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Special: Aluminium
smelting industry
innovatherm – benchmark
in firing technology and
flue gas purification
Airware – more than
an aluminium alloy
innovatherm
Competitive strategies
of emerging and
advanced economies
Volume 87 · July / August 2011
International Journal for Industry, Research and Application
7/8
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EDITORIAL
Volker Karow
Chefredakteur
Editor in Chief
Aluminiumwelt
derzeit in Ordnung
Aluminium world
in good shape
ALUMINIUM · 7-8/2011
Die Wirtschaftsnachrichten werden seit Wochen und Monaten von der Eurokrise beherrscht und wer über den europäischen Tellerrand hinausschaut, blickt unweigerlich auf
den gigantischen US-amerikanischen Schuldenturm. Haushaltssanierung und Ausgabenkürzungen sind angesagt und doch finden sich
weiterhin Politiker und Regierungsvertreter,
die die Senkung von Steuern ganz oben auf
ihre Agenda setzen. In China steigen die Preise, besonders für Lebensmittel, auf Rekordniveau und die Geldpolitik dort versucht eine
Gradwanderung zwischen Preisdämpfung
und Wirtschaftswachstum. Angesichts dieser
globalen Krisenfaktoren läuft die Realwirtschaft derzeit ziemlich rund. Das erwartete
Weltwirtschaftswachstum ist nach wie vor
robust, die Weltbank prognostiziert aktuell
einen globalen BIP-Zuwachs von 3,2 Prozent
für 2011 und für 2012/13 sogar einen Anstieg von jeweils 3,6 Prozent.
Auch die Aluminiumwelt scheint derzeit in
Ordnung. Nimmt man die jüngsten Quartalszahlen des US-Konzerns Alcoa als Maßstab,
stehen die Ampeln auf Grün. Alcoa hat seinen
Umsatz im zweiten Quartal um mehr als ein
Viertel (auf 6,6 Mrd. Dollar) gesteigert und
sein Nettoergebnis (auf 322 Mio. Dollar) mehr
als verdoppelt. Das Unternehmen profitierte
von einer Rekordnachfrage nach Aluminium
und gestiegenen Rohstoffpreisen. Der Ausblick bleibt positiv – sowohl für Alcoa als auch
für die Branche insgesamt.
Auch die deutsche Aluminiumindustrie hat
nach einem gelungenen Jahresauftakt ihren
Wachstumskurs im zweiten Quartal fortgesetzt, heißt es von Verbandsseite. Bis Mai
stieg die Produktion in der Erzeugung um
5,3 Prozent, in der Halbzeugindustrie um 6,0
Prozent und in der Weiterverarbeitung um
4,6 Prozent. Der Maschinen- und Anlagenbau
konnte seine Produktion in den ersten fünf
Monaten dieses Jahres um stattliche 18 Prozent steigern, die Auftragseingänge legten in
dieser Zeit sogar um 28 Prozent zu. Wichtigster Exportabnehmer ist und bleibt China. Für
die kommenden Monate zeichnet sich zwar
eine ruhigere Gangart ab, was angesichts der
Engpass-Situation vieler Unternehmen aber
nicht weiter problematisch ist.
Langfristig wird die Aluminiumnachfrage
weiter steigen. Für dieses Jahr prognostiziert
Alcoa-Chef Klaus Kleinfeld ein Nachfragewachstum von 12 Prozent, Ende dieses Jahrzehnts werde sich die Nachfrage verdoppelt
haben. Treibende Kraft ist die dynamische
Wirtschaftsentwicklung in Asien und der weiter wachsende Einsatz von Aluminium, vor
allem in den Mobilitätssektoren Automobil,
Flugzeugbau und Schienenfahrzeuge.
Business news has been dominated for weeks
and months by talk of the euro crisis, and anyone who has taken a peek beyond the European horizon has inevitably been confronted
by the USA’s enormous mountain of debt.
Budget reorganisation and cuts in expenditure
are needed, but one can still find politicians
whose top priorities include cutting taxes.
Prices, especially food prices, have reached
record levels in China, and monetary policy
there is treading the narrow line between
curbing inflation and encouraging economic
growth. Despite economic factors pointing to
a possible global crisis, the real economy is
actually performing quite well at the moment.
World economic growth is expected to remain
robust: the World Bank is currently forecasting growth in GDP globally of 3.2 percent in
2011, and even higher in 2012 and 2013, up
3.6 percent in each case.
Things also appear to be fine in the aluminium world at present. The signals are on green
if one takes the latest quarterly figures from
Alcoa as a benchmark. The US company increased revenues in the second quarter of this
year by 27 percent (to USD6.6bn) and more
than doubled net income (to USD322m). It
benefited from record demand for aluminium
and increased prices for raw materials. The
outlook remains positive – both for Alcoa and
the rest of the industry as a whole.
Following a successful start to the year,
the German aluminium industry also continued on its path of growth in the second quarter,
the industry’s trade association reported. In
the year to Mai 2011, aluminium production
rose 5.3 percent, semi-finished products reported an 6.0 percent rise and downstream
processing was 4.6 percent higher. Mechanical
and plant engineering increased production
by a hefty 18 percent in the first five months
of the year and orders received showed an
even bigger rise in the same period: 28 percent. The most important export market for
German products was, and remains, China.
For the coming months, there may be signs of
developments continuing at a somewhat gentler pace, but this will not be a problem given
the bottlenecks that many companies are already facing.
In the long term, demand for aluminium
will continue to rise. Alcoa’s boss Klaus
Kleinfeld is forecasting growth in demand of
12 percent this year, and demand will have
doubled by the end of the decade. The driving force is dynamic economic development
in Asia and continuing growth in the use of
aluminium, especially in the mobility sectors
automotive, aircraft construction and railed
vehicles.
3
I N H A LT
EDITORIAL
A l um i n i umwe l t de rz e i t i n O rdn u n g
A l um i n i um wo rl d i n go o d s h a p e .......................................... ........... 3
A KT U E L L E S • N E W S I N B R I E F
S p än e re c yc l i n g: U mwe l t t e ch n i k p re i s fü r AR P-Z yk l o n -Te ch n o l o gi e .......... 6
WVM : En e rgi e we n de n u r mi t de r N E -Me t a l l i n du st ri e .......................... 6
N ove l i s in ve st s i n n e w c o n t i n u o u s c a st i n g l i n e ....................... ........... 7
A DB I C an d Gu l f E x t ru s i o n s t o s e t u p e x t ru s i o n p l a n t i n Ab u Dh abi........ 7
A m c o r i nve st i e rt i n de n Au s b a u de s Ve re dl u n gs we rke s i n Si n ge n ......... 8
C h i n e s i s ch e CITIC Di c a st a l ü b e rn i mmt K SM
C ast i n g s u n d e rwe i t e rt Al u mi n i u mgu s s ko mp e t e n z ................... ........... 8
C ar b o n pri c e p u t s Au st ra l i a n a l u mi n i u m i n du st ry a t ri s k .................... 9
S + C Ed e lst a h l -Ak a de mi e : Wo rk s h o p i n de n N i e de rl a n de n ......... ........... 9
E m al g e ts a p p rova l fo r e x p a n s i o n p ro je c t ......................................... 9
A l umi n i u m o f Gre e c e t o re p ay st a t e a i d ............................................ 9
38
WIRTSCHAFT • ECONOMICS
DR.GRAF-Personalberatung: Auf der steten Suche nach Top-Leuten
DR. GRAF-Personnel Consultancy: Always on the look-out for top people .. 10
Pro d uk t i o n s da t e n de r de u t s ch e n Al u mi n i u mi n du st ri e ............... .......... 11
A l umi n i u mp re i s e ......................................................................... 12
Th e g l o ba l i z i n g a l u mi n i u m i n du st ry – Pa rt 1 / 3 :
Co mp e t i ti ve st ra t e gi e s o f e me rgi n g a n d a dva n c e d e c o n o mi e s ............. 14
A l umi n i u m ma rke t st ro n g, o i l p ri c e ma i n ri s k fo r fu t u re growt h .......... 18
S M S g rou p n u t z t Ch a n c e n i m Au fs ch wu n g
SMS group grasps opportunities of the upswing ................................ 22
A L U M I N I U M S M E LT I N G I N D U S T R Y
Dub al – wo rl d-c l a s s i n a l u mi n i u m s me l t i n g ..................................... 24
G ul f A l umi n i u m Co u n c i l : “A fo ru m t o de ve l o p st ra t e gi e s fo r
c o mmo n i s s u e s ” . Ma h mo o d Dayl a mi , Ge n e ra l Se c re t a ry
o f t h e GAC, i n a t a l k wi t h In t e rn a t i o n a l ALU MIN IU M Jo u rn a l ............. 26
i n n ovat h e rm – Be n ch ma rk b e i Fe u e ru n gst e ch n o l o gi e u n d
R a uch g as re i n i gu n g: „ De n P ro z e s s a l s Ga n z e s i m Bl i ck “
i n n ova t he rm – b e n ch ma rk i n fi ri n g t e ch n o l o gy a n d
f l ue g as p u ri fi c a t i o n : “ Vi e wi n g t h e p ro c e s s a s a wh o l e ” ....................28
Der Aluminium-Branchentreff
des Giesel Verlags: www.alu-web.de
4
Ha p p y b i rt h day, a l u mi n i u m! 12 5 ye a rs a ddi n g va l u e t o s o c i e t y .......... 35
CONTENTS
25 ye a r s of R& D C a r b o n : a s uc c e s s s i n c e 19 8 6 ................................ 36
News f rom t he a l u m i n i um s m e l t i n g i n d ust r y . . ................................. 38
Suppl i e r s t o t he pr i m ar y s m e l t i n g i n d ust r y . . . . ................................. 41
B&P CK- 7 0 0 - C P Ko - K n e a d e r – f o r p re m i um qua l i t y a n o de p a st e .........42
T E CH N O LO G I E • T E CH N O LO GY
H o fm a nn W ä r m et e ch n i k – Ü b e r ko p f - O f e n an l age n a u s Ö st e rre i ch ....... 43
0
1911 bi s 2011 – S t ra n g p re s s e n b e i E r b s l ö h . . . . ................................. 44
Const el l i u m G l oba l ATI ‘A i r ware’ – mo re t h an a n a l u mi n i u m a l l o y ...... 47
Recyc l i ng von A l u m i n i um s p än e n • A l um i n i um s wa rf re c yc l i n g .............50
Improve d m onol i t h i c ma t e r i al s f o r l i n i n g al umi n i u m
hold i n g a n d m el t i n g f ur n ac e s – ro o f , up p e r wa l l s a n d fl u e ............... 52
AUTOMOTIVE
Alumi n i u m m a t r i x c o m p o s i t e s i n aut o m o t i ve ap p l i c a t i o n s .................. 55
Z F er w i r bt H onsel -We r k i n N ür n b e rg
Z F ta ke s ove r Nu remb e rg p l an t f ro m d i e - c ast sp e c i a l i st Ho n s e l .......... 57
5
C O M PA N Y N E W S W O R L D W I D E
The a l u m i ni u m sm e l t i n g i n d ust r y . . . . . . . . . . . . . . . . . ..................................38
Bauxi t e a n d a l u m i n a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................................58
Seco n da r y sm el t i ng an d re c yc l i n g . . . . . . . . . . . . . . . . ..................................58
Alumi n i u m sem i s . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................................59
Suppl i e r s . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 41 / 60
Inserenten dieser Ausgabe
List of advertisers
O n the m ove . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................. 61
RESEARCH
Invest i g a t i on of t h e i n f l ue n c e o f l ow
cycle be n di ng on t h e p ro p e r t i e s o f t h i n s h e e t s ................................ 62
ABB Schweiz AG, Switzerland
33
Aumund Fördertechnik GmbH
27
Buss AG, Switzerland
41
Buss ChemTech AG, Switzerland
Carli Precimeter GmbH
39
22
Coiltec Maschinenvertriebs GmbH
23
Drache Umwelttechnik GmbH
15
Dubai Aluminium Co. Ltd, UAE
13
FLSmidth Hamburg GmbH
25
D O C U M E N TAT I O N
GDA Gesamtverband der
Aluminiumindustrie e.V.
35
Paten t e . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................................64
Hertwich Engineering GmbH, Austria
Impre ssu m • Im pre s s um . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................................. 81
Vors cha u • P rev i ew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................................82
BEZUGSQUELLENVERZEICHNIS
2
Hofmann Wärmetechnik
GmbH, Österreich
43
Inotherm Industrieofenund Wärmetechnik GmbH
23
Bernd Münstermann GmbH & Co. KG
19
Neotechnik GmbH
19
R&D Carbon Ltd, Switzerland
37
Wagstaff Inc., USA
84
S U P P L I E R S D I R E C T O R Y . . . . . . . . . . . . . . . . . . . . ..................................68
5
AKTUELLES
Spänerecycling: Umwelttechnikpreis für ARP-Zyklon-Technologie
Die ARP GmbH & Co. aus Alpirsbach ist mit
dem Umwelttechnikpreis 2011 des badenwürttembergischen Umweltministeriums in
der Kategorie „Materialeffizienz“ ausgezeichnet worden. Die „ARP-Zyklon-Technologie“
reduziert beim Recyceln von Aluminium nicht
nur die Abbrandverluste deutlich, sondern
auch den Energieverbrauch und damit die
CO2-Emissionen.
Recyclinganlagen mit ARP-Zyklon-Technologie werden zum Beispiel in der Felgenproduktion eingesetzt, wo pro Tag bis zu 60
Tonnen Aluminiumspäne anfallen. Bei einem
konventionellen Ofen kommt es zu einem
Abbrand, bei dem drei bis fünf Prozent des
zu recycelnden Aluminiums verloren gehen.
Über drei Faktoren kann man die Menge des
Abbrands und den Energieverbrauch während
des Schmelzprozesses positiv beeinflussen:
Die Aluminiumspäne müssen frei von Ölrückständen sein, vor dem Einführen in die
Schmelzkammer erhitzt werden und sie müs-
sen sich möglichst schnell mit dem flüssigen
Metall vermischen. Die Anlagen von ARP
nutzen diese drei Faktoren aus – so werden
die Abbrandverluste auf unter ein Prozent
verringert.
Die ARP-Technologie setzt bei der Beschleunigung der Vermischung von flüssigem
Metall und Spänen an. Das Prinzip des Fliehkraftabscheiders zur Trennung fester Teilchen
aus Strömungen wird hier umgekehrt und dafür verwendet, die Späne schneller unter die
Oberfläche des Schmelzbades zu führen, um
eine übermäßige Oxid- und Schlackenbildung
zu vermeiden. Das flüssige Aluminium wird
im Schmelzofen an einer Stelle in Bewegung
gebracht und bildet einen Strudel oder Zyklon. Diesem Strudel werden die gereinigten,
heißen Späne kontrolliert zugeführt und durch
das flüssige Medium eingeschmolzen.
Drei Prozent weniger Abbrand entsprechen 30 Kilogramm zusätzlicher Ausbeute
beim Recyceln einer Tonne Aluminium. Bei
einer Anlagenleistung von 24 Tonnen pro Tag
und einer jährlichen Betriebsdauer von 330
Tagen ergeben sich rund 230 Tonnen mehr
Aluminium pro Jahr. Zudem verringert sich
die Energiemenge, die für das Einschmelzen
notwendig ist, von 1,5 kWh/kg auf circa 0,8
kWh/kg – da die Abwärme aus der thermischen Nachverbrennung des Schmelzofenabgases über einen Wärmetauscher zur Erwärmung der Späne genutzt wird, die Distanz zwischen Wärmetauscher und Ofen sehr gering
und das System geschlossen ist, sodass kaum
Wärme verloren geht.
Mit dem geringeren Energiebedarf geht
eine CO2-Reduzierung von mehr als 1.100
Tonnen pro Jahr und Anlage einher. „Uns
war es wichtig, den kompletten Vorgang zu
betrachten und mit den Verbesserungen nicht
nur an einer einzelnen Schraube zu drehen“,
erklärt Wolfgang Riegert, Geschäftsführender
Gesellschafter bei ARP.
WVM: Energiewende nur mit der NE-Metallindustrie
Die politisch gewollte Neuausrichtung und
Umsetzung der Energiepolitik sei ohne die
energieintensiven Industrien nicht möglich.
„Ohne energieintensive Grundstoffe wie Aluminium, Kupfer, Zink, Blei, Nickel und andere Metalle wird kein Kraftwerk gebaut, kein
Stromnetz betrieben, kein Strom aus Erneuerbaren produziert und keine Speicher hergestellt. Festzuhalten bleibt, dass viele gesetzliche Regelungen richtig sind, einige überstürzt
getroffen wurden und manche Regulierungen
unrealistisch bleiben“, sagte Martin Kneer,
Hauptgeschäftsführer der WirtschaftsVereinigung Metalle (WVM).
Die Folgen des Kernkraft-Ausstiegs, der
beschleunigte Ausbau erneuerbarer Energien
sowie der Emissionshandel sind für die energie- und wertschöpfungsintensive NE-Metallindustrie in Deutschland so zu gestalten, dass
Strom sicher und bezahlbar bleibt.
„Die Exporterfolge der deutschen Industrie und die Attraktivität des Industriestandortes Deutschland für Investoren hängen
nicht zuletzt von einer jederzeit zuverlässigen
Stromversorgung zu international wettbewerbsfähigen Preisen ab“, unterstrich Kneer.
„Mit den jetzigen Beschlüssen sind politische
Eckpunkte fixiert. Der Realitätscheck wird in
einem kontinuierlichen Monitoringverfahren
erfolgen müssen. Gesellschaft und Industrie
6
stehen bei der künftigen Energiepolitik vor
großen Herausforderungen und vielen offenen Fragen, die den Standort Deutschland
massiv tangieren. Die Energiewende wird nur
mit einer bei Strompreisen und Netzsicherheit
international wettbewerbsfähigen deutschen
Industrie gelingen“, so Kneer weiter.
Das Potenzial zu- und abschaltbarer Leistung besser nutzen
Die NE-Metallbranche begrüßt den Beschluss
des Bundeskabinetts, durch Änderung des
Energiewirtschaftsgesetzes die rechtliche
Grundlage für Verträge zwischen Netzbetreibern und Industrieunternehmen über zu- und
abschaltbare Leistung zu verbessern. Jetzt
müssten angemessene Entgelte vereinbart
werden, so Kneer. Übertragungsnetzbetreiber
und die Bundesnetzagentur würden flächendeckende Stromausfälle in Zukunft nicht mehr
ausschließen, da Kraftwerksleistung zur Aufrechterhaltung stabiler Stromnetze fehle. Die
Zahl kritischer Netzzustände habe seit Beginn
des Kernenergie-Moratoriums stark zugenommen.
„Wir lehnen Zwangsabschaltungen energieintensiver Unternehmen in angespannten
Netzsituationen ab“, so Kneer. Einige Branchenunternehmen, bei denen dies technisch
möglich ist, seien jedoch auf Basis klarer
vertraglicher Regelungen bereit, Beiträge zur
Netzstabilisierung zu leisten. Das vorhandene
Potenzial zu- und abschaltbarer Lasten der
Branche werde bisher ungenügend genutzt.
Für die Umsetzung der Energiewende sei
ein Monitoring erforderlich. „Die Bundesregierung muss regelmäßig überprüfen, ob die
Gesetze die gewünschte Wirkung haben und
die Stromversorgung sicher und bezahlbar
ist“, sagte Kneer. Gegebenenfalls müsse nachjustiert werden.
Strompreiskompensation: „Es
besteht noch Verhandlungsbedarf“
Die von der Bundesregierung angestrebte
Strompreiskompensation für die energieintensive Industrie aufgrund des Emissionshandels
ab 2013 stößt in Brüssel weiter auf Schwierigkeiten. „Es bestehe noch Verhandlungsbedarf“, erklärte Bundeswirtschaftsminister
Philipp Rösler nach Gesprächen mit EUWettbewerbskommissar Joaquín Almunia.
Die Bundesregierung strebt Entlastungsbeihilfen für die Industrie von bis zu 1,3 Milliarden
Euro an. Derartige Kompensationsregelungen
sind ab 2013 zwar EU-seitig erlaubt, müssen
jedoch mit dem EU-Beihilferecht in Einklang
stehen.
NEWS IN BRIEF
Novelis invests in new continuous casting line
Novelis Inc. is to invest USD15.8 million in a
new continuous casting line at its production
facility in Pieve Emanuele, Italy. The new line
will recycle painted scrap to produce rolled
aluminium sheet. The announcement follows
the company’s stated commitment in May to
increase the amount of recycled metal it uses
in its worldwide rolling operations from 34%
today to 80% by 2020.
“This is one step towards Novelis reaching
our ambitious global recycling target,” said Tadeu Nardocci, president of Novelis Europe and
senior vice president of Novelis Inc. “It also
makes sound business sense to install a fifth
continuous caster at our Pieve plant so that
we can better meet the demands for material
across our European operations.”
The decision will see the largest single investment in the company’s Italian facilities in
twelve years. The plant at Pieve Emanuele is
an integrated continuous casting, rolling and
finishing operation. The aluminium sheet and
coil produced there is sold to distributors
and end users in a number of industrial and
construction markets. The Pieve plant is also
the supplier of aluminium coil to the nearby
Novelis mill at Bresso, where it is processed
into pre-painted, textured and bright finish
material for use in transport, construction and
industrial applications. Applications include
roofing, architectural cladding and domestic
appliances.
The use of continuous casting technology
also brings logistical advantages as a key production step is brought in-house, thus saving
transport and other costs. The investment will
also free up capacity where it is needed elsewhere in the Novelis Europe system to meet
the growing demand for other high-end products such as can body sheet and automotive
sheet.
The painted scrap from Novelis’ Italian operations, as well as other low-grade used aluminium from external sources, will be recycled
into high quality rolled aluminium on the new
equipment. The environmental benefits are
significant as recycling aluminium uses only
five percent of the energy required to make
the metal from raw materials and avoids 95
percent of the greenhouse gases associated
with primary aluminium production.
Installation of the new line, which will include a double-chamber melting furnace, continuous casting line and ancillary equipment,
will be completed by the end of 2012. The installation will be followed by a commissioning
and ramp-up period.
ADBIC and Gulf Extrusions to set up extrusion plant in Abu Dhabi
international map and will unlock new inter- of Gulf Extrusions, said: “This joint venture
national markets,” said Eng. Jamal Al Dhaheri, underlines the immense growth potential of
CEO of ADBIC. “This is one of a series of the Middle East’s aluminium industry and likeindustrial projects by ADBIC and an example wise reaffirms our commitment to further
of the public-private partnership model pur- strengthen the region’s reputation as a leading
sued by us. I look forward to a successful long supplier in the global market. A world-class,
term partnership with Al Ghurair Group and state-of-the-art facility such as Taweelah Aluwill continue to build on this foundation with minium Extrusion Company will be crucial
Emal and Khalifa Industrial Zone Abu Dhabi in opening more business opportunities and
to attract investments,
promote the industrial
sector, and diversify the
economy in line with
the directives and guidance of our esteemed
leadership,” he added.
Mr Majid Al Gurair,
CEO of Al Ghurair
Group (to which Gulf
Extrusion
belongs),
said: “We are excited to
move forward with this
new project as it is part
of our ongoing thrust
to expand into high- The joint venture to set up Taweelah Aluminium Extrusion Co. was signed
growth sectors. Gulf by Eng. Jamal Salem Al Dhaheri, CEO of ADBIC, and Majid Al Ghurair, CEO of
Al Ghurair Group
Extrusions will play a
very important role in nurturing Taweelah creating new possibilities to cater to emergAluminium Extrusion to be a key industry ing demand in new markets. Gulf Extrusions is
player and in maintaining the high standards therefore eager to offer its technical expertise
of excellence in the production of premium- and in-depth knowledge of the aluminium inquality aluminium products.”
dustry to help ensure the sustained growth and
Mr. Modar Al Mekdad, general manager success of this joint venture.“
ABDIC
Abu Dhabi Basic Industries Corp. (ADBIC)
and Gulf Extrusions have signed a joint venture agreement to set up Taweelah Aluminium
Extrusion Co. in Abu Dhabi. The company will
invest USD200 million in establishing a stateof-the-art extrusion plant, which will be the
first of its kind in the MENA region and also
the first industrial project to be launched in
Khalifa Industrial Zone Abu Dhabi (Kizad)
after the Emal smelter.
Kizad, with its 417 square kilometres of
prime industrial land, is conveniently located
between Abu Dhabi and Dubai, and is a statement of intent by the Government of Abu
Dhabi, creating a wealth of opportunities on a
global scale. This 50,000 tonnes facility will be
built on a 235,000 square metres plot of land
adjacent to Emal, one of the largest industrial
projects in the UAE outside the oil and gas
sector. The feedstock of liquid aluminium and
aluminum billets will be supplied by Emal.
Taweelah Aluminium Extrusion will produce a diversified product range of aluminum
extruded profiles, fabricated profiles as well
as substructures and systems. The product
range will cater to the industrial, automotive
and transportation sectors as well as to the
top end building and construction projects,
meeting the most stringent standards of local,
regional and international customers.
“This project with a strong and well established UAE group puts UAE generated knowhow and manufacturing excellence on the
7
AKTUELLES
Auf Initiative der Firma Steinhoff fand am 10.
Mai 2011 Köln ein Symposium zum Thema
Kaltwalzen statt – der Cold Rolling Day. Die
Veranstaltung wurde von neun Firmen durchgeführt, zu deren Kunden u. a. die Kaltwalzindustrie gehört. Die Firmen waren Steinhoff
als Kaltwalzenhersteller, Henkel für Walzöle
und Emulsionen, Lechler Kühlsysteme, Rebs
Zentralschmieranlagen, Schaeffler Technologies als Wälzlagerhersteller, Maschinenfabrik
Herkules für Schleifmaschinen, Lismar für
Walzenprüfsysteme, Atlantic als Schleifscheibenhersteller und das Fraunhofer-Institut für
zerstörungsfreie Werkstoffprüfung. Jede von
ihnen ist als Lieferant der Kaltwalzindustrie
weltweit bekannt. Jede dieser Firmen hielt
einen technisch orientierten Vortrag über
ihre Produkte und deren Anwendung in der
Kaltwalzindustrie. Eingeladen waren vorwiegend die Techniker der europäischen Stahl-,
Aluminium- und NE-Metallindustrie sowie die
Walzwerkshersteller. Insgesamt besuchten 150
Teilnehmer aus 14 Ländern die Veranstaltung,
auf der es ausreichend Gelegenheit gab, mit
den Firmenvertretern Einzelgespräche zu
führen. Aufgrund der durchweg positiven
Resonanz wird 2013 der nächste Cold Rolling
Day stattfinden, dann in Düsseldorf.
Der richtige Umgang mit Aluminiumkrätzen – Ein Leitfaden
für die NE-Metallindustrie
Aluminiumkrätzen sind ein Musterbeispiel
dafür, dass die NE-Metallindustrie seit langem
effizient und ressourcenschonend arbeitet.
Der hohe Metallwert des Aluminiums verbunden mit der hohen Gesamttonnage an
Aluminiumkrätzen hat zur Etablierung eines
gut funktionierenden Recyclingnetzes geführt.
Die NE-Metallindustrie richtet sich mit einem
neuen Leitfaden an alle, die mit aluminiumhaltigen Krätzen umgehen. Er soll die
Unternehmen in der Praxis unterstützen und
auf eventuelle Gefährdungen aufmerksam
machen. Das Kapitel zur Einstufung von Krätzen und die umfassenden Anhänge bieten bei
der Erfüllung der Compliance-Pflichten eine
hilfreiche Übersicht. Dieser Leitfaden ist auch
für den Vollzug eine wertvolle Hilfe, denn gerade bei der gefahrgutrechtlichen Einstufung
bzw. Prüfung tauchen im Zusammenhang
mit Krätzen immer wieder Fragen auf. Der
kostenpflichtige Leitfaden kann über die WirtschaftsVereinigung Metalle bezogen werden.
8
Amcor investiert in den Ausbau
des Veredlungswerkes in Singen
Amcor Flexibles Europe & Americas inves- Verpackungen werden künftig ausschließlich
tiert 6,7 Mio. Euro in das Veredelungswerk in speziellen Produktionsbereichen hergein Singen, um die Kapazitäten zur Produktion stellt, die die sehr hohen Sauberkeits- und
pharmazeutischer Verpackungen zu erweitern Hygienestandards der pharmazeutischen Inund die klassische Veredlung pharmagerecht dustrie erfüllen.
zu modernisieren. Der Standort ist mit seinen
integrierten Folienwalzwerken
und Veredelungsanlagen auf
die Herstellung hochwertiger
aluminiumbasierter Packstoffe spezialisiert und beliefert
weltweit Unternehmen der
Pharma- und Nahrungsmittelindustrie. Das Werk beschäftigt
1.100 Mitarbeiter.
Im Zuge der Investition
wird das vor drei Jahren eröffnete Pharma-Clean-Center
„LKM24“ um einen Anbau mit
drei Rollenschneidmaschinen
erweitert. Sensible PharmaAmcor-Werk in Singen
Amcor
„Cold Rolling Day“ in Köln
Chinesische CITIC Dicastal übernimmt KSM
Castings und erweitert Aluminiumgusskompetenz
CITIC Dicastal Wheel Manufacturing Co., Ltd.
hat mit Cognetas LLP eine Vereinbarung zum
Erwerb der deutschen KSM Castings Gruppe
mit Sitz in Hildesheim getroffen. KSM bietet
ein breites Spektrum an Leichtmetallkomponenten, besonders Antriebsstrang- und Karosserieteile wie Radträger, Vorderachshilfsrahmen, Lenk- und Getriebsgehäuse und anderen
Komponenten für Motor und Getriebe. Mit
sechs Produktionsstätten in Europa und China ist KSM ein Markt- und Technologieführer
im Bereich Leichtmetallguss für den Automobilbau. Mit einer weltweiten Belegschaft von
über 2.700 Mitarbeitern erzielte das Unternehmen im Geschäftsjahr 2011 einen Umsatz
von 401 Mio. Euro. KSM wird zukünftig als
unabhängiger Geschäftsbereich in der CITIC
Dicastal geführt und weiter vom derzeitigen
Management geleitet.
Die Übernahme von KSM ist der erste ausländische Zukauf in der Firmengeschichte von
CITIC Dicastal. Sie bietet dem Unternehmen
die horizontale Expansion in die Bereiche
Fahrwerk, Antriebsstrang und Karosserie und
die Erweiterung der technologischen Kompetenz. Sie ist Ausdruck des Entwicklungstrend
zum automobilen Leichtmetallguss, der auch
durch Initiativen der chinesischen Regierung
zur Reduktion des Kraftstoffverbrauchs ge-
fördert wird. Die Transaktion unterliegt der
Zustimmung der chinesischen Regierung sowie der zuständigen Kartellbehörden.
Über CITIC Dicastal: Das Unternehmen
wurde 1988 gegründet. Hauptsitz ist in Qinhuangdao in der chinesischen Provinz Hebei.
Gemessen am Umsatz für 2010 ist das Unternehmen der weltweit größte Hersteller
von Felgen aus Aluminiumlegierungen für
die Automobilindustrie. Das Unternehmen
ist eine 100%ige Tochter der CITIC Gruppe,
eines der größten chinesischen Konglomerate
in staatlichem Besitz.
Über KSM Castings: Das Unternehmen ist
ein führender Anbieter von sicherheitsrelevanten, komplexen Aluminium- und Magnesiumteilen für die internationale Automobilindustrie. Der Produktschwerpunkt liegt auf
Komponenten für die Bereiche Fahrwerk und
Antriebsstrang. Das Unternehmen betreibt
vier Produktionsstandorte in Deutschland, einen in der Tschechischen Republik und einen
im Norden Chinas.
Über Cognetas: Cognetas ist eine unabhängige europäische Private-Equity-Gesellschaft
und hatte KSM Castings (vormals ThyssenKrupp Fahrzeugguss) 2005 von der ThyssenKrupp AG erworben.
NEWS IN BRIEF
Carbon price puts Australian
aluminium industry at risk
Efficient and competitive Australian alumina
and aluminium operations are at risk of leakage under a carbon price, according to the
Australian Aluminium Council (AAC), which
recently released the 2010 energy intensity
and greenhouse gas emissions data. AAC executive director Miles Prosser said: “These
figures go to the heart of the current carbon
pricing debate. If a carbon price reduces production and investment in Australian facilities,
the increase in production elsewhere could
be less energy efficient. The increase in other
countries’ greenhouse gas emissions will wipe
out any apparent reductions here in Australia.
That means we would be harming the Australian economy and regional jobs but gaining
no reduction in global greenhouse gas emissions.”
The 2010 energy use and greenhouse gas
emission data show that Australia’s alumina
and aluminium plants are world class for energy efficiency. Energy used in alumina production was 9.7 GJ per tonne, significantly less
than the global average of 11.9 GJ per tonne.
Energy used in aluminium smelting was 15.0
GWh per tonne, that is lower than the global
average of 15.2 GWh per tonne.
Furthermore, reductions in greenhouse gas
emissions achieved as a result of significant
investment by the Australian industry since
1990 have been maintained. Alumina green-
house gas emissions were 0.73 tonnes CO2e
per tonne of alumina in 2010, a reduction of
23% since 1990. Aluminium greenhouse gas
emissions were 15.62 tonnes CO2e per tonne
of aluminium, a reduction of 26%.
Mr Prosser pointed to competing countries
and said that future improvements in emissions reduction were at risk: “China is a key
competitor and has significantly higher emissions intensity for alumina refining and would
represent no improvement for aluminium
smelting. We know that Chinese producers
are facing a carbon price of only $0.85 per
tonne of carbon dioxide and this won’t rise
to more than a few dollars for more than a
decade. Middle East producers are facing
no carbon cost. The Australian Government
must ensure that the exposure of Australian
producers to a carbon cost moves in parallel
with our competitors, not dangerously ahead
of them. This can be done but we are yet to
see the Government commit to it.”
The Australian alumina and aluminium
industry is Australia’s highest value-add processor of resources and the largest processed
export earner. Operations in the Australian
alumina and aluminium industries have a replacement value of over $50 billion and annually produce more than $14 billion of product.
The industry directly employs around 17,000
people, many in regional areas.
Schmidt + Clemens Edelstahl-Akademie
2. Internationaler Workshop in den Niederlanden
Vom 14. bis 16. September 2011 findet der 2.
Internationale Workshop „Aluminium Extrusion“
im Rahmen der S+C Edelstahl-Akademie statt.
Die Veranstaltung wird in Zusammenarbeit mit
dem Aluminium Zentrum der Niederlande organisiert. Auszug aus dem Programm:
• Eigenschaften von Werkzeugstahl, Tobias Orbach, S+C Extrusion Tooling Solutions GmbH
• Design und Entwicklung von Blockaufnehmern, Jan Walter, S+C Extrusion Tooling Solutions GmbH
• Heizsysteme im Strangpressprozess,
Stefan Beer, I. A . S. GmbH & Co. KG
• Simulation des Strangpressprozesses,
A. J. Koopman, Alko Engineering
• Serviceleistungen für Strangpressen,
Steffen Wächtler, SMS Meer GmbH
• Oberflächentechnologie und Vakuumwärme-
behandlung, Dr. Christoph Escher, Dörrenberg
Edelstahl GmbH.
Im Rahmen der Edelstahl-Akademie ist auch
ein Besuch von Nedal Aluminium geplant. Jeder
Teilnehmer erhält ausführliche Seminarunterlagen und ein Teilnahmezertifikat.
Weitere Informationen erhalten sind beim
Leiter der S+C Edelstahl-Akademie, Dr. Gernot
Strehl. Der Teilnahmebeitrag für die Veranstaltung beträgt 295,00 €, inkl. Seminarunterlagen,
Verpflegung und Abendveranstaltung. Veranstaltungsort: Aluminium Centrum, Voorveste 2,
3990 DC Houten, Niederlande. Anmeldungen
an: S+C Extrusion Tooling Solutions GmbH, Postfach 11 40, 51779 Lindlar, Deutschland.
Exklusiver Medienpartner der S+C EdelstahlAkademie in den Niederlanden ist das International ALUMINIUM Journal der Giesel Verlag GmbH.
Emal gets approval
for expansion project
Emal’s board of directors has approved the
USD4.5bn investment to double production
capacity to 1.3 million tonnes, making the company one of the largest single-site producers of
primary aluminium in the world.
The Emal Phase II project will entail the
construction of a new potline within the smelter
complex at Al Taweelah, Abu Dhabi. The line
will comprise 444 reduction cells powered by
increasing the onsite power plant capacity to
3,000 MW, which will yield an additional annual production capacity of 520,000 tonnes.
The new generation DX+ reduction technology
(developed in-house by Dubal) will be installed,
which operates at 420 kA and offers substantial
benefits in terms of energy-efficiency and environmental protection.
In addition, the technology installed in
Emal Phase I will be upgraded – a project that
will take the production yield from the existing 756 cells (in two potlines) by 50,000 tpy
to 800,000 tonnes by the end of 2012. This
will boost Emal’s total production capacity to
around 1.3 million tonnes by the end of 2014.
Aluminium of Greece
to repay state aid
The EU Commission has concluded that lower
electricity tariffs granted in 2007/08 by the
Greek state-owned Public Power Corp. (PPC)
to Aluminium of Greece granted an undue
advantage to the company, in breach of
EU state aid rules. As a result, Greece must
recover the aid from the beneficiary. The
Commission also investigated the financing of
a gas pipeline by the state-owned Public Gas
Corp., connecting Aluminium of Greece to the
national gas grid, but concluded that it was
carried out on market terms and did therefore not involve state aid.
The decision follows an in-depth investigation opened in January 2010. Aluminium of
Greece benefited from a difference between
its preferential tariffs and the standard rates
for large industrial consumers during the
period concerned, which totals 17.4 million
euros. The preferential tariffs go back to 1960
and were supposed to expire in March 2006.
But they resumed in January 2007 until
March 2008, at which point PPC won an appeal to have them terminated. Greece must
recover the aid plus interest.
9
WIRTSCHAFT
DR.GRAF-Personalberatung
DR. GRAF – Personnel Consultancy
Auf der steten Suche
nach Top-Leuten
Always on the lookout for top people
Ein kleines, aber feines Unternehmen im
oberschwäbischen Bad Waldsee hat sich
in den letzten Jahren als Top-Adresse für
die Besetzung von Führungspositionen
der internationalen Metallindustrie etabliert. Werner J. Graf, (Gründer und Inhaber der DR.GRAF-Personalberatung) ist
quasi „gelernter Aluminium-Mann“ und
war lange Zeit in operativer Verantwortung in der Branche tätig.
A small, but choice company in Bad
Waldsee in Upper Swabia has established itself in recent years as the best
place to go for filling leading positions
in the international metals industry.
Werner J. Graf (founder and proprietor
of DR.GRAF – Personnel Consultancy) is,
as it were, a ‘trained aluminium man’ and
held positions of responsibility in the sector for a long time.
Graf kennt die Metallindustrie wie kaum ein
Zweiter aus seinem Gewerbe und ist entsprechend gut vernetzt. Bis Mitte 2006 war
er als Vorsitzender der Geschäftsführung der
deutschen Walz- und Strangpressaktivitäten
von Corus Aluminium,
heute Aleris Inc., tätig und
in dieser Funktion auch in
diversen Verbänden auf
nationaler und internationaler Ebene eingebunden.
„Wenn man die Metallindustrie und ihre Eigenarten
so gut kennt, bleibt man halt
mit diesem Industriezweig
sozusagen auf ewig verbunden“, erklärt er.
Seit nunmehr fünf Jahren berät er mit seinem
Team Unternehmen der
internationalen Metallin- Werner J. Graf
dustrie – vor allem bei der
Besetzung von Top-Positionen. Recherchiert
wird ausschließlich über die Direktansprache.
„Die Entwicklung der letzten Jahre war für uns
trotz Krise sehr rasant. Wir sind sehr zufrieden
mit dieser Entwicklung und haben natürlich
noch viel vor in den nächsten Jahren.“
Schnell kommt er ins Schwärmen, wenn
es um das Walzen, Pressen, Schmieden und
Gießen von Metallen geht. Im Laufe der Jahre
hat sich das Spektrum seiner Personalberatung
auch auf wichtige Kunden der Aluminiumindustrie erweitert. „Wir sind stolz, dass heute
führende Unternehmen aus Bau, Verpackung
und Transport zu unserem Mandantenkreis
gehören. Auch der Maschinen- und Anlagenbau um die Metallindustrie herum bedient sich
zwischenzeitlich unserer Dienstleistungen.“
Jede Branche hat ihre Spezifika, weiß Graf.
Das gilt auch für die Aluminiumindustrie. Er
kennt seine Branche, und seine Mandanten
wissen das zu schätzen. „Aktuell sehen wir
Mr Graf knows the metals industry better than
almost anyone else in the personal consultant
business, and has correspondingly excellent
contacts. Until the middle of 2006 he served as
chairman of the board for the rolling and extrusion activities of Corus Aluminium – now Aleris Inc.
– in Germany, and in that
capacity was also involved
in various Associations at
national and international
level. “When you know
the metals industry and
its characteristics so well,
you remain everlastingly
bound up with this sector
of industry,” he explains.
For five years now he
and his team have advised
companies in the international metals industry –
Foto: Dr. GRAF
above all about the filling of top positions. Searches are conducted
exclusively by direct approach. “Despite the
crisis, our development in these years has
been very rapid. We are very satisfied with
that development and of course expect it
to go much farther in the years to come.”
Mr Graf soon goes into raptures when talking about the rolling, extrusion, forging and
casting of metals. Over the years the scope of
his personnel consultancy has also extended
to important customers in the aluminium
industry. “We are proud that today, leading
companies in the construction, packaging and
transport sectors are among our circle of clients. Also, mechanical and plant engineering
companies related to the metals industry have
in the meantime begun using our services.”
Every sector has its specific features, he
points out. This also applies to the aluminium
industry. He has a thorough knowledge of the
sector, and his clients know how to appreciate
that. “At present we foresee a big shortage of
technically and managerially specialised personnel in our industry,” he says. To close that
gap, the resources of the companies themselves
will not be sufficient. So the personnel consultant is convinced that for companies in the
sector it is becoming more and more important
to find top people for the metals industry, even
coming from abroad. But movement in the opposite direction is also becoming increasingly
relevant. The demand created by globalisation
for branch specialists from Germany who are
prepared to spend a few years or even longer
working abroad, is continually increasing.
It is not actually cheap to commission Graf
to seek out top candidates, but “We offer
more than the mere filling of vacant posts. We
view ourselves not just as ‘head-hunters’, but
rather as trusted and reliable sparring partners
and advisors for decision-makers when questions of strategy, organisation and the filling
of leading positions arise. In other words, we
have to know what our client is talking about
– and we do. Our job is to make sure that our
clients get to fill their vacant posts in the best
possible way, because at the end of the day
it is always people who make the difference
between success or failure.”
N
eine große Lücke an Fach- und Führungskräften auf unsere Industrie zukommen“, sagt
er. Um diese Lücke zu schließen, werden die
eigenen Unternehmensressourcen nicht ausreichen. Daher werde es für die Branchenunternehmen immer wichtiger, auch im Ausland
Topleute für die Metallindustrie zu finden, ist
Graf überzeugt. Aber auch der umgekehrte
Weg werde zunehmend relevanter. Die Nachfrage nach deutschen Branchenspezialisten,
die bereit sind, für einige Jahre oder auch länger ins Ausland zu gehen, steige ständig.
Es ist nicht gerade billig, Graf mit der Suche
nach dem/der Topkandidaten/in zu beauftra-
gen, aber „wir bieten auch mehr als die bloße
Besetzung von offenen Positionen. Wir sehen
uns nicht nur als Headhunter, sondern vielmehr als zuverlässiger Sparringspartner und
Ratgeber für Entscheidungsträger, wenn es
um Strategie, Organisation und die Besetzung
von Führungspositionen geht. Das heißt, wir
müssen wissen, wovon unser Mandant spricht
und das tun wir. Unsere Aufgabe ist es, dafür
zu sorgen, dass unsere Mandanten ihre offenen
Positionen optimal besetzt bekommen. Denn
am Ende sind es noch immer die Menschen,
die den Ausschlag geben über Erfolg oder
N
Misserfolg“ – davon ist Graf überzeugt.
10
WIRTSCHAFT
Produktionsdaten der deutschen Aluminiumindustrie
Primäraluminium
Sekundäraluminium
Walzprodukte > 0,2 mm
Press- & Ziehprodukte**
Produktion
(in 1.000 t)
+/in % *
Produktion
(in 1.000 t)
+/in % *
Produktion
(in 1.000 t)
+/in % *
Produktion
(in 1.000 t)
+/in % *
Mai
34,4
96,8
53,5
16,7
162,4
35,3
47,4
41,2
Jun
34,7
91,1
56,7
16,4
165,5
21,9
53,7
43,2
Jul
36,5
83,0
49,7
-4,2
158,3
6,2
50,5
23,6
Aug
36,9
79,9
46,0
6,4
167,6
27,0
48,4
27,1
Sep
36,0
69,4
53,6
-3,8
161,0
14,2
50,9
17,3
Okt
37,1
53,2
52,0
-5,4
161,8
12,5
50,7
11,0
Nov
35,9
46,3
52,6
-4,4
158,2
6,1
50,8
11,8
Dez
37,2
42,2
41,7
-1,6
123,4
12,9
31,3
17,7
Jan 11
37,1
37,7
45,2
-1,5
154,9
11,9
44,8
18,2
Feb
33,8
32,2
49,3
-3,2
161,1
9,2
47,3
11,1
Mär
37,0
21,9
54,0
-6,0
173,7
0,8
53,1
4,0
Apr
35,7
15,1
48,3
-5,3
156,6
-2,3
47,3
7,4
Mai
37,1
7,9
50,9
-4,9
168,3
3,7
56,1
18,3
* gegenüber dem Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf
Primäraluminium
Walzprodukte > 0,2 mm
Sekundäraluminium
Press- und Ziehprodukte
11
WIRTSCHAFT
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2003
2004
2005
2006
2007
2008
2009
2010
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2003
2004
2005
2006
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2008
2009
2010
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2003
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2006
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12
ECONOMICS
The present trilogy is based on the ground-breaking article: Which globalization for the aluminium industry – a normative analysis exploring alternative business models, published in ALUMINIUM 1-2/2008 and 3/2008 as well as on the opening speech with
the title ‘How globalization is changing competition in the aluminium industry’, held at the ‘Aluminium Two Thousand” congress
from 17 to 19 May 2011 in Bologna.
The globalizing aluminium industry – Part 1/3:
Competitive strategies of emerging and advanced economies
Bruno G. Rüttimann, Horgen
China and other BRIC countries have been
experiencing during the past years average
growth rates of about 10% whilst advanced
economic areas such as Europe suffered
from stagnation or had to be content with
slight growth. With increased self-confidence,
backed-up with a very competitive cost structure, new competitors are successfully entering
the international markets. Emblematic is the
Chinese export success of extruded products
to America having reached from scratch in less
than ten years a 15% market share, and that in
fragmented markets characterized by regional
transaction patterns. The damage in fragmented type 2a globalization markets inflicted by
the opportunistic low-cost type 1c globalization is deleterious for the local industry in
14
high-cost countries.
At the same time,
whilst in Europe the
primary metal industry is declining due to
high energy cost, new
big smelters are being
put into operation, not
only in the Gulf region,
to satisfy the rising
demand for primary
aluminium. Western
industrialized countries needed 100 years
to build-up today’s
aluminium industry. Fig. 1: Contingent factors influencing corporate strategy orientation
Emerging economies
will not need another 100 years to reach the The intrinsic nature of the different business
same level, shortening learning curves with types combined with striving to maximize
the help of Western partners, and will benefit profit exploiting global growth opportunities
from already available product and process are leading to different but very characteristic
technology. One thing is for sure: the econom- globalization patterns and strategies. Four of
ic gravity centre will shift – a new economic the seven basic globalization types (Fig. 2) and
order will be established where the emerging relative macro business strategies are relevant
economies will have their lion’s part. The car- to us: type 1a, type 1b, type 1c and type 2a [1,
dinal question is now: what will companies in 2]. The understanding of these basic globaliemerging economies most likely do? What is zation patterns is essential in order to underthe resulting spectrum of possible strategies stand not only the strategy scope but also the
for the longstanding players in the light of in- threat or opportunity deriving from globalizacreasing importance of emerging competitors, tion along the different levels of the value-add
changing the competition rules?
chain. Relevant is also the governing industry
logic of the industry life cycle and how supply
chains are evolving. This topic will be analyzed
Globalization patterns and strategy
more deeply in the second part of this trilogy.
The cardinal question is: how will globaliza- The industry logic evolves and embraces new
tion impact corporate strategies. Corporate key success factors generated by discontinuistrategies are not fully free to choose and are ties of the second type, i. e. disruptive changes,
subject to change influenced by the changing leading to new competitive moves. The indusindustry logic. Under the ‘leitmotif’ of maxi- try logic is therefore the associated governing
mizing profit, global strategy formulation has rational of industry life cycle and changes with
to be seen within the company-extern as well its stage of maturity.
as company-intern context which is evolving
Possible strategies depend largely on the
and depends on (Fig. 1):
resources and skills available to the company
• The business type and industry logic
but also to the intrinsic type of business [3]. It
• The external local resource endowment
is a fact that resources, such as bauxite, cheap
• The internal accumulated skills
energy and cheap labour, are mainly abundant
• The mission and vision of the company.
in emerging economies. In advanced econo-
Images: Rüttimann
During the past 20 years, the aluminium
industry has been experiencing fundamental changes. The concentration of big aluminium groups and the de-verticalization
of the formerly integrated value-chain are
the consequences of the globalizing aluminium business. In addition, new competitors from emerging economic regions
are entering the international scene and
play their role for the conquest of market
shares. The result is a new competitive
environment with new rules of the game.
The globalization of the aluminium business is modifying the industry logic. Proven business models will be abandoned and
new ones will emerge within an eclectic
market. With the present trilogy, the
author analyses the variables driving the
next future of the globalizing aluminium
industry and how the resulting aluminium
competitive system could look like. He
covers topics such as the normative strategies of emerging and advanced economies, the arising new industry logic, as
well as the possible consequences to the
European aluminium industry. In this first
part, the possible macro-strategy moves of
companies from emerging and advanced
economies are analysed.
ECONOMICS
mies skills are dominating, such as know-how
and technology. It seems obvious that companies from advanced economies have to concentrate on technology to keep the advantage
whereas companies from emerging economies
will concentrate at the beginning on exploiting
abundant resources, even supported by Western companies. This seems to lead directly
to Pareto optimality of supply chains within
a global multi-country system, each country
concentrating on the stage of transformation
where it posses the best endowment in resources or skills. With the different endowment of
resources we clearly see that companies from
emerging and advanced economies will have
a different spectrum of strategies available.
Emerging and advanced economies are also on
different stage of maturity regarding the industry life cycle [4, 5, 6]. The question arises: what
is the overall predominant resulting industry
logic? The governing industry logic will be the
one with the most efficient supply chain along
the value-add chain. Therefore cost again will
most probably dominate over efficacy.
The corporate mission is derived from external and internal factors and more precise, it
is conceived within the field-force of competi-
tors move, product/service differentiation and
own skills in order to have an advantageous
position to serve targeted customers. But it is
also influenced by the political framework as
well as set by social guidelines dictated from
ethical beliefs of the shareholders and of the
board of directors. In a winning customer-centric mission, everything has to be deducted
from customer’s critical requirements and expectations. We can deduce that the mission,
and therefore the corporate strategy, have a
limited degree of freedom, because they are
restricted to the available resources and have
to comply with the governing industry logic in
order to be successful. Therefore it is essential
to identify the governing industry logic and to
become best-in-class, or to set new rules of the
game. The company vision then refers to the
objectives, i. e. the quantitative targets in term
of profitability, market share, and degree of
international action scope.
The rational of opportunistic
low-cost globalization
Let us have a look of what consists the biggest
threat for the companies in advanced econo-
Spouts and Stoppers
mies. We will refer here to the semis industry,
such as rolling, extrusion and castings. The aluminium semis production being a fragmented
business with regionally limited action scope
belongs to the type 2a globalization form [4,
5]. This leads to a regionally limited monopoly
with imperfect competition scheme according
to Chamberlin and Robinson. In such markets
we usually do not expect to have competition
from far-flung countries. But if the price differential for a non-differentiated product is high
enough, exports from the low-cost region to
the high-price economy may materialize according to the type 1c globalization pattern
(Fig. 2). This happened extensively in the North
American extrusion market during the period
2002 to 2010 [7, 8, 9, 10]. Imports from China
alone reached more than 15% market share
of the American extrusion market in 2010, before being stopped in 2011 by 300% import
duties. The Chinese extrusion exports to the
US had attained 200,000 tonnes in 2010 corresponding to more than ten extrusion plants
with two presses and totalling more than 1,000
employees laid-off. The figures show that the
damage inflicted to the local economy can be
immense if not appropriate reactions are taken.
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For Aluminium DC Casting
w w w.drache-gmbh.de
·
[email protected]
15
ECONOMICS
Therefore, this threat is not hypothetically but
realistic. The exports of type 1c from low-cost
countries can be modelled as follows [1]:
tZK =
(
pK PZ
VK, ΔpZK, sZK, ⎯⎯,
⎯⎯
pZ VZ
)
where tZK denotes the trade volume from the
low-cost country Z to the high-price country
K. This export volume depends on the market volume VK in the high-price region K,
the absolute price difference ΔpZK of the two
economic regions, as well as on a factor sZK
summarizing the logistic aspects. Furthermore,
pK and pZ are the respective prices in the high
and low-price economies and VZ and PZ are
respectively the demand and production capacity in the low-cost economy. This shows
that the trade volume between Z and K depends mainly on price differences between the
two economies and the capacity utilization in
country Z.
From the above causal relation, we can
further assume that if pK/pZ > 1, i. e. absolute
price difference is assumed, then capacity of
the low-cost country Z will be dedicated to
exports (if the demand side quality and service
requirement can be fulfilled), i. e. the company
in the low-price economy will act according
to the rational economic law of maximizing
profit.
Let us have a look at the capacity situation. When PZ > VZ, exports will materialize
and they will materialize the higher the price
difference will be. When PZ < VZ, exports will
hardly materialize, even if the price difference seems to be advantageous, because stateowned national interest will prevail, as long as
the production capacity has not been adjusted.
This will fuel the set-up of additional capacities in Z to exploit the advantage. From that
we see that the production capacity situation
in low-cost region Z is the essential triggering
for exports to high-price regions. This fact will
help us to understand the big difference of peculiarities of the BRIC countries compared to
other economic regions, such as the Gulf.
Indeed, exports will not be the primary
strategy scope of China, the primary scope is
to satisfy the rapid and huge growth of internal
demand, but exports help to finance the huge
need for capacity investment. Therefore, exports will be confined, until internal demand
is growing. We can only hope that big lowcost economies, such as China, will continue to
grow. If growth will stagnate, exceeding capacities will be oriented to the high-price economies with all its consequences for companies
in fragmented type 2a markets.
This situation is completely different from
that one of the Gulf region because there will
16
be established structurally an overcapacity,
exceeding largely the home-market demand.
The aluminium demand in the Gulf region
was 2010 approximate 600.000 tonnes for a
population of 38 million. The excess of lowcost primary aluminium production will be
a benison for all the countries with lack of
endowment of natural resources. The foreseeable investment in downstream production
in the Gulf region is a question of time, not
only to supply the increasing local demand for
semi-fabricated products but to export higher
value-add products.
sions are restricted due to mutual interactions.
Two dimensions emerge to be decisive to understand the evolution of competition: the
economy type and the action scope.
Indeed, within the matrix of normative
strategy options [11], advanced and emerging
economies can choose between concentrating
their activity either to a regionally local scope
or to expanding their activity on global level,
revealing four different basic strategy options
(Fig. 3).
Develop home market: Emerging economies focussing their attention mainly on the lo-
Fig. 2: Nature of different globalization types
Indeed, exporting semis according to the type
1c globalization logic based on low-cost advantage is obvious. The type 1c globalization
form is a non-natural but a transient type of
globalization form, existing as long as the advantage exists – but it will last long enough to
hurt high-price economies. It is obvious that
this type 1c globalization form can cause unemployment in high-price economies. If this
situation persists, the price pressure on Western semi-fabricators will increase, and reactive
strategies have to be actuated.
Matrix of normative strategy options
Now, let us come to the cardinal question:
what can competitors of advanced economies
do in light of what new competitors of emerging economies most likely will do relative to
the action scope in the globalizing competition
system. As we have seen before the response
is not freely choosable but the strategy deci-
cal home market pursue the mission to buildup a national industry in order to satisfy the
local rising demand; this is mainly the case in
very large countries, such as the BRICs. By the
way, these companies have a social responsibility to fuel internal growth and to sustain the
development of their country. An integrated
approach along the whole value chain is most
suitable because usually in these countries
bauxite ore and cheap renewable energy also
exist. Investment in downstream operation is
necessary to satisfy the industry demand for
extrusions, sheets or castings. Companies following mainly this approach are: CBA, UC
Rusal, Hindalco and Chinalco. It goes without
saying that this categorization is only approximate because also these companies are exporting, but the exports are for certain goods only
a side-business.
Exploit cost advantage: Competitors of
rather smaller emerging economies but which
are rather well endowed with cheap labour,
ECONOMICS
cheap energy and ore reserves may pursue
a rather different approach. Also they have
the intention of building-up the home market
but, leveraged with export focus, exploiting
economies of scale to be able to serve the local market in the best way. Focussing only on
the small home market would impede building industries with sizes exploiting economies
of scale. Companies belonging to this strategy
type are, for example, Alba, Dubal, Emal and
Ma’aden. These competitors are following the
type 1a globalization form as well as the type
1c. Exceptions are found also here: e.g. Kam
Kiu, a big Chinese extruder, is also heavily
exporting not because its home market is too
small! Exploiting the cost advantage of emerging economies is typical, per antonomasia, in
type 1c globalization pattern. Therefore, if exports to high-price countries are made on the
same stage of the value chain this might have
serious consequences to the local industry of
high-price economies [1, 7, 8, 9, 10]. Exports
of products following the globalization type 1a
pattern, on the other hand, are highly appreci-
Fig. 3: Matrix of normative strategy options
ated by the companies of high-price countries,
working hand in hand along the value chain;
this gives a synergic supply chain, leaving
space for any actor in the aluminium industry
value-add chain, in emerging and advanced
economies coming very close to the Pareto
optimality to maximize wealth.
Exploit know-how: How should competitors from advanced economies respond to this
globalization challenge? Aluminium semi-fabricated products show a rather fragmented
type 2a industry structure impeding exports
over a long distance if it is not a very special
semis-product of type 1b. Competitors wanting to grow have therefore to implement a
strategy based on FDI (Foreign Direct Investment), wholly owned or via joint ventures. The
need may also arise, forced by internationally
active customers, to follow them globally. In
addition, from the Central Theorem of Globalization, a globalized activity reduces the
portfolio risk [1]. The strategy of this business
idea is based on brand marketing, following
on international customers and knowing how
to best run such types of plants. It may be
obvious that those multinational enterprises
(MNE) are competing locally in emerging
markets against local competitors, but usually
they are competing at arm’s length and with
preferred customer relationships. Companies
belonging to this strategy type are: Novelis,
Sapa as well as partially Aleris and Constellium, the former Alcan EP downstream business. It has to be remarked that, Novelis belongs to the Birla group, which indicates that
also the MNEs of emerging economies are
beginning to have their own foothold on the
global market and not only on local ones, as
just described above, or try to get Western
technology.
Defend local market: The last basic strategy
box is reserved mainly for small medium enterprises (SME), managed by an entrepreneurial small industry group or even family-owned,
but also for the facilities of advanced MNE in
their home markets. Semis fabrication is typical for this constellation. These companies may
facing a hard future: exports are usually possible only on a limited scale, their home markets
may still grow but that depends on the customer or application segment, and in addition, they
have to face potentially increased competition
from low-cost competitors exploiting the type
1c globalization pattern. The basic strategy to
survive is customer relationship management,
integrated by Lean and Six Sigma management philosophy based on service. This can
be achieved also by SME, having an already
lean cost structure; what has to be established
is the right response to customers need.
Mutually interactive strategies
From the analysis of the matrix of normative
strategy options results that competition advantage is asymmetric in favour of the emerging economies. Indeed, whereas the strategies
of advanced economies show a win-win constellation, this is not true for both options of
emerging economies. Implementing a type 2a
strategy implies to build-up local capacities
for the local market. This increases market
share and profit for the advanced economies
in fragmented markets, and at the same time
it brings wealth and know-how to the emerging economy. An immediate idea to increase
further shareholder profit could be to export
these low-cost capacities to advanced highprice economies according to an opportunistic
type 1c strategy; of course this should not be
initiated by profit oriented Western management lacking of ethical principles. As we have
already discussed, this low-cost exports can
harm local industry of advanced economies
especially in fragmented markets with low
differentiation degree (remember the before
cited American-Chinese extrusion case); this
semis industry is vital to a well functioning
downstream industry.
Different is the situation of complementary steps in the value-add chain optimizing
the supply chain according to type 1a globalization. The lack of commodities in high-price
countries such as Europe leads to think about
the whole value chain. Whether the control of
the supply chain is made through participation
or preferred customer-supplier relationship is
a contingent question. Due to the fact, that
more and more semis-conversion will be made
also at the origin of the commodities helping to
industrialize the commodity-supplying country, physical globalization of type 1a export
could reach a temporary peak to advanced
economies in future, substituted partially by
exporting more value-add products of type 1c
logic. At that stage at the latest, companies in
advanced economies will have to enforce their
strategy planning department and politicians
in advanced economies should have created
the best suitable conditions for a sustainable
industry politics in their countries.
Summary, first part
Corporate strategies cannot be chosen deliberately but have to comply with the industry
logics, or they have to revolutionize the industry logic. Due to the different external and
internal resource endowments, strategies for
companies in emerging and advanced countries will be different, where the opportunistic low-cost globalization is more than only a
noise factor and will hurt companies in highcost countries. The rough spectrum of possible
strategies for companies in emerging and advanced countries, how to behave in the global
context, is shown in the Matrix of Normative
Strategy Options.
References
[1] Rüttimann B., Modeling Economic Globalization – A Post-Neoclassic View on Foreign Trade
and Competition, 2007, MV-Wissenschaft, ISBN
978-3-86582-447-9
[2] Rüttimann B., Globalisierung verstehen bedeutet Märkte beherrschen, io new Management,
5/2010 Springer Verlag
[3] Rüttimann B., Strategy and Tactics in the Aluminium Semis-finished Products Industry, ALU-
17
ECONOMICS
MINIUM 78 (2002) 1/2 and 4, Giesel Verlag
[4] Rüttimann B., Which Globalization for the Aluminium Industry – A Normative Analysis Exploring
Alternative Business Models, Part 1 in ALUMINIUM 1/2-2008 and Part 2 in ALUMINIUM 3-2008,
Giesel Verlag
[5] Rüttimann B., Which Globalization for the Aluminium Industry, proceedings of the ALUMINIUM
2008 World Trade Fair and Conference, Sept 23-25,
2008, Essen
[6] Rüttimann B., Which form of globalisation for
the aluminium industry?, report on the Aluminium
2008 Essen presentation, Aluminium International
Today, Vol. 20, No. 6, Nov-Dec 2008, dmg world
media, Redhill Surrey UK
[7] Rüttimann B., The Globalization Trap of the Aluminum Extrusion Industry, proceedings of the 9th
International Extrusion Technology Congress ET08,
May 13-16, 2008 Orlando FL USA
[8] Rüttimann B., Challenges of the Globalizing
Aluminium Industry, proceedings of Aluminium
2010 World Trade Fair and Conference, Sept 1416, 2010, Essen
[9] Rüttimann B., The effects of Chinese hegemony
and the increased volatility of metal markets, ALUMINIUM 11-2010, Giesel Verlag
[10] Rüttimann B., Werden die chinesischen Halbzeugexporte die Märkte überfluten?, Dow Jones
NE Metalle Monitor, 1/2011
[11] Rüttimann B., How Globalization is Changing
Competition in the Aluminium Industry, proceedings of 7th World Congress ‘Aluminium Two Thousand’, May 17-19, 2011, Bologna Italy
Author
Bruno G. Rüttimann, Dr.-Ing. MBA, has been active for 20 years in the aluminium industry. Today
he advises institutions and companies. He is invited
keynote speaker at international congresses with
focus on strategy and globalization. At Inspire/ETH
Zürich, he teaches Lean Six Sigma principles for the
Swissinstitute for Systems Engineering. More details
at www.brunoruettimann.de
Aluminium market strong,
oil price main risk for future growth
G. Djukanovic, Podgorica
At the end of June, while writing this
article, the aluminium price was again at
the level it was at the beginning of the
year, just below USD2,500 per tonne.
In the meantime, the 3-month price rose
above USD2,800 per tonne in early May,
the highest level since August 2008. The
main support for all base metals prices
came from high oil prices and optimism
about the growth prospects of important
economic regions. However, weak economic parameters coming from the USA
in recent weeks, concern about the renewed Greek debt crisis in Europe, continued anti-inflation measures in China
and already ongoing recession in Japan
have all together put pressure on oil and
metal prices in recent weeks. The general feeling is that in the conduct of their
economic policies, governments react too
slowly to counter and prevent possible
economic crises in time.
Surprisingly, the copper price has still remained high, holding at around USD9,000 per
tonne with potential for further growth in the
second half of the year. This is mainly due to
low stocks in China and expectations that local
consumers will soon start to buy more from
abroad. The expected rise of copper price may
be the main support for the aluminium price
in coming months. On the other hand, metals
prices have been very sensitive to the US dollar’s relation to the Euro, so currency analysts
could provide better clues about which direction prices may move in by the end of the year.
Strengthening of the dollar towards 1.2 per
Euro, as some analysts forecast in the next 6
18
to 12 months if the Greek crisis spreads to
other European countries, may push down the
aluminium price to as low as USD2,100-2,150
per tonne. On the other hand, any move towards EUR/USD1.5 or higher, along with support by the oil, copper and other metals prices,
may result in USD3,000 per tonne for the aluminium price during the same period. This is
also approximately the range metals analysts
put their forecasts for the aluminium price in
the latest base metals polls, for 2011 and 2012.
However, the aluminium price has remained
stable in Euros during this year and this trend
should continue for the rest of the year.
Supply difficulties support the price
Some 70% of the aluminium in LME warehouses is tied up in financing deals (over 3m
t); this will continue to support the aluminium
price, at least in the second half of the year.
Deficient availability of LME aluminium may
slow or even prevent a switch from copper
to aluminium, even though the price of alu-
minium is almost four times lower. Industry
experts say that current technology would allow about 20% of copper applications to be
replaced by aluminium, amounting to about
3.8 million tpy. For example, newly installed
overhead power lines in China are now mostly
made of aluminium, instead of copper.
Recently Coca Cola Co. was one of several
companies and many traders that complained
to the London Metal Exchange about the supply of aluminium. The Wall Street Journal
reported on 17 June that Coca Cola accused
Goldman Sachs of restricting the supply that
leaves its warehouses in Detroit, trying instead
to increase stockpiles and artificially boost the
price that producers can charge. The Detroit
warehouses hold around 25% of LME’s total inventory. According to the current LME
procedure only 1,500 tonnes per day are allowed to leave the warehouses, thus creating
supply bottlenecks. “It takes two weeks to put
aluminium in, and six months to get it out.
The situation has been organised artificially to
drive premiums up,” said Dave Smith, Coca
Cola’s strategic procurement manager. Proposed recommendations by LME to increase load-out rates by next April are too little
and too late, as the market landscape may be vastly altered over
the next ten months, aluminium market players in USA agreed.
They have voiced concern over the long lead times to get metal
out of US warehouses, particularly in Detroit. Market players say
it will take until Feb/March 2012 to get metal out of Detroit.
At a meeting in mid-June, the LME board agreed that the loadout requirement will be linked to the amount of metal stored,
rather than to the square metre storage capacity. The rate will
be set at a minimum of 1,500 t/day for up to 300,000 tonnes
stored; 2,000 t/day for 300,000 to 600,000 tonnes; 2,500 t/day
for 600,000 to 900,000 tonnes; and 3,000 t/day for more than
900,000 tonnes. The changes would be effective as from 1 April
2012, thus allowing “ample time for the warehouse companies
to prepare for the new regime and for the market to digest the
consequences of the change.” Most US traders believe that the
changes will ease rather than fully resolve the problem. “Too little,
too late” is the general opinion.
The supply difficulties also maintain near record high premiums in USA and Europe. US premiums had come down to 8-8.5
cents per pound in the second half of June, down from record
high of 9.5-10 cents per pound (USD220 per t) in May. Premiums for duty-paid physical aluminium in Europe also slightly
eased from record highs, to USD205-235 per tonne over LME
cash prices in mid-June. This compared with quotes of USD210240 in May. Premiums for duty unpaid material were quoted at
USD140-150 per tonne.
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Investors worried about commodities
According to a Barclays Capital survey, commodities have fallen
sharply out of favour among institutional investors during the
second quarter. Just 15% of nearly 900 respondents expect commodities to be the best performing asset class in the coming three
months, down from 41% previously. Commodities have plunged
from being the most popular asset class to the least popular, with
a fifth of investors favouring equities and nearly a third bonds.
The asset class has fallen more than 15% since early April, according to the S&P GCSI, a broad commodity index. Obviously investors are not any more as optimistic about global growth prospects
as they were in early 2011. Although most of them are worried,
none is expecting another, deeper recession. The Chinese economy has been a major source of uncertainty, with 67% of investors
in emerging markets citing a significant Chinese slowdown as the
biggest risk to the markets.
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Stocks falling, following the price
Aluminium inventories in warehouses monitored by the LME fell
to 4.52 million tonnes at the end of June, the lowest since January.
LME stocks reached 4.71 million tonnes in May (the highest since
1998). Thus both the aluminium price and LME stocks returned
to the values they had at the beginning of the year. The fact that
both moved in the same direction, first up and then down, indicates that some other, non market parameters are influencing the
price, such as the already mentioned supply difficulties out of LME
warehouses. Significant amounts of the metal were removed from
US and South Korean warehouses in June. Analysts at Citi Global Commodities said that LME cancelled warrants have surged
ECONOMICS
rise year-on-year. Increased supply put pressure on alumina prices, prompting merchants
to mull alumina exports. Alumina production
costs in China amount to about 2,100-2,200
yuan per tonne, making the current spot prices
attractive to them. China’s imports of alumina
slumped to a multi-year low of 113,500 tonnes
in May. Imports fell by 16% last year and the
cumulative January to May total imports of
945,000 tonnes marked a 57% y-o-y drop.
China
to extremely high levels in recent weeks. The
issue now is to decide whether this is merely
a large holding being transferred to another
warehouse on the back of a better rent deal,
or whether consumers are cancelling in anticipation of long delays in getting hold of their
material.
Alumina
Major producers of alumina have obviously
drawn inspiration from selling iron ore at an
index-based price and on a monthly basis, are
keen to apply the same to alumina pricing
too. Rio Tinto Alcan believes that index-based
pricing will “give a good signal that alumina
prices should be linked to potential investments because somewhere along the line,
there will be a shortage”. The migration to
the new index-based pricing of alumina began
in the second half of 2010, with most major
producers referring to an index or a basket
of indices for selling the material, including
long-term contracts. The index is based on reported transactions in an effort to more clearly
reflect the physical alumina market. Alcoa, the
world’s largest third-party seller of alumina,
and UC Rusal, the world’s leading aluminium
producer, are using a basket of indexes to get
as close as possible to the underlying costs of
making the material and also in order not to
be seen as favouring one index over the other. Indices produced by Platts, Metal Bulletin
and CRU have become the principal reference
points for alumina prices.
At the end of June, Platts alumina index
PAX FOB Australia stood at USD388 per
tonne. Metal Bulletin alumina index fell to
20
USD384.33 from the previous USD391.67 per
tonne, after thin buying and increased supplies.
UC Rusal’s alumina index was USD395.48 per
tonne, on FOB basis, down from USD409.75
per tonne at the end of May. The market seems
saturated by increased production in China
and reduced imports there, which have resulted in a lower alumina index price; that trend
may continue during the summer, while the
alumina index may fall to USD350 per tonne.
Moreover, the alumina index may stagnate or
fall farther even if the aluminium price starts
rising due to eventual production reduction,
especially in China. In this case alumina inventories will continue to rise for a certain time
and put pressure on the alumina index price.
China’s alumina prices have fallen
7% since March due to increased supply, prompting merchants to consider
exporting the raw material used for
primary aluminium production to a
steadier international market, industry sources said recently. Spot alumina was traded at about 2,550 to
2,650 yuan (USD394-409) per tonne
early in June in China, down from
about 2,800 yuan in March, while international prices have firmed about
3% over the period due to increased
demand. Industry sources expect the
alumina price in China to fall farther
this summer.
Output of alumina reached a record
3.119 million tonnes in May, up from
the previous record of 2.987 million
tonnes in April. China produced 14.3
million tonnes of alumina in the first
5 months of 2011, that is a 13.3%
Chinese primary aluminium production in
May reached a record high of 1.536 million
tonnes, up 5.3% from the previous month and
8.7% from a year ago. Daily average production hit a fresh all-time record high of 49,700
tonnes in May, equivalent to an annualised
18.14 million tonnes. Total global output in
May also increased to a fresh high of 43.66
million tonnes annualised. Chinese smelters
have lifted run rates by an annualised 3.47
million tonnes so far this year and the same
amount may enter production by the end of
the year. China has not been a major exporter
of primary aluminium since the end of 2006,
when a 15% duty on exports was introduced.
Since then China became a growing exporter
of aluminium products, which surged by 56%
to 2.18 million tonnes in 2010, and by an average 30% a month, to 10.37 million tonnes in
the first five months of 2011 – mainly due to
firm demand from the automobile and property sectors.
In May alone exports of products accelerated to a new all-time high of 340,000 tonnes,
obviously in a rush prior to an expected de-
ECONOMICS
crease in tax rebates. These tax rebates on
exports of selected products, in contrast to
the high duty on primary metal exports, have
supported the rise of exports in previous
years. This means that part of China’s internal
consumption of aluminium is merely to produce products for export. Based on official
figures for the January to April 2011 period,
exports of products accounted for 11% of total products output. The rebate on exports of
some semi-finished aluminium products could
be cut to 8 or 9%, from the present 13%, as
the government intends to limit exports and
encourage consolidation in the energy-intensive aluminium sector.
Power supply is a major concern for China
this summer. The country is undergoing the
worst power cuts since 2004, and has instituted
rationing for industrial users. These shortages
will likely affect aluminium production in July
and August. This, together with lower rebates,
would support the aluminium price at LME.
The Chinese government has recently ordered a halt to all planned smelter projects. If
enforced, the order could delay or eliminate
some 7 million tonnes of planned smelting capacity, according to estimates by local analysts.
Previous attempts to curb the industry have
met with only limited success. Even if successful, it is probably too late to prevent some 3
million tonnes of smelting capacity expansion
already underway from entering production
this year. China could significantly influence
the aluminium market and prices in the following months and years if these measures are
implemented. In the near future, however, it
would be more likely that power shortages
would not cut aluminium production to any
great extent and that the government policy
would allow smelting capacity to satisfy local
demand. Primary aluminium production and
consumption are expected to be balanced this
year, or to have a smaller surplus.
Japan
Just a few words about the economy in Japan,
which shrank much more than expected in the
first quarter and slipped into recession after the
triple disaster in March – earthquake, tsunami
and nuclear catastrophe. Shipments of rolled
aluminium products from Japan increased
0.8% in May, the first gain in three months as
demand recovered. Supplies to domestic and
export markets increased to 166,885 tonnes in
May, up from 165,638 tonnes a year earlier,
according to the Japan Aluminium Association. That was the first increase since February,
when shipments rose 2.3% to 168,092 tonnes.
The growth was led by demand from can mak-
ers as producers accelerated output before the
start of the high-sales season for beer and soda.
Shipments of aluminium products for use in
cans jumped 23% to 43,521 tonnes in May,
while demand from builders expanded 8.9%.
Shipments to the automotive industry dropped
29% since carmakers are still working to restore full operations.
The Japan government ordered industrial
power users to cut electricity consumption by
15% as from 1 July to help cope with short-
ages after the March earthquake destroyed
the nuclear power complex in Fukushima. The
restrictions are to take effect by 22 September in areas covered by Tokyo Electric Power
Company (TEPCO), the operator of the disabled plants.
The premium for primary aluminium shipments to Japan in the third quarter of 2011
has been set at USD120 per tonne, up from
USD113 in the second quarter this year, according to industry sources directly involved
in premium talks.
Aluminium price well supported in H2
The aluminium price should remain supported
during the summer due to the threat of production cuts in China, reduced product exports
from China and in general healthy global demand. There have been consistent optimistic
forecasts about the aluminium price in the remainder of this year and 2012 by Alcoa and
UC Rusal, while Rio Tinto, BHP Billiton and
Hydro have been cautious in the near term
outlook (2012/13), but optimistic in the longer term. Alcoa expects a 12% global demand
growth rate in 2011 over 2010. Excluding
China, the company looks forward to an 11%
increase in demand for this year.
German car producer Volkswagen expects
to use more aluminium in 2012, compared
with 2011, in the effort to farther cut carbon
dioxide emissions. Volkswagen hedges up
to 75% of its aluminium need for up to ten
years ahead, according to a company official.
Similar announcements of increased use have
come from other major car producers. The aircraft industry as well placed
record orders at the Paris
Air Show in June, and this
will boost the aluminium
demand in this field of application too.
In the author’s opinion,
high oil prices remain the
major risk for sustainable
recovery of the major global economies. Despite the
fall in recent weeks, oil
prices will rise again on any
sign of economic growth, so
limiting and undermining
full recovery of the global
economy. Even if economic
growth stagnates in the second half of this year the oil
price will remain stable and
relatively high. Only the
scenario of entering recession again would produce
a steep fall in oil prices. The main question
is whether the global economy would avoid
a significant fall, as occurred in the previous
recession, or would it be inevitable once markets lose momentum? Global economic policy
makers have to find a preventative economic
model to avoid higher oil prices that would
drag economies down to even deeper and
more prolonged depression.
The conclusion might be that even improved
conditions for the aluminium market, followed
by a double-digit rise in demand this year, may
not be a guarantee that this trend will continue
in the coming months and even years, resulting in higher prices. The reason for this is that
high oil prices, around and over USD110 per
barrel Brent Crude Oil Futures, may not give
the world economy time to draw breath for a
higher and substantial growth.
Author
Goran Djukanovic is an aluminium market analyst
and a consultant/advisor to the Montenegrin government on aluminium and energy markets. Email:
[email protected]. He is located in Podgorica,
Montenegro.
21
WIRTSCHAFT
SMS group nutzt Chancen im Aufschwung
Der Auftragseingang der SMS-Gruppe betrug
2010 gut 2,9 Mrd. Euro (+25,2%). Der Umsatz ging auf 3,0 Mrd. Euro (-22%) zurück,
doch verbesserte sich die Umsatzrentabilität
auf 8,6 Prozent (2009: 5,7%). Das Gruppenergebnis vor Steuern in Höhe von 262 Mio.
Euro stieg gegenüber dem Vorjahr um 17,5
Prozent. Die beiden Unternehmensbereiche
SMS Siemag und SMS Meer profitierten
etwa in gleichem Maße von der Erholung
der Märkte. So stieg der Auftragseingang der
SMS Siemag um 28 Prozent auf 1,9 Mrd.
Euro und der SMS Meer um 20,6 Prozent auf
1,0 Mrd. Euro. 2010 waren im Jahresdurchschnitt 9.209 Mitarbeiter (2009: 9.001) bei
SMS beschäftigt.
Der Markt für hütten- und walzwerkstechnische Anlagen hat sich im Jahr 2010 spürbar
erholt. Die Zahl der vergabereifen Projekte
ist nach Überwindung der Krise wieder angestiegen, die Auslastung der Kapazitäten in den
Unternehmen der SMS bis Frühjahr 2012 im
Wesentlichen gesichert, wie Heinrich Weiss,
Vorsitzender der SMS group, auf der Jahrespressekonferenz im Juni deutlich machte.
Während sich die Kunden in den Industrieländern weitgehend auf Modernisierungen
SMS group grasps opportunities of the upswing
Recovery in order intake, stable profit,
higher investment in production facilities
and technological innovations are the key
features that characterise the SMS business development in 2010.
The SMS group of metallurgical plant and machinery construction companies attracted an
order intake in business year 2010 totalling
2.9 billion euros (+25.2%). Sales decreased to
3.0 billion euros (-22%); however, net operating margin improved to 8.6% (2009: 5.7%).
The net result for the group, at 262 million
euros, increased by 17.5% compared with the
previous year. The two business areas SMS
Siemag and SMS Meer profited equally from
the upswing on their markets. Specifically, order intake at SMS Siemag was up by 28% to
1.9 billion euros and at SMS Meer by 20.6%
to 1.0 billion euros. The average number of
employees in the SMS group over the year
2010 totalled 9,209 (2009: 9,001).
The market for metallurgical plants and
rolling mill technology bounced back noticeably in 2010. Now, after the crisis has been
overcome, the number of projects open for
bidding has increased and capacity utilisation
in the group companies is essentially ensured
until early 2012, according to Heinrich Weiss,
chairman and chief executive of the SMS
group.
Foto & Grafik: SMS
Erholung beim Auftragseingang, stabiler
Gewinn, höhere Investitionen in Fertigungsstätten und technische Innovationen
– das sind die Schlüsselmerkmale der
SMS-Geschäftsentwicklung im vergangenen Jahr.
Der SMS-Vorsitzende Heinrich Weiss erwartet für
2011 einen weiter steigenden Auftragseingang
SMS chairman and CEO Heinrich Weiss is expecting
a further increase in order intake in the current
business year
While customers in the industrialised countries
are mainly focusing on revamps and business
with new plants is still slow, the situation in the
emerging economies is different. Since the end
of the credit crunch, these countries have resumed their industrialisation drive and investment in new plants is on the rise again. There
is a strong demand for metallurgical plants
above all in India, China, Brazil and smaller
Asian and South American
countries.
In 2010, SMS Siemag
registered healthy interest
in plants for the production
of aluminium and other nonferrous metals, whilst the
group’s other business area,
SMS Meer, achieved its best
results with long product
rolling mills. Project activity
in China was slightly lower
because so much new capacity has already been built up
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further
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the Middle East. Per-capita
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metal consumption in these
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22
ECONOMICS
USA, political instability in the Middle East beschränken und das Neuanlagengeschäft Grundsätzlich rechnet die SMS-Gruppe mit
and the high volatility of prices for raw materi- noch schleppend verläuft, setzt sich der Indus- weiterem Wachstum in Indien, China, Südals all create uncertainty about further growth trialisierungsprozess und damit die Investiti- amerika und dem Nahen Osten. Diese Regionen weisen einen noch vergleichsweion these markets.
se geringen Pro-Kopf-Verbrauch bei
Mr
Weiss
Metallen auf. Allerdings gebe es vor
pointed out: “We
dem Hintergrund der ungelösten Schulmade good use
denkrise in Europa und den USA, der
of the breather
politischen Instabilität im Nahen Osten
provided by the
und der hohen Volatilität der Rohstofffinancial
and
preise Unsicherheiten bezüglich des
economic crisis.
weiteren Wachstums dieser Märkte, so
Bucking the genWeiss.
eral trend, we
Er wies darauf hin, dass man die
increased investZeit der Finanz- und Wirtschaftskrise
ments, put even
genutzt und gegen den allgemeinen
more effort into
Trend die Investitionen erhöht, die
technological detechnische Entwicklung intensiviert,
velopment, updie Fertigungskapazitäten modernisiert
graded our manund die herausgehobene Marktstellung
ufacturing capacider Gruppe auf Zukunftsfeldern wie
ties and enhanced
der Umwelttechnik und der Energieour already strong
einsparung ausgebaut habe.
market position
So hat SMS Meer im Oktober 2010
in areas vital to
eine für rund 22 Mio. Euro errichtete
the future such as
Werkstatt in Shanghai in Betrieb gegreen technology
nommen. Und in Hilchenbach, dem
and energy sav- Auftragseingang nach Geschäftsbereichen in Mio. Euro: insgesamt (grau), SMS Siemag
(rot), SMS Meer (blau) und SMS Kunststofftechnik (gelb)
Stammsitz des vor über 140 Jahren geing.”
gründeten Familienunternehmens, entAs an example, Order intake in million euros: in total (grey column), SMS Siemag (red), SMS Meer (blue)
steht zurzeit eine der modernsten
SMS Meer built a and SMS Kunststofftechnik (plastics technology) (yellow)
Schwermaschinenbau-Werkstätten
new workshop in
Shanghai for some 22 million euros; it was onen in neue Anlagen in den Schwellenlän- Europas mit Investitionen von über 80 Mio.
commissioned in October 2010. Currently, dern nach der Überwindung der Finanzie- Euro. Für das laufende Geschäftsjahr sind InSMS is investing more than 80 million euros rungsengpässe fort. Hierbei werden besonders vestitionen von rund 100 Mio. Euro geplant.
in one of Europe’s most modern heavy ma- Hüttenwerke in Indien, China, Brasilien und Ein Großteil dessen entfällt auf die Errichkleineren asiatischen und lateinamerika- tung und den Ausbau von Fertigungs- und
Service-Werkstätten in China und Indien,
nischen Staaten nachgefragt.
Advertisement
2010 verzeichnete der Unternehmensbe- die weitere Modernisierung der Werkstatt in
reich SMS Siemag ein besonderes Interesse Mönchengladbach und die Fortsetzung der
an Anlagen für die Erzeugung von Aluminium Werksmodernisierung am Standort Hilchenund sonstigen Metallen. Im Unternehmensbe- bach.
Angesichts der regen Anfragetätigkeit erreich SMS Meer entwickelte sich insbesondere der Markt für Profilwalzwerke positiv. In wartet Weiss für 2011 einen Anstieg beim
China war die Projekttätigkeit etwas gerin- Auftragseingang. „Bei Umsatz und Ergebnis
ger, weil bereits in den vergangenen Jahren erwarten wir eine Größenordnung in Höhe
chinery construction workshops in Hilchen- umfangreiche Kapazitäten aufgebaut worden des abgelaufenen Geschäftsjahres“, sagte er.
bach, the seat of the family-owned company sind.
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founded more than 140 years ago. Over the
current business year, SMS plans to invest
some 100 million euros. The majority of this
is earmarked for the erection and expansion
of production and service workshops in China
n
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Based on an improved level of inquiries,
Mr Weiss expects an increase in order intake.
“As for sales and profits, we anticipate that the
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figures for 2011 will be similar to those of the
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N
23
Dubal – world-class in aluminium smelting
In 2010, for the first time
in the its 31-year history,
the Jebel Ali operations of
Dubai Aluminium Company
Limited (Dubal) produced
more than one million metric tonnes of molten aluminium in a single year. Achieving this major milestone
has not only consolidated
the entirely state-owned
enterprise’s standing as one
of the world’s largest singlesite producers of primary
aluminium, but also its determination over the years
to grow into a world-class
global player in a sustainable manner.
Aerial view of Dubal
So says Ali H A M Al Zarouni, vice president
of Smelter Operations, who confirms that
Dubal’s hot metal yield in 2010 amounted
to 1,002,014 tonnes; thereby exceeded the
budget for the year by 9,986 tonnes. “This
success can be attributed to a combination
of factors, starting with the Dubal vision to
rank among the world’s top five in terms of
capacity, the able leadership and guidance our
executive management, and the tremendous
team work across the plant,” says Al Zarouni.
“At plant level, improving our operating pa-
rameters – particularly amperage increases in all potlines –
boosted our production capacity significantly. Other
ongoing improvements in pot
control strategies, operational
practices and technological
advancements also helped us
reach this milestone.”
Topping the one million
metric tonnes mark represents
the culmination of a calculated
growth strategy at Dubal. At
its inception, the company’s
smelter operations comprised
360 smelter pots arranged in
three potlines. Having bathed
up and energised the first pot
(in Potline 1) on 1 November
Photo: Dubal
1979, Dubal produced just
152 tonnes of hot metal in that year. By May
1981, the fledgling plant was fully commissioned, giving an annual production capacity
of approximately 148,000 tonnes.
Following various expansions and modifications, Dubal today has 1,573 operational
Fig. 1: Dubal hot metal production, 1979 to 2010
Fig. 2: Dubal current efficiency (%), 1979 to 2010
Fig. 3: Dubal average amperage (kA), 1979 to 2010
Fig. 4: Dubal specific energy (kWh/kg Al), 1979 to 2010
24
SPECIAL
ward, driven by further productivity gains.
From a technology perspective, Dubal’s
smelter pots feature range of alumina feed
mechanism including Centre Break and Feed
(CB Pots) and Poor Man Point Feed (retrofitted CB pots). The smelter has four different
types of pots (and related reduction technologies), namely CD 20, D20, DX and DX+, each
successive technology enabling higher amperages than its predecessor (see Fig. 3),” says Al
Zarouni. “Many operational and productivity
improvements were also obtained by implementing creative ideas from our continuous
improvement teams and employee participation in the Dubal Suggestion Scheme.”
Importantly, the improved productivity,
capacity and efficiency of the company’s operations has been achieved while maintaining
the highest standards of environmental conservation – particularly reduced energy consumption (as shown in Fig. 4) and emissions.
“In 2010, the specific energy consumption of
our DX Technology pots was less than 13.05
kWh/kg aluminium – which is very favourably against the world average of 15.8 kWh/
kg aluminium1 for our industry,” says Al Za-
rouni. “Perfluorocarbon emissions from our
DX Technology cells were contained at 0.008
CO2eqt/t aluminium, which is far lower than
the industry average of 0.27 CO2eq/t aluminium1. Likewise, the total fluoride emission
level from our Jebel Ali plant was just 0.63
kg/t aluminium, compared to the industry
average of 1.12 kg/t aluminium1. These performance standards will be sustained, if not
bettered, in the year ahead.”
In closing, Al Zarouni lists the following
as the more important contributing factors
to achieve the production record of more
than one million tonnes of hot metal in 2010:
“The excellent co-operation and coordination
among various stakeholders and service departments within Dubal – such as purchasing
and shipping, docks, raw material handling,
power plant, carbon clant, potrooms, casthouse, metal transport, laboratory, maintenance and I.T. – was key,” he concludes. “By
working towards our common goals, we demonstrated Dubal’s corporate slogan – Together,
we shine.”
N
1
International Aluminium Institute
DUBAL
smelter pots arranged in seven potlines. “In
other words, the number of aluminium reduction cells in our Jebel Ali plant has increased
more than three-fold over the years while our
company’s production has risen about sevenfold,” adds Al Zarouni. “In total, Dubal produced 12,341,664 tonnes between the first
metal tapped and 31 December 2010.”
Importantly, Dubal’s annual production
volumes have consistently exceeded design
specifications. “By using advanced in-house
developed technologies, which offer improved
productivity and other operating benefits, and
simultaneously maximising ‘creep’ through
technical and operational improvements to
our existing facilities, we have effectively increased our production capacity,” Al Zarouni
says. The annual growth in Dubal’s hot metal
production is more than 9.8 percent since
1995, as depicted in Fig. 1.
The installed capacity at Dubal’s Jebel Ali
Plant, at 100 percent smelter pot availability
and high current efficiency, is now 1,021,000
tonnes (as shown in Fig. 2, average current efficiency at Dubal in 2010 was close to 95%).
Ever-higher hot metal production is going for-
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25
Gulf Aluminium Council
“A forum to develop strategies for common issues”
Mahmood Daylami, General Secretary of the GAC, in a talk with International ALUMINIUM Journal
Diagrams: GAC
Asked to outline the Gulf Aluminium Council’s objectives, Mr Daylami stressed the
specific difference between GAC and other
aluminium associations in different parts of
the world. “We are not focused on political
lobbying. GAC is more business orientated.
Our main objective is to provide a forum to
develop strategies for common issues related
to operations, logistics, environment, human
resources or health and safety – and to share
best practices so as to improve the efficiency
of the six member smelters.
of our industry all in
“We want to play a catalyst
all,” he said. Accordrole for companies which
ingly, GAC takes care
have aluminium business
not to get involved in
interest in the Gulf and
competitive-relevant
to encourage them to escommercial issues like
tablish their base in the
marketing, production
region,” he said. The aim is
procedures, efficiency
to improve the availability
improvement or negoof related materials, servtiations with suppliers.
ices, spare parts, expertise
As an example of
and logistics, and to reduce
common interest, Mr
cost and time for all parties.
Daylami pointed to
“We are the only body able
the topic of Spent Pot
Lining (SPL). With the
to bring six CEOs to a comanticipated
increase
mon meeting for a technolin the volume of SPL Mr Daylami, general secretary of the GAC
ogy supplier to present his
generation following
project. So he doesn’t need
the start-up of new smelters in the region, a to visit them at six places.”
special GAC task force has been formed with
GAC is a non-profit organisation financed
the mandate to establish a common approach by its member companies. “We also generate
to this subject. As a result, it was decided to ap- small income by offering training or by organpoint a leading technology supplier to conduct ising the Gulf Aluminium Dinner.” Over 250
a feasibility study into building a centralised guests attended this event in March this year:
plant for all Gulf smelters to treat SPL mate- senior executives from aluminium companies,
rials. Another example of common interest: technology providers and equipment supplito reinforce its members’ commitments to ers, power generation manufacturers, traders,
safety and environment protection, GAC will industrial aluminium users, raw material prointroduce annual Safety and Environmental ducers, service organisations, banks, suppliers
Awards – separately for smelters and down- and government officials. “The idea is to have
stream processes – that will honour best prac- chief executives from different parts of the
tice initiatives.
world to get together in an informal, casual
GAC has created a Business Development way – and thus to network and strengthen
Task Force consisting of senior representatives business relationship among one another,” he
said.
How important is the aluminium industry to the Gulf region, compared with other
industrial sectors? “Aluminium is the major
non-oil industry in the Gulf”, Mr Daylami
said. “The total investment is about 40 billion
US-dollars. Another 10.5 billion US-dollars
will be added by the Ma’aden project. The
aluminium industry contributes four to twelve
percent to the GDP, depending on the Gulf
state. It employs some 11,000 people directly
and about 30,000 indirectly. It is creating a lot
of other small- and medium-size companies
that feed the sector. The aluminium industry
is also contributing toward training people in
industrial business. We see a new generation
of skilled people going into industry. Even
women are joining the industry, which is a
very positive sign.”
ALUMINIUM
The aluminium industry in the Gulf has
been developing into a substantial hub
in global terms. Not only has production
capacity been established and expanded
in various Gulf countries, but also diverse
downstream industries have emerged
over the years. Against this background,
the GAC (Gulf Aluminium Council) was
founded in March 2010 by the six primary aluminium smelters in the region –
Alba, Dubal, Emal, Ma’aden, Qatalum
and Sohar – to promote the interests of
the aluminium industry within the region.
Meanwhile, all the major companies engaged in downstream businesses – Alupco, Altaiseer Aluminium, Elite Extrusion,
Garmco, Gulf Extrusions, Kalexco, Oman
Aluminium Processing Industries – have
become members too. At the Aluminium
Dubai exhibition in May this year, this
journal talked to Mahmood Daylami,
general secretary of the GAC.
26
SPECIAL
And the aluminium downstream industry is developing too. Every
Gulf state has got its own development programme. Mr Daylami is convinced that in the long term the downstream sector is
a big growth market. But not in multiplying existing business –
more extrusion companies, a rolling mill and then another one.
“I think, automobile and solar energy could offer good business
opportunities.”
The aluminium industry in the Gulf is mainly export orientated.
80 percent of the products are sold outside the region. “We are
strategically well located to supply the European, Asian and US
markets. The production capacity of our industry exceeds home
market needs by far. The nameplate capacity for primary aluminium in 2011 is 3.5 million tonnes, with Qatalum going into full
production in the course of this year and Emal producing at full
capacity since the beginning of the year. In 2015, capacity will be
about five million tonnes a year with Ma’aden coming on stream
and the expansion project at Emal taken into account.”
Yet, Mr Daylami does not fear overcapacity. “In view of annual
growth in worldwide demand of five percent, we will see a market
requirement of about 70 million tonnes in 2020, compared with
42 million tonnes this year. Five percent, that corresponds to two
or three smelters a year,” he pointed out.
The primary aluminium smelters in the Gulf are low-cost producers due to low energy prices. “But energy supply is still one of
the biggest challenges for our industry. Although the Gulf region
as a whole is rich in oil and gas and all the smelters and their
expansion programmes are secured, the demand for electricity is
rapidly growing in
the Gulf – by ten
to twelve percent a
year,” Mr Daylami
said. That is twice
as much as the
world average of
about six percent.
And some countries have no gas.
“There is a lot of
exploration taking
place in the Gulf states for the discovery of natural gas as an energy
resource for power stations, especially in Saudi-Arabia, Kuwait
and Bahrain. But there are also competing uses for gas. Some
Gulf states are already negotiating with Qatar for the purchase of
gas, as only Qatar has a surplus of this energy source.”
How to quench the thirst for power, apart from buying gas
from Qatar? “Alternatively to gas, you can use crude oil for power generation. In oil-rich Saudi-Arabia, lots of power stations are
run by crude oil or refined products. But that goes along with
higher capital expenditure, and is environmentally more challenging. Last but not least, some consideration was given to
building nuclear power stations in the Gulf. It is difficult to
estimate the impact that the nuclear accident in Japan will have
on this approach.”
Asked to comment on the Aluminium Dubai exhibition taking
place while having this discussion, he said: “I am very pleased with
the exhibition this year. The good thing about the exhibition is that
it is growing. The numbers of participants and visitors have been
growing over the years. But, of course, there is also potential for
improving the activities of the exhibition.”
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innovatherm – Benchmark bei Feuerungstechnologie und Rauchgasreinigung
„Den Prozess als Ganzes im Blick“
Im Jahr 1991 gegründet, hat sich die
innovatherm Prof. Dr. Leisenberg
GmbH + Co. KG in nur zwei Jahrzehnten
zum Weltmarktführer bei Feuerungs- und
Prozessleitsystemen für Anodenbrennöfen entwickelt. Die Ursprünge des
Unternehmens liegen in der Entwicklung
und Herstellung von Gas- und Ölbrennern für Tunnelöfen in der Keramischen
Industrie unter der Manfred Leisenberg
KG. Mit der Gründung von innovatherm
wurde der Fokus verstärkt auf die Aluminiumindustrie gelegt. Bis heute sind mehr
als 130 Produktionsfeuer auf über 50
verschiedenen Anodenöfen im Einsatz.
2006 hat innovatherm erfolgreich begonnen, mit der Rauchgasreinigung von
Anodenbrennöfen ein weiteres Geschäftsfeld zu entwickeln. ALUMINIUM sprach
mit Geschäftsführer Detlef Maiwald und
Vertriebsleiter Domenico Di Lisa über die
Unternehmensentwicklung, Prozesstechnologie und Positionierung im Markt.
Aller Anfang ist schwer, daher verwundert
es nicht, dass in den ersten zehn Jahren nach
Firmengründung zunächst nur wenige Anodenbrennöfen mit Feuerungs- und Prozessleitsystemen von innovatherm ausgerüstet bzw.
auf deren Technologie umgerüstet wurden.
Nachdem dann erste Referenzen nachweisen
konnten, dass der Retrofit bestehender und
Geschäftsführer Detlef Maiwald: „Unsere Anlagen
laufen in einem Automatikbetrieb von über 96
Prozent.“
Managing director Detlef Maiwald: “Our plants
run automatically to an extent of more than 96
percent.”
28
innovatherm – benchmark in firing technology and flue gas purification
“Viewing the process as a whole”
Founded in 1991, in only two decades
innovatherm Prof. Dr. Leisenberg
GmbH + Co. KG became the world market leader for firing and process control
systems for anode baking furnaces. The
root of the company was the development and production of gas and oil
burners for tunnel kilns in the ceramics
industry, under Manfred Leisenberg KG.
With the foundation of innovatherm the
focus was directed more to the aluminium
industry. To date over 130 production
fires on more than 50 different anode
baking furnaces are in operation. In 2006
innovatherm made a successful diversification in developing a new field of business: fume treatment plants for anode
baking furnaces. ALUMINIUM talked to
managing director Detlef Maiwald and
sales director Domenico Di Lisa about the
development of the company, its process
technology and its position in the market.
Beginnings are always difficult and it is therefore not a surprise that in the first ten years
after the company’s foundation only a few
anode baking furnaces were equipped with
firing and process control systems from innovatherm, or converted to its technology. But
once the first references had demonstrated
that the retrofitting of existing and old firing systems brings substantial improvements
of anode quality along with lower operating
costs, the point had been made. “Since 2001
we have seen very dynamic development in
our equipment business for aluminium smelters and anode plants respectively. Our customer’s list includes almost every name, whether
large or small, in the sector,” Mr Maiwald
emphasises.
innovatherm offers two major product lines
for the aluminium industry: namely ProBake
firing and control system for anode baking
furnaces (preheat systems, burner ramps and
cooling systems), and ProClean, fume treatment centres for anode baking furnaces.
A third area of business is ProCast, a charging and melting management system for optimising the production in primary or secondary
casthouses. As Mr Di Lisa explains, this is “a
niche which we want to develop further. We
do have the necessary resources and have already equipped some plants.” However, it is
not easy to extend this business unit as innovatherm does not build melting furnaces but is
specialised toward automation. But Mr Di Lisa
is optimistic that after the economic crisis of
recent years ProCast can be revitalised. “The
product is good and references are available,”
he says, and points, among others, to Alba in
Bahrain, Voerde Aluminium and the Hydro
casthouse in Neuss.
These three product areas represent around
90 percent of innovatherm’s business, while
the remaining ten percent cover the products ProZinc (firing systems for zinc distilling
columns, to produce high-purity zinc for the
cosmetics industry), ProCeram (firing systems
for tunnel kilns) and NovaTronic (plasticity
and moisture control systems for extruders
and forming machines).
The greatest success is certainly ProBake,
which generates most of innovatherm’s business. A look at the present order list shows
company names such as Vedanta, Aluar,
Alumar, Aluminij Mostar and Ma’aden. Most
of the work consists in modernising existing systems originally supplied by competitors, while at the end of the day greenfield
Vertriebsleiter Domenico Di Lisa: „Mit unserer
ProClean-Technologie setzen wir die Benchmark bei
der Rauchgasreinigung, obwohl wir die jüngsten im
Markt sind.“
Sales director Domenico Di Lisa: “Our ProClean
fume treatment technology is benchmark in the
world, although we are the most recent entry in
the market.”
SPECIAL
smelters and new anode plants are not build
‘monthly’. When this does happen, however,
innovatherm is routinely involved – as in the
Ma’aden/Alcoa project. Here, at the beginning of this year an order was received for
the design and supply of seven fires for two
anode baking furnaces in Ras Az Zawr, Saudi
Arabia. The latest ProBake technology will be
installed. The order also covers the design and
supply of the main gas skid systems for both
furnaces. This auxiliary plant will be delivered
already by the end of 2011. In the middle of
next year the first anodes should be produced,
and correspondingly the firing systems will be
provided in the spring of 2012.
ProClean technology
ensure lowest emission values
in die Jahre gekommener Feuerungssysteme
eine deutliche Verbesserung der Anodenqualität und geringere Betriebskosten mit sich
bringt, war der Knoten geplatzt. „Seit 2001
erleben wir eine sehr dynamische Entwicklung
im Ausrüstungsgeschäft für Aluminiumhütten
bzw. Anodenfabriken. Zu unseren Kunden
zählen fast alle großen und kleinen Namen
der Branche“, betont Maiwald.
Im Wesentlichen bietet innovatherm zwei
große Produktlinien für die Aluminiumindustrie: ProBake, das sind die Feuerungs- und
Leitsysteme für Anodenbrennöfen (Vorwärm-, Brenner- und Kühlsysteme), sowie
ProClean, das sind die Rauchgasreinigungsanlagen für Anodenbrennöfen.
Ein drittes Geschäftsfeld ist ProCast, ein
Leitsystem zur Chargenablaufplanung und automatischen Berechnung der Chargenzusammensetzung und Chargierung in Primär- und
Sekundärgießereien. Wie Di Lisa ausführt,
handelt es sich um „eine Nische, die wir gerne weiterentwickeln wollen, wo wir auch über
die notwendigen Ressourcen verfügen und
bereits Anlagen gebaut haben.“ Der Ausbau
dieses Standbeins ist jedoch nicht ganz einfach, weil innovatherm keinen Ofenbau hat,
sondern rein auf die Automation ausgerichtet
ist. Di Lisa zeigt sich jedoch optimistisch, nach
der Wirtschaftskrise der vergangenen Jahre
mit ProCast wieder durchzustarten. „Das
Produkt ist gut und die Referenzen sind vorhanden“, sagt er und verweist unter anderem
auf Alba in Bahrain, Voerde Aluminium und
die Hydro-Gießerei in Neuss.
Diese drei Produktfelder machen heute
rund 90 Prozent des Geschäftes von innovatherm aus, die restlichen zehn Prozent erstrecken sich auf die Produkte ProZinc (Feuerungssysteme für Zink-Destillationskolonnen, um Reinstzink für die Kosmetikindustrie
herzustellen), ProCeram (Feuerungssysteme
für Tunnelöfen) und NovaTronic (Plastizitätsund Feuchteregelungen für Extruder und
Formmaschinen).
Die Cashcow ist zweifellos ProBake, hier
generiert innovatherm die meisten Aufträge.
Wer sich die Auftragsliste des letzten Dreivierteljahres anschaut, dem begegnen Unternehmensnamen wie Vedanta, Aluar, Alumar,
Fotos & Grafik: innovatherm
In the ProClean business sector the situation
is similar to that of ProBake: it is not only or
even mainly about equipping new anode furnaces with a new fume treatment centre. Many
plants in the world that have already existed
for a long time operate entirely without FTC
Das Konzept einer integrierten Rauchgasreinigung und Feuerung wurde erstmals 2008 bei Aluminij Mostar in Bosnien-Herzegowina in die Praxis umgesetzt
The concept of an integrated fume treatment plant and firing system was first put into practice in 2008 at Aluminij Mostar in Bosnia-Herzegovina
29
Aluminij Mostar und Ma’aden. Meist handelt
es sich um die Modernisierung bestehender
Systeme von Wettbewerbern, der Neubau
von Hütten und damit verbunden von Anodenfabriken findet schließlich nicht alle Tage
statt. Wenn doch, ist innovatherm regelmäßig
mit im Geschäft – wie im Ma’aden/AlcoaProjekt: Hier konnte Anfang dieses Jahres
der Auftrag zum Bau von sieben Feuern
für zwei Anodenbrennöfen in Ras Az Zawr,
Saudi-Arabien, gewonnen werden. Installiert
wird die neueste ProBake-Technologie, zum
Auftrag gehört auch die Gaseingangsstrecke
für beide Öfen. Diese Nebenanlage wird bereits Ende 2011 ausgeliefert. Mitte nächsten
Jahres soll die erste Anode produziert werden,
entsprechend werden die Feuerungssysteme
im Frühjahr 2012 bereitgestellt.
Proclean-Technologie sichert
niedrigste Emissionswerte
Im Geschäftfeld ProClean verhält es sich ähnlich wie bei ProBake: Es geht nicht nur oder
vorrangig um die Ausrüstung neuer Anodenfabriken mit einer Rauchgasreinigung. Manche schon lange bestehenden Fabriken in der
Welt arbeiten ganz ohne Rauchgasreinigungsanlage (FTC – Fume Treatment Centre) oder
mit einer veralteten Technologie – und dies
nicht nur in Schwellenländern, sondern teilweise auch in den USA. „Interessant ist neben
dem Neubau, bestehende FTCs mit veralteter
Technik auf den heutigen Stand moderner
Technik aufzurüsten, wie wir es zum Beispiel
bei Aluar in Argentinien gemacht haben“, sagt
Maiwald.
Hier hat innovatherm Anfang dieses Jahres
einen Großauftrag zur Lieferung einer integrierten Anlage erhalten, bestehend aus einer
Trockenadsorbtions-Rauchgasreinigung und
einer neuen Feuerung. Aluar ist ein Altkunde,
der bereits drei Ofenanlagen mit innovathermFeuerungssystemen betreibt. Die bestehende
Rauchgasreinigung wird auf die hoch verfügbare ProClean-Technologie umgerüstet: So
wird ein neuer Konditionierturm gebaut, die
gesamte Trockenadsorbtion erneuert und neue
Filter eingebaut. Durch die direkte Kopplung
von Rauchgasreinigung und Feuerung wird
eine Schnittstelle eliminiert und der Prozess
mit Blick auf die Emissionen wesentlich optimiert. Die Rauchgasreinigung wird zudem
kapazitiv erweitert, da zwei geschlossene Öfen
in offene Öfen konvertiert werden sollen –
eine „echte Herausforderung, das Anlagenlayout mit seinen Gegebenheiten in unsere
Technologie zu konvertieren“, sagt Di Lisa.
Das Konzept einer integrierten Rauchgasreinigung und Feuerung wurde erstmals im
30
Juni 2008 bei Aluminij Mostar in BosnienHerzegowina in die Praxis umgesetzt. Der
Vorteil dieses Konzeptes ist, dass auf eine
regenerative thermische Nachverbrennung
(RTO – Regenerative Thermal Oxidiser) von
Schadstoffen verzichtet werden kann. Dies
spart Investitions- und Betriebskosten einer
solchen Anlage. Bei Mostar konnte seinerzeit
gezeigt werden, dass die strengen Vorschriften
der neuen deutschen TA Luft 2002 auch ohne
RTO eingehalten und unterschritten werden.
Mit der ProClean-Technologie werden
gegenüber Altanlagen sehr niedrige Emissionswerte erreicht: zum Beispiel Fluorverbindungen < 1 mg/Nm3, Reststaub ≈ 5 mg/Nm3,
gesamter organischer Kohlenstoff (TOC)
< 1 mg/Nm3, PAKs < 0,1 mg/Nm3. Bei der
Schwefeladsorbtion werden Minderungen
bis zu 50 Prozent erreicht. Dies gelingt unter
anderem durch verfahrenstechnische Verbesserungen im Konditionierturm, in dem
die Rauchgase vorbereitet und so abgekühlt
werden, dass die Schadstoffe besser adsorbiert werden. So erzeugen spezielle Zweistoffdüsen einen feinsten Wassernebel, durch
den sich Aerosole aus den Schadstoffen im
Gas bilden, die dann in der Reaktorkammer
an Aluminiumoxid als Adsorbent angelagert
werden.
Di Lisa weist darauf hin, dass die spezifische
Prozesstechnologie, wie sie innovatherm entwickelt hat, ein gewisses Alleinstellungsmerkmal aufweist – indem die bekannte Technologie der Trockenadsorption mit innovativem
Verfahrens-Knowhow vereint wird. „Das
Rauchgasreinigungsprinzip – Trockenadsorp-
fume gas cleaning (FTC – Fume Treatment
Centres) or with antiquated technology – and
this, not only in developing countries but in
some cases even in the USA. “Besides newly
built plants, it is interesting to retrofit existing FTCs whose technology is outdated and
bring them up to present-day technological
standards, as we did for example at Aluar in
Argentina,” Mr Maiwald says.
From there, at the beginning of this year
innovatherm received a large order for the
supply of an integrated plant consisting of a
dry-adsorption fume treatment plant and a
new firing system. Aluar is an ‘old’ customer
and already operating three furnaces with innovatherm firing systems. The existing fume
treatment plant is being retrofitted with the
high-availability ProClean technology: a new
cooling tower for gas conditioning and cooling
is being built, the entire dry-adsorption unit is
being renewed and new filters are being incorporated. Thanks to the direct link of the fume
treatment plant and the firing, an interface is
eliminated and the process substantially improved in relation to emissions. The capacity
of the plant is also being enlarged since two
closed furnaces are to be converted to open
furnaces. “To convert the plant layout with its
particular features to our technology is a real
challenge,” Mr Di Lisa says.
The concept of an integrated fume treatment plant and firing system was first put into
practice in 2008 at Aluminij Mostar in BosniaHerzegovina. The advantage of the concept is
that it does not ask for a Regenerative Thermal
Oxidiser (RTO) to treat harmful pollutants.
Anfang 2011 wurde innovatherm von Aluar beauftragt, die Rauchgasreinigung zu modernisieren und eine
neue Feuerung zu installieren
Early in 2011, innovatherm received a large order from Aluar to retrofit the fume treatment plant and to
install a new firing system
SPECIAL
tion – ist bei allen Anbietern gleich: Jeder
hat einen Konditionierturm, jeder eine Art
der Alumina-Aufgabe
und jeder das Herzstück der Anlage, den
Gewebefilter. Aber wo
man Alumina aufgibt,
wie man rezierkuliert,
wie man mit Temperaturen spielt, wie ich
Wasser eindüse, wie
ich das Gas im Kühlturm führe, sind die
kleinen Spezialitäten,
in denen sich die UnAluminium Bahrain (Alba) war 2002 die erste Top-Referenz für die ProBakeTechnologie
ternehmen unterscheiden.“
innovatherm
With the installation of the ProBake technology at Aluminium Bahrain (Alba)
in 2002 the success story ‘took off’
nimmt für sich in Anspruch, hier BenchThis saves the investment and operating costs marks zu setzen, „und dies, obwohl wir die
of such a unit. At the same time it was shown jüngsten im Markt sind“, so Di Lisa.
Bei Mostar erhielt innovatherm auch den
at Mostar that the strict provisions of the new
German TA Luft 2002 were complied with Auftrag für das Feuerungssystem des Brennofens. Der Vorteil der integrierten Lösung
and improved upon, even without RTO.
Compared with old plants, very low emis- aus FTC und Feuerung liegt auf der Hand.
sion values are achieved with ProClean tech- „Die Feuerung produziert die Rauchgase, wir
nology: for example fluorine compounds kennen ihre Zusammensetzung, und das FTC
< 1 mg/Nm3 (Nm3 – standard cubic metre), re- muss sie reinigen. Es gibt also nicht nur eine
sidual dust ≈ 5 mg/Nm3, total organic carbon konzeptionelle, sondern auch eine physische
(TOC) < 1 mg/Nm3, PAHs < 0.1 mg/Nm3. With Verbindung durch Rohrleitungen“, sagt Di
sulphur adsorption, reductions of up to 50 Lisa.
Die Zusammensetzung der Rauchgase
percent are achieved. This happens, inter alia,
by virtue of process-technological improve- hängt unter anderem von den Temperaturen
ments in the gas conditioning tower in which ab, mit denen der Feuerungsprozess gefahren
the fumes are prepared and therefore cooled wird. Feuer, das heißt Gas einbringen und
so that the pollutants are better adsorbed. Verbrennungsluft heranführen, eine TemSpecial two-phase nozzles produce a very peratur von etwa 1.160 °C erzeugen, damit
fine water mist by which aerosols are formed die Anode verkokt, die Anoden kontrolliert
from the pollutants present in the gas, which aufheizen und kühlen sowie die Rauchgase
are then adsorbed on aluminium oxide in the absaugen und reinigen. „Das alles bezeichnen
wir als ein Feuer. Wir haben es allerdings mit
reactor chamber as an adsorbed deposit.
Mr Di Lisa points out that the specific proc- einem Zyklus aus mehreren Feuern zu tun,
ess technology developed by innovatherm has die auf dem Anodenofen umlaufen. Dieser
a certain unique feature, in that the known dry- komplexe Vorgang verlangt unterschiedlichsadsorption technology is combined with in- tes Fachwissen, das bei uns über Feuerungsnovative innovatherm
process
know-how.
“The fume treatment
technology – dry adsorption – is the same
from any supplier: they
all have a conditioning
tower, an alumina injection, and the core
of the unit, the fabric
filter. But where the
alumina adsorbs, how
Temperaturabweichungen beim Anodenbrennen seit 1970
recirculation
takes
Standard deviation of anode temperature distribution since 1970
bauer, Brenner- und Prozessspezialisten und
Automatisierer verfügbar ist. Auf diese Weise
haben wir den Prozess als Ganzes im Blick –
ein maßgeblicher Faktor unseres Erfolges“,
sagt Maiwald.
ProBake – niedriger Energieverbrauch
bei verbesserter Anodenqualität
Früher, vor 20, 30 Jahren war die Anodenqualität entscheidend von der Erfahrung des
Feuermannes abhängig, die Feuerungssysteme
wurden manuell gesteuert, zum Teil ist dies
sogar heute noch der Fall. „Die Erfahrung
der Feuerleute haben wir in mathematische
Modelle umgesetzt, um einen automatisierten
Betrieb mit reproduzierbarer, gleichbleibend
hoher Anodenqualität sicherzustellen. Unsere Anlagen laufen in einem Automatikbetrieb
von über 96 Prozent. Damit geht eine enorme
Qualitätsverbesserung einher“, so Maiwald.
Das lässt sich auch an der Glockenkurve (s.
Grafik) ablesen: Um 1970 lagen die Temperaturabweichungen beim Anodenbrennen bei
+/-60 °C (rote Kurve). Mit der Einführung einer automatisierten Temperatursteuerung der
Feuerschächte in den 1980er Jahren konnte
dieser Wert auf +/-30 bis 40 °C verringert
werden (blaue Kurve). Dieser Wert repräsentiert in etwa den Industriedurchschnitt im
Praxisbetrieb. Mit der automatisierten und optimierten Steuerung der Wärmeübertragung in
der Vorwärmzone über den gesamten Brennzyklus konnte diese Temperaturabweichung
auf +/-15 °C weiter verringert werden (gelbe
Kurve), dies kennzeichnet den heutigen Stand
der Technik. innovatherm bewegt sich dank
weiterer Optimierungsmodule laut Maiwald
entlang der grünen Kurve mit einer Abweichung von nur noch +/-10 °C. Durch diese
ausgezeichnete Temperaturverteilung in den
Anoden sind lokale Überhitzungen ausgeschlossen, was ihrer Qualität zugute kommt.
Zwei technologische Besonderheiten bei
innovatherm: Die Abgase werden schon an
der Brennrampe gemessen und auf eine bessere Rauchgasqualität geregelt. Der Kühlprozess ist zudem mit einer Nulldruckrampe
ausgestattet, auf die der eine oder andere Anbieter verzichtet. Diese Rampe verteuert das
Investment, doch geht sie mit weiteren Energieeinsparungen und einer besseren Anodenqualität einher. innovatherm beherrsche den
Prozess auch ohne Nulldruckrampe, so Di
Lisa, und in den ersten Jahren komme man
vielleicht ohne eine solche Komponente aus.
„Aber der Ofen altert kontinuierlich und man
will ja auch in zehn, 15 Jahren noch eine gute
Anodenqualität produzieren. Die Rampe kann
dazu einen wichtigen Beitrag leisten“, sagt er.
31
Bei Sohar Aluminium in Oman hat innovatherm 2009 erstmalig drei Feuer mit zehn
Feuerschächten in ProBake-Technologie installiert. Das Feuerungssystem weist mit 1,76
GJ pro Tonne Anode den niedrigsten Energieverbrauch branchenweit auf – „die absolute
Benchmark in der Welt“, so Maiwald.
Dahin zu kommen war ein Weg von etwa
zehn Jahren. 2001 hatte das Unternehmen
Kontakt zu Alba in Bahrain, wo drei Öfen mit
Wettbewerbssystemen liefen, die von innovatherm modernisiert wurden. „Wir konnten
mit unserer Technologie 20 Prozent Energie
einsparen und die Anodenqualität deutlich
verbessern. Für uns war Alba damals die
Top-Referenz und Initialzündung. Die Hütte betreibt heute fünf Anodenbrennöfen, die
alle mit unseren Systemen ausgestattet sind“,
so Di Lisa. Das Unternehmen produzierte im
vergangenen Jahr 850.000 Tonnen Aluminium und entsprechend rund 425.000 Tonnen
Anoden.
Mit Alba nahm die dynamische Erfolgsgeschichte ihren Lauf, die Referenzliste von
Folgeaufträgen in den darauf folgenden Jahren umfasst Unternehmen wie Nalco, Alcan
Lynemouth und Sebree, Hydro Ardal, Dubal, Alouette, Rusal Sayanogorsk, Noranda.
Im April 2006 wurde mit dem weltgrößten
Aluminiumproduzenten Alcoa ein Master
Agreement abgeschlossen. „Seitdem sind wir
alleiniger Ausrüster für Alcoa weltweit“, erklärt Maiwald, „und haben eine Vielzahl von
Alcoa-Werken und -beteiligungen aus- und
umgerüstet.“ Maiwald führt u. a. Massena,
Tennessee, Point Henry, Portland, Mosjoen
(Norwegen) an. Ganz aktuell ist der Auftrag
von Alumar in Brasilien, wo Alcoa eine Mehrheit hält. Dabei geht es um die Modernisierung der Feuerungssysteme auf den Öfen 1, 2,
und 3 und die Umstellung von Dieselöl auf
Flex-Gas.
Natürlich ist der Ma’aden-Auftrag von
Anfang 2011 ein besonderes Highlight. Mit
dem Bau von sieben Feuern für zwei Anodenbrennöfen ist er ein Großauftrag, wenngleich
nicht der größte. Für Vedanta in Indien arbeitet innovatherm den größten Einzelauftrag
ab, der je vergeben wurde: 15 Feuer auf sechs
Brennöfen. Bei Ma’aden wird die Anlage mit
zehn Heizkanälen nebeneinander gebaut, üblich sind acht oder neun Feuerschächte. Eine
solche Anlage wurde erstmals bei Sohar gebaut und spiegelt womöglich einen Trend zu
immer breiteren Anlagen wieder. „Die normale Rampenbreite ist 12 Meter, hier reden wir
von 15 Metern, mit mehr Regelkreisen“, sagt
Di Lisa.
Bei Ma’aden wird zudem die neueste Anlagensicherheits-Philosophie integriert – gemäß
32
Die ProBake-Feuerung bei Sohar Aluminium weist branchenweit den niedrigsten spezifischen Energiewert auf
The ProBake firing at Sohar Aluminium has the lowest specific energy consumption anywhere in the sector
der Sicherheitsnorm EN 746 – Industrielle
Thermoprozessanlagen / Teil 2: Sicherheitsanforderungen an Feuerungen und Brennstoffführungssysteme – die 2010 novelliert wurde.
„Diese Novelle hat enorme neue Anforderungen an die Sicherheitstechnik von Feuerungssystemen gebracht“, sagt Maiwald. Die
Anforderung, die EN 746 umzusetzen, kam
vom Kunden, da Saudi Arabien in diesem Bereich keine eigene Norm hat.
Das Geschäft läuft also auf Hochtouren.
Die Wirtschaftskrise, die Ende 2008 den
Stopp sämtlicher Branchenprojekte innerhalb
weniger Wochen mit sich brachte und über das
gesamte Jahr 2009 zu einer Durststrecke für
sämtliche Ausrüster der Aluminiumindustrie
führte, ist Vergangenheit.
Seit 2006 hatte das Unternehmen eine
Vertretung in den USA, seit Anfang 2009
gibt es dort eine Tochtergesellschaft, die den
nordamerikanischen Markt bedient. Seit
2001/02 gibt es ein 50:50 Joint Venture in
Indien, mittlerweile auch Vertretungen in
China, Russland, Bahrain und Venezuela.
„Damit haben wir über die Jahre ein Netzwerk aufgebaut, mit dem wir in allen Kontinenten vertreten sind“, erklärt Maiwald.
Selbst Australien ist seit dem Master Agreement mit Alcoa und der jüngsten Vertretung
durch Webb Australia längst kein weißer
Fleck mehr. Neben den Retrofits für AlcoaHütten wurden auch ProBake-Projekte für
Rio Tinto Alcan (Boyne Smelter) gewonnen,
sodass rund 60 Prozent des australischen
Marktes mit innovatherm-Technologie ausgerüstet ist.
place, how the temperatures are controlled,
how the water is sprayed, how the gas is guided into the cooling tower: these are the little,
specialised details in which companies differ.”
Innovatherm claims to set benchmarks in these
respects “and this, although we are the most
recent entry to the market,” he says.
At Mostar innovatherm also received the
order for the firing system of the baking furnace. The advantage of the integrated FTC
and firing solution is easy to understand. “The
fire produces the fumes, we know their composition, and the job of the FTC is to clean
them. Thus, there is not only a physical connection via ducts but in particularly a conceptual
association,” he explains.
The composition of the fumes depends,
among others, on the temperatures at which
the firing process is operated. A fire – that is
drawing in gas, adding combustion air, producing a temperature of around 1,160°C so that
the anode is carbonised, heating and cooling
the anode in a controlled manner, and drawing
off and purifying the fumes. “We call all of
that a ‘fire’. But we have to deal with a cycle
of fires that circulate in the anode furnace.
This complex process demands a wide range of
technical knowledge, which is available to us
from firing engineers via burner and process
specialists to automation experts. In that sense
we view the process as a whole – a decisive
factor for our success,” Mr Maiwald says.
N
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ity depended decisively on the experience of
the furnace operator, the firing systems were
controlled manually, and this is sometimes
still the case nowadays. “We have interpreted
the experience of the furnace operator in
terms of mathematical models in order to ensure automated operation with reproducible,
constant and high anode quality. Our plants
run automatically to an extent of more than
96 percent. This results in enormous quality
improvement,” he says.
This can also be seen from a bell-shaped
curve (see diagram): in the 1970s the temperature spread of the final anode temperature was ± 60°C (red curve). With automatic
control of the flue temperatures in the 1980s
the spread could be
reduced
between
± 30°C and ± 40°C (blue
curve). That value represents approximately
the industrial average
in practical operation.
Including the automatic
and optimised control
of the heat transfer in
the preheat area over
the full baking cycle, the spread can be
brought down to ± 15°C
(yellow curve). This is
now the typical state of
the art. But according
to Mr Maiwald, thanks
to further optimisation
modules innovatherm
is moving along the green curve, still with
some scatter but now only ± 10°C. Owing
to this outstanding temperature distribution
in the anodes local overheating is excluded,
much to the benefit of anode quality.
Two special technological features at innovatherm are: the exhaust gases are already
measured at the burner ramp and adjusted for
a better fume quality. The cooling process is
also equipped with a zero-point ramp, which
some suppliers do without. This ramp admittedly adds cost to the investment, but brings
further energy savings and better anode quality. innovatherm masters the process without
a zero-point ramp, says Mr Di Lisa, and in
the early years one could perhaps omit such a
component. “But any furnace is getting older
all the time, whereas one wants still to produce good-quality anodes in 10 or 15 years.
The ramp can make an important contribution
toward this,” he says.
At Sohar Aluminium in Oman, in 2009 innovatherm installed three fires on a ten flue
baking furnace. Operated with only 1.76 GJ
per tonne of baked anodes the firing system
has the lowest energy consumption anywhere
in the sector – “the absolute benchmark worldwide,” Mr Maiwald says.
To arrive at this point has taken around ten
years. In 2001 the company made contact with
Alba in Bahrain, where three furnaces with
systems supplied by competitors were modernised by innovatherm. “With our technology we were able to achieve energy savings
of up to 20 percent along with substantially
improved anode quality. For us, at the time
Alba was the top reference and our ‘ignition
point’. Today the smelter operates five anode
baking furnaces, all of them equipped with
our systems,” says Mr Di Lisa. Last year the
furnaces, it is a major contract although not
the largest. innovatherm is working on the
largest individual contract ever awarded in
the industry. For Vedanta Aluminium in India
15 fires for six baking furnaces are being built.
At Ma’aden the furnaces are being built with
ten flues, the usual number being eight or nine
flues. Such a plant was built for the first time
at Sohar and, if anything, reflects a trend toward ever-wider carbon bakes. “The normal
ramp length is around 12 metres, but here we
are talking about 15 metres and more, with
more control loops,” Mr Di Lisa says.
At Ma’aden the latest plant safety philosophy is also being integrated – in accordance
with Safety Standard EN 746 – Industrial thermoprocessing equipment / Part 2: Safety requirements for combustion and fuel handling
systems – as amended
in 2010. “This amendment has imposed huge
new requirements on
the safety technology
of firing systems,” Mr
Maiwald says. The request to design the firing system according to
the European Standard
EN 746 came from the
customer, since Saudi
Arabia has no standard
of its own in this field.
So business is proceeding briskly. The
economic crisis, which at the end of 2008 put
a stop to all projects in the sector within a few
weeks and, during the whole of 2009, led to
hard times for all the aluminium industry’s
equipment suppliers, is a thing of the past.
Since 2006 the company had a representing agency in the USA and since the beginning of 2009 a subsidiary has been serving
the North-American market. Since 2001/02
there has been a 50:50 Joint Venture in India,
and meanwhile agencies have been set up in
China, Russia, Bahrain and Venezuela. “So
over the years we have built up a network
with which we are represented on every continent,” Mr Maiwald underlines. Since the
Master Agreement with Alcoa and a representation by Webb Australia, the Australian
market has no longer been a blank patch on
the map. Besides retrofits for Alcoa smelters,
ProBake projects for Rio Tinto Alcan (Boyne
smelter) have also been ordered, so that about
60 percent of the Australian market is or will
be equipped with innovatherm technology.
innovatherm customers – worldwide
34
company produced 850,000 tonnes of aluminium and, correspondingly, around 425,000
tonnes of anodes.
With Alba the dynamic success story ‘took
off’: the reference list of follow-up orders in
the years after includes companies such as
Nalco, Alcan Lynemouth and Sebree, Hydro
Ardal, Dubal, Alouette, Rusal Sayanogorsk
and Noranda. In 2006 a Master Agreement
was concluded with Alcoa, the world’s largest aluminium producer. “Since then we have
been the sole equipment supplier for Alcoa
worldwide,” Mr Maiwald points out, “and we
have equipped and retrofitted many Alcoa
plants.” Among others, he mentions Massena,
Tennessee, Point Henry, Portland and Mosjøen (Norway). Just now there is an order
from Alumar in Brazil, in which Alcoa holds
a majority. This involves modernising the firing systems of the furnaces 1, 2 and 3 and
converting from diesel oil to flex-gas.
Of course, the Ma’aden contract in early
2011 is a particular highlight. Involving the
supply of seven fires for two anode baking
N
SPECIAL
Happy birthday, aluminium!
125 years adding value to society
This year marks the anniversary of a
discovery that has not only improved
our lives, but plays an eminent role for
sustainable development. Safer and more
fuel efficient transportation, energy efficient buildings, infinitely recyclable packaging, all that has been possible with the
help of this discovery made 125 years ago
which enabled the production and the use
of aluminium on an industrial scale.
The smelting process to produce aluminium
was discovered almost simultaneously but independently in 1886 by Charles Martin Hall in
the United States and Louis Toussaint Héroult
in France. Both men dissolved aluminium oxide in molten cryolite and then extracted the
aluminium by fused-salt electrolysis – the
foundation for a dynamically developing industry in the past 100 years. Whereas world
production of aluminium was 46,000 tonnes
in 1911, world production in 2011 will rise to
more than 46 million tonnes.
The first aluminium smelter to start production, in August 1888, was Aluminiumindustrie AG (AIAG) in Neuhausen am Rheinfall
in Switzerland. There followed a smelter in
Pittsburgh, USA, in December 1888 and then
two smelters in France in 1889. Further developments were needed, however, so at first
aluminium production remained modest. It
was also necessary to first establish sales channels. There was an upswing when AIAG reduced the price of aluminium to a quarter of
its previous value in 1890/91. The first smelter
in Germany was built by AIAG in BadischRheinfelden in 1897. However, until the patents of Héroult and Hall expired, in 1903 and
1906 respectively, the number of companies
and smelters remained small.
Today, thousands of products can be made
safer, lighter, more energy efficient and fully
recyclable thanks to aluminium: from cars,
trains or aircraft to cookware, packaging and
electrical conductors. Almost three-quarters of
all aluminium ever manufactured (700m t) is
still in use thanks to its and excellent recyclability. No material other than aluminium can
combine the advantages of being light and
strong, totally recyclable, resistant to corrosion, completely impermeable, and an excellent conductor of heat and electricity.
“In the 125 years since this discovery,
the variety of applications for aluminium has
grown apace and will continue to contribute
to sustainable development and energy efficiency gains in Europe,” says Patrick de
Schrynmakers, secretary general of the European Aluminium Association (EAA), which
has recently released the third edition of its
sustainable development indicators (SDIs) report, available at www.eaa.net. This latest iteration of the SDI exercise includes, for the first
time, indicators covering the use of aluminium
in key applications in addition to more than
thirty sustainable development indicators on
the production phase. The report clearly demonstrates the sectors contribution to achieving
overall sustainability goals.
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25 years of R & D Carbon: a success since 1986
By Werner K. Fischer, Dr. Ulrich Mannweiler and Jean-Claude Fischer, R & D Carbon
R & D Carbon, based in Sierre, Switzerland is celebrating its 25th anniversary this year. From
humble beginnings, the company now has a worldwide established presence in the industry.
After 20 years of successful development
work in the field of carbon materials at
Swiss Aluminium Ltd. (Alusuisse), Werner
K. Fischer started his own business in 1986.
He took over carbon materials development
projects from Alusuisse, which had decided to
abandon this sector. He had a clear vision of
what the industry needed: an ever better understanding of how anode quality depends on
raw material properties and on process parameters. He built a technology centre in Sierre,
Switzerland, where employees of the former
carbon research group of Alusuisse found
a new workplace. Together with Ulrich Mannweiler, also a former Alusuisse man who
joined RDC in 1988, he set up a new strategy
which is still valid today:
R&D Carbon (RDC) shall become the
world leading supplier of know-how in the
field of carbon technology. A multi-disciplinary and laterally thinking team shall serve the
aluminium, petroleum coke, pitch and electrode industries worldwide. With its extensive
experience, and through intensive research in
carbon technology, RDC will improve anode
quality, so reducing metal production costs
and lowering capital investment for production plants.
RDC established six distinct areas of activity, each having its clear role:
• Research & Development
• Laboratory Test Equipment
• Technical Services
• Baking Furnace Production Control System
• Technology Development
• Training and Workshops
What has been achieved in the past 25
years?
Research & development
Together with universities in New Zealand,
Switzerland and China, seven PH.D dissertations were completed, relating to raw material
and to process improvement. The subjects include anode properties and anode behaviour,
heat treatment of anodes during baking, as
well as an in-depth understanding of Chinese
raw materials.
More than 100 technical papers were published in renowned journals. Several com-
36
prehensive handbooks were published, e. g.
Anodes for the Aluminium Industry, Fundamentals in Anode Baking. 20 international
awards were received from TMS, Light Metals,
Chalco, DKG and other societies.
More than 50 patents in process and product development were granted.
Laboratory test equipment
65% of the worldwide anode production is
currently evaluated using equipment sold by
RDC. In more than 100 laboratories on all
continents RDC has installed and maintains
some 1,200 instruments for testing properties
of raw material and anodes. The corresponding test methods have all been approved by
ISO, DIN or ASTM.
Technology development
During three decades RDC has collected extensive results from research and development
work, as well as through quality improvement
programs.
Through its know-how and practical experience in operating and optimising anode
plants for customers all over the world, RDC
has proposed and implemented many modern,
efficient concepts and designs for paste plants
and anode baking furnaces.
Low investment and operating cost, as well
as efficient reduction of emissions, make these
concepts attractive for new green-field plants
as well as for refurbishing existing anode
plants.
Training and workshops
Technical services
Technical services provided to many customers around the globe are one of RDC’s core
businesses. The services range from technical
support for the production of all carbon materials, to plant audits and process optimisations. In its technology centre, RDC conducts
pilot or bench scale trials, as well as any kind
of laboratory tests and analysis, according to
standardized ISO methods.
Technical assistance to companies active
in worldwide trading is an important way to
improve anode and cathode qualities supplied
to the world market. An example of its success
is the ‘Swiss Anodes Made in China Quality
Model’, operated together with RDC’s American partner Aminco Resources LLC. During
ten years of cooperation, this model has assured the quality of more than 1 Mt of anodes
produced, tested, and exported to customers
worldwide.
RDC organises conferences in the field of carbon products for the aluminium industry, as
well as training courses on anode raw materials, anode production and anode behaviour
in smelters. Training courses are held in Switzerland or abroad (Middle East, China, North
America, Brazil) on-site, tailored to customers
needs.
R&D Carbon Technology Centre
Its headquarters in Sierre, Switzerland employs 20 engineers and skilled technical staff.
They serve more than 150 customers worldwide, and maintain an excellent network with
technology and trading companies.
Cooperation with well-known business development companies has led to new business
around the globe. During the past ten years
RDC’s focus has been China.
The future
Baking furnace
production control system
Thanks to 30 years experience in developing,
manufacturing and operating baking furnace
process control systems, RDC systems today
operate 40 bake furnaces (100 fires) worldwide. The control system is an integral part of
the overall production control.
A new generation of young engineers are
taking over important tasks in the business.
The succession is guaranteed as Jean-Claude
Fischer, the owner’s son, already plays an
active role in the business of R&D Carbon.
The future for RDC is bright. More details at
www.rd-carbon.com
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News from the aluminium smelting industry
Commissioning of power plant
further delays Qatalum ramp-up
The power plant is being built for Qatalum by
a consortium between General Electric (GE)
and Doosan under a turn-key contract, but
is now significantly delayed compared to the
original project plan. Hydro will revert with
an update on the status of the power plant and
production ramp-up at its second quarter 2011
earnings release on 26 July.
is soon expected to become a net importer of
primary aluminium because of booming demand and stagnant local production.
on regulatory approvals and an agreement on
the price of electricity, among other things, he
said. The aluminium smelter will have a capacity of 750,000 tpy, according to the initial
plan. According to media reports, 1Malaysia
Development plans to complement the smelter
with other associated factories including an
aluminium rolling mill, a cable plant, a casting plant and ten extrusion outfits with an additional investment of USD1.8bn. Mubadala
will not participate in those ventures.
The projects are expected to create 10,000
jobs during construction and 2,000 specialist
jobs on completion.
The expected growth in aluminium demand
is about six percent a year for the next ten
years, according to industry representatives.
Related to a consumption of about 42 million
tonnes in 2011, 6% growth necessitates an
dditional production of 2.4m to 2.5m tonnes
every year. Much of that new production is
expected to come from the Gulf and Asia. In
addition to Emal, the Gulf has some of the
world’s biggest new smelter projects, including
in Oman, Qatar and Saudi Arabia.
Norsk Hydro
Qatalum, the 50/50 joint venture aluminium plant between
Qatar Petroleum and Hydro, is
experiencing further delays in
reaching full production due to
challenges with the commissioning of the power plant’s steam
turbines. Qatalum, currently
producing at 70% capacity, now
expects to reach full production
by the end of September 2011.
Further ramp-up is dependent
on successful commissioning
and performance testing of the
two steam turbines. According
to the former ramp-up plan,
Qatalum should have run at
full 585,000 tpy capacity from
June 2011. Currently, 490 pots
of a total of 704 are in operation, representing about 70 %
of total capacity. The producing
pots are operating well and according to specifications.
Qatalum is expected to reach full production by the end of Q3
Argentina’s Aluar looks to enter
Brazilian aluminium market
Aluar, Argentina’s sole primary aluminium
producer, is looking to enter the Brazilian
market and may build a plant in the country.
The company will postpone the final phase
of the primary aluminium expansion at its
Puerto Madryn smelter – to 520,000 tpy from
460,000 tpy – to focus on increasing extrusion billet capacity. The additional billet will
be mainly for the Brazilian market, where
demand is booming and imports of several
aluminium products, including ingot and billet, are increasing.
The billet expansion at Puerto Madryn is
expected to cost USD80m. Brazil receives
some 30% of Aluar’s export shipments at
present. Some 139,551 tonnes of aluminium
products were exported to Brazil between
January and April, nearly double the 71,059
tonnes exported in the corresponding period
of 2010. Of these totals Argentina accounted
for 24,394 tonnes in the first four months of
2011 from 13,141 tonnes a year earlier. Brazil
38
Mubadala Development and
1Malaysia Development to build
a USD4bn aluminium plant in Malaysia
Mubadala Development, Abu Dhabi’s strategic
investment company, has launched a joint venture to build a USD4bn aluminium complex
in Malaysia. The preliminary deal with 1Malaysia Development is to deepen the involvement of Mubadala Development in one of
the world’s fastest-growing metals markets.
“We want to invest in aluminium smelters in
places that have similar advantages to Abu
Dhabi with competitive energy costs and good
logistics,” said Waleed al Muhairi, Mubadala’s
chief operating officer, according to media
reports.
The agreement to build the smelter in
Sarawak, on the island of Borneo, was still
preliminary and its execution would hinge
Tom Johansen new CEO of Qatalum
Tom Petter Johansen (53) from Hydro has
taken over as chief executive of Qatalum on 1
July. He succeeds Jan Arve Haugan, who is
taking on a new position as CEO of Norwegian
oil and gas contractor Kvaerner. To date, Mr
Johansen was in charge of Hydro’s fully owned
smelters. He has been with Hydro since 1985,
holding a number of management positions,
including sector president of Hydro Magnesium and of Hydro Automotive Structures
North Europe. He has also been plant manager
at Høyanger primary aluminium and at Årdal
primary aluminium plants in Norway.
SPECIAL
INNOVATION LEADS TO A NEW GENERATION
USE THE ORIGINAL
BCT PASTE KNEADER – FOR MORE
Productivity
Efficiency
Reliability
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BUSS ChemTech AG
Hohenrainstrasse 12A, 4133 Pratteln 1, Switzerland
Tel. +41 (0) 618 256 462, Fax +41 (0) 618 256 737
[email protected]
www.buss-ct.com
Rusal starts modernising
Urals and Siberian plants
UC Rusal is launching an environmental modernisation at four of its plants. The total investment into these projects is expected to amount
to RUR5.5bn (approx. USD200m).
New environmental projects have started at
three Urals plants – the Bogoslovsky Aluminium Smelter, the Urals Aluminium Smelter,
the Urals Silicon Plant – and at the Achinsk
Alumina Refinery (AAR) in Siberia.
At AAR Rusal will reconstruct the gas purification systems of sintering furnaces 5 and
6 and will create a new waste storage area.
After the reconstruction, plant efficiency will
reach 99.8% and the new waste storage area
will enable the refinery to extend the waste
storage terms up to 20 years in compliance
with all the environmental law requirements.
Total environmental investment at AAR will
exceed RUR2.5bn.
Rusal will install a dry gas purification
system at its Urals Silicon Plant. This should
decrease mineral dust emissions 150-fold
with SiO2 > 70%. The company estimates this
project to cost up to RUR650m. The Urals
Aluminium Smelter is going to reconstruct the
waste storage field 2 and reconstruct waste
storage field 3 to prolong its service up to
2027. The cost of the project is expected to
be RUR750m. An extended RUR1.5bn waste
storage field will also be built at the Bogoslovsky Aluminium Smelter. The realisation
of these environmental projects will establish
a base for Rusal’s future growth and enable
production increase in accordance with environmental standards as the world’s demand
for aluminium continues to rise.
The environmental actions of the company
serve to modernise and to upgrade 50 to 60
years old production facilities and to develop
new environmentally friendly aluminium production technologies for greenfield developments. Rusal is committed to minimising the
impact of its operations on the environment.
About 80% of their aluminium is produced
using climate-neutral hydro energy. Rusal is
also the first Russian company to join UNDP
Climate Change Initiative.
Alba sales soar 4.3% in H1
Aluminium Bahrain (Alba) improved sales
in the first half of 2011 by 4.3% to 445,370
tonnes, compared with the corresponding period in 2010. Production figures in the year to
June were up by 3.5% from 421,659 tonnes.
The company has boosted value-added sales
in the European market, and the opening of
a sales office in Zurich, Switzerland, will further support this development. For at least the
next few years the smelter’s full production is
earmarked for customers in the Middle East,
Europe and Asia.
Alba, which operates a primary aluminium
smelter in Bahrain, sells about 45% of its output in Bahrain, 12 to 13% to neighbouring
Saudi Arabia and 12 to 13% to the rest of
the Middle East, as well as some 15 to 20%
to buyers in Europe and Asia. If the company
Alcoa’s leadership in energy efficiency recognised by Hydro-Quebec
Alcoa’s three aluminium smelters in Quebec,
Canada, have been recognised by Hydro-Quebec
for their energy efficiency, and are members of
the power company’s select Energy Savers’ Circle
network.
Alcoa’s Deschambault smelter was just raised
to Elite status, having been a member of the
Energy Savers’ Circle since 2008, and the BaieComeau smelter was newly inducted into the Circle. In 2010, the Bécancour plant was named an
Elite component of the Energy Savers’ Circle. Furthermore, Alcoa’s Deschambault and Bécancour
plants are two of only five locations designated
Elite members because of their exceptional energy performance, and are deemed ambassadors
in energy efficiency.
Alcoa’s Baie-Comeau smelter joined the Energy Savers’ Circle by reducing its annual power
consumption by more than 68 GWh through
improved performance of its electrolytic cells and
through for some time optimising its compressed
air system.
Deschambault was awarded Elite status after
lowering its annual electricity use by more than
300 GWh – equivalent to the consumption of
18,000 Quebec households in a year.
Alcoa’s Bécancour smelter, the first Alcoa
smelter to attain Elite status, reached new
heights in effectiveness by accomplishing energy
efficiency gains of more than 250 GWh. The
40
smelter acted on its consumption of compressed
air, motive power, heating and lighting of facilities as well as power used for its electrolytic
cells.
Between 2007 to 2010, Alcoa’s Canadian
smelters posted total cumulative energy efficiency gains of more than 600 GWh. In addition,
both the Bécancour and Deschambault facilities
received awards for their energy efficiency initiatives in the 2011 Énergia competition.
Alcoa Canada Global Primary Products (GPP
Canada) operates four facilities in Quebec: the
Baie-Comeau, Bécancour (ABI) and Deschambault
smelters as well as the Bécancour Rod Plant.
These four plants have an annual production
capacity of roughly one million tonnes of ingots,
castings, billets and aluminium rods. GPP Canada
employs nearly 3,300 people and its activities
generate economic spin-offs of over USD1.2bn
annually in Québec.
Alcoa smelter Deschambault – energy savings of more than 300 GWh a year
Photo: Alcoa
SPECIAL
moves forward with its proposed expansion
plans, some of that incremental volume could
make its way to the United States.
Alba’s possible build-out could come in one
of two forms – an expansion of Potlines 4 and
5 or the addition of a new potline. An additional potline, which could come online by the
end of 2014, would add an estimated 400,000
tonnes a year. The company is now undergoing
an energy study to help determine the plant’s
optimal energy flow, which in turn will help the
company decide whether to proceed with the
expansion plan (80,000 tpy over three years)
or an additional potline – or both.
If Alba moves forward with Line 6,
North America could see some 50,000
to 100,000 tonnes of that incremental
capacity. Another 100,000 tonnes likely would head to Europe, 100,000 to
150,000 tonnes to the Middle East and
the remainder to Asia.
1.994 million tonnes (+7.8%), in Eastern &
Central Europe 2.127 million tonnes (+2.1%),
in Australia and New Zealand 1.140 million
tonnes (+1.7%) and in Africa 0.886 million
tonnes (+3.7%).
Suppliers
UC Rusal signs agreement
to recycle spent carbon pot lining
UC Rusal has signed a cooperation agreement
with the Kemerovo Region administration and
Environmental Regional Centre (ERC) on recycling waste to innovative products for ferrous metallurgy. The first stage provides for
recycling by ERC of all spent carbon pot lining
(aluminium production wastes) coming from
the Novokuznetsk smelter in the amount of
up to 3,000 tpy. In the future, ERC will also
recycle the stored pot lining from the waste
site, increasing the site’s lifespan. The agreement will be valid until the end of 2015 and
may be extended afterwards.
No additional investment is required from
Rusal. The company will provide ERC with
wastes and let it use its industrial sites for in-
WWW.BUSSCORP.COM
LME changes warehousing rules
The London Metal Exchange (LME)
has changed its warehousing rules by
doubling the minimum loading out rate
for the largest warehouses from 1,500
to 3,000 tonnes a day, starting in April
2011. Aluminium processing companies
as well as their customers like CocaCola or GM have criticised the decision
as not going far enough. Nick Madden,
chief procurement officer at Novelis, is
“disappointed” that the LME has made
only a “relatively minor adjustment to
this critical problem” (Financial Times).
This half-hearted decision will prolong
anomalous pricing and supply chain issues for both manufacturers and consumers in the market, he says.
The leading Mixing Technology
Global aluminium production
up 5% in the first half of 2011
for Anode Pastes
Latest IAI statistics show global primary
aluminium production in the first half
of 2011 of 12.621 million tonnes, which
is a 6.2% rise compared to the corresponding period a year earlier. The region with the biggest growth in production was the GAC / Gulf countries with
an increase of 33.6% to 1.671 million
tonnes. Aluminium production in North
America was 2.430 million tonnes
(+3.7%), in South America 1.096 million tonnes (-4%), in Asia 1.277 million
tonnes (+2.9%), in Western Europe
For over 50 years BUSS KE and CP series Kneaders have been
the benchmark for reliable, cost-effective compounding of
anode pastes. Now we go one step further.
41
stallation of recycling equipment. Purchase of
the equipment required will be financed by
ERC under a soft loan with the support of the
Kemerovo Region administration. The wastes
will be recycled by ERC to synthetic flux used
in cast iron and steel production, which are a
substitute to natural flux (fluor spar). Compared to natural flux, synthetic one is cheaper,
has a lesser inert content and a higher calorific value under a lower fusion temperature
among other advantages.
ERC has already signed supply contracts
with the West Siberian, Novokuznetsk and
Nizhny Tagil metallurgical works. The longterm demand for synthetic flux from these
plants amounts to 6,000 to 8,000 tonnes
monthly. The project is included into the Kemerovo Region investment projects’ list and is
currently unique for Russia. This project will
help Rusal increase the amount of recycled
wastes up to 80,000 tonnes by 2013.
minium industry. The prototypes will be tested
by Rusal’s Siberian facilities. GAZ engineering
specialists are developing a pot crust breaking machine, metal handling trucks, alumina
loading machines and a stud cleaning unit.
This project is part of the large-scale modernisation programme underway at Rusal’s
operations, and promotes the use of advanced
machinery to automate the process and to
improve labour productivity. The joint project
aims to upgrade Rusal’s aluminium production process in terms of safety and efficiency. The new prototypes will be tested at the
Novokuznetsk, Krasnoyarsk and Bratsk aluminium smelters. Following the testing of the
prototypes, the company will consider buying
the new machines for all of its smelters. One
of the possible options is to launch the manufacturing of the machines directly at Rusal’s
sites.
Coperion: New Service
Centre for the Middle East
UC Rusal and GAZ
to develop new machinery
for aluminium production
UC Rusal has started a joint project with GAZ
group to develop new machinery for the alu-
Coperion Middle East, a joint venture between
Coperion and the Saudi Arabian company
Golden Wing, extends Coperion’s world-wide
service network by an additional service centre.
As a longstanding partner of Coperion in the
Middle East, Golden Wing has already taken
care of numerous high-capacity compounding
lines for Coperion during their assembly and
installation, including the local servicing. The
joint venture will now enable Coperion to realise its projects in the Middle East even more
efficiently and faster than hitherto. Coperion
Middle East is based in Jubail, Saudi Arabia.
The managing director of the joint venture is
Ayman Gabr of Golden Wing.
The Middle East is one of the world’s most
important core regions of the petrochemical
industry. Moreover, the region has a strong
and rapidly growing aluminium industry for
which Coperion has already designed and
manufactured a multitude of materials handling installations.
A benefit afforded by the new service
centre lies in the now optimised attendance
to all planned and existing installations in the
region. This service embraces local project
coordination and procurement just as much
as the making available of processing knowhow or the drafting of machine modification
studies, thus boosting local wealth creation. In
addition, Coperion Middle East shortens the
delivery routes to rapidly growing target markets: e.g. for handling and logistics systems for
the aluminium producing industries.
N
B&P CK-700-CP Ko-Kneader – for premium quality anode paste
B&P Process Equipment ships the fourth CK-700CP Ko-Kneader to go into production. Hailed
as the largest capacity anode paste mixer to be
placed into production, the CK-700-CP represents
the largest single anode paste mixing line to be
installed in China.
With installations in Norway and the United
Arab Emirates, B&P’s machine has become the
industry benchmark in terms of large capacity
production of green anode paste and continues
to gain attention as an affordable and flexible
unit. Buyers can choose from several options to
fully automate the line or to simplify and keep
capital expenses low.
Based upon a rugged, high-reliability design,
the CK-700-CP is meant for high-availability and
premium quality anode paste. By closely controlling the specific mechanical energy that is input
into the paste mixture, the CK-700-CP is producing some of the highest density green anodes in
the world at production rates capable of reaching
75 metric tonnes.
This latest CK-700-CP Ko-Kneader shipment
is headed for Yunnan Yuanxin Carbon Co., Ltd
42
and, under the contract, B&P is also providing
the coke pre-heating unit which will operate upstream of the Ko-Kneader. A single control system
provided by B&P Process Equipment will tie the
two systems together making for a high degree
of automation.
B&P Process Equipment, headquartered in
Saginaw, Michigan, USA, has been providing rug-
B&P Ko-Kneader for Yunnan Yuanxin Carbon
ged and reliable mixing and separation systems
for the chemical processing industries for more
than 120 years. The hallmark of the B&P name
lies in engineering high-precision, high-reliability
machines that are considered affordable, flexible
and simple to operate. B&P considers their customers long-term partners and place a high value
on after-market service and support.
Photo: B&P
TECHNOLOGIE
Hofmann Wärmetechnik – Überkopf-Ofenanlagen aus Österreich
Die Firma Hofmann Wärmetechnik mit
Sitz im oberösterreichischen Hellmonsödt
wurde in den letzten Jahren als Sonderofenbauer für die Aluminiumindustrie
bekannt. Die Ofenanlagen werden von
Hofmann selbst geplant, gebaut und in
Betrieb genommen.
Hofmann
Hofmann Wärmetechnik hat sich aus dem
Standardofenbau entwickelt und fokussierte sich im Laufe der Zeit immer stärker auf
kundenspezifische Lösungen. Mittlerweile ist
die das Unternehmen ein reiner Sondermaschinenbauer und tritt mit modernen, kundenorientierten Lösungen auf. Dazu zählt auch
die Herstellung von Überkopfofenanlagen,
sogenannten „Vergüteautomaten“, für die
Aluminiumindustrie.
Bei den Vergüteautomaten handelt es sich
um Industrieofenanlagen, die sich dadurch
auszeichnen, dass sowohl das Lösungsglühen
wie das Abschrecken und wahlweise auch das
Auslagern bzw. Altern von Aluminiumteilen
in einer Anlage vollautomatisch durchgeführt
wird. Als Überkopfofen wird die Anlage von
unten beschickt. Der Ofen wirkt somit als
Wärmeglocke. Die warme Luft bleibt länger
im Ofen, was sich wiederum positiv auf den
Energieverlust während des Chargenwechsels
auswirkt.
Vergüteautomaten werden von Kunden
aus der Automobil- bzw. Luftfahrtindustrie,
jedoch auch von Kunden aus der aluminiumverarbeitenden Industrie benötigt.
Dieser Ofentyp ist speziell für Kunden bestimmt, die hochwertige Produkte herstellen,
da die Chargendaten
über den kompletten
Ablauf der Wärmebehandlung aufgezeichnet und archiviert bzw.
dokumentiert werden.
Die Anlage entspricht
den gängigen Anforderungen in Bezug auf
Temperaturgenauigkeiten, welche in den
einschlägigen Normen
(AMS 2750D, NADCAP, T6 etc.) gefordert werden. Die für
die Einhaltung der
Vorschriften erforderlichen
Temperaturgleichmäßigkeits- und Systemgenauigkeitstest
können weitgehend von außen (während des
Betriebes) durchgeführt werden. Es werden
in diesen Anlagen auch die sehr kurzen „Abschreckverzögerungen“ von bis zu 7 Sekunden realisiert.
Anlagen mit Roboterbeschickung laufen vollautomatisch, mannlos im Vierschichtbetrieb.
Der Wartungsaufwand ist sehr gering, „da
wir nur bewährte Technik einsetzen und die
Anlagen für schwierige Verhältnisse und erschwerte Einsatzbedingungen ausgelegt werden“, heißt es bei Hofmann. Neben diesen
Vorteilen müsse der Kunde beim Kauf einer
Überkopfofenanlage auch nicht auf die Flexibilität verzichten, die bei großem Produktmix
gewünscht wird. Generell gilt: Je mehr kleinere Kammern, desto mehr Flexibilität.
Hofmann Wärmetechnik bietet verschiedene Systemvarianten an:
• Verfahrbares Abschreckbecken und Öfen
mit Ofenwinde für kürzeste Abschreckzeiten sowie große Chargenabmessungen
und Gewichte
• Fixes Abschreckbecken und übersetzen ins
Abschreckbecken mit Scherenhubtisch und
Gabelmanipulator. Kombination für kleinere Chargen (bis 2 Tonnen) und große
Chargenvielfalt.
Als Anlagenoption bietet Hofmann:
• Gasbeheizt (direkt / indirekt) oder
elektrisch beheizt
• Luftabkühlung, Wasser- oder Polymer/
Glykolabschreckung
• Heizung für Becken elektrisch oder über
Wärmetauscher
• Beckenkühlung/Rückkühlung über
Wärmetauscher, auch komplett mit
Kühlkreislauf und Wasseraufbereitung
• Andockstationen oder Energieketten für
fahrbare Abschreckbecken
• Umfangreiche vor- und/oder nachgelagerte
Fördertechnik (Rollgänge, Kettenförderer,
Roboter etc.
N
43
TECHNOLOGIE
Fotos: Erbslöh
1911 bis 2011 – Strangpressen bei Erbslöh
1.000-t-Presse, die erste Strangpressanlage bei Erbslöh
The first extrusion press at Erbslöh
Unter diesem Motto fand am 27. Mai
2011 bei der Erbslöh Aluminium GmbH
in Velbert ein Symposium statt, das
nicht nur die 100 Jahre Strangpressen
würdigte, auf die Erbslöh zurückblicken
kann, sondern auch Produkt- und Markttrends in der Aluminiumindustrie weltweit beleuchtet. Die beiden Geschäftsführer der Erbslöh Aluminium GmbH,
Frank Busenbecker und Norbert Sucke,
begrüßten mehr als 150 Gäste aus dem
Kunden-, Lieferanten- und Branchenumfeld.
Bereits 1911 wurde bei Erbslöh in WuppertalWupperfeld die erste wasserhydraulisch betriebene Strangpresse in Betrieb genommen.
Bis heute ist das Strangpressen von Aluminiumhalbzeugen für die Automobilindustrie
und verschiedene Industriemärkte die Kerntechnologie der Erbslöh Aluminium GmbH.
Anhand klarer Kriterien wird heute über
die Anschaffung einer Strangpresse entschieden. Die Wirtschaftlichkeitsberechnung dazu
basiert auf Annahmen über die Produktionskapazität und die Produktionskosten einer
Anlage sowie vor allem über die Absatzprognose. Aktuell kann man auf technische Erfahrungswerte und Marktstudien zurückgreifen.
Welche Überlegungen aber haben vor 100
Jahren dazu geführt, das Strangpressen bei
Erbslöh einzuführen?
44
„Der Auslöser zu dieser für die damalige Zeit
sehr gewagten Investitionsentscheidung war
keine romantische Technikverliebtheit. Tatsächlich spielten schon damals Kriterien wie
Marktpotenzial, Wirtschaftlichkeit und Innovationskraft, aber auch unternehmerisches
Risiko eine ähnliche Rolle wie heute“, führte
Sucke aus.
Die Grundlage war fast 30 Jahre zuvor
gelegt worden. Bei Erbslöh wurden damals
plattierte Bleche für Schmuck, Knöpfe, Gürtelschnallen und Bilderrahmen produziert.
Verarbeitet wurden Kupfer, Zink und Messing; plattiert wurde unter anderem mit Silber
und Gold. Mit diesen dekorativen Artikeln
hatte sich das Unternehmen einen guten Ruf
erarbeitet. Doch der Absatz war gefährdet,
denn Aluminium war in Mode gekommen
und drohte die silberplattierten Bleche zu ersetzen.
Auf der Weltausstellung 1878 in Paris
konnten sich die Eigentümer des ErbslöhStammhauses erstmals über das noch recht
neue Aluminium informieren. Seit 1882 wurden erste Gieß- und Walzversuche mit dem
damals noch chemisch gewonnenen Aluminium durchgeführt. Ab etwa 1890 stand elektrolytisch erzeugtes Aluminium zur Verfügung,
das nun erschwinglich wurde. Zunächst wurde
es zu Blechen verarbeitet, aus denen Kochgeschirr sowie einfache Gebrauchsgegenstände gefertigt wurden, weitere Anwendungen
kamen rasch hinzu, sodass größere Teile der
Produktion auf die Aluminiumverarbeitung
eingerichtet wurden.
Inzwischen war aus modischen Gründen
der Absatz der dekorativen Bleche deutlich
eingebrochen, mit den Aluminium-Walzblechen hatte sich das Unternehmen jedoch ein
neues Standbein errichtet.
Anfang des 20. Jahrhunderts stieg der
Bedarf an Kupfer durch die steigende Elektrifizierung im Verkehrsbereich und in der
Antriebstechnik. Spekulationen beeinflussten
jedoch den Kupferpreis, sodass nach Ersatz-
850-PS-Dampfmaschine zum Betreiben der Strangpresse
850-HP steam engine for operating the extrusion press
TECHNOLOGY
materialien gesucht wurde. Allerdings war
von 1901 bis 1908 durch das Kartell der
Aluminiumproduzenten der Aluminiumpreis
ebenfalls hoch gehalten worden. Im Jahr
1907 führten stark steigende Kupferpreise
dazu, dass die Elektrizitätsindustrie nach
Auswegen suchte. Unter den Mitgliedern der
„Vereinigung der Elektrizitätswerke“ wurde
deshalb eine Umfrage erhoben, die auch die
Verwendung von Aluminium für Maschinen,
Transformatoren, Schaltanlagen, Kabel und
Freileitungen betraf.
In dieser Zeit hatte man bei Erbslöh mit
der Herstellung von Aluminiumdrähten begonnen. Das Herstellungsverfahren war allerdings sehr aufwendig:
• Von der Aluminium AG Neuhausen in der
Schweiz wurde das Aluminium in Form
sogenannter Zweiteiler mit 3 bis 4 kg
Gewicht geliefert.
• Daraus wurden Blöcke in der Größe von
20 x 250 x 40 mm gegossen. Die Blöcke
wurden zu Blechen ausgewalzt. Die
Antriebskraft der Walzen setzte den
technischen Möglichkeiten Grenzen.
• Mittels Rundschere wurde der Draht
spiralförmig abgetrennt.
• Die Abschnitte wurden durch Kalibrierwalzen rund gewalzt.
• Anschließend wurden die Drähte gezogen.
Auch auf einem weiteren Gebiet wurden
aufgrund des technischen Fortschritts neue
Lösungen gesucht. Elektrische Triebwagen
von Lokomotiven oder Straßenbahnen waren
Gießerei zur Herstellung der Rundbarren für die 1.000-t-Presse
Casthouse for producing round bars for the 1,000-tonne press
vornehmlich mit Rollenstromabnehmern ausgestattet. Die steigenden Geschwindigkeiten
führten bei den kleinen Rollen zu hohen Drehzahlen. Abhilfe sollten Aluminium-Schleifbügel schaffen.
Um 1900 entwickelte Siemens & Halske
solche Stromabnehmer. Doch der Verschleiß
war sehr hoch, sodass man versuchte, durch
Gießen einen U-förmigen Schleifbügel herzustellen, um in der Längsnut Schmierfett
einbringen zu können. Doch die gegossenen
Schleifbügel waren sehr fehleranfällig.
Bei Erbslöh hatte man mit der Verwendung
legierten Aluminiums begonnen, um dessen
Festigkeit zu steigern. Vor allem das Zulegieren von Kupfer verhalf dem Aluminium zu
einem deutlichen Festigkeitsanstieg. Siemens
& Halske fragte bei Erbslöh U-förmige Schleifbügel aus legiertem Aluminium an, und mit
Blick auf das zu erwartende Absatzpotenzial
stellte man sich der technischen Herausforderung. Plattierwalzen wurden zu Profilwalzen
1911 to 2011 – Extrusion at Erbslöh
Erbslöh Aluminium GmbH in Velbert, Germany,
looks back over 100 years of extrusion. At
the anniversary celebration, combined with a
symposium, held at the end of May this year
the company traced its development from the
beginning up to today.
The origins of Erbslöh’s business lie in the production of c lad sheet for costume jewellery, knobs,
belt buckles and picture-frames of copper, zinc
and brass. With rolled aluminium sheet the
company entered a new field when, for fashionrelated reasons, the sales of decorative sheet collapsed. In the first decade of the 20th century Erbslöh also began producing aluminium wires – at
that time a very difficult process. With U-shaped
sliding bows for the current collectors of trams
the company finally started doing business with
aluminium profiles. For this, the existing cladding
rollers were converted to profile rollers so as then
to form rolling slabs into profiles instead of wires.
The extension of this business and the wish
for an economical production process led to the
design of an extrusion press with extrusion load
1,000 tonnes, which after a year of planning
and construction work went into operation in
Wuppertal in 1911. The press was operated by a
water-hydraulic system and all press movements
still had to be controlled manually. In 1914 the
casting capacity was increased in order to ensure
self-supply of high-quality alloyed round bars. For
that the aluminium, melted in coal-fired furnaces,
was cast into metal moulds so that the bars could
be taken out after releasing a sleeve.
“So that was how extrusion began at Erbslöh.
In the past 100 years a number of product life
cycles have gone by,” explained Norbert Sucke,
technical director of Erbslöh Aluminium GmbH.
Today the company produces aluminium profiles for the automobile industry and for various
other industrial applications. The product range
for the car industry includes, besides thin-walled
multi-chamber profiles for heat exchangers, for
example B-column panels, water deflectors,
window holders, roof strips and edging strips.
Among industrial applications the company
focuses on very fine aluminium profiles with
highly decorative surfaces, produced inter alia for
sanitary ware and for the electronics industry. For
example, bright-alloyed profiles under the brand
name Alminox are found in high-end audio,
video and multi-media products manufactured
by Bang & Olufsen.
Over the period 2001 to 2010 the company’s
turnover increased from 89 to around 130 million
euros, while over the same period over 60 million
euros have been invested. Production amounting
to 16,500 tonnes in 2001 is forecast by commercial director Frank Busenbecker to total 24,500
tonnes by the end of this year.
45
TECHNOLOGIE
umgebaut, um Walzbleche statt zu Drähten Ein weiterer Trend setzte 1992 mit der Klimanun zu Profilen zu walzen. „Die Versuche tisierung von Pkws ein. Für die zugehörigen
gelangen, und das erste Erbslöh-Profil war Wärmetauscher werden dünnwandige Mehrkammerprofile benötigt. Durch die Produktigeschaffen“, so Sucke.
Kaum war der U-förmige Schleifbügel ein on von Abstandhaltern war Erbslöh mit dem
Erfolg, wurden immer neue Profilformen er- mehrsträngigen Strangpressen dünnwandigsdacht. Für Bergbahnen wurden zum Beispiel ter Profile vertraut. Wandstärken von 0,2 mm
dachförmige Profile benötigt. Die ohnehin waren lange undenkbar. Heute betreibt Erbsschon sehr aufwendige Drahtherstellung wur- löh Aluminium eine der weltweit leistungsfäde um einen weiteren Arbeitsgang ergänzt. higsten Strangpressen für diesen Markt. Die
Gleichzeitig entstand der
Wunsch nach einem wirtschaftlicheren
Herstellungsprozess.
Mit der Anpassung der
Produktion an den stark
steigenden Aluminiumbedarf wurde der damalige
technische Direktor, Hugo
Lohmann, beauftragt. Ein
umfangreicher
Neubau
schaffte Platz für die neuen Anlagen. Neben der
Strangpresse mussten auch
eine große Bandwalzanlage und die erforderliche
850-PS-Dampfmaschine
projektiert werden.
1911 wurde nach rund
einjähriger Planung und
Bauzeit die 1.000-TonnenStrangpresse bei Erbslöh
in Wuppertal-Wupperfeld
in Betrieb genommen. Die
Presse war wasserhydraulisch betrieben, und alle
Pressenbewegungen mussten von Hand gesteuert Alminox-Dachleisten in unterschiedlicher Oberflächenanmutung
werden. Als Anerkennung Alminox roof strips in different surface look
für seinen unschätzbaren
Einsatz erhielt Lohmann Gesellschaftsanteile Gebäudeklimatisierung bietet aktuell weitere
am Unternehmen Erbslöh.
Wachstumschancen.
1914 wurde die Gießkapazität erweitert,
Einer der auch heute noch wichtigsten
um die Eigenversorgung mit legierten Rund- Märkte für das Unternehmen ist das Autobarren in guter Qualität sicherzustellen. mobilgeschäft. In den frühen 1920er Jahren
Dazu goss man das in kohlebeheizten Öfen wurde die aufkommende Automobilprodukerschmolzene Aluminium in Kokillenschalen, tion als Wachstumsmarkt erkannt. Zuvor hatte
um nach dem Lösen der Manschette die Rund- das Unternehmen dekorative Bleche für die
barren zu entnehmen.
Verzierung von Kutschen gefertigt. Nun aber
„Das also war der Beginn des Strangpres- konnte die Formgebung durch das Strangpressens bei Erbslöh. In den vergangenen 100 sen für Fensterrahmen, Regenleisten, ZierJahren wurden einige Produktlebenszyklen leisten, Trittschienen und Frontschutzbügel
durchlaufen. Ab etwa 1960 wurden Profile genutzt werden.
Die Anforderungen der Kunden an Strangfür die boomende Bauindustrie hergestellt.
Nach der Ölkrise 1973 zählte Erbslöh mit pressprofile stiegen stetig. Aus den ursprüngPUR-isolierten Bauprofilen zu den ersten lich nur funktionalen Bauteilen sind durch
Anbietern wärmeisolierender Fenstersyste- Oberflächenveredlung Designelemente geme. Unter dem Markennamen Ekonal wurden worden, die dem Fahrzeug Kontur geben,
Bausysteme in der ganzen Welt vertrieben“, Wertigkeit ausstrahlen und den Wiedererkennungswert bestimmen.
so Sucke.
46
Schon die kleinsten Oberflächenfehler und
Verunreinigungen marktüblicher Profile führen in einer anspruchsvollen Weiterverarbeitung zu Ausschuss und Nacharbeit. Die konsequente Reduzierung aller profilbedingten
Fehler hat sich Erbslöh zur Aufgabe gemacht.
Unter dem Markennamen Alminox produziert
und vertreibt Erbslöh Aluminium heute Profile, die diesem Anspruch gerecht werden.
Vor allem in den letzten zehn Jahren waren erhebliche Aufwendungen für die Erweiterung und Modernisierung der Strangpressanlagen erforderlich. So
erlebte das Presswerk
nach der Übernahme
der Erbslöh AG durch
die Walter Klein GmbH
& Co. KG im Jahr
2000 einen deutlichen
Aufwind. Der Reparaturstau im Presswerk
konnte beseitigt und Investitionen in das erste
Alminox-Schmelzwerk
sowie in eine 44-MNPresse schnell und
unbürokratisch
entschieden werden. „Die
kurzen Entscheidungswege eines familiengeführten Unternehmens
waren damals und sind
auch heute ein entscheidender Wettbewerbsvorteil“, so Sucke.
Erbslöh Aluminium
hat sich im vergangenen
Jahrzehnt sehr dynamisch entwickelt: Der Umsatz stieg von 89 auf
rund 130 Mio. Euro, die Produktion von
16.500 Tonnen 2001 wird Ende dieses Jahres
bei 24.500 Tonnen liegen. Das Investitionsvolumen 2001 bis 2010 betrug mehr als 60
Mio. Euro, wie Geschäftsführer Busenbecker
ausführte. Das Spektrum an Profilanwendungen für die Automobilindustrie umfasst
neben den Wärmetauscherprofilen unter
anderem B-Säulenblenden, Wasserabweiser,
Fenstereinfassungen, Dachleisten und Bordkanten. Bei den Industrieanwendungen fokussiert das Unternehmen auf filigrane Aluminiumprofile mit hoch dekorativen Oberflächen,
die unter anderem für das Sanitärwesen und
die Elektronikindustrie hergestellt werden.
Die glänzlegierten Alminox-Profile finden
sich beispielsweise auch in hochwertigen Audio-, Video-, und Multimediaprodukten von
Bang & Olufsen.
N
TECHNOLOGY
Constellium Global ATI
‘Airware’ – more than an aluminium alloy
Images: Constellium
B. Rieth, Meerbusch
In the run-up to this year’s aviation show
in Le Bourget the aerospace division of
the former Alcan Engineered Products
has taken the opportunity to present itself and its Airware range under the new
corporate name Constellium Global ATI
(Aerospace, Transportation and Industry).
The backbone of Airware certainly consists of the aluminium alloys developed
by Alcan’s research centres in Voreppe
and Lausanne. In addition, today Airware
denotes an integrated system solution
based on rolled, extruded and precisioncast aluminium products tailor-made for
the future demands of the growing aerospace sector.
The development of new materials for aviation is increasingly driven by the pressures
to which this sector is already subjected and
will be even more so in the future. Besides
reducing CO2 emissions these involve above
all measures to cut costs and to invest in new
aircraft types and flight operations. Among
other things the intention is to achieve these
objectives by lower fuel consumption and
higher payloads.
On the way towards that a competition
between materials has emerged in the development of the latest aircraft models. This is
evident on the one hand in the form of new
aluminium alloys with higher strength along
with lower density, and on the other hand in
the use of composite materials. As regards
composites Constellium sees no development
potential for itself and thus no challenges for
its R & D activities. In this connection the company points out that the high costs of the manufacturing process are hardly justified by the
production run sizes that would correspond to
growth forecasts in the aviation industry. To
be specific, according to Constellium the 40
new aircraft per month planned by Airbus and
Boeing alone at present could never be built
without the use of aluminium alloys.
The declared aim of Constellium is, with
the Airware concept, to offer the aviation industry materials and technologies that satisfy
the following essential requirements:
• weight saving of up to 25 percent
• time until the first so-termed D-Check up
to 12 years
• reduced CO2 emissions, along with 100%
recyclability of the materials used.
To find the answers for this it is necessary,
together with aircraft manufacturers, to think
far ahead into the future: and this, against
the background that the materials available,
which once epitomised development advances
in aerospace, are now coming up against the
limits of what can be expected from them. To
transcend those limits new and ‘smart’ materials are needed, which will be able to meet
more complex demands. Whereas in the past
the basis material aluminium was alloys primarily with weight and cost considerations in
mind, in the development of the A380 generation the criterion of production optimisation
was added. Even though that step is now a
few years behind us, today and all the more
so tomorrow other dimensions are gaining
importance, for example environmental aspects. At the currently foreseeable end of this
development – and this is the claim of Con-
Constellium to invest €3.8m
in its French extrusion plants
Constellium will invest about 3.8 million euros to
enhance the performance of its French extrusion
sites of Nuits-Saint-Georges and Saint Florentin
in order to address increasing demand within
the market. Several projects have already started
to be implemented as part of this investment
programme.
The plant of Saint Florentin (department of
Yonne), which specialises in high value-added
products for industry as well as the building and
construction market, will spend close to 1 million
euros to purchase new equipment for the press
P2, such as lead out table, air quenching device,
run out table, hot movable saw and two new
pullers. The volume of aluminium scrap will be
reduce by about 500 tonnes.
The plant of Nuits-Saint-Georges (department of Côte d’Or), which supplies the automotive and industry markets, will invest 800,000
euros in the renovation of its welding system
in order to reduce the volume of scrap. The hot
saw stroke and puller machines will be modernised, the cooling table and the stretcher will be
moved and the cold saw conveyor lengthened.
Further investments will take place before
the end of 2011 on the two sites, reaching a total of 2 million euros invested in Saint-Florentin
and 1.8 million euros in Nuits-Saint-Georges.
47
TECHNOLOGY
stellium’s Airware philosophy – is
multi-functionality of the material
aluminium and the innovations
that can be derived from that.
Constellium – formerly as Alcan
Engineered Products – has already
for years pursued the strategy of
developing new alloys with lithium,
copper, zirconium and silver, that
enable lower component weight at
the same time as greater rigidity
and higher safe damage tolerance,
and this in combination with new
construction and manufacturing
methods. This approach is much
approved of by major customers
such as Airbus, Boeing and Bombardier. What could more clearly
Airware plate for aerospace applications. Airware enables aircraft designers
and manufacturers to meet demands for a new generation of lighter, more
efficient and greener aircraft.
emphasise the course embarked
upon by Constellium than the decision now to invest some 42 million
euros at the Issoire plant and the
Voreppe research centre – among
other things for a new casthouse
specially designed for producing
the newly developed aerospace alloys?
The availability of new alloys will
also put Constellium in a position to
face other challenges of the aviation
market and thus offer multi-dimensional solutions, which ultimately
amount to weight reduction along
with increasing transport volume.
This includes the introduction of a
‘patchwork’ technique comparable
Alcoa, Aleris and Kaiser sign multi-year contract with Airbus
Alcoa has been awarded a multi-year supply
agreement with Airbus, worth USD1.0 billion,
for aluminium sheet and plate products utilising
the company’s current and newly developed aluminium alloys. The agreement was reached at the
Paris Air Show in June.
Alcoa’s aluminium solutions will be used
across virtually all Airbus commercial aircraft
programmes, from short-range, single-aisle jets to
long-haul, twin-aisle jets including the A380 and
range from fuselage panels to structural components to Airbus’ newest wing skins. The diverse
rolled products will be supplied from the company’s plants in Davenport, Iowa in the US, Kitts
Green in the UK and Belaya Kalitva in Russia.
Similar to Constellium, Alcoa recently announced
the development of a completely new set of aluminium-based solutions for the aerospace market
that would allow airframers to build dramatically
lighter and lower-cost short-range airplanes at
significantly lower production risk than composite-intensive planes. The new solutions, which
combine new alloys and advanced structural
technologies, use Alcoa sheet, plate, forgings
and hard alloy extrusion products across aircraft
structures, including airplane wings and fuselage
elements.
The combination of Alcoa solutions results
in short range aircraft that meet or exceed
airframer targets for corrosion resistance, aerodynamic drag, maintenance requirements and
fuel efficiency along with improved buy-to-fly
ratios. According to the company, the improvements developed by Alcoa for a new short-range
48
aircraft can generate up
to a 12% increase in fuel
efficiency. Included in the
new solutions portfolio
are advanced alloys and
third-generation aluminium lithium alloys that
result in up to 7% lower
density in major structural
applications along with
critically important corrosion resistance.
Aleris
Aleris
Alcoa
Aleris has signed a fiveAirbus and Aleris procurement team at the Aleris exhibition stand in
Paris on the occasion of signing the multi-year contract. From left to
year contract to provide
right: Elmar Lütjen (Airbus), Steven Demetriou (Aleris), Klaus Richter
aluminium plate and
(Airbus), Olli-Matti Saksi and Roeland Baan (Aleris), Eric Zanin and
Guido Locatelli (Airbus), Johan Petry, Serge Mouillard and Matthias
sheet in a range of alloys
Miermeister (Aleris).
to Airbus for its global
programmes. The agreement covers supply for the years 2012 through
Kaiser
2016 and includes the development of a recycling
programme, where Aleris will recycle scrap for
Kaiser Aluminium has too reached an agreement
Airbus. Further details of the contract were not
with Airbus to supply aluminium plate and sheet
disclosed.
for use in the production of commercial aircraft.
The flat rolled products will be produced at
The multi-year agreement is subject to definithe Aleris plants in Koblenz, Germany, and in
tive documentation, will commence upon the
Duffel, Belgium. Furthermore, Aleris will supply
completion of the companies’ existing supply
plate to Airbus from its new plate mill in China
agreement, and will extend Kaiser’s longstanding
when construction of that plant is completed in
role as a supplier of high quality semi-fabricated
late 2012. “We believe that our USD300 million
aluminium products to Airbus. ”We are confident
investment in the China plant uniquely positions
that our recently launched KaiserSelect solutions
Aleris to supply plate from Asia to customers in
will significantly contribute to Airbus‘s success,”
a variety of industries,” said Steven J. Demetriou,
said Jack A. Hockema, president, chief executive
Aleris chairman and chief executive.
and chairman of the company.
TECHNOLOGY
to the ‘tailored blanks’ which have long been
used successfully in lightweight automotive
engineering. In this case structural components
are no longer made from a single homogeneous
piece, but rather consist, in a manner optimised
according to local stresses, of components with
different thicknesses and properties. For joining these components to produce a lighter but
at least comparably strong structural assembly,
Constellium can have recourse to the experience available in Voreppe in the use of modern welding technologies such as friction stir
welding. An example of this is a new top-hat
stringer design, which is 20 percent lighter but
at the same time 14 percent stronger than its
conventional counterpart.
An example of how aluminium components can be ‘smart’, is provided by the rolled
and extruded components developed by Constellium with embedded optical fibres. Already
during the production of the semifabricate,
glass optical fibres are incorporated into the
aluminium body, which help to recognise material structures and identify any fractures in
the material without costly and elaborate material investigations.
In close collaboration with the developers
and designers of the new, high-performance
aircraft, Airware also aims to simplify and extend the maintenance intervals of aircraft. The
predictability of material behaviour afforded
by aluminium in contrast to composites simplifies the design, production and maintenance of
new aircraft types. It is also simpler to repair
minor damage to the aircraft, which cannot be
excluded even with the most careful manoeuvring in airports. Together with the greater
corrosion resistance and fatigue resistance
of aluminium, the aim of 12-year intervals
between heavy maintenance checks – the sotermed D-Checks – becomes realistic.
After ‘Specialty Sheet’, the Global ATI
product range is the second-largest in Constellium’s portfolio. The worldwide 3,400 of
9,500 employees in total mainly produce Airware products for the aerospace industry. In
addition, however, Global ATI also supplies
aluminium plates for applications in shipping
and road and rail transport.
Airware products come from the two highly specialised plants in Issoire, France, and
Ravenswood in the USA. They receive strong
support from the research centres in Voreppe
and Lausanne. Whereas in Lausanne a so-
termed ‘Innovation Cell’ co-operates closely
in the context of a strategic partnership with
the highly regarded EPFL (Ecole Polytechnique Fédéral de Lausanne) in that city and the
marketing organisation for new materials and
applications is also established there, Voreppe
is run by Constellium as its central research
facility. There, 170 scientists and technicians
from ten countries develop mainly new aluminium alloys and new joining technologies.
Considered overall, it can also be seen
that Airware is an integrated system solution
in which, however, the materials represent a
very important partial aspect. Thus, Airware
is by no means a future aspiration but already
a reality, since it is used in the new Airbus
models A350 XWB and in the C-Series of
Bombardier. Most recently, in the context of
a long-term agreement Constellium is supplying new aluminium-lithium alloys for the
primary structure. Airware products account
for up to 20 percent of all the materials in
this advanced aircraft type. The fuselage is
made from a combination of aluminium rolled
products and extrusions for the outer shell, the
stringers, the airframe and the floor beams.
For its C-Series programme, designed for the
100- to 149-seater market, Bombardier anticipates that compared with similar conventional
models it will achieve 15 percent lower cash
operating costs, a fuel saving of 20 percent and
thus correspondingly lower CO2 emissions.
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.
49
TECHNOLOGIE
Recycling von Aluminiumspänen
Studie bestätigt: Brikettieren von Aluminiumspänen ermöglicht Rückgewinnungsquote von knapp 99 Prozent
Aluminiumspäne sind wertvoller Rohstoff. Doch wie lässt sich zu einem bestmöglichem Preis-/Leistungsverhältnis
eine maximale Rückgewinnung erzielen?
Mit dieser Frage beschäftigt sich eine von
Ruf-Brikettieranlagen in Auftrag gegebene Studie des Ingenieurbüros Dr. Urbach (IMR). Die Versuchsreihen zeigen,
dass durch das Brikettieren der Aluminiumspäne eine Gesamtausbeute von rund
99 Prozent erreichbar ist und damit noch
weitere Vorteile einhergehen.
Scientific studies confirm that briquetting aluminium
swarf results in a recovery rate of almost 99 percent
Aluminium swarf is a valuable raw material. But what is the most cost-effective
way of achieving the maximum recovery
rate? To find out the answer to this, Ruf
commissioned consulting engineer Dr.
Urbach (IMR) to carry out a study. A
series of tests were run which show that
a total yield of around 99% is achievable through aluminium swarf briquetting
and that the process also brings with it a
range of other advantages.
Planing, turning, drilling or sawing aluminium
during manufacture constantly creates waste
in the form of swarf, which is in itself a valuable resource. It is just a question of how to
use it efficiently. In order to do this, it is important that the melting yield should be as high as
possible and that the processing costs remain
as low as possible.
There are two main ways of processing
swarf: the fast, cost-effective way involving
briquetting or the more time-consuming process of centrifuging the swarf, drying it and then
melting it in furnaces using the submerged
melting procedure. Manufacturers of the latter systems claim that melting yields of up to
98% can be achieved. The study carried out by
consulting engineer Dr. Urbach shows a total
yield of 98.6% for the briquetting process.
Aluminium swarf briquetting also offers
further significant advantages which more
and more companies are benefiting from. For
example, the coolant which is pressed out of
the swarf can be quickly filtered and then fed
back directly into the manufacturing process.
Another benefit is that the briquettes’ low volume means they take up much less storage
space and transport costs are reduced. And
finally, the extreme compression of the swarf
means that the oxidising surface is reduced to
a minimum.
Testing conditions and procedures
The aim of the tests carried out was to define the melting yield of swarf briquettes. An
AlMg3 alloy was chosen in order to achieve
clearer, more realistic data. This material’s
magnesium content means it is one of the
more easily oxidising alloys and as a result it
achieves lower melting yields. The briquettes
used were seven days old. Four tests were carried out in total. In the first test, briquettes
with a dry weight of 3.843 kg and residual
moisture of 2.7% were put into a pre-heated
empty crucible and melted. The result of this
test then served as a comparison result for
the subsequent tests and formed a point of
reference between direct melting and classic
submerged melting.
In the other three tests, 4 kg of aluminium
was melted as a sample and heated up to approximately 750°C. Then the test engineers
put in a maximum of three briquettes. As
these briquettes had been produced on Ruf
machines they had a consistent density of
between 2.22 g/cm3 and 2.27 g/cm3, thus ensuring that they would submerge more than
90% in the melting bath. The next batch was
added once these briquettes had completely
melted. After the last briquette had melted,
Fotos: Ruf
Durch das Fräsen, Drehen, Bohren oder Sägen von Aluminiumrohlingen entsteht neben
dem gewünschten Endprodukt auch stets ein
Abfallprodukt in Form von Spänen, das gleichzeitig wertvoller Rohstoff ist. Diesen gilt es,
effizient zu nutzen. Dabei sollen die Schmelzausbeute möglichst hoch und die Prozesskosten gering sein.
Prinzipiell führen zwei Wege der Späneaufbereitung zum Ziel: das schnelle und kostengünstige Brikettieren oder das kosten- und
verfahrensintensivere Zentrifugieren mit
anschließendem Trocknen der Späne und
Schmelzen in Ofenaggregaten mit Einrühranlagen (Submerged Melting). Letzteres wird
von den Herstellern derartiger Systeme mit einer erreichbaren Schmelzausbeute von etwa
98 Prozent angegeben. Eine vom Ingenieurbüro Dr. Urbach durchgeführte Studie weist
für die Variante Brikettieren eine Gesamtausbeute von 98,6 Prozent nach.
Dabei bietet das Brikettieren der Aluminiumspäne noch weitere Vorteile, die sich
immer mehr Betriebe zunutze machen. So
Aluminium swarf recycling
Für die Versuchsreihen wurden Aluminiumspäne der Legierung AlMg3 verwendet und auf Brikettieranlagen der Firma Ruf zu handlichen Briketts gepresst
Aluminium swarf from AlMg3 alloy was used for testing and pressed into practical briquettes using Ruf briquetting machinery
50
TECHNOLOGY
the whole molten metal bath was in turn heated to around 750°C and then run off into a
collection pan.
The melting yield in figures
As expected, the first test (where the swarf
briquettes were put straight into the furnace
without a metal sample) produced a relatively
low total yield of 93.11%. The proportionate
amount of dross (low-value melting product)
was relatively high at 9.06%. However, according to the testing team, the dross produced
still has some value, and as it has estimated
metal yields of around 80% it can be sold on
to remelters.
Two tests under realistic conditions produced almost identical results: total yields
were 98.55% and 98.73% respectively.
These yields include average dross proportions of 1.5%. These excellent results reveal
the extremely low oxidation rate of these melt
alternatives.
The result of the other test is a little unusual
as a technical problem meant that run-off had
to be done at 830°C rather than at 750°C as
planned. The proportion of dross was just over
4% which reduced the total yield to 97.75%.
This is still a good result, but it shows that the
oxidation of liquid aluminium increases significantly at temperatures above 770°C.
Overall the test results show that the costefficient process of briquetting aluminium
swarf with subsequent melting in a molten
metal bath can hold its own against the much
more elaborate process of centrifuging, drying and mixing. In addition, the processing of
swarf briquettes in hearth furnaces
or converters in
both the primary and secondary aluminium
industry with
a yield of
around 93%
presents
a
high-performance alternative to the
conventional
process
of
treating swarf
in salt-bath
rotary drum
furnaces,
which
only
achieves yields
of
around
90%.
N
lässt sich das aus den Spänen gepresste Kühlschmiermittel nach einer kurzen Aufbereitung
mit Filteranlagen direkt in den Fertigungsprozess zurückführen. Außerdem benötigen Briketts erheblich weniger Lagerplatz und sind
durch das geringere Volumen für den Verkauf
preiswerter zu transportieren. Und schließlich
sorgt die starke Komprimierung der Späne
dafür, dass die oxidierende Oberfläche auf ein
Minimum reduziert wird.
Die Schmelzausbeute in Zahlen
Versuchsbedingungen und -ablauf
Im Fokus der IMR-Untersuchungen lag die
Bestimmung der schmelzbaren Ausbeute
der Spänebriketts. Um realistische und nachvollziehbare Daten zu erhalten, fiel die Entscheidung bei der Materialauswahl auf eine
AlMg3-Legierung. Diese gehört aufgrund
ihres Magnesiumgehaltes zu den leichter
oxidierbaren Legierungen und erzielt somit
eher niedrigere Schmelzausbeuten. Die verwendeten Briketts waren jeweils sieben Tage
alt. Die Wissenschaftler führten insgesamt
vier Versuche durch. Im ersten wurden Briketts mit einem Trockengewicht von 3,843 kg
und einer Restfeuchte von 2,7 Prozent in den
vorgeheizten leeren Tiegel gegeben und aufgeschmolzen. Das Ergebnis sollte als Vergleich
zu den nachfolgenden Versuchen dienen und
eine Referenz zwischen direktem Einschmelzen und dem klassischen Tauchschmelzen
(Submerged Melting) bilden.
Bei den folgenden drei Versuchen wurde
zunächst eine Menge von 4 kg Aluminium als
Vorlage eingeschmolzen und
auf eine Temperatur von
etwa 750 °C erhitzt. Nachfolgend setzten die Tester
jeweils maximal drei Briketts ein. Da diese auf Ruf-
Ruf machine for the production of swarf briquettes
Anlagen hergestellt wurden und zuverlässig
eine Dichte von 2,22 bis 2,27 g/cm3 erzielen,
war gewährleistet, dass sie im Schmelzbad zu
mehr als 90 Prozent untertauchen. Waren die
Briketts vollständig aufgeschmolzen, erfolgte
die nächste Zugabe. Nach dem Aufschmelzen
der letzten Briketts wurde das Gesamtmetallbad wiederum auf etwa 750 °C erhitzt und
dann in einer Auffangwanne abgestochen.
Wie erwartet, brachte der erste Versuch (bei
dem die Spänebriketts ohne Metallvorlage direkt in den Ofen eingesetzt wurden) eine relativ geringe Gesamtausbeute der Späne von
93,11 Prozent. Die anteilige Krätzemenge
(geringwertige Schmelzausbringung) war mit
9,06 Prozent verhältnismäßig hoch. Den Wissenschaftlern zufolge verfügen jedoch auch
die entstehenden Krätzen über eine Werthaltigkeit mit geschätzten Metallausbeuten von
rund 80 Prozent und können daher an Umschmelzwerke verkauft werden.
Zwei Versuche unter realistischen Bedingungen zeigten nahezu identische Ergebnisse: Die Gesamtausbeuten lagen bei 98,55
Prozent und 98,73 Prozent. Darin enthalten
sind Krätze-Anteile von durchschnittlich 1,5
Prozent. Diese sehr guten Werte dokumentieren die extrem niedrige Oxidationsrate dieser
Schmelzvariante.
Das Ergebnis des zusätzlichen Versuchs
fällt etwas aus dem Rahmen, da aufgrund
eines technischen Defekts der Abstich nicht
bei den geplanten 750 °C, sondern erst bei
830 °C erfolgen konnte. Der auf knapp über
vier Prozent gestiegene Krätzeanteil reduzierte die Gesamtausbeute auf 97,75 Prozent.
Ein noch immer gutes Ergebnis, das jedoch
deutlich macht, dass die Oxidation des flüssigen Aluminiums ab einer Temperatur von
über 770 °C stark zunimmt.
Die Versuchsergebnisse machen in Summe
deutlich, dass das kostengünstige Brikettieren
von Aluminiumspänen mit nachfolgendem
Schmelzen im Metallbad jedem Vergleich mit
dem aufwendigeren Verfahren des Zentrifugierens, Trocknens und Einrührens Stand hält.
Darüber hinaus erscheint auch die Verarbeitung von Spänebriketts in Herdschmelzöfen
oder Konvertern in der Primär- und auch der
Sekundäraluminiumindustrie mit einer Ausbeute von rund 93 Prozent als leistungsstarke
Alternative zum herkömmlichen Prozess der
Verarbeitung von Spänen in Salzbad-Drehtrommelöfen, bei denen die Ausbeute lediglich bei etwa 90 Prozent liegen soll.
N
Ruf-Anlage zur Herstellung von Spänebriketts
51
TECHNOLOGY
Improved monolithic materials for lining aluminium
holding and melting furnaces – roof, upper walls and flue
Andy Wynn, John Coppack and Tom Steele; Morgan Thermal Ceramics
Over the last 30 years, a group of monolithic
technologies has emerged which have been
designed specifically to perform within the
unique environment of aluminium melt-hold
furnaces. These aluminium-resistant grades
often contain ‘non-wetting’ additives, particularly in the metal contact areas, to minimise
interaction between the refractory and the
melt to suppress damage to the lining from
‘corundum growth’ [1].
Morgan Thermal Ceramics has recently
developed a monolithic material specifically
to improve performance in the superstructure
zone – roof, upper walls and flue, areas which
have to cope with excessively high levels of
alkali vapour and thermal shock. This article
reviews the operating conditions found in the
superstructure areas (as shown in Fig. 1) of a
typical melting and holding furnace and the
implications these have on monolithic lining
material design and performance. The improved behaviour of the newly developed
monolithic material against the critical performance criteria in these furnace regions is
demonstrated in the laboratory, compared to
existing industry leading materials, using industry standard test methods.
52
Fig. 1: Furnace lining zones in a typical aluminium melt-hold furnace
Key performance parameters
To understand the operating conditions in the
superstructure region of an aluminium melthold furnace in more detail, Morgan Thermal
Ceramics worked with a number of leading
aluminium producers. By studying working
practices and furnace operating conditions,
and through post mortem analysis of exhausted furnace linings, the company has identified
that the two primary factors which limit service life of linings are excessive alkali vapour
and extreme thermal shock. An increase in the
use of more powerful fluxes to deliver higher
productivity and more exotic alloy compositions, coupled with higher chamber temperatures, particularly in melt furnaces, is leading
to higher concentrations of alkali vapour in
the upper chamber region. In the vapour state,
these alkalis can easily enter refractory linings
through the pore structure to chemically interact with the base materials. Such reactions
can often lead to expansion effects, leading to
extreme changes in volume, causing cracking
and ultimately to the catastrophic failure of a
lining. The rate of chemical attack is affected
by temperature, furnace atmosphere, furnace
housekeeping and composition and structure
of the refractory lining.
The superstructure region is also subject
to considerable thermal stress as chamber
temperatures rise and fall rapidly during the
opening and closing of the furnace door and in
the areas around the gas burners. This leads to
rapid contraction / expansion of the surface of
the furnace lining, microcracking the structure
and ultimately leading to lining failure.
Other environmental factors can also play a
secondary contribution in limiting service life
of the refractory lining in the superstructure,
particularly in the upper wall region. The upper walls are subject to mechanical abrasion
during cleaning operations, so some degree of
abrasion resistance is necessary in the refractory lining to cope with the mechanical stress
endured during cleaning. Also, although not
normally in contact with molten metal, the
upper walls can be subject to intermittent contact from metal splashing, produced during
stirring and cleaning operations. It is therefore
important that the refractory in this region also
has some degree of ‘non-wetting’ capability to
ensure corundum growth does not nucleate
and grow at these splash points.
Testing the materials
Three existing monolithic materials used by
several aluminium producers in the superstructure region of melt-hold furnaces were
selected as baseline materials for the study.
The performance of these materials in service
is well established and so any test results can
serve as useful benchmarks against which to
Images: Morgan Thermal Ceramics
As aluminium producers strive to increase
productivity, the environment within furnaces for holding and melting aluminium
is becoming more aggressive. Chamber
temperatures are increasing and more
aggressive fluxes are being used, necessitating more frequent and severe cleaning
operations of the refractory wall. A key
requirement for maintaining high levels
of productivity is the need to minimise
the frequency and duration of furnace
downtime. The more aggressive conditions within which the refractory lining
has to work today means that the aluminium resistant lining materials developed
in the past to cope with these applications
are now being used beyond their original
intended design boundaries and their
service performance is under threat, leading to more frequent lining repairs. In order to minimise the frequency of furnace
downtime, a new breed of aluminium
resistant products are needed, specifically
designed to perform within today’s more
aggressive operating environment.
Fig. 2: Mould & test sample for alkali resistance tests
TECHNOLOGY
Fig. 3: Thermal shock resistance of test materials
rial technologies
Standard 1 Standard 2 Standard 3 New Material
was then used
49
45
76
42
as the basis for % Al2O3
40
49
6
54
% SiO2
a series of re% CaO
7
1.7
8.8
2
formulations to
1
1.5
3
1
% TiO2
find the optimum
0.8
0.9
5
0.7
balance of bond % Fe2O3
%
Alkalis
0.2
0.2
0.2
0.2
and
aggregate
chemistry and Table 2: Chemical analysis of materials studied
product granulometry that produced the Nine ‘Cup’ samples (5 cm cubes, each with a
maximum improvement in 2.2 cm diameter, 2.5 cm deep hole) are prealkali and thermal shock pared for each test composition (Fig. 2), along
performance
without with a lid (5 cm square, 0.6 cm thick) for each
negatively affecting other cube. Samples are allowed to set overnight,
important properties. The results of perform- then demoulded, cured and dried at 110°C
ance and property measurements of the final, for 18 hours. Three of the dried sample cups
optimised development composition com- produced are each filled with 8 grams of potaspared to the baseline standards are presented sium carbonate, three with 8 grams of sodium
below. All materials in the study were tested carbonate and three with a 50:50 mixture of 8
against the four key performance param- grams of both potassium carbonate and sodium
eters using industry standard test methods; carbonate. Samples of each of the alkali mixtures are fired to 900°C, 1 000°C and 1 100°C
Primary performance parameters
1. Thermal shock resistance test (ASTM for 5 hours. After sectioning vertically, samC1100-88 {1998} – ribbon ples are visually inspected for cracks, bulges,
test); Pre-fired samples (230 depth of penetration and colour change.
x 115 x 64 mm) are subjected Secondary performance parameters
to five alternating heating and 1. Abrasion resistance test (ASTM C704);
cooling cycles on one face us- Samples pre-fired to 815°C are blasted with a
ing a ribbon burner. The Mod- stream of silicon carbide grit of specified grain
ulus of Elasticity (E-modulus) size for a set time. Tested samples are then
of samples is measured non- cross-sectioned and the amount of material
destructively by ultrasonics abraded across the section is measured and
before and after testing. The reported in cubic centimetres.
percentage of retained E-mod- 2. Aluminium resistance ‘cup’ test; Sample
ulus is used as a measure of preparation is similar to the Alkali resistance
cup test, except no lid is used during testing.
retained strength.
2. Alkali resistance ‘cup’ test; Instead of alkali, the samples are filled with
Fig. 4: Standard 1 after alkali testing with
K2CO3 (poor rating)
Na2CO3 (poor rating)
K2CO3 / Na2CO3 (poor rating)
K2CO3 (excellent rating)
Na2CO3 (excellent rating)
K2CO3 / Na2CO3 (excellent rating)
Fig. 10: New material after alkali testing with
K2CO3 (excellent rating)
Na2CO3 (excellent rating)
K2CO3 / Na2CO3 (excellent rating)
Water (%)
110°C
Bulk
800°C
Density
1000°C
(kg/m3)
1300°C
800°C
PLC
1000°C
(%)
1300°C
110°C
800°C
CCS
(MPa) 1000°C
1300°C
11-12.5
5.5-6.5
11-13
5.8-6.3
2130
2300
2560
2250
2020
2280
2440
2240
2020
2280
2410
2230
2040
2280
2440
2220
-0.2
-0.2
-0.1
-0.3
-0.2
-0.3
-0.2
-0.3
-0.8
-0.3
+0.8
-0.3
46
80
45
80
26
80
40
70
25
90
23
70
27
90
23
70
Table 1: Phyiscal properties of materials studied
compare new developments. A detailed analytical investigation of the baseline materials was
undertaken in order to identify those aspects
of the materials technology that were considered to be either promoting or constraining
performance in terms of alkali and thermal
shock resistance and were thus controlling
failure mechanisms. This knowledge of the
strengths and weaknesses of the existing mate-
53
TECHNOLOGY
7075 alloy. Samples are heated at 1 000°C for
100 hours. After cooling, the samples are sectioned vertically and visually assessed for the
degree of metal penetration and corundum
growth. Full details of the test method are described in the literature [2].
Results and discussion
The physical characteristics and chemical composition of the optimised new material compared to the standard baseline materials are
displayed in tables 1 and 2.
Thermal shock resistance test results of several
of the materials studied are presented in Fig.
3. After five test cycles, Standard 1 lost 50%
of its E-modulus and Standard 2 lost 95%,
compared to only 40% loss for the new optimised material. These results suggest that the
new material is capable of delivering a 20%
improvement on thermal shock resistance
compared to Standard 1 and a twelve-fold
improvement compared to Standard 2. Since
the baseline materials are used routinely in
aluminium melt-hold furnaces, it was expected
that all would possess some degree of resistance to alkali attack. However, the alkali resistance testing displayed some extremes of
behaviour. Standards 1 and 3 displayed very
poor resistance to alkali attack, with samples
being severely disrupted by major cracking
and erosion all over (Fig. 4-6; samples tested
at 900°C (left), 1 000°C (middle) and 1 100°C
(right)).
This behaviour contrasted with the results
of Standard 2, which demonstrated excellent
resistance to the alkali tests (Fig. 7-9; samples tested at 900°C (left), 1 000°C (middle)
and 1 100°C (right)). The final optimised new
composition, which builds on the performance
mechanisms in Standard 2, passed all Alkali
contact testing with potassium carbonate and
sodium carbonate and delivered an excellent
rating (Fig. 10-12; samples tested at 900°C
(left), 1 000°C (middle) and 1 100°C (right)).
Secondary performance parameters
The abrasion resistance test results of the
Fig. 14: Aluminium ‘Cup’ test for new material –
pre-fired sample
54
materials, an important performance parameter for materials in the upper walls to resist
the abrasive action of cleaning operations,
are presented in Fig. 13. Standards 1 and 3
display relatively poor resistance to abrasion
compared to Standard 2. The target for abrasion resistance in this region was greater than
10 cm3 and Standards 1 and 3 do not achieve
this. The newly developed material incorporates technologies utilised in Standard 2 to
deliver excellent abrasion resistance.
To ensure the new material was safe from
metal splashing in the upper wall region, such
that corundum growth would not be an issue,
it was pre-fired at 1 200°C and tested against
metal contact with 7075 alloy at 1 000°C for
100 hours. This is a more aggressive test than
most aluminium producers use in their material
approval procedures [2]. Standard 1 produced
a poor result, with all other materials achieving
a good rating in the test, with only minimal
interaction with the test alloy (Fig. 14).
Summary
The results of the tests, which can be seen
in table 3, show that some baseline materials demonstrated superior behaviour for one
of the primary performance parameters but
poor performance for the other. The summary
shows that the new material combines all the
best performance features of the baseline
materials, but without any of the weaknesses
and so displays the optimum blend of performance features required for service in the superstructure of aluminium melt-hold furnaces.
For improved ease of installation, the new
Monolithic material has been
designed as a vibrocast grade,
requiring only minimal water
addition to achieve good flow
and is now on trial in the superstructure area of melt-hold
furnaces at several aluminium
producers around the world.
But faster melting leads to increased metal
losses from surface oxidation and to segregation from large heat gradients. These effects
are countered by increased use of fluxes and
increased stirring. Given the increasingly
challenging environment within which the
refractory lining has to work, traditional lining solutions can no longer be relied upon to
provide the service lives that were previously
achieved. Therefore, a new generation of furnace lining materials is required to cope with
today’s aluminium furnace.
The results from Morgan Thermal Ceramics’ tests suggest that the new material should
be capable of surviving the unique set of service conditions in the superstructure region of
aluminium melt-hold furnaces better than the
existing materials used in the industry and thus
deliver longer service life. Extended service
life in the superstructure area is expected to
reduce the frequency of furnace downtime
and thus allow aluminium producers to run
longer production campaigns, increasing productivity and minimising the need for expensive repairs.
References
[1] D. Jones, A. M. Wynn and T. J. Coppack: The
Development and Application of an Aluminium Resistant Castable, UNITECR ’93, Sao Paulo, Brasil
(Oct 31-Nov 3, 1993)
[2] A. M. Wynn, T. J. Coppack and T. Steele: Methods of Assessing Monolithic Refractories for Material Selection in Aluminium Melt-Hold Furnaces,
53rd International Refractories Colloquium, Aachen,
Germany (Sept. 8-9, 2010)
Conclusion
Aluminium producers continue to increase productivity
through their melt-hold furFig. 13: Abrasion loss resistance of test materials
naces to maintain
competitiveness and
the use of more
Thermal shock resistance
Good
Poor
Fair
Excellent
powerful
burners
Alkali resistance
Poor
Excellent
Poor
Excellent
to increase heat inSecondary performance parameters
put to the furnace
Abrasion resistance
Poor
Excellent
Fair
Excellent
is therefore becomAluminium resistance
Poor
Good
Good
Good
ing
increasingly
common practice. Table 3: Summary of test results against target performance parameters
AUTOMOTIVE
Aluminium matrix composites in automotive applications
Md. AI Mehedi, Bangladesh University of Engineering and Technology (BUET)
Aluminium matrix composites (AMCs) have
become a very high-grade material for the automotive world nowadays. AMCs are highly
used in producing cylinder boxes, brake rotors
and drums, driveshafts, camshafts, crankshafts
and other parts of cars.
Steel is used as the main manufacturing alloy in the automotive industry. But the use
of aluminium and magnesium is increasing
in the automotive sector due to their light
weight, which contributes toward reducing
the fuel consumption. In fact, a weight reduction of 10% can lead to 5% reduction in fuel
consumption (1). Aluminium is also useful in
having a high strength-to-weight ratio and better stiffness.
AMCs are generally reinforced with ceramic particles and fibres to obtain improved
mechanical and wear properties. The reinforcement improves the fatigue resistance and
lowers the thermal expansion. For example,
the addition of 60 vol.-% of alumina (Al2O3)
fibres to aluminium increases its elastic modu-
lus from 70 GPa to 240 GPa, and reduces the
coefficient of expansion from 24 to 7 ppm/°C.
The wear resistance of Al9Si reinforced with
20 vol.-% of SiC increases by varying degrees,
up to values better than or equivalent to very
hard grey cast iron (2).
Car manufacturers are finding ways to use
AMCs for several components, depending on
the model. Recently the Germany-based automotive supplier KS Aluminium Technologie
AG has developed a MMC cylinder lining for
Porsche cars, for better wear resistance (2).
Toyota launched a new engine built with TiAl-V alloy reinforced with TiB2 particles, a costeffective way to achieve very high wear resistance as well as tensile and fatigue strength (3).
Why aluminium is replacing steel
With the growing concern about greenhouse
effects, the use of aluminium is overtaking
that of steel. As aluminium has one third the
density of steel, its lightness is used by technologists to reduce the weight of vehicles so
as to reduce fuel consumption. Beside this the
characteristic properties of aluminium, good
formability, good corrosion resistance, high
strength and stiffness-to-weight ratio and re-
before. This is because the vehicle consumes
less fuel and less capacity is therefore needed
for the fuel tank. It is estimated that a vehicle
weight reduction of 10% results in 8 to 10%
fuel economy improvement (6).
For chassis applications, aluminium castings are used for about 40% of wheels and
for brackets, brake components, suspension
(control arms, supports), steering components
(air bag supports, steering shafts, knuckles,
housings, wheels) and instrument panels.
Aluminium matrix composites
Metal matrix composites have become a regularly used component in the automotive world
nowadays. When a metal matrix is mixed with
particles or fibres of one or more other materials, this is termed a Metal Matrix Composite
(MMC) where the materials are insoluble in
each other and have superior desired properties. Ceramic particles or fibres such as SiC,
Al2O3, TiB2, carbon, etc. are mainly used as
the added element in aluminium matrix.
Metal matrix composites have better mechanical and wear properties than the matrix
metal. These materials posses higher strength,
stiffness, corrosion resistance and wear resist-
Source & Diagram: GDA
The increasing use of Aluminium Matrix
Composites (AMCs) has become an economic issue in the modern automotive
world. Although AMCs are quite costly
compared with traditional materials, they
have potential to replace traditional materials like steel or cast iron or even Al/
Mg alloys, because they provide higher
strength, stiffness, wear resistance, corrosion resistance, high fatigue limit and
lower thermal expansion. These properties can lead to higher value addition such
as long life of engines, wheels and brakes
as well as better service from them. The
market for aluminium matrix composites
was projected to exceed USD68 million
by 2010. The main use of AMCs in the
automotive industry includes brake discs
and drums, cylinder blocks, cylinder
liners, pistons, crankshafts, camshafts,
valves, pushrods, connecting rods, brake
callipers, turbo exchangers etc. According
to a report by Global Industry Analyst,
Inc. the use of AMCs in ground transportation amounts to 57% of the total uses
of metal matrix composites, with an 8%
Compound Annual Growth Rate (CAGR)
in the 2001 to 2010 time period. In the
near future AMCs instead of steel can be
introduced into the body panel and structure of cars.
Fig. 1: Average use of aluminium in passenger cars produced in Europe and differentiated by application (4)
cyclability, make it an ideal metal to replace
heavier steel.
The use of aluminium in the automobile
sector has almost doubled in the last ten years
(see Fig. 1). Total use of aluminium per vehicle
is predicted to rise to 250 kg or 340 kg, with
or without taking body panel or structure into
account (5).
It is reported that the use of aluminium enables car manufacturers to use smaller engine
blocks for the same vehicle performance as
ance. In recent years the use of aluminium
in the automobile sector has been increasing
substantially. However, aluminium has very
poor wear resistance on its own, which makes
it incompatible for use in many inner and outer
parts of a car. If ceramic particles or fibres are
added, or even carbon, the wear resistance is
increased to very high value. This characteristic helps to increase the use of aluminium
metal matrix (AMC) in the automobile sector.
55
AUTOMOTIVE
Use of AMC in various applications
The use of aluminium matrix composite was
initiated by Toyota in 1983. The company
launched a piston for a diesel engine by selective reinforcement of an aluminium matrix
with chopped fibres preformed in the ring
groove area of pistons. This AMC improved
the fatigue and wear resistance of the piston.
It also helped to lower the coefficient of thermal expansion, and so reduced the tendency
to cracking and distortion.
The engine is the hottest spot in a car. Thus
the material inside the engine needs high temperature strength and good fatigue strength as
pistons produce cyclic loads inside the chamber and on the surface of the cylinder block,
and also on the piston itself. To avoid wear loss
of pistons, cylinders and other engine components it is highly recommended to use AMCs.
The applications of AMCs in different engine parts and beyond are as follows:
Pistons: The piston is one of the most vital
parts of an automobile. Pistons are generally
exposed to a dynamic thermal and mechanical
environment. Thus they need good high temperature strength and fatigue strength, low
thermal expansion and good wear resistance.
To ensure these properties, the car manufacturers are now concentrating on the use of
AMCs. The selectively reinforced pistons have
better wear resistance and a lower coefficient
of thermal expansion. They also have better
heat exchanging properties and high tolerance
to cracking. Although AMCs are more expensive than traditional materials, mass production involves only a single step and this optimises the cost with value-added service (7).
Due to the low CTE of AMCs, the clearance
between cylinder wall and piston can be reduced, which results in less noise and less wear
of both surfaces.
Cylinder blocks: The cylinder block is a
high-temperature chamber where ignition
takes place. The cylinder block accommodates
continuous impacts from the pistons, and must
therefore have very good wear resistance, fatigue strength and creep resistance. The use of
AMCs in cylinder blocks provides these properties. Al-Mg or Al-Si alloys with ~30% SiC
or Al2O3 are mainly used in cylinder blocks.
The Porsche 911, Boxster, Toyota Celica and
Honda Prelude are some examples of models
where AMCs are used in the cylinder block.
Cylinder liners: Cylinder liners are provided to reduce the friction between the
piston and the cylinder wall. Cylinder liners
contribute mainly toward increasing the wear
resistance.
AMCs have better wear resistance than
56
traditionally used liners made of cast iron. In
addition, AMC liners can contribute a weight
reduction of almost 20%. AMC liners have
better thermal conductivity which helps the
engine to operate at lower temperatures. This
phenomenon increases the engine life quite remarkably (8). Honda was the first company to
start using an AMC by adding a hybrid mixture
of 9% graphite and Al2O3 to the aluminium
matrix. In recent years Honda, Toyota and
Porsche have been using hybrid composite
liners in some of their models.
Crankshafts and camshafts: The crankshaft
is an associated part of the cylinder block,
which is attached to the cylinders and transfers energy by reciprocal movement. Camshafts are associated with tappets to open or
close valves. Crankshafts and camshafts have
to have very good fatigue strengths and wear
resistance for a long lifetime. High thermal coefficiency is also an issue while selecting materials for crankshafts and cam shafts. AMCs are
a very good option for providing the desired
properties for these parts.
Driveshafts: The driveshaft is a mechanical
device associated with the torque or rotation
transmission to the gearbox. In large vehicles
generally two driveshafts are used for length
restriction. With AMCs this problem can be
resolved, because the use of AMCs enables
the use of driveshafts of a certain length with
a small diameter or a certain diameter with a
smaller length. The critical speed is well maintained with this system, along with a minimum
weight saving of 9 kg.
Aluminium wrought alloy 6061 with 10%
Al2O3 powder particles is widely used in
driveshafts nowadays. The GM Corvette, GM
trucks, Ford Crown police cars and a number
of racing cars use driveshafts of this type.
Brake discs and drums: In brake discs and
drums, AMCs have brought a new era of fuel
economy and service life. In traditional cars
cast iron is used as the manufacturing material of the brake system. But AMCs are more
beneficial due to their light weight, better wear
resistance and thermal conductivity. The use
of AMCs also contributes to the increase of acceleration and reduces the braking distance; it
also provides less noise and wear in the system.
Mainly Al-Mg or Al-Si-Mg alloys with 20
to 30% SiC are used in the brake system. The
use of these materials was initiated by the
‘Lotus Elise’ in 1996 when four disc rotors of
directly reinforced aluminium (DRA) were introduced. The temperature in the AMC brake
rotors never exceeds 380ºC, which leads to
less heating in brake discs and drums.
Various car manufactures are using AMCs
in some of their models. Some significant
names are VW Lupo, Toyota RAV-4EV, Plymouth Prowler, GM EV-1 and various racing
cars.
Brake callipers and pads: The use of AMCs
in brake callipers enables very rapid stopping
of wheel rotation compared with cast iron.
Formula 1 racing cars use 2124/SiC/25p which
supports the cars with great acceleration and
quick stopping. Currently, apart from ceramic
matrix composites AMCs are also used in
brake pads.
Pushrods: Pushrods are components which
transfer motion from the camshaft to valves.
In high-speed cars, it is necessary to have very
high rpm (revolutions per minute) to have great
speed and acceleration, which is unobtainable
with traditional steel used in cars. AMCs are
the best materials for obtaining higher rpm due
to their good stiffness along with very good
wear resistance and fatigue strength. 3M Corporation initiated the use of AMCs in pushrods with 30% Al2O3 in an aluminium matrix
instead of 4340 steel. The new material provided almost 25% higher stiffness and twice
the damping capacity compared with the traditionally used 4340 steel. This AMC increases
the engine speed to 250 to 400 rpm. 3M expects further development of AMC pushrods
with the optimisation of camshafts.
Connecting rods: Connecting rods connect
the pistons and crank shafts in reciprocating
engines. The rods have to be relatively lightweight to avoid any secondary vibration forces. In fact lower reciprocating loads can lead
to lower friction loads and can thus increase
fuel efficiency. Some prototype connecting
rods have been produced by using AMCs, but
bulk production is not yet due because of the
very high cost involved. Further research may
lead to a new era of using AMCs in connecting rods.
Body panels and structure: Using metal matrix composites in the car body panel is one of
the most widely discussed issues today. AMCs
provide good mechanical properties to be used
instead of steel but their wear resistance is
slightly lower than that of steel. If the AMC
sheets can replace steel sheets and the joining
technique is modified, then there will be no
hindrance in using AMCs in the car chassis or
body structure.
Others: AMCs are used in energy transmitting devices, wheels, valves, etc. In the gearbox
there are certain uses of AMCs due to their low
CTE and other thermal properties.
Economic impact of AMCs
In the last decade the use of AMC in the
transport sector has increased remarkably. A
AUTOMOTIVE
research report prepared by Global Industry
Analysts, Inc. states: “The aluminium matrix
composites market is projected to exceed
USD68 million by 2010. Among the various
end-use industries for metal matrix composites, the ground transport market, with a share
estimated at 57% for 2008, forms the largest, while the aerospace market is expected to
emerge as the fastest-growing, with a CAGR
of 7% over 2001-2010.”
References
1) G. Cole, A. Glove, R. Jeryan, G. Davies, s.l.: Steel
World, Vol. 2 (1) (1997), pp. 75–83.
2) Surappa, M. K. Feb/April 2003, s.l.: S¯adhan¯a,
pp. 319–334, Vols. Vol. 28, Parts 1 & 2.
3) Cost effective Titanium Matrix Composite. s.l.:
2002, Toyota Central R&D Lab, Inc.
4) GDA Gesamtverband der Aluminiumindustrie
(German Aluminium Association)
5) Automotive Engineering: Strategic Overview 2
(1). Sears, K.
6) Aluminium alloys for automobile applications,
in: A. Morita.
7) Automotive Applications of Metal-Matrix Composites. Hunt, W. H., Miracle, D.B., s.l.: OH: ASM
International, 2001. pp. 1029-1032.
8) Kevorkijan, V. M. (No. 11), s.l.: JOM, Vol. 51.
9) Aluminium alloys for automobile applications. A.
Morita. 2010, Wear, pp. 124-126.
Author
Md. A.I. Mehedi is an undergraduate student of the
Bangladesh University of Engineering and Technology (BUET). He is doing his B.Sc. on Materials and
Metallurgical Engineering. His primary interest lies
in metal matrix composites, renewable energy materials and failure analysis of materials. He is on the
Dean’s list of the university and has been awarded
the university merit scholarship for extraordinary
academic performance. Contact: aminulmehedi_
[email protected], Tel: +88-01726294358.
ZF erwirbt Honsel-Werk in Nürnberg
Die ZF Friedrichshafen AG erwirbt das Werk ZF takes over Nuremberg plant
Nürnberg des Automobilzulieferers Honsel.
Das Gesamtunternehmen wurde unlängst im from die-cast specialist Honsel
Rahmen des Insolvenzverfahrens vom Bieterkonsortium Martinrea/Anchorage übernom- ZF Friedrichshafen AG, located in Germany, Honsel, with total sales of lately about 650
men. Vorbehaltlich der Zustimmung durch die acquires the Nuremberg plant from the auto- million euros and around 4,000 employKartellbehörden übernimmt ZF von diesem motive supplier Honsel. The entire company ees worldwide, operates plants in Meschede
Bieterduo nun das Nürnberger Werk mit
(headquarters), Soest
rund 750 Mitarbeitern und knapp 150 Leihand Nuremberg, Gerarbeitern. Der Zulieferkonzern ZF sichert
many. In the current
damit seine Lieferkette für Pkw-Automatbusiness year, the
getriebe ab. Bereits vor einem halben Jahr
Nuremberg plant is to
hatte ZF die französische Honsel-Tochter
achieve sales of some
Fonderie Lorraine übernommen.
150 million euros. In
Honsel mit einem Gesamtumsatz von
Nuremberg, Honsel
zuletzt rund 650 Mio. Euro und weltmainly produces pasweit etwa 4.000 Mitarbeitern betreibt in
senger car transmisDeutschland Werke am Stammsitz Mesion housings and
schede sowie in Soest und Nürnberg. Das
transmission compoWerk Nürnberg erzielt im laufenden Genents from aluminschäftsjahr etwa 150 Mio. Euro Umsatz.
ium and magnesium.
In Nürnberg produziert Honsel vor allem
All employees will be
Pkw-Getriebegehäuse und Getriebeteile
taken over by ZF, so
aus Aluminium und Magnesium. Alle Mit- In Nürnberg produziert Honsel vor allem Pkw-Getriebegehäuse und Getriebeteile, they can keep their
arbeiter werden von ZF übernommen und wie sie für die Montage des 8-Gang-Automatgetriebes am ZF-Standort Saarjobs.
brücken eingesetzt werden
behalten ihren Arbeitsplatz
The plant achieves
The Honsel plant in Nuremberg produces passenger car transmission housings
Das Werk macht rund zwei Drittel and transmission components from aluminium which are used in ZF’s 8 speed
around two thirds of
Photo: ZF
seines Umsatzes mit dem ZF-Konzern, automatic transmission assembly in Saarbruecken
its sales with the ZF
der unter anderem Gehäuse für seine
group, which, among
Sechsgang-, Achtgang- und Doppelkupp- had been taken over recently by the tender others, obtains housings for its 6- and 8-speed
lungsgetriebe sowie Getriebe-Steuerteile consortium Martinrea/Anchorage within the and dual-clutch transmissions as well as transaus Nürnberg bezieht. „Das Werk Nürnberg scope of the insolvency proceedings. Subject mission control parts from Nuremberg. “The
dient uns als Druckguss-Keimzelle, mit der to approval by the cartel authorities, ZF now plant in Nuremberg serves as a die-casting
wir unsere Leichtbaukompetenz erhöhen“, takes over the Nuremberg plant with around centre which enhances our lightweight compoerklärt ZF-Chef Hans-Georg Härter. „Dort 750 employees and roughly 150 temporary nent expertise,” explains ZF-CEO Hans-Georg
haben wir genügend Ressourcen, um flexibel workers from the two tenderers. Automo- Härter. “This is where we have sufficient reauf die Kundennachfrage reagieren zu kön- tive supplier ZF thus secures its supply chain sources to be able to react flexibly to our cusnen. Selbstverständlich beliefern wir auch die for automatic passenger car transmissions. tomers’ demand. Of course, like in the past, we
anderen Kunden aus dem Werk Nürnberg in Only half a year ago, ZF acquired the French will also continue to supply the other customgewohntem Umfang weiter.“
ers from the Nuremberg plant.”
N Honsel subsidiary Fonderie Lorraine.
N
57
CO M PA N Y N E W S W O R L D W I D E
Norsk Hydro
Bauxite and alumina activities
Rio Tinto and Chinalco form
JV for exploration in China
Chinalco and Rio Tinto will explore mainland
China for world-class mineral deposits under
a joint venture. Once established the JV will
operate under the name Chinalco Rio Tinto
Exploration Co. Ltd (CRTX).
CRTX combines business expertise from a
leading Chinese company with cutting-edge
technologies and global mining and exploration experience from one of the world’s top
miners. Chinalco will hold a 51% interest in
the JV, and Rio Tinto will hold a 49% interest.
Chinalco will nominate three directors including the chairman plus the chief financial officer, deputy general manager and compliance
supervisor. Rio Tinto will appoint two directors
and the general manager, who will be responsible for day-to-day operations. It is expected
the CRTX headquarters will be in Beijing.
Trafigura buys Ormet bulk terminal
Ormet Corp. has found a buyer for its Louisiana marine terminal after a more than fouryear search. Impala Warehousing (US) LLC, a
wholly owned subsidiary of the Swiss trading
house Trafigura Beheer BV, acquired the idled
terminal in Burnside / Louisiana, for USD28m.
Trafigura plans to invest some USD100m to
reopen and expand the bulk terminal, which
will primarily be used to ship coal.
The bulk terminal will also ship some alumina and bauxite, including offloading and
discharging material for Ormet’s soon-to-berestarted alumina refinery in Burnside. A 30year Terminal Services Agreement (TSA) was
included as part of the sale and is intended to
provide reliable loading and unloading services to the Burnside refinery. The refinery is not
58
included in the sale.
After completing
its planned refurbishment and expansion of the terminal,
Trafigura is targeting a throughput of
some 10m tpy. The
Trafigura deal is an
important step for
the company, especially since USD10m
of the net proceeds
will be used to pay
down Ormet’s debt.
This is not the first time Trafigura and
Ormet have worked together in the US market. Ormet’s Hannibal smelter earmarks some
61% of its aluminium output for tolling arrangements with Trafigura and competitor
trading house Glencore International AG.
Hydro planning Brazilian capacity hike
Norsk Hydro will look to increase output
at its Alumina do Norte do Brasil SA (Alunorte) alumina refinery and Paragominas
bauxite mine this year as it folds the Brazilian upstream assets into its project portfolio.
Hydro aims to raise annual output levels to
more than 6m tonnes this year at Alunorte,
which expanded its capacity to 6.3m tonnes
in 2008 from 4.4m tonnes. Hydro has started
working on some identified bottlenecks. This
should improve results from both sites in the
near future. Hydro acquired majority stakes
in both projects when it closed its previously
announced takeover of Vale SA’s upstream
aluminium assets in February.
Rusal announces project for extraction
of low-iron bauxite in the Komi Republic
UC Rusal is launching a project to extract
low-iron bauxite in the Republic of Komi by
Timan Bauxite, a subsidiary of the company.
Future bauxite production is estimated to
reach 250,000 tpy. Bauxite will be extracted by open-cut mining at the Middle Timan
bauxite deposit. Timan Bauxite will launch
preparatory works at the new mine in order
to produce the first 90,000 tonnes of bauxite
by 2012. In addition, in 2011 Timan Bauxite
plans to acquire a highly efficient crushing and
sorting plant and to start production of basalt
rubble at the deposit. Year to date, over 100m
roubles have been already invested in these
two projects.
For information: the low iron bauxite is a
type of bauxite with a Fe2O3 content of less
than 4% in the calcined material. This bauxite is used for the manufacture of refractories
(chamotte bricks and clay), which can withstand temperatures up to 1,600°C; they are
resistant to chemicals and have a good thermal
conductivity.
Worsley efficiency and growth project
BHP Billiton announced the completion of the
budget and schedule review for the Worsley
Efficiency and Growth (E&G) project. The
capital cost estimate for the project, encompassing the development of the Marradong
mine, a refinery expansion and a connection
to a multi-fuel cogeneration unit, has increased
to almost USD3bn (BHP share). First production is now scheduled for the first quarter of
calendar year 2012.
The USD2.86bn (100% basis), 1.1m tpy refinery expansion is being executed within the
existing footprint of the facility, making it one
of the most complex brownfield projects undertaken. Such complexity has resulted in significantly lower levels of construction progress
than previously anticipated, while broader inflationary pressures and the strengthening of
the Australian dollar have also contributed to
the cost increase.
When complete the Worsley refinery will
be able to produce 4.6m tpy of smelter grade
alumina. Worsley Alumina is a joint venture
between BHP (86%), Japan Alumina Associates (Australia) Pty Ltd (10%) and Sojitz Alumina Pty Ltd (4%).
N
Secondary smelting
and recycling
Alcoa to invest USD21m
in advanced recycling process
Alcoa announced it will install an advanced
recycling and casting process that will reduce
energy consumption and greenhouse gas emissions as part of a USD21m expansion of B&C
Research, part of the company’s Wheel and
Transportation Products business. The new
facility, the first of its kind in North America,
will use innovative new technology to produce
billet from remelted aluminium scrap. The billet will then be used for new wheels.
According to Alcoa, the new recycling and
casting process is more efficient than conventional systems, lowering the company’s carbon
footprint by a 25% reduction in energy consumption. The expansion is scheduled to be
completed in the second half of 2012.
New records in US can recycling
The US recycling rate for aluminium beverage cans has reached its highest level in eleven years, with 58.1% of all cans recycled in
2010 – a rate that is more than double that
of any other beverage container, according to
The Aluminum Association and other industry bodies. Nearly 56bn aluminium cans were
recycled last year. The amount of energy saved
just from recycling cans in 2010 is equal to the
energy equivalent of 17m barrels of crude oil,
or nearly two days of all US oil imports.
Aluminium beverage cans can be infinitely
recycled back into new cans, keeping waste
out of landfills and providing a significant
amount of the material to make new cans. Indeed aluminium cans not only have the highest
recycling rate of all beverage packages, they
also have the greatest amount of recycled content – by far – at 68%.
“As the first link in the manufacturing supply chain, the scrap recycling industry provides
vital feedstock material sought after by industrial customers around the world, including
more than 4.6m tonnes of aluminium scrap
processed in the United States and shipped
throughout the US and more than 50 countries in 2010,” said Robin Wiener, president
of the Institute of Scrap Recycling Industries.
„Aluminium cans represent a valuable portion
of these recyclable commodities. Recycling is
much, much bigger than the bin at the curb.
Our industry provided a USD77bn boost to
the US economy in 2010, protected our environment and helped save energy and natural
resources.”
In 2008, the Aluminum Association adopted a goal of recycling 75% of aluminium cans
by 2015. The recycling rate at that time was
54.2%, and it has been gradually climbing upward since then; the 2009 UBC (Used Beverage Can) recycling rate was 57.4%.
N
EAFA
Aluminium semis
Groundbreaking ceremony for
aluminium rolling mill in Sohar
The Aluminium Rolling Mill Company, owned
by Takamul Investment Co., held the groundbreaking ceremony for its facility in Sohar
Industrial Estate on 19 June. The USD385m
investment is the biggest aluminium project in
the Sultanate. An estimated 140,000 tonnes
of multipurpose aluminium sheet will be manufactured at the rolling mill.
The construction of the project will be carried out by Fata EPC (a division of Fata SpA)
over a period of 31
months, and it is
expected to provide
more than 270 direct jobs, along with
a number of investment opportunities.
All
environmental and safety requirements for the
project were considered during the
designing
phase,
which included implementing the latest technology for
manufacturing aluminium flat rolled products.
Takamul Investment is involved in the development of value-added projects in the field
of petrochemicals, metals and mining. Takamul Investment is a 90% subsidiary of Oman Oil
Company; the remaining shares are owned by
Abu Dhabi Water and Electricity Authority and
Al Maha Strategic Industries for Investments.
With an annual capacity of 160,000 tonnes,
the facility will contain a Hazelett continuous
caster, while Fata Hunter will supply a hot rolling mill along with a world-class cold rolling
and finishing equipment. The plant will use
molten aluminium supplied by Sohar Aluminium for manufacturing rolled coils. This will
enable the company to produce aluminium
sheet of very thin gauges and high surface
quality with shorter product delivery time and
lower energy cost.
Norsk Hydro will boost
Brazilian extrusion operations
Norsk Hydro is investing NOK300m (USD
55m) to add another extrusion press at its aluminium extrusion plant in Brazil. The plant,
known as Hydro Alumínio Acro, is located in
Itú, near São Paulo, and supplies the South
American market with aluminium profiles and
precision tubing for use in the transport and
construction industries. Hydro has three presses at the plant, with one of the three dedicated
to heat transfer components and solutions,
while the other two are used to serve general
extrusion customers. The new extrusion press
will be operational by January 2013.
Annual per capita consumption of aluminium extrusions in Brazil is less than half
the figure in the USA, so there is considerable room for growth, and the investment is
in line with Hydro’s strategy of focussing on
emerging markets. Just recently the company
approved the addition of two new presses at
its plant in China.
The Brazilian plant was acquired by Hydro
in 1997. The company has some 330 employees. Hydro also has the precision tubing operation, which handles heat transfer applications,
and a remelting facility at the Itú site.
Sapa Profiles consolidates
European capacities
Sapa Profiles is optimising the operational
structure of its European business. In other
words: the company will consolidate its capacity in Belgium, the Netherlands and Portugal and reduce its workforce there. Sapa has
started a consultation process with employee
representatives.
Amcor invests in
Singen converting plant
Amcor Flexibles Europe & Americas has announced the investment of €6.7m in its Singen
converting plant in Germany. This will extends
the capacity for the production of pharmaceutical packaging and upgrades the classic
converting facility meeting the needs of the
59
pharmaceutical industry. The aluminum foil
rolling and converting plant, employing 1,100
people, has integrated mills and supplies high
quality multilayer aluminum-based packaging
materials to customers all over the world in
the pharmaceutical and food industries.
This investment will enlarge the Pharma
Clean Centre (LKM24) inaugurated three
years ago, with a further production hall housing three additional reel slitting machines. In
the future, sensitive packaging will be made
only in specific production areas in order to
meet the high cleanliness and hygiene standards of the pharmaceutical industry.
RTA Dubuc Works to increase production of Constellium Airware alloys
Rio Tinto Alcan’s (RTA) Dubuc plant in Quebec, Canada will increase its production of
highly specialised ‘Airware’ alloys for the
aeronautical industry by more than 50% following the signing of a contract with Constellium’s Global Aerospace division. To meet
the requirements of the new contract, Dubuc
Works will expand its operations. Construction work is already underway and should
continue over the next several months.
Constellium, formerly Alcan Engineered
Products, is a global leader in the development
and manufacturing of value-added aluminium
products for a wide range of markets and applications, including aerospace, mass transportation, automotive, packaging, energy and
construction. Headquartered in Paris, France,
Constellium is owned by Apollo Management (51%), Rio Tinto (39%) and the Fonds
Stratégique d’Investissement (10%). The company’s turnover was USD4.4bn in 2010 (see
also pp 47-49 this issue).
N
reduce unit costs considerably, while shortening lead times at the same time. The expansion
of the heavy-equipment bay will further improve production processes, in particular.
Aleris chooses Fröhling’s ‘Diamond
Mill’ technology for Duffel plant
Aleris has chosen Danieli Fröhling’s 6-high
‘Diamond Mill’ technology for the enhancement of the existing plant in Duffel, Belgium.
With the order, Danieli Fröhling is responsible for the overall supply of all mechanical,
electrical and automation equipment including
major auxiliary equipment such as the company’s innovative fume cleaning and oil recovery system DANECO2 as well as the DANPurity filter system. Besides the technological
equipment, Danieli Fröhling is also in charge
for erection and commissioning of the equipment to be supplied.
Fata EPC awards contract to Kampf
Fata EPC (Engineering, Procurement and
Construction) was assigned a large turn-key
project by Oman Aluminium Rolling Co. in
April 2011. The scope of this order includes
equipment for all processes of aluminium
sheet and medium gauge foil production:
caster, hot and cold rolling mill and finishing
equipment.
Kampf Schneid- und Wickeltechnik from
Germany has been selected to supply the slitting line for this new facility. The convincing
‘tight-line’ concept for this form of foil slitting
was one of a variety of reasons for placing
this order with Kampf. The Centurial Slitting
Line includes a web coating station for application of a range of oil-types to both sides of
the foil and Kampf’s profound knowledge with
this form of surface treatment also figured
prominently. This unique oiling system permits very precise dosing at all web-speeds.
The Centurial 20/15 is designed to slit foils
in the range of thickness from 75 μm up to
350 μm at production-speeds up to 800 m/
min, and winds the material to finished reels
having diameters up to 1,500 mm. This machine embodies all of the attributes of the
tried-and-tested, strong and rigidly constructed Kampf, type RKW 1003. Delivery of the
Centurial 20/15 will take place in mid-2012
to Sohar, Oman, and there it will be commissioned by Kampf engineers.
Hertwich continuous caster
increases production at Nalco
Hertwich Engineering, Austria, has successfully commissioned a horizontal continuous
caster for T-bars at the National Aluminium
Co. Ltd (Nalco) in India. The plant forms part
of an expansion project at the Angul works
in the state of Orissa which will expand Nalco’s capacity to 115,000 tpy, of which 60,000
tonnes of T-bars will be produced on the new
horizontal continuous caster from Hertwich.
Horizontally cast T-bars have clear quality
advantages: a fine, uniform microstructure,
minimum inclusions and oxides, no surface
cracks or pores and an exact geometry. The
scope of supply includes the casting plant with
flying saw and the downline transport and
packaging facilities. The caster is 3,000 mm
Suppliers
SMS Meer, Germany, a company of the SMS
group, will be investing around €60m in the
expansion of its Mönchengladbach site by
2015. “We are increasing productivity, reducing delivery times and thereby safeguarding jobs at the site over the long term,” said
Joachim Schönbeck (see photo, 3rd from left),
president and CEO of the leading specialist in
plant construction and mechanical engineering, at the symbolic ‘turning of the first sod’
in mid-July.
The modernisation of the machinery will
60
SMS Meer
SMS Meer invests €60m in
its Mönchengladbach site
‘Turning of the first sod’ at SMS Meer in Mönchengladbach
wide. T-bars of 850 x 300 mm are cast continuously in three strands and then sawn to lengths
of 1,050 mm.
Alcan International Network up for sale
Apollo Global Management LLC has put Alcan International Network (AIN) up for sale
following its acquisition of Alcan EP (now
Constellium). The private equity firm is believed to have received several expressions
of interest for AIN. The potential suitors are
from the financial community rather than
from the metals sector.
AIN is part of the engineered products division of Constellium. A sale would be logical
as the business does not fit into the new company strategy. Under the new ownership, AIN
does not have an exclusive supply or sales
agreement with Constellium, for example.
AIN has a network of 27 agencies supplying raw materials to the aluminium, steel and
foundry industries, semi-fabricated products
for construction, transportation, general engineering, packaging and industrial markets
mainly in North America and Asia, as well as
minerals and specialty chemicals, generating
USD2bn in sales in 2009.
Vimetco withdraws from
its joint venture with Interagro
Vimetco N.V. has decided to withdraw from
its joint venture project for a coal fired power
plant in the city of Turnu Magurele, Romania.
The project, intended to be developed together
with the Romanian company Interagro S.A.,
is currently suspended due to the impact of
the international financial crisis. In recent
The Author
The author, Dipl.-Ing. R. P. Pawlek, is founder
of TS+C, Technical Info Services and Consulting, Sierre (Switzerland), an established 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 the Alu Media GmbH in Düsseldorf, Germany.
years, Vimetco has focused on developing its
Romanian operations and has invested in increasing the efficiency of its aluminium operations. In 2009, Vimetco’s aluminium smelter,
Alro S.A., restarted its alumina refinery, Alum
Tulcea, thereby ensuring the necessary raw
materials for the plant in Slatina. This year,
the company further consolidated its business
in Romania, after its subsidiary, Alum S.A.,
took over the operation of the company’s
bauxite mines in Sierra Leone.
Bolzoni Auramo and Meyer
establishes subsidiary in Russia
Bolzoni Auramo and Meyer, a leading manufacturer of forklift attachments, lift tables and
forks in Europe, is further developing its business structure in the CIS and Baltic countries
– markets that are currently significantly growing. Already in 2010, the import volumes of
forklift trucks reached a pre-crisis level.
In April 2011 the company established
a subsidiary company in Moscow: ‘Hans H.
Meyer OOO’ LLC, which provides the full
Bolzoni Auramo and Meyer range of high
quality forklift truck attachments, lift tables
and forks, and a customer-oriented product
consultation.
“This new organisational structure is aiming to increase the level of service to our Russian customers,” says Denis Babushkin, managing director of the newly founded company.
“It is planned to actively develop, alongside
to our continuous sales activities, a broad variety of after sales and services elements, offering more than just product advice to our
customers for the entire life of our products.
Supplies of spare parts, repairs, refurbishing of
used attachments and rental are some of these
elements,” he says.
In addition, a local stock of new attachments, based in Moscow, has been made available to the market already since July 2011,
soon to be followed by the establishment of
the after sales activities. The subsidiary will
also continue to coordinate the business activities for the markets in Ukraine, Belorussia, Kazakhstan, Moldova and the Baltic States. N
On the move
Alba announced the appointment of Boris
Santosi as the new sales manager for the European market. Mr Santosi will be based at Alba’s
new European sales office in Zurich. He will be
reporting directly to chief marketing officer Jean
Baptiste Lucas.
Primary aluminium producer Ormet Corp. has
named Matthew T. Powell as commercial vice
president, effective 1 July.
Alcoa’s Asia-Pacific regional president Jinya
Chen has been elected by the company’s board
to serve as a vice president. In addition to continuing to oversee the region, Chen will now
also be accountable for Alcoa’s China strategy.
Jiming Zhu will join Alcoa as president of its
Chinese rolled products unit. Zhu replaces Mark
Vrablec, who has been named vice president of
global rolled products technology and engineering, and will relocate to the US. The Alcoa board
voted to name Kay Meggers vice president in a
new role that will add to an existing stable of
vice presidents.
Cape Alumina, the Australian bauxite exploration company, has appointed Graeme Sherlock
its new CEO.
Aleris International has appointed Steven
Faas senior vice president and chief information
officer, with responsibility for all information
technology activities for the company.
Tom Petter Johansen from Hydro will take over
as CEO of Qatalum on 1 July. Johansen succeeds
Jan Arve Haugan, who is taking on a new position as CEO of Norwegian oil and gas contractor
Kvaerner ASA.
The annual general meeting approved the
new composition of Vimetco’s board of directors, appointing two new members: Marian
Nastase, as an executive member of the board
and chief financial officer of the company, and
Pavel Machitski, as executive member of the
board. Frank Mueller’s mandate as a board
member and CEO of the company has expired
and was not renewed. Vimetco’s board of directors appointed Gheorghe Dobra acting CEO,
while Mr Mueller was appointed managing
director for production and development of
value-added products.
Paul May, CEO of Wagstaff Inc., retired in
May. Kevin Person, vice president of sales and
marketing, has assume the role of CEO and Lee
Swartling, area sales manager for Russia, Romania and Ukraine, has become vice president of
sales and marketing.
Takaaki Takeuchi, managing director
of Alucon Public Co. Ltd, has been elected
president of the International Organisation of
Aluminium Aerosol Container Manufacturers
(Aerobal).
61
RESEARCH
Investigation of the influence of low cycle
bending on the properties of thin sheets
M. Hepke1), M. Rodman1), H. von Senden gen. Haverkamp1), J. V. Zilberg2), A. A. Briukhanov3),
D. Bormann1), M. Schaper1), Fr.-W. Bach1)
1)
2)
Institute for Materials Science, Leibniz-University, Garbsen, Deutschland,
National Metallurgical Academy of the Ukraine, 3) Odessa University, Ukraine
Low cycle, alternating bending is a common type of forming during the manufacture and processing of thin sheets. This
forming occurs during the rolling-up into
and rolling-out from coils, whilst passing through rolling equipment during
the etching process, washing, coating,
straightening, bending and deep drawing.
Investigations of the mechanical properties, the microstructure and texture
of sheets made of the magnesium alloy
AZ31, technically pure aluminium and
low carbon steels were carried out following cyclic bending on a 3-roller bending
machine and on an 11-roller straightening
machine. A significant influence of this
type of forming on the sheet’s properties was established, in particular for
materials possessing hcp crystal lattice
structures. Pronounced anisotropic properties were observed in the latter material
which can be explained by the effect of
texture softening. This can be attributed
to the activation of twin formation mechanisms in the bending direction.
During the rolling of thin sheet, the material
is subjected to multiple forming by means of
alternating bending loads at different stages
of the manufacturing process. This occurs
during rolling-up into and rolling-out from
coils, during the etching, washing, coating and
straightening. These processes operate under
conditions of single, low deformations and do
not lead to geometric changes in the sheet’s
dimensions. However, they can influence the
sheets properties. Previous investigations have
shown that this type of forming can have a decisive influence on the stress-strain curves and
the mechanical properties [1, 3]. In the current work, results are presented for investigations of the mechanical properties, the sheet’s
microstructure and texture for different materials which possess bcc, fcc and hcp crystal
lattices. The corresponding materials include
a low carbon steel DC01, a technically pure
aluminium Al (99.9%) and a magnesium alloy (AZ31).
62
Fig. 1: Stress-strain diagrams in the rolling (0°) and transverse (90°) directions following 0, 0.5 and 3
bending cycles; a – AZ31, b – Al, c – DC01
EXPERIMENTS
The cyclic bending was performed on a pipe
bending machine using a bending radius of
25 mm and a fraction of the specimens was
deformed on a straightening machine using
11, 25 mm radius rollers of width 100 mm.
One bending cycle consisted of bending in one
direction, then bending flat to the horizontal
position, subsequently bending in the other direction and then bending flat to the horizontal
again. The number of cycles using the pipebending machine are varied between 1 and 18,
and 5.5 cycles per pass can be realised using
the straightening machine. A fraction of the
specimens was subjected to cyclic, cruciform
straightening where the sheets were rotated
through 90° after each pass. Some specimens
were annealed after bending. Following the
tests, specimens were taken from the sheets
for the tensile tests (longitudinal, transverse
and at 45°), the metallographic examinations
and the textural measurements using pole figures.
RESULTS
Stress-strain-diagrams: An analysis of the
stress-strain diagrams shows that, in the case
of the AZ31 magnesium alloy’s deformation,
the cyclic bending has a decisive influence on
the diagrams’ form. Subsequent to 3 bending
cycles, a kink is formed in the curves, which
accompanies a reduction in the yield strength
within the forming range between 0.5% and
1.0%. This effect can be observed in specimens
which were manufactured in the bending direction (see Fig. 1a). Under analogous conditions,
the monotonic characteristic of the curves are
not changed in the transverse specimens: Although the stress level is elevated. Generally,
the level of the flow stresses in the longitudinal
specimens is lower than those in the transverse
specimens. Materials with fcc and bcc crystal
lattices retain the monotonic character of their
stress-strain curves following cyclic bending.
Here, the stress level for aluminium tested in
the longitudinal direction is more strongly elevated than for that tested in the transverse
direction whereas for steel, the level is raised
equally for both directions (see Fig. 1c). It was
generally possible to establish that the stressstrain curves’ character had already stabilised
after 3 bending cycles.
Investigations of the mechanical properties
showed that cyclic bending has the largest influence on the yield point RP0.2, in which the
influence significantly differs for both crystal
lattices. For the magnesium alloy AZ31, which
has a hcp crystal lattice, the work softening
effect in the bending direction already attains
its maximum after one bending cycle and remained constant in the course of further loading. In comparison to the initial material prior
to the bending, the yield point RP0.2 is reduced
by 40%, whereas a work hardening of 7%
RESEARCH
Fig. 2: Changes in the yield point (a, b, c) and tensile strength (b) plotted against bending cycles as a
function of the testing direction: a, b – AZ31; c – Al; d – DC01
can be observed in the transverse direction
after 3 bending cycles. This effect induces significant isotropy in the sheet’s properties (see
Fig. 2a).
For the aluminium and the steel, the cyclic
bending load leads to an elevation of RP0.2 but
the anisotropy is minimal for both the longitudinal as well as for transverse specimens, (see
Fig. 2c and d). The severest work hardening
can be observed following 0.5 bending cycles
in aluminium. In the course of further bending, the work hardening stabilises. In steel, the
work hardening linearly rises also after one
bending cycle. After 3 bending cycles, the aluminium and steel work harden to approx. 30%.
The influence of the cyclic bending is significantly smaller on the tensile strength Rm, which
is determined at considerably higher levels of
forming than the yield point RP0.2. Whilst, for
the magnesium alloy AZ31, a work hardening
of 5% to 6% is observed in the transverse
direction following 3 bending cycles, this can
not be established in the longitudinal direction
(see Fig. 2b). A change in the tensile strength
Rm of aluminium and steel can not be observed
following cyclic bending.
The values of the fracture strain A and the
uniform strain Agl are isotropic and uniform in
the longitudinal and transverse directions following cyclic bending. The largest reduction in
the fracture strain A (by 15% to 20%) can be
observed for the magnesium alloy AZ31 after
3 cycles. Here, the uniform strain is reduced by
10%. The corresponding reductions of these
parameters are 5% and 10% for aluminium
and 5% for steel.
Texture analysis: The investigations of the texture carried out using the pole figure method
showed that the alloy AZ31 exhibits a typical,
ideal basal-orientation with a maximum intensity at the centre. Following 3 bending cycles,
the pole figure exhibits a scattering (stretching)
in the bending direction. In the same direction, the maximum intensity is translated and,
in doing so, its amount decreases. Simultaneously, a change in the pole figure can be observed with increasing maximum intensities
for the prismatic planes (see Fig. 3a). In these
planes, twins are formed in magnesium alloys,
for which the required stress is considerably
smaller than for deforming in the basal and the
pyramidal planes. The formation of twins under cyclic bending conditions obviously has a
large influence of the sheet’s properties for the
magnesium alloy AZ31. This is reflected in the
change of the stress-strain curves’ trajectories,
within the range of small levels of forming, and
in the level of the mechanical properties.
An analysis of the aluminium’s and steel’s
pole figures shows almost no influence of
the cyclic bending on the texture (see Fig. 3b
and c).
Metallographic examinations have shown
that, following 3 bending cycles, a large number
of twins can be observed in the surface layers
of the alloy AZ31’s sheet, whereas no twins
are established in the region of the sheet’s
neutral fibres. For aluminium and steel, no
changes can be observed either at the surface
or in the deeper layers (see Fig. 4b and c).
Results of the performed investigations
show cyclic bending exerts the largest influence on the properties of the sheet made of a
material which possesses a hcp crystal lattice.
Investigations of the 1 mm thick sheets’ texture for the magnesium alloy AZ31 (see Fig. 5)
show that the pole figures at the surface and at
a depth of 0.25 mm are almost the same (see
Fig. 5b and c). Adjacent to the sheet’s neutral
fibres, the pole figure exhibits a typical basal
texture, such as that in the initial material prior
to bending (see Fig. 5a). Forming by means of
alternating bending loads activate the system
of twin formation which results in a texture
with a deviation of the basal pole’s angle of
approx. 30 %, (see Fig. 5b and c). The sheets
are softened and their properties are anisotropic with respect to both the plane and the
thickness.
DISCUSSION
Fig. 3: Pole figures as a function of the number of bending cycles; a – AZ31; b – Al; c – DC01
The large influence of cyclic bending loads on
the sheets made of the magnesium alloy AZ31
can be explained by the limited possibilities
for basal slip subject to the conditions of low
63
RESEARCH
erties can be observed within the first bending
cycles.
3) Materials possessing a hpd lattice structure
show strain softening in longitudinal and strain
hardening in transversal direction; this induces significant anisotropy in the sheet’s properties.
4) Materials possessing a kfz and krz lattice
structure show no significant anisotropy in the
sheet’s properties.
5) Cyclic bending has the largest influence
on the yield point RP0.2, whereas the tensile
strength and the fracture strain show very little
change.
6) The strain softening of metals possessing a
hdp lattice structure can be explained by the
formation of texture, which is caused by formation of twins.
Fig. 4: Microstructure longitudinal to the bending direction as a function of the number of bending
cycles; a – AZ31; b – Al; c – DC01
ACKNOWLEDGEMENTS
The authors would like to express their thanks
to the Deutsche Forschungs-Gemeinschaft
DFG (German Research Foundation) for the
support of this projekt.
REFERENCES
Fig. 5: (002) pole figure (AZ31) for the initial material (a); of the bent sheet (1 bending cycle), on the surface (b) and at a depth of 0.25 mm (c)
level cold forming. Here, a significant part of
the deformation takes place by means of the
mechanism of twin formation. For the sheets
of aluminium and steel, the mechanism of twin
formation plays a minor role. For this reason,
isotropic work hardening with an elevated
dislocation density can be observed for these
materials subject to the conditions of cyclic
bending.
The consequences of anisotropic properties
can ensue during straightening which in turn
affects the quality during the deep drawing
process. Special experiments were carried out
which demonstrate that the anisotropic prop-
erties of sheet material made of magnesium
alloy AZ31, which arise due to monotonic
forming (5% to 10%) during rolling followed
by cruciform straightening, can be minimised
by heating the metal from 200 to 250 °C during the final pass and then subsequently annealing [2].
Patentblatt April 2011
Membranelement und Verfahren zum Verkleiden von Flächen, insbesondere von Decken
oder Wänden. Greiner, Switbert, Dr., 70771
Leinfelden-Echterdingen, DE; Gutmann, Christofer, Dr., 77855 Achern, DE. (E04B 9/30, PS 50
2008 000 474, EP 2099980, EP-AT: 07.01.2008)
Fortsetzung aus ALUMINIUM 6/2011
Lötverfahren für Wärmetauscher und Solarkollektoren. Hydro Aluminium Deutschland
GmbH, 53117 Bonn, DE. (B23K 1/00, EPA
2295182, EP-AT: 09.09.2010)
Verfahren zur Herstellung von Solarkollektoren. Hydro Aluminium Deutschland GmbH,
53117 Bonn, DE. (B23K 1/00, EPA 2295183, EPAT: 09.09.2010)
64
CONCLUSIONS
1) Cyclic bending has large influence on the
materials properties of thin sheest, especiallay
for metals possessing a hdp lattice structure.
2) The strongest alternation in materials prop-
Verfahren und Sprühvorrichtung zum Aufbringen eines Oberflächenbehandlungsmittels auf eine Formwand einer Gussform. KS
Aluminium-Technologie GmbH, 74172 Neckarsulm, DE. (B05D 1/02, PS 10 2009 010 361, AT:
25.02.2009)
[1] Bach, Fr.-W.; Rodman, M.; Rossberg, A.: High
Quality Magnesium Sheets for Automotive Applications, Proceeding of the International Conference
’Sheet Metal 2005’, Erlangen 5-8 April 2005, pp.
665-672, ISBN 0-87849-972-5.
[2] Bach, Fr.-W.; Rodman, M.; Hepke, M.; Bormann,
D.: Investigation of the Mechanical Properties of
Magnesium Alloy AZ31 Sheets due to a Straightening Process, Proceeding of the 8th International
Conference ’Magnesium Alloys and their Application’, 2009, pp. 830-835, 26-29 Oktober 2009,
Weimar, ISBN 978-3-527-32732-4.
[3] Hepke, M.; Rodman, M.; Bach, Fr.-W.; Zilberg,
J. V.: Einfluss einer alternierenden Biegebeanspruchung auf die mechanischen Eigenschaften der Magnesiumlegierung AZ31; ALUMINIUM 5/2010, p.
55-58
Contact: [email protected]
Fenster- oder Türkonstruktion in bevorzugt
wärmegedämmter Ausführung. Norsk Hydro
ASA, Oslo, NO. (E06B 7/10, GM 20 2010 016
800, AT: 18.12.2010)
Fenster- oder Türflügelkonstruktion. Hermann
Gutmann Werke AG, 91781 Weißenburg,
DE. (E06B 3/56, PS 10 2006 002 820, AT:
19.01.2006)
Verfahren zur Herstellung eines Kolbens einer
Brennkraftmaschine mittels induktiver Energiezufuhr und Laserbestrahlung. KS Kolben-
PAT E N T E
schmidt GmbH, 74172 Neckarsulm, DE. (C22F
3/00, OS 10 2009 025 064, AT: 10.06.2009)
Gießen von thixotropem halberstarrten Metall. Honda Motor Co., Ltd., Tokyo 107-8556, JP.
(B22D 17/32, EPA 2292353 u. EPA 2289650, EPAT: 29.06.2004)
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)
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)
Abstandhalter für Scheiben von Mehrfachisoliergläsern. Erbslöh Aluminium GmbH, 42553
Velbert, DE. (E06B 3/663, EP 1 554 455, WO
2004/038155, EP-AT: 22.10.2003, WO-AT:
22.10.2003)
Zylinderkurbelgehäuse für Kraftfahrzeuge. KS
Aluminium-Technologie GmbH, 74172 Neckarsulm, DE. (B22D 19/14, PS 50 2006 006 651, EP
1924373, EP-AT: 11.09.2006)
Vorrichtung und Verfahren zum waagerechten
Gießen und Schneiden von Metallknüppeln.
Novelis Inc., Toronto, Ontario M5J 1S9, CA. (B22D
11/126, EPA 2286940, EP-AT: 09.12.2004)
Oxidrückhaltung beim gleichzeitigen Gießen
von Metallen. Novelis, Inc., Toronto, ON
M8Z 1J5, CA. (B22D 7/02, EPA 2288456, WO
2009/140762, EP-AT: 21.05.2009, WO-AT:
21.05.2009)
Verfahren und Vorrichtung zum Entfernen
von Kühlwasser aus Blöcken mittels Wasserstrahlen. Novelis Inc., Toronto, ON M8Z 1J5, CA.
(B22D 7/12, EPA 2293892, WO 2009/146527,
EP-AT: 28.05.2009, WO-AT: 28.05.2009)
Verbundrohre. Novelis Inc., Toronto, ON M8Z
1J5, CA. (B32B 1/08, EPA 2293929, WO 2009/
146993, EP-AT: 07.05.2009, WO-AT: 07.05.
2009)
Gießform mit Gasdrucksteuerung. Nippon
Light Metal, Co., Ltd., Shinagawa-ku, Tokyo
140-8628, JP. (B22D 11/041, EPA 2292351,
WO 2010/001459, EP-AT: 30.06.2008, WO-AT:
30.06.2008)
Verfahren zur Herstellung von Aluminiumtitanatkeramik. Sumitomo Chemical Co., Ltd.,
Tokio 104-8260, JP. (C04B 35/46, EPA 2295388,
WO 2009/154219, EP-AT: 17.06.2009, WO-AT:
17.06.2009)
Patentblatt Mai 2011
Aluminium-Diamant-Verbundstoff und Herstellungsverfahren dafür. Denki Kagaku Kogyo
Kabushiki Kaisha, Tokyo 103-8338, JP. (B22D
19/00, EPA 2305400, WO 2010/007922, EP-AT:
08.07.2009, WO-AT: 08.07.2009)
Verschmolzene Körner aus Oxiden mit Al, Ti,
Mg und Zr sowie Keramikprodukte mit derartigen Körnern. Saint-Gobain Centre de Recherches et d’Etudes Européen, 92400 Courbevoie, FR.
(C04B 35/462, EPA 2303796, WO 2010/001065,
EP-AT: 02.07.2009, WO-AT: 02.07.2009)
Al-Zn-Mg-Cu-Legierung. Corus Aluminium Walzprodukte GmbH, 56070 Koblenz, DE. (C22C 21/10,
OS 11 2004 000 603, WO-AT: 09.04.2004)
Verfahren zur Herstellung eines Bandes aus
Aluminium für Verpackungszwecke und derart
hergestelltes Band. Hydro Aluminium Deutschland GmbH, 53117 Bonn, DE. (B21H 7/00, EPA
2303489, WO 2009/127730, EP-AT: 17.04.2009,
WO-AT: 17.04.2009)
Verfahren und Vorrichtung zur Bildung von
Legierungen auf Titan-Aluminium-Basis. Commonwealth Scientific & Industrial Research
Organisation, Campbell, Australian Capital Territory 2612, AU. (B01J 19/18, EPA 2296805,
WO 2009/129570, EP-AT: 21.04.2009, WO-AT:
21.04.2009)
Aluminiumhaltige Wasserglaslösungen. Cognis
IP Management GmbH, 40589 Düsseldorf,
DE. (C01B 33/32, EPA 2305603, EP-AT:
05.10.2009)
Al-Cu-Mg-Legierungen mit Zusätzen von
Lithium. Alcoa Inc., Pittsburgh, PA 152125858, US. (C22C 21/16, EPA 2305849, EP-AT:
27.09.2004)
Verbessertes Verfahren zur Filterung von
geschmolzenem Aluminium und geschmolzenen Al-Legierungen. Porvair PLC, King’s Lynn,
Norfolk PE30 2HS, GB. (C22B 21/06, EPA
2304065, WO 2010/005716, EP-AT: 16.06.2009,
WO-AT: 16.06.2009)
Feuerfestes Chrom-Aluminium-Material. Harbison-Walker Refractories Co., Moon Township,
PA 15108, US. (C04B 35/057, EPA 2303795,
WO 2010/011516, EP-AT: 13.07.2009, WO-AT:
13.07.2009)
Einstückig
spritzgegossener
AluminiumHarz-Artikel und Verfahren zur Herstellung
dieses Artikels. Nippon Light Metal Co., Ltd.,
Tokyo 140-8628, JP; Polyplastics Co., Ltd., Tokyo 108-8280, JP. (B29C 45/14, EPA 2298525,
WO 2009/151099, EP-AT: 11.06.2009, WO-AT:
11.06.2009)
Verminderung der Hochtemperatur-HalogenKorrosion in Verbrennungsanlagen durch
den Einsatz von Aluminium-Verbindungen in
Wirkstoffmischungen. Gellermann, Siegfried
T., 55124 Mainz, DE; Külps, Heinz-Jürgen, Dr.,
55278 Dalheim, DE; Müller, Martin, Dr., 55578
Wallertheim, DE. (F23G 5/44, PS 101 43 136, AT:
03.09.2001)
Korrosionsschutzbeschichtungen, insb. für
Aluminium, und Mischungen zu ihrer Herstellung. Fraunhofer-Gesellschaft zur Förderung
der angewandten Forschung e.V., 80686 München, DE. (B05D 7/24, OS 10 2009 052 399, AT:
10.11.2009)
Verfahren und Systeme zum Vorhersagen von
Ermüdungsbeständigkeit in Aluminium-Gussteilen. GM Global Technology Operations LLC,
Detroit, Mich., US. (B22D 46/00, OS 10 2009 019
366, AT: 29.04.2009)
Sequenzielles Auslagern von Al-Si-Gusslegierungen. GM Global Technology Operations LLC,
Detroit, Mich., US. (C22F 1/043, OS 10 2009 024
190, AT: 08.06.2009)
Gelöteter Aluminium-Wärmeübertrager. Behr
GmbH & Co. KG, 70469 Stuttgart, DE. (F28F
21/00, OS 10 2009 055 608, AT: 25.11.2009)
Aluminium-Formgussprodukte und ihre Umwandlung. Hitachi, Ltd., Tokyo, JP. (C22C 21/02,
OS 10 2010 039 556, AT: 20.08.2010)
Warmumformwerkzeuge für Aluminium- und
Magnesiumbleche. GM Global Technology Operations LLC, Detroit, Mich., US. (B21D 22/02, OS
11 2009 000 494, WO-AT: 02.03.2009)
Aluminium-Systembalkon. Döring, Martin,
42551 Velbert, DE. (E04B 1/00, GM 20 2004 014
203, AT: 13.09.2004)
Anschlusskasten aus Mg-Al-Legierung für ein
Photovoltaik-Modul. Ningbo Renke Photovoltaic
Appliance Co., Ltd., Ningbo, CN. (H02G 3/16,
GM 21 2010 000 007, WO 2011/012008, AT:
19.05.2010, WO-AT: 19.05.2010)
Fahrwerksteil aus Al-Verbundwerkstoff. Hydro Aluminium Deutschland GmbH, 51149
Köln, DE. (C22C 21/06, EPA 2302087, EP-AT:
15.09.2009)
Lithium-Aluminium-Silikatglas mit kurzen
Keramisierungszeiten. Schott AG, 55122 Mainz,
DE. (C03C 10/12, PS 50 2006 007 025, EP
1837312, EP-AT: 20.03.2006)
Aluminium-Lastwiderstand. Türk + Hillinger
GmbH, 78532 Tuttlingen, DE. (H01C 1/036, EP
2 182 529, EP-AT: 24.10.2009)
Aluminium-Gusslegierung. Corus Aluminium
Voerde GmbH, 46562 Voerde, DE. (C22C
21/08, PS 601 41 789, EP 1167560, EP-AT:
20.04.2001)
Verfahren und Vorrichtung zur Produktion von
Aluminium. Aleris Aluminum Koblenz GmbH,
56070 Koblenz, DE. (C25C 3/24, PS 60 2006 014
108, EP 1863953, EP-AT: 27.03.2006)
Verfahren zur Herstellung eines Indium-Gallium-Aluminium-Nitrid-Dünnfilms auf einem
Siliziumsubstrat. Lattice Power (Jiangxi) Corp.,
Nanjing East Jiangxi, CN. (H01L 33/00, EP 930
957, WO 2007/036163, EP-AT: 29.09.2006,
WO-AT: 29.09.2006)
Verfahren zur Trennung von schmelzflüssigem
Aluminium und festen Einschlüssen. Aleris
Switzerland GmbH, Schaffhausen, CH. (C22B
21/06, EP 2 029 785, WO 2007/147587, EP-AT:
20.06.2007, WO-AT: 20.06.2007)
Texturgehärtetes alpha-aluminiumbeschichte-
65
PAT E N T E
tes Werkzeug. Seco Tools AB (publ), Fagersta, SE.
(C23C 14/40, EP 1 953 258, EP-AT: 29.01.2008)
(C22C 1/02, EP 1 721 996, WO 2005/080617, EPAT: 21.02.2005, WO-AT: 21.02.2005)
Verfahren zur Herstellung eines Hartlötbleches
aus einer Aluminiumlegierung und leichte hartgelötete Wärmetauscheranordnungen. Aleris
Aluminium Koblenz GmbH, 56070 Koblenz,
DE. (B32B 15/01, PS 60 2005 021 902, EP
1802457, EP-AT: 30.09.2005)
Verfahren zur Reduktion einer Korrosion zwischen Magnesium und einem weiteren Metall.
GM Global Technology Operations LLC, Detroit,
Mich., US. (C23C 4/12, OS 10 2009 056 672, AT:
02.12.2009)
Selbst abgeschiedene Beschichtungen auf Magnesiumlegierungen. GM Global Technology
Operations LLC, Detroit, Mich., US. (C25D 13/04,
OS 11 2009 001 005, WO-AT: 22.04.2009)
Systeme und Verfahren zur Vorhersage von
Ermüdungslebensdauern von Aluminiumlegierungen unter mehrachsiger Beanspruchung.
Mich., US. (B22D 46/00, OS 10 2010 009 318,
AT: 25.02.2010)
Verfahren zum anodischen Oxidieren metallischer Legierung, insb. für die Wärmetauscher
aus Aluminiumlegierung und dergleichen für
Brennwertgeräte. Unical AG S.p.A., 46033 Castel d’Ario (MN), IT. (C25D 11/02, EPA 2298967,
EP-AT: 09.09.2010)
Magnesium-Titan-Mischkristalllegierungen.
Mich., US. (C23C 14/00, OS 11 2008 002 388,
WO-AT: 02.09.2008)
Legierungen auf Magnesiumbasis mit hoher
Festigkeit/Duktilität für konstruktive Anwendungen. GM Global Technology Operations LLC,
Detroit, Mich., US. (C22C 23/02, OS 11 2007 001
169, WO-AT: 16.05.2007)
Aluminiumlegierung und -verfahren zu ihrer
Herstellung. Aleris Aluminum Bonn GmbH,
53117 Bonn, DE. (C22C 21/02, EP 0 936 278,
EP-AT: 17.02.1998)
Aluminiumlegierung für Motorbauteile. GM
Global Technology Operations LLC, Detroit,
Mich., US. (C22C 21/12, PS 10 2007 042 099,
AT: 05.09.2007)
Wärmebehandlung mit direktem Abschrecken für Aluminiumlegierungs-Gussteile. GM
Global Technology Operations LLC, Detroit,
Mich., US. (C22F 1/04, OS 10 2009 049 999, AT:
20.10.2009)
Verfahren zum Verbessern der mechanischen
Eigenschaften von Druckgussteilen aus einer
Aluminiumlegierung. GM Global Technology
Operations LLC, Detroit, Mich., US. (C22F 1/04,
OS 10 2010 009 005, AT: 24.02.2010)
Gießen einer Aluminiumlegierung mit gesteuerter Erstarrung. United Technologies Corp.,
Hartford, Conn., US. (B22D 30/00, EP 1 767 292,
EP-AT: 19.09.2006)
Verfahren zum Bilden einer mehrfarbigen
Aluminiumlegierung. Hsu, Chia-Wei, Taiching
City, TW. (C25D 11/04, EP 2 177 647, EP-AT:
25.08.2009)
Verbessertes Warmauslagerungsverfahren für
Aluminiumlegierungen. GM Global Technology
Operations LLC, Detroit, Mich., US. (C22F 1/04,
PS 10 2009 011 258, AT: 02.03.2009
Metallbehandlung zur Eliminierung von Warmrissdefekten in Aluminiumlegierungen mit
niedrigem Siliziumgehalt. GM Global Technology Operations LLC, Detroit, Mich., US. (C22C
21/02, PS 10 2009 015 316, AT: 27.03.2009)
Ein beschleunigter Lösungsbehandlungsprozess
für Aluminiumlegierungen. GM Global Technology Operations LLC, Detroit, Mich., US. (C22C
21/02, OS 10 2009 029 848, AT: 22.06.2009)
Verfahren zur Verbesserung der Eigenschaften
von Aluminiumlegierungen, die durch Festkörperverbindung hergestellt worden sind. The
Boeing Co., Chicago, Ill., US. (B23K 20/00, PS 60
2005 021 732, EP 1634670, EP-AT: 12.09.2005)
Verschweißen von Leichtmetall-Werkstücken
durch Reaktionsmetallurgie. GM Global Technology Operations LLC, Detroit, Mich., US. (B23K
20/233, OS 10 2010 013 894, AT: 07.04.2010)
Verfahren zur Herstellung einer Wasserstoffeinschlusslegierung auf Basis von Mg-REM-Ni.
Japan Metals and Chemicals Co., Ltd., Tokyo, JP.
66
Einbruchsicherung für eine Tür oder ein Fenster. Norsk Hydro ASA, Oslo, NO. (E06B 5/11,
OS 10 2009 053 531, AT: 18.11.2009)
Verfahren zum Anodisieren von Magnesium
und Magnesiumlegierungen und zur Herstellung von leitfähigen Schichten auf einer anodisierten Oberfläche. Alonim Holding Agricultural
Cooperative Society Ltd., Alonim, IL. (C22C 1/00,
PS 602 36 006, EP 1436435, EP-AT: 25.06.2002,
WO-AT: 25.06.2002)
Verfahren zur Herstellung von hochbelastbaren Bauteilen aus TiAl-Legierungen. Leistritz
Turbinenkomponenten Remscheid GmbH, 42859
Remscheid, DE; Rolls-Royce Deutschland Ltd. &
Co KG, 15827 Dahlewitz, DE. (B21J 5/00, PS 101
50 674, AT: 17.10.2001)
Verfahren zum Herstellen einer Mg-Legierung
durch Strangpressen und Verwendung der
stranggepressten Halbzeuge und Bauteile.
Volkswagen AG, 38440 Wolfsburg, DE. (C22C
23/00, EP 1 295 957, EP-AT: 03.04.2000)
Aluminiumlegierungsstreifen für gelötete
Wärmetauscherrohre.
Alcan International
Ltd., Montreal, Quebec H3A 3G2, CA. (B23K
35/02, EPA 2296844, WO 2009/156607, EP-AT:
28.05.2009, WO-AT: 28.05.2009)
Kriechbeständige Magnesiumlegierung. GKSSForschungszentrum Geesthacht GmbH, 21502
Geesthacht, DE. (C22C 23/02, PS 10 2008 039
683, AT: 26.08.2008)
Verpackung mit durch ein Deckelorgan verschließbarem Verpackungsbehälter. Alcan
Technology & Management AG, Neuhausen am
Rheinfall, CH. (B65D 77/20, GM 20 2008 001
867, AT: 05.02.2008)
Verfahren zum Bilden eines beschichteten Gegenstandes, welcher eine Magnesiumlegierung
umfasst. GM Global Technology Operations LLC,
Detroit, Mich., US. (C22C 23/00, OS 10 2010 018
004, AT: 23.04.2010)
Element aus anodisierter Magnesiumlegierung, Verfahren zu seiner Herstellung und
Transporter daraus. Yamaha Hatsudoki K.K.,
Iwata-shi, Shizuoka-ken, JP. (C22B 26/22, PS 60
2008 001 079, EP 2003218, EP-AT: 11.06.2008)
Implantat aus einer biologisch abbaubaren
Magnesiumlegierung. Biotronik VI Patent AG,
Baar, CH. (C22C 23/06, EP 2 169 090, EP-AT:
30.09.2008)
Erholungswärmebehandlung zum Verbessern
der Formbarkeit von Magnesiumlegierungen.
Mich., US. (C22F 1/06, OS 10 2009 034 570, AT:
24.07.2009)
Hochduktile und hochfeste Magnesiumlegierungen. GM Global Technology Operations
LLC, Detroit, Mich., US. (C22C 23/04, OS 10 2009
048 450, AT: 07.10.2009)
Bilden von Magnesiumlegierungen mit verbesserter Duktilität. GM Global Technology Operations LLC, Detroit, Mich., US. (C22C 23/00, OS 11
2008 001 968, WO-AT: 30.05.2008)
Reibrührschweißverfahren von unterschiedlich metallischen Bauteilen mit einem doppelt
wirkenden drehenden Werkzeug zum Füllen
des vom Stift erzeugten Loches. Sumitomo
Light Metal Industries, Ltd., Tokyo, JP. (B23K
20/12, PS 60 2006 013 968, EP 1884308, EP-AT:
04.08.2006)
ALUMINIUM veröffentlicht unter dieser
Rubrik regelmäßig einen Überblick über
wichtige, den Werkstoff Aluminium betreffende Patente. Die ausführlichen Patentblätter
und auch weiterführende Informationen dazu
stehen der Redaktion nicht zur Verfügung. Interessenten können diese beziehen oder einsehen bei der
Mitteldeutschen Informations-, Patent-,
Online-Service GmbH (mipo),
Julius-Ebeling-Str. 6,
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Tel. 0345/29398-0
Fax 0345/29398-40,
www.mipo.de
Die Gesellschaft bietet darüber hinaus weitere
Patent-Dienstleistungen an.
PAT E N T E
Aluminiumlegierungsprodukt mit verbesserten Eigenschaftskombinationen. Alcoa Inc.,
Pittsburgh, PA 15212-5858, US. (C22C 21/10,
EPA 2309011, EP-AT: 17.11.2003)
Metallbleche und Metallplatten mit reibungsmindernden, strukturierten Oberflächen und
Herstellungsverfahren dafür. Alcoa Inc., Pittsburgh, PA 15212-5858, US. (F15D 1/12, EPA
2307740, WO 2010/017289, EP-AT: 05.08.2009,
WO-AT: 05.08.2009)
Selbstreinigende Substrate und Verfahren zu
dessen Herstellung. Alcoa Inc., Pittsburgh, PA
15212-5858, US. (C23C 26/00, EPA 2302100,
EP-AT: 29.09.2010)
Verfahren zur Metallreinigung und Abtrennung von gereinigtem Metall aus einer Metallmutterflüssigkeit wie Aluminiumschmelze.
Aleris Switzerland GmbH, Schaffhausen, CH.
(C22B 21/06, EP 2 047 002, WO 2008/003505,
EP-AT: 05.07.2007, WO-AT: 05.07.2007)
Korrosionsbeständiger
Aluminiumverbundwerkstoff für eine Fahrzeugkarosserie. Hydro Aluminium Deutschland GmbH, 51149
Köln, DE. (C22C 21/06, EPA 2302086, EP-AT:
15.09.2009)
Verfahren und Vorrichtung zum Positionieren
beim Ersatz von Anoden in einer Elektrolysezelle. Norsk Hydro ASA, Oslo, NO. (C25C
3/06, PS 60 2004 027 070, EP 1689914, EP-AT:
15.11.2004)
Befestigungssystem eines Paneels aus zerbrechlichem Material, wie etwa Glas, auf einem feststehenden Rahmenwerk in der Fassade eines
Gebäudes. Norsk Hydro ASA, Oslo, NO; SaintGobain Glass France, Courbevoie, FR. (E04B 2/96,
EP 2 053 174, EP-AT: 24.10.2008)
Wetterschutzschiene sowie Tür bzw. Fenster.
Gutmann AG, 91781 Weißenburg, DE. (E06B
1/34, GM 20 2008 008 486, AT: 26.06.2008)
Verbundmaterial auf Aluminiumbasis und
Verfahren zu dessen Herstellung. Honda Motor Co., Ltd., Tokyo, JP. (C22C 1/10, PS 11 2005
003 373, WO 2006/075431, AT: 26.10.2005, WOAT: 26.10.2005)
Verfahren zum Gießen und Gießvorrichtung.
Honda Motor Co., Ltd., Tokyo, JP; The Japan Steel
Works, Ltd., Tokyo, JP. (B22D 27/08, PS 60 2006
014 101, EP 1859879, EP-AT: 15.03.2006)
Kolben, insbesondere Kühlkanalkolben, mit
drei Reibschweißzonen. KS Kolbenschmidt
GmbH, 74172 Neckarsulm. (F02F 3/00, PS 50
2005 009 435, EP 1926902, EP-AT: 17.09.2005)
Kolben für einen Verbrennungsmotor und Verfahren zu seiner Herstellung. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/16, PS 50
2006 006 954, EP 1977102, EP-AT: 15.12.2006)
Homogenisierung und Wärmebehandlung
von Gussmetallen. Novelis Inc., Toronto, ON
M8Z 1J5, CA. (B22D 7/00, EPA 2305397, EPAT: 27.10.2006)
Regenschutzschiene. Gutmann AG, 91781 Weißenburg, DE. (E06B 1/34, GM 20 2008 014 277,
AT: 27.10.2008)
nagement, 8212 Neuhausen am Rheinfall, CH.
(B23K 9/173, EPA 2318171, WO 2010/003595,
EP-AT: 03.07.2009, WO-AT: 03.07.2009)
Fensterbankhalter. Gutmann AG, 91781 Weißenburg, DE. (E06B 1/70, OS 10 2008 059 103,
AT: 26.11.2008)
Funktionsverfahren einer Wärmeausrüstung,
die von Komponenten auf Aluminium- und
Titanbasis versorgt wird, um das Rosten und
die Verschmutzung bei hohen Temperaturen
zu reduzieren. GE Energy Products France SNC,
90000 Belfort, FR. (C10L 1/12, EPA 2316911, EPAT: 08.09.2009)
Sequenzielles Gießen von Metallen mit ähnlichem Gefrierbereich. Novelis, Inc., Toronto,
ON M8Z 1J5, CA. (B22D 7/021, EPA 2303490,
WO 2010/012099, EP-AT: 30.07.2009, WO-AT:
30.07.2009)
Horizontalstranggießen von Metallen. Novelis,
Inc., Toronto, Ontario, CA. (B22D 11/045, PS 60
2004 026 923, EP 1704004, EP-AT: 10.12.2004)
Mit Antihaftpolymer beschichtete Aluminiumfolie. Reynolds Foil Inc., Richmond, Va., US.
(B05D 5/08, PS 601 42 058, EP 1318874, EP-AT:
24.05.2001)
Verfahren zur Herstellung eines teilchenförmigen ¡-Aluminiumoxids. Sumitomo Chemical
Co., Ltd., Osaka, JP. (C01F 7/30, OS 10 2004 010
208, AT: 02.03.2004)
Verfahren zum Erwärmen von Gießformen.
Metal Casting Technology, Inc., Milford, N.H., US.
(B22C 9/02, PS 603 32 373, EP 1551578, EP-AT:
06.08.2003)
Gliederheizkessel aus Gusseisen oder Aluminium. Robert Bosch GmbH, 70442 Stuttgart, DE.
(F24H 1/32, EPA 2313698, WO 2010/018187,
EP-AT: 12.08.2009, WO-AT: 12.08.2009
Verfahren zur Herstellung von Aluminium in
einer Elektrolysezelle. Rio Tinto Alcan International Ltd., Montréal, QC H3A 3G2, CA. (C25C
3/20, EPA 2315863. WO 2009/152975, EP-AT:
05.06.2009, WO-AT: 05.06.2009)
Aluminiumverbund-Technologie zum Verbinden von Kunststoff- mit Aluminiumprofilen zu
Komplettprofilen für die Fertigung von Aluminiumfenstern und -türen. Meyer, Christian,
29416 Pretzier, DE. (E06B 3/263, EPA 2314816,
EP-AT: 17.10.2009),
Patentblatt Juni 2011
Alkaliresistenter Erdalkali-Aluminium-Wärmedämmstoff, Verfahren zu seiner Herstellung
und seine Verwendung. Calsitherm Verwaltungs
GmbH, 33175 Bad Lippspringe, DE. (C04B 40/02,
OS 10 2009 055 723, AT: 26.11.2009)
Verfahren zur Herstellung einer Platte aus AlMg-Si-Legierung. Showa Denko K.K., Tokyo,
JP. (C22F 1/05, EP 1 482 065, WO 2003/074750,
EP-AT: 28.02.2003, WO-AT: 28.02.2003)
Bilden von komplexen Formen in Al- und MgLegierungswerkstücken. GM Global Technology Operations LLC, Detroit, Mich., US. (B23P 17/
00, OS 10 2010 035 136, AT: 23.08.2010)
Verschmolzene Körner aus Oxiden mit Al, Ti
und Mg sowie Keramikprodukte mit solchen
Körnern. Saint-Gobain Centre de Recherches et
D’Etudes Europeen SAS, 92400 Courbevoie, FR.
(C04B 35/478, EPA 2310338, WO 2010/001064,
EP-AT: 02.07.2009, WO-AT: 02.07.2009)
Finnen-Kühlkörper aus Aluminium-Kupfer-Verbundwerkstoff mit integriertem Wärmeleitrohr zur Kühlung von wärmeabgebenden elektrischen und elektronischen Bauteilen. Richard
Wöhr GmbH, 75339 Höfen, DE. (H05K 7/20, GM
20 2005 003 502, AT: 04.03.2005)
Verfahren zur Steuerung von Variationen einer
Al-Ti-B-Legierungs-Granverfeinerungskapazität durch Steuerung des Kompressionsverhältnisses. Sun Xing Chemical & Metallurgical
Materials (Shenzhen) Co. Ltd., Shenzhen, Guangdong 518000, CN. (C22F 1/04, EPA 2314731,
WO 2011/022984, EP-AT: 10.05.2010, WO-AT:
10.05.2010)
Schutzverkleidung für Holzfenster in Edelstahl
und/oder Aluminium. Gröner, Wolfgang, 89555
Steinheim, DE. (E06B 3/30, GM 20 2010 014 578,
AT: 21.10.2010)
Zn-Al-Mg-Si-legiertes und geplättetes Stahlprodukt mit exzellenten Anti-Korrosions-Eigenschaften. Nippon Steel & Sumikin Coated Sheet
Corp., Tokyo, JP; Nippon Steel Corp., Tokyo, JP.
(C23C 2/12, EP 1 225 246, WO 2001/011100,
EP-AT: 09.08.2000, WO-AT: 09.08.2000)
Vorbereitungsverfahren vor dem Schweißen
von Produkten aus Lithium-Aluminium-Legierung. Alcan Rhenalu, 92400 Courbevoie, FR.
(C21D 1/68, EPA 2321436, WO 2010/004132,
EP-AT: 03.07.2009, WO-AT: 03.07.2009 )
Schmelzschweißverfahren zur Verbindung von
Aluminium und Titan. Alcan Technology & Ma-
Passivierendes Gleitschleifen, insb. für Aluminium, Magnesium und Zink. Henkel AG & Co.
KGaA, 40589 Düsseldorf, DE. (C23C 22/73, EP 2
217 742, WO 2009/068366, EP-AT: 16.10.2008,
WO-AT: 16.10.2008)
Verfahren zum Vollformgießen von Aluminium mit beschichtetem Modell. General Motors
LLC, Detroit, Mich., US. (B22C 3/00, PS 698
18 379, EP 0899038, AT: 31.07.1998, EP-AT:
31.07.1998)
Oberflächenbehandeltes Stahlprodukt, versehen mit einer auf Zinn oder Aluminium basierenden Plattierung. Nippon Steel Corp., Tokyo,
JP. (C23C 2/08, PS 600 44 434, EP 1184478,
EP-AT: 17.03.2000)
Fortsetzung in ALUMINIUM 9/2011
67
LIEFERVERZEICHNIS
1 Smelting technology
Hüttentechnik
1.1 Raw materials
1.2 Storage facilities for smelting
1.3 Anode production
1.4 Anode rodding
1.4.1 Anode baking
1.4.2 Anode clearing
1.4.3 Fixing of new anodes to the
anodes bars
1.5 Casthouse (foundry)
1.6 Casting machines
1.7 Current supply
1.8 Electrolysis cell (pot)
1.9 Potroom
1.10 Laboratory
1.11 Emptying the cathode shell
1.12 Cathode repair shop
1.13 Second-hand plant
1.14 Aluminium alloys
1.15 Storage and transport
1.16 Smelting manufactures
1.1 Rohstoffe
1.2 Lagermöglichkeiten in der Hütte
1.3 Anodenherstellung
1.4 Anodenschlägerei
1.4.1 Anodenbrennen
1.4.2 Anodenschlägerei
1.4.3 Befestigen von neuen Anoden
an der Anodenstange
1.5 Gießerei
1.6 Gießmaschinen
1.7 Stromversorgung
1.8 Elektrolyseofen
1.9 Elektrolysehalle
1.10 Labor
1.11 Ofenwannenentleeren
1.12 Kathodenreparaturwerkstatt
1.13 Gebrauchtanlagen
1.14 Aluminiumlegierungen
1.15 Lager und Transport
1.16 Hüttenerzeugnisse
1.2 Storage facilities for
smelting
Unloading/Loading equipment
Lagermöglichkeiten i.d. Hütte
FLSmidth MÖLLER GmbH
www.flsmidthmoeller.com
see Storage facilities for smelting 1.2
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
Entlade-/Beladeeinrichtungen
ALUMINA AND PET COKE SHIPUNLOADERS
Contact: Andreas Haeuser, [email protected]
Auto firing systems
Automatische Feuerungssysteme
RIEDHAMMER GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 0, Fax: -5218 231
Internet: www.riedhammer.de
1.3 Anode production
Anodenherstellung
Outotec GmbH
Albin-Köbis-Str. 8, D-51147 Köln
Phone: +49 (0) 2203 / 9921-0
E-mail: [email protected]
www.outotec.com
Herstellung von Anoden
Bulk materials Handling
from Ship to Cell
Solios Carbone – France
www.fivesgroup.com
Bulk materials Handling from Ship to Cell
www.coperion.com
mailto: [email protected]
Conveying systems bulk materials
Förderanlagen für Schüttgüter
(Hüttenaluminiumherstellung)
Internet: www.flsmidthmoeller.com
68
Hydraulic presses for prebaked
anodes / Hydraulische Pressen zur
Storvik AS
Industriveien 13
6600 SUNNDALSØRA/NORWAY
Tel.: +47 71 69 95 00 | Fax: +47 71 69 95 55
www.storvik.no | [email protected]
LAEIS GmbH
Am Scheerleck 7, L-6868 Wecker, Luxembourg
Phone:
+352 27612 0
Fax:
+352 27612 109
Internet: www.laeis-gmbh.com
Contact: Dr. Alfred Kaiser
Anode Technology &
Mixing Equipment
Buss ChemTech AG, Switzerland
Phone:
+4161 825 64 62
E-Mail:
[email protected]
Internet: www.buss-ct.com
SUPPLIERS DIRECTORY
Mixing Technology for
Anode pastes
Mischtechnologie für Anodenmassen
1.4.2 Anode clear ing
Anodenschlägerei
Separation of spent anodes
from the anode bars
Trennen von den Anodenstangen
Buss AG
CH-4133 Pratteln
Phone:
+41 61 825 66 00
E-Mail:
[email protected]
Internet: www.busscorp.com
Open top and closed
type baking furnaces
Offene und geschlossene Ringöfen
SERMAS INDUSTRIE
see Casting Machines 1.6
1.4.3 Fixing of new anodes
to the anodes bars
Befestigen von neuen
Anoden a. d. Anodenstange
Fixing the nipples to the
anodes by casting in
Befestigen der Nippel mit der
Anode durch Eingießen
RIEDHAMMER GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 0, Fax: -5218 231
Internet: www.riedhammer.de
SERMAS INDUSTRIE
Anodenanschlägerei
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
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
Dross skimming of the melt
Abkrätzen der Schmelze
1.5 Casthouse (foundry)
Gießerei
1.4 Anode rodding
Degassing, filtration and
grain refinement
Hampshire House, High Street, Kingswinford,
West Midlands DY6 8AW, UK
Tel.: +44 (0) 1384 279132
Fax: +44 (0) 1384 291211
www.mechatherm.com
see Casting machines 1.6
Furnace charging with
molten metal
Ofenbeschickung mit Flüssigmetall
Melting/holding/casting furnaces
Removal of bath residues from
the surface of spent anodes
Entfernen der Badreste von der Oberfläche der verbrauchten Anoden
Hornstraße 19
D-45964 Gladbeck
Telefon 02043 / 9738-0
Telefax 02043 / 9738-50
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstraße 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
Internet: www.hertwich.com
INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH
Konstantinstraße 1a
D 41238 Mönchengladbach
Telefon +49 (02166) 987990
Telefax +49 (02166) 987996
Internet: www.inotherm-gmbh.de
1.4.1 Anode baking
Anodenbrennen
Anode charging/Anodenchargieren
SERMAS INDUSTRIE
Anode storage/Anodenlager
SERMAS INDUSTRIE
see Equipment and accessories 3.1
Stopinc AG
Bösch 83 a
CH-6331 Hünenberg
Tel. +41/41-785 75 00
Fax +41/41-785 75 01
Internet: www.stopinc.ch
Schmelz-/Halte- und Gießöfen
Gautschi
Engineering GmbH
Solios Thermal UK
www.fivesgroup.com
see Casthouse (foundry) 1.5
Sistem Teknik Ltd. Sti.
DES San. Sit. 102 SOK No: 6/8
Y.Dudullu, TR-34775 Istanbul/Turkey
Tel.: +90 216 420 86 24
Fax: +90 216 420 23 22
Internet: www.sistemteknik.com
Metal treatment in the
holding furnace
Metallbehandlung in Halteöfen
Gautschi
Engineering GmbH
69
LIEFERVERZEICHNIS
Transfer to the casting furnace
Überführung in Gießofen
GmbH
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
Gautschi
Engineering GmbH
Pig casting machines (sow casters)
Masselgießmaschine (Sowcaster)
Gautschi
Engineering GmbH
Transport v. Flüssigmetall in Gießereien
see Billet Heating Furnaces 1.5
Rolling and extrusion ingot
and T-bars
Gautschi
Engineering GmbH
Horizontal continuous casting
Horizontales Stranggießen
Gautschi
Engineering GmbH
Wagstaff, Inc.
3910 N. Flora Rd.
Spokane, WA 99216 USA
+1 509 922 1404 phone
+1 509 924 0241 fax
Internet: www.wagstaff.com
Gautschi
Engineering GmbH
1.8 Electrolysis cell (pot)
Behandlung der Gießereiabgase
Gautschi
Engineering GmbH
Vertical semi-continuous DC
casting / Vertikales Stranggießen
MARX GmbH & Co. KG
www.marx-gmbh.de
see Melt operations 4.13
Treatment of casthouse
off gases
Formatebehandlung (homogenisieren)
Gautschi
Engineering GmbH
Formatgießerei (Walzbarren oder
Pressbolzen oder T-Barren)
Transport of liquid metal
to the casthouse
Heat treatment of extrusion
ingot (homogenisation)
Elektrolyseofen
Bulk materials Handling
from Ship to Cell
Bulk materials Handling from Ship to Cell
www.solios.com
Scales / Waagen
Gautschi
Engineering GmbH
Gießmaschinen
www.coperion.com
mailto: [email protected]
Calcium silicate boards
Calciumsilikatplatten
Sawing / Sägen
GAPCast TM: the Swiss casting solution
see Casting machines and equipment 4.7
Gautschi
Engineering GmbH
Promat GmbH – Techn. Wärmedämmung
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
[email protected], www.promat.de
Exhaust gas treatment
www.mechatherm.com
see Smelting technology 1.5
RIHS ENGINEERING SA
see Casting machines and equipment 4.7
70
343 Chemin du Stade
38210 Saint Quentin sur Isère
Tel. +33 (0) 476 074 242
Fax +33 (0) 476 936 776
Internet: www.sermas.com
Abgasbehandlung
Solios Environnement
www.fivesgroup.com
Pot feeding systems
Beschickungseinrichtungen
für Elektrolysezellen
www.flsmidthmoeller.com
SUPPLIERS DIRECTORY
1.9 Potroom
Elektrolysehalle
T.T. Tomorrow Technology S.p.A.
Via dell’Artigianato 18
Due Carrare, Padova 35020, Italy
Telefon +39 049 912 8800
Telefax +39 049 912 8888
Contact: Giovanni Magarotto
Anode changing machine
Dry absorption units for
electrolysis exhaust gases
Trockenabsorptionsanlage für
Elektrolyseofenabgase
1.14 Aluminium Alloys
Aluminiumlegierungen
Solios Environnement
www.fivesgroup.com
Tapping vehicles/Schöpffahrzeuge
Anodenwechselmaschine
RHEINFELDEN ALLOYS GmbH & Co. KG
A member of ALUMINIUM RHEINFELDEN Group
Postfach 1703, 79607 Rheinfelden
Tel.: +49 7623 93-490
Fax: +49 7623 93-546
Internet: www.rheinfelden-alloys.eu
1.11 Emptying the cathode shell
Anode transport equipment
Anoden Transporteinrichtungen
Crustbreakers / Krustenbrecher
2
Ofenwannenentleeren
Cathode bar casting units
Kathodenbarreneingießanlage
1.15 Storage and transport
Lager und Transport
SMS Siemag AG
see Rolling mill technology 3.0
Extrusion
Strangpressen
2.1 Extrusion billet preparation
2.1.1 Extrusion billet production
2.2 Extrusion equipment
2.3 Section handling
2.4 Heat treatment
2.5 Measurement and control equipment
2.6 Die preparation and care
2.7 Second-hand extrusion plant
2.8 Consultancy, expert opinion
2.9 Surface finishing of sections
2.10 Machining of sections
2.11 Equipment and accessories
2.12 Services
2.1 Pressbolzenbereitstellung
2.1.1 Pressbolzenherstellung
2.2 Strangpresseinrichtungen
2.3 Profilhandling
2.4 Wärmebehandlung
2.5 Mess- und Regeleinrichtungen
2.6 Werkzeugbereitstellung und -pflege
2.7 Gebrauchte Strangpressanlagen
2.8 Beratung, Gutachten
2.9 Oberflächenveredlung von Profilen
2.10 Profilbearbeitung
2.11 Ausrüstungen und Hilfsmittel
2.12 Dienstleistungen
2.1.1 Extrusion billet
production
2.1 Extrusion billet preparation
Pressbolzenbereitstellung
Pressbolzenherstellung
Billet heating furnaces
Öfen zur Bolzenerwärmung
MARX GmbH & Co. KG
www.marx-gmbh.de
Am großen Teich 16+27
D-58640 Iserlohn
Tel. +49 (0) 2371 / 4346-0
Fax +49 (0) 2371 / 4346-43
Internet: www.ias-gmbh.de
www.alu-web.de
www.mechatherm.com
Billet transport and storage
equipment
Bolzen-Transport- u. Lagereinricht.
DES San. Sit. 102 SOK No: 6/8
Y. Dudullu, TR-34775 Istanbul/Turkey
Tel.: +90 216 420 86 24
Fax: +90 216 420 23 22
Internet: www.sistemteknik.com
SERMAS INDUSTRIE
See Casting Machines 1.6
www.alu-web.de
71
LIEFERVERZEICHNIS
2.2 Extrusion equipment
Strangpresseinrichtungen
2.3 Section handling
Profilhandling
Packaging equipment
Verpackungseinrichtungen
Section transport equipment
Profiltransporteinrichtungen
SMS Meer GmbH
see Extrusion equipment 2.2
www.mechatherm.com
Oilgear Towler GmbH
Im Gotthelf 8
D 65795 Hattersheim
Tel. +49 (0) 6145 3770
Fax +49 (0) 6145 30770
Internet: www.oilgear.de
CTI Systems S.A.
Z.I. Eselborn – Lentzweiler
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
Internet: www.ctisystems.com
SMS Meer GmbH
Schloemann Extrusion
Ohlerkirchweg 66
41069 Mönchengladbach, Germany
Tel. +49 (0) 2161 350-0
Fax +49 (0) 2161 350-1667
Internet: www.sms-meer.com
Containers / Rezipienten
Stackers / Destackers
Stapler / Entstapler
SMS Meer GmbH
Vollert Anlagenbau GmbH
Stadtseestraße 12
D-74189 Weinsberg
Tel.
+49 (0) 7134 / 52-220
Fax
+49 (0) 7134 / 52-222
E-Mail [email protected]
Internet www.vollert.de
SMS Meer GmbH
Nijverheidsweg 3
NL-7071 CH Ulft Netherlands
Tel.: +31 315 641352
Fax: +31 315 641852
Internet: www.unifour.nl
Sales Contact: Paul Overmans
Puller equipment
Stretching equipment
Reckeinrichtungen
SMS Meer GmbH
Ausziehvorrichtungen/Puller
Press control systems
Pressensteuersysteme
Oilgear Towler GmbH
see Extrusion Equipment 2.2
SMS Meer GmbH
Section cooling
Transport equipment for
extruded sections
Transporteinrichtungen
für Profilabschnitte
Profilkühlung
SMS Meer GmbH
SMS Meer GmbH
see Packaging equipment 2.3
Section saws
Temperature measurement
Temperaturmessung
SMS Meer GmbH
Profilsägen
SMS Meer GmbH
Section store equipment
Heating and control
equipment for intelligent
billet containers
Heizungs- und Kontrollausrüstung
für intelligente Blockaufnehmer
MARX GmbH & Co. KG
www.marx-gmbh.de
72
Profil-Lagereinrichtungen
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
Hier könnte Ihr
BezugsquellenEintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
SUPPLIERS DIRECTORY
2.4 Heat treatment
Wärmebehandlung
2.5 Measurement and
control equipment
Mess- und Regeleinrichtungen
Extrusion plant control systems
Presswerkssteuerungen
SMS Meer GmbH
2.11 Equipment and
accessories
Ausrüstungen und
Hilfsmittel
Inductiv heating equipment
Induktiv beheizte
Erwärmungseinrichtungen
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
2.6 Die preparation and care
Werkzeugbereitstellung
und -pflege
Die heating furnaces
Am großen Teich 16+27
D-58640 Iserlohn
Tel. +49 (0) 2371 / 4346-0
Fax +49 (0) 2371 / 4346-43
Internet: www.ias-gmbh.de
Werkzeuganwärmöfen
MARX GmbH & Co. KG
www.marx-gmbh.de
Could not find your
www.mechatherm.com
„keywords“?
Please ask for
Heat treatment furnaces
our complete
Wärmebehandlungsöfen
„Supply sources for the
aluminium industry“.
E-Mail:
[email protected]
Homogenising furnaces
Homogenisieröfen
Nijverheidsweg 3
Tel.: +31 315 641352
Fax: +31 315 641852
Ageing furnace for extrusions
Auslagerungsöfen für
Strangpressprofile
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
Nijverheidsweg 3
Tel.: +31 315 641352
Fax: +31 315 641852
73
LIEFERVERZEICHNIS
3 Rolling mill technology
Walzwerktechnik
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
Casting equipment
Rolling bar machining
Rolling bar furnaces
Hot rolling equipment
Strip casting units and accessories
Cold rolling equipment
Thin strip / foil rolling plant
Auxiliary equipment
Adjustment devices
Process technology /
Automation technology
Coolant / lubricant preparation
Air extraction systems
Fire extinguishing units
Storage and dispatch
Second-hand rolling equipment
Coil storage systems
Strip Processing Lines
Productions Management Systems
3.0 Rolling mill technology
Walzwerktechnik
see Cold rolling units / complete plants 3.6
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
Gießanlagen
Walzbarrenbearbeitung
Walzbarrenvorbereitung
Warmwalzanlagen
Bandgießanlagen und Zubehör
Kaltwalzanlagen
Feinband-/Folienwalzwerke
Nebeneinrichtungen
Adjustageeinrichtungen
Prozesstechnik /
Automatisierungstechnik
Kühl-/Schmiermittel-Aufbereitung
Abluftsysteme
Feuerlöschanlagen
Lagerung und Versand
Gebrauchtanlagen
Coil storage systems
Bandprozesslinien
Produktions Management Systeme
3.1 Casting equipment
Gießanlagen
www.mechatherm.com
Electromagnetic Stirrer
Elektromagnetische Rührer
Solios Thermal UK
www.fivesgroup.com
SMS Siemag Aktiengesellschaft
Eduard-Schloemann-Straße 4
40237 Düsseldorf, Germany
Telefon: +49 (0) 211 881-0
Telefax: +49 (0) 211 881-4902
Internet: www.sms-siemag.com
Geschäftsbereiche:
Warmflach- und Kaltwalzwerke
Wiesenstraße 30
57271 Hilchenbach-Dahlbruch, Germany
Telefon: +49 (0) 2733 29-0
Telefax: +49 (0) 2733 29-2852
Bandanlagen
Walder Straße 51-53
40724 Hilden, Germany
Telefon: +49 (0) 211 881-5100
Telefax: +49 (0) 211 881-5200
Elektrik + Automation
Ivo-Beucker-Straße 43
Telefon: +49 (0) 211 881-5895
Telefax: +49 (0) 211 881-775895
Graf-Recke-Straße 82
Telefon: +49 (0) 211 881-0
Telefax: +49 (0) 211 881-4902
74
LOI Thermprocess GmbH
Am Lichtbogen 29
D-45141 Essen
Germany
Telefon +49 (0) 201 / 18 91-1
Telefax +49 (0) 201 / 18 91-321
Internet: www.loi-italimpianti.com
Solios Thermal UK
www.fivesgroup.com
Melt purification units
Filling level indicators and controls
Füllstandsanzeiger und -regler
Gautschi
Engineering GmbH
Schmelzereinigungsanlagen
Gautschi
Engineering GmbH
Metal filters / Metallfilter
Gautschi
Engineering GmbH
Wagstaff, Inc.
Metal pumps / Metallpumpen
Melting and holding furnaces
www.solios.com
Schmelz- und Warmhalteöfen
Gautschi Engineering GmbH
Konstanzer Straße 37
CH 8274 Tägerwilen
Telefon +41 71 666 66 66
Telefax +41 71 666 66 77
Internet: www.gautschi.cc
Kontakt: Sales Departement
3.2 Rolling bar machining
Walzbarrenbearbeitung
Band saws / Bandsägen
SMS Meer GmbH
SUPPLIERS DIRECTORY
Slab milling machines
Barrenfräsmaschinen
SMS Meer GmbH
Roller tracks
Rollengänge
Hot rolling units /
complete plants
Warmwalzanlagen/Komplettanlagen
Gautschi
Engineering GmbH
SMS Siemag AG
3.3 Rolling bar furnaces
Walzbarrenvorbereitung
see Heat Treatment 2.4
3.4 Hot rolling equipment
Warmwalzanlagen
3.6 Cold rolling equipment
Kaltwalzanlagen
Annealing furnaces
Glühöfen
EBNER Industrieofenbau Ges.m.b.H.
Ruflinger Str. 111, 4060 Leonding/Austria
Tel. +43 / 732 / 6868
Internet: www.ebner.cc
Gautschi
Engineering GmbH
Achenbach Buschhütten GmbH
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
Coil transport systems
Bundtransportsysteme
see Heat Treatment 2.4
Coil annealing furnaces
Bundglühöfen
Gautschi
Engineering GmbH
schwartz GmbH
see Heat treatment 2.4
Solios Thermal UK
www.fivesgroup.com
Bar heating furnaces
Barrenanwärmanlagen
CTI Systems S.A.
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
EBNER Industrieofenbau Ges.m.b.H.
see Annealing furnaces 3.3
Gautschi
Engineering GmbH
Coil transport systems
Homogenising furnaces
Homogenisieröfen
Gautschi
Engineering GmbH
Drive systems / Antriebe
Bundtransportsysteme
SMS Siemag AG
Rolling mill modernisation
Walzwerksmodernisierung
SMS Siemag AG
Spools / Haspel
Solios Thermal UK
www.fivesgroup.com
SMS Siemag AG
CTI Systems S.A.
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
75
LIEFERVERZEICHNIS
Cold rolling units /
complete plants
Slitting lines-CTL
Längs- und Querteilanlagen
Kaltwalzanlagen/Komplettanlagen
Strip shears/Bandscheren
Thin strip / foil rolling mills /
complete plant
Feinband- / Folienwalzwerke /
Komplettanlagen
SMS Siemag AG
SMS Siemag AG
Drive systems / Antriebe
SMS Siemag AG
Rolling mill modernization
Walzwerkmodernisierung
SMS Siemag AG
Heating furnaces / Anwärmöfen
Gautschi
Engineering GmbH
Trimming equipment
Besäumeinrichtungen
3.9 Adjustment devices
SMS Siemag AG
Adjustageeinrichtungen
Sheet and plate stretchers
Blech- und Plattenstrecker
3.7 Thin strip /
foil rolling plant
Process optimisation systems
Process simulation
Prozesssimulation
Gautschi
Engineering GmbH
Feinband-/Folienwalzwerke
Cable sheathing presses
Prozessoptimierungssysteme
Gautschi
Engineering GmbH
SMS Meer GmbH
Kabelummantelungspressen
SMS Meer GmbH
Cable undulating machines
Kabelwellmaschinen
SMS Meer GmbH
SMS Siemag AG
Roll exchange equipment
Walzenwechseleinrichtungen
SMS Siemag AG
Coil annealing furnaces
Bundglühöfen
Gautschi
Engineering GmbH
Rolling mill modernization
schwartz GmbH
see Cold colling equipment 3.6
Heating furnaces
Anwärmöfen
76
Querteilanlagen
SERMAS INDUSTRIE
3.10 Process technology /
Automation technology
Prozesstechnik /
Automatisierungstechnik
Process control technology
Walzwerkmodernisierung
Transverse cutting units
Gautschi
Engineering GmbH
Prozessleittechnik
SMS Siemag AG
Wagstaff, Inc.
SUPPLIERS DIRECTORY
Strip flatness measurement
and control equipment
Roll Force Measurement equipment
Walzkraftmesseinrichtungen
Bandplanheitsmess- und
-regeleinrichtungen
3.12 Air extraction systems
Abluft-Systeme
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
Internet: www.abb.com/pressductor
ABB Automation
Force Measurement
Phone: +46 21 325 000
Fax: +46 21 340 005
Strip Width & Position
Measurement equipment
Bandbreiten- und
Bandlaufmesseinrichtungen
Strip thickness measurement
and control equipment
Banddickenmess- und
-regeleinrichtungen
Abluft-Reinigungssysteme (aktiv)
SMS Siemag AG
SMS Siemag AG
Exhaust air purification
systems (active)
ABB Automation
Force Measurement
Phone: +46 21 325 000
Fax: +46 21 340 005
3.11 Coolant / lubricant
preparation
3.14 Storage and dispatch
Lagerung und Versand
SMS Siemag AG
3.16 Coil storage systems
Bundlagersysteme
Kühl-/SchmiermittelAufbereitung
ABB Automation
Force Measurement
Phone: +46 21 325 000
Fax: +46 21 340 005
Rolling oil recovery and
treatment units
Walzöl-Wiederaufbereitungsanlagen
SMS Siemag AG
Filter for rolling oils and emulsions
SMS Siemag AG
Strip Tension
Measurement equipment
Bandzugmesseinrichtungen
CTI Systems S.A.
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
Filter für Walzöle und Emulsionen
SMS Siemag AG
Rolling oil rectification units
Walzölrektifikationsanlagen
3.17 Strip Processing Lines
Bandprozesslinien
Lithographic Sheet Lines
ABB Automation
Force Measurement
Phone: +46 21 325 000
Fax: +46 21 340 005
SMS Siemag AG
Lithografielinien
www.bwg-online.com
see Strip Processing Lines 3.17
77
LIEFERVERZEICHNIS
Colour Coating Lines
Strip Annealing Lines
Bandlackierlinien
www.bwg-online.com
Stretch Levelling Lines
Bandglühlinien
www.bwg-online.com
Produktions Management
Systeme
Strip Processing Lines
Bandprozesslinien
Streckrichtanlagen
www.bwg-online.com
3.18 Production
Management systems
BWG Bergwerk- und WalzwerkMaschinenbau GmbH
Mercatorstraße 74 – 78
D-47051 Duisburg
Tel.: +49 (0) 203-9929-0
Fax: +49 (0) 203-9929-400
Internet: www.bwg-online.com
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
4 Foundry
Gießerei
4.1 Work protection and ergonomics
4.2 Heat-resistant technology
4.3 Conveyor and storage technology
4.4 Mould and core production
4.5 Mould accessories and accessory materials
4.6 Foundry equipment
4.7 Casting machines and equipment
4.8 Handling technology
4.9 Construction and design
4.10 Measurement technology and materials testing
4.11 Metallic charge materials
4.12 Finshing of raw castings
4.13 Melt operations
4.14 Melt preparation
4.15 Melt treatment devices
4.16 Control and regulation technology
4.17 Environment protection and disposal
4.18 Dross recovery
4.19 Gussteile
4.2 Heat-resistent technology
Feuerfesttechnik
Refractories / Feuerfeststoffe
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
Arbeitsschutz und Ergonomie
Feuerfesttechnik
Förder- und Lagertechnik
Form- und Kernherstellung
Formzubehör, Hilfsmittel
Gießereianlagen
Gießmaschinen und Gießeinrichtungen
Handhabungstechnik
Konstruktion und Design
Messtechnik und Materialprüfung
Metallische Einsatzstoffe
Rohgussnachbehandlung
Schmelzbetrieb
Schmelzvorbereitung
Schmelzebehandlungseinrichtungen
Steuerungs- und Regelungstechnik
Umweltschutz und Entsorgung
Schlackenrückgewinnung
Cast parts
4.3 Conveyor and storage
technology
78
Formzubehör, Hilfmittel
Fluxes
Promat GmbH – Techn. Wärmedämmung
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
[email protected], www.promat.de
4.3 Conveyor and storage
technology
4.5 Mold accessories and
accessory materials
Flussmittel
CTI Systems S.A.
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
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
SUPPLIERS DIRECTORY
Manipulators
4.6 Foundry equipment
Manipulatoren
Gießereianlagen
www.mechatherm.com
Competence in EMC and ASC casting
RIHS ENGINEERING SA
Tel.: +41 27 455 54 41
Internet: www.maschko.ch
Casting machines
Gießmaschinen
Aluminium alloys
4.11 Metallic charge
materials
Metallische Einsatzstoffe
Wagstaff, Inc.
SERMAS INDUSTRIE
Continuous ingot casting
lines and aluminium rod lines
Kokillengieß- und Aluminiumdraht-Anlagen
Aluminiumlegierungen
METALLHANDELSGESELLSCHAFT
SCHOOF & HASLACHER MBH & CO. KG
Postfach 600714, D 81207 München
Telefon 089/829133-0
Telefax 089/8201154
Internet: www.metallhandelsgesellschaft.de
Wärmebehandlungsöfen
Pre alloys / Vorlegierungen
METALLHANDELSGESELLSCHAFT
SCHOOF & HASLACHER MBH & CO. KG
Postfach 600714, D 81207 München
Telefon 089/829133-0
Telefax 089/8201154
Internet: www.metallhandelsgesellschaft.de
ELPO GmbH
Kuchengrund 18
71522 Backnang
Telefon 07191 9572-0
Telefax 07191 9572-29
Internet: www.elpo.de
Mould parting agents
Kokillentrennmittel
and equipment
Gießereimaschinen
und Gießeinrichtungen
Schröder KG
Schmierstofftechnik
Postfach 1170
D-57251
Freudenberg
Tel. 02734/7071
Fax 02734/20784
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
www.schroeder-schmierstoffe.de
4.13 Melt operations
4.8 Handling technology
Schmelzbetrieb
Handhabungstechnik
GAPCast TM: the Swiss casting solution
Casting Technology / Automation
Tel.: +41 27 455 57 14
Internet: www.gap-engineering.ch
www.mechatherm.com
CTI Systems S.A.
12, op der Sang
L-9779 Lentzweiler
Tel.: +352 2685 2000
Fax: +356 2685 3000
Wärmebehandlungsanlagen
Molten Metall Level Control
Ostra Hamnen 7
SE-430 91 Hono / Schweden
Tel.: +46 31 764 5520, Fax: +46 31 764 5529
Internet: www.precimeter.com
Sales contact: Jan Strömbeck
www.mechatherm.com
79
LIEFERVERZEICHNIS
Melting furnaces
Schmelzöfen
4.14 Melt preparation
4.15 Melt treatment devices
Schmelzvorbereitung
Schmelzbehandlungseinrichtungen
Degassing, filtration
Büttgenbachstraße 14
D-40549 Düsseldorf/Germany
Tel.: +49 (0) 211 / 5 00 91-43
Fax: +49 (0) 211 / 50 13 97
Internet: www.bloomeng.com
Sales Contact: Klaus Rixen
Gautschi
Engineering GmbH
Entgasung, Filtration
GmbH
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: http://www.drache-gmbh.de
Gautschi
Engineering GmbH
Metaullics Systems Europe B.V.
Ebweg 14
NL-2991 LT Barendrecht
Tel. +31-180/590890
Fax +31-180/551040
Internet: www.metaullics.com
4.17 Environment protection
and disposal
Umweltschutz und
Entsorgung
Dust removal
Entstaubung
Melt treatment agents
Schmelzebehandlungsmittel
Gautschi
Engineering GmbH
MARX GmbH & Co. KG
Lilienthalstr. 6-18
D-58638 Iserhohn
Tel.: +49 (0) 2371 / 2105-0, Fax: -11
Internet: www.marx-gmbh.de
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
Holding furnaces
Warmhalteöfen
Büttgenbachstraße 14
D-40549 Düsseldorf/Germany
Tel.: +49 (0) 211 / 5 00 91-43
Fax: +49 (0) 211 / 50 13 97
Internet: www.bloomeng.com
Sales Contact: Klaus Rixen
Gautschi
Engineering GmbH
6
Machining and Application
Bearbeitung und Anwendung
6.1 Surface treatment
processes
Prozesse für die
Oberflächenbehandlung
Henkel AG & Co. KGaA
siehe Prozesse für die Oberflächentechnik 6.1
Anodising / Anodisation
Joining / Fügen
Wärmebehandlungsanlagen
Gautschi
Engineering GmbH
NEOTECHNIK GmbH
Entstaubungsanlagen
Postfach 110261, D-33662 Bielefeld
Tel. 05205/7503-0, Fax 05205/7503-77
[email protected], www.neotechnik.com
D-40191 Düsseldorf
Tel. +49 (0) 211 / 797-30 00
Fax +49 (0) 211 / 798-23 23
Internet: www.henkel-technologies.com
Cleaning / Reinigung
80
Adhesive bonding / Verkleben
Pretreatment before coating
Vorbehandlung vor der Beschichtung
ALLGEMEINES
suppliers directory
ALLGEMEINES
6.3 Equipmentforforging
andimpactextrusion
6.2 Semiproducts
Halbzeuge
Wires/Drähte
drAHtWerk eLISentAL
W. erdmann GmbH & co.
Werdohler Str. 40, D-58809 neuenrade
Postfach 12 60, D-58804 neuenrade
Tel. +49(0)2392/697-0, Fax 49(0)2392/62044
Internet: www.elisental.de
www.alu-web.de
International
ALUMINIUM
Journal
87.
87. Jahrgang
Jahrgang 1.1.2011
1.1.2011
Verlag
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Dipl.-Ing. Rudolf
Rudolf P.
P. Pawlek
Pawlek
Dipl.-Ing.
Hüttenindustrie und
und Recycling
Recycling
Hüttenindustrie
[email protected]
[email protected]
Dipl.-Ing. Bernhard Rieth
Walzwerkstechnik und Bandverarbeitung
Walzwerkstechnik und Bandverarbeitung
[email protected]
[email protected]
Objektleitung / General Manager
Objektleitung
/ General Manager
Material Publication
Material
Publication
Dennis Roß
Dennis
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Tel. 0821
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8
Literature
Literatur
Technicalliterature
Fachliteratur
taschenbuch des Metallhandels
Fundamentals of extrusion technology
LAScO umformtechnik GmbH
Hahnweg 139, D-96450 Coburg
Tel. +49 (0) 9561 642-0
Fax +49 (0) 9561 642-333
Internet: www.lasco.com
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VORSCHAU / PREVIEW
IM NÄCHSTEN HEFT
IN THE NEXT ISSUE
Special: Aluminiumguss
Special: aluminium casting
Wir berichten über Unternehmen und Ausrüster der Gießereibranche: über neue Projekte und innovative Entwicklungen. Beiträge unter anderem:
We will report on companies and equipment partners of the
aluminium foundry industry, with emphasis on new projects
and technological developments.
•
•
•
•
•
•
•
•
•
•
Gießereien wieder auf Wachstumskurs
Energieeffiziente Lösungen von Bühler Druckguss
Gießprozess-Simulation als strategisches Werkzeug
Neue Trennstoffschicht für Druckgussformen
Energieeffiziente Herstellung von Magnesiumlegierungen
Foundries achieve growth again
Energy-efficient solutions from Bühler Druckguss
Simulation of the casting process as strategic tool
New high performance coating for die cast moulds
Energy-saving production of magnesium alloys
Weitere Themen
Further topics
• Globalisierung der Aluminiumindustrie –
Wettbewerbsstrategien aufstrebender und
fortgeschrittener Ökonomien, Teil 2
• Die bulgarische Aluminiumindustrie
• Feuerfestsysteme für die NE-Metallindustrie
• The globalising aluminium industry – competitive
strategies of emerging and advanced economies, part 2
• The Bulgarian aluminium industry
• Refractory systems for the non-ferrous industry
Erscheinungstermin:
Anzeigenschluss:
Redaktionsschluss:
5. September 2011
22. August 2011
11. August 2011
Date of publication:
Advertisement deadline:
Editorial deadline:
5 September 2011
22 August 2011
11 August 2011
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