g - ALU-WEB.DE
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g - ALU-WEB.DE
Special: Aluminium smelting industry Innovative energy and fluoride recovery Improvements for the operation of anode baking furnaces Modelling cathode cooling after power shutdown ECL Improvement of thickness tolerances for a two-stand aluminium cold rolling mill Volume 88 · January / February 2012 International Journal for Industry, Research and Application Aluminium market outlook 1/2 Compact type remelt State-of-the-art Scrap Recycling Leading technology in the aluminum casthouse There are many benefits in one-stop-shopping of industrial goods. At Hertwich Engineering we provide customer oriented service throughout the project duration and service life of equipment. We design and build plants to meet both, our own stringent standards and individual customers specifications. Based on many years of experience, we cover the full range of equipment in a modern aluminum casthouse. Compact type remelt plant Q Q Q Q Major benefits Hertwich Engineering is well-known for leading edge technology. Our valued customers deserve to get the best value for money. Commitment to innovation, solid engineering and own R&D are instrumental for staying ahead with continuous improvements and new products. Q Q Q Most efficient installation for recycling of inhouse and purchased scrap One single fully automated process, starting with charging of scrap and finishing with homogenized billets, ready for extruding or forging Lowest labor costs, one to two operators per shift only Special design for remelting scrap contaminated with paint, plastic or oil, also with chip melting system available Optionally equipped with vertical DC caster Capacity 2,000 to 30,000 tons/year More than 25 plants installed HERTWICH ENGINEERING GMBH Weinbergerstrasse 6 5280 Braunau, Austria Phone: +43 (0) 7722 806-0 Fax: +43 (0) 7722 806-122 E-mail: [email protected] Internet: www.hertwich.com EDITORIAL Volker Karow Chefredakteur Editor in Chief Aluminiumnachfrage bleibt hoch Demand for aluminium stays high ALUMINIUM · 1-2/2012 Nach dem sehr kräftigen Wachstum von 5,1 Prozent 2010 dürfte die globale Wirtschaftsleistung 2011 nur noch um etwa 3,8 Prozent gestiegen sein. Für 2012 erwarten alle Wirtschaftsanalysten eine weitere Abschwächung der Weltproduktion. Lediglich über das Ausmaß der Bremsspur gehen die Meinungen auseinander. Dem Prinzip Hoffnung folgend wird jedoch für 2013 wieder ein Anziehen der globalen Produktion vorausgesagt. Genährt wird diese Hoffnung davon, dass Europa in eine nur milde Rezession fällt, die USA moderat wächst und die Dynamik in den Schwellenländern anhält. Dennoch birgt das laufende Jahr zahlreiche alte und neue Unwägbarkeiten und Herausforderungen. Die Stichworte lauten: Staatsschuldenkrise in Europa und den USA, Handlungsfähigkeit der US-Administration im Wahljahr, Ölembargo gegen den Iran und seine Folgen. Trotzdem ist die Stimmung in der Industrie nicht durchweg negativ, auch nicht in der Aluminiumindustrie. Alcoa-Boss Klaus Kleinfeld hat sich bei der Vorstellung der jüngsten Quartalszahlen optimistisch gezeigt, was die Aluminiumnachfrage betrifft. Er erwartet für das aktuelle Jahr eine Wachstumsrate von sieben Prozent. Der Zuwachs wäre damit zwar niedriger als 2011 und 2010 (10% bzw. 13%), aber dennoch bemerkenswert hoch. Kleinfeld steht mit seiner Einschätzung nicht alleine da; auch andere Konzernchefs gehen davon aus, dass die kurzfristige Marktnachfrage nach Aluminium überdurchschnittlich steigt. Die mittel- und langfristige Entwicklung sieht die Branche ohnehin in rosigen Farben. Angetrieben wird diese aktuelle Nachfrage vor allem aus dem Transportsektor, besonders aus dem Flugzeug- und Automobilbau, gefolgt von den Zielmärkten Bau und Verpackung. Dies und die inzwischen einsetzenden Kürr zungen bei der Aluminiumproduktion führen nach Einschätzung von Kleinfeld zu einer globalen Angebotslücke von etwa 600.000 Tonnen Primäraluminium in diesem Jahr. Das sollte eine stabilisierende Wirkung auf den Aluminiumpreis ausüben und die Talfahrt seit April 2011 vielleicht beenden können. Doch gehen die Erwartungen der Analysten über die weitere Entwicklung des Aluminiumpreises weit auseinander (s. Ausblick auf den Aluminiummarkt, Seite 19-24). Wie in den vergangenen Jahren widmet sich die Jan./Febr.-Ausgabe der ALUMINIUM traditionell der Hüttenaluminiumindustrie und ihren Ausrüstern. Auch diesmal konnten wieder eine Reihe hoch interessanter, technisch orientierter Beiträge eingesammelt werr den, die zeigen, dass es in der Branche keinen technischen Stillstand gibt. After the very robust growth of 5.1 percent in 2010 the world’s economic performance is likely to have risen farther by only about 3.8 percent during 2011, the year just ended. For 2012 all economic analysts anticipate a continuing downturn of world production: opinions differ only about how severe this will be. Driven by a spirit of hope, however, a recovery of global production is forecast for the following year, 2013. That hope is nourished by the expectation that the recession in Europe is only mild, moderate growth is taking place in the United States, and the dynamic is persisting in developing countries. Yet, the current year harbours many old and new uncertainties and challenges. The key words are: national debt crises in Europe and the USA, the US Administration’s freedom of action in an election year, the oil embargo against Iran and it consequences. Despite all that the mood in industry is not all gloomy and the same is true in the aluminium industry. When presenting the latest quarterly figures, Alcoa boss Klaus Kleinfeld waxed optimistic about the demand for aluminium. For this year he anticipates growth of seven percent and although this would indeed be lower than in 2011 and 2010 (with 10% and 13%, respectively), it is still remarkably high. Mr Kleinfeld is not alone in his estimate: the CEOs of other aluminium groups too are expecting the short-term market demand for aluminium to increase at an above-average rate. As things stand, the sector views the medium- and long-term development in a rosy light. The current demand level is driven above all by the transport sector, especially aircraft and automotive engineering, followed by the target markets of building and packaging. This, together with the aluminium production cutbacks occurring meanwhile, will in Kleinfeld’s view lead to a global supply shortfall of around 600,000 tonnes of primary aluminium during the course of this year. That is likely to have a stabilising effect on the aluminium price and could well be able to bring the decline since April 2011 to an end. Yet, the expectations of analysts about the further development of aluminium prices are widely different (see Aluminium market outlook, pages 19-24). As in previous years, the January / February issue of ALUMINIUM is traditionally devoted to the aluminium smelting industry and its suppliers. This time too a number of highly interesting and technically orientated contributions have been assembled, which demonstrate that there is no technical standstill in our industry. 3 I N H A LT EDITORIAL A l umi n i u mn a chfra ge b l e i b t h o ch • De ma n d fo r a l u mi n i u m stay s high ... 3 A KT U E L L E S • N E W S I N B R I E F En e rgie i n t e n s ive In du st ri e st ab i l i s i e rt St ro mn e t z e .............................. 6 A l e ri s b a u t Gi e ß e re i fü r Al -Li -Le gi e ru n ge n ........................................ 6 A l c o a c u t s gl o b a l c a p a c i t y b y 12 p e rc e n t .......................................... 7 A l e ri s b u i l ds c a st i n g fa c i l i t y fo r a l u mi n i u m-l i t h i u m a l l o ys .................... 7 M e ta l l gi e ß e re i Sch e e f – P ro du k t i o n s e rwe i t e ru n g i n Bra n de nburg ........ . 8 M a g n a a c qu i re s BDW c a st i n gs o p e ra t i o n s ......................................... 9 Ko b e St e e l t o fo rm a l u mi n i u m jo i n t ve n t u re i n Ch i n a ......................... 9 SM S: Auft ra gs e i n ga n g 2 011 ü b e r Vo rja h re s n i ve au ............................. 10 11. Umfo rmt e ch n i s ch e s Ko l l o qu i u m Da rmst a dt , 6 ./ 7. Mä rz 2012 .......... 10 TC Pri s ma – a p owe rfu l ma t e ri a l p re c i p i t a t i o n mo de l l i n g s of tware ....... 11 26 6 th Mi ddl e E a st Al u mi n i u m 2 012 Co n fe re n c e .................................... 11 WIRTSCHAFT • ECONOMICS A l umi n i u mpre i s e ......................................................................... 12 Pro d u k t i o n s dat e n de r de u t s ch e n Al u mi n i u mi n du st ri e ......................... 14 A ra ba l 2 011 fo c u s i n g o n O ma n’s a l u mi n i u m i n du st ry ......................... 16 A l umi n i u m ma rke t o u t l o o k – a ye a r o f u n c e rt a i n t y a n d ch allenge ....... 19 A L U M I N I U M S M E LT I N G I N D U S T R Y 32 TM S 2 012 – wi de ra n ge o f t e ch n i c a l s ymp o s i a .................................24 Duba l p ro p ri e t a ry t e ch n o l o gy l i c e n s e d t o E ma l P h a s e II .....................26 S h ap e d c a t h o de fo r t h e mi n i mi s a t i o n o f t h e Ha l l -Hé ro u l t p ro c e s s s p e c i fi c e n e rgy c o n s u mp t i o n .............................28 Pre c i s i o n p o t fe e di n g fo r b e t t e r e n vi ro n me n t a l p ro t e c t i o n .................32 Tre nds i n mo de rn re c t i fi e rs – e n e rgy e ffi c i e n c y a n d ava i l a bility ...........34 I n n ova t i ve e n e rgy a n d fl u o ri de re c ove ry ..........................................39 E C L – re n own e d e qu i p me n t s u p p l i e r t o t h e p ri ma ry a l u mi n i u m i n du st ry .................................................44 4 I m p rove me n t s fo r t h e o p e ra t i o n o f a n o de b a k i n g fu rn a c e s .................46 Te st i n g c e l l c o n t ro l l e r a l go ri t h ms u s i n g a dyn a mi c c e l l s i mulator .........50 Der Aluminium-Branchentreff des Giesel Verlags: www.alu-web.de 4 Te st i n g o f c a rb o n ma t e ri a l s fo r re s e a rch a n d i n du st ri a l p u rposes .........55 ALUMINIUM · 1-2/2012 CONTENTS Anode handling and cleaning systems for modern aluminium smelters ......59 S m e l t er l ogi st i c s up g ra d e . . . . . . . . . . . . . . . . . . . . . ........................................ 61 A l l i a n ces i n t h e a l um i n i um i n d ust r y . . . . . . . . ........................................63 Mode l l i ng ca t h o d e c o o l i n g a f t e r p owe r s hu t down ............................65 A u m u nd cool i n g c o n ve yo r f o r h o t b a t h m a t e ri a l ...............................68 G A P E ng i neer i n g – a n e w g l o b a l s up p l i e r of a l u m i ni u m c a st i n g t e ch n o l o g i e s . . . . . . . . . ........................................ 71 T E CH N O LO G I E • T E CH N O LO GY Ve r besser u n ge n d e r Di cke n t o l e ran z e n an e i n e m z we i ge rü st ig e n A l u m i ni u m - Kal t wa l z we r k • I m p rove m e n t o f t h i ck n e s s t o l e ra n c e s f or a t wo- st a n d a l um i n i um c o l d ro l l i n g mi l l .....................................73 M i croS t re a m - S t rö mun g s s ch l e ife n für p rä z is e E n db e a rb e i t u n g Mi croS t re a m fl ow g r i n d i n g f o r h i g h - p re c i s i o n fi n i s h ma ch i n i n g ...........78 A N W E N D U N G • A P P L I C AT I O N D er neu e M erc e d e s - B e n z S L s e t z t a uf A l um i n i u m T h e new M erc e d e s - B e n z S L – a l mo st e n t i re l y ma de o f a l u mi n i u m .......80 This issue contains an enclosure from GDA Gesamtverband der Aluminiumindustrie e.V. to which we draw your kind attention. C O M PA N Y N E W S W O R L D W I D E Inserenten dieser Ausgabe A l u m i ni u m sme l t i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................82 B a u x i t e a n d a l umi n a . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................83 R ecycl i n g a n d s e c o n d ar y s m e l t i n g . . . . . . . . . . ........................................84 Al u m i n i u m semi s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................84 List of advertisers ABB Switzerland 47 Buss AG, Switzerland 49 Buss ChemTech AG, Switzerland 35 Coiltec Maschinenvertriebs GmbH 9 CRU Events, UK 21 O n t h e m ove .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................85 Drache Umwelttechnik GmbH 27 Dubai Aluminium Co. Ltd, UAE 15 Su ppl i e r s . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................86 ECL, France 23 Edimet S.p.a., Italy 23 FLSmidth Hamburg GmbH 29 Glama Maschinenbau GmbH 25 RESEARCH D a s a e c ( a l u mi n i um e n g i n e e r i n g c e n t e r ) i n Aa ch e n – We l t we i t größtes Hochschulzentrum für Aluminiumforschung und -lehre, Teil I .......87 D O C U M E N TAT I O N Hertwich Engineering GmbH, Austria 41 Inotherm Industrieofenund Wärmetechnik GmbH 65 Messe Düsseldorf GmbH 17 Micro-Epsilon Messtechnik GmbH & Co. KG 75 R&D Carbon Ltd, Switzerland Pa t e n te . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................89 I m pre ssu m • I mp r i n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................................... 105 Vor scha u • P re vi e w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................................... . 106 B E Z U G S Q U E L L E N V E R Z E I C H N I S • S U P P L I E R S D I R E C T O R Y .....92 ALUMINIUM · 1-2/2012 2 Innovatherm Prof. Dr. Leisenberg GmbH & Co. KG Reed Exhibition China 53 107 Rösler Oberflächen GmbH 11 SGL Carbon GmbH 31 SMS Siemag Aktiengesellschaft 108 Storvik AS, Norway 45 Thermo-Calc Software, Sweden 33 Wagstaff Inc., USA 13 5 AKTUELLES Energieintensive Industrie stabilisiert Stromnetze Die energieintensiven Industrien haben Be- würde. Sie verweisen darauf, dass nur rund mit tragen sie erheblich zur Netzstabilität bei hauptungen zur teilweisen Befreiung von Netz- 20 statt mehrere Hundert Unternehmen unter und haben so sogar eine kostendämpfende entgelten einem „Faktencheck“ unterzogen, die Ausnahmeregelung fallen und die Mehrr Wirkung auf die Netznutzung, von der alle um falsche oder unvollständige Informationen kosten für den Endverbraucher bei 0,1 Cent je Stromnutzer profitieren. Würden die großen Kilowattstunde liegen. Die energieintensiven Stromabnehmer die Netze so unregelmäßig in der Berichterstattung zurechtzurücken. So wird in dem Branchenstatement die Industrien spielen damit nur eine untergeord- nutzen wie Privathaushalte (starke Nutzung Behauptung zurückgewiesen, bei tagsüber, wenig in der Nacht), der Verabschiedung des Enerr wäre der Bedarf an Regelenergie giepaketes sei „klammheimlich“ zur gleichmäßigen Auslastung eine Neuregelung der Stromnetzder Netze deutlich höher, so die entgeltverordnung untergebracht WVM. Dementsprechend würden worden. Eine teilweise Befreiung auch die Netzkosten für alle deutenergieintensiver Unternehmenlich höher liegen. von den Netzentgelten, so die Err Vor diesem Hintergrund könwiderung, sei keineswegs neu. Mit ne von einem „ungerechtfertigten Bonus“ der energieintensiven der Novelle des EnergieleitungsUnternehmen keine Rede sein, so ausbaugesetzes im Jahr 2009 müssen Unternehmen mit einem der Branchenverband. Die GroßStrombezug von mehr als 7.000 verbraucher seien wegen der staStunden pro Jahr seit 2011 ein bilisierenden Wirkung, die sie auf individuelles Netzentgelt entrichdas Stromnetz ausübten, mit der ten, das mindestens 20 Prozent Neufassung der Stromnetzentgeltdes regulären Netzentgeltes beverordnung von den Netzentgelträgt. Die Schwelle wurde damit Großverbraucher stabilisieren die Netze durch ihren gleichmäßigen Stromten befreit worden. VoraussetFoto: ALUMINIUM schon vor Jahren von 50 Prozent bezug, betont die Wirtschaftsvereinigung Metalle (WVM) zung für die Ausnahmeregelung auf 20 Prozent abgesenkt. Mit sei, dass die befreiten UnternehVerabschiedung der Energiewende wurde nete Rolle bei den Strompreiserhöhungen der men mehr als 7.000 Stunden im Jahr (von insbeschlossen, dass Unternehmen mit mehr als jüngsten Zeit, so die Wirtschaftsvereinigung gesamt 8.750 Jahresstunden) und insgesamt 7.000 Stunden Strombezug und einem Strom- Metalle (WVM). mehr als 10 GWh Strom im Jahr beziehen. verbrauch von über 10 Gigawattstunden Auch die Behauptung, die energieinten- Damit seien tatsächlich nur Unternehmen von rückwirkend ab Januar 2011 vom regulären siven Unternehmen belasteten durch ihren den Ausnahmen berührt, die kontinuierlich Netzentgelt befreit sind. hohen Stromverbrauch das Netz besonders sehr viel Strom verbrauchen. Ihre Befreiung Die energieintensiven Industrien weisen stark, trifft nicht zu. Das Gegenteil sei der von den Netzentgelten sei also kein Bonus, auch die Behauptung zurück, dass mehrere Fall, betont die WVM. Die Großabnehmer, sondern resultiere aus ihrer wichtigen Rolle hundert Großverbraucher aus der Industrie so die Erwiderung, sorgten durch ihren gleich- für das Netz, so die Wirtschaftsvereinigung eine Ausnahme bei den Netzentgelten erhal- mäßigen Strombezug über das ganze Jahr für Metalle. ten und Strom dadurch für alle anderen teurer eine gleichmäßige Belastung der Netze. Da- Aleris baut Gießerei für Al-Li-Legierungen Aleris wird eine spezielle Gießerei für Aluminium-Lithium-Platten und -Bleche bauen. Die Anlage wird am Standort Koblenz gebaut; die Produkte sind vor allem für die Luft- und Raumfahrtbranche bestimmt. Aluminium-Lithium-Legierungen zeichnen sich durch geringeres Gewicht als herkömmliche Flugzeuglegierungen bei, ohne die Festigkeit, Korrosionsbeständigkeit und Ermüdungsbeständigkeit zu beeinträchtigen. Die neue Anlage wird in der Lage sein, besonders große Blöcke für Tests sowie für die Serienfertigung von Aluminium-Lithium-Pro- 6 dukten einzusetzen. Das Design der Anlage wird auch die Entwicklung neuer, konventioneller Legierungen vereinfachen, um den Kunden modernste und nachhaltige Lösungen anzubieten. Die Produktion in der neuen Gießerei soll im ersten Quartal 2013 starten. Bühler integriert Druckk gussgeschäft in AG Zum 1. Januar 2012 hat das Technologieunternehmen Bühler sein Druckgussgeschäft, die Bühler Druckguss AG, in die Bühler AG integriert. Gleichzeitig wurde die deutsche Niederlassung Bühler Druckgiessysteme GmbH in die Bühler GmbH integriert. Die Integrationsmaßnahmen dienen der Vereinfachung von Prozessen und Abläufen. Dadurch soll der Kundennutzen weiter verbessert werden. Bühler plant, den Standort Deutschland zu stärken, indem der Verkauf und Kundendienst ausgebaut wird. Die Geschäftsprozesse in der Schweiz und in Deutschland wurden der neuen Situation bereits angepasst. Für Kunden und Lieferanten ändert sich fast nichts, die bisherigen Ansprechpartner in Verkauf und Service bleiben bestehen. Bühler ist in über 140 Ländern tätig und beschäftigt weltweit rund 7.800 Mitarbeiter. Im Geschäftsjahr 2010 erwirtschaftete das Unternehmen einen Umsatz von 1,9 Mrd. Schweizer Franken. ALUMINIUM · 1-2/2012 NEWS IN BRIEF Alcoa cuts global capacity by 12 percent Alcoa Aluminium flagship Alcoa has announced it will close or curtail about 531,000 tonnes (12%) of its global smelting capacity, to lower its position on the global aluminium cost curve and improve competitiveness. The company will permanently close its smelter in Tennessee, which was curtailed in 2009, along with Ingots produced at Alcoa Tennessee two of the six idled potlines at its Rockdale smelter in Texas. Together, these closures will reduce Alcoa’s global smelting capacity of 4.5 million tpy by 291,000 tonnes, which corresponds to seven percent. Some days later, Alcoa added it would curtail operations at three European aluminium smelters as part of the capacity cutback. This applies to the company’s Portovesme smelter in Italy as well as to the La Coruña and Avilés smelters in Spain. These facilities are among the highest-cost producers in the Alcoa system. At Portovesme, Alcoa will begin the consultation process to permanently close the 150,000 tpy smelter. The La Coruña and Avilés curtailments are planned to be partial and temporary. Capacity at La Coruña and Avilés is 87,000 and 93,000 tpy, respectively. The cutbacks of the three European smelters will reduce Alcoa’s global smelting capacity by an additional 240,000 tonnes or about five percent, and are expected to be complete by the first half of 2012. The curtailments will contribute to Alcoa’s long-term goal of improving its position on the world aluminium production cost curve by 10 percentage points and thus increase the company’s competitiveness in the current volatile aluminium marketplace. Aluminium prices have fallen more than 27 percent from their peak in 2011. “These are difficult but necessary steps to improve Alcoa’s competitiveness, preserve and grow shareholder value and protect jobs in the rest of the Alcoa system,” says Alcoa chairman and CEO Klaus Kleinfeld. In addition to the curtailments, Alcoa will accelerate actions to reduce the escalating cost of raw materials. Alcoa’s alumina production will be reduced across the global refining system to reflect the final curtailments in smelting as well as prevailing market conditions. This will contribute to the company’s long-term goal of lowering its position on the world aluminium production cost curve by ten percentage points. Alcoa announced a loss from continuing operations of USD193m in Q4 2011 on restructuring charges associated with the closure and curtailment of high-cost production capacity, lower aluminium prices and continued market weakness. Excluding the net negative impact of restructuring and other special items, the loss from continuing operations was USD34m. Aleris builds casting facility for aluminium-lithium alloys Aleris will build a specialised casting facility for aluminium-lithium plate and sheet products. The facility will be built at the company’s German plant in Koblenz; the products are destined to meet the needs of the aerospace market. Aluminium-lithium alloys enable aircraft manufacturers to increase fuel efficiency through the weight reduction provided by aluminium while maintaining strength as well as corrosion and fatigue resistance. ALUMINIUM · 1-2/2012 The new facility will be able to cast full-scale ingots for trials as well as for serial production of aluminium-lithium products. Moreover, the design of the facility will facilitate the development of new conventional alloys to provide customers with the most advanced and sustainable solutions. Production in the new casting facility is expected to start in the first quarter of 2013. New BA president for Sapa Profiles The recent years’ rapid growth has made Sapa the largest aluminium profiles company in the world. In order to better capitalise on the synergies within the profiles area and streamline the operation, Sapa Profiles will be organised as one business area. New business area president will be John Thuestad, as from 1 February 2012. He will be a part of the corporate management team at Sapa and report to Sapa president and CEO, Svein Tore Holsether. In addition he will take on the role as business area president for Profiles Europe. Sapa Profiles will set up its new head office in Lausanne, Switzerland, and John Thuestad will re-locate there. Novelis to invest USD50m for new Brazil can stock coating line Aluminium producer Novelis Inc. will invest some USD50m to install a coating line for beverage can end stock at its Brazilian rolling and recycling complex in Pindamonhangaba, the company has recently said. In November last year, Novelis announced plans to invest USD32m to expand recycling capacity at its Pindamonhangaba complex, which will nearly double the plant’s used beverage can (UBC) recycling capacity from 200,000 to 390,000 tpy. That investment came on top of a previously announced USD300m rolling mill expansion at Pindamonhangaba. Hydro curtails production in Kurri Kurri, Australia In response to low metal prices and the uncertain market outlook Hydro has decided to cut production at its Kurri Kurri aluminium smelter in Australia. This step will be done by closing Potline 1, representing an annual production of 60,000 tonnes. The production line is expected to be fully curtailed in March. 150 jobs will consequently become redundant. The cost of curtailing Potline 1 is estimated at approx. USD20 million. Kurri Kurri, fully owned by Hydro, has three production lines with a total annual production capacity of 180,000 tonnes. 7 AKTUELLES Wechsel im Vorstand W der SMS Siemag AG Kay Mayland, Vorstandsvorsitzender der SMS Siemag AG und Mitglied der Geschäftsführung der SMS Holding GmbH, ist Ende 2011 wie geplant aus Altersgründen ausgeschieden und in den Aufsichtsrat der SMS Siemag AG gewechselt. Burkhard Dahmen, Vorstandsmitglied Stahlwerke / Stranggießtechnik der SMS Siemag, hat mit Wirkung zum 1. Januar 2012 den Vorstandsvorsitz der Gesellschaft übernommen. Er wird gleichzeitig Mitglied der Geschäftsführung der SMS Holding. Seine Nachfolge als Vorstand der SMS Siemag tritt Guido Kleinschmidt an, bislang Mitglied der Geschäftsbereichsleitung Stahlwerke /Stranggießtechnik der Gesellschaft. Alexander Tutsek, Inhaber der Refratechnik, verstorben Im September 2011 verstarb im Alter von 84 Jahren Alexander Tutsek, der Inhaber der Refratechnik Feuerfest Gruppe. Alexander Tutsek baute die 1950 als Steinwerke Feuerfest Karl Albert gegründete Firma unter dem Namen Refratechnik zu einem weltweit agierenden Konzern mit rund 400 Millionen Euro Jahresumsatz und 1.500 Mitarbeitern aus. Refratechnik ist heute Weltmarktführer im Bereich basische Steine und Komplettanlagen in der Zementindustrie und Systemanbieter vor allem in der Stahl- und Aluminiumindustrie. Refratechnik hat mit Produktionsstätten in Deutschland, Spanien und China eine Jahreskapazität von circa 400.000 Tonnen an gebrannten Steinen, 50.000 Tonnen an ungeformten Produkten und 120.000 Tonnen MgO in Kanada. Alexander Tutsek war bis zuletzt als Vorsitzender der Geschäftsführung der Refratechnik Holding GmbH aktiv. Die Rechtsnachfolger sind die gemeinnützige Alexander-TutsekStiftung und eine Familienstiftung. Beide Stiftungen garantieren als neue Gesellschafter die Fortführung des Unternehmens im Sinne von Alexander Tutsek. Die operativen Geschäfte werden von den Firmen Refratechnik Cement GmbH in Göttingen, Refratechnik Asia Ltd. in Hongkong, Refratechnik Steel GmbH in Düsseldorf und Baymag Inc. in Calgary, Kanada, weitergeführt. 8 Metallgießerei Scheef Produktionserweiterung in Brandenburg Die Metallgießerei Scheeff produziert seit mehr als 50 Jahren im bayerischen Nersingen Aluminiumguss, durchschnittlich mit jährr lich zweistelligen Zuwachsraten, wie der geschäftsführende Gesellschafter Manfred Meier betont. Mit der Zeit wurde es in Nersingen immer schwieriger, den Mengenzuwachs auf dem vorhandenen Areal zu produzieren. Eine bereits geplante Werkserweiterung in Thüringen wurde 2008 wegen der allgemeinen Wirtschaftskrise nicht umgesetzt. In einem neuen Anlauf entschied man sich für die Expansion im brandenburgischen Hennersdorf. Die Scheef GmbH wird an diesem Standort mit der Kokillengussfertigung beginnen. Später soll mit zwei Formanlagen Sandguss produziert werden, was auch Hallenerweite- rungen notwendig macht. Außerdem wird derr zeit eine neue Formanlage installiert, deren Anlauf im Februar 2012 vorgesehen ist. Diese Formanlage wird die größte und modernste Anlage in der Aluminiumgießereibranche sein, so Meier. Auch die Peripherie wird komplett modernisiert. Das gesamte Investitionsvolumen beträgt rund 16 Mio. Euro bis 2014. Die Kunden des Unternehmens wie Audi, Porsche, VW, MAN, Deutz, Liebherr, Daimler, Volvo, Scania verlangen nach immer größeren Bauteilen. Ziel von Scheef ist es, in allen Baugrößen am Markt tätig zu sein. In Hennersdorf ist beabsichtigt, Stückgewichte von 0,5 bis 12 kg zu gießen, in Nersingen richtet man sich auf größere Gewichte pro Gussteil bis maximal 80 kg ein. DIN EN 1090 im Fokus Ausführung von Stahl- und Aluminiumtragwerken Die europäische Einheit bei Stahl- und Aluminiumbauten rückt näher. Um europaweit auf einheitliche Standards für Stahl- und Aluminiumtragwerke zurückgreifen zu können, gibt es die Eurocodes für die Bemessung und DIN EN 1090 für die Ausführung. Die dreiteilige europäische Normenreihe DIN EN 1090 wird ab dem 1. Juli 2012 in ganz Europa verbindlich gelten und die in Deutschland bisher gültigen Normen DIN 18800-7 für Stahlbauten und DIN V 4113-3 für Aluminiumkonstruktionen ablösen. Bis dahin gilt jedoch eine Koexistenzphase, während der Metallbauten weiterhin nach den bisherigen nationalen Regeln für die Bemessung und Ausführung hergestellt werden können. Dennoch sollte man sich schon jetzt mit den anstehenden Änderungen verr traut machen. DIN EN 1090 enthält umfangreiche Angaben zur Zertifizierung der werkseigenen Produktionskontrolle. Diese Vorgaben müssen künftig auch solche Metallbaubetriebe berücksichtigen, die bisher der Klasse A nach DIN 18800-7 zuzuordnen waren. Die Umstellung auf die europaweit gültige Norm ist für viele Unternehmen eine große Herausforderung. Die vorliegende Publikation hilft, die Umstellung erfolgreich zu meistern: Deshalb sind die DVS-Richtlinie 1711 und das DVS-Merkblatt 1712 Bestandteil dieser Veröffentlichung. Während die DVSRichtlinie 1711 „Voraussetzungen und Verr fahren für die Zertifizierung von Herstellern nach DIN EN 1090-1“ enthält, beschreibt das DVS-Merk-blatt 1712 die „Werkseigene Produktionskontrolle nach DIN EN 1090-1/-2 am Beispiel eines Anbaubalkons in EXC 1“. DVS 1712 gibt vor allem den Betrieben, die bisher der Klasse A zugeordnet wurden, Hilfestellung bei der Umsetzung der Anforderungen an die werkseigene Produktionskontrolle. Darüber hinaus finden sich in dieser Veröffentlichung auch erläuternde Informationen darüber, welche Metallbauprodukte welcher Ausführungsklasse (EXC) zuzuordnen sind. Auf Initiative des DVS wurden diese Erläuterungen 2010 verfasst und von der Fachkommission Bautechnik der Bauministerkonferenz in den DIBt-Mitteilungen bereits publiziert. Diese Veröffentlichung soll dabei helfen, auf dem Weg zu einer europäischen Einheit bei Stahl- und Aluminiumbauten die Orientierung zu behalten. Es lohnt sich, den Neuerungen von DIN EN 1090 offen gegenüberzustehen und sich den Änderungen zu stellen. Denn die europaweit geltenden Standards machen Produkte und Leistungen messbar und vergleichbar. Die Unternehmen, die sich an diesen Standards orientieren, verbessern ihre Chancen im europäischen Wettbewerb. DIN EN 1090 im Fokus: Ausführung von Stahl- und Aluminiumtragwerken, 56 Seiten, 5 Abb., 14 Tab., ISBN: 978-3-87155-607-4, erschienen: September 2011, EUR 58,- ALUMINIUM · 1-2/2012 NEWS IN BRIEF Magna acquires BDW castings operations sales of approximately 160 million euros. On completion of the transaction, Cosma will acquire two operations in Germany, one in Poland and one in Hungary. BDW’s current customers include Volkswagen, Audi, Porsche, Mercedes-Benz, Ferrari and ZF. Closing of the transaction is expected to occur BDW Cosma, an operating unit of Canadian Magna International Inc., has signed an agreement with the shareholders of BDW technologies, pursuant to which Cosma will acquire BDW’s four operations. BDW is an industry leader in vacuum high-pressure aluminium die casting and expects full-year 2011 total in the first quarter of 2012, subject to obtaining all necessary regulatory approvals including anti-trust approvals. The acquisition expands and complements Cosma’s ability to deliver lightweight solutions for complex body-in-white structural and chassis components in steel, aluminium or aluminium-steel hybrid to customers around the world. The combination of Cosma’s proven record for body structure and chassis engineering with thin-wall aluminium casting capabilities will further enhance its position in the industry. “The technologies gained from BDW will complement the low-pressure casting capabilities we recently acquired from Grenville Castings in Ontario, Canada,” said Horst Prelog, president of Cosma. Cosma International manufactures a comprehensive range of metal body systems, components, assemblies and modules including complete vehicle frames, chassis systems and body-in-white systems using a variety of innovative processes such as hydroforming, stamping and roll forming. Cosma International has 47 manufacturing facilities and 25 product development and engineering centres worldwide. BDW casting cell with closing force of 3.200 tonnes Kobe Steel to form aluminium joint venture in China Kobe Steel has tied up with Jiangsu Alcha Aluminium, a major producer of aluminium rolled products in China, to expand its aluminium business. Kobe Steel and Alcha have signed a letter of intent to establish a joint venture in Baotou, Inner Mongolia, to produce and sell aluminium coil and sheet. After conducting a detailed feasibility study, both companies plan to sign the final agreement in spring 2012. The joint venture, which is planned to be established in January 2013, is envisaged to be 80% owned by Kobe Steel and 20% by Alcha. Capital investment is earmarked at approx. 40 billion yen (€402m). The company will produce mainly aluminium coil and sheet for automobiles and beverage cans. Production capacity at the joint venture will be 200,000 tpy. While the company name is yet to be decided, the operation will be capitalised at 2 billion RMB (about 24bn yen). Start-up of operations is anticipated in 2015. With demand for aluminium sheet in China rapidly increasing in recent years, Japanese, US and European customers have accelerated ALUMINIUM · 1-2/2012 their push into the Chinese market. Demand for aluminium sheet for automobiles and beverage cans, which are major products at Kobe Steel, is anticipated to grow significantly in the coming years. But only a limited number of manufacturers in China can currently make these products as advanced production technology is required. The new joint venture will produce aluminium sheet in an integrated operation, from melting and casting to hot and cold rolling. T the joint venture plans to install state-of-the- art equipment to produce some of the world’s largest aluminium coils. Baotou in Inner Mongolia, where the plant will be constructed, is close to abundant energy resources and has a skilled workforce. These factors will give the joint venture a competitive edge, says Kobe. Listed on the Shenzhen Stock Exchange, Alcha is a major manufacturer of aluminium rolled products. The partner companies are working on starting up the joint venture, with Alcha assisting in equipment procurement and permitting. n n3 -/ 3 n44-/3 n'/5//33-//3 '/5//3 '/5 n 3-6 -/ 3-6 n+/ +/ n4// 4 n /3 n-33-/ / n03 /3 0 /3 n,4./6/ -/ ,4./6/ / n!73423// 42 n&23// n*-1/0332 3 2 ',! - /5/33/.# .$ )%',!(-/5/33/.# .$8+./31-4/8"3/4/./3 */8"-7 * / 666//8/ -0// 6 6 / / - 9 AKTUELLES SMS: Auftragseingang 2011 über Vorjahresniveau Industrieländern. Die Auslastung der Kapazitäten in der SMS-Gruppe ist aufgrund des gestiegenen Auftragsbestands dennoch bis weit SMS Der Auftragseingang der SMS group betrug 2011 vorläufigen Zahlen zufolge rund 3,4 Mrd. Euro. Wie Heinrich Weiss, Vorsitzender SMS Meer Werkstatt in Möchengladbach der SMS-Gruppe, in einer Unternehmensmeldung erklärte, sei die Zahl der vergabereifen Projekte noch stabil, doch seit Mitte des letzten Jahres eine zunehmende Zurückhaltung bei der Auftragsvergabe spürbar – sowohl bei größeren Projekten in den Entwicklungs- und Schwellenländern als auch in den klassischen in 2012 gesichert. Die Zahl der Mitarbeiter in der SMS group ist durch die Übernahme von mehr als 90 Prozent der Anteile an der ele- xis AG, Wenden, und infolge eines weiteren Mitarbeiteraufbaus in China und Indien auf rund 10.600 Mitarbeiter angestiegen, das ist ein Plus von 15 Prozent. Wie Weiss weiter erklärte, habe SMS die zurückliegende Zeit genutzt, um die technische Entwicklung weiter zu intensivieren und Abläufe zu rationalisieren. Nun komme es darauf an, auch die Herstellkosten durch ferr tigungsoptimierte Konstruktionen, höhere Effizienz in der Logistik und steigende Produktivität bei Engineering und Fertigung weiter zu senken. Dazu würden die verabschiedeten Investitionsprogramme planmäßig fortgeführt. Dazu gehören auch die 60 Mio. Euro schweren Investitionen der SMS Meer in den Standort Mönchengladbach. Dort werden drei Viertel aller bestehenden Werkzeugmaschinen ausgetauscht. Zudem wird die Schwerlasthalle um rund 4.000 Quadratmeter Fläche erweitert. Daneben errichtet die SMS Siemag zurzeit für rund 20 Mio. Euro eine Werkstatt in der Nähe von Shanghai, die im Frühjahr 2012 fertiggestellt sein wird. In Hilchenbach, dem Stammsitz des vor über 140 Jahren gegründeten Familienunternehmens, werden die über mehrere Jahre angelegten Investitionen von insgesamt 80 Mio. Euro zur Schaffung einer der modernsten Schwermaschinenbau-Werkstätten im Laufe dieses Jahres abgeschlossen sein. 11. Umformtechnisches Kolloquium Darmstadt, 6./7. März 2012 „Flexible Umformtechnik“ Kuka erhält Großauftrag aus der Autoindustrie Kuka Systems hat im vierten Quartal 2011 einen Großauftrag zum hochpräzisen Fügen von Aluminium-Karosseriebauteilen erhalten. Ein internationaler Premiumhersteller beauftragte die Gesellschaft mit dem Engineering und Bau sowie der Montage und Inbetriebnahme von drei automatisierten Produktionszellen. Der Anlagenbau hat einen Auftragsumfang im mittleren zweistelligen Millionen-EuroBereich. Auf der Anlage werden Karosserieteile wie Kotflügel und Motorhauben geformt. Kuka integriert dabei 125 Industrieroboter in den Zellen und programmiert die Steuerung, um die Prozessaufgaben wie Clinchen, Kleben und Falzen der Bauteile in höchster Qualität zu garantieren. 10 Das Umformtechnische Kolloquium Darmstadt (UKD) ist eine zweitägige Vortragsveranstaltung, die traditionsgemäß alle drei Jahre im Frühjahr in Darmstadt stattfindet. Als Infoveranstaltung und Kommunikationsplattform richtet sich das UKD insbesondere an Fach- und Führungskräfte produktionstechnischer Unternehmen sowie an Wissenschaftler aus der Produktionstechnik und angrenzenden Fachgebieten. Referenten aus Industrie und Forschung berichten in ihren Vorträgen über aktuelle Entwicklungen und Innovationen in der Produktions- und Umformtechnik, aber auch über die Produktivität eines Unternehmens im Hinblick auf die vom Kunden immer mehr geforderte Flexibilität in der Produktion. Das Tagungsprogramm umfasst 20 Vorträge an vier Halbtagen. Vortragsthemen sind unter anderem: „Modulares Maschinen- und Vorschub- system für die Stanztechnik“, „Flexibilisierung der Fertigung umformtechnisch erzeugter Bauteile durch prozessangepasste Halbzeuge“, „Festwalzen mit Minimalmengenschmierung bei hydrostatischen Werkzeugen“, „Walzprofilieren im Wandel“, „Warmumformung von Magnesium-Flachprodukten“, „Entwicklung hoch umformbarer Aluminiumlegierungen für den Automobilbau“. Die Vortragslänge beträgt rund 25 Minuten mit je anschließender Kurzdiskussion. Erwartet werden rund 200 Teilnehmer aus dem Maschinen- und Anlagenbau, der Automobil- und Zulieferindustrie sowie von Universitäten und Verbänden. Veranstaltungsort ist das Lufthansa Training & Conference Center in Seeheim-Jugenheim. Weitere Informationen unter www. ukd2012.ptu-darmstadt.de ALUMINIUM · 1-2/2012 NEWS IN BRIEF Call for papers begins for TC Prisma – a powerful material precipitation modelling software the conference parallel to ALUMINIUM 2012 trade fair Thermo-Calc Software AB and QuesTek In- We’re excited to have partnered with ThermoThe German Aluminium Association GDA (Gesamtverband der Aluminiumindustrie) together with Reed Exhibitions are planning and organising the conference accompanying the ALUMINIUM 2012 trade fair. Under the name ‘Aluminium – Material for the Future’ presentations are planned on the subjects of processes, transport, automotive, surface and aluminium markets. Specialists from companies, research institutes and universities are warmly invited to submit presentations on these subjects. The submitted contributions will be examined by a programme committee, which may also permit other subject areas. The contributions will be compiled into a publication and made available. The submission deadline for the abstracts is 23 March 2012. Details on the call for papers can be found at www.aluminium-conference.de novations LLC have jointly developed ‘TCPrisma’, a new user-friendly software package available from Thermo-Calc Software for modelling precipitation in multi-component and multi-phase systems, which is used in conjunction with well-established Thermo-Calc and ‘Dictra’ software. TC-Prisma evaluates concurrent nucleation, growth and coarsening, and incorporates key models and algorithms from QuesTek’s ‘PrecipiCalc’ precipitation simulation software, which QuesTek has used as part of its ‘Materials by Design’ technology to computationally design novel new alloys such as ‘Ferrium’ M54, S53, C61 and C64 for use in aerospace, defence, energy, racing and other industries. Charlie Kuehmann, QuesTek’s president and CEO, commented: “The launch of TCPrisma software is very timely given President Obama’s recent establishment of the Materials Genome Initiative, since TC-Prisma is an important new tool for materials design engineers to computationally design materials. Calc Software, a premier leader in scientific software and databases that involve computational thermodynamics and diffusion-controlled simulations, to accelerate the adoption of integrated computational materials engineering (i.e. ICME) tools.” Anders Engström, Thermo-Calc Software’s president, added: “TC-Prisma is new, robust, precipitation modelling software built by two globally-recognised leaders in computational modelling, analysis and material design, which significantly enhances Thermo-Calc and Dictra. To develop TC-Prisma we’re pleased to have partnered with QuesTek and incorporated key aspects of their PrecipiCalc software, since QuesTek is well-known for their application of computational materials engineering, software and databases to rapidly design new materials that meet user-defined needs.” More information about TC-Prisma at www. thermocalc.com/TC-Prisma.htm 6th Middle East Aluminium 2012 Conference, 5 to 7 March in Dubai, UAE The 6th Middle East Aluminium 2012 Conference gathers together the key aluminium producers and downstream fabricators to discuss the opportunities connected with the massive expansion of the regional aluminium sector. Middle East Aluminium 2012 will be discussing the region’s progress towards becoming a leading player in the global aluminium market through updates on production capac- ity, dynamic demand and the development of the downstream business. The comprehensive agenda will also look at the forward pricing of aluminium and the market opportunities and challenges ahead. Join C-level executives and senior representatives across the aluminium value chain including aluminium end-users, extruders, rolling mills, casthouses, smelters, traders, equipment and technology providers and consultants at this premium gathering for the region’s aluminium industry. Key speakers include representatives from Midal Cables, Garmco, Balexco, Gulf Aluminium Council, EAFA, Oman Aluminium Rolling Co., CRU Group, London Metal Exchange. More information about the conference at www.middleeastaluminium.com 03.03.2012, hall 15, booth F 46. you‘re in good hands ... ... we have all the pieces. www.rosler.com BDA5024K58=8B78=6KUKB7>CK1;0BC8=6 Innovative solutions from the world‘s leader in surface finishing 3ÚTMFS0CFSGMÊDIFOUFDIOJL(NC)t6OUFSNFS[CBDIt(FSNBOZt5FMt'BYt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–50 2003 2004 2005 2006 2007 2008 2009 2010 2011 0)7<7)285',6',2-776:)57) 2.500 )<)1&)5 39)1&)5 /73&)5 )47)1&)5 8+867 80- 2.000 853 853 853 853 853 853 1.500 2003 2004 2005 2006 2007 2008 2009 2010 2011 1.000 5.000 0)7<7)232%76)2(:)57) )<)1&)5 39)1&)5 /73&)5 )47)1&)5 8+867 80- 3 3 3 3 3 3 4.000 3.000 2.000 1.000 2003 2004 2005 2006 2007 2008 2009 2010 2011 0 00)2+%&)2%8*(-)6)5)-7)6-2(829)5&-2(0-', 8)00) !!=%/78)00)#)57)827)5:::75-1)7()3()51-7()5 44*@5(%6-,32) 12 ALUMINIUM · 1-2/2012 ' ( /+ /' /,)- /+* /- / - - "%!&&##"$!$. 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 % * 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 50,4 9,9 154,9 11,9 44,8 18,2 Feb 33,8 32,2 54,2 6,4 161,1 9,2 47,3 11,1 Mär 37,0 21,9 58,5 1,9 173,7 0,8 53,1 4,0 Apr 35,7 15,1 53,2 4,5 156,6 -2,3 47,3 7,4 Mai 37,1 7,9 56,7 5,8 168,3 3,7 56,1 18,3 Jun 35,9 3,3 51,1 -10,0 133,5 -19,3 49,2 -8,4 Jul 36,7 0,5 52,3 5,2 164,9 4,2 50,7 0,4 Aug 37,0 0,3 45,9 -0,3 159,5 -4,8 50,8 5,0 Sep 35,1 -2,3 54,9 2,4 152,2 -5,4 53,8 5,8 Okt 36,1 -2,9 53,5 2,8 148,6 -8,1 49,8 -1,9 Nov 35,2 -1,9 57,0 8,5 152,8 -3,5 53,2 4,7 * gegenüber dem Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf Primäraluminium Walzprodukte > 0,2 mm W 14 Sekundäraluminium Press- und Ziehprodukte ALUMINIUM · 12/2011 Higher quality. Increased productivity. Reduced environmental impact. Let us show you how. Ali H A M Al Zarouni Vice President: Smelter Operations Developing best in class smelter technologies through innovation. Since our inception in 1979 we have dedicated ourselves to establishing DUBAL as a world-class supplier of aluminium to global markets. You might put our success down to an unswerving focus on quality and the unparalleled 99.99% purity of our products. But it is also the innovative thinking behind our proprietary, high amperage DX and DX+ smelter technologies which has helped make us what we are today. Leadership through innovation. ThatÕs what sets us apart. And you can quote us on that. Together we shine For more information call: +971 4 884 6666 www.dubal.ae ECONOMY Conference report Arabal 2011 focusing on Oman’s aluminium industry From 13 to 15 November 2011 over 400 delegates from 30 countries attended the Arabal Conference, held for the first time in Muscat, the Capital city of the Sultanate of Oman. The participants came mainly from the aluminium world in Arabia, but from Europe and Asia as well. The host of this year’s event was Sohar Aluminium. Under the heading ‘Global Challenges for Sustainable Growth in the Aluminium Industry and the Role of the Gulf Smelters’, the more than 20 lectures dealt mainly with the further development of the aluminium industry in Arab countries. Held for the first time in Oman, the Arabal Conference focused on the growing importance of the aluminium downstream business in the Sultanate. Images: Arabal B. Rieth, Meerbusch HE Sheikh Saad Bin Mohammad Al Saadi, Minister of Commerce and Industry in Oman At present, in Sohar Aluminium the Omanisation policy has achieved a success rate of 70 percent, which is to increase to 85 percent by 2015. This should not only ensure that in the medium term a job is available for every citizen, but also reduce the country’s dependence on a foreign workforce. In this connection the flagship Sohar Aluminium is not just regarded as an aluminium smelter, but as the centre of a cluster in which, in the future, 60 percent of the smelter aluminium produced will be fur- executive of the group, also stressed the importance of Sohar Aluminium and does not exclude a possible capacity enlargement there by 2014. RTA has a close relationship with Oman through its 20 percent shareholding in Sohar Aluminium. Globally, RTA anticipates a yearly aluminium production growth rate of six percent. A reason for this dynamic growth is the increasing urbanisation in the economically developing countries, which will go hand in hand with a rapid increase in demand from the building, transport and packaging sectors. In the medium term RTA expects to see a doubling of the present production levels of both aluminium and copper. Sohar Aluminium – a benchmark in the aluminium smelting industry In his welcoming address HE Sheikh Saad To the participants in Arabal 2011 and those Bin Mohammad Al Saadi, Minister of Comwho went on the plant tour of the smelter some merce and Industry in the host country Oman, 200 km away in Sohar, Sohar Aluminium was stressed the importance for his country of the the perfect host. The company was formed extension of an aluminium industry that inin September 2004 to undertake a landcludes the entire value chain, from smelter mark greenfield aluminium smelter project production to further processing. Besides the in the Sultanate of Oman. Jointly owned by development of infrastructure, including the Oman Oil Company (40%), Abu Dhabi Naenlargement of the port of Sohar tional Energy Company PJSC and the domestic power generation – TAQA (40%) and Rio Tinto industry, it is a particular concern Alcan (20%), Sohar Aluminium of the country to create jobs. In reached full capacity on 19 Febthis respect Oman differs from its ruary 2009 and some 30 months neighbours where, at least in the later celebrated its one-millionth initial phase, substantial capacitonne of aluminium produced. ties for the production of smelter In that time capacity was upaluminium on the basis of cheap graded from 350,000 to 375,000 energy and foreign workers have tonnes a year. The total costs for been created and from there the this smelter capacity amount to metal is exported to industrialised USD2.4 billion. and developing countries all over The national importance of the world for value-adding further the company is demonstrated by processing. The Sultanate of Oman the fact that 56 percent of its anregards its gas and oil reserves as nual spend is in the local market, valuable raw material for ensuring The Arabal Conference attracted some 400 delegates from over 30 countries which equated to USD50 million its future national prosperity, by in 2010. the rational use of which urgently needed jobs ther processed into semis and finished prodSohar Aluminium is supported by an imfor the coming generation should be provided. ucts. Since reaching its full capacity of 375,000 pressive and comprehensive infrastructure. The proportion of people under 20 years old tonnes a year in February 2009, the plant in Its facilities include one of the world’s fastestthe port city of Sohar has already created growing ports and a power plant and smelter in Oman is higher than 40 percent. In the implementation of this strategy – the 1,000 jobs in the area close to the smelter. In which use the latest technology and employ ‘Omanisation’ of the economy – Sohar Alu- addition, a further 2,500 jobs should be cre- the best practices. Within the Port of Sohar the minium is playing an important part. The aim ated in the downstream sectors. company has its own dedicated port facility, of Omanisation is to replace foreign workers With regard to the global activities of which supports vessels with a capacity of up to by Omani citizens active in the jobs available. Rio Tinto Alcan (RTA), Jacynthe Côté, chief 75,000 tonnes for receiving raw materials and 16 ALUMINIUM · 1-2/2012 for exporting primary aluminium. The port facility includes a bulk material ship unloader with connecting conveyors and a range of silos for storing alumina (2 x 60,000 t), petroleum coke (2 x 15,000 t) and liquid pitch (2 x 5,000 t). The Sohar Aluminium Power Plant (SAPP) lies at the core of Sohar Aluminium’s operations. SAPP is a state of the art 1,000 MW combined-cycle, captive power plant. It achieves close to 50 percent efficiency in converting gas energy into electricity and meets the stringent requirements set out by Oman’s environmental agency MECA. SAPP is strategically positioned to maximise access to the region’s plentiful natural gas reserves and to have access to the Gulf of Oman for cooling water. SAPP excels by achieving high levels of efficiency, reliability and availability of power whilst ensuring low emissions, operating costs and environmental impact. Sohar Aluminium operates the world’s longest single potline with a length of 1.2 km and is the first smelter in the world that uses Rio Tinto Alcan’s AP36 smelting technology – one of the most energy-efficient and productive smelting technologies commercially &$ !$ '$ $%"%) "$ $ $) %"' & $ % ''$ $) $ $ $$ ''%' $$ $ %#$ $%"%) Sohar Aluminium " & %' $ $) Sohar Aluminium potline complex available. With an operating current of 360 kA which has gradually been increased to 375 kA, the company produces 375,000 tonnes of aluminium a year at purities of p1020 and above. The smelter also has an on-site carbon facility for the production of rods and its own anodes, to ensure maximum efficiency and availability to the smelter. The Rhodax crusher used on site has one of the highest production capacities in the world. The casthouse is another source of pride. The company operates an ingot caster with a throughput of 27 tonnes an hour, which is the world’s highest known output performance. The casthouse also features a 25-tonnes an hour sow caster. Sohar Aluminium produces metal in three formats: 23.7-kg ingots, 700-kg sows and liquid metal available to local downstream partners to reduce energy consumption in subsequent processing. Aluminium semis, which in the present phase of enlargement cannot yet be absorbed by local markets, are sold by RTA to Asian markets such as China, Malaysia and Indonesia. %$$%(%$' "%# % %"' "$ ' % $ " $') "%%'")$ (%%%%&% ' $# % " %) "% &$% ! #! %' $ ! %%! % '% %!$#! "!)"$%$ $") "$ ! %!% %!$% % "!)"% &$%%% (% $ ) *&%!' *''"% #$) Sohar Free Zone – Oman’s future aluminium centre Part of Sohar Aluminium’s overall strategy is to promote and support the establishment of a robust downstream aluminium industry in Oman, to create added value for primary aluminium and to develop Oman’s economy, in order to create further employment and business opportunities. Two hundred hectares of land adjacent to the smelter site in ALUMINIUM · 1-2/2012 ## )##!" !#$ )##!" " ( ' &&&##%##!" ECONOMY tonnes a year is on the one hand lower than the economically viable limit of a conventional plant consisting of a rolling slab casting unit and hot and cold rolling mills, but on the other hand relatively high for the alternative possible use of twinroll casting machines, a different solution was decided upon: the molten aluminium delivered by the smelter will be delivered via holding furnaces to a twin-belt caster. In this it will solidify into strips 2,032 mm wide and 13 to 21 mm thick. The solidified strip will go directly to a hot rolling mill where it will be reduced down to a thickness of 1 to 2 mm in an in-line/hot rolling process, and then coiled. This will then be followed by the usual cold-rolling process on a four-high reversing rolling stand with the necessary intermediate and final annealing operations. The capacity of such an in-line/ hot rolling unit, for Fata EPC the Sohar Industrial Estate are set aside for downstream industry development. In future up to 60 percent of the annual production capacity of Sohar Aluminium will be sold on to the local downstream industry. Local companies can take advantage of liquid metal sales to manufacture all kinds of aluminium products. Besides aluminium processors such as OAPIL (aluminium rod and overhead line conductors), which have already been established in the vicinity of the smelter, from 2014 the Oman Aluminium Rolling Company (OARC) will be the largest purchaser of molten aluminium. This company, 100%-owned by Takamul Investment Co., is currently investing USD387 million to build a major aluminium strip-rolling plant with a capacity of 160,000 tonnes a year, a level which should Schematic layout of the OARC rollling mill be reached after five years of operation. The main supplier is Fata EPC in Italy, which is at the same time acting as the general contractor. For this purpose Fata EPC is enlarging its establishment if Qatar with an additional location in Oman. The plant is designed for the production of strips made from alloys of the 1xxx, 3xxx and 8xxx groups, in widths up to 1,900 mm and in the thickness range 0.075 1.5 mm in the form of semi-finished coil products, i.e. foil stock for converter foil, packaging foil and cable wrap. In addition it will produce finished coil products such as fin stock and semi-rigid container foil, for example for aluminium food containers but also for the construction of cooling aggregates in the automobile and building sectors. Further products planned will be tension-levelled industrial sheet for building products in the thickness range 0.3 to 1.5 mm, and hot strip from 1.5 to 8 mm thick and up to 1,900 mm wide. The established strip and foil rolling plant Garmco in Bahrain, which from the first showed interest in the project, will undertake the marketing of OARC products during the initial phase. The concept of the plant is worthy of particular attention. Since the capacity of 160,000 18 a cast width of 2,000 mm, certainly amounts to 250,000 to 300,000 tonnes a year. This means that when the cold rolling and finishing capacities are increased accordingly, the plant can be adapted for future market developments with relatively little effort and costs. Provided in the finishing area are specialised slitting operations, a coil pain line and a specialised coil coating application. Aluminium production worldwide remain on the way to growth Besides the considerations relevant to Oman, during the event other matters of current interest in the context of a larger economic area were also discussed. Having regard to the present and future development of the worldwide aluminium market, even in the Near East it is hardly possible to avoid a glance at the Chinese market. Ultimately, China is a major purchaser of the primary aluminium produced in the Gulf area, but it is also a not insignificant supplier of aluminium finished products. Aluminium production in China, at any rate in the country’s eastern provinces, is confronted by rising energy prices. This is one of the reasons why over the coming few years expansion into the substantially more favourable North-Western provinces will take place. In summary, it was emphasised that despite all obstacles such as rising prices for energy and raw materials (alumina), but assisted by lower capital expenditure of less than USD2,000 a tonne of aluminium compared with up to USD4,000 a tonne elsewhere, for the next several years China will remain the driving force for the growth of worldwide aluminium production. The fact is, however, that 15 million tonnes of the worldwide production total of 21 million tonnes planned by 2016 will be produced by additional smelter capacities in China. In addition extensive investments in further processing, namely in new rolling and extrusion capacities, should not be overlooked. These are making China a net exporter of aluminium semis. Rather daring forecasts assume that China will in a few years reach the same per-capita consumption of aluminium (including the exported fraction) as is now typical of western industrialised countries. Very great potential for covering the future aluminium needs, besides the construction of new smelters, is seen in the promotion of recycling processes. The International Aluminium Institute (IAI) expects that in 2020, of the total demands amounting to around 110 million tonnes of aluminium, about 30 percent will be covered by recycling. Even in the Gulf, where the recycling of process scrap and end-of-life products is still hardly an issue for lack of a hitherto underdeveloped downstream industry, the concept of recycling is beginning to gain ground. In this connection a plan was discussed, for building up Oman as a recycling centre for the whole of the Gulf region. At any rate, by 2020 the scrap yield is expected to be about 270,000 tonnes. With the event held in Muscat, Arabal showed that this conference is one of the most important occasions for the international aluminium industry. This also finds expression in the fact that the event, first held in 1983, no longer takes place as originally in a two-year cycle in one or other of the Arabian countries, but annually since 2010. So the next Arabal Conference will take place in 2012, in Qatar in November. The host will then be Qatalum, the joint venture between Qatar Petroleum and Norsk Hydro. 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. ALUMINIUM · 1-2/2012 ECONOMY Aluminium market outlook A year of uncertainty and challenge As the European debt crisis is spreading there were no words of optimism to be heard during December concerning not just the European economic outlook for 2012, but for the rest of the world too. At the beginning of this year, Spain’s government announced that its budget deficit in 2011 could be even higher than the last forecast of 8%. This would imply additional and continued pressure on the euro versus US dollar in the coming months and lead to stagnant or even lower base metals prices. However, support may come eventually from a rising oil price which will depend on developments in Iran, especially after the United States and the European Union introduced new sanctions as a reaction to reports that Iran is progressing with its nuclear programme. In response, Iran has warned it could shut the strategically important Strait of Hormuz, a narrow shipping lane in the Persian Gulf, which would severely impede oil supplies, and has started testing long-range missiles. Against this background it is to be expected that despite a bleak economic outlook, the Brent oil price will remain volatile and relatively high – around and above USD110 during the first half of 2012 – with the possibility to rise sharply if there are further threats to shut the Strait of Hormuz. In this case base metals prices might get short-term support from high oil prices, only to plunge once the situation over Iran calms and the world economy becomes even more affected by high oil prices. 2012 or 2013, if not both years, would then turn out to be worse for base metals prices than in 2011. Moreover, 2012 would definitely be politically and economically more challenging than last year, but base metals prices may bottom out in 2013. Review of the economic situation Better than expected latest economic figures in the USA – the trend of unemployment during December fell to the lowest level in more ALUMINIUM · 1-2/2012 than three years – brought a much needed breath of optimism to the equity markets, which cheered base metals prices too. The December 2011 ISM Manufacturing Report, which tracks the manufacturing activity, heralded good news too: the PMI (Purchasing Managers Index) climbed from 52.7 index points in November to 53.9 points in December, which was above the expectations of analysts polled by Bloomberg. The Index has remained above the 50-level for twentynine consecutive months, indicating sustainable growth in the manufacturing sector of the world’s largest economy. The annualised December PMI corresponds to a 4% increase in real GDP annually, according to the report issued by the Institute of Supply Management early in January. China’s December PMI rebounded to 50.3 index points, compared with 49 points in November, indicating that the country’s manufacturing activity is expanding. A PMI reading above 50 demarcates expansion from contraction. However, this rise may be the result of seasonal bias in the lead-up to the Chinese Lunar Year, so December’s growth should be regarded with some caution. In that context, the sub-index for overall new orders increased to 46.9 in December from November’s 45, but also showed falling demand (below 50). New export orders dipped, reflecting waning de- mand from the US and Europe, but input costs incurred by Chinese manufacturers continue to moderate. The Euro zone Manufacturing Purchasing Managers Index rose slightly in December to 46.9 points from November’s 28-month low of 46.4, but still marked a fifth month below the 50 mark that denotes contraction. Germany made a good start in the new year G. Djukanovic G. Djukanovic, Podgorica with strong manufacturing, consumption and labour data in Europe’s largest economy. The closely watched Markit Manufacturing Indicator rose to 48.4 in December, up from 47.9 in November, reflecting the continued strength of Germany’s key industrial sector. The Ifo Confidence Index rose to 107.2 in December, from 106.6 a month earlier. According to the Ifo Institute, Germany’s economy will grow by a meagre 0.4% this year, down from around 3% in 2011, and could slide into recession if the Euro zone debt crisis deepens. The US economy may grow by at most 1.5% in the author’s opinion, despite the latest forecast by the Federal Reserve that growth would be in the range of 2.5 to 2.9% in 2012, down from the 3.3 to 3.7% Fed forecast in June. Lower GDP growths in Europe and the USA would negatively affect GDP growth in China, bringing it down to a range of 7 to 8% in 2012 from around 9% in the last quarter of 2011. In case of a recession in Europe, economic growth in China might fall even more. Due to the European debt crisis, the Euro will remain under strong pressure in the coming months, heading towards 1.25 EUR/USD by the second quarter of 2012. Market participants remain sceptical in expectation of whether rating agencies will continue to downgrade European countries, with Slovenia being the last one, something that permanently undermines the Euro. The European Union summit early in December ended with an agreement by 26 of its 27 members to adopt measures aimed at easing the sovereign debt crisis in the short term and improving member states’ fiscal positions over the longer term. Each country’s government will have to ensure an annual budget deficit of no more than 0.5% of GDP with automatic fines for governments that breach a 3% deficit limit. Leaders in the European parliament have also proposed a ‘road map’ for common Euro-region bonds in a new European treaty on fiscal discipline. © 19 ECONOMY Aluminium demand slowing During November 2011, traders announced that large quantities of aluminium would enter LME warehouses before year-end, which proved to be the case. LME registered stocks increased by around 300,000 tonnes in just four working days in mid-December, ending the year at 4.97m tonnes which is an all-time record. However, most of these stocks are still vember (30 days) was 2.121m tonnes, down from a revised 2.199m tonnes in October (31 days) but up from 2.057m tonnes in November 2010. Total world production is expected to amount to around 44.7m tonnes in 2011, an increase of some 7% y-o-y, while consumption will expand close to 8% to around 43.8m tonnes, compared to an increase of around 17% in 2010. tied up in financing deals of banks. Traders and analysts estimate that total aluminium inventories around the world stand at about 12m tonnes, though large quantities have been tied up in financing deals that were put in place in 2008/09. Industry experts believe that some 30 to 35% of the world’s smelters are unprofitable with current aluminium prices below USD2,000/t. What industry experts do not say is the percentage of those who protect the selling price by longer term purchasing contracts at levels higher than the current LME cash price and even higher than their production cost. This partially explains why about a quarter of world producers are still operating. Another explanation is that until recently most of the marginal (money losing) producers hoped market conditions would improve by the end of 2011 so that losses could then be compensated in the first quarter of 2012. Latest developments, however, have slashed such hopes and very soon producers will start to reduce their production or even close their smelters. World primary aluminium production averaged 70,700 tonnes/day in November 2011, down from a revised average of 70,900 t/day in October but up from 68,600 t/day in November 2010, according to the International Aluminium Institute. Total production in No- The aluminium price will trade in the range of USD2,000-2,350/t in the next six months, according to the median estimate of 17 analysts surveyed by Bloomberg in early November. EUROPE: According to several trading sources European aluminium orders fell by around 20% in the fourth quarter of 2011 compared to the same quarter a year earlier, while aluminium premiums have dropped 25% since mid-2011. Some areas of demand, such as the packaging and construction industries, have contracted sharply, according to traders, especially in southern Europe. An aluminium trader for a large trading house describes Italy as a ‘disaster zone’. “Everyone has been having pushback on contracts this year in the second half,” he said. Traders were bearish on demand for the first half of 2012 and expect volumes to be lower, although this estimate might be politically induced and aims at lowering premiums, traders admit. Consumers have mostly deferred 2012 orders during the last two months in 2011 due to Europe’s deteriorating outlook which has led to producers’ metal becoming more freely available, metals industry sources say. The producers cleaned up their balance sheets for the fiscal year-end while most market participants wanted to sell, rarely to buy. This resulted in lower premiums for Western duty- 20 paid aluminium in the Rotterdam warehouse, quoted mostly in the USD145-165/t range in mid-December, down from USD200-220/t in August. Duty unpaid premiums were quoted at USD100-130/t in that time. CHINA: China shut down about 630,000 tpy of primary aluminium smelting capacity in December due to negative margins, the China Economic Information Centre (CEIC), which is a unit of the state’s Xinhua news agency, reported. At least 1.4m tonnes of annual capacity had already been made idle before December, taking the total idle capacity to around 2.03m tpy. More cutbacks are expected if aluminium prices fail to rebound, the report says. The CEIC put the production cost of China’s higher-cost aluminium smelters at Yuan 18,000/t (USD2,185/t), notably those in the south-western regions, although Chinalco general manager Weiping Xiong gave the average Chinese production cost as Yuan 16,500/t (USD2,002/t) at a recent industry conference. China imported 174,100 tonnes of primary aluminium between January and November 2011 and exported 76,500 tonnes during the same period, hence logging a net import of 118,100 tonnes compared with a net import of 40,300 tonnes for the same 2010 period, CEIC said. Demand from the semi-finished sector has remained healthy as semis output rose 2.5% month-on-month and 9.8% yearon-year to 2.128m tonnes in November. However, end consumption has shown signs of softening, especially in the sectors of home appliances and auto vehicles, coupled with flattening semis exports, according to CEIC, Platts reported. Chinese output of primary aluminium rose 10.2% y-o-y to 16.28m tonnes in the year to November, slowing from a 22.6% growth in the same period of 2010. Production in November was 1.4m tonnes. NORTH AMERICA: US service centres shipped 120,800 tonnes of aluminium products during November 2011, a 1.4% decline from October’s 128,000 tonnes total, but a 9.5% increase against November 2010. Aluminium shipments from US centres until November 2011 were 1.392m tonnes, a 15.5% increase against the 2010 period. As November ended, the centres had aluminium product inventories of 359,500 tonnes, a 3.4% increase against November 2010 inventories and a 0.4% increase against October’s inventory level. At the current shipping rate, US service centres have a 3-months supply of aluminium products, a 5.5% decrease from November 2010. In Canada, service centres shipped 13,200 tonnes of aluminium products during Novem- ALUMINIUM · 1-2/2012 th 17 World Aluminium Conference 30 April-2 May 2012, Fairmont, Abu Dhabi, United Arab Emirates "%*%**+ + *) ,*+) ! så ! $%$) )*)(* så ! % så så # +)* *(* så +) så så #"!" * så .)(') “ ” "%) ))* - % *)*$ +( *) & $ ECONOMY ber, a 7.3% rise compared with the October total of 12,300 tonnes, and an increase of 4.7% compared with the October 2010 result. In the year to November 2011, Canadian centres shipped 136,700 tonnes of aluminium products, an 8.3% rise over the corresponding 2010 period. Canada’s centres reported 35,300 tonnes of aluminium in inventory at the end of November 2011, an increase of 14.0% against November 2010 and a decrease of 2.9% from October 2011. At the current shipping rate, this represents 2.7 months of supply of aluminium, up 8.8% from the corresponding figure in November 2010. According to data published by the US Census Bureau, US primary metal producers and metal fabricators registered a sharp drop in shipments during November compared with October, while inventories fell just slightly. Over eleven months, primary metals shipments grew 29.8% and new orders rose 26.1%. Fabricators’ shipping values in November declined 6.3%, with new orders also down 6%. Meanwhile, shipping values up until November grew 6% and new orders increased by 7.9%. Primary metal inventory values inched down 0.7% while fabricators saw that figure fall by just 0.1%. The US Midwest premium fell to USD7.70 a pound in early December, down from USD8.20 two months ago, according to CRU. JAPAN: Japan’s shipments of rolled aluminium products decreased 6% in November y-o-y, the sixth straight month of decline as overseas demand weakened and cut exports. Supplies to domestic and export markets dropped to 172,576 tonnes in November from 183,613 tonnes a year earlier, the Japan Aluminium Association announced. The pace of decline accelerated from a 2.8% drop in October. Japanese exports of flat-rolled and extruded products slumped 34% in November after floods in Thailand disrupted the supply of components and reduced the production of cars and electric machinery. Aluminium premiums for Japan’s buyers were down 5% for the first quarter of 2012 compared to the previous quarter, and have been mostly set at USD112/t over the LME cash price. Buyers pay a premium in addition to the LME cash price to cover freight and insurance and to reflect regional supply and demand. Japan imports around 2m tpy of primary aluminium. Aluminium stocks at key ports in Japan – Yokohama, Nagoya and Osaka – totalled 221,500 tonnes at the end of November, down 6% against the month before, trading house Marubeni reported. BRAZIL: Brazilian smelters produced 22 120,200 tonnes of primary aluminium in November 2011, down 4.9% compared with November 2010, according to the country’s national association Abal. Up until November 2011 production was down 6.6% to 1.31m tonnes. Norsk Hydro’s Albras produced the highest volume in November, 36,700 tonnes, down 2.1% year-on-year. CBA came second with 36,200 tonnes, a 5.5% decrease. Alcoa produced the same 29,100 tonnes as in November 2010, while BHP Billiton reported a 2.8% increase to 14,600 tonnes. Novelis produced 3,600 tonnes, a drop of 50.7%, since it closed one of its two smelters in Brazil late in 2010. Processed aluminium consumption in Brazil is expected to increase 9.3% y-o-y to reach 1.42m tonnes. For the first three quarters in 2011, consumption reached 1.04m tonnes, up 10.4%. The highest increase came from wire and cable, which accumulated 120,800 tonnes, a boost of 85.8%. This leads to the conclusion that Brazil is switching from copper to aluminium for the national electricity grid and other uses. Consumption of castings rose 10.9% to 176,500 tonnes in the first nine months of 2011. Sheet and plates rose 4% to 383,200 tonnes, extruded products 3.8% to 214,300 tonnes and foils 1.8% to 66,100 tonnes, all figures reported by Abal. On the back of the large increase of aluminium consumption, Abal expects imports to rise 48% to 399,300 tonnes in 2011. Imports totalled 305,500 tonnes in the first three quarters of 2011, up 74.7% y-o-y, while exports fell by 11.4% to 497,600 tonnes in the corresponding period, and are expected to reach 649,200 tonnes, a 14% decrease in 2011. Imports have been rising in Brazil because local smelters have not been investing in expansion or greenfield projects, as energy prices are considered very high in the country. As a consequence, Brazil is soon expected to become a net importer of primary aluminium. Alumina price on the decrease Spot alumina prices and alumina indexes continue to fall, in parallel with the aluminium price, ending the year at around USD300/t on a fob basis, with low market activity in expectation of an ongoing decrease of the price. Some traders expect the price to slip below USD300/t in January, though China has lately been a stabilising influence, with several parties expressing potential demand for February shipments at around USD300/t. European and Asian consumer sources put buying offers at USD305-335/t, with the selling interest rangebound at USD340-350/t in recent weeks. Chi- na’s costlier domestic alumina cargoes and yuan-denominated trade financing rates have been fuelling interest in imported alumina, sources said. Platts Chinese domestic alumina assessment at Yuan 2,650/t (USD420/t) exworks Henan would have equated to USD325/ t in import parity terms, after taking into account Yuan 80/t in domestic handling costs, the day’s yuan-dollar exchange rate, 17% in VAT and USD23/t in freight for 30,000 tonnes from Western Australia to Qingdao in northern China, for shipment in February. Chinese alumina production may reach 43.5m tonnes in 2012, which is an 11.5% rise y-o-y, compared to a gain of 25% to 39m tonnes expected for 2011, the state research agency Antaike forecasts. The production capacity of alumina in China may rise 11% to 55m tonnes in 2012, from 49.5m tonnes forecast for 2011. This would finally result in higher imports of bauxite in the following years. India’s Nalco has finalised its third 2012 alumina term sell tender, comprising 240,000 tonnes at 16.39% of the three-month LME aluminium price on a fob basis. The Switzerland-based buyer will receive the alumina in batches between January and December this year, Ansuman Das, commercial director at Nalco, told Reuters. Nalco had awarded to Glencore its first 2012 term contract in October comprising 300,000 tonnes at 16.1% of the LME 3-month price. The second contract for 270,000 tonnes went to Standard Bank at 16.2% (source: Platts). In early November Alcoa announced it would sell 40% of its alumina production on spot or index contracts by the end of 2012. Ship-owners were divided over what they should consider a reasonable freight rate for February. One put the market at USD2222.50/t while another one quoted USD23.5024/t. The first source said there was a recent ALUMINIUM · 1-2/2012 ECONOMY prompt fixture done at USD18-19/t; the other valued the prompt market at USD22-22.50/t, Platts reported. Banks’ expectations Credit Suisse was quite pessimistic in its latest report, forecasting an aluminium price of USD1,750/t by the end of the first quarter 2012 and USD1,850/t by the end of the year. The bank stated that “both momentum and trend indicators have turned negative and hint at further weakness ahead as persisting deleveraging pressures and deteriorating technicals may lead the market to undershoot fundamental fair value further”. Another Swiss investment bank, UBS, forecasts an average aluminium price in 2012 at USD2,226/t and at USD2,535/t in 2013. “We see an inevitable deceleration of global growth in H1 2012 after the multiple crises of H2 2011; this is likely to put downward and volatile pressure on commodity prices until improved conditions prevail in H2 2012. The oil and energy sectors should continue to lead commodity sentiment,” the bank stated in its latest report on the global commodities outlook for 2012. Standard Chartered expects the aluminium price to average USD2,100/t in Q1 2012 and USD2,300/t in Q4 2012, before it rebounds to USD2,500/t in Q1 2013. According to this bank, based in London, 2012 promises to be another volatile year, particularly in the first half as the crisis in Europe will continue. The bank expects equity markets to have a significantly better year than in 2011, after a challenging start, and very strong gains in the second half of the year as quantitative easing gives results. Danske bank in its latest research report said the worrying signs from China persist, and is still looking for a Chinese recovery in 2012. “While we remain cautious in the short to medium term and look for commodity prices to remain under pressure, on the longer-term horizon (6 to 12 months) we continue to see good value in commodities,” the bank said. It predicted that the aluminium price would average USD2,100/t in Q1 and USD2,400/ t in H2, with an average over the year of USD2,275/t. What to expect in 2012? The aluminium price outlook for 2012, especially for the first half, is very bleak and it would not be a surprise to see the price stagnate around or even below the USD2,000/t limit during the first two quarters. However, there is no consensus among analysts regarding aluminium price performance in 2012, with some leading institutions conflicting in their forecasts, which range between USD1,8002,650/t. What is certain is that the European debt crisis and tensions in the Persian Gulf will not be resolved any time soon, and the whole of 2012 may be affected if these two developments change for the worse. It would be a rather exhausting play: the Euro zone trying to overcome disintegration and, in parallel, the global economy in the stranglehold of high oil prices. Answers to both questions may be given this year with the start of resolutions. The third major question important for aluminium price performance this year relates to the Chinese economy. Even though it is expected to ease slightly from last year, there is no visible surprise on the horizon. Chinese E X T R U S I O N - D I E C A S T I N G - F O U N DRY - R OL L I N G - F I N I SH I N G - MAC H I N I N G - W EL D I N G - R ECYCLING &+!)&+#'&$ !+$* ,"##+#'& INTE ERNAT RNATIONA RNA IONAL IONA L ALUMINIU ALUM INIU NIUM M EXHIBI EXHIBI HIBITION TION ALUMINIUM · 1-2/2012 INTERN INTERNAT NATIONA IONAL L FOUNDR FO DR RY EQUIPMEN EQUI PMENT PMEN T EXHIBI EXHIBITION T N Organizi Organizi n ng gS Secre ecr tari ecre tariat: at: - Tel. Tel.l +39 39 030 9981 9981045 045 - Fax Fax + +39 030 030 99998105 81055 info@met info @metef ef com ef.c com - - iinfo@ nfo@foun nfo foun o deq. q com c - %!+$)# # $' '%)! '%+!,(' '% 23 A L U M I N I U M S M E LT I N G I N D U S T R Y production should satisfy demand this year too, without significant exports or imports of primary aluminium and aluminium products. Imports may be higher in the first half of the year and exports in the second half, making a balance for the year. The global market will remain in surplus, at around 1m tonnes, while expected production cuts will be compensated by new capacities entering production in India and the Middle East. The price is expected to oscillate even more frequently than last year but it should not wander far from the USD2,000/t level in either direction. Only exceptional spikes of the oil price could push it substantially higher temporarily, though for a short period. 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. TMS 2012 – wide range of technical symposia topics will include (1) deformation / damage / fracture mechanisms in light metals and alloys subjected to various loading conditions, (2) deformation and damage / crack growth in the presence of multiple damage mechanisms such as corrosion, creep and fretting, (3) alloy development, structural characterisation, mechanical properties, and in-situ characteriTMS 2012 will feature almost 4,000 technisations utilising state-of-the-art techniques, cal presentations and 70 unique symposia. (4) multi-scale modelling and multi-physics The conference will focus on varied technical approaches of deformation, damage and fracthemes: • Advanced Characterisation, Modelture. ling and Materials Performance • High PerElectrode Technology for Aluminium formance Materials • Light Metals: AluminProduction: This seminar is a component of ium, Magnesium and Titanium • Materials and the Light Metals Symposium and will focus Society: Energy and Sustainable Production • on carbon anode raw materials and properMaterials Processing and Production • Nanosties, paste plant design and operation, cale and Amorphous Materials. baking furnace design and operation, The Light Metals programme rodding room design and operation, brings together representatives from anode quality and performance, soluthe world’s largest light metals comtions for carbon plant environmental panies and research organisations to issues and safety, cathode and cathode discuss the latest developments in the materials, cell preheating and start-up field. Planned symposia include: (as related to pot life); spent potlining, Aluminium Alloys – Fabrication, Characterisation and Applications: inert electrode fabrication and materiThis symposium covers all aspects of als science. Magnesium Technology 2012: the physical and mechanical metallurThis symposium is one of the largest gy of aluminium alloys. It addresses yearly gatherings of magnesium spefundamental and applied research as cialists in the world. Papers are prewell as product development, testing sented on all aspects of magnesium and implementation of aluminium technology, ranging from primary foil, sheet, plate, extrusions, forgings production to applications and recyand composites for end applications As in 2011, TMS 2012 will include a three-day exhibition, which will cling as well as from basic research including transportation, packaging bring together industry leaders buyers, engineers, scientists and researchers from all major countries Photo: ALUMINIUM to industrialisation. and other key product segments. TMS 2012 will include a three-day exhibiAlumina & Bauxite: This symposium, along Cast Shop for Aluminium Production: This with Cast Shop Technology, Aluminium Re- symposium will cover the areas: charge mate- tion, which will bring together industry leadduction Technology and Electrode Technology rials, pre-furnace treatment, melting, fluxing, ers, buyers, engineers, scientists and researchcollectively form the Light Metals Symposium, filtration, cast processes, automation, process ers from all major countries. Companies will where industry experts and academia from all modelling and control, environmental issues, showcase their products and services at the over the world meet each other and share in- grain refinement, cast structure, and safety. exhibition, which will be held from 12 to 14 Papers on carry-over impact and prevention, March. formation. Aluminium Processing: Lectures will be metal loss, metal purity capture, sodium and given on the areas of machine design, process other impurities, and equipment and logistics For more information on TMS 2012 registration and accommodations, and the schedule control, production scheduling, measurement enhancement, will also be featured. Deformation, Damage, and Fracture of of programming and events, visit www.tms. technology, microstructure evolution and characterisation, process modelling, material Light Metals and Alloys: The Symposium org/tms2012. The Minerals, Metals & Materials Society’s (TMS) 141th Annual Meeting & Exhibition will be taking place from 11 to 15 March 2012 in Florida. The meeting will again feature a wide range of technical programming and events. 24 modelling, tribology, heat transfer, surface generation, defect measurement and control. Aluminium Reduction Technology: Papers are invited on the following subject areas: aluminium reduction technology, cell start-up and early operation, cell modernisation and productivity increase, process control, modelling of cell design, environmental aspects, fundamentals, bath chemistry, power modulation, power supply improvements, inert anode operation, emerging reduction processes, safety issues in reduction lines, aluminium trend and market demand, energy saving initiatives in reduction process, changes / initiatives in reduction operation to cope with the financial crisis. ALUMINIUM · 1-2/2012 A L U M I N I U M S M E LT I N G I N D U S T R Y Images: Dubal Dubal proprietary technology licensed to Emal Phase II Dubal Emal Technology Licensing Agreement signing ceremony on 22 December 2011. From left: Saeed Al Mazrooei and Yusuf Bastaki of Emal; Ali H A M Al Zarouni and Abdulla Kalban of Dubal The substantial sums of money and human intellect invested by Dubai Aluminium (Dubal) in research and development over the past quarter century has rewarded the company through excellent growth in aluminium production per pot at the company’s Jebel Ali smelter, rising from 1.46 to 1.77 tonnes per day per pot between 2000 and 2011. This, together with a series of sequential expansions to a hot metal capacity of one million tonnes per year, has transformed the entirely stateowned enterprise into the world largest single-site pre-baked anodes aluminium smelter in the world. In December 2011, Dubal and Emal formalised the licensing of Dubal’s proprietary high amperage DX+ smelting technology at Emal Phase II. Ongoing investment in research and development has recently earned Dubal recognition as a provider of advanced reduction cell technologies that rank among the best available in the market. A case in point is Dubal’s proprietary DX technology, developed in 2005. It has been installed in the 756 cells (in two potlines) that constitute Phase I of Emirates Aluminium (Emal) – the greenfield smelter development at Al Taweelah, Abu Dhabi, which is owned jointly by Dubal and Mubadala Development Company (in equal shareholding). Operating stably at 350 kA, the DX cells at Emal Phase I were fully commissioned by the end of December 2010, giving the plant a nominal production capacity of 740,000 tpy in 2011. The 26 that both DX and DX+ technology were fully in-house designed, modelled, tested and optimised. “The evolution of DX+ technology from DX technology was also driven by an ongoing quest to decrease the capital cost per tonne. We spent months modelling and engineering the designs, testing various parameters before building five DX+ technology cells in the Eagle pilot section of our plant. The DX+ cells were energised between June and August 2010, and have achieved the desired performance standards as per our modelled predictions from November 2010 onwards,” he says. Mr Zarouni explains that the main physical difference between the two technologies is the size of the cell. “The DX+ cells are similar to DX cells, but larger in size: the potshell is 0.3 m wider and 0.6 m longer. However, the potto-pot distance is unchanged at 6.3 m – i. e. the same as in DX cells. The net result is that the productivity per square metre of potroom is increased by more than 17 percent,” he says. The most significant difference is that the amperage of the DX+ cells is higher than of the DX cells. “DX+ cells were designed to operate at 420 kA initially but are ultimately anticipated to operate at up to 460 kA. The busbar configuration for the two technologies is the same. However, the busbar cross-section in DX+ cells is larger to accommodate the higher amperage. While both cells have 36 anodes, the size of the DX+ anode has been increased to match the greater potshell dimensions and to maintain the current density at higher amperage,” he says. amperage of the cells has been increased to 353 kA over the course of the year. This, together with improved efficiencies, will result in increased metal production levels to 750,000 tpy as well as yielding associated benefits in terms of energy-efficiency and environmental protection. DX technology has also been installed in a dedicated 40-cell line within the Dubal smelter. Operating stably at 380 kA, the line yielded 42,500 tonnes in 2010. More recently, Dubal’s new generation DX+ technology (developed in 2010) has been specified for Emal Phase II, which will entail the construction of a KPI of DX+ Eagle demonstration cells (at 430 kA) and industrial design third 444-cell potline Average of 5 DX+ Emal Phase II within the Emal comKey performance indicators (KPI) DX+ cells (Design criteria) plex. Operating initially Amperage (kA) 429.7 420 – 460 at 420 kA, the DX+ Current efficiency (%) 95.0 > 95.0 cells are expected to Cell voltage (V) 4.18 < 4.25 yield an additional anSpecific energy* (kWh/kg Al) 13.11 < 13.33 nual production capacNet carbon consumption (kg C/kg Al) 0.405 < 0.415 ity of 520,000 tonnes Aluminium purity (%) 99.93 > 99.89 (start-up is scheduled for December 2013). A * Based on 4.31 V actual minus 0.13 V for design changes (including larger busbar cross-section) in the industrial version of DX+ simultaneous upgrade to Emal’s DX cells, by implementing improvements designed and As the key performance indicators confirm tested by Dubal, will boost the production (see table), Dubal has successfully achieved yield from Emal Phase I by 50,000 tonnes. its objectives through DX+ technology – speThis means that, by the end of 2014, Emal will cifically to improve productivity while reduchave an annual capacity of 1.3 million tonnes ing the operations’ impact on the environ– all of it produced using Dubal’s reduction ment through improved energy efficiency and minimised emission levels. Al Zarouni technologies. Dubal’s Ali H A M Al Zarouni (vice presi- points out that, for expediency and timedent of Smelter Operations) proudly states saving, the DX busbars were retained in the ALUMINIUM · 1-2/2012 SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y Emal celebrates million tonne milestone DX+ cell in Dubal’s Eagle section DX+ Eagle demonstration cells, with minor variations to improve cell stability at higher amperage. “This was a disadvantage, as the cell-to-cell voltage would be higher than in an industrial implementation. At industrial scale, with the planned amperage increases, the performance of DX+ technology would be even better,” he says. N Spouts and Stoppers In November 2011, less than two years since the commission of its Al Taweelah smelter in December 2009, Emirates Aluminium heralded the production of one million tonnes of aluminium. The average daily metal production since 2009 has been 1,400 tonnes. Current production stands at 2,035 tonnes of hot metal per day. Al Mazrooei said: “With Phase Two construction now underway and expected to reach full production by 2014, Emal is well on track to meet future increased global aluminium demand. It is also significant that we have achieved this major landmark without compromising our commitment to the health and safety of our employees and our responsibility for the environment.” He referred to safe working conditions, most notably with no lost time injuries on its reduction potlines in 2011; equivalent to five million man hours. Ceramic Foam Filters For Aluminium DC Casting w w w.drache-gmbh.de ALUMINIUM · 1-2/2012 · [email protected] 27 A L U M I N I U M S M E LT I N G I N D U S T R Y Shaped cathode for the minimisation of the Hall-Héroult process specific energy consumption R. von Kaenel and J. Antille, KAN-NAK S.A. More and more aluminium smelters are testing new shapes of cathode to reduce their specific energy consumption. This paper compares the cathode voltage drop, the cell magneto-hydrodynamic stability, and the total specific energy consumption for four potential cathode designs. The lowest cathode voltage drop is not a necessary condition to realise the lowest specific energy consumption. It is well known that the biggest potential for decreasing the specific energy consumption Case 0: Reference cathode Case 1: Electrical insulation around collector bar? Case 2: Step in the cathode? Case 4: Groves on cathode surface and insulated collector bars (40 cm) Fig. 1: Five cathode designs for the same cell technology 28 Images: KAN-NAK Case 3: Blocks on cathode surface of electrolysis cells still lies in reducing the anode to cathode distance (ACD). Unfortunately, lowering the ACD leads sooner or later to detrimental magneto-hydrodynamic instabilities as waves provoke short-circuits and so harm the current efficiency and specific energy consumption. There are at least two ways of modifying the cathode to help decrease waves, and so the ACD. The first method consists in improving the magneto-hydrodynamic cell stability by changing the current distribution in the liquid metal, while still keeping a standard flat cathode surface. The interaction of the current density with the magnetic field in the liquid aluminium determines the critical ACD. This critical ACD can be lowered by modifying the cathode dimensions, as well as its properties, its collector bar design and / or the busbars. The second method consists of changing the shape of the cathode surface. Indeed, liquid metal waves that are generated by the magneto-hydrodynamic cell state can be damped by using uneven cathode surfaces. This has some similarities with how water waves are damped by turbulence when reaching shallow water. This paper analyses the potential advantages that can be expected from using these two techniques. The analysis needs the determination of the full thermal, electrical and magneto-hydrodynamic cell state in the presence of liquid aluminium waves in the cell. The analysis was performed with a specialised software that was presented earlier [1-4]. Many designs of shaped cathode can be considered, and we will restrict this study to geometries that have been published earlier [5-7]. In order to decrease the ACD while maintaining thermal balance, between heat input and heat losses, it is necessary to change other parameters. Increasing the current is the most common way to go, but one can also consider decreasing the metal level and / or improving the thermal insulation. Both methods achieve improved specific energy consumption in given ranges but they may lead to quite different electric power needs for the plant. Every cell technology is different. Technologies differ in their overall geometry, in their anode current density, in their busbar system, in their bath chemistry, and so on. We must therefore analyse each specific case to identify its potential for improvement. However, in order to get a quantified feeling of the impact of changing the cathode, we have considered a ‘typical’ side-by side-cell design operated at 350 kA with an anode current density of 0.9 A/cm2. Cathode design The change of cathode design affects the current density in liquid aluminium, the magnetic field, the velocity field, the ledge shape, the thermal heat losses, and many other parameters, so as to finally define a new cell state for any given current. It also defines the lowest achievable ACD for a given current in the line. Fig. 1 shows the five different cathode designs that were considered for the discussion. There are many parameters that must be checked to achieve a good cell technology. As it would be too tedious to present the full interaction of all these parameters, we will present the impact of cathode change on a few parameters, namely: • the surface current density on the cathode • the electrical potential inside the liquid metal • the cathode voltage drop (CVD) • the damping factor for the metallic waves • the specific energy consumptions. In this analysis the current is increased until the cell reaches instability at the limit of magneto-hydrodynamic stability. While the current is being increased, the ACD must be decreased to keep a constant internal heat production. All calculations are performed on a full three-dimensional model considering the neighbouring potline cells. Results Fig. 2 shows the shape of the electrical potential in the liquid metal, the current density at the liquid metal – cathode interface, and the cathode voltage drop. The current density is calculated in the upper part of the cathode, close to the interface. It represents the local current density that the cathode blocks must tolerate over time. A high current density causes a high rate of electro-erosion, and it should be avoided as it may compromise the cell life. In the liquid metal, the current is flowing perpendicular to the lines of equal electrical potential. Large and horizontal current densities represent a ALUMINIUM · 1-2/2012 SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y improves the situation drastically. However, a current density of 1.43 A/cm2 remains at the corner of the step. Only the magneto-hydrodynamic calculations can tell which situation is best. The CVD is a little lower when compared to the reference case. Fig. 5 shows the results for the blocks on the cathode surface. The current density is very high because the current flows around the carbon blocks (liquid metal is a better electrical conductor than carbon). The CVD is slightly lower (the mean cathode thickness has been decreased by the height of the carbon blocks). The collector bars should be insulated over a suitable length to avoid the horizontal current in the liquid metal. Fig. 6 shows the results for Case 4 (groves on cathode surface, and insulated collector bars). The maximum current density is decreased from 2.5 A/cm2 to 1.6 A/cm2 which is equivalent to the reference case. The CVD is increased to 377 mV, but the current is flowing vertically. The solution looks interesting. The most important data are summarised in Table 1, which shows the potential of each solution for higher production, assuming that the current can be increased. The current DUBAL potential destabilising factor for the cell magneto-hydrodynamic state. It is very clear that in this reference cell, too much current is moving horizontally in the liquid metal, leading to a high current density about 1.5 A/cm2 close to the edge of the cathode. The first idea for Fig. 2: Electrical potential lines, current density and CVD for improving the current the reference cathode blocks (Case 0) distribution is to insulate the outer end of collector bars as shown in the maximum current density to 1.09 A/cm2, Fig. 3 (next page). The resulting change of cur- but the flow directions now almost vertical in rent density is quite impressive and it depends the liquid metal. This will give an important largely on the length of insulation. The maxi- potential to decrease the ACD before reachmum current density is just above 1 A/cm2 ing the cell magneto-hydrodynamic instability. when the length of electrical insulation is 40 This is a must for compensating the increased cm around the collector bars. This first modi- CVD to 383 mV. Fig. 4 shows the results for the step cathfication helps to reduce the maximum current density by 22%, and it demonstrates the ad- ode. The step does not help very much for the vantage of keeping the CVD at 261 mV. The current distribution in the liquid metal. It is longer insulation helps drastically to even out still flowing mostly horizontally. Insulating the the current density. Not only has it reduced collector bars combined with the step cathode ("$ !"#%# # 4 ."()&)!1'#."-*#-#(-#!((!#(,#(!*,)/,'(. ,.#)(()''#--#)(#(!) *(/'.#'.,#&"(&#(!-1-.'- ),./,(%1*,)$.- ()'*)((.- ),."&/'#((/-.,1),'),."( 1,-."3,("- -.)) ),"#!"+/&#.1-.(,-1-.'-0#."'),."( , ,(-0),&0# ! " #$# ,-&(,.,s #((,!s&s"'/,!5-'#.")' &# ! A L U M I N I U M S M E LT I N G I N D U S T R Y Fig. 5: Electrical potential lines, current density and CVD for blocks on the cathode surface (Case 3) Fig. 3: Electrical potential lines, current density and CVD when insulating part of collector bars (Case 1) Fig. 6: Electrical potential lines, current density and CVD for groves on cathode surface and with insulated collector bars (Case 4) was increased until the cell stability damping factor was roughly the same for each case, this is to say, equivalent to the reference case. Increasing the current through improved cell magneto-hydrodynamic stability is the most efficient way for decreasing the cell specific energy consumption. As the cell operates at the same level of stability, the current efficiency was assumed to be unchanged. Conclusions Fig. 4: Electrical potential lines, current density and CVD for the step cathode (Case 2) 30 Four different cathode design changes were studied for a given cell reference design. The cathode plays a fundamental role in the cell’s magneto-hydrodynamic state and it can trigger drastic changes in the specific energy consumption. The lowest CVD does not reflect the lowest specific energy consumption. A shaped cathode in terms of steps, blocks or groves may help considerably to stabilise the metal pad, however, the current distribution also requires correct design in order to achieve the benefit. Horizontal current density in the liquid metal is one of the most sensitive parameters to consider in the design. The use of sharp changes at the surface of the cathode automatically leads to local high current densities that may be detrimental for the cell life. In this study, no consideration was given to the cell life and operation conditions. Any of the four analysed solution need to be tuned to the spe- ALUMINIUM · 1-2/2012 SPECIAL Case Modifications 0 1 Reference 2 3 4 Collector bars insulation Step cathode Blocks on the surface Groves in the cathode A L U M I N I U M S M E LT I N G I N D U S T R Y Col. Bars Insulation (cm) Current (kA) 0.00 0.15 0.40 0.00 0.40 0.00 0.40 345 355 370 365 390 370 400 MHD Specific Production CVD Internal damping energy increase (mV) heat (kW) factor (1/s) (kWh/kg) (%) -0.005 -0.005 -0.006 -0.005 -0.006 -0.005 -0.006 262 261 383 259 334 254 377 681 681 688 687 681 688 676 13.33 13.17 13.02 13.08 12.70 13.02 12.55 3% 7% 6% 13% 7% 16% Table 1: Specific energy consumption as function of cathode design cific cell technology in order to achieve a good magneto-hydrodynamic state. There are many more possibilities to change the cathode surface, and the authors believe that there is still a large potential for improving cell efficiency and productivity. kA aluminium reduction cells with a new type of cathode design, Light Metals 2010, ed. J. A. Johnson (TMS, Warrendale, Pa), pp. 485-488 References ALUMINIUM · 1-2/2012 René von Kaenel received his diploma of physicist from The Swiss Federal Institute of Technology Lausanne (EPFL) with a specialisation in plasma physics before working for ICL in London and specializing in computer science. In 1981 he joined Alusuisse and became head of the modelling activities for smelting technology. In 2000, he received the title of Electrolysis director in the new Alcan organisation and further supervised Alcan’s modelling activities. Since 1981 he has participated in many smelter modernisation projects all over the world, leading to large productivity increases. He has published many articles on electrolysis cells, casting processes and inert anode technology. In 2004 he created KAN-NAK S.A., a specialised company for &$7+2'(6 & ERQ &DU ERQDQ RQDQ QG* *UDS DS SKLW KLWH3 KL H3 H 3URGXFW URG RGX XFWWV V IRU3U IRU 3U 3ULPD LPD P U\$OX U\ \ $OX $OXPLQ PLQ QLXP XP6P 6P 6P 6 PHOW HOWHUV HUV HUV 6* *U 6*/ * RXS *U RXS¤ ¤¤ 7KH ¤ 7KH&D K &D &DUUER &D ERQ&R Q& &RPS RPSDQ\¤ RPSDQ\ DQ\ Q\¤ ¤¤ PDQ PD PDQ DQXID XIIDFWX DFFWX WXUHV UHVKL KL K JK KL J SHU HUUIRU IR PDQ QFH FH FDW FD KRGH KRG GH H SUR SURGXF URGXFFWV WV DQG GFD FDWKR FD WKRGLF WK WKR GLFV\ GLF V\ V\VWH V\VWH VWHPV PVV IRUUFR PV P F VW V HIIILF LFL LFLHQW FLHQW HQ Q SU SURGX SU RG RGX R GXFWL FW RQ RQRI RQ R SUL RI RI S P PDUU\D \ DOXP OXP OX XPLQX LQX QXP QX P P 2 EU 2XU 2X EURDG EU R GED RDG EDVH E VH FRQ FRQVLV VLVVWLQJR WLLQJR WLQ J RIP IP PDWH D ULD DOV OV KLJ JKW KWHPS HPS H P HUD PS UDWXU WX HWHF WXU H WHFK HW HFKQRO QR R RJ\DQ RJ\ J DQ DQ QG G DSSOLF DSS SSOLF OLFDWL DWL WLRQ RQ RQ RQ QNQR NQRZ NQR ZK KRZ R HQD RZ QD DEOH HV V LQQ LQQRYD QQRYD RYD RY DWLY WLYHV WL H ROX HV ROXWLR WL QV WLR QV IRU RUWKHS RUWK WK WK KHS H ULP ULPDU\ DU\ DU\ DOXPLQ DOX O PLQ PLQLXP LXP XP PLQ LQ QGXV G WU\ WU\H H HJ RX J RXUS RX US SDWH DWHQWH DWHQWH QWHG G G 9 'VR 96 96' VR VROXW X LRQ XW R IR RQ IRUH IR IRUH U H[WH WHQGH WH WHQGH HGS G SRWO SRWO RWOLIH LIH I DQ IHDQ DQG G UHG HG GXFH FH HGH G HQH QHU H J\ J\\ FRQ R VXP RQ VXPSWL PSWL SWLRQ RQ R RQ Q :H :H H VWU VW LYH VW YH HWR REH EH HWK WKHV WK HVVXSS HV VXSSOLH XS XSS S OLH O UR U RIF I FKRL KRLFH FH IRU FH IRU FFDU DUUERQ UERQ E DQ DQGJ DQ GJ JUDS UDS SKLW K WHF HFDWK HF DWK KRG RGH GH G HEO E EO EORFN R NV RFN V V VLG LGHZD LG HZD ZD DOOEOR OOO EOR O FNV OR FNNVVU DPP PPLQJ PP LQJ LQ QJ JSD SDVWH SD VWH HVVD VDQG QG QG J HV JOX 3OHDVH 3OHDVH D FRQWD WDFW WD FFW W XV XVV IRURX IRU RURX RXUF UFFXVWWRPL P VHG VHG VRO ROXWLRQV &$ [1] J. Descloux, M. Flück and M.V. Romerio, Modelling for instabilities in Hall-Héroult cells: mathematical and numerical aspects. Magneto-hydrodynamics in process metallurgy, Light Metals 1992, ed. E.R.Cutshall (TMS, Warrendale, Pa), pp. 1195-1198 [2] J. Descloux, Y. Jaccard and M.V. Romerio, Stability in aluminium reduction cells: a spectral problem solved by an iterative procedure, Light Metals 1994, ed. U. Mannweiler (TMS, Warrendale, Pa), pp. 275-281, [3] R. von Kaenel and J. P. Antille, On the stability of alumina reduction cells, 5th Australasian Aluminium Smelter Conference, 1995, Sydney, Australia, ed. B. Welch and M. Skyllas-Kazacos, pp. 530-544 [4] J. Descloux, M.Flück and M. V. Romerio, Modelling of the stability of aluminium electrolysis cell, Non-linear partial differential equations and their applications, Collège de France, Seminaire Volume XIII, Ed Longman 1998, pp. 117-133 [5] R. von Kaenel and J. P. Antille, Modelling of energy saving by using cathode design and inserts, Light Metals 2011, ed. S J. Lindsay (TMS, Warrendale, Pa), pp. 569-574 [6] J. Li and X.-J. Lu, Industrial test of low-voltage energy saving aluminium reduction cell, Light Metals 2010, ed. J. A. Johnson (TMS, Warrendale, Pa), pp. 399404 [7] Z. Wang and M. Feng, Study of surface oscillation of liquid aluminium in 168 Authors &DWKRGHV)XUQDFH/LQLQJV_6*/&$5%21*PE+ :LHVEDGHQ*HUPDQ\_FDWKRGHV#VJOFDUERQFRP %URDG%DVH%HVW6ROXWLRQV_ZZZVJOJURXSFRP 31 A L U M I N I U M S M E LT I N G I N D U S T R Y the optimisation of processes, in particular the HallHéroult process. Dr. Jacques Antille obtained a degree in Physics at the University of Lausanne in 1978 and his PhD at the European Centre of Nuclear Research (CERN) in 1984. Soon after he joined the Alusuisse Technology and Management Ltd and worked on modelling projects of the Hall-Héroult process and cast- ing processes. In 2004 he joined KAN-NAK S.A. where he is leading magneto-hydrodynamic studies for the optimisation of the electrolysis process as well as all measurement techniques. Precision pot feeding for better environmental protection P. Eggestig, Bosch Rexroth In 2000 Rexroth had already come into contact with a project from Kubal in Sundsvall, Sweden, as a part of which environmental protection was to be assured according to the new EU emission limits. The primary goal focussed on reducing fluoride gas emissions by 70 percent. Kubal is Sweden’s only aluminium plant, owned by UC Rusal. A while ago, Rusal had considered discontinuing its production in Sundsvall. However, thanks to a large-scale conversion and a new manufacturing process in which Rexroth’s new solution for process control plays a key role, Kubal in Sundsvall will be able to operate highly cost-effectively in the near future. The new technology is implemented in all of Kubal’s 262 electrolysis pots in Plant 2 in Sundsvall. The goal for reducing fluoride gas emissions by 70 percent has been achieved. Moreover, metal production will also increase by 40 percent after the conversion: 1.1 tonnes of aluminium will be extracted from each furnace daily. Images: Bosch Rexroth Fluoride gas emissions were reduced by 70 percent in aluminium production with pneumatic crust breakers. Rexroth has developed a product with the potential to revolutionise aluminium smelting. A newly developed process for adding alumina enables a more comprehensive process control, lower maintenance costs, improved aluminium quality and reduced emissions for across-the-board environmental protection. Kubal’s capacity is about 130,000 tpy of aluminium which corresponds to roughly half of the aluminium consumption in Sweden The double-acting cylinders have a diameter of 160 mm and a length of 600 mm. Chisels bore two holes into the crust, enabling aluminium oxide and fluoride to be injected into the molten cryolite at two places. The more uniformly and evenly the two materials are added, the more primary aluminium can be produced. This also significantly reduces polluting emissions. If the chisel does not penetrate the crust during the first attempt, the pneumatic pressure is tripled to six bar during the next attempt. If this also fails, the control system New process with dosed supply In order to achieve the dramatic reduction in fluoride gas emissions, Kubal discontinued its former alumina addition process, which involved the bulk transfer of hundreds of kilograms of aluminium oxide with one large ‘delivery’ to the furnaces. Now a dosed supply technique is used; smaller doses of one to two kilograms are supplied approximately once every minute. During this process, two pneumatic crustbreaker cylinders penetrate an approx. 10 cm-thick oxide crust above the molten metal. 32 Melting furnaces in Kubal’s Plant 2 casthouse in Sundsvall. The goal for reducing fluoride gas emissions by 70 percent has been achieved. ALUMINIUM · 1-2/2012 SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y operator. The crust-breaker cylinders operate approximately every minute, 24 hours a day, all year round. When the shaft on the crust breaker cylinders penetrates the crust, it should not enter more than the necessary minimum depth into the melt. With excessive penetration, an undesired quantity of iron dissolves into the cryolite, contaminating the aluminium. Also the chisel suffers increased wear and must be replaced, leading to higher costs. System optimisation Covering the melt is an approx. 10 cm-thick crust of solid cryolite and alumina that the pneumatic piston must break before every feeding. The crust breaker chisel penetrates the scrust and maintains the opening. Alumina and aluminium fluoride can then be fed through this aperture. switches to high-energy impact function. The chisel then chops up the surface crust. If that also does not work, an alarm signal is sent to an Rexroth has developed a system in which the chisel that penetrates the melt has as little contact with the melt as possible. This system, named ‘System Optimiser’, is patented [1]. Each of the 262 electrolysis cells operates in series with 160 kA and about 4 V per pot to convert alumina to aluminium. Thus, an electric potential is present in the pot, which instruments register when the chisel penetrates the crust and comes into contact with the melt. The System Optimiser receives a voltage signal as the shaft touches the melt and signals to the Kubal control system that an opening has been created in the crust. The Kubal control then introduces alumina and aluminium fluoride into the melt in the correct quantities. The traditional solution to date was that the piston was extended until it reached its end position in order to ensure that the opening produced in the crust remained open. This long stroke resulted in a number of disadvantages: About Kubal Kubal is the largest metal processing operation in the Swedish Province of Västernorrland, and is Sweden’s sole smelter of primary aluminium. Of the aluminium manufactured in Sundsvall, approx. 50% goes to customers in Sweden and 50% is shipped to buyers in the rest of Europe to make a large number of different products – from aluminium foil and packaging of all kinds, to construction material and vehicle components. The smelter’s capacity was increased from an initial 2,000 tpy to about 130,000 tpy today. That corresponds to roughly half of the aluminium consumption in Sweden. Thermo-Calc Software Thermodynamic and Diffusion Simulation Software for Aluminium alloys Thermo-Calc: 9 Predictions of stable and metastable phases for multicomponent alloys 9 New database TCAL1 with 26 elements 9 6FKHLOVROLGL¿FDWLRQVLPXODWLRQV DICTRA: 9 Diffusion controlled phase transformation simulation 9 Microsegregation kinetics during casting 9 Homogenization treatment and aging TC-PRISMA: 9 Modelling of nucleation, growth and coarsening 9 Time-Temperature-Precipitation (TTP) diagram 9 Size distribution, number density and mean radius Thermo-Calc Software AB Email: [email protected] Phone: +46-8-545 959 30 Fax: +46-8-673 37 18 www.thermocalc.com For a listing of local agents and DI¿OLDWHVLQ\RXUUHJLRQSOHDVH visit our website and look under Contact. A L U M I N I U M S M E LT I N G I N D U S T R Y unnecessary wear to the chisel and piston, an unwanted introduction of iron contamination and, first and foremost, Kubal did not obtain complete control over the electrolysis process. Although the piston reached ist end position, it did not always penetrate the crust, but sometimes only been pressed the crust further into the melt. In this case it created no opening, and the electrolysis process continued on this faulty basis. The additives could not dissolve in the bath, causing the pot to ‘run on empty’. This lack of alumina causes an anode effect with excess voltage and fluoride gas emissions. However, the worst-case scenario involved the delayed supply of too much alumina into the pot within a short time. Too much alumina cannot all dissolve, and results in deposits as sludge. This overfeeding effect causes an increase in resistance, voltage and temperature, seriously reducing the pot’s service life. By avoiding overfeeding, the system reduces gas emissions – primarily fluoride gas – by 70 percent. The new technology has achieved considerable gains in efficiency as well as exceedingly positive cost synergies. but also left the best impression, gaining points with technical support and fast response times so as to secure this large contract. Reference [1] C. Tour, Crust-breaking device operating system for metal melts has inductive position sensor to report impact of chisel, DE patent 10 2008 010 175 (application date 20 February 2008) Success factors Rexroth was able to offer the most technically advanced process. As a matter of course, other factors also play a role in such a transaction. Rexroth did not only have the best technology, Author Peter Eggestig is Bosch-Rexroth’s sales manager pneumatic in Sweden. He has directed the Rexroth project with its sale at Kubal since 2000. Trends in modern rectifiers – energy efficiency and availability Specific power losses can be reduced using higher voltages which correspond to a higher number of pots in series, beyond 360 pots in one potline. Today’s trend is to still higher production capacities at optimum investment costs and higher efficiency. This requires a rectifier with higher DC voltages up to 2,000 VDC. The rectifier system being one of the key elements in aluminium smelters, this makes the availability (reliability) of power supply most essential for economical performance. Aside from new plants, revamping old potlines requires increased DC voltage. This paper briefly discusses efficiency aspects of new plants as well as the economic aspects of revamping old potlines and the corresponding requirements of rectifier systems. It also describes power availability aspects related to designing a higher voltage rectifier system, as well as areas related to network performance. The way to meet these requirements involves using a systemic approach to find special solutions. Efficiency improvements – in other words, lower losses per million tonnes smelted – are achieved by operating rectifiers at higher voltages to serve a larger number of pots in series. Improvements in pot technology reduced individual pot voltage from 4.3 V to almost 3.85 V, thereby significantly improving process efficiency. The paper presents results based on design calculations for rectifier systems up to 2,000 VDC. A reliable and flexible 34 Images: ABB S. Tambe, ABB Switzerland Fig. 1 control system with a state-of-the-art optical DC metering system is also an integral part of the DC power supply. A modern DC metering system not only meets primary requirements, but it also has lower auxiliary power consumption. This also contributes to improved efficiency. Rectifier systems are a vital power element in the aluminium smelting process. Continuous availability of DC supply is a major factor affecting the economic performance of these plants. Unscheduled shutdowns result in huge financial losses. While efficiency is important, an availability is vital to avoid unplanned shutdowns. Modern technologies are designed to avoid such situations even when potlines employ local generation, sometimes operating in islanded mode. Initial investment costs are high for alu- minium potlines. These costs have two components: fixed cost and variable cost proportional to number of pots and parts. On an average 33 percent of smelter production cost is electrical energy. Due to increasing energy tariffs around the world, aluminium production is viable only when conversion and electrical efficiencies are high, thus reducing some of the major variable costs. Today, potlines can have more than 400 pots. More pots demand special logistics considering the requirements of metal tapping, anode replacement, maintenance work, such as beam raising, bath crushing, covering. A higher number of pots means higher DC voltage. The electrical insulation for the pot tending assembly cranes and workers does not appear to be a constraint. Electrical shock hazard does not appear to be a problem either. However, one must follow local safety regula- ALUMINIUM · 1-2/2012 SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y tions and take the necessary procedures into ment. Optimising losses in rectifier systems is account. The risk of open circuits is not higher. not easy due to physical constraints. As shown in Fig. 1 [1], some losses are The major challenge is the ability of rectifiers to supply higher DC voltage. Because the re- constant for a given potline current and some quired cross section of the busbars depends vary with current. This leads to the important on current, we can keep the same number of conclusion that for a given potline current in rectifier units, DC isolators, DC measuring a potline with a large number of pots, constant system and the buffer voltage to handle an- losses become relatively smaller as a percentode effect (with modern anode effect handling age of output or, in other words, losses are technique). This allows a lower initial invest- smaller per million tonnes output of aluminment per million tonnes smelted with a higher ium. number of pots. In short, economies of scale Power losses, maintenance costs and manrequire a higher number of pots, and hence power requirements for plant operations are technology needs to be adapted for higher lower and so economically more viable when voltages. There is a new trend in revamping old potlines. The number of rectifier units is reduced by connecting two or more potlines in series. Such revamping is carried out while the plant is in operation. Therefore it requires a high level of expertise. Smelters are moving to increased pot amperage and to longer potrooms with higher DC voltages in order to make capital savings on rectifiers, transformer bays and switchgear as well as some savings on the operational losses. Also, this simplifies the maintenance cost of the rectifier and its auxiliary equipment. Maintenance cost savings are reflected in reduced manpower requirements. If two potlines are connected in series, the electrical maintenance cost INNOVATION LEADS TO can be reduced by 40 percent. Manufacturing rectifiers for higher voltages presents various challenges. The soluUSE THE ORIGINAL tions to these challenges lie in BCT PASTE KNEADER – FOR MORE designing a reliable and safe rectifier system. Productivity Solution for higher efficiency Rectifiers, busbars and transformers are major sub-systems that are important sources of energy losses, although there are other auxiliaries and measuring systems that also contribute to losses. Transformer losses are easy to optimise because it is a question of initial invest- ALUMINIUM · 1-2/2012 potlines have more pots, that is, when they operate at higher voltages. Therefore, if power is available, it is more economical to plan a longer potline in advance than to build several shorter potlines. When power losses are calculated from voltage measurements, then transformer losses are not taken into account. Fig. 2 shows rectifier losses per MW output for 105 kA units, up 2,000 VDC. Overall efficiency improvement [1] The above discussion on losses relates to the rectifier system only. However, the transform- A NEW GENERATION Efficiency Reliability Get 100% paste – with max energy input – save 25% energy Get 100% performance – with optimised process zone – save 10% space Get 100% the original – with BCT spare and wear parts – save costs In its 6th generation the BCT Paste Kneader is a fully revised unit with new gearbox, new bearing system, embedded auxiliaries and more. Y O U R PA R T N E R F O R T E C H N O L O G I E S )<::*OLT;LJO(. /VOLUYHPUZ[YHZZL(7YH[[LSU:^P[aLYSHUK ;LS-H_ PUMV'I\ZZJ[JVT ZZZEXVVFWFRP A L U M I N I U M S M E LT I N G I N D U S T R Y Fig. 2 er is also a major part of the system, and so its overall efficiency is of prime importance. A case study showing improvement in overall efficiency is provided below. This study compares the losses for two options, firstly for 1,300 VDC and a capacity of 245,000 tpy of aluminium, and secondly for 1,380 VDC and a capacity of 260,000 tpy of aluminium. This comparison is based on actual measurements. In the first case, rectifier and transformer losses are 4,885 kW with five rectifiers in operation, whereas in the second case, losses are expected to be 5,065 kW with all five rectifiers in operation. In both cases, the potline current is 320 kA. Calculating further, we find that losses per million tonnes equivalent amount to 19,939 kW in the first case and to 19,481 kW in the second case. Thus an increase of about 6.2 percent in potline voltage leads to a reduction of losses by 2.3 percent. So the potline with higher voltage is preferable. We extend the above results further to compare a potline designed for 1,650 VDC (27% increase from 1,300 VDC) and a capac- ity of 340,000 tpy of aluminium. In this case losses per million tonnes also decrease significantly to 14,239 kW (29% reduction) with five rectifier units in operation. But when the potline voltage increases to 2,000 VDC, the losses do not decrease linearly. This is because the increase in diode semiconductor voltage rating caused additional losses. Fig. 3 shows voltage versus losses for a given potline current. Efficiency improvements and life enhancement Potlines built up to the end of 1980s used to have fewer pots due to technical limitations in many areas, including the rectifier systems. The typical potline voltage used to be up to 800 VDC. At the beginning of the 1990s the voltage could be increased beyond 1,000 VDC. In the old potlines, which are more than 28 years in operation, major electrical components would have reached the end of their life cycle [2]. Therefore many plants need to replace DC power supplies. As the duration of the plant and process life still exceeds 30 years, it was natural to replace electrical equipment, including rectifier systems [3]. Availability today of higher voltage rectifiers up to 2,000 VDC has made it possible to unite two old potlines by connecting them in series, and to replace a large number of old rectifiers with less than half the number of new rectifiers. This not only increases efficiency, but it also significantly reduces operational costs [4]. Some results published to one of the reequipped smelters show savings due to connecting potlines in series. Before connecting in series: • Potlines 1&2: losses of 12 rectifier / transformer units (2 potlines) approx. 6,500 kW • Potline 3&4: losses of 16+1 rectifier / transformer units (2 potlines) approx. 9,000 kW • Total losses approx. 15,500 kW. After connecting in series: • New substation after connecting each pair of potlines in series will have together 7,000 kW; reduction of 8,500 kW • Assuming the cost per kWh of 3 US cents; cost savings of USD2.2m per year. ABB carried out one more case study to prove the saving in energy by connecting two 190 kA, 720 VDC potlines in series (see Fig. 4), and the results were very encouraging. Before connecting in series: • Estimated losses for 2 potlines with existing transformers and rectifiers are 5,710 MW* • Step down transformer + regulating transformer + 6 rectifier transformers + rectifiers: 2855.1 kW • Output = 190 x 727 = 138.13 MW • Efficiency = Output / (Output + Losses) = 97.97% (actual* will be less) • * The above losses do not include saturable reactor losses, harmonics and auxiliary losses. After connecting in series: • New rectifier system rated at 5 x 55 kA, 1,650 VDC units • Potline operating at 190 kA and 1,454 VDC • Estimated losses of two potlines in series are 3.139 MW* • Expected savings in losses are 2.571 MW • * The above losses do not include saturable reactor losses, harmonics and auxiliary losses. Availability considerations for high voltage rectifiers Fig. 3 36 Fig. 5 shows a rectifier designed for 103 kA, 1,650 VDC, ABB frame type construction: Design methods and systemic approach: A reliable rectifier system can only be ensured ALUMINIUM · 1-2/2012 SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y Over-voltage protection This circuit is adapted for the selected topology, the selected semiconductor, the transformer parameters, the network parameters and according to the operation for the process. The critical components that form the overvoltage protection circuit are metal oxide surge suppressors, capacitors and electrolytic capacitors. Plant layout and busbar engineering Plant layout and busbar engineering play a crucial role in the initial investment and efficiency. Excessive unsupported lengths should be avoided, so keeping the safe distances to withstand short-circuit forces. Busbar layout also plays an important role in electro-mechanical forces, and so affects the design of support structures. Optimum busbar cross section determines losses and so ultimately efficiency. Heat from the busbar system must be evacuated to atmosphere without the need for an additional cooling system. Fig. 4: Loss calculations at 190 kA and 720 VDC if critical areas are designed with a systemic approach. The adapted topology, sizing, redundancy, etc. is based on various plant system parameters. Some of these are: • Whether the plant draws all its power from the grid, or whether it generates most of its power locally • How much import / export of power can occur before getting into islanding mode • How much system redundancy is based on process parameters. The selection of topology and components has to consider electrical network parameters as well as process requirements [1]. Some critical areas are: • Mechanical contact stability • Ability to withstand electro-mechanical forces in abnormal conditions to avoid capital damage • Tests for coordination of components such as semiconductors, fuses, etc. and checks for selectivity with simulations for network parameters • Rugged over-voltage protection and protection philosophy. All insulating materials used to isolate higher potentials are non absorbent for water. Air strike distances are adequate for the DC voltage level. To avoid flash-over between phases, insulating plates separate the AC phases. Welded ‘frame construction’ provides rigidity to the structure so as to withstand very high electro-mechanical forces. Double commutation paths reduce current by half and hence reduce forces. This also improves cur- ALUMINIUM · 1-2/2012 rent distribution in the semiconductors. Nickel-plated aluminium surfaces give the contact surface, which ensures many years of mechanical and electrical contact stability. Constant clamping pressure maintains good contact and elimination of contact corrosion between heat-sinks and semiconductors, resulting in constant heat transfer efficiency for years of operation. A closed loop ‘de-ionised’ water-cooling system provides efficient and clean cooling. Ionic corrosion, which is very chronic at higher voltages, is practically eliminated by using the right materials for the cooling circuit. Appropriate lengths of de-ionised water pipes are selected based on higher rectifier voltages. Control system The AC 800 PEC (Power Electronic Controller): The control system function includes closed loop current control, alarms, trips, protections, various controls, metering, communication, trends, etc. This requires a highly reliable and flexible system. Fault tolerant challenge In the case of old thyristor plants, a major problem is tripping during under-voltages, ground Clear separation of power and control wiring There is an interface between power circuit and control system. Fuse monitoring, temperature monitoring, etc. are located on the power circuit but are monitored in the control system. Isolation between these two systems is very critical. Various monitoring functionalities such as busbar temperature, fuse monitoring micro switches, etc. are part of rectifier system. These signals are wired to control system input devices, while the connection of the over-voltage protection circuit is wired to the power circuit. All of this wiring is clearly separated and isolated. Wires have minimum sag to minimise the effects of vibration. Fig. 5: 103 kA, 1,650 VDC rectifier 37 A L U M I N I U M S M E LT I N G I N D U S T R Y faults and unexpected, very brief unbalance between phases. Old analogue circuits could not maintain the proper pulse positioning under such conditions. This could result i n thyristor sensing fibre looped around the current-carrying busbars. A single loop is commonly sufficient for high DC currents. The field (proportional to DC Current) dependent phase shift (Fig. 7) between two light waves is a direct and accurate measure of the DC Current. Auxiliary power requirement for scale production of primary aluminium requires rectifier systems for potline voltages up to 2,000 VDC. References [1] S. Tambe, C. Winter and S. Dhareshwar, ‘Rectifiers for Higher Voltages in Aluminium Smelters – Challenges and Solutions’, Metal Bulletin, 2007, Mumbai, India. [2] S. Tambe and J. Frisch, ‘Upgrading rectifier systems – How to improve efficiency, increase reliability and reduce down time’, in PCIC IEEE, 2004 failures and a plant outage. The only alternative to avoid unscheduled outages is the revamping or replacement of the control system [5]. The AC 800 PEC control system is able to maintain correct firing at up to 60 percent of nominal voltage, and it provides ride through functionality even if a phase is lost. The controller has built-in filters that clean synchronising voltages, avoid noise amplification, and for certain durations can also block pulses without tripping. This greatly increases the availability and increases the safety of the process. Fibre-Optic Current Sensor (FOCS) The ABB FOCS is a family of highly accurate fibre-optic current sensors developed for measuring high DC currents. This technical innovation is characterised by its easy and flexible use. Based on the magneto-optic effect (Faraday effect) in a single-ended optical fibre around the current conductor, the FOCS can measure uni- or bi-directional DC currents up to 500 kA with an accuracy of 0.1% of the measured value. The main benefits can be described as: • Fast and easy assembly and installation • Simple to transport • Special building structure to house sensor is not needed • Immune to electromagnetic interferences (magnetic centring, magnetic overload, etc.) • Low power consumption • No shunts. The sensors also recover AC current components up to 4 kHz. The signal is independent of the particular busbar arrangement, and it is insensitive to magnetic stray fields from neighbouring busbars. Two light waves with orthogonal linear polarisations travel from the sensor electronics, which include a semiconductor light source, via a sensor fibre cable to the single-ended 38 Fig. 6: AC 800 PEC controller FOCS requires only about 30 W constant against about 20 W / kA measured by conventional measuring system. Energy requirements for 300 kA FOCS would be 262 kWh, as against 52,560 kWh per year for a conventional system. Conclusion Energy efficiency and availability are keys for successful operation of aluminium plant. A single potline with a higher number of pots is energy efficient and cost effective. The best way to achieve higher efficiency for old potlines, operating under 800 VDC, is to connect two potlines in series. Today, the competitive [3] E. Knall, ‘ABB retrofitting concept for Rectifier Plants’, ABB Industrie AG. [4] S. Tambe and S. Dhareshwar, ‘Limits of Conventional Maintenance and Needs of Upgrading / Revamping for High Power Rectifier Systems’, National workshop on power electronics, June 2005, India [5] S. Tambe, ‘Upgrading Control System with AC 800 PEC for Rectifier Systems’, Light Metals 2006, ed. T. J. Galloway TMS, Warrendale, Pa), pp. 265270 Author Shripad Tambe, Master of Technology, IIT Kanpur, started in 1977 with HBB (Hindustan Brown Boveri), India. In HBB India he was a senior research and development manager. Up to 1999 Shripad Tambe worked in various technical departments including system engineering, ABB Switzerland. He is the inventor of two patents registered in many countries in the area of rectifiers for DC arc furnaces. From October 1999 to 2005, he was responsible worldwide for retrofit, revamp and upgrades of rectifier plants for electrolysis and arc furnaces. Contact: [email protected] Fig. 7: DC FOCS and measuring principle ALUMINIUM · 1-2/2012 SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y Innovative energy and fluoride recovery B. Herrlander, Alstom Power In April 2011, the world’s largest singlesite greenfield aluminium smelter complex held an official grand opening of phase one (Fig. 1, next page). The Emal smelter complex is being built in two phases. Phase one includes two potlines with a total of 756 pots at 350 kA to produce 750,000 tpy of aluminium. The first pot was started 2 December 2009, and in January 2011 the two potlines hit full production. At the end of 2012, the phase one capacity will be increased to 800,000 tpy of aluminium through a technology upgrade to 380 kA. Phase two of the smelter began in September 2011 and has one potline with 444 pots at 420 kA. When phase two is finished in December 2014, the smelter will be the largest in the world with a capacity of 1.3m tpy. Alstom is selected supplier of Gas Treatment The fluoride loop Centres (GTC), Fume Treatment Centres (FTC) and the pot feed system for phase 1, and of GTC and FTC for phase 2. Only 15 years ago a new smelter of 200,000 tpy was considered normal. Today smelters of more than 800,000 tpy of capacity are being built. Over the same period typical new pot amperage has increased from 180 to 350 kA, and will go higher as demonstrated in the Emal phase two. In an existing smelter amperage increase creep is one of the more cost efficient ways to increase the specific production. However, the concentration of HF in the off-gas from pots has risen correspondingly from typically 150 to 180 mg/Nm3 to 350 to 400 mg/Nm3. At the same time, the limits for allowable fluoride emissions from GTC and FTC stacks have been reduced from approx. 2.5 to 0.7 mg/Nm3. Alstom pioneered the dry recovery of fluorides from pot off gases by adsorption on alumina deploying a fabric filter. Over the years the developments have resulted in the wellproven Abart GTC technology. The Abart is a two-stage counter-current process, even though the stages internally operate in co-current mode. This principle reduces the effects of moderate variations in upstream conditions, such as varying fluoride concentration as well as alumina flow and quality. The operating mode is as follows. Fresh alumina is injected into the gas in the filter stage, downstream of the patented reactor where the pot off gases enter the Abart. The high capacity fresh alumina is therefore used at the tail end of the process, where the remaining fluoride concentration is low. This dramatically increases the www. alu-web.de Find out what’s going on in the industrry evven faster! Read aboutt thee burninng issues even eaarlieer! Aluminnium-eePaper – your added PLUS to the print medium! As a special thank-you gift for your orrder, we will allso send you the book “Fundam mentals of Extrrusion”! Hans-Böckler-Allee 9 30173 Hannover · Germany Tel. +49 511 - Fax +49 511 7304-233 [email protected] A L U M I N I U M S M E LT I N G I N D U S T R Y structure, in most cases avoiding possible conflict with other equipment. The system consists of a limited number of modules, thus reducing stocks of spare parts and allowing for easy and cost-efficient maintenance. These design elements make the Alfeed system ideal for both new installations and for retrofitting. Images: Alstom Optimising GTC operating temperature Fig. 1: Emal Gas Treatment Centre (GTC) ‘driving force’ for adsorption by the alumina, resulting in a stable, low emission level. The alumina from the filter is lead to the reactor, where it is blended into recycled alumina. A part of the recycled alumina is continuously diverted back to the pots. Alstom has developed a pot feeding system (Alfeed) (Fig. 2) that brings the fluorideenriched alumina from the Abart back to the pots, thus replacing traditional crane filling systems. The Alfeed system is a further development of the state-of-the-art alumina distribution arrangement that has been used in Abart systems for more than thirteen years. The Alfeed pot feed system is a horizontal transport and distribution system based on a supply-on-demand concept. It employs a boiling-bed fluidisation air slide, which is located alongside the pot room building. Alumina is discharged from the fluoride enriched alumina silo into the main air slide through a rotary feeder which is followed by a fluidised control screen (patent filed) that removes oversize particles. The main air slide distributes alumina along the pot line. From this air slide the enriched alumina is distributed to the pots by means of individual pressurised air slides. These have outlets that enable each pot hopper to be filled as alumina is consumed. Valves are operated during shutdown or maintenance only. The pots and pot point feeder system are always filled with alumina. Fine dust is separated from the main air slide and is fed directly to the individual pots. The system is completely enclosed and the exhaust air is led into the collecting gas ducts for the Abart. Thus the fines are contained within the system and are distributed evenly among the pots. The slim profile of the Alfeed design integrates well with the top of the pot super- Fig. 2: Alfeed system Fig. 3: Relative HF emission versus gas temperature 40 As pot gas temperature rises above 100 °C, there is a sharp rise in fluoride emissions from the GTC, as shown in Fig. 3. With the new high-amperage pots the gas temperature increases from formerly about 140 to around 180 °C, which makes it even more difficult to meet the new, low emission limit values. For this reason, a number of smelters have already had difficulty staying in compliance during the summer. The traditional way of cooling high-temperature gas is to bleed-in ambient air to cool it to acceptable gas treatment temperatures (110 to 115 ºC). However, with an ambient temperature of up to 50 °C, this dilution may increase the throughput of the GTC by more than 50%, and increase the fan power requirement accordingly. Also, the additional filter bags increase maintenance costs. Installing a heat exchanger to cool the off gas is an alternative solution that not only reduces the size of the GTC, but also makes large savings in the main fan power consumption and also reduces in total HF emissions. In addition, the value of the recovered heat energy alone can justify the added investment cost of the heat exchanger. In the event that not all of the heat energy is used, and part is vented to the atmosphere through dump heat exchangers. However, fouling from scale formation has been the main reason for the failure of heat exchangers in this application. In particular, the cross-flow type has been tested for pot gas. Control or elimination of heat exchanger fouling on heat exchanger surfaces has been the main driver behind Alstom’s development of the new fire tube heat exchanger. Alstom has long-term experience with fire tube heat exchangers on similar or more difficult flue gases, such as from Fe/Si- and Si-metal furnaces. The fire tube heat exchanger (HEX) may be arranged in the duct- ALUMINIUM · 1-2/2012 SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y ing between the pots and the GTC, or it may be integrated into the Abart. The dust-laden hot gas feeds into several parallel, straight tubes immersed in water that cools the outside of the tubes. The water flows in counter-current to the pot gas from bottom to the top when the HEX is arranged vertically, and consequently the gas is cooled as it flows through the HEX tubes from top to bottom. The counter-current flows achieve optimum cooling at reduced cost. This type of heat exchanger has reduced fouling, and the thickness of deposits stays in a stable, thin self-cleaning state. Several HEX have been tested at Alba and Alcoa Mosjøen. The version integrated (IHEX) to Abart is shown in Fig. 4. The HEX is now available for commercial projects. The recovered heat may be used for district heating or cooling, or for sea water desalination or for electric power production. District heating is obviously a choice for colder cli- Fig. 4: Integrated heat exchanger (IHEX) into Abart mates, whereas absorption chillers could be wisely used to generate cool air especially in hot climates, such as for the Middle East and Asia. One particularly interesting application to cool inlet air to on-site gas turbines. This may boost the power output of the turbine significantly (10 to 25%) during summer conditions. Thermal desalination plants are another option that typically requires relatively low temperatures < 120 °C for heating of the process salt water ‘brine’ to avoid excessive corrosion. The principle is shown in Fig. 5. This gives a near perfect match for the recovered heat. Even the quantity of the recovered energy, which may exceed 100 MW in these locations, is typically no problem to consume in a desalination plant. Power production from low-temperature sources may be through the Organic Rankine cycle, where the hot water, steam or oil carries the heat energy to be converted to electric energy. The efficiency of these machines is modest at low temperatures, but may become attractive as the energy cost increases. The amount of energy available for use depends both on the temperature difference between the pot gas and the 42 heat sink. This process is typically applied for low-temperature sources where part of the energy is used as district heating in the cold season, and more energy is converted to electricity in the hot season when the demand for heating is less. Fig. 5: Example of deployment of heat energy Sulphur dioxide abatement Also the typical sulphur dioxide emission from the pot is increasing, because of higher sulphur content in the petroleum coke used to make anodes, which is going up typically to 3 to 5%. Thus there is an increasing need to remove sulphur dioxide to comply with emissions limit values. Such limits are already enforced at smelters in Scandinavia and in parts of North America. New smelters starting up in Qatar and Abu Dhabi will have sulphur dioxide abatement system. Alstom pioneered the development of sulphur dioxide scrubbers for the pulp and paper industry, and later also for power plants. Today there are several processes available to remove sulphur dioxide. Absorption in an alkaline solution is an alternative for inland aluminium smelters without access to seawater. A typical strong alkali absorbent is sodium hydroxide. This permits a compact design and good absorbent utilisation. For smelters located on the coast, scrubbing with seawater is an excellent alternative. It exploits seawater’s inherent acid buffer capacity. The sulphur dioxide is transformed into sulphate in the scrubber process. Sulphate is a harmless and natural constituent of seawater. Depending on recipient conditions and on local regulations, aeration of the effluent may be required to speed up a return to normal pH value, and to provide for biological oxygen demand. Both seawater and alkali processes are extremely efficient, typically removing more than 99% of the sulphur dioxide. Decentralised distributed dry scrubber The centralised Abart technology is now being developed further to become the Decentralised Distributed Scrubber technology (DDS). Traditionally the GTC is sited in the courtyard between potrooms, and it is made up of identical compartments which can number as many as thirty or more. These compartments operate in parallel to optimise gas and alumina flow and to secure operational flexibility. It is difficult to tune and operate these as well as to detect failures or faults among the individual units. As an alternative to the GTC, Alstom is now launching the patented DDS, a solution that divides the traditional GTC into smaller sub-centres. These sub-centres are distributed along the pot rooms instead of being placed in between them. A typically DDS will handle Fig. 6: Sunndal sea water flue gas desulphurisation ALUMINIUM · 1-2/2012 SPECIAL gas from fifteen pots (~220.000 m3/h). As an example, twelve DDS will replace one GTC. This solution includes allowance for running two of the pots simultaneously on forced draft (~24,000m3/h) for each section. The benefits of the DDS are many, but there are also challenges and some disadvantages. For the discussion, the assumption is that fresh alumina is stored in one central silo, and the dense phase is transported up to each individual DDS. Now, DDS represent a significant saving in power consumption, due to less ducting compared with a GTC. This reduces the pot gas pressure drop for a DDS set by about 15% compared with the equivalent GTC. However, as the DDS is closer to pots, the pot gas temperature may be about 15 to 20 °C higher. The higher pot gas temperature yields a significantly higher heat energy (about 50 kW per pot), since the heat is recovered in the integrated heat exchanger. This mode of operation ensures the optimal temperature for fluoride recovery. The DDS provides enhanced operational flexibility, because each DDS compartment can be individually finetuned through frequency-controlled drives on the gas flow exhaust fan, and matched for fresh alumina feed and for enriched alumina recycling. To handle higher sulphur dioxide concentration in the pot gas, a wet scrubber may optionally be integrated into the top of the DDS. There is a choice available between an alkaline solution or seawater. Alumina storage and handling is integrated into the DDS. The fresh alumina storage is normally sufficient for two days of pot consumption. From the DDS the fluoride-enriched alumina may be fed directly to the pots through the Alfeed system. This avoids intermediate silos and alumina transfer points which tend to increase alumina segregation. It increases robustness as there are less transports. It also saves significantly on equipment cost for alumina transport and for silo fluidisation. The overall steel weight of the DDS arrangement generally saves 30% compared with a GTC. DDS also simplifies the total electrical layout, and it operates on medium voltage (440 V), compared with a GTC which needs substations for both high and medium voltage. However, each DDS will have to be electrified from a central source, which means the number of power and instrument cables will increase for a DDS arrangement. On the other hand the number of monitors is reduced by extracting gas from each mini-stack into a laser-based analyser. HF and dust measuring equipment is easily accessed from the filter top. The DDS may be fully shop-manufactured, as the size of a DDS compartment meets road ALUMINIUM · 1-2/2012 A L U M I N I U M S M E LT I N G I N D U S T R Y Fig. 7: Årdal Decentralised Distributed Dry Scrubber transportation requirements. Shop fabrication ensures a uniformly high quality of work. Several DDS can be erected simultaneously and independently. This also allows for stepwise smelter expansion. The bolted design eases the installation in an operating smelter, since strong magnetic fields can disturb assembly by welding. Civil work for a GTC installation is a significant part of total cost. The GTC foundations for the heavy silos, for filter compartment support and for main fans are extensive compared with simpler and lighter arrangements for the DDS. Finally the footprint is reduced to half. One DDS requires approx. 90 m2. Thus twelve DDS will take almost 1,100 m2, while the corresponding GTC needs about 2,300 m2. Removal of tar, fluorides and dust from the baking furnace gases is traditionally handled in a FTC with Abart technology. A conditioning tower cools the gas ahead of Abart for efficient capture of tars and PAHs. Alstom intends to replace the conditioning towers with its emerging heat exchanger for condensables. This, combined with the DDS technology, constitutes a cost-efficient new FTC technology, which includes heat recovery and improved tar control. Summary and conclusion For more than 50 years Alstom has served the aluminium industry through continuous development of air emissions abatement technologies. The GTC size has increased significantly over recent years to match the ever larger smelters. The current innovative heat exchanger technologies optimise the off gas temperature for better fluoride recovery in the GTC so as to meet the gas emission challenge of new high amperage pots. These heat exchangers may be installed in the flue gas duct at the pot, or before the GTC, or be costefficiently integrated to the GTC. Depending on the smelter location, the recovered heat energy may optionally be deployed for district heating, or for driving a cooler, or for de-salting sea water. The Alfeed system closes the fluoride-enriched alumina feed loop back to the pots. This demonstrates that the principles of centralisation do not always reduce cost and ease operation of a system. The DDS solution has many advantages and benefits. It reduces cost and power consumption, and in addition it reduces total footprint by 50% and combines optional waste heat recovery. DDS has the flexibility and operational performance that will meet future emission requirements. Incorporating a sulphur dioxide scrubber in the DDS system makes it a cost-efficient, multipollutant gas treatment technology. Alstom’s new and emerging technologies contribute significantly to the sustainability of the aluminium industry as the smelters grow further in size and output. For these reasons Alstom is the natural choice for complete environmental and power-generating solutions to the aluminium industry. Author Bo Herrlander is global marketing manager Industry & Power of Alstom Power, based in Växjö, Sweden. Contact: [email protected] 43 A L U M I N I U M S M E LT I N G I N D U S T R Y ECL – renowned equipment supplier to the primary aluminium industry Since its inception in Lille, France, in 1947 ECL has become a world leader in the provision of key equipment for the production of primary aluminium. The company is part of the Rio Tinto Alcan group and its products are used in the reduction, carbon and metal areas of smelters. The product range is centred on pot tending machines, cranes and transfer equipment for the reduction lines. It further includes a wide range of products and services for the carbon sector including green and baked anode handling equipment, together with specialised cranes, complete anode rodding shop, and metal and bath handling systems. The involvement of ECL does not end with the conception, production, erection and commissioning of its products. The company offers a wide range of supporting services including training, technical assistance and the provision of spare parts, as well as on-site maintenance management, equipment audits, refurbishment and upgrades. The machines are adaptable to all the reduction technologies used in today’s smelters. To be closer to its customers – more than 150 plants located worldwide – ECL set up eight subsidiaries around the world. The first one was opened in Quebec in 2000. The following year saw the establishment of three more operations – ECL Services Africa Engineering in Richards Bay, South Africa; ECL Services Nl. Bv. in Vlissingen, The Netherlands, and ECL Services Pty. Ltd. Australia, based in Brisbane and Portland. In 2002, ECL Africa opened an office in Maputo, Mozambique, and in 2003 a subsidiary in Shanghai, Republic of China. In 2006, a project office was opened in India. 2007 has seen the opening of a new office in Dubai, UAE. The advantages of having offices close to its main customers are obvious. ECL provides fast and efficient services on a 24/7 basis. Customers benefit from on-site after-sales services, from refurbishment or upgrade services, and from technical support and maintenance. Images: ECL A.-G. Hequet, ECL Anode rodding shop dedicated to the manufacture of equipment specifically for the primary aluminium industry. The company’s flagship product is doubtless the pot tending machine (PTM) which this year celebrates its 50th anniversary. More than 1,150 PTMs have been sold in fifty years. Innovation A wide range of products and services Reduction: ECL prides itself on being entirely 44 Each model is adaptable to all the reduction technologies used and it is designed to match each smelter’s specifications. The ECL cranes benefit from many patented or patent pending innovations. Pot equipment is a significant part of the company’s offer, with more than 15,000 pots equipped by ECL worldwide. This sector includes anode beam raising mechanisms, anode jacking frames, crust breaking and feeding devices, J hooks and fixings, anode clamps and sealing jaws. Carbon: ECL offers equipment for the whole carbon sector, from single machines to turnkey rodding shops (including the building) for all types of anodes. Around the world the company has installed 190 furnace tending assemblies, 28 anode rodding shops and 15 anode handling and storage shops. Metal: ECL also provides its customers with metal handling systems for both potroom and casthouse. Fifty years have gone by since ECL commissioned the first pot tending machine in the French Rioupéroux smelter (closed in 1991), thus leading the mechanisation of the aluminium smelter industry. Fifty years of innovation, research and development to improve performance in terms of commissioning time, productivity, availability rate, safety, impact on the environment and reliability. Fifty years during which the PTM has become lighter and more compact, equipped with new tools and radically new options such as the new pot hood handling device, which is operating with great success in modern smelters around the world. Fifty years of collaboration with AP Technology in order to constantly increase efficiency and safety of every single smelter. Fifty years of taking into account smelters’ needs and achieving significant capex and opex savings over contemporary designs. ECL pot tending machine of the latest generation ECL is also renowned for introducing innovative concepts to the industry. Amongst recent technological advances are the potline shutdown and restart solutions. Shutdown and restart solutions: After accidental shutdowns, many potlines have been unable to restart without total relining lasting many months. Still today, whatever ALUMINIUM · 1-2/2012 SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y it, to increase productivity, and to make sure the equipment meets the ever increasing environmental and safety requirements. Project Management Another ECL strength is its team of project managers dedicated to overseeing the manufacturing and installation phases of each piece of equipment. The manager coordinates the work of all the teams contributing to the project, both inside and outside ECL, until the equipment is operating to the terms of the contract. The project manager is also responsible for seeing that the project is delivered both on time and to the agreed cost. More than just offering products, ECL prides itself on delivering solutions in order to assist its customers at every step of their project and at every milestone of any equipment’s life cycle. Shutdown and restart tools Dual air compressor the technology for aluminium electrolysis, reduction pot shutdown and restart, planned or unplanned, remain extremely critical operations, especially due to the need for human intervention. During the shutdown phase the operator must manually use mechanical tools to introduce short-circuiting wedges between the electrical conductors, so as to by-pass the current to the following pot, and then later he must remove the wedges to restart the pot. The working area situated about one metre below the floor level is quite confined, and it puts the operator in a very uncomfortable and hazardous situation where he is at risk of serious injuries. Furthermore, speed is of the utmost importance. If the wedges are not removed fast enough during the restart phase, the high current density may produce electrical arcs which can damage the conductors. Therefore to reduce conductor maintenance costs, but above all to put the operator in a safe working environment, ECL along with AP Technology, designed a remotely-controlled wedge extraction system which is entirely operated from the working level and is connected with the pot tending machine. This is only one result of a programme which has seen 30,000 hours devoted to research and development. Dual air compressor on PTM: Another instance of bringing value to the customer is the development of a twin air compressor which provides both energy saving and backup capability. Since the first pot tending machine commissioned by ECL, all the new options, tools and technical solutions have been conceived and designed with the sole aim of meeting Author smelters’ challenges, to reduce energy consumption and consequently allow significant Anne-Gaëlle Hequet is external communication cost savings, and to ensure safe and secure manager of ECL, based in Ronchin, France. operations. In close collaboration with a world-class air compressor designer and manufacturer, ECL has therefore developed and equipped its pot tending machine with a new standard of +$/9LEURFRPSDFWRUIRUPDQXIDFWXULQJRI air compressor: the twin JUHHQDQRGHV8QLTXHDQGSDWHQWHGYL air compressor. Instead of EUDWLRQXQLWLQWRSRIWKHPRXOGPDNHV having just one big energyLWSRVVLEOHWRSURGXFHJUHHQDQRGHV intensive compressor, the ZLWKKLJKJUHHQDQRGHGHQVLW\DQG JRRGDQRGHTXDOLW\7KHWHFKQRORJ\ PTM has two smaller and LVRZQHGE\+\GUR$OXPLQLXPDQG lighter compressors, which 6WRUYLNOLFHQFHWKHWHFKQRORJ\IRUVDOHV are used separately most of WRLQWHUQDWLRQDODOXPLQLXPLQGXVWU\ the time (anode changes), +LJK&DSDFLW\ except when tapping off DQRGHVKRXUDWVYLEUDWLRQWLPH liquid metal. The two com (DV\/RJLVWLFV ²6PDOOGLPHQVLRQVDWW\SLFDOO\[[P pressors run alternately at (DV\0DLQWHQDQFH only 90 percent of their full ²6ZLWFKLQJPRXOGVZLWKLQKRXUV capacity. This means they *RRG4XDOLW\ ²*UHHQGHQVLW\W\SLFDOJFP save a substantial amount /RZ,QYHVWPHQW of energy and in addition /RZPDLQWHQDQFHDQGRSHUDWLRQDOFRVW have a longer operational life. Furthermore, the reduced size and weight of each compressor greatly ease maintenance operations of this new standard. The ECL R&D department is constantly working on new ways to make 6WRUYLN$6 7OI the aluminium production ,QGXVWULYHLHQ )D[ 16XQQGDOV¡UD :HEZZZVWRUYLNQR (PDLOVWRUYLN#VWRUYLNQR &(57,),('$&&72,62 process safer, to facilitate ALUMINIUM · 1-2/2012 +$/ 9,%52&203$&725 45 A L U M I N I U M S M E LT I N G I N D U S T R Y Improvements for the operation of anode baking furnaces D. Maiwald, D. Di Lisa and P. Mnikoleiski, Innovatherm refractory • Performance of firing equipment for combustion • Performance of automation, control and communication. Images: Innovatherm Improvement for the lifetime of furnace refractory Fig. 1: Fire arrangement ProBake on an open pit anode baking furnace This paper discusses some important aspects of how to optimise the firing equipment to improve the operation and performance of the anode baking process, with emphasis on the following major topics: the improvements for the lifetime of furnace refractory, the performance of firing equipment for combustion and the performance of automation, control and communication. The performance of an anode baking furnace is strongly influenced by the availability and reliability of the installed firing equipment. Design and construction of key components have to take into account the severe environment in and around an open pit anode baking furnace. Another specific constraint is, that the Fig. 2: Temperature distribution around a ‘hot spot’ on low velocity burners 46 mobile equipment must be moved every 24 to 26 hours, and it is consequently exposed to a high rate of wear and tear. So all process disturbances which are related to the corporate firing equipment can have a very high impact on production quantity, quality and operational safety. Fig. 1 shows mobile burners and exhaust pipes for a typical fire arrangement on an open pit anode baking furnace. This paper highlights some important aspects of how to optimise the firing equipment to improve the operation and performance of the anode baking process, with emphasis on the following major topics: • Improvements for the lifetime of furnace Fig. 3: High velocity low NOx burner The lifetime of the furnace refractory is primarily influenced by thermal stress. The thermal stress is caused by the type of burner introducing the fuel between the flue walls. Low velocity burners at continuous or slow pulse operation cause peak temperatures and hot spots on the refractory causing wear and resulting in high maintenance, repair and replacements intervals. Fig. 2 shows a typical hot spot scenario on a low velocity burner arrangement. Improvement no. 1: high velocity low NOx burner. The latest ‘high velocity low NOx burner’ technology provides a sophisticated flame characteristic which is finally responsible for a smart, controlled heat distribution within the flue walls. The access to a defined heat distribution below the critical refractory temperature range also results in maximum controlled energy efficiency and a very low temperature deviation within the anodes themselves. Fig. 3 shows the special Innovatherm burner design for this application. The specific fuel gas injection at a speed of 360 m/sec, achieves complete combustion resulting in the best fuel efficiency as well as in a homogenised waste gas for the following burners and the downstream combustion of volatiles escaping from the green anodes. Fig. 4 shows the same temperature plot after installation of the high speed burner technology. Improvement no. 2: flue condition module. Fig. 4: Temperature distribution with high speed burner technology ALUMINIUM · 1-2/2012 Lower plant investment and operation costs? Certainly. To power your operation while lowering consumption we provide you with stable, highly efficient electrical energy systems and products for all power conversion and distribution applications. To increase productivity and engineering efficiency, ensure environmental compliance and maintain product quality, apply our automation, optimization and expert solutions. To improve dynamic performance and reduce power losses, we provide drive systems based on direct torque control technology. Maximize the return on project investment through our vast know-how and extensive experience. Using ABB quality products helps you achieve industry leading productivity. www.abb.com/aluminium ABB Switzerland Ltd 5405 Baden 5 Dättwil Phone: +41 58 586 84 44 Fax: +41 58 586 73 33 E-mail: [email protected] A L U M I N I U M S M E LT I N G I N D U S T R Y Fig. 5: Exhaust ramp with soot deposit Fig. 7: Long life burner (Innovatherm) The furnace refractory is exposed to thermal stress from day one of production. The manual inspection of the condition of each flue after each fire cycle is a big maintenance issue. The latest technology called ‘flue condition module’ collects all measured process values from the firing equipment and verifies abnormal conditions. A highly sophisticated fuzzy logic module indicates analogue variations of individual flue wall conditions according to the various control parameters so as to maintain production targets. The module also produces a ‘flue wall quality index’ which automatically indicates the condition of the refractory of each flue wall and finally modifies the related heating regime for each specific flue. The flue condition module output results in a better flue wall protection against peak temperatures and consequently in less flue wall maintenance sequences. Performance of the firing equipment Fig. 8: Long life solenoid gas pulse valve (Innovatherm) Fig. 9: Measurement drift of different types of thermocouples over operation hours 48 Less cleaning cycles. The combustion quality is only affected by the performance of the firing equipment. Poor combustion results in soot deposits, which will require regular maintenance for intensive cleaning of the exhaust manifolds as well as the ring main ducts and filter equipment. Fig. 5 shows an exhaust ramp at poor combustion quality. The controlled combustion at the burner ramps and the highly sophisticated oxygen management result in complete fuel and volatile combustion, so that the exhaust ramps as well as the main ducts right through to the fume treatment plant remain clean of Fig. 6: Exhaust ramp at optimised combustion excess soot and unburned pitch. This avoids all related maintenance and cleaning procedures. Avoiding cleaning procedures will also lengthen operation times and therefore reduce running costs and lower long term investment costs. Fig. 6 shows the boot and damper of the exhaust ramp on optimised combustion condition. Long lifetime of the burner: The high velocity, low NOx burner is especially designed for use in the anode baking furnace. The material used as well as the proven design ensures a long operation time, even when exposed to the severe conditions of furnace atmosphere and temperature. The expected operation lifetime will be more than five years. Since the first operation start (1999) all of the installed burners are still in operation and they perform much better than ever expected. Fig. 7 shows a burner after five years of operation without any maintenance. Customers’ long-term experiences concerning performance and maintenance aspects are in all respects positive. Long life solenoid valves: Due to the very high pulse frequency required for efficient burner operation in the baking furnace, Inno- Fig. 10: Thermocouple Type S with SIC tube ALUMINIUM · 1-2/2012 SPECIAL vatherm developed a long-life solenoid valve especially for this application. A standard solenoid valve available on the market lasts for approx. 4 million operation cycles at maximum. Innovatherm’s long life solenoid valve delivers more than 500 million (!) operation cycles. This ensures an almost maintenance free operation with an average lifetime of more than 12 years at a very critical point of the process, as shown in Fig. 8. Temperature measurement in the flues: All anode baking staff all over the world describe the temperature measurement inside the anode baking furnace as a constant maintenance issue. Normally people use thermocouples Type N with stainless steel protection tube. These have to be replaced on average every four months. And this not only because of the wear of the stainless steel protection tube, but also due to the enormous measurement drift of the type N thermocouple as shown in Fig. 9 at operation temperature of 1180 °C. So hundreds of thermocouples have to be checked and changed per year, which becomes an intensive issue in maintenance and cost. As also can be seen from the diagram above: the thermocouple type S is the only one which performs adequately in the operation temperature range of up to 1250 °C. This is why Innovatherm designed a special long life Silicon Carbide protection tube (SICsheath) which withstands thermal shocks and constantly changing temperature over a very long period (operation time of several years). By combining a low drift thermocouple with a long life protection sheath, the average lifetime of this temperature measurement was improved to more than four years. As a result clients are benefiting reduced overall running costs as well as minimised maintenance frequency and so realising an enormous operational advantage. Fig. 10 shows this type of thermocouple. Auto zero pressure transmitter: The continuous measurement and control of the negative flue pressure is essential for the performance of the anode baking furnace. Usually these pressure transmitters have to be checked and recalibrated on a frequent basis to maintain the required accuracy. To minimise calibration maintenance, the pressure transmitters used ALUMINIUM · 1-2/2012 A L U M I N I U M S M E LT I N G I N D U S T R Y on the exhaust ramps, as well as on the measurement and zero point ramps, are equipped with an auto zero calibration. The auto calibration function is triggered when energising of the unit as well as every hour, to ensure fully automatic recalibration of the unit. This function reduces to almost zero the specific maintenance activities for this calibration and improves the quality of control tremendously. Automation control and communication Wireless and Ethernet communication: The anode baking furnace is embedded in a rough ambient area. This coal dust environment is a big risk for sensitive equipment and for the whole communication system via network cables and plugs. This is a major maintenance issue. The only adequate solution therefore was to develop a complete wireless communication within the anode baking area. The communication is now moved into a clean and safe background location requiring much less maintenance activities. Duplicate process control: A standard control system always contains at least two PC stations running two independent, fully identical ProBake programmes. This dupli- WWW.BUSSCORP.COM The leading Mixing Technology for Anode Pastes 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. 49 A L U M I N I U M S M E LT I N G I N D U S T R Y one PC fails, the second (redundant) PC takes over the control within less than one minute, without any interruption and on full performance. The maintenance team has now plenty of time to repair or reconfigure the defective PC. Fig. 11 shows the duplicate PC equipment in the operators’ room of the baking area. Fig. 11: Duplicate control PC equipment for ProBake firing system cate control architecture is designed to ensure the maximum operation availability. In case Summary This paper indicated several technological parts of an anode baking process to address briefly the problems of the operation and possible improvements. All inventions and modifications as shown are the results of carefully designed technologies and longterm testing. Intensive communications with customers, frequent after sales visits and appropriate production observations have continuously improved the design and abilities, ensuring optimised product performance in all aspects of customers expectations. Authors Detlef Maiwald is managing director, Domenico Di Lisa is sales director and Peter Mnikoleiski is senior process specialist of Innovatherm GmbH + Co. KG, based in Butzbach, Germany. Contact: dmaiwald@ innovatherm.de Testing cell controller algorithms using a dynamic cell simulator M. Dupuis, GeniSim Inc. The two main tasks of an aluminium reduction cell controller are firstly to collect and process the raw cell amperage and voltage, and then secondly to use that information to manage the cell efficiency. For this it must send instructions both to the point breaker feeder in order to control the dissolved alumina concentration in the bath, and to the anode beam to control the Anode Cathode Distance (ACD). There is obviously a major advantage to be able to test a modification to the cell controller algorithms using a simulated cell instead of putting real cells at risk. This is true as long as the behaviour of the simulated cell is realistic enough to provide reliable feedback. In order to achieve that goal, the Dyna/Marc cell simulator has been continuously improved since 1994. It has already demonstrated its ability to reproduce measured cell dynamic evolution, as shown in previous publications [1, 2]. release. The level of the added noise is function of the ACD, the thickness of the metal pad, the amount of sludge and the fraction of the anode surface covered by frozen bath. This noise level, which can be made to affect current efficiency, can be reduced by automated voltage treatment since version 1.4 issued in 1999. The cell controller cannot directly use the noisy cell voltage to calculate the slope of the cell resistance, since this would lead to useless results. Since version 13.0 issued in 2011, Dyna/Marc offers linear and quadratic Root Mean Square (RMS) noise filtration algorithms [3]. Fig. 1 shows the comparison between the noise-free and the noisy evolution of the cell pseudo-resistance, which is the slope of the voltage/current curve. The purpose of the noise filtration algorithm is to allow the cell controller to use the noisy data so as to estimate the evolution of the slope of the noisefree curve. This slope can serve to estimate percent dissolved alumina and so to control the feeding rate. Fig. 2 compares the target noise-free slope evolution with three estimates of the slope evolution estimated using three Fig. 1 Since version 1.0 issued in 1998, the Dyna/ Marc has offered the option of adding noise to the amperage and voltage tracks in the simulation. For the cell voltage that noise is an output from the simulation. Thus at the end of each time step noise is added to the calculated noise free-voltage to present disturbances by the bath-metal interface motion and by bubble 50 Images: GeniSim Testing cell voltage noise filtration algorithms ALUMINIUM · 1-2/2012 SPECIAL different mathematical modes of noise filtration applied to Fig. 1. In Fig. 2 the first curve on the left results from linear RMS fitting using 60 datapoints that are themselves each an averaged value of the raw cell voltage measured over 5 seconds at a 10 Hz frequency. As can be seen, the resulting estimation is still a bit noisy. The second curve in the middle results from using 120 datapoints instead of 60 datapoints. The result is almost noise-free, but now the estimation is lagging 5 minutes behind the noise-free target slope that is being estimated. This is to be expected, as it is the best linear fit of cell voltage evolution using the last 10 minutes of datapoints collected, so it best represents the state of the slope 5 minutes ago. In the example presented in Fig. 2, the slope doubles in 5 minutes during a no-feed observation, so the estimated value is noise-free, but it is about half of the real value. The third mode of filtration on the right of Fig. 2 shows the result of quadratic RMS fitting, also using 120 datapoints. Quadratic RMS fitting of the cell voltage evolution eliminates the drag in the slope estimation, which is important, but for the same number of datapoints used, RMS generates a more noisy estimation. A L U M I N I U M S M E LT I N G I N D U S T R Y of the slope of the cell pseudo-resistance in blue. It also presents the estimated slope evolution that results from using linear RMS fit- ting with 60 datapoints, each datapoint being the results of 5 seconds cell pseudo-resistance evolution averages. At that time scale, the 2.5 Fig. 2 Fig. 3 Testing feed control algorithms These days, the majority of algorithms used to control alumina feed in aluminium reduction cell are based on continuous tracking or else on underfeeding and overfeeding cycles, where the shift from underfeeding to overfeeding is dictated by a trigger value, which is based on either the slope of the cell pseudoresistance or the slope of the cell normalised voltage. One of the earliest versions of that algorithm can be found in Fig. 3 [4]. That algorithm is available in Dyna/Marc simulator under the name Pechiney Tracking Feed Control [5]. The basic concept that lead to the development of that algorithm was the observation that the cell current efficiency is maximised by operating very lean in alumina, and so very close to the anode effect conditions. The algorithm then takes advantage of the fact that during underfeeding, the slope of the cell pseudo-resistance starts to rise significantly before the anode affect. Fig. 3 shows the results by running that feed control algorithm in Dyna/Marc. The top graphic shows the 24 hours evolution of the cell pseudo-resistance. Metal is tapped out at noon and anodes are changed at 18 hours. It can be seen that the cell is more noisy after the anode change. The middle graph shows the noise-free evolution ALUMINIUM · 1-2/2012 Fig. 4 51 A L U M I N I U M S M E LT I N G I N D U S T R Y minutes delay of the noise-free pseudo-resistance evolution compared to the estimated pseudo-resistance evolution is not noticeable, Fig. 5 Fig. 6 Fig. 7 52 but it does affect the timing of the feeding regime shift. The third, lowest graphic shows the feeding periods resulting from the algorithm decision. The underfeeding rate is 70% of the nominal feeding rate while the overfeeding rate is 140% of the nominal feeding rate. The overfeeding rate duration was set to 1 hour. As a result, the resulting evolution of the dissolved alumina concentration in the bath in the same graph varies from around 2% to around 2.5%, 2% being the alumina concentration that would trigger an anode effect. It is important to notice when the feeding rate is increased that the alumina concentration continues to decrease by about 0.1% before starting to increase because the alumina takes time to dissolve. That delayed response will trigger an anode effect if the increase in feeding regime is done too late; hence the importance of eliminating as far as possible the delay in the pseudo-resistance slope estimation. Fig. 4 shows the resulting 24-hour averaged specific power consumption and current efficiency: 12.96 kWh/kg and 94.71% respectively. It is now well recognised that this type of continuous tracking feed control algorithm achieves significantly increased current efficiency over compared with feed control algorithms which used a steady feeding rate most of the time. It is also well known that the shorter feeding cycle also increases current efficiency; this can be tested using the cell simulator. Fig. 5 shows results obtained using a shorter, 40 minutes overfeeding rate duration. As a result, the dissolved alumina concentration only varies from around 2% to around 2.3%. This leads to a predicted improvement of the current efficiency from 94.71% to 94.78%, and a slight increase of the specific power consumption to 13.01 kWh/kg if the ACD is kept constant. The demand feed control algorithm developed by Kaiser and implemented in Celtrol cell controller [6] is also available in Dyna/Marc. The same reduction of the feeding cycle study presented above can be repeated, this time using the demand feed control algorithm. Fig. 6 presents the base case results: 12.91 kWh/kg and 94.67% current efficiency, while Fig. 7 presents results for the case with shorter feed cycles: 13.09 kWh/kg and 94.65% current efficiency. Despite a very similar increase of the feed cycles and reduction of the range variation of the dissolved alumina concentration, the two algorithms predict different results on the global process efficiency: the current efficiency is hardly affected and the specific power consumption increases more. The reason for these differences is that with Kaiser algorithm, it was not possible to maintain the same average ACD and operating temperature, which both increased for the shorter cycles case. ALUMINIUM · 1-2/2012 ! " #$ % #& '! " #$ % #& & (! )*) )( ) )( A L U M I N I U M S M E LT I N G I N D U S T R Y Developing and testing new feed control algorithms A dynamic cell simulator can be even more useful for developing a completely new feed control algorithm without putting real cells at risk. One such innovative new feed control algorithm was recently tested using Dyna/Marc cell simulator: it is the in situ feed control algorithm [3, 7-9]. The main innovation of the new in situ feed control algorithm is that it can indirectly measure the concentration of dissolved alumina in the bath during a no feed track. It does this by numerically establishing the relationship between the alumina concentration and the slope of the normalised cell voltage. In fact, that correlation is implicitly used in all continuous tracking algorithms that monitor the slope of the pseudo-resistance (or the slope of the normalised cell voltage) to decide when it is time to shift from underfeeding to overfeeding. The cell simulator can quite easily verify that there is a unique correlation between the concentration of dissolved alumina in the bath and the slope of the normalised cell voltage, and can numerically establish that unique correlation if it exits. Fig. 8 presents the results by running the in situ feed control algorithm in Dyna/Marc for 24 hours. A no feed-track is called every 3 hours in order to evaluate the dissolved alumina concentration. Fig. 9 shows the correlation between the slope of the normalised cell voltage and the falling dissolved alumina concentration. At the top of the hysteresis loop, the black line is the fit of the average path during the tracking, and all 8 tracks follow the same trajectory. This is why the in situ feed algorithm can use the equation shown to establish the alumina concentration at the end of each track. So there is a unique correlation, because each track starts from identical conditions, the conditions the in situ feed algorithm is trying to maintain. The second innovation at the core of the in situ feed control algorithm is its use of the primary calibration surface [3], at the end of each track, to estimate the ACD after it has estimated the dissolved alumina concentration. Then, based on an estimated evolution rate of the ACD, that same primary calibration surface is used, together with an assumed ACD value, to estimate every 5 minutes the dissolved alumina concentration from the cell normalised voltage. Finally, a simple PID controller serves to maintain the estimated dissolved alumina concentration on its target value. In the example shown in Fig. 8, that target concentration was set to 2.25%. 54 Fig. 10 presents the results of a second run, calling for a track every 12 hours only, this time with the normal anode change event that was removed in the previous run in order to keep things more simple. The corresponding 24-hour averaged specific power consumption Fig. 8 Fig. 9 Fig. 10 ALUMINIUM · 1-2/2012 SPECIAL and current efficiency are: 13.02 kWh/kg and 94.77% respectively. Those results are quite similar to those obtained using the continuous tracking feed control algorithm with shorter cycles, but with far less risk of having anode effects. Conclusions The author hopes that this demonstration study highlights the value of using a dynamic cell simulator to optimise existing cell controller algorithms, and to test new ones, without putting real cells at risk. The Dyna/Marc cell simulator used in this study is available to the whole aluminium industry through GeniSim Inc. Version 13 included the linear and quadratic RMS noise filtration algorithms and the in situ feed controller algorithm. The Dyna/Marc cell simulator can also be used as a cell design tool, as demonstrated in [10]. A L U M I N I U M S M E LT I N G I N D U S T R Y References [1] I. Tabsh and M. Dupuis, ‘Process Simulation of Aluminum Reduction Cells’, Light Metals 1996, ed. W. Hale (TMS, Warrendale, Pa), 451-457. [2] M. Dupuis, I. Eick and F. Waldman, ‘Modelling Thermal Dynamic Response to a 3-Hour Total Power Shutdown Event’, 9th Australasian Aluminium Smelting Technology Conference and Workshops, (2007). [3] M. Dupuis and M. C. Schneller, ‘Testing In Situ Aluminium Cell Control with the Dyna/Marc Cell Simulator’, COM, (2011), to be published. [4] Y. Macaudiere, ‘Recent Advances in Process Control of the Potline’, Light Metals, 1988, ed. L. G. Boxall (TMS, Warrendale, Pa.), 607-612. [5] M. Dupuis and H. Côté, Dyna/Marc Version 13 User‘s Guide, (2011). [6] K. R. Robilliard and B. Rolofs, ‘A Demand Feed Strategy for Aluminium Electrolysis Cells’, Light Metals, TMS (1989), 269-273. [7] M. C. Schneller, ‘In Situ alumina feed control’, JOM, 61(2009)11, 26-29. [8] M. C. Schneller, ‘In Situ aluminum feed control’, Light Metals 2010, ed. J. A. Johnson (TMS, Warrendale, Pa), 563-568. [9] M. C. Schneller, ‘A new approach to alumina feed control’, ALUMINIUM, 86 (2010) 9, 98-102. [10] M. Dupuis and V. Bojarevis, ‘Retrofit of a 500 kA Cell Design into a 600 kA Cell design’, ALUMINIUM 87 (2011) 1-2, 52-55. Author Dr. Marc Dupuis is a consultant specialised in the applications of mathematical modelling for the aluminium industry since 1994, the year when he founded his own consulting company GeniSim Inc (www.genisim.com). Before that, he graduated with a Ph.D. in chemical engineering from Laval University in Quebec City in 1984, and then worked ten years as a research engineer for Alcan International. His main research interests are the development of mathematical models of the Hall-Héroult cell dealing with the thermo-electric, thermo-mechanic, electro-magnetic and hydrodynamic aspects of the problem. He was also involved in the design of experimental high amperage cells and the retrofit of many existing cell technologies. Contact: dupuis@ genisim.com Testing of carbon materials for research and industrial purposes Markus W. Meier, Raymond C. Perruchoud and Jean-Claude Fischer, R & D Carbon In 1986 Werner Fischer founded the new company R & D Carbon by a management buyout from Alusuisse, where he had headed the carbon research group since 1966. With a clear vision for the needs of the aluminium industry, he had formulated the following mission statement: “Through application of our long experience and know-how in anode technology and through our constant search to improve anode quality, we at R & D Carbon contribute substantially to lowering capital investment for aluminium smelters and to reducing their operating cost.” Together with his team, Werner Fischer defined six areas of work, which are still in operation today: • Research and development • Sales of laboratory test equipment and ALUMINIUM · 1-2/2012 numerous times, including several Light Metstandards als awards [6-8]. Comprehensive handbooks • Technical services were published that are considered today as • Bake furnace firing and control systems indispensable reference books for every per• Technology development son working in the carbon area or dealing with • Training and conferences. Fundamental research and development carbon related topics of aluminium smelters. To pass on the findings of its extended projects have been most important since the research and practical development projects, foundation of R & D Carbon. In the past 25 R & D Carbon regularly organises training years, seven PhD dissertations were completcourses for which the company has gained a ed in collaboration with universities in New particular reputation and recognition. Zealand, Switzerland and China. Their topics The international training course ‘Anodes covered fundamental questions related to an– from Raw Materials to Pot Performance’ is ode raw material characteristics and reactivity organised in Switzerland every second year behaviour [1], to green mill operation [2], to heat treatment during baking [3], to anode properties, and to anode burning, dusting and cracking behaviour [4], as well as an in-depth understanding of Chinese raw materials [5]. The results of these extended investigations were published as technical papers in renowned journals, for which R & D Carbon was honoured Werner Fischer, the founder of R&D Carbon Images: R & D Carbon R & D Carbon Ltd operates a worldwide unique pilot plant and laboratory to study virtually all carbonaceous materials used in the aluminium and steel industries. Sophisticated research projects are conducted in parallel with extensive testing of carbonaceous materials for a wide range of customers. This paper reviews the numerous activities and capabilities of the technology centre located in Sierre, Switzerland. 55 A L U M I N I U M S M E LT I N G I N D U S T R Y (the next course is scheduled for 8-12 October 2012) with participants from all over the world. Today’s focus of research As outlined above, in the first two decades since the foundation of R & D Carbon, the aims of research activities were mostly to improve the performance of smelter anodes so as to reduce carbon consumption and thus cost of producing aluminium. These investigations Attendees of the 2010 training course in Martigny are ongoing, as today’s changing quality of anode raw materials (lower coke density and lower QI in pitch) create new challenges that the industry has to deal with. With the introduction of graphitised cathodes in aluminium potlines, limited abrasion resistance became the determining factor for the pot life. This has activated a new research activity of R & D Carbon to investigate how alternative coke types can be used to make graphitised cathodes with higher abrasion resistance [9]. Currently various potential alternatives are being tested that promise significantly improved expected lifetime over ordinary graphitised cathodes. The steel industry is suffering from a shortage of needle coke to manufacture graphite electrodes. Emerging countries such as China, India and Russia produce and consume large quantities of graphite electrodes. For this they need ever more premium needle coke with a low coefficient of thermal expansion, as their steel industries install more ultrahigh-power Electric Arc Furnaces (EAF). But western countries and Japan cannot supply much more needle coke from their scarce feed stocks of low sulphur decant oil. Therefore in the years to come there is an urgent need to develop and produce first class coke by delayed coking of coal tar pitch so as to respond to the increased demand. 56 Pilot plant – from green coke calcination to electrode graphitisation ter machining the samples to 50 mm diameter rods, the final step is to graphitise them. The rods are placed in a lengthwise column for graphitisation in an 80 kW pilot furnace. The cores remain under pressure during the entire process. The incremental change in length of the sample provides vital information on their puffing behaviour in the temperature range of 1 200 to 1 700 °C and on their graphitisation pattern up to 3 000 °C. Needless to say that R & D Carbon uses its versatile pilot plant not only for research purposes, but also regularly conducts assessments or optimisation trials as part of the technical assistance to customers who manufacture or use carbon products. In its technology centre in Switzerland, R & D Carbon operates a most advanced pilot plant with a range of equipment that makes it unique worldwide. Pilot calcination: The choice of both calcining technologies and of the corresponding calcination parameters are of primary importance for the calcined coke quality. In the pilot plant of R & D Carbon, green coke can be calcined either in a rotary kiln or in a shaft calciner. This plant can produce up to 20 kg per hour using appropriate heat Laboratory: Reference treatment and resi- authority in carbon testing dence time so as to guarantee the correct When it comes to the characterisation of cardegree of calcination bon products, the test equipment installed in for each of the differ- the laboratory of R & D Carbon does not leave ent applications. any questions open. Virtually the entire array Preparation of of carbon materials used for the metallurgical green paste: The dry industry may be characterised using reference aggregate is prepared methods, as the following roster shows. through continuous sieving in fractions Green coke / Anthracite Standard methods and through continuous grinding in an air jet Ash content (%) ISO 8005 mill. The paste is mixed either in an intensive Elements XRF (%/ppm) ISO 12980 impeller mixer or in a sigma blade mixer. Sev- Hardgrove grindability index (-) ISO 5074 eral batches are mixed with different amounts Sieving analysis (%) ISO 12984 of binder so as to determine the best binder Volatile matter (%) ISO 9406 content. Water content (%) ISO 11412 Pilot forming of carbon artefacts: Depend- Calcined coke and crushed butts ing on the product type and application, the Air reactivity (%/min) ISO 12982-1 paste is formed in a bench scale press (50 mm App. Hg density (kg/dm3) DIN 66133 diameter), in a pilot scale press or vibrocom- Ash content (%) ISO 8005 pactor (147 mm diameter) or in a 400-tonne CHON analysis (%/ppm) ASTM 5291-02 extrusion press (80 mm rod). ISO 12981-1 CO2 reactivity (%) Pilot baking: The formed green carbon Crystallite size Lc (Å) ISO 20203 items are baked in an electrically-heated pilot Elements XRF (%/ppm) ISO 12980 bake furnace to a final temperature between 1 050 and 1 250 °C to remove the pitch volatiles and to increase the real density so as to achieve optimum physical and chemical properties of the final product. For Søderberg applications, the green paste is baked in a dedicated Søderberg baking furnace where the paste is baked under pressure. Forming area of pilot plant with vibrocompactor, extrusion press, pilot press Graphitisation: Af- and bench scale unit ALUMINIUM · 1-2/2012 SPECIAL Testing with high precision and capacity Grain stability (%) ISO 10142 Oil content (%) ISO 8723 ISO 8004 Real density in xylene (kg/dm3) Sieving analysis (%) ISO 12984 Spec. electr. resistance (μΩm) ISO 10143 ISO 10236 Tapped bulk density (kg/dm3) Water content (%) ISO 11412 Pitch Ash content (%) ISO 8006 Coking value (%) ISO 6998 Elements XRF (%/ppm) ISO 12980 Quinoline insoluble (%) ISO 6791 Real density in water (kg/dm3) ISO 6999 Softening point Mettler (°C) ISO 5940-2 Toluene insoluble (%) ISO 6376 Viscosity (mPas) ISO 8003 Water content (%) ISO 5939 Prebaked and Søderberg anodes, and butts Air permeability (nPm) ISO 15906 Air reactivity (%) ISO 12989-1 Apparent density (kg/dm3) ISO 12985-1 Ash content (%) ISO 8005 Binder content (%) ISO 14423 ISO 12988-1 CO2 reactivity (%) Compressive strength (MPa) ISO 18515 ISO 20203 Crystallite size Lc (A) Dyn. elasticity modulus (GPa) DIN 51915 Elements XRF (%/ppm) ISO 12980 Flexural strength (MPa) ISO 12986-1 Fracture energy (J/m2) RDC 184 Open porosity (%) ISO 12985-2 ISO 9088 Real density in xylene (kg/dm3) Spec. electr. resistance (μΩm) ISO 11713 Static elasticity modulus (GPa) ISO 18515 Thermal conductivity (W/mK) ISO 12987 Thermal expansion (10-6/K) ISO 14420 Cathode Air permeability (nPm) ISO 15906 ISO 12985-1 Apparent density (kg/dm3) Ash content (%) ISO 8005 Compressive strength (MPa) ISO 18515 Dyn. elasticity modulus (GPa) DIN 51915 Elements XRF (%/ppm) ISO 12980 Flexural strength (MPa) ISO 12986-1 RDC 184 Fracture energy (J/m2) ALUMINIUM · 1-2/2012 A L U M I N I U M S M E LT I N G I N D U S T R Y erate their own laboratory. But the test results provided by R & D Carbon are usually broader and are accompanied by an evaluation of current trends that are presented graphically. The short lead time makes it also interesting for plants, who could send the samples to their corporate laboratory. The third party opinion given in comprehensive reports is an important support for the responsible plant personnel in their decisions about raw material procurement and plant operation. Shipment certification and arbitration: Together with Aminco Resources, R & D Carbon has developed a business model to produce ‘Swiss Anodes Made in China’. Stringent specifications and technical support provided by R&D Carbon, starting with raw material selection and during the entire production, allows Aminco to offer world-class and consistent quality anodes. Since the late 1990s Aminco has supplied more than 1.5 million tonnes of baked anodes to customers all over the world. Samples of each shipment have been analysed in the laboratory of R & D Carbon to issue the quality certificate and to assure that the anodes meet the specifications. Many suppliers of coke, pitch and prebaked anodes, but also of special products (such as Søderberg briquets or ramming paste) appreciate the service of R & D Carbon for independTechnical assistance for a ent certification of their product shipments. broad field of customers The quality sheet as part of the technical report Indeed, R&D Carbon tests carbonaceous ma- brings an added value to their products, since terials for customers with completely different the specific advantages which the producer goals, but all of them rely on sound test results, claims become much more transparent. often combined with clear recommendations R & D Carbon is also regularly contacted as for optimisation. an independent party for arbitrage questions. Routine analysis for aluminium smelters as Either suppliers or consumers send samples part of a service agreement: Prebaked and Sø- for analysis to crosscheck whether products derberg anode plants regularly send samples meet the specifications. of anodes and raw materials for analysis of Plant audits and optimisation trials: Every the relevant properties at weekly, bi-weekly or major smelter decides at some stage to submonthly intervals. Often, these plants also op- mit its production site to an audit by an external party having the appropriate experience. For audits of the carbon area, R & D Carbon has gained a distinct reputation due to the clarity of the information it provides [10]. The systematic methodology of R & D Carbon involves taking samples at every relevant processing step along the material stream, from the The laboratory is kept clean and tidy to ensure impeccable testing conditions at all times anode raw material Open porosity (%) ISO 12985-2 Rapoport expansion (%) ISO 15379-1 Real density in xylene (kg/dm3) ISO 9088 Sodium vapour resistance (%) RDC 192 Spec. electr. resistance (μΩm) ISO 11713 Static elasticity modulus (GPa) ISO 18515 Thermal conductivity (W/mK) ISO 12987 Thermal expansion (10-6/K) ISO 14420 As well as the above mentioned carbon materials, R&D Carbon also analyses in its laboratory other special carbon materials, such as: • Ramming paste • Stub collar paste • Søderberg briquets for Si arc furnaces • Electrodes for steel production. Sophisticated research equipment and corresponding techniques are applied to link the macrostructure and bulk properties of the carbon materials to their porosity, crystallinity and microstructure. Among them, X-ray spectrometry and diffractometry, mercury pressure porosimetry and microscopy image analyser have been proven as very efficient tools in the laboratory of R & D Carbon. The combination of the long experience, specific know-how and wide range of infrastructure allows R & D Carbon to give a real added value to the technical services provided to its customers. 57 A L U M I N I U M S M E LT I N G I N D U S T R Y notice. Such activities may include a quick evaluation of raw material. The procurement department of a smelter may send some coke samples of a new supplier to check the compatibility with the existing raw materials. In such a case R & D Carbon conducts a full analysis of the new and of the reference coke, followed by a bench scale test which provides valuable information long before the potential new coke is Fischer today is as valid as ever. All employees of R & D Carbon are dedicated to serve the industry by providing the best possible products and services. For carbon testing, the address in Switzerland is a first choice. References intake to the potrooms. These samples are analysed in the laboratory of R & D Carbon for the relevant properties. The comparison of the properties with a vast database allows a judgement of each processing step in relation to the worldwide average and benchmark. Consequently, R & D Carbon can quantify the potential for improvement at every processing step based on neutral criteria. As an outcome of the plant audit, the smelter operator may decide that this justifies a dynamic process optimisation in the paste plant (DPO [11]) or bake furnace [12]. These are very powerful methodologies to boost production and product quality, often without any investment in hardware. In either case, the systematic tests conducted are based on a large number of samples. The samples generated during a plant audit and during a process optimisation exceed by far the capacity of an ordinary laboratory of a smelter. Therefore these samples are analysed in the laboratory of R & D Carbon that is equipped and prepared to examine large amounts of samples. Non-routine testing and evaluations: It is evident that many activities of the laboratory occur on an irregular basis and at short In 2011 R & D Carbon celebrated its 25th anniversary. From humble beginnings, the company now has a worldwide presence in the industry. A new generation of young engineers is taking over important tasks in the business. The mission statement defined by Werner [1] Sheralyn Hume, ‘Influence of Raw Material Properties’, R&D Carbon, Switzerland, 1993/1999 [2] Kirstine Hulse, ‘Raw Materials Formulation and Processing Parameters’, R&D Carbon, Switzerland, 2000 [3] Felix Keller and Peter Sulger, ‘Baking of Anodes for the Aluminium Industry’, R&D Carbon, Switzerland, 2008 [4] Markus W. Meier, ‘Cracking Behaviour of Anodes’, R&D Carbon, Switzerland, 1996 [5] Liu Fengqin, ‘Blending of Chinese Carbon Materials for the Production of Anodes for the Aluminium Industry’, R&D Carbon, 2004 [6] Werner K. Fischer and Raymond C. Perruchoud, ‘Influence of Coke Calcining Parameters on Petroleum Coke Quality’, Light Metals 1985, (TMS, Warrendale, Pa.), 811-826 [7] Sheralyn M. Hume, Werner K. Fischer, Raymond C. Perruchoud, James B. Metson and R. Terry K. Baker, ‘Influence of Petroleum Coke Sulphur Content on the Sodium Sensitivity of Carbon Anodes’, Light Metals 1993, (TMS, Warrendale, Pa), 535541 [8] Raymond C. Perruchoud, Markus W. Meier, Werner K. Fischer, ‘Survey on Worldwide Prebaked Anode Quality’, Light Metals 2004, (TMS, Warrendale, Pa), 573-578 [9] Raymond C. Perruchoud, Werner K. Fischer, Markus W. Meier and Ulrich Mannweiler, ‘Coke Selection Criteria for Abrasion Resistant Graphitized Cathodes’, Light Metals 2011, (TMS, Warrendale, Pa), 1067-1072 [10] Nils Einar Saue, Jon Ola Ystgaard, Jon-Inge Johannessen, Markus W. Meier and Raymond C. Perruchoud, ‘Improvement of Anode Paste Quality and Performance of Alcoa Lista’, Light Metals 2012 (TMS, Warrendale, Pa) to be published [11] Raja Javed Akhtar, Saleh Ahmad Rabba, and Markus W. Meier, ‘Dynamic Process Optimisation in Paste Plant’, Light Metals 2006, (TMS, Warrendale, Pa), 571-575 [12] Vinicius Piffer, Ciro Kato, Markus Meier, Raymond Perruchoud, and Peter Sulger, ‘Process Optimisation in Bake Furnace’, Light Metals 2007, (TMS, Warrendale, Pa), 959-964 Raymond Perruchoud, VP Research & Development: “The trickier, the more interesting.” Markus Meier, VP Technical Services: “We aim to surpass customer expectations.” Jean-Claude Fischer, Director: “Every day we strive for continuous learning and education.” Mobile laboratory shipped onsite for dynamic process optimisation DPO of paste plant 58 processed in the plant. Preliminary tests may be conducted when a plant experiences problems in its potrooms, such as a problem with carbon dusting or anode cracking. The information gained from these tests often gives valuable indications to help identify the potential root cause(s) of the problem. This allows a much more efficient resolution of the actual problem during the subsequent plant visit. Assuring testing accuracy: R & D Carbon regularly conducts round robin tests to support other laboratories and to ensure the accuracy of their measurements. For owners of laboratory test equipment from R & D Carbon, a support service is available for maintenance, repair and certification. This assures the comparability of the test results found on carbon materials. Outlook ALUMINIUM · 1-2/2012 SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y Anode handling and cleaning systems for modern aluminium smelters K. Williams, Advanced Dynamics Images: Advanced Dynamics the system that ties all From the storage building, green anodes are of the above independ- then conveyed and raised to the baking furent production plants nace operating floor, which is usually about together is the anode six metres above ground level. From there, the handling and cleaning anode handling system must re-orient the ansystem. Fig. 1 shows odes and group them into a suitable package a simplified process for furnace loading by the FTA crane. Usually, the anode handling system will include flow: This anode han- a furnace central conveyor which will deliver dling and cleaning sys- the packages of anodes adjacent to the furnace tem is made up of the section currently being loaded. From the bake following sub-systems: furnace central conveyor, anodes are picked (a) the green anode up by the FTA and deposited into the approprihandling system, (b) ate section of the anode baking furnace. the green and baked After the green anodes have been processed anode storage and through the baking cycle, the FTAs will remanagement system, move the now baked anodes from the bake pit Fig. 1: Anode block production process (c) the baked anode sections and deliver them to the baked anode handling system, (d) handling system. Baked anodes coming from the baked anode the furnace can be as hot as 450 °C and will cleaning system, (e) be covered with loose metallurgical packing ancillary equipment, coke. The baked anode handling equipment (f) level 0, 1 and 2 inte- must be designed to handle the hot anodes grated control systems and it must be able to work reliably with fallincluding the required ing coke deposits. Conveying equipment up to wired and wireless in- the cleaning machine will be equipped with terfaces with the GAP, either manual, semi-automatic or fully autothe FTAs, the anode matic packing coke recovery systems. stacker cranes and the If there are mixing problems in the GAP rodding shop. or if there are control problems in the ABF, Green anodes com- then baked anodes can become stuck or fused ing from the paste together. An optional feature in a modern anFig. 2: Typical green roller conveyor in anode storage building plant arrive at a steady ode handling and cleaning system is a baked A modern aluminium smelter depends on the rate and are usually pushed onto a roller con- anode splitter (Fig. 4). The splitter is a selfcontinuous supply of the pre-baked anodes, veyor from the anode cooling conveyor dis- contained hydraulic press that will develop which requires the following independent pro- charge system in the GAP. Roller conveyors, several tonnes of splitting force to ensure it turntables, 90 degree pushers, etc. transport transmits only separated baked anodes for duction and operation facilities: the anodes and then • The Green Anode Plant (GAP) which accumulate them in mixes the raw materials for carbon blocks groups for storage in and presses them into the proper shape the anode storage fafor the given technology cility. When a package • A bake furnace plant including anode of anodes is in position bake furnace (ABF), Fume Treatment for the anode storPlant (FTP), Furnace Tending Cranes age crane, the anode (FTAs) and firing systems management system • Green and baked anode storage facility, will signal the crane to usually fully automatic storage and retrieve these anodes retrieval using overhead cranes and will provide the (anode stacker cranes) • The rodding shop – the plant that removes crane with the storage address where it must the spent carbon from the used anode deposit them. See Fig. stems and welds new stubs and fixes new 2 of a roller conveyor carbon blocks to the cleaned-up stems for running through an an- Fig. 3: Anode conveyors, elevators and manipulators delivering green anodes return to the electrolytic cells. to bake furnace In a fully integrated and automated smelter, ode storage building. ALUMINIUM · 1-2/2012 59 A L U M I N I U M S M E LT I N G I N D U S T R Y Fig. 4: Anode splitter / separator Fig. 5: Anodes in the baking furnace delivery to the cleaning station. Before the baked anodes can be sent to storage or to the rodding shop, the anode cleaning system must remove all the loose packing coke adhering to them. This is done in a series of three or four steps depending upon the anode design. In the first step, the anode is pushed through a set of hardened steel scrapers that scrape the packing coke off of two of the four vertical faces of the anode block. In the second step, the anode is pushed Fig. 7: Anode cleaner dust enclosure 60 through a second set of scrapers (Fig. 6) which cleans the remaining two vertical surfaces as well as the top and bottom surfaces. The third step is hole cleaning which uses a rotating tool and an air blast to remove all packing coke from the anode stub holes. This hole cleaning machine can also be set-up to machine the bottom of the anode flat for optimal mating with the anode stems in the rodding shop. Fig. 5 shows how such anode hole deformation can occur in baking furnace. The anode cleaning machine with scrapers and hole cleaners may also incorporate a slot cleaner if the anode technology includes slots (which help gas to escape and so reduce anode effect and increase potroom efficiency). These slots can be pre-formed in the anode in the GAP. In order to contain dust and collect the cleaned off packing coke, the anode cleaning machine will have a dust enclosure (as seen in Fig. 7) and an associated dust collection system as illustrated in Fig. 8. In a state-of-the-art automated system, packing coke is collected and pneumatically conveyed back to the bake furnace for re-use in the baking process, and fine carbon dust is collected and pneumatically conveyed back to the GAP for recy- Fig. 6: Anode scraper section cling and re-use in making new green anodes. Clean, baked anodes leaving the cleaning machine are delivered to either baked anode storage or to the rodding shop via elevators, roller conveyors and other orientation manipulators such as turntables, pushers, etc. Complete anode handling and cleaning systems are integrated with state-of-the-art control systems that conform to customer-specific standards. In modern smelters where capacity exceeds 500,000 tpy, these systems can comprise of 150 to 200 individual pieces of equipment and thousands of I/O. The systems communicate with the GAP, ABF and rodding shop processes via an industrial control network. RF networking provides communication with the anode storage cranes and furnace tending cranes. The control system assures a fully automatic process flow, and it is the key component that ties all of the anode production processes together. Author Kevin Williams is the vice president of Business Development at Advanced Dynamics Corp. Ltd. He is a mechanical engineer with 24 years of experience in the design of mechanical and control systems, project management and solutions architecture of heavy duty automated material handling systems for the aluminium industry. Contact: [email protected] Fig. 8: Dust collection system ALUMINIUM · 1-2/2012 SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y Smelter logistics upgrade A. Wolf, Claudius Peters Projects The primary aluminium industry is one of the world’s most energy-intensive industries and also one of the most polluting. The use of aluminium can be largely attributed to its light weight. Its specific weight of 2.7 g/cm3 is approximately a third of that of other common metals such as steel. In combination with light weight, aluminium alloys can show very high strength in comparison with many other metals. In addition, the very good electrical and thermal conductivity and optical reflecting make aluminium very attractive to various industries. Today the global economy imposes a more severe competitive environment for aluminium production, requiring more efficiency through the entire production process. Competitive pressures are increasing steadily together with the cost of materials, personnel and transportation. Management must critically evaluate production processes to determine their effectiveness in bringing maximum value to customers at reduced cost. Management for aluminium production must also determine the best available technology and working practice to protect the environment in compliance with local and international laws. The energy and environmental constraints reconfigurate the value chain in the aluminium industry, leading to a ALUMINIUM · 1-2/2012 T1 T2 T3 T4 T5 T6 – – – – – – Ship unloader entry From ship unloader to primary silo Alumina transport to primary silo entry Alumina discharge from primary silo Alumina charge to day silo Alumina discharge day silo T7 – Transport from discharge day silo to GTC / FTP T8 – Alumina charge to secondary silo entry T9 – Alumina discharge from secondary silo to entry potroom T10 – Alumina distribution system in potroom T11 – Alumina potfeeding Fig. 1: Typical logistic overview material process chain with transition points (T1 – T11) To systematically identify the area(s) with the greatest potential for optimisation, we must consider the many systems and identified components of a typical aluminium processing plant, which are joined to processing systems with several transition points (Fig. 1). Each transition point in the processing system can have an effect – good or bad – on the quality of the material process chain. rapid increase in production cost. Stricter environmental regulations and the pressures to reduce capital expenditure (capex) and operational expenditure (opex) direct us to look at the entire production chain. There are various factors forcing the management of the processing aluminium plant to evaluate the plant performance. Listed below are some major factors which influence the value chain reconfiguration: • Energy consumption • Energy cost • Product quality • Raw material consumption • Raw material cost • High opex • Strict environmental regulations (reduced emissions output) • Technology employed (incompatible or outdated technology) • New and more energy-efficient technology • Production cost savings • Equipment life cycle • Replication (automation) • Operator (labour cost and training) • Increased competition. Establishing project requirements and objectives Images: Claudius Peters The fast-moving and growing global market, with its competitive pressures is forcing aluminium producers to raise output and quality within a short period of time. Smelters need to develop innovative tools to evaluate and improve the current status of their process control and to measure, track and analyse the entire process chain with all transition points. This will help to operate the plant cost-effectively and in an environmentally friendly manner. This investigation and analysis can be vital to enable an aluminium company to remain competitive in the industry and it will guide the decisions for technical improvement to and for investments in state-of-the-art technology. The evaluation of the current status and of new trends within the aluminium industry typically requires strategic planning through business development. This paper provides guidance for the decision making process for current and future plant activities. Fig. 2: Unloading station Typically, the need to upgrade or modernise an aluminium plant is identified by the plant management or a third party. An upgrade or modernisation project should be treated as any other project in terms of the formal application and approval process. The requirements of an upgrade or modernisation project should be written down in a project specification document. This document should include information about the project scope, estimated costs, project schedule (implementation and time frames) and priorities. It is essential to develop and conduct a project cost / benefit analysis to verify the overall budgetary estimate provided in the project specification. To understand the production plant process in the logistic overview material process chain a strong process and productivity analysis has to be performed to investigate the current status of operation. The task is to identify and determine the performance of single components and systems (breakdown) within the material process chain using process flow sheets and components and / or performance reviews. Summarised: save costs by reducing the production cost, increase the productivity, improve the competitiveness, identify the unnecessary process steps in the workflow and optimise the material flow. © 61 A L U M I N I U M S M E LT I N G I N D U S T R Y Fig. 3: Pneumatic conveying transport Case study and practical considerations for upgrade projects Transition point alumina unloading station: In the production process there are many transition points, as shown in Fig. 1. In our case study the alumina is delivered by train to the alumina unloading station of the aluminium smelter plant (Fig. 2). There is a known risk of spillage during the handling of alumina. To avoid alumina spillage it is important to use a closed sealed discharge system for the material transfer. Alumina spillage means material loss, leads to dust development, pollutes the environment and is a large loss of investment. Transition point pneumatic conveying: Either mechanical or pneumatic conveying systems can serve to transport alumina between different plant areas. The advantage of pneumatic conveying systems is that they simplify plant design and conveying routing, and that they are closed and therefore environmentally friendly. Disadvantages compared to the mechanical conveying are that the system inherently consumes higher power and tends to suffer increased wear. Alternatively Fig. 3 shows the ‘Fluidcon’, a pneumatic conveying system that substantially reduces these disadvantages. A system for handling and transporting alumina must be able to operate at extremely low transport velocity and relatively low energy consumption. Specific technical targets for the systems include: • No grain abrasion and no grain fracture • No increase in the portion of particles < 45 mm, which is critical for further processing • No segregation according to grain size; this means that the critical portion < 45 mm must not accumulate during transport or storage etc., neither spatially nor over time • Wear-resistant design and only low wear during operation • Dust-free operation • Up-to-date energy saving technology. The system must be able to start-up with full conveying line and to restart conveying an interruption by, for example, a power failure. 62 point feeding is a fully functional control of the alumina distribution process (Fig. 5) under the constant control of key parameters (input/ output). Feedback regulation of the cell ensures optimum distribution, using signals from the automated feeding system linked to the automated control system. The alumina distribution system serves to transport and distribute alumina and fluoride to the pot superstructures in the potroom (Fig. 6). Typically, a fume treatment plant is the upstream interface. This distribution should be an enclosed, self-regulating and unmanned system. Required is a controlled, smooth, uniform and dust-free transport of the material. To improve its performance, control of the material distribution should be supported by an automation system, ensuring that the cell pointfeeders inject just enough alumina at just the right time. The standard operating and control technology should include aan utomatic control system, an operation procedure manual and a supervisory management system. Starting up with a full line will not be a problem with a state-of-the-art conveying systems like Fluidcon (Fig. 4). Existing systems already used in the alumina handling process have proven that such restarts can be accomplished and they are now a standard procedure in many aluminium plants today. Transition point alumina storage silos: The purpose of the alumina silo (Fig. 5) is to store a large amount of alumina economically, safely and reliably. The silo design depends on the specified material and on the material properties, such as grain size, particle density and particle shape, fluidisation behaviour and moisture content. High capacity alumina storage silos are designed with the following features: Implementation in plant • dry and safe storage operation and validation • closed storage system • automated controlled charging and The principal strategy is to determine and esdischarging system tablish a data validation process so as to con• uniform storage pattern duct improvements in the entire process chain. • maximum storage capacity utilisation This will provide the measurement data and • prevent excessive dust development results which are the basis for selecting poten• avoid alumina segregation tial improvements, and for choosing energy• maintain the grain size distribution saving technology developed by the supplier • maintain uniform flow pattern. company. To improve performance, a supThe employed silo discharge technology en- plier company utilises in-house development sures a safe, automated and therefore con- with own R&D support as well as outsourcing trollable material flow into the process chain. to technology suppliers who provide proven The silo design influences the amount of dust ‘packages’ for design, operating systems and development and segregation. It will therefore training. have an impact on the alumina quality and so determine the overall silo performance. Transition point electrolysis feeding systems: The main challenge in improving the management of higher amperage pots is to ensure a precise and reliable automated alumina supply to electrolysis cells. Compared to existing alumina distribution Fig. 4: Typical pneumatic conveying system equipped with conveying systems, transition pipe ‘Fluidcon’ ALUMINIUM · 1-2/2012 SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y verification of inventory modifications are estimated from the current plant status and the potential performance results. Conclusions Fig. 5: Alumina distribution systems Capex financed plants often suffer from poor support from their technology suppliers (cheap and dirty), and therefore their opex is very high. Such plants could benefit from the opportunity to outsource individual design work to specialist engineering companies. The expected improvements and the necessary Whether operating a new state-of-the-art assembled production line or investing in modern technology to modify existing equipment, it is Fig. 6: Potroom imperative to record the performance of plant systems and components. Such records will support the decision-making process for current and future plant activities, especially with regard to investments in energy-saving technology developed by the technology and system supplier. Author Andreas Wolf is business development manager Aluminium with Claudius Peters Projects GmbH, based in Buxtehude, Germany. Contact: andreas. [email protected] Alliances in the aluminium industry Three leaders of high-performing alliances from WorleyParsons share their insights on achieving long term success for their customers BSL S. Clough, WorleyParsons Boyne Smelters Ltd Strategic alliances are often the method of choice for strengthening an enterprise’s position by increasing efficiencies and by accessing new or critical resources. For many asset operators, an alliance based on sustainable capital works is an attractive way of achieving the business growth they require. But with a high failure rate, ALUMINIUM · 1-2/2012 the viability of such growth strategies depends critically on a company’s alliance capability. Since the 1990s WorleyParsons has been heavily involved in alliances to deliver sustaining industrial projects within the aluminium industry, and it is considered a leader in this kind of alliancing within the resources sector. Shane Burns, together with Danie Swemmer on the customer side, manages the alliance for Boyne Smelters Ltd (BSL), Australia’s largest aluminium smelter, located near Gladstone in Queensland. BSL was commissioned in 1982, and the operating plant has grown extensively since then. The smelter underwent an AU$1bn expansion in 1997, introducing a third reduction line which increased aluminium production from 260,000 to more than 558,000 tpy. BSL currently employs around 1,400 staff and contractors. WorleyParsons has been an alliance partner since 2004. Chris Lovelock is alliance manager at Tomago Aluminium, one of Australasia’s leading aluminium smelters. Constructed in the early 1980s, at the time of first production it was the world’s first large-scale AP18 plant in the world, with two potlines and a capacity of about 240,000 tpy. Tomago Aluminium currently employs around 1,100 people and produces 530,000 tpy of aluminium. Ian Waterman was until recently the alliance manager at Hydro’s Kurri Kurri smelter, which commenced operation in 1969 and is located near Newcastle in New South Wales, Australia. Hydro produces various types of 63 A L U M I N I U M S M E LT I N G I N D U S T R Y ingots which are used to produce a vast range of products, including roofing materials, foil, truck bodies, boats, doors, windows, commercial shop fronts, cables, tubing. Current production capacity is approx. 180,000 tpy. Alignment, engagement and trust According to Shane Burns, being aligned with the customer’s goals and expectations for the business is the first step to building a successful alliance. The alliance team at BSL is an integrated team made up of BSL and WorleyParsons personnel. This is helpful for team alignment, but in Burns’ opinion, this level of alignment is just not enough. “Making sure the people on the team are all on the same page is critical, but you need to get right the fundamentals that come before the team is even formed. Understanding customer needs, and creating targets that will improve outputs to deliver to these needs, these are important if both parties are to be engaged, and it takes a lot of listening, open communication and planning,” he says. Trust, Ian Waterman says, is a vital part of the equation, and it can only be built over time, with shared successes and with the learning that comes from experience. “The whole concept of alliances can initially be daunting for some, especially those coming from corporate cultures where it’s normal to keep certain information close to one’s chest. Alliancing turns that whole paradigm on its head,” he says. While the Hydro alliance is not an integrated team model like the one at BSL, it emphasises transparency in information, from resource planning to how the customer is billed down to the last hour, and this is perhaps even more paramount to the process of building the level of trust needed to deliver outstanding results, according to Waterman. Chris Lovelock agrees that an alliance can only work for both parties if trust is built from the start. “There must be an atmosphere of trust that can only occur through the appreciation of each other’s goals. In that sense, a successful alliance is the purest example of win/win that comes to mind,” he says. WorleyParsons sees its expertise in alliance building as a valuable differentiator. Thus the teams that the company puts in place need not only capability of high calibre in regard to skill set, but they need to be also made up of people who thrive on growing their interpersonal leadership skills. Being a highly competent designer or project manager no longer depends wholly on technical skills. There has to be a willingness to learn from others and to be coachable, and this requires a level of hu- 64 mility and trust in others for which the stockstandard high performers of old are not always renowned. At BSL, the alliance operates as a one-team culture co-led onsite by Danie Swemmer on the BSL side and Burns as contractor lead, so there is no hiding from results or performance. This type of openness uncovers capability, but it also uncovers any weaknesses, and this is where the trust factor reaps dividends in learning and support. Burns explains: “When a weakness is highlighted, the culture of the team is to rally around to close any gaps that may be apparent. When the team’s interest is focussed on providing value to the organisation, then that support is a natural position for the team to take, and it really shows a mature relationship which is a rewarding thing to be a part of here.” Continuous improvement replacement at Tomago. The existing HTF blend (to heat anode paste in Paste Plants 1 and 2) had become degraded and required replacement within twelve months. The degraded fluid and the associated sludge were causing isolation valves to leak and were damaging existing seals and pumps. The alliance team engaged specialists from WorleyParsons’ oil and gas division, so as to document the existing HTF system and to recommend the best strategy to achieve the change-out. Working closely with Tomago, a cross functional team was engaged to develop a project execution plan and to seek the necessary funds to undertake the recommendations. The existing fluid was drained from the system and the extensive sludge build-up was cleared from the tanks and pipe work using newly installed hatches and drain valves. Finally, the system was completely flushed with a flushing fluid and then refilled with the new non-hazardous HTF. The HTF change-out was a success with no recordable injuries experienced throughout the project. This risk project was completed within an eight day shutdown and with no impact on the site’s aluminium production. “The overall project came in under budget, and with positive feedback from Tomago. Ready access to global experts within WorleyParsons was a massive advantage to the customer, and this helped the alliance identify further opportunities to take advantage of everything our entire company had to offer, not just within the alliance,” says Lovelock. Similarly, Waterman says one of the great advantages to the Hydro alliance is its ability An example of an improvement born from the BSL alliance is demonstrated by a large initiative (made up of quite a number of smaller initiatives) to improve how projects are delivered. The idea was to reduce the cycle time taken to get a potential cost saving project from an idea to the point where it is delivering value. In December of 2010, we set a target to reduce cycle time to 460 days from the average 495 they were then achieving. Fast forward to today, and the current 12 month rolling average for project cycle time stands at around 286 days, so delivering much faster returns. Successes like these are the bonus factor that adds value, and this success story will be shared more widely across industries at the next Leading Practices Forum in March 2012 – a knowledge sharing crossindustry conference initiated by Transfield Worley Services. An example demonstrated Members of the alliance leadership team at Boyne Smelters Ltd recently how Back row (from left to right): Glenn Hannan (superintendent – Growth Projects), John Rann (comthe power of missioning and start-up leader CBF 4), Graeme Byrne (manager – Growth Projects), Shane Smith (area – Reduction Services), Nathan Jones (area leader – Reduction Lines), James Roberts (area leader the alliance leader – Carbon), Dave Egner (specialist – Project Asset Management) yields results, Front row (from left to right): Scott Polkinghorne (superintendent – Construction), Mark Lord (area when a Heat leader – Plant Modifications and Process Support), Danie Swemmer (manager – Projects and EngineerTransfer Fluid ing), Shane Burns (alliance manager – WorleyParsons), Ben Vandenberg (function leader – Project (HTF) needed Controls and Pre-Engineering) ALUMINIUM · 1-2/2012 SPECIAL to tap into the Geelong centre of excellence in aluminium technology – a resource among many resources available as part of the global network of WorleyParsons experts. “There have been numerous examples over the years where we have been able to engage experts not normally associated with our projects at Hydro, the most recent case being the design of a flue wall building station. The innovative solutions that have come, hassle-free, from outside the alliance are seen as a great valueadd to our customer,” he says. A L U M I N I U M S M E LT I N G I N D U S T R Y put appropriate change management in place to control the situation. The customer likes to know we are managing their budget, and that way there are no surprises,” he says. Another measurable sign of successful alliancing is any improvement in safety. At the BSL alliance, the One Way to Zero Harm culture embraced by the company permeates everything from design to team meetings. At the time of writing, the BSL alliance team Advertisement Measuring success Swemmer and Burns lead an empowered group aligned by a shared vision at BSL – every project manager’s dream team. But how exactly does a successful alliance embed the behaviours driven by a set of shared values and goals? Burns is a big believer in measurement, and he insists that it is only through commitment to measuring performance on every level that success can be achieved. As prerequisites he lists having highly motivated leaders, along with having a set of performance metrics which are updated and discussed on a weekly basis, more often if necessary. “We measure very closely and openly things like cash flow, schedule delivery, staff turnover, budget performance and safety incidents. The performance metrics are updated constantly, and they are there in front of everyone. I can look out of my office and see the charts on the wall on display for everyone to see.” Waterman uses a purpose-built Leading Practices Control tool and he credits this as being a major factor in helping WorleyParsons’ performance to remain strong in the alliance. The tool provides real time data related to forecasting and cost scheduling, and is valuable not only from an individual project perspective but also for overall portfolio management. Waterman says this visibility is a huge advantage in identifying potential cost overruns. “The tool allows us to flag any problem areas so we can had achieved 2050 days injury-free including subcontractors under their control. This is an impressive statistic considering the harsh working environment and the nature of the activities performed on site. Both Swemmer and Burns are intent on avoiding complacency, and after a spate of near misses they have taken pro-active steps to maintain focus on safety. They called in Luc Herwin, sustainability manager and safety and risk specialist with WorleyParsons. Luc visited the site and reviewed a wide range of safety procedures and processes. He recommended a number of changes in communications, shutdowns hazards and contractor management. Along with this suite of recommendations, Luc also suggested tracking the Near Miss Frequency Rate, a leading indicator and measure of best practice across industries. buzzwords when it comes to running a successful alliance. Waterman recounts how, after the global financial crisis, the price of aluminium dropped and the Australian dollar spiked, which could have lead to unpleasant losses for both customer and contractor. “We were proactive and saw that we had to do more with less, so we immediately moved many of our people onto other alliances and projects within the business, without the customer having to ask for this. Alliancing essentially shields the customer from having to go through redundancies when economic factors dictate a reduction in capital projects and in associated engineering personnel,” he says. Burns highlights that another ongoing challenge can be staff retention, and he is pleased that in his team the turnover rates have dropped to less than 10%. “There is a sense of community here. Admittedly, it is a great place to live for people with families and for singles alike, but without job satisfaction there is no way our turnover would be so low,” he says. Waterman says that visitors often comment on the atmosphere at the Hydro alliance, and they leave energised by the enthusiasm exuding from a team fully engaged in delivering successful outcomes. Listening to Burns and Waterman talk about the importance of culture, it seems that successful alliancing is all about the quality of relationships, both those between individual colleagues, and those between customer and contractor. Has culture then, become more important than strategy? “I don’t know about that,” says Burns, “but certainly building a strong culture is part of our strategy for success. I don’t think you can ever separate the two.” Author Ongoing challenges Burns, Lovelock and Waterman all agree that the main challenge that keeps them on their toes is to ensure they are constantly able to demonstrate the value of the alliance to the customer. Flexibility and agility are not just Stuart Clough is WorleyParsons’ industry director – Aluminium. He has over 20 years of experience in the aluminium industry and has been involved in projects for Emal, Mozal, Rio Tinto Alcan Bell Bay, Hydro Aluminium Kurri Kurri and Tomago Aluminium. Stuart is currently based in Abu Dhabi. Contact: [email protected] Modelling cathode cooling after power shutdown M. Dupuis, Jonquière and A. Tabereaux, Muscle Shoals When a long power outage imposes a shut-down and restart of electrolysis cells at aluminium smelters, this causes irreversible and non-repairable damage to the cathodes. Experience has shown that this damage shortens pot life on average ALUMINIUM · 1-2/2012 by about 200 days, but the loss in pot life varies from 100 to 400 days at different aluminium smelters. Cooling cells to ambient temperature causes the formation of numerous and often deep cooling cracks on the top surface of the carbon cathode lining, both in individual cathode blocks and in the seams between blocks. The mechanism for the formation the cooling cracks has not previously been determined. Although there have been numerous publications regarding the pre- 65 Images: GeniSim A L U M I N I U M S M E LT I N G I N D U S T R Y Fig. 1: 1 metre length of transverse cathode cooling crack heating of cathode lining of aluminium electrolysis cells, this work represents the first to effectively model the cooling of cathode linings due to a power outage. It is also the first to report the extent and consequence of thermal gradients formed in the cathode lining during cooling, and to relate these to stresses and crack formation. Power interruptions at aluminium smelters: During the past ten years there has been an increase in the shutdown and restart of aluminum potlines due to long power interruptions (of more than three hours) at aluminum smelters [1]. Aluminium companies have been very successful in using amperage creep to increase productivity and profitability at most existing aluminium smelters. But this increase has come at a price, as it tends to shorten the lifetime of transformer/rectifier systems. For instance, the majority of long power interruptions were due to failure of the transformer/ rectifier systems, especially those at older aluminum smelters built 20 to 40 years ago. Harsh weather conditions, such as ice storms, snow and high wind velocity, are also major factors in causing long power interruptions, and are frequent in China during the Winter. A somewhat surprising development is that several modern high-amperage smelters (e. g. Fjardaal, Qatar and Dubal) have experienced recent shutdown of potlines due to failures at their power generation stations and/or in national grid system. Cooling the electrolyte to below 850 °C causes the bath to solidify and risks the shutdown of the operating cells. It requires a great deal of effort, prior planning and experience to survive power interruptions that last longer than three hours. However, it is astonishing that there are a few reported instances in which potlines have survived power interruptions of up to eight hours. Cathode cooling cracks: The rapid cooling of aluminium cells from an operating electrolyte temperature ~960 °C to ambient 25 °C due to potline shutdown generates cooling cracks on the cathode surface; this phenomenon is observed in almost all cells in which the solidified metal pads are removed and the surface cleaned for inspection. The cracks are certainly formed in the cathode block during cooling, and not during cell operation, because there is no bath or a yellow film of aluminium carbide on the surfaces of the cracks as shown in Fig. 1. The width of observed cooling cracks is generally from 1.6 to 3 mm and may extend the length of the cathode blocks (~300 cm). The distances between cooling cracks vary widely, but are typically found to occur about two cathode blocks apart. Fracture behaviour of carbon: The thermoelectro-mechanical behaviour of new cathode carbon has been described as elastoplastic [2]. Carbon cathode blocks initially behave elastically, with reversible deformation as stress is applied; however, when the stress continues to increase, the carbon material starts to behave in a more plastic manner, and undergoes irreversible deformation until fracture occurs. Micro-cracks can be Fig. 2: Average metal pad cooling rate, from the quarter cell model 66 generated during calcining and graphitisation of cathode carbon materials; but under compressive loading the micro-cracks tend to gradually close with volume contraction. Thereafter, when stresses become high, macrocracks are again initiated in the material and they begin to propagate until failure occurs. The cathode carbon is weakened as it undergoes ductile-brittle transformation during cell operation. The cathode lining eventually becomes saturated, (more than 3%) with interstitial sodium absorbed into the carbon lattice. This sodium causes swelling and changes the properties of the carbon lining, making the cathode material less ductile and more brittle. In addition, the cathode blocks are significantly weakened by micro-cracking caused by the diffusion of sodium into the carbon lattice. Thermal gradients in the cathode lining: This paper explains how rapid cooling of cathodes due to power interruption generates an uneven temperature distribution in the cathode lining. The temperature gradient results in a thermally induced mechanical stress which is sufficient to cause cracking. During cooling, the top of the cathode blocks cools faster than the bottom, resulting in large temperature gradients. Sørlie and Øye report that “due to the very limited elastoplastic deformation properties of carbon during rapid thermo-mechanical strain, the accumulated stress will be released as surface energy in the form of bottom cooling cracks” [3]. Cooling cracks weaken the carbon lining, as some of them may fill with aluminium upon restart; some cracks continue to expand and link up, and so become a basis for later pot failure. Thermal modelling results Cathode cooling rate: When a cell loses pow- Fig. 3: Temperature after 24 hours of cooling, from the 3D quarter cell model ALUMINIUM · 1-2/2012 SPECIAL er, it initially continues to dissipate the same amount of heat. But there is no more heat input, so the cell starts to cool down. The average cooling rate depends on the intensity of the heat loss, which itself depends on the operating conditions prior to the power shutdown, and on the cell’s thermal mass. Modern high amperage cells are typically designed and operated to maximise production, so they work at very high current density and correspondingly high cell superheat, with thin side ledge thickness and high side wall heat flux. As the authors demonstrated in [4], it is possible to model cathode cooling. The cell design and cell operating conditions used in that previous study were typical of early 1990 high amperage conditions, so the resulting cooling rate was correspondingly less than the rate recently measured [5]. Fig. 2 shows the average metal pad cooling rate measured on a retrofitted cell design with SiC side blocks. This cell operated at a higher current density and correspondingly higher superheat prior to the shutdown. Its average cooling rate is very similar to that shown in Fig. 10 of [5]. Fig. 3 presents the cell temperature distribution after 24 hours of cooling, calculated from the full quarter cell model, while Fig. 4 presents only A L U M I N I U M S M E LT I N G I N D U S T R Y the cathode panel temperature section. It can be seen that the temperature on the cathode panel surface is lower than that directly below at the collector bar level. Cathode cooling cracks: This cell cooling is sufficient to cause cooling cracks on the cathode surface. The cracks run mostly in the transverse direction of the cell, like the one shown in figure 1. A longitudinal tension stress of at least 8 MPa is needed to generate those cracks, according to the cathode block properties presented in [6]. It was not possible to predict that level of longitudinal tension stress in the previous study [4]. In that model, the cathode panel was prevented from deflecting down, but it was free to contract in both horizontal directions. By using this limited type of displacement constraint, the level of tension stress predicted was only around 2 MPa, which is about four times less than that required to generate cooling cracks. Yet, already in that previous study, the longitudinal tension stress was sufficient to generate cooling cracks when the 2D thermal stress model was solved in plain strain mode. Fig. 6 shows the longitudinal stress component obtained using the 2D thermal stress model in plain strain mode, using the thermal gradient after 24 hours, as shown in Fig. 5. Figure 5 is itself the result of the new transient analysis model which produces the faster cooling rate. As in the previous study [4], the thermal gradient used for the thermal stress analysis is the difference between the initial steady state temperature and the temperature calculated after 24 hours of cooling. When assuming plain strain, the 2D model does predict longitudinal tension stresses high enough to cause cracking, as it did in the initial study. But those results were then considered unrealistic, as they are based on the assumption that the cathode is restrained from shrinking longitudinally. After discussing the issue with Morten Sørlie, the authors reconsidered the situation; according to Sørlie, the collector bars which are anchored by the pier substantially prevent the cathode panel from shrinking freely in the longitudinal direction. Fig. 7 shows the longitudinal stress component obtained using the 3D quarter cathode panel model. This assumes that the collector bars prevent the vertical carbon faces in the slots from moving longitudinally. As can be seen in Fig. 7, this type of restraint generates enough longitudinal tension stress to cause transversal cracks. So it is safe to assume that as Sørlie pro- Fig. 4: Temperature of the cathode panel after 24 hours of cooling, from the 3D quarter cell model Fig. 6: Longitudinal stress component in the cathode block after 24 hours of cooling, from the 2D model Fig. 5: Relative thermal gradient in the cathode block after 24 hours of cooling, from the 2D model Fig. 7: Longitudinal stress component in the cathode panel after 24 hours of cooling, from the 3D quarter cathode cell model ALUMINIUM · 1-2/2012 67 A L U M I N I U M S M E LT I N G I N D U S T R Y poses, collector bars do substantially present the cathode panel from shrinking freely in the longitudinal direction of the cell. Looking to a cure to the cathode cooling cracks problem: In the previous study [4], it was suggested that since it is the metal pad that generates the reversed vertical thermal gradient in the cathode blocks, then tapping the metal pad as quickly as possible after the power shutdown should reduce the risk of cooling crack formation. This conclusion assumes that the tension stress and the corresponding cooling cracks arise because the cathode panel is not free to bend down. Under that assumption, reducing the intensity of the reversed vertical thermal gradient did significantly reduce the top surface tension stress. Yet, that stress intensity was already four times less than is required to produce cooling cracks! The new assumption is that the cathode panel as a whole, but more so the top section, wants to shrink, but that the collector bars anchor the bottom section of the cathode panel, so preventing it from shrinking. Under those conditions the only stress relief option left to the cathode panel is to generate cooling cracks. This was confirmed by model results. In a way, the cooling cracks problem was already identified in the previous study [4]: the cell lining design needs to be modified so as to avoid anchoring the collector bars in the pier region. A third study could demonstrate this stress reduction, assuming that there is a structural solution to this new collector bar design requirement. So far, such a solution is far from obvious. Conclusions This paper demonstrates that mathematical modelling can explain the cooling crack formation because the cathode panel as a whole tries to shrink, but the collector bars prevent this. The metal pad cools the top section of the cathode panel faster, which compounds the problem, but this is not the main factor. It therefore appears that only a cell lining design change can be expected to provide a cure. The aim of such a cell lining design would be to prevent the pier from rigidly anchoring the collector bars. References [1] A.T. Tabereaux, ‘Electrical Power Interruptions: An Escalating Challenge for Aluminum Smelters’, Light Metal Age 69 (2011)1, 26-32. [2] G. D’Amours, M. Fafard, A. Gakwaya, and A.A. Mirchi, ‘Mechanical Behavior of Carbon Cathode: Understanding, Modeling and Identification’, Light Metals 2003, ed. P. N. Crepeau (TMS, Warrendale, Pa.), 633-640. [3] M. Sørlie and H.A. Øye, ‘Cathodes in Aluminium Electrolysis,’ Aluminium-Verlag Marketing & Kommunikation GmbH, Düsseldorf, Germany, 3rd Edition 2010, 662 pp. [4] M. Dupuis and A. Tabereaux, ‘Modeling Cathode Cooling due to Power Interruption’, Light Metals 2012, (TMS, Warrendale, Pa) to be published. [5] K. F. Lalonde, W. Cotton and R. M. Beeler, ‘Rate of Metal Cooling in Aluminum Reduction Cell removed from Line Current – Method and Model’, Light Metals 2006, ed. T. J. Galloway (TMS, Warrendale, Pa.), 291-295. [6] J. Hop, A. Store, T. Foosnaes and H.A. Øye, ‘Chemical and Physical Changes of Cathode Carbon by Aluminium Electrolysis’, VII International Conference on Molten Slags Fluxes and Salts, The South African Institute of Mining and Metallurgy, (2004), 775-781. Authors Dr. Marc Dupuis is a consultant specialised in the applications of mathematical modelling for the aluminium industry since 1994, the year when he founded his own consulting company GeniSim Inc. (www.genisim.com). Before that, he graduated with a Ph.D. in chemical engineering from Laval University in Quebec City in 1984, and then worked ten years as a research engineer for Alcan International. His main research interests are the development of mathematical models of the Hall-Héroult cell, dealing with the thermo-electric, thermo-mechanic, electro-magnetic and hydrodynamic aspects of the problem. He was also involved in the design of experimental high amperage cells and in the retrofit of many existing cell technologies. Dr. Alton Tabereaux is a technical consultant in resolving issues and improving productivity at aluminum smelters since 2007. He graduated with a PhD in Chemistry from the University of Alabama in 1971 and then worked for 33 years as a manager of research and process technology for both Reynolds and Alcoa Primary Metals. He was Recipient of JOM Best Technical Paper Award in 1994 and 2000, editor of Light Metals in 2004 and received TMS Light Metals Distinguished Service Award in 2007. He is a lecturer at the annual International Course on Process Metallurgy of Aluminium held in Trondheim, Norway, and is an instructor at annual TMS Industrial Aluminum Electrolysis Courses. He has published over 65 technical papers and obtained 17 US patents in advances in the aluminium electrolysis process. Aumund cooling conveyor for hot bath material Aumund supplies equipment for handling raw materials in the cement, iron, steel and primary aluminium industries. In these industries, the handling of hot and abrasive bulk material needs custombuilt machinery to meet each customer’s specific requirements. The company has designed a cooling conveyor for the primary aluminium industry which provides full control of the cooling process for hot bath material. More than other materials, hot and abrasive bulk material is technologically most demanding to handle, especially when extremely hot. For this reason Aumund found its way into the famous Guinness Book of Records when 68 it’s Metallurgy division installed the longest bucket apron conveyor for 800 °C Hot Compacted Iron (HCI). The company has designed a cooling conveyor for the primary aluminium industry which provides full control of the cooling process for hot bath material. This hot bath material is charged from the pots at 800 to 900 °C into a hot bath crusher (SMV brand) Images: Aumund C. Niedzwiedz, Aumund Fördertechnik Fig. 1: Aumund cooling principle ALUMINIUM · 1-2/2012 SPECIAL Fig. 2: Example of fluoride emissions per minute from hot bath material and is then fed onto the cooling conveyor. Subsequently, the hot bath material is cooled down to between 300 and 100 °C, supported by the downstream equipment. Thanks to a specially designed hood on the Aumund cooling conveyor, the HF-gases emitting throughout the cooling can be collected and fed into the existing dry scrubbing system. The cooling conveyors are operating successfully today in several smelters throughout Europe. The flagship installation, the largest aluminium cooling conveyor, is being operated by Emirates Aluminium (Emal). Aumund has a history of providing custom-built conveying equipment. For nearly 90 years now, conveyor technology of the highest standard has been designed and built in Rheinberg, Germany, and supplied to the bulk handling business. Reliable, top quality products have established an outstanding reputation for themselves. The professional approach to customers’ individual challenges, and the efficiency of the solutions provided, are well acknowledged by the market. Some 12,000 references in over 100 countries, and spanning a wide range of industries, bear witness to that. Responsibility for equipment for the nonferrous industry sector, and particularly for primary aluminium production, is located in Aumund’s Metallurgy division. Benefiting from research, patents and long-term experience in the mining and steel sector, this equipment plays an important role in the aluminium industry today. The products have been constantly matched to the technical progress in the industry. Scope of supply includes bauxite and alumina handling both in refineries and primary aluminium smelters, as well as conveying and cooling of cryolite (hot bath material). Currently the company is developing a cooling system for dross in the primary and secondary aluminium industry, where the company has applied for a patent. Cooling is performed under inert atmosphere on a special cooling conveyor. The defined cooling of cryolite was jointly invented in 1995 when SØR Norge Alumin- ALUMINIUM · 1-2/2012 A L U M I N I U M S M E LT I N G I N D U S T R Y ium came up with a specific enquiry. Based on a problem Søral had in their Norwegian plant, Aumund, in conjunction with Søral’s engineering department manager and a Norwegian crusher expert, designed a new kind of conveyor to handle 850 °C hot bath material. The first step was a general analysis of the problem. An important aspect resulted directly from the production method: using the prebake technology, when anode butts are removed they take with them a substantial quantity of hot bath material. Until then, the fluoride-rich material was collected in containers and put to one side to cool on its own. The inherent problem was that owing to the large but variable amount of hot bath material in the containers, no prediction could be made as to when the bath lumps would reliably have cooled down to 100 °C or less. Even after 24 hours of cooling time, the bath material could still be too hot. Since the material must not be hotter than 100 °C before further processing, the cooling time is an important factor in efficient production. In addition, throughout this ‘natural’ cooling of the cryolite, the emerging fluoride gas escaped uncontrolled into the building. Applying forced convection to the containers did not have the desired success. When starting to develop a specific Aumund solution, the aim was to achieve a reliable final temperature of approx. 100 °C and an equally reliable duration of no longer than 12 hours in order to attain that goal. Prior to the cooling process, a specially designed crusher from the Norwegian company SMV processes the hot bath material and crushes it down to a lump size of about 200 mm. Below the crusher, the Aumund cooling conveyor receives the still red hot material. With a variable speed of between 0.15 m/min and 0.5 m/min the conveyor functions like a moveable storage and is able to adapt to the discontinuous operation of a smelting plant. In Norway the hot material needed a cooling conveyor featuring a 1,400 mm belt width and a length of 95 m. After that the about now 80 °C warm bath material was ready for further processing. In 2005 measurements proved that HF-gas evaporates into the environment at temperatures higher than 400 °C thus endangering employees’ health in the pot-room. The Aumund solution includes a suction device that extracts air already at the point where the 850 °C hot bath material is fed into the crusher. From here the HF-gas is fed into the existing dry scrubbing system. As the cooling progresses, the emissions decrease and finally become negligible at a material temperature lower than 400 °C. The cooling conveyor is covered by a hood Fig. 3: Covered conveyor at Trimet Aluminium in Essen, Germany, connected to a dry scrubbing system and connected to the existing dry scrubbing system through suction points. Measurements show that the suction system on average absorbs approximately 60 g/t of bath emissions during a 3-shift operation. When the first conveyor was being developed 2.1 t/h had to be cooled. Today the challenge has grown significantly. Today Aumund builds cooling conveyors which can handle up to 34 t/h. A conventional design for cooling capacities higher than 40 t/h would not make economic sense. The investment in infrastructure, civil work, etc. would be too great, if one includes all costs applicable to conventional technology, these being far more expensive than the proposed technology. Comparing only single subranges is not realistic, as the technical solution is highly complex. A serious comparison must include all stages, aspects and costs of alternative solutions, such as indicated below for cooling in skips. Based on these requirements, Aumund started investigations at a primary smelter in 2006. In Slovakia the Slovalco plant had already been operating the Aumund cooling conveyor since 2002. They gave permission to install a new conveyor section equipped with a data logger and six thermocouples. The data taken during normal operation of the primary aluminium smelter gave Aumund valuable results to use as a basis for new thermodynamic calculation software. This software (Fig. 4) has replaced the old conventional method of designing cooling conveyors, and it is based on parameters such as material layer 69 A L U M I N I U M S M E LT I N G I N D U S T R Y in conveyor length or airflow capacities in accordance with our customers’ references. The main purpose of this software is to reduce costs in infrastructure, such as avoiding the need to build bath skip storage for the period when baths are cooling prior to crushing. Skips for cooled baths are no longer necessary. This also avoids other operational costs, such as duplicate handling of skips, associated vehicles and their operators. The defined cooling of bath material removes nearly all of the fluoride gas by controlled suction. This draFig. 4: Conveyor section equipped with heat matically enhances clean bath handling, health protection box for data logger inside and safety conditions in the pot-room. The Aumund cooling conveyor for hot bath depth, airflow above the conveyor, number material can be designed with pan widths of of suction points, conveyor width, conveyor up to 2,400 mm and lengths of up to 200 m. speed and lump size of the bath material. An Side-plate height depends on the material layadditional option is to incorporate restrictions er depth. The cryolite can be cooled down from 850 °C to temperatures which allow safe operation of downstream equipment. The cooling capacity of cooling conveyors supplied has increased rapidly over the last few years (Fig. 6). In April 2009, the company supplied a cooling conveyor for hot bath material (Model: Aumund KZB-K 2400/250/6) with a centre distance of apFig. 5: Cooling curves for different thicknesses of bath material prox. 153 m for Emal. This cooling conveyor is the largest and longest conveyor of its type ever built; its capacity for this application is 34 t/h. With rising aluminium capacities, smelters need higher cryolite cooling capacity. Fig. 6: Evolution of cooling capacity: average capacity of new installations But still, in most plants space is restricted. To deal with that challenge Aumund has developed a new cooling technology with a cooling tower that combines the advantages of increased cooling capacity with a smaller footprint. It consists of several modules of the well-known deepdrawn pan conveyors Fig. 7: Aumund cooling tower flowsheet 70 arranged not one after the other, but on top of each other. They are specifically designed for efficient cooling. The number of modules combined in the tower depends on the capacity needed and on the outlet temperature required. As the air around each of the installed pan conveyors can be exhausted separately, cooling is a lot more efficient than with the long cooling conveyor version. In addition, several material transfers expose the hotter, interior layers so increase cooling efficiency. All in all, the Aumund cooling tower has a capacity of more than 40 t/h. Feeding is possible with a lifting system for bins or with Aumund pan conveyors (KZB). Employing a bucket elevator is not practicable because mechanical wear due to the grain size and the high temperature of the bath material would involve a great deal of maintenance work. Maintenance requirements are modest thanks to utilisation of Aumund’s standard conveyor technology. The tower is, however, equipped with maintenance doors to allow access to the relevant points in case of emergency. A walkway surrounds the cooling tower, so most of the maintenance and control duties can be performed without further technical support. A hood encloses most areas of the tower, both enhancing a long service life and protecting the steelwork. The Aumund cooling tower needs less than 75% of the space that a conventional cooling conveyor would require. A quite common dimension of this new equipment is 35 m long, 10 m high and 7 m wide. It in fact combines both higher cooling capacity and lower footprint. Plus, the cooling tower runs completely automatically, and so can be integrated into the plants’ automation systems. Conclusion Installing modified metallic pan conveyors for the cooling of hot bath material significantly improves the health and safety environment in pot-rooms. It combines clean bath handling with defined cooling of the bath material, and it removes the toxic fluoride gas by controlled suction. Reduced operating and investment cost have contributed decisively to the success of this product. Author Christian Niedzwiedz is project manager in the metallurgy division at Aumund Fördertechnik, based in Rheinberg, Germany. Contact: Niedzwiedz@ aumund.de ALUMINIUM · 1-2/2012 SPECIAL A L U M I N I U M S M E LT I N G I N D U S T R Y GAP Engineering A new global supplier of aluminium casting technologies Images: GAP C. Briguet, J. Valloton and M. Bolliger, Sierre Fig. 1: Vertical DC casting unit for rolling slabs, with metal level control in the mould (new plant) The continually increasing requirements for productivity and quality of foundry products require consideration in the design concept of the whole plant. This applies in particular to the choice of casting technology, to the mechanical design of the installation and to choosing suitable process automation (especially with regard to quality and product traceability). Process support during commissioning as well as possible later support in recipe development and optimisation are other important factors which contribute to an optimal technology transfer. This applies to new installations as well as Fig. 3: DC continuous casting unit for rolling slabs and for extrusion ingot ALUMINIUM · 1-2/2012 Fig. 2: Vertical DC casting unit for rolling slabs, with metal level control in the mould (retroffiting) to retrofitting of existing plants. To satisfy all installing new plant as well as for modernising of these requirements it is a great advantage existing plant. The competence in the area of to obtain the entire system from one supplier. aluminum is mainly concentrated on: Worldwide, there are not many suppliers who • casting machines can on the one hand offer their own casting • extrusion lines technologies, but also are willing to include • milling centres for thick plates the casting technologies from competitors • sawing centres when designing new plant or upgrading exist- • thermal processes (quenching, heat treatment) ing plant. For all these reasons, GAP (Global Auto- • induction furnaces. mation Process) Engineering SA decided, as In the field of casting techniques, engineers of from 1 Jan. 2011, to take over the activities GAP already contributed decisively in Alusuof the company Rihs Engineering AG, and at isse/Alcan to the development of Valcast 5, the same time to reinforce its capacity in cast- which in the meantime has been developed ing technologies. GAP Engineering and Rihs to the present GAPcast [2, 3], one of today’s Engineering have each been successfully ac- leading casting automation systems. Technological know-how of the various tive for many years in their traditional areas. For about 30 years Rihs Engineering was casting processes is important in realising the an exclusive engineering supplier of foun- projects. To consolidate this know-how, GAP dry equipment for the Technology Centre Engineering has contractually engaged several Alusuisse / Alcan in Chippis, which resold this equipment within the Alusuisse group and also to third parties. GAP Engineering was founded in 2000 by former Alusuisse employees with more than 15-years experience. The activities of GAP Engineering concern mainly the execution of global automation solutions for Fig. 4: EMC continuous casting unit for rolling slabs (new plant) 71 A L U M I N I U M S M E LT I N G I N D U S T R Y Fig. 5: EMC continuous casting unit for rolling slabs (retrofitting) process engineers with many years of professional experience in these processes. The task of these process experts is also to familiarise the employees of GAP Engineering with these different technologies and to train the customers’ employees when commissioning the equipment. In the previous structure before the merger, both companies have worked closely together, but as independent suppliers, to realise a large number of casting systems. These casting processes were for billet and slab casting (for hot-top or for electromagnetic casting, casting with floats or with liquid level regulation in the mould) as well as for strip casting. Fig. 1 shows a casting unit using Wagstaff moulds to produce five rolling slabs. This unit has an automatic level regulation in the moulds. The moulds can be rolled aside on a car, and the other casting equipment is also arranged to move out of the way, which greatly helps in the handling of ingots and equipment. The plant shown in Fig. 2 can cast 2, 3 or 4 slabs at a time. This plant is also equipped with automatic metal level control in the mould and with a mobile mould car. According to the product mix in a foundry, the continuous casting unit can also be installed so as to operate in different modes. Fig. 3 shows a DC continuous casting unit which, for instance, can cast extrusion ingots with float regulation or alternatively can cast rolling slabs using automatic metal level control in the mould. EMC casting (Electromagnetic Casting: a magnetic field prevents mould contact) also belongs to both companies’ expertise [1]. EMC is mainly used for alloys which tend strongly to hot cracking (2xxx, 7xxx) or to cold cracking (3xxx, 5xxx), and where the products must meet high quality requirements for surface and for internal structure. Fig. 4 shows a 6- 72 Fig. 6: Vertical EMC continuous casting unit for extrusion ingot fold EMC continuous casting unit which can also employ Wagstaff LHC moulds. This is a new casting unit. Fig. 5 shows an originally DC casting unit which has been modified for EMC casting. The use of EMC for very wide, oval extrusion billets allows a much higher extrusion speed, and hence productivity, thanks to the very thin surface segregation zone. In order to reach the same productivity, conventionally cast ingots generally need to be scalped (milled) on both flat sides to remove the much thicker segregation zone. Fig. 6 shows such a 6-fold casting unit with mobile moulds on a casting car. Together with a hot-top process, the project can in principle combine any of the casting units currently available on the market. To modernise existing roll caster or rotary caster units, customers can of course also call on the know-how of GAP Engineering (Fig. 7). Today, worldwide (in North America, China, Belgium, Germany, France, Greece, Iceland, Austria, Switzerland and Czech Republic) about 50 such different casting units are successfully in operation. By extending this range of offers, and in particular its technological know-how, GAP Engineering is now in a position to do technical work on the most diverse casting equipment, from the simplest Fig. 7: Rotary strip casting unit to the most complicated. Thus the process range includes practically all continuous casting processes which are now available on the market, whether for new plant or for modernising existing plant. This establishes a firm basis for a very flexible and competent treatment of the most diverse customer requirements. References [1] M. Bolliger and B.F. Prillhofer: EMC confirms its quality lead, Increase in capacity at Amag casting in Ranshofen, ALUMINIUM 86 (2010) 7-8, p. 44-47 [2] C. Briguet and M. Bolliger: GAPCast control makes aluminium vertical casting safer and more efficient, ALUMINIUM 87 (2011) 1-2, p. 56-58 [3] GAP Engineering SA: Description of GAPCast automation, 2010 Authors Christian Briguet is co-owner of GAP Engineering SA, a SME company located in Switzerland, in the heart of the Swiss Alps. He had worked for Alusuisse / Alcan Technology & Management Ltd in Chippis / Switzerland from 1996 to 2001 and participated in Valcast 5 development. After the closing of Alcan Technology & Management in 2004, he contributed to the development of the new ‘GAPCast’ automation concept and to its deployment. He designed and installed more than 30 casting machines (Valcast 5 then ‘GAPCast’) all around Europe. Contact: [email protected] Julien Valloton, mechanical engineer, is the general manager of Rihs Engineering AG. He is in charge for the transfer, maintaining and optimisation of mechanical engineering and process knowhow in casting technology at GAP Engineering. Martin Bolliger, a casting technology consultant, was formerly assistant vice-president of Alusuisse/ Alcan Technology & Management Ltd in Switzerland. He has designed and installed EMC [1] and conventional casting machines at many different sites and is an independent expert in this area. ALUMINIUM · 1-2/2012 TECHNOLOGY Verbesserungen der Dickentoleranzen an einem zweigerüstigen Aluminium-Kaltwalzwerk L. Witham, Alunorf; A. Brickwedde, ABB Automation Improvement of thickness tolerances for a two-stand aluminium cold rolling mill L. Witham, Alunorf; A. Brickwedde, ABB Automation The implementation of additional control loops to compensate backup roll eccentricity and harmonic hardness variation allows a significant improvement in strip thickness performance. These measures were successfully implemented as an automation extension to an existing twostand aluminium cold rolling mill at Aluminium Norf GmbH in Germany. An essential quality characteristic in the cold rolling sector is the minimum thickness deviation that can be achieved at final gauge, i. e. from the finishing pass. However, the need to maximise productivity requires that tight thickness tolerances have to be achieved even under sub-optimal mill and entry strip condi- tions. To meet this requirement there is a need for improved, intelligent control concepts. The analysis of a two-stand aluminium cold rolling mill has shown that process-related disturbances such as backup roll eccentricities and harmonic strip hardness variations can make it difficult to meet the target thickness tolerance. Backup roll eccentricity is not only the result of grinding and roll assembly tolerances, but can also be thermally induced during work roll changes and other stoppages. Strip hardness variation is less well understood, but an earlier ABB study has shown that for thin strip, cyclic hardness variations as small as 2% in the incoming strip can have a large impact on thickness deviation. Such hardness variations can easily occur in aluminium alloys as Regelungskonzept mit Erweiterung um die Funktionalitäten für Rec und Hdc (gelb) Control loops for eccentricity compensation (Rec) and hardness compensation (Hdc) Images: ABB Abb. / Fig. 1 Dickenabweichung Bandzug Walzspaltposition Moment Drehzahl V dv/dt En Ex Afc Geschwindigkeit Beschleunigung Eingang Ausgang Planheitsregelung dh Thickness deviation FT Tension S Roll gap position Tq Torque n Speed Tenff Tension feed forward v dv/dt En Ex Afc Velocity Acceleration Entry Exit Automatic flatness control dh FT s Tq n ALUMINIUM · 1-2/2012 Coi Haspelregelung Mdr Walzmotorregelung Rol Umlenkrollenregelung Dfc Zugregelung Zugregelung über ItcV Geschwindigkeit Coi Coiler control Mdr Mill drive control Rol Roll control Dfc Tension Control tcV Tension control via velocity Rgc Thfb Thff Rbc Rsc Walzspaltregelung Monitorregelung Dickenvorsteuerung Biegeregelung Verschieberegelung Rgc Roll gap control Thfb Thickness feedback Thff Thickness feed forward Rbc Roll bending control Rsc Roll shift control Rec Roll eccentricity control Der Einsatz von zusätzlichen regelungstechnischen Maßnahmen wie Stützwalzen-Exzentrizitätskompensation und die Kompensation von drehzahlharmonischen Härteschwankungen erlauben eine signifikant verbesserte Banddickenqualität. Erfolgreich umgesetzt wurden diese Maßnahmen als technologische Erweiterung an einem vorhandenen zweigerüstigen Aluminium-Kalzwalzgerüst bei der Aluminium Norf GmbH. Ein wesentliches Qualitätsmerkmal beim Kaltwalzen ist die nach dem letzten Stich err zielbare Dickentoleranz. Die Nachfrage und Notwendigkeit der Einhaltung von engen Dickentoleranzen ist vor allem auch bei nichtoptimalen Anlagen- und Vorbandzuständen zu erreichen. Um diesen Anforderungen gerecht werden zu können, besteht der Bedarf nach verbesserten, optimierten und intelligenten Regelkonzepten. Analysen an einem zweigerüstigen Aluminium-Kaltwalzgerüst haben gezeigt, dass durch prozessbedingte Störungen wie Stützwalzen-Exzentrizitäten und harmonische Härteschwankungen die Einhaltung der geforderten Dickentoleranzen problematisch sein kann. Stützwalzen-Exzentrizitäten können z.B. durch thermische Effekte verursacht sein. Eine frühere ABB-Studie hat gezeigt, dass bei dünnen Bändern Härteschwankungen von nur zwei Prozent für eine enge Dickentoleranz problematisch sein können. Solche Härteschwankungen können bei Aluminiumlegierungen durch ungleichmäßige Abkühlung leicht entstehen. Dabei ist die harmonische Härteschwankung synchron mit der Drehzahl des Bundes am Abwickler, und die Frequenz ändert sich bzw. wächst stetig auch bei konstanter Walzgeschwindigkeit, bedingt durch die Abhängigkeit der Drehzahl des Abwicklers von dem sich ändernden Bunddurchmesser. Die Besonderheit des gewählten Konzeptes zur Kompensation harmonischer Störungen besteht in einer aktiven reglerbasierten Lösung, die sich automatisch an die sich ändernden Randbedingungen der Anlage anpassen kann. Während bei der Kompensation von harmonischen Stützwalzen-Exzentrizitäten auf bereits erprobte regelungstechnische Konzepte zurückgegriffen werden konnte, wurde bei der Kompensation von derartigen harmonischen 73 TECHNOLOGIE a result of uneven cooling. Typically the hardness variation occurs as a soft (or hard) region on the circumference of the coil. The variation is thus synchronous with the rotational speed of the decoiler and the frequency increases steadily even at constant rolling speed, as the decoiler speed rises with decreasing entry coil diameter. The key feature of the selected approach for compensating harmonic disturbances is the use of active controllers which automatically adapt to the changing conditions of the system. While the use of active controllers to compensate harmonic backup roll eccentricities is well established, applying this concept to the compensation of harmonic hardness variations was a step in a new direction and presented new challenges. Therefore it was decided to first analyse, verify and optimise these concepts within the framework of a simulation study before implementation on the plant. Simulation study Simulationslauf mit Zuschalten der Exzentrizitätskompensation bei T = 70 s 1 Walzengeschwindigkeit [m/s] für Gerüst 1 und Gerüst 2 2 Einlaufdickenstörung basierend auf realen Messschrieben 3 Simulierte Stützwalzen-Exzentrizitätsstörung Auslaufdicke nach dem 1. Gerüst (grün mit Kompensation) 4 5 Auslaufdicke nach dem 2. Gerüst (grün mit Kompensation) Simulation run with activation of Abb. / Fig. 2 eccentricity compensation at T = 70 s 1 Roll speed [m/s] of Stand 1(blue) and Stand 2 (green) 2 Entry thickness disturbance based on actual measurement data 3 Simulated backup roll eccentricity disturbance 4 Exit thickness after the 1st stand (green: with compensation after 70 s) 5 Exit thickness after the 2nd stand (green: with compensation after 70 s) Härteschwankungen zusätzliches Neuland beschritten, denn die Härteschwankungen stellen eine besondere Herausforderung dar. Deshalb wurde entschieden, diese Konzepte zuerst im Rahmen einer Simulationsstudie zu analysieren, zu verifizieren und zu optimieren, bevor die Implementierung auf der Anlage erfolgen sollte. Simulationsstudie Im Rahmen der Simulationsstudie sollten die neuen Konzepte zur aktiven Kompensation der Dickenstörungen durch Stützwalzen-Exzentrizitäten (Rec) und harmonischen Härteschwankungen (Hdc) getestet und optimiert werden. Zu diesem Zweck wurde die zweigerüstige Anlage inklusive Ab- und Aufwickler und Regelung modelliert und simuliert. Die von ABB verwendete und entwickelte Simulationsplattform in „Matlab/Simulink“ ermöglicht eine skalierbare, modulare und dynamische Simulation von ein- und mehrr gerüstigen Walzanlagen zur Entwicklung und Analyse von neuen Regelverfahren. Die Anlage wird basierend auf Modulen wie Antrieb und Antriebsstrang, Walzgerüst, Auf- und Abwickler, Bandmaterial, Sensorik, Störgrößen, Regelung zu einer Gesamtanlage zusam- 74 mengesetzt und gemäß den realen Anlagenparametern parametriert. Die Regelung umfasst Antriebsregelung, Positionsregelung (Gerüst), Zugregelung und Dickenregelung inklusive Vorsteuerungen. Bei der Nachbildung der Sensorik für die Banddickenmessung wird die bandgeschwindigkeitsabhängige Transportzeit berücksichtigt. Für Auf- und Abwickler werden der variable Radius bzw. Massenträgheitsmoment, indirekte Zugregelung, der als Mehrmassensystem nachgebildete Antriebstrang und die Antriebsregelung simuliert. Für das Walzgerüst werden der Mehrmassen-Antriebsstrang mit den Walzen, die Antriebsregelung und die nichtlineare Verformung im Walzspalt nachgebildet. Die Nachbildung des Materialbandes berücksichtigt die unterschiedlichen Materialsteifigkeiten in Abhängigkeit von Material, Banddicke und -breite, die bandgeschwindigkeitsabhängige Transportzeit und das Tracking der Bunde und der Schweißnaht. Die Nachbildung von Störgrößen umfasst zum Beispiel Einlaufdickenstörungen, Störungen durch Härteschwankungen und Stützwalzen-Exzentrizitäten, Bundschlag von Auf- und Abwickler oder Reibungseffekte in den Walzgerüsten. Die Einlaufdickenstörungen werden basierend auf real an der Anla- Within the framework of the simulation study the new concepts for active compensation of thickness disturbances due to backup roll eccentricities (Rec) and harmonic hardness variations (Hdc) were to be tested and optimised. For this purpose the two-stand mill (Fig. 1) including decoiler, coiler and all relevant control loops was modelled and simulated. The simulation platform in ‘Matlab/ Simulink’ as used and developed by ABB enables a scalable, modular and dynamic simulation of single and multi-stand rolling mills for the development and analysis of new control concepts. The plant to be simulated is configured on the basis of modules, such as drive and drive train, mill stand, decoiler and coiler, strip material, sensors, disturbances and control loops, and is parameterised with the actual plant parameters. The control systems consist of drive control, position control (roll gap control), tension control and thickness control, including feed-forward control loops. In the modelling of strip thickness measurement the speed-dependent transport delays are taken into consideration. For the decoiling and coiling processes, the variation in radius and inertia over the strip length, the indirect tension control, the coiler drive trains (modelled as multi-mass and spring systems) and the drive controllers are all included in the simulation. The mill stand model includes the drive train with the rolls (as a multi-mass and spring system), drive controllers and the non-linear deformation in the roll-bite. The simulation of the strip takes ALUMINIUM · 1-2/2012 into account the varying stiffness depending on the material, strip thickness and width, the strip speed-dependent transport delay and the tracking of the coils and weld seam. The disturbances that are simulated include entry thickness disturbances, disturbances due to hardness variations and backup roll eccentricities, coil bump from the decoiler and coiler as well as friction effects in the mill stand. The thickness disturbances are entered into the simulation based on real data measured in the mill. The effective control of mass flow in Stand 1 is decisive for the strip thickness tolerance at the mill exit. For this reason backup roll eccentricity is especially critical in Stand 1. Analyses have shown that for hardness variations, compensation in both stands may be necessary. For the intended investigations, in addition to the existing control, new control loops for eccentricity compensation (Rec) (Fig. 1) and hardness compensation (Hdc) were implemented. The harmonic disturbances from backup roll eccentricities and hardness variations are detected and separated while rolling using a real-time analysis of the (from mass flow) calculated strip exit thickness in each stand. In a second step the Rec and Hdc controllers actively suppress these disturbances by feeding correction signals to the position reference of the mill stands. During this process, the compensation follows the changing frequencies as functions of both backup roll and decoiler speed. The hardness compensation presents a special challenge since the decoiler is constantly changing its rotational speed and therefore frequency even at constant rolling speed, due to the decreasing coil diameter. ge gemessenen Größen in die Simulation eingespielt. Entscheidend für die Dickentoleranzen am Auslauf ist die Beruhigung des Massenflusses bereits in Gerüst 1. Bei den Analysen hatte sich gezeigt, dass die Stützwalzen-Exzentrizität vor allem im Gerüst 1 ein Problem darstellt, während zur Härtekompensation eine Kompensation an beiden Gerüsten notwendig ist. Für die geplanten Untersuchungen wurr den daher zusätzlich zur bereits vorhandenen Regelung die neuen Regelkreise zur Exzentrizitätskompensation (Rec) (Abb. 1) und Härtekompensation (Hdc) implementiert. Die harmonischen Störungen von Stützwalzen-Exzentrizitäten und Härteschwankungen werden im Betrieb basierend auf einer zeitnahen Auswertung der über die Massenflussbeziehung erfassten Auslaufdicke nach dem jeweiligen Gerüst erfasst und separiert, und dann im zweiten Schritt mit Hilfe einer Regelung mit Aufschaltung der Korrekturgrößen zur Kompensation auf die Walzgerüstanstellung aktiv unterdrückt. Dabei folgt die Kompensation den sich ändernden Frequenzen als Funktion von Walz- und Abwicklergeschwindigkeit. Insbesondere die Härtekompensation stellt hier eine besondere Herausforderung dar, da der Abwickler seine rotatorische Geschwindigkeit und damit Frequenz auch bei konstanter Walzgeschwindigkeit laufend mit dem sich ändernden Bunddurchmesser ändert. Regelkreise zur Kompensation wurden vorr gesehen für die drei ersten Harmonischen von Stützwalzen-Exzentrizität und Härteschwankung, wobei die erste Harmonische typischerweise dominant ist. Kenndaten der Anlage: Aluminium, Al-Legierung Material MEHR PRÄZISION BANDDICKE& PROFIL laser-optisch mit thicknessCONTROL GESCHWINDIGKEIT & LÄNGE optisch mit ASCOspeed 3-Sigma-Dickenqualitätsverbesserung nach Aktivierung der neuen Regelung mit Auswertung von Fertigstichen (normiert auf UCL = Upper Control Limit). Abb. / Fig. 3 3-Sigma thickness quality improvement after activation of the new control based on evaluation of coils after the finishing pass (normalised to UCL = Upper Control Limit) www.micro-epsilon.de ALUMINIUM · 1-2/2012 Micro-Epsilon Messtechnik 94496 Ortenburg · Tel. 0 85 42/168-0 [email protected] TECHNOLOGIE Stützwalzen-Exzentrizität- und Härtekompensation Backup roll eccentricity and hardness compensation Exzentrizitäten und Härteschwankungen Abb. / Fig. 4 auf dem ABB-Automatisierungssystem 800xA (Controller AC 800PEC) implementiert und an die vorr handene ABB-Automatisierungsplattform MP200 (Master Piece 200) aus dem Jahre 1994 angebunden. Die notwendigen Messwerte wie Bandgeschwindigkeiten, Ein-/Auslaufdicken und rotatorische Geschwindigkeiten der Walzenantriebe und des Abwicklers wurr den parallel an den AC 800PEC Controller angebunden, um den hohen Anforderungen an die Zykluszeiten mit Zugriffszeiten von bis zu 2 ms gerecht zu Auswertung der Dickenqualität mit und ohne Evaluation of thickness quality with and without werden. Die PositionsKompensation von Stützwalzen-Exzentrizitäten compensation of backup roll eccentricities and harmonic hardness disturbances. und harmonischen Härtestörungen. Sollwerte zur Kompen1 Exit speed [m/min] 1 Auslaufgeschwindigkeit [m/min] sation werden als Zu2 2 Einlaufdickenabweichung vor Gerüst 1 [%] Entry thickness deviation before Stand 1 [%] 3 Auslaufdickenabweichung nach Gerüst 1 [%] 3 Exit thickness deviation after Stand 1 [%] satz-Sollwerte an die 4 Exit thickness deviation after Stand 2 [%] 4 Auslaufdickenabweichung nach Gerüst 2 [%] vorhandene MP2005 Compensation signal Stand 1 for Rec [μm] 5 Kompensationssignal Gerüst 1 für Rec [μm] 6 Compensation signal Stand 1 for Hdc [μm] 6 Kompensationssignal Gerüst 1 für Hdc [μm] Regelung übergeben. 7 Standard deviation exit thickness 7 Standardabweichung Auslaufdicke after Stand 1 and 2 [%] nach Gerüst 1 und 2 [%] Die Messdatenauswerr tung erfolgt über einen Bandbreite 1.600 – 2.150 mm vorhandenen IBA durch direkte Ankopplung Bundgewicht 29.000 kg über einen optischen Link an den Controller Bunddurchmesser 2.700 mm AC 800PEC. Eingangsdicke 0,7 – 3,5 mm Keine Unterbrechung des AnlagenbeAusgangsdicke 0,2 – 1,5 mm triebs: In einem Beobachtungsbetrieb konnten Max. Bandgeschw. 900 / 1.500 m/min die Funktionalitäten zur Exzentrizität- und Bandzug Einlaufseite 7 – 75 kN Härtekompensation parallel zum normalen Bandzug Auslaufseite 6 – 65 kN Betrieb überprüft und voroptimiert werden, ohne dabei den laufenden Betrieb der Anlage zu beeinflussen. Zusätzliche ÜberwachungsErgebnisse der Simulationsstudie funktionen wurden vorgesehen, um zum BeiDie folgenden Schriebe demonstrieren die spiel beim Ausfall von wichtigen Messgrößen im Rahmen der Simulationsstudie erfolgreich oder auch bei möglichen Unplausibilitäten durchgeführten Tests zur Kompensation von in der Erfassung oder Unterdrückung der Stützwalzen-Exzentrizitäten (Abb. 2) und harmonischen Störungen auf einen Backupharmonischen Härteschwankungen. Um die Modus umzuschalten oder gegebenenfalls die Verbesserungen zu verdeutlichen, wurde die Kompensation abzuschalten. Wird wieder ein Kompensation zu einem definierten Zeitpunkt normaler Betrieb erkannt, werden die Komzugeschaltet. pensationskreise automatisch und stoßfrei Implementierung auf der zweigerüstigen zugeschaltet. Kaltwalzstraße: Im Anschluss an die erfolgReaktion auf Ausfall der Bandgeschwinreiche Simulationsstudie erfolgte die Imple- digkeitsmessung: Eine Besonderheit ist der mentierung der Regelkonzepte an dem zwei- bei mehrgerüstigen Anlagen recht typische gerüstigen Kaltwalzgerüst. Zu diesem Zweck Ausfall des Zwischengerüst-Lasers zur Bandwurde die Regelung zur Kompensation von geschwindigkeitserfassung. Da das Signal zur 76 Control loops for compensation were provided for the first three harmonics of backup roll eccentricity and hardness variation, with the first harmonic typically being dominant. Plant characteristics Material Aluminium, Al-alloy Strip width range 1,600 – 2,150 mm Max. coil weight 29,000 kg Max. coil diameter 2,700 mm Entry thickness range 0.7 – 3.5 mm Exit thickness range 0.2 – 1.5 mm Max. stand speeds 900 / 1,500 m/min Strip tension entry side 7 – 75 kN Strip tension exit side 6 – 65 kN Results of the simulation study Fig. 2 shows one of the results of some of the tests that were successfully performed within the framework of the simulation study for compensation of backup roll eccentricities (Fig. 2) and harmonic hardness variations. In order to demonstrate the improvements, the compensation was activated after a defined time. Implementation on the two-stand cold rolling mill: After the successful simulation study, the control concepts were implemented on the two-stand cold rolling mill. For this purpose the new controllers for compensating eccentricity and hardness variations were programmed in the ABB Automation System 800xA (Controller AC 800PEC) and connected to the existing ABB Automation Platform MP200 (Master Piece 200) from 1994. The necessary process signals to be measured, such as strip speeds, entry / exit thicknesses and rotational speeds of the mill drives and the decoiler, were connected in parallel to the AC 800PEC controller to allow fast signal analysis with update times down to 2 ms. The position corrections for compensation are sent to the existing MP200 controller and added to the position references. Data collection is performed by an existing IBA PDA system, which was connected via an optical link to the AC 800PEC Controller. Uninterrupted mill operation: In observation mode the functions for eccentricity and hardness compensation could be monitored and pre-optimised in parallel to normal operation with no effect on the current operation of the mill. Additional monitoring functions were provided to safeguard against signal errors, e.g. to switch to a backup mode or deactivate the compensation should important signals fail or the evaluation or suppression of harmonic disturbances give implausible results. If normal operation is detected again, the compensation loops are automatically ALUMINIUM · 1-2/2012 TECHNOLOGY blue: old control strategy red: new control strategy Abb. / Fig. 5 Statistische 3-Sigma-Auswertung von Fertigbunden über einen längeren Zeitraum. (normiert auf UCL = Upper Control Limit). Statistical 3-Sigma evaluation of coils after the finishing pass over a longer time period (normalized to UCL = Upper Control Limit). and bumplessly reactivated. Response to failure of strip speed measurement: A special case that was considered is the typical failure of the interstand laser strip speed measurement due to oil or oil mist. Since this signal is used for the calculation of the exit thickness based on the mass flow for each stand, a failure would lead to deactivation of the compensation loops and this is certainly not desired. Therefore an alternative interstand strip speed is continuously calculated based on an online estimation of forward slip. The compensation loops are automatically and bumplessly switched to this estimated variable if the interstand laser speed measurement fails. This method was first verified within the framework of the simulation study and then implemented and successfully tested on the mill. The individual control loops for the compensation of harmonic disturbances were put into operation and optimised step by step, and here again it could be shown, as in the simulation study, that thickness disturbances due to eccentricity and hardness variations could be successfully suppressed and that the thickness deviation could be significantly reduced as a result. Results of disturbance compensation Several measurement plots demonstrate the improvements achieved in thickness quality with both backup eccentricity and hardness deviation compensation. The additional compensation loops were switched on or off while rolling actual coils to demonstrate the improvements due to the respective control loops. Furthermore, statistical evaluations over a longer period before and after the changeover verify the significant improvements achieved in thickness quality (Figs 3-5). ALUMINIUM · 1-2/2012 It must be taken into account that plant- or product-related quality problems can always occur, that have other causes than backup roll eccentricity or harmonic hardness variation. It is also true that harmonic disturbances from backup roll eccentricity or hardness variations are not dominant or present in all coils, and when these particular problems are not present, no reduction in thickness deviation from the additional controllers can be obtained. Fig. 4 shows an example of a coil with both backup eccentricity and hardness deviation errors. When activating the compensation for hardness variations (HdcPosAdd Stand 1), the lower-frequency components were suppressed in the exit thickness signal. When activating the eccentricity compensation (RecPosAdd Stand 1) the higher-frequency components were suppressed. Afterwards both compensation loops were switched off again. Fig. 3 shows improvements in 3-Sigma thickness quality after activation of the new control loops for compensation of eccentricities and harmonic hardness variations. The coils from 614 on were rolled with the additional new controllers active. The 3-Sigma quality improvement can be clearly seen and rises by approx. 20%. In Fig. 5 the thickness quality of coils after the finishing pass was evaluated over a longer period. Here again the improvements achieved in the exit thickness quality are clearly noticeable. The number of coils in the < 0.8 UCL (Upper Control Limit) tolerance band was increased from 72 to 92%. Summary Two new control concepts for the active suppression of typical harmonic disturbances in single and multi-stand rolling mills were suc- zeitnahen Erfassung / Berechnung der Auslaufdicke nach den Gerüsten über die Massenflussbeziehung verwendet wird, ist eine ausfallbedingte Abschaltung der Kompensationskreise natürlich unerwünscht. Daher wird über eine Online-Schätzung eine Zwischengerüst-Bandgeschwindigkeit berechnet. Auf diese Schätzgröße werden die Kompensationskreise bei Ausfall der Lasermessgröße automatisch und stoßfrei umgeschaltet. Auch dieses Verfahren wurde zuerst im Rahmen der Simulationsstudie verifiziert und dann auf der realen Anlage implementiert und erfolgreich getestet. Die einzelnen Regelkreise zur Kompensation der harmonischen Störungen konnten Schritt für Schritt in Betrieb genommen und optimiert werden, und auch hier zeigte sich, wie bereits in der Simulationsstudie, dass die durch Exzentrizität und Härteschwankungen verursachten Dickenstörungen erfolgreich unterdrückt und damit die Dickenqualität wesentlich verbessert werden konnte. Ergebnisse der Störgrößenkompensation Zahlreiche Messschriebe verdeutlichen die Verbesserungen in der Dickenqualität mit und ohne Kompensation. Auch hier wurden zur Veranschaulichung der Verbesserungen die jeweiligen zusätzlichen Regelkreise zu- bzw. abgeschaltet. Zusätzliche statistische Auswerr tungen über einen längeren Zeitraum vor und nach dem Umbau belegen die deutlichen Verr besserungen in der erzielten Dickenqualität (s. Abb. 3-5). Dabei ist zu berücksichtigen, dass es grundsätzlich immer zu anlagen- oder produktbedingten Problemen kommen kann, die jedoch nicht ursächlich mit der Kompensation im Zusammenhang stehen, und dass nicht bei allen Bunden die harmonischen Störungen von Stützwalzen-Exzentrizität oder Härteschwankungen dominant oder vorhanden sind, das heißt dass in diesen Fällen natürlich auch keine Verbesserungen erzielt werden können. Abb. 4 zeigt beispielhaft: Beim Zuschalten der Kompensation der Härteschwankungen (HdcPosAdd Stand 1) werden die niederr frequenteren Anteile im Dickensignal unterr drückt. Beim Zuschalten der Exzentrizitätskompensation (RecPosAdd Stand 1) werden die höherfrequenten Anteile unterdrückt. Danach wurden beide Kompensationen wieder abgeschaltet. Abb. 3 zeigt die Verbesserungen in der 3Sigma-Dickenqualität nach der Zuschaltung der neuen Regelkreise zur Kompensation von Exzentrizitäten und harmonischen Härr teschwankungen. Die Bunde ab 614 wurden 77 TECHNOLOGIE cessfully implemented and tested. The concepts for backup roll eccentricity compensation and for the suppression of harmonic hardness variations were first analysed and verified within the framework of a simulation study and then implemented and tested under real plant conditions. The additional technological controllers have been in successful operation for more than a year and statistical evaluations have demonstrated a considerable improvement in the exit thickness deviation achieved. mit zusätzlicher neuer Regelung gewalzt. Die Verbesserungen in der 3-Sigma-Qualität sind deutlich zu erkennen und verbessern sich um circa 20 Prozent. In Abb. 5 wurde eine Auswertung der Dickenqualität von Fertigbunden über einen längeren Zeitraum durchgeführt. Auch hier sind die erzielten Verbesserungen in der Auslaufdickenqualität eindeutig zu erkennen. Die Anzahl der Bunde im < 0,8 UCL-Toleranzband konnte von 72 auf 92 Prozent erhöht werden. getestet werden. Die Verfahren zur Stützwalzen-Exzentrizitätskompensation und zur Unterdrückung von harmonischen Härteschwankungen wurden zuerst im Rahmen einer Simulationsstudie analysiert und verifiziert und dann unter realen Anlagenbedingungen implementiert und getestet. Die zusätzlichen technologischen Regelkonzepte sind seit mehr als einem Jahr erfolgreich im Einsatz, und die statistischen Auswertungen demonstrieren die deutlichen Qualitätsverbesserungen in der err zielbaren Auslaufdicke. Authors Zusammenfassung Autoren Lawrie Witham, Aluminium Norf GmbH, Neuss. Contact: [email protected] Axel Brickwedde, ABB Automation GmbH, Mannheim. Contact: [email protected] Zwei neue Regelkonzepte zur aktiven Unterdrückung von typischen harmonischen Störgrößen in ein- und mehrgerüstigen Walzstraßen konnten erfolgreich umgesetzt und Lawrie Witham, Aluminium Norf GmbH, Neuss. Kontakt: [email protected] Axel Brickwedde, ABB Automation GmbH, Mannheim. Kontakt: [email protected] MicroStream-Strömungsschleifen für präzise Endbearbeitung Zunehmende Miniaturisierung sowie steigende Anforderungen an Oberflächen und Funktionskanten führen dazu, dass herkömmliche Verfahren zur Bearbeitung der Werkteile oftmals nicht ausreichen. Zudem steigen die Anforderungen an die Standfestigkeit der Teile im gleichen Maße wie die Toleranzen in der Fertigung kleiner werden. Das „MicroStream“Strömungsschleifen der Micro Technica Technologies GmbH aus Kornwestheim bietet hier höchste Wiederholgenauigkeit und Prozesssicherheit. Charakteristisch für das Verfahren ist, dass die Herstellung des Flächenkontaktes zwischen Werkstück und abrasiven Medium ohne ein formübertragendes Gegenstück zustande kommt. Damit ist das Strömungsschleifen (auch Druckfließläppen genannt) auch dann einsetzbar, wenn konventionelle Verfahren durch konstruktiv bedingte Einschränkunken scheitern. Das Strömungsschleifen ermöglicht die Bearr beitung von innenliegenden Oberflächen und das Entgraten an schwer zugänglichen Stellen. Im Vordergrund stehen dabei eine bessere Wirtschaftlichkeit sowie Präzision und Standfestigkeit der Werkstücke. Micro Technica Technologies hat ein spezielles, hoch viskoses Schleifmittel (Streamer) entwickelt, das aus einem Polymer-Kunststoff sowie Schleifkornanteilen besteht. Die Kunststoffmasse dient als flexibles Trägermaterial für 78 das Schleifmittel, das je nach Aufgabenstellung und zu bearbeitendem Werkstoff unterschiedlich gekörnt und konzentriert sein kann. Dieser Streamer wird mit speziellem Druck in und über das Werkstück oder Bauteil gelenkt und beginnt dort mittels der Strömung, die durch die Hubbewegung der Maschine entsteht, seine gezielte abrasive Tätigkeit. Das Ergebnis ist eine äußerst feine und glatte Struktur der Oberfläche. Das so bearbeitete, entgratete und geschliffene Werkstück ist präzise gerundet und nahezu frei von Reibungswiderständen und sonstigen störenden Einflüssen. Die MicroStream-Schleifmaschine hat zwei Aufgaben: das Klemmen der Werkstückaufnahme sowie das Pumpen des Mediums. Der MicroStream flow grinding for high-precision finish machining The result if increasing miniaturisation and stricter demands relating to surface quality and functional edges is that conventional workpiece machining methods are often inadequate. Moreover, the demand for component endurance is increasing while at the same time manufacturing tolerances are becoming smaller. For many applications the ‘MicroStream’ flow grinding process developed by Micro Technica Technologies, offers maximum reproduction accuracy and process reliability. A feature of the method is that surface contact between the workpiece and the abrasive medium takes place without any shape-imparting counter-component. Thus, flow grinding (also known as pressure-flow lapping) can be used even when conventional methods are excluded because of restrictions imposed by design. Flow grinding enables internal surfaces to be machined and deburred in areas where access is difficult. Its major advantages are greater economy, workpiece precision and endurance. Micro Technica Technologies has developed a special, high-viscosity grinding medium (known as the streamer) which consists of a polymer plastic containing grinding grain fractions. The plastic mass serves as a flexible vehicle for the grinding medium, whose grain size and concentration can be varied according to the task concerned and the material to be machined. The streamer is directed into and over the workpiece or component at a controlled pressure, where by virtue of the flow produced by the stroke movement of the machine it begins its targeted abrasive action. The result is an exceptionally fine and smooth surface structure. The workpiece machined, deburred ALUMINIUM · 1-2/2012 Abbildungen: g MicroStream TECHNOLOGY MicroStream-Strömungschleifen vorher und nachher MicroStream flow grinding before and afterwards and ground in this way is rounded off precisely and is virtually free from frictional resistances and other interfering effects. The MicroStream grinding machine has to do two things: clamp the workpiece holder and pump the medium. The streamer is, as it were, a ‘tool’ specially formulated for the application concerned, which circulates in a closed circuit within the machine. The streamer for deburring contains an additive which envelops individual grinding grains present in the polymer with a protective film during laminar flow. This film prevents detectable material removal from surfaces contacted by the medium. At the instant of a change in direction, however, as happens for example at an edge, due to inertia a point of the grinding rain breaks through the protective film and can cut material away. After the direction change the grain is enveloped again and the protective film acts as before. A grinding medium with these properties is ideal for the finish machining of high-precision components without adverse effect on existing tolerances in the μm range. A more frequent change of the flow direction results in uniform radius formation on the geometry being ground. For components requiring precise deburring of areas not easily accessible, along with the production of an excellent surface finish, MicroStream grinding is particularly suitable. A decisive factor for the technical development of the flow grinding process more than ALUMINIUM · 1-2/2012 Streamer ist hierbei ein speziell für den jeweiligen Anwendungsfall hergestelltes „Werkzeug“, das in einem geschlossen Kreislauf innerhalb der Maschine zirkuliert. Der Streamer zum Entgraten enthält einen Zusatz, der das einzelne im Polymer befindliche Schleifkorn bei laminarer Strömung mit einem Schutzfilm umgibt. Dieser Film verhindert auf mediumkontaktierten Flächen messbaren Werkstoffabtrag. Im Moment der Richtungsänderung, wie er beispielsweise an einer Kante erfolgt, tritt aufgrund der Trägheit eine Spitze des Schleifkorns aus dem Schutzfilm aus und kann Material spanend bearbeiten. Nach der Richtungsänderung wird das Korn wieder umhüllt und der Schutzfilm wirkt wie zuvor beschrieben. Ein Schleifmedium mit diesen Eigenschaften ist hervorragend zur Endbearbeitung hoch genauer Bauteile geeignet, ohne dass bestehende Toleranzen im μm-Bereich verletzt werden. Ein häufiger Wechsel der Fließrichtung ergibt eine gleichmäßige Radienbildung an der geschliffenen Geometrie. Für Bauteile, bei denen präzises Entgraten von schwierig zugänglichen Stellen und das gleichzeitige Erzeugen einer hochwertigen Oberfläche gewünscht wird, ist das MicroStream-Schleifen besonders geeignet. Ausschlaggebend für die technologische Entwicklung des Strömungsschleifverfahrens vor mehr als 30 Jahren waren erhebliche Unzulänglichkeiten bei der Bearbeitung innenliegender Werkstückgeometrien wie Bohrungsverschneidungen und Durchbrüche unter Verwendung konventioneller Fertigungsverfahren. Prinzipiell hat sich an der Aufgabenstellung bis heute nichts geändert. Aus der verfahrensimmanenten Möglichkeit der flexiblen Anpassung an bestehende Werkstückgeometrien und deren Bearbeitung resultiert auch das Gros an Einsatzfällen. Die konstruktive Auslegung der zur Innenbearbeitung genutzten Vorrichtungen kann aufgrund der Werkstückgeometrie auf den Einbau kostenintensiver, weil stark mediumkontaktierter, querschnittsreduzierender Kerr ne verzichten. Der kleinste Querschnitt mit der höchsten Fließgeschwindigkeit und dem stärksten Materialabtrag ist im Werkstück lokalisiert. Daher unterliegt die Vorrichtung keinem verfahrensbedingten Verschleiß. Insgesamt besteht die Vorrichtung aus weniger Einzelteilen und ist mit geringerem Fertigungsaufwand als eine Vorrichtung zur Außenbearbeitung herzustellen und daher auch kostengünstiger. Bei Endbearbeitungsverfahren sehr komplizierter, dreidimensionaler Konturen ist der Einsatz des Strömungsschleifens besonders geeignet. Die Erzeugung solcher Konturen err folgt auf mehrachsigen Werkzeugmaschinen mit Oberflächenwerten, die den gestellten Bauteilanforderungen jedoch nicht genügen r und nur durch das Strömungsschleifen erreicht werden können. Die zu bearbeitenden komplizierten Konturen bedingen zwangsläufig auch einen erheblich höheren Konstruktions- und Fertigungsaufwand beim Vorrichtungsbau. Im Gegensatz zur Innenbearbeitung muss bei der Außenbearbeitung durch die Anordnung einer Gegenform ein Durchflussquerschnitt erst geschaffen werden. Vielfach ist diese Vorgabe nur durch den Einsatz von gießbaren Polyurethanen zu verr wirklichen. Da die Gegenform verfahrensbedingt ständig dem abrasiven Mediumfluss ausgesetzt wird, ist der zu erwartende Vorr richtungsverschleiß erheblich höher als bei der Innenbearbeitung. Trotz der Mehraufwendungen und offensichtlichen Nachteile im Vergleich zur Innenbearbeitung gibt es derzeit kein alternatives Fertigungsverfahren für derr art kompliziert geformte Bauteile im Bereich der Oberflächenendbearbeitung. Die präzise Form sowie die Oberflächenstruktur der strömungsgeschliffenen Bauteile ist einzigartig. Deshalb wird das Verfahren vor allem in hoch technisierten Industrien mit hohen Qualitäts- und Präzisionsansprüchen eingesetzt. Anwendungsbeispiele findet man heute unter anderem in der Medizintechnik (Membranen, Ventile, Pumpen), in der Kunststoff- und Aluminiumindustrie, in der Luftund Raumfahrttechnik (Turbinen, Brennkammern, Leitschaufeln), im Werkzeug und Forr menbau (Fittings, Formen, Matrizen). Der Streamer ist das Werkzeug zum Strömungsschleifen. Entsprechend der Bearbeitungsaufgabe ist zwischen den Arbeitsgängen Entgraten und / oder Polieren zu unterscheiden. Den daraus resultierenden Anforderungen wird zuallererst durch die Medienzusammensetzung und danach mittels geeigneter Bearbeitungsparameter entsprochen. Der wesentliche Unterschied zwischen einem Entgrat- und einem Poliervorgang beim Strömungsschleifen besteht in dem lokal und geometrisch bestimmten Materialabtrag an einer Kante (Entgraten) bzw. auf einer Fläche (Polieren), siehe Abbildungen. Das abzutragende Materialvolumen kann in beiden Einsatzfällen durchaus eine gleiche Größenordnung besitzen und hat deshalb für die Auswahl der Korngröße und der Viskosität des Mediums keine Bedeutung. Diese Parameter werden ausschließlich durch den am oder im Werkstück befindlichen Durchflussquerr schnitt bestimmt. N 79 ANWENDUNG 30 years ago was that when conventional methods were used, there were considerably inadequacies in the machining of internal workpiece geometries, such as bore intersections and perforations. In principle nothing about such jobs has changed. Most industrial applications are related to the process-inherent possibility of flexible adaptation to, and the machining of existing workpiece geometries. Thanks to the workpiece geometry, in the design of the devices used for internal machining it is not necessary to incorporate cores, which are cost-intensive because they are severely affected by contact with the abrasive medium and which reduce the cross-section. The smallest cross-section with the highest flow rate and hence the greatest removal of material is localised inside the workpiece. Thus, the device itself is not affected by processrelated wear. Overall, the device comprises fewer individual components, it costs less to produce than a device for external machining, and is therefore comparatively inexpensive. The use of flow grinding is especially well suited for the final machining of very complex, three-dimensional contours. Such contours are produced using multi-axis machine-tools, but have surface quality values which often do not meet specified component requirements, which can only be achieved by flow grinding. The machining of complex contours necessarily entails considerably greater design and production cost and effort for the construction of the machining device. In contrast to internal machining, for external machining a throughflow cross-section must first be created by a suitably positioned counter-shape. This requirement can often only be realised by the use of castable polyurethanes. Since by the nature of the process the counter-shape is constantly exposed to the flow of abrasive medium, the wear of the device can be expected top be substantially greater than in the case of internal machining. However, despite the additional cost and effort and the clear disadvantages compared with internal machining, at present there is no alternative production method for components of such complex shape when it comes to surface finish-machining. The highly precise shape and surface structure of components finished by flow grinding are unique. Accordingly, the technique is used in high-tech industries where the demand for quality and precision is strict. Nowadays, examples of its application exist in medical technology (membranes, valves, pimps), in the plastics and aluminium industries for tool and hardened metal fabrication (dies, tablet-making moulds, drawing dies, removal of eroded layers), in aerospace technology (blisks, turbines, combustion chambers, vanes), in die and mould fabrication (fittings, moulds, dies) and in numerous other applications. Streamer selection The streamer is in effect the flow-grinding tool. Depending on the machining task, a distinction is made between the work steps for deburring and / or for polishing. The requirements resulting from this are met above all by formulating the composition of the medium, and then by the choice of suitable operating parameters. The essential difference between a deburring and a polishing process during flow grinding consists in the local and geometry-related determined removal of material at an edge (deburring) or over a surface (polishing), see images. In the two cases the volume of material to be removed can be about the same, and this is therefore not an important factor for choosing the grain size and viscosity of the medium. These parameters are determined exclusively by the through-flow cross-section that exists over or in the workpiece. N Der neue Mercedes-Benz SL setzt auf Aluminium Mit dem komplett neu entwickelten SL setzt Mercedes-Benz fast vollständig aus Aluminium und erzielt damit eine Gewichtsersparnis von bis zu 140 Kilogramm gegenüber dem Vorgängermodell. Konsequente Gewichtsreduzierung gehört wie beim Ur-Modell von 1952 mit seinem leichten Rohrrahmen auch im neuen SL zu den herausragenden konstruktiven Merkmalen. Dafür verwirklicht Mercedes-Benz erstmals einen hoch steifen Vollaluminium-Rohbau in der Großserie. Nur wenige Teile bestehen aus anderen Materialien. Für die Abdeckung hinter dem Tank verwenden die Konstrukteure 80 The new Mercedes-Benz SL Almost entirely made of aluminium The completely redeveloped MercedesBenz SL has been produced almost entirely from aluminium and weighs up to 140 kilograms less than its predecessor. Consistent weight reduction is one of the most outstanding design features in the new SL as was the case in its namesake, the original SL of 1952 with its lightweight tubular frame. For the first time Mercedes-Benz has implemented a highly rigid all-aluminium bodyshell in a se- ries-production model. Only very few components consist of other materials. The designers use the even lighter magnesium for the cover behind the tank. High-strength steel tubing is integrated in the A-pillars for safety reasons. The new aluminium bodyshell weighs around 110 kilograms less than it would using the steel technology from the predecessor. The result is perceptible and measurable, as less weight means more dynamism and less consumption. ALUMINIUM · 1-2/2012 Mercedes-Benz APPLICATION Mercedes-Benz SL 350, Edition 1 teilweise das noch leichtere Magnesium. In die A-Säulen sind aus Sicherheitsgründen hochfeste Stahlrohre integriert. Der neue Aluminium-Rohbau wiegt rund 110 Kilogramm weniger, als er in der StahlTechnologie des Vorgängers wiegen würde. Das Ergebnis ist spür- und messbar, denn weniger Gewicht bedeutet mehr Dynamik und weniger Verbrauch. Die Alu-Struktur ist nicht nur leichter, sondern der Stahlausführung des Vorgängers auch hinsichtlich Steifigkeit, Sicherheit und Schwingungsverhalten überlegen. Dafür sorgt intelligenter Leichtbau mit für den jeweiligen Einsatzzweck optimierten Bauteilen. So kommen unterschiedliche Aluminiumverarbeitungen zum Einsatz. Die Bauteile werden je nach Aufgabe in Kokillenguss oder in VakuumDruckguss gefertigt, zu Strang-pressprofilen verarbeitet oder als Aluminiumbleche mit unterschiedlichen Wandstärken eingesetzt. Obwohl der neue SL noch komfortabler ist und mehr Assistenzsysteme als sein Vorgänger an Bord hat und deshalb einen Teil des durch den Alu-Rohbau erzielten Gewichtsvorteils wieder einbüßt, zeigt die Waage erstaunliche Zahlen: Der neue SL 500 (1.785 kg) wiegt insgesamt rund 125 Kilogramm weniger als sein Vorgänger, der SL 350 (1.685 kg) ist sogar 140 Kilogramm leichter. Dies ist vielen weiteren intelligenten Detailverbesserungen zur Gewichtsreduzie- ALUMINIUM · 1-2/2012 The aluminium structure is not only lighter but also proves superior to the predecessor’s steel construction in terms of rigidity, safety and comfort. This is achieved thanks to its intelligent lightweight construction with components optimised for their specific task. Thus, diverse processes are used to make different kinds of aluminium depending on the use the component is to be given: the parts are made by chill casting or vacuum die-casting, worked into extruded aluminium profiles or into aluminium panels of different thicknesses. The result: high rigidity, high safety levels and better vibration characteristics. Although the new SL is even more comfortable and has more assistance systems onboard than its predecessor and therefore sacrifices some of the weight saved through the aluminium bodyshell, the scales show some astonishing figures: the new SL 500 (1,785 kg) weighs some 125 kg less than its predecessor. On balance, the SL 350 (1,685 kg) is even 140 kg lighter – all thanks to a host of other intelligent enhanced details to reduce weight, which has also been implemented in the new SL in addition to the aluminium bodyshell. The SL suspension features intelligent lightweight construction too. For instance, the steering knuckles and spring links on the front axle are also made out of aluminium to reduce the unsprung masses. The same also applies to virtually all the wheel location components on the rear axle. Thanks to the crash-optimised aluminium structure, standard-fit ‘Pre-Safe’ and assistance systems on the same high level as the S-Class, the SL is the world’s safest roadster, Mercedes says. The rigid aluminium bodyshell forms a sturdy passenger compartment along with precisely defined deformation zones in the front and rear ends. In case of the vehicle overturning, A-pillars made out of a mix of steel and aluminium and two roll-over bars protect the passenger compartment. N rung zu verdanken, die im neuen Modell zusätzlich zum Aluminium-Rohbau verwirklicht wurden. Auch das Fahrwerk zeichnet sich durch intelligenten Leichtbau aus. Zur Reduzierung der ungefederten Massen bestehen Achsschenkel und Federlenker der Vorderachse aus Aluminium. Das gilt auch für fast alle Radführungsteile der Hinterachse. Die crashoptimierte Alu-Struktur und umfassende Sicherheits-Assistenzsysteme machen den SL zum sichersten Roadster der Welt, so Mercedes-Benz. Der steife Alu-Rohbau bildet eine stabile Fahrgastzelle sowie präzise definierte Deformationszonen an der Front und am Heck. Bei einem Überschlag schützen A-Säulen in Stahl-Alu-Materialmix und zwei N Überrollbügel den Passagierraum. 81 CO M PA N Y N E W S W O R L D W I D E Hydro Aluminium smelting industry Acquisition of additional interest in Alouette aluminium smelter Marubeni Corp. and Investissement Quebec (IQ) have reached an agreement whereby Marubeni will acquire an additional 6.66% ownership interest in the Alouette smelter in Sept Îles, Canada. The acquisition price is approx. USD180m. Following the transaction, Marubeni’s ownership interest in Alouette will increase from 6.67 to 13.33% and its allocation of metal will correspondingly increase from 38,000 to 76,000 tpy. Aluminerie Alouette’s production capacity of 575,000 tpy makes it the largest aluminium smelter in the Americas. The plant is going to expand its capacity up to 930,000 tpy (Phase III project) and will start a full scale feasibility study in 2012. Total investment for the expansion project is estimated at C$2bn. In October 2011 Hydro-Quebec had been authorised to provide Alouette with an additional 500 MW energy block for the Phase III project. After this transaction, Marubeni’s worldwide volume (equity owned) of aluminium will increase from 160,000 to nearly 200,000 tonnes. Due to continuously strong aluminium demand, especially in the rapidly growing emerging economies such as China, India and Brazil, Marubeni will continue to focus on further investment in aluminium and new investment in such areas as bauxite and alumina. Rio Tinto gives green light to additional Kitimat investment Rio Tinto has given the green light to an additional USD2.7bn capital investment to mod- 82 ernise its aluminium smelter in Kitimat, British Columbia. This new investment will allow for completion of the USD3.3bn project in 2014. The modernisation project will increase the smelter’s current production capacity by more than 48% to approx. 420,000 tpy. First metal is expected to come on stream in the first half of 2014, with an expected ramp-up time of nine months. The modernised smelter will be powered exclusively by wholly-owned hydropower and will use RTA’s AP40 technology to reduce the smelter’s CO2 emissions intensity by 50%. Rio Tinto Alcan intends to close Lynemouth smelter RTA intends to close its Lynemouth aluminium smelter in Northumberland, England. The company is also in exclusive talks on selling the power station at the site. The smelter is no longer a sustainable business, says RTA, because its energy costs are increasing significantly, due largely to emerging legislation. The management is confident that the power station can remain in operation under new ownership. The Lynemouth smelter employs 515 people; an additional 111 are employed at the power station. A power outage in the Northumberland region has left parts of RTA’s smelter in Lynemouth out of commission. Some power was restored, allowing the Montreal-based aluminium producer to restore 123 of its 164 pots in the smelter’s No. 1 line. But the No. 2 line remains out of operation, a spokesman says. Alba achieves highest production in its history Aluminium Bahrain (Alba), one of the world’s largest aluminium smelters, produced 850,700 tonnes in 2011, which was the highest level ever recorded in the company’s 40year history and a substantial increase from the 850,700 tonnes produced in 2010. Alba CEO Laurent Schmitt said this result was accomplished without incurring any additional expenditure. “Alba’s introduction of Six-Sigma to strengthen quality initiatives across the organisation as well as the implementation of lean management techniques played a substantial role in enabling Alba to achieve this record,” he said. Alba’s high-grade aluminium product range includes standard and T-ingots, extrusion billets, rolling slab and molten aluminium. They are produced to high purity standards that exceed 99.9%. Rusal welcomes government commission’s decision on the Bogoslovsk Smelter Rusal is satisfied with the results of the Government Commission session dedicated to analysis the situation at the Bogoslovsk aluminium smelter and to the development prospects of the whole Urals aluminium production cluster. The company has always emphasised that the key condition for stable operations of aluminium smelters is energy supply tariff enabling competitive production. As from 1 January 2012, the Bogoslovsk smelter will be able to enter into a direct energy supply contract with Federal Grid Company. Furthermore, Rusal will purchase the Bogoslovsk Power Plant from IES Holding, including rights on the contracts project for the 230 MW Novobogoslovsk Power Plant capacity allocation, allowing the company to create a leading energy and metals and mining complex in Urals Region. The Author The author, Dipl.-Ing. R. P. Pawlek is founder of TS+C, Technical Info Services and Consulting, Sierre (Switzerland), a service for the primary aluminum 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 aluminum smelters of the world. They are available as loose-leaf files and / or CD-ROMs from Beuth-Verlag GmbH in Berlin. ALUMINIUM · 1-2/2012 CO M PA N Y N E W S W O R L D W I D E In turn, Rusal agreed to focus on bringing the smelter to break-even, and over the next five years it will upgrade the Bogoslovsk smelter’s production facilities. The upgrade will provide production rates no lower than in 2011 levels, whilst increasing the smelter’s energy efficiency, bringing it in-line with modern technology. Rusal’s alloys to be qualified by leading European automotive companies China will remain a net importer of aluminium China will be a net importer of primary aluminium over the long-term as demand grows and production costs related to bauxite and Rusal completes VAZ redesign UC Rusal completed redesigning its Volkhov aluminium smelter (VAZ) and the increase of its production capacity as a result of the redesign. Total investment to the project amounted to USD3m. VAZ completed the installation of new equipment in the casthouse enabling the smelter to start a large-scale production of alloys and increase the casting capacity from 24,000 to 32,000 tpy. The share of alloys in the smelter’s production will grow up to 96%. Automotive and aerospace industries will be main consumers of the alloys produced. The smelter will also produce grade A356.2 aluminium alloy used in cast automotive wheel production. The upgraded casthouse includes a 20- ALUMINIUM · 1-2/2012 electricity prices increase. The recent capacity shutdowns among Chinese aluminium producers underscore the high-cost structure that burdens a significant proportion of China’s aluminium capacity. Further production cuts are expected after the LME aluminium price dipped below USD2,000 per tonne for the first time in over a year at the end of November. China became a net importer of alumina in 2000 and of bauxite in 2005. Net aluminium imports will grow due to the appreciating domestic currency and further increases in power costs. A renminbi appreciation of 10% combined with a USD5-per-MW increase in electricity costs would mean producers face a USD250-per-tonne cost increase. Given that global demand will grow 6% per year until the end of the decade, Chinese imports will rapidly increase. N Bauxite and alumina activities with 2010. In 2010 the Nikolaev alumina refinery produced 1.534m tonnes of alumina, with a total capacity of 1.57m tonnes. Rusal considers bauxite production in Sierra Leone Hydro Rolling slabs produced at UC Rusal’s smelters have been successfully qualified by semis flagship Novelis. Rusal is also working on the qualification of its products by BMW and Volkswagen. The 5754 and 5182 alloys qualified by Novelis are used in car body production. The trial consignment of the slabs was produced at the Bratsk aluminium smelter. Irkutsk and Sayanogorsk smelters currently have their cast wheel alloys going through the qualification process. The trial consignment of AlSi7MgSr cast alloy was successfully processed at Volkswagen. Now the German car producer has ordered another 175-tonne consignment for the second stage of the qualification. Two other alloys, AlSi11MgSr for Volkswagen and AlSiCu for BMW, are also going through the qualification step. In 2012 Rusal plans to supply about 40% of all alloys produced by Aluminium Division West (about 500,000 tpy) to European markets. European countries account for more than 15% of global aluminium consumption with the automotive industry being responsible for the major part of this consumption. On average, the EU transport contains 8.6% of aluminium, the highest rate globally. tonne holding furnace with a mixer to prepare alloys, a conveyor with an ingot stacker for standard ingot production, a filtration facility, a travelling degassing and fluxing facility and an automatic control system. The installation was carried out by German contractor Jasper GmbH and Russian ‘Centerenergotsvetmet’ company. The upgraded casthouse started production at the end of 2011 just before the smelter’s anniversary. VAZ, the oldest aluminium smelter in Russia, will mark 80 years of operations in 2012. Rusal’s Nikolaev refinery reached record production level UC Rusal’s Nikolaev alumina refinery has delivered a record annual production level of 1.6m tonnes of alumina during 2011. This output was reached following a USD350m capex programme that the refinery undertook since 2000, resulting in significant upgrades to the refinery’s sectors. Especially the lime burning kiln was reconstructed with its conversion to heating gas, a fifth calcination kiln was built and the captive power plant was reconstructed. The output increase in 2011 was also made possible via implementation of Rusal’s production system, raising the equipment utilisation ratio by 2.6% in 2011 compared UC is in talks with Sierra Leone authorities responsible for developing its natural resources sector and bringing investment from overseas into the country. The Russian aluminium producer is now planning to carry out a feasibility study on future bauxite mining projects and the development of transport infrastructure. Rusal’s participation in the development of the country’s natural resources is of significant interest to its economic development. A memorandum of understanding is to be developed, defining Rusal’s future involvement in the development of Sierra Leone’s mineral resources, as well as mutual obligations to maintain good conditions for the company’s investments in mining there. N © 83 CO M PA N Y N E W S W O R L D W I D E Secondary smelting and recycling European scrap exports to stagnate by 2014 European scrap aluminium export volumes will level off by 2014, increasing the availability of scrap in domestic European markets. In future, Asian markets are expected to generate more scrap, decreasing the need for longdistance imports. From 2014 onwards, scrap exports are expected to stagnate at around 1m tpy. Demand for aluminium will grow in response to CO2 reduction. Europe currently exports about 600,000 tpy of aluminium scrap. Globally, about 10.6m tonnes of aluminium scrap are collected each year, with 2.6m tonnes collected in Europe. China lags behind Europe and the USA: in 2009 there were 300 recycling plants in the USA, 273 in Europe and just 72 in China, but Chinese domestic volumes will grow. Going forward, almost 50% of global scrap collected will be collected in China. But China will need to vastly improve its scrap utilisation if it is to halt the growth of its dependency on imported scrap. Demand for scrap in China will double by 2020. The resulting increased availability of scrap in Europe may not be enough to satisfy demand, though, which will grow in response to CO2 reduction targets, to requirements on recycled content quotas for aluminium products, because the recycled crediting debate and marketing campaigns aim for over 90% recycled content of products. N Alunorf Aluminium semis Embraer and Alcoa to develop aluminium aircraft Embraer SA and Alcoa have signed a technology sharing agreement that involves the use of Alcoa’s aluminium alloys to support Embraer’s development of metallic fuselage and wings for its aircraft. Brazilian company Embraer manufactures commercial jets of up to 120 seats. Alcoa is a leading supplier of aluminium sheet, plate, extrusions and forgings to the aerospace industry. In June, the company launched a number of new aerospace products designed to lower the weight, cost and maintenance of new short-range aircraft, compared to composites. The new agreement will employ Alcoa’s aerospace technology to help Embraer develop high-performance aluminium aircraft using 84 the newest aluminium products including aluminium-lithium alloys, advanced design approaches and structural technologies, and the latest fastener and joining technologies. Bombardier Aerospace’s CSeries aircraft, also optimised for the sub-150 seat market, employs aluminium-lithium for most of the fuselage and carbon composite for the majority of the wing, the empennage and the nacelles. Coca-Cola and Novelis sign multi-year agreement for supply of can sheet Coca-Cola Bottlers’ Sales & Services Company (CCBSS) and Novelis have signed a multiyear agreement for the supply of aluminium can sheet. The agreement took effect on 1 January this year. CCBSS is the Coca-Cola entity purchasing aluminium can sheet for the Coca-Cola System in North America. The agreement covers the supply of aluminium can body, can end and can tab stock to the various producers of beverage cans for Coca-Cola in North America. The contract continues a decades-long relationship between the two companies and maintains Novelis’ role as the primary supplier of aluminium can sheet to Coca-Cola in North America. Terms of the contract were not disclosed. Novelis completes financing for acquisition of minority interest in Korean subsidiary Novelis has completed the financing for its acquisition of the outstanding minority interest in its Korean subsidiary. The company previously announced it would purchase 31.2% of the outstanding shares in its Korean subsidiary for USD350m, raising its ownership to more than 99%. Novelis has borrowed USD225m through a secured term loan, and plans to fund the remaining purchase price with existing liquidity sources. The new term loan was borrowed under, and will have the same terms as, the company’s existing USD1.5bn term loan facility. On 18 November, Novelis agreed with Taihan Electric Wire and other minority shareholders of Novelis Korea Ltd to purchase 31.2% of the outstanding shares in the Korean corporation for USD350m, adding to the 67.9% Novelis currently owns. Sapa closes deal to acquire extrusion plant in China In September 2011 Sapa entered into an agreement to purchase an extrusion plant 150 km North West of Shanghai. This deal was closed on 7 December. The plant is now operated under Sapa’s management and is doing business under the name Sapa Profiles Jiangy in Co. Ltd. The plant has 15 presses with the total production capacity of 60,000 tpy and has nearly 300 employees. It is one of the larger extrusion operations in the Yangtze River Delta region. The facility is also equipped with casting, anodising, horizontal powder coating, thermal break and fabrication capabilities. Constellium Ravenswood mill ramping up output after stretcher installed Constellium has successfully installed a new stretcher at its rolling mill in Ravenswood, West Virginia, and is in the process of ramping up production. A few years ago, the old ALUMINIUM · 1-2/2012 CO M PA N Y N E W S W O R L D W I D E stretcher developed some cracks due to fatigue and other maintenance problems. The Parisbased aluminium producer had begun ramping up output at Ravenswood last summer to build inventory ahead of the planned stretcher outage in August. Roughly 95% of the plate will be sold to the aerospace industry. Previously, Century Aluminum’s Ravenswood smelter supplied Constellium with molten metal, but since Century’s smelter was shut in February 2009 Constellium has recycled aluminium from internal production and bought additional metal units externally. Alcom commissions manufacturing expansion in Malaysia Aluminium Company of Malaysia Berhad (Alcom), a subsidiary of Novelis, announced the commissioning of a USD5m expansion at its Bukit Raja facility in Malaysia. The expansion consists of a tension leveller system, designed to improve coil flatness and surface cleanliness for overall quality and to enhance product mix. The new equipment will provide improvements across the existing range of aluminium sheet and heavy gauge foil products. In addition, the investment will enable Alcom to enter the growing market for aluminium sheet used in consumer electronics. Owned 59% by Novelis, Alcom is a publicly traded company located in Bukit Raja, Selangor, Malaysia. The rolling mill uses continuous caster technology to produce a variety of rolled products, ranging from sheet and coil to heavy-gauge foil products. The plant is the leading supplier of rolled products in Southeast Asia, serving the bare and coated heat exchanger markets, along with specialty common alloy and foil segments. Furukawa-Sky to build rolling mill in Thailand Japan’s Furukawa-Sky Aluminium will build an aluminium rolling mill in Thailand as it looks to shift focus there from imports to Thai production. The move comes in response to a growing demand for locally sourced material from automakers, many of them Japanese, based in Thailand. Construction of the factory in Rayong province is expected to start in March 2012, with production to begin in January 2014 at an initial annual capacity of 60,000 tpy. The company will transfer two cold-strip rolling machines from Japan to equip the new unit. The machines are currently idle af- ALUMINIUM · 1-2/2012 ter discontinuation of upstream processing at the firm’s Nikko plant. In a second phase, the company will relocate a third rolling machine, along with equipment for melting, forging and hot rolling, to give the Rayong site its start-tofinish production capability. This will also increase the unit’s capacity to 100,000 tpy by late 2014, about 22% of the firm’s domestic capacity. Output from the new mill will be shipped not only within Thailand but also to other parts of Southeast Asia, China and India. Furukawa-Sky is targeting ¥40 billion (USD0.5bn) in annual sales from the new mill within four or five years. USD17m on the modernisation of its three foil and foil packaging plants Sayanal, Ural Foil and Armenal, lifting foil production from 80,000 to 100,000 tpy. Rusal’s investments in Sayanal will amount to USD4m. The site’s production capacity will increase from 38,000 to 42,000 tpy. This investment in Sayanal will occur by 2014, while, in total, Rusal plans to invest USD7m in this site. Modernisation at Ural Foil will raise the plant’s capacity from 16,000 to 24,000 tpy at a cost of USD7m. Capacity of the Armenal plant is to be increased from 26,000 to 33,600 tpy, at a cost of USD6m. Kizad signs lease agreement with Talex Khalifa Industrial Zone Abu Dhabi (Kizad) has announced the signing of a long-term ground development lease agreement with the Taweelah Extrusion Co. (Talex). Already in May 2011, Abu Dhabi Basic Industries Corp. (ADBIC) signed a joint-venture agreement with Gulf Extrusions to set up the Dhs735m (USD200m) aluminium plant Talex. The extrusion plant will be a great attraction to Kizad’s aluminium cluster, alongside Emirates Aluminium (Emal), who is the core tenant within this cluster. Jindal Aluminium invests USD160m in Karnataka plants Rusal will spend USD17m to increase foil output to 100,000 tpy UC Rusal will raise its foil output by 25% by 2014, and for this the company will spend Jindal Aluminium will invest USD160m to set up two new aluminium manufacturing plants near Bangalore, in the Indian state of Karnataka. The first plant, costing USD100m, will have a capacity of 50,000 tpy of aluminium sheet and foil and is expected to start up in April 2012. The finished products will be used in packaging applications, which have significant export potential. The second plant, expected to be operational by July 2013, will produce powder-coated and anodised aluminium extrusions. Jindal holds a 25% share of the Indian aluminium extrusion market, and supplies sectors such as construction, transport, electrical, electronics and aerospace. Its facility near Bangalore has a capacity to produce 70,000 On the move Orbite Aluminae has named Yves Noël vice president of sales and marketing. Robert O’Leary has been named a director on Aleris’s board, replacing Ara Abrahamian, who resigned in December. Wise Metals Group LLC has named Andrew Logsdon president of Wise Recycling. Argentina’s foreign trade undersecretary Iván Heyn, a board member of Aluar has been found dead in a hotel in Montevideo, the capital of Uruguay. Deputy director María José Pérez Van Morlegan has replaced Mr Heyn in his role on the board. Aleris named John Zhu president of Aleris China. Mr Zhu is responsible for directing Aleris’ Rolled Products and Extrusions operations in China, and for developing and executing the Aleris growth strategy across the region. Rolled aluminum producer JW Aluminum Co. has promoted Chester L. Roush to chief commercial officer (CCO) and has also hired Wesley Tomaszek as chief financial officer (CFO). Roush will oversee all sales, marketing, inside sales, credit and logistics. Kay Meggers has been named president, Alcoa Global Rolled Products (GRP), succeeding Helmut Wieser, who retired at the end of 2011. Century Aluminum Co. has named Michael Bless as acting president and chief executive officer in the wake of Logan Kruger’s sudden exit from the company. Constellium has named former Alcan Inc. and Rio Tinto Alcan veteran Richard B. Evans as interim chairman and CEO, following the departure of chief executive officer Christel Bories. 85 CO M PA N Y N E W S W O R L D W I D E tpy of aluminium products, and exports to 27 countries including the USA, UK and Brazil, generating an annual turnover of USD160m. Suppliers Siemens VAI awarded two contracts by Novelis Korea Siemens VAI Siemens VAI has received an order from Novelis Korea Ltd to extend its aluminium rolling mill in Ulsan. To this end, a three-stand finishing line will be added to the plant. The project is aimed at boosting capacity and enabling future production of high-grade aluminium strip. The first strip is already to be rolled in July 2013. Up to now, the hot rolling mill, which was equipped by Siemens in 1993, operated by Novelis in the Korean city of Ulsan consisted of a single reversing stand with two coilers and the necessary secondary systems. Siemens is supplying the mechanical and electrical equipment for the new, three-stand tandem rolling mill including a coiler and a coil handling system. In future, the existing reversing stand will function as a roughing mill. Lightweight cropping shears will also be installed in the entry to the finishing line. Novelis Korea has placed a second order with Siemens VAI to equip its new aluminium cold rolling mill with automation and drive systems. The plant, which is located in Yeongju, will produce high-quality flat strip for the beverage can industry. The mill is scheduled to start production in 2013. Novelis is planning to construct a tandem mill to increase the capacity of the cold aluminium rolling plant in Yeongju. Siemens will supply all the electrical engineering and equipment. The technological control systems with integrated gauge, strip tension and Aluminum rod mill from Siemens VAI 86 After the expansions, the company hopes to increase the turnover to USD400m. N flatness control are an important part of the automation equipment. They are required in order to achieve the extremely tight manufacturing tolerances demanded for the end product. The scope of supply also includes a Level 2 process computer which will enable the pre-setting of the stands to be calculated online in advance on the basis of analytical mathematical models. All the drive systems, which include main and ancillary motors, will be powered by three-phase current. Siemens will install synchronous main motors for the stands and reels. Sinamics SM150 mediumvoltage and S120 low-voltage converters will be used in the drives. All the systems and components used will be taken from the integrated Siroll ALU solution platform for aluminium cold rolling mills. Siemens VAI awarded a contract for aluminium rod mill Siemens VAI has received an order from the Southwire Company, located in Carrollton, Georgia, to supply an aluminium rod rolling mill for end costumer Beauty Sun Holdings Ltd. The new mill will be located in Yixing, Jiangsu Province, China; commissioning is expected during the first quarter of 2012. Siemens is responsible for the engineering, manufacturing and commissioning of the rolling mill and coiler equipment for a Southwire SCR AL 7000 rolling mill. The new mill will produce aluminium rod for the power conductor market. The scope includes eleven stands, which will run 15 tonnes per hour, producing rods that are 9.5 mm, 12 mm and 15 mm in diameter. The contract also includes entry shear and table, and a dual reel coiler. The aluminium rolling mill will complement the company’s existing Southwire copper rod system, which was also equipped by Siemens. Beauty Sun Holdings Ltd, part of the Heaven and Earth Dragon group, is located in Yixing. Southwire has worked together with Siemens VAI for more than 40 years. During that time, the company built more than 80 non-ferrous mills for Southwire customers. Swedish Kubal orders stub straightening machine from VHE Inward bending of anode stubs, generally known as ‘toe-in’, is a well understood occurrence in all pre-bake aluminium smelters. The difference in linear expansion of the carbon anode and the steel yoke or spider of the anode rod at high temperatures in the reduction cell means that the yoke expands more than the anode, bending the stubs which are anchored in the anode block. Stubs become bent inwards just above the iron thimble, changing the geometry of the yoke, and stubs can no longer be correctly located in the anode holes during subsequent rodding. Ultimately the stubs will no longer fit into the holes. The machine to be supplied to Kubal (Kubikenborg Aluminium), located in Sweden, will be designed for the 2 x 2 150 mm stub diameter technology in use at that smelter and will be delivered in mid-2012. VHE of Iceland has proven solutions suitable for different reduction technologies. For smaller diameter stubs, ambient temperature straightening is an economical approach. For larger stub diameters, hot straightening is often a better solution. Stubs heated to 650 °C need considerably less straightening force, and the cost of an induction pre-heating unit is to a large extent offset by savings in the heavy duty steelwork and hydraulic systems which would otherwise be needed. UC Rusal approves nanocoatings from ItN Nanovation UC Rusal and Rusnano have announced that Rusal’s Irkutsk Aluminium Smelter and specialists from Rusal’s Engineering and Technology Centre, have successfully tested Nanocomp Metcast, nanocoatings developed by Rusnano’s project company ItN Nanovation AG in Germany. Nanocomp Metcast are innovative nanocoatings tailored to casting machinery. They extend the service life of moulds and lengthen the intervals for maintenance of casting conveyors. As a result, the casting process becomes more efficient at a lower cost. Presently specialists from ItN Nanovation and Rusal study large-scale introduction of Nanocomp Metcast at Rusal’s aluminium smelters. Rusnano acquired an interest in ItN Nanovation in May 2011. N ALUMINIUM · 1-2/2012 RESEARCH Das aec (aluminium engineering center) in Aachen – Weltweit größtes Hochschulzentrum für Aluminiumforschung und -lehre, TTeil I Das aec (aluminium engineering center e.V.) zählt zu den weltweit größten Hochschulzentren für Aluminiumforschung und -lehre. Als kompetenter Forschungsund Entwicklungspartner für industrielle und anwendungsorientierte Forschung bietet es einen Pool von mehr als 250 hoch qualifizierten Werkstofftechnikern und Ingenieuren sowie eine hervorragende Infrastruktur und Ausstattung der Institute. Durch den Einsatz modernster Anlagen, Prozesse, Analysetechniken und Computersoftware werden zum Beispiel neue Legierungen und Leichtbaulösungen möglich. Das aec fördert die interdisziplinäre, institutsübergreifende Forschung und Entwicklung für Aluminium und leistet so einen systematischen Knowhow-Aufbau und -Erhalt für Aluminium-Werkstoffe, -Prozesse und -Anwendungen. Durch die enge Verzahnung der Forr schung und Entwicklung mit dem Lehrbetrieb der RWTH bildet das aec beständig exzellente Ingenieure für die Aluminiumindustrie und deren Kunden aus. Mit der Gründung des aec ist die Vision verbunden, Aluminium als wichtigen Struktur- und Leichtbauwerkstoff in Lehre und Forr schung an der RWTH Aachen zu fördern und das aec zu einem weltweit führenden Center of Excellence für die aluminiumbezogene Forr schung und Entwicklung sowie akademische Aus- und Weiterbildung zu entwickeln. Die auch in der Vereinssatzung festgeschriebenen strategischen Ziele des aec sind: die Förderung der Aus- und Weiterbildung, die interdisziplinäre Forschung und Entwicklung und die Präsentation und Kommunikation des Werkstoffpotenzials. Die Realisierung der Vision und die Umsetzung der strategischen Ziele setzt eine enge strategische Partnerschaft mit der Aluminiumindustrie voraus. Das aec ist jederzeit offen für neue Kooperationen mit allen Unternehmen der Aluminiumbranche und den Anwenderr industrien. Die zehn Mitgliedsinstitute des aec geben einen Überblick über die Erzeugung, das Urr formen, Umformen, Fügen, Beschichten, die Anwendung im Kraftfahrzeug- und Bausektor, das Recycling und die damit verbundenen Technologien. ALUMINIUM · 1-2/2012 Typische Forschungsschwerpunkte der zehn aec Mitgliedsinstitute sind im Folgenden darr gestellt. I.A.R. (Institut für Aufbereitung und Recycling); Prof. T. T Pretz, B. Wens Forschung zum Recycling beginnt an der Rohstoffquelle, der anthropogenen Ressourr ce „Abfall“. Metallische Abfälle, und hier Die aus Verbrennungsrückständen erzeugten NE-Vorkonzentrate weisen zwar höhere Metallgehalte, sind aber hinsichtlich der automatischen Sortentrennung problematischer (z.B. wegen mineralischer Oberflächenverschmutzungen). Ein möglichst effizienter Zugriff auf die circa fünf Millionen Tonnen Müllverr brennungs-Rostaschen verlangt daher eine Kombination von klassischen physikalischen Trennprozessen mit angepasster sensorischer I.A.R. aec, B. Jaroni insbesondere Nicht-Eisen-Metalle, sind als Ressource sowohl unter ökonomischen als auch ökologischen Gesichtspunkten besonders interessant. Auf diese Ressourcen, die in heterogenen Abfallgemischen (z.B. Hausmüll) enthalten sind, konzentriert sich die Forschung am I.A.R. In Deutschland werden beispielsweise etwa ein Drittel des Hausmülls einer mechanischen und zwei Drittel einer thermischen Behandlung unterzogen. Die Anreicherung von NE-Metallen bei der mechanischen Behandlung führt zu stark verr schmutzten, nicht sortenreinen Vorkonzentraten mit Metallgehalten zwischen 30 und 60 Prozent. Um die metallischen Ressourcen aus solchen „armen“ Vorkonzentraten heben zu können, muss eine weitere Aufkonzentrierung der Metalle und eine Sortentrennung durchgeführt werden. In dem von der EU-Kommission geförderten Eco-Innovation-Vorhaben SATURN (ECO/08/239051/SI2.534294) wird unter Verwendung moderner sensorischer Sortiertechnik die Sortentrennung automatisiert. In unterschiedlichen Kombinationen lassen sich Röntgen-, Nah-Infrarot- und induktive Sensoren mit Bildauswertungsverfahren kombinieren und so Konzentrate mit enger definierten Legierungseigenschaften erzeugen. Sortiertechnik, die in einem r³-Forschungsvorr haben mit industrieller Beteiligung erforscht werden. IME (Institut für Metallurgische Prozesstechnik und Metallrecycling); Prof. B. Friedrich; S. Gül Im Bereich des Leichtmetallrecyclings, besonders des Aluminiumrecyclings, ist das IME eines der führenden Forschungsinstitute Europas. Die Untersuchungen entsprechen den Bedürfnissen der Aluminiumindustrie und reichen von der Grundlagenforschung bis in die Umsetzung von Up-Scale-Versuchen im Pilotmaßstab. Ein typisches Beispiel ist die thermische Zersetzung organischer Bestandteile im Mehrkammerofen beim Aluminiumrecycling. Neben der angestrebten höheren Ausbeute und Qualität des wertvollen Werkstoffs, kann der Heizwert der organischen Bestandteile genutzt und der Erdgaseinsatz künftig reduziert werden. Daher ist eines der Ziele, den Prozess und hier insbesondere den Vorbehandlungsschritt zu optimieren um die de-coating-Effizienz zu steigern. Ein weiterer Forschungsschwerpunkt ist 87 das Salzbadtrennverfahren, das vor allem bei stark verunreinigten Schrotten und Aluminiumverbundwerkstoffen zum Einsatz kommt. Im Zuge der Projektarbeit ist am IME ein konduktiv beheizter Ofen zum Salzbadtrennverfahren als Demonstrator für die Industrie geplant. Die Abbildung zeigt den kippbaren Drehtrommelofen des IMEs. Das Ofenvolumen beträgt 1 m3 Aluminium. Der stufenlose Luft-/Sauerstoffbrenner verfügt über 0,5 MW Leistung, Die Reduzierung des Energieverbrauchs und Verwendung regenerativer Energie ist für die nachhaltige Entwicklung der Industrie und ihrer Prozesse unerlässlich. Zum Einsatz von Biomasse zur Einsparung fossiler Brennstoffe wird am IME aktuell die Entwicklung eines Brenners angestrebt. Neben der Prozessoptimierung und dem Aufbau einer Demonstrationsanlage werden Grundlagenuntersuchungen zur Optimierung der Salzeigenschaften für das Aluminiumrecycling im IME durchgeführt. Hierzu werden Eigenschaften wie Viskosität, Oberflächenspannung und Dichte ermittelt. Auch Untersuchungen zu unterschiedlichen Flussmitteln für die Oxid/Metall-Trennung sind Gegenstand der aktuellen Forschung. IMM (Institut für Metallkunde und Metallphysik); Prof. G. Gottstein, C. Günster Das Institut für Metallkunde und Metallphysik (IMM) befasst sich mit Forschung über Eigenschaften metallischer Werkstoffe und den physikalischen Mechanismen, die ihnen zugrunde liegen. Ein zentraler Gegenstand der Forschung ist derzeit die Nutzung des 88 3D-Kornstruktur, simuliert nach dem 3D-VertexModell [3] von Materialeigenschaften während des Herr stellungsprozesses, um den Kosten- und Zeitaufwand der Werkstoffentwicklung spürbar zu verringern. Die entwickelten Modelle sind über eine Interr netplattform extern verfügbar. Das Institut für Bildsame Formgebung (IBF) der RWTH Aachen beschäftigt sich im Bereich Aluminium sowohl mit der Umformung durch Walzen, Ringwalzen, Schmieden und verschiedenste Blechumformverfahren als auch mit der Prozess- und Werkstoffmodellierung von Umformprozessen und Prozessketten. Eine aktuelle technologische Neuentwicklung stellt das Riblet-Walzen zur Herstellung strömungsoptimierter Oberflächen in Aluminiumblechen dar. Hierzu wird die Oberfläche des Blechwerkstoffs in einem Walzstich mit kleinsten Rillenstrukturen versehen. Diese sogenannten Riblets können zur Verminderung von Reibungsverlusten auf umströmten oder in durchströmten Körpern verwendet werden. Zum Einsatz dieser Strukturen auf großen Oberflächen – zum Beispiel an Zügen, Flugzeugen oder in Pipelines – müssen geeignete Strukturierungsverfahren gefunden und optimiert werden. Das Walzen bietet die Möglichkeit, derartige funktionalen Strukturen mit Hilfe einer negativ strukturierten Masterr walze mit hoher Effizienz auch auf großflächige metallische Werkstücke zu übertragen. Am Institut für Bildsame Formgebung werden verschiedene Verfahren untersucht, um Walzen entsprechend zu strukturieren. Hierdurch entstand beispielsweise eine „Microwind“-Walze, die mit einem sehr dünnem Draht umwickelt wird, dessen minimaler Durchmesser circa 90 μm beträgt. Mit dieser Walze wurden bereits erfolgreich Riblets in Aluminiumbleche gewalzt. Es ergibt sich ein halbkreisförmiges Profil, das vorteilhafte strömungstechnische Eigenschaften mit einer vergleichsweise einfachen und kostengünstigen Fertigung verbindet. Fortsetzung in ALUMINIUM 3/2012 [1]: M. Crumbach, Dissertation, RWTH Aachen (2005). [2]: R. Sebald, G. Gottstein, Acta Mater. 50, (2002), 1587-98. [3]: L. BarralesMora, Dissertation, RWTH Aachen (2008) IBF Kippbarer Drehtrommelofen am IME IBF (Institut für Bildsame Formgebung); Prof. G. Hirt, Dr. M. Bambach metallkundlichen Verständnisses zur Berechnung von Werkstoffeigenschaften längs der Prozesskette auf dem Computer. So wurden am IMM unter anderem Modelle zur Simulation der plastischen Verforr mung hinsichtlich Verfestigung (3IVM+), Verr formungstextur (GIA) und Rekristallisation (CORe) [1, 2], sowie des Kornwachstums mit Hilfe von Netzwerkmethoden (3D-Vertex) entwickelt. Die Zuverlässigkeit der Simulationsergebnisse bezüglich der Entwicklung von Walz- und Rekristallisationstexturen im Lauf der Prozesskette (Through-Process Modeling) wurde durch den Vergleich mit experimentell ermittelten Texturen bewertet und im Laufe der Jahre durch Modifikation besagter Modelle immer weiter verbessert. Das übergeordnete Ziel dieser Aktivitäten ist eine zuverlässige und akkurate Vorhersage und daraus resultierend eine Optimierung IMM IME RESEARCH ALUMINIUM · 1-2/2012 PAT E N T E Patentblatt Oktober 2011 Fortsetzung aus ALUMINIUM 12/2011 Schiebefenster oder -tür mit einer Schließeinrichtung. Alcoa Aluminium Deutschland, Inc., 58642 Iserlohn, DE. (E06B 3/44, EPA 2360343, EP-AT: 09.02.2011, WO-AT: 09.02.2011) Draht aus Magnesiumbasislegierung und Herstellungsverfahren dafür. Sumitomo (SEI) Steel Wire Corp., Itama, Hyogo, JP; Sumitomo Electric Industries, Ltd., Osaka, JP. (C22C 23/02, PS 602 37 820, EP 1400605, WO 2002/099148, AT: 16.05.2002, EP-AT: 16.05.2002, WO-AT: 16.05.2002) Gießsystem für hohe Produktivität. MRB Aluminium LLC, Sterling Heights, Mich., US. (B22D 47/00, PS 60 2006 016 819, EP 1918045, AT: 16.11.2006, EP-AT: 16.11.2006) Patentblatt November 2011 Verbundwerkstoffe für benetzbare Kathoden und Verwendung derselben für die Herstellung von Aluminium. Hydro-Quebec, Montréal, Québec H2Z 1A4, CA. (C22C 29/00, EPA 2373823, WO 2010/037220, EP-AT: 29.09.2009, WO-AT: 29.09.2009) Verfahren zur Herstellung eines gebrannten Produkts auf Aluminium-Titanat-Basis. Sumitomo Chemical Company, Ltd., Tokyo 104-8260, JP. (C04B 35/46, EPA 2368866, WO 2010/067859, EP-AT: 11.12.2009, WO-AT: 11.12.2009) Entkohlungsverfahren für carbothermisch hergestelltes Aluminium. Alcoa Inc., Pittsburgh, PA 15212-5858, US. (C22B 5/06, EPA 2366037, WO 2010/074845, EP-AT: 18.11.2009, WO-AT: 18.11.2009) Eisen-Chrom-Aluminium-Legierung mit hoher Lebensdauer und geringen Änderungen im Warmwiderstand. Thyssen Krupp VDM GmbH, 58791 Werdohl, DE. (C22C 38/18, PS 10 2008 018 135, AT: 10.04.2008) Verminderung des elektrischen Kontaktwiderstandes zwischen Stahlnippel und Kohlenstoffanode in der Aluminium-Schmelzflusselektrolyse. Wilkening, Siegfried, Dr.-Ing., 53347 Alfter, DE. (C25C 3/12, OS 10 2010 020 030, AT: 11.05.2010) Widerstandspunktschweißen von Aluminium an Aluminium und Stahl an Stahl. GM Global Technology Operations LLC (n.d.Ges.d. Staates Delaware), Detroit, Mich., US. (B23K 11/30, OS 10 2010 024 569, AT: 22.06.2010) Schutzverkleidung für Holzfenster, Balkontüren und Terrassentüren in Edelstahl oder Aluminium. Gröner, Wolfgang, 89555 Steinheim, DE. (E06B 3/30, GM 20 2011 102 081, AT: 21.06.2011) Effektpigmente mit Aluminium- oder Aluminiumlegierungskern, Verfahren zu deren Herstellung und Verwendung derselben. Eckhart GmbH, 90763 Fürth, DE. (C09C 1/00, OS 50 2004 003 724, EP 1685198, WO 2005/049739, AT: 19.11.2004, EP-AT: 19.11.2004, WO-AT: 19.11.2004) Verfahren zur Herstellung eines Bauteils aus einem mit einem Al-Si-Überzug versehenen Stahlprodukt und Zwischenprodukt eines solchen Verfahrens. Thyssen Krupp Steel Europe AG, 47166 Duisburg, DE. (C23C 2/28, EP 2 240 622, WO 2009/095427, AT: 29.01.2009, EP-AT: 29.01.2009, WO-AT: 29.01.2009) Reaktor zur Abtrennung von Aluminium aus Mehrschichtfolienmaterialien. Korea Institute of Industrial Technology, Cheonan, KR. (C22B 21/00, EP 2 142 677, WO 2008/136542, AT: 02.05.2007, EP-AT: 02.05.2007, WO-AT: 02.05.2007) Einkapselung von Kohlenstoffmaterial in Aluminium. Dayou Smart Aluminium Co., Ltd., Seo, Gwangju, KR; Sungkyunkwan University Foundation for Corporate Collaboration, Suwon, Kyonggi, KR. (C23C 26/00, PS 60 2008 003 181, EP 2072635, AT: 24.07.2008, EP-AT: 24.07.2008) Überwachung der Isolierung von Interventionseinheiten, die in einem Elektrolyseraum zur Herstellung von Aluminium durch Schmelzelektrolyse verwendet werden. E.C.L., Ronchin, FR. (C25C 3/20, EP 2 257 657, WO 009/115689, AT: 20.02.2009, EP-AT: 20.02.2009, 86)WO-AT: 20.02.2009) Hochreine Aluminium-Sputtertargets. Praxair S.T. Technology, Inc., North Haven, Conn., US. (C22F 1/04, PS 602 37 911, EP 1444376, WO 2003/042421, AT: 23.10.2002, EP-AT: 23.10.2002, WO-AT: 23.10.2002) Abriebresistente gesinterte Aluminiumlegierung mit hoher Festigkeit und Herstellungsverfahren hierfür. Hitachi Powdered Metals Co., Ltd., Matsudo, Chiba, JP. (C22C 21/10, PS 10 2005 032 544, AT: 12.07.2005) Herstellungsverfahren für Blech aus Aluminiumlegierung. Nippon Light Metal Co. Ltd., Tokio, JP; Honda Motor Co., Ltd., Tokio, JP; Novelis, Inc., Toronto, Ontario, CA. (C22C 21/06, EP 1 771 590, WO 2006/011242, AT: 30.07.2004, EP-AT: 30.07.2004, WO-AT: 30.07.2004) 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) Herstellungsverfahren für aus einer wärmebeständigen Aluminiumlegierung geformte Produkte und aus einer wärmebeständigen Aluminiumlegierung geformtes Produkt. (C22F 1/00, PS 60 2007 009 604, EP 1881084, AT: 14.06.2007, EP-AT: 14.06.2007) Kupfer-Nickel-Aluminiumlegierung. Fossil, Inc., Richardson, TX 75082, US. (C22C 9/00, EPA 17.03.2011, WO-AT: 2369024, EP-AT: 17.03.2011) Al-Kunststoff-Fenster mit Klebebandfixierung. Gutmann AG, 91781 Weißenburg, DE. (E06B 3/30, PS 10 2006 054 427, AT: 16.11.2006) ALUMINIUM · 1-2/2012 Verfahren zur Herstellung eines mit guter Biegbarkeit versehenen Bleches aus Aluminiumlegierung. Novelis, Inc., Toronto, Ontario, CA. (C22C 21/02, EP 1 392 877 , WO 2002/090609, AT: 03.05.2002, EP-AT: 03.05.2002, WO-AT: 03.05.2002) Modulträger aus Leichtmetall-Strangpresskomponenten für ein Fahrzeug. Volkswagen AG, 38440 Wolfsburg, DE. (B62D 25/00, OS 10 2004 044 056, AT: 11.09.2004) Verbindungsanordnung zweier zumindest im Wesentlichen aus einem Leichtmetall gebildeten Bauteile. Daimler AG, 70327 Stuttgart, DE. (F16B 5/02, OS 10 2011 013 389, AT: 09.03.2011) Magnesiumlegierung für die Raumtemperatur und Herstellungsverfahren dafür. Korea Institute of Industrial Technology, Choongcheongnamdo 331-825, KR.(C22C 1/06, EPA 2374906, EPAT: 24.03.2011, WO-AT: 24.03.2011) Motorfahrzeugsitz mit Rücklehnenrahmen aus einer monolithischen Struktur aus einer Magnesiumlegierung. Lear Corporation Italia S.r.l., 10121 Torino, IT. (B60N 2/64, EPA 1950086, EPAT: 20.12.2007, WO-AT: 20.12.2007) Magnesiumlegierung und Magnesiumlegierungsguss. Kabushiki Kaisha Toyota Jidoshokki, Kariya-shi Aichi 448-8671, JP. (C22C 23/02, EPA 2369025, WO 2010/055897, EP-AT: 06.11.2009,WO-AT: 06.11.2009) Schmiedeprodukt aus Magnesiumlegierung mit ausgezeichneter Formbarkeit und Verfahren zu dessen Herstellung. Primometal Co., Ltd., Anyang, KR. (C22C 23/00, PS 60 2005 024, EP 1759029, WO 2006/075814, AT: 11.03.2005, EP-AT: 11.03.2005, WO-AT: 11.03.2005) Magnesiumbasierte Legierung für hohe Temperaturen und Herstellungsverfahren dafür. Korean Institute of Industrial Technology, Cheonan-si Chungcheongnam-do 331-825, KR. (C22C 1/06, EPA 2374905, EP-AT: 24.03.2011, WO-AT: 24.03.2011) © ALUMINIUM veröffentlicht unter dieser Rubrik regelmäßig einen Überblick über wichtige, den Werkstoff Aluminium betreffende Patente. Die ausführlichen Patentblätter und auch weiterführende Informationen dazu stehen der Redaktion nicht zur Verfügung. Interessenten können diese beziehen oder einsehen bei der Mitteldeutschen Informations-, Patent-, Online-Service GmbH (mipo), Julius-Ebeling-Str. 6, D-06112 Halle an der Saale, Tel. 0345/29398-0 Fax 0345/29398-40, www.mipo.de Die Gesellschaft bietet darüber hinaus weitere Patent-Dienstleistungen an. 89 PAT E N T E Herstellungsverfahren für Teile aus Magnesiumlegierungen. Matsuda, Yutaka, Takaratuka, Hyougo, JP. (C22C 47/12, PS 600 45 156, EP 1195448, WO 2000/070114, AT: 11.05.2000, EP-AT: 11.05.2000, WO-AT: 11.05.2000) Aluminiumoxid bildende Legierung auf Nickelbasis. Sandvik Intellectual Property Ab, 811 81 Sandviken, SE. (C22C 19/05, EPA 2367963, WO 2010/059105, EP-AT: 06.11.2009, WO-AT: 06.11.2009) Stranggepresstes Rohrteil aus Aluminiumlegierung für Wärmetauscher mit natürlichem Kühlmittel. Denso Corp., Kariya-city, Aichi-pref., JP; Furukawa-Sky Aluminium Corp., Tokio, JP. (C22C 21/00, PS 60 2006 017 768, EP 1721998, AT: 09.05.2006, EP-AT: 09.05.2006) Fassade oder Glasdach in Brandschutzausführung mit einer aus vertikalen und horizontalen Profilen bestehenden Tragkonstruktion. Norsk Hydro ASA, 0240 Oslo, NO. (E04B 1/94, PS 501 11 116, EPA 1120504, AT: 20.01.2001, EP-AT: 20.01.2001) Schließrahmen einer Schiebetür oder eines Schiebefensters, der einen verdeckten Pfosten umfasst. Bezault SAS, Longue, FR; Norsk Hydro ASA, Oslo, NO. (E06B 3/263, PS 60 2008 003 039, EP 1953327, AT: 30.01.2008, EP-AT: 30.01.2008) Verfahren und Werkzeug zur Oberflächenbehandlung. KS Aluminium-Technologie GmbH, 74172 Neckarsulm, DE. (B23P 9/00, PS 10 2009 058 178, AT: 15.12.2009) Titanaluminid-Legierungen mit guter Kriechfestigkeit. Avco Corp., Providence, R.I., US; Howmet Corporation, Independence, Ohio, US. (C22C 14/00, OS 694 00 848, EPA 0636701, AT: 16.05.1994, EP-AT: 16.05.1994) Plattierplatte und Herstellungsverfahren dafür. Showa Denko K.K., Tokyo, JP. (C22C 21/00, PS 60 2006 017 415, EP 1939312, WO 2007/026481, AT: 25.07.2006, EP-AT: 25.07.2006, WO-AT: 25.07.2006) Bodenflächenelement sowie Bodenfläche und Verwendung einer Bodenfläche. Alcan Centre de Recherches de Voreppe, F-38341 Voreppe Cedex, FR. (E04F 15/06, EPA 2372040, EP-AT: 25.03.2011, WO-AT: 25.03.2011) Lagerlegierung auf Aluminiumbasis und Verfahren zu deren Herstellung. Daido Metal Co., Ltd., Nagoya, JP. (C22C 21/04, OS 10 2011 075 580, AT: 10.05.2011) Geschäumte Kunststoffplatte. Alcan Technology & Management Ltd., Neuhausen am Rheinfall, CH. (B32B 3/18, PS 503 03 984, EP 1536944, WO 2004/024434, AT: 16.08.2003, EP-AT: 16.08.2003, WO-AT: 16.08.2003) Bearbeitetes Produkt mit optischem Sensor und Herstellungsverfahren dafür. Alcan Rhenalu, Courbevoie, FR. (B21C 23/22, PS 60 2008 003 200, EP 2125259, WO 2008/129178, AT: 18.03.2008, EP-AT: 18.03.2008, WO-AT: 18.03.2008) Verfahren zur Herstellung von Konstruktionselementen durch maschinelle Bearbeitung dicker Platten. Alcan Rhenalu, Paris, FR. (C22F 1/ 00, PS 603 34 731, EP 1573080, WO 2004/ 056501, AT: 17.12.2003, EP-AT: 17.12.2003, WO-AT: 17.12.2003) Längliches Halteelement. Corus Bausysteme GmbH, 56070 Koblenz, DE. (E04D 3/362, GM 203 80 217, WO 2004/022877, AT: 29.08.2003, WO-AT: 29.08.2003) Verfahren zum Herstellen eines Hohlprofils. Aleris Aluminum Koblenz GmbH, 56070 Koblenz, DE; Daimler AG, 70327 Stuttgart, DE. (B21C 37/08, OS 10 2010 018 504, AT: 28.04.2010) Verfahren zur Herstellung einer Baustrebe durch Crimpen und so erhaltene Baustrebe. Norsk Hydro ASA, 0240 Oslo, NO. (E06B 3/273, EP 2 055 883, EP-AT: 23.10.2008, WO-AT: 23.10.2008) Vorrichtung zum Befüllen einer Schwerkraftgießform mit einer flüssigen Schmelze. KS Aluminium-Technologie GmbH, 74172 Neckarsulm, DE. (B22C 9/08, PS 10 2010 010 322, AT: 04.03.2010) 90 Profilanordnung und Einfassprofil für eine Profilanordnung. MayTec Aluminium Systemtechnik GmbH, 85221 Dachau, DE. (F16B 5/06, GM 203 21 258, AT: 24.04.2003) Verbindungsvorrichtung zum schrägen Verbinden eines Hohlprofils mit einem weiteren Profil quer zu dessen Längsrichtung. MayTec Aluminium Systemtechnik GmbH, 85221 Dachau, DE. (F16B 7/04, GM 203 21 707, AT: 24.04.2003) Verbindungsvorrichtung zum Verbinden eines Hohlprofils mit einem weiteren Profil. MayTec Aluminium Systemtechnik GmbH, 85221 Dachau, DE. (F16B 7/04, GM 203 21 709, AT: 24.04.2003) Hochfeste, schweißbare Al-Mg-Legierung. Aleris Aluminum Koblenz GmbH, 56070 Koblenz, DE. (C22C 21/06, EP 1 917 373, WO 2007/ 020041, AT: 14.08.2006, EP-AT: 14.08.2006, WO-AT: 14.08.2006) Verfahren zur Herstellung eines Bauteiles und Bauteile aus einer Titan-Aluminium-Basislegierung. Böhler Schmiedetechnik GmbH & Co. KG, 8605 Kapfenberg, AT. (C22C 1/04, EPA 2386663, EP-AT: 26.04.2011, WO-AT: 26.04.2011) Verfahren zum flusslosen Löten von Aluminium und Lötblech zur Verwendung darin. Aleris Aluminum Koblenz GmbH, 56070 Koblenz, DE. (B32B 15/01, EPA 2382087, WO 2010/052231, EP-AT: 04.11.2009, WO-AT: 04.11.2009) System zur Produktion von hoch isolierenden Fenster- und Türrahmen aus einem AluminiumHolz-Gemisch. DFV S.R.L., 73030 Surano (LE), IT. (E06B 3/30, EPA 2385207, EP-AT: 14.02.2011, WO-AT: 14.02.2011) Korrosionsschutzschicht für Al- und Mg-Legierungen. EADS Deutschland GmbH, 85521 Ottobrunn, DE; TU Wien, 1040 Wien, AT. (C08G 77/26, EPA 2379623, WO 2010/081757, EP-AT: 07.01.2010, WO-AT: 07.01.2010) Produkte aus einer Aluminium-Kupfer-Lithium-Legierung. Constellium France, 92400 Courbevoie, FR. (C22C 21/00, EPA 2364378, WO 2010/055225, EP-AT: 10.11.2009, WO-AT: 10.11.2009) Vorrichtung zur Sicherung von als Paket gelagerten Aluminium-Stranggussprodukten, sog. Masseln, zu Transportzwecken. Signode System GmbH, 46535 Dinslaken, DE. (B65D 85/20, GM 20 2006 012 782, AT: 21.08.2006) Fenster- und/oder Türflügelelement bestehend aus thermisch getrennten Aluminium-Hohlkammerprofilen mit eingefassten Glasscheiben. heroal – Johann Henkenjohann GmbH & Co. KG, 33415 Verl, DE. (E06B 3/42, GM 20 2010 008 622, AT: 24.09.2010) Kohlenstoffmaterial in Aluminium. Dayou Smart Aluminium Co., Ltd., Seo, Gwangju, KR; Sungkyunkwan University Foundation for Corporate Collaboration, Suwon, Kyonggi, KR. C23C 26/00, PS 60 2008 003 181, EP 2072635, AT: 24.07.2008, EP-AT: 24.07.2008) Verfahren zum Herstellen eines Aluminium-Dotierungsprofils. Infineon Technologies AG, 85579 Neubiberg, DE. (H01L 21/225, OS 593 07 362, EP 0560085, AT: 15.02.1993, EP-AT: 15.02.1993) Verbundmaterial auf Aluminiumbasis und Verfahren zu dessen Herstellung. Honda Motor Co., Ltd., Tokio, JP. (C22C 1/10, PS 11 2005 003 373, WO 2006/075431, AT: 26.10.2005, WOAT: 26.10.2005) Schweißbares Strukturbauteil aus einer Aluminiumlegierung. Aleris Aluminum Koblenz GmbH, 56070 Koblenz, DE. (B32B 15/01, EP 1 169 177, WO 2000/054967, AT: 17.03.2000, EPAT: 17.03.2000, WO-AT: 17.03.2000) Patentblatt Dezember 2011 Al-Ti-Ru-N-C-Hartstoffschicht. Ceratizit Austria Ges.m.b.H., Reutte, Tirol, AT. (C23C 16/30, PS 50 2008 001 850, EP 2179073, WO 2009/003206, AT: 26.06.2008, EP-AT: 26.06.2008, WO-AT: 26.06.2008) Aluminiumschnalle für Tragegurte. Stührmann, Jan-Marc, 28211 Bremen, DE. (A44B 11/04, GM 20 2005 016 661, AT: 21.10.2005) Aluminium-Werkstoff für Rohre von Kraftfahrzeug-Wärmetauschern. Furukawa-Sky Aluminium Corp., Tokio, JP. (C22C 21/00, PS 60 2007 010 872, EP 1892308, AT: 23.08.2007, EP-AT: 23.08.2007) Verfahren zum Herstellen eines Gegenstandes aus Metall, insb. aus einer hochfesten Aluminiumlegierung sowie Verfahren zum Richten eines solchen Gegenstandes. Otto Fuchs KG, 58540 Meinerzhagen, DE. (B23P 13/00, PS 10 2008 003 882, AT: 10.01.2008) ALUMINIUM · 1-2/2012 PAT E N T E Erdbohrdrehbohrmeißel mit Meißelkörpern, die Borkarbidteilchen in Aluminium oder Legierungsmatrixmaterialien auf Aluminiumbasis aufweisen sowie Verfahren zur Herstellung solcher Meißel. Baker Hughes Inc., Houston, Tex., US. (E21B 10/42, EP 2 079 898, WO 2008/042328,AT: 28.09.2007,EP-AT: 28.09.2007, WO-AT: 28.09.2007) Vorrichtung und Verfahren zur Entfernung von Kaffeesatz aus speziellen Kaffeekapseln aus Aluminium und zur Verkleinerung dieser Kapseln. Franssen, Guy-Jacques-Marie, Spa, BE. (A47J, EP 2 146 608, WO 2008/139322, AT: 23.04.2008, EP-AT: 23.04.2008, WO-AT: 23.04.2008) Verfahren zur Herstellung einer Aluminiumlegierung. Nippon Light Metal, Co., Ltd., Shinagawa-ku, Tokio 140-8628, JP. (C22C 1/02, EPA 2379759, WO 2010/079677, EP-AT: 10.12.2009, WO-AT: 10.12.2009) Aluminiumlegierung für einen Gussmotorblock, Gusszylinderblock für einen Verbrennungsmotor sowie Verwendung der Aluminiumlegierung. General Motors Corp., Detroit, Mich., US. (C22C 21/02, PS 11 2004 001 160, WO 2005/010224, AT: 26.03.2004, WO-AT: 26.03.2004) Schmiedekolben aus Aluminiumlegierung. Pechiney Aviatube, Carquefou, FR. (C22C 21/02, GM 20 2005 014 834, AT: 20.09.2005) Metallschäume aus einer Aluminiumlegierung, ihre Verwendung und Verfahren zur Herstellung. Helmholtz-Zentrum Berlin für Materialien und Energie GmbH, 14109 Berlin, DE. (C22C 1/08, EP 2 143 809, AT: 09.06.2009, EP-AT: 09.06.2009) Verfahren zur Herstellung von hochfesten Aluminiumlegierungen, die intermetallische L12-Dispersoide enthalten. United Technologies Corp., Hartford, CT 06101, US. (B22F 3/02, EPA 2385884, WO 2010/077735, EP-AT: 09.12.2009, WO-AT: 09.12.2009) Schweißbare, hochfeste Aluminiumlegierungen. The Boeing Company, Chicago, IL 60606-2016, US. (C22C 21/06, EPA 2384373, WO 2010/080661, EP-AT: 23.12.2009, WO-AT: 23.12.2009) Aluminiumlegierungen, Aluminiumlegierungsprodukte und Herstellungsverfahren dafür. Alcoa Inc., Pittsburgh, PA 15212-5858, US. (C22C 21/00, EPA 2382334, WO 2010/083245, EP-AT: 13.01.2010, WO-AT: 13.01.2010) Sandgießverfahren zur Herstellung von Bauteilen aus Magnesium- oder Aluminiumlegierungen. Rolls-Royce Deutschland Ltd. & Co. KG, 15827 Blankenfelde, DE. (B22D 27/08, OS 10 2010 025 061, AT: 25.06.2010) Bodenflächenelement sowie Bodenfläche und Verwendung einer Bodenfläche. Alcan Technology & Management AG, Neuhausen am Rheinfall, CH. (E04F 15/06, OS 10 2010 013 918, AT: 01.04.2010) ALUMINIUM · 1-2/2012 L12-verstärkte amorphe Aluminiumlegierungen. United Technologies Corporation, Hartford, Conn., US. (C22C 21/00, EP 2 112 241, AT: 31.03.2009, EP-AT: 31.03.2009) Schutzgaszusammensetzung für geschmolzene Nichteisenmetalle wie Magnesium. Honeywell International Inc., Morristown, N.J., US. (C22B 9/00, EP 2 038 439, WO 2008/005920, AT: 02.07.2007, EP-AT: 02.07.2007, WO-AT: 02.07.2007) Legierung auf Magnesiumbasis mit verbesserter Fluidität und Heißreißfestigkeit und Herstellungsverfahren dafür. Korean Institute of Industrial Technology, Cheonan-si Chungcheongnamdo 331-825, KR. (C22C 23/00, EPA 2381002, EP-AT: 24.03.2011, WO-AT: 24.03.2011) Verfahren und System zur Überwachung des Betriebes einer Kohlenstoffblockbrennanlage. Rio Tinto Alcan International Ltd., Montreal, QC H3A 3G2, CA. (F27B 13/14, EPA 2379974, WO 2010/072907, EP-AT: 08.12.2009, WO-AT: 08.12.2009) Zelle zur Elektrogewinnung von Metallen mit Elektrolytreiniger. Rio Tinto Alcan International Ltd., Montreal, Quebec, CA. (C25C 3/06, EP 1 654 401, WO 2005/017234, AT: 10.08.2004, EPAT: 10.08.2004, WO-AT: 10.08.2004) Verfahren zur Herstellung von grobkörnigem Aluminiumhydroxyd. Rio Tinto Alcan International Ltd., Montreal, CA. (C01F 7/14, OS 698 36 962, EPA 0997435, AT: 28.10.1998, EP-AT: 28.10.1998) Fußgängersichere Motorhaube mit Verstärkungsschaumstoff. Alcoa Inc., Pittsburgh, Pa., US. (B62D 25/10, PS 60 2008 003 413, EP 2121419, WO 2008/109811, AT: 07.03.2008, EP-AT: 07.03.2008, WO-AT: 07.03.2008) Beschichtetes Fahrzeugrad und Verfahren. Alcoa Inc., Pittsburgh, Pa., US. (B05D 1/36, PS 603 35 657, EP 1578540, WO 2004/028833, AT: 25.09.2003, EP-AT: 25.09.2003, WO-AT: 25.09.2003) Verfahren zur Herstellung eines Aluminiumlegierungsplattenprodukts mit niedriger Restspannung. Aleris Aluminum Koblenz GmbH, 56070 Koblenz, DE. (C22F 1/04, EPA 2379765, WO 2010/081889, EP-AT: 15.01.2010, WO-AT: 15.01.2010) Verfahren zur Herstellung eines wärmegedämmten Verbundprofils. Norsk Hydro ASA, Oslo, NO. (E06B 3/263, PS 10 2009 054 178, AT: 21.11.2009) Lamellenanordnung für Fassaden. Norsk Hydro ASA, Oslo, NO. (E04F 10/08, EP 1 816 279, AT: 27.01.2007, EP-AT: 27.01.2007) Horizontal stranggegossener Aluminiumlegierungsstab und Verfahren und Vorrichtung zur Herstellung des Stabs. Showa Denko K.K., Tokio, JP. (B22D 11/16, OS 11 2004 000 509, WO 2004/085096, AT: 26.03.2004, WO-AT: 26.03.2004) Tür oder Fenster mit seitlicher Führung des freien Randes einer zentralen Dichtungsverbindung. Norsk Hydro ASA, Oslo, NO. (E06B 7/22, PS 60 2008 003 600, EP 1972749, AT: 22.02.2008, EP-AT: 22.02.2008) Koaxialprofil. Erbslöh Aluminium GmbH, 42553 Velbert, DE. (F16L 9/02, GM 20 2008 006 379, AT: 09.05.2008) Vorrichtung zur Halterung von Bauteilen. Erbslöh AG, 42553 Velbert, DE. (F16M 11/20, GM 20 2010 007 497, AT: 02.06.2010) Korrosionsgeschütztes System für einen Wärmetauscher. Erbslöh Aluminium GmbH, 42553 Velbert, DE. (B23K 1/19, GM 20 2011 101 606, AT: 09.06.2011) Regenschutzschiene. Gutmann AG, 91781 Weißenburg, DE. (E06B 1/34, GM 20 2008 014 277, AT: 27.10.2008) Verfahren zur Herstellung eines Kolbens einer Brennkraftmaschine. KS Kolbenschmidt GmbH, 74172 Neckarsulm, DE. (B23P 15/10, PS 10 2008 034 428, AT: 24.07.2008) Verfahren zur Herstellung eines Kolbens für einen Verbrennungsmotor. Mahle GmbH, 70376 Stuttgart, DE. (B23P 15/10, OS 10 2004 056 519, AT: 24.11.2004) Kolben mit einem Kühlkanal für einen Verbrennungsmotor und Verfahren zur Herstellung des Kolbens. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/22, OS 10 2004 056 870, AT: 25.11.2004) Zweiteiliger Kolben für einen Verbrennungsmotor. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/26, OS 10 2004 057 625, AT: 30.11.2004) Kolben für einen Verbrennungsmotor. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/22 u. F16J 1/00 , OS 10 2010 025 507 u. OS 10 2010 025 508 , AT: 29.06.2010) Gebauter Kolben für einen Verbrennungsmotor. Mahle GmbH, 70376 Stuttgart, DE. (F02F 3/00, PS 50 2005 010 583, EP 1761697, WO 2005/ 124137, AT: 20.06.2005, EP-AT: 20.06.2005, WO-AT: 20.06.2005) Zweiteiliger Kolben für einen Verbrennungsmotor. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/00, PS 50 2006 008 456, EP 1960653, WO 2007/068222, AT: 07.06.2006, EP-AT: 07.06.2006, WO-AT: 07.06.2006) Kolben. Mahle König Kommanditgesellschaft GmbH & Co., Rankweil, AT. (F02F 3/24, EP 2 167 806, WO 2009/006650, AT: 27.03.2008, EP-AT: 27.03.2008, WO-AT: 27.03.2008) Zweiteiliger Kolben für einen Verbrennungsmotor. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/00, EP 2 189 644, AT: 13.11. 2009, EP-AT: 13.11.2009) Fortsetzung in ALUMINIUM 3/2012 91 /,()(59(5=(,&+1,6 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 1.2 Storage facilities for smelting Lagermöglichkeiten i.d. Hütte FLSmidth MÖLLER GmbH Haderslebener Straße 7 D-25421 Pinneberg Telefon: 04101 788-0 Telefax: 04101 788-115 E-Mail: [email protected] Internet: www.flsmidthmoeller.com Kontakt: Herr Dipl.-Ing. Timo Letz Bulk materials Handling from Ship to Cell Bulk materials Handling from Ship to Cell 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 1.3 Anode production Anodenherstellung Solios Carbone – France www.fivesgroup.com Storvik AS Industriveien 13 6600 SUNNDALSØRA/NORWAY A Tel.: +47 71 69 95 00 | Fax: +47 71 69 95 55 www.storvik.no | [email protected] Auto firing systems Automatische Feuerungssysteme Anode Technology & Mixing Equipment Buss ChemTech AG, Switzerland Phone: +4161 825 64 62 E-Mail: [email protected] Internet: www.buss-ct.com www.alu-web.de Mixing Technology for Anode pastes Mischtechnologie für Anodenmassen www.coperion.com mailto: [email protected] Conveying systems bulk materials Förderanlagen für Schüttgüter (Hüttenaluminiumherstellung) FLSmidth MÖLLER GmbH Internet: www.flsmidthmoeller.com see Storage facilities for smelting 1.2 Unloading/Loading equipment RIEDHAMMER GmbH D-90411 Nürnberg Phone: +49 (0) 911 5218 0, Fax: -5218 231 E-Mail: [email protected] Internet: www.riedhammer.de Hydraulic presses for prebaked anodes / Hydraulische Pressen zur Herstellung von Anoden 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 Entlade-/Beladeeinrichtungen FLSmidth MÖLLER GmbH www.flsmidthmoeller.com see Storage facilities for smelting 1.2 ALUMINA AND PET COKE SHIPUNLOADERS Contact: Andreas Haeuser, [email protected] LAEIS GmbH Am Scheerleck 7, L-6868 Wecker, Luxembourg Phone: +352 27612 0 Fax: +352 27612 109 E-Mail: [email protected] Internet: www.laeis-gmbh.com Contact: Dr. Alfred Kaiser RIEDHAMMER GmbH D-90411 Nürnberg Phone: +49 (0) 911 5218 0, Fax: -5218 231 E-Mail: [email protected] Internet: www.riedhammer.de $/80,1,80³ 6833/,(56',5(&725< Melting/holding/casting furnaces 1.4 Anode rodding Schmelz-/Halte- und Gießöfen Anodenanschlägerei Removal of bath residues from the surface of spent anodes Entfernen der Badreste von der Oberfläche der verbrauchten Anoden GLAMA Maschinenbau GmbH Hornstraße 19 D-45964 Gladbeck Telefon 02043 / 9738-0 Telefax 02043 / 9738-50 1.4.1 Anode baking Anodenbrennen HERTWICH ENGINEERING GmbH Maschinen und Industrieanlagen Weinbergerstraße 6, A-5280 Braunau am Inn Phone +437722/806-0 Fax +437722/806-122 E-Mail: [email protected] Internet: www.hertwich.com INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH Konstantinstraße 1a D 41238 Mönchengladbach Telefon +49 (02166) 987990 Telefax +49 (02166) 987996 E-Mail: [email protected] Internet: www.inotherm-gmbh.de Gautschi Engineering GmbH see Casting equipment 3.1 Solios Thermal UK www.fivesgroup.com HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 Anode charging/Anodenchargieren SERMAS INDUSTRIE E-Mail: [email protected] see Casting Machines 1.6 Anode storage/Anodenlager SERMAS INDUSTRIE E-Mail: [email protected] see Casting Machines 1.6 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 E-Mail: [email protected] Internet: www.stopinc.ch Sistem Teknik Ltd. Sti. DES San. Sit. 102 SOK No: 6/8 Y Y.Dudullu, TR-34775 Istanbul/Turkey Tel.: +90 216 420 86 24 Fax: +90 216 420 23 22 E-Mail: [email protected] Internet: www.sistemteknik.com Metal treatment in the holding furnace Metallbehandlung in Halteöfen 1.4.2 Anode clearing Anodenschlägerei Separation of spent anodes from the anode bars Trennen von den Anodenstangen SERMAS INDUSTRIE E-Mail: [email protected] 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 Degassing, filtration and grain refinement Gautschi Engineering GmbH see Casting equipment 3.1 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 Transfer to the casting furnace Überführung in Gießofen GLAMA Maschinenbau GmbH see Anode rodding 1.4 Drache Umwelttechnik GmbH Werner-v.-Siemens-Straße 9/24-26 D 65582 Diez/Lahn Telefon 06432/607-0 Telefax 06432/607-52 Internet: www.drache-gmbh.de SERMAS INDUSTRIE E-Mail: [email protected] see Casting Machines 1.6 GLAMA Maschinenbau GmbH see Anode rodding 1.4 Gautschi Engineering GmbH see Casting equipment 3.1 1.5 Casthouse (foundry) E-Mail: [email protected] see Casting machines 1.6 Transport of liquid metal to the casthouse Gießerei Transport v. Flüssigmetall in Gießereien Hampshire House, High Street, Kingswinford, West Midlands DY6 8AW, UK Tel.: +44 (0) 1384 279132 Fax: +44 (0) 1384 291211 E-Mail: [email protected] www.mechatherm.com $/80,1,80³ Furnace charging with molten metal GLAMA Maschinenbau GmbH see Anode rodding 1.4 Ofenbeschickung mit Flüssigmetall GLAMA Maschinenbau GmbH see Anode rodding 1.4 MARX GmbH & Co. KG www.marx-gmbh.de see Melt operations 4.13 /,()(59(5=(,&+1,6 Treatment of casthouse off gases Behandlung der Gießereiabgase Gautschi Engineering GmbH see Casting equipment 3.1 Scales / Waagen Gautschi Engineering GmbH see Casting equipment 3.1 Wagstaff, Inc. 3910 N. Flora Rd. Spokane, WA 99216 USA +1 509 922 1404 phone +1 509 924 0241 fax E-Mail: [email protected] Internet: www.wagstaff.com HERTWICH ENGINEERING GmbH 1.8 Electrolysis cell (pot) 1.6 Casting machines Gießmaschinen see Casthouse (foundry) 1.5 GAPCast : the Swiss casting solution see Casting machines and equipment 4.7 TM www.alu-web.de Elektrolyseofen Bulk materials Handling from Ship to Cell Bulk materials Handling from Ship to Cell Sawing / Sägen www.mechatherm.com see Smelting technology 1.5 Gautschi Engineering GmbH see Casting equipment 3.1 www.coperion.com mailto: [email protected] Calcium silicate boards Calciumsilikatplatten Promat GmbH – Techn. Wärmedämmung Scheifenkamp 16, D-40878 Ratingen Tel. +49 (0) 2102 / 493-0, Fax -493 115 [email protected], www.promat.de RIHS ENGINEERING SA see Casting machines and equipment 4.7 HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 Pig casting machines (sow casters) Abgasbehandlung Masselgießmaschine (Sowcaster) Gautschi Engineering GmbH see Casting equipment 3.1 Rolling and extrusion ingot and T-bars Solios Environnement www.fivesgroup.com 343 Chemin du Stade 38210 Saint Quentin sur Isère Tel. +33 (0) 476 074 242 Fax +33 (0) 476 936 776 E-Mail: [email protected] Internet: www.sermas.com Formatgießerei (Walzbarren oder Pressbolzen oder T-Barren) Gautschi Engineering GmbH see Casting equipment 3.1 Exhaust gas treatment Heat treatment of extrusion ingot (homogenisation) Formatebehandlung (homogenisieren) Gautschi Engineering GmbH see Casting equipment 3.1 HERTWICH ENGINEERING GmbH Pot feeding systems Beschickungseinrichtungen für Elektrolysezellen FLSmidth MÖLLER GmbH www.flsmidthmoeller.com see Storage facilities for smelting 1.2 1.9 Potroom Elektrolysehalle T T. T. T Tomorrow Technology S.p.A. Via dell’Artigianato 18 Due Carrare, Padova 35020, Italy Telefon +39 049 912 8800 Telefax +39 049 912 8888 E-Mail: [email protected] Contact: Giovanni Magarotto see Casthouse (foundry) 1.5 HERTWICH ENGINEERING GmbH Horizontal continuous casting see Casthouse (foundry) 1.5 Anode transport equipment see Billet Heating Furnaces 1.5 Vertical semi-continuous DC casting / Vertikales Stranggießen HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 Anodenwechselmaschine GLAMA Maschinenbau GmbH see Anode rodding 1.4 Horizontales Stranggießen Gautschi Engineering GmbH see Casting equipment 3.1 Anode changing machine Gautschi Engineering GmbH see Casting equipment 3.1 Anoden Transporteinrichtungen GLAMA Maschinenbau GmbH see Anode rodding 1.4 Crustbreakers / Krustenbrecher GLAMA Maschinenbau GmbH see Anode rodding 1.4 $/80,1,80³ 6833/,(56',5(&725< Dry absorption units for electrolysis exhaust gases Trockenabsorptionsanlage für Elektrolyseofenabgase Solios Environnement www.fivesgroup.com Tapping vehicles/Schöpffahrzeuge GLAMA Maschinenbau GmbH see Anode rodding 1.4 www.alu-web.de 2 1.11 Emptying the cathode shell Ofenwannenentleeren 1.14 Aluminium Alloys Aluminiumlegierungen Cathode bar casting units Kathodenbarreneingießanlage E-Mail: [email protected] see Casting machines 1.6 Could not find your „keywords“? Please ask for our complete „Supply sources for the aluminium industry“. E-Mail: [email protected] RHEINFELDEN ALLOYS GmbH & Co. KG A member of ALUMINIUM RHEINFELDEN Group Postfach 1703, 79607 Rheinfelden Tel.: +49 7623 93-490 Fax: +49 7623 93-546 E-Mail: [email protected] Internet: www.rheinfelden-alloys.eu 1.15 Storage and transport Lager und Transport SMS Siemag g 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 Extrusion billet preparation 2.1.1 Extrusion billet production Pressbolzenbereitstellung Pressbolzenherstellung mfw-maschinenbau.com • Log/Bolzenlager Handling • Bolzensäge, Bolzenfügen Billet heating furnaces MARX GmbH & Co. KG www.marx-gmbh.de see Melt operations 4.13 Hier könnte Ihr Bezugsquellen-Eintrag stehen. Rufen Sie an: Tel. 0821 / 31 98 80-34 Dennis Ross Billet transport and storage equipment Bolzen-Transport- u. Lagereinricht. SERMAS INDUSTRIE E-Mail: [email protected] See Casting Machines 1.6 2.2 Extrusion equipment Strangpresseinrichtungen Öfen zur Bolzenerwärmung www.mechatherm.com see Smelting technology 1.5 Am großen Teich 16+27 D-58640 Iserlohn Tel. +49 (0) 2371 / 4346-0 Fax +49 (0) 2371 / 4346-43 E-Mail: [email protected] Internet: www.ias-gmbh.de $/80,1,80³ Sistem Teknik Ltd. Sti. DES San. Sit. 102 SOK No: 6/8 Y Dudullu, TR-34775 Istanbul/Turkey Y. Tel.: +90 216 420 86 24 Fax: +90 216 420 23 22 E-Mail: [email protected] Internet: www.sistemteknik.com Oilgear Towler GmbH Im Gotthelf 8 D 65795 Hattersheim Tel. +49 (0) 6145 3770 Fax +49 (0) 6145 30770 E-Mail: [email protected] Internet: www.oilgear.de /,()(59(5=(,&+1,6 SMS Meer GmbH see Extrusion equipment 2.2 SMS Meer GmbH Schloemann Extrusion Ohlerkirchweg 66 41069 Mönchengladbach, Germany Tel. +49 (0) 2161 350-0 Fax +49 (0) 2161 350-1667 E-Mail: [email protected] Internet: www.sms-meer.com H+H HERRMANN + HIEBER GMBH Rechbergstraße 46 D-73770 Denkendorf/Stuttgart Tel. +49 711 93467-0, Fax +49 711 34609-11 E-Mail: [email protected] Internet: www.herrmannhieber.de Verpackungseinrichtungen SMS Meer GmbH see Extrusion equipment 2.2 Pressensteuersysteme Oilgear Towler GmbH see Extrusion Equipment 2.2 CTI Systems S.A. Z.I. Eselborn – Lentzweiler 12, op der Sang L-9779 Lentzweiler Tel.: +352 2685 2000 Fax: +356 2685 3000 E-Mail: [email protected] Internet: www.ctisystems.com SMS Meer GmbH www.alu-web.de Temperaturmessung CTI Systems S.A. Z.I. Eselborn – Lentzweiler 12, op der Sang L-9779 Lentzweiler Tel.: +352 2685 2000 Fax: +356 2685 3000 E-Mail: [email protected] Internet: www.ctisystems.com KASTO Maschinenbau GmbH & Co. KG Industriestr. 14, D-77855 Achern Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300 [email protected] / www.kasto.de Hersteller von Band- und Kreissägemaschinen sowie Langgut- und Blechlagersystemen see Extrusion equipment 2.2 Temperature measurement Profil-Lagereinrichtungen Packaging equipment Containers / Rezipienten Press control systems Section store equipment mfw-maschinenbau.com • Automatik Verpackung • Packtische, Profilpaketheber • Spacerhandling und Konzepte Vollert Anlagenbau GmbH see Packaging equipment 2.3 SMS Meer GmbH see Extrusion equipment 2.2 Heating and control equipment for intelligent billet containers Heizungs- und Kontrollausrüstung für intelligente Blockaufnehmer 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 Section transport equipment Profiltransporteinrichtungen SMS Meer GmbH see Extrusion equipment 2.2 Puller equipment Ausziehvorrichtungen/Puller SMS Meer GmbH MARX GmbH & Co. KG www.marx-gmbh.de see Melt operations 4.13 see Extrusion equipment 2.2 Section cooling Nijverheidsweg 3 NL-7071 CH Ulft Netherlands Tel.: +31 315 641352 Fax: +31 315 641852 E-Mail: [email protected] Internet: www.unifour.nl Sales Contact: Paul Overmans Profilkühlung 2.3 Section handling Profilhandling SMS Meer GmbH Stackers / Destackers Stapler / Entstapler see Extrusion equipment 2.2 Section saws Profilsägen $EHUOH$XWRPDWLRQ*PE+&R.* Daimlerstraße 40 74211 Leingarten Tel. 07131 9059-0, Fax 07131 9059-59 Internet: www.aberle-automation.com mfw-maschinenbau.com • Kurzlängensäge automatisiert mfw-maschinenbau.com • 7 und 14 m De- u. Stacker • Kombianlagen $/80,1,80³ 6833/,(56',5(&725< SMS Meer GmbH see Extrusion equipment 2.2 www.mechatherm.com see Smelting technology 1.5 Stretching equipment Reckeinrichtungen SMS Meer GmbH see Extrusion equipment 2.2 Transport equipment for extruded sections Heat treatment furnaces Wärmebehandlungsöfen INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH see Casthouse (foundry) 1.5 Nijverheidsweg 3 NL-7071 CH Ulft Netherlands Tel.: +31 315 641352 Fax: +31 315 641852 E-Mail: [email protected] Internet: www.unifour.nl Sales Contact: Paul Overmans 2.9 Surface finishing of sections Transporteinrichtungen für Profilabschnitte see Billet Heating Furnaces 2.1 Oberflächenveredlung von Profilen Homogenising furnaces Homogenisieröfen mfw-maschinenbau.com • Strahlanlagen CTI Systems S.A. Z.I. Eselborn – Lentzweiler 12, op der Sang L-9779 Lentzweiler Tel.: +352 2685 2000 Fax: +356 2685 3000 E-Mail: [email protected] Internet: www.ctisystems.com HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 2.11 Equipment and accessories Ausrüstungen und Hilfsmittel Inductiv heating equipment Induktiv beheizte Erwärmungseinrichtungen mfw-maschinenbau.com • Skip Handling, Spacer • Kettenförderer see Billet Heating Furnaces 2.1 Vollert Anlagenbau GmbH see Packaging equipment 2.3 2.4 Heat treatment Wärmebehandlung 2.5 Measurement and control equipment Mess- und Regeleinrichtungen Am großen Teich 16+27 D-58640 Iserlohn Tel. +49 (0) 2371 / 4346-0 Fax +49 (0) 2371 / 4346-43 E-Mail: [email protected] Internet: www.ias-gmbh.de www.alu-web.de Extrusion plant control systems Presswerkssteuerungen SMS Meer GmbH Ageing furnace for extrusions Auslagerungsöfen für Strangpressprofile see Extrusion equipment 2.2 2.6 Die preparation and care 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 Werkzeugbereitstellung und -pflege Die heating furnaces Werkzeuganwärmöfen MARX GmbH & Co. KG www.marx-gmbh.de see Melt operations 4.13 schwartz GmbH see Equipment and accessories 3.1 $/80,1,80³ see Billet Heating Furnaces 2.1 see Heat treatment 2.4 Nijverheidsweg 3 NL-7071 CH Ulft Netherlands Tel.: +31 315 641352 Fax: +31 315 641852 E-Mail: [email protected] Internet: www.unifour.nl Sales Contact: Paul Overmans /,()(59(5=(,&+1,6 3 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 Rolling mill technology Walzwerktechnik 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 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 see Cold rolling units / complete pllants 3.6 www.mechatherm.com see Smelting technology 1.5 www.alu-web.de 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 E-Mail: [email protected] Internet: www.sms-siemag.com Geschäftsbereiche: Warmflach- und Kaltwalzwerke Wiesenstraße 30 57271 Hilchenbach-Dahlbruch, Germany Telefon: +49 (0) 2733 29-0 Telefax: +49 (0) 2733 29-2852 Bandanlagen Walder Straße 51-53 40724 Hilden, Germany Telefon: +49 (0) 211 881-5100 Telefax: +49 (0) 211 881-5200 Elektrik + Automation Ivo-Beucker-Straße 43 40237 Düsseldorf, Germany Telefon: +49 (0) 211 881-5895 Telefax: +49 (0) 211 881-775895 Graf-Recke-Straße 82 40239 Düsseldorf, Germany Telefon: +49 (0) 211 881-0 Telefax: +49 (0) 211 881-4902 Filling level indicators and controls Füllstandsanzeiger und -regler Gautschi Engineering GmbH see Casting equipment 3.1 LOI Thermprocess GmbH Am Lichtbogen 29 D-45141 Essen Germany Telefon +49 (0) 201 / 18 91-1 Telefax +49 (0) 201 / 18 91-321 E-Mail: [email protected] Internet: www.loi-italimpianti.com Solios Thermal UK www.fivesgroup.com Melt purification units Schmelzereinigungsanlagen Gautschi Engineering GmbH see Casting equipment 3.1 Metal filters / Metallfilter Wagstaff, Inc. see Casting machines 1.6 Melting and holding furnaces Schmelz- und Warmhalteöfen Gautschi Engineering GmbH see Casting equipment 3.1 3.2 Rolling bar machining Walzbarrenbearbeitung Band saws / Bandsägen SMS Meer GmbH Gautschi Engineering GmbH Konstanzer Straße 37 CH 8274 Tägerwilen Telefon +41 71 666 66 66 Telefax +41 71 666 66 77 E-Mail: [email protected] Internet: www.gautschi.cc Kontakt: Sales Departement see Extrusion equipment 2.2 Slab milling machines Barrenfräsmaschinen SMS Meer GmbH see Extrusion equipment 2.2 $/80,1,80³ 6833/,(56',5(&725< 3.3 Rolling bar furnaces Walzbarrenvorbereitung 3.4 Hot rolling equipment Warmwalzanlagen 3.6 Cold rolling equipment Kaltwalzanlagen g BSN Thermprozesstechnik GmbH see Heat Treatment 2.4 Annealing furnaces Glühöfen EBNER Industrieofenbau Ges.m.b.H. Ebner-Platz 1, 4060 Leonding/Austria Tel. +43 / 732 / 6868-0 E-Mail: [email protected] Internet: www.ebner.cc Gautschi Engineering GmbH see Casting equipment 3.1 Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de see Cold rolling units / complete pllants 3.6 Coil transport systems Bundtransportsysteme Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de BSN Thermprozesstechnik GmbH see Heat Treatment 2.4 www.alu-web.de Coil annealing furnaces Bundglühöfen see Equipment and accessories 3.1 schwartz GmbH see Heat treatment 2.4 Solios Thermal UK www.fivesgroup.com Bar heating furnaces Barrenanwärmanlagen Gautschi Engineering GmbH see Casting equipment 3.1 CTI Systems S.A. Z.I. Eselborn – Lentzweiler 12, op der Sang L-9779 Lentzweiler Tel.: +352 2685 2000 Fax: +356 2685 3000 E-Mail: [email protected] Internet: www.ctisystems.com see Equipment and accessories 3.1 schwartz GmbH see Heat treatment 2.4 EBNER Industrieofenbau Ges.m.b.H. see Annealing furnaces 3.3 Gautschi Engineering GmbH see Casting equipment 3.1 Homogenising furnaces Homogenisieröfen Vollert Anlagenbau GmbH see Packaging equipment 2.3 Coil transport systems Bundtransportsysteme Drive systems / Antriebe SMS Siemag g AG see Rolling mill technology 3.0 Gautschi Engineering GmbH see Casting equipment 3.1 Rolling mill modernisation Walzwerksmodernisierung SMS Siemag g AG see Rolling mill technology 3.0 CTI Systems S.A. Z.I. Eselborn – Lentzweiler 12, op der Sang L-9779 Lentzweiler Tel.: +352 2685 2000 Fax: +356 2685 3000 E-Mail: [email protected] Internet: www.ctisystems.com HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 schwartz GmbH see Heat treatment 2.4 Spools / Haspel SMS Siemag g AG see Rolling mill technology 3.0 Solios Thermal UK www.fivesgroup.com Roller tracks Rollengänge Gautschi Engineering GmbH see Casting equipment 3.1 $/80,1,80³ Hot rolling units / complete plants H+H HERRMANN + HIEBER GMBH Rechbergstraße 46 D-73770 Denkendorf/Stuttgart Tel. +49 711 93467-0, Fax +49 711 34609-11 E-Mail: [email protected] Internet: www.herrmannhieber.de Warmwalzanlagen/Komplettanlagen SMS Siemag g AG see Rolling mill technology 3.0 Vollert Anlagenbau GmbH see Packaging equipment 2.3 /,()(59(5=(,&+1,6 Cold rolling units / complete plants Strip shears/Bandscheren Kaltwalzanlagen/Komplettanlagen see Cold rolling units / complete pllants 3.6 SMS Siemag g AG see Rolling mill technology 3.0 Thin strip / foil rolling mills / complete plant Feinband- / Folienwalzwerke / Komplettanlagen SMS Siemag g AG see Rolling mill technology 3.0 SMS Siemag g AG see Rolling mill technology 3.0 Trimming equipment Besäumeinrichtungen Rolling mill modernization Walzwerkmodernisierung Drive systems / Antriebe SMS Siemag g AG see Cold rolling units / complete pllants 3.6 see Rolling mill technology 3.0 Heating furnaces / Anwärmöfen Gautschi Engineering GmbH see Casting equipment 3.1 schwartz GmbH see Heat treatment 2.4 SMS Siemag g AG see Rolling mill technology 3.0 3.7 Thin strip / foil rolling plant Feinband-/Folienwalzwerke Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de SMS Siemag g AG see Cold rolling units / complete pllants 3.6 Coil annealing furnaces see Extrusion equipment 2.2 Kabelummantelungspressen SMS Meer GmbH see Extrusion equipment 2.2 Bundglühöfen see Rolling mill technology 3.0 Roll exchange equipment SMS Meer GmbH Cable sheathing presses Prozesssimulation Gautschi Engineering GmbH see Casting equipment 3.1 Adjustageeinrichtungen Blech- und Plattenstrecker Prozessoptimierungssysteme Process simulation 3.9 Adjustment devices Sheet and plate stretchers Process optimisation systems Gautschi Engineering GmbH see Casting equipment 3.1 Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de Gautschi Engineering GmbH see Casting equipment 3.1 Walzenwechseleinrichtungen Cable undulating machines Kabelwellmaschinen SMS Meer GmbH SMS Siemag g AG see Extrusion equipment 2.2 see Rolling mill technology 3.0 see Equipment and accessories 3.1 Transverse cutting units Querteilanlagen Vollert Anlagenbau GmbH see Packaging equipment 2.3 Rolling mill modernization Walzwerkmodernisierung schwartz GmbH see Cold colling equipment 3.6 Heating furnaces Anwärmöfen Gautschi Engineering GmbH see Casting equipment 3.1 Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de see Cold rolling units / complete pllants 3.6 SERMAS INDUSTRIE E-Mail: [email protected] See Casting Machines 1.6 INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH see Casthouse (foundry) 1.5 3.10 Process technology / Automation technology Prozesstechnik / Automatisierungstechnik Process control technology Prozessleittechnik SMS Siemag g AG see Rolling mill technology 3.0 Slitting lines-CTL Längs- und Querteilanlagen Wagstaff, Inc. see Cold rolling units / complete pllants 3.6 see Casting machines 1.6 $/80,1,80³ 6833/,(56',5(&725< Strip flatness measurement and control equipment Roll Force Measurement equipment Walzkraftmesseinrichtungen Bandplanheitsmess- und -regeleinrichtungen 3.12 Air extraction systems Abluft-Systeme see Cold rolling units / complete pllants 3.6 ABB Automation Force Measurement S-72159 Västeras, Sweden Phone: +46 21 325 000 Fax: +46 21 340 005 E-Mail: [email protected] Internet: www.abb.com/pressductor ABB Automation Force Measurement S-72159 Västeras, Sweden Phone: +46 21 325 000 Fax: +46 21 340 005 E-Mail: [email protected] Internet: www.abb.com/pressductor Strip Width & Position Measurement equipment Bandbreiten- und Bandlaufmesseinrichtungen Exhaust air purification systems (active) Abluft-Reinigungssysteme (aktiv) Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de SMS Siemag g AG see Rolling mill technology 3.0 Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de SMS Siemag g AG see Rolling mill technology 3.0 Strip thickness measurement and control equipment Banddickenmess- und -regeleinrichtungen 3.14 Storage and dispatch Lagerung und Versand ABB Automation Force Measurement S-72159 Västeras, Sweden Phone: +46 21 325 000 Fax: +46 21 340 005 E-Mail: [email protected] Internet: www.abb.com/pressductor SMS Siemag g AG see Rolling mill technology 3.0 3.16 Coil storage systems Bundlagersysteme 3.11 Coolant / lubricant preparation Kühl-/SchmiermittelAufbereitungg ABB Automation Force Measurement S-72159 Västeras, Sweden Phone: +46 21 325 000 Fax: +46 21 340 005 E-Mail: [email protected] Internet: www.abb.com/pressductor see Cold rolling units / complete pllants 3.6 Rolling oil recovery and treatment units Walzöl-Wiederaufbereitungsanlagen SMS Siemag g AG see Rolling mill technology 3.0 Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de CTI Systems S.A. Z.I. Eselborn – Lentzweiler 12, op der Sang L-9779 Lentzweiler Tel.: +352 2685 2000 Fax: +356 2685 3000 E-Mail: [email protected] Internet: www.ctisystems.com Filter for rolling oils and emulsions Filter für Walzöle und Emulsionen SMS Siemag g AG see Rolling mill technology 3.0 SMS Siemag g AG see Rolling mill technology 3.0 Strip Tension Measurement equipment Bandzugmesseinrichtungen Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de Vollert Anlagenbau GmbH see Packaging equipment 2.3 Rolling oil rectification units Walzölrektifikationsanlagen 3.17 Strip Processing Lines Bandprozesslinien ABB Automation Force Measurement S-72159 Västeras, Sweden Phone: +46 21 325 000 Fax: +46 21 340 005 E-Mail: [email protected] Internet: www.abb.com/pressductor $/80,1,80³ Achenbach Buschhütten GmbH Siegener Str. 152, D-57223 Kreuztal Tel. +49 (0) 2732/7990, [email protected] Internet: www.achenbach.de SMS Siemag g AG see Rolling mill technology 3.0 REDEX Zone Industrielle F-45210 Ferrieres Telefon +33 (2) 38 94 42 00 E-mail: [email protected] Internet: www.tension-leveling.com /,()(59(5=(,&+1,6 Colour Coating Lines Strip Annealing Lines Bandlackierlinien www.bwg-online.com see Strip Processing Lines 3.17 Bandglühlinien 3.18 Production Management systems Produktions Management Systeme www.bwg-online.com see Strip Processing Lines 3.17 Lithographic Sheet Lines www.alu-web.de Lithografielinien www.bwg-online.com see Strip Processing Lines 3.17 Strip Processing Lines 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 Bandprozesslinien see Cold rolling units / complete plants 3.6 Stretch Levelling Lines Streckrichtanlagen www.bwg-online.com see Strip Processing Lines 3.17 BWG Bergwerk- und WalzwerkMaschinenbau GmbH Mercatorstraße 74 – 78 D-47051 Duisburg Tel.: +49 (0) 203-9929-0 Fax: +49 (0) 203-9929-400 E-Mail: [email protected] Internet: www.bwg-online.com Hier könnte Ihr Bezugsquellen-Eintrag stehen. Rufen Sie an: Tel. 0821 / 31 98 80-34 Dennis Ross 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 Förder- und Lagertechnik 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 Förder- und Lagertechnik Vollert Anlagenbau GmbH see Packaging equipment 2.3 CTI Systems S.A. Z.I. Eselborn – Lentzweiler 12, op der Sang L-9779 Lentzweiler Tel.: +352 2685 2000 Fax: +356 2685 3000 E-Mail: [email protected] Internet: www.ctisystems.com H+H HERRMANN + HIEBER GMBH Rechbergstraße 46 D-73770 Denkendorf/Stuttgart Tel. +49 711 93467-0, Fax +49 711 34609-11 E-Mail: [email protected] Internet: www.herrmannhieber.de Could not find your „keywords“? Please ask for our complete „Supply sources for the aluminium industry“. E-Mail: [email protected] $/80,1,80³ 6833/,(56',5(&725< 4.5 Mold accessories and accessory materials Formzubehör, Hilfmittel 4.8 Handling technology www.mechatherm.com see Smelting technology 1.5 Handhabungstechnik Fluxes Flussmittel Solvay Fluor GmbH Hans-Böckler-Allee 20 D-30173 Hannover Telefon +49 (0) 511 / 857-0 Telefax +49 (0) 511 / 857-2146 Internet: www.solvay-fluor.de 4.6 Foundry equipment Molten Metall Level Control Ostra Hamnen 7 SE-430 91 Hono / Schweden Tel.: +46 31 764 5520, Fax: +46 31 764 5529 E-Mail: [email protected] Internet: www.precimeter.com Sales contact: Jan Strömbeck Gießereianlagen www.mechatherm.com see Smelting technology 1.5 CTI Systems S.A. Z.I. Eselborn – Lentzweiler 12, op der Sang L-9779 Lentzweiler Tel.: +352 2685 2000 Fax: +356 2685 3000 E-Mail: [email protected] Internet: www.ctisystems.com www.alu-web.de Vollert Anlagenbau GmbH see Packaging equipment 2.3 Casting machines Gießmaschinen Manipulators Manipulatoren see Equipment and accessories 3.1 Competence in EMC and ASC casting RIHS ENGINEERING SA Tel.: +41 27 455 54 41 E-Mail: [email protected] Internet: www.maschko.ch 4.11 Metallic charge materials HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 Metallische Einsatzstoffe Wagstaff, Inc. Heat treatment furnaces see Casting machines 1.6 Wärmebehandlungsöfen Continuous ingot casting lines and aluminium rod lines ELPO GmbH Kuchengrund 18 71522 Backnang Telefon 07191 9572-0 Telefax 07191 9572-29 E-Mail: [email protected] Internet: www.elpo.de see Billet Heating Furnaces 2.1 4.7 Casting machines and equipment Gießereimaschinen und Gießeinrichtungen GAPCast TM: the Swiss casting solution Casting Technology / Automation Tel.: +41 27 455 57 14 E-Mail: [email protected] Internet: www.gap-engineering.ch $/80,1,80³ SERMAS INDUSTRIE E-Mail: [email protected] See Casting Machines 1.6 Kokillengieß- und Aluminiumdraht-Anlagen Via Emilia Km 310 26858 Sordio-LO Tel. +39.02.988492-1 Fax +39.02.9810358 E-mail: [email protected] q p p Internet: www.properzi.com p p Mould parting agents Kokillentrennmittel Schröder KG Schmierstofftechnik Postfach 1170 D-57251 Freudenberg Tel. 02734/7071 Fax 02734/20784 www.schroeder-schmierstoffe.de Recycling / Recycling Chr. Otto Pape GmbH Aluminiumgranulate Berliner Allee 34 D-30855 Langenhagen Tel:+49(0)511 786 32-0 Fax: -32 Internet: www.papemetals.com E-Mail: [email protected] WEIMA Maschinenbau GmbH E-mail: [email protected] Internet: www.weima.com 4.13 Melt operations Schmelzbetrieb www.mechatherm.com see Smelting technology 1.5 Heat treatment furnaces Wärmebehandlungsanlagen see Billet Heating Furnaces 2.1 /,()(59(5=(,&+1,6 Melting furnaces 4.15 Melt treatment devices Schmelzöfen Büttgenbachstraße 14 D-40549 Düsseldorf/Germany Tel.: +49 (0) 211 / 5 00 91-0 Fax: +49 (0) 211 / 5 00 91-14 E-Mail: [email protected] Internet: www.bloomeng.de Sales Contact: Tim Hennig Melting furnaces Schmelzbehandlungseinrichtungen HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 see Equipment and accessories 3.1 4.14 Melt preparation Schmelzöfen Gautschi Engineering GmbH see Casting equipment 3.1 HERTWICH ENGINEERING GmbH see Casthouse (foundry) 1.5 see Equipment and accessories 3.1 Schmelzvorbereitung Metaullics Systems Europe B.V. Ebweg 14 NL-2991 LT Barendrecht Tel. +31-180/590890 Fax +31-180/551040 E-Mail: [email protected] Internet: www.metaullics.com 4.17 Environment protection and disposal Umweltschutz und Entsorgung Degassing, filtration Entgasung, Filtration Drache Umwelttechnik GmbH Werner-v.-Siemens-Straße 9/24-26 D 65582 Diez/Lahn Telefon 06432/607-0 Telefax 06432/607-52 Internet: http://www.drache-gmbh.de 5 Dust removal Entstaubung NEOTECHNIK GmbH Entstaubungsanlagen Postfach 110261, D-33662 Bielefeld Tel. 05205/7503-0, Fax 05205/7503-77 [email protected], www.neotechnik.com Materials and Recycling Werkstoffe und Recycling Granulated aluminium Aluminiumgranulate MARX GmbH & Co. KG Lilienthalstr. 6-18 D-58638 Iserhohn Tel.: +49 (0) 2371 / 2105-0, Fax: -11 E-Mail: [email protected] Internet: www.marx-gmbh.de WEIMA Maschinenbau GmbH E-mail: [email protected] Internet: www.weima.com www.alu-web.de Chr. Otto Pape GmbH Aluminiumgranulate Berliner Allee 34 D-30855 Langenhagen Tel:+49(0)511 786 32-0 Fax: -32 Internet: www.papemetals.com E-Mail: [email protected] Holding furnaces Warmhalteöfen Büttgenbachstraße 14 D-40549 Düsseldorf/Germany Tel.: +49 (0) 211 / 5 00 91-0 Fax: +49 (0) 211 / 5 00 91-14 E-Mail: [email protected] Internet: www.bloomeng.de Sales Contact: Tim Hennig 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 Joining / Fügen Gautschi Engineering GmbH see Casting equipment 3.1 see Equipment and accessories 3.1 Anodising / Anodisation Henkel AG & Co. KGaA siehe Prozesse für die Oberflächentechnik 6.1 Henkel AG & Co. KGaA D-40191 Düsseldorf Tel. +49 (0) 211 / 797-30 00 Fax +49 (0) 211 / 798-23 23 Internet: www.henkel-technologies.com Cleaning / Reinigung Henkel AG & Co. KGaA siehe Prozesse für die Oberflächentechnik 6.1 Heat treatment furnaces Wärmebehandlungsanlagen Gautschi Engineering GmbH see Casting equipment 3.1 Adhesive bonding / Verkleben Pretreatment before coating Vorbehandlung vor der Beschichtung Henkel AG & Co. KGaA Henkel AG & Co. KGaA siehe Prozesse für die Oberflächentechnik 6.1 siehe Prozesse für die Oberflächentechnik 6.1 $/80,1,80³ 6833/,(56',5(&725< 6.2 Semi products Halbzeuge 6.3 Equipment for forging and impact extrusion Wires / Drähte Ausrüstung für Schmiedeund Fließpresstechnik DRAHTWERK ELISENTAL T W. Erdmann GmbH & Co. Werdohler Str. 40, D-58809 Neuenrade Postfach 12 60, D-58804 Neuenrade Tel. +49(0)2392/697-0, Fax 49(0)2392/62044 E-Mail: [email protected] Internet: www.elisental.de www.alu-web.de International ALUMINIUM Journal 88. Jahrgang 1.1.2012 Verlag / Publishing house V Giesel Verlag GmbH Postfach 5420, 30054 Hannover Hans-Böckler-Allee r 9, 30173 Hannover Tel. 0511 7304-0, Fax 0511 7304-157 [email protected], www.giesel-verla w g.de Postbank / postal cheque account Hannover, BLZ / routing code: 25010030; Kto.-Nr./ account no. 90898-306, Bankkonto/bank account Commerzbank AG, BLZ/routing code: 25040066, Kto.-Nr./account no. 1500222 Geschäftsleitung f / Managing Director Klaus Krause Redaktion / Editorial office f Dipl.-Vw. V Volker Karow Chefredakteur, Editor in Chief F Franz-Me yers-Str. 16, 53340 Meckenheim Tel. +49(0)2225 8359643 Fax +49(0)2225 18458 [email protected] Dipl.-Ing. Rudolf P. Pawlek Hüttenindustrie und Recyclin c g [email protected] Dipl.-Ing. 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Beiträge unter anderem: • Jasper GmbH: Innovative Entwicklungen an und um den industriellen Ofenbau • Vom volumenreichen Alu-Span zum kleinen Brikett • Bartz Maschinenbau liefert komplettes Schmelzwerk nach Frankreich • Aktuelle IME-Forschungsprojekte zum Recycling We will report on companies and equipment partners of the remelt and recycling industry, with emphasis on new machines and plants, projects and technological developments. Topics include: • Jasper GmbH: Innovations and developments for industrial furnaces • From high-volume aluminium swarf to compact briquettes • Bartz supplies complete remelt plant to France • Current research projects on aluminium recycling at IME / RWTH Aachen Weitere Themen Other topics • VAR/OEA Druckgusswettbewerb 2012 – die Gewinner • E-Mobilität und ihre Auswirkungen auf die aluminiumverarbeitende Industrie und die Thermoprozesstechnik Erscheinungstermin: Anzeigenschluss: Redaktionsschluss: • VAR/OEA Die Casting Competition 2012 – the winners • Latest news from the aluminium industry 12. März 2012 27. Februar 2012 20. Februar 2012 Date of publication: Advertisement deadline: Editorial deadline: 12 March 2012 27 February 2012 20 February 2012 Abonnement-Bestellung Subscription-Order U Ja, wir möchten die Zeitschrift ALUMINIUM ab sofort zum Jahresbezugspreis von EUR 289,- (Inland inkl. Mehrwertsteuer und Versandkosten) abonnieren. Das Magazin erscheint zehn Mal pro Jahr. 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Whether in new plant construction or revamp projects, our solid process know-how encompasses the complete production cycle, including the integration of the latest electrical engineering and automation solutions. Confidence through performance – SMS Siemag. SMS SIEMAG AG Eduard-Schloemann-Strasse 4 40237 Düsseldorf, Germany Phone: +49 (0) 211 881-0 Fax: +49 (0) 211 881-4902 E-mail: [email protected] Internet: www.sms-siemag.com