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Official media partner<br />
of 17 th Arabal Conference<br />
Special: <strong>Alu</strong>minium<br />
smelting industry<br />
Achieving maximum<br />
output when insulating<br />
electrolysis cells<br />
The new ingot casting<br />
plant at Trimet <strong>Alu</strong>minium<br />
New melting and casting<br />
furnace increases Amag’s<br />
casthouse capacity<br />
Amag<br />
CRU Conference 2013:<br />
Key turning point<br />
Volume 89 · July/August 2013<br />
International Journal for Industry, Research and Application7-8
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EDITORIAL<br />
Volker Karow<br />
Chefredakteur<br />
Editor in Chief<br />
Die Musik spielt in<br />
Asien und am Golf<br />
Asia and the Golf<br />
region are where<br />
it’s all happening<br />
Die jüngsten Quartalszahlen von Alcoa, speziell<br />
das operative Ergebnis, fielen besser aus<br />
als von vielen Analysten erwartet – trotz <strong>de</strong>s<br />
anhalten<strong>de</strong>n Abwärtstrends bei <strong>de</strong>n <strong>Alu</strong>miniumnotierungen.<br />
Was auf <strong>de</strong>r Hüttenseite<br />
belastet, wird in <strong>de</strong>r Verarbeitung offenbar<br />
überkompensiert. Der Konzern berichtet von<br />
einer starken Nachfrage aus <strong>de</strong>r Luftfahrt-,<br />
Automotive- und Verpackungsindustrie. Auf<br />
<strong>de</strong>r Hüttenseite reagiert das Unternehmen,<br />
wie an<strong>de</strong>re Flagschiffproduzenten à la Rusal<br />
und Chalco, mit Produktionskürzungen und<br />
<strong>de</strong>r Schließung von Werken. Über die bereits<br />
brach liegen<strong>de</strong>n Kapazitäten von einer halben<br />
Million Jahrestonnen hinaus prüft Alcoa<br />
weitere Produktionsstilllegungen fast in gleicher<br />
Höhe. In <strong>de</strong>r Baie-Comeau-Hütte in<br />
Kanada wer<strong>de</strong>n zwei Sø<strong>de</strong>rberg-Linien bis<br />
September stillgelegt, in Italien wird die Fusina-Hütte<br />
bei Venedig endgültig geschlossen.<br />
Letzteres wirft erneut die Frage nach <strong>de</strong>r<br />
langfristigen Zukunft europäischer Hütten<br />
auf, sollte aber nicht überbewertet wer<strong>de</strong>n,<br />
diese Frage begleitet die europäische <strong>Alu</strong>miniumindustrie<br />
seit mehr als zwei Jahrzehnten.<br />
Ohnehin sind die Produktionskosten, insbeson<strong>de</strong>re<br />
die Stromkosten für <strong>Alu</strong>miniumhütten<br />
in <strong>de</strong>n EU-Län<strong>de</strong>rn recht unterschiedlich,<br />
sodass die Frage nach <strong>de</strong>r Zukunft <strong>de</strong>r europäischen<br />
Hütten nicht pauschal beantwortet<br />
wer<strong>de</strong>n kann. Immerhin han<strong>de</strong>lt es sich allein<br />
in Westeuropa um eine Jahresproduktion von<br />
3,6 Mio. Tonnen Primäraluminium.<br />
Die Erweiterung und <strong>de</strong>r Neubau von<br />
Hütten, das zeigt sich seit Jahren, fin<strong>de</strong>t vor<br />
allem in China und <strong>de</strong>n Golfstaaten statt.<br />
China ist Selbstversorger, mo<strong>de</strong>rnisiert seit<br />
Jahren seine Hüttenstruktur, mustert kleine<br />
und technologisch veraltete Betriebe aus<br />
und ersetzt sie durch große, energieeffiziente<br />
Produktionsanlagen, die internationalen<br />
Standards entsprechen. Möglicherweise entschei<strong>de</strong>t<br />
sich China <strong>de</strong>reinst, Hütten außerhalb<br />
<strong>de</strong>r Lan<strong>de</strong>sgrenzen zu bauen o<strong>de</strong>r sich<br />
an entsprechen<strong>de</strong>n Projekten zu beteiligen,<br />
zumal rohstoff- und energieseitig Engpässe<br />
bestehen. Von <strong>de</strong>n großen Hüttenbetreibern<br />
im Land wird eine Rückwärtsintegration in <strong>de</strong>r<br />
Wertkette erwartet, um sich beim Bauxit und<br />
Oxid abzusichern.<br />
Am Golf schreitet <strong>de</strong>r Kapazitätsausbau<br />
weiter voran. Er zielt, vorerst noch, stark auf<br />
<strong>de</strong>n Export und die Versorgung Asiens, aber<br />
auch Amerikas und Europas mit Primäraluminium.<br />
Doch etabliert sich am Golf Schritt<br />
für Schritt eine Downstream-Industrie. Die<br />
Arabal-Konferenz im November in Abu Dhabi<br />
wird ein Schlaglicht auf die Region und ihre<br />
Entwicklungsten<strong>de</strong>nzen werfen. Darauf darf<br />
man gespannt sein.<br />
Despite the continuing downward trend in<br />
aluminium prices, the latest quarterly figures<br />
from Alcoa were better than many analysts<br />
had expected, e<strong>special</strong>ly operating income.<br />
Difficulties on the smelter si<strong>de</strong> (upstream) are<br />
apparently being overcompensated for by the<br />
processing si<strong>de</strong> (downstream): the company<br />
reported strong <strong>de</strong>mand from the aerospace,<br />
automotive and packaging industries. Upstream<br />
the company reacted à la Rusal and<br />
Chalco and ma<strong>de</strong> cuts in production and closed<br />
plants. Despite having already mothballed capacity<br />
totalling half a million tonnes a year,<br />
Alcoa is now consi<strong>de</strong>ring further production<br />
closures of almost the same magnitu<strong>de</strong>. Two<br />
Sø<strong>de</strong>rberg lines at the Baie-Comeau smelter<br />
in Canada will be shut down until September<br />
and the smelter at Fusina near Venice in Italy<br />
has been closed permanently.<br />
The latter again raises the question of the<br />
long-term future of European smelters but<br />
too much should not be read into this: it is a<br />
question that has been dogging the European<br />
aluminium industry for more than two <strong>de</strong>ca<strong>de</strong>s.<br />
Production costs, and e<strong>special</strong>ly electricity<br />
costs, differ quite markedly in the different<br />
EU countries so that the question of the future<br />
of European smelters cannot be answered in<br />
a wholesale manner. After all, in Western Europe<br />
alone we are talking about some 3.6m<br />
tonnes of primary aluminium a year.<br />
It has been apparent for some years that<br />
the expansion of existing smelters and the<br />
erection of new ones are mainly taking place<br />
in China and the Gulf Arab states. China is<br />
self-sufficient in aluminium: production and<br />
consumption are balanced to a large extent. It<br />
has been mo<strong>de</strong>rnising its smelter capacity for<br />
years and is taking small and technologically<br />
obsolete smelters out of service and replacing<br />
them with large, energy-efficient production<br />
plants that are on a par with international<br />
standards. Someday China will possibly <strong>de</strong>ci<strong>de</strong><br />
to build smelters beyond its bor<strong>de</strong>rs or<br />
participate in such projects, e<strong>special</strong>ly as there<br />
are bottlenecks where raw materials and energy<br />
are concerned. The country’s large smelter<br />
operators are expected to un<strong>de</strong>rtake a backward<br />
integration in the value chain in or<strong>de</strong>r<br />
to safeguard supplies of bauxite and alumina.<br />
The expansion of smelter capacity in the<br />
Gulf Arab states is continuing apace and is<br />
strongly oriented, at least at first, at exports<br />
and supplying primary aluminium to Asia as<br />
well as the USA and Europe. However, the<br />
Gulf region is steadily establishing a downstream<br />
industry. The Arabal conference in<br />
Abu Dhabi in November will highlight the<br />
region and <strong>de</strong>velopments there. We can look<br />
forward to that with anticipation.<br />
ALUMINIUM · 7-8/2013 3
INHALT<br />
EDITORIAL<br />
Die Musik spielt in Asien und am Golf<br />
Asia and the Golf region are where it’s all happening ........................ 3<br />
AKTUELLES • NEWS IN BRIEF • EVENTS<br />
18<br />
Amag schließt Großvertrag mit EADS<br />
Amag signs major contract with EADS .......................................... 6/7<br />
GDA schreibt <strong>Alu</strong>-Druckguss-Wettbewerb 2014 aus<br />
International <strong>Alu</strong>minium Pressure Die Casting Competition 2014 ....... 6/7<br />
Georg Fischer receives major or<strong>de</strong>r from Audi ................................... 7<br />
Hermann-Josef Hanny Vorsitzen<strong>de</strong>r <strong>de</strong>s GDA-Fachverbands <strong>Alu</strong>recycling ... 8<br />
Trimet vor Übernahme zweier <strong>Alu</strong>miniumwerke in Frankreich ............... 8<br />
Magna erhält Supplier Innovation Award von BMW ........................... 8<br />
Mubadala and ICD establish Emirates Global <strong>Alu</strong>minium ..................... 9<br />
Emal celebrates instal lation of steel structure for Phase II potline ........ 9<br />
30<br />
European <strong>Alu</strong>minium Congress 2013 – The programme is ready ......... 10<br />
ICEB – Intl Conference on Extrusion and Benchmark ........................ 10<br />
Metef 2014 aiming to add new field of excellence to Italy’s three Fs .....11<br />
<strong>Alu</strong>minium China 2013 celebrates record attendance ........................11<br />
WIRTSCHAFT • ECONOMICS<br />
<strong>Alu</strong>miniumpreise .........................................................................12<br />
Produktionsdaten <strong>de</strong>r <strong>de</strong>utschen <strong>Alu</strong>miniumindustrie .........................14<br />
44<br />
„Metalle pro Klima“-Veranstaltung bei Otto Fuchs:<br />
Klimaschutz durch energieeffiziente Produktion ...............................16<br />
SMS group 2012: Auftragseingang zurückgegangen –<br />
Umsatz gestiegen – stabiles Ergebnis • SMS group in<br />
2012: lower or<strong>de</strong>r intake – higher sales – stable result .....................18<br />
CRU’s World <strong>Alu</strong>minium Conference 2013<br />
in London: Key turning points ..................................................... 22<br />
New alumina project approach – <strong>de</strong>dicated <strong>de</strong>sign, compact capacity . . 24<br />
Lage <strong>de</strong>r Schweizer <strong>Alu</strong>miniumindustrie weiterhin angespannt ........... 29<br />
Latest News<br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
52<br />
ALUMINIUMHÜTTENINDUSTRIE<br />
ALUMINIUM SMELTING INDUSTRY<br />
Primary aluminium industry during the first half of 2013, Part I ......... 30<br />
Keops Technologies <strong>de</strong>ploys a new<br />
standard aluminium smelter MES solution .......................................37<br />
„Duro<strong>de</strong>nse“ – <strong>Alu</strong>miniumoxid-För<strong>de</strong>rtechnologie für Dubal erfolgreich<br />
4 ALUMINIUM · 7-8/2013
CONTENTS<br />
in Betrieb genommen • ‘Duro<strong>de</strong>nse’ – <strong>Alu</strong>mina feeding<br />
technology successfully commissioned at Dubal ............................... 38<br />
Optimisation of grain refinement in a<br />
range of casthouse aluminium alloys ............................................. 40<br />
Achieving maximum output when insulating electrolysis cells ............ 42<br />
Die neue Masselgießanlage <strong>de</strong>r Trimet <strong>Alu</strong>minium im Werk<br />
Essen range of casthouse aluminium alloys • The new ingot<br />
casting plant at the Essen works of Trimet <strong>Alu</strong>minium ...................... 44<br />
TECHNOLOGIE • TECHNOLOGY<br />
56<br />
Neuer Schmelz- und Gießofen <strong>de</strong>r Amag erhöht Gießereikapazität<br />
New melting and casting furnace increases Amag’s casthouse capacity . 48<br />
Alcoa further extends sheet capacity ..............................................50<br />
Besucherwoche bei Achenbach Buschhütten<br />
Visitors’ week at Achenbach Buschhütten ........................................52<br />
Kampf eröffnet neue Montagehallen am Standort Mühlen<br />
Kampf opens new assembly halls at the Mühlen site .........................54<br />
HPI errichtet Horizontal-Stranggießanlage in Shanghai ......................55<br />
62<br />
<strong>Alu</strong>mec setzt auf umweltschonen<strong>de</strong>n Korrosionsschutz<br />
<strong>Alu</strong>mec adopts to ecologically sound corrosion protection technology ....56<br />
Recycling of wrought aluminium alloys from post-consumed scrap ......58<br />
Dryplus process drastically reduces sludge volumes from anodising lines ...61<br />
Präziser Schnitt aus <strong>Alu</strong>miniumblöcken ...........................................62<br />
Novelis überwacht Maschinenschwingungen mit Condition<br />
Monitoring von iba • Novelis monitors machine vibrations with<br />
iba Condition Monitoring ..............................................................63<br />
This issue contains<br />
an enclosure from<br />
GDA Gesamtverband<br />
<strong>de</strong>r <strong>Alu</strong>miniumindustrie<br />
to which we draw<br />
your kind attention.<br />
COMPANY NEWS WORLDWIDE<br />
<strong>Alu</strong>minium smelting industry .........................................................66<br />
Bauxite and alumina activities .......................................................67<br />
Secondary smelting and recycling ..................................................68<br />
<strong>Alu</strong>minium semis .........................................................................69<br />
On the move, Suppliers ................................................................70<br />
DOCUMENTATION<br />
Patente .....................................................................................72<br />
Impressum • Imprint ....................................................................90<br />
Vorschau • Preview .....................................................................90<br />
LIEFERVERZEICHNIS • SUPPLIERS DIRECTORY .............76<br />
Inserenten dieser Ausgabe<br />
List of advertisers<br />
ABB Switzerland 33<br />
Coperion GmbH, Germany 37<br />
Didion International Inc., USA 25<br />
Dubai <strong>Alu</strong>minium, UAE 15<br />
Emirates <strong>Alu</strong>minium, UAE 13<br />
ECL, France 39<br />
FLSmidth Hamburg GmbH, Germany 35<br />
Hertwich Engineering GmbH, Austria 2<br />
Inotherm Industrieofen- und<br />
Wärmetechnik GmbH, Germany 11<br />
Innovatherm Prof, Dr. Leisenberg<br />
GmbH & Co. KG 31<br />
Kasto Maschinenbau GmbH & Co. KG 29<br />
Messe Essen GmbH, Germany 21<br />
Micro-Epsilon Messtechnik<br />
GmbH & Co. KG, Germany 19<br />
Outotec, Germany 91<br />
SDV-Santioli AG, Switzerland 41<br />
SMS Siemag AG, Germany 92<br />
ALUMINIUM · 7-8/2013 5
AKTUELLES<br />
GDA schreibt <strong>Alu</strong>-Druckguss-<br />
Wettbewerb 2014 aus<br />
Der Gesamtverband <strong>de</strong>r <strong>Alu</strong>miniumindustrie<br />
(GDA), Düsseldorf, schreibt <strong>de</strong>n internationalen<br />
Wettbewerb für <strong>Alu</strong>minium-Druckguss<br />
2014 aus. Partner bei <strong>de</strong>r Durchführung <strong>de</strong>s<br />
Wettbewerbs sind <strong>de</strong>r Bun<strong>de</strong>sverband <strong>de</strong>r<br />
Deutschen Gießereiindustrie (BDG) und die<br />
European <strong>Alu</strong>minium Association (EAA). Einreichungen<br />
für <strong>de</strong>n Wettbewerb sind bis zum<br />
31. Oktober 2013 möglich.<br />
Der Wettbewerb ist seit vielen Jahren eine<br />
bewährte Plattform, um die hohe Qualität<br />
von <strong>Alu</strong>minium-Druckgussteilen aufzuzeigen.<br />
Bisher wur<strong>de</strong> <strong>de</strong>r Wettbewerb vom Verband<br />
<strong>de</strong>r <strong>Alu</strong>miniumrecycling-Industrie (VAR) durchgeführt,<br />
<strong>de</strong>r zum 1. April 2013 als Fachverband<br />
<strong>Alu</strong>miniumrecycling in <strong>de</strong>n GDA aufgegangen<br />
ist. Der Fachverband <strong>Alu</strong>miniumrecycling wird<br />
zunächst das bisherige Leistungsspektrum <strong>de</strong>s<br />
VAR erhalten und mittelfristig weiter ausbauen.<br />
Hierzu gehört auch <strong>de</strong>r <strong>Alu</strong>minium-Druckguss-Wettbewerb.<br />
Kriterien für die Bewertung <strong>de</strong>r teilnehmen<strong>de</strong>n<br />
Gussstücke beim Wettbewerb 2014<br />
sind die druckgussgerechte Konstruktion und<br />
die Verwendung von Recyclingaluminium. Gießereien<br />
können beliebig viele Gussstücke einreichen.<br />
Das Gussteil sollte aus einer gängigen<br />
<strong>Alu</strong>miniumgusslegierung hergestellt sein. Die<br />
Gussteile, die <strong>de</strong>n Anfor<strong>de</strong>rungen an Qualität,<br />
Aktualität, innovative Lösungsansätze und<br />
technischen Fortschritt entsprechen, wer<strong>de</strong>n<br />
durch Urkun<strong>de</strong>n ausgezeichnet.<br />
Die Preisverleihung <strong>de</strong>r besten Einsendungen<br />
erfolgt anlässlich <strong>de</strong>r Euroguss 2014<br />
(14. bis 16. Januar 2014) in Nürnberg. Die<br />
prämierten Gussstücke wer<strong>de</strong>n dort und auf<br />
weiteren Messen ausgestellt.<br />
Die Wettbewerbsunterlagen können auf<br />
<strong>de</strong>n Websites <strong>de</strong>r Verbän<strong>de</strong> in <strong>de</strong>utscher und<br />
englischer Sprache heruntergela<strong>de</strong>n wer<strong>de</strong>n:<br />
www.aluinfo.<strong>de</strong>, www.bdguss.<strong>de</strong><br />
Produktion von <strong>Alu</strong>folie<br />
legt auf breiter Front zu<br />
Erstmals seit Mitte 2011 ist die Produktion<br />
von <strong>Alu</strong>folie wie<strong>de</strong>r in allen Dickenbereichen<br />
gestiegen. Wie <strong>de</strong>r europäische <strong>Alu</strong>folienverband<br />
EAFA mitteilte, legte die Produktion im<br />
ersten Quartal dieses Jahres insgesamt um 3,7<br />
Prozent auf 209.400 Tonnen zu (2012: 201.900<br />
t). Auch <strong>de</strong>r Export <strong>de</strong>r europäischen Hersteller<br />
stieg um 10,3 Prozent an. Damit konnte<br />
das Momentum von En<strong>de</strong> 2012 in das erste<br />
Quartal dieses Jahres mitgenommen wer<strong>de</strong>n.<br />
Amag schließt Großvertrag<br />
mit EADS<br />
Die Amag Austria Metall AG mit Sitz im österreichischen<br />
Ranshofen ist zum 1. Januar 2013<br />
einen Großvertrag mit EADS eingegangen,<br />
<strong>de</strong>r die Lieferung von <strong>Alu</strong>miniumplatten und<br />
-blechen für die Fertigung von Struktur- und<br />
Außenhautteilen vorsieht. Das Auftragsvolumen<br />
beträgt bis zu 100 Mio. Euro. Die mehrjährige<br />
Vereinbarung umfasst die Lieferung<br />
von Platten, Blechen und Bän<strong>de</strong>rn für alle<br />
aktuellen Airbus-Flugzeugtypen.<br />
Der Amag-Standort wird <strong>de</strong>rzeit mit einem<br />
Investitionsvolumen von 220 Mio. Euro ausgebaut,<br />
um vor allem das Geschäft im Transportbereich<br />
(Luftfahrt und Automobil) und<br />
Leichtbau weiterzuentwickeln. Mit <strong>de</strong>r Investition<br />
erweitert das Unternehmen sein Portfolio<br />
zu größeren Dicken und Breiten auch für<br />
hochfeste Produkte in <strong>de</strong>r Luftfahrtindustrie.<br />
Für Amag-Chef Gerhard Falch ist <strong>de</strong>r Auftrag<br />
„ein weiterer Beweis für unsere hohe Kompetenz<br />
in <strong>de</strong>r Luftfahrt.“ Bei<strong>de</strong> Unternehmen<br />
arbeiten bereits seit 2005 zusammen.<br />
<strong>Alu</strong>minium ist nach wie vor <strong>de</strong>r bevorzugte<br />
Basiswerkstoff in <strong>de</strong>r Luftfahrt. Marktprognosen<br />
von Airbus zufolge wer<strong>de</strong>n bis 2031<br />
mehr als 28.000 neue Passagier- und Frachtflugzeuge<br />
gebaut. Diese Zahl unterstreicht<br />
die langfristigen Wachstumsaussichten für<br />
die Luftfahrtindustrie und damit auch für <strong>de</strong>n<br />
<strong>Alu</strong>miniumbedarf. Das Marktforschungsinstitut<br />
CRU erwartet ein beständiges Wachstum<br />
<strong>de</strong>s Verbrauchs von <strong>Alu</strong>miniumwalzprodukten<br />
in <strong>de</strong>r Luftfahrtindustrie von <strong>de</strong>rzeit<br />
390.000 Tonnen auf 536.000 Tonnen im Jahr<br />
2017 allein für Nordamerika und Europa.<br />
Durch die Investition in das neue Walzwerk<br />
in Ranshofen schafft Amag die Voraussetzungen,<br />
um am wachsen<strong>de</strong>n <strong>Alu</strong>bedarf in <strong>de</strong>r<br />
Luftfahrtindustrie zu partizipieren.<br />
Oetinger insolvent<br />
Das <strong>Alu</strong>miniumschmelzwerk Oetinger mit<br />
Standorten in Weißenhorn, Neu-Ulm, Hannover<br />
und Berlin hat Insolvenz angemel<strong>de</strong>t.<br />
Zum vorläufigen Insolvenzverwalter wur<strong>de</strong><br />
<strong>de</strong>r Düsseldorfer Rechtsanwalt Frank Kebekus<br />
bestellt, <strong>de</strong>r in <strong>de</strong>r Sanierung von <strong>Alu</strong>miniumfirmen<br />
erfahren ist. Seine Aufgabe ist nun, Investoren<br />
zu fin<strong>de</strong>n um das Schmelzwerk mit<br />
seinen 500 Arbeitsplätze zu retten.<br />
Der Betrieb <strong>de</strong>s Unternehmens wird <strong>de</strong>rzeit<br />
aufrechterhalten, Aufträge seien vorhan<strong>de</strong>n,<br />
zitiert die Regionalpresse Günter Frey von <strong>de</strong>r<br />
© Amag<br />
Amag-Luftfahrtplatten bei <strong>de</strong>r Ultraschall-Prüfanlage,<br />
die eine mehrfach schnellere Qualitätsprüfung<br />
erlaubt<br />
Die Be<strong>de</strong>utung dieses Geschäftes für Amag<br />
spiegelt sich auch darin wi<strong>de</strong>r, dass das Unternehmen<br />
auf <strong>de</strong>r 50. Paris Air Show in Le<br />
Bourget im Juni ihr Produktportfolio an hochfesten<br />
Blechen und Platten für die Luftfahrtindustrie<br />
<strong>de</strong>r Fachwelt präsentierte.<br />
Gewerkschaft IG Metall. Probleme bereiteten<br />
die niedrigen Preise für Gussteile aus <strong>Alu</strong>minium,<br />
die das Unternehmen vor allem an die<br />
Automobilindustrie liefert. Als eine Ursache<br />
dafür wer<strong>de</strong>n die darben<strong>de</strong>n Schmelzwerke<br />
in Sü<strong>de</strong>uropa ausgemacht, die angesichts freier<br />
Kapazitäten sehr niedrige Preise anbieten<br />
können.<br />
Oetinger zählt zu <strong>de</strong>n größten Herstellern<br />
von <strong>Alu</strong>minium-Gusslegierungen in Europa.<br />
Der Standort in Gorcy in Frankreich ist von<br />
<strong>de</strong>r Insolvenz nicht berührt.<br />
6 ALUMINIUM · 7-8/2013
NEW S IN BRIEF<br />
Amag aerospace plates at the ultrasonic inspection<br />
line where quality testing is completed several<br />
times more quickly<br />
Amag Austria Metall AG, based in Ranshofen,<br />
Austria, conclu<strong>de</strong>d a multi-year contract with<br />
EADS, effective 1 January 2013, for the supply<br />
of aluminium plate and sheet to manufacture<br />
structural and skin components. The or<strong>de</strong>r<br />
Amag signs major<br />
contract with EADS<br />
volume is up to 100 million euros. The agreement<br />
covers the supply of aluminium plate,<br />
sheet and strip for all current Airbus aircraft<br />
types.<br />
The Austrian factory is being expan<strong>de</strong>d,<br />
with an investment of 220 million euros,<br />
primarily to drive the commitment in transportation<br />
(aircraft and automotive) and lightweight<br />
construction. The investment is aimed<br />
at extending Amag’s portfolio to inclu<strong>de</strong><br />
larger thicknesses and widths also for highstrength<br />
products for the aircraft industry.<br />
Amag CEO Gerhard Falch commented: “This<br />
or<strong>de</strong>r is further proof of our high level of expertise<br />
in products for the aircraft industry.<br />
Amag and EADS have been cooperating since<br />
2005.<br />
<strong>Alu</strong>minium continues to be the preferred<br />
principal material for aircraft applications.<br />
According to Airbus’ market forecasts, the<br />
<strong>de</strong>mand for aircraft will rise to more than<br />
28,000 new passenger and cargo planes by<br />
2031. This forecast un<strong>de</strong>rlines the long-term<br />
growth prospects for the aircraft industry. The<br />
market research institute CRU (Commodity<br />
Research Unit) expects the consumption<br />
of aluminium flat rolled products in the aircraft<br />
industry to steadily grow from currently<br />
390,000 to 536,000 tonnes in 2017 in North<br />
America and Europe. Due to the investment<br />
in the new rolling mill, Amag is i<strong>de</strong>ally positioned<br />
to participate in the growing consumption<br />
of aluminium in the aircraft industry.<br />
As the aircraft business is of growing importance<br />
to Amag, the company presented its<br />
product portfolio of high-strength sheet and<br />
plate <strong>de</strong>stined for the aircraft industry at the<br />
50 th International Paris Air Show at Le Bourget<br />
in June.<br />
Georg Fischer receives major or<strong>de</strong>r from Audi<br />
GF Automotive, a division of Georg Fischer,<br />
has been awar<strong>de</strong>d a major or<strong>de</strong>r from Audi,<br />
worth more than CHF400 million. The light<br />
structural parts for the German car manufacturer<br />
will be produced by aluminium pressure<br />
die casting in Europe and China starting in the<br />
next few years.<br />
The or<strong>de</strong>r comprises suspension strut<br />
domes, which will be built into several new<br />
Audi mo<strong>de</strong>ls and replace conventional wel<strong>de</strong>d<br />
sheet metal assembling. The new <strong>de</strong>sign features<br />
a better functionality and a much lower<br />
number of components resulting in a weight<br />
reduction of over 50 percent.<br />
Ten production sites worldwi<strong>de</strong><br />
GF Automotive, located in Switzerland, is<br />
one of the leading automotive suppliers<br />
worldwi<strong>de</strong> and a <strong>de</strong>velopment partner and<br />
manufacturer for the automotive industry. It<br />
manufactures some 600,000 tonnes of iron,<br />
aluminium and magnesium at ten production<br />
plants in Germany, Austria and China.<br />
International <strong>Alu</strong>minium Pressure<br />
Die Casting Competition<br />
The German <strong>Alu</strong>minium Association GDA announces<br />
the International <strong>Alu</strong>minium Pressure<br />
Die Casting Competition 2014. Partners in<br />
organising the competition are the Fe<strong>de</strong>ration<br />
of the German Foundry Industry (BDG) and<br />
the European <strong>Alu</strong>minium Association (EAA).<br />
Submissions to the competition can be ma<strong>de</strong><br />
until 31 October 2013.<br />
For years the competition has been a<br />
proven platform for showing off the high<br />
standard of quality in aluminium pressure<br />
die casting. The goal of the competition is to<br />
strengthen interest in aluminium as versatile<br />
working material and to <strong>de</strong>monstrate new<br />
areas of application. Until now the aluminium<br />
pressure die casting competition was held by<br />
the German Association of the <strong>Alu</strong>minium<br />
Recycling Industry (VAR), which disban<strong>de</strong>d in<br />
March. As of 1 April the GDA puts its aluminium<br />
recycling division into action. Initially, they<br />
will continue the former programme of activities<br />
of VAR, and expand it in the mid term.<br />
This inclu<strong>de</strong>s the die casting competition.<br />
The evaluation criteria for cast pieces submitted<br />
to the competition inclu<strong>de</strong> a proper<br />
die cast construction and the use of recycled<br />
aluminium. Foundries can submit any number<br />
of die cast pieces, which should be ma<strong>de</strong> of<br />
an aluminium alloy commonly used in die<br />
casting. Pieces which meet the requirements<br />
on quality, topicality, innovative approaches to<br />
solving problems and technical advancement<br />
will receive awards.<br />
The award ceremonies for the best submissions<br />
will take place at Euroguss 2014 (14<br />
to 16 January) in Nuremberg. The winning<br />
pieces will be exhibited there and at other<br />
tra<strong>de</strong> fairs.<br />
Competition forms can be downloa<strong>de</strong>d in<br />
German and English from the <strong>web</strong>sites of the<br />
associations: www.aluinfo.<strong>de</strong>, www.bdguss.<strong>de</strong><br />
<strong>Alu</strong>foil sees production<br />
growth on all fronts<br />
First quarter 2013 figures for aluminium foil<br />
showed growth across all gauges for the<br />
first time since mid-2011. Overall first quarter<br />
production grew by 3.7% to 209,400 tonnes<br />
(2012: 201,900 t). Meanwhile exports from<br />
European manufacturers maintained the momentum<br />
seen in the later part of 2012 with<br />
a first quarter growth of 10.3%, according to<br />
figures released by the European <strong>Alu</strong>minium<br />
Foil Association (EAFA).<br />
ALUMINIUM · 7-8/2013 7
AKTUELLES<br />
Hermann-Josef Hanny<br />
Vorsitzen<strong>de</strong>r <strong>de</strong>s GDA-<br />
Fachverbands <strong>Alu</strong>recycling<br />
Hermann-Josef Hanny (46), Commercial<br />
Director Foundry Alloys und Bereichsleiter<br />
Gusslegierungen bei <strong>de</strong>r Aleris Recycling<br />
(German Works) GmbH, Grevenbroich, ist<br />
neuer Vorsitzen<strong>de</strong>r <strong>de</strong>s Fachverband <strong>Alu</strong>miniumrecycling<br />
im Gesamtverband <strong>de</strong>r <strong>Alu</strong>miniumindustrie<br />
(GDA), Düsseldorf.<br />
Diplom-Kaufmann Hanny hat langjährige<br />
Erfahrungen in <strong>de</strong>r <strong>Alu</strong>miniumrecycling-Industrie<br />
und im Metallhan<strong>de</strong>l. In <strong>de</strong>n vergangenen<br />
15 Jahren war er unter an<strong>de</strong>rem bei<br />
Bayer, Agfa-Gevaert, VAW-Imco, Honsel International<br />
Technologies und bei Oetinger in<br />
diesem Marktbereich in verantwortlicher Position<br />
tätig.<br />
Der GDA hat <strong>de</strong>n Fachverband <strong>Alu</strong>miniumrecycling<br />
im April 2013 aktiviert. Mitglie<strong>de</strong>r<br />
im Fachverband sind unter an<strong>de</strong>rem<br />
die Mitgliedsunternehmen <strong>de</strong>s Verban<strong>de</strong>s <strong>de</strong>r<br />
<strong>Alu</strong>miniumrecycling-Industrie (VAR), <strong>de</strong>r sich<br />
zum 31. März 2013 aufgelöst hat. Die Aktivierung<br />
<strong>de</strong>s neuen Fachverbands erfolgt vor<br />
<strong>de</strong>m Hintergrund <strong>de</strong>r wachsen<strong>de</strong>n Be<strong>de</strong>utung<br />
<strong>de</strong>s <strong>Alu</strong>miniumrecyclings, das in Deutschland<br />
und Europa als Rohstoffquelle immer wichtiger<br />
wird. Um <strong>de</strong>n Rohstoff in Deutschland<br />
noch intensiver zu verwerten, investieren<br />
<strong>de</strong>utsche <strong>Alu</strong>miniumbetriebe in <strong>de</strong>n Ausbau<br />
<strong>de</strong>r Recyclingkapazitäten und greifen dabei<br />
auf mo<strong>de</strong>rnste Anlagentechnik zurück. Angesichts<br />
<strong>de</strong>s fortschreiten<strong>de</strong>n Abbaus von Hüttenkapazitäten<br />
in <strong>de</strong>r EU wird die Nachfrage<br />
nach Recyclingmaterial weiter wachsen.<br />
Trimet vor Übernahme zweier<br />
<strong>Alu</strong>miniumwerke in Frankreich<br />
Trimet <strong>Alu</strong>minium hat ein verbindliches Angebot<br />
abgegeben, um zwei Produktionswerke<br />
in Frankreich von Rio Tinto Alcan (RTA) zu<br />
übernehmen. Mit <strong>de</strong>r Übernahme <strong>de</strong>r <strong>Alu</strong>miniumwerke<br />
in Saint-Jean-<strong>de</strong>-Maurienne und<br />
Castelsarrasin will das Unternehmen weiter<br />
wachsen und sein Portfolio spezialisierter<br />
Produkte aus Leichtmetall erweitern. Die<br />
mit RTA getroffene Vereinbarung sieht eine<br />
Kooperation mit <strong>de</strong>m französischen Energieversorger<br />
EdF (Électricité <strong>de</strong> France) vor und<br />
muss noch von <strong>de</strong>n Aufsichtsbehör<strong>de</strong>n genehmigt<br />
wer<strong>de</strong>n.<br />
Während es sich bei <strong>de</strong>m Werk Saint-Jean<strong>de</strong>-Maurienne<br />
um eine <strong>Alu</strong>miniumhütte mit<br />
einer Produktionskapazität von 140.000 Jahrestonnen<br />
han<strong>de</strong>lt (RTA-Produktion 2012:<br />
93.000 t), stellt das Werk Castelsarrasin Gießwalzdraht<br />
her (RTA-Jahresproduktion 8.000<br />
t), <strong>de</strong>r unter an<strong>de</strong>rem zu elektrischen Leitungen<br />
in <strong>de</strong>r Energiewirtschaft und zu Verbindungselementen<br />
in <strong>de</strong>r Automobilindustrie<br />
weiterverarbeitet wird. Die Hütte beschäftigt<br />
480 Mitarbeiter, das Gießwalzdrahtwerk 35<br />
Mitarbeiter.<br />
„Die Standorte fügen sich hervorragend in<br />
die strategische Ausrichtung <strong>de</strong>r Trimet ein.<br />
Die Konditionen <strong>de</strong>r Übernahme erlauben<br />
uns zu<strong>de</strong>m eine verlässliche und langfristige<br />
Investitionsplanung“, erklärte Heinz-Peter<br />
Schlüter, Inhaber und Vorsitzen<strong>de</strong>r <strong>de</strong>s Aufsichtsrates<br />
<strong>de</strong>r Trimet <strong>Alu</strong>minium SE.<br />
Die Übernahmevereinbarung sichert laut<br />
Trimet die langfristige Versorgung mit Toner-<br />
Die Essener Trimet-Gießerei hat Mitte Juni die<br />
siebenmillionste Tonne <strong>Alu</strong>minium seit Bestehen<br />
<strong>de</strong>s Werks gegossen. Das „Jubiläums“-<strong>Alu</strong>minium<br />
wur<strong>de</strong> als hochspezialisierter Walzbarren an <strong>de</strong>n<br />
langjährigen Kun<strong>de</strong>n Constellium Singen geliefert.<br />
Das Foto zeigt Trimet-Chef Martin Iffert (links) und<br />
Robert Gabor, verantwortlich für Metallbeschaffung<br />
bei Constellium Singen.<br />
<strong>de</strong> (<strong>Alu</strong>miniumoxid) und elektrischem Strom,<br />
<strong>de</strong>n für die <strong>Alu</strong>miniumproduktion essenziellen<br />
Grundstoffen. Laut RTA wird Trimet eine<br />
Mehrheitsbeteiligung von 60 Prozent an <strong>de</strong>n<br />
Produktionswerken halten, EdF übernimmt<br />
35 Prozent <strong>de</strong>r Anteile und die staatliche französische<br />
Fonds Stratégique d’Investisse (FSI)<br />
fünf Prozent <strong>de</strong>r Anteile.<br />
Martin Iffert, Vorsitzen<strong>de</strong>r <strong>de</strong>s Vorstands<br />
<strong>de</strong>r Trimet <strong>Alu</strong>minium, sagte: „Bei <strong>de</strong>r weiterverarbeiten<strong>de</strong>n<br />
Industrie in Europa besteht<br />
ein großer Bedarf an <strong>Alu</strong>miniumdraht. Als<br />
Anbieter komplexer Legierungen und maßgeschnei<strong>de</strong>rter<br />
Lösungen stärken wir mit<br />
dieser Produktgruppe auch langfristig unsere<br />
Kernkompetenz als Spezialitätenanbieter.“<br />
© Trimet<br />
Magna erhält Supplier Innovation Award von BMW<br />
Die Magna BDW technologies GmbH hat als<br />
einer von acht Zulieferern <strong>de</strong>n BMW Supplier<br />
Innovation Award für herausragen<strong>de</strong><br />
Leistungen im Bereich Innovation und Entwicklung<br />
erhalten. Die BMW Group hat diesen<br />
Preis ihren Lieferanten 2013 zum zweiten<br />
Mal verliehen und in München überreicht.<br />
BDW technologies ist eine in Markt-Schwaben<br />
ansässige Einheit von Cosma International<br />
– <strong>de</strong>r Gruppe, die im Magna-Konzern für<br />
Karosserien zuständig ist. Sie bekam die Auszeichnung<br />
in <strong>de</strong>r Kategorie „Leichtbau“ für<br />
ein aus <strong>Alu</strong>minium gegossenes Hochvoltspeicher-Gehäuse<br />
für Batterien. Cosma ist es gelungen,<br />
eine Vielzahl komplexer Funktionen<br />
in einem Bauteil zu vereinen und somit das<br />
Gewicht <strong>de</strong>r Batterie <strong>de</strong>utlich zu reduzieren.<br />
Außer<strong>de</strong>m konnte <strong>de</strong>r Produktionsprozess<br />
um einige Schritte verschlankt wer<strong>de</strong>n.<br />
Für die BMW Group sind die innovativsten<br />
Zulieferer wichtige Partner, die bei <strong>de</strong>r erfolgreichen<br />
Umsetzung neuer Entwicklungen eine<br />
entschei<strong>de</strong>n<strong>de</strong> Rolle spielen. Der Supplier Innovation<br />
Award wur<strong>de</strong> konzipiert, um diese<br />
Leistungen zu würdigen.<br />
Hauptgeschäftsführung<br />
<strong>de</strong>s BDG neu aufgestellt<br />
Christian Wilhelm (56) ist seit <strong>de</strong>m 1. Juli<br />
neues Mitglied in <strong>de</strong>r Hauptgeschäftsführung<br />
<strong>de</strong>s Bun<strong>de</strong>sverban<strong>de</strong>s <strong>de</strong>r Deutschen Gießerei-Industrie<br />
(BDG), wo er <strong>de</strong>n Bereich Technik<br />
übernimmt. Er war zuvor langjähriger Mitarbeiter<br />
<strong>de</strong>r Mannheimer Eisengießerei von<br />
Merce<strong>de</strong>s-Benz, zuletzt leitete er das Kompetenzzentrum<br />
Gießerei und war zugleich stellvertreten<strong>de</strong>r<br />
Gießereileiter.<br />
Er übernimmt das Ressort von Erwin Flen<strong>de</strong>r,<br />
<strong>de</strong>r interimsweise die technische Hauptgeschäftsführung<br />
<strong>de</strong>s BDG seit April 2012 innehatte.<br />
Flen<strong>de</strong>r ist seit Oktober 2012 auch<br />
Präsi<strong>de</strong>nt <strong>de</strong>s BDG und wird weiterhin die<br />
Geschäftsführung <strong>de</strong>s Vereins Deutscher<br />
Gießereifachleute (VDG) wahrnehmen. Max<br />
Schumacher leitet <strong>de</strong>n Bereich Wirtschaft und<br />
ist zum 1. Juli zum Sprecher <strong>de</strong>r BDG-Hauptgeschäftsführung<br />
berufen wor<strong>de</strong>n. Gerhard<br />
Klügge bleibt weiterhin für <strong>de</strong>n Bereich Finanzen<br />
zuständig.<br />
8 ALUMINIUM · 7-8/2013
NEW S IN BRIEF<br />
Mubadala and ICD establish Emirates Global <strong>Alu</strong>minium<br />
In a move that will form a new industrial giant<br />
in the United Arab Emirates, Mubadala<br />
Development Company of Abu Dhabi and the<br />
Investment Corporation of Dubai (ICD) have<br />
announced the creation of Emirates Global<br />
<strong>Alu</strong>minium – a jointly-held, equal-ownership<br />
company that will integrate the businesses<br />
of Dubai <strong>Alu</strong>minium (Dubal) and Emirates<br />
<strong>Alu</strong>minium (Emal) – with plans for significant<br />
local growth and international expansion.<br />
Pending required approvals, the formal commencement<br />
of joint operations is expected to<br />
be completed within the first half of 2014.<br />
Emirates Global <strong>Alu</strong>minium will be the<br />
fifth largest aluminium company by production<br />
when Phase II of Emal is completed mid-<br />
2014, and will serve over 440 customers in 55<br />
countries, with a joint production capacity of<br />
2.4m tpy of aluminium on the completion of<br />
Emal Phase II.<br />
The accord builds on a successful partnership<br />
that started with the formation of Emal in<br />
2006, a joint venture of Mubadala and Dubal.<br />
Emirates Global <strong>Alu</strong>minium will have an aggregate<br />
enterprise value of more than USD15<br />
billion and will be the fifth-largest global aluminium<br />
company by production once Emal<br />
Phase II is complete in the first half of 2014.<br />
Building on the heritage of Emal and Dubal,<br />
the new company will look to expand along<br />
the value chain, from aluminium smelting to<br />
alumina refining and bauxite mining overseas.<br />
Given its scale, Emirates Global <strong>Alu</strong>minium<br />
will also continue to attract downstream manufacturing<br />
and ancillary businesses related to<br />
aluminium smelting and alumina refining as it<br />
grows, thereby indirectly creating additional<br />
jobs.<br />
Emirates Global <strong>Alu</strong>minium will be managed<br />
by a board of directors that will be chaired<br />
by H. E. Khaldoon Khalifa Al Mubarak, current<br />
chairman of Emal, while H. E. Saeed Mohammed<br />
Ahmed Al Tayer, vice-chairman of<br />
Dubal, will become its vice-chair. The board<br />
will also inclu<strong>de</strong> H. E. Sultan Al Jaber, Abdulla<br />
Kalban, Khaled Al Qubaisi, Ahmed Yahia Al<br />
Idrissi, Abdul Wahed Mohammad Al Fahim;<br />
and Khalid Al Bakhit.<br />
The new company will be led by two wellestablished<br />
lea<strong>de</strong>rs in the UAE, both veterans<br />
in the aluminium industry. Abdulla Kalban,<br />
presi<strong>de</strong>nt and CEO of Dubal with 28 years<br />
of experience, will be managing director and<br />
CEO; and Saeed Al Mazrooei, presi<strong>de</strong>nt and<br />
CEO of Emal and lea<strong>de</strong>r of its rise in the industry,<br />
will become CEO of UAE Operations.<br />
“The creation of a new global industrial champion<br />
anchored in the UAE is an important<br />
step towards realising our vision for a diversified<br />
and sustainable economy. It is e<strong>special</strong>ly<br />
inspiring that UAE technology contributed to<br />
the success of this business and that it will continue<br />
to be led by UAE Nationals as it grows<br />
locally and globally,” said Al Mubarak, CEO<br />
of Mubadala. “Emirates Global <strong>Alu</strong>minium<br />
will build on strong foundations of lea<strong>de</strong>rship,<br />
to become a major industrial champion<br />
and engine of economic <strong>de</strong>velopment for our<br />
people.”<br />
H. E. Mohammed I. Al Shaibani, the CEO<br />
of ICD, said: “Today’s announcement builds<br />
on what these two outstanding organisations<br />
have created and reflects the UAE’s long-term<br />
industrial strategy. Emirates Global <strong>Alu</strong>minium<br />
will accelerate employment with 2,000<br />
direct jobs being created by 2020 adding to<br />
more than 6,200 direct jobs already in existence.<br />
We also conservatively estimate that a<br />
further 6,000 indirect jobs will be generated,<br />
<strong>de</strong>livering total employment of over 33,000<br />
people by the UAE aluminium sector through<br />
the end of this <strong>de</strong>ca<strong>de</strong>.”<br />
The agreement signed by Mubadala and<br />
ICD unifies the Jebel Ali and Taweelah<br />
smelter assets as well as interests in Guinea<br />
<strong>Alu</strong>mina Corp. and Cameroon <strong>Alu</strong>mina Ltd.<br />
© Emal<br />
Emal celebrates installation<br />
of steel structure<br />
for Phase II potline<br />
Emirates <strong>Alu</strong>minium (Emal) has recently celebrated<br />
the installation of the final steel structure<br />
for the potline of its Phase II expansion.<br />
With the last of 120 <strong>special</strong>ly <strong>de</strong>signed steel<br />
All the major civil and mechanical work on the world’s longest single potline of 1.7 km is now complete<br />
structures now in place, all the major civil<br />
and mechanical work on the world’s longest<br />
single potline of 1.7 km is now complete and<br />
Emal remains on target to <strong>de</strong>liver its ambitious<br />
expansion plans.<br />
The first steel structure was raised in July<br />
last year, which means that completion was<br />
within the anticipated target of 12 months. The<br />
project was also completed without a single<br />
Lost Time Injury (LTI) – the industry standard<br />
for measuring success in health and safety.<br />
Emal’s Phase II expansion project will increase<br />
primary aluminium production to 1.3<br />
million tonnes a year by the end of 2014, from<br />
today’s 800,000 tonnes a year. Early works<br />
on the estimated USD4.5 billion Phase II expansion<br />
began early in 2011, making Emal one<br />
of the largest industrial projects in the United<br />
Arab Emirates outsi<strong>de</strong> oil and gas and one of<br />
the key projects leading to the diversification<br />
of the UAE’s economy.<br />
Emal has created 2,000 jobs with Emiratisation<br />
at the core of its employment strategy,<br />
which will rise to approximately 3,000 upon<br />
completion of Phase II.<br />
ALUMINIUM · 7-8/2013 9
EVENTS<br />
European <strong>Alu</strong>minium Congress 2013 – The programme is ready<br />
The programme for the EAC – European<br />
<strong>Alu</strong>minium Congress 2013 is ready. The<br />
international congress with its theme<br />
‘<strong>Alu</strong>minium Automotive<br />
Applications –<br />
Tomorrow’s Design and<br />
Sustainable Performance’<br />
will be held by the German<br />
<strong>Alu</strong>minium Association<br />
GDA in Düsseldorf<br />
on 25 and 26 November<br />
2013. The programme<br />
of the EAC 2013 shows<br />
presentations on possible<br />
applications of aluminium<br />
in motor vehicle manufacturing,<br />
but also presentations<br />
on further <strong>de</strong>velopments<br />
with potential for<br />
making vehicles of the<br />
future even lighter and<br />
more energy efficient.<br />
<strong>Alu</strong>minium has become an<br />
indispensable material in the motor car: castings<br />
for engine housings, cylin<strong>de</strong>r heads, and<br />
gearbox housings or for structural parts in the<br />
auto body. Today this is state-of-the-art. But<br />
semi-finished products in the form of sheets,<br />
extru<strong>de</strong>d profiles and forgings<br />
are also being used more and<br />
more in vehicles. Some examples<br />
of this are car body structural<br />
parts, sheets for the outer<br />
shell or crash-related parts,<br />
such as bumper crossbeams or<br />
longitudinal beam structures.<br />
Even more examples can be<br />
found in the form of extru<strong>de</strong>d<br />
profiles used as <strong>de</strong>corative<br />
strips for visual enhancement,<br />
or as safety related parts in the<br />
area of the chassis.<br />
The increasingly intensive<br />
competition between the different<br />
materials has prompted<br />
car manufacturers and aluminium<br />
suppliers to work<br />
more closely together. With<br />
its investments in application-oriented<br />
research and <strong>de</strong>velopment, the<br />
aluminium industry has repeatedly improved<br />
the characteristics of its material, <strong>de</strong>veloped<br />
new products, and optimised production processes.<br />
Innovations in processes and materials<br />
are strong drivers behind the <strong>de</strong>velopment of<br />
efficient lightweight construction solutions<br />
and their implementation in series production,<br />
such as energy-saving components for chassis,<br />
engine and gearbox.<br />
The EAC congress ‘<strong>Alu</strong>minium Automotive<br />
Applications’ is divi<strong>de</strong>d into a total of<br />
five sessions, <strong>de</strong>aling with the subjects <strong>de</strong>sign,<br />
body structure, subframes, process technologies,<br />
joining technologies and surfaces as well<br />
as markets, recycling and sustainability. Notable<br />
speakers from international companies<br />
will offer information and real-life examples<br />
in all the sessions of the congress.<br />
Conference language is English. All presentations<br />
will be simultaneously translated into<br />
German. More information on the congress<br />
<strong>web</strong>site at www.aluminium-congress.com.<br />
Your contact at organiser GDA:<br />
Georg Grumm<br />
Phone: +49 (0)211 4796 160<br />
E-mail: georg.grumm@aluinfo.<strong>de</strong><br />
ICEB – Intl Conference on Extrusion and Benchmark, 8-9 October 2013<br />
The International Conference on Extrusion<br />
and Benchmark (ICEB) has become<br />
the biggest event in Europe related to<br />
the recent <strong>de</strong>velopments on extrusion<br />
technologies and their analysis by FEM<br />
simulation. The fourth edition is planned<br />
for 8-9 October 2013 in Dortmund, Germany.<br />
More than 150 <strong>de</strong>legates atten<strong>de</strong>d the<br />
2011 edition, with participants from over<br />
27 countries including America and the Far<br />
East. With two-thirds of the participants<br />
coming from the industry and with representatives<br />
from all the multinationals of<br />
aluminium, a strong interest was evi<strong>de</strong>nced<br />
in getting and sharing knowledge on these<br />
topics of technological frontier. The aim of<br />
the conference is to join together technical<br />
and scientific experts, to wi<strong>de</strong>spread their<br />
knowledge and to form an international<br />
community for the discussion of state of<br />
the art, as well as future <strong>de</strong>velopments, in<br />
the field of extrusion and in its most powerful<br />
tool, the numerical simulation.<br />
ICEB is a two-in-one event, merging a conference<br />
on the ‘Latest advances in the extrusion<br />
of light alloys’ with an industrial worldwi<strong>de</strong><br />
contest: ‘FEM co<strong>de</strong>s Benchmark’.<br />
• In the conference sessions invited papers<br />
from aca<strong>de</strong>mia as well as from industries will<br />
<strong>de</strong>scribe the most recent <strong>de</strong>velopments in the<br />
analysis, optimisation and research of the light<br />
alloys extrusion processing.<br />
• In the benchmark sessions, participants<br />
will be asked to simulate the extrusion of an<br />
industrial case (a <strong>special</strong>ly <strong>de</strong>signed die for<br />
emphasising selected process-related issues),<br />
on the base of die geometries, material properties,<br />
ram speed and tools temperatures, as<br />
they were monitored by the organisers. Only<br />
during the conference the blind simulations<br />
results will be discussed and compared to<br />
the data recor<strong>de</strong>d during experimental trials,<br />
thus allowing a clear and equal comparison<br />
of different FEM co<strong>de</strong>s and simulating approaches.<br />
This two-in-one event provi<strong>de</strong>s a unique<br />
opportunity to:<br />
• learn about innovation and simulation<br />
capabilities in the extrusion of light alloys<br />
• get gui<strong>de</strong>lines for best process analysis<br />
and product optimisation<br />
• un<strong>de</strong>rstand the potential of your current<br />
simulation tool<br />
• have the wi<strong>de</strong>st possible range of information<br />
on extrusion simulation today.<br />
The conference heads toward extru<strong>de</strong>rs<br />
(technicians, R&D divisions, production<br />
managers), extru<strong>de</strong>d profile users, aca<strong>de</strong>mic<br />
and industrial researchers, die makers,<br />
alloys <strong>special</strong>ists, software houses and software<br />
distributors, press and equipment buil<strong>de</strong>rs.<br />
More information at www.ice-b.net. ■<br />
10 ALUMINIUM · 7-8/2013
EVENTS<br />
Metef 2014 aiming to add new<br />
field of excellence to Italy’s three Fs<br />
The Metef tra<strong>de</strong> fair, one of the leading<br />
international events for aluminium and<br />
innovative metals, will be held for the<br />
tenth time from 11 to 13 June 2014 at<br />
the Verona Exhibition Centre in Italy.<br />
It will have a new format: it will be accompanied<br />
by Foun<strong>de</strong>q and Metalriciclo-<br />
Recomat as in previous years but will<br />
inclu<strong>de</strong> the new <strong>Alu</strong>motive fair for the<br />
first time.<br />
Advertisement<br />
The whole production chain for innovative materials<br />
will be presented at Metef 2014: from<br />
primary and secondary production through<br />
to the processing, machining and finishing of<br />
extrusions, castings and rolled products, including<br />
surface treatment. The new addition<br />
is expected to meet its ambitious target of covering<br />
the whole production chain for aluminium<br />
in the transport and transportation sector.<br />
The organisers are hoping 2014 will be a<br />
turning point for Metef. In 2012, Alfin-Edimet<br />
signed a strategic agreement with Veronafiere<br />
that saw Veronafiere acquire a 50% share in<br />
a newly formed company that took over the<br />
assets of Alfin-Edimet. This partnership gave<br />
Metef Foun<strong>de</strong>q 2012 a global dimension<br />
thanks to the presence of over 500 exhibitors<br />
from 29 countries and of 15,000 visitors, nearly<br />
a third from 69 foreign countries. “The 2014<br />
edition will represent the whole Italian aluminium<br />
and innovative material production chain<br />
on the international arena, where competitiveness<br />
is more and more challenging,” said Veronafiere’s<br />
presi<strong>de</strong>nt Ettore Riello at a recent<br />
press conference. “Veronafiere then becomes<br />
a gui<strong>de</strong> for the organisational management of<br />
this exhibition in or<strong>de</strong>r to consolidate Metef as<br />
b2b show and to represent the whole Italian<br />
manufacturing sector,” he ad<strong>de</strong>d.<br />
Italy is world renowned for its three Fs:<br />
fashion, food and furniture. Metef 2014 is<br />
aiming to add a new field of excellence: a customised<br />
facility for the aluminium and innovative<br />
metals technologies that represent the<br />
core of the country’s manufacturing industry.<br />
This has enabled Italy to <strong>de</strong>velop the <strong>de</strong>sign<br />
and manufacturing skills nee<strong>de</strong>d to produce<br />
high-value products and tailored solutions.<br />
Mario Bertoli, presi<strong>de</strong>nt of Alfin-Edimet,<br />
stressed that the market had changed; globalisation<br />
has altered where many goods are now<br />
being produced and consumed, including in<br />
the metals sector, but he said that this had<br />
not affected Italian excellence. Customised<br />
plants, machinery and technologies are still<br />
Italy’s key strengths; they are well known and<br />
highly regar<strong>de</strong>d all over the world. He ad<strong>de</strong>d<br />
that Metef has been a major source of sector<br />
growth over the last <strong>de</strong>ca<strong>de</strong> and more than<br />
ever now provi<strong>de</strong>s a great opportunity for the<br />
whole production chain to present itself internationally.<br />
Metalriciclo-Recomat focuses on<br />
recycling of industrial materials<br />
Metalriciclo-Recomat will again <strong>de</strong>al with the<br />
recovery and recycling of industrial materials<br />
and will be offering <strong>special</strong>ist information on<br />
products, machinery and technologies in this<br />
sector. The show will benefit from Metef’s internationality<br />
and Veronafiere’s global organisation<br />
and contacts.<br />
Despite the overall <strong>de</strong>cline in the consumption<br />
and production of secondary materials in<br />
<strong>Alu</strong>minium China 2013, Asia’s leading aluminium<br />
exhibition, looks back on a record breaking<br />
number of visitors from around the globe at the<br />
Shanghai New International Expo Centre in July.<br />
With 462 exhibitors (121 first-time participants)<br />
from China, Asia and further abroad, the exhibition<br />
attracted more than 15,200 visitors, an<br />
increase of 28% over last year. This <strong>de</strong>velopment<br />
in number of visitors reflects the rich potential<br />
of Asia’s aluminium markets today driven by a<br />
large number of exhibiting industry giants at<br />
the show such as Kobe Steel, Shanghai Jieru,<br />
Novelis, Wagstaff, Qatalum and SMS Group, to<br />
mention just a few.<br />
<strong>Alu</strong>minium China 2013 also presented two<br />
new feature areas: semi-finished products for<br />
transportation and other key industries, and<br />
packaging products supported by the EAFA’s<br />
<strong>Alu</strong>foil Trophy Award. Alongsi<strong>de</strong> the new<br />
Italy in recent years, the quantity of recovered<br />
and recycled materials is still high. The growth<br />
in metals and materials recycling in all sectors<br />
has led to a significant <strong>de</strong>velopment of<br />
machinery, systems and technologies ma<strong>de</strong><br />
in Italy for the recovery and recycling of materials.<br />
Metef offers the industry’s players an<br />
opportunity to present themselves internationally<br />
and open up new business opportunities.<br />
The Metalriciclo-Recomat fair is aimed at<br />
car breakers, metal collection and recovery<br />
companies, scrap users for downstream hot<br />
processing, waste disposers, recycled metal<br />
tra<strong>de</strong>rs as well as authorities, associations and<br />
institutions involved in the recycling sector.<br />
<strong>Alu</strong>motive at Metef for first time<br />
The <strong>Alu</strong>motive exhibition will present innovative<br />
solutions, components and technological<br />
materials for original equipment in the transportation<br />
sector and will be part of Metef for<br />
the first time in 2014. The show will promote<br />
a sector that in terms of products and number<br />
of employees is one of the traditional strengths<br />
of the manufacturing industry in Italy. It will<br />
be a welcome and useful addition to Metef.<br />
Companies engaged as second and third<br />
tier suppliers will constitute the largest sector<br />
at <strong>Alu</strong>motive; their fields of activity inclu<strong>de</strong><br />
innovative materials, <strong>de</strong>sign and production<br />
of components, processing systems, robots,<br />
engineering, mould making, machining and<br />
finishing.<br />
■<br />
<strong>Alu</strong>minium China 2013 celebrates record attendance<br />
feature areas, the show also launched the <strong>Alu</strong>minium<br />
Downstream Processing Forum, where<br />
the audience gained insights into latest <strong>de</strong>velopments<br />
across closely related application sectors.<br />
The EAFA’s display zone was also combined with<br />
a forum on future opportunities for aluminium<br />
packaging applications in China.<br />
© Reed Exhibitions China<br />
ALUMINIUM · 7-8/2013 11
WIRTSCHAFT<br />
<strong>Alu</strong>minium im Monatsrückblick<br />
Ein Service <strong>de</strong>r TRIMET <strong>Alu</strong>minium SE<br />
Die LME 3-Monatsnotierung für High<br />
Gra<strong>de</strong> <strong>Alu</strong>minium erlebte Mitte Juni an<br />
<strong>de</strong>r LME einen regelrechten Ausverkauf<br />
und rutschte auf ein neues 4-Jahrestief<br />
von USD 1.764,50. Gerüchte über<br />
einen drohen<strong>de</strong>n Liquiditätsengpass<br />
Chinas, die Sorge über <strong>de</strong>n Verlauf <strong>de</strong>r<br />
Euroschul<strong>de</strong>nkrise und die politische Entwicklung<br />
im Nor<strong>de</strong>n Afrikas sorgten für<br />
die eher hastigen Verkaufsaktivitäten<br />
im Metallmarkt. Dagegen stiegen die<br />
LME-Lagerhausbestän<strong>de</strong> erneut an und<br />
markierten mit 5,45 Millionen Tonnen<br />
ein neues Allzeithoch, allerdings wer<strong>de</strong>n<br />
die For<strong>de</strong>rungen nach neuen Lagerhaus-<br />
Regularien durch die LME immer lauter.<br />
Auf- bzw. Abschlag für 3-Monatstermin<br />
Letzten 6 Durchschnittswerte LME<br />
Juni 2013 30,36 Euro<br />
Mai 2013 24,80 Euro<br />
April 2013 25,22 Euro<br />
März 2013 30,79 Euro<br />
Februar 2013 31,22 Euro<br />
Januar 2013 27,92 Euro<br />
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013<br />
0<br />
50<br />
–50<br />
<strong>Alu</strong>minium High Gra<strong>de</strong>, Kasse<br />
Letzten 6 Durchschnittswerte LME 2.500<br />
Juni 2013 1.376,16 Euro<br />
Mai 2013 1.410,51 Euro<br />
April 2013 1.424,60 Euro<br />
März 2013 1.475,92 Euro<br />
Februar 2013 1.538,20 Euro<br />
Januar 2013 1.531,99 Euro<br />
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013<br />
2.000<br />
1.500<br />
1.000<br />
<strong>Alu</strong>minium Lagerbestän<strong>de</strong><br />
Letzten 6 Monatsendwerte LME<br />
Juni 2013 5.435.600 t.<br />
Mai 2013 5.202.000 t.<br />
April 2013 5.157.625 t.<br />
März 2013 5.237.400 t.<br />
Februar 2013 5.162.050 t.<br />
Januar 2013 5.156.975 t.<br />
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013<br />
6.000<br />
5.000<br />
4.000<br />
3.000<br />
2.000<br />
1.000<br />
0<br />
Alle Angaben auf dieser Seite sind unverbindlich.<br />
Quelle: TRIMET <strong>Alu</strong>minium SE – aktuelle LME-Werte unter www.trimet.<strong>de</strong> o<strong>de</strong>r per TRIMET-App auf das iPhone.<br />
12 ALUMINIUM · 7-8/2013
WIRTSCHAFT<br />
Produktionsdaten <strong>de</strong>r <strong>de</strong>utschen <strong>Alu</strong>miniumindustrie<br />
Primäraluminium Sekundäraluminium Walzprodukte > 0,2 mm Press- & Ziehprodukte**<br />
Produktion<br />
(in 1.000 t)<br />
+/-<br />
in % *<br />
Produktion<br />
(in 1.000 t)<br />
+/-<br />
in % *<br />
Produktion<br />
(in 1.000 t)<br />
+/-<br />
in % *<br />
Produktion<br />
(in 1.000 t)<br />
+/-<br />
in % *<br />
Mai 34,4 -7,4 54,3 -4,1 160,7 -4,5 48,9 -12,7<br />
Juni 33,0 -8,0 54,6 6,9 161,0 20,6 49,1 -0,3<br />
Juli 34,8 -5,0 56,0 7,1 166,4 0,9 46,9 -7,4<br />
Aug 34,9 -5,8 47,2 2,9 161,4 1,2 44,9 -11,8<br />
Sep 33,6 -4,4 52,5 -4,3 164,5 8,1 44,6 -17,2<br />
Okt 35,2 -2,5 53,3 -0,3 162,5 9,4 46,1 -7,4<br />
Nov 34,2 -2,9 53,4 -6,4 152,9 0,1 42,5 -20,1<br />
Dez 35,1 -2,1 43,4 -7,0 117,2 7,4 23,3 -22,8<br />
Jan 13 35,4 0,3 52,2 -3,5 159,3 9,5 42,8 -7,6<br />
Feb 33,8 4,4 52,6 -5,3 158,9 6,5 44,3 -7,2<br />
Mär 39,9 17,0 54,4 -5,0 163,1 -1,7 45,5 -9,8<br />
Apr 40,3 20,2 53,9 1,0 173,1 17,6 48,7 8,2<br />
Mai 42,3 23,1 51,5 -5,1 163,2 1,5 45,3 -7,4<br />
* gegenüber <strong>de</strong>m Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung <strong>de</strong>s Gesamtverban<strong>de</strong>s <strong>de</strong>r <strong>Alu</strong>miniumindustrie (GDA), Düsseldorf<br />
Primäraluminium<br />
Sekundäraluminium<br />
Walzprodukte > 0,2 mm<br />
Press- und Ziehprodukte<br />
14 ALUMINIUM · 7-8/2013
WIRTSCHAFT<br />
„Metalle pro Klima“-Veranstaltung bei Otto Fuchs<br />
Klimaschutz durch energieeffiziente Produktion<br />
Die zwölfte Regionalveranstaltung <strong>de</strong>r<br />
Unternehmensinitiative „Metalle pro Klima“<br />
fand Anfang Juli bei <strong>de</strong>r Otto Fuchs<br />
KG in Meinerzhagen statt. Hinrich Mählmann,<br />
persönlich haften<strong>de</strong>r Gesellschafter<br />
<strong>de</strong>s Unternehmens, betonte <strong>de</strong>n Beitrag<br />
<strong>de</strong>r Industrie für <strong>de</strong>n Klimaschutz.<br />
„Wir reduzieren unsere CO 2 -Emissionen<br />
durch Energieeffizienz in <strong>de</strong>r industriellen<br />
Produktion in beträchtlichem Umfang<br />
und kontinuierliche Innovationen und Investitionen“,<br />
erklärte er. Welchen Beitrag<br />
Otto Fuchs zu Klimaschutz, Energie- und<br />
Ressourceneffizienz beiträgt, unterstrich<br />
das Unternehmen mit mehreren Best-<br />
Practice-Beispielen. Der Hersteller von<br />
Produkten aus <strong>Alu</strong>minium, Titan, Magnesium,<br />
Nickel und Kupfer für die Luft- und<br />
Raumfahrt, Automobil- und Bauindustrie<br />
ist Mitglied <strong>de</strong>r Initiative <strong>de</strong>r NE-Metallindustrie.<br />
Draufsicht <strong>de</strong>r bei<strong>de</strong>n neu installierten Zweikammer-Schmelzöfen<br />
Das traditionsreiche Familienunternehmen<br />
aus <strong>de</strong>m Sauerland hat in <strong>de</strong>n zurückliegen<strong>de</strong>n<br />
zehn Jahren an <strong>de</strong>n <strong>de</strong>utschen Standorten<br />
mehr als 300 Millionen Euro investiert. Allein<br />
im laufen<strong>de</strong>n Jahr wer<strong>de</strong>n 40 Millionen Euro<br />
für <strong>de</strong>n Standort in Meinerzhagen aufgebracht.<br />
Investitionen in energieeffiziente Maßnahmen<br />
haben daran einen erheblichen Anteil. Mählmann<br />
sprach seine Erwartungen an die Politik<br />
<strong>de</strong>utlich aus: „Wir setzen auf gute und verlässliche<br />
Rahmenbedingungen für die Industrie in<br />
<strong>de</strong>r Energie- und Steuerpolitik. Dazu gehört<br />
auch <strong>de</strong>r Ausbau und <strong>de</strong>r Erhalt einer mo<strong>de</strong>rnen,<br />
flächen<strong>de</strong>cken<strong>de</strong>n Infrastruktur für das<br />
Industrieland Deutschland.“<br />
Martin Kneer, Hauptgeschäftsführer <strong>de</strong>r<br />
WirtschaftsVereinigung Metalle (WVM), unterstrich<br />
auf <strong>de</strong>r Veranstaltung: “Die Grundstoffindustrie<br />
ist ein wesentlicher Faktor in<br />
<strong>de</strong>r Wertschöpfungskette und legt die Grundlagen<br />
für ein stabiles Bruttosozialprodukt, das<br />
wir mehr <strong>de</strong>nn je benötigen. Unser Ziel ist es,<br />
mittels Best-Practice-Beispielen aus <strong>de</strong>r industriellen<br />
Produktion einen offenen Dialog mit<br />
Politik, Wirtschaft und Medien zu führen.“<br />
Im direkten Gespräch mit Abgeordneten<br />
aus Bun<strong>de</strong>s- und Landtag, Kommunalpolitikern<br />
sowie zahlreichen Personen aus <strong>de</strong>m<br />
öffentlichen Leben <strong>de</strong>r Region stellten die<br />
Experten <strong>de</strong>r Otto Fuchs KG ihre Beiträge<br />
zu Klimaschutz, Energie- und Ressourceneffizienz<br />
vor. Die Politiker, darunter <strong>de</strong>r Wirtschaftsexperte<br />
Matthias Hei<strong>de</strong>r sowie die Sozialpolitiker<br />
Johannes Vogel und Petra Crone,<br />
sprachen einmütig ihre Unterstützung für <strong>de</strong>n<br />
Metallverarbeiter am Standort Meinerzhagen<br />
aus. Sie zeigten sich beeindruckt von <strong>de</strong>n umgesetzten<br />
Maßnahmen zur klimaschonen<strong>de</strong>n<br />
und energieeffizienten Verarbeitung von<br />
Metallen. Die Botschaft, dass Energie sicher,<br />
sauber und bezahlbar sein müsse, sei angekommen.<br />
Kneer und Mählmann for<strong>de</strong>rten mehr Akzeptanz<br />
in Gesellschaft und Politik für die Belange<br />
<strong>de</strong>r Industrie ein. „Schließlich hat uns<br />
die Realwirtschaft durch die Krise geführt. Das<br />
sollte von einem Mentalitätswechsel begleitet<br />
wer<strong>de</strong>n, <strong>de</strong>r letztlich zu ausbalancierten politischen<br />
Entscheidungen führt“, betonten sie.<br />
Optimierte Schmelztechnik erhöht<br />
Materialeffizienz bei Otto Fuchs<br />
„Metall wird bei <strong>de</strong>r Otto Fuchs KG direkt<br />
zurück in <strong>de</strong>n Produktionskreislauf geführt.<br />
„Dies ist für uns sowohl<br />
ökologisch als auch<br />
ökonomisch sinnvoll“,<br />
erklärte Gießereileiter<br />
Frank Vieweg bei <strong>de</strong>r<br />
Vorstellung von Best-<br />
Practice-Beispielen zur<br />
Ressourceneffizienz<br />
und zum Klimaschutz.<br />
Die Stranggießerei <strong>de</strong>s<br />
Unternehmens verarbeitet<br />
fast das gesamte<br />
Kreislaufmaterial, das<br />
in <strong>de</strong>r Produktion im<br />
Werk Meinerzhagen<br />
anfällt. In insgesamt<br />
acht Induktions- und<br />
drei gasbeheizten<br />
Schmelzöfen wird das Material getrennt nach<br />
Legierungen erschmolzen und im Strangguss<br />
zu Rundbarren vergossen.<br />
Im Jahr 2010 wur<strong>de</strong>n vier elektrisch beheizte<br />
Induktionsschmelzöfen nach 40 Jahren<br />
Betrieb durch zwei gasbeheizte Zweikammer-<br />
Schmelzöfen neuester Bauart ersetzt. Dies<br />
spare jährlich rund 6.000 Tonnen CO 2 direkt<br />
auf <strong>de</strong>r Energieseite von Otto Fuchs plus etwa<br />
3.000 Tonnen CO 2 indirekt durch die Erhöhung<br />
<strong>de</strong>r Metallproduktion ein, hob Vieweg<br />
hervor.<br />
Die beson<strong>de</strong>ren Merkmale <strong>de</strong>s Zweikammer-Schmelzofens<br />
liegen in <strong>de</strong>r betont energiesparen<strong>de</strong>n<br />
Schmelztechnik, die auch die<br />
am Einsatzmaterial anhaften<strong>de</strong>n organischen<br />
Bestandteile als Energieträger nutzt. Gleichzeitig<br />
wer<strong>de</strong>n hohe Schmelzleistungen bei<br />
flexibler Schrottart und -qualität erreicht.<br />
Die eingesetzten Öfen arbeiten nach folgen<strong>de</strong>m<br />
Prinzip: Zunächst wird das einzuschmelzen<strong>de</strong><br />
Material in die Chargierkam-<br />
Steuerzentrale (links) und Wärmerückgewinnungseinheit mit Rauchgaskamin (rechts)<br />
© Otto Fuchs<br />
16 ALUMINIUM · 7-8/2013
WIRTSCHAFT<br />
mer <strong>de</strong>s Ofens gefüllt, dort vorgewärmt und<br />
getrocknet. Nach<strong>de</strong>m die Kammer mit <strong>de</strong>m<br />
Rücklaufmaterial befüllt wur<strong>de</strong>, wird bereits<br />
flüssiges Metall von <strong>de</strong>r Hauptkammer<br />
in die Chargierkammer gepumpt. Der Füllstand<br />
steigt an und das Einsatzmaterial wird<br />
geschmolzen. Gleichzeitig wer<strong>de</strong>n die beim<br />
Vorwärmen entstehen<strong>de</strong>n energiehaltigen<br />
Schwelgase (am Rücklaufmaterial anhaften<strong>de</strong><br />
Schmierstoffe) in die Hauptkammer geführt<br />
und dort als Energieträger genutzt. Anschließend<br />
wird die <strong>Alu</strong>miniumschmelze in einem<br />
optimierten Übergabeprozess in <strong>de</strong>n Gießofen<br />
überführt und vergossen.<br />
Der Energiebedarf für das Recycling <strong>de</strong>r<br />
<strong>Alu</strong>miniumlegierungen liegt<br />
mit rund 600 kWh/t bei nur<br />
etwa fünf Prozent <strong>de</strong>s Energiebedarfes,<br />
<strong>de</strong>r zur Herstellung<br />
von Hüttenaluminium notwendig<br />
ist. Außer<strong>de</strong>m ist <strong>de</strong>r<br />
Logistikaufwand durch Transporte<br />
beim werksinternen Recycling<br />
vergleichsweise gering.<br />
„Bei<strong>de</strong>s wirkt positiv auf <strong>de</strong>n<br />
Klimaschutz, da große Mengen<br />
an CO 2 eingespart wer<strong>de</strong>n“, so<br />
Vieweg. Durchschnittlich fünf<br />
Lkw-Fahrten je Woche zum<br />
Transport <strong>de</strong>s Rücklaufmaterials<br />
wer<strong>de</strong>n so vermie<strong>de</strong>n.<br />
Recycling ist in Deutschland<br />
mit etwa zwei Dritteln<br />
<strong>de</strong>s erzeugten Materials eine<br />
<strong>de</strong>r wesentlichen Rohstoffquellen für die heimische<br />
Industrie. Die Gießerei von Otto Fuchs<br />
bezieht vier Fünftel <strong>de</strong>s eingesetzten <strong>Alu</strong>miniums<br />
aus Rücklaufmaterialien <strong>de</strong>s internen<br />
Fertigungsprozesses. Das „Inhouse“-Recycling<br />
von Überschüssen aus <strong>de</strong>r Produktion –<br />
Grate, Pressreste o<strong>de</strong>r Späne – generiert neben<br />
<strong>de</strong>n positiven Auswirkungen auf <strong>de</strong>n<br />
Klimaschutz auch erhebliche wirtschaftliche<br />
Vorteile wie Absicherung <strong>de</strong>r Vormaterialversorgung,<br />
Erhöhung <strong>de</strong>r Flexibilität o<strong>de</strong>r<br />
Senkung <strong>de</strong>r Logistikkosten.<br />
Energieschonen<strong>de</strong> Metallverarbeitung<br />
durch Wärmerückgewinnung<br />
Das Wärmerückgewinnungssystem im Stammwerk<br />
ist ein weiteres Beispiel für die Steigerung<br />
<strong>de</strong>r Energie- und Ressourceneffizienz.<br />
„Mit Hilfe <strong>de</strong>r Wärmerückgewinnung aus<br />
Rauchgas konnten wir seit September 2010<br />
über vier Millionen Kilowattstun<strong>de</strong>n Energie<br />
einsparen und <strong>de</strong>n Ausstoß um 985 Tonnen<br />
Kohlendioxid verringern“, erläuterte Harald<br />
Dewinklo, Prokurist und Leiter Einkauf bei<br />
Otto Fuchs.<br />
Schmie<strong>de</strong>prozess von <strong>Alu</strong>-Rä<strong>de</strong>rn<br />
Bei <strong>de</strong>m neuen, in Zusammenarbeit mit <strong>de</strong>r<br />
ONI Wärmetrafo GmbH aus Lindlar entwickelten<br />
Verfahren wird das bis zu 900 °C<br />
heiße Rauchgas über einen frequenzgeregelten<br />
Heißluftventilator aus <strong>de</strong>m bestehen<strong>de</strong>n<br />
Kamin angesaugt und über einen Wärmetauscher<br />
geleitet. Die zurückgewonnene Wärme<br />
wird für die Warmwasserbereitung genutzt.<br />
Dadurch wird das Kesselhaus entlastet und<br />
Nutzenergie unabhängig von diesem bereitgestellt.<br />
„Die Rückgewinnung thermischer Energie<br />
minimiert <strong>de</strong>n Primärenergieverbrauch,<br />
reduziert überflüssige CO 2 -Emissionen und<br />
erfüllt energiewirtschaftliche und ökologische<br />
Ziele“, betonte Dewinklo.<br />
Die als Baukastensystem entwickelte Lösung<br />
kann als Grundkonzept für Betriebe mit vergleichbaren<br />
Öfen und Warmwasserbetriebsnetzen<br />
genutzt wer<strong>de</strong>n. Der flexible Aufbau<br />
mit Regelkomponenten an <strong>de</strong>n einzelnen Bausteinen<br />
ist beliebig kombinierbar.<br />
Schmie<strong>de</strong>rä<strong>de</strong>r aus <strong>Alu</strong>minium<br />
für klimaschonen<strong>de</strong> Mobilität<br />
Die Begrenzung <strong>de</strong>s CO 2 -Ausstoßes von Pkw<br />
ist für eine klimaschonen<strong>de</strong> Mobilität nicht<br />
nur ein europäisches, son<strong>de</strong>rn zunehmend<br />
auch globales Thema. Der Kraftstoffverbrauch<br />
von Pkw ist von zahlreichen Faktoren abhängig,<br />
vor allem aber vom Gewicht: 36 Prozent<br />
<strong>de</strong>s Kraftstoffverbrauchs ist gewichtsbedingt.<br />
Leichtbau trägt daher entschei<strong>de</strong>nd dazu bei,<br />
einen geringeren Verbrauch bzw. eine höhere<br />
Nutzlast bei Fahrzeugen zu erreichen und damit<br />
auch die Abgasbelastung zu reduzieren.<br />
„Schmie<strong>de</strong>rä<strong>de</strong>r aus <strong>Alu</strong>minium sind ein<br />
beliebtes Designelement an Fahrzeugen und<br />
leisten beson<strong>de</strong>rs bei großen Radabmessungen<br />
einen signifikanten Beitrag zur Gewichtseinsparung<br />
und damit zur Minimierung <strong>de</strong>r CO 2 -<br />
Emissionen“, beschreibt Bernd Velten, Leiter<br />
Technischer Vertrieb und Marketing bei Otto<br />
Fuchs das verbin<strong>de</strong>n<strong>de</strong> Element von Mobilität,<br />
Design und Klimaschutz.<br />
Der Gewichtsvorteil eines Schmie<strong>de</strong>ra<strong>de</strong>s<br />
liegt bei etwa 15 Prozent gegenüber einem<br />
Gussrad (durchschnittliches Gewicht ca. 11<br />
kg), was zu einem Gewichtsunterschied von<br />
netto 1,65 Kilogramm führt. Das be<strong>de</strong>utet<br />
eine Emissionsreduzierung von circa 0,165<br />
Gramm CO 2 je Rad und Kilometer Fahrleistung.<br />
Die Einsparung setzt sich aus zwei<br />
Teilen zusammen, jeweils im Vergleich zu<br />
gegossenen <strong>Alu</strong>-Rä<strong>de</strong>rn: zum einen aus <strong>de</strong>r<br />
direkten Verbrauchsmin<strong>de</strong>rung infolge <strong>de</strong>r<br />
Gewichtseinsparung, zum an<strong>de</strong>ren<br />
aus <strong>de</strong>r Einsparung an<br />
Primärenergie zur Erzeugung<br />
von Hüttenaluminium. Für<br />
das auf die Herstellung geschmie<strong>de</strong>ter<br />
<strong>Alu</strong>-Rä<strong>de</strong>r spezialisierte<br />
Unternehmen Otto<br />
Fuchs – Fertigungsvolumen<br />
jährlich 1,6 Mio. Rä<strong>de</strong>r – errechnet<br />
sich bei einer durchschnittlichen<br />
Fahrleistung von<br />
15.000 Jahreskilometern eine<br />
direkte Einsparung von jährlich<br />
4.000 Tonnen CO 2 plus<br />
weiteren 24.000 Tonnen CO 2<br />
dadurch, dass 2.600 Tonnen<br />
weniger Hüttenaluminium benötigt<br />
wer<strong>de</strong>n.<br />
In <strong>de</strong>n 1960er Jahren erfand<br />
Otto Fuchs die Kombination von sogenannten<br />
Gesenkschmie<strong>de</strong>n und Fließdrücken als<br />
wesentliche Voraussetzung für die Fertigung<br />
einteiliger Schmie<strong>de</strong>rä<strong>de</strong>r. Bis heute ist diese<br />
Technologie das technische Alleinstellungsmerkmal<br />
von Otto Fuchs im hart umkämpften<br />
Markt <strong>de</strong>r Pkw-Rä<strong>de</strong>r aus <strong>Alu</strong>minium.<br />
Die Technologie <strong>de</strong>r Schmie<strong>de</strong>radherstellung<br />
baut auf jahrzehntelangen Erfahrungen<br />
auf. Im Zuge <strong>de</strong>r politisch und öffentlich gewollten<br />
Gewichtsreduzierung bei <strong>de</strong>r PKW-<br />
Herstellung wer<strong>de</strong>n ihre Möglichkeiten <strong>de</strong>utlich<br />
höher bewertet. Ganz beson<strong>de</strong>rs gilt dies<br />
für innovative Fahrzeuge mit Elektroantrieb,<br />
<strong>de</strong>nn die Reichweitenproblematik erfor<strong>de</strong>rt<br />
maximale Anstrengungen bei <strong>de</strong>r Gewichtseinsparung.<br />
Außer<strong>de</strong>m erlauben Schmie<strong>de</strong>rä<strong>de</strong>r<br />
die Herstellung aerodynamisch günstiger<br />
und trotz<strong>de</strong>m leichter Rä<strong>de</strong>r und senken somit<br />
im doppelten Sinne <strong>de</strong>n Fahrwi<strong>de</strong>rstand.<br />
Hintergrundinformationen und Best-<br />
Practice-Beispiele zu weiteren Anwendungen<br />
von NE-Metallen wie <strong>Alu</strong>minium,<br />
Kupfer, Zink fin<strong>de</strong>n sich auf <strong>de</strong>m Internetportal<br />
von „Metalle pro Klima“ unter<br />
www.metalleproklima.<strong>de</strong>.<br />
■<br />
ALUMINIUM · 7-8/2013 17
W irtSCh A ft<br />
SMS group 2012: Auftragseingang zurückgegangen –<br />
Umsatz gestiegen – stabiles Ergebnis<br />
Die SMS group musste 2012 gegenüber<br />
<strong>de</strong>m Vorjahr einen Auftragseinbruch von<br />
rund 17 Prozent auf 2,8 Milliar<strong>de</strong>n Euro<br />
hinnehmen. Der Umsatz stieg dagegen<br />
um fünf Prozent auf 3,2 Mrd. Euro. Das<br />
Gruppenergebnis vor Steuern in Höhe<br />
von 258 Millionen Euro lag annähernd<br />
auf Vorjahresniveau. Wie Heinrich Weiss,<br />
Vorsitzen<strong>de</strong>r <strong>de</strong>r SMS group auf <strong>de</strong>r Jahrespressekonferenz<br />
erläuterte, spürten<br />
bei<strong>de</strong> Unternehmensbereiche – SMS Siemag<br />
und SMS Meer – die Zurückhaltung<br />
<strong>de</strong>r Kun<strong>de</strong>n bei <strong>de</strong>r Auftragsvergabe.<br />
In seinem Ausblick erklärte Weiss, <strong>de</strong>r zum<br />
1. Juli 2013 <strong>de</strong>n Vorsitz <strong>de</strong>r Geschäftsführung<br />
nie<strong>de</strong>rgelegt und <strong>de</strong>n Vorsitz im Aufsichtsrat<br />
übernommen hat: „Wir gehen trotz einer weiterhin<br />
zurückhalten<strong>de</strong>n Investitionsneigung<br />
unserer Kun<strong>de</strong>n bis zum En<strong>de</strong> <strong>de</strong>s Jahres von<br />
einer leichten Erholung <strong>de</strong>s Marktumfelds aus.<br />
Vor <strong>de</strong>m Hintergrund unseres nach wie vor<br />
hohen Auftragsbestands und unter Berücksichtigung<br />
<strong>de</strong>r Auswirkungen <strong>de</strong>r erstmaligen<br />
Konsolidierung von Paul Wurth im laufen<strong>de</strong>n<br />
Geschäftsjahr erwarten wir beim Umsatz eine<br />
leichte Steigerung gegenüber 2012, aber ein<br />
rückläufiges Ergebnis.“<br />
SMS setzt weiterhin auf die Qualitätsfertigung<br />
<strong>de</strong>r anspruchsvollsten Komponenten<br />
<strong>de</strong>r Maschinen und Anlagen in Deutschland.<br />
Dazu wur<strong>de</strong> in <strong>de</strong>n letzten Jahren erheblich<br />
SMS group in 2012: lower or<strong>de</strong>r<br />
intake – higher sales – stable result<br />
Fertigungswerkstatt <strong>de</strong>r SMS Siemag in Hilchenbach<br />
SMS Siemag’s manufacturing shop in Hilchenbach, Germany<br />
The SMS group had to face a significant <strong>de</strong>cline<br />
in or<strong>de</strong>rs intake in 2012 of about 17<br />
percent to 2.8 billion euros. However, sales<br />
increased by five percent to 3.2 billion euros,<br />
and the net group result of 258 million<br />
euros was almost matching the previous<br />
year’s level. At the company’s annual press<br />
conference, Heinrich Weiss, chairman and<br />
chief executive of the SMS group, stated<br />
that both business areas, SMS Siemag and<br />
SMS Meer, had clearly felt the impact of<br />
customers’ restraint in placing or<strong>de</strong>rs.<br />
© SMS group<br />
Wechsel in Aufsichtsrat und<br />
Geschäftsführung <strong>de</strong>r SMS group<br />
Changes in the supervisory and<br />
managing board of SMS group<br />
Heinrich Weiss, seit 45 Jahren für <strong>de</strong>n Aufbau<br />
und die Führung <strong>de</strong>r SMS group verantwortlich,<br />
hat sein Mandat in <strong>de</strong>r Geschäftsführung zum 1.<br />
Juli 2013 nie<strong>de</strong>rgelegt und <strong>de</strong>n Vorsitz im Aufsichtsrat<br />
übernommen. Der bisherige Vorsitzen<strong>de</strong>,<br />
Manfred Bischoff, wird <strong>de</strong>m Unternehmen als<br />
AR-Mitglied verbun<strong>de</strong>n bleiben. Joachim Schönbeck,<br />
bisher bereits Mitglied <strong>de</strong>r Geschäftsführung,<br />
wur<strong>de</strong> zum Sprecher <strong>de</strong>s Unternehmens ernannt.<br />
Gemeinsam mit seinen Kollegen Burkhard<br />
Dahmen und Eckhard Schulte wird er weiterhin<br />
die Geschäftsführung <strong>de</strong>r SMS GmbH bil<strong>de</strong>n.<br />
Joachim Schönbeck wird wie bisher primär für<br />
SMS Meer zuständig sein und Burkhard Dahmen<br />
für SMS Siemag (inkl. <strong>de</strong>r Mehrheitsbeteiligung<br />
Paul Wurth). Eckhard Schulte ist Finanzchef <strong>de</strong>r<br />
Gruppe.<br />
Heinrich Weiss, seit 1. Juli Vorsitzen<strong>de</strong>r <strong>de</strong>s Aufsichtsrates<br />
<strong>de</strong>r SMS group<br />
Heinrich Weiss, chairman of the supervisory board<br />
of the SMS group since 1 July<br />
With effect from 1 July, Heinrich Weiss, who has<br />
been responsible for the <strong>de</strong>velopment and lea<strong>de</strong>rship<br />
of the group of companies for the last 45 years, has<br />
resigned from his post on the managing board and<br />
assumed the chairmanship of the supervisory board.<br />
The present chairman, Manfred Bischoff, will retain<br />
his commitment to the company as a member of<br />
the supervisory board. Joachim Schönbeck, who is<br />
already a member of the managing board, has been<br />
appointed to represent the company externally with<br />
effect from 1 July. Jointly with his colleagues, Burkhard<br />
Dahmen and Eckhard Schulte, he will continue<br />
to constitute the management of SMS GmbH. Mr<br />
Schönbeck will be primarily responsible for SMS Meer<br />
as before, Mr Dahmen will be responsible for SMS<br />
Siemag (including the Paul Wurth majority holding)<br />
and Mr Schulte will be the CFO of the group.<br />
18 ALUMINIUM · 7-8/2013
Looking ahead Mr Weiss, who resigned from<br />
his post on the managing board on 1 July and<br />
at the same time assumed the chairmanship of<br />
the supervisory board, commented: “Despite<br />
a persistent reluctance of our customers to invest,<br />
we expect a slight recovery on the market<br />
by the end of the year. Based on the continued<br />
high level of or<strong>de</strong>rs in hand, and taking<br />
into account the effects of the first full year<br />
of consolidation of the Paul Wurth group this<br />
year, we anticipate a mo<strong>de</strong>st increase in sales<br />
compared to 2012, but a <strong>de</strong>cline in profit.”<br />
To ensure high quality, SMS remains committed<br />
to producing the most complex components<br />
of its machinery and plants in Germany.<br />
That is why the company invested heavily over<br />
recent years in expanding and upgrading its facilities<br />
in Hilchenbach and Mönchengladbach.<br />
Yet, parallel to these measures, it expan<strong>de</strong>d its<br />
production capacity in China. Here it is mainly<br />
about better customer service on the ground<br />
as well as <strong>special</strong> products <strong>de</strong>signed for the<br />
Chinese market and produced at a lower price<br />
locally: in view of the aluminium extrusion<br />
business this, for example, applies to mediumstandard<br />
presses up to 35 MN.<br />
Overall, the aim is to further cut manufacturing<br />
costs by focusing on productionoptimised<br />
<strong>de</strong>sign, greater efficiency in logistics,<br />
plus increased productivity in both engineering<br />
and production. Using the same strategy as<br />
that pursued in the years after the first financial<br />
crisis, the company will make the most of<br />
the weaker or<strong>de</strong>r intake to drive technological<br />
<strong>de</strong>velopment. Equally important to the management<br />
is intensifying onthejob training and<br />
qualification of experienced core personnel as<br />
well as training new staff.<br />
SMS is also expanding its presence outsi<strong>de</strong><br />
Europe by hiring qualified personnel as well<br />
as building production and service facilities in<br />
the key markets China and India. “This is how<br />
we will be able to meet <strong>de</strong>mands in China for<br />
a locallyproduced share of supplies without<br />
increasingly losing these types of or<strong>de</strong>rs to local<br />
competitors,“ said Mr Weiss, adding that<br />
there was still an increased <strong>de</strong>mand for plants<br />
for the aluminium industry in China.<br />
SMS Siemag – still high <strong>de</strong>mand<br />
for aluminium rolling mills<br />
ALUMINIUM · 7-8/2013<br />
in <strong>de</strong>n Ausbau und die Mo<strong>de</strong>rnisierung <strong>de</strong>r<br />
Betriebe in Hilchenbach und Mönchengladbach<br />
investiert. Parallel dazu sind aber auch<br />
die Werkstattkapazitäten in China erweitert<br />
wor<strong>de</strong>n. Hier geht es vor allem um einen besseren<br />
Kun<strong>de</strong>nservice vor Ort und <strong>de</strong>n Bau<br />
von speziellen Produkten, die auf <strong>de</strong>n chinesischen<br />
Markt zugeschnitten sind und dort<br />
kostengünstiger hergestellt wer<strong>de</strong>n können,<br />
im <strong>Alu</strong>miniumsegment beispielsweise mittlere<br />
Standardpressen bis 35 MN.<br />
Insgesamt wird daran gearbeitet, die Herstellkosten<br />
durch fertigungsoptimierte Konstruktionen,<br />
eine höhere Effizienz in <strong>de</strong>r<br />
Logistik und Produktivitätssteigerungen bei<br />
Engineering und Fertigung weiter zu senken.<br />
Wie schon in <strong>de</strong>n Jahren nach <strong>de</strong>r ersten Finanzkrise<br />
wird die schwächere Auftragslage<br />
genutzt, um die technische Entwicklung<br />
voranzutreiben und die Weiterbildung und<br />
Qualifikation <strong>de</strong>s Stammpersonals sowie die<br />
Ausbildung <strong>de</strong>r Nachwuchskräfte zu intensivieren.<br />
Die Präsenz <strong>de</strong>r Gruppe außerhalb Europas<br />
wird durch die weitere Einstellung von<br />
qualifiziertem Personal und <strong>de</strong>n Bau von<br />
Fertigungs und Serviceeinrichtungen in <strong>de</strong>n<br />
Hauptmärkten China o<strong>de</strong>r Indien weiter ausgebaut.<br />
„So können wir die in China gefor<strong>de</strong>rten<br />
lokalen Lieferanteile sicherstellen,<br />
ohne die wir solche Aufträge zunehmend<br />
gegen die Konkurrenzanbieter vor Ort verlieren<br />
wür<strong>de</strong>n“, sagte Weiss. In China bestehe<br />
weiterhin eine verstärkte Nachfrage nach<br />
Anlagen für die <strong>Alu</strong>miniumindustrie.<br />
SMS Siemag – Nachfrage nach<br />
<strong>Alu</strong>miniumanlagen hält an<br />
Die seit Jahren anhaltend hohe Nachfrage<br />
nach <strong>Alu</strong>miniumanlagen <strong>de</strong>r SMS Siemag<br />
hat sich 2012 fortgesetzt. Sowohl <strong>de</strong>r Auftragseingang<br />
als auch <strong>de</strong>r Umsatz legten zu.<br />
Für das laufen<strong>de</strong> Jahr 2013 rechnet SMS mit<br />
einem weiteren, mo<strong>de</strong>raten Anstieg.<br />
Entsprechend <strong>de</strong>m Wunsch vieler <strong>Alu</strong>miniumkun<strong>de</strong>n<br />
nach einer vollständigen Lieferung<br />
hat SMS Siemag das speziell auf das<br />
<strong>Alu</strong>miniumwalzen abgestimmte Automatisierungssystem<br />
<strong>Alu</strong>Control entwickelt. Mit<br />
diesem System konnte <strong>de</strong>r Anteil <strong>de</strong>r <strong>Alu</strong><br />
Walzwerke, die komplett mit Elektrik und<br />
Automatisierung geliefert wur<strong>de</strong>n, 2012 auf<br />
über 80 Prozent gesteigert wer<strong>de</strong>n.<br />
Eines von mehreren Großprojekten für<br />
die <strong>Alu</strong>miniumindustrie ist die Warmwalzlinie<br />
von Henan Zhongfu Industrial. Bereits<br />
einen Monat vor <strong>de</strong>m vertraglich fixierten<br />
Termin und nach einer nur sechswöchigen<br />
Inbetriebnahmephase lief im Dezember<br />
MEHR PRÄZISION<br />
Already high in recent years, <strong>de</strong>mand for aluminium<br />
plants remained strong in 2012. SMS<br />
Siemag was able to further increase both or<strong>de</strong>r<br />
intake and sales. Another mo<strong>de</strong>rate increase<br />
looks likely in 2013. Responding to the wishes<br />
of many aluminium customers for a complete<br />
supply package, SMS Siemag has <strong>de</strong>veloped<br />
<strong>Alu</strong>Control, an automation system specifi<br />
BANDDICKE-<br />
& PROFIL<br />
laser-optisch mit<br />
thicknessCONTROL<br />
GESCHWINDIGKEIT<br />
& LÄNGE<br />
optisch mit<br />
ASCOspeed<br />
www.micro-epsilon.<strong>de</strong><br />
Micro-Epsilon Messtechnik<br />
94496 Ortenburg · Tel. 0 85 42/168-0<br />
info@micro-epsilon.<strong>de</strong>
W irtSCh A ft<br />
2012 das Band mit einer<br />
Breite von 1.330 mm und<br />
einer Enddicke von 6 mm<br />
aus <strong>de</strong>r Anlage in Gongyi<br />
in <strong>de</strong>r Provinz Henan.<br />
Künftig sollen auf <strong>de</strong>r neuen<br />
Anlage 760.000 Tonnen<br />
<strong>Alu</strong>miniumwarmband im<br />
Jahr für ein breites Anwendungsspektrum<br />
wie<br />
Folien, Verpackungen, Getränkedosen,<br />
Automotive,<br />
Fassa<strong>de</strong>nbleche und die<br />
Druckindustrie produziert<br />
wer<strong>de</strong>n. Das Unternehmen<br />
vergab an SMS Siemag zu<strong>de</strong>m<br />
<strong>de</strong>n Auftrag für eine<br />
Farbbeschichtungslinie<br />
für 70.000 Tonnen Dosenband;<br />
die Anlage wird<br />
2014 in Betrieb gehen.<br />
Außer<strong>de</strong>m wur<strong>de</strong>n zwei<br />
Aufträge zur Lieferung von<br />
GATVSch<strong>web</strong>ebandöfen<br />
für <strong>Alu</strong>miniumBandbehandlungsanlagen<br />
hereingeholt<br />
– ein Auftrag ist<br />
von Henan Zhongfu Industrial,<br />
ein weiterer vom Ma’a<strong>de</strong>n Alcoa Joint<br />
Venture, wo ab 2014 jährlich 50.000 Tonnen<br />
<strong>Alu</strong>miniumband für die Automobilindustrie<br />
geglüht und chemisch behan<strong>de</strong>lt wer<strong>de</strong>n sollen.<br />
In bei<strong>de</strong>n Linien überzeugt <strong>de</strong>r GATV<br />
Sch<strong>web</strong>ebandofen durch ein kompaktes Design,<br />
eine gleichmäßige Erwärmung und Kühlung<br />
<strong>de</strong>s Ban<strong>de</strong>s über <strong>de</strong>n gesamten Querschnitt<br />
sowie eine beson<strong>de</strong>rs hohe Energieeffizienz<br />
und Umweltfreundlichkeit.<br />
SMS Meer profitiert weiterhin<br />
von Nachholbedarf in China<br />
Die Son<strong>de</strong>rkonjunktur in <strong>de</strong>r <strong>Alu</strong>miniumindustrie<br />
setzte sich auch bei SMS Meer weiter<br />
fort. Hier ist – im Gegensatz zum Stahlmarkt –<br />
infolge eines großen Nachholbedarfs die<br />
Volksrepublik China nach wie vor <strong>de</strong>r Wachstumstreiber.<br />
Bei <strong>de</strong>n hydraulischen Pressen<br />
führte dies zu neuen Dimensionen in <strong>de</strong>n Abmessungen.<br />
So bestellte Jilin Liyuan <strong>Alu</strong>minium<br />
aus Liaoyuan (Provinz Jilin) bei SMS Meer<br />
zwei neue Pressen: ein 160MNFrontla<strong>de</strong>r<br />
und eine 60MNDirekt/IndirektRohrpresse.<br />
Die neue 160MNAnlage wird die größte<br />
mo<strong>de</strong>rne Frontla<strong>de</strong>rStrangpresse sein, die<br />
weltweit in Betrieb ist. Damit kann Jilin Liyian<br />
Profile bis zu einem Meter Breite herstellen.<br />
Die Länge <strong>de</strong>r Profile erreicht bis zu 28 Meter<br />
– das entspricht <strong>de</strong>r Waggonlänge mo<strong>de</strong>rner<br />
Hochgeschwindigkeitszüge wie <strong>de</strong>m ICE<br />
18-MN-Presse, in <strong>de</strong>r Werkstatt von SMS Meer in Shanghai gebaut<br />
18-MN press, being built at SMS Meer’s manufacturing shop in Shanghai<br />
o<strong>de</strong>r TGV. Jilin Liyuan kann damit Bauteile<br />
für einen Zugwaggon in einem Pressvorgang<br />
herstellen, was Zeit, Energie und Kosten spart.<br />
Außer<strong>de</strong>m sind das Leichtbau<strong>de</strong>sign und die<br />
hohe Recyclingfähigkeit wichtige Antworten<br />
auf ökologische For<strong>de</strong>rungen.<br />
Ecomelt-Schmelzöfen – hohe<br />
Energieeffizienz und Metallausbeute<br />
Das Einschmelzen von <strong>Alu</strong>miniumschrotten<br />
gewinnt seit Jahren an Be<strong>de</strong>utung. Hier sind<br />
die EcomeltSchmelzöfen <strong>de</strong>r SMSTochter<br />
Hertwich Engineering gefragt, die sich durch<br />
Energieeffizienz und geringe Metallverluste<br />
auszeichnen. Aufträge zur Lieferung von EcomeltÖfen<br />
wur<strong>de</strong>n 2012 von Novelis Italia,<br />
vom slowenischen Unternehmen Impol und<br />
von Constellium in Tschechien erteilt.<br />
<strong>Alu</strong>minium Mostar, BosnienHerzegowina,<br />
bestellte bei Hertwich eine Masselgießlinie.<br />
Die Anlage umfasst einen Schmelz und Gießofen<br />
sowie ein luftgekühltes Masselgießband.<br />
Trimet <strong>Alu</strong>minium nahm 2012 eine Masselgießanlage<br />
in Betrieb. Eine Beschreibung <strong>de</strong>r<br />
Anlage fin<strong>de</strong>t sich auf <strong>de</strong>n Seiten 44ff.<br />
Aus <strong>de</strong>n GolfStaaten erhielt Hertwich von<br />
<strong>de</strong>n <strong>Alu</strong>miniumhütten Dubal und Emal <strong>de</strong>n<br />
Auftrag über Ultraschallprüfanlagen zur Qualitätskontrolle<br />
für Rundbarren. Emal bestellte<br />
darüber hinaus auch zwei Kammerhomogenisierungsöfen.<br />
■<br />
cally <strong>de</strong>signed for aluminium rolling. Due to<br />
this system, the share of aluminium rolling<br />
mills supplied complete with electrics and automation<br />
could be increased to more than 80<br />
percent in 2012.<br />
One of several major projects for the aluminium<br />
industry is the new hot rolling mill at<br />
Henan Zhongfu Industrial. In midDecember,<br />
a whole month before the contractual <strong>de</strong>adline<br />
and after a commissioning phase of just<br />
six weeks, the first 1,330 mmwi<strong>de</strong> strip with<br />
a final gauge of 6 mm rolled off the line in<br />
Gongyi, Henan Province. In the future, the<br />
new plant will produce 760,000 tonnes of hot<br />
strip for a wi<strong>de</strong> application spectrum such as<br />
foil, packaging, beverage cans, automotive and<br />
faca<strong>de</strong> panels, and printing industry supplies.<br />
for your benefit:<br />
Suppliers Directory<br />
On pages 76 to 89,<br />
leading equipment suppliers<br />
to the aluminium industry<br />
present their product portfolios<br />
and ranges of services.<br />
Take advantage of this<br />
useful information.<br />
20 ALUMINIUM · 7-8/2013
ECo N o M i CS<br />
The Chinese company also awar<strong>de</strong>d SMS Siemag<br />
the contract for a colour coating line for<br />
70,000 tonnes of strip in the form of can stock;<br />
commissioning of the plant is scheduled for<br />
the year 2014.<br />
Moreover, SMS Siemag attracted two or<strong>de</strong>rs<br />
for GATV strip flotation ovens for aluminium<br />
strip processing plants – one or<strong>de</strong>r is, again,<br />
from Henan Zhongfu while the other one is<br />
from the Ma’a<strong>de</strong>n Alcoa joint venture, where,<br />
as from 2014, 50,000 tonnes of aluminium<br />
strip a year will be annealed and chemically<br />
treated for the automotive industry. Particularly<br />
impressive features of the GATV strip<br />
flotation ovens in both lines are the compact<br />
<strong>de</strong>sign, even strip heating and cooling over the<br />
entire crosssection, plus extrahigh energy efficiency<br />
and ecofriendliness.<br />
SMS Meer benefits from<br />
backlog of <strong>de</strong>mand<br />
The exceptional boom in the aluminium industry<br />
continued in 2012 and generated high <strong>de</strong>mand,<br />
particularly in China which remains the<br />
engine of growth because of its huge backlog<br />
of <strong>de</strong>mand. For the hydraulic presses this led<br />
to new dimensions in product sizes. Jilin Liyuan<br />
<strong>Alu</strong>minium in Liaoyuan (Jilin Province)<br />
or<strong>de</strong>red two new presses from SMS Meer: a<br />
160MN frontloading press and a 60MN direct/indirect<br />
tube press. The 160MN machine<br />
will be the world’s largest mo<strong>de</strong>rn extrusion<br />
press of its type in operation today. It will enable<br />
Jilin Liyuan to manufacture profiles up<br />
to one metre in width. The maximum profile<br />
length is 28 metres – equivalent to the railcar<br />
length of mo<strong>de</strong>rn highspeed trains such as the<br />
ICE or the TGV. With the new machine, Jilin<br />
will be able to manufacture railcar components<br />
in a single extrusion process. That saves<br />
time, energy and money. Extra benefits are the<br />
lightweight <strong>de</strong>sign and high recycling capability<br />
that meet green requirements.<br />
Ecomelt furnaces – high energy<br />
efficiency and low metal loss<br />
The melting of aluminium scrap has been gaining<br />
in importance for years. Here Ecomelt<br />
furnaces from Hertwich Engineering are in<br />
<strong>de</strong>mand as they consume much less gas than<br />
conventional melting furnaces. The results are<br />
lower energy costs, and the immersion melting<br />
process reduces metal loss to below three<br />
percent. Or<strong>de</strong>rs for the supply of Ecomelt<br />
furnaces were placed by Novelis Italia, Impol<br />
in Slovenia and Constellium in the Czech Republic.<br />
<strong>Alu</strong>minij Mostar, BosniaHerzegovina, or<strong>de</strong>red<br />
a belttype billet casting line from Hertwich<br />
to boost its productivity and flexibility.<br />
The plant comprises a melting and casting furnace<br />
as well as an aircooled belttype billet<br />
casting line. Trimet <strong>Alu</strong>minium in Germany<br />
commissioned a billet casting line in 2012; a<br />
<strong>de</strong>tailed <strong>de</strong>scription of the plant is given on<br />
pages 44ff.<br />
Hertwich received or<strong>de</strong>rs from the aluminium<br />
producers Dubal and Emal for ultrasonic<br />
testing facilities for the quality control of billets.<br />
Furthermore, Emal awar<strong>de</strong>d a contract<br />
for the supply of two chamber homogenising<br />
furnaces.<br />
■<br />
Join together.<br />
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16–21 SEPT. 2013 ESSEN GERMANY<br />
Meet over 1,000 exhibitors and experts from all<br />
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and surfacing.<br />
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industry’s hot spot.<br />
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ECo N o M i CS<br />
CRU’s World <strong>Alu</strong>minium Conference 2013 in London<br />
Key turning points<br />
Principal issues that have been affecting<br />
the aluminium industry over the past<br />
couple of years are reaching key turning<br />
points. This sentiment was echoed by<br />
a number of speakers at CRU’s World<br />
<strong>Alu</strong>minium Conference in London this<br />
year. Recurrent themes surrounding the<br />
functionality of the LME and its warehouses,<br />
legislative impacts on the industry<br />
and un<strong>de</strong>rstanding where the value is in<br />
the supply chain were among the hotly<br />
<strong>de</strong>bated topics engaging the conference’s<br />
250 <strong>de</strong>legates.<br />
the LME – help or hindrance?<br />
The primary aluminium market is currently in<br />
a state of gross oversupply. It is estimated that<br />
approximately five million tonnes of metal is<br />
stored in LME warehouses, whilst consumers<br />
are waiting for access to their metal due to excessively<br />
long queuing times. The link between<br />
LME warehouses, price premiums and the<br />
continuous state of oversupply brought into<br />
question the role of the LME in the industry.<br />
The consensus was that the situation is now<br />
critical and needs to be addressed by major<br />
players in the market to restore balance.<br />
One of the keynote speakers, Oleg Mukhamedshin,<br />
<strong>de</strong>puty CEO at UC Rusal, called<br />
for greater transparency in LME pricing<br />
mechanisms and a push for these prices to<br />
greater reflect actual market fundamentals. A<br />
question repeatedly raised by <strong>de</strong>legates was<br />
why aluminium smelters were still producing<br />
at historically high rates <strong>de</strong>spite <strong>de</strong>pressed<br />
prices and an already plentiful stockpile in<br />
warehouses. In addition to this, estimates that<br />
20 to 30% of all producers (excluding China)<br />
were making a loss at today’s price levels<br />
fuelled further questions surrounding producer<br />
responsibility and controls on production.<br />
Tim Reyes, presi<strong>de</strong>nt of Alcoa Minerals<br />
Management, explained that the influence of<br />
the financial community on the LME pricing<br />
system was unlikely to change in the nearterm.<br />
He believes that capital will continue<br />
to flow through the industry, and that people<br />
will be keen to hold onto their assets. Instead<br />
of waiting for a turn in the financial markets,<br />
the industry must look towards producers for<br />
swift implementation of curtailments. Alcoa,<br />
for example, are advancing their programme<br />
to curtail capacity, with over 560,000 tonnes<br />
of primary aluminium shutdown in 2012, and<br />
plans to review additional curtailments over<br />
the coming months. Other major producers including<br />
Rusal are thought to be implementing<br />
similar strategies to counter market surplus.<br />
In this context, CRU believes that if prices<br />
fall a further 5 to 10% below current levels,<br />
it could have a significant impact on the volume<br />
of curtailments. The mutual <strong>de</strong>pen<strong>de</strong>nce<br />
of the power as well as aluminium industry<br />
as one of the drivers behind escalating warehouse<br />
stocks is an alternative view on the situation.<br />
With energy intensive industries such<br />
as aluminium often providing an i<strong>de</strong>al outlet<br />
for stran<strong>de</strong>d power, an intimate relationship<br />
has <strong>de</strong>veloped between the two. The result<br />
has seen the power industry and governments<br />
with surplus power dictating the construction<br />
of aluminium smelters instead of the reverse.<br />
In a market of significant surplus, consumers<br />
should be the winners, benefitting from<br />
the low prices associated with plentiful supply.<br />
This, however, is not the case for most consumers<br />
at present. The problem the consumer<br />
faces in the current market is that LME warehouses<br />
have ma<strong>de</strong> access to metal a difficult<br />
and lengthy process. Not only are consumers<br />
unable to hedge the premiums associated with<br />
the metal, a large proportion of LME aluminium<br />
is held at two main locations: Vlissingen<br />
in The Netherlands and Detroit in the United<br />
States. Despite new legislation <strong>de</strong>signed to<br />
make access to the metal easier, long queues<br />
persist at these locations.<br />
Will China <strong>de</strong>liver?<br />
Another potential solution to the market surplus<br />
seen today would be the realisation of<br />
the long predicted ‘China effect’ taking hold of<br />
the aluminium industry. For a number of<br />
years, China has been singled out as a key contributor<br />
to booming commodity markets, fuelling<br />
unprece<strong>de</strong>nted growth in industries such<br />
as iron ore. The aluminium industry had, until<br />
recently, been predicting similar increases in<br />
<strong>de</strong>mand and a drawdown of primary metal<br />
to supplement domestic supply gaps. These<br />
predictions have yet to materialise and it is<br />
seemingly less likely that such significant supply<br />
gaps with actually transpire.<br />
CRU believes that while government policies<br />
will favour the import of energy intensive<br />
products such as aluminium, the current high<br />
primary production levels and wi<strong>de</strong>spread<br />
overcapacity leaves little scope for China to<br />
increase imports. Despite this, there is some<br />
hope that activity in China may provi<strong>de</strong> some<br />
support in restoring balance to the primary<br />
aluminium market.<br />
China’s recently elected government has<br />
proposed four main options to <strong>de</strong>al with overcapacity:<br />
increasing <strong>de</strong>mand for primary aluminium,<br />
moving capacity to other countries,<br />
encouraging greater industry consolidation<br />
and closure of old, outdated capacity. By far<br />
the least explored option, moving capacity,<br />
has seen an increase in recent activity with<br />
Rusal and Chalco signing an MoU to build<br />
a Siberian smelter, following in the footsteps<br />
of Rusal, China Xinfa Group and China’s<br />
Citic who have also ma<strong>de</strong> steps to establish<br />
themselves abroad. Whilst there is indication<br />
of <strong>de</strong>velopment in all of the aforementioned<br />
options, the collective impact may do little<br />
to the overall balance if China pushes ahead<br />
with new smelter capacity in Xinjiang.<br />
the raw materials challenge<br />
China will need to look for alternative supply<br />
for their booming smelter and refinery industry,<br />
e<strong>special</strong>ly with the Indonesian export ban<br />
anticipated in 2014. With further evi<strong>de</strong>nce<br />
of a push towards resource nationalism from<br />
a number of countries, securing future feedstock<br />
supply will be a key challenge not only<br />
for China, but for primary producers across<br />
the globe. Since the Indonesian government<br />
ma<strong>de</strong> clear their intention to restrict raw<br />
material exports back in 2009, resource nationalism<br />
has become a central theme of the<br />
upstream aluminium industry.<br />
An Indonesian ban on bauxite exports is<br />
anticipated to heavily impact China as Indonesia<br />
is the country’s largest supplier of gibbsite<br />
bauxite. It is likely that traditional Chinese<br />
importers will look to secure resources<br />
by investing in refining facilities in Indonesia.<br />
In addition to the muchdiscussed Indonesian<br />
bauxite ban, numerous other policies were<br />
touched upon in key producing regions: MRRT<br />
and carbon tax in Australia, bauxite export<br />
bans in India, an export ban in Vietnam and<br />
reviews for the royalty system in Brazil. The<br />
push for these policies will greatly impact the<br />
security of bauxite supply for producers and<br />
led some to question if bauxite would become<br />
the new iron ore.<br />
The consensus amongst the panel for the<br />
Raw Materials and Cost Trends Session was<br />
that while there are some issues surrounding<br />
access to bauxite and difficulty in bringing<br />
projects online, the world’s bauxite resource<br />
base is plentiful. Therefore, whilst prices are<br />
expected to increase, the consensus is that it is<br />
22 ALUMINIUM · 7-8/2013
unlikely to reach the levels that iron ore has.<br />
Where is the value?<br />
There was agreement that value is diverging,<br />
with a movement upstream towards bauxite<br />
and downstream towards rolled products.<br />
The challenging environment <strong>de</strong>veloping<br />
at the upper end of the value chain has contributed<br />
to the shift in profitability. As supply<br />
of feedstock tightens and sources become<br />
less clear, prices are expected to rise and<br />
lesser known bauxite producing countries<br />
will emerge as front runners of supply. It is<br />
thought that this uncertainty in the upstream<br />
industry could potentially be the production<br />
constraint that the industry needs to curtail<br />
primary production.<br />
At the other end of the spectrum, the rolled<br />
products market is benefitting from a surge in<br />
<strong>de</strong>mand driven by the transport and construction<br />
sectors. Investments into research and<br />
<strong>de</strong>velopment for aluminium uses have been<br />
prolific in recent years, and with the automotive<br />
and aerospace industries in particular<br />
realising the benefits of aluminium, there is<br />
scope for significant growth. Low primary<br />
prices have benefitted the downstream industry<br />
and increased the competitiveness of<br />
aluminium as a substitute for other materials<br />
in transport sector.<br />
<strong>Alu</strong>minium is able to provi<strong>de</strong> automotive<br />
manufacturers with significant weight<br />
reductions and therefore better fuel savings<br />
and lower emissions. For every 10% saving<br />
in weight, a 5 to 7% saving can be ma<strong>de</strong> on<br />
fuel. This has a number of beneficial knockon<br />
effects for: (a) the consumer as cars require<br />
less fuel, (b) the producer as weight saving improves<br />
performance and (c) the environment<br />
as automotive emissions are reduced.<br />
the <strong>de</strong>mand for sustainability<br />
With respect to ‘recycling’, there was agreement<br />
that legislation would, in time, need to<br />
be revised to better represent the changes in<br />
consumer usage today. Scrap was i<strong>de</strong>ntified as<br />
a major opportunity for Europe to retain aluminium<br />
production while primary producers<br />
suffer with tougher operating environments.<br />
The <strong>de</strong>mand for <strong>special</strong>ised alloys from secondary<br />
material is also growing strongly, driven<br />
primarily by the automotive sector.<br />
Europe has the opportunity to capitalise on<br />
this growth to ensure that it is not merely a<br />
scrap exporter, but that it is following in the<br />
footsteps of other regions and ensuring that<br />
value is being ad<strong>de</strong>d to resources before<br />
export. In this case, Europe’s resource is its<br />
significant scrap pool, which, un<strong>de</strong>r current<br />
forecast consumption rates will continue to be<br />
a major source of aluminium for many years<br />
to come.<br />
Growing importance of sustainability within<br />
the industry is <strong>de</strong>monstrated by Novelis<br />
Europe with an ambitious target for 80% of<br />
their material to be from recycled products<br />
by 2020.<br />
What does the future hold<br />
for the aluminium industry?<br />
The outlook for aluminium, according to many<br />
industry experts, remains <strong>de</strong>pen<strong>de</strong>nt on the<br />
actions of the LME. Tackling the issues surrounding<br />
premiums and warehousing are integral<br />
to improving the current imbalance in<br />
the market. Others believe much of the<br />
blame lies with producers who continue to<br />
ignore ‘free market commercial signals’ that<br />
call for greater control and curtailment in<br />
production. In reality, it is perhaps the responsibility<br />
of both the aluminium producers and<br />
the LME to take active steps towards a resolution.<br />
Producers must cut high cost capacity<br />
and ensure that capacity is built in response<br />
to <strong>de</strong>mand instead of other industry factors.<br />
Meanwhile the LME, facilitators of the current<br />
surplus market, must look for a way to reduce<br />
the influence of the financial community on<br />
the LME price, and instead adopt a pricing<br />
mechanism that better represents the fundamentals<br />
of the market. The most recent commitments<br />
by companies to curtail production<br />
will steadily reduce surplus, and this, paired<br />
with strengthening <strong>de</strong>mand across the value<br />
chain, provi<strong>de</strong>s potential respite for the situation.<br />
<strong>Alu</strong>minium, unlike a number of other metal<br />
markets, has never seen the commodities supercycle<br />
reflected in its pricing. The boom in<br />
commodities prices, partially fuelled by China,<br />
had significant impacts on the iron ore and<br />
copper markets but the fundamentals of the<br />
aluminium market have worked against such<br />
significant price escalation. With the easing of<br />
Chinese growth, sentiment in such Chinacentric<br />
markets has suffered, and now the lack of<br />
a supercycle in the aluminium industry can be<br />
viewed as a benefit.<br />
Over the next few years, as other industries<br />
struggle with changes in market factors that<br />
are essentially out of their hands, aluminium<br />
is in a stronger position to make the necessary<br />
changes from within the industry itself.<br />
Author<br />
Pernelle Nunez, consultant, CRU Strategies<br />
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New alumina project approach –<br />
<strong>de</strong>dicated <strong>de</strong>sign, compact capacity<br />
P.-h. ter Weer, tWS Services & Advice<br />
1. Synopsis<br />
As discussed elsewhere the <strong>de</strong>sign / initial refinery<br />
production capacity of greenfield alumina<br />
projects outsi<strong>de</strong> China has evolved from<br />
about 0.51.0m tpy 25 to 30 years ago to about<br />
1.53 + m tpy for more recently constructed and<br />
future planned projects [1]. Despite this large<br />
scale increase economics did not structurally<br />
improve, mainly as a result of large capital cost<br />
increases for alumina projects in this period.<br />
The increase in project scale had major consequences:<br />
• Significantly increased project complexity:<br />
planning and management, extensive government<br />
involvement, huge capital cost (multibillion<br />
USD, project financing, multiparty joint<br />
ventures).<br />
• Worldwi<strong>de</strong> only a limited number of large<br />
companies are left with the resources to <strong>de</strong>velop<br />
greenfield projects, and only a few engineering<br />
firms with the skills and experience<br />
to implement these projects.<br />
• Typically a project life of 30 + years applies<br />
to the significant investment of a greenfield<br />
bauxite and alumina project. For projects with<br />
a captive refinery this means that the bauxite<br />
<strong>de</strong>posit on which they are based should sustain<br />
refining operations for such a period of time.<br />
Therefore only (very) large bauxite <strong>de</strong>posits<br />
are <strong>de</strong>veloped, indicatively 200300 million<br />
tonnes and more.<br />
• Summarising: worldwi<strong>de</strong> only a small num<br />
ber of companies <strong>de</strong>velop mostly very large<br />
greenfield bauxite and alumina projects which<br />
often takes a <strong>de</strong>ca<strong>de</strong> or more.<br />
This paper <strong>de</strong>scribes a new twostage approach<br />
to improve on the state of affairs<br />
outlined above: first and foremost base any<br />
greenfield project on a <strong>de</strong>dicated <strong>de</strong>sign and<br />
layout for a specified production capacity, and<br />
secondly apply this methodology to a compact<br />
refinery capacity. Objectives are to improve<br />
alumina project economics and to <strong>de</strong>velop<br />
an option of smaller greenfield bauxite and<br />
alumina projects at acceptable economics.<br />
The economic basis of the new approach is<br />
discussed in section 3, technical aspects are<br />
covered in section 4.<br />
2. Commodities and<br />
current refinery <strong>de</strong>sign<br />
Commodities such as concrete, steel, mechanical<br />
bulks (e.g. valves), piping, wire and cable,<br />
etc. represent a significant element (typically<br />
~30%) of a refinery’s capital cost as illustrated<br />
in the lefthand column (Current <strong>de</strong>sign) of<br />
Table 1 (see next page) for a typical current<strong>de</strong>sign<br />
1.5m tpy ‘lowtemperature digestion’<br />
alumina refinery.<br />
Importantly commodity amounts and the<br />
related capital costs reflect plant <strong>de</strong>sign and<br />
layout. Current alumina refineries are <strong>de</strong>signed<br />
to accommodate additional future digestion<br />
units (and all of the other required process<br />
units – e.g. precipitation, evaporation), i.e.<br />
plant <strong>de</strong>sign is not optimised for its initial production<br />
capacity. Plant layout is characterised<br />
by an ‘open architecture’ as illustrated in Fig.<br />
1 by the main piperack layout of recently<br />
<strong>de</strong>signed 1.5m tpy alumina refineries, which<br />
represents at best a compromise between the<br />
limited layout requirements for the initial /<br />
<strong>de</strong>sign capacity and the more extensive requirements<br />
to accommodate future additional<br />
process units. And at worst consists of a largecapacity<br />
plant part of which is built, resulting<br />
in an inefficient plant layout for the <strong>de</strong>sign /<br />
initial capacity. In summary plant <strong>de</strong>sign is<br />
not optimised for its <strong>de</strong>sign / initial production<br />
capacity.<br />
3. New project approach<br />
3.1 Step 1 – Dedicated <strong>de</strong>sign & layout<br />
The new approach is based on a <strong>de</strong>dicated<br />
refinery <strong>de</strong>sign and layout for a specified production<br />
capacity, i.e. tailoring the <strong>de</strong>sign to the<br />
equipment and infrastructure requirements<br />
(earth works, power, water supply, piperacks,<br />
roads, cable trays) of the selected production<br />
capacity. This approach enables optimising<br />
plant layout for the targeted production capacity<br />
e.g. with respect to positioning similar<br />
equipment close to each other, and the use of<br />
common spares; it impacts positively on commodity<br />
volumes, and it focuses on a ‘lean’<br />
<strong>de</strong>sign. Consequentially the <strong>de</strong>sign exclu<strong>de</strong>s<br />
provisions for future expansions, which should<br />
be justified on their own economic merits.<br />
This more ‘closed’ layout architecture results<br />
in a more efficient plant layout, reflected for<br />
example in the <strong>de</strong>sign of the main plant piperacks<br />
as illustrated in Fig. 2 for a 1.5m tpy<br />
refinery (compare with the piperack layouts<br />
of Fig. 1 which are on the same scale).<br />
This new approach impacts positively on<br />
commodity volumes (refer to [2] for <strong>de</strong>tails):<br />
for the same production capacity commodity<br />
volumes for steel, concrete, piping, etc. for a<br />
greenfield plant <strong>de</strong>signed along this approach<br />
are similar to that of a brownfield expansion<br />
Fig. 1: Typical main piperack layout current-<strong>de</strong>sign 1.5m tpy alumina refineries<br />
Fig. 2: Main piperack layout <strong>de</strong>dicated <strong>de</strong>sign 1.5m<br />
tpy alumina refinery<br />
24 ALUMINIUM · 7-8/2013
ECo N o M i CS<br />
Cost item<br />
in million USD<br />
Direct costs<br />
Equipment 1<br />
Commodities 2<br />
Total direct costs<br />
1.5m tpy production capacity<br />
Current <strong>de</strong>sign<br />
244<br />
558<br />
802<br />
of an existing refinery. In other words per<br />
annual tA production capacity significantly<br />
lower amounts of commodities are required<br />
for greenfield projects based on this approach<br />
compared with current, resulting in lower<br />
costs. The effect on refinery capital cost is illustrated<br />
in the righthand column of Table<br />
1 for a <strong>de</strong>dicated <strong>de</strong>sign 1.5m tpy ‘low temperature<br />
digestion’ refinery: the capital cost<br />
per annual tA capacity improves indicatively<br />
by about 10%.<br />
3.2 Step 2 – Compact production capacity<br />
The second step of the new approach addresses<br />
the issues of complexity and huge capital<br />
cost of current alumina projects: by applying<br />
the <strong>de</strong>dicatedcapacity approach to a compact<br />
refinery capacity of about 300,000 to 600,000<br />
tpy the resulting project has a simple and limited<br />
scope. The higher end of this range is limited<br />
by the objective to end up with a total project<br />
capital cost well below USD1bn (mega project<br />
threshold); the lower end is <strong>de</strong>termined<br />
by logistical limitations (e.g. with respect to<br />
raw materials shipping). As a result some indirect<br />
capital cost items <strong>de</strong>crease more than<br />
proportionately such as costs related to temporary<br />
construction and startup support, camp<br />
and other construction related items, and<br />
Dedicated <strong>de</strong>sign<br />
Table 1: 1.5m tpy greenfield refinery capital cost comparison<br />
(indicative numbers)<br />
234<br />
474<br />
708<br />
Total indirect costs 3 730 663<br />
Contingency 167 150<br />
Total refinery capital cost<br />
USD/annual tA<br />
Cost item<br />
in million USD<br />
Direct costs<br />
Equipment 1<br />
Commodities 2<br />
Total direct costs<br />
1,699<br />
1,133<br />
400,000 tpy<br />
production capacity<br />
Dedicated <strong>de</strong>sign<br />
99<br />
183<br />
283<br />
Total indirect costs 196<br />
Contingency 60<br />
Total refinery capital cost 3<br />
USD/annual tA<br />
539<br />
1,347<br />
Table 2: 400,000 tpy <strong>de</strong>dicated <strong>de</strong>sign refinery capital<br />
cost (indicative numbers)<br />
1<br />
Incl. steam and power generation, sub stations, residue<br />
disposal, water supply, communication and info systems<br />
2<br />
Incl. concrete, steel, mechanical bulks, piping, wire and<br />
cable, etc.<br />
3<br />
Incl. freight, EPCM, temporary construction, start-up,<br />
commissioning, owner’s engineering<br />
1,521<br />
1,014<br />
owner’s costs, improving plant<br />
capital cost indicatively by an<br />
additional 10% relative to a<br />
current<strong>de</strong>sign plant of similar<br />
size.<br />
As illustration a production<br />
capacity for a greenfield<br />
400,000 tpy <strong>de</strong>dicated <strong>de</strong>sign<br />
plant is used here, and its related<br />
capital cost (indicative<br />
numbers) is shown in Table 2.<br />
Table 2 shows that the capital<br />
cost per annual tA (1,347<br />
USD/AnntA) is higher than that of the much<br />
larger 1.5m tpy <strong>de</strong>dicated plant (1,014 USD/<br />
AnntA – refer Table 1), however is at a level<br />
which could result in a project with acceptable<br />
economics provi<strong>de</strong>d infrastructure capital cost<br />
is limited (refer [2] for further <strong>de</strong>tails). At the<br />
same time a project based on a compact plant<br />
capacity has very limited infrastructural requirements<br />
and has several advantages over a<br />
large plant, particularly if the project is located<br />
close to an existing port, e.g. it may be allowed<br />
closer to resi<strong>de</strong>ntial areas (i.e. is closer to existing<br />
infrastructure); the existing infrastructure<br />
may be sufficient for a small plant, but not<br />
for a big plant; a suitable location for a small<br />
residue disposal area is easier to find than for<br />
a large one, etc. The table also shows that the<br />
total capital cost is at a level which would enable<br />
many more companies to <strong>de</strong>velop such<br />
a project without necessarily requiring the<br />
formation of multiparty joint ventures, simplifying<br />
overall project management and thus<br />
enabling to <strong>de</strong>crease the capital cost further.<br />
Note that the new approach is in<strong>de</strong>pen<strong>de</strong>nt<br />
of the selected refinery technologies.<br />
4. 400,000 tpy capacity alumina refinery<br />
The above outlined DCS approach (Dedicated<br />
Compact Sustainable – this last aspect is not<br />
discussed here) has been applied by mo<strong>de</strong>lling<br />
a 400,000 tpy lowtemperature digestion<br />
refinery in a benchmark version of the Bayer<br />
process (refer [3] for further <strong>de</strong>tails). The<br />
steam temperature and pressure required for<br />
lowtemperature digestion enables first using<br />
high pressure boiler steam for the cogeneration<br />
of power. This results in an energy and<br />
capital efficient refining process.<br />
4.1 Equipment sparing<br />
• Key role for equipment cleaning / <strong>de</strong>scaling.<br />
• Substantial use of common spare equipment.<br />
• If an outage would result in an immediate<br />
alumina production loss, a spare or equipment<br />
bypassing facilities are installed or extra capacity<br />
in upstream / downstream equipment is<br />
inclu<strong>de</strong>d. This also applies to frequently maintained<br />
equipment.<br />
• No sparing is inclu<strong>de</strong>d for the bauxite residue<br />
washers and flash vessels which can be bypassed,<br />
accepting transient process efficiency<br />
reductions; a spare precipitator is installed and<br />
the third precipitator in line can be used both<br />
as agglomerating as well as growth precipitator.<br />
• The refinery operates continuously, with<br />
planned outages (accounted for in the overall<br />
plant operating factor) being used to service<br />
equipment. The sparing philosophy assumes<br />
no scheduled exten<strong>de</strong>d total plant shutdowns.<br />
• The sparing philosophy may require adjusting<br />
to a specific plant location.<br />
4.2 Plant <strong>de</strong>sign elements<br />
• The digestion and liquor evaporation areas<br />
positioned next to each other, enabling sharing<br />
a common spare train of heat exchangers.<br />
Advantages: equipment standardisation, simplified<br />
operations and maintenance, less (types<br />
of) spare parts.<br />
• The bauxite residue discharging from the<br />
CCD wash train contains less than ~8 g/l<br />
caustic soda in the adhering liquor, enhancing<br />
disposal options.<br />
• The last two online precipitators operate<br />
with agitators allowing varying slurry levels,<br />
thus accommodating volume takeup when<br />
<strong>de</strong>scaling a tank.<br />
• Precipitators are mechanically cleaned /<br />
<strong>de</strong>scaled. Main advantages: no major plant<br />
volume / plant liquor caustic concentration<br />
fluctuations, i.e. better control of both. Put<br />
differently: tank cleaning and plant volume /<br />
liquor concentration control have been separated.<br />
Other advantages: no further spare precipitators<br />
/ tanks of similar size are required<br />
and steam savings (caustic cleaning).<br />
• The filters for hydrate to calcination, for<br />
fine seed to precipitation and for oxalate removal<br />
are located in one building. Advantages:<br />
equipment standardisation, operating procedures,<br />
etc.<br />
• A hydrate storage facility between precipitation<br />
and calcination, enabling the Bayer<br />
circuit to operate in<strong>de</strong>pen<strong>de</strong>ntly and as undisturbed<br />
as possible from calcination. Two<br />
calciners are installed, both normally in operation.<br />
By uncoupling the Bayer circuit from<br />
calcination, product quality control can be<br />
optimised.<br />
4.3 Layout consi<strong>de</strong>rations<br />
The key advantage of the DCS <strong>de</strong>sign is that<br />
the plant layout is optimised. This may be realised<br />
in various ways, <strong>de</strong>pending on bauxite<br />
quality (boehmite, TOC, oxalate, etc.), select<br />
26 ALUMINIUM · 7-8/2013
ECo N o M i CS<br />
Fig. 3: Layout of digestion / evaporation areas<br />
Fig. 4: Layout of residue settling,<br />
washing and lime areas<br />
Fig. 5: Layout of hydrate classification / filtration<br />
and oxalate removal areas<br />
ed process technologies<br />
(digestion, impurity<br />
removal, equipment<br />
types – filters,<br />
heat exchangers, etc.),<br />
plant location specifics<br />
(rainfall – water<br />
balance, legal requirements,<br />
soil conditions,<br />
gravity flow between<br />
precipitators, etc.), and<br />
operating and maintenance<br />
philosophies.<br />
The following layout<br />
consi<strong>de</strong>rations are<br />
based on the selected<br />
refining process, <strong>de</strong>sign,<br />
equipment sparing,<br />
operating parameters<br />
and equipment.<br />
However most of these<br />
would (fully or partly)<br />
apply also if other choices are ma<strong>de</strong>.<br />
• Position the digestion and liquor evaporation<br />
areas next to each other (refer Fig. 3).<br />
The causticiser feed heat exchanger is located<br />
in the digestion / evaporation area because<br />
evaporation export steam and digestion flash<br />
con<strong>de</strong>nsate is used to heat the CCDwasher<br />
overflow to causticisation. Attention should be<br />
given to maintain the free caustic concentration<br />
in the spent liquor through evaporation<br />
at the hot end within acceptable levels.<br />
• Place the bauxite residue settler and washers<br />
in a horseshoe shape for easy access to<br />
washer overflow standpipes and pumps, etc.<br />
(refer Fig. 4). Lime related areas are positioned<br />
next to each other (similar operating and<br />
maintenance requirements) and close to the<br />
washer train.<br />
• Place the filters for hydrate to calcination,<br />
fine seed for precipitation and oxalate removal,<br />
as well as the cyclone classification areas<br />
in one building (similar equipment, operating<br />
and maintenance procedures, spare parts,<br />
sharing of common spare tanks and pumps,<br />
etc.) (refer Fig. 5).<br />
• Position security filtration related equipment<br />
close to each other for operating and<br />
maintenance efficiency reasons; the heat interchange,<br />
precipitation and interstage cooling<br />
close to each other as these have many<br />
interactions (minimising liquor / slurry pipeline<br />
distances); and the main steam consumers<br />
(digestion and evaporation) and the steam<br />
and power plant close to each other to minimise<br />
energy losses; and place if feasible the<br />
bauxite crushing, grinding and pre<strong>de</strong>silication<br />
areas close to each other and to the digestion<br />
area to minimise slurry pipeline distances.<br />
• Construct in the centre of the plant a facility<br />
accommodating the plant control room (including<br />
control of the steam and power plant),<br />
operations office and plant laboratory.<br />
• Create good crane access to all major equipment<br />
from 15 m wi<strong>de</strong> plant roads, and if economically<br />
justifiable consi<strong>de</strong>r pipe trenches<br />
instead of piperacks for road crossings (ease<br />
of access).<br />
4.4 Overall plant layout<br />
An overall process plant layout for a 400,000<br />
tpy DCS plant is shown in Fig. 6, showing that<br />
the new approach leads to a compact, simple<br />
and efficient layout with a small Bayer loop,<br />
illustrating that the goal to tailor the <strong>de</strong>sign<br />
to the equipment and infrastructure requirements<br />
of the specified production capacity is<br />
achievable: most of the infrastructure is integrated<br />
in the process areas and only limited<br />
infrastructure is required outsi<strong>de</strong> those. ➝<br />
ALUMINIUM · 7-8/2013 27
ECo N o M i CS<br />
5. Advantages of the new approach<br />
The main advantages of the new approach<br />
are:<br />
• Reduced capital cost (lower risk) enabling<br />
the <strong>de</strong>velopment of bauxite and alumina<br />
projects by smaller companies without a need<br />
to form joint ventures, thus increasing the<br />
number of companies potentially interested in<br />
<strong>de</strong>veloping bauxite <strong>de</strong>posits. More competition,<br />
more efficient use of (capital and bauxite)<br />
resources.<br />
• Small and simple projects carrying less risk<br />
require less time to <strong>de</strong>velop, construct and<br />
startup, positively impacting economics.<br />
• <strong>Alu</strong>mina refining projects based on this<br />
approach require a small bauxite <strong>de</strong>posit (a<br />
<strong>de</strong>posit of about 40m tonnes could support a<br />
400,000 tpy project for 30 years), i.e. worldwi<strong>de</strong><br />
the number of bauxite <strong>de</strong>posits lending<br />
themselves to <strong>de</strong>velopment increases, again<br />
improving the use of resources.<br />
• This new <strong>de</strong>velopment mo<strong>de</strong>l may also be<br />
applied to the <strong>de</strong>velopment of part(s) of a<br />
large <strong>de</strong>posit.<br />
• In some cases the new approach enables<br />
value creation through alumina refining rather<br />
than being limited to bauxite export (attrac<br />
tive to the host country and to companies <strong>de</strong>veloping<br />
bauxite & alumina projects).<br />
• An adapted version of the new <strong>de</strong>velopment<br />
mo<strong>de</strong>l may in some cases enable bauxite<br />
<strong>de</strong>posit <strong>de</strong>velopment even in locations with<br />
little existing infrastructure, albeit at a larger<br />
than compact scale (see below).<br />
6. Possible project locations<br />
Examples of bauxite <strong>de</strong>posits that may lend<br />
themselves to <strong>de</strong>velopment via the proposed<br />
approach are (between brackets the potential<br />
alumina export port):<br />
• Ha<strong>de</strong>n, Queensland, Australia (Brisbane)<br />
• Bindoon, Western Australia (Fremantle)<br />
• Central Northern Tasmania (Devon Port /<br />
Bell Bay)<br />
• El Palmar, Venezuela (Ciudad Guayana)<br />
• Trelawny, Jamaica (Discovery Bay)<br />
• Kibi, Ghana (Tema).<br />
In addition some bauxite <strong>de</strong>posits which in<br />
view of their large size could support the current<br />
<strong>de</strong>velopment approach with largecapacity<br />
alumina refining projects, may also lend<br />
themselves to stagewise <strong>de</strong>velopment applying<br />
the new approach. In this case these <strong>de</strong>posits<br />
could support several (smaller) greenfield<br />
bauxite and alumina projects in an adapted<br />
version of this new <strong>de</strong>velopment mo<strong>de</strong>l – e.g.<br />
a <strong>de</strong>dicated 1.5m tpy capacity project. Example:<br />
some of the Eastern Ghats <strong>de</strong>posits<br />
in Orissa and Andhra Pra<strong>de</strong>sh, India, e.g. the<br />
Kutrumali <strong>de</strong>posit (with Visakhapatnam as potential<br />
alumina export port).<br />
7. references<br />
1. P.J.C. ter Weer, Significance of Increased Greenfield<br />
<strong>Alu</strong>mina Refinery Design Capacity, International<br />
ALUMINIUM Journal, Jan/Feb 2011, Vol.<br />
87, pp 2022.<br />
2. P.J.C. ter Weer, New Development Mo<strong>de</strong>l for<br />
Bauxite Deposits (paper presented at Light Metals<br />
2011, San Diego, California), pp 511.<br />
3. P.J.C. ter Weer, New Development Mo<strong>de</strong>l for<br />
Bauxite Deposits – Dedicated Compact Refinery<br />
(paper presented at Light Metals 2013, San Antonio),<br />
pp 97102.<br />
Author<br />
PeterHans ter Weer, TWS Services & Advice, Bauxite<br />
<strong>Alu</strong>mina Consultancy. For further information,<br />
please contact P.J.C. ter Weer at +31.646143965,<br />
email to twsservices@tiscali.nl or visit www.<br />
twsservices.eu.<br />
Fig. 6: Overall 400,000 tpy DCS process plant layout<br />
28 ALUMINIUM · 7-8/2013
W irtSCh A ft<br />
Lage <strong>de</strong>r Schweizer <strong>Alu</strong>miniumindustrie weiterhin angespannt<br />
Die im <strong>Alu</strong>minium-Verband Schweiz zusammengeschlossenen<br />
Unternehmen blicken überwiegend auf ein unbefriedigen<strong>de</strong>s<br />
Ergebnis 2012. Die Auswirkungen <strong>de</strong>r Frankenstärke und <strong>de</strong>r<br />
Schul<strong>de</strong>nkrise in Europa belasteten <strong>de</strong>n Geschäftsverlauf <strong>de</strong>r<br />
zu 80 Prozent exportorientierten Schweizer <strong>Alu</strong>miniumindustrie.<br />
Dennoch konnten die Walz- und Presswerke ihre Gesamtproduktion<br />
inklusive <strong>de</strong>r Ausfuhren leicht um 0,4 Prozent auf<br />
184.850 Tonnen gegenüber 2011 steigern. Im laufen<strong>de</strong>n Jahr<br />
zeigt sich die konjunkturelle Entwicklung weiter verhalten.<br />
„Den mo<strong>de</strong>raten Zuwachs von gesamthaft 0,4 Prozent inklusive <strong>de</strong>r<br />
Exporte 2012 gegenüber <strong>de</strong>m Vorjahr verdankt unsere Industrie vor<br />
allem einer stark gesteigerten Produktion von <strong>Alu</strong>Walzerzeugnissen<br />
für <strong>de</strong>n Transport und Automobilsektor. Dagegen mussten die<br />
Presswerke Einbußen von bis zu 15 Prozent hinnehmen“, erklärte<br />
Verbandsgeschäftsführer Marcel Menet.<br />
Bei <strong>de</strong>n Schweizer Leichtmetallgießern reduzierten sich die verarbeiteten<br />
Mengen im vergangenenJahr auf 17.970 Tonnen (14%).<br />
Der LeichtmetallSandguss produzierte 2.740 Tonnen (37%), <strong>de</strong>r<br />
Druckguss 12.770 Tonnen (7%) und <strong>de</strong>r Kokillenguss 2.460 Tonnen<br />
(10%). Der gesamte <strong>Alu</strong>miniumeinsatz im Inland ging um 0,6<br />
Prozent auf 207.900 Tonnen zurück.<br />
Auftragseingänge im ersten Quartal rückläufig<br />
Die Krise hat sich nicht entschärft: „Auch bei <strong>de</strong>n Auftragseingängen<br />
im ersten Quartal 2013 verzeichnen die Pressprodukte ein Minus von<br />
rund 13 Prozent“, gab Menet an. Verantwortlich dafür sind in erster<br />
Linie <strong>de</strong>r weiterhin starke Franken, <strong>de</strong>r auch 2012 die Margen erodieren<br />
ließ, sowie ausbleiben<strong>de</strong> Bestelleingänge, verursacht durch<br />
die schlechte Wirtschaftslage in <strong>de</strong>n europäischen Län<strong>de</strong>rn. „Aufgrund<br />
<strong>de</strong>s tiefen Euros drängten zu<strong>de</strong>m verstärkt ausländische Anbieter<br />
in <strong>de</strong>n Binnenmarkt. Dies führte zu einem enormen Preisdruck<br />
und zu zusätzlichen Auftragsverlusten für unsere heimische Industrie“,<br />
erläuterte Verbandspräsi<strong>de</strong>nt Markus Tavernier die Situation.<br />
Einbußen erlitt die Schweizer <strong>Alu</strong>miniumbranche vor allem durch<br />
geringere Bestelleingänge seitens <strong>de</strong>r Maschinen und Elektrotechnik<br />
sowie <strong>de</strong>s Textilmarktes. Diese Industriezweige reagierten vor allem<br />
mit <strong>de</strong>r Beschaffung einfacher, in großer Serie hergestellter <strong>Alu</strong>miniumBasisteile<br />
im günstigeren Euroraum.<br />
Dagegen zählte für die Kun<strong>de</strong>n im Verpackungsbereich, im Bauwesen<br />
und Energiesektor sowie in <strong>de</strong>r Medizinaltechnik auch 2012<br />
die gewohnt hohe Schweizer Qualität, Flexibilität und Servicebereitschaft<br />
mehr als <strong>de</strong>r Preisdruck. Hier verhielten sich die Auftragseingänge<br />
nahezu konstant und auch im laufen<strong>de</strong>n Jahr wird mit keinen<br />
größeren Einbrüchen gerechnet.<br />
Den größten Zuwachs bescherte erneut das Transportwesen. Dank<br />
<strong>de</strong>m großen Knowhow und <strong>de</strong>r ungebrochenen Investitionsbereitschaft<br />
in neue Entwicklungen und Fertigungsanlagen konnte die<br />
Schweizer <strong>Alu</strong>miniumindustrie 2012 Neuaufträge und Produktionssteigerungen<br />
für <strong>de</strong>n Flugzeug und Schiffsbau sowie für Schienenfahrzeuge,<br />
Nutzfahrzeuge und Automobile erzielen: mit komplexen<br />
Konstruktionen im UltraleichtbauStrukturguss zur Reduzierung <strong>de</strong>s<br />
Gewichts und <strong>de</strong>s CO 2 Ausstoßes genauso wie mit Walzprodukten<br />
und hochwertig anodisierten <strong>Alu</strong>miniumteilen.<br />
„Durch aufwändige Produktentwicklungen, Qualität und Lieferzuverlässigkeit<br />
sowie erweiterte Dienstleistungsangebote wie die<br />
Gesamtablieferungen von Walz- und Pressprodukten in <strong>de</strong>r Schweiz, in Tonnen<br />
verlängerte Werkbank für unsere Kun<strong>de</strong>n haben sich unsere Mitgliedsfirmen<br />
eine Alleinstellung erarbeitet“, so Tavernier. Auch für 2013<br />
zeichnen sich hier bereits jetzt die größten Steigerungsraten ab.<br />
Das Motto „Klasse statt Masse“ bringt die Überlebensstrategien <strong>de</strong>r<br />
Schweizer Branche auf <strong>de</strong>n Punkt: Um die Wettbewerbsfähigkeit zu<br />
erhöhen, wird zunehmend die Serienherstellung standardisierter Bauteile<br />
in eigens dafür gegrün<strong>de</strong>te Fabriken im Ausland verlagert. Zahlreiche<br />
Mitgliedsfirmen investieren aber auch zweistellige Millionenbeträge<br />
in ihre F&EAbteilungen und spezialisierten Fertigungsstätten<br />
an <strong>de</strong>n Schweizer Standorten, wie Tavernier weiter ausführte. ■<br />
EMO Hannover | 16.-21.09.2013 | Halle 015 / Stand D26<br />
Mehr Flexibilität.<br />
Beim Sägen und<br />
Lagern von Metall<br />
sind wir Technologieführer.<br />
Als kompetenter<br />
Partner<br />
schaffen wir Mehrwerte,<br />
die sich sehen<br />
lassen können.<br />
www.kasto.<strong>de</strong><br />
Effizientes Arbeiten, wie Gehrungsschnitte<br />
in <strong>de</strong>r Metallverarbeitung,<br />
verlangt Maschinen, die vielseitig<br />
einsetzbar sind. So wie Kreis- und<br />
Bandsägen von KASTO. Sie sind die<br />
universellen Partner für Werkstattbetriebe.<br />
Für mehr Flexibilität in<br />
je<strong>de</strong>m Unternehmen.<br />
Sägen. Lager. Mehr.<br />
© <strong>Alu</strong>minium-Verband Schweiz<br />
ALUMINIUM · 7-8/2013 29
ALUMINIUM SMELTING INDUSTRY<br />
Primary aluminium industry during the first half of 2013, Part I<br />
Rudolf P. Pawlek, Sierre<br />
© Alcoa<br />
This overview covers the events of the<br />
primary aluminium industry during the<br />
first half of 2013. Part I focuses on the<br />
regions Africa, America, Oceania and<br />
Europe while Part II, which will be published<br />
in our next issue, will look at the<br />
Middle East and Asia.<br />
In January Alcoa announced it expects aluminium<br />
<strong>de</strong>mand to increase by 7% to 49.4m<br />
tonnes in 2013, up 1 percentage point from<br />
the 6% growth seen in 2012. The bump in<br />
global <strong>de</strong>mand will be bolstered by an 11%<br />
expansion in <strong>de</strong>mand from China, as well as<br />
strong growth from Brazil (3%), Russia (1%)<br />
and India (3%). The change in <strong>de</strong>mand from<br />
North America and Europe should remain<br />
relatively similar to 2012, with North America<br />
seeing a 4% increase in <strong>de</strong>mand (equal to the<br />
2012 growth figure) and European <strong>de</strong>mand,<br />
which fell by 2% in 2012, <strong>de</strong>clining by just<br />
1% year-on-year in 2013. As a result of the<br />
expected <strong>de</strong>mand growth, Alcoa is projecting<br />
a 200,000-tonne alumina <strong>de</strong>ficit and a<br />
535,000-tonne aluminium surplus in 2013.<br />
Given the size of these markets, however, the<br />
figures show that supply and <strong>de</strong>mand are essentially<br />
balanced. Alcoa also predicts a recovery<br />
in LME prices, linked more to the global<br />
economic situation than to market fundamentals.<br />
Chinese output will reach 23.35m tonnes,<br />
while its <strong>de</strong>mand will be 23m tonnes, leaving<br />
a small surplus which has grown from 100,000<br />
tonnes in 2012. In the rest of the world, production<br />
of primary aluminium output will be<br />
26.61m, with <strong>de</strong>mand forecast to be 26.42m<br />
tonnes.<br />
In May Alcoa announced that it will review<br />
460,000 tpy of smelting capacity over<br />
the next 15 months for possible curtailment<br />
to secure the company’s competitiveness, as<br />
aluminium prices have fallen more than a third<br />
since their peak in 2011. Rusal and Chalco<br />
have announced production cuts too. Rusal<br />
will reduce primary aluminium production by<br />
300,000 tonnes by year-end, and Chalco said<br />
it would temporarily close 380.000 tpy of production<br />
capacity.<br />
AFRICA<br />
Alcoa will close two Sø<strong>de</strong>rberg potlines at its Baie-Comeau smelter in Quebec<br />
GUINEA: In March Russian aluminium giant<br />
Rusal quietly abandoned plans for a multibillion-dollar<br />
aluminium smelter in Guinea.<br />
NIGERIA: In mid-March, the Alscon board<br />
of directors <strong>de</strong>ci<strong>de</strong>d to suspend aluminium<br />
production at the plant. Previously, Rusal had<br />
covered the plant’s losses, expecting to find<br />
a sustainable gas supply which would enable<br />
Alscon to operate at its full capacity. Despite<br />
all measures un<strong>de</strong>rtaken by Rusal, Alscon does<br />
not have a reliable and continuous gas supply.<br />
<strong>Alu</strong>minium production at the plant is <strong>de</strong>eply<br />
loss-making, which ren<strong>de</strong>rs it impossible to<br />
fully utilise the existing capacities. However,<br />
Alscon will continue to generate electricity.<br />
During the suspension period, the main ef-<br />
forts of Rusal will be focused on securing continuous<br />
gas <strong>de</strong>livery, obtaining judicial <strong>de</strong>termination<br />
that Rusal is the rightful owner of<br />
Alscon, and preparing to restart operations.<br />
Smelting will resume as soon as the legal uncertainty<br />
has been resolved and the continuous<br />
power supply has been secured.<br />
In July Nigeria’s supreme court ruled that<br />
former state-owned Alscon should have been<br />
sold to a US-based firm, not to Rusal, but did<br />
not question Rusal’s ownership. Rusal acquired<br />
a 75% stake in Alscon in 2007 and now<br />
owns 85% of its assets.<br />
AMERICA<br />
BRAZIL: In January Brazil announced it<br />
would cut electricity costs by more than a<br />
third across different sectors. Electricity tariffs<br />
for industry, agriculture and retail would<br />
be reduced by 32% while the reduction was<br />
18% for resi<strong>de</strong>nces. The cut is larger than the<br />
16.2% for resi<strong>de</strong>nces and 28% for industries<br />
announced in September 2012. The impact of<br />
the reductions will amount to an additional<br />
expenditure of 8.46bn Reais (USD4.14bn).<br />
The energy cost for Brazil’s aluminium industry<br />
is 329 Reais per MWh (USD161/MWh)<br />
on average, according to the industrial fe<strong>de</strong>ration<br />
of Rio <strong>de</strong> Janeiro. This is much higher<br />
than China’s average electricity rate, equivalent<br />
to 142 Reais per MWh (USD69/MWh).<br />
Rates of 27 countries compared averages<br />
about 215.5 Reais per MWh (USD105/MWh).<br />
The country also plans to double its installed<br />
capacity over the next 15 years from<br />
the present 121,000 MW. Last year, about<br />
4,000 MW and 2,700 kilometres of transmission<br />
lines were installed. For 2013, the objective<br />
is to install another 7,500 kilometres of<br />
transmission lines and generate additional<br />
8,500 MW of energy.<br />
CANADA: In May Alcoa announced the<br />
permanent closure of two ol<strong>de</strong>r potlines at<br />
its Baie-Comeau smelter in Quebec, and to<br />
postpone the construction of a new potline by<br />
three years as it looks to cut costs. The two<br />
Sø<strong>de</strong>rberg potlines, which have a capacity of<br />
105,000 tpy, are scheduled to be closed by<br />
August. Restructuring charges related to the<br />
closures are forecast to be USD135-155m<br />
after tax in 2013. The potline closures come<br />
after Alcoa announced to cut as much as<br />
460,000 tpy of smelter capacity globally over<br />
the next 15 months in the face of low alu-<br />
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ALUMINIUM SMELTING INDUSTRY<br />
Primary aluminium smelters in Africa, America, Europe, Russia and Oceania:<br />
Nameplate capacities and shutdown capacities on a temporary basis<br />
Country Location Nameplate<br />
capacity<br />
(tpy)<br />
Shutdown<br />
capacity<br />
(tpy)<br />
AFRICA<br />
Cameroon Edéa 100,000 50,000<br />
Egypt Nag Hammadi 320,000<br />
Ghana Tema 200,000 160,000<br />
Mozambique Maputo 565,000<br />
Nigeria Ikot Abasi 200,000 200,000<br />
South Africa Richards Bay, Baysi<strong>de</strong> 100,000<br />
Richards Bay, Hillsi<strong>de</strong> 720,000<br />
AMERICA<br />
Argentina Puerto Madryn 465,000<br />
Brazil Belem 460,000 15,000<br />
Saramenha 51,000 5,000<br />
Poços <strong>de</strong> Caldas 106,000<br />
São Louis 460,000 30,000<br />
Sorocaba 475,000 20,000<br />
Santa Cruz 95,000 95,000<br />
Canada Arvida 163,000<br />
Alma 443,000<br />
Gran<strong>de</strong> Baie 220,000<br />
Kitimat 210,000 50,000<br />
Laterrière 235,000<br />
Shawinigan Falls 100,000<br />
Bécancour 420,000<br />
Sept-Îles 600,000<br />
Deschambault 260,000<br />
Baie Comeau 335,000<br />
USA Sebree 205,000 90,000<br />
Mount Holly 229,000<br />
Evansville 270,000<br />
Massena 135,000<br />
Rockdale 191,000 191,000<br />
Wenatchee 184,000 41,000<br />
Ferndale 280,000 41,000<br />
Hawesville 250,000<br />
New Madrid 280,000<br />
Hannibal 270,000 90,000<br />
Ravenswood 180,000 180,000<br />
St. Lawrence 125,000<br />
Venezuela Puerto Ordaz 170,000 123,000<br />
Mantanzas 448,000 270,000<br />
EUROPE & RUSSIA<br />
Bosnia Mostar 130,000<br />
France Dunkirk 273,000 29,000<br />
St. Jean <strong>de</strong> Maurienne 140,000 60,000<br />
Compiled by R. P. Pawlek, June 2013<br />
Germany Hamburg 135,000<br />
Voer<strong>de</strong> 96,000<br />
Essen 170,000<br />
Neuss 230,000 80,000<br />
Greece St. Nicolas 166,000 31,000<br />
Iceland Straumsvik 190,000<br />
Fjardaal 346,000<br />
Grundartangi 285,000<br />
Italy Portoscuso 159,000<br />
Montenegro Podgorica 120,000 60,000<br />
The Netherlands Delfzijl 170,000<br />
Norway Lista 127,500<br />
Mosjoen 221,500<br />
Aardal 233,000<br />
Hoyanger 60,000<br />
Karmoy 170,000<br />
Sunndalsora 400,000 85,000<br />
Husnes 185,000 95,000<br />
Romania Slatina 290,000<br />
Slovenia Kidricevo 75,000<br />
Slovkia Ziar nad Hronom 160,000 16,000<br />
Spain Aviles 93,000 31,500<br />
La Coruña 87,000 31,500<br />
San Ciprian 250,000<br />
Swe<strong>de</strong>n Sundsvall 135,000<br />
United Kingdom Fort William 42,000<br />
Ukraine Zaporozhye 120,000 120,000<br />
Russia Bratsk 1,010,000<br />
Kamensk 75,000<br />
Kandalaksha 75,000<br />
Krasnoturinsk 50,000<br />
Krasnoyarsk 1,010,000<br />
Nadvoitsy 80,000<br />
Novokuznetsk 320,000 30,000<br />
Sayanogorsk 542,000 40,000<br />
Sayanogorsk II 300,000<br />
Volgograd 170,000<br />
Volkhov 24,000<br />
OCEANIA<br />
Australia<br />
Point Henry 190,000<br />
Portland 358,000 30,000<br />
Boyne Island 550,000<br />
Tomago 540,000<br />
Bell Bay 180,000<br />
New Zealand Tiwai Point 351,000<br />
minium prices. Pushing back construction of<br />
the new potline from 2016 to 2019 also comes<br />
because of current market conditions.<br />
In addition, Alcoa would invest USD100m<br />
in the Baie-Comeau smelter over the next<br />
three years, with USD30m of that money earmarked<br />
for upgrading the plant’s casthouse<br />
operations as the company looks to support<br />
growing <strong>de</strong>mand from the automotive sector.<br />
That money comes in addition to USD75m<br />
already scheduled to be spent to rebuild the<br />
plant’s port facilities.<br />
PARAGUAY: In May, it was reported<br />
that Paraguay’s new elected presi<strong>de</strong>nt, Horacio<br />
Cartes, is supportive of the USD4bn aluminium<br />
smelter project planned by Rio Tinto,<br />
which had been opposed by the previous<br />
presi<strong>de</strong>nt Fernando Lugo.<br />
The country is attractive for aluminium production,<br />
due to its partnership with Brazil in<br />
the Itaipu hydro-electric dam project – one of<br />
the biggest in the world – and with Argentina<br />
in the Yacyreta hydro-electric plant. Itaipu<br />
alone provi<strong>de</strong>s 17.3% of all the energy consumed<br />
in Brazil and 75.2% of that used by<br />
Paraguay.<br />
As the country does not use all of the en-<br />
32 ALUMINIUM · 7-8/2013
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ALUMINIUM SMELTING INDUSTRY<br />
ergy it generates with its hydro-electric plants,<br />
it sells the surplus to its Latin American partners.<br />
USA: In April Century <strong>Alu</strong>minum announced<br />
its Hawesville smelter in Kentucky<br />
would close in mid-August if it cannot secure<br />
competitively priced power. The 244,000 tpy<br />
primary aluminium smelter has a power contract<br />
with Big Rivers Electric Corp. The contract<br />
expires on 20 August. Century remains<br />
resolved to finding a solution that will support<br />
the plant’s continuing operations, and is<br />
in discussions with the power provi<strong>de</strong>r.<br />
At the end of April, the company entered<br />
into a <strong>de</strong>finitive agreement to acquire substantially<br />
all of the assets of the Sebree aluminium<br />
smelter from Rio Tinto Alcan (RTA).<br />
Sebree, located in Hen<strong>de</strong>rson County, Kentucky,<br />
has production capacity of 205,000 tpy<br />
of aluminium. Early in June Century completed<br />
the transaction with RTA to acquire all<br />
of the assets of the Sebree smelter. The transaction<br />
is subject to certain closing conditions,<br />
including the consent of Kenergy Corp. to the<br />
assignment of the smelter’s existing power<br />
contract, which will terminate on 31 January<br />
2014.<br />
In May Alcoa announced that it will review<br />
460,000 tpy of smelting capacity over<br />
the next 15 months for possible curtailment<br />
to maintain the company’s competitiveness,<br />
as aluminium prices have fallen more than<br />
a third since their peak in 2011. The review<br />
inclu<strong>de</strong>s facilities across the Alcoa system,<br />
and will focus on higher-cost plants and plants<br />
that have long-term risk due to factors such<br />
as energy costs or regulatory uncertainty. The<br />
possible curtailments could affect 11% of Alcoa’s<br />
global smelting capacity. Up to then, Alcoa<br />
had 13%, or 568,000 tonnes of smelting<br />
capacity idle.<br />
When reviewing smelting capacity for possible<br />
curtailment, Alcoa will consi<strong>de</strong>r a wi<strong>de</strong><br />
variety of alternative actions, ranging from<br />
discontinuing pot relining to full plant curtailments<br />
and / or permanent shutdowns. Alcoa’s<br />
alumina refining system will also be reviewed<br />
to reflect any curtailments in smelting as well<br />
as prevailing market conditions.<br />
Alcoa’s review of its primary metals operations<br />
is consistent with its 2015 goal of<br />
lowering its position on the world aluminium<br />
production cost curve by 10% points and the<br />
alumina cost curve by 7% points.<br />
Early in June Alcoa released it is piloting<br />
a new emissions reduction technology at its<br />
baked ano<strong>de</strong> and calcined coke facility in<br />
Lake Charles, Louisiana, that will reduce sulphur<br />
dioxi<strong>de</strong>, particulate matter and hydrogen<br />
fluori<strong>de</strong> emissions at the plant by up to 90%.<br />
The new technology also offers significantly<br />
lower installation costs than more established<br />
emission-cleansing technology, as well as lower<br />
operating cost, using half as much water and<br />
30% less energy.<br />
Whereas conventional wet scrubbers pump<br />
a limestone or sodium-based solution to the<br />
top of a 100-foot (31 metre) tower and spray it<br />
onto flue gas, Alcoa’s in-duct scrubber moves<br />
flue gas from the smelter or boiler into a horizontal<br />
chamber and sprays a sodium-based<br />
solution in the same direction as the gas flow.<br />
This high-velocity, horizontal scrubbing process<br />
allows up to three times more gas to be<br />
treated than in an equivalent conventional<br />
scrubber space, and it requires 30% less energy<br />
to operate. The technology treats upwards<br />
of 90% of sulphur dioxi<strong>de</strong> in less than onefifth<br />
of a second, compared to traditional wet<br />
scrubbers, which could take 10-15 seconds.<br />
Commissioning and testing of the new technology<br />
is expected to be complete by August<br />
2014.<br />
In May bankrupt aluminium company<br />
Ormet was sold to an entity owned by private<br />
equity firm Wayzata (Minn) Investment<br />
Partners. The Ohio-based company had originally<br />
been scheduled to go to auction, but the<br />
auction was cancelled because no bids besi<strong>de</strong>s<br />
that from stalking-horse bid<strong>de</strong>r Smelter Acquisition,<br />
a Wayzata entity, were received.<br />
The exact purchase price for Ormet was<br />
not disclosed. The company reported assets of<br />
USD407m and total liabilities of USD416m<br />
when it filed for Chapter 11 bankruptcy. High<br />
legacy and power costs as well as low aluminium<br />
prices pushed the company to seek<br />
bankruptcy protection.<br />
Ormet’s smelter in Hannibal can produce<br />
up to 270,000 tpy of primary aluminium when<br />
operating at full capacity, and its alumina refinery<br />
in Burnsi<strong>de</strong>, Louisiana, can produce<br />
540,000 tpy of smelter-gra<strong>de</strong> alumina.<br />
In June, the US Bankruptcy Court for the<br />
District of Delaware approved the sale of<br />
substantially all of the assets of Ormet Corp.,<br />
to Smelter Acquisition, LLC, a portfolio company<br />
owned by private investment funds managed<br />
by Wayzata Investment Partners LLC.<br />
For this restructuring, the company received<br />
aggregate commitments of USD90m of DIP<br />
Financing, consisting of USD30m in Term<br />
DIP financing from Wayzata, as well as a US-<br />
D60m DIP facility from Wells Fargo, which<br />
replaced its USD60m pre-petition revolver<br />
with Ormet. The DIP financings provi<strong>de</strong>d the<br />
Company with sufficient liquidity to meet its<br />
ongoing obligations and to ensure that its operations<br />
continue without interruption during<br />
the restructuring.<br />
The purchase from bankruptcy by Smelter<br />
Acquisition means that the business will shed<br />
substantially all of its legacy liabilities and will<br />
emerge with a much stronger balance sheet<br />
and sole equity sponsor in Wayzata. The company<br />
does not anticipate that the acquisition<br />
will impact Ormet’s ordinary course of operations.<br />
In June Ormet’s sale to Smelter Acquisition<br />
was approved by the US Bankruptcy<br />
Court in Delaware.<br />
VENEZUELA: In February aluminium<br />
producer CVG Alcasa said it will increase its<br />
output to 170,000 tpy, using new machinery<br />
obtained with a USD402m investment approved<br />
by Presi<strong>de</strong>nt Hugo Chávez back in<br />
2012. The new equipment was supplied by<br />
China <strong>Alu</strong>minium International Engineering<br />
Corp. (Chalieco), and will be incorporated<br />
progressively over the next two years. It<br />
represents the first technological a<strong>de</strong>quation<br />
process ma<strong>de</strong> by Alcasa in 25 years.<br />
OCEANIA<br />
NEW ZEALAND: In April Rio Tinto’s Pacific<br />
<strong>Alu</strong>minium unit was still in talks with energy<br />
supplier Meridian to renegotiate terms for<br />
New Zealand’s only aluminium smelter, after<br />
it rejected a short-term subsidy by the government<br />
to keep the plant running. Pacific <strong>Alu</strong>minium’s<br />
view is that a commercial agreement<br />
can be reached through a NZAS electricity<br />
supply contract, that is in the best interests of<br />
NZAS, Meridian, the New Zealand Government<br />
and the people of Southland. Un<strong>de</strong>r the<br />
existing contract, NZAS must operate until<br />
2016, and can then be progressively closed,<br />
and it would be expensive for Rio Tinto to<br />
shut it down faster.<br />
NZAS uses about 15% of the nation’s<br />
electricity output. Closure of the plant would<br />
mean a massive power surplus in the nation<br />
that is looking to divest stakes in three stateowned<br />
electricity firms. About 90% of output<br />
by NZAS is exported, with Japan being its<br />
biggest market. NZAS contributes USD525m<br />
to the Southland economy annually – about<br />
3% of New Zealand’s GDP – and supports<br />
more than 3,200 direct and indirect jobs in<br />
Southland.<br />
EUROPE<br />
BOSNIA: Early in June Bosnian aluminium<br />
smelter <strong>Alu</strong>minij Mostar announced to shut<br />
down all operations in mid-June due to losses<br />
ma<strong>de</strong> on high power costs and low aluminium<br />
prices. On 20 June the company said that it<br />
had <strong>de</strong>ci<strong>de</strong>d to <strong>de</strong>lay the closure by 17 July<br />
34 ALUMINIUM · 7-8/2013
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY<br />
Still in operation or shut down? A critical date for the future of loss-making <strong>Alu</strong>minium Mostar was<br />
17 July (after editorial <strong>de</strong>adline).<br />
© <strong>Alu</strong>minij Mostar<br />
“due to positive <strong>de</strong>velopments that occurred<br />
after we had informed the public on our <strong>de</strong>cision.”<br />
CEO Ivo Bradvica’s proposal to close operations<br />
was unanimously approved by the<br />
company’s supervisory board after reviewing<br />
a business report for the first four months<br />
of 2103. This revealed losses of 9.7m marks<br />
(USD6.5m) per month since the start of the<br />
year.<br />
The <strong>de</strong>cision had been taken during a supervisory<br />
board session, which the lea<strong>de</strong>rship<br />
of the in<strong>de</strong>pen<strong>de</strong>nt tra<strong>de</strong> union also atten<strong>de</strong>d.<br />
These representatives of the plant’s employees<br />
also realised that there is no alternative to<br />
the closure. <strong>Alu</strong>minij produces about 130,000<br />
tpy of aluminium through a tolling agreement<br />
with Glencore Xstrata, and employs around<br />
900 people.<br />
FRANCE: At the end of 2012, Rio Tinto Alcan<br />
was or<strong>de</strong>red to stop insisting that companies<br />
licensing its <strong>Alu</strong>minium Pechiney smelting<br />
technology must also buy pot-tending assembly<br />
handling equipment from its subsidiary<br />
Electrification Charpente Levage (ECL). The<br />
European Commission ma<strong>de</strong> legally binding<br />
Rio Tinto’s promise in August 2012 to end the<br />
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ALUMINIUM SMELTING INDUSTRY<br />
practice as a condition of lifting a threat of<br />
anti-trust fines in the European Union. Brussels<br />
had feared that Rio Tinto was potentially<br />
dominating the aluminium smelter equipment<br />
market through its licensing system, damaging<br />
competition within the EU.<br />
Un<strong>de</strong>r the agreement, users of Rio Tinto<br />
Alcan’s technology can not only choose from<br />
recommen<strong>de</strong>d suppliers, but Rio Tinto must<br />
also provi<strong>de</strong> competing pot-tending assembly<br />
suppliers with technical specifications, to ensure<br />
their equipment can work in <strong>Alu</strong>minium<br />
Pechiney smelters.<br />
Brussels’ investigation began after Francebased<br />
crane manufacturer Réel complained<br />
about the practice, for which Rio Tinto offered<br />
commitments in August 2012, which have now<br />
been accepted by the Commission and ma<strong>de</strong><br />
legally binding. If the company breaches the<br />
conditions, the Commission could impose a<br />
fine of up to 10% of Rio Tinto’s total turnover.<br />
GERMANY: Trimet <strong>Alu</strong>minium, Germany’s<br />
largest producer of primary aluminium,<br />
confirmed in March that the company was in<br />
talks with Rio Tinto Alcan to acquire two aluminium<br />
plants in France, namely the sites at<br />
Castelsarrasin and Saint-Jean <strong>de</strong> Maurienne.<br />
The Saint-Jean <strong>de</strong> Maurienne plant in eastern<br />
France is an aluminium smelter of about<br />
140,000 tpy. Talks are still un<strong>de</strong>rway.<br />
ITALY: In June, Alcoa agreed to maintain<br />
the shuttered Portovesme aluminium smelter<br />
in Italy until the end of June 2014, rather than<br />
just to the end of 2013, to allow more time<br />
for a possible sale. However, the ministry does<br />
not take for granted the failure of the <strong>de</strong>al<br />
with Klesch, and reserves the right to contact<br />
the group again to further investigate the<br />
terms of negotiation. Simultaneously, it said<br />
it would continue scouting for other potential<br />
buyers at both the national and international<br />
level. The Portovesme smelter had fully<br />
ceased production in November 2012, after a<br />
possible sale to Glencore fell through.<br />
After more than three years of reduced<br />
production, Alcoa finally <strong>de</strong>ci<strong>de</strong>d to permanently<br />
close its Fusina smelter in Venice. The<br />
closure will reduce Alcoa’s global production<br />
capacity of 4.2m tpy by 44,000 tonnes. This<br />
tonnage is in addition to the 460,000 tonnes<br />
of operating smelting capacity that Alcoa previously<br />
announced was un<strong>de</strong>r review. The<br />
Alcoa Fusina rolling mill operates separately<br />
from the smelter and is not affected by this<br />
<strong>de</strong>cision.<br />
NORWAY: In March Hydro said it was <strong>de</strong>veloping<br />
new and energy-efficient aluminium<br />
production technology as the foundation for<br />
its long-term efforts. Hydro is therefore studying<br />
the potential for testing next-generation<br />
electrolysis technology at a pilot plant with<br />
a capacity of about 70,000 tpy at Karmøy in<br />
Norway. If the pilot project is realised, Karmøy<br />
will host the most energy-efficient aluminium<br />
production in the world, according to Hydro.<br />
There are a number of elements that must<br />
fall into place before Hydro can break ground.<br />
The power grid in the region must be dimensioned<br />
to meet the <strong>de</strong>mands of the offshore<br />
power industry and industrial <strong>de</strong>velopment.<br />
The company must also secure enough power<br />
un<strong>de</strong>r competitive conditions and establish an<br />
agreement with Enova on financing, in which<br />
Enova can contribute consi<strong>de</strong>rable – and crucial<br />
– support. Enova is owned by the Norwegian<br />
Ministry of Petroleum and Energy and<br />
has as its goal to promote environmentally<br />
friendly alternatives in energy consumption<br />
and energy production in Norway.<br />
In June Hydro signed an agreement with<br />
Rio Tinto Alcan to acquire its 50% ownership<br />
share in the Vigeland Metal Refinery AS and<br />
100% ownership share in the AS Vigelands<br />
Brug hydropower station, located in southern<br />
Norway. Hydro held a 50 % ownership<br />
share in Vigeland Metal Refinery AS prior to<br />
the transaction, and was the sole off-taker of<br />
its production of high-purity aluminium. High<br />
purity aluminium plays a vital part in semiconductors<br />
and in several electronic applications<br />
such as LCD screens for TVs, computers, cell<br />
phones and tablets.<br />
Located in Vennesla at the lower part of<br />
the Otra River, the Vigeland Metal Refinery,<br />
has a capacity of 8,500 tpy of high-purity aluminium.<br />
The transaction will be notified to the Norwegian<br />
Competition Authority, and Hydro<br />
will also apply to Norwegian authorities for<br />
an approval to acquire the hydropower assets<br />
in AS Vigelands Brug.<br />
RUSSIA: In February Rusal announced<br />
that it started pilot testing of inert ano<strong>de</strong> technology<br />
in a 3 kA amperage cell at the Krasnoyarsk<br />
aluminium smelter (KrAZ). For inert<br />
ano<strong>de</strong> technology Rusal has <strong>de</strong>veloped a completely<br />
new pot <strong>de</strong>sign. Following successful<br />
pilot tests, Rusal will start industrial tests in<br />
inert ano<strong>de</strong> pots in 2015 at KrAZ. From 2017<br />
Rusal may start shifting smelting capacities<br />
to inert ano<strong>de</strong> technology, starting at KrAZ.<br />
The burning speed of an inert ano<strong>de</strong> is 300<br />
to 400 times slower than that of a traditional<br />
carbon ano<strong>de</strong>, and wears away only 1-2 cm<br />
per year, compared to 1-2 cm per day with<br />
the carbon ano<strong>de</strong>. The project joined the<br />
Skolkovo foundation in June 2011. Planned<br />
co-financing of the inert ano<strong>de</strong> aluminium<br />
production research from the foundation<br />
amounts to RUR750m (USD25m) until 2015.<br />
To date, RUR130m (USD4.3m) has already<br />
been spent by Skolkovo.<br />
In June the first phase of the Boguchansky<br />
aluminium plant (BoAZ) was 75% complete.<br />
As of 1 May the partners had already invested<br />
about USD862m in the construction, which<br />
needs another USD749m to complete the<br />
first phase of BoAZ’s production capacity of<br />
298,000 tpy. The first metal is expected in Q4<br />
2013. Full capacity of the first phase will be<br />
reached by the end of this year.<br />
Also in June Rusal and IES Holding announced<br />
an agreement on the sale of Rusal’s<br />
Bogoslovsk aluminium smelter, which will enable<br />
Rusal to form a single production facility<br />
in Krasnoturinsk. The <strong>de</strong>al will be closed in<br />
August 2013. Creation of a single industrial<br />
complex will enable Rusal to reduce the cost<br />
of production of alumina in the Bogoslovsk<br />
aluminium plant. Rusal will keep the alumina<br />
refinery which will be part of the <strong>Alu</strong>mina<br />
division.<br />
In June Rusal signed an agreement with<br />
the Leningrad region and the tra<strong>de</strong> union<br />
committee Volkhov <strong>Alu</strong>minium Plant (VAZ)<br />
concerning plans to reorganise production in<br />
the industrial area VAZ. The reorganisation<br />
involves changing from producing primary<br />
aluminium to producing high value ad<strong>de</strong>d<br />
products such as aluminium automotive components.<br />
The parties signed an agreement in<br />
or<strong>de</strong>r to save jobs, to create joint ventures with<br />
potential investors producing end products<br />
for mechanical engineering, and to establish<br />
conditions for the long-term <strong>de</strong>velopment of<br />
industry in the region.<br />
n<br />
Suppliers Directory – for your benefit<br />
On pages 76 to 89, leading equipment suppliers to the aluminium industry present their<br />
product portfolios and ranges of services. Take advantage of this useful information.<br />
36 ALUMINIUM · 7-8/2013
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY<br />
Keops Technologies <strong>de</strong>ploys a new<br />
standard aluminium smelter MES solution<br />
Keops Technologies, Inc. is currently <strong>de</strong>ploying<br />
a new standard aluminium MES<br />
(Manufacturing Execution System) solution<br />
for the Ma’a<strong>de</strong>n/Alcoa joint venture.<br />
Encompassing the electro<strong>de</strong>, general<br />
plant, and casthouse areas, the <strong>de</strong>ployed<br />
functionalities will enhance the ability of<br />
the site to manage its production.<br />
After months <strong>de</strong>veloping a standard MES application<br />
based on Alcoa smelter and casthouse<br />
functionalities, Keops Technologies – a leading<br />
provi<strong>de</strong>r of MES systems serving the aluminium<br />
industry – is presently on site, <strong>de</strong>ploying<br />
process and production control applications<br />
with planning and scheduling functionalities<br />
for managing daily operations.<br />
The Ma’a<strong>de</strong>n project represents specific<br />
challenges given the integration with the rolling<br />
mill and high quantity of daily metal production.<br />
This increases the complexity of the<br />
casthouse scheduling system that Keops has<br />
<strong>de</strong>signed, having to respond to a very shortterm<br />
<strong>de</strong>mand. The coordination between upstream<br />
molten metal flows from the potline<br />
and downstream remelt and cold scrap management<br />
from the rolling mill has been mo<strong>de</strong>lled<br />
to sequence all operations: pot tapping,<br />
trip scheduling of crucibles to the casthouse<br />
and shipments of casthouse products to the<br />
rolling mill, while respecting quality, equipment<br />
and process constraints.<br />
In addition, the MES tool supports managers,<br />
supervisors and engineers to optimise<br />
their business processes by providing timely<br />
information directly collected from the many<br />
equipment and systems from the port to the<br />
casthouse, through the carbon and reduction<br />
areas. Connecting to PLC and external systems<br />
– for example the LIMS – through proprietary<br />
interfaces, the Keops MES solution provi<strong>de</strong>s<br />
an integrated view of production information<br />
to support critical <strong>de</strong>cision-making processes.<br />
The <strong>de</strong>tailed execution plan or process data is<br />
then interfaced in two directions: either downward<br />
to the production systems with production<br />
and process parameters, or upward towards<br />
the ERP or rolling mill MES. Production<br />
information is also fed to the manufacturing<br />
infrastructure, which plant personnel can use<br />
as nee<strong>de</strong>d to monitor production performance<br />
and to drill down into <strong>de</strong>tailed data.<br />
The <strong>de</strong>ployment is concentrated over a<br />
short period of time by taking advantage of<br />
Keops’ experience in greenfield and brownfield<br />
projects, and its agility in quickly providing<br />
a wi<strong>de</strong> range of subject matter experts<br />
for each of the sectors and subsystems. Keops<br />
also benefits from its large library of interfaces<br />
with third-party applications, accumulated<br />
with various industry vendors during its<br />
over-30 years of experience in the aluminium<br />
industry.<br />
n<br />
compounding & extrusion materials handling service<br />
Why we enjoy an unloading challenge. Because time is money and this is also very true<br />
when it comes to alumina and petcoke unloading. With our Vacuum Ship Unloa<strong>de</strong>r VSU, featuring<br />
leading-edge technology and our <strong>de</strong>ep process know-how, we can guarantee short<br />
ship lay times and ensure gentle and reliable unloading of your product. That’s what we<br />
mean when we say „confi<strong>de</strong>nce through partnership“ . www.coperion.com<br />
For unloading capacities up to 1.000 t/hr<br />
Double or single boom technology
ALUMINIUMHÜTTENINDUSTRIE<br />
„Duro<strong>de</strong>nse“ – <strong>Alu</strong>miniumoxid-För<strong>de</strong>rtechnologie<br />
für Dubal erfolgreich in Betrieb genommen<br />
Die Coperion GmbH, Weingarten, hat ihr För<strong>de</strong>rsystem<br />
„Duro<strong>de</strong>nse“ zur automatischen<br />
Beschickung von Elektrolysezellen für die<br />
Potline 1 <strong>de</strong>r <strong>Alu</strong>miniumhütte von Dubai<br />
<strong>Alu</strong>minium (Dubal), VAE, erfolgreich in Betrieb<br />
genommen. Das System versorgt 64<br />
Elektrolysezellen vom Typ D18 und D18+ mit<br />
<strong>Alu</strong>miniumoxid. Es ersetzt die bisherige Zuführung<br />
per Kran und erhöht <strong>de</strong>ssen Verfügbarkeit<br />
für an<strong>de</strong>re Anwendungen; außer<strong>de</strong>m<br />
spart es Arbeitskräfte und vermei<strong>de</strong>t umweltbelasten<strong>de</strong><br />
Staubemissionen.<br />
Mit <strong>de</strong>r neuen Technologie vervollständigt<br />
Coperion das Vorhaben von Dubal, <strong>de</strong>n Energieverbrauch<br />
älterer Zellen durch höhere Effizienz<br />
zu verringern sowie die Emission von<br />
Perfluorcarbon zu senken, um auch bei<br />
<strong>de</strong>r Umweltverträglichkeit <strong>de</strong>n Stand<br />
an<strong>de</strong>rer fortschrittlicher Technologien<br />
aufzuweisen. Einmal mehr hat Coperion<br />
als Spezialist für Schüttgutsysteme<br />
in <strong>de</strong>r <strong>Alu</strong>miniumindustrie mit diesem<br />
Projekt gezeigt, dass das Unternehmen<br />
ein kompetenter Partner ist, wenn es um<br />
technologisch anspruchsvolle Mo<strong>de</strong>rnisierungsprojekte<br />
in <strong>de</strong>r Branche geht.<br />
Mit Duro<strong>de</strong>nse bietet Coperion eine<br />
nachhaltige Lösung für die Zuführung<br />
von <strong>Alu</strong>miniumoxid zum Elektrolyseprozess.<br />
Das System erfüllt die hohen<br />
Anfor<strong>de</strong>rungen bei neu errichteten<br />
<strong>Alu</strong>miniumhütten sowie bei Mo<strong>de</strong>rnisierungsprojekten<br />
in bestehen<strong>de</strong>n Anlagen.<br />
Hohe Betriebssicherheit<br />
Duro<strong>de</strong>nse ist aus einem modularen<br />
Systemkörper aufgebaut, <strong>de</strong>r aus run<strong>de</strong>n<br />
Standardrohren besteht und mit<br />
interner Fluidisierung für einen äußerst<br />
schonen<strong>de</strong>n Produkttransport sorgt.<br />
Durch das schlanke Design ist die Streckenführung<br />
<strong>de</strong>s Systems sehr flexibel.<br />
Dadurch wird auch die Montage an <strong>de</strong>r<br />
bzw. die Führung durch die Wandstruktur <strong>de</strong>r<br />
Elektrolysehalle vereinfacht. Beson<strong>de</strong>rs vorteilhaft<br />
ist dies auch im Hinblick auf <strong>de</strong>n Gesamtaufbau<br />
<strong>de</strong>r Elektrolysezellen, weil an<strong>de</strong>re<br />
Systeme einen größeren Platzbedarf haben,<br />
hebt Coperion hervor. Die Verwendung von<br />
Standardkupplungen und -rohren minimiert<br />
Probleme in Bezug auf Dichtungen und thermische<br />
Aus<strong>de</strong>hnung.<br />
Das Duro<strong>de</strong>nse-System weist eine sehr<br />
‘Duro<strong>de</strong>nse’ – <strong>Alu</strong>mina feeding technology<br />
successfully commissioned at Dubal<br />
Coperion GmbH, located in Weingarten, Germany,<br />
has successfully commissioned their<br />
automatically operating ‘Duro<strong>de</strong>nse’ pot feeding<br />
technology at Potline 1 in the smelter<br />
of Dubai <strong>Alu</strong>minium (Dubal), UAE. The<br />
system supplies primary and secondary<br />
alumina to 64 cells of the Dubal D18 and<br />
D18+ reduction cell technology. It replaces<br />
the regular crane feeding operation thus<br />
increasing its disposability for other operations,<br />
saving labour and avoiding dust emissions<br />
to the environment.<br />
Außenansicht auf die Anlage mit 64 Elektrolyezellen, die mit <strong>de</strong>m För<strong>de</strong>rsystem<br />
Duro<strong>de</strong>nse zur automatischen Beschickung von Elektrolysezellen<br />
aufgerüstet wur<strong>de</strong>n<br />
Exterior view of the plant with 64 electrolysis cells, upgra<strong>de</strong>d with the<br />
fully automatic pot feeding system Duro<strong>de</strong>nse for alumina<br />
With this Coperion complements Dubal’s<br />
un<strong>de</strong>rtaking to retrofit their ol<strong>de</strong>r potlines<br />
to optimise energy consumption with higher<br />
efficiency and reduced perfluorcarbone emissions<br />
being environmentally par with other advanced<br />
technologies. With this project, Coperion<br />
has proven once again to be the competent<br />
partner for a technologically driven mo<strong>de</strong>rnisation<br />
project in the aluminium industry.<br />
With Duro<strong>de</strong>nse, Coperion offers a sustainable<br />
solution to supply alumina to the reduction<br />
process in aluminium smelters. It meets<br />
the requirements of new greenfield smelter<br />
projects as well as of brownfield mo<strong>de</strong>rnisation<br />
projects.<br />
High operating reliability<br />
Duro<strong>de</strong>nse is built of a modular system body<br />
consequently using round shaped standard<br />
piping with internal product fluidisation for<br />
the most gentle product transport. Due to<br />
such slim <strong>de</strong>sign the routing<br />
of the system is very flexible<br />
and as a consequence the installation<br />
at and the penetration<br />
through an existing pot<br />
room wall structure is eased.<br />
This is also advantageous e<strong>special</strong>ly<br />
at the pot superstructure<br />
compared to other, more<br />
space requiring systems, says<br />
Coperion. With the utilisation<br />
of standard couplings the use<br />
of standard piping minimises<br />
problems with sealing and<br />
thermal expansion.<br />
The Duro<strong>de</strong>nse system has<br />
its very high operating reliability<br />
due to the following facts:<br />
• The main distribution pipe<br />
along the potroom is constantly<br />
filled to almost 100 percent<br />
with alumina. The whole<br />
© Coperion<br />
system serves as an alumina<br />
buffer located close to the<br />
cells. Through this fact very<br />
high instantaneous filling rates<br />
into a cell hopper are possible.<br />
Even cell technologies with a<br />
strong fluctuating filling level<br />
in the cell hopper can be filled immediately.<br />
• The system is equipped with a <strong>special</strong> air<br />
distribution system insi<strong>de</strong> its fluidisation elements.<br />
These <strong>de</strong>vices assure that in case of<br />
plug formation the air cannot bypass the plug<br />
but is forced into the alumina plug and dissolves<br />
it.<br />
• The air consumption for the total system<br />
from silo to pot during normal operation is<br />
less than 0.6 to 0.7 m 3 /min per pot and very<br />
38 ALUMINIUM · 7-8/2013
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY<br />
constant. This leads to a very low material<br />
velocity in the piping and avoids the risk of<br />
scaling. The low and constant air consumption<br />
causes a low impact on the gas balance of the<br />
potroom, a low impact on the gas treatment<br />
centre (GTC) and a low impact on the roof<br />
emissions as well. This is a very important<br />
benefit e<strong>special</strong>ly for revamping projects with<br />
existing GTCs and related gas balances.<br />
• The system does not need any sensor or actor<br />
(gates, valves) at the pots; it is completely<br />
self-regulating. This eliminates the investment<br />
cost for sensors, actors and related cabling<br />
and control boxes compared to other existing<br />
automatic systems.<br />
These features of the Duro<strong>de</strong>nse pot feeding<br />
system provi<strong>de</strong> clear benefits for new<br />
smelter projects as well as for mo<strong>de</strong>rnisation<br />
projects.<br />
After the successful realisation of the alumina<br />
and petcoke handling and storage facilities<br />
in the port of Qatalum and the bulk handling<br />
facilities in the courtyard areas of the<br />
Ma’a<strong>de</strong>n smelter, Coperion now completes<br />
the material handling chain with the successful<br />
operation of the Duro<strong>de</strong>nse pot feeding system<br />
in the Dubal smelter.<br />
n<br />
hohe Betriebssicherheit auf, <strong>de</strong>nn<br />
• das Hauptverteilerrohr entlang <strong>de</strong>s Elektrolyseraumes<br />
ist permanent fast vollständig<br />
mit <strong>Alu</strong>miniumoxid gefüllt. Das gesamte System<br />
fungiert als Oxidspeicher in unmittelbarer<br />
Zellennähe. Dadurch sind verzögerungsfrei<br />
hohe Füllraten in einen Zellenbehälter möglich.<br />
Sogar bei Zelltechnologien mit stark<br />
schwanken<strong>de</strong>m Füllstand ist eine sofortige<br />
Nachbefüllung möglich.<br />
• das System ist mit einem speziellen Luftverteilungssystem<br />
innerhalb seiner Fluidisierelemente<br />
ausgestattet. Diese Vorrichtung stellt<br />
bei <strong>de</strong>r Entstehung eines Pfropfens sicher, dass<br />
die Luft diesen nicht umgehen kann, son<strong>de</strong>rn<br />
in <strong>de</strong>n Pfropfen eingeblasen wird und ihn somit<br />
auflöst<br />
• bei normalem Betrieb ist <strong>de</strong>r sehr konstante<br />
Luftverbrauch <strong>de</strong>s gesamten Systems vom<br />
Silo zur Zelle geringer als 0,6 bis 0,7 m 3 /min<br />
pro Zelle. Dies führt zu einer sehr geringen<br />
För<strong>de</strong>rgeschwindigkeit in <strong>de</strong>n Rohren und<br />
vermei<strong>de</strong>t das Risiko von Anbackungen<br />
(„scaling“). Durch <strong>de</strong>n geringen und gleichmäßigen<br />
Luftverbrauch wird die Gasbalance<br />
<strong>de</strong>r Elektrolysehalle, <strong>de</strong>r Gasreinigungsanlage<br />
und ebenso die Dachemissionen kaum beeinflusst.<br />
Dies ist ein großer Vorteil speziell bei<br />
Umbauprojekten von existieren<strong>de</strong>n Gasreinigungsanlagen<br />
und <strong>de</strong>m damit zusammenhängen<strong>de</strong>n<br />
Gasgleichgewicht.<br />
• Das System arbeitet vollständig selbstregulierend<br />
und ohne Sensoren o<strong>de</strong>r Aktoren (z. B.<br />
Schieber, Weichen) an <strong>de</strong>n Elektrolysezellen.<br />
Dadurch entfallen im Vergleich zu an<strong>de</strong>ren<br />
automatischen Systemen die Investitions,-<br />
Betriebs- und Instandhaltungskosten für diese<br />
Bauteile sowie für die sonst erfor<strong>de</strong>rlichen<br />
Kabel und Schaltschränke.<br />
Diese Merkmale <strong>de</strong>s Duro<strong>de</strong>nse-För<strong>de</strong>rsystems<br />
zur Zellenbeschickung mit <strong>Alu</strong>miniumoxid<br />
bringen <strong>de</strong>utlichen Nutzen sowohl in<br />
neuen als auch bei bestehen<strong>de</strong>n <strong>Alu</strong>miniumhütten.<br />
Nach <strong>de</strong>r erfolgreichen Realisierung <strong>de</strong>r<br />
För<strong>de</strong>rung und Lagerung von Oxid und Petrolkoks<br />
im Hafen von Qatalum und <strong>de</strong>r<br />
Schüttgutaufbereitung auf <strong>de</strong>m Gelän<strong>de</strong> <strong>de</strong>r<br />
Ma’a<strong>de</strong>n-<strong>Alu</strong>miniumhütte hat Coperion seine<br />
Prozesskette in <strong>de</strong>r Schüttgutaufbereitung<br />
mit <strong>de</strong>m erfolgreichen Betrieb <strong>de</strong>r Duro<strong>de</strong>nse-Zellenbeschickung<br />
bei Dubal nun vervollständigt.<br />
n<br />
Innovation in motion<br />
Innovation is in everything we do and in all<br />
the equipment we <strong>de</strong>sign and build.<br />
For over 60 years, ECL has been the<br />
benchmark for reliable, high quality and<br />
cost-effective equipment for aluminium<br />
smelters, for all technologies.<br />
We will maintain that focus now and in the<br />
future.<br />
www.ecl.fr
ALUMINIUM SMELTING INDUSTRY<br />
Optimisation of grain refinement in a<br />
range of casthouse aluminium alloys<br />
M. Bryant, MQP<br />
Fig. 1: Instrumentation used in the Opticast system<br />
MQP Ltd recently presented a paper at<br />
the 2013 TMS Conference in San Antonio,<br />
Texas, about optimising the grain<br />
refining process for aluminium alloys [1].<br />
The article is based on that presentation,<br />
including some new information, and<br />
looks at<br />
• the optimisation technique used<br />
• a new powerful and consistent grain<br />
refiner, Optifine<br />
• and their combined effect on a range<br />
of aluminium alloys currently being<br />
produced at a casthouse involved in<br />
the study.<br />
Optimisation<br />
The Opticast system is proving to be an invaluable<br />
tool in carrying out assessment and control<br />
of grain refinement practice in industrial<br />
Fig. 2: Grain refiner curves for two master alloys with different efficiency<br />
casthouses by using data generated from sampling<br />
the melt in real time. Originally conceived<br />
by Lennart Backerud [2] and co-workers at<br />
Stockholm University, and since that time extensively<br />
<strong>de</strong>veloped, tested and refined, the<br />
Opticast technology is today being used for<br />
optimisation and control of grain refinement<br />
practice in casthouses worldwi<strong>de</strong>.<br />
It produces rapid and reliable results so<br />
that accurate conclusions can be quickly ma<strong>de</strong><br />
regarding implementation of optimised grain<br />
refining practice.<br />
Implementation of the Opticast system in<br />
the casthouse entails the following steps: calibration<br />
and sampling in casting furnace.<br />
Calibration involves establishing how a<br />
specific alloy responds to addition of fresh<br />
nuclei via the grain refining rod, in other<br />
words establishing the equations for the grain<br />
refinement curves as shown in Fig. 2. It shows<br />
a test carried out with<br />
two different batches of<br />
the same grain refiner<br />
in the same alloy melt.<br />
Obviously one batch<br />
is more efficient than<br />
the other and it follows<br />
that if both grain refiners<br />
are being used in a<br />
casthouse, the calibration<br />
must be done to handle<br />
any variations in the grain<br />
refiner efficiencies, that is<br />
© MQP<br />
a best and worst case scenario. This means that<br />
the calibration equation must be set up for the<br />
upper of the two curves and is for the lower<br />
one as well. The practical implication of this is<br />
that there is much to gain if the grain refiners<br />
used have a consistently high efficiency from<br />
batch to batch.<br />
Optifine<br />
Establishing that grain refiner variability is an<br />
important consi<strong>de</strong>ration factor in achieving a<br />
fully optimised practice has led to the <strong>de</strong>velopment<br />
of a consistently powerful titanium boron<br />
master alloy grain refiner, Optifine.<br />
Optifine is produced via a <strong>special</strong> production<br />
route, which substantially optimises its<br />
nucleation potential. In standard TiBAl grain<br />
refiners only 1% of particles are active, and<br />
large bori<strong>de</strong> particles and agglomerates lead<br />
to preferential formation of large grains<br />
whereas studies have shown that particles in<br />
the size range 1-3µ are optimum for nucleation.<br />
Optifine has been found to have over six<br />
times more active nuclei per ppm of boron<br />
Fig. 3: Microstructure of a standard TiBAl<br />
Fig. 4: Microstructure of Optifine<br />
40 ALUMINIUM · 7-8/2013
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY<br />
than standard grain refiners and promotes<br />
fine equiaxed structures. Its efficiency as a<br />
grain refiner is at least twice, sometimes up to<br />
thirty times higher than standard Ti Bal refiners<br />
normally used.<br />
An in<strong>de</strong>pen<strong>de</strong>nt metallographic study also<br />
shows that Optifine grain refiner has a very<br />
Fig. 5: Addition rates for standard TiBAl grain refiner (light blue-series<br />
1) and Optifine (dark blue-series 2) for a range of AA alloys<br />
uniform microstructure (Fig. 4) without <strong>de</strong>nu<strong>de</strong>d<br />
zones or TiB2 clusters that can be seen<br />
in the typical standard Ti Bal grain refiner<br />
(Fig. 3).<br />
Casthouse trials at a<br />
remelt casthouse – Hulamin<br />
A trial programme carried out using the Opticast<br />
system in conjunction<br />
with Optifine grain refiner<br />
showed that a<strong>de</strong>quate<br />
grain refinement could be<br />
achieved in all of the AA alloy<br />
groups that Hulamin produces<br />
with additions in the<br />
range 0.1 kg/t up to 0.24 kg/<br />
t compared to the 0.34 kg/t<br />
up to 0.78 kg/t previously<br />
used with a standard TiBAl<br />
(Fig. 5). Expressed in percentages<br />
this means reductions<br />
of 56-81% in addition<br />
rates.<br />
Following these trials<br />
Optifine usage has been implemented<br />
in full production<br />
resulting in overall grain refiner usage<br />
being reduced to 45 tpy.<br />
Conclusion<br />
Optifine is a very potent grain refiner which<br />
allows reduction of addition rates to extremely<br />
low levels over a range of AA alloys. Since<br />
Optifine has a consistent high potency, and the<br />
grain refinement process can be closely monitored<br />
with the Opticast method, there is no<br />
risk for cracking of ingots and billets.<br />
Improvements in cast ingot quality can be<br />
expected due to consistent grain size, lower<br />
levels of bori<strong>de</strong>s, bori<strong>de</strong> agglomerates and oxi<strong>de</strong>s<br />
introduced as a result of the substantial<br />
reduction in grain refiner addition as well as<br />
the uniform nature of the Optifine grain refiner<br />
microstructure.<br />
References<br />
[1] R. Vainik, J. Courtenay, B. Saglam: Optimisation<br />
of grain refinement, Light Metals, 2013<br />
[2] L. Backerud and R. Vainik: Method for optimised<br />
aluminium grain refinement, Light Metals<br />
2001, 951-954<br />
Author<br />
Michael Bryant is marketing manager at MQP Ltd.<br />
BRUSHING AND GRINDING MACHINES<br />
SDV-Santioli AG/<br />
DEMIS Wi<strong>de</strong> Belt Processing Systems<br />
Industriestrasse 10<br />
CH-8157 Dielsdorf<br />
Tel. +41 44 854 0908<br />
Fax +41 44 854 0920<br />
www.<strong>de</strong>mis.ch<br />
Material width up to 3000 mm<br />
Material thickness up to 205 mm
ALUMINIUM SMELTING INDUSTRY<br />
Achieving maximum output when insulating electrolysis cells<br />
S. N. Bertel and H. R. Østergaard, Skamol A/S<br />
A wi<strong>de</strong> variety of insulating materials are<br />
available on the market and it can be difficult<br />
to un<strong>de</strong>rstand the benefits of one<br />
material compared to another. However,<br />
key factors to consi<strong>de</strong>r, when insulating<br />
electrolysis cells in the aluminium industry,<br />
are the products’ impact on heat loss,<br />
cell efficiency and installation process.<br />
These factors can among other things improve<br />
performance efficiencies, prolong<br />
the lifetime of the cells and increase time<br />
between relining.<br />
Insulation – a key to<br />
an efficient production<br />
One of the challenges often faced in the aluminium<br />
industry is achieving a cost-efficient<br />
electrolysis cell. This involves being able to<br />
keep a stable heat balance in or<strong>de</strong>r to reduce<br />
energy costs and to minimise the risks and the<br />
effects of penetrating gasses, bath and molten<br />
aluminium. It also involves a more efficient<br />
relining process, where time is the key factor,<br />
but also a process that embraces the fact that<br />
the physical environment in many work places<br />
is becoming increasingly important. Insulating<br />
the electrolysis cells with highly efficient insulation<br />
materials can contribute to a solution<br />
to these challenges by bringing benefits like<br />
an energy-efficient production with focus on<br />
reducing heat loss, improving cell efficiency<br />
and also contributing to an efficient relining<br />
process.<br />
Testing insulating materials<br />
There is a wi<strong>de</strong> range of materials available<br />
on the market and among these<br />
are calcium silicate insulating boards<br />
and fibre-based boards. These products<br />
are among some of the world’s most<br />
efficient materials when insulating electrolysis<br />
cells – their low thermal conductivity<br />
combined with their specific<br />
product characteristics provi<strong>de</strong>s highly<br />
insulating solutions that are easily installed<br />
thus ensuring an efficient production<br />
with a minimum of heat loss.<br />
Low thermal conductivity contributing<br />
to a stable heat balance<br />
Calcium silicate and fibre-based boards<br />
are both highly insulating products and<br />
the use of either product can contribute<br />
It is the needle-like micro-structure of the calcium<br />
silicate that provi<strong>de</strong>s significant strength to the<br />
boards and maintains it at high temperatures<br />
to reduced heat loss, energy savings and to an<br />
improved control of the production process<br />
by contributing to maintaining a stable heat<br />
balance insi<strong>de</strong> the cells. The calcium silicate<br />
insulating boards, Super-Isol and Super 1100<br />
E from Skamol A/S, both have a thermal conductivity<br />
of 0.14 W/(m*K) at 800 °C, which is<br />
among the lowest in the industry. Recent in<strong>de</strong>pen<strong>de</strong>nt<br />
tests conducted to ASTM C-201/182<br />
in 2013 conclu<strong>de</strong> that the thermal conductivity<br />
of these two calcium silicate insulating<br />
boards is 27% lower than a leading bio-soluble<br />
fibre-based board between the operating<br />
temperatures of 600 to 800 °C. The test was<br />
conducted at several temperatures from 250<br />
to 800 °C and the results vary from a difference<br />
of 18% at 600 °C to 27% at 800 °C – all<br />
in favour of calcium silicate. The reason for<br />
the low thermal conductivity of calcium silicate<br />
can be found in the structure of the product.<br />
To obtain a good insulation value at high<br />
temperatures, the insulating product has to<br />
Calcium silicate pot set from Skamol installed in an electrolysis cell. The pot<br />
set was <strong>de</strong>livered according to the specific measurements of this cell, which<br />
reduced installation time significantly.<br />
© Skamol<br />
have a well-<strong>de</strong>fined pore size – the smaller the<br />
pores, the higher insulation value is obtained<br />
when exposed to high temperatures. The structure<br />
of small pores with relatively short distances<br />
from fix point to fix point makes the<br />
calcium silicate highly insulating compared to<br />
fibre-based boards that are structured by large<br />
pores and, as a result, have a lower insulation<br />
value.<br />
A prolonged lifetime of the cell<br />
Besi<strong>de</strong>s finding a highly insulating solution,<br />
another aspect to consi<strong>de</strong>r is the strength<br />
and compressibility of the product in or<strong>de</strong>r<br />
to avoid damages to the insulation material<br />
from heaving catho<strong>de</strong> blocks. When infiltrating<br />
the catho<strong>de</strong> blocks, gas, bath and molten<br />
aluminium can cause the blocks to heave and<br />
the insulation material becomes in danger of<br />
compressing due to the increased pressure.<br />
When the insulation material is compressed,<br />
the insulation value of the product will be <strong>de</strong>creased<br />
and the direct result is a significant<br />
increase in heat loss (cell voltage drop) and<br />
the electrolysis cell will be taken out of operation.<br />
The Super-Isol and Super 1100 E calcium<br />
silicate boards both have a compressive<br />
strength of 2.6 MPa at room temperature making<br />
them 700-800% stronger than comparable<br />
bio-soluble fibre-based boards that have<br />
a compressive strength of approx. 0.30 MPa.<br />
The reason for this difference is evi<strong>de</strong>nt when<br />
looking at the structure of the products. To obtain<br />
strength to the fibre-based<br />
boards, an organic bin<strong>de</strong>r is<br />
ad<strong>de</strong>d in the manufacturing<br />
process and the compressive<br />
strength reaches approx. 0.30<br />
MPa. However, this bin<strong>de</strong>r<br />
burns off at approx. 400 °C<br />
and so the strength disappears<br />
with the consequence of the<br />
fibre-based boards compressing<br />
and the insulating lining<br />
becoming unstable. This is not<br />
the case with calcium silicate<br />
due to its microstructure and<br />
the fact that the pores insi<strong>de</strong><br />
this product are intertwined,<br />
which makes the use of bin<strong>de</strong>r<br />
unnecessary. Calcium silicate,<br />
therefore, is able to maintain<br />
strength better than fibrebased<br />
boards.<br />
42 ALUMINIUM · 7-8/2013
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY<br />
Increasing space and<br />
enhancing protection<br />
Efficient insulation not only means a highly<br />
insulating and strong product, it also refers to<br />
a product that is, to a certain extent, able to<br />
resist the influences from <strong>de</strong>structive gasses,<br />
etc. In the aluminium industry and e<strong>special</strong>ly<br />
in electrolysis cells, the risk of fluori<strong>de</strong> and<br />
sodium gasses, bath and molten aluminium<br />
penetrating the catho<strong>de</strong>s, graphite blocks,<br />
ramming paste and lining material is always<br />
present. These facts make it important to have<br />
a solid layer of barrier bricks that is able to<br />
withstand this kind of aggressive environment<br />
and un<strong>de</strong>rneath it, a strong insulation material<br />
that is able to withstand these substances<br />
if these <strong>de</strong>structive forces should reach them,<br />
thus avoiding damage to the entire cell.<br />
The calcium silicate boards from Skamol<br />
contain a lot of small pores, which provi<strong>de</strong><br />
them with low gas permeability. These small<br />
pores make it hard for the gasses to penetrate<br />
the product and hence, the insulation value<br />
remains intact. Combined with the low <strong>de</strong>gree<br />
of compressibility and the fact that they retain<br />
significant strength up to approx. 900 °C with<br />
only a 5% creep in compression, the calcium<br />
silicate insulating boards will provi<strong>de</strong> a stable<br />
lining that is protected from gas attacks. The<br />
fibre-based boards, however, consist of large<br />
pores, making them vulnerable to e.g. gas attacks,<br />
because of the fact that the gasses con<strong>de</strong>nse<br />
and freeze insi<strong>de</strong> the boards at 700 to<br />
720 °C thus diminishing the thermal conductivity.<br />
Combined with the risk of creating gaps<br />
insi<strong>de</strong> the cell, due to the risk of the material<br />
compressing, gas etc. can penetrate the lining<br />
and a risk of damage to the lining and increasing<br />
heat loss is created.<br />
Although carefully lined with a strong insulating<br />
product and highly resistant barrier<br />
bricks, gas, bath or molten aluminium will<br />
always, to some extent, be able to penetrate<br />
the carbon / graphite. Therefore, many smelters<br />
are trying to figure out ways of increasing<br />
the protective layer of barrier bricks while<br />
maintaining a highly efficient insulation of<br />
their electrolysis cells in or<strong>de</strong>r to protect the<br />
lining material. Even at small thicknesses,<br />
the low thermal conductivity of the calcium<br />
silicate insulation board opens up for the<br />
possibility of <strong>de</strong>creasing the thickness of the<br />
insulating lining – making more room for an<br />
increased layer of barrier bricks. The calcium<br />
silicate insulating board, Super-Isol and Super<br />
1100 E from Skamol, can be <strong>de</strong>livered with<br />
a single layer up to 100 mm thickness while<br />
maintaining a low thermal conductivity of<br />
0.14 W/(m*K). Besi<strong>de</strong>s being able to increase<br />
the layer of barrier bricks, reducing the thickness<br />
of the insulating material also makes it<br />
possible to install bigger catho<strong>de</strong>s. This can,<br />
other things being equal, prolong the lifetime<br />
of the cell due to the fact that most cells are<br />
taken out of operation, when the catho<strong>de</strong><br />
block is worn down. A combination of a reduced<br />
refractory layer and bigger catho<strong>de</strong>s<br />
is also possible – making the cell even more<br />
efficient.<br />
Using calcium silicate can not only provi<strong>de</strong><br />
more space and protection of the electrolysis<br />
cells, it can also be installed in combination<br />
Calcium silicate boards are easily installed and dismantled<br />
without health risks<br />
with castable material. In cases where castable<br />
material is applied directly onto the back-up<br />
lining material in or<strong>de</strong>r to e.g. even out gaps<br />
between the materials, calcium silicate boards,<br />
like the Super-Isol and Super 1100 E, can be<br />
surface-treated to be water-repellent. The water<br />
repellent surface makes them unable to<br />
absorb water from the castable material and<br />
the risk of using this product, whether installing<br />
barrier bricks or applying castable material<br />
directly onto the boards, is non-existent.<br />
Shortening the installation process while<br />
improving the physical environment<br />
Relining electrolysis cells lasts approx. 5 to 7<br />
days from when the cell is turned off to restarting<br />
it again including the cooling and relining<br />
time, <strong>de</strong>pending on the size of the cell and<br />
the complexity of the process at the specific<br />
aluminium smelter. This is done manually and<br />
a contractor is often hired to do the work and<br />
it is a process that is connected with many<br />
costs. Combined with the pursuit of minimising<br />
cost due to the <strong>de</strong>crease in aluminium prices,<br />
these costs are often sought reduced.<br />
Insulation materials like the calcium silicate<br />
insulating boards and fibre-based boards are<br />
mostly <strong>de</strong>livered as whole boards in standard<br />
sizes making it necessary to cut the products<br />
before installation as the electrolysis cells are<br />
often shaped with round corners and conical<br />
walls. Although both products are easily<br />
handled and cut, more and more smelters in<br />
the aluminium industry see the advantages of<br />
installing pre-cut boards ready for installation<br />
without further adjustments. This opens<br />
up for the possibility of reducing installation<br />
time significantly as no further measurements<br />
and machining of the product is necessary and<br />
the product can easily and quickly be installed.<br />
The calcium silicate pot sets from Skamol can<br />
be placed on the pallets according to the sequence<br />
that they will be used on site, reducing<br />
the inventory and shortening the installation<br />
process significantly.<br />
Although relining can be done more efficiently<br />
and a long lifetime of the cell can<br />
be achieved using the right combination of<br />
production process and insulating material,<br />
relining will continue to be a recurrent event<br />
for aluminium smelters and so, protecting the<br />
health of the people working with and around<br />
the cells during relining is still an important<br />
factor. The calcium silicate board, Super-Isol<br />
and Super 1100 E, has been classified as nonhazardous<br />
by government bodies worldwi<strong>de</strong>,<br />
so there is no risk of handling the product.<br />
This is due to the fact that the product is manufactured<br />
as 100% fibre- and shot-free and<br />
therefore does not emit hazardous dust. This<br />
is also the case during dismantling of the product<br />
opposed to fibre-based boards – though<br />
easily managed and cut – the silica insi<strong>de</strong> the<br />
fibre boards crystallises over time and they<br />
thereby pose a health risk e<strong>special</strong>ly during<br />
dismantling which makes it important to wear<br />
a lot of personal protective equipment. Calcium<br />
silicate is therefore a healthier solution.<br />
Calcium silicate insulating<br />
boards from Skamol<br />
Calcium silicate insulating boards from Skamol<br />
were <strong>de</strong>veloped and introduced to the market<br />
in the 1980s. Since then, the material has been<br />
used extensively throughout many industries,<br />
including the aluminium industry, where it is<br />
primarily used as sub-cathodic and si<strong>de</strong>wall<br />
insulation to improve the thermal efficiency<br />
of energy-intensive processes. Skamol is one<br />
of the leading suppliers of insulation solutions<br />
to the aluminium industry, and the Skamol<br />
calcium silicate board is used by aluminium<br />
smelters all over the world from Norway to<br />
New Zealand, Canada and Abu Dhabi etc.<br />
Authors<br />
Søren Nørgaard Bertel is application manager, <strong>Alu</strong>minium<br />
Industry, Skamol A/S at Nykøbing Mors,<br />
Denmark.<br />
Holger Raun Østergaard is business director, <strong>Alu</strong>minium<br />
Industry, Skamol A/S at Nykøbing Mors,<br />
Denmark.<br />
ALUMINIUM · 7-8/2013 43
ALUMINIUMHÜTTENINDUSTRIE<br />
Die neue Masselgießanlage <strong>de</strong>r Trimet <strong>Alu</strong>minium im Werk Essen<br />
H. Koch, D. Bramhoff, U. Kremer, Trimet <strong>Alu</strong>minium; F. Nie<strong>de</strong>rmair, Hertwich Engineering<br />
Trimet <strong>Alu</strong>minium SE hat im Werk Essen<br />
eine luftgekühlte Masselgießanlage errichtet.<br />
Die von Hertwich Engineering<br />
gelieferte Einrichtung komplettiert das<br />
Anlagenspektrum <strong>de</strong>r Gießerei und erweitert<br />
die Liefermöglichkeiten <strong>de</strong>s Unternehmens.<br />
Das Geschäftsmo<strong>de</strong>ll <strong>de</strong>r in Essen ansässigen<br />
Trimet <strong>Alu</strong>minium hat es <strong>de</strong>m Unternehmen<br />
erlaubt, unter <strong>de</strong>n nicht einfachen Standortbedingungen<br />
in Deutschland erfolgreich<br />
<strong>Alu</strong>minium zu produzieren. Dabei versteht<br />
sich Trimet als Werkstoffpartner <strong>de</strong>r <strong>Alu</strong>miniumverarbeiter,<br />
<strong>de</strong>r mit maßgeschnei<strong>de</strong>rten<br />
Produkten auf seine Kun<strong>de</strong>n zugeht. Im Sinne<br />
dieses Anspruchs hat das Unternehmen sein<br />
Lieferprogramm kontinuierlich erweitert.<br />
Derzeit hat Trimet circa 150 verschie<strong>de</strong>ne<br />
Abmessungen in 450 Legierungen (auch<br />
Glanzwerkstoffe) sowie Son<strong>de</strong>rqualitäten<br />
nach Kun<strong>de</strong>nspezifikationen im Programm.<br />
Eine wichtige Rolle dabei spielen Produkte<br />
zur Herstellung von Sicherheitsteilen für die<br />
Automobilindustrie, die nach Prüfung auf<br />
Europas mo<strong>de</strong>rnster Ultraschallprüfanlage<br />
mit Null-Fehler-Garantie ausgeliefert wer<strong>de</strong>n<br />
können.<br />
Gießereierweiterung für neue Produkte<br />
Für dieses umfangreiche Lieferprogramm ver-<br />
The new ingot casting plant at the<br />
Essen works of Trimet <strong>Alu</strong>minium<br />
H. Koch, D. Bramhoff, U. Kremer, Trimet <strong>Alu</strong>minium;<br />
F. Nie<strong>de</strong>rmair, Hertwich Engineering<br />
At its plant in Essen Trimet <strong>Alu</strong>minium<br />
SE has set up an air-cooled ingot casting<br />
unit. The installation, supplied by Hertwich<br />
Engineering, supplements the range<br />
of equipment at the casthouse in Essen<br />
and extends the company’s <strong>de</strong>livery options.<br />
The business mo<strong>de</strong>l of Trimet <strong>Alu</strong>minium has<br />
ma<strong>de</strong> it possible for the company to produce<br />
aluminium successfully even un<strong>de</strong>r the by no<br />
means favourable local conditions that prevail<br />
in Germany. Trimet regards itself as a materials<br />
partner for aluminium processors, offering<br />
its customers tailor-ma<strong>de</strong> products. In support<br />
of that claim the company has continually exten<strong>de</strong>d<br />
its product range.<br />
Currently Trimet produces some 150 different<br />
formats in 450 alloys (including bright<br />
materials) as well as <strong>special</strong> gra<strong>de</strong>s in accordance<br />
with customer specifications. In this, an<br />
important role is played by products for the<br />
manufacture of safety-relevant components<br />
for the automotive industry, which can be supplied<br />
with a zero-<strong>de</strong>fect guarantee after being<br />
tested on Europe’s most mo<strong>de</strong>rn ultrasonic<br />
(US) testing unit.<br />
Casthouse extension for new products<br />
For its extensive product range the casthouse<br />
in Essen has the following equipment in total:<br />
• 14 furnace units and another furnace for<br />
melting down swarf and chips<br />
• nine vertical continuous-casting units for<br />
semis in various formats<br />
• one continuous-throughput and eight<br />
batch homogenising furnaces<br />
• a fully automatic US-testing unit for<br />
round bars<br />
• a horizontal continuous-casting unit for<br />
ingot production, and<br />
• an R & D continuous-casting plant,<br />
including its own homogenising furnace.<br />
The plant produces around 250,000 tonnes<br />
a year, of which 160,000 tonnes come from<br />
the company’s own primary production and<br />
90,000 tonnes from recycled material.<br />
Ingots of casting alloys can optionally be<br />
produced by horizontal continuous casting<br />
© Hertwich<br />
Die neue Massel-Gießanlage von Trimet<br />
The new ingot casting plant at Trimet<br />
44 ALUMINIUM · 7-8/2013
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY<br />
or by casting into moulds. In Essen, until now<br />
only one automatic, 24-strand horizontal casting<br />
machine was available for producing such<br />
material for <strong>de</strong>livery. By supplying mould-cast<br />
ingots Trimet can now satisfy the expectations<br />
of many of its customers.<br />
Another aspect of this is that Trimet anticipates<br />
increasing <strong>de</strong>mand for casting alloys,<br />
some of which, such as hypereutectic AlSi and<br />
AlCu alloys, cannot be cast using a horizontal<br />
continuous-casting unit.<br />
New ingot casting plant with air cooling<br />
For that reason too, among others, in 2011<br />
Trimet <strong>de</strong>ci<strong>de</strong>d to invest in a mo<strong>de</strong>rn ingot<br />
casting plant. As its equipment partner for the<br />
project Trimet opted for Hertwich Engineering,<br />
a subsidiary of the SMS group and market<br />
lea<strong>de</strong>r in the field of casthouse equipment for<br />
the aluminium industry.<br />
Hertwich produces<br />
both horizontal continuous-casting<br />
machines<br />
and batch-type<br />
ingot casting units<br />
(with metallic moulds).<br />
The present-day mould<br />
casting concept goes<br />
back to the year 2000:<br />
at that time Austria<br />
Secondary <strong>Alu</strong>minium<br />
(ASA) set Hertwich<br />
the task of providing a<br />
new type of ingot casting<br />
unit whose concept Cooling zone<br />
differed from the versions<br />
then available on the market in a number<br />
of particular respects. The criteria, among others,<br />
were:<br />
• a plant fully automated from the pouring<br />
of the metal to the bundle of ingots ready<br />
for dispatch, having high performance and<br />
being <strong>de</strong>signed in a space-saving manner<br />
• Primary cooling as far as complete solidification<br />
in the mould should be done with<br />
air; until then water cooling was standard.<br />
The result was the concept of an air-cooled and<br />
water-cooled casting belt, with which the solidification<br />
can be controlled very precisely. This<br />
<strong>de</strong>sign, which combines high product quality<br />
with economical and environmentally acceptable<br />
operation, proved persuasive to Trimet in<br />
its investment <strong>de</strong>cision.<br />
Plant and working method<br />
The plant installed at Trimet for ingots weighing<br />
between six and ten kilograms achieves a<br />
maximum casting rate of ten tonnes an hour.<br />
Kühlstrecke<br />
fügt die Essener Gießerei über insgesamt<br />
• 14 Ofenanlagen sowie einen Späneofen<br />
• neun vertikale Stranggießanlagen für<br />
Halbzeugformate<br />
• eine Durchlauf- und acht Kammerhomogenisieranlagen<br />
• eine vollautomatische Ultraschallprüfanlage<br />
für Rundbarren<br />
• eine Horizontal-Stranggießanlage für die<br />
Masselproduktion sowie<br />
• eine F&E-Stranggießanlage einschließlich<br />
Homogenisieranlage.<br />
Die Jahresproduktion <strong>de</strong>s Werkes beträgt <strong>de</strong>rzeit<br />
etwa 250.000 Tonnen, die sich aus 160.000<br />
Tonnen eigener Primärerzeugung und 90.000<br />
Tonnen Recyclingmaterial zusammensetzt.<br />
Gusslegierungsmasseln können wahlweise<br />
im Horizontal-Strangguss o<strong>de</strong>r im Formguss<br />
erzeugt wer<strong>de</strong>n. In Essen stand für diese<br />
Lieferform bisher ausschließlich eine automatische<br />
24-strängige Horizontal-Stranggießanlage<br />
zur Verfügung. Mit <strong>de</strong>r Lieferung von<br />
Formgussmasseln entspricht Trimet nun <strong>de</strong>n<br />
Erwartungen vieler Gießereikun<strong>de</strong>n.<br />
Hinzu kommt ein weiterer Aspekt: Zukünftig<br />
wer<strong>de</strong>n nach Einschätzung <strong>de</strong>r Trimet<br />
verstärkt Gusslegierungen nachgefragt, die<br />
nicht auf einer horizontalen Stranggießanlage<br />
gegossen wer<strong>de</strong>n können, wie beispielsweise<br />
übereutektische AlSi- und AlCu-Legierungen.<br />
Neue Masselgießanlage mit Luftkühlung<br />
Auch aus diesem Grun<strong>de</strong> hat sich Trimet 2011<br />
zur Investition einer mo<strong>de</strong>rnen Masselgießanlage<br />
entschlossen. Als Ausrüstungspartner<br />
entschied sich das Unternehmen für die österreichische<br />
Hertwich Engineering, ein Tochterunternehmen<br />
<strong>de</strong>r SMS group und Marktführer<br />
bei Gießereiausrüstungen für die <strong>Alu</strong>miniumindustrie.<br />
Hertwich baut sowohl horizontale Stranggießanlagen<br />
als auch Masselgießanlagen (Kokille).<br />
Das mo<strong>de</strong>rne Kokillen-Gießkonzept<br />
geht auf das Jahr 2000 zurück: Damals hatte<br />
die Austria Sekundär <strong>Alu</strong>minium (ASA) Hertwich<br />
aufgefor<strong>de</strong>rt, eine neuartige Masselgießanlage<br />
anzubieten, <strong>de</strong>ren Konzept sich von <strong>de</strong>n<br />
seinerzeit am Markt erhältlichen Bauformen<br />
durch eine Reihe beson<strong>de</strong>rer Merkmale unterschied.<br />
Kriterien waren unter an<strong>de</strong>rem:<br />
• eine vom Metalleinguss bis zum versandfertigen<br />
Masselbund voll automatisierte<br />
Anlage mit hoher Leistungsfähigkeit und<br />
in platzsparen<strong>de</strong>r Ausführung<br />
• die Primärkühlung bis zur vollständigen<br />
Erstarrung in <strong>de</strong>r Form sollte mit Luft<br />
erfolgen; bis dahin war die Wasserkühlung<br />
Standard.<br />
Im Ergebnis entstand das Konzept <strong>de</strong>s luftund<br />
wassergekühlten Gießban<strong>de</strong>s, bei <strong>de</strong>m<br />
sich die Erstarrung sehr präzise steuern lässt.<br />
Diese Bauform, die eine hohe Produktqualität<br />
mit wirtschaftlicher und umweltgerechter Betriebsweise<br />
verbin<strong>de</strong>t, hatte auch Trimet bei<br />
<strong>de</strong>ren Investitionsentscheidung überzeugt.<br />
Anlage und Arbeitsweise<br />
An <strong>de</strong>r bei Trimet installierten Anlage für<br />
Masseln zwischen sechs und zehn Kilogramm<br />
erreicht die Gießrate maximal zehn Tonnen<br />
je Stun<strong>de</strong>.<br />
Gießstation: Die abgebil<strong>de</strong>te Gesamtanlage<br />
zeigt links zwei Gießöfen mit Durchflussregelung.<br />
Zwei unabhängige Ofenanlagen sind<br />
zweckmäßig, um beim Legierungswechsel <strong>de</strong>n<br />
kontinuierlichen Betrieb aufrechtzuerhalten.<br />
Über eine feuerfeste Gießrinne gelangt das<br />
etwa 700 °C heiße Metall über einen Keramikfilter<br />
zum Gießtrog, <strong>de</strong>r während <strong>de</strong>s Gießprozesses<br />
synchron mit <strong>de</strong>m Gießband verfährt.<br />
Die höhenverstellbaren Gießöffnungen<br />
gewährleisten dabei eine präzise Dosierung<br />
und einen weitgehend turbulenzfreien<br />
Schmelzefluss. Die abgebil<strong>de</strong>te Einrichtung<br />
füllt jeweils fünf (vorgewärmte) Kokillen<br />
gleichzeitig.<br />
Die Kokillen durchlaufen, auf einem umlaufen<strong>de</strong>n<br />
Gießband montiert, die Kühlzone.<br />
Der entschei<strong>de</strong>n<strong>de</strong> Vorteil <strong>de</strong>r neuen Masselgießeinrichtung<br />
ist die <strong>de</strong>utlich geringere<br />
Oxidbildung. Dieser Aspekt gehört zu <strong>de</strong>n<br />
qualitätsbestimmen<strong>de</strong>n Kriterien, da Oxi<strong>de</strong>inschlüsse<br />
das Schmelzbad beim Wie<strong>de</strong>reinschmelzen<br />
verunreinigen. Als ein weiterer<br />
Vorteil kommt die präzise Gießsteuerung<br />
hinzu, die unterschiedliche Masselgewichte<br />
ausschließt.<br />
Primärkühlung mit Luft: Um Erstarrungsrisse<br />
zu vermei<strong>de</strong>n, kommt es zu Beginn <strong>de</strong>r<br />
Erstarrung darauf an, <strong>de</strong>n Temperaturgradienten<br />
zwischen Kern und Randbereich gering<br />
ALUMINIUM · 7-8/2013 45
ALUMINIUMHÜTTENINDUSTRIE<br />
zu halten. Die erste Zone <strong>de</strong>r Kühlstrecke ist<br />
<strong>de</strong>shalb so ausgelegt, dass Temperaturschocks<br />
o<strong>de</strong>r Wellenbewegungen <strong>de</strong>r Schmelzeoberfläche<br />
vermie<strong>de</strong>n wer<strong>de</strong>n.<br />
Die Primärkühlung erfolgt <strong>de</strong>shalb mittels<br />
Luft. Die Kühlluftkanäle sind zwischen<br />
<strong>de</strong>m Ober- und Untergurt <strong>de</strong>s Gießban<strong>de</strong>s<br />
angeordnet, sodass die Kühlluft nicht direkt<br />
auf die flüssige Metalloberfläche auftrifft.<br />
Die erwärmte Luft wird mittels zusätzlicher<br />
Ventilatoren über <strong>de</strong>m Gießband abgeführt.<br />
Wenn die Oberfläche komplett erstarrt ist,<br />
gelangen die Kokillen in einen Bereich intensiverer<br />
Luftkühlung. In diesem Bereich <strong>de</strong>s<br />
Gießban<strong>de</strong>s wird die Erstarrung vollen<strong>de</strong>t.<br />
Die Kühlintensität ist über die Ventilatorsteuerung<br />
regulierbar.<br />
Diese Art <strong>de</strong>r Kühlung besitzt gegenüber<br />
<strong>de</strong>r Wasserkühlung metallurgische und wirtschaftliche<br />
Vorteile. Im Hinblick auf die Produktqualität<br />
sind dies unter an<strong>de</strong>rem:<br />
• dichtes Masselgefüge durch gezielt<br />
gesteuerte Kühlwirkung<br />
• optimale Einstellung <strong>de</strong>r Kokillentemperatur<br />
• Kokillen kommen nicht mit Wasser in<br />
Kontakt.<br />
Hinzu kommen be<strong>de</strong>uten<strong>de</strong> wirtschaftliche<br />
Vorzüge <strong>de</strong>r Luftkühlung:<br />
• Nahezu unbegrenzte Kokillenlebensdauer<br />
(keine Temperaturschocks)<br />
• kein zusätzlicher Kühlwasserverbrauch,<br />
keine Nebenanlagen o<strong>de</strong>r Maßnahmen<br />
zur Aufbereitung<br />
• geringer Wartungsaufwand an Kokillen<br />
und Gießband.<br />
Sekundärkühlung mit Wasser: Die<br />
Masseltemperatur nach <strong>de</strong>m Gießband<br />
beträgt noch etwa 350 °C. Für<br />
das weitere Handling – beson<strong>de</strong>rs für<br />
das Farbmarkieren, für das Abbin<strong>de</strong>n<br />
mit Metall- o<strong>de</strong>r Kunststoffband sowie<br />
für das Etikettieren – muss die Temperatur<br />
unter circa 50 °C abgesenkt wer<strong>de</strong>n.<br />
Für diesen Kühlabschnitt setzt Trimet<br />
Wasser als Kühlmedium ein.<br />
Dazu durchlaufen die zuvor ausgeformten<br />
Masseln einen Kühltunnel, in<br />
<strong>de</strong>m Sprühdüsen installiert sind. Die<br />
einstellbaren Sprühköpfe erlauben es,<br />
die Kühlung für die jeweilige Aufgabe<br />
zu optimieren. Am En<strong>de</strong> <strong>de</strong>s Kühltunnels<br />
wer<strong>de</strong>n die herunter gekühlten<br />
Masseln mittels Druckluft getrocknet.<br />
Die Kühlwasserversorgung ist Teil<br />
<strong>de</strong>s zentralen Wasserkreislaufes <strong>de</strong>s<br />
Werkes. Hinter <strong>de</strong>m Kühltunnel wird<br />
das Wasser wie<strong>de</strong>r in diesen Kreislauf<br />
zurückgeführt. Beson<strong>de</strong>re Einrichtungen<br />
sind für die Wasserversorgung<br />
<strong>de</strong>r Masselgießanlage nicht erfor<strong>de</strong>rlich.<br />
Stapeln, Verpacken, Umreifen: Am En<strong>de</strong> <strong>de</strong>s<br />
Kühlprozesses schließlich stehen voll automatisierte<br />
Anlagen zum Stapeln, Markieren, Umreifen<br />
sowie zum Wiegen zur Verfügung.<br />
Im ersten Arbeitsschritt wer<strong>de</strong>n die gekühlten<br />
Masseln stirnseitig signiert, paarweise (bei<br />
Fußmasseln) bzw. lagenweise zum Stapeln<br />
vorbereitet und schließlich von einem Industrieroboter<br />
im anschließen<strong>de</strong>n Verpackungssystem<br />
abgelegt. Beim Stapeln wer<strong>de</strong>n die Lagen<br />
über Kreuz auf <strong>de</strong>n zuvor positionierten<br />
Fußmasseln abgelegt. Mit einem Tintenstrahldrucker<br />
wird je<strong>de</strong> Massel markiert.<br />
In <strong>de</strong>r Umreifungsmaschine wird <strong>de</strong>r Masselstapel<br />
schließlich mit Umreifungsbän<strong>de</strong>rn<br />
versehen. Dabei verfügt Trimet über mehrere<br />
optionale Möglichkeiten: So ist eine Auswahl<br />
zwischen verschie<strong>de</strong>nen Bandmaterialien, <strong>de</strong>r<br />
Anbringung einer Querumreifung für gesteigerte<br />
Stabilität o<strong>de</strong>r die Bildung von Doppelstapeln<br />
möglich.<br />
Im Rahmen <strong>de</strong>r Versandvorbereitung wird<br />
<strong>de</strong>r Stapel verwogen und etikettiert. Die Daten<br />
wer<strong>de</strong>n vom Rechner an die Produktionssteuerung<br />
und <strong>de</strong>n Versand übermittelt.<br />
Automatisierung: Der gesamte Ablauf vom<br />
Eingießen in die Kokillen bis zur Entnahme<br />
fertiger Stapel ist voll automatisiert. Je<strong>de</strong>r<br />
einzelne Arbeitsschritt wird von speziellen<br />
Überwachungs- und Diagnoseprogrammen<br />
kontrolliert. Bei Abweichungen reagiert die<br />
Steuerung unverzüglich. Es wird eine Fehlermeldung<br />
generiert, die Aufschluss über die<br />
Ursache <strong>de</strong>r Störung sowie Vorschläge zur<br />
Problemlösung enthält.<br />
Masselstapel vor <strong>de</strong>r Umreifung<br />
Stack of ingots before strapping<br />
Casting station: The overall view of the plant<br />
pictured shows on the left two casting furnaces,<br />
each with throughput regulation. It is best<br />
to have two in<strong>de</strong>pen<strong>de</strong>nt furnace units in or<strong>de</strong>r<br />
to maintain continuous operation even when<br />
changing alloys.<br />
By way of a refractory laun<strong>de</strong>r the metal, at<br />
around 700 °C, flows via a ceramic filter into<br />
the pouring trough. During the pouring process<br />
the pouring trough moves synchronously<br />
with the casting belt. During this the pouring<br />
openings, whose height is adjustable, ensure<br />
precise metering and largely turbulence-free<br />
flow of the melt. The equipment illustrated<br />
fills five (preheated) moulds simultaneously.<br />
Positioned on a circulating casting belt,<br />
the moulds pass through a cooling zone. The<br />
<strong>de</strong>cisive advantage of the new ingot casting<br />
equipment is that much less oxi<strong>de</strong> is formed.<br />
This is one of the quality-<strong>de</strong>termining criteria,<br />
since oxi<strong>de</strong> inclusions contaminate the melt<br />
bath when remelting. Another advantage is<br />
the precise control of the casting process,<br />
which prevents variation of the ingot weight.<br />
Primary cooling with air: To avoid solidification<br />
cracks, at the beginning of solidification<br />
the temperature gradient between the core<br />
and edge areas must be kept small. The first<br />
part of the cooling zone is therefore <strong>de</strong>signed<br />
to prevent thermal shock or wave movements<br />
of the melt’s surface.<br />
Accordingly, primary cooling is done with<br />
air. The cooling air ducts are arranged between<br />
the upper and lower strands of the casting belt<br />
so that the air does not impinge directly on<br />
the surface of the molten metal. The heated<br />
air is drawn off by additional fans above the<br />
casting belt. When the surface has solidified<br />
completely, the moulds pass into a zone of<br />
more intense air cooling. In this section of the<br />
casting belt solidification is brought to completion.<br />
The cooling intensity can be regulated by<br />
the fan control system.<br />
Compared with water cooling, this cooling<br />
method has both metallurgical and economic<br />
advantages. As regards product quality these<br />
are, among others:<br />
• a compact ingot such that due to<br />
selectively controlled cooling action<br />
• optimum mould temperature adjustment<br />
• no contact between the moulds and water.<br />
To the above can be ad<strong>de</strong>d some important<br />
economic advantages of air cooling:<br />
• virtually unlimited mould life<br />
(no temperature shocks)<br />
• no additional cooling water consumption<br />
and no auxiliary plant or preparation<br />
measures<br />
• less maintenance effort and expense for<br />
the moulds and the casting belt.<br />
46 ALUMINIUM · 7-8/2013
SPECIAL<br />
ALUMINIUM SMELTING INDUSTRY<br />
Secondary cooling with water: After the casting<br />
belt, the ingot temperature is still around<br />
350 °C. For the subsequent handling procedures<br />
– particularly colour marking, binding<br />
with metallic or plastic strips and labelling –<br />
the temperature has to be lowered to less than<br />
around 50 °C. For the section in which this<br />
takes place Trimet uses water as the cooling<br />
medium.<br />
For this the ingots, previously removed<br />
from their moulds, pass through a cooling<br />
tunnel in which spray nozzles are fitted. The<br />
adjustable spray heads enable the<br />
cooling to be optimised for the<br />
job concerned. At the end of the<br />
cooling tunnel the ingots, now sufficiently<br />
cooled down, are dried by<br />
compressed air.<br />
The cooling water supply is taken<br />
from the plant’s central water<br />
circuit. After the cooling tunnel the<br />
water is returned to that circuit. No<br />
<strong>special</strong> equipment is nee<strong>de</strong>d for the<br />
supply of water to the ingot casting<br />
plant.<br />
Stacking, packing and strapping:<br />
Finally, at the end of the cooling<br />
process fully automatic machines<br />
are available for stacking, marking,<br />
strapping and weighing the ingots.<br />
In the first work step the cooled<br />
ingots are marked on their end<br />
faces in pairs (in the case of baselayer<br />
ingots), prepared in layers for<br />
stacking, and finally transferred by<br />
an industrial robot to the nearby<br />
packing station. During stacking the layers are<br />
laid cross-wise onto the previously positioned<br />
base-layer ingots. Each ingot is marked by an<br />
inkjet printer.<br />
In the strapping machine the stack of ingots<br />
is then bound with strapping strips. For this<br />
Trimet has a number of options: a choice between<br />
various strip materials, the application<br />
of cross-strapping for greater stability or the<br />
formation of double stacks are all possible.<br />
As part of the preparation for dispatch the<br />
stack is then weighed and labelled. The data<br />
are relayed by computer to the production<br />
control and dispatch systems.<br />
Automation: The entire sequence from<br />
pouring into the moulds up to the dispatch of<br />
finished stacks is fully automated. Each individual<br />
work step is controlled by <strong>special</strong> monitoring<br />
and diagnosis programs. In the event<br />
of any <strong>de</strong>parture from the norm the control<br />
system reacts immediately. An error message<br />
is generated, which contains conclusions about<br />
the cause of the disturbance and proposals for<br />
solving the problem.<br />
In accordance with the stored or<strong>de</strong>r data, up<br />
to three different or<strong>de</strong>rs can be processed in<br />
a single batch. For each or<strong>de</strong>r the following<br />
parameters can be programmed individually:<br />
• ingot marking<br />
• stack type<br />
• stack weight<br />
• base-layer ingots<br />
• printing and <strong>de</strong>sign of the weighing label<br />
• strapping pattern (number of strips) and<br />
• nature of strapping strip.<br />
Moveable pouring trough during the filling process<br />
Future prospects<br />
The plant installed in Essen began operating<br />
with no problems and is working to the customer’s<br />
satisfaction. With a yearly production<br />
volume of 35,000 tonnes, it is now already<br />
fully occupied.<br />
Clearly, the customers too appreciate this<br />
new, additional supply form. Trimet answers<br />
questions about the plant’s workload ambiguous:<br />
“200 percent!” Accordingly, it may well<br />
prove necessary to increase the casting capacity<br />
even more in the foreseeable future.<br />
Authors<br />
Dr. Hubert Koch is head of R&D at Trimet <strong>Alu</strong>minium<br />
SE, Essen, Germany.<br />
Dr. Dietmar Bramhoff is head of the casthouse at<br />
Trimet <strong>Alu</strong>minium SE, Essen, Germany.<br />
Uwe Kremer is head of factory planning, maintenance<br />
and projects at Trimet <strong>Alu</strong>minium SE, Essen,<br />
Germany.<br />
Franz Nie<strong>de</strong>rmair is managing director at Hertwich<br />
Engineering, Braunau, Austria.<br />
Gemäß <strong>de</strong>n gespeicherten Auftragsdaten können<br />
in einer Charge bis zu drei unterschiedliche<br />
Bestellungen produziert wer<strong>de</strong>n. Für<br />
je<strong>de</strong> Bestellung lassen sich die folgen<strong>de</strong>n Parameter<br />
individuell programmieren:<br />
• Masselsignierung<br />
• Stapelform<br />
• Stapelgewicht<br />
• Fußmassel<br />
• Ausdruck und Gestalt <strong>de</strong>s Wiegeetiketts<br />
• Umreifungsbild (Anzahl <strong>de</strong>r Bän<strong>de</strong>r) und<br />
• Art <strong>de</strong>s Umreifungsban<strong>de</strong>s.<br />
Verfahrbarer Gießtrog während <strong>de</strong>s Füllvorganges<br />
Ausblick<br />
Die in Essen installierte Anlage ist reibungslos<br />
in Betrieb gegangen und arbeitet zur Zufrie<strong>de</strong>nheit<br />
<strong>de</strong>s Kun<strong>de</strong>n. Sie ist mit einem jährlichen<br />
Produktionsvolumen von 35.000 Tonnen<br />
<strong>de</strong>rzeit bereits voll ausgelastet.<br />
Offensichtlich schätzen auch die Kun<strong>de</strong>n<br />
diese neue, zusätzliche Lieferform. Trimet beantwortet<br />
die Frage nach <strong>de</strong>r Auslastung viel<strong>de</strong>utig:<br />
„200 Prozent“. Es könnte sich danach<br />
als notwendig erweisen, die Gießkapazität in<br />
absehbarer Zeit sogar noch zu erweitern.<br />
Autoren<br />
Dr. Hubert Koch, Leiter Forschung und Entwicklung,<br />
Trimet <strong>Alu</strong>minium SE, Essen.<br />
Dr. Dietmar Bramhoff, Leiter Gießerei, Trimet <strong>Alu</strong>minium<br />
SE, Essen.<br />
Uwe Kremer, Leiter Werkplanung, Instandhaltung<br />
und Projekte, Trimet <strong>Alu</strong>minium SE, Essen.<br />
Franz Nie<strong>de</strong>rmair, Managing Director, Hertwich<br />
Engineering GmbH, Braunau, Österreich.<br />
ALUMINIUM · 7-8/2013 47
TECHNOLOGIE<br />
Der gesamte Schmelz- und Gießofenkomplex im Bereich <strong>de</strong>s neuen Ofens<br />
The complete melting and casting furnace complex in the area of the new furnace<br />
Neuer Schmelz- und Gießofen <strong>de</strong>r Amag erhöht Gießereikapazität<br />
Die Amag casting GmbH hat durch die<br />
Investition in einen weiteren Schmelzofen<br />
mit integrierter Gießfunktion an <strong>de</strong>r<br />
Produktionslinie EMC II eine <strong>de</strong>utliche<br />
Kapazitätserweiterung bei Walzbarren in<br />
EMC-Technologie geschaffen. Mit <strong>de</strong>r an<br />
dieser Anlage erzeugten Produktqualität<br />
und <strong>de</strong>r Erweiterung <strong>de</strong>s Produktspektrums<br />
wird die Position <strong>de</strong>r Amag als<br />
Premiumhersteller von Walzprodukten<br />
weiter gefestigt.<br />
Erstklassige Walzbarren sind die Grundvoraussetzung<br />
für hochwertige Walzprodukte.<br />
Die Walzbarrengießerei <strong>de</strong>r Austria Metall<br />
AG (Amag) aus Ranshofen, Österreich, gießt<br />
ausschließlich für <strong>de</strong>n Bedarf <strong>de</strong>s eigenen<br />
Walzwerks. Die Vielfalt an Walzprodukten<br />
stellt beson<strong>de</strong>re Anfor<strong>de</strong>rungen an die Kompetenz<br />
und Flexibilität <strong>de</strong>r Gießerei. Unter<br />
einem Dach wer<strong>de</strong>n alle Al-Legierungsfamilien<br />
von 1xxx- bis 8xxx-Werkstoffen vergossen,<br />
wobei ein beson<strong>de</strong>res Knowhow in <strong>de</strong>r<br />
Verarbeitung von hoch- und höchstfesten<br />
Legierungen <strong>de</strong>r 2xxx- und 7xxx-Familien<br />
aufgebaut wur<strong>de</strong>.<br />
New melting and casting furnace<br />
increases Amag’s casthouse capacity<br />
By investing in an additional melting furnace<br />
with integrated casting function at<br />
the EMC II production line, Amag casting<br />
GmbH has significantly increased the<br />
capacity for rolling slabs using EMC technology.<br />
The product quality achieved at<br />
this line and the extension of the product<br />
range contribute to further strengthening<br />
Amag’s position as a premium manufacturer<br />
of rolled products.<br />
First-class rolling slabs are a basic requirement<br />
for premium rolled products. The products<br />
of Austria Metall AG’s rolling-slab casthouse<br />
are solely inten<strong>de</strong>d for Amag’s own rolling<br />
mill in Ranshofen. The wi<strong>de</strong> range of rolled<br />
products places <strong>special</strong> <strong>de</strong>mands on the expertise<br />
and flexibility of the casthouse. All<br />
families of aluminium alloys, from 1xxx- to<br />
8xxx-materials, are cast at one location; specific<br />
know-how has been <strong>de</strong>veloped in the<br />
processing of high-strength and super-highstrength<br />
alloys of the 2xxx- and 7xxx-families.<br />
Various continuous casting processes from<br />
conventional vertical continuous casting and<br />
LHC (Low Head Composite Casting) to EMC<br />
(Electromagnetic Casting) are available to<br />
meet the individual product requirements. As<br />
Amag is continuously increasing the output<br />
of rolled products, the company has to adapt<br />
the casthouse capacity for rolling slabs. When<br />
<strong>de</strong>signing new facilities, the focus is always<br />
on meeting quality requirements and increasing<br />
flexibility to satisfy customer needs.<br />
The appropriate furnace technology<br />
for different type of scrap<br />
When scrap metal is melted that contains aluminium,<br />
it is essential to select the appropriate<br />
furnace technology for the different raw<br />
materials. Therefore, the scraps must be exactly<br />
sampled and classified as soon as they<br />
48 ALUMINIUM · 7-8/2013
TECHNOLOGY<br />
are <strong>de</strong>livered. Covered storage of the scraps,<br />
sorted by type, and batch planning based on<br />
gui<strong>de</strong>lines enable high-gra<strong>de</strong> alloys and sizes<br />
to be produced using raw materials in a costefficient<br />
manner. Standardised gui<strong>de</strong>lines also<br />
ensure that, out of the large number of different<br />
furnaces, the optimum melting technology<br />
is selected for the individual scrap type.<br />
The multi-chamber shaft melting furnace<br />
technology is best suited for small-sized, thinwalled<br />
and highly contaminated scraps. The<br />
single-chamber melting furnace has proven<br />
successful for largesized, slightly contaminated<br />
scraps at Amag.<br />
Capacity increase of the EMC machine<br />
When a second electromagnetic casting machine<br />
(EMC II) and a multi-chamber shaft melting<br />
furnace were installed in 2009, the rolling<br />
slab production capacity was significantly<br />
increased in the wrought-alloy casthouse. In<br />
late 2012, a new single-chamber melting furnace<br />
with combined casting function, with a<br />
bath capacity of up to 70 tonnes, was additionally<br />
put into operation and integrated into<br />
the existing site in a particularly space-saving<br />
manner. This additional capacity increase at<br />
the same time provi<strong>de</strong>s more flexibility for<br />
the alloy mix. The new casting unit also al-<br />
© Amag<br />
Entsprechend <strong>de</strong>n Produktanfor<strong>de</strong>rungen<br />
stehen unterschiedliche Stranggießverfahren<br />
vom konventionellen Vertikalstrangguss über<br />
LHC-Guss (Low Head Casting) bis hin zum<br />
EMC-Guss (Elektro-Magnetic Casting) zur<br />
Verfügung. Die kontinuierliche Steigerung <strong>de</strong>r<br />
Produktionsmenge bei Walzprodukten zieht<br />
folglich auch eine Anpassung <strong>de</strong>r Gießereikapazität<br />
für Walzbarren nach sich. Bei <strong>de</strong>r<br />
Planung <strong>de</strong>r Neuanlagen stehen dabei immer<br />
Qualitätsanfor<strong>de</strong>rungen und die Erhöhung <strong>de</strong>r<br />
Flexibilität zur Erfüllung von Kun<strong>de</strong>nwünschen<br />
im Vor<strong>de</strong>rgrund.<br />
Die richtige Ofentechnologie<br />
je nach Einsatzmaterial<br />
Ein wesentlicher Punkt beim Schmelzen von<br />
aluminiumhaltigen Metallabfällen ist die Wahl<br />
<strong>de</strong>r richtigen Ofentechnologie für die verschie<strong>de</strong>nen<br />
Einsatzmaterialien. Daher müssen die<br />
Schrotte bereits bei Anlieferung genau bemustert<br />
und klassifiziert wer<strong>de</strong>n. Die sortenreine<br />
Lagerung <strong>de</strong>r Schrotte unter Dach und eine<br />
auf Richtlinien basierte Chargenplanung ermöglichen<br />
die Produktion hochwertiger Legierungen<br />
und Formate mit wirtschaftlichem<br />
Einsatzmaterial. Standardisierte Richtlinien<br />
gewährleisten, dass aus <strong>de</strong>r Vielzahl an unterschiedlichen<br />
Öfen die Wahl auf die optimale<br />
Technologie zum Schmelzen <strong>de</strong>r jeweiligen<br />
Schrotte fällt.<br />
Für kleinstückige, dünnwandige und stärker<br />
verunreinigte Schrotte wird <strong>de</strong>r Mehrkammer-Schachtschmelzofen<br />
als die am besten<br />
geeignete Technologie betrieben. Bei Einsatz<br />
von grobstückigen, nur leicht verunreinigten<br />
Schrotten hat sich <strong>de</strong>r Einkammer-<br />
Schmelzofen bei <strong>de</strong>r Amag bewährt.<br />
Kapazitätserhöhung <strong>de</strong>r EMC-Gießanlage<br />
Mit <strong>de</strong>r Installation einer zweiten elektromagnetischen<br />
Gießanlage (EMC II) und eines<br />
Mehrkammer-Schachtschmelzofens im Jahr<br />
2009 wur<strong>de</strong> in <strong>de</strong>r Knetlegierungsgießerei<br />
die Produktionskapazität für Walzbarren signifikant<br />
erhöht. Gegen En<strong>de</strong> 2012 wur<strong>de</strong> nun<br />
ein neuer Einkammerschmelzofen mit kombinierter<br />
Gießfunktion mit einem Badinhalt<br />
von bis zu 70 Tonnen ergänzend in Betrieb<br />
genommen und beson<strong>de</strong>rs platzsparend am<br />
bestehen<strong>de</strong>n Standort integriert. Mit dieser<br />
neuerlichen Kapazitätserhöhung wur<strong>de</strong><br />
gleichzeitig auch die Flexibilität in Hinblick<br />
auf <strong>de</strong>n Legierungsmix gesteigert. Die neue<br />
Gießgruppe erlaubt es auch, die neuen größeren<br />
Barrenformate für das in Bau befindliche<br />
Warmwalzwerk zu fertigen und ein breites<br />
Legierungsspektrum mit einem hohen Anteil<br />
an wie<strong>de</strong>rverwerteten Schrotten abzu<strong>de</strong>cken.<br />
Der neue Ofen ist kippbar und mit Regenerativbrennern<br />
sowie einer elektromagnetischen<br />
Pumpe ausgestattet. Dadurch kann das<br />
Erschmelzen und Reinigen <strong>de</strong>s Schrotts sowie<br />
das anschließen<strong>de</strong> Gießen <strong>de</strong>s flüssigen Metalls<br />
in einem Aggregat erfolgen. Die Regenerativbrenner<br />
gewährleisten eine optimale<br />
Schmelzleistung bei geringem Energieverbrauch<br />
und stark reduzierten CO 2 -Emissionen.<br />
Die patentierte Brennertechnologie und<br />
die <strong>de</strong>m Ofen angepasste Anordnung <strong>de</strong>r<br />
Brennerlanzen verhin<strong>de</strong>rt zu<strong>de</strong>m die Bildung<br />
von Stickoxi<strong>de</strong>n. Die <strong>de</strong>utliche Senkung <strong>de</strong>s<br />
Energieverbrauchs gegenüber herkömmlichen<br />
Brennern reduziert Kosten und CO 2 -Emissionen.<br />
Eine zusätzliche Regelung <strong>de</strong>s Gas-Luft-<br />
Verhältnisses in Abhängigkeit vom Restsauerstoffgehalt<br />
im Abgas macht <strong>de</strong>n Energieinhalt<br />
von geringfügigen organischen Schrottverunreinigungen<br />
für <strong>de</strong>n Prozess nutzbar. Dadurch<br />
wer<strong>de</strong>n Abgase auf ein Minimum reduziert.<br />
Selbstverständlich wur<strong>de</strong> mit <strong>de</strong>m Ofen auch<br />
eine hoch mo<strong>de</strong>rne Filteranlage errichtet. Damit<br />
liegen die Emissionswerte <strong>de</strong>s Ofens bezüglich<br />
aller relevanten Schadstoffe weit unter<br />
<strong>de</strong>n gesetzlichen Vorschriften.<br />
Die Ofenanlage besitzt zusätzlich eine elektromagnetische<br />
Rohrpumpe mit Zwischenbehälter,<br />
<strong>de</strong>r seitlich angebracht ist. Dies ermöglicht<br />
neben <strong>de</strong>m Rühren auch ein effizientes<br />
Auflegieren von Legierungsmetallen bei geringer<br />
Oxidbildung. Ein weiterer Vorteil <strong>de</strong>r<br />
Schmelzehomogenisierung ist die Vermeidung<br />
von Überhitzungen an <strong>de</strong>r Oberfläche (Hot-<br />
Spots) und <strong>de</strong>r verbesserte Wärmeaustausch<br />
innerhalb <strong>de</strong>r Schmelze.<br />
Amag erhält Energiemanagement-<br />
Zertifikat ISO 50001<br />
Seit Mai darf Amag ein beson<strong>de</strong>res Zertifikat<br />
ausweisen: Als Vorreiter unter <strong>de</strong>n metallerzeugen<strong>de</strong>n<br />
Unternehmen Österreichs erfüllt<br />
Amag die weltweit gültige Norm ISO 50001<br />
für <strong>de</strong>n Bereich Energiemanagement. Die<br />
Zertifizierung erfolgte durch die renommierte<br />
Lloyd’s Register Quality Assurance.<br />
Ziel dieser energiespezifischen Norm ist<br />
es, Systeme und Prozesse im Unternehmen<br />
aufzubauen, die <strong>de</strong>n Energieverbrauch, die<br />
Energiekosten, die Klimagasemissionen und<br />
an<strong>de</strong>re Umweltbelastungen reduzieren. Maßgeblich<br />
für die erfolgreiche Zertifizierung <strong>de</strong>r<br />
Amag war die Optimierung <strong>de</strong>r Energiebilanz<br />
in allen Unternehmensteilen. Dabei wur<strong>de</strong>n<br />
neben Energieaspekten auch Umweltfaktoren<br />
wie Wasser, Abfall, Chemikalien und Gebäu<strong>de</strong>-Energiemanagement<br />
berücksichtigt. Ý<br />
ALUMINIUM · 7-8/2013 49
TECHNOLOGIE<br />
Amag setzt durch die ressourcenschonen<strong>de</strong><br />
Erzeugung von Primäraluminium mit Strom<br />
aus Wasserkraft im kanadischen Alouette-<br />
Werk sowie durch das Recycling mit mo<strong>de</strong>rnsten<br />
energie- und emissionsoptimierten<br />
Schmelztechnologien in Ranshofen bereits<br />
Industriestandards beim Energieeinsatz und<br />
bei <strong>de</strong>n CO 2 -Emissionen. Dies gilt auch für<br />
die Großinvestition „Amag 2014“ mit einem<br />
Projektvolumen von 220 Mio. Euro am Hauptsitz<br />
in Ranshofen.<br />
Im Gesamtaudit 2013 bescheinigte die Zertifizierungsgesellschaft<br />
Lloyd’s <strong>de</strong>r Amag einen<br />
hohen Standard sowohl im<br />
• QM allgemein – ISO 9001 als auch bei <strong>de</strong>r<br />
• QM Automobilindustrie – ISO TS 16949<br />
• QM Luftfahrtindustrie – AS /EN 9100<br />
• Umweltmanagement – ISO 14001 und<br />
• Arbeitssicherheit – OHSAS 18001. n<br />
lows producing new, larger slab sizes for the<br />
rolling mill un<strong>de</strong>r construction and covering a<br />
broad range of alloys with a large proportion<br />
of recycled scrap.<br />
The new furnace can be tilted and is<br />
equipped with regenerative burners and an<br />
electromagnetic pump, so scrap can be melted<br />
and cleaned and the liquid metal be cast in<br />
one unit. The regenerative burners provi<strong>de</strong><br />
for an optimum melting capacity, while at the<br />
same time minimising power consumption<br />
and CO 2 emissions. Moreover, the patented<br />
burner technology and burner lance arrangement<br />
adjusted to the furnace prevent formation<br />
of nitrogen oxi<strong>de</strong>s. The significant reduction<br />
of power consumption compared to<br />
conventional burners results in a reduction of<br />
costs and CO 2 emissions.<br />
The gas-to-air ratio is additionally controlled<br />
as a function of the residual oxygen content<br />
in the waste gas, so the energy content<br />
of minor organic scrap contaminants can be<br />
utilised for the process. Accordingly, waste<br />
gases are minimised. It goes without saying<br />
that a state-of-the-art filter system was installed<br />
together with the furnace. As a result,<br />
the emission values of the furnace with respect<br />
to all of the relevant pollutants are well<br />
below the legal limit values.<br />
The furnace is additionally equipped with<br />
an electromagnetic pump, which is provi<strong>de</strong>d<br />
with an intermediate tank mounted at the<br />
si<strong>de</strong>, to enable stirring and efficient alloying<br />
of alloying materials to be performed at a<br />
low oxi<strong>de</strong> formation rate. Another advantage<br />
of melt homogenisation is that hot spots are<br />
avoi<strong>de</strong>d and heat exchange in the melt is improved.<br />
n<br />
Alcoa further extends sheet capacity<br />
Investment addresses North American auto <strong>de</strong>mand<br />
Alcoa has announced its plans for a second<br />
major expansion in North America<br />
to meet what it sees as a growing <strong>de</strong>mand<br />
for light, durable and recyclable aluminium<br />
sheet used in automotive production.<br />
The company is to invest USD275 million over<br />
the next three years to expand and convert<br />
capacity at its rolling mill in Tennessee to<br />
support automotive manufacturers’ plans for<br />
using more aluminium sheet to increase fuel<br />
efficiency, safety, durability and performance<br />
of cars and light trucks. This latest <strong>de</strong>velopment<br />
follows Alcoa’s previously announced<br />
USD300 million expansion of its Davenport,<br />
Iowa plant due for completion by year-end.<br />
Alcoa claims that the expansion in Tennessee<br />
is a great example of how its edge in technology<br />
and innovation is securing growth opportunities<br />
in its value-ad<strong>de</strong>d mid- and downstream<br />
businesses. Klaus Kleinfeld, chairman<br />
and chief executive of Alcoa, emphasises:<br />
“More and more auto producers are turning<br />
to aluminium to increase the fuel efficiency<br />
and quality of their vehicles – we anticipate a<br />
quadrupling of auto sheet volume by 2015 and<br />
a tenfold increase by 2025.”<br />
Alcoa’s Tennessee expansion will add 200<br />
full-time, high-value jobs upon completion. In<br />
addition, more than 400 jobs will be created<br />
during the construction phase of the expansion,<br />
welcomed by the state in its continued<br />
growth in the automotive sector. The project<br />
will convert some of the plant’s can sheet<br />
capacity to high-strength automotive production,<br />
as well as installing incremental automotive<br />
capacity. The expansion project is<br />
scheduled to begin shortly and be completed<br />
© Alcoa<br />
Alcoa Tennessee rolling plant – here, 96-inch mill…<br />
…and cold roll storage<br />
50 ALUMINIUM · 7-8/2013
TECHNOLOGY<br />
Alcoa Davenport, Iowa rolling plant – here, horizontal heat-treat furnace<br />
by mid-2015, enabling the plant to be a key<br />
supplier for both the packaging and automotive<br />
markets. Alcoa says that a high proportion of<br />
the output planned from the automotive expansion<br />
is already earmarked with long-term<br />
supply agreements.<br />
Mr Kleinfeld points out that this year marks<br />
both the 100 th anniversary of Alcoa’s Tennessee<br />
operations and the company’s 125 th anniversary.<br />
He stresses that there was a very<br />
<strong>de</strong>dicated and highly engaged workforce in<br />
Tennessee and a very supportive community.<br />
Bonding innovation<br />
The project will incorporate, through Alcoa’s<br />
supply chain, the proprietary ‘Alcoa 951’ pretreatment<br />
bonding technology which enables<br />
adhesive bonding of automotive structures<br />
and is facilitating more cost-effective, mass<br />
production of aluminium-intensive vehicles.<br />
This technology, the company maintains, has<br />
become the new pretreatment bonding standard<br />
for aluminium sheet, extrusion and casting<br />
suppliers across the automotive industry,<br />
and the technology solutions are helping to<br />
drive the continued penetration of aluminium<br />
into the automotive market. Ray Kilmer, executive<br />
vice-presi<strong>de</strong>nt and chief technology<br />
officer of Alcoa, says: “We are enabling not<br />
just increased penetration, but we are working<br />
with OEMs to do it cost effectively in high-volume<br />
automotive applications which, in turn,<br />
necessitates our automotive expansions.”<br />
The use of aluminium in cars is expected<br />
to nearly double by 2025 according to automotive<br />
original equipment manufacturers<br />
(OEMs), and today is already the secondmost-used<br />
material to produce cars. As OEMs<br />
work to continue to make vehicles more<br />
fuel-efficient, many are extending the use of<br />
aluminium from the present array of parts,<br />
such as heat exchangers, wheels, drive shafts,<br />
engine blocks, bonnets<br />
and <strong>de</strong>ck lids, to <strong>de</strong>veloping<br />
aluminium-intensive<br />
vehicles (AIVs)<br />
through the conversion<br />
of the body in white, or<br />
body structure, to allaluminium.<br />
However,<br />
the use of aluminium<br />
body structures to improve<br />
fuel efficiency<br />
requires new joining<br />
and assembly methods<br />
and Alcoa 951 offers a<br />
non-chrome solution<br />
for enhancing bond<br />
durability and enables<br />
more cost-effective, mass production of<br />
AIVs.<br />
In customer trials, Alcoa 951 has been<br />
proven to be up to nine times more durable<br />
than titanium-zirconium based applications<br />
formerly used in the automotive industry and<br />
these results encouraged OEMs to specify<br />
Alcoa 951 and request Alcoa to license it to<br />
other suppliers in the industry. The technology,<br />
through an exclusive global distribution<br />
<strong>de</strong>al, has now been licensed to Chemetall, a<br />
leading global supplier of surface treatments<br />
for automotive components.<br />
Furthermore, Alcoa 951 technology is being<br />
incorporated into the company’s current<br />
automotive expansion projects un<strong>de</strong>rway at<br />
Tennessee and Davenport, Iowa Works.<br />
“We look forward to partnering with Chemetall<br />
to provi<strong>de</strong> Alcoa 951 to help enable<br />
commercialisation of adhesive bonding of aluminium<br />
structures in high-volume automotive<br />
Chemetall’s chrome-free pretreatment for<br />
aluminium extrusions and die castings<br />
© Chemetall<br />
applications. This, in turn, will drive lighter<br />
vehicle weights and enable the integration of<br />
sheet, extrusions and castings to ultimately improve<br />
fuel efficiency,” Mr Kilmer adds.<br />
The process was <strong>de</strong>veloped as a result of<br />
collaboration between Alcoa’s automotive<br />
business and the company’s Technical Centre,<br />
the world’s largest light metals research facility,<br />
located near Pittsburgh, PA.<br />
About Alcoa 951 adhesive bonding<br />
Alcoa 951 employs an organic, environmentally-friendly<br />
system tailored for both the aluminium<br />
substrate and the structural adhesives<br />
used for joining. The pre-treatment <strong>de</strong>livers<br />
far superior bond durability compared to<br />
conversion coating systems such as the titanium-zirconium<br />
wi<strong>de</strong>ly used in the past. Alcoa<br />
claims that customer trials show 951 bonding<br />
is up to nine times stronger than Ti-Zr surface<br />
treatments.<br />
The surface treatment is applied through an<br />
immersion or spray application in which the<br />
organic components bond with oxi<strong>de</strong>s present<br />
on the metal surface. The molecular structure<br />
chemically binds aluminium oxi<strong>de</strong> with one<br />
end, and adhesive with the other. This creates<br />
a strong link at the molecular level resulting<br />
in long-life, durable joints for automotive<br />
structures.<br />
The minimal level of treatment on the surface<br />
makes it essentially ‘transparent’ in downstream<br />
operations in the automotive manufacturing<br />
process, such as forming, resistance spot<br />
welding and painting.<br />
Other commercially available conversion<br />
coatings, which generally contain heavy metals<br />
and are measurably thicker, lead to potential<br />
environmental concerns and diminished<br />
performance in further stages in the manufacturing<br />
process. The attractiveness of Alcoa<br />
951 is essentially centres on its repeatability<br />
and simplicity. It does not incorporate exotic<br />
components that threaten the ability to<br />
implement the product on a large scale, and<br />
it <strong>de</strong>livers a minimal environmental impact<br />
<strong>de</strong>man<strong>de</strong>d by the ‘cradle-to-cradle’ life cycle<br />
required for aluminium.<br />
About Chemetall<br />
Chemetall, headquartered in Frankfurt, Germany,<br />
and a division of Rockwood Holdings,<br />
is a leading global supplier of <strong>special</strong> chemicals,<br />
with some 40 operations worldwi<strong>de</strong> and<br />
a focus on processes for the surface treatment<br />
of metals and plastics.<br />
Ken Stanford, contributing editor<br />
ALUMINIUM · 7-8/2013 51
TECHNOLOGIE<br />
Ein Blick hinter die Kulissen für Gäste aus 22 Län<strong>de</strong>rn<br />
Besucherwoche bei Achenbach Buschhütten<br />
G. Barten, Achenbach<br />
Unter <strong>de</strong>m Motto „Get in Touch with<br />
Achenbach Technology“ war die<br />
Besucherwoche 2013 bei Achenbach mit<br />
einer Führung durch die Montagehallen<br />
und einer Vielfalt an technischen Vorträgen<br />
bei gleichzeitig individueller Kun<strong>de</strong>nbetreuung<br />
nicht nur eine Demonstration<br />
<strong>de</strong>r Leistungsfähigkeit, son<strong>de</strong>rn zu<strong>de</strong>m<br />
Ausdruck <strong>de</strong>s großen Leistungswillens <strong>de</strong>s<br />
traditionsreichen Lieferanten erstklassiger<br />
Walzwerkanlagen und Folienschneidmaschinen.<br />
Die Resonanz im Kun<strong>de</strong>nkreis<br />
war sowohl von <strong>de</strong>r Anzahl <strong>de</strong>r Besucher<br />
her als auch von ihrem Urteil über das,<br />
was geboten wur<strong>de</strong>, uneingeschränkt<br />
positiv: Stammkun<strong>de</strong>n fühlten sich in<br />
ihrer Lieferantenwahl bestätigt, neue<br />
Geschäftskontakte konnten geknüpft und<br />
zukunftsweisen<strong>de</strong> Investitionsprojekti<strong>de</strong>en<br />
entwickelt wer<strong>de</strong>n.<br />
A glimpse behind the scenes for guests from 22 countries<br />
Visitors’ week at Achenbach Buschhütten<br />
G. Barten, Achenbach<br />
Durchschnittlich 60 bis 80 Personen täglich<br />
wur<strong>de</strong>n in <strong>de</strong>r Zeit vom 10. bis 14. Juni in<br />
Kleingruppen durch die Produktionshallen geführt,<br />
wo ein breites Spektrum an Maschinen<br />
und Anlagen vormontiert o<strong>de</strong>r in <strong>de</strong>r Vorinbetriebnahme<br />
mit Material präsentiert und<br />
von Spezialisten an <strong>de</strong>n einzelnen Stationen<br />
vertieft erläutert wur<strong>de</strong>n. Aus <strong>de</strong>m Bereich<br />
Walzwerkanlagen waren dies zunächst ein<br />
<strong>Alu</strong>minium-Bandwalzwerk für Bandbreiten<br />
bis 2.150 mm, Eingangsdicken bis 6,5 mm, die<br />
<strong>de</strong>mnächst mit großer Geschwindigkeit bis an<br />
eine Enddicke von 0,15 mm verwalzt wer<strong>de</strong>n.<br />
Zusammen mit <strong>de</strong>m dazugehörigen Feinbandwalzwerk<br />
wer<strong>de</strong>n diese Walzwerke künftig<br />
Lithographiebleche höchster Oberflächengüte<br />
produzieren. Neben dieser anspruchsvollen<br />
Walzaufgabe sind die hohen<br />
Coilgewichte von 32 Tonnen,<br />
die das Bandwalzwerk bewältigt,<br />
hervorzuheben sowie<br />
das integrierte Prozessdatenerfassungssystem,<br />
das vorgesehen<br />
ist, um die OEE (Overall<br />
Equipment Efficiency) im<br />
Produktionsprozess beim<br />
Kun<strong>de</strong>n zu optimieren.<br />
Weitgehend vormontiert<br />
konnten ferner zwei Folienwalzwerke<br />
für 1.700 mm bzw.<br />
1.850 mm breite Bän<strong>de</strong>r von<br />
<strong>de</strong>n Besuchern begutachtet<br />
wer<strong>de</strong>n. Hervorzuheben war<br />
Internationales Publikum vor <strong>de</strong>r Optifoil Heavyslit<br />
Besuchergruppe vor einem <strong>Alu</strong>minium-Folienwalzwerk<br />
Visitors in front of an aluminium foil rolling mill<br />
International guests in front of the Optifoil Heavyslit<br />
According to the motto ‘Get in Touch<br />
with Achenbach Technology’, the visitors’<br />
week 2013 took place at Achenbach<br />
in Buschhütten. Gui<strong>de</strong>d tours through the<br />
production halls, a wi<strong>de</strong> variety of <strong>special</strong>ist<br />
presentations and individual customer<br />
support did not only express the<br />
ability to perform, but also the willingness<br />
to perform and the accommodating<br />
service philosophy of the traditional supplier<br />
for first-class rolling mill machinery<br />
and foil slitting machines. The feedback<br />
by the customers was unrestrictedly positive,<br />
which was evi<strong>de</strong>nt by the quantity of<br />
visitors on the one hand and by their reception<br />
towards the visitors’ programme<br />
on the other hand. Long-term customers<br />
felt vindicated by their supplier selection,<br />
new business relations could be<br />
established and trendsetting investment<br />
projects could be <strong>de</strong>veloped.<br />
In the time between 10 th and 14 th June, an<br />
average number of 60 to 80 people per day<br />
was gui<strong>de</strong>d through the production halls in<br />
small groups. There, a wi<strong>de</strong> variety of machinery<br />
and systems was presented in<br />
pre-assembled condition or even in precommissioning<br />
stage with material. Specialists<br />
held <strong>de</strong>tailed presentations on the<br />
single stations. The following machinery<br />
was presented: for the rolling mill field,<br />
an aluminium strip rolling mill for strip<br />
widths of up to 2,150 mm, an entry thickness<br />
of up to 6.5 mm, which is to be rolled<br />
to a final thickness of 0.15 mm with high<br />
speed, was presented. Together with the<br />
respective thin-strip rolling mill, these<br />
rolling mills will produce litho sheets of<br />
highest quality in the future. Apart from<br />
this challenging rolling task, the high coil<br />
weights of 32 tonnes as well as the inte-<br />
© Achenbach<br />
52 ALUMINIUM · 7-8/2013
TECHNOLOGY<br />
grated process data recording system must be<br />
emphasised, which is planned to optimise the<br />
OEE (Overall Equipment Efficiency) in the<br />
customers’ production process.<br />
Moreover, two nearly pre-assembled foil<br />
rolling mills for strip widths of 1,700 mm<br />
and 1,850 mm could be inspected by the visitors.<br />
The installation of highly-mo<strong>de</strong>rn nozzle<br />
valve technology for the coolant distribution<br />
and the use of most mo<strong>de</strong>rn drive technology<br />
in these rolling mills were <strong>special</strong> highlights<br />
of this week. Trendsetting media systems,<br />
which are part of the scope of supply such as<br />
Superstack II rolling oil micro-filtration system,<br />
WOR rectification system or – in case of<br />
the foil rolling mill 1,700 mm – an Airpure<br />
exhaust air purification system. These systems<br />
are to purify the rolling mill exhaust air of<br />
this and two other Achenbach rolling mills on<br />
the customer’s premises. The recovered rolling<br />
oil can be redirected to the rolling process in<br />
as-good-as-new quality. The gui<strong>de</strong>d tour also<br />
stopped in the Optiroll workshop, where key<br />
components such as the various types of flatness<br />
measuring rolls were presented.<br />
The foil slitting machines also attracted<br />
great attention. Several foil slitting machines<br />
could be presented in pre-commissioning stage<br />
with material. The huge Optifoil Heavyslit,<br />
which is the presently biggest Achenbach-built<br />
roll slitting machine for the aluminium foil industry<br />
having a finish roll weight of 18 tonnes<br />
and a rewinding diameter of 1,800 mm, was<br />
very impressive to the visitors.<br />
Other highly interesting stations on this<br />
gui<strong>de</strong>d tour were the Optifoil Varioslit – e<strong>special</strong>ly<br />
<strong>de</strong>veloped for the processing industry<br />
– for smaller finish roll diameters of up to 800<br />
mm and the Optifoil Jumboslit roll slitting machine<br />
for higher finish roll diameters of up to<br />
1,200 mm. These very universally usable machines<br />
for paper, aluminium, laminates, plastic<br />
and compound foils can be exten<strong>de</strong>d by smart<br />
<strong>de</strong>tail solutions, if required.<br />
Another attraction on the gui<strong>de</strong>d tour was<br />
the Optifoil Separator in test operation with<br />
material. The separator is part of the Alf Miniplant,<br />
which was <strong>de</strong>veloped as compact, experience-based<br />
complete plant for aluminium<br />
foil production and which is highly <strong>de</strong>man<strong>de</strong>d<br />
e<strong>special</strong>ly on the Indian market. In principal,<br />
the Miniplant comprises an aluminium foil<br />
rolling mill, an Optifoil Separator / Slitter, a<br />
roll grinding machine and three annealing<br />
furnaces.<br />
The gui<strong>de</strong>d tour through the production<br />
halls was roun<strong>de</strong>d off by a view into the new<br />
production hall, where from now on those<br />
components will be manufactured, which are<br />
essential for quality and speed of the Achen-<br />
hier beson<strong>de</strong>rs <strong>de</strong>r Einbau neuester Düsenventiltechnik<br />
für die Kühlmittelverteilung<br />
o<strong>de</strong>r <strong>de</strong>r Einsatz mo<strong>de</strong>rnster Antriebstechnik.<br />
Hinzu kommen mo<strong>de</strong>rne verfahrenstechnische<br />
Anlagen, die mit zum Lieferumfang<br />
zählen wie eine Superstack II Walzölfeinstfiltrationsanlage,<br />
WOR-Rektifikationsanlage<br />
o<strong>de</strong>r im Falle <strong>de</strong>s 1.700 mm breiten Folienwalzwerks<br />
eine Airpure-Abluftreinigungsanlage,<br />
die die Walzwerkabluft dieses und zwei<br />
weiterer Achenbach-Walzwerke beim Kun<strong>de</strong>n<br />
reinigen und das rückgewonnene Walzöl<br />
neuwertig wie<strong>de</strong>r in Walzprozess einführen<br />
wird. Die Führung machte auch in <strong>de</strong>r Optiroll-Werkstatt<br />
halt, wo Schlüsselkomponenten<br />
wie die unterschiedlichen Typen an Messrollen<br />
gezeigt und erläutert wur<strong>de</strong>n.<br />
Große Aufmerksamkeit zog auch <strong>de</strong>r Bereich<br />
<strong>de</strong>r Folienschneidmaschinen auf sich,<br />
von <strong>de</strong>nen gleich mehrere in <strong>de</strong>r Vorinbetriebnahme<br />
mit Material gezeigt wer<strong>de</strong>n konnten.<br />
Beson<strong>de</strong>rs eindrucksvoll war allem voran die<br />
riesige Optifoil<br />
Heavyslit,<br />
die mit einem<br />
Fertigrollengewicht<br />
von 18<br />
Tonnen und<br />
einem Wickeldurchmesser<br />
von 1.800 mm<br />
in <strong>de</strong>r Aufwicklung<br />
die<br />
bislang größte<br />
von Achenbach<br />
gebaute<br />
Rollenschneidmaschine<br />
für<br />
die <strong>Alu</strong>miniumfolienindustrie<br />
darstellt.<br />
Weitere interessante Stationen auf <strong>de</strong>m<br />
Rundgang zum Thema Schnei<strong>de</strong>n und Wickeln<br />
waren die speziell für <strong>de</strong>n Verarbeitermarkt<br />
entwickelte Optifoil Varioslit für kleinere<br />
Fertigrollendurchmesser bis 800 mm und die<br />
Rollenschnei<strong>de</strong>r Optifoil Jumboslit für größere<br />
Fertigrollendurchmesser bis 1.200 mm.<br />
Diese sehr universell einsetzbaren Maschinen<br />
für Papier, <strong>Alu</strong>minium, Laminate, Kunststoffund<br />
Verbundfolien können zu<strong>de</strong>m bei Bedarf<br />
durch pfiffige Detaillösungen in ihrem Anwendungsbereich<br />
noch erweitert wer<strong>de</strong>n.<br />
Anziehungspunkt während <strong>de</strong>r Führung<br />
war nicht zuletzt <strong>de</strong>r Optifoil Separator im<br />
Testlauf mit Material. Er ist Teil einer Achenbach<br />
Alf Miniplant, die als kompakte erfahrungsbasierte<br />
Gesamtanlage zur <strong>Alu</strong>miniumfolienproduktion<br />
entwickelt wur<strong>de</strong> und speziell<br />
im indischen Markt auf rege Nachfrage<br />
Optifoil Separator als Teil einer Achenbach Miniplant<br />
Optifoil Separator as part of the Achenbach Miniplant<br />
stößt. Die Miniplant umfasst im Wesentlichen<br />
ein <strong>Alu</strong>minium-Folienwalzwerk, einen Optifoil<br />
Separator / Slitter, eine Walzenschleifmaschine<br />
und drei Glühöfen.<br />
Abgerun<strong>de</strong>t wur<strong>de</strong> die Führung durch die<br />
Montagehallen durch einen Blick in die neue<br />
Fertigungshalle, in <strong>de</strong>r von nun an die Fertigung<br />
aller Komponenten, die wesentlich für<br />
die Qualität und Geschwindigkeit <strong>de</strong>r Achenbach-Produktionsanlagen<br />
sind, hergestellt<br />
wer<strong>de</strong>n. Die Fertigung wur<strong>de</strong> dabei nach<br />
einem mo<strong>de</strong>rnen Materialflusskonzept organisiert<br />
und weiter ausgebaut.<br />
Auf großes Interesse stießen auch die zwölf<br />
technischen Impulsvorträge zu be<strong>de</strong>uten<strong>de</strong>n<br />
Weiterentwicklungen, die Achenbach in <strong>de</strong>r<br />
letzten Zeit mit Fokus auf einen möglichst<br />
großen Kun<strong>de</strong>nnutzen vorangetrieben hat. Zu<br />
<strong>de</strong>n Themen zählten beispielsweise Ausführungen<br />
zur „Einzelkontaktwalzentechnologie“<br />
o<strong>de</strong>r zu „Mo<strong>de</strong>l Predictive Control“. Die<br />
je nach Interessenlage individuell zugewiesenen<br />
Vorträge brachten <strong>de</strong>n Fachbesuchern<br />
neue Erkenntnisse und führten zu intensiven<br />
Gesprächen, die beim allabendlichen Get together<br />
im Achenbach-Gästehaus häufig weiter<br />
fortgesetzt wur<strong>de</strong>n.<br />
Zusammenfassend kann man sagen, dass<br />
<strong>de</strong>r integrative Ansatz von Achenbach, Walzwerkanlagen<br />
und Folienschneidmaschinen<br />
zum <strong>Alu</strong>miniumfolienwalzen, -doppeln, -separieren<br />
und -schnei<strong>de</strong>n gemeinsam zu vertreiben,<br />
mittlerweile weltweit im Markt angekommen<br />
ist: „Alles aus einer Hand“ vor <strong>de</strong>m<br />
Hintergrund eines Ma<strong>de</strong> in Germany, das<br />
nach wie vor weltweit große Strahlkraft besitzt,<br />
zählt zu <strong>de</strong>n Alleinstellungsmerkmalen,<br />
die Achenbach für sich beanspruchen kann.<br />
Immer größer wird zum an<strong>de</strong>ren aber auch<br />
die Nachfrage nach Optifoil-Schneidmaschinen<br />
seitens <strong>de</strong>r Convertingindustrie, und dies<br />
ALUMINIUM · 7-8/2013 53
TECHNOLOGIE<br />
Inhaberfamilie Barten in <strong>de</strong>r 7. und 8. Generation<br />
Owner family in the 7 th and 8 th generation<br />
beson<strong>de</strong>rs dann, wenn es um das Schnei<strong>de</strong>n<br />
beson<strong>de</strong>rs empfindlicher Materialien, beson<strong>de</strong>rs<br />
schmaler Nutzen o<strong>de</strong>r beson<strong>de</strong>rs großer<br />
Coils in erstklassiger Qualität und mit hoher<br />
Produktivität geht.<br />
In allen Projekten arbeitet Achenbach<br />
traditionell sehr eng mit seinen Kun<strong>de</strong>n zusammen.<br />
Angeboten wer<strong>de</strong>n im Walzwerkanlagen-<br />
wie im Folienschneidmaschinenbau<br />
keine Standardlösungen, son<strong>de</strong>rn das<br />
Knowhow, die Zukunftsi<strong>de</strong>en <strong>de</strong>r Kun<strong>de</strong>n<br />
maßgeschnei<strong>de</strong>rt in erstklassige Maschinenund<br />
Anlagentechnik umzusetzen. Dabei hat<br />
die 125-jährige Erfahrung im Bau komplexer<br />
Maschinen und Anlagen gezeigt, dass es vor<br />
allem in zukunftsweisen<strong>de</strong>n ehrgeizigen Projekten<br />
stets um die Balance geht zwischen <strong>de</strong>r<br />
Solidität eines bewährten Maschinenbaus und<br />
<strong>de</strong>m Mut, technisch immer ausgefeiltere Lösungen<br />
zu entwickeln.<br />
n<br />
bach production machinery.<br />
The manufacturing process was<br />
therefore organised and further<br />
exten<strong>de</strong>d according to a mo<strong>de</strong>rn<br />
material flow concept.<br />
Twelve technical keynote<br />
presentations on <strong>de</strong>cisive innovations,<br />
Achenbach has recently<br />
pushed focussing on the greatest<br />
possible customer’s benefit,<br />
were of great interest. Two of<br />
the topics presented were Single<br />
Contact Roller Technology<br />
and Mo<strong>de</strong>l Predictive Control.<br />
The individually planned presentations<br />
revealed new knowledge<br />
and resulted in intensive<br />
conversation, which was often<br />
continued on occasion of the ‘Get together’<br />
in the Achenbach guesthouse, which was held<br />
every evening.<br />
Summarising, it can<br />
be said that the integrative<br />
technological<br />
approach by Achenbach<br />
to market rolling<br />
mill machinery and<br />
foil slitting machines<br />
for doubling, separating<br />
and slitting aluminium<br />
foils has now<br />
arrived on the world<br />
market: ‘Everything<br />
from a single source’<br />
and the well-known<br />
Ma<strong>de</strong> in Germany,<br />
still having worldwi<strong>de</strong><br />
charisma, are<br />
the unique characteristics of Achenbach<br />
Buschhütten. Above that, the <strong>de</strong>mand for<br />
Optifoil slitting machines in the converting<br />
industry is steadily growing, e<strong>special</strong>ly, when<br />
slitting of highly sensitive materials such as<br />
very small or big coils to high-class quality<br />
with high productivity is concerned.<br />
In all projects, Achenbach is traditionally<br />
working closely with its customers. Neither in<br />
building rolling mill machinery nor in building<br />
foil slitting machines standard solutions are offered,<br />
but the know-how to turn future concepts<br />
of the customers into tailored machinery<br />
and plant technology. 125 years of experience<br />
in building highly complex plants and machinery<br />
have shown that trendsetting and competitive<br />
projects always need the balance between<br />
both, the solidity of experienced engineering<br />
and the courage to continuously <strong>de</strong>velop ever<br />
more refined solutions.<br />
n<br />
Abendliches Get together im Garten <strong>de</strong>s Gästehauses<br />
Get together in the guesthouse gar<strong>de</strong>n in the evenings<br />
Kampf eröffnet neue Montagehallen am Standort Mühlen<br />
Im Rahmen eines festlichen Empfangs hat<br />
die Kampf Schneid- und Wickeltechnik<br />
GmbH & Co. KG Mitte Juli ihre neuen<br />
Montagehallen am Hauptstandort Mühlen<br />
eingeweiht. Der Vorstand <strong>de</strong>r Jagenberg<br />
AG, Vertreter aus Politik und Presse sowie<br />
die mit <strong>de</strong>r Planung und Umsetzung<br />
<strong>de</strong>s Bauprojektes betrauten Lieferanten<br />
und Mitarbeiter waren <strong>de</strong>r Einladung von<br />
Geschäftsführer Lutz Busch gefolgt.<br />
Der Startschuss für die Erweiterung <strong>de</strong>r Produktionsfläche<br />
erfolgte im Juli 2012. Neben<br />
<strong>de</strong>r Mo<strong>de</strong>rnisierung und Instandsetzung <strong>de</strong>r<br />
vorhan<strong>de</strong>nen Gebäu<strong>de</strong> entstan<strong>de</strong>n vier neue<br />
Hallen mit 6.400 m 2 Gesamtfläche, davon<br />
Kampf opens new assembly<br />
halls at the Mühlen site<br />
Kampf Schneid- und Wickeltechnik officially<br />
opened new assembly halls at its<br />
headquarters in Mühlen, Germany, in<br />
mid-July. The executive board of Jagenberg<br />
AG, representatives from politics<br />
and the media as well as suppliers and<br />
employees entrusted with the planning<br />
and implementation of the construction<br />
project accepted the invitation from managing<br />
director Lutz Busch.<br />
The expansion of the production area began<br />
in July 2012. In addition to the mo<strong>de</strong>rnisation<br />
and restoration of the existing buildings, four<br />
new halls with a total usable area of 4,400 m 2 ,<br />
plus 450 m 2 for staff facilities, were constructed.<br />
The crane system has a load capacity of up<br />
to 60 tonnes.<br />
The persistently high number of or<strong>de</strong>rs<br />
received by Kampf necessitated the urgent<br />
expansion of capacity. The company had temporarily<br />
hired external assembly space. This<br />
situation led to logistics problems and did not<br />
represent a permanent solution. In his opening<br />
54 ALUMINIUM · 7-8/2013
TECHNOLOGY<br />
speech, Lutz Busch<br />
emphasised that<br />
Kampf was oriented<br />
to the future. The<br />
high-tech machines<br />
<strong>de</strong>livered from the<br />
Mühlen site were<br />
characterised by<br />
highest quality in<br />
terms of performance,<br />
precision,<br />
reliability and longevity<br />
and enjoyed<br />
an excellent reputation<br />
worldwi<strong>de</strong>, he<br />
said. The completed<br />
new production areas<br />
would increase<br />
efficiency.<br />
Further construction<br />
projects<br />
will start this summer.<br />
A new office<br />
building and an additional<br />
hall for customer service will be built<br />
by mid-2014. Furthermore, Kampf intends to<br />
create a new training workshop by the end of<br />
2013. The capital expenditure for the entire<br />
construction project amounts to around 11<br />
million euros in total.<br />
Kampf has been a technology lea<strong>de</strong>r in slitting<br />
and winding of various materials for over<br />
90 years. The company employs around 600<br />
people. It has subsidiaries in the US, China<br />
and India as well as international service and<br />
sales outlets. The product range comprises rewin<strong>de</strong>rs,<br />
unwin<strong>de</strong>rs and win<strong>de</strong>rs; slitters for<br />
the converter industry and for thinnest types<br />
of foil, including the appropriate handling systems;<br />
separators and doubling machines for<br />
the production of aluminium foil as well as<br />
slitters for aluminium foil and strip.<br />
Durch das gemeinsame Durchtrennen eines Ban<strong>de</strong>s wur<strong>de</strong>n die neuen Montagehallen offiziell freigegeben:<br />
(von links) Erich W. Bröcker (Vorstand Jagenberg AG), Werner Becker-Blonigen (Bürgermeister <strong>de</strong>r<br />
Stadt Wiehl), Jan Kleinewefers (Vorsitzen<strong>de</strong>r <strong>de</strong>s Aufsichtsrats <strong>de</strong>r Jagenberg AG), Lutz Busch (Geschäftsführer<br />
Kampf), Stefan K. Kranzbühler (Vorstand Jagenberg AG) und Andre Lang (Planungsbüro Lang &<br />
Stranzenbach)<br />
The new assembly halls were officially opened by the joint cutting of a ribbon: (from left) Erich Bröcker<br />
(member of the executive board at Jagenberg AG), mayor Werner Becker-Blonigen, Jan Kleinewefer<br />
(chairman of the supervisory board at Jagenberg AG), Kampf managing director Lutz Busch, Stefan<br />
Kranzbühler (member of the executive board at Jagenberg AG) and Andre Lang (Lang & Stranzenbach<br />
planning office).<br />
n<br />
4.400 m 2 Nutzfläche plus 450 m 2 für die Sozialtrakte.<br />
Die Krananlagen können teilweise<br />
bis zu 64 Tonnen tragen.<br />
Der anhaltend hohe Auftragseingang bei<br />
Kampf hatte die Erweiterung <strong>de</strong>r Kapazitäten<br />
dringend notwendig gemacht. Das Unternehmen<br />
hatte vorübergehend externe Montageflächen<br />
zur Auftragsabwicklung angemietet.<br />
Diese Situation führte zu logistischen Problemen<br />
und konnte keine andauern<strong>de</strong> Lösung<br />
sein. Geschäftsführer Busch betonte in seiner<br />
Eröffnungsre<strong>de</strong>, dass Kampf auf die Zukunft<br />
ausgerichtet sei. Die vom Standort Mühlen<br />
ausgelieferten Hightech-Maschinen zeichneten<br />
sich durch höchste Qualität hinsichtlich<br />
Leistungsfähigkeit, Präzision, Zuverlässigkeit<br />
und Langlebigkeit aus und hätten weltweit einen<br />
hervorragen<strong>de</strong>n Ruf, sagte er.<br />
Bis zum Sommer nächsten<br />
Jahres wer<strong>de</strong>n weitere<br />
Baumaßnahmen<br />
durchgeführt. So soll ein<br />
neues Bürogebäu<strong>de</strong> und<br />
eine zusätzliche Halle<br />
für <strong>de</strong>n Kun<strong>de</strong>ndienst<br />
entstehen. Darüber hinaus<br />
will Kampf bis<br />
En<strong>de</strong> dieses Jahres eine<br />
neue Ausbildungswerkstatt<br />
schaffen. Das Investitionsvolumen<br />
für die<br />
gesamte Baumaßnahme<br />
beträgt insgesamt rund<br />
11 Mio. Euro.<br />
Kampf Schneid- und<br />
Wickeltechnik ist seit<br />
mehr als neun Jahrzehnten<br />
einer <strong>de</strong>r Technologieführer<br />
in <strong>de</strong>r<br />
Schneid- und Wickeltechnik.<br />
Das Unternehmen<br />
beschäftigt insgesamt<br />
fast 600 Mitarbeiter. Das Produktprogramm<br />
bietet unter an<strong>de</strong>rem Schneid- und Wickelmaschinen,<br />
Wickler sowie Schmalschnittund<br />
Spezialmaschinen zur Herstellung und<br />
Verarbeitung von bahnförmigen Kunststofffolien,<br />
Verbundmaterialien, Laminaten und<br />
<strong>Alu</strong>miniumfolien.<br />
Kampf ist weltweit <strong>de</strong>r größte Hersteller<br />
von Rollenschneid- und Wickelmaschinen und<br />
Wicklern für Folien. Der Exportanteil beträgt<br />
90 Prozent. Das Unternehmen hat Tochtergesellschaften<br />
in <strong>de</strong>n USA, China und Indien<br />
sowie internationale Service- und Vertriebsnie<strong>de</strong>rlassungen.<br />
Schwerpunkte <strong>de</strong>s umfangreichen<br />
Portfolios bil<strong>de</strong>n Rollenschneidmaschinen<br />
und Wickler bis 10.400 mm Materialbreite<br />
für Kunststofffolien sowie Doppler- und<br />
Separiermaschinen für <strong>Alu</strong>miniumfolien.<br />
n<br />
HPI errichtet Horizontal-Stranggießanlage in Shanghai<br />
High Performance Industrietechnik (HPI),<br />
eine 51%-Beteiligung <strong>de</strong>r Salzburger <strong>Alu</strong>minium<br />
AG, hat für das japanische Unternehmen<br />
Kobe Steel eine Horizontal-Stranggießanlage<br />
entwickelt, die in China montiert<br />
und in Betrieb genommen wird. Auf dieser<br />
Anlage wer<strong>de</strong>n für die Automobilindustrie<br />
<strong>Alu</strong>minium-Schmie<strong>de</strong>bolzen produziert, die<br />
einen Durchmesser zwischen 60 und 100 mm<br />
sowie eine Länge von 2.700 bis 3.500 mm<br />
haben. Maximal 16 Stränge können gleichzeitig<br />
gegossen wer<strong>de</strong>n. Das Schmie<strong>de</strong>n erfolgt<br />
in einem nachgeschalteten Arbeitsschritt mit<br />
Exzenterpressen, <strong>de</strong>ren Presskräfte 8.000<br />
Tonnen und mehr betragen.<br />
SAG Engineering lieferte für dieses Projekt<br />
das komplette Steuerungssystem und<br />
zeichnet auch für die gesamten elektrischen<br />
Funktionen verantwortlich. Als Basis dient<br />
eine Hochleistungs-CPU mit elektrischen Servomotor-Systemen<br />
für die acht integrierten<br />
Servomotorachsen.<br />
Schon im Jahr 2000 hat HPI seine Kompetenz<br />
in <strong>de</strong>r Kokillentechnik bewiesen und<br />
<strong>de</strong>n Zuschlag für die Konstruktion <strong>de</strong>r ersten<br />
Kobe-Anlage in Daian (Japan) erhalten. Derzeit<br />
betreibt das Unternehmen HPI-Anlagen<br />
in Japan, Amerika und China.<br />
Zur Montage und Inbetriebnahme sind<br />
Mitarbeiter <strong>de</strong>r bei<strong>de</strong>n Firmen 2012 erstmals<br />
nach China an <strong>de</strong>n Kobe Steel-Standort Suzhou<br />
geflogen. Nach neun Wochen in China<br />
wur<strong>de</strong> die Anlage erfolgreich in Betrieb genommen.<br />
Folgeaufträge sind bereits in Umsetzung.<br />
Die nächste Anlage für Kobe Steel<br />
ist <strong>de</strong>rzeit im Bau und wird noch dieses Jahr<br />
in Bowling Green (Kentucky, USA) in Betrieb<br />
genommen, ebenfalls mit einer elektrischen<br />
Ausrüstung und Knowhow <strong>de</strong>r SAG. n<br />
ALUMINIUM · 7-8/2013 55
TECHNOLOGIE<br />
<strong>Alu</strong>mec setzt auf umweltschonen<strong>de</strong>n Korrosionsschutz<br />
<strong>Alu</strong>miniumvorbehandler macht gute Erfahrungen mit Alodine 5992 von Henkel<br />
Wer morgens gerne eine Dusche nimmt,<br />
hat gute Chancen, dabei in einer Kabine<br />
aus <strong>Alu</strong>profilen zu stehen, die von <strong>de</strong>r<br />
italienischen <strong>Alu</strong>mec Srl hergestellt wur<strong>de</strong>n.<br />
Metallvorbehandlungsprodukte von<br />
Henkel helfen <strong>de</strong>m Unternehmen dabei,<br />
auf umweltschonen<strong>de</strong> Weise perfekten<br />
Korrosionsschutz und zugleich eine exzellente<br />
Optik zu erreichen.<br />
„Die richtige Leichtmetallvorbehandlung ist<br />
zentral für die Qualität eines fertigen <strong>Alu</strong>miniumprofils“,<br />
sagt Giuolio Marianelli,<br />
verantwortlicher Ingenieur<br />
bei <strong>Alu</strong>mec. Darauf legt man bei<br />
<strong>de</strong>m im norditalienischen Rudiano<br />
ansässigen Unternehmen großen<br />
Wert. So hat sich <strong>Alu</strong>mec in <strong>de</strong>n<br />
vergangenen 35 Jahren weit über<br />
Italiens Grenzen hinaus hohes<br />
Ansehen als Qualitätsanbieter erworben.<br />
Zu <strong>de</strong>n Kun<strong>de</strong>n gehören bekannte<br />
Hersteller von Duschkabinen,<br />
Fenster und Türen, Produzenten<br />
von Markisen und Jalousetten<br />
aus <strong>Alu</strong>lamellen sowie Architekten,<br />
die mit <strong>Alu</strong>-Elementen<br />
Fassa<strong>de</strong>n gestalten. Der Großteil<br />
<strong>de</strong>r Produktion geht ins Ausland.<br />
<strong>Alu</strong>mec verfügt über einen eigenen Strangpressbereich,<br />
in <strong>de</strong>m aus <strong>de</strong>n <strong>Alu</strong>minium-<br />
Rundbarren die unterschiedlichsten Profile<br />
hergestellt wer<strong>de</strong>n. Diese gehen anschließend<br />
gemeinsam mit von Auftragskun<strong>de</strong>n angelieferten<br />
Profilen in die Lackierung, <strong>de</strong>m zweiten<br />
Produktionstrakt bei <strong>Alu</strong>mec. Rund 20 Tonnen<br />
an Profilen kann das Unternehmen dort<br />
täglich verarbeiten. Mehrere Produkte von<br />
Henkel kommen dabei zum Einsatz, darunter<br />
auch Alodine 5992, das <strong>de</strong>n Konversionsprozess<br />
umweltschonen<strong>de</strong>r macht.<br />
Die Vorbehandlung erfolgt in einem speziell<br />
konstruierten schmalen Tunnel, durch<br />
<strong>de</strong>n die hängen<strong>de</strong>n Werkstücke mit einer Geschwindigkeit<br />
von ein bis zwei Metern pro Minute<br />
langsam hindurchgezogen wer<strong>de</strong>n. Dabei<br />
fließt kaska<strong>de</strong>nhaft Flüssigkeit von oben über<br />
die Profile o<strong>de</strong>r sie wer<strong>de</strong>n von allen Seiten<br />
mit <strong>de</strong>r jeweiligen Lösung besprüht.<br />
Der Prozess beginnt mit <strong>de</strong>r alkalischen<br />
Entfettung <strong>de</strong>r Profile. Hier kommt Ridoline<br />
2105 von Henkel zum Einsatz. Nach zwei Spülungen<br />
mit Wasser folgt die Behandlung mit<br />
<strong>de</strong>m ungiftigen Henkel Deoxidizer 1095. Es<br />
folgen zwei weitere Wasserspülungen, bevor<br />
<strong>Alu</strong>mec adopts to ecologically sound<br />
corrosion protection technology<br />
<strong>Alu</strong>minium finisher reports good results with Alodine 5992 from Henkel<br />
As you take your shower in the morning,<br />
there is a good chance that you will<br />
be standing insi<strong>de</strong> a cubicle framed by<br />
aluminium extrusions manufactured by<br />
the Italian company <strong>Alu</strong>mec Srl. Metal<br />
pretreatment products from Henkel help<br />
Die extrudierten <strong>Alu</strong>miniumprofile wer<strong>de</strong>n für die Vorbehandlung vorbereitet<br />
The extru<strong>de</strong>d aluminium profiles are prepared for treatment<br />
<strong>Alu</strong>mec achieve exceptional corrosion<br />
protection results combined with an outstanding<br />
surface finish using environmentally<br />
compatible methods.<br />
“Choosing the right pretreatment is central to<br />
the quality of a finished aluminium profile,”<br />
says Giuolio Marianelli, chief engineer at<br />
<strong>Alu</strong>mec. Quality is something that the company,<br />
located in Rudiano in the north of Italy,<br />
takes particularly seriously. In the last 35<br />
years, <strong>Alu</strong>mec has acquired a notable reputation<br />
well beyond Italy’s bor<strong>de</strong>rs as a quality<br />
supplier. Its customers inclu<strong>de</strong> well-known<br />
shower cubicle manufacturers, renowned window<br />
and door producers, makers of marquees,<br />
fly screens and venetian blinds with aluminium<br />
slats, and even architects keen on <strong>de</strong>signing<br />
their faca<strong>de</strong>s with aluminium elements.<br />
The majority of the company’s production<br />
goes abroad.<br />
<strong>Alu</strong>mec has its own extrusion facility in<br />
which billets of aluminium alloy are drawn<br />
into a range of profiles. These are then taken<br />
together with extrusions supplied by contract<br />
customers to the conversion and coating <strong>de</strong>partment,<br />
the second major production facility<br />
that <strong>Alu</strong>mec operates. The company can finish<br />
around 20 tonnes of profiles there each day,<br />
using a range of Henkel products in the process.<br />
These inclu<strong>de</strong> Alodine 5992, a conversion<br />
coating product with particularly sound<br />
environmental cre<strong>de</strong>ntials.<br />
The pretreatment process takes<br />
place in a <strong>special</strong>ly <strong>de</strong>signed, narrow<br />
tunnel through which the<br />
suspen<strong>de</strong>d workpieces are slowly<br />
drawn at a speed of between<br />
one and two metres per minute.<br />
The profiles are drenched in the<br />
relevant treatment liquid either<br />
from above in a casca<strong>de</strong> system or<br />
sprayed from all si<strong>de</strong>s.<br />
The process begins with the<br />
alkaline <strong>de</strong>greasing of the extrusions,<br />
for which the Henkel product<br />
Ridoline 2105 is used. After<br />
two water rinsing cycles, the treatment<br />
continues with non-toxic<br />
Henkel Deoxidizer 1095. There<br />
then follow two further water rinses before<br />
the workpieces pass through the conversion<br />
section where they are treated with Alodine<br />
5992.<br />
© Henkel<br />
Corrosion protection for pow<strong>de</strong>rcoated<br />
and non-coated aluminium<br />
Alodine 5992 is a recent innovation from the<br />
house of Henkel, technology lea<strong>de</strong>r in the<br />
field of surface treatment and a company with<br />
a reputation for setting industry-wi<strong>de</strong> standards<br />
with its extensive product portfolio. In<br />
contrast to toxic chromium(VI)-containing<br />
passivation media, the conversion coating<br />
created with this process consists of non-toxic<br />
chromium(III) compounds. In view of the<br />
many statutory regulations governing environmental<br />
protection and occupational health<br />
and safety, Alodine 5992 constitutes a viable<br />
alternative to traditional chromium(VI) conversion<br />
treatments. The trivalent layer offers<br />
bare metal corrosion resistance for uncoated<br />
aluminium surfaces as well as an optimum<br />
keyed surface for any subsequent coating operation.<br />
56 ALUMINIUM · 7-8/2013
TECHNOLOGY<br />
“We have been particularly impressed with<br />
the product in terms of its health and safety<br />
benefits, as it means we no longer have to <strong>de</strong>al<br />
with toxic chromium compounds in our facility,”<br />
affirms Mr Marianelli. The performance<br />
of Alodine 5992 also impresses the <strong>Alu</strong>mec<br />
expert. “We are very happy with the conversion<br />
process, as are our customers,” he says.<br />
Lineguard 2001 as the<br />
pretreatment process controller<br />
At <strong>Alu</strong>mec, the complete aluminium pretreatment<br />
process is monitored and regulated by<br />
the Lineguard 2001 system provi<strong>de</strong>d by Henkel.<br />
This fully automatic supervisor ensures<br />
that the product concentration in the tanks is<br />
constantly kept at the right level, saving labour<br />
time and ensuring more precision and reliability<br />
throughout the process. Employees can<br />
take thus care of other tasks, while the problem<br />
of human measurement or replenishment<br />
error is also avoi<strong>de</strong>d. And with the Lineguard<br />
2001, operatives are also spared over-frequent<br />
contact with the chemicals.<br />
The last process stage at <strong>Alu</strong>mec – following<br />
yet another rinse operation with <strong>de</strong>mineralised<br />
water and drying of the workpieces – is<br />
that of pow<strong>de</strong>r-coating the profiles. Alodine<br />
5992 is Qualicoat-certified and also meets<br />
the MIL Spec requirements for use on the<br />
products in the aircraft industry. As a Qualicoat-certified<br />
company, <strong>Alu</strong>mec is regularly<br />
audited, as required by the associated directive,<br />
to ensure that it continues to satisfy the<br />
specified standards.<br />
The use of Alodine 5992 in the conversion<br />
process prior to the pow<strong>de</strong>r-coating operation<br />
also greatly facilitates wastewater treatment<br />
and disposal at <strong>Alu</strong>mec because the<br />
previously required reduction of hexavalent<br />
chromium into the trivalent form is no longer<br />
nee<strong>de</strong>d. This is an important aspect for the<br />
company because, in Italy as in many other<br />
countries in the European Union, effluent is<br />
subjected to a strict monitoring regime with<br />
heavy penalties being imposed in the event<br />
of stipulated limit values being excee<strong>de</strong>d.<br />
<strong>Alu</strong>mec is appreciative not only of Henkel’s<br />
products but also of the service that the<br />
company provi<strong>de</strong>s. Customer service managers<br />
travel from Henkel to the plant once a<br />
month on average, with extra visits assured<br />
if problems should arise. However, the Latin<br />
proverb ‘previ<strong>de</strong>t ac provi<strong>de</strong>t’ (prevention is<br />
better than cure), which hangs in Marianelli’s<br />
office, is also something to which <strong>Alu</strong>mec’s<br />
technology partners from Henkel are fully<br />
committed.<br />
n<br />
Das Vorbehandlungsverfahren vollzieht sich in<br />
einem speziellen Tunnel, durch <strong>de</strong>n die hängen<strong>de</strong>n<br />
Werkstücke hindurchgezogen wer<strong>de</strong>n<br />
The treatment process takes place in a <strong>special</strong>ly<br />
<strong>de</strong>signed narrow tunnel through which the suspen<strong>de</strong>d<br />
workpieces are slowly drawn<br />
die Werkstücke die Konversion mit Alodine<br />
5992 durchlaufen.<br />
Korrosionsschutz für lackiertes<br />
und unlackiertes <strong>Alu</strong>minium<br />
Alodine 5992 ist eine Innovation aus <strong>de</strong>m<br />
Hause Henkel, das mit seinem breiten Produktportfolio<br />
industrieweit Maßstäbe setzt.<br />
Im Gegensatz zu toxischen Chrom(VI)-haltigen<br />
Passivierungen basiert die mit diesem<br />
Verfahren erzeugte Konversionsbeschichtung<br />
auf ungiftigen Chrom(III)-Verbindungen. Angesichts<br />
<strong>de</strong>r vielfältigen gesetzlichen Auflagen<br />
zum Umwelt- und Arbeitsschutz stellt<br />
Alodine 5992 eine Alternative zu traditionellen<br />
Chrom(VI)-Konversionsbehandlungen<br />
dar. Die dreiwertige Schicht bietet Blankmetallkorrosionsbeständigkeit<br />
für unlackierte<br />
<strong>Alu</strong>mec-Ingenieur Giuolio Marianelli bei <strong>de</strong>r Kontrolle <strong>de</strong>r Anlagenfunktion<br />
<strong>Alu</strong>mec’s chief engineer Giuolio Marianelli checks the facility’s functions<br />
<strong>Alu</strong>miniumoberflächen und einen optimalen<br />
Haftgrund für die Lackierung.<br />
„Uns hat das Produkt überzeugt, auch in<br />
Punkto Arbeitssicherheit, da wir keine giftigen<br />
Chromverbindungen mehr im Betrieb haben“,<br />
sagt Marianelli. Auch die Performance von<br />
Alodine 5992 überzeugt ihn. „Wir sind sehr<br />
zufrie<strong>de</strong>n mit <strong>de</strong>r Qualität <strong>de</strong>r Konversion und<br />
unsere Kun<strong>de</strong>n sind es auch,“ ergänzt er.<br />
Lineguard 2001 steuert Vorbehandlung<br />
Den kompletten Prozess <strong>de</strong>r <strong>Alu</strong>miniumvorbehandlung<br />
kontrolliert bei <strong>Alu</strong>mec das von<br />
Henkel installierte System Lineguard 2001.<br />
Die vollautomatische Steuerung sorgt für die<br />
korrekte Produktkonzentration in <strong>de</strong>n Tanks.<br />
Das spart Arbeitszeit und sorgt für mehr Präzision<br />
und Sicherheit im gesamten Verfahren.<br />
Mitarbeiter können sich um an<strong>de</strong>re Aufgaben<br />
kümmern, machen keine Mess- o<strong>de</strong>r Nachfüllfehler<br />
und vermei<strong>de</strong>n häufigen Kontakt mit<br />
<strong>de</strong>n Chemikalien, während Lineguard 2001<br />
<strong>de</strong>n Prozess steuert.<br />
Letzter Arbeitsschritt nach <strong>de</strong>m erneuten<br />
Abspülen mit <strong>de</strong>mineralisiertem Wasser und<br />
Trocknen <strong>de</strong>r Werkstücke ist die Pulverlackierung<br />
<strong>de</strong>r Profile. Alodine 5992 ist Qualicoat-zertifiziert<br />
und erfüllt zu<strong>de</strong>m die MIL-<br />
Spec-Anfor<strong>de</strong>rungen für <strong>de</strong>n Einsatz in <strong>de</strong>r<br />
Luftfahrtindustrie. <strong>Alu</strong>mec ist ein Qualicoatzertifiziertes<br />
Unternehmen und wird richtlinienkonform<br />
auf die Einhaltung <strong>de</strong>r gefor<strong>de</strong>rten<br />
Standards überprüft.<br />
Der Einsatz von Alodine 5992 im Konversionsverfahren<br />
vor <strong>de</strong>r Lackierung erleichtert<br />
auch die Abwasserbehandlung und Entsorgung<br />
bei <strong>Alu</strong>mec, da die Reduktion <strong>de</strong>s sechswertigen<br />
Chroms in die dreiwertige Form entfällt.<br />
Ein wichtiger Punkt für das Unternehmen, da<br />
in Italien wie in vielen an<strong>de</strong>ren EU-Län<strong>de</strong>rn<br />
eine ausgesprochen strenge Abwasserkontrolle<br />
erfolgt und hohe Strafen bei <strong>de</strong>r Überschreitung<br />
von Grenzwerten drohen.<br />
Nicht nur die Produkte,<br />
auch <strong>de</strong>r Service<br />
von Henkel hat <strong>Alu</strong>mec<br />
überzeugt. Etwa einmal<br />
im Monat kommen Kun<strong>de</strong>nbetreuer<br />
von Henkel<br />
in das Werk – auch dann,<br />
wenn es keine Probleme<br />
gibt. Dem lateinischen<br />
Wahlspruch „previ<strong>de</strong>t<br />
ac provi<strong>de</strong>t“ (besser vorbeugen<br />
als heilen), <strong>de</strong>r in<br />
Marianellis Büro hängt,<br />
fühlen sich auch <strong>Alu</strong>mecs<br />
Technologiepartner von<br />
Henkel verpflichtet. n<br />
ALUMINIUM · 7-8/2013 57
TECHNOLOGY<br />
Recycling of wrought aluminium alloys from post-consumed scrap<br />
Part one: Mo<strong>de</strong>lling of alternative wrought aluminium alloy compositions for required properties<br />
V. Kevorkijan, Maribor<br />
1. Introduction<br />
The sustainability of wrought aluminium alloys<br />
for <strong>de</strong>manding structural applications<br />
(e. g. in transportation) is still relatively low.<br />
The prevailing raw materials for their production<br />
are primary aluminium and pure alloying<br />
elements, in combination with internal and<br />
new scrap. For this reason, a significant part<br />
of world production of primary aluminium<br />
is actually consumed for the production of<br />
wrought aluminium alloys. The main technological<br />
reason for that is in the fact that<br />
wrought aluminium alloys are still very difficult<br />
to formulate by recycling post-consumed<br />
aluminium scrap, while the economic reason<br />
lies in the generally higher average cost of<br />
wrought in comparison with cast aluminium<br />
end-products.<br />
The share of wrought aluminium alloys in<br />
world production of aluminium alloys varies<br />
in different parts of world, <strong>de</strong>pending on the<br />
stage of <strong>de</strong>velopment and the structure of regional<br />
industry. The percentage is higher in<br />
the more <strong>de</strong>veloped regions of the world, with<br />
the dominant share from the transport industry.<br />
Similar ratios between wrought and cast<br />
alloys also exist in post-consumed aluminium<br />
scrap collected in different parts of world.<br />
Generally, due to the higher cost of wrought<br />
alloys, aluminium recyclers are always interested<br />
in transforming wrought post-consumed<br />
scrap into new wrought instead of cast alloys.<br />
In the case of internal and also new wrought<br />
aluminium scrap, this is already well practised,<br />
due to the well <strong>de</strong>fined composition of the incoming<br />
materials, which are suitable only for<br />
direct remelting (but not recycled in such a<br />
way so as to be transformed at the end into a<br />
new wrought alloy). However, the precondition<br />
for recycling – the process by which the<br />
virgin metal from post-consumed wrought<br />
aluminium scrap is cycled back into wrought<br />
alloys – is an appropriate level of sorting into<br />
individual compositional streams suitable for<br />
further blending. Here, the existing technical<br />
difficulties in achieving sufficient productivity<br />
and precision in automatic sorting, together<br />
with the high cost of this operation continue<br />
to reduce the amount of wrought post-consumed<br />
scrap recycled back into wrought alloys.<br />
Nowadays, a significant part of post-consumed<br />
wrought aluminium scrap is still consumed for<br />
the production of comparatively cheaper cast<br />
alloys, in that way losing<br />
an important part<br />
of the potentially available<br />
ad<strong>de</strong>d value.<br />
These trends will<br />
also continue in the<br />
future and, most probably,<br />
even be intensified.<br />
It is reasonable<br />
to expect that with further<br />
reduction in the production of primary<br />
aluminium, its share used for the production<br />
of cast alloys will also be reduced. On the<br />
other hand, due to the long-term projected<br />
higher cost of primary aluminium caused by<br />
the higher cost of energy, the producers of<br />
wrought aluminium alloys will try to replace,<br />
besi<strong>de</strong> existing substitution with internal and<br />
new industrial scrap, the maximum amount<br />
of primary aluminium with post-consumed<br />
wrought aluminium scrap.<br />
Without technological <strong>de</strong>velopments toward<br />
increasing the share of post-consumed<br />
scrap in wrought aluminium alloys, one can<br />
expect that in the future most of the technologically<br />
<strong>de</strong>manding wrought aluminium alloys<br />
would be produced from primary aluminium<br />
in combination with remelting of internal as<br />
well as new industrial scrap. In contrast to this,<br />
most cast alloys will be produced from costbeneficial<br />
post-consumed scrap. This trend,<br />
which is already practised in the aluminium<br />
industry to some extent, could significantly reduce<br />
the sustainability of wrought aluminium<br />
alloys. It restricts the recycling of aluminium<br />
in the true sense of that process (‘re-usage of<br />
post-consumed aluminium in an end product<br />
for the same purpose’), mostly to cast alloys,<br />
while in wrought alloys mostly to remelting of<br />
internal and new industrial scrap.<br />
The main difficulty in recycling wrought<br />
aluminium alloys from post-consumed scrap<br />
is caused by the existing composition of those<br />
alloys, prescribed by international standards<br />
[1]. Currently, on the market there are more<br />
than 200 different compositions of wrought<br />
aluminium alloys divi<strong>de</strong>d into eight classes<br />
based on the applied alloying elements. From<br />
the narrow compositional tolerance limits of<br />
alloying elements in practically all wrought<br />
aluminium alloys [1], it is evi<strong>de</strong>nt that such<br />
chemical compositions could be producible<br />
only by using raw materials of well <strong>de</strong>fined<br />
chemical composition (i. e. alloying elements<br />
Fig. 1: Examples of standard and non-standard tolerance limits with the<br />
relevant <strong>de</strong>notations used in the mo<strong>de</strong>l<br />
and primary aluminium of the appropriate<br />
chemical purity, as well as aluminium scrap<br />
streams with carefully prescribed chemical<br />
composition). On the other hand, the presence<br />
of sufficiently narrow compositional tolerance<br />
limits in wrought aluminium alloys is necessary<br />
to provi<strong>de</strong> the proper (standard) combination<br />
of various alloy properties (mechanical,<br />
electrical, chemical, etc.), exactly prescribed<br />
by end users.<br />
Post-consumed aluminium scrap exists in<br />
waste with changeable, non-exact chemical<br />
composition and <strong>de</strong>finitely not as a raw material<br />
fabricated with respect with customer’s<br />
<strong>de</strong>mands. Hence, it is clear that the share of<br />
post-consumed scrap in wrought aluminium<br />
alloys could be increased either by sorting<br />
to fractions with the required chemical composition<br />
and/or by broa<strong>de</strong>ning the standard<br />
compositional tolerance limits of alloying<br />
elements. The first solution requires hand<br />
or automatic sorting of post-consumed scrap<br />
as alloys or groups of alloys to the <strong>de</strong>gree of<br />
separation sufficient to enable the blending of<br />
standard compositions of wrought alloys [2,<br />
3]; the second solution is much more radical,<br />
predicting changes in the existing standards<br />
for wrought aluminium alloys toward nonstandard<br />
alloys but yet having properties acceptable<br />
for customers [4]. In this case, the <strong>de</strong>gree<br />
of separation of incoming post-consumed<br />
scrap required is much less <strong>de</strong>manding.<br />
Nevertheless, to be of interest for customers,<br />
broa<strong>de</strong>ning the compositional tolerance<br />
limits of wrought aluminium alloys should<br />
result in alloy properties which are still of<br />
value for end users. In or<strong>de</strong>r to tailor the required<br />
(combination and individual values of)<br />
properties in wrought aluminium alloys with<br />
alternative composition, it is necessary to <strong>de</strong>velop<br />
the ability to predict the properties from<br />
a given chemical composition and vice versa –<br />
starting from alloy properties, to predict the<br />
necessary chemical composition of post-con-<br />
58 ALUMINIUM · 7-8/2013
TECHNOLOGY<br />
Alloying elements 1 2 3 …… n<br />
Concentration insi<strong>de</strong> the<br />
tolerance limits, X (%)<br />
Concentration outsi<strong>de</strong> the<br />
tolerance limits, X (%)<br />
sumed scrap streams or, in other words, the<br />
necessary level of scrap sorting. Such prediction<br />
algorithms for wrought aluminium alloys<br />
have been reported by several authors-for a<br />
review see Ref. [5], but are not focused on the<br />
recycling of wrought aluminium alloys from<br />
post-consumed scrap.<br />
Thus, the purpose of this paper is to present<br />
possibilities for numerical mo<strong>de</strong>lling 1 of both<br />
technological options for increasing the amount<br />
of post-consumed aluminium scrap in wrought<br />
aluminium alloys. Based on the mo<strong>de</strong>l <strong>de</strong>veloped,<br />
the optimal solution was suggested as<br />
the starting point for further <strong>de</strong>velopment and<br />
implementation of the appropriate technology<br />
of wrought aluminium alloy recycling.<br />
2. Mo<strong>de</strong>lling of wrought aluminium<br />
alloy properties as a function of<br />
their chemical composition<br />
X 1 ±∆X 1 X 2 ±∆X 2 X 3 ±∆X 3 …… X n ±∆X n<br />
X 1 ±∆X 1 X 2 ±∆X 2 X 3 ±∆X 3 …… X n ±∆X n<br />
Table 1: Wrought aluminium alloy compositions consi<strong>de</strong>red in the mo<strong>de</strong>l<br />
Generally, the selected properties of a wrought<br />
aluminium alloy (e. g. yield strength – YS, ultimate<br />
strength – US, elongation – L and hardness<br />
– H) can be all expressed as different<br />
functions of the alloy composition:<br />
YS = F (X 1 , X 2 , X 3 , … , X n ) (1)<br />
US = G(X 1 , X 2 , X 3 , … , X n ) (2)<br />
L = L(X 1 , X 2 , X 3 , … , X n ) (3)<br />
H = H(X 1 , X 2 , X 3 , … , X n ) (4)<br />
Here, X 1 , X 2 , X 3 , … , X n represent the concentrations<br />
of particular alloying elements.<br />
On the other hand, the concentrations of<br />
alloying elements in wrought aluminium alloys,<br />
e<strong>special</strong>ly in recycled ones, are most often<br />
<strong>de</strong>signed for achieving maximal strength.<br />
To achieve the proper combination of properties<br />
(not only mechanical but also electrical,<br />
thermal, corrosion resistant, etc.), the concentrations<br />
of alloying elements should be insi<strong>de</strong><br />
the standard tolerance limits.<br />
However, in wrought compositions containing<br />
an increased amount of scrap, usually<br />
it is not easy and certainly not cost-effective<br />
to assure such narrow compositions. Therefore,<br />
producers of recycled wrought alloys<br />
try to <strong>de</strong>velop so-called ‘recycling friendly’<br />
compositions with broa<strong>de</strong>r tolerance limits,<br />
which at the same time do<br />
not significantly influence<br />
the selected (usually some<br />
of the mechanical) properties<br />
of the alloys.<br />
The achievement of<br />
standard wrought alloy<br />
composition by mixing various fractions of<br />
scrap with different chemical composition is<br />
practically impossible. Statistically, in the real<br />
mixture obtained by combining such different<br />
fractions of scrap from the scrap yard, the<br />
concentration of some of the alloying elements<br />
will be higher than those prescribed by<br />
the standard, the concentration of others will<br />
be lower and there will also be some alloying<br />
elements whose concentrations will fit the<br />
standard requirements.<br />
The situation is illustrated in Fig. 1 where<br />
the concentration X 1 of the alloying element<br />
1 in the scrap mixture prepared for melting is<br />
insi<strong>de</strong> the standard interval of concentrations,<br />
the concentration X 2 of the alloying element<br />
2 is higher and the concentration X 3 of the alloying<br />
element 3 is lower. However, all three<br />
concentrations are insi<strong>de</strong> the alternative interval<br />
of concentrations formulated for a ‘recycling<br />
friendly’ composition.<br />
The mathematical condition for ‘recycling<br />
friendly’ alloy compositions un<strong>de</strong>r which the<br />
selected alloy properties will all remain the<br />
same is expressed by Eqs.(5) - (8):<br />
dYS = 0 (5)<br />
dUS = 0 (6)<br />
dL = 0 (7)<br />
dH = 0 (8)<br />
In this way, the mo<strong>de</strong>l <strong>de</strong>veloped gives the<br />
combination of non-standard and standard<br />
tolerance limits (∆X i ) un<strong>de</strong>r which the selected<br />
alloy’s properties YS, US, A and H remain the<br />
same. The <strong>de</strong>termination of such a combination<br />
of non-standard and standard tolerance<br />
limits (i.e. intervals of concentrations for each<br />
of alloying elements appearing in the alloy)<br />
proceeds in two steps. In the first step, the<br />
intervals ∆X i for alloying elements are <strong>de</strong>termined<br />
by consi<strong>de</strong>ring each of the properties<br />
individually. After that, in the second step,<br />
the limits obtained for alloying element were<br />
reduced to the intersection of particular intervals,<br />
un<strong>de</strong>r which all the selected properties<br />
(YS, US, A and H) are to remain constant simultaneously.<br />
Mathematically speaking, in the first step<br />
we solve the individual equations (5)-(8). Note<br />
that the solution of each of these equations is<br />
the enlistment of the intervals of concentration<br />
(∆X i ). In the second step, the solution of the<br />
system of Eqs. (5)-(8) un<strong>de</strong>r which the selected<br />
properties remain constant is obtained as<br />
the intersection of these various intervals obtained<br />
for each particular alloying element.<br />
3. Practical application of the mo<strong>de</strong>l<br />
Let us consi<strong>de</strong>r a wrought alloy with standard<br />
composition and concentrations of alloying<br />
elements insi<strong>de</strong> the tolerance limits, and the<br />
alternative (‘recycling friendly’) alloy with<br />
concentrations of alloying elements slightly<br />
outsi<strong>de</strong> the standard tolerance limits (Table 1).<br />
Experimentally available data are collected<br />
in Table 2 where the yield strength (YS) was<br />
measured and correlated with the actual alloy<br />
composition <strong>de</strong>termined by emission spectroscopy.<br />
Let us further assume that the selected alloy<br />
properties (e. g. yield strength – YS, ultimate<br />
strength – US, elongation – L and hardness<br />
– H) are polynomial functions of the alloy<br />
composition.<br />
Note that in each of the equations in the<br />
system of Eqs. (5) - (8), the tolerance limits, ∆X i<br />
(i = 1, 2, 3, … , n) of the individual alloying<br />
elements appear as n in<strong>de</strong>pen<strong>de</strong>nt variables.<br />
Hence, the exact solution of these equations is<br />
not possible. The particular solution of whichever<br />
equations of the system of Eqs. (5) - (8) is,<br />
theoretically speaking, the randomly selected<br />
combination of tolerance limits ∆X i (i = 1, 2,<br />
3, … , n) for which the right hand si<strong>de</strong> of the<br />
equation is equal to zero. However, in the<br />
practical case the values of the tolerance limits<br />
of recycling-friendly wrought aluminium alloy<br />
cannot be selected randomly but should be as<br />
close as possible to the standard ones. Note<br />
that these minimal <strong>de</strong>viations of each alloying<br />
element from the standard concentrations<br />
Mo<strong>de</strong>lling of the <strong>de</strong>gree of post-consumed scrap sorting for recycling-friendly wrought<br />
compositions<br />
Sample<br />
Yield strength<br />
(MPa)<br />
Ultimate<br />
strength(MPa)<br />
Elongation(%)<br />
Harness<br />
Alloying elements (1,2,…n)<br />
and their concentrations (%)<br />
1 2 ….. n<br />
1<br />
Following the editorial request to avoid exten<strong>de</strong>d formulas<br />
and <strong>de</strong>manding mathematical explanations, the<br />
mo<strong>de</strong>l <strong>de</strong>veloped is presented in this article only in a<br />
<strong>de</strong>scriptive way. However, the <strong>de</strong>tailed mathematical approach<br />
can be sent by the author on request.<br />
1 YS 1 US 1 L 1 H 1 X 1,1 X 2,1 X n,1<br />
2 YS 2 US 2 L 2 H 2 X 1,2 X 2,2 X n,2<br />
m YS m US m L m H m X 1,m X 2,m X n,m<br />
Table 2: Experimentally measured data for yield strength (YS), ultimate strength (US), elongation (L) and<br />
hardness (H) as a function of the concentrations of alloying elements<br />
ALUMINIUM · 7-8/2013 59
TECHNOLOGY<br />
Fig. 2: Organisation of scrap yard for recycling<br />
of wrought aluminium alloys from<br />
post-consumed scrap in accordance with<br />
the mo<strong>de</strong>l<br />
Fig. 3: Providing the pre-melt ‘recycling-friendly’<br />
composition of<br />
wrought aluminium alloy by combining<br />
different scrap streams of postconsumed<br />
scrap<br />
are <strong>de</strong>termined by the chemical composition<br />
of the individual scrap streams available in<br />
the scrap yard and involved in creating the incoming<br />
scrap mixture pre-melt composition.<br />
In practice, the system of equations (24) is<br />
applied to numerical mo<strong>de</strong>lling of the recycling-friendly<br />
composition, or, in other words,<br />
for selecting the (proper combination of) tolerance<br />
limits, ∆X i (i = 1, 2, 3, … , n), of alloying<br />
elements un<strong>de</strong>r which: (i) the selected<br />
mechanical properties of the alloy remain the<br />
same as in the standard one,<br />
and (ii) the chemical composition<br />
of the recycling-friendly<br />
alloy is the same as the premelt<br />
chemical composition of<br />
the incoming scrap mixture<br />
(formulated with the minimal<br />
addition of primary aluminium<br />
and alloying elements).<br />
The main priorities in formulation<br />
of the recyclingfriendly<br />
compositions are:<br />
1. The minimal addition of<br />
primary aluminium and alloying<br />
elements<br />
2. The maximal consumption<br />
of regular scrap streams,<br />
daily available in the scrap yard<br />
3. The non-standard alloy composition for<br />
which the selected mechanical properties remain<br />
the same as in the standard one.<br />
The practical way to do this is by mo<strong>de</strong>lling,<br />
starting from the chemical composition of<br />
the scrap streams. The precondition is that the<br />
chemical composition of the recycling-friendly<br />
Fig. 4: Processing steps in mo<strong>de</strong>lling the ‘recycling-friendly’ composition for the <strong>de</strong>sired alloy properties<br />
alloy should be the same as the pre-melt composition<br />
of the incoming mixture consisting<br />
of the combination of various scrap streams<br />
with no or minimal addition of primary aluminium<br />
and alloying elements. In addition, the<br />
<strong>de</strong>viations of the recycling-friendly from the<br />
standard concentrations of alloying elements<br />
should be as small as possible.<br />
In the first step it is necessary to consi<strong>de</strong>r<br />
the impact of alloying elements with maximal<br />
<strong>de</strong>viation of their concentrations from the<br />
standard prescribed. The negative impact of<br />
these elements on alloy properties should be<br />
reduced by minimising the concentration of<br />
others which finally results in the same alloy<br />
properties.<br />
The recycling-friendly compositions of<br />
wrought aluminium alloys should be mo<strong>de</strong>lled<br />
in accordance with the following two<br />
criteria: (i) the selected chemical composition<br />
and compositional tolerance limits of a recycling-friendly<br />
wrought aluminium alloy should<br />
fulfil market expectations regarding the alloy<br />
properties; and (ii) the prescribed recyclingfriendly<br />
alloy composition should be routinely<br />
achievable by mixing scrap streams fabricated<br />
in the scrap yard by scrap separation (with or<br />
without minimal addition of primary aluminium<br />
and alloying elements).<br />
In or<strong>de</strong>r to achieve these two goals, it is<br />
necessary to <strong>de</strong>fine the industrial levels of<br />
wrought aluminium scrap sorting. An example<br />
of the practical levels of sorting of post-consumed<br />
wrought aluminium scrap is presented<br />
in Table 3. Planning the optimal number of<br />
scrap streams, as illustrated in Fig. 2, their<br />
chemical composition and the compositional<br />
tolerance limits of alloying elements for effective<br />
blending of the pre-melting mixture, Fig.<br />
3, with minimal (or even without) addition of<br />
pure alloying elements and primary aluminium<br />
is essential for successful running of the<br />
recycling plant and the final business result.<br />
Therefore, a<strong>de</strong>quate organisation of the<br />
scrap separation streams should provi<strong>de</strong> answers<br />
to the following key questions of scrap<br />
processing:<br />
• How many scrap streams should be<br />
produced by sorting wrought aluminium<br />
wastes in the scrap yard<br />
• How many alloys (just a single one,<br />
a mixture of two or more) should be<br />
involved in these streams<br />
• What should the chemical compositions<br />
be (qualitatively, regarding alloying<br />
elements and also quantitatively,<br />
consi<strong>de</strong>ring their concentrations as<br />
well as the compositional tolerance<br />
limits) of those streams, and finally<br />
• For which wrought aluminium alloys<br />
60 ALUMINIUM · 7-8/2013
TECHNOLOGY<br />
Level of<br />
scrap sorting<br />
Description<br />
1. Separation of incoming scrap into cast and wrought aluminium scrap<br />
2. Scrap of wrought aluminium alloys within the same series<br />
3.<br />
Scrap of wrought aluminium alloys within the same series having the<br />
same combination of alloying elements<br />
4.<br />
Scrap of wrought aluminium alloys within the same series consisting of<br />
more than 2 compositionally similar/comparable alloys<br />
5.<br />
Scrap of wrought aluminium alloys consisting of 2 alloys within the<br />
same series compositionally similar/comparable<br />
6. Scrap streams of single wrought aluminium alloys<br />
Table 3: Possible industrial levels practiced in wrought aluminium scrap sorting<br />
and un<strong>de</strong>r which production scenarios should<br />
the sorted streams used?<br />
A possible way of providing the answers<br />
to the above questions is by calculating the<br />
appropriate composition of the pre-melt mixture<br />
blen<strong>de</strong>d from various scrap streams of<br />
different chemical composition, as presented<br />
in Fig. 4.<br />
The mo<strong>de</strong>l enables: (i) computation of the<br />
recycling-friendly compositions of (wrought)<br />
aluminium alloys based on the known chemical<br />
compositions and compositional tolerance<br />
limits of scrap streams formulated by scrap<br />
sorting in the scrap yard, or (ii) vice versa,<br />
computation of the chemical composition and<br />
compositional tolerance limits of scrap streams<br />
starting from the known composition and tolerance<br />
limits for alloying elements in the selected<br />
aluminium alloy.<br />
The same sorting levels should be applied<br />
to clean and aluminium scrap contaminated<br />
with organics or<br />
other impurities.<br />
Conclusions<br />
The mo<strong>de</strong>l presented<br />
in this<br />
work enables the<br />
<strong>de</strong>sign of optimal<br />
(standard<br />
and non-standard<br />
‘recyclingfriendly’)<br />
compositions and properties of<br />
wrought aluminium alloys with significantly<br />
increased amounts of post-consumed scrap.<br />
The following two routes were mo<strong>de</strong>lled in<br />
<strong>de</strong>tail: (i) the blending of standard and nonstandard<br />
compositions of wrought aluminium<br />
alloys starting from post-consumed aluminium<br />
scrap sorted to various <strong>de</strong>grees simulated<br />
by the mo<strong>de</strong>l; and (ii) changing the initial<br />
standard composition of wrought aluminium<br />
alloys to non-standard ‘recycling friendly’<br />
ones – with broa<strong>de</strong>r concentration tolerance<br />
limits of alloying elements, without influencing<br />
the selected alloy properties, specified in<br />
advance.<br />
The applied algorithms were found to be<br />
very useful in the industrial <strong>de</strong>sign of both<br />
procedures: (i) computation of the required<br />
chemical composition of the scrap streams<br />
obtained by sorting (or, in other words, the<br />
post-consumed scrap sorting level), necessary<br />
for achieving the standard wrought alloy composition;<br />
and (ii) transformation of standard<br />
to non-standard (recycling-friendly) compositions<br />
with the key alloy properties (e. g. tensile<br />
strength, elongation) remaining the same.<br />
The most beneficial and particularly promising<br />
approach might be the integral (or combined)<br />
approach, assuring both possibilities:<br />
(i) the standard chemical composition of the<br />
alloy achieved by a sufficient level of post-consumed<br />
scrap sorting predicted by the mo<strong>de</strong>l,<br />
and (ii) mo<strong>de</strong>lling the non-standard alloy<br />
composition by less <strong>de</strong>manding (and more<br />
cost-effective) sorting, but yet providing end<br />
users with the <strong>de</strong>sired alloy properties.<br />
References<br />
[1] ASM Specialty Handbook, <strong>Alu</strong>minium and <strong>Alu</strong>minium<br />
Alloys, ed. J. R. Davis, ASM, Materials Park,<br />
USA, 1998, 20.<br />
[2] G. Gaustad, E. Olivetti, R. Kirchian, Resources,<br />
Conservation and Recycling 58 (2012) 79<br />
[3] A. Gesing, L. Berry, R. Dalton, R. Wolanski, TMS<br />
2002, 3<br />
[4] S. K. Das, Light Metals 2006, TMS 2006, 911<br />
[5] J. T. Staley, R. E. San<strong>de</strong>rs, Jr., Handbook of <strong>Alu</strong>minium,<br />
Vol. 2, ed. G. E. Totten, D. S. MacKenzie,<br />
CRC, New York, USA 2003, 319<br />
Author<br />
Varuzan Kevorkijan, In<strong>de</strong>pen<strong>de</strong>nt Researcher, Betnavska<br />
cesta 6, 2000 Maribor, Slovenia. Contact:<br />
varuzan.kevorkijan@impol.si<br />
Quick payback – ecological benefits – small investment<br />
Dryplus process drastically reduces sludge volumes from anodising lines<br />
The patented Dryplus process <strong>de</strong>veloped by<br />
Mo<strong>de</strong>na-based Italtecno aims to significantly<br />
increase the dry matter in the sludge from aluminium<br />
anodising treatment lines. It enables<br />
dry fractions to be obtained that are equivalent<br />
to 40-50% of the total aluminium hydroxi<strong>de</strong><br />
sludge instead of the usual 20-25% achieved<br />
in traditional processes.<br />
The environmental benefit of using Dryplus<br />
technology is clearly evi<strong>de</strong>nt: the sludge<br />
volume is halved and consi<strong>de</strong>rably less truck<br />
journeys are nee<strong>de</strong>d to transport the sludge.<br />
This results in significant cost advantages<br />
compared with traditional methods (see table).<br />
The Dryplus process consists of a polypropylene<br />
reactor with a volume of 10-15 m 3<br />
that is suitable for use with alkaline solutions,<br />
such as those from the concentrated rinse tank.<br />
The alkalinity is neutralised in the reactor using<br />
concentrates from the Freeal unit as well<br />
as water from the acid rinse.<br />
<strong>Alu</strong>minium hydroxi<strong>de</strong> is precipitated out<br />
with the help of a <strong>special</strong> flocculant from Italtecno,<br />
leading to neutralisation of the concentrated<br />
solutions un<strong>de</strong>r wellcontrolled<br />
dynamic physical<br />
conditions.<br />
As a result of this treatment,<br />
the aluminium hydroxi<strong>de</strong><br />
precipitate has a higher sludge disposal<br />
Estimated cost of<br />
<strong>de</strong>nsity than in the standard<br />
Annual cost of<br />
process: the dry fraction (40- sludge disposal<br />
50%) is twice what can be<br />
achieved with the conventional<br />
processes used today.<br />
Dryplus has been successfully<br />
applied un<strong>de</strong>r actual industrial conditions.<br />
Dryplus can be connected to any existing<br />
waste water treatment plant, which will not<br />
be adversely affected; instead it will be subjected<br />
to less <strong>de</strong>manding conditions on a dayto-day<br />
basis because the Dryplus technology<br />
will handle the water with the highest impurity<br />
content.<br />
Parameter* Standard process Dryplus process<br />
Dry fraction in sludge 20% 45%<br />
Sludge production 1,300 tpy 578 tpy<br />
80 €/t 80 €/t<br />
104 46,222<br />
Annual saving - 57,778<br />
Based on treatment of water from an anodising line with 30,000 A<br />
installed capacity<br />
The savings in operating costs attributable to<br />
Dryplus are significant and are summarised in<br />
the table.<br />
■<br />
ALUMINIUM · 7-8/2013 61
TECHNOLOGIE<br />
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Die Anlage zeichnet sich unter an<strong>de</strong>rem<br />
durch eine gleichbleiben<strong>de</strong> Qualität bei<br />
hoher Schnittleistung, einfache Bedienung<br />
und geringe Stillstandzeiten aus.<br />
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gegenüber vergleichbaren Maschinen.<br />
Die Schnittgeschwindigkeit <strong>de</strong>r Anlage ist<br />
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Durch <strong>de</strong>n Einsatz mo<strong>de</strong>rnster Konstruktionstechnologie<br />
und Fertigungsverfahren wer<strong>de</strong>n<br />
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in Plattendicken zwischen 5 bis 600 mm her,<br />
die aus <strong>Alu</strong>-Gussblöcken mit <strong>de</strong>r Abmessung<br />
2.000 x 4.000 x 800 mm gesägt wer<strong>de</strong>n. Das<br />
Unternehmen beschäftigt 190 Mitarbeiter und<br />
beliefert weltweit Kun<strong>de</strong>n aus <strong>de</strong>n Branchen<br />
Maschinenbau, Luft- und Raumfahrt, Werkzeug-<br />
und Formenbau, Automotive und Bauwesen.<br />
Um die Produktion zu optimieren,<br />
suchte das Unternehmen für Präzisionsplatten<br />
nach einer Lösung, die die Sägekapazität<br />
bei durchgehend gleichbleiben<strong>de</strong>r Qualität<br />
erhöht.<br />
Das Projekt wur<strong>de</strong> in enger Kooperation<br />
zwischen Auftraggeber und Auftragnehmer<br />
realisiert. Die Kun<strong>de</strong>nwünsche flossen in die<br />
Konstruktion <strong>de</strong>r neu entwickelten Maxcut A6<br />
x 16 <strong>Alu</strong> ein. „Das Konzept von Kasto hat uns<br />
überzeugt“, so Andreas Sieg, Produktionsleiter<br />
bei Gleich <strong>Alu</strong>miniumwerke. Die Maxcut<br />
ersetzt bei <strong>de</strong>m Kaltenkirchener Unternehmen<br />
zwei bisher verwen<strong>de</strong>te Sägemaschinen.<br />
Eine <strong>de</strong>r stärksten Maschinen am Markt<br />
Die Hochleistungs-Bandsägemaschine mit 12<br />
Metern Länge und 6,8 Metern Breite überzeugt<br />
durch eine hohe Verfügbarkeit und<br />
einfache Bedienung. Bei einem Wechsel <strong>de</strong>r<br />
<strong>Alu</strong>miniumblöcke wird zu<strong>de</strong>m wenig Zeit vergeu<strong>de</strong>t:<br />
Die Stillstandzeiten liegen unter drei<br />
Minuten. Darüber ist <strong>de</strong>r vollautomatische Betrieb<br />
<strong>de</strong>r Maschine über mehrere Tage hinweg<br />
gewährleistet. Die Maxcut ist eine <strong>de</strong>r stärksten<br />
Maschinen am Markt und aufgrund ihrer<br />
extrem schweren Bauart für <strong>de</strong>n mittleren bis<br />
sehr harten Produktionseinsatz ausgelegt, so<br />
Kasto, und für <strong>de</strong>n Einsatz von Bi-Metall- und<br />
Hartmetallbän<strong>de</strong>rn geeignet.<br />
Die Bandstandzeiten konnten durch <strong>de</strong>n<br />
Einsatz <strong>de</strong>r Maschine <strong>de</strong>utlich verbessert<br />
wer<strong>de</strong>n. Sie wur<strong>de</strong>n im Vergleich zu <strong>de</strong>n früher<br />
genutzten Anlagen auf 3.000 Quadratmeter<br />
verdoppelt. Zu <strong>de</strong>n weiteren Stärken <strong>de</strong>r<br />
Bandsägemaschine gehören die Vernetzung<br />
zum kun<strong>de</strong>nseitigen ERP-System und die<br />
Mittels Vakuumsystem wer<strong>de</strong>n die Platten nach <strong>de</strong>m Sägen zur weiteren Verwendung abgelegt<br />
laut Kasto eine beson<strong>de</strong>rs hohe Laufruhe und<br />
ein vibrationsfreies Arbeiten erreicht. Dies<br />
be<strong>de</strong>utet kürzere Schnitt- und höhere Werkzeugstandzeiten.<br />
Die Führung <strong>de</strong>r Sägeeinheit<br />
erfolgt über zwei senkrecht außerhalb <strong>de</strong>s<br />
Arbeitsraumes stehen<strong>de</strong>, groß dimensionierte<br />
Führungssäulen. An je<strong>de</strong>r Führungssäule sind<br />
jeweils zwei Linearführungseinheiten mit je<br />
sechs spielfrei eingestellten Führungswagen<br />
angeordnet. Dieses System gewährleistet hohe<br />
Steifigkeit, maximale Dämpfung und Schnittpräzision,<br />
stellt Kasto heraus.<br />
Wartungsaufwand minimiert<br />
Die Maschine ist mit einer Schrägstellung <strong>de</strong>s<br />
Sägewerkzeugs durch asymmetrische Anordnung<br />
<strong>de</strong>r bei<strong>de</strong>n Sägeköpfe ausgestattet. Dies<br />
bewirkt eine verkürzte Werkzeugeingriffslänge<br />
während <strong>de</strong>r Eintauchphase und schont<br />
dadurch das Sägeband. Die Verfahrgeschwindigkeit<br />
lässt sich auf Kun<strong>de</strong>nwunsch stufenlos<br />
von 0,5 bis 500 mm/min regeln. Die Hydraulikanlage<br />
ist von außen leicht zugänglich. Dadurch<br />
wer<strong>de</strong>n Wartungszeiten wie Ölkontrolle<br />
und Filterwechsel erheblich reduziert.<br />
Die Anlage ist mit <strong>de</strong>r Sägemaschinensteuerung<br />
TechnoControl ausgestattet. Sie<br />
Plattendicken-/Stückzahlkombinationen<br />
ausgelegt. Die Sägeblattkühlung erfolgt über<br />
ein Minimalmengen-Schmiersystem mit Füllstandüberwachung.<br />
Die <strong>Alu</strong>-Gussblöcke mit einem Gewicht<br />
von rund 15 Tonnen wer<strong>de</strong>n <strong>de</strong>r Maxcut automatisch<br />
über Rollenbahn und Querför<strong>de</strong>rer<br />
zugeführt. Nach <strong>de</strong>m Sägevorgang wird je<strong>de</strong><br />
einzelne Platte mit einem Vakuummanipulator<br />
von <strong>de</strong>r Säge entnommen und auf eine Rollenbahn<br />
zum Weitertransport in das Lager o<strong>de</strong>r<br />
die Fertigung gelegt. Die Vakuumtransportanlage<br />
ist mit mehreren Saugern ausgestattet,<br />
die bis zu 3,5 Tonnen bewegen können.<br />
Platten mit einem höheren Gewicht wer<strong>de</strong>n<br />
manuell mit einem Hallenkran beför<strong>de</strong>rt.<br />
Eine Son<strong>de</strong>rrollenbahn ermöglicht die<br />
beidseitige Werkstückentnahme – ein Kun<strong>de</strong>nwunsch,<br />
<strong>de</strong>n Kasto nachträglich erfüllte.<br />
Alle Rollen <strong>de</strong>r Bahn mit einer Länge von 4,5<br />
Metern sind angetrieben. Bei <strong>de</strong>r Umsetzung<br />
<strong>de</strong>s Zusatzwunsches wur<strong>de</strong> großes Augenmerk<br />
auf die Sicherheit gelegt. Voraussetzung<br />
für prozesssicheres Arbeiten ist, dass vorher<br />
das Werkstück korrekt angelegt ist. Vor <strong>de</strong>r<br />
Übergabe wird diese Position überwacht. Ist<br />
die Position nicht korrekt, wird <strong>de</strong>r automatische<br />
Ablauf gestoppt.<br />
n<br />
© Kasto<br />
62 ALUMINIUM · 7-8/2013
TECHNOLOGY<br />
Novelis überwacht Maschinenschwingungen mit Condition Monitoring von iba<br />
Kritische Schwingungen online aufgespürt<br />
U. Lettau, iba AG; D. Skingley Wright, Novelis Inc.<br />
In Walzanlagen können zahlreiche<br />
Schwingungen mit unterschiedlichen<br />
Resultaten auftreten. Diese können sich<br />
negativ auf die Lebensdauer und <strong>de</strong>n Zustand<br />
<strong>de</strong>r Anlage, aber auch auf die Produktqualität<br />
auswirken. In je<strong>de</strong>m Fall ist<br />
es erfor<strong>de</strong>rlich, das Schwingungsverhalten<br />
<strong>de</strong>r eigenen Anlage genau zu kennen,<br />
um Verschleiß und Defekte entsprechend<br />
überwachen zu können. Der <strong>Alu</strong>miniumproduzent<br />
Novelis weiß um die nachteiligen<br />
Auswirkungen von Schwingungen<br />
und nutzt zur Analyse und Intervention<br />
das neuartige Condition-Monitoring-<br />
System <strong>de</strong>r iba AG. Dieses online basierte<br />
System kann Prozessdaten aus <strong>de</strong>r Anlage<br />
zusammen mit <strong>de</strong>n Schwingungsdaten<br />
auswerten.<br />
Novelis monitors machine vibrations with iba Condition Monitoring<br />
Tracking critical vibrations online<br />
U. Lettau, iba AG; D. Skingley Wright, Novelis Inc.<br />
Schwingungen in Walzwerken können sich<br />
negativ auf die Produktivität, die Produktqualität<br />
und die Lebensdauer einzelner Anlagenkomponenten<br />
auswirken. Die Anlage kann<br />
so beeinträchtigt wer<strong>de</strong>n, dass Schädigungen<br />
wie Getriebe<strong>de</strong>fekte o<strong>de</strong>r Spin<strong>de</strong>lbruch auftreten.<br />
Insbeson<strong>de</strong>re beim Kaltwalzen nehmen<br />
Schwingungen einen entschei<strong>de</strong>n<strong>de</strong>n<br />
Einfluss auf die Produktqualität in Form von<br />
Chatter-Marks (Rattermarken) – das sind<br />
quer zur Walzrichtung meist periodisch verlaufen<strong>de</strong><br />
Wellen auf <strong>de</strong>r Bandoberfläche im<br />
µm-Bereich. Die Folgen sind ein<strong>de</strong>utig: Das<br />
Endprodukt ist von min<strong>de</strong>rer Qualität o<strong>de</strong>r<br />
Ausschuss, die Walzgeschwindigkeiten müssen<br />
in einen schwingungsfreien Bereich reduziert<br />
wer<strong>de</strong>n und Stillstandszeiten nehmen<br />
zu. Problematisch sind diese Effekte vor <strong>de</strong>m<br />
Hintergrund steigen<strong>de</strong>r Qualitätsansprüche<br />
und <strong>de</strong>r Ten<strong>de</strong>nz zu immer höherer Produktivität<br />
in Walzwerken.<br />
Die Anfor<strong>de</strong>rungen an die Anlagen bezüglich<br />
Zuverlässigkeit, Lebensdauer und<br />
Prozessstabilität sind enorm gestiegen. Die<br />
Betriebssicherheit <strong>de</strong>r Anlagen lässt sich am<br />
besten mit einer Prozess- und Zustandsüberwachung<br />
herstellen. Der international tätige<br />
Konzern Novelis mit Hauptsitz in Atlanta,<br />
USA, produziert an 31 Standorten auf vier<br />
Kontinenten nahezu 20 Prozent <strong>de</strong>r gewalzten<br />
<strong>Alu</strong>miniumerzeugnisse weltweit. Um diese<br />
Position zu festigen, optimiert das Unternehmen<br />
seine Fertigungsprozesse, die Auslastung<br />
und die Produktivität stetig.<br />
➝<br />
In rolling mills, numerous vibrations with<br />
diverse results can appear. These might<br />
have negative effects on the life cycle and<br />
the condition of the plant as well as on<br />
product quality. Anyway, it is necessary<br />
to know exactly the vibration behaviour<br />
of the own plant for being able to monitor<br />
appropriately wear and tear as well as<br />
<strong>de</strong>fects. The aluminium producer Novelis,<br />
knows about the negative effects of vibrations<br />
and uses the new Condition Monitoring<br />
system by iba AG for evaluation<br />
and invention.<br />
Vibrations in rolling mills can have a negative<br />
effect on productivity, product quality and<br />
service life of single machine components.<br />
The plant can be adversely affected in a way<br />
that damages like gearbox <strong>de</strong>fects or breakings<br />
of the spindle might occur. E<strong>special</strong>ly during<br />
cold rolling, the vibrations exert a <strong>de</strong>cisive<br />
influence on product quality in the form of<br />
the so-called chatter marks. Chatter marks are<br />
waves on the strip surface in the µm range<br />
that run horizontally to the rolling direction,<br />
mostly periodically. The consequences are<br />
clear: The end product is of inferior quality<br />
or even waste, the rolling speeds have to be<br />
reduced to a vibration-free range and plant<br />
downtimes are increasing. These effects are e<strong>special</strong>ly<br />
problematic consi<strong>de</strong>ring the growing<br />
quality standards and the trends towards an<br />
ever higher productivity in rolling mills.<br />
The <strong>de</strong>mands on the machines regarding<br />
reliability, service life and process stability<br />
have been growing enormously. The operational<br />
safety of the plants can be established<br />
best using process- and condition monitoring.<br />
The globally operating group Novelis, with its<br />
headquarters in Atlanta, produces at 31 locations<br />
on four continents almost 20 percent of<br />
the rolled aluminium products world-wi<strong>de</strong>.<br />
For consolidating this position, the company<br />
continuously optimises its production processes,<br />
the capacity utilisation and the productivity.<br />
Monitoring the machine vibrations in coldrolling<br />
mills in a data-based and conditionrelated<br />
manner, <strong>de</strong>riving diagnoses from<br />
these data and intervening with appropriate<br />
measures are one element of this objective.<br />
Novelis wants to reach that goal with the<br />
© iba<br />
ALUMINIUM · 7-8/2013 63
TECHNOLOGIE<br />
Ein Element dieser Zielsetzung ist, die Maschinenschwingungen<br />
an <strong>de</strong>n Kaltwalzanlagen<br />
datenbasiert und zustandsbezogen zu<br />
überwachen, daraus Diagnosen abzuleiten<br />
und mit entsprechen<strong>de</strong>n Maßnahmen zu intervenieren.<br />
Dies will Novelis mit <strong>de</strong>m Condition-Monitoring-System<br />
„ibalnSpectra factory“<br />
erreichen, das als Pilotprojekt in <strong>de</strong>n<br />
Anlagen im Werk Nachterstedt für online basiertes<br />
Chatter-Monitoring installiert ist.<br />
Zwei Features in einem System vereint<br />
Am Standort Nachterstedt in Sachsen-Anhalt<br />
hatte Novelis schon länger ein Schwingungsmesssystem<br />
in Betrieb. Da dieses über eine<br />
separate Auswertung lief, konnten die Prozessdaten<br />
aus <strong>de</strong>r Anlage nicht zusammen<br />
mit <strong>de</strong>n Schwingungsdaten ausgewertet wer<strong>de</strong>n.<br />
Um die Schwingungen beim Walzen nicht<br />
nur zu erkennen, son<strong>de</strong>rn gleichzeitig aus <strong>de</strong>n<br />
erfassten Daten Defekte zu diagnostizieren,<br />
Kennwerttrends zu analysieren und daraus<br />
Maßnahmen für die Instandhaltung und Prozessoptimierung<br />
zu generieren, tauschte Novelis<br />
das bisherige Schwingungsmesssystem<br />
gegen ein System <strong>de</strong>r iba AG aus. „In <strong>de</strong>n Gerüsten<br />
hatten wir zur Prozessanalyse sowieso<br />
das Prozess-Daten-Aufzeichnungssystem<br />
ibaPDA eingesetzt. Deshalb war es sinnvoll,<br />
das ibalnSpectra als zusätzliches Add-On<br />
dieses Systems für das Chatter-Monitoring zu<br />
nutzen“, erklärt Robert Krumbach, Leiter <strong>de</strong>s<br />
Kaltwalzwerks in Nachterstedt bei <strong>de</strong>r Novelis<br />
Deutschland GmbH.<br />
Das ibalnSpectra ist ein neuartiges Condition-Monitoring-System,<br />
das die erfassten<br />
Signale nicht nur unter Maßgabe von Condition-Monitoring-Vorgaben<br />
auswertet, son<strong>de</strong>rn<br />
auch alle an<strong>de</strong>ren relevanten Betriebsparameter<br />
nutzt. Nur mit <strong>de</strong>m iba-System kann die<br />
Überwachung von Condition Monitoring relevanten<br />
Daten bei gleichzeitiger Prozessüberwachung<br />
mit allen Maschinen-, Prozess-, Material-<br />
und Qualitätsdaten realisiert wer<strong>de</strong>n.<br />
Die iba AG bietet das lnSpectra in variabler<br />
Skalierung für verschie<strong>de</strong>ne Anwendungsszenarien<br />
an. Für die Überwachung im Kontext<br />
einer komplexen Anlage wie bei Novelis ist<br />
„ibalnSpectra factory“ die geeignete Lösung.<br />
Mit ihr lassen sich die relevanten Rohdaten für<br />
das Condition Monitoring und die Prozessüberwachung<br />
fertigungsweit und produktionsübergreifend<br />
erfassen.<br />
Zu<strong>de</strong>m lässt sich ibalnSpectra herstellerneutral<br />
in je<strong>de</strong>s gängige Automatisierungssystem<br />
integrieren. In dieser Konnektivität <strong>de</strong>r<br />
Condition-Monitoring-Module sieht das Kaltwalzwerk<br />
von Novelis einen weiteren wichtigen<br />
Vorteil <strong>de</strong>s CM-Systems. Das Projekt in<br />
Nachterstedt startete im Februar 2012, seit<br />
Anfang dieses Jahres ist das Chatter-Monitoring<br />
nun in Betrieb. Wenn sich das Pilotprojekt<br />
in Nachterstedt als praktikabel erweist, plant<br />
Novelis ibalnSpectra konzernweit zur Anwendung<br />
zu bringen. Die Konnektivität <strong>de</strong>r<br />
iba-Module ist Voraussetzung, um in einem<br />
Konzern wie Novelis mit rund 30 Produktionsstandorten<br />
weltweit eine Gesamtoptimierung<br />
vorzunehmen.<br />
Schwingungen mit Abtastrate<br />
bis zu 100 kHz erkennen<br />
Kaltwalzanlagen verfügen über ein komplexes<br />
Schwingungsverhalten ausgehend von Eigenschwingungen<br />
<strong>de</strong>r Anlagenmechanik über<br />
Anregungen aus <strong>de</strong>n Getrieben o<strong>de</strong>r Lagern<br />
bis hin zu Anregungen durch Defekte o<strong>de</strong>r<br />
Drehzahlverän<strong>de</strong>rungen. Während <strong>de</strong>s Walzens<br />
können sich Schwingungsanregungen<br />
unterschiedlicher Entstehungsmechanismen<br />
und Frequenzen überlagern und sich gegenseitig<br />
verstärken. Prozessbedingt sind Schwingungen<br />
bei neuen wie auch alten Anlagen<br />
nicht zu verhin<strong>de</strong>rn. Vielmehr geht es darum,<br />
sie mithilfe geeigneter Metho<strong>de</strong>n so zu überwachen,<br />
dass Schä<strong>de</strong>n jeglicher Art vermie<strong>de</strong>n<br />
wer<strong>de</strong>n.<br />
Bei Novelis in Nachterstedt hat man die<br />
Erfahrung gemacht, dass Gerüstschwingungen<br />
in Abhängigkeit vom Belastungszustand unterschiedlich<br />
zu beurteilen sind: „Beim Kaltwalzen<br />
wird das Coil an unseren Gerüsten<br />
bis auf eine Geschwindigkeit von bis zu 1.250<br />
Meter pro Minute beschleunigt. Während<br />
<strong>de</strong>r Beschleunigungsphase registrieren wir<br />
verschie<strong>de</strong>ne Schwingungszustän<strong>de</strong> mit unterschiedlichen<br />
Auswirkungen auf die Anlage<br />
und das Produkt“, erklärt Krumbach. Die<br />
Walzen wer<strong>de</strong>n in sogenannten Einbaustücken<br />
gelagert. Die Schwingungen, die unter<br />
an<strong>de</strong>rem über die Einbaustücke initiiert wer<strong>de</strong>n,<br />
übertragen sich sofort auf das Gerüst.<br />
Deshalb hat Novelis an <strong>de</strong>n Einbaustücken<br />
<strong>de</strong>r bei<strong>de</strong>n Walzgerüste Beschleunigungssensoren<br />
angebracht, die das Schwingungsverhalten<br />
überwachen und damit Aufschluss über<br />
das Schwingungsverhalten <strong>de</strong>s kompletten<br />
Gerüsts geben. Der Walzwerksleiter erläutert:<br />
„Die Einbaustücke verfügen über eine<br />
Eigenfrequenz im Nie<strong>de</strong>rfrequenzbereich.<br />
Sie schwingen bei Anregung also sehr langsam.<br />
Wenn aus <strong>de</strong>n nie<strong>de</strong>rfrequenten Schwingungen<br />
hochfrequente wer<strong>de</strong>n, können wir<br />
zum Beispiel auf Frem<strong>de</strong>rregung schließen.“<br />
Um die Ursache für die Fremdschwingungen<br />
ermitteln zu können, bedarf es einer genauen<br />
Kenntnis <strong>de</strong>r Schwingungsfrequenzen<br />
aller Elemente im Gerüst. Die AuswerteeinibalnSpectra<br />
Factory Condition Monitoring<br />
system, which has been installed in the machines<br />
as pilot project in the Nachterstedt plant<br />
in Saxony-Anhalt, Germany, for online based<br />
chatter monitoring.<br />
Two features united in one system<br />
At the Novelis Nachterstedt plant, a vibration<br />
measurement system has been in operation<br />
for a longer time. As this measurement system<br />
ran over a separate analysis, the process<br />
data from the plant could not be analysed together<br />
with the vibration data. For not only<br />
<strong>de</strong>tecting the vibrations in the rolling process<br />
but also diagnosing <strong>de</strong>fects from the acquired<br />
data, analysing trends of characteristic values<br />
and generating from these values measures for<br />
maintenance and process optimisation, Novelis<br />
replaced the existing vibration measurement<br />
system by a system from iba AG. „In the rolling<br />
stands, we used the ibaPDA process data<br />
recording system, anyway. For this reason, it<br />
ma<strong>de</strong> sense to use ibalnSpectra as add-on for<br />
this system for chatter monitoring“, explains<br />
Robert Krumbach, manager of the Nachterstedt<br />
cold-rolling mill at Novelis Germany.<br />
ibalnSpectra is an innovative Condition<br />
Monitoring system which does not only evaluate<br />
the acquired signals regarding the Condition<br />
Monitoring gui<strong>de</strong>lines but also uses all<br />
the other relevant operating parameters. Only<br />
the iba system allows monitoring the data<br />
relevant for Condition Monitoring and simultaneously<br />
monitoring the processes with all<br />
machine, process, material and quality data.<br />
iba AG offers lnSpectra in variable scaling<br />
for diverse application scenarios. For monitoring<br />
in the context of a complex plant, like<br />
the Novelis plant, ibalnSpectra Factory is the<br />
appropriate solution. With this solution, the<br />
relevant raw data for Condition Monitoring<br />
and process monitoring can be acquired in a<br />
production-wi<strong>de</strong> manner.<br />
Moreover, ibalnspectra can co-operate with<br />
every common automation system, in<strong>de</strong>pen<strong>de</strong>nt<br />
of the manufacturer. The staff of the Novelis<br />
cold-rolling mill consi<strong>de</strong>rs this connectivity<br />
of the Condition Monitoring modules to<br />
be another important advantage of the CM<br />
system. The Nachterstedt project started in<br />
February 2012 and since the beginning of<br />
this year, the chatter monitoring has been in<br />
operation. In case the Nachterstedt project<br />
proves to be successful, Novelis will introduce<br />
ibalnSpectra across the whole company. The<br />
connectivity of the iba modules is the prerequisite<br />
for making an overall optimisation in a<br />
company like Novelis with about 30 production<br />
sites world-wi<strong>de</strong>.<br />
64 ALUMINIUM · 7-8/2013
TECHNOLOGY<br />
© Novelis<br />
Detecting vibrations with a<br />
sampling rate of up to 100 kHz<br />
Cold rolling mills show a complex vibration<br />
behaviour, beginning with natural vibrations<br />
of the system mechanics, over excitations<br />
coming from the gearboxes or bearings up to<br />
the excitations originating from <strong>de</strong>fects or<br />
varying speeds. In course of the rolling process,<br />
the vibration excitations originating from<br />
diverse mechanisms and frequencies can superimpose<br />
and mutually reinforce. Due to the<br />
process, the vibrations cannot be prevented<br />
neither in new nor in old systems. It is rather<br />
a question of monitoring the vibrations using<br />
<strong>Alu</strong>minium coils at Novelis<br />
appropriate methods and hence preventing<br />
any damages.<br />
At the Novelis Nachterstedt plant, experience<br />
has shown that the vibrations of the<br />
roll stands need to be evaluated differently<br />
<strong>de</strong>pending on the load: “In the cold rolling<br />
process the coil on our roll stand is accelerated<br />
up to a speed of 1,250 m/min. During the<br />
acceleration phase, we are noticing different<br />
vibration states which exert different effects<br />
on the machines and the product,“ explains<br />
Mr Krumbach. The rolls are stored in the<br />
so-called chocks. The vibrations that are initiated<br />
among other things by the chocks, are<br />
immediately transferred to the roll stands.<br />
This is why Novelis has mounted acceleration<br />
sensors on the chocks of the two roll stands,<br />
which are monitoring the vibration behaviour<br />
<strong>Alu</strong>miniumcoils bei Novelis<br />
heit <strong>de</strong>s CM-Systems, das Messwerterfassungssystem<br />
ibaPDA-V6, erfasst alle Sensoren<br />
mit bis zu 100 kHz Abtastrate zeitsynchron,<br />
kontinuierlich und auf physikalische Einheiten<br />
skaliert. ibaPDA-V6 wird in mehreren Varianten<br />
bezüglich <strong>de</strong>r Signalanzahl angeboten.<br />
Zur Verfügung stehen Lizenzen für 64 bis<br />
2.048 Signale sowie für eine unbegrenzte<br />
Anzahl Signale. Für die normale Messdatenerfassung<br />
stehen Zeitbasen von 1 bis 1.000<br />
ms zur Auswahl. Für höhere Signalän<strong>de</strong>rungsgeschwindigkeiten<br />
können auch kürzere Erfassungsraten<br />
bis zu 10 μs realisiert wer<strong>de</strong>n.<br />
Ist ein Bauteil beschädigt, verursacht dieses<br />
Schwingungen in einem bestimmten Frequenzband.<br />
Die von <strong>de</strong>r Auswerteeinheit erfassten<br />
Zusatzschwingungen können auf Basis<br />
dieser Werte konkreten Bauteilen zugeordnet<br />
wer<strong>de</strong>n. Ist beispielsweise ein Kugellager mechanisch<br />
<strong>de</strong>fekt, verursacht es hochfrequente<br />
Zusatzschwingungen von 1.200 Hz. Ab diesem<br />
Frequenzband <strong>de</strong>uten die Schwingungen<br />
zum Beispiel auf Lagerschä<strong>de</strong>n hin.<br />
Komplexes Schwingungsverhalten<br />
online überwachen<br />
Eine erfolgreiche Zuordnung <strong>de</strong>r Maschinenschwingungen<br />
ist möglich, wenn die Condition-Monitoring-Daten<br />
und Prozessdaten miteinan<strong>de</strong>r<br />
in Echtzeit in Verbindung gebracht<br />
wer<strong>de</strong>n können. Dank <strong>de</strong>s ibalnSpectra ist<br />
es bei Novelis Nachterstedt erstmals möglich,<br />
Daten wie Geschwindigkeit, Walzkraft,<br />
Drehmomente, Temperatur und Walzöldruck<br />
online mit <strong>de</strong>n Schwingungsdaten zu korrelieren.<br />
Um die Schwingungen positiv beeinflussen<br />
und sie minimieren zu können, kann<br />
Novelis die Einflussgrößen auf das Schwingungsverhalten<br />
mit <strong>de</strong>m ibaInSpectra auch<br />
online variieren. Dazu wer<strong>de</strong>n die Messdaten<br />
mit <strong>de</strong>m ibaQPanel auf <strong>de</strong>m Steuerstand <strong>de</strong>r<br />
Leittechnik in Echtzeit visualisiert. Zusätzlich<br />
können Alarmmeldungen generiert wer<strong>de</strong>n,<br />
die entwe<strong>de</strong>r eine automatische Anpassung<br />
<strong>de</strong>r Walzengeschwindigkeit auslösen o<strong>de</strong>r<br />
eine manuelle Einstellung anstoßen. Bevor das<br />
Chatter-Monitoring-System von iba eingesetzt<br />
wur<strong>de</strong>, gab es keinen exakten Rückschluss auf<br />
Ursachen für die entstehen<strong>de</strong>n Schwingungszustän<strong>de</strong><br />
<strong>de</strong>s Kaltwalzgerüstes.<br />
Die Analysemöglichkeiten <strong>de</strong>s ibalnSpectra<br />
reichen von einfachen Kennwertbildungen<br />
aus <strong>de</strong>n Zeitsignalen wie Minimum, Maximum<br />
o<strong>de</strong>r RMS-Wert bis zu komplexen<br />
Auswertungen im Frequenzbereich wie Amplitu<strong>de</strong>nspektren,<br />
Hüllkurvenspektren o<strong>de</strong>r<br />
Cepstrum-Analyse. Es können Frequenzspektren<br />
mittels Fast Fourier Transformation (FFT)<br />
und statistische Kennwerte berechnet wer<strong>de</strong>n.<br />
Es besteht die Möglichkeit von Drag-und-<br />
Drop <strong>de</strong>s parametrierten Analyseobjektes in<br />
die Visualisierung und die Extraktion aussagekräftiger<br />
Kennwerte aller relevanten Maschinen-,<br />
Prozess-, Material- und Qualitätsdaten<br />
in eine Datenbank. Flexible, leistungsfähige<br />
Analysewerkzeuge ermöglichen die frühzeitige<br />
Erkennung signifikanter Korrelationen<br />
zwischen diesen Daten. Für die werksübergreifen<strong>de</strong><br />
Analyse <strong>de</strong>r Messdaten ist es von<br />
Vorteil, dass die Geräte <strong>de</strong>r InSpectra-Produktlinien<br />
zwar autark betrieben wer<strong>de</strong>n<br />
können, aber die Daten über verschie<strong>de</strong>ne<br />
Netzwerkschnittstellen an die zentrale Auswerteeinheit<br />
übertragen wer<strong>de</strong>n.<br />
Nur durch die Zusammenführung verschie<strong>de</strong>ner<br />
Maßnahmen in ein online basiertes<br />
Chatter-Monitoring-System, das die Prozessoptimierung<br />
und Anlagenüberwachung<br />
beinhaltet, kommen Walzwerkbetreiber <strong>de</strong>r<br />
Wunschvorstellung von betriebssicheren und<br />
fehlerfreien Produkten nahe. Gemeinsam<br />
konnten die iba AG und Novelis Nachterstedt<br />
hier einen <strong>de</strong>utlichen Schritt nach vorn gehen.<br />
Autoren<br />
Dr. Ulrich Lettau ist Vorstandsvorsitzen<strong>de</strong>r <strong>de</strong>r iba<br />
AG mit Sitz in Fürth.<br />
Dr. David Skingley Wright ist Leiter Technologie<br />
und Entwicklung für <strong>de</strong>n Bereich Kaltwalzen bei<br />
Novelis Inc.<br />
ALUMINIUM · 7-8/2013 65
COMPANY NEWS WORLDWIDE<br />
and hence provi<strong>de</strong> information on the vibration<br />
behaviour of the whole roll stand. The<br />
manager of the rolling mill explains: „The<br />
chocks have a natural frequency in the low<br />
frequency range. Hence, when being excited,<br />
they show a very slow vibration. When low<br />
frequency vibrations become high frequency<br />
vibrations, we can conclu<strong>de</strong> that we are <strong>de</strong>aling<br />
with external excitation.”<br />
For being able to <strong>de</strong>termine the external<br />
vibrations, the staff needs to know exactly<br />
the vibration frequencies of all elements in<br />
the roll stand. The evaluation unit of the CM<br />
system – the ibaPDA-V6 measurement value<br />
acquisition system – acquires all sensors with a<br />
sampling rate of up to 100 kHz time synchronously,<br />
continuously and scaled to physical<br />
units. ibaPDA-V6 is offered in several variants<br />
regarding the number of signals. Licenses for<br />
64 to 2,048 signals as well as for an unlimited<br />
number of signals are available. For the<br />
normal measurement data acquisition, there<br />
are time bases of 1 to 1,000 ms available. For<br />
higher speeds of signal changes, also shorter<br />
acquisition rates of up to 10 μs can be realised.<br />
In case a machine component is damaged, it<br />
causes vibrations of a certain frequency band.<br />
The additional vibrations that are acquired<br />
by the evaluation unit, can be clearly assigned<br />
– on the basis of these values – to certain<br />
components. If e.g. a ball bearing is mechanically<br />
<strong>de</strong>fective, it causes additional high frequency<br />
vibrations of 1,200 Hz. Within this<br />
frequency band, the vibrations imply <strong>de</strong>fective<br />
bearings.<br />
Online monitoring of<br />
complex vibration behaviours<br />
The machine vibrations can be assigned successfully,<br />
if the Condition Monitoring data<br />
and the process data can be related to each<br />
other in real time. Due to ibalnSpectra it is<br />
possible at the Novelis Nachterstedt plant to<br />
establish online correlations between data<br />
like speed, rolling force, torque, temperature,<br />
rolling oil pressure on the one hand and vibration<br />
data on the other. For being able to<br />
exert a positive influence on the vibrations<br />
and thus minimising them, Novelis can – using<br />
ibalnSpectra – also adjust the influencing<br />
variables on the vibration behaviour online<br />
during the process. For that purpose, the<br />
measurement data are visualised by means of<br />
ibaQPanel in the control pulpit in real time.<br />
Moreover, alarm messages can be generated<br />
which either trigger an automatic adaptation<br />
of the rolling speed or initiate a manual adjustment.<br />
Before the implementation of the<br />
chatter monitoring system, no exact conclusions<br />
could be drawn concerning the causes<br />
for the vibration conditions of the cold rolling<br />
mill.<br />
The analysis options of ibalnSpectra range<br />
from simple parameter calculations from time<br />
signals like minimum, maximum or RMS values<br />
to complex evaluations in the frequency<br />
range like amplitu<strong>de</strong> spectra, envelope curve<br />
spectra or Cepstrum analysis. Frequency spectra<br />
can be calculated using the Fast Fourier<br />
Transformation (FFT). Also statistical parameters<br />
can be calculated. Using drag & drop,<br />
the parameterised analysis object can be used<br />
in the visualisation. Significant values of all<br />
machine-, process-, material- and quality data<br />
can be extracted to a database. Flexible and<br />
efficient analysis tools allow for the early<br />
<strong>de</strong>tection of significant correlations between<br />
these data. For the cross-plant analysis of the<br />
measurement data it is an advantage that the<br />
<strong>de</strong>vices of the lnSpectra product lines can be<br />
operated autonomously, but also that the data<br />
can be transferred to a central evaluation unit<br />
via diverse network interfaces.<br />
Only by combining different measures in<br />
an online based chatter monitoring system<br />
that inclu<strong>de</strong>s the process optimisation and<br />
plant monitoring, the operators of a rolling<br />
mill come as close as possible to their i<strong>de</strong>al<br />
of reliable and fault-free products. Together,<br />
iba AG and Novelis Nachterstedt have taken<br />
a significant step forward in this matter.<br />
Authors<br />
Dr Ulrich Lettau is CEO of iba AG, which is located<br />
in Fürth, Germany.<br />
Dr David Skingley Wright is manager Technology<br />
and Development, Cold Rolling at Novelis Inc.<br />
<strong>Alu</strong>minium smelting industry<br />
(USD782m) yuan. Chalco follows in Alcoa’s<br />
and Rusal’s footsteps: both companies have<br />
only recently announced production cuts.<br />
Alcoa will close two So<strong>de</strong>rberg potlines at its<br />
Baie-Comeau smelter in Québec representing<br />
a production capacity of 105,000 tpy while<br />
Rusal announced production cuts of around<br />
300,000 tpy.<br />
Trimet to acquire two<br />
aluminium plants in France<br />
© Dubal<br />
Chalco cuts aluminium production<br />
<strong>Alu</strong>minium Corp. of China (Chalco) has announced<br />
it will temporarily close 380.000 tpy<br />
of production capacity due to weak market<br />
conditions. The curtailment corresponds to<br />
9% of the company’s annual aluminium output.<br />
Low aluminium prices and rising costs led<br />
to a net annual loss of 8.2bn yuan (USD1.3bn)<br />
in 2012 and an operating loss of 4.8bn<br />
German aluminium producer Trimet has submitted<br />
a binding offer to acquire two Rio Tinto<br />
Alcan (RTA) plants in France: namely the aluminium<br />
smelter in Saint-Jean-<strong>de</strong>-Maurienne<br />
with a production capacity of 140,000 tpy<br />
and the Castelsarrasin plant which produces<br />
aluminium wire rod for electric cabling and<br />
connecting elements for the automobile indus-<br />
66 ALUMINIUM · 7-8/2013
COMPANY NEWS WORLDWIDE<br />
try. The aluminium smelter produced 93,000<br />
tonnes of aluminium in 2012 and the wire rod<br />
plant 8,000 tonnes.<br />
The purchase agreement will secure the<br />
long-term supply of alumina and electric power,<br />
which are key requirements for the production<br />
of aluminium. Trimet will have a 60%<br />
majority stake in the production plants while<br />
energy supplier EdF will take a minority stake<br />
of 35%. Another 5% will be held by the staterun<br />
Fonds Stratégique d’Investisse (FSI).<br />
The transaction is conditional upon the approval<br />
of the regulatory authorities and the<br />
execution of an energy supply agreement and<br />
a partnership arrangement with EdF, said Trimet.<br />
Slovalco smelter signs<br />
LoI for power supply<br />
Hydro’s part-owned aluminium smelter in<br />
Slovakia, Slovalco, has signed a Letter of Intent<br />
(LoI) for power supply with Slovenské<br />
Elektrárne. The LoI covers electricity supply<br />
over an eight-year period as from 1 January<br />
2014 with a total <strong>de</strong>livery of 19 TWh. The<br />
LoI is a first move towards securing the total<br />
framework that will enable continued operations<br />
at Slovalco.<br />
Since entering into the existing power<br />
contract with Slovenské Elektrárne 20 years<br />
ago, power prices in Slovakia have increased.<br />
Slovalco will strengthen its competitiveness<br />
through efficiency measures and cost cuts,<br />
while in parallel working to achieve a competitive<br />
future power supply. Slovalco is a fully<br />
consolidated smelter in Hydro, owned 55%<br />
by Hydro <strong>Alu</strong>minium AS. The plant has a production<br />
capacity of 165,000 tpy.<br />
Alba Potline 5 upgra<strong>de</strong>d<br />
<strong>Alu</strong>minium Bahrain (Alba) has announced<br />
that Potline 5 has been upgra<strong>de</strong>d to AP37<br />
technology following an increase in the line<br />
current to 370 kA. The upgra<strong>de</strong> increases the<br />
smelter capacity by around 10,000 tpy.<br />
Inalum to become 100%<br />
state-owned company<br />
The Indonesian government will completely<br />
take over Indonesia Asahan <strong>Alu</strong>minium,<br />
known as Inalum, in November, although negotiations<br />
are still ongoing. That is what the<br />
Indonesian Industry Minister M. S. Hidayat<br />
told journalists recently. He said that the government<br />
had already earmarked Rp7 trillion<br />
(USD707m) for the takeover. Initially the government<br />
had plans to sell its stakes to other investors,<br />
but then changed mind to turn Inalum<br />
into a state-run enterprise, in expectation of<br />
larger state revenue from aluminium sales.<br />
Inalum is currently 58.88% controlled<br />
by the Japanese consortium Nippon Asahan<br />
<strong>Alu</strong>minium and 41.12% controlled by the Indonesian<br />
government. The smelter has a production<br />
capacity of 260,000 tpy. There are<br />
plans of the Industry Ministry to increase the<br />
capacity to 450,000 tpy to meet domestic <strong>de</strong>mand.<br />
At present 40% of the output is sold on<br />
the domestic market and 60% on the Japanese<br />
market.<br />
n<br />
Bauxite and<br />
alumina activities<br />
<strong>Alu</strong>fer’s Bel Air project in<br />
Guinea hit by licensing <strong>de</strong>lays<br />
Junior bauxite producer <strong>Alu</strong>fer Mining has<br />
<strong>de</strong>layed construction of its Bel Air bauxite<br />
project in Guinea by a year, due to licensing<br />
<strong>de</strong>lays. Construction is now predicted to start<br />
in 2014, with product shipment expected in<br />
2016. The <strong>de</strong>lay at Bel Air stems from the<br />
Guinea government’s steps to tie mining licenses<br />
to their revised mining co<strong>de</strong>. <strong>Alu</strong>fer<br />
submitted its licence application in October<br />
2012, but Guinean authorities could not issue<br />
the licence before concluding amendments to<br />
the September 2011 mining co<strong>de</strong>.<br />
The junior miner has lined up financiers<br />
and suppliers for Bel Air, and one of the <strong>de</strong>als<br />
involves China’s Hongfan Industries, which<br />
has agreed to a 5m tpy bauxite offtake arrangement<br />
and to a prepayment arrangement<br />
to help Bel Air into commercial production<br />
within 24 months. Hongfan will buy half of<br />
the planned production from Bel Air and will<br />
pre-finance mine <strong>de</strong>velopment.<br />
Bel Air requires a USD310m capital outlay,<br />
the bulk of which is targeted for supporting<br />
infrastructure.<br />
Hydro issues force majeure notice<br />
due to power outages at <strong>Alu</strong>norte<br />
Hydro issued a notice of force majeure to its<br />
alumina customers as power outages and lowered<br />
production at <strong>Alu</strong>norte alumina refinery<br />
may affect alumina <strong>de</strong>liveries to customers.<br />
On 18 May the refinery experienced a blackout<br />
in its electrical power supply system due<br />
to unexpected external events. As a consequence,<br />
<strong>Alu</strong>norte suffered a partial electrical<br />
power outage. On 2 June, while in the process<br />
of stabilising and resuming production, <strong>Alu</strong>norte<br />
experienced another, shorter black-out<br />
caused by an unrelated external event. These<br />
events caused serious disruption so that the<br />
refinery has not been able to resume full production<br />
of alumina.<br />
<strong>Alu</strong>norte production levels will be lower<br />
in the second quarter than in the first, and are<br />
expected to remain unsatisfactory also for the<br />
rest of the year. As a measure, Hydro has established<br />
a team of experts aiming to stabilise<br />
and increase production at the refinery.<br />
<strong>Alu</strong>norte is the world’s largest alumina<br />
refinery, with a nameplate capacity of 6.3m<br />
tonnes.<br />
Orbite signs offtake<br />
agreement with Glencore<br />
Orbite <strong>Alu</strong>minae Inc. has signed an offtake<br />
agreement with Glencore International for<br />
the purchase of smelter-gra<strong>de</strong> alumina from<br />
the corporation’s first proposed smelter-gra<strong>de</strong><br />
alumina (SGA) plant in Quebec, Canada. The<br />
agreement provi<strong>de</strong>s for the purchase for an<br />
initial term of ten years from the beginning<br />
of commercial production. The agreement also<br />
foresees that Orbite and Glencore will un<strong>de</strong>rtake<br />
negotiations relating to Glencore’s potential<br />
financial participation in the ownership<br />
and operation of the corporation’s proposed<br />
SGA plant in Quebec.<br />
Glencore Xstrata, the parent company of<br />
Glencore International, is one of the world’s<br />
largest global diversified natural resource companies<br />
with revenues of USD236bn in 2012.<br />
Well Harvest builds alumina<br />
refinery in Indonesia<br />
Well Harvest Winning <strong>Alu</strong>mina Refinery, a<br />
joint venture between Indonesian conglomerate<br />
Harita Group and China’s Hongqiao<br />
Group, has started construction of the first<br />
alumina refinery in Indonesia. The USD1bn,<br />
2m tpy plant will be built in Ketapang, West<br />
Kalimantan. The refinery will be built in two<br />
phases, with Phase I complete in 2015. The<br />
initial phase is expected to cost USD500m<br />
and will leave the facility with a capacity of<br />
about 1m tpy. Completion of Phase II is scheduled<br />
for 2017. Output from the refinery is inten<strong>de</strong>d<br />
to be sold to Inalum, an Indonesian-<br />
Japanese joint venture that will be taken over<br />
ALUMINIUM · 7-8/2013 67
COMPANY NEWS WORLDWIDE<br />
by the Indonesian government in November.<br />
The refinery will process bauxite from the<br />
Harita’s mines. The company owns 26 mining<br />
permits in West Kalimantan, with proven<br />
bauxite reserves of some 700m tonnes. Harita<br />
owns 30% of Well Harvest through its subsidiary<br />
Cita Mineral Investindo, while Hongqiao<br />
owns the rest.<br />
n<br />
Secondary smelting and recycling<br />
products, in sizes compatible with the largest<br />
aluminium aerospace components in service<br />
today. The Lafayette expansion should be<br />
completed and online by the end of 2014.<br />
Alcoa’s new aluminium-lithium alloys combine<br />
the best strength-to-weight performance<br />
with better stiffness, damage tolerance and<br />
corrosion resistance.<br />
© Hydro<br />
Oetinger goes into administration<br />
Secondary aluminium company Oetinger from<br />
Germany has ma<strong>de</strong> a request to begin insolvency<br />
proceedings. The company ma<strong>de</strong> the<br />
request for its four German units in Weißenhorn,<br />
Hanover, Berlin and Neu-Ulm. The company’s<br />
French unit, Affinage <strong>de</strong> Lorraine, will<br />
not be affected. Oetinger is Europe’s largest<br />
foundry aluminium producer, with a production<br />
of 300,000 tpy. The market can hardly<br />
accept the loss of this capacity. This will be<br />
the prime role of the insolvency administrator:<br />
to ensure that the works keep on running.<br />
Novelis celebrates roofing ceremony<br />
for its recycling plant in Germany<br />
Novelis Inc. has celebrated the roofing of its<br />
USD250m aluminium recycling and casting<br />
centre at its plant in Nachterstedt, Germany.<br />
Located adjacent to the company’s existing<br />
aluminium rolling mill, the new centre will<br />
produce up to 400,000 tpy of aluminium sheet<br />
ingot from recycled material. It is projected<br />
to be the world’s largest aluminium recycling<br />
centre, which remains on track for completion<br />
in July 2014. The centre will process used beverage<br />
cans as well as numerous other forms of<br />
aluminium scrap from across continental Europe.<br />
Novelis expects the centre to create 200<br />
new jobs when commissioned in 2014.<br />
The Nachterstedt expansion is the latest<br />
in a series of recycling and casting expansion<br />
projects launched by Novelis over the past two<br />
years. These total nearly USD450m, including<br />
the commissioning in 2012 of the company’s<br />
new integrated recycling and casting<br />
centre in Yeongju, Korea. These projects, and<br />
others un<strong>de</strong>rway across the world, are <strong>de</strong>signed<br />
to increase Novelis’ recycling and casting<br />
capacity to 2.1m tonnes by 2015.<br />
Alcoa completes aluminium-lithium<br />
expansion project in UK<br />
Alcoa has completed the expansion of aluminium<br />
lithium alloy capacity at its Kitts Green<br />
facility in the UK to serve the growing <strong>de</strong>mand<br />
for the company’s third generation aluminium<br />
lithium alloys. Alcoa projects its aluminium<br />
lithium revenues will quadruple over the next<br />
six years to nearly USD200m. The Kitts Green<br />
expansion was the second phase of Alcoa’s<br />
three-part expansion programme to satisfy<br />
customer <strong>de</strong>mand for advanced aerospace<br />
products and patented alloys, which allow<br />
aircraft manufacturers to build more fuel-efficient<br />
and lower-cost airplanes than with composite<br />
alternatives.<br />
Alcoa upgra<strong>de</strong>d and expan<strong>de</strong>d casting capacity<br />
at the Kitts Green plant, and also expan<strong>de</strong>d<br />
capacity at its technology centre in<br />
Pennsylvania by 30%. The third phase of the<br />
expansion is a new USD90m facility un<strong>de</strong>r<br />
construction adjacent to the company’s plant<br />
in Lafayette, Indiana, that will provi<strong>de</strong> an additional<br />
20,000 tonnes of aluminium-lithium.<br />
The new facility will supply round and rectangular<br />
ingot for rolled, extru<strong>de</strong>d and forged<br />
Constellium seeks buyer<br />
for plant in France<br />
Paris-based Constellium is seeking a buyer<br />
for its precision castings operations in Ussel,<br />
France. The company hopes to find a buyer<br />
committed to the facility’s future <strong>de</strong>velopment,<br />
but it could not predict the terms un<strong>de</strong>r<br />
which a <strong>de</strong>al might be conclu<strong>de</strong>d, or what any<br />
potential buyers’ plans for the plant might be.<br />
But Constellium plans to retain the Ussel plant<br />
if no “suitable buyer” is found. The Ussel plant<br />
employs about 230 people, and it recor<strong>de</strong>d<br />
revenues of €26m (USD34m) in 2012. The<br />
company as a whole reported 2012 revenues<br />
of €3.6bn.<br />
Boeing and Alcoa to boost recycling<br />
of aluminium aerospace alloys<br />
Boeing and Alcoa have formed a closed-loop<br />
programme to significantly increase the recycling<br />
of internal aluminium aerospace alloys<br />
used in Boeing airplanes. The programme will<br />
entail inter-modal transport of aluminium alloy<br />
scrap, including advanced alloys, from<br />
Boeing facilities in Auburn and Wichita, and<br />
from third-party processors in Auburn, to<br />
Alcoa’s Lafayette facility in Indiana. The programme<br />
calls for melting and recycling into<br />
new aerospace materials of aluminium alloys<br />
(2xxx and 7xxx series) used in the production<br />
of wing and fuselage components of Boeing<br />
airplanes. The forms will inclu<strong>de</strong> aluminium<br />
extrusions, sheet and plate products, amounting<br />
at the outset to 3,630 tpy.<br />
The new programme also lays the groundwork<br />
for extending the recycling system to<br />
Boeing sub-contractors, and later including<br />
other aluminium scrap forms, such as chips<br />
that remain after the machining of parts.<br />
Alcoa facility to cut in half energy used<br />
to recycle aluminium for forged wheels<br />
Alcoa has announced that its USD21m Wheel<br />
and Transportation Products casthouse expansion<br />
at its Barberton plant in Ohio is expected<br />
68 ALUMINIUM · 7-8/2013
COMPANY NEWS WORLDWIDE<br />
© Hydro<br />
<strong>Alu</strong>minium semis<br />
Constellium sells its French plants<br />
in Ham and Saint-Florentin<br />
Constellium has sold its French extrusion<br />
plants in Ham and Saint-Florentin to Open-<br />
Gate Capital. The plants produce aluminium<br />
profiles inten<strong>de</strong>d mainly for the building and<br />
construction industry. Details on the transaction<br />
were not disclosed. OpenGate Capital,<br />
The Author<br />
The author, Dipl.-Ing. R. P. Pawlek is foun<strong>de</strong>r<br />
of TS+C, Technical Info Services and Consulting,<br />
Sierre (Switzerland), a service for the primary<br />
aluminium industry. He is also the publisher<br />
of the standard works <strong>Alu</strong>mina Refineries and<br />
Producers of the World and Primary <strong>Alu</strong>minium<br />
Smelters and Producers of the World. These<br />
reference works are continually updated, and<br />
contain useful technical and economic information<br />
on all alumina refineries and primary<br />
aluminium smelters of the world. They are<br />
available as loose-leaf files and / or CD-ROMs<br />
from Beuth-Verlag GmbH in Berlin.<br />
to cut in half the specific amount of energy<br />
used to recycle aluminium for forged wheels,<br />
so reducing greenhouse gases and increasing<br />
the overall efficiency and sustainability of the<br />
company’s manufacturing process. The recycling<br />
facility, the first of its kind in North<br />
America, uses advanced technology to produce<br />
wheels from re-melted and scrap aluminium.<br />
Construction of the 4,000 m 2 facility<br />
began in July 2011. It is now up and running<br />
at full capacity.<br />
Recycled aluminium scrap of 43,500 tpy is<br />
enough to make 2m new Alcoa forged aluminium<br />
wheels. The casthouse takes chips<br />
and solids from an existing Alcoa wheel machining<br />
plant on the same campus in Barberton,<br />
as well as from Alcoa’s Cleveland forging<br />
plant, and recycles them into aluminium<br />
billets. The billets are then shipped to other<br />
wheel-processing facilities to forge into aluminium<br />
wheels.<br />
The casthouse is expected to significantly<br />
reduce energy use through a combination of<br />
process improvements and reduced transportation<br />
needs.<br />
n<br />
LLC is a global private buyout firm <strong>special</strong>ised<br />
in the acquisition and operation of businesses<br />
seeking revitalisation through growth and operational<br />
improvements.<br />
Novelis boosts auto sheet<br />
capacity in Europe<br />
Novelis has expan<strong>de</strong>d its automotive sheet<br />
production capacity in Europe by adapting<br />
its Goettingen plant in Germany to help meet<br />
growing <strong>de</strong>mand for recyclable aluminium<br />
sheet for automobile manufacture. The Goettingen<br />
plant will produce 20,000 tpy of automotive<br />
sheet, and a planned second phase will<br />
double that capacity.<br />
The Goettingen plant currently produces<br />
high-quality sheet for the lithographic and<br />
packaging markets, as well as painted sheet<br />
for a variety of applications. It also produces<br />
aluminium bottles, cartridges, cans and housings<br />
using the impact extrusion process.<br />
Novelis is investing around the world to<br />
boost its automotive finishing capabilities. In<br />
North America, an expansion at the Oswego<br />
plant in New York will add 240,000 tpy, and<br />
a new plant un<strong>de</strong>r construction in Changzhou,<br />
China, will have a capacity of 120,000 tpy.<br />
Besi<strong>de</strong>s, Novelis has announced a price increase<br />
of €160/t for all of its automotive aluminium<br />
sheet products in Europe. The price adjustment<br />
is effective immediately for all new or<strong>de</strong>rs<br />
not covered by current supply agreements.<br />
Novelis and ThyssenKrupp agree<br />
to <strong>de</strong>velop aluminium car parts<br />
<strong>Alu</strong>minium rolled products producer Novelis<br />
and a subsidiary of steelmaker ThyssenKrupp<br />
signed a co-operation agreement to produce<br />
aluminium parts for the automotive industry.<br />
Novelis and ThyssenKrupp Tailored Blanks,<br />
which produces a combination of steel sheets,<br />
will produce individual aluminium sheet of<br />
different gra<strong>de</strong>, thickness and coating that can<br />
be joined to produce customised stamping<br />
blanks used by carmakers for the production<br />
of lightweight body parts such as doors and<br />
bonnets.<br />
The use of tailored blanks can lead to higher<br />
safety standards due to the selective use<br />
of high-strength aluminium alloys. The product<br />
range of tailored aluminium blanks connects<br />
the extensive potential for lightweight<br />
of aluminium with the engineering service<br />
of tailoring the body and chassis <strong>de</strong>sign on a<br />
mass scale.<br />
Hydro and Kobe Steel cooperate<br />
on automotive body panels<br />
Kobe Steel has entered into a technical cooperation<br />
agreement with Hydro <strong>Alu</strong>minium<br />
Rolled Products GmbH in Germany for aluminium<br />
sheet used in automotive body panels.<br />
The agreement covers the exchange of technical<br />
information regarding the use of aluminium<br />
in automobile bodies and structural<br />
parts, the licensing of intellectual property and<br />
manufacturing know-how as well as technical<br />
assistance.<br />
Demand for aluminium sheet used in automotive<br />
body panels is anticipated to increase<br />
to meet the need for lighter cars due to stricter<br />
fuel economy standards. Kobe Steel’s aluminium<br />
sheet business is focusing on expanding<br />
sales in this area. The company currently supplies<br />
a large share of automotive aluminium<br />
sheet to Japanese car makers. In the future, it<br />
anticipates expanding sales to European and<br />
US car makers as well. As car makers grow<br />
their businesses, there is a rising need to locally<br />
procure the same quality of materials<br />
worldwi<strong>de</strong>.<br />
➝<br />
ALUMINIUM · 7-8/2013 69
COMPANY NEWS WORLDWIDE<br />
Kobe Steel is planning to build a global supply<br />
network for aluminium body panels, as<br />
announced in its medium-term business plan<br />
at the end of May. In addition, the agreement<br />
with Hydro strengthens the company’s capability<br />
to meet the global procurement needs<br />
of its customers.<br />
Alcoa and Rusnano sign MoU<br />
to produce aluminium drill pipe<br />
with antiwear coating<br />
Alcoa and OJSC Rusnano will produce technologically<br />
advanced oil and gas aluminium<br />
drill pipe finished with a life-extending antiwear<br />
coating un<strong>de</strong>r an MoU signed by the<br />
companies. With the help of the Alcoa Technical<br />
Centre, the parties intend to pursue the<br />
potential application of a nanotechnologybased<br />
coating for the aluminium drill pipe to<br />
enhance its wear resistance in harsh corrosive<br />
drilling environments. The nano-coating is<br />
expected to extend the life of the aluminium<br />
pipe by 30-40% in aggressive and corrosive<br />
drilling environments compared to uncoated<br />
On the move<br />
Alba’s board has appointed Ali Al-Baqali CFO<br />
with immediate effect. Amin Sultan is the<br />
company’s new power station director. Khalid<br />
A. Latif has been appointed the new engineering<br />
manager at Alba.<br />
Glencore Xstrata has appointed three new<br />
directors to its board with immediate effect:<br />
John Mack and Peter Grauer have been appointed<br />
in<strong>de</strong>pen<strong>de</strong>nt non-executive directors,<br />
while Peter Coates has been appointed an<br />
executive director.<br />
The London Metal Exchange has appointed<br />
Robin Paine chief technology officer. He<br />
will report to the LME chief operating officer,<br />
Diarmuid O’Hegarty.<br />
Marc Rich, the commodities tra<strong>de</strong>r who<br />
foun<strong>de</strong>d Glencore and is accredited with<br />
inventing the spot market for oil, has died<br />
aged 78 after suffering a stroke at a hospital<br />
in Lucerne.<br />
Abdulla J M Kalban, presi<strong>de</strong>nt and CEO of<br />
Dubal, received an Institute of Directors (IOD)<br />
Distinguished Fellowship Award in recognition<br />
of his contribution to transforming Dubal into<br />
a global giant and a benchmark organisation<br />
for comparison all over the world.<br />
Vedanta has appointed Deepak Parekh<br />
an in<strong>de</strong>pen<strong>de</strong>nt non-executive director on its<br />
board.<br />
aluminium pipe.<br />
With facilities in Samara and Belaya Kalitva,<br />
Alcoa is Russia’s largest producer of<br />
fabricated aluminium, manufacturing a wi<strong>de</strong><br />
range of flat rolled products, forgings and extrusions<br />
for a variety of end markets including<br />
aerospace and automotive. Un<strong>de</strong>r terms of<br />
the MoU, Alcoa will leverage its Samara facility<br />
to produce aluminium drill pipe with<br />
hot fit tool joints for the country’s oil and<br />
gas market. Rusnano Capital, a subsidiary of<br />
OJSC Rusnano, will contribute capital.<br />
Midas wins major contract from<br />
CNR Changchun Railway Vehicles<br />
Jilin Midas <strong>Alu</strong>minium Industries Co., Ltd has<br />
won an RMB44.3m (USD7.2m) contract from<br />
CNR Changchun Railway Vehicles Co., Ltd for<br />
Changchun Metro Lines 1 and 2. Jilin Midas<br />
will supply aluminium profiles for 44 train sets<br />
(one set corresponds to six train cars) from<br />
2013 to 2015.<br />
Jilin Midas is a subsidiary of Midas Holding<br />
Ltd, which was foun<strong>de</strong>d in 2000. Midas<br />
is the leading manufacturer of aluminium alloy<br />
extrusion products for the passenger rail<br />
transportation sector in China. Over the years,<br />
the company has built an established track<br />
record in supplying to the PRC passenger<br />
rail transportation sector, which inclu<strong>de</strong>s participation<br />
in landmark contracts such as trains<br />
for the Beijing-Tianjin High Speed Train<br />
Project. Midas’ customers inclu<strong>de</strong> domestic<br />
PRC licensed train manufacturers from China<br />
South Locomotive & Rolling Stock Corp. Ltd<br />
and China CNR Corp. Ltd as well as international<br />
customers such as Alstom Transport,<br />
Siemens AG and Bombardier Transportation.<br />
Logan <strong>Alu</strong>minum rewar<strong>de</strong>d<br />
for energy efficiency efforts<br />
Logan <strong>Alu</strong>minum in Russellville, Kentucky,<br />
is saving electricity and money on its power<br />
bills at its production facility through energy<br />
efficiency efforts in partnership with the Tennessee<br />
Valley Authority. The manufacturer<br />
of flat rolled aluminium sheet, primarily for<br />
beverage cans, refitted its lighting systems<br />
and upgra<strong>de</strong>d equipment including pumps and<br />
air dryers through the EnergyRight Solutions<br />
for Industry Programme offered by TVA and<br />
Russellville Electric Plant Board. The projects<br />
reduced the mill’s annual power consumption<br />
by more than 2m kWh, which is enough energy<br />
to supply about 150 homes in the Russellville<br />
district for a year. The energy savings<br />
also earned the company a cash incentive of<br />
USD182,400 from TVA.<br />
TVA’s EnergyRight Solutions for Industry<br />
offers 10 cents per kWh on first-year savings<br />
or 70% of project cost, whichever is less, to<br />
programme participants for approved energy<br />
efficiency projects. “Energy efficiency helps<br />
keep rates low, reduces costs associated with<br />
meeting consumer <strong>de</strong>mand, conserves natural<br />
resources and produces zero emissions,” said<br />
Brent Powell, one of the managers of the TVA<br />
energy savings programme in Kentucky.<br />
ThyssenKrupp Aerospace<br />
expands aluminium business<br />
ThyssenKrupp Aerospace continues to expand<br />
its business. The German division of Thyssen-<br />
Krupp Materials CA Ltd recently opened its<br />
first facility in Tunisia. The newly constructed<br />
site at Aerospace Park Mghira commenced<br />
business in April. This inclu<strong>de</strong>s cutting block<br />
drafts from aircraft gra<strong>de</strong> aluminium plates,<br />
the exclusive distribution of metal plate and<br />
sheet as well as aluminium profiles. With an<br />
expected number of 12 employees, the facility<br />
will supply sheet metal, plate metal and<br />
aluminium profile to the regional aerospace<br />
industry, specifically to customers Aerolia<br />
Tunesia, Figeac Aero and Mecahers.<br />
ThyssenKrupp Aerospace has also renewed<br />
and expan<strong>de</strong>d a six-year contract with Bombardier<br />
Aerospace as the service provi<strong>de</strong>r<br />
for cut-to-size aluminium plate, sheet and<br />
extrusions and related supply chain services.<br />
Work will be performed at the existing ThyssenKrupp<br />
Aerospace facility in Baie D’Urfé<br />
Québec, Canada.<br />
Further, ThyssenKrupp Aerospace North<br />
America has entered into a three-year contract<br />
extension with Cessna Aircraft Co. to remain<br />
its service provi<strong>de</strong>r for aluminium sheet products<br />
and related supply chain services. The<br />
company will service Cessna’s facilities in<br />
Wichita, Kansas, as well as Cessna’s key subcontractors<br />
throughout the North American<br />
region. The just-in-time <strong>de</strong>liveries and valuead<strong>de</strong>d<br />
services will be supported from its existing<br />
facility in Hutchinson, Kansas. n<br />
Suppliers<br />
LOI wins or<strong>de</strong>r for coil annealing<br />
line by Ma’a<strong>de</strong>n-Alcoa<br />
Tenova LOI Thermprocess has been awar<strong>de</strong>d<br />
a contract for the installation of a heat treat-<br />
70 ALUMINIUM · 7-8/2013
COMPANY NEWS WORLDWIDE<br />
© Tenova LOI Thermprocess<br />
ment line for aluminium strip coils for the<br />
Ma’a<strong>de</strong>n-Alcoa facility in Saudi-Arabia. The<br />
line consists of single-coil lifting hearth furnaces<br />
which allow the individual heat treatment<br />
of coils. The installation is scheduled for<br />
2013.<br />
This heat treatment line allows adapted<br />
heat treatment according to the specific needs<br />
of the individual strip within short time, instead<br />
of heat treatment in a batch of several<br />
coils, which would require an average heat<br />
treatment or the combination of a batch of<br />
i<strong>de</strong>ntical strip coils. The heat treatment and<br />
cooling can be processed in protective atmosphere.<br />
The system works fully automatically<br />
from taking the coil out of the storage area<br />
until the heat treated coil is placed into the<br />
storage area again.<br />
The <strong>special</strong> plant and furnace <strong>de</strong>sign has<br />
been invented in 1998 by LOI Thermprocess<br />
and has been installed first at Alcan Singen,<br />
Germany. To date LOI has installed more than<br />
fifty units.<br />
Seco/Warwick Allied supplies<br />
soaking pit furnaces to Hindalco<br />
Seco/Warwick Allied has recently installed<br />
seven soaking pit furnaces at Hindalco Industries<br />
in Hirakud in eastern India. The furnaces<br />
feature si<strong>de</strong>-mounted fans, which improve<br />
maintenance access, and a combination of fan<br />
and heater arrangements to produce separate<br />
control zones along the vertical length of the<br />
slabs as well as a patented adjustable baffle<br />
<strong>de</strong>sign. The furnaces are <strong>de</strong>signed for vertical<br />
loa<strong>de</strong>d slabs to process can body stock.<br />
Each furnace is <strong>de</strong>signed for a maximum load<br />
of 128 tonnes. The overall charge height is<br />
five metres maximum and 3.5 metres minimum<br />
from eight to 16 slabs per batch. An<br />
adjustable baffle has been provi<strong>de</strong>d for<br />
proper air circulation in the event shorter slab<br />
heights are loa<strong>de</strong>d. The furnace is <strong>de</strong>signed<br />
for electrical heating with individual self-propelled<br />
lid (cover) trolley mechanism, and is<br />
equipped with PLC-based control and monitoring<br />
system.<br />
New Otto Junker induction heater<br />
for Hydro <strong>Alu</strong>minium Nenzing<br />
Otto Junker has received an or<strong>de</strong>r from Hydro<br />
<strong>Alu</strong>minium Nenzing for another induction-type<br />
heater including log storage and log<br />
handling equipment. More than 30 years ago,<br />
Otto Junker supplied one of the world’s first<br />
induction-type aluminium log heaters with a<br />
downstream hot shear to Hydro’s Nenzing<br />
works. In 2007, this system was upgra<strong>de</strong>d to<br />
3,600 kW by adding an Otto Junker-supplied<br />
IGBT converter system; as a result, it now attains<br />
a throughput of nearly 80 billets per hour.<br />
The consistently positive experience gathered<br />
with this plant prompted Hydro <strong>Alu</strong>minium<br />
Nenzing to opt for an Otto Junker furnace<br />
system of nearly i<strong>de</strong>ntical <strong>de</strong>sign when a new<br />
investment <strong>de</strong>cision came up.<br />
The system comprises a feed table with<br />
chain conveyor, a vertical log magazine for<br />
up to 60 logs, a feed conveyor, and an induction<br />
furnace measuring around five metres<br />
in length in which the logs are heated to a <strong>de</strong>sired<br />
temperature profile before being cut to<br />
length in the existing hot shear prior to entering<br />
the press.<br />
Logs are <strong>de</strong>livered to the chain-type log<br />
magazine by forklift truck and are stored and<br />
managed according to alloy type. On the feed<br />
conveyor, the length of each log is accurately<br />
measured for the required ‘odd end’ optimisation<br />
process. Heating is carried out in a multilayer<br />
low-loss induction coil which, like in<br />
the existing heater, consists of six individually<br />
controlled coil sections.<br />
The billet heating operation relies on an<br />
IGBT converter system <strong>de</strong>veloped by Otto<br />
Junker. This converter system is based on<br />
transistor technology and offers the advantage<br />
of steplessly adjustable power control in addition<br />
to high efficiency and low maintenance<br />
needs. Designed by Otto Junker around ten<br />
years ago, the technology has since proven its<br />
merits in over 170 billet heating and induction<br />
melting furnace applications.<br />
Mechatherm mo<strong>de</strong>rnises<br />
Dubal’s casting pit DC1<br />
Mechatherm had been awar<strong>de</strong>d an or<strong>de</strong>r to<br />
completely rebuild Dubal’s casting pit DC1.<br />
The contract involved significant mechanical,<br />
hydraulic, electrical and combustion work to<br />
three furnaces and to a vertical aluminium billet<br />
casting machine. It required consi<strong>de</strong>rable<br />
<strong>de</strong>molition followed by civil work organised<br />
by Dubal. Only then could the new equipment<br />
be installed and commissioned with a complete<br />
new Mechatherm software automation<br />
system. Work was projected to take twelve<br />
weeks, during which the casting pit would be<br />
shut down completely, with no production.<br />
Due to the excellent collaboration with Dubal<br />
engineers, Mechatherm and its sub-contractors<br />
managed to complete the work and get<br />
the pit into production in less than eight weeks.<br />
Thus Dubal could cast over 5,000 tonnes of<br />
extrusion billet above their predicted output.<br />
Rusal begins installing hot bath<br />
crushing equipment from Outotec<br />
Rusal has begun the installation of hot bath<br />
crushing equipment at its Boguchany aluminium<br />
smelter in the Krasnoyarsk region of<br />
Russia. This fully automated equipment, supplied<br />
by German company Outotec, processes<br />
crushed hot bath to the required fraction of<br />
any size. It will cost €5.1m (USD6.7m).<br />
The line is one of the most advanced on the<br />
market and will be used for the first time in<br />
Russia. It has a capacity of 40 tph, which will<br />
ALUMINIUM · 7-8/2013 71
PATENTE<br />
meet the smelter’s needs, and is equipped with<br />
mo<strong>de</strong>rn suction systems, aimed at providing<br />
dust control at every step of the process. The<br />
installation is supervised by representatives<br />
from the Russian office of Outotec.<br />
Siemens acquires <strong>special</strong>ist in<br />
rolling mill repair and refurbishing<br />
Siemens Industry, Inc. has completed the<br />
acquisition of Service Gui<strong>de</strong>, an Ohio-based<br />
company that has provi<strong>de</strong>d repair and refurbishing<br />
services for steel and aluminium mills<br />
since 1964. The agreement inclu<strong>de</strong>s three of<br />
the company’s four local operating facilities<br />
in Warren and Cortland, Ohio. The fourth<br />
facility, Oakes Foundry, will continue to be<br />
owned by the Oakes Family Trust.<br />
The acquired facilities provi<strong>de</strong> the rolling<br />
mill industry with repair and refurbishing<br />
services as well as the manufacture and sale<br />
of spare parts and components. Service Gui<strong>de</strong><br />
customers are based in the US, Canada and<br />
Mexico. Headquartered in Cortland, Ohio,<br />
the company will be fully integrated into the<br />
Metals Technologies business unit and Customer<br />
Services division of the Siemens Industry<br />
Sector. The acquired facilities will continue<br />
to operate from their current locations, and<br />
around 110 employees have joined the Siemens<br />
business structure.<br />
HPI sets up a horizontal continuous<br />
casting plant in Shanghai<br />
High Performance Industrietechnik (HIP),<br />
51% SAG owned, has <strong>de</strong>veloped a horizontal<br />
continuous casting plant for Kobe Steel,<br />
a Japanese metal and machinery equipment<br />
manufacturer and supplier to the car industry.<br />
The equipment, which will be assembled and<br />
commissioned in China, has been <strong>de</strong>signed to<br />
produce aluminium forging billets for the automotive<br />
industry. The billets can range from<br />
a diameter of 60 to 100 mm and a length of<br />
2,700 to 3,500 mm, produced in a simultaneous<br />
casting operation of a maximum of 16 parallel<br />
strands. The forging will be done in succeeding<br />
steps in excenter presses of some 8,000<br />
tonnes and more pressing strength capacity.<br />
SAG Engineering was commissioned to<br />
supply the entire control system and is also<br />
responsible for the complete <strong>de</strong>sign of electrical<br />
functions including the programming of<br />
the memory programmed controls, the servo<br />
systems and all control panels. The base for<br />
this is a high performance CPU with electrical<br />
servo motor systems for eight integrated servo<br />
motor axles.<br />
Already in 2000 HPI have proved its expertise<br />
in die technology and received the or<strong>de</strong>r<br />
for the construction for the first plant in Daian,<br />
Japan. For the time being Kobe Steel operates<br />
HPI plants in Japan, USA and China. n<br />
Patentblatt Mai 2013<br />
Verschmolzene Körner aus Oxi<strong>de</strong>n mit Al, Ti,<br />
Mg und Zr sowie Keramikprodukte mit <strong>de</strong>rartigen<br />
Körnern. Saint-Gobain Centre <strong>de</strong> Recherches<br />
et d‘Etu<strong>de</strong>s Européen, Courbevoie, FR.<br />
(C04B 35/478, EP 2 303 796, WO 2010/001065,<br />
AT: 02.07.2009, EP-AT: 02.07.2009, WO-AT:<br />
02.07.2009)<br />
<strong>Alu</strong>minium-Kupfer-Terminal und Verfahren zur<br />
Herstellung <strong>de</strong>sselben. Weitkowitz Kabelschuhe<br />
und Werkzeuge GmbH, 31224 Peine, DE. (H01R<br />
4/62, EPA 2579390, EP-AT: 05.10.2011, WO-AT:<br />
05.10.2011)<br />
Verbundbauteil aus Kunststoff und einer <strong>Alu</strong>miniumlegierung<br />
sowie Verfahren zur Herstellung.<br />
(B32B 157088, EPA 2572876, EP-AT:<br />
07.12.2006, WO-AT: 07.12.2006)<br />
Verfahren und System zur Herstellung einer<br />
Al-Si-Legierung. Dow Corning Corp., Midland,<br />
Michigan 48686-0994, US; Dow Corning Silício<br />
do Brasil Indústria e Comércio Ltda., Santos Dumont<br />
- MG, 36240.000, BR. (C22C 21/02, EPA<br />
2572010, WO 2011/146814, EP-AT: 20.05.2011,<br />
WO-AT: 20.05.2011)<br />
Al-Cu-Li-Legierung für niedrigeres Oberflächenelement.<br />
Constellium France, 75008 Paris, FR.<br />
(C22C 21/00, EPA 2569456, WO 2011/141647,<br />
EP-AT: 11.05.2011, WO-AT: 11.05.2011)<br />
Funktionsverfahren einer Wärmeausrüstung,<br />
die von Komponenten auf <strong>Alu</strong>minium- und<br />
Titanbasis versorgt wird, um das Rosten und<br />
die Verschmutzung bei hohen Temperaturen<br />
zu reduzieren. GE Energy Products France SNC,<br />
Belfort, FR. (C10L 1/12, EP 2 316 911, AT:<br />
08.09.2009, EP-AT: 08.09.2009)<br />
Verfahren zur Herstellung eines alkaliresistenten<br />
Erdalkali-<strong>Alu</strong>minium-Wärmedämmstoffs,<br />
dieser selbst und seine Verwendung. Calsitherm<br />
Verwaltungs- GmbH, 33175 Bad Lippspringe,<br />
DE. (C04B 40/02, PS 10 2009 055 723,<br />
AT: 26.11.2009)<br />
Eine <strong>Alu</strong>miniumgrundplatte mit einer Wärmeableitschicht.<br />
Ruiyun Optoelectronics Light Technology<br />
Ltd., Ningbo, Zhejiang, CN. (F21V 29/00,<br />
OS 10 2011 054 944, AT: 31.10.2011)<br />
Verfahren zur Herstellung von dünnwandigen<br />
rotationssymmetrischen Bauteilen aus <strong>Alu</strong>minium<br />
o<strong>de</strong>r <strong>Alu</strong>miniumlegierung. Magna BDW<br />
technologies GmbH, 85570 Markt Schwaben, DE.<br />
(B23P 13/00, PS 10 2011 056 942, AT: 22.12.<br />
2011)<br />
Elektrolysezelle, insb. zur Herstellung von <strong>Alu</strong>minium,<br />
mit einer wannenförmigen Katho<strong>de</strong>.<br />
SGL Carbon SE, 65201 Wiesba<strong>de</strong>n, DE. (C25C<br />
3/08, OS 10 2011 086 040, AT: 09.11.2011)<br />
Herstellung eines hochfesten <strong>Alu</strong>minium-<br />
Schaumkörpers und entsprechen<strong>de</strong>r Schaumkörper.<br />
Daimler AG, 70327 Stuttgart, DE. (C22C<br />
1/08, OS 10 2011 118 295, AT: 10.11.2011)<br />
<strong>Alu</strong>minium-Titan-Bauteil. ThyssenKrupp VDM<br />
GmbH, 58791 Werdohl, DE. (F16S 3/02, GM 20<br />
2010 017 720, AT: 01.03.2010)<br />
Min<strong>de</strong>stens zwei abwechseln<strong>de</strong> Modi, die jeweils<br />
eine Vorschubsgeschwindigkeit aufweisen,<br />
verwen<strong>de</strong>n<strong>de</strong>s gepulstes Reibrührschweißverfahren,<br />
wobei sich die mittleren Vorschubs-<br />
Geschwindigkeiten <strong>de</strong>utlich unterschei<strong>de</strong>n.<br />
Constellium France, Paris, FR. (B23K 20/12, EP 2<br />
318 173, WO 2010/004109, AT: 16.06.2009, EP-<br />
AT: 16.06.2009, WO-AT: 16.06.2009)<br />
<strong>Alu</strong>minium-Naphthalindicarboxylat als poröses<br />
metallorganisches Gerüstmaterial. BASF SE,<br />
67063 Ludwigshafen, DE. (B01J 35/00, PS 50<br />
2007 009 833, EP 2089153, WO 2008/052916,<br />
AT: 24.10.2007, EP-AT: 24.10.2007, WO-AT:<br />
24.10.2007)<br />
Verfahren zum Ätzen von <strong>Alu</strong>minium und<br />
Vorrichtung dazu. Lorin Industries, Inc., Muskegon,<br />
Mich., US. (C23G 1/22, EP 1 227 174, AT:<br />
20.12.2001, EP-AT: 20.12.2001)<br />
Vorrichtung und Verfahren zur Begrenzung <strong>de</strong>r<br />
beim Kühlen von <strong>Alu</strong>minium- o<strong>de</strong>r Stahlblechen<br />
unter Gasströmung auftreten<strong>de</strong>n Bandvibrationen.<br />
Cockerill Maintenance & Ingéniérie<br />
S.A., Seraing, BE. (F27B 9/12, EP 1 655 383, AT:<br />
11.10.2005, EP-AT: 11.10.2005)<br />
ALUMINIUM veröffentlicht unter dieser Rubrik<br />
regelmäßig einen Überblick über wichtige,<br />
<strong>de</strong>n Werkstoff <strong>Alu</strong>minium betreffen<strong>de</strong> Patente.<br />
Die ausführlichen Patentblätter und auch<br />
weiterführen<strong>de</strong> Informationen dazu stehen<br />
<strong>de</strong>r Redaktion nicht zur Verfügung. Interessenten<br />
können diese beziehen o<strong>de</strong>r einsehen<br />
bei <strong>de</strong>r<br />
Mittel<strong>de</strong>utschen Informations-, Patent-,<br />
Online-Service GmbH (mipo),<br />
Julius-Ebeling-Str. 6,<br />
D-06112 Halle an <strong>de</strong>r Saale,<br />
Tel. 0345/29398-0<br />
Fax 0345/29398-40,<br />
www.mipo.<strong>de</strong><br />
Die Gesellschaft bietet darüber hinaus weitere<br />
Patent-Dienstleistungen an.<br />
72 ALUMINIUM · 7-8/2013
PATENTE<br />
Plättchenförmiges <strong>Alu</strong>miniumpigment auf<br />
plättchenförmigem <strong>Alu</strong>minium als Substrat,<br />
Herstellungsverfahren und darauf basieren<strong>de</strong><br />
Farbe. Toyo <strong>Alu</strong>minium Kabushiki Kaisha, Osakashi,<br />
Osaka, J. (C09C 1/64, PS 60 2004 037 404,<br />
EP 1647581, WO 2004/078854, AT: 16.02.2004,<br />
EP-AT: 16.02.2004, WO-AT: 16.02.2004)<br />
Herstellungsverfahren für gegossene <strong>Alu</strong>minium-Wärmesenken.<br />
Nippon Light Metal Co.<br />
Ltd., Tokio, JP. (C22C 21/02, EP 2 275 584, AT:<br />
05.04.2005, EP-AT: 05.04.2005)<br />
Elektrolysebehälter zum Erhalt von <strong>Alu</strong>minium.<br />
Carbone Savoie, Venissieux, FR. (C25C 3/08,<br />
EP 2 013 381, WO 2007/125195, AT: 25.04.2007,<br />
EP-AT: 25.04.2007, WO-AT: 25.04.2007)<br />
Verbesserung <strong>de</strong>s Abzapfens von <strong>Alu</strong>minium<br />
durch Anlegen eines gezielten elektromagnetischen<br />
Felds. Alcoa Inc., Pittsburgh, Pa., US.<br />
(C25C 3/06, EP 2 391 746, WO 2010/087916,<br />
AT: 17.12.2009, EP-AT: 17.12.2009, WO-AT:<br />
17.12.2009)<br />
Verfahren zum Herstellung eines Strukturbestandteils<br />
<strong>de</strong>r Automobil-<strong>Alu</strong>miniumlegierung,<br />
Blech <strong>de</strong>r AA7xxx-Serie. Aleris <strong>Alu</strong>minum<br />
Duffel BVBA, 2570 Duffel, BE. (B32B 15/01,<br />
EPA 2581218, EP-AT: 12.09.2012, WO-AT:<br />
12.09.2012)<br />
Mit einer feuervere<strong>de</strong>lten <strong>Alu</strong>miniumlegierung<br />
beschichtetes Stahlmaterial von hervorragen<strong>de</strong>r<br />
Schnittkanten- und Oberflächenkorrosionsfestigkeit<br />
und Korrosionsfestigkeit verarbeiteter<br />
Teile sowie Herstellungsverfahren<br />
dafür. Nippon Steel & Sumitomo Metal Corp.,<br />
Tokio 100-8071, JP. (C23C 2/12, EPA 2578719,<br />
WO 2011/152381, EP-AT: 31.05.2011, WO-AT:<br />
31.05.2011)<br />
Verfahren zur Herstellung von dünnwandigen,<br />
rotationssymmetrischen Bauteilen aus <strong>Alu</strong>minium<br />
o<strong>de</strong>r Al-Legierung. Magna BDW technologies<br />
GmbH, 85570 Markt Schwaben, DE. (B23P<br />
13/00, PS 10 2011 056 942, AT: 22.12.2011)<br />
<strong>Alu</strong>miniumlegierung und Verfahren zum Herstellen<br />
<strong>de</strong>rselben. Hyundai Motor Co., Seoul,<br />
KR; Kia Motors Corp., Seoul, KR. (C22C 21/04,<br />
OS 10 2012 106 022, AT: 05.07.2012)<br />
<strong>Alu</strong>miniumlegierung zum kontinuierlichen Gießen<br />
und Verfahren zum Herstellen <strong>de</strong>rselben.<br />
Hyundai Motor Co., Seoul, KR; Kia Motors Corp.,<br />
Seoul, KR. (C22C 21/04, OS 10 2012 211 699,<br />
AT: 05.07.2012)<br />
Schwingungsgedämpftes Präzisionsguss-Kraftfahrzeugelement<br />
aus einer <strong>Alu</strong>miniumlegierung<br />
für einen Fahrzeugantriebsstrang und<br />
Verfahren zum Herstellen <strong>de</strong>sselben. GM Global<br />
Technology Operations LLC (n.d. Ges. d. Staates<br />
Delaware), Detroit, Mich., US. (B22D 17/00, OS<br />
10 2012 220 087, AT: 05.11.2012)<br />
Verfahren zum Verbin<strong>de</strong>n von <strong>Alu</strong>miniumlegierungen.<br />
Furukawa-Sky <strong>Alu</strong>minium Corp.,<br />
Tokio 101-8970, JP. (B23K 20/00, EPA 2578345,<br />
WO 2011/152556, EP-AT: 06.06.2011, WO-AT:<br />
06.06.2011)<br />
<strong>Alu</strong>miniumlegierung. Audi AG, 85057 Ingolstadt,<br />
DE. (C22C 21/02, EP 2 088 216, AT: 23.01.2009,<br />
EP-AT: 23.01.2009)<br />
Herstellungsverfahren für einen aus einer <strong>Alu</strong>miniumlegierung<br />
gegossenen Kühlkörper mit<br />
komplexer Struktur o<strong>de</strong>r einem dünnwandigen<br />
Teilbereich mit hervorragen<strong>de</strong>r thermischer<br />
Leitfähigkeit. Nippon Light Metal Co. Ltd., Tokio,<br />
JP. (C22C 21/02, EP 2 281 909, AT: 05.04.2005,<br />
EP-AT: 05.04.2005)<br />
Verfahren und Vorrichtung zur Herstellung<br />
von Leichtmetall-Gussteilen. Audi AG, 85057<br />
Ingolstadt, DE; Belte AG, 33129 Delbrück,<br />
DE. (B22D 21/04, OS 10 2011 119 002, AT:<br />
21.11.2011)<br />
Verfahren zur Erzeugung einer schwarzen<br />
oxidkeramischen Oberflächenschicht auf einem<br />
Bauteil aus einer Leichtmetalllegierung. Verein<br />
zur För<strong>de</strong>rung von Innovationen durch Forschung,<br />
Entwicklung und Technologietransfer e.V.<br />
(Verein Innovent e.V.), 07745 Jena, DE. (C25D<br />
11/10, PS 10 2011 055 644, AT: 23.11.2011)<br />
Wärmeübertragungszusammensetzungen<br />
für Magnesium o<strong>de</strong>r Magnesiumlegierungen<br />
enthalten<strong>de</strong> Kühlsysteme. Prestone Products<br />
Corp., Danbury, Conn., US. (C23F 11/08, EP 1<br />
941 076, WO 2007/050568, AT: 25.10.2006, EP-<br />
AT: 25.10.2006, WO-AT: 25.10.2006)<br />
Magnesiumlegierung für Schmie<strong>de</strong>anwendungen.<br />
Commonwealth Scientific and Industrial<br />
Research Organisation, Campbell, Australian<br />
Capital Territory 2612, AU. (C22C 23/00, EPA<br />
2576851, WO 2011/146970, EP-AT: 24.05.2011,<br />
WO-AT: 24.05.2011)<br />
Verbundmaterial, Stranggusskomponente,<br />
Stranggussdüse, Stranggussverfahren, Gussmaterial<br />
und Material für eine Gussspule aus<br />
einer Magnesiumlegierung. Sumitomo Electric<br />
Industries, Ltd., Osaka-shi, Osaka 541-0041, JP.<br />
(B22D 11/06, EPA 2578334, WO 2011/152529,<br />
EP-AT: 03.06.2011, WO-AT: 03.06.2011)<br />
Element aus Magnesiumlegierung. Nissan Motor<br />
Co. Ltd., Yokohama, Kanagawa, JP. (C09J<br />
5/02, EP 2 281 858, AT: 14.06.2010, EP-AT:<br />
14.06.2010)<br />
Schutz von Magnesiumlegierungen durch <strong>Alu</strong>miniumplattierung<br />
aus ionischen Flüssigkeiten.<br />
Sikorsky Aircraft Corp., Stratford, CT 06615, US.<br />
(C25D 3/44, EPA 2573214, EP-AT: 21.09.2012,<br />
WO-AT: 21.09.2012)<br />
Magnesiumlegierung für die Wasserstoffspeicherung.<br />
Hydrexia Pty Ltd, St Lucia, Queensland,<br />
AU. (C22C 23/00, PS 60 2005 033 777, EP<br />
1838887, WO 2006/060851, AT: 02.12.2005, EP-<br />
AT: 02.12.2005, WO-AT: 02.12.2005)<br />
Schutzschicht für eine aluminiumhaltige Legierung<br />
für <strong>de</strong>n Einsatz bei hohen Temperaturen<br />
sowie Verfahren zur Herstellung einer solchen<br />
Schutzschicht. Forschungszentrum Jülich GmbH,<br />
52428 Jülich, DE. (C23C 8/02, PS 50 2004 013 461,<br />
EP 1706518, WO 2005/071132, AT: 20.11.2004,<br />
EP-AT: 20.11.2004, WO-AT: 20.11.2004)<br />
Schweißbare, korrosionsbeständige Al-Mg-<br />
Legierungen, insb. für die Verkehrstechnik.<br />
EADS Deutschland GmbH, 85521 Ottobrunn,<br />
DE. (C22C 1/00, OS 599 07 283, EP 1027466,<br />
WO 2000/011229, AT: 14.08.1999, EP-AT:<br />
14.08.1999, WO-AT: 14.08.1999)<br />
Halteeinrichtung für Tür- o<strong>de</strong>r Fensterflügel.<br />
Alcoa <strong>Alu</strong>minium Deutschland, Inc., 58642 Iserlohn,<br />
DE. (E05D 15/26, EP 2 578 786, EP-AT:<br />
01.10.2012, WO-AT: 01.10.2012)<br />
Flügelpfosten für <strong>de</strong>n Mittelschlussbereich<br />
eines verschiebbaren Flügels. Alcoa <strong>Alu</strong>minium<br />
Deutschland, Inc., 58642 Iserlohn, DE. (E06B<br />
3/263, EPA 2578789, EP-AT: 01.10.2012, WO-<br />
AT: 01.10.2012)<br />
Verfahren zum Herstellen einer Profilanordnung<br />
und <strong>de</strong>ren Verwendung. Alcoa <strong>Alu</strong>minium<br />
Deutschland, Inc., 58642 Iserlohn, DE. (E06B<br />
3/263, PS 50 2010 000 844, EP 2360341, AT:<br />
10.02.201, EP-AT: 10.02.2010)<br />
Reflektor mit resistenter Oberfläche. Alanod<br />
<strong>Alu</strong>minium-Veredlung GmbH & Co. KG, 58256<br />
Ennepetal, DE; Constellium Switzerland AG,<br />
Zürich, CH. (F21V 7/22, OS 598 09 364, EPA<br />
1129318, WO 2000/029784, AT: 12.11.1998,<br />
EP-AT: 12.11.1998, WO-AT: 12.11.1998)<br />
Verfahren zur Verbindung einer <strong>Alu</strong>miniumlegierungslamelle<br />
an ein Stahlrohr und daraus<br />
hergestellter Wärmetauscher. Aleris <strong>Alu</strong>minum<br />
Koblenz GmbH, 56070 Koblenz, DE. (B32B<br />
15/01, EPA 2574453, EP-AT: 30.09.2011, WO-<br />
AT: 30.09.2011)<br />
Kühlkörper und Verfahren zur Herstellung<br />
<strong>de</strong>sselben. Aleris <strong>Alu</strong>minum Vogt GmbH, 88267<br />
Vogt, DE. (H01L 23/36, PS 101 57 240, AT:<br />
22.11.2001)<br />
Profilschiene. Aleris Vogt GmbH, 88267 Vogt,<br />
DE. (E06B 3/30, GM 20 2007 006 536, AT:<br />
04.05.2007)<br />
Plattiertes Blechprodukt. Aleris <strong>Alu</strong>minum Duffel<br />
BVBA, Duffel, BE. (B32B 15/01, GM 20 2007<br />
018 795, AT: 19.04.2007)<br />
Stützprofil sowie ein damit versehenes Stützsystem.<br />
Aleris <strong>Alu</strong>minum Vogt GmbH, 88267<br />
Vogt, DE. (E04F 13/21, GM 20 2010 004 465,<br />
AT: 01.04.2010)<br />
Feststellvorrichtung eines Öffnungselements<br />
eines Bauelements, das über Hilfsmittel zum<br />
Verriegeln und Entriegeln <strong>de</strong>s Öffnungselements<br />
verfügt. Norsk Hydro ASA, 0240<br />
Oslo, NO. (E05B 47/00, EPA 2578778, EP-AT:<br />
05.10.2012, WO-AT: 05.10.2012)<br />
<strong>Alu</strong>miniumverbundwerkstoff mit AlMgSi-<br />
Kernlegierungsschicht. Hydro <strong>Alu</strong>minium Rolled<br />
Products GmbH, 41515 Grevenbroich, DE.<br />
(B32B 15/01, EPA 2570257, EP-AT: 15.09.2011,<br />
WO-AT: 15.09.2011)<br />
Walze mit Kühlsystem. Hydro <strong>Alu</strong>minium Rolled<br />
Products GmbH, 41515 Grevenbroich. (B22D<br />
11/06, OS 10 2011 055 066, AT: 04.11.2011) ➝<br />
ALUMINIUM · 7-8/2013 73
PATENTE<br />
Verfahren zur Herstellung eines Hohlprofilverbunds.<br />
Hydro <strong>Alu</strong>minium Deutschland GmbH,<br />
41515 Grevenbroich, DE. (B29C 69/00, OS 10<br />
2005 052 612, AT: 02.11.2005)<br />
Verfahren zur Herstellung eines Absorberblechs<br />
für Sonnenkollektoren. Hydro <strong>Alu</strong>minium<br />
Deutschland GmbH, 41515 Grevenbroich,<br />
DE. (B05D 7/14, OS 10 2006 039 804, AT:<br />
25.08.2006)<br />
Verfahren und Vorrichtung zum Erzeugen einer<br />
Konversionsschicht. Hydro <strong>Alu</strong>minium Deutschland<br />
GmbH, 41515 Grevenbroich, DE. (C23C<br />
22/76, OS 10 2007 052 770, AT: 02.11.2007)<br />
Verfahren zur Herstellung eines Ban<strong>de</strong>s für Verpackungszwecke.<br />
Hydro <strong>Alu</strong>minium Deutschland<br />
GmbH, 41515 Grevenbroich, DE. (B21B<br />
15/00, OS 10 2008 019 768, AT: 18.04.2008)<br />
Vorrichtung und Verfahren zur Herstellung einer<br />
Metallfolie. Hydro <strong>Alu</strong>minium Deutschland<br />
GmbH, 41515 Grevenbroich, DE. (B21B 1/40, OS<br />
10 2008 037 520, AT: 06.11.2008)<br />
Verfahren zum Herstellen einer Metallfolie und<br />
entsprechend hergestellte Metallfolie. Hydro<br />
<strong>Alu</strong>minium Deutschland GmbH, 41515 Grevenbroich,<br />
DE. (B21B 1/40, OS 10 2008 037 619, AT:<br />
01.12.2008)<br />
Lötverfahren für Wärmetauscher und Solarkollektoren.<br />
Hydro <strong>Alu</strong>minium Deutschland GmbH,<br />
41515 Grevenbroich, DE. (B23K 1/005, OS 10<br />
2009 043 985, AT: 11.09.2009)<br />
Verfahren zur Herstellung von Konvektorblechen<br />
für Heizkörper. Caradon Stelrad B.V.,<br />
Herentals, BE; Hydro <strong>Alu</strong>minium Deutschland<br />
GmbH, 41515 Grevenbroich, DE. (B21D 53/04,<br />
OS 10 2009 059 283, AT: 22.12.2009)<br />
Verfahren zur Herstellung eines Architekturblechelements.<br />
Hydro <strong>Alu</strong>minium Deutschland<br />
GmbH, 41515 Grevenbroich, DE. (B05D 1/30,<br />
OS 10 2010 000 449, AT: 17.02.2010)<br />
Beschlag. Norsk Hydro ASA, Oslo, NO. (E05C<br />
9/18, OS 10 2011 055 037, AT: 04.11.2011)<br />
Lithoband und Verfahren zu seiner Herstellung.<br />
Hydro <strong>Alu</strong>minium Deutschland GmbH,<br />
41515 Grevenbroich, DE. (C22C 21/06, OS 199<br />
56 692, AT: 25.11.1999)<br />
Verfahren zur Herstellung eines walzplattierten,<br />
hochglänzen<strong>de</strong>n <strong>Alu</strong>miniumban<strong>de</strong>s.<br />
Hydro <strong>Alu</strong>minium Deutschland GmbH, 41515<br />
Grevenbroich, DE. (B23B 15/00, EP 1 849 542,<br />
EP-AT: 25.04.2006)<br />
Verfahren zur Entfernung und Rückgewinnung<br />
von CO 2 aus einem Abgas. Norsk Hydro ASA,<br />
Oslo, NO. (B01D 53/62, PS 60 2005 027 893, EP<br />
1827656, WO 2006/043820, AT: 12.10.2005, EP-<br />
AT: 12.10.2005, WO-AT: 12.10.2005)<br />
Extrudierte Dicht- o<strong>de</strong>r Abschlussleiste. WKW<br />
Erbslöh Automotive GmbH, 42349 Wuppertal,<br />
DE. (B60J 10/02, GM 20 2007 004 123, AT:<br />
21.03.2007)<br />
Verfahren zur Konditionierung <strong>de</strong>r Oberfläche<br />
eines Lithobands. Hydro <strong>Alu</strong>minium Rolled<br />
Products GmbH, 41515 Grevenbroich, DE.<br />
(B41N 1/08, PS 60 2007 021 896, EP 2024190,<br />
WO 2007/141300, AT: 06.06.2007, EP-AT:<br />
06.06.2007, WO-AT: 06.06.2007)<br />
Bauteil aus <strong>Alu</strong>miniummaterial mit einer partiellen<br />
o<strong>de</strong>r vollständigen Beschichtung <strong>de</strong>r<br />
Oberflächen für die Hartverlötung. Erbslöh <strong>Alu</strong>minium<br />
GmbH, 42553 Velbert, DE. (C23C 4/12,<br />
GM 20 2005 004 807, AT: 22.03.2005)<br />
Dachträgeranordnung. WKW Erbslöh Automotive<br />
GmbH, 42349 Wuppertal, DE. (B60R 9/04,<br />
GM 20 2007 001 742, AT: 07.02.2007)<br />
Dekoratives Bauteil. WKW Erbslöh Automotive<br />
GmbH, 42349 Wuppertal, DE. (B60R 13/04, GM<br />
20 2007 002 233, AT: 12.02.2007)<br />
Vorrichtung zum Halten und/o<strong>de</strong>r Kontaktieren<br />
eines zu behan<strong>de</strong>ln<strong>de</strong>n Substrates. WKW<br />
Erbslöh Automotive GmbH, 42349 Wuppertal,<br />
DE. (C25D 17/06, GM 20 2007 004 024, AT:<br />
20.03.2007)<br />
Toleranzausgleichseinrichtung. WKW Erbslöh<br />
Automotive GmbH, 42349 Wuppertal, DE. (F16B<br />
5/02, GM 20 2010 002 447, AT: 17.02.2010)<br />
Sicherungselement für Fenster o<strong>de</strong>r Tür. Gutmann<br />
AG, 91781 Weißenburg, DE. (E06B 5/11,<br />
GM 20 2011 109 477, AT: 23.12.2011)<br />
Kolben und Verfahren zu seiner Herstellung.<br />
KS Kolbenschmidt GmbH, 74172 Neckarsulm,<br />
DE. (B23B 5/24, OS 10 2011 085 434, AT:<br />
28.10.2011)<br />
Kolben und Verfahren zu seiner Kühlung.<br />
KS Kolbenschmidt GmbH, 74172 Neckarsulm,<br />
DE. (F02F 3/18, OS 10 2011 085 444, AT:<br />
28.10.2011)<br />
Zylindrische Lauffläche sowie Verfahren zur<br />
Herstellung einer zylindrischen Lauffläche. KS<br />
<strong>Alu</strong>minium-Technologie GmbH, 74172 Neckarsulm,<br />
DE. (F02F 1/00, EP 2 112 359, AT:<br />
15.01.2002, EP-AT: 15.01.2002)<br />
Kolben für einen Verbrennungsmotor. Mahle<br />
International GmbH, 70376 Stuttgart, DE. (F02F<br />
3/00, OS 10 2006 013 905, AT: 25.03.2006)<br />
sowie (F02F 3/22, OS 10 2011 119 525, AT:<br />
26.11.2011)<br />
Kolben. Mahle International GmbH, 70376 Stuttgart,<br />
DE. (F02F 3/00, OS 10 2011 085 254, AT:<br />
26.10.2011) sowie (F02F 3/10, OS 10 2012 211<br />
440, AT: 02.07.2012)<br />
Gießform für einen Kolben. Mahle International<br />
GmbH, 70376 Stuttgart, DE. (B22D 15/02, OS 10<br />
2011 086 411, AT: 15.11.2011)<br />
Verfahren zur Herstellung einer <strong>Alu</strong>miniumstruktur<br />
sowie <strong>Alu</strong>miniumstruktur. Sumitomo<br />
Electric Industries, Ltd., Chuo-ku Osaka-shi<br />
Osaka 541-0041, JP. (C25D 1/08, EPA 2570518,<br />
WO 2011/142338, EP-AT: 10.05.2011, WO-AT:<br />
10.05.2011)<br />
Kolben für einen Verbrennungsmotor und Verfahren<br />
zu seiner Herstellung. Mahle International<br />
GmbH, 70376 Stuttgart, DE. (F02F 3/22, OS<br />
10 2011 119 527, AT: 26.11.2011)<br />
Gebauter, flüssigkeitsgekühlter Kolben. Mahle<br />
International GmbH, 70376 Stuttgart, DE.<br />
(F02F 3/00, EP 1 922 478, WO 2007/028364,<br />
AT: 02.09.2006, EP-AT: 02.09.2006, WO-AT:<br />
02.09.2006)<br />
Herstellverfahren für AlMgSi-<strong>Alu</strong>miniumband.<br />
Hydro <strong>Alu</strong>minium Rolled Products GmbH, 41515<br />
Grevenbroich, DE. (C22F 1/05, EPA 2570509, EP-<br />
AT: 15.09.2011, WO-AT: 15.09.2011)<br />
Dreidimensionales, netzartiges, poröses <strong>Alu</strong>miniummaterial.<br />
Sumitomo Electric Industries,<br />
Ltd., Chuo-ku Osaka-shi Osaka 541-0041, JP; Sumitomo<br />
Electric Toyama Co., Ltd., Imizu-shi Toyama<br />
934-0031, JP. (H01M 4/13, EPA 2579364,<br />
WO 2011/152280, EP-AT: 26.05.2011, WO-AT:<br />
26.05.2011)<br />
Verfahren zur Herstellung eines <strong>Alu</strong>miniumlegierungs-Wärmetauschers.<br />
Sumitomo Light Metal<br />
Industries, Ltd., Minato-ku Tokio 105-8601, JP.<br />
(B23K 1/00, EPA 2578344, WO 2011/148781,<br />
EP-AT: 10.05.2011, WO-AT: 10.05.2011)<br />
Patentblatt Juni 2013<br />
Herstellungsverfahren für einen mit einer<br />
<strong>Alu</strong>miniumlegierung verbun<strong>de</strong>nen Körper.<br />
Showa Denko K.K., Tokio 105-8518, JP. (C22F<br />
1/053, EPA 2592170, WO 2011/155609, EP-AT:<br />
10.06.2011, WO-AT: 10.06.2011)<br />
Al-Zn-Mg-Cu-Legierung. Aleris Rolled Products<br />
Germany GmbH, 56070 Koblenz, DE. (C22C<br />
21/10, OS 11 2004 003 147 u. OS 11 2004 000<br />
603, WO 2004/090185, AT: 09.04.2004, WO-AT:<br />
09.04.2004)<br />
Wasserreaktives, Al-basiertes Verbundsmaterial;<br />
wasserreaktiver, Al-basierter, thermisch<br />
gespritzter Film; Verfahren für die Herstellung<br />
eines solchen Al-basierten, thermisch gespritzten<br />
Films und Bestandteil für eine Filmbildungskammer.<br />
Ulvac, Inc., Chigasaki-shi, Kanagawa, JP.<br />
(C23C 4/06, WO 2012 026349, AT: 12.08.2011,<br />
WO-AT: 12.08.2011)<br />
Al-Cu-Li Legierungsprodukt, welches für eine<br />
Luftfahrzeuganwendung geeignet ist. Aleris<br />
Rolled Products Germany GmbH, 56070 Koblenz,<br />
DE. (C22C 21/12, GM 20 2008 018 370, AT:<br />
16.09.2008)<br />
Zn-Al-Mg-Si-legiertes und geplättetes (plattiertes)<br />
Stahlprodukt mit exzellenten Anti-Korrosions-Eigenschaften.<br />
Nippon Steel & Sumikin<br />
Coated Sheet Corp., Tokyo, JP; Nippon Steel &<br />
Sumitomo Metal Corp., Tokyo, Chiyoda-ku, JP.<br />
(C23C 2/12, OS 600 45 924, EPA 1225246,<br />
WO 2001/011100, AT: 09.08.2000, EP-AT:<br />
09.08.2000, WO-AT: 09.08.2000)<br />
<strong>Alu</strong>miniumlegierung. Novelis Inc., Toronto, ON<br />
M8Z 1J5, CA. (C22C 21/02, EPA 2592165, EP-<br />
AT: 11.11.2011, WO-AT: 11.11.2011)<br />
74 ALUMINIUM · 7-8/2013
PATENTE<br />
Knetprodukt aus Al-Cu-Mg-Legierung für das<br />
Strukturbauteil eines Flugzeugs. Constellium<br />
France, Paris, FR. (C22C 21/12, EP 1 382 698,<br />
AT: 09.07.2003, EP-AT: 09.07.2003)<br />
Modifikation von salzhaltigen Schlacken aus<br />
<strong>de</strong>n Verfahren <strong>de</strong>r zweiten Schmelzung von<br />
<strong>Alu</strong>minium und <strong>de</strong>ren Verwendung als Adsorptionsmittel<br />
<strong>de</strong>r erhaltenen Produkte.<br />
Universidad Pública De Navarra, 31006 Pamplona<br />
(Navarra), ES. (B01J 20/08, EPA 2586525,<br />
WO 2011/161290, EP-AT: 15.06.2011, WO-AT:<br />
15.06.2011)<br />
Vorrichtung zur Entfernung von Kurzschlussblockierungen<br />
bei <strong>de</strong>r Inbetriebnahme einer<br />
Elektrolysezelle zur Herstellung von <strong>Alu</strong>minium.<br />
Rio Tinto Alcan Intl Ltd., Montréal, QC<br />
H3A 3G2, CA. (C25C 3/16, EPA 2585624, WO<br />
2012/001242, EP-AT: 23.06.2011, WO-AT:<br />
23.06.2011)<br />
Vorrichtung zur Entnahme von Kurzschlussdistanzscheiben<br />
für die Inbetriebnahme einer<br />
Elektrolysezelle zur Herstellung von <strong>Alu</strong>minium.<br />
E.C.L., 59790 Ronchin, FR; Rio Tinto Alcan<br />
Intl Ltd., Montréal, QC H3A 3G2, CA. (C25C<br />
3/16, EPA 2585625, WO 2012/001243, EP-AT:<br />
23.06.2011, WO-AT: 23.06.2011)<br />
Verfahren zur Behandlung einer Legierung aus<br />
<strong>Alu</strong>minium und Titan zur Verbesserung <strong>de</strong>r<br />
Oxidationsbeständigkeit dieser Legierungen<br />
zwischen 800 °C und 1000 °C und Verwendung<br />
<strong>de</strong>s Verfahrens. Dechema-Forschungsinstitut,<br />
60486 Frankfurt, DE. (C23C 22/34, PS 100 17<br />
187, AT: 07.04.2000)<br />
Mischungen von <strong>Alu</strong>minium-Hydrogenphosphiten<br />
mit <strong>Alu</strong>miniumsalzen, Verfahren zu<br />
ihrer Herstellung sowie ihre Verwendung.<br />
Clariant International Ltd., Muttenz, CH. (C01B<br />
25/163, OS 10 2011 120 190, AT: 05.12.2011)<br />
<strong>Alu</strong>minium-Hydrogenphosphite, ein Verfahren<br />
zu ihrer Herstellung sowie ihre Verwendung.<br />
Clariant International Ltd., Muttenz, CH. (C01B<br />
25/163, OS 10 2011 120 192, AT: 05.12.2011)<br />
Bremsscheibe aus einer <strong>Alu</strong>minium-Matrix-<br />
Verbundlegierung mit Siliziumcarbid-Partikeln<br />
und Herstellungsverfahren hierfür. Daimler AG,<br />
70327 Stuttgart, DE; TU Chemnitz, 09111 Chemnitz,<br />
DE. (C22C 21/02, OS 10 2011 121 292, AT:<br />
15.12.2011)<br />
Magnetische Separierung von Eisen aus Alo<strong>de</strong>r<br />
Mg-Legierungsschmelzen. GM Global<br />
Technology Operations LLC (n.d. Ges. d. Staates<br />
Delaware), Detroit, Mich., US. (C22B 21/00, OS<br />
10 2012 222 434, AT: 06.12.2012)<br />
Feuerlöscharmaturen aus <strong>Alu</strong>minium o<strong>de</strong>r Al-<br />
Legierung mit trinkwassertauglicher Oberflächenbeschichtung.<br />
Max Wi<strong>de</strong>nmann KG Armaturenfabrik,<br />
89537 Giengen, DE. (A62C 35/00,<br />
GM 20 2004 015 858, AT: 13.10.2004)<br />
Versiegelungsreagens für <strong>Alu</strong>miniumlegierung.<br />
BYD Co. Ltd., Shenzhen, Guangdong, CN.<br />
(C25D 11/24, EP 2 350 356, WO 2010/060358,<br />
AT: 16.11.2009, EP-AT: 16.11.2009)<br />
Teilpigmentierung einer Deckschicht zur Vermeidung<br />
von Interferenzen bei <strong>Alu</strong>miniumbauteilen<br />
o<strong>de</strong>r <strong>Alu</strong>minium aufweisen<strong>de</strong>n Bauteilen.<br />
Süd<strong>de</strong>utsche <strong>Alu</strong>minium Manufaktur GmbH,<br />
89558 Böhmenkirch, DE. (B44 1/00, PS 50 2008<br />
007 171, EP 1970214, AT: 07.03.2008, EP-AT:<br />
07.03.2008)<br />
Verfahren zur Herstellung eines Ban<strong>de</strong>s aus<br />
<strong>Alu</strong>minium für Verpackungszwecke und <strong>de</strong>rart<br />
hergestelltes Band. Hydro <strong>Alu</strong>minium Rolled<br />
Products GmbH, 41515 Grevenbroich, DE.<br />
(B21H 7/00, PS 50 2009 003 753, EP 2303489,<br />
WO 2009/127730, AT: 17.04.2009, EP-AT:<br />
17.04.2009, WO-AT: 17.04.2009)<br />
Mikro-Kanalreaktor mit Katalysator auf thermisch<br />
gewachsenem <strong>Alu</strong>minium, Verwendung<br />
<strong>de</strong>sselben sowie Katalysator und seine Herstellung.<br />
Velocys, Inc., Plain City, Ohio, US.<br />
(B01J 19/00, PS 60 2005 034 349, EP 1755777,<br />
WO 2006/036193, AT: 23.03.2005, EP-AT:<br />
23.03.2005, WO-AT: 23.03.2005)<br />
Verfahren zur Bildung einer aluminium- und<br />
zirkonhaltigen Schutzbeschichtung auf einem<br />
Metall. SNECMA, Paris, FR. (C23C 10/14, PS 60<br />
2009 007 050, EP 2260120, WO 2009/112581,<br />
AT: 13.03.2009, EP-AT: 13.03.2009, WO-AT:<br />
13.03.2009)<br />
Gießbare, wärmebeständige <strong>Alu</strong>miniumlegierung.<br />
Norsk Hydro ASA, 0240 Oslo, NO;<br />
Montupet S.A., 92112 Clichy Ce<strong>de</strong>x, FR. (C22C<br />
21/02, EPA 2582855, WO 2011/159169, EP-AT:<br />
16.06.2011, WO-AT: 16.06.2011)<br />
System und Verfahren zum Herstellen einer<br />
7xxx-Serie-<strong>Alu</strong>miniumlegierung im F-Zustand.<br />
Ford Global Technologies, LLC, Dearborn,<br />
Mich., US. (C22F 1/00, OS 10 2012 221 602, AT:<br />
27.11.2012)<br />
<strong>Alu</strong>miniumlegierung vom Typ AlZnMg und Verfahren<br />
zu <strong>de</strong>ren Herstellung. <strong>Alu</strong>minium Lend<br />
Gmbh & Co. Kg., Lend, AT. (C22C 21/10, EP 2 061<br />
912, WO 2008/028208, AT: 03.09.2007, EP-AT:<br />
03.09.2007, WO-AT: 03.09.2007)<br />
Direktschmie<strong>de</strong>n und -walzen von L12-<strong>Alu</strong>miniumlegierungen<br />
für Panzerungsanwendungen.<br />
United Technologies Corp., Hartford,<br />
Conn., US. (C22C 1/05, EP 2 253 725, AT:<br />
31.03.2010, EP-AT: 31.03.2010)<br />
Verfahren zur Abreicherung von Magnesium<br />
und Anreicherung von Lithium in chloridisch<br />
geprägten Salzlösungen. TU Bergaka<strong>de</strong>mie Freiberg,<br />
09599 Freiberg, DE; Universidad Autónoma<br />
Tomas Frias, Potosi, BO. (C01D 3/06, PS 10 2010<br />
019 554, AT: 05.05.2010)<br />
Magnesiumlegierung. AIT Austrian Institute<br />
of Technology GmbH, 1220 Wien, AT. (C22C<br />
23/04, EPA 2591132, WO 2012/003522, EP-AT:<br />
15.06.2011, WO-AT: 15.06.2011)<br />
Bauteil aus einer Magnesiumlegierung und<br />
Verfahren zu <strong>de</strong>ssen Herstellung. Hon Hai Precision<br />
Industry Co. Ltd., Tu-cheng City, Taipei<br />
Hsien, TW. (F16S 5/00, OS 10 2008 060 794, AT:<br />
05.12.2008)<br />
Verfahren zum Transport von pulverförmigen<br />
Materialien ohne Entmischung. Rio Tinto Alcan<br />
Intl Ltd., Montreal, Quebec, CA. (B65G 53/18, EP<br />
2 185 450, WO 2009/010667, AT: 26.06.2008,<br />
EP-AT: 26.06.2008, WO-AT: 26.06.2008)<br />
Mehrlagiges, lötbares Blech. Alcoa Inc., Pittsburgh,<br />
Pa., US; Kobe Steel, Ltd., Kobe, Hyogo, JP.<br />
(B32B 15/01, EP 2 015 932, WO 2007/133286,<br />
AT: 21.11.2006, EP-AT: 21.11.2006, WO-AT:<br />
21.11.2006)<br />
Gießen von Nichteisenmetallen. Alcoa Inc.,<br />
Pittsburgh, Pa., US. (B22D 11/06, EP 1 545<br />
812, WO 2004/018124, AT: 13.06.2003, EP-AT:<br />
13.06.2003, WO-AT: 13.06.2003)<br />
Profilschiene zur Abstützung einer Terrasse o.<br />
dgl. Aleris <strong>Alu</strong>minum Vogt GmbH, 88267 Vogt,<br />
DE. (E04F 15/02, GM 20 2007 010 332, AT:<br />
23.07.2007)<br />
Vorrichtung zur Abstützung eines Plattenelementes.<br />
Aleris <strong>Alu</strong>minum Vogt GmbH, 88267<br />
Vogt, DE. (E04D 13/18, GM 20 2007 010 520,<br />
AT: 28.07.2007)<br />
Hartlötblech. Aleris <strong>Alu</strong>minum Koblenz GmbH,<br />
56070 Koblenz, DE. (B32B 15/01, EP 1 183<br />
151, WO 2000/063008, AT: 12.04.2000, EP-AT:<br />
12.04.2000, WO-AT: 12.04.2000)<br />
Messung und Steuerung <strong>de</strong>r Strömung von<br />
fließfähigen Materialien. Comalco <strong>Alu</strong>minium<br />
Ltd., Brisbane, Queensland, AU; Auckland Uniservices<br />
Ltd., Auckland, NZ. (G01F 1/76, PS<br />
600 47 195, EP 1192425, WO 2000/057139,<br />
AT: 24.03.2000, EP-AT: 24.03.2000, WO-AT:<br />
24.03.2000)<br />
Profil für eine Stoßstange eines Fahrzeuges,<br />
Haltewerkzeug und Rohrprofil dafür sowie<br />
Verfahren zur Herstellung <strong>de</strong>s Profils. Constellium<br />
Switzerland AG, Zürich, CH. (B60R 19/18,<br />
PS 10 2006 062 294, AT: 27.12.2006)<br />
Walze mit Kühlsystem. Hydro <strong>Alu</strong>minium Rolled<br />
Products GmbH, 41515 Grevenbroich, DE.<br />
(B22D 11/06, EPA 2589446, EP-AT: 29.10.2012,<br />
WO-AT: 29.10.2012)<br />
Beschlag. Norsk Hydro ASA, 0240 Oslo, NO.<br />
(E06B 3/263, EPA 2589739,.EP-AT: 02.11.2012)<br />
Eloxalverfahren eines Metallprofils auf <strong>Alu</strong>miniumbasis<br />
mit Motiv und so erhaltenes Profil.<br />
Norsk Hydro ASA, 0240 Olso, NO. (C25D 11/16,<br />
EPA 2586894, EP-AT: 18.10.2012, WO-AT:<br />
18.10.2012)<br />
Verfahren zur Herstellung einer Metallbandkante.<br />
Hydro <strong>Alu</strong>minium Deutschland GmbH,<br />
51149 Köln, DE. (B23P 9/00, PS 10 2009 026<br />
235, AT: 23.07.2009)<br />
Vorrichtung zum Fügen von min<strong>de</strong>stens zwei<br />
Bauteilen aus artverschie<strong>de</strong>nen Werkstoffen.<br />
Hydro <strong>Alu</strong>minium Deutschland GmbH, 51149<br />
Köln, DE. (B23K 20/12, GM 20 2005 021 318,<br />
AT: 28.04.2005)<br />
Fortsetzung in ALUMINIUM 9/13<br />
ALUMINIUM · 7-8/2013 75
LIEFERVERZEICHNIS<br />
1<br />
Smelting technology<br />
Hüttentechnik<br />
• Auto firing systems<br />
Automatische Feuerungssysteme<br />
1.1 Raw materials<br />
Rohstoffe<br />
1.2 Storage facilities for smelting<br />
Lagermöglichkeiten in <strong>de</strong>r Hütte<br />
1.3 Ano<strong>de</strong> production<br />
Ano<strong>de</strong>nherstellung<br />
1.4 Ano<strong>de</strong> rodding<br />
Ano<strong>de</strong>nschlägerei<br />
1.4.1 Ano<strong>de</strong> baking<br />
Ano<strong>de</strong>nbrennen<br />
1.4.2 Ano<strong>de</strong> clearing<br />
Ano<strong>de</strong>nschlägerei<br />
1.2 Storage facilities for<br />
smelting<br />
Lagermöglichkeiten i.d. Hütte<br />
FLSmidth MÖLLER GmbH<br />
Ha<strong>de</strong>rslebener Straße 7<br />
D-25421 Pinneberg<br />
Telefon: 04101 788-0<br />
Telefax: 04101 788-115<br />
E-Mail: moeller@flsmidth.com<br />
Internet: www.flsmidthmoeller.com<br />
Kontakt: Herr Dipl.-Ing. Timo Letz<br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
• Bulk materials Handling<br />
from Ship to Cell<br />
Bulk materials Handling from Ship to Cell<br />
www.coperion.com<br />
mailto: info.cc-mh@coperion.com<br />
• Conveying systems bulk materials<br />
För<strong>de</strong>ranlagen für Schüttgüter<br />
(Hüttenaluminiumherstellung)<br />
FLSmidth MÖLLER GmbH<br />
Internet: www.flsmidthmoeller.com<br />
see Storage facilities for smelting 1.2<br />
1.4.3 Fixing of new ano<strong>de</strong>s to the<br />
ano<strong>de</strong>s bars<br />
Befestigen von neuen Ano<strong>de</strong>n<br />
an <strong>de</strong>r Ano<strong>de</strong>nstange<br />
1.5 Casthouse (foundry)<br />
Gießerei<br />
1.6 Casting machines<br />
Gießmaschinen<br />
1.7 Current supply<br />
Stromversorgung<br />
1.8 Electrolysis cell (pot)<br />
Elektrolyseofen<br />
1.9 Potroom<br />
Elektrolysehalle<br />
1.10 Laboratory<br />
Labor<br />
1.11 Emptying the catho<strong>de</strong> shell<br />
Ofenwannenentleeren<br />
1.12 Catho<strong>de</strong> repair shop<br />
Katho<strong>de</strong>nreparaturwerkstatt<br />
1.13 Second-hand plant<br />
Gebrauchtanlagen<br />
1.14 <strong>Alu</strong>minium alloys<br />
<strong>Alu</strong>miniumlegierungen<br />
1.15 Storage and transport<br />
Lager und Transport<br />
1.16 Smelting manufactures<br />
Hüttenerzeugnisse<br />
Paul Hedfeld GmbH<br />
Hun<strong>de</strong>icker Str. 20<br />
D-58285 Gevelsberg<br />
Phone: +49 (0) 2332 6371<br />
E-mail: verkauf@hedfeld.com<br />
Internet: www.hedfeld.com<br />
• Unloading/Loading equipment<br />
Entla<strong>de</strong>-/Bela<strong>de</strong>einrichtungen<br />
FLSmidth MÖLLER GmbH<br />
www.flsmidthmoeller.com<br />
see Storage facilities for smelting 1.2<br />
ALUMINA AND PET COKE SHIPUNLOADERS<br />
Contact: Andreas Haeuser, ha@neuero.<strong>de</strong><br />
1.3 Ano<strong>de</strong> production<br />
Ano<strong>de</strong>nherstellung<br />
Solios Carbone – France<br />
www.fivesgroup.com<br />
Storvik AS<br />
Industriveien 13<br />
6600 SUNNDALSØRA/NORWAY<br />
Tel.: +47 71 69 95 00 | Fax: +47 71 69 95 55<br />
www.storvik.no | storvik@storvik.no<br />
RIEDHAMMER<br />
CARBON BAKING TECHNOLOGY<br />
RIEDHAMMER GmbH<br />
D-90411 Nürnberg<br />
Phone: +49 (0) 911 5218 0, Fax: -5218 231<br />
E-Mail: thomas.janousch@riedhammer.<strong>de</strong><br />
Internet: www.riedhammer.<strong>de</strong><br />
• Hydraulic presses for prebaked<br />
ano<strong>de</strong>s / Hydraulische Pressen zur<br />
Herstellung von Ano<strong>de</strong>n<br />
LAEIS GmbH<br />
Am Scheerleck 7, L-6868 Wecker, Luxembourg<br />
Phone: +352 27612 0<br />
Fax: +352 27612 109<br />
E-Mail: info@laeis-gmbh.com<br />
Internet: www.laeis-gmbh.com<br />
Contact: Dr. Alfred Kaiser<br />
• Ano<strong>de</strong> Technology &<br />
Mixing Equipment<br />
Buss ChemTech AG, Switzerland<br />
Phone: +4161 825 64 62<br />
E-Mail: info@buss-ct.com<br />
Internet: www.buss-ct.com<br />
• Mixing Technology for<br />
Ano<strong>de</strong> pastes<br />
Mischtechnologie für Ano<strong>de</strong>nmassen<br />
Buss AG<br />
CH-4133 Pratteln<br />
Phone: +41 61 825 66 00<br />
E-Mail: info@busscorp.com<br />
Internet: www.busscorp.com<br />
1.4 Ano<strong>de</strong> rodding<br />
Ano<strong>de</strong>nanschlägerei<br />
• Removal of bath residues from<br />
the surface of spent ano<strong>de</strong>s<br />
Entfernen <strong>de</strong>r Badreste von <strong>de</strong>r Ober -<br />
fläche <strong>de</strong>r verbrauchten Ano<strong>de</strong>n<br />
GLAMA Maschinenbau GmbH<br />
Hornstraße 19<br />
D-45964 Gladbeck<br />
Telefon 02043 / 9738-0<br />
Telefax 02043 / 9738-50<br />
• Rodding shop<br />
www.brochot.fr<br />
76 ALUMINIUM · 7-8/2013
SUPPLIERS DIRECTORY<br />
1.4.1 Ano<strong>de</strong> baking<br />
Ano<strong>de</strong>nbrennen<br />
• Open top and closed<br />
type baking furnaces<br />
Offene und geschlossene Ringöfen<br />
RIEDHAMMER<br />
CARBON BAKING TECHNOLOGY<br />
RIEDHAMMER GmbH<br />
D-90411 Nürnberg<br />
Phone: +49 (0) 911 5218 0, Fax: -5218 231<br />
E-Mail: thomas.janousch@riedhammer.<strong>de</strong><br />
Internet: www.riedhammer.<strong>de</strong><br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
1.5 Casthouse (foundry)<br />
Gießerei<br />
Furnaces<br />
casting machines<br />
transport crucibles<br />
info@bartz-maschinenbau.<strong>de</strong><br />
www.bartz-maschinenbau.<strong>de</strong><br />
MOBILE<br />
EQUIPMENT<br />
Phone: +31.315.683941<br />
info@hencon.com · www.hencon.com<br />
HERTWICH ENGINEERING GmbH<br />
Maschinen und Industrieanlagen<br />
Weinbergerstraße 6, A-5280 Braunau am Inn<br />
Phone +437722/806-0<br />
Fax +437722/806-122<br />
E-Mail: info@hertwich.com<br />
Internet: www.hertwich.com<br />
INOTHERM INDUSTRIEOFEN-<br />
UND WÄRMETECHNIK GMBH<br />
Konstantinstraße 1a<br />
D 41238 Mönchengladbach<br />
Telefon +49 (02166) 987990<br />
Telefax +49 (02166) 987996<br />
E-Mail: info@inotherm-gmbh.<strong>de</strong><br />
Internet: www.inotherm-gmbh.<strong>de</strong><br />
see Equipment and accessories 3.1<br />
Stopinc AG<br />
Bösch 83 a<br />
CH-6331 Hünenberg<br />
Tel. +41/41-785 75 00<br />
Fax +41/41-785 75 01<br />
E-Mail: interstop@stopinc.ch<br />
Internet: www.stopinc.ch<br />
• Degassing, filtration and<br />
grain refinement<br />
Entgasung, Filtern, Kornfeinung<br />
Drache Umwelttechnik<br />
GmbH<br />
Werner-v.-Siemens-Straße 9/24-26<br />
D 65582 Diez/Lahn<br />
Telefon 06432/607-0<br />
Telefax 06432/607-52<br />
Internet: www.drache-gmbh.<strong>de</strong><br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
• Dross skimming of liquid metal<br />
Abkrätzen <strong>de</strong>s Flüssigmetalls<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
• Furnace charging with<br />
molten metal<br />
Ofenbeschickung mit Flüssigmetall<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
• Ingot Casting Line<br />
Bartz GmbH<br />
www.brochot.fr<br />
see Casthous (foundry) 1.5<br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
• Melting/holding/casting furnaces<br />
Schmelz-/Halte- und Gießöfen<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
Sistem Teknik Endüstryel Firinlar LTD. STI.<br />
TOSB – TAYSAD OSB 1.Cad. 14.Sok. No.: 3<br />
Gebze, Kocaeli / Turkey<br />
Tel.: +90 262 658 22 26<br />
Fax: +90 262 658 22 38<br />
E-Mail: info@sistemteknik.com<br />
Internet: www.sistemteknik.com<br />
Solios Thermal UK<br />
www.fivesgroup.com<br />
• Metal treatment in the<br />
holding furnace<br />
Metallbehandlung in Halteöfen<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
• Transfer to the casting furnace<br />
Überführung in Gießofen<br />
Drache Umwelttechnik<br />
GmbH<br />
Werner-v.-Siemens-Straße 9/24-26<br />
D 65582 Diez/Lahn<br />
Telefon 06432/607-0<br />
Telefax 06432/607-52<br />
Internet: www.drache-gmbh.<strong>de</strong><br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
• Transport of liquid metal<br />
to the casthouse<br />
Transport v. Flüssigmetall in Gießereien<br />
Bartz GmbH<br />
see Casthous (foundry) 1.5<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
• Treatment of casthouse<br />
off gases<br />
Behandlung <strong>de</strong>r Gießereiabgase<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
1.6 Casting machines<br />
Gießmaschinen<br />
Hampshire House, High Street, Kingswinford,<br />
West Midlands DY6 8AW, UK<br />
Tel.: +44 (0) 1384 279132<br />
Fax: +44 (0) 1384 291211<br />
E-Mail: sales@mechatherm.co.uk<br />
www.mechatherm.com<br />
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A<br />
Avenida Cervantes Nº6<br />
48970 – Basauri – Bizkaia – Spain<br />
Tel: +34 944 409 420<br />
E-mail: Insertec@insertec.biz<br />
Internet: www.insertec.biz<br />
GAPCast<br />
TM : the Swiss casting solution<br />
see Casting machines and equipment 4.7<br />
www.mechatherm.com<br />
see Smelting technology 1.5<br />
ALUMINIUM · 7-8/2013 77
LIEFERVERZEICHNIS<br />
RIHS ENGINEERING SA<br />
see Casting machines and equipment 4.7<br />
• Pig casting machines (sow casters)<br />
Masselgießmaschine (Sowcaster)<br />
Bartz GmbH<br />
see Casthous (foundry) 1.5<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
• Rolling and extrusion ingot<br />
and T-bars<br />
Formatgießerei (Walzbarren o<strong>de</strong>r<br />
Pressbolzen o<strong>de</strong>r T-Barren)<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
• Horizontal continuous casting<br />
Horizontales Stranggießen<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
sermas@sermas.com<br />
• Heat treatment of extrusion<br />
ingot (homogenisation)<br />
Formatebehandlung (homogenisieren)<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
• Vertical semi-continuous DC<br />
casting / Vertikales Stranggießen<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
Wagstaff, Inc.<br />
3910 N. Flora Rd.<br />
Spokane, WA 99216 USA<br />
+1 509 922 1404 phone<br />
+1 509 924 0241 fax<br />
E-Mail: info@wagstaff.com<br />
Internet: www.wagstaff.com<br />
1.8 Electrolysis cell (pot)<br />
Elektrolyseofen<br />
• Bulk materials Handling<br />
from Ship to Cell<br />
Bulk materials Handling from Ship to Cell<br />
1.9 Potroom<br />
Elektrolysehalle<br />
MOBILE<br />
EQUIPMENT<br />
Phone: +31.315.683941<br />
info@hencon.com · www.hencon.com<br />
T.T. Tomorrow Technology S.p.A.<br />
Via <strong>de</strong>ll’Artigianato 18<br />
Due Carrare, Padova 35020, Italy<br />
Telefon +39 049 912 8800<br />
Telefax +39 049 912 8888<br />
E-Mail: gmagarotto@tomorrowtechnology.it<br />
Contact: Giovanni Magarotto<br />
• Ano<strong>de</strong> changing machine<br />
Ano<strong>de</strong>nwechselmaschine<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
• Ano<strong>de</strong> transport equipment<br />
Ano<strong>de</strong>n Transporteinrichtungen<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
• Crustbreakers / Krustenbrecher<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
• Dry absorption units for<br />
electrolysis exhaust gases<br />
Trockenabsorptionsanlage für<br />
Elektrolyseofenabgase<br />
Solios Environnement<br />
www.fivesgroup.com<br />
• Scales / Waagen<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
• Sawing / Sägen<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
www.coperion.com<br />
mailto: info.cc-mh@coperion.com<br />
• Calcium silicate boards<br />
Calciumsilikatplatten<br />
Promat GmbH High Performance Insulation<br />
Scheifenkamp 16, D-40878 Ratingen<br />
Tel. +49 (0) 2102 / 493-0, Fax -493 115<br />
verkauf3@promat.<strong>de</strong>, www.promat.<strong>de</strong><br />
• Exhaust gas treatment<br />
Abgasbehandlung<br />
Solios Environnement<br />
www.fivesgroup.com<br />
• Pot feeding systems<br />
Beschickungseinrichtungen<br />
für Elektrolysezellen<br />
FLSmidth MÖLLER GmbH<br />
www.flsmidthmoeller.com<br />
see Storage facilities for smelting 1.2<br />
• Pot ramming Machine<br />
www.brochot.fr<br />
• Tapping vehicles/Schöpffahrzeuge<br />
GLAMA Maschinenbau GmbH<br />
see Ano<strong>de</strong> rodding 1.4<br />
1.12 Catho<strong>de</strong> repair shop<br />
Katho<strong>de</strong>nreparatur-<br />
Werkstatt<br />
• Catho<strong>de</strong> Sealing Bench<br />
Eingießen von Katho<strong>de</strong>nbarren<br />
Sermas Industrie<br />
sermas@sermas.com<br />
see Smelting technology 1.6<br />
78 ALUMINIUM · 7-8/2013
SUPPLIERS DIRECTORY<br />
1.14 <strong>Alu</strong>minium Alloys<br />
<strong>Alu</strong>miniumlegierungen<br />
2.2 Extrusion equipment<br />
Strangpresseinrichtungen<br />
RHEINFELDEN ALLOYS GmbH & Co. KG<br />
A member of ALUMINIUM RHEINFELDEN Group<br />
Postfach 1703, 79607 Rheinfel<strong>de</strong>n<br />
Tel.: +49 7623 93-490<br />
Fax: +49 7623 93-546<br />
E-Mail: alloys@rheinfel<strong>de</strong>n-alloys.eu<br />
Internet: www.rheinfel<strong>de</strong>n-alloys.eu<br />
1.15 Storage and transport<br />
Lager und Transport<br />
www.brochot.fr<br />
2<br />
Extrusion<br />
Strangpressen<br />
2.1 Extrusion billet preparation<br />
Pressbolzenbereitstellung<br />
2.1.1 Extrusion billet production<br />
Pressbolzenherstellung<br />
2.2 Extrusion equipment<br />
Strangpresseinrichtungen<br />
2.3 Section handling<br />
Profilhandling<br />
2.4 Heat treatment<br />
Wärmebehandlung<br />
2.1 Extrusion billet preparation<br />
Pressbolzenbereitstellung<br />
see Coil transport systems 3.4<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
Hier könnte Ihr<br />
Bezugsquellen-Eintrag<br />
stehen.<br />
Rufen Sie an:<br />
Tel. 0821 / 31 98 80-34<br />
Dennis Ross<br />
2.5 Measurement and control<br />
equipment<br />
Mess- und Regeleinrichtungen<br />
2.6 Die preparation and care<br />
Werkzeugbereitstellung<br />
und -pflege<br />
2.7 Second-hand extrusion plant<br />
Gebrauchte Strangpressanlagen<br />
2.8 Consultancy, expert opinion<br />
Beratung, Gutachten<br />
2.9 Surface finishing of sections<br />
Oberflächenveredlung<br />
von Profilen<br />
2.10 Machining of sections<br />
Profilbearbeitung<br />
2.11 Equipment and accessories<br />
Ausrüstungen und Hilfsmittel<br />
2.12 Services<br />
Dienstleistungen<br />
• Billet heating furnaces<br />
Öfen zur Bolzenerwärmung<br />
www.mechatherm.com<br />
see Smelting technology 1.5<br />
Oilgear Towler GmbH<br />
Im Gotthelf 8<br />
D 65795 Hattersheim<br />
Tel. +49 (0) 6145 3770<br />
Fax +49 (0) 6145 30770<br />
E-Mail: info@oilgear.<strong>de</strong><br />
Internet: www.oilgear.<strong>de</strong><br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
• Press control systems<br />
Pressensteuersysteme<br />
Oilgear Towler GmbH<br />
see Extrusion Equipment 2.2<br />
• Heating and control<br />
equipment for intelligent<br />
billet containers<br />
Heizungs- und Kontrollausrüstung<br />
für intelligente Blockaufnehmer<br />
MARX GmbH & Co. KG<br />
www.marx-gmbh.<strong>de</strong><br />
see Melt operations 4.13<br />
2.3 Section handling<br />
Profilhandling<br />
CTI Systems S.A.<br />
Z.I. Eselborn-Lentzweiler<br />
12, op <strong>de</strong>r Sang | L- 9779 Lentzweiler<br />
Tel. +352 2685 2000 | Fax +352 2685 3000<br />
cti@ctisystems.com | www.ctisystems.com<br />
extrutec GmbH<br />
Fritz-Reichle Ring 2<br />
D-78315 Radolfzell<br />
Tel. +49 7732 939 1390<br />
Fax +49 7732 939 1399<br />
E-Mail: info@extrutec-gmbh.<strong>de</strong><br />
Internet: www.extrutec-gmbh.<strong>de</strong><br />
mfw-maschinenbau.com<br />
• Log/Bolzenlager Handling<br />
• Bolzensäge, Bolzenfügen<br />
see Casthouse (foundry) 1.5<br />
Could not find your<br />
„keywords“?<br />
Please ask for our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
E-Mail: anzeigen@giesel.<strong>de</strong><br />
H+H HERRMANN + HIEBER GMBH<br />
Rechbergstraße 46<br />
D-73770 Denkendorf/Stuttgart<br />
Tel. +49 711 93467-0, Fax +49 711 34609-11<br />
E-Mail: info@herrmannhieber.<strong>de</strong><br />
Internet: www.herrmannhieber.<strong>de</strong><br />
Vollert Anlagenbau GmbH<br />
Stadtseestraße 12, D-74189 Weinsberg<br />
Tel. +49 7134 52 220 l Fax +49 7134 52 222<br />
E-Mail intralogistik@vollert.<strong>de</strong><br />
Internet www.vollert.<strong>de</strong><br />
ALUMINIUM · 7-8/2013 79
LIEFERVERZEICHNIS<br />
• Packaging equipment<br />
Verpackungseinrichtungen<br />
• Section transport equipment<br />
Profiltransporteinrichtungen<br />
2.4 Heat treatment<br />
Wärmebehandlung<br />
mfw-maschinenbau.com<br />
• Automatik Verpackung<br />
• Packtische, Profilpaketheber<br />
• Spacerhandling und Konzepte<br />
see Coil transport systems 3.4<br />
see Coil transport systems 3.4<br />
Nijverheidsweg 3<br />
NL-7071 CH Ulft Netherlands<br />
Tel.: +31 315 641352<br />
Fax: +31 315 641852<br />
E-Mail: info@unifour.nl<br />
Internet: www.unifour.nl<br />
Sales Contact: Paul Overmans<br />
BSN Thermprozesstechnik GmbH<br />
Kammerbruchstraße 64<br />
D-52152 Simmerath<br />
Tel. 02473-9277-0 · Fax: 02473-9277-111<br />
info@bsn-therm.<strong>de</strong> · www.bsn-therm.<strong>de</strong><br />
Ofenanlagen zum Wärmebehan<strong>de</strong>ln von <strong>Alu</strong>miniumlegierungen,<br />
Buntmetallen und Stählen<br />
• Section saws<br />
Profilsägen<br />
see Section handling 2.3<br />
mfw-maschinenbau.com<br />
• Kurzlängensäge automatisiert<br />
• Section store equipment<br />
Profil-Lagereinrichtungen<br />
Hier könnte Ihr<br />
Bezugsquellen-Eintrag<br />
stehen.<br />
Rufen Sie an:<br />
Tel. 0821 / 31 98 80-34<br />
Dennis Ross<br />
• Stackers / Destackers<br />
Stapler / Entstapler<br />
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A<br />
Avenida Cervantes Nº6<br />
48970 – Basauri – Bizkaia – Spain<br />
Tel: +34 944 409 420<br />
E-mail: Insertec@insertec.biz<br />
Internet: www.insertec.biz<br />
see Equipment and accessories 3.1<br />
www.mechatherm.com<br />
see Smelting technology 1.5<br />
www.ctisystems.com<br />
see Section handling 2.3<br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
KASTO Maschinenbau GmbH & Co. KG<br />
Industriestr. 14, D-77855 Achern<br />
Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300<br />
kasto@kasto.<strong>de</strong> / www.kasto.<strong>de</strong><br />
Hersteller von Band- und Kreissägemaschinen<br />
sowie Langgut- und Blechlagersystemen<br />
mfw-maschinenbau.com<br />
• 7 und 14 m De- u. Stacker<br />
• Kombianlagen<br />
• Transport equipment for<br />
extru<strong>de</strong>d sections<br />
Transporteinrichtungen<br />
für Profilabschnitte<br />
www.ctisystems.com<br />
see Section handling 2.3<br />
SECO/WARWICK EUROPE S.A.<br />
ul. Šwierczewskiego 76<br />
66-200 Šwiebodzin, POLAND<br />
Tel: +48 68 38 19 800<br />
E-mail: europe@secowarwick.com.pl<br />
Internet: www.secowarwick.com<br />
Could not find your „keywords“?<br />
Please ask for our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
E-Mail: anzeigen@giesel.<strong>de</strong><br />
• Heat treatment furnaces<br />
Wärmebehandlungsöfen<br />
INOTHERM INDUSTRIEOFEN-<br />
UND WÄRMETECHNIK GMBH<br />
see Casthouse (foundry) 1.5<br />
see Coil transport systems 3.4<br />
see Section handling 2.3<br />
mfw-maschinenbau.com<br />
• Skip Handling, Spacer<br />
• Kettenför<strong>de</strong>rer<br />
see Section handling 2.3<br />
ERNST REINHARDT GMBH<br />
Güterbahnhofstrasse 1<br />
D-78048 Villingen-Schwenningen<br />
Tel. +49 (0) 7721 8441-0, Fax -44<br />
E-Mail: info@ernstreinhardt.<strong>de</strong><br />
Internet: www.ernst-reinhardt.com<br />
80 ALUMINIUM · 7-8/2013
SUPPLIERS DIRECTORY<br />
• Homogenising furnaces<br />
Homogenisieröfen<br />
2.10 Machining of sections<br />
Profilbearbeitung<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
see Casthouse (foundry) 1.5<br />
2.6 Die preparation and care<br />
Werkzeugbereitstellung<br />
und -pflege<br />
• Billet saw<br />
Bolzensägen<br />
Sermas Industrie<br />
sermas@sermas.com<br />
see Smelting technology 1.6<br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
2.11 Equipment and<br />
accessories<br />
Ausrüstungen und<br />
Hilfsmittel<br />
• Ageing furnace for extrusions<br />
Auslagerungsöfen für<br />
Strangpressprofile<br />
see Extrusion billet preparation 2.1<br />
see Heat treatment furnaces 2.4<br />
see Casthouse (foundry) 1.5<br />
Nijverheidsweg 3<br />
NL-7071 CH Ulft Netherlands<br />
Tel.: +31 315 641352<br />
Fax: +31 315 641852<br />
E-Mail: info@unifour.nl<br />
Internet: www.unifour.nl<br />
Sales Contact: Paul Overmans<br />
Could not find your „keywords“?<br />
Please ask for our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
E-Mail: anzeigen@giesel.<strong>de</strong><br />
• Die heating furnaces<br />
Werkzeuganwärmöfen<br />
3<br />
Rolling mill technology<br />
Walzwerktechnik<br />
schwartz GmbH<br />
see Extrusion billet preparation 2.1<br />
Nijverheidsweg 3<br />
NL-7071 CH Ulft Netherlands<br />
Tel.: +31 315 641352<br />
Fax: +31 315 641852<br />
E-Mail: info@unifour.nl<br />
Internet: www.unifour.nl<br />
Sales Contact: Paul Overmans<br />
see Heat treatment 2.4<br />
Hier könnte Ihr<br />
Bezugsquellen-Eintrag stehen.<br />
Rufen Sie an:<br />
Tel. 0821 / 31 98 80-34<br />
Dennis Ross<br />
2.9 Surface finishing<br />
of sections<br />
Oberflächenveredlung<br />
von Profilen<br />
mfw-maschinenbau.com<br />
• Strahlanlagen<br />
3.1 Casting equipment<br />
Gießanlagen<br />
3.2 Rolling bar machining<br />
Walzbarrenbearbeitung<br />
3.3 Rolling bar furnaces<br />
Walzbarrenvorbereitung<br />
3.4 Hot rolling equipment<br />
Warmwalzanlagen<br />
3.5 Strip casting units<br />
and accessories<br />
Bandgießanlagen<br />
und Zubehör<br />
3.6 Cold rolling equipment<br />
Kaltwalzanlagen<br />
3.7 Thin strip / foil rolling plant<br />
3.0 Rolling mill technology<br />
Walzwerktechnik<br />
see Cold rolling units / complete plants 3.6<br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
Feinband-/Folienwalzwerke<br />
3.8 Auxiliary equipment<br />
Nebeneinrichtungen<br />
3.9 Adjustment <strong>de</strong>vices<br />
Adjustageeinrichtungen<br />
3.10 Process technology /<br />
Automation technology<br />
Prozesstechnik /<br />
Automatisierungstechnik<br />
3.11 Coolant / lubricant preparation<br />
Kühl-/Schmiermittel-Aufbereitung<br />
3.12 Air extraction systems<br />
Abluftsysteme<br />
3.13 Fire extinguishing units<br />
Feuerlöschanlagen<br />
3.14 Storage and dispatch<br />
Lagerung und Versand<br />
3.15 Second-hand rolling equipment<br />
Gebrauchtanlagen<br />
3.16 Coil storage systems<br />
Coil storage systems<br />
3.17 Strip Processing Lines<br />
Bandprozesslinien<br />
3.18 Productions Management Sytems<br />
Produktions Management Systeme<br />
Siemens plc, Metals Technologies<br />
Sheffield Business Park, Europa Link<br />
Sheffield S9 1XU<br />
Phone: +44 1709 726500<br />
Fax:+44 1142 611719<br />
aluminiummill.metals@siemens.com<br />
ALUMINIUM · 7-8/2013 81
LIEFERVERZEICHNIS<br />
• Melting and holding furnaces<br />
Schmelz- und Warmhalteöfen<br />
• Annealing furnaces<br />
Glühöfen<br />
Bartz GmbH<br />
see Casthous (foundry) 1.5<br />
SMS Siemag Aktiengesellschaft<br />
Eduard-Schloemann-Straße 4<br />
40237 Düsseldorf, Germany<br />
Telefon: +49 (0) 211 881-0<br />
Telefax: +49 (0) 211 881-4902<br />
E-Mail: communications@sms-siemag.com<br />
Internet: www.sms-siemag.com<br />
Geschäftsbereiche:<br />
Warmflach- und Kaltwalzwerke<br />
Wiesenstraße 30<br />
57271 Hilchenbach-Dahlbruch, Germany<br />
Telefon: +49 (0) 2733 29-0<br />
Telefax: +49 (0) 2733 29-2852<br />
Bandanlagen<br />
Wal<strong>de</strong>r Straße 51-53<br />
40724 Hil<strong>de</strong>n, Germany<br />
Telefon: +49 (0) 211 881-5100<br />
Telefax: +49 (0) 211 881-5200<br />
Elektrik + Automation<br />
Ivo-Beucker-Straße 43<br />
40237 Düsseldorf, Germany<br />
Telefon: +49 (0) 211 881-5895<br />
Telefax: +49 (0) 211 881-775895<br />
Graf-Recke-Straße 82<br />
40239 Düsseldorf, Germany<br />
Telefon: +49 (0) 211 881-0<br />
Telefax: +49 (0) 211 881-4902<br />
Ein Eintrag (s/w) in<br />
diesem Format kostet<br />
pro Ausgabe + Stichwort<br />
110,00 € + MwSt.<br />
Weitere Informationen unter<br />
Tel. +49 (0) 821 / 31 98 80 - 34<br />
3.1 Casting equipment<br />
Gießanlagen<br />
www.mechatherm.com<br />
see Smelting technology 1.5<br />
• Electromagnetic Stirrer<br />
Elektromagnetische Rührer<br />
Solios Thermal UK<br />
www.fivesgroup.com<br />
• Filling level indicators and controls<br />
Füllstandsanzeiger und -regler<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
Wagstaff, Inc.<br />
see Casting machines 1.6<br />
Gautschi Engineering GmbH<br />
Konstanzer Straße 37<br />
CH 8274 Tägerwilen<br />
Telefon +41 71 666 66 66<br />
Telefax +41 71 666 66 77<br />
E-Mail: info@gautschi.cc<br />
Internet: www.gautschi.cc<br />
Kontakt: Sales Departement<br />
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A<br />
see Heat treatment 2.4<br />
LOI Thermprocess GmbH<br />
Am Lichtbogen 29<br />
D-45141 Essen<br />
Germany<br />
Telefon +49 (0) 201 / 18 91-1<br />
Telefax +49 (0) 201 / 18 91-321<br />
E-Mail: info@loi-italimpianti.<strong>de</strong><br />
Internet: www.loi-italimpianti.com<br />
Solios Thermal UK<br />
www.fivesgroup.com<br />
• Melt purification units<br />
Schmelzereinigungsanlagen<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
• Metal filters / Metallfilter<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
3.2 Rolling bar machining<br />
Walzenbarrenbearbeitung<br />
• Plate saw<br />
Plattensägen<br />
Sermas Industrie<br />
sermas@sermas.com<br />
see Smelting technology 1.6<br />
• Slab saw<br />
Barrensägen<br />
Sermas Industrie<br />
sermas@sermas.com<br />
see Smelting technology 1.6<br />
3.3 Rolling bar furnaces<br />
Walzbarrenvorbereitung<br />
BSN Thermprozesstechnik GmbH<br />
see Heat Treatment 2.4<br />
EBNER Industrieofenbau Ges.m.b.H.<br />
Ebner-Platz 1, 4060 Leonding/Austria<br />
Tel. +43 / 732 / 6868-0<br />
E-Mail: sales@ebner.cc<br />
Internet: www.ebner.cc<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
schwartz GmbH<br />
see Equipment and accessories 3.1<br />
Solios Thermal UK<br />
www.fivesgroup.com<br />
see Heat treatment 2.4<br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
• Bar heating furnaces<br />
Barrenanwärmanlagen<br />
EBNER Industrieofenbau Ges.m.b.H.<br />
see Annealing furnaces 3.3<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
• Homogenising furnaces<br />
Homogenisieröfen<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
schwartz GmbH<br />
Solios Thermal UK<br />
www.fivesgroup.com<br />
• Roller tracks<br />
Rollengänge<br />
see Heat treatment 2.4<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
82 ALUMINIUM · 7-8/2013
SUPPLIERS DIRECTORY<br />
3.4 Hot rolling equipment<br />
Warmwalzanlagen<br />
• Rolling mill mo<strong>de</strong>rnisation<br />
Walzwerksmo<strong>de</strong>rnisierung<br />
3.6 Cold rolling equipment<br />
Kaltwalzanlagen<br />
Achenbach Buschhütten GmbH & Co. KG<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
see Cold rolling units / complete plants 3.6<br />
www.siemens.vai.com<br />
see Rolling mill technology 3.0<br />
• Coil transport systems<br />
Bundtransportsysteme<br />
MINO S.p.A.<br />
Via Torino, 1 – San Michele<br />
15122 ALESSANDRIA – ITALY<br />
Telefon: +39 0131 363636<br />
Telefax: +39 0131 361611<br />
E-Mail: sales@mino.it<br />
Internet: www.mino.it<br />
Sales contact: Mr. Luciano Ceccopieri<br />
www.siemens.vai.com<br />
see Rolling mill technology 3.0<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
Achenbach Buschhütten GmbH & Co. KG<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
ANDRITZ Sundwig GmbH<br />
Stephanopeler Str. 22, D-58675 Hemer<br />
Telefon: +49 (0) 2372 54-0, Fax -200<br />
E-mail: sundwig_welcome@andritz.com<br />
Internet: www.andritz.com<br />
BSN Thermprozesstechnik GmbH<br />
see Heat Treatment 2.4<br />
www.ctisystems.com<br />
see Section handling 2.3<br />
SMS LOGISTIKSYSTEME GMBH<br />
Obere Industriestraße 8<br />
D-57250 Netphen<br />
Telefon: +49 2738 21-0<br />
Telefax: +49 2738 21-1002<br />
E-Mail: info@sms-logistics.com<br />
www.sms-logistiksysteme.com<br />
see Section handling 2.3<br />
• Drive systems / Antriebe<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
Hier könnte Ihr<br />
Bezugsquellen-Eintrag<br />
stehen.<br />
Rufen Sie an:<br />
Tel. 0821 / 31 98 80-34<br />
Dennis Ross<br />
Could not find your<br />
„keywords“?<br />
Please ask for our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
E-Mail: anzeigen@giesel.<strong>de</strong><br />
• Spools / Haspel<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
• Hot rolling units /<br />
complete plants<br />
Warmwalzanlagen/Komplettanlagen<br />
MINO S.p.A.<br />
Via Torino, 1 – San Michele<br />
15122 ALESSANDRIA – ITALY<br />
Telefon: +39 0131 363636<br />
Telefax: +39 0131 361611<br />
E-Mail: sales@mino.it<br />
Internet: www.mino.it<br />
Sales contact: Mr. Luciano Ceccopieri<br />
www.siemens.vai.com<br />
see Rolling mill technology 3.0<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
• Surface finishing<br />
of sheets and coils<br />
Oberflächenvere<strong>de</strong>ling<br />
von Blechen und Coils<br />
DEMIS Wi<strong>de</strong> Belt Processing Systems<br />
see Process techn./Automation Techn. 3.10<br />
www.siemens.vai.com<br />
see Rolling mill technology 3.0<br />
• Coil annealing furnaces<br />
Bundglühöfen<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
schwartz GmbH<br />
see Equipment and accessories 3.1<br />
see Heat treatment 2.4<br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
• Coil transport systems<br />
Bundtransportsysteme<br />
www.ctisystems.com<br />
see Section handling 2.3<br />
H+H HERRMANN + HIEBER GMBH<br />
Rechbergstraße 46<br />
D-73770 Denkendorf/Stuttgart<br />
Tel. +49 711 93467-0, Fax +49 711 34609-11<br />
E-Mail: info@herrmannhieber.<strong>de</strong><br />
Internet: www.herrmannhieber.<strong>de</strong><br />
see Coil transport systems 3.4<br />
ALUMINIUM · 7-8/2013 83
LIEFERVERZEICHNIS<br />
see Section handling 2.3<br />
• Rolling mill mo<strong>de</strong>rnization<br />
Walzwerkmo<strong>de</strong>rnisierung<br />
3.7 Thin strip /<br />
foil rolling plant<br />
Feinband-/Folienwalzwerke<br />
• Cold rolling units /<br />
complete plants<br />
Kaltwalzanlagen/Komplettanlagen<br />
Achenbach Buschhütten GmbH & Co. KG<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
see Cold rolling units / complete plants 3.6<br />
Achenbach Buschhütten GmbH & Co. KG<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
see Cold rolling units / complete plants 3.6<br />
MINO S.p.A.<br />
Via Torino, 1 – San Michele<br />
15122 ALESSANDRIA – ITALY<br />
Telefon: +39 0131 363636<br />
Telefax: +39 0131 361611<br />
E-Mail: sales@mino.it<br />
Internet: www.mino.it<br />
Sales contact: Mr. Luciano Ceccopieri<br />
www.siemens.vai.com<br />
see Rolling mill technology 3.0<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
• Drive systems / Antriebe<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
• Heating furnaces / Anwärmöfen<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
• Process optimisation systems<br />
Prozessoptimierungssysteme<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
• Process simulation<br />
Prozesssimulation<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
• Roll exchange equipment<br />
Walzenwechseleinrichtungen<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
MINO S.p.A.<br />
Via Torino, 1 – San Michele<br />
15122 ALESSANDRIA – ITALY<br />
Telefon: +39 0131 363636<br />
Telefax: +39 0131 361611<br />
E-Mail: sales@mino.it<br />
Internet: www.mino.it<br />
Sales contact: Mr. Luciano Ceccopieri<br />
• Slitting lines-CTL<br />
Längs- und Querteilanlagen<br />
see Cold rolling units / complete plants 3.6<br />
Could not find your<br />
„keywords“?<br />
Please ask for our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
E-Mail: anzeigen@giesel.<strong>de</strong><br />
• Strip shears/Bandscheren<br />
see Cold rolling units / complete plants 3.6<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
• Surface finishing<br />
of sheets and coils<br />
Oberflächenvere<strong>de</strong>ling<br />
von Blechen und Coils<br />
DEMIS Wi<strong>de</strong> Belt Processing Systems<br />
see Process techn./Automation Techn. 3.10<br />
• Trimming equipment<br />
Besäumeinrichtungen<br />
see Cold rolling units / complete plants 3.6<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
www.siemens.vai.com<br />
see Rolling mill technology 3.0<br />
• Coil annealing furnaces<br />
Bundglühöfen<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
see Equipment and accessories 3.1<br />
schwartz GmbH<br />
see Cold colling equipment 3.6<br />
• Heating furnaces<br />
Anwärmöfen<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
INOTHERM INDUSTRIEOFEN-<br />
UND WÄRMETECHNIK GMBH<br />
see Casthouse (foundry) 1.5<br />
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A<br />
see Heat treatment 2.4<br />
schwartz GmbH<br />
see Heat treatment 2.4<br />
• Thin strip / foil rolling mills /<br />
complete plant<br />
Feinband- / Folienwalzwerke /<br />
Komplettanlagen<br />
MINO S.p.A.<br />
Via Torino, 1 – San Michele<br />
15122 ALESSANDRIA – ITALY<br />
Telefon: +39 0131 363636<br />
Telefax: +39 0131 361611<br />
E-Mail: sales@mino.it<br />
Internet: www.mino.it<br />
Sales contact: Mr. Luciano Ceccopieri<br />
84 ALUMINIUM · 7-8/2013
SUPPLIERS DIRECTORY<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
Hier könnte Ihr<br />
Bezugsquellen-Eintrag stehen.<br />
Rufen Sie an:<br />
Tel. 0821 / 31 98 80-34<br />
Dennis Ross<br />
• Rolling mill mo<strong>de</strong>rnization<br />
Walzwerkmo<strong>de</strong>rnisierung<br />
Achenbach Buschhütten GmbH & Co. KG<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
• Strip thickness measurement<br />
and control equipment<br />
Banddickenmess- und<br />
-regeleinrichtungen<br />
• Surface finishing<br />
of sheets and coils<br />
Oberflächenvere<strong>de</strong>ling<br />
von Blechen und Coils<br />
Wi<strong>de</strong> Belt Processing Systems<br />
SDV-Santioli AG<br />
Industriestrasse 10 | CH-8157 Dielsdorf | Switzerland<br />
Tel. +41 44 854 0908 | info@<strong>de</strong>mis.ch | www.<strong>de</strong>mis.ch<br />
• Roll Force Measurement equipment<br />
Walzkraftmesseinrichtungen<br />
Achenbach Buschhütten GmbH & Co. KG<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
MINO S.p.A.<br />
Via Torino, 1 – San Michele<br />
15122 ALESSANDRIA – ITALY<br />
Telefon: +39 0131 363636<br />
Telefax: +39 0131 361611<br />
E-Mail: sales@mino.it<br />
Internet: www.mino.it<br />
Sales contact: Mr. Luciano Ceccopieri<br />
3.10 Process technology /<br />
Automation technology<br />
Prozesstechnik /<br />
Automatisierungstechnik<br />
• Process control technology<br />
Prozessleittechnik<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
ABB Automation<br />
Force Measurement<br />
S-72159 Västeras, Swe<strong>de</strong>n<br />
Phone: +46 21 325 000<br />
Fax: +46 21 340 005<br />
E-Mail: pressductor@se.abb.com<br />
Internet: www.abb.com/pressductor<br />
Achenbach Buschhütten GmbH & Co. KG<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
• Strip Tension<br />
Measurement equipment<br />
Bandzugmesseinrichtungen<br />
ABB Automation<br />
Force Measurement<br />
S-72159 Västeras, Swe<strong>de</strong>n<br />
Phone: +46 21 325 000<br />
Fax: +46 21 340 005<br />
E-Mail: pressductor@se.abb.com<br />
Internet: www.abb.com/pressductor<br />
• Strip Width & Position<br />
Measurement equipment<br />
Bandbreiten- und<br />
Bandlaufmesseinrichtungen<br />
ABB Automation<br />
Force Measurement<br />
S-72159 Västeras, Swe<strong>de</strong>n<br />
Phone: +46 21 325 000<br />
Fax: +46 21 340 005<br />
E-Mail: pressductor@se.abb.com<br />
Internet: www.abb.com/pressductor<br />
3.11 Coolant / lubricant<br />
preparation<br />
Kühl-/Schmiermittel-<br />
Aufbereitung<br />
Wagstaff, Inc.<br />
see Casting machines 1.6<br />
• Strip flatness measurement<br />
and control equipment<br />
Bandplanheitsmess- und<br />
-regeleinrichtungen<br />
ABB Automation<br />
Force Measurement<br />
S-72159 Västeras, Swe<strong>de</strong>n<br />
Phone: +46 21 325 000<br />
Fax: +46 21 340 005<br />
E-Mail: pressductor@se.abb.com<br />
Internet: www.abb.com/pressductor<br />
see Cold rolling units / complete plants 3.6<br />
• Rolling oil recovery and<br />
treatment units<br />
Walzöl-Wie<strong>de</strong>raufbereitungsanlagen<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
ABB Automation<br />
Force Measurement<br />
S-72159 Västeras, Swe<strong>de</strong>n<br />
Phone: +46 21 325 000<br />
Fax: +46 21 340 005<br />
E-Mail: pressductor@se.abb.com<br />
Internet: www.abb.com/pressductor<br />
Ein Eintrag (s/w) in<br />
diesem Format kostet<br />
pro Ausgabe + Stichwort<br />
110,00 € + MwSt.<br />
Weitere Informationen unter<br />
Tel. +49 (0) 821 / 31 98 80 - 34<br />
• Filter for rolling oils and emulsions<br />
Filter für Walzöle und Emulsionen<br />
Achenbach Buschhütten GmbH & Co. KG<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
ALUMINIUM · 7-8/2013 85
LIEFERVERZEICHNIS<br />
• Rolling oil rectification units<br />
Walzölrektifikationsanlagen<br />
3.16 Coil storage systems<br />
Bundlagersysteme<br />
• Coil & Colour Coating Lines<br />
Bandlackierlinien<br />
Achenbach Buschhütten GmbH & Co. KG<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
Could not find your<br />
„keywords“?<br />
Please ask for<br />
our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
E-Mail:<br />
anzeigen@giesel.<strong>de</strong><br />
3.12 Air extraction systems<br />
Abluft-Systeme<br />
see Cold rolling units / complete plants 3.6<br />
• Exhaust air purification<br />
systems (active)<br />
Abluft-Reinigungssysteme (aktiv)<br />
www.ctisystems.com<br />
see Section handling 2.3<br />
H+H HERRMANN + HIEBER GMBH<br />
Rechbergstraße 46<br />
D-73770 Denkendorf/Stuttgart<br />
Tel. +49 711 93467-0, Fax +49 711 34609-11<br />
E-Mail: info@herrmannhieber.<strong>de</strong><br />
Internet: www.herrmannhieber.<strong>de</strong><br />
see Coil transport systems 3.4<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
see Section handling 2.3<br />
3.17 Strip Processing Lines<br />
Bandprozesslinien<br />
see Cold rolling equipment 3.6<br />
BWG Bergwerk- und Walzwerk-<br />
Maschinenbau GmbH<br />
Mercatorstraße 74 – 78<br />
D-47051 Duisburg<br />
Tel.: +49 (0) 203-9929-0<br />
Fax: +49 (0) 203-9929-400<br />
E-Mail: bwg@bwg-online.<strong>de</strong><br />
Internet: www.bwg-online.com<br />
Bronx International Pty Ltd<br />
Email: sales@bronx.com.au<br />
Internet: www.bronxintl.com<br />
www.bwg-online.com<br />
see Strip Processing Lines 3.17<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
• Lithographic Sheet Lines<br />
Lithografielinien<br />
www.bwg-online.com<br />
see Strip Processing Lines 3.17<br />
see Cold rolling units / complete plants 3.6<br />
• Stretch Levelling Lines<br />
Streckrichtanlagen<br />
www.bwg-online.com<br />
see Strip Processing Lines 3.17<br />
• Strip Annealing Lines<br />
Bandglühlinien<br />
www.bwg-online.com<br />
see Strip Processing Lines 3.17<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
Achenbach Buschhütten GmbH & Co. KG<br />
Siegener Str. 152, D-57223 Kreuztal<br />
Tel. +49 (0) 2732/7990, info@achenbach.<strong>de</strong><br />
Internet: www.achenbach.<strong>de</strong><br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
3.14 Storage and dispatch<br />
Lagerung und Versand<br />
see Coil transport systems 3.4<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
REDEX<br />
Zone Industrielle<br />
F-45210 Ferrieres<br />
Telefon +33 (2) 38 94 42 00<br />
E-mail: info@re<strong>de</strong>x-group.com<br />
Internet: www.tension-leveling.com<br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
• Anodizing Lines<br />
Anodisier-Linien<br />
SMS Siemag AG<br />
see Rolling mill technology 3.0<br />
3.18 Production<br />
Management systems<br />
Produktions Management<br />
Systeme<br />
PSI Metals Non Ferrous GmbH<br />
Software Excellence in Metals<br />
Carlo-Schmid-Str. 12, D-52146 Würselen<br />
Tel.: +49 (0) 2405 4135-0<br />
info@psimetals.<strong>de</strong>, www.psimetals.com<br />
see Coil transport systems 3.4<br />
86 ALUMINIUM · 7-8/2013
SUPPLIERS DIRECTORY<br />
4 Foundry<br />
Gießerei<br />
4.1 Work protection and ergonomics<br />
Arbeitsschutz und Ergonomie<br />
4.2 Heat-resistant technology<br />
Feuerfesttechnik<br />
4.3 Conveyor and storage technology<br />
För<strong>de</strong>r- und Lagertechnik<br />
4.4 Mould and core production<br />
Form- und Kernherstellung<br />
4.5 Mould accessories and accessory<br />
materials<br />
Formzubehör, Hilfsmittel<br />
4.2 Heat-resistent technology<br />
Feuerfesttechnik<br />
• Refractories / Feuerfeststoffe<br />
4.6 Foundry equipment<br />
Gießereianlagen<br />
4.7 Casting machines and equipment<br />
Gießmaschinen<br />
und Gießeinrichtungen<br />
4.8 Handling technology<br />
Handhabungstechnik<br />
4.9 Construction and <strong>de</strong>sign<br />
Konstruktion und Design<br />
4.10 Measurement technology<br />
and materials testing<br />
Messtechnik und Materialprüfung<br />
4.11 Metallic charge materials<br />
Metallische Einsatzstoffe<br />
4.12 Finishing of raw castings<br />
Rohgussnachbehandlung<br />
4.13 Melt operations<br />
Schmelzbetrieb<br />
4.14 Melt preparation<br />
Schmelzvorbereitung<br />
4.15 Melt treatment <strong>de</strong>vices<br />
Schmelzebehandlungseinrichtungen<br />
4.16 Control and regulation technology<br />
Steuerungs- und<br />
Regelungstechnik<br />
4.17 Environment protection<br />
and disposal<br />
Umweltschutz und Entsorgung<br />
4.18 Dross recovery<br />
Schlackenrückgewinnung<br />
4.19 Cast parts<br />
Gussteile<br />
Promat GmbH High Performance Insulation<br />
Scheifenkamp 16, D-40878 Ratingen<br />
Tel. +49 (0) 2102 / 493-0, Fax -493 115<br />
verkauf3@promat.<strong>de</strong>, www.promat.<strong>de</strong><br />
H+H HERRMANN + HIEBER GMBH<br />
Rechbergstraße 46<br />
D-73770 Denkendorf/Stuttgart<br />
Tel. +49 711 93467-0, Fax +49 711 34609-11<br />
E-Mail: info@herrmannhieber.<strong>de</strong><br />
Internet: www.herrmannhieber.<strong>de</strong><br />
see Coil transport systems 3.4<br />
see Section handling 2.3<br />
4.5 Mold accessories and<br />
accessory materials<br />
Formzubehör, Hilfmittel<br />
• Fluxes<br />
Flussmittel<br />
Solvay Fluor GmbH<br />
Hans-Böckler-Allee 20<br />
D-30173 Hannover<br />
Telefon +49 (0) 511 / 857-0<br />
Telefax +49 (0) 511 / 857-2146<br />
Internet: www.solvay-fluor.<strong>de</strong><br />
4.6 Foundry equipment<br />
Gießereianlagen<br />
HENCON MOBILE EQUIPMENT<br />
see section Casthouse 1.5<br />
www.mechatherm.com<br />
see Smelting technology 1.5<br />
• Casting machines<br />
Gießmaschinen<br />
Via Brallo, 2 – 27010 Siziano (PV), Italy<br />
Tel: +39 0382 6671413<br />
E-mail: sales_<strong>de</strong>pt@erediscabini.com<br />
Internet: www.erediscabini.com<br />
Refratechnik Steel GmbH<br />
Schiessstrasse 58<br />
40549 Düsseldorf / Germany<br />
Phone +49 211 5858 0<br />
Fax +49 211 5858 46<br />
Internet: www.refra.com<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A<br />
Avenida Cervantes Nº6<br />
48970 – Basauri – Bizkaia – Spain<br />
Tel: +34 944 409 420<br />
E-mail: Insertec@insertec.biz<br />
Internet: www.insertec.biz<br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
4.3 Conveyor and storage<br />
technology<br />
För<strong>de</strong>r- und Lagertechnik<br />
Paul Hedfeld GmbH<br />
Hun<strong>de</strong>icker Str. 20<br />
D-58285 Gevelsberg<br />
Phone: +49 (0) 2332 6371<br />
E-mail: verkauf@hedfeld.com<br />
Internet: www.hedfeld.com<br />
see Equipment and accessories 3.1<br />
• Heat treatment furnaces<br />
Wärmebehandlungsöfen<br />
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A<br />
see Heat treatment 2.4<br />
see Casthouse (foundry) 1.5<br />
ALUMINIUM · 7-8/2013 87
LIEFERVERZEICHNIS<br />
4.7 Casting machines<br />
and equipment<br />
Gießereimaschinen<br />
und Gießeinrichtungen<br />
GAPCast<br />
TM : the Swiss casting solution<br />
Casting Technology / Automation<br />
Tel.: +41 27 455 57 14<br />
E-Mail: info@gap-engineering.ch<br />
Internet: www.gap-engineering.ch<br />
www.mechatherm.com<br />
see Smelting technology 1.5<br />
Precimeter Control AB<br />
Ostra Hamnen 7<br />
SE-475 42 Hono / Swe<strong>de</strong>n<br />
Tel.: +46 31 764 5520, Fax: +46 31 764 5529<br />
E-Mail: marketing@precimeter.com<br />
Internet: www.precimeter.com<br />
Sales contact: Jonatan Lindstrand<br />
Competence in EMC and ASC casting<br />
RIHS ENGINEERING SA<br />
Tel.: +41 27 455 54 41<br />
E-Mail: info@maschko.ch<br />
Internet: www.maschko.ch<br />
• Mould parting agents<br />
Kokillentrennmittel<br />
Schrö<strong>de</strong>r KG<br />
Schmierstofftechnik<br />
Postfach 1170<br />
D-57251<br />
Freu<strong>de</strong>nberg<br />
Tel. 02734/7071<br />
Fax 02734/20784<br />
www.schroe<strong>de</strong>r-schmierstoffe.<strong>de</strong><br />
Ein Eintrag (s/w) in<br />
diesem Format kostet<br />
pro Ausgabe + Stichwort<br />
110,00 € + MwSt.<br />
Weitere Informationen unter<br />
Tel. +49 (0) 821 / 31 98 80 - 34<br />
4.10 Measurement technology<br />
and materials testin<br />
Messtechnik und<br />
Materialprüfung<br />
ratioTEC Prüfsysteme GmbH<br />
In <strong>de</strong>r Au 17<br />
D-88515 Langenenslingen<br />
Tel.: +49 (0)7376/9622-0<br />
Fax: +49 (0)7376/9622-22<br />
E-Mail: info@ratiotec.com<br />
Internet: www.ratiotec.com<br />
• Burner System<br />
Brennertechnik<br />
Büttgenbachstraße 14<br />
D-40549 Düsseldorf/Germany<br />
Tel.: +49 (0) 211 / 5 00 91-0<br />
Fax: +49 (0) 211 / 5 00 91-14<br />
E-Mail: info@bloomeng.<strong>de</strong><br />
Internet: www.bloomeng.<strong>de</strong><br />
see Extrusion 2.4.<br />
• Heat treatment furnaces<br />
Wärmebehandlungsanlagen<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A<br />
see Heat treatment 2.4<br />
see Equipment and accessories 3.1<br />
Wagstaff, Inc.<br />
see Casting machines 1.6<br />
Hier könnte Ihr<br />
Bezugsquellen-Eintrag<br />
stehen.<br />
Rufen Sie an:<br />
Tel. 0821 / 31 98 80-34<br />
Dennis Ross<br />
• Continuous ingot casting<br />
lines and aluminium rod lines<br />
Kokillengieß- und <strong>Alu</strong>miniumdraht-Anlagen<br />
Via Emilia Km 310<br />
26858 Sordio-LO<br />
Italy<br />
Tel. +39.02.988492-1 . hq@properzi.it<br />
Fax +39.02.9810358 . www.properzi.com<br />
www.alu-<strong>web</strong>.<strong>de</strong><br />
4.11 Metallic charge<br />
materials<br />
Metallische Einsatzstoffe<br />
• Recycling / Recycling<br />
Chr. Otto Pape GmbH<br />
<strong>Alu</strong>miniumgranulate<br />
Berliner Allee 34<br />
D-30855 Langenhagen<br />
Tel:+49(0)511 786 32-0 Fax: -32<br />
Internet: www.papemetals.com<br />
E-Mail: info@papemetals.com<br />
4.13 Melt operations<br />
Schmelzbetrieb<br />
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A<br />
see Heat treatment 2.4<br />
www.mechatherm.com<br />
see Smelting technology 1.5<br />
• Holding furnaces<br />
Warmhalteöfen<br />
Bartz GmbH<br />
see Casthous (foundry) 1.5<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A<br />
see Heat treatment 2.4<br />
see Equipment and accessories 3.1<br />
Could not find your<br />
„keywords“?<br />
Please ask for our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
E-Mail: anzeigen@giesel.<strong>de</strong><br />
• Melting furnaces<br />
Schmelzöfen<br />
Bartz GmbH<br />
see Casthous (foundry) 1.5<br />
88 ALUMINIUM · 7-8/2013
SUPPLIERS DIRECTORY<br />
Gautschi<br />
Engineering GmbH<br />
see Casting equipment 3.1<br />
HERTWICH ENGINEERING GmbH<br />
see Casthouse (foundry) 1.5<br />
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A<br />
see Heat treatment 2.4<br />
see Equipment and accessories 3.1<br />
MARX GmbH & Co. KG<br />
Lilienthalstr. 6-18<br />
D-58638 Iserhohn<br />
Tel.: +49 (0) 2371 / 2105-0, Fax: -11<br />
E-Mail: info@marx-gmbh.<strong>de</strong><br />
Internet: www.marx-gmbh.<strong>de</strong><br />
4.14 Melt preparation<br />
Schmelzvorbereitung<br />
• Degassing, filtration<br />
Entgasung, Filtration<br />
Drache Umwelttechnik<br />
GmbH<br />
Werner-v.-Siemens-Straße 9/24-26<br />
D 65582 Diez/Lahn<br />
Telefon 06432/607-0<br />
Telefax 06432/607-52<br />
Internet: http://www.drache-gmbh.<strong>de</strong><br />
4.15 Melt treatment <strong>de</strong>vices<br />
Schmelzbehandlungseinrichtungen<br />
Metaullics Systems Europe B.V.<br />
Ebweg 14<br />
NL-2991 LT Barendrecht<br />
Tel. +31-180/590890<br />
Fax +31-180/551040<br />
E-Mail: info@metaullics.nl<br />
Internet: www.metaullics.com<br />
4.17 Environment protection<br />
and disposal<br />
Umweltschutz und<br />
Entsorgung<br />
• Dust removal<br />
Entstaubung<br />
NEOTECHNIK GmbH<br />
Entstaubungsanlagen<br />
Postfach 110261, D-33662 Bielefeld<br />
Tel. 05205/7503-0, Fax 05205/7503-77<br />
info@neotechnik.com, www.neotechnik.com<br />
5 Materials<br />
and<br />
Recycling<br />
Werkstoffe<br />
und Recycling<br />
• Granulated aluminium<br />
<strong>Alu</strong>miniumgranulate<br />
Chr. Otto Pape GmbH<br />
<strong>Alu</strong>miniumgranulate<br />
Berliner Allee 34<br />
D-30855 Langenhagen<br />
Tel:+49(0)511 786 32-0 Fax: -32<br />
Internet: www.papemetals.com<br />
E-Mail: info@papemetals.com<br />
6 Machining +<br />
Application<br />
Bearbeitung +<br />
Anwendung<br />
6.1 Equipment to produce<br />
castplate<br />
Ausrüstungen für<br />
Gussplattenproduktion<br />
• Slicing saw & Milling machines<br />
Folienschneidmaschinen<br />
Fräsmaschinen<br />
Sermas Industrie<br />
sermas@sermas.com<br />
see Smelting technology 1.6<br />
6.2 Semi products<br />
Halbzeuge<br />
• Wires / Drähte<br />
DRAHTWERK ELISENTAL<br />
W. Erdmann GmbH & Co.<br />
Werdohler Str. 40, D-58809 Neuenra<strong>de</strong><br />
Postfach 12 60, D-58804 Neuenra<strong>de</strong><br />
Tel. +49(0)2392/697-0, Fax 49(0)2392/62044<br />
E-Mail: info@elisental.<strong>de</strong><br />
Internet: www.elisental.<strong>de</strong><br />
Ein Eintrag (s/w) in<br />
diesem Format kostet<br />
pro Ausgabe + Stichwort<br />
110,00 € + MwSt.<br />
Weitere Informationen unter<br />
Tel. +49 (0) 821 / 31 98 80 - 34<br />
6.3 Equipment for forging<br />
and impact extrusion<br />
Ausrüstung für Schmie<strong>de</strong>und<br />
Fließpresstechnik<br />
• Hydraulic Presses<br />
Hydraulische Pressen<br />
LASCO Umformtechnik GmbH<br />
Hahnweg 139, D-96450 Coburg<br />
Tel. +49 (0) 9561 642-0<br />
Fax +49 (0) 9561 642-333<br />
E-Mail: lasco@lasco.<strong>de</strong><br />
Internet: www.lasco.com<br />
Could not find your „keywords“?<br />
Please ask for our complete<br />
„Supply sources for the<br />
aluminium industry“.<br />
E-Mail: anzeigen@giesel.<strong>de</strong><br />
8 Literature<br />
Literatur<br />
• Technical literature<br />
Fachliteratur<br />
Taschenbuch <strong>de</strong>s Metallhan<strong>de</strong>ls<br />
Fundamentals of Extrusion Technology<br />
Giesel Verlag GmbH<br />
Hans-Böckler-Allee 9, 30173 Hannover<br />
Tel. 0511 / 73 04-125 · Fax 0511 / 73 04-233<br />
Internet: www.alu-bookshop.<strong>de</strong><br />
• Technical journals<br />
Fachzeitschriften<br />
Giesel Verlag GmbH<br />
Hans-Böckler-Allee 9, 30173 Hannover<br />
Tel. 0511/8550-2638 · Fax 0511/8550-2405<br />
GDMB-Informationsgesellschaft mbH<br />
Paul-Ernst-Str.10, 38678 Clausthal-Zellerfeld<br />
Telefon 05323-937 20, Fax -237, www.gdmb.<strong>de</strong><br />
ALUMINIUM · 7-8/2013 89
VORSCHAU / PREVIEW<br />
IM NÄCHSTEN HEFT<br />
Special: Die <strong>Alu</strong>miniumindustrie am Golf<br />
Vom 5. bis 7. November 2013 fin<strong>de</strong>t in Abu Dhabi die<br />
Arabal Conference statt, die vom Hüttenproduzenten<br />
Emirates <strong>Alu</strong>minium ausgerichtet wird. Als Mediapartner<br />
<strong>de</strong>r Veranstaltung berichten wir in unserem Special über<br />
aktuelle Entwicklungen am Golf. Beiträge unter an<strong>de</strong>rem:<br />
• Interview mit Saeed Fadhel Al Mazrooei, CEO von Emal<br />
• Mo<strong>de</strong>rnste Walzwerkstechnologie für die Golfregion<br />
• Das <strong>Alu</strong>miniumcluster in Kizad nimmt Gestalt an<br />
• EPCM-Projekte in <strong>de</strong>r <strong>Alu</strong>miniumindustrie<br />
Weitere Themen<br />
• Belte AG – Spezialist in <strong>de</strong>r Wärmebehandlung<br />
von <strong>Alu</strong>miniumbauteilen<br />
• Innovative Lösungen für das Strahlen von Gussteilen<br />
• <strong>Alu</strong>minium S.A. steigert Produktion, senkt Kosten<br />
IN THE NEXT ISSUE<br />
Special: The aluminium industry in the Gulf<br />
The Arabal Conference 2013, hosted by Emirates <strong>Alu</strong>minium,<br />
will be taking place from 5-7 November in Abu<br />
Dhabi. As a media partner of the event ALUMINIUM will<br />
be reporting on recent <strong>de</strong>velopments in the Gulf region.<br />
Topics inclu<strong>de</strong>:<br />
• Interview with Emal CEO Saeed Fadhel Al Mazrooei<br />
• Best rolling mill technology for the Gulf region<br />
• Kizad aluminium cluster is taking shape<br />
• EPCM – a vital activity in the world of aluminium<br />
Other topics<br />
• Belte AG – <strong>special</strong>ist in the heat treatment of<br />
aluminium components<br />
• <strong>Alu</strong>minium S.A. increases production, reduces costs<br />
• Innovative shot blasting solutions for foundries<br />
Erscheinungstermin: 02. September 2013<br />
Anzeigenschluss: 16. August 2013<br />
Redaktionsschluss: 09. August 2013<br />
Date of publication: 02 September 2013<br />
Advertisement <strong>de</strong>adline: 16 August 2013<br />
Editorial <strong>de</strong>adline: 09 August 2013<br />
International<br />
ALUMINIUM<br />
Journal<br />
89. Jahrgang 1.1.2013<br />
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82 90 ALUMINIUM · 7-8/2013 · 5/2012
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SMS SIEMAG AG<br />
Eduard-Schloemann-Strasse 4 Phone: +49 211 881-0 E-mail: communications@sms-siemag.com<br />
40237 Düsseldorf, Germany Fax: +49 211 881-4902 Internet: www.sms-siemag.com