Volume 90 · May 2014 International Journal for - ALU

SPECIAL: MELTING,
CASTING AND
HEAT TREATMENT
Hertwich Engineering:
Into the next decade
with powerful products
© Hertwich Engineering
LOI Thermprocess: “The
world market is huge”
Volume 90 · May 2014
International Journal for Industry, Research and Application
Ebner Industrieofenbau:
A rush of orders for
heat treatment lines
for automobile strip
Andritz Maerz: Back
in market for aluminium melting furnaces
5
Melting Furnaces
State-of-the-art scrap and dross remelting
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EDITORIAL
Volker Karow
Chefredakteur
Editor in Chief
Hersteller von Schmelzöfen
profitieren von steigender
Aluminiumnachfrage
Melting furnace manufacturers benefit from
rising aluminium demand
ALUMINIUM · 5/2014
Viel ist in letzter Zeit über die guten Wachstumsaussichten für den Werkstoff Aluminium
geschrieben worden. Natürlich auch in dieser Zeitschrift, die sich dem Leichtmetall
und der Aluminiumindustrie mit den ihr verbundenen Ausrüstern verschrieben hat. Die
Primäraluminiumproduktion ist allein in den
vergangenen fünf Jahren laut IAI-Statistik um
mehr als ein Viertel gestiegen. Und die Nachfrage nach Aluminiumprodukten entwickelt
sich seit Jahren überproportional zur globalen
Wirtschaftsleistung. Für dieses Jahr rechnen
Branchenunternehmen und Analysten mit
einem Wachstum der weltweiten Aluminiumnachfrage von sechs bis sieben Prozent, getrieben vor allem von der Entwicklung in
den Schwellenländern, in denen der Bedarf
teilweise zweistellig steigt wie in China oder
Indien. Hier ist die Urbanisierung und Entwicklung der Infrastruktur ein entscheidender
Wachstumsfaktor.
Ein weiterer ist, dass die europäischen und
amerikanischen Automobilhersteller aus der
Notwendigkeit heraus, ihre Fahrzeuge immer
leichter, spritsparender und klimafreundlicher
zu machen, in den neu auf den Markt kommenden Modellen vermehrt Aluminium einsetzen, speziell auch als Blech in der Fahrzeugkarosserie, und nicht nur in den obersten
Preisklassen. Auch darüber ist in den vergangenen Monaten berichtet worden, vor allem
im Zusammenhang mit den Investitionsankündigungen mehrerer Halbzeugunternehmen dieser Branche, entsprechende Automobilkapazitäten auszubauen.
Von dieser Entwicklung profitieren zahlreiche Ausrüsterindustrien, unter anderem
auch die industriellen Ofenbauer, sei es als
Hersteller von Schmelz- und/oder Wärmebehandlungsöfen. Manche Anbieter sind in beiden Produktlinien unterwegs.
Der Markt für Schmelz- und Recyclingöfen
hat in den nächsten Jahren gute Wachstumsaussichten, schließlich nimmt zum einen der
Bedarf, Fertigungsschrotte einzuschmelzen,
mit der steigenden Aluminiumnachfrage zu,
und zum anderen kommen künftig vermehrt
auch Gebrauchtschrotte aus der Konsumsphäre zurück. Von dieser Entwicklung werden besonders jene Ofenbauer profitieren,
deren Anlagen sich durch hohe Metallausbeute, geringen Energieverbrauch und niedrige
Abgaswerte auszeichnen. Denn Aluminium
ist auch als Gebrauchtmetall sehr werthaltig,
und jede Verbesserung in der Ofentechnologie, die die Metallausbeute auch nur um ein
Zehntel Prozent erhöht, kann fünfstellige
Zusatzgewinne generieren, wie bei den Gesprächen mit Herstellern von Schmelzöfen
für diese Ausgabe deutlich wurde.
A lot has recently been written about the
good growth prospects for aluminium, needless to say also in this journal, which is devoted to the light metal and the aluminium
industry with its dedicated suppliers. According to IAI statistics, in the past five years alone
primary aluminium production has risen by a
quarter and the demand for aluminium products has been developing for years over-proportionally compared with global economic
performance. Aluminium companies and
analysts estimate that worldwide demand for
aluminium will increase by six to seven percent, driven above all by advances in the developing countries, in some of which, such as
China and India, demand is growing at a rate
in the two-digit range. In such cases urbanisation and infrastructure development are the
decisive growth factors.
A further factor is that driven by the need
to make their vehicles lighter, more fuel-efficient and more climate-friendly, automobile
manufacturers in Europe and America are
using more and more aluminium in the new
models coming on the market, particularly
in the form of sheet for vehicle bodies, and
this is happening not only in high-end vehicle categories. This has also been reported in
recent months, especially in connection with
investment announcements by several semis
manufacturers in that sector that they are correspondingly increasing their capacities for
automotive materials.
This development is to the benefit of numerous equipment supplier industries, among
them also manufacturers of industrial furnaces, whether for melting or for heat treatment. Many suppliers, of course, deal in both
product lines.
In the coming years the market for melting and recycling furnaces has good growth
prospects, since ultimately, on the one hand
the need to remelt production scrap is increasing due to the rising demand for aluminium, and on the other hand in future
larger quantities of used metal will be coming back from the consumer sphere. This
development will particularly benefit those
furnace manufacturers whose equipment is
characterised by high metal yields, low energy consumption and low waste gas emission
values. Since even as a used metal aluminium
is worth a great deal, any improvement of
furnace technology which increases the metal
yield, even by only a tenth of one percent,
can generate five-figure additional profits, as
is made clear by the discussions with melting furnace manufacturers reported in this
issue.
3
I N H A LT
EDITORIAL
He r st e l l e r vo n Sch me l z ö fe n p ro fi t i e re n vo n st e i ge n de r
A l umi n i u mn a ch fra ge • Me l t i n g fu rn a c e ma n u fa c t u re rs
b e n e fi t fro m ri s i n g a l u mi n i u m de ma n d ............................................ 3
A K T U E L L E S • N E W S I N B R I E F ........................................... 6
WIRTSCHAFT • ECONOMICS
22
A l - Pre i s e , P ro du 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 strie ....... 10/12
En e rgi e i n t e n s i ve In du st ri e z u fri e de n mi t Brü s s e l e r
B e i h i l fe l e i t l i n i e n u n d de n E E G-R e fo rmvo rs ch l ä ge n ............................. 14
G ut e Ko n ju n k t u r fü r Al u ve rp a ck u n ge n ............................................ 15
Th e Hi gh Co u rt vs . LME ru l e s – W h a t mi gh t b e t h e re p e rc u ssions? .......16
C an Al u mi n ij Mo st a r avo i d b a n k ru p t c y? ......................................... 20
SCHMELZEN, GIESSEN UND WÄRMEBEHANDLUNG
M E LT I N G , C A S T I N G A N D H E AT T R E AT M E N T
27
4 0 J a h re He rt wi ch E n gi n e e ri n g: Mi t st a rke n P ro du k t e n
i n s nä ch st e Ja h rz e h n t • He rt wi ch E n gi n e e ri n g – 4 0 ye a rs old :
I n t o t h e n e x t de c a de wi t h p owe rfu l p ro du c t s ...................................22
Eb n er In du st ri e o fe n b a u : Au ft ra gs b o o m b e i Ve rgü t e l i n i e n für Auto m o bi l b a n d a u s Al u mi n i u m / Dre i st a rke P ro du k t l i n i e n fü r d ie Alum in i um i n du st ri e • E b n e r In du st ri e o fe n b a u : A ru s h o f o rde rs f or heat
t re a t me n t l i n e s fo r a l u mi n i u m a u t o mo b i l e st ri p / Th re e p owerf ul
p ro du c t i o n l i n e s fo r t h e a l u mi n i u m i n du st ry ............................... 27 / 30
Te n ova LO I Th e rmp ro c e s s : „ De r We l t ma rk t i st ri e s i g“
Te n ova LO I Th e rmp ro c e s s : “ Th e wo rl d ma rke t i s h u ge ” ......................33
A n d ri t z Ma e rz : Z u rü ck a m Ma rk t fü r Al u mi n i u ms ch me l z ö fe n
A n d ri t z Ma e rz : Ba ck i n ma rke t fo r a l u mi n i u m me l t i n g fu rn aces ..........39
A l um i n i c a st e – A n e w re me l t fa c i l i t y i n Me x i c o ...............................44
N e w me l t i n g fu rn a c e e a rn s fu e l s avi n gs re b a t e fo r U S di e caster .........46
33
C asti n g ma t e ri a l s a n d p ro c e s s c o mb i n a t i o n
d e l i ve rs c o mp o n e n t b e n e fi t s .........................................................46
Pre ss u re di e c a st e r c o l l a b o ra t e s wi t h
un i ve rs i t i e s o n p ro du c t de ve l o p me n t re s e a rch ..................................48
M o d e l l i n g re s e a rch dri ve s a l l o y i n t e gri t y .........................................49
Ho nda l a u n ch e s p i st o n p ro du c t i o n i n Vi e t n a m • Su p e ri o r
I n d u st ri e s e x p a n di n g i n Me x i c o • In s u l a t i n g ma t e ri a l b o o st s
d o s i n g fu rn a c e p e rfo rma n c e i n a l u mi n i u m fo u n dri e s • N e w
t h e rma l i n s u l a t i o n p ro du c t fro m Mo rga n Th e rma l Ce ra mi c s ................ 51
T E CH N O LO G I E • T E CH N O LO GY
44
4
Th e N ove l i s U l s a n h o t l i n e e x p a n s i o n..............................................52
Alfun beauftragt Maschinenfabrik Georg mit „Hybrid“-Querteilanlage
ALUMINIUM · 5/2014
CONTENTS
Alfun and Georg conclude a contract for ‘hybride’ cut-to-length line .....55
Innovative Roboterlösung: vollautomatischer Gleitschliffprozess
Innovative robotic solution: Fully automatic vibratory finishing ............56
Lasox-Coat: Neuartiges Verfahren zur selektiven
Oxidation von Aluminiumoberflächen vor der Serienreife
Lasox-Coat: Novel method for the selective oxidation
of aluminium surfaces prior to serial production ................................57
APPLICATION
J a gu a r X E w i t h ad va n c e d al umi n i um m o n oc o qu e a rch i t e c t u re .............58
Wi n dk ra f t a nl a g e n ut z t A l um i n i um vo n N ove l i s
Wi n d t u r bi n e d e s i g n e d w i t h a l um i n i um f rom N ove l i s .........................59
C O M PA N Y N E W S W O R L D W I D E . . ....................................... 6 0
D O C U M E N TAT I O N
Pa t e n t e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................65
Vor scha u • P re vi e w / I m p re s s um • I m p r i nt ......................................82
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 .............67
ALUMINIUM · 5/2014
Latest News
www.alu-web.de
Inserenten dieser Ausgabe
List of advertisers
Didion International Inc., USA
Dimasimma Srl, Italy
Emirates Global Aluminium
extrutec GmbH, Germany
Fizeta Srl, Italy
Gautschi Engineering, Switzerland
Hertwich Engineering GmbH, Austria
Inotherm Industrieofen- und
Wärmetechnik GmbH, Germany
Joh. Clouth Maschinenbau Eltmann
GmbH & Co. KG, Germany
LOI Thermprocess, Germany
Magma GmbH, Germany
Novelis PAE, France
Reed Exhibition China, PRC
Rudolf Uhlen GmbH, Germany
Siemens VAI, UK
Storvik AS, Norway
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13
49
19
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9
11
35
47
84
21
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53
61
5
AKTUELLES
Hydro verkauft Aluminiumgießerei in Hannover
© Hydro
beinhaltet.
Die Gießerei
Hannover konzentriert sich auf Speziallegierungen,
vor allem auf
harte Legierungen
für die Luft- und
Raumfahrtindustrie. Durch die Vereinbarung erwirbt
IQ 100 Prozent
der Anteile an der
Hydro Gießerei
Bearbeitungszentrum für Rundbarren in der Gießerei Hannover
Hannover GmbH.
Hydro hat einen bindenden Vertrag mit der Die Gießerei wurde von Hydro bei der InteIQ Industrial Holding S. à r. l. aus Luxemburg gration der VAW aluminium AG im Jahr 2002
geschlossen, der den Verkauf der Aluminium- übernommen und zählt nicht zum Kerngegießerei für Speziallegierungen in Hannover schäft. Die Gießerei liefert ihre Produkte aus
harten Legierungen vor allem an einen direkt
benachbarten Kunden. Sie beschäftigt rund
30 Mitarbeiter und produzierte rund 12.000
Tonnen Aluminiumprodukte im vergangenen
Jahr. Die Transaktion wird voraussichtlich im
zweiten Quartal 2014 vollzogen.
Die Gießerei ist mit zwei kippbaren 50Tonnen-Induktionsrinnenöfen und einer vertikalen Stranggießanlage ausgestattet, mit der
Rundbarren in Gießlängen bis max. 6.300 mm
Länge in Durchmessern von 178 bis 433 mm
produziert werden können. Mitte der 1930er
Jahre wurde an diesem Standort das Stranggussverfahren erfunden, das zum Weltstandard für die Herstellung von Knetlegierungen
wurde.
IQ Industrial Holding ist eine private Industrie-Holdinggruppe mit Aktivitäten in ganz
Europa.
Siemens liefert Antriebstechnik für Warmwalzwerk von Alunorf
© Siemens
Die Aluminium Norf GmbH hat bei Siemens
Metals Technologies Antrieb- und Automatisierungstechnik für die Erweiterung und Modernisierung der Warmwalzstraße 1 im Werk
Neuss bestellt. Die Umbauarbeiten werden
in mehreren Stufen durchgeführt und sollen
Anfang 2016 abgeschlossen sein.
Mittelspannungsumrichter Sinamics SM150
Im Zuge eines mehrstufigen Programms zur
Kapazitätserweiterung erhält die Fertigstraße
des Warmwalzwerks ein zusätzliches Walzgerüst. Weiterhin werden Änderungen an den
vorhandenen Getrieben durchgeführt. Das
letzte Gerüst der Fertigstraße und die Haspelanlage werden mit neuen Drehstromantrieben
ausgerüstet. Beide Maßnahmen erhöhen die
Walzgeschwindigkeit und damit die Produktionskapazität.
Die Lieferung umfasst einen Synchronmotor mit Vollpolläufer für das letzte Walz-
6
gerüst, das bisher mit einem Gleichstrommotor ausgestattet ist, sowie einen Asynchronmotor für die Haspelanlage. Dieser ersetzt
drei Gleichstrommotoren, die an eine Welle
angeordnet sind. Dabei kommen Mittelspannungsumrichter vom Typ Sinamics SM150
zum Einsatz. Siemens übernimmt auch die
gesamten Demontage- und Montagearbeiten sowie die
Inbetriebnahme der
Elektrokomponenten. Der abgebaute
Gleichstrommotor
des letzten Walzgerüsts wird in einer
Siemens-Werkstatt
überholt, neu montiert und danach für
das neue Walzgerüst
weiterverwendet.
Alunorf ergänzt die für das zusätzliche Walzgerüst benötigte Automatisierungshardware,
während Siemens die notwendigen Softwareanpassungen ausführt.
Für die Umbauten werden die bereits geplanten Stillstände der Anlage genutzt. Dies
vermeidet zusätzliche Produktionseinbußen.
Das Lösungskonzept von Siemens stellt sicher,
dass bestehende Komponenten und Systeme
weitestgehend weiterverwendet werden können. Gleichzeitig werden die erforderlichen
Grundlagen für eine Ablösung durch zukünf-
tige Gerätegenerationen geschaffen. Dies erhöht die Investitionssicherheit für Alunorf.
Alunorf betreibt in Neuss das weltgrößte
Aluminiumschmelz- und -walzwerk. Der Absatz beträgt rund 1,5 Mio. Tonnen warm- und
kaltgewalztes Aluminiumband pro Jahr.
StrikoWestofen eröffnet
neuen Standort in Asien
Neuer Firmensitz für StrikoWestofen Asien:
Anfang April wurde im chinesischen Taicang
nahe Shanghai das neue Firmengebäude der
StrikoWestofen Group eröffnet. Umzug und
Ausbau der Kapazitäten waren notwendig
geworden, da der Absatz in den chinesischen
Märkten innerhalb von 18 Monaten laut Unternehmen um rund 300 Prozent gestiegen
war. „Ein gesteigertes Umweltbewusstsein
in China und die Effizienz unserer Schmelzund Dosiersysteme geben den Ausschlag für
unser überdurchschnittliches Wachstum“,
sagte Rainer Erdmann, der Geschäftsführer
von StrikoWestofen Asien. Ein Ende des Aufschwungs sei nicht in Sicht. Auch außerhalb
Chinas konnte StrikoWestofen in den letzten
Jahren wichtige Märkte in Asien erschließen
und das Vertriebsnetz ausbauen. „Unser Firmenstandort in Taicang ist sozusagen das neue
Produktions- und Logistik-Zentrum für die
asiatischen Märkte“, so Erdmann.
ALUMINIUM · 5/2014
NEWS IN BRIEF
World aluminium casting industry in growth but facing serious challenges
One prominent research analyst organisation, whilst predicting significant growth for
the global aluminium casting market, believes
the industry could well be curtailed by some
serious challenges. In its recent comprehensive
report Global Aluminium Castings Market
2014-2018 Research and Markets forecast the
world’s aluminium castings market will grow
at a CAGR of 9.96% over the period 20132018. One of the key factors contributing to
this market growth, the report findings claim,
is the industrialisation and development in
the Asian-Pacific region.
The global aluminium castings market has
also been witnessing the shift of manufacturing units to emerging countries. However, the
increase in energy requirements could pose a
challenge to the growth of this market. Key
players dominating this sector and referenced
in the report include the companies Alcoa,
Ryobi, Gibbs Die Casting, and Dynacast. Other
companies referenced in the report are Alcast,
Alcoa Howmet Castings, Bodine Aluminum
and Consolidated Metco.
Commenting on the report, an analyst from
Research and Markets’ team said: “Over the
last four decades, a staggering number of ability of cheap labour are increasingly attracfoundries in developed countries have closed tive inducements encouraging exploitation of
down because of escalating costs of labour, the untapped potential of these geographical
production and raw materials, and also recent- market areas. This is especially the case across
ly, the low demand triggered
by the global recession. Following the continued recovery
from the world’s economic
downturn, many organisations have been looking to
expand their manufacturing
operations across the world.
And spurred by a variety of
positive supporting factors,
manufacturers are preferring
to establish production facilities in emerging countries.
The shift is also driven by rigid environmental legislation The aluminium castings market will grow at nearly 10% annually over
and initiatives with regard to the next years
waste, energy, and environmental taxation by governments in Western the APAC region where manufacturers plan
to tap the potential of rapidly growing markets
countries.
In emerging countries on the other hand, having already penetrated countries such as
abundant supply of raw materials – albeit China and India.
Ken Stanford, contributing editor
sometimes inferior in quality – and the avail-
Two-in-one event: Aluminium Two Thousand Congress and ICEB
Conference a joint meeting point for aluminium specialists in May 2015
The 9th Aluminium Two Thousand Congress together with the 5th International
Conference on Extrusion and Benchmark
(ICEB) will take place at Palazzo degli
Affari in Florence, Italy, from 12 to 16
May 2015.
derstanding the latest researches, developments and the trends for the future.
The Aluminium Two Thousand Congress
has become a meeting point for highly qualified professionals in the aluminium industry.
Experts from companies, universities and associations from all over the world
to present innovative technologies and applications to a specialised and international audience.
The ICEB has become the
biggest event in Europe related
to developments on extrusion
technology and its analysis by
FEM simulation. The aim of the
conference is to bring together
technical and scientific experts
to exchange their knowledge
Plenary session at a Aluminium Two Thousand Congress
and discuss state-of-the-art and
future
developments
in the field of extrusion
The two events will bring together aluminium
and
in
its
most
powerful
tool, the numerical
and light alloys specialists in a single venue,
simulation.
thus creating an attractive and unique opporWhat is the goal of the ‘united’ congress?
tunity for industry managers, technicians,
To
analyse all the aspects of the aluminium
researchers, technology suppliers and other
chain,
to meet colleagues from around the
industry representatives for meeting and un-
ALUMINIUM · 5/2014
world, to exchange ideas and to give your
own view regarding the development in the
aluminium industry and the improvement of
technology.
What are the issues of the event? Metallurgy, extrusion, surface finishing, corrosion,
foundry, rolling, environmental technologies
and much more.
Who is participating in the congress? Representatives from extrusion companies, their
equipment partners and customers; academic
and industrial researchers, alloys specialists,
software houses and distributors, suppliers of
instruments, devices and products for extrusion industry, manufacturers of architectural
frames for windows, curtain wall, manufacturers in automotive sector, etc.
Aluminium Two Thousand and the ICEB
congress also aim at aluminium distributors,
architectural designers, and mechanical engineers – particularly those in the extrusion and
casting industry. Financial investors will also
be interested.
For more details visit www.aluminium
2000.com and www.ice-b.net.
7
AKTUELLES / NEWS IN BRIEF
Bruker Elemental im Projektausschuss Al-G.I.S.S.
Im Oktober 2013 startete das Forschungsvorhabens Al-G.I.S.S. (Gated Integration of Single
Sparks), dessen Ziel es ist, die Detektion und
Bewertung von Einschlüssen in Aluminiumlegierungen mittels Einzelfunken-Spektrometrie ein Stück näher an die industrielle Anwendung heranzubringen.
Gefördert wird das Vorhaben im Rahmen
der industriellen Gemeinschaftsforschung
(IGF) vom Bundesministerium für Wirtschaft
und Technologie über die Arbeitsgemeinschaft
industrieller Forschungsvorhaben (AiF). Mit
der Durchführung des Projektes wurde das
Gießerei-Institut der RWTH Aachen von der
Forschungsvereinigung Gießereitechnik e. V.
beauftragt. Das Projekt wird von einem projektbegleitenden Ausschuss des BDG (Bun-
desverband der Deutschen Gießerei-Industrie) fachlich betreut. Bruker Elemental ist
als namhafter Gerätehersteller von optischen
Emissionsspektrometern im Projektausschuss
vertreten.
Welche Einschlüsse sich wie in den Funkenbildern bemerkbar machen und wie sich
die untersuchten Wertecluster automatisiert
auswerten und als Qualitätskriterium darstellen lassen, sind die wesentlichen wissenschaftlichen Fragestellungen des Projektes. Durch
die Mitarbeit industrieller Vertreter, sowohl
von Legierungsherstellern wie der verarbeitenden Industrie, ist der Bezug zu den Anforderungen der Gießereiindustrie gesichert.
Bruker Elemental kann an Arbeiten mit dem
Q8 Magellan einen wesentlichen Beitrag
in diesem Projekt leisten.
Das Q8 Magellan ist ein Vakuum-Spektrometer mit digitalem Plasmaerzeuger, unbegrenzter Einzelfunken- und Zeitauflösung und
hoch robustem, wartungsarmen Funkenstativ
mit co-axialer Argonführung. Äußerst wartungsarme Systeme und eine konsequent auf
ihre speziellen Anforderungen maßgeschneiderte Software unterstreichen die Ausnahmestellung dieses Highend-Produktes für die
Elementanalyse in der Metall erzeugenden
und verarbeitenden Industrie. Es wird in drei
abgestuften Modellen angeboten und ist damit sowohl für den Routinebetrieb in ihren
Laboratorien als auch für den Einsatz in den
Produktionsstätten ausgelegt.
Aluminium China 2014 introduces new theme pavilions
Aluminium China is Asia’s top trading,
sourcing, networking and branding platform
for the aluminium industry and its equipment suppliers. It features leading industry
representatives, cutting edge technologies and
advanced applications. This year, over 500
international exhibitors from 30 countries will
showcase their newest solutions across an ex-
© Reed Exhibitions
Asia’s leading international light metals exhibition, Aluminium China, will be bolstered
this year by the introduction of three theme
pavilions. The Surface Treatment Pavilion,
the Furnaces & Heat Treatment Equipment
Pavilion and the Extrusion Aluminium Product Pavilion are a direct response to customer
feedback from last year’s event. This year the
Around 16,000 visitors are expected at Aluminium China 2014 in July
exhibition will take place from 9 to 11 July,
again at the Shanghai New International Expo
Centre but with a new layout to explore the
show site by focusing on categories that are of
special interest to visitors.
8
hibition area of 35,000 square metres. They
will represent the entire aluminium production chain – from aluminium raw materials,
semi-finished and finished products to production and processing machinery and acces-
sories. The exhibitors will interact with 16,000
professionals and buyers from China, Asia
and globally emerging markets.
Processing of aluminium is central to this
year’s exhibition. Today, the exploration of
downstream fields is hot in China’s aluminium
manufacturing landscape. Surface treatment
and extrusion processing are key to downstream production. Purchasing managers
from established aluminium manufacturers in
China and the rest of Asia will be onsite to
seek suppliers who offer technologies and
equipment to fulfil their needs. Pollution
reduction and energy conservation are two
more subjects this year, in light of current environmental concerns. New technology used
in plant and furnaces will certainly be of high
interest among aluminium manufacturers.
Fuelled by rapid urbanisation, China is the
world’s fastest growing and second largest
economy. Nearly half of the country’s GDP
stems from industrial growth that is driving
demand for aluminium and raw materials.
Over the last decade, China has quadrupled
demand, and is expected to account for 52
percent of the world’s aluminium consumption by 2025. All these factors are fuelling
optimism within the aluminium industry,
with experts predicting a sustained period of
prosperity and growth over the coming years,
even without double-digit growth figures.
Contact for exhibitor: Elaine.huang@
reedexpo.com.cn. More information at
www.aluminiumchina.com/en/home2014
ALUMINIUM · 5/2014
NEWS IN BRIEF
Sapa acquires UKbased aluminium
components company
Sapa is strengthening its range of advanced
aluminium solutions with the acquisition of
UK-based Holden Aluminium Technologies
Ltd. Sapa has taken over the operation with
effect from 1 April 2014. Holden’s extrusion fabrication plant is located in Bromyard,
England, and employs around 60 people. The
site specialises in the supply of formed and
machined aluminium components for sectors
including construction, transport and general
engine
The Bromyard plant will become part of
Sapa’s extrusion business in the UK, joining sister operations in Birtley, Cheltenham,
Gloucester, Redditch, Rotherham and Tibshelf. “Holden have a strong reputation in
the market and have established themselves at
the cutting edge of forming technology,” says
vice-president Alain Couturier, who leads
Sapa’s UK unit.
Holden, a privately owned company, has
been in business for over 50 years and has long
associations in Bromyard.
Constellium to build new
casthouses at Issoire plant
Constellium plans to increase the production
capacity of its Issoire plant in France to meet
accelerating demand for its Airware technology – the company’s patented range of aluminium-lithium alloys for aerospace applications. One of the two new casthouses is part
of the initial €52m investment announced in
2013. The company is ready to make an additional investment of about €43m to build a
second casthouse and Airware-specific recycling capacity.
Building on the experience of the first casthouse officially opened in March 2013, which
is already producing Airware at industrial
scale, the two new casthouses are expected
to start and ramp-up production in 2015 and
2016, respectively. These two additional casthouses will allow Constellium to nearly triple its production of Airware alloys, which
were selected to be part of major aerospace
programmes including Airbus’ A350 XWB,
Bombardier’s C-Series and SpaceX’s Falcon 9
Launcher. The investment will allow Constellium to meet greater demand than anticipated
under contract.
The Airware technology demonstrates a
ALUMINIUM · 5/2014
unique combination of strength, lightness and
improved corrosion resistance. Taking advantage of lower alloy density and improved
material properties, Airware enables the redesign of structural parts and allows aircraft
manufacturers to reduce the weight of aerospace components by up to 25 percent.
billion of which were delivered globally in
2013 – are typically a mix of materials such
as cardboard type paper, plastics and thin aluminium.
Alcoa expands Brazil rolling mill to meet growing
demand for specialty foil
Alcoa has announced a USD40 million investment in its Itapissuma rolling mill in Brazil The Itapissuma packaging facility is located in
to increase production of specialty foils for the state of Pernambuco and employs some
aseptic and flexible packages. Demand for 700 people. The expansion is expected to
specialty packaging in Brazil is expected to add 50 jobs at the plant following ramp-up of
rise seven percent annually over the next three production. Initial work for the expansion is
years due to population growth and consumer underway and commissioning is expected to
begin in 2016.
preference.
This investment is part of Alcoa’s ongoAlcoa has a leading market position in speing
portfolio transformation to build out its
cialty foil in Latin America where value-add
value-added
mid- and downstream businesses
aluminium is essential for producing highly
to
capture
profitable
growth.
differentiated packaging. “A growing number
of consumers prefer this type of packaging because it keeps products fresher, longer
and our expansion
GmbH
will enable Alcoa
Face protection for every application
and our customers
to capture that risRudolf Uhlen GmbH is a manufacturer of personal protective
equipment (PPE) for face protection. Especially for the steel and
ing demand,” said
aluminium industry we provide special solutions in the field of IRAquilino Paolucci,
protection. We produce:
head of Alcoa Latin
American and the
x Visor carriers
x PC-visors
Caribbean.
x Gold-coated visors
x Head Gears
Aseptic
and
x Mesh visors
x Electric arc protection
flexible packaging
made with specialty foil is the most
highly differentiated type of container in packaging. Leading food
and beverage companies around the
world use aseptic
packaging, which
allows liquid food
products to retain
more nutrients and
taste, and remain
ready for consumption for up
to twelve months,
even if unrefrigerRUDOLF UHLEN GmbH
Telefon: (02129) 1444
ated. The packages
Am Höfgen 13 - 42781 Haan Telefax: (02129) 59980
www.aschua-uhlen.de
[email protected]
– more than 175
RUDOLF UHLEN
AschuA
9
WIRTSCHAFT
Aluminium im Monatsrückblick
Ein Service der TRIMET Aluminium SE
Am 27. März 2014 fällte das Hohe
Gericht in Großbritannien ein Urteil, wodurch die von der LME angekündigten
neuen Lagerhausregeln auf unbestimmte Zeit auf Eis gelegt wurden. Die neuen Regeln, die am 1. April in Kraft treten
sollten, hatten zum Ziel, die langen Wartezeiten an den LME-Lagerhäusern zu
reduzieren. Die direkten Konsequenzen
dieser Entscheidung waren sowohl steigende Produktprämien als auch steigende LME-Notierungen. Der „All-In-Preis“
für Aluminium dürfte damit tendenziell
gute Unterstützung finden.
Prämien und Preise sollten jedoch ebenfalls von den jüngsten Produktionskürzungen der Hütten in Brasilien sowie
der steigenden Nachfrage in den Industriestaaten unterstützt werden. Auf
der anderen Seite dürften anhaltende
Überkapazitäten in China den SHFE-Preis
drücken, was wiederum ein Hemmschuh
für eine echte Rally der LME-Preise sein
dürfte.
Auf- bzw. Abschlag für 3-Monatstermin
Letzte 6 Durchschnittswerte LME
März
Februar
Januar
Dezember
November
Oktober
2014
2014
2014
2013
2013
2013
31,36 Euro
30,07 Euro
33,32 Euro
33,44 Euro
34,06 Euro
34,56 Euro
50
0
–50
2005
2006
2007
2008
2009
2010
2011
2012
2013
Aluminium High Grade, Kasse
Letzte 6 Durchschnittswerte LME
März
Februar
Januar
Dezember
November
Oktober
2014
2014
2014
2013
2013
2013
1.233,10 Euro
1.240,21 Euro
1.231,77 Euro
1.268,18 Euro
1.296,56 Euro
1.328,78 Euro
2.500
2.000
1.500
2005
2006
2007
2008
2009
2010
2011
2012
2013
1.000
Aluminium Lagerbestände
Letzte 6 Monatsendwerte LME
März
Februar
Januar
Dezember
November
Oktober
2014
2014
2014
2013
2013
2013
5.381.900 t.
5.311.300 t.
5.423.550 t.
5.458.075 t.
5.470.425 t.
5.375.725 t.
6.000
5.000
4.000
3.000
2.000
1.000
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.
10
ALUMINIUM · 5/2014
SPEZIALISTEN
FÜR SAUBERE PROZESSE
Schaberhalter und Schaber
für rotierende Rollen-, Walzenund Zylinderoberflächen
Mehr Effizienz
Produktionsbedingte Verunreinigungen auf den Rollen/Walzen
werden stark reduziert, die Verfügbarkeit der Anlagen steigt.
Mehr Sicherheit
Durch den Einsatz unserer Systeme
erfolgt eine Reduzierung manueller
Eingriffe in den Prozess, wodurch
das Verletzungsrisiko sinkt.
Mehr Qualität
Weniger Ablagerungen und damit
weniger Qualitätseinbußen am
Produkt.
Alle unsere Produkte werden in
Deutschland entwickelt.
Auch für Ihre Produktionsumgebung bi
bietet
t unser B
Baukastenk t
system eine Lösung oder wir entwickeln sie individuell für Sie!
Joh. Clouth Maschinenbau
Eltmann GmbH & Co. KG
Industriestraße 25
97483 Eltmann, Deutschland
Telefon: +49 (0) 95 22 94 24 - 0
Telefax: +49 (0) 95 22 94 24 - 24
E-Mail: [email protected]
www.clouth-eltmann.com
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 % *
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
Juni
41,7
26,2
51,1
-6,3
162,9
1,2
48,4
-1,4
Juli
43,3
24,4
52,0
-7,1
164,4
-1,2
48,3
2,9
Aug
43,1
23,4
45,4
-3,8
159,8
-0,9
46,3
3,2
Sep
41,9
24,7
49,9
-5,1
161,4
-1,9
47,2
5,8
Okt
43,5
23,8
48,0
-10,0
171,8
5,7
49,5
7,3
Nov
42,9
25,6
46,2
-13,4
165,6
8,3
45,4
6,7
Dez
44,3
26,2
40,1
-7,7
129,6
10,5
28,0
20,0
Jan 14
44,4
25,3
50,4
-3,5
153,7
-3,5
45,6
6,7
Feb
40,0
18,3
51,0
-3,0
147,8
-7,0
46,7
5,3
* gegenüber dem Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf
Primäraluminium
Walzprodukte > 0,2 mm
12
Sekundäraluminium
Press- und Ziehprodukte
ALUMINIUM · 5/2014
WIRTSCHAFT
Energieintensive Industrie zufrieden mit Brüsseler
Beihilfeleitlinien und den EEG-Reformvorschlägen
Die energieintensiven Industrien in
Deutschland können aufatmen. Die von
der EU-Kommission beschlossenen beihilferechtlichen Leitlinien für die Förderung
erneuerbarer Energien lassen weiterhin
Ausnahmeregelungen für energieintensive Betriebe zu, die ihnen das Überleben
in Europa ermöglicht. Der Streit mit der
Bundesregierung in dieser Frage ist beigelegt, und eine massive, milliardenteure
Rückzahlung bisher gewährter Ökostromrabatte scheint ebenfalls vom Tisch. EUWettbewerbskommissar Joaquín Almunia
erklärte, Brüssel werden anhand der neuen Leitlinien die bisherige Rabattierung
in den vergangenen zwei Jahren prüfen.
Der mit den neuen Leitlinien vereinbare
Teil sei unproblematisch, doch werde
der Teil zurückgefordert, der damit nicht
vereinbar sei.
14
© Trimet
von vier Prozent der betrieblichen Brutto- europäischen Wettbewerbsrecht vereinbar ist.
wertschöpfung. Betriebe außerhalb der EU- Das über den Firmen schwebende DamoklesListe können ebenfalls begünstigt werden, Schwert der europäischen Beihilfepolitik sei
wenn ihre Stromkostenintensität, also das Ver- damit beseitigt. Die zwischen der EU-Komhältnis von Stromkosten zur
betrieblichen Bruttowertschöpfung, mindestens 20 Prozent
beträgt und sie einer Branche
mit mindestens vier Prozent
Handelsintensität angehören.
Die von Wirtschaftsminister
Sigmar Gabriel vorgelegte
EEG-Reform deckelt zudem
die Belastung für besonders
energieintensive Unternehmen
wie Alu-Hütten bei einer betrieblichen Bruttowertschöpfung von 0,5 Prozent.
Große Erleichterung: Die Hüttenproduktion von Aluminium hat
Oliver Bell, Präsident der auch unter den neuen EU-Beihilfeleitlinien in Europa eine Zukunft
Wirtschaftsvereinigung Metalle
(WVM), zeigte sich alles in allem zufrieden mission und Gabriel ausgehandelten SchwelDie EU-Leitlinien sehen vor, dass Unterneh- mit den neuen Regelungen. Der Entwurf zur lenwerte stellten „wirksame Entlastungen für
men aus 65 Branchen, die durch eine hohe Reform des Erneuerbare-Energien-Gesetzes besonders energieintensive Unternehmen
Handels- und Stromkostenintensität gekenn- (EEG) mit den geplanten Rabatten bei der dar“, so Bell.
Laut Gabriel werden künftig voraussichtzeichnet sich, begünstigt werden können. Ökostromumlage gefährde nicht die internalich
400 Firmen weniger als bisher unter die
tionale
Wettbewerbsfähigkeit
der
deutschen
Doch werden diese Industriebetriebe künftig
Ausgleichregelung
fallen. Derzeit sind rund
NE-Metallindustrie.
Dennoch
leiste
die
Instärker als bisher zur Finanzierung des Aus2.100
Unternehmen
begünstigt, die durch die
dustrie
einen
erheblichen
Finanzierungsbeibaus erneuerbarer Energien herangezogen.
Rabattregelung
insgesamt
gut fünf Milliarden
trag.
Positiv
sieht
der
WVM-Präsident,
dass
Sie müssen künftig 15 Prozent der EEG-UmEuro
sparen.
das
neue
EEG
künftig
vollständig
mit
dem
lage zahlen, aber nur bis zu einer Obergrenze
Der Industrieverband appellierte an die Politiker in Bund und Ländern, am ehrgeizigen
Zeitplan für die Gesetzesnovelle festzuhalten
Auszüge aus dem Statement von Wirtschaftsminister Gabriel
und das neue EEG am 1. August planmäßig in
anlässlich der Pressekonferenz zur beschlossenen EEG-Reform:
Kraft zu setzen. Gefordert seien vor allem die
Bundesländer. „Das EEG ist kein Gesetz der
giepreise
haben
…
„ ... Wir haben in Deutschland gut 45.000
Regionalförderung erneuerbarer Energien“,
Und
wenn
wir
in
diesen
Tagen
feststellen,
Betriebe, von denen nicht etwa 40.000 privisagte Bell. „Auch die Länder sind für den Erdass
es
Deutschland
wesentlich
besser
geht
als
legiert sind, sondern ganze 2.000 bisher. Also
halt der Wettbewerbsfähigkeit der gesamten
den
meisten
anderen
Staaten
um
uns
herum,
die Vermutung, die ganze deutsche Wirtschaft
Industrie verantwortlich.“
dann
hat
das
einen
wesentlichen
Grund:
Das
sei irgendwie mit Ausnahmen überzogen, ist
Hoffnungen, eine höhere Beteiligung der
23
Prozent
industrielle
Wertschöpfung
in
diefalsch. Denn von den 45.000 Betrieben sind
Industrie
an den Kosten für den Ausbau der
sem
Land
immer
noch
da
sind
und
nicht
wie
in
derzeit 2.000 von der besonderen Ausgleichsreerneuerbaren
Industrien könnte die BelastunFrankreich
knapp
über
zehn
Prozent
oder
wie
in
gel betroffen. Insgesamt trägt die Industrie zur
gen
der
Stromverbraucher
insgesamt verrinItalien,
glaub
ich,
rund
15
Prozent
...
EEG-Umlage derzeit 7,4 Milliarden Euro bei. Die
gern,
sind
nach
Ansicht
der
WVM nicht beUnd
um
mal
zu
sagen,
was
es
bedeuten
privaten Haushalte tragen ungefähr acht Millirechtigt,
da
das
neue
EEG
die
bestehenden
würde,
wenn
wir
überhaupt
keine
Ausnahmen
arden Euro bei, so dass man keinesfalls sagen
Anlagen
in
vollem
Umfang
weiterfördert
und
machen
würden
für
die
deutsche
Industrie:
kann, dass die Industrie nichts und die privaten
auch
bei
den
Neuanlagen
keine
einschneiWenn
wir
die
gesamten
fünf
Milliarden
Euro,
Haushalte alles dazu beitragen ...
denden Kürzungen vorsehe. Marktwirtschaftdie derzeit an Entlastung da ist, einnehmen
Wenn wir nicht wollen, dass wir in Deutschliche Instrumente seien im neuen Gesetz zuwürden und dann umlegen auf die EEG-Umlage,
land Arbeitsplätze im Stahl, in der Aluminiumdem nur in Ansätzen erkennbar oder würden
dann würde das für die deutschen Verbraucher
verhüttung, beim Kupfer, bei der Chemie, bei
durch großzügige Prämien abgesichert. Inbedeuten, dass vielleicht im Jahr bei einem 3Kunststoff – wenn wir diese Arbeitsplätze nicht
sofern sei das neue EEG allenfalls eine temPersonen-Haushalt, vielleicht 40 Euro im Jahr
verlieren wollen, dann müssen wir dafür sorgen,
poräre Strompreisbremse, weitere Reformen
gespart werden ...“
dass wir international wettbewerbsfähige Enermüssten folgen.
ALUMINIUM · 5/2014
ECONOMICS
Gute Konjunktur für
Aluverpackungen
Der Zuwachs bei den Ablieferungen verteilte
sich auf die verschiedenen Endmärkte wie
folgt: Alutuben + 4,7% und Alu-Aerosoldosen + 8,6%. Alufolien verzeichneten dagegen
einen Rückgang um drei Prozent.
Bei den Tuben führte der Marktausstieg
einiger europäischer Konkurrenten zu höheren Verkaufszahlen von deutschen Anbietern.
Bei Körperpflegeprodukten hält der Trend zu
kleineren Losgrößen und immer aufwendiger
geformten Dosen an. Dank des perfekten
Barriereschutzes von Aluminium gegen äußere Einflüsse und der positiven hygienischen
Eigenschaften werde der pharmazeutische
Markt für Tuben und Aerosoldosen weiterhin
wichtige Wachstumsimpulse bieten, so Gregor
Spengler, Leiter Verpackung beim GDA.
Bei den Alufolien entwickelten sich die
Marktsegmente Pharma und Süßwaren befriedigend, während die Nachfrage nach Molke-
Production of aluminium
aerosol cans on record level
Aerobal, the International Organisation of Aluminium Aerosol Container Manufacturers, has
reported a record result for 2013. With output
2% up to more than seven billion cans, the industry continued its upward trend. Aluminium cans
account for nearly 50% of the total worldwide
output of aerosol cans. The further prospects
for this packaging material are quite positive,
says Aerobal secretary general Gregor Spengler.
Whereas the European market seems compara-
ALUMINIUM · 5/2014
Alu-Kompetenzzentrum zur interpack
© GDA
Die Produktion von Verpackungen
aus und mit Aluminium hat sich 2013
in Deutschland dynamisch entwickelt.
In fast allen Marktsegmenten konnten
deutliche Zuwachsraten erzielt werden.
Insgesamt profitierte die Branche von der
allgemein guten Konsumstimmung. „Die
Verbraucher setzen hohes Vertrauen in
eine positive wirtschaftliche Entwicklung. Das unterstützt den Konsum, und
die Nachfrage nach unseren Produkten
wächst“, erklärte Christian Wellner, Geschäftsführer des Gesamtverbandes der
Aluminiumindustrie (GDA), Düsseldorf,
und ergänzt: „Die guten Auftragseingänge bei den Aluminium-Verpackungsherstellern zu Beginn des Jahres stellen die
Wachstumsampel auf Grün.“
cher greifen zur Dose – von Bier über Soft-,
Mix- und Wellness-Drinks bis hin zu Wein
und Prosecco. Auch die großen Supermarktketten, die vermehrt kleine City-Märkte für
die Einkaufsmöglichkeit auf der Durchreise
oder dem Nachhauseweg eröffnen, setzen auf
kleine, verbraucherfreundliche Verpackungseinheiten wie die Getränkedose.
Optimismus für 2014: Angesichts des guten Jahresstarts mit teilweise zweistelligen
Wachstumsraten blicken die Hersteller von
Aluverpackungen optimistisch auf das erste
Halbjahr 2014. „Bei der Getränkedose erwarten wir zusätzliches Marktpotenzial durch
die Fußball-Weltmeisterschaft, wo beim Public Viewing aus Sicherheitsgründen auf Glas
verzichtet wird“, so Spengler.
Immer mehr Verbraucher greifen zur Getränkedose
reiprodukten und Lebensmitteln teils deutlich
rückläufig war. Folien und dünne Bänder aus
Aluminium litten mit ihrem hohen Exportanteil unter der konjunkturellen Krise der Volkswirtschaften in Europa.
Alu-Getränkedose auf dem Vormarsch
Sehr zufrieden zeigt sich der GDA mit der
Entwicklung bei der Alu-Getränkedose. „Getränkedosen sind auf dem Vormarsch, der
Aufwärtstrend setzt sich weiter fort“, hob
Wellner hervor. Insgesamt wurden 2013 in
Deutschland 3,5 Prozent mehr Getränkedosen
aus Aluminium und Weißblech verkauft, das
liegt über dem europäischen Durchschnitt.
Aluminium, so der GDA, profitiert von
diesem Trend überdurchschnittlich, da einer
der beiden großen Anbieter in Deutschland
seine Dosenlinien von Weißblech auf Aluminium umgestellt hat. Immer mehr Verbrau-
tively saturated, there is substantial potential
for growth in the emerging markets of Asia and
South America. About 80% of total production
continues to go to cosmetics; the remaining part
aims at the pharmaceutical and food industries.
European tube industry
continues expanding
The manufacturers of aluminium, plastic and
laminate tubes belonging to the European Tube
Manufacturers Association (etma) managed once
Einen Konjunkturschub für die Aluminiumverpacker erwarten die GDA-Mitgliedsfirmen von der interpack 2014, der weltgrößten
Packmittelmesse. Zahlreiche Branchenunternehmen werden auf der Messe in Düsseldorf
vom 8. bis 14. Mai 2014 ihre Innovationen
und Verpackungssysteme vorstellen.
Auch der GDA präsentiert sich mit einem
eigenen Messestand in Halle 11, Stand A 37.
Mitaussteller sind die unter dem Dach des
GDA geführten Packmittelverbände für die
Tube (etma) und die Aerosoldosen (Aerobal).
Auch die Deutsche Aluminium Verpackung
Recycling GmbH (DAVR) ist mit im Bunde.
Die Verbände informieren auf der interpack
über ihre Serviceleistungen und beraten als
Aluminium-Kompetenzzentrum über die
verschiedenen Anwendungen des Werkstoffs
im Verpackungssektor. Zentrale Themen auf
dem Gemeinschaftsstand sind Marktentwicklung, Nachhaltigkeit und Recycling. Zudem
werden zahlreiche Beispiele innovativer und
intelligenter Verpackungen aus und mit Aluminium präsentiert.
more to achieve growth in 2013. The output of
etma members totalled almost 10.5 billion tubes
(+1%). Aluminium tubes account for 40% of the
total European production output.
Gregor Spengler, etma secretary general, commented: “The long-term stable trend for tubes in
a still difficult economic climate is what makes us
so confident. Our member companies have given
impressive proof in recent years that they can
fully satisfy the demands of their customers for
ever-shorter production times and smaller batch
sizes, for ever-more flexible delivery conditions
and tougher quality standards.”
15
ECONOMICS
The High Court vs. LME rules – What might be the repercussions?
G. Djukanovic, Podgorica
Long awaited new warehouse delivery
rules will not be implemented yet by the
London Metal Exchange (LME), after The
High Court in London ruled in favour of
UC Rusal. The reforms were announced
in November last year and scheduled to
start on 1 April; however, the Russian
aluminium producer launched a lawsuit,
motivated by concern that the current
record high aluminium premiums would
fall in response to the LME’s measures
to make owners of warehouses in the
exchange’s global network deliver metal
more quickly to consumers. Consumers
and manufacturers were disappointed by
The High Court decision whereas shares
of the primary aluminium producers
Alcoa, Hindalco and others rose sharply
on the news (Alcoa 52-week high). Premiums have not increased immediately in
reaction to the news, but any falls in the
short term are unlikely, traders say.
This came as a surprise for most of those involved in the aluminium market, from producers via traders and analysts through to
final consumers. “It’s a huge surprise,” said
Nic Brown, head of commodities research at
16
Natixis SA in London. He expects the ruling
will push aluminium prices lower and premiums higher. “This is something the LME desperately needed to do, to restore some credibility to the aluminium market. It will result,
at the very least, in a delay before the rules
can be implemented,” he said according to
Bloomberg.
The LME now has to decide whether to
appeal or to go through the consultation process again, both of which may take some time.
LME said that other reforms would go ahead,
including a logistical review, a new physical
markets committee and new position data. The
reforms, intended to reduce artificial backlogs
that inflate the cost of the metal, need to be
reviewed in further consultations between the
LME, warehouse owners and consumers. In
the meantime aluminium premiums will remain elevated and queues at warehouses may
become even longer.
Earlier, Rusal had warned that the proposed
reforms of the LME’s warehousing policy
could cost the company “at the very least tens
of millions of pounds”. Rusal sought a judicial
review on three grounds: procedural unfairness, failure to undertake a sufficient inquiry
and a breach of its human rights. The judge
said he found the LME’s
consultation “to have
been unfair and unlawful
on the first two grounds
advanced by Rusal.”
He added that the third
ground was “plainly arguable”. The LME said it
was disappointed by the
ruling: “The court found
in favour of Rusal on
one specific procedural
issue, that the consultation should have encompassed or made reference
to the option of banning
or capping rent in
queues,” the LME stated.
However, that is a
contentious issue. “The
LME cannot set rents
because of clear competition issues,” David
Wilson, an analyst at
Citigroup, said in a phone
interview to Bloomberg.
“The judge is almost saying, ‘we want you to look
at the option that appears to contradict competition rules’. Uncertainty on rules is not good
for the market.”
How it started
The LME, which licenses about 700 warehouses worldwide, said in November that it
would require storage operators where withdrawals took more than 50 calendar days to
ship out more metal than they take in, as part
of a package of warehousing reforms. Many
consumers have been waiting for the implementation of new rules in the hope that premiums will then fall. Now they may rush to
buy before premiums possibly increase even
higher.
Since the global financial crisis in 2009,
stockpiling of aluminium has become a highly
profitable business for large banks and commodity trading companies that own warehouses, due to the long-term financial deals
and low interest rates. This has led to a rise
of inventories, long delays for the release of
metal from warehouses and increasing premiums, while banks and traders have profited
from rents on metal in warehouses.
The LME first responded to concerns
about the queues in October 2010, when it
commissioned Europe Economics to prepare
an independent assessment on whether the
then-existing load-out rates were satisfactory.
A summary of the review findings were published in May 2011, and the following actions
were taken:
• In November 2011, the LME announced an
increase in the minimum load-out rates, which
took effect on 1 April 2012.
• In August 2012, the LME confirmed the additional delivery out rates for nickel and tin,
which took effect on 1 April 2013.
• In December 2012, the LME introduced
additional requirements on warehouse companies to address the effect that long queues
for one metal may have on the availability of
other metals. This also took effect on 1 April
2013.
Several antitrust lawsuits were filed last
year on behalf of dozens of US aluminium
consumers, such as beverage can producers
and extruders, accusing banks, trading companies and the LME of conspiring to reduce
aluminium availability and increase aluminium prices and premiums by manipulating
warehouse inventories.
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of Vlissingen in The Netherlands, home to
warehouses holding the biggest combined inventory of LME aluminium, and the waiting
time is 20.7 months at locations in Detroit,
the second-largest, according to Texas-based
research house Harbor Intelligence. Premiums
added to the LME aluminium price reached a
record in Europe and the US in the first two
months of 2014, and they are at an all-time
high in Japan.
In a 70-page slideshow seen by Reuters,
the LME showed charts demonstrating that
waiting times have dwindled since last summer for three out of the five locations that had
big stockpiles (queues greater than 50 calendar days). It could be concluded (according to
the charts) that the warehouse games were
over. In the other two locations, however,
the queues have lengthened to between 550
and 650 calendar days, the charts showed.
Although the cities were not named, it is not
hard to conclude they were Detroit, where a
third of the LME’s 5.3 million tonnes of aluminium is held by Metro, owned by Goldman
Sachs, and Vlissingen, where Pacorini, which
is owned by GlencoreXstrata, operates sheds.
A new aluminium contract
High premiums and the Court’s decisions to
put the LME plan on hold will be beneficial for
the aluminium contract planned by the CME
Group, owner of the world’s biggest futures
exchange. This might be the main repercussion
of the Court’s decision in the near future and
lead to decreasing LME shares in metal trade
and, in parallel, to falling premiums. CME is
in the process of preparing and convincing
consumers and traders to upend three and
a half decades of LME pricing and switch to
CME’s upstart contract.
The CME’s director of metals research,
Young-Jin Chang, said at a conference in
March that three formats of aluminium – ingots, sows and T-Bars – will be deliverable
against the contract. The new contract will
start physically-delivered North American
aluminium futures on 6 May and has the approval of at least one large consumer of aluminium, MillerCoors, which uses the metal
to make beverage cans and has criticised
LME’s handling of the problem. “This is their
best opportunity to try and grab some liquidity from the LME,” Natixis’ analyst Brown
said. “At the moment, the liquidity is still
firmly with the LME.” The CME started aluminium premium swap futures in 2012 that
are cash-settled. The LME will continue working on a potential contract to hedge premiums,
it said in a notice to members. Aluminium is
18
the most active LME contract, with 66.6 million futures and options traded last year. Each
futures contract is for 25 tonnes.
The LME expects to launch its new aluminum premium contract by Q1 2015 at the latest, CEO Garry Jones said in April.
Regulators expected to act
The LME is regulated by the UK’s Financial
Conduct Authority, but the CFTC (US Commodity Futures Trading Commission) has jurisdiction over its US business. Commodities
trade houses will come under increased scrutiny by Britain’s Financial Conduct Authority (FCA) as those firms play an increasingly
critical role in the global economy, FCA director of Markets, David Lawton, said in a
report published in March. The FCA said it
would keep a close eye on commodities warehousing to ensure that reforms in storage policies by the LME and NYSE Liffe are carried
out effectively.
A series of meetings during March between
the new LME (by the new CEO Garry Jones)
and its staunchest critics in the US (Novelis,
MillerCoors and The CocaCola Co.) resulted
in a small but significant shift in a years-long
crisis over the exchange’s warehousing policy,
according to sources who attended the meet-
ings. It seems there is a growing recognition
that the LME may have reached the limit of
what it can do. Mr Jones was cited saying:
“We understand your argument and we don’t
disagree with you. The queues are bad for us
too because it damages our price mechanism,
but we can’t make a rash change,” according to
the source following the Chicago meeting.
After The High Court decision, the hope
is that US regulators and politicians will take
up the fight for even tougher oversight of the
world’s oldest and biggest metals market and
its warehousing network, sources say. The
Beer Institute, whose members include MillerCoors and Anheuser-Busch InBev, will ask US
policymakers and regulators to increase oversight of LME warehousing as the exchange
has “difficulty self-regulating”.
After all, it is not excluded that The High
Court’s decision will initiate decisive and even
stronger reactions, especially by US regulators, to solve warehousing problems. Finally,
it may encourage US courts to order compensation to consumers.
Author
Goran Djukanovic is an aluminium market analyst.
He is located in Podgorica, Montenegro. Email:
[email protected].
Novelis reacts to verdict in Rusal lawsuit against LME
After the UK High Court decided to uphold
certain aspects of the complaint by UC Rusal and
subsequently quash the LME’s proposal to implement new load-in load-out rules, Phil Martens,
president and CEO of Novelis, stated: “We are
very disappointed with the outcome of the legal
process in the UK. We have worked closely with
the LME and other stakeholders for two-and-ahalf years to push for changes. Unfortunately,
Rusal’s unilateral action resulting in this court
decision will stifle the LME’s proposal to alleviate
the unprecedented backlog at LME warehouses
and will be very destructive to the market.”
He went on: “It is indefensible that queues of
more than a year exist at warehouses and unconscionable that players in the aluminium market
are actively working to maintain the status quo
to protect artificially inflated premiums. The divergence between the LME price and the physical
market price is undermining the credibility of the
industry’s pricing discovery process and causing
havoc in the fabricating and consuming end of
the industry. This is a global issue.
“Primary aluminium producers, traders and
banks have created an artificial global shortage
and driven spot premiums to ridiculously high
levels. The change in the LME load-out rate was
intended to restore equity in the LME system and
remove the queues which are directly responsible
for driving up the premiums in the first place.
“This recent legal action taken outside of the
LME’s consultation process is grievous – it sanctions the continuation of this destructive regime.
At the same time, the producers are continuing
to make outsized windfall gains, which a year
ago we estimated to be USD3 billion, but are
now twice that level. This exploitation of an
artificial market squeeze appears to us to be
blatant, and the effects are being felt further
down the supply chain and ultimately by the
end consumer.
“Novelis had hoped that the LME changes
together with possible regulatory actions would
identify any wrong doing that may have taken
place and dramatically improve the scrutiny of
the market and market convergence. The court
decision, unfortunately, throws yet another
wrench in the works and does nothing to settle the ongoing supply chain risk to aluminium
fabricators and beverage marketers and other
customers where premiums are at the highest
levels in history.”
ALUMINIUM · 5/2014
ECONOMICS
G. Djukanovic, Podgorica
The low aluminium LME price and high
input costs, especially for electricity, have
brought Aluminij Mostar to the brink of
bankruptcy. The aluminium plant has
been under constant threat of curtailing
production as it is short of money to pay
its bills for electricity and raw material
feedstock, such as alumina and petrolcoke. This situation is reminiscent of
Montenegro’s KAP, which went bankrupt
last summer.
Hope now rests with the federal government
of Bosnia and Herzegovina (with the Bosnian-Croat Federation entity to be precise),
although it has limited financial resources to
help. Aluminij’s management claims that at
€52/MWh its costs for electricity are the highest for aluminium smelters in Europe. That
means electricity accounts for over 50% of
total production cost. Aluminij is currently
losing USD600/tAl produced, says the management.
Total debts and obligations amounted
to nearly €200m at the end of last year, of
which around €110m were bank loans. The
local power utility, Elektroprivreda Hrvatske
Zajednice Herceg-Bosne (EP HZHB) blocked
the company’s bank account on 1 April as
non-paid electricity bills had reached 88.4m
Bosnian marks (€44m) at the end of February. The utility is threatening to reduce the
electricity supply to Aluminij, which would
lead to production cuts. The debt for electricity reportedly exceeds the company’s book
value, estimated to be some €38m. Željko
Kordic, Aluminij’s general manager, cannot
see any obvious solution. He has offered to
step down, but the supervisory board reject-
ed his resignation at its
meeting on 8 April. The
prime minister of Croatia, Ivo Josipovic, has
promised to help Aluminij Mostar to survive,
which is most likely the
main reason why Kordic
decided to remain ‘on
board’.
The president of the
Bosnian-Croat Federation, Živko Budimir, said
it was not only high electricity costs that were to
blame for the difficult
situation at Aluminij Mostar: bad (resource)
management was also a factor and adverse
supply and sales contracts had contributed
to the rising debt pile and the imminent insolvency. He concluded that only mutual efforts by experts and politicians could save the
company from bankruptcy and closure.
Aluminij Mostar’ net loss in 2013 was
around €43m (2012: 33.7m). Total revenues
were €263m. The company sells some 60,000
tpy of aluminium to the Croatian rolling mill
TLM in Sibenik, mostly as slabs but also as
billets. Some ten percent of total production
is sold to local extruders, while the rest is
delivered to GlencoreXstrata under a longterm contract. Aluminij employs 856 people
and its production capacity is around 160,000
tpy (130,000 tpy of primary aluminium,
mostly Al 99.8). Production capacity of baked
anodes is around 73,000 tpy and average net
consumption of anodes is 412 kg/tAl. Electricity consumption is 13.9 kWh/kgAl.
Muslim-Croat Federation officials and Aluminij’s private shareholders agreed in June
2013 to split the stake in the firm to 44%
© Aluminij Mostar
Can Aluminij Mostar avoid bankruptcy?
Aluminij Mostar’s casthouse
each, ending a dispute dating back to the end
of Bosnia’s 1992-95 war. In return the government obligated itself to support Aluminij
in securing cheaper electricity supplies. The
Croatian government owns the remaining
12%.
The difficult patch that Aluminij is currently going through is exactly the same as the
one Montenegro’s KAP experienced before
declaring bankruptcy last summer: inability
to pay electricity bills and the need for state
aid (subsidised electricity prices, guarantees
to banks for debt), with both companies claiming to be indispensable for the local community and the country’s economy and therefore
needing to be kept operating. The two companies have something else in common: the high
salaries paid to top management. According to
CCI, a local NGO, top managers at Aluminiij
Mostar net 6,500 to 12,000 euros per month,
similar to those at KAP before it went bankrupt – and this despite the huge losses both
companies have piled up over the years.
The future of Aluminij Mostar depends
largely on substantially higher LME aluminium prices (which are not very likely this year
or next), a much lower electricity price (but
there is no cheap power source on the horizon) and continued and substantial support by
the federal government. However, this support is financially weak and will not be of
much help if the aluminium price remains low
and power costs stay high.
Author
Electricity consumption at Aluminij Mostar is 13.9 kWh/kgAl
20
Goran Djukanovic is an aluminium market analyst.
He is located in Podgorica, Montenegro. Email:
[email protected].
ALUMINIUM · 5/2014
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Schmelzen, gieSSen und Wärmebehandeln
40 Jahre Hertwich Engineering
mit starken Produkten ins nächste Jahrzehnt
b. rieth, meerbusch
Hertwich Engineering – 40 years old
into the next decade with powerful products
B. Rieth, Meerbusch
At the 40th anniversary of Hertwich
Engineering GmbH in Braunau, Austria,
the company shows outstanding form.
Occasional market downturns in the aluminium industry could and can still be
overcome by the company thanks to its
successful products and marketing strategy, and it always offers the market new
and advanced products for the economical and quality-orientated melting, casting
and homogenising of aluminium semis.
For Franz Niedermair, CEO of Hertwich
Engineering for many years, the anniversary is an opportunity to look back, not
without pride, on market successes so
far but at the same time, in a talk with
our editor, to lay down clear lines for the
further development of the company and
the market.
After working for seven years as a design and
development engineer at Aluminium Ranshofen (now Amag) and SAG (Salzburger
Aluminium Gesellschaft), Günther Hertwich
decided to start his own business in Braunau, the centre for aluminium production and
machining in Austria. His first orders were
for the construction of a horizontal casting
machine and other special machinery for the
metals industry.
Already in 1980 the young company could
present to the technical world the first fully
© Hertwich Engineering
Zum 40-jährigen Jubiläum der Hertwich
Engineering GmbH in Braunau, Österreich, zeigt sich das Unternehmen in hervorragender Verfassung. Gelegentliche
Marktschwächen der Aluminiumindustrie
konnte und kann das Unternehmen
weiterhin dank der erfolgreichen Produkt- und Marktstrategie meistern und
dem Markt immer wieder neue und
weiterentwickelte Produkte zum wirtschaftlichen und qualitätsorientierten
Schmelzen, Gießen und Homogenisieren
von Aluminiumhalbzeug anbieten. Für
Franz Niedermair, den langjährigen CEO
von Hertwich Engineering, ist das Jubiläum ein Anlass, nicht ohne Stolz auf
die bisherigen Erfolge im Markt zurückzublicken, gleichzeitig aber auch in dem
Gespräch mit unserer Redaktion klare
Linien für die weitere Entwicklung des
Unternehmens und des Marktes aufzuzeigen.
Durchlaufhomogenisierungsanlage
22
Continuoushomogenisingplant
ALUMINIUM · 5/2014
SPecial
integrated continuous homogenising unit,
destined for Amag. This order was soon followed by smaller and larger plants for VAW
and other aluminium producers. A unit supplied to Hydro in Norway in 1988 had already achieved a capacity of 110,000 tonnes
a year. What could better underline the importance of continuous homogenising than
the fact that today, at Dubal in the UAE, of
the 1.1 million tonnes of primary aluminium
melted each year up to 800,000 tonnes are
processed as extrusion logs and billets in four
continuous homogenising units manufactured
by Hertwich?
Looking back, this development can be
identified as the first milestone for Hertwich
Engineering. In the next few years that product was literally devoured by the market. So
far the company has built more that 120 continuous homogenising units worldwide for
extrusion logs and billets – about half of them
for primary smelters and the rest for secondary smelting plants. On this, Mr Niedermair
says: “With the continuous homogenising furnace, at that time we took off from a standing start and achieved a breakthrough on the
world market. That technology has sustained
the company’s development for many years
and is even today still an important part of
our portfolio.” Of the more than 120 units
built, over 110 are still in use and so create the
prerequisite for producing six to eight million
tonnes of reliably constant quality each year.
Like all technical products, so too the
continuous homogenising has an initially rising and then declining life cycle. In this case,
however, that has nothing to do with the development of any better follow-up technologies, but quite simply results from the fact that
with a market share of over 90 percent Hertwich has virtually saturated the relevant
market for this technology. The reference list
reads like a Who is Who of the aluminium
industry. In the smelter sector all the noted
plants in Europe, North America and the
Near East are on that list, but so too are major
extrusion plants which, to ensure their quality,
operate remelting and billet casting plants of
their own and do not wish to forego the advantages of continuous homogenising.
In the context of continuous homogenising Mr Niedermair reports another interesting
development – the rebirth of batch homogenising. The growing proportion of qualitatively
high-grade extruded products, for example
for the automotive and aviation industries,
often demands individual treatment for special alloys which are mostly produced in small
batch sizes or which require very long holding times. For this, chamber furnaces have
ALUMINIUM · 5/2014
m e lt i n g , c a S t i n g a n d h e at t r e at m e n t
Im Jahr 1974 entschloss sich Günther Hertwich nach siebenjähriger Berufserfahrung als
Konstrukteur und Entwicklungsingenieur bei
Aluminium Ranshofen (heute Amag) sowie
der Salzburger Aluminium Gesellschaft, sich
Batchhomogenisingfurnace
im österreichischen Braunau, einem Zentrum
der Aluminiumherstellung und Bearbeitung,
selbständig zu machen. Schwerpunkt war
eine horizontale Gießmaschine und andere
Sondermaschinen für die Metallindustrie.
Bereits 1980 konnte das junge Unternehmen der Fachwelt die erste durch Amag
beauftragte voll integrierte Durchlaufhomogenisierungsanlage vorstellen. Dieser folgten
rasch weitere kleinere und größere Anlagen
für VAW und andere Aluminiumproduzenten.
Eine 1988 an Hydro in Norwegen gelieferte
Anlage hatte bereits eine Kapazität von
110.000 Jahrestonnen. Was könnte die Be-
FranzNiedermair,Geschäftsführer
ManagingdirectorFranzNiedermair
deutung der Durchlaufhomogenisierung besser unterstreichen als die Tatsache, dass bei
Dubal in der UAE heute von den erschmolzenen 1,1 Mio. Tonnen Primäraluminium bis zu
800.000 Tonnen als Strangpressstangen und
Kammerhomogenisierungsanlage
-bolzen unter anderem in vier Durchlaufhomogenisierungen von Hertwich bearbeitet
werden.
Rückblickend kann man diese Entwicklung
als den ersten großen Meilenstein für Hertwich Engineering bezeichnen. Dieses Produkt
wurde in den Folgejahren vom Markt buchstäblich aufgesogen. Bis heute hat Hertwich
weltweit über 120 Durchlaufhomogenisierungsanlagen für Strangpressstangen und -Bolzen gebaut – je etwa zur Hälfte für Primärhütten und Umschmelzgießereien. Niedermair hierzu: „Mit der Durchlaufhomogenisierung haben wir damals nahezu aus dem Stand
den Durchbruch auf dem Weltmarkt geschafft.
Diese Technologie hat die Entwicklung des
Unternehmens über viele Jahre nachhaltig
getragen und ist auch heute noch ein wichtiger Bestandteil unseres Portfolios.“ Von den
mehr als 120 gebauten Anlagen sind noch immer über 110 im Einsatz und bilden damit die
Voraussetzung dafür, dass jährlich sechs bis
acht Millionen Tonnen Stangen und Bolzen in
zuverlässig gleichbleibender Qualität erzeugt
werden.
Wie alle technischen Produkte unterliegt
auch die Durchlaufhomogenisierung einem
auf- und absteigenden Lebenszyklus. Im
vorliegenden Fall hat das aber nichts mit der
Entwicklung eventuell besserer Nachfolgetechnologien zu tun, sondern ganz einfach
damit, dass Hertwich mit einem Marktanteil
von über 90 Prozent den für die Technologie
relevanten Markt praktisch gesättigt hat. Die
23
Schmelzen, gieSSen und Wärmebehandeln
Referenzliste liest sich wie das Who is Who
der Aluminiumbranche. Hüttenseitig sind alle
prominenten Werke in Europa, Nordamerika
und dem Nahen Osten vertreten. Aber auch
große Strangpresswerke, die zur Sicherung
ihrer Qualität ein eigenes Umschmelzwerk mit
Bolzengießerei betreiben, wollen nicht auf
die Vorteile der Durchlaufhomogenisierung
verzichten.
Im Kontext der Durchlaufhomogenisierung berichtet Niedermair von einer anderen interessanten Entwicklung – der Renaissance der Kammerhomogenisierung. Der
zunehmende Anteil qualitativ hochwertiger
Strangpresserzeugnisse, zum Beispiel für die
Automobil- und Luftfahrtindustrie, verlangt
oftmals nach einer individuellen Behandlung
besonderer Legierungen, die zumeist nur in
kleinen Losgrößen anfallen oder sehr lange
Haltezeiten verlangen. Hierfür hat sich die
Kammerhomogenisierung als die deutlich
flexiblere Lösung erwiesen. Kunden, die vor
Jahren ausschließlich auf die Durchlaufhomogenisierung setzten, haben diese inzwischen
teilweise um Einrichtungen zur Kammerhomogenisierung erweitert. Die neuen Kammerhomogenisierungsöfen von Hertwich gelten
heute als technologische Benchmark. Effiziente „High-speed Reverse-air“-Technik mit
Umschaltzeiten von nur 2 bis 3 Sekunden und
einer Genauigkeit der Temperaturführung im
Bereich von ± 2 °C in der Haltephase, erzeugt
über die Reibungswärme der Umwälzung, sowie die Automatisierung zum Beispiel des
variablen Spacer-Handlings sorgen dafür,
dass die neuen Kammeröfen nahezu an die
Performance der Konti-Anlagen herankommen. Der aktuelle Trend ist, Durchlauf- mit
Kammerhomogenisierung in einer Anlage
voll automatisiert zu verbinden und die Stangen einer gemeinsamen Prüf- und Sägenlinie zuzuführen (s. ALUMINIUM 09/12 und
10/12). Das heißt, aus dem ursprünglichen
Wettbewerb der Systeme wird eine Partnerschaft zum Nutzen der Betreiber.
ein neuer meilenstein
Durchlaufhomogenisierungen haben in den
Jahren zwischen 1988 und 2002 nicht nur
den Geschäftsverlauf der Hertwich Engineering entscheidend getragen, sondern mit dem
verdienten Geld dazu beigetragen, dass das
Unternehmen neue Produkte für die Aluminiumindustrie entwickeln konnte, mit denen
es inzwischen Weltgeltung erlangt hat. Gemeint sind komplette Mehrkammerschmelzund Gießanlagen für Walzbarren und Strangpressstangen. Bei letzteren kommt der Durchlaufhomogenisierung nach wie vor große Bedeutung zu, wobei die Kombination der Aggregate zum Konzept der „Kompakt-Umschmelzanlage“ (Compact Type Remelt Plant,
CTRP) führte. Hatten die Konti-Anlagen in
der Spitze einen Anteil von 80 Prozent am
Hertwich-Umsatz, sind das heute noch rund
20 Prozent, allerdings bei einem gewachsenen Auftragsvolumen. Schmelz- und Gießan-
AufstellungsübersichteinerautomatisiertenHomogenisierungsanlage,dieKammer-undDurchlaufofen
miteinanderkombiniert/Schematicconfigurationofanautomatichomogenisingunit,whichcombines
batchandcontinuoushomogenisingfurnaces
24
proved to be a substantially more flexible solution. Customers who some years ago used
continuous homogenising furnaces exclusively have since partially extended these with
equipment for batch homogenising. The new
batch homogenising furnaces manufactured
by Hertwich are today regarded as the technological benchmark. Efficient ‘high-speed reverse-air’ technology with switch-over times
of only two to three seconds and a temperature control precision in the range of ± 2°C
during the holding phase, produced by the
frictional heat of the recirculation, and the
automation for example of the variable
spacer handling, ensure that the new batch
furnaces almost match the performance of
Conti-units. The current trend is to combine
continuous and batch homogenising units in a
fully automated plant and then pass the logs
on to a conjoint inspection and sawing line
(see ALUMINIUM 09/12 and 10/12). This
means that from the initial competition between these systems a partnership to the benefit of the operator has been created.
a new milestone
In the years between 1988 and 2002 continuous homogenising systems not only decisively sustained the course of business for Hertwich Engineering, but with money earned
from that contributed toward the company’s
activity in developing new products for the
aluminium industry, with which it has since
then achieved worldwide recognition. This refers to complete multi-chamber melting and
casting units for rolling ingots and extrusion
logs. In the latter case continuous homogenising is still very important, and this has led
to the concept of the Compact type Remelt
Plant (CTRP). Whereas at their peak Contiunits accounted for 80 percent of Hertwich’s
turnover, this has now declined to around 20
percent but with a larger volume of orders.
Melting and casting plants nowadays account
for 60 to 70 percent and are therefore Hertwich’s new cash cow.
The melting and casting plant product is of
major economic importance for the company
for another reason: a complete plant for melting, casting and homogenising, with an order
volume about ten times as large, nevertheless entails processing only a single order and
only mobilising one site.
In its own self-image Hertwich supplies
melting and casting plants as a ‘system-integrating plant manufacturer’ according to need,
in a variety of designs. The basic components
are always the Ecomelt melting furnace, the
horizontal or vertical casting machine, a con-
ALUMINIUM · 5/2014
SPecial
HertwichEcomeltPS-120atImpolinSlovenia
tinuous and / or batch-type homogenising unit
and the ultrasonic testing equipment, saws
and packing machinery. Typical of that product line is a complete remelt plant (turnkey)
supplied by Hertwich in 2010 to Hammerer
Aluminium Industries (HAI) in Romania.
With a production capacity of 80,000 tonnes
a year, that plant is now regarded as world’s
most modern melting and casting plant. Its
reputation as a reference has already generated further orders for Hertwich, such as most
recently a similar plant for the new Talex extrusion plant in Abu Dhabi.
The plant in Romania is a fully automated
casthouse for which Hertwich supplied everything from the scrap store to the ready packed
extrusion billets. “For such a remelt plant”,
explains Mr Niedermair, “we also write the
automation program as far as the integration
of Levels 2 and 3.” In cooperation with HAI,
Hertwich also integrated the scrap optimisation process in the L3 control level. The system recognises the various types of scrap in
the scrap store and decides the proportions in
which these are to be charged into the melting furnace in order to produce a particular
new alloy. “We provide the operator not only
with the hardware, but also the plant organisation as a whole. The central HAI desk in
Braunau knows, in real time and with a glance
at the monitor screen, what is happening at the
plant in Romania”, says Mr Niedermair.
For Hertwich the development of the melting furnace is very important. “I deliberately
say multi-chamber and not two-chamber furnace, since with our development of scrap preheating and the submersion melting process
ALUMINIUM · 5/2014
m e lt i n g , c a S t i n g a n d h e at t r e at m e n t
HertwichEcomeltPS-120beiImpolinSlowenien
lagen liegen heute dafür bei 60 bis 70 Prozent
und sind damit Hertwichs neue „Cash Cow“.
Das Produkt Schmelz- und Gießanlagen ist
aus einem weiteren Grund von großer wirtschaftlicher Bedeutung für das Unternehmen: So bedeutet eine Komplettanlage zum
Schmelzen, Gießen und Homogenisieren bei
etwa zehnfachem Auftragsvolumen trotzdem
nur eine Auftragsabwicklung und nur eine Mobilisierung der Baustelle.
Schmelz- und Gießanlagen liefert Hertwich
in seinem Selbstverständnis als „systemintegrierender Anlagenbauer“ bedarfsorientiert
in unterschiedlichen Ausführungen. Grundkomponenten sind jeweils der EcomeltSchmelzofen, die Horizontal- oder VertikalGießmaschine, eine Durchlauf- und / oder
Kammerhomogenisierung sowie die Ultraschallprüfung, Säge- und Verpackungsanlage.
Repräsentativ für diese Produktlinie ist ein
komplettes Umschmelzwerk (Turnkey), das
Hertwich 2010 an Hammerer Aluminium
Industries (HAI) in Rumänien lieferte. Mit
einer Jahreskapazität von 80.000 Tonnen
gilt dieses Werk als die derzeit weltweit modernste Schmelz- und Gießanlage. Ihre Referenzwirkung hat bereits weitere Aufträge für
Hertwich generiert, wie zuletzt eine ähnliche
Anlage für das neue Strangpresswerk Talex
in Abu Dhabi.
In Rumänien handelt es sich um eine voll
automatisierte Gießerei mit einem Lieferumfang von Hertwich, der vom Schrottplatz bis
zum fertigen verpackten Pressbolzen reicht.
„Für ein solches Umschmelzwerk schreiben
wir auch die Automatisierungsprogramme bis
zur Integration von Level 2 und 3“, so Nieder-
mair. In Zusammenarbeit mit HAI hat Hertwich auch die Schrottoptimierung in die L3Steuerung integriert. Das System kennt die auf
dem Schrottplatz lagernden unterschiedlichen
Schrottarten und entscheidet, in welchen Anteilen diese am Schmelzofen chargiert werden,
um eine bestimmte neue Legierung herzustellen. „Wir liefern dem Betreiber nicht nur die
Hardware, sondern die gesamte Organisation.
Die HAI-Zentrale in Braunau weiß in Echtzeit
beim Blick auf den Bildschirm, was im Werk
in Rumänien abläuft“, so Niedermair.
Große Bedeutung hat für Hertwich die Entwicklung der Schmelzöfen. „Ich sage bewusst
Mehrkammer- und nicht Zweikammerofen,
da wir mit unserer Entwicklung der Schrottvorwärmung und des Tauchschmelzverfahrens der konventionellen Schmelztechnik
für Post-consumer-Schrotte um Jahre voraus
sind“, so Niedermair, und fährt fort: „Für uns
zählt in erster Linie neben Faktoren wie Energieeinsparung und Umweltverträglichkeit die
höchstmögliche Metallausbeute.“ Auch wenn
man bei Hertwich den Faktoren Energieverbrauch und Umweltverträglichkeit bei der
Produktentwicklung hohe Aufmerksamkeit
schenkt, so wichtig ist Niedermair der Energieinhalt im Aluminium. „Wir setzen in erster
Linie auf eine höchst mögliche Metallausbeute. Deren Wert relativ zum Wert der Energie
ist deutlich höher. Ein Prozentpunkt mehr in
der Metallausbeute bedeutet bei einem Recyclingvolumen von 40.000 Jahrestonnen einen
Gewinn in der Größenordnung von deutlich
über einer halben Million Euro.“ Auch bei der
Krätze sieht Niedermair den wirtschaftlichen
Erfolg nicht in deren Behandlung, sondern
in deren Minimierung. Hertwich’s Ziel lautet deshalb: Reduzierung der Oxide. Erreicht
wird dies durch das Tauchschmelzverfahren,
bei dem der zugeführte Schrott im bereits
flüssigen Aluminium geschmolzen wird, was
die Karbidbildung unterdrückt und die Oxidbildung stark einschränkt.
Niedermair’s Credo für Umschmelzanlagen lässt sich in dem Satz zusammenfassen:
„Durch das Erreichen höchster Qualität sollen aus Schrotten wieder Wertstoffe werden.“
Das Ziel ist, aus Dosenschrott wieder hochwertiges Dosenband herzustellen und damit
einem Downgrading zu minderen Produkten
entgegenzuwirken. Als jüngstes Beispiel nennt
er einen für Audi gebauten Mehrkammerofen, der dort aus Rücklaufmaterial aus der
eigenen Gussteilefertigung wieder hochwertiges Metall für den Druckguss erzeugt.
Jüngste erfolge auf wichtigen märkten
Hertwichs derzeit aktivste Marktregionen sind
25
Schmelzen, gieSSen und Wärmebehandeln
Nordamerika und Westeuropa, in denen Aluminium sowohl als Primärwerkstoff, aber in
zunehmendem Maße auch als Recyclingprodukt schon immer einen hohen Stellenwert
hatte. Hier wird Hertwichs Technologie von
jenen Hütten und Umschmelzbetrieben geschätzt, für die Produktqualität, Wirtschaftlichkeit und Umweltverträglichkeit gleichrangige
Ziele sind. Niedermair: „Diese Firmen kennen
und schätzen uns. Für uns besteht dort keine
Gefahr, kopiert zu werden“.
Beim Blick auf die aktuelle Referenzliste
findet sich unter vielen anderen ein Auftrag
von einem prominenten Aluminiumhersteller in Zentralamerika, wo Hertwich zurzeit
eine Kompakt-Umschmelzanlage baut, die
aus einem 3-Kammer-Schmelzofen, einer Horizontal-Stranggießanlage und einer Durchlaufhomogenisierung mit Ultraschallprüfung
besteht. Interessant ist, dass in dieser Anlage,
die für 40.000 Jahrestonnen ausgelegt wird,
sehr große Mengen Späne aus der eigenen
Herstellung von geschmiedeten Felgen verarbeitet und diese als Stangen wieder in den
Produktionskreislauf zurückführt werden.
„Wir erreichen hier, bezogen auf die Trockenmasse, eine Metallausbeute von 99 Prozent –
ein Wert, den man selbst mit einem Induktionsschmelzofen kaum erreicht“, betont Niedermair und weist darauf hin, dass ähnliche
Werte für Hertwich auch beim Einschmelzen
von Dosenschrott (UBC) gelten.
Für Amag casting in Österreich baut Hertwich derzeit einen Ecomelt PS-250 Mehrkammer-Schmelzofen und einen 100-Tonnen-Gießofen. Diese erschmelzen künftig
die Automobil- und Flugzeuggüten, die als
Walzbarren in dem im Bau befindlichen neuen Warmwalzwerk eingesetzt werden. Das
Homogenisieren der Walzbarren erfolgt in
Kammerhomogenisierungsöfen mit Barrenmanipulation, ebenfalls von Hertwich.
Ein wichtiger Markt für Hertwich war, ist
und bleibt die Golfregion. Nachdem bereits
alle großen Hütten von Alba über Dubal und
Emal bis hin zu Qatalum ihre Gießereien mit
Hertwich-Anlagen ausgerüstet haben, konnte
das Unternehmen gerade einen Auftrag für
eine Kompakt-Schmelz- und Gießanlage von
Taweelah Aluminium Extrusion (Talex) in
Abu Dhabi gewinnen. Das neue Strangpresswerk wird eine der ersten Anlagen innerhalb
des geplanten Aluminium Clusters der Industriezone Kizad in Abu Dhabi, die im Umfeld
der Hütte von Emirates Aluminium entsteht.
Hertwich liefert hier das komplette Casthouse. Dessen Produktionskapazität wird zur
Hälfte mit Flüssigaluminium von Emal versorgt. Daneben wird es mit Schrott gespeist,
der hauptsächlich in der zukünftigen Ferti-
26
we are years ahead of conventional melting
technology for post-consumer scrap,” he says,
and goes on: “For us, besides factors such as
energy saving and environmental tolerance,
the highest possibly metal yield is all-important.” Even though at Hertwich great attention is paid during product development to
the energy consumption and environmental
tolerance factors, the energy content in the
aluminium is just as important for Mr Niedermair. “Above all we aim for the maximum
possible metal yield. Its value, relative to the
cost of energy, is substantially greater. With
a recycling volume of 40,000 tonnes a year,
increasing the metal yield by just one percentage point brings a profit boost of the order
of substantially more than half a million euros.” With dross as well, he regards economic
success as governed not by its treatment, but
rather, by minimising it. So Hertwich’s aim
can be expressed as reducing oxide production. This is achieved by the submersion melting process, in which the scrap brought in is
melted in already molten aluminium, which
suppresses carbide formation and greatly restricts oxide production.
AnlagezumStapeln,WiegenundUmreifen
Mr Niedermair’s credo for remelting plants
can be summarised in the sentence: “By
achieving the highest quality, scrap can be reconverted to valuable materials again.” The
aim is to convert can scrap back into highgrade can stock and in that way counteract any
downgrading to lesser products. As the most
recent example he mentions a multi-chamber
furnace built for Audi, which there produces
high-grade metal for pressure diecasting from
material returned from the company’s own
casting production shop.
latest successes in important markets
Hertwich’s currently most active market re-
gions are North America and Western Europe,
in which aluminium has always played an important part both as a primary material, but to
an increasing extent also as a recycling product. Here, Hertwich’s technology is highly esteemed by every smelter and remelting operation for whom the product quality achieved,
economy and environmental tolerance are
equally valued aims. Mr Niedermair says:
“Those companies know and esteem us. For
us, there is no risk of being copied there.”
A look at the current reference list reveals, among many others, an order from a
well-known aluminium producer in Central
America, where Hertwich is at present building a compact type remelt plant consisting of
a three-chamber melting furnace, a horizontal
continuous casting machine and a continuous
homogenising unit with ultrasonic testing. It is
interesting that this plant, which is designed
for an output of 40,000 tonnes a year, will be
processing very large amounts of machining
chips from its own production line for forged
wheel-rims and feeding the product back as
logs into the production cycle. “Here, relative
to the dry mass we are achieving a metal yield
Stacking,weighingandstrappingsystem
of 99 percent – a value hardly to be achieved
even with an induction melting furnace”,
stresses Mr Niedermair, who also points out
that Hertwich furnaces also achieve similar values when melting beverage can scrap
(UBC).
Hertwich is currently building an Ecomelt
PS-250 multi-chamber furnace and a 100tonnes casting furnace for Amag casting in
Austria. These furnaces will in future melt the
automobile and aircraft materials that will be
used as rolling ingots in the hot-rolling plant
currently under construction. The rolling ingots will be homogenised in batch-type homogenising furnaces with ingot manipulation,
also from Hertwich.
ALUMINIUM · 5/2014
SPecial
The Gulf region has been, is and will remain
an important market for Hertwich. Now that
already all the major smelters, from Alba,
through Dubal and Emal to Qatalum, have
equipped their casthouses with Hertwich
units, the company has just received an order
for a compact melting and casting plant from
Taweelah Aluminium Extrusion (Talex) in
Abu Dhabi. The new extrusion plant will be
one of the first plants within the planned
Aluminium Cluster in the Kizad Industrial
Zone in Abu Dhabi, which is being set up in
the neighbourhood of the Emal smelter. Hertwich will be supplying the complete casthouse
there. Half of its production capacity will be
covered by molten aluminium delivered by
Emal. In addition it will be fed with scrap
mainly produced by the future production
m e lt i n g , c a S t i n g a n d h e at t r e at m e n t
operations. For this, Hertwich is supplying a
Compact plant with a 50-tonne melting furnace, and a casting furnace, a vertical log-casting machine, a continuous homogenising plant
with ultrasonic testing equipment and a sawing and packing unit. The casthouse is scheduled to begin operating in the spring of 2015.
To begin with the capacity will amount to
30,000 to 35,000 tonnes, but if all goes well
it can later be boosted to 40,000 to 45,000
tonnes a year.
gung anfällt. Dafür liefert Hertwich eine Kompaktanlage mit einem 50-Tonnen-Schmelzofen, einen Gießofen, eine Vertikal-Stangengießmaschine, eine Durchlaufhomogenisierung mit Ultraschallprüfanlage sowie eine
Säge- und Verpackungsanlage. Die Inbetriebnahme der Gießerei soll im Frühjahr 2015
erfolgen. Zunächst wird die Kapazität bei
30.000 bis 35.000 Tonnen liegen, bei entsprechender Fahrweise kann sie später auf 40.000
bis 45.000 Tonnen gesteigert werden.
author
autor
Dipl.-Ing. Bernhard Rieth is a marketing specialist
and freelance technical journalist. As proprietor of
Marketing Xpertise Rieth in Meerbusch, Germany,
he advises equipment partners of the NF metals
semis industry on marketing-related matters.
Dipl.-Ing. Bernhard Rieth ist Marketingspezialist
und freier Fachjournalist. Als Inhaber der Marketing Xpertise Rieth in Meerbusch berät er Ausrüstungspartner der NE-Metall-Halbzeugindustrie in
Marketingfragen.
Ebner Industrieofenbau
Ebner Industrieofenbau
auftragsboom bei Vergütelinien für automobilband
aus aluminium
a rush of orders for
heat treatment lines for
aluminium automobile strip
b. rieth, meerbusch
b. rieth, meerbusch
Die österreichische Ebner Industrieofenbau GmbH kann auf
eine mehr als 60-jährige Firmengeschichte zurückblicken,
während der sich das in der dritten Generation familiengeführte Unternehmen weltweit einen hervorragenden Ruf als
Hersteller von Anwärm- und Wärmebehandlungsöfen für
Stahl-, Aluminium- und Buntmetall-Halbzeuge erworben hat.
Getragen wurde diese Entwicklung von der Spezialisierung auf
Hochtechnologie unter dem Logo HICON (High Convection),
der Qualität aus den eigenen Fertigungsbetrieben und einer
stetigen, vorausschauenden Produktentwicklung. Vor diesem
Hintergrund ist es dem Unternehmen gelungen, die 2008
einsetzende Nachfrageschwäche des bis dahin stärksten Umsatzbringers „Stahlindustrie“ durch Auftragszuwächse aus der
Aluminiumindustrie nicht nur auszugleichen, sondern gleichzeitig zu verdoppeln.
The Austrian Ebner Industrieofenbau GmbH can look back
over a history of more than 60 years during which the company, now still managed by the third generation of the family, has acquired an outstanding reputation worldwide as a
manufacturer of heating and heat treatment furnaces for steel,
aluminium and other non-ferrous metal semis. This development has been supported by specialisation in high technology
under the logo HICON (High Convection), which achieves top
quality by virtue of the company’s own manufacturing operations and consistent, forward-looking product development.
Against that background the company has managed not only
to compensate the fall in demand that began in 2008 in the
‘steel industry’ division, until then greatest contributor to its
turnover, but even to double it thanks to a rush of orders from
the aluminium industry.
Interview mit
Geschäftsführer Robert Ebner
Interview with CEO Robert Ebner
ALUMINIUM: Seit unserem letzten Besuch und der damaligen Vorstellung Ihres Unternehmens in unserer Zeitschrift sind einige Jahre
vergangen. Uns interessiert, wie sich die Firma Ebner in dieser Zeit
entwickelt hat und wo sie heute steht?
Robert Ebner: Wir sind ein familiengeführtes Unternehmen und
können uns im harten Geschäft des internationalen metallurgischen
Anlagenbaus nur erfolgreich behaupten, wenn wir langfristig voraus-
ALUMINIUM · 5/2014
ALUMINIUM: A few years have gone by since our last visit and the
presentation of your company in our journal at that time. We would
be interested to know how the company Ebner has developed during
that period and where it stands today.
Robert Ebner: We are a family-run company and can only maintain our position successfully in the harshly competitive business of
international metallurgical plant engineering, by considering far in
advance and analysing what products will be needed on the market
and how we can design them so as to enable users to achieve reliable
27
Schmelzen, gieSSen und Wärmebehandeln
denken und analysieren, welche Produkte der Markt in Zukunft benötigen wird und wie wir diese so gestalten können, dass sie den
Anwendern von Anfang an eine sichere und qualitativ hochwertige
Produktion ermöglichen. Um dieses Ziel zu verwirklichen sind wir
über alle Jahre unserem Grundsatz treu geblieben, umfassend in
Forschung und Entwicklung zu investieren. Mindestens acht Prozent
unseres jährlichen Umsatzes geht in die Forschung und Entwicklung.
Das ist aus meiner Sicht der wichtigste Punkt, der unsere heutige
hervorragende Marktposition beschreibt.
ALUMINIUM: Können Sie dies an einem aktuellen Beispiel aus dem
Aluminiumbereich verdeutlichen?
Ebner: Seit zwei Jahren erleben wir eine enorme Nachfrage nach
Bandschwebeöfen mit integrierter Wasserquench zum Einsatz in sogenannten CASH-Linien (CASH = Continuous Annealing Solution
Heat Treatment) zur Erzeugung von speziellen Aluminium-Band-
Die Kunden wissen heute, dass die Wärmebehandlungs- und Quench-Technologie ausschlaggebend für die Qualität des Endproduktes ist
© Ebner Industrieofenbau
qualitäten für die Automobilindustrie und in einigen Fällen auch für
den Flugzeugbau. Dieser Boom hat uns innerhalb kurzer Zeit zehn
Aufträge über Bandschwebeanlagen gebracht und zu einer nahezu
100-prozentigen Marktdurchdringung mit unseren Anlagen auf dem
Gebiet der Automobilbleche geführt.
ALUMINIUM: Worauf führen Sie das zurück?
Ebner: Wir waren zur rechten Zeit, sprich zu Beginn der Entscheidung
der Automobilindustrie, Aluminiumbleche in wichtigen Komponenten der Karosserie einzusetzen, mit dem rechten Produkt, den Bandschwebeanlagen, am Markt.
ALUMINIUM: Können Sie das bitte näher erläutern?
Ebner: Kontinuierliche Bandglühlinien bauen wir bereits seit vielen
Jahren für die Aluminiumindustrie. Diese Linien waren ursprünglich eine Alternative zur Wärmebehandlung einzelner Bunde in Einoder Mehrbund-Kammeröfen, wenn es darum ging, eine gleich bleibende hohe Produktqualität in großen Losgrößen zu gewährleisten,
wie das von der Automobilindustrie gefordert wird. Beispiele dafür
sind unsere erste Linie für Amag in Ranshofen, die 1999 in Betrieb
ging, und etwas später eine noch größere Anlage für Aleris
in Duffel. Für beide
Linien lieferten wir
den Wärmebehandlungs- und Kühltechnologieteil.
ALUMINIUM:
Das war vor etwa
zehn Jahren. Und
wie ging es weiter?
Ebner: Bereits damals war uns klar,
dass es mit der
berührungsfreien
Erwärmung
im
Bandschwebeofen
alleine nicht getan
ist. Um die Kunden
GeschäftsführerRobertEbner
CEORobertEbner
28
and high-grade production from the very beginning. To realise that
aim, throughout the years we have remained true to our principle
of investing comprehensively in research and development. At least
eight percent of our annual turnover is ploughed back into R & D.
In my view that is the most important point that leads to the outstanding market position we enjoy today.
ALUMINIUM: Could you illustrate that with a current example from
the aluminium sector?
Ebner: For two years now we have seen an enormous demand for
floating strip furnaces with integrated water quenching, in so-termed
CASH lines (CASH = Continuous Annealing Solution Heat Treatment), for the production of special aluminium strip grades for the
automobile industry and in some cases also for aircraft manufacture.
In a short time that boom has brought us ten orders for floating strip
furnaces and has led to almost 100-percent market penetration with
our units in the field of automobile sheet.
ALUMINIUM: To what do you attribute this?
Ebner: We came onto the market with the right product at just the
right time, namely at the very beginning of the automobile industry’s decision to use aluminium sheet in important components of
the bodywork.
ALUMINIUM: Could you explain that in more detail?
Ebner: We have already been building continuous strip-annealing
lines for the aluminium industry for many years. These lines were
originally an alternative to the heat treatment of individual coils in
batch-type furnaces that accommodated one or more coils, when it
Nowadays, customers are aware that heat
treatment and quenching technology are
decisive for the quality of the end product
became necessary to ensure consistent high product quality in large
production runs, as required by the automobile industry. Examples
of that are our first lines for Amag in Ranshofen, which began operating in 1999, and a little later an even larger unit for Aleris in
Duffel. For both lines we supplied the heat treatment and cooling
technology equipment.
ALUMINIUM: That was about ten years ago. And what has been
happening since then?
Ebner: Already at that time it was clear to us that no-contact heating in a floater furnace for strip alone was not enough. To convince
customers, at that time we built a number of test units, up to full-size
(scale 1:1) in which we tried locating the water quench immediately
after the continuous furnace and optimised its effect.
ALUMINIUM: After 2001 the market for the continuous annealing
of aluminium became very quiet.
Ebner: That’s right. We used the time to perfect our development
in the sector. When a few years ago, under the pressure of statutory
prescriptions for the reduction of greenhouse gas emissions by saving weight, the automobile industry worldwide began intensifying
the more abundant use of aluminium, we were already able to offer
convincing solutions for the heat treatment of aluminium strip. So we
enjoyed the fruition of what we had sown years earlier.
ALUMINIUM: What influence did the dynamic development of the
aluminium industry in general have on your company’s development?
Ebner: Until 2008 out order intakes had for decades been accounted
for to an extent averaging 60 to 70 percent by the steel industry. As
an example I can mention bell annealers for wire and strip coils, in
ALUMINIUM · 5/2014
SPecial
m e lt i n g , c a S t i n g a n d h e at t r e at m e n t
which we still today have a leading market position, especially in
the use of 100-percent hydrogen (Hicon/H2). At that time around a
quarter of our orders came from the aluminium industry, above all
for plate tempering units and pusher-type furnaces, while the rest
concerned the heat treatment of other non-ferrous metals.
ALUMINIUM: And today?
Ebner: Today, order intake from the aluminium industry is close to
70 percent, and this in the context of a doubled order volume by our
group over the past four years. The steel and non-ferrous industries
still provide us with some interesting contracts, although the major
projects and numbers of units of the past no longer arise.
ALUMINIUM: What role does the global orientation of your company play?
Ebner: Our decision at the time, to have production facilities in the
three locations of Austria, the USA and China, has proved the right
zu überzeugen, haben wir damals in unserem Technikum mehrere
Versuchsanlagen bis hin zum Maßstab 1:1 aufgebaut, in denen wir
die Wasserquench unmittelbar hinter dem Durchlaufofen untersucht
und in ihrer Wirkung optimiert haben.
ALUMINIUM: Nach 2001 war der Markt für das Kontiglühen von
Aluminium sehr ruhig.
Ebner: Das ist richtig. Wir haben die Zeit genutzt, um unsere Entwicklung auf diesem Sektor zu perfektionieren. Als vor einigen Jahren die weltweite Automobilindustrie begann, unter dem Druck der
gesetzlichen Auflagen zur Reduzierung von Treibhausgasen durch
Gewichtseinsparungen den verstärkten Einsatz von Aluminiumblech
zu forcieren, konnten wir bereits überzeugende Lösungen für die
Wärmebehandlung von Aluminiumbändern anbieten. Wir konnten
damit die Früchte ernten, die wir Jahre zuvor gesät hatten.
ALUMINIUM: Welchen Einfluss hatte die dynamische Entwicklung
der Aluminiumindustrie generell auf die Entwicklung Ihres
Unternehmens?
Ebner: Bis 2008 war unser Auftragseingang über Jahrzehnte
im Schnitt zu 60 bis 70 Prozent von der Stahlindustrie geprägt.
Als Beispiel nenne ich Haubenöfen für Draht- und Bandbunde, bei denen wir speziell beim Einsatz von 100 Prozent Wasserstoff (Hicon/H2) auch heute noch eine führende
Marktposition haben. Etwa ein Viertel der Aufträge kamen
damals aus der Aluminiumindustrie, vor allem für Plattenvergüteanlagen und Stoßöfen, der Rest betraf die Wärmebehandlung von Buntmetallen.
ALUMINIUM: Und heute?
Ebner: Heute liegt der Bestelleingang aus der Aluminiumindustrie näher bei 70 Prozent, und das bei einem in den letzten vier Jahren verdoppelten Auftragsvolumen der Gruppe.
Die Stahl- und Buntmetallindustrie beschert uns nach wie
vor interessante Aufträge, wenngleich die großen Projekte
und Stückzahlen der Vergangenheit derzeit fehlen.
ALUMINIUM: Welche Rolle spielt die globale Ausrichtung
Ihres Unternehmens?
Bandschwebeofen–mitWasserquench(rechtsvorne)undOfenteil(hinten)
Ebner: Unsere damalige Entscheidung, an den drei StandFloaterfurnaceforstrip–withwaterquenchunit(front,right)andfurnace(attheback)
orten Österreich, USA und China zu produzieren, hat sich
von
Anfang
an als richtig erwiesen – gerade auch mit Blick auf die
one from the beginning – particularly also having regard to the deEntwicklung
der Aluminiumindustrie in den USA und in China. Und
velopment of the aluminium industry in the USA and China. And
wir haben überall dort, wo viele unserer Anlagen arbeiten, eigene
wherever several of our plants are in operation, we have set up service
Servicestationen mit erfahrenen Technikern eingerichtet – in Länstations of our own with experienced technical staff – in countries
dern wie Brasilien, Indien, Japan, Taiwan und – obwohl so nah an
such as Brazil, India, Japan, Taiwan and – despite its proximity to our
unserem Hauptsitz – in Deutschland.
headquarters – even in Germany.
ALUMINIUM: Wie beurteilen Sie die geschäftliche Entwicklung der
ALUMINIUM: How do you assess the business prospects in the next
nächsten Jahre?
few years?
Ebner: Besonders stolz sind wir auf die Tatsache, dass wir zuletzt mit
Ebner: We are particularly proud about the fact that we recently
KUMZ in Russland und Tianjin Zhongwang in China zwei Großhave been able to persuade two major customers, KUMZ in Russia
kunden überzeugen konnten, sämtliche Anwärm- und Wärmebeand Tianjin Zhongwang in China, to order all the heating and heat
handlungsöfen für ihre neuen Werke bei uns zu bestellen. Das stimmt
treatment equipment for their new plants from us. That makes us
uns zuversichtlich für weitere Großprojekte. Aluminium wird unconfident that other major projects will follow. Aluminium will conseren Auftragseingang auch in den nächsten beiden Jahren domitinue to dominate our order intake for the next two years. Driven
nieren. Getrieben von den heute absehbaren Planungen der Autoby the plans of the automobile industry that can be foreseen today,
mobilindustrie wird es eine in etwa gleichmäßige Verteilung der Aufthere will be an approximately even distribution of orders from the
regions of Europe, America and Asia. In the case of steel, as a result
träge aus den Regionen Europa, Amerika und Asien geben. Beim
of aluminium’s recent successes we think the sector has developed
Stahl rechnen wir als Folge der jüngsten Aluminiumerfolge damit,
new high-strength steel materials and new processes such as pressdass die Branche neue hochfeste Stahl-Werkstoffe und neue Verfahhardening. But there too, solution approaches are called for which we
ren wie das Presshärten entwickelt. Aber auch da sind dann Lösungsare already working on.
ansätze gefragt, an denen wir bereits arbeiten.
ALUMINIUM: Mr Ebner, many thanks for this discussion.
ALUMINIUM: Herr Ebner, vielen Dank für das Gespräch.
(See also report on the Ebner product lines on the following pages)
(Siehe auch nachfolgenden Bericht über die Ebner-Produktlinien)
ALUMINIUM · 5/2014
29
Schmelzen, gieSSen und Wärmebehandeln
ebner: drei starke Produktlinien für die aluminiumindustrie
30
ebner: three powerful production
lines for the aluminium industry
© Ebner Industrieofenbau
Ebners Ofenanlagen für die Aluminiumindustrie werden nahezu ausschließlich von Flachwalzwerken eingesetzt und zwar zum Homogenisieren und Anwärmen von Walzbarren
sowie für die Wärmebehandlung von Bändern,
Blechen und Platten.
Hier handelt es sich vor allem um Produktlinien, mit denen Ebner bereits seit vielen Jahren am Markt ist bzw. mit denen das Unternehmen durch vorausschauende Forschung
und Entwicklung genau zum Zeitpunkt des
entstehenden Bedarfs dem Markt die gesuchten Lösungen bieten konnte.
Bandschwebeöfen für CASH-Linien kann
man innerhalb des Portfolios von Ebner mit
Blick auf die letzten beiden Jahre als die eigentlichen „Shooting Stars“ bezeichnen. Zehn
Anlagen, die in dieser Zeit von Aluminiumwalzwerken in den USA, China, Taiwan und
Russland für maximale Bandbreiten zwischen
2.100 und 2.800 mm und Dicken zwischen
0,2 und 6,35 mm bestellt wurden, sprechen
eine deutliche Sprache. Diese starke Position
führt Robert Ebner darauf zurück, dass die
Kunden inzwischen erkannt haben, dass die
geforderten Werkstoffeigenschaften und die
qualitätsbestimmende Technologie heute im
Ofen und in der Wasserquench erzeugt werden. Das Knowhow von Ebner liegt in der
Kombination aus der Gleichmäßigkeit der
Temperaturführung im Ofen mit einer Temperaturgleichmäßigkeit von ± 3 °C während
der Haltezeit, im Beherrschen des Schwebevorgangs angesichts einer breiten Fächerung
der zu behandelnden Banddicken sowie in
der Kenntnis, wie gewünschte metallurgische
Eigenschaften durch gezielte Abkühlvorgänge
in der Quench erzeugt werden. Dies wird dadurch unterstrichen, dass Bandschwebeöfen
von Ebner noch nie ohne nachgeschaltete
Quench geliefert wurden.
Eine wichtige Komponente bei den sogenannten CASH-Linien ist neben der gezielten
Erwärmung und Abkühlung die kontinuierliche Bandführung und die chemische Behandlung der Bandoberfläche – das Passivieren.
Um den Kunden eine integrierte Lösung aus
einer Hand und ohne Schnittstellen anbieten
zu können, wird mit namhaften Anlagenbauern für Bandbehandlungslinien zusammengearbeitet. Bei neuen Projekten wird Ebner
als der Technologie-bestimmende Part in der
Regel als Erster von den künftigen Betreibern
angesprochen. Der Bandanlagenbauer kommt
später hinzu. „Mit unserer erfahrenen Mannschaft sehen wir uns heute in der Lage, die
Konsortialführung für ein derartiges Projekt
Stoßofen–Entnahmeseite
Ebner furnace units for the aluminium industry are almost exclusively used by flat-rolling
plants, namely for homogenising and heating
rolling ingots and for the heat treatment of
strip, sheet and plate. The product lines concerned are in particular ones that Ebner has
already been offering on the market for several years or ones which, by virtue of forward-looking research and development, the
company has been able to offer the market
just at the time when a need for them arises.
Floating strip furnaces for CASH lines can
be regarded, among Ebner’s portfolio and
having regard to the last two years, as a real
‘shooting star’. The fact that ten plants have
been ordered during that time by aluminium
rolling plants in the USA, China, Taiwan and
Russia, for max. strip widths between 2,100
and 2,800 mm and thicknesses between 0.2
and 6.35 mm, speaks for itself. Robert Ebner
attributes this strong position to the customers’ understanding that the required material
properties and the quality-determining technology are now produced in the furnace and
the water-quench stage that follows it. Ebner’s
know-how lies in the combination of accurate
temperature control in the furnace, with a
temperature uniformity of ± 3 °C during the
Pusher-typefurnace–unloadingside
holding time, mastery of the floating process
in light of a wide diversity of the strip thicknesses to be treated, and knowledge of how
the desired metallurgical properties are produced by controlled cooling processes in the
quench phase. This is underlined by the fact
that Ebner’s floater furnaces for strip are still
never supplied without downstream quenching equipment.
Besides the controlled heating and cooling, an important component in so-termed
CASH lines is the continuous guiding of the
strip and the chemical treatment of its surface,
namely passivation. To be able to offer the
customer an integrated solution all from one
source and without interfaces, Ebner collaborates with noted equipment builders of strip
treatment lines. In the case of new projects
Ebner, as the technology-determining partner,
is as a rule the first to be approached by the
future operators. The strip plant constructor is
brought in later. “With our experienced staff
we now regards ourselves as capable of undertaking the leading consortium management
role for a project of this type and therefore
relieving the customer of responsibility for the
interfacing,” explains Mr Ebner. “Our technicians have meanwhile become so experienced
ALUMINIUM · 5/2014
SPecial
that we can assess the various plant constructors not only in relation to their mechanical
component competence, but also as regards
chemical processes such as strip cleaning and
passivation.”
Roller-hearth furnaces for the heat treatment of plates have already for many years
been a successful Ebner product. One of the
milestones of this development, ten years ago
now, was the plant for Alcoa in Davenport,
USA, in which aluminium plates for the aviation industry are heat treated. Thanks to the
rapid development of the aviation industry
noted producers of aluminium plates have
since then decided to go for Ebner technology. With these horizontal continuous rollerhearth furnaces, besides expertise in furnace
construction the company can bring to bear
its experience in the design of the subsequent
water-quench equipment with integrated drier,
by means of which the desired material properties are above all achieved. The quenching
process is carried out by means of spray nozzles whose height is adjustable. Plate distortion is minimised by the symmetrical flow
m e lt i n g , c a S t i n g a n d h e at t r e at m e n t
zu übernehmen und dem Kunden damit die
Schnittstellenverantwortung abzunehmen“,
so Ebner. „Unsere Techniker sind inzwischen
so erfahren, dass wir die verschiedenen Anlagenbauer nicht nur hinsichtlich ihrer Kompetenz der mechanischen Komponenten, sondern auch hinsichtlich der chemischen Vorgänge wie Bandreinigung und Passivierung
beurteilen können.“
Rollenherdöfen für die Plattenvergütung
sind bereits seit vielen Jahren ein Erfolgsprodukt von Ebner. Ein Meilenstein in der
Entwicklung war vor zehn Jahren die Anlage
für Alcoa in Davenport, USA, auf der Aluminiumplatten für den Flugzeugbau wärmebehandelt werden. Dank der starken Entwicklung der Luftfahrtindustrie entschieden sich
namhafte Hersteller von Aluminiumplatten
seitdem für die Ebner-Technologie. Auch bei
diesen horizontalen Durchlaufanlagen setzt
Ebner neben der Expertise im Ofenbau auf
seine Erfahrungen in der Auslegung der sich
anschließenden Wasserabschreckeinrichtung
mit integriertem Trockner, mit der erst die angestrebten Werkstoffeigenschaften eingestellt
werden. Der Abschreckvorgang wird über
höhenverstellbare Spritzdüsen durchgeführt.
Durch die symmetrische Wasserbeaufschlagung über die gesamte Plattenbreite und der
absolut geraden Wasserlinienführung bei Abkühlbeginn wird der Plattenverzug auf ein
Minimum reduziert.
Ergänzt werden diese Rollenherdöfen
durch Kammeröfen für die Warmauslagerung
der Platten. In diesen erhalten sie erst ihre
endgültige Härte
Stoßöfen zum Homogenisieren und Anwärmen von Walzbarren haben zahlenmäßig
immer noch den höchsten Anteil an Ebners
Lieferungen an die Aluminiumindustrie. Das
liegt einmal an den zahlreichen neuen Warmwalzwerken, die vor allem in China, aber auch
in anderen Regionen gebaut wurden. Zum
anderen ist die Kapazität der einzelnen Anlagen in den letzten drei Jahren so gewachsen, dass nicht mehr wie früher ein oder zwei
Stoßöfen, sondern fünf und mehr vor einem
Warmwalzwerk installiert werden. Bis 2008
konnte das Unternehmen auf 35 verkaufte
Stoßöfen verweisen; heute sind es bereits
Gautschi Engineering GmbH
Konstanzer Strasse 37 | 8274 Tägerwilen
www.gautschi.cc | [email protected]
Tel. +41 71 666 66 66
For our location in Switzerland,
we are looking for:
Responsibilities
‡ Evaluate customer requirements
‡ Establish processes veri¿cation of technol
gies used with the equipment, including
related processes like scrap processing (all
formats), metal transfer & casting
for Round Top Charged Aluminium
‡ Design of process chains for heating systems
Melting Furnaces
used on the equipment
‡ Internal evaluation on equipment improvement to meet and surpass future legal/
Gautschi Engineering GmbH with its location production requirements (emission control,
energy consumption, …)
in Switzerland, Germany and in the Peoples
‡ External consultation to customers to streamRepublic of China supplies Cast House
line or improspeci¿c production equipment,
Equipment to the Aluminium Industry worldincluding thruput¶, cycletime, Àuxing, degaswide for more than 90 years. The company
sing, ¿ltration, mold technologies and casting
belongs to a medium sized family owned
equipment
group of companies. Customers include the
‡ Conduct / support performance test
entire range of reputed Aluminum Groups
‡ Train operations in complete production
operating worldwide as well as small sized
processes, refractories, maintenance, cast
privately owned businesses.
house safety, health, environment & explosion risk
‡ Complete refractory management-selection,
methodology, materials, life, costs, installatiFor additional details visit our homepage:
on & emergency situations
www.gautschi.cc
Technology Manager
ALUMINIUM · 5/2014
Expectations
‡ Long term, 15+ years, experience in Aluminium Cast House & Rolling Operations, with
Round Top Charged Melting Furnaces, with
above responsibilities
‡ Excellent knowledge on processes in Remelt,
& Molten Metal Transfer, Refractories,
Casting Technology, Quality Systems (APQP/
ISO/TS), Safety, Maintenance Management,
Project Management & Materials Management; also experienced in Project Sales &
Tendering
‡ Master or Bachelor degree in Engineering
‡ Excellent English language skills
‡ Prepared for extensive travelling
Please forward your application to
Mrs. Elisabeth Rebsamen ([email protected]).
Feel free to contact us if you have any
questions.
31
Schmelzen, gieSSen und Wärmebehandeln
Rollenherdofen–BlickindieWasserquench
Roller-hearthfurnace–aviewintothewaterquenchunit
über 80. Für das Unternehmen ergeben sich
große Vorteile aus diesen Stückzahlen: Die
dafür vorgesehenen Mitarbeiter können kontinuierlich das Produkt „Stoßofen“ betreuen
und dabei auch laufend neue Entwicklungen
berücksichtigen.
Den Grund für den Erfolg der Stoßöfen
sieht Robert Ebner in ihrer energetischen Effizienz und der reproduzierbar hohen Gleichmäßigkeit der Erwärmung.
Der zunehmende Trend zur Flexibilisierung der Produktionsabläufe im Hinblick auf
eine Vielzahl kleiner Losgrößen hat Ebner
veranlasst, neben dem klassischen Stoßofen,
der am wirtschaftlichsten bei großen Walzlosen arbeitet, einen neuen Ofen zu entwickeln, in dem nur wenige Walzbarren
mit ungefräster oder gefräster Oberfläche und teilweise ungünstigen Breiten- / Dickenverhältnissen gleichzeitig
homogenisiert und /oder erwärmt werden. Es handelt sich um einen Kammerofen, der von vorne mit nur einer Reihe von senkrecht auf der Längskante
stehenden Walzbarren beschickt wird.
Diesen Ofentyp betrachtet man bei
Ebner als ideale Ergänzung zu den für
gleichbleibend hohe Stückzahlen ausgelegten Stoßöfen.
of the water over the full width of the plates
and the absolutely straight water-line layout
at the beginning of the cooling process.
These roller-hearth furnaces are supplemented by chamber furnaces for the artificial
ageing of the plates. In these, they achieve
their final hardness.
Pusher-type furnaces for homogenising
and heating rolling ingots still account, in
numerical terms, for the largest fraction of
Ebner’s deliveries to the aluminium industry. That, in particular, is because of the large
number of new hot-rolling plants built above
all in China but in other regions too. On the
other hand, the capacity of individual plants
has increased in the last three years to a point
where no longer, as earlier, are one or two
pusher furnaces, but more commonly five or
more of them installed ahead of a hot-rolling plant. Until 2008 the company had sold
35 pusher furnaces, whereas until today the
number has risen to more than 80. For the
company this increase of unit numbers has
great advantages: the workers involved in
their production can continually monitor the
‘pusher-furnace’ product and during this, also
take new developments into account.
Robert Ebner considers that the reason for
the success of these furnaces is their energy
efficiency and the reproducibly high uniformity of their heating.
The increasing trend toward making production sequences more flexible in relation
to a larger number of smaller batch sizes has
motivated Ebner, besides the classical pusher
furnace which works most economically with
large batch sizes, to develop also a new furnace in which only a few rolling ingots at a
time, with scalped or unscalped surfaces and
sometimes less favourable width / thickness ratios, can be homogenised and / or heated at the
same time. This is a chamber furnace which is
loaded at the front with only one row of rolling ingots positioned perpendicularly to the
longitudinal edge. At Ebner this furnace type
is regarded as an ideal supplement to furnaces
designed for consistently large unit numbers.
author
Dipl.-Ing. Bernhard Rieth is a marketing specialist
and freelance technical journalist. As proprietor of
Marketing Xpertise Rieth in Meerbusch, Germany,
he advises equipment partners of the NF metals
semis industry on marketing-related matters.
autor
Dipl.-Ing. Bernhard Rieth ist Marketingspezialist und freier Fachjournalist. Als
Inhaber der Marketing Xpertise Rieth
in Meerbusch berät er Ausrüstungspartner der NE-Metall-Halbzeugindustrie in
Marketingfragen.
32
Rollenherdofen–AuslaufausWasserquench
Roller-hearthfurnace–run-outfromthewaterquench
ALUMINIUM · 5/2014
SPecial
m e lt i n g , c a S t i n g a n d h e at t r e at m e n t
Tenova LOI Thermprocess
„der Weltmarkt ist riesig“
zweikammer-Schmelzofen tcF –
wachsende nachfrage
Im Recycling bedient LOI Thermprocess mit
seinen Schmelzöfen die ganze Bandbreite der
zugänglichen Materialien: sowohl Rücklaufschrott, der meist aus dem Walzwerk kommt,
als auch Marktschrotte der unterschiedlichsten
Legierungsgruppen. In den vergangenen Jahren hat sich vor allem der Zweikammer-
© LOI Thermprocess
Die zur Tenova gehörende LOI Thermprocess GmbH mit Sitz in Essen zeichnet sich in der Ofentechnik durch das
Schmelzen, Gießen und Wärmebehandeln von Aluminium aus, wobei sich
der Zweikammer-Schmelzofen TCF für
beschichtete und kontaminierte Schrotte
in den vergangenen Jahren zu einem
„Bestseller“ für das Unternehmen entwickelt hat. Das zweite wichtige Standbein
ist die Wärmebehandlung insbesondere
von Walzbarren, Coils, Bändern und Folien. ALUMINIUM sprach mit Hermann
Meyer, verantwortlich für den Geschäftsbereich „Anlagen Leichtmetalle“ bei LOI
über technologische Entwicklungen und
vertriebliche Aktivitäten in diesen beiden
Produktbereichen.
Zweikammer-SchmelzofenmitChargiermaschinebeiAlunorf
Twin-ChamberMeltingFurnacewithchargingmachineatAlunorf
Tenova LOI Thermprocess
“the world market is huge”
LOI Thermprocess GmbH, with its headquarters in Essen, Germany, and which
belongs to Tenova, is noted in furnace
technology for the melting, casting and
heat treatment of aluminium. Over the
years its Twin-Chamber Melting Furnace
(TCF) for coated and contaminated scrap
has developed to become a company
best-seller. Its second important pillar is
heat treatment, in particular of rolling ingots, coils, strips and foils. ALUMINIUM
talked with Hermann Meyer, who is in
charge of the Light Metal Plant business
sector at LOI, about the technological
developments and marketing activities in
these two product areas.
two-chamber melting Furnace
tcF – growing demand
HermannMeyer:„WirhabeninChinamitunseren
Schmelz-undRecyclingöfenreüssiertundsindnun
inderFolgedortauchmitWärmebehandlungs-
anlagenerfolgreich.“
HermannMeyer:“InChinawehaveprovedsuccessfulwithourmeltingandrecyclingfurnaces,
andwearenowfollowinguptherewithsome
successinthecontextofheattreatmentplants.”
ALUMINIUM · 5/2014
In the recycling context, with its melting furnaces LOI Thermprocess serves the entire
range of accessible materials: both recycling
scrap, mostly coming from rolling mills, and
also market scrap of the most varied alloy
groups. In past years the Twin-Chamber Melting Furnace TCF has developed into a sales
success-story. “At present we are working on
ten of those units,” says Mr Meyer, “namely
furnaces with output capacities ranging from
80 to 160 tonnes of molten metal per day.”
The orders come from companies in China.
At present this regional dominance is outshining the fact that in the past Europe too has
been an important market region for this type
of furnace, and it still is. On the other hand,
the market success in China is proof that efforts are certainly being made there on behalf
of the environment, since the TCF is noted
for high metal yield, low energy consumption
and low exhaust gas emission values.
This special kind of furnace is designed
for the melting of coated, contaminated scrap
which is melted in an integrated process
without any pretreatment. The pyrolysis for
removing paint takes place in the scrap chamber. The fumes generated there are passed into
the heating chamber, where they are combusted directly without further intermediate
steps, and the energy released thereby is used.
“From the environmental standpoint it is important for the after-burning in the heating
chamber to be done for long enough and at a
sufficiently high temperature for problematic
harmful gases to be completely thermally decomposed. Then, in the TCF process the com-
33
Schmelzen, gieSSen und Wärmebehandeln
Kippbarer50-Tonnen-HerdschmelzofenbeiTaluminSlowenien
50-tonnehearthmeltingfurnace(tiltingdesign)atTalum,inSlovenia
Schmelzofen zu einem Verkaufsschlager entwickelt. „Aktuell haben wir zehn dieser Anlagen in der Abwicklung“, so Meyer, „das sind
Öfen mit Kapazitäten von 80 bis 160 Tonnen
Flüssigmetall pro Tag.“ Die Aufträge kommen
von Unternehmen aus China. Diese regionale
Dominanz überstrahlt derzeit die Tatsache,
dass auch Europa in den vergangenen Jahren
eine wichtige Marktregion für diesen Ofentyp
war und ist. Der Markterfolg in China spiegelt
andererseits wider, dass es dort durchaus Bestrebungen gibt, mehr für den Umweltschutz
zu tun. Denn der Zweikammer-Schmelzofen
zeichnet sich durch eine hohe Metallausbeute,
niedrigen Energieverbrauch und unproblematische Abgaswerte aus.
Konzipiert ist er für das Einschmelzen von
beschichteten, kontaminierten Schrotten, die
in einem integrierten Prozess ohne weitere
Vorbehandlung eingeschmolzen werden. Die
Pyrolyse zur Entlackung erfolgt in der Schrottkammer. Die dabei entstehenden Schwelgase
werden in die Heizkammer geführt, dort direkt ohne weitere Zwischenschritte verbrannt
und die so freigesetzte Energie genutzt. „Aus
Umweltsicht ist es wichtig, dass die Nachverbrennung in der Heizkammer lange genug
und bei ausreichend hohen Temperaturen erfolgt, damit problematische Schadgase thermisch vollständig zersetzt werden. Anschließend werden im TCF-Prozess die Verbrennungsgase schnell abgeschreckt, um eine Rekombination von Schadgasen zu verhindern
und gleichzeitig die Filteranlage klein zu halten“, erklärt Meyer.
LOI Thermprocess vermarktet den Zweikammer-Schmelzofen seit mehr als 25 Jahren
34
sehr erfolgreich. Und natürlich wurde die
Prozesstechnik in den vergangenen Jahren
weiterentwickelt, insbesondere die Prozessregelung aufgrund der Erfahrungen mit unterschiedlichsten Einsatzmaterialien. „Dabei
geht es darum, was wir im Ofen messen und
wie wir die Messergebnisse bewerten und was
wir daraus für die Regelung und Steuerung des
Prozesses ableiten. Wir messen verschiedene
Prozessparameter wie zum Beispiel Sauerstoff im Abgasaustritt, Volumenströme, Brennerleistung, Temperaturen und den Druck im
Ofenraum.“ Alle Messwerte werden in ein
Gesamtmodell eingebracht und ausgewertet,
und der Ofen auf dieser Grundlage gesteuert.
Die entsprechende Steuerungs-Software,
die von LOI entwickelt wurde, gibt auch Auskunft darüber, ob und wann wieder chargiert
werden darf. „Das haben wir früher über den
Faktor Zeit bestimmt, aber bei der Bandbreite an Schrotten, die heute eingesetzt werden,
ist das unbefriedigend. Je nachdem, wie hoch
der Anteil an Kontaminat ist, muss der Ofen
unterschiedlich lange geschlossen bleiben, bevor wieder chargiert werden darf. Dies lässt
sich durch die Summe der Messwerte präziser
ermitteln.“
Eine Chargiermaschine ist integraler Bestandteil des Zweikammer-Schmelzofens.
Sie ermöglicht eine schnelle Beschickung des
Ofens und stellt so eine hohe Produktivität
sicher.
Auch der Energieverbrauch konnte in den
vergangenen Jahren weiter abgesenkt werden.
Die Öfen sind mit Regenerativbrennern ausgerüstet, wobei heute eine neue Brennergeneration mit einer angepassten Verbrennungs-
bustion gases are quenched rapidly in order
to prevent any recombination of harmful
gases and at the same time to keep the size of
the filters small,” explains Mr Meyer.
LOI has been marketing the Twin-Chamber Melting Furnace successfully for over 25
years. And of course over the years the process technology has been developed further,
in particular the process regulation on the
basis of experience with different charge materials. “What is important in this is what we
measure in the furnace, how we evaluate the
measurement results and what we can deduce
from that about the regulation and control of
the process. We determine various process
parameters, such as oxygen in the waste gases
emitted, volume flows, burner power, temperatures and the pressure in the furnace chamber.” All the measured values are fed into an
overall model and evaluated, and the furnace
is controlled on that basis.
The corresponding control software, developed by LOI itself, also gives information
about whether and when a furnace can be recharged. “Earlier, we used to determine that
as a function of time, but with the wide range
of scrap types used nowadays that is no longer
satisfactory. Depending on how large a fraction of contaminates is present, the furnace
has to remain closed for different times before it can be charged again. That can be determined more precisely from the sum of the
measured values.”
A charging machine is an integral part of
the TCF. It enables rapid charging of the furnace and so ensures high productivity.
Over the years it has also been possible to
reduce the energy consumption further. The
furnaces are equipped with regenerative burners and today a new burner generation with
an adapted combustion characteristic is used.
“With today’s burners the flame in the heating
chamber burns rather in the manner of a gas
cloud than, as earlier, as a direct flame. That
avoids local overheating and is easier on the
refractory material.”
The energy consumption during routine
operation is substantially less than 600 kWh
per tonne of aluminium, says Mr Meyer. “Although the energy consumption will always
depend on how the furnace is operated and
what materials are used.”
The scrap is melted not by the burner, but
below the surface of the bath. The scrap is
first deposited on a bridge, where the drying
and pyrolysis take place. The scrap is then
pushed into the bath, where it sinks slowly
and melts. This process sequence also ensures
that no humid material enters the bath.
Already shortly after the charging process
ALUMINIUM · 5/2014
SPecial
m e lt i n g , c a S t i n g a n d h e at t r e at m e n t
and before the surface of the charge is close
to its melting temperature, the scrap chamber is largely free from oxygen so that no
oxidation, and thus no combustion loss due to
free oxygen can take place. “With the TwinChamber Melting Furnace we therefore
achieve two things at once: a high metal yield
and low energy consumption, each of these
supporting the other,” explains Mr Meyer.
The TCF is virtually an all-purpose unit
and suitable for the most varied production
scrap – milling swarf (which is placed into the
charge well), oily coil residues, compacted
sheet offcuts, etc. Only the metal from used
beverage cans (UBCs) should be pre-treated,
says Mr Meyer, because the specific surface
area is relatively large and many residual
substances such as paints and contaminants
adhere to it.
Yet, as ever, the classical hearth furnace
which is also in LOI’s product range still has
its place in the semis foundry, since a TCF
demands a higher investment so that, where
clean block material is available (extrusion
billets, offcuts from sections or rolling ingots),
the classical melting furnace is certainly a
charakteristik zum Einsatz kommt. „Bei den
heutigen Brennern brennt die Flamme in der
Heizkammer eher als Gaswolke denn wie früher als straffe Flamme. Das vermeidet lokale
Überhitzungen und schont das Feuerfestmaterial.“
Der Energieverbrauch im betrieblichen
Alltag liegt laut Meyer deutlich unter 600 kWh
pro Tonne Aluminium. „Dabei hängt der Energieverbrauch immer auch von der Fahrweise
des Ofens und den eingesetzten Materialien
ab“.
Das Schmelzen des Schrottes erfolgt nicht
über die Brenner, sondern unter Bad. Zunächst wird der Schrott auf einer Brücke abgelegt, wo die Trocknung und Pyrolyse stattfindet. Dann wird der Schrott ins Bad geschoben, wo er langsam absinkt und aufschmilzt.
Dieser Prozessablauf stellt zugleich sicher,
dass kein feuchtes Material ins Bad gelangt.
Bereits kurz nach der Chargierung und
bevor die Charge an ihrer Oberfläche bereits
nahe der Schmelztemperatur ist, ist die Schrottkammer weitgehend sauerstofffrei, sodass keine Oxidation und damit kein Metallabbrand
durch freien Sauerstoff erfolgen kann. „Mit
dem Zweikammer-Schmelzofen erreichen wir
so beides – eine hohe Metallausbeute bei geringem Energieverbrauch, wobei das eine das
andere unterstützt“, erläutert Meyer.
Der Zweikammer-Schmelzofen TCF ist
ein weitgehender Alleskönner und für unterschiedlichste Fertigungsschrotte – Frässpäne
(die in den Charge-Well eingebracht werden),
verölte Coil-Reste, Blechknäuel etc. – geeignet. Lediglich bei gebrauchtem Dosenmaterial
sollte laut Meyer eine weitere Vorbehandlung
erfolgen, weil die spezifische Oberfläche relativ groß ist und viele Restbestandteile, wie
Lacke und Verunreinigungen, anhaften.
Doch nach wie vor hat auch der klassische
Herdofen, den LOI ebenfalls im Programm
hat, seinen Platz in der Halbzeuggießerei, da
der Zweikammer-Schmelzofen ein höheres
Investment erfordert, sodass dort, wo sauberes
Blockmaterial anfällt (Pressbolzen, Profiloder Walzbarrenabschnitte), der klassische
Schmelzofen durchaus eine wirtschaftlichere
Alternative ist. Der Zweikammer-Schmelzofen TCF bietet dafür mehr Flexibilität.
So wichtig der chinesische und europäische
Markt in den vergangenen Jahren für LOI
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ALUMINIUM · 5/2014
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35
Schmelzen, gieSSen und Wärmebehandeln
waren, so sieht Meyer auch Marktpotenzial
für den Zweikammer-Schmelzofen TCF in allen anderen Regionen der Welt.
Generell zeigt sich, dass der Markt für
Schmelzöfen längst nicht ausgereizt ist. Die
jüngsten Investitionsankündigungen in der
Aluminiumwalzindustrie, der stetig wachsende Bedarf nach Aluminiumhalbzeug sowie
die in den kommenden Jahren vermehrt
aus dem Markt zurückkommenden Gebrauchtschrotte, gepaart mit dem Streben vieler Halbzeugfirmen und Endproduktanbieter,
den Recyclinganteil in ihren Produkten zu
erhöhen – all dies erfordert Investitionen in
Recycling- und Schmelzöfen. Davon werden
Ofenbauer wie LOI Thermprocess auch in den
kommenden Jahren profitieren.
Wärmebehandlung –
die Walzwerke im Fokus
Das gilt übrigens in ähnlicher Form auch für
Projekte im Bereich der Wärmebehandlung
zur Einstellung definierter Werkstoffeigenschaften. In den klassischen Industrieländern
ist die Wärmebehandlung eine feste Größe
innerhalb der Fertigungskette. Aber auch in
Asien oder im mittleren Osten gewinnt mit
dem steigenden Industrialisierungsgrad die
Wärmebehandlung an Bedeutung. Das zeigt
sich gerade auch dort, wo Walzwerkskapazitäten aufgebaut werden. Zum Beispiel das
Ma’aden-Alcoa-Walzwerk in Saudi-Arabien:
LOI Thermprocess liefert eine Wärmebehandlungslinie für Aluminiumband, die aus EinzelBund-Hubherdöfen zur individuellen Wärmebehandlung von Coils besteht. Die Anlage
arbeitet von der Entnahme aus dem Lager bis
zur Wiedereinlagerung des wärmebehandelten Coils vollautomatisch.
Meyer stellt insgesamt eine verstärkte
Projekttätigkeit im Bereich der Wärmebehandlung fest – und dass manche Kunden,
die zunächst Recyclingöfen bestellt haben,
nach einigen Jahren auch mit Anfragen und
Aufträgen für Wärmebehandlungsanlagen auf
LOI zukommen. „So zum Beispiel ein Kunde
in China, an den wir zunächst einen Zweikammer-Schmelzofen TCF geliefert haben.
Derzeit sind drei weitere in Bau und auch der
Vertrag für eine Wärmebehandlungsanlage
von Coils ist unter Dach und Fach. Wir stellen
Einzel-Bund-HubherdofenzurindividuellenWärmebehandlungvonCoils
36
cheaper alternative although the Twin-Chamber Melting Furnace offers more flexibility.
As important as the Chinese and European
markets have been for LOI in past years, Mr
Meyer also sees market potential for TCFs in
other parts of the world as well.
In general terms it is evident that the market for melting furnaces is far from exhausted.
The most recent investment announcements
in the aluminium rolling industry, the steadily growing demand for aluminium semis and
the increasing quantities of used scrap that
will be coming back from the market in the
coming years, coupled with the efforts by
many semis companies and end product suppliers to increase the recycling fraction in
their products, all this demands investment in
recycling and melting furnaces. This will be to
the benefit of furnace manufacturers such as
LOI in the years to come as well.
heat treatment – rolling
plants at the focus
Incidentally, this also applies in similar form
to projects in the sector of heat treatment for
Single-CoilLiftingHearthFurnacefortheindividualheattreatmentofcoils
ALUMINIUM · 5/2014
SPecial
the production of defined material properties.
In the traditional industrial countries heat
treatment is standard practice in production
chains. But in Asia too, or the Middle East, the
increasing level of industrialisation is adding
importance to heat treatment. That is particularly evident precisely wherever rolling plant
capacities are being created or extended. For
example the Ma’aden-Alcoa rolling plant in
Saudi-Arabia: LOI Thermprocess is supplying a heat treatment line for aluminium strip,
which consists of Single-Coil Lifting Hearth
Furnaces (SCLs) for the individual heat treatment of coils. From the recovery from store
up to the return of the heat treated coil to
the warehouse, this plant operates fully automatically.
All in all, Mr Meyer perceives increased
project activity in the sector of heat treatment
– and observes that many customers who first
ordered recycling furnaces also come to LOI
after a few years with inquiries about and orders for heat treatment units. “For example,
there is a customer in China to whom we first
supplied a TCF. Now, three more of them are
being built and a contract for a heat treatment plant for coils has also been signed and
sealed. We are finding that the trend toward
heat treatment is becoming more marked in
China.” This involves among other things
plants for finish-annealing (softening annealing) of foils. “For that we have chamber furnace designs in which a number of roll sets
are assembled into a single charge and placed
on annealing racks. The heat treatment times
are relatively long. The racks can be loaded
manually or automatically.”
Intermediate annealing between the individual rolling processes is carried out in SCLs,
in which the individual coils are annealed as
required in order to produce the specified
properties. These SCLs, which LOI developed
and brought to readiness for marketing around
15 years ago, have proved very successful for
the company. The loading and removal of the
strip coils between the warehouse and the
heat treatment line, and the heat treatment
itself, take place fully automatically.
For diecast components, particularly structural components for automobiles, solutionannealing, quenching and ageing take place
in a fully automatic process. The load carriers are loaded and unloaded by robots when
necessary, and quenching takes place according to need with air, water or polymer. For
aviation products the demands on temperature uniformity with high reproducibility and
on the delay time before quenching are very
strict indeed. “For this, our overhead furnace
principle is ideal. It enables the components
ALUMINIUM · 5/2014
m e lt i n g , c a S t i n g a n d h e at t r e at m e n t
to be immersed in water completely within
seven seconds from the opening of the furnace door.” Aviation products are mainly preformed frame and sheet structural components
subjected to heat treatment.
The order situation for heat treatment
plants is currently very good. “There are
enough projects in the market, from both the
aviation and the automotive industries,” says
Mr Meyer. “In that respect we are in a good
position, even in China which is a market not
to be underestimated.”
With LOI Thermprocess (Tianjin) Co. Ltd
the company has a subsidiary in China, which
operates with both local and imported components. The company is an engineering bu-
ChargierungeinesFolienglühofens
Chargingofanannealingfurnaceforaluminiumfoil
reau with around 160 employees, exclusively
Chinese including the management. The overall technology comes from Essen in Germany
while production technology adaptations and
execution and assembly take place in China.
The company was founded in China in the
mid-1990s, and since then there have been
four expansions. Such a company development speaks for itself.
At present LOI can point to two plants for
the automobile industry in China: one is already in operation, while the other is currently still under construction. “These plants are
constructed by LOI in China in accordance
with German know-how, that is on the basis
of the technology that we develop and install
here in Europe, and fully commissioned on
site. Some special components come from
Germany. In other words: the plant will later
fest, dass der Schub in Richtung Wärmebehandlung in China stärker wird.“ Dabei handelt es sich unter anderem um Anlagen zum
Finishglühen (Entfestigungsglühen) von Folie.
„Dafür haben wir Kammerofenkonzepte, wo
mehrere Rollensets zu einer Charge zusammengestellt und auf Glühgestellen positioniert
werden. Die Wärmebehandlungszeiten sind
relativ lang. Die Beschickung der Glühgestelle
kann manuell oder automatisch erfolgen.“
Das Zwischenglühen zwischen den einzelnen Walzprozessen erfolgt in Einzel-BundHubherdöfen, in denen die einzelnen Coils
entsprechend der geforderten Eigenschaften,
die eingestellt werden sollen, individuell geglüht werden. Mit dem Einzel-Bund-Hubherdofen, den LOI vor circa
15 Jahren entwickelt
und zur Marktreife
gebracht hat, ist man
weiterhin sehr erfolgreich unterwegs.
Beschickung und Entnahme der Bandbunde
zwischen Lager und
Wärmebehandlungslinie und die Wärmebehandlung erfolgen
dabei vollautomatisch.
Für Druckgussteile,
insbesondere für Automobil-Strukturbauteile, erfolgt das Lösungsglühen, Abschrecken und Auslagern
in einem vollautomatischen Prozess. Das
Beladen der Warenträger und auch die
Entnahme
erfolgt
gegebenenfalls
mit
Robotern, die Abschreckung je nach Bedarf mit Luft, Wasser oder Polymer. Für
Luftfahrtprodukte sind die Anforderungen an die Temperaturgleichmäßigkeit mit
hoher Reproduzierbarkeit und die Abschreckverzögerungszeit extrem hoch. „Dafür bietet
sich unser Überkopfofen-Prinzip an. Es ermöglicht, die Teile innerhalb von sieben Sekunden, vom Öffnen der Tür gerechnet, komplett ins Wasser zu tauchen.“ Bei den Luftfahrtprodukten handelt es sich insbesondere
um vorgeformte Rahmen- und Blechstrukturteile, die einer Wärmebehandlung unterzogen
werden.
Für Anlagen zur Wärmebehandlung ist die
Auftragslage derzeit recht gut. „Es gibt genügend Projekte im Markt, sowohl aus der Luftfahrt- als auch aus der Automobilindustrie“,
sagt Meyer. „Hier sehen wir uns gut positio-
37
Schmelzen, gieSSen und Wärmebehandeln
niert, auch in China, das ein weiterhin nicht
zu unterschätzender Markt ist.“
Das Unternehmen verfügt mit LOI Thermprocess (Tianjin) Co. Ltd. über eine Tochterfirma in China, in der mit lokalen und importierten Komponenten gearbeitet wird.
Die Gesellschaft ist ein Ingenieurbüro mit
rund 160 Mitarbeitern – ausschließlich Chinesen einschließlich des Managements. Die
gesamte Technologie kommt aus Essen, die
fertigungstechnischen Anpassungen sowie
die Ausführung und Montage finden in China statt. Gegründet wurde die Gesellschaft
in China Mitte der 1990er Jahre, in der
Zwischenzeit ist man im Zuge von Erweiterungen vier Mal umgezogen. Diese Entwicklung der Gesellschaft spricht für sich.
LOI kann aktuell auf zwei in der Abwicklung befindliche Anlagen für die Automobilindustrie in China verweisen: Eine ist bereits
in Betrieb, die andere derzeit in der Fertigung.
„Diese Anlagen werden nach deutschem
Knowhow, also basierend auf der Technik, die
wir hier in Europa entwickeln und installieren, bei LOI in China gebaut und komplett in
Betrieb genommen. Gewisse Spezialteile kommen aus Deutschland. Mit anderen Worten:
Die Anlage hat später chinesischen Stahl mit
deutscher Technik und europäischen Komponenten“, so Meyer.
consist of Chinese steel, with German technology and European components.”
großes Wachstumspotenzial
im aluminiumsektor
great potential for growth
in the aluminium sector
Aus dem Gespräch heraus entsteht der Eindruck, dass China für LOI Thermprocess mittlerweile eine wichtige Rolle spielt, „jedenfalls
bei Schmelz- bzw. Recyclingöfen. Bei den
Anlagen zur Wärmebehandlung ist das keineswegs so. Hier waren und sind wir stärker
in Europa unterwegs. In gewisser Weise ist das
ein natürlicher Prozess. Wir haben in China
mit unseren Schmelz- und Recyclingöfen reüssiert und sind nun in der Folge dort auch
mit Wärmebehandlungsanlagen erfolgreich.“
Auch der amerikanische Markt ist laut
Meyer wieder in Bewegung. Derzeit sind einige Projekte in der Bearbeitung und aktuell
wird eine Multi-Coil-Ofenanlage samt Chargiermaschine für einen Kunden modernisiert.
Insgesamt sieht er auch in den nächsten Jahren
deutliches Wachstumspotenzial im Aluminiumsektor, sowohl hinsichtlich der Wärmebehandlung als auch des Schmelzens. „Von einer
Marktberuhigung kann keine Rede sein. Und
der Weltmarkt ist riesig“, so Meyer.
■
From the discussion the impression emerged
that for LOI Thermprocess, China is meanwhile playing an important role, “at any rate
in the sector of melting and recycling furnaces.
In the case of plants for heat treatment, we
have been and still are doing much better
in Europe. To some extent that is natural. In
China we have proved successful with our
melting and recycling furnaces, and we are
now following up there with some success in
the context of heat treatment plants.”
Mr Meyer point out that the American
market is again beginning to move. At present
a few projects are underway and currently a
multi-coil furnace unit with charging machine
is being modernised for a customer. Overall,
he deems that there is substantial potential for
growth in the aluminium sector in the coming
years, both in the context of heat treatment
and also that of melting. “There can be no suggestion that the market is falling off. And the
total world market is huge”, he says.
n
BeschickungeinesWärmebehandlungsofensfürAutomobilteile
38
Chargingofaheattreatmentfurnaceforautomotiveparts
ALUMINIUM · 5/2014
SPecial
m e lt i n g , c a S t i n g a n d h e at t r e at m e n t
andritz maerz: zurück am markt für aluminiumschmelzöfen
andritz maerz: back in market
for aluminium melting furnaces
that are also widely known in the aluminium industry.
As far as furnace technology for
aluminium is concerned, it is primarily
Andritz Bricmont in the USA that has focussed attention on Andritz Metals in the
last two years. Düsseldorf-based Andritz
Maerz GmbH has been engaged actively
and systematically in this segment of the
market since the beginning of the year
– more or less since it exhibited at the
Euroguss trade fair in Nuremberg. ALUMINIUM spoke to Holger Schwarz, head
of sales of the newly formed Aluminium
division within Andritz Maerz, about the
direction being taken by the revitalised
aluminium business.
Andritz Maerz is focussing on melting furnaces for ferrous and non-ferrous metals. In
Düsseldorf some 90 employees are engaged
mainly in engineering and sales. With regards
manufacturing, the company can call upon the
resources of Bricmont in Canonsburg, Pennsylvania, which was acquired by the Andritz
© Andritz
The Andritz Group is one of the world’s
leading suppliers of plant, equipment and
services for hydroelectric power plants,
the pulp and paper, metal processing and
steel industries and for communal and industrial solid-liquid separation. The listed
technology concern employs around
23,700 people and is headquartered in
Graz, Austria. Andritz has over 250 production facilities and service and sales
companies worldwide. The group ranks
among the world’s market leaders in all
four areas where it operates.
Andritz Metals, one of these four
business divisions, supplies a very broad
range of plant and machinery for metal
forming as well as turnkey furnace systems for the steel, copper and aluminium
industries. The division includes wellknown companies like Andritz Sandwig
(rolling-mill technology), Andritz AG
(formerly Ruthner, chemical process
engineering), Andritz Bricmont (furnace
technology), Andritz FBB (burner systems
and refractory materials) – companies
HIT.E.Q.-MiniMelterwerdenmitSchmelzratenvon200bis500kg/hangeboten.DaskompakteZwei-
kammer-DesignerlaubtdasSchmelzen/WarmhaltendirektanderGießstation,wasHandlingkostenfür
denFlüssigtransportunddiedarausresultierendenTemperaturschwankungenvermeidet.
HIT.E.Q.MiniMeltersareavailablewithmeltratesof200to500kg/h.Thecompactdual-chamberdesign
allowsmeltingandholdingdirectlyatthecastingstation,whicheliminateshandlingcoststotransfer
moltenmetalandtheassociatedtemperaturefluctuationsthatresult.
ALUMINIUM · 5/2014
Die Andritz-Gruppe ist einer der weltweit führenden Lieferanten von Anlagen,
Ausrüstungen und Serviceleistungen für
Wasserkraftwerke, die Zellstoff- und
Papierindustrie, die Metall verarbeitende
Industrie und Stahlindustrie sowie die
kommunale und industrielle Fest-FlüssigTrennung. Der Hauptsitz des börsennotierten Technologiekonzerns, der rund
23.700 Mitarbeiter beschäftigt, befindet
sich in Graz, Österreich. Andritz verfügt
über mehr als 250 Produktionsstätten sowie Service- und Vertriebsgesellschaften
auf der ganzen Welt. Die Gruppe zählt
in allen ihren vier Geschäftsbereichen zu
den Weltmarktführern.
Andritz Metals, einer der vier Geschäftsbereiche, liefert ein sehr breites
Produktspektrum an Anlagen und Maschinen zur Metallumformung sowie von
schlüsselfertigen Ofensystemen für die
Stahl-, Kupfer- und Aluminiumindustrie.
Zum Unternehmensbereich zählen renommierte Firmen wie Andritz Sundwig
(Walzwerktechnik), Andritz AG (vorm.
Ruthner, chemische Prozesstechnik), Andritz Bricmont (Ofentechnologie), Andritz
FBB (Brennersysteme und Feuerfestmaterial) – Firmen, die auch in der Aluminiumindustrie weithin bekannt sind.
Soweit es die Ofentechnologie für den
Werkstoff Aluminium betrifft, ist Andritz
Metals in den vergangenen beiden Jahren vor allem durch die Firma Andritz
Bricmont in den USA, in Erscheinung
getreten. Seit Anfang dieses Jahres, quasi
gleichzeitig mit dem Messeauftritt auf
der Euroguss in Nürnberg, bearbeitet
auch die Andritz Maerz GmbH mit Sitz
in Düsseldorf wieder aktiv und systematisch dieses Marktsegment. ALUMINIUM
sprach mit Holger Schwarz, dem Leiter
Vertrieb des neu gegründeten Geschäftsbereichs Aluminium innerhalb der Andritz Maerz, über die Ausrichtung des
wiederbelebten Aluminiumgeschäftes.
Andritz Maerz konzentriert sich auf Schmelzöfen für NE- und Eisen-Metalle. Die rund 90
Mitarbeiter in Düsseldorf sind überwiegend
mit dem Engineering und Vertrieb befasst.
Soweit es die Fertigung betrifft, kann auf
Ressourcen der 2012 von der Andritz-Gruppe erworbenen Bricmont in Canonsburg,
Pennsylvania, zurückgegriffen werden. Die
Schwestergesellschaft ist mit einem breiten
Spektrum an Schmelz- und Halteöfen bis hin
39
Schmelzen, gieSSen und Wärmebehandeln
zu kompletten Gießsystemen und der metallurgischen Metallbehandlung am Markt aktiv.
„Darüber hinaus steht mit Andritz FBB in
Mönchengladbach gruppenintern ein Lieferant für Brennersysteme und Feuerfestmaterial für die Ofenauskleidung zur Verfügung“,
sagt Schwarz.
In den vergangenen Jahren standen bei
Andritz Maerz vor allem Ofensysteme für
Kupfer- und Eisenwerkstoffe im Vordergrund.
Was hat nun den Sinneswandel zugunsten
von Aluminium ausgelöst? „Wir haben, nicht
zuletzt durch den Erwerb von Bricmont, gesehen, dass der Markt für Aluminium-Schmelzöfen offen für weitere Anbieter ist. Der Markt
wächst dynamisch, sowohl international als
auch hier in Deutschland und Europa, und
wir sehen uns mit unserer Ofentechnologie
gut aufgestellt. Die HI T.E.Q. Linie von Bricmont ist bereits seit mehr als 30 Jahren in Nordamerika erfolgreich. Mit ihr wollen wir jetzt
auch auf dem europäischen Markt Fuß fassen.
Die Anfragen von potenziellen Kunden, die
bei uns seit Anfang des Jahres eingegangen
sind, sind sehr ermutigend.“
Und nicht nur die Anfragen. Konkret sind
zwei Aluminium-Aufträge in Deutschland in
Abwicklung, die noch aus dem Vorjahr herrühren. Dabei handelt es sich um Schmelzöfen
für Sekundärmaterial mit einer Schmelzleistung von 15 Tonnen pro Stunde. Weitere
Details zu Auftraggeber und Projektbeschreibung sind Schwarz nicht zu entlocken. Aber
dies zeigt, dass Andritz Maerz in den zurückliegenden Jahren doch nicht ganz weg vom
Marktsegment Aluminium war, auch wenn
man jetzt mit frischem Schwung neu startet.
Weitere Aufträge aus Europa, und zwar aus
Österreich und Tschechien, sind unter Dach
und Fach. Mit einem Kunden in der Türkei
steht man derzeit in abschließender Verhandlung. In diesen drei Projekten geht es um die
Lieferung von Schachtschmelzöfen, die für
Andritz Maerz einen geschäftlichen Schwerpunkt darstellen werden.
Europa ist laut Schwarz ein attraktiver
Markt, auch in den kommenden Jahren: „Ich
habe in der europäischen Region Angebote
für fast 20 Millionen Euro ausliegen, die in
den nächsten Wochen und Monaten noch besprochen werden.“ Der Markt ist im Wesentlichen von der Automobilproduktion getrieben. Hier spielt der zunehmende Einsatz von
Aluminium im PKW und die damit verbun-
Group in 2012. The sister company is actively
engaged in the market with a broad range of
products from melting and holding furnaces
through to complete casting systems and metallurgical metal treatment. “On top of this,”
adds Mr Schwarz, “we also have Andritz FBB
of Mönchengladbach which supplies burner
systems and refractory materials for furnace
lining within the group.”
In recent years, Andritz Maerz has focussed
mainly on furnace systems for copper- and
iron-based materials. So what has brought
about this change of mind in favour of aluminium? “Not least because of the acquisition of
Bricmont we have seen that there is an opportunity for additional suppliers in the market
for aluminium melting furnaces. The market
is growing dynamically, not only internationally but also here in Germany and Europe, and
we are well positioned here with our furnace
technology. Bricmont’s HI-T.E.Q. line has already been enjoying success for over 30 years
in North America. We now want to use it to
gain a foothold in the European market. The
enquiries that we have received from potential customers since the beginning of the year
have been very encouraging.”
HIT.TE.Q.SchaftschmelzöfenwardenmitSchmelzratenvon500bis4.500kg/hangeboten.DieseÖfenkennzeichneteingeringerEnergieverbrauch,
hoheProduktivitätundniedrigeKostenfürAbgasreinigung.DiessicherteineschnelleAmortisationderInvestition.
HIT.E.Q.stackmeltersareavailablewithmeltratesof500to4,500kg/h.Thestackmelter’senergysavings,increasedproductivityandreduced
emissionscontrolcostsofferaluminiumcastersaquickpaybackontheirinvestment.
40
ALUMINIUM · 5/2014
SPecial
And not only the enquiries. The company is
presently processing two orders for aluminium
furnaces in Germany that it received last year.
They are for melting furnaces for secondary
material with melting rates of 15 tonnes an
hour. Mr Schwarz was not willing to reveal
further details about the client or the project;
however, this projects demonstrate that Andritz Maerz had not completely ignored the aluminium market segment in recent years even
though the company is now addressing it with
renewed vigour. Further orders have been received from elsewhere in Europe, namely from
Austria and the Czech Republic. The company
is currently finalising an agreement with a
customer in Turkey. All three projects involve
the supply of stack melters, which will be one
of Andritz Maerz’ business focuses in future.
According to Mr Schwarz, Europe is an
attractive market and will continue to be so
in the coming years: “In Europe I have offers
totalling almost 20 million euros that will be
negotiated in the coming weeks and months.”
The market is being driven primarily by carmaking. The increasing use of aluminium in the
motorcar and the resultant material substitution is playing a central role here, but total
car production worldwide is also growing. The
demand for melting plant in foundries is thus
increasing accordingly.
The company is also looking beyond the
European horizon, of course. The Asian region
is equally important, not only China, where
30 Andritz furnaces are already in use for
melting down aluminium. In the past five years
the company has sold ten melting furnaces to
China, including to Prime Wheel Corporation, which operates a plant for cast aluminium wheels in Kunshan. Singapore, Malaysia,
Indonesia and Vietnam are also regions that
are growing dynamically and firmly in the
company’s sights. South America and Mexico
are developing into interesting markets or
production locations as well.
Although there is a certain division of
work with respect to furnace construction
within Andritz Metals, there is no exclusivity.
“Bricmont is strong in North America but we
at Maerz have also received enquiries from
South America and the USA. Conversely,
Bricmont has received enquiries from Europe.
We make companies aware of our colleagues
based locally, of course, but if customers do
not want to deal with them, for example because of established business connections, we
naturally comply with their wishes. After all,
the customer is king.”
As part of a globally active group with numerous production facilities and service locations, the company can also offer a prompt
ALUMINIUM · 5/2014
m e lt i n g , c a S t i n g a n d h e at t r e at m e n t
dene Werkstoffsubstitution eine zentrale Rolle, aber auch, dass die Weltautomobilproduktion insgesamt weiter wächst. Entsprechend
steigt die Nachfrage nach Schmelzanlagen in
den Gießereien.
Natürlich geht der Blick auch über den
europäischen Tellerrand hinaus. Der asiatische Raum ist gleichermaßen interessant,
nicht nur China, wo 30 Andritz-Öfen zum
Einschmelzen von Aluminium stehen. In den
letzten fünf Jahren wurden zehn Schmelzöfen nach China verkauft, unter anderem an
Prime Wheel Corporation, die in Kunshan
ein Werk für Alu-Gussräder betreiben. Auch
Singapur, Malaysia, Indonesien und Vietnam
sind dynamisch wachsende Regionen und fest
im Blick. Südamerika und Mexiko entwickeln
sich ebenfalls zu interessanten Märkten bzw.
Produktionsstandorten.
Zwar gibt es beim Ofenbau innerhalb von
Andritz Metals eine gewisse Arbeitsteilung,
aber keine Ausschließlichkeit. „Bricmont ist
stark in Nordamerika, aber wir hatten bei der
Maerz auch schon Anfragen aus Südamerika
und den USA. Umgekehrt gab es aus Europa
Anfragen an Bricmont. Man verweist natürlich auf die Kollegen vor Ort, aber wenn der
Kunde das beispielsweise aufgrund alter Geschäftskontakte nicht möchte, kommen wir
seinem Wunsch selbstverständlich nach. Der
Kunde ist schließlich König.“
Und als Teil einer weltweit agierenden
Gruppe mit zahlreichen Produktionsstätten
und Service-Standorten kann auch ein zeitnahes After-Sales-/Ersatzteil-Geschäft mit lokaler Betreuung und Problemlösungskompetenz angeboten werden.
Sind denn die erforderlichen Ressourcen,
sprich Fachleute im eigenen Haus in Düsseldorf vorhanden, um dieses neue Marktsegment zu bearbeiten? Schwarz weist darauf
hin, dass man noch vor sieben Jahren Aluminium-Schmelzöfen gebaut hat, bevor man sich
auf Kupfer und Stahl konzentrierte. Natürlich
werde der neue Bereich noch personell verstärkt, aber das Knowhow an Ofentechnologie
sei vorhanden. Und so grundverschieden sei
der Ofenbau für Kupfer und Aluminium nicht.
„Da muss man mit anderen Materialien bei
der Auskleidung arbeiten, wegen der unterschiedlichen Schmelzpunkte. Durch die speziellen Aluminiumlegierungen, die bei Automotive-Produkten zum Einsatz kommen, gibt
es spezielle Anforderungen an den Ofenbeton,
aber da ist nichts, das nicht beherrschbar ist.“
Die Andritz Maerz Öfen werden in unterschiedlichen Ausführungen angeboten: zum
Befüllen der Transportpfannen kippbar oder
statisch, dann mit Abstichventil oder mit einer
seitlichen Kammer, in der eine kontinuier-
liche Pumpe arbeitet, die ein bestimmtes Badniveau in der Kammer erzeugt, um das Metall
kontinuierlich zu entnehmen. Ein Markttrend
zu einer speziellen Ausführung lässt sich nicht
ausmachen. Eine kippbare Version ist relativ
aufwendig und erfordert große Hydraulikstempel unter dem Ofen. Das kostet, und ist
die Hydraulik defekt, lässt sich kein Metall
abgießen. Öfen mit Abstichventil sind nicht
unproblematisch, weil der Bediener, der den
Abstich vornimmt, in unmittelbarer Nähe
zum heißen Flüssigmetall arbeitet.
Secondary Öfen und
Schachtschmelzöfen im Fokus
Im Wesentlichen sind es zwei Ofensegmente,
in denen das Geschäft von Andritz Maerz
neu anläuft. Zum einen Großschmelzöfen
für Secondary Aluminium, also für Schrotteinschmelzer, und zum anderen Schachtschmelzöfen. Letztere weisen einen mehrere
Meter hohen Schacht auf, in den von oben mit
entsprechenden Vorrichtungen chargiert wird.
Das Material rutscht winkelbedingt langsam
nach und nach auf die Schmelzbrücke, wo es
abgeschmolzen wird und ins Bad fließt.
Was unterscheidet diese beiden Ofen-Segmente? Die Secondary Öfen bietet Andritz
Maerz mit einer Schmelzleistung von fünf bis
25 Tonnen pro Stunde an. Diese Anlagen zielen in erster Linie auf Altschrotte und Rücklaufmaterialien aus Gießereien oder anderen
Verarbeitungsbetrieben. Die Öfen sind mit
energieeffizienten, regenerativen Brennern
von Andritz FBB ausgestattet, mit einer Brennerleistung von typischerweise 5.000 kW,
und halten die neuesten NOx-Werte kleiner
300 mg/Nm3 ein.
„Unsere Anlagen, egal ob es sich dabei um
einen Schacht- oder klassischen Einschmelzofen handelt, sind so ausgelegt, dass sie den
Energiebedarf von Bestandsanlagen um zehn
bis 15 Prozent reduzieren“, sagt Schwarz. Er
bezieht sich dabei auf den (DIN-)Normwert
für das Einschmelzen von Aluminium, der bei
650 kWh pro Tonne liegt.
Bei der Vermarktung von Schachtschmelzöfen wird auf die HI T.E.Q. Linie von Andritz
Bricmont zurückgegriffen. Hierbei handelt es
sich um Anlagen für Druck- und Niederdruckgießereien mit Schmelzleistungen ab 300 Kilogramm aufwärts bis fünf Tonnen pro Stunde.
„Diese Öfen schmelzen keine Altschrotte,
sondern vor allem Masselpakete aus Primäraluminium oder sauberes Rücklaufmaterial
aus der eigenen Verarbeitung“, so Schwarz.
Die Entscheidung des Betreibers für einen
Schachtschmelzofen hängt mit dem Bedarf
an kontinuierlicher Abschmelze zusammen.
41
Schmelzen, gieSSen und Wärmebehandeln
Daher finden sich diese Öfen vielfach bei
Automobilgießereien, die sehr viel Flüssigmetall pro Tag benötigen und deshalb oft ein
halbes Dutzend oder auch mehr Schachtöfen
betreiben, um Material mit identischen Legierungen einzuschmelzen.
Bei den Secondary Öfen wird in der Regel
heterogenes Schrottmaterial über den Markt
gekauft, eingeschmolzen und nach Bedarf
nachlegiert. Beim Einschmelzen gilt es, durch
Spülsteine und magnetische Rührer eine gereinigte und homogene Schmelze zu erzielen. Über ein Rinnensystem geht die flüssige
Schmelze auf ein Masselband, um dort die
fertigen Masseln abzugießen, die dann zum
Beispiel an Formgießereien mit ihren Schachtschmelzöfen geliefert werden. Dort wird das
Material wieder aufgeschmolzen, um das Endprodukt, zum Beispiel einen Motorblock, zu
gießen.
Meist werden die Anlagen mit einer Abgasreinigung versehen, um strenge Reinigungswerte einzuhalten. Es lassen sich die Abgase
im Ofen aber auch so über das Bad führen,
dass eine Verbrennung erfolgt, sodass eine
Filteranlage nicht in jedem Fall erforderlich
ist. Sind die Rücklaufmaterialien jedoch stark
kontaminiert, zum Beispiel mit Schneidöl aus
der Fertigung oder mit Graphitschmiermitteln
am Anguss eines Gussteils, entstehen Dämpfe
beim Einschmelzen, sodass man um eine Filteranlage nicht herumkommt. Dass darauf in
manchen Schwellenländern aus Kostengründen dennoch gerne verzichtet wird, ist kein
Geheimnis.
Werden lackierte und / oder verunreinigte
Schrotte eingeschmolzen, ist ein höherer Abbrand, sprich Metallverlust zu verzeichnen als
bei Schachtschmelzöfen, die deutlich reineres
Material einsetzen. Schwarz nennt für moderne Schachtschmelzöfen einen Abbrand von
ein bis drei Prozent. Hier wie bei den Secondary Öfen liegt ein enormes Einsparpotenzial.
„Ein niedriger Metallverlust zahlt sich in barer
Münze aus“, betont Schwarz. „Das kann sich
aufs Jahr gerechnet zu Hunderttausenden
Euro addieren, wenn der Metallverlust durch
einen neuen, modernen Ofen allein um einen
Prozentpunkt reduziert wird.“
Ein Schachtschmelzofen bietet energetisch
und auch mit Blick auf die Metallausbeute
gewisse Vorteile. Unabhängig vom Ofentyp
lassen sich die Abgase zum Vorwärmen des
Einsatzmaterials nutzen, doch ist der Aufwand
unterschiedlich hoch. Im Schachtofen erfolgt
die Vorwärmung durch die aufsteigenden
Abgase bereits im Schacht. Beim klassischen
Schmelzofen ist eine separate Vorwärmkammer notwendig und das Abgas muss entsprechend umgeleitet werden. Prinzipiell ist
42
after-sales service and spares business with
support and problem-solving capabilities locally.
Does the company have the necessary resources, in other words the necessary in-house
specialists, at the Düsseldorf location to service this new market segment? Mr Schwarz
points out that the company had previously
built aluminium melting furnaces, seven years
ago before it concentrated on copper and
steel. Additional personnel will obviously be
employed in the new division but the necessary expertise in furnace technology is already
available. And furnace construction for copper and aluminium are not entirely different.
“One has to work with different materials
for the furnace lining
because of the differing melting points. The
special aluminium alloys used for automotive products have distinctive requirements
with respect to the
furnace concrete, but
that is not something
we cannot control.”
Different types of
Andritz Maerz furnace
are available: tiltable
or static for filling the
transport ladle, with
a tapping valve or a
side hearth in which
a continuously operDankmoderner3D-KonstruktionstoolskanndasLayoutvonSchmelz-/Halteating pump maintains
GießzellenentworfenundmitdemKundennochvordemerstenSpatenstich
a certain bath level in
diskutiertwerden
Melterandholdercastingcellutilising3DdesigntoolshelpAndritzengineers the hearth, allowing
metal to be removed
todevelop,understandanddiscussthelayoutbeforeanysoilisbroken
continuously. There is
metrie des Schachtes oder der Schmelzbrücke no apparent market trend towards a specific
type of furnace. A tiltable version is relatively
lässt sich Energie einsparen.
Auf die Frage, ob nicht auch Modernisie- complex and requires a large hydraulic ram
rungen eine Alternative zu Neuinvestitionen underneath the furnace. This is expensive and
sind, um die Energieeffizienz zu erhöhen, metal cannot be poured if the hydraulics fail.
spricht Schwarz nicht grundsätzlich dagegen, Furnaces with a tapping valve are not without
verweist aber darauf, dass auch Modernisie- their problems either because the operator
rungen mit erheblichem Aufwand und Inve- who carries out the tapping has to work in the
stitionen verbunden sind. „Es müssen schließ- vicinity of hot molten metal.
lich neue Brenner eingesetzt oder der Ofen
muss umgebaut werden, um andere Winkel Focus on secondary furnaces
für die Brennerposition zu erhalten. Ich kann and stack melters
auch keinen Ofen im Betriebszustand modifizieren, er muss abkühlen, das ruiniert die Basically, Andritz Maerz is accruing new busiAusmauerung, und bei Stillstand entgehen ness in two segments of the furnace market:
dem Betreiber wichtige Einnahmen. Wenn es large melting furnaces for secondary aluminkeine Platzprobleme gibt, spricht vieles für ei- ium, in other words companies that melt down
nen Neubau.“ Schwarz sieht im Geschäft mit scrap, and stack melters. The latter are charNeuanlagen auch den Arbeitsschwerpunkt acterised by a stack several metres high that
von Andritz Maerz.
■ is charged from above using the appropriate
natürlich auch möglich, die Abgase nicht zur
Vorwärmung zu nutzen, sondern über einen
Wärmetauscher zur Erzeugung von heißem
Wasser oder zur Beheizung der Gießerei.
„Es wird heute immer mehr Wert auf solche
Komplettlösungen gelegt und natürlich arbeiten wir auf Wunsch entsprechende Lösungsvorschläge aus“, so Schwarz.
Bei einer direkten Einwirkung der Brenner
auf das kalte Einsatzmaterial entsteht automatisch ein höherer Abbrand, als wenn das
Material bereits im Schacht vorgewärmt ist,
sodass es sanfter und schneller durch die
Brenner abgeschmolzen wird. Das spart Energie und führt zu geringerem Abbrand. Auch
durch konstruktive Veränderungen der Geo-
ALUMINIUM · 5/2014
SPecial
equipment. Dictated by the angle chosen, the
charge slides slowly step by step to the melting bridge, where it melts and then flows into
the bath.
What’s the difference between the two
market segments? Andritz Maerz offers secondary furnaces with melting rates of five
to 25 tonnes an hour. These units are aimed
primarily at melting post-consumer scrap or
process scrap from foundries or other metalprocessing plants. The furnaces are fitted with
energy-efficient regenerative burners from
Andritz FBB, typically with a burner capacity
of 5,000 kW, and meet the latest NOx requirements of less than 300 mg/Nm3.
“Regardless of whether it is a stack melter
or a classical melting furnace, our plants are
designed in such a way that they reduce the
energy requirement of existing installations
by ten to 15 percent,” says Mr Schwarz. He
bases this figure on the (DIN) standard value
for melting down aluminium of 650 kWh a
tonne.
The HI T.E.Q. line from Andritz Bricmont
will be used to market stack melters. These
units are used in foundries for pressure and
low-pressure die-casting with melting rates
from 300 kilograms up to five tonnes an hour.
According to Mr Schwarz: “These furnaces
are not used to melt post-consumer scrap but
mainly small primary aluminium ingots or
clean in-house process scrap.” The decision by
a plant owner to choose a stack melter depends
on the need for continuous melting. In many
cases, these furnaces are therefore found in
car-plant foundries that require large amounts
of liquid metal a day and thus often operate
half a dozen or more stack melters to melt
down identically alloyed material.
In the case of secondary furnaces, heterogeneous scrap is usually bought in, melted
down and subsequently alloyed as required.
During melting down, a cleaned and homogenous melt is obtained using porous plugs and
magnetic stirrers. The molten melt flows via
a channel system onto an ingot mould chain,
where the finished ingots are cast and then
shipped, for example, to shape-casting foundries operating stack melters. There the material is melted again in the foundry in order
to be able to cast it into the finished product,
such as an engine block.
Units are mostly equipped with flue-gas
cleaning to satisfy stringent permitted emission levels. It is also possible to channel the
flue gases in the furnace across the bath in
such a way that combustion occurs and a filter
is then not necessary in every case. However,
if the recycled materials are badly contaminated, for example with cutting oil from the
ALUMINIUM · 5/2014
It‘s a pure waste of time
... if you make do with anything less!
manufacturing process or with graphite lubricants on the gate system of a casting, vapours
are produced on melting down and a filter
unit is unavoidable. Nevertheless, in certain
emerging countries it is no secret that some
companies gladly forego such systems for reasons of cost.
If painted and / or contaminated scrap is
melted down in secondary furnaces, there is
greater burn-off, in other words loss of metal,
than in stack melters, which use significantly
cleaner charge material. Mr Schwarz puts a
figure of one to three percent on the burnoff in modern stack melters. As with secondary furnaces, there is enormous potential for
savings here. “A lower metal loss pays off in
hard cash,” he emphasises. “If a new modern
furnace only reduces the metal loss by a single
percentage point, it can amount to savings of
several hundred thousand euros a year.”
A stack melter offers certain benefits from
both energy and metal yield viewpoints. Regardless of the furnace type, the flue gases can
be used to preheat the charge material, but
there are differences in the effort involved.
In stack melters, the upward rising flue gases
already result in preheating place in the stack.
In a classical melting furnace, a separate preheating hearth is required and the flue gases
have to be channelled accordingly. In principle, it is also possible, of course, not to use the
flue gases for preheating but to produce hot
water or heating for the foundry via a heat
exchanger. “Today, ever more value is placed
on such complete solutions and on request
we offer proposals for suitable solutions.”
If a burner impinges directly onto cold
charge material, there is automatically greater
burn-off than when the material is preheated
in the stack such that the burner melts it down
more gently and more quickly. This saves energy and leads to less burn-off. It is also possible to save energy by changing the geometry
of the stack or the melting bridge.
Asked whether refurbishment might not
be a possible alternative to a new investment
in order to increase energy efficiency, Mr
Schwarz is not fundamentally opposed to the
idea but points to the fact that refurbishments
also involve considerable effort and investments. “Ultimately, new burners have to be
installed or the furnace has to be reconstructed
to obtain other burner angles. Additionally, I
cannot modify a furnace while it is in operation; it has to cool down and this ruins the lining
and the plant owner loses important revenues
during the shutdown. If there are no limitations on space, there are a lot of arguments in
favour of a new build.” He sees Andritz Maerz
focussing its efforts on new units as well. n
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M E LT I N G , C A S T I N G A N D H E AT T R E AT M E N T
Aluminicaste – a new remelt facility in Mexico
© Aluminicaste
“We can ship anywhere in the world from our plant”
The casthouse with one of the two DC casting lines in the foreground
Situated on a fertile plateau in the
Guanajuato State in Central Mexico,
Aluminicaste Fundicion de Mexico
(Aluminicaste) is well located to actively
support the northern and southern hemispheres with a wide range of high quality aluminium products. The most asked
question is: “Why Mexico?” Looking to
the future of aluminium supply in the
two hemispheres, one can easily track the
supply lines flowing into the US, Mexico,
Central and South America.
Due to the demand for inexpensively supplied electrical power, the continuing decline
of primary aluminium production is well written. This has allowed groups of entrepreneurs
who see the future of aluminium production
as smaller, very nimble, regionally focused
remelt facilities in the support of the industry.
This change in the supply paradigm started
in the early 1990s as individuals studied the
supply structure amidst the multiple consolidations happening within the primary producers. These consolidations seemed to not
take into account the extruder and his or her
44
desire to maintain control over their purchasing process. Adapting a company’s marketing
programme to fit the client base is much better than attempting to adapt a client base to a
company’s marketing programme.
While many saw the need for the construction of new regionally located remelt facili-
ties, few had the necessary capital to create a
plant to join the market and serve it efficiently.
When looking at the extruder locations, one
can pick out regions which are attractive for
the development of a remelt facility. The Upper Midwest of the US has seen an explosion
of new facility growth over the last decade
Equipment supplier Wagstaff was chosen for the billet casting systems
ALUMINIUM · 5/2014
SPECIAL
M E LT I N G , C A S T I N G A N D H E AT T R E AT M E N T
Aluminicaste is equipped with two 35tonne DC casting lines, heat treatment facilities, sawing and packaging stations. The
plant layout allows the installation of three
additional casting lines.
Though focused on the production of
extrusion billet and log, the company is
also capable of producing rolling slab and
forging ingot.
Each casting line is fed by two 40tonne, single-chamber melting / holding
furnaces, designed by GNA alutech. Feedstock is clean aluminium production scrap.
GNA was also awarded the supply of three
70-tonne homogenising furnaces and a
cooling chamber.
The billet casting system is from Wagstaff.
One of the two 40-tonne single-chamber melting / holding furnaces
and a half while reports continue to advise
of an even larger new facility under review.
The Northeast region of the US has also seen
some growth in these cast house programmes.
While some will argue there are underserved
regions in the US, very few were looking outside the US. The increased usage of aluminium throughout Mexico, Central and South
America has been documented but gets lost
as the industry seems to focus on the larger
US market.
Mexico’s per capita usage of aluminium
rose from 2.5 kg in 1980 to an expected 11.2
kg per capita by 2025. A strong automotive production market continues to grow in
Central Mexico and multiple new aerospace
facilities underway will continue to expand.
The investor, developers and managers of
Aluminicaste saw these new growth markets
tying into the State of Guanajuato’s vision to
create better infrastructure to support export
of the products produced by these new facilities. Aluminicaste agreed with these worldclass companies that the State of Guanajuato was an efficient, well-placed location for
growth. Based centrally in the country, Aluminicaste is equidistance from both coasts.
Served very well by truck and rail, the company can efficiently transport its products to
the border, where working with top-rated
brokers, we can manage a supply line as if the
client was simply across town.
Breaking ground in September of 2011, the
first commissioning cast took place in December 2012. Having the ability to cast 6”, 7”, 8”
and 10” cut-to-length billet and log, Alumincaste can produce a wide range of alloys in
the 2xxx, 3xxx, 5xxx, 6xxx and 7xxx series.
ALUMINIUM · 5/2014
Adding 9” in mid-2014, the remelter is already looking to the future and the need for
even a wider range of diameters and product
lengths. Offering both soft and hard alloys is
unique to Aluminicaste. While capital investment with some of the groups developing
these casthouses was the deciding factor, the
vision and decision to build a plant which can
service multiple aluminium extrusion or rolling clients puts Aluminicaste at the tip of the
spear in supporting a wider industry.
“We are a plant dedicated to achieving
aerospace and automotive quality certificates,” stated Shaun Hamer, Aluminicaste VP
of Engineering, and: “We will be growing the
company, adding volume and technology
which will be needed by the extruder, rolling mill or forging operation.” Sander Huang,
VP of Administration and Operations, added:
“We developed this plant after reviewing the
logistic capabilities of this area. We can ship
anywhere in the world from our plant and intend to support this industry.”
Logistics support allowing for the delivery
of its product anywhere, anytime. Top-tier
product quality added to a first class work
force committed to safely producing products
the clients need. The strength, desire and ability to grow with the industry in support of the
regional and wider client base creates something new, innovative and exciting. We are redefining aluminium. We are Aluminicaste.” ■
Billet before being ultrasonically tested and homogenised
45
M E LT I N G , C A S T I N G A N D H E AT T R E AT M E N T
StrikoWestofen shaft furnace
Chicago White Metal Casting Inc. in the USA
has ordered a new StrikoMelter shaft furnace
for its aluminium, magnesium, and zinc diecasting operations, according to equipment
supplier StrikoWestofen America. This specific furnace, CWM says, was selected for having the lowest energy consumption by weight
of any in its class by weight of aluminium
melted. The StrikoMelter design uses the thermal energy generated by melting to preheat
ingots or returns, and also reduces heat loss
due by reducing turbulence during metal
transfer to the holding vessel.
The investment is expected to deliver immediate returns, it is claimed, since the metalcaster will realise significant fuel-savings by
operating the new furnace, and this will qualify the company to claim credit on its fuel purchases up to 50 percent of the project cost.
The Bensenville, Illinois producer of cast
metal parts offers design for manufacturing services, machining, and various custom
surface treatments. It also provides assembly of finished parts under turnkey contract.
StrikoWestofen America is an operating unit
of StrikoWestofen in Germany, manufacturer
of melting and holding furnaces for light metal
die casting, sand casting, permanent mould
casting and low-pressure casting.
The StrikoMelter is of shaft furnace design,
incorporating a patented ETAmax system that
combines charge preheating, heating and melting phases efficiently in a single melting channel, or ‘shaft’. While metal returns and ingots
are melted in the lower section, the combustion gases preheat the new charge material in
the shaft area above it.
Molten metal is transferred to the holding
bath without turbulence, the furnace designer
stresses, which reduces waste and maintains
a pre-set holding temperature with accuracy.
According to the company, the recuperative
concept is simple and effective, delivering significant savings in fuel consumption and reductions in metal loss.
By operating the new melting furnace Chicago White Metal will qualify for the Nicor
Gas Energy Efficiency Programme, an energypurchase rebate scheme funded by the Nicor
Gas Company of Northern Illinois. While
there are similar rebate programmes offered
by various utility companies, the Nicor initia-
© CWM
© StrikoWestofen
New melting furnace earns fuel savings rebate for US die caster
Aluminium baseplate for dental workstation: the
6 x 8.5 inch component design earned CWM a
die casting award due to an optimum gating and
runner system die design that allowed consistent
metal flow
tive currently rebates USD1 per therm saved,
per annum, up to USD500,000 – or 50 percent
of the total project cost, whichever is lower.
Alloy A380 – the die
casting workhorse material
Entries by Chicago White Metal Casting have
been winners in each of their categories in recent Die Casting Design Contests organised by
the North American Die Casting Association.
In the 1-10 lb Aluminium Die Casting category, CWM has won the award for a baseplate
control support structure casting for a dental
workstation. This component serves as a rigid
platform for mounting air, water and pneumatic control lines concealed by a cosmetic
cover. Cut-out features over a 6-inch (15.2
cm) length across the 8.5-inch (21.6 cm) centre
width of this plate restricts the edge-to-edge
metal flow, which poses a challenging die fill.
CWM employed the Magmasoft simulation
software in developing the optimum gating
system required in casting this component.
A380 aluminium is one of the most popular
metal choices for die casting due to its performance. Of all the available types of alloys,
CWM prefers to cast with A380 because it offers the best combination of both mechanical
and physical properties in all aluminium die
cast operations options. Not only highly durable, alloy 380 die castings deliver a range
of overall process and product benefits: lightweight; retains high dimensional stability with
thin walls and complex shapes; corrosionresistant; good mechanical properties; high
thermal and electrical conductivity, and high
strength, even at high temperatures.
With ten aluminium die casting machines
installed, ranging from 300 to 800 tonnes of
locking force, CWM has the plant capability to
produce castings in a range of sizes from 0.75
x 0.75 inch (1.90 x 1.90 cm) to 18 x 18 inch
(45.7 x 45.7 cm).
Ken Stanford, contributing editor
Casting materials and process combination delivers component benefits
Counter Pressure Casting is a useful and tried
and tested technique for producing lightweight
components subjected to high stress, notably
in the vehicle construction industry. The CPC
process is particularly suited to the casting of
aluminium alloy components such as wheel
46
carriers and steering knuckles. One leading
company in this field, KSM Castings Group
GmbH, based in Hildesheim, Germany, has
taken the process technology to another level
in developing a new high-strength aluminium
casting alloy for use with CPC in the produc-
tion of suspension components, optimising the
benefits of both process and product.
Explaining this work, KSM says that using
a typical AlSi7Mg alloy such as A356 or EN
AC-42100, yield strengths above 260 MPa
and elongation rates above eight percent are
ALUMINIUM · 5/2014
SPECIAL
systems followed before the system was approved for series production.
Basic principle
© KSM
possible to obtain in high volume production.
Although these are very good values for aluminium castings, the yield strength has to be
improved to increase the potential benefits of
light weight offered by such components.
KSM’s R & D work shows how this goal
could be achieved by the development of aluminium casting alloy metallurgy. Besides the
modification of Si and Mg content, the addition of Cr leads to an additional dispersion
hardening effect. In this way, yield strength
above 310 MPa combined with an elongation
of 7% can be assured in the CPC process after a T6 heat treatment. Fundamental microstructural investigations were required as well
as the results of tensile tests, high temperature
strength, corrosion behaviour and static and
dynamic component testing. All the results
considered were from tests on actual components such as steering knuckles and not on
merely cast test bars.
To demonstrate the weight reduction potential of the new alloy, the product development of a steering knuckle for a typical premium car was performed and prototypes were
M E LT I N G , C A S T I N G A N D H E AT T R E AT M E N T
Automotive component produced by KSM
Castings using the CPC process and its
proprietary high strength aluminium alloy
produced using the CPC process. The first facility of this type in Europe was installed at
the Hildesheim site in 2002; after intensive
testing during a pilot phase including full static
and dynamic procedures, results showed that
the components fulfilled the requirements.
Further development for chassis component
Counter Pressure Casting is a well established
and proven technique used for the production
of extremely high quality aluminium castings.
The basic principle of this procedure is similar
to that for conventional low-pressure die casting. The primary difference of this process is
that not only the furnace is pressurised, but
also the permanent mould area. These two
factors result in a distinctly enhanced quality
of the casting microstructure and lead to improved component properties. On the basis of
this feature, counter pressure casting is wellsuited as the production process of choice for
highly stressed safety components, for example those used in the vehicle manufacturing
industry (wheel carriers, swivel bearings, etc.).
In addition to enhanced quality and a higher
degree of automation and short cycle times,
the counter pressure technique also provides
a distinctly higher material yield than the con-
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M E LT I N G , C A S T I N G A N D H E AT T R E AT M E N T
ventional permanent mould casting process.
The range of attractive features and benefits of the CPC process include:
• Solidification of the melting charge at
elevated pressure
• High feeding pressure during the
back-feed phase
• Controlled and low-turbulence mould
filling, and
• High degree of automation.
Ken Stanford, contributing editor
Pressure die caster collaborates with
universities on product development research
A prominent aluminium high-pressure
die caster in the UK has joined forces
with the Universities of Birmingham
and Brunel to undertake collaborative
research work on four projects, which on
fruition could lead to major changes in
the way castings are manufactured.
© JVM
and trial our products in cutting-edge facilities. Our main project at present, in conjunction with the UK Government’s Technology
Strategy Board (TSB), involves research into
A20X, a new material developed jointly by
JVM, Jaguar Land Rover, Aeromet International, LSM Aluminium and Birmingham
University.”
Mr Ruffle explains
further: “A20X is the
strongest commercially available cast aluminium alloy. Its advantages include offering reduced weight
and cost over current
manufacturing alternatives in both the aerospace and automotive
industries.”
Another TSB collaboration, which is
being researched by
Brunel
University,
JVM and a number
of other local firms, is
exploring the potential
Nadca Award winning aluminium casting – JVM’s B Pillar chassis component
of creating an alloy
from
recycled
content.
The successful outJVM Castings Ltd, with three die casting opercome
on
completion
of
this research would
ations in the UK Midlands, is currently enenable
JVM
to
use
a
greater
proportion of regaged on four separate projects dedicated to
cycled
content
in
their
castings
whilst reducexploring advanced die casting materials and
ing
the
reliance
on
primary
grade
aluminium.
methods. The objective is to create lighter
This
would
significantly
reduce
not
only the
weight, stronger, more cost-effective products
cost
of
production,
but
also
the
carbon
footwith a reduced carbon footprint, enabling the
print.
UK Midlands to manufacture products that
Innovation, JVM acknowledges, is all about
would normally have to be sourced from Eugenerating
new ideas and ways of working
rope.
and
in
all
areas
of its business, the company
These projects bridge the gap between
stresses
that
it
promotes
an open-minded apacademia and real world commercialisation
proach
to
problem
solving
and continuous imand include working with a number of loprovement.
As
well
as
harnessing
the talent
cal industrial partners including Jaguar Land
of
its
own
employees,
the
company
continues
Rover and aluminium alloy ingot manufacto actively collaborate with leading UK univerturer, JBMI Group.
Simon Ruffle, group design director at sities and research bodies, in developing new
JVM, said: “Constant research is the only way materials and process techniques to enhance
to make sure new developments take place in casting performance. The scope and aims of
our industry, and by collaborating with local its collaborative programmes are reflected in
universities we are able to share great ideas the current schedule of project activities:
48
• Improving the mechanical properties of alloy LM24, by melt conditioning – partnered
with Brunel University.
• Improved defect prediction, through the
correlation of simulated versus actual defects
– with Birmingham University – ongoing.
• Supporting the development of a new primary alloy for structural components – with
Warwick and Brunel Universities – ongoing.
• Utilising recycled material in the manufacture of primary material – JVM with its Stakeholders – ongoing.
JVM die casting attracts NADCA honour
For the second time in its 84-year history
JVM been commended in the prestigious International Die Casting Awards, sponsored
by the North American Die Casters Association (Nadca). The company gained an award
in the Structural Aluminium Casting category for its innovative B Pillar casting for the
Jaguar F-type deluxe saloon car. This is a
heat-treated body chassis component manufactured in an aluminium alloy, which delivers
casting greater ductility and superior mechanical properties in the casting compared with
conventional alloys used in high pressure die
casting.
Ken Stanford, contributing editor
Typical JVM integrity aluminium casting
ALUMINIUM · 5/2014
SPECIAL
M E LT I N G , C A S T I N G A N D H E AT T R E AT M E N T
Modelling research drives alloy integrity
More than a half of aluminium produced
in the world, including sheet rolling ingot,
is cast by the Direct Chill (DC) process.
Now, through a collaborative research
project – recently concluded in Norway –
with a focus on this specific field, modelling tools have been developed that illustrate the impact on aluminium casthouse
products of even minute adjustments to
the casting process. These findings of
the project titled ‘Modelling-assisted Innovation for the Aluminium DC Casting
Process (Minac)’ will, it is claimed, afford
the Norwegian aluminium industry a significant competitive advantage.
The researchers acknowledged that the aluminium industry is facing three challenges
in particular: increasingly complex products,
demanding customers, and ever more stringent recirculation and recycling requirements.
This means that the industry is in need of a
predictable, consistent and reliable casting
process that is not based on trial and error.
The research being carried out in the Minac
project is of interest both for the quality-focused automotive industry, which is striving
to develop cars that are lighter and more environment-friendly, and for the construction
industry, where the products used must also
satisfy stringent requirements.
aluminium exported is in the form of primary
products, produced via electrolytic reduction.
But the industry is changing and the emerging
trend is to use more recycled materials in cars
as well as in construction as the total amount
of energy needed for the recycling of aluminium scrap is only a fraction (5%) of that used
originally. So recycling helps to reduce the
carbon footprint of the end-user industries.
World leaders in casting models
The key factor behind the project’s success
has been the expertise of the Institute of Energy Technology (IFE) and Sintef Materials
and Chemistry. These organisations are world
leaders in the development of casting models
for the aluminium industry, according to Hydro Aluminium’s Dr Ole Runar Myhr, project
manager of the Minac project.
Aluminium is one of Norway’s largest export products and the international automotive and construction industries are major consumers of Norwegian aluminium. Most of the
Simulating outcomes
The aluminium casting process entails multiple challenges, resulting from, among other
things, impurities and variations in chemical
composition in the material to be cast. Both
factors can compromise the final product
through the formation of cracks, uneven surface quality and more.
For example, if intrusions or overly large
particles arise during the casting process, the
resulting ingots that are subsequently rolled
into aluminium sheet and foil may contain
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Extrusion Technology
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ALUMINIUM · 5/2014
E-Mail: [email protected]
Web: www.extrutec-gmbh.de
49
M E LT I N G , C A S T I N G A N D H E AT T R E AT M E N T
a sounder sub-surface structure by adjusting
pivotal in making the project so successful.
“The Minac project was concluded in the the casting parameters or chemical composisummer of 2013, having achieved most of tion. Even if the method can not predict an
what we had set out to do. It is particularly outcome with complete accuracy, the models
satisfying to see one of the most important ob- provide a very reliable indication of how castjectives fulfilled – developing an entirely new ing defects arise and how to avoid them. In
model capable of solving the problem of vari- other words, this is a tremendous advance
ations in the chemical composition through over learning by trial and error.”
the cast product,” explains
Myhr.
Promise in combining models
Dr Kjerstin Ellingsen,
senior research scientist Once the aluminium industry has improved
at Sintef Materials and the casting process so that light alloy comChemistry, offers further ponents can be produced faster, in the corproject details: “In addi- rect shape, with fewer defects and thus more
tion, we have further de- uniformly, the results will be of great signifiveloped modules designed cance to the ever widening range of increasto help to reduce the risk ingly discerning customers. Developing alloys
of casting defects during for new products also boosts competitiveness
production and to tailor significantly. Even minor improvements in the
microstructure formation casting process can have an enormous impact.
during casting and subse- For one, the use of modelling tools makes it
quent heat treatment. All possible to reduce the amount of time needed
new modules have been to certify new alloys for use in the automotive
New, user-friendly modelling tools enable the aluminium industry
to simulate the results of choosing certain alloys and casting
adopted and implemented industry.
parameters, thereby increasing processability
by the industrial partners
Another important objective of the Minac
following
the
development
and testing carried project has been to devise the models to be
to simulate the outcomes of choosing certain
user-friendly as possible. Ellingsen from Sintef
alloys and casting parameters, thereby increas- out during the project.”
As
the
project
leaders
explain,
designing
explains that the models in question are very
ing process efficiency and product quality.
models
of
this
type
is
a
protracted,
demanddata-intensive and that it previously took up
Greater predictability in the casting process reing
effort
and,
in
this
context,
long-term
supto several days to carry out a new calculation.
duces the occurrence of casting defects, which
port
from
a
stable
funding
partner
like
the
ReNot only has the process become quicker, it is
otherwise result in large additional costs.
search
Council
has
been
invaluable.
also possible to carry out more complicated
Another increasingly important area of apcalculations. “This is an area that requires
plication for the simulation tools developed
further work, both to improve the models in
under the Minac project include the certifica- Predictive approach
terms of computational speed and to enable
tion of new alloys for high-demand customers
in the transport and construction sectors.
Ellingsen and Myhr are both enthusiastic them to deal with a more complex range of
about the potential of these models to enhance metallurgy and physics problems. The potenthe competitiveness of the Norwegian alu- tial for combining these models with other
Modelling modules already in use
minium industry. In the global market, com- models further down in the value chain is very
The roster of participants in the Minac project panies such as Hydro Aluminium and Alcoa promising,” she concludes.
Ken Stanford, contributing editor
reflects the keen interest displayed by leading are often competing against producers of aluglobal aluminium producers in the develop- minium in countries where the material can
ment of simulation tools: notably, leading in- be produced at a much lower
dustrial partners in the project include Hydro cost.
Myhr explains that none
Aluminium, Alcoa and Aleris. These three
companies, although competitors in several of Hydro’s rivals have such
areas, have come together to form a forward- advanced models at their
looking consortium that will continue even disposal. “It is simply amazing to be able to know ahead
after the Minac project’s lifetime.
Other key project partners include the of time how fast the casting
Research Council of Norway’s Programme process can be carried out
for User-driven Research-based Innovation without any defects arising,
(BIA), Sintef Materials and Chemistry and or that it is possible to predict
the Institute for Energy Technology (IFE). The that adding a certain amount
BIA programme has provided vital funding of a different element to an
for the project of some NOK10.2 million alloy can increase its strength
(€1.25m), while the specialist combined know- by, for example ten percent,”
ledge and expertise of IFE and Sintef in the he says, adding: “We can Sheet ingot production – project findings could boost alloy metallurgy
development of advanced models have been also render a product with and casting process efficiency, productivity and product quality
© Hydro
© Sintef
weaknesses and tear easily, and the final
product quality may be compromised defects
could arise.
Launched in 2009, the Minac project builds
on researcher-driven expertise from as far
back as the early 1970s. The objective has
been to create and further refine modelling
tools that the aluminium industry can deploy
50
ALUMINIUM · 5/2014
SPECIAL
Honda launches piston
production in Vietnam
Honda Motor Co. Ltd has launched a new automotive components plant in Vietnam, due
to start production of aluminium pistons in
April, with the aim of increasing the rate of
locally sourced parts for the motorcycles it
manufactures there. Honda’s Vietnam operation already produces around two million cast
aluminium engine parts annually, as part of
the company’s infrastructure supporting manufacturing of motorcycles in that market.
Honda Metal Industries Vietnam Co. was
established in 1996, and recently celebrated
production of the 15 millionth unit of its
popular Air Blade bike, first introduced in
Vietnam in and now one of the leading models in the market. Piston production will be
housed in a 3,000 m2 facility built on the
Honda Vietnam production campus in Phuc
Thang, in the northeast of the country. The
cost for the new installation is estimated to
be around USD10.8 million – a firm indicator, Honda says, of its commitment to longterm and sustainable investment in Vietnam.
According to its announcement, Honda views
the new piston plant as the next step toward
establishing an infrastructure that will be “a
firm foundation for local manufacturing and
export expansion.”
In addition to its existing casting operations, the site also includes sintering (2.3m
units a year), a spare parts centre and extruding operations. The manufacturer indicated it
aims to produce up to 2.4 million aluminium
pistons annually at the new operation.
Superior Industries
expanding in Mexico
Superior Industries International Inc., with
headquarters in Van Nuys, California, is expanding with another plant in Chihuahua,
Mexico, to produce aluminium wheels for
the automotive market. Italian company LPM
will be supplying 42 low pressure casting machines and furnaces, as well as a tool shop for
die production. Project lead Jorge Caballero
will assume responsibility as general manager
once the facility is operational, according to
the company. It is anticipated that the facility
will be operational in early 2015.
Superior Industries is one of the world’s
largest OEM suppliers of cast aluminium road
wheels for the automotive industry. It operates
five manufacturing facilities, which employ
ALUMINIUM · 5/2014
M E LT I N G , C A S T I N G A N D H E AT T R E AT M E N T
around 4,000 people in the USA and Mexico,
producing wheels for the major vehicle platforms of the world’s leading vehicle and light
truck manufacturers including Ford, General
Motors, Chrysler, BMW, Mitsubishi, Nissan,
Subaru, Toyota and Volkswagen.
Insulating material boosts
dosing furnace performance
in aluminium foundries
The application of energy-saving dosing furnaces represents the latest technologies available in aluminium foundries. Foseco is now
able to supply a new, multi-part and highly
insulating lining for these type of furnaces,
made of ‘Insural’, which is delivered ready to
install and provides a high longevity. Installation of a new lining in this material can be
achieved in three to four days with no ongoing
hydrogen issues. In comparison, linings cast in
situ have to be dried for several weeks before
all the combined water is removed.
The low wettability of Insural enables the
furnace cavity to be easily cleaned and the
liquid metal to be protected against unwanted
impurities. In addition, due to the dry installation a sintering process is not necessary and
the good insulation properties lead to energy
savings of up to 17%. Additional benefits are
the extreme low build-up of Corundum, due
to the absence of joints, resistance to cracking
in the area of the heating tubes and simple
removal when relining is required.
Foseco also offer Insural dosing tubes, Insural or clay-graphite filling funnels, Isoprime
protection tubes for the heating elements,
Ekatherm thermo element protection tubes
and Zyarock launders for insulation and prevention of oxide build-up.
New thermal insulation
product from Morgan
Thermal Ceramics
Morgan Thermal Ceramics reports on the
availability of its FireMaster FireBarrier 135
sprayed refractory cement, which is claimed
to offer optimum fire protection coupled with
simple, cost-effective installation.
This high performance thermal insulation
product – for example in the form of refractory
cement and mortar – due to its properties and
performance, is ideally suited to a variety of
applications and environments. The material
is ideal in fire protection of concrete tunnel
linings, ventilation shafts, escape routes and
refuges, as well as other critical systems such
as water mains and communication cables.
The refractory material has been specially
developed for the high temperatures associated with tunnel fires. Unlike most other
products used for tunnel fire protection, Fire
Master FireBarrier 135 can withstand repeated and prolonged exposure to high-temperature environments, up to 1 350 °C. It can be
installed onto concrete or metal substrates using standard spray equipment, and with very
low spraying wastage during installation, its
single layer application makes it fast and easy
to install. It is adhesive to most construction
materials and its rapid application helps reduce
labour costs without compromising the final
product’s quality and proven reliability.
FireMaster FireBarrier 135 has extremely
high adhesion strength typically eight times
its weight, allowing fixings to be attached directly to it. It can be trowelled flat to provide
a high-quality surface finish that can be used
as the final tunnel lining surface, with optional painting, avoiding the need for expensive
secondary cladding. The material can also be
cast into sheet form and installed as a dry
board or shape for applications where spraying is not convenient.
Comprehensive and extensive testing of
the new refractory material, according to
stringent requirements of world standards,
has proven that the material resists environmental conditions found in tunnels, making
it ideal for tunnel fire protection. The material
is resistant to water jet sprays used to clean
tunnel linings, and will not spall when subjected to water hose sprays at high temperature,
increasing fire-fighting safety.
Apart from being one of the most comprehensively fire-tested and approved materials
for tunnel applications, it is also approved
for A60 class fire protection of steel decks in
floating floor constructions.
The spray-applied refractory cement also
offers an optimum technical solution for fire
protection of general structural steelwork and
also, for example, in skirts of vessels used
in metal processing applications. FireMaster
FireBarrier are building material grade fire insulation products, normally installed by spraying deliver the following keybenefits, both in
installation and process application: excellent
quality surface finish – consistent and smooth;
good adhesion strength; made from refractory
materials offering high-temperature resistance; fast and easy installation – generous
thicknesses can be applied in one single layer
and spray rebound is extremely low.
Ken Stanford, contributing editor
51
TECHNOLOGY
The Novelis Ulsan hot line expansion
© Siemens
Stuart Leflay, senior hot mill expert, Siemens Metals Technologies
Twin coiler hot mill (1993)
In 1991 Hyundai in Ulsan, South Korea, placed
an order with Siemens (formerly Davy Mckee
(Poole) Ltd) for a new 150,000 tpy aluminium
rolling plant. This plant consisted of a 2.8 m
wide single-stand twin coiler hot mill and two
2.2 m wide 4-high VC cold mills. This plant
was started up in 1993 and then purchased
by Novelis (formerly Alcan) in 2000 and the
single-stand hot mill rolled 198,000 tonnes in
2011 of coil and plate products.
In 2011 Novelis decided to expand automotive sheet production in Asia and placed
an order with Siemens for a new tandem hot
finishing mill to be installed at the end of the
existing hot mill exit tables. The existing hot
mill now operates with the new tandem mill
and is now used for roughing passes on thin
coil products (≤ 6 mm) and for all thick coil
and plate products.
The new tandem mill installation was designed to minimise disruption to the plant
production and started up in June 2013 after
only a total of ten days of shutdown on the
existing hot mill. This is the fourth aluminium
hot tandem mill supplied by Siemens since
2005 and further strengthens the company’s
position as a leading supplier of aluminium hot
strip mills.
pneumatic down holder to minimise fire risk.
• Double raked blades with ‘V’ cutting profile to assist threading / avoid refusals.
• Scrap handling with motorised traverse and
elevator to floor level for fast bin change.
The tandem mill
• Top mounted double acting roll load cylinders and bottom mounted continuous wedge
pass-line height adjustment to maintain a constant strip pass-line.
Tandem mill, technical data
Work rolls
Backup rolls
Maximum load
F3 speed
Mill drive power
Roll bend
Ø 750 x 2500 mm
Ø 1500 x 2400 mm
40,000 kN
0 / 180 / 450 m/min
3 x 5,000 kW (AC)
± 2,000 kN
• ‘E’ block positive and negative work roll
bend on all stands with automatic change to‘
roll balance force prior to strip tail-out of each
stand to prevent roll skidding.
• The back-up rolls are mounted on cylindrical roller bearings for low eccentricity values.
Note the back-up bearings are also interchangeable with the existing twin coiler hot
mill.
• Side shifting automatic work roll change
with automatic connection of all drive side
services.
• Work roll chock mounted scratch brushes
(nylon bristle), with hydraulic load control
and chock mounted mechanical penetration
stops, internal brush lubrication, variable
speed A.C. drives and zero dwell oscillation.
• Siemens ISV pulse modulated work roll
sprays on both entry and exit side of all stands,
for effective thermal crown control and hence
improved strip profile and shape. Strip wipes
and blow offs on both side of all stands to prevent coolant carry-over and hence raise strip
temperature. Inter-stand strip cooling sprays
to lower strip temperature and to maximise
pass speeds.
• Driven strip tension measuring rolls with
oscillating cleaning brushes are installed between the stands.
• Multi-channel X-ray gauge for feedback of
strip gauge and profile for in-coil control by
the process control system. Entry and exit side
calibrated pyrometers for in-coil strip temperature control with mill speed control.
• Provision for future stand with foundations,
entry tables and guides designed specifically
to accommodate the F0 stand.
➝
The light duty shear
• Fully hydraulic up / down cut shear with no
hydraulics above or near the hot product and
Light duty shear, technical data
3003
60 mm
Maximum thickness
at ≥ 250 °C
Maximum cutting force
52
5182
45 mm
4,000 kN
3-stand hot finishing mill (2013)
ALUMINIUM · 5/2014
Visit us at:
Aluminium
2014 Messe
Dusseldorf, Hall
9, Booth 9E40
Focus on Precision, Yield
and Green
Set the benchmark in Aluminum Rolling!
siemens-vai.com
During the past five decades we have supplied hundreds of
new and modernized mills setting the benchmark for
producing quality strip in an efficient manner. The market
is ever changing and demands highest yield and tolerances
while minimizing environmental impact. Siemens VAI is at
the forefront of this challenge.
As a total solution provider the Dynamic Shape Roll DSR©
has been developed as a variable force distribution
actuator, replacing a conventional solid back-up roll,
Improving mill productivity and reducing operating costs.
design mills. True dynamic control is achieved by fast
response of the pads to changes in the force distribution
reference.
DSR© Benefits:
ƒ Yield Savings – Achieves target flatness quicker and
retains longer during tail out.
ƒ No warm-up coils required during mill start-up or width
change.
The DSR© enables you to meet market challenges of today
and the future. Your mill will produce a harder, wider and
thinner product portfolio ensuring product flatness,
increase your schedule flexibility, reduce material
breakages and roll changes.
ƒ Rolling passes reduced.
The Intelligent flatness control algorithm uses feedback
from the shape roll to generate signals to vary the force
distribution across strip width.
ƒ Number of Back Up roll changes reduced.
The DSR©’s performance is impressive; eliminating
undesirable roll contact and stress peaks. The control
range is considerably larger than 6hi and contoured roll
ƒ Rolling speed increased.
ƒ Productivity increased (product mix dependant).
ƒ Retrofitting of DSR© requires minimal downtime and
recommissioning.
Be the leader in the field – with SIROLL ALU solutions from
Siemens VAI, a global supplier and your local partner.
Answers for industry.
TECHNOLOGY
Edge trimmer
• Trimming blades are automatically positioned for strip width and blade horizontal
and vertical clearances by the mill set-up computers.
• Offset adjustment for optimum yield on
high magnesium alloys and toe-out adjustment for edge quality and ease of threading
are also provided.
• Separate drum type scrap chopper with 6
off helical blades per drum located below strip
pass-line with independent drive.
Edge trimmer, technical data
Blade diameter
Maximum thickness
Maximum speed
Ø 610 mm
6 mm, all alloys
550 m/min
Coiling equipment
The down coiling equipment is operated with
a maximum threading speed of 4 m/s. It comprises a driven deflector roll with oscillating
brush, tailing roll, down coiler and high speed
belt wrapper. The coiler mandrel is fitted with
liners requiring no lubrication, hence preventing contamination of the coil bore.
Coils are automatically removed from
the coiler mandrel, transferred for sidewall
temperature measurement and then to floor
level by a coil car with high lift. The coil is
transferred automatically across the mill bay
by a floor mounted coil buggy, to the weighing
station and walking beam located in the coil
storage bay.
Coiling equipment, technical data
Mandrel diameter
Maximum tension
Maximum speed
Drive power
Ø 610 mm
236 kN
500 m/min
1 x 1,500 kW (AC)
The edge trimmer
smooth operation of the mill. Installation of
vacuum filters, tramp oil skimmers, heaters,
coolers, make-up systems as well as modern
pressure control using variable speed pump
drives and comprehensive monitoring maintains the coolant in its optimum condition.
The roll coolant is used extensively for work
and back-up roll cooling, strip cooling, bite lubrication, scratch brush cleaning, lubrication
of the edge trimmer blades, side guide rolls
and pass line rolls to prevent the build-up of
Aluminium on the surfaces.
Commissioning
The majority of the existing mill entry roller
tables were replaced with heavy duty tables
to receive the slabs from the new pusher furnace in January 2013 during a nine day shutdown. The existing mill was only shutdown
again for less than 30 hours in June 2013 to
implement the changes and communication
with the existing 20 year old mill computers.
The first coil was then successfully rolled on
20th June 2013 on the first attempt less than
two years from order placement. All basic
automation was commissioned on limited test
coils until the first trimmed coil was rolled on
the 4th July 2013.
Production was then slowly built up with
all coils being trimmed and the full range of
alloys rolled including 5182 / 5083 with over
800 coils rolled in October. The minimum
gauge of 1.8 mm (3104) was rolled successfully in November 2013 for the first time. Final
acceptance tests were started with equipment
functional performance tests in August 2013
and product performance tests starting in November 2013. The agreed products tested for
gauge, profile and temperature performance
were as follows:
1235 at 3 mm x 1,690 mm
3104 at 2.2 mm x 1,555 mm
5052 at 2.7 mm x 1,265 mm and 1,670 mm
5182 at 2.7 mm x 1,550 mm
All tests were completed successfully and the
Final Acceptance Certificate signed by Novelis
on 14th February 2014.
■
Typical F.A.T. product performance
Fluids systems
Fluid systems are installed to provide the tandem mill with operating media:
• Roll coolant systems for mill stands and inter stand strip cooling.
• High pressure hydraulic systems for light
duty shear, mill load and roll bending.
• Medium pressure hydraulic systems for all
other equipment.
• Centralised oil lubrication systems for tandem mill drive, edge trimmer and coiler gearboxes.
• Oil-air lubrication systems for mill rolls and
strip pass-line rolls.
Roll coolant condition has a significant
impact on the finished strip quality and the
54
ALUMINIUM · 5/2014
TECHNOLOGIE
Alfun beauftragt Maschinenfabrik
Georg mit „Hybrid“-Querteilanlage
ALUMINIUM · 5/2014
Mit der Investition setzt man bei Alfun auf
fortschrittliche Georg-Technologie, um den
Herausforderungen und dem gesteigerten
Fertigungsaufkommen des neuen Markttrends
auch zukünftig optimal gerecht zu werden.
Mit dem Verkauf einer dritten Queranlage
für die Kombination Edelstahl und Aluminium
zeigt sich, dass es richtig war, vor drei Jahren
den Schritt auf diesem Gebiet der Hybridanlagentechnik gewagt zu haben. Das HybridKonzept hat sich damit erfolgreich im Markt
etabliert.
Alfun and Georg conclude a contract
for ‘hybride’ cut-to-length line
and stainless steel: The line has been designed
for strip widths of 300-2,050 mm. The thicknesses of the strips are between 0.4 and 3 mm.
The coils with a weight of max. 30 tonnes
are decoiled at a speed of up to 60 m/min,
levelled, continuously cut to sheets with the
eccentric shear and
then stacked to sheet
packages by the vacuum belt stacker.
In order to meet the
requirements for the
combination of stainless
steel and aluminium the
line offers some special
characteristics. Besides
a paper and foil unwinder in front of the
cut-to-length shear a
high-precision leveller
in change cassette design has been provided.
Two change cassettes
Hybrid-Querteilanlage von Georg
Hybrid cut-to-length line from Georg
are available. Thus, the
large
thickness
range
can
be covered optimalthe semis producer asked for a cut-to-length
ly
and
precisely
levelled
non-standard
sheets
line of 1.600 mm width, but during the first
can
be
produced.
technical discussions at the site in Bruntal,
For depositing the sensitive non-standard
Czech Republic, they decided on a line of
sheets
a vacuum belt stacker with two com2.000 mm width. This line should be designed
binable
stacking positions is used. This stacker
to process both aluminium and stainless
is
characterised
by its very silent operation
steel.
mode
and
a
smooth
stacking of sheets at high
Georg has recently manufactured two lines
accuracy.
With
this
investment
Alfun focuses
of a very similar design. In the beginning of
on
advanced
Georg
technologies,
thus being
October 2013 a delegation of Alfun visited
able
to
optimally
meet
the
challenges
and the
one of these reference lines at the company
Sauter Edelstahl AG in Möhlin, Switzerland, increased production of the new market trend
and was impressed of the Georg quality, espe- also in the future.
Now, after having sold the third combined
cially of the produced sheet stacks regarding
flatness, cutting quality and stacking accuracy. cut-to-length line, Georg is sure to have made
The positive feedback as well as the good re- the right step in the field of hybride line techsults of the Georg lines in production have nology three years ago. The hybride concept
– to produce stainless steel and aluminium
convinced Alfun of this hybride concept.
The technical parameters of the cut-to- with one line – has meanwhile successfully
length line for the combination of aluminium established itself in the market.
■
The first contacts between Alfun a.s. and the
German mechanical engineering company
Georg have already been established a few
years ago. In the autumn of 2013 the Georg
finishing lines division received an inquiry
from Alfun for a cut-to-length line. Initially
© Georg
Bereits vor einigen Jahren gab es den ersten
Kontakt zwischen Alfun a.s. und Georg. Im
Herbst 2013 bekam Georg Bandanlagen eine
Anfrage für eine Querteilanlage. Nachdem
anfangs noch eine 1.600 mm breite Anlage
angefragt wurde, konnte man sich beim ersten technischen Gespräch vor Ort in Bruntal,
Tschechien, auf eine 2.000 mm breite Anlage verständigen. Auf der Anlage soll neben
Aluminium auch Edelstahl bearbeitet werden
können.
Georg hat genau in diesem Bereich zwei
junge Referenzanlagen mit sehr ähnlichem
Aufbau. Anfang Oktober letzten Jahres wurde mit dem Kunden Alfun eine vergleichbare
Anlage in Möhlin, Schweiz, bei der Sauter
Edelstahl AG besichtigt. Die Verantwortlichen
bei Alfun zeigten sich beeindruckt von der
Qualität der Georg-Querteilanlage und den
fertig produzierten Tafelpaketen hinsichtlich
Planheit, Schnittqualität und Stapelgenauigkeit. Das positive Feedback und die guten Ergebnisse der bereits laufenden Georg-Anlagen
waren denn auch ausschlaggebend dafür, dass
Georg Bandanlagen die Firma Alfun mit diesem Konzept überzeugen konnte.
Zu den technischen Parametern der Querteilanlage von Georg: Sie wird ausgelegt für
eine Bandbreite von 300 bis 2.050 mm. Die
Banddicken der zu verarbeitenden Aluminium- und Edelstahlbänder beträgt 0,4 bis 3 mm.
Die bis zu 30 Tonnen schweren Coils werden
mit einer Geschwindigkeit bis zu 60 m/min
abgewickelt, plan gerichtet, mittels Exzenterschere kontinuierlich zu Tafelmaterial geschnitten und mittels Vakuumbandstapler zu
Blechpaketen gestapelt.
Um die Anforderungen für die Kombination von Edelstahl und Aluminium zu erfüllen, bietet die Anlage einige besondere
Ausstattungsmerkmale. Neben einem Papierund Folienabwickler vor der Querteilschere
kommt zusätzlich eine Fein-Richtmaschine in
Wechselkassettenbauweise zum Einsatz. Hier
stehen zwei Wechselkassetten zur Verfügung.
So können die Materialeigenschaften sowie
der große Materialdickenbereich abgedeckt
und optimal gerichtete Fixmaßbleche produziert werden.
Zum Ablegen der empfindlichen Fixmaßbleche wird ein Vakuumbandstapler mit zwei
kombinierbaren Stapelstellen eingesetzt. Dieser zeichnet sich durch eine sehr leise Arbeitsweise und schonendes Abstapeln der Bleche
mit hoher Stapelgenauigkeit aus.
■
55
TECHNOLOGIE
Innovative Roboterlösung: vollautomatischer Gleitschliffprozess
Ein Novum stellt der vollautomatisierte Prozessablauf dar. Die Anlage ist dafür mit einem
Roboter mit unterschiedlichen Greifern für
die verschiedenen Werkstückvarianten ausgestattet. Er greift jeweils vier Teile, die mit
einem Förderband aus der spanenden Bearbeitung zur Anlage transportiert werden, in
einer definierten Position. Für den ersten Behandlungsschritt – das Entfetten und Reinigen
– taucht der Roboter die Werkstücke in ein
Reinigungsbad. Dann geht es weiter in den
eigentlichen Gleitschliff-HFF-Prozess, dem
ein Spül- und Abblasschritt folgt. Anschließend legt der Roboter die Aluminiumteile
wieder auf dem Förderband ab, das sie zum
nächsten Fertigungsprozess transportiert.
Für das HFF werden die an den Greifern
des Roboters aufgespannten Werkstücke in
das Bearbeitungsmedium (Edelstahlkugeln)
eingetaucht. Dort sorgen die gleichzeitige Vibrationsbewegung der Werkstückaufnahmen
mit 3.000 U/min und die Strömungsbewegung
des Mediums dafür, dass die Werkstücke
allseitig bearbeitet werden. Darüber hinaus
können die Teile während des Prozesses aus
dem Bearbeitungsmedium herausgenommen
und gedreht werden. Durch die Kombination
der beiden voneinander unabhängigen Bewegungen und exakt auf diesen Prozess abgestimmte Verfahrensmittel (Schleifkörper und
Compound) wird in einer sehr kurzen Bearbeitungszeit ein homogenes und reproduzierbares Entgrat- und Polierergebnis erzielt.
Der Gesamtprozess inklusive Aufnehmen
und Ablegen der Teile dauert je nach zu bearbeitendem Werkstück zwischen drei und fünf
Minuten.
■
56
Innovative robotic solution:
Fully automatic vibratory finishing
finishing process including a rinsing and blow off
phase. Finally, the robot
places the aluminium
components back on the
conveyor belt for transport to the next manufacturing operation.
During the HFF process the robot gently
dips the high frequency
vibratory gripper with
the four mounted work
pieces into the work
bowl filled with spherical stainless steel media.
The gripper vibration
Der neue Gleitschliffprozess HFF ermöglicht bei kürzesten Bearbeitungszeiten ein homogenes und reproduzierbares Entgrat- und Polierergebnis /
with 3,000 rpm and the
The new HFF process produces excellent and absolutely repeatable deburrmovement of the steel
ing and polishing results in very short cycle times
media induced by the
vibratory
drive
of
the
mass finishing machine
A customer of the company Rösler
produce
an
intensive
and
homogeneous meGmbH in Germany has been using vidia
flow
around
the
work
pieces.
Furthermore,
bratory finishing for the deburring and
during
the
finishing
process
the
robot
can take
polishing of delicate precision aluminium
the
work
pieces
out
of
the
work
bowl
to turn
components for many years. However,
them
at
a
defined
angle
and
dip
them
back
until now the components had to be
into
the
media
mass.
These
two
independent
protected against ‘nicking’ during the
media movements, in combination with the
finishing process requiring time-consumcompound and media precisely adapted to this
ing and expensive manual labour. This
process, yield excellent and absolutely repeat‘challenge’ was solved by the installation
of an innovative, fully automatic cleaning, able deburring and polishing results in very
short cycle times.
deburring and polishing system which alDepending on size and shape of the respeclows the finishing of around 30 different
tive
work pieces, the complete operation, inwork pieces without the parts ever touchcluding
picking the parts up and placing them
ing each other during the process. For this
back on the conveyor belt, lasts between three
challenging application Rösler not only
and five minutes.
developed the material handling concept
■
but, with the High-Frequency-Finishing
(HFF) system, also a completely new vibratory finishing method.
© Rösler
Das Entgraten und Polieren empfindlicher Präzisionsteile aus Aluminium
nach der mechanischen Bearbeitung
erfolgte bei einem Kunden der Rösler
Oberflächentechnik GmbH immer schon
in einem Gleitschliffprozess. Allerdings
war ein hoher manueller Aufwand erforderlich, um die berührungssensitiven
Werkstücke während der Bearbeitung zu
schützen. Gelöst wurde dieses „Problem“
durch eine innovative Anlage für vollautomatisches Reinigen, Entgraten und Polieren. Sie ermöglicht die berührungsfreie
Bearbeitung von rund 30 verschiedenen
Werkstückvarianten. Rösler entwickelte
dafür nicht nur ein entsprechendes Maschinenkonzept, sondern mit dem HighFrequency-Finishing (HFF) auch einen
komplett neuen Gleitschliffprozess.
At the centre of this groundbreaking fully automatic system is a robot equipped with a gripper
that vibrates at very high frequencies during
the HFF process. Different grippers are utilised to accommodate the various work piece
shapes and sizes. After the machining operation the parts are placed on a conveyor belt in
an exactly defined position. Once they arrive
at the finishing system the robot picks up four
parts at a time. In a first step – degreasing and
cleaning – the robot dips the parts into a cleaning tank. This is followed by the HFF vibratory
Der Roboter greift jeweils vier Werkstücke in definierter Position und durchläuft mit ihnen die Prozessschritte Entfetten, HFF, Spülen und Abblasen
The robot picks up four work pieces at a time
from the conveyor belt and runs them through the
process steps, degreasing, HFF, rinsing and blow off
ALUMINIUM · 5/2014
TECHNOLOGY
Lasox-Coat: Neuartiges Verfahren zur selektiven
Oxidation von Aluminiumoberflächen vor der Serienreife
Aus der Idee, ein Beschichtungsverfahren ohne den Einsatz von Chemie zu
betreiben, entwickelte AHC Oberflächen-
technik mit Sitz in Kerpen ein neuartiges
Verfahren zur Oxidation von Aluminiumoberflächen. Hiermit können Bauteile
© AHC
Lasox-Coat: Novel method for the selective oxidation
of aluminium surfaces prior to serial production
Aluminiumbauteil mit Flächen, die mit dem neuen Lasox-Coat-Verfahren beschichtet sind
Aluminium workpiece with surfaces coated with the new Lasox-Coat process
From the idea to operate a coating process without the use of chemicals, AHC
Oberflächentechnik in Germany developed a novel method for the oxidation
of aluminium surfaces. With this process
components can be protected selectively against wear and corrosion. A pilot
plant is located in the French subsidiary
Faulquemont. Now, the process is ready
for serial production.
The so-called Lasox-Coat treatment by AHC
is used for the selective coating of aluminium surfaces via laser. While the workpiece
is under an oxygen atmosphere, the laser is
targeted along the surface to be coated. The
laser starts to melt the alloy and some particles
will vaporise. Together with the oxygen this
leads to the formation of an oxygen plasma.
The oxygen plasma – which consists of ionised
atoms – and the molten aluminium react to
aluminium oxide which now covers the treated
surface. The thickness of this corundum layer
is typical around 6-10 µm, while the remol-
ALUMINIUM · 5/2014
ten area is about 100 µm thick. The hardness
of the aluminium oxide is around 2,000 HV.
The hardness of the remolten zone depends
on the used alloy, and with Si-containing alloys (Si > 8%) the hardness can increase by
50% relative to the original alloy.
The major advantage of this process in contrast to galvanic processes lies in the complete
abandonment of chemicals. Also no pores are
formed in the aluminium oxide layer which
explains the increased hardness. Pores in the
basic material will affect the layer growth
negatively. Silicon helps to grow a thicker but
slightly rougher layer and even alloys with
more than 20% silicon can be coated with
Lasox-Coat. The possibilities of the selective
coating are plenty, like writings, single lines,
complex forms or patterns. While flat surfaces
are preferred, round surfaces are also possible. An integration of Lasox-Coat into existing production lines is also planned. LasoxCoat is best for wear protection but can also
be used to reduce corrosion on the workpiece.
■
partiell vor Verschleiß und auch Korrosion geschützt werden. Eine Pilotanlage
befindet sich im französischen Werk Faulquemont. Nun steht das Verfahren vor
der Serienreife.
Bei dem mit Lasox-Coat bezeichneten Verfahren der AHC Oberflächentechnik handelt
es sich um eine selektive Oxidation von Aluminiumoberflächen mittels Laser. In einer
Sauerstoffatmosphäre wird auf die Oberfläche eines zu bearbeitenden Werkstücks ein
Laserstrahl gerichtet. Unter dem Einfluss
des Lasers beginnen Legierungspartikel zu
schmelzen und zu verdampfen. Das Sauerstoffplasma, das aus ionisierten Atomen besteht, und ein Teil des geschmolzenen Aluminiums reagieren zu Aluminiumoxid (Korund, Al2O3), das nun die behandelte Oberfläche bedeckt. Die Korundschicht hat eine
Dicke von etwa 6 bis 10 µm, während die
Umschmelzzone etwa 100 µm stark ist. Die
Härte des Aluminiumoxids beträgt rund
2.000 HV. Die Härte der Umschmelzzone
hängt von der verwendeten Legierung ab.
Bei Silizium-haltigen Legierungen (Si > 8%)
kann die Härte um 50 Prozent gegenüber der
Härte der ursprünglichen Legierung gesteigert
werden.
Der große Vorteil gegenüber galvanischen
Prozessen besteht im Verzicht auf Prozesschemikalien wie Elektrolytsäuren. Es bilden
sich zudem prozessbedingt keine Poren in
der Aluminiumoxidschicht, was die hohe
Härte erklärt. Bereits im Grundmaterial vorhandene Poren werden das Schichtwachstum negativ beeinflussen. Siliziumkörner im
Grundwerkstoff unterstützen das Wachstum
einer dicken, aber leicht raueren Schicht.
Sogar Aluminiumlegierungen mit Siliziumgehalten über 20 Prozent können mit Lasox-Coat beschichtet werden. Mit dem selektiven Beschichtungsverfahren lassen sich
Beschriftungen, einzelne Linien oder komplexe Formen und Muster erzeugen. Flache
Oberflächen werden bevorzugt, jedoch sind
auch abgerundete Oberflächen beschichtbar.
Das Lasox-Coat-Verfahren ist auch für die
Integration in eine bestehende Fertigungslinie vorgesehen. Lasox-Coat eignet sich am
besten zum Verschleißschutz, kann aber ebenso zur Reduzierung von Korrosion auf einem
Werkstück eingesetzt werden.
■
57
© Jaguar Land Rover
APPLICATION
Jaguar XE – the new premium sports sedan with
advanced aluminium monocoque architecture
Jaguar has announced the name of its allnew mid-sized premium sports sedan at
the Geneva Auto Show. The name:Jaguar
XE. It will be the first aluminium monocoque product in the C/D segment and is
set to be the most advanced, efficient and
refined sports sedan in its class. The new,
advanced aluminium architecture was
showcased for the first time in the C-X17
concept car at the Frankfurt Auto Show
in 2013 (see ALUMINIUM 10/13, p 59).
Global rollout of the XE, the first series model
built on the new aluminium platform, will begin from mid-2015. It brings all the benefits
of aluminium to the customers: lightness and
stiffness for extraordinary handling, performance, refinement and efficiency. The new Ingenium engines and aluminium chassis complement each other perfectly.
The XE will be the first user of the Ingenium
engines in four-cylinder, two-litre petrol and
diesel variants. They will be built at Jaguar
Land Rover’s (JLR) new engine manufacturing facility in the UK. Power will be provided
by engines with a wide range of capacities
and output, all delivering inspirational performance and offering the latest innovations
in fuel-efficient technologies without sacrificing drivability. Utilising the most flexible engine architecture ever produced by JLR, with
an advanced design configured to suit in-line
and transverse installations for rear-wheel
58
drive and all-wheel drive configurations, the
new engines will be both efficient and powerful – including top speeds of over 300 km/h
(186 mph), and emissions lower than 100 gram
of CO2 per km.
Aluminium architecture:
Underpinning the future
The aluminium-intensive architecture will be
modular and scalable, providing a high degree
of flexibility and making it possible to produce a wider bandwidth of models and derivatives than ever before. It is lightweight,
extremely stiff and incorporates innovative
technologies that emphasises Jaguar’s commitment to sustainability, such as a new highstrength alloy made from almost 100 percent
recycled raw material. Already today more
than half of the light metal used at
Jaguar is made from recycled
aluminium. Until 2020
this figure will be
increased
to
at least 75 percent, says carmaker Jaguar.
By the flexibility that this architecture
will provide, Jaguar designers and engineers
can deliver a new portfolio of products less
restricted by technical or manufacturing constraints. The new architecture will allow the
carmaker to move into higher volume production, without compromising the unique character, breath-taking design, outstanding vehicle dynamics, performance and luxury that
Jaguar is famous for. The new architecture
will enable the manufacture of different products on the same production line at the same
time. The highly efficient, state-of-the-art
production process will allow rapid response
to variations in market demand for individual
models by balancing production volume accordingly.
■
Jaguar XE monocoque body in white
ALUMINIUM · 5/2014
ANWENDUNG
Aluminium im Aufwind
Windkraftanlage nutzt Aluminium von Novelis für das Design der äußeren Hülle
ALUMINIUM · 5/2014
Aluminium on upswing
Wind turbine’s outer shell designed with Novelis anodised aluminium
© Simon Kennedy
The perfect combination, complementing both
ecological and economic perspectives: a platform to produce renewable energy clad with
aluminium, an environmentally friendly and
recyclable material. The wind turbine ‘Northwind 100’ is part of the sustainability concept
at the British Sky Broadcasting Group. The
wind turbine is expected to provide over 133
MWh a year of renewable energy to the headquarters of Sky in Osterley, West London.
The Sky Studio building and the wind turbine, standing at 55 metres tall, have an exterior skin which is unmatched in shape and
form, covered with Novelis batch-anodised
aluminium J57S. The wind turbines elongated
triangular-pyramid mast coils upwards in a
twisting motion, architecturally expressing the
rotational dynamics of
the turbine and tapering
at the top.
For the surface cladding of 1,600 square
metres United Anodisers
(HMF) in Huddersfield
anodised 13 tonnes of
J57S. The project execution was carried out by
KME Architectural Solutions in Kirby, Merseyside. The exceptional
design was developed
by the Wintech-Group,
which consider the ambitious facade technology as art of aesthetic solution for ecological
and structural considerations.
© Novelis
© Simon Kennedy
Eine perfekte Ergänzung sowohl aus ökologischer wie ökonomischer Sicht: Ein Bauwerk
zur Produktion erneuerbarer Energien – bekleidet mit einem umweltfreundlich recycelbaren Werkstoff. Die Windkraftanlage „Northwind 100“ ist Teil des Nachhaltigkeitskonzeptes der British Sky Broadcasting Group. Mit
einer Leistung von 133 MWh im Jahr versorgt
die Anlage den Firmensitz von Sky in West
London Campus in Osterley mit erneuerbarer
Energie.
Das Studio und die Windkraftanlage mit
einer Oberfläche aus Aluminium J57S von
Novelis ist in Form und Konstruktion einzigartig. Über eine Höhe von 55 Metern schraubt
sich der dreieckige Northwind-Pyramidenmast in einer Drehbewegung nach oben –
gleichsam als architektonischer Ausdruck für
die Rotationsdynamik der Turbine.
Für die Oberflächenbekleidung der Anlage
und Gebäude wurden rund 1.600 Quadratmeter Aluminium, eloxiert von United Anodisers (HMF) in Huddersfield, UK, mit einem
Gesamtgewicht von 13 Tonnen verarbeitet.
Die Projektausführung erfolgte durch KME
Architectural Solutions in Kirby, Merseyside.
Das außergewöhnliche Design entwickelte
die Wintech-Group, UK, die anspruchsvolle
Fassadentechnologie als Kunst der ästhetischen Lösung nach ökologischen und strukturellen Gesichtpunkten sieht.
Mit dem eloxierten Aluminium J57S in
hoher Brillanz wurde ein Fassadenmaterial für
das Sky Studio eingesetzt, das nicht nur extrem widerstandsfähig sowie sehr witterungsund korrosionsbeständig ist, sondern sich
auch exzellent verformen lässt und vielfältige
Weiterverarbeitungsmöglichkeiten bietet.
Für die markante Form und komplexe Geometrie der Windkraftanlage war es erforderlich, rund 200 eloxierte Lochbleche im Proteus CS System auf den Turbinenmast aufzubringen. Ausschlaggebend für das geometrische Design war dabei die Positionierung
der in Größe und Form unterschiedlichen
Bleche. Mit einem maßgeschneiderten Designprogramm erfolgte die Konstruktion der individuellen Bleche automatisiert mittels einer
speziell dafür entwickelten Software.
Die Lochungen der Bleche sind so ausgebildet, dass verdeckte Befestigungspunkte eine
Anbringung auf ein vertikales Trägersystem
ermöglichen. Dadurch sind zahlreiche Projektdesigns und individuelle Gestaltungsmöglichkeiten mit Lochblechen realisierbar.
■
With the anodised aluminium J57S in high
brilliance a facade material for the Sky Studio
was used, which is highly resistant to weathering as well as corrosion and has an excellent
ductility for further processing.
The distinctive complex geometry form
was designed to comprise of around 200 Proteus SC perforated anodised aluminium panels on the turbine mast. A specifically tailored
software was used to model the perforated
facade construction and automate the production of the manufacturing information for
each of the individual facade panels and ancillary components.
The perforations of the sheets are constructed to enable an installation of covered
fastening points on a vertical subconstruction.
As a result numerous project designs and individual design options are feasible with perforated sheets.
■
59
CO M PA N Y N E W S W O R L D W I D E
© Rusal
Aluminium smelting industry
Rusal upgrades design and
process parameters of RA-400 cells
UC Rusal has announced the status of its RA400 cells modernisation project. The cell’s
upgraded design and process parameters will
reduce electricity consumption to less than
12,900 kWh/tAl, with a current efficiency of
better than 95.5% and an amperage of 435 kA.
The total project investment including the testing in a pilot area, is estimated at USD70m.
The RA-400 cell is Rusal’s own technology
developed by the in-house Engineering and
Technology Centre, and aims to create an innovative cell with unique upgraded features.
This would operate at 400-440 kA, producing 3,300 kg of aluminium per day and total
fluoride emissions less than 0.2 kg per tonne.
Sixteen RA-400 cells have been tried at the
testing centre of the Sayanogorsk aluminium
smelter. The engineering of the RA-400 upgrade project is expected to be completed by
late 2014.
Alcoa slashes production in Brazil
Alcoa plans to stop smelting aluminium at its
first plant in Brazil and will further cut production at another smelter. The company,
which cut 34,000 tpy at its Poços de Caldas
smelter in Brazil in 2013, now plans to idle
the last three potlines, which have capacity of
62,000 tpy. Alcoa also intends to curtail production at the plant’s alumina refinery, but it
will not be idled. The Poços de Caldas bauxite mine, aluminium powder plant and casthouse will continue normal operations. The
60
Poços de Caldas plant, established in 1965,
was Alcoa’s first operation in Brazil.
Alcoa also plans to reduce production at
its Consorcio de Aluminio do Maranhao (Alumar) smelter in Sao Luis, Brazil, by 85,000
tpy after slashing 97,000 tonnes of capacity
in 2013. Before the cuts, Alcoa’s share of production at the facility was 268,000 tpy, which
means the company will have 86,000 tpy once
the cuts are implemented. Alumar, formed in
1984, is a consortium of Alcoa and Australiabased BHP Billiton. The owners each have
their own share of capacity.
Aluminium producers have cut capacity in
the wake of steep declines in aluminium prices
over the past year. Alcoa said in May 2013
it had placed 460,000 tonnes of its smelting
capacity under review for possible shutdown.
The company will have 21% of its smelting
capacity – or about 800,000 tpy – offline once
the announced cuts and closures have been
made. The curtailments are expected to be
complete by the end of May 2014.
Qatalum uses automated
cover handlers
The pot tending machines (PTM) at Qatalum
automate the anode changing process. Historically anode changing has evolved from a
manual process to a semi-mechanised one, still
used by smelters today. At Qatalum the process has been moved into the future with the
use of a semi-automatic cover handling unit.
Of all the tasks done with the PTM, one
particular task is the removal and placing of
the pot covers during the anode change and
anode covering task that shield the exposed
portion of the pots. All the PTM’s at Qatalum
are fitted with a dedicated cover handling
unit. Qatalum is the only smelter in the world
practicing semi-automatic cover handling, the
company says. The advantages of this are twofold: increased safety and reduced emissions.
Vehicular and mechanical traffic are the
predominant causes of safety-related incidents in a potroom, and Qatalum reduces the
risks by automating traditionally manual processes, notably with the PTM cover handling
unit within the potroom. All other pots remain
closed preventing emissions escaping into the
atmosphere
Simply stated, the lack of human interaction on the potroom floor avoids accidents.
Moreover, in Qatar’s hot conditions it also
avoids employee exposure to over 50 °C
working conditions. Instead, the whole anode
changing process, of which cover handling is a
part, is executed by a single operator sitting in
an air conditioned PTM cabin.
At Qatalum, when covers are removed
to facilitate an anode change, several factors
come into play. The inbuilt suction process is
tripled creating a negative pressure within the
pot hood. All emissions and dust are sucked
into the filtration system, preventing their escape into the local environment.
Emissions measured from the potroom
roof at Qatalum are currently measured at
0.15 kg of fluorides per tonne of aluminium
produced – the lowest in the business, and directly associated with cover handlers and the
fume suction process.
Rusal expects aluminium
premiums to stay strong
Rusal expects aluminium premiums to stay
at high levels in 2014 due to physical market
tightness and robust financial demand. The
demand will be primarily driven by China,
other Asian countries, the USA and the European Union. About 3m tonnes of Chinese aluminium output is expected to be cut in 2014
due to low aluminium prices but Chinese aluminium market will remain balanced in 2014.
Chinese semis exports are not expected to
have a significant impact on the global primary
metal balance outside of China.
A growing deficit in the market in the years
ahead will help unwind stocks and allow the
industry to become more fit and healthy for
a new period of growth. Global aluminium
ALUMINIUM · 5/2014
CO M PA N Y N E W S W O R L D W I D E
deficit excluding China will reach 1.3m tonnes
this year from 455,000 tonnes in 2013. About
1-1.5m tonnes of the global aluminium production out of China is expected to be idled
in 2014.
Rusal accounted for 8% of global production of aluminium and 7% of alumina in 2013.
The company posted a loss of USD3.2bn in
2013, compared with a USD528m loss in
2012. It has suspended primary aluminium
production at its least-efficient smelting facilities, resulting in a 7.6% decrease in metal
output to 3.9m.
BHP cuts production at Alumar
BHP Billiton has announced production cuts
of 58,000 tpy at the Alumar smelter in Brazil, in which BHP holds a 40% stake. The
curtailment will start in the June quarter. Already in 2013 BHP suspended production of
45,000 tpy at Alumar. The smelter is operated
by Alcoa.
In January, BHP commenced formal stakeholder consultation regarding the termination
of aluminium smelting activities and associated services at the Bayside smelter in South
Africa from the end of June 2014. The Bayside
casthouse will be supplied by BHP’s Hillside
smelter.
Nippon Light Metal discontinued
aluminium electrolysis business
Nippon Light Metal Co., Ltd discontinued
aluminium electrolysis business operated in
Kambara Works at the end of March. The firm
will supply refined bare metal (high-purity
bare metal) based on import bare metal. Kambara Works had only been continuing aluminium smelting business in Japan because
the works owned hydro-electric generation.
Hence, this closure shows passing of aluminium smelting in Japan.
■
Bauxite and
alumina activities
Mercuria acquires J.P. Morgan’s
physical commodities business
Mercuria Energy Group has reached a definitive agreement with J.P. Morgan Chase & Co.
to acquire its physical commodities business.
The all cash transaction is expected to close in
ALUMINIUM · 5/2014
the third quarter of 2014, subject to regulatory approvals. During that period, Mercuria
will work closely with J.P. Morgan to ensure a
smooth transition of the business. This transaction is a major step in the development of
Mercuria. It will reinforce the group’s strong
position in the energy and commodities markets.
Mercuria was founded in 2004. Turnover
in 2012 was USD98bn, with a total trading
volume of 182m tonnes. The Mercuria network encompasses 37 offices in 28 countries
and the group employs more than 1,000 people of 40 nationalities. The group trades in
more than 50 countries, and has established
base metals teams for the trading of NF metals such as copper and aluminium in Shanghai
and London.
BHP considers divestment of
aluminium and bauxite assets
ery, the second largest in the southern hemisphere.
BHP also owns 36% of the Alumar refinery and 40% of the Alumar smelter, both operated by Alcoa. The operations, and their integrated port facility, are located at Sao Luis in
the Maranhao province of Brazil. Mineração
Rio do Norte, Brazil, is operated as an incorporated joint venture between BHP (14.8%),
Alcoa and affiliates (18.2%), Vale (40%), Rio
Tinto Alcan (12%), Votorantim (10%) and
Hydro (5%). BHP’s portion of the bauxite offtake is supplied to the Alumar refinery.
Loading of alumina at Alunorte
suspended, but production
continues unaffected
The Pará State Environmental Secreteriate
(Sema) has suspended Alunorte’s environmental operational license for loading of alumina at its port, Vila do Conde, effective since
1 April 2014. This results in the suspension
of all loading of alumina. The production of
alumina at Alunorte continues unaffected.
Mining giant BHP Billiton is considering a
divestment of numerous non-core assets in a
transaction that could create a new USD20bn
resources
company.
Among possible spin-offs
are the aluminium and
bauxite assets. BHP will
streamline its business to
the ‘four pillars’ iron ore,
petroleum, copper and
coal. Potash remains a
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passes the fully owned
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smelter in Mozambique
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is a joint venture in
‡ /RZ,QYHVWPHQW
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which BHP has a 47.1%
interest. There are two
operations in Western
Australia: BHP owns
86% of the Boddington
bauxite mine and Worsley alumina refinery in a
joint venture with Japan
Alumina and Sojitz. The
Boddington mine sup6WRUYLN$6
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61
CO M PA N Y N E W S W O R L D W I D E
Sema argues that Alunorte has not fulfilled
one of the conditions under the license, which
is to present a plan to reduce emissions of
alumina dust in the port loading operation.
Alunorte claims it is already using one of the
best available technologies for alumina loading and disagrees with Sema’s position that
the license condition is not fulfilled. Alunorte
will continue its dialogue with SEma and expects that the matter will be resolved and that
the loading of alumina will resume without
affecting production.
Alunorte has a nameplate capacity of 6.3m
tonnes and is the world’s largest alumina refinery.
MetroCoal makes offer
to buy Cape Alumina
Australian energy company MetroCoal has
made an unconditional cash offer to ac-
quire all of bauxite explorer Cape Alumina.
Cape Alumina is capitalised at about A$5m
(USD4.53m). The plan for a deal was released
in September 2013, when MetroCoal and
Cape Alumina said they would merge to create
a diversified bauxite and thermal coal business. But the Queensland state government
effectively banned the company’s flagship Pisolite Hills project when it declared the area
part of the Steve Irwin Wildlife Reserve on
Cape York Peninsula in December. The merger
fell through, and Cape Alumina’s share price
fell. It turned instead to its Bauxite Hills mine
and port project north of Weipa on western
Cape York, Queensland.
MetroCoal now plans to use its excess cash
to develop the Bauxite Hills project as the
new owner of Cape Alumina, rather than its
merger partner. Cape Alumina has reportedly
advised its shareholders to take no action
while the terms of the bid are considered. ■
© Hertwich
Recycling and secondary smelting
Beauty care brand Fa to use
recycled aluminium for aerosol can
Henkel and Ball Corp. have collaborated to
launch a new, lighter aluminium aerosol can
for Fa, the popular beauty care brand. Ball
manufactures the can using new metal technology, which utilises recycled aluminium to
create a metal alloy that exhibits increased
strength and allows lightweighting of the container by as much as 10%. Further lightweighting is expected in the future, according to the
company.
Ball is the world’s largest producer of recyclable aluminium beverage cans and aluminium ‘slugs’, or metal disks that are impact
62
extruded to produce aerosol product packaging for body sprays, sun screens, hair sprays
and the like. After months of collaboration,
Ball developed a method that will allow the
company to use either post-consumer recycled aluminium or aluminium recycled from
its global beverage can operations to produce
its new slugs. Currently, almost all extruded
aluminium aerosol packaging is made from
‘virgin’ aluminium slugs.
Aleris considers the sale
of its recycling businesses
Aleris has announced that it is formally eval-
uating the potential sale of its Recycling and
Specification Alloys businesses. “While the
businesses remain steady and profitable with
excellent long-term growth potential, we are
always reviewing our operations to ensure that
Aleris is optimising the value of its portfolio,”
said Aleris chairman and CEO Steve Demetriou. Following a comprehensive review,
Aleris may choose to retain the business. ■
Aluminium semis
Hydro agrees to sell aluminium
casthouse in Hannover
Hydro has entered into a binding agreement
to sell its special alloy aluminium casthouse
in Hannover to IQ Industrial Holding in Luxembourg, a private industrial holding group
with operations across Europe. The Hannover
casthouse is focused on special aluminium
alloys, mainly hard alloys for the aerospace
industry. Through the agreement, IQ Industrial Holding will acquire 100% of the shares
in Hydro Gießerei Hannover GmbH.
The casthouse was taken over by Hydro
through the acquisition of VAW aluminium
AG in 2002 and is considered non-core business. It supplies hard alloy products mainly to
a customer located wall-to-wall. The Hannover casthouse employs around 30 people and
produced some 12,000 tonnes of aluminium
products in 2013. The transaction is expected
to close during the second quarter of 2014.
The casthouse is equipped with two 50tonne, tiltable channel-type induction furnaces and a vertical DC casting unit. The foundry
can produce billets with a maximum length
of 6,300 mm and diameters of 178 up to 433
mm. The direct chill (DC) casting process, developed at this plant in mid-1930, has gained
acceptance worldwide for the casting of aluminium wrought alloys.
Sapa to close extrusion plant in Miami
Sapa is closing its aluminium extrusion plant
in Miami to optimise its organisation and
production capacity in the North American
market. “The Miami location has provided
Sapa with valuable production capacity and
has been an asset for us,” says Patrick Lawlor,
executive vice president and head of Sapa’s
Extrusion Americas business area. “However,
we need to optimise our capacity utilisation
in the southeast region and better align our
product offerings with their market needs.”
ALUMINIUM · 5/2014
CO M PA N Y N E W S W O R L D W I D E
Sapa expects to complete the closure process
by the end of June. The company employs
nearly 60 people at the Florida site. The plant
has two extrusion presses as well as fabrication and surface treatment facilities. Sapa has
already begun the transition of its existing
Miami customers to sister locations in St. Augustine, Florida, and Delhi, Louisiana.
Sapa will continue to be North America’s
leader in aluminium solutions, in market share
as well as capacity, after the closure of the Miami plant. Sapa has activities in 23 locations in
the US alone, employing some 5,000 people.
Aleris completes acquisition
of Nichols Aluminum
Aleris has completed its acquisition of Nichols
Aluminum, a leading producer of aluminium
sheet for numerous industries in North America. “Adding the Nichols’ sites to our portfolio is consistent with our strategy to grow our
geographic footprint, expand our finishing
capacity and add supply chain flexibility in our
Rolled Products segment in North America –
all of which will enhance our level of service
to our customers,” Steve Demetriou, Aleris
chairman and CEO said. The acquisition includes two production facilities in Davenport, Iowa, a facility in Decatur, Alabama,
and a facility in Lincolnshire, Illinois. The
company has agreed to pay USD110m in an
all-cash transaction.
Highlander Partners acquires
Profile Extrusion Company
Rexam starts construction
work on new Swiss plant
Rexam, a leading global beverage can manufacturer and the number one can maker in
Europe, has commenced construction of its
new plant in Switzerland. The ground-breaking ceremony was officially launched at the
end of March the building which represents
an investment of £115m in total.
Located in Widnau, the plant will be a
wall-to-wall facility, and when complete will
run as a three line operation producing various sizes of Slim and Sleek cans. Built to the
On the move
Novelis has named former US Zinc Corp. executive Manfred Stanek vice-president of strategy
and chief commercial officer, effective 1 April.
Stanek succeeds Brad Soultz, who left the
aluminium producer in January. His duties will
include leading the commercial organisations for
Novelis’ automotive, can and speciality products
business.
Andrew Baldock has joined the metals sales
team of Jefferies Bache. Jefferies Bache is a category II member of the LME.
Glenn Miller has been promoted to CFO of
Alcoa’s Global Rolled Products (GRP) business,
effective 1 May. He succeeds Judy Schrecker
who will retire from Alcoa after 34 years of service. Miller will be responsible for managing all
aspects of the global GRP financial and information technology organisations.
The Aluminum Association, Arlington, appointed Ryan Olsen as vice-president of business
information and statistics.
Gareth Turner, who was assigned to Noranda’s board by Apollo, and Columbia University
senior executive vice-president Robert A Kasdin
resigned. Turner has been replaced by Robert J
Kalsow-Ramos, another Apollo appointee and
an ‘investment professional’ at the company.
Kasdin has been replaced by Elliot G Sagor, a
partner at New York-based law firm Mintz &
Gold LLP. Sagor will serve on the board’s com-
ALUMINIUM · 5/2014
latest environmental specifications, the plant
will minimise traffic to-and-from the site and
optimise logistic costs.
The first line in Widnau is due to come
on stream in 2015 and the plant will have an
incremental capacity when fully built of 2.2bn
cans a year.
pensation committee as well as its nominating
and governance committee.
Pål Kildemo has been appointed head of
Investor Relations in Norsk Hydro, and will be
responsible for Hydro’s contact with investors
and financial markets. He will report to executive
vice-president and CFO Eivind Kallevik. Kildemo
succeeds Rikard Lindqvist, who will leave Hydro
to pursue other opportunities.
CME Group hired Liz Milan, former managing director of LME Asia, as a consultant within
its metals division on a contract basis. She will be
based in Singapore. Milan will report to Harriet
Hunnable, CME Group metals products managing director. The CME Group will launch North
American physically-delivered aluminium futures
contracts from 5 May.
Aleris has appointed Sean Stack executive
vice-president and CEO, North America Rolled
Products. He will report to company chairman
and CEO Steve Demetriou.
PT Aneka Tambang’s (Antam) operations director Winardi has been appointed PT Indonesia
Asahan Aluminium’s (Inalum) president director.
South African power utility Eskom has appointed Collin Matjila Interim CEO as current
chief executive Brian Dames stepped down at
the end of March. Collin Matjila will assume the
position of Interim CEO until Eskom finds a suitable permanent ceo
Private investment firm Highlander Partners,
L.P. has acquired the aluminium extrusion
assets of Profile Extrusion Company located
in Rome, Georgia, USA. The operations will
continue to operate from the Georgia location
under the name of Profile Custom Extrusions,
LLC (PCE) with the current management team
continuing to lead the business. PCE is a provider of aluminium extrusions to the industrial and residential construction, electrical,
hurricane shutter and interior décor markets
throughout the south-eastern part of the
United States. The company operates three
extrusion presses with a total annual capacity
of 18,140 tonnes, along with a vertical wet
paint line and a thermal fill and de-bridge line.
Highlander is a long-term investor that is engaged in the aluminium extrusion business.
Novelis marks commercial debut of
‘evercan’ aluminium beverage can sheet
The Red Hare Brewing Company has launched
the first commercial use of evercan which is
Novelis’ independently certified high-recycled
content aluminium sheet for beverage cans.
Red Hare craft beer is expected to be on store
shelves beginning in May 2014 in key markets throughout the south-eastern US. Novelis
guarantees a minimum 90% recycled content
of evercan aluminium sheet.
Red Hare is one of the fastest-growing
micro-breweries in the US. The company selected Novelis’ evercan aluminium as part of
its commitment to reduce its environmental
footprint, while preserving the freshness and
enhancing the taste of its finely crafted beer.
Red Hare was the first craft brewery in Georgia to package its products in aluminium cans,
following a trend in the micro-brewery industry to move from bottles to cans as a way to
expand distribution and appeal to on-the-go
consumers. Nearly 400 craft brewers in nearly
every state in the US are canning more than
1,300 different beers.
Novelis’ efforts to increase the recycling
of beverage cans is a key component of its
63
CO M PA N Y N E W S W O R L D W I D E
strategy to dramatically increase the recycled
content of its products across its global operations to 80% by 2020. Already the world’s
largest recycler of aluminium, the company
has announced capital investments of around
USD500m over the last two years that will
double its global recycling capacity to 2.1m
tonnes by 2015.
by Shanghai Metals Market. Last year, operating rate was still 70%. One reason for this
development is the weakening property sector
in China.
The situation for rolling mills is similar to the
extrusion sector: operating rate for aluminium
sheet, strip, plate and foil was 63% in April,
the same as a month earlier.
■
Suppliers
Rio Tinto Alcan and the National Research
Council (NRC) of Canada have signed a fiveyear deal to develop aluminium extrusions
for the ground transportation sector. The
agreement, valued at C$3.25m (USD2.94m),
would see work conducted at NRC facilities
in Saguenay, Quebec, and at the company’s
Arvida Research and Development Centre in
Saguenay-Lac Saint-Jean, Québec. The NRC
and Rio Tinto Alcan will work to make new
aluminium components not only for cars and
trucks but also for trains, buses and recreational vehicles. Rio Tinto Alcan will contribute
C$1.4m to the project.
Aluminium companies have built or have
announced plans to add new capacity to meet
forecast gains in demand from the transportation sector. Attention has largely focused on
aluminium sheet for body-in-white applications for mass produced vehicles, but extruders are also pressing to add capacity and develop new capabilities.
Low operating rates in China’s
aluminium semis industry
The operating rate at aluminium extrusion
producers in China is further declining. The
rate was 64% in April, according to a survey
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.
64
© SMS Siemag
Rio Tinto Alcan boosts R&D
for transportation extrusions
Two finish coaters for colour coating: a U-roll coater for coating
the upper strip surface and an S-roll coater for two-sided coating
Tianjin Zhongwang orders
colour coating line from SMS
Siemag for aluminium can stock
All plant components for the new colour
coating line for Tianjin Zhongwang Aluminium Co., Ltd will be supplied by SMS Siemag,
Germany, from a single source. An outstanding feature of the plant design is the compact
coating process. The chemical pre-treatment
section, the subsequent strip coating process
and the drying furnace are perfectly harmonised. For many products, the drying furnace
uses only energy recovered from the process.
This ensures low consumption of resources
and energy while achieving a high product
quality.
In addition to the coating process equipment, SMS Siemag’s scope of supply comprises all mechanical equipment and the entire
electrical and automation systems for the
lines. Beside the design and manufacturing of
the equipment, SMS will be responsible for
the supervision of installation and commissioning.
The line is designed for strips with a thickness of 0.15 to 0.5 mm and widths ranging
from 950 to 2,000 mm. In the process section
the strip will be coated at a process speed of
250 m/min, whereas in the entry and exit
section speeds of up to 300 m/min can be at-
tained. The production
range includes 3xxx
series aluminium alloys, as well as 5052
and 5182 alloys.
Main components
of the line are two uncoilers and cross-cut
shears, a stitching machine, entry accumulator, cleaning section,
chemical coater, two
finish coaters, a floatation furnace, exit accumulator, inspection
section, wax coater,
oiling machine, side
trimmer, flying shear
and two coilers.
Nanshan America puts 82-MN
extrusion press into operation
Nanshan America in Lafayette, Indiana, USA,
has successfully put into operation its 82-MN
extrusion press which was supplied by SMS
Meer, Germany. The heavy-duty front-loading extrusion press is capable to extrude 1,800
mm long billets with a diameter of 457 mm.
The target markets for the large and heavy
profiles are the transport and construction
industries.
Outotec to deliver technology
for Orbite Aluminae’s high
purity alumina plant in Canada
Outotec has agreed with Orbite Aluminae
Inc. on the delivery of a new calcination system for Orbite’s high purity alumina production facility located in Cap-Chat, Québec. The
contract value is below €10m. The scope of
delivery includes engineering and proprietary
equipment for a specialised fluidised bed
application of decomposing and calcining
high purity alumina. The plant is scheduled
to start production in early 2015. This delivery
complements the technology package Outotec has delivered to Orbite Aluminae during
an earlier stage of this project in 2012.
ALUMINIUM · 5/2014
PAT E N T E
High purity alumina, produced from aluminous clay, is used in a variety of high-end
technology applications. Half of the world’s
annual production of ultra-pure alumina goes
into producing synthetic sapphire which is
used in fibre optics and, more recently, in LED
lighting for home and automotive markets. It
is also essential in various new applications in
the electronics industry.
Rusal invests in aluminiumzirconia wire rod production
Russian aluminium producer Rusal has announced a USD5.5m investment in aluminium-zirconia wire rod production. The first
samples of high-tech products have already
been certified by consumers. This is the first
wire rod production for electric power industry to be launched in Russia. The production
will be sited at the Irkutsk aluminium smelter
(IrkAZ). The investment refers to R&D and
thermal treatment equipment.
Rusal has signed a contract with Seco
Warwick to supply electrothermal equipment, which will be delivered to the IrkAZ
site in September 2014. The planned production levels are expected to be fully reached in
early 2015. Once the equipment is installed,
IrkAZ’s wire rod production capacity will be
up to 3,000 tpy. Rusal’s share in the Russian
aluminium-zirconia wire rod market is expected to be up to 80% .
The use of conductors made from aluminium-zirconia wire rod instead of traditional
rod will result in a two-fold increase in trans-
Patentblatt Februar 2014
Fortsetzung aus ALUMINIUM 4/2014
Vorrichtung und Verfahren zur pneumatischen
Beförderung von Schüttgütern im Dichtstromverfahren. Rio Tinto Alcan International Ltd.,
Montreal, Quebec, CA. (B65G 53/52, EP 1 776
301, WO 2006/015702, AT: 22.07.2005, EP-AT:
22.07.2005, WO-AT: 22.07.2005)
Verfahren zum Löten einer Ti-Al-Legierung
und hergestelltes Werkstück davon. Onera,
Châtillon, FR. (B23K 31/02, EP 1 648 651, WO
2005/018867, AT: 15.07.2004, EP-AT: 15.07.
2004, WO-AT: 15.07.2004)
Verschleißfester
Aluminiumlegierungswerkstoff mit hervorragender Bearbeitbarkeit
und Herstellungsverfahren dafür. Okamoto,
Yasuo, Kitakata-shi Fukushima 966-0845, JP.
C22C 21/02, PS 60 2007 028 128, EP 2085491,
WO 2008/056738, AT: 08.11.2007, EP-AT:
08.11.2007, WO-AT: 08.11.2007)
ALUMINIUM · 5/2014
mission capacity of existing power lines, says
Rusal. JSC Russian Grids will be the major
consumer of the products in Russia.
Siemens to supply drives
technology for Alunorf mill
Siemens Metals Technologies has won an order from Aluminium Norf GmbH (Alunorf)
in Neuss, Germany, to supply automation and
drives systems to expand and modernise hot
rolling mill No. 1. The conversion work will
be performed in several stages, and should be
completed by the start of 2016.
In the course of a multi-stage programme
to expand capacity, an extra rolling stand
will be added to the finishing line of the hot
rolling mill. Modifications will also be made
to the existing gear units. The last stand on
the finishing mill and the coiler will be fitted
with new AC drives. Both measures will increase rolling speed and therefore production
capacity.
Siemens will be supplying a synchronous
motor with a non-salient pole rotor for the
last rolling stand, which is currently equipped
with a DC motor, and an induction motor for
the coiler. This will replace three DC motors
mounted on one shaft. As well as installing
Sinamics SM150 medium voltage converters,
Siemens will also handle the entire dismantling
and reassembly work, as well as the commissioning of the electrical components. The DC
motor from the last rolling stand will be overhauled in a Siemens workshop, re-assembled
and then used again in the new rolling stand.
Herstellung einer Masterlegierung für glasige Legierungen auf Aluminiumbasis. United
Technologies Corp., Hartford, Conn., US. (B22D
21/04, EP 2 567 764, AT: 26.04.2012, EP-AT:
26.04.2012)
Stoßfänger für Kraftfahrzeuge mit integriertem Fußgängerschutzsystem. Constellium Singen GmbH, 78224 Singen, DE. (F16F 7/12, EPA
2676046, WO 2012/110208, EP-AT: 06.02.2012,
WO-AT: 06.02.2012)
Inline-Oberflächenbehandlung zur Herstellung
von Aluminiumstrangpressprofilen mit korrosionsbeständiger Beschichtung. Constellium
Extrusions Deutschland GmbH, 74564 Crailsheim, DE. (B21C 23/00, EP 2 489 448, AT: 16.02.
2011, EP-AT: 16.02.2011)
Dachrelinganordnung für ein Kraftfahrzeug.
Erbslöh Aluminium GmbH, 42553 Velbert,
DE. (B60R 9/04, GM 20 2013 105 598, AT:
10.12.2013)
Alunorf will supply the automation hardware
required for the new rolling stand, while
Siemens will make the necessary adaptations
to the software.
The modernisation work will be performed
during scheduled plant shutdowns to avoid
additional production losses. The solution
proposed by Siemens will ensure that existing
components and systems can be used again
to the greatest possible extent. This will also
create the technical pre-requisites for their
future replacement, which will increase the
security of Alunorf’s investment.
Aluminium Norf is a joint venture of
Novelis Deutschland and Hydro Aluminium
Rolled Products, and operates the world’s
largest aluminium smelting plant and rolling
mill in Neuss. The company sells 1.5m tpy of
hot and cold-rolled aluminium strip.
Mechatherm completes first cast
for Phase 2 at China Steel, Taiwan
Mechatherm successfully completed the first
cast under full automation control for Phase 2
of the China Steel Aluminium Co. Kaohsiung
casthouse modernisation and expansion. This
follows the successful testing of all items of
equipment installed in Phase 1. All production rates, fuel consumptions and performance parameters have been met by the charging machine, dual and single chamber melting
furnace, holding furnace and casting machine
with MMLC for Phase 1. Phase 2 construction and final commissioning will be completed in the next few months.
■
Verfahren zur Herstellung eines Absorberblechs für Sonnenkollektoren, nach dem Verfahren hergestelltes Absorberblech und dessen Verwendung. Hydro Aluminium Deutschland GmbH, 41515 Grevenbroich, DE. (B05D
7/14, PS 10 2006 039 804, AT: 25.08.2006)
Verfahren zur Herstellung einer Baustrebe
durch Crimpen und so erhaltene Baustrebe.
Norsk Hydro ASA, Oslo, NO. (E06B 3/273, EP 2
055 883, AT: 23.10.2008, EP-AT: 23.10.2008)
Optimierung und Steuerung von metallurgischen Eigenschaften während der Homogenisierung einer Legierung. Kaiser Aluminum,
Foothill Ranch, Calif., US. (C22F 1/04, EP 2 508
642, AT: 27.03.2012, EP-AT: 27.03.2012)
Gekühlter Kolben und Verfahren zu dessen
Herstellung. KS Kolbenschmidt GmbH, 74172
Neckarsulm, DE. (F02F 3/22, EPA 2681436,
WO 2012/116987, EP-AT: 28.02.2012, WO-AT:
28.02.2012)
➝
65
PAT E N T E
Verfahren zur Herstellung einer Aluminiumstruktur und Aluminiumstruktur. Sumitomo
Electric Industries Ltd., Osaka, JP. (C25D 1/08,
WO 2012 165214, AT: 22.05.2012, WO-AT:
22.05.2012)
Homogenisierung und Wärmebehandlung von
Gussmetallen. Novelis Inc., Atlanta, Ga., US.
(B22D 11/00, EP 2 474 374, AT: 27.10.2006, EPAT: 27.10.2006)
Kolben mit einer lokalen Ringnut- und / oder
Muldenrandverstärkung. KS Kolbenschmidt
GmbH, 74172 Neckarsulm, DE. (F02F 3/00, OS
10 2012 214 681, AT: 17.08.2012)
Kolben für einen Verbrennungsmotor sowie
Verfahren zu seiner Herstellung. Mahle International GmbH, 70376 Stuttgart, DE. (F02F
3/00, EPA 2681435, WO 2012/119590, EP-AT:
02.03.2012, WO-AT: 02.03.2012) sowie (F02F
3/00, F02F 3/22, EPA 2681435 u. EPA 2681437,
WO 2012/119590 u. WO 2012/119591, EP-AT:
02.03.2012, WO-AT: 02.03.2012)
Verfahren zur Herstellung eines Kolbens für
einen Verbrennungsmotor. Mahle International
GmbH, 70376 Stuttgart, DE. (B21K 1/18, EPA
2680989, WO 2012/119583, EP-AT: 02.03.2012,
WO-AT: 02.03.2012)
Kolben für einen Verbrennungsmotor. Mahle
International GmbH, 70376 Stuttgart, DE. (F16J
1/09, F02F 3/22, EPA 2681469, WO 2012/
119584, EP-AT: 02.03.2012, WO-AT: 02.03.
2012)
Kolben. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/22, OS 10 2012 213 558, AT:
01.08.2012)
Kolben mit einem Kühlkanal für einen Verbrennungsmotor und Verfahren zur Herstellung des Kolbens. Mahle International GmbH,
70376 Stuttgart, DE. (F02F) 3/22, PS 50 2005 013
413, EP 1815123, WO 2006/056185, AT: 24.11.
2005, EP-AT: 24.11.2005, WO-AT: 24.11.2005)
Magnesiumlegierung und dazugehöriges Herstellungsverfahren. Biotronik VI Patent AG,
Baar, CH. (C22C 23/04, EP 1 840 235, AT: 22.03.
2007, EP-AT: 22.03.2007)
Superplastisches Umformen von hochfesten
L12-Aluminiumlegierungen. United Technologies Corp., Hartford, Conn., US. (B22F 3/10, PS
60 2010 004 889, EP 2343141, AT: 14.09.2010,
EP-AT: 14.09.2010)
Schmiedeverformung von L12-Aluminiumlegierungen. United Technologies Corp., Hartford,
Conn., US. (C22C 1/04, EP 2 325 343, AT:
19.08.2010, EP-AT: 19.08.2010)
Verbindungsanordnung zweier zumindest im
Wesentlichen aus einem Leichtmetall gebildeten Bauteile. Fischer, Sven, 75365 Calw, DE.
(F16B 5/02, OS 10 2011 013 389, AT: 09.
03.2011)
Beschichtete Bauteile aus Aluminiumlegierungen zum Eingießen in Leichtmetalllegie-
66
rungen und deren Herstellungsverfahren.
Daimler AG, 70327 Stuttgart, DE. (B22D 19/16,
OS 10 2007 026 005, AT: 04.06.2007)
Minato-ku,Tokyo 105-8601, JP. (C22C 21/06,
EPA 2695959, EP-AT: 21.06.2013, WO-AT:
21.06.20134)
Magnesium-Walzwerk. Fata Hunter, Inc., Riverside, CA 92507, US. (B21B 3/00, EPA 2683499,
WO 2012/125498, EP-AT: 09.03.2012, WO-AT:
09.03.2012)
Stresskorrosionsbeständiger Getränkeflaschenverschluss aus Aluminium. Ball Corp., Broomfield, CO 80021, US. (B21D 51/30, EPA 2688696,
WO 2012/128863, EP-AT: 14.02.2012, WO-AT:
14.02.2012)
Bilderrahmen. Erbslöh Aluminium GmbH, 42553
Velbert, DE. (A47G 1/06, GM 20 2005 019 600,
AT: 15.12.2005)
Verfahren zum chemischen Entgraten von Magnesium. deburit Chemical Engineering GmbH,
47829 Krefeld, DE. (C23G 1/12, OS 10 2012 214
719, AT: 20.08.2012)
Hochfeste und hoch zähe Magnesiumlegierung
und Herstellungsverfahren dafür. Kawamura,
Yoshihito, Kumamoto, JP. (C22C 23/06, EP 1 688
509, WO 2005/052203, AT: 26.11.2004, EP-AT:
26.11.2004,WO-AT: 26.11.2004)
Patentblatt März 2014
Keramische Leiterplatte mit Al-Kühlkörper. CeramTec GmbH, 73207 Plochingen, DE. (H01L
23/367, EPA 2695189, WO 2012/136579, EP-AT:
30.03.2012, WO-AT: 30.03.2012)
Mg-Al-Ca-basierte Masterlegierung für Mg-Legierungen und Herstellungsverfahren dafür.
Korea Institute of Industrial Technology, Chungcheongnam-do 331-825, KR. (C22C 23/00, EPA
2692883, WO 2012/134243, EP-AT: 30.03.2012,
WO-AT: 30.03.2012)
Ti-Al-Ta-basierte Beschichtung mit einer verbesserten Temperaturbeständigkeit. Oerlikon Trading AG, Trübbach, Trübbach, CH. (C22C 29/16,
OS 10 2012 017 731, AT: 08.09.2012)
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, PS 60 2009 013 949, EP 2303796,
WO 2010/001065, AT: 02.07.2009, EP-AT:
02.07.2009, WO-AT: 02.07.2009)
Al-Zn-Mg-Legierungsprodukt mit verringerter Quetschempfindlichkeit. Aleris Rolled Products Germany GmbH, 56070 Koblenz, DE.
(C22C 21/10, EP 2 288 738, WO 2009/156283,
AT: 12.06.2009, EP-AT: 12.06.2009, WO-AT:
12.06.2009)
Verfahren für das Beschichten einer Aluminiumoberfläche eines Aluminiumteils, Aluminiumteil und Bügeleisensohle aus Aluminium.
BSH Bosch und Siemens Hausgeräte GmbH,
81739 München, DE. (D06F 75/38, EPA 2694720,
WO 2012/137124, EP-AT: 02.04.2012, WO-AT:
02.04.2012)
Aluminiumlegierungsblech, das nach Anodisierung eine hervorragende Oberflächenqualität aufweist, und Verfahren zur Herstellung
davon. Sumitomo Light Metal Industries Ltd.,
Artikel mit einer Verbindung zwischen einer
Aluminiumkomponente und einem Hartmetall
mit einem an die Aluminiumkomponente geschweißten Aluminium-Bronze-Übergangsteil:
Verfahren zum Verbinden solcher Artikel. Allectra Ltd., Sheffield Park, Sussex TN22 3HQ, GB.
(B23K 15/00, EPA 2686130, WO 2012/123740,
EP-AT: 14.03.2012, WO-AT: 14.03.2012)
Verfahren zur Herstellung planarer Kohlenstoff-Nanopartikel und Verfahren zur Herstellung eines Aluminium-/Kohlenstoffverbundmaterials damit. Research & Business Foundation
Sungkyunkwan University, Suwon-si, Gyeonggido 440-746, KR; Dayou Smart Aluminium Co.,
Ltd., Gwangju 502-834, KR. (C01B 31/02, EPA
2687485, WO 2013/133467, EP-AT: 15.03.2012,
WO-AT: 15.03.2012)
Fenstertragegriff für Hohlkammerprofile aus
Kunststoff, Aluminium oder Stahl. Bermann, Irena, 39167 Eichenbarleben, DE.(B65G 7/12, OS 10
2012 017 632, AT: 06.09.2012)
Verfahren zur Herstellung eines Halbzeugs aus
einer Aluminium-Eisen-Legierung sowie nach
dem Verfahren erhältliche Halbzeuge. Audi AG,
85045 Ingolstadt, DE; Volkswagen AG, 38440
Wolfsburg, DE. (C22C 21/00, OS 10 2012 018
934, AT: 26.09.2012)
Widerstandspunktschweißen von Aluminium
an Aluminium und Stahl an Stahl. GM Global
Technology Operations, LLC (n.d. Ges. d. Staates
Delaware), Detroit, Mich., US. (B23K 11/30, OS
10 2013 218 275, AT: 12.09.2013)
Heißversiegelungsmasse für Aluminium- und
Polyethylenterephthalatfolien gegen Polypro-
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
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Tel. 0345/29398-0
Fax 0345/29398-40,
www.mipo.de
Die Gesellschaft bietet darüber hinaus weitere
Patent-Dienstleistungen an.
ALUMINIUM · 5/2014
PAT E N T E
(C22C 21/02, PS 60 2005 038 516, EP 2281909,
AT: 05.04.2005, EP-AT: 05.04.2005)
broich, DE. (B32B 15/01, EPA 2692524, EP-AT:
18.01.2008, WO-AT: 18.01.2008)
Aluminiumlegierung. Audi AG, 85057 Ingolstadt, DE. (C22C 21/02, PS 50 2009 006 511, EP
2088216, AT: 23.01.2009, EP-AT: 23.01.2009)
Modularer Sonnenkollektor. Hydro Aluminium
Deutschland GmbH, 51149 Köln, DE. (F24J 2/20,
GM 20 2006 020 157, AT: 20.01.2006)
Hochleitfähige Aluminiumlegierung für elektrisch leitfähige Produkte. Hydro Aluminium
Rolled Products GmbH, 41515 Grevenbroich, DE.
(C22C 21/00, EP 2 527 479, AT: 27.05.2011, EPAT: 27.05.2011)
Verfahren zur Herstellung eines Formkörpers.
Norsk Hydro ASA, Oslo, NO. (B23K 1/00, PS
602 37 595, EP 1383625, WO 2003/037559,
AT: 02.05.2002, EP-AT: 02.05.2002, WO-AT:
02.05.2002)
Magnesium-Dichlorid-Alkohol-Addukte
und
dadurch erhaltene Katalysatorkomponenten.
Basell Poliolefine Italia S.r.l., 20127 Milano, IT.
(C08F 4/654, EPA 2692743, EP-AT: 03.08.2012,
WO-AT: 03.08.2012)
Vorrichtung zum Befestigen einer Profilleiste an
einer Befestigungsfläche eines Kraftfahrzeuges.
WKW Erbslöh Automotive GmbH, 42349 Wuppertal, DE. (B60R 9/058, GM 20 2011 001 619,
AT: 17.01.2011)
Verwendung eines Drehtrommelofens zum
Umschmelzen von Aluminium. Stöby, Manfred,
Mattighofen, AT. (F27B 7/20, PS 598 03 247, EP
0886118, AT: 17.06.1998, EP-AT: 17.06.1998)
Magnesium-Gadolin-Legierungen. Magnesium
Elektron Limited, Salford, GB. (C22C 23/06, PS
60 2007 028 565, EP 2074236, WO 2008/032087,
AT: 12.09.2007, EP-AT: 12.09.2007, WO-AT:
12.09.2007)
Vorrichtung zum Befestigen einer Träger- oder
Zierleiste. WKW Erbslöh Automotive GmbH,
42349 Wuppertal, DE. (B60R 9/04, GM 20 2011
001 621, AT: 17.01.2011)
Kontinuierliche Hydrierung von aromatischen
Nitroverbindungen unter Verwendung eines
Katalysators mit geringem Gehalt an Aluminium. Vencorex France, Saint-Priest, FR. (C07C
209/36, OS 601 00 719, EP 1138665, AT:
27.03.2001, EP-AT: 27.03.2001)
Magnesiumlegierung. Advanced Technologies,
Inc., Gotenba-shi, Shizuoka 412-0047, JP; Osaka Prefecture University Public Corp., Osaka
599-8531, JP. (C22C 23/02, EPA 2692884, WO
2012/133522, EP-AT: 28.03.2012, WO-AT:
28.03.2012)
Verfahren zum Ätzen von Aluminium und
Vorrichtung dazu. Lorin Industries, Inc., Muskegon, Mich., US. (C23G 1/22, PS 601 47 756, EP
1227174, AT: 20.12.2001, EP-AT: 20.12.2001)
Verfahren zur Herstellung eines Bandes aus
einer Magnesiumlegierung mit gutem Umformverhalten. MgF Magnesium Flachprodukte
GmbH, 09599 Freiberg, DE. (B22D 11/06, OS 10
2012 108 648, AT: 14.09.2012)
pylen-Polyvinylchlorid- und Polystyrolbehälter.
Evonik Röhm GmbH, 64293 Darmstadt, DE.
(C08L 51/08, EP 1 989 258, WO 2007/098816,
AT: 19.12.2006, EP-AT: 19.12.2006, WO-AT:
19.12.2006)
Aluminium-Aminocarboxylate als poröse, metallorganische Gerüstmaterialien. BASF SE,
67063 Ludwigshafen, DE. (B01J 20/22, PS 50
2008 009 342, EP 2150338, WO 2008/142059,
AT: 20.05.2008, EP-AT: 20.05.2008, WO-AT:
20.05.2008)
Verwendung von Korrosionsschutzadditiven
zum Schutz von Aluminium und / oder Aluminiumlegierungen für Fertigungsverfahren. Rhein
Chemie Rheinau GmbH, 68219 Mannheim, DE.
(C23F 11/10, PS 50 2009 006 355, EP 2312019,
AT: 01.10.2009, EP-AT: 01.10.2009)
Mit Harz beschichteter, nahtloser Dosenkörper
aus Aluminium. Toyo Seikan Kaisha, Ltd., Tokio,
JP. (B65D 1/16, PS 60 2004 041 102, EP 2426057,
AT: 22.06.2004, EP-AT: 22.06.2004)
Elektrolysebehälter zum Erhalt von Aluminium.
Carbone Savoie, Venissieux, FR. (C25C 3/08, PS
60 2007 029 328, EP 2013381, WO 2007/125195,
AT: 25.04.2007, EP-AT: 25.04.2007, WO-AT:
25.04.2007)
Verfahren zur Reparatur eines Bauteiles aus
einer Aluminiumlegierung. Ge Avio S.r.l., Rivalta di Torino, IT. (B23P 6/00, EPA 2688708,
WO 2012/127457, EP-AT: 26.03.2012, WO-AT:
26.03.2012)
Aus einer Aluminiumlegierung hergestelltes
Schwellerstrangpressprofil eines Kraftfahrzeugs. Audi AG, 85057 Ingolstadt, DE. (B62D
25/02, PS 10 2004 002 297, AT: 16.01.2004)
Aluminiumlegierung und deren Verwendung
für ein Gussbauteil, insbesondere eines Kraftwagens. BDW technologies GmbH, 85570 Markt
Schwaben, DE. (C22C 21/04, PS 50 2007 002
755, EP 2041328, WO 2008/006908, AT: 13.07.
2007, EP-AT: 13.07.2007, WO-AT: 13.07.2007)
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.
ALUMINIUM · 5/2014
Inerte Anodenanordnung. Alcoa Inc., Pittsburgh,
PA 15212-5858, US. (H01M 6/00, EPA 2688130,
EP-AT: 19.11.2003, WO-AT: 19.11.2003)
Hybride Manschette für Befestigungssysteme.
Alcoa Inc., Pittsburgh, PA 15212-5858, US. (F16B
19/05, EPA 2689149, WO 2012/129390, EP-AT:
22.03.2012, WO-AT: 22.03.2012)
Stiftverriegelung mit einer Zwischenposition.
Alcoa Inc., Pittsburgh, PA 15212-5858, US. (E05C
1/06, )EPA 2686513, WO 2012/125437, EP-AT:
09.03.2012, WO-AT: 09.03.2012)
Mehrlagige Lötfolie. Alcoa Inc., Pittsburgh, PA
15212-5858, US. (B32B 15/01, EPA 2686165,
WO 2012/125929, EP-AT: 16.03.2012, WO-AT:
16.03.2012)
Isolationseinsatz für einen aus Profilen gebildeten Rahmen. Alcoa Aluminium Deutschland,
Inc., 58642 Iserlohn, DE. (E06B 3/263, EP 2 527
580, AT: 22.05.2012, EP-AT: 22.05.2012)
Verfahren zum Gießen eines Verbundbarrens. Aleris Rolled Products Germany GmbH,
56070 Koblenz, DE. (B22D 19/00, EP 2 293
894, WO 2010/000553, AT: 03.06.2009, EP-AT:
03.06.2009, WO-AT: 03.06.2009)
Verbundwerkstoff mit Korrosionsschutzschicht
und Verfahren zu dessen Herstellung. Hydro
Aluminium Deutschland GmbH, 41515 Greven-
Kontaktierung und Befestigung eines Bauteils,
Klebkontaktierung. WKW Erbslöh Automotive
GmbH, 42349 Wuppertal, DE. (F16B 11/00, GM
20 2013 005 800, AT: 28.06.2013)
Fahrzeugbauteil. WKW Erbslöh Automotive
GmbH, 42349 Wuppertal, DE. (B60R 13/02, GM
20 2013 105 627, AT: 11.12.2013)
Dosierofen für eine Druckgussanlage und Verfahren zum Dosieren von Schmelze in eine
Gießform mit einem derartigen Dosierofen. KS
Aluminium-Technologie GmbH, 74172 Neckarsulm, DE. (B22D 39/06, OS 10 2012 108 511,
AT: 12.09.2012)
Hochdrucknebelsprühverfahren und Sprühvorrichtung zum Behandeln einer Formwand einer
Gussform. KS Aluminium-Technologie GmbH,
74172 Neckarsulm, DE. (B05D 1/02, OS 10 2012
108 969, AT: 24.09.2012)
Zweiteilig aufgebauter Kolben einer Brennkraftmaschine. KS Kolbenschmidt GmbH, 74172
Neckarsulm, DE. (B23K 31/02, OS 10 2013 218
709, AT: 18.09.2013)
Zylindrische Lauffläche sowie Verfahren zur
Herstellung einer zylindrischen Lauffläche. KS
Aluminium-Technologie GmbH, 74172 Neckarsulm, DE. (F02F 1/00, PS 502 15 739, EP 2112359,
AT: 15.01.2002, EP-AT: 15.01.2002)
Kolben für einen Verbrennungsmotor. Mahle
International GmbH, 70376 Stuttgart, DE. (F02F
3/18, OS 10 2012 017 218, AT: 31.08.2012)
Kolben. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/22, OS 10 2012 215 541, AT:
31.08.2012)
Verfahren zum Reibrührschweißen von zweitphasigen Partikeln enthaltenden Aluminiumlegierungsmaterialien, und damit hergestellte
Aluminiumlegierungsplatte. Sumitomo Light
Metal Industries Ltd., Minato-ku,Tokio 1058601, JP. (B23K 20/12, EPA 2687313, EP-AT:
18.07.2012, WO-AT: 18.07.2012)
■
67
LIEFERVERZEICHNIS
1
Smelting technology
 Anode Technology &
Mixing Equipment
Hüttentechnik
1.5
1.6
1.7
1.8
1.9
1.10
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
1.11
1.12
1.13
1.14
1.15
1.16
1.17
Befestigen von neuen Anoden
an der Anodenstange
Casthouse (foundry)
Gießerei
Casting machines
Gießmaschinen
Current supply
Stromversorgung
Electrolysis cell (pot)
Elektrolyseofen
Potroom
Elektrolysehalle
Laboratory
Labor
Emptying the cathode shell
Ofenwannenentleeren
Cathode repair shop
Kathodenreparaturwerkstatt
Second-hand plant
Gebrauchtanlagen
Aluminium alloys
Aluminiumlegierungen
Storage and transport
Lager und Transport
Refractory products
Feuerfesttechnik
Protective Clothing
Schutzkleidung
Buss ChemTech AG, Switzerland
Phone:
+4161 825 64 62
E-Mail:
[email protected]
Internet: www.buss-ct.com
 Auto firing systems
Automatische Feuerungssysteme
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
 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
68
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 · 5/2014
SUPPLIERS DIRECTORY
1.4.1 Anode b aking
Anodenbrennen
 Open top and closed
type baking furnaces
Offene und geschlossene Ringöfen
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
 Degassing, filtration and
grain refinement
Entgasung, Filtern, Kornfeinung
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
 Dross skimming of liquid metal
Abkrätzen des Flüssigmetalls
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: [email protected]
1.5 Casthouse (foundry)
Gießerei
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
 Furnace charging with
molten metal
Ofenbeschickung mit Flüssigmetall
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
 Ingot Casting Line
Bartz GmbH
Furnaces
casting machines
transport crucibles
[email protected]
www.bartz-maschinenbau.de
see Casthous (foundry) 1.5
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
Solios Thermal UK
www.fivesgroup.com
 Metal treatment in the
holding furnace
Metallbehandlung in Halteöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
 Transfer to the casting furnace
Überführung in Gießofen
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
www.brochot.fr
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
 Melting/holding/casting furnaces
Schmelz-/Halte- und Gießöfen
 Transport of liquid metal
to the casthouse
MOBILE
EQUIPMENT
Phone: +31.315.683941
[email protected] · www.hencon.com
Transport v. Flüssigmetall in Gießereien
ANDRITZ Maerz GmbH
Corneliusstr. 36, 40215 Düsseldorf
Tel. +49 (0) 211-38425-0, Fax -20
E-Mail: [email protected]
Internet: www.andritz.com/metals
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
Gautschi
Engineering GmbH
see Casting equipment 3.1
Bartz GmbH
see Casthous (foundry) 1.5
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
 Treatment of casthouse
off gases
Behandlung der Gießereiabgase
HERTWICH ENGINEERING GmbH
Gautschi
Engineering GmbH
see Casting equipment 3.1
see Casthouse (foundry) 1.5
1.6 Casting machines
Gießmaschinen
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
see Equipment and accessories 3.1
ALUMINIUM · 5/2014
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
69
LIEFERVERZEICHNIS
 Heat treatment of extrusion
ingot (homogenisation)
Formatebehandlung (homogenisieren)
Gautschi
Engineering GmbH
see Casting equipment 3.1
 Sawing / Sägen
Gautschi
Engineering GmbH
see Casting equipment 3.1
see Casthouse (foundry) 1.5
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
 Vertical semi-continuous DC
casting / Vertikales Stranggießen
Gautschi
Engineering GmbH
see Casting equipment 3.1
Bartz GmbH
see Casthous (foundry) 1.5
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
MOBILE
EQUIPMENT
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
 Anode changing machine
Anodenwechselmaschine
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
 Pig casting machines (sow casters)
Masselgießmaschine (Sowcaster)
Elektrolysehalle
Phone: +31.315.683941
[email protected] · www.hencon.com
HERTWICH ENGINEERING GmbH
HERTWICH ENGINEERING GmbH
1.9 Potroom
1.8 Electrolysis cell (pot)
Elektrolyseofen
 Bulk materials Handling
from Ship to Cell
Bulk materials Handling from Ship to Cell
 Anode transport equipment
Anoden Transporteinrichtungen
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
 Crustbreakers / Krustenbrecher
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
 Dry absorption units for
electrolysis exhaust gases
Trockenabsorptionsanlage für
Elektrolyseofenabgase
www.coperion.com
mailto: [email protected]
 Calcium silicate boards
Calciumsilikatplatten
Promat GmbH High Performance Insulation
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
[email protected], www.promat.de
HERTWICH ENGINEERING GmbH
Solios Environnement
www.fivesgroup.com
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: [email protected]
see Casthouse (foundry) 1.5
 Exhaust gas treatment
 Scales / Waagen
Gautschi
Engineering GmbH
see Casting equipment 3.1
Abgasbehandlung
 Pot ramming Machine
Solios Environnement
www.fivesgroup.com
www.brochot.fr
 Pot feeding systems
Beschickungseinrichtungen
für Elektrolysezellen
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
70
FLSmidth MÖLLER GmbH
www.flsmidthmoeller.com
see Storage facilities for smelting 1.2
 Tapping vehicles/Schöpffahrzeuge
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
ALUMINIUM · 5/2014
SUPPLIERS DIRECTORY
1.14 Aluminium Alloys
Aluminiumlegierungen
SMS Siemag AG
see Rolling mill technology 3.0
 Billet heating furnaces
Öfen zur Bolzenerwärmung
1.16 Refractory Products
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
Feuerfesttechnik
Refratechnik Steel GmbH
Schiessstrasse 58
40549 Düsseldorf / Germany
Phone +49 211 5858 0
Fax +49 211 5858 46
Internet: www.refra.com
Am Großen Teich 16+27
D-58640 Iserlohn
Tel. +49 (0) 2371 / 4346-0
Fax +49 (0) 2371 / 4346-43
E-Mail: [email protected]
Internet: www.ias-induction.com
Lager und Transport
1.17 Protective Clothing
www.brochot.fr
Schutzkleidung
see Casthouse (foundry) 1.5
2.2 Extrusion equipment
Strangpresseinrichtungen
see Coil transport systems 3.4
2
www.charnaud.co.za
www.charnaud.eu
+27 (0)11794 6040
+44 (0)1133 507651
Extrusion
Strangpressen
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
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
www.alu-web.de
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
 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
 Press control systems
Pressensteuersysteme
Oilgear Towler GmbH
see Extrusion Equipment 2.2
2.1 Extrusion billet preparation
Pressbolzenbereitstellung
see Section handling 2.3
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
ALUMINIUM · 5/2014
Hier könnte Ihr
Bezugsquellen-Eintrag stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
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
71
LIEFERVERZEICHNIS
 Transport equipment for
extruded sections
I - 20142 Milano, Tel +39 059782817
Email: [email protected]
Internet: www.dimasimma.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
see Section handling 2.3
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
Transporteinrichtungen
für Profilabschnitte
www.ctisystems.com
see Section handling 2.3
see Section handling 2.3
MFW Maschinenbau GmbH
A-4813 Altmünster, AUSTRIA
see Coil transport systems 3.4
2.4 Heat treatment
Wärmebehandlung
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
see Section handling 2.3
 Section transport equipment
Profiltransporteinrichtungen
 Packaging equipment
Verpackungseinrichtungen
see Section handling 2.3
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
see Section handling 2.3
see Coil transport systems 3.4
see Coil transport systems 3.4
see Section handling 2.3
 Section saws
Profilsägen
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
 Stackers / Destackers
Stapler / Entstapler
Hütte GmbH
Hüttenstraße 33, D-52355 Düren
Phone:
+49 (0) 24 21 591 507-0
Fax:
+49 (0) 24 21 591 507-99
E-Mail: [email protected]
Internet: www.huette-tpt.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
see Section handling 2.3
see Equipment and accessories 3.1
 Section store equipment
Profil-Lagereinrichtungen
www.ctisystems.com
see Section handling 2.3
72
see Section handling 2.3
Could not find your „keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: [email protected]
SECO/WARWICK EUROPE Sp. zo.o.
ul. Šwierczewskiego 76
66-200 Šwiebodzin, POLAND
Tel: +48 68 38 19 800
E-mail: [email protected]
Internet: www.secowarwick.com
ALUMINIUM · 5/2014
SUPPLIERS DIRECTORY
 Heat treatment furnaces
Wärmebehandlungsöfen
2.9 Surface finishing
of sections
Oberflächenveredlung
von Profilen
ANDRITZ Maerz GmbH
see Melting/holding/casting furnaces 1.5
INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH
see Casthouse (foundry) 1.5
Auslagerungsöfen für
Strangpressprofile
see Extrusion billet preparation 2.1
see Section handling 2.3
2.11 Equipment and
accessories
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
 Ageing furnace for extrusions
see Heat treatment furnaces 2.4
Ausrüstungen und
Hilfsmittel
 Inductiv heating equipment
see Casthouse (foundry) 1.5
Induktiv beheizte
Erwärmungseinrichtungen
 Homogenising furnaces
Homogenisieröfen
see 2.1 Billet heating furnaces
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
www.alu-web.de
3
Rolling mill technology
Walzwerktechnik
see Casthouse (foundry) 1.5
2.6 Die preparation and care
Werkzeugbereitstellung
und -pflege
 Die heating furnaces
Werkzeuganwärmöfen
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
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
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
ALUMINIUM · 5/2014
see Cold rolling units / complete plants 3.6
www.alu-web.de
Siemens plc, Metals Technologies
Sheffield Business Park, Europa Link
Sheffield S9 1XU
Phone: +44 1709 726500
Fax:+44 1142 611719
[email protected]
73
LIEFERVERZEICHNIS
 Melting and holding furnaces
Schmelz- und Warmhalteöfen
 Annealing furnaces
Glühöfen
ANDRITZ Maerz GmbH
see Melting/holding/casting furnaces 1.5
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
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: [email protected]
Bartz GmbH
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
Gießanlagen
Gautschi
Engineering GmbH
see Casting equipment 3.1
see Equipment and accessories 3.1
schwartz GmbH
see Heat treatment 2.4
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
see Heat treatment 2.4
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
 Metal filters / Metallfilter
3.1 Casting equipment
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
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
 Homogenising furnaces
Homogenisieröfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
 Electromagnetic Stirrer
Elektromagnetische Rührer
Solios Thermal UK
www.fivesgroup.com
3.3 Rolling bar furnaces
Walzbarrenvorbereitung
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
BSN Thermprozesstechnik GmbH
see Heat Treatment 2.4
schwartz GmbH
see Heat treatment 2.4
 Filling level indicators and controls
Füllstandsanzeiger und -regler
Gautschi
Engineering GmbH
see Casting equipment 3.1
Wagstaff, Inc.
74
see Casting machines 1.6
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
Solios Thermal UK
www.fivesgroup.com
 Roller tracks
Rollengänge
Gautschi
Engineering GmbH
see Casting equipment 3.1
ALUMINIUM · 5/2014
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
 Hot rolling units /
complete plants
3.6 Cold rolling equipment
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
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
Warmwalzanlagen/Komplettanlagen
Kaltwalzanlagen
ANDRITZ Sundwig GmbH
www.siemens.vai.com
see Rolling mill technology 3.0
www.siemens.vai.com
see Rolling mill technology 3.0
SMS Siemag AG
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
see Rolling mill technology 3.0
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
 Coil transport systems
Bundtransportsysteme
 Rolling mill modernisation
Walzwerksmodernisierung
www.siemens.vai.com
see Rolling mill technology 3.0
 Coil annealing furnaces
Bundglühöfen
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
Gautschi
Engineering GmbH
see Casting equipment 3.1
see Equipment and accessories 3.1
www.ctisystems.com
see Section handling 2.3
see Section handling 2.3
schwartz GmbH
www.siemens.vai.com
see Rolling mill technology 3.0
SMS Siemag AG
see Rolling mill technology 3.0
see Heat treatment 2.4
www.alu-web.de
 Coil transport systems
Bundtransportsysteme
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]
see Section handling 2.3
 Drive systems / Antriebe
 Spools / Haspel
SMS Siemag AG
SMS Siemag AG
see Rolling mill technology 3.0
ALUMINIUM · 5/2014
www.ctisystems.com
see Section handling 2.3
see Rolling mill technology 3.0
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
75
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
www.siemens.vai.com
see Rolling mill technology 3.0
www.siemens.vai.com
see Rolling mill technology 3.0
Längs- und Querteilanlagen
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
 Drive systems / Antriebe
SMS Siemag AG
see Rolling mill technology 3.0
 Heating furnaces / Anwärmöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
see Equipment and accessories 3.1
Hier könnte Ihr
BezugsquellenEintrag
stehen.
 Process optimisation systems
Prozessoptimierungssysteme
Gautschi
Engineering GmbH
see Casting equipment 3.1
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
 Process simulation
Prozesssimulation
Gautschi
Engineering GmbH
see Casting equipment 3.1
SMS Siemag AG
see Rolling mill technology 3.0
 Strip shears/Bandscheren
see Cold rolling units / complete plants 3.6
 Trimming equipment
Besäumeinrichtungen
 Roll exchange equipment
Walzenwechseleinrichtungen
SMS Siemag AG
see Rolling mill technology 3.0
76
see Cold rolling units / complete plants 3.6
SMS Siemag AG
see Rolling mill technology 3.0
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
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 · 5/2014
SUPPLIERS DIRECTORY
SMS Siemag AG
see Rolling mill technology 3.0
 Strip flatness measurement
and control equipment
Bandplanheitsmess- und
-regeleinrichtungen
 Strip Tension
Measurement equipment
Bandzugmesseinrichtungen
 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
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
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
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
Hier könnte Ihr
Bezugsquellen-Eintrag stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
see Rolling mill technology 3.0
3.10 Process technology /
Automation technology
Prozesstechnik /
Automatisierungstechnik
 Plate handling/Packaging
equipment
 Strip Width & Position
Measurement equipment
 Strip thickness measurement
and control equipment
Banddickenmess- und
-regeleinrichtungen
Plattenhandling/Verpackungsanlagen
MFW Maschinenbau GmbH
A-4813 Altmünster, AUSTRIA
 Process control technology
Prozessleittechnik
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
SMS Siemag AG
see Casting machines 1.6
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.
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 Cold rolling units / complete plants 3.6
 Filter for rolling oils and emulsions
Filter für Walzöle und Emulsionen
see Rolling mill technology 3.0
 Roll Force Measurement equipment
Walzkraftmesseinrichtungen
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 · 5/2014
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: [email protected]
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
 Rolling oil recovery and
treatment units
Walzöl-Wiederaufbereitungsanlagen
SMS Siemag AG
see Rolling mill technology 3.0
77
LIEFERVERZEICHNIS
 Rolling oil rectification units
Walzölrektifikationsanlagen
www.bwg-online.com
see Strip Processing Lines 3.17
see Coil transport systems 3.4
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
SMS Siemag AG
see Rolling mill technology 3.0
see Rolling mill technology 3.0
 Lithographic Sheet Lines
SMS Siemag AG
Lithografielinien
see Rolling mill technology 3.0
3.12 Air extraction systems
see Section handling 2.3
www.bwg-online.com
see Strip Processing Lines 3.17
Abluft-Systeme
see Cold rolling units / complete plants 3.6
3.17 Strip Processing Lines
 Exhaust air purification
systems (active)
Abluft-Reinigungssysteme (aktiv)
see Cold rolling equipment 3.6
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
see Coil transport systems 3.4
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
 Stretch Levelling Lines
Streckrichtanlagen
www.bwg-online.com
see Strip Processing Lines 3.17
3.14 Storage and dispatch
Lagerung und Versand
see Cold rolling units / complete plants 3.6
Bandprozesslinien
REDEX
Zone Industrielle
F-45210 Ferrieres
Telefon +33 (2) 38 94 42 00
E-mail: [email protected]
Internet: www.tension-leveling.com
SMS Siemag AG
 Strip Annealing Lines
Bandglühlinien
www.bwg-online.com
see Strip Processing Lines 3.17
SMS Siemag AG
see Rolling mill technology 3.0
see Rolling mill technology 3.0
3.16 Coil storage systems
Bundlagersysteme
www.ctisystems.com
see Section handling 2.3
Via Monte Rosa, 93
20149 Milan, ITALY
Telefon +39 02 4384 7402
E-Mail: [email protected]
Internet: www.tenova.com
Sales Contact: Stefano Marelli
 Anodizing Lines
3.18 Production
Management systems
Produktions Management
Systeme
Anodisier-Linien
SMS Siemag AG
see Rolling mill technology 3.0
see Section handling 2.3
 Coil & Colour Coating Lines
Bandlackierlinien
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
78
Bronx International Pty Ltd
Email: [email protected]
Internet: www.bronxintl.com
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
see Coil transport systems 3.4
ALUMINIUM · 5/2014
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
4.6 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
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
4.2 Heat-resistent technology
Feuerfesttechnik
 Refractories / Feuerfeststoffe
Promat GmbH High Performance Insulation
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
[email protected], www.promat.de
 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
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
4.3 Conveyor and storage
technology
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
Förder- und Lagertechnik
Avenida Cervantes Nº6
48970 – Basauri – Bizkaia – Spain
Tel: +34 944 409 420
E-mail: [email protected]
Internet: www.insertec.biz
see Section handling 2.3
Paul Hedfeld GmbH
www.alu-web.de
ALUMINIUM · 5/2014
Hundeicker Str. 20
D-58285 Gevelsberg
Phone: +49 (0) 2332 6371
E-mail: [email protected]
Internet: www.hedfeld.com
see Equipment and accessories 3.1
 Heat treatment furnaces
Wärmebehandlungsöfen
ANDRITZ Maerz GmbH
see Melting/holding/casting furnaces 1.5
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
see Heat treatment 2.4
79
LIEFERVERZEICHNIS
 Mould parting agents
Kokillentrennmittel
see Casthouse (foundry) 1.5
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
4.7 Casting machines
and equipment
Gießereimaschinen
und Gießeinrichtungen
Schröder KG
Schmierstofftechnik
Postfach 1170
D-57251
Freudenberg
Tel. 02734/7071
Fax 02734/20784
 Heat treatment furnaces
Wärmebehandlungsanlagen
ANDRITZ Maerz GmbH
see Melting/holding/casting furnaces 1.5
Gautschi
Engineering GmbH
see Casting equipment 3.1
www.schroeder-schmierstoffe.de
4.10 Measurement technology
and materials testin
Messtechnik und
Materialprüfung
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
see Heat treatment 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
www.alu-web.de
see Equipment and accessories 3.1
 Holding furnaces
Warmhalteöfen
ANDRITZ Maerz GmbH
GAPCast TM: the Swiss casting solution
Casting Technology / Automation
Tel.: +41 27 455 57 14
E-Mail: [email protected]
Internet: www.gap-engineering.ch
Precimeter Control AB
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
4.11 Metallic charge
materials
see Melting/holding/casting furnaces 1.5
Bartz GmbH
Metallische Einsatzstoffe
 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]
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
see Equipment and accessories 3.1
4.13 Melt operations
Schmelzbetrieb
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
Wagstaff, Inc.
see Heat treatment 2.4
see Casting machines 1.6
 Melting furnaces
Schmelzöfen
ANDRITZ Maerz GmbH
see Melting/holding/casting furnaces 1.5
Bartz GmbH
 Continuous ingot casting
lines and aluminium rod lines
Kokillengieß- und Aluminiumdraht-Anlagen
see Casthous (foundry) 1.5
see Extrusion 2.4.
 Burner System
Brennertechnik
Via Emilia Km 310
26858 Sordio-LO
Italy
Tel. +39.02.988492-1 . [email protected]
Fax +39.02.9810358 . www.properzi.com
80
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
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: [email protected]
ALUMINIUM · 5/2014
SUPPLIERS DIRECTORY
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
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
4.17 Environment protection
and disposal
Umweltschutz und
Entsorgung
5
Materials
and
Recycling
Werkstoffe
und 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]
Could not find your
„keywords“?
Please ask for our
complete
„Supply sources for the
aluminium industry“.
E-Mail:
[email protected]
6.2 Semi products
 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
Giesel Verlag GmbH
Hans-Böckler-Allee 9, 30173 Hannover
Tel. 0511/8550-2638 · Fax 0511/8550-2405
GDMB-Informationsgesellschaft mbH
Paul-Ernst-Str.10, 38678 Clausthal-Zellerfeld
Telefon 05323-937 20, Fax -237, www.gdmb.de
 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
6.3 Equipment for forging
and impact extrusion
Ausrüstung für Schmiedeund Fließpresstechnik
 Hydraulic Presses
Hydraulische Pressen
Entstaubung
ALUMINIUM · 5/2014
Literatur
Halbzeuge
 Dust removal
NEOTECHNIK GmbH
Entstaubungsanlagen
Postfach 110261, D-33662 Bielefeld
Tel. 05205/7503-0, Fax 05205/7503-77
[email protected], www.neotechnik.com
8
Literature
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
Hier könnte Ihr
BezugsquellenEintrag
stehen.
Rufen Sie an:
Tel. 0821/31 98 80-34
Dennis Ross
www.alu-web.de
81
VORSCHAU / PREVIEW
IM NÄCHSTEN HEFT
IN THE NEXT ISSUE
Special: ALUMINIUM China 2014
Special: ALUMINIUM China 2014
Die Juni-Ausgabe dieser Zeitschrift steht im Zeichen
der ALUMINIUM China 2014, die vom 9. bis 11. Juli in
Shanghai stattfindet. In einem Sonderteil werden Beiträge
in Mandarin von Ausrüstern der Aluminiumindustrie veröffentlicht. Darüber hinaus werden neue Projekte und Aufträge für den chinesischen Markt vorgestellt.
In our June issue we will be highlighting ALUMINIUM
China 2014, which will be taking place from 9 to 11 July
in Shanghai. There will be a special section in Mandarin
with reports from equipment suppliers for the aluminium
industry. We will also be reporting on new projects and
contracts for the Chinese market.
Weitere Themen
Other topics
• Chinas Weg zu einer nachhaltigen und ausgewogenen
Aluminiumindustrie
• Aktuelle wirtschaftliche Lage der Schweizer
Aluminiumindustrie
• Constantia Teich automatisiert Coiltransporte
• Aktuelle News aus der globalen Aluminiumindustrie
• China’s recent moves towards a sustainable and
balanced aluminium industry
• Present economic situation of the aluminium industry
in Switzerland
• Constantia Teich automates coil transport
• Latest news from the global aluminium industry
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05. Juni 2014
21. Mai 2014
10. Mai 2014
International
ALUMINIUM
90. Jahrgang 1. 1. 2014
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