special - Alu-web.de

Special:
Aluminium Middle East
Dubal: Technology advances
improve environmental
performance
Energy-optimised
route from aluminium
scrap to extruded
semi-finished products
Low-energy aircooled
electromagnetic
stirring systems
Dubal
Portable metal
analysers support
recycling operations
Volume 89 · March 2013
International Journal for Industry, Research and Application3

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EDITORIAL
Volker Karow
Chefredakteur
Editor in Chief
Die Golf-Region –
künftiges „Powerhouse“
der Aluminiumindustrie
The Gulf region –
future ‘powerhouse’ of
the aluminium industry
Wenige Wochen vor der Aluminium Middle
East 2013 in Dubai blicken wir im Special
dieses Heftes auf die Golf-Region. Die Aluminiumprojekte
der vergangenen Jahre waren
stark vom Ausbau der Hüttenindustrie geprägt
– nicht zuletzt dank der konkurrenzlos
günstigen Energiepreise, was die Entwicklung
dieses Branchensektors auch in den kommenden
Jahren vorantreiben wird. Ma’aden
Alcoa wird seine Ende 2012 in Betrieb genommene
Hütte im Laufe dieses Jahres auf
eine Jahresproduktion von 750.000 Tonnen
hochfahren. Der Hüttenausbau bei Emal ist
beschlossene Sache, die Produktionskapazitäten
werden bis Ende 2014 auf 1,3 Mio.
Tonnen fast verdoppelt. Alba wird seine Kapazitäten
in ähnlicher Größenordnung bis 2015
ausbauen. Die Golf-Region wird damit in
den nächsten Jahren zu einem „Powerhouse“
für die Produktion von Primäraluminium.
In Zukunft wird aber auch die Verarbeitung
zu Aluminiumhalbzeugen eine wichtigere
Rolle in der Golf-Region spielen. Im Strangpressbereich
gibt es bereits seit vielen Jahren
renommierte Werke, die hohe Qualitäten und
nicht nur für die Bauwirtschaft produzieren.
Erst jüngst sind dort weitere Investitionen in
moderne Strangpressen getätigt worden. Überhaupt
zeichnen sich die Investitionsprojekte –
egal, ob im Hüttenbereich oder in der Verarbeitung
– dadurch aus, das hoher Wert auf
erstklassige Anlagenqualität gelegt wird. Das
sieht man u. a. daran, dass vielfach angesehene
europäische Ausrüster beauftragt werden.
Neben die Produktion von Strangpressprodukten
tritt verstärkt die Herstellung von
Walzerzeugnissen. In Oman wird derzeit ein
Walzwerkskomplex mit Warm-, Kalt- und
Fertigstraße gebaut, der Mitte dieses Jahres
fertig gestellt sein soll. Die Anlage wird hochwertige
Produkte in dünnen Abmessungen
und hohen Oberflächengüten herstellen.
Ebenfalls dieses Jahr wird das Warm- und
Kaltwalzwerk von Ma’aden Alcoa in Saudi-
Arabien in Betrieb gehen und 2014 die Glühund
Beschichtungslinie für Automobil-Qualitäten
die Produktion aufnehmen.
Interessant ist in diesem Zusammenhang,
dass Jaguar Land Rover eine Machbarkeitsstudie
in Auftrag gegeben hat, die den Bau
eines Automobilwerks in Saudi-Arabien zum
Gegenstand hat. Das ist auch insofern interessant,
als die Premiummodelle des Autoherstellers
– Jaguar XJ und der neue Range
Rover – eine Aluminiumkarosserie haben
und der Autobauer in Middle East hohe Verkaufszuwächse
erwartet.
Die Golf-Region entwickelt sich und die
Aluminiumindustrie ist ein kraftvoller Motor
dieser Entwicklung.
A few weeks before Aluminium Middle East
2013 in Dubai, in the Special section of this
issue we are taking a look at the Gulf region.
There, the aluminium projects of the past years
have focused strongly on the extension of the
smelting industry – not least thanks to the incomparably
low energy prices in the region,
which will continue driving forward the development
of the sector for years. The Ma’aden
Alcoa smelter, which began operating at the
end of 2012, will boost its annual output
to 750,000 tonnes this year. The smelter enlargement
at Emal is now an accomplished
fact and its output will be almost doubled to
1.3m tonnes by the end of 2014, while Alba
will increase its capacity to a similar level by
2015. So in the coming years the Gulf region
will become a ‘powerhouse’ for the production
of primary aluminium: in a year or two
the region will be contributing around 15%
of global primary aluminium production.
In times to come, moreover, the processing
of aluminium semis will also play a more
important part in the Gulf region. In the extrusion
sector for many years already there
have been renowned plants which manufacture
high-grade products, and this not only
for the building industry. Just recently further
investments have been made in modern extrusion
presses. In general – and as much in
the smelting sector as in processing – such investment
projects have focused on first-rate
plant quality, as demonstrated inter alia by
the many orders placed with respected European
equipment suppliers.
Besides the production of extrusions the
manufacture of rolled products is also gaining
ground. In Oman a rolling plant complex
with hot and cold mills and a finishing line
is currently under construction and is scheduled
for completion by the middle of this
year. The plant will produce high-grade products
in thin dimensions and with excellent
surface quality. Also this year the Ma’aden Alcoa
hot and cold rolling plant in Saudi Arabia
will come on line and in 2014 the additional
heat treatment and coating lines for automobile-grade
products will start operating.
In this connection it is interesting that Jaguar
Land Rover has commissioned a feasibility
study on the building of an automobile
factory in Saudi Arabia. That is particularly
interesting since the premium models of the
car manufacturer – the Jaguar XJ and the
new Range Rover – have aluminium bodies
and the car manufacturer expects to see burgeoning
sales figures in the Middle East.
The Gulf region is developing apace and
the aluminium industry is a powerful driving
force of that development.
ALUMINIUM · 3/2013 3

INHALT
EDITORIAL
Die Golf-Region – künftiges „Powerhouse“ der Aluminiumindustrie
The Gulf region – future ‘powerhouse’ of the aluminium industry ........ 3
AKTUELLES • NEWS IN BRIEF ...................................... 6
WIRTSCHAFT • ECONOMICS
23
Aluminiumpreise ......................................................................... 10
Produktionsdaten der deutschen Aluminiumindustrie ..........................12
Schweizer Gießerei-Industrie 2012 drastisch eingebrochen ...................14
Urban Mining – Rohstoffquelle der Zukunft: „Aluminium
ist Aluminium“ • Urban Mining – Raw materials source of
the future: “Aluminium is aluminium” .............................................16
ALUMINIUM MIDDLE EAST
Aluminium Middle East 2013 – Expand your reach within the region ....22
Inserenten dieser Ausgabe
List of advertisers
34
ABB Switzerland 33
Alteco Aluminiumtechnologie, Austria 21
Arabal, UAE 25
A.t.i.e. Uno Informatica Srl, Italy 32
Beta Lasermike, USA 64
BWG Bergwerk- und Walzwerk-
Maschinenbau GmbH, Germany 13
Joh. Clouth Maschinenbau Eltmann
GmbH & Co. KG, Germany 15
De Winter Engineering, The Netherlands 42
Didion International Inc., USA 17
Dubai Aluminium Co. Ltd, UAE 11
Emirates Aluminium, UAE 92
extrutec GmbH, Germany 23
Fata Hunter SpA, Italy 31
Frenzelit Werke GmbH, Germany 29
Getriebebau Nord, Germany 5
Glama Maschinenbau GmbH, Germany 39
Hertwich Engineering GmbH, Austria 2
IBB Maschinenbau, Germany 57
Inotherm Industrieofen- und
Wärmetechnik GmbH, Germany 21
Magma GmbH, Germany 7
Micro-Epsilon Messtechnik
GmbH & Co. KG, Germany 61
Mino SpA, Italy 43
OMAV SpA, Italy 19
Otto Junker GmbH, Germany 45
R&D Carbon Ltd, Switzerland 37
Rösler Oberflächentechnik
GmbH, Germany 63
Seco/Warwick S.A., Poland 51
Salico Hispania S.A., Spain 27
SMS Siemag AG, Germany 40/41
Storvik AS, Norway 67
Wagstaff Inc, USA 35
Aluminium industry in the Middle East during 2012 ..........................23
Advancements in reduction technology improve specific energy
consumption and reduce greenhouse gas emissions at Dubal ............. 34
Emal – Well positioned to meet future demand for aluminium ...........38
TECHNOLOGIE • TECHNOLOGY
Protective clothing for the aluminium industry from South Africa ........42
Otto Junker: Energy-optimised route from aluminium
scrap to extruded semi-finished products ........................................ 44
Altek: Low-energy air-cooled electromagnetic stirring systems ...........49
Portable metal analysers support recycling operations .......................53
Kurtz liefert Niederdruck-Gießmaschinen an BMW
Kurtz supplies low pressure casting machines to BMW ...................... 55
BMW setzt auf energieeffiziente Schmelzöfen von ZPF Therm
ZPF Therm supplies energy-efficient smelting furnaces to BMW .......... 56
Frenzelit: Mit technischen Textilien hohe Temperaturen im
Hüttenprozess beherrschen • Frenzelit: Controlling high
temperatures in smelting using technical textiles .............................. 58
Fata Hunter – further success in flat rolled product business ..............59
SMS Siemag liefert Warmwalzlinie und Kaltwalzanlage
für Automobilprodukte an Shandong Nanshan Aluminium
SMS Siemag to supply hot mill and cold rolling mill for
automotive products for Shandong Nanshan Aluminium .................... 60
Alteco: Automated profile measurement for aluminium extrusions ......62
Outotec wins order for liquid pitch storage from Emal ......................63
4 ALUMINIUM · 3/2013

CONTENTS
US Government funds projects to develop
higher performance materials for road vehicles ................................ 64
COMPANY NEWS WORLDWIDE
Aluminium smelting industry .........................................................65
Bauxite and alumina activities ......................................................65
Aluminium semis .........................................................................66
On the move ..............................................................................66
Suppliers ...................................................................................67
RESEARCH
53
Versagensbeschreibung beim Tiefziehen von
Aluminiumfeinblech mit Biegeüberlagerung .....................................69
DOCUMENTATION
Patente .....................................................................................73
Impressum • Imprint ....................................................................89
Vorschau • Preview .....................................................................90
LIEFERVERZEICHNIS • SUPPLIERS DIRECTORY .............76
59
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for the metal industry
Motor
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22941 Bargteheide, Rudolf-Diesel-Str. 1
Fon: +49 (0) 45 32 / 289 - 0, Fax: +49 (0) 45 32 / 289 -2253
info@nord.com, www.nord.com
Member of the NORD DRIVESYSTEMS GROUP

AKTUELLES
Euroguss feiert zehntes Messe-Jubiläum
Vom 14. bis 16. Januar 2014 trifft sich die
Druckguss-Fachwelt auf der Euroguss, die im
kommenden Jahr ihre zehnte Auflage feiert.
Was mit 93 Ausstellern 1996 in Sindelfingen
als Fachausstellung begann, hat sich mit zuletzt
knapp 400 Ausstellern und über 8.500
Fachbesuchern zu einer erfolgreichen Fachmesse
für Druckgusstechnologie entwickelt.
Die Vorbereitungen für die Jubiläumsmesse
laufen bereits beim Veranstalter in Nürnberg.
Die Euroguss ist die einzige Messe, die
die gesamte Druckguss-Wertschöpfungskette
abbildet. Das Angebot umfasst das komplette
Spektrum an Druckguss-Technik, -Prozessen
und -Produkten. Das Publikum dieser Messe
ist international und hoch qualifiziert, jeder
vierte Besucher reist aus dem Ausland an.
Zwei Drittel sind in Beschaffungsentscheidungen
ihres Unternehmens einbezogen. Die
Fachbesucher kommen vor allem aus der
Automobil(zuliefer)industrie sowie aus dem
Fahrzeugbau (45%), aus Druckgießereien
(13%), dem Maschinen- und Anlagenbau
(11%), dem Formenbau (6%) sowie der Elektroniksparte
(4%).
Messebeirat erweitert
Seit Dezember 2012 ist der Messebeirat der
Euroguss um ein Mitglied erweitert, und zwar
um Gerd Röders, dem neuen Präsidenten des
Verbandes Deutscher Druckgießereien (VDD)
und Geschäftsführer von G. A. Röders. „Mit
Gerd Röders haben wir einen Vertreter einer
traditionsreichen, mittelständischen Druckgießerei
aus Deutschland gewonnen, der unseren
Messebeirat optimal ergänzt“, freut sich
Heike Slotta, Leiterin Veranstaltungen bei der
Nürnberg Messe. „Der Messebeirat ist unser
Ohr am Markt und berät uns in allen fachlichen
und messestrategischen Punkten rund
um das Thema Druckguss.“
13. Druckgusstag am 19. März 2013
Im Euroguss-freien Jahr 2013 findet der Internationale
Deutsche Druckgusstag wieder
in Sindelfingen statt, genauer am 19. März.
Den Auftakt zur Veranstaltung macht der
Gießerabend am 18. März 2013, ausgerichtet
von der Oskar Frech GmbH + Co. KG, Schorndorf.
Themen des Druckgusstages unter anderem:
• Die Perspektiven der Herstellung von Al-
Gusslegierungen in Deutschland
• Druckgussindustrie aus Sicht einer Bank
• Steigerung der Profitabilität auf der Marktseite
– Pricing als zentraler Gewinntreiber
• Energiemanagementsysteme und Carbon
Footprint – Chancen und Nutzen
• Salzkerntechnik – eine faszinierende
Wachstumschance
• Tendenzen und Perspektiven im
Werkzeugbau
• Aktuelle und zukünftige Herausforderungen
für Druckgießereien
• Wirtschaftliche und technische Vorteile
durch den Einsatz wasserbasierter Trennstoffkonzentrate.
Die Vorträge werden simultan jeweils in
Deutsch bzw. Englisch übersetzt. Das komplette
Programm ist unter www.euroguss.de
abrufbar. 2014 läuft der Druckgusstag dann
wieder parallel zur Fachmesse Euroguss in
Nürnberg.
© Euroguss
KSM Castings baut US-Werk
KSM Castings, ein führender Lieferant von
Produkten aus Leichtmetallguss, errichtet ein
Werk in Shelby, North Carolina. Der Schritt
in den nordamerikanischen Markt ist Teil der
globalen Wachstumsstrategie des Unternehmens.
Mit dem neuen Produktionsstandort
sollen Alt- und Neukunden lokal beliefert
werden. KSM verspricht sich von dem anhaltenden
Trend zu ressourcenschonenden Produkten
eine steigende Nachfrage nach seinen
Gussteilen aus Aluminium und Magnesium.
Das Werk Shelby wird Anfang 2014 die Produktion
aufnehmen.
Das Unternehmen gehört seit Oktober 2011
dem chinesischen Räderhersteller Citic Dicastal
und betreibt sechs Werke in Deutschland,
Tschechien und China mit insgesamt
2.900 Mitarbeitern. Zu den Kunden zählen
führende Automobilhersteller und Zulieferer.
KSM erzielte im Geschäftsjahr 2012 einen
Umsatz von 465 Mio. Euro.
HAI übernimmt Riftec
Die österreichische Hammerer Aluminium
Industries Holding GmbH (HAI) hat zum 1.
Februar 2013 die Geesthachter Riftec GmbH
übernommen. Der Name Riftec bleibt dabei
ebenso erhalten wie die wesentliche Struktur
des Unternehmens. Riftec ist Spezialist im industriellen
Rührreibschweißen. Im Fokus stehen
Aluminiumbauteile mit Nahtlängen unter
drei Meter, zum Teil mit komplexen Geometrien,
mehrdimensionale Fügeverbindungen
sowie das Verbinden unterschiedlicher Werkstoffe
wie Aluminium und Edelstahl oder Aluminium
und Kupfer.
Riftec hatte im Sommer 2012 Insolvenz angemeldet.
Ursache waren hohe Investitionen
im Vorjahr gepaart mit einem unerwarteten
Auftragseinbruch und einer daraus resultierenden
Liquiditätskrise. Mit HAI soll Riftec
wieder auf Erfolgskurs gebracht werden.
6 ALUMINIUM · 3/2013

NEW S IN BRIEF
Euroguss exhibition celebrates 10 th anniversary
The die casting experts will meet at the Euroguss
trade fair from 14 to 16 January 2014 to
celebrate next year’s tenth edition. What began
as a trade fair with 93 exhibitors in Sindelfingen
in 1996 has developed into a successful
exhibition for die casting technology with
about 400 exhibitors and more than 8,500
trade visitors at the last event. The organiser
has already started preparations for the 2014
show in Nuremberg.
Euroguss is the only exhibition that presents
the whole die casting value chain: the
products on display cover the complete range
of die casting technology, processes and
products. The visitors are international and
highly qualified. Every fourth visitor to Euroguss
travels from abroad. Two-thirds are
involved in procurement decisions in their
companies. The visitors come mainly from
the automotive industry and its suppliers and
from automotive engineering (45%), die casting
foundries (13%), machinery and plant
construction (11%), mould making (6%) and
the electronics industry (4%).
Exhibition committee
welcomes extra member
In December Gerd Röders was appointed new
member of the Euroguss exhibition committee.
He is president of the VDD (Association
of German Die Casting Foundries) and managing
director of G. A. Röders. “With Gerd
Röders we have gained a representative of
an old-established, medium-sized die casting
foundry in Germany, who will supplement our
committee in an optimum way,” says Heike
Slotta, exhibition director at Nürnberg Messe.
“The exhibition committee is our link with
the market and advises us on all technical and
exhibition strategy matters concerning die
casting.”
Die Casting Congress 2013 on 19 March
Euroguss takes a scheduled break in 2013
and the International Die Casting Congress returns
to Sindelfingen on 19 March. The event
kicks off with the Die Casters Evening on
18 March. The lectures programme includes:
• Prospects to the manufacturing of
aluminium alloys in Germany
• Die casting industry from a banks view
• Increasing profitability on the market
side – pricing as a central profit driver
• Energy management systems and carbon
footprinting – opportunities and benefits
• Lost core technology – a challenging
growth opportunity
• Trends and outlook for the mould making
industry
• Present and future challenges for die casting
foundries: resource and energy efficiency,
flexibility and growing competitive
pressure
• Economical and technical advantages by
using waterbased concentrated release
agents.
The lectures are translated simultaneously
in English. The complete programme can be
downloaded at www.euroguss.de. In 2014
the congress will take place again in Nuremberg
parallel to the Euroguss trade fair.
RELIABLE DECISIONS !
Casting is a complex manufacturing process that involves many
critical variables. From design to production, process steps and
parameters need to be controlled and systematically optimized.
Casting process simulation, together with your technical expertise,
leads to decisions that get the job done right the first time, every time.
MAGMA GmbH
Kackertstraße 11
52072 Aachen, Germany
Telefon +49 241 88 901-0
Fax +49 241 88 901-60
info@magmasoft.de
www.magmasoft.de

AKTUELLES
Dreidimensionale Fassadengestaltung
mit Aluminium von Novelis
© Novelis
Wie ein geschliffener Diamant:
Architektur-Highlight auf der „Bau 2013“
Blickfang und Besuchermagnet auf der BAU
2013 war der Novelis-Messestand mit der originalen
Fassadenkonstruktion des Titanic Signature
Project in Belfast. Die Fassadenkonstruktion
des Titanic Museums war Gewinner
des EAA Aluminium Award 2012. Wie ein
geschliffener Diamant, der in wechselnden
Farben erstrahlt, so erschien den Besuchern
die Titanic-Fassadenkonstruktion aus Novelis
Aluminium J 57 S. Architekten und Fassadenbauer
aus aller Welt zeigten sich begeistert.
Mit der Titanic-Fassade hat der Fassadenbauer
EDM Spanwall aus Irland eine neue Ära für
Metallfassaden eingeleitet.
Novelis präsentierte auf der Bau 2013
funktionale wie dekorative Oberflächen aus
Aluminium für eine variantenreiche und anspruchsvolle
Außen- und Innenarchitektur.
Verpackungsrecycling erreicht
neue Bestmarke
Das Recycling von Alu-Verpackungen in
Deutschland hat einen neuen Höchstwert erreicht.
Von den 2011 im Markt eingesetzten
93.700 Tonnen wurden laut Gesellschaft für
Verpackungsmarktforschung (GVM), Mainz,
82.200 Tonnen verwertet. Dies entspricht
einer Recyclingrate von 87,8 Prozent. „Die
hohen Recyclingraten belegen, dass wir in
Deutschland über ein hervorragend funktionierendes
Verpackungsrecycling verfügen.
Die gelbe Tonne ist etabliert und erfolgreich.
Moderne Trenntechnologie wie effiziente
Wirbelstromabscheider werden flächendeckend
eingesetzt. Es bietet sich an, dieses
System als sogenannte Wertstofftonne jetzt
auch für andere gebrauchte Produkte aus
Metall zu öffnen“, kommentierte Hans-Jürgen
Schmidt, Geschäftsführer der Deutsche
Aluminium Verpackung Recycling GmbH
(DAVR), Grevenbroich, die positiven Verwertungszahlen.
Die GVM ermittelt jährlich das Aufkommen
und die Verwertung von Verpackungsabfällen
in Deutschland – auch im Auftrag
des Umweltbundesamtes, Berlin. Die Verwertungsmengen
der verschiedenen dualen
Systeme sowie die Rückführung gebrauchter
Verpackungen über sonstige Organisationen
und Erfassungswege werden berücksichtigt.
„Die aktuellen Zahlen der GVM dokumentieren
den hohen Stellenwert des Recyclings
für die Aluminiumindustrie“, sagte Christian
Wellner, Geschäftsführer des Gesamtverbandes
der Aluminiumindustrie (GDA),
Düsseldorf. Der Wiederverwertung von gebrauchtem
Aluminium aus Verpackungen,
Fahrzeugen und weiteren Anwendungen
komme eine immer größere Bedeutung zu.
„Der GDA wird deshalb das Recycling von
Aluminium in Zukunft noch stärker unterstützen
und hat dazu seinen Fachverband Aluminiumrecycling
aktiviert“, so Wellner.
The European Aluminium Foil Association (EAFA)
has announced that the third Global Aluminium
Foil Roller Conference (Glafco) will take place
from 15 to 17 January 2014 in Dubai. Delegates
from the international aluminium foil roller industry
are expected to continue the coordinated
actions on foil sustainability and promotion to
support market growth globally and highlight
innovative developments.
Stefan Glimm, executive director of EAFA,
comments: “Our objective is to gather more
than 90 percent of the global foil market in
Dubai – ten percent more than last time. The
industry wants to continue building one global
voice for foil on sustainable and promotion issues
to support further growth. Both in packaging
and technical applications aluminium foil has
the great advantage of saving more resources
Basierend auf den jetzt erreichten Verwertungsraten
betragen die jährlichen Einsparungen
von Treibhausgasen nach Berechnungen
der DAVR mehr als 430.000 Tonnen
sogenannter CO 2 -Äquivalente. Aufwendungen
für Sammlung, Aufbereitung und Recycling
sowie auftretende Materialverluste wurden
dabei berücksichtigt. Die CO 2 -Einsparung
entspricht dem jährlichen Treibstoffverbrauch
von etwa 180.000 Autos auf Deutschlands
Straßen.
3 rd Global Aluminium Foil Roller Conference 2014 in Dubai
than it consumes, through the complete value
and supply chain.”
The first joint project ‘A Global Moment with
Alufoil’ was launched at the last conference. It
comprises a brochure in several languages and
the multilingual website www.global-alufoil.
org. The report demonstrates alufoil’s versatility
and shows the methods the industry is using
to provide solutions for a world facing growing
population, urbanisation, climate change, and
depletion of scarce resources.
Glafco is open for foil rollers worldwide.
Previous conferences were held in Oman and
Thailand. Supporters are Achenbach Buschhütten,
Kampf, Novelis PAE, Thiel & Hoche and
the International Aluminium Institute (IAI). The
strategic partner is CRU.
8 ALUMINIUM · 3/2013

NEW S IN BRIEF
Guangzhou, China, 9-12 Sept 2013
5 th Intl Aluminium Profile Technology Seminar & Expo
The 5 th International Aluminium Profile Technology
Seminar & Exposition – Lw 2013 will
be held in Guangzhou, China, from 9 to 12
September 2013. Lw 2013 will be the fifth
event in its series held once every three years
to promote technological exchanges and cooperation
across the industry and academia.
It is expected to be once again a premier
industrial event in China for extruders, universities,
research institutes and suppliers of
equipment, extrusion tooling and tooling materials
for the aluminium extrusion industry.
It will provide an excellent opportunity for
the participants to meet extrusion experts
from all over China and abroad, and get updated
about the current situation and future
trends of China’s aluminium extrusion industry.
At the event, presentations in English
are highly welcome, although the majority of
conference sessions and materials will be in
Chinese.
Call for papers is open: email your abstract
to wangzitao@vip.163.com in the Word file
format. The deadline for the submission of
full-length paper is 30 June 2013. Conference
proceedings will be distributed during
the conference, after proofreading and editing.
Selected papers will be recommended for
publication in relevant journals.
A limited number of exhibit booths are
available for exhibitors to showcase their
products and equipment. Promotional sessions
during the conference can be arranged.
For details about the event and promotional
opportunities please contact:
Aluminium Processing Technology Centre,
Mr. Zitao Wang, 5-B-304, No.168, Niuligang
Beijie, Guangzhou Dadaobei, Guangzhou,
Guangdong 510510, China. Tel: +86-20-
8770 0895; Fax: +86-20-8724 2261; Email:
wangzitao@vip.163.com
Cold Rolling Day 2013
Based on the success of the first Cold Rolling
Day in 2011, the nine supporting companies
decided to hold a second Cold Rolling Day
to present their latest developments and the
possibilities of application. This second event
will be taking place in Düsseldorf, Germany,
on 16 May 2013. Lectures, among others: •
Steinhoff: Advances in Destructive and Non-
Destructive Testing of Cold Rolls • Henkel:
Multi-Discipline Technologies in Cold Rolling
Lubrication • Atlantic: Challenges of Roll
Grinding • Lechler: Selective Roll Cooling
Systems and new Spray Nozzle Solutions •
Schaeffler: Solutions for Cold Rolling Mills
to increase machine availability and quality
• Herkules: Herkules Roll Grinders – Value
Adding Technology. All lectures will be translated
simultaneously into German. For further
information (e.g. complete programme of lectures
and registration form), please contact:
Jürgen Dickmann, Fax: +49 2064 500 29,
Email: juergen.dickmann@steinhoff.eu
Jaguar Land Rover signs
LoI with Saudi Arabian
government
Already in December Jaguar Land Rover
(JLR) and the National Industrial Clusters
Development Programme (NICDP), Saudi
Arabia, signed a letter of intent paving the way
for an automotive partnership in the Kingdom
of Saudi Arabia. A detailed feasibility study
is to determine the viability of setting up an
automotive facility. Ralf Speth, chief executive
of JLR, said: “Saudi Arabia is an attractive
potential development option, complementing
our existing advanced facilities in Britain and
recent manufacturing plans to expand in other
countries including India and China.”
Discussions between JLR and the Saudi
Government are at a preliminary stage, although
opportunities have already been identified
in aluminium component production –
an area where JLR has established a strong
market position. Jaguar Land Rover has pioneered
aluminium body development in the
premium car segment, using lightweight metals
for its Jaguar XJ model and the all-new
Range Rover, the first luxury sports utility vehicle
with an all-aluminium monocoque body
structure.
The announcement follows a sharp rise in JLR
sales to emerging markets, contributing to a
30% increase in global retail sales to 357,773
vehicles in 2012 – a record breaking year for
the car manufacturer. In the year to November,
sales in the Middle East and North Africa
have increased by more than 9% to 11,418
units. “This is an exciting project that could
enable Jaguar Land Rover to establish a joint
venture partnership in a part of the world
where luxury vehicle sales are expected to
rise,” added Mr Speth.
Günter Kirchner is retiring
Günter Kirchner (65) will retire on 1 April
2013. He has been managing the business of
the European Organisation of the Aluminium
Recycling Industry OEA and the corresponding
German association VAR (Verband der
Aluminiumrecycling-Industrie) very successfully
since January 1983. He started his career
as managing director of the Verein Deutscher
Metallhändler (German Association of Metal
Traders) in 1978.
In order to take account to the ongoing
structural changes in the aluminium industry
in Germany and Europe, he has now at the end
of his active working life created the conditions
for a fundamental reorganisation of the
representation of interests by the associations.
As from 1 April 2013 the Fachverband Aluminiumrecycling
will represent the interests
of the aluminium recycling industry within
the GDA Gesamtverband der Aluminiumindustrie
(German Association of the Aluminium
Industry).
The OEA will largely relocate its business to
Brussels, where it will represent the interests
of the European aluminium recycling industry
under the umbrella of the European Aluminium
Association (EAA). Gerd Götz will
be Secretary General of OEA as from 1 April
2013. On 1 January he already started his activity
as director general of EAA.
© VAR
ALUMINIUM · 3/2013 9

W IRTSCHAFT
Aluminium im Monatsrückblick
Ein Service der TRIMET ALUMINIUM AG
res ($1.850/t) deutlich erhöht. Der Grund
hierfür ist die schwindende Angst vor
einer weltweiten Rezession. Die Marktteilnehmer
sind inzwischen deutlich
optimistischer, was den Ausblick für 2013
angeht. Diese positive Stimmung ist auch
Die Aluminium LME 3M-Notierung
verhielt sich im Januar weitestgehend
lustlos. Die Handelsspanne seit November
liegt zwischen $2.000 bis $2.150/t.
Jedoch hat sich der Boden dieser Spanne
im Vergleich zum April des letzten Jahan
stärkere Wachstumsaussichten für
China gekoppelt. Das Prämienniveau
blieb auch im Januar auf unverändert
hohem Niveau.
Auf- bzw. Abschlag für 3-Monatstermin
Letzten 6 Durchschnittswerte LME
Januar 2013 27,92 Euro
Dezember 2012 9,78 Euro
November 2012 14,42 Euro
Oktober 2012 21,42 Euro
September 2012 10,86 Euro
August 2012 27,78 Euro
2004 2005 2006 2007 2008 2009 2010 2011 2012
0
50
–50
Aluminium High Grade, Kasse
Letzten 6 Durchschnittswerte LME 2.500
Januar 2013 1.531,99 Euro
Dezember 2012 1.590,85 Euro
November 2012 1.513,95 Euro
Oktober 2012 1.522,53 Euro
September 2012 1.595,26 Euro
August 2012 1.482,26 Euro
2004 2005 2006 2007 2008 2009 2010 2011 2012
2.000
1.500
1.000
Aluminium Lagerbestände
Letzten 6 Monatsendwerte LME
Januar 2013 5.156.975 t.
Dezember 2012 5.210.050 t.
November 2012 5.207.225 t.
Oktober 2012 5.077.375 t.
September 2012 5.055.850 t.
August 2012 4.870.050 t.
2004 2005 2006 2007 2008 2009 2010 2011 2012
6.000
5.000
4.000
3.000
2.000
1.000
0
Alle Angaben auf dieser Seite sind unverbindlich.
Quelle: TRIMET ALUMINIUM AG – aktuelle LME-Werte unter www.trimet.de oder per TRIMET-App auf das iPhone.
10 ALUMINIUM · 3/2013

W IRTSCHAFT
Produktionsdaten der deutschen Aluminiumindustrie
Primäraluminium Sekundäraluminium Walzprodukte > 0,2 mm Press- & Ziehprodukte**
Produktion
(in 1.000 t)
+/-
in % *
Produktion
(in 1.000 t)
+/-
in % *
Produktion
(in 1.000 t)
+/-
in % *
Produktion
(in 1.000 t)
Dez 35,9 -3,5 46,7 12,1 109,2 -11,5 30,2 -3,5
Jan 12 35,3 -4,7 54,1 7,2 145,4 -6,1 46,3 3,3
Feb 32,4 -4,1 55,6 2,6 149,3 -7,3 47,7 0,9
Mär 34,1 -8,0 57,2 -2,2 165,9 -4,5 50,4 -5,1
Apr 33,5 -6,1 53,3 0,2 147,2 -6,0 45,0 -4,9
+/-
in % *
Mai 34,4 -7,4 54,3 -4,1 160,7 -4,5 48,9 -12,7
Juni 33,0 -8,0 54,6 6,9 161,0 20,6 49,1 -0,3
Juli 34,8 -5,0 56,0 7,1 166,4 0,9 46,9 -7,4
Aug 34,9 -5,8 47,2 2,9 161,4 1,2 44,9 -11,8
Sep 33,6 -4,4 52,5 -4,3 164,5 8,1 44,6 -17,2
Okt 35,2 -2,5 53,3 -0,3 162,5 9,4 46,1 -7,4
Nov 34,2 -2,9 53,4 -6,4 152,9 0,1 42,5 -20,1
Dez 35,1 -2,1 43,4 -7,0 117,2 7,4 23,9 -20,9
* gegenüber dem Vorjahresmonat, ** Stangen, Profile, Rohre; Mitteilung des Gesamtverbandes der Aluminiumindustrie (GDA), Düsseldorf
Primäraluminium
Sekundäraluminium
Walzprodukte > 0,2 mm
Press- und Ziehprodukte
12 ALUMINIUM · 3/2013

Visit us.
ALUMINIUM
Middle East 2013

W IRTSCHAFT
Schweizer Gießerei-Industrie 2012 drastisch eingebrochen
Die Schweizer Gießerei-Industrie bilanziert
für 2012 einen Rückgang der abgelieferten
Tonnagen von minus 20% über
alle Werkstoffgruppen hinweg. Für das
laufende Jahr wird eine weitere Konjunkturabschwächung
erwartet.
Über das gesamte Jahr 2012 hat sich die negative
Entwicklung bestätigt, die sich schon
im vierten Quartal 2011 abzeichnete. Die 52
überwiegend klein- und mittelständischen
Unternehmen des Gießerei-Verbandes der
Schweiz (GVS) exportieren zu rund 80 Prozent
in den Euroraum. „Auch wenn sich der
Euro-Wechselkurs augenblicklich leicht verbessert
hat, ändert dies nichts an der Tatsache,
dass die Schweizer Gießerei-Industrie
2012 unter dem starken Schweizer Franken
Einziger Lichtblick war der Schienfahrzeugsektor
mit einem Mengenwachstum und der
Fahrzeugbau, der sich dank Neuanläufen auf
hohem Niveau halten konnte. Grundsätzlich
gelte aber auch hier, dass „trotz viel Aufwand
wenig Ertrag bei unseren Mitgliedsfirmen
erwirtschaftet werden konnte“, wie
Verbandsgeschäftsführer Marcel Menet die
ernüchternde Situation zusammenfasste. Besonders
ab Mitte 2012 verlor der Fahrzeugbau
als tragende Säule der Gießerei-Industrie
spürbar an Dynamik. Zudem gingen im Maschinenbausektor
die Bestelleingänge signifikant
zurück. Anhaltend positiv verliefen die
Aufträge aus der Verpackungsindustrie, Medizinaltechnik
und dem Bauwesen. „Dies führte
zu einer extrem heterogenen Situation mit teils
noch ausgelasteten Unternehmen einerseits
Entwicklung Leichtmetallguss
gelitten hat. Dazu kam der generell negative
weltweite Konjunkturverlauf“, stellte Markus
Schmidhauser, GVS-Präsident und Geschäftsführer
der Wolfensberger AG (Bauma), anlässlich
auf der Jahrespresskonferenz des
Verbandes fest.
Nicht nur das Exportgeschäft litt unter der
Eurokrise, auch im heimischen Markt mussten
empfindliche Einbußen hingenommen werden,
da zunehmend Wettbewerber aus dem
kostengünstigeren Ausland bei der Auftragsvergabe
die Nase vorn hatten. „Die Einkäufer
orientieren sich im Euro-Raum und viele
Kunden aus unseren heimischen Anwendermärkten
verlagern ihre Produktionsbetriebe
ins Ausland“, so Schmidhauser.
und in Kurzarbeit befindlichen Gießereien
andererseits“, erklärte Schmidhauser.
Insgesamt sanken die abgelieferten Tonnagen
2012 bei den Eisen- und Stahl-Gießereien
im Vergleich zum Vorjahr um 24 Prozent auf
47.850 Tonnen.
Bei den Schweizer Leichtmetallgießern reduzierten
sich die verarbeiteten Tonnagen auf
17.970 Tonnen (-14%). Beim Leichtmetall-
Sandguss musste ein Minus von 37 Prozent
auf 2.740 Tonnen hingenommen werden,
beim Druckguss eine Rückgang von sieben
Prozent auf 12,770 Tonnen. Der Kokillenguss
schrumpfte um zehn Prozent auf 2.460
Tonnen.
Über alle Werkstoffgruppen hinweg ge-
© GVS
sehen lieferte die Schweizer Gussindustrie
69.400 Tonnen (-20%). Bei diesen Tonnagen
müsse jedoch berücksichtigt werden, dass
viele Gussteile dank innovativer Entwicklungen
dünnwandiger produziert werden und dadurch
zum Teil mit weniger Materialeinsatz
mehr Gussteile hergestellt werden konnten,
sagte Menet.
Ausblick 2013 – globale
Wirtschafslage lähmt Entwicklung
„Für das laufende Jahr rechnet die Branche
mit einem weiteren Rückgang von bis zu fünf
Prozent. Als Hauptursachen werden dafür
die weltweite Wirtschaftslage und Schuldenkrise
im Euroraum, die fortschreitende
Globalisierung von Fertigungsbetrieben auf
Kundenseite sowie die gravierenden Folgen
des Euro-Wechselkurses ausgemacht – kaum
zu beeinflussende äußere Faktoren, denen
sich die Schweizer Gießerei-Industrie stellen
muss. „Aufgrund des starken Schweizer Frankens
und der hohen Lohnkosten ist unsere
Industrie nur noch mit hochwertigen Produkten
mit tiefem Lohnanteil bzw. hoher
Automation konkurrenzfähig“, erklärte der
Verbandspräsident dazu. Auch die Perspektiven
im Fahrzeugbau hingen in erster Linie
von den Entwicklungen außerhalb Europas
ab, konkret von den Nachfragen im US-Markt
und aus China. Mit einer Entspannung wird
erst im kommenden Jahr gerechnet.
Bis dahin gelte es, durch innovative Produktentwicklungen,
den Einsatz neuer Fertigungstechnologien,
hohe Qualitätsstandards
und Termintreue sowie durch innerbetriebliche
Prozessoptimierungen und gut ausgebildete
Mitarbeiter die Marktposition auch unter
den erschwerten Rahmenbedingungen zu halten.
„Dies wird ein harter, steiniger Weg, der
Kapital und Knowhow verlangt“, lautete das
abschließende Urteil von Verbandsgeschäftsführer
Menet.
■
Für
Neugierige
www.alu-web.de
Tagesaktuelle News
14 ALUMINIUM · 3/2013

Saubere Oberflächen – am laufenden Band
Qualitätssteigerung. Arbeitssicherheit. Ausschussminimierung.
Joh. Clouth Maschinenbau Eltmann GmbH & Co. KG ist
spezialisiert auf die Sauberhaltung und Sonderbehandlung
von rotierenden Walzen- und Rollenoberflächen in der
Aluminium- und Stahlindustrie.
Die Sicherheit in Ihrer Anwendung garantieren wir durch unsere langjährige
Erfahrung und präzise Fertigungstechniken gepaart mit exzellentem Detailwissen.
Wir sorgen mit unseren Reinigungssystemen für Qualitätssteigerung,
Arbeitssicherheit und Ausschussminimierung.
Haben wir Ihr Interesse geweckt? Dann kontaktieren Sie uns!
Marcus Herziger
Leiter Verkauf
+49 (0) 9522-9424-20
+49 (0) 173-5557173
marcus.herziger@clouth.com
Wir sind der zuverlässige Partner von namhaften Unternehmen
rund um den Globus. Gemeinsam mit unseren Kunden entwickeln
wir überzeugende Produkte und intelligente Lösungen.
Joh. Clouth Maschinenbau
Eltmann GmbH & Co. KG
Industriestr. 25
D-97483 Eltmann
Tel.: +49 (0) 9522-9424-20
Fax: +49 (0) 9522-9424-24
info@clouth-eltmann.com
www.clouth-eltmann.com

W IRTSCHAFT
Urban Mining – Rohstoffquelle der Zukunft
„Aluminium ist Aluminium“
Christian Wellner, GDA
Als Rohstoffe werden üblicherweise
natürliche, unbearbeitete Ressourcen
bezeichnet, die in der Erde schlummern
und auf bergbauliche Gewinnung warten.
Diese klassische Rohstoff-Begrifflichkeit
greift heute aus mehreren Gründen zu
kurz. Zum einen markieren „Nachhaltigkeit“
und „Kreislaufwirtschaft“ zentrale
umweltpolitische Anforderungen an die
industrielle Produktion. Zum anderen
erleben wir die Verknappung strategisch
wichtiger Ressourcen, die Fragen der
Rohstoffversorgung und Rohstoffsicherheit
aufwirft. Dies umso mehr, als mit
aufstrebenden Schwellenländern wie
China, Indien und Brasilien neue, sich dynamisch
entwickelnde Wettbewerber um
knappe Ressourcen auf den Plan treten.
Eine sichere, effiziente, umweltverträgliche
– kurz: nachhaltige Rohstoffund
Metallversorgung in einem rohstoffarmen
Land wie Deutschland – das gilt
für weite Teile Europas ähnlich – muss
nicht nur die Versorgung mit Erzen bzw.
den Vorprodukten der Metallerzeugung
sicherstellen, sondern den Blick auf alle
Ressourcen richten, die sich zur Deckung
des Metallbedarfs eignen. Das gilt besonders
für das NE-Metall Aluminium, dem
nach Stahl wichtigsten Gebrauchsmetall
mit Anwendungen in fast allen Gebieten
der Technik und des Alltags.
Neben das Geo-Mining am Beginn der industriellen
Wertschöpfungskette tritt am Ende
des Produktlebens das Urban Mining: Die
Stadt, der urbane Raum mit seinen Produkten
und Abfällen wird zum Rohstoffspeicher, zur
Rohstoffmine der Zukunft. Produktion, Konsum,
Entsorgung und Aufbereitung sind die
vier Lagerstätten einer urbanen Mine. Häuser,
Autos und Handys werden zu urbanen
Rohstoffschätzen, die nach ihrer Nutzung zu
einem wertvollen, heimischen Rohstoffreservoir
werden anstelle von Abfall und Müll, den
es zu entsorgen gilt.
In Deutschland sind wir mit dieser Vorstellung
schon einigermaßen vertraut – auch dank
Grünem Punkt und Gelbem Sack und, seit
Neuerem, der Wertstofftonne. Bereits heute
werden Deponien wieder aufgeschlossen und
die versiegelten Müllberge als Wertstoffminen
wiederentdeckt, um knapper werdende mine-
Urban Mining – raw materials source of the future
“Aluminium is aluminium”
Christian Wellner, GDA
Usually, raw materials are considered
to be natural, unprocessed resources
dormant in the ground and waiting to be
extracted by mining. Nowadays, for many
reasons this classical conception is incomplete.
For a start, ‘sustainability’ and ‘the
recycling economy’ express central demands
that environmental policy makes
on industrial production. Secondly, we
are experiencing imminent shortages of
strategically important resources, which
bring up questions about raw material
supplies and raw material security. This
the more so, now that rapidly developing
countries such as China, India and Brazil
are becoming dynamically advancing
competitors for already scarce resources.
A secure, efficient and environmentally
harmless – in short: sustainable –
raw material and metal supply in a country
with scarce raw materials, such as
Germany – and the same applies to many
other parts of Europe – must not only ensure
supplies of ores and the pre-products
for metal production, but also look to all
other resources which can help to cover
metal requirements. This applies particularly
to aluminium, which comes second
only to steel as the most important consumer
metal with applications in almost
every sector of technology and everyday
use.
Besides geo-mining at the beginning of the
industrial value chain, at the end of product
life the so-termed ‘urban mining’ becomes relevant.
Towns and cities, in other words urban
areas with their products and wastes, are becoming
the raw materials stores or ‘mines’ of
the future. Production, consumption, disposal
and preparation are the four depositories of an
urban mine. Houses, automobiles and mobile
phones are becoming raw materials treasuries
which, after their useful life, can become
valuable domestic reservoirs of raw materials
instead of waste and refuse that has to be disposed
of.
In Germany we are rather committed to that
idea: among other things thanks to an comprehensive
disposal system for used packaging
– the so-called ‘Green Dot’ and ‘Yellow
Bin’ – and more recently, the recyclables bin.
Already today dump-sites are being opened
up and sealed rubbish-tips uncovered again
as mines for materials so as to recover and
preserve mineral raw materials that are becoming
scarcer for future generations.
Aluminium scrap as an
urban raw material
Applied to the aluminium economy, this means
that besides the geo-raw-material bauxite as
the starting product, aluminium metal extraction
can also turn to urban materials such as
scrap aluminium for the manufacture of new
products. Hand in hand with the mineral raw
material ore, metallic raw material aluminium
scrap is available. The earlier distinction between
primary and secondary raw material is
now outdated.
Qualitatively, there is no real difference be-
GDA-Geschäftsführer Christian Wellner
Christian Wellner, executive director of the GDA
© GDA
16 ALUMINIUM · 3/2013

W IRTSCHAFT
tween smelter and recycling aluminium. Nobody
can see what source of aluminium has
been used to make an engine block. The same
applies to window profiles, beverage cans or
any other aluminium product. Decisive for the
product’s design is the question of what properties
– such as strength and formability – the
aluminium product should have. This is determined
by which material and which alloying
elements in it should be used, and whether the
semifabricate or end product needs to be heat
treated. In contrast, whether the metal used
comes from aluminium oxide or old scrap, is
immaterial.
This is particularly so because even if aluminium
scrap has been remelted many times,
it is not downgraded. Metallurgically speaking:
the metal lattice does not become worn. Just
the same products can be made from melted
scrap as from
processed bauxite
ore. And the best
thing: Each tonne
of aluminium
scrap melted down
for new products
preserves an average
of about four
tonnes of bauxite
for use by future
generations, and
saves more than
95 percent of the
power consumed
for the reduction
of aluminium oxide
(alumina) to
the metal by the
electrolysis process.
In that sense
aluminium scrap
can be characterised as a raw material, the
starting material for new products. Just as
bauxite ore has to be extracted and has to
undergo several process steps to produce the
material used for aluminium electrolysis, so
too aluminium scrap has to be prepared, separated,
sorted and analysed before it can be
melted in correctly composed furnace charges.
At the inception of an aluminium product
obtained from ore is the bauxite mine. At the
end of the product’s use is a house that is demolished,
an automobile that is dismantled,
or packaging that is separated into various
packaging material fractions. Needless to say,
there is still a lot to be done for the recovery
of used products: not all materials make their
way back into the material cycle. In many
countries energy utilisation at the end of prodralische
Rohstoffe für künftige Generationen
zu bewahren.
Aluminiumschrott als urbaner Rohstoff
Auf die Aluminiumwirtschaft übertragen heißt
dies, neben dem Geo-Rohstoff Bauxiterz als
Ausgangsprodukt der Aluminium-Metallgewinnung
auch den urbanen Rohstoff Aluminiumschrott
zur Herstellung neuer Produkte
heranzuziehen. An die Seite des mineralischen
Rohstoffs Erz tritt der metallische Rohstoff
Aluminiumschrott. Die frühere Unterscheidung
zwischen Primär- und Sekundärrohstoff
hat sich überlebt.
Qualitativ gibt es ohnehin keine Unterscheidung
zwischen Hütten- und Recyclingaluminium.
Einem Motorblock sieht man nicht
an, aus welcher Aluminiumquelle er gespeist
ist. Das selbe gilt für
ein Fensterprofil,
eine Getränkedose
oder jedes andere
Aluminiumprodukt.
Entscheidend
beim Produktdesign
ist die Frage, welche
Eigenschaften –
etwa Festigkeit und
Verformbarkeit –
das Aluminiumprodukt
aufweisen
soll. Daran orientiert
sich, welcher
Werkstoff mit welchen
Legierungselementen
einzusetzen
ist und ob
das Halbzeug oder
Endprodukt ggf. einer
Wärmebehandlung
zu unterziehen
ist. Ob das eingesetzte Metall aus Aluminiumoxid
oder Altschrott gewonnen wurde, spielt
dagegen keine Rolle.
Auch weil es kein Downgrading nach dem
x-ten Einschmelzen von Aluminiumschrott
gibt. Metallurgisch gesprochen: Das Metallgitter
nutzt sich nicht ab. Aus eingeschmolzenen
Schrotten lassen sich die gleichen Produkte
herstellen wie aus dem aufgeschlossenen
Bauxiterz. Und das Schöne daran: Jede Tonne
Aluminiumschrott, die für neue Produkte
eingeschmolzen wird, bewahrt durchschnittlich
mehr als vier Tonnen Bauxit für die Nutzung
durch künftige Generationen und erspart
rund 95 Prozent des Stroms, der mittels
Schmelzfluss-Elektrolyse für die Reduktion
von Aluminiumoxid zu Metall eingesetzt
wird.
In diesem Sinne lassen sich Aluminiumschrotte
als Rohstoffe charakterisieren, als Ausgangsmaterialien
für neue Produkte. So wie
Bauxiterz aufgeschlossen werden muss und
erst über mehrere Verfahrensstufen zum Einsatzstoff
für die Aluminiumelektrolyse wird,
so müssen Altschrotte aufbereitet, getrennt,
sortiert und analysiert werden, bevor sie chargengerecht
eingeschmolzen werden.
Am Anfang eines Aluminiumproduktes,
das aus Erz gewonnen wird, steht die Bauxitmine.
Am Ende der Produktnutzung steht ein
Haus, das abgerissen, ein Auto, das zerlegt
wird und Verpackungen, die in verschiedene
Packstofffraktionen getrennt werden. Natürlich
gibt es bei der Rückgewinnung von ausgedienten
Produkten noch viel zu tun: Nicht
alle Materialien wandern zurück in den Stoffkreislauf.
In manchen Ländern ist auch die
energetische Verwertung am Produktlebensende
eine Option. Verschwiegen werden soll
auch nicht, dass bei der Vorbehandlung und
dem Einschmelzen von Schrotten ein kleiner
Prozentsatz Abbrand und Metallverlust entsteht.
Massiver Ausbau der Aluminiumproduktion
aus urbanen Rohstoffen
Für Aluminium jedoch gilt, dass der hohe Materialwert
eine umfassende Rückgewinnung
dieses Metalls garantiert. In langlebigen Anwendungen
bei Automobilen oder Gebäuden
werden schon heute Recyclingraten von rund
95 Prozent erreicht. Für relativ kurzlebige
Aluminiumprodukte aus dem Verpackungssektor
beträgt die Recyclingrate in Deutsch-
Der urbane Raum mit seinen Produkten und Abfällen wird zum Rohstoffspeicher, zur Rohstoffmine der Zukunft
Urban areas with their products and wastes are becoming the raw materials stores or ‘mines’ of the future
© Wolkes
18 ALUMINIUM · 3/2013

www.grafocom.it
SINCE 1952
Quality Reliability Service
ALUMINUM EXTRUSION HANDLING SYSTEM
ALUMINUM FURNACES AND COMPLETE CASTHOUSE PLANT
OMAV S.p.A.
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E-mail: sales@omav.com - www.omav.com

W IRTSCHAFT
Despite every effort to recover and reuse aluminium,
it will not be possible to do without
the production of the metal from bauxite ore.
Aluminium is a metal still ‘young’ in terms of
its industrial use, which has still far from
reached its zenith. In aviation engineering a
lot is said about fibre-composite materials,
but the majority of even modern, new aircraft
are based on the light metal aluminium. The
same applies in automotive engineering, where
more and more of the light metal is incorporated,
and not just in the form of cast products
but also as wrought materials for auto-body
applications. Many operators of aluminium
rolling mills are extending their capacities all
over the world for new automotive and aviation
applications, and one only has to look at
China’s investment programme for the extenland
über 87 Prozent – ein durchaus beeindruckender
Wert. Die Rücklaufquote für Alu-
Getränkedosen liegt im Pfandsystem hierzulande
inzwischen sogar bei über 95 Prozent.
Dies ist die höchste Recyclingrate in ganz
Europa.
Um diese „urbanen“ Rohstoffquellen noch
intensiver zu nutzen, investieren Aluminiumbetriebe
in Deutschland seit mehreren Jahren
massiv in den Ausbau der Recyclingkapazitäten
und greifen dabei auf eine Anlagentechnik
zurück, die den Benchmark in der Welt
setzt. So wurden unter anderem an den Standorten
Norf und Hamburg in den vergangenen
Jahren neue Recyclingöfen mit Regenerativ-
Brennertechnologie und damit noch besseren
Energiewerten installiert. In Nachterstedt soll
bis 2014 ein Aluminium-Recyclingwerk mit
einer beeindruckenden Jahreskapazität von
400.000 Tonnen (!) errichtet werden. Diese
Investition wird die Aluminiumproduktion
aus Schrotten, die 2011 rund 634.400 Tonnen
in Deutschland betrug, weiter nach oben
treiben.
End-of-Life-Schrotte decken
Aluminiumbedarf nur zum Teil
Bei allen Anstrengungen zur Rückgewinnung
und Verwertung von Aluminium wird man
auf die Erzeugung des Metalls aus Bauxiterz
nicht verzichten können. Aluminium ist ein
noch junges industriell genutztes Metall, das
seinen Zenit noch lange nicht erreicht hat. Im
Flugzeugbau wird viel über Faserverbundwerkstoffe
geredet, aber der Großteil auch
moderner, neuer Flugzeuge setzt auf das
Leichtmetall Aluminium. Das gleiche trifft
auf den Automobilbau zu, wo immer mehr
Leichtmetall verbaut wird, und nicht nur als
Gussprodukt, sondern auch als Knetwerkstoff
für Karosserieanwendungen. Viele Betreiber
von Aluminiumwalzwerken erweitern ihre
Kapazitäten weltweit für neue Automobilund
Luftfahrtanwendungen, und schaut man
sich das Investitionsprogramm Chinas für den
Ausbau des Hochgeschwindigkeits-Schienennetzes
an, versteht man, warum so viele Aufträge
aus China für große Aluminium-Strangpressen
erteilt werden.
Der Aluminiumbedarf wird noch auf viele
Jahrzehnte nicht allein durch den Rückfluss
von End-of-Life-Schrotten gedeckt werden
können. Dies trifft allenfalls für gut ein Drittel
des Bedarfs zu. Daran wird sich solange
nichts ändern, wie die globale Nachfrage nach
Aluminium stärker wächst als der Rückfluss
von Aluminiumschrotten. Für den Ausbau
von Recyclingsystemen spielt es daher keine
Rolle, wie hoch der Anteil an Recyclingmaterial
in einem konkreten Produkt ist. Solange
die Aluminiumnachfrage größer ist als der Recycling-Pool,
aus dem diese Nachfrage gestillt
werden kann, findet Altaluminium immer
eine Verwendung: Wenn nicht für Produkt A,
dann für Produkt B.
Viel wichtiger ist die Frage, woher die
massiv ausgebauten Recyclingkapazitäten
in einigen Jahren ihren Input erhalten. Seit
zehn Jahren ist Europa Nettoexporteur von
Aluminiumschrotten. Allein 2011 wurden fast
eine Million Tonnen Alu-Schrott (955.285
t) in Drittländer exportiert, während die Importe
aus Drittländern rund 40 Prozent dieser
Menge betrugen (378.214 t). Der Abfluss
an Aluminiumschrotten aus Europa betrug
somit 577.071 Tonnen. Seit 2001 ist Europa
kein Nettoimporteur von Aluminiumschrott.
uct life is also an option. It should also not be
ignored that during the pre-treatment and
remelting of scrap a small percentage of combustion
and metal loss occurs.
Massive extension of aluminium
production from urban raw material
In the case of aluminium, however, the high
value of the material ensures comprehensive
recovery of the metal. In long-term applications
such as automobiles or buildings, already
today recycling rates of around 95 percent
are achieved. For relatively short-lived
aluminium products from the packaging sector
the recycling rate in Germany is higher than
87 percent – a very impressive figure. The return
quota of aluminium beverage cans under
the deposit system in Germany has meanwhile
increased to even higher than 95 percent, the
highest recycling rate anywhere in Europe.
To make still more intensive use of this
‘urban’ raw material source, aluminium companies
in Germany have for many years been
investing heavily in the extension of their recycling
capacities and for this they use plant
technology which sets the benchmark all over
the world. Thus, among others, at the Norf and
Hamburg sites new recycling furnaces with
regenerative burner technology and hence
much better energy values have been installed
in recent years. In Nachterstedt, by 2014 an
aluminium recycling plant with an impressive
annual capacity of 400,000 tonnes (!) will be
built. That investment will increase the aluminium
production from scrap in Germany,
which amounted to about 634,400 tonnes in
2011, to still higher levels.
End-of-life scrap only partially
covers the demand for aluminium
© DAVR
Selbst für kurzlebige Aluminium-Verpackungsprodukte beträgt die Recyclingrate in Deutschland inzwischen
über 87 Prozent / Even for short-lived aluminium products from the packaging sector the recycling rate in
Germany is higher than 87 percent
20 ALUMINIUM · 3/2013

E C O N O MICS
sion of its high-speed rail network, to understand
why there have been so many orders
from China for large aluminium extrusion
presses.
For many decades to come the demand
for aluminium will not be able to be covered
by the return flow of end-of-life scrap alone.
At best, that will cope with a good third of
Advertisement
the requirements. Nothing will change in that
respect so long as the global demand for aluminium
continues growing more rapidly than
the return flow of aluminium scrap. Thus, for
the extension of recycling systems it is immaterial
how large a proportion of recycled material
there is in a particular product. So long
as the aluminium demand remains larger than
the recycling pool from which that demand
can be satisfied, aluminium will always find a
use, if not for product A, then for product B.
Much more important is the question of
where the massively extended recycling capacities
will get their input from in a few years.
For a decade Europe has been a net exporter
of aluminium scrap. In 2011 alone, almost a
million tonnes of aluminium scrap (955,285 t)
were exported to third countries, while imports
from third countries amounted to
around 40 percent of that quantity (378,214 t).
So the outflow of aluminium scrap from Europe
amounted to 577,071 tonnes. Since 2001
Europe has never been a net importer of aluminium
scrap and over the period since then
a total of 4.7 million tonnes have flowed out.
That is: 4.7 million tonnes of valuable raw ma-
terial, collected with much cost and effort, and
in which approx. 66 million megawatts of energy
are stored: an amount of energy with which
a big city like Munich in Germany could be
supplied with power for almost nine years.
Securing domestic urban raw materials
This largely unimpeded outflow of urban raw
materials from the EU is all the more undesirable
in that the European Union regards itself
as leading the way internationally in the
field of climate policy. On the other hand
countries such as Russia and the Ukraine,
which were previously important raw material
sources for Europe’s recycling industry,
have put up export barriers – export duties
or export bans – on scrap. And China, the
world’s largest importer of aluminium scrap,
has put up numerous trade barriers thanks to
which Chinese scrap buyers can pay higher
prices than European remelters.
Free world trade and open markets require
economic development, and this in a world
which is ever more strongly interlinked. But
free trade must take place in accordance
with clear rules that apply equally to all. In
that respect Europe would be well advised, in
light of its own scarcity of geo-raw-materials
and its demanding climate policy targets, to
campaign for a level playing field that ensures
fair trade with urban raw material sources.
Summary
aluminium plants & machinery
Marketing & Sale of
Used Machinery & Plants
www.alteco.at
In contrast to many non-metallic raw materials,
aluminium can always be remelted without
loss of quality and processed to make new
products. It is outdated to draw a distinction
between primary and secondary aluminium,
that is aluminium produced from ores or from
scrap. Already today metal melted from scrap
is often mixed with smelted metal because it
contains important
alloying elements.
Thus, urban raw materials
are gaining in
importance for the
MELTING & CASTING
EXTRUSION
ROLLING
FOIL ROLLING
FOIL CONVERSION
ALTECO Aluminiumtechnolgie Vertriebs u. Consulting GmbH
Bogendorf 5, A-5145 Neukirchen, Austria
Tel. +43(7729)2871-0 Fax: +43(7729)28714 Email: office@alteco.at
raw materials supply
and security of
our economy.
Author
Christian Wellner is
the executive director
of the GDA (German
Association of the
Aluminium Industry),
located in Düsseldorf.
Seitdem flossen unterm Strich 4,7 Millionen
Tonnen aus Europa ab. 4,7 Millionen Tonnen
wertvoller urbaner Rohstoffe, die mit hohem
Aufwand gesammelt wurden und in denen
rund 66 Millionen Megawattstunden Energie
gespeichert sind. Eine Energiemenge, mit der
die Stadt München fast neun Jahre lang mit
Strom versorgt werden könnte.
Heimische urbane Rohstoffe sichern
Dieser weitgehend ungehinderte Abfluss an
urbanen Rohstoffen aus der EU ist umso ärgerlicher,
als die Europäische Union sich als
internationaler Vorreiter in der Klimapolitik
sieht. Auf der anderen Seite haben Länder
wie Russland und die Ukraine, die früher
einmal wichtige Rohstoffquellen für die europäische
Aluminiumrecyclingindustrie waren,
Exportschranken – Exportzölle bzw. Exportverbote
– auf Schrott errichtet. Und China,
der weltweit größte Importeur von Aluminiumschrott,
hat zahlreiche Handelsbarrieren
aufgebaut, dank derer chinesische Schrottaufkäufer
einen höheren Schrottpreis zahlen
können als europäische Umschmelzer.
Freier Welthandel und offene Märkte fördern
die Entwicklung von Volkswirtschaften,
erst recht in einer Welt, die immer stärker
vernetzt ist. Freier Handel muss aber nach
klaren und für alle gleichen Spielregeln erfolgen.
Handelsbarrieren wie angedeutet widersprechen
diesen Spielregeln. Hier ist Europa
gut beraten, sich angesichts knapper eigener
Geo-Rohstoffe und anspruchsvoller klimapolitischer
Zielsetzungen für ein Level Playing
Field einzusetzen, das einen fairen Handel
mit urbanen Rohstoffquellen garantiert.
Fazit
Im Gegensatz zu manchen nicht-metallischen
Rohstoffen lässt sich Aluminium ohne Qualitätsverlust
immer wieder aufs Neue einschmelzen
und zu neuen hochwertigen Produkten
verarbeiten. Eine Unterscheidung
zwischen Primär- und Sekundäraluminium,
aus Erzen oder aus Schrotten erzeugtem
Aluminium, ist überholt. Bereits heute wird
dem Hüttenmetall oft aus Schrotten erschmolzenes
Metall beigefügt, weil sie wichtige Legierungselemente
enthalten. Urbane Rohstoffquellen
gewinnen daher eine wachsende
Bedeutung für die Rohstoffversorgung und
-sicherheit unserer Volkswirtschaft.
Autor
Christian Wellner ist Geschäftsführer des Gesamtverbandes
der Aluminiumindustrie e.V. mit Sitz in
Düsseldorf.
ALUMINIUM · 3/2013 21

ALUMINIUM MI DDL E EAST
Modern Dubai (City
Plaza) and historic
quarter (Al Bastakiya)
© ALUMINIUM
Aluminium Middle East 2013 –
Expand your reach within the region
‘Aluminium Middle East’ is the leading exhibition
for aluminium products, technologies
and investments in the Middle East. Formerly
known as ‘Aluminium Dubai’, the exhibition
is on its third edition and brings together international
industry front-runners including
producers, manufacturers and processors of
raw materials and end products made from
aluminium components, as well as suppliers
of technologies and accessories for aluminium
production, processing and refinement.
The past success and growth of Aluminium
Dubai has helped the show broaden its horizons
and will now return in its third edition
as Aluminium Middle East with a larger base
of exhibitors and visiting industry professionals,
enabling participants to expand their reach
within the region and also on a global scale.
The 2013 event will feature the Middle
East and North African region’s fast growing
role in the global aluminium industry, highlighting
investment plans in new smelters and
expansion of existing capacities by the regional
market players from the Gulf Co-operation
Council (GCC) countries. The event is expected
to welcome more than 3,500 renowned in-
dustrial and manufacturing sector representatives
– an increase of 25% on 2011 – from over
70 countries, and 200 exhibitors from more
than 20 countries representing companies producing
and processing aluminium as well as
equipment and technology suppliers who are
interested in taking up a profitable business in
the Mena region.
The Aluminium Middle East exhibition will
be taking place from 23 to 25 April at the
Dubai International Convention & Exhibiting
Centre. Further details at www.aluminiummiddleeast.com
■
Development of the aluminium
scrap and recycling
market in the GCC
Rising production of primary aluminium coupled
with parallel development of downstream industries
has led to an increase in the scope of using
more of aluminium scrap in remelting activities
for downstream players by procuring the right
alloy grade, recycling and thereby saving cost.
According to the consulting firm Frost & Sullivan,
the aluminium scrap and recycling market in the
GCC was an estimated 292,281 tonnes in 2010,
and is expected to reach 593,434 tonnes in 2017
at a compound annual growth rate of 10.6% between
2010 and 2017.
The aluminium recycling market is at a nascent
stage in the GCC, as it is predominantly an
export driven market. Moreover, the aluminium
downstream industry is yet to establish itself as
a major scrap procurer in this region. The current
market volume for aluminium scrap in the GCC
is growing. It gets 35-40% from used beverage
cans, 30-35% from used doors and windows
while other scrap types are engines (11%), wheels
(5%), sheet (4%), cables and other type of mixed
alloy scraps constituting about 5-7%. The aluminium
remelting facilities that consume the scrap
and form alloy grades based on customer requirements
are majorly present in the UAE, Bahrain
and Kingdom of Saudi Arabia with few players in
the rest of the region.
“The GCC is one of the fastest growing aluminium
markets in the world. With the development
of new smelters and expansions, more
secondary remelting opportunities will arise.
Downstream players are moving towards the
scrap recycling market in order to reduce significant
energy costs and be efficient operationally to
cut input costs and reduce the carbon footprint.
These are some of the factors driving growth in
the aluminium recycling industry in the region.
Additionally, the emergence of the packaging
industry, growth in automotive, construction and
consumer sectors in the GCC are expected to
further drive the aluminium scrap generation,”
says Frost & Sullivan. F&S therefore anticipates
the secondary aluminium market in the GCC to
be a key contributor to the recycling industry and
create huge employment opportunities in the
next ten years.
Frost & Sullivan’s study on the aluminium
scrap and recycling market in the GCC indicates
that the individual aluminium remelting facilities
play a huge role in converting scrap and making
secondary alloy ingots based on customer
requirements. In addition, as major scrap recyclers
look at more export opportunities, downstream
players are left with limited sources of scrap in
the region. F&S recommends implementation of
new export policies so that the scrap generated
in the GCC is used within the region for better
energy utilisation and to obtain economies of
scale.
22 ALUMINIUM · 3/2013

S P E CIAL
ALUMINIUM MIDDL E EAST
Aluminium industry in the Middle East during 2012
Rudolf P. Pawlek, Sierre
Aluminium output among the Gulf Cooperation
Council (GCC) nations will
soon reach 10-11% of global production
levels. The GCC has some great advantages,
including low power costs and
cheap gas, favourable logistics owing to
well-connected airports and sea ports to
all global destinations, as well as skilled
manpower supply from Asian neighbours
who provide knowledge transfer to local
manpower and add to their employment
opportunities. The GCC also has the support
of the region’s government ministries
who promote the aluminium industries’
development by facilitating rapid planning
clearance and awarding subsidies for
greenfield projects.
There are planned expansions at Dubai Aluminium,
whose production reached 1m tpy
in 2011, and at Emirates Aluminium, whose
750,000 tpy production capacity grew by
50,000 tonnes in 2012 during the smelter’s
first phase of development, followed by a doubling
of production to 1.3m tpy in the second
phase.
In addition, the 740,000 tpy Ma’aden Alcoa
smelter in Saudi Arabia started production
at the end of 2012. Considering the fact
that Ma’aden, a sixth smelter in Saudi Arabia,
became operational by 2012, while Emal’s expansion
is scheduled for completion by 2014,
the GCC is already poised to become a primary
aluminium production powerhouse. The
region expects to contribute more than 13%
of the world’s aluminium production by 2013.
Mahmood Daylami, secretary general of
the Gulf Aluminum Council, said that aluminium
production in the GCC will reach 7m
tpy by 2020, from around 3.6m tpy today.
The increase in production in the GCC as a
proportion of global levels will be supported
by production cuts seen in western regions, as
producers in Europe and North America face
high power costs that are not imposed by the
Middle East.
Abu Dhabi
In June 2012 Emirates Aluminium (Emal) released
a milestone in its two-and-a-half year
history since commissioning its aluminium
smelter in December 2009 – the production
of 1.5m tonnes of hot metal. Not a single pot
was lost since the beginning.
Emal, the joint venture between Mubadala
and Dubal, announced the approval of the
Phase II expansion project in July 2011. This
new 444-cell potline now under construction,
should, together with a technology upgrade
of the existing cells, increase Emal’s production
capacity to 1.3m tpy by the end of 2014.
Construction so far is funded by the share-
We stand for
Extrusion Technology
Log and Billet Storage and Transport Equipment
Log Preheating Magazine (Horizontal-/ Vertical Design)
Log and Billet Cleaning Devices
Gas fired Billet Heaters
Gas-/Induction Heater Combination (Inline Solution)
Hot Log Shears
Hot Log Saws
Die Heaters
Ageing Ovens
extrutec GmbH
Fritz-Reichle-Ring 2
D-78315 Radolfzell
Tel.: +49 (7732) 9391390
Fax.:+49 (7732) 9391399
E-Mail: info@extrutec-gmbh.de
Web: www.extrutec-gmbh.de
ALUMINIUM · 3/2013 23

ALUMINIUM MI DDL E EAST
© Emal
holders, while a comprehensive debt financing
package is finalised.
In September, Emal powered its Phase I
potline amperage up from 350 to 380 kA,
improving current efficiency to increase aluminium
production from 750,000 to 800,000
tpy. To achieve this, Emal invested in two
rectiformers to increase power in each potline
to 87.5 kA. In addition, the carbon plant has
been upgraded to start producing larger carbon
anodes.
Emal marked a major milestone in the construction
of its USD4.5bn Phase II smelter
expansion in mid-April 2012: the pouring of
the first concrete of the world’s longest potline
when complete. The pouring was conducted
by Emal and its contractors AF Carillion and
SNC Lavalin II. Emal employees celebrated
the latest additions to its Phase II expansion:
the arrival of the complete first potshell and
the superstructure. The components were
manufactured and supplied by a local UAE
supplier.
The potshells are designed to use the new
DX+ reduction technology developed by Dubal,
and they are longer, wider and lighter than
Emal’s existing pots. Their design makes the
new potshells more productive and efficient.
444 new pots will be installed as part of Phase
II, and each will produce 3.2 tonnes of aluminium
per day, a 10% increase on Phase I
potshells (More information about Emal on
Emal not only complies with all applicable local environmental legislation but is also committed to the
more stringent European standards
Hertwich commissions homogenising
and sawing lines at Emal
Hertwich Engineering, Austria, comissioned
two integrated homogenising and sawing
lines at Emal in 2012. Installed were two ultrasonic
testing stations, two continuous homogenising
plants, two cooling stations and four
billet saws with downline packaging stations.
The scope of supply also included their complete
automation and process integration.
pages 38-39). The superstructure provides
support for a variety of pot functions.
In December the Sultanate of Abu Dhabi
invited foreign investors to profit from proven
and cost-efficient suppliers in the industrial
estate of Khalifa:
• Current supply for less than
USD0.04/kWh; world-class infrastructure
• Zero percent taxes and the possibility to
• Found a taxfree enterprise in a
• Taxfree area with
• 100% possibility of property.
Emirates Aluminium will host the 17 th International
Arab Aluminium (Arabal) Conference
and Exhibition 2013 in Abu Dhabi late
this year.
Bahrain
In July 2012 Aluminium Bahrain (Alba) reported
that it recently replaced and upgraded
the indirect coke cooler at its petroleum coke
calciner. The indirect coke cooler had exceeded
its design service life by three years,
and hence a replacement was necessary. The
new equipment – weighing 180 tonnes – was
shipped from Germany in a single piece, installed
and commissioned in 30 days against
the original plan of 45 days.
Alba is one of two aluminium smelters in
the world to have a dedicated petroleum coke
calciner. This was erected on over 140,000 m 2
of reclaimed land at the Alba marine terminal
in May 2001. In 2011, the plant produced
425,000 tonnes of calcined petroleum coke
and 24,500 m 3 per day of drinking water.
Alba will boost production at its smelter to
about 1.3m tpy by 2015, from over 890,000
tonnes in 2012. There will be a similar expansion
in casthouse capacity, as the company
aims to ensure that value added products account
for 70% of its global sales. Alba sells
15% of its products in Europe and the same
amount in Asia, with the remaining 70% sold
to the Middle East and North Africa (Mena),
including its domestic Bahraini market.
In addition to primary metal ingots, and
liquid aluminium that it sells to downstream
industries in Bahrain, Alba makes rolling slab,
foundry alloys and extrusion billet. It is these
products that will increase its market share in
Europe and Asia, and will develop its customer
base in North America.
Alba placed an order for a fleet of 20 customised
personnel carriers for its potlines as
part of its on-going modernisation of its equipment.
The modernisation drive began in 2011
with the aim of replacing high-maintenance
equipment with more efficient, safer, reliable
and environmentally friendly equipment. The
all-aluminium personnel carriers will be used
for light maintenance work, taking employees
from one end to the other, etc.
In September, the board approved the appointment
of BNP Paribas as the financial
advisor for the proposed Potline 6 expansion
project. Alba remains committed to achieve
zero harm across the plant, as demonstrated
by its recent investment of nearly USD0.1m
in installing new air ventilation louvers in the
north side of both Potlines 4 and 5. The ventilation
louver project began in 2011 in order
to improve work conditions for employees on
a regular basis, to bolster increased productivity
and to enhance performance levels.
The ventilation louvers will basically operate
as heat evacuation mechanisms. They
will allow fresh air to enter the shop floor, so
cooling down the workplace, and will benefit
operators working in the north side of the potlines
who are involved in activities like anode
changing, pot maintenance, etc. The louvers
have been further designed to close in winter
and to open in summer, and thereby provide
24 ALUMINIUM · 3/2013

ALUMINIUM MI DDL E EAST
© Alba
increased flexibility to Alba’s employees.
In October Alba’s board appointed Tim
Murray the new chief executive. Prior to his
new position he was working as Alba’s chief
finance and supply officer. Laurent Schmitt,
who served Alba as CEO from January 2010
to September 2012, will be working directly
with Alba’s chairman Al Kooheji in further
developing the aluminium downstream industry
in the Kingdom of Bahrain.
Alba has been successful in its Bahrainisation
drive, and in 2012, 87% of its 3,000 employees
were Bahraini nationals.
The company has awarded Bechtel Canada
a letter of intent to perform a bankable feasibility
study for the Line 6 expansion project.
The study will include the economic analysis
for the construction of a new Potline 6 and
Power Station 5. The project is expected to
add some 400,000 tpy to the company’s current
production capacity of 890,000 tpy. The
feasibility study is based on the use of Dubal’s
DX+ technology. Dubal currently has five pilot
DX+ pots which began operating at 420 kA
and are now running at 440 kA (see also ALU-
MINIUM 1-2/13 page 15 and pages 18-22).
The increase in line current is part of an
initiative to raise performance in accordance
with the recent upgrade of Potline 5 from
AP 30 to AP 36 technology. The upgrade
enables Alba to boost output, since each 1 kA
increase will yield 950 tpy of extra aluminium
production.
This accomplishment was achieved by an
internal team comprising members from the
Power, Carbon Operations and Maintenance,
Process Control and Development, Reduction
Operation and Maintenance departments. The
team succeeded in achieving this task without
any significant capital investment, the
company says. Plans are also under way to
achieve the same level of success in the Potlines
3 and 4, as well as further raise Line 5’s
current to 363-365 kA.
In December Alba entered into term loan
agreements to refinance the USD169m bond
expiring in March 2013. The term loans include
a bilateral five year loan of USD85m
between Alba and Gulf International Bank. It
In addition to primary metal ingots, Alba produces rolling slab, foundry alloys and extrusion billet
also includes a syndicated three year loan of
USD84m between Alba and a syndicate comprising
of Ahli United Bank, National Bank
of Bahrain, Tokyo-Mitsubishi UFJ Ltd, Arab
Banking Corporation and Bank of Bahrain
and Kuwait.
Dubai
The Gulf Aluminium Council (GAC) Carbon
Conference took place in Dubai early in September
and was arranged for GAC members
only. The agenda focussed on the quality of
raw materials used (especially in terms of impurities
and sulphur content), on the anode
production process and on the performance
of the anodes in the cells. For Dubal the conference
offered an opportunity to demonstrate
its leadership in the local, regional and
international aluminium industry. The GAC
was officially launched in 2010. The council’s
membership comprises all of the primary
aluminium smelters in the region and several
downstream businesses.
Dubai Aluminium (Dubal) has been an active
player in the European market since 1996,
shipping substantial product volumes each
year to Germany, the Netherlands, Italy, the
Czech Republic, Poland, France and Greece.
The company has enjoyed good market share
growth over the years, and this trend is set to
continue. For 2012, the company expects that
over 27% of the 1.795m tonnes which Dubal
and Emal together produced will be shipped
to Europe, with the major proportion of this
volume comprising billet and foundry remelt
products. Further ahead, the fact that the European
Union as a whole needs to import some
60% of its primary aluminium requirements
offers excellent prospects for future market
share growth for both Dubal and Emal.
Dubal provided comprehensive operator
training to 65 new recruits of Ma’aden Aluminium
Company (MAC). The trainees, all
Saudi nationals, were trained in batches at Dubal’s
Jebel Ali site between February and September
last year. With every trainee receiving
more than 54 days’ training over the period,
the project involved a total of 3,555 training
days. The trainees were exposed to a combination
of classroom and on-the-job practical
experience across the potline, carbon (greenmill,
baking kilns and rodding room) and casthouse
areas of a smelter’s operations. Some
125 different training modules were used,
each based on Dubal’s well-established procedures
and practices, but customised to MAC’s
specific needs where necessary.
Dubal has whole-heartedly implemented
the initiatives mandated by the Dubai Supreme
Council of Energy (DSCE) in April –
resulting in energy-savings of approx. 11m
kWh over the initial 15 months since implementing
the directives (i.e. to end-June 2012).
Dubal’s overall target is energy-savings of approx.
22m kWh per year by 2013.
In December, reflecting the national pride
that permeates the organisation, Dubal expressed
its tangible support for the Union Tree
initiative launched by H H Sheikh Mohammed
bin Rashid Al Maktoum (vice president and
prime minister of the UAE and ruler of Dubai)
to commemorate the 41 st UAE National Day,
by planting a tree outside its corporate head
office in Jebel Ali. Trees have been planted on
the Dubal site since 1980, soon after the commissioning
of the smelter complex at the end
of 1979, with the aim of creating a pleasant
environment and a contiguous habitat for wild
26 ALUMINIUM · 3/2013

ALUMINIUM MI DDL E EAST
plant and animal life. Today Dubal has a wellestablished
green belt that is home to 1,840
trees, including species that are pollutantsensitive,
thus providing an early warning system
for higher than expected emission levels.
At year-end it was also reported that to date
a total of 143 employees have worked at Dubal
for three decades.
Dubal is playing an active role in specific
initiatives to fulfil DIES 2030 – notably
through an investment of AED20m in the
Sheikh Mohammed bin Rashid Solar Park, as
released by the Dubai Supreme Council of
Energy in February 2012. Phase I of the
Sheikh Mohammed bin Rashid Solar Park will
yield 10 MW by 2013, and the project will
be scaled-up in successive phases to produce
1,000 MW by 2030. In addition, Dubal is participating
in a feasibility study relating to the
establishment of clean coal-fired power stations
in the United Arab Emirates.
Egypt
In a country still suffering from political instability
and an uncertain future, Egyptian
state aluminium producer Egyptalum remains
upbeat about its own outlook. The company
is moving ahead with plans to increase its
production from 320,000 tpy to full capacity
of 400,000 tpy. A specific time frame has yet
to be set out, meanwhile, as concerns remain
over increases of power tariffs in Egypt.
The situation in the country has generally
improved, however, as transport routes between
Egyptalum’s base in Nag Hammady and
the port in Alexandria, from which it ships its
material, are also gradually reopening.
The increase in energy tariffs was a result
of financial difficulties in Egypt. This is true
of businesses across Egypt, as the increase in
electricity prices adds significantly to the cost
of production. As part of an industry with
intensive energy consumption, aluminium
companies currently pay 27.3 piaster (4.5
US cents) per kWh, compared with Kima, the
Egyptian chemical industry company, which
pays 4.7 piaster per kWh.
The company has also been affected by a
lack of subsidies for the aluminium industry
overall.
Security risks also continue to pose problems
for Egyptalum and for its peers, as well
as the decline in LME aluminium prices. Rising
raw material costs have also placed a burden
on the industry in Egypt.
Egyptalum is a significant producer and
supplier of aluminium and aluminium products
in the Gulf region, and is not burdened
by import tariffs. Profits after tax for the
full year 2010-11 were up 35% compared
with the period a year earlier, to E£479.8m
(USD79.5m). Egyptal’s main markets are
Europe, the US, some Arab and some Asian
countries and Turkey.
Qatar
Qatalum signed an ocean transport agreement
with the National Shipping Company of Saudi
Arabia (NSCSA). The deal ensures the unimpeded
distribution of extrusion ingots over
six metres long to markets, covering shipment
sizes of 3,000-6,000 tonnes. This agreement
is part of a growing number of developments
for Qatalum seeking to capitalise on the global
move of aluminium production and expertise
from the West to Asia, with Qatar contributing
to the GCC’s expansion.
Qatalum improved its US distribution in
2012 after signing a new shipping contract.
In February 2012, the company confirmed it
would increase the amount of billet shipped to
North America, amid strong demand. A total
of around 110,000 tonnes was planned to be
shipped to North America, up from around
70,000 to 80,000 tonnes in 2011.
A new cooperation strengthens research
on aluminium in Qatar and establishes ties
across borders. Students and professors at the
Qatar University and the Norwegian University
of Science and Technology (NTNU) meet
with representatives from Qatar Petroleum
and Hydro, which together own Qatalum. All
take an interest in aluminium, and are eager
to develop more knowledge about the properties
and potential applications of the multifaceted
metal.
Qatalum recently released its first sustainability
report which details the company’s approach,
perspective and progress on several
sustainability indicators. The report goes into
specific details of the ‘Qatalum Way’ – a clear
mission supported by values and principles
collectively reflected in Qatalum’s governance
and integrated management systems; the
Qatarisation policy that seeks to increase the
number of local hires; the international management
systems which Qatalum has incorporated
into its assessment structures (ISO 9001:
Quality Management System; ISO/TS 16949:
Automotive Industry Specific Quality Management
System; OHSAS 18001: Occupational
Health and Safety Management Systems;
and ISO 14001: Environmental Management
System); and extensive HSE commitments
ABB wins order to upgrade
Qatalum’s power infrastructure
All of Qatalum‘s production will be shipped in the form of value-added, alloyed casthouse products
ABB won an order worth USD16m from Qatalum
early in 2012, for upgrading the power
distribution network at its aluminium smelter.
The project includes re-engineering and reinforcement
of the existing distribution system
to help increase availability and reliability of
power supply to key areas such as the substations,
electrical equipment, server rooms,
office buildings and workshop. The project is
scheduled for completion by 2013.
ABB has previously supplied the electrical
equipment for the power plant as well as the
220 kV gas-insulated switchgear substation
for Qatalum.
ABB also won a USD9m contract from
OARC in 2012. The full service concept comprises
the entire maintenance function at the
company’s rolling mill plant in Sohar.
28 ALUMINIUM · 3/2013

S P E CIAL
ALUMINIUM MIDDL E EAST
implementing these systems.
The last part of the report concerns measures
taken to mitigate Qatalum’s ecological
footprint. The report argues that the company’s
operations emphasise efficiency as the
first method of achieving environmental protection:
greater efficiency will lead to ‘greener’
operations. An environmental management
manual detailing sources of environmental impact
and Qatalum’s approach to tackling each
major area of focus, including climate change,
water consumption, and waste management.
Special focus is given to air quality and
emissions – the main environmental concerns
of any aluminium smelting facility. The high
levels of energy required for primary aluminium
production lead to high levels of GHG
emissions, which contribute directly to global
climate change. The report states that the
company tackles both of these issues via proactive
tracking and measuring of our emissions
and through active mitigation efforts to
reduce and minimise emissions.
Water conservation and waste management
complete the report, defining techniques
and guidelines to minimise water consumption
and to manage all types of waste produced
by Qatalum’s operations and facilities.
In January 2013 Qatalum and Dutco Mc-
Connell Dowell (Qatar) signed a USD28.5m
contract to construct the workshop which will
reline all pots reaching the end of their operational
life. The new facility will be outside
the existing Qatalum Phase 1 smelter. Qatalum
will lease this area from MIC. The contract includes
the following:
• Construction of land bridge between the
Qatalum smelter and the new site
• Relining buildings, with associated systems
and equipment
• Anode superstructure workshop, with
associated systems and equipment
• Offices, restrooms, with furnishing and
associated systems
• Cathode cooling and parking station
• Area for storage of spent pot lining (SPL)
containers.
An important part of the project consists of
reinforcing four of five existing ramps, and reinforcing
two additional quarter passageways
within the existing smelter potrooms.
Oman
OARC awards Fata EPC
turnkey EPC contract
The turnkey EPC contract being executed by
Fata EPC was awarded in April 2011, along
with gas and electrical transmission line contracts.
The anticipated project implementation
period was 31 months.
The plant will use a Hazelett Model AS
2000 twin-belt casting maschine which continuously
casts 2-metre wide strip at 50 tph. For
the inline tandem rolling mill configuration,
Fata Hunter is providing the hot rolling and
cold rolling mill as well as the tension levelling
line. Other equipment provided is as follows:
• Furnaces by GNA Alutech of Canada
• Filters by Stas Canada
• Coil annealers by Otto Junker, Germany
• Slitter by Kampf GmbH of Germany
• Roll grinding equipment by Tenova Pomini
of Italy.
This combination of machinery will enable
OARC to produce aluminium sheet in very
thin gauges and high surface quality, with
shorter product delivery time and low production
costs. The first coil set is for mid-August
this year.
The USD387m project is a full EPC lump
sum turnkey package for setting up a complete
aluminium flat production facility, and
will be the largest downstream user of metal
from Sohar Aluminium.
In July Sohar Aluminium signed a Memorandum
of Understanding (MoU) with PACI
to set up a training centre on the company’s
premises in Sohar for aluminium craft work.
PACI will provide trainers and study material,
while Sohar Aluminium will provide the faculties
and funding for the programme. The
centre will train selected women from lowincome
families in the local community in
aluminium craft manufacturing. The two-year
training programme is expected to enable
women to become entrepreneurs and to produce
aluminium handicrafts.
The Oman Aluminium Rolling Company
(OARC) will be a world-class light gauge sheet
rolling facility, with combined hot and cold
rolling and finishing operations. It is located
close to the Sohar Aluminium smelter in the
Sohar Industrial Area. The latest technology
in aluminium rolling will enable the plant to
use molten aluminium from the smelter for
manufacturing rolled coils.
Facing numerous challenges, construction
at the greenfield OARC site is progressing on
schedule, and the plant will be ready for partial
handover to OARC by August this year.
At full production, the OARC will employ
275 people and provide other employment
opportunities for many supporting businesses.
At the height of construction, 1,200 Fata employees
worked on the site to build the facility
and install the equipment. Fata’s total project
manpower is some 1,600 people throughout
the whole construction period.
After the handover in August, initial production
is scheduled to begin at a level of
around 55,000 tpy, with up to a five year
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ALUMINIUM MI DDL E EAST
production ramp up to the 160,000 tpy design
capacity. The project is designed to deliver
high quality and short lead time products to
its customers. OARC is owned by Takamul
Investment Co. SOAC, and is the largest aluminium
project to date. Takamul is in turn
90% owned by Oman Oil Co. The project fits
with its strategy of adding value to existing local
raw material, and developing economically
attractive downstream investments in Oman
industries. These in turn contribute to creating
sustainable employment, expanding of the
local industrial network, and increasing and
Automated cranes for OARC
SCX Special Projects are automating two of
the plant’s 25-tonne cranes that will take
hot coils into and out of storage, as well as
between a variety of other process lines. Easily
switched from manual to automatic, SCX’s
complex Crane Management System (CMS)
will record information on type, date / time
of any movement and on what onward processes
are required for each and every roll.
The CMS will then use this information to organise
the coil’s predetermined process paths
into the most efficient network possible, getting
the coils to their destination in the shortest
time, sharing the workload equally between
the two cranes, and ensuring they do
not obstruct each other.
diversifying revenues for the local economy.
Liquid aluminium brought in from the
adjacent smelter is processed into coils, which
are then distributed around the plant by 12
street cranes ranging from 7.5 to 80 tonnes
SWL (Safe Working Load). The hoists, carriages
and control panels have already been
shipped, the bridge steelwork has been
sourced locally, and the final piece of puzzle,
SCX Special Project’s complex automation
system, is about to be sent out to the Middle
East for installation.
Millions of dollars were spent in education
programmes for the Omani workforce. The
start-up team will have been through eight
months of training prior to the commissioning
phase. Currently there are 105 full-time
employees, with 80% being Omani nationals.
There are also people from eight different
countries.
Retired in 2009, Buddy Stemple was elected
CEO of OARC in March 2011. As a Canadian
he has been living since then in Oman.
Saudi Arabia
In February 2012 joint-venture partners Alcoa
and Ma’aden (Saudi Arabian Mining Co.)
poured the first concrete for the alumina refinery
at their integrated aluminium complex
in Ras Al Khair in Saudi Arabia’s Eastern
Province. A month later Ma’aden Bauxite &
Alumina, the joint venture body owned by
Ma’aden (74.9%) and Alcoa (25.1%), awarded
Hyundai Engineering & Construction a
contract to build the alumina refinery for its
new aluminium plant. The EPC contract, which
includes pre-commissioning, commissioning
and start-up assistance as well as training, is
worth more than 5.6bn riyals (USD1.5bn).
Since 2009, Ma’aden and Alcoa have
worked on the construction of a multi-billiondollar
aluminium-making complex in Ras Al
Khair. The complex is designed to produce
1.8m tpy of alumina, mainly for domestic consumption.
The investment is part of a wider
industrialisation of the Arab world’s richest
country, so as to reduce its reliance on imported
materials for construction and energy
projects.
The Ma’aden contract to Hyundai reduces
a joint venture by WorleyParsons and Fluor
International, which had been in line for the
EPC contract, to a project management role.
The refinery is scheduled for completion by
the end of 2014.
Alcoa and Ma’aden have recorded a safety
milestone during construction of their aluminium
smelter: 25m hours worked without
a lost work day injury. The lost work day accomplishment
was achieved by 39 construction
companies employing a diverse multinational
workforce that speaks more than 15
languages and represents upwards of 25 countries
and cultures. The number of workers including
contractors grew from less than 200
to 12,400 during this period.
Ma’aden has secured 7bn riyals (USD1.86-
Alupco – leading manufacturer of extrusions in Saudi Arabia
With a total production capacity of more than
60,000 tonnes a year, Aluminium Products Company
Ltd (Alupco) is the leading manufacturer
of extrusions of high standard in Saudi Arabia.
Established in 1975, the company is also wellknown
for a variety of surface treatments like
electrostatic powder coating, anodising, polishing
and wood finish coating.
The corporate headquarters is in Dammam
where the firm owns and operates four presses
with extrusion loads between 1,650 and 3,500
tonnes. At its Jeddah plant Alupco operates four
presses in the range of 2,135 to 2,500 tonnes.
Further facilities include two anodising lines
(with a capacity of 12,000 t) and five powder
coating lines (33,000 t), a die manufacturing
plant capable of producing 4,000 dies a year and
a casthouse. The company employs over 800
people of different nationalities.
In the Middle East Alupco is the first aluminium
extrusion company which was awarded
with the prestigious ISO 9001 certificate in 1995
and ISO 2000 certificate in 2004. To maintain
the high quality of its products, European (EN),
German (DIN), British (BS), American (ASTM) and
the Saudi (SASO) standards are strictly followed
in its operations.
Alupco profiles are used in building and
construction, and in other industries for a wide
range of products: windows, doors and curtain
walls as well as profiles in various shapes and
alloys for the electrical and furniture fabrication
industries, to name just a few target markets
– with special finish for decorative purposes, if
demanded.
Alupco invests in new extrusion line
Only recently Alupco has placed a contract with
the co-operation partners Omav and SMS Meer
for a complete extrusion line. This is the exact
blue print of a line that the two equipment
suppliers already delivered in 2011: a 25/27 MN
extrusion press by SMS Meer and the complete
handling system by Omav which in this case is
the contractor and responsible for project management
and assembly.
The extrusion press will be built according
to the construction plans of SMS Meer, and executed
at the Omav workshop in Rodengo
Saiano, Italy. This corresponds to the projectrelated
co-operation agreement from autumn
last year – an agreement which refers to full-line
solutions for extrusion presses up to 32/35 MN,
with one overall contract for the complete line
and with a special focus on ‘cost-driven markets’
(For details of the co-operation see ALUMINIUM
12/2012, page 7).
Delivery of the extrusion line is scheduled in
the course of 2013.
30 ALUMINIUM · 3/2013

ALUMINIUM MI DDL E EAST
Ma’aden Alcoa JV orders slitting
line from Danieli Fröhling, again
Already in 2010 Danieli Fröhling (DF) received
an order for the supply of two cutting lines
for the first phase of the Alcoa Ma’aden rolling
mill. In 2012, the joint venture awarded
DF another order for a slitting line with connected
packaging and slit coil handling area.
The new line to be supplied includes the full
scope starting from coil entry area, pre-leveler
to reduce coil-set, inline coil preparation with
drum shear, the longitudinal cutting area,
strip braking and electrostatic oiling section
and recoiling area. All auxiliary units as well as
the automation and electrics will be supplied
too. The line will be supplied in 2013, and will
process the first material in 2014.
bn) in the form of a five-year Murabaha revolving
loan from thirteen banks. The deal
was 2.5 times oversubscribed, which demonstrates
the trust in Ma’aden’s credit-worthiness.
Murabaha is an Islamic agreement
whereby the financier buys a physical asset,
or goods, and sells it to the customer (in this
case, Ma’aden) at a marked-up price to what
it was bought for, so avoiding any interestrelated
loans, which are banned.
Zurich-based ABB won orders worth
around USD24m from Ma’aden Aluminium
Co. to execute a fast-track transmission substation
project. The orders were booked in the
second quarter of 2012. ABB will design, engineer
and supply a new 380 kV outdoor gasinsulated
switchgear (GIS) substation at the
Raz Al Khair power plant that will export
800 MW of power from the plant to the national
transmission grid, and will feed the new
smelter. The project is scheduled for completion
within ten months. Scope and supply
include high-voltage outdoor GIS, communication
and auxiliary systems and IEC 61850
compliant substation automation, control and
protection.
Ma’aden and Alcoa celebrated the production
of first hot metal on 12 December. This
marks the successful commissioning of the
first of 720 pots, and is an important step toward
commercial production at the smelter.
Start of production was achieved in only 25
months from the pouring of first concrete.
Engineer Abdullah Busfar, chairman of the
Ma’aden Aluminium JV, commented: “From
the outset this has been a project managed to
achieve both cost and schedule targets. It is
just 29 months since the joint venture issued
Bechtel with a Notice to Proceed with construction.”
On 12 December, Alcoa and Ma’aden
also broke ground for the construction of expanded
rolling mill capabilities at Ras Al Khair.
This will enable the facility to supply aluminium
automotive, building and construction
sheet, and foil stock to the Kingdom’s developing
new industry and other global markets
beginning in 2014. The hot and cold rolling
mill as well as the annealing and coating line
will be supplied by SMS Siemag. The machine
builder is responsible for the design, manufacture,
erection supervision and commissioning
of the line. The whole rolling mill complex
is to go on stream this year while the annealing
and coating line will start production
in 2014.
Author
Dipl.-Ing. R. P. Pawlek is founder of TS+C, Technical
Info Services and Consulting, Sierre (Switzerland)
and a well-known expert of the global aluminium
industry.
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ALUMINIUM MI DDL E EAST
Advancements in reduction technology improve specific energy
consumption and reduce greenhouse gas emissions at Dubal
© Dubal
Established to add value to the energy resources
of the Emirate, Dubai Aluminium
(Dubal) began operating in November
1979 and has since been a substantial
contributor to the national and regional
economy. Today, Dubal operates the
world’s largest single-site smelter using
pre-bake technology: 1,573 reduction
cells arranged in seven potlines produce
over one million tonnes of molten aluminium
a year (2012: 1,025,266 t), the
bulk of which (about 88%) is exported
to close on 300 customers in 57 countries
around the world.
The demand for electrical power to maintain
this production level is about 1,900 MW. This
is more than met through Dubal’s captive
combined cycle power station, which has an
installed power generation capacity of 2,350
MW (at 30 °C). While Dubal’s gas turbines
are fuelled primarily by natural gas, for which
DX+ pilot line
supply is available, the cogeneration and combined
cycle configuration of the Dubal Power
Plant means that approx. 36.8% of the power
generated at Dubal is fuel-free: a position that
reflects the company’s deep-seated awareness
of the energy-intensive nature of aluminium
smelting and its associated corporate commitment
to energy optimisation across its operations.
This commitment is evident in the inherently
responsible expansion of Dubal’s smelter
complex over the years. The fledgling smelter
complex, built on a 480 hectare site in Jebel
Ali, 35 km from the city of Dubai, comprised
360 Kaiser P69 cells arranged in three potlines.
An ongoing quest for sustainable, organic,
innovation-based growth, led to the cells in
these potlines being upgraded to D18 technology.
A fourth potline of 144 cells was built in
1990 and further cells were added in 2008 and
2010, bringing the total number of D18 cells
at Dubal to 520. At the same time, a series
of other expansion projects were completed
between 1998 and 2008 – each phase incorporating
more advanced reduction technologies
that operated at higher amperage levels and
thus produced more metal per unit of power
consumed.
Driven to achieve operating excellence
through continuous improvement, Dubal simultaneously
invested substantial resources
in advancing its aluminium smelting processes
and technologies with the aim of not only increasing
productivity, but also reducing the
impact of its smelter operations on the environment
– the latter through improved energy
efficiency and minimised emission of levels.
In essence, lower energy consumption would
mean reduced depletion of fossil fuels and an
associated decline in carbon dioxide (CO2)
produced during the combustion of these
fuels; while enhanced process control would
curtail emissions of other greenhouse gases –
specifically perfluorocarbons (PFCs).
This quest culminated in the development
in 2005 of Dubal’s proven in-house developed
DX technology – a UAE flagship technology
that has been installed in a dedicated 40-cell
potline at the Dubal smelter in Jebel Ali, Dubai;
and in the 756-cell first phase of Emirates
Aluminium (Emal) in Al Taweelah, Abu
Dhabi. The amperage of the DX cells at Dubal
was ramped up from 340 kA at start-up to
380 kA within the first two years of operation.
Operating stably at this level, these cells
produce 2.91 tonnes of aluminium per pot
per day at exceptionally high purity levels of
99.92%, with specific energy consumption
of 13.2 kWh/kg of aluminium produced and
current efficiency of 95.2%. These performance
parameters translate into measurable
energy conservation and associated operating
cost reductions, as well as reduced environmental
impact through lower fossil fuel
consumption. The DX cells at Emal
Phase I, which began operating at
350 kA, now also operate at 380 kA
– giving an production capacity of
800,000 tonnes a year.
While extremely proud of DX
technology, Dubal’s hunger for continuous
improvement has not been
satiated. To the contrary, ongoing
R&D activities at Dubal have resulted
in a re-design of the DX cells to
enable operating at even higher amperages.
Five new generation cells –
known as DX+ technology and
another UAE flagship innovation –
were built in a pilot line at Dubal’s
Jebel Ali smelter and began operating
at 420 kA at the end of August
2010. The amperage of these pilot
cells has since gradually increased
and reached 440 kA in February
2012, with stable results. Daily output
is 3.37 tonnes of aluminium per
pot, at purity levels of 99.93%, with specific
energy consumption of 13.27 kWh/kg of aluminium
produced. Ultimately, DX+ cells are
expected to operate at 460 kA.
Based on its demonstrated performance,
DX+ technology has been licensed to Emal
Phase II, where a single 444-cell potline is
currently under construction. At this industrial
scale, DX+ is targeted to achieve specific energy
consumption of less than 13.33 kWh/kg
34 ALUMINIUM · 3/2013

S P E CIAL
ALUMINIUM MIDDL E EAST
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of aluminium, with an average daily yield of
3.4 tonnes per pot. Moreover, Aluminium
Bahrain (Alba) announced in December last
year that it had chosen Dubal’s DX+ technology
for its Line 6 Bankable Feasibility Study,
which aims to determine the viability of Alba’s
sixth potline expansion project that targets a
production increase of 400,000 tonnes of aluminium
a year.
D18+ cells
Importantly, the anode effect frequency of
both DX technology and DX+ technology
is very low (0.05 per pot per day and 0.07
per pot per day respectively) and the duration
of AEs is less than 10 seconds (a world
benchmark). As a result, PFC emissions from
both technologies are contained to 7 kg CO 2 eq
per tonne of aluminium. This achievement
strongly supports Dubal’s unceasing efforts
to reduce PFC emissions overall, where
various initiatives have resulted in the PFC
emission intensity being just 120 kg CO 2 eq
per tonne of aluminium in 2012, which is
88% lower than in 1990.
Reflecting Dubal’s corporate ambition for
continuous improvement, substantial effort
has also been invested over the years to increase
the efficiency and production output
of its D18 technology cells. Initiatives have
included conversion pseudo-point feeding,
additional busbar, modification of the cell
lining design, increased anode size and cell
control logic improvements. These changes facilitated
increases in amperage (from 150 to
202 kA), improved current efficiency and reduced
specific energy consumption, and lower
PFC emissions.
Acknowledging that further progress in
optimising the performance of the cells required
a breakthrough approach, Dubal initiated
a pilot project in 2012 to completely
revise and modernise the cell technology in
its original potlines. To ensure economic and
operational viability, specific criteria were imposed
on the new cell design – notably maintaining
the cell-to-cell distance; maintaining
the overall cell height (to accommodate existing
critical equipment); keeping the amperage
availability limits within the existing rectifiers;
and maintaining the existing fume treatment
plants (FTPs). Satisfying these criteria, the new
in-house design, designated D18+, not only
utilises the existing footprint of the original
D18 potline infrastructure but also incorporates
the major advances made in cell technology
in recent decades, such as magnetic
compensation and proper point feeders.
To validate the new design, seven D18+
cells were constructed in Dubal’s Potline 1
and started-up in March 2012, with stable
operation achieved within a few weeks. Since
then, the D18+ test cells have not only met
but exceeded the original design targets – thus
delivering significant operating improvements
over D18 cells. For example, specific energy
consumption in D18+ technology, at 12.74
DC kWh/kg Al, is measurably lower than that
achieved by D18 technology (15.14 DC kWh/
kg Al) and current efficiency has improved to
95.1% (D18: 92.34%). Dramatic reductions
in anode effect frequency (0.015 AE per pot
per day versus 0.44 AE per pot per day) and
duration (down from 57 seconds to 31 seconds)
means that the volume of PFC emitted
by D18+ technology cells (6 kg CO 2 eq per
tonne aluminium) is nominal by comparison
with D18 technology cells (312 kg CO 2 eq per
tonne aluminium). These and other parameters
confirm that D18+ technology has met its
main objectives, namely to improve Dubal’s
D18 cells in terms of energy efficiency and
reduce greenhouse gas emissions, while maintaining
or increasing current levels of production.
The new D18+ technology was fully modelled,
engineering and executed using Dubal’s
in-house technology development and operations
resources; and the conversion of the
seven pilot cells to D18+ technology was
achieved while the remainder of the potline
continued to operate normally. Indeed, the
overall success of Dubal’s D18+ pilot project
provided clear evidence that it is technically
and practically possible to update and replace
cell technology within an existing, operating
potline. Consequently, a study into the feasibility
and optimal engineering pathway for
retrofitting the Dubal’s remaining 513 D18
technology cells with D18+ technology is currently
underway. The company aims to complete
the modernisation of the original potlines
within 2013.
■
36 ALUMINIUM · 3/2013

S P E CIAL
ALUMINIUM MIDDL E EAST
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Emal – well positioned to meet future demand for aluminium
© Emal
Emirates Aluminium (Emal) is a company
whose reputation is growing as quickly as
its order books are filling. With all production
sold in 2012 and production set
to increase in 2013, the company is well
positioned to meet the growing global
demand for aluminium and is set to continue
its impressing rise to become one of
the leading players in the industry.
Operating from its state-of-the-art facility in
Al Taweelah, Abu Dhabi, the smelter supplies
customers from around the world with highquality
ISO9001 certified aluminium. Products
include standard ingots, sow, sheet ingots
and extrusion billets. In 2012, Emal added
foundry alloys to its production portfolio.
Initially, it was the vision of the UAE leaders
which provided the concept of Emal as a flagship
for industrial diversification. The 2030
vision provided a road map for development
and goals for the company to achieve.
Emal is a joint venture between Dubai
Aluminium (Dubal) and the Abu Dhabi investment
company Mubadala. Based on an
initial investment of USD5.7 billion, Phase I
of the smelter was completed on budget and
ahead of schedule. Full production capacity
of 750,000 tonnes a year was reached at the
end of 2011.
Once Phase I was completed Emal did not
stand still. With confidence in the future market
for aluminium, the company announced a
further investment of USD4.5 billion for expansion
and a production
rise in its Phase I
potlines by increasing
amperage from 350
to 380 kA. As soon as
Phase II is completed
in 2014, Emal will
be among the largest
single-site aluminium
smelters in the world
with a production capacity
of 1.3 million
tonnes a year.
As part of Phase II,
Emal is using the Emirati-developed
DX+ Reduction
Cell Technology
for its new potline
of 444 reduction cells.
DX+ enables aluminium
to be produced using
less energy without
compromising on quality.
This means Emal is
able to almost double
production, while not
having to double the
number of pots it operates.
Once completed
the potline at Emal will be the longest single
potline in the world at 1.7 km.
As part of the expansion the dedicated
power plant at Emal will increase by 50% to
3,000 MW, making it one of the largest power
stations in the Gulf region. This reliable
source of energy is just one of the reasons
why Emal is perfectly placed to respond to
the changes in the market. Another reason is
the casthouse at Emal, which uses the latest
technology to provide greater flexibility in
product output. This ensures the company is
able to respond quickly to customer demand,
especially for high grade products.
Allied to these sound business advantages,
Emal also enjoys the benefits of a united and
stable political environment within the UAE.
This security and ‘an open for business’ approach
from the government has helped build
the foundations for success.
Emal’s commitment
The Phase I development was achieved ahead
of time and on budget due to the very effective
planning regime instigated and the engagement
of quality contractors working effectively
with the Emal staff. This project management
was aligned to a workforce committed
to Emal values and determined to successfully
deliver this mega industrial project. The continued
hard work and dedication of the staff
was only too evident in the recent achievement
of being the fastest ever smelter to produce
1.5 million tonnes of hot metal. It is this
type of commitment which will ensure Emal
delivers the ambitious goals set.
Emal has embedded health and safety into
everyday working practices by introducing
Environment, Health and Safety (EHS) representatives
into every facet of its operations.
These representatives work as part of each
team ensuring health and safety considerations
remain paramount in the workplace. It
is this kind of commitment which saw Emal
set an industry-leading figure of two years
and over 10 million man hours without a
38 ALUMINIUM · 3/2013

S P E CIAL
ALUMINIUM MIDDL E EAST
single lost time incident in 2012. This commitment
is also clear in how the company is seeking
to develop a sustainable business which
minimises its impact on the environment.
Emal has invested more than USD700 million
in state-of-the-art technologies in Phase I for
reducing emissions.
The company not only complies with all
applicable local environmental legislation,
but is also committed to the more stringent
European standards. Fluoride emissions at
the Al Taweelah smelter are below the IPPC
standard. In order to reinforce this commitment,
Emal also goes beyond what is legally
required by undertaking additional voluntary
initiatives. One such scheme is the monitoring
of the sea water temperature around the
smelter to ensure that there is no impact on
the marine environment.
Aluminium market
World aluminium demand is forecast to increase
by 6% year-on-year over ten years.
Current annual demand for aluminium is 40
million tonnes, this is estimated to reach over
70 million tonnes by the year 2020. Total
production at Emal in 2011 was 750,000
tonnes which will increase to 800,000 tonnes
in 2013. Once Phase II is completed annual
production will almost double to 1.3 million
tonnes ensuring Emal is well placed to meet
future demand for aluminium: internationally,
regionally and locally.
While Emal’s reach is a global one – over
80% of the company’s production is delivered
to the markets in Europe, Asia and the Americas
– the company also has its eyes fixed on
markets closer to home. The market within
the region is also set to grow in the future.
Between them Emal and Dubal sell about
250,000 tonnes of aluminium in the Middle
East and North Africa Region (Mena). Both
companies have 100% of market share in the
UAE and Oman and 90% share in the markets
of Lebanon, Syria, Morocco, Tunisia and
Algeria.
Sales to Mena represented around 15%
of Emal’s total sales in 2012. The vast majority
of sales in the region are within the GCC
(93% of regional sales). Although the Mena
market is relatively small, it remains important
for Emal. It is not a mature market, but
indicators suggest it has the capacity to grow.
One of the projects likely to fuel growth is
the building of the GCC rail network. As a
result, Emal is forecasting a 20% growth of it
sales to the Mena region in 2013.
In the future Emal’s target is to expand the
customer base in the Mena market with the focus
on Turkey as a country of importance, and
with a special view on extrusion billets. Total
consumption in Turkey is 750,000 tonnes a
year and Dubal and Emal currently supply a
small fraction of this market.
Emal’s home market remains a priority
objective. Current consumption in the UAE is
just under 200,000 tonnes a year, the supply
of which is split equally between the UAE’s
two primary smelters – Emal and Dubal. The
quality and value of the aluminium produced
by the two plants means local customers do
not need to source their supply from outside
of the country. The majority of Emal’s downstream
customers in the UAE are involved in
construction, power and oil and gas.
Made in the United Arab Emirates and
achieving a world reputation in the global
competitive market in such a short period
of time is something on which the company
prides itself.
■
GLAMA Maschinenbau GmbH
Hornstraße 19 D- 45964 Gladbeck / Germany
phone + 49 (0) 2043 9738 0 fax + 49 (0) 2043 9738 50 email: info@glama.de
web: www.glama.de

Sustainable or profitable?
It‘s AND, not or.
Ecoplants is the new mark for sustainable solutions from SMS that
offer our customers economic and ecological advantages. Economic
because savings in energy and raw materials reduce costs; ecological
because the conservation of resources is becoming ever more
important. Ecoplants solutions from SMS give due consideration to
both aspects – to the benefit of our customers.
The SMS group is a group of global players in plant construction
and mechanical engineering for the steel and nonferrous metals
processing industry. It consists of the Business Areas SMS Siemag,
SMS Meer, and the industrial participations.
SMS group
Eduard-Schloemann-Strasse 4 Phone: +49 211 881-0 E-mail: communications@sms-group.com
40237 Düsseldorf, Germany Fax: +49 211 881-4902 Internet: www.sms-ecoplants.com

TECHNOLOGY
Protective clothing for the aluminium industry from South Africa
A. Charnaud, Charnaud & Co. (Pty) Ltd
© Charnaud
A. J. Charnaud & Co. (Pty) Ltd has
been manufacturing industrial protective
clothing (PPC) since 1975. Hot metal
splash-resistant protective work wear for
the aluminium industry was added in the
late 1990s after IPAI, now known as the
IAI (International Aluminium Institute),
changed the goal posts and increased the
required protection levels. They introduced
a standard test that has become
known as ‘Procedure B’, which has become
the benchmark for IAI members to
follow.
ALu-SAFE protecting clothing
Because IPAI raised the minimum performance
standard, most of the PPC being used
in the global aluminium industry fell short of
this standard. The race was then on to develop
Example: mobile gas treatment system and
furnace covers with gas exhaust
products which could meet the new standard.
It was in response to this challenge that
Charnaud decided to develop its ALu-SAFE
product in South Africa.
Today ALu-SAFE has become a global
standard in many smelters as well as in downstream
operations across the world under a
wide range of climatic conditions. Charnaud
is the only producer in the industry who controls
the quality of its product through all the
manufacturing stages, starting with the raw
fibre, and down to the finished garment.
The company’s holistic approach to PPC
and personal protective
equipment (PPE), brought to
live the ‘Head to Foot’ concept
of protection. The aim
of the company is to provide
protection of the worker exposed
to molten aluminium
and cryolite splash, not only
by supplying items of clothing,
but through a complete
protective ‘kit’.
The ALu-SAFE range
of protective clothing and
equipment consists of head
and neck visors, knitted undergarments,
casting coats
and suits, shirts and trousers,
socks, footwear, winter
warm coats, and electric arc
flash garments, to name but
a few. The range of protective wear was developed
whilst taking into account the workers’
special protection requirements when
exposed to both molten aluminium and cryolite.
The range is
triple certified
and meets the requirements
of the
US ASTM standards,
European
standard EN ISO
Revamping solutions 11612:2008, plus
IPAI Procedure B
and tailor made for molten aluminium
and cryolite,
aluminium melting
and where appropriate
the garments are
and holding furnaces
also CE certified.
Today the Charnaud
and ALu-SAFE
brands have become
synonymous
with the ultimate in overall hot metal protection.
The range contains some unique products,
including a fabric which offers D3 protection
against molten aluminium, B65 protection
against molten cryolite, plus HRC2 protection
against electric arc
flash for workers
carrying out
electrical work in
the hot metal
areas.
E20300 with
red insert
For foot protection a special hot metal sock
was developed. Apart from offering molten
splash protection and being inherently flame
resistant, the Charnaud Thermal Sock has a
permanent anti-bacterial feature built into
the fibres. The anti-bacterial treatment lasts
for the life of the sock and ensures the sock
says free of odours for several days.
Workers can choose between two specialised
protective work boots, depending of the
type of hazard they face in their workplace.
The Charnaud Smelter Boot and the E20300
Work Boot both carry the necessary certification
for work in the hot metal industry. The
ultra-high temperature sole of the Smelter
Boot will protect the wearer even in the event
of a direct dip into molten metal. This boot
was the first of only two in the market that
meet the new European standard for hot metal
and furnace footwear EN ISO 20349:2010.
The E20300 is a unique general purpose hot
metal boot that is completely metal free. The
boot has a 300 °C tolerant sole that is electric
shock resistant up to 20,000 V.
Charnaud not only provides world-class
head-to-toe protection, but also assists customers
with garment care and laundering to
ensure that the PPC and PPE last as long as
possible. We are proud to be the total solution
for PPC and PPE to the aluminium industry.
Author
Andrew Charnaud is chairman of A. J. Charnaud &
Co. (Pty) Ltd based in Honeydew, South Africa.
42 ALUMINIUM · 3/2013

...since 1840
manufacturer of high performance
Hot, Cold and Foil Rolling Mills for Aluminium strip
MINO OSpA S.p.A.
Via Torino, 1 – San Michele – 15122 ALESSANDRIA – ITALY
Tel. +39 0131 363636 Fax +39 0131 361611 - E-mail: mino@mino.it
www.mino.it

TECHNOLOGY
Energy-optimised route from aluminium
scrap to extruded semi-finished products
G. Valder, Otto Junker; H. Pfeifer, RWTH Aachen
In light of the European Union’s demanding
CO 2 -reduction targets and indirectly
rising energy costs, European aluminium
semis producers are exposed to increasing
competition pressure. For almost a
decade now German plant manufacturing
industry in particular has very successfully
been exporting production plants,
especially to Asia. But with every exported
production unit there is also a
transfer of know-how. Particular contributions
to this are made by joint ventures
or the employment of consultants from
western Europe. In the medium term it
is to be expected that as regards saleable
aluminium semis, in relation to quality
and productivity and with conditions otherwise
the same (e.g. materials and tools
used) there will no longer be significant
differences and Asiatic manufacturers will
increasingly move into other export markets.
As a direct result sales prices will
drop. At the same time European manufacturers
of aluminium semis are burdened
by comparatively high personnel,
natural gas and electric power costs, and
in particular by the fact that the cost of
energy is expected to rise by more than
the rate of inflation. Falling prices on the
one hand and rising costs on the other
hand have a sustained downward effect
on profits, which restricts the scope for
investments. However, to ensure the necessary
innovative advances investments
are urgently needed. That aspect provides
reason enough to concern oneself with
energy potentials, so the focus of this
article is on costs for thermal energy converted
essentially from gaseous fuels such
as natural gas or propane.
However, for plant manufacturers and aluminium
semis producers the optimisation of
operating costs is no new challenge. Thus, the
consumption of thermal energy in foundries
and extrusion plants could be cut by roughly
14%, simply if the heat process equipment
in use today all conformed with the most advanced
state of the art [1].
Thus, the political aim of cutting CO 2 emissions
has only increased public awareness of
energy efficiency. High energy efficiency levels
of production plants have for many years
Thermal process unit
Two-chamber hearth furnace
Table 1: Thermal energy demand in the billet casthouse and the extrusion plant
been the common objective of engineers working
in the contexts of both plant manufacturers
and plant operators. The fact that many
existing approaches toward improving energy
efficiency are not being implemented is evident
from a consideration of the determinants
of an economics computation: those include
investment costs, which on the assumption of
a particular interest rate have to be set against
operating cost savings. The break-even point
of the function obtained is the amortisation
time.
If investment costs are regarded as fixed,
then the remaining parameters for further consideration
are operating cost savings and amortisation
time, and it then becomes clear why
the energy efficiency of the equipment stock
lags behind the technical possibilities: the amortisation
periods expected by investors – as a
rule, one to three years – are either too short
and/or energy costs are still too low.
In this article we shall consider what saving
potentials in thermal process technology
could still be developed if there were a possibility
of building a new continuous casting
plant and extrusion plant ‘greenfield’. In this
the limiting factor is economy, i. e. the possible
approach of replacing thermal energy
by electrical energy is ruled out because in
that way, depending on the current mix, CO 2
reduction would be achieved in operational
terms but not economically.
Thermal process equipment in foundries
and extrusion plants – the state of the art
The present state of the art serves as a basis
for the analysis, inasmuch as it is assumed that
the individual thermal process units in operation
today have already undergone measures
to reduce their energy consumption:
State of the art
‘Primary exhaust gas utilisation’
Combustion air preheating with regenerator,
if possible using the heat content of organics
Energy demand
(kWh th /t Al )
660 – 700
Casting/holding furnace Combustion air preheating with recuperator 30 – 50
Homogenising furnace Combustion air preheating with recuperator 195 – 205
Billet heating furnace
Combustion air preheating with recuperator
and preheating of the charge
175 – 215
Aging furnace Combustion air preheating with recuperator 75 – 85
Thermal energy demand 1,135 – 1,255
• The combustion air of the burners used is
preheated by regenerators or recuperators
(centrally or de-centrally)
• From the instrumental and control standpoint
the regulation of the burners is
designed for wide control ranges (1:10 or
more) and long periods of being switched
on (reduction in the number of switching
operations)
• Combustion takes place, for example
thanks to the use of λ-probes, always as
close as possible to the stoichiometric air
ratio (λ = 1)
• The loading pattern and filling level
ensure that the thermal process unit is
operated close to its design point, i. e. its
nominal performance rating
• Design measures to optimise furnace efficiency
1 (structure of the insulation, avoidance
of apertures, the use of appropriate
seals) are adopted, and maintenance work
is carried out carefully.
Table 1 shows the thermal energy demand
that can be expected from modern thermal
process equipment if the above-mentioned
assumptions are fulfilled [1]. The values are
referred to the mass of aluminium used. It is
also assumed that the alloys processed can
predominantly be made with the use of recycled
material or aluminium procured from
outside ‘as necessary’. The consideration also
does not take account of high-strength components
that have to be heat treated (such as
by T6 annealing).
The objective is to optimise the energy demand
in the billet casthouse and the extrusion
plant. As an approach toward achieving this,
in what follows the available options will be
1
From the furnace efficiency the colloquialism ‘idle value’
is derived
44 ALUMINIUM · 3/2013

TECHNOLOGY
Fig. 1: Example of a typical recycling furnace (Otto Junker/Thermcon design)
discussed for combining thermal process units
with one another in such manner that heat energy,
once introduced, can be used in as many
process steps as possible.
Casthouse production area
At the beginning of the process chain is the
melting furnace. In view of the need for economically
viable energy
optimisation, as
many billets as possible
should be produced from secondary aluminium,
i. e. aluminium scrap. For that purpose it
is best to use a two-chamber hearth furnace
(Fig. 1) as the recycling aggregate. In 2010
aluminium production in Europe was typically
characterised by proportions of 1 tonne of
Fig. 2: Qualitative variation of the total energy costs for aluminium production
(primary and secondary), Quinkertz [2]
secondary metal to every 3.5 tonnes of primary
aluminium. According to the investigations
by Quinkertz [2], until the energetically optimum
proportion of around 75% is reached
there is still considerable useful economic potential
for aluminium recycling (Fig. 2). Bene-
© Otto Junker

TECHNOLOGY
Fig. 3: Furnace technological efficiency (natural gas H, excess air 15%) [4]
ficial in addition to the favourable energy balance
2 are the waste collection systems which
operate comparatively well in Europe, thanks
to which the availability of suitable scrap can
be ensured.
The state of the art is to equip two-chamber
hearth furnaces with regenerator burners. For
economical operation these require exhaust
gas temperatures higher than 750 °C. The
relative air heating that can be achieved with
regenerators amounts to ε ≈ 0.8, which means
that about 80% of the heat content of the exhaust
gas can be recovered. Consequently the
preheat temperature of the combustion air is
800 °C when starting with a typical hot-chamber
temperature of about 1 000 °C (Fig. 3).
After the regenerator there is still available
an exhaust gas heat content of approx. 200
kWh th /t Al at a temperature of 150 to 250 °C.
The melting furnace is usually followed by
a holding or casting furnace. The need for this
depends mainly on the metallurgy, and the
energy consumption almost exclusively on
transfer losses and hot-holding times. Thus,
both of the two last-mentioned factors must
always be kept as small as possible.
Since neither cold-air burners, which are
still used today, nor regenerator burners can
be used in a holding / casting furnace to optimum
energetic effect, the use of recuperator
burners is to be recommended. The resulting
residual exhaust gas heat content of only
20 kWh th /t Al at about 350 to 400 °C can only
be used rationally in an exhaust gas combination
with the melting furnace.
Clearly there is a possible association between
the continuous casting plant and the
downstream homogenising furnace (Fig. 4).
A widespread practice is to bring the billets
into the homogenising
furnace only after they
have cooled to room
temperature. On the
one hand this practice
arises from understandable
infrastructural
and production
planning reasons, and
on the other hand there
are also restrictions of
a thermo-process technological
nature: for
space and time related
reasons homogenising
furnaces are operated
at excess temperatures
at least until the beginning of the equalisation
phase. A prerequisite for this is that the cast
aluminium billet should be introduced into
the homogenising furnace isothermally.
In the first place, however, from a metallurgical
standpoint it is not critical whether the
isotherm amounts to 300 to 350 °C instead of
room temperature, and secondly, from the
standpoint of thermo-process technology it
is unproblematic to carry out a homogenising
process with excess temperatures of less
than ± 10 K. Accordingly the two operating
methods, batch and continuous, have to be
compared against one another. At first sight
it seems advantageous for the batch method
that the billets cast in one batch can then also
be homogenised in one batch. To keep the
waiting times after casting as short as possible
and thereby to maintain a starting temperature
as high as possible, it may be necessary,
compared with the conventional production
sequence and for an otherwise equal annual
production, to provide more homogenising
and cooling capacities. In particular, the cooling
chamber could be used as a buffer – if
turned off below 350 °C.
The higher one-off investment (number of
homogenising units, space occupied) needed
for this is set against the permanent halving of
the energy consumption: with a charge temperature
of 300 °C, in a typical homogenisation
half the amount of energy previously
used is saved, namely approx. 100 kWh th /t Al .
The larger amount of space occupied is a disadvantage.
With the production of homogenised
billets the task of the casthouse is accomplished
and the interface to the downstream
extrusion plant is formed as a rule by a (cold)
billet store, because the typical batch sizes of
(vertical) casting and homogenising in a batch
process do not match the typical extrusion
production runs.
Extrusion plant production area
Having regard to the aspect of optimising energy
use, the question of how real production
continuity can be achieved between the casthouse
and the extrusion plant that comes after
it. Ultimately, the aluminium billets delivered
for extrusion are already re-heated, typically
to 480 °C, in a first working step before deformation.
Considering, however, that after the
homogenisation process, from the metallurgical
standpoint it is only necessary to cool the
metal to 300 °C instead of to room temperature,
it becomes really obvious to look at the
link to the extrusion plant. This approach is
not new, but it has also not been implemented
widely before now and it can therefore be
worth the trouble to discuss this against the
2
Producing one tonne of primary aluminium demands a
consumption of around 13,500 kWh th+el /t Al [3], whereas
a tonne of secondary aluminium demands only a fraction
of that, see Table 1.
Fig. 4: Example of a typical billet homogenising system consisting of two batch furnaces and a cooling
chamber (Otto Junker design, as in the following photos)
46 ALUMINIUM · 3/2013

TECHNOLOGY
Fig. 5: Example of a typical vertical
magazine used as a cold store
background of constantly developing technology.
Assuming a capacity of about 4 t/h and
8,000 working hours a year, a casthouse produces
about 32,000 tonnes of aluminium billets
a year. In the subsequent extrusion plant
that quantity demands the operation of two
extrusion presses. In practice it is assumed that
the aluminium profiles produced will be made
not only from different alloys (according to
the requirements of their subsequent use) but
also from different billet diameters (to limit the
degree of deformation). It must also be borne
in mind that depending on the size of an order,
only one billet of a given alloy may be needed.
These boundary conditions set the requirement
that it must be possible at any time to
deliver to the extrusion plant individual billets
containing residual heat, but having different
diameters and made of different alloys.
The conversion of the cold vertical magazine
into a hot, or heat-retaining vertical magazine
is a typical engineering task, i. e. there is
no obvious reason to doubt its feasibility.
However, it should be borne in mind that
the temperature uniformity of the heated billets
is not very good. Both the frequent access
to the vertical magazine (5 to 10 times
an hour) and its spatial extension (≈ 400 m 3 )
have a negative effect when exhaust gas is fed
in as the energy carrier at a low dynamic pressure
for keeping the temperature up over a
large area. From this the boundary condition
is derived that the heating furnace upstream
from the extrusion press must be capable of
equalising inhomogeneous entry temperatures.
The use of conventional heating furnaces,
in which the heat transfer takes place by the
direct action of flame with a correspondingly
higher excess temperature, is not suitable for
this purpose owing to the risk of melting. In
contrast, a convection furnace is perfect for
the purpose.
In that case the heat transfer takes place at
temperatures slightly above the deformation
temperature required, so that even if boundary
conditions are unfavourable a temperature
tolerance of ± 5 K can be guaranteed. Here
too, from the aspect of energy efficiency there
is at present no more suitable aggregate [5].
From the standpoint of energy optimisation,
in summary, it can be said that the heating
of aluminium billets held at about 300 °C
after homogenising instead of being cooled,
to a first approximation results in a saving
of 60% of the previous energy consumption,
namely around 105 to 125 kWh/t Al .
The convection furnace (Fig. 6) is heated
by recuperator burners and operated at approximately
500 °C. With a relative air preheat
of ε = 0.6 the exhaust gas temperature
still amounts to about 200 °C and the exhaust
gas heat content at least 55 kWh th /t Al . Owing
to the temperature after
the recuperator this
exhaust gas cannot be
used to keep the magazine
hot and should
therefore be returned
to the exhaust gas system
in the casthouse.
From the above it
follows that the vertical
magazine has to
be kept hot with the
exhaust gases from the
homogenising furnace:
here, even after the
supply of aluminium
billets hot from casting,
an exhaust gas heat
content of approx. 85
kWh th /t Al is still available. The recuperator
should be designed for an exhaust gas temperature
of 320 °C, to cover energy losses
in the vertical magazine. Theoretically, this
exhaust gas, with a heat content of around
60 kWh th /t Al , could then be returned to the
existing exhaust gas system at a temperature
of 300 °C.
Finally, it still remains to consider the ageing
furnace (Fig. 7): at first sight it seems reasonable
to suppose that the section temperature
after emerging from the extrusion press
(about 500 to 550 °C) in fact supplies some
heat to the ageing furnace. Closer consideration,
however, shows that this optimisation
route is not effective: for metallurgical reasons
it is very often necessary to cool the sections
very carefully and/or subsequently to stretch
them, so that after the run-out system the extruded
sections are stacked cold in racks and
then taken to the ageing furnace.
There, the aluminium profiles have to be
heated to 185 °C and held at that temperature
for several hours. Owing to the low process
temperatures and the associated risk of falling
below the dew-point (staining), ageing furnaces
are indirectly fuel-fired and this, mostly,
with cold-air burners. Depending on the surface
load of the radiator tube the exhaust gas
temperature after the burner is up to 280 °C.
To optimise energy utilisation the medium of
choice is to use recuperator burners, since energy
efficiency increases, the closer is the link
between the primary process and the measures
for improving efficiency. Behind the recuperator
the temperature can still be expected to be
around 120 °C. Although the energy saving
achieved then amounts to only 10 kWk th /t Al in
absolute terms, that is more than ten percent
of the previous energy consumption.
Further use of the exhaust gas – for ex-
Fig. 6: Combi-gas convection furnace (patent applied for)
ALUMINIUM · 3/2013 47

TECHNOLOGY
ample in the proposed
exhaust gas system – is
not appropriate in light
of the temperature
level after the recuperator.
The effect of the
exhaust gas system can
now be estimated now
that all the fuel-heated
thermo-process units
have been considered: in total, from the recycling
furnace, the holding/casting furnace,
the heated vertical magazine and the billet
heating furnace an exhaust gas heat content
of 335 kWh th /t Al is obtained, at a temperature
of approx. 250 °C with adiabatic mixing.
Only 30 kWh th /t Al are needed for preheating
the scrap supplied to the recycling furnace
to 100 °C and drying it. Now, instead of storing
the scrap coming from within and outside
in heaps, a scrap bunker heated by the energy
flow from the exhaust gas system should be
provided. A possible approach would be to
set up a system of circulating ‘pick-and-place’
charging troughs: in a cyclic system these
would be charged with incoming scrap, parked
automatically in the heated bunker, and as
necessary or after an appropriate dwell time,
removed for charging the recycling furnace.
Possible result
For the foundry and extrusion plant production
sector various approaches have been discussed
for reducing energy demand:
• spatial combination of the casthouse and
the extrusion plant
• construction of an exhaust gas system for
preheating the scrap to 80 °C
• beginning homogenisation at 300 °C
instead of from room temperature
• beginning billet heating at 300 °C instead
of from room temperature
• using recuperator burners in the ageing
furnace.
The measures described above lead to an energy
saving of 245 to 265 kWh th /t Al , which
corresponds to 22% (Table 2). With an average
industrial natural gas price (EU 28) of
0.039 €/kWh th [6] and the assumed annual
production of 32,000 tonnes, in the casthouse
and extrusion plant energy costs between
305,000 and 330,000 euros can be saved.
Thermo-process plant Saving (kWh th /t Al )
Optimised energy demand
(kWh th /t Al )
Two-chamber hearth furnace 30 630 – 670
Casting/holding furnace none 20 – 40
Homogenising furnace 100 95 – 105
Billet heating furnace 105 – 125 70 – 90
Ageing furnace 10 65 – 75
Thermal energy demand opt. 245 – 265 880 – 980
Table 2: Thermal energy demand in the continuous casting plant and the
extrusion plant, after optimisation
there are a series of measures which could be
implemented when planning a new plant. Nevertheless
in individual cases higher investment
costs have to be allowed for, which become
economical only if longer amortisation times
are acceptable. Alternatively, only (even)
higher energy costs would produce the necessary
incentive for action. The first approach is
to be preferred – lower energy needs reduces
demand and lowers the price.
At the same time it is clear that to make
use of the potentials whose existence is not
in doubt, requires interdisciplinary collaboration
between various fields of engineering
science. However, it must be admitted that at
the locations existing today, restrictions are in
force which enable only some of the measures
described.
For the sake of completeness, there is an
important aspect which should not be left unmentioned:
the above considerations imply
that between the recycling furnace and the
ageing furnace some 32,000 tonnes of aluminium
a year are processed without losses.
This, of course, is not the case. In fact, for the
actual sale of 32,000 tonnes of profiles as a
rule more than 42,000 tonnes of aluminium
have to be charged into the recycling furnace.
In the form of combustion loss, overfill losses,
billet offcuts, billet and extrusion discards,
profile scrap and rejects, it is usual for more
than 30% of the material originally charged to
be returned back into the cycle. That fact often
is the first to justify the operation of a casthouse
in combination with an extrusion plant.
To that extent, improving productivity also has
high potential for reducing energy demand.
References
[1] Valder, G.: Ermittlung des Energieeinsparpotenzials
und Bestimmung von CO 2 -Produktbenchmarks
bei der Herstellung stranggepresster Halbzeuge aus
Sekundäraluminium, Dissertation RWTH Aachen,
2011, S. 120
[2] Quinkertz, R.: Optimierung der Energienutzung
bei der Aluminiumherstellung, Dissertation RWTH
Aachen, 2002, S. 78
[3] Hajek, A.: Entwicklungen auf dem Rohstoffmarkt,
Forum für Zukunftsenergien e.V., 23. Sitzung
am 16. März 2005
[4] VDMA: Leitfaden Energieeffizienz von Thermoprozessanlagen,
Eigenverlag VDMA, 3/2009, S. 19
[5] Gauvain, M. et al.: Otto Junker successfully commissions
a new type of high-efficiency billet heating
unit at Sapa Offenburg, (Article published also
in German language), International ALUMINIUM
Journal, 5/2012, S. 62-66;
[6] Destatis: Daten zur Energiepreisentwicklung,
Statistisches Bundesamt, Wiesbaden, https://www.
destatis.de/.../EnergiepreisentwicklungPDF_
5619001.pdf, 11/2012, S. 22
Authors
Dr.-Ing. Günter Valder heads the Thermal Process
Plant division at Otto Junker GmbH, Simmerath.
Prof. Dr.-Ing. Herbert Pfeifer is head of the Institute
for Industrial Furnace Construction and Heat Technology
at RWTH Aachen.
Summary
The analysis of potentials for saving thermal
energy was carried out on the assumption of a
‘greenfield’ investment. It has been shown that
Fig. 7: Example of a typical ageing furnace
48 ALUMINIUM · 3/2013

TECHNOLOGY
Low-energy air-cooled electromagnetic stirring systems
A. Peel, Altek
The benefits of metal circulation in aluminium
reverberatory furnaces have been
very well documented over the years, especially
the higher productivity, reduced
fuel consumption and reduced dross
generation, along with excellent alloy and
temperature homogeneity. One popular
method to achieve circulation is electromagnetic
stirring. That said, this technology
has traditionally had certain drawbacks
which limited its wider acceptance.
Financial drawbacks included high capital
and operating costs (especially power
consumption and maintenance of water
cooling systems). Technical drawbacks included
customers’ reluctance to use water
in close proximity to molten metal – in
the basement under the furnace hearth,
and in some cases the system was unable
to operate through full-thickness refractory
hearths. There have also been cases
where existing systems did not work in an
effective way through the side wall.
This article describes a technology
which amounts to a reinvention of the
traditional electromagnetic stirring device,
effectively addressing all of the
above negative aspects of traditional systems.
This article also discusses some of
these aspects and results in more detail.
The application of electromagnetic (EM) stirring,
which was initially introduced into the
aluminium industry in the 1960s, has grown
significantly since the late 1990s. Fig. 1 shows
the huge growth in application of different
types of EM stirring or pumping technologies
to circulate liquid aluminium in furnaces.
This was reported some years ago, but the
market has continued to grow significantly as
customers recognise the huge benefits to be
gained from stirring metal.
There are many different types of stirrers
available today, as the above graph shows, and
all will have more or less the same operational
benefits within the furnace. However, the big
difference between these devices is how they
achieve that result from the point of view of
installation, reliability and operational cost.
Water-cooled stirrers have predominated
until now, as there had not been a credible
alternative. Over the past three to four years
Altek’s air-cooled electromagnetic stirring
technology, Siber Force, has become increasingly
accepted in many of the world’s leading
aluminium operations as a credible alternative
to water-cooled EM stirring. Users include
Hydro, Constellium, Novelis, Hulamin, Sapa,
Kaiser Aluminum, Rusal, Nichols Aluminum,
Bridgenorth Aluminium, Carcano, China Steel
Aluminium, etc.
The Altek Siber Force technology ensures
that the stirrer has no direct contact with the
aluminium. There are no slots, channels, hollow
copper water tubing or water pipes, and
there is no risk or effect from the aluminium
bath content on the stirrer operation. The stirrer
can be started and stopped as required
without any risk to the stirrer operation or any
risk of blocking or plugging of dross into any
tubes or channels. It is a highly reliable piece
of equipment.
The technology – originally developed in
the MHD Centre in Krasnoyarsk in the 1990s
and then implemented widely throughout
Rusal – has been totally transformed by Altek
to meet the stringent requirements of international
aluminium operations. The technology
today is 100% designed and manufactured in
the UK and incorporates the very latest manufacturing
and control system techniques. It
has been progressively introduced into various
aluminium
operations,
each with different
operating
characteristics
and installation
requirements, and has been thoroughly tested
and proven. Several key factors have driven
its growing acceptance as an alternative to the
traditional water-cooled EM technology.
Low energy consumption operation: Traditional
water-cooled stirring devices consumed
quite large amounts of electrical energy because
their designs were quite inefficient in
view of energy consumption. Comparisons
with the new air-cooled technology discussed
in this article have shown the savings could
run into many hundred’s of thousands of euros
per year. Over five years this can add up to a
significant sum.
Air-cooling: It has become increasingly
apparent that customers are more and more
nervous of having water circulating systems
within the basement areas under the furnace
hearth. There have been one or two accidents
where a furnace has leaked aluminium into
the pit (due to a premature refractory failure
for instance), and having water under the
hearth in these situations increases the risk of
a catastrophic explosion. It is also not uncommon
to encounter flooded basements / pools
of water due to a water leak on a coil or water
feed hose.
EM stirrer design
To achieve the above differentiating points,
the design of the Altek Siber Force electromagnetic
stirrer features several fundamentally
different aspects and we will discuss each of
these in turn below.
Cooling medium: The inductor coils are
made from solid copper bar (not hollow tubing)
of certain dimensions and configured in a
special way around the laminated Fe core, so
as to reduce the resistance heating effect of
the electrical current as it passes through the
copper coils. In conventional devices this current
generates a lot of heat, and the water cooling
must remove this large I 2 R loss.
The cooling medium serves to remove the
heat that is generated by the electrical current
passing through the copper inductor. The Al-
Fig. 1: The application of electromagnetic stirring and pumping devices has grown
hugely since the late 1990s
Fig. 2: A solid
copper inductor
dissipates less heat
ALUMINIUM · 3/2013 49

TECHNOLOGY
Fig. 3: A hollow copper inductor dissipates
more heat, and so requires water for cooling
tek stirrer generates only low I 2 R losses which
an air flow at a certain speed and mass flow
can easily remove. Our stirrers have been designed
to optimise this cooling air flow.
For the water cooled inductor the heat
generated is so much higher that air-cooling
cannot remove it. This is why it needs water
with all of the associated complexities of supply
systems, piping, quality sealing and glands
to avoid leaks, as well as emergency back-up
water systems etc.
The Altek air-cooling system is designed to
ensure that the heat generated by the inductor
coil is easily dissipated by the cooling air flow.
The variables that affect this are:
• Inlet air temperature
• Size of current being applied to the
copper coil
• Radiated heat from the furnace
• Local ambient air temperature.
This design allows the air to be applied in a
special way within the inductor so as to remove
the lesser heat generated by the current
applied to the inductor coil. A secondary
benefit of this type of coil construction is that
promotes a very long life of the inductor by
reducing the risk of overheating of the coil,
which can easily cause serious damage to a
hollow copper tube type inductor coil.
As an example, the oldest solid inductor
installed in 1994 is still in operation today.
Energy consumption: There has long been
a myth that you need to use huge amounts
of electrical energy with EM stirring technology
to obtain a good mixing effect within the
furnace. This may be the case with alternative
designs, but the Siber Force technology has
significantly reduced the input energy needed
to achieve efficient stirring.
Thus one of the big differentiating factors
of the Altek stirring technology is its lower
electrical energy operating costs (due to the
special inductor design and control system).
This unique design and operation of the Altek
technology allows very low energy operation
such that some customers use less than 100
Fig. 4: Altek air-cooled side-mounted stirrer fitted
to the side of an 80-tonne dry-hearth furnace
kWh in total for a whole four-hour melting
cycle on a 50-tonne scrap melting furnace.
Clearly the amount of energy used very much
depends on the type of furnace, the type of
operation (scrap melting or holding / casting
furnace) etc.
The key focus of this stirring system is to
deliver the Lorenz Force within the aluminium
bath in the proximity
of the stirrer.
This impetus in the
liquid aluminium generates
a very effective
mass flow of aluminium
throughout
© Altek
the whole bath. Some
of the smaller models
of Siber Force stirrers
are being utilised on
furnace capacities of >
60 tonnes. The size of
stirring model chosen
is based upon the following
factors:
1. Size of furnace
2. Type of operation
(melter, holder, liquid,
dry hearth)
3. Refractory thickness
– to obtain correct
penetration of the
magnetic flux into the
bath
4. Available space.
A specially designed
and patented technique
for driving the inductor
coil, a technology
utilised in the induction
heating industry, allows us to use a relatively
low input current to the control system
from the clients facility (the input kVA range
is between 80 and 150 depending upon the
stirrer model size). Coupled with the special
stirring controls utilised in the cycle, we are
able to adapt and modify the stirring patterns,
depending upon the particular requirement at
that stage of the furnace cycle.
Furnace installations: There are many stationary
furnaces around the world that do not
have basements and therefore have no space
for bottom-mounted stirrers. Fig. 4 shows the
side stirrer fitted on a 80-tonne dry-hearth
scrap melting furnace with a relatively small
footprint.
Multiple furnace operation
Fig. 5 shows an increasingly common solution
for customers who are looking to share a
common inductor between several furnaces.
This fully integrated system can serve two
melting furnaces; it moves automatically between
the furnaces and is controlled by the
furnace master control system. A similar system
has been working very well in a large aluminium
company for the past 12 months.
When you consider continual movement of
Fig. 5: Altek stirrer in stirrer basement under two reverb furnaces, and
designed to serve multiple furnaces
Fig. 6: Altek type 500 stirrer for multiple furnaces undergoing FAT testing in
the Altek factory
50 ALUMINIUM · 3/2013

TECHNOLOGY
stirrers between furnaces 24/7 for 365 days a year, the design and
equipment choice becomes very important in order to ensure continuous
and reliable operation. It is very important to consider the design
of the movement mechanisms and the cooling feed mechanisms so
as to minimise future maintenance or operational issues. The Altek
design and engineering team have many years of experience of supplying
electrical induction equipment to aluminium casthouses (and
steel plants), and have spent a lot of time in designing their turnkey
solutions to ensure a reliable system.
By using air-cooling we have removed the need for mobile water
hoses/couplings and the associated maintenance problems which can
occur, such as movement cycling under the aluminium furnaces. Altek
also believe a turnkey supply responsibility is important for the
stirrers and for their associated movement mechanisms, and for this
reason we undertake the full supply not just of the stirrer and control
system but also of the scissor lift / hydraulic trolley and movement
systems.
The movement systems that we have applied in the market are very
robust and efficient, giving repeatable operation. Each system undertakes
full factory acceptance testing (FAT) as indicated in Fig. 6.
For an Altek stirrer that will serve a melting furnace pair the installation
is designed to be controlled from the operator pulpit through
the furnace master control, so as to allow movement between the
two furnaces by an electrically driven trolley. Local control is also
available.
The cooling air fan can be either towed behind the stirrer or remain
fixed in position on it with a unique connection adaptor. Automatic
and hydraulically operated latches will secure the trolley under
the furnace once the correct position for operation has been detected
by the proximity detectors. This is important to ensure the
stirrer cannot move once it starts operating.
Fig. 7 shows the new Altek type 700 stirrer in its basement position on a
multiple furnace operation
The stirrer rises on its hydraulically operated scissor lift to the designated
position under the stainless steel plate (leaving a 10 mm air
gap) in the furnace hearth, and then to start the stirring action.
The speed of stirring (frequency), direction of stirring (forward or
reverse), power of stirring (current) are all controlled from the furnace
control PLC supplied by the furnace supplier. This sends instructions
to the stirrer controls system via Ethernet link.
This multiple furnace system has been in operation at other facilities
in Europe (Hydro) and it works very effectively. We are currently
supplying a similar multi-furnace system (to serve 4 furnaces with
2 inductor systems) to CSAC, Taiwan, and also to Carcano, Italy.
Performance results
Melt rate and energy savings: The Altek side mounted stirrer shown
in Fig. 4 earlier (as presented at TMS 2011) achieved a very good
ALUMINIUM · 3/2013

TECHNOLOGY
Fig. 8 shows the actual stirrer in position under a
dome-type melting furnace in Hulett Aluminium,
South Africa
melt rate (20% increase, Fig. 9) and energy
economy (14% reduction, Fig. 10), with electrical
energy operating costs of between 2 and
4 kWh/t. The total energy reduction for the
whole melt cycle (inductor, controls and air
cooling fan) is 155 kWh.
Alloying benefits: One customer who
makes AlSi alloys (9% and 11% Si) found
that using the EM stirrer improved his Si yield
significantly towards 99%. Also, by changing
his alloying practices was able to reduce his
dross generation as is shown in Fig 11.
A second benefit was that the titanium
purchase costs could be significantly reduced
due to different alloy purchasing. Many plants
use Ti waffle as it is easier to get into solution
without stirring. However, the EM stirrer
(whether bought for production or for energy
saving reasons) may also allow savings from
purchasing less soluble forms of alloying elements
that may now be
easy to get into solution
using a stirrer. Fig.
12 shows the different
costs of Ti additions.
Clearly each aluminium
casthouse will
utilise different levels
of Ti additions depending
upon their particular
circumstances and
what level of support
they are looking for to
help grain refining or
reduce cracking, but
if we assume a typical
smelter casthouse using
200 tonnes of TiAl
10% waffle per year:
200 t of TiAl 10% W =
20 t of Ti units. Based
on the numbers above,
this works out at a total cost of USD379,500.
If the plant instead uses Ti80%zf tablets for
example, thanks to having a stirrer to aid the
dissolution of the Ti into the melt, then the table
above gives a Ti cost of USD168,000. This
leads to yearly savings of USD211,500.
Furnace modelling
Excellent and powerful circulation is being
Fig. 11: Reduced dross generation/cycle and increased Si yield
Fig.: 9
Fig. 12: Table showing different Ti alloy costs by alloy type
Fig.: 10
Fig. 13: Furnace circulation modelling with a bottom mounted stirrer (120-
tonne furnace)
52 ALUMINIUM · 3/2013

TECHNOLOGY
Fig. 14: Furnace circulation modelled of a side mounted stirrer on a side well furnace (110 tonnes)
achieved within the furnace bath, as our modelling
had already predicted (see Fig. 13 for a
bottom mounted stirrer and Fig. 14 for a side
mounted stirrer on a side well furnace). This
allows an increase in melt rate, a reduction
in energy consumption, a reduction in dross
generation as well as improved alloy and temperature
homogeneity. This is all possible also
without interfering with the bath, as there is
no contact between the Altek EM stirrer and
the bath because the inductor’s magnetic field
passes through the furnace shell and refractory
(up to 750 mm distance). This makes the use
of this technology for stirring furnaces very
reliable. It also means you only use it when
required. So for example on a dry-hearth furnace
you would only switch it on (this can also
be done automatically) when required at the
correct time in the cycle, and once a liquid
heel is available.
Altek have applied their stirring technology
to furnaces from 40 to 120 tonnes, situated
either for under hearth stirring or for side
mounted stirring. Their stirrers have the ability
to operate through furnace hearths between
350 and up to 750 mm thick, while also operating
at the ultra low energy consumptions.
Author
Alan M. Peel CEng, is managing director of Altek,
based in Castle Donington, UK.
Portable metal analysers support recycling operations
Apart from monitoring key process variables
and parameters in recycling operations,
such as through temperature control,
alloy additions and filtration, final
quality of metal as supplied to customers
also depends critically on the composition
of the input material. Whether it is
a modest local scrap melting facility or a
multi-location integrated recycling / remelt
plant, a pivotal stage in the process loop
involves initial sorting and identification
of the scrap metal, and here portable
XRF analysers can realise tremendous improvements
in performance.
The use of scrap metal has become an integral
part of the modern metal processing industry:
metal recycling is big business – and clearly,
its economic and environmental impacts make
real savings in natural resources, energy and
money. However, the increasing globalisation
of trade in scrap metal, alloy stock, and finished
products, coupled with price volatility in
the market, has increased the downside costs
of inaccurate alloy specifications for suppliers,
distributors, and industrial consumers alike.
X-ray fluorescence – XRF
XRF analytical and positive material inspection
analysers significantly improve quality control
and assurance in the metal manufacturing
and fabrication industries. They are used for
compositional analysis and alloy grade identification,
in broad applications ranging from
critical components and raw materials through
to welds. And particularly, handheld portable
analysers are successful in rapidly sorting scrap
by alloy identification such as for delivering
instant scrap valuations and for downstream
melting and casting operations.
Efficient materials identification and fast,
accurate analysis in scrap metal sorting is
fundamental to profitability for scrap recycling
operations. And with volatile commodity
prices, this need has never been more important.
Advances in scrap sorting technology,
pioneered around the world, have revolutionised
the way that major scrap metal recyclers
and processors conduct their operations. In
fact, 95% of the world’s largest metals recyclers
now use XRF and now, even smaller
regional recyclers and independent yards recognise
the benefits of employing this technology,
including for upgrading stock, increasing
value of inventory or providing a higher quality
product to customers.
‘End-of-life’ products are the most common
source of
Principles of XRF technology
recycled metals, such as from vehicles, appliances,
machinery, wiring, piping and containers,
construction materials, and from industrial
process scrap. The recycled materials are used
variously by smelters, refiners, ingot makers,
foundries and other manufacturers.
The most efficient and cost-effective recycling
method employed is to melt scrap of a
known composition, adjusting the alloy constituents
during the melting process. So, it is
vital to know the precise composition of metal
charges to monitor downstream quality and
characterise alloy content accurately. In order
to maximise the value of scrap metal, it must
first be sorted and graded. Early, rapid and
accurate identification of an alloy improves
certainty and efficiency in the scrap sorting
process, significantly upgrading the value of
the scrap metal.
In the past, the use of analytical testing
equipment was relatively rare. Metal sorters
identified alloys using grinding for visual spark
analysis, or tested with magnets and simple
chemical procedures. Most
of these methods are subjective,
inaccurate, timeconsuming
and require
extensive experience by
the operator.
But in today’s market,
efficient metal alloy
sorting and analysis are
critical for profitability.
Handheld XRF metal
analysers take the uncertainty
out of scrap sorting
ALUMINIUM · 3/2013 53

TECHNOLOGY
© Bruker
© Oxford Instruments
Scrap metal sorting supported by Oxford Instruments’ XMET 7000 …
by positive identification of alloy grades and
scrap composition in seconds. Latest instruments
quickly and reliably detect the valuable
content of scrap as well as deleterious ‘tramp’
elements without the need for highly-trained
operators.
Most handheld XRF instruments are designed
for use in harsh conditions, such as on
factory floors and in all outdoor conditions,
and are capable of making several thousand
analyses within an 8-hour work day. This enables
large volumes of metal to be analysed and
sorted quickly – and almost any type of alloy
to be identified, including aluminium and zinc
alloys.
All shapes and sizes
The size or shape of the sample is not a problem
– latest handheld XRF analysers can measure
everything from single wires up to large
components and structures. It is a simple case
of point-and-shoot with most of these instruments
that now automatically correct results
for size, shape and curvature to ensure accurate
analysis of all types of samples.
These devices offer the freedom to work
in the labo-
ratory, on the
shop floor or
in the field and
flexible instrument
configurations
allow a
choice of model
that best fits your
application.
Latest instruments
developments
give substantially improved
accuracy and
speed; taking just a few
seconds to obtain reliable
chemistry and grade
identification. One of
Bruker S1 Titan the main improvements
seen in the latest generations
of handheld XRF
instruments is their
capability with light
metals. These devices
can effectively analyse
certain light elements,
such as magnesium,
aluminium, titanium,
and zirconium, without
the need for helium or
vacuum purging. This
further improves the
reliability of material
identification and ensures
correct assessment of the material.
One of the strengths of the modern handheld
XRF instruments is their versatility. Metal
sorting is the most common recycling application
for these portable devices, but they can
be used in recycling of many other materials
as well, such as plastics in the recycling stream,
or for example to accurately analyse recycled
automotive catalytic converters to determine
high value metal content. This technology can
also be used in the recycling of waste electronics,
providing quick verification of the presence
of hazardous heavy elements or valuable
precious metals.
Overall, these devices are proven to be
easy-to-use, reliable, and accurate tools for
sorting all types of metal scrap. Both the economical
models and the top of the line can increase
efficiency and profitability at all stages
of the scrap metal recycling process.
A wide range of companies manufacture
these types of devices and a selection is outlined
here.
The new ‘xSort’ from Spectro Analytical
is a compact energy dispersive X-ray fluorescence
spectrometer for continuous, fatiguefree
handheld analysis and sorting of metals.
Innovative engineering delivers utmost precision,
speed and safety of this system. The
device enables laboratory-like analyses for up
to 41 elements in seconds, including light elements
Mg, Al, Si.
Skyray’s range of handheld XRF instruments
are claimed to be very versatile offering
complete flexibility in scrap metal sorting,
positive material identification, or laboratory
NDT analysis. The instruments are said to be
robust and reliable, lightweight and durable
and deliver results in seconds. A range of
analysers and software applications can be
tailored to suit specific needs.
Weighing just 1.44 kg including battery, the
new ‘S1 Titan’ from Bruker is among the lightest
tube-based handheld XRF analysers currently
on the market. The innovative device,
said to be fast and accurate, includes features
such as a integrated touch-screen colour display
and an extremely tough housing that is
sealed against humid and dusty environments.
Now available with recently developed
Thermo Scientific geometrically optimised
large area drift detector (GOLDD) technology,
the Niton/Thermofisher ‘XL3T’ and ‘XL2’ series
x-ray fluorescence alloy devices deliver
faster, more accurate metal testing results. The
lightweight, rugged XRF device is claimed to
be ideal for most metal alloy testing applications
and offers notable improved performance
on elements below atomic number 17
(Mg, Al, Si, P, S, Cl) without the use of helium
purging or vacuum pumps.
… and by Niton XL3T
Ukrainian company, Elvatech has launched
the ‘ElvaX ProSpector’, the latest device in
its range of handheld XRF elemental analysis
systems, is said designed to be intuitive, highly
flexible and user-friendly. The light element
option has a broad detectable range from Mg
to U. The new instrument features a high resolution
4-inch touch-screen display.
Latest Olympus/Delta handheld XRF units,
such as the ‘InnovX’ are claimed to enable fast,
reliable alloy sorting and analysis of metals,
plastics, and glass and offer precise, dependable
compositional measurements faster than
ever before, even for aluminium and other
light alloys. They are designed for durability
in the toughest processing environments.
The new Oxford Instruments ‘X-MET7000’
hand-held XRF dispersive analyser is said to
have been designed with the latest needs in
mind. The device’s enhanced ergonomic design
provides total reliability, even in the harshest
environments. This rugged and rapid multi-element
analyser delivers an exceptional level
of analytical performance and features a new
touch screen and superior graphics.
Ken Stanford, contributing editor
© Niton
54 ALUMINIUM · 3/2013

TECHNOLOGY
© Kurtz
Kurtz liefert Niederdruck-Gießmaschinen an BMW
Um Qualität und Produktivität bei der
Herstellung von Zylinderkurbelgehäusen
für Reihenvierzylindermotoren aus Aluminium
weiter zu steigern, war die BMW
Group vor einiger Zeit an den Gießereimaschinenbauer
Kurtz GmbH herangetreten.
Der Automobilhersteller setzt
bereits seit mehreren Jahren auf Niederdruckgießmaschinen
von Kurtz.
Niederdruck-Kokillengießmaschine AL 18-12 SO der Kurtz GmbH für
hochwertige BMW-Zylinderkurbelgehäuse
Low pressure die casting machine Kurtz AL 18-12 SO for high-quality
BMW cylinder crank cases
Das Unternehmen mit Sitz in Kreuzwertheim
stellt Gießereimaschinen für den Niederdruckguss
für Aluminium- und Magnesiumlegierungen
in Kokillen, Sand-, Keramik- und
Gipsformen her. Zudem liefert Kurtz Entgratpressen
und -technologie bis hin zur kompletten
Anlage – auch für die Druckgusstechnologie.
Die BMW-Verantwortlichen für den Motorenguss
hatten den Spezialisten des Kurtz
Gießereimaschinenbaus die ehrgeizigen Projektziele
und ihre hohen Anforderungen an
das Niederdruck-Gießverfahren im Vorfeld
klar definiert. Die Besonderheit in diesem
Fall war die zweifache Belegung der Kokille,
um die Produktivität maßgeblich zu steigern.
Dass damit eine echte Herausforderung an
den Maschinenbauer gestellt wurde, zeigte
sich bei näherer Betrachtung der Technologie
und des Prozesses: Eine Mehrfachbelegung
von Kokillen ist zwar schon länger Stand der
Technik und damit im Grunde nichts Neues –
nicht jedoch bei Gussteilen dieser Größenordnung
und den gießtechnischen Anforderungen
von Motorblöcken.
Die aus den Gussteilabmessungen
von circa
1.000 x 400 x 400 mm
und rund 70 kg Gewicht
resultierende Größe der
Kokille und deren Komplexität
stellen besondere
Anforderungen an
die Kokillenkühlung, die
Installation der Medienführung
und den Zugang
für die Wartung an der
Kokille dar. Eine Zweifachbelegung
der Kokille
mit derartigen Teilen, wie
sie nun mit Kurtz-Niederdruckgießmaschinen
realisiert
wurde, ist daher
bislang einzigartig. Damit
und mit weiteren innovativen
maschinentechnologischen
Details ist es gelungen,
die Produktivität
mehr als zu verdoppeln.
Die in Zusammenarbeit
mit BMW entstandene
Niederdruck-Gießmaschine
AL 18-12 SO setzt
damit neue Maßstäbe in
der Produktion von qualitativ
hochwertigen Motorenteilen.
Sie zeigt zudem, dass das Niederdruckgießverfahren
auch für die Produktion
von Großserienmotoren erste Wahl ist.
Nachdem die erste Gießmaschine des genannten
Typs bei BMW bereits erfolgreich im
Einsatz ist und Kurtz auch in der Projektabwicklung
und Gesamtbetreuung überzeugen
konnte, platzierte BMW nun einen Großauftrag
über weitere Serienmaschinen dieses
Typs. Damit wird die Kurtz GmbH ihrem ausgezeichneten
Ruf in der Automobilindustrie
einmal mehr gerecht und kann im Geschäftsbereich
Gießereimaschinen zuversichtlich ins
Jahr 2013 blicken.
■
Kurtz supplies low
pressure casting
machines to BMW
Some time ago, the BMW group contacted
the casting machine manufacturer Kurtz
GmbH with the task to significantly increase
quality and productivity when casting
aluminium cylinder crank cases for inline
four-cylinder engines. BMW has been
relying on Kurtz low pressure die casting
machines for several years already.
Kurtz, which is based in Kreuzwertheim/Germany,
produces low pressure casting machines
for aluminium and magnesium alloys in permanent
dies, sand, ceramic and plaster moulds
for the casting industry. Furthermore, Kurtz
supplies trimming presses and technology, as
well as complete plants – not only for low pressure
but also for high pressure die casting
Those responsible for engine castings at
BMW have clearly defined their ambitious
goals and high demands on the low pressure
die casting process to the specialists of the
Kurtz. The special feature in this case was the
two-cavity mould in order to increase productivity
significantly. It became clear that this
was a real challenge for the machine manufacturer
when taking a closer look at the technology
and process. Albeit multiple cavity dies
have been state of the art for some time, castings
of this size with such high demands on
casting technology are fairly new.
The size of the mould and its complexity
resulting from the dimensions of the casting
of approx. 1,000 x 400 x 400 mm and about
70 kg weight demands special requirements
on die cooling, installation of media supply
and the access for maintenance on the die. A
two-cavity mould for these types of castings
with Kurtz low pressure casting machines has
so far been unique. With this and further innovative
technical details of the Kurtz low
pressure casting machine technology, the
productivity could be more than doubled.
The innovative Kurtz AL 18-12 SO low pressure
casting machine built in cooperation with
BMW sets new standards for the production
of high-quality engine parts. Therefore, it
proves that low pressure castings are the first
choice for series production of engines.
As the first Kurtz AL 18-12 SO casting
machine is successfully in operation at BMW,
they have now placed a major order for further
serial machines of this type. Thus, once
again, Kurtz GmbH justifies their excellent
reputation in the automobile industry and can
face the future with confidence. ■
ALUMINIUM · 3/2013 55

TECHNOLOGIE
BMW setzt auf energieeffiziente Schmelzöfen von ZPF Therm
Die ZPF Therm Maschinenbau GmbH
hat an die neu gebaute Schmelzerei des
BMW-Werks in Landshut sechs gasbeheizte
Aluminium-Schmelz- und Warmhalteöfen
mit einer Schmelzleistung von
je drei Tonnen pro Stunde geliefert. Die
Anlagen bilden das Herzstück der neuen
Schmelzerei.
„Wir sind sehr stolz darauf, dass sich die
Leichtmetallgießerei des BMW-Werks Landshut
im Zuge ihrer richtungweisenden Änderung
im Produktionsprozess – nämlich der
Umstellung von Flüssig- auf Festmetallanlieferung
– der energieeffizienten Ofenanlagen
von ZPF bedient“, sagt der Geschäftsführer
der ZPF Group, Holger Groß. Die an das
Werk Landshut gelieferten Ofenanlagen gehören
zur ST-Baureihe von ZPF und damit zu
den großen Öfen der Produktpalette – nicht
nur hinsichtlich der
Schmelzkapazität. Die
Abmessungen und das
Gewicht von circa 70
Tonnen je Anlage waren
auch logistisch eine
Herausforderung – sowohl
bei der Anlieferung
als auch beim
Platzieren am Standort,
im oberen Stockwerk
der Schmelzerei.
Die ST-Baureihe
zeichnet sich durch das
geschlossene Ofensystem
und die umgekehrte
Abgasführung
aus. Die Schmelzbrenner erhitzen den
Schmelzschacht, dabei werden die Heißgase
im Schacht verwirbelt. Um die verbleibende
Wärmeenergie zu nutzen, werden die Heißgase
anschließend über das Warmhaltebad
geleitet, das sich durch die Restwärme des
Schmelzvorgangs erwärmt. Der Badbrenner
greift nur regulierend oder im reinen Warmhaltebetrieb
ein. Die Heißgase gelangen nach
der Schmelzzone in die Nachverbrennungszone,
wo die thermische Nachverbrennung
einsetzt.
Durch die hohe Temperatur und eine entsprechend
lange Verweilzeit werden praktisch
alle organischen Schadstoffe zersetzt. Dieses
Verfahren ist das optimale und lufthygienisch
beste Verfahren, da die Abgase bis auf die
Fremdelemente Stickstoff, Schwefel und Halogene
komplett zu Wasser und Kohlendioxid
umgesetzt werden. Für die Nachverbrennung
ZPF Therm supplies energyefficient
smelting furnaces to BMW
ZPF Therm Maschinenbau GmbH has
supplied six gas-fired aluminium smelting
and holding furnaces, each with a smelting
capacity of three tonnes per hour, for
the newly-built smelting plant at BMW
in Landshut. The furnaces form the core
of the new smelting plant.
Die ST-Baureihe von ZPF zeichnet sich durch das geschlossene Ofensystem
und die umgekehrte Abgasführung aus / ZPF’s ST series features an enclosed
furnace system and inverted exhaust gas routing
“We are very proud that the light alloy
foundry at BMW’s Landshut works is deploying
ZPF’s energy-efficient furnaces in the
course of their pioneering production process
change from liquid to solid metal delivery,”
says Holger Gross, general manager of
the ZPF group. The furnaces delivered to the
Landshut factory come from ZPF’s ST series
and are therefore the big furnaces in the
product range – and not only in terms of their
smelting capacity. Their size, and the fact that
each furnace weighs around 70 tonnes, also
meant that not only delivery to the site but
also manoeuvring them into place on the upper
floor of the smelting plant presented a
major logistical challenge.
The ST series features an enclosed furnace
system and inverted exhaust gas routing.
The smelt burners heat the melting shaft,
which causes swirling in the hot gases in the
shaft. In order to make use of the remaining
energy, the hot gases are subsequently routed
over the holding bath. The holding bath is
therefore heated by residual heat from the
smelting process. The bath burner only cuts
in to regulate the temperature or purely in
holding mode. The hot gases reach the reburn
zone behind the smelting zone where
© ZPF Therm
thermal post-combustion takes place.
Practically all organic contaminants are
broken down by the high temperature and
a correspondingly long dwell time. Thermal
post-combustion is the optimum process in
relation to air quality because apart from
external elements of nitrogen, sulphur and
halogens the exhaust gases are completely
converted to water and carbon dioxide. No
additional fuel is required for reburning. The
necessary 750 to 1000 °C come exclusively
from the smelting process.
The purified exhaust gases are discharged
from the furnace behind the post-combustion
zone. No additional air filtering equipment
is required. These extremely hot and
clean gases can be used to further optimise
energy management (heat recovery, water
heating, cold production, factory heating, preheating
chambers for aluminium).
Hydraulic loading systems are used to load
the smelting plants. The material containers
used at BMW are transported into the loading
system in a filling station. Between each
of the three pairs of furnaces there is a loading
system which fills either the furnace to
the left or the right with recycled material as
required. The compact packages of aluminium
are placed directly on the smelting ramp
by a fork lift truck. This permits an additional
large lift door on the front of the furnace.
In ZPF’s estimation, two major trends can
be detected amongst vehicle manufacturers.
Firstly, the alloy needed for casting will in
future be supplied mainly as solid metal and
less as liquid metal. Secondly, manufacturers
no longer send back most of the recycled
material which accumulates during casting
to a refining works but melt it down again in
their own smelting and holding furnaces. Both
developments point to growth potential for
the ZPF group.
ZPF Therm Maschinenbau has been building
and supplying customer-specific furnaces
for the light alloy processing industry for
almost 20 years. The company pays particular
attention in its products to the increasing
demands of the sector in terms of energy,
raw materials and environmental efficiency.
Each of ZPF’s furnaces is an illustration of
the fact that highly cost-effective production
and ecological sustainability are by no means
mutually exclusive.
■
56 ALUMINIUM · 3/2013

TECHNOLOGY
wird kein zusätzlicher
Brennstoff benötigt.
Die nötigen 750 bis
1 000 °C kommen
ausschließlich vom
Schmelzprozess.
Die gereinigten
Abgase werden nach
der Nachverbrennungszone
aus dem
Ofen geschleust.
Hierbei werden keine
weiteren Luftfilteranlagen
benötigt. Diese
sehr heißen Reingase
können zur weiteren
Optimierung des
Energiemanagements
(Wärmerückgewinnung,
Warmwasseraufbereitung,
Kälteproduktion,
Hallenbeheizung,
Vorwärmkammern
für Aluminium)
eingesetzt
werden.
Zum Beschicken der Schmelzanlagen
werden hydraulische Chargiersysteme eingesetzt.
Die bei BMW verwendeten Materialbehälter
werden in einer Umfüllstation in das
Chargiersystem überführt. Zwischen jedem
der drei Schmelzofenpaare steht ein Chargiersystem,
das je nach Anforderung den
Schmelzofen links oder rechts mit Kreislaufmaterial
befüllt. Die kompakten Aluminium-
Die Entscheidung für die Herstellung von Flüssigmetall im eigenen Werk ist ein entscheidender
Kostenfaktor / The decision to produce liquid metal in the plant is a decisive cost factor
Masselpakete werden mit dem Stapler direkt
auf der Schmelzbrücke abgestellt. Dies ermöglicht
eine zusätzliche große Hubtüre an
der Vorderseite der Ofenanlage.
Nach Einschätzung von ZPF lassen sich
zwei wesentliche Trends bei den Automobilherstellern
erkennen. Zum einen wird das für
den Guss benötigte Leichtmetall zukünftig
überwiegend als Fest- und weniger als Flüssigmetall
angeliefert.
Zum anderen wird
das beim Gießen anfallende
Kreislaufmaterial
größtenteils
nicht mehr in
ein Umschmelzwerk
zurück geliefert,
sondern in selbst betriebenen
Schmelzund
Warmhalteöfen
wieder eingeschmolzen.
Beide Entwicklungen
bergen
Wachstumspotenzial
für die ZPF-
Gruppe.
Seit fast 20 Jahren
konstruiert und
liefert die ZPF
Therm Maschinen-
bau GmbH kundenspezifische
Ofenanlagen
für die Leichtmetall
verarbeitende
Industrie. Ein besonderes
Augenmerk legt die Firma bei ihren
Produkten auf die steigenden Anforderungen
der Branche hinsichtlich der Energie-, Rohstoff-
und Umwelteffizienz. Die Anlagen von
ZPF sind vielfach ein Beispiel dafür, dass
sich eine hoch wirtschaftliche Produktion und
ökologische Nachhaltigkeit nicht ausschließen.
■
Flüssigmetall-Transport TRANSMETALL TM 1800
Gabelstapler-Anbaugerät TRANSMETALL TM 1800:
Pfanneninhalt: 1800 kg Aluminium
Pfannenschnauze für geschlossenen Gießstrahl
Vorteile:
Schnell: Pfannenwechsel in Minuten
Sicher: Pfannenverriegelung und freie Sicht auf Fahrweg und Pfanne
Bewährt: Pfannenkippachse in Schnauzennähe, kein Nachjustieren
beim Ausgießen
Optional: Pfannendeckel für weite Fahrstrecken
Wirtschaftlich: Nur 5t-Stapler für 1800 kg Flüssigmetall
Herwig Baumann
Talweg 8
75433 Maulbronn
Fon : +49 (0) 70 43 / 20 96
Fax : +49 (0) 70 43 / 88 05
Internet : www.ibb-baumann.de
E-mail : info@ibb-baumann.de
Funktionen:
Pfanne verriegeln
Pfanne schwenken, links/rechts je 90°
Pfanne auskippen, Kippwinkel 95°
www.prh-werbung.de
ALUMINIUM · 3/2013 57

TECHNOLOGIE
Mit technischen Textilien hohe
Temperaturen im Hüttenprozess beherrschen
© HS / Frenzelit
In der Erzeugung von Hüttenaluminium
sind an vielen Stellen im Prozess extreme
thermische und oft auch hohe mechanische
Belastungen zu handhaben. Um
die hohen Temperaturen zu beherrschen
und die daraus resultierenden Maßnahmen
zur Instandhaltung zu minimieren,
kommen vielfach Isolationsmaterialien
von Frenzelit zum Einsatz.
Um dem hohen Verschleiß an Mineralwollplatten
bei der Isolierung von Elektrolysezellen
entgegenzuwirken, entwickelte Frenzelit
das Startup-Kissen aus „isoGlas“. Beim Hochfahren
der Elektrolysezellen nach Revisionsarbeiten
und Ausmauerung wurden die Zellen
bisher mit Mineralwollplatten abgedeckt, die
bereits nach einmaligem Gebrauch entsorgt
werden mussten. Das isoGlas-Kissen kann
dagegen mehrmals zum Abdecken der Elektrolysezellen
verwendet werden. Beim Hochfahren
werden die Aluminiumdeckel durch
Stahldeckel ersetzt.
Kissen aus dem Material isoGlas helfen
auch gegen das Ansaugen von Falschluft beim
Brennen von Anoden. Die kompakten Kissen
dichten den Abgasansaugstutzen gegenüber
dem Ofendeckel ab. Dank einer V4A-Drahtverstärkung
sind sie sehr verschleißfest. Das
Basismaterial dieses Gewebes sind E-Gläser.
Die Texturierung sorgt für ein großes Speichervolumen
und somit für gute Isolationswerte.
Dort, wo die Aluminiumschmelze aus der
Elektrolysezelle gesaugt wird, muss eine Textildichtung
den Tiegeldeckel abdichten, um
den Unterdruck im Gefäß zu gewährleisten.
Diese Aufgabe übernehmen „novaTex Gold
AL-Extra-Packungen“ mit hervorragenden
Dichteigenschaften. Die Umflechtung mit
dieser speziellen Textildichtung hat im Vergleich
zur Standard-Glaspackung eine bis zu
isoGlas-Kissen zum Abdecken der Elektrolysezellen
isoGlas pillows for covering up the pot cells
Controlling high temperatures in
smelting using technical textiles
Textildichtungen aus novaTex Gold AL-Extra-
Packungen und isoTherm HT dichten Saugtiegel
und -rüssel ab / Textile gaskets made from novaTex
Gold AL-Extra packings and isoTherm HT seal off
the blast crucible and piping
Extremely high temperatures and often
high mechanical stresses too have to be
handled in many areas of the primary
aluminium production. Insulation materials
made by Frenzelit help to control
these temperatures and minimise the
maintenance measures that are needed as
a result.
To counteract the high wear of mineral wool
panels in the insulation of pot cells, Frenzelit
has developed the start-up pillow made from
‘isoGlas’. When the pot cells
are started up after inspection
work and lining, the cells have
been covered with mineral wool
panels in the past. They must be
disposed of after they have been
used only once. The isoGlas pillow,
by contrast, can be used to
cover up the pot cells several
times. The aluminium covers are
replaced by steel covers in the
start-up process.
Pillows made from the material
isoGlas help to make sure
the wrong air is not sucked in
during anode production. The
compact pillows seal the exhaust
gas intake manifold off against
the furnace cover. V4A wire reinforcement
makes them very
wear-resistant. E-glass is the basic
material for this woven fabric.
The texturing ensures a large storage volume
and thus good insulation performance.
When the molten aluminium is sucked out
of the pot cell, a textile gasket needs to seal
the crucible cover in order to maintain the vacuum
in the crucible. ‘novaTex Gold AL-Extra
packings’ with excellent sealing properties
carry out this assignment. Braiding with nova-
Tex Gold makes service life up to five times
longer than a standard glass packing.
The suction pipe flange connections too
require a gasket made from a highly temperature-resistant
woven fabric. ‘isoTherm HT’ resists
temperatures of up to 850 °C. When two
layers are used, uneven sealing surfaces are
compensated for, so that a vacuum is created.
The flexible and adaptable packing made
from ‘isoTherm 800’ makes sure that the launder
segments and weirs are sealed reliably.
Service life has been extended by a factor of
15, thus reducing maintenance costs.
The launder is covered with insulation pillows
to reduce the heat to which the launders
are exposed, while saving energy at the same
time. The pillows minimise the heat losses during
the casting process, so the temperature of
the casting furnace can be reduced. A lower
smelting temperature reduces dross formation
and improves the quality of the metal. ■
Die Schlauchpackung isoTherm 800 dichtet zuverlässig Gießrinnen-
Segmente und Wehre ab. Ihre Standzeit wurde um den Faktor 15
verlängert. / The flexible isoTherm 800 packing seals launder segments
and weirs off reliably. Their service life has been extended
by a factor of 15.
58 ALUMINIUM · 3/2013

TECHNOLOGY
fünf Mal längere Standzeit. Aber auch die
Saugrohrflanschverbindungen benötigen eine
Dichtung aus hoch temperaturbeständigem
Gewebe. „isoTherm HAT“ weist eine Temperaturbeständigkeit
bis 850 °C auf. Bei Verwendung
von zwei Lagen werden Unebenheiten
der Dichtflächen ausgeglichen, sodass ein
Vakuum erzeugt wird.
Für eine zuverlässige Abdichtung der Gießrinnen-Segmente
und Wehre sorgt die weiche
und anpassungsfähige Schlauchpackung aus
„isoTherm 800“. Die Standzeit konnte so laut
Frenzelit um den Faktor 15 verlängert und
die Instandhaltungskosten dadurch reduziert
werden.
Um die Wärmebestrahlung der Gießrinnen
zu reduzieren und gleichzeitig Energie einzusparen,
wird die Gießrinne mit Isolierkissen
abgedeckt. Aufgrund der geringeren Wärmeverluste
während des Gießprozesses kann
die Temperatur des Gießofens verringert
werden. Eine geringere Schmelztemperatur
wiederum reduziert die Krätzenbildung und
verbessert die Qualität des Aluminiums. ■
Fata Hunter – further success in flat rolled product business
Indicating the Fata group’s continuing importance
as a global technology partner
and equipment supplier to the rolling industry,
key automation system contracts
in China were recorded late last year,
another cold roll mill contract in Thailand
and a cold roll mill plus tension levelling
line order for Poland. And, as further
measure of its penetration in the Gulf Region,
Fata is establishing a branch facility
in Abu Dhabi, UAE, whilst also securing
further business consolidation in China
with key trade cooperation agreements.
Since the 1950s, Fata Hunter has been one of
the world leaders in key equipment engineering
and manufacturing for the aluminium flat
rolled product industries. Fata Hunter’s ability
and expertise in all production ranges offer
a natural advantage for elaborating complete
plant lines.
The company operates a stringent policy
of ‘Think Total Process’ reflecting its commitment
to advancing aluminium casting, rolling
and coil coating technologies and to meeting
its customers’ requirements cost-effectively –
from the initial feasibility study through to
Operating as the contracting arm of Fata
SpA, Fata EPC division is a leading world
player in project management, including industrial
plant engineering, procurement and
construction. Besides holding a strong position
as part of a comprehensive major manufacturer
of all the technology and equipment
required in its traditional operating sectors,
Fata EPC has developed an outstanding capability
in general contracting based on over
50 years’ experience, providing customised,
state-of-the-art technology and environmentally
consistent solutions for its various industries:
particularly primary aluminium smelters
and downstream projects, oil and gas, and
power generation plants.
© Fata Hunter
6-high cold rolling mill from Fata Hunter
the commissioning phase of a project. As a
proven single-source quality technology provider,
Fata’s expertise and scope of supply includes
complete provision of state-of-the-art
continuous casting lines, cold rolling and foil
rolling mills, finishing equipment, coil coating
lines and packaging plants.
With more than 630 single lines and almost
50 complete plants implemented worldwide,
Fata has become a world leader for turnkey
projects in this field, providing long-term technical
and specialist engineering assistance and,
whenever required, management of the plant.
It is a service focused company and provides
its customers with a full range of after-sales
support, including the supply of spare parts.
New contracts from the FRP industry
Fata Hunter was recently awarded a contract
from Poland to supply a 2 metre wide cold
rolling mill and a tension levelling line to Eurometal
SA in Stalowa Wola. The equipment
is to be installed at a greenfield plant located
on the new Kleszczów Industrial Park.
All the equipment for this new facility has
been selected on the basis of its advanced design
to make the facility one of the most modern,
efficient and environmentally friendly
aluminium rolling plants in Europe. The mill
features state-of-the-art controls that allow it
to roll a wide variety of products, from foil
stock to can body with tolerances that meet
or exceed quality standards of the world’s
leading producers. The tension levelling line
continues Fata’s leadership in design of this
type of equipment, which produces exceptional
quality strip while combining an innovative
cleaning section that minimises the use of
chemicals employed on conventional lines.
Fata Hunter and Eurometal have forward
plans for further expansion of the plant and
both companies look forward to building a
long-term partnership for the successful development
of this new enterprise.
Eurometal is a leading European supplier of
aluminium extrusions. The company is part of
the Eko-Świat Group – a major Polish producer
of extrusion billet, and primary and secondary
alloys, produced by continuous casting.
In September last year Fata Hunter secured
a contract for the supply of two new hSystem
ALUMINIUM · 3/2013 59

TECHNOLOGIE
Fata Hunter’s proprietary hSystem
automation system to Baotou Alcha Aluminium
Technology Co. Ltd in China. The first
of the two systems is being installed on a
roughing cold rolling mill and the second one
on a finishing cold rolling mill also complemented
by Automatic Gauge Control (AGC),
Automatic Flatness Control (AFC), Roll Eccentricity
Compensation (REC), massflow
and feedforward control, flatness measurement
systems and coolant spray bars.
Both mills will feature an integrated Level
2 control system which handles automatic
pass schedule calculation, primary mill data
management and process data acquisition and
recording.
Also in September, Fata Hunter gained
another contract in China to supply four new
hSystem automation packages to Deli Group
Co., Ltd, Zouping. This contract follows the
successful installation of the first three systems
on cold mills and this latest equipment
will be installed at Deli on one roughing
foil mill, one intermediate foil mill and two
foil finishing rolling mills. The systems will
be complemented by AGC, AFC, a flatness
measurement system and coolant spray bars.
Trade cooperation agreements
Once again, all
the mills will feature
an integrated
Level 2 control
system for automatic
pass schedule
calculation,
primary mill data
management and
recording system.
A common process
data acquisition
system is also
planned for installation.
In December, Fata’s further business potential
in China was given a real boost by a cooperation
agreement forged between the Italian
Government and the Chinese Ministry
of Commerce when a top-level trade delegation
visited Rome. A range of trade cooperation
agreements were ratified, including a
long term strategic agreement between Fata
and Genertec – China General Technology
(Group) Holding Co., Ltd.
Genertec and Fata have been successfully
cooperating in China for many years and
have built up a good working relationship.
Both companies say that they plan to identify
further business synergies in order to boost
collaboration in China and in other specified
markets with the benefit of their joint technology
capabilities and financing.
The two companies will also market and
promote their respective products and competences
with potential clients in emerging
markets.
In late November last year, the final acceptance
certificate for a 4-high non-revers-
ible aluminium cold rolling mill was signed by
Fata and Aluminium Chue Chin Hua Co. Ltd
in Thailand. The rolling facility was initially
installed in early 2012 with final commissioning
successfully completed in September. Key
to the project elaboration Fata reports that
it enjoyed a good working relationship with
ACCH, and excellent project support was
provided by the customer’s management and
technical teams.
As a result of this cooperation, the new
aluminium cold rolling mill is now operating
to the customer’s process requirements and
specifications, providing high quality output.
In this respect, the mill is also equipped with
the Fata hsystem for process control to ensure
a high level of consistent quality production.
New office in Abu Dhabi
The contracts in China, Thailand and Poland,
coupled with the news of further business
consolidation were complemented by Fata’s
announcement of a new facility in the Gulf
region. In October, the company reported it
was establishing a Fata SpA branch office in
Abu Dhabi, UAE, further strengthening its
presence in the region, supporting existing
facilities in Oman and Qatar.
This is reinforced with an agreement with
Multi World General Trading LLC, a 100%
locally owned company serving a range of
business sectors of the UAE economy and also
representing foreign companies.
Through its contracting arm Fata EPC, the
company is planning to pursue various opportunities
via undertaking EPC projects, in
addition to the aluminium sector and other
industries, notably relating to oil and gas in
the UAE and other GCC countries.
Ken Stanford, contributing editor
SMS Siemag liefert Warmwalzlinie und Kaltwalzanlage
für Automobilprodukte an Shandong Nanshan Aluminium
Shandong Nanshan Aluminium Co. Ltd.,
eine Tochter der Nanshan Group, rangiert
in China unter den führenden Herstellern
von Aluminiumprodukten. Im
November 2012 erteilte Shandong Nanshan
SMS Siemag den Auftrag über die
Lieferung einer 1+5-Warmwalzlinie für
Aluminium und Aluminiumlegierungen.
Wenig später erfolgte die Bestellung einer
Kaltwalzanlage für besondere Aufgaben.
SMS Siemag to supply hot mill and
cold rolling mill for automotive products
for Shandong Nanshan Aluminium
In China, Shandong Nanshan Aluminium
Co. Ltd, a subsidiary of the Nanshan
Group, is among the leading manufacturers
of aluminium products. In November
2012 the company contracted SMS Siemag
for the delivery of a 1+5 hot rolling
mill for aluminium and aluminium alloys.
Shortly afterwards, an order was placed
60 ALUMINIUM · 3/2013

for a cold rolling mill for special tasks.
The 1+5 hot rolling mill, which consists of
a plate mill and a five-stand finishing mill,
will produce aluminium strips in Yantei,
Shandong province, starting at the end of
2014. These will be used for manufacturing
beverage cans and producing plates for the
automotive and aeronautical industries. During
the first construction phase, a production
capacity of 300,000 tonnes a year will be
implemented. The scope of delivery includes
all utility systems, an off-line coil inspection
station and a pallet conveyor system for coil
logistics.
In the first construction stage, the product
scope includes plate widths of 3,800 mm and
a strip width of 2,800 mm. The minimum finish
thickness of hot strips is approx. 1.8 mm.
In a later stage of construction, the plant is to
be extended by an additional hot plate rolling
mill for particularly wide products.
The new hot rolling mill is to be equipped
with the latest actuators and technological
control systems. All core components of the
mill stands are manufactured in the workshop
of SMS Siemag in Hilchenbach, Germany,
and provide Shandong Nanshan with a plant
quality that is the basis for high-quality rolled
products.
Cold rolling mill: Thanks to the new cold
rolling mill, the aluminium strip obtains its
special material properties that are particularly
important for further processing in the
automotive industry. It has been designed for
a production of more than 130,000 tonnes a
year and is scheduled to roll the first plate in
the winter of 2014.
The technologically fully equipped cold
rolling mill in CVC plus 6-high design rolls
extremely wide strips of up to 2,650 mm with
entry gauges of up to 7.5 mm to final gauges
as small as 0.2 mm. For special automotive
grades, it will be possible to carry out the
MEHR PRÄZISION
Die 1+5-Warmwalzlinie, bestehend aus Plattengerüst
und fünfgerüstiger Fertigstraße,
wird ab Ende 2014 am Standort Yantai, Provinz
Shandong, Aluminiumbänder erzeugen,
die zur Herstellung von Getränkedosen und
zur Produktion von Platten und Blechen für
die Automobil- und Luftfahrtindustrie eingesetzt
werden. In der ersten Bauphase wird
eine jährliche Produktionskapazität von
300.000 Tonnen realisiert. Im Lieferumfang
enthalten sind alle Medienanlagen, eine Offline-Bundinspektionslinie
sowie ein Palettentransportsystem
für Bundlogistik.
Die Produkte reichen in der ersten Ausbaustufe
bis zu einer Plattenbreite von 3.800
mm und einer Bandbreite von 2.800 mm. Die
minimale Enddicke der Warmbänder liegt bei
rund 1,8 mm. In einer späteren Ausbaustufe
soll eine zusätzliche besonders breite Warm-
Plattenwalzanlage hinzukommen.
Das neue Warmwalzwerk wird mit hochmodernen
Stellgliedern und technologischen
Regelungen ausgerüstet. Sämtliche Kernkomponenten
der Walzgerüste werden in der
SMS Siemag Werkstatt in Hilchenbach gefertigt
und bieten Shandong Nanshan eine Anlagenqualität,
welche die Basis für qualitativ
hochwertige Walzprodukte ist.
Kaltwalzwerk: Mit Hilfe der neuen Kaltwalzanlage
erhält das Aluminiumband die
besonderen Materialeigenschaften, die für
die Weiterverarbeitung in der Automobilindustrie
wichtig sind. Sie ist für eine Jahresproduktion
von mehr als 130,000 Jahrestonnen
ausgelegt und soll im Winter 2014 das erste
Band walzen.
Das technisch voll ausgestattete Kaltwalzwerk
in CVC plus Sextobauweise walzt extrem
breite Bänder bis 2.650 mm mit Eingangsdicken
bis 7,5 mm auf Enddicken bis
0,2 mm. Für spezielle Automobilgüten kann
der letzte Walzstich als Dressierstich ausgeführt
werden. Dabei wird die Bandoberfläche
mit einer definierten Oberflächenrauheit ver-
BANDDICKE-
& PROFIL
laser-optisch mit
thicknessCONTROL
GESCHWINDIGKEIT
& LÄNGE
optisch mit
ASCOspeed
© SMS Siemag
Hot rolling mill for Shandong Nanshan
ALUMINIUM · 3/2013
Warmwalzlinie für Shandong Nanshan
HANNOVER MESSE
08.04.2013 - 12.04.2013
Halle 9 / Stand D05
www.micro-epsilon.de
Micro-Epsilon Messtechnik
94496 Ortenburg · Tel. 0 85 42/168-0
info@micro-epsilon.de

TECHNOLOGIE
Aluminium-Kaltwalzanlage ähnlicher Bauart
sehen, die später den hohen Anforderungen
an die Oberfläche von Außenhautbauteilen
dient. Dies ermöglichen sogenanntes EDT-
Walzen (Electro Discharge Texturing), die
zum Dressieren eingesetzt werden.
Um die beim Dressieren üblichen niedrigen
Walzkräfte kontrolliert aufbringen zu
können, wird das Kaltwalzwerk mit dem
dafür neuartigen Erweiterten Biegesystem
(EBS) von SMS Siemag ausgerüstet. Dabei
wird die obere Stützwalze abgehoben, während
die benötigte geringe Walzkraft allein
durch die Zwischenwalzenbiegung erreicht
wird.
Das Kaltwalzwerk wird komplettiert durch
Bundvorbereitungsstation, Palettentransportsystem,
Bundinspektionslinie, Medienanlagen
und Filtersysteme, einschließlich Multiplate-
Filter und Airwash-Abluftreinigungsanlage.
Mit den beiden neuen Aufträgen beweist
Shandong Nanshan bereits zum dritten Mal
Vertrauen in Walzwerkstechnik von SMS
Siemag. Die Vorlieferungen umfassen zwei
eingerüstige Kaltwalzwerke mit CVC plus
und eine dreigerüstige Kalttandemstraße, die
2012 den Betrieb aufgenommen hat und die
zudem die erste Walzanlage dieses Typs in
China ist.
■
last pass as skin-passing.
In this case, the strip
surface will be provided
with a defined surface
roughness that will meet
the high re-quire-ments
placed on the surfaces of
outer-shell components.
This is achieved by means
of so-called EDT rolls
(Electro Discharge Texturing)
which are used for
skin-passing.
To apply the low rolling
forces which are typical
for skin-passing, the
aluminium cold rolling
mill will be equipped with
the novel extended bending
system (EBS) from
SMS Siemag. Here, the
upper backup roll is lifted
off, while the low rolling
force required is attained
solely by means of intermediate roll bending.
The cold rolling mill is completed by a coil
preparation station, a pallet conveyor system,
a coil inspection line, utility systems and filter
systems including MultiPlate filters and an Airwash
exhaust air-purification system.
These two new orders testify to Shandong
Nanshan’s faith in SMS Siemag’s rolling mill
technology for the third time. The initial deliveries
include two single-stand cold rolling
mills with CVC plus and a 3-stand tandem
cold mill that was put into operation in 2012
and is the first rolling mill of this type in
China.
■
Similar aluminium cold rolling mill
Automated profile measurement for aluminium extrusions
Often the top three quality issues faced by
aluminium extruders include out-of-tolerance
profile dimensions. Dimensional
profile integrity is affected by many variables;
however, the conventional approach
to measuring dimensions at the press is the
use of manual tools such as a calliper and
micrometer. The result is a reactive stance
in the extrusion process where unnecessary
costs are incurred due to running bad dies,
increased labour for rework or customer returns
and lower press productivity. Clearly
the need for an effective automated measurement
system exists to enable a proactive
approach to dimensional quality in aluminium
extrusion.
Reliable ‘Promex Expert’ measurement system at the press
© Ascona
Therefore Ascona GmbH, a leader in
optical measurement technology, has
developed with ‘Promex Expert’ a
system where the common issues of
system location, sample preparation
and system ease-of-use have been
solved. Proactive quality requires
the measurement system to support
frequency, productivity and traceability.
The result improved dimensional
quality and press operations – or
restated, improved profits for the extruder
and improved quality assurance
and tighter tolerances for the
customer.
■
62 ALUMINIUM · 3/2013

TECHNOLOGY
Outotec wins order for liquid pitch storage from Emal
Dubal’s liquid pitch facility at Jebel Ali Port
Outotec provides leading technologies
and services for the sustainable use of
earth’s natural resources. As the global
leader in minerals and metals processing
technology, the company has developed
over decades many breakthrough technologies.
Outotec also provides innovative
solutions for industrial water treatment,
the utilisation of alternative energy
sources and the chemical industry.
As a technology supplier for the primary aluminium
industry, Outotec concentrates on
the design and supply of equipment, plant
and technologies for the carbon anode production.
The office in Cologne, Germany, is
the technology centre for green anode manufacturing
and related process areas, while the
office in Burlington, Canada, is the technology
centre for anode rodding shops and casthouse
equipment. The two offices work together,
with support from Outotec’s local market area
offices, such as Abu Dhabi, Shanghai, Kolkata,
Johannesburg
and St. Petersburg.
In 2012,
Emirates Aluminium
(Emal)
awarded an
EPC contract
to Outotec for
the design,
supply and installation
of the
third 10,000-
tonne liquid
pitch storage
tank at Dubal’s
raw materials facility at Jebel Ali Port. Dedicated
ships supply liquid pitch from abroad
to this facility where it is further distributed
to both the Dubal and Emal smelters.
The construction of the third liquid pitch
tank is to meet the liquid pitch requirements
of the Dubal and Emal smelters, especially
now that Emal has proceeded with the Phase
2 expansion of the
company’s green anode
plant.
For its new cell relining
facility, Emal
awarded another contract
to Outotec for
the design and supply
of a pot shell straightening
machine for
the straightening of
deformed pot shells
after they have been
taken out of service.
This machine is custom-designed
for the particular pot shells in
use at Emal. Outotec was able to demonstrate
its expertise in this field through an earlier
supply of a similar machine to Aluminij d.d.
Mostar, Bosnia and Herzegovina.
At the Vedanta Aluminium Ltd, Jharsuguda
smelter in Orissa India, Outotec was
awarded a contract in 2012 to supply a hydraulic
crusher for full size green and baked
reject anodes, for the Plant II smelter. This is
an EPC contract with Outotec India taking
care of the local portion of the work. Technically,
the contract is a repeat order as this
facility is very similar to the crusher project
supplied by Outotec for the original Jharsuguda
Smelter Plant I in 2007.
To offer complete carbon plant solutions,
Outotec cooperates with Riedhammer, Nuremberg
/ Germany – a well-known supplier
of anode baking technologies. Through this
partnership, Outotec is able to offer complete
carbon plants covering raw material handling,
green anode plants, bake furnace and anode
rodding shop.
■
Pot shell straightening machine produced by Outotec
© Outotec
you‘re in good hands ...
Hannover Messe
08.04.-12.04.13
Hall 3 Stand B34
... we have all the pieces.
www.rosler.com
Innovative solutions from the world‘s leader in surface finishing

TECHNOLOGY
US Government funds projects to develop
higher performance materials for road vehicles
The US Government’s Department of
Energy (DOE) has selected a range of
new projects for funding with the aim of
boosting the development and deployment
of stronger and lighter materials
for the next generation of road vehicles.
These projects include research into
new lightweight, high-strength alloys for
energy-efficient car and truck engines,
as well as the development and validation
of modelling tools to deliver higher
performing carbon fibre composites and
advanced steels.
The Energy Department has already provided
some USD8 million through 2012 for these
awards, and has requested an additional
USD13.75 million for this year, to support
the completion of these projects over the next
two to four years. DOE’s investments are also
leveraging an additional USD11 million from
the private sector.
These projects support the previously posted
Materials Genome Initiative, announced
by US president Obama to double the speed
and cut the cost of discovering, developing
and deploying new high-tech materials in
the United States. Furthermore, this is with a
background of a stated US federal government
proposal that fuel standard requirements
should reach 54.5 mpg (US) (23.17 km/litre)
for cars and light-duty trucks by 2025. The
DOE recognises that advanced, improved performance
materials are essential for boosting
the fuel economy of road vehicles, while also
maintaining and improving safety and performance.
Replacing cast iron and traditional
steel components with lightweight materials –
including advanced aluminium and magnesium
alloys, high-strength steels, and carbon
fibre composites – allows vehicle manufacturers
to include additional safety devices, integrated
electronic systems and emissions control
equipment on vehicles without increasing
their weight, DOE noted. Using lighter materials
also reduces a vehicle’s fuel consumption:
Cutting a vehicle’s weight by 10%, for example,
can improve its fuel economy by 6-8%.
Another benefit of such competitive programmes
is that advances can be spurred in particular
materials sector technologies through
consideration of parallel developments with
General Motors 1.4 litre Ecotec car engine: GM’s
Flint Engine Operations, Michigan – current project
funding coupled with company investment will
support engine production for current and future
fuel-efficient small cars
competing materials. Also, for example, manufacturing
and processing technologies can be
transferred between
materials sectors
and, in some cases,
optimised materials
in individual sectors
can be used in combination
to realise the
best application solutions.
In this context,
the new investments
announced support
materials innovation
in various critical
areas, including:
Improving Carbon
Fibre Composites
and Advanced Steels
© General Motors
Through Computational Design; and, notably,
Advanced Alloy Development for Automotive
and Heavy-Duty Engines. In this latter
category, several projects will investigate and
develop lightweight, high-strength alloys for
specific auto applications such as heavy-duty
engine blocks and cylinder heads.
One project, led by Ford Motor Company,
will be supported with USD3.3 million funding
to progress ICME Guided Development of
Advanced Lightweight Cast Aluminium Alloys
for Automotive Engine Applications. The aim
is to develop a new class of high performance,
cost-competitive aluminium casting alloys, using
ICME tools, to deliver a 25% improvement
in component strength relative to components
made with A319 or A356 alloys using sand
and semi-permanent casting processes for
high-performance engine components.
Another USD3.5 million project to be carried
out at Oak Ridge National Laboratory will
investigate High Performance Cast Aluminium
Alloys for Next Generation Passenger Vehicle
Engines. The federal funds are part of a deal
with automakers to develop and implement
cost-effective and improved high performance
cast aluminium alloys that would enable
the design of higher efficiency and cost-competitive
light-duty passenger vehicle engines.
Small batch castings of identified alloys will be
harvested for property measurements.
A project at General Motors will be funded
with USD3.5 million to investigate Computational
Design and Development of a New,
Lightweight Cast Alloy for Advanced Cylinder
Heads in High-efficiency, Light-duty Engines.
The use of ICME tools will be employed to
accelerate the development of a new, highperformance
cast alloy for critical structure
applications, e. g. to produce high-efficiency
automotive engines with minimum lead-time
and cost. Comprehensive cost models will
also be developed for annual production runs
up to 500,000 units of cylinder heads using
the new alloy. This research will particularly
centre on GM’s Flint Engine Operation in
Michigan that produces drive units for several
vehicles, including the Buick Enclave, GMC
Acadia and Chevrolet Volt.
Overall, this range of topical and truly
smart projects are considered to have great
potential, and the results may eventually reap
benefit not only in the USA but also through
technology transfer around the world: lighter
vehicles boost efficiency, and lead to reductions
in fuel consumption, oil imports, GHG
emissions, climate extremes – and, furthermore,
on-going operation costs.
Ken Stanford, contributing editor
64 ALUMINIUM · 3/2013

COMPANY NEWS W O R L DWI D E
Aluminium smelting industry
Rusal and Guinea agree
details of Dian-Dian
© Dubal
Vale announces write-down of assets
Vale’s fourth-quarter earnings for 2012 were
hit by a USD4.2bn write-down of its nickel
and aluminium assets. Vale has reduced the
market value of its 22% stake in Hydro to
below the book value, mainly due to the
downward volatility of aluminium prices and
to macroeconomic uncertainties about the
European economy. Based on Hydro share
prices on 30 September 2012, Vale is recognising
an impairment charge before tax of
USD1.3bn, which will impact its 2012 fourth
quarter net earnings. The write-down will not
have any effect on Vale’s cash flow.
UC Rusal starts pilot tests of inert anodes
1-2 cm per day with the carbon anode.
The project joined the Skolkovo foundation
in June 2011. Planned co-financing of the
inert anode aluminium production research
from the foundation amounts to RUR750m
(USD25m) until 2015. To date, RUR130m
(USD4.3m) has already been spent by Skolkovo.
Viktor Mann, technical director at Rusal,
said: “Inert anode technology may have a
revolutionary impact on the global aluminium
industry. Each stage of development brings
us closer to a technological breakthrough and
we hope to begin switching our smelters,
working on the Soederberg technology, to inert
anode technology in the next five years,
as we build on our leading position in the industry.”
■
UC Rusal signed the annex to the agreement
with the Republic of Guinea specifying project
details for the development of Dian-Dian,
the world’s largest bauxite deposit, with the
company being the owner of rights to develop
this site. According to this document, the
project development will be divided into four
phases.
The first phase of the project, which is to
be completed by the end of 2015, involves
the development of a bauxite mine with a
capacity of 3m tpy of bauxite. In addition,
also by the end of 2015, Rusal will complete
a feasibility study of a project to increase the
bauxite production at the mine up to 6m tpy,
as well as a feasibility study for construction
of an alumina refinery with an annual capacity
of 1.2m tpy.
The second phase, to be accomplished by
the end of 2019, foresees bauxite production
increasing to 9m tpy. The third phase, also
planned for completion by the end of 2019,
involves the construction of an alumina refinery
with a capacity of 1.2m tpy of alumina,
with a corresponding increase in the bauxite
production to meet the needs of the plant.
The document signed also foresees the
fourth phase of the project, the development
of which remains at the discretion of Rusal
and will depend on the global economic situation
and its needs. The fourth phase includes
expanding alumina capacity to 2.4m tpy and
increasing bauxite production to 12m tpy.
UC Rusal started pilot testing of inert anode
technology in a small electrolysis pot. Pilot
tests will be run on a 3 kA amperage at the UC
Rusal Krasnoyarsk Engineering and Technology
Centre. For inert anode technology Rusal
has developed a completely new pot design.
Following successful pilot tests, Rusal plans
industrial tests in inert anode pots in 2015 at
the Krasnoyarsk aluminium smelter (KrAZ).
From 2017 Rusal may start shifting smelting
capacities to inert anode technology, starting
at KrAZ.
The current electrolysis process generates
CO, CO 2 and poly-aromatic hydrocarbons to
the atmosphere whereas the new generation
pots produce a tonne of oxygen for every
900 kg of aluminium produced. Scaled up to
KrAZ this figure will reach 900,000 tonnes
of oxygen per year. The burning speed of an
inert anode is 300 to 400 times slower than
that of a traditional carbon anode and discharges
only 1-2 cm per year, compared to
Bauxite and
alumina activities
Vinacomin to produce up to
300,000 tonnes of alumina in 2013
Vietnam National Coal Minerals Industries
Group (Vinacomin) plans to produce between
200,000 and 300,000 tonnes of alumina in
2013. Located in Lam Dong province in the
Central Highlands, the company’s Tan Rai alumina
plant has a capacity of about 600,000
tpy. Marubeni helped Vinacomin arrange a
USD300m syndicated loan from overseas
banks, out of the USD700m total project
costs. Chalco’s subsidiary, China Aluminium
International Engineering, is the engineering
and construction contractor for the project.
State-owned Vinacomin is Vietnam’s largest
mining company, focussing mainly on coal.
Hindalco acquires Novelis Brazil’s
bauxite mines and alumina refinery
Hindalco has acquired the bauxite mines and
alumina refinery from its subsidiary Novelis
Brazil. Novelis’ alumina refinery, located in
Ouro Preto in Brazil’s Minas Gerais state, has
mining rights for over 50m tonnes of bauxite
reserves and a capacity of 145,000 tpy. The
transaction will be done by transferring the
alumina assets of Novelis do Brasil into a
new company to be formed in Brazil, and the
acquisition of all the shares of the new company
by AV Minerals Netherlands BV.
Orbite Aluminae and Veolia Environmental
co-operate in recycling red mud
Canadian Orbite Aluminae and Veolia Environmental
Services have signed an exclusive
co-operation agreement for the treatment and
ALUMINIUM · 3/2013 65

COMPANY NEWS W O R L DWI D E
Period
Reported primary aluminium production
(Thousands of metric tonnes)
North
America
South
America
West
Europe
East & Central
Europe
GAC
Gulf Region
Asia
(ex China)
China Oceania Africa
Unreported
(estimate)
Total
Year 2008 5,783 2,660 4,618 4,658 – 3,923 13,105 2,297 1,715 732 39,491
Year 2009 4,759 2,508 3,722 4,117 – 4,400 12,964 2,211 1,681 624 36,986
Year 2010 4,689 2,305 3,800 4,253 2,724 2,500 16,131 2,277 1,742 732 41,153
Year 2011 4,969 2,185 4,027 4,319 3,483 2,533 17,786 2,306 1,805 576 43,989
Year 2012 4,851 2,053 3,605 4,323 3,658 2,535 19,754 2,178 1,636 600 45,193
© IAI
© Hydro
recycling of red mud generated by industrial
alumina production using the Bayer process.
The partnership includes the construction of
the first plant to treat red mud using Orbite’s
patented process.
Red mud is a caustic waste that is difficult
to treat because existing purification processes
are complicated, costly and ineffective.
Red mud often remains stored in situ, which
increases the risk of accidental spills. To meet
this environmental and complex challenge,
the two companies endeavour to bring the
solution to treat the red mud stockpiled
around the world in an economically and
Aluminium semis
Midal is to set up factory in Mozambique
Midal of Bahrein, a leading producer of aluminium
rod and wire, is reported to set up a
factory in Mozambique, using the aluminium
ingots produced at the Mozal smelter at Beluluane
as its raw material. The two companies
signed an agreement in mid-February under
which Mozal will supply 50,000 tpy of aluminium
ingots to Midal. The new factory is to
be built by June 2014, and will initially employ
150 Mozambican workers, rising eventually
socially sustainable manner. According to
the company, the Orbite process is the only
proven and commercially viable eco-friendly
technology for treating Bayer process tailings;
it recovers their entire commercial value and
can extend the lifespan of Bayer plants.
Worldwide stocks of untreated red mud are
estimated at nearly 3bn tonnes. “By partnering
together, Orbite and Veolia become the
global leader in the treatment and recycling
of red mud, which is one of the main environmental
challenges for the aluminium industry,”
stresses Richard Boudreault, president
and CEO of Orbite.
■
to 400. Until now, the 580,000 tonnes of
aluminium produced annually by Mozal has
been exported. The deal with Midal means
that, for the first time, there will be a downstream
industry, using some of the Mozal ingots
to produce rods and cables.
Vimetco commissions new aluminium
mill at Henan Zhongfu Industry
In December Vimetco NV produced the first
hot rolled coil at its Chinese subsidiary Henan
Zhongfu Industry. The new hot rolling mill
is part of Vimetco’s strategy to turn Henan
Zhongfu Industry into an integrated main
supplier for high value products, primarily for
the Chinese market. Currently, the Zhongfu
unit has an integrated production structure
with smelters, casthouses – and the new rolling
mill.
On the move
London Metal Exchange CEO Martin Abbott
has been appointed co-head of the newly
created global markets division of Hong Kong
Exchanges (HKEx) and Clearing. Working with
Romnesh Lamba, previously HKEx’s head of
market development, Abbott will oversee the
equities, fixed income and currencies businesses,
as well as the commodities, mainland
development and business development and
strategy departments. Abbott will continue to
serve as CEO of the LME.
David Graham, who sat on the UK Takeover
Panel and the equivalent panel of the US
Securities and Futures Commission, became
HKEx’s chief regulatory, while Gerald Greiner,
formerly COO, has been appointed head of
global clearing. Mr Greiner will stand down as
CEO of the Stock Exchange of Hong Kong and
Hong Kong Futures Exchange.
William F. Oplinger is named Alcoa CFO,
effective 1 April 2013, succeeding Charles D.
McLane, Jr., who will retire after 40 years
with the company. Robert Wilt will succeed
Oplinger as COO of global primary products.
John Martin has been named president
of Alcoa Global Primary Products – US. In this
role, he oversees six operating smelters, an
alumina refinery and a spent potlining recycling
facility.
Ken Giacobbe was named CFO of Alcoa
Engineered Products and Solutions.
Tyler Robbins was promoted to Customer
Service Manager at Wagstaff.
66 ALUMINIUM · 3/2013

COMPANY NEWS W O R L DWI D E
Vimetco invested in a casthouse for slabs with
an initial production capacity of 380,000 tpy,
and in a 1+4 hot rolling mill with a capacity
of 750,000 tpy. The hot rolling mill has stateof-the-art
technology, supplied by German
plant manufacturer SMS Siemag. Its electrical
components and control systems are from
Siemens. The hot line will be able to roll coils
close to 2,200 mm wide and weighing more
than 30 tonnes.
Following the commissioning of its mill to
make high-value products, Henan Zhongfu
Industry will serve the Chinese market with
sheet for aluminium beverage cans and other
products. The completion of the mill is another
step towards fulfilling the company’s long
term strategy of consolidating its position as
an integrated aluminium producer.
Vimetco has been the majority shareholder
in Henan Zhongfu Industry since 2006, with
a 51.68% stake. Henan Zhongfu Industry is
among the 500 biggest companies in China,
and is one of the biggest Chinese aluminium
producers with a capacity of 850,000 tpy.
The group also has smelting plants in Gong
Yiand Linzhou as well as processing and casting
facilities in Zhengzhou, with a capacity of
150,000 tpy of cold rolled products.
For the past six years, Vimetco’s investment
programme in China has focussed on
increasing product range and quality, particularly
in the high added value range. In 2011,
the company focussed on the construction of
a new hot and cold rolling mill. The installation
of the 450,000-tpy cold rolling mill and
finishing equipment is scheduled for completion
at the end of 2014.
Southwest Aluminium qualified
to produce automotive sheet
Southwest Aluminium Co. has become China’s
first globally-recognised supplier of automotive
materials. The company received
certification early in January, and aims to line
up 3-5 car manufacturers in 2013 as the company’s
first trial users of its products. China’s
domestic demand for automotive aluminium
is expected to reach over 100,000 tpy in the
next 2-3 years.
■
Suppliers
From waste to resource
Hydro has recently signed a contract to supply
spent pot linings (SPL) from the production
of primary aluminium to Rockwool International,
a producer of firesafe insulation.
The agreement ensures that pot linings will
be reused to benefit both the environment
and Hydro’s bottom line. Since SPL contains
fluorides, among other things, it is classified
as hazardous waste. For a number of years,
Hydro’s primary metal plants in Norway have
delivered this waste to disposal sites operated
by the company NOAH on Langøya, outside
Holmestrand in Vestfold county. In future
Hydro will separate the carbon-rich material
from the SPL and deliver it to Rockwool’s
preprocessing plant in Germany. There Rockwool
will crush the carbon and prepare it
for use in its production of rock wool, which
is an important component in fireproof insulation.
Hydro had previously set a target to reduce
the 2010 level of waste to landfill by 60% by
2020. In addition, the Primary Metal division
has a target that 70% of annual waste generated
will be recycled by 2020. This contract
is an important step to meeting these goals,
since it ensures that approximately 45% of
Hydro’s used pot linings will be recycled.
Hydro already signed
another contract in 2012
to supply anode waste to
Norcem’s cement plant
in Brevik in Telemark
county.
In addition to an environmentally
beneficial
impact, the agreement
with Rockwool should
result in annual savings
of about NOK5m
(USD890,000).The
agreement runs initially
to the end of 2013, with
an option for both parties
to extend and renegotiate.
It needs a formal
export approval from
Norway’s Climate and
Pollution Agency (Klif)
before the agreement
can be implemented.
Unique logistics system
makes for costeffective
shipping
A newly developed computer
system for managing
shipping could
help cut logistic costs
at Hydro’s Norwegian
aluminium smelters by several million kroner
per year. The system was developed by Hydro
in cooperation with the information technology
firm Seamless, with assistance from government
agency Innovation Norway.
At any particular moment, Hydro has a
number of ships in transport, moving raw materials
to the company’s plants and finished
products to the global market. Planning all this
traffic is of complex nature. Hydro accounts
for about 1,200 port calls a year in Norway
alone, with a number of ships in traffic to
and from Brazil, Continental Europe and the
United States.
In 2009, Hydro figured that these extra
costs for waiting ships at the wharf totalled
about NOK16m. It is these costs that the new
system can make a thing of the past. The developed
program is a planning tool that gives
an overview of all of the ports and all ships
that are in traffic, and has a number of builtin
functions for cost control at local ports. It
is unique that a company as large as Hydro
can now use just one system across borders
and business areas. In January 2013 Hydro
employees began training on the system. ➝
HA
IBROCOMACOR
Storvik AS
Industriveien 13
N- 6600 Sunndalsøra
E-mail: storvik@storvik.no
Tlf: +47 71 69 95 00
Fax: +47 71 69 95 55
Web: www.storvik.no
CERTIFIED ACC. TO ISO 9001:2008
ALUMINIUM · 3/2013 67

COMPANY NEWS W O R L DWI D E
Riedhammer’s baking furnace
technology selected by Rusal
Riedhammer has signed an agreement with
Rusal whereby the latter will use Riedhammer’s
open-top baking technology for its new
aluminium smelter located in the Taishet district
of the Irkutsk region. The anode baking
facility will be equipped with two state-of-theart
Riedhammer open top baking furnaces,
each of which will consist of 64 sections. To assure
themselves about Riedhammer’s furnace
technology a Rusal delegation visited anode
baking facilities in the UAE where Riedhammer
baking furnaces have been in full operation
for many years.
Aluminij Mostar orders
air-cooled ingot caster
Aluminij d.d. Mostar, Bosnia and Herzegovina,
has placed an order with Hertwich Engineering,
Austria, for the supply of a belttype
ingot casting line. The line comprises a
melting and casting furnace and an air-cooled
belt-type ingot caster. It has a design capacity
of 10 tonnes of ingots per hour with a unit
weight of 7 to 10 kg. The air-cooling system
ensures a high metallurgical quality. In addition,
it can efficiently cast high-silicon and
other eutectic and hypereutectic alloys. The
downstream equipment includes automated
stacking, packing and marking units. Commissioning
is scheduled for the first quarter
of 2013.
LTB receives order for fume treatment
plant from Century Aluminum Vlissingen
Antitrust: EU Commission renders legally
binding commitments from Rio Tinto Alcan
Rio Tinto Alcan has been ordered by the EU
Commission to end the practice of contractually
tying the licensing of its Aluminium Pechiney
(AP) smelting technology to the purchase of
handling equipment, namely pot tending assemblies
(PTAs) from its subsidiary ECL. PTAs
are specialty cranes used in aluminium smelters
for the handling of anodes. Rio Tinto Alcan
committed to modify its future technology
transfer agreements so as to enable licensees
of its AP technology to purchase PTAs from
any recommended supplier.
The commitments introduce an objective
and non-discriminatory process for selecting
qualified suppliers of PTAs. The company will
provide competing PTA suppliers with the
necessary technical specifications to ensure
that their equipment is capable of operating
in smelters using AP technologies. Compliance
with these commitments will be monitored by
an independent expert. After market testing
an initial commitments’ proposal in August
2012, the Commission concluded that the
final commitments offered by Rio Tinto Alcan
(which introduced several improvements in
response to some requests raised during the
market test) are suitable to address its competition
concerns.
Commission Vice-President Joaquín Almunia
commented: “Rio Tinto Alcan’s commitments
will open up the market for equipment used in
aluminium smelters. As a result, the customers
of aluminium technology and equipment will
have more choice.” If Rio Tinto Alcan were to
breach its commitments, the Commission could
impose a fine of up to 10% of the company’s
total turnover without having to prove a violation
of EU competition rules.
As part of Century Aluminum’s plan to restart
anode production at the Vlissingen plant
in The Netherlands, the company placed an
order with LTB to supply a fume treatment
system for the baking furnaces, which offers
the newest technology for lowest emission
values. The primary aluminium producer
supplies standard-grade, high-purity
and value-added products at a rated production
capacity of 785,000 tpy. The company
acquired the former Zalco anode manufacturing
plant in Vlissingen to ensure the supply
of anodes for their smelter in Grundartangi,
Iceland.
To improve the health and safety conditions,
a new fume treatment plant for the
baking furnaces was ordered from Luft- and
Thermotechnik Bayreuth, Germany (LTB).
The system’s technology consists of several
treatment stages. A combination of the proven
ROxiTherm regenerative thermal oxidiser and
the ‘Sulflex’ wet scrubber ensure lowest emission
values for volatile organic compounds
(PAH, HF and sulphur dioxide). Using three
ROxiTherm in parallel ensure a 100% redundancy.
The new system will result in significantly
lower emissions compared to existing
systems in Europe and the Netherlands.
LTB is a leading supplier of air pollution
control equipment serving the carbon anode
manufacturing within the aluminium industry.
Rio Tinto Alcan puts homogenising and
sawing line from Hertwich into operation
Hertwich Engineering, Austria, has handed
over the first expansion phase of a homogenising
and sawing line to aluminum producer
Rio Tinto Alcan in Hafnarfjörður, Iceland.
With this investment, Rio Tinto Alcan Iceland
will be able to produce top-quality billets.
When changing between standard and special
alloys with different holding times a special
furnace design ensures high flexibility and
throughput. The plant is designed for a production
capacity of 157,000 tpy of standard
alloys.
The supply package comprises a linear
ultrasonic inspection station (UT), a preparation
station for retrofitting a helical UT and
an upstream billet saw including specific scrap
removal. Other supply items are an electrically
heated continuous homogenising furnace,
cooling station as well as a downstream
packaging station. A robot is used for the first
time to assemble the strapping machine with
wooden planks which are placed in deposits
for an entire shift are then transferred from
the robot to the strapping machine. Consequently,
the strapping device operates fully
automatically over the entire shift.
Step 2 of the expansion project is scheduled
to be commissioned in 2014.
■
The Author
The author, Dipl.-Ing. R. P. Pawlek is founder
of TS+C, Technical Info Services and Consulting,
Sierre (Switzerland), a service for the
primary aluminium industry. He is also the
publisher of the standard works Alumina
Refineries and Producers of the World and
Primary Aluminium Smelters and Producers of
the World. These reference works are continually
updated, and contain useful technical
and economic information on all alumina refineries
and primary aluminum smelters of the
world. They are available as loose-leaf files
and / or CD-ROMs from Beuth-Verlag GmbH
in Berlin.
68 ALUMINIUM · 3/2013

RESEAR CH
Versagensbeschreibung beim Tiefziehen von
Aluminiumfeinblech mit Biegeüberlagerung
Marie-Louise Flörchinger, Mathias Liewald; IFU
Die Ermittlung der Grenzformänderungen
von Leichtbauwerkstoffen ist für
die immer wichtiger werdende Prozesssimulation
in der Blechumformung von
großer Bedeutung. Die versuchstechnischen
Methoden zur Aufnahme von
Grenzformänderungskurven (Forming
Limit Curve, FLC) unterliegen dabei
unterschiedlichen Einflüssen, die sowohl
zu optimistische als auch zu konservative
Bewertungen des simulierten Umformprozesses
hervorrufen können. In diesem
Beitrag wird einer dieser Faktoren, der
Biegeeinfluss, simulativ und experimentell
untersucht. Hierfür wird eine mittels
des konventionellen Nakajima-Versuchs
nach ISO/DIS 12004-2 ermittelte, biegeüberlagerte,
mit einer mittels Kerbzugproben
ermittelte, biegefreie Grenzformänderungskurve
des gleichen Werkstoffs
verglichen. Dies ermöglicht sowohl eine
qualitative als auch eine quantitative
Beurteilung des Einflusses der Biegeüberlagerung
auf die maximal erreichbaren
Grenzformänderungen von Aluminiumfeinblech.
Bei diesem Vergleich wird
ein geringer Unterschied zwischen den
Formänderungsgrenzen im uniaxialen
und ein größerer Unterschied im plane
strain Bereich festgestellt. Dieser Beitrag
stellt eine Methode zur Ermittlung des
Biegeeinflusses bei Aluminiumblechwerkstoffen
dar.
Der Einsatz von Leichtbauwerkstoffen, wie
zum Beispiel hoch- und höherfeste Aluminiumlegierungen,
rückt im Bereich des Karosseriebaus
immer stärker in den Vordergrund.
Die simulative Auslegung des Umformprozesses
bedingt in diesem Zusammenhang eine
detaillierte Werkstoffcharakterisierung, die
aussagekräftige Parameter der Versagensbeschreibung
erfordert. Das Grenzformänderungsdiagramm
wird beispielsweise zur Bewertung
von Umformprozessen verwendet
und dient in der Blechumformung als Versagenskriterium
bei proportionalen Belastungsverhältnissen
[Vol12]. In diesem Diagramm
sind unterschiedliche Kombinationen aus
Hauptformänderung (ϕ 1 ) und Nebenformänderung
(ϕ 2 ) zum Zeitpunkt der Dehnungslokalisierung
eingetragen und zu einer Kurve,
der sogenannten Grenzformänderungskurve
(FLC), verbunden. Die
unterschiedlichen
Dehnpfade sowie
ein Beispiel für eine
Grenzformänderungskurve
sind in Abb. 1
dargestellt.
Derzeit weit verbreitete
Versuchsanordnungen
zur Ermittlung
von Grenzformänderungen
bilden den
im realen Bauteil auftretenden
Spannungs-
Dehnungszustand
aufgrund unterschiedlicher
Faktoren jedoch
nicht hinreichend ab.
Als Einflussfaktor auf
die Lage und Form der
Grenzformänderungskurve
sind neben der Reibung die Blechdicke
[Mer06] sowie Vordehnungen des Materials,
wie zum Beispiel in [Wer12] an Aluminiumblech
untersucht, und die Beanspruchungsart,
insbesondere die Überlagerung durch Biegung
zu nennen. Die experimentell ermittelte FLC
repräsentiert somit häufig nicht die in der
Realität auftretende umformtechnische Versagensgrenze.
In der vorliegenden Untersuchung
wird daher der Einfluss der Biegeüberlagerung
bei Aluminiumfeinblech sowohl
qualitativ als auch quantitativ ermittelt.
Abb. 1: Grenzformänderungsdiagramm mit Dehnpfaden und Grenzformänderungen
nach [Has78] und [Int06]
Biegeüberlagerung in
der Blechumformung
Einfluss des Biegeanteils
auf die Grenzformänderungen
Erste Untersuchungen hinsichtlich des Einflusses
der Biegeüberlagerung auf die Grenzformänderungskurve
sind in [Gho74] und
[Gho74a] zu finden. In diesen Arbeiten wurde
eine Verschiebung der Grenzformänderungen
zu höheren Werten festgestellt, verursacht
durch Biegeüberlagerung im Nakajima- und
Abb. 2: Grenzformänderungskurven des Werkstoffs AA5051, aufgenommen mittels hemisphärischen Ziehstempeln
mit unterschiedlichen Krümmungsradien, nach [Atz10]
ALUMINIUM · 3/2013 69

RESEAR CH
Abb. 3: Verwendete Nakajima-Probengeometrien nach ISO/DIS 12004-2 (links) und Skizze der Versuchsanordnung (rechts)
© IUL
hydraulischen Tiefungsversuch. Charpentier
stellte in [Cha75] ebenfalls den Anstieg der
Grenzformänderung eines Stahlblechwerkstoffs
mit steigender Stempelkrümmung fest
und empfahl, die im jeweiligen Anwendungsfall
vorliegende Krümmung des Bauteils bei
der experimentellen Ermittlung der FLC zu
berücksichtigen. Mittels unterschiedlicher
halbkugel- und ellipsenförmiger Stempel untersuchte
er den Biegeeinfluss auf die Lage
der FLC im ersten Quadranten des Grenzformänderungsdiagramms,
wobei verschiedene
Dehnpfade durch Variation oder Weglassen
des Schmierstoffs erreicht wurden. Unterschiedliche
Verfahren zur Ermittlung von
Formänderungsgrenzen des Stahlwerkstoffs
DC04 stellte Hasek in [Has78] vor. Zur Ermittlung
der Grenzformänderungen im zweiten
Quadranten unter ebener Beanspruchung
wurden Zugversuche mit gekerbten Probengeometrien
durchgeführt. Des Weiteren wurde
mittels eines Streckziehversuchs, ähnlich
dem in ISO/DIS 12004-2 vorgeschriebenen
Versuchsaufbau, eine FLC aufgenommen.
Ferner wendete er den hydraulischen Tiefungsversuch
(Bulge-Test) zur Ermittlung der
Grenzformänderungen im ersten Quadranten
an. Die Grenzformänderungen waren hierbei
jedoch trotz Biegeüberlagerung im Vergleich
zu anderen biegefreien Versuchsmethoden
am niedrigsten. In [Mer06] wurde der Einfluss
Abb. 4: Hydraulischer Spannrahmen am Institut für Umformtechnik (Draufsicht)
der Biegeüberlagerung auf die Grenzformänderungen
eines hochfesten Stahlblechs als gering
ermittelt; die FLCs zeigen Schwankungen,
die auch durch unterschiedliche Hersteller
und Chargen auftreten könnten. In [Til08]
wurde in Versuchen mit einem AHSS Werkstoff
festgestellt, dass bei simultaner Tiefzieh-
und Biegebeanspruchung eine Abhängigkeit
der maximalen Umformbarkeit von
dem jeweiligen Biegeanteil besteht. Atzema
variierte zur Validierung des Biegeeinflusses
in [Atz10] den Nakajima-Versuch, indem er
Stempelradius und Probengeometrien skalierte
und mit Versuchsaufbauten geringerer
Abmessungen Grenzformänderungskurven,
unter anderem für den Aluminiumwerkstoff
AA5051, aufnahm. Dabei wurde festgestellt,
dass der Anstieg der FLC für AA5051 mit
steigendem Biegeeinfluss im plane strain Bereich
am höchsten, im uniaxialen Bereich sehr
gering und für den rechten Ast der FLC moderat
ausfiel (siehe Abb. 2). Ferner wurde vermutet,
dass der Anstieg der FLC mit steigendem
Biegeeinfluss einem nichtproportionalen Zusammenhang
unterliegt.
Probengeometrien zur Abbildung von
biegefreien plane strain Dehnungen
In [Has78] dienten Zugproben mit unterschiedlichen
Kerbradien zur Ermittlung der
Grenzformänderungen ohne Biegeüberlagerung
im zweiten Quadranten.
Sowohl das
Einschnür- und Bruchverhalten
als auch die
Auswertemethode und
das Versagenskriterium
wurden hier jedoch
nicht thematisiert.
Wagoner entwickelte
in [Wag80] eine Probe
mit behinderter
Querkontraktion, mit
der der plane strain
Zustand abgebildet
werden kann. Die charakteristischen
Merkmale
dieser Probengeometrie
sind ein geringes Längen- zu
Breitenverhältnis und große trapezförmige
Kerben. Der ebene Dehnungszustand ist jedoch
lediglich in der Probenmitte zu finden.
Aus diesem Grund definierte Wagoner circa
75 bis 80% der Probenbreite in der Mitte
der Probe als auszuwertenden Bereich und
vernachlässigte die uniaxialen Dehnungsbereiche
an den Kerbgründen. Dabei befand
sich die Grenze zwischen uniaxialer und plane
strain Dehnung definitionsgemäß im Bereich
ϕ ⎯1
ϕ
> 5.
2
Zielsetzung und Vorgehensweise
Ziel dieser Arbeit ist es, den qualitativen und
quantitativen Einfluss der Biegeüberlagerung
auf Grenzformänderungskurven von Aluminiumblechwerkstoffen
zu ermitteln und Aussagen
über das Versagensverhalten treffen
zu können. Hierfür wird im Folgenden eine
Methode zur Aufnahme einer Grenzformänderungskurve
im zweiten Quadranten mit
ebener Versuchsanordnung vorgestellt. Im
Fokus steht hierbei die Ermittlung geeigneter
Probengeometrien sowie einer geeigneten
Auswertemethode, die zu den Dehnungen
bei Probeneinschnürung führt, die in das
Grenzformänderungsdiagramm eingetragen
werden. Darüber hinaus soll der Versuchsaufbau
vollkommen reibungsfrei sein, damit
möglichst keine weiteren Parameter das Ergebnis
beeinflussen. Als Versuchswerkstoff
Abb. 5: Verwendete Kerbzugprobengeometrien
70 ALUMINIUM · 3/2013

RESEAR CH
Abb. 6: Dehnungslokalisierung an Kerbzugproben
während des Versuchs. Oben: Kerbzugprobe mit
R = 10 mm, unten: Kerbzugprobe mit R = 60 mm,
aufgenommen mit GOM Aramis
wird Aluminiumfeinblech der Güte 6xxx
und Dicke s = 1,04 mm gewählt, das üblicherweise
für Außenhautteile von Karosserien
eingesetzt wird. Für diesen Blechwerkstoff
wird mittels der nachfolgend vorgestellten
Versuchsmethodik eine ebene, das heißt biegefreie,
und zum Vergleich eine klassische
Grenzformänderungskurve nach Nakajima
aufgenommen.
radialen Kerben die für die vorliegende Anwendung
am besten geeignete Probenformen
darstellen. Aufgrund der Möglichkeit zur Variation
des Kerbradius können unterschiedliche
Dehnpfade im zweiten Quadranten des
Grenzformänderungsdiagramms recht einfach
realisiert werden.
Zur Bestimmung der Dehnungen während
der Durchführung der Experimente wird das
optische Messsystem Aramis der Fa. GOM
mbH verwendet. In der Vorbereitung werden
die Proben mit einem stochastischen Muster
lackiert. Durch den Vergleich des ursprünglichen
mit dem verzerrten Muster auf der
Probenoberfläche können die aufgebrachten
Dehnungen messtechnisch erfasst werden.
Hierfür nehmen die beiden Kameras des
optischen Messsystems den Umformprozess
während des Versuchs auf. Diese inline-
Messung ermöglicht sowohl eine Ermittlung
des Dehnpfads als auch der erreichten Dehnungen.
Die Aufnahme der biegeüberlagerten
Grenzformänderungskurve erfolgt nach ISO/
DIS 12004-2 mittels Proben nach Nakajima.
Die Versuchsgeometrien, die zur Aufnahme
der Nakajima-FLC verwendet werden, sind
in Abb. 3 (links) dargestellt. Zur Reibungsminimierung
wird aufgrund der besseren
Schmiereigenschaften das in der ISO/DIS
12004-2 empfohlene komplexe Schmierpaket
verwendet. Die Versuchsanordnung ist in
Abb. 3 (rechts) schematisch dargestellt.
Zur Ermittlung der biegefreien Grenzformänderungen
wird der am Institut für Umformtechnik
entworfene und gebaute hydraulische
Spannrahmen verwendet (Abb. 4). Auf dieser
Anlage können Proben mit einer maximalen
Länge von L = 540 mm gereckt werden, sodass
ein ausreichend großes homogenes Dehnungsfeld
erzielt werden kann. Die Zangen
dieses Spannrahmens sind einzeln ansteuerbar
und deren Geschwindigkeit variabel. Die
zur Aufnahme der biegefreien Grenzformänderungskurve
gewählten Kerbzugproben sind
in Abb. 5 zu sehen.
Um das Einschnürverhalten der unterschiedlichen
Proben näher zu untersuchen,
werden die Bruchflächen mit einem Rasterelektronenmikroskop
analysiert. Aufgrund
der kontrastreichen Vergrößerung kann sowohl
der Grad der Einschnürung als auch die
Versagensart durch Analyse der jeweiligen
Bruchfläche ermittelt werden.
Auswertung der Versuchsproben
Die Grenzformänderung bezeichnet jenen
Dehnungszustand, bei dem unter einer bestimmten
dreiachsigen Beanspruchung eine
korrespondierende Dehnungslokalisierung
im Werkstoff auftritt, die Probe somit eine
Einschnürung erfährt. Zur Erstellung eines
Grenzformänderungsdiagramms wird daher
für jede Probe der Zeitpunkt der Einschnürung
bestimmt.
Der Vergleich des ursprünglichen mit dem
verzerrten Muster auf der Probenoberfläche
ermöglicht die Berechnung der aufgebrachten
Dehnungen. Dabei wird zur Auswertung der
Nakajimaproben an der letzten Aufnahme
vor Riss das Linienschnittverfahren nach
ISO/DIS 12004-2 angewendet. Es werden
fünf Schnitte orthogonal zur Risslinie gelegt.
Aus den dort auftretenden Haupt- und Nebenformänderungen
wird die FLC erstellt.
Da die hohen Dehnungsgradienten zu nicht
Simulative Auslegung der biegefreien
Probengeometrien und experimentelle
Ermittlung der Grenzformänderungen
Die Probengeometrien zur Abbildung der unterschiedlichen
Dehnungen ohne Biegeüberlagerung
werden simulativ mit dem Programm
eta/Dynaform als Schalenmodelle entwickelt.
Die dabei auftretenden Dehnpfade der Probengeometrien
werden durch Experimente
abgeglichen, das heißt, es werden mehrere
Iterationsschleifen bei der Probenentwicklung
durchlaufen. Dabei werden in der Simulation
keine physischen Klemmen eingesetzt, sondern
es wird von einer idealen Klemmung der
Probe ausgegangen, sodass die Einspannbereiche
der Probe lediglich als Angriffspunkte
zur Krafteinleitung definiert werden. Die Belastungssimulation
unterschiedlicher Probengeometrien
ergibt, dass Kerbzugproben mit
Abb. 7: Grenzformänderungskurven: Biegeüberlagerte Nakajima-FLC und biegefreie Kerbzugproben-FLC
(Simulation und Experiment)
ALUMINIUM · 3/2013 71

RESEAR CH
Abb. 8: Einschnürverhalten einer uniaxial versagten Kerbzugprobe (Draufsicht Bruchfläche)
REM-Aufnahmen
aussagekräftigen Maxima führen, wird nicht
diese Dehnung verwendet, sondern es wird
mittels der Bragard-Methode der Beginn der
Einschnürung festgestellt und die entsprechenden
Haupt- und Nebenformänderungen
werden abgelesen. Diese in der Praxis eingesetzten
Grenzformänderungen werden dabei
durch ein in der Aramis-Software implementiertes
Makro generiert. Die Ermittlung der
maximalen Dehnungen der simulierten Kerbzugproben
erfolgt an einzelnen Elementen in
der Mitte der Probengeometrien. Dabei wird
der Einschnürbeginn der Proben und somit
das Versagen durch Membraninstabilität für
den jeweiligen Dehnpfad durch die zuvor im
Nakajima-Versuch ermittelte Grenzformänderungskurve
vorgegeben.
Die Vorgehensweise zur Auswertung der
mittels Kerbzugproben experimentell erzeugten
Dehnungen unterscheidet sich von der
Auswertung der Nakajima-Proben, da Annahmen
zum Versagenszeitpunkt der Proben
getroffen werden müssen. Grund ist die Kerbwirkung
bei den Proben mit kleinem Radius
(r = 10 mm), die einen Rissbeginn im Kerbgrund
unter nahezu uniaxialem Dehnungszustand
bewirken, während der plane strain
Zustand lediglich in der Mitte der Probe zu
finden ist (siehe Abb. 6, oben). Daher wird
in Anlehnung an [Wag80] nur der Bereich in
der Probenmitte betrachtet, der ca. 30% der
Probenbreite entspricht. Eine Probe gilt dabei
als zerstört, wenn ein deutlicher Riss im
Kerbgrund auftritt. Zur Auswertung der Kerbzugproben
mit Radius R = 0; 20; 40; 60 wird
entsprechend ISO/DIS 12004-2 das letzte Bild
vor Riss verwendet.
Die Dehnungen zum Zeitpunkt der Einschnürung
werden auf die gleiche Weise ermittelt,
wie es für die Nakajimaversuche der
Fall war; das heißt, es werden die Dehnungen
zum Zeitpunkt der Einschnürung ermittelt.
Hierfür wird das Datenformat der experimentell
bestimmten Dehnungen der Kerbzugproben
an die Aramis-Software angepasst und
mittels des hinterlegten Makros zur Bestimmung
von Grenzformänderungskurven die
Kerbzugproben-FLC ermittelt.
Ergebnisse und Diskussion
Grenzformänderungen unter ebener
und biegeüberlagerter Beanspruchung
In Abb. 7 sind die ermittelten Grenzformänderungskurven
abgebildet. Der Unterschied zwischen
der simulierten und der experimentell
ermittelten FLC, die mittels Kerbzugproben
ermittelt wurde, ist vernachlässigbar gering.
Dies macht deutlich, dass die simulative Auslegung
der Kerbzugproben realistische Dehnungsergebnisse
hervorbringt. Bei der dritten
Kurve im Grenzformänderungsdiagramm
Abb. 9: Bruchfläche einer Nakajima-Probe (uniaxial, Stegbreite 30 mm), REM-Aufnahmen
handelt es sich um die konventionell ermittelte
Nakajima-FLC. Während die Grenzformänderung
aus den Nakajima-Versuchen im
plane strain Bereich die seitliche Verschiebung
aufgrund der anisotropen Vordehnung
aufzeigt [Gra93], wird mittels Kerbzugprobe
in diesem Bereich die gewünschte Nebenformänderung
von ϕ 2 = 0 erreicht. Aus dem
Grenzformänderungsdiagramm wird ersichtlich,
dass die Grenzformänderungen bei biegefreier
Versuchsdurchführung im Bereich
zwischen ϕ 1 = -ϕ 2 bis einschließlich ϕ 2 = 0
betragsmäßig geringer sind als bei biegeüberlagerter.
Die Unterschiede sind im plane strain
Bereich besonders hoch und nehmen in Richtung
uniaxialer Belastung ab. Der maximale
Unterschied ist zwischen den tiefsten Punkten
der Grenzformänderungskurven festzustellen.
Während bei der Nakajimakurve die
mittels plane strain Probe ermittelte Hauptformänderung
ϕ 1 = 0,22 beträgt, liegt sie für
die biegefreie FLC bei ϕ 1 = 0,09. Dabei ist an
dieser Stelle die Auswertemethode der plane
strain Kerbzugprobe zu berücksichtigen, da,
wie bereits in Abschnitt 4.1 erläutert, nicht
die maximal erreichten Formänderungen zur
Auswertung herangezogen, sondern die Dehnungen
nach Definition ermittelt wurden. Im
weiteren Verlauf der Kurven zeigt sich, dass
der Unterschied der maximalen Dehnungen
bei kleineren Nebenformänderungen geringer
ist, das heißt, dass sich die Grenzformänderungskurven
in Richtung uniaxialer Formänderung
annähern.
Einschnürverhalten biegeüberlagerter
und biegefreier Versuchsproben
Nachfolgend wird auf das Einschnürverhalten
der verschiedenen Versuchsanordnungen eingegangen.
In Abb. 8 ist die Bruchfläche einer
uniaxialen Kerbzugprobe zu sehen. Auf makroskopischer
Ebene ist die für Werkstoffe mit
kfz-Gitter typische lokale Einschnürung zu erkennen
[Ost07], die hier ca. 50% beträgt und
auf einen duktilen Bruch hindeutet. Bei 300-
facher Vergrößerung (Abb. 8, rechts) wird die
Wabenstruktur der Bruchfläche sichtbar, die
verdeutlicht, dass es sich um einen vorwiegend
transkristallinen Bruch [Ost07] handelt.
Die Bruchfläche einer entsprechenden uniaxialen
Nakajima-Probe mit einer Stegbreite
von B = 30 mm ist in den Aufnahmen in Abb.
9 zu sehen. Bei einer Gegenüberstellung mit
der zuvor betrachteten uniaxialen biegefreien
Probe wird deutlich, dass die Dehnungslokalisierung
in Form der Einschnürung hier
geringer ausfällt.
Der Unterschied in den Einschnürungen
spiegelt sich auch bei den Grenzformänderungen
wider: Während die Nebenformän-
72 ALUMINIUM · 3/2013

RESEAR CH
derung bei der uniaxialen Nakajimaprobe
zu ϕ 2 = -0,095 ermittelt wird, ist sie bei der
flachen Probe um ca. 25% höher und beträgt
ϕ 2 = 0,0126. Sowohl die biegeüberlagerten als
auch die biegefrei geprüften Proben weisen
wabige Strukturen auf, die für einen vorwiegend
transkristallinen Scherbruch stehen.
Zusammenfassung und Ausblick
In den vorliegenden Untersuchungen wurde
der Einfluss der Biegeüberlagerung auf die
Grenzformänderungskurve eines Aluminiumblechwerkstoffs
experimentell untersucht.
Hierfür wurden mittels simulativ ausgelegter
Kerbzugproben biegefreie Grenzformänderungen
ermittelt. Die daraus erstellte Grenzformänderungskurve
im zweiten Quadranten
des Grenzformänderungsdiagramms wurde
mit einer nach ISO/DIS 12004-2 konventionell
aufgenommenen FLC verglichen. Darüber
hinaus wurde das Einschnürverhalten bei
biegeüberlagerter und biegefreier Belastung
an ausgewählten Proben mit Hilfe rasterelektronenmikroskopischer
Aufnahmen untersucht.
Es konnte festgestellt werden, dass
insbesondere im Bereich der plane strain
Dehnung der Einfluss der Biegeüberlagerung
ausgeprägt ist.
Um Aussagen über den Einfluss auf die gesamte
Grenzformänderungskurve treffen zu
können, sind weitere biege- und reibungsfreie
Versuchsanordnungen zur Ermittlung der
Grenzformänderungen im ersten Quadranten
zu entwickeln. Darüber hinaus ist eine Standardisierung
sowohl der Probengeometrien
zur Ermittlung der Grenzformänderungen
ohne Biegeüberlagerung als auch der Auswertemethoden
anzustreben. Mittels einer
solchen Prüfmethode soll eine Möglichkeit
gegeben werden, den in der Realität auftretenden
Versagenszeitpunkt im Postprocessing
von Simulationen realitätsnäher zu ermitteln.
Darüber hinaus soll ermöglicht werden, den
Biegeeinfluss anteilig in der Simulation aufzunehmen,
das heißt, einen funktionalen Zusammenhang
zwischen Biegeanteil und Versagenszeitpunkt
für alle relevanten Dehnpfade
im Grenzformäderungsdiagramm herzustellen
und somit Bauteilbereichen ohne
Biegeeinfluss eine andere Versagensgrenze
zuzuordnen als biegeüberlagerten Bereichen.
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Dipl.-Ing. (FH) Marie-Louise Flörchinger ist Doktorandin
der GSaME (Graduate School of excellence
Advanced Manufacturing Engineering) am Institut
für Umformtechnik der Universität Stuttgart, Abteilung
Werkstoffe.
Prof. Dr.-Ing. Mathias Liewald MBA ist Direktor
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Elektromagnetischer Induktionsschmelzofen
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(B21H 7/00, OS 50 2009 003 753, EP 2303489,
WO 2009/127730, AT: 17.04.2009, EP-AT:
17.04.2009, WO-AT: 17.04.2009)
Bindung von Perfluorelastomeren an Aluminium.
E.I. du Pont de Nemours and Co., Wilmington,
Del., US. (B29C 43/18, EP 1 855 864, WO
2006/099235, AT: 09.03.2006, EP-AT: 09.03.
2006, WO-AT: 09.03.2006)
Formteil aus Cu-Al-Legierung mit hoher mechanischer
Festigkeit und hoher Kriechbeständigkeit.
Rio Tinto Alcan Intl Ltd., Montréal, QC
H3A 3G2, CA. (C22C 21/12, EPA 2516687,
WO 2011/083209, EP-AT: 07.12.2010, WO-AT:
07.12.2010)
Vorbereitungsverfahren vor dem Schweißen
von Produkten aus Li-Al-Legierung. Constellium
France, Paris, FR. (B23K 26/42, EP 2 321
436, WO 2010/004132, AT: 03.07.2009, EP-AT:
03.07.2009, WO-AT: 03.07.2009)
Wasserfeste Membranen basierend auf mit
Polymeren modifiziertem Bitumen mit Aluminium-Silicatzenosphären.
Polyglass SpA, Milano,
IT. (C08K 3/34, EP 2 264 092, AT: 11.06.
2010, EP-AT: 11.06.2010)
Aluminiumlegierung für ein Gleitlager, Gleitlager
und Verfahren zu seiner Herstellung. Taiho
Kogyo Co., Ltd, Toyota-shi Aichi 471-8502, JP.
(C22C 21/00, EPA 2518172, WO 2011/078255,
EP-AT: 22.12.2010, WO-AT: 22.12.2010)
Aluminiumlegierung zur Anodisierung und
Aluminiumlegierungskomponete. Showa Denko
K.K., Tokio 105-8518, JP. (C22C 21/00, EPA
2518171, WO 2011/078080, EP-AT: 17.12.2010,
WO-AT: 17.12.2010)
Honverfahren für Aluminiumlegierungen.
Nagel Maschinen- und Werkzeugfabrik GmbH,
72622 Nürtingen, DE. (B24B 33/02, PS 10 2006
003 994, AT: 24.01.2006)
Verfahren zur Punktwiderstandsschweißung
von Aluminiumlegierungen. Constellium Switzerland
AG, Zürich, CH. (B23K 11/11, PS 60
2007 018 749, EP 1973686, WO 2007/077393,
AT: 04.01.2007, EP-AT: 04.01.2007, WO-AT:
04.01.2007)
Verfahren zur Herstellung eines Radsterns
eines einteiligen Leichtmetall-Fahrzeugrades.
Audi AG, 85045 Ingolstadt, DE. (B23P 13/00, OS
10 2011 102 848, AT: 30.05.2011)
Graphitkörper imprägniert mit einer Leichtmetall-Legierung,
Verfahren zu dessen Herstellung
und seine Verwendung. SGL Carbon SE,
65201 Wiesbaden, DE. (C04B 35/52, PS 10 2009
048 006, AT: 02.10.2009)
Verfahren zur Herstellung von anorganisch
gebundenen Formen und Kernen für Gießereizwecke,
insbesondere für das Leichtmetallgießen.
Otto-von-Guericke-Universität Magdeburg,
39106 Magdeburg, DE. (B22C 9/12, OS 10 2006
026 796, AT: 07.06.2006)
Abschalt- und Anschaltverfahren einer elektrolytischen
Zelle. Rio Tinto Alcan Intl Ltd., Montréal,
QC H3A 3G2, CA. (C25C 3/20, EPA 2519662,
WO 2011/075820, EP-AT: 17.12.2010, WO-AT:
17.12.2010)
Profil für eine Stoßstange eines Fahrzeuges,
Haltewerkzeug und Rohrprofil dafür sowie
Verfahren zur Herstellung des Profils. Constellium
Switzerland AG, Zürich, CH. (B60R 19/18,
PS 10 2006 062 294, AT: 27.12.2006)
Verfahren zur Rezyklierung von Aluminiumlegierungsschrott
aus der Luftfahrtindustrie.
Constellium France, Paris, FR. (C22B 21/06, EP
2 038 440, WO 2007/147962, AT: 18.06.2007,
EP-AT: 18.06.2007, WO-AT: 18.06.2007)
Gießverfahren für Al-Legierungen. Constellium
France, Paris. (B22D 11/10, EP 2 398 609,2010/
094852, AT: 15.02.2010, EP-AT: 15.02.2010)
Sichtschutz- oder Stütz-Wand. Corus Aluminium
Profiltechnik GmbH, 88267 Vogt, DE. (E04B
2/74, GM 20 2006 015 391, AT: 07.10.2006)
Verfahren zum Stanznieten von Aluminiumlegierungsblech.
Aleris Aluminium Duffel BVBA,
2570 Duffel, BE. (B21J 15/02, EPA 2514537, EP-
AT: 20.09.2011, WO-AT: 20.09.2011)
Verfahren zum Verbinden von Aluminiumlegierungsblech.
Aleris Aluminium Duffel BVBA,
2570 Duffel, BE. (B21J 15/02, EPA 2514538,
EP-AT: 07.10.2011, WO-AT: 07.10.2011)
Fahrzeugbauteil und Verfahren zu seiner
Herstellung. Aleris Aluminium Koblenz GmbH,
56070 Koblenz, DE. (B62D 29/00, OS 10 2011
078 032, AT: 24.06.2011)
Verfahren zur Herstellung eines Aluminiumlegierungsplattenprodukts
mit niedriger Restspannung.
Aleris Aluminium Koblenz GmbH,
56070 Koblenz, DE. (C22F 1/04, EP 2 379 765,
WO 2010/081889, AT: 15.01.2010, EP-AT:
15.01.2010)
Vorrichtung zur Überprüfung der Schälfestigkeit
von Siegelnähten. Hydro Aluminium Rolled
Products GmbH, 41515 Grevenbroich, DE. (G01N
19/04, OS 10 2011 050 708, AT: 30.05.2011)
Elementmodul zum Einbau in Fassaden und
dergleichen. Norsk Hydro ASA, Oslo, NO.
(E06B 1/00, PS 50 2005 012 119, EP 1674648,
AT: 08.12.2005, EP-AT: 08.12.2005)
Modularer Sonnenkollektor. Hydro Aluminium
Deutschland GmbH, 51149 Köln, DE. (F24J 2/20,
PS 10 2006 003 096, AT: 20.01.2006)
Deckleiste für Fenster. Norsk Hydro ASA,
Oslo, NO. (E06B3/30, PS 60 2006 025 989, EP
1712719, AT: 04.04.2006, EP-AT: 04.04.2006)
Eckverbindung für ein Flügelrahmenabdeckprofil.
Gutmann AG, 91781 Weißenburg, DE.
(E06B 3/30, EPA 2518253, EP-AT: 28.04.2011,
WO-AT: 28.04.2011)
Rohrprodukt einer Extrusionsaluminiumlegierung.
Aleris Aluminium Koblenz GmbH, 56070
Koblenz, DE. (B23K 35/22, EPA 2514555, EP-
AT: 21.04.2011, WO-AT: 21.04.2011)
Anordnung zur Reinigung eines Röhrentrenners.
Norsk Hydro ASA, Oslo, NO. (B01D 17/00,
EP 1 861 581, WO 2006/098636, AT: 15.03.
2006, EP-AT: 15.03.2006, WO-AT: 15.03.2006)
Anordnung oder Bereitstellung eines Sensors
oder eines Fühlers zum Messen eines Zustandes
in einem Rohr oder dergleichen. Norsk Hydro
ASA, Oslo, NO. (F16L 23/16, PS 60 2005 031
387, EP 1800044, WO 2006/031124, AT: 09.09.
2005, EP-AT: 09.09.2005, WO-AT: 09.09.2005)
Abdichtungsstruktur zum Befestigen an einem
Kraftfahrzeug. WKW Erbslöh Automotive
GmbH, 42349 Wuppertal, DE. (B60R 13/06, GM
20 2006 016 434, AT: 26.10.2006)
Druckfester Kern mit verbessertem Binder. KS
Aluminium-Technologie GmbH, 74172 Neckarsulm,
DE. (B22C 9/10, PS 50 2008 005 831, EP
2082819, AT: 22.10.2008, EP-AT: 22.10.2008)
Verfahren zur Herstellung eines Kolbens für
einen Verbrennungsmotor sowie mittels
dieses Verfahrens herstellbarer Kolben. Mahle
International GmbH, 70376 Stuttgart, DE, (F02F
3/00, EPA 2513462, WO 2011/072656, EP-AT:
17.12.2010, WO-AT: 17.12.2010)
Verfahren zur Herstellung eines Aluminiumtitanatkeramikelements.
Sumitomo Chemical
Co., Ltd., Tokio 104-8260, JP. (C04B 35/46,
EPA 2520554, WO 2011/081217, EP-AT: 24.12.
2010, WO-AT: 24.12.2010)
Aluminiumlegierungsdraht. Autonetworks
Technologies, Ltd., Yokkaichi-shi, Mie, JP; Sumitomo
Wiring Systems, Ltd., Yokkaichi-shi, Mie,
JP; Sumitomo Electric Industries, Ltd., Osaka-shi,
Osaka, JP. (C22C 21/00, WO 2011 052644, AT:
27.10.2010, WO-AT: 27.10.2010)
Patentblatt Januar 2013
Schneidewerkzeuge mit mehrschichtigen Al-
Cr-B-N-/Ti-Al-N-Beschichtungen. Oerlikon Trading
AG, Trübbach, 9477 Trübbach, CH. (C23C
14/06, EPA 2531633, WO 2011/095292, EP-AT:
25.01.2011, WO-AT: 25.01.2011)
Alpha-Aluminium und seine Verwendung,
Syntheseverfahren und Vorrichtung. Baikowski,
74330 Poisy, FR. (C01F, EPA 2534101,
WO 2011/098511, EP-AT: 10.02.2011, WO-AT:
10.02.2011)
Feinkristalline Al 2 O 3 -Keramik. CeramTec GmbH,
73207 Plochingen, DE. (C04B 35/111, OS 10 2005
059 099, AT: 08.12.2005)
Fortsetzung in ALUMINIUM 4/2013
ALUMINIUM · 3/2013 75

LIEFERVERZEICHNIS
1
Smelting technology
Hüttentechnik
• Auto firing systems
Automatische Feuerungssysteme
1.1 Raw materials
Rohstoffe
1.2 Storage facilities for smelting
Lagermöglichkeiten in der Hütte
1.3 Anode production
Anodenherstellung
1.4 Anode rodding
Anodenschlägerei
1.4.1 Anode baking
Anodenbrennen
1.4.2 Anode clearing
Anodenschlägerei
1.4.3 Fixing of new anodes to the
anodes bars
Befestigen von neuen Anoden
an der Anodenstange
1.5 Casthouse (foundry)
Gießerei
1.6 Casting machines
Gießmaschinen
1.7 Current supply
Stromversorgung
1.8 Electrolysis cell (pot)
Elektrolyseofen
1.9 Potroom
Elektrolysehalle
1.10 Laboratory
Labor
1.11 Emptying the cathode shell
Ofenwannenentleeren
1.12 Cathode repair shop
Kathodenreparaturwerkstatt
1.13 Second-hand plant
Gebrauchtanlagen
1.14 Aluminium alloys
Aluminiumlegierungen
1.15 Storage and transport
Lager und Transport
1.16 Smelting manufactures
Hüttenerzeugnisse
RIEDHAMMER
CARBON BAKING TECHNOLOGY
RIEDHAMMER GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 0, Fax: -5218 231
E-Mail: thomas.janousch@riedhammer.de
Internet: www.riedhammer.de
• Hydraulic presses for prebaked
anodes / Hydraulische Pressen zur
Herstellung von Anoden
LAEIS GmbH
Am Scheerleck 7, L-6868 Wecker, Luxembourg
Phone: +352 27612 0
Fax: +352 27612 109
E-Mail: info@laeis-gmbh.com
Internet: www.laeis-gmbh.com
Contact: Dr. Alfred Kaiser
www.alu-web.de
• Anode Technology &
Mixing Equipment
1.2 Storage facilities for
smelting
Lagermöglichkeiten i.d. Hütte
FLSmidth MÖLLER GmbH
Haderslebener Straße 7
D-25421 Pinneberg
Telefon: 04101 788-0
Telefax: 04101 788-115
E-Mail: moeller@flsmidth.com
Internet: www.flsmidthmoeller.com
Kontakt: Herr Dipl.-Ing. Timo Letz
www.alu-web.de
• Bulk materials Handling
from Ship to Cell
Bulk materials Handling from Ship to Cell
www.coperion.com
mailto: info.cc-mh@coperion.com
• Conveying systems bulk materials
Förderanlagen für Schüttgüter
(Hüttenaluminiumherstellung)
FLSmidth MÖLLER GmbH
Internet: www.flsmidthmoeller.com
see Storage facilities for smelting 1.2
Paul Hedfeld GmbH
Hundeicker Str. 20
D-58285 Gevelsberg
Phone: +49 (0) 2332 6371
E-mail: verkauf@hedfeld.com
Internet: www.hedfeld.com
• Unloading/Loading equipment
Entlade-/Beladeeinrichtungen
FLSmidth MÖLLER GmbH
www.flsmidthmoeller.com
see Storage facilities for smelting 1.2
ALUMINA AND PET COKE SHIPUNLOADERS
Contact: Andreas Haeuser, ha@neuero.de
1.3 Anode production
Anodenherstellung
Solios Carbone – France
www.fivesgroup.com
Storvik AS
Industriveien 13
6600 SUNNDALSØRA/NORWAY
Tel.: +47 71 69 95 00 | Fax: +47 71 69 95 55
www.storvik.no | storvik@storvik.no
Buss ChemTech AG, Switzerland
Phone: +4161 825 64 62
E-Mail: info@buss-ct.com
Internet: www.buss-ct.com
• Mixing Technology for
Anode pastes
Mischtechnologie für Anodenmassen
Buss AG
CH-4133 Pratteln
Phone: +41 61 825 66 00
E-Mail: info@busscorp.com
Internet: www.busscorp.com
1.4 Anode rodding
Anodenanschlägerei
• Removal of bath residues from
the surface of spent anodes
Entfernen der Badreste von der Ober -
fläche der verbrauchten Anoden
GLAMA Maschinenbau GmbH
Hornstraße 19
D-45964 Gladbeck
Telefon 02043 / 9738-0
Telefax 02043 / 9738-50
76 ALUMINIUM · 3/2013

SUPPLIERS DIRECTORY
• Rodding shop
www.brochot.fr
1.4.1 Anode baking
Anodenbrennen
• Open top and closed
type baking furnaces
Offene und geschlossene Ringöfen
RIEDHAMMER
CARBON BAKING TECHNOLOGY
RIEDHAMMER GmbH
D-90411 Nürnberg
Phone: +49 (0) 911 5218 0, Fax: -5218 231
E-Mail: thomas.janousch@riedhammer.de
Internet: www.riedhammer.de
1.5 Casthouse (foundry)
Gießerei
• Degassing, filtration and
grain refinement
Entgasung, Filtern, Kornfeinung
Drache Umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
Gautschi
Engineering GmbH
see Casting equipment 3.1
• Dross skimming of liquid metal
Abkrätzen des Flüssigmetalls
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
• Furnace charging with
molten metal
Ofenbeschickung mit Flüssigmetall
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
• Ingot Casting Line
• Metal treatment in the
holding furnace
Metallbehandlung in Halteöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
• Transfer to the casting furnace
Überführung in Gießofen
Gautschi
Engineering GmbH
see Casting equipment 3.1
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
Drache Umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: www.drache-gmbh.de
• Transport of liquid metal
to the casthouse
Transport v. Flüssigmetall in Gießereien
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
HERTWICH ENGINEERING GmbH
Maschinen und Industrieanlagen
Weinbergerstraße 6, A-5280 Braunau am Inn
Phone +437722/806-0
Fax +437722/806-122
E-Mail: info@hertwich.com
Internet: www.hertwich.com
www.brochot.fr
• Melting/holding/casting furnaces
Schmelz-/Halte- und Gießöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
• Treatment of casthouse
off gases
Behandlung der Gießereiabgase
Gautschi
Engineering GmbH
see Casting equipment 3.1
INOTHERM INDUSTRIEOFEN-
UND WÄRMETECHNIK GMBH
Konstantinstraße 1a
D 41238 Mönchengladbach
Telefon +49 (02166) 987990
Telefax +49 (02166) 987996
E-Mail: info@inotherm-gmbh.de
Internet: www.inotherm-gmbh.de
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
1.6 Casting machines
Gießmaschinen
GAPCast
TM : the Swiss casting solution
see Casting machines and equipment 4.7
see Equipment and accessories 3.1
Hampshire House, High Street, Kingswinford,
West Midlands DY6 8AW, UK
Tel.: +44 (0) 1384 279132
Fax: +44 (0) 1384 291211
E-Mail: sales@mechatherm.co.uk
www.mechatherm.com
Stopinc AG
Bösch 83 a
CH-6331 Hünenberg
Tel. +41/41-785 75 00
Fax +41/41-785 75 01
E-Mail: interstop@stopinc.ch
Internet: www.stopinc.ch
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
Avenida Cervantes Nº6
48970 – Basauri – Bizkaia – Spain
Tel: +34 944 409 420
E-mail: Insertec@insertec.biz
Internet: www.insertec.biz
Sistem Teknik Endüstryel Firinlar LTD. STI.
TOSB – TAYSAD OSB 1.Cad. 14.Sok. No.: 3
Gebze, Kocaeli / Turkey
Tel.: +90 262 658 22 26
Fax: +90 262 658 22 38
E-Mail: info@sistemteknik.com
Internet: www.sistemteknik.com
Solios Thermal UK
www.fivesgroup.com
www.mechatherm.com
see Smelting technology 1.5
RIHS ENGINEERING SA
see Casting machines and equipment 4.7
• Pig casting machines (sow casters)
Masselgießmaschine (Sowcaster)
Gautschi
Engineering GmbH
see Casting equipment 3.1
ALUMINIUM · 3/2013 77

LIEFERVERZEICHNIS
• Rolling and extrusion ingot
and T-bars
Formatgießerei (Walzbarren oder
Pressbolzen oder T-Barren)
Gautschi
Engineering GmbH
see Casting equipment 3.1
• Heat treatment of extrusion
ingot (homogenisation)
Formatebehandlung (homogenisieren)
Gautschi
Engineering GmbH
see Casting equipment 3.1
1.9 Potroom
Elektrolysehalle
T.T. Tomorrow Technology S.p.A.
Via dell’Artigianato 18
Due Carrare, Padova 35020, Italy
Telefon +39 049 912 8800
Telefax +39 049 912 8888
E-Mail: gmagarotto@tomorrowtechnology.it
Contact: Giovanni Magarotto
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
• Horizontal continuous casting
Horizontales Stranggießen
Gautschi
Engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
• Scales / Waagen
Gautschi
Engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
www.alu-web.de
• Vertical semi-continuous DC
casting / Vertikales Stranggießen
Gautschi
Engineering GmbH
see Casting equipment 3.1
Wagstaff, Inc.
3910 N. Flora Rd.
Spokane, WA 99216 USA
+1 509 922 1404 phone
+1 509 924 0241 fax
E-Mail: info@wagstaff.com
Internet: www.wagstaff.com
1.8 Electrolysis cell (pot)
Elektrolyseofen
• Bulk materials Handling
from Ship to Cell
Bulk materials Handling from Ship to Cell
• Anode changing machine
Anodenwechselmaschine
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
• Anode transport equipment
Anoden Transporteinrichtungen
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
• Crustbreakers / Krustenbrecher
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: anzeigen@giesel.de
Hier könnte Ihr
Bezugsquellen-Eintrag stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
• Sawing / Sägen
Gautschi
Engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
sermas@sermas.com
www.coperion.com
mailto: info.cc-mh@coperion.com
• Calcium silicate boards
Calciumsilikatplatten
Promat GmbH High Performance Insulation
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
verkauf3@promat.de, www.promat.de
• Exhaust gas treatment
Abgasbehandlung
Solios Environnement
www.fivesgroup.com
• Pot feeding systems
Beschickungseinrichtungen
für Elektrolysezellen
FLSmidth MÖLLER GmbH
www.flsmidthmoeller.com
see Storage facilities for smelting 1.2
• Dry absorption units for
electrolysis exhaust gases
Trockenabsorptionsanlage für
Elektrolyseofenabgase
Solios Environnement
www.fivesgroup.com
• Pot ramming Machine
www.brochot.fr
www.alu-web.de
• Tapping vehicles/Schöpffahrzeuge
GLAMA Maschinenbau GmbH
see Anode rodding 1.4
78 ALUMINIUM · 3/2013

SUPPLIERS DIRECTORY
1.12 Cathode repair shop
Kathodenreparatur-
Werkstatt
• Cathode Sealing Bench
Eingießen von Kathodenbarren
Sermas Industrie
sermas@sermas.com
see Smelting technology 1.6
1.14 Aluminium Alloys
Aluminiumlegierungen
RHEINFELDEN ALLOYS GmbH & Co. KG
A member of ALUMINIUM RHEINFELDEN Group
Postfach 1703, 79607 Rheinfelden
Tel.: +49 7623 93-490
Fax: +49 7623 93-546
E-Mail: alloys@rheinfelden-alloys.eu
Internet: www.rheinfelden-alloys.eu
2
Extrusion
Strangpressen
2.1 Extrusion billet preparation
Pressbolzenbereitstellung
2.1.1 Extrusion billet production
Pressbolzenherstellung
2.2 Extrusion equipment
Strangpresseinrichtungen
2.3 Section handling
Profilhandling
2.1 Extrusion billet preparation
Pressbolzenbereitstellung
extrutec GmbH
Fritz-Reichle Ring 2
D-78315 Radolfzell
Tel. +49 7732 939 1390
Fax +49 7732 939 1399
E-Mail: info@extrutec-gmbh.de
Internet: www.extrutec-gmbh.de
1.15 Storage and transport
Lager und Transport
www.brochot.fr
SMS Siemag AG
see Rolling mill technology 3.0
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
2.4 Heat treatment
Wärmebehandlung
2.5 Measurement and control
equipment
Mess- und Regeleinrichtungen
2.6 Die preparation and care
Werkzeugbereitstellung
und -pflege
2.7 Second-hand extrusion plant
Gebrauchte Strangpressanlagen
2.8 Consultancy, expert opinion
Beratung, Gutachten
2.9 Surface finishing of sections
Oberflächenveredlung
von Profilen
2.10 Machining of sections
Profilbearbeitung
2.11 Equipment and accessories
Ausrüstungen und Hilfsmittel
2.12 Services
Dienstleistungen
mfw-maschinenbau.com
• Log/Bolzenlager Handling
• Bolzensäge, Bolzenfügen
Hier könnte Ihr
Bezugsquellen-Eintrag stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
• Billet heating furnaces
Öfen zur Bolzenerwärmung
INDUKTIONS-ANLAGEN + SERVICE GmbH & Co. KG
Am großen Teich 16+27
D-58640 Iserlohn
Tel. +49 (0) 2371 / 4346-0
Fax +49 (0) 2371 / 4346-43
E-Mail: verkauf@ias-gmbh.de
Internet: www.ias-gmbh.de
see Casthouse (foundry) 1.5
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: anzeigen@giesel.de
2.2 Extrusion equipment
Strangpresseinrichtungen
www.mechatherm.com
see Smelting technology 1.5
Oilgear Towler GmbH
Im Gotthelf 8
D 65795 Hattersheim
Tel. +49 (0) 6145 3770
Fax +49 (0) 6145 30770
E-Mail: info@oilgear.de
Internet: www.oilgear.de
www.alu-web.de
• Press control systems
Pressensteuersysteme
Oilgear Towler GmbH
see Extrusion Equipment 2.2
• Heating and control
equipment for intelligent
billet containers
Heizungs- und Kontrollausrüstung
für intelligente Blockaufnehmer
MARX GmbH & Co. KG
www.marx-gmbh.de
see Melt operations 4.13
ALUMINIUM · 3/2013 79

LIEFERVERZEICHNIS
2.3 Section handling
Profilhandling
2.4 Heat treatment
Wärmebehandlung
CTI Systems S.A.
Z.I. Eselborn-Lentzweiler
12, op der Sang | L- 9779 Lentzweiler
Tel. +352 2685 2000 | Fax +352 2685 3000
cti@ctisystems.com | www.ctisystems.com
H+H HERRMANN + HIEBER GMBH
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 711 93467-0, Fax +49 711 34609-11
E-Mail: info@herrmannhieber.de
Internet: www.herrmannhieber.de
Vollert Anlagenbau GmbH
Stadtseestraße 12, D-74189 Weinsberg
Tel. +49 7134 52 220 l Fax +49 7134 52 222
E-Mail intralogistik@vollert.de
Internet www.vollert.de
• Packaging equipment
Verpackungseinrichtungen
KASTO Maschinenbau GmbH & Co. KG
Industriestr. 14, D-77855 Achern
Tel.: +49 (0) 7841 61-0 / Fax: +49 (0) 7841 61 300
kasto@kasto.de / www.kasto.de
Hersteller von Band- und Kreissägemaschinen
sowie Langgut- und Blechlagersystemen
Nijverheidsweg 3
NL-7071 CH Ulft Netherlands
Tel.: +31 315 641352
Fax: +31 315 641852
E-Mail: info@unifour.nl
Internet: www.unifour.nl
Sales Contact: Paul Overmans
see Section handling 2.3
• Section transport equipment
Profiltransporteinrichtungen
• Stackers / Destackers
Stapler / Entstapler
BSN Thermprozesstechnik GmbH
Kammerbruchstraße 64
D-52152 Simmerath
Tel. 02473-9277-0 · Fax: 02473-9277-111
info@bsn-therm.de · www.bsn-therm.de
Ofenanlagen zum Wärmebehandeln von Aluminiumlegierungen,
Buntmetallen und Stählen
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
Avenida Cervantes Nº6
48970 – Basauri – Bizkaia – Spain
Tel: +34 944 409 420
E-mail: Insertec@insertec.biz
Internet: www.insertec.biz
see Equipment and accessories 3.1
www.mechatherm.com
see Smelting technology 1.5
mfw-maschinenbau.com
• Automatik Verpackung
• Packtische, Profilpaketheber
• Spacerhandling und Konzepte
• Section saws
Profilsägen
see Section handling 2.3
mfw-maschinenbau.com
• Kurzlängensäge automatisiert
• Section store equipment
Profil-Lagereinrichtungen
mfw-maschinenbau.com
• 7 und 14 m De- u. Stacker
• Kombianlagen
• Transport equipment for
extruded sections
Transporteinrichtungen
für Profilabschnitte
www.ctisystems.com
see Section handling 2.3
mfw-maschinenbau.com
• Skip Handling, Spacer
• Kettenförderer
SECO/WARWICK EUROPE S.A.
ul. Šwierczewskiego 76
66-200 Šwiebodzin, POLAND
Tel: +48 68 38 19 800
E-mail: europe@secowarwick.com.pl
Internet: www.secowarwick.com
• Heat treatment furnaces
Wärmebehandlungsöfen
HOFMANN Wärmetechnik GmbH
Gewerbezeile 7
A - 4202 Helmonsödt
Tel. +43(0)7215/3601
E-Mail: office@hofmann-waermetechnik.at
Internet: www.hofmann-waermetechnik.at
INOTHERM INDUSTRIEOFEN-
UND WÄRMETECHNIK GMBH
see Casthouse (foundry) 1.5
• Homogenising furnaces
Homogenisieröfen
www.ctisystems.com
see Section handling 2.3
see Section handling 2.3
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
80 ALUMINIUM · 3/2013

SUPPLIERS DIRECTORY
2.10 Machining of sections
Profilbearbeitung
• Billet saw
Bolzensägen
Sermas Industrie
sermas@sermas.com
see Smelting technology 1.6
• Ageing furnace for extrusions
Auslagerungsöfen für
Strangpressprofile
see Extrusion billet preparation 2.1
see Casthouse (foundry) 1.5
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
2.11 Equipment and
accessories
Ausrüstungen und
Hilfsmittel
• Inductiv heating equipment
Induktiv beheizte
Erwärmungseinrichtungen
INDUKTIONS-ANLAGEN + SERVICE GmbH & Co. KG
Am großen Teich 16+27
D-58640 Iserlohn
Tel. +49 (0) 2371 / 4346-0
Fax +49 (0) 2371 / 4346-43
E-Mail: verkauf@ias-gmbh.de
Internet: www.ias-gmbh.de
see Casthouse (foundry) 1.5
Could not find your „keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: anzeigen@giesel.de
Nijverheidsweg 3
NL-7071 CH Ulft Netherlands
Tel.: +31 315 641352
Fax: +31 315 641852
E-Mail: info@unifour.nl
Internet: www.unifour.nl
Sales Contact: Paul Overmans
2.6 Die preparation and care
Werkzeugbereitstellung
und -pflege
• Die heating furnaces
Werkzeuganwärmöfen
schwartz GmbH
see Extrusion billet preparation 2.1
Nijverheidsweg 3
NL-7071 CH Ulft Netherlands
Tel.: +31 315 641352
Fax: +31 315 641852
E-Mail: info@unifour.nl
Internet: www.unifour.nl
Sales Contact: Paul Overmans
see Heat treatment 2.4
2.9 Surface finishing
of sections
Oberflächenveredlung
von Profilen
mfw-maschinenbau.com
• Strahlanlagen
3
Rolling mill technology
Walzwerktechnik
3.1 Casting equipment
Gießanlagen
3.2 Rolling bar machining
Walzbarrenbearbeitung
3.3 Rolling bar furnaces
Walzbarrenvorbereitung
3.4 Hot rolling equipment
Warmwalzanlagen
3.5 Strip casting units
and accessories
Bandgießanlagen
und Zubehör
3.6 Cold rolling equipment
Kaltwalzanlagen
3.0 Rolling mill technology
Walzwerktechnik
see Cold rolling units / complete plants 3.6
3.7 Thin strip / foil rolling plant
Feinband-/Folienwalzwerke
3.8 Auxiliary equipment
Nebeneinrichtungen
3.9 Adjustment devices
Adjustageeinrichtungen
3.10 Process technology /
Automation technology
Prozesstechnik /
Automatisierungstechnik
3.11 Coolant / lubricant preparation
Kühl-/Schmiermittel-Aufbereitung
3.12 Air extraction systems
Abluftsysteme
3.13 Fire extinguishing units
Feuerlöschanlagen
3.14 Storage and dispatch
Lagerung und Versand
3.15 Second-hand rolling equipment
Gebrauchtanlagen
3.16 Coil storage systems
Coil storage systems
3.17 Strip Processing Lines
Bandprozesslinien
3.18 Productions Management Sytems
Produktions Management Systeme
www.alu-web.de
ALUMINIUM · 3/2013 81

LIEFERVERZEICHNIS
• Melting and holding furnaces
Schmelz- und Warmhalteöfen
• Annealing furnaces
Glühöfen
SMS Siemag Aktiengesellschaft
Eduard-Schloemann-Straße 4
40237 Düsseldorf, Germany
Telefon: +49 (0) 211 881-0
Telefax: +49 (0) 211 881-4902
E-Mail: communications@sms-siemag.com
Internet: www.sms-siemag.com
Geschäftsbereiche:
Warmflach- und Kaltwalzwerke
Wiesenstraße 30
57271 Hilchenbach-Dahlbruch, Germany
Telefon: +49 (0) 2733 29-0
Telefax: +49 (0) 2733 29-2852
Bandanlagen
Walder Straße 51-53
40724 Hilden, Germany
Telefon: +49 (0) 211 881-5100
Telefax: +49 (0) 211 881-5200
Elektrik + Automation
Ivo-Beucker-Straße 43
40237 Düsseldorf, Germany
Telefon: +49 (0) 211 881-5895
Telefax: +49 (0) 211 881-775895
Graf-Recke-Straße 82
40239 Düsseldorf, Germany
Telefon: +49 (0) 211 881-0
Telefax: +49 (0) 211 881-4902
3.1 Casting equipment
Gießanlagen
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
Avenida Cervantes Nº6
48970 – Basauri – Bizkaia – Spain
Tel: +34 944 409 420
E-mail: Insertec@insertec.biz
Internet: www.insertec.biz
www.mechatherm.com
see Smelting technology 1.5
• Electromagnetic Stirrer
Elektromagnetische Rührer
Solios Thermal UK
www.fivesgroup.com
www.alu-web.de
• Filling level indicators and controls
Füllstandsanzeiger und -regler
Gautschi
Engineering GmbH
see Casting equipment 3.1
Wagstaff, Inc.
see Casting machines 1.6
Gautschi Engineering GmbH
Konstanzer Straße 37
CH 8274 Tägerwilen
Telefon +41 71 666 66 66
Telefax +41 71 666 66 77
E-Mail: info@gautschi.cc
Internet: www.gautschi.cc
Kontakt: Sales Departement
LOI Thermprocess GmbH
Am Lichtbogen 29
D-45141 Essen
Germany
Telefon +49 (0) 201 / 18 91-1
Telefax +49 (0) 201 / 18 91-321
E-Mail: info@loi-italimpianti.de
Internet: www.loi-italimpianti.com
Solios Thermal UK
www.fivesgroup.com
• Melt purification units
Schmelzereinigungsanlagen
Gautschi
Engineering GmbH
see Casting equipment 3.1
• Metal filters / Metallfilter
Gautschi
Engineering GmbH
see Casting equipment 3.1
www.alu-web.de
3.2 Rolling bar machining
Walzenbarrenbearbeitung
• Plate saw
Plattensägen
Sermas Industrie
sermas@sermas.com
see Smelting technology 1.6
• Slab saw
Barrensägen
Sermas Industrie
sermas@sermas.com
see Smelting technology 1.6
3.3 Rolling bar furnaces
Walzbarrenvorbereitung
BSN Thermprozesstechnik GmbH
see Heat Treatment 2.4
EBNER Industrieofenbau Ges.m.b.H.
Ebner-Platz 1, 4060 Leonding/Austria
Tel. +43 / 732 / 6868-0
E-Mail: sales@ebner.cc
Internet: www.ebner.cc
Gautschi
Engineering GmbH
see Casting equipment 3.1
schwartz GmbH
see Equipment and accessories 3.1
Solios Thermal UK
www.fivesgroup.com
• Bar heating furnaces
Barrenanwärmanlagen
see Heat treatment 2.4
EBNER Industrieofenbau Ges.m.b.H.
see Annealing furnaces 3.3
Gautschi
Engineering GmbH
see Casting equipment 3.1
• Homogenising furnaces
Homogenisieröfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
schwartz GmbH
Solios Thermal UK
www.fivesgroup.com
see Heat treatment 2.4
www.alu-web.de
• Roller tracks
Rollengänge
Gautschi
Engineering GmbH
see Casting equipment 3.1
82 ALUMINIUM · 3/2013

SUPPLIERS DIRECTORY
3.4 Hot rolling equipment
Warmwalzanlagen
• Hot rolling units /
complete plants
Warmwalzanlagen/Komplettanlagen
see Section handling 2.3
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
see Cold rolling units / complete plants 3.6
• Coil transport systems
Bundtransportsysteme
www.ctisystems.com
see Section handling 2.3
see Section handling 2.3
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: sales@mino.it
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
SMS Siemag AG
see Rolling mill technology 3.0
3.6 Cold rolling equipment
Kaltwalzanlagen
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
BSN Thermprozesstechnik GmbH
see Heat Treatment 2.4
• Coil annealing furnaces
Bundglühöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
• Cold rolling units /
complete plants
Kaltwalzanlagen/Komplettanlagen
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: sales@mino.it
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
SMS Siemag AG
see Rolling mill technology 3.0
www.alu-web.de
• Drive systems / Antriebe
SMS Siemag AG
see Rolling mill technology 3.0
• Drive systems / Antriebe
SMS Siemag AG
see Rolling mill technology 3.0
• Rolling mill modernisation
Walzwerksmodernisierung
see Equipment and accessories 3.1
schwartz GmbH
see Heat treatment 2.4
www.alu-web.de
• Heating furnaces / Anwärmöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
• Process optimisation systems
Prozessoptimierungssysteme
Gautschi
Engineering GmbH
see Casting equipment 3.1
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: sales@mino.it
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
SMS Siemag AG
see Rolling mill technology 3.0
• Spools / Haspel
SMS Siemag AG
see Rolling mill technology 3.0
• Coil transport systems
Bundtransportsysteme
www.ctisystems.com
see Section handling 2.3
H+H HERRMANN + HIEBER GMBH
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 711 93467-0, Fax +49 711 34609-11
E-Mail: info@herrmannhieber.de
Internet: www.herrmannhieber.de
• Process simulation
Prozesssimulation
Gautschi
Engineering GmbH
see Casting equipment 3.1
SMS Siemag AG
see Rolling mill technology 3.0
• Roll exchange equipment
Walzenwechseleinrichtungen
SMS Siemag AG
see Rolling mill technology 3.0
ALUMINIUM · 3/2013 83

LIEFERVERZEICHNIS
• Rolling mill modernization
Walzwerkmodernisierung
3.7 Thin strip /
foil rolling plant
Feinband-/Folienwalzwerke
• Rolling mill modernization
Walzwerkmodernisierung
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
see Cold rolling units / complete plants 3.6
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: sales@mino.it
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
• Slitting lines-CTL
Längs- und Querteilanlagen
see Cold rolling units / complete plants 3.6
• Strip shears/Bandscheren
see Cold rolling units / complete plants 3.6
SMS Siemag AG
see Rolling mill technology 3.0
• Trimming equipment
Besäumeinrichtungen
see Cold rolling units / complete plants 3.6
SMS Siemag AG
see Rolling mill technology 3.0
Hier könnte Ihr
Bezugs-
quellen-
Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
see Cold rolling units / complete plants 3.6
• Coil annealing furnaces
Bundglühöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
see Equipment and accessories 3.1
schwartz GmbH
see Cold colling equipment 3.6
www.alu-web.de
• Heating furnaces
Anwärmöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
INOTHERM INDUSTRIEOFEN-
UND WÄRMETECHNIK GMBH
see Casthouse (foundry) 1.5
schwartz GmbH
see Heat treatment 2.4
• Thin strip / foil rolling mills /
complete plant
Feinband- / Folienwalzwerke /
Komplettanlagen
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: sales@mino.it
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
SMS Siemag AG
see Rolling mill technology 3.0
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
MINO S.p.A.
Via Torino, 1 – San Michele
15122 ALESSANDRIA – ITALY
Telefon: +39 0131 363636
Telefax: +39 0131 361611
E-Mail: sales@mino.it
Internet: www.mino.it
Sales contact: Mr. Luciano Ceccopieri
3.10 Process technology /
Automation technology
Prozesstechnik /
Automatisierungstechnik
• Process control technology
Prozessleittechnik
SMS Siemag AG
see Rolling mill technology 3.0
Wagstaff, Inc.
see Casting machines 1.6
www.alu-web.de
• Strip flatness measurement
and control equipment
Bandplanheitsmess- und
-regeleinrichtungen
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/pressductor
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
SMS Siemag AG
see Rolling mill technology 3.0
84 ALUMINIUM · 3/2013

SUPPLIERS DIRECTORY
• Strip thickness measurement
and control equipment
Banddickenmess- und
-regeleinrichtungen
• Strip Width & Position
Measurement equipment
Bandbreiten- und
Bandlaufmesseinrichtungen
• Exhaust air purification
systems (active)
Abluft-Reinigungssysteme (aktiv)
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/pressductor
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
SMS Siemag AG
see Rolling mill technology 3.0
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: anzeigen@giesel.de
• Strip Tension
Measurement equipment
Bandzugmesseinrichtungen
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/pressductor
3.11 Coolant / lubricant
preparation
Kühl-/Schmiermittel-
Aufbereitung
see Cold rolling units / complete plants 3.6
• Rolling oil recovery and
treatment units
Walzöl-Wiederaufbereitungsanlagen
SMS Siemag AG
see Rolling mill technology 3.0
• Filter for rolling oils and emulsions
Filter für Walzöle und Emulsionen
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
SMS Siemag AG
see Rolling mill technology 3.0
3.14 Storage and dispatch
Lagerung und Versand
SMS Siemag AG
see Rolling mill technology 3.0
3.16 Coil storage systems
Bundlagersysteme
www.ctisystems.com
see Section handling 2.3
H+H HERRMANN + HIEBER GMBH
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 711 93467-0, Fax +49 711 34609-11
E-Mail: info@herrmannhieber.de
Internet: www.herrmannhieber.de
SMS Siemag AG
see Rolling mill technology 3.0
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/pressductor
www.alu-web.de
• Rolling oil rectification units
Walzölrektifikationsanlagen
see Section handling 2.3
3.17 Strip Processing Lines
Bandprozesslinien
• Roll Force Measurement equipment
Walzkraftmesseinrichtungen
ABB Automation
Force Measurement
S-72159 Västeras, Sweden
Phone: +46 21 325 000
Fax: +46 21 340 005
E-Mail: pressductor@se.abb.com
Internet: www.abb.com/pressductor
Achenbach Buschhütten GmbH & Co. KG
Siegener Str. 152, D-57223 Kreuztal
Tel. +49 (0) 2732/7990, info@achenbach.de
Internet: www.achenbach.de
SMS Siemag AG
see Rolling mill technology 3.0
3.12 Air extraction systems
Abluft-Systeme
see Cold rolling units / complete plants 3.6
REDEX
Zone Industrielle
F-45210 Ferrieres
Telefon +33 (2) 38 94 42 00
E-mail: info@redex-group.com
Internet: www.tension-leveling.com
• Anodizing Lines
Anodisier-Linien
SMS Siemag AG
see Rolling mill technology 3.0
ALUMINIUM · 3/2013 85

LIEFERVERZEICHNIS
• Colour Coating Lines
Bandlackierlinien
www.bwg-online.com
see Strip Processing Lines 3.17
SMS Siemag AG
see Rolling mill technology 3.0
• Lithographic Sheet Lines
Lithografielinien
www.bwg-online.com
see Strip Processing Lines 3.17
see Cold rolling units / complete plants 3.6
• Stretch Levelling Lines
Streckrichtanlagen
www.bwg-online.com
see Strip Processing Lines 3.17
• Strip Annealing Lines
Bandglühlinien
www.bwg-online.com
see Strip Processing Lines 3.17
SMS Siemag AG
see Rolling mill technology 3.0
4 Foundry
Gießerei
4.1 Work protection and ergonomics
Arbeitsschutz und Ergonomie
4.2 Heat-resistant technology
Feuerfesttechnik
4.3 Conveyor and storage technology
Förder- und Lagertechnik
4.4 Mould and core production
Form- und Kernherstellung
4.5 Mould accessories and accessory
materials
Formzubehör, Hilfsmittel
4.6 Foundry equipment
Gießereianlagen
4.7 Casting machines and equipment
Gießmaschinen
und Gießeinrichtungen
4.8 Handling technology
Handhabungstechnik
4.9 Construction and design
Konstruktion und Design
4.10 Measurement technology
and materials testing
Messtechnik und Materialprüfung
4.11 Metallic charge materials
Metallische Einsatzstoffe
4.12 Finishing of raw castings
Rohgussnachbehandlung
4.13 Melt operations
Schmelzbetrieb
4.14 Melt preparation
Schmelzvorbereitung
4.15 Melt treatment devices
Schmelzebehandlungseinrichtungen
4.16 Control and regulation technology
Steuerungs- und
Regelungstechnik
4.17 Environment protection
and disposal
Umweltschutz und Entsorgung
4.18 Dross recovery
Schlackenrückgewinnung
4.19 Cast parts
Gussteile
• Strip Processing Lines
Bandprozesslinien
BWG Bergwerk- und Walzwerk-
Maschinenbau GmbH
Mercatorstraße 74 – 78
D-47051 Duisburg
Tel.: +49 (0) 203-9929-0
Fax: +49 (0) 203-9929-400
E-Mail: bwg@bwg-online.de
Internet: www.bwg-online.com
3.18 Production
Management systems
Produktions Management
Systeme
PSI Metals Non Ferrous GmbH
Software Excellence in Metals
Carlo-Schmid-Str. 12, D-52146 Würselen
Tel.: +49 (0) 2405 4135-0
info@psimetals.de, www.psimetals.com
4.2 Heat-resistent technology
Feuerfesttechnik
• Refractories / Feuerfeststoffe
Calderys Deutschland GmbH
In der Sohl 122
56564 Neuwied
E-mail: germany@calderys.com
Internet: www.calderys.de
INSERTEC-INGENIERÍA Y SERVICIOS TÉCNICOS, S.A
Avenida Cervantes Nº6
48970 – Basauri – Bizkaia – Spain
Tel: +34 944 409 420
E-mail: Insertec@insertec.biz
Internet: www.insertec.biz
Promat GmbH High Performance Insulation
Scheifenkamp 16, D-40878 Ratingen
Tel. +49 (0) 2102 / 493-0, Fax -493 115
verkauf3@promat.de, www.promat.de
www.alu-web.de
Refratechnik Steel GmbH
Schiessstrasse 58
40549 Düsseldorf / Germany
Phone +49 211 5858 0
Fax +49 211 5858 46
Internet: www.refra.com
4.3 Conveyor and storage
technology
Förder- und Lagertechnik
www.ctisystems.com
see Section handling 2.3
Paul Hedfeld GmbH
Hundeicker Str. 20
D-58285 Gevelsberg
Phone: +49 (0) 2332 6371
E-mail: verkauf@hedfeld.com
Internet: www.hedfeld.com
86 ALUMINIUM · 3/2013

SUPPLIERS DIRECTORY
H+H HERRMANN + HIEBER GMBH
Rechbergstraße 46
D-73770 Denkendorf/Stuttgart
Tel. +49 711 93467-0, Fax +49 711 34609-11
E-Mail: info@herrmannhieber.de
Internet: www.herrmannhieber.de
see Section handling 2.3
4.5 Mold accessories and
accessory materials
Formzubehör, Hilfmittel
• Fluxes
Flussmittel
Solvay Fluor GmbH
Hans-Böckler-Allee 20
D-30173 Hannover
Telefon +49 (0) 511 / 857-0
Telefax +49 (0) 511 / 857-2146
Internet: www.solvay-fluor.de
4.6 Foundry equipment
Gießereianlagen
www.mechatherm.com
see Smelting technology 1.5
• Casting machines
Gießmaschinen
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
see Equipment and accessories 3.1
www.alu-web.de
• Heat treatment furnaces
Wärmebehandlungsöfen
HOFMANN Wärmetechnik GmbH
Gewerbezeile 7
A - 4202 Helmonsödt
Tel. +43(0)7215/3601
E-Mail: office@hofmann-waermetechnik.at
Internet: www.hofmann-waermetechnik.at
see Casthouse (foundry) 1.5
4.7 Casting machines
and equipment
Gießereimaschinen
und Gießeinrichtungen
GAPCast
TM : the Swiss casting solution
Casting Technology / Automation
Tel.: +41 27 455 57 14
E-Mail: info@gap-engineering.ch
Internet: www.gap-engineering.ch
www.mechatherm.com
see Smelting technology 1.5
Precimeter Control AB
Ostra Hamnen 7
SE-475 42 Hono / Sweden
Tel.: +46 31 764 5520, Fax: +46 31 764 5529
E-Mail: marketing@precimeter.com
Internet: www.precimeter.com
Sales contact: Jonatan Lindstrand
Competence in EMC and ASC casting
RIHS ENGINEERING SA
Tel.: +41 27 455 54 41
E-Mail: info@maschko.ch
Internet: www.maschko.ch
Wagstaff, Inc.
see Casting machines 1.6
Could not find your
„keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: anzeigen@giesel.de
• Continuous ingot casting
lines and aluminium rod lines
Kokillengieß- und Aluminiumdraht-Anlagen
Via Emilia Km 310
26858 Sordio-LO
Italy
Tel. +39.02.988492-1 . hq@properzi.it
Fax +39.02.9810358 . www.properzi.com
• Mould parting agents
Kokillentrennmittel
Schröder KG
Schmierstofftechnik
Postfach 1170
D-57251
Freudenberg
Tel. 02734/7071
Fax 02734/20784
www.schroeder-schmierstoffe.de
4.8 Handling technology
Handhabungstechnik
www.ctisystems.com
see Section handling 2.3
Ein Eintrag (s/w) in
diesem Format kostet
pro Ausgabe + Stichwort
110,00 € + MwSt.
Weitere Informationen unter
Tel. +49 (0) 821 / 31 98 80 - 0
4.10 Measurement technology
and materials testin
Messtechnik und
Materialprüfung
ratioTEC Prüfsysteme GmbH
In der Au 17
D-88515 Langenenslingen
Tel.: +49 (0)7376/9622-0
Fax: +49 (0)7376/9622-22
E-Mail: info@ratiotec.com
Internet: www.ratiotec.com
www.alu-web.de
4.11 Metallic charge
materials
Metallische Einsatzstoffe
• Recycling / Recycling
Chr. Otto Pape GmbH
Aluminiumgranulate
Berliner Allee 34
D-30855 Langenhagen
Tel:+49(0)511 786 32-0 Fax: -32
Internet: www.papemetals.com
E-Mail: info@papemetals.com
ALUMINIUM · 3/2013 87

LIEFERVERZEICHNIS
4.13 Melt operations
Schmelzbetrieb
www.mechatherm.com
see Smelting technology 1.5
• Burner System
Brennertechnik
Büttgenbachstraße 14
D-40549 Düsseldorf/Germany
Tel.: +49 (0) 211 / 5 00 91-0
Fax: +49 (0) 211 / 5 00 91-14
E-Mail: info@bloomeng.de
Internet: www.bloomeng.de
see Extrusion 2.4.
Hier könnte Ihr
Bezugsquellen-Eintrag
stehen.
Rufen Sie an:
Tel. 0821 / 31 98 80-34
Dennis Ross
• Heat treatment furnaces
Wärmebehandlungsanlagen
Gautschi
Engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
see Equipment and accessories 3.1
• Holding furnaces
Warmhalteöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
see Equipment and accessories 3.1
• Melting furnaces
Schmelzöfen
Gautschi
Engineering GmbH
see Casting equipment 3.1
HERTWICH ENGINEERING GmbH
see Casthouse (foundry) 1.5
see Equipment and accessories 3.1
MARX GmbH & Co. KG
Lilienthalstr. 6-18
D-58638 Iserhohn
Tel.: +49 (0) 2371 / 2105-0, Fax: -11
E-Mail: info@marx-gmbh.de
Internet: www.marx-gmbh.de
4.14 Melt preparation
Schmelzvorbereitung
• Degassing, filtration
Entgasung, Filtration
Drache Umwelttechnik
GmbH
Werner-v.-Siemens-Straße 9/24-26
D 65582 Diez/Lahn
Telefon 06432/607-0
Telefax 06432/607-52
Internet: http://www.drache-gmbh.de
4.15 Melt treatment devices
Schmelzbehandlungseinrichtungen
Metaullics Systems Europe B.V.
Ebweg 14
NL-2991 LT Barendrecht
Tel. +31-180/590890
Fax +31-180/551040
E-Mail: info@metaullics.nl
Internet: www.metaullics.com
4.17 Environment protection
and disposal
Umweltschutz und
Entsorgung
• Dust removal
Entstaubung
NEOTECHNIK GmbH
Entstaubungsanlagen
Postfach 110261, D-33662 Bielefeld
Tel. 05205/7503-0, Fax 05205/7503-77
info@neotechnik.com, www.neotechnik.com
4.18 Dross recovery
Schlackenrückgewinnung
ALTEK EUROPE LTD
Lakeside House, Burley Close
Chesterfield, Derbyshire. S40 2UB
UNITED KINGDOM
Tel: UK: +44 (0)1246 383737
Tel: USA: +1 484 713 0070
Internet: www.altek-al.com
5 Materials
and
Recycling
Werkstoffe
und Recycling
• Granulated aluminium
Aluminiumgranulate
Chr. Otto Pape GmbH
Aluminiumgranulate
Berliner Allee 34
D-30855 Langenhagen
Tel:+49(0)511 786 32-0 Fax: -32
Internet: www.papemetals.com
E-Mail: info@papemetals.com
6 Machining +
Application
Bearbeitung +
Anwendung
6.1 Equipment to produce
castplate
Ausrüstungen für
Gussplattenproduktion
• Slicing saw & Milling machines
Folienschneidmaschinen
Fräsmaschinen
Sermas Industrie
sermas@sermas.com
see Smelting technology 1.6
6.2 Semi products
Halbzeuge
• Wires / Drähte
DRAHTWERK ELISENTAL
W. Erdmann GmbH & Co.
Werdohler Str. 40, D-58809 Neuenrade
Postfach 12 60, D-58804 Neuenrade
Tel. +49(0)2392/697-0, Fax 49(0)2392/62044
E-Mail: info@elisental.de
Internet: www.elisental.de
88 ALUMINIUM · 3/2013

SUPPLIERS DIRECTORY
6.3 Equipment for forging
and impact extrusion
Ausrüstung für Schmiedeund
Fließpresstechnik
• Hydraulic Presses
Hydraulische Pressen
LASCO Umformtechnik GmbH
Hahnweg 139, D-96450 Coburg
Tel. +49 (0) 9561 642-0
Fax +49 (0) 9561 642-333
E-Mail: lasco@lasco.de
Internet: www.lasco.com
www.alu-web.de
8 Literature
Literatur
• Technical literature
Fachliteratur
Taschenbuch des Metallhandels
Fundamentals of Extrusion Technology
Giesel Verlag GmbH
Hans-Böckler-Allee 9, 30173 Hannover
Tel. 0511 / 73 04-125 · Fax 0511 / 73 04-233
Internet: www.alu-bookshop.de
Could not find your „keywords“?
Please ask for our complete
„Supply sources for the
aluminium industry“.
E-Mail: anzeigen@giesel.de
• Technical journals
Fachzeitschriften
Giesel Verlag GmbH
Hans-Böckler-Allee 9, 30173 Hannover
Tel. 0511/8550-2638 · Fax 0511/8550-2405
GDMB-Informationsgesellschaft mbH
Paul-Ernst-Str.10, 38678 Clausthal-Zellerfeld
Telefon 05323-937 20, Fax -237, www.gdmb.de
International
ALUMINIUM
Journal
89. Jahrgang 1.1.2013
Verlag / Publishing house
Giesel Verlag GmbH
Post fach 5420, 30054 Hannover
Hans-Böckler-Allee 9, 30173 Hannover
Tel. +49(0)511 7304-0, Fax +49(0)511 7304-157
info@giesel.de, www.giesel-verlag.de
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Tel. +49(0)2225 8359643
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Dipl.-Ing. Rudolf P. Pawlek
Hüttenindustrie und Recycling
rudolf.pawlek@span.ch
Dipl.-Ing. Bernhard Rieth
Walzwerkstechnik und Bandverarbeitung
rollingmill-technology@t-online.de
Ken Stanford, Contributing Editor
kstanford2004@yahoo.co.uk
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Tel. +49(0)821 319880-34, d.ross@giesel.de
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ALUMINIUM · 3/2013 89

VORSCHAU / PREVIEW
IM NÄCHSTEN HEFT
Special: Die internationale
Aluminium-Strangpressindustrie
Wir berichten über Unternehmen und Ausrüster der Strangpressindustrie,
über Anlagentechnik und neue Projekte.
Themen unter anderem:
• Richter Aluminium nimmt 45-MN-Presse in Betrieb
• SMS Meer Leichtmetall-Strangpressen: Mit neuen
Vertriebsansätzen weitere Marktpotenziale heben
• Zur Anlageneffektivität von Strangpresslinien, Teil II
• Inline-Bolzenerwärmung – aus der Nähe betrachtet
Weitere Themen
• Isal installiert drei Homogenisierlinien für
Strangpress-Vormaterial
Research
• Simulation der Längspressnahtlage beim Strangpressen
Erscheinungstermin: 08. April 2013
Anzeigenschluss: 25. März 2013
Redaktionsschluss: 11. März 2013
IN THE NEXT ISSUE
Special: The international
aluminium extrusion industry
We will report on companies and equipment partners of the
extrusion industry, with emphasis on plant technology and
new projects. Topics include:
• Richter Aluminium commissions new extrusion press
• SMS Meer, Light Metal Extrusion Presses: Tapping
further market potential with a new sales approach
• Overall Equipment Effectiveness for extrusion plants, II
• In-line billet heating – in close-up view
Other topics
• Isal installs three homogenising lines for
extrusion pre-material
Research
• Methods to inhibit localised recrystallisation in
AA7020 alloy extrusions
Date of publication: 08 April 2013
Advertisement deadline: 25 March 2013
Editorial deadline: 11 March 2013
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