,
Iowa plant due for completion by year-end.
Alcoa claims that the expansion in Tennessee is a great example of how its edge in technology and innovation is securing growth opportunities in its value-added mid- and downstream businesses. Klaus Kleinfeld, chairman
and chief executive of Alcoa, emphasises:
“More and more auto producers are turning
to aluminium to increase the fuel efficiency
and quality of their vehicles – we anticipate a
quadrupling of auto sheet volume by 2015 and
Alcoa Tennessee rolling plant – here, 96-inch mill…
50
…and cold roll storage
TECHNOLOGY
© Chemetall
engine blocks, bonnets
and deck lids, to developing aluminium-intensive vehicles (AIVs)
through the conversion
of the body in white, or
body structure, to allaluminium. However,
the use of aluminium
body structures to improve fuel efficiency
requires new joining
and assembly methods
and Alcoa 951 offers a
non-chrome solution
for enhancing bond
Alcoa Davenport, Iowa rolling plant – here, horizontal heat-treat furnace
durability and enables
more
cost-effective,
mass production of
by mid-2015, enabling the plant to be a key
AIVs.
supplier for both the packaging and automotive
In customer trials, Alcoa 951 has been
markets. Alcoa says that a high proportion of
proven
to be up to nine times more durable
the output planned from the automotive exthan
titanium-zirconium
based applications
pansion is already earmarked with long-term
formerly
used
in
the
automotive
industry and
supply agreements.
these
results
encouraged
OEMs
to specify
Mr Kleinfeld points out that this year marks
th
Alcoa
951
and
request
Alcoa
to
license
it to
both the 100 anniversary of Alcoa’s Tennesth
other
suppliers
in
the
industry.
The
technolsee operations and the company’s 125 anniversary. He stresses that there was a very ogy, through an exclusive global distribution
dedicated and highly engaged workforce in deal, has now been licensed to Chemetall, a
Tennessee and a very supportive community. leading global supplier of surface treatments
for automotive components.
Furthermore, Alcoa 951 technology is beBonding innovation
ing incorporated into the company’s current
The project will incorporate, through Alcoa’s automotive expansion projects underway at
supply chain, the proprietary ‘Alcoa 951’ pre- Tennessee and Davenport, Iowa Works.
“We look forward to partnering with Chetreatment bonding technology which enables
metall
to provide Alcoa 951 to help enable
adhesive bonding of automotive structures
commercialisation
of adhesive bonding of aluand is facilitating more cost-effective, mass
minium
structures
in high-volume automotive
production of aluminium-intensive vehicles.
This technology, the company maintains, has
become the new pretreatment bonding standard for aluminium sheet, extrusion and casting suppliers across the automotive industry,
and the technology solutions are helping to
drive the continued penetration of aluminium
into the automotive market. Ray Kilmer, executive vice-president and chief technology
officer of Alcoa, says: “We are enabling not
just increased penetration, but we are working
with OEMs to do it cost effectively in high-volume automotive applications which, in turn,
necessitates our automotive expansions.”
The use of aluminium in cars is expected
to nearly double by 2025 according to automotive original equipment manufacturers
(OEMs), and today is already the secondmost-used material to produce cars. As OEMs
work to continue to make vehicles more
fuel-efficient, many are extending the use of
aluminium from the present array of parts, Chemetall’s chrome-free pretreatment for
such as heat exchangers, wheels, drive shafts, aluminium extrusions and die castings
applications. This, in turn, will drive lighter
vehicle weights and enable the integration of
sheet, extrusions and castings to ultimately improve fuel efficiency,” Mr Kilmer adds.
The process was developed as a result of
collaboration between Alcoa’s automotive
business and the company’s Technical Centre,
the world’s largest light metals research facility, located near Pittsburgh, PA.
About Alcoa 951 adhesive bonding
Alcoa 951 employs an organic, environmentally-friendly system tailored for both the aluminium substrate and the structural adhesives
used for joining. The pre-treatment delivers
far superior bond durability compared to
conversion coating systems such as the titanium-zirconium widely used in the past. Alcoa
claims that customer trials show 951 bonding
is up to nine times stronger than Ti-Zr surface
treatments.
The surface treatment is applied through an
immersion or spray application in which the
organic components bond with oxides present
on the metal surface. The molecular structure
chemically binds aluminium oxide with one
end, and adhesive with the other. This creates
a strong link at the molecular level resulting
in long-life, durable joints for automotive
structures.
The minimal level of treatment on the surface makes it essentially ‘transparent’ in downstream operations in the automotive manufacturing process, such as forming, resistance spot
welding and painting.
Other commercially available conversion
coatings, which generally contain heavy metals and are measurably thicker, lead to potential environmental concerns and diminished
performance in further stages in the manufacturing process. The attractiveness of Alcoa
951 is essentially centres on its repeatability
and simplicity. It does not incorporate exotic components that threaten the ability to
implement the product on a large scale, and
it delivers a minimal environmental impact
demanded by the ‘cradle-to-cradle’ life cycle
required for aluminium.
About Chemetall
Chemetall, headquartered in Frankfurt, Germany, and a division of Rockwood Holdings,
is a leading global supplier of special chemicals, with some 40 operations worldwide and
a focus on processes for the surface treatment
of metals and plastics.
Ken Stanford, contributing editor
51
TECHNOLOGIE
Ein Blick hinter die Kulissen für Gäste aus 22 Ländern
Besucherwoche bei Achenbach Buschhütten
G. Barten, Achenbach
A glimpse behind the scenes for guests from 22 countries
Visitors’ week at Achenbach Buschhütten
G. Barten, Achenbach
Durchschnittlich 60 bis 80 Personen täglich
wurden in der Zeit vom 10. bis 14. Juni in
Kleingruppen durch die Produktionshallen ge- Internationales Publikum vor der Optifoil Heavyslit
führt, wo ein breites Spektrum an Maschinen
und Anlagen vormontiert oder in der Vorin- According to the motto ‘Get in Touch
betriebnahme mit Material präsentiert und with Achenbach Technology’, the visivon Spezialisten an den einzelnen Stationen tors’ week 2013 took place at Achenbach
vertieft erläutert wurden. Aus dem Bereich in Buschhütten. Guided tours through the
Walzwerkanlagen waren dies zunächst ein production halls, a wide variety of speAluminium-Bandwalzwerk für Bandbreiten cialist presentations and individual cusbis 2.150 mm, Eingangsdicken bis 6,5 mm, die tomer support did not only express the
demnächst mit großer Geschwindigkeit bis an ability to perform, but also the willingeine Enddicke von 0,15 mm verwalzt werden. ness to perform and the accommodating
Zusammen mit dem dazugehörigen Feinband- service philosophy of the traditional supwalzwerk werden diese Walzwerke künftig plier for first-class rolling mill machinery
Lithographiebleche höchster Oberflächengüte and foil slitting machines. The feedback
produzieren. Neben dieser anspruchsvollen by the customers was unrestrictedly posiWalzaufgabe sind die hohen
Coilgewichte von 32 Tonnen,
die das Bandwalzwerk bewältigt, hervorzuheben sowie
das integrierte Prozessdatenerfassungssystem, das vorgesehen ist, um die OEE (Overall Equipment Efficiency) im
Produktionsprozess
beim
Kunden zu optimieren.
Weitgehend vormontiert
konnten ferner zwei Folienwalzwerke für 1.700 mm bzw.
1.850 mm breite Bänder von
den Besuchern begutachtet Besuchergruppe vor einem Aluminium-Folienwalzwerk
werden. Hervorzuheben war Visitors in front of an aluminium foil rolling mill
52
© Achenbach
Unter dem Motto „Get in Touch with
Achenbach Technology“ war die
Besucherwoche 2013 bei Achenbach mit
einer Führung durch die Montagehallen
und einer Vielfalt an technischen Vorträgen bei gleichzeitig individueller Kundenbetreuung nicht nur eine Demonstration
der Leistungsfähigkeit, sondern zudem
Ausdruck des großen Leistungswillens des
traditionsreichen Lieferanten erstklassiger
Walzwerkanlagen und Folienschneidmaschinen. Die Resonanz im Kundenkreis
war sowohl von der Anzahl der Besucher
her als auch von ihrem Urteil über das,
was geboten wurde, uneingeschränkt
positiv: Stammkunden fühlten sich in
ihrer Lieferantenwahl bestätigt, neue
Geschäftskontakte konnten geknüpft und
zukunftsweisende Investitionsprojektideen entwickelt werden.
International guests in front of the Optifoil Heavyslit
tive, which was evident by the quantity of
visitors on the one hand and by their reception towards the visitors’ programme
on the other hand. Long-term customers
felt vindicated by their supplier selection, new business relations could be
established and trendsetting investment
projects could be developed.
In the time between 10th and 14th June, an
average number of 60 to 80 people per day
was guided through the production halls in
small groups. There, a wide variety of machinery and systems was presented in
pre-assembled condition or even in precommissioning stage with material. Specialists held detailed presentations on the
single stations. The following machinery
was presented: for the rolling mill field,
an aluminium strip rolling mill for strip
widths of up to 2,150 mm, an entry thickness of up to 6.5 mm, which is to be rolled
to a final thickness of 0.15 mm with high
speed, was presented. Together with the
respective thin-strip rolling mill, these
rolling mills will produce litho sheets of
highest quality in the future. Apart from
this challenging rolling task, the high coil
weights of 32 tonnes as well as the inte-
TECHNOLOGY
grated process data recording system must be
emphasised, which is planned to optimise the
OEE (Overall Equipment Efficiency) in the
customers’ production process.
Moreover, two nearly pre-assembled foil
rolling mills for strip widths of 1,700 mm
and 1,850 mm could be inspected by the visitors. The installation of highly-modern nozzle
valve technology for the coolant distribution
and the use of most modern drive technology
in these rolling mills were special highlights
of this week. Trendsetting media systems,
which are part of the scope of supply such as
Superstack II rolling oil micro-filtration system, WOR rectification system or – in case of
the foil rolling mill 1,700 mm – an Airpure
exhaust air purification system. These systems
are to purify the rolling mill exhaust air of
this and two other Achenbach rolling mills on
the customer’s premises. The recovered rolling
oil can be redirected to the rolling process in
as-good-as-new quality. The guided tour also
stopped in the Optiroll workshop, where key
components such as the various types of flatness measuring rolls were presented.
The foil slitting machines also attracted
great attention. Several foil slitting machines
could be presented in pre-commissioning stage
with material. The huge Optifoil Heavyslit,
which is the presently biggest Achenbach-built
roll slitting machine for the aluminium foil industry having a finish roll weight of 18 tonnes
and a rewinding diameter of 1,800 mm, was
very impressive to the visitors.
Other highly interesting stations on this
guided tour were the Optifoil Varioslit – especially developed for the processing industry
– for smaller finish roll diameters of up to 800
mm and the Optifoil Jumboslit roll slitting machine for higher finish roll diameters of up to
1,200 mm. These very universally usable machines for paper, aluminium, laminates, plastic
and compound foils can be extended by smart
detail solutions, if required.
Another attraction on the guided tour was
the Optifoil Separator in test operation with
material. The separator is part of the Alf Miniplant, which was developed as compact, experience-based complete plant for aluminium
foil production and which is highly demanded
especially on the Indian market. In principal,
the Miniplant comprises an aluminium foil
rolling mill, an Optifoil Separator / Slitter, a
roll grinding machine and three annealing
furnaces.
The guided tour through the production
halls was rounded off by a view into the new
production hall, where from now on those
components will be manufactured, which are
essential for quality and speed of the Achen-
hier besonders der Einbau neuester Düsen- stößt. Die Miniplant umfasst im Wesentlichen
ventiltechnik für die Kühlmittelverteilung ein Aluminium-Folienwalzwerk, einen Optioder der Einsatz modernster Antriebstechnik. foil Separator / Slitter, eine WalzenschleifmaHinzu kommen moderne verfahrenstechni- schine und drei Glühöfen.
Abgerundet wurde die Führung durch die
sche Anlagen, die mit zum Lieferumfang
Montagehallen
durch einen Blick in die neue
zählen wie eine Superstack II WalzölfeinstFertigungshalle,
in der von nun an die Fertifiltrationsanlage, WOR-Rektifikationsanlage
gung
aller
Komponenten,
die wesentlich für
oder im Falle des 1.700 mm breiten Foliendie
Qualität
und
Geschwindigkeit
der Achenwalzwerks eine Airpure-Abluftreinigungsanbach-Produktionsanlagen
sind,
hergestellt
lage, die die Walzwerkabluft dieses und zwei
werden.
Die
Fertigung
wurde
dabei
nach
weiterer Achenbach-Walzwerke beim Kuneinem
modernen
Materialflusskonzept
orgaden reinigen und das rückgewonnene Walzöl
neuwertig wieder in Walzprozess einführen nisiert und weiter ausgebaut.
Auf großes Interesse stießen auch die zwölf
wird. Die Führung machte auch in der Optitechnischen
Impulsvorträge zu bedeutenden
roll-Werkstatt halt, wo Schlüsselkomponenten
Weiterentwicklungen,
die Achenbach in der
wie die unterschiedlichen Typen an Messrolletzten
Zeit
mit
Fokus
auf einen möglichst
len gezeigt und erläutert wurden.
großen
Kundennutzen
vorangetrieben
hat. Zu
Große Aufmerksamkeit zog auch der Beden
Themen
zählten
beispielsweise
Ausführeich der Folienschneidmaschinen auf sich,
von denen gleich mehrere in der Vorinbetrieb- rungen zur „Einzelkontaktwalzentechnolonahme mit Material gezeigt werden konnten. gie“ oder zu „Model Predictive Control“. Die
Besonders eindrucksvoll war allem voran die je nach Interessenlage individuell zugewieriesige Optifoil Heavyslit,
die mit einem
Fertigrollengewicht von 18
Tonnen und
einem Wickeldurchmesser
von 1.800 mm
in der Aufwicklung die
bislang größte
von
Achenbach gebaute
Rollenschneidmaschine für
die Alumini- Optifoil Separator als Teil einer Achenbach Miniplant
umfolienindu- Optifoil Separator as part of the Achenbach Miniplant
strie darstellt.
Weitere interessante Stationen auf dem senen Vorträge brachten den Fachbesuchern
Rundgang zum Thema Schneiden und Wickeln neue Erkenntnisse und führten zu intensiven
waren die speziell für den Verarbeitermarkt Gesprächen, die beim allabendlichen Get toentwickelte Optifoil Varioslit für kleinere gether im Achenbach-Gästehaus häufig weiter
Fertigrollendurchmesser bis 800 mm und die fortgesetzt wurden.
Zusammenfassend kann man sagen, dass
Rollenschneider Optifoil Jumboslit für größere Fertigrollendurchmesser bis 1.200 mm. der integrative Ansatz von Achenbach, WalzDiese sehr universell einsetzbaren Maschinen werkanlagen und Folienschneidmaschinen
für Papier, Aluminium, Laminate, Kunststoff- zum Aluminiumfolienwalzen, -doppeln, -seund Verbundfolien können zudem bei Bedarf parieren und -schneiden gemeinsam zu verdurch pfiffige Detaillösungen in ihrem An- treiben, mittlerweile weltweit im Markt angekommen ist: „Alles aus einer Hand“ vor dem
wendungsbereich noch erweitert werden.
Anziehungspunkt während der Führung Hintergrund eines Made in Germany, das
war nicht zuletzt der Optifoil Separator im nach wie vor weltweit große Strahlkraft beTestlauf mit Material. Er ist Teil einer Achen- sitzt, zählt zu den Alleinstellungsmerkmalen,
bach Alf Miniplant, die als kompakte erfah- die Achenbach für sich beanspruchen kann.
rungsbasierte Gesamtanlage zur Aluminium- Immer größer wird zum anderen aber auch
folienproduktion entwickelt wurde und spe- die Nachfrage nach Optifoil-Schneidmaschiziell im indischen Markt auf rege Nachfrage nen seitens der Convertingindustrie, und dies
53
TECHNOLOGIE
Inhaberfamilie Barten in der 7. und 8. Generation
Owner family in the 7th and 8th generation
besonders dann, wenn es um das Schneiden
besonders empfindlicher Materialien, besonders schmaler Nutzen oder besonders großer
Coils in erstklassiger Qualität und mit hoher
Produktivität geht.
In allen Projekten arbeitet Achenbach
traditionell sehr eng mit seinen Kunden zusammen. Angeboten werden im Walzwerkanlagen- wie im Folienschneidmaschinenbau keine Standardlösungen, sondern das
Knowhow, die Zukunftsideen der Kunden
maßgeschneidert in erstklassige Maschinenund Anlagentechnik umzusetzen. Dabei hat
die 125-jährige Erfahrung im Bau komplexer
Maschinen und Anlagen gezeigt, dass es vor
allem in zukunftsweisenden ehrgeizigen Projekten stets um die Balance geht zwischen der
Solidität eines bewährten Maschinenbaus und
dem Mut, technisch immer ausgefeiltere Lösungen zu entwickeln.
n
bach production machinery. the unique characteristics of Achenbach
The manufacturing process was Buschhütten. Above that, the demand for
therefore organised and further Optifoil slitting machines in the converting
extended according to a modern industry is steadily growing, especially, when
material flow concept.
slitting of highly sensitive materials such as
Twelve technical keynote very small or big coils to high-class quality
presentations on decisive inno- with high productivity is concerned.
vations, Achenbach has recently
In all projects, Achenbach is traditionally
pushed focussing on the great- working closely with its customers. Neither in
est possible customer’s benefit, building rolling mill machinery nor in building
were of great interest. Two of foil slitting machines standard solutions are ofthe topics presented were Sin- fered, but the know-how to turn future congle Contact Roller Technology cepts of the customers into tailored machinery
and Model Predictive Control. and plant technology. 125 years of experience
The individually planned pres- in building highly complex plants and machinentations revealed new knowl- ery have shown that trendsetting and competiedge and resulted in intensive tive projects always need the balance between
conversation, which was often both, the solidity of experienced engineering
continued on occasion of the ‘Get together’ and the courage to continuously develop ever
in the Achenbach guesthouse, which was held more refined solutions.
n
every evening.
Summarising, it can
be said that the integrative technological
approach by Achenbach to market rolling
mill machinery and
foil slitting machines
for doubling, separating and slitting aluminium foils has now
arrived on the world
market: ‘Everything
from a single source’
and the well-known
Made in Germany,
still having world- Abendliches Get together im Garten des Gästehauses
wide charisma, are Get together in the guesthouse garden in the evenings
Kampf eröffnet neue Montagehallen am Standort Mühlen
Im Rahmen eines festlichen Empfangs hat
die Kampf Schneid- und Wickeltechnik
GmbH & Co. KG Mitte Juli ihre neuen
Montagehallen am Hauptstandort Mühlen
eingeweiht. Der Vorstand der Jagenberg
AG, Vertreter aus Politik und Presse sowie die mit der Planung und Umsetzung
des Bauprojektes betrauten Lieferanten
und Mitarbeiter waren der Einladung von
Geschäftsführer Lutz Busch gefolgt.
Der Startschuss für die Erweiterung der Produktionsfläche erfolgte im Juli 2012. Neben
der Modernisierung und Instandsetzung der
vorhandenen Gebäude entstanden vier neue
Hallen mit 6.400 m2 Gesamtfläche, davon
54
Kampf opens new assembly
halls at the Mühlen site
Kampf Schneid- und Wickeltechnik officially opened new assembly halls at its
headquarters in Mühlen, Germany, in
mid-July. The executive board of Jagenberg AG, representatives from politics
and the media as well as suppliers and
employees entrusted with the planning
and implementation of the construction
project accepted the invitation from managing director Lutz Busch.
The expansion of the production area began
in July 2012. In addition to the modernisation
and restoration of the existing buildings, four
new halls with a total usable area of 4,400 m2,
plus 450 m2 for staff facilities, were constructed. The crane system has a load capacity of up
to 60 tonnes.
The persistently high number of orders
received by Kampf necessitated the urgent
expansion of capacity. The company had temporarily hired external assembly space. This
situation led to logistics problems and did not
represent a permanent solution. In his opening
TECHNOLOGY
speech, Lutz Busch
Bis zum Sommer nächemphasised
that
sten Jahres werden weiKampf was oriented
tere
Baumaßnahmen
to the future. The
durchgeführt. So soll ein
high-tech machines
neues Bürogebäude und
delivered from the
eine zusätzliche Halle
Mühlen site were
für den Kundendienst
characterised
by
entstehen. Darüber hihighest quality in
naus will Kampf bis
terms of performEnde dieses Jahres eine
ance,
precision,
neue Ausbildungswerkreliability and lonstatt schaffen. Das Invegevity and enjoyed
stitionsvolumen für die
an excellent reputagesamte Baumaßnahme
tion worldwide, he
beträgt insgesamt rund
said. The completed
11 Mio. Euro.
new production ar- Durch das gemeinsame Durchtrennen eines Bandes wurden die neuen Montagehallen offiziell freigegeKampf Schneid- und
eas would increase ben: (von links) Erich W. Bröcker (Vorstand Jagenberg AG), Werner Becker-Blonigen (Bürgermeister der
Wickeltechnik ist seit
Stadt Wiehl), Jan Kleinewefers (Vorsitzender des Aufsichtsrats der Jagenberg AG), Lutz Busch (Geschäftsefficiency.
mehr als neun Jahrführer Kampf), Stefan K. Kranzbühler (Vorstand Jagenberg AG) und Andre Lang (Planungsbüro Lang &
Further
con- Stranzenbach)
zehnten einer der Techstruction projects The new assembly halls were officially opened by the joint cutting of a ribbon: (from left) Erich Bröcker
nologieführer in der
(member of the executive board at Jagenberg AG), mayor Werner Becker-Blonigen, Jan Kleinewefer
will start this sum- (chairman of the supervisory board at Jagenberg AG), Kampf managing director Lutz Busch, Stefan
Schneid- und Wickelmer. A new office Kranzbühler (member of the executive board at Jagenberg AG) and Andre Lang (Lang & Stranzenbach
technik. Das Unternehbuilding and an ad- planning office).
men beschäftigt insgeditional hall for customer service will be built 4.400 m2 Nutzfläche plus 450 m2 für die So- samt fast 600 Mitarbeiter. Das Produktproby mid-2014. Furthermore, Kampf intends to zialtrakte. Die Krananlagen können teilweise gramm bietet unter anderem Schneid- und Wicreate a new training workshop by the end of bis zu 64 Tonnen tragen.
ckelmaschinen, Wickler sowie Schmalschnitt2013. The capital expenditure for the entire
Der anhaltend hohe Auftragseingang bei und Spezialmaschinen zur Herstellung und
construction project amounts to around 11 Kampf hatte die Erweiterung der Kapazitäten Verarbeitung von bahnförmigen Kunststoffmillion euros in total.
dringend notwendig gemacht. Das Unterneh- folien, Verbundmaterialien, Laminaten und
Kampf has been a technology leader in slit- men hatte vorübergehend externe Montage- Aluminiumfolien.
ting and winding of various materials for over flächen zur Auftragsabwicklung angemietet.
Kampf ist weltweit der größte Hersteller
90 years. The company employs around 600 Diese Situation führte zu logistischen Proble- von Rollenschneid- und Wickelmaschinen und
people. It has subsidiaries in the US, China men und konnte keine andauernde Lösung Wicklern für Folien. Der Exportanteil beträgt
and India as well as international service and sein. Geschäftsführer Busch betonte in seiner 90 Prozent. Das Unternehmen hat Tochtersales outlets. The product range comprises re- Eröffnungsrede, dass Kampf auf die Zukunft gesellschaften in den USA, China und Indien
winders, unwinders and winders; slitters for ausgerichtet sei. Die vom Standort Mühlen sowie internationale Service- und Vertriebsthe converter industry and for thinnest types ausgelieferten Hightech-Maschinen zeichne- niederlassungen. Schwerpunkte des umfangof foil, including the appropriate handling sys- ten sich durch höchste Qualität hinsichtlich reichen Portfolios bilden Rollenschneidmatems; separators and doubling machines for Leistungsfähigkeit, Präzision, Zuverlässigkeit schinen und Wickler bis 10.400 mm Materialthe production of aluminium foil as well as und Langlebigkeit aus und hätten weltweit ei- breite für Kunststofffolien sowie Doppler- und
slitters for aluminium foil and strip.
Separiermaschinen für Aluminiumfolien. n
n nen hervorragenden Ruf, sagte er.
HPI errichtet Horizontal-Stranggießanlage in Shanghai
High Performance Industrietechnik (HPI),
eine 51%-Beteiligung der Salzburger Aluminium AG, hat für das japanische Unternehmen Kobe Steel eine Horizontal-Stranggießanlage entwickelt, die in China montiert
und in Betrieb genommen wird. Auf dieser
Anlage werden für die Automobilindustrie
Aluminium-Schmiedebolzen produziert, die
einen Durchmesser zwischen 60 und 100 mm
sowie eine Länge von 2.700 bis 3.500 mm
haben. Maximal 16 Stränge können gleichzeitig gegossen werden. Das Schmieden erfolgt
in einem nachgeschalteten Arbeitsschritt mit
Exzenterpressen, deren Presskräfte 8.000
Tonnen und mehr betragen.
SAG Engineering lieferte für dieses Projekt das komplette Steuerungssystem und
zeichnet auch für die gesamten elektrischen
Funktionen verantwortlich. Als Basis dient
eine Hochleistungs-CPU mit elektrischen Servomotor-Systemen für die acht integrierten
Servomotorachsen.
Schon im Jahr 2000 hat HPI seine Kompetenz in der Kokillentechnik bewiesen und
den Zuschlag für die Konstruktion der ersten
Kobe-Anlage in Daian (Japan) erhalten. Der-
zeit betreibt das Unternehmen HPI-Anlagen
in Japan, Amerika und China.
Zur Montage und Inbetriebnahme sind
Mitarbeiter der beiden Firmen 2012 erstmals
nach China an den Kobe Steel-Standort Suzhou geflogen. Nach neun Wochen in China
wurde die Anlage erfolgreich in Betrieb genommen. Folgeaufträge sind bereits in Umsetzung. Die nächste Anlage für Kobe Steel
ist derzeit im Bau und wird noch dieses Jahr
in Bowling Green (Kentucky, USA) in Betrieb
genommen, ebenfalls mit einer elektrischen
Ausrüstung und Knowhow der SAG.
n
55
TECHNOLOGIE
Alumec setzt auf umweltschonenden Korrosionsschutz
Aluminiumvorbehandler macht gute Erfahrungen mit Alodine 5992 von Henkel
Wer morgens gerne eine Dusche nimmt,
hat gute Chancen, dabei in einer Kabine
aus Aluprofilen zu stehen, die von der
italienischen Alumec Srl hergestellt wurden. Metallvorbehandlungsprodukte von
Henkel helfen dem Unternehmen dabei,
auf umweltschonende Weise perfekten
Korrosionsschutz und zugleich eine exzellente Optik zu erreichen.
Alumec adopts to ecologically sound
corrosion protection technology
Aluminium finisher reports good results with Alodine 5992 from Henkel
As you take your shower in the morning, there is a good chance that you will
be standing inside a cubicle framed by
aluminium extrusions manufactured by
the Italian company Alumec Srl. Metal
pretreatment products from Henkel help
© Henkel
partment, the second major production facility
that Alumec operates. The company can finish
around 20 tonnes of profiles there each day,
using a range of Henkel products in the process. These include Alodine 5992, a conver„Die richtige Leichtmetallvorbehandlung ist
sion coating product with particularly sound
zentral für die Qualität eines fertigen Alumienvironmental credentials.
niumprofils“, sagt Giuolio MariaThe pretreatment process takes
nelli, verantwortlicher Ingenieur
place
in a specially designed, narbei Alumec. Darauf legt man bei
row
tunnel
through which the
dem im norditalienischen Rudiano
suspended
workpieces
are slowly
ansässigen Unternehmen großen
drawn
at
a
speed
of
between
Wert. So hat sich Alumec in den
one
and
two
metres
per
minute.
vergangenen 35 Jahren weit über
The
profiles
are
drenched
in the
Italiens Grenzen hinaus hohes
relevant
treatment
liquid
either
Ansehen als Qualitätsanbieter erfrom
above
in
a
cascade
system
or
worben.
sprayed
from
all
sides.
Zu den Kunden gehören beThe process begins with the
kannte Hersteller von Duschkabialkaline
degreasing of the extrunen, Fenster und Türen, Produsions, for which the Henkel prodzenten von Markisen und Jalouuct Ridoline 2105 is used. After
setten aus Alulamellen sowie Architekten, die mit Alu-Elementen Die extrudierten Aluminiumprofile werden für die Vorbehandlung vorbereitet two water rinsing cycles, the treatment continues with non-toxic
Fassaden gestalten. Der Großteil The extruded aluminium profiles are prepared for treatment
Henkel Deoxidizer 1095. There
der Produktion geht ins Ausland.
then follow two further water rinses before
Alumec verfügt über einen eigenen Strang- Alumec achieve exceptional corrosion
the workpieces pass through the conversion
pressbereich, in dem aus den Aluminium- protection results combined with an outRundbarren die unterschiedlichsten Profile standing surface finish using environmen- section where they are treated with Alodine
5992.
hergestellt werden. Diese gehen anschließend tally compatible methods.
gemeinsam mit von Auftragskunden angelieferten Profilen in die Lackierung, dem zweiten “Choosing the right pretreatment is central to Corrosion protection for powderProduktionstrakt bei Alumec. Rund 20 Ton- the quality of a finished aluminium profile,” coated and non-coated aluminium
nen an Profilen kann das Unternehmen dort says Giuolio Marianelli, chief engineer at
täglich verarbeiten. Mehrere Produkte von Alumec. Quality is something that the com- Alodine 5992 is a recent innovation from the
Henkel kommen dabei zum Einsatz, darunter pany, located in Rudiano in the north of Italy, house of Henkel, technology leader in the
auch Alodine 5992, das den Konversionspro- takes particularly seriously. In the last 35 field of surface treatment and a company with
zess umweltschonender macht.
years, Alumec has acquired a notable reputa- a reputation for setting industry-wide standDie Vorbehandlung erfolgt in einem spe- tion well beyond Italy’s borders as a quality ards with its extensive product portfolio. In
ziell konstruierten schmalen Tunnel, durch supplier. Its customers include well-known contrast to toxic chromium(VI)-containing
den die hängenden Werkstücke mit einer Ge- shower cubicle manufacturers, renowned win- passivation media, the conversion coating
schwindigkeit von ein bis zwei Metern pro Mi- dow and door producers, makers of marquees, created with this process consists of non-toxic
nute langsam hindurchgezogen werden. Dabei fly screens and venetian blinds with alumin- chromium(III) compounds. In view of the
fließt kaskadenhaft Flüssigkeit von oben über ium slats, and even architects keen on design- many statutory regulations governing envidie Profile oder sie werden von allen Seiten ing their facades with aluminium elements. ronmental protection and occupational health
mit der jeweiligen Lösung besprüht.
The majority of the company’s production and safety, Alodine 5992 constitutes a viable
Der Prozess beginnt mit der alkalischen goes abroad.
alternative to traditional chromium(VI) conEntfettung der Profile. Hier kommt Ridoline
Alumec has its own extrusion facility in version treatments. The trivalent layer offers
2105 von Henkel zum Einsatz. Nach zwei Spü- which billets of aluminium alloy are drawn bare metal corrosion resistance for uncoated
lungen mit Wasser folgt die Behandlung mit into a range of profiles. These are then taken aluminium surfaces as well as an optimum
dem ungiftigen Henkel Deoxidizer 1095. Es together with extrusions supplied by contract keyed surface for any subsequent coating opfolgen zwei weitere Wasserspülungen, bevor customers to the conversion and coating de- eration.
56
TECHNOLOGY
“We have been particularly impressed with
the product in terms of its health and safety
benefits, as it means we no longer have to deal
with toxic chromium compounds in our facility,” affirms Mr Marianelli. The performance
of Alodine 5992 also impresses the Alumec
expert. “We are very happy with the conversion process, as are our customers,” he says.
Lineguard 2001 as the
pretreatment process controller
Lineguard 2001 steuert Vorbehandlung
At Alumec, the complete aluminium pretreatment process is monitored and regulated by
the Lineguard 2001 system provided by Henkel. This fully automatic supervisor ensures
that the product concentration in the tanks is
constantly kept at the right level, saving labour
time and ensuring more precision and reliability throughout the process. Employees can
take thus care of other tasks, while the problem of human measurement or replenishment
error is also avoided. And with the Lineguard
2001, operatives are also spared over-frequent
contact with the chemicals.
The last process stage at Alumec – following
yet another rinse operation with demineralised water and drying of the workpieces – is
that of powder-coating the profiles. Alodine
5992 is Qualicoat-certified and also meets
the MIL Spec requirements for use on the
products in the aircraft industry. As a Qualicoat-certified company, Alumec is regularly
audited, as required by the associated directive, to ensure that it continues to satisfy the
specified standards.
The use of Alodine 5992 in the conversion
process prior to the powder-coating operation also greatly facilitates wastewater treatment and disposal at Alumec because the
previously required reduction of hexavalent
chromium into the trivalent form is no longer
needed. This is an important aspect for the
company because, in Italy as in many other
countries in the European Union, effluent is
subjected to a strict monitoring regime with
heavy penalties being imposed in the event
of stipulated limit values being exceeded.
Alumec is appreciative not only of Henkel’s products but also of the service that the
company provides. Customer service managers travel from Henkel to the plant once a
month on average, with extra visits assured
if problems should arise. However, the Latin
proverb ‘previdet ac providet’ (prevention is
better than cure), which hangs in Marianelli’s
office, is also something to which Alumec’s
technology partners from Henkel are fully
committed.
n
Aluminiumoberflächen und einen optimalen
Haftgrund für die Lackierung.
„Uns hat das Produkt überzeugt, auch in
Punkto Arbeitssicherheit, da wir keine giftigen
Chromverbindungen mehr im Betrieb haben“,
sagt Marianelli. Auch die Performance von
Alodine 5992 überzeugt ihn. „Wir sind sehr
zufrieden mit der Qualität der Konversion und
unsere Kunden sind es auch,“ ergänzt er.
Den kompletten Prozess der Aluminiumvorbehandlung kontrolliert bei Alumec das von
Henkel installierte System Lineguard 2001.
Die vollautomatische Steuerung sorgt für die
korrekte Produktkonzentration in den Tanks.
Das spart Arbeitszeit und sorgt für mehr Präzision und Sicherheit im gesamten Verfahren.
Mitarbeiter können sich um andere Aufgaben
Das Vorbehandlungsverfahren vollzieht sich in
einem speziellen Tunnel, durch den die hängenden
kümmern, machen keine Mess- oder NachfüllWerkstücke hindurchgezogen werden
fehler und vermeiden häufigen Kontakt mit
The treatment process takes place in a specially
den Chemikalien, während Lineguard 2001
designed narrow tunnel through which the susden Prozess steuert.
pended workpieces are slowly drawn
Letzter Arbeitsschritt nach dem erneuten
die Werkstücke die Konversion mit Alodine Abspülen mit demineralisiertem Wasser und
Trocknen der Werkstücke ist die Pulverla5992 durchlaufen.
ckierung der Profile. Alodine 5992 ist Qualicoat-zertifiziert und erfüllt zudem die MILKorrosionsschutz für lackiertes
Spec-Anforderungen für den Einsatz in der
und unlackiertes Aluminium
Luftfahrtindustrie. Alumec ist ein QualicoatAlodine 5992 ist eine Innovation aus dem zertifiziertes Unternehmen und wird richtliHause Henkel, das mit seinem breiten Pro- nienkonform auf die Einhaltung der geforderduktportfolio industrieweit Maßstäbe setzt. ten Standards überprüft.
Der Einsatz von Alodine 5992 im KonverIm Gegensatz zu toxischen Chrom(VI)-halsionsverfahren
vor der Lackierung erleichtert
tigen Passivierungen basiert die mit diesem
auch
die
Abwasserbehandlung
und Entsorgung
Verfahren erzeugte Konversionsbeschichtung
bei
Alumec,
da
die
Reduktion
des sechswerauf ungiftigen Chrom(III)-Verbindungen. Antigen
Chroms
in
die
dreiwertige
Form entfällt.
gesichts der vielfältigen gesetzlichen AuflaEin
wichtiger
Punkt
für
das
Unternehmen,
da
gen zum Umwelt- und Arbeitsschutz stellt
in
Italien
wie
in
vielen
anderen
EU-Ländern
Alodine 5992 eine Alternative zu traditionellen Chrom(VI)-Konversionsbehandlungen eine ausgesprochen strenge Abwasserkondar. Die dreiwertige Schicht bietet Blankme- trolle erfolgt und hohe Strafen bei der Übertallkorrosionsbeständigkeit für unlackierte schreitung von Grenzwerten drohen.
Nicht nur die Produkte, auch der Service
von Henkel hat Alumec
überzeugt. Etwa einmal
im Monat kommen Kundenbetreuer von Henkel
in das Werk – auch dann,
wenn es keine Probleme
gibt. Dem lateinischen
Wahlspruch „previdet
ac providet“ (besser vorbeugen als heilen), der in
Marianellis Büro hängt,
fühlen sich auch Alumecs
Technologiepartner von
Alumec-Ingenieur Giuolio Marianelli bei der Kontrolle der Anlagenfunktion
Henkel verpflichtet. n
Alumec’s chief engineer Giuolio Marianelli checks the facility’s functions
57
TECHNOLOGY
Recycling of wrought aluminium alloys from post-consumed scrap
Part one: Modelling of alternative wrought aluminium alloy compositions for required properties
V. Kevorkijan, Maribor
1. Introduction
The sustainability of wrought aluminium alloys for demanding structural applications
(e. g. in transportation) is still relatively low.
The prevailing raw materials for their production are primary aluminium and pure alloying
elements, in combination with internal and
new scrap. For this reason, a significant part
of world production of primary aluminium
is actually consumed for the production of
wrought aluminium alloys. The main technological reason for that is in the fact that
wrought aluminium alloys are still very difficult to formulate by recycling post-consumed
aluminium scrap, while the economic reason
lies in the generally higher average cost of
wrought in comparison with cast aluminium
end-products.
The share of wrought aluminium alloys in
world production of aluminium alloys varies
in different parts of world, depending on the
stage of development and the structure of regional industry. The percentage is higher in
the more developed regions of the world, with
the dominant share from the transport industry. Similar ratios between wrought and cast
alloys also exist in post-consumed aluminium
scrap collected in different parts of world.
Generally, due to the higher cost of wrought
alloys, aluminium recyclers are always interested in transforming wrought post-consumed
scrap into new wrought instead of cast alloys.
In the case of internal and also new wrought
aluminium scrap, this is already well practised,
due to the well defined composition of the incoming materials, which are suitable only for
direct remelting (but not recycled in such a
way so as to be transformed at the end into a
new wrought alloy). However, the precondition for recycling – the process by which the
virgin metal from post-consumed wrought
aluminium scrap is cycled back into wrought
alloys – is an appropriate level of sorting into
individual compositional streams suitable for
further blending. Here, the existing technical
difficulties in achieving sufficient productivity
and precision in automatic sorting, together
with the high cost of this operation continue
to reduce the amount of wrought post-consumed scrap recycled back into wrought alloys.
Nowadays, a significant part of post-consumed
wrought aluminium scrap is still consumed for
the production of comparatively cheaper cast
58
alloys, in that way losing an important part
of the potentially available added value.
These trends will
also continue in the
future and, most probably, even be intensi- Fig. 1: Examples of standard and non-standard tolerance limits with the
fied. It is reasonable relevant denotations used in the model
to expect that with further reduction in the production of primary and primary aluminium of the appropriate
aluminium, its share used for the production chemical purity, as well as aluminium scrap
of cast alloys will also be reduced. On the streams with carefully prescribed chemical
other hand, due to the long-term projected composition). On the other hand, the presence
higher cost of primary aluminium caused by of sufficiently narrow compositional tolerance
the higher cost of energy, the producers of limits in wrought aluminium alloys is neceswrought aluminium alloys will try to replace, sary to provide the proper (standard) combibeside existing substitution with internal and nation of various alloy properties (mechanical,
new industrial scrap, the maximum amount electrical, chemical, etc.), exactly prescribed
of primary aluminium with post-consumed by end users.
Post-consumed aluminium scrap exists in
wrought aluminium scrap.
Without technological developments to- waste with changeable, non-exact chemical
ward increasing the share of post-consumed composition and definitely not as a raw mascrap in wrought aluminium alloys, one can terial fabricated with respect with customer’s
expect that in the future most of the technolog- demands. Hence, it is clear that the share of
ically demanding wrought aluminium alloys post-consumed scrap in wrought aluminium
would be produced from primary aluminium alloys could be increased either by sorting
in combination with remelting of internal as to fractions with the required chemical comwell as new industrial scrap. In contrast to this, position and/or by broadening the standard
most cast alloys will be produced from cost- compositional tolerance limits of alloying
beneficial post-consumed scrap. This trend, elements. The first solution requires hand
which is already practised in the aluminium or automatic sorting of post-consumed scrap
industry to some extent, could significantly re- as alloys or groups of alloys to the degree of
duce the sustainability of wrought aluminium separation sufficient to enable the blending of
alloys. It restricts the recycling of aluminium standard compositions of wrought alloys [2,
in the true sense of that process (‘re-usage of 3]; the second solution is much more radical,
post-consumed aluminium in an end product predicting changes in the existing standards
for the same purpose’), mostly to cast alloys, for wrought aluminium alloys toward nonwhile in wrought alloys mostly to remelting of standard alloys but yet having properties acceptable for customers [4]. In this case, the deinternal and new industrial scrap.
The main difficulty in recycling wrought gree of separation of incoming post-consumed
aluminium alloys from post-consumed scrap scrap required is much less demanding.
Nevertheless, to be of interest for customis caused by the existing composition of those
alloys, prescribed by international standards ers, broadening the compositional tolerance
[1]. Currently, on the market there are more limits of wrought aluminium alloys should
than 200 different compositions of wrought result in alloy properties which are still of
aluminium alloys divided into eight classes value for end users. In order to tailor the rebased on the applied alloying elements. From quired (combination and individual values of)
the narrow compositional tolerance limits of properties in wrought aluminium alloys with
alloying elements in practically all wrought alternative composition, it is necessary to dealuminium alloys [1], it is evident that such velop the ability to predict the properties from
chemical compositions could be producible a given chemical composition and vice versa –
only by using raw materials of well defined starting from alloy properties, to predict the
chemical composition (i. e. alloying elements necessary chemical composition of post-con-
TECHNOLOGY
which at the same time do reduced to the intersection of particular internot significantly influence vals, under which all the selected properties
the selected (usually some (YS, US, A and H) are to remain constant siof the mechanical) proper- multaneously.
ties of the alloys.
Mathematically speaking, in the first step
The achievement of we solve the individual equations (5)-(8). Note
Table 1: Wrought aluminium alloy compositions considered in the model
standard wrought alloy that the solution of each of these equations is
composition
by
mixing
various fractions of the enlistment of the intervals of concentration
sumed scrap streams or, in other words, the
scrap
with
different
chemical
composition is (∆Xi). In the second step, the solution of the
necessary level of scrap sorting. Such predicpractically
impossible.
Statistically,
in the real system of Eqs. (5)-(8) under which the selecttion algorithms for wrought aluminium alloys
mixture
obtained
by
combining
such
differed properties remain constant is obtained as
have been reported by several authors-for a
ent
fractions
of
scrap
from
the
scrap
yard,
the the intersection of these various intervals obreview see Ref. [5], but are not focused on the
concentration
of
some
of
the
alloying
eletained for each particular alloying element.
recycling of wrought aluminium alloys from
ments will be higher than those prescribed by
post-consumed scrap.
Thus, the purpose of this paper is to present the standard, the concentration of others will 3. Practical application of the model
possibilities for numerical modelling1 of both be lower and there will also be some alloytechnological options for increasing the amount ing elements whose concentrations will fit the Let us consider a wrought alloy with standard
of post-consumed aluminium scrap in wrought standard requirements.
composition and concentrations of alloying
The situation is illustrated in Fig. 1 where elements inside the tolerance limits, and the
aluminium alloys. Based on the model developed, the optimal solution was suggested as the concentration X1 of the alloying element alternative (‘recycling friendly’) alloy with
the starting point for further development and 1 in the scrap mixture prepared for melting is concentrations of alloying elements slightly
implementation of the appropriate technology inside the standard interval of concentrations, outside the standard tolerance limits (Table 1).
Experimentally available data are collected
of wrought aluminium alloy recycling.
the concentration X2 of the alloying element
2 is higher and the concentration X3 of the al- in Table 2 where the yield strength (YS) was
loying element 3 is lower. However, all three measured and correlated with the actual alloy
2. Modelling of wrought aluminium
concentrations are inside the alternative inter- composition determined by emission spectrosalloy properties as a function of
val of concentrations formulated for a ‘recy- copy.
their chemical composition
Let us further assume that the selected alloy
cling friendly’ composition.
The mathematical condition for ‘recycling properties (e. g. yield strength – YS, ultimate
Generally, the selected properties of a wrought
aluminium alloy (e. g. yield strength – YS, ulti- friendly’ alloy compositions under which the strength – US, elongation – L and hardness
mate strength – US, elongation – L and hard- selected alloy properties will all remain the – H) are polynomial functions of the alloy
composition.
ness – H) can be all expressed as different same is expressed by Eqs.(5) - (8):
Note that in each of the equations in the
dYS = 0 (5)
functions of the alloy composition:
system of Eqs. (5) - (8), the tolerance limits, ∆Xi
dUS = 0 (6)
YS = F (X1, X2, X3, … , Xn)
(1)
dL = 0 (7)
US = G(X1, X2, X3, … , Xn)
(i = 1, 2, 3, … , n) of the individual alloying
(2)
dH = 0 (8)
elements appear as n independent variables.
L = L(X1, X2, X3, … , Xn)
(3)
H = H(X1, X2, X3, … , Xn)
(4) In this way, the model developed gives the Hence, the exact solution of these equations is
Here, X1, X2, X3, … , Xn represent the concen- combination of non-standard and standard not possible. The particular solution of whichtolerance limits (∆Xi) under which the selected ever equations of the system of Eqs. (5) - (8) is,
trations of particular alloying elements.
On the other hand, the concentrations of alloy’s properties YS, US, A and H remain the theoretically speaking, the randomly selected
alloying elements in wrought aluminium al- same. The determination of such a combina- combination of tolerance limits ∆Xi (i = 1, 2,
loys, especially in recycled ones, are most of- tion of non-standard and standard tolerance 3, … , n) for which the right hand side of the
ten designed for achieving maximal strength. limits (i.e. intervals of concentrations for each equation is equal to zero. However, in the
To achieve the proper combination of proper- of alloying elements appearing in the alloy) practical case the values of the tolerance limits
ties (not only mechanical but also electrical, proceeds in two steps. In the first step, the of recycling-friendly wrought aluminium alloy
thermal, corrosion resistant, etc.), the concen- intervals ∆Xi for alloying elements are deter- cannot be selected randomly but should be as
trations of alloying elements should be inside mined by considering each of the properties close as possible to the standard ones. Note
the standard tolerance limits.
individually. After that, in the second step, that these minimal deviations of each alloyHowever, in wrought compositions con- the limits obtained for alloying element were ing element from the standard concentrations
taining an increased amount of scrap, usually
it is not easy and certainly not cost-effective Modelling of the degree of post-consumed scrap sorting for recycling-friendly wrought
to assure such narrow compositions. There- compositions
fore, producers of recycled wrought alloys
Yield strength
Ultimate
Alloying elements (1,2,…n)
Sample
Elongation(%) Harness
(MPa)
strength(MPa)
and their concentrations (%)
try to develop so-called ‘recycling friendly’
1
2
…..
n
compositions with broader tolerance limits,
Alloying elements
1
2
3
……
n
Concentration inside the
X1±∆X1 X2±∆X2 X3±∆X3 …… Xn±∆Xn
tolerance limits, X (%)
Concentration outside the
X1±∆X1 X2±∆X2 X3±∆X3 …… Xn±∆Xn
tolerance limits, X (%)
1
Following the editorial request to avoid extended formulas and demanding mathematical explanations, the
model developed is presented in this article only in a
descriptive way. However, the detailed mathematical approach can be sent by the author on request.
1
2
m
YS1
YS2
YSm
US1
US2
USm
L1
L2
Lm
H1
H2
Hm
X1,1
X1,2
X1,m
X2,1
X2,2
X2,m
Xn,1
Xn,2
Xn,m
Table 2: Experimentally measured data for yield strength (YS), ultimate strength (US), elongation (L) and
hardness (H) as a function of the concentrations of alloying elements
59
TECHNOLOGY
Fig. 2: Organisation of scrap yard for recycling of wrought aluminium alloys from
post-consumed scrap in accordance with
the model
for selecting the (proper combination of) tolerance limits, ∆Xi (i = 1, 2, 3, … , n), of alloying elements under which: (i) the selected
mechanical properties of the alloy remain the
same as in the standard one,
and (ii) the chemical composition of the recycling-friendly
alloy is the same as the premelt chemical composition of
the incoming scrap mixture
(formulated with the minimal
addition of primary aluminium
and alloying elements).
The main priorities in formulation of the recyclingfriendly compositions are:
1. The minimal addition of
primary aluminium and alloyFig. 3: Providing the pre-melt ‘recycling-friendly’ composition of
ing elements
wrought aluminium alloy by combin2. The maximal consumping different scrap streams of postconsumed scrap
tion of regular scrap streams,
daily available in the scrap yard
3. The non-standard alloy composition for
are determined by the chemical composition
of the individual scrap streams available in which the selected mechanical properties rethe scrap yard and involved in creating the in- main the same as in the standard one.
The practical way to do this is by modelcoming scrap mixture pre-melt composition.
In practice, the system of equations (24) is ling, starting from the chemical composition of
applied to numerical modelling of the recy- the scrap streams. The precondition is that the
cling-friendly composition, or, in other words, chemical composition of the recycling-friendly
Fig. 4: Processing steps in modelling the ‘recycling-friendly’ composition for the desired alloy properties
60
alloy should be the same as the pre-melt composition of the incoming mixture consisting
of the combination of various scrap streams
with no or minimal addition of primary aluminium and alloying elements. In addition, the
deviations of the recycling-friendly from the
standard concentrations of alloying elements
should be as small as possible.
In the first step it is necessary to consider
the impact of alloying elements with maximal
deviation of their concentrations from the
standard prescribed. The negative impact of
these elements on alloy properties should be
reduced by minimising the concentration of
others which finally results in the same alloy
properties.
The recycling-friendly compositions of
wrought aluminium alloys should be modelled in accordance with the following two
criteria: (i) the selected chemical composition
and compositional tolerance limits of a recycling-friendly wrought aluminium alloy should
fulfil market expectations regarding the alloy
properties; and (ii) the prescribed recyclingfriendly alloy composition should be routinely
achievable by mixing scrap streams fabricated
in the scrap yard by scrap separation (with or
without minimal addition of primary aluminium and alloying elements).
In order to achieve these two goals, it is
necessary to define the industrial levels of
wrought aluminium scrap sorting. An example
of the practical levels of sorting of post-consumed wrought aluminium scrap is presented
in Table 3. Planning the optimal number of
scrap streams, as illustrated in Fig. 2, their
chemical composition and the compositional
tolerance limits of alloying elements for effective blending of the pre-melting mixture, Fig.
3, with minimal (or even without) addition of
pure alloying elements and primary aluminium is essential for successful running of the
recycling plant and the final business result.
Therefore, adequate organisation of the
scrap separation streams should provide answers to the following key questions of scrap
processing:
• How many scrap streams should be
produced by sorting wrought aluminium wastes in the scrap yard
• How many alloys (just a single one,
a mixture of two or more) should be
involved in these streams
• What should the chemical compositions be (qualitatively, regarding alloying elements and also quantitatively,
considering their concentrations as
well as the compositional tolerance
limits) of those streams, and finally
• For which wrought aluminium alloys
TECHNOLOGY
Level of
Description
scrap sorting
1.
Separation of incoming scrap into cast and wrought aluminium scrap
2.
Scrap of wrought aluminium alloys within the same series
Scrap of wrought aluminium alloys within the same series having the
3.
same combination of alloying elements
Scrap of wrought aluminium alloys within the same series consisting of
4.
more than 2 compositionally similar/comparable alloys
Scrap of wrought aluminium alloys consisting of 2 alloys within the
5.
same series compositionally similar/comparable
6.
Scrap streams of single wrought aluminium alloys
with organics or
other impurities.
Conclusions
The model presented in this
work enables the
design of optimal (standard
and non-standTable 3: Possible industrial levels practiced in wrought aluminium scrap sorting
ard ‘recyclingand under which production scenarios should friendly’) compositions and properties of
wrought aluminium alloys with significantly
the sorted streams used?
A possible way of providing the answers increased amounts of post-consumed scrap.
to the above questions is by calculating the The following two routes were modelled in
appropriate composition of the pre-melt mix- detail: (i) the blending of standard and nonture blended from various scrap streams of standard compositions of wrought aluminium
different chemical composition, as presented alloys starting from post-consumed aluminin Fig. 4.
ium scrap sorted to various degrees simulated
The model enables: (i) computation of the by the model; and (ii) changing the initial
recycling-friendly compositions of (wrought) standard composition of wrought aluminium
aluminium alloys based on the known chemi- alloys to non-standard ‘recycling friendly’
cal compositions and compositional tolerance ones – with broader concentration tolerance
limits of scrap streams formulated by scrap limits of alloying elements, without influencsorting in the scrap yard, or (ii) vice versa, ing the selected alloy properties, specified in
computation of the chemical composition and advance.
compositional tolerance limits of scrap streams
The applied algorithms were found to be
starting from the known composition and tol- very useful in the industrial design of both
erance limits for alloying elements in the se- procedures: (i) computation of the required
lected aluminium alloy.
chemical composition of the scrap streams
The same sorting levels should be applied obtained by sorting (or, in other words, the
to clean and aluminium scrap contaminated post-consumed scrap sorting level), necessary
for achieving the standard wrought alloy composition; and (ii) transformation of standard
to non-standard (recycling-friendly) compositions with the key alloy properties (e. g. tensile strength, elongation) remaining the same.
The most beneficial and particularly promising approach might be the integral (or combined) approach, assuring both possibilities:
(i) the standard chemical composition of the
alloy achieved by a sufficient level of post-consumed scrap sorting predicted by the model,
and (ii) modelling the non-standard alloy
composition by less demanding (and more
cost-effective) sorting, but yet providing end
users with the desired alloy properties.
References
[1] ASM Specialty Handbook, Aluminium and Aluminium Alloys, ed. J. R. Davis, ASM, Materials Park,
USA, 1998, 20.
[2] G. Gaustad, E. Olivetti, R. Kirchian, Resources,
Conservation and Recycling 58 (2012) 79
[3] A. Gesing, L. Berry, R. Dalton, R. Wolanski, TMS
2002, 3
[4] S. K. Das, Light Metals 2006, TMS 2006, 911
[5] J. T. Staley, R. E. Sanders, Jr., Handbook of Aluminium, Vol. 2, ed. G. E. Totten, D. S. MacKenzie,
CRC, New York, USA 2003, 319
Author
Varuzan Kevorkijan, Independent Researcher, Betnavska cesta 6, 2000 Maribor, Slovenia. Contact:
[email protected]
Quick payback – ecological benefits – small investment
Dryplus process drastically reduces sludge volumes from anodising lines
The patented Dryplus process developed by
Modena-based Italtecno aims to significantly
increase the dry matter in the sludge from aluminium anodising treatment lines. It enables
dry fractions to be obtained that are equivalent
to 40-50% of the total aluminium hydroxide
sludge instead of the usual 20-25% achieved
in traditional processes.
The environmental benefit of using Dryplus technology is clearly evident: the sludge
volume is halved and considerably less truck
journeys are needed to transport the sludge.
This results in significant cost advantages
compared with traditional methods (see table).
The Dryplus process consists of a polypropylene reactor with a volume of 10-15 m3
that is suitable for use with alkaline solutions,
such as those from the concentrated rinse tank.
The alkalinity is neutralised in the reactor us-
ing concentrates from the Freeal unit as well be adversely affected; instead it will be subjected to less demanding conditions on a dayas water from the acid rinse.
Aluminium hydroxide is precipitated out to-day basis because the Dryplus technology
with the help of a special flocculant from Italt- will handle the water with the highest impurity
ecno, leading to neutralisation of the concen- content.
trated solutions under wellParameter*
Standard process
Dryplus process
controlled dynamic physical
conditions.
Dry fraction in sludge
20%
45%
As a result of this treatSludge production
1,300 tpy
578 tpy
ment, the aluminium hydroxEstimated cost of
80 €/t
80 €/t
ide precipitate has a higher
sludge disposal
density than in the standard
Annual cost of
104
46,222
process: the dry fraction (40sludge disposal
50%) is twice what can be
Annual saving
57,778
achieved with the conventional processes used today. Based on treatment of water from an anodising line with 30,000 A
Dryplus has been successfully installed capacity
The savings in operating costs attributable to
applied under actual industrial conditions.
Dryplus can be connected to any existing Dryplus are significant and are summarised in
waste water treatment plant, which will not the table.
■
61
TECHNOLOGIE
Präziser Schnitt aus Aluminiumblöcken
Die Gleich Aluminiumwerke GmbH & Co.
KG in Kaltenkirchen stellt Aluminiumplatten
in Plattendicken zwischen 5 bis 600 mm her,
die aus Alu-Gussblöcken mit der Abmessung
2.000 x 4.000 x 800 mm gesägt werden. Das
Unternehmen beschäftigt 190 Mitarbeiter und
beliefert weltweit Kunden aus den Branchen
Maschinenbau, Luft- und Raumfahrt, Werkzeug- und Formenbau, Automotive und Bauwesen. Um die Produktion zu optimieren,
suchte das Unternehmen für Präzisionsplatten nach einer Lösung, die die Sägekapazität
bei durchgehend gleichbleibender Qualität
erhöht.
Das Projekt wurde in enger Kooperation
zwischen Auftraggeber und Auftragnehmer
realisiert. Die Kundenwünsche flossen in die
Konstruktion der neu entwickelten Maxcut A6
x 16 Alu ein. „Das Konzept von Kasto hat uns
überzeugt“, so Andreas Sieg, Produktionsleiter bei Gleich Aluminiumwerke. Die Maxcut
ersetzt bei dem Kaltenkirchener Unternehmen zwei bisher verwendete Sägemaschinen.
Eine der stärksten Maschinen am Markt
Die Hochleistungs-Bandsägemaschine mit 12
Metern Länge und 6,8 Metern Breite überzeugt durch eine hohe Verfügbarkeit und
einfache Bedienung. Bei einem Wechsel der
Aluminiumblöcke wird zudem wenig Zeit vergeudet: Die Stillstandzeiten liegen unter drei
Minuten. Darüber ist der vollautomatische Betrieb der Maschine über mehrere Tage hinweg
gewährleistet. Die Maxcut ist eine der stärksten Maschinen am Markt und aufgrund ihrer
extrem schweren Bauart für den mittleren bis
sehr harten Produktionseinsatz ausgelegt, so
Kasto, und für den Einsatz von Bi-Metall- und
Hartmetallbändern geeignet.
Die Bandstandzeiten konnten durch den
Einsatz der Maschine deutlich verbessert
werden. Sie wurden im Vergleich zu den früher genutzten Anlagen auf 3.000 Quadratmeter verdoppelt. Zu den weiteren Stärken der
Bandsägemaschine gehören die Vernetzung
zum kundenseitigen ERP-System und die
62
deutliche Verbesserung der Späneabsaugung
gegenüber vergleichbaren Maschinen.
Die Schnittgeschwindigkeit der Anlage ist
stufenlos von 300 bis 3.000 m/min regelbar.
Durch den Einsatz modernster Konstruktionstechnologie und Fertigungsverfahren werden
ermöglicht die automatische Zuordnung der
Schnitttechnologie für die entsprechenden
Materialqualitäten und des eingesetzten Sägeblattes (HSS oder HM). Bis zu 2.000 Materialdaten können gespeichert werden, der Auftragsspeicher ist für die Eingabe von 1.000
© Kasto
Die neu entwickelte Hochleistungs-Bandsägemaschine Maxcut A6 x 16 Alu der Firma Kasto Maschinenbau sorgt bei Gleich
Aluminiumwerke für saubere, hoch präzise Schnitte aus Aluminium-Gussblöcken.
Die Anlage zeichnet sich unter anderem
durch eine gleichbleibende Qualität bei
hoher Schnittleistung, einfache Bedienung und geringe Stillstandzeiten aus.
Mittels Vakuumsystem werden die Platten nach dem Sägen zur weiteren Verwendung abgelegt
laut Kasto eine besonders hohe Laufruhe und
ein vibrationsfreies Arbeiten erreicht. Dies
bedeutet kürzere Schnitt- und höhere Werkzeugstandzeiten. Die Führung der Sägeeinheit erfolgt über zwei senkrecht außerhalb des
Arbeitsraumes stehende, groß dimensionierte
Führungssäulen. An jeder Führungssäule sind
jeweils zwei Linearführungseinheiten mit je
sechs spielfrei eingestellten Führungswagen
angeordnet. Dieses System gewährleistet hohe
Steifigkeit, maximale Dämpfung und Schnittpräzision, stellt Kasto heraus.
Wartungsaufwand minimiert
Die Maschine ist mit einer Schrägstellung des
Sägewerkzeugs durch asymmetrische Anordnung der beiden Sägeköpfe ausgestattet. Dies
bewirkt eine verkürzte Werkzeugeingriffslänge während der Eintauchphase und schont
dadurch das Sägeband. Die Verfahrgeschwindigkeit lässt sich auf Kundenwunsch stufenlos
von 0,5 bis 500 mm/min regeln. Die Hydraulikanlage ist von außen leicht zugänglich. Dadurch werden Wartungszeiten wie Ölkontrolle und Filterwechsel erheblich reduziert.
Die Anlage ist mit der Sägemaschinensteuerung TechnoControl ausgestattet. Sie
Plattendicken-/Stückzahlkombinationen
ausgelegt. Die Sägeblattkühlung erfolgt über
ein Minimalmengen-Schmiersystem mit Füllstandüberwachung.
Die Alu-Gussblöcke mit einem Gewicht
von rund 15 Tonnen werden der Maxcut automatisch über Rollenbahn und Querförderer
zugeführt. Nach dem Sägevorgang wird jede
einzelne Platte mit einem Vakuummanipulator
von der Säge entnommen und auf eine Rollenbahn zum Weitertransport in das Lager oder
die Fertigung gelegt. Die Vakuumtransportanlage ist mit mehreren Saugern ausgestattet, die bis zu 3,5 Tonnen bewegen können.
Platten mit einem höheren Gewicht werden
manuell mit einem Hallenkran befördert.
Eine Sonderrollenbahn ermöglicht die
beidseitige Werkstückentnahme – ein Kundenwunsch, den Kasto nachträglich erfüllte.
Alle Rollen der Bahn mit einer Länge von 4,5
Metern sind angetrieben. Bei der Umsetzung
des Zusatzwunsches wurde großes Augenmerk auf die Sicherheit gelegt. Voraussetzung
für prozesssicheres Arbeiten ist, dass vorher
das Werkstück korrekt angelegt ist. Vor der
Übergabe wird diese Position überwacht. Ist
die Position nicht korrekt, wird der automatische Ablauf gestoppt.
n
TECHNOLOGY
Novelis überwacht Maschinenschwingungen mit Condition Monitoring von iba
Kritische Schwingungen online aufgespürt
U. Lettau, iba AG; D. Skingley Wright, Novelis Inc.
Schwingungen in Walzwerken können sich
negativ auf die Produktivität, die Produktqualität und die Lebensdauer einzelner Anlagenkomponenten auswirken. Die Anlage kann
so beeinträchtigt werden, dass Schädigungen
wie Getriebedefekte oder Spindelbruch auftreten. Insbesondere beim Kaltwalzen nehmen Schwingungen einen entscheidenden
Einfluss auf die Produktqualität in Form von
Chatter-Marks (Rattermarken) – das sind
quer zur Walzrichtung meist periodisch verlaufende Wellen auf der Bandoberfläche im
µm-Bereich. Die Folgen sind eindeutig: Das
Endprodukt ist von minderer Qualität oder
Ausschuss, die Walzgeschwindigkeiten müssen in einen schwingungsfreien Bereich reduziert werden und Stillstandszeiten nehmen
zu. Problematisch sind diese Effekte vor dem
Hintergrund steigender Qualitätsansprüche
und der Tendenz zu immer höherer Produktivität in Walzwerken.
Die Anforderungen an die Anlagen bezüglich Zuverlässigkeit, Lebensdauer und
Prozessstabilität sind enorm gestiegen. Die
Betriebssicherheit der Anlagen lässt sich am
besten mit einer Prozess- und Zustandsüberwachung herstellen. Der international tätige
Konzern Novelis mit Hauptsitz in Atlanta,
USA, produziert an 31 Standorten auf vier
Kontinenten nahezu 20 Prozent der gewalzten
Aluminiumerzeugnisse weltweit. Um diese
Position zu festigen, optimiert das Unternehmen seine Fertigungsprozesse, die Auslastung
und die Produktivität stetig.
➝
Novelis monitors machine vibrations with iba Condition Monitoring
Tracking critical vibrations online
U. Lettau, iba AG; D. Skingley Wright, Novelis Inc.
© iba
In Walzanlagen können zahlreiche
Schwingungen mit unterschiedlichen
Resultaten auftreten. Diese können sich
negativ auf die Lebensdauer und den Zustand der Anlage, aber auch auf die Produktqualität auswirken. In jedem Fall ist
es erforderlich, das Schwingungsverhalten
der eigenen Anlage genau zu kennen,
um Verschleiß und Defekte entsprechend
überwachen zu können. Der Aluminiumproduzent Novelis weiß um die nachteiligen Auswirkungen von Schwingungen
und nutzt zur Analyse und Intervention
das neuartige Condition-MonitoringSystem der iba AG. Dieses online basierte
System kann Prozessdaten aus der Anlage zusammen mit den Schwingungsdaten
auswerten.
In rolling mills, numerous vibrations with
diverse results can appear. These might
have negative effects on the life cycle and
the condition of the plant as well as on
product quality. Anyway, it is necessary
to know exactly the vibration behaviour
of the own plant for being able to monitor appropriately wear and tear as well as
defects. The aluminium producer Novelis,
knows about the negative effects of vibrations and uses the new Condition Monitoring system by iba AG for evaluation
and invention.
Vibrations in rolling mills can have a negative
effect on productivity, product quality and
service life of single machine components.
The plant can be adversely affected in a way
that damages like gearbox defects or breakings
of the spindle might occur. Especially during
cold rolling, the vibrations exert a decisive
influence on product quality in the form of
the so-called chatter marks. Chatter marks are
waves on the strip surface in the µm range
that run horizontally to the rolling direction,
mostly periodically. The consequences are
clear: The end product is of inferior quality
or even waste, the rolling speeds have to be
reduced to a vibration-free range and plant
downtimes are increasing. These effects are especially problematic considering the growing
quality standards and the trends towards an
ever higher productivity in rolling mills.
The demands on the machines regarding
reliability, service life and process stability
have been growing enormously. The operational safety of the plants can be established
best using process- and condition monitoring.
The globally operating group Novelis, with its
headquarters in Atlanta, produces at 31 locations on four continents almost 20 percent of
the rolled aluminium products world-wide.
For consolidating this position, the company
continuously optimises its production processes, the capacity utilisation and the productivity.
Monitoring the machine vibrations in coldrolling mills in a data-based and conditionrelated manner, deriving diagnoses from
these data and intervening with appropriate
measures are one element of this objective.
Novelis wants to reach that goal with the
63
TECHNOLOGIE
Ein Element dieser Zielsetzung ist, die Maschinenschwingungen an den Kaltwalzanlagen datenbasiert und zustandsbezogen zu
überwachen, daraus Diagnosen abzuleiten
und mit entsprechenden Maßnahmen zu intervenieren. Dies will Novelis mit dem Condition-Monitoring-System „ibalnSpectra factory“ erreichen, das als Pilotprojekt in den
Anlagen im Werk Nachterstedt für online basiertes Chatter-Monitoring installiert ist.
Nachterstedt startete im Februar 2012, seit
Anfang dieses Jahres ist das Chatter-Monitoring nun in Betrieb. Wenn sich das Pilotprojekt
in Nachterstedt als praktikabel erweist, plant
Novelis ibalnSpectra konzernweit zur Anwendung zu bringen. Die Konnektivität der
iba-Module ist Voraussetzung, um in einem
Konzern wie Novelis mit rund 30 Produktionsstandorten weltweit eine Gesamtoptimierung vorzunehmen.
Zwei Features in einem System vereint
Schwingungen mit Abtastrate
bis zu 100 kHz erkennen
Am Standort Nachterstedt in Sachsen-Anhalt
hatte Novelis schon länger ein Schwingungsmesssystem in Betrieb. Da dieses über eine
separate Auswertung lief, konnten die Prozessdaten aus der Anlage nicht zusammen
mit den Schwingungsdaten ausgewertet werden. Um die Schwingungen beim Walzen nicht
nur zu erkennen, sondern gleichzeitig aus den
erfassten Daten Defekte zu diagnostizieren,
Kennwerttrends zu analysieren und daraus
Maßnahmen für die Instandhaltung und Prozessoptimierung zu generieren, tauschte Novelis das bisherige Schwingungsmesssystem
gegen ein System der iba AG aus. „In den Gerüsten hatten wir zur Prozessanalyse sowieso das Prozess-Daten-Aufzeichnungssystem
ibaPDA eingesetzt. Deshalb war es sinnvoll,
das ibalnSpectra als zusätzliches Add-On
dieses Systems für das Chatter-Monitoring zu
nutzen“, erklärt Robert Krumbach, Leiter des
Kaltwalzwerks in Nachterstedt bei der Novelis
Deutschland GmbH.
Das ibalnSpectra ist ein neuartiges Condition-Monitoring-System, das die erfassten
Signale nicht nur unter Maßgabe von Condition-Monitoring-Vorgaben auswertet, sondern
auch alle anderen relevanten Betriebsparameter nutzt. Nur mit dem iba-System kann die
Überwachung von Condition Monitoring relevanten Daten bei gleichzeitiger Prozessüberwachung mit allen Maschinen-, Prozess-, Material- und Qualitätsdaten realisiert werden.
Die iba AG bietet das lnSpectra in variabler
Skalierung für verschiedene Anwendungsszenarien an. Für die Überwachung im Kontext
einer komplexen Anlage wie bei Novelis ist
„ibalnSpectra factory“ die geeignete Lösung.
Mit ihr lassen sich die relevanten Rohdaten für
das Condition Monitoring und die Prozessüberwachung fertigungsweit und produktionsübergreifend erfassen.
Zudem lässt sich ibalnSpectra herstellerneutral in jedes gängige Automatisierungssystem integrieren. In dieser Konnektivität der
Condition-Monitoring-Module sieht das Kaltwalzwerk von Novelis einen weiteren wichtigen Vorteil des CM-Systems. Das Projekt in
64
Kaltwalzanlagen verfügen über ein komplexes
Schwingungsverhalten ausgehend von Eigenschwingungen der Anlagenmechanik über
Anregungen aus den Getrieben oder Lagern
bis hin zu Anregungen durch Defekte oder
Drehzahlveränderungen. Während des Walzens können sich Schwingungsanregungen
unterschiedlicher Entstehungsmechanismen
und Frequenzen überlagern und sich gegenseitig verstärken. Prozessbedingt sind Schwingungen bei neuen wie auch alten Anlagen
nicht zu verhindern. Vielmehr geht es darum,
sie mithilfe geeigneter Methoden so zu überwachen, dass Schäden jeglicher Art vermieden
werden.
Bei Novelis in Nachterstedt hat man die
Erfahrung gemacht, dass Gerüstschwingungen
in Abhängigkeit vom Belastungszustand unterschiedlich zu beurteilen sind: „Beim Kaltwalzen wird das Coil an unseren Gerüsten
bis auf eine Geschwindigkeit von bis zu 1.250
Meter pro Minute beschleunigt. Während
der Beschleunigungsphase registrieren wir
verschiedene Schwingungszustände mit unterschiedlichen Auswirkungen auf die Anlage und das Produkt“, erklärt Krumbach. Die
Walzen werden in sogenannten Einbaustücken gelagert. Die Schwingungen, die unter
anderem über die Einbaustücke initiiert werden, übertragen sich sofort auf das Gerüst.
Deshalb hat Novelis an den Einbaustücken
der beiden Walzgerüste Beschleunigungssensoren angebracht, die das Schwingungsverhalten überwachen und damit Aufschluss über
das Schwingungsverhalten des kompletten
Gerüsts geben. Der Walzwerksleiter erläutert: „Die Einbaustücke verfügen über eine
Eigenfrequenz im Niederfrequenzbereich.
Sie schwingen bei Anregung also sehr langsam. Wenn aus den niederfrequenten Schwingungen hochfrequente werden, können wir
zum Beispiel auf Fremderregung schließen.“
Um die Ursache für die Fremdschwingungen ermitteln zu können, bedarf es einer genauen Kenntnis der Schwingungsfrequenzen
aller Elemente im Gerüst. Die Auswerteein-
ibalnSpectra Factory Condition Monitoring
system, which has been installed in the machines as pilot project in the Nachterstedt plant
in Saxony-Anhalt, Germany, for online based
chatter monitoring.
Two features united in one system
At the Novelis Nachterstedt plant, a vibration
measurement system has been in operation
for a longer time. As this measurement system ran over a separate analysis, the process
data from the plant could not be analysed together with the vibration data. For not only
detecting the vibrations in the rolling process
but also diagnosing defects from the acquired
data, analysing trends of characteristic values
and generating from these values measures for
maintenance and process optimisation, Novelis replaced the existing vibration measurement
system by a system from iba AG. „In the rolling stands, we used the ibaPDA process data
recording system, anyway. For this reason, it
made sense to use ibalnSpectra as add-on for
this system for chatter monitoring“, explains
Robert Krumbach, manager of the Nachterstedt cold-rolling mill at Novelis Germany.
ibalnSpectra is an innovative Condition
Monitoring system which does not only evaluate the acquired signals regarding the Condition Monitoring guidelines but also uses all
the other relevant operating parameters. Only
the iba system allows monitoring the data
relevant for Condition Monitoring and simultaneously monitoring the processes with all
machine, process, material and quality data.
iba AG offers lnSpectra in variable scaling
for diverse application scenarios. For monitoring in the context of a complex plant, like
the Novelis plant, ibalnSpectra Factory is the
appropriate solution. With this solution, the
relevant raw data for Condition Monitoring
and process monitoring can be acquired in a
production-wide manner.
Moreover, ibalnspectra can co-operate with
every common automation system, independent of the manufacturer. The staff of the Novelis cold-rolling mill considers this connectivity of the Condition Monitoring modules to
be another important advantage of the CM
system. The Nachterstedt project started in
February 2012 and since the beginning of
this year, the chatter monitoring has been in
operation. In case the Nachterstedt project
proves to be successful, Novelis will introduce
ibalnSpectra across the whole company. The
connectivity of the iba modules is the prerequisite for making an overall optimisation in a
company like Novelis with about 30 production sites world-wide.
TECHNOLOGY
Detecting vibrations with a
sampling rate of up to 100 kHz
© Novelis
Cold rolling mills show a complex vibration
behaviour, beginning with natural vibrations
of the system mechanics, over excitations
coming from the gearboxes or bearings up to
the excitations originating from defects or
varying speeds. In course of the rolling process, the vibration excitations originating from
diverse mechanisms and frequencies can superimpose and mutually reinforce. Due to the
process, the vibrations cannot be prevented
neither in new nor in old systems. It is rather
a question of monitoring the vibrations using
heit des CM-Systems, das Messwerterfassungssystem ibaPDA-V6, erfasst alle Sensoren
mit bis zu 100 kHz Abtastrate zeitsynchron,
kontinuierlich und auf physikalische Einheiten
skaliert. ibaPDA-V6 wird in mehreren Varianten bezüglich der Signalanzahl angeboten.
Zur Verfügung stehen Lizenzen für 64 bis
2.048 Signale sowie für eine unbegrenzte
Anzahl Signale. Für die normale Messdatenerfassung stehen Zeitbasen von 1 bis 1.000
ms zur Auswahl. Für höhere Signaländerungsgeschwindigkeiten können auch kürzere Erfassungsraten bis zu 10 μs realisiert werden.
Ist ein Bauteil beschädigt, verursacht dieses
Schwingungen in einem bestimmten Fre-
Aluminium coils at Novelis
appropriate methods and hence preventing
any damages.
At the Novelis Nachterstedt plant, experience has shown that the vibrations of the
roll stands need to be evaluated differently
depending on the load: “In the cold rolling
process the coil on our roll stand is accelerated up to a speed of 1,250 m/min. During the
acceleration phase, we are noticing different
vibration states which exert different effects
on the machines and the product,“ explains
Mr Krumbach. The rolls are stored in the
so-called chocks. The vibrations that are initiated among other things by the chocks, are
immediately transferred to the roll stands.
This is why Novelis has mounted acceleration
sensors on the chocks of the two roll stands,
which are monitoring the vibration behaviour
Aluminiumcoils bei Novelis
quenzband. Die von der Auswerteeinheit erfassten Zusatzschwingungen können auf Basis
dieser Werte konkreten Bauteilen zugeordnet
werden. Ist beispielsweise ein Kugellager mechanisch defekt, verursacht es hochfrequente
Zusatzschwingungen von 1.200 Hz. Ab diesem Frequenzband deuten die Schwingungen
zum Beispiel auf Lagerschäden hin.
Komplexes Schwingungsverhalten
online überwachen
Eine erfolgreiche Zuordnung der Maschinenschwingungen ist möglich, wenn die Condition-Monitoring-Daten und Prozessdaten miteinander in Echtzeit in Verbindung gebracht
werden können. Dank des ibalnSpectra ist
es bei Novelis Nachterstedt erstmals mög-
lich, Daten wie Geschwindigkeit, Walzkraft,
Drehmomente, Temperatur und Walzöldruck
online mit den Schwingungsdaten zu korrelieren. Um die Schwingungen positiv beeinflussen und sie minimieren zu können, kann
Novelis die Einflussgrößen auf das Schwingungsverhalten mit dem ibaInSpectra auch
online variieren. Dazu werden die Messdaten
mit dem ibaQPanel auf dem Steuerstand der
Leittechnik in Echtzeit visualisiert. Zusätzlich
können Alarmmeldungen generiert werden,
die entweder eine automatische Anpassung
der Walzengeschwindigkeit auslösen oder
eine manuelle Einstellung anstoßen. Bevor das
Chatter-Monitoring-System von iba eingesetzt
wurde, gab es keinen exakten Rückschluss auf
Ursachen für die entstehenden Schwingungszustände des Kaltwalzgerüstes.
Die Analysemöglichkeiten des ibalnSpectra reichen von einfachen Kennwertbildungen aus den Zeitsignalen wie Minimum, Maximum oder RMS-Wert bis zu komplexen
Auswertungen im Frequenzbereich wie Amplitudenspektren, Hüllkurvenspektren oder
Cepstrum-Analyse. Es können Frequenzspektren mittels Fast Fourier Transformation (FFT)
und statistische Kennwerte berechnet werden.
Es besteht die Möglichkeit von Drag-undDrop des parametrierten Analyseobjektes in
die Visualisierung und die Extraktion aussagekräftiger Kennwerte aller relevanten Maschinen-, Prozess-, Material- und Qualitätsdaten
in eine Datenbank. Flexible, leistungsfähige
Analysewerkzeuge ermöglichen die frühzeitige Erkennung signifikanter Korrelationen
zwischen diesen Daten. Für die werksübergreifende Analyse der Messdaten ist es von
Vorteil, dass die Geräte der InSpectra-Produktlinien zwar autark betrieben werden
können, aber die Daten über verschiedene
Netzwerkschnittstellen an die zentrale Auswerteeinheit übertragen werden.
Nur durch die Zusammenführung verschiedener Maßnahmen in ein online basiertes Chatter-Monitoring-System, das die Prozessoptimierung und Anlagenüberwachung
beinhaltet, kommen Walzwerkbetreiber der
Wunschvorstellung von betriebssicheren und
fehlerfreien Produkten nahe. Gemeinsam
konnten die iba AG und Novelis Nachterstedt
hier einen deutlichen Schritt nach vorn gehen.
Autoren
Dr. Ulrich Lettau ist Vorstandsvorsitzender der iba
AG mit Sitz in Fürth.
Dr. David Skingley Wright ist Leiter Technologie
und Entwicklung für den Bereich Kaltwalzen bei
Novelis Inc.
65
CO M PA N Y N E W S W O R L D W I D E
and hence provide information on the vibration behaviour of the whole roll stand. The
manager of the rolling mill explains: „The
chocks have a natural frequency in the low
frequency range. Hence, when being excited,
they show a very slow vibration. When low
frequency vibrations become high frequency
vibrations, we can conclude that we are dealing with external excitation.”
For being able to determine the external
vibrations, the staff needs to know exactly
the vibration frequencies of all elements in
the roll stand. The evaluation unit of the CM
system – the ibaPDA-V6 measurement value
acquisition system – acquires all sensors with a
sampling rate of up to 100 kHz time synchronously, continuously and scaled to physical
units. ibaPDA-V6 is offered in several variants
regarding the number of signals. Licenses for
64 to 2,048 signals as well as for an unlimited number of signals are available. For the
normal measurement data acquisition, there
are time bases of 1 to 1,000 ms available. For
higher speeds of signal changes, also shorter
acquisition rates of up to 10 μs can be realised.
In case a machine component is damaged, it
causes vibrations of a certain frequency band.
The additional vibrations that are acquired
by the evaluation unit, can be clearly assigned
– on the basis of these values – to certain
components. If e.g. a ball bearing is mechanically defective, it causes additional high frequency vibrations of 1,200 Hz. Within this
frequency band, the vibrations imply defective bearings.
Online monitoring of
complex vibration behaviours
The machine vibrations can be assigned successfully, if the Condition Monitoring data
and the process data can be related to each
other in real time. Due to ibalnSpectra it is
possible at the Novelis Nachterstedt plant to
establish online correlations between data
like speed, rolling force, torque, temperature,
rolling oil pressure on the one hand and vibration data on the other. For being able to
exert a positive influence on the vibrations
and thus minimising them, Novelis can – using ibalnSpectra – also adjust the influencing
variables on the vibration behaviour online
during the process. For that purpose, the
measurement data are visualised by means of
ibaQPanel in the control pulpit in real time.
Moreover, alarm messages can be generated
which either trigger an automatic adaptation
of the rolling speed or initiate a manual adjustment. Before the implementation of the
chatter monitoring system, no exact conclusions could be drawn concerning the causes
for the vibration conditions of the cold rolling
mill.
The analysis options of ibalnSpectra range
from simple parameter calculations from time
signals like minimum, maximum or RMS val-
ues to complex evaluations in the frequency
range like amplitude spectra, envelope curve
spectra or Cepstrum analysis. Frequency spectra can be calculated using the Fast Fourier
Transformation (FFT). Also statistical parameters can be calculated. Using drag & drop,
the parameterised analysis object can be used
in the visualisation. Significant values of all
machine-, process-, material- and quality data
can be extracted to a database. Flexible and
efficient analysis tools allow for the early
detection of significant correlations between
these data. For the cross-plant analysis of the
measurement data it is an advantage that the
devices of the lnSpectra product lines can be
operated autonomously, but also that the data
can be transferred to a central evaluation unit
via diverse network interfaces.
Only by combining different measures in
an online based chatter monitoring system
that includes the process optimisation and
plant monitoring, the operators of a rolling
mill come as close as possible to their ideal
of reliable and fault-free products. Together,
iba AG and Novelis Nachterstedt have taken
a significant step forward in this matter.
Authors
Dr Ulrich Lettau is CEO of iba AG, which is located
in Fürth, Germany.
Dr David Skingley Wright is manager Technology
and Development, Cold Rolling at Novelis Inc.
Aluminium smelting industry
(USD782m) yuan. Chalco follows in Alcoa’s
and Rusal’s footsteps: both companies have
only recently announced production cuts.
Alcoa will close two Soderberg potlines at its
Baie-Comeau smelter in Québec representing
a production capacity of 105,000 tpy while
Rusal announced production cuts of around
300,000 tpy.
© Dubal
Trimet to acquire two
aluminium plants in France
Chalco cuts aluminium production
Aluminium Corp. of China (Chalco) has announced it will temporarily close 380.000 tpy
of production capacity due to weak market
66
conditions. The curtailment corresponds to
9% of the company’s annual aluminium output. Low aluminium prices and rising costs led
to a net annual loss of 8.2bn yuan (USD1.3bn)
in 2012 and an operating loss of 4.8bn
German aluminium producer Trimet has submitted a binding offer to acquire two Rio Tinto
Alcan (RTA) plants in France: namely the aluminium smelter in Saint-Jean-de-Maurienne
with a production capacity of 140,000 tpy
and the Castelsarrasin plant which produces
aluminium wire rod for electric cabling and
connecting elements for the automobile indus-
try. The aluminium smelter produced 93,000
tonnes of aluminium in 2012 and the wire rod
plant 8,000 tonnes.
The purchase agreement will secure the
long-term supply of alumina and electric power, which are key requirements for the production of aluminium. Trimet will have a 60%
majority stake in the production plants while
energy supplier EdF will take a minority stake
of 35%. Another 5% will be held by the staterun Fonds Stratégique d’Investisse (FSI).
The transaction is conditional upon the approval of the regulatory authorities and the
execution of an energy supply agreement and
a partnership arrangement with EdF, said Trimet.
ernment had already earmarked Rp7 trillion
(USD707m) for the takeover. Initially the government had plans to sell its stakes to other investors, but then changed mind to turn Inalum
into a state-run enterprise, in expectation of
larger state revenue from aluminium sales.
Inalum is currently 58.88% controlled
by the Japanese consortium Nippon Asahan
Aluminium and 41.12% controlled by the Indonesian government. The smelter has a production capacity of 260,000 tpy. There are
plans of the Industry Ministry to increase the
capacity to 450,000 tpy to meet domestic demand. At present 40% of the output is sold on
the domestic market and 60% on the Japanese
market.
n
Slovalco smelter signs
LoI for power supply
Bauxite and
alumina activities
Hydro’s part-owned aluminium smelter in
Slovakia, Slovalco, has signed a Letter of Intent (LoI) for power supply with Slovenské
Elektrárne. The LoI covers electricity supply
over an eight-year period as from 1 January
2014 with a total delivery of 19 TWh. The
LoI is a first move towards securing the total
framework that will enable continued operations at Slovalco.
Since entering into the existing power
contract with Slovenské Elektrárne 20 years
ago, power prices in Slovakia have increased.
Slovalco will strengthen its competitiveness
through efficiency measures and cost cuts,
while in parallel working to achieve a competitive future power supply. Slovalco is a fully
consolidated smelter in Hydro, owned 55%
by Hydro Aluminium AS. The plant has a production capacity of 165,000 tpy.
Alba Potline 5 upgraded
Aluminium Bahrain (Alba) has announced
that Potline 5 has been upgraded to AP37
technology following an increase in the line
current to 370 kA. The upgrade increases the
smelter capacity by around 10,000 tpy.
Inalum to become 100%
state-owned company
The Indonesian government will completely
take over Indonesia Asahan Aluminium,
known as Inalum, in November, although negotiations are still ongoing. That is what the
Indonesian Industry Minister M. S. Hidayat
told journalists recently. He said that the gov-
Alufer’s Bel Air project in
Guinea hit by licensing delays
Junior bauxite producer Alufer Mining has
delayed construction of its Bel Air bauxite
project in Guinea by a year, due to licensing
delays. Construction is now predicted to start
in 2014, with product shipment expected in
2016. The delay at Bel Air stems from the
Guinea government’s steps to tie mining licenses to their revised mining code. Alufer
submitted its licence application in October
2012, but Guinean authorities could not issue
the licence before concluding amendments to
the September 2011 mining code.
The junior miner has lined up financiers
and suppliers for Bel Air, and one of the deals
involves China’s Hongfan Industries, which
has agreed to a 5m tpy bauxite offtake arrangement and to a prepayment arrangement
to help Bel Air into commercial production
within 24 months. Hongfan will buy half of
the planned production from Bel Air and will
pre-finance mine development.
Bel Air requires a USD310m capital outlay, the bulk of which is targeted for supporting infrastructure.
Hydro issues force majeure notice
due to power outages at Alunorte
Hydro issued a notice of force majeure to its
alumina customers as power outages and lowered production at Alunorte alumina refinery
may affect alumina deliveries to customers.
On 18 May the refinery experienced a black-
out in its electrical power supply system due
to unexpected external events. As a consequence, Alunorte suffered a partial electrical
power outage. On 2 June, while in the process
of stabilising and resuming production, Alunorte experienced another, shorter black-out
caused by an unrelated external event. These
events caused serious disruption so that the
refinery has not been able to resume full production of alumina.
Alunorte production levels will be lower
in the second quarter than in the first, and are
expected to remain unsatisfactory also for the
rest of the year. As a measure, Hydro has established a team of experts aiming to stabilise
and increase production at the refinery.
Alunorte is the world’s largest alumina
refinery, with a nameplate capacity of 6.3m
tonnes.
Orbite signs offtake
agreement with Glencore
Orbite Aluminae Inc. has signed an offtake
agreement with Glencore International for
the purchase of smelter-grade alumina from
the corporation’s first proposed smelter-grade
alumina (SGA) plant in Quebec, Canada. The
agreement provides for the purchase for an
initial term of ten years from the beginning
of commercial production. The agreement also
foresees that Orbite and Glencore will undertake negotiations relating to Glencore’s potential financial participation in the ownership
and operation of the corporation’s proposed
SGA plant in Quebec.
Glencore Xstrata, the parent company of
Glencore International, is one of the world’s
largest global diversified natural resource companies with revenues of USD236bn in 2012.
Well Harvest builds alumina
refinery in Indonesia
Well Harvest Winning Alumina Refinery, a
joint venture between Indonesian conglomerate Harita Group and China’s Hongqiao
Group, has started construction of the first
alumina refinery in Indonesia. The USD1bn,
2m tpy plant will be built in Ketapang, West
Kalimantan. The refinery will be built in two
phases, with Phase I complete in 2015. The
initial phase is expected to cost USD500m
and will leave the facility with a capacity of
about 1m tpy. Completion of Phase II is scheduled for 2017. Output from the refinery is intended to be sold to Inalum, an IndonesianJapanese joint venture that will be taken over
67
by the Indonesian government in November.
The refinery will process bauxite from the
Harita’s mines. The company owns 26 mining permits in West Kalimantan, with proven
bauxite reserves of some 700m tonnes. Harita
owns 30% of Well Harvest through its subsidiary Cita Mineral Investindo, while Hongqiao
owns the rest.
n
Secondary smelting and recycling
products, in sizes compatible with the largest
aluminium aerospace components in service
today. The Lafayette expansion should be
completed and online by the end of 2014.
Alcoa’s new aluminium-lithium alloys combine the best strength-to-weight performance
with better stiffness, damage tolerance and
corrosion resistance.
© Hydro
Constellium seeks buyer
for plant in France
Oetinger goes into administration
Secondary aluminium company Oetinger from
Germany has made a request to begin insolvency proceedings. The company made the
request for its four German units in Weißenhorn, Hanover, Berlin and Neu-Ulm. The company’s French unit, Affinage de Lorraine, will
not be affected. Oetinger is Europe’s largest
foundry aluminium producer, with a production of 300,000 tpy. The market can hardly
accept the loss of this capacity. This will be
the prime role of the insolvency administrator:
to ensure that the works keep on running.
Novelis celebrates roofing ceremony
for its recycling plant in Germany
Novelis Inc. has celebrated the roofing of its
USD250m aluminium recycling and casting
centre at its plant in Nachterstedt, Germany.
Located adjacent to the company’s existing
aluminium rolling mill, the new centre will
produce up to 400,000 tpy of aluminium sheet
ingot from recycled material. It is projected
to be the world’s largest aluminium recycling
centre, which remains on track for completion
in July 2014. The centre will process used beverage cans as well as numerous other forms of
aluminium scrap from across continental Europe. Novelis expects the centre to create 200
new jobs when commissioned in 2014.
The Nachterstedt expansion is the latest
in a series of recycling and casting expansion
projects launched by Novelis over the past two
68
years. These total nearly USD450m, including the commissioning in 2012 of the company’s new integrated recycling and casting
centre in Yeongju, Korea. These projects, and
others underway across the world, are designed to increase Novelis’ recycling and casting capacity to 2.1m tonnes by 2015.
Alcoa completes aluminium-lithium
expansion project in UK
Alcoa has completed the expansion of aluminium lithium alloy capacity at its Kitts Green
facility in the UK to serve the growing demand
for the company’s third generation aluminium
lithium alloys. Alcoa projects its aluminium
lithium revenues will quadruple over the next
six years to nearly USD200m. The Kitts Green
expansion was the second phase of Alcoa’s
three-part expansion programme to satisfy
customer demand for advanced aerospace
products and patented alloys, which allow
aircraft manufacturers to build more fuel-efficient and lower-cost airplanes than with composite alternatives.
Alcoa upgraded and expanded casting capacity at the Kitts Green plant, and also expanded capacity at its technology centre in
Pennsylvania by 30%. The third phase of the
expansion is a new USD90m facility under
construction adjacent to the company’s plant
in Lafayette, Indiana, that will provide an additional 20,000 tonnes of aluminium-lithium.
The new facility will supply round and rectangular ingot for rolled, extruded and forged
Paris-based Constellium is seeking a buyer
for its precision castings operations in Ussel,
France. The company hopes to find a buyer
committed to the facility’s future development, but it could not predict the terms under
which a deal might be concluded, or what any
potential buyers’ plans for the plant might be.
But Constellium plans to retain the Ussel plant
if no “suitable buyer” is found. The Ussel plant
employs about 230 people, and it recorded
revenues of €26m (USD34m) in 2012. The
company as a whole reported 2012 revenues
of €3.6bn.
Boeing and Alcoa to boost recycling
of aluminium aerospace alloys
Boeing and Alcoa have formed a closed-loop
programme to significantly increase the recycling of internal aluminium aerospace alloys
used in Boeing airplanes. The programme will
entail inter-modal transport of aluminium alloy scrap, including advanced alloys, from
Boeing facilities in Auburn and Wichita, and
from third-party processors in Auburn, to
Alcoa’s Lafayette facility in Indiana. The programme calls for melting and recycling into
new aerospace materials of aluminium alloys
(2xxx and 7xxx series) used in the production
of wing and fuselage components of Boeing
airplanes. The forms will include aluminium
extrusions, sheet and plate products, amounting at the outset to 3,630 tpy.
The new programme also lays the groundwork for extending the recycling system to
Boeing sub-contractors, and later including
other aluminium scrap forms, such as chips
that remain after the machining of parts.
Alcoa facility to cut in half energy used
to recycle aluminium for forged wheels
Alcoa has announced that its USD21m Wheel
and Transportation Products casthouse expansion at its Barberton plant in Ohio is expected
to cut in half the specific amount of energy
used to recycle aluminium for forged wheels,
so reducing greenhouse gases and increasing
the overall efficiency and sustainability of the
company’s manufacturing process. The recycling facility, the first of its kind in North
America, uses advanced technology to produce wheels from re-melted and scrap aluminium. Construction of the 4,000 m2 facility
began in July 2011. It is now up and running
at full capacity.
Recycled aluminium scrap of 43,500 tpy is
enough to make 2m new Alcoa forged alu-
minium wheels. The casthouse takes chips
and solids from an existing Alcoa wheel machining plant on the same campus in Barberton, as well as from Alcoa’s Cleveland forging plant, and recycles them into aluminium
billets. The billets are then shipped to other
wheel-processing facilities to forge into aluminium wheels.
The casthouse is expected to significantly
reduce energy use through a combination of
process improvements and reduced transportation needs.
a new plant under construction in Changzhou,
China, will have a capacity of 120,000 tpy.
Besides, Novelis has announced a price increase of €160/t for all of its automotive aluminium sheet products in Europe. The price adjustment is effective immediately for all new orders not covered by current supply agreements.
n
Aluminium rolled products producer Novelis
and a subsidiary of steelmaker ThyssenKrupp
signed a co-operation agreement to produce
aluminium parts for the automotive industry.
Novelis and ThyssenKrupp Tailored Blanks,
which produces a combination of steel sheets,
will produce individual aluminium sheet of
different grade, thickness and coating that can
be joined to produce customised stamping
blanks used by carmakers for the production
of lightweight body parts such as doors and
bonnets.
The use of tailored blanks can lead to higher safety standards due to the selective use
of high-strength aluminium alloys. The product range of tailored aluminium blanks connects the extensive potential for lightweight
of aluminium with the engineering service
of tailoring the body and chassis design on a
mass scale.
© Hydro
Aluminium semis
Constellium sells its French plants
in Ham and Saint-Florentin
Constellium has sold its French extrusion
plants in Ham and Saint-Florentin to OpenGate Capital. The plants produce aluminium
profiles intended mainly for the building and
construction industry. Details on the transaction were not disclosed. OpenGate Capital,
The Author
The author, Dipl.-Ing. R. P. Pawlek is founder
of TS+C, Technical Info Services and Consulting,
Sierre (Switzerland), a service for the primary
aluminium industry. He is also the publisher
of the standard works Alumina Refineries and
Producers of the World and Primary Aluminium
Smelters and Producers of the World. These
reference works are continually updated, and
contain useful technical and economic information on all alumina refineries and primary
aluminium smelters of the world. They are
available as loose-leaf files and / or CD-ROMs
from Beuth-Verlag GmbH in Berlin.
LLC is a global private buyout firm specialised
in the acquisition and operation of businesses
seeking revitalisation through growth and operational improvements.
Novelis boosts auto sheet
capacity in Europe
Novelis has expanded its automotive sheet
production capacity in Europe by adapting
its Goettingen plant in Germany to help meet
growing demand for recyclable aluminium
sheet for automobile manufacture. The Goettingen plant will produce 20,000 tpy of automotive sheet, and a planned second phase will
double that capacity.
The Goettingen plant currently produces
high-quality sheet for the lithographic and
packaging markets, as well as painted sheet
for a variety of applications. It also produces
aluminium bottles, cartridges, cans and housings using the impact extrusion process.
Novelis is investing around the world to
boost its automotive finishing capabilities. In
North America, an expansion at the Oswego
plant in New York will add 240,000 tpy, and
Novelis and ThyssenKrupp agree
to develop aluminium car parts
Hydro and Kobe Steel cooperate
on automotive body panels
Kobe Steel has entered into a technical cooperation agreement with Hydro Aluminium
Rolled Products GmbH in Germany for aluminium sheet used in automotive body panels.
The agreement covers the exchange of technical information regarding the use of aluminium in automobile bodies and structural
parts, the licensing of intellectual property and
manufacturing know-how as well as technical
assistance.
Demand for aluminium sheet used in automotive body panels is anticipated to increase
to meet the need for lighter cars due to stricter
fuel economy standards. Kobe Steel’s aluminium sheet business is focusing on expanding
sales in this area. The company currently supplies a large share of automotive aluminium
sheet to Japanese car makers. In the future, it
anticipates expanding sales to European and
US car makers as well. As car makers grow
their businesses, there is a rising need to locally procure the same quality of materials
worldwide.
➝
69
Kobe Steel is planning to build a global supply network for aluminium body panels, as
announced in its medium-term business plan
at the end of May. In addition, the agreement
with Hydro strengthens the company’s capability to meet the global procurement needs
of its customers.
Alcoa and Rusnano sign MoU
to produce aluminium drill pipe
with antiwear coating
Alcoa and OJSC Rusnano will produce technologically advanced oil and gas aluminium
drill pipe finished with a life-extending antiwear coating under an MoU signed by the
companies. With the help of the Alcoa Technical Centre, the parties intend to pursue the
potential application of a nanotechnologybased coating for the aluminium drill pipe to
enhance its wear resistance in harsh corrosive
drilling environments. The nano-coating is
expected to extend the life of the aluminium
pipe by 30-40% in aggressive and corrosive
drilling environments compared to uncoated
On the move
Alba’s board has appointed Ali Al-Baqali CFO
with immediate effect. Amin Sultan is the
company’s new power station director. Khalid
A. Latif has been appointed the new engineering manager at Alba.
Glencore Xstrata has appointed three new
directors to its board with immediate effect:
John Mack and Peter Grauer have been appointed independent non-executive directors,
while Peter Coates has been appointed an
executive director.
The London Metal Exchange has appointed Robin Paine chief technology officer. He
will report to the LME chief operating officer,
Diarmuid O’Hegarty.
Marc Rich, the commodities trader who
founded Glencore and is accredited with
inventing the spot market for oil, has died
aged 78 after suffering a stroke at a hospital
in Lucerne.
Abdulla J M Kalban, president and CEO of
Dubal, received an Institute of Directors (IOD)
Distinguished Fellowship Award in recognition
of his contribution to transforming Dubal into
a global giant and a benchmark organisation
for comparison all over the world.
Vedanta has appointed Deepak Parekh
an independent non-executive director on its
board.
70
aluminium pipe.
With facilities in Samara and Belaya Kalitva, Alcoa is Russia’s largest producer of
fabricated aluminium, manufacturing a wide
range of flat rolled products, forgings and extrusions for a variety of end markets including aerospace and automotive. Under terms of
the MoU, Alcoa will leverage its Samara facility to produce aluminium drill pipe with
hot fit tool joints for the country’s oil and
gas market. Rusnano Capital, a subsidiary of
OJSC Rusnano, will contribute capital.
also earned the company a cash incentive of
USD182,400 from TVA.
TVA’s EnergyRight Solutions for Industry
offers 10 cents per kWh on first-year savings
or 70% of project cost, whichever is less, to
programme participants for approved energy
efficiency projects. “Energy efficiency helps
keep rates low, reduces costs associated with
meeting consumer demand, conserves natural
resources and produces zero emissions,” said
Brent Powell, one of the managers of the TVA
energy savings programme in Kentucky.
Midas wins major contract from
CNR Changchun Railway Vehicles
ThyssenKrupp Aerospace
expands aluminium business
Jilin Midas Aluminium Industries Co., Ltd has
won an RMB44.3m (USD7.2m) contract from
CNR Changchun Railway Vehicles Co., Ltd for
Changchun Metro Lines 1 and 2. Jilin Midas
will supply aluminium profiles for 44 train sets
(one set corresponds to six train cars) from
2013 to 2015.
Jilin Midas is a subsidiary of Midas Holding Ltd, which was founded in 2000. Midas
is the leading manufacturer of aluminium alloy extrusion products for the passenger rail
transportation sector in China. Over the years,
the company has built an established track
record in supplying to the PRC passenger
rail transportation sector, which includes participation in landmark contracts such as trains
for the Beijing-Tianjin High Speed Train
Project. Midas’ customers include domestic
PRC licensed train manufacturers from China
South Locomotive & Rolling Stock Corp. Ltd
and China CNR Corp. Ltd as well as international customers such as Alstom Transport,
Siemens AG and Bombardier Transportation.
ThyssenKrupp Aerospace continues to expand
its business. The German division of ThyssenKrupp Materials CA Ltd recently opened its
first facility in Tunisia. The newly constructed
site at Aerospace Park Mghira commenced
business in April. This includes cutting block
drafts from aircraft grade aluminium plates,
the exclusive distribution of metal plate and
sheet as well as aluminium profiles. With an
expected number of 12 employees, the facility will supply sheet metal, plate metal and
aluminium profile to the regional aerospace
industry, specifically to customers Aerolia
Tunesia, Figeac Aero and Mecahers.
ThyssenKrupp Aerospace has also renewed
and expanded a six-year contract with Bombardier Aerospace as the service provider
for cut-to-size aluminium plate, sheet and
extrusions and related supply chain services.
Work will be performed at the existing ThyssenKrupp Aerospace facility in Baie D’Urfé
Québec, Canada.
Further, ThyssenKrupp Aerospace North
America has entered into a three-year contract
extension with Cessna Aircraft Co. to remain
its service provider for aluminium sheet products and related supply chain services. The
company will service Cessna’s facilities in
Wichita, Kansas, as well as Cessna’s key subcontractors throughout the North American
region. The just-in-time deliveries and valueadded services will be supported from its existing facility in Hutchinson, Kansas.
n
Logan Aluminum rewarded
for energy efficiency efforts
Logan Aluminum in Russellville, Kentucky,
is saving electricity and money on its power
bills at its production facility through energy
efficiency efforts in partnership with the Tennessee Valley Authority. The manufacturer
of flat rolled aluminium sheet, primarily for
beverage cans, refitted its lighting systems
and upgraded equipment including pumps and
air dryers through the EnergyRight Solutions
for Industry Programme offered by TVA and
Russellville Electric Plant Board. The projects
reduced the mill’s annual power consumption
by more than 2m kWh, which is enough energy to supply about 150 homes in the Russellville district for a year. The energy savings
Suppliers
LOI wins order for coil annealing
line by Ma’aden-Alcoa
Tenova LOI Thermprocess has been awarded
a contract for the installation of a heat treat-
© Tenova LOI Thermprocess
length in the existing hot shear prior to entering the press.
Logs are delivered to the chain-type log
magazine by forklift truck and are stored and
managed according to alloy type. On the feed
conveyor, the length of each log is accurately
measured for the required ‘odd end’ optimisation process. Heating is carried out in a multilayer low-loss induction coil which, like in
the existing heater, consists of six individually
controlled coil sections.
The billet heating operation relies on an
IGBT converter system developed by Otto
Junker. This converter system is based on
transistor technology and offers the advantage
of steplessly adjustable power control in addition to high efficiency and low maintenance
needs. Designed by Otto Junker around ten
years ago, the technology has since proven its
merits in over 170 billet heating and induction melting furnace applications.
ment line for aluminium strip coils for the
Ma’aden-Alcoa facility in Saudi-Arabia. The
line consists of single-coil lifting hearth furnaces which allow the individual heat treatment of coils. The installation is scheduled for
2013.
This heat treatment line allows adapted
heat treatment according to the specific needs
of the individual strip within short time, instead of heat treatment in a batch of several
coils, which would require an average heat
treatment or the combination of a batch of
identical strip coils. The heat treatment and
cooling can be processed in protective atmosphere. The system works fully automatically
from taking the coil out of the storage area
until the heat treated coil is placed into the
storage area again.
The special plant and furnace design has
been invented in 1998 by LOI Thermprocess
and has been installed first at Alcan Singen,
Germany. To date LOI has installed more than
fifty units.
Seco/Warwick Allied supplies
soaking pit furnaces to Hindalco
Seco/Warwick Allied has recently installed
seven soaking pit furnaces at Hindalco Industries in Hirakud in eastern India. The furnaces
feature side-mounted fans, which improve
maintenance access, and a combination of fan
and heater arrangements to produce separate
control zones along the vertical length of the
slabs as well as a patented adjustable baffle
design. The furnaces are designed for vertical
loaded slabs to process can body stock.
Each furnace is designed for a maximum load
of 128 tonnes. The overall charge height is
five metres maximum and 3.5 metres minimum from eight to 16 slabs per batch. An
adjustable baffle has been provided for
proper air circulation in the event shorter slab
heights are loaded. The furnace is designed
for electrical heating with individual self-propelled lid (cover) trolley mechanism, and is
equipped with PLC-based control and monitoring system.
New Otto Junker induction heater
for Hydro Aluminium Nenzing
Otto Junker has received an order from Hydro Aluminium Nenzing for another induction-type heater including log storage and log
handling equipment. More than 30 years ago,
Otto Junker supplied one of the world’s first
induction-type aluminium log heaters with a
downstream hot shear to Hydro’s Nenzing
works. In 2007, this system was upgraded to
3,600 kW by adding an Otto Junker-supplied
IGBT converter system; as a result, it now attains a throughput of nearly 80 billets per hour.
The consistently positive experience gathered
with this plant prompted Hydro Aluminium
Nenzing to opt for an Otto Junker furnace
system of nearly identical design when a new
investment decision came up.
The system comprises a feed table with
chain conveyor, a vertical log magazine for
up to 60 logs, a feed conveyor, and an induction furnace measuring around five metres
in length in which the logs are heated to a desired temperature profile before being cut to
Mechatherm modernises
Dubal’s casting pit DC1
Mechatherm had been awarded an order to
completely rebuild Dubal’s casting pit DC1.
The contract involved significant mechanical,
hydraulic, electrical and combustion work to
three furnaces and to a vertical aluminium billet casting machine. It required considerable
demolition followed by civil work organised
by Dubal. Only then could the new equipment
be installed and commissioned with a complete new Mechatherm software automation
system. Work was projected to take twelve
weeks, during which the casting pit would be
shut down completely, with no production.
Due to the excellent collaboration with Dubal
engineers, Mechatherm and its sub-contractors managed to complete the work and get
the pit into production in less than eight weeks.
Thus Dubal could cast over 5,000 tonnes of
extrusion billet above their predicted output.
Rusal begins installing hot bath
crushing equipment from Outotec
Rusal has begun the installation of hot bath
crushing equipment at its Boguchany aluminium smelter in the Krasnoyarsk region of
Russia. This fully automated equipment, supplied by German company Outotec, processes
crushed hot bath to the required fraction of
any size. It will cost €5.1m (USD6.7m).
The line is one of the most advanced on the
market and will be used for the first time in
Russia. It has a capacity of 40 tph, which will
71
PAT E N T E
meet the smelter’s needs, and is equipped with
modern suction systems, aimed at providing
dust control at every step of the process. The
installation is supervised by representatives
from the Russian office of Outotec.
Siemens acquires specialist in
rolling mill repair and refurbishing
Siemens Industry, Inc. has completed the
acquisition of Service Guide, an Ohio-based
company that has provided repair and refurbishing services for steel and aluminium mills
since 1964. The agreement includes three of
the company’s four local operating facilities
in Warren and Cortland, Ohio. The fourth
facility, Oakes Foundry, will continue to be
owned by the Oakes Family Trust.
The acquired facilities provide the rolling mill industry with repair and refurbishing
services as well as the manufacture and sale
Patentblatt Mai 2013
Verschmolzene Körner aus Oxiden mit Al, Ti,
Mg und Zr sowie Keramikprodukte mit derartigen Körnern. Saint-Gobain Centre de Recherches et d‘Etudes Européen, Courbevoie, FR.
(C04B 35/478, EP 2 303 796, WO 2010/001065,
AT: 02.07.2009, EP-AT: 02.07.2009, WO-AT:
02.07.2009)
Aluminium-Kupfer-Terminal und Verfahren zur
Herstellung desselben. Weitkowitz Kabelschuhe
und Werkzeuge GmbH, 31224 Peine, DE. (H01R
4/62, EPA 2579390, EP-AT: 05.10.2011, WO-AT:
05.10.2011)
Verbundbauteil aus Kunststoff und einer Aluminiumlegierung sowie Verfahren zur Herstellung. (B32B 157088, EPA 2572876, EP-AT:
07.12.2006, WO-AT: 07.12.2006)
Verfahren und System zur Herstellung einer
Al-Si-Legierung. Dow Corning Corp., Midland,
Michigan 48686-0994, US; Dow Corning Silício
do Brasil Indústria e Comércio Ltda., Santos Dumont - MG, 36240.000, BR. (C22C 21/02, EPA
2572010, WO 2011/146814, EP-AT: 20.05.2011,
WO-AT: 20.05.2011)
Al-Cu-Li-Legierung für niedrigeres Oberflächenelement. Constellium France, 75008 Paris, FR.
(C22C 21/00, EPA 2569456, WO 2011/141647,
EP-AT: 11.05.2011, WO-AT: 11.05.2011)
Funktionsverfahren einer Wärmeausrüstung,
die von Komponenten auf Aluminium- und
Titanbasis versorgt wird, um das Rosten und
die Verschmutzung bei hohen Temperaturen
zu reduzieren. GE Energy Products France SNC,
Belfort, FR. (C10L 1/12, EP 2 316 911, AT:
08.09.2009, EP-AT: 08.09.2009)
72
of spare parts and components. Service Guide
customers are based in the US, Canada and
Mexico. Headquartered in Cortland, Ohio,
the company will be fully integrated into the
Metals Technologies business unit and Customer Services division of the Siemens Industry Sector. The acquired facilities will continue
to operate from their current locations, and
around 110 employees have joined the Siemens business structure.
High Performance Industrietechnik (HIP),
51% SAG owned, has developed a horizontal continuous casting plant for Kobe Steel,
a Japanese metal and machinery equipment
manufacturer and supplier to the car industry.
The equipment, which will be assembled and
commissioned in China, has been designed to
produce aluminium forging billets for the automotive industry. The billets can range from
a diameter of 60 to 100 mm and a length of
2,700 to 3,500 mm, produced in a simultaneous
casting operation of a maximum of 16 parallel
strands. The forging will be done in succeeding steps in excenter presses of some 8,000
tonnes and more pressing strength capacity.
SAG Engineering was commissioned to
supply the entire control system and is also
responsible for the complete design of electrical functions including the programming of
the memory programmed controls, the servo
systems and all control panels. The base for
this is a high performance CPU with electrical
servo motor systems for eight integrated servo
motor axles.
Already in 2000 HPI have proved its expertise in die technology and received the order
for the construction for the first plant in Daian,
Japan. For the time being Kobe Steel operates
HPI plants in Japan, USA and China.
n
Verfahren zur Herstellung eines alkaliresistenten Erdalkali-Aluminium-Wärmedämmstoffs,
dieser selbst und seine Verwendung. Calsitherm Verwaltungs- GmbH, 33175 Bad Lippspringe, DE. (C04B 40/02, PS 10 2009 055 723,
AT: 26.11.2009)
Aluminium-Naphthalindicarboxylat als poröses
metallorganisches Gerüstmaterial. BASF SE,
67063 Ludwigshafen, DE. (B01J 35/00, PS 50
2007 009 833, EP 2089153, WO 2008/052916,
AT: 24.10.2007, EP-AT: 24.10.2007, WO-AT:
24.10.2007)
Eine Aluminiumgrundplatte mit einer Wärmeableitschicht. Ruiyun Optoelectronics Light Technology Ltd., Ningbo, Zhejiang, CN. (F21V 29/00,
OS 10 2011 054 944, AT: 31.10.2011)
Verfahren zum Ätzen von Aluminium und
Vorrichtung dazu. Lorin Industries, Inc., Muskegon, Mich., US. (C23G 1/22, EP 1 227 174, AT:
20.12.2001, EP-AT: 20.12.2001)
Verfahren zur Herstellung von dünnwandigen
rotationssymmetrischen Bauteilen aus Aluminium oder Aluminiumlegierung. Magna BDW
technologies GmbH, 85570 Markt Schwaben, DE.
(B23P 13/00, PS 10 2011 056 942, AT: 22.12.
2011)
Vorrichtung und Verfahren zur Begrenzung der
beim Kühlen von Aluminium- oder Stahlblechen unter Gasströmung auftretenden Bandvibrationen. Cockerill Maintenance & Ingéniérie
S.A., Seraing, BE. (F27B 9/12, EP 1 655 383, AT:
11.10.2005, EP-AT: 11.10.2005)
HPI sets up a horizontal continuous
casting plant in Shanghai
Elektrolysezelle, insb. zur Herstellung von Aluminium, mit einer wannenförmigen Kathode.
SGL Carbon SE, 65201 Wiesbaden, DE. (C25C
3/08, OS 10 2011 086 040, AT: 09.11.2011)
Herstellung eines hochfesten AluminiumSchaumkörpers und entsprechender Schaumkörper. Daimler AG, 70327 Stuttgart, DE. (C22C
1/08, OS 10 2011 118 295, AT: 10.11.2011)
Aluminium-Titan-Bauteil. ThyssenKrupp VDM
GmbH, 58791 Werdohl, DE. (F16S 3/02, GM 20
2010 017 720, AT: 01.03.2010)
Mindestens zwei abwechselnde Modi, die jeweils eine Vorschubsgeschwindigkeit aufweisen, verwendendes gepulstes Reibrührschweißverfahren, wobei sich die mittleren VorschubsGeschwindigkeiten deutlich unterscheiden.
Constellium France, Paris, FR. (B23K 20/12, EP 2
318 173, WO 2010/004109, AT: 16.06.2009, EPAT: 16.06.2009, WO-AT: 16.06.2009)
ALUMINIUM veröffentlicht unter dieser Rubrik regelmäßig einen Überblick über wichtige,
den Werkstoff Aluminium betreffende Patente.
Die ausführlichen Patentblätter und auch
weiterführende Informationen dazu stehen
der Redaktion nicht zur Verfügung. Interessenten können diese beziehen oder einsehen
bei der
Mitteldeutschen Informations-, Patent-,
Online-Service GmbH (mipo),
Julius-Ebeling-Str. 6,
D-06112 Halle an der Saale,
Tel. 0345/29398-0
Fax 0345/29398-40,
www.mipo.de
Die Gesellschaft bietet darüber hinaus weitere
Patent-Dienstleistungen an.
PAT E N T E
Plättchenförmiges Aluminiumpigment auf
plättchenförmigem Aluminium als Substrat,
Herstellungsverfahren und darauf basierende
Farbe. Toyo Aluminium Kabushiki Kaisha, Osakashi, Osaka, J. (C09C 1/64, PS 60 2004 037 404,
EP 1647581, WO 2004/078854, AT: 16.02.2004,
EP-AT: 16.02.2004, WO-AT: 16.02.2004)
Herstellungsverfahren für gegossene Aluminium-Wärmesenken. Nippon Light Metal Co.
Ltd., Tokio, JP. (C22C 21/02, EP 2 275 584, AT:
05.04.2005, EP-AT: 05.04.2005)
Elektrolysebehälter zum Erhalt von Aluminium. Carbone Savoie, Venissieux, FR. (C25C 3/08,
EP 2 013 381, WO 2007/125195, AT: 25.04.2007,
EP-AT: 25.04.2007, WO-AT: 25.04.2007)
Verbesserung des Abzapfens von Aluminium
durch Anlegen eines gezielten elektromagnetischen Felds. Alcoa Inc., Pittsburgh, Pa., US.
(C25C 3/06, EP 2 391 746, WO 2010/087916,
AT: 17.12.2009, EP-AT: 17.12.2009, WO-AT:
17.12.2009)
Verfahren zum Herstellung eines Strukturbestandteils der Automobil-Aluminiumlegierung,
Blech der AA7xxx-Serie. Aleris Aluminum
Duffel BVBA, 2570 Duffel, BE. (B32B 15/01,
EPA 2581218, EP-AT: 12.09.2012, WO-AT:
12.09.2012)
Mit einer feuerveredelten Aluminiumlegierung beschichtetes Stahlmaterial von hervorragender Schnittkanten- und Oberflächenkorrosionsfestigkeit und Korrosionsfestigkeit verarbeiteter Teile sowie Herstellungsverfahren
dafür. Nippon Steel & Sumitomo Metal Corp.,
Tokio 100-8071, JP. (C23C 2/12, EPA 2578719,
WO 2011/152381, EP-AT: 31.05.2011, WO-AT:
31.05.2011)
Aluminiumlegierung. Audi AG, 85057 Ingolstadt,
DE. (C22C 21/02, EP 2 088 216, AT: 23.01.2009,
EP-AT: 23.01.2009)
Herstellungsverfahren für einen aus einer Aluminiumlegierung gegossenen Kühlkörper mit
komplexer Struktur oder einem dünnwandigen
Teilbereich mit hervorragender thermischer
Leitfähigkeit. Nippon Light Metal Co. Ltd., Tokio,
JP. (C22C 21/02, EP 2 281 909, AT: 05.04.2005,
EP-AT: 05.04.2005)
Flügelpfosten für den Mittelschlussbereich
eines verschiebbaren Flügels. Alcoa Aluminium
Deutschland, Inc., 58642 Iserlohn, DE. (E06B
3/263, EPA 2578789, EP-AT: 01.10.2012, WOAT: 01.10.2012)
Verfahren zur Erzeugung einer schwarzen
oxidkeramischen Oberflächenschicht auf einem
Bauteil aus einer Leichtmetalllegierung. Verein zur Förderung von Innovationen durch Forschung, Entwicklung und Technologietransfer e.V.
(Verein Innovent e.V.), 07745 Jena, DE. (C25D
11/10, PS 10 2011 055 644, AT: 23.11.2011)
Verfahren zum Herstellen einer Profilanordnung und deren Verwendung. Alcoa Aluminium Deutschland, Inc., 58642 Iserlohn, DE. (E06B
3/263, PS 50 2010 000 844, EP 2360341, AT:
10.02.201, EP-AT: 10.02.2010)
Wärmeübertragungszusammensetzungen
für Magnesium oder Magnesiumlegierungen
enthaltende Kühlsysteme. Prestone Products
Corp., Danbury, Conn., US. (C23F 11/08, EP 1
941 076, WO 2007/050568, AT: 25.10.2006, EPAT: 25.10.2006, WO-AT: 25.10.2006)
Magnesiumlegierung für Schmiedeanwendungen. Commonwealth Scientific and Industrial Research Organisation, Campbell, Australian
Capital Territory 2612, AU. (C22C 23/00, EPA
2576851, WO 2011/146970, EP-AT: 24.05.2011,
WO-AT: 24.05.2011)
Verfahren zur Herstellung von dünnwandigen,
rotationssymmetrischen Bauteilen aus Aluminium oder Al-Legierung. Magna BDW technologies GmbH, 85570 Markt Schwaben, DE. (B23P
13/00, PS 10 2011 056 942, AT: 22.12.2011)
Aluminiumlegierung und Verfahren zum Herstellen derselben. Hyundai Motor Co., Seoul,
KR; Kia Motors Corp., Seoul, KR. (C22C 21/04,
OS 10 2012 106 022, AT: 05.07.2012)
Element aus Magnesiumlegierung. Nissan Motor Co. Ltd., Yokohama, Kanagawa, JP. (C09J
5/02, EP 2 281 858, AT: 14.06.2010, EP-AT:
14.06.2010)
Aluminiumlegierung zum kontinuierlichen Gießen und Verfahren zum Herstellen derselben.
Hyundai Motor Co., Seoul, KR; Kia Motors Corp.,
Seoul, KR. (C22C 21/04, OS 10 2012 211 699,
AT: 05.07.2012)
Schutz von Magnesiumlegierungen durch Aluminiumplattierung aus ionischen Flüssigkeiten.
Sikorsky Aircraft Corp., Stratford, CT 06615, US.
(C25D 3/44, EPA 2573214, EP-AT: 21.09.2012,
WO-AT: 21.09.2012)
Schwingungsgedämpftes Präzisionsguss-Kraftfahrzeugelement aus einer Aluminiumlegierung für einen Fahrzeugantriebsstrang und
Verfahren zum Herstellen desselben. GM Global
Technology Operations LLC (n.d. Ges. d. Staates
Delaware), Detroit, Mich., US. (B22D 17/00, OS
10 2012 220 087, AT: 05.11.2012)
Magnesiumlegierung für die Wasserstoffspeicherung. Hydrexia Pty Ltd, St Lucia, Queensland, AU. (C22C 23/00, PS 60 2005 033 777, EP
1838887, WO 2006/060851, AT: 02.12.2005, EPAT: 02.12.2005, WO-AT: 02.12.2005)
Halteeinrichtung für Tür- oder Fensterflügel.
Alcoa Aluminium Deutschland, Inc., 58642 Iserlohn, DE. (E05D 15/26, EP 2 578 786, EP-AT:
01.10.2012, WO-AT: 01.10.2012)
Verfahren und Vorrichtung zur Herstellung
von Leichtmetall-Gussteilen. Audi AG, 85057
Ingolstadt, DE; Belte AG, 33129 Delbrück,
DE. (B22D 21/04, OS 10 2011 119 002, AT:
21.11.2011)
Verbundmaterial,
Stranggusskomponente,
Stranggussdüse, Stranggussverfahren, Gussmaterial und Material für eine Gussspule aus
einer Magnesiumlegierung. Sumitomo Electric
Industries, Ltd., Osaka-shi, Osaka 541-0041, JP.
(B22D 11/06, EPA 2578334, WO 2011/152529,
EP-AT: 03.06.2011, WO-AT: 03.06.2011)
Verfahren zum Verbinden von Aluminiumlegierungen. Furukawa-Sky Aluminium Corp.,
Tokio 101-8970, JP. (B23K 20/00, EPA 2578345,
WO 2011/152556, EP-AT: 06.06.2011, WO-AT:
06.06.2011)
Schweißbare, korrosionsbeständige Al-MgLegierungen, insb. für die Verkehrstechnik.
EADS Deutschland GmbH, 85521 Ottobrunn,
DE. (C22C 1/00, OS 599 07 283, EP 1027466,
WO 2000/011229, AT: 14.08.1999, EP-AT:
14.08.1999, WO-AT: 14.08.1999)
Schutzschicht für eine aluminiumhaltige Legierung für den Einsatz bei hohen Temperaturen
sowie Verfahren zur Herstellung einer solchen
Schutzschicht. Forschungszentrum Jülich GmbH,
52428 Jülich, DE. (C23C 8/02, PS 50 2004 013 461,
EP 1706518, WO 2005/071132, AT: 20.11.2004,
EP-AT: 20.11.2004, WO-AT: 20.11.2004)
Reflektor mit resistenter Oberfläche. Alanod
Aluminium-Veredlung GmbH & Co. KG, 58256
Ennepetal, DE; Constellium Switzerland AG,
Zürich, CH. (F21V 7/22, OS 598 09 364, EPA
1129318, WO 2000/029784, AT: 12.11.1998,
EP-AT: 12.11.1998, WO-AT: 12.11.1998)
Verfahren zur Verbindung einer Aluminiumlegierungslamelle an ein Stahlrohr und daraus
hergestellter Wärmetauscher. Aleris Aluminum Koblenz GmbH, 56070 Koblenz, DE. (B32B
15/01, EPA 2574453, EP-AT: 30.09.2011, WOAT: 30.09.2011)
Kühlkörper und Verfahren zur Herstellung
desselben. Aleris Aluminum Vogt GmbH, 88267
Vogt, DE. (H01L 23/36, PS 101 57 240, AT:
22.11.2001)
Profilschiene. Aleris Vogt GmbH, 88267 Vogt,
DE. (E06B 3/30, GM 20 2007 006 536, AT:
04.05.2007)
Plattiertes Blechprodukt. Aleris Aluminum Duffel BVBA, Duffel, BE. (B32B 15/01, GM 20 2007
018 795, AT: 19.04.2007)
Stützprofil sowie ein damit versehenes Stützsystem. Aleris Aluminum Vogt GmbH, 88267
Vogt, DE. (E04F 13/21, GM 20 2010 004 465,
AT: 01.04.2010)
Feststellvorrichtung eines Öffnungselements
eines Bauelements, das über Hilfsmittel zum
Verriegeln und Entriegeln des Öffnungselements verfügt. Norsk Hydro ASA, 0240
Oslo, NO. (E05B 47/00, EPA 2578778, EP-AT:
05.10.2012, WO-AT: 05.10.2012)
Aluminiumverbundwerkstoff mit AlMgSiKernlegierungsschicht. Hydro Aluminium Rolled Products GmbH, 41515 Grevenbroich, DE.
(B32B 15/01, EPA 2570257, EP-AT: 15.09.2011,
WO-AT: 15.09.2011)
Walze mit Kühlsystem. Hydro Aluminium Rolled Products GmbH, 41515 Grevenbroich. (B22D
11/06, OS 10 2011 055 066, AT: 04.11.2011) ➝
73
PAT E N T E
Verfahren zur Herstellung eines Hohlprofilverbunds. Hydro Aluminium Deutschland GmbH,
41515 Grevenbroich, DE. (B29C 69/00, OS 10
2005 052 612, AT: 02.11.2005)
Verfahren zur Herstellung eines Absorberblechs für Sonnenkollektoren. Hydro Aluminium Deutschland GmbH, 41515 Grevenbroich, DE. (B05D 7/14, OS 10 2006 039 804, AT:
25.08.2006)
Verfahren und Vorrichtung zum Erzeugen einer
Konversionsschicht. Hydro Aluminium Deutschland GmbH, 41515 Grevenbroich, DE. (C23C
22/76, OS 10 2007 052 770, AT: 02.11.2007)
Verfahren zur Herstellung eines Bandes für Verpackungszwecke. Hydro Aluminium Deutschland GmbH, 41515 Grevenbroich, DE. (B21B
15/00, OS 10 2008 019 768, AT: 18.04.2008)
Vorrichtung und Verfahren zur Herstellung einer Metallfolie. Hydro Aluminium Deutschland
GmbH, 41515 Grevenbroich, DE. (B21B 1/40, OS
10 2008 037 520, AT: 06.11.2008)
Verfahren zum Herstellen einer Metallfolie und
entsprechend hergestellte Metallfolie. Hydro
Aluminium Deutschland GmbH, 41515 Grevenbroich, DE. (B21B 1/40, OS 10 2008 037 619, AT:
01.12.2008)
Lötverfahren für Wärmetauscher und Solarkollektoren. Hydro Aluminium Deutschland GmbH,
41515 Grevenbroich, DE. (B23K 1/005, OS 10
2009 043 985, AT: 11.09.2009)
Verfahren zur Herstellung von Konvektorblechen für Heizkörper. Caradon Stelrad B.V.,
Herentals, BE; Hydro Aluminium Deutschland
GmbH, 41515 Grevenbroich, DE. (B21D 53/04,
OS 10 2009 059 283, AT: 22.12.2009)
Verfahren zur Herstellung eines Architekturblechelements. Hydro Aluminium Deutschland
GmbH, 41515 Grevenbroich, DE. (B05D 1/30,
OS 10 2010 000 449, AT: 17.02.2010)
Beschlag. Norsk Hydro ASA, Oslo, NO. (E05C
9/18, OS 10 2011 055 037, AT: 04.11.2011)
Lithoband und Verfahren zu seiner Herstellung. Hydro Aluminium Deutschland GmbH,
41515 Grevenbroich, DE. (C22C 21/06, OS 199
56 692, AT: 25.11.1999)
Verfahren zur Herstellung eines walzplattierten, hochglänzenden Aluminiumbandes.
Hydro Aluminium Deutschland GmbH, 41515
Grevenbroich, DE. (B23B 15/00, EP 1 849 542,
EP-AT: 25.04.2006)
Verfahren zur Entfernung und Rückgewinnung
von CO2 aus einem Abgas. Norsk Hydro ASA,
Oslo, NO. (B01D 53/62, PS 60 2005 027 893, EP
1827656, WO 2006/043820, AT: 12.10.2005, EPAT: 12.10.2005, WO-AT: 12.10.2005)
Extrudierte Dicht- oder Abschlussleiste. WKW
Erbslöh Automotive GmbH, 42349 Wuppertal,
DE. (B60J 10/02, GM 20 2007 004 123, AT:
21.03.2007)
74
Verfahren zur Konditionierung der Oberfläche eines Lithobands. Hydro Aluminium Rolled Products GmbH, 41515 Grevenbroich, DE.
(B41N 1/08, PS 60 2007 021 896, EP 2024190,
WO 2007/141300, AT: 06.06.2007, EP-AT:
06.06.2007, WO-AT: 06.06.2007)
Bauteil aus Aluminiummaterial mit einer partiellen oder vollständigen Beschichtung der
Oberflächen für die Hartverlötung. Erbslöh Aluminium GmbH, 42553 Velbert, DE. (C23C 4/12,
GM 20 2005 004 807, AT: 22.03.2005)
Dachträgeranordnung. WKW Erbslöh Automotive GmbH, 42349 Wuppertal, DE. (B60R 9/04,
GM 20 2007 001 742, AT: 07.02.2007)
Dekoratives Bauteil. WKW Erbslöh Automotive
GmbH, 42349 Wuppertal, DE. (B60R 13/04, GM
20 2007 002 233, AT: 12.02.2007)
Vorrichtung zum Halten und/oder Kontaktieren eines zu behandelnden Substrates. WKW
Erbslöh Automotive GmbH, 42349 Wuppertal,
DE. (C25D 17/06, GM 20 2007 004 024, AT:
20.03.2007)
Toleranzausgleichseinrichtung. WKW Erbslöh
Automotive GmbH, 42349 Wuppertal, DE. (F16B
5/02, GM 20 2010 002 447, AT: 17.02.2010)
Sicherungselement für Fenster oder Tür. Gutmann AG, 91781 Weißenburg, DE. (E06B 5/11,
GM 20 2011 109 477, AT: 23.12.2011)
Kolben und Verfahren zu seiner Herstellung.
KS Kolbenschmidt GmbH, 74172 Neckarsulm,
DE. (B23B 5/24, OS 10 2011 085 434, AT:
28.10.2011)
Kolben und Verfahren zu seiner Kühlung.
KS Kolbenschmidt GmbH, 74172 Neckarsulm,
DE. (F02F 3/18, OS 10 2011 085 444, AT:
28.10.2011)
Zylindrische Lauffläche sowie Verfahren zur
Herstellung einer zylindrischen Lauffläche. KS
Aluminium-Technologie GmbH, 74172 Neckarsulm, DE. (F02F 1/00, EP 2 112 359, AT:
15.01.2002, EP-AT: 15.01.2002)
Kolben für einen Verbrennungsmotor. Mahle
International GmbH, 70376 Stuttgart, DE. (F02F
3/00, OS 10 2006 013 905, AT: 25.03.2006)
sowie (F02F 3/22, OS 10 2011 119 525, AT:
26.11.2011)
Kolben. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/00, OS 10 2011 085 254, AT:
26.10.2011) sowie (F02F 3/10, OS 10 2012 211
440, AT: 02.07.2012)
Gießform für einen Kolben. Mahle International
GmbH, 70376 Stuttgart, DE. (B22D 15/02, OS 10
2011 086 411, AT: 15.11.2011)
Verfahren zur Herstellung einer Aluminiumstruktur sowie Aluminiumstruktur. Sumitomo Electric Industries, Ltd., Chuo-ku Osaka-shi
Osaka 541-0041, JP. (C25D 1/08, EPA 2570518,
WO 2011/142338, EP-AT: 10.05.2011, WO-AT:
10.05.2011)
Kolben für einen Verbrennungsmotor und Verfahren zu seiner Herstellung. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/22, OS
10 2011 119 527, AT: 26.11.2011)
Gebauter, flüssigkeitsgekühlter Kolben. Mahle
International GmbH, 70376 Stuttgart, DE.
(F02F 3/00, EP 1 922 478, WO 2007/028364,
AT: 02.09.2006, EP-AT: 02.09.2006, WO-AT:
02.09.2006)
Herstellverfahren für AlMgSi-Aluminiumband.
Hydro Aluminium Rolled Products GmbH, 41515
Grevenbroich, DE. (C22F 1/05, EPA 2570509, EPAT: 15.09.2011, WO-AT: 15.09.2011)
Dreidimensionales, netzartiges, poröses Aluminiummaterial. Sumitomo Electric Industries,
Ltd., Chuo-ku Osaka-shi Osaka 541-0041, JP; Sumitomo Electric Toyama Co., Ltd., Imizu-shi Toyama 934-0031, JP. (H01M 4/13, EPA 2579364,
WO 2011/152280, EP-AT: 26.05.2011, WO-AT:
26.05.2011)
Verfahren zur Herstellung eines Aluminiumlegierungs-Wärmetauschers. Sumitomo Light Metal Industries, Ltd., Minato-ku Tokio 105-8601, JP.
(B23K 1/00, EPA 2578344, WO 2011/148781,
EP-AT: 10.05.2011, WO-AT: 10.05.2011)
Patentblatt Juni 2013
Herstellungsverfahren für einen mit einer
Aluminiumlegierung verbundenen Körper.
Showa Denko K.K., Tokio 105-8518, JP. (C22F
1/053, EPA 2592170, WO 2011/155609, EP-AT:
10.06.2011, WO-AT: 10.06.2011)
Al-Zn-Mg-Cu-Legierung. Aleris Rolled Products
Germany GmbH, 56070 Koblenz, DE. (C22C
21/10, OS 11 2004 003 147 u. OS 11 2004 000
603, WO 2004/090185, AT: 09.04.2004, WO-AT:
09.04.2004)
Wasserreaktives, Al-basiertes Verbundsmaterial; wasserreaktiver, Al-basierter, thermisch
gespritzter Film; Verfahren für die Herstellung
eines solchen Al-basierten, thermisch gespritzten Films und Bestandteil für eine Filmbildungskammer. Ulvac, Inc., Chigasaki-shi, Kanagawa, JP.
(C23C 4/06, WO 2012 026349, AT: 12.08.2011,
WO-AT: 12.08.2011)
Al-Cu-Li Legierungsprodukt, welches für eine
Luftfahrzeuganwendung geeignet ist. Aleris
Rolled Products Germany GmbH, 56070 Koblenz,
DE. (C22C 21/12, GM 20 2008 018 370, AT:
16.09.2008)
Zn-Al-Mg-Si-legiertes und geplättetes (plattiertes) Stahlprodukt mit exzellenten Anti-Korrosions-Eigenschaften. Nippon Steel & Sumikin
Coated Sheet Corp., Tokyo, JP; Nippon Steel &
Sumitomo Metal Corp., Tokyo, Chiyoda-ku, JP.
(C23C 2/12, OS 600 45 924, EPA 1225246,
WO 2001/011100, AT: 09.08.2000, EP-AT:
09.08.2000, WO-AT: 09.08.2000)
Aluminiumlegierung. Novelis Inc., Toronto, ON
M8Z 1J5, CA. (C22C 21/02, EPA 2592165, EPAT: 11.11.2011, WO-AT: 11.11.2011)
PAT E N T E
Knetprodukt aus Al-Cu-Mg-Legierung für das
Strukturbauteil eines Flugzeugs. Constellium
France, Paris, FR. (C22C 21/12, EP 1 382 698,
AT: 09.07.2003, EP-AT: 09.07.2003)
Modifikation von salzhaltigen Schlacken aus
den Verfahren der zweiten Schmelzung von
Aluminium und deren Verwendung als Adsorptionsmittel der erhaltenen Produkte.
Universidad Pública De Navarra, 31006 Pamplona (Navarra), ES. (B01J 20/08, EPA 2586525,
WO 2011/161290, EP-AT: 15.06.2011, WO-AT:
15.06.2011)
Vorrichtung zur Entfernung von Kurzschlussblockierungen bei der Inbetriebnahme einer
Elektrolysezelle zur Herstellung von Aluminium. Rio Tinto Alcan Intl Ltd., Montréal, QC
H3A 3G2, CA. (C25C 3/16, EPA 2585624, WO
2012/001242, EP-AT: 23.06.2011, WO-AT:
23.06.2011)
Vorrichtung zur Entnahme von Kurzschlussdistanzscheiben für die Inbetriebnahme einer
Elektrolysezelle zur Herstellung von Aluminium. E.C.L., 59790 Ronchin, FR; Rio Tinto Alcan
Intl Ltd., Montréal, QC H3A 3G2, CA. (C25C
3/16, EPA 2585625, WO 2012/001243, EP-AT:
23.06.2011, WO-AT: 23.06.2011)
Verfahren zur Behandlung einer Legierung aus
Aluminium und Titan zur Verbesserung der
Oxidationsbeständigkeit dieser Legierungen
zwischen 800 °C und 1000 °C und Verwendung
des Verfahrens. Dechema-Forschungsinstitut,
60486 Frankfurt, DE. (C23C 22/34, PS 100 17
187, AT: 07.04.2000)
Mischungen von Aluminium-Hydrogenphosphiten mit Aluminiumsalzen, Verfahren zu
ihrer Herstellung sowie ihre Verwendung.
Clariant International Ltd., Muttenz, CH. (C01B
25/163, OS 10 2011 120 190, AT: 05.12.2011)
Aluminium-Hydrogenphosphite, ein Verfahren
zu ihrer Herstellung sowie ihre Verwendung.
Clariant International Ltd., Muttenz, CH. (C01B
25/163, OS 10 2011 120 192, AT: 05.12.2011)
Bremsscheibe aus einer Aluminium-MatrixVerbundlegierung mit Siliziumcarbid-Partikeln
und Herstellungsverfahren hierfür. Daimler AG,
70327 Stuttgart, DE; TU Chemnitz, 09111 Chemnitz, DE. (C22C 21/02, OS 10 2011 121 292, AT:
15.12.2011)
Magnetische Separierung von Eisen aus Aloder Mg-Legierungsschmelzen. GM Global
Technology Operations LLC (n.d. Ges. d. Staates
Delaware), Detroit, Mich., US. (C22B 21/00, OS
10 2012 222 434, AT: 06.12.2012)
Feuerlöscharmaturen aus Aluminium oder AlLegierung mit trinkwassertauglicher Oberflächenbeschichtung. Max Widenmann KG Armaturenfabrik, 89537 Giengen, DE. (A62C 35/00,
GM 20 2004 015 858, AT: 13.10.2004)
Versiegelungsreagens für Aluminiumlegierung. BYD Co. Ltd., Shenzhen, Guangdong, CN.
(C25D 11/24, EP 2 350 356, WO 2010/060358,
AT: 16.11.2009, EP-AT: 16.11.2009)
Teilpigmentierung einer Deckschicht zur Vermeidung von Interferenzen bei Aluminiumbauteilen oder Aluminium aufweisenden Bauteilen. Süddeutsche Aluminium Manufaktur GmbH,
89558 Böhmenkirch, DE. (B44 1/00, PS 50 2008
007 171, EP 1970214, AT: 07.03.2008, EP-AT:
07.03.2008)
Verfahren zur Herstellung eines Bandes aus
Aluminium für Verpackungszwecke und derart hergestelltes Band. Hydro Aluminium Rolled Products GmbH, 41515 Grevenbroich, DE.
(B21H 7/00, PS 50 2009 003 753, EP 2303489,
WO 2009/127730, AT: 17.04.2009, EP-AT:
17.04.2009, WO-AT: 17.04.2009)
Mikro-Kanalreaktor mit Katalysator auf thermisch gewachsenem Aluminium, Verwendung
desselben sowie Katalysator und seine Herstellung. Velocys, Inc., Plain City, Ohio, US.
(B01J 19/00, PS 60 2005 034 349, EP 1755777,
WO 2006/036193, AT: 23.03.2005, EP-AT:
23.03.2005, WO-AT: 23.03.2005)
Verfahren zur Bildung einer aluminium- und
zirkonhaltigen Schutzbeschichtung auf einem
Metall. SNECMA, Paris, FR. (C23C 10/14, PS 60
2009 007 050, EP 2260120, WO 2009/112581,
AT: 13.03.2009, EP-AT: 13.03.2009, WO-AT:
13.03.2009)
Gießbare, wärmebeständige Aluminiumlegierung. Norsk Hydro ASA, 0240 Oslo, NO;
Montupet S.A., 92112 Clichy Cedex, FR. (C22C
21/02, EPA 2582855, WO 2011/159169, EP-AT:
16.06.2011, WO-AT: 16.06.2011)
System und Verfahren zum Herstellen einer
7xxx-Serie-Aluminiumlegierung im F-Zustand.
Ford Global Technologies, LLC, Dearborn,
Mich., US. (C22F 1/00, OS 10 2012 221 602, AT:
27.11.2012)
Aluminiumlegierung vom Typ AlZnMg und Verfahren zu deren Herstellung. Aluminium Lend
Gmbh & Co. Kg., Lend, AT. (C22C 21/10, EP 2 061
912, WO 2008/028208, AT: 03.09.2007, EP-AT:
03.09.2007, WO-AT: 03.09.2007)
Direktschmieden und -walzen von L12-Aluminiumlegierungen
für
Panzerungsanwendungen. United Technologies Corp., Hartford,
Conn., US. (C22C 1/05, EP 2 253 725, AT:
31.03.2010, EP-AT: 31.03.2010)
Verfahren zur Abreicherung von Magnesium
und Anreicherung von Lithium in chloridisch
geprägten Salzlösungen. TU Bergakademie Freiberg, 09599 Freiberg, DE; Universidad Autónoma
Tomas Frias, Potosi, BO. (C01D 3/06, PS 10 2010
019 554, AT: 05.05.2010)
Magnesiumlegierung. AIT Austrian Institute
of Technology GmbH, 1220 Wien, AT. (C22C
23/04, EPA 2591132, WO 2012/003522, EP-AT:
15.06.2011, WO-AT: 15.06.2011)
Bauteil aus einer Magnesiumlegierung und
Verfahren zu dessen Herstellung. Hon Hai Precision Industry Co. Ltd., Tu-cheng City, Taipei
Hsien, TW. (F16S 5/00, OS 10 2008 060 794, AT:
05.12.2008)
Verfahren zum Transport von pulverförmigen
Materialien ohne Entmischung. Rio Tinto Alcan
Intl Ltd., Montreal, Quebec, CA. (B65G 53/18, EP
2 185 450, WO 2009/010667, AT: 26.06.2008,
EP-AT: 26.06.2008, WO-AT: 26.06.2008)
Mehrlagiges, lötbares Blech. Alcoa Inc., Pittsburgh, Pa., US; Kobe Steel, Ltd., Kobe, Hyogo, JP.
(B32B 15/01, EP 2 015 932, WO 2007/133286,
AT: 21.11.2006, EP-AT: 21.11.2006, WO-AT:
21.11.2006)
Gießen von Nichteisenmetallen. Alcoa Inc.,
Pittsburgh, Pa., US. (B22D 11/06, EP 1 545
812, WO 2004/018124, AT: 13.06.2003, EP-AT:
13.06.2003, WO-AT: 13.06.2003)
Profilschiene zur Abstützung einer Terrasse o.
dgl. Aleris Aluminum Vogt GmbH, 88267 Vogt,
DE. (E04F 15/02, GM 20 2007 010 332, AT:
23.07.2007)
Vorrichtung zur Abstützung eines Plattenelementes. Aleris Aluminum Vogt GmbH, 88267
Vogt, DE. (E04D 13/18, GM 20 2007 010 520,
AT: 28.07.2007)
Hartlötblech. Aleris Aluminum Koblenz GmbH,
56070 Koblenz, DE. (B32B 15/01, EP 1 183
151, WO 2000/063008, AT: 12.04.2000, EP-AT:
12.04.2000, WO-AT: 12.04.2000)
Messung und Steuerung der Strömung von
fließfähigen Materialien. Comalco Aluminium
Ltd., Brisbane, Queensland, AU; Auckland Uniservices Ltd., Auckland, NZ. (G01F 1/76, PS
600 47 195, EP 1192425, WO 2000/057139,
AT: 24.03.2000, EP-AT: 24.03.2000, WO-AT:
24.03.2000)
Profil für eine Stoßstange eines Fahrzeuges,
Haltewerkzeug und Rohrprofil dafür sowie
Verfahren zur Herstellung des Profils. Constellium Switzerland AG, Zürich, CH. (B60R 19/18,
PS 10 2006 062 294, AT: 27.12.2006)
Walze mit Kühlsystem. Hydro Aluminium Rolled Products GmbH, 41515 Grevenbroich, DE.
(B22D 11/06, EPA 2589446, EP-AT: 29.10.2012,
WO-AT: 29.10.2012)
Beschlag. Norsk Hydro ASA, 0240 Oslo, NO.
(E06B 3/263, EPA 2589739,.EP-AT: 02.11.2012)
Eloxalverfahren eines Metallprofils auf Aluminiumbasis mit Motiv und so erhaltenes Profil.
Norsk Hydro ASA, 0240 Olso, NO. (C25D 11/16,
EPA 2586894, EP-AT: 18.10.2012, WO-AT:
18.10.2012)
Verfahren zur Herstellung einer Metallbandkante. Hydro Aluminium Deutschland GmbH,
51149 Köln, DE. (B23P 9/00, PS 10 2009 026
235, AT: 23.07.2009)
Vorrichtung zum Fügen von mindestens zwei
Bauteilen aus artverschiedenen Werkstoffen.
Hydro Aluminium Deutschland GmbH, 51149
Köln, DE. (B23K 20/12, GM 20 2005 021 318,
AT: 28.04.2005)
Fortsetzung in ALUMINIUM 9/13
75
LIEFERVERZEICHNIS
1
Smelting technology
 Auto firing systems
Automatische Feuerungssysteme
Hüttentechnik
1.1 Raw materials
Rohstoffe
1.2 Storage facilities for smelting
Lagermöglichkeiten in der Hütte
1.3 Anode production
Anodenherstellung
1.4 Anode rodding
Anodenschlägerei
1.4.1 Anode baking
Anodenbrennen
1.4.2 Anode clearing
Anodenschlägerei
1.4.3 Fixing of new anodes to the
anodes bars
Befestigen von neuen Anoden
an der Anodenstange
1.5 Casthouse (foundry)
Gießerei
1.6 Casting machines
Gießmaschinen
1.7 Current supply
Stromversorgung
1.8 Electrolysis cell (pot)
Elektrolyseofen
1.9 Potroom
Elektrolysehalle
1.10 Laboratory
Labor
1.11 Emptying the cathode shell
Ofenwannenentleeren
1.12 Cathode repair shop
Kathodenreparaturwerkstatt
1.13 Second-hand plant
Gebrauchtanlagen
1.14 Aluminium alloys
Aluminiumlegierungen
1.15 Storage and transport
Lager und Transport
1.16 Smelting manufactures
Hüttenerzeugnisse
RIEDHAMMER
CARBON BAKING TECHNOLOGY
RIEDHAMMER GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 0, Fax: -5218 231
E-Mail: [email protected]
Internet: www.riedhammer.de
 Hydraulic presses for prebaked
anodes / Hydraulische Pressen zur
Herstellung von Anoden
LAEIS GmbH
Am Scheerleck 7, L-6868 Wecker, Luxembourg
Phone:
+352 27612 0
Fax:
+352 27612 109
Internet: www.laeis-gmbh.com
Contact: Dr. Alfred Kaiser
 Anode Technology &
Mixing Equipment
Buss ChemTech AG, Switzerland
Phone:
+4161 825 64 62
E-Mail:
[email protected]
Internet: www.buss-ct.com
 Mixing Technology for
Anode pastes
1.2 Storage facilities for
smelting
Lagermöglichkeiten i.d. Hütte
FLSmidth MÖLLER GmbH
Haderslebener Straße 7
D-25421 Pinneberg
Telefon: 04101 788-0
Telefax: 04101 788-115
Internet: www.flsmidthmoeller.com
Kontakt: Herr Dipl.-Ing. Timo Letz
Paul Hedfeld GmbH
Hundeicker Str. 20
D-58285 Gevelsberg
Phone: +49 (0) 2332 6371
Internet: www.hedfeld.com
 Unloading/Loading equipment
Entlade-/Beladeeinrichtungen
www.flsmidthmoeller.com
see Storage facilities for smelting 1.2
Bulk materials Handling from Ship to Cell
ALUMINA AND PET COKE SHIPUNLOADERS
Contact: Andreas Haeuser, [email protected]
Solios Carbone – France
www.fivesgroup.com
 Conveying systems bulk materials
Förderanlagen für Schüttgüter
(Hüttenaluminiumherstellung)
Internet: www.flsmidthmoeller.com
76
1.4 Anode rodding
 Removal of bath residues from
the surface of spent anodes
Entfernen der Badreste von der Oberfläche der verbrauchten Anoden
1.3 Anode production
Anodenherstellung
www.coperion.com
mailto: [email protected]
Buss AG
CH-4133 Pratteln
Phone:
+41 61 825 66 00
E-Mail:
[email protected]
Internet: www.busscorp.com
Anodenanschlägerei
www.alu-web.de
 Bulk materials Handling
from Ship to Cell
Mischtechnologie für Anodenmassen
GLAMA Maschinenbau GmbH
Hornstraße 19
D-45964 Gladbeck
Telefon 02043 / 9738-0
Telefax 02043 / 9738-50
 Rodding shop
Storvik AS
Industriveien 13
6600 SUNNDALSØRA/NORWAY
Tel.: +47 71 69 95 00 | Fax: +47 71 69 95 55
www.storvik.no | [email protected]
www.brochot.fr
SUPPLIERS DIRECTORY
1.4.1 Anode baking
Anodenbrennen
 Open top and closed
type baking furnaces
Offene und geschlossene Ringöfen
Stopinc AG
Bösch 83 a
CH-6331 Hünenberg
Tel. +41/41-785 75 00
Fax +41/41-785 75 01
Internet: www.stopinc.ch
 Degassing, filtration and
grain refinement
RIEDHAMMER
Entgasung, Filtern, Kornfeinung
CARBON BAKING TECHNOLOGY
RIEDHAMMER GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 0, Fax: -5218 231
Internet: www.riedhammer.de
www.alu-web.de
1.5 Casthouse (foundry)
Gießerei
Drache Umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
Gautschi
Engineering GmbH
see Casting equipment 3.1
MOBILE
EQUIPMENT
Phone: +31.315.683941
[email protected] · www.hencon.com
Solios Thermal UK
www.fivesgroup.com
 Metal treatment in the
holding furnace
Metallbehandlung in Halteöfen
Gautschi
Engineering GmbH
 Dross skimming of liquid metal
 Transfer to the casting furnace
see Anode rodding 1.4
GmbH
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
Abkrätzen des Flüssigmetalls
Furnaces
casting machines
transport crucibles
[email protected]
www.bartz-maschinenbau.de
Sistem Teknik Endüstryel Firinlar LTD. STI.
TOSB – TAYSAD OSB 1.Cad. 14.Sok. No.: 3
Gebze, Kocaeli / Turkey
Tel.: +90 262 658 22 26
Fax: +90 262 658 22 38
Internet: www.sistemteknik.com
 Furnace charging with
molten metal
Ofenbeschickung mit Flüssigmetall
Überführung in Gießofen
Gautschi
Engineering GmbH
 Ingot Casting Line
Bartz GmbH
see Casthous (foundry) 1.5
 Transport of liquid metal
to the casthouse
Transport v. Flüssigmetall in Gießereien
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstraße 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
Internet: www.hertwich.com
INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH
Konstantinstraße 1a
D 41238 Mönchengladbach
Telefon +49 (02166) 987990
Telefax +49 (02166) 987996
Internet: www.inotherm-gmbh.de
Bartz GmbH
www.brochot.fr
www.alu-web.de
 Melting/holding/casting furnaces
Schmelz-/Halte- und Gießöfen
Gautschi
Engineering GmbH
see Casthouse (foundry) 1.5
 Treatment of casthouse
off gases
Behandlung der Gießereiabgase
Gautschi
Engineering GmbH
Gießmaschinen
see Equipment and accessories 3.1
Hampshire House, High Street, Kingswinford,
West Midlands DY6 8AW, UK
Tel.: +44 (0) 1384 279132
Fax: +44 (0) 1384 291211
www.mechatherm.com
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
Avenida Cervantes Nº6
48970 – Basauri – Bizkaia – Spain
Tel: +34 944 409 420
Internet: www.insertec.biz
GAPCast TM: the Swiss casting solution
see Casting machines and equipment 4.7
www.mechatherm.com
see Smelting technology 1.5
77
LIEFERVERZEICHNIS
1.9 Potroom
Elektrolysehalle
RIHS ENGINEERING SA
see Casting machines and equipment 4.7
 Pig casting machines (sow casters)
Masselgießmaschine (Sowcaster)
Bartz GmbH
[email protected]
 Heat treatment of extrusion
ingot (homogenisation)
Formatebehandlung (homogenisieren)
Gautschi
Engineering GmbH
Gautschi
Engineering GmbH
 Rolling and extrusion ingot
and T-bars
Formatgießerei (Walzbarren oder
Pressbolzen oder T-Barren)
Gautschi
Engineering GmbH
 Horizontal continuous casting
Horizontales Stranggießen
Gautschi
Engineering GmbH
 Sawing / Sägen
Gautschi
Engineering GmbH
78
Anoden Transporteinrichtungen
Wagstaff, Inc.
3910 N. Flora Rd.
Spokane, WA 99216 USA
+1 509 922 1404 phone
+1 509 924 0241 fax
Internet: www.wagstaff.com
1.8 Electrolysis cell (pot)
 Bulk materials Handling
from Ship to Cell
Bulk materials Handling from Ship to Cell
www.coperion.com
mailto: [email protected]
 Calcium silicate boards
Promat GmbH High Performance Insulation
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
[email protected], www.promat.de
 Exhaust gas treatment
 Crustbreakers / Krustenbrecher
 Dry absorption units for
electrolysis exhaust gases
Trockenabsorptionsanlage für
Elektrolyseofenabgase
Solios Environnement
www.fivesgroup.com
 Pot ramming Machine
www.brochot.fr
 Tapping vehicles/Schöpffahrzeuge
Abgasbehandlung
Solios Environnement
www.fivesgroup.com
Beschickungseinrichtungen
für Elektrolysezellen
Anodenwechselmaschine
 Anode transport equipment
 Pot feeding systems
 Anode changing machine
Gautschi
Engineering GmbH
Calciumsilikatplatten
T.T. Tomorrow Technology S.p.A.
Via dell’Artigianato 18
Due Carrare, Padova 35020, Italy
Telefon +39 049 912 8800
Telefax +39 049 912 8888
Contact: Giovanni Magarotto
 Scales / Waagen
Gautschi
Engineering GmbH
Phone: +31.315.683941
[email protected] · www.hencon.com
 Vertical semi-continuous DC
casting / Vertikales Stranggießen
Elektrolyseofen
MOBILE
EQUIPMENT
www.flsmidthmoeller.com
1.12 Cathode repair shop
KathodenreparaturWerkstatt
 Cathode Sealing Bench
Eingießen von Kathodenbarren
Sermas Industrie
[email protected]
SUPPLIERS DIRECTORY
1.14 Aluminium Alloys
2.2 Extrusion equipment
Aluminiumlegierungen
Strangpresseinrichtungen
see Coil transport systems 3.4
RHEINFELDEN ALLOYS GmbH & Co. KG
A member of ALUMINIUM RHEINFELDEN Group
Postfach 1703, 79607 Rheinfelden
Tel.: +49 7623 93-490
Fax: +49 7623 93-546
Internet: www.rheinfelden-alloys.eu
1.15 Storage and transport
Lager und Transport
SMS Siemag AG
see Rolling mill technology 3.0
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
www.brochot.fr
2
Pressbolzenbereitstellung
extrutec GmbH
Fritz-Reichle Ring 2
D-78315 Radolfzell
Tel. +49 7732 939 1390
Fax +49 7732 939 1399
Internet: www.extrutec-gmbh.de
mfw-maschinenbau.com
• Log/Bolzenlager Handling
• Bolzensäge, Bolzenfügen
www.alu-web.de
 Press control systems
Pressensteuersysteme
see Extrusion Equipment 2.2
Strangpressen
2.1 Extrusion billet preparation
Oilgear Towler GmbH
Im Gotthelf 8
D 65795 Hattersheim
Tel. +49 (0) 6145 3770
Fax +49 (0) 6145 30770
Internet: www.oilgear.de
Oilgear Towler GmbH
Extrusion
2.1 Extrusion billet preparation
Pressbolzenbereitstellung
2.1.1 Extrusion billet production
Pressbolzenherstellung
2.2 Extrusion equipment
Strangpresseinrichtungen
2.3 Section handling
Profilhandling
2.4 Heat treatment
Wärmebehandlung
www.mechatherm.com
2.5 Measurement and control
equipment
Mess- und Regeleinrichtungen
2.6 Die preparation and care
Werkzeugbereitstellung
und -pflege
2.7 Second-hand extrusion plant
Gebrauchte Strangpressanlagen
2.8 Consultancy, expert opinion
Beratung, Gutachten
2.9 Surface finishing of sections
Oberflächenveredlung
von Profilen
2.10 Machining of sections
Profilbearbeitung
2.11 Equipment and accessories
Ausrüstungen und Hilfsmittel
2.12 Services
Dienstleistungen
 Billet heating furnaces
Öfen zur Bolzenerwärmung
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
 Heating and control
equipment for intelligent
billet containers
Heizungs- und Kontrollausrüstung
für intelligente Blockaufnehmer
MARX GmbH & Co. KG
www.marx-gmbh.de
see Melt operations 4.13
2.3 Section handling
Profilhandling
CTI Systems S.A.
Z.I. Eselborn-Lentzweiler
12, op der Sang | L- 9779 Lentzweiler
Tel. +352 2685 2000 | Fax +352 2685 3000
[email protected] | www.ctisystems.com
H+H HERRMANN + HIEBER GMBH
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 711 93467-0, Fax +49 711 34609-11
Internet: www.herrmannhieber.de
Vollert Anlagenbau GmbH
Stadtseestraße 12, D-74189 Weinsberg
Tel. +49 7134 52 220 l Fax +49 7134 52 222
E-Mail [email protected]
Internet www.vollert.de
79
LIEFERVERZEICHNIS
 Packaging equipment
Verpackungseinrichtungen
 Section transport equipment
Profiltransporteinrichtungen
2.4 Heat treatment
Wärmebehandlung
• Automatik Verpackung
• Packtische, Profilpaketheber
• Spacerhandling und Konzepte
see Section handling 2.3
 Section saws
Profilsägen
• Kurzlängensäge automatisiert
Nijverheidsweg 3
NL-7071 CH Ulft Netherlands
Tel.: +31 315 641352
Fax: +31 315 641852
Internet: www.unifour.nl
Sales Contact: Paul Overmans
Hier könnte Ihr
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
BSN Thermprozesstechnik GmbH
Kammerbruchstraße 64
D-52152 Simmerath
Tel. 02473-9277-0 · Fax: 02473-9277-111
[email protected] · www.bsn-therm.de
Ofenanlagen zum Wärmebehandeln von Aluminiumlegierungen, Buntmetallen und Stählen
Tel: +34 944 409 420
 Stackers / Destackers
Stapler / Entstapler
 Section store equipment
www.mechatherm.com
Profil-Lagereinrichtungen
www.ctisystems.com
• 7 und 14 m De- u. Stacker
• Kombianlagen
 Transport equipment for
extruded sections
www.alu-web.de
KASTO Maschinenbau GmbH & Co. KG
Industriestr. 14, D-77855 Achern
Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300
[email protected] / www.kasto.de
Hersteller von Band- und Kreissägemaschinen
sowie Langgut- und Blechlagersystemen
80
Transporteinrichtungen
für Profilabschnitte
www.ctisystems.com
SECO/WARWICK EUROPE S.A.
ul. Šwierczewskiego 76
66-200 Šwiebodzin, POLAND
Tel: +48 68 38 19 800
Internet: www.secowarwick.com
Could not find your „keywords“?
 Heat treatment furnaces
Wärmebehandlungsöfen
• Skip Handling, Spacer
• Kettenförderer
ERNST REINHARDT GMBH
Güterbahnhofstrasse 1
D-78048 Villingen-Schwenningen
Tel. +49 (0) 7721 8441-0, Fax -44
Internet: www.ernst-reinhardt.com
SUPPLIERS DIRECTORY
 Homogenising furnaces
Homogenisieröfen
2.10 Machining of sections
Profilbearbeitung
 Billet saw
see Heat treatment furnaces 2.4
Bolzensägen
Sermas Industrie
[email protected]
www.alu-web.de
2.11 Equipment and
accessories
Ausrüstungen und
Hilfsmittel
Nijverheidsweg 3
Tel.: +31 315 641352
Fax: +31 315 641852
 Ageing furnace for extrusions
Auslagerungsöfen für
Strangpressprofile
2.6 Die preparation and care
Werkzeugbereitstellung
und -pflege
 Die heating furnaces
Werkzeuganwärmöfen
see Extrusion billet preparation 2.1
3
Rolling mill technology
Walzwerktechnik
see Extrusion billet preparation 2.1
schwartz GmbH
see Heat treatment 2.4
Nijverheidsweg 3
Tel.: +31 315 641352
Fax: +31 315 641852
Hier könnte Ihr
Bezugsquellen-Eintrag stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
2.9 Surface finishing
of sections
Oberflächenveredlung
von Profilen
3.1 Casting equipment
Gießanlagen
3.2 Rolling bar machining
Walzbarrenbearbeitung
3.3 Rolling bar furnaces
Walzbarrenvorbereitung
3.4 Hot rolling equipment
Warmwalzanlagen
3.5 Strip casting units
and accessories
Bandgießanlagen
und Zubehör
3.6 Cold rolling equipment
Kaltwalzanlagen
3.7 Thin strip / foil rolling plant
Feinband-/Folienwalzwerke
3.8 Auxiliary equipment
Nebeneinrichtungen
3.9 Adjustment devices
Adjustageeinrichtungen
3.10 Process technology /
Automation technology
Prozesstechnik /
Automatisierungstechnik
3.11 Coolant / lubricant preparation
Kühl-/Schmiermittel-Aufbereitung
3.12 Air extraction systems
Abluftsysteme
3.13 Fire extinguishing units
Feuerlöschanlagen
3.14 Storage and dispatch
Lagerung und Versand
3.15 Second-hand rolling equipment
Gebrauchtanlagen
3.16 Coil storage systems
Coil storage systems
3.17 Strip Processing Lines
Bandprozesslinien
3.18 Productions Management Sytems
Produktions Management Systeme
3.0 Rolling mill technology
Walzwerktechnik
Siemens plc, Metals Technologies
see Cold rolling units / complete plants 3.6
• Strahlanlagen
www.alu-web.de
Sheffield Business Park, Europa Link
Sheffield S9 1XU
Phone: +44 1709 726500
Fax:+44 1142 611719
[email protected]
81
LIEFERVERZEICHNIS
 Melting and holding furnaces
Schmelz- und Warmhalteöfen
Bartz GmbH
SMS Siemag Aktiengesellschaft
Eduard-Schloemann-Straße 4
40237 Düsseldorf, Germany
Telefon: +49 (0) 211 881-0
Telefax: +49 (0) 211 881-4902
Internet: www.sms-siemag.com
Geschäftsbereiche:
Warmflach- und Kaltwalzwerke
Wiesenstraße 30
57271 Hilchenbach-Dahlbruch, Germany
Telefon: +49 (0) 2733 29-0
Telefax: +49 (0) 2733 29-2852
Bandanlagen
Walder Straße 51-53
40724 Hilden, Germany
Telefon: +49 (0) 211 881-5100
Telefax: +49 (0) 211 881-5200
Elektrik + Automation
Ivo-Beucker-Straße 43
Telefon: +49 (0) 211 881-5895
Telefax: +49 (0) 211 881-775895
Graf-Recke-Straße 82
Telefon: +49 (0) 211 881-0
Telefax: +49 (0) 211 881-4902
Ein Eintrag (s/w) in
diesem Format kostet
pro Ausgabe + Stichwort
110,00 € + MwSt.
Weitere Informationen unter
Tel. +49 (0) 821 / 31 98 80 - 34
 Annealing furnaces
Glühöfen
Gautschi Engineering GmbH
Konstanzer Straße 37
CH 8274 Tägerwilen
Telefon +41 71 666 66 66
Telefax +41 71 666 66 77
Internet: www.gautschi.cc
Kontakt: Sales Departement
EBNER Industrieofenbau Ges.m.b.H.
Ebner-Platz 1, 4060 Leonding/Austria
Tel. +43 / 732 / 6868-0
Internet: www.ebner.cc
Gautschi
Engineering GmbH
schwartz GmbH
LOI Thermprocess GmbH
Am Lichtbogen 29
D-45141 Essen
Germany
Telefon +49 (0) 201 / 18 91-1
Telefax +49 (0) 201 / 18 91-321
Internet: www.loi-italimpianti.com
Solios Thermal UK
www.fivesgroup.com
 Melt purification units
Schmelzereinigungsanlagen
Gautschi
Engineering GmbH
Solios Thermal UK
www.fivesgroup.com
www.alu-web.de
 Bar heating furnaces
Barrenanwärmanlagen
EBNER Industrieofenbau Ges.m.b.H.
see Annealing furnaces 3.3
Gautschi
Engineering GmbH
 Metal filters / Metallfilter
3.1 Casting equipment
Gießanlagen
www.mechatherm.com
 Electromagnetic Stirrer
Elektromagnetische Rührer
Solios Thermal UK
www.fivesgroup.com
 Filling level indicators and controls
Füllstandsanzeiger und -regler
Gautschi
Engineering GmbH
Gautschi
Engineering GmbH
3.2 Rolling bar machining
82
Gautschi
Engineering GmbH
 Plate saw
Plattensägen
Sermas Industrie
[email protected]
 Slab saw
schwartz GmbH
Sermas Industrie
[email protected]
Solios Thermal UK
www.fivesgroup.com
Barrensägen
Walzbarrenvorbereitung
see Casting machines 1.6
Homogenisieröfen
Walzenbarrenbearbeitung
3.3 Rolling bar furnaces
Wagstaff, Inc.
 Homogenising furnaces
see Heat Treatment 2.4
 Roller tracks
Rollengänge
Gautschi
Engineering GmbH
SUPPLIERS DIRECTORY
3.4 Hot rolling equipment
Warmwalzanlagen
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
 Rolling mill modernisation
Walzwerksmodernisierung
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
3.6 Cold rolling equipment
Kaltwalzanlagen
ANDRITZ Sundwig GmbH
www.siemens.vai.com
 Coil transport systems
www.siemens.vai.com
SMS Siemag AG
Stephanopeler Str. 22, D-58675 Hemer
Telefon: +49 (0) 2372 54-0, Fax -200
Internet: www.andritz.com
see Heat Treatment 2.4
Bundtransportsysteme
www.ctisystems.com
SMS LOGISTIKSYSTEME GMBH
Obere Industriestraße 8
D-57250 Netphen
Telefon: +49 2738 21-0
Telefax: +49 2738 21-1002
www.sms-logistiksysteme.com
Could not find your
„keywords“?
 Spools / Haspel
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
schwartz GmbH
www.alu-web.de
MINO S.p.A.
Telefon: +39 0131 363636
Telefax: +39 0131 361611
Hier könnte Ihr
Gautschi
Engineering GmbH
Bundglühöfen
Warmwalzanlagen/Komplettanlagen
SMS Siemag AG
 Coil annealing furnaces
SMS Siemag AG
 Hot rolling units /
complete plants
 Drive systems / Antriebe
www.siemens.vai.com
 Coil transport systems
Bundtransportsysteme
www.ctisystems.com
www.siemens.vai.com
SMS Siemag AG
 Surface finishing
of sheets and coils
Rechbergstraße 46
Tel. +49 711 93467-0, Fax +49 711 34609-11
Oberflächenveredeling
von Blechen und Coils
see Process techn./Automation Techn. 3.10
83
LIEFERVERZEICHNIS
 Rolling mill modernization
Walzwerkmodernisierung
Feinband-/Folienwalzwerke
 Cold rolling units /
complete plants
Kaltwalzanlagen/Komplettanlagen
3.7 Thin strip /
foil rolling plant
MINO S.p.A.
Telefon: +39 0131 363636
Telefax: +39 0131 361611
MINO S.p.A.
Telefon: +39 0131 363636
Telefax: +39 0131 361611
 Coil annealing furnaces
Bundglühöfen
 Slitting lines-CTL
Längs- und Querteilanlagen
www.siemens.vai.com
www.siemens.vai.com
Gautschi
Engineering GmbH
SMS Siemag AG
Could not find your
 Drive systems / Antriebe
„keywords“?
SMS Siemag AG
 Heating furnaces / Anwärmöfen
Gautschi
Engineering GmbH
 Process optimisation systems
Prozessoptimierungssysteme
Gautschi
Engineering GmbH
 Process simulation
Prozesssimulation
Gautschi
Engineering GmbH
SMS Siemag AG
 Strip shears/Bandscheren
Walzenwechseleinrichtungen
SMS Siemag AG
84
schwartz GmbH
see Cold colling equipment 3.6
 Heating furnaces
Anwärmöfen
Gautschi
Engineering GmbH
SMS Siemag AG
of sheets and coils
see Process techn./Automation Techn. 3.10
 Trimming equipment
Besäumeinrichtungen
 Roll exchange equipment
SMS Siemag AG
schwartz GmbH
 Thin strip / foil rolling mills /
complete plant
Feinband- / Folienwalzwerke /
Komplettanlagen
MINO S.p.A.
Telefon: +39 0131 363636
Telefax: +39 0131 361611
SUPPLIERS DIRECTORY
SMS Siemag AG
of sheets and coils
Hier könnte Ihr
Bezugsquellen-Eintrag stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
 Rolling mill modernization
Walzwerkmodernisierung
MINO S.p.A.
Telefon: +39 0131 363636
Telefax: +39 0131 361611
3.10 Process technology /
Automation technology
Prozesstechnik /
Automatisierungstechnik
 Process control technology
Prozessleittechnik
SMS Siemag AG
SMS Siemag AG
 Strip thickness measurement
and control equipment
 Strip flatness measurement
and control equipment
Bandplanheitsmess- und
-regeleinrichtungen
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
Internet: www.abb.com/pressductor
Wide Belt Processing Systems
SDV-Santioli AG
Industriestrasse 10 | CH-8157 Dielsdorf | Switzerland
Tel. +41 44 854 0908 | [email protected] | www.demis.ch
 Roll Force Measurement equipment
Walzkraftmesseinrichtungen
Banddickenmess- und
-regeleinrichtungen
ABB Automation
Force Measurement
Phone: +46 21 325 000
Fax: +46 21 340 005
ABB Automation
Force Measurement
Phone: +46 21 325 000
Fax: +46 21 340 005
 Strip Width & Position
Measurement equipment
Bandbreiten- und
Bandlaufmesseinrichtungen
SMS Siemag AG
 Strip Tension
Measurement equipment
Bandzugmesseinrichtungen
ABB Automation
Force Measurement
Phone: +46 21 325 000
Fax: +46 21 340 005
3.11 Coolant / lubricant
preparation
Kühl-/SchmiermittelAufbereitung
Wagstaff, Inc.
ABB Automation
Force Measurement
Phone: +46 21 325 000
Fax: +46 21 340 005
 Rolling oil recovery and
treatment units
Walzöl-Wiederaufbereitungsanlagen
SMS Siemag AG
 Filter for rolling oils and emulsions
Filter für Walzöle und Emulsionen
110,00 € + MwSt.
Tel. +49 (0) 821 / 31 98 80 - 34
85
LIEFERVERZEICHNIS
3.16 Coil storage systems
 Coil & Colour Coating Lines
www.ctisystems.com
Bronx International Pty Ltd
Email: [email protected]
Internet: www.bronxintl.com
SMS Siemag AG
Rechbergstraße 46
Tel. +49 711 93467-0, Fax +49 711 34609-11
 Rolling oil rectification units
Walzölrektifikationsanlagen
Bundlagersysteme
„keywords“?
our complete
www.bwg-online.com
see Strip Processing Lines 3.17
SMS Siemag AG
Could not find your
Please ask for
Bandlackierlinien
 Lithographic Sheet Lines
SMS Siemag AG
Lithografielinien
www.bwg-online.com
E-Mail:
[email protected]
3.17 Strip Processing Lines
Streckrichtanlagen
Bandprozesslinien
www.bwg-online.com
3.12 Air extraction systems
Abluft-Systeme
 Stretch Levelling Lines
see Cold rolling equipment 3.6
 Strip Annealing Lines
Bandglühlinien
 Exhaust air purification
systems (active)
Abluft-Reinigungssysteme (aktiv)
SMS Siemag AG
BWG Bergwerk- und WalzwerkMaschinenbau GmbH
Mercatorstraße 74 – 78
D-47051 Duisburg
Tel.: +49 (0) 203-9929-0
Fax: +49 (0) 203-9929-400
Internet: www.bwg-online.com
REDEX
Zone Industrielle
F-45210 Ferrieres
Telefon +33 (2) 38 94 42 00
Internet: www.tension-leveling.com
3.14 Storage and dispatch
Lagerung und Versand
SMS Siemag AG
86
www.alu-web.de
www.bwg-online.com
SMS Siemag AG
3.18 Production
Management systems
Produktions Management
Systeme
PSI Metals Non Ferrous GmbH
Software Excellence in Metals
Carlo-Schmid-Str. 12, D-52146 Würselen
Tel.: +49 (0) 2405 4135-0
[email protected], www.psimetals.com
 Anodizing Lines
Anodisier-Linien
SMS Siemag AG
SUPPLIERS DIRECTORY
4
Foundry
Gießerei
4.1 Work protection and ergonomics
Arbeitsschutz und Ergonomie
4.2 Heat-resistant technology
Feuerfesttechnik
4.3 Conveyor and storage technology
Förder- und Lagertechnik
4.4 Mould and core production
Form- und Kernherstellung
4.5 Mould accessories and accessory
materials
Formzubehör, Hilfsmittel
4.2 Heat-resistent technology
Feuerfesttechnik
 Refractories / Feuerfeststoffe
4.6 Foundry equipment
Gießereianlagen
4.7 Casting machines and equipment
Gießmaschinen
und Gießeinrichtungen
4.8 Handling technology
Handhabungstechnik
4.9 Construction and design
Konstruktion und Design
4.10 Measurement technology
and materials testing
Messtechnik und Materialprüfung
4.11 Metallic charge materials
Metallische Einsatzstoffe
4.12 Finishing of raw castings
Rohgussnachbehandlung
4.13 Melt operations
Schmelzbetrieb
4.14 Melt preparation
Schmelzvorbereitung
4.15 Melt treatment devices
Schmelzebehandlungseinrichtungen
4.16 Control and regulation technology
Steuerungs- und
Regelungstechnik
4.17 Environment protection
and disposal
Umweltschutz und Entsorgung
4.18 Dross recovery
Schlackenrückgewinnung
4.19 Cast parts
Gussteile
Promat GmbH High Performance Insulation
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
[email protected], www.promat.de
Rechbergstraße 46
Tel. +49 711 93467-0, Fax +49 711 34609-11
4.5 Mold accessories and
accessory materials
Formzubehör, Hilfmittel
 Fluxes
Flussmittel
Solvay Fluor GmbH
Hans-Böckler-Allee 20
D-30173 Hannover
Telefon +49 (0) 511 / 857-0
Telefax +49 (0) 511 / 857-2146
Internet: www.solvay-fluor.de
4.6 Foundry equipment
Gießereianlagen
HENCON MOBILE EQUIPMENT
see section Casthouse 1.5
www.mechatherm.com
 Casting machines
Gießmaschinen
Refratechnik Steel GmbH
Via Brallo, 2 – 27010 Siziano (PV), Italy
Tel: +39 0382 6671413
Internet: www.erediscabini.com
Schiessstrasse 58
40549 Düsseldorf / Germany
Phone +49 211 5858 0
Fax +49 211 5858 46
Internet: www.refra.com
www.alu-web.de
Tel: +34 944 409 420
4.3 Conveyor and storage
technology
Förder- und Lagertechnik
Wärmebehandlungsöfen
Paul Hedfeld GmbH
www.alu-web.de
Hundeicker Str. 20
D-58285 Gevelsberg
Phone: +49 (0) 2332 6371
Internet: www.hedfeld.com
87
LIEFERVERZEICHNIS
and equipment
Gießereimaschinen
und Gießeinrichtungen
GAPCast TM: the Swiss casting solution
Casting Technology / Automation
Tel.: +41 27 455 57 14
Internet: www.gap-engineering.ch
www.mechatherm.com
 Mould parting agents
Kokillentrennmittel
Schröder KG
Schmierstofftechnik
Postfach 1170
D-57251
Freudenberg
Tel. 02734/7071
Fax 02734/20784
Ostra Hamnen 7
SE-475 42 Hono / Sweden
Tel.: +46 31 764 5520, Fax: +46 31 764 5529
Internet: www.precimeter.com
Sales contact: Jonatan Lindstrand
Tel. +49 (0) 821 / 31 98 80 - 34
4.10 Measurement technology
and materials testin
Messtechnik und
Materialprüfung
Competence in EMC and ASC casting
RIHS ENGINEERING SA
Tel.: +41 27 455 54 41
Internet: www.maschko.ch
Wagstaff, Inc.
 Burner System
Brennertechnik
www.schroeder-schmierstoffe.de
110,00 € + MwSt.
Precimeter Control AB
see Extrusion 2.4.
ratioTEC Prüfsysteme GmbH
In der Au 17
D-88515 Langenenslingen
Tel.: +49 (0)7376/9622-0
Fax: +49 (0)7376/9622-22
Internet: www.ratiotec.com
Büttgenbachstraße 14
D-40549 Düsseldorf/Germany
Tel.: +49 (0) 211 / 5 00 91-0
Fax: +49 (0) 211 / 5 00 91-14
Internet: www.bloomeng.de
Wärmebehandlungsanlagen
Gautschi
Engineering GmbH
 Holding furnaces
Hier könnte Ihr
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
 Continuous ingot casting
lines and aluminium rod lines
Kokillengieß- und Aluminiumdraht-Anlagen
www.alu-web.de
4.11 Metallic charge
materials
Metallische Einsatzstoffe
Warmhalteöfen
Bartz GmbH
Gautschi
Engineering GmbH
 Recycling / Recycling
Chr. Otto Pape GmbH
Aluminiumgranulate
Berliner Allee 34
D-30855 Langenhagen
Tel:+49(0)511 786 32-0 Fax: -32
Internet: www.papemetals.com
4.13 Melt operations
Schmelzbetrieb
Could not find your
„keywords“?
Via Emilia Km 310
26858 Sordio-LO
Italy
Tel. +39.02.988492-1 . [email protected]
Fax +39.02.9810358 . www.properzi.com
88
 Melting furnaces
Schmelzöfen
www.mechatherm.com
Bartz GmbH
SUPPLIERS DIRECTORY
Gautschi
Engineering GmbH
5
Werkstoffe
und Recycling
MARX GmbH & Co. KG
Lilienthalstr. 6-18
D-58638 Iserhohn
Tel.: +49 (0) 2371 / 2105-0, Fax: -11
Internet: www.marx-gmbh.de
4.14 Melt preparation
Schmelzvorbereitung
 Degassing, filtration
Entgasung, Filtration
GmbH
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: http://www.drache-gmbh.de
4.15 Melt treatment devices
Schmelzbehandlungseinrichtungen
Metaullics Systems Europe B.V.
Ebweg 14
NL-2991 LT Barendrecht
Tel. +31-180/590890
Fax +31-180/551040
Internet: www.metaullics.com
Materials
and
Recycling
 Granulated aluminium
Aluminiumgranulate
Chr. Otto Pape GmbH
Aluminiumgranulate
Berliner Allee 34
D-30855 Langenhagen
Tel:+49(0)511 786 32-0 Fax: -32
Internet: www.papemetals.com
6
 Dust removal
Entstaubung
NEOTECHNIK GmbH
Entstaubungsanlagen
Postfach 110261, D-33662 Bielefeld
Tel. 05205/7503-0, Fax 05205/7503-77
[email protected], www.neotechnik.com
Ausrüstung für Schmiedeund Fließpresstechnik
 Hydraulic Presses
Hydraulische Pressen
LASCO Umformtechnik GmbH
Hahnweg 139, D-96450 Coburg
Tel. +49 (0) 9561 642-0
Fax +49 (0) 9561 642-333
Internet: www.lasco.com
Machining +
Application
Bearbeitung +
Anwendung
6.1 Equipment to produce
castplate
Ausrüstungen für
Gussplattenproduktion
 Slicing saw & Milling machines
Folienschneidmaschinen
Fräsmaschinen
Sermas Industrie
[email protected]
6.2 Semi products
8 Literature
Literatur
 Technical literature
Fachliteratur
Taschenbuch des Metallhandels
Fundamentals of Extrusion Technology
Giesel Verlag GmbH
Hans-Böckler-Allee 9, 30173 Hannover
Tel. 0511 / 73 04-125 · Fax 0511 / 73 04-233
Internet: www.alu-bookshop.de
 Technical journals
Fachzeitschriften
Halbzeuge
 Wires / Drähte
DRAHTWERK ELISENTAL
W. Erdmann GmbH & Co.
Werdohler Str. 40, D-58809 Neuenrade
Postfach 12 60, D-58804 Neuenrade
Tel. +49(0)2392/697-0, Fax 49(0)2392/62044
Internet: www.elisental.de
4.17 Environment protection
and disposal
Umweltschutz und
Entsorgung
6.3 Equipment for forging
and impact extrusion
Giesel Verlag GmbH
Tel. 0511/8550-2638 · Fax 0511/8550-2405
110,00 € + MwSt.
Tel. +49 (0) 821 / 31 98 80 - 34
GDMB-Informationsgesellschaft mbH
Paul-Ernst-Str.10, 38678 Clausthal-Zellerfeld
Telefon 05323-937 20, Fax -237, www.gdmb.de
89
VORSCHAU / PREVIEW
IM NÄCHSTEN HEFT
IN THE NEXT ISSUE
Special: Die Aluminiumindustrie am Golf
Special: The aluminium industry in the Gulf
Vom 5. bis 7. November 2013 findet in Abu Dhabi die
Arabal Conference statt, die vom Hüttenproduzenten
Emirates Aluminium ausgerichtet wird. Als Mediapartner
der Veranstaltung berichten wir in unserem Special über
aktuelle Entwicklungen am Golf. Beiträge unter anderem:
The Arabal Conference 2013, hosted by Emirates Aluminium, will be taking place from 5-7 November in Abu
Dhabi. As a media partner of the event ALUMINIUM will
be reporting on recent developments in the Gulf region.
Topics include:
• Interview mit Saeed Fadhel Al Mazrooei, CEO von Emal
• Interview with Emal CEO Saeed Fadhel Al Mazrooei
• Modernste Walzwerkstechnologie für die Golfregion
• Best rolling mill technology for the Gulf region
• Das Aluminiumcluster in Kizad nimmt Gestalt an
• Kizad aluminium cluster is taking shape
• EPCM-Projekte in der Aluminiumindustrie
• EPCM – a vital activity in the world of aluminium
Weitere Themen
Other topics
• Belte AG – Spezialist in der Wärmebehandlung
von Aluminiumbauteilen
• Innovative Lösungen für das Strahlen von Gussteilen
• Aluminium S.A. steigert Produktion, senkt Kosten
• Belte AG – specialist in the heat treatment of
aluminium components
• Aluminium S.A. increases production, reduces costs
• Innovative shot blasting solutions for foundries
Erscheinungstermin: 02. September 2013
Anzeigenschluss:
16. August 2013
Redaktionsschluss:
09. August 2013
International
ALUMINIUM
89. Jahrgang 1. 1. 2013
Journal
Verlag / Publishing house
Giesel Verlag GmbH
Postfach 5420, 30054 Hannover
Tel. +49(0)511 7304-0, Fax +49(0)511 7304-157
[email protected], www.giesel-verlag.de
Postbank / postal cheque account Hannover, BLZ / routing
code: 25010030; Kto.-Nr. / account no. 90898-306,
Bankkonto/bank account Commerzbank AG, BLZ/routing
code: 25040066, Kto.-Nr./account no. 1500222
Geschäftsleitung / Managing Director
Klaus Krause
Redaktion / Editorial office
Dipl.-Vw. Volker Karow
Chefredakteur, Editor in Chief
Franz-Meyers-Str. 16, 53340 Meckenheim
Tel. +49(0)2225 8359643, Fax +49(0)2225 18458
[email protected]
Dipl.-Ing. Rudolf P. Pawlek
Hüttenindustrie und Recycling
[email protected]
Dipl.-Ing. Bernhard Rieth
Walzwerkstechnik und Bandverarbeitung
[email protected]
Ken Stanford, Contributing Editor
[email protected]
Objektleitung / General Manager
Material Publication
Dennis Roß
Tel. +49(0)821 319880-34, [email protected]
Anzeigenpreise / Advertisement rates
Preisliste Nr. 53 vom 1. Oktober 2012
Price list No. 53 from 1 Oct. 2012
Druckunterlagen / Print documents
[email protected]
Tel. +49(0)511 8550-2625, Fax +49(0)511 8550-2401
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Date of publication:
Advertisement deadline:
Editorial deadline:
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[email protected]
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16 August 2013
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ALUMINIUM
ALUMINIUM
· 7-8/2013
· 5/2012
use of Earth’s natural resources
We offer leading technology solutions and services for the processing of bauxite to
alumina and further to aluminium products based on extensive R&D and proprietary
equipment. Contact us for more information on our extensive reference list of green
anode plants, anode rodshops, carbon recycling, and hot bath treatment plants.
www.outotec.com
Simply closer to
your products.
Your technology partner in the aluminum industry
How do we meet the growing demands of our customers
in the aluminum industry worldwide? By supplying allinclusive mechatronic solutions. Whatever you want to
manufacture from this material, or what product quality you
aim to achieve – at SMS Siemag we know what it takes.
That’s because we listen!
And because we draw on our holistic process know-how
and experience. Our plants – whether new facilities, conversions or revamps – always ensure that our solutions encompass the latest developments in aluminum production and
processing.
Always closer to you – SMS Siemag.
SMS SIEMAG AG
Eduard-Schloemann-Strasse 4
Phone: +49 211 881-0
Fax:
+49 211 881-4902
Internet: www.sms-siemag.com

SMS Siemag AG - ALU

Transcrição

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