SMS Siemag AG - ALU

AL U MIN IU M 9
Official media partner of 17th Arabal Conference
Special:
The aluminium industry
in the Gulf / Arabal 2013
Interview with Emal CEO
Saeed Fadhel Al Mazrooei
Kizad aluminium
cluster taking shape
EPCM – a vital activity in
the world of aluminium
89. Volume
September 2013
© Emal
Best technology for the
rolling industry in the Gulf
Volume 89 · September 2013
International Journal for Industry, Research and Application
9
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EDITORIAL
Volker Karow
Chefredakteur
Editor in Chief
Die Aluminiumwelt
trifft sich in Abu Dhabi
Aluminium world to
meet in Abu Dhabi
ALUMINIUM · 9/2013
Zum zweiten Mal in diesem Jahr blicken wir
in unserem Special auf die Golfregion. Nach
der Aluminium Middle East 2013 im April in
Dubai steht im November ein zweites Großereignis vor der Tür, dann in Abu Dhabi: die
Arabal Conference 2013, dieses Jahr ausgerichtet von Emirates Aluminium. Der Veranstaltungsort ist vorausschauend gewählt: In
Abu Dhabi entsteht mit Kizad ein riesiges Industriegebiet, das sowohl heimische wie ausländische Investoren und unterschiedlichste
Branchen anziehen will. Dieses Industrieprojekt ist weit sichtbarer Ausdruck dessen,
dass sich die Golf-Staaten im globalen Wirtschaftsgeschehen längst nicht mehr nur auf
Öl und Gas exportierende Länder reduzieren
lassen. Stattdessen sind sie auf dem Weg zu
wirtschaftlich diversifizierten Gesellschaften,
die ihrer Bevölkerung neue Entwicklungsperspektiven eröffnen.
Die dreitägige Veranstaltung steht im Zeichen jüngster und künftiger Entwicklungen
und Projekte aus dem Upstream- und Downstream-Sektor der Aluminiumindustrie am
Golf. Darüber hinaus wird der Bogen zu den
globalen Marktfragen und wirtschaftlichen
Herausforderungen der Branche gespannt –
bis hin zu Aspekten des LME-Warehousing,
das in jüngster Zeit durch die Ereignisse um
Goldman Sachs besondere Aktualität erfährt.
Details des Programms können in dieser Ausgabe nachgelesen werden (S. 32).
Dass die Konferenz von Emal ausgerichtet wird, versteht sich fast von selbst. In Abu
Dhabi ansässig spielt Emal eine zentrale Rolle
beim Aufbau des Aluminiumclusters in Kizad. Obendrein entsteht derzeit Emals dritte
Ofenlinie, mit der das Unternehmen seine
Hüttenproduktion auf 1,3 Mio. Tonnen fast
verdoppeln wird. Den Konferenzteilnehmern
bietet sich Gelegenheit zu einer Besichtigungstour, die einen bleibenden Eindruck von diesem Produktionsstandort hinterlassen wird.
ALUMINIUM sprach jüngst mit Emal President und CEO Saeed Fadhel Al Mazrooei
über die Entwicklung des Unternehmens, seine Marktstellung, die Erwartungen an die Arabal-Konferenz und die Integration von Dubal
und Emal zu Emirates Global Aluminium.
Auch für die Ausrüster der Aluminiumindustrie sind die Golf-Staaten von wachsender Bedeutung geworden. Das betraf in den
letzten Jahren zum einen die Anbieter von
Maschinen und Anlagen für Anodenfabriken,
Hütten und Gießereien, zum anderen die
Ausrüster für Strangpresswerke. Inzwischen
sind mit Oman Aluminium Rolling Co. und
dem Ma’aden-Alcoa-Walzkomplex zwei Flagschiffprojekte für Walzprodukte hinzugekommen, die kurz vor Fertigstellung stehen.
For the second time this year our Special
is looking at the Gulf region. Following Aluminium Middle East 2013 in Dubai, a second
major event is fast approaching and will take
place in November: the Arabal Conference
2013, this year hosted by Emirates Aluminium. The venue has been chosen with foresight:
in Abu Dhabi a superlative industrial development project – Kizad – is nascent which aims
to attract both domestic and foreign investors
and the most varied industry sectors. This industrial project is a highly visible demonstration that nowadays the Gulf States are much
more than oil and gas exporting countries. Instead, they are on the way towards becoming
economically diversified societies which are
opening up new development prospects for
their population.
The three-day event will be taking place
against the background of recent and future
developments in the Gulf region. Naturally, the
focus is on regional projects in the upstream
and downstream sectors of the aluminium industry. Moreover, an approach will be made
to global market questions and the economic
challenges faced by the industry – including
aspects related to LME warehousing which
has recently become particularly topical in the
light of events surrounding Goldman Sachs.
For details of the programme see page 32.
That the conference is being organised by
Emirates Aluminium is almost self-explanatory. Located in Abu Dhabi, the company plays
a central role in building up the aluminium
cluster in Kizad. On top of everything else
Emal’s third potline is under construction,
with which the company will almost double
its aluminium output to 1.3 million tonnes.
Conference participants will be offered the
opportunity to be taken on a site tour which
will certainly leave them with a lasting impression of this smelter complex. Recently ALUMINIUM had the opportunity to talk with the
president and CEO of Emal, Saeed Fadhel Al
Mazoorei – about the company’s development, its market position, what is expected
from the Arabal Conference, and the merger
of Dubal and Emal into Emirates Global Aluminium (see pp. 26-30).
For equipment suppliers to the aluminium
industry the Gulf countries have become increasingly important. In recent years that has
concerned on the one hand suppliers of plant
and machinery for anode plants, smelters and
casthouses, and on the other hand suppliers
of extrusion plants. Meanwhile, with Oman
Aluminium Rolling Co. and the Ma’adenAlcoa rolling complex two flagship projects
for rolled products have been added, both of
them nearing completion.
3
I N H A LT
EDITORIAL
Di e Al u mi n i u mwe l t t ri fft s i ch i n Ab u Dh a b i
A l umi n i u m wo rl d t o me e t i n Ab u Dh a b i ........................................... 3
A K T U E L L E S • N E W S I N B R I E F • E V E N T S ................... 6 - 10
WIRTSCHAFT • ECONOMICS
A l - P re i s e / P ro du k t i o n s da t e n de r de u t s ch e n Al u mi n i u mi n du str ie ..... 12/ 14
26
A l umi n i u m S.A. i n c re a s e s p ro du c t i o n , re du c e s c o st s .......................... 16
A l umi n i u m – Th e t ra n s p o rt a t i o n ma t e ri a l o f t h e fu t u re ...................... 19
Pr i ma ry a l u mi n i u m i n du st ry du ri n g t h e fi rst h a l f o f 2 013 , Par t II ........ 20
A L U M I N I U M I N D U S T R Y I N T H E G U L F • A R A B A L 2 0 13
I n t e rvi e w wi t h E ma l p re s i de n t a n d CE O , Sa e e d Fa dh e l Al
M a zro o e i : “ We c a n c o mp e t e wi t h a n y c o mp a n y i n t h e wo rl d” ............ 26
17 th Ara b In t e rn a t i o n a l Al u mi n i u m Co n fe re n c e 2 013 ......................... 32
B e st t e ch n o l o gy fo r t h e a l u mi n i u m ro l l i n g i n du st ry i n t h e G ulf ........... 34
38
K i z ad a l u mi n i u m c l u st e r t a k i n g s h a p e ............................................ 38
E PCM – a vi t a l a c t i vi t y i n t h e wo rl d o f a l u mi n i u m ........................... 42
In Europe, Middle East and Africa contact: COMEXALE
4
TEL
+33-3-83-354649
FAX
+33-3-83-355092
WWW.comexale.com
ALUMINIUM · 9/2013
CONTENTS
B ech t e l keeps b ui l d i n g h i st o r y . . . . . . . . . . . . . . . ....................................... 46
Al u m i n i u m B a h rai n – O n e o f t h e l arg e st an d
most m ode r n a l um i n i um s m e l t e r s i n t h e wo rl d ................................ 48
Su cce ssf u l st a r t - up o f t h e f um e t re at me n t
c e n t re a t R a s A l K h ai r al umi n i um s me l t e r ....................................... 50
Hi g h pe r f or m an c e o f ‘ E o l i o s’ p i t ch f ume
t re a t m e n t sy st e m at Q at a l um p a st e p l an t ....................................... 54
T E CH N O LO G I E • T E CH N O LO GY
42
K öl l e m a n n G m b H – ma r ke t l e ad e r f o r p e t c o ke p re h e a t e rs .................56
I n t e g ra t i on de r G a t t i e r un g s re ch n un g m ach t R e c yc l i n g
n och e f f i z i e n t e r • I n t e g rat e d ch arg e a n d al l o y
c a l cu l a t i on m a ke s re c yc l i n g e ve n mo re e f f i c i e n t .............................. 58
Tu r l a t a rget s e qui p m e n t qual i t y a n d
p e r f or m a nce fo r c ust o m e r s uc c e s s. . . . . . . . . . ........................................62
B el t e AG – S p e z i al i st f ür d i e Wä r m e b e h a ndl u n g vo n
Al u m i n i u m ba ut e i l e n : „Wi r s i n d st ä n d i g b e st re b t , P ro z e s s e
we i t er z u en t w i cke l n “ • B e l t e AG – S p e c i a l i st i n t h e
h ea t t re a t m e n t o f al umi n i um c o mp o n e n t s : “ We c o n st a n t l y
st r i ve t o devel o p o ur p ro c e s s e s f ur t h e r ” . . ........................................66
54
Infrared heat transfer for thin-walled aluminium automotive castings ....69
E u rog u ss 2 014 : „ A n me l d e st a n d d e r Vo r ve ra n st a l t u n g
bere i t s e r re i ch t “ • Euro g us s 2 014 : “ L e ve l o f
a ppl i ca t i ons f o r p re vi o us e ve n t al re a d y re a ch e d” .............................. 71
Gießtechnisch verbunden: Hybride CFK-AluminiumFügeverbindung für den Leichtbau . . . . . . . . . . ........................................72
ACTech nimmt Stoßwellenanlage zur
Entkernung komplexer Gussteile in Betrieb .......................................72
Automated band saws for precise linear cuts ....................................73
Innovative Lösungen für das Strahlen von Gussprodukten
Innovative shot blasting solutions for foundries .................................74
A N W E N D U N G • A P P L I C AT I O N
Inserenten dieser Ausgabe
List of advertisers
Aluminium Bahrain, Bahrain
41
Arabal Conference 2013, UAE
33
Aumund Fördertechnik GmbH, Germany 47
Brochot, France
43
Buss AG, Switzerland
57
Castool Tooling Systems, Canada
4
De Winter Engineering, The Netherlands 75
Didion International Inc., USA
Dubal Aluminium, UAE
21
100
Emirates Aluminium UAE
13
Eredi Scabini Srl, Italy
51
Fata Hunter SpA, Italy
29
Al u m i n i u m t u be f e i e r t 10 0 J a h re E r f o l g s g e sch i ch t e
Al u m i n i u m t u b e c e l e b rat e s c e n t e n ar y . . . . . ........................................76
Fives Solios, France
31
Hertwich Engineering GmbH, Austria
2
O pel st el l t n eue n Vo l l a l u- Dre i z yl i n d e r auf IAA vo r
O pel pre sen t s n e w a l l - a l um i n i um 3 - c yl i n d e r a t IAA ...........................77
IMS Messsysteme GmbH, Germany
7
C O M PA N Y N E W S W O R L D W I D E . . ................................... 78-82
D O C U M E N TAT I O N
Pa t en t e . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................82
I m pressu m • I mp r i n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................98
Vor scha u • P re vi e w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................98
L I E F E R V E R Z E I C H N I S • S U P P L I E R S D I R E C T O R Y .............84
ALUMINIUM · 9/2013
Gautschi Engineering GmbH, Switzerland 35
Inotherm Industrieofen- und
Wärmetechnik GmbH, Germany
19 , 75
Italtecno, Italy
17
IUL – TU Dortmund, Germany
99
Kizad, Abu Dhabi
27
Maka Systems GmbH, Germany
25
Mino SpA, Italy
15
Precimeter Control AB, Sweden
37
Refratechnik Steel GmbH, Germany
39
Riedhammer GmbH, Germany
45
Rösler Oberflächentechnik GmbH, Germany 71
Siemens Plc, UK
11
Wagstaff Inc., USA
23
Yxlon International, Germany
9
5
AKTUELLES
© Amag
Amag voll ausgelastet, Ergebnis schwächer
Luftaufnahme vom Amag-Standort in Ranshofen, Österreich
Die Amag-Gruppe war im ersten Halbjahr
2013 in den drei Segmenten Metall, Gießen
und Walzen voll ausgelastet. Die Auftragslage entwickelte sich im zweiten Quartal trotz
eines schwierigeren Konjunkturumfeldes zufriedenstellend. Die gesamte Absatzmenge
konnte in den ersten sechs Monaten dieses
Jahres auf 181.900 Tonnen (+1%) gesteigert
werden, wobei der Zuwachs im Segment Wal-
zen (+4%) die Rückgänge in den Segmenten
Gießen und Metall (-2% bzw. -1%) ausglich.
Gegenüber dem Vorjahresquartal blieb die
Absatzmenge mit 93.700 Tonnen annähernd
stabil.
Der Halbjahresumsatz 2013 ging gegenüber dem Vorjahreszeitraum um fünf Prozent
auf 412,4 Mio. Euro zurück – vor allem bedingt durch den um acht Prozent niedrigeren
durchschnittlichen Aluminiumpreis. Das
Ergebnis vor Zinsen, Steuern und Abschreibungen (Ebitda) verringerte sich um 9,4 Prozent auf 65,4 Mio. Euro.
Amag konnte Anfang 2013 einen Großauftrag von EADS gewinnen, der die Lieferung
von Aluplatten und -blechen für Struktur- und
Außenhautteile vorsieht. Das Auftragsvolumen beträgt bis zu 100 Mio. Euro. Der Werksausbau, mit dem die Produktionskapazität in
Ranshofen um 50 Prozent ausgeweitet wird,
liegt laut Unternehmen voll im Plan. Das neue
Walzwerk werde im zweiten Halbjahr 2014
in Betrieb gehen, so Vorstandschef Gerhard
Falch.
Amag geht für das dritte Quartal von weiterhin voll ausgelasteten Kapazitäten aus.
Ende Juli lag der LME-Preis für Aluminium
bei 1.800 Dollar je Tonne. Auch bei diesem
niedrigen Preisniveau könne die AlouetteHütte in Kanada aufgrund ihrer sehr guten
Kostenposition „einen wesentlichen Ergebnisbeitrag liefern“, so das Unternehmen. Aufgrund des niedrigeren Aluminiumpreises und
hohen Margendrucks erwartet der Vorstand
ein niedrigeres Gruppenergebnis als im Vorjahr. Das Ebitda werde in der Bandbreite von
116 bis 121 Mio. Euro liegen.
Deutsche Aluminiumindustrie wächst in Erzeugung und Verarbeitung
Hüttenaluminium (+15,1%) und 315.718
Tonnen Recyclingaluminium (-4,1%). GDAGeschäftsführer Christian Wellner dazu: „Im
ersten Halbjahr 2013 hat die deutsche Hüttenaluminiumproduktion den höchsten Wert
seit der Wirtschaftskrise 2008/09 erreicht.
Damit bleibt die Erzeugung von Aluminium
ein wichtiger Wertschöpfungsbestandteil der
Aluminiumindustrie in Deutschland.“
Die Erzeugung von
A l u m i n i u m h a lb z e u g
– Walz- und Strangpressprodukte sowie Drähte
und Schmiedeteile – betrug 1,266 Mio. Tonnen
(+3,2%).
Die Produktion von
Aluminiumguss – Sand-,
Kokillen- und Druckguss
– sank dagegen deutlich,
und zwar auf 403.412
Tonnen (-7,2%). Im Juni
wurden dagegen 76.075
Tonnen
und damit so viel
Die Produktion von Walzprodukten legte im ersten Halbjahr 2013 zu
© ALUMINIUM
Die deutsche Aluminiumindustrie hat sich im
ersten Halbjahr 2013 gut behauptet. Die Produktion konnte in vielen Bereichen deutlich
zulegen. Für das zweite Halbjahr erwartet die
Branche weiteres Mengenwachstum.
Die Erzeugung von Rohaluminium stieg
auf 549.081 Tonnen und damit um 3,3 Prozent gegenüber dem Vorjahreszeitraum.
Die Menge teilt sich auf in 233.363 Tonnen
6
wie im Vorjahresmonat produziert.
175.378 Tonnen (+0,5%) wurden in der
Weiterverarbeitung hergestellt. Sie gliedert
sich in die Segmente Folien und dünne Bänder
(+0,2%), Tuben, Aerosol- und sonstige Dosen
(+5,7%) sowie Metallpulver (+5,0%).
Das konjunkturelle Umfeld war im ersten
Halbjahr relativ schwach und durch eine hohe
Unsicherheit gekennzeichnet. Nach Ansicht
von Andreas Postler, Leiter Volkswirtschaft
und Statistik beim GDA, hat sich die deutsche Aluminiumindustrie in diesem Umfeld
jedoch gut behauptet. „Unsere Industrie hat
ihre Wettbewerbsfähigkeit in den letzten Jahren durch Modernisierungen und Restrukturierungen deutlich gesteigert. So konnten unsere Unternehmen im ersten Halbjahr 2013
– trotz einer rückläufigen Mengenkonjunktur
– in vielen Segmenten Marktanteile gewinnen.“ Postler erwartet eine Fortsetzung dieser
positiven Entwicklung: „Das konjunkturelle
Umfeld hellt sich wieder auf. Für das zweite
Halbjahr gehen wir von einer leicht anziehenden Mengenkonjunktur aus.“
ALUMINIUM · 9/2013
NEWS IN BRIEF
Deliveries of aluminium foil products moved
ahead in Q2 2013, confirming that the recovery in demand seen in 2012 continues. Overall production for the year to date reached
419,800 tonnes, a rise of 2.5% compared with
the first half of 2012. Exports too maintained
momentum, increasing by 3.2% in Q2 2013,
helping first half sales outside the European
market to an impressive 6.6% rise.
Q2 results showed thinner gauges, used
largely for flexible packaging and household
foils, once again led the way with a rise of
2.3%. Thicker gauges, used typically for semirigid containers and technical applications,
dropped back by just 1.8%, indicating recovery is more uneven for these products. Total
deliveries were 210,400 tonnes, which is an
increase of 1.3% compared with Q2 2012.
Manfred Mertens, EAFA vice-president
and Roller Group chairman, commented:
“While the outlook is still somewhat uncertain
there are clear signs that the trend is upward,
although there may still be some negative
quarters in some areas, the ‘downs’ seem to
be smaller and the ‘ups’ larger.”
Alufoil Trophy 2014 –
a chance to ‘shine’
in aluminium foil!
ing on the launch of this year’s competition
Guido Aufdemkamp, director Communication
at EAFA, said: “The Alufoil Trophy 2014 is
a special opportunity for companies to bring
worldwide attention to their latest ideas and
products. We look forward to an exciting and
hotly contested competition.”
Entries will be accepted until 29 November
2013. More details on www.alufoil.org.
The launch of the Alufoil Trophy 2014, organised by the European Aluminium Foil Association (EAFA), offers companies the chance to
enter and place the spotlight on their latest
innovations and technologies using alufoil, in
the most prestigious competition of its kind.
Five categories for entries provide ample
scope for all kinds of creativity and technological developments – across the entire range of
industrial applications and covering the most
crucial challenges for alufoil and aluminium
closure manufacturers. The categories are:
Marketing & Design, Consumer Convenience, Resource Efficiency, Product Preservation and Technical Innovation. Comment-
© EAFA
Alufoil: production and
deliveries on the rise
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[email protected] | www.ims-gmbh.de
ALUMINIUM · 9/2013
7
AKTUELLES
© Trimet
Trimet präsentiert sich auf der IAA
Strukturbauteile für Pkw
Auf der Internationalen Automobil-Ausstellung (IAA), die in diesem Jahr vom 12. bis
22. September in Frankfurt am Main stattfindet, präsentiert sich die Trimet Aluminium
SE als leistungsstarker Partner der Automobilindustrie. Der mittelständische Werkstoffspezialist behauptet sich mit Produkten und
Dienstleistungen aus einer Hand als Systemlieferant der Branche. Der steigende Bedarf
nach Strukturteilen erweist sich für Trimet als
Wachstumstreiber. Marktentscheidend sind
unter anderem die Speziallegierungen, die Trimet im eigenen Forschungslabor entwickelt.
Trimet hat im vergangenen Jahrzehnt für
rund 200 Mio. Euro die beiden Produktionsstandorte in Harzgerode und Sömmerda ausgebaut, um das Produktportfolio zu erweitern
und den wachsenden Kundenstamm aus der
Scholz-Gruppe kündigt
Restrukturierung an
australischen Recyclinggruppe CMA eingestellt werden. Auch das Standortportfolio in
Europa wird bereinigt, Randaktivitäten wie
die Aluminiumproduktion sollen abgestoßen
werden. Im Übrigen werden die klassischen
Instrumente zur Ergebnisverbesserung und
Entschuldung eingesetzt: Kosteneinsparungen
und Stellenabbau, der bereits im zweiten
Halbjahr erfolgen soll.
Die Euler Hermes Rating hat unterdessen
das Rating der Scholz AG auf B herabgestuft;
der Ausblick wurde von „stabil“ auf „unbestimmt“ gesetzt.
Die Recyclingbranche ist derzeit in einer
schwierigen Marktverfassung, gekennzeichnet
durch niedrige Verkaufspreise und partielle
Überkapazitäten. Einer der größten Aluminiumrecycler in Deutschland, die Firma Oetinger, ist insolvent, während die Scholz AG
ein umfassendes Restrukturierungs- und Entschuldungsprogramm ankündigt, das bis 2015
umgesetzt werden soll.
Die Scholz-Gruppe, die mit einem Ausstoß von fast 10 Mio. Tonnen an Sekundärrohstoffen zu den Marktführern beim Handel
und der Aufbereitung von Eisen und NEMetallen in Europa zählt und 2012 einen
Umsatz von 4,7 Mrd. Euro erwirtschaftete, will sich künftig auf das Kerngeschäft
Recycling von Eisen- und NE-Metallen konzentrieren und ihr Beteiligungsportfolio bereinigen. So soll das Asiengeschäft deutlich
reduziert und die Geschäftsbeziehungen zur
8
Hydro-Ausschreibung
für Tonerde-Logistik
Hydro hat in Deutschland eine Online-Ausschreibung für die Logistik zur Oxidversorgung
des Rheinwerks in Neuss platziert. Interessierte
Dienstleister sind aufgefordert, nachhaltigere
Lösungen mit einer weiteren Minderung der
spezifischen CO2-Emissionen vorzuschlagen.
Automobilindustrie zu bedienen. Zu den
Schwerpunkten im Automotive-Geschäft zählen Getriebe- und Kupplungsgehäuse für Direktschaltgetriebe. Zudem ist Trimet seit 2009
Alleinlieferant von Fahrwerksteilen für einen
namhaften deutschen Automobilhersteller.
Die im Kokillenguss hergestellten Fahrwerksteile werden in Deutschlands modernster
Schwerkraftkokillenguss-Anlage am Standort
Harzgerode produziert.
Als wesentlicher Wachstumstreiber zeigt
sich immer mehr der steigende Bedarf der Automobilindustrie an Strukturteilen. In Verbindung mit den von Trimet anwendungsspezifisch entwickelten Aluminiumlegierungen ist
dies zu einer weiteren tragenden Säule im
Automotive-Bereich geworden. „Unsere eigene Metallbasis, das damit verbundene Werkstoff-Knowhow und die Ausrichtung auf komplexe Gussteile mit großer Bearbeitungstiefe
erweist sich auch für unsere Kunden als nachhaltige Strategie. Der steigende Bedarf stärkt
die Standorte und schafft neue Arbeitsplätze“, sagt Trimet-Vorstandsmitglied Thomas
Reuther.
Trimet versorgt alle namhaften Automobilhersteller und -zulieferer mit maßgeschneiderten Lösungen und Leichtbauteilen.
Mit einem Maschinenpark von 530 bis 4.100
Tonnen deckt das Unternehmen ein breites
Produktportfolio bei seinen Kunden ab.
Vom zweiten Halbjahr 2014 an soll der geplante Kontrakt die gesamte Logistik für jährlich 300.000 Tonnen Tonerde abdecken. Der
Dienstleister transportiert dabei Aluminiumoxid von den Ladestellen in Stade und vom
Rotterdamer Hafen. Er ist verantwortlich für
alle Zwischenlagerungs- und Umschlagsaktivitäten bis hin zum Einblasen des Oxids in
die Silos im Rheinwerk. Außerdem umfasst
der Auftrag innerbetriebliche Umfuhren von
Sekundäraluminiumoxidmengen.
Der Logistikvertrag soll auch Nachhaltigkeitsaspekten Rechnung tragen. „Hier sehen
wir noch großes Potenzial und deshalb steht
für uns die Ausarbeitung eines ganzheitlich,
innovativen Logistikkonzeptes sowie eine
langfristige Partnerschaft mit dem Logistikdienstleister im Vordergrund“, sagt Irmtraud
Pawlik, in der Geschäftsfeldleitung von Rolled
Products verantwortlich für das Rheinwerk.
Die Ausschreibung betrifft ein Volumen
von mehreren Millionen Euro und startet
exklusiv auf der Ausschreibungsplattform
Cargoclix.
ALUMINIUM · 9/2013
NEWS IN BRIEF
Dubal products rated
Rio Tinto abandons
for sustainable builddivestment of
ing by LEED and DGNB Pacific Aluminium
mine and an alumina refinery. Media have
recently reported that Rio Tinto plans to sell
13 aluminium facilities in Australia, Europe
and the US, as it looks to trim its Alcan business. The Anglo-Australian company did not
disclose how much it expects to raise from the
sales.
Tom Albanese, Rio’s chief executive, said:
“The assets identified for divestment are
sound businesses that are well-managed with
productive workforces. But they are no longer aligned with our strategy, and we believe
they have a bright future under new ownership. We can choose the most opportune timing to divest these assets, which may not occur until the economic climate improves.”
Products manufactured by Dubai Aluminium Mining giant Rio Tinto has abandoned the
(Dubal), UAE, have been declared suitable for plan to sell its loss-making aluminium operasustainable building practices, as per the crite- tions in Australia and New Zealand. “Followria defined by the US Green Building Coun- ing a comprehensive review we have detercil’s Leadership in Energy and Environmental mined that the divestment of Pacific AluminDesign (LEED) rating system and the Deutsche ium for value is not possible in the current
Gesellschaft für Nachhaltiges Bauen (DGNB, environment and it will be reintegrated into
the German Sustainable Building Council). the Rio Tinto Alcan group,” the company
Both declarations, which follow a rigorous says. Pacific Aluminium’s operations include
assessment process by an independent agen- four aluminium smelters as well as a bauxite
cy, attest to Dubal’s commitment to sustainability and
environment protection.
“This is a major development for Dubal, as more
than 60 percent of our annual production comprises
aluminium billets that are
used extensively by extruders to produce construction
components – such as window and door frames,” says
Walid Al Attar, executive
vice president for Marketing
and Sales. “The international
Q Digital X-ray inspection of multiple parts and sizes
rating by LEED and DGNB
Q High-resolution images in 2D and 3D
places these products in a
strong position to be speciQ Digital radiography and computed tomography
fied by end-users in the buildup to 600 kV
ing and construction industry
Q Manual, semi-automatic and fully automated
worldwide.”
inspection
The two sustainability
ratings are an important differentiator in the local market, where billets account
Please contact our sales
for the major proportion of
organization:
annual sales. Al Attar points
Essener Bogen 15,
out that new laws have been
22419 Hamburg, Germany
enacted in Dubai, whereby
Phone +49 40 527 29 - 101
or visit us at
the incorporation of sustainwww.yxlon.com
able measures will be mandatory in all new construction
projects in the Emirate as of
next year. “The suitability
of our products is tangible
evidence of Dubal’s support
for the government’s green
building agenda, simultaneously confirming the success of our efforts to produce
‘green metal’ as part of our
overall strategy to minimise
the impact of our business on
the environment,” he says.
Whatever your task
... we have the solution
Technology with Passion
ALUMINIUM · 9/2013
EVENTS
Weltleitmesse „Schweißen & Schneiden“ lädt nach Essen ein
Globales Innovationsschaufenster öffnet vom 16. bis 21. September 2013
Als internationales Innovationsschaufenster
bietet die Messe das optimale Umfeld für die
Vorstellung neuer Produkte, Verfahren und
Dienstleistungen. Alle großen Industrienationen und namhaften Hersteller sind in Essen
vertreten. Die größte Ausstellergruppe stellt
Deutschland mit 379 Unternehmen, gefolgt
von China (170 Aussteller), Italien (96) und
den USA (41). Die ausländische Beteiligung
liegt insgesamt bei rund 61 Prozent – ebenfalls
ein sehr guter Wert, der das Renommee der
Messe als wichtigste internationale Branchenplattform für Wissenstransfer, Networking
und Nachwuchsförderung unterstreicht.
Viele Länder nutzen die Fachmesse, um
auf nationalen Gemeinschaftsständen die
Leistungskraft ihrer Unternehmen kompakt
zu präsentieren. Dazu zählen die USA, die
mit zwei Ständen in den Hallen 7 und 8 vertreten sind, sowie China mit drei nationalen
Auftritten in den Hallen 7, 8.1 und 9.1. Weitere Gemeinschaftsstände werden von Frankreich, Japan, Taiwan, Italien sowie erstmals
Südkorea unterhalten.
Zu den innovativen Exponaten der Schweißen & Schneiden zählen Geräte, Anlagen und
Werkstoffe – nicht nur für das Schweißen
und Schneiden, sondern auch für verwandte Verfahren wie Löten, Wärmebehandlung
oder Thermisches Spritzen. So demonstrieren
13 Mitgliedsunternehmen der Gemeinschaft
Thermisches Spritzen e.V. (GTS) an einem
Gemeinschaftsstand in Halle 5 verschiedene
leistungsfähige Beschichtungsverfahren, die
hoch beanspruchte Oberflächen vor Verschleiß und Korrosion schützen. Junge innovative Unternehmen feiern Messepremiere.
Seit ihrer Premiere 1952 ist die Schweißen & Schneiden auch eine Plattform für den
fachlichen Austausch, der in diesem Jahr zu-
10
© Messe Essen
Es ist wie bei den Olympischen Spielen:
Alle vier Jahre wird die Schweißen &
Schneiden zum globalen Treffpunkt der
fügetechnischen Fachwelt. 2013 kommen
die internationalen Experten der Füge-,
Trenn- und Beschichtungstechnik bereits
zum 18. Mal in Essen zusammen. Vom
16. bis 21. September präsentieren rund
1.000 Aussteller aus mehr als 40 Nationen ihre Innovationen. Die Messe Essen
und ihr ideeller Partner DVS (Deutscher
Verband für Schweißen und verwandte
Verfahren e. V.) erwarten zudem rund
55.000 Besucher aus über 100 Ländern.
Schweißen & Schneiden 2009. Auch dieses Jahr erwartet der Veranstalter volle Hallen.
As in 2009 the organiser of Schweißen & Schneiden expects full halls
sätzliches Gewicht bekommt. Unmittelbar vor
der Messe lädt das International Institute of
Welding (IIW) vom 11.-15. September 2013
zu seiner Jahresversammlung im Congress
Center Essen. Zu dieser Veranstaltung sowie
zur zweitägigen IIW-Konferenz „Automation
in Welding“ (16.-17. Sept. 2013) werden rund
1.000 Experten aus aller Welt erwartet. Wäh-
rend der Messe werden außerdem renommierte Fachleute auf dem DVS Congress 2013
Forschungsergebnisse, Marktentwicklungen
und Lösungen für Hersteller und Anwender
der Füge-, Trenn- und Beschichtungstechnik
vorstellen. Der DVS Congress 2013 findet im
Forum auf dem DVS/GSI-Gemeinschaftsstand
in Halle 12 statt.
Schweißen & Schneiden is inviting to Essen
It is just like the Olympic Games: every
four years, Schweißen & Schneiden becomes the global meeting place of the
expert world of welding technology. In
2013, the international experts in joining, cutting and surfacing technology
will come together in Essen for the 18th
time already. From 16-21 September,
around 1,000 exhibitors from more than
40 nations will present their innovations.
Moreover, Messe Essen and its ideal partner, DVS (German Welding Society), are
expecting around 55,000 visitors from
more than 100 countries.
As an international innovation showcase, the
exhibition will offer the best environment for
the introduction of new products, processes
and services. All the major industrial nations
and notable manufacturers will be represented
in Essen. The largest group of exhibitors will
be provided by Germany with 379 companies
followed by China (170 exhibitors), Italy (96)
and the USA (41). The foreign participation
will be around 61% in total – also a very good
value which highlights the reputation of the
fair as the most important international sectoral platform for know-how transfer, networking and the promotion of the next generation.
A lot of countries will also use the top-ranking trade fair in order to present the efficiency
of their companies in a compact way on national cooperative booths. These will include
the USA which will be represented with two
booths in Halls 7 and 8 as well as PR of China
with three national appearances in Halls 7, 8.1
and 9.1. Further cooperative booths will be set
up by France, Japan, Taiwan, Italy as well as,
for the first time, South Korea.
ALUMINIUM · 9/2013
Focus on Precision, Yield and Green
Set the benchmark in Aluminum Rolling!
siemens-vai.com
We know what we’re talking about when it
comes to aluminum rolling.
During the past five decades we have
supplied hundreds of new and modernized
mills that set the benchmark for producing
quality strip in an efficient manner. The
market is ever changing and now demands
highest yield and tolerances while
minimizing environmental impact.
Siemens VAI is at the forefront of this
challenge.
full range of vertically integrated supply
packages. With specialized technologies for
thickness, profile and flatness control, the
strictest quality and tolerance demands are
met for all downstream product
requirements.
At every stage of a mill’s productive
lifetime, we have the right solution to
ensure that your mill performs at its peak
level. Our portfolio includes:
‡ New plants and mill modernizations
On the basis of immense process knowhow and engineering experience,
Siemens VAI works with our customers to
meet their targets for productivity, quality,
yield and flexibility.
‡ Complete equipment supply
As a total solution provider, maximum mill
performance is assured with the latest
equipment design, advanced technological
packages, sophisticated electrical,
automation, environmental systems, and a
‡ Worldwide, around-the-clock services
‡ Electrical and automation systems
‡ Consultancy services and mill audits
‡ Customized mill products
Be the leader in the field – with SIROLL
ALU solutions from Siemens VAI, a
global supplier but your local partner.
Answers for industry.
WIRTSCHAFT
Aluminium im Monatsrückblick
Ein Service der TRIMET Aluminium SE
Die LME 3-Monatsnotierung konnte
sich nach dem regelrechten Ausverkauf
im vergangenen Monat wieder erholen und notierte im Hoch wieder oberhalb der Marke von € 1.400 per Tonne. Unerwartet gute Konjunktur- und
Wirtschaftswachstumszahlen aus dem
Euroraum beflügelten alle LME-Basismetallnotierungen und auch die Sorge um
den Liquiditätsengpass Chinas schien
mehr als unbegründet. Nachdem die
LME-Lagerhausbestände im Juni ein neues Allzeithoch bei 5,45 Millionen Tonnen
markierten, erlebten sie im Juli einen wei-
teren Anstieg auf 5,49 Millionen Tonnen,
sodass die umstrittene LME-Lagerhauspolitik weiterhin für sehr viel Zündstoff
und erhitzte Gemüter unter den Verbrauchern sorgte. Daher werden die Stimmen
nach einem Eingreifen in das Geschehen
immer lauter.
Auf- bzw. Abschlag für 3-Monatstermin
Letzten 6 Durchschnittswerte LME
Juli
Juni
Mai
April
März
Februar
2013
2013
2013
2013
2013
2013
33,88 Euro
30,36 Euro
24,80 Euro
25,22 Euro
30,79 Euro
31,22 Euro
50
0
–50
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
Aluminium High Grade, Kasse
Letzten 6 Durchschnittswerte LME
Juli
Juni
Mai
April
März
Februar
2013
2013
2013
2013
2013
2013
1.351,17 Euro
1.376,16 Euro
1.410,51 Euro
1.424,60 Euro
1.475,92 Euro
1.538,20 Euro
2.500
2.000
1.500
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
1.000
Aluminium Lagerbestände
Letzten 6 Monatsendwerte LME
Juli
Juni
Mai
April
März
Februar
2013
2013
2013
2013
2013
2013
5.478.525 t.
5.435.600 t.
5.202.000 t.
5.157.625 t.
5.237.400 t.
5.162.050 t.
6.000
5.000
4.000
3.000
2.000
1.000
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
0
Alle Angaben auf dieser Seite sind unverbindlich.
Quelle: TRIMET Aluminium SE – aktuelle LME-Werte unter www.trimet.de oder per TRIMET-App auf das iPhone.
12
ALUMINIUM · 9/2013
WIRTSCHAFT
Produktionsdaten der deutschen Aluminiumindustrie
Primäraluminium
Sekundäraluminium
Walzprodukte > 0,2 mm
Press- & Ziehprodukte**
Produktion
(in 1.000 t)
+/in % *
Produktion
(in 1.000 t)
+/in % *
Produktion
(in 1.000 t)
+/in % *
Produktion
(in 1.000 t)
+/in % *
Juni
33,0
-8,0
54,6
6,9
161,0
20,6
49,1
-0,3
Juli
34,8
-5,0
56,0
7,1
166,4
0,9
46,9
-7,4
Aug
34,9
-5,8
47,2
2,9
161,4
1,2
44,9
-11,8
Sep
33,6
-4,4
52,5
-4,3
164,5
8,1
44,6
-17,2
Okt
35,2
-2,5
53,3
-0,3
162,5
9,4
46,1
-7,4
Nov
34,2
-2,9
53,4
-6,4
152,9
0,1
42,5
-20,1
Dez
35,1
-2,1
43,4
-7,0
117,2
7,4
23,3
-22,8
Jan 13
35,4
0,3
52,2
-3,5
159,3
9,5
42,8
-7,6
Feb
33,8
4,4
52,6
-5,3
158,9
6,5
44,3
-7,2
Mär
39,9
17,0
54,4
-5,0
163,1
-1,7
45,5
-9,8
Apr
40,3
20,2
53,9
1,0
173,1
17,6
48,7
8,2
Mai
42,3
23,1
51,5
-5,1
163,2
1,5
45,3
-7,4
Juni
41,7
26,2
51,1
-6,3
162,9
1,2
48,4
-1,4
* gegenüber dem Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf
Primäraluminium
Walzprodukte > 0,2 mm
14
Sekundäraluminium
Press- und Ziehprodukte
ALUMINIUM · 9/2013
...since 1840
manufacturer of high performance
Hot, Cold and Foil Rolling Mills for Aluminium strip
MINO
O S.p.A.
SpA
Via Torino, 1 – San Michele – 15122 ALESSANDRIA – ITALY
Tel. +39 0131 363636 Fax
x +39 0131 361611 - E-mail: [email protected]
w w w. m i n o. i t
ECONOMICS
Aluminium S.A. increases production, reduces costs
G. Djukanovic, Podgorica
Aluminium S. A., located in St Nicolas at the
north coast of the Gulf of Corinth, started
production in 1966 as a Pechiney plant, then
under the name ADG. Later it was a base
for the development of the aluminium manufacturing industry in Greece with numerous
facilities all over the country. Today annual
turnover amounts to more than €2bn. Over
40,000 people are directly and indirectly employed in the sector. In 2003 ADG became
part of Alcan after the Canadian company
took over Pechiney in France. Alcan sold it to
the Greek private company Mytilineos Group
in 2005.
Aluminium S.A. achieved a steady production in the past two years of 164,000 tpy of
aluminium (124,000 tonnes of alloyed billets and 40,000 tonnes of slabs) and around
800,000 tpy of metallurgical grade alumina.
According to a company presentation sales
amounted to €506m and Ebitda to €21m in
2012, whereas sales were €521m in 2011 and
Ebitda €32m. In recent years, since it became
a fully owned subsidiary of Mytilineos Group,
Aluminium S.A. has not published separate
financial reports.
In view of market uncertainty and falling
aluminium prices, the management took the
initiative to develop a strategic growth plan.
The so-called ‘Future’ programme, launched
in 2011, refers to the implementation of a
new, ambitious plan for cutting operating
costs, and to a preliminary agreement for the
acquisition of the bauxite operations of S&B,
the largest bauxite mining company in Greece.
The Future programme – scheduled for completion by the end of this year – focuses on
ten key areas that the company is addressing.
In 2012 the group launched a new ‘Mellon’ programme (‘Mellon’ = ‘Future’ in Greek),
a large-scale cost-saving programme in order
to further internationalise the group’s metallurgy and mining business activity. The Mellon
programme will remain a key priority for the
group in 2013, as it works as a crucial safety
16
valve in the challenging business environment of limited liquidity. According to this
programme cost savings of €110m a year are
planned and some €90m of cost benefits have
already been achieved. The remaining amount
mainly relates to bauxite sourcing and to production mergers.
In November 2011, Mytilineos Group and
S&B Industrial Minerals S.A. announced the
initial agreement for the gradual acquisition
of S&B’s bauxite operations by Mytilineos’
© Metka
Aluminium S.A., earlier known as Aluminium of Greece (AoG) and Aluminium
de Grèce (ADG), is the sole vertically
integrated aluminium producer in Europe
with all production facilities concentrated
in one location. It is the largest alumina
producer in Southern and Eastern Europe
and the second largest primary aluminium producer next to Romanian Alro.
View of the cogeneration plant at Aluminium S.A.,
with two HRSGs and two gas turbines
subsidiary Aluminium S.A. However, following completion of thorough due diligence, a
final agreement was not reached. Evaluating
the challenges presented by the domestic and
international environment, the two companies
will continue to pursue ways to improve the
competitiveness of bauxite mining activities,
whereas their commercial collaboration will
continue without impediments.
Aluminium S.A. has full ownership of Delphi-Distomon bauxite mines, the second largest in the country, with current annual production of around 650,000 tonnes. It is located in
the nearby Amfissa region and employs some
100 people. Despite the fact that the area
is rich in bauxite with over 100m tonnes of
proven reserves (of a total of 650m tonnes in
Greece), the company started importing tropical bauxite in 2000 (about 200,000 tpy) that is
mixed with Greek bauxite in a process called
‘sweetening’. The reason for this is to facilitate the process because Greek bauxite has a
relatively high content of silica which is more
difficult to process.
Commercial contracts with Glencore
The Mytilineos Group signed a USD2bn deal
in July 2008 to provide Swiss-based trader
Glencore International (now Glencore Xstrata
Plc) with all surplus alumina over a ten-year
period. AoG will deliver more than 5m tonnes
of alumina to Glencore during the period.
Production of alumina will amount 770,000
to 800,000 tpy during the FY2012-2014 period with a selling price of 13.5% of the LME
3-month aluminium price, which refers to the
contract price and market price for remaining
volumes sold in the spot market (according to
National Securities). The alumina refinery operates at full capacity of 800,000 tpy; around
60% of the production is sold to third parties,
mainly to Glencore for the contract-linked
price of about 14% of the LME 3-month aluminium price (according to Eurobank Equities
Research).
In January 2013 Aluminium S.A. signed
a new contract with Glencore for the sale of
75,000 tonnes of aluminium in billets and
slabs, for a total of USD200m. The metal will
be exported to the EU and US markets from
January 2013 to June 2014.
Production costs decreasing
Alumina production costs have been exceeding USD300/t in recent years while Aluminium S.A. has been ranked in the third quartile.
After implementing significant cost reduction
measures the cash production costs now stand
at around USD250/t (2013 estimate) which
corresponds to the first to second quartile of
the global alumina cost curve.
The smelter costs were ranked in the fourth
quartile of the global cost curve until recently.
The management expects that after full and
successful implementation of ‘Mellon’, production costs will be around USD2,000/t. This
would place the company in the second quartile of the cost curve. However, it is more realistic to expect costs hardly below USD2,200/t
(3rd quartile), mainly due to relatively high
electricity prices. In 2013 production costs are
expected to be around USD2,300/t, according
to company reports.
ALUMINIUM · 9/2013
ECONOMICS
Major investments in
environment protection
© Mytilineos Group
Since the construction of the cogeneration
power plant was completed in 2008 (€191m)
investments of Aluminium S.A. have comprised bauxite residues recovery facilities and
filter presses, with the installation of two additional presses in the last few years. At the
same time, studies have been carried out to
examine the potential for the utilisation of
bauxite residues in other industry sectors.
The company’s goal is to discharge the full
quantity of bauxite residues ashore, in an area
specially set aside for this within its terrain.
Other investments aim at increasing aluminium production to 174,000 tpy in 2014
and alumina production to 810,000 tpy.
Electricity costs
According to the Regulating Authority for
Energy (RAE) procedure issued in May 2012,
the provisional electricity price for Aluminium S.A. is 42 €/MWh (plus €6/MWh tax and
transfer costs, according to Eurobank Equities
Research). It is estimated that at this price
DRYPLUS
Aluminium S.A. has been subsidised by some
€10m annually.
Another €10m a year could be saved by
using steam from the cogeneration plant. Application of the provisional price, according to
the rationale of the RAE decision, refers to
all operating hours of Aluminium S.A., in the
light of the single-zone tariff that matches its
consumption profile for the entire period of
the day; this will remain in force until the final
decision by the arbitrators to whom Aluminium S.A. and PPC (the national electricity dis-
Less Sludge – Less Costs
Weniger Schlamm – Weniger Kosten
DrasƟc reducƟon of sludge volumes from anodizing lines
Überragende Reduzierung der
Schlammmengen von Eloxal-Linien
With DRYPLUS you reduce
by 50% the volume of aluminium hydroxide sludge!
Mit DRYPLUS reduzieren Sie 50% des
Aluminiumhydroxid-Schlamms!
Standard
Standard
With Dryplus
Mit Dryplus
Dry percentage of the sludge [%]
Anteil des Trockenschlamms [%]
20%
45%
Sludge producƟon [tons/year]
SchlammprodukƟon [Tonnen/Jahr]
1300
578
80
80
€ 104.000
€ 46.222
Considered Parameters (waters treatment from an
anodizing line with 30.000 A installed capacity)
BerücksichƟgte Parameter (Wasserbehandlung
einer Eloxal-Linie mit einer Kapazität von 30.000 A)
EsƟmated Cost for sludge disposal [€/ton]
Geschätzte Kosten für die
Schlammentsorgung [€/Tonne]
Cost for disposing of the sludge [€/year]
Kosten für die Schlammentsorgung [€/Jahr]
Total Saving [€/year] - Ersparnis [€/Jahr]
€ 57.778
Technical and Įnancial data are indicaƟve and only provided for informaƟonal purposes. Italtecno will be keen to submit a tailor-made proposal. Feel free to ask!
Technische Daten und Kosten sind indikaƟv und nur zu InformaƟonszwecken bereitgestellt. Italtecno wird Ihnen gerne ein persönliches Angebot unterbreiten. Fragen Sie uns einfach!
Via Gino Marinuzzi 38 - 41122 Modena (Italy) - Tel. +39 059 280362 - Fax +39 059 280462
[email protected] - www.italtecno.com - www.diecleaningplant.com
ALUMINIUM · 9/2013
17
Exemplary in safety
Aluminium S.A. has a long tradition in safety
performance since it was part of the Pechiney
group, and the management is very proud of
that. It is regarded as one of the safest aluminium plants in the world for workers, with
only few accidents a year (and only one injury at work in 2006) .
In December 2012 a new collective agreement was made between the management of
Aluminium S.A. and the company’s labour
union. The agreement resulted in preserving
all employment positions and the production
capacity of the plant as well as significant cost
streamlining on a viable and long-term basis.
Technical features
Aluminium S.A. uses tried and tested Pechiney
technology, a point-feeder system, enclosed
pot cells and pre-baked anodes. Potlines A
and B (since 1986) operate at 70 kA (520 pots)
and potline C at 90 kA (since 1971, 260 pots).
Since 1995 the plant has been equipped with
central computer control and graphic tracking of the production process in all potlines.
Current efficiency is 93% and electricity consumption is 13,200 kWh/t. Consumption of
anodes is 405 kg/tAl, aluminium fluoride is 10
kg/t, alumina 1,900 kg/t, so the plant has the
lowest specific consumption of raw materials
and consumables compared to all other producers in the region. Aluminium S.A. processes around 1.4m tonnes of Greek bauxite
and 200,000 tonnes of imported (tropical)
bauxite; it produces around 800,000 tpy of
alumina (460,000 tpy for export) and 164,000
tpy of primary metal (around 90,000 tpy for
18
the Greek market). The anode plant has a production capacity of 90,000 tpy of anodes.
Average pot life is 100 months (more than
eight years), which is one of the best results for
this type of cell and technology in the world.
The plant’s port is capable of accommodating and serving ships of tonnages up to 50,000
tonnes. It is equipped with three electric rail
cranes, the alumina ship loader and all necessary storage facilities for raw materials and
products. The loading installations for the alumina cargo to be exported (bulk cargo) can
achieve loading rates exceeding 600 tph.
The smelter uses Tardis equipment for its
dross handling. Tardis is a fully patented process of rapid cooling and pressing. The equipment, which was awarded a Queen’s Award
for Enterprise in the Innovation category, has
been designed to maximise aluminium recovery from dross, whilst eliminating the associated dust and fume.
The new 334-MW high-efficiency combined heat and power (CHP) plant, or cogeneration plant, is located within the complex
of Aluminium S.A. It is connected to the regional gas pipeline that comes from Russia
and across Bulgaria to Athens and the port of
Piraeus. The plant came into operation in 2008
and is equipped with the latest technology. It
operates using natural gas and, apart from
electricity, produces steam which is used in
the alumina production process. Any surplus
electricity produced is fed into the national
electricity grid.
Author
Goran Djukanovic is an independent aluminium
market analyst. He is located in Podgorica, Montenegro. Email: [email protected].
© Djukanovic
tributor) have referred their dispute (source:
Annual report 2012). This information leads
to the conclusion that the gas cogeneration
power plant, built within the production complex of Aluminium S.A., has not contributed
to reducing electricity costs to an extent that
would be suitable and profitable for Aluminium S.A.
This price per megawatt hour is lower
by about €20/MWh than the price that PPC
had been charging Aluminium S.A. following
a unilateral decision and despite the lack of
contract for the period of July 2010 up until
mid-May 2012 (date when the decision was
made by RAE, deciding on a temporary price).
The impact of CO2 emissions charges implemented in 2013 may additionally increase
electricity costs by €6/MWh unless the state
implements subsidises for energy intensive industries, including Aluminium S.A.
Source: Eurobank Equities Research
ECONOMICS
EU Commission refers Greece to court for failure
to recover incompatible aid from AoG
In July the EU Commission has referred Greece
to the European Court of Justice for failing to
comply with two distinct Commission decisions
that ordered Greece to recover incompatible
state aid from three Greek casinos and from Aluminium of Greece S.A. (AoG). In both cases, over
two years after the Commission decisions, the
full aid amounts have still not been paid back.
The EU Commission requested Greece to
recover incompatible state aid in the form of
preferential electricity tariffs from AoG. The aid
amount is calculated as the difference between
PCC’s revenues from the standard tariff between
January 2007 and March 2008 and the revenues
from the tariff that was actually applied to AoG
in the same period. The Commission calculated
the aid principal as amounting to 17.4 million
euros.
The aid given to AoG has not been recovered
up to date. The recovery procedure has been
suspended by a national court, in clear violation
of EU law. AoG has appealed the Commission’s
2011 decisions before the EU General Court.
However, no interim measures have been requested nor granted and the appeals have no
suspensive effect.
ALUMINIUM · 9/2013
ECONOMICS
Aluminium – The transportation material of the future
F. Awadhalla, Dubal
The diversity of applications for aluminium is
huge. It is used in virtually every sector – from
cooking pots, through housing and other infrastructure construction, to all types of transportation, military and marine applications.
This is reflected in the growing volumes of
aluminium used worldwide: the annual growth
rate of primary aluminium consumption is 46%. This is double the growth rate of the global population, GDP and IP over the last five
years.
At present, more than 50% of aluminium
consumption is utilised in two sectors: transportation and construction. Analysts predict
that aluminium consumption will almost double in the next ten years, with the greatest
growth taking place in the transportation and
construction sectors.
Within the transportation sector, aluminium is used extensively in all sub-sectors –
namely aviation, marine transport, space and
land transportation. In aviation, about 33,500
new aeroplanes and freighters are required
between 2011 and 2030, with a total market
value of USD4 trillion. In marine transportation, the usage of primary aluminium in
ship-building will grow by 2.2% in the next
five years. For space vehicles, the forecast
growth in aluminium usage is around 3.5%.
The growth trend in land transportation is
predicted at 4.3%, with aluminium usage
growing from 15 million tonnes in 2015 to 19
million tonnes in 2020.
This reflects the increasing use of aluminium as a substitute for other metals in the
automotive sector. The reason for this is the
numerous advantages offered by aluminium,
summarised as follows:
• Efficiency – Aluminium is unmatched for its
contribution to fuel conservation, due mainly
to the associated reduction in vehicle weight.
Statistics show that for every 10% reduction
in weight a fuel-saving of 5-7% is achieved.
The lighter weight of aluminium vehicle bodies also means reduced frequency of charging
ALUMINIUM · 9/2013
the battery in hybrid electric cards, which will
no doubt make these vehicles more competitive and thus more attractive to consumers.
• Sustainability – Aluminium is the most
abundant metallic element in the earth because it is infinitely recyclable. Nearly 75% of
aluminium produced in 1988 is still in usage
and almost 90% of automotive aluminium is
covered and recycled without degrading the
metal’s properties.
© Dubal
The importance of aluminium in the
transportation sector is without question.
In the automotive segment, in particular,
the growth in demand and application of
aluminium is, for several reasons, on a
continuous expansion trend. The article is
based on a presentation the author gave
at the CRU World Aluminium Conference 2013 in London.
Fadi Awadhalla at the CRU conference
• Safety – Many people wrongly believe that
the lighter weight of aluminium-based vehicles
reduces their safety. However, the opposite
holds true due to the mechanical properties
of aluminium (especially compared to steel).
The density of aluminium is one-third that of
steel, which means that car manufactures can
double the cross-section of metal plates and
still produce a lighter-weight vehicle. Also,
because of the mechanical folding property of
aluminium, it can absorb double the amount
of crash energy compared to steel.
• Durability – Most aluminium alloys are engineered for extended service life. Moreover,
aluminium is known for being long-lasting
and rust resistant, which thus reduces the need
for rust repair and increases the vehicle life
span.
• Performance – All car manufacturers look
to provide end-users improved performance.
Since vehicles made with aluminium are
lighter in weight, they perform better overall –
they accelerate faster, have a shorter braking
distance, and provide full maneuverability
and handling for the driver.
• Design – Aluminium provides greater flexibility for designers to design the shape desired
to perform better in different applications.
• Cost-effectiveness – Lighter-weight vehicles
boast lower fuel consumption and highly reliable parts with reduced maintenance liabilities. The net result is greatly improved cost of
ownership to consumers.
At the outset of aluminium usage in the automotive sector, the metal was used primarily
in four areas – wheels, engine, transmitter and
heat exchangers. The current usage is vastly
greater, with aluminium being used in place of
steel for many different parts of the vehicle.
Based on this, the potential growth of aluminium usage in the automotive industry is set to
from 9-16%.
Naturally, a key factor in the switch to aluminium usage is the environmental benefits.
Statistics show that for every 100 kg reduction in vehicle weight, the fuel consumption
declines by 0.3 to 0.5 litre per 100 km. This
then reduces CO2 emissions from 0.8 to 1.1
kg per 100 km.
In closing, the success of the aluminium
industry going forward depends on how efficiently it is managed – from the raw materials
(alumina) to power station set up and smelter
productivity and value added products in the
casting operations. By maintaining our focus
on the correct parameters, our industry will
continue to grow sustainability – with minimal
impact on the environment.
Author
Fadi Awadhalla is senior casthouse manager at
Dubai Aluminium, UAE.
Planung, Konstruktion und Ausführung von Industrieofenanlagen
Konstantinstraße 1a
41238 Mönchengladbach
Telefon
Telefax
E-mail
Internet
+49 (0) 2166 / 98 79 90
+49 (0) 2166 / 98 79 96
[email protected]
www.inotherm-gmbh.de
19
ECONOMICS
Primary aluminium industry during the first half of 2013, Part II
Rudolf P. Pawlek, Sierre
© Emal
This overview covers the events of
the primary aluminium industry
during the first half of the year
2013. While Part I, published in
ALUMINIUM 7-8/2013, focused
on Africa, America, Australia and
Europe, Part II looks at the Middle East and Asia. One of the latest
highlights in the aluminium industry
was the announcement of Mubadala
Development Co. of Abu Dhabi and
ICD of Dubai to merge the businesses of Dubai Aluminium and
Emirates Aluminium and thus create
‘Emirates Global Aluminium’ – the
fifth-largest global aluminium company by production.
Ingots from Emal, waiting for shipment
MIDDLE EAST & ASIA
ABU DHABI: In June Emirates Aluminium
(Emal) celebrated the installation of the final
steel structure for the potline of its Phase II
expansion. With the last of 120 specially designed steel structures in place, all the major
civil and mechanical work on the world’s longest single potline of 1.7 km is complete by
now, and Emal remains on target to deliver
its ambitious expansion plans. The first steel
structure was raised in July last year, which
means that completion was within the anticipated target of 12 months. The work was done
without a single lost time injury – the industry
standard for measuring success in health and
safety.
Emal’s Phase II expansion project will increase aluminium production to 1.3m tpy by
the end of 2014, from today’s 800,000 tpy.
Early works on the estimated USD4.5bn
Phase II expansion began in early 2011, making Emal one of the largest industrial projects
in the UAE outside oil and gas and one of the
key projects leading to the diversification of
the UAE’s economy.
BAHRAIN: Aluminium Bahrain (Alba) has
begun a bankable feasibility study to determine the viability of the expansion of its sixth
potline. The expansion project is expected to
add another 400,000 tpy to the company’s current capacity of 890,000 tpy. Alba will use Dubal DX+ technology in the bankable feasibility
study. Dubal currently has five pilot DX+ pots
which began operating at 420 kA and are now
running at 440 kA. DX+ is an updated version
of the DX technology which is in use at Dubal
and Emal Phase I plants.
At the end of December 2012, Alba announced it remains on track in broadening
its production capacity by increasing its line
current of Potline 5 from AP30 to AP36 technology. The upgrade will enable Alba to boost
output since each 1 kA increase is expected
to yield 950 tpy of extra aluminium production. The Alba team succeeded in achieving
this goal without any significant capital investment. Plans are also underway to achieve the
same level of success in Potlines 3 and 4.
In June Alba announced that its process
technology achieved a significant milestone
with the upgrade of Potline 5 to AP37 technology following an increase in the line current
to 370 kA. The upgrade increases the smelter
capacity by around 10,000 tpy.
➝
Primary aluminium smelters in the Middle East:
Nameplate capacities and shutdown capacities on a temporary basis
Compiled by R. P. Pawlek, June 2013
Country
Location
Nameplate Shutdown
Capacity
Capacity
(tpy)
(tpy)
800,000
MIDDLE EAST
Abu Dhabi
Taweelah
Azerbaijan
Ganja
50,000
Bahrain
Askar
900,000
India
Jharsuguda
500,000
Korba
900,000
Renukoot
345,000
Hirakud
213,000
Angul
475,000
Kuala Tanjung
265,000
Indonesia
20
Iran
Japan
Kazakhstan
Malaysia
Oman
Qatar
Tajikistan
Turkey
UAE
Arak
Arak (2)
Bandar Abbas
Bandar Abbas (2)
Kambara
Pavlodar
Sarawak
Sohar
Mesaieed
Regar
Seydisehir
Jebel Ali
90,000
110,000
110,000
147,000
20,000
250,000
120,000
390,000
625,000
450,000
65,000
1,040,000
100,000
60,000
175,000
ALUMINIUM · 9/2013
ECONOMICS
Primary aluminium smelters in China:
Nameplate capacities and shutdown capacities on a temporary basis
Compiled by R. P. Pawlek, June 2013
Location
PR CHINA
Aba
Baise Yinhai
Baotou Shi
Baotou East Hope
Changjiang
Chiping Xinfa
Chongqing Tiantai
Chongqing Dongsheng
Chuangyuan
Danjiankou Shi
Datong Xian
Dengfeng
Dianneng Gejiu
Dongfang Xiwang
Emeishan
Faxiang
Fukang
Fushun Shi
Gansu Lonxi
Gongyi
Guangxi Baise Xinghe
Guangyuan Qimingxing
Guanlu (old)
Guanlu (new)
Guanyuan Aostar
Guiyang Shi
Guizhou
Haizhou
Hejin Xian
Hongjun
Honglu Aluminium
Huadong
Huanghe
Huasheng Jiangquan
Huaxin
Huayu
Jiaozuo Shi
Jilin
Jinning
Nameplate
Capacity
(tpy)
100,000
200,000
610,000
400,000
62,000
550,000
55,000
50,000
100,000
50,000
260,000
65,000
50,000
780,000
355,000
70,000
413,000
350,000
240,000
25,000
320,000
114,000
110,000
220,000
420,000
240,000
410,000
40,000
120,000
1,060,000
150,000
70,000
80,000
112,000
70,000
100,000
420,000
65,000
350,000
Shutdown
Capacity
(tpy)
20,000
70,000
220,000
60,000
For two consecutive years, Alba has achieved
record output through deployment of lean
management techniques and operational efficiency initiatives. In January, the company
announced that the 2012 production was
890,217 tonnes, which is an increase of 8,907
tonnes on 2011 figures.
CHINA: In January Chalco announced it
purchased a 23.66% stake in Ningxia Electric
Power Group in what the company considers
to be a milestone in its cost-cutting efforts.
Chalco completed the purchase from Huadian Power International Corp. at the end
22
Jingxi
Jnneng
Ke’ao
Laibin Yunhai
Lanjiang Shi
Lanzhou Shi
Lanzhou Liancheng
Linfeng
Lintao
Linzhou
Longlin
Longquan Aluminium
Longxiang
Meishan Qimingxing
Mianchi Aluminium
Nanping Shi
Nanshan
Ningxia
Ningxia St. Dehua
Nongliushi Xinjiang
Panshi Xian
Pingguo Xian
Pingyin
Qiaotou
Qinao
Qinghai
Qinghai Huanghe
Qinghai Xinheng
Qinghai Xinye
Qingtongxia Shi
Qinyang
Qiya
Sanmenxia Shi
Shandong Aluminium
Shandong Donghai
Shangdian
Shanxian Hengkang
Shanxi-Huaze
Shenhuo (old)
Shenhuo (new)
Shihezi
Sichuan Emei
160,000
80,000
135,000
250,000
30,000
700,000
260,000
160,000
50,000
240,000
50,000
400,000
55,000
130,000
80,000
73,000
406,000
370,000
50,000
590,000
25,000
140,000
26,000
350,000
90,000
436,000
500,000
500,000
575,000
685,000
500,000
400,000
120,000
78,000
200,000
125,000
220,000
350,000
160,000
420,000
400,000
350,000
20,000
70,000
20,000
32,000
110,000
of 2012, becoming Ningxia Electric’s biggest
shareholder. At present, Ningxia has a thermal power generation capacity of 3,874 MW,
wind electricity capacity of 1,039 MW and
photovoltaic power generation capacity of 103
MW. Ningxia Electric also has a coal reserve
of 2.38bn tonnes and a production capacity
of 16m tpy.
In January the country’s Ministry of Industry and Information Technology (MIIT),
National Development and Reform Commission (NDRC) and ten other ministries set out
guidelines for the future structure of nine in-
Sichuan Qiya
Taian
Taiyuan Shi
Tianyuan
Tongshuan Xinguang
Tongshuan
Tongshun
Wanji Aluminium
Wujiaqu
Xichuan
Xiezhou
Xinfa
Xinjang Yihe
Xinjiang
Xinjiang Easthope
Xinwang
Yangquan Shi
Yangquan Aluminium
Yichuan Aluminium
Yinhai Aluminium
Yongan Aluminium
Yongcheng Xian
Yongcheng City
Yugang Longquan
Yulian Power
Yungcheng Shanhe
Yuncheng Shi
Yunnan
Yunnan Dongyuan
Yunnan Runxin
Yunnan Yongxin
Zhaofeng Aluminium
Zheijiang Huadong
Zhengxing Aluminium
Zhengzhou Shi
Zhonghe
Zhongfu
Zhongning Aluminium
Zibo Shi
Zouping
Zunyi Xian
350,000
50,000
100,000
130,000
110,000
150,000
50,000
530,000
740,000
90,000
330,000
175,000
400,000
370,000
860,000
76,000
60,000
68,000
600,000
100,000
60,000
60,000
500,000
600,000
120,000
65,000
220,000
500,000
240,000
50,000
35,000
61,000
70,000
120,000
58,000
495,000
308,000
370,000
55,000
141,000
242,000
40,000
60,000
70,000
dustries, including aluminium, rare earths and
steel. According to the guidelines, China aims
to have a few aluminium business conglomerates with core competitiveness and international influence by 2015, and have the top 10
smelters accounting for 90% of the country’s
total production capacity.
Other likely players in consolidating China’s aluminium industry are smelters in Henan
province, where combined output of aluminium would be higher than Chalco’s. To meet
the top 10 / 90% target, major smelters in Henan province may have to be merged into one,
ALUMINIUM · 9/2013
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ECONOMICS
24
chasing a 20% stake in a calciner development
project as part of a joint venture with Sinoway Carbon Energy Holdings, Hong Kong, for
an undisclosed sum. The new venture, known
as Sinoway Carbon Co. Ltd, entails the construction of a 560,000 tpy petroleum coke
calciner in Shandong, China.
Calcined petroleum coke (CPC), is a strategic raw material for the aluminium smelting
industry, where it is used in the manufacture
of carbon anodes for the electrolytic process.
Dubal will be entitled to an annual off-take
volume of CPC for its smelting operations.
The Sinoway calciner is being
built in two equal phases. Construction of the first phase was
completed in May. The second
phase is scheduled for completion
in Q4 2013. The plant will employ Chinese shaft technology –
a well-proven, simple-to-install,
easy-to-operate system that gives
better yield than other technologies at substantially lower capital
and operating expense. China has
a surplus supply of green petroleum coke (GPC). Indeed, China
currently produces more than
40% of annual global GPC/CPC
production, with several GPC refineries being in close proximity
to the Sinoway development site.
Dubal’s investment in Sinoway
represents a strategic opportunity
to mitigate the company’s supply
and quality concerns, thus contributing to business continuity.
CPC is one of the main drivers
for cost of production, and is hence
an important factor in the business
equation. With a secure supply
of suitable quality CPC from Sinoway calciner, Dubal will be well
placed to counter this trend, with
direct benefits to the bottom-line.
At the beginning of June, in a
move that will form a new industrial giant in the UAE, Mubadala
Development Co. of Abu Dhabi and the Investment Corp. of Dubai (ICD) announced the
creation of Emirates Global Aluminium. This
jointly-held, equal-ownership company will
integrate the businesses of Dubal and Emal
and has plans for significant local growth and
international expansion.
The accord builds on a successful partnership that started with the formation of Emal
in 2006, a joint venture of Mubadala and Dubal. Emirates Global Aluminium will have an
aggregate enterprise value of more than US© Dubal
as China has dozens of smelters of that similar stimulus package, spurred by local government incentives aimed at creating employment.
size. Such talk has been initiated years ago.
Henan is China’s largest province for But widespread overcapacity and consequent
aluminium production, with the major five cost pressures throughout the aluminium incompanies being Zhongfu Industrial, Shen- dustry are now driving state policies aimed at
huo Group, JiaoZuo WanFang Aluminum reversing the trend. In any case, small capacManufacturing Co., Henan Wanji Aluminium ity units have already begun to cut production
Co. and Henan Yugang Longquan Aluminum amid low metal prices, particularly in high-cost
Co. All of them have a production capacity of areas such as Henan province.
Cathode and anode exporters are unlikely
0.7-0.8m tpy. Zhongfu is publicly traded on
to
be
affected by the rule change, since most
Shanghai Stock Exchange, while both Shenplants
in China’s primary export regions are
huo and Jiaozuo are listed on Shenzhen Stock
more
sizeable.
Exchange.
In February it was announced
that China’s government aims
to “vigorously” eliminate obsolete aluminium capacity in 2013
through economic measures such
as differential power rates. The decommissioning of technologically
backward smelters is a key work
area in 2013.
Economic measures such as
power rates differentiation will
be studied and employed so as
to raise production input costs to
impel obsolete smelters to exit the
market. In addition, the authorities
aim to set new entry requirements
for the aluminium industry, as already exist for secondary aluminium producers.
China had 27.65m tonnes of
aluminium capacity at the end of
2012, with utilisation rates at only
72%. Only 45% of the total capacities are operated with self-run
power stations, while those relying on the state grid’s power are
deeply in the red.
Metal prices are expected to
vary little in 2013, with periodic
recovery opportunities depending
on global monetary easing and on
China’s investment policies.
China’s drive to crack down on
surplus non-ferrous metal produc- Extrusion billets from Dubal
tion capacity will extend to small
Early in April it was reported that China concarbon cathode and anode plants as of May.
The guidelines place anode block plants sumed 0.5% less energy year-on-year in 2012
with an annual capacity of 80,000 tpy or less, per tonne of primary aluminium produced.
and cathode block plants with a capacity of Electricity consumed per tonne of primary
20,000 tpy or less, in the government’s ‘re- aluminium dropped on average to 13,8 kWh
stricted’ category, meaning new investment in 2012, down 69 kWh from a year ago, and
proposals for such small plants are likely to equal to a reduction in carbon dioxide emisbe rejected. Those operating existing facilities sion of 63 kg/t of aluminium produced. China
that fall under the guidelines may face in- thereby saved 1.4bn kWh in 2012.
DUBAI: In March Dubai Aluminium (Ducreasing regulatory and cost pressures.
Such small capacities proliferated on the bal) announced it has expanded its interest in
back of the government’s post-financial-crisis the upstream (raw materials) sector by pur-
ALUMINIUM · 9/2013
ECONOMICS
ALUMINIUM · 9/2013
CNC - Spezialmaschinen
© iStock
D15bn, and it will be the fifth-largest global aluminium company
by production, once Emal’ Phase II expansion project is complete
in the first half of 2014.
Building on the heritage of Emal and Dubal, the new company
will look to expand along the value chain, from aluminium smelting to alumina refining and bauxite mining overseas. Given its
scale and growth, Emirates Global Aluminium will also continue to
attract downstream manufacturing as well as ancillary businesses
related to aluminium smelting and alumina refining, thereby indirectly creating additional jobs.
The new company will accelerate employment with 2,000 direct
jobs being created by 2020, adding to more than 6,200 direct jobs
(Dubal 3,800; Emal 2,500) already in existence. A further 6,000
indirect jobs will be generated, delivering total employment of over
33,000 people by the UAE aluminium sector through the end of
this decade.
Emirates Global Aluminium will serve over 440 customers in
55 countries, with a joint production capacity of 2.4m tpy of aluminium on the completion of Emal Phase II.
Pending required approvals, the formal commencement of
joint operations is expected to be completed within the first half
of 2014.
The combination agreement signed by Mubadala and ICD unifies the Jebel Ali and Taweelah smelter assets, as well as interests
in Guinea Alumina Corp. and Cameroon Alumina Ltd.
Energy costs for major aluminium producers range from
USD255-368/t in the Middle East, while in India electricity prices
range from USD514-904/t.
INDONESIA: The Indonesian government will completely take
over Indonesia Asahan Aluminium, known as Inalum, in November, although negotiations are still ongoing. That is what the Indonesian Industry Minister M.S. Hidayat told journalists in June.
He added that the government had already earmarked Rp7 trillion (USD707m) for the take-over. Originally the government had
plans to sell its stakes to other investors, but then changed mind
because it wants to turn Inalum into a new state-owned enterprise.
Inalum is currently 58.88% controlled by Japanese consortium
Nippon Asahan Aluminium and 41.12% controlled by the Indonesian government.
TURKEY: In April the European Bank for Reconstruction &
Development (EBRD) announced it has drafted plans to promote
the use of pre-baked anode technology in the Turkish aluminium
smelter through a USD50m loan to Eti Aluminyum. The money
would help to modernise the company’s aluminium smelter located in Konya, in southern Anatolia, by converting the existing
Søderberg electrolysis technology to proven pre-baked anode
technology. The privately-owned company produces alumina, hydrate, liquid aluminium and other alumina products from its bauxite mining operations, located south of Konya.
Eti Aluminyum had promised to develop advanced corporate
social responsibility practices, reporting publicly on such policies
from 2015. It had also agreed to develop and implement integrated
energy and carbon management systems under ISO 50001 standards. The new unit would meet European Union standards and
best available technologies.
The company’s entire modernisation plan should cost
USD232m, and involve the phasing out or upgrading of the old
Soviet-designed open cell electrolysis pots. Eti Aluminyum awaits
final decision on the loan from the EBRD board of directors. ■
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ALUMINIUM INDUSTRY IN THE GULF
Interview with Emal president and CEO, Saeed Fadhel Al Mazrooei
© Emal
“We can compete with any company in the world”
President and CEO Saeed Fadhel Al Mazrooei:
“Emal has a strong global market demand, and the
local market and the downstream industry in the
UAE are also growing.”
ALUMINIUM’s editor-in-chief recently had
the opportunity to visit Emirates Aluminium
(Emal) in Abu Dhabi and talk to president
and CEO, Saeed Fadhel Al Mazrooei, about
the company’s future development, its Phase
II expansion project, the Arab Aluminium
Conference 2013 in Abu Dhabi in November, which will be hosted by Emal, and the
recent announcement of the unification taking
place between Emal and Dubal. Emal is currently expanding its production capacity from
800,000 to 1.3 million tonnes of aluminium
and construction work at the site is in full
swing. Once Phase II has been commissioned,
Emal will be one of the largest single-site aluminium smelter in the world.
ALUMINIUM: Mr Al Mazrooei, the Emal site
and technical facilities are really impressive
compared with the relatively small European
smelters. There is a lot of construction work
underway for the Phase II expansion. Is everything on schedule?
Al Mazrooei: Yes, Phase II will be completed
on schedule, and within budget. We will start
energising the first cell early in the fourth
quarter of this year. First hot metal will be
produced at year-end, with full production
being reached around mid-2014. Then we
will not only have the longest potline in the
world – 1.7 kilometres long – but also the best
smelter technology available today.
ALUMINIUM: … the DX+ technology from
Dubai Aluminium.
Al Mazrooei: The DX+ technology is a further
26
development of the DX technology and will
be used in our Phase II potline. Our Phase I
potline uses the DX technology, now at 380
kA, upgraded from the 350 kA previously.
This upgrade has boosted our aluminium production from 750,000 to 800,000 tonnes a
year. The DX+ cells of the potline under construction will initially operate at 440 kA, and
have the potential to operate at 460 kA. For
that we have ordered the world’s largest rectifier ever being built. The current efficiency of
the DX+ potline will be the benchmark for
the rest of the industry.
ALUMINIUM: Emal is already one of the most
cost-efficient smelters in the world thanks to
the low cost of natural gas from Abu Dhabi.
This low-cost situation will improve further
when the third potline comes on stream.
Al Mazrooei: There are three main criteria for
our outstanding position. One is energy, ‘clean
energy’ as we call it. The second is the DX
technology we use. It is the latest technology
and has been developed to produce metal in
a highly energy-efficient manner. And thirdly
we should mention that we have implemented
processes and procedures in our plant that
promotes high productivity of our workforce.
ALUMINIUM: The third potline will boost
production to 1.3 million tonnes a year. Most
of your production is destined for export.
Where do you sell your products?
Al Mazrooei: Today our products are sold to
over 150 customers in almost 36 countries
worldwide. 80 percent of our products are
delivered to Asia, the US and Europe. About
30 percent of our products are delivered to
South Asia, for example to Korea and Japan.
We sell almost 200,000 tonnes a year to the
US. We also sell our products to Europe, with
Germany our largest market there. The Middle East takes part of the volumes, as do local
markets in the Gulf. Our products are ISO
9001 certified so we comply fully with international standards.
ALUMINIUM: The Middle East and Asia are
on your doorstep whereas the United States
and Europe are farther away. Does distance
to market hinder your business in any way?
Al Mazrooei: We are located in the middle of
the world so we are able to deliver to Europe
without any problems. The same applies to the
US.
ALUMINIUM: There are still EU customs duties on imports of aluminium to protect the
European smelters. These must be a thorn in
your flesh.
Al Mazrooei (laughing): EU competitors are
trying to protect their business but I think it is
necessary to look at the industry as a whole.
Downstream manufacturers should benefit
from access to international markets. The European smelters were built many years ago
and do not have the best energy efficiency.
I think the European aluminium industry
should encourage the downstream business
because that is where the real added value is
to be found. The same companies that push for
EU customs duties come to the UAE and build
new production facilities, albeit targeting the
Asian rather than the European market. ➝
Emal potline, based on Dubal technology
ALUMINIUM · 9/2013
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ALUMINIUM INDUSTRY IN THE GULF
Business between the Gulf and Europe is built
on long-term relationships and the aluminium
business should be based on that concept too.
A free trade agreement should really be considered where the most efficient competitors
survive and the most economical and environmentally-friendly businesses flourish.
ALUMINIUM (provoking): Would you dare
to make a prediction when the last aluminium
smelter will be shut down in Europe?
Al Mazrooei (again smiling): If I could see into
the future I wouldn’t be sitting here. But to be
serious: in the end it all depends on economics, on the cost of producing aluminium. And
there are many cost drivers for European
smelters such as electricity tariffs, taxation
and environmental costs. But business models
have to survive too. You need a business that
is sustainable. That is what the Gulf is doing
ing at the present market situation we see a
lot of overcapacity, imbalance in supply and
demand, with rather weak aluminium prices.
Is that the right time to expand?
Al Mazrooei: That’s the general market you
describe. However, when I look at our books
there is no reason to complain. Demand for
our products is greater than what we can deliver. Last year, demand for our products was
around one million tonnes whereas our plant
can only produce 800,000 tonnes a year. We
are doing well on market penetration. We are
market-driven and customer-focused. And
from a capex point of view, today is the best
time to build a new smelter because investment
costs are low. At a time of market stagnation
it is easier to find the money for well justified
investment projects. And there is good reason that the market imbalances will diminish
In April Emal was celebrating 25 million hours worked without a single lost time incident
today. Here you find competitive energy prices, the most modern production technology
and state-of-the-art equipment for environmental protection; this allows the Gulf smelters to produce on a more efficient basis.
ALUMINIUM: The conditions are ideal for
you to expand beyond your current project.
When I toured the site an hour ago I saw that
there is space for a Phase III potline.
Al Mazrooei: We have space to grow but every
new investment must be built on a strong business case. When Emal seeks finance, it does
not go to the governments of Abu Dhabi or
Dubai but to the international financial markets. Therefore the business model has to be
structurally strong to convince long-term investors to commit themselves financially. We
have to justify our business model and to look
20 to 25 years down the road. A Phase III expansion is an option, but at present we are focused on the start-up of our Phase II project.
ALUMINIUM: Finance is one thing, but the
market conditions have to be right too. Look-
28
over the coming years. But again, we are fully
booked and will be producing at full capacity.
Furthermore, although the LME price for aluminium is rather low at present, premiums are
high and offset the weak aluminium price.
ALUMINIUM: Are you confident you will be
able to sell the additional volumes from the
third potline right away?
Al Mazrooei: I don’t think there is an issue
for selling. Emal has a strong global market
demand, and the local market and the downstream industry in the UAE are also growing.
There are already five potential downstream
companies planning to operate in the UAE
and one is under construction today at Al
Taweelah in Kizad, the Khalifa Industrial
Zone – Abu Dhabi, and will come on stream
soon.
ALUMINIUM: You refer to the Al Taweelah
Aluminium Extrusion Company…
Al Mazrooei: … That will be the starting point
of the so-called ‘hot metal road’ between Emal
and downstream companies to deliver molten
aluminium at further reduced costs and environmental impacts. It will encourage other
manufacturing companies to settle in Kizad.
Most of the production will go into building
and construction but there is a multitude of
target markets.
ALUMINIUM: Do you expect the automotive
industry to settle here too?
Al Mazrooei: Not yet. That might happen
later. The manufacturing of aluminium wheels
and other high-value niche products could
be an approach in addition to cable, wire and
rod. But most of the production will be for
export.
ALUMINIUM: Health, safety and environment protection are of great importance to
Emal. That applies to other companies too, but
from what I’ve read your records are particularly impressive.
Al Mazrooei: Yes, we are proud of our records
in these fields. Take safety, for an example.
Today, early in July, we are looking at 35 million work hours without an accident on the
Phase II construction site. That is a record for
the industry. We are looking at more than 15
million work hours without a lost-time incident in our operations during the last three
years. We do a lot to take care of our employees. For example, just this morning we
had a crew member meeting where all the
staff, 12,000 project workers, was assembled
to be informed about the symptoms and risks
of dehydration and how to protect against it.
We encourage our employees to take care of
each other and to be aware of the emergency
numbers you can call in case your colleague
suffers from dehydration. We take care that
our employees are conscious of risks at the
workplace. Every new employee undergoes
safety induction. We reward them when they
do things properly and safely. Then we give
them a token; three tokens will give them
some credits they can trade in for money. I
could list similar success items when it comes
to environment protection. We have spent a
good deal of money – more than 700 million
US dollars for Phase I – in environment-related equipment to minimise our emissions
and to monitor them.
ALUMINIUM: Do you have also a continuous
improvement programme?
Al Mazrooei: We have a suggestion scheme
that allows workers to make any kind of proposal that is related to the production process
or to safety at work. The suggestions go to a
committee to check if it is worth being implemented or not. Our employees get a reward
for making the suggestion, and get rewarded
when it is implemented. Up to date we have
had more than 12,000 suggestions with more
ALUMINIUM · 9/2013
ALUMINIUM INDUSTRY IN THE GULF
than half of them implemented. Our motto is:
Everything can be improved.
ALUMINIUM: There was recent announcement by your parent company Mubadala that
it is going to merge the businesses of Dubal and
Emal to create Emirates Global Aluminium.
What is the reason behind this decision?
Al Mazrooei: Although Dubal and Emal
have been separate companies, we have always worked closely together on different
platforms, for example on technology, logistics and material supply. We rely on Dubal
to procure all our materials and utilise their
experience in sales and marketing. When we
started the production of Phase I in 2009 our
employees were trained at Dubal. So there is
a lot of Dubal culture embedded at Emal. The
only difference was in the ownership, which
has now changed. Mubadala owns fifty percent
of both Dubal and Emal. Dubal, which previously owned fifty percent of Emal, transferred
its ownership in Emal to ICD, a Dubai Gov-
perspective than Emal on its own.
ALUMINIUM: What about the brand names
‘Emal’ and ‘Dubal’ as references for high-quality aluminium? Will these brands be replaced
by a brand name like ‘Emirates Aluminium’?
Al Mazrooei: We have worked hard to establish ‘Emal’ as a brand. Dubal too has its
own highly renowned brand backed by thirty
years’ effort to establish a strong position in
the market. It wouldn’t be wise to give up this
goodwill. In future, we will operate under the
same umbrella with two smelters at different
sites. There will be one sales team, but for two
different products – Dubal and Emal.
ALUMINIUM: Has this integration already
started or will that be implemented at a later
date?
Al Mazrooei: We are still waiting for endorsements from regulatory authorities in all regions
where we sell our products. We hope to have
all approvals in place by the end of the first
quarter of 2014.
Emal has spent more than USD700m in environment-related equipment to minimise emissions from
aluminium production
ernment investment fund that owns the other
half of Dubal. In principle, there will not be
much of an operational change. It is mainly
the ownership that has changed.
ALUMINIUM: Does that mean Emirates
Global Aluminium is a kind of holding company?
Al Mazrooei: It is a corporation that will look
after many types of operation. For example,
Mubadala and Dubal have stakes in projects
in Guinea and elsewhere. Dubal has a stake
in a calciner project in China for the manufacture of carbon anodes. There is a feasibility
study underway for an alumina refinery at Al
Taweelah. In other words: Emirates Global
Aluminium will have a much bigger business
30
ALUMINIUM: I understand you will become
CEO of UAE operations.
Al Mazrooei: Both for the operations at Emal
and Dubal and for any future UAE Project. Mr
Abdulla Kalban, formerly president and CEO
of Dubal, will be the MD and the CEO of Emirates Global Aluminium and in charge of UAE
and global operations.
ALUMINIUM: Do you regard this merger as
a big opportunity to grow?
Al Mazrooei: Yes, that is the goal – to grow,
not to shrink, and to realise synergies while we
grow. If you look at mergers in Europe or elsewhere, they are mostly executed in order to
reduce overhead and cut costs. Our approach
is the other way round. Nobody will lose his
job, people will maintain their present work
but there will be synergies for the system and
procedures.
ALUMINIUM: Emal is hosting the Arabal
Conference in November in Abu Dhabi? What
is the principal idea behind this conference?
Al Mazrooei: To bring people from the global aluminium industry together. To promote
the UAE as an attractive location for industry
in general and especially for the aluminium
industry. To show potential investors where
we stand today and what we can offer. There
are many opportunities in the Gulf and the
UAE for starting up businesses. As you know,
when doing business you have to look at your
competitors, at the markets and technologies,
and where the business is going to develop.
We are looking forward to many company
representatives participating in the event. We
are targeting particular companies that we
want to be part of the conference. There will
be a good balance of presentations and time
for networking. And of course, part of the
programme will be workshops and a site tour
for all visitors that are interested in getting an
impression of our smelter.
ALUMINIUM: So you are not only expecting
attendees from the primary aluminium industry, but from the industry as a whole and from
all over the world?
Al Mazrooei: Yes, from the upstream and
downstream sectors, from suppliers and customers, bankers and investors. We want to
bring industry experts and decision makers –
politicians and senior executives – to Arabal.
We are very proud to host this conference and
are working hard to make it a unique event –
in terms of the material that is presented, the
people that will be attending and the speakers.
The conference will start two days after another exciting event in Abu Dhabi: the Formula 1 Grand Prix. That will be a good opportunity to combine business with pleasure.
ALUMINIUM: A final word about Emal’s
market position: do you see Emal as one of
the top three smelters in the world?
Al Mazrooei: Not only as one of the top three,
but as No 1: not in terms of volumes, but the
different platforms we have just talked about.
We are No 1 on start-up commissioning and
ramp-up; nobody has broken our record yet.
We are No 1 in project execution: we have the
lowest capex per tonne of aluminium. We are
No 1 in safety record: we recently won a safety
award from the RoSPA, the Royal Society for
the Prevention of Accidents. I am proud to say
that we can compete with any industry and
aluminium company in the world.
ALUMINIUM: Mr Al Mazrooei, many thanks
for this discussion.
■
ALUMINIUM · 9/2013
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Driving progress
ALUMINIUM INDUSTRY IN THE GULF
17th Arab International Aluminium Conference 2013
Arabal is the premier trade event for the
aluminium industry in the Middle East,
and the only conference in the world attended by every single primary aluminium manufacturer in the region.
The story began in 1983 with Kuwait Aluminium Co. bringing together the leading figures
in Middle East Aluminium to strengthen ties
and discuss the issues of the day to provide an
overview about the entire aluminium industry.
Over the past three decades, the Arabal Conference has grown to attract heads of industry
from around the world to attend, speak, and
exhibit, and by 2011 Arabal attracted more
than 450 delegates.
Since its foundation, and until 2009, the
conference has been hosted in a different
country in the Middle East region bi-annually.
As of the 2010 conference in Oman, due to
the impact and significant role of Arabal, the
steering committee agreed to hold the conference on an annual basis. This year, the conference is hosted by Emirates Aluminium. International ALUMINIUM Journal is the official
media partner of the conference.
Confirmed speakers
Arabal 2013 is proud to confirm the following speakers, who will be participating at this
year’s event: H. E. Juma Mohammed Ahmed
Al Kait, Assistant Undersecretary for Foreign
Trade Affairs, Ministry of Economy. Mohammed Al Naki, Chairman of Arabal. Tim Murray, CEO of Alba. Khalid Abdulla Al-Luhaidan, Vice President, Aluminum SBU, Ma’aden.
Yousuf Bastaki, Vice President EHSSQ, Emal.
ARABAL CONFERENCE 2013 – Provisional agenda
16:00
Tuesday, 5 November 2013
10:00
12:00
14:00
18:00
19:00
Pre-conference workshop
Dubai Aluminium (Dubai)
Lunch
Site tour to the Emal smelter complex
Registration
Welcome reception
Wednesday, 6 November 2013
8:30
9:00
10:30
11:00
13:00
14:30
15:30
32
Opening address:
The Patron; Arabal host; Emal host
Session 1
The Global economy and its challenges
Economic overview of GCC; European and global
marketplace; featuring HE Jumaa Al Kait and his
views on the European and GCC relationship
Moderator: Mahmood Al Daylami, secretary
general Gulf Aluminium Council
Coffee break
Session 2
GCC smelters – opportunities, investments and
future plans
Panel discussion with representatives from Emal,
Dubal, Qatalum, Maaden, Sohar and Alba
Moderator: Raju Daswani, Metal Bulletin
Lunch
Session 3
Warehousing, financing deals and future of
metal exchanges
Warehousing rules and the impact on aluminium
inventory; featuring first deputy chief executive of Rusal
Coffee break
17:15
18:30
19:00
Ali Al Zarouni, Vice President, Smelting Operations, Dubal. Vladislav Soloviev, First
Deputy CEO of Rusal. Kamil Wlazly, Senior
Metal Analyst, Metals Bulletin. Marco Georgiou, Head of Aluminium Primary and Products, CRU Group. Edgardo Gelsomino, Senior
Analyst at Wood Mackenzie. David Wilson,
Director, Metals Research and Strategy, Citi
Research. Walid Al Attar, VP Marketing and
Sales, Emal and Dubal. Joe Lombard, Group
Managing Director, Hatch. Mudar Al Mekdad,
General Manager, Gulf Extrusions Co. LLC.
Hamid Al Zayani, Managing Director, Midal
Cables. Khaled Salmeen, CEO and Managing Director, Kizad. Diran Apelian, AlcoaHowmet Professor, Mechanical Engineering,
Worcester Polytechnic Institute. Nick Madden, Senior Vice President and Chief Procurement Officer, Novelis Inc.
■
Session 4
Aluminium market price outlook
Panel discussion with industry pricing analysts from MB,
CRU, Wood Mackenzie and Citi Research
Moderator: Zaid Aljanabi, senior industry analyst, Emal
End of Day
Transportation to gala dinner premises
Reception, followed by gala dinner
Thursday, 7 November 2013
9:00
10:00
10:30
12:00
13:30
14:15
14:45
15:15
Session 5
Casthouse product mix and downstream initiatives
in the Mena region
Presentation by VP Marketing and Sales of Emal,
Dubal and GMD of Hatch
Coffee break
Session 5 continued
Casthouse product mix ...
Presentations on successfully established downstream
projects and on the industrial infrastructure in the
Mena region
Lunch
Session 6
Environmental drivers
Presentations on R&D for aluminium products in the
GCC and the future of recycling for the aluminium
industry in the Middle East
Coffee Break
Session Six continued
Environmental drivers
Featuring presentations on the GCC smelters, the best
supply partners for future generations and clean
energy supplies to the aluminium sector
Closing speech
ALUMINIUM · 9/2013
ALUMINIUM INDUSTRY IN THE GULF
Best technology for the aluminium rolling industry in the Gulf
B. Rieth, Meerbusch
The aluminium industry in the GCC
countries has for many years achieved
impressive growth. Whereas in 2000
the production of primary aluminium
amounted to around one million tonnes,
today it has already reached 3.7 times as
much. From 2015 when the new Ma’aden
smelter in Saudi Arabia and the third
potline of Emal in the UAE will come
into production, the region will have
capacities of almost five million tonnes a
year. In contrast, no such dynamics can
be seen where the further processing of
aluminium into semis is concerned. Here,
growth has until now been governed by
need. However, a new impetus has been
provided by the objective of no longer
just converting the available oil and
gas ‘into solid form’ as aluminium, but
achieving at least some value addition in
the region by virtue of further processing,
for example to make rolled products.
of a rolling slab casting unit and hot and cold
rolling mills, but relatively high for the alternative possible use of twin roll casting machines. Accordingly a different solution was
decided upon: the molten aluminium will be
delivered via holding furnaces to a twin-belt
caster and solidified into strips 2,032 mm wide
and 13 to 21 mm thick.
The solidified strip will go directly to a hot
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 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.
Specialised slitting and coil coating operations are provided in the finishing area.
Major project in Saudi Arabia
A further aluminium rolling mill is at present
being built as the first construction stage of
an integrated mining, smelter and rolling complex together with the aluminium smelter in
Saudi Arabia’s Ras Az Zawr at the northern
end of the Arabian Gulf. There, at present the
US producer Alcoa Inc. and the Saudi Arabian mine operator Ma’aden (Saudi Arabian
Mining Company) are together implementing
an ambitious smelter project as a joint venture, Ma’aden-Alcoa. The aluminium smelter
built as the first stage celebrated in December 2012 the successful commissioning of the
first of 720 smelting pots – a key step towards
commercial production at the smelter.
© Fata
Until now the aluminium semis industry in
the Gulf region has been developing at various rates. Whereas the building boom of previous years encouraged the creation of numerous extrusion plants since the 1990s, other
aluminium semis and finished products were
previously produced only by a few plants.
Among others this applies to rolled products,
of which the GCC countries have always been
a net importer until now.
Aluminium flat products have until now
been produced in the region only by Gulf
Aluminium Rolling Mill (Garmco) in Bahrain.
That plant was set up in 1981 as part of the
aluminium cluster around the smelter of Aluminium Bahrain (Alba). Garmco operates hot,
cold and foil rolling mills which have repeatedly been modernised and brought up to the
latest state of the art. They produce cold rolled
coils and sheet in 1xxx, 3xxx, 5xxx and 8xxx
series alloys for a wide range of applications,
from food containers and stylish up-market
hollow-ware to high-profile architecture and
paint industry in gauges from 0.25 to 3.2 mm
and up to 1,560 mm wide.
From next year onwards there will be two
more major aluminium rolling mills in the
region, which will steadily boost the quantity produced over the coming years from its
present level of around 200,000 tonnes up to
about one million tonnes a year.
A new supplier of aluminium flat products is arising with Oman Aluminium Rolling Company, LLC (OARC). This company,
100%-owned by Takamul Investment Co., is
currently commissioning a USD387 million
aluminium strip-rolling plant with a production capacity of 160,000 tonnes a year. The
main supplier is Fata EPC in Italy, which is also
acting as the general contractor.
OARC will be the largest purchaser of molten aluminium from the neighbouring Sohar
Aluminium smelter.
The plant is designed for the production
of strips made from alloys of the 1xxx, 3xxx
and 8xxx series, in widths up to 1,950 mm
and in the thickness range of 0.075 to 1.5 mm
in the form of semi-finished coil products,
i.e. foil stock for converter and packaging foil,
and cable wrap. In addition it will produce
finished coil products such as semi-rigid container foil, for example for aluminium food
containers and fin stock for the air conditioning and automotive heat exchanger markets.
Further products planned will be tension-levelled industrial sheet for building products in
the thickness range 0.3 to 1.5 mm.
The concept of the plant is worthy of particular attention. The capacity of 160,000
tonnes a year is lower than the economically
viable limit of a conventional plant consisting
Hazelett caster from Fata Hunter…
34
… and cold rolling mill for OARC
ALUMINIUM · 9/2013
SPECIAL ARABAL
The hot-rolling mill will be fed with rolling
slabs, for the production of which Wagstaff
Inc., USA, will supply cutting-edge ingot and
billet casting systems with integrated automated controls, which have been shown to deliver improved recovery rates as well as higher
levels of workplace convenience and safety.
The casting facility will also feature Alcoa’s
advanced proprietary ingot casting technology
which provides rolling ingots with a highly improved surface finish with consequential gains
in rolling efficiency and product quality.
The rolling slabs will be heated in two pusher-type furnaces from Ebner Industrieofenbau, Austria. The two ‘Hicon’ pusher furnaces
each hold 30 aluminium rolling slabs of maximum dimensions 635 x 2,100 x 9,000 mm.
Besides the tried and tested Ebner-specific
Hicon plant components, which are decisively
necessary in order to achieve great temperature uniformity in the slabs and high energy
efficiency, the most up-to-date process control
has been called for. In that context the twodimensional temperature computation model
TREATperfect developed by Ebner suits the
purpose admirably. In this, each rolling slab
is computationally divided into individual ele-
ALUMINIUM INDUSTRY IN THE GULF
ments. Within these elements the heat transfer in a particular time frame are determined
mathematically.
Throughout the annealing process TREATperfect compares the pre-calculated temperature variations with those actually taking
place, and can therefore react to perturbations or changes of circumstances and adapt
the planned annealing time.
Besides the furnaces, the equipment supplied by Ebner includes the complete slab handling system, from slab reception to transfer
of the heat-treated slab onto the roller track
of the hot mill.
The integrated rolling complex, currently
being assembled, consists of a hot-rolling mill
with capacity 650,000 tonnes a year and two
cold-rolling mills. The first cold mill, with a
capacity of 400,000 tonnes of aluminium strip,
serves to produce food-grade can stock which
has many applications including the manufacture of beverage cans. The second cold mill
has a capacity of more than 150,000 tonnes
and mainly produces high-grade strip for
the automobile industry. The new plant will
not just boost the creation of a local further
processing industry. Thanks to its geo-strategi-
cally favourable position the investors surely
also have their sights on growth markets for
aluminium flat products which are capable of
development, e. g. in the Middle East.
The main supplier of the complete integrated hot and cold rolling plant, including its electric and automation systems, is SMS Siemag.
For the hot-rolling plant SMS Siemag is
supplying the complete 1 + 4 pre-rolling and
finishing line. The pre-rolling section consists
of a quarto preliminary stand which rolls down
the in-coming aluminium slabs up to 635 mm
thick and weighing up to 32.5 tonnes. The
preliminary line also includes a heavy and
light hydraulic cropping shear for intermediate cropping and for removing the leading and
trailing ends of the preliminary strip.
The quarto-designed four-stand hot finishing line rolls the preliminary strip coming in
with a thickness of about 30 mm, down to
final thickness of 2 to 7 mm in a single pass.
In the run-out area of the finishing line the
finished strip is trimmed and taken up by a
hot-strip spool with belt wrapper.
After the hot mill the plant has two coldrolling lines, designed for the production of
various strip qualities.
➝
© SMS Siemag
ALUMINIUM INDUSTRY IN THE GULF
3D layout of the SMS Siemag aluminium cold rolling mill…
The first plant, with a rolling capacity of more
than 400,000 tonnes a year, produces mainly
can stock. For this, SMS Siemag is supplying
the complete cold mill and coil preparation
station in the run-in area and an off-line strip
inspection facility in the run-out area. The efficient, four-stand tandem line of quarto design
rolls the in-coming aluminium hot-rolled strip
up to 2,100 mm wide down to a minimum
final thickness of 0.15 mm. The tandem line
is equipped with tried and tested control elements such as hydraulic positioning, positive
and negative working-roll bending and CVCplus technology. The control systems ensure
optimum strip flatness,
strip thickness tolerances and a perfect strip
surface.
The hot mill and
tandem cold mill are
equipped with all the
control and regulation
systems needed to ensure reliable process
management of the
fully automatic rolling
process. For this AluControl is used, an automation system matched
to the process requirements of aluminium rolling, which is part of
the ‘X-Pact’ electric and automation system
of SMS Siemag. In both plants Alu-Control
covers the levels from Level 0 to Level 2.
After leaving the cold tandem line the coils
go on to a fully automatic coil-coating line
supplied by BWG Bergwerk- und Walzwerk
Maschinenbau GmbH in Germany.
In addition to the clearing and coating sections this has a drying oven which, like the
36
complete electric and automation systems of
the plant, is also included in the BWG technology package. The line is designed in accordance with the most up-to-date specifications
as implemented many times over in similar
units recently supplied by BWG to other Alcoa companies.
A second cold rolling mill will enable the
Ma’aden Alcoa joint venture to include capability for producing about 150,000 tonnes of
a wide range of products suitable for further
downstream manufacturing in the complex’s
product lines. They include automotive heattreated and non-heat-treated sheet, building
for Saudis, as well as enabling the replacement of
a wide range of imports
with cost-effective, highquality domestic products, and encouraging the
expansion of the national
industrial base,” says Khalid Mudaifer, Ma’aden’s
president and CEO.
The order for SMS
Siemag comprises a single-stand cold-rolling mill
with an annealing and
coating line that is especially suitable for automotive grades of aluminium.
Feedstock for the new
plant will be coils up to
2,100 mm wide and weighing 30 tonnes and these will be supplied from
the hot-rolling mill of the first phase.
The new line will be equipped with a 4high rolling stand with CVC plus, working roll
bending, multi-zone coiling and a dry-strip
system in order to meet the requirements for
the automotive grades of aluminium to be
rolled. An annealing and coating line with an
annual production capacity of 50,000 tonnes
of 5000 and 6000 series alloys will adjoin
the cold-rolling mill. Cold-rolled strip up to
2,100 mm wide in the thickness range 0.8
to 3.5 mm will be annealed and coated in a
continuous process. This line is built in col-
… and annealing and coating line for Ma’aden
and construction sheet and foil stock sheet.
An order has been released to SMS Siemag
for the supply of the mill equipment and heat
treatment line. “These new capabilities will
help establish downstream industries in Saudi
Arabia using aluminium that has been mined,
refined, smelted and rolled in the Kingdom.
It is also fully compatible with the national
strategy of developing national resources to
create sustainable wealth and employment
laboration between the Strip Processing Lines
and Thermal Process Technology divisions of
SMS Siemag.
One of the core elements is the GATV
floater furnace with high-performance water quenching. Uniform mechanical properties such as a grain size and hardness will be
obtained in a reproducible manner over the
whole length and width of the strip. High
cooling rates immediately after stress reliev-
ALUMINIUM · 9/2013
ing are one of the prerequisites for producing the quality
demanded by the automotive
industry. To achieve these,
the unit will be equipped with
a high-performance air-cooling facility and water cooling.
Besides
continuousthroughput strip treatment
Ma’aden-Alcoa will also be
able to heat treat single strip
coils individually. This unit is
particularly suitable for being able to fulfil annealing
contracts flexibly and costeffectively with a demonstrably controlled
heat treatment, as is often called for by the
automobile industry. To achieve that objective Ma’aden-Alcoa has ordered from Tenova
LOI Thermprocess in Germany a complete
line of single-coil lifting hearth furnaces. A
number of individually loaded and operated
furnace chambers together form a furnace
battery. The overhead arrangement enables
space-saving charging by an automotive transport system, from below.
This line allows adapted heat treatment according to the specific needs of the individual
strip within a short time, instead of heat treatment in batches of several coils, which would
require an average heat treatment or the assembling of a batch of identical strip coils.
The heat treatment including cooling can be
carried out under a protective atmosphere.
The system works fully automatically from
taking the coil out of the storage area until
the heat treated coil is placed into the storage
area again.
Tenova LOI Thermprocess was the first to
invent and design this type of furnace. The
first unit was installed in 1998 by Constellium
(formerly Alcan) in Singen, Germany, for automotive sheet applications. By now the company has built 68 such single-coil lifting hearth
furnaces in batteries up to 17 units.
Before the rolled, heat-treated and surfacetreated coils are sent for dispatch, they must
again be trimmed and cut to the dimensions
specified. Danieli Fröhling in Germany, one
of the noted suppliers for aluminium coldrolling mills and a market leader for aluminium cutting machinery, already supplied for
the first cold mill two technologically sophisticated cutting units and two associated packaging machines. These units are designed for the
strictest quality and quantity demands.
For the second cold mill the company is
also supplying a longitudinal slitting machine
with downstream packaging of the finished
coil, specially designed for automotive needs.
ALUMINIUM · 9/2013
ALUMINIUM INDUSTRY IN THE GULF
© Danieli Fröhling
SPECIAL ARABAL
Danieli Fröhling line for Ma’aden from run-in side to packaging
The plant’s structure and special features re- in the development of the first fully integratlating to strip movement and equipment were ed aluminium complex,” says Ken Wisnoski,
developed in close collaboration with the end president of Alcoa’s Global Primary Products
customers, in order to satisfy all the special Growth business.
customer requirements. This process was
greatly influenced by the wealth of experience gained by both Alcoa and Fröhling from Author
previous projects.
The plant includes the complete range of Dipl.-Ing. Bernhard Rieth is a marketing specialist
and freelance technical journalist. As proprietor of
equipment supplied, beginning from the run- Marketing Xpertise Rieth in Meerbusch, Germany,
in side: the conditioning machine for reducing he advises equipment partners of the NF metals
the coil-set, inline strip preparation by means semis industry on marketing-related matters.
of drum shears, the
cutting zone with
CNC shear and
exchange station,
the strip braking
zone and the electrostatic oiling unit,
as far as coil winding and transfer to
the packaging unit.
Within the downstream packaging
unit, depending on
the programme the
coils are isolated,
weighed, packed in
foil and stacked on
pallets. The work
steps throughout
7KH3UR+'LJLWDO&DPHUD6HQVRUFRPELQHV
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automatically, with
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of the new plant
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35(&,0(7(5&21752/$%
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gVWUD+DPQHQ6(+|Q|6(
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bia. “The rolling
mill will be a significant milestone
Molten Metal Level Control
37
ALUMINIUM INdUstry IN the GULf
Kizad aluminium cluster taking shape
B. rieth, Meerbusch
theport,KizadislinkedtotheAbuDhabito
Dubaihighway,thustothewholeoftheGulf
region’s road network. Three international
airports,AbuDhabi,AlMaktoumandDubai,
canbereachedquicklyviathisnetwork.An
impressive rail link is also currently under
constructionthroughEtihadRail,thatwillsee
lines eventually running from Khalifa Port
toseveraltradelinksthroughouttheregion.
Thanks to Kizad’s outstanding geo-strategic
location, goods produced at this industrial
zone can be shipped quickly and cheaply to
thegrowingmarketsoftheArabianPeninsula,
WesternEurope,AfricaandEastAsiawhere
over4.5billionpeoplearelessthanfourtime
zonesaway.
Theplannedindustryclustersarevertical-
ly integrated and organised according to industrysectors.Ananchortenantwillproduce
the necessary raw materials, which will be
supplied to downstream processors in the
respectivevaluechain.Thisaddedvaluewill
notonlybecreatedduringproductionofthe
basic materials, such as aluminium, but also
alongthewholevaluechain.
© Kizad
A large part of the Emirate of Abu
Dhabi’s 2030 economic vision is based on
diversification of the economy. Several
ambitious projects have been initiated
in the emirate to broaden and diversify
its economic base. The Khalifa Industrial
Zone Abu Dhabi, or Kizad as it is better
known, is aimed at establishing an additional source of economic activity in
the form of light and heavy industries together with related trading and services.
The emirate wants to attract not only
domestic investors, but also top-class foreign companies wishing to locate there.
By developing Kizad, the emirate is also
aiming at providing suitable employment
for its growing workforce of young and
well-educated nationals as well as attracting experts from other countries to work
in the Gulf region.
Khalifa Port, a modern deepwater port that
has been fully operational since September
2012,isamajorassettotheinvestorsinKizad;
designedandownedbyAbuDhabiPortsCom-
Aerial view of midstream aluminium industries with Hot Metal Road
pany (ADPC), it is the only semi-automated
portintheregion.Kizadcoversanareaofover
417squarekilometres,splitbetweenAreaA
andB,andincludesseveralsector-orientedindustryclustersaswellasresidentialandcommercialareas.Besideshavingdirectaccessto
38
TodayKizadcaterstothefollowingindustrial
clusters:aluminium,steel,engineeredmetals,
glass, paper, print and packaging, trade and
logistics,aswellasmixedusessuchaspetrochemicals,chemicalsandplastics,construction
and building materials, pharmaceuticals and
medical products, high-tech and clean tech,
andfoodprocessing.
Besides the purely vertical integration
within the individual clusters, it is also conceivablethattherewillbesynergiesbetween
theclusters.Forexample,aluminiumfoilfrom
thealuminiumclustermightbeusedbyconverters from the pharmaceuticals, food and
packagingclusters.
efficiency through vertical integration
Thealuminiumclusterisagraphicexampleof
Kizad’sinnovativeimplementationofitsverticalclusteringconcept.Plansweremadeatan
earlystagetoestablishaluminiumprocessing
plantslocallyandthusincreasetheaddedvaluegeneratedlocallytoensurethatthecheaply
producedaluminiumisnotmerelyexportedin
theformof’solidifiedenergy’.Thefirstsuccessesarealreadytangible.Companiesfocusingonfinishedaluminiumproductsforlocal
and regional markets are moving to locate
here,partiallyasaresultofthehighlevelof
imports of such products in the Gulf region.
However,theprimaryattractionforproducing finished aluminium products in the Gulf
region and supplying the world market will
becostbenefitsforenergyandlabourcoupled
withtheextensivefacilitationofinvestments
forforeigninvestors.
At the centre is Emal, Emirates Aluminium,withoneofthemostadvancedaluminiumsmeltersintheworld.Emalistheanchor
tenantforKizad’saluminiumcluster.Itsmost
modern aluminium smelter has a capacity
of 800,000 tonnes a year and has been on
stream since 2010. At the end of 2011, the
companyannouncedthatithadcreated2,000
new jobs. Emal supplies its products – sows,
standardingots,sheetingotsandextrusionbillets–primarilytoEurope,theUSAandAsia.
Thesiteincludesa2,000MWpowerplant,a
carbonplantandacasthouse.Rawmaterials
are transported directly from the sea to the
smelterviaanexclusivepurpose-builtwharf
atKhalifaPort.
Theproductioncapacityiscurrentlybeing
expanded to 1.3 million tonnes a year with
fullproductionisexpectedbymid-2014.This
will make Emal the fifth largest aluminium
producerintheworld.
Aspecialfeatureofthealuminiumcluster,
referredtoinKizadastheHotMetalRoad,
is a unique and innovative supply route for
ALUMINIUM · 9/2013
“Wouldn‘t it be great
if we could get our
plant back to working
temperature in less time?”
“Sure – no problem!”
www.refra.com
Faster plant availability thanks to intelligent refractory technology?
Perfectly feasible. For example by using mixes based on our
pioneering cement-free Nanobond binder technology, which
permits much faster heat-up after repairs – plus a simultaneous
increase of temperature resistance.
Let‘s talk about your goals. We‘ll find the right way.
Results first.
Intelligent RefractoryTechnology
REFRATECHNIK
Refratechnik Steel GmbH
Schiessstraße 58
40549 Düsseldorf
Germany
Phone +49 211 5858 0
[email protected]
ALUMINIUM INdUstry IN the GULf
taineddirectlyfromEmalasextrusionbillets.
WiththesupportofEmalandKizad,Talex
will contribute further to the diversification
plansetoutinAbuDhabi’sVision2030.MajidAlGhurair,CEOofAlGhurairGroupand
managingdirectorofGulfExtrusions,isvery
positive about the joint venture with ADBIC: “It is another step towards positioning
ourselvesasaleadingregionalplayerinthe
aluminiumextrusionindustry.Thelocationof
TalexinKizadisveryimportantintermsof
being closer
to our raw
material supplier(Emal)as
well as close
to the Khalifa
Port. With its
state-of-theart equipment,
Taweelah Aluminium Extrusion Company will be
a world-class
company competingwiththe
best extruders
in global marketsbyoffering
premiumqualThe Emal smelter is the anchor tenant for Kizad’s aluminium cluster
ity products.
This reaffirms our commitment to further
New downstream additions
strengthen the region’s reputation as a leadto aluminium cluster
ingsupplierintheextrusionmarket.”
Cast Aluminium Industries (CAI), a midSeveral aluminium processors have already
recognisedthebenefitsoflocatinginthealu- stream aluminium producer and recycler, is
miniumcluster.Extrudedprofilesareatypi- another company planning to settle in the
cal downstream product and Taweelah Alu- aluminiumcluster.Ona33,000squaremetre
minium Extrusion Company (Talex) will be site,thecompanyiserectingaplantforrecyproducing them in the aluminium cluster in clingaluminiumdrossandotheraluminiumfuture.TalexisajointventurebetweenSenaat bearingwastematerialsproducedbysmelters.
andGulfExtrusions.Thelatterhasbeenop- CAI will be the first to represent ’horizoneratingamodernextrusionplantwithseveral talintegration’inthecluster.Thereisazero
wastetargetwithCAIalsointendingtoplayan
presslinesinDubaiforseveralyears.
At the end of 2011,Talex signed a long- instrumentalroleinthewaste-recoverymanterm agreement with Kizad for a 200,000 agement of other investors in the cluster.
square metre site. The company will be in- CAIhasawidearrayofclientsinprimaryaluvestinginitiallyintwonewpresslines,which miniumsmeltersacrosstheUAE(Dubaland
arecurrentlybeingengineeredandbuiltinEu- Emal) and the wider region including Alba,
rope.Thecompany’saimistoproducehigh- Qatalum and other secondary smelters. CAI
qualityextrusionproductstomeetthespecific isexpectedtocommenceoperationsinKizad
needs of the automotive market; end prod- inthethirdquarterof2014.
CAI is Kizad’s first recycler and also the
ucts will also include transportation and in-
dustrialmaterials,electricalandsolarequip- firstcompanythatrepresentshorizontalintement, road furniture and architectural mate- grationinthecluster.Kizadhasazero-waste
rials.Emalwilldelivermoltenaluminiumto targetandCAIisintendingtoplayaninstruTalexviatheHotMetalRoad.Specialalumin- mental role in waste-recovery management
iumgradeswillbealloyedandcastatTalex’s forothersinthecluster.KhaledSalmeenAl
own casthouse; standard grades can be ob- Kuwari,CEOandmanagingdirectorofKizad,
© Emal
thewholesite.Theroad,whichhasbeenspecificallybuilttohandleheavygoodsvehicles,
willlinkthesmelterwiththeprocessingplants.
Moltenaluminiumwillbetransportedincrucibles on special vehicles directly from the
smelter’scasthousetotheenduser.Besides
just-in-time delivery, this allows savings in
energycostsforremeltingand/orreheating;
furthermore,userscanspecifythealuminium
alloyneededtomeettheirindividualrequirements.
40
said:“Recyclingisnotacommoninitiativein
thelocalindustrialbusiness,thereforesecuringCastAluminiumasapartnerwhowillplay
aleadingroleinwaste-recoverymanagement
willchangethenatureofthisbusinessinthe
UAE.Byencouragingthis,Kizadisworking
towards two of our economic vision’s core
pillars:economicandenvironmentalsustainability.”
CAI already operates three tilting rotary
furnaceswithacombinedcapacityof32,000
tonnesayearatitsDubaiplant,withoxy-fuel
burnersfromtheUSandUK.Awasteminimisation programme initiated in 2004 successfully reduced flux usage from 28 to 13 per-
cent; investment in a so-called ’alchemizer’,
whichinvolvesamechanicalsegregationprocesstoenrichthealuminiumdross,hasresultedinfurtherreductiontoninepercent.CAI
is also working with different companies to
utilise the alumina-rich dust from the alchemizer,sofarwithpromisingfeedback.
Opportunities still
available for investors
The new investors mentioned above are a
promisingsignforthesustainabilityofKizad’s
aluminiumcluster.Negotiationsarealsotakingplacewithotherpotentialinvestors.One
importantmissinglinkisarollingmillforflat
aluminiumproducts.Eventhoughsuchplants
are currently being built in Saudi Arabia and
Oman,theUAEoughtalsotobeaninterestinglocationforforeigninvestors.Besidesthe
possibilityoferectingaconventionalhotand
coldmillthatprocessessheetingotssupplied
by Emal, the Hot Metal Road also opens up
the opportunity to produce small quantities
economicallyusingastrip-castingmachineinsteadofahot-rollingstand.Foilstockforaluminiumfoilcouldalsobeproducedinsucha
plant,possiblybyanadditionalinvestor.
The Hot Metal Road might also be interesting for the construction of an aluminium
foundry,forexampleforcarwheelsforboth
thedomesticmarketandexport.
Giventhediversityofpossiblefinishedaluminiumproducts,onecoulddrawupapracticallyendlesslistofpossibleinvestments.But
onethingiscertain:therewillsoonbeother
investorswhoappreciatethebenefitsoffered
bylocatingintheKizadaluminiumcluster.
Author
Dipl.-Ing.BernhardRiethisamarketingspecialist
andfreelancetechnicaljournalist.Asproprietorof
MarketingXpertiseRiethinMeerbusch,Germany,
he advises equipment partners of the NF metals
semisindustryonmarketing-relatedmatters.
ALUMINIUM · 9/2013
ALUMINIUM INdUstry IN the GULf
ePCM – a vital activity in the world of aluminium
The construction of aluminium production facilities ranks alongside the biggest
of world projects, rivalled only by major
chemical process plants, city infrastructure schemes, new underground transport
systems, harbour facilities and the like:
all huge enterprises elaborated on a massive scale and involving a tremendous
complexity of operations – and of course,
associated multi-billion dollar costs.
eringprojects–fromconceptdesignthrough
tobeneficialoperation.Thisincludessuccessfully overseeing all elements of project and
construction management services, requiring
dedicated expertise at the cutting edge of a
diverserangeofactivities,including:
Feasibility studies and front end engineering design:EPCMcompaniesmustensurethat
their imperatives of innovation, efficiency,
building capability and safety are embodied
intothefullyintegratedfeasibilityanddetailed
design services offered, ensuring that all the
involved services are complementary. Cost-
effectivefeasibilitystudies,embracingallsectorsandprojectlocations,whichtakeintoaccountthemyriadoflocalandregionalinfluencingfactors,ensurethatprojectsareevaluated accurately prior to the decision being
takentoprogresstothenextstageofdesign
andconstruction.
Project and risk management:Projectmanagementandanalysisofriskisakeyelement
oftheservicesprovidedinallphasesofEPCM
work. Experienced project management per-
agementservicesarenaturallytailoredtothe
uniquedemandsofboththeclientandproject.
In all cases, construction health, safety and
environmentaresomeofthekeyconsiderationsviewedtobeofparamountimportance.
Construction management teams are responsibleforensuringthatbuildingworkon
siteisinaccordancewiththeprojectspecifications, drawings and relevant standards indicatedbytheintegratedmulti-disciplinedesign
team. The main considerations here include
quality assurance, project site management
andprojectcostestimating,controlandprocurement
Once the EPCM gets the green light for
the proposed project, it is crucial that the
concluded work meets the stated objectives
and is delivered within the agreed cost and
time frame parameters. This requires robust
systems such as for value engineering and
analysis, cost estimating, reporting, managementandforecasting.
Multi-discipline engineering, detail design
and 3D modelling: Essentially,EPCMcompa-
© Emal
The work required in building a major alu-
miniumsmelter–greenfieldorbrownfield–
oranupgradeofdownstreamfacilities,isinvariably on a massive scale, involving many
considerations,activitiesandcomplexcomponents.Thenecessaryworksinvolveextremely
closeandcarefulcoordinationofalltheindividualkeypartsoftheprojectleadingtocompletion of the whole. Certain organisations
specialiseinthisvitalworkbasedessentially
onaccumulatedexperience,knowledge–and
globalreach.
EPCM – Engineering, Procurement and
ConstructionManagement–isacommon
form of contracting arrangement within
the aluminium/construction industry.
InanEPCMarrangement,theclient,in
order to involve an experienced player
inlargeprojects,selectsamaincontractorwhomanagesthewholeprojectonits
behalf.TheEPCMcontractoressentially
ensuresthatthewholeprojectiscompleted as required to the client’s specificationsandontime.Normally,thisinvolves
theEPCMcontractorcompletingthebasic work such as site surveys, obtaining
clearancesfromauthorities,undertaking
thebasicengineeringandalsopreparing
thesitefortheEPCcontractors.Further,
themaincontractorchoosesthevarious
EPCcontractorsandensurestheelaborationoftheprojectasplanned.
An EPCM contract is a natural progression for an EPC contractor since, if
thecontractorhasthecapabilitytohan- Construction work at the Emal Phase I smelter in spring 2009. SNC Lavalin was EPCM contractor for the Phase I
dletheEPCworkrequiredinaproject project and is also handling the EPCM services contract for the Phase II expansion.
thensecuringawiderroleviaanEPCM
job is advantageous.This helps to exploit its sonnel focus on developing an intimate un- niesworktoaddvaluetoaclient’sbusiness,
currentcompetencieswhilealsoensuringbet- derstanding of the client’s strategy, culture through creative and innovative thinking in
ter control over the project.Also, the value andprojectneedsfromconceptionthroughto engineeringdesign.Integratedmulti-discipline
engineeringexpertiseacrossallrelatedfields
of the project managed through an EPCM completion.
contractisfargreaterthantheindividualEPC Aluminiumindustryprojectscanrangefrom is deployed to deliver an optimum solution,
small-scalestudiestomulti-milliondollarnew baseduponbestpracticeandtheverylatest
contracts.
projectfeedbackavailable.
A range of specialist EPCM companies is builds.
A range of recent EPCM projects in the
Construction management:EPCMorganicalledupontooffertotalflexibility,andboth
nationalandinternationalexperienceindeliv- sationsmustensurethatitsconstructionman- worldaluminiumsectorreflectthehugescale
42
ALUMINIUM · 9/2013
NEW
2013
NEW GENERATION OF VEHICLES
Reduced size and weight
Latest-generation electronics
Reinforced components for increased lifting
capacity
Long-comfort suspension cabin and swivel seat
Mobile alarm and data acquisition/
transmission system
Micro-controller management system and
on-board shock sensor
Smoother steering
Low maintenance costs
Check it out at the CIAC from October 21 to 25, 2013, in Montreal (booth B02)
and at the ARABAL conference from November 5 to 7, 2013, in Abu Dhabi (booth #16).
www.brochot.fr
ALUMINIUM INdUstry IN the GULf
oftheindividualtasksinvolvedforthesemain
contractingcompaniesandalsofortheirdelegated contractors down the line in meeting
the customers total plant requirements and
specifications.
Middle east projects
© Qatalum
SNC Lavalin: Montreal,Canada-basedSNCLavalinisoneoftheleadingengineeringand
constructiongroupsintheworldandamajor
playerintheownershipofinfrastructure,and
in the provision of operations and maintenanceservices.Thecompanyishandlingthe
EPCMservicescontractfortheEmiratesAluminium(Emal)PhaseIIsmelterexpansionin
AlTaweelah,AbuDhabi.Thecontractcovers
the work to build a new aluminium facility,
includinga1,000MWpowerplantanda1.7
km-longpotline,thelongesteverbuilt.Once
completedandfullyoperationalin2014,the
newfacilitywillproduce525,000tpyofaluminiumusinganupgradedversionofDubal
DXtechnology,whichallowsforgreateroperatingefficiencies.
ThislatestcontractfollowedSNC-Lavalin’s
successfulcompletionofitsEPCMmandatefor
PhaseIoftheEmalsmelter,whichhasapro-
on maintaining long-term relations with our
clients.WevalueEmal’srelationshipandtrust,
andwearedelightedwiththisnewopportunitytoworktogethertobuildthislandmark
projectfortheUnitedArabEmirates.”
Fata EPC:FataEPC,adivisionofItaly/US
outfitFataHunter,wastheEPCMcontractor
forthecasthousebuildprojectattheQatalum
primaryaluminiumsmelterinQatar,anequal
joint venture between Qatar Petroleum and
HydroAluminiumofNorway.Thecasthouse
technologywassuppliedbyNorskHydrodelivering an extrusion billet VDC capacity of
350,000tpyand275,000tpyfrom10and20
kgcasters.Hycasthotmetalalkalineremoval
andin-linefiltersanddegasserswereinstalled
alongwithautomaticcastingsequencing.The
installationensuresthatallequipmentfumes
aretreatedbydustcollectors.
Inaparallelcontract,FataEPCalsohandledworktobuildananodebakingplantat
theQatalumfacilitywithtechnologysupplied
byPechineytoprovideatotalplantcapacity
of 368,000 anodes per year. The plant uses
sevenfireswith116sectionsandisfuelledby
natural gas with fume treatment employing
dryscrubbing.Storageprovisionwasrequired
for 18,000 green anodes and 13,000 baked
Fata EPC was EPCM contractor for the casthouse project at Qatalum
ductioncapacityof800,000tpyandincluded
theconstructionofa2,000MWpowerplant.
“SNC-Lavalinisaworldleaderinthedesignandconstructionofaluminiumsmelters,
andweconsiderthisnewawardasaclearacknowledgementoftheleading-edgetechnical
capabilitiesandexperiencewedemonstrated
withPhaseIoftheproject,”declaredRiadh
Ben Aïssa, executive vice-president, SNCLavalinGroup.“Justasimportant,itreflects
theeffortandimportanceSNC-Lavalinplaces
anodes–andstorageandretrievalisviaautomaticcraneandtransfer.
Further,FataEPChasalsoelaboratedaseriesofdownstreamprojectsinthealuminium
industry including others in the Gulf region,
such as the one currently in construction at
Oman Aluminium Rolling Company in Sohar.AsthemainappointedEPCMcontractor
to build the planned 160,000 tpy greenfield
facility, Fata EPC is managing the activities
involvedtoprocureandinstallcompleteroll
plant systems to feature the latest available
technologyincasting,rollingandfinishing.The
newfacilityincludesaHazelettcasteranda
hot rolling mill along with world-class cold
rolling and finishing equipment supplied by
Fata Hunter, the equipment division of Fata
SpA.For further project details, see report on
pages 34-37.
In Iran, Fata handled the second potline
expansionattheAlmahdiAluminiumSmelter
inBandarAbbaswithkeytechnology(providedbyImidro).Theplant’sPotline2comprises
twopotroomsbuilt32metresapart,each750
metres long and 20 metres wide. A total of
228 pots, with 20 anodes per pot, employ
DubalD20celltechnology,operatingat240
kAand13.6kWh/kgAlandusingafluidflow
aluminafeedingsystem.Productioncapacity
is147,000tpyofaluminium.
Bechtel: Also in the Gulf, major EPCM
organisation Bechtel is extending its long
heritage of mega projects in the region by
managingthegreenfieldconstructionproject
in SaudiArabia for what is slated to be the
world’slargestaluminiumsmelter.Thescope
ofworkinvolvedinthisUSD4billionproject,
handled by Bechtel’s Mining & Metals division,coversoverallengineering,procurement,
andconstructionmanagement.
The new smelter, a Ma’aden-Alcoa joint
venture, is the cornerstone of the Ras Al
KhairMineralsIndustrialCity,whichwillbecomethecountry’saluminiumandphosphate
centre, north ofAl Jubail in the Saudi EasternProvince.Thisispartofanewintegrated
USD10.8 billion aluminium complex, which
inadditiontothesmelterwillincludeamine,
aluminarefineryandrollingmill.Thesmelter
facilitywillhaveacapacityof740,000tpyof
aluminium. Bauxite feedstock will be transportedviaapurpose-builtraillinefromanew
mineatAlBa’ithaforrefiningandreduction
atRasAlKhair.Firstcommercialproduction
fromthesmelteranddownstreamrollingmill
isscheduledfor2013.For further project details, see separate report on pages 46-47.
AgainintheGulfregion,Bechtel’sCanada
operationhasreceivedaLetterofIntent(LoI)
fromAluminiumBahrain(Alba)toconducta
BankableFeasibilityStudy(BFS)forthesmelter’splannedPotline6expansionproject,valued at some USD2.5 billion.The study also
includes an economic analysis for the constructionofafifthpowerstationrequiredfor
theplantexpansion.Alba’sLine6isexpected
toproduceanadditional400,000tpyofaluminiumaddingtoitscurrent881,000tpy,with
DubalDX+celltechnologybeingusedasthe
basisofthestudy.
Bechtelhasconsiderablespecificindustry
A
Th
an
R
C
44
ALUMINIUM · 9/2013
ALUMINIUM INdUstry IN the GULf
© Bechtel
sPeCIAL ArABAL
Construction work at the Ma’aden-Alcoa joint venture early this year, with Bechtel the EPCM contractor.
From left to right: field engineers Fadi Elmourad, Muthukumaran Kuppusamy, Mohamad El Samad and
planner Lamont Berry.
experience in the region having operated as
the EPCM contractor for the previous Line
4 and 5 expansions.The BFS is expected to
be completed by the third quarter this year,
Fluor Corporation’sGreenville,SouthCarolinaofficeiselaboratingadesignandprocurementcontractawardedbytheaforementioned
Ma’aden-Alcoajointventuretobuildanintegratedautomotivesheetmanufacturingplant
that forms part of the aluminium complex.
ThescopeofFluor’sworkwillincludedesign,
constructionandcommissioningoftheplant,
which will have the capability to produce a
range of products suitable for further downstreammanufacturinginthealuminiumcomplex.
Oncecomplete,theautomotivesheetfacilitywillproducelightweightaluminiumtobe
usedinvehiclemanufacturing.Theseproducts
willincludeautomotiveheat-treatedandnonheat-treatedsheet,buildingandconstruction
sheet,andfoilstock.“Thisnewmanufacturing
facilitywillhelpmeettheglobalautomotive
industry’s growing demands for new, lighter
materials,”saidFluorheadofMining&Metals
businessRickKoumouris.
andAlbaprojectsthatthenewlinecouldbe further ePCM projects
completedbyearly2015.AlongsideBechtel,
BNPParibasisactingasthefinancialadviser HRV Engineering / Hatch: In Iceland, Rio
fortheproject.
Tinto Alcan is updating equipment, increas-
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ALUMINIUM INdUstry IN the GULf
ing production capability and improving the
production process at its smelter casthouse
inStraumsvik.Theprojectisaimedatboostingproductivityby20%,toaround230,000
tpy, along with increasing the effectiveness
of air purification equipment and increasing
operational security by updating the electrical equipment. Iceland outfit HRV Engineering,inco-operationwithHatch,managedthe
IsalproductionupgradeprovidingfullEPCM
services in a project costing some USD500
million.
The plant’s operational reliability will be
increased with the upgrade and installation
of new HRV equipment and rectifiers. Plant
productionisboostedby40,000tpy,involving
anamperageincreaseandanupgradeofthe
twopotlines,bathrecyclingplantandrodding
shop. New additional gas treatment centres
areincluded,alongwithaluminahandlingand
anupgradedgeneralplantinfrastructure.
Theoutputisalsobeingchangedoverfrom
rollingslabtoextrusionbillet,whichrequires
modificationofcastingequipmentandinstallationofthreenewcontinuoushomogenising
furnaces.
Ausenco: Australian project contracting
companyAusencoisprogressingtheInnovate
andCreatephasetowardsprovidingdetailed
engineeringdesignandconstructionmanagementservicesfortheexpansionandupgrade
ofacarbonandpasteplantatRioTintoAlan’s
aluminiumsmelterinKitimat,BritishColumbia,Canada.Thisnewworkisscheduledtobe
completedbySeptember2013andbuildson
Ausenco’spreviousearlyphaseworkonthe
projectduring2008.
Ausenco’s CEO Mimi Make sums up his
company’s role in another huge aluminium
industry project, and also the importance of
EPCMorganisationsacrossthesectoringeneral:“Thesecontractawardsdemonstratethe
depthofourserviceofferingandgeographic
reachofourbusiness.OurProcessInfrastructurebusinesshasachievedstandoutearnings
growththispastyearandtheselatestwinsfurtherdemonstratethebenefitsofourdiversificationstrategyandourglobalreputationfor
projectdeliverytounderpinfurthergrowth.”
Ken Stanford, contributing editor
Bechtel keeps building history
Recognisedinthe2012BechtelCorporateExcellenceAwards as the Project Management
TeamoftheYear,theentireprojectteamis
achieving some remarkable feats in this demandingenvironment.
setting the standard for
safety attitude and performance
As of year-end 2012, the project team had
achieved32millionjobhourswithoutalost
timeincident,withthecustomerteamcalling
Bechtel’s safety performance ‘world class’.
Manycontractorshavenotedthattheproject
representsaturningpointintheirrespective
firm’ssafetyattitudeandperformance.
“We’ve had exceptional success in buildingastrongsafetycultureamongmorethan
© Bechtel
Engineering challenges do not come much
bigger than building the world’s largest
greenfield aluminium smelter project –
Ras Al Khair – located on the Arabian
Gulf, approximately 125 km north of
Jubail in the isolated north east corner of
Saudi Arabia. This location presented all
the usual challenges, including workforce,
equipment and permanent material logistics. The USD4 billion project for the
Ma’aden-Alcoa joint venture is a key element of the new Ras Al Khair Industrial
City – a showcase of Saudi Arabia’s industrial diversification. It is all part of an
overall USD10.8 billion Ma’aden-Alcoa
investment that, in addition to the smelter, includes an alumina refinery, rolling
mill, automotive mill and bauxite mine.
Smelter alumina silos overlooking potrooms D to A north
46
13,000workersfromaroundtheworldwith
differentlevelsofexperienceandexposureto
thistypeofwork,”saysBobSabo,Bechtel’s
RasAlKhairsitemanager.“Wemustneverget
complacentaboutsafety,though.Everyday,
wehavenewchallenges,newcontractors,new
disciplinesandnewworkerscomingontoour
site.”
“Oursuccessesinsafetyhavebeengained
through a one-team, compliance-driven approach with each stakeholder providing full
supporttoourzeroaccidentsphilosophyand
programmes,”saysTerryLyons,Bechtel’senvironment,safetyandhealthmanageratRas
AlKhair.“Iamalwayspleasedtobeableto
discussanissueorproposedinitiativeandsee
itputintoactiondaily.”
Within budget, ahead of schedule
“We have to-date safely achieved all of our
milestones ahead of schedule and within
budget,” says Denis Garrity, Bechtel project
director. “However, we cannot lose sight of
thefinalmilestone–thatallpotsarereadyto
startbyendof2013.Itistheabilitytosafely
deliveraquality,well-engineeredproduct,on
time and to budget, that has critical import-
ancetoourcustomer.”
Unlike large, single potline aluminium
smelter projects previously completed by
Bechtel,suchasSoharinOmanandFjardaal
inIceland,theRasAlKhairsmelterincludes
two high-amperage potlines and, at 740,000
tpy,willhavenearlytwicetheirtotalcapacity.
Bechtel’sworkalsoincludesacathodesealing
facility,acarbonplantforanodeproduction
ALUMINIUM · 9/2013
sPeCIAL ArABAL
aswellasportfacilitiesforhandlingalumina,cokeandliquidpitch,
andtheworld’slargestintegratedcasthouse.
founding success
Bechtel’srelationshipwithMa’adenbeganwhentheywereawarded
thefeasibilitystudyfortheAzZabirahAluminiumProjectin2003.
ThecompanywasthenawardedthefeasibilitystudyfortheRasAl
Khair Project’s bauxite mine and alumina refinery.That study was
expanded to what will now be the world’s largest greenfield – and
SaudiArabia’sfirst–aluminiumsmelter.Bechtel’sCivilbusinessunit
isalsoperformingmasterplanningfortheoverallRasAlKhairMiner-
alsIndustrialCityandservingasprogrammemanagerforthenearby
JubailIIProject–aUSD10billionmajorexpansionofthecity’sin-
dustrialandresidentialareas,togetherwithamajorportaddition.
ALUMINIUM INdUstry IN the GULf
W E
C O N V E Y
Q U A L I T Y
Defined Cooling of
Hot Bath Material
strong, predictable performance
Bechtel’sperformanceatRasAlKhair,SoharandFjardaalisreplicatedinalonglineofsuccessfulgreenfieldandbrownfieldalumin-
iumsmelterandaluminarefinerydevelopments.
TheYarwun 2Alumina Refinery Upgrade Project in Gladstone,
Australia was completed in 2012 on schedule, under budget and
ramped-up
on
plan. The project
expandedtheoriginalrefineryBechtel completed in
2004(which,atthe
time, was the first
greenfield alumina
refinery constructedanywhereinthe
worldin20years).
Bechtel shares a
long,
successful
history with Gladstone’saluminaindustry,havingalso
builttheBoyneIslandsmelterinthe
early 1980s. This
facilitywasalsoexpandedbyBechtel
in1996.
The company
is also currently
Gas treatment centre No. 1 and potrooms A and B in
operation with the green anode plant in the backcompleting the
ground
feasibility study
fortheLine6ExpansionProjectinBahrainforAlba,andmodernising the 60-year-old Kitimat aluminium smelter in Canada for Rio
TintoAlcan(RTA).ModernisingKitimatwillcreateanenvironmentally superior, safer and more productive plant, elevating RTA’s
BritishColumbiaOperationsentitytoaworld-classaluminiumproducer.
WithRasAlKhairdueforcompletioninlate2013andKitimatdue
toproduceitsfirstaluminiuminlate2014,Bechtelhasanexciting
fewyearsahead.Taskedwithdeliveringtwodemandingprojectsin
twopolaroppositeenvironments,Bechtelisonceagainmeetingthe
challenge.
■
ALUMINIUM · 9/2013
For the Primary Aluminium
Smelting Process
s #OOLINGFROM²#DOWNTOBELOW²#
s 2EDUCTIONOF(&EMISSION
s #LEANANDENVIRONMENTALLYSAFECONVEYING
ANDCOOLING
AUMUND Foerdertechnik GmbH
3AALHOFFER3TRs2HEINBERGs'ERMANY
4ELq&AX
EMAILMETALLURGY AUMUNDDEqWWWAUMUNDCOM
ALUMINIUM INdUstry IN the GULf
Company profile: Aluminium Bahrain B.S.C.
One of the largest aluminium smelters in the world
Alba’searlysuccessestablishedablueprintfor
othernon-oilindustriestofollow,includinga
thrivingdownstreamaluminiumindustry.Today, the company is a major contributor to
the social, industrial and economic developmentoftheKingdomofBahrain,employing
over3,000people,ofwhomaround90%are
Bahrainis.
The entire plant operates to the Environmental Management System standard ISO
9001:2000 and the casthouses and marketingarealsooperatingtotheISO9002Quality Management System. Recently, the casthouse was upgraded to the 2008 version of
ISO9001,enablingAlbatobethefirstmetals
manufacturingcompanyinBahraintoreceive
thismajorupgrade.
Thecompanyhaswonanumberofawards
includingtheinauguralShaikhKhalifabinSal-
It supports numerous community oriented
programmes and social activities that have
underlineditsstatusasoneofBahrain’sleadingindustrialorganisationsthatremainscommittedtowardsupholdingitscorporatesocial
responsibilities. Alba’s inception marks the
beginning of Bahrain’s strategy to diversify
itseconomicbaseandreduceitsdependence
on oil.The aim was to establish an industry
that would provide valuable
export earnings, develop the
country’sresourcesandcreate
training and employment opportunitiesforalargenumber
of Bahrainis.Alba was therefore incorporated by Charter
in 1968 and officially commencedoperationsin1971as
a120,000tpysmelter.
Albatodayproducesmore
than890,000tpyofthehighest
grade aluminium, with productsincludingstandardandTingots,extrusionbillets,rolling
slab,properziingotsandmoltenaluminium.Around50%of
outputissuppliedtoBahrain’s
downstreamaluminiumindustry, with the rest exported to
regionalandinternationalcustomersintheMiddleandFar
East, South EastAsia,Africa,
EuropeandNorthAmerica.
The Alba plant comprises
five reduction lines, three
casthouses,adedicatedcarbon
plant,a550,000tpycokecalciningplant,awaterdesalina- Aerial view of the Alba site
tion plant, eleven fume treatmentplants,amarineterminal,anda2,225 man Al Khalifa Award for Industrial ExcelMW power plant, consisting of four power lence,theInternationalMillenniumBusiness
stations.Theplantalsofeaturesatenhectare AwardforEnvironmentalAchievementfrom
‘green’oasis,withmorethan7,600treesand the United Nations, safety awards from the
shrubs,afruitandvegetablegarden,andan BritishSafetyCouncilandTheRoyalSociety
forthePreventionofAccidents,andaGCCartificiallake.
48
wideawardforhumanresourcesdevelopment
andnationalisationoftheworkforce.
The shareholders of Alba are Bahrain
Mumtalakat Holding Company (69.38%),
SabicInvestmentCompany(20.62%)andthe
GeneralPublic(10%).
Main highlights
Line 6 expansion project: Alba is progressing to become one of the largest single site
aluminiumsmeltersintheworldthroughthe
Line6expansionproject,whichisexpectedto
add400,000tonnestoAlba’scurrentproductioncapacityof890,000tonnes,bringingthe
totalannualproductiontoaround1.3million
tonnes.
A major phase in Alba’s growth history,
theLine6expansionprojecthasgainedsignificant momentum with the
launch of the Bankable Feasibility Study (BFS) in December2012.BechtelCanada
hasbeenawardedaLetterof
Intent (LoI) to perform the
BFSfortheLine6expansion
project,andDubalDX+technologywillbeusedasthebasis
for this study.The BFS is expectedtobecompletedbythe
firstquarterof2014.
Continued focus on safety:
SafetyisregardedasanintrinsicpartoftheworklifeinAlba
and the company is committed to continuously providing
asafeandhealthyworkenvironmentforeveryone.
To strengthen the company’sfocusonsafety,theAlba
SafeWay Programme was
launched in the second half
of 2012 with three main objectives: ownership of safety
is everyone’s responsibility;
working safely is a condition
of employment; and all workrelated injuries and illnesses
are preventable. In addition,
activities and programmes to increase safety
awarenessinallaspectsoftheemployees’life,
both at work and at home, were conducted
andimplementedonaplant-widebasis.Some
ofthesearehighlightedbelow:
• ThefirstHSEWeekwaslaunchedfrom25
© Alba
Aluminium Bahrain B.S.C. (Alba) consistently ranks as one of the largest and most
modern aluminium smelters in the world.
Known for its technological strength and
innovative policies, Alba enforces strict
environmental guidelines, maintains high
track record for safety and is widely regarded as one of the top ten performers
on a global scale.
ALUMINIUM · 9/2013
sPeCIAL ArABAL
Aluminium billets, ready for shipment
Februaryto4March2013andaimedatcreatingacultureofzeroaccidentworkenvironment
ALUMINIUM INdUstry IN the GULf
tion, heat related illness, proper food
habits, road safety, contractor safety
awareness,etc.
• The eBehavioural Observation
programme, a key leadership activity,
wasfurtherenhancedandimplemented
acrossdepartmentstoincreasesafebehaviouramongstemployees.
Other significant achievements: Alba
increaseditssalesforthefirstsixmonths
of 2013 by 1.9% year-on-year thanks
to a focused marketing strategy while
productionforthesameperiodroseby
2%y-o-yonthebackofstrongoperationalimprovements.
The company’s physical premiums
remainedstrongandvalue-addedproducts accounted for 66% of total ship-
mentsinthefirsthalfof2013.
Potline 5 was up-graded using inhouse expertise and technical skills to
operateat370kA.
Successful completion of USD169
• ThesecondHSEWeekfrom30Juneto4 million local bond facility refinancing in the
July2013highlightedsummersafetyaware- firstquarterof2013.
■
nessbyfocusingonheatstress,heatexhaus-
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ALUMINIUM INdUstry IN the GULf
successful start-up of the fume treatment
centre at ras Al Khair aluminium smelter
J. de Weerdt, P. Klut; danieli Corus
Two FTC’s were built in Ras Al Khair,
Kingdom of Saudi Arabia, as part of the
Ma’aden aluminium complex. These
FTC’s treat the fumes of two anode
bake furnaces that supply anodes to the
740,000 tpy aluminium smelter. FTC 2
was commissioned in October 2012 and
is currently running at full capacity. The
cold commissioning of FTC 1 was done
in January 2013, and hot commissioning
took place in June 2013. As with all startups, there were some challenges to overcome, but currently FTC 2 is fully operational and FTC 1 is running at about 50%
of its capacity because not all fires at the
anode bake furnace 1 are in operation
yet. Both FTCs are performing satisfactory. FTC 2 performance tests have taken
place in the first week of July 2013.
client requirements in terms of ease of operation, high online reliability, maintenance
friendlinesswhileperformingtocomplywith
thestringentlocalenvironmentallegislations
onairborneemissions.Thefumecomposition
and maximum emission levels are listed in
Table2.
TheRasAlKhairaluminiumsmelterproject
is a USD10.8 billion joint venture between
Saudi Arabian Mining Company (Ma’aden)
andAlcoa.Theaimofthesmelterprojectis
to realise world’s largest and most efficient
aluminiumcomplexwithayearlycapacityof
740,000tonnes.Theproject’saluminarefinery,aluminiumsmelterandrollingmillarelocatedatRasAlKhair,90kmnorthofJubail.
Thealuminiumsmelterconsistsoftwopotlinesof360potseach,usingAP37technology.
There are two anode bake furnaces, ABF 1
havingfourfiresandABF2havingthreefires,
that produce anodes for the potlines. Both
ABF’shavetheirowndedicatedFTCtotreat
the fumes from the fires. FTC 1 consists of
sixbaghousesandfourmainexhaustfans(of
which3dutyand1standby)treatingthefumes
ofABF1.FTC2consistsoffivebaghousesand
threemainexhaustfans(ofwhich2dutyand
1standby)treatingthefumesofABF2.Table
1summarisestheprocessdesigndataforFTC
1andFTC2.
TheobjectiveoftheFTC’sistomeetthe
Themostnotableachievementinthisproject
wastheshorttimerequiredfortheengineering
andfabricationofbothFTC’s.Thetotaltime
fortheengineeringoftwocompleteFTC’swas
Process Variable
FTC 1
Fume composition
[mg/Nm3]
Maximum
emission
[mg/Nm3]
Gaseousfluorides
0–200
<0.5
Particulatefluorides
0–50
<0.6
Totalparticulates
0–200
<5.7
Condensedsolubletars
0–200
<1.7
Table 2: Fume composition and maximum emission
levels
© Danieli Corus
the ftC design
Fig. 1: Modular design, left – preassembled baghouse, right – fully fabricated cooling tower
FTC 2
245,000 180,000
Fumevolume(Am3/h)
Fumetemperature(°C)
220
220
UnderpressureatABF(kPa)
-2,000
-2,000
Numberofbaghouses
6
5
Numberofmainexhaustfans 3+1
2+1
6
4
Aluminautilisation(t/hr)
Table 1: FTC 1 and FTC 2 process design data
50
Type of pollutant
onlyninemonths,whileonlyfivemonthafterplacementofthepurchaseordersthefirst
FTC2equipmentarrivedonsite.
DanieliCoruspurchasedequipmentworldwideandtransportedittositeinordertomeet
the tight schedule. Despite the sometimes
challenging custom clearance, availability of
material within KSA, working pressure and
deadlines that had to be met, all equipment
arrivedatsitewithinarelativelyshortperiod
oftime.
Furthermore,theequipmentwassupplied
in large module delivery which had a major
impactonsitelabourrequirementssinceless
siteweldingwasrequiredcomparedtocombining a series of smaller components.Also,
thecompletepipingsystemwasprefabricated
inordertoreducesitelabourrequired.
This type of modularisation in combina-
tionwiththesplitofresponsibilitiesbetween
manufacturing and the erection could only
be accomplished with a detailed 3D model
toavoidinterferencesonsite.Adetailed3D
modelforbothFTC’swasmadeinwhichthe
Fig. 2: Modular design, left – preassembled stack section in laydown area, right – installation of preassembled stack section
ALUMINIUM · 9/2013
ALUMINIUM INdUstry IN the GULf
vironmentforallemployees.
This was achieved by
implementinganextensive
Lock-out Tag-out (LoTo)
system.This LoTo system
made it possible to conductbothconstructionand
commissioningatthesame
time in a safe manner. In
addition,theLoTosystem
didnotdelayconstruction
work, while still ensuring
a safe working environment.
Constructionwasdone
in cooperation with
DC’s affiliate company
Inbesco,withasolidbaseandextensiveexperienceinthemiddleEast.Duetothissuccessfulpartnership,itwaspossibletocompletethe
constructionworkforbothFTC1andFTC2
in an effective way from quality as well as
safetyandtimingpointofview.
Also client engineer Bechtel was closely
involvedinthedesign,constructionandcommissioningphases.ThecooperationwithBechtel was very fruitful and sped up the whole
process as Bechtel took care of issues that
couldhaveledtodelays.Also,weeklycommissioningmeetingwereinitiatedbyBechtel
inwhichpotentialconstructionandcommissioningissueswerediscussedandresolved.
theperformanceandforfuturereference.
Safety:Aswitheveryconstructionproject,
safety was given paramount priority. For
everystageofthecommissioning,athorough
checklistwasmadeincorporatingacomplete
anddetailedsafetyanalysis.Allaspectsofthe
safety plan were discussed with all contractorsandtradedisciplinesandmutuallyagreed
to comply with the project safety standards.
Also,DanieliCorusmaintaineditsownLoTo
systemtoensureasafeworkingenvironment
forallemployees.
Cold commissioning
Start-up/cold commissioning is the process
ofplacingasystemorportionofasystemin
operation for the first time under ‘live conditions’toensurecorrectplantfunctionality.
3D models of the steel structure, equipment
Thecoldcommissioningstartedwhenpre-opand piping layout were combined into one
singlemodelfortheentireFTC.
erationaltestingactivitieshadbeencompleted
Someadditionalitemsrequestedbytheclibythecommissioningteam.Itwasscheduled
to minimise interference with bake furnace
ent were implemented in the Danieli Corus
start-up.
design,includingaburnertoreheatthegases
from theABF in order to prevent acid conFTC 2:ColdcommissioningofFTC2went
satisfactory and was completed in time for
densation.
thedry-outofABF2.Duringthedry-out,the
No substantial design modifications with
respecttotheprovenandtestedDanieliCorus
FTCwasoperatinginbypassmodeandfumes
designFTC’sweremade,butnumeroussmall
withhighmoisturecontentbutnopollutants
modifications were introduced in the design
wereextractedfromtheABF.
andfabricationprocessinordertoreducethe
FTC 1:ColdcommissioningofFTC1took
requiredtimefromthestartoftheprojectunplace in January and February 2013 and
tookaboutfourweeksintotal,includingall
til mechanical completion and to supply the
pre-commissioningactivitiesandturnoverto
FTCsmeetingclient’srequirementsandspeciclient. Because both FTC’s are identical and
fications. In addition, design and constructa- Preparations
some issues that had been found during the
bility improvements that were identified in
previous FTC’s designed by Danieli Corus Commissioning checklists: During the engi- commissioningofFTC2hadbeenaddressed
were incorporated in these two FTC’s. This neering phase of this project, a commission- for FTC 1 already, the cold commissioning
includestheFTCcompacdesign,inwhichthe ingmanualwasmadeandapprovedbyBech- wentverysmoothandnomajorissueswere
stackandcoolingtowerareinstalledadjacent, telandMa’aden.Thismanualwasusedasa found.
DuetoefficientcooperationwithInbesco,
leading to structural advantages and more guidelineforthisjob.Thisincludedbasicmeconvenient access for daily operation and chanicalequipmentchecklistsforconstruction itwaspossibletoresolveallpunchlistitems
completionandpre-commismaintenance.
Due to these features, the time between sioning. Process parameter
the start of the installation preparations and tables such as pressure and
the mechanical completion of the two FTCs amperagevalueswerenoted
wasonlyoneyear.
on the checklists as means
ofreference.
During any future reOperating environment
commissioningactivities,the
The construction of FTC 2 was nearly com- original parameters would
pleted at the end of August 2012, and cold be useful in re-establishing
commissioningstartedatthistime.Oneofthe thesuccessfuloperation.
On site, these basic
major challenges during the commissioning
ofFTC2wasthatconstructionworkonFTC guidelines were refined in
1wasstillongoing,whileFTC2wasalready closecooperationofBechtel
completedandbeingcommissioned.Thisre- andMa’adentodevelopthe
quiredstrictsafetymeasuresandcarefulco- best hand over package to
ordinationofconstructionandcommissioning the owner.The documentaworktocreateasafeandsecureworkingen- tion was used to evaluate Fig. 4: FTC 1 (front) and FTC 2 (back)
Fig. 3: 3D model for FTC 1 (front) and FTC 2 (back)
52
ALUMINIUM · 9/2013
sPeCIAL ArABAL
waste
A L U M I N I U M I N d U s t r y It‘s
I Na pure
the
G UofL time
f
... if you make do with anything less!
forFTC1aswellasFTC2andleavesitewith tosub-systemsforwhich,aftercarefulinspecthebothFTC’shandedovertotheclient,FTC tion,alistofpunchlistitemswasprepared.
Once a sub-system had been completed,
2 in full operation and FTC 1 ready for hot
the client was invited for a walk-down to
fumes.
identify any additional punch list items and
to verify the punch items that had been refirst ‘hot fumes in’
solved.Whenall‘A’punchitemshadbeenreFTC 2: Dry-outofABF2startedinthebegin- solved,thesub-systemgainedthepurple-tag
ningofOctober2012andcontinuedforabout status (mechanical completion), after which
fourweeks.Duringthistime,FTC2wasoper- the commissioning could start. During comatedinbypassmodeandonlyprovideddraft missioning, the remaining ‘B’ and ‘C’ punch
totheABF,butnofumesweretreated.On5 list items were resolved and after a second
December, the first hot pollutant containing walk-down with the client, the sub-system
fumesweretreatedbyFTC2.Atthistime,the was grey-tagged (practical completion) and
FTC was operated with only two baghouses officiallyhandedovertotheclient.
AlongwiththehandoveroftheFTCitself,
andoneMEFbecauseofthelowamountof
also an extensive handover document packfumes.
age was prepared including construction and engineering documents, specifications, as well as
test procedures, commissioning
documents, and manuals. Once
these documents and the punch
listshadbeensigned-offbytheclient,theFTCwasofficiallyhanded
over and operated by Ma’aden
employeesfromthatmomenton.
Guarantee measurements
Atthetimethisarticleisbeingissued,theguaranteemeasurements
for FTC 2 just have taken place.
Fig. 5: DC lock-out Tag-out system with equipment locks (red)
and personal locks (green)
GuaranteemeasurementsofFTC
1 will take place whenABF 1 is
Excessairhadtobewithdrawnthroughthe runningstablewithallfourfiresinoperation.
ABFdilutionairdampertoensuresufficient Currently,onlytwofiresareinoperationof
airflow at the MEF.This situation continued whichoneisfordry-out.
for about four weeks and the operation becamemorestablewhenalsothesecondand Conclusions
thirdfiresoftheABFweretakenintooperation.
Thestart-upofbothFTC’sonMa’adenABF
Currently,FTC2isoperationatfullcapac- 1 and ABF 2 was successfully completed to
ity and performing excellent. The fresh alu- thesatisfactionofallparties.TheFTCincor-
minarateofabout1.5tphandcarboncontents porated new design features from Danieli
arewellbelowmaximumacceptablelevel.
Corusthatenhancethesafetyandoperability,
FTC 1: BecauseABF 1 was not ready to maintainabilityandemissionsperformance.It
start producing anodes when the cold com- was a clean start-up with the new furnace,
missioning of FTC 1 was finished, hot com- thankstotheclosecoordinationofDC,Inbes-
missioningofFTC1tookplaceinJune2013. coandBechtelduringhotandcoldcommisLikethecoldcommissioning,thehotcommis- sioning. There were minimal by-pass events
sioningofFTC1wentsmoothandcouldbe whichmeantemissionsweremaintainedeven
duringthecommissioningphases.
completedwithinoneweek.
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Authors
Handovertotheclientwasorganisedthrough
an extensive procedure which involved mechanicalaswellaspracticalcompletion.With-
inthisprocedure,bothFTC’sweredividedin-
Peter Klut is senior process engineer at Danieli
CorusB.V.,Velsen-Noord,TheNetherlands
JandeWeerdtisprocessengineeratDanieliCorus
B.V.,Velsen-Noord,TheNetherlands
ALUMINIUM · 9/2013
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ALUMINIUM INdUstry IN the GULf
high performance of ‘eolios’ pitch fume
treatment system at Qatalum paste plant
neverreachedbeforeforsuchinstallation. With 1 mg/Nm3 of PAH 16
(according to the NS 9815 NorwegianStandard),itcanbeconsidered
anewbenchmarkintheGulf.
© Fives Solios
Coal tar pitch – the source
of PAhs emissions
RTO plant at Qatalum
Since the introduction of paste-coolers
in the anode manufacturing process, the
amount of volatile compounds has drastically increased; in parallel, standards of
emission levels became more stringent.
Consequently, the technologies to treat
such emissions must cope with more concentrated streams at inlet and lower emission requirements at outlet. Solios has
developed the ‘Eolios’ system which is an
optimised combination of a dry scrubber
based on the adsorption of PAH on coke
fines, and a RTO (Regenerative Thermal
Oxidiser) using oxidation technology.
This combination minimises the energy
consumption while maximising the treatment efficiency.
ThefirstEoliossystemwasinstalledattheAlcoaMoesjenanodeplantinNorwayin2007
totreatthehigherconcentrationstreamscomingfromthepaste-cooler.Soliosobserveddestructionefficiencyfrom97to99%onPAH.
In2010asecondEoliossystemwasimplementedatQatalum.InJanuarythisyear,Solios successfully completed the performance
tests for the pitch fume treatment system at
theQatalumgreenanodeplant.Withaproduction capacity of 60 tph, it is the world’s
largestsinglelinegreenanodeplant.
ThePAHsamplingandanalysis,donebya
thirdparty,demonstratealevelofemissions
54
PAHs are the main components of
coaltarpitch,whichisusedasabinderforthefabricationofanodes.Coal
tarpitchisasolidmaterialatambient
temperature;tobeusedinthemanufactureofanodesitmustbeheatedto
becomeliquidandtobemixedwith
aggregate(calcinedpetroleumcoke)
toobtainahomogeneouspaste:this
stepisdoneatapprox.160-200°C.
Atsuchrangeoftemperature,the
coaltarpitchreleasesahighamount
of CoalTar PitchVolatiles (CTPV),
whicharemainlycomposedofPolycyclicAromatic Hydrocarbons (PAH). Some
of these molecules are known or suspected
to be highly carcinogenic.The PAHs can be
dividedintotwogroups:thelightandheavy
fractions. This classification depends on the
numberofaromaticringspresentinthePAH
molecule.WhenthePAHiscomposedof,at
least,threearomaticrings,wecansaythatit
is a heavy PAH. Depending upon their molecularweights,PAHsexisteitherundersolid
form(particulatePAHs)orgaseousform(gaseousPAHs),orboth.
Theadditionofwatertocooldowntheanode
pastelowersthepartialpressureofthevapour
generated by the paste, which displaces the
equilibrium towards production of the light
fraction; so all the PAHs with a low partial
pressure (the light fractions) are released in
gaseousform.
Consequently, the addition of water into
thepaste-coolerhasdrasticallyincreasedthe
amountoflightPAHs.Thisphenomenonwas
confirmed in the Deschambault paste plant
before and after the installation of a pastecooler:thePAHemissionsincreasedbyafactorof6.
Pitchfumesaregeneratedinallequipment
wherecoaltarpitchisusedathightemperature (160-200 °C). It was observed that the
pitchvolatilesconcentrationisdoubledwhen
thetemperatureoftheliquidpitchincreases
by20°C.Sothemixingtemperatureisalsoa
parameterwithimpactonthePAHemissions.
Conventional coke dry scrubbing system
Thedryscrubbersystemisderivedfromthe
potlinealuminadryinjectionscrubbingtechnology.Itconsistsininjectionofcokefinesin
a gas stream loaded by pitch fumes.An adsorptionphenomenaoccursbetweenthecoke
and the pitch fumes: the large specific area
(6,000to7,000Blaine)andoppositeelectricalchargeofthecokefinesallowadsorption
ofpollutants.
The fines fraction of coke readily availableforthepreparationoftheanodepasteis
injected counter-currently to the fume-laden
stream.Turbulence and highly efficient contactbetweenthepitchfumesandaerosolsare
Coke + Pitch
Paste mixer
+ Water
Paste cooler
Coke fines injection
Anode former area
Fig. 1: Dry scrubbing process
ALUMINIUM · 9/2013
sPeCIAL ArABAL
promoted in the Venturi
reactor. Pitch loaded fines
arethencollectedbyadust
collector(bagfilter)andare
reintroduced into the anodepasterecipe.Theclean
gases are then released to
theatmosphere(Fig.1).
The pitch loaded fines
arethenrecycledandused
into the recipe for the anode manufacturing process:thereisneitherwaste
streamnorproductloss.
The
global
capture efficiency of dry scrubbing for PAH
is about 95%; this efficiency is higher
forheavyPAH(upto99%).
The dry scrubbing system philosophy is
based on the ability of PAH to condensate:
thisallowstobeadsorbedonthefinescoke
surface.So,theefficiencyisbetterwithheavy
PAH that condensate easily. For the lighter
PAH, mainly emitted from the cooler as
noted above, the efficiency of this technologyislimited:ifthereisnocondensation,no
adsorptionwilloccurandthepollutantspass
throughthebagfilterwithoutbeingcaptured.
Thecondensationdepends,obviously,ofthe
ambient temperature: in cold countries the
captureefficiencyofthedryscrubberisbetter(upto98%).
Forthisreasonnewtechnologiesbasedon
oxidation reaction are used in order to improvelightPAHstreatmentefficiency.
rtO – an effective method
of destroying PAhs
The Regenerative Thermal Oxidation (RTO)
isbasedontheoxidationprinciple.PAHsare
mainly composed by C-H bonds which are
easilycrackedbyoxidationaccordingtothe
RedOxreaction(combustionreaction):
CaH2b+(a+b/2)O2→aCO2+bH2O+Heat
AllPAHsareconvertedintocarbondioxide
andwatervapour.
TheRTOisacompactequipmentcomposed
ofthreemainelements:
• Thecombustionchamberwheretheoxidation reaction occurs.The temperature in the
combustionchamberisabout850-900°C.
• Theceramicsbeds,whichareusedasheat
exchangers. The aim is to store heat and to
recoverifforpreheatingtheinletgasflow,and
thussaveenergy.
• The valve box: two valves for inlet and
outletducts,andonevalveforpurgeforeach
chamber.
The raw gas (1) is introduced via the valve
ALUMINIUM · 9/2013
ALUMINIUM INdUstry IN the GULf
A set of FID (Flame Ionisation Detector)
measurements were performed in order to
estimatetherelationshipbetweenRTOtemperature and destruction efficiency. The gas
sampleiscontinuouslysampledintotheFID
which measures the concentration of total
volatilesorganiccompounds.
TheFIDmeasurementsdoneattheQatalumplantshowthathighertemperaturecombustion creates an improved RTO efficiency
due to the increase of organic compounds
destruction:
Fig. 2: RTO – schematic diagram
box into the tower B, and pre-heated passing through the ceramics (5) to achieve the
required temperature for the combustion of
PAH(atleast850°C).Theresidencetimein
thecombustionchamber(6)isabout1-2sec,
this time will do to destroy PAH.The combustionofPAHgeneratesheatwhichreduces
theconsumptionoftheburner(7).Theclean
gasisconveyedfromthecombustionchamber
intothesecondheatexchangerA,andisthen
releasedthroughtheexitstack(9).Thethird
heatexchangerCisinpurgemodeinorderto
removetheremainingrawgasresidues(Fig.2).
eolios at Qatalum paste plant –
an innovative solution for
optimum emission performances
At the Qatalum paste plant, the highly concentratedfumes,whicharecollectedfromthe
pastecoolerandwhichcontainmainlywater
vapour and light PAH fractions, are specifi-
callytreatedbytheRTOunit.Toavoidcondensationoftarintheduct,itisnecessaryto
heat up the fumes with hot air in a mixing
pot,situatedonthepastecooler.Aftermixing,
dilutedfumesenterintotheRTOunitatatemperatureof150°C.AftertheRTOtreatment,
thecleangasisrejectedtotheatmosphere.
Allotherssuctionpoints(mixer,vibrocompactorarea,etc.)aretreatedbythedryscrubbingsystem(Fig.3).
RTO efficiency
840°C
870°C
91.2%
96.2%
ThePAHsamplingandanalysis,doneinthe
commonstack,confirmthehighefficiencyof
theoptimisedcombinationofadryscrubbing
system and RTO with a level of emissions
never reached before for such installation,
andwhichisnowconsideredasanewbenchmarkintheGulfat1mg/Nm3ofPAH16accordingtotheNS9815NorwegianStandard.
Environmental emissions are becoming
more and more stringent, especially for carcinogensubstancessuchasPAHsfrompitch
vapour.Eolios,whichcombinesdryscrubbing
andRTO,allowstooperatethegreenanode
plantwhilemaintainingthePAH’semissions
at stack below such stringent requirements.
Eolios leads to lower operating costs and
a smaller carbon footprint than alternative
technologiessuchasfullRTO,forinstance.
The first industrial implementations of
EoliosattheMoesjenpasteplantandrecently
at the Qatalum paste plant confirm the performance and benefits associated with this
■
technology.
Stack
Dry scubbing system
Calcined
petroleum coke +
liquid pitch
Paste mixer
RTO combustion
temperature
Coke Fines Injection
Others suctions point
(anode forming area
mixer....)
RTO
+ Water
Paste cooler
Fig. 3: Eolios system at the Qatalum paste plant
55
teChNOLOGy
Shipped all over the world from the Eifel region
Köllemann GmbH from Germany is engaged in every industrial sector where
there is a need for bulk solids to be
conveyed, heated and cooled
in a continuous process. For
the aluminium industry, the
company designs and builds
petcoke preheaters, which are
used in the production of anodes. Köllemann preheaters are among the largest on the market. They are designed to
ensure optimal mixing of the petcoke,
with minimal deviations in temperature
and a long service life that requires little
maintenance.
isASMEandISO9001certified;pressurevesselsaremanufacturedinaccordancewithAD
2000regulations.
Thecompanysuppliesitsmachinesworldwidetoanumberofrawmaterialsprocessing
KöllemannGmbHwasfoundedinthe1960s sectors,suchasthechemical,petrochemical,
andisbasedinAdenau,Germany,nearthefa- cement and metal industries and the power
mousNürburgringmotor-racingcircuit.Origi- sector, as well as for wastewater treatment
nallyowner-managed,thecompanyisnowin plants,tonamebutafew.
the hands of financial investors. It has been
undernewtechnicalandcommercialmanage- “We want to intensify
ment since the middle of last year, although contact with end-users”
corepersonnelengagedindesignandmanufacturing are still with the company. “The For the aluminium industry, Köllemann dechangeofmanagementhasgiventhecompany signsandmanufacturesthepetcokepreheatanewimpetus,”explainsGuidoFiedler,head ers, used in anode-making. The preheater
ofDevelopmentandDesign.“Wearework- heatsupthepetcokeandmixesitthoroughly
ingintensivelytofurtherimproveourwork- toahomogenousmass.Thismixtureissubseingproceduresandtoadoptamoreproactive quentlyblendedinakneaderwithhotpitch
approachtomarketingourproducts.”
andanodebuttstoproducegreenanodes.This
Thecompanyisactiveinallsectorswhere isacontinuousconveyingprocess.
thereisaneedforacombinationofconveying,
Thepreheatersusescrewflightsasthemain
heating and cooling of bulk solids in a con- heat-transfersurface;thesearebasedonthe
tinuousprocess.Importantkeywordshereare hollow-flightprinciple.Thermaloilactsasthe
thedosing,sealing,metering,mixing,heating, heattransfermediumandflowsthroughthe
hollowflights.“Withourlargestunitswecan
conveyingandfeedingofbulksolids.
Köllemann’sstandardportfoliocoversro- heatupto60tonnesofpetcokeanhourtoa
tary valves, screw heat exchangers, petcoke temperatureof220°C,”saysprojectmanager
preheaters and contact dryers.The company MatthiasGinster.Fourwormshaftsareused.
The heat-exchanging surface is 300
Product level
square metres or more and the units
weighsome80tonnes.
Köllemannregardsitselfastheundisputedmarketleaderforpetcokepreheaters:“Wesupplysomethree-quarters of the global preheater market,”
says Mr Ginster. “Nevertheless, we
rarelydealdirectlywithplantoperators.
This is because we don’t usually supply
totheend-user,buttothesupplierofthe
plantthatmakesthekneadersfortheanodepaste.Fromaprocessengineeringpoint
ofview,kneaderandpreheateroperateasa
Hollow flights
singleunit.”
Tube with annular gap
Köllemann is a hidden champion, so to
Double-walled trough
56
© Köllemann
Köllemann Gmbh – market leader for petcoke preheaters
Köllemann preheaters
are of modular design, with
easy access for maintenance
speak.However,infuturethecompanywants
togetmoreinvolvedinthemarketanddeal
directlywithend-users.“Wewanttoboostour
businessstillfurtherandgrow.Toachievethis,
we want to intensify contact with end-users
andbecomemoreinvolvedinthemarketing
of our preheaters.We think that it will also
be beneficial for the operators of our plant
tohaveclosercontactwithourcompany,for
exampleinordertoobtaindirectsupportwith-
outhavingtotakearoundaboutrouteviathe
supplierofthekneaders,”saysMrFiedler.
WhenaskedwhatdifferentiatesKöllemann
machines from those of its competitors, Mr
Ginster replies: “Our machines are particularly durable, require little maintenance and
areeasilyaccessible.Thewholeunitisamodularconstruction.”Allpreheaterssuppliedby
Köllemannareconstructedinaccordancewith
thecustomer’sspecification,startingwiththe
machinesize,connectionsandotherproductrelated aspects. “On request we can supply
turnkeymachineswiththepipeworkalready
completelyinstalled.Ourdesignsarebasedin
principle on the German industry standard.
Thismeansweonlyeveruseplanetarygears
forpetcokepreheatersthathaveaservicelife
thatisatleastequaltothatofthemachineitself.Ifcustomerswantdrivesystemsormeasuringequipmentfromspecificmanufacturers,
theycanhavetheseaswell.”
Köllemannguaranteesthesupplyofspare
partsformanydecades.Thecompanystillhas
details of machines it supplied in the 1960s,
fromthedayswhennobodyhadevendreamt
ofPCsandCAD.
special design features of coke preheaters
TherearethreeidenticalKöllemannpreheatersintheanodeplantatEmiratesAluminium
(Emal):twopreheatershaveanhourlycapacityof40tonnesandathirdunitoperatesasa
cooler,coolingtheanodebuttsaftertheyhave
beencrushedintosmallpieces.
ALUMINIUM · 9/2013
teChNOLOGy
whichthusincreasesitsservicelife.Wealso
useadoublebearingsothatthetoothedgears
mesh accurately, which is also very maintenance-friendly.”
The preheaters are also characterised by
very good insulation and thanks to which
there are hardly any heat losses. The thick
insulation does not only ensure high energy
efficiencythough:aboveallitisimportantfor
occupationalsafety.“Ourpreheatersareonly
lukewarm on the outside even though there
isthermaloilat300°Cflowingthroughthe
shafts.Wethusconformtothelatestmachinerydirectiveeventhoughthepreheatersare
usedincountrieswheresuchrequirementsdo
notapply.”
Theinsulation(rockwool)isalsoofmodular
designandcanberemovedandinstalledagain
withoutdamage.Itiscassette-typeinsulation
withclipsholdingthecassettestogether.
fit for the future
Köllemann is already undertaking developmentworkforanewgenerationofpreheatersinordertobewellpreparedwhenhightemperaturepitchisincreasinglyusedinafew
years’time;suchpitchdoesnotmeltuntilit
reaches300°C,incontrasttothe180°Cthat
isthecasewiththestandardpitchcommonly used today.The reason for this change is
thatanewenvironmentaldirectivethatforbids
WWW.BUSSCORP.COM
Thestandardpracticewithsuchlargepreheatersistohavetworight-handshaftsandtwo
left-hand shafts, with only one shaft being
motor-drivenandtheotherthreeshaftsbeing
drivenbytoothedgears.“ForEmal,theshaft
drivenbytoothedgearsisidenticalinconstructiontothemotor-drivenshaft.Althoughthis
requiresmoredesigneffort,aswellasmore
material,itreducesthesparesthathavetobe
keptinstockshouldafaultoccur.Therefore
only one right-hand shaft and one left-hand
shaftareneededforallthreeunits.”
MrGinsterpointsoutthatthelargestmachinesavailablehavealwaysbeensuppliedby
Köllemann.Forexample,thereisapreheater
withacapacityof50tonnesanhouratAlcoa
MosjøeninNorway.Köllemann
also recently supplied a 60t/hunittoananodeplantinChina
–thelargestpreheatercurrently
availableonthemarket.
Köllemann preheaters have
anumberofdistinguishingfeatures.Smallmixingpaddlesare
attached to the outside of the
shaft to better loosen and mix
theproduct,andensurethatthe
kneadercanthoroughlywetthe
petcokewithpitchwithoutdifficulty;thisresultsinoptimal,homogenousmixingofthepetcoke
andavoidshotspots.
Thepreheatersaredesigned
so that they are very easy to
service:allpartsoftheunitare
readily accessible to maintain
the shaft exits and the sealing
elements.Furthermore,theseals
where the shafts exit the machine housing can be removed
completelyfromthetopwithout
having to dismantle the whole
console. The worm itself does
not require any maintenance
and is characterised by a long
service life, measured in terms
ofdecades.
Thebearings,too,havebeen
speciallydesigned.“Ihaveseen
competitive products which
havetheriskiestdesignsofbearing possible,” says Mr Ginster.
“However, at the ends we use
maintenance-free high-temperaturebearingsmadefromspecial
graphite; these allow the shaft
to be swivelled slightly and to
movefreelyalongitslength.This
means thermal expansion does
notexertanystressontheshaft,
ALUMINIUM · 9/2013
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.
teChNOLOGIe
Köllemann recently supplied a 60t/h coke preheater to an anode plant in China – the largest machine currently
available on the market
theuseofstandardpitchwillcome
intoforceinChinain2016/17.
“Fortheuseofhigh-temperature
pitchonerequiresheat-transfermedia that can reach temperatures of
upto400°C.Wearecurrentlyevaluating various heat-transfer media
with respect to their suitability and
arealsoworkingonaspecialproject
with an external institute,” says
MrFiedler,addingthathedoesnot
wish to reveal any further details
at the moment for competitive reasons.
■
Integration der Gattierungsrechnung
macht recycling noch effizienter
Um Aluminiumschrotte effektiv und
qualitätsgesichert in der laufenden Produktion einsetzen zu können, ist eine
optimale Gattierungsrechnung unerlässlich. Sie wird jedoch oft als Insellösung
betrieben, was Zeit bei der Einstellung
der gewünschten Qualitäten kostet.
Durch die intelligente Integration in ein
Produktionsmanagementsystem können
Aluminiumrecycler ihre Prozesse nun an
zentraler Stelle optimieren. Und entscheidende Wettbewerbsvorteile erlangen:
Da alle Informationen zu jeder Zeit an
jedem Ort in Echtzeit zur Verfügung
stehen, kann mit einer schnellen und präzisen Analyse der Schmelze die Zahl der
Nachlegierungszyklen deutlich gesenkt
werden. In der Praxis werden damit
Raten zwischen 1 und 1,5 erreicht. Das
steigert nicht nur die Durchsatzrate, sondern optimiert auch Lagermanagement,
Energiebilanz und Einkauf. Das Ergebnis:
ein transparenter, maximal produktiver
Regelkreislauf und hochwertige Endprodukte mit zuverlässiger Rückverfolgbarkeit.
Integrated charge and alloy calculation
makes recycling even more efficient
In order to effectively use and ensure
the quality of aluminium scrap in ongoing production, optimum calculation of
charge and alloy materials is crucial. This
is often operated as an island solution and
takes time when it comes to setting the
required qualities. Thanks to intelligent
integration into a production management system, aluminium recyclers can
now optimise their processes at a central
point, thus giving them an edge over
competitors. Now that all the information is always available everywhere in
real-time, a fast and precise analysis of
the melt can reduce the number of alloying cycles significantly. In practical
applications, average rates between 1
and 1.5 were in fact achieved. This not
only boosts the throughput rate, it also
improves warehouse management, the
energy balance and purchasing. The result
is a more transparent loop with maximum
productivity and high-quality end prodStändig steigende Energiekosten und der ucts with reliable traceability.
Wunsch nach optimaler Ressourceneffizienz
habensortenreineProduktionsabfällezueiner Thepersistentriseinenergycostsanddemand
wichtigenRohstoffquellefürdieMetallindus- for optimum resource efficiency have made
triegemacht.DiesgiltinsbesonderefürAlu- sorted produced waste an important source
miniumschrotte, denn mit einem Anteil von ofrawmaterialforthemetalssector.Thisapetwa20ProzentanderweltweitenGesamt- plies particularly to aluminium scrap which,
produktionhatdasRecyclingvonAluminium accounting for around 20% of total global
einen beachtlichen Stellenwert erlangt. Das production, has made aluminium recycling
liegt insbesondere am enormen Einsparpo- extremely important. This is largely due to
tenzial:VerglichenmitderPrimärherstellung theenormoussavingspotential.Comparedto
brauchtmandortimSchnitt90Prozentwe- primaryproduction,recyclingusesonaverage
58
90% less energy; far fewer difficult residual
materialsareproducedand,intermsofquality,thefinalproductcannotbedistinguished
fromnewlyproducedaluminium.
On the other hand, it must be noted that
recyclingscrapmetalisaverycomplexprocess
that calls for outstanding organisation along
theentireprocesschaininordertoarriveat
a high-quality, profitable and safe product.
ThisorganisationhasbeenpickedupbyPSI
Metals, an IT company based in Düsseldorf,
Germany,thatspecialisesinproductionmanagementsystemsforthemetalsindustry.By
integratingthecentralchargeandalloycalculation, the entire production process can be
optimised.
the optimum combination of input
materials makes all the difference
Regardless of the different sizes, alloys and
soilingofthealuminiumscrap–whetheritis
externallypurchasedscraporscrapmetalfrom
yourownproductionwastewhichistoberecycled,theaimistoproduceamaterialthat
featuresthealloyrequestedbythecustomer
andwhichpreciselymeetstherespectiverequirements and properties. What’s crucial
here is efficient organisation of the alloying
processbasedonthechargeandalloycalculation.Atthesametime,thechemicalanalysis
ofthealloysinthemeltingfurnaceisadecisivefactorfortheefficiencyoftheentirepro-
ductionprocess.Thatisbecauseprecisemeasuringresultsthathavebeengeneratedquickly
ALUMINIUM · 9/2013
teChNOLOGy
© Hydro Aluminium
effizienterkanndiegesamteProzessketteorganisiertwerden.
GroßesOptimierungspotenzialliegthierbei
ineinerintegriertenGattierungsrechnung,die
PSIMetalsmitdemAlloyCalculatoranbietet.
DieserregeltnichtnurdieLegierungsanalyse,
sondern ist in das ProduktionsmanagementsystemvonPSIMetalssointegriert,dassvon
derAnlieferungdesSchrottesüberdasLagermanagementbishinzurSchmelzealleorganisations- bzw. produktionsrelevanten Daten
inEchtzeiterfasstundaufoptimaleWeisedie
Gattierungüberwachtundgesteuertwird.In
diesemSystemistsomitdieGattierungsrechnungalszentraleBezugs-undRegelgrößefür
alleorganisatorischenundstrategischenProzesse der Produktion etabliert. Die Abfolge
einzelnerArbeitsschrittewirdalsdynamischer
Kreislaufbegriffenundvisualisiert,mitjedem
Der integrierte Monitor liefert in Echtzeit alle relevanten Informationen
ArbeitsschrittwirddergesamteKreislaufakThe integrated monitor supplies all relevant information in realtime
tualisiert,undalleInformationensindzujeanddirectlyarewhatmakeitpossibletoor- nigerEnergie;esfallendeutlichwenigerpro- demZeitpunkteinszueinsabrufbar.Solassen
ganisetheentireprocesschaininamoretrans- blematischeReststoffeanunddasEndprodukt sichgeradeankritischenSchnittstellenwieLaparentandefficientmanner.
ist qualitativ nicht von Hüttenaluminium zu germanagement/Produktion/LaboroderEinkaufUmwege,MissverständnisseundFehler
Integratedchargeandalloycalculationof- unterscheiden.
DiesenVorteilenstehtdieTatsachegegen- vermeiden.NotwendigeEntscheidungenwerfers considerable potential for optimisation
and PSI Metals offers this in the form of its über,dassdieWiederverwertungvonSchrot- denanhandjederzeitaktuellerInformationen
Alloy Calculator. This not only controls the tensehrkomplexistundentlangdergesamten schneller,flexiblerundpräzisergetroffen.
alloyanalysis,ithasbeenintegratedintothe ProzesskettehöchsteorganisatorischeAnforPSI Metals production management system derungenstellt,wennamEndeeinhochwer- der erste schritt: eine
so that all data related to organisation and tiges,rentablesundsicheresQualitätsprodukt lückenlose Materialverfolgung
production, from the delivery of scrap to stehensoll.PSIMetals,eininDüsseldorfanwarehousemanagement,arecapturedinreal- sässiges IT-Unternehmen und Spezialist für InderPraxiszeigensichdieVorteilederPSItimeandthenusedtoperfectlymonitorand Produktionsmanagementsysteme in der Me- Lösungsehrkonkret.ZunächsterfasstdasSyscontrolchargingandalloying.Inthissystem, tallindustrie, setzt genau hier an: Durch die temalleSchrotteimMomentihrerLieferung
thechargeandalloycalculationservesasthe Integration der zentralen Gattierungsrech- oderihrerEntstehungindereigenenFertigung
centralreferenceandcontrolvariableforall nung wird der gesamte Produktionsprozess (interner Kreislauf); so kann im nächsten
organisationalandstrategicproductionproc- optimiert.
SchritteinesaubereSortierungundVisualisieesses.Thesequenceofindividualworksteps
rungderLagerbeständeerfolgen.Dielückenis understood and visualised as a dynamic die optimale Kombination der
loseMaterialverfolgungermöglichtauflange
loop.Witheachworkstep,theentireloopis einsatzstoffe macht den Unterschied
SichteineOptimierungdesLagerplatzes:Vom
updated and all the information can be acZeitpunktderLieferunganerfolgteineklare
cessedatanypointintime.Thisrulesoutun- Unabhängig von den Stückigkeiten, Legie- ZuordnungnachLegierungen,sodassspätere
necessarytrips,misunderstandingsanderrors, rungen und Verschmutzungsgraden des zu Umsortierungen,diezuVermischungenoder
especiallyatcriticalinterfaces,suchasware- verarbeitendenAluminiumschrotts–obüber- zusätzlichenVerunreinigungendesSchrottes
housemanagement,production,laboratoryor wiegend fremder Schrott oder werkseigener führenkönnen,vermeidbarsind.
Vor allem aber erleichtert es das zügige
purchasing. The necessary decisions can be Fabrikationsabfall verwertet wird: Produktimadefaster,moreflexiblyandmoreprecisely onsziel ist ein Werkstoff, der die vom Kun- Auffinden des gewünschten Materials. Geht
onthebasisofthelatestinformation.
den jeweils gewünschte Legierung aufweist eine bestimmte Legierung in Produktion, so
und die entsprechendenAnforderungen und hat der Staplerfahrer schnellen Zugriff: Ein
Eigenschaftengenauestenserfüllt.Dreh-und in den Gabelstapler integrierter Monitor inthe first step: continuous
Angelpunkt ist hierbei die effiziente Organi- formiert online über die benötigten Legiematerial tracking
sation des Nachlegierungsprozesses auf der rungen.PerTouchscreenkannsichderFahrer
In practical application, the advantages of GrundlagederGattierungsrechnung.Zugleich dann eine Übersicht über die Lagerbestände
PSI’ssolutionbecomeveryclear.Firstofall, istdiechemischeAnalysederimSchmelzofen verschaffen und erhält den entsprechenden
thesystemrecordsallscrapmetaltheminute befindlichenLegierungeneinentscheidender Schrottlagerplatzdirektangezeigt.Zielgerichitisdeliveredorproducedinyourownpro- FaktorinBezugaufdieEffizienzdergesam- teteTransportaufträgeundderenexakteVerduction (internal loop); in the next step, the ten Produktion: Je präziser die Messergeb- folgung senken die Fehlerquote und sparen
scrapmetalissortedandstocksarevisualised. nisseausfallen,jeschnellerundgezieltersie definitivZeit.DerFahrermussnichterstlanInthelongrun,continuousmaterialtracking generiert werden, desto transparenter und genacheinemirgendwovermutetenMaterial
ALUMINIUM · 9/2013
59
© Hydro Aluminium
teChNOLOGIe
Die Schmelze: Präzision beim Kernprozess zahlt sich aus
The melts: precision in the core process pays off
suchen,sondernkannsichdurchdievisuelle
Lagerdarstellung schnell orientieren und sofortdierichtigeBoxanfahren.
Eine ebenfalls in den Stapler integrierte
Waage verkürzt den Transport- und Chargiervorgang – so geht keine Zeit durch eine
Extrafahrt zu einer Wiegestation verloren.
EinwichtigerAspektderexaktenMaterialverfolgungistzudemdieKlassifizierungeigener
Reststoffe (z.B. Kopf- und Fußschrotte, Besäumschrotte), deren Zusammensetzung bekanntistundsichdahernochschnellerinden
Recyclingprozesseinbindenlassen.
Best Practice: ein durchschnitt
von 1,2 Nachlegierungszyklen
Je schneller die richtige Legierung erreicht
ist,umsowenigerNachlegierungszyklensind
erforderlich,destowenigerEnergiewirdverbrauchtundumsobesseristdieAusnutzung
der Schmelzöfen. Zur Optimierung der Legierungsanalyse liefert der Alloy Calculator
schnelleundpräziseErgebnisse,diewiederum
unmittelbar im Produktionsmanagementsystemumgesetztundgenutztwerden.Nachnur
etwa15MinutenliegtdasAnalyseergebnisim
System vor, sodass unmittelbar entschieden
werdenkann,welcheElementederLegierung
noch zugefügt werden müssen. Diese Information geht online und automatisch an den
Staplerfahrer,derdadurchinnerhalbkürzesterZeitdierichtigeMengedesMaterialsanliefert, das zur Optimierung des Produktes
benötigtwird.WertundGewichtdesgelieferten Materials werden im System registriert,
die Verringerung des Lagerbestandes wird
60
automatisch gebucht. Auch der Zeitverlust
durchÜbertragungsfehlerbeimanuellerSteuerungentfällt.
PräziseAnalyseergebnisse,dieumgehende
Neukalkulation des Materialeinsatzes, InformationeninEchtzeitsowiederdirekteZugriff
auf das Materiallager ermöglichen es, den
Gattierungsprozessdeutlichzuverkürzenund
die Zahl der erforderlichen Nachlegierungszyklenzusenken:EineZyklusdauerzwischen
45Minutenund2,5Stunden(jenachLegierung) sowie ein Mittel von 1,2 Zyklen pro
Produktionsvorgang–dieseZahlensprechen
fürsich.DerentscheidendeGewinn:diesignifikanteSteigerungderDurchsatzrateunddie
damit verbundene deutliche Energieeinsparung pro Schmelze. Denn durch dieVerkürzungderZyklenverringertsichdieRuhezeit
derÖfen,indenendienochunfertigeSchmelze auf Temperatur gehalten werden muss.
Durch die bessere zeitliche Planbarkeit aller
Abläufe lässt sich zudem der Produktions-
planinsgesamtstraffenundeinebestmögliche
AuslastungderÖfenimSinneeineseffizien-
tenEnergiemanagementserreichen.
strategischer einkauf und
effizientes Lagermanagement
AuchLagermanagementundEinkaufprofitierenvonderintegriertenGattierungsrechnung
undeinerpräzisenMaterialverfolgung.Durch
die Transparenz der Lagerbestände und der
jeweils vorliegenden Legierungen kann der
Einkaufpunktgenauermitteln,welcheZukäufeerforderlichsindbzw.zueinembestimmten
Zeitpunkt der Produktionsplanung erforder-
optimises space in the warehouse because
from the time the scrap metal is delivered
it is clearly allocated according to alloys, so
that later sorting, which could result in mixingoradditionalsoilingofthescrap,canbe
avoided.
More importantly, however, the required
materialcanbefoundmuchfaster.Ifacertain
alloyistobeusedinproduction,thedriverof
theforklifttruckwillhavenotroublefinding
it. That is because a monitor integrated into
the fork lift truck informs the driver online
ofthealloysneeded.Usingthetouchscreen,
the driver can then view all the stocks and
directlyknowsthelocationofthescrapmetal
inquestion.Targetedtransportjobsandtheir
precise tracking reduce error rates and cer-
tainlysavetime.Thedrivernolongerhasto
searchformaterialthatisthoughttobesomewhere,insteadhecanquicklyfindhiswayusingthewarehousedisplayanddrivedirectly
totherightbox.
A weighing device also integrated into
theforklifttruckshortensthetransportand
chargingprocesssincenotimeislostduetoan
extra trip to a weighing station. Another
important aspect of precise material trackingisalsotheclassificationofyourownrest
material (e.g. head and foot scrap, trimming
scrap)whereitscompositionisknownandcan
hence be integrated faster into the recycling
process.
Best practice: an average of
around 1.2 alloying cycles
Thefastertherightalloyisreachedthefewer
alloying cycles are needed and this means
lessenergyandbetterutilisationofthemelt-
ing furnace. In order to optimise the alloy
analysis, the Alloy Calculator delivers fast
andpreciseresultswhichcanthenbeimplemented and used directly in the production
management system. After just a quarter of
anhour,theanalysisresultisavailablesothat
the operator can immediately decide which
elementsofthealloystillhavetobeadded.
Theinformationgoesonlineandisautomaticallysenttotheforklifttruckdriverwhocan
then quickly deliver the correct quantity of
materialneededtooptimisetheproduct.The
valueandweightofthematerialdeliveredis
recordedinthesystemandthereductionin
stocksisautomaticallyposted.Thisalsomeans
nomoretimelostduetorecordingerrorswith
manualprocedures.
Preciseanalysisresults,immediatere-calculationofthematerialinput,informationin
real-timeaswellasdirectaccesstothematerials warehouse make it possible to shorten
ALUMINIUM · 9/2013
teChNOLOGy
thechargeandalloyprocessandhencereduce
thenumberofalloyingcyclesrequired:One
cycle of between 45 minutes to 2.5 hours
(depending on the alloy) with an average of
around 1.2 cycles per production process –
thesefiguresspeakforthemselves.Themost
decisive benefit is the significant increase in
throughputrateandthehugeenergysavings
foreachmelt.Thatisbecausethefewerthe
cycles, the less idle time for furnaces where
theunfinishedmelthastobekeptataconstant
temperature.Thankstoimprovedplanningfor
all steps of the process, the production plan
itselfcanbestreamlinedinordertoachieve
thebest-possibleutilisationofthefurnacesin
theinterestofefficientenergymanagement.
strategic purchasing and
efficient warehouse management
Bothwarehousemanagementandpurchasing
also benefit from integrated charge and alloycalculationandprecisematerialtracking.
Thankstotransparentwarehousestocksand
the alloys available, purchasing can identify
precisely which purchases are necessary or
willbecomenecessaryatacertainpointinproductionplanning.Doubleorincorrectorders
duetoapooroverviewofstocksandofwhere
material is located can now be largely ruled
out.Ontopofthat,allofthescrapmetalstored
inthewarehouseisrecordedwithitsspecific
alloy values and can be quickly found. This
meansthatitiseasiertocalculateproduction
costs more precisely and the necessary productionworkflowscanbeoptimallyplanned.
Isitadvisabletouseyourownscrapmetalor
doescertainscraphavetobepurchased?Isit
cheapertoaddpureelementsorwhichscrap
price is acceptable? Strategic questions like
thesecanbespecificallyansweredonthebasis
ofindexdatasuppliedbytheproductionmanagementsystemandtheAlloyCalculator.
Better traceability
Thetraceabilityofthematerialsusedisacriterionthatisbecomingincreasinglyrelevantdue
tothetighteningofproductliabilitylegislation.
Productionmanagementmakesitpossibleto
ensurethatmaterialcanbetraced.Asadigital
archive,itdocumentsthecompositionofthe
materials produced right down to the scrap
metal used, thus providing a long-term, reliableandcontinuoushistory.Andthisiswhere
theloopcloses:themoreyouknowaboutyour
scrapstocksthankstopersistentmaterialtracking,efficientwarehousemanagementandpreciseanalysisvalue,themoretransparentyour
productwillbeandthebetteritcanbetraced.
lich sein werden. Doppel- oder FehlbestellungendurchmangelndenÜberblicküberdie
BeständeundüberdenVerbleibvonMaterial
lassensichweitgehendvermeiden.Und:IstjederimLagervorhandeneSchrottmitseinen
spezifischenLegierungswertenhinterlegtund
schnellauffindbar,solassensichdieProduktionskosteneinerLegierungpreislichwieorganisatorischbesserkalkulierenunddienotwendigenProduktionsabläufeoptimalplanen.Ob
es ratsam ist, eigenen Schrott zu verwenden
oderobbestimmterSchrottzugekauftwerden
muss;obesgünstigerist,reineElementezuzufügenundwelcherSchrottpreisakzeptabelist
– solche strategischen Fragen lassen sich anhandderKenndaten,diedasProduktionsmanagementsystem inklusive Alloy Calculator
liefert,konkretbeantworten.
Bessere rückverfolgbarkeit
Conclusion: huge potential for
optimisation all along the line
Die Rückverfolgbarkeit eingesetzter Materialien, ein Kriterium, das angesichts der VerschärfungendesProdukthaftungsgesetzesim-
mer relevanter wird, lässt sich mithilfe des
Produktionsmanagements besser gewährleisten. Als digitales Archiv dokumentiert es
langfristigundzuverlässigdieZusammensetzungderproduziertenMaterialienbiszurück
zum eingesetzten Schrott in einer lückenlo-
sen Historie. Auch hier schließt sich ein
Kreislauf:JebesserdieKenntnisdereigenen
SchrottbeständedurchkonsequenteMaterialverfolgung,eineffizientesLagermanagement
und präzise Analysewerte, desto transparenter das eigene Produkt und desto besser
seineRückverfolgbarkeit.
© Fotolia
Theproductionmanagementsystemwithintegratedchargeandalloycalculationisthekey
to efficient planning and control of production based on the latest actual situation and
requirementsandthusopensuphugepotentialforoptimisation.
Fromanoperatorperspective,itbecomes
clear that integration means huge benefits:
greaterefficiencyforchargeandalloycalculationhasimpactsontheentireprocesschain;
thepotentialforoptimisationcanbedirectly
passedontoallareasupstreamordownstream
from the core process of the melt. Further,
thealuminiumindustrycanshapeitsprocesses
in a more flexible manner so that it can respondfastertomanydifferentdemands.The fazit: hohes Optimierungslattermeanssavingsinthemostimportantre- potenzial auf ganzer Linie
sources,i.e.material,timeandenergy.
■
DasProduktionsmanagementsystemmitintegrierter Gattierungsrechnung ermöglicht die
effizientePlanungundSteuerungderProduktionaufderGrundlagetatsächlicher,aktueller
GegebenheitenundAnforderungenundsetzt
großesOptimierungspotenzialfrei.
AusAnwenderperspektivezeigtsich,dass
gerade die Integration den hohen Nutzen
bringt: Die gesteigerte Effizienz der Gattie-
rung wirkt auf die gesamte Prozesskette zurück; das Optimierungspotenzial lässt sich
auf alle Bereiche, die dem Kernprozess der
Schmelze vor- und nachgeschaltet sind, unmittelbarumlegen.ZudemkanndieAluminiumindustrieihreProzesseflexiblergestalten
und schneller auf unterschiedlichste Anforderungen reagieren. Letztlich bedeutet dies
Einsparungen der wichtigsten Ressourcen:
Produktionsabfälle und Schrotte – Ausgangsmaterial beim Alurecycling
Material,ZeitundEnergie.
Starting material for aluminium recycling: production waste and scrap
■
ALUMINIUM · 9/2013
61
TECHNOLOGY
Turla targets equipment quality and
performance for customer success
Gutmann Group buys Turla new extrusion press – complete with all upstream and downstream equipment
ALUMINIUM: Turla is well known as a major
world player in extrusion production systems
– but can you outline some of the history and
heritage related to the business that have led
up to your enviable position in the industry?
Turla: Initially founded in 1967 in Brescia,
Lombardy, Northern Italy, the company was
first involved in heavy steel machinery. Subsequently we began working in the aluminium extrusion field in 1972, manufacturing
wrapping machines and complete packing
lines for extruded aluminium. The plant progressed to designing and manufacturing single
machines for the extrusion process, including
pullers and walking beams. Within just a few
years Turla’s product catalogue covered the
entire extrusion production line, from the
billet heating furnace through to the ageing
oven. By the second half of the 1980s Turla
had established a reputation in Europe for the
quality of its products. During the late 1980s
and early 1990s we also progressed to become
one of the major suppliers of handling systems
to Hydro Aluminium, having built some 28
installations for this major organisation, and
in fact, the 29th is in the pipeline for delivery
to Hydro Nenzing, Austria in 2014.
Today Turla is a well recognised partner
of other major international aluminium extrusion companies, such as Constellium and
Sapa amongst others. We think that our work
approach over these 40 years has been firmly
supported and improved by the continuous
cooperation with these companies. In fact, we
consider our customers’ production managers,
plant operators and maintenance crew to be
our own engineers. This is because in reality,
it is through several years of cooperation with
these qualified professionals, that we have
been positioned to improve machines year on
year in terms of operation, maintenance and
reliability, all aimed at a short payback period,
62
© Turla
Italian company Turla Srl, for more than
40 years a specialist in building aluminium extrusion systems, has progressed
to be a world leader in this field. ALUMINIUM was most privileged to meet
recently with the company to learn more
about the past, present and future of the
well-known enterprise, together with its
continuing business success in securing
further project contracts.
Extrusion press entirely pre-installed at Turla facilities
greater productivity and a long service life.
What are your present locations and extent
of operations?
Turla is currently active at its two production sites and further expansion is currently
underway with a new building – all three are
located in the Brescia region of Northern
Italy. 100% of our products are engineered
and manufactured in-house by experienced
Turla personnel. This also includes all related
hardware and software, designed and manufactured by our daughter company TF Automation.
Turla site number 2, located in Paderno
Franciacorta, has been in operation since 1996
and hosts the headquarters, together with
engineering activities, sales, administration offices and manufacturing of handling
systems. With a generous floor
space of over 9,000 square metres,
this facility houses all the work to
build machinery for aluminium extrusion handling systems, including
all manufacturing stages such as engineering, welding, machining, assembly and
dry testing.
Turla’s third site was completed in 2008
to provide additional production capacity
and its launch coincided with the start of the
company’s extrusion press manufacturing.
The ground floor of the new facility was purposely designed to enable building complete
extrusion line installations and including dry
testing. This is a practice we use to start and
test the machines before we ship them to our
customers. This provides a great benefit both
for us and for clients by significantly minimising the start-up phase at customers’ sites.
The new facility is also home to our daughter company TF-Automation, which is active
in the production of hardware and software
for our extrusion systems and employs more
than 30 people covering different activities
such as electrical cabinet preparation, electrical schematics, I/O list engineering, PLC
programming and even customer care. In fact
TF-Automation, through our Teleservice connection to other Turla installations is able to
monitor our machine parameters 24/7 as well
as adjust and modify working cycles to ensure optimum performance.
This feature is appreciated by
our customers since technical parameters can readily
be viewed and possible problems directly solved without
need to be physically at the
extrusion site.
Could you summarise the company’s overall philosophy underpinning your success?
Our company policy can be simply summarised by our motto: Only quality generates quality. The word ‘Quality’ for us is not
only a mere word to be included in promotion or certificates. Quality is not related to
machines but solely to professionalism – in
ALUMINIUM · 9/2013
TECHNOLOGY
people, resources, methods, tools
and knowledge. This presents the
complete picture of what we can
offer. It is only possible to be truly
productive and satisfy customers
when real quality is cultivated
every day and in every activity that
is carried out in the company. We
deeply believe in this motto and
we continue to work towards constant improvement. And this is true
also in an extrusion plant, because
quality profiles are not produced
through quality machines alone,
but also by quality people.
We are truly confident that all
the passion, the care and the preci- Press main cylinder forged as a single part, without welding
sion that we put in to our everyday work produce the real essence of the top- and not standard production solutions – particularly those that can meet the needs of adquality machines that we design and build.
At the same time, we strongly believe – and vanced customers in delivering the maximum
this is confirmed by the conversations that we productivity and the optimum profitability
have every day with our customers – that high from their production lines. This approach to
quality profiles can only be produced through design has resulted in innovative machines
high quality machines and this is our daily being built primarily for ‘non-standard’ aptarget: making outstanding extrusion handling plications, and in turn have become high persystems that will produce defect-free, high formance standard machines for primary extruders, which we can now offer to the market
quality extrusions.
In conclusion, quality has always been a as longtime proven solutions.
For example, our air and water quenching
very important factor for Turla and it is very
important to highlight that we were the first systems represent a must-have product for
and the only Italian company active in manu- every extruder involved in leading automofacturing extrusion handling systems to obtain tive production. This is also the case, however,
ISO 9001 certification, which we did in 2003. for other equipment such as billet heaters, hot
Could you outline typical examples of billet saws, presses, pullers, stretchers, finishing saws and basket transportation systems. At
Turla’s extensive product range?
Our machines have proven their ability to the end of the day we are one of the few supguarantee minimal or zero equipment down- pliers able to supply a complete turnkey solutime. Construction details and quality are not
a minor issue for us. This is why Hydro, Sapa,
Constellium and other major world players
have continued to select Turla systems for
their extrusion projects.
Why buy a cheaper machine, when a sixmonth delay in production start-up can cost
you up to ten million euros in production
losses and then after five years most of the
equipment is ready to be scrapped?
We are open and ready every day for transparent technical discussions with our customers to consider relative machine comparisons,
which consistently show that Turla is the most
convenient choice that a customer can ever
make for their new machines. In other words
our machines are the least expensive in terms
of global and life cycle costs.
Additionally, we have always been known
for being able to ‘tailor a suit made-to-measure’. This capacity derives predominantly from
working with clients who need customised Water and air spray quench model QAH
ALUMINIUM · 9/2013
tion, from billet through to profile
finishing, including the extrusion
presses. We offer all types of extrusion systems, from ultra-light
profiles to those involved in the
production of large components,
such as for structural, railway and
aircraft applications.
Turla’s after-sales services and
customer care activities are supported by our Teleservice mentioned earlier and the company’s capacity to ship spare parts
promptly around the world is well
recognised.
How have the company’s evolution and developing technologies continued to support the business?
Turla has organised itself to accomplish
continuous improvement both in designing
and manufacturing point of view, trying to get
the best value from the professional growth
of its employees and the best practices applied
in the manufacturing operations. For example
we have developed very powerful calculation
tools for profiles cooling simulations and now
this technology is definitely a major competitive advantage when offering quenching systems all over the world.
Another significant improvement in the last
ten years is the particular care we devote to
the electrical hardware and software preparation of the machines. These activities represent
for Turla a point of strength in the engineering and consolidation of machines reliability.
The fact that everything is made, inspected
and proved in-house before shipment to the
63
TECHNOLOGY
Stretcher tailstock
customer is a further indication of our quality, in operation. We have been frequently chosen in recent years by customers looking for
spirit and dedication to our systems.
Importantly, we ensure that safety and products to help them in dramatically reducing
reliability of our machines are in-built and their environmental impact. In just one examcritically linked. A reliable machine cannot be ple, a STeP5 billet heater installed to replace
unsafe, and a safe machine cannot deliver a an old heater has resulted in a reduction of
low productivity for customers. All of our ma- CO2 emissions of around 380 tpy, equivalent
chines are therefore supplied with automatic to a reduction in emissions from 150 medicontrols that maximise their reliability and the um-size cars! This figure clearly illustrates the
safety in operation.
huge potential for lowering atmospheric polluHow important are new ideas, innovations tion.
and developments to Turla, in both technolThe Turla website – translated into English,
ogy and business?
Russian and German languages – enables all
Turla’s main thrust in design work involves customers to calculate the annual tonnages of
continuous improvement of our existing ma- CO2 emissions that can be avoided by installchinery range. Regular interfacing between ing a Turla STeP5 in their extrusion lines.
our own engineers and customers provides
Intensive quench QAH Air / Water spray:
vital feedback for us to understand how ma- Over the past decade this equipment has been
chines can be improved and even more closely installed with success in the most advanced
aligned to individual customer needs. Over- extrusion facilities in Europe, where the proall, the most significant innovations in the duction focus is mainly on automotive profiles.
past ten years have centred on three prod- This machine, greatly appreciated for its high
ucts that have been very well received by the extrusion industry:
Turla’s STeP5 gas-fired billet
heater offers the lowest gas consumption and atmospheric pollution levels possible worldwide:
This heater, with a proved thermal
efficiency of 81%, is by far the
most efficient device of its type
on the market in terms of operational costs, maintenance and CO2
pollution. Our customers have to
deal every day with rising energy
costs and new carbon taxes that
clearly disadvantage less efficient
extrusion plants where old and
excessively polluting equipment is Flying cut double puller, model DPC-TV
64
cooling power and flexibility, using both water
spray and air, is designed to suit the most demanding cooling cycles required by specified
profile tolerances.
Extrusion press: The recent order from
Nordalu, a plant in the Hermann Gutmann
Group Neumunster, Germany, marks the start
of Turla’s penetration in central Europe, including the supply of extrusion presses. The
Turla 18FR7 model, denoting 18-MN press
force with front-loading design and 240 bars
for 7-inch billets, requires no special foundations since there is no force on the ground due
to precise engineering design and tolerances.
All main parts are forged and the whole machine is delivered pre-stressed to the customer.
The press will be equipped with the Turlaengineered ‘Eco + Logic’ package which delivers a considerable energy saving of some
90,000 euros worth of electricity per year.
Only the energy required for extrusion will
be used, the rest will be saved as a result of
a smart software program entirely developed
by Turla through five years of investigation in
SW development.
All systems will be fully pre-installed at
Turla: the STeP5, the HLS-7 hot billet saw and
18FR7 extrusion press model will be fully assembled at the company’s Brescia facility in
early 2014. Hot profiles will actually be extruded in the works, prior to shipment of the
machinery to the customer in Germany for
on-site installation. Turla is also organising a
‘Press Open Week’ at this time, when interested world-class extruders will be invited to
attend.
Does Turla enjoy any special partnership relationships with its extruder customer
base?
Leading extrusion operations have recently
chosen Turla as partner for their most strategic projects. Orders from such well-known
companies as Constellium Singen and Nordalu in Germany, Hydro Nenzing
in Austria, Sapa Profiles Kft in
Hungary and Bonnell Aluminum
in the United States, show clearly
that high technology extruders
are seeking high technology suppliers. But, one of the things that
we pride ourselves on even more
in our day by day business is that
our customers return to us for every new project, and this is absolute
proof of true customer satisfaction.
We are really proud to have customers that have purchased our
products repeatedly for more than
25 years. In some factories it is easy
to see, in the space of just a few
ALUMINIUM · 9/2013
TECHNOLOGY
square metres the complete history
of Turla machinery – equipment
built in the late 1970s and early
1980s is still working perfectly
alongside latest solutions we have
installed in recent years.
What new marketing innovations does the company exploit?
Turla employs all the modern
communication means available
but we try to avoid impersonal
communication since the very valuable information involved must
be properly communicated securely to our customers and potential
customers. We have also made
available in the secure area of our
website a series of interactive tools Finishing saw
that provide useful and interesting
tips for customers when they are considering of the press, to be supplied with an innovative
and unique intensive air / water spray quench,
a new extrusion handling system.
Could you point to any specific recent flying cut puller, 120-tonne stretcher and finproject references in Europe that particularly ishing saw. The installation project has been
concluded with complete success for which we
stand out?
Amongst examples of recent projects Turla received compliments from the Constellium
has carried out in the European region, we Singen management.
Hydro Nenzing: We were awarded an orcan highlight four in particular.
Constellium Singen: In what is probably der earlier this year for a 16-MN press extruthe most important project in Germany to sion handling system. This project is an endate for Turla in the last ten years, we have dorsement of all our previous first-class work
recently concluded the final commissioning with Hydro Nenzing where we installed the
of the extrusion handling system for the cus- first Turla system in 1995. Originally equipped
tomer’s new 44-MN press, entirely dedicated with the Pinze System, invented by Turla,
to the production of automotive parts. Turla the system is still perfectly operational. Since
was awarded the contract in March 2012 for then we have always been a reliable partner
the supply of a complete system downstream for this plant that is one the most produc-
The most efficient and least polluting billet heater
ALUMINIUM · 9/2013
tive facilities in the entire Hydro
Group in terms of productivity and
quality.
Sapa Profiles kft Szekesfehervar:
We recently received an order
for the modernisation of the 35MN extrusion handling system at
Sapa’s biggest extrusion plant in
Europe. The contract will mainly
comprise an intensive air and water spray quench system (model
QAH) and a double puller flying
cut machine, all with very stringent
requirements in terms of productivity and final product quality.
Nordalu Neumunster – Gutmann Group: As reported above
we have recently received the order
for a complete extrusion handling
system consisting of our low consumption billet
heater SteP5, a Turla 18-MN extrusion press and
a complete handling system through to the
profile stacker. We are very pleased that an
important company such as Gutmann has honoured us with such an important order that
represents a critical development point for the
group’s Nordalu site in Neumunster.
Looking to the future – how do you see
the current status and trends in aluminium
extrusion?
We think that in the coming years the entire extrusion market will undergo an extensive reorganisation. As part of this, unfortunately, increased competition will lead to the
shut-down of non-competitive sites. This could
be viewed generally as a negative thing due to
contraction of the market but we are totally
confident that companies that have invested
considerably in terms of new products and
new machines will grow their business – and,
of course, we will be there to support them
with our innovative products.
Does the company have any other points
or observations on the industry in general that
you would like to stress?
Our company is medium-sized and familyowned and in fact the owners take an active
part in the management. We bear a great responsibility in proudly displaying the ‘Turla’
name on all our machines – presses, pullers,
heaters and handling systems – the same kind
of responsibility taken in the past by worldfamous Italian makers of beautiful, handcrafted cars, such as Ferrari, Lamborghini and
Maserati. This is Turla and our passion is profoundly interwoven with technological improvement on a daily basis, each and every
day.
Many thanks for your time and most interesting information.
■
65
TECHNOLOGIE
Belte AG – Spezialist für die Wärmebehandlung von Aluminiumbauteilen
„Wir sind ständig bestrebt, Prozesse weiterzuentwickeln“
Die Belte AG ist fast ausschließlich für die
Automobilindustrie tätig. Praktisch alle deutschen Autohersteller zählen zum Kundenkreis, wenn es um die Wärmebehandlung von
Motoren, Fahrwerks- oder Strukturbauteilen
aus Aluminium geht. Gegründet hat Markus
Belte seine Firma 1998 – praktisch als EinMann-Unternehmen und mit dem Knowhow
der Polymerabschreckung von Kurbelgehäusen, die seinerzeit für einen Premiumhersteller im kleinen Rahmen erprobt werden sollte.
Heute beschäftigt das Unternehmen rund 180
Mitarbeiter.
Markus Belte kommt ursprünglich aus dem
Bereich der Produktentwicklung. Für einen
amerikanischen Konzern entwickelte er chemische Produkte für die Wärmebehandlung
von Stahl (Härteöle, Polymerlösungen) und
Kühlschmierstoffe zur mechanischen Bearbeitung von Aluminiumteilen. Anfang der
1990er Jahre wurden dann erste Produkte
für die spannungsarme Wärmebehandlung
von Automobilkomponenten aus Aluminium
entwickelt. Ziel damals war es, Probleme mit
der Rissbildung bei Kurbelwellenlagersitzen
zu beheben.
Dazu wurde für den Abschreckprozess
nach der Wärmebehandlung ein wasserlösliches Polymer entwickelt. Belte erläutert die
Vorteile: „In dem Moment, wo das Bauteil in
diese Lösung eintaucht, verdampft das Wasser
an der Oberfläche und der Polymerfilm legt
sich praktisch wie Honig auf die Oberfläche.
Der Film ist an den dünneren Querschnitten
dicker als an den dickeren Querschnitten. Die
Wärme im Bauteil versucht zu entweichen,
der Film wird abgesprengt und bildet sich in
Bruchteilen einer Sekunde sofort wieder neu.
Dieser sich kontinuierlich wiederholende
Prozess sorgt dafür, dass die dünnwandigen
Bereiche ähnlich schnell abkühlen wie die
dickwandigen. Man erhält so während der
Abkühlphase einen Temperaturausgleich
66
Belte AG – Specialist in the heat treatment of aluminium components
“We constantly strive to develop our processes further”
© Belte AG
Die Belte AG aus Delbrück ist ein anerkannter Spezialist im Bereich der Wärmebehandlung von Aluminiumbauteilen.
Das Unternehmen agiert als reiner
Dienstleister und zeichnet sich durch seine hohe Kompetenz bei der Entwicklung
innovativer Wärmebehandlungsverfahren
und Abschreckmedien aus. ALUMINIUM
sprach mit dem Gesellschafter und Vorstand, Markus Belte, über die Entwicklung des Unternehmens.
Wärmebehandlungsanlage für Gussteile
Belte AG in Delbrück is a recognised
specialist in the field of heat treatment
for aluminium components. The company
is active as a pure service provider and is
noted for its high competence in the development of innovative heat treatment
methods and quench media. ALUMINIUM spoke to the managing proprietor
and CEO, Markus Belte, about the
development of the company.
Almost all of the activity of Belte AG relates
to the automobile industry. Virtually all the
auto manufacturers in Germany are among
its customers when they need aluminium
engines, chassis components or structural
components to be heat treated. Markus Belte
founded his company in 1998 – virtually as a
one-man company, and with know-how about
the polymer quenching of crank-cases, which
at the time were being tested for a premium
manufacturer on a small scale. Today the
company employs around 180 people.
Markus Belte originally came from the sector of product development. For an American
company he developed chemical products for
the heat treatment of steel (hardening oils,
polymer solutions) and coolant lubricants
for the mechanical machining of aluminium
components. At the beginning of the 1990s
Heat treatment plant for castings
the first products were developed for the
low-stress heat treatment of aluminium auto
components. The problem at the time was to
eliminate crack formation in crankshaft bearing seats.
For this, for the quenching process after
heat treatment a water-soluble polymer was
developed. Mr Belte explains the advantages
thus: “At the instant when the component
Markus Belte
ALUMINIUM · 9/2013
TECHNOLOGY
is immersed in the solution, the water evap- im Bauteil. Durch die sehr gleichmäßig Aborates at the surface and a polymer film forms kühlung ist das Spannungsniveau im Bauteil
almost like honey over the surface. The film sehr gering, wodurch sich eine große Reserve
is thicker over thin cross-sections than over zum Beispiel auf die Streckgrenze bezogen
thicker cross-sections. The heat in the com- ergibt.“
Beltes Ziel seinerzeit war, das Polymer an
ponent tries to escape and the film becomes
Wärmebehandler
zu verkaufen. Da es damals
detached but re-forms again in fractions of
jedoch
keinen
Dienstleister
gab, der die Wära second. This continually repeated process
mebehandlung
von
Aluteilen
mit Polymer
ensures that the thin-walled areas cool at a
durchführen
wollte,
entschloss
er sich nach
similar rate to the thick-walled ones. So duranfänglichem
Zögern
und
dem
Zuspruch
von
ing the cooling phase the temperature in the
Autoherstellern,
in
die
Wärmebehandlung
component is equalised. Thanks to this very
uniform cooling the stress level in the compo- einzusteigen. Die Entscheidung dazu und die
nent is very low, so there is a large margin, for sich daraus ergebenden unternehmerischen
Anfänge wären eine eigene, zum Teil abenexample, in relation to the yield strength.”
At the time, Belte’s aim was to market the teuerliche Geschichte wert, auf die hier jedoch
polymer to heat treaters. However, since at verzichtet werden muss.
Waren die ersten beiden Jahre nach Firthe time there were no service providers who
wanted to heat treat aluminium components mengründung noch von kleinen Anfängen mit
with polymer, after
some hesitation and
with encouragement
from some car manufacturers he decided to
begin heat treatment
himself. The decision
to do this and the resulting inception of the
company are another,
partly
adventurous
story we cannot go into
detail here.
The first two years
after the company’s
foundation were still
marked by small beginnings with very few
workers, and with orders mainly from Audi
(for the A2 model of Charge mit Gussteilen vor Abschreckung im Polymerbad
that time) and BMW; Batch of castings, ready for polymer quenching
over the next few years
from 2003 Belte expanded by works enlarge- wenigen Mitarbeitern geprägt, und von Aufment, new production locations and company trägen vor allem für Audi (für das damalige
takeovers. As is known the financial crisis of A2-Modell) und BMW, expandierte Belte in
2008/09, which seriously affected the auto- den Folgejahren ab 2003 durch Werkserweimobile industry, was also bad news for foun- terung, neue Produktionsstandorte und Firdries and other supplier industries – and Belte menübernahmen. Die Finanzkrise 2008/09,
too experienced from one month to the next die die Automobilindustrie massiv erfasste,
an extreme collapse of orders and payment zog bekanntermaßen Gießereien und andere
default because of insolvency on the customer Zulieferindustrien arg in Mitleidenschaft –
side. However, thanks to a capital increase by und auch Belte erlebte von einem Monat auf
bringing in financial investors from Bahrain den nächsten einen extremen Auftragseinand to the sale of companies acquired only a bruch und Zahlungsausfälle aufgrund von
few years earlier, Belte AG was able to over- Insolvenzen auf Kundenseite. Dank einer
Kapitalerhöhung durch Einbeziehung von Ficome the financial and economic crisis.
At present the company is working at full nanzinvestoren aus Bahrain und des Verkaufs
capacity, running four shifts seven days in the der wenige Jahre zuvor erworbenen Firmen
week, and this despite the declining registra- konnte die Belte AG die Finanz- und Wirttion figures in Europe for passenger cars. This schaftskrise jedoch überstehen.
ALUMINIUM · 9/2013
Derzeit arbeitet die Firma auf Hochtouren:
vierschichtig, sieben Tage in der Woche –
trotz der in Europa rückläufigen Zulassungszahlen bei Pkw. Auch ein Zeichen dafür, dass
der Aluminiumleichtbau im Automobil weiter auf dem Vormarsch ist – nicht zuletzt
dadurch, dass der Gießprozess mit anschließender Wärmebehandlung komplexe, multifunktionelle Bauteile ermöglicht, die früher
aus vielen separaten Einzelkomponenten teuer zusammengefügt werden mussten.
„Aufhängung und Chargierung der
Bauteile von großer Bedeutung“
Kerngeschäft und Kernkompetenz des Unternehmens sind heute wieder die Wärmebehandlung und Entwicklung innovativer Wärmebehandlungsverfahren. „Punktuell kommt
auch die Legierungsentwicklung mit ins Spiel,
weil Legierung und erfolgreiche Wärmebehandlung zwei Seiten einer Medaille sind.
Darüber hinaus bieten wir auch mechanische
Bearbeitungen an, zum Beispiel bei Strukturbauteilen. Bei Fahrwerksteilen führen wir
neben der Wärmebehandlung auch eine Röntgen- und Rissprüfung durch“, so Belte.
Bei Strukturbauteilen ist die mechanische
Bearbeitung am weitesten fortgeschritten. Die
Teile kommen aus der Gießerei, werden bei
Belte entgratet, lösungsgeglüht und abgeschreckt, automatisch gerichtet, warmausgelagert und mechanisch bearbeitet, schließlich
werden Helicoils (Drahtgewindeeinsätze) und
andere Elemente montiert. Die Bauteile werden noch KTL-beschichtet (KTL = kathodische Tauchlackierung), anschließend verpackt und verschickt.
Bei der Wärmebehandlung inklusive Abschreckung geht es immer um die Faktoren
Streckgrenze, Bruchdehnung, Zugfestigkeit,
Eigenspannung und vermehrt auch Korrosionsbeständigkeit, die sich durch Wärmebehandlung beeinflussen lassen. Neben der Anlagentechnik, Temperatur- und Zeitführung
sowie Abschreckung spielen die Warenträger
eine wichtige Rolle für die optimale Wärmebehandlung. „Wenn ich Strukturteile oder
Druckgussteile auf 460 bis 490 °C aufheize,
nähere ich mich einem Temperaturbereich,
wo die Bauteile anfangen, sich plastisch zu
verformen. Daher kommt ihrer Aufhängung
und Chargierung eine große Bedeutung zu.
Wir haben uns viel Knowhow im Bereich der
Warenträger erarbeitet und Lösungen entwickelt, wie die Bauteile im Ofen beschickt und
fixiert werden müssen, sodass ein möglichst
geringer Verzug auftritt“, sagt Belte.
Wie oben bereits skizziert, ist auch der
Abschreckprozess wichtig, damit die Bau-
67
TECHNOLOGIE
teile möglichst gleichmäßig abkühlen. Als
Abschreckmedien kommen Luft, Wasser
und Polymer infrage. Welche Abschreckung
gewählt wird, hängt vom Bauteil ab, von
seiner Geometrie und den mechanischen Eigenschaften, die erzielt werden sollen. Die
Polymer-Abschreckung ist beispielsweise für
komplexe Bauteile wie Kurbelgehäuse interessant. Strukturteile wie Längsträger, die eine
große Oberfläche bei vergleichsweise geringer Masse aufweisen, lassen sich gut mit Luft
abschrecken. Luftkühlung bei Belte heißt
HISAQ (High Speed Air Quenching), also
Luftabschreckung bei hoher Geschwindigkeit.
Belte hat diese Entwicklung für die Wärmebehandlung von Kokillenguss- und Druckgussteilen im Jahr 2003 zum Patent angemeldet.
Entwicklungsarbeiten mit Strahlungswärme statt Luftumwälzung
Typischweise wird bei der Wärmebehandlung
mit Konvektion gearbeitet. Die Öfen sind so
aufgebaut, dass der Ofenraum per Luftumwälzung aufgeheizt wird und die Bauteile
mit der heißen Luft in Kontakt kommen.
Das Unternehmen erprobt derzeit ein neues
Verfahren, bei dem die Bauteile direkt durch
Infrarotstrahler bestrahlt werden. „Auf diese
Weise lassen sich die Bauteile mit sehr hoher
Geschwindigkeit punktgenau auf Temperatur
bringen. Praktisch in wenigen Minuten“, so
Dan Dragulin, Leiter F & E bei der Belte AG.
Mit solchen Versuchen für Audi wurde bereits
vor drei Jahren begonnen.
Bei der Wärmebehandlung geht es immer
um mechanische Eigenschaften, aber auch um
Kosten. „Bei einem großen Ofenraum mit
Konvektionserwärmung dauert die Aufwärmphase 45 Minuten und länger, zum Beispiel
auf einer Durchlaufanlage für Zylinderköpfe.
Mit der Infrarotaufheizung haben wir es in
Versuchsanordnungen geschafft, solche Bauteile innerhalb von sieben Minuten auf Temperatur zu bringen. Ich kann so nicht nur die
Verweilzeit im Ofen verkürzen, sondern habe
durch die schnellere Aufheizung noch bessere
mechanische Eigenschaften“, hebt Belte hervor. Zu den Versuchsergebnissen an einem
Strukturgussteil für Audi siehe nachfolgenden
Bericht.
Mit diesem Verfahren befindet sich Belte
noch im frühen Versuchsstadium. Ob und
in welcher Form diese Methode in Zukunft
marktfähig wird, ist noch nicht ausgemacht.
Die Entwicklungsarbeiten daran aber zeigen,
„dass wir nicht der klassische Dienstleister
sind, der Wärmebehandlung nach Vorschrift
macht, sondern ständig bestrebt sind, Prozesse weiterzuentwickeln“, betont Belte.
■
68
Überwachung der automatischen Prozesse der Belte AG
Controlling automatic processes at Belte AG
is yet another sign that lightweight construction with aluminium in automobiles is advancing. Not least, because the casting process
with subsequent heat treatment enables the
production of complex and multi-functional
components which previously had to be expensively assembled from several separate
individual components.
chassis components, besides heat treatment we
also carry out X-ray and crack testing,” says
Mr Belte.
Mechanical machining is most advanced in
the case of structural components. The parts
come from the foundry, they are deburred at
Belte, then solution-annealed and quenched,
automatically straightened, artificially aged
and mechanically machined. Finally helicoils
(wire-wound inserts) and other elements are
“The jigging and charging of the
fitted. The components are then CIL-coated
components is very important”
(CIL = Cathodic Immersion Lacquering),
The company’s core business and competence packed, and sent off.
In heat treatment and quenching the critiis still today heat treatment and the development of innovative heat treatment methods. cal factors are always yield strength, fracture
“Now and then alloy development is also in- strength, tensile strength, internal stresses
volved since the alloy and its successful heat and to an increasing extent also corrosion retreatment are two sides of the same coin. sistance, all of which are influenced by heat
Moreover, we also offer mechanical machin- treatment. Besides plant technology, teming, for example of structural components. For perature and time control and quenching, the
supporting jigs also
play an important part
for optimum heat treatment. “When we heat
structural components
or castings to 460 to
490 °C, we are approaching a temperature range in which the
components begin to
deform plastically. So
the way they are jigged
and charged is very
important. We have
developed a great deal
of know-how about
the supporting jigs and
worked out solutions
about how to load the
components into the
furnace and fix them
in it, to ensure the least
Bearbeitung eines Strukturbauteils
Machining a structural component
ALUMINIUM · 9/2013
TECHNOLOGY
possible distortion”, says Mr Belte.
As already outlined earlier, the quenching
process is also important if the components
are to cool as uniformly as possible. The
quench media used are air, water and polymer solutions. Which quenching media are
chosen depends on the component, its geometry, and the mechanical properties to be produced in it. For example, polymer quenching
is interesting for complex components such
as crank-cases. Structural components such
as longitudinal support members, which have
a large surface area with only comparatively
low mass, can be effectively air-quenched. At
Belte air cooling is called HISAQ (High Speed
Air Quenching), i.e. quenching in air at a high
rate. In 2003 Belte applied for a patent for this
development for the heat treatment of gravity
and pressure diecast components.
Development work on radiated
heat instead of air circulation
Typically, heat treatment is carried out by
convection. The furnaces are designed so that
the furnace chamber is heated by air circulation and the components come in contact with
the hot air. At present the company is testing
a new method in which the components are
irradiated directly by infra-red radiation. “In
this way the components can be brought to
temperature very quickly and with pinpoint
accuracy: almost in a few minutes,” says Dan
Dragulin, head of R&D at Belte AG. Such
tests started for Audi already three years ago.
The important factors in heat treatment
are always mechanical properties, but also the
cost. “In a large furnace chamber with convection heating the heat-up phase takes 45
minutes or more, for example in a continuous-throughput unit for cylinder heads. With
infra-red heating, in test runs we managed to
bring such components to temperature within seven minutes. In this way I can not only
shorten the dwell time in the furnace, but
achieve even better mechanical properties
due to the rapid heating,” stresses Mr Belte.
For the test results on a structural casting for
Audi, see the following report.
This process is still at an early stage of testing. Whether and in what form the process
will in the future become marketable, is not
yet clear. However, the development work
so far indicates “that we are not a classical
service provider which carries out heat treatment according to specification, but that we
always strive to develop our processes further,” stresses Mr Belte.
■
Infrared heat transfer for thin-walled aluminium automotive castings
A novelty in the field of aluminium high pressure die casting
demonstrating the high versatility of aluminium as all around material
Fig. 1: Casting exposed to IR – between arrows: the zone under direct exposure
to radiation; distance between casting and IR-module: left: 10 cm, right: 30 cm
Preamble
The use of infrared radiation in the field of
aluminium processing enables easier automation and control of the heat transfer processes and contributes to productivity enhancement. The electrical hardware of the
infrared module allows for drastic improvements in the efficiency factor of the industrial
equipment used for aluminium processing,
while also reducing the pollution degree.
ALUMINIUM · 9/2013
© Belte AG
D. Dragulin, M. Belte, Belte AG
Fig. 2: Inappropriate position of the casting within the IR-module
Dr. Dimitrie Popescu, Associate Professor, Old
Dominion University, Norfolk, Virginia, USA
its corresponding mechanical properties. All
experiments were realised using Audi-structural castings.
Abstract
The application of infra-red radiation to heat
treatment of thin-walled aluminium high pressure die castings is a process that is in the
early stages of its development. The objective
of the experiment presented here was to analyse the heating rate of the casting and to study
Experimental conditions
The casting process was realised by Trimet.
• IR module
Ground coverage: 108 kW
• Casting
• Weight: 2.5 kg
69
TECHNOLOGY
IE
Fig. 3: Influence of various operating conditions on the heating rate – not
coated
red: warm start in a encased module – 3.39 °C/s between 40 °C and 470 °C
green: warm start – 2.39 °C/s between 40 °C and 470 °C
blue: cold start – 1.84 °C/s between 40 °C and 470 °C
black: cold start and an inappropriate position of the casting within the
IR-module – 0.78 °C/s between 40 °C and 470 °C
• Weight of the zone under direct
exposure to radiation: 1.5 kg
• Surface of the zone under direct exposure to radiation: 0.078 m2 per side
• Wall thickness of the zone under direct
exposure to radiation: 3-5 mm.
Fig. 2 presents an inappropriate position of
the casting within the IR-module; this leads
to a massive loss of the heating rate (see Fig.
3) and as consequence to a corresponding
reduction of the productivity.
The influence of various operating conditions on the heating rate is shown in Fig. 3.
After the heating process the castings were
submitted to both a forced air and water cooling and to a subsequent overaging (see Figs
4-5).
Experimental results
Under the oversimplification: merely the
zone under direct exposure to radiation will
be taken into consideration. Instant power
consumption was 8.42 kW per side
The mechanical properties (average of four
tests) are presented in Table 1.
Fig 4: Influence of the state of the surface on the heating rate;
warm start in a partially encased module
red: not coated – 2.85 °C/s between 40 °C and 470 °C
green and blue: two different coatings – 3.84 °C/s
respectively 3.94 °C/s between 40°C and 470°C
Conclusion and
future prospects
The obtained mechanical properties are more
than encouraging.
The design of the
IR-module is very
important for the optimisation of the heat
transfer process. Modern IR equipment can
be adapted to the casting geometry.
Fig 5: Overaging (convection kiln)
Acknowledgement
The authors would like to thank Audi, Heraeus, LOI-Italimpianti and Trimet for their
support.
as cast
Rp0.2 [MPa]
Rm [MPa]
At [%]
154
301
7.6
References
[1] C. Samoila, L. Druga, L.Stan, Cuptoare si Instalatii de Incalzire, EDP, Bukarest, 1983.
air cooling water cooling
120
214
12.6
223
300
7.2
Heating regimes correspond to the red curve in Fig. 4
Table 1: Mechanical properties
Authors
Dr. Dan Dragulin is head of Research and Development at Belte AG, Delbrück, Germany.
Markus Belte is CEO of Belte AG, Delbrück, Germany.
y
Suppliers Directory – for your benefit
On pages 84 to 97, leading equipment suppliers to the aluminium industry present their
product portfolios and ranges of services. Take advantage of this useful information.
70
ALUMINIUM · 9/2013
3Ú
GB_D
TECHNOLOGY
Euroguss 2014: „Anmeldestand der
Vorveranstaltung bereits erreicht“
Vom 14. bis 16.
Januar kommen
erneut DruckgussSpezialisten aus
ganz Europa zur Euroguss-Messe nach Nürnberg, um sich über Produktneuheiten und
Trends zu informieren. Zum aktuellen Stand
der Anmeldungen und zur erwarteten Ausstellerzahl erklärt Heike Slotta, Leiterin Veranstaltungen bei der Nürnberg Messe GmbH:
„Die Akquise läuft sehr gut. Wir haben den
Anmeldestand der Vorveranstaltung jetzt
schon (redaktionelle Anm.: Stand Juli) erreicht. Viele Unternehmen haben ihre Standflächen vergrößert, weil die Euroguss für sie
eine wichtige Plattform zur Kontaktpflege
und zum Aufbau von neuen Geschäftsbeziehungen ist. Ich rechne mit rund 400 Ausstellern auf der Messe im Januar. Auch die internationale Beteiligung auf Ausstellerseite
entwickelt sich sehr erfreulich, zum Teil auch
aus Ländern, die bisher noch nicht so zahlreich auf der Messe waren, wie die Türkei.
Besonders stark vertreten sind Unternehmen
aus Italien und Schweden, die mit je einem
Gemeinschaftsstand dabei sind.
Zu den Angebotsbereichen, die auf der
Euroguss zu sehen sind, sagte sie weiter:
„Das Messeangebot bildet die gesamte Druckguss-Wertschöpfungskette ab – von der Technik über die Prozesse bis hin zu den Produkten. Die Aussteller sind Druckgießereien,
also die Hersteller von Gussteilen und Komponenten, sowie deren Zulieferer, Ausrüster
und Dienstleister. Sie zeigen Druckgusstechnologie, Angebote zur Nachbehandlung von
Gussteilen, Trenn- und Betriebsstoffe, die im
Herstellungsprozess notwendig sind, Möglichkeiten der Qualitätskontrolle, Steuerungsund Antriebstechnik sowie das weite Feld der
Software.“
Die Euroguss findet 2014 zum zehnten Mal
statt. Zu den Highlights der Jubiläums-Veranstaltung sagte sie: „Dieses Messejubiläum
möchten wir zusammen mit allen Ausstellern
und Besuchern feiern und organisieren aus
diesem Anlass eine Sonderschau, die die Entwicklung des Druckgusses beleuchtet und
den Bogen von der Vergangenheit bis in die
Zukunft spannt. Sie ist während der Messe
im Eingangsbereich zu sehen. Dazu feiern
wir natürlich eine ordentliche Geburtstagsparty und planen noch ein paar weitere Jubiläumsaktionen. Darüber hinaus gibt es natürlich wieder die beliebte Sonderschau „Forschung, die Wissen schaf(f)t“, den Internationalen Deutschen Druckgusstag mit spannenden Fachvorträgen von Experten für Experten sowie die Verleihungen des Internationalen Aluminium-Druckguss-Wettbewerbs
und des Zinkdruckguss-Wettbewerbs.
■
Euroguss 2014: “Level of applications
for previous event already reached”
From 14 to 16 January 2014 die casting specialists from all over Europe will be visiting
the Euroguss trade fair in Nuremberg to update on new products and trends. Regarding
the current level of applications and the expected number of exhibitors, Heike Slotta, director Exhibitions at Nürnberg Messe GmbH,
said: “The acquisition of exhibitors is going
very well and we have already (editorial
note: in July) reached the level of applications
for the previous event. Many companies have
enlarged their stand spaces because Euroguss
offers them a major platform for cultivating
contacts and establishing new business relationships. I expect around 400 exhibitors at
the exhibition in January. The number of international exhibitors is also developing very
encouragingly, in some cases also from countries that have not previously sent so many
firms, such as Turkey. Companies from Italy
and Sweden, each present with a pavilion, are
particularly strongly represented.
Regarding the product segments that will
be on show at Euroguss she continued: “The
product spectrum reflects the whole die casting value chain: from technology and processes through to products. The exhibitors are
die casting foundries, that is the manufactur-
ers of castings and components, and their
component suppliers, equipment suppliers
and service providers. They show die casting
technology, products for after-treatment of
castings, parting agents and operating materials that are necessary in the manufacturing
process, quality control facilities, control systems, drive technology and the broad field of
software.
Euroguss will be taking place for the tenth
time in 2014. What are the highlights at the
jubilee event? “We would like to celebrate
this anniversary with all exhibitors and visitors
and are organising a special show to mark the
occasion. This will examine the development
of die casting and span the period from the
past to the future. The show takes place in
the entrance area during the exhibition. The
occasion obviously calls for a real birthday
party and we are also planning a few more
anniversary specials. In addition, the popular
special show ‘Research for Knowledge’, the
International German Die Casting Congress
with interesting presentations by experts for
experts, and the presentation of awards for
both the International Aluminium and Zinc
Die Casting Competitions are naturally on the
programme again.
■
you‘re in good hands ...
EMO Hannover
16.09.-21.09.13
Hall 11 Stand E48
... we have all the pieces.
BDA5024K58=8B78=6KUKB7>CK1;0BC8=6
www.rosler.com
Innovative solutions from the world‘s leader in surface finishing
3ÚTMFS0CFSGMÊDIFOUFDIOJL(NC)t6OUFSNFS[CBDIt(FSNBOZt5FMt'BYtJOGP!SPTMFSDPN
GB_DE_2C_210X79.indd 1
05.08.2013 09:41:05
TECHNOLOGIE
Gießtechnisch verbunden: Hybride CFKAluminium-Fügeverbindung für den Leichtbau
Für die unterschiedlichsten Branchen können
integrale Übergangsstrukturen zwischen Aluminium und CFK gewünschte konstruktive
und fertigungstechnische Möglichkeiten bieten: eine Reduzierung von Gewicht, Bauraum
und Fertigungsschritten. Einsatzgebiete sind
nicht nur in der Luftfahrtindustrie zu finden,
auch bei Windkraftanlagen und im allgemeinen Maschinenbau steigt die Nachfrage nach
leichten Bauweisen. Im modernen Automo- Glasfasern oder Titan bestehen können, ist die
bilbau setzen Fahrzeughersteller bereits kom- fertigungstechnisch einfache direkte Integraplette CFK-Karosserien in Serienfahrzeugen tion in Aluminiumbauteile mithilfe des Aluein. Der Fahrzeugrahmen, der als separates miniumgusses, der im Bereich der GießereiBauteil hergestellt wird, ist dabei aus Alumini- technologie am Fraunhofer Ifam untersucht
um gefertigt. Zur Montage beider Bauteile ist und erarbeitet wird. Unterstützt werden diese
wiederum eine Verbindungstechnik zwischen Arbeiten durch die Abteilung Plasmatechnik
dem Alurahmen und der CFK-Karosserie erforderlich, die hier meist über eine
kombinierte Verbindung aus Nieten und
Kleben erzielt wird.
Wissenschaftler am FraunhoferInstitut für Fertigungstechnik und
Angewandte Materialforschung haben neue Lösungsansätze für verschiedeneVerbindungsarten im Druckguss entwickelt. Alle untersuchten Systeme verfolgen dabei die gemeinsame Strategie einer sogenannten Übergangsstruktur zwischen den zu fügenden Materialien
Aluminium und CFK. Dieser Übergang Hybridverbindung zwischen einem Aluminium-Druckgussvom Metall zum Faserverbundwerkstoff bauteil und CFK
wird unter der Berücksichtigung von fasergerechtem Design sowie – im Vergleich zu und Oberflächen am Fraunhofer Ifam. Hier
konventionellen Verbindungstechniken – re- werden geeignete Oberflächenmodifikationen
duziertem Bauraum und Gewicht entwickelt. der Übergangsstrukturen entwickelt, die die
Das eingebrachte Verbindungselement führt mechanischen und korrosiven Eigenschaften
zu einer galvanischen Entkopplung zwischen der Verbindungen verbessern.
Das Projekt „Bauweisen für CFK-Aluminiden Werkstoffen und verringert somit das
Korrosionsverhalten des Werkstoffverbundes um-Übergangsstrukturen im Leichtbau“ wird
Aluminium-CFK. Besonderer Vorteil dieser durch die Deutsche Forschungsgemeinschaft
Übergangsstrukturen, die aus hitzebeständigen (DFG) gefördert.
■
© Ifam
Leichtbau gilt als Schlüsseltechnologie.
Wo immer es um geringes Gewicht geht
und Massen bewegt werden müssen,
sind sie gefragt: Leichtmetalle, aber auch
Faserverbundwerkstoffe. Eine Methode,
die besten Eigenschaften verschiedener
Werkstoffe miteinander zu verbinden,
ist die Hybridbauweise. Sinnvolle Kombinationen unterschiedlicher Materialien
sind zum Beispiel CFK und Aluminium.
Derzeit erfolgt das Verbinden dieser
Komponenten über ein adhäsives oder
mechanisches Fügen. Mit Blick auf gewichtsoptimierte, integrale Strukturen
mit verbesserten mechanischen Eigenschaften sind jedoch neue Konstruktionsbzw. Fügemöglichkeiten von Interesse.
Wissenschaftler am Fraunhofer-Institut
für Fertigungstechnik und Angewandte
Materialforschung haben neue Lösungsansätze für verschiedene Verbindungsarten im Druckguss entwickelt.
ACTech nimmt Stoßwellenanlage zur Entkernung komplexer Gussteile in Betrieb
Die ACTech GmbH, Entwickler und Hersteller von Gussteilprototypen mit Hauptsitz in
Freiberg / Sachsen, hat eine neue Anlage mit
Stoßwellentechnik zur Entkernung von Gussteilen in Betrieb genommen. Mit der flexibel
einsetzbaren Technologie kann die Produktionszeit von Gussteilen mit anspruchsvoller
Innengeometrie deutlich verkürzt werden.
ACTech ist nun bestens gerüstet für die Fertigung von Bauteilen mit zunehmend komplexer werdender Kerngeometrie, zum Beispiel
von Hochleistungs-Zylinderköpfen. Derartige
Teile waren bislang nur mit extremem Aufwand realisierbar.
Dank der neuen Technologie muss das
Bauteil nicht mehr mehrere Tage in den Glühofen, wenige Minuten im Wasserbad genügen.
Die Stoßwellentechnologie ersetzt neben ther-
72
mischen auch mechanische Entkernverfahren
wie das Entkernungsstrahlen und das damit
verbundene Risiko einer Beschädigung des
Bauteils. Außerdem reduziert die neue Anlage die notwendigen Endoskopien zur Kontrolle des Reinigungsfortschritts. Nach Abschluss eines viermonatigen Testlaufs mit
mehr als 200 entkernten Teilen ist die Stoßwellenanlage bei ACTech nun im Regelbetrieb
im Einsatz. Vor allem Kunden aus der Automobilbranche profitieren von den verkürzten
Produktionszeiten. ACTech kann Gussteilprototypen nun noch schneller und kostengünstiger ohne Qualitätseinbußen herstellen.
Bei der Stoßwellen-Entkernung wird das
Bauteil in einem Wasserbad vor zwei Elektroden positioniert. Über die Elektroden werden
hoch aufgeladene Kondensatoren schlagar-
tig entladen. Das löst eine hochenergetische,
hochfrequente Schockwelle aus, die das Gussteil durchläuft, vorhandene Kernreste zerstört und die Verschmutzungen ins Wasser
spült. Neben der Entfernung von Gusskernresten lässt sich die Stoßwellenanlage auch
zur Beseitigung von keramischen Kernresten
bei Feingussverfahren und von festsitzenden
Spänen nach der mechanischen Bearbeitung
einsetzen.
Die positive Kosten-/Nutzen-Rechnung
sowie die Flexibilität der Stoßwellentechnologie und die guten Ergebnisse vorangegangener
Tests führten dazu, dass ACTech bereits ein
Jahr nach den ersten externen Tests eine eigene Stoßwellenanlage in Freiberg in den Regelbetrieb nimmt.
■
ALUMINIUM · 9/2013
TECHNOLOGY
Automated band saws for precise linear cuts
terised by convenient tool changing and highly ing clamp features plastic plates to achieve
reliable operation. Following the separation effective clamping of packages, for example
process the profiles are transported onwards with rectangular tubes.
via the roller conveyors either to the packing
location for dispatch or into an intermediate High efficiency and maximum precision
storage area for subsequent processing.
A second HBP800-1201 of aluminium with The HBM540ALU automatic band saw ena cutting range of sures high performance machining with enorup to 1,200 mm mous precision. “The cutting performance is
in height and 800 many times higher than with conventional
mm in width oper- band saws,” testifies Mr Müller. A servo drive
ates independently and ball screw enable point-precise, rapid inwithout connection feed to the band saw as well as a highly conto other systems. stant and precisely adjustable saw feed rate.
This is equipped Constant cutting feed rate or constant cutting
with a 25 metre- force can be optionally specified, and this enlong feed and dis- sures an optimal service life of the tool and
charge roller con- optimal separation results as well.
veyor, and loading
Sawing and retracting is also dynamic with
of the machine is the HMB540ALU. As with the HBP800-1201
via a hall crane large band saws, the benefits are optimal cut
from a blank piece edges with the separation of tubes and profiles
storage area. Fol- as well as protection of the band. The high eflowing the separa- ficiency band saw has an extended supply axis
tion process the and the stroke length of the feed gripper is
crane
takes up the 1,440 mm. With this version the feed gripper
Integrated in an existing roller conveyor system, the HBP800-1201 aluminium
bandsaw from Behringer ensures fast, high-precision cutting of the lightweight
cross-cut profiles is configured permanently for linear directions
material
and deposits them and the fixed jaw automatically moves away
for
subsequent
dispatch.
from the stop edge during the return stroke.
With an annual volume of 500,000 tonnes,
Both
large
band
saws
feature
a
saw
band
A hydraulic vertical tensioning device enables
the company is one of the major processors
inclined
by
four
degrees
for
efficient
cutting
economic sawing of packages and layers. A
for aluminium. Window and door profiles
of
grouped,
square
hollow
sections.
Controlcutting channel extension means the saw band
are mainly manufactured for the private
led
by
computer,
the
feed
function
and
cutting
can be freely retracted following the separaand industrial sectors as well as components
speed
of
the
saw
band
are
adapted
automatition process.
for ships, aircraft and for the energy sector.
cally
to
the
input
material
width.
A
cut
moniWith this investment in the new saw maProcessing is usually with profiles and tubes
toring
system
controls
cutting
progression
of
chines
the company has not only planned for
but also solid materials with highly diverse
the
material
to
be
cut.
Dynamic
sawing
and
rethe
moment.
“A further expansion of produccross-sections and diameters. In the past years
tracting
achieves
increased
band
service
life
as
tion
capacity
is expected, and the currently
Behringer from Kirchardt in Germany has
well
as
optimal
cut
edges.
The
ejection
height
existing
machine
park readily permits such an
supplied a total of four partly automated band
of
the
chip
container
is
1,200
mm
due
to
the
increase,”
summarises
Mr Müller.
saws that with their highly precise linear cuts
■
large
volume
of
chips
produced
ensure ready-to-mount sections that are postduring aluminium sawing.
processing redundant.
Both HBP800-1201 aluminium
saw systems also feature
First pressed, then sawn
a hydraulic vertical tensioning
Two of the saw systems are each connected device with a wide thrust piece
to large aluminium presses for bringing the installed to the machine. The
profiles into form prior to sawing. “The horizontal tensioning device
HBP800-1201 and HBP410-923N straight cut and this supplementary vertical
aluminium band saws are not isolated solu- tensioning device enable sevtions but were integrated into an existing pe- eral tubes in a single position
riphery consisting of diverse roller conveyors or package to be cut up to the
and cross conveyor systems,” explains Achim height of the fastening clamps.
Müller, head of Sales at Behringer. They take All fastening clamps have a
the place of two large circular saws that were smooth, hardened surface for
previously integrated in the peripheral setup avoidance of imprints into the Aluminium profiles with different diameters are cut with maximum
and ensure problem-free processing, charac- material. The movable fasten- speed and precision on Behringer bandsaws
© Behringer
Four modern band saw systems from
Behringer GmbH separate parts for largescale industrial and private constructions,
subway and aircraft construction and the
machine construction and energy sectors for an Asian customer of Behringer
GmbH.
ALUMINIUM · 9/2013
73
TECHNOLOGIE
Innovative Lösungen für das Strahlen von Gussprodukten
Die Strahltechnik zählt in der Gießereibranche zu den unverzichtbaren Verfahren, um erforderliche Oberflächenbeziehungsweise Produkteigenschaften
herzustellen. Dabei ermöglichen neue
Entwicklungen für das automatisierte
Strahlen eine deutlich wirtschaftlichere
sowie qualitativ hochwertigere Bearbeitung von Gussprodukten und erweitern
das Einsatzspektrum.
Geht es zum Beispiel um die Bearbeitung und
das Oberflächenfinish von Gussteilen für die
Automobilindustrie, sind die Anforderungen
an Qualität, Wirtschaftlichkeit und Durchsatz
extrem hoch. Dies waren auch die Vorgaben
eines süddeutschen Automobilherstellers bei
der Auswahl eines Strahlsystems für das Restentsanden und Oberflächenfinish von Zylinderköpfen an verschiedene Strahlanlagenhersteller. Gefertigt werden die 510 x 320 x 150
mm (L x B x H) großen und 18,8 kg schweren
Werkstücke im Schwerkraft-Kokillenguss.
Die Rösler Oberflächentechnik GmbH entwickelte ein entsprechend den Kundenanforderungen ausgelegtes Anlagenkonzept auf
Basis des Roboblasters – einer für unterschiedliche strahltechnische Bearbeitungsverfahren
vom Entgraten, Entsanden bis zum Verdichtungsstrahlen (Kugelstrahlen) einsetzbaren
Kombination aus Strahlanlage und Sechsachsroboter. Mitentscheidend beim Zuschlag
für dieses System RROB 800/750-4 waren
auch die guten Erfahrungen des Autobauers
mit einem bereits eingesetzten RoboblasterStrahlsystem aus Untermerzbach und die
Einhaltung der vorgegebenen Werkstückdurchsatzmenge.
Innovative shot blasting solutions for foundries
In the foundry industry shot blasting is
a key surface treatment technology for
producing the required surface finishes.
Recent developments in the automation
of shot blast processes have contributed
towards significant improvements in the
cost effectiveness and quality of the surface preparation function, at the same
time they have expanded the range of applications for this technology.
ety of applications: from bur and sand removal
all the way up to shot peening. Key factors in
the customer’s decision for the Rösler RROB
800/750-4 were the excellent performance of
a similar Roboblaster shot blast system from
Rösler running at one of the car manufacturer’s facilities and the supplier’s compliance
with the capacity requirements.
A 16 second shot blast cycle time
The Rösler shot blast system consists of two
machines and one robot alternately loading
parts into the two blast machines. This concept
complies with the ‘redundancy’ requirement,
that is in case one shot blast machine becomes
in-operational, the manufacturing process
does not have to be stopped. The specified
cycle time limit of only 16 seconds was met
with a dual gripper allowing the robot to pick
up two parts at the same time.
The cylinder heads are transported to the
robotic shot blast cell with a roller conveyor
equipped with a cross transfer unit. There the
parts are precisely positioned for pick up by
the robot gripper. In the blast chamber the
duplex gripper places the cylinder heads on
parts-specific work piece fixtures
and, subsequently, moves out
of the blast chamber. After the
blast chamber door has been
closed, the hinged turbine
flaps open to initiate the flow
of blast media, whilst at the
same time the work piece
fixtures with the mounted
cylinder heads start rotatStrahlen im 16-Sekundentakt
ing. This rotational movement ensures a homogeneBei dieser Lösung beschickt ein Roboous and complete coverage
ter abwechselnd zwei Strahlanlagen.
of
the part surface without
Dies ermöglicht die geforderte redunany
‘shadow’ effect.
dante Auslegung des Strahlprozesses
The
blast media consists of
und verhindert, dass es beim Ausfall
stainless
steel shot with sizes
einer Anlage zum Produktionsstillof
0.5
to
0.8 mm. After the
stand kommt. Die vorgegebene, enge
blast
cycle
the turbine flaps
Taktzeit von nur 16 Sekunden pro
are
closed
to
stop the media
Werkstück realisierte der Anlagenbauflow.
The
work
piece fixtures
er mit einem Doppelgreifer, durch den
continue
rotating
until the
der Roboter jeweils zwei Werkstücke
chamber
door
is
completely
gleichzeitig aufnehmen kann.
Das Bearbeitungsspektrum dieser Hochleistungsstrahlanlage mit Einarmroboter
open. This allows the initial
Die Zuführung der Zylinderköpfe reicht vom Entgraten über Oberflächenfinish bis zum Shotpeening schlagempfindlicher Werkstücke unterschiedlicher Dimensionen. / The operating scope of this
removal of residual blast
zur Roboterzelle erfolgt über eine
high performance blasting system ‘Roboblaster’ with one arm robot comprises demedia and core sand from
Rollenbahn mit Seitentransferein- burring, surface finishing as well as shot peening of impact sensitive components
the parts while they are still
heit. Dort werden diese von einem of various dimensions.
© Rösler
For example, when it comes to the quality of
the surface finish and cost efficiency of high
volume production castings for the automotive industry, the technical and cost requirements are extremely challenging. This was also
the case with the specifications for a shot blast
system for the removal of residual core sand
and general blast cleaning of cylinder heads
which a car manufacturer in Southern Germany presented to various shot blast equipment suppliers. The products with dimensions
of 510 x 320 x 150 mm (L x W x H) and a
weight of 18.8 are produced by gravity die
casting technology.
In compliance with the customer specifications the German company Rösler developed
a blast system concept on the basis of the
innovative Roboblaster; the combination
of a shot blast machine with a 6-axis
robot that can be used for a vari-
74
ALUMINIUM · 9/2013
TECHNOLOGY
in the blast chamber.
Each blast machine is equipped with four
high performance turbines, type Hurricane
H42, with a diameter of 420 mm and an installed drive power of 15 kW each. The optimum placement of the turbines with their required tilt angle was determined by the Rösler
engineers using a 3D simulation of the shot
blast process.
To minimise the equipment wear caused by
the high blast intensity, the blast chamber and
work piece fixtures are made from extremely
wear resistant manganese steel. In addition,
the inside of the blast chamber is lined with
easy to replace overlapping 12 mm thick manganese steel plates.
The challenging task of
removing residual blast media
The stringent customer requirements did not
only apply to cycle time and precision of the
automated process but also extended to the
allowable residual blast media/core sand in the
cylinder heads. The specification of only 0.5
grams per part required a highly sophisticated
solution: After the shot blast process the robot
transfers the cylinder heads in pairs of two into
a blast media removal system comparable to a
Ferris wheel. The parts are moving in a precise
orbit while at the same time being rotated in
different, pre-defined directions. In addition, a
vibratory motor mounted to the wheel frame
induces vibrations in the cylinder heads which
help shake out blast media from the difficult to
reach areas in the water channels.
The small sand quantity in the blast media (only residual core sand) did not require a
magnetic separator. It was possible to handle
the media classification with a more economical dual stage air wash separator. This cleaning
system ensures full compliance with the specified residual contamination in the blast media
of less than 0.1 % of the media volume and
media loss of less than 1% during the media
classification process.
When it comes to space requirements, the
Roboblaster could also fully meet the customer’s expectations, including an all-around noise
protection cabin the complete system could be
placed in an area of only 10.4 x 8.6 m. To allow
maintenance work on the shot blast machines
during the 3-shift operation, the work area of
the robot is enclosed with a safety fence. The
complete shot blast system was installed on
the first floor of the customer’s foundry. The
system components were broken down so that
they could easily be transported in the on-site
heavy duty elevator with dimensions of 6 x
4 x 3 m.
■
ALUMINIUM · 9/2013
Ausrichtsystem positionsgenau auf die Übernahme durch den Robotergreifer vorbereitet.
In der Strahlanlage positioniert der Duplexgreifer die Zylinderköpfe an teilespezifisch
gestalteten Werkstückaufnahmen und fährt
wieder aus der Strahlkammer. Nach dem
Schließen der Kammertür geben die TurbinenSchotts den Strahlmittelzufluss frei, gleichzeitig werden die Gussteile über die Werkstückaufnahmen in Rotation versetzt. Diese kontinuierliche Lageveränderung gewährleistet,
dass die Zylinderköpfe allseitig gleichmäßig,
ohne Schatteneffekte gestrahlt werden.
Als Strahlmittel kommt Edelstahl in einer
Korngröße von 0,5 bis 0,8 mm zum Einsatz.
Nach der vorgegebenen Strahlzeit verschließen die Schotts wieder die Turbinen, während
sich die Werkstückaufnahmen bis zum vollständigen Öffnen der Strahlkammer weiter
drehen. Dies bewirkt, dass die Werkstücke
bereits im Strahlraum vorentleert werden.
Ausgestattet ist jede Strahlanlage mit insgesamt vier Hochleistungsturbinen vom Typ
Hurricane H42 mit 420 mm Durchmesser und
einer Antriebsleistung von jeweils 15 kW. Die
optimale Platzierung und erforderlichen Neigungswinkel der Turbinen ermittelte Rösler
in der Konstruktionsphase durch 3D-Simulation des Strahlprozesses.
Um der starken Beanspruchung durch die
hohe Strahlintensität vorzubeugen, sind die
Anlagengehäuse und Werkstückaufnahmen
aus extrem verschleißfestem Manganstahl
ausgeführt. Zusätzlich sind die Arbeitskammern mit 12 mm starken, spaltfrei verlegten
Manganstahlplatten ausgekleidet.
Herausforderung Strahlmittelentleerung
Hohe Anforderungen galt es aber nicht nur
hinsichtlich Taktzeit und Präzision zu erfüllen,
sondern auch beim Restsand-/Strahlmittelgehalt. Die Vorgabe
von lediglich 0,5
Gramm pro Werkstück machte hier
ebenfalls eine sehr
ausgeklügelte
Lösung erforderlich: Nach dem
Strahlen übergibt
der Roboter die
Zylinderköpfe
paarweise in eine
vergleichbar mit
einem Rhönrad
gestaltete Entleereinheit. Die Werkstücke bewegen
sich in einer ex-
akt festgelegten Bahn, wobei sie in definierte
Richtungen gedreht werden. Hierbei werden
über einen Unwuchtmotor am Drehgestell
Anzeige
Vibrationen in das Werkstück geleitet, durch
welche das Strahlmittel auch aus schwer zugänglichen Stellen des Wasserraumes gerüttelt
wird.
Der eher geringe Restsandgehalt machte es
bei dieser Anlage möglich, auf einen Magnetseperator zu verzichten und die Strahlmittelaufbereitung über eine kostengünstigere
Doppelkaskadenwindsichtung zu lösen. Sie
gewährleistet, dass sowohl der geforderte
Restschmutzwert kleiner 0,1 Vol.% im Strahlmittelfluss als auch die Vorgabe hinsichtlich
des Strahlmittelaustrags bei der Aufbereitung
von kleiner 1% eingehalten werden.
Das Roboblaster-Strahlsystem auch hinsichtlich des erforderlichen Platzbedarfs sehr
wirtschaftlich: Es wurde auf einer Fläche von
nur 10,40 x 8,60 Metern untergebracht und
ist komplett in eine Schalldämmkabine eingehaust. Um die Strahlanlagen während des
Dreischichtbetriebs warten zu können, ist der
Arbeitsbereich des Roboters zusätzlich mit
einem Schutzgitter abgegrenzt. Aufgestellt
wurde das Gesamtkonzept im ersten Stock der
Gießerei des Autobauers und war dabei auch
so flexibel, dass es im Lastenfahrstuhl (6 m x 4
m x 3 m) transportiert werden konnte.
■
Engineering,
construction and
revamping
reva
re
vamp
mpin
ing
g of m
melting
elti
el
ting
ng
and holding
g furnaces for
the non-ferro industry
y
75
ANWENDUNG
Aluminiumtube feiert 100 Jahre Erfolgsgeschichte
Der erste Weltkrieg stoppte zunächst den
weiteren Markterfolg der Aluminiumtube,
doch war der Grundstein für den Aufbau der
modernen Tubenindustrie gelegt. Die Entwicklung der massenhaften Produktion der
Aluminiumtube erfolgte schließlich in den
1920er und besonders in den 1930er Jahren
in Deutschland. Bis dahin dienten zur Herstellung der Metalltuben ausschließlich Zinn, Blei
und verzinntes Blei. Zinn war jedoch sehr teuer, kostete Devisen und unterlag ebenso wie
Blei zeitweise der Zwangsbewirtschaftung. Die
Verwendung von Blei für Tuben war zudem
durch das Lebensmittelgesetz beschränkt. So
übertraf bereits 1939 die Produktionsmenge
der Alutuben diejenigen aus Weichmetall.
Der Siegeszug der Aluminiumtube hatte
begonnen und setzte sich auch nach dem zweiten Weltkrieg fort. Auch heute noch stehen
die Tuben aus Aluminium mit ihren Produktionszahlen an der Spitze aller hergestellten
Tuben. Die Mitgliedsfirmen der etma (european tube manufacturers association), die für
über 80 Prozent der gesamten europäischen
Tubenproduktion stehen, meldeten für 2012
ein Rekordergebnis von über zehn Milliarden
produzierten Tuben. Davon waren knapp
über 40 Prozent aus Aluminium, mit jeweils
circa 30 Prozent am Gesamtvolumen teilen
sich Kunststofftuben und Tuben aus Laminat
die restliche Produktionsmenge.
Genau 100 Jahre nach den ersten Anfängen hat die Alutube offensichtlich nichts an
ihrer Attraktivität eingebüßt. Ganz im Gegenteil: Der rasante Fortschritt in der Druck- und
Veredelungstechnologie macht sie heute optisch so interessant und vielseitig wie nie zuvor. Dazu kommen ihre bekannten Vorteile
wie das leichte Gewicht, die einfache Handhabung, ihre exzellenten Hygienestandards, die
hervorragenden Barriereeigenschaften und
ihr optimaler Produktschutz, um nur einige
der wichtigsten Aspekte zu nennen.
Aluminiumtuben werden daher heute vor
allem im Lebensmittelbereich, in der Pharma-
76
zie und in der Kosmetikindustrie eingesetzt.
Und die ausgezeichnete Recyclingfähigkeit
der Alutube macht sie auch 100 Jahre nach
ihrer Erfindung gerade in der heutigen Zeit,
in der Ressourceneffizienz und Nachhaltigkeit
ganz oben auf der Agenda stehen, besonders
aktuell.
■
Aluminium tube celebrates centenary
Eine Erfolgsgeschichte – die Aluminiumtube
Exactly one hundred years ago a new
technical development made the industrial-scale production of aluminium tubes
feasible, and marked the start of a unique
success story. In 1913 Alfons Mall, who
was 28 years old and living in Baden in
Germany at the time, developed and constructed a range of machines for the mass
production of tubes. In the same year,
tests were carried out to manufacture
tubes from aluminium, first in Switzerland and then in Germany.
The First World War then put a temporary
stop to any further market success of the aluminium tube. However, the foundation stone
for the modern tube industry had been laid.
The large-scale production of aluminium tubes
took place in Germany after the war, in the
1920s and particularly in the 1930s. Metal
tubes had previously only been made from
tin, lead or tin-plated lead. However, tin was
very expensive and required foreign currency;
and just like lead, it was subject to controls
for a time. Further, food legislation limited the
use of lead for tubes. By 1939, more tubes
were produced from aluminium than from the
soft metal.
The triumphant advance of the aluminium
tube had begun, and it continued unabated
The aluminium tube – a success story
© etma
Vor 100 Jahren wurden die technischen
Voraussetzungen für die einzigartige
Erfolgsstory der Aluminiumtube geschaffen: 1913 entwickelte und konstruierte
der damals 28-jährige Alfons Mall in
Baden (Deutschland) ein Maschinenprogramm eigens für die Massenproduktion
von Tuben. Nahezu zeitgleich fanden
in der Schweiz und bald darauf auch in
Deutschland erste Versuche statt, Tuben
aus Aluminium herzustellen.
after the Second World War. Production figures for the aluminium tube still top the list
of tubes produced even today. The member
companies of etma, the European tube manufacturers association that represents over 80%
of all tube production in Europe, reported a
record result in 2012, with over ten billion
tubes produced. Of these, slightly more than
40% were alu tubes, with plastic and laminate tubes accounting for the remaining production, each with a share of roughly 30% of
total volume.
As it celebrates its centenary, the aluminium tube has lost none of its attractiveness.
On the contrary: rapid developments in printing and conversion technology have made it
visually more interesting and versatile today
than it has ever been. On top of this there
are the well-known benefits like light weight,
easy handling, its excellent standards of hygiene, outstanding barrier properties and optimal product protection.
Alu tubes are now used primarily in the
food and pharmaceutical sectors and in the
cosmetics industry. And particularly in today’s
world, where resource efficiency and sustainability are right at the top of the agenda, the aluminium tube’s excellent recyclability means it
is still a highly modern form of packaging that
is very much in keeping with the times.
■
ALUMINIUM · 9/2013
APPLICATION
Opel stellt neuen Vollalu-Dreizylinder auf IAA vor
Der deutsche Automobilhersteller Opel
wird auf der Internationalen Automobilausstellung (IAA) in Frankfurt im September seinen neu konstruierten Vollaluminium-Dreizylinder vorstellen. Der
direkteinspritzende Turbobenziner mit
einem Liter Hubraum sei nicht nur umweltfreundlich, sondern zeichne sich auch
durch eine vorbildliche Laufkultur aus,
betont Opel.
Das 85 kW / 115 PS starke Aggregat liefert ein
beachtliches Drehmoment von 166 Nm über
von Verbrauch und Emissionen. Wir wollten
zeigen, dass ein Dreizylinder mindestens
ebenso viel Laufkultur an den Tag legen kann
wie Triebwerke mit vier und mehr Zylindern“,
erklärte Opel-Ingenieur Matthias Alt.
Der Motorblock aus Aluminium-Druckguss
ist nicht nur leicht, seine Konstruktion dämmt
auch die Abstrahlung strukturbedingter Triebwerksgeräusche ein. Die Hochdruck-Einspritzanlage ist vom Zylinderkopf isoliert, um
die Übertragung von Schwingungen zu vermeiden.
Die Integration des Auspuffkrümmers in den
Alu-Zylinderkopf ist ein Beispiel für Präzisionsarbeit: Der Krümmer ist unmittelbar
mit dem agilen, wassergekühlten Turbolader
verschraubt. Diese kompakte Konfiguration
fördert das spontane Ansprechverhalten des
Laders bereits bei niedrigen Drehzahlen.
Das maximale Drehmoment von 166 Nm
liegt ab 1.800 U/min an. Damit hat der neue
Dreizylinder bei gleicher Drehzahl 30 Prozent mehr Durchzugskraft zu bieten als der
1,6-Liter-Motor.
■
Opel presents new all-aluminium 3-cylinder at IAA
© GM Company
The German car manufacturer Opel will
be celebrating a new all-aluminium threecylinder at the Frankfurt International
Motor Show (IAA) in September. The
1.0-litre turbo gasoline engine is not only
climate-friendly, it also represents a new
benchmark for refinement in three-cylinder engines, says Opel.
Der neue 1-Liter-Dreizylinder von Opel
Opel’s all-new 1.0-liter direct injection engine
ein breites Drehzahlband von 1.800 bis 4.700
U/min hinweg. Damit generiert der 1,0-LiterTurbo mehr Durchzugskraft als viele größere
Triebwerke in der gleichen Leistungsklasse.
Gleichzeitig sei der neue Motor ein Fünftel
sparsamer als der aktuelle 1,6-Liter-Saugbenziner von Opel mit gleicher Leistung.
Sein Debüt feiert der Dreizylinder zusammen mit einem ebenfalls neu entwickelten,
manuellen Sechsgang-Getriebe in Leichtbauweise nächstes Jahr im Opel Adam. Mit 37
Kilogramm Trockengewicht ist es rund 30
Prozent leichter als die aktuelle Ausführung.
Der 1.0 SIDI (Spark Ignition Direct Injection), mit zwölf Ventilen ist das erste Mitglied
einer neuen, modular aufgebauten Motorenfamilie von Drei- und Vierzylinder-Benzinern
im Hubraumspektrum bis 1,6 Liter. Schlüsselmerkmale dieser Familie sind modernste
Technologien wie SIDI, variable Ventilsteuerung und der Leichtbau-Motorblock aus Aluminium. „Bei der Entwicklung dieses Motors
erreichten wir weit mehr als die Reduzierung
ALUMINIUM · 9/2013
as well as reduce weight. The high-pressure
fuel rail and injectors are also structurally isolated from the cylinder head to minimise the
transmission of pulsing, while the fuel pump
and fuel line are acoustically treated.
The integration of the exhaust manifold
inside the aluminium cylinder head is another
example of precision engineering. The exhaust manifold is bolted directly to the lowinertia, water-cooled turbocharger. This compact installation contributes to the delivery of
a fast boost charge for strong, low-end power.
Maximum torque of 166 Nm from just 1,800
rpm is almost 30% higher than the 1.6-litre
engine generates at the same rpm.
The 1.0 SIDI Turbo is mated to an all-new,
six-speed manual gearbox specially designed
for medium torque applications. With a dry
weight of only 37 kilograms, it is about 30%
lighter than its current counterpart.
■
Developing 85 kW / 115 hp, this pocket powerhouse also delivers high low-end torque of
166 Nm all the way from 1,800 to 4,700 rpm.
The 1.0 SIDI Turbo (Spark Ignition Direct
Injection) generates more torque throughout
its operating range than equally powerful,
higher displacement engines, while fuel efficiency is improved by 20% compared to
Opel’s current 1.6-liter naturally aspirated
power unit.
To be launched in the ‘Adam’ small car
next year with an all-new six-speed gearbox,
the 12-valve, 1.0 turbo is the first
in a new, modular family of three
and four-cylinder gasoline engines
in the up to 1.6 litres class. Stateof-the-art technologies such as
direct injection, continuously variable valve timing, and a lightweight
aluminium cylinder-block, are key
efficiency enablers.
“In developing this small engine, we not only set out to minimise fuel consumption and CO2
emissions, we also wanted to demonstrate that three cylinders can
be just as refined as four or more,”
says Opel engineer Matthias Alt.
The cylinder block made of Der 1.0 SIDI Turbo ist an ein neu konstruiertes Sechsganghigh pressure die-cast aluminium Schaltgetriebe gekoppelt
is designed to reduce radiated The 1.0 SIDI Turbo is mated to an all-new, six-speed manual
and structure-borne engine noise, gearbox
77
CO M PA N Y N E W S W O R L D W I D E
© Dubal
Aluminium smelting industry
Alcoa starts modernising Massena plant
Alcoa has officially broken ground on work
to upgrade its operations in Massena, New
York, including the planned construction of a
new potline at its Massena East facility. The
project is supported by a USD10m loan from
the North Country Economic Development
Loan Fund, and a power agreement with the
New York Power Authority (NYPA).
New York has committed to supply 478
MW of low-cost electricity to Alcoa’s Massena
complex, a step that led the company to move
forward with its modernisation plans and allowed it to retain 1,000 jobs at the facility.
NYPA, the largest state power organisation in
the USA, and Alcoa have agreed to a hydropower contract until 2045, with an option for
Alcoa to extend the agreement until 2055.
Under the terms of the contract, agreed to
in 2009, Alcoa committed to making capital
investments of at least USD600m, of which
USD42m is represented by the potline expansion.
Alcoa to further cut smelting capacity
Alcoa will close or curtail 164,000 tonnes of
aluminium smelting capacity in the US and
Brazil as part of its review announced in May.
One potline representing 40,000 tonnes at
the Massena East plant in New York will be
permanently closed. In addition, the company
has started to temporarily curtail 124,000
tonnes at its smelters in Brazil. The measures
will be complete by the end of September.
Bob Wilt, president of Alcoa’s Global Primary Products, commented: “Aluminium
prices, including premiums, have fallen to
four-year lows and we continue to operate in
78
an uncertain, volatile market.” To date, Alcoa has announced closures or curtailments
representing 269,000 tonnes of the 460,000
tonnes placed under review in May. This includes the permanent closure of 105,000
tonnes of capacity announced earlier at Alcoa’s
Baie-Comeau smelter in Canada. In addition,
the company is to close its Fusina smelter in
Italy representing 44,000 tonnes that was not
part of the May review.
Once the Massena and Brazil closures and
curtailments are complete, Alcoa will have
646,800 tonnes or 16% of smelting capacity idle. Alcoa’s review of its primary metals
operations is consistent with the company’s
2015 goal of lowering its position on the world
aluminium production cost curve by ten percentage points and the alumina cost curve by
seven percentage points.
the signing of a long-term electricity agreement. New Zealand Aluminium Smelters
Ltd (NZAS), the company that operates the
smelter, signed the deal with Meridian Energy
Ltd after 12 months of negotiations. The previous contract, which came into effect from
1 January 2013, had included price increases
which threatened the future of the smelter
in the face of falling aluminium prices and
the strong New Zealand dollar. The revised
contract sets new reduced pricing from 1
July 2013, though details were not disclosed.
Separately, the NZ Government has provided
a USD30m payment to NZAS on finalisation
of contractual negotiations to secure the medium term future of the smelter, one of New
Zealand’s largest industrial facilities.
Rio Tinto Alcan curtails
aluminium production in Quebec
Rio Tinto Alcan will immediately curtail
50,000 tonnes of production at its Shawinigan
smelter in Quebec and will progressively curtail the remaining 50,000 tonnes of capacity
by the end of November 2013. The company
refers to dated smelter technology and continued weakness in aluminium prices. Located
in Quebec, Canada, the Shawinigan smelter
was commissioned in 1942 and employs 425
people. Rio Tinto Alcan will provide any employees impacted as a result of the curtailment
of production with re-training and job-search
assistance through the company’s employee
assistance programme and through collaboration with regional and provincial partners.
Alcoa to close Fusina aluminium smelter
Alcoa is to permanently close its Fusina primary aluminium smelter in Venice, Italy, removing a further 44,000 tpy from its 4.2m tpy
global smelting system. The plant has been
curtailed since June 2010. The Fusina rolling
mill operates separately from the smelter and
is not affected by the closure. Total restructuring-related charges are expected to be between USD30-35m after-tax of which about
50% is non-cash. In November 2012, Alcoa
curtailed its Portovesme smelter in Italy too.
NZAS signs new electricity
agreement for Tiwai Point smelter
The future of New Zealand’s Tiwai Point aluminium smelter has been secured through
Ormet curtails half its operations
At the end of July, the Public Utilities Commission of Ohio denied the timing of Ormet’s
request for relief from the current power rate
with Ohio Power and affirmed the matter
has been set for formal hearing at the end of
August. Ormet was forced to file for bankruptcy in February due to low metal prices
and exceedingly high power costs. The Ohio
Power industrial rate which establishes the
base rate for Ormet to procure power has
increased from USD39.66/MWh when the
Unique Arrangement was established in 2009
to USD62.83/MWh in June 2013, which is an
increase of some 58%. The Unique Arrangement was created as an incentive to maintain
and create jobs, which Ormet has successfully
ALUMINIUM · 9/2013
CO M PA N Y N E W S W O R L D W I D E
2012, up 1.8% from the year before.
done to date. In 2013 these rate increases will
virtually eliminate the benefits provided by
the Unique Arrangement.
The consequence of this decision is Ormet
must immediately begin the shutdown of half
of its existing operations to conserve cash.
This means three out of six potlines or a capacity of 135,000 tpy will be shut down.
Vendanta restarts alumina refinery
Vedanta Aluminium Ltd has restarted its alumina refinery at Lanjigarh in Odisha, about
seven months after the company had shut
down the plant due to shortage of bauxite.
The company has revived its plant by procuring bauxite from Jharkhand, Chhattisgarh
and Gujarat. The refinery has a nameplate capacity of 1m tpy, but will initially run at 60%
of its capacity.
■
Secondary smelting and recycling
Bosnia’s primary aluminium smelter Aluminij
Mostar has secured a power contract with
Slovenian GEN-I on the supply of 100 MW for
a 5-month period as from 1 August. The power contract offers better conditions than the
previous one with Croatian HEP, especially
when transmission costs are taken into account, says CEO Ivo Bradvica. The new price
scheme, however, was not disclosed. Aluminij’s need of electricity amounts to 225 MW.
The remaining 125 MW will be supplied by
Elektroprivreda HZ Herceg-Bosna. The smelter was under threat of closure due to high
electricity prices paid previously.
© Hydro
Aluminij Mostar secures
power contract until year-end
Alumetal doubles capacity at
secondary aluminium plant
EU Commission approves
merger of Emal and Dubal
The European Commission has approved the
merger of Dubal and Emal into the newly
created joint venture Emirates Global Aluminium. The deal would not raise competition concerns in the EU because of the very
limited overlap between the parties’ activities
and the presence of other competitors, which
are not capacity constrained.
■
Bauxite and
alumina activities
Vale mulls divesting stake in
Brazilian bauxite producer MRN
Miner Vale is considering selling its stake in
Brazilian bauxite producer Mineração Rio
do Norte (MRN). Vale SA is currently MRN’s
main stakeholder with 40% shares, followed
by BHP Billiton (14.8%), Rio Tinto Alcan
(12%) and other stakeholders. Vale’s strategy
is to have a smaller portfolio, focused on its
more profitable divisions. Iron ore remains
Vale’s main business along with coal.
MRN produced 17.1m tonnes of bauxite in
ALUMINIUM · 9/2013
Foundry alloy producer Alumetal has doubled
the capacity of its Nowa Sol facility in western
Poland to 66,000 tpy with the launch of a second production line. Alumetal operates three
production sites in Poland with a total capacity
of 170,000 tpy of aluminium alloy, following
the latest expansion at Nowa Sol. The company expects to produce 120,000 tonnes of
aluminium alloy in 2013 as the new production line is ramped up to full capacity. Its two
other facilities are in Gorzyce, in south-east
Poland, and Kety, in southern Poland.
MRT invests in new
automated die casting cell
UK-based company MRT Castings has commissioned a new advanced die casting cell
that further enhances the high quality of its
die casting facilities. The Colosio PFO 250 die
casting cell’s innovative features include:
• Real-time shot control: by monitoring and
storing process data, the advanced control
system of the new machine affords MRT accurate repetition of all the injection parameters,
pressures, speeds and strokes to ensure consistent high quality casting at all times.
• Fully integrated two-axis automatic die
sprayer – enabling fast, effective and consist-
ent lubrication of even the most complex die
forms.
• Robotic casting extractor with integrated
cooling conveyor – increasing productivity
and improving repeatability.
• A new Ramsell-Naber gas-fired melting
furnace with recuperative burner technology,
thus reducing energy consumption and emissions.
The Colosio PFO 250 delivers a locking
force of 250 tonnes, making it suitable for
aluminium components up to 3.5 kg.
Alupro: That calls for a Carlsberg!
The UK Aluminium Packaging Recycling
Organisation (Alupro) has announced that
Carlsberg UK has become its newest member
and has also joined the funding partners of
the ‘Every Can Counts’ recycling programme.
Carlsberg UK is the first brewer to join Alupro and its membership marks the company’s
commitment to increase the recovery and recycling of its aluminium cans used across its
portfolio of beer and cider brands.
Through its funding partnership of the
Every Can Counts programme, Carlsberg aims
to take the ‘away from home’ recycling message directly to consumers, in particular at outdoor events such as music festivals. Already
this summer Carlsberg UK staff have been
supporting recycling promotions under the
79
CO M PA N Y N E W S W O R L D W I D E
Every Can Counts brand at Latitude Festival
in July and at Leeds Festival in August.
Matt Winterburn, head of Corporate Social
Responsibility (CSR) at Carlsberg UK said:
“Joining Alupro and in particular working
with its Every Can Counts programme, helps
us to engage with our customers, suppliers
and consumers on a variety of CSR initiatives,
specifically on the aluminium recycling message. We aim to demonstrate leadership in
social responsibility and this partnership with
Alupro further underlines our commitment to
being engaged with society.”
Constellium is to sell its
Sabart plant in France
Constellium N.V. is exploring the potential
sale of its plant in Sabart, France. The plant
is a European supplier of hard alloy billets,
and has only limited synergies with Constellium’s core businesses. With 34 employees, the
facility generated about €16m of the €3.6bn
of revenue Constellium generated in 2012.
The company only recently announced that
it is seeking a buyer for its precision castings
operations in Ussel, France.
Befesa sold to Triton
Abengoa has closed the sale of its subsidiary
Befesa to funds advised by Triton, following the approval by competition authorities.
Spain-based Befesa specialises in the integral
management of industrial waste – steel dust
and salt slags recycling – with plants in Europe,
Middle East and South America.
Befesa had signed an agreement in April
with rolling mill company Novelis to manage
the scrap from its new USD250m aluminium
recycling centre in Nachterstedt, Germany.
Befesa is going to build a new €30m 50,000
tpy aluminium recycling plant in Bernburg,
which will come on stream by the first quarter of 2014.
■
Aluminium semis
casting complex dedicated to rolling slab production, where it delivered safety and quality
improvements and increased casting capacity.
The second project replaced a pusher furnace,
dedicated to homogenising and preheating
slabs before rolling. This should decrease energy consumption while increasing throughput
and optimising quality.
Two new similar projects, also involving the
modernisation of an additional casting complex and the replacement of another pusher
furnace, have been launched for start up in
2014.
Noranda to invest USD45m
in aluminium rod mill
Noranda Aluminum will invest USD45m to
expand its operation in New Madrid, Missouri.
The expansion will allow production of redraw rod for electrical infrastructure applications. Tennessee-based Noranda will receive
a package of incentives from the state of Missouri if the company meets job-creation and
investment criteria.
Novelis opens aluminium
rolling operations in Brazil
© Hydro
Novelis Inc. has opened its expanded aluminium rolling facility in Pindamonhangaba,
Brazil, as it looks to meet growing demand
for flat-rolled products in South America. The
USD340m expansion should boost capacity
at the plant by approx. 50% to more than
600,000 tpy of aluminium sheet. The project
also represents Novelis’ biggest investment in
South America in the past decade. The project included installing a third cold-rolling mill
at the Pindamonhangaba complex as well as
Mitsubishi Aluminium to boost
capacity in USA and Thailand
Mitsubishi Aluminium Co. will spend ¥1.7bn
(USD20m) to increase production capacity in
the US and Thailand. The company plans to
spend nearly ¥950m on Thermalex, its subsidiary in Alabama, to install a new press for
processing heat exchanger parts. The factory’s
capacity is expected to rise from its current
capacity of 10,000 tpy to 13,000 tpy by November 2014. The company will also spend
¥790m by August 2014 to boost output at its
Thailand plant by 50% to 7,200 tpy.
Demand for heat exchangers has been
growing as a result of brisk car production in
80
North America and Southeast Asia, with output in the two regions expected to continue
growing at an annual rate of 4-6%.
Constellium invests in plant
modernisation at Neuf-Brisach
Constellium N.V. has finalised modernising its
rolling and recycling facility in Neuf-Brisach,
France. The plant is a major supplier and recycler of rolled aluminium products to the
beverage, food packaging and automotive
markets. Two major projects, representing a
total investment of €23m, upgrade the NeufBrisach facility. The first project modernised a
The Author
The author, Dipl.-Ing. R. P. Pawlek is founder
of TS+C, Technical Info Services and Consulting,
Sierre (Switzerland), a service for the primary
aluminium industry. He is also the publisher
of the standard works Alumina Refineries and
Producers of the World and Primary Aluminium
Smelters and Producers of the World. These
reference works are continually updated, and
contain useful technical and economic information on all alumina refineries and primary
aluminium smelters of the world. They are
available as loose-leaf files and / or CD-ROMs
from Beuth-Verlag GmbH in Berlin.
ALUMINIUM · 9/2013
CO M PA N Y N E W S W O R L D W I D E
On the move
Constellium N. V. appointed Paul Blalock as
head of Investor Relations US. He will be
responsible for managing the company’s communications and relationships with investors,
analysts and shareholders in the USA.
Alcoa promoted Roy Harvey to COO for
the company’s Global Primary Products (GPP)
business, effective immediately. He will focus
on the day-to-day operations of Alcoa’s 22
aluminium smelters and nine alumina refineries worldwide, as well as bauxite assets.
Succeeding Harvey as GPP CFO is Leigh Ann
Fisher, who had been group controller for
GPP.
Aditya Birla Group flagship Hindalco Industries has named Satish Pai the next CEO
of its aluminium business in India.
Alcoa appointed Libby Archell vice
president of Corporate Affairs. Reporting to
Klaus Kleinfeld, Alcoa chairman and CEO,
Ms. Archell will be a member of Alcoa’s
executive council and have responsibility for
communications activities that impact Alcoa’s
reputation, relationships with the media and
employee engagement.
Former Marc Rich & Co. and Glencore
executive Isaac Querub has joined Michael
Armbruester on the board of BlueQuest
Resources. Trading firm BlueQuest Resources
was known as JB Commodities until early July
2013, when ex-Glencore aluminium trader
Josef Bermann ended his association with the
company.
Production of rolled
aluminium in Japan down 5.3%
Japanese production of rolled aluminium
products for the first half of 2013 decreased
by 5.3% from the previous year to 952,406
tonnes. According to Japan Aluminium Association the result for the first half of calendar year decreased for the first time in two
years.
■
Suppliers
tion site in Harbin, in the Chinese province of
Heilongjiang, Northeast Light Alloy now has
an installed production capacity of 85,000 tpy
of aluminium cold strip. The rolling mill features latest equipment, designed to produce
premium-grade strips. Technological features
of the mill include CVC plus, hot edge spraying and DS systems. The up to 1,900-mm-wide
strips are rolled to minimum final gauges of
0.1 mm to be used, among others, as input
material in foil production.
In addition to the rolling mill, SMS Siemag
also supplied the equipment for coil preparation and coil transport as well as the media
supply system.
Potroom insulation measurement
VHE’s enhanced ohmmeter can measure the
electrical resistance between points of different voltage potential. Conventional ohmmeters do not have this capability. Much of
the equipment installed in aluminium smelter
potrooms has significant electrical potential
to earth (or ground). The series connection of
the pot busbar system means that pots frequently have a potential to earth of 1,500 V
dc, and in the most recent systems this can
exceed 2,000 V dc. Alumina dust and metallic
objects can compromise the installed electrical
insulation, and so it is necessary to monitor
insulation performance on a regular basis.
SMS Siemag cold rolling
plant for Nela rolls first strip
The new six-high cold rolling mill at Northeast
Light Alloy Co. Ltd. (Nela) successfully rolled
its first strip at the end of May. At its produc-
Luoyang Wanji grants FAC for
two SMS Siemag rolling mills
Following the smooth and efficient commissioning of two new CVC plus six-high cold
rolling mills, Chinese aluminium producer
Luoyang Wanji Processing C. issued the Final
Acceptance Certificate (FAC) for both mills to
SMS Siemag, Germany.
On cold rolling mill No. 1, the first strip
had already been rolled in 2012. The FAC was
granted before the end of the year, marking
the successful completion of the hot commissioning phase, with the rolling mill becoming an integral part of production operations.
This success was repeated at the end of March
this year, when the FAC was also granted for
cold rolling mill No. 2.
Luoyang Wanji’s new production facilities
in the province of Henan in East China now
boast installed production capacities totalling 260,000 tpy. The commissioning of these
© SMS Siemag
an ingot casting centre and a pusher furnace
for the operation’s hot-rolling mill.
The investment bolsters Novelis’s position
in the beverage can and aluminium packaging markets and should allow the company to
take advantage of expected growth in the automotive sector as well. That’s because Brazil
has set carbon dioxide-emission reduction
targets that should see carmakers looking to
make lighter weight and more fuel-efficient
vehicles.
Pindamonhangaba already has the biggest aluminium recycling centre in South America and
plans to expand further, increasing the use of
aluminium scrap and developing new alloys
that contain more recycled content.
Brazil recycles 98% of all cans sold compared with slightly more than 50% in the US.
The expansion comes as Brazil prepares for
the 2014 World Cup and the 2016 Olympics,
which should see increased beverage can consumption in the country.
Exit area of the new cold rolling mill at Nela
ALUMINIUM · 9/2013
81
PAT E N T E
plants is a milestone in Luoyang Wanji’s entry
into the production of premium aluminium
cold strip in widths of up to 2,150 mm and
final gauges of up to 0.1 mm for a wide range
of applications.
Traditional instruments for this purpose
have been large and cumbersome. VHE’s enhanced ohmmeter is portable, lightweight and
fitted with comfortable shoulder straps, freeing both hands to use the measuring probes.
The instrument has a clear digital display and
Patentblatt Juni 2013
Fortsetzung aus ALUMINIUM 7-8/2013
Aluminiumlegierungsband mit verbesserter
Oberflächenoptik. Hydro Aluminium Deutschland GmbH, 53117 Bonn, DE. (C22C 21/00, GM
20 2012 012 549, AT: 17.07.2012)
Konditionierung eines Lithobands. Hydro Aluminium Rolled Products GmbH, 41515 Grevenbroich, DE. (C23G 1/12, PS 60 2006 029 941,
EP 1896631, WO 2006/122852, AT: 05.04.2006,
EP-AT: 05.04.2006, WO-AT: 05.04.2006)
Schneckenextruder zum kontinuierlichen Extrudieren von Materialien mit hoher Viskosität. Norsk Hydro ASA, Oslo, NO. (B21C 23/21,
EP 2 086 697, WO 2008/063076, AT: 19.11.2007,
EP-AT: 19.11.2007, WO-AT: 19.11.2007)
Flügelrahmen einer Schiebetür oder eines
Schiebefensters, der einen verdeckten Pfosten
umfasst. Norsk Hydro ASA, Oslo, NO. (E06B
3/263, EP 1 953 326, AT: 30.01.2008, EP-AT:
30.01.2008)
Halteprofil für ein Rahmenprofil sowie rahmenintegrierte Absturzsicherung. Gutmann AG,
91781 Weißenburg, DE. (E06B 7/28, GM 20 2013
101 629, AT: 17.04.2013)
Kolben eines Verbrennungsmotors. Honda
Motor Co., Ltd., Tokyo, JP. (F02F 3/02, EP 2 184
477, WO 2009/028128, AT: 20.05.2008, EPAT: 20.05.2008, WO-AT: 20.05.2008)
Kolben für Brennkraftmaschinen. KS Kolbenschmidt GmbH, 74172 Neckarsulm, DE. (F02F
3/16, OS 10 2011 088 066, AT: 09.12.2011)
Gießform eines Kolbens. Mahle International
GmbH, 70376 Stuttgart, DE. (B22D 15/02, OS 10
2011 082 935, AT: 19.09.2011)
Verfahren zur Herstellung eines Zylinders für
einen Zweitaktmotor sowie Gusskern hierfür.
Mahle International GmbH, 70376 Stuttgart, DE.
(F02F 1/22, EPA 2591223, WO 2012/010144,
EP-AT: 05.07.2011, WO-AT: 05.07.2011)
Feueraluminiertes Stahlblech mit hervorragender Beständigkeit gegenüber thermischer
Schwärzung und Verfahren zu seiner Herstel-
82
works just like any other ohmmeter but with
the added ability to measure live conductors.
Batch homogenising plant from
Hertwich commissioned at Dubal
Hertwich Engineering, Austria, has commissioned a batch homogenising facility and a
cooling station at Dubai Aluminium. The homogenising plant is the third of its kind that
lung. Nippon Steel & Sumitomo Metal Corporation, Tokyo 100-8071, JP. (C23C 2/12, EPA
2584059, WO 2011/161833, EP-AT: 21.06.2010,
WO-AT: 21.06.2010)
Aus welligen Metallrohren geformte Metallabschnitte. Novelis, Inc., Toronto, ON M8Z 1J5, CA.
(B65D 19/24, EPA 2585379, WO 2011/160224,
EP-AT: 20.06.2011, WO-AT: 20.06.2011)
Rahmenkonstruktion für Fenster und/oder Türen. Gutmann AG, 91781 Weißenburg, DE. (E06B
3/30, GM 20 2007 005 388, AT: 12.04.2007)
Verkleidungsmaterial. Showa Denko K.K., Tokio, JP. (C22C 21/00, OS 10 2012 223 048, AT:
13.12.2012)
Patentblatt Juli 2013
Al-Cu-Li-Legierungsprodukt, das für eine
Luftfahrzeuganwendung geeignet ist. Aleris
Rolled Products Germany GmbH, 56070 Koblenz, DE. (C22C 21/12, OS 11 2008 002 522,
WO 2009/036953, AT: 16.09.2008, WO-AT:
16.09.2008)
Verfahren und Werkzeug zur zylindrischen
Verformung einer Al-Hülse auf das Kernmaß
des innen liegenden Kunststoffverschlusses,
als Vorbereitung einer diffusionsdichtenden
Pressverbindung innerhalb der beiden Bauteile. Boehringer Ingelheim International GmbH,
55218 Ingelheim, DE. (B21D 39/04, PS 50 2009
003 891, EP 2340134, WO 2010/040791, AT:
08.10.2009, EP-AT: 08.10.2009)
Verfahren zum Erreichen verbesserter epitaxialer Qualität (Oberflächenstruktur und Defektdichte) auf freistehenden (Aluminium, Indium, Gallium) Nitrid ((Al, In, Ga)N)-Substraten
für optoelektronische und elektronische Vorrichtungen. Cree, Inc., Durham, N.C., US. (C30B
23/02, EP 2 290 136, AT: 27.06.2001, EP-AT:
27.06.2001)
Verfahren zum Herstellen eines Verbundprofils.
Constellium Switzerland AG, Zürich, CH. (B60M
1/30, PS 10 2006 009 604, AT: 02.03.2006)
Cordierit-Aluminium-Magnesium-TitanatZusammensetzungen und keramische Artikel damit. Corning Inc., Corning, New York
Hertwich supplied to Dubal. The batch homogenising facility is designed for extra-fast
heating of billets. A reversing air concept and
regulation by flaps accelerates the heating by
an estimated 20%, and achieves improved
temperature uniformity. The plant is fully automated and regulated via measured air and
metal temperatures. The same concept also
provides more efficient cooling in the air-cooling station.
■
14831, US. (C04B 35/478, EPA 2594543, EP-AT:
27.06.2007, WO-AT: 27.06.2007)
Baustoffteil aus Si-reicher, Mg-haltiger Al-Legierung und Herstellungsverfahren dafür. Northeastern University, Shenyang, Liaoning, CN.
(C22C 21/02, EP 2 172 572, WO 2009/003365,
AT: 30.06.2008, EP-AT: 30.06.2008, WO-AT:
30.06.2008)
Verlötbarer Fluidkanal für einen Wärmetauscher aus Aluminium. Behr GmbH & Co. KG,
70469 Stuttgart, DE. (B23K 35/28, EPA 2593269,
WO 2012/007452, EP-AT: 12.07.2011, WO-AT:
12.07.2011)
Hochtemperaturbelastbarer, mit Scandium legierter Al-Werkstoff mit verbesserter Extrudierbarkeit. Airbus Operations GmbH, 21129
Hamburg, DE. (C22C 21/00, EPA 2598664,
WO 2012/013185, EP-AT: 25.07.2011, WO-AT:
25.07.2011)
Kathodenblock für eine Aluminium-Elektrolysezelle und ein Verfahren zu seiner Herstellung. SGL Carbon SE, 65201 Wiesbaden, DE.
(C25C 3/08, EPA 2598675, WO 2012/013772,
EP-AT: 29.07.2011, WO-AT: 29.07.2011)
Verfahren zur Herstellung eines Kathodenblocks für eine Aluminium-Elektrolysezelle und
einen Kathodenblock. SGL Carbon SE, 65201
ALUMINIUM veröffentlicht unter dieser Rubrik regelmäßig einen Überblick über wichtige,
den Werkstoff Aluminium betreffende Patente.
Die ausführlichen Patentblätter und auch
weiterführende Informationen dazu stehen
der Redaktion nicht zur Verfügung. Interessenten können diese beziehen oder einsehen
bei der
Mitteldeutschen Informations-, Patent-,
Online-Service GmbH (mipo),
Julius-Ebeling-Str. 6,
D-06112 Halle an der Saale,
Tel. 0345/29398-0
Fax 0345/29398-40,
www.mipo.de
Die Gesellschaft bietet darüber hinaus weitere
Patent-Dienstleistungen an.
ALUMINIUM · 9/2013
PAT E N T E
Wiesbaden, DE. (C25C 3/08, EPA 2598673 u. EPA
2598674, WO 2012/013767 u. WO 2012/013769,
EP-AT: 29.07.2011, WO-AT: 29.07.2011)
Gerippter Rohrwärmetauscher aus Aluminium.
Carrier Corp., Farmington, CT 06034, US. (F28F
19/00, EPA 2598821, WO 2012/018536, EP-AT:
21.07.2011, WO-AT: 21.07.2011)
Aluminium-Strangpresslegierung. Aleris Aluminum Duffel BVBA, Duffel, BE; Aleris Aluminum
Koblenz GmbH, 56070 Koblenz, DE. (C22C 21/
14, PS 600 43 605, EP 1059362, AT: 07.06.2000,
EP-AT: 07.06.2000)
Heizkörper aus extrudiertem Aluminium. Siemens AG, 80333 München, DE. (F03D 11/00,
EPA 2599999, EP-AT: 02.12.2011, WO-AT:
02.12.2011)
Elektronische Einbruchsicherung für Haustüren,
Wohnungseingangstüren aus Aluminium,
Stahl, Holz und Kunststoff. Nahrson, Wilhelm,
26219 Bösel, DE. (E06B 5/11, GM 20 2013 002
875, AT: 25.03.2013)
Wasserreaktives, Al-basiertes Verbundsmaterial, wasserreaktiver, Al-basierter, thermisch
gespritzter Film, Verfahren für die Herstellung
eines solchen Al-basierten, thermisch gespritzten Films und Bestandteil für eine Filmbildungskammer. ULVAC, Inc., Chigasaki-shi, Kanagawa, JP. (C23C 4/06, WO 2012 026349, AT:
12.08.2011, WO-AT: 12.08.2011)
Al-Si-Gusslegierung und Verfahren zu ihrer
Herstellung. TU Clausthal-Zellerfeld, 38678
Clausthal-Zellerfeld, DE. (C22C 21/02, PS 50
2008 007 369, EP 1978120, AT: 31.03.2008, EPAT: 31.03.2008)
Anordnung zum Kontaktieren eines Aluminium enthaltenden elektrischen Leiters. Nexans,
Paris, FR. (H01R 4/52, PS 50 2008 007 537, EP
1968161, AT: 16.02.2008, EP-AT: 16.02.2008)
Verwendung einer Eisen-Chrom-AluminiumLegierung mit hoher Lebensdauer und geringen Änderungen im Warmwiderstand. Outokumpu VDM GmbH, 58791 Werdohl, DE.
(H05B 3/12, PS 50 2008 007 580, EP 2127472,
WO 2008/092420, AT: 15.01.2008, EP-AT:
15.01.2008, WO-AT: 15.01.2008)
Vorbehandlung für Aluminium und Aluminiumlegierungen. The United States of America as
represented by The Secretary of The Navy, Patuxent River, Md., US. (C23C 22/05, EP 1 585
848, WO 2004/065642, AT: 21.01.2004, EP-AT:
21.01.2004, WO-AT: 21.01.2004)
Verfahren zum Laser-Lichtbogen-Schweißen
von metallischen Werkstücken, die eine Beschichtung aus im Wesentlichen Aluminium
und Silizium enthalten. L'Air Liquide, Société
Anonyme pour l'Etude et l'Exploitation des Procédés Georges Claude, Paris, FR. (B23K 26/14, EP
2 168 710, AT: 22.06.2007, EP-AT: 22.06.2007)
Kolben. Mahle International GmbH, 70376 Stuttgart, DE. (F02F 3/00, OS 10 2012 200 749, AT:
19.01.2012)
ALUMINIUM · 9/2013
Zusammensetzung der Korrosionsschutzbeschichtung für eine Zn-haltige Aluminiumlegierung. United Technologies Corp. (n.d.Ges.d.
Staates Delaware), Hartford, Conn., US. (C23C
22/40, PS 60 2008 016 288, EP 2011899, AT:
24.06.2008, EP-AT: 24.06.2008)
Dichtungsvorrichtung für einen Mittelstoßbereich einer Schieberahmenanordnung sowie
Schieberahmenanordnung mit einer Dichtungsvorrichtung. Alcoa Aluminium Deutschland, Inc.,
58642 Iserlohn, DE. (E06B 7/22, EPA 2599946,
EP-AT: 01.10.2012, WO-AT: 01.10.2012)
Filter zur Gießung von Teilen aus Al-, Mg-, Cuund ähnlichen Legierungen. Saint Jean Industries, Saint Jean d'Ardieres, FR. (C22B 9/02, PS
60 2009 007 347, EP 2274451, WO 2009/122048,
AT: 16.02.2009, EP-AT: 16.02.2009, WO-AT:
16.02.2009)
Verfahren zum Stanznieten von Aluminiumlegierungsblech. Aleris Aluminum Duffel BVBA,
2570 Duffel, BE. (B21J 15/02, EPA 2514537, EPAT: 20.09.2011, WO-AT: 20.09.2011)
Gerillte Anode für einen Elektrolysetank. Rio
Tinto Alcan Intl Ltd., Montreal, CA. (C25C 3/12,
EP 2 459 777, WO 2011/015718, AT: 21.07.
2010, EP-AT: 21.07.2010)
Legierung auf Mg-Al-Basis mit Kornverfeiner.
Helmholtz-Zentrum Geesthacht Zentrum für
Material- und Küstenforschung GmbH, 21502
Geesthacht, DE. (C22C 1/03, EP 2 481 822, AT:
01.02.2011, EP-AT: 01.02.2011)
Sandgießverfahren zur Herstellung von Bauteilen aus Magnesium- oder Aluminiumlegierungen. Rolls-Royce Deutschland Ltd. & Co KG,
15827 Blankenfelde-Mahlow, DE. (B22D 27/08,
OS 10 2010 025 061, AT: 25.06.2010)
Verfahren zur Herstellung eines Formkörpers
aus Aluminiumlegierung und Formkörper aus
Aluminiumlegierung. Showa Denko K.K., Tokio, JP. (C22F 1/043, PS 60 2004 038 235, EP
1716265, WO 2005/059195, AT: 17.12.2004,
EP-AT: 17.12.2004, WO-AT: 17.12.2004)
Rohrmaterial aus hochfester Aluminiumlegierung mit langer Lebensdauer und hoher
Durchhangbeständigkeit. Sapa Heat Transfer
AB, Finspong, SE. (C22C 21/00, EP 1 580 286,
AT: 11.03.2005, EP-AT: 11.03.2005)
Verfahren zur Herstellung eines mit mindestens einem Hohlraum versehenen Leichtmetall-Bauteils. Martinrea Honsel Germany GmbH,
59872 Meschede, DE. (B22D 21/04, OS 10 2012
100 458, AT: 20.01.2012)
Magnesiumlegierung. Cast Centre Pty., Ltd.,
St. Lucia, Queensland, AU. (C22C 23/06, PS 60
2006 030 303, EP 1866452, WO 2006/105594,
AT: 04.04.2006, EP-AT: 04.04.2006, WO-AT:
04.04.2006)
Magnesiumlegierung und Herstellungsverfahren dafür. Kabushiki Kaisha Kobe Seiko
Sho, Kobe-shi, Hyogo, JP. (C22C 23/06, PS 60
2009 007 905, EP 2264200, WO 2009/123084,
AT: 30.03.2009, EP-AT: 30.03.2009, WO-AT:
30.03.2009)
Verfahren zur Herstellung geschmiedeter Bauteile aus einer TiAl-Legierung und entsprechend hergestelltes Bauteil. MTU Aero Engines
GmbH, 80995 München, DE. (C21D 1/00, OS 10
2012 201 082, AT: 25.01.2012)
Kolben für einen Verbrennungsmotor. Mahle
International GmbH, 70376 Stuttgart, DE. (F02F
3/02, OS 10 2011 115 639, AT: 28.09.2011)
Verfahren zum Verbinden von Aluminiumlegierungsblech. Aleris Aluminum Duffel BVBA,
2570 Duffel, BE. (B21J 15/02, EPA 2514538, EPAT: 07.10.2011, WO-AT: 07.10.2011)
AlMgSi-Band für Anwendungen mit hohen
Umformungsanforderungen. Hydro Aluminium Deutschland GmbH, 41515 Grevenbroich,
DE. (C22F 1/05, EP 2 270 249, AT: 30.06.2009,
EP-AT: 30.06.2009)
Kantenversiegelter Spiegel und Verfahren zu
dessen Herstellung. Hydro Aluminium Rolled
Products GmbH, 41515 Grevenbroich, DE. (G02B
5/08, OS 10 2012 100 293, AT: 13.01.2012)
Verfahren zur Verbesserung der Umformbarkeit bei der Herstellung von Bauteilen aus
Leichtmetallband. Hydro Aluminium Deutschland GmbH, 41515 Grevenbroich, DE. (C22F
1/00, PS 196 19 034, AT: 30.04.1996)
Modularer Sonnenkollektor. Hydro Aluminium
Deutschland GmbH, 41515 Grevenbroich, DE.
(F24J 2/20, EP 1 811 245, AT: 15.01.2007, EPAT: 15.01.2007)
Korrosionsbeständiger
Aluminiumverbundwerkstoff für eine Fahrzeugkarosserie. Hydro
Aluminium Rolled Products GmbH, 41515 Grevenbroich, DE. (B23K 20/04, EP 2 302 086, AT:
15.09.2009, EP-AT: 15.09.2009)
Verfahren zur Herstellung eines Kühlkanalkolbens für Brennkraftmaschinen und derart hergestellter Kolben. KS Kolbenschmidt
GmbH, 74142 Neckarsulm, DE. (B21K 1/18, EPA
2595771, WO 2012/010285, EP-AT: 18.07.2011,
WO-AT: 18.07.2011)
Plattenförmiger Wärmeüberträger für eine
mindestens eine Wärmeübertragerpaket aufweisende Kühleinrichtung. Behr GmbH & Co.
KG, 70469 Stuttgart, DE; Mahle Behr Industry
GmbH & Co. KG, 70469 Stuttgart, DE. (F28F
1/32, EPA 2601474, WO 2012/017044, EP-AT:
04.08.2011, WO-AT: 04.08.2011)
Verfahren zum Abtrennen von Kühlschmierstoff aus Lagerschmiermittel. Hydro Aluminium Deutschland GmbH, 41515 Grevenbroich,
DE. (C10M 175/00, OS 10 2012 000 588, AT:
16.01.2012)
Verfahren zur Herstellung von Aluminiumkristallen. Umitomo Metal Mining Co., Ltd., Tokio
105-8716, JP; Tohoku University, Sendai-shi, Miyagi 980-8577, JP. (C30B 29/38, EPA 2594666,
WO 2012/008545, EP-AT: 14.07.2011, WO-AT:
14.07.2011)
■
83
LIEFERVERZEICHNIS
1
Smelting technology
 Auto firing systems
Automatische Feuerungssysteme
Hüttentechnik
1.5
1.6
1.7
1.8
1.9
1.10
1.1 Raw materials
Rohstoffe
1.2 Storage facilities for smelting
Lagermöglichkeiten in der Hütte
1.3 Anode production
Anodenherstellung
1.4 Anode rodding
Anodenschlägerei
1.4.1 Anode baking
Anodenbrennen
1.4.2 Anode clearing
Anodenschlägerei
1.4.3 Fixing of new anodes to the
anodes bars
1.11
1.12
1.13
1.14
1.15
1.16
1.17
Befestigen von neuen Anoden
an der Anodenstange
Casthouse (foundry)
Gießerei
Casting machines
Gießmaschinen
Current supply
Stromversorgung
Electrolysis cell (pot)
Elektrolyseofen
Potroom
Elektrolysehalle
Laboratory
Labor
Emptying the cathode shell
Ofenwannenentleeren
Cathode repair shop
Kathodenreparaturwerkstatt
Second-hand plant
Gebrauchtanlagen
Aluminium alloys
Aluminiumlegierungen
Storage and transport
Lager und Transport
Smelting manufactures
Hüttenerzeugnisse
Protective Clothing
Schutzkleidung
RIEDHAMMER
CARBON BAKING TECHNOLOGY
RIEDHAMMER GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 0, Fax: -5218 231
E-Mail: [email protected]
Internet: www.riedhammer.de
 Hydraulic presses for prebaked
anodes / Hydraulische Pressen zur
Herstellung von Anoden
LAEIS GmbH
Am Scheerleck 7, L-6868 Wecker, Luxembourg
Phone:
+352 27612 0
Fax:
+352 27612 109
E-Mail: [email protected]
Internet: www.laeis-gmbh.com
Contact: Dr. Alfred Kaiser
 Anode Technology &
Mixing Equipment
Buss ChemTech AG, Switzerland
Phone:
+4161 825 64 62
E-Mail:
[email protected]
Internet: www.buss-ct.com
 Mixing Technology for
Anode pastes
1.2 Storage facilities for
smelting
Lagermöglichkeiten i.d. Hütte
FLSmidth MÖLLER GmbH
Haderslebener Straße 7
D-25421 Pinneberg
Telefon: 04101 788-0
Telefax: 04101 788-115
E-Mail: [email protected]
Internet: www.flsmidthmoeller.com
Kontakt: Herr Dipl.-Ing. Timo Letz
Paul Hedfeld GmbH
Hundeicker Str. 20
D-58285 Gevelsberg
Phone: +49 (0) 2332 6371
E-mail: [email protected]
Internet: www.hedfeld.com
 Unloading/Loading equipment
Entlade-/Beladeeinrichtungen
FLSmidth MÖLLER GmbH
www.flsmidthmoeller.com
see Storage facilities for smelting 1.2
Bulk materials Handling from Ship to Cell
ALUMINA AND PET COKE SHIPUNLOADERS
Contact: Andreas Haeuser, [email protected]
Solios Carbone – France
www.fivesgroup.com
 Conveying systems bulk materials
Förderanlagen für Schüttgüter
(Hüttenaluminiumherstellung)
FLSmidth MÖLLER GmbH
Internet: www.flsmidthmoeller.com
see Storage facilities for smelting 1.2
84
1.4 Anode rodding
 Removal of bath residues from
the surface of spent anodes
Entfernen der Badreste von der Oberfläche der verbrauchten Anoden
1.3 Anode production
Anodenherstellung
www.coperion.com
mailto: [email protected]
Buss AG
CH-4133 Pratteln
Phone:
+41 61 825 66 00
E-Mail:
[email protected]
Internet: www.busscorp.com
Anodenanschlägerei
www.alu-web.de
 Bulk materials Handling
from Ship to Cell
Mischtechnologie für Anodenmassen
GLAMA Maschinenbau GmbH
Hornstraße 19
D-45964 Gladbeck
Telefon 02043 / 9738-0
Telefax 02043 / 9738-50
 Rodding shop
Storvik AS
Industriveien 13
6600 SUNNDALSØRA/NORWAY
Tel.: +47 71 69 95 00 | Fax: +47 71 69 95 55
www.storvik.no | [email protected]
www.brochot.fr
ALUMINIUM · 9/2013
SUPPLIERS DIRECTORY
1.4.1 Anode baking
Anodenbrennen
 Open top and closed
type baking furnaces
Offene und geschlossene Ringöfen
Stopinc AG
Bösch 83 a
CH-6331 Hünenberg
Tel. +41/41-785 75 00
Fax +41/41-785 75 01
E-Mail: [email protected]
Internet: www.stopinc.ch
 Degassing, filtration and
grain refinement
RIEDHAMMER
Entgasung, Filtern, Kornfeinung
CARBON BAKING TECHNOLOGY
RIEDHAMMER GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 0, Fax: -5218 231
E-Mail: [email protected]
Internet: www.riedhammer.de
www.alu-web.de
1.5 Casthouse (foundry)
Gießerei
Drache Umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
Gautschi
Engineering GmbH
see Casting equipment 3.1
MOBILE
EQUIPMENT
Phone: +31.315.683941
[email protected] · www.hencon.com
Solios Thermal UK
www.fivesgroup.com
 Metal treatment in the
holding furnace
Metallbehandlung in Halteöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
 Dross skimming of liquid metal
 Transfer to the casting furnace
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
Drache Umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
Abkrätzen des Flüssigmetalls
Furnaces
casting machines
transport crucibles
[email protected]
www.bartz-maschinenbau.de
Sistem Teknik Endüstryel Firinlar LTD. STI.
TOSB – TAYSAD OSB 1.Cad. 14.Sok. No.: 3
Gebze, Kocaeli / Turkey
Tel.: +90 262 658 22 26
Fax: +90 262 658 22 38
E-Mail: [email protected]
Internet: www.sistemteknik.com
 Furnace charging with
molten metal
Ofenbeschickung mit Flüssigmetall
Überführung in Gießofen
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
Gautschi
Engineering GmbH
see Casting equipment 3.1
 Ingot Casting Line
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
Bartz GmbH
see Casthous (foundry) 1.5
 Transport of liquid metal
to the casthouse
Transport v. Flüssigmetall in Gießereien
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstraße 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
E-Mail: [email protected]
Internet: www.hertwich.com
INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH
Konstantinstraße 1a
D 41238 Mönchengladbach
Telefon +49 (02166) 987990
Telefax +49 (02166) 987996
E-Mail: [email protected]
Internet: www.inotherm-gmbh.de
Bartz GmbH
www.brochot.fr
www.alu-web.de
 Melting/holding/casting furnaces
Schmelz-/Halte- und Gießöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
see Casthous (foundry) 1.5
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
 Treatment of casthouse
off gases
Behandlung der Gießereiabgase
Gautschi
Engineering GmbH
see Casting equipment 3.1
1.6 Casting machines
Gießmaschinen
see Equipment and accessories 3.1
Hampshire House, High Street, Kingswinford,
West Midlands DY6 8AW, UK
Tel.: +44 (0) 1384 279132
Fax: +44 (0) 1384 291211
E-Mail: [email protected]
www.mechatherm.com
ALUMINIUM · 9/2013
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
Avenida Cervantes Nº6
48970 – Basauri – Bizkaia – Spain
Tel: +34 944 409 420
E-mail: [email protected]
Internet: www.insertec.biz
GAPCast TM: the Swiss casting solution
see Casting machines and equipment 4.7
www.mechatherm.com
see Smelting technology 1.5
85
LIEFERVERZEICHNIS
 Pig casting machines (sow casters)
1.9 Potroom
Masselgießmaschine (Sowcaster)
Bartz GmbH
see Casthous (foundry) 1.5
Gautschi
Engineering GmbH
see Casting equipment 3.1
 Rolling and extrusion ingot
and T-bars
Elektrolysehalle
[email protected]
 Heat treatment of extrusion
ingot (homogenisation)
Formatebehandlung (homogenisieren)
Gautschi
Engineering GmbH
see Casting equipment 3.1
Formatgießerei (Walzbarren oder
Pressbolzen oder T-Barren)
Gautschi
Engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
 Horizontal continuous casting
Horizontales Stranggießen
Gautschi
Engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
see Casthouse (foundry) 1.5
Phone: +31.315.683941
[email protected] · www.hencon.com
T.T. Tomorrow Technology S.p.A.
Via dell’Artigianato 18
Due Carrare, Padova 35020, Italy
Telefon +39 049 912 8800
Telefax +39 049 912 8888
E-Mail: [email protected]
Contact: Giovanni Magarotto
 Anode changing machine
Anodenwechselmaschine
 Vertical semi-continuous DC
casting / Vertikales Stranggießen
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
Gautschi
Engineering GmbH
see Casting equipment 3.1
 Anode transport equipment
Anoden Transporteinrichtungen
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
Wagstaff, Inc.
3910 N. Flora Rd.
Spokane, WA 99216 USA
+1 509 922 1404 phone
+1 509 924 0241 fax
E-Mail: [email protected]
Internet: www.wagstaff.com
1.8 Electrolysis cell (pot)
HERTWICH ENGINEERING GmbH
MOBILE
EQUIPMENT
Elektrolyseofen
 Bulk materials Handling
from Ship to Cell
Bulk materials Handling from Ship to Cell
 Crustbreakers / Krustenbrecher
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
 Dry absorption units for
electrolysis exhaust gases
Trockenabsorptionsanlage für
Elektrolyseofenabgase
Solios Environnement
www.fivesgroup.com
 Scales / Waagen
Gautschi
Engineering GmbH
see Casting equipment 3.1
www.coperion.com
mailto: [email protected]
 Calcium silicate boards
Calciumsilikatplatten
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
 Sawing / Sägen
Gautschi
Engineering GmbH
see Casting equipment 3.1
Promat GmbH High Performance Insulation
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
[email protected], www.promat.de
 Exhaust gas treatment
Solios Environnement
www.fivesgroup.com
Beschickungseinrichtungen
für Elektrolysezellen
see Casthouse (foundry) 1.5
86
www.brochot.fr
 Tapping vehicles/Schöpffahrzeuge
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
Abgasbehandlung
 Pot feeding systems
HERTWICH ENGINEERING GmbH
 Pot ramming Machine
FLSmidth MÖLLER GmbH
www.flsmidthmoeller.com
see Storage facilities for smelting 1.2
1.12 Cathode repair shop
KathodenreparaturWerkstatt
 Cathode Sealing Bench
Eingießen von Kathodenbarren
Sermas Industrie
[email protected]
see Smelting technology 1.6
ALUMINIUM · 9/2013
SUPPLIERS DIRECTORY
1.14 Aluminium Alloys
2.2 Extrusion equipment
Aluminiumlegierungen
Strangpresseinrichtungen
see Coil transport systems 3.4
RHEINFELDEN ALLOYS GmbH & Co. KG
A member of ALUMINIUM RHEINFELDEN Group
Postfach 1703, 79607 Rheinfelden
Tel.: +49 7623 93-490
Fax: +49 7623 93-546
E-Mail: [email protected]
Internet: www.rheinfelden-alloys.eu
1.15 Storage and transport
SMS Siemag AG
www.mechatherm.com
see Smelting technology 1.5
1.17 Protective Clothing
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
see Rolling mill technology 3.0
Schutzkleidung
Lager und Transport
www.brochot.fr
2
www.alu-web.de
www.charnaud.co.za
www.charnaud.eu
+27 (0)11794 6040
+44 (0)1133 507651
see Extrusion Equipment 2.2
Strangpressen
2.1 Extrusion billet preparation
Pressbolzenbereitstellung
extrutec GmbH
Fritz-Reichle Ring 2
D-78315 Radolfzell
Tel. +49 7732 939 1390
Fax +49 7732 939 1399
E-Mail: [email protected]
Internet: www.extrutec-gmbh.de
mfw-maschinenbau.com
• Log/Bolzenlager Handling
• Bolzensäge, Bolzenfügen
ALUMINIUM · 9/2013
Pressensteuersysteme
Oilgear Towler GmbH
Extrusion
2.1 Extrusion billet preparation
Pressbolzenbereitstellung
2.1.1 Extrusion billet production
Pressbolzenherstellung
2.2 Extrusion equipment
Strangpresseinrichtungen
2.3 Section handling
Profilhandling
2.4 Heat treatment
Wärmebehandlung
 Press control systems
2.5 Measurement and control
equipment
Mess- und Regeleinrichtungen
2.6 Die preparation and care
Werkzeugbereitstellung
und -pflege
2.7 Second-hand extrusion plant
Gebrauchte Strangpressanlagen
2.8 Consultancy, expert opinion
Beratung, Gutachten
2.9 Surface finishing of sections
Oberflächenveredlung
von Profilen
2.10 Machining of sections
Profilbearbeitung
2.11 Equipment and accessories
Ausrüstungen und Hilfsmittel
2.12 Services
Dienstleistungen
 Billet heating furnaces
Öfen zur Bolzenerwärmung
see Casthouse (foundry) 1.5
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: [email protected]
 Heating and control
equipment for intelligent
billet containers
Heizungs- und Kontrollausrüstung
für intelligente Blockaufnehmer
MARX GmbH & Co. KG
www.marx-gmbh.de
see Melt operations 4.13
2.3 Section handling
Profilhandling
CTI Systems S.A.
Z.I. Eselborn-Lentzweiler
12, op der Sang | L- 9779 Lentzweiler
Tel. +352 2685 2000 | Fax +352 2685 3000
[email protected] | www.ctisystems.com
H+H HERRMANN + HIEBER GMBH
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 711 93467-0, Fax +49 711 34609-11
E-Mail: [email protected]
Internet: www.herrmannhieber.de
Vollert Anlagenbau GmbH
Stadtseestraße 12, D-74189 Weinsberg
Tel. +49 7134 52 220 l Fax +49 7134 52 222
E-Mail [email protected]
Internet www.vollert.de
87
LIEFERVERZEICHNIS
 Packaging equipment
Verpackungseinrichtungen
 Section transport equipment
Profiltransporteinrichtungen
2.4 Heat treatment
Wärmebehandlung
see Coil transport systems 3.4
mfw-maschinenbau.com
• Automatik Verpackung
• Packtische, Profilpaketheber
• Spacerhandling und Konzepte
see Coil transport systems 3.4
see Section handling 2.3
 Section saws
Profilsägen
mfw-maschinenbau.com
• Kurzlängensäge automatisiert
Nijverheidsweg 3
NL-7071 CH Ulft Netherlands
Tel.: +31 315 641352
Fax: +31 315 641852
E-Mail: [email protected]
Internet: www.unifour.nl
Sales Contact: Paul Overmans
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
BSN Thermprozesstechnik GmbH
Kammerbruchstraße 64
D-52152 Simmerath
Tel. 02473-9277-0 · Fax: 02473-9277-111
[email protected] · www.bsn-therm.de
Ofenanlagen zum Wärmebehandeln von Aluminiumlegierungen, Buntmetallen und Stählen
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
Avenida Cervantes Nº6
48970 – Basauri – Bizkaia – Spain
Tel: +34 944 409 420
E-mail: [email protected]
Internet: www.insertec.biz
see Equipment and accessories 3.1
 Stackers / Destackers
Stapler / Entstapler
 Section store equipment
www.mechatherm.com
see Smelting technology 1.5
Profil-Lagereinrichtungen
www.ctisystems.com
see Section handling 2.3
mfw-maschinenbau.com
• 7 und 14 m De- u. Stacker
• Kombianlagen
 Transport equipment for
extruded sections
www.alu-web.de
KASTO Maschinenbau GmbH & Co. KG
Industriestr. 14, D-77855 Achern
Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300
[email protected] / www.kasto.de
Hersteller von Band- und Kreissägemaschinen
sowie Langgut- und Blechlagersystemen
see Coil transport systems 3.4
see Section handling 2.3
88
Transporteinrichtungen
für Profilabschnitte
www.ctisystems.com
see Section handling 2.3
SECO/WARWICK EUROPE S.A.
ul. Šwierczewskiego 76
66-200 Šwiebodzin, POLAND
Tel: +48 68 38 19 800
E-mail: [email protected]
Internet: www.secowarwick.com
Could not find your „keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: [email protected]
 Heat treatment furnaces
Wärmebehandlungsöfen
INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH
see Casthouse (foundry) 1.5
mfw-maschinenbau.com
• Skip Handling, Spacer
• Kettenförderer
see Section handling 2.3
ERNST REINHARDT GMBH
Güterbahnhofstrasse 1
D-78048 Villingen-Schwenningen
Tel. +49 (0) 7721 8441-0, Fax -44
E-Mail: [email protected]
Internet: www.ernst-reinhardt.com
ALUMINIUM · 9/2013
SUPPLIERS DIRECTORY
 Homogenising furnaces
Homogenisieröfen
2.10 Machining of sections
Profilbearbeitung
 Billet saw
see Heat treatment furnaces 2.4
Bolzensägen
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
Sermas Industrie
[email protected]
see Smelting technology 1.6
see Casthouse (foundry) 1.5
www.alu-web.de
2.11 Equipment and
accessories
Ausrüstungen und
Hilfsmittel
Nijverheidsweg 3
NL-7071 CH Ulft Netherlands
Tel.: +31 315 641352
Fax: +31 315 641852
E-Mail: [email protected]
Internet: www.unifour.nl
Sales Contact: Paul Overmans
 Ageing furnace for extrusions
see Casthouse (foundry) 1.5
Auslagerungsöfen für
Strangpressprofile
2.6 Die preparation and care
Werkzeugbereitstellung
und -pflege
 Die heating furnaces
Werkzeuganwärmöfen
see Extrusion billet preparation 2.1
3
Rolling mill technology
Walzwerktechnik
see Extrusion billet preparation 2.1
schwartz GmbH
see Heat treatment 2.4
Nijverheidsweg 3
NL-7071 CH Ulft Netherlands
Tel.: +31 315 641352
Fax: +31 315 641852
E-Mail: [email protected]
Internet: www.unifour.nl
Sales Contact: Paul Overmans
Hier könnte Ihr
Bezugsquellen-Eintrag stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
2.9 Surface finishing
of sections
Oberflächenveredlung
von Profilen
Could not find your „keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: [email protected]
3.1 Casting equipment
Gießanlagen
3.2 Rolling bar machining
Walzbarrenbearbeitung
3.3 Rolling bar furnaces
Walzbarrenvorbereitung
3.4 Hot rolling equipment
Warmwalzanlagen
3.5 Strip casting units
and accessories
Bandgießanlagen
und Zubehör
3.6 Cold rolling equipment
Kaltwalzanlagen
3.7 Thin strip / foil rolling plant
Feinband-/Folienwalzwerke
3.8 Auxiliary equipment
Nebeneinrichtungen
3.9 Adjustment devices
Adjustageeinrichtungen
3.10 Process technology /
Automation technology
Prozesstechnik /
Automatisierungstechnik
3.11 Coolant / lubricant preparation
Kühl-/Schmiermittel-Aufbereitung
3.12 Air extraction systems
Abluftsysteme
3.13 Fire extinguishing units
Feuerlöschanlagen
3.14 Storage and dispatch
Lagerung und Versand
3.15 Second-hand rolling equipment
Gebrauchtanlagen
3.16 Coil storage systems
Coil storage systems
3.17 Strip Processing Lines
Bandprozesslinien
3.18 Productions Management Sytems
Produktions Management Systeme
3.0 Rolling mill technology
Walzwerktechnik
Siemens plc, Metals Technologies
see Cold rolling units / complete plants 3.6
mfw-maschinenbau.com
• Strahlanlagen
ALUMINIUM · 9/2013
www.alu-web.de
Sheffield Business Park, Europa Link
Sheffield S9 1XU
Phone: +44 1709 726500
Fax:+44 1142 611719
[email protected]
89
LIEFERVERZEICHNIS
 Melting and holding furnaces
Schmelz- und Warmhalteöfen
Bartz GmbH
SMS Siemag Aktiengesellschaft
Eduard-Schloemann-Straße 4
40237 Düsseldorf, Germany
Telefon: +49 (0) 211 881-0
Telefax: +49 (0) 211 881-4902
E-Mail: [email protected]
Internet: www.sms-siemag.com
Geschäftsbereiche:
Warmflach- und Kaltwalzwerke
Wiesenstraße 30
57271 Hilchenbach-Dahlbruch, Germany
Telefon: +49 (0) 2733 29-0
Telefax: +49 (0) 2733 29-2852
Bandanlagen
Walder Straße 51-53
40724 Hilden, Germany
Telefon: +49 (0) 211 881-5100
Telefax: +49 (0) 211 881-5200
Elektrik + Automation
Ivo-Beucker-Straße 43
40237 Düsseldorf, Germany
Telefon: +49 (0) 211 881-5895
Telefax: +49 (0) 211 881-775895
Graf-Recke-Straße 82
40239 Düsseldorf, Germany
Telefon: +49 (0) 211 881-0
Telefax: +49 (0) 211 881-4902
Ein Eintrag (s/w) in
diesem Format kostet
pro Ausgabe + Stichwort
110,00 € + MwSt.
Weitere Informationen unter
Tel. +49 (0) 821 / 31 98 80 - 34
 Annealing furnaces
Glühöfen
see Casthous (foundry) 1.5
Gautschi Engineering GmbH
Konstanzer Straße 37
CH 8274 Tägerwilen
Telefon +41 71 666 66 66
Telefax +41 71 666 66 77
E-Mail: [email protected]
Internet: www.gautschi.cc
Kontakt: Sales Departement
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
see Heat treatment 2.4
EBNER Industrieofenbau Ges.m.b.H.
Ebner-Platz 1, 4060 Leonding/Austria
Tel. +43 / 732 / 6868-0
E-Mail: [email protected]
Internet: www.ebner.cc
Gautschi
Engineering GmbH
see Casting equipment 3.1
see Equipment and accessories 3.1
schwartz GmbH
LOI Thermprocess GmbH
Am Lichtbogen 29
D-45141 Essen
Germany
Telefon +49 (0) 201 / 18 91-1
Telefax +49 (0) 201 / 18 91-321
E-Mail: [email protected]
Internet: www.loi-italimpianti.com
Solios Thermal UK
www.fivesgroup.com
 Melt purification units
Schmelzereinigungsanlagen
Gautschi
Engineering GmbH
see Casting equipment 3.1
see Heat treatment 2.4
Solios Thermal UK
www.fivesgroup.com
www.alu-web.de
 Bar heating furnaces
Barrenanwärmanlagen
EBNER Industrieofenbau Ges.m.b.H.
see Annealing furnaces 3.3
Gautschi
Engineering GmbH
see Casting equipment 3.1
 Metal filters / Metallfilter
3.1 Casting equipment
Gießanlagen
www.mechatherm.com
see Smelting technology 1.5
 Electromagnetic Stirrer
Elektromagnetische Rührer
Solios Thermal UK
www.fivesgroup.com
 Filling level indicators and controls
Füllstandsanzeiger und -regler
Gautschi
Engineering GmbH
see Casting equipment 3.1
Gautschi
Engineering GmbH
see Casting equipment 3.1
3.2 Rolling bar machining
90
Gautschi
Engineering GmbH
see Casting equipment 3.1
 Plate saw
Plattensägen
Sermas Industrie
[email protected]
see Smelting technology 1.6
HERTWICH ENGINEERING GmbH
 Slab saw
schwartz GmbH
Sermas Industrie
[email protected]
see Smelting technology 1.6
Solios Thermal UK
www.fivesgroup.com
see Casthouse (foundry) 1.5
see Heat treatment 2.4
Barrensägen
Walzbarrenvorbereitung
see Casting machines 1.6
Homogenisieröfen
Walzenbarrenbearbeitung
3.3 Rolling bar furnaces
Wagstaff, Inc.
 Homogenising furnaces
BSN Thermprozesstechnik GmbH
see Heat Treatment 2.4
 Roller tracks
Rollengänge
Gautschi
Engineering GmbH
see Casting equipment 3.1
ALUMINIUM · 9/2013
SUPPLIERS DIRECTORY
3.4 Hot rolling equipment
Warmwalzanlagen
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
see Cold rolling units / complete plants 3.6
 Rolling mill modernisation
Walzwerksmodernisierung
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: [email protected]
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
3.6 Cold rolling equipment
Kaltwalzanlagen
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
ANDRITZ Sundwig GmbH
www.siemens.vai.com
see Rolling mill technology 3.0
 Coil transport systems
www.siemens.vai.com
see Rolling mill technology 3.0
SMS Siemag AG
see Rolling mill technology 3.0
Stephanopeler Str. 22, D-58675 Hemer
Telefon: +49 (0) 2372 54-0, Fax -200
E-mail: [email protected]
Internet: www.andritz.com
BSN Thermprozesstechnik GmbH
see Heat Treatment 2.4
Bundtransportsysteme
www.ctisystems.com
see Section handling 2.3
SMS LOGISTIKSYSTEME GMBH
Obere Industriestraße 8
D-57250 Netphen
Telefon: +49 2738 21-0
Telefax: +49 2738 21-1002
E-Mail: [email protected]
www.sms-logistiksysteme.com
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: [email protected]
 Spools / Haspel
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
ALUMINIUM · 9/2013
schwartz GmbH
see Heat treatment 2.4
www.alu-web.de
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: [email protected]
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
Hier könnte Ihr
Bezugsquellen-Eintrag
Gautschi
Engineering GmbH
see Casting equipment 3.1
see Equipment and accessories 3.1
see Section handling 2.3
see Rolling mill technology 3.0
Bundglühöfen
see Rolling mill technology 3.0
Warmwalzanlagen/Komplettanlagen
SMS Siemag AG
 Coil annealing furnaces
SMS Siemag AG
 Hot rolling units /
complete plants
 Drive systems / Antriebe
www.siemens.vai.com
see Rolling mill technology 3.0
 Coil transport systems
Bundtransportsysteme
www.ctisystems.com
see Section handling 2.3
www.siemens.vai.com
see Rolling mill technology 3.0
SMS Siemag AG
see Rolling mill technology 3.0
 Surface finishing
of sheets and coils
H+H HERRMANN + HIEBER GMBH
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 711 93467-0, Fax +49 711 34609-11
E-Mail: [email protected]
Internet: www.herrmannhieber.de
Oberflächenveredeling
von Blechen und Coils
DEMIS Wide Belt Processing Systems
see Process techn./Automation Techn. 3.10
see Coil transport systems 3.4
91
LIEFERVERZEICHNIS
 Rolling mill modernization
Walzwerkmodernisierung
Feinband-/Folienwalzwerke
see Section handling 2.3
 Cold rolling units /
complete plants
Kaltwalzanlagen/Komplettanlagen
3.7 Thin strip /
foil rolling plant
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
see Cold rolling units / complete plants 3.6
see Cold rolling units / complete plants 3.6
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: [email protected]
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: [email protected]
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
 Coil annealing furnaces
Bundglühöfen
 Slitting lines-CTL
Längs- und Querteilanlagen
www.siemens.vai.com
see Rolling mill technology 3.0
www.siemens.vai.com
see Rolling mill technology 3.0
Gautschi
Engineering GmbH
see Casting equipment 3.1
see Cold rolling units / complete plants 3.6
SMS Siemag AG
see Rolling mill technology 3.0
Could not find your
 Drive systems / Antriebe
„keywords“?
SMS Siemag AG
Please ask for our complete
see Rolling mill technology 3.0
„Supply sources for the
aluminium industry“.
 Heating furnaces / Anwärmöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
 Process optimisation systems
Prozessoptimierungssysteme
Gautschi
Engineering GmbH
see Casting equipment 3.1
 Process simulation
Prozesssimulation
Gautschi
Engineering GmbH
see Casting equipment 3.1
SMS Siemag AG
see Rolling mill technology 3.0
E-Mail: [email protected]
 Strip shears/Bandscheren
Walzenwechseleinrichtungen
SMS Siemag AG
see Rolling mill technology 3.0
92
schwartz GmbH
see Cold colling equipment 3.6
 Heating furnaces
Anwärmöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
INOTHERM INDUSTRIEOFENUND WÄRMETECHNIK GMBH
see Casthouse (foundry) 1.5
see Cold rolling units / complete plants 3.6
SMS Siemag AG
see Rolling mill technology 3.0
 Surface finishing
of sheets and coils
Oberflächenveredeling
von Blechen und Coils
DEMIS Wide Belt Processing Systems
see Process techn./Automation Techn. 3.10
 Trimming equipment
Besäumeinrichtungen
 Roll exchange equipment
see Equipment and accessories 3.1
see Cold rolling units / complete plants 3.6
SMS Siemag AG
see Rolling mill technology 3.0
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
see Heat treatment 2.4
schwartz GmbH
see Heat treatment 2.4
 Thin strip / foil rolling mills /
complete plant
Feinband- / Folienwalzwerke /
Komplettanlagen
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: [email protected]
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
ALUMINIUM · 9/2013
SUPPLIERS DIRECTORY
SMS Siemag AG
 Surface finishing
of sheets and coils
see Rolling mill technology 3.0
Hier könnte Ihr
Bezugsquellen-Eintrag stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
 Rolling mill modernization
Walzwerkmodernisierung
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: [email protected]
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
3.10 Process technology /
Automation technology
Prozesstechnik /
Automatisierungstechnik
 Process control technology
Prozessleittechnik
SMS Siemag AG
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
SMS Siemag AG
see Rolling mill technology 3.0
 Strip thickness measurement
and control equipment
see Casting machines 1.6
 Strip flatness measurement
and control equipment
Bandplanheitsmess- und
-regeleinrichtungen
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: [email protected]
Internet: www.abb.com/pressductor
ALUMINIUM · 9/2013
Wide Belt Processing Systems
SDV-Santioli AG
Industriestrasse 10 | CH-8157 Dielsdorf | Switzerland
Tel. +41 44 854 0908 | [email protected] | www.demis.ch
 Roll Force Measurement equipment
Walzkraftmesseinrichtungen
Banddickenmess- und
-regeleinrichtungen
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: [email protected]
Internet: www.abb.com/pressductor
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: [email protected]
Internet: www.abb.com/pressductor
 Strip Width & Position
Measurement equipment
Bandbreiten- und
Bandlaufmesseinrichtungen
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
SMS Siemag AG
see Rolling mill technology 3.0
 Strip Tension
Measurement equipment
Bandzugmesseinrichtungen
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: [email protected]
Internet: www.abb.com/pressductor
3.11 Coolant / lubricant
preparation
Kühl-/SchmiermittelAufbereitung
see Rolling mill technology 3.0
Wagstaff, Inc.
Oberflächenveredeling
von Blechen und Coils
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: [email protected]
Internet: www.abb.com/pressductor
see Cold rolling units / complete plants 3.6
 Rolling oil recovery and
treatment units
Walzöl-Wiederaufbereitungsanlagen
SMS Siemag AG
see Rolling mill technology 3.0
Ein Eintrag (s/w) in
diesem Format kostet
pro Ausgabe + Stichwort
 Filter for rolling oils and emulsions
Filter für Walzöle und Emulsionen
110,00 € + MwSt.
Weitere Informationen unter
Tel. +49 (0) 821 / 31 98 80 - 34
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
93
LIEFERVERZEICHNIS
3.16 Coil storage systems
 Coil & Colour Coating Lines
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
www.ctisystems.com
see Section handling 2.3
Bronx International Pty Ltd
Email: [email protected]
Internet: www.bronxintl.com
SMS Siemag AG
H+H HERRMANN + HIEBER GMBH
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 711 93467-0, Fax +49 711 34609-11
E-Mail: [email protected]
Internet: www.herrmannhieber.de
 Rolling oil rectification units
Walzölrektifikationsanlagen
see Rolling mill technology 3.0
Bundlagersysteme
„keywords“?
our complete
„Supply sources for the
www.bwg-online.com
see Strip Processing Lines 3.17
SMS Siemag AG
see Rolling mill technology 3.0
Could not find your
Please ask for
Bandlackierlinien
 Lithographic Sheet Lines
see Coil transport systems 3.4
SMS Siemag AG
see Rolling mill technology 3.0
Lithografielinien
www.bwg-online.com
see Strip Processing Lines 3.17
aluminium industry“.
see Cold rolling units / complete plants 3.6
E-Mail:
[email protected]
see Section handling 2.3
3.17 Strip Processing Lines
Streckrichtanlagen
Bandprozesslinien
www.bwg-online.com
see Strip Processing Lines 3.17
3.12 Air extraction systems
Abluft-Systeme
 Stretch Levelling Lines
see Cold rolling equipment 3.6
 Strip Annealing Lines
Bandglühlinien
see Cold rolling units / complete plants 3.6
 Exhaust air purification
systems (active)
Abluft-Reinigungssysteme (aktiv)
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, [email protected]
Internet: www.achenbach.de
SMS Siemag AG
see Rolling mill technology 3.0
BWG Bergwerk- und WalzwerkMaschinenbau GmbH
Mercatorstraße 74 – 78
D-47051 Duisburg
Tel.: +49 (0) 203-9929-0
Fax: +49 (0) 203-9929-400
E-Mail: [email protected]
Internet: www.bwg-online.com
REDEX
Zone Industrielle
F-45210 Ferrieres
Telefon +33 (2) 38 94 42 00
E-mail: [email protected]
Internet: www.tension-leveling.com
3.14 Storage and dispatch
Lagerung und Versand
see Coil transport systems 3.4
SMS Siemag AG
see Rolling mill technology 3.0
94
www.alu-web.de
www.bwg-online.com
see Strip Processing Lines 3.17
SMS Siemag AG
see Rolling mill technology 3.0
3.18 Production
Management systems
Produktions Management
Systeme
PSI Metals Non Ferrous GmbH
Software Excellence in Metals
Carlo-Schmid-Str. 12, D-52146 Würselen
Tel.: +49 (0) 2405 4135-0
[email protected], www.psimetals.com
 Anodizing Lines
Anodisier-Linien
SMS Siemag AG
see Rolling mill technology 3.0
see Coil transport systems 3.4
ALUMINIUM · 9/2013
SUPPLIERS DIRECTORY
4
Foundry
Gießerei
4.1 Work protection and ergonomics
Arbeitsschutz und Ergonomie
4.2 Heat-resistant technology
Feuerfesttechnik
4.3 Conveyor and storage technology
Förder- und Lagertechnik
4.4 Mould and core production
Form- und Kernherstellung
4.5 Mould accessories and accessory
materials
Formzubehör, Hilfsmittel
4.2 Heat-resistent technology
Feuerfesttechnik
 Refractories / Feuerfeststoffe
4.6 Foundry equipment
Gießereianlagen
4.7 Casting machines and equipment
Gießmaschinen
und Gießeinrichtungen
4.8 Handling technology
Handhabungstechnik
4.9 Construction and design
Konstruktion und Design
4.10 Measurement technology
and materials testing
Messtechnik und Materialprüfung
4.11 Metallic charge materials
Metallische Einsatzstoffe
4.12 Finishing of raw castings
Rohgussnachbehandlung
4.13 Melt operations
Schmelzbetrieb
4.14 Melt preparation
Schmelzvorbereitung
4.15 Melt treatment devices
Schmelzebehandlungseinrichtungen
4.16 Control and regulation technology
Steuerungs- und
Regelungstechnik
4.17 Environment protection
and disposal
Umweltschutz und Entsorgung
4.18 Dross recovery
Schlackenrückgewinnung
4.19 Cast parts
Gussteile
Promat GmbH High Performance Insulation
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
[email protected], www.promat.de
H+H HERRMANN + HIEBER GMBH
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 711 93467-0, Fax +49 711 34609-11
E-Mail: [email protected]
Internet: www.herrmannhieber.de
see Coil transport systems 3.4
see Section handling 2.3
4.5 Mold accessories and
accessory materials
Formzubehör, Hilfmittel
 Fluxes
Flussmittel
Solvay Fluor GmbH
Hans-Böckler-Allee 20
D-30173 Hannover
Telefon +49 (0) 511 / 857-0
Telefax +49 (0) 511 / 857-2146
Internet: www.solvay-fluor.de
4.6 Foundry equipment
Gießereianlagen
HENCON MOBILE EQUIPMENT
see section Casthouse 1.5
www.mechatherm.com
see Smelting technology 1.5
 Casting machines
Gießmaschinen
Refratechnik Steel GmbH
Via Brallo, 2 – 27010 Siziano (PV), Italy
Tel: +39 0382 6671413
E-mail: [email protected]
Internet: www.erediscabini.com
Schiessstrasse 58
40549 Düsseldorf / Germany
Phone +49 211 5858 0
Fax +49 211 5858 46
Internet: www.refra.com
www.alu-web.de
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
Avenida Cervantes Nº6
48970 – Basauri – Bizkaia – Spain
Tel: +34 944 409 420
E-mail: [email protected]
Internet: www.insertec.biz
4.3 Conveyor and storage
technology
Förder- und Lagertechnik
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
see Equipment and accessories 3.1
 Heat treatment furnaces
Wärmebehandlungsöfen
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
see Heat treatment 2.4
Paul Hedfeld GmbH
www.alu-web.de
ALUMINIUM · 9/2013
Hundeicker Str. 20
D-58285 Gevelsberg
Phone: +49 (0) 2332 6371
E-mail: [email protected]
Internet: www.hedfeld.com
see Casthouse (foundry) 1.5
95
LIEFERVERZEICHNIS
4.7 Casting machines
and equipment
Gießereimaschinen
und Gießeinrichtungen
GAPCast TM: the Swiss casting solution
Casting Technology / Automation
Tel.: +41 27 455 57 14
E-Mail: [email protected]
Internet: www.gap-engineering.ch
www.mechatherm.com
see Smelting technology 1.5
 Mould parting agents
Kokillentrennmittel
Schröder KG
Schmierstofftechnik
Postfach 1170
D-57251
Freudenberg
Tel. 02734/7071
Fax 02734/20784
Ostra Hamnen 7
SE-475 42 Hono / Sweden
Tel.: +46 31 764 5520, Fax: +46 31 764 5529
E-Mail: [email protected]
Internet: www.precimeter.com
Sales contact: Jonatan Lindstrand
Ein Eintrag (s/w) in
diesem Format kostet
pro Ausgabe + Stichwort
Weitere Informationen unter
Tel. +49 (0) 821 / 31 98 80 - 34
4.10 Measurement technology
and materials testin
Messtechnik und
Materialprüfung
Wagstaff, Inc.
ratioTEC Prüfsysteme GmbH
see Casting machines 1.6
Hier könnte Ihr
BezugsquellenEintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
 Continuous ingot casting
lines and aluminium rod lines
Kokillengieß- und Aluminiumdraht-Anlagen
 Burner System
Brennertechnik
www.schroeder-schmierstoffe.de
110,00 € + MwSt.
Precimeter Control AB
see Extrusion 2.4.
In der Au 17
D-88515 Langenenslingen
Tel.: +49 (0)7376/9622-0
Fax: +49 (0)7376/9622-22
E-Mail: [email protected]
Internet: www.ratiotec.com
Büttgenbachstraße 14
D-40549 Düsseldorf/Germany
Tel.: +49 (0) 211 / 5 00 91-0
Fax: +49 (0) 211 / 5 00 91-14
E-Mail: [email protected]
Internet: www.bloomeng.de
 Heat treatment furnaces
Wärmebehandlungsanlagen
Gautschi
Engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
see Heat treatment 2.4
see Equipment and accessories 3.1
 Holding furnaces
www.alu-web.de
4.11 Metallic charge
materials
Metallische Einsatzstoffe
Warmhalteöfen
Bartz GmbH
see Casthous (foundry) 1.5
Gautschi
Engineering GmbH
see Casting equipment 3.1
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
see Heat treatment 2.4
 Recycling / Recycling
Chr. Otto Pape GmbH
Aluminiumgranulate
Berliner Allee 34
D-30855 Langenhagen
Tel:+49(0)511 786 32-0 Fax: -32
Internet: www.papemetals.com
E-Mail: [email protected]
4.13 Melt operations
Schmelzbetrieb
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
see Equipment and accessories 3.1
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: [email protected]
see Heat treatment 2.4
Via Emilia Km 310
26858 Sordio-LO
Italy
Tel. +39.02.988492-1 . [email protected]
Fax +39.02.9810358 . www.properzi.com
96
 Melting furnaces
Schmelzöfen
www.mechatherm.com
see Smelting technology 1.5
Bartz GmbH
see Casthous (foundry) 1.5
ALUMINIUM · 9/2013
SUPPLIERS DIRECTORY
Gautschi
Engineering GmbH
see Casting equipment 3.1
5
Werkstoffe
und Recycling
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
see Heat treatment 2.4
see Equipment and accessories 3.1
MARX GmbH & Co. KG
Lilienthalstr. 6-18
D-58638 Iserhohn
Tel.: +49 (0) 2371 / 2105-0, Fax: -11
E-Mail: [email protected]
Internet: www.marx-gmbh.de
4.14 Melt preparation
Schmelzvorbereitung
 Degassing, filtration
Entgasung, Filtration
Drache Umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: http://www.drache-gmbh.de
4.15 Melt treatment devices
Schmelzbehandlungseinrichtungen
Metaullics Systems Europe B.V.
Ebweg 14
NL-2991 LT Barendrecht
Tel. +31-180/590890
Fax +31-180/551040
E-Mail: [email protected]
Internet: www.metaullics.com
Materials
and
Recycling
 Granulated aluminium
Aluminiumgranulate
Chr. Otto Pape GmbH
Aluminiumgranulate
Berliner Allee 34
D-30855 Langenhagen
Tel:+49(0)511 786 32-0 Fax: -32
Internet: www.papemetals.com
E-Mail: [email protected]
6
 Dust removal
Entstaubung
NEOTECHNIK GmbH
Entstaubungsanlagen
Postfach 110261, D-33662 Bielefeld
Tel. 05205/7503-0, Fax 05205/7503-77
[email protected], www.neotechnik.com
ALUMINIUM · 9/2013
Ausrüstung für Schmiedeund Fließpresstechnik
 Hydraulic Presses
Hydraulische Pressen
LASCO Umformtechnik GmbH
Hahnweg 139, D-96450 Coburg
Tel. +49 (0) 9561 642-0
Fax +49 (0) 9561 642-333
E-Mail: [email protected]
Internet: www.lasco.com
Could not find your „keywords“?
Please ask for our complete
Machining +
Application
Bearbeitung +
Anwendung
6.1 Equipment to produce
castplate
Ausrüstungen für
Gussplattenproduktion
 Slicing saw & Milling machines
Folienschneidmaschinen
Fräsmaschinen
Sermas Industrie
[email protected]
see Smelting technology 1.6
6.2 Semi products
„Supply sources for the
aluminium industry“.
E-Mail: [email protected]
8 Literature
Literatur
 Technical literature
Fachliteratur
Taschenbuch des Metallhandels
Fundamentals of Extrusion Technology
Giesel Verlag GmbH
Hans-Böckler-Allee 9, 30173 Hannover
Tel. 0511 / 73 04-125 · Fax 0511 / 73 04-233
Internet: www.alu-bookshop.de
 Technical journals
Fachzeitschriften
Halbzeuge
 Wires / Drähte
DRAHTWERK ELISENTAL
W. Erdmann GmbH & Co.
Werdohler Str. 40, D-58809 Neuenrade
Postfach 12 60, D-58804 Neuenrade
Tel. +49(0)2392/697-0, Fax 49(0)2392/62044
E-Mail: [email protected]
Internet: www.elisental.de
4.17 Environment protection
and disposal
Umweltschutz und
Entsorgung
6.3 Equipment for forging
and impact extrusion
Giesel Verlag GmbH
Hans-Böckler-Allee 9, 30173 Hannover
Tel. 0511/8550-2638 · Fax 0511/8550-2405
Ein Eintrag (s/w) in
diesem Format kostet
pro Ausgabe + Stichwort
110,00 € + MwSt.
Weitere Informationen unter
Tel. +49 (0) 821 / 31 98 80 - 34
GDMB-Informationsgesellschaft mbH
Paul-Ernst-Str.10, 38678 Clausthal-Zellerfeld
Telefon 05323-937 20, Fax -237, www.gdmb.de
97
VORSCHAU / PREVIEW
IM NÄCHSTEN HEFT
IN THE NEXT ISSUE
Special: Die internationale
Aluminium-Strangpressindustrie
Special: The international
aluminium extrusion industry
Wir berichten über Unternehmen und Ausrüster der Strangpressindustrie, über Anlagentechnik und neue Projekte.
Themen unter anderem: :
We will report on companies and equipment partners of the
extrusion industry, with emphasis on plant technology and
new projects. Topics include:
• Entwicklung der europäischen Strangpressindustrie 2013
• Development of the European extrusion industry in 2013
• Innovatives Pressenkonzept HybrEx von SMS Meer
ermöglicht deutliche Energieeinsparung
• Innovative extrusion press concept HybrEx from
SMS Meer enables significant energy savings
• IAS weltweit erfolgreich mit induktiver Erwärmungstechnologie
• IAS worldwide successful with induction heating
technology
• Neue Strangpresse sichert Gutmann-Standort Neumünster
• New extrusion line for Gutmann subsidiary Nordalu
Weitere Themen
Other topics
• Die Rolle der Finanzakteure in Rohstoffmärkten:
Verzerren die LME Marktpreise statt Referenzpreise
abzubilden?
• Geschichte der Aluminiumindustrie in Russland
• Understanding the role of financial operators in commodity markets: Is the LME distorting instead of making
reference market prices?
• History of the aluminium industry in Russia
Erscheinungstermin:
02. Oktober 2013
Anzeigenschluss:
18. September 2013
Redaktionsschluss:
09. September 2013
International
ALUMINIUM
89. Jahrgang 1. 1. 2013
Journal
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ALUMINIUM · 9/2013
5/2012
Institute of Forming Technology
and Lightweight Construction
technische universität
dortmund
International Extrusion Event 2013
Retrospect
INTERNATIONAL
CONFERENCE
ON
EXTRUSION
AND
BENCHMARK
th
th
October 8 -9 ,
2013
Dortmund, Germany
Organized by the DIEM Department, University of
Bologna, Italy, and the Institute of Forming Technology
and Lightweight Construction (IUL), TU Dortmund
University, Germany, the last International Conference on
Extrusion and Benchmark (ICEB) was held in Bologna in
September 2011. More than 150 participants from more
than 27 different countries worldwide attended the
conference. 2/3 of the participants were from industry
comprising global players in aluminum production and
extrusion as well as small and medium sized companies
specializing in die building or software development.
Program
th
Wednesday, October 8 , 2013
Conference „Latest Advances in Extrusion
Technology and Simulation“, invited keynotes,
oral presentations of papers
Thursday, October 9th, 2013
th
5 Extrusion Benchmark, presentation of the
experiments, presentation and discussion of the
simulation results, oral presentations of papers
Benchmark die 2013
Scope
The demand for distinct properties and qualities of
extruded profiles pushes extrusion experts and die
makers to the limits of their potential: increasing
complexity of sections, hard alloys, emerging
technologies, and microstructure control are just some of
manufacturers’ everyday concerns.
Key factors for innovation and competitiveness are skilled
engineering analyses and reliable software; however, no
reference community exists for the extrusion analyst and
there is no common base for evaluating commercial code
capabilities.
This two-in-one event provides a unique opportunity:
• to learn about the state-of-the-art of emerging
technologies, innovation and simulation capabilities in
the extrusion of light alloys;
• to acquire guidelines for best process analysis and
product optimization;
• to understand the potential of your current simulation
tool;
Participants
• Extrusion experts (R&D division, production,
managers)
• Academic and industrial researchers
• Die makers (project managers, R&D)
• Software houses, software distributors
• Press and equipment builders
Conference website
www.ice-b.net
Features:
• Extensive temperature monitoring
• Pressure in the die cavity
• Deflection of the mandrel
Registration
th
Registration (until October 7 , 2013):
Authors and coauthors: 450 € ; delegates: 650 €
th
On desk registration (after October 7 , 2013):
delegates: 700 €
Organizer
Conference chair:
Prof. Dr.-Ing. Dr.-Ing. E.h.
A. Erman Tekkaya
Contact:
Dr.-Ing. Andreas Jäger
Institute of Forming Technology
and Lightweight Construction (IUL)
Technische Universität Dortmund
Baroper Str. 301
D-44227 Dortmund
E-mail: [email protected]
Phone: +49 231 755-6923
Fax: +49 231 755-2489