SMS Siemag AG - ALU
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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. There are many benefits in one-stop shopping of industrial goods. At Hertwich Engineering we provide customer oriented service throughout the project duration and service life of equipment. We design and build plants to meet both, our own stringent standards and individual customers specifications. Based on many years of experience, we cover the full range of equipment in a modern aluminum casthouse. Major benefits Hertwich Engineering is well-known for leading edge technology. Our valued customers deserve to get the best value for money. Commitment to innovation, solid engineering and own R&D are instrumental for staying ahead with continuous improvements and new products. Billet sawing and packing plants Q Complete lines including all auxiliary equipment from one supplier Q Fully automated billet conveying, ultrasonic testing, cutting with scrap removal, pin marking, stacking, strapping, swarf briquetting Q Various configurations and options in order to streamline the plant to the client’s requirements Q Billet diameter range from 125 to 700 mm Billet (slug) lengths from 100 to 8,000 mm Q Sophisticated control system with intuitive user interface, automatic restarting program, error detection and detailed diagnosis Q More than 100 plants installed HERTWICH ENGINEERING GMBH Weinbergerstrasse 6 5280 Braunau, Austria Phone: +43 7722 806-0 Fax: +43 7722 806-122 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 ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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. ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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. ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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 E-mail: [email protected] 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. ■ ALUMINIUM · 7-8/2013 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. ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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) ALUMINIUM · 7-8/2013 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. ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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. ALUMINIUM · 7-8/2013 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. Join together. INTERNATIONAL TRADE FAIR JOINING CUTTING SURFACING 16–21 SEPT. 2013 ESSEN GERMANY Meet over 1,000 exhibitors and experts from all over the world. Discover innovative solutions in joining, cutting and surfacing. Take advantage of the opportunities in the industry’s hot spot. Join your industry in Essen! MESSE ESSEN GmbH Tel. +49(0)201-72 44-800 [email protected] www.schweissen-schneiden.com ■ 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 ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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 Test it now! YES, regular I would like to receive information on the latest trends and technologies! Please send me a sample copy at no obligation. I wish to subscribe to INTERNATIONAL ALUMINIUM JOURNAL The subscription price is EUR 297.00 a year incl. p&p and VAT (Outside Europe: US$ 393.00). INTERNATIONAL ALUMINIUM JOURNAL is published monthly with double editions in January/February and in July/August. Subscriptions are initially valid for a year. Company Name, first name Street, No. Postcode, town Tel. Fax Email Q The subscription price is to be paid by credit card: Q VISA Q American Express Q Euro-/Mastercard Number Cardholder Valid until Q The price is to be debited from our account (only possible within Germany) Bank Bank code Account no Q The price will be remitted on receipt of the invoice Date Signature Pernelle Nunez, consultant, CRU Strategies Subscription service [email protected] Fax +49 (0)511 7304-233 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 ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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 · 7-8/2013 © 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 Mehr Flexibilität. Beim Sägen und Lagern von Metall sind wir Technologieführer. Als kompetenter Partner schaffen wir Mehrwerte, die sich sehen lassen können. www.kasto.de Effizientes Arbeiten, wie Gehrungsschnitte in der Metallverarbeitung, verlangt Maschinen, die vielseitig einsetzbar sind. So wie Kreis- und Bandsägen von KASTO. Sie sind die universellen Partner für Werkstattbetriebe. Für mehr Flexibilität in jedem Unternehmen. Sägen. Lager. Mehr. 29 A L U M I N I U M S M E LT I N G I N D U S T R Y 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. ALUMINIUM · 7-8/2013 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. Integrated Technology Firing and Fume Treatment for Anode Baking Furnaces ProBake Advanced Firing Systems Lowest energy consumption Total pitch burn Higher quality consistency innovatherm 06/2013 ProClean Fume Treatment Technology Higher adsorbtion ratios Lower emissions Higher reliability Your Sustainable Partner [email protected] www.innovatherm.de 216 x 303 One Design · One Technology · One Company A L U M I N I U M S M E LT I N G I N D U S T R Y 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- ALUMINIUM · 7-8/2013 G 5 a Keeping your production running day and night? Certainly. ABB’s history of powering primary aluminium plants started 45 years ago. Since then, we have supplied complete electrification solutions and substations to more than 60 aluminium smelters worldwide. The modernization of an existing plant to the latest standards and production and efficiency levels – performed while it is still in operation – requires a different set of skills and competencies than building a greenfield plant. ABB has in-depth knowledge of the aluminium production process and the experience necessary to execute complex projects – always with the objective to keep your production running day and night. For more information, visit us at www.abb.com/aluminium Global Product Group Aluminium 5405 Baden 5 Dättwil, Switzerland [email protected] A L U M I N I U M S M E LT I N G I N D U S T R Y 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 ALUMINIUM · 7-8/2013 A L U M I N I U M S M E LT I N G I N D U S T R Y 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 Higher performance with MÖLLER Alumina handling systems Through MÖLLER® technology, FLSmidth® specializes in design, engineering, procurement, erection and commissioning of pneumatic material handling systems for turnkey projects and components for the Alumina Industry. For more than 75 years the MÖLLER brand has stood for high quality standard systems with more than 5.000 references worldwide. MÖLLER Alumina handling systems - High performance, high efficiency. FLSmidth Hamburg GmbH Haderslebener Str. 7 s25421 Pinneberg, Germany Tel: +49 4101 788-0 s hamburg@flsmidth.com www.flsmidth.com © DUBAL © Aluminij Mostar SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y 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 ALUMINIUM · 7-8/2013 ! ! w t s m SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y 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 ALUMINIUMHÜTTENINDUSTRIE „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 ALUMINIUM · 7-8/2013 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 A L U M I N I U M S M E LT I N G I N D U S T R Y 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 A L U M I N I U M S M E LT I N G I N D U S T R Y 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 ALUMINIUM · 7-8/2013 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 A L U M I N I U M S M E LT I N G I N D U S T R Y 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 A L U M I N I U M S M E LT I N G I N D U S T R Y 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 ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 A L U M I N I U M S M E LT I N G I N D U S T R Y 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 ALUMINIUMHÜTTENINDUSTRIE 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 ALUMINIUM · 7-8/2013 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. ALUMINIUM · 7-8/2013 A L U M I N I U M S M E LT I N G I N D U S T R Y 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 ALUMINIUMHÜTTENINDUSTRIE 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. ALUMINIUM · 7-8/2013 SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y 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. ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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- ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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- ALUMINIUM · 7-8/2013 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- ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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- ALUMINIUM · 7-8/2013 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 differ- ed 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. ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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- ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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. ➝ ALUMINIUM · 7-8/2013 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. ALUMINIUM · 7-8/2013 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 ALUMINIUM · 7-8/2013 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- ALUMINIUM · 7-8/2013 CO M PA N Y N E W S W O R L D W I D E 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- ALUMINIUM · 7-8/2013 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 CO M PA N Y N E W S W O R L D W I D E 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 ALUMINIUM · 7-8/2013 CO M PA N Y N E W S W O R L D W I D E 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. ALUMINIUM · 7-8/2013 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 CO M PA N Y N E W S W O R L D W I D E 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- ALUMINIUM · 7-8/2013 CO M PA N Y N E W S W O R L D W I D E © 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. ALUMINIUM · 7-8/2013 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. ALUMINIUM · 7-8/2013 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) ALUMINIUM · 7-8/2013 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) ALUMINIUM · 7-8/2013 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) ALUMINIUM · 7-8/2013 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 E-Mail: [email protected] 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 E-Mail: [email protected] Internet: www.flsmidthmoeller.com Kontakt: Herr Dipl.-Ing. Timo Letz Paul Hedfeld GmbH Hundeicker Str. 20 D-58285 Gevelsberg Phone: +49 (0) 2332 6371 E-mail: [email protected] Internet: www.hedfeld.com Unloading/Loading equipment Entlade-/Beladeeinrichtungen FLSmidth MÖLLER GmbH 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) FLSmidth MÖLLER GmbH Internet: www.flsmidthmoeller.com see Storage facilities for smelting 1.2 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 ALUMINIUM · 7-8/2013 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 E-Mail: [email protected] 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 E-Mail: [email protected] 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 see Casting equipment 3.1 Dross skimming of liquid metal Transfer to the casting furnace GLAMA Maschinenbau GmbH see Anode rodding 1.4 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 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 E-Mail: [email protected] Internet: www.sistemteknik.com Furnace charging with molten metal Ofenbeschickung mit Flüssigmetall Überführung in Gießofen GLAMA Maschinenbau GmbH see Anode rodding 1.4 Gautschi Engineering GmbH see Casting equipment 3.1 Ingot Casting Line GLAMA Maschinenbau GmbH see Anode rodding 1.4 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 E-Mail: [email protected] Internet: www.hertwich.com INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH Konstantinstraße 1a D 41238 Mönchengladbach Telefon +49 (02166) 987990 Telefax +49 (02166) 987996 E-Mail: [email protected] 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 Casting equipment 3.1 HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 see Casthous (foundry) 1.5 GLAMA Maschinenbau GmbH see Anode rodding 1.4 Treatment of casthouse off gases Behandlung der Gießereiabgase Gautschi Engineering GmbH see Casting equipment 3.1 1.6 Casting machines 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 E-Mail: [email protected] www.mechatherm.com ALUMINIUM · 7-8/2013 INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A Avenida Cervantes Nº6 48970 – Basauri – Bizkaia – Spain Tel: +34 944 409 420 E-mail: [email protected] 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 see Casthous (foundry) 1.5 [email protected] Heat treatment of extrusion ingot (homogenisation) Formatebehandlung (homogenisieren) Gautschi Engineering GmbH see Casting equipment 3.1 Gautschi Engineering GmbH see Casting equipment 3.1 Rolling and extrusion ingot and T-bars Formatgießerei (Walzbarren oder Pressbolzen oder T-Barren) Gautschi Engineering GmbH see Casting equipment 3.1 HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 Horizontal continuous casting Horizontales Stranggießen Gautschi Engineering GmbH see Casting equipment 3.1 HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 see Casthouse (foundry) 1.5 see Casthouse (foundry) 1.5 Sawing / Sägen Gautschi Engineering GmbH see Casting equipment 3.1 78 Anoden Transporteinrichtungen GLAMA Maschinenbau GmbH see Anode rodding 1.4 Wagstaff, Inc. 3910 N. Flora Rd. Spokane, WA 99216 USA +1 509 922 1404 phone +1 509 924 0241 fax E-Mail: [email protected] 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 GLAMA Maschinenbau GmbH see Anode rodding 1.4 Dry absorption units for electrolysis exhaust gases Trockenabsorptionsanlage für Elektrolyseofenabgase Solios Environnement www.fivesgroup.com Pot ramming Machine www.brochot.fr Tapping vehicles/Schöpffahrzeuge GLAMA Maschinenbau GmbH see Anode rodding 1.4 Abgasbehandlung Solios Environnement www.fivesgroup.com Beschickungseinrichtungen für Elektrolysezellen see Casthouse (foundry) 1.5 Anodenwechselmaschine Anode transport equipment Pot feeding systems HERTWICH ENGINEERING GmbH Anode changing machine Gautschi Engineering GmbH see Casting equipment 3.1 Calciumsilikatplatten HERTWICH ENGINEERING GmbH 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 E-Mail: [email protected] Contact: Giovanni Magarotto GLAMA Maschinenbau GmbH see Anode rodding 1.4 Scales / Waagen Gautschi Engineering GmbH see Casting equipment 3.1 Phone: +31.315.683941 [email protected] · www.hencon.com Vertical semi-continuous DC casting / Vertikales Stranggießen Elektrolyseofen HERTWICH ENGINEERING GmbH MOBILE EQUIPMENT FLSmidth MÖLLER GmbH www.flsmidthmoeller.com see Storage facilities for smelting 1.2 1.12 Cathode repair shop KathodenreparaturWerkstatt Cathode Sealing Bench Eingießen von Kathodenbarren Sermas Industrie [email protected] see Smelting technology 1.6 ALUMINIUM · 7-8/2013 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 E-Mail: [email protected] 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 E-Mail: [email protected] Internet: www.extrutec-gmbh.de mfw-maschinenbau.com • Log/Bolzenlager Handling • Bolzensäge, Bolzenfügen ALUMINIUM · 7-8/2013 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 E-Mail: [email protected] 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 see Smelting technology 1.5 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 see Casthouse (foundry) 1.5 Could not find your „keywords“? Please ask for our complete „Supply sources for the aluminium industry“. E-Mail: [email protected] 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 E-Mail: [email protected] 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 see Coil transport systems 3.4 mfw-maschinenbau.com • Automatik Verpackung • Packtische, Profilpaketheber • Spacerhandling und Konzepte see Coil transport systems 3.4 see Section handling 2.3 Section saws Profilsägen mfw-maschinenbau.com • Kurzlängensäge automatisiert Nijverheidsweg 3 NL-7071 CH Ulft Netherlands Tel.: +31 315 641352 Fax: +31 315 641852 E-Mail: [email protected] Internet: www.unifour.nl Sales Contact: Paul Overmans Hier könnte Ihr Bezugsquellen-Eintrag 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 INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A Avenida Cervantes Nº6 48970 – Basauri – Bizkaia – Spain Tel: +34 944 409 420 E-mail: [email protected] Internet: www.insertec.biz see Equipment and accessories 3.1 Stackers / Destackers Stapler / Entstapler Section store equipment www.mechatherm.com see Smelting technology 1.5 Profil-Lagereinrichtungen www.ctisystems.com see Section handling 2.3 mfw-maschinenbau.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 see Coil transport systems 3.4 see Section handling 2.3 80 Transporteinrichtungen für Profilabschnitte www.ctisystems.com see Section handling 2.3 SECO/WARWICK EUROPE S.A. ul. Šwierczewskiego 76 66-200 Šwiebodzin, POLAND Tel: +48 68 38 19 800 E-mail: [email protected] Internet: www.secowarwick.com Could not find your „keywords“? Please ask for our complete „Supply sources for the aluminium industry“. E-Mail: [email protected] Heat treatment furnaces Wärmebehandlungsöfen INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH see Casthouse (foundry) 1.5 mfw-maschinenbau.com • Skip Handling, Spacer • Kettenförderer see Section handling 2.3 ERNST REINHARDT GMBH Güterbahnhofstrasse 1 D-78048 Villingen-Schwenningen Tel. +49 (0) 7721 8441-0, Fax -44 E-Mail: [email protected] Internet: www.ernst-reinhardt.com ALUMINIUM · 7-8/2013 SUPPLIERS DIRECTORY Homogenising furnaces Homogenisieröfen 2.10 Machining of sections Profilbearbeitung Billet saw see Heat treatment furnaces 2.4 Bolzensägen HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 Sermas Industrie [email protected] see Smelting technology 1.6 see Casthouse (foundry) 1.5 www.alu-web.de 2.11 Equipment and accessories Ausrüstungen und Hilfsmittel Nijverheidsweg 3 NL-7071 CH Ulft Netherlands Tel.: +31 315 641352 Fax: +31 315 641852 E-Mail: [email protected] Internet: www.unifour.nl Sales Contact: Paul Overmans Ageing furnace for extrusions see Casthouse (foundry) 1.5 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 NL-7071 CH Ulft Netherlands Tel.: +31 315 641352 Fax: +31 315 641852 E-Mail: [email protected] Internet: www.unifour.nl Sales Contact: Paul Overmans 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 Could not find your „keywords“? Please ask for our complete „Supply sources for the aluminium industry“. E-Mail: [email protected] 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 mfw-maschinenbau.com • Strahlanlagen ALUMINIUM · 7-8/2013 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 E-Mail: [email protected] 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 40237 Düsseldorf, Germany Telefon: +49 (0) 211 881-5895 Telefax: +49 (0) 211 881-775895 Graf-Recke-Straße 82 40239 Düsseldorf, Germany 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 see Casthous (foundry) 1.5 Gautschi Engineering GmbH Konstanzer Straße 37 CH 8274 Tägerwilen Telefon +41 71 666 66 66 Telefax +41 71 666 66 77 E-Mail: [email protected] Internet: www.gautschi.cc Kontakt: Sales Departement INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A see Heat treatment 2.4 EBNER Industrieofenbau Ges.m.b.H. Ebner-Platz 1, 4060 Leonding/Austria Tel. +43 / 732 / 6868-0 E-Mail: [email protected] Internet: www.ebner.cc Gautschi Engineering GmbH see Casting equipment 3.1 see Equipment and accessories 3.1 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 E-Mail: [email protected] Internet: www.loi-italimpianti.com Solios Thermal UK www.fivesgroup.com Melt purification units Schmelzereinigungsanlagen Gautschi Engineering GmbH see Casting equipment 3.1 see Heat treatment 2.4 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 see Casting equipment 3.1 Metal filters / Metallfilter 3.1 Casting equipment Gießanlagen www.mechatherm.com see Smelting technology 1.5 Electromagnetic Stirrer Elektromagnetische Rührer Solios Thermal UK www.fivesgroup.com Filling level indicators and controls Füllstandsanzeiger und -regler Gautschi Engineering GmbH see Casting equipment 3.1 Gautschi Engineering GmbH see Casting equipment 3.1 3.2 Rolling bar machining 82 Gautschi Engineering GmbH see Casting equipment 3.1 Plate saw Plattensägen Sermas Industrie [email protected] see Smelting technology 1.6 HERTWICH ENGINEERING GmbH Slab saw schwartz GmbH Sermas Industrie [email protected] see Smelting technology 1.6 Solios Thermal UK www.fivesgroup.com see Casthouse (foundry) 1.5 Barrensägen Walzbarrenvorbereitung see Casting machines 1.6 Homogenisieröfen Walzenbarrenbearbeitung 3.3 Rolling bar furnaces Wagstaff, Inc. Homogenising furnaces BSN Thermprozesstechnik GmbH see Heat Treatment 2.4 see Heat treatment 2.4 Roller tracks Rollengänge Gautschi Engineering GmbH see Casting equipment 3.1 ALUMINIUM · 7-8/2013 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 see Cold rolling units / complete plants 3.6 Rolling mill modernisation Walzwerksmodernisierung MINO S.p.A. Via Torino, 1 – San Michele 15122 ALESSANDRIA – ITALY Telefon: +39 0131 363636 Telefax: +39 0131 361611 E-Mail: [email protected] Internet: www.mino.it Sales contact: Mr. Luciano Ceccopieri 3.6 Cold rolling equipment Kaltwalzanlagen Achenbach Buschhütten GmbH & Co. KG Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de ANDRITZ Sundwig GmbH www.siemens.vai.com see Rolling mill technology 3.0 Coil transport systems www.siemens.vai.com see Rolling mill technology 3.0 SMS Siemag AG see Rolling mill technology 3.0 Stephanopeler Str. 22, D-58675 Hemer Telefon: +49 (0) 2372 54-0, Fax -200 E-mail: [email protected] Internet: www.andritz.com BSN Thermprozesstechnik GmbH see Heat Treatment 2.4 Bundtransportsysteme www.ctisystems.com see Section handling 2.3 SMS LOGISTIKSYSTEME GMBH Obere Industriestraße 8 D-57250 Netphen Telefon: +49 2738 21-0 Telefax: +49 2738 21-1002 E-Mail: [email protected] www.sms-logistiksysteme.com Could not find your „keywords“? Please ask for our complete „Supply sources for the aluminium industry“. E-Mail: [email protected] Spools / Haspel stehen. Rufen Sie an: Tel. 0821 / 31 98 80-34 Dennis Ross ALUMINIUM · 7-8/2013 schwartz GmbH see Heat treatment 2.4 www.alu-web.de MINO S.p.A. Via Torino, 1 – San Michele 15122 ALESSANDRIA – ITALY Telefon: +39 0131 363636 Telefax: +39 0131 361611 E-Mail: [email protected] Internet: www.mino.it Sales contact: Mr. Luciano Ceccopieri Hier könnte Ihr Bezugsquellen-Eintrag Gautschi Engineering GmbH see Casting equipment 3.1 see Equipment and accessories 3.1 see Section handling 2.3 see Rolling mill technology 3.0 Bundglühöfen see Rolling mill technology 3.0 Warmwalzanlagen/Komplettanlagen SMS Siemag AG Coil annealing furnaces SMS Siemag AG Hot rolling units / complete plants Drive systems / Antriebe www.siemens.vai.com see Rolling mill technology 3.0 Coil transport systems Bundtransportsysteme www.ctisystems.com see Section handling 2.3 www.siemens.vai.com see Rolling mill technology 3.0 SMS Siemag AG see Rolling mill technology 3.0 Surface finishing of sheets and coils H+H HERRMANN + HIEBER GMBH Rechbergstraße 46 D-73770 Denkendorf/Stuttgart Tel. +49 711 93467-0, Fax +49 711 34609-11 E-Mail: [email protected] Internet: www.herrmannhieber.de Oberflächenveredeling von Blechen und Coils DEMIS Wide Belt Processing Systems see Process techn./Automation Techn. 3.10 see Coil transport systems 3.4 83 LIEFERVERZEICHNIS Rolling mill modernization Walzwerkmodernisierung Feinband-/Folienwalzwerke see Section handling 2.3 Cold rolling units / complete plants Kaltwalzanlagen/Komplettanlagen 3.7 Thin strip / foil rolling plant Achenbach Buschhütten GmbH & Co. KG Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de Achenbach Buschhütten GmbH & Co. KG Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de see Cold rolling units / complete plants 3.6 see Cold rolling units / complete plants 3.6 MINO S.p.A. Via Torino, 1 – San Michele 15122 ALESSANDRIA – ITALY Telefon: +39 0131 363636 Telefax: +39 0131 361611 E-Mail: [email protected] Internet: www.mino.it Sales contact: Mr. Luciano Ceccopieri MINO S.p.A. Via Torino, 1 – San Michele 15122 ALESSANDRIA – ITALY Telefon: +39 0131 363636 Telefax: +39 0131 361611 E-Mail: [email protected] Internet: www.mino.it Sales contact: Mr. Luciano Ceccopieri Coil annealing furnaces Bundglühöfen Slitting lines-CTL Längs- und Querteilanlagen www.siemens.vai.com see Rolling mill technology 3.0 www.siemens.vai.com see Rolling mill technology 3.0 Gautschi Engineering GmbH see Casting equipment 3.1 see Cold rolling units / complete plants 3.6 SMS Siemag AG see Rolling mill technology 3.0 Could not find your Drive systems / Antriebe „keywords“? SMS Siemag AG Please ask for our complete see Rolling mill technology 3.0 „Supply sources for the aluminium industry“. Heating furnaces / Anwärmöfen Gautschi Engineering GmbH see Casting equipment 3.1 Process optimisation systems Prozessoptimierungssysteme Gautschi Engineering GmbH see Casting equipment 3.1 Process simulation Prozesssimulation Gautschi Engineering GmbH see Casting equipment 3.1 SMS Siemag AG see Rolling mill technology 3.0 E-Mail: [email protected] Strip shears/Bandscheren Walzenwechseleinrichtungen SMS Siemag AG see Rolling mill technology 3.0 84 schwartz GmbH see Cold colling equipment 3.6 Heating furnaces Anwärmöfen Gautschi Engineering GmbH see Casting equipment 3.1 INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH see Casthouse (foundry) 1.5 see Cold rolling units / complete plants 3.6 SMS Siemag AG see Rolling mill technology 3.0 Surface finishing of sheets and coils Oberflächenveredeling von Blechen und Coils DEMIS Wide Belt Processing Systems see Process techn./Automation Techn. 3.10 Trimming equipment Besäumeinrichtungen Roll exchange equipment see Equipment and accessories 3.1 see Cold rolling units / complete plants 3.6 SMS Siemag AG see Rolling mill technology 3.0 INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A see Heat treatment 2.4 schwartz GmbH see Heat treatment 2.4 Thin strip / foil rolling mills / complete plant Feinband- / Folienwalzwerke / Komplettanlagen MINO S.p.A. Via Torino, 1 – San Michele 15122 ALESSANDRIA – ITALY Telefon: +39 0131 363636 Telefax: +39 0131 361611 E-Mail: [email protected] Internet: www.mino.it Sales contact: Mr. Luciano Ceccopieri ALUMINIUM · 7-8/2013 SUPPLIERS DIRECTORY SMS Siemag AG Surface finishing of sheets and coils see Rolling mill technology 3.0 Hier könnte Ihr Bezugsquellen-Eintrag stehen. Rufen Sie an: Tel. 0821 / 31 98 80-34 Dennis Ross Rolling mill modernization Walzwerkmodernisierung Achenbach Buschhütten GmbH & Co. KG Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de MINO S.p.A. Via Torino, 1 – San Michele 15122 ALESSANDRIA – ITALY Telefon: +39 0131 363636 Telefax: +39 0131 361611 E-Mail: [email protected] Internet: www.mino.it Sales contact: Mr. Luciano Ceccopieri 3.10 Process technology / Automation technology Prozesstechnik / Automatisierungstechnik Process control technology Prozessleittechnik SMS Siemag AG Achenbach Buschhütten GmbH & Co. KG Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de SMS Siemag AG see Rolling mill technology 3.0 Strip thickness measurement and control equipment see Casting machines 1.6 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 E-Mail: [email protected] Internet: www.abb.com/pressductor ALUMINIUM · 7-8/2013 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 S-72159 Västeras, Sweden Phone: +46 21 325 000 Fax: +46 21 340 005 E-Mail: [email protected] Internet: www.abb.com/pressductor ABB Automation Force Measurement S-72159 Västeras, Sweden Phone: +46 21 325 000 Fax: +46 21 340 005 E-Mail: [email protected] Internet: www.abb.com/pressductor Strip Width & Position Measurement equipment Bandbreiten- und Bandlaufmesseinrichtungen Achenbach Buschhütten GmbH & Co. KG Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de SMS Siemag AG see Rolling mill technology 3.0 Strip Tension Measurement equipment Bandzugmesseinrichtungen ABB Automation Force Measurement S-72159 Västeras, Sweden Phone: +46 21 325 000 Fax: +46 21 340 005 E-Mail: [email protected] Internet: www.abb.com/pressductor 3.11 Coolant / lubricant preparation Kühl-/SchmiermittelAufbereitung see Rolling mill technology 3.0 Wagstaff, Inc. Oberflächenveredeling von Blechen und Coils ABB Automation Force Measurement S-72159 Västeras, Sweden Phone: +46 21 325 000 Fax: +46 21 340 005 E-Mail: [email protected] Internet: www.abb.com/pressductor see Cold rolling units / complete plants 3.6 Rolling oil recovery and treatment units Walzöl-Wiederaufbereitungsanlagen SMS Siemag AG see Rolling mill technology 3.0 Ein Eintrag (s/w) in diesem Format kostet pro Ausgabe + Stichwort Filter for rolling oils and emulsions Filter für Walzöle und Emulsionen 110,00 € + MwSt. Weitere Informationen unter Tel. +49 (0) 821 / 31 98 80 - 34 Achenbach Buschhütten GmbH & Co. KG Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de 85 LIEFERVERZEICHNIS 3.16 Coil storage systems Coil & Colour Coating Lines Achenbach Buschhütten GmbH & Co. KG Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de www.ctisystems.com see Section handling 2.3 Bronx International Pty Ltd Email: [email protected] Internet: www.bronxintl.com SMS Siemag AG H+H HERRMANN + HIEBER GMBH Rechbergstraße 46 D-73770 Denkendorf/Stuttgart Tel. +49 711 93467-0, Fax +49 711 34609-11 E-Mail: [email protected] Internet: www.herrmannhieber.de Rolling oil rectification units Walzölrektifikationsanlagen see Rolling mill technology 3.0 Bundlagersysteme „keywords“? our complete „Supply sources for the www.bwg-online.com see Strip Processing Lines 3.17 SMS Siemag AG see Rolling mill technology 3.0 Could not find your Please ask for Bandlackierlinien Lithographic Sheet Lines see Coil transport systems 3.4 SMS Siemag AG see Rolling mill technology 3.0 Lithografielinien www.bwg-online.com see Strip Processing Lines 3.17 aluminium industry“. see Cold rolling units / complete plants 3.6 E-Mail: [email protected] see Section handling 2.3 3.17 Strip Processing Lines Streckrichtanlagen Bandprozesslinien www.bwg-online.com see Strip Processing Lines 3.17 3.12 Air extraction systems Abluft-Systeme Stretch Levelling Lines see Cold rolling equipment 3.6 Strip Annealing Lines Bandglühlinien see Cold rolling units / complete plants 3.6 Exhaust air purification systems (active) Abluft-Reinigungssysteme (aktiv) Achenbach Buschhütten GmbH & Co. KG Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de SMS Siemag AG see Rolling mill technology 3.0 BWG Bergwerk- und WalzwerkMaschinenbau GmbH Mercatorstraße 74 – 78 D-47051 Duisburg Tel.: +49 (0) 203-9929-0 Fax: +49 (0) 203-9929-400 E-Mail: [email protected] Internet: www.bwg-online.com REDEX Zone Industrielle F-45210 Ferrieres Telefon +33 (2) 38 94 42 00 E-mail: [email protected] Internet: www.tension-leveling.com 3.14 Storage and dispatch Lagerung und Versand see Coil transport systems 3.4 SMS Siemag AG see Rolling mill technology 3.0 86 www.alu-web.de www.bwg-online.com see Strip Processing Lines 3.17 SMS Siemag AG see Rolling mill technology 3.0 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 see Rolling mill technology 3.0 see Coil transport systems 3.4 ALUMINIUM · 7-8/2013 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 H+H HERRMANN + HIEBER GMBH Rechbergstraße 46 D-73770 Denkendorf/Stuttgart Tel. +49 711 93467-0, Fax +49 711 34609-11 E-Mail: [email protected] Internet: www.herrmannhieber.de see Coil transport systems 3.4 see Section handling 2.3 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 see Smelting technology 1.5 Casting machines Gießmaschinen Refratechnik Steel GmbH Via Brallo, 2 – 27010 Siziano (PV), Italy Tel: +39 0382 6671413 E-mail: [email protected] 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 INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A Avenida Cervantes Nº6 48970 – Basauri – Bizkaia – Spain Tel: +34 944 409 420 E-mail: [email protected] Internet: www.insertec.biz 4.3 Conveyor and storage technology Förder- und Lagertechnik HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 see Equipment and accessories 3.1 Heat treatment furnaces Wärmebehandlungsöfen INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A see Heat treatment 2.4 Paul Hedfeld GmbH www.alu-web.de ALUMINIUM · 7-8/2013 Hundeicker Str. 20 D-58285 Gevelsberg Phone: +49 (0) 2332 6371 E-mail: [email protected] Internet: www.hedfeld.com see Casthouse (foundry) 1.5 87 LIEFERVERZEICHNIS 4.7 Casting machines and equipment Gießereimaschinen und Gießeinrichtungen GAPCast TM: the Swiss casting solution Casting Technology / Automation Tel.: +41 27 455 57 14 E-Mail: [email protected] Internet: www.gap-engineering.ch www.mechatherm.com see Smelting technology 1.5 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 E-Mail: [email protected] Internet: www.precimeter.com Sales contact: Jonatan Lindstrand Ein Eintrag (s/w) in diesem Format kostet pro Ausgabe + Stichwort Weitere Informationen unter 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 E-Mail: [email protected] 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 E-Mail: [email protected] 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 E-Mail: [email protected] Internet: www.bloomeng.de Heat treatment furnaces Wärmebehandlungsanlagen Gautschi Engineering GmbH see Casting equipment 3.1 HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A see Heat treatment 2.4 see Equipment and accessories 3.1 Holding furnaces see Casting machines 1.6 Hier könnte Ihr Bezugsquellen-Eintrag 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 see Casthous (foundry) 1.5 Gautschi Engineering GmbH see Casting equipment 3.1 INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A see Heat treatment 2.4 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 E-Mail: [email protected] 4.13 Melt operations Schmelzbetrieb INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A see Equipment and accessories 3.1 Could not find your „keywords“? Please ask for our complete „Supply sources for the aluminium industry“. E-Mail: [email protected] see Heat treatment 2.4 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 see Smelting technology 1.5 Bartz GmbH see Casthous (foundry) 1.5 ALUMINIUM · 7-8/2013 SUPPLIERS DIRECTORY Gautschi Engineering GmbH see Casting equipment 3.1 5 Werkstoffe und Recycling HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A see Heat treatment 2.4 see Equipment and accessories 3.1 MARX GmbH & Co. KG Lilienthalstr. 6-18 D-58638 Iserhohn Tel.: +49 (0) 2371 / 2105-0, Fax: -11 E-Mail: [email protected] Internet: www.marx-gmbh.de 4.14 Melt preparation Schmelzvorbereitung Degassing, filtration Entgasung, Filtration Drache Umwelttechnik GmbH Werner-v.-Siemens-Straße 9/24-26 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 E-Mail: [email protected] 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 E-Mail: [email protected] 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 ALUMINIUM · 7-8/2013 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 E-Mail: [email protected] Internet: www.lasco.com Could not find your „keywords“? Please ask for our complete Machining + Application Bearbeitung + Anwendung 6.1 Equipment to produce castplate Ausrüstungen für Gussplattenproduktion Slicing saw & Milling machines Folienschneidmaschinen Fräsmaschinen Sermas Industrie [email protected] see Smelting technology 1.6 6.2 Semi products „Supply sources for the aluminium industry“. E-Mail: [email protected] 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 E-Mail: [email protected] Internet: www.elisental.de 4.17 Environment protection and disposal Umweltschutz und Entsorgung 6.3 Equipment for forging and impact extrusion Giesel Verlag GmbH Hans-Böckler-Allee 9, 30173 Hannover Tel. 0511/8550-2638 · Fax 0511/8550-2405 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 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 Hans-Böckler-Allee 9, 30173 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. 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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 40237 Düsseldorf, Germany Phone: +49 211 881-0 Fax: +49 211 881-4902 E-mail: [email protected] Internet: www.sms-siemag.com